Construction Robotics MULE ML150 Owner's Manual

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MULE ML150

OWNER'S MANUAL

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Summary of Contents for Construction Robotics MULE ML150

Page 1 MULE ML150 OWNER’S MANUAL...
Page 2 Page Intentionally Left Blank CR005220A Page ii...
Page 3 Should there be any discrepancies discovered throughout any published documentation issued by Construction Robotics or its authorized affiliates, the following order of precedence shall prevail: 1. Written documents issued by Construction Robotics (Technical Bulletins, letters, etc.)
Page 4: Table Of Contents
Ground Base Mounted to Wheel set Table of Contents Fork Tubes A INTRODUCTION Working with Mast Ties Assembling the Mast and Installing MULE INTRODUCTION Raising MULE Height (Adding Mast Sections) 27 Moving MULE on a Jobsite Safe Operating Guidelines General Location Requirements for MULE28 System Overview Free Standing Ground Base Wheel Set...
Page 5 Primary Arm Daily Secondary Arm Weekly Monthly Virtual Limits Wire Rope Controller Menu Inspection Virtual Limits (V-limits) Lubrication Speed Menu Required Replacement Criteria SET Weight Slack Detection Anti-Drop Tool Weight Replacement Diagnostics Software Flowchart Pneumatic System Air Compressor Pneumatic System Water Separator Air Compressor Pneumatic Connection Diagram...
Page 6: Aintroduction
It is essential that the competent person be appropriately trained in the installation, dismantlement, proper use and safe operation of the MULE and its accessories. Construction robotics can assist owners/employers in providing this training.
Page 7: System Overview
If the desired setup exceeds any of the requirements or limits described throughout this manual, contact Construction Robotics with specific details for non-standard engineering approval. Additional engineering charges may apply. If any uncertainties with the contents of this manual arise or clarifications are required, contact Construction Robotics immediately.
Page 8: Product Warranty
4.2 Warranty Policy All warranty claims will be determined after inspection at a designated facility. A Returned Material Authorization (RMA) is required for all warranty claims. Contact Construction Robotics Customer Support at 844-476-2684 for a RMA. 5 Acronyms and Abbreviations...
Page 10: B System Summary
B SYSTEM SUMMARY 1 Meet MULE The MULE is a smart material handling tool designed for construction that does the heavy lifting for you. Features and benefits:  MULE makes materials up to 150 pounds seem weightless (depending on the specific gripper configuration) ...
Page 11: Weights
Figure B-4 3 MULE Accessories Below is a list of some basic MULE accessories. Construction Robotics offers a variety of additional options, and is developing new ones. Custom accessories can be developed upon request, contact Construction Robotics for more information.
Page 12: Ground Base Wheel Set
3.1 Ground Base Wheel Set Installs onto the bottom of the Ground Base, allows for MULE to be rolled between setup locations on jobsite. Capacity of 3200 lb Weight: 530 lb 3.2 Hydro Mobile Mast Adapters Allow for using HM mast as the mast for MULE, also can be used to attach MULE to the top of a HM mast supported by something other than a CR base.
Page 13: Wire Rope Extensions
SECTION B – SYSTEM SUMMARY 3.6 Wire Rope Extensions Wire Rope Extensions allow for vertically moving the 11’ working zone further from MULE. They attach to the Wire Rope and coil cords the same way that the Controller does. The Controller is then attached to the extensions.
Page 14: System Dimensions
4 System Dimensions CR005220A Page 8...
Page 15 SECTION B – SYSTEM SUMMARY CR005220A Page 9...
Page 16: Safety Features
Inches (Centimeters) 5 Safety Features Rotation Lock When power is removed from MULE, a pin is engaged to lock the rotation of the Primary Arm. This is primarily used in 2 situations; when building/dismantling MULE and moving MULE. When MULE is being transported between sites, there is a pin that can be inserted to prevent the lock from coming disengaged.
Page 17: Basic Requirements
SECTION B – SYSTEM SUMMARY Overload Protection The software running MULE is constantly monitoring the load on the Wire Rope. If the capacity of 150lb is exceeded the software will only allow for the controller to be lowered at a slow speed. This feature prevents heavy loads from being lifted and possibly damaging the unit or risking a tip-over.
