Lampson International modernizes classic crawler cranes

Several years ago, Lampson International was presented with the challenge of being one of the world’s largest owners of traditional Manitowoc crawler cranes that were rapidly becoming obsolete due solely to their mechanical operating systems.

The Millennium combines the structural integrity and versatility of the original Manitowoc cranes with the safety and ease of operations of the new generation hydraulic operating system cranes.

At one time the original VICON system was thought by many to be the safest and most advanced crane operating control system available. With the advance of computer systems designed for safer operations in all types of industrial applications, cranes would not be not far behind. Use of these types of systems, although somewhat in their infancy, were destined to change the crane world forever. Elimination of mechanically operated controls allowed for more precise operation with built in safeguards to prevent operator error and ease the physical demands of manual operation.

Knowing that Lampson’s fleet of traditional Manitowoc cranes still had many years of structural viability in them, the Lampson team made the decision to research ways to convert or repower these cranes in such a manner that they would be operationally on par with the newer machines. Lampson decided to embark on remanufacturing its older cranes, converting them to its Millennium series.

Millennium series

The first-generation of Lampson Millennium Cranes attempted to “trick” the existing mechanical system into operating similar to the newer machines. They utilized joystick controls coupled with an on-board controller that activated brakes, throttle and hoisting mechanisms causing the crane to react very close to a true hydraulic machine. Unfortunately, very close and very good were two totally different results.

The original Millennium crane was developed in Australia and sent to the U.S. for trials and refinement. Our engineers determined that if the long-term goal was to make the crane “very good,” it would require a full hydraulic re-power and control system re-vamp.

Lampson Millennium 4600 Maximum Capacity: Series 5 – 350 tons/with RINGER 750 tons Maximum line pull for main drum and auxiliary drum: 65,000 pounds Maximum main boom length: 310 feet/with RINGER 400 feet

The Manitowoc platform was a “very good” starting point. When combined with the available attachments, particularly the RINGER, the crane fit the capacity and performance requirements of many crane users. Building off this robust platform, Lampson’s team looked at newer innovations in crane design to determine if they should be incorporated into the Millennium. A rudimentary VPC was installed in the first machine, and the possible need for self-erection capabilities and changing the travel to add counter-rotational ability were all considered, but none justified the increased cost.

Lampson opted for a complete mechanical re-power by removing and replacing all of the inherent gear, chain and friction components with state-of-the-art hydraulic pumps, motors and planetaries. All of these would be controlled by a new, but proven, digital control system from Parker Hydraulics. This system allowed for precise throttle, hoisting, lowering and braking control.

The new operating system allows for precise throttle, hoisting, lowering and braking control.

By not changing the weight distribution, or the center of gravity of the crane structure, the load charts and crane stability characteristics were not affected. Utilizing the existing house and hook roller rotation arrangement assured the swing operational feel that the Model 4100 was known for remained.

Retaining this original design eliminated the high cost of installation of a new style slewing bearing. Engines were replaced with newer emissions-friendly models sourced from Cummins, which feature good performance curves for horsepower, torque and fuel use. In addition, all crane components – including the standard boom and jib – still fit the repowered machine.

Lampson’s team designed and built new winch drums that have increased line pull and spooling capacity over the originals. The existing boom hoist is used intact, but entirely rebuilt prior to re-installation. The use of hydraulic power distribution allowed for the option of a third drum mounted on the existing gantry that can be used for any of a variety of purposes dictated by the end user.

Modified to work

An all new cab was designed and constructed with operator comfort and visibility at the forefront. The steel crane side panels were replaced with aluminum to make installation and removal easier and safer. Crane monitoring systems were installed to monitor operating parameters and advise the operator of approaching limits during operations.

These modified machines all sport the familiar “Lampson Blue” paint scheme with enhanced graphics and some chromed accessories, giving the machine a sleeker and more polished look.

These re-powered machines are made available in four options, including the purchase of an entire Millennium Edition 4100 and 4600 with all MEC attachments; purchase of a re-powered machine house only; re-power of a client’s existing machine house; or exchange of a client’s machine house with an allowed credit for return of their existing house.

Whichever option, the result is a tried and true “work-tested crane” equipped with the latest mechanical and operating technology available.