Construction Robotics MULE ML150 User manual

MULE ML150
OWNER’S MANUAL

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Page Intentionally Left Blank

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Revision Sheet
Release No.
Date
Revision Description
Rev A
4/5/21
Initial Release
CR Customer Support: [phone]
NOTE
All assembly and operation instructions located on the MULE units and
accessories take precedence over information contained in this manual.
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.)
2. Recall instructions
3. Supplemental assembly or operational instructions provided with
the MULE or MULE accessories
4. Owner’s Manual
Any use of a MULE unit, in a configuration or
manner not explicitly described in this manual is not
recommended without the prior written permission
of Construction Robotics, LLC.

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Table of Contents
AINTRODUCTION
AINTRODUCTION 1
1
1Safe Operating Guidelines 1
2System Overview 2
3Owner’s Manual Use 2
4Product Warranty 3
4.1 Warranty Period 3
4.2 Warranty Policy 3
5Acronyms and Abbreviations 3
BSYSTEM SUMMARY 4
1Meet MULE 4
2Standard System Components 4
2.1 Component Names 4
2.2 Weights 5
3MULE Accessories 5
3.1 Ground Base Wheel Set 6
3.2 Hydro Mobile Mast Adapters 6
3.3 Fork Tubes Adapter Plate 6
3.4 Two-Button Handle 6
3.5 CMU Gripper 1” - 2 1/4” 6
3.6 Wire Rope Extensions 7
4System Dimensions 8
5Safety Features 10
6Basic Requirements 11
7Your Machine 11
CSYSTEM SETUP 12
1Owner’s Manual Limitations 12
2Powering MULE 12
2.1 Power Requirements 12
2.2 Generator Power 12
2.3 Using Additional Extension Cords 12
3Setup Process 13
3.1 Base Distance from Wall 13
3.2 Outrigger Position 14
3.3 Base Leveling and Capacity 15
15
3.4 Wire Rope Extensions 15
3.5 Controller Installation 16
3.6 Handle Installation 16
3.7 Gripper Installation 16
3.8 Ground Base Wheel Set Installation 17
3.9 Fork Tube Disassembly 17
4Maximum Mast Height 19
4.1 Ground Base 19
4.2 Mounted to Wheel set 20
4.3 Fork Tubes 20
5Working with Mast Ties 21
6Assembling the Mast and Installing MULE 22
7Raising MULE Height (Adding Mast Sections) 27
8Moving MULE on a Jobsite 28
8.1 General Location Requirements for MULE28
8.2 Free Standing Ground Base 28
8.3 Wheel Set 29
8.4 System with Wall Ties 30
9MULE Dismantling and Packing for Transport 31
DSYSTEM SETUP ON MAST
CLIMBING PLATFORM 32
1Introduction 32
2Strap-over Deck Mount 32
2.1 Overview 32
2.2 Installation 32
2.3 Leveling the Base 32
2.4 Adding Masts and MULE 33
2.5 Moving MULE and Mount 33
3On Existing Hydro Mobile Mast Tower 33
ESYSTEM OPERATION 34
1Controller Buttons 34
1.1 RUN STOP 34
1.2 Manual/Calibrate Up/Down 34
1.3 Speed 34
1.4 Float 34
1.5 Auto Retract 34
1.6 Retract Height 34
2External Buttons - Gripper and Handle 35
2.1 Grip 35
2.2 Set 35
3Typical Use Cycle 35
3.1 Common User Errors 35
4Hook Mode 36
4.1 Set Button 36
4.2 Grip Button 36
5Primary Arm Rotation Lock 37
FTRANSPORT AND STORAGE 38
1Shipping Position 38
1.1 Tie Down Locations 38
1.2 Orientation on Open Trailer 38
2Controller Transport 38
GSETTINGS & TROUBLESHOOTING 39
1Key Access Areas 39
2Friction Brake Adjustment 39