Page 18: C System Setup
1 Owner’s Manual Limitations If the desired setup exceeds any of the requirements or limits described throughout this manual, contact Construction Robotics with specific details for non-standard engineering approval. Additional engineering charges may apply. If any uncertainties with the contents of this manual arise or clarifications are required, contact your Dealer.
Page 19: Setup Process
SECTION C – SYSTEM SETUP 3 Setup Process 3.1 Base Distance from Wall The distance MULE sits from the wall face determines how many lineal feet of wall can be worked in a single setup. In some cases, MULE must be set further back than desired due to site obstacles. The arms must remain free to rotate as the wall is worked.
Page 20: Outrigger Position
MULE must be mounted in the center of the Ground Base. Contact CR for approval on specific setups as required. Be sure to follow all Local, State and Federal regulations on clearance distances to Electrical Lines. As a reference, North American regulations typically require a minimum of 10’ of clearance on lines less than 50,000V.
Page 21: Base Leveling And Capacity
SECTION C – SYSTEM SETUP 3.3 Base Leveling and Capacity The maximum capacity of the Ground Base is 3700 lb. Do not exceed this capacity; use the weights above in the document to determine how much non-MULE weight can be supported at any time. Ensure the ground or bearing surface under the jacks has the necessary capacity to support the total load.
Page 22: Controller Installation
3.5 Controller Installation The Controller MUST be connected before MULE is plugged in. Attach the Controller to the Wire Rope loop using the clevis pin at the top. Secure the clevis pin with the lock pin. Strain Relief - The black coil cord is secured to a fixture that is attached to the wire rope to provide strain relief.
Page 23: Ground Base Wheel Set Installation
SECTION C – SYSTEM SETUP 3.8 Ground Base Wheel Set Installation For MULE to be assembled to the Wheel Set, the mast must be no taller than 6 ft. To lift the Ground Base, move the pin in the jacks to the 2 position and crank the jacks evenly to lift the pallet high enough to allow the Ground Base...
Page 24 If further disassembly is desired, the Fork Tubes can be broken down into 4 pieces that can be carried by hand by removing the bolts in Figure C-8. Figure C-7 – Fork Tube Removal Figure C-8 – Fork Tube Disassembly CR005220A Page 18...
Page 25: Maximum Mast Height
SECTION C – SYSTEM SETUP 4 Maximum Mast Height This manual provides the standard cases for using MULE. Contact CR for approval on special scenarios not outlined in this manual. Mast Type Base Type CR Mast HM Mast Ground Base – Freestanding 4 Sections 22’...
Page 26: Mounted To Wheel Set
4.2 Mounted to Wheel set When operating on the Wheel set, the wind requirements are:  Operation: Maximum 30 mph  Not in Operation on Wheels: Maximum 30 mph  Not in Operation on Jacks: Maximum 45 mph  Remove MULE from top of Mast: above 45 mph When not in operation, there should be no load on the gripper.
Page 27: Working With Mast Ties
SECTION C – SYSTEM SETUP 5 Working with Mast Ties When site conditions require MULE to be built taller than Free Standing will allow, the Mast can be tied into existing structure. Wall ties are required every 15 ft beginning 3-10ft from the base. There must be no more than 15 ft of mast above the last tie.
Page 28: Assembling The Mast And Installing Mule
6 Assembling the Mast and Installing MULE Once you have determined how high you are building MULE and if you are required to use wall ties, it is time to assemble. As a rule of thumb, MULE can build as high as the top of the upper mast section. *** CR suggests that MULE be powered on to ensure the Primary Arm Rotation Lock disengages prior to raising MULE.
Page 29 SECTION C – SYSTEM SETUP Building from the Top-Down (typically preferred) If wall ties are being used, this section will not apply. Follow the guidelines in Error! Reference source not found. below. Assuming more than one 5 ft section of mast is being used, lift MULE up with the Fork Tubes.
Page 30 If using rigging to attach MULE, use the rigging points as shown in Figure C-14 (FOLLOW STANDARD RIGGING PRACTICES). As the rigging points on MULE have a maximum capacity of 500 lb in addition to the arm and powerpack (Fork pocket, mast sections, plates etc), the entire mast stack cannot be assembled in the same fashion as when assembling from the Top-Down.
