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Manitowoc MLC80A-1 - User Manual

Manitowoc MLC80A-1
188 pages
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Service/Maintenance Manual
Manitowoc
MLC80A-1/MLC90A-1/
MLC100A-1/MLC100-1
FOR REFERENCE
ONLY

Table of Contents

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Manitowoc MLC80A-1 Specifications

General IconGeneral
Engine Power300 hp
Main Boom Length12.7 m to 54.9 m
Fixed Jib Length40 ft
Boom Length12.7 m to 54.9 m
Travel Speed1.6 km/h

Summary

SECTION 1 INTRODUCTION

CONTINUOUS INNOVATION

Information subject to change; contact dealer for updates.

SAFETY MESSAGES

Alerts to hazards; uses symbols and signal words to indicate seriousness.

SAFE MAINTENANCE PRACTICES

Essential precautions for safe operation and maintenance procedures.

PROTECTION OF THE ENVIRONMENT

Guidelines for proper disposal of waste fluids and materials.

IDENTIFICATION AND LOCATION OF MAJOR COMPONENTS

Details on identifying and locating key crane components.

SECTION 2 HYDRAULIC SYSTEM

HYDRAULIC SCHEMATIC

Diagram illustrating the crane's hydraulic circuits and flow.

HYDRAULIC SYSTEM OVERVIEW

General functional description of major hydraulic components.

MOTOR IDENTIFICATION

Details on identifying various hydraulic motors used in the system.

ROTATING BED HYDRAULIC VALVES

Description and location of hydraulic valves on the rotating bed.

HYDRAULIC SYSTEM MAINTENANCE

Procedures and safety precautions for maintaining the hydraulic system.

INSPECTING THE HYDRAULIC SYSTEM

Guidelines for regular visual inspection of the hydraulic system.

INSPECTING AND REPLACING HYDRAULIC HOSES

Procedures for inspecting and replacing hydraulic hoses.

REPLACING HYDRAULIC FILTERS

Step-by-step guide for replacing hydraulic filter elements.

CHANGING HYDRAULIC OIL

Instructions for draining and refilling the hydraulic system oil.

HYDRAULIC TESTS AND CALIBRATIONS

Procedures for testing and calibrating hydraulic system functions.

DISC BRAKE OPERATIONAL TEST

Weekly test procedure for ensuring disc brake functionality.

ACCUMULATOR MAINTENANCE

Procedures for testing and maintaining the hydraulic accumulator.

SECTION 3 ELECTRICAL SYSTEM

ELECTRICAL SCHEMATIC

Diagram of the crane's electrical system wiring.

ELECTRICAL POWER SEQUENCE

Explanation of how electrical power is supplied and distributed.

CRANE ELECTRICAL POWER DISTRIBUTION

Details on power distribution through breakers and relays.

CRANE ELECTRICAL SYSTEM GROUND POINTS

Locations of frame ground connection points on the crane.

CIRCUIT BREAKERS, FUSES, AND RELAYS

Identification and location of protective electrical components.

INSPECT ELECTRICAL COMPONENTS

Guidelines for inspecting electrical harnesses and connections.

DEGRADATION DUE TO SEVERE ENVIRONMENT

Impact of climate zones and salt on electrical components.

CAN BUS CONTROL SYSTEM

Overview of the crane's serial communication network.

CONTROL MODULES

Description of control modules and naming conventions.

CONTROL MODULE DEVICES

Operation of devices controlled by or interfacing with control modules.

LIMIT SWITCHES-DUAL CONTACT

Function and application of dual-contact limit switches.

LIMIT SWITCHES-SINGLE CONTACT

Function and application of single-contact limit switches.

SOLENOID VALVE IDENTIFICATION

Mapping of solenoid valve numbers to control module pins.

CONTROL MODULE TEST VOLTAGES

Test voltages for various control modules (CCM-10, IOLC30).

SECTION 4 BOOM

GENERAL MAINTENANCE

Maintenance and adjustment instructions for boom limit devices.

ROTATING BED LEVEL SENSOR

Description and adjustment of the sensor measuring rotating bed angle.

BOOM ANGLE INDICATOR

Description of the boom angle sensor and its function.

AUTOMATIC BOOM STOP LIMIT SWITCH

Operation, maintenance, and adjustment of the automatic boom stop.

PHYSICAL BOOM STOP

Purpose and operation of the physical boom stop mechanism.

LATTICE SECTION INSPECTION AND LACING REPLACEMENT

Instructions for inspecting lattice sections and replacing lacing.

BOOM ELECTRICAL DIAGRAM

Schematic detailing the boom's electrical system.

SECTION 5 HOISTS

GENERAL

Operational information for Hoist Systems (Drums 1-4).

ALL DRUMS

General operation and safety for all hoist drums.

DRUMS 1 AND 2

Overview of the hydraulic and control systems for Drums 1 and 2.

DRUM 3

Overview of the hydraulic and control systems for Drum 3.

DRUM 4

Overview of the hydraulic circuit and pawl system for Drum 4.

FREE FALL SYSTEM (OPTIONAL)

Operation and function of the free fall system.

DRUM GEARBOX OIL CHANGE

Procedures for checking and changing oil in drum gearboxes.

DRUM 4 PAWL

Operation, maintenance, and adjustment of the Drum 4 pawl system.

DRUM 1 AND 2 MINIMUM BAIL LIMIT

Function and adjustment of the minimum bail limit switch.

