Rated Capacity Indicator/Limiter TOC

18000 Liftcrane
Folio 2239 8/17/2011 Crane Inspection After An Overload
Folio 2006 06/10/2010 Rated Capacity Indicator/Limiter Operation
ST167 05/08/2009 Crane Software Installation

12122011
 Manitowoc

Folio 2239
Crane Inspection After An Overload
Manitowoc Lattice-Boom Crawler Cranes

Published 08-17-2011 F2239-1

 Crane Inspection After An Overload

2011 Manitowoc.

Due to continuing product innovation, specifications in this manual are subject to change without notice.

F2239-2 Published 08-17-2011

Crane Inspection After An Overload

Contents

Introduction ......................................................................................................... 5
General ....................................................................................................................................................... 5
Overload Inspection .................................................................................................................................... 5

Boom Inspection ................................................................................................ 6

Upperworks Inspection ...................................................................................... 8

Lowerworks Inspection .................................................................................... 10

Manitowoc Published 08-17-2011 F2239-3

 Crane Inspection After An Overload

THIS PAGE LEFT INTENTIONALLY BLANK.

F2239-4 Published 08-17-2011

Crane Inspection After An Overload Introduction

1.0 Introduction

1.1 General

This publication supplements the Rated Capacity Limiter (RCL) / Rated Capacity Indicator supplied with each
Manitowoc lattice boom crawler crane.

1.2 Overload Inspection

When the operator/RCI/RCL system has acknowledged an overload on your crane, you must carry out specified
inspections on the crane.
The inspections given in this publication apply only to overloads up to 50%. For overloads of 50% or higher, crane
operation must be stopped immediately and Crane Care must be contacted for corrective action.

WARNING
Overload Hazard!
To avoid an accident caused by overload damage to your crane:
Perform the inspections outlined in this publication for overloads up
to 50%.
Stop operating the crane and contact Manitowoc Crane Care
immediately for overloads of 50% and higher.

NOTE: If your crane is equipped with CraneSTAR, an overload warning will posted to the web site for review by
the crane owner.
Overload warnings do NOT indicate real time events! Warnings could be sent 24 hours (or more) after the
actual event.

Manitowoc Published 08-17-2011 F2239-5

Boom Inspection Crane Inspection After An Overload

2.0 Boom Inspection

NOTE: The term boom in this publication applies to all of the lattice members of the cranes attachment: boom,
jib, mast, and struts.

5
4

1 1

3
6

1
2

1
10
11

8
9

F2239-6 Published 08-17-2011

Crane Inspection After An Overload Boom Inspection

Overload less than 25%

1 Sheaves Inspect all for damage.
Overload from 25% to 49%
See topic in Hoists section of
2 Hooks Inspect each for cracks and distortion.
Service Manual.
See topic in Hoists section of
3 Wire Rope Inspect all for damage.
Service Manual.
Inspect for bent or twisted sections. String the boom See topic in Boom section of
4 Boom
to check for straightness Service Manual.
See topic in Boom section of
5 Lacings Inspect for twisted or bent lacings and chords.
Service Manual.
Inspect for twisted, bent, or stretched straps. Inspect See topic in Boom section of
6 Straps
for elongated holes. Service Manual.
Inspect for bent or twisted sections. String the mast to
7 Mast
check for straightness.
Inspect for bent or twisted sections. String the gantry
8 Gantry
to check for straightness.
9 Boom Stops Make sure they are not bent or otherwise damaged.
10 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
11 Paint
stretched, or compressed members.

Manitowoc Published 08-17-2011 F2239-7

Upperworks Inspection Crane Inspection After An Overload

3.0 Upperworks Inspection

5 4

6
7

F2239-8 Published 08-17-2011

Crane Inspection After An Overload Upperworks Inspection

Overload less than 25%

1 Sheaves Inspect all for damage.
Turntable See topic in Swing section of
2 Check bolts for proper torque.
Bearing Service Manual.
Overload from 25% to 49%
Turntable See topic in Swing section of
2 Check bolts for proper torque.
Bearing Service Manual.
See topic in Hoists section of
3 Wire Rope Inspect all for damage.
Service Manual.
Inspect each for damage. Brakes must hold rated line
4 Drums
pull.
Inspect counterweight attachment for cracks and other
5 Counterweight damage. Check that counterweight is securely
attached to crane
6 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
7 Paint
stretched, or compressed members.

Manitowoc Published 08-17-2011 F2239-9

Lowerworks Inspection Crane Inspection After An Overload

4.0 Lowerworks Inspection

6
7

2
3

F2239-10 Published 08-17-2011

Crane Inspection After An Overload Lowerworks Inspection

Overload from 25% to 49%

Inspect counterweight attachment for cracks and other
1 Counterweight damage. Check that counterweight is securely
attached to crane.
2 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
3 Paint
stretched, or compressed members.
Crawler Inspect each for cracks and other damage. Check that
4
Frames crawlers are securely attached to crane.
Crawler
5 Inspect for damage.
Rollers

Manitowoc Published 08-17-2011 F2239-11

 Manitowoc
RATED CAPACITY INDICATOR/LIMITER OPERATION
Model 555, 1015, and 18000

TABLE OF CONTENTS
General .......................................................................................2
Control Console Identification .....................................................3
Display ................................................................................ 3
Warning Light ...................................................................... 3
Caution Light ....................................................................... 3
Percent Of Capacity Bar...................................................... 3
Select / Confirm Rocker ...................................................... 3
Scroll Up / Down Rocker ..................................................... 3
Display Contrast Switch ...................................................... 3
Working Screen...........................................................................4
Language Screen ................................................................ 5
Option Screen .............................................................................5
Configuring RCI/RCL ..................................................................6
Calibrating RCI/RCL....................................................................8
Calibrate Boom Angle Potentiometers ................................ 8
Calibrate Luffing Jib Angle Potentiometers ......................... 9
Calibrate Load ..................................................................... 9
Calibrate Load With Load Links........................................... 9
Calibrate Load With Load Sheaves ................................... 10
Diagnostic Screen .....................................................................11
Load Link Installation ................................................................12
Wireless Load Link - PN A04237 or A04689 ..................... 12
Replacing Batteries in Link (PN A04237/A04689) .......12
Wireless Load Link - PN A15346....................................... 13
Replacing Batteries in Link (PN A15346) ....................13
Hard Wired Load Link - PN A15488 .................................. 13
2010 European Requirements ..................................................14
Reduced Speeds for 100-110% Rated Capacity Loads .... 14
RCI/RCL External Override Switch.................................... 14
Model 18000 Boom and Jib Sheave Identification ....................15
Model 555 Boom and Jib Sheave Identification ........................16
Model 1015 Boom and Jib Sheave Identification ......................16

WARNING
Overload Hazard!
The Rated Capacity Indicator/Limiter (RCI/RCL) has been installed
on crane to aid operator.
Presence of (RCI/RCL) on crane in no way substitutes for, or
lessens, requirement that operator knowledge, experience, and
judgment are required to ensure safe operation of crane.
Some programming steps may be necessary before each lift. If (RCI/
RCL) is not programmed correctly, it will not properly sense load and
alert operator to overload conditions. Before using (RCI/RCL),
operator shall read and understand instructions in this publication.

