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MLC80A-1
Manitowoc MLC80A-1 User Manual
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Service/Maintenance Manual
Manitowoc
MLC80A-1/MLC90A-1/
MLC100A-1/MLC100-1
FOR
REFERENCE
ONLY
2
Table of Contents
See End of this Manual for Alphabetical Index
5
Table of Contents
5
Section 1
13
Continuous Innovation
13
Safety Messages
13
Safety Alert Symbol
13
Signal Words
13
Safe Maintenance Practices
14
Authorized Repair Personnel Only
14
Basic Crane Maintenance Safety
14
Before Starting a Maintenance Procedure
14
Precautions While Working on the Crane
14
Read this Manual
14
Chemical Handling Precautions
15
Fire Hazard Precautions
15
Maintaining Structural Integrity of the Crane
15
Stored Energy Safety Precautions
15
Welding Hazard Avoidance
15
Protection of the Environment
16
Identification and Location of Major Components
16
Returning the Crane to Service
16
Section 2 Hydraulic System
19
Section 2
19
Hydraulic Schematic
21
Hydraulic System Overview
21
Hydraulic Pump Locations
21
Pump 1
22
Pump 2
22
Pump 3
23
Pump 4
23
Pump 5
24
Drum 1 and 2 Motors
25
Drum 3 Motor
25
Motor Identification
25
Drum 4 Motor
26
Travel Motors
27
High Pressure Accessory Valve
28
Low Pressure Accessory Valve
28
Rotating Bed Hydraulic Valves
28
Swing Motors
28
Main Control Valve
29
Hydraulic System Maintenance
32
Disposing of Hydraulic Oil and Parts
32
Safety
32
Storing and Handling Oil
32
Storing and Handling Parts
32
Inspecting the Hydraulic System
33
Inspecting and Replacing Hydraulic Hoses
34
Periodic Inspection
34
Periodic Replacement
34
Replacing Breather
35
Filter
36
Replacing Hydraulic Filters
36
Servicing Suction Strainer
37
Changing Hydraulic Oil
39
Servicing Pumps
39
Replacing Pressure Transducers
41
Replacing a Pressure Transducer
41
Testing a Pressure Transducer
41
Shop Procedures
41
Initial Hydraulic Oil Fill
41
Hydraulic Tests and Calibrations
43
Charge Pressure Test
43
Controls Calibration
43
Drum Speed Test
43
High Pressure Test
43
Pressure Sender Calibration
43
Swing Speed Test
43
Travel Speed Test
43
Disc Brake Operational Test
45
Free Fall Brake Operational Test
45
Accumulator Maintenance
46
Section 3 Electrical System
47
Section 3
47
Electrical Schematic
49
Electrical Power Sequence
49
Battery Power
49
Battery Power Disconnect
49
Crane Electrical Power Distribution
50
Cab Right Console Ground Points
51
Crane Electrical System Ground Points
51
General
51
Rotating Bed and Cab Mount Ground Points
52
Circuit Breakers, Fuses, and Relays
53
Inspect Electrical Components
56
Degradation Due to Severe Environment
56
Every Month or 200 Hours
56
CAN Bus Control System
57
CAN Bus System Overview
57
CAN Bus System Chart
58
Control Module Input/Output (I/O) Types
59
Control Module Naming Conventions
59
Control Modules
59
Crane Control Module (CCM)
60
Safety Control Module (SCM)
60
Input/Output-Large (IOL) Module
61
Input/Output-Small (IOS) Module
61
Control Module Devices
62
Motor Speed Sensors
62
Pressure Transducers
62
Alarms
63
Angle Sensors
63
Fuel Level Sensor
63
Hydraulic Fluid Level Switch
63
Limit Switches-Dual Contact
63
Limit Switches-Single Contact
63
Load Link Sensors
63
Pressure and Vacuum Switches
63
Solenoids
63
Temperature Sensors
63
Control Module Test Voltages
64
Foot Throttle
64
Hand Throttle
64
Proximity Sensors
64
Pump and Motor Voltages and Currents
64
Pump Displacement Controls
64
RCL Beacon
64
Relays
64
Travel and Free-Fall Brake Pedals
64
Wind Speed Indicators
64
Alphabetical Index of Controller Devices
65
Solenoid Valve Identification
66
Test Voltages
67
Section 4 Boom
75
Section 4
75
General Maintenance
77
Rotating Bed Level Sensor
77
Boom Angle Indicator
79
Automatic Boom Stop Limit Switch
81
Automatic