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2.1 Primary Arm 39
2.2 Secondary Arm 40
3Virtual Limits 41
4Controller Menu 41
4.1 Virtual Limits (V-limits) 41
4.2 Speed Menu 41
4.3 SET Weight 41
4.4 Anti-Drop Tool Weight 41
4.5 Diagnostics 41
4.6 Software Flowchart 42
5Pneumatic System 44
5.1 Air Compressor 44
5.2 Pneumatic Connection Diagram 44
6Electrical Information 45
6.1 Transformer Adjustments 45
6.2 Electrical Connection Diagram 47
7Primary Arm Rotation Lock 48
8Troubleshooting 49
8.1 Common Issues 49
8.2 Error Codes 51
9Shut Down 51
HPREVENTATIVE MAINTENANCE AND
BASIC SERVICE 52
1Maintenance Summary 52
1.1 Daily 52
1.2 Weekly 52
1.3 Monthly 52
2Wire Rope 52
2.1 Inspection 52
2.2 Lubrication 53
2.3 Required Replacement Criteria 53
2.4 Slack Detection 54
2.5 Replacement 56
3Pneumatic System 61
3.1 Air Compressor 61
3.2 Water Separator 61
4Structural Inspection 61
5Power Cord 61
5.1 Daily Inspection 61
5.2 Monthly Inspection 62
6Rollers on Arm 62
6.1 Primary Arm Rollers 62
6.2 Secondary Arm Roller 62
7Fan Filter 62
8Inclinometers 63

SECTION A –INTRODUCTION
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A INTRODUCTION
1 Safe Operating Guidelines
There is no one single factor that is more important for minimizing the possibility of personal injury to the operator and
those working in the area, or damage to property, equipment, or material than being familiar with the equipment and
using Safe Operating Practices.
The MULE is designed for lifting and transporting of material only. Under no circumstances, either during initial
installation or in any other use, should the hoist be used for lifting or transporting personnel.
No operator should be permitted to use the equipment that is not familiar with its operation, is not physically or
mentally fit, or has not been schooled in safe operating practices. The misuse of MULE can lead to certain hazards
which cannot be protected against by mechanical means; hazards which can only be avoided by the exercise of
intelligence, care, and common sense.
Safe Operating Practices also involve a program of periodic inspection and preventative maintenance (covered in a
separate section). Part of the operator’s training should be an awareness of potential malfunctions/hazards requiring
adjustments or repairs, and bringing these to the attention of supervision for corrective action.
Supervision and management also have an important role to play in any safety program by ensuring that a maintenance
schedule is adhered to, and that the equipment provided for the operators is suitable for the job intended without
violation of one or more of the rules covering safe operating practices and good common sense.
Do’s and Don’ts (Safe Operation of MULE)
The following are Do’s and Don’ts for safe operation of MULE. A few minutes spent reading these rules can make an
operator aware of dangerous practices to avoid and precautions to take for their own safety and the safety of others.
Frequent examinations and periodic inspections of the equipment as well as a conscientious observance of safety rules
may save lives as well as time and money.
DON’TS:
Never lift or transport a load until all personnel are clear and do not transport the load over
personnel.
Do not allow any unqualified personnel to operate hoist.
Never pick up a load beyond the capacity rating appearing on the MULE. Overloading can be
caused by jerking as well as by static overload.
Never carry personnel on the gripper, the hook or the load.
Do not operate MULE if you are not physically fit.
Do not operate MULE to extreme limits of travel of cable without first checking for proper
limit switch action.
Do not tamper with or adjust any parts of the MULE unless specifically authorized to do so.
Never use the wire rope as a sling.
Do not divert attention from load while operating hoist.
WARNINGS
1. All users should read the Owner’s Manual before operating the unit.
2.
The installation and operation of MULE is subject to hazards that can be avoided only by
using extreme care and common sense. 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.

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Never leave a suspended load unattended.
Never operate a MULE that has an inherent or suspected mechanical or electrical defect.
Do not jog controls unnecessarily.
Do not operate MULE if cable is twisted, kinked, or damaged.
Do not remove or obscure label.
DO’s:
Read and follow manufacturer’s instruction, installation, and maintenance manuals. When
repairing or maintaining a MULE, use only manufacturer’s recommended parts and materials.
Read and follow all instruction and warning information on or attached to the MULE.
Remove the MULE from service and thoroughly inspect and repair, as necessary, if unusual
performance or visual defects (such as peculiar noise, jerky operations, travel in improper
direction, or obviously damaged parts) are noticed.
Establish a regular schedule of inspection and maintain records for all MULEs with special
attention given to hooks, grippers, wire rope, brakes, and limit switches.
Check operation of brakes for excessive drift.
Never lift loads over people, etc.
Check for damaged hooks, grippers and wire rope.
Keep wire rope clean and well maintained.
Check the wire rope for improper seating, twisting, kinking, wear, or other defects before
operating the MULE.
Make sure a load clears neighboring stockpiles, machinery, or other obstructions when raising,
lowering, or traveling the load.
Avoid swinging of load or load gripper when traveling the MULE.
Be sure the load attachment is properly seated in the saddle of the gripper or hook. Balance load
properly before handling. Avoid gripper tip loading.
2 System Overview
MULE is a work area tool used to assist in the lifting and placement of units and material up to 150lb over an 11’
vertical distance.
Grippers and hook devices are developed for many specific applications. Specialized gripper or attachment devices
can be developed upon requests. Please contact Construction Robotics (CR) for more information.
3 Owner’s Manual Use
This manual is for use with the following Construction Robotics products:
MULE ML150 (Arm, Power Pack and Control Box)
Ground Base Package
MCWP Package
Basic Accessories
This manual provides instructions for operating within the typical uses of MULE.
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.