Page 31 SECTION C – SYSTEM SETUP Hydro Mobile Mast When utilizing the HM mast on the CR Ground Base, no climbing of the HM mast is allowed If you are utilizing Hydro Mobile Mast for MULE the adapters need to be installed on the Ground Base and at the bottom of MULE.
Page 32 Building from the Top-Down If wall ties are being used, this section will not apply. Follow the guidelines in Building from the Bottom-Up below. Lift MULE up with the Fork Tubes; attach a single HM mast section to the bottom of MULE using the hardware built into the HM Mast.
Page 33: Raising Mule Height (Adding Mast Sections)
SECTION C – SYSTEM SETUP 7 Raising MULE Height (Adding Mast Sections) Once MULE is assembled and needs to be raised to change the work zone, Mast sections need to be added. Before unplugging MULE, raise the Controller as high as possible to avoid excessive slack in the rope.
Page 34: Moving Mule On A Jobsite
Lift the rigging so that there is tension on it but you are not lifting more than 500 lb in addition to the arm and powerpack (Fork pocket, mast sections, plates etc). Remove the bolts at the junction you intend to add mast to and lift the unit.
Page 35: 8.3 Wheel Set
SECTION C – SYSTEM SETUP Once the move is complete, do not move the Fork Truck until releveling. Re-level MULE to within 1/2° using the built in indicators above the Fork Tubes. Figure C-20 - Inclinometer during operation If it is necessary to move an assembled MULE with a Fork Truck using the Ground Base, the amount of mast may not exceed 8’.
Page 36: System With Wall Ties
8.4 System with Wall Ties If the maximum free stand height is exceeded and wall ties are required, MULE cannot be moved without some level of disassembly. If the mast length is less than or equal to 15 ft (if moving with an overhead crane in a fixed position, any mast length up to 20 ft is acceptable), then the Ground Base and mast stack can be moved as 1 piece.
Page 37: Mule Dismantling And Packing For Transport
SECTION C – SYSTEM SETUP 9 MULE Dismantling and Packing for Transport When MULE is finished working on a site it can be packed into a convenient package for transport. This packaging is solely for convenience; see Section F for shipping requirements. Remove Controller and place in Transport box.
Page 38: D System Setup On Mast Climbing Platform
D SYSTEM SETUP ON MAST CLIMBING PLATFORM 1 Introduction As Mast Climbing Work Platforms’ (MCWP) are so critical in construction, CR has made special mounting solutions to optimize the valuable deck space and decrease overall system weight. CR has different styles of dedicated MCWP mounts. Refer to the documentation that came with your specific mount for details.
Page 39: Adding Masts And Mule
SECTION D – SYSTEM SETUP ON MAST CLIMBING PLATFORM 2.4 Adding Masts and MULE The Fork Tubes must be well supported on a level surface. Remove MULE from the Fork Tubes using the rigging points. Add the mast adapter plate to the Fork Tubes and install the standard mast sections to it.
Page 40: E System Operation
E SYSTEM OPERATION 1 Controller Buttons 1.1 RUN STOP The RUN STOP button disables all functionality on the Controller and Actuator. When pressed the screen will show “E-STOP ENGAGED” 1.2 Manual/Calibrate Up/Down Typically used as the calibration for the load weight in Float Mode. This is also the method to directly drive the Wire Rope Up or Down at a variable speed (the further the button is depressed the faster it moves).
Page 41 SECTION E – SYSTEM OPERATION 2 External Buttons - Gripper and Handle Depending on the configuration of your unit, you may have 1 or 2 buttons on your handle and possibly 2 buttons on the gripper. Buttons on the gripper and handles are labeled with their function. 2.1 Grip The GRIP button engages and disengages the clamping mechanism on the Gripper.
Page 42 The gripper will not retract although the AUTO RETRACT button is pressed This is typically caused by one of two conditions: 1) The gripper binding on the load or being held after placing. 2) The retract height is set below the place height When in Float Mode with AUTO RETRACT pressed, once the load is placed the gripper will try to move up to the programmed Retract Height.