2010 Manitowoc
Published: 06-10-2010
F2006-1
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

A1226a
12 12 13
5 6
4 7
2
1
8 9 10 11

12 12 12 15
3
16 16 16 17

14
14

Item Description Item Description

1 Control Console 10 Boom Top RCL Receiver 1
2 RCL Display 11 Boom Node Controller
3 Capacity Bar 12 Load Sensing Sheave 2
4 Warning Light 13 Boom Angle Potentiometer
5 Caution light 14 Jib Node Controller
6 Select/Confirm Rocker 15 Jib Angle Potentiometer
7 Scroll Up/Down Switch 16 Load Link 1
8 RCL Contrast Switch (on lower console) 17 Hard Wired Load Sensing Link
9 Master Node Controller
1
Standard on Model 1015 and 18000, optional on Model 555.
2
Standard on Model 555, optional on Model 18000.
FIGURE 1

GENERAL ANGLE SENSING POTENTIOMETERS located in

node controllers on boom butt and, if equipped, on
This publication provides qualified operators with operation luffing jib butt.
and calibration instructions for the Manitowoc Rated
Capacity Indicator/Limiter (RCL) with load links or sheaves. LOAD SENSING SHEAVES located at boom and jib
points (standard on Model 555, optional on Model
The system is designed to aid the operator in identifying
18000).
overload conditions, which can cause structural failure of the
boom and jib or loss of stability (tipping). LOAD SENSING LINKS located at boom top and jib
points (standard on Model 1015 and 18000, optional on
The RCL system is part of the crane CAN bus system
Model 555). Load links are attached to wire rope dead
software. The RCL charts are different for each crane
ends. Up to three load links can be programmed at a
model.The Rated Capacity Indicator/Limiter is an electronic
time.
and mechanical load sensing system consisting of the
following components shown in Figure 1: LOAD LINK TRANSMITTER part of load link sends
remote signal to boom top RCL receiver (standard on
CONTROL CONSOLE mounted on the front console
Model 1015 and 18000, optional on Model 555).
in the operators cab.
HARD WIRED LOAD SENSING LINKS attached to
MASTER NODE CONTROLLER mounted in front
boom top or jib top dead ends. A hard wired cable is
console receives input signals from boom node
connected between boom or jib top link and boom or jib
controller.
node.
BOOM NODE CONTROLLER sends input signals
RCL RECEIVER receives input signals from load link
from the load sheaves, load links, block up limits, and
transmitters (standard on Model 1015 and 18000,
angle sensing potentiometers to the master node
optional on Model 555).
controller.

F2006-2
555, 1015 and 18000
AMBER BEACON (not shown) on cranes equipped
with European requirements, a rotating amber light and
continuous tone horn are mounted on the outside of the
operators cab to alert job site personnel to an overload
or tipping condition.
The RCL monitors programmed inputs and signals from the
drum load sensor and angle sensing potentiometers. It
compares the input data with the capacity charts stored in
the RCL and displays the load information on the control
console screen.
When the system detects an overload condition, the operator
is alerted both visually and audibly. If the limiter is ON, the
programmable controller disables the following crane
functions until the overload condition is corrected:
Hoist UP.
Boom DOWN.
Luffing jib DOWN.
NOTE: When equipped with a luffing jib, you can operate
at any boom angle between the minimum and
maximum boom chart angles. The boom hoist is
automatically disabled if you operate more than 5
above the maximum boom chart angle or more
than 5 below the minimum boom chart angle. If
you operate between two boom chart angles, the
luffing jib capacity is de-rated.
CONTROL CONSOLE IDENTIFICATION
The control console consists of the following controls (refer
to Figure 1).
Display
Use the display to access the following screens:
Working screen
Option screen
Configuration screens
Calibration screens
Diagnostic screen
Warning Light
Glows RED and a buzzer (in control console) comes on to
alert the operator to an overload condition.
Manitowoc
RATED CAPACITY INDIC ATOR/LIMITER OPERATION
Caution Light
Glows YELLOW and a beeper (in control console) comes on
to alert the operator to an approaching overload condition.
Percent Of Capacity Bar
The graphical indication of how close the crane is to its
maximum capacity (Figure 2). The bar moves to the right
above the color coded scale as drum load increases. The
color coded scale is divided into three sections:
GREEN = Safe Working Area.
YELLOW = Use Caution (approaching an overload
condition).
RED = Maximum Load Condition.
Select / Confirm Rocker
This rocker serves two purposes:
Switch the mode of the scroll up/down rocker from
SELECT to PROGRAM and vice versa.
CONFIRM programmed data.
NOTE: Select is not active when programming in
configuration screens.
Scroll Up / Down Rocker
Depress TOP of rocker to:
In SELECT mode (*), SCROLL UP from item to item in a
screen or from screen to screen. The cursor stops only
at programmable items.
In PROGRAM mode (>), INCREASE data for a selected
item.
Depress BOTTOM of rocker to:
In SELECT mode (*), SCROLL DOWN from line to line
in a screen or from screen to screen. The cursor stops
only at programmable items.
In PROGRAM mode (>), DECREASE data for a
selected item.
Display Contrast Switch
Turn in either direction to adjust display screen to desired
contrast.
F2006-3
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

Fixed Jib Special Chart Capacity

Boom Luffing Line
Length Configurations Chart Deduct
Length Jib Pull
in Use
Length Chart
Parts of
Angle 1
Line

120 70 80 4 29500 8200

TARE 000 LBS [8103A] RAD 80 FT
LOAD 50000 LBS CONFIRM CAP 29500 LB

Percent of
Capacity Bar

Safe Working Use Caution Maximum Load

Area Condition FIGURE 2

WORKING SCREEN 4 - is the parts of line.

No items can be programmed on the working screen.
The working screen (Figure 2) identifies the current
configuration and displays data for the load drum being
operated. When operation is switched from one drum to
another, the working screen automatically switches to
display load information for the drum selected, without
having to reprogram. Automatic switching can be turned off
by selecting Not Used when programming crane
configuration (Figure 6).
Working screen appears when power is applied and RCL is
turned ON. The RCL goes through a system test when first
turned ON. The CONFIRM message flashes until TOP of
confirm/select rocker is depressed to CONFIRM the present
configuration. If there are no changes, operator can start
operating the crane without going to any other screen.
The units of measure displayed in the working screen
correspond to the type of chart selected:
Feet and pounds for an ANSI capacity chart.
Meters and Metric Tons for a metric or European
capacity chart.
The working screen displays the following information:
Configuration is a coded representation of the crane/chart
configuration:
120 - is the boom length.
70 - is the luffing jib length.
_ - is the fixed jib length.
80 - is the chart angle:
- Jib offset (for fixed jib chart or boom chart with fixed
jib attached).
- Boom to luffing jib (for boom chart with luffing jib
attached).
- Boom (for luffing jib chart).
_ - is the special chart configurations:
29500 - it the line pull in units in lb (U.S. SYSTEM) or in
kg (METRIC).
8200 - is the deduct to chart capacity. The RCL does not
automatically compensate for any deducts required by
the various capacity charts (jib and wire rope, load
blocks, slings, below boom and jib points). Operator is
responsible for determining and calculating deducts
specified on applicable capacity charts and for
entering data. Always round calculations UP to the
nearest hundred (if calculated deduct is 1,675 lbs,
enter 1,700 lbs).
Crane can be overloaded tipping or structural
failure can occur if required deducts are not
entered.
For assistance in determining and calculating deducts,
refer to Guide for Determining Total Load in Capacities
Section of Operators Manual.
8103A - is the MCC chart number.
TARE - is the load subtracted from the displayed LOAD. The
actual load being lifted equals line pull times parts of line
minus tare. This feature allows operator to view load
differences. For example: wire rope, load block or weight
ball, and lifting slings can be tared (deducted) so that
displayed load equals only the load that is being lifted.
Tare is subtracted only from displayed load. Tare does not
effect the percent of capacity display.
LOAD - is actual load being lifted that equals line pull times
parts of line minus tare.
RAD - is the horizontal distance (radius) from the cranes
centerline of rotation to the center of the freely suspended
load block or single-part load line. Radius is calculated from
boom and jib length, boom and jib angle, and the link/sheave
sensor.
C A P - i s t h e c a p a c i t y c h a r t r a t i n g f o r t h e c r a n e s
programmed configuration. Maximum capacity is always the
least of the following values:

- Barge list in degrees (0, 1, 2, 3). Manitowoc capacity chart.