SPEED SENSOR-HOIST MOTORS

Description and replacement of speed sensors for hoist motors.

SPEED SENSOR-FREE FALL

Description and replacement of speed sensors for free fall drums.

ANTI TWO BLOCK (A2 B) SWITCH

Operation, locking, and unlocking of the A2B switch.

TWO-BLOCKING DEFINITION

Explanation of the two-blocking condition and its hazards.

WIRE ROPE INSPECTION AND REPLACEMENT

Guidelines for wire rope inspection, care, and replacement.

LOAD BLOCK AND HOOK-AND-WEIGHT BALL INSPECTION

Procedures for inspecting load blocks and hook-and-weight balls.

SECTION 6 SWING SYSTEM

GENERAL

Operational information for the Swing System.

SWING SYSTEM OVERVIEW

Description of the hydraulic pump and motor for the swing system.

SWING BRAKE OPERATION

Function of the spring-applied, hydraulically-released swing brake.

SWING OPERATION

How the swing pump and joystick control crane swing.

SWING PUMP CONTROL

Electronic control of the swing pump's output volume and direction.

SWING LEFT

Operation of the swing system when moving left.

SWING RIGHT

Operation of the swing system when moving right.

COASTING

Description of how the swing system coasts when joystick is neutral.

SWING BRAKE MANUAL RELEASE

Procedure for manually releasing the swing brake for servicing.

SWING GEARBOX OIL CHANGE

Procedures for checking and changing oil in the swing gearbox.

SECTION 7 POWER TRAIN

BATTERY INFORMATION

Safety guidelines and information for crane batteries.

LOOSE HOLD-DOWNS

Risks associated with loose battery hold-downs and acid leaks.

MULTIPLE BATTERY SYSTEM

Description of the 24V system using two 12V batteries.

CHECKING BATTERY STATE OF CHARGE

Methods for determining battery charge level using a voltmeter.

TROUBLESHOOTING-SLOW CRANKING

Diagnosing slow engine cranking related to battery connections.

CHARGING

Procedures and precautions for charging crane batteries.

BATTERY MAINTENANCE

Quarterly maintenance procedures for batteries.

BATTERY DISCONNECT SWITCH

Function and use of the battery disconnect switch.

BATTERY CHARGER (OPTIONAL)

Information on the optional APU for battery charging.

ENGINE CONTROLS

Overview of engine start/stop procedures and speed control.

ENGINE ACCESS PANELS

Identification and safety for accessing engine service panels.

ENGINE MAINTENANCE

Reference to engine manufacturer's manual for maintenance intervals.

ENGINE BELT ROUTING

Diagram showing the routing of engine drive belts.

AIR CLEANER MAINTENANCE

Periodic maintenance for the engine's air cleaner system.

CHANGING THE AIR CLEANER FILTERS

Step-by-step guide for replacing primary and secondary filters.

ENGINE RADIATOR

Procedures for checking coolant level and changing coolant.

ADJUSTING THE ENGINE THROTTLE

Assembly and calibration procedures for the electronic foot throttle.

EXHAUST AFTERTREATMENT SYSTEM

Description of components for reducing exhaust emissions.

SECTION 8 UNDERCARRIAGE

GENERAL

Operational information for the crane's Travel System.

HYDRAULIC TRAVEL SYSTEM

Overview of the travel system's hydraulic circuits.

TRAVEL 2-SPEED OPERATION

Selecting between low and high speed for crawler travel.

TRAVEL CRUISE OPERATION

Using the cruise control feature for continuous travel.

FORWARD TRAVEL OPERATION

Conditions and procedure for moving the crane forward.

REVERSE TRAVEL OPERATION

Conditions and procedure for moving the crane in reverse.

TRAVEL MOTOR FLUSHING

Purpose and operation of the travel motor flushing circuit.

CRAWLER PREVENTIVE MAINTENANCE

Weekly maintenance for crawler components.

CRAWLER TREAD SLACK MEASUREMENT

Procedure for measuring and maintaining correct tread slack.

CRAWLER TREAD SLACK ADJUSTMENT

Instructions for adjusting crawler tread slack tension.

INTERMEDIATE ROLLER BOLT TORQUE

Checking and torquing intermediate roller bolts.

CRAWLER HAND PUMP AND CYLINDER

Operation and maintenance of the crawler adjustment hand pump.

TURNTABLE BEARING ALIGNMENT

Procedure for aligning and installing the turntable bearing.

TIGHTENING TURNTABLE BEARING BOLT

Torque specifications and sequence for turntable bearing bolts.

REPLACING TURNTABLE BOLTS

Procedure for installing and torquing new turntable bearing bolts.

CRAWLER GEARBOX OIL CHANGE

Procedures for checking and changing oil in crawler gearboxes.

SECTION 9 LUBRICATION

LUBRICATION

General information and procedures for crane lubrication.

SECTION 10 ACCESSORIES

COUNTERWEIGHT PINS

Operation and control of the counterweight pins system.

COUNTERWEIGHT LIMIT SWITCH

Function of the limit switch for counterweight installation.

GANTRY CYLINDER OPERATION

Operation and control of the gantry cylinders.

BOOM HOIST OPERATION

How to operate the boom hoist using the remote control.

CRAWLER POSITIONING CYLINDERS OPERATION

Operation and control of the crawler positioning cylinders.

HYDRAULIC COOLING FAN OPERATION

Control of the hydraulic cooling fan based on oil temperature.

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