Page 43 SECTION E – SYSTEM OPERATION 5 Primary Arm Rotation Lock The Primary Arm is equipped with a locking mechanism to prevent the arm from swinging when MULE is not powered. The lock is driven by the pneumatic system and can be manually operated if desired. Sometimes it is necessary to rotate the arm while not powered.
Page 44 F TRANSPORT AND STORAGE 1 Shipping Position MULE can be shipped attached only to the Fork Tubes or assembled with masts and the Ground Base as it was initially received. In either case, it is important to support both of the arms in both the up and down directions. Ensure that the Primary Arm rotation lock is engaged and that the lock pin is preventing the lock from releasing (See Section E5).
Page 45 SECTION G – SETTINGS AND TROUBLESHOOTING G SETTINGS AND TROUBLESHOOTING 1 Key Access Areas Arm Access Panel Powerpack Service Panel 2 Friction Brake Adjustment The friction brakes control how fast the arms move and how quickly they start and stop. Looser friction brakes allow the arm to move easier but also allow for more unintended movement.
Page 46: Secondary Arm
With the panel removed, a hole near the rigging eye is exposed. Insert the extension into the silver piece below and attach the breaker bar or ratchet. Little adjustment is needed to change the feel of the arm, adjust the nut no more than 1/8 of a turn at a time. Do not loosen or tighten more than 1 turn from factory delivered setting.
Page 47: Virtual Limits
SECTION G – SETTINGS AND TROUBLESHOOTING 3 Virtual Limits If work is being performed repeatedly in the same height range, limits can be set to prevent the Controller from travelling up or down further than intended. To set and adjust Virtual Limits see the Controller Menu in section G4. 4 Controller Menu The current software version is V1.02, for any other versions refer to information specific for that version.
Page 48: Software Flowchart
4.6 Software Flowchart CR005220A Page 42...
Page 49 SECTION G – SETTINGS AND TROUBLESHOOTING CR005220A Page 43...
Page 50: Pneumatic System
5 Pneumatic System 5.1 Air Compressor MULE contains an integrated Air Compressor to power the gripper and rotation lock. This compressor’s integrated regulator is set to 80 psi. 5.2 Pneumatic Connection Diagram CR005220A Page 44...
Page 51: Electrical Information
SECTION G – SETTINGS AND TROUBLESHOOTING 6 Electrical Information 6.1 Transformer Adjustments MULE requires a specific voltage range in order to function. In the event that your voltage supply does not match the listed requirements, there is an adjustable transformer on board to compensate for this. CR005220A Page 45...
Page 52 Adjust selector switch to maintain reading between 220 and 242 Volts If the Powerpack Service Panel is removed, you will notice a digital readout on the electrical enclosure. For MULE to operate properly this number needs to read between 220 and 242 Volts at all times. Based on your specific power supply scenario the voltage may decrease when additional load is quickly added by MULE (such as when the Air Compressor starts) or external sources.
Page 53: Electrical Connection Diagram
SECTION G – SETTINGS AND TROUBLESHOOTING 6.2 Electrical Connection Diagram Power Control CR005220A Page 47...
Page 54: Primary Arm Rotation Lock
7 Primary Arm Rotation Lock The Primary Arm Rotation Lock should be disengaged when MULE is powered on. If it fails to release, there are a couple of items to check. Check that the lock can be manually raised. If it does not release, the lock pin is likely still engaged from transport.
Page 55: Troubleshooting
SECTION G – SETTINGS AND TROUBLESHOOTING 8 Troubleshooting 8.1 Common Issues Failure Possible Solution  Briefly press one of the MANUAL CALIBRATE buttons until the Controller Controller screen shows “EXCESSIVE PAUSE” moves  Ensure MULE is plugged in Primary arm rotation lock will ...
Page 56  Check the I/O block is seeing input (Section G4 on page 41)  Unplug air from Controller, check for mechanical binding Only 1 cam moves  Listen for air leaks  Unplug air from Controller Air is leaking from the ...
Page 57: Error Codes
SECTION G – SETTINGS AND TROUBLESHOOTING 8.2 Error Codes In case of certain actuator and other electrical errors, a message will be displayed on the Controller Screen. There are 3 different types of messages that will display based on the error; Drive Fault, Command Fault and Command Warning Drive Fault: Faults detected in the motor controller that result in an Actuator Shutdown.