F2006-4
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

Rope line pull. OPTION SCREEN

Drum torque capacity. The configure LMI, diagnostic screen, calibrate angle, and
PERCENT OF CAPACITY BAR - is the graphical indication calibrate load screens are accessed from the option screen
of how close the crane is to its maximum capacity. The bar (Figure 4).
moves to the right above the color coded scale as load
* CONFIGURE LMI CALIBRATE ANGLE
increases. CALIBRATE LOAD
DIAGNOSTIC SCREEN

LANGUAGE SCREEN SCROLL or SELECT Item

Access language screen on working screen (Figure 3) by
pressing SELECT. The program cursor (>) appears next to
FIGURE 4
the LANGUAGE on screen. Scroll up or down to select
desired language. CONFIRM when desired language To access the option screen, scroll up or down as required
appears to program the selected language on all screens. until the screen appears. Continue to scroll up or down until
the select cursor (*) appears next to the desired option.
Depress BOTTOM of confirm/select rocker to SELECT.
>LANGUAGE ENGLISH
The operator can toggle back to the working screen by
scrolling up or down until the working screen appears.
SCROLL or CONFIRM

FIGURE 3

Manitowoc F2006-5
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

CONFIGURING RCI/RCL On POINT configuration screen (Figure 8) the program

The DRUM configuration screen (Figure 5) appears when
Configure LMI is selected on option screen. The program
requires the operator to confirm all configuration screens
before returning to the working screen. The program cursor
(>) appears next to first item on each screen. Select is not
active when programming in configuration screens. The
program automatically moves to the next configuration
screen when TOP of confirm/select rocker is depressed to
CONFIRM.
NOTE: For tandem drum operation each load drum must
be configured with the same capacity chart.
The last programmed chart and crane configuration for each
drum is retained in memory. This allows the operator to
switch between drums without having to reprogram the
configurations, assuming no changes have been made
(parts of lines, boom length).
NOTE: If multiple loads from one point are used, both lines
must be configured before being selected.
[>Drum 1 Configuration]
SCROLL to Change CONFIRM to Continue
FIGURE 5
On SENSOR configuration screen (Figure 6) the program
cursor (>) appears next to the SENSOR selection. Scroll up
or down as required to select and program the desired
sensor SHEAVE 1, 2, 3, 4 or LINK or Not Used.
NOTE: Refer to the diagrams at the end of this publication
for identification of the sheaves and links.
Wired load links are configured as sheaves.
cursor (>) appears next to the POINT selection. Only select
upper point when there is an upper point on the boom, fixed
jib or luffing jib. When configured with a fixed jib, the lower
point is generally selected.
It is allowable to use load pin 1 or load pin 2 connections on
boom junction boxes. Load pin connections must match
sheave numbers or corresponding wired link numbers when
configuring the points.
[Drum 1 Configuration]
>POINT UPPER
SCROLL to Change CONFIRM to Continue
FIGURE 8
On CAPACITY CHART configuration screen (Figure 9) the
program cursor (>) appears next to the capacity chart
number (8103A in this example). Once this screen is
selected, data in the bottom three lines changes
automatically while scrolling through the possible chart
configurations.
If you program data for any item without confirming it,
data will be lost when computer is turned off and
previously stored data will take effect when computer is
turned back on.
The program will not allow any data to be changed if
corresponding drum detects a line pull greater than
3,300 lbs (1-1/2 Metric Tons).
A four-digit number and either one or two alpha characters
identify each capacity chart. A single alpha character (A, B,
etc.) identifies an ANSI (United States) approved capacity
chart. A single alpha character followed by an M (AM, BM,
etc.) identifies a metric or European approved capacity chart.

If LINK is selected, the load link (TxID) screen >8103A [Drum 1 Configuration]
appears next. BOOM 160 BOOM ANG LIST
JIB1 JIB1 ANG CRAWLER
[Drum 1 Configuration] JIB2 JIB2 ANG CTWT
>SENSOR SHEAVE 3

SCROLL to Change CONFIRM to Continue FIGURE 9

The following items are programmed for the selected chart
FIGURE 6 configuration:

The load link TxID screen (Figure 7) appears if LINK is CHART - is the chart number.
selected on the previous screen. Scroll up or down as BOOM - is the boom length.
required to select and program the desired load link
identification number. The number is etched into the link as JIB1 - is the luffing jib length.
shown in Figure 22. JIB2 - is the fixed jib length.
[Drum 1 Configuration] BOOM ANG - is the boom angle if luffing jib chart.
>TxID 0000 JIB1 ANG - is the boom to luffing jib angle if Boom Chart with
luffing jib attached.
SCROLL to Change CONFIRM to Continue
JIB2 ANG - is the fixed jib offset.
LIST - is the list angle if barge chart.
FIGURE 7

F2006-6
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

CRAWLER - is the crawler extended (out) or retracted (in) 1. Lift all items that are to be tared out clear of ground (load
on certain models only. block and lifting slings).
STINGER - MAX-ER trailer arm length. 2. Note displayed LOAD value.
CTWT - is the total counterweight in pounds of kilograms 3. Scroll up or down until tare value equals displayed load
(MAX-ER only). value noted earlier. The load value goes to zero as this
step is performed.
On PARTS configuration screen (Figure 10) the program
cursor (>) appears next to the PARTS selection. Scroll up or 4. CONFIRM tare value. The displayed LOAD equals net
down as required to select and program desired parts of line. load (tare value is subtracted automatically).
NOTE: For tandem drum operation enter parts of line To turn tare off:
number for that line only. If a 20 part block is used, 1. Scroll up or down until tare value equals zero.
enter 10 parts for each drum.
2. CONFIRM zero tare value.
[Drum 1 Configuration]
3. Displayed LOAD value equals total load (weight of load
>PARTS 4 lines, load block or weight ball, rigging, and lifted load).

SCROLL to Change CONFIRM to Continue NOTE: For tandem drum operation enter tare for drum 1
only. Drum 2 must be set for zero.

FIGURE 10 [Drum 1 Configuration]

>TARE 0000 LBS LOAD 000000 LBS
On LINEPULL configuration screen (Figure 11) the
program cursor (>) appears next to the LINEPULL selection.
Scroll up or down as required to select and program the SCROLL to Change CONFIRM to Continue
required single line pull for the selected drum configuration.
Several line pull options are available. To determine FIGURE 13
required SINGLE line pull for drum in use, refer to On optional ALARM configuration screen (Figure 14) the
Capacities Chart and Wire Rope Specifications Chart for program cursor (>) appears next to the ALARM selection.
boom or boom and jib in use. Scroll up or down as required to select and program desired
NOTE: Single line pull equals maximum load divided by alarm/load limiter condition.
parts of line. Three choices are available:
Copies of charts are located in the operators cab. ALARM LOAD LIMITER
[Drum 1 Configuration] OFF OFF
>LINEPULL 29500 LBS ON OFF
ON ON
SCROLL to Change CONFIRM to Continue
The alarm item indicates whether alarms (warning/caution
FIGURE 11 lights in cab, beeper/buzzer in cab, amber light/horn outside
cab) are ON or OFF.
On DEDUCT configuration screen (Figure 12) the program
cursor (>) appears next to the DEDUCT selection. Scroll up When Load Limiter is off, OFF flashes on the screen.
or down as required to select and program the desired Depress TOP of confirm/select rocker to CONFIRM selected
deduct value. As the DEDUCT value is increased, the screen and return to working screen.
capacity value is subtracted the same amount.
[Drum 1 Configuration]
For assistance in determining and calculating deducts, refer
>ALARM ON Load Limiter OFF
to Guide for Determining Total Load in Capacities Section of
Operators Manual provided with crane.
SCROLL to Change CONFIRM to Continue
[Drum 1 Configuration]
>DEDUCT 0000 LBS Cap 0000000 LBS FIGURE 14

SCROLL to Change CONFIRM to Continue

FIGURE 12 Repeat the configuration steps for each drum and point the
crane is equipped with.
On TARE configuration screen (Figure 13) the program
cursor (>) appears next to the TARE selection.
For an unknown tare value:

Manitowoc F2006-7
RATED CAPACITY INDIC ATOR/LIMITER OPERATION
CALIBRATING RCI/RCL
General
The calibration screens are used to calibrate the drum and
boom/luffing jib angle sensing potentiometers. The proper
chart and crane configuration must be programmed and
confirmed before performing the calibration procedure.
The last programmed crane and chart configuration for each
drum is retained in memory (even if engine is stopped). This
allows the operator to switch between drums without having
to reprogram the configurations, assuming no changes
have been made (parts of lines, boom length).
The units of measure displayed on the calibration screen
correspond to the type of chart selected:
Feet and pounds for an ANSI capacity chart.
Metric Tons for a metric or European capacity chart.
The first calibration screen (Figure 15) appears when
Calibrate Angle or Calibrate Load is selected and confirmed
on the option screen. The program cursor (>) appears next to
CODE #. The operator or technician must scroll up or down
as required to enter code number before the calibration
screens can be accessed. Depress TOP of confirm/select
rocker to CONFIRM and to enter boom/luffing jib angle or
load calibration screens.
>CODE # SCROLL or CONFIRM
FIGURE 15
Check calibration and calibrate if required, at the following
intervals (see Calibration Procedure for detailed
instructions):
Before the first time use of any potentiometer, load
sheave or load link.
It is not necessary to recalibrate a drum for each type of
attachment, once it is calibrated.
Load link 1 is tied with drum 1, load link 2 is tied with
drum 2, etc.
When a known lifted load and displayed load are in error
more than plus or minus 400 lbs (181kg) or 4%,
whichever is greater. Perform this check daily when first
known load is lifted on each hook.
When any part of the system is replaced.
Yearly.
The following items must be programmed in the calibration
screens:
CODE # - is calibration access code. The number 128 must
be programmed to allow calibration.
F2006-8
555, 1015 and 18000
BOOM - is the boom angle sensing potentiometer must be
calibrated at two angles, LOW ANGLE and HIGH ANGLE.
Measure angles with an accurate angle indicator on the
centerline of the boom butt as described in the calibration
procedure or by measured radius.
JIB ANGLE - is the luffing jib angle sensing potentiometer
must be calibrated at two angles, LOW ANGLE and HIGH
ANGLE. Measure jib angle by measuring radius from
centerline of rotation to the centerline of the freely
suspended load block or weight ball.
Calibrate Boom Angle Potentiometers
To calibrate boom potentiometers, proceed as follows:
1. Depress BOTTOM of confirm/select rocker to select
CALIBRATE ANGLE.
2. Cursor appears next to CODE #.
3. Scroll up or down until CODE # 128 is selected. RCL
cannot be calibrated until this step is performed.
4. Depress TOP of confirm/select rocker to CONFIRM and
to enter boom angle calibration screen (Figure 16). The
select cursor (*) appears before BOOM or LUFF JIB.
5. If LUFF JIB appears, depress BOTTOM of confirm/
select rocker to SELECT and scroll until BOOM
appears. SCROLL to Change or CONFIRM Item
appears on bottom line of screen.
6. Depress TOP of confirm/select rocker to CONFIRM.
7. Depress BOTTOM of confirm/select rocker to SELECT
Program cursor (>). Cursor appears before LOW
ANGLE. Lower to MIN ANGLE. Enter ANGLE. Confirm
appears on bottom line of screen.
.
Calibrate *BOOM
LOW ANGLE 82.0 DEGS RAD 50 FT
HIGH ANGLE 08.74 VOLTS
SCROLL or SELECT Item CONFIRM to Return
FIGURE 16
8. Position boom between 10 and 30. Measure boom
angle with an electronic angle indicator on centerline of
boom butt or by measuring radius of load line.
a. Measure and mark (on ground) largest valid radius
given in boom capacity chart.
b. Position boom so centerline of load block or weight
ball is at radius marked on ground.
9. Scroll up or down until BOOM ANGLE on calibration
screen equals angle measured in step above or radius
on calibration screen equals measured radius.
10. Depress TOP of confirm/select rocker to CONFIRM.
11. The select cursor (*) appears before HIGH ANGLE.
12. Depress BOTTOM of confirm/select rocker to SELECT.
Program cursor (>). Cursor appears before HIGH
ANGLE. Raise to MAX ANGLE. Enter ANGLE. Confirm
appears on bottom line of screen.
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

13. Position boom between 65 and 80. Measure boom
angle with an electronic angle indicator on centerline of
boom butt or by measuring radius of load line.
14. Scroll up or down until BOOM ANGLE on calibration
screen equals angle measured in step above or radius
on calibration screen equals measured radius.
15. Depress TOP of confirm/select rocker to CONFIRM.
Calibrate Luffing Jib Angle Potentiometers
If equipped with a luffing jib, calibrate boom angle first, and
then proceed as follows:
1. On option screen, depress BOTTOM of confirm/select
rocker and select CALIBRATE ANGLE.
2. Cursor appears next to CODE #.
3. Scroll up or down until CODE # 128 is selected. RCL
cannot be calibrated until this step is performed.
16. Measure and mark (on ground) a valid radius from
luffing jib capacity chart that corresponds to a jib angle
between 65 and 80.
17. Position luffing jib so centerline of load block or weight
ball is at radius marked on ground in step above.
18. Scroll up or down until RADIUS on calibration screen
equals measured radius in step above.
19. Depress TOP of confirm/select rocker to CONFIRM.
Calibrate Load
The procedure for load calibration with links and sheaves is
different. The following instructions include both load links
and load sheaves.
NOTE: Each load link must be calibrated separately when
rigged in tandem block, using 1/2 parts and 1/2
load.

4. Depress TOP of confirm/select rocker to CONFIRM and 1. Turn off tare so that load lines, load block or weight ball,
to enter luffing jib angle calibration screen (Figure 17). and all rigging are included in calibration.
The select cursor (*) appears before LUFF JIB or 2. On option screen, depress BOTTOM of confirm/select
BOOM. rocker to SELECT and select CALIBRATE LOAD.
5. If BOOM appears, depress BOTTOM of confirm/select 3. Cursor appears next to CODE #.
rocker to SELECT and scroll until LUFF JIB appears.
4. Scroll up or down until CODE # 128 is selected. RCL
SCROLL to Change or CONFIRM Item appears on
cannot be calibrated until this step is performed.
bottom line of screen.
6. Depress TOP of confirm/select rocker to CONFIRM. Calibrate Load With Load Links
7. Scroll through luffing jib angle calibration screen until NOTE: This includes wireless links or wired links
select cursor (*) appears before luffing jib LOW ANGLE. configured as sheaves.
.

To calibrate the load with load links, first perform the 4 steps
Calibrate *LUFF JIB
LOW ANGLE 82.0 DEGS RAD FT in Calibrate Load above.
HIGH ANGLE 08.74 VOLTS 1. Depress TOP of confirm/select rocker to CONFIRM and
SCROLL or SELECT Item CONFIRM to Return to enter load calibration screen (Figure 18). Select
cursor (*) appears before selected drum link.

FIGURE 17 Calibrate *Drum 1 LINK

LOAD 1000 LBS
8. Depress BOTTOM of confirm/select rocker to SELECT.
Program cursor (>). Cursor appears before LOW
SCROLL or SELECT Item CONFIRM to Return
ANGLE. Lower to MIN ANGLE. Enter ANGLE. Confirm
appears on bottom line of screen.
9. Accurately position boom at lowest specified boom FIGURE 18
angle given in appropriate luffing jib capacity chart. 2. Depress BOTTOM of confirm/select rocker to SELECT.
10. Measure and mark (on ground) largest valid radius given Program cursor (>). Scroll to desired load link.
in luffing jib capacity chart. 3. Depress TOP of confirm/select rocker to CONFIRM
11. Position luffing jib so centerline of load block or weight desired load link. Program cursor (>) appears next to
ball is at radius marked on ground in step above. LOAD.