SECTION A –INTRODUCTION
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4 Product Warranty
4.1Warranty Period
Refer to your purchase agreement for the warranty period of your MULE and accessories.
4.2Warranty 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
CMU: Concrete Masonry Unit MULE: Material Unit Lift Enhancer
CR: Construction Robotics MCWP: Mast Climbing Work Platform
GFCI: Ground-Fault Circuit Interrupters RMA: Returned Material Authorization
HM: Hydro Mobile

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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)
Eliminates the fatigue and physical wear and tear associated with repetitive heavy lifting
Designed for efficiency and comfort in the construction working environment
Simple control and operation
Increased productivity
Flexible deployment, multiple base configurations, works from the ground, traditional
scaffold or mast climbing work platforms
Can free stand up to 20+ feet
Runs off 120V AC power
2 Standard System Components
2.1Component Names
Powerpack –Houses power management and distribution devices, air compressor and Lifting Cable actuator.
Primary Arm –1st Boom element closest to the mast. The Powerpack is attached to the Primary Arm and
rotates around the rotation mast.
Gripper
Handle
Controller
Secondary Arm
Primary Arm
Powerpack
Fork Tubes
Ground Base
Mast
Power Cord

SECTION B –SYSTEM SUMMARY
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Figure B-2
Secondary Arm –2nd Boom element. Rotates around the end of the Primary Arm. Data coil cord, coil airline
and Wire Rope come down from the end of the Secondary Arm.
Fork Tubes –The Fork Tubes is attached to the bottom of the rotation mast and is used to pick, transport, and
lift MULE. Cross pockets allow the Fork Tubes to be picked from all four sides. System can rest on level
ground on the Fork Tubes. The Fork Tubes can be disconnected to decrease weight or remove obstacles.
Ground Base –The Ground Base is the platform MULE is built on. It can be picked in all 4 directions for
easy transport. Its slim size allows for it to fit through 36” openings while the incorporated outriggers and
jacks provide for a level and stable footprint.
Power Cord –MULE comes standard with a 50’ power cord that can be plugged into most wall or generator
outlets.
Mast –The mast sections allow for MULE to be built to different heights depending on the situation.
During transport the mast sections can be removed to create a compact package, which can then be
assembled to a variety of heights on the jobsite.
Controller –The main operational interface for MULE where most of the functions are located. The
Controller attaches to the working end of the Wire Rope.
Handles –The Handle provides a convenient grip to operate MULE from. These handles attach to the
bottom of the Controller. There are multiple handle options available to support different preferences and
button configurations. Grippers attach to the bottom of the Handle and can be configured in multiple
orientations and installed using a quick-change pin.
Grippers –The gripper or hook type device attaches to the Handle through a U-Joint connection.
Different grippers allow for grabbing of different materials and the incorporated U-Joint allow for the tilt
of the load to be precisely controlled during placement.
2.2Weights
MULE 150
Figure B-1 - As shown: 1160lb
BASES
Ground Base
Figure B-2 - As shown: 950 lb
Fork Tubes
Figure B-3 - As shown: 290 lb
MASTS
Figure B-4
Length
Weight
2’
135 lb
2.5’
145 lb
4’
180 lb
5’
200 lb
6’
225 lb
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.
Figure B-1
Figure B-3
Figure B-4

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3.1Ground 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
3.2Hydro 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.
Weight of adapter pair: 205 lb
3.3Fork Tubes Adapter Plate
Allows Mast Sections to be directly mounted to the Fork Tubes. Without special
engineering approval, this is only for use with Strap-over style MCWP mounts.
Weight of adapter plate: 75 lb
3.4Two-Button Handle
This handle has the GRIP and SET buttons built in for easy access when the Gripper is
unloaded. This allows for a typical place cycle to be done without releasing the handle.
3.5CMU Gripper 1” - 2 1/4”
The CMU Gripper 1” - 2 1/4”. This gripper is capable of picking CMU with center webs
between 1” and 2-1/4” thick.