Page 58: H Preventative Maintenance And Basic Service
H PREVENTATIVE MAINTENANCE AND BASIC SERVICE 1 Maintenance Summary 1.1 Daily  Pre-shift inspection on Wire Rope  Pre-shift inspection on MULE Power Cord  Drain Air Compressor Tanks  Inspect for structural damage and loose parts 1.2 Weekly  Clean the fan filter on the bottom of the Powerpack, replace as needed ...
Page 59: Lubrication
SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE 2.2 Lubrication MULE’s Wire Rope comes pre-lubricated from the Factory. As MULE is used and the Wire Rope flexes the lubricant will need to be replenished. CR recommends that the Wire Rope is lubricated with Prelube 6 which is available through CR. OSHA prohibits the use of any Wire Rope lubricants that hinder inspection.
Page 60: Slack Detection
2.4 Slack Detection The slack detection system prevents damage to the Wire Rope and actuator when the load is placed. Quick Check A quick test suitable for monthly preventative maintenance is accomplished by taking the empty controller out of float mode (release the FLOAT button), and then manually running it onto the ground using the MANUAL/CALIBRATE DN button.
Page 61 SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE Adjustment Unplug MULE Remove the air compressor side panel Remove the actuator cover above the air compressor Figure H-5 If 5 pound weight was able to drive down (most common) Figure H-5 Loosen the eye bolt nut on the top side of the bracket.
Page 62: Replacement
2.5 Replacement Warning: Wire Rope replacement is to be performed by qualified maintenance personnel only. Tools:  Table or similar flat surface  3mm Allen key  4mm Allen key  5mm Allen key  6mm Allen key  7mm wrench ...
Page 63 SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE Fully press in the spring loaded screw, hold in position. Apply tension to the Wire Rope with your right hand and jog down until rotation stops. Unplug the limit switch assembly from the circuit board Using the 4mm Allen key, remove the 4 bolts fastening the circuit board bracket to the actuator, carefully tilt the bracket down once loose.
Page 64 Using the 3mm Allen key, remove 2 bolts from the rope retainer. Slide retainer off the Wire Rope. Push rope with Right Hand into the drum to unseat the stop sleeve. The rope should now be free of the actuator. Remove the Secondary Arm cover (including attached joint cover), removing the 2- 19mm bolts will allow this assembly to slide out.
Page 65 SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE Using the 3mm Allen key, 6mm Allen key, 8mm wrench and 17mm wrench remove the 2 bolts holding the pulley block at the end of the arm. CR005220A Page 59...
Page 66 Using the 3mm Allen key and 7mm wrench, remove the 3 bolts holding the plastic pulley block together. The Wire Rope should now be completely free. Installing New Wire Rope Take care to keep new rope clean and orderly during installation. Avoid twisting or kinking Wire Rope. Slide the stop sleeve end of the Wire Rope through the arm to the actuator.
Page 67: Pneumatic System
SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE 3 Pneumatic System Any service to the air system should be performed with the compressor drained and the valve locked in the open position to prevent accidental pressurization. 3.1 Air Compressor To drain the air compressor, unplug MULE and open the ball valve at the bottom of the Powerpack. Filter The compress filter should be cleaned monthly to increase longevity and performance.
Page 68: Monthly Inspection
 Indications of possible internal damage. 5.2 Monthly Inspection During the monthly inspection the power cord must be check for the following issues (OSHA 1926.404):  Deformed or missing pins on plug.  Insulation Damage.  Indications of possible internal damage. ...
Page 69: Inclinometers
SECTION H – PREVENTATIVE MAINTENANCE AND BASIC SERVICE 8 Inclinometers Inclinometers have been installed to provide a visual indicator of how plumb MULE is. Calibration should be checked as part of the monthly inspection. To check calibration, plumb the rotation mast in both directions using a 2’ level (it is important not to do this on the mast stack itself) When the rotation mast is plumb, check each inclinometer for accuracy.
Page 70 CR005220A Page 64...
Page 71 Page Intentionally Left Blank...
Page 72 7871 Lehigh Xing Victor, NY 14564 (585)-742-2004 info@robotics.build www.robotics.build © 2021 Construction Robotics, LLC All Rights Reserved CR Customer Support: (844) 476-2684 CR005220A Page 66...