12. Scroll up or down until RADIUS on calibration screen
equals measured radius in step above.
13. Depress TOP of confirm/select rocker to CONFIRM.
14. The select cursor (*) appears before HIGH ANGLE.
15. Depress BOTTOM of confirm/select rocker to SELECT.
Program cursor (>). Move cursor before HIGH ANGLE.
Raise to MAX ANGLE. Enter ANGLE. Confirm appears
on bottom line of screen.
NOTE: For tandem drum operation add a second load link
in dead end of the opposite load line. Each load link
must be calibrated.
4. Calibrate load link with ball or block with light load only.
5. Turn off (zero) tare so that load lines, load block or
weight ball, and all rigging are included in calibration.
6. Raise weight ball or load block in the air.

Manitowoc F2006-9
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

7. Scroll in the LOAD. Enter load and Confirm appears on

bottom line of screen. Calibrate *Drum 1 SHEAVE
LIGHT LOAD 1000 LBS 000 V
8. CONFIRM to save load sensor calibration data. (HEAVY LOAD)
NOTE: RCL always reads multiple sensors and displays SCROLL or SELECT Item CONFIRM to Return
accumulating percent of load on bar graph.

Calibrate Load With Load Sheaves FIGURE 19

To calibrate the load with load sheaves, first perform the 4 4. Depress BOTTOM of confirm/select rocker to SELECT.
steps in Calibrate Load above. Program cursor (>). Scroll to desired load drum sheave.

1. Two known loads are required to properly calibrate the 5. Depress TOP of confirm/select rocker to CONFIRM
load sensing sheaves. desired load drum sheave.

2. Turn off tare so that load lines, load block or weight ball,
and all rigging are included in calibration.
Light load - produces single line pull less than 3,300
lbs (1-1/2 metric tons).
Heavy load - which is greater than 2/3 drums rated
single line pull.
NOTE: When calibrating a load the operator can use two
different loads. A prompt appears to indicate if lifted
load is suitable for calibration.
LESS REQD - indicates that weight must be
removed to complete calibration.
MORE REQD - indicates that more weight must be
added to complete calibration.
3. Depress TOP of confirm/select rocker to CONFIRM and
to enter load calibration screen (Figure 19). Select
cursor (*) appears before selected drum sheave.
6. Move select cursor (*) to LIGHT LOAD. SCROLL or
SELECT Item. CONFIRM to Return appears on bottom
line of screen.
7. Depress BOTTOM of confirm/select rocker to SELECT.
Program cursor (>). Move cursor to LIGHT LOAD. Lift
LIGHT LOAD. Enter LOAD. Confirm appears on bottom
line of screen.
8. With known light weight suspended, scroll up or down
until the weight is displayed on calibration screen.
9. Depress TOP of confirm/select rocker to CONFIRM.
10. Move select cursor (*) to HEAVY LOAD. SCROLL or
SELECT Item. CONFIRM to Return appears on bottom
line of screen.
11. Depress BOTTOM of confirm/select rocker to SELECT.
Program cursor (>). Move cursor to HEAVY LOAD. Lift
HEAVY LOAD. Enter LOAD. Confirm appears on bottom
line of screen.
12. With known heavy weight suspended, scroll up or down
until the weight is displayed on calibration screen.
13. Depress TOP of confirm/select rocker to CONFIRM.
NOTE: RCL always reads multiple sensors and displays
accumulating percent of load on bar graph.

F2006-10
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

DIAGNOSTIC SCREEN Three underlined bank numbers at bottom right of diagnostic

screen indicates a binary code fault number for the following
The diagnostic screen (Figure 20) contains the following items.
program items for use by factory service personnel when
troubleshooting RCI/RCL problems. Bank 1 Description of sensor that is out of range fault:
(1) = Drum 1 load sensor.
Mem 0 Shv 1 1.05 Lk 1 + 3 0000
Volt Deg Shv 2 1.03 Lk 2 + 5 0003 (2) = Drum 2 load sensor.
Boom 0.0 0.0 Shv 3 0.00 Lk 3 0 0000 (4) = Drum 3 load sensor.
Jib 0.0 0.0 Shv 4 0.00 01 02 03
(16) = Boom angle sensor.
(32) = Luffing angle sensor.
FIGURE 20
Bank 2 Type of RCL fault:
The memory (Mem) item should be 0. If there is an error, the
total of the binary numbers corresponds to the items listed in (1) = Simple overload.
Table 1. (2) = Luffing Jib off chart (high).
1 = Flash memory error (Configuration).
(4) = Main boom off chart (high).
2 = Flash memory error (Capacity).
(8) = Sensor fault (see Bank 1 above).
4 = A drum has not been configured.
8 = An active drum is not calibrated. (16) = Multi-load fault (see Bank 3 below).
Bank 3 Multiple load at same time fault:
Table 1 Memory Errors
(1) = Front load drum.
1
2
4
8

1 (2) = Rear load drum.

2 (4) = Auxiliary load drum.
3
4
Table 2 contains voltages for various drum and angles. The
5
voltages are a starting point guide only and may have an
6
error of 10% to 15%, depending on the type of drum, boom
7
top, and wrap angle.
8 Load links transmit counts to the receiver. The count number
9 indicates pounds as shown in Table 2.
10
11 Table 2 Boom and Luffing Jib Angle Voltages
12 Boom/Luffing Jib Angle Link (Non-Calibrated)
13
Approximate
14 Degree Voltage Counts
Loads (lbs.)
15 -60 0.74 10 1,000
The link number is tied to drum, for example: if drum 2 uses a -45 1.16 50 5,000
link with ID number 0003, it appears as link 2 on diagnostics 0 2.40 100 10,000
screen. +45 3.66 200 20,000
+60 4.08 300 30,000
+70 4.36 400 40,000
+80 4.67 500 50,000

Manitowoc F2006-11
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

LOAD LINK INSTALLATION 4. Move switch (2) to ON (use pencil to move white switch).

Check the part number on the load link to be installed and NOTE: Not all battery packs have switch (2).
follow the procedure for that specific load link. 5. Move switch (3) to RUN.
A wireless load link is installed at the weight ball and a hard 6. Check that batteries (5) are properly installed and
wired load link is normally installed at the boom top or jib top. secured in holders with straps.
7. Securely reinstall battery pack cover.

Replacing Batteries in Link (PN A04237/A04689)

Load Link
See Figure 22 for following procedure.
Part
Number Load links transmit counts to the receiver on the boom. The
receiver sends load information to the boom node controller.
TxID
Number When the low battery threshold of a link is reached, a
message is sent to the crane master node controller through
FIGURE 21 the data package. This message is displayed on the
Wireless screen (see Crane Diagnostics publication) to
NOTE: If a wireless load link is attached to boom/jib top indicate that link (1, 2, or 3) batteries must be replaced soon.
dead end, the antenna (opposite side of covers)
must be facing toward crane. To replace batteries:
1. Lower boom/jib to ground to access links.
Wireless Load Link - PN A04237 or A04689
2. Remove screws from battery pack side of indicated link.
See Figure 22 for following procedure.
3. Lift off cover and remove existing batteries.
The power is turned off when a new wireless load link is
4. Replace with two D size and two 9 volt batteries (6).
shipped from the factory. To turn load link power on, proceed
as follows: NOTE: Some links do not have 9 volt batteries.
1. Remove battery pack cover (6) from link (1). 5. Reinstall battery pack cover on link.
2. Turn cover over (View B). 6. Screw battery pack to link.
3. Connect plug (4) to receptacle inside link (View B).
1 P2037