SECTION B –SYSTEM SUMMARY
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3.6Wire 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. Multiple extensions can be hooked together for long reaches.
The extensions will decrease the allowable load by the weight of the extension.

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4 System Dimensions

SECTION B –SYSTEM SUMMARY
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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.
Preventing the Load from Dropping
When MULE is placing a load utilizing the GRIP button, it will not release the block until it senses that the load
weight is being carried by something else. This prevents a load from dropping unexpectedly when the GRIP
button is accidentally triggered.
Loss of Air
If air pressure is lost for any reason MULE is still in a safe condition. When air pressure is lost, the Primary Arm
Rotation Lock will engage keeping the arm and any possible load from drifting away. Also the design of the
Grippers prevents loads from being dropped by requiring air pressure to release. If air is not available, the unit
will no longer operate but will be in a safe condition.

SECTION B –SYSTEM SUMMARY
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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. Repeated overload will cause
premature failure of components.
6 Basic Requirements
Power: 20A@120V AC, 60Hz
Load to be placed: 10-135 lb
7 Your Machine
As each MULE is made up of several main components, there are multiple serial numbers on each machine to
allow for product tracking. For your records it is smart to record these numbers upon receipt.
Serial Number Stickers can be found in the following locations:
Equipment
Part Number
Serial #
Picture
Controller
Arm
Powerpack
Ground
Base
Note: This sticker is in a
protected location and
therefore difficult to access.

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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.
2 Powering MULE
MULE requires clean, steady power to run. When running off a standard wall outlet with no extension cord, no
issues should be encountered during standard operation.
If a generator or extension cord is being used, be sure to follow the guidelines in the sections below to ensure
smooth operation of MULE.
2.1Power Requirements
Voltage: 120V (+/- 6V) (if voltage is out of range, see section G6.1 on page 45 to adjust MULE)
Amperage: 20A (at full speed and full capacity)
Frequency: 60 Hz
OSHA requires that MULE be powered through a GFCI receptacle when using temporary site power or
generators over 5000W (1926.404).
Be sure to follow all OSHA procedures for all power connections.
2.2Generator Power
When site conditions require the use of a generator, it is important to have capable equipment available.
Many standard jobsite generators with less than 4000 Starting Watts do not have the power to handle the
peak loads of MULE without creating power conditions that will cause faults. The newer inverter style
generators provide cleaner power than standard generators.
When using a generator CR recommends using Honda EB2800i with Eco mode turned off.
2.3Using Additional Extension Cords
Ensure MULE is fully assembled and the Controller is connected prior to
plugging MULE in
MULE comes standard with 50’ of power cord. Whenever possible, it is best to bring the power source into
the range of MULE’s power cord.
If it is necessary to add an extension cord, refer to the chart below for the proper gauge based on the length
that is needed. Use of a smaller gauge cord than specified may lead to errors that prevent machine function.
Extension Cord Length
Minimum Extension Cord Size
Up to 50’
12AWG
50’-75’
10AWG
75’-100’
8AWG

SECTION C –SYSTEM SETUP
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3 Setup Process
3.1Base 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. No problems will typically be encountered if the area in Figure C-1 is free
from obstructions.
The following table illustrates how much wall can be reached by one MULE:
Figure C-1 –Required MULE Clearance

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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.
Consult OSHA standards 1926.1407, 1926.1408 and 1926.1409 for more information.
3.2Outrigger Position
Before assembling MULE the outriggers within the Ground
Base have to be extended and locked into position. These
allow MULE to be stable while making the Ground Base able
to fit through a 36” opening.
To extend the outriggers, pull the center pin out completely,
this will allow both outriggers on one end of the Ground Base
to slide freely.
Once the outrigger is free to move, slide it out until the line on the outrigger is lined up with the edge of the
Ground Base. Be sure that the correct side of the outrigger is facing up.
Once the outrigger is extended to the correct position slide the center pin back in to lock them in place.
This procedure needs to be done on both ends of the Ground Base for all 4 outriggers.
Install the jacks in the outriggers, with the handle pointing up.