2
Item Description
6 1 Load Link
2 Switch - ON
3 Switch - RUN
4 Plug A
5 D-Cell Batteries
6 Battery Pack Cover
P2034

VIEW C
VIEW A
3
5

+
+

+ 4

+ P2036
VIEW D

9-volt Batteries
(not on all links)
P2035
VIEW B FIGURE 22

F2006-12
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

Wireless Load Link - PN A15346 Replacing Batteries in Link (PN A15346)

See Figure 23 for following procedure.
The power is turned off when a new wireless load link is
shipped from the factory. To turn load link power on, proceed
as follows:
1. Remove power switch cover (2) from link.
2. Press power on/off button (5). When link is powered up,
red LED (Item 7) turns on for about one second.
3. On configuration screen (see Load/Limiter Alarm) set
drums not used with configuration to Not Used.
4. Select drums being used and enter in link Network ID
(see Load Link Sensor Calibration Procedure).
5. After 30 seconds link communication should be
established.
6. If link is not installed correctly a wireless system fault
appears.
7. Test switch is for testing communication between link
and receiver. (factory use only).
8. Replace power switch cover when link is operating
correctly.
See Figure 23 for following procedure.
Load links transmit counts to the receiver on boom. The
receiver sends load information to boom node controller.
When the low battery threshold of a link is reached, a
message is sent to the crane master node controller through
the data package. This message is displayed on the
Wireless screen (see Crane Diagnostics publication) to
indicate that link (1, 2, or 3) batteries must be replaced soon.
To replace batteries:
1. Lower load line to ground to access link.
2. Remove screws from battery cover (4) of link.
3. Lift off cover and remove existing batteries.
4. Replace with six D size Alkaline batteries.
5. Reinstall battery pack cover on link.
6. Screw battery pack cover to link.
Hard Wired Load Link - PN A15488
See Figure 23 for items in this procedure.
Install wired link (9) at boom top or jib top dead end with
cable connector facing toward crane.
Connect cable between boom or jib top node and hard wired
link.

P2341
3 5
10
A10868

4
VIEW B
8 7 6
Link with covers removed
2 11
Item Description 9
1 Wireless Load Link (
1 2 Battery Pack Cover
3 Six D-Cell Batteries
4 Power Button Cover
5 Power Button
6 Test Switch (factory use only)
P2340 VIEW C
7 Red LED Hard Wired Link
VIEW A
Link With Covers Installed
8 Antenna (under cover) (typical)
9 Hard Wired Link (boom/jib top)
10 Cable Between Link and Junction Box
11 Boom or Jib Top Junction Box
FIGURE 23

Manitowoc F2006-13
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

2010 EUROPEAN REQUIREMENTS

The following features apply only to current production RCL/RCI Override
cranes meeting 2010 European requirements. Switch

Reduced Speeds for 100-110% Rated

Capacity Loads
Operators
While operating between 100% and 110% rated capacity Cab
(bypass switch in cab must be held in bypass position) the
speed of the crane functions is limited to 15% of their
maximum speed. See Section 3 in Crane Operators Manual
for identification and operation of the bypass switch on the
front console in the cab.

RCI/RCL External Override Switch

DANGER
Improper use of RCI/RCL external override switch
Lockable
could result in: Box
DEATH OR SERIOUS INJURY
THIS SWITCH BYPASSES THE LIMITER
(SHUTDOWN) FUNCTION OF THE RCI/RCL.
The switch may only be used by authorized
FIGURE 24
personnel during emergency operation as indicated
below.
Operate in safe direction only: raise boom or lower
load to prevent tipping or structural damage.

An RCL/RCI override switch is provided outside the cab in a

lockable box (see Figure 24).
The override switch allows emergency operation of the crane
functions in case of RCL/RCI component failures: boom
angle sensor, luffing jib angle sensor, and load sensing
sheaves (load pins).
When the external override is on, the speed of the crane
functions is limited to 15% of their maximum speed for
load increasing actions.
Actuation of the external override and all relevant data is
recorded in a data recorder.
Depress the top end of the rocker to TURN ON the external
override. The external override is automatically turned off
after 30 minutes of continued operation, engine shutdown,
and/or crane shutdown.
Depress the top end of the rocker again to manually TURN
OFF the external override.
When the external override is turned on, the operating limit
fault will come on and RCL OVERRIDE will appear on the
system fault screen in the cab.

F2006-14
555, 1015 and 18000 RATED CAPACITY INDIC ATOR/LIMITER OPERATION

MODEL 18000 BOOM AND JIB SHEAVE IDENTIFICATION

NOTE: For detailed wiring connections, see the Boom Wiring and
6
Limits Drawing at the end of Section 4 in the Crane
Operators Manual. L OR S4
5 S3

4
3
L OR S2

L OR S2 S1
2

1
1
Item Description
S1
1 Lower Boom Point
S1 or
2 Upper Boom Point
S1 and S2 Extended Upper Boom Point
3
Tandem Drum
(lower sheave)
Reeving Extended Upper Boom Point
4
(upper sheave)
#79A Boom Top 5 Lower Jib point
6 Upper Jib point
L OR S4

Item Description 5 S3 or
S1 SHEAVE 1 (wired link) L OR S4
S3 and S4
S2 SHEAVE 2 (wired link)
Tandem Drum
S3 SHEAVE 3 (wired link) Reeving
6
S4 SHEAVE 4 (wired link)
5 S3 or
L LINK (wireless link)
S3 and S4
Tandem Drum
Reeving
3

L OR S2
2 L OR S2

1 1 1 1

S1 S1 S1 or
S1 or
S1 and S2
S1 and S2 Tandem Drum
Tandem Drum Reeving
Reeving

#55 or 55A Boom Top

FIGURE 25

Manitowoc F2006-15
RATED CAPACITY INDIC ATOR/LIMITER OPERATION 555, 1015 and 18000

MODEL 555 BOOM AND JIB SHEAVE IDENTIFICATION 3

Item Description
S1 SHEAVE 1 (wired link) 5 S4 or L
S2 SHEAVE 2 (wired link)
S3 SHEAVE 3 (wired link)
S4 SHEAVE 4 (wired link) S3 or L
L LINK (wireless link)
4

S1 or L

3
Item Description
1 Lower Boom Point
S3 2 Upper Boom Point
3 Fixed Jib point
4 Intermediate Luffing Jib Point
5 Luffing Jib Point
2

1 1
S2

S1 S1

FIGURE 26

MODEL 1015 BOOM AND JIB SHEAVE IDENTIFICATION

2 3

1
L
L

L Item Description
L LINK (wireless link)

1
Item Description
1 Lower Boom Point
L 2 Upper Boom Point
3 Fixed Jib point

FIGURE 27

F2006-16
 CRANE SOFTWARE INSTALLATION
All Models (Software rev00c or rev00f or newer)

TABLE OF CONTENTS SOFTWARE INSTALLATION

General .......................................................................... 1
Personnel....................................................................... 1
Software Installation Requirements ............................... 1
Installing Program on Laptop ......................................... 1
Installing Software and Charts On Laptop ..................... 3
Downloading Software and Charts To Crane PC........... 4
Non-CAN bus Software........................................... 4
Installing Software Program rev00c.................. 4
Installing Software Program rev00f or Newer ... 5
CAN Bus Software .................................................. 6
Installing Software Program rev00c.................. 6
Installing Software Program rev00f or Newer ... 7
Rules-Discarding Files ................................................... 8
Documentation............................................................... 8
Form 00SVFM045 .................... at end of this Publication
GENERAL
This publication provides qualified service technicians with
instructions for installing crane software and capacity chart
files on Manitowoc cranes equipped with an EPIC control
system either non-CAN bus or CAN bus.
Crane software terms:
REQUIREMENTS
To successfully install crane software and capacity chart
files, the following items are required:
A laptop PC with a user friendly operating system. The
laptop must have a RS 232 serial port.
Data downloading cable Manitowoc # A06301-0.
Current version of crane software installed on laptop PC.
INSTALLING PROGRAM ON LAPTOP
The MCC Controls Application is updated when necessary.
You should verify your program version with Manitowoc
Crane Care Customer Service before installing software or
capacity charts.
The MCC Controls Application can be ordered on compact
disc (CD) from Manitowoc Crane Care Customer Service at
the time you order crane software and chart software for a
particular crane.
Before the crane software program can be installed, a folder
must be created on the laptops hard drive (C drive), as
follows:

MCC Controls Application Personal computer 1. Click on My Computer Icon.

application used to download crane software and 2. Click on C drive icon.
capacity chart information.
3. Click on File menu.
Crane Software EPIC controller program designated 4. Click on New.
by the .HEX suffix in 4X40 programs and the .H86 suffix
in CAN-bus programs. 5. Select Folder.

Chart Software Crane capacity chart information 6. A folder is created in C drive called New Folder.
designated by the .IHX suffix. 7. Click on New Folder icon to rename folder.
NOTE: Chart software is serial number specific and should 8. Enter new name MCC Controls, for example.
not be used on any other crane.
MCC Controls
PERSONNEL
Crane software and capacity chart files must be installed
only by a qualified, trained technician as instructed in this
document. MCC Controls

To become qualified to install software, the technician must

be trained by a qualified instructor. Properly completed
Software Installation Training Form OOSVFM044 (at end of
MCC Controls
this document) must be submitted to Manitowoc Crane Care
Customer Service verifying technician training.

MCC Controls

FIGURE 1
To install crane software and capacity chart files from CD:

2009 Manitowoc
Published: 05-08-2009 ST 167-1
CRANE SOFTWARE INSTALLATION

1. Insert CD disc into laptops CD drive. 9. On the MCC Controls Setup screen (see Figure 6),
click Change Directory to set location to the pre-
2. Click on My Computer Icon (see Figure 1).
created MCC Controls folder.
3. Click on CD disc drive icon to reveal folder similar to
rev00c or rev00f or newer (see Figure 2).

FIGURE 2
FIGURE 6
4. Click on folder icon to install loading program.
10. Locate the MCC Controls folder on the C drive and click
5. Click on package folder icon (see Figure 3).
OK (see Figure 7).

FIGURE 3
6. Click on setup.exe icon (see Figure 4). MCC Controls

FIGURE 7
11. Click on the Computer icon to proceed with the
installation of the download program into the MCC
Controls folder (see Figure 8).

FIGURE 4
7. The program will begin to copy some files and proceed
to the setup screen.
8. When the MCC Controls Setup program screen is
displayed, click OK (see Figure 5).
MCC Controls

FIGURE 8
12. When asked to verify Program group, click Continue.
13. While in setup, a pop up screen may be displayed
indicating a newer file exists on your laptop. Click Yes to
keep your newer existing file.
14. The screen will indicate when setup is complete. Click
on OK.
FIGURE 5
15. A desktop shortcut to the download program may be
desired. To create a shortcut:

ST 167-2
 CRANE SOFTWARE INSTALLATION

a. Select My Computer icon on the desktop screen INSTALLING SOFTWARE AND CHARTS ON
and click. LAPTOP
b. Select C drive and click. The software provided will be for a specific crane unless
c. Select MCC Controls folder and Left click. advised differently.

d. In the folder Right click on MCC Control App.exe
and select Create Shortcut and click. A shortcut
icon will then be displayed.
e. Move shortcut icon to desktop or other desired area.
16. When a new MCC Controls Application version
becomes available, the older version must first be
removed from the laptop before the new program can be
loaded. To remove an old program:
a. Click on Start for menu column in bottom left corner
of screen.
b. Click on Settings.
1. Before installing new crane software, a folder must be
created on laptops desktop, as follows:
a. Right click on desktop (main screen) for menu bar
and select New. A secondary menu screen is
displayed.
b. Click on Folder on secondary menu. A folder called
New Folder becomes visible on desktop screen.
c. Rename folder. For example, you could use the
crane serial number (2251025).
2. Open crane software files. Right click MEC2.HEX (non-
CAN bus) or Master.H86 (CAN bus) file icon.

c. Click on Control Panel. 3. When menu bar becomes visible, click Save As
4. When Save Attachment screen appears, select
d. Click on Add/Remove Programs icon.
desktop location to locate renamed folder created in
e. Select MCC Controls App.exe from menu (see step 1c.
Figure 9).
5. When Save Attachment screen for intended folder
C/ becomes visible, click on Save button.
MEC2.HEX or Master.H86 file is now saved to selected
folder. Do not change names of files.
6. Return to crane software files and right click on
lmidata.ihx (non-CAN bus) or candata.ihx (CAN bus)
file icon.
7. When menu bar becomes visible, click Save As
8. Save Attachment screen for intended folder should
FIGURE 9
become visible, (if not, select from desktop location).
17. Click Add/Remove button and existing program will be 9. Click on Save button. lmidata.ihx or candata.ihx file is
removed from C drive of the laptop. now saved to selected folder.

ST 167-3
CRANE SOFTWARE INSTALLATION

DOWNLOADING SOFTWARE AND CHARTS 6. Wait until program switches from Bootstrap screen to
TO CRANE PC working screen.
7. Connect download harness to install port and to RS 232
The procedure for downloading non-CAN bus crane
serial port on laptop (see Figure 10).
software is different from the procedure for downloading
CAN bus crane software. Refer to proper procedure. 8. Press Reset and Load Hex button in lower center (see
Figure 12). A screen will drop down called Open.
Non-CAN bus Software 9. Locate and open crane MCC Controls folder (example:
Before installing non-CAN bus software and capacity charts, 2251123 folder).
perform following steps:
10. Locate and click on Mec2.hex icon to select file and then
PARK all crane functions. click on Open button (see Figure 12). The hex file will
now download the program. A screen displays bootstrap
STOP engine. It must be off for entire procedure.
information during download process and controls
TURN ON cab power. application shows data address.
RECORD current configuration settings (handle,
chart numbers, etc.) before downloading new
software. When download is complete, use this
information to confirm crane is configured as it was
before download.

Laptop computer connector

for loading software and Front
programming functions on Console
non-CAN bus cranes.

FIGURE 12
11. When laptop interface screen displays Process
Complete/Timed Out the screen closes automatically.
12. Select and press Load Charts button at bottom of
A1261
FIGURE 10 screen. A screen will drop down called Open.
13. To reduce chart loading time, scroll up or down one
Installing Software Program rev00c
screen from display working screen to menu screen.
1. Click on shortcut icon MCC Controls App. The selected Locate on Open screen and click on lmidata.ihx icon to
folder appears (see Figure 11). select file (see Figure 13).
2. Click on MCC Controls App.exe icon to launch
program (see Figure 11).
MCC Controls App.

FIGURE 11
3. Manitowoc Controls Interface - rev00c screen is
displayed (see Figure 12).
4. Select desired laptop serial port to be used as well as
LMI (see Figure 12). FIGURE 13
5. Turn on cab power. Do not start engine. 14. Click on Open button to open file. Capacity charts will
now begin to load. While charts are loading the screen

ST 167-4
 CRANE SOFTWARE INSTALLATION

will display status (Erasing page or Load data good) in 6. Wait until program switches from Bootstrap screen to
the lower left corner of display menu screen. working screen.
15. When screen changes to indicate in Status bar that 7. Connect download harness to install port and to RS 232
programming is finished (example: Load Data in serial port on laptop (see Figure 10).
Address 49480 Close File), the capacity charts are fully
8. Select and press Reset and Load Hex button in lower
loaded into cranes rated capacity indicator/limiter (load
center (see Figure 15).
moment indicator) system. Click Exit button on control
interface screen (see Figure 13) and disconnect cable. 9. A screen will drop down called Open as shown in Figure
Scroll up or down on display and working screen will 16.
return. 10. Locate and open crane MCC Controls folder (example:
16. Check configuration screen to ensure the system is 2251123 folder).
configured as it was before chart loading. Lift a few
different loads to determine if system is weighing loads
ihx
correctly.
17. Right click on serial number folder (example: 2251123). mec2.hex

Select delete on bar and click to remove folder from

laptop.
18. Fill in Field Software Installation form OOSVFM045 and
return form to Manitowoc Crane Care Customer Service
as instructed on form.

Installing Software Program rev00f or Newer mec2.hex

1. Click on shortcut icon MCC Controls App. The selected

folder appears (see Figure 14).
2. Open folder and click on MCC Controls App.exe icon to
start program installation (see Figure 14).
MCC Controls App.
FIGURE 14
3. Manitowoc Controls Interface - rev00f or newer
screen is displayed (see Figure 15).
FIGURE 16
11. Locate and click mec2.HEX icon to select file (see
Figure 16). The hex file will now download the program.
The screen will display Process Complete/Timed Out
when files are fully loaded and file closes automatically.
12. Go back to the Manitowoc Controls Interface - rev00f
or newer screen (see Figure 15).
13. Select and press Load Charts button at bottom of
screen.
14. A screen will drop down called Open (see Figure 17).

Imidata.ihx

FIGURE 17

15. Locate and click Imidata.ihx icon to select file (see

FIGURE 15 Figure 17). The hex file will now download the capacity
charts. The screen will display Process Complete/
4. The 4 X 40 program is for all Non CAN-Bus Systems. Timed Out when files are fully loaded and file closes
5. TURN ON cab power (RUN) position. Do not start automatically.
engine.

ST 167-5
CRANE SOFTWARE INSTALLATION

16. Click Exit button on control interface screen (see Figure Installing Software Program rev00c
15) and disconnect cable. Scroll up or down on display
1. Click on shortcut icon MCC Controls App. The selected
and working screen will return.
folder appears (see Figure 14).
17. Check configuration screen to ensure system is
configured as it was before chart loading. Lift a few MCC Controls App.

different loads to determine if system is weighing loads

correctly.
18. Right click on serial number folder. Select delete on bar
and click to remove folder from laptop.
19. Fill in Field Software Installation form OOSVFM045 and
return form to Manitowoc Crane Care Customer Service
as instructed on form.
FIGURE 19
CAN Bus Software 2. Click on MCC Controls App.exe icon to launch
The CAN bus software includes capacity charts. Before program (see Figure 19).
installing CAN bus software, perform following steps: 3. Manitowoc Controls Interface screen is displayed (see
1. PARK all crane functions. Figure 20). Press button under Control System, located
in upper left corner of screen.
2. STOP engine. It must be off for entire procedure.
4. Select desired laptop serial port to be used as well as
3. RECORD current capacity chart configuration settings CAN shown in Figure 20.
(handle, chart numbers, etc.) before downloading new
CAN bus software. When download is complete, use 5. TURN ON cab power (RUN) position. Do not start
this information to confirm crane is configured as it was engine.
before download.
4. Cab power must be OFF to start download.
5. Connect download harness to console CAN bus install
port and to RS 232 serial port on laptop (see Figure 18).
6. Determine if you have software program rev00c (go to
installing rev00c topic) or rev00f or newer (go to
installing rev00f or newer topic).
A05717

Laptop computer connector

for loading software and
programming functions on
CAN bus cranes.

FIGURE 20
6. Select and press Load Hex button in lower left corner
(see Figure 20). A screen will drop down called Open.
7. Click side of box displaying MCC Controls icon. Scroll
up or down to desktop icon and click on desktop icon.
FIGURE 18 8. Locate and open the crane folder (crane serial number
file).
9. Locate and click Master.H86 icon to select file and then
click on Open button (see Figure 21). The hex file will
now download into the bus system. While loading the
file, the screen will display rows of squares and the
status bar will indicate address of download. When the
controls interface MCC Controls App. displays
Process Complete/Timed Out the files are fully loaded
and the screen closes automatically.

ST 167-6
 CRANE SOFTWARE INSTALLATION

Installing Software Program rev00f or Newer

1. Click on shortcut icon MCC Controls App. The selected
folder appears (see Figure 23).
MCC Controls App.

2.
FIGURE 21 3.
10. Select and press Load Charts button in lower left part of
screen. A screen will drop down called Open.
11. Locate and open the crane model folder.
12. Select and click on candata.ihx icon to select file (see
Figure 22). Click on Open button to open file. Rated
capacity charts will now begin to load.
FIGURE 23
Open folder and click on MCC Controls App.exe icon to
start program installation.
Manitowoc Controls Interface screen is displayed
Manitowoc Controls Interface - rev00f or newer (see
Figure 24).

candata.ihx

candata.ihx
FIGURE 24

4. Press button under Control Type, in upper left corner of

screen to select controller type to be loaded. The
controller options are:
a. Master: Master Node
b. Bin: Bin Node
FIGURE 22 c. Boom: Boom or Jib Node
13. When screen changes to indicate a Status bar that d. Display: Graphic Interface
programming is finished (Load Data in Address and e. Remote: Remote Controller
Close File), the charts will be fully loaded into the cranes
f. Universal: Universal Node (2 through 9)
CAN bus system. Click Exit button on control interface
screen (see Figure 22) and disconnect download cable. g. Engine: Engine Node
h. 4 X 40: Non CAN-Bus System
14. Scroll up or down on rated capacity screen and working
screen will return. 5. Select the communication port (Port 1 or 2) that your
computer is connected to.
15. Check configuration screen to ensure system is
configured as it was before chart loading. Lift a few 6. TURN ON cab power (RUN) position. Do not start
different loads to determine if system is weighing load engine.
correctly. 7. Select and press Load Hex button in lower left corner
16. Right click on serial number folder, select delete on bar, (see Figure 24). A screen will drop down called Open as
and click to remove folder from laptop. shown in Figure 25.
17. Fill in Field Software Installation form OOSVFM045 and
return form to Manitowoc Crane Care Customer Service
as instructed on form.

ST 167-7
CRANE SOFTWARE INSTALLATION
FIGURE 25
8. Locate and click Master.H86 icon to select file (see
Figure 25). The hex file will now download the selected
controller. The controls interface main screen will display
Process Complete/ Timed Out when files are fully
loaded and file closes automatically.
9. Go back to the Manitowoc Controls Interface - rev00f or
newer screen (see Figure 26).
FIGURE 26
10. Select and press Load Charts button in lower left. A
screen will drop down called Open.
11. Locate on Open screen and click on candata.ihx icon to
select file (see Figure 27). Click on Open button to open
file. Rated capacity charts will now begin to load.
FIGURE 27
ST 167-8
12. When screen changes to indicate a Status bar that
programming is finished (Load Data in Address and
Close File), the charts will be fully loaded into the cranes
CAN bus system. Click Exit button on control interface
screen (see Figure 22) and disconnect download cable.
13. Click Exit button on control interface screen (see Figure
22) and disconnect cable. Scroll up or down on display
and working screen will return.
14. Check configuration screen to ensure system is
configured as it was before chart loading. Lift a few
different loads to determine if system is weighing loads
correctly.
15. Right click on serial number folder. Select delete on bar
and click to remove folder from laptop.
16. Fill in Field Software Installation form OOSVFM045 and
return form to Manitowoc Crane Care Customer Service
as instructed on form.
RULES-DISCARDING FILES
1. Only install files to crane systems that you are instructed
to or that are agreed upon. Authorization by Manitowoc
Crane Care Customer Service to download a particular
system is the key to this program.
2. Manitowoc Crane Care Customer Service is to be
informed in writing when files have been installed. Serial
number of crane and version of files must be included.
3. Files must be deleted from the laptop when installation is
completed.
4. Failing to abide by these rules will result in forfeiture of
this privilege.
DOCUMENTATION
Field Software Installation Form 00SVFM045 (at end of this
document) must be completed and returned to Manitowoc
Crane Care Customer Service at the time of software
installation. If the software is installed on more than one
crane, a form must be completed for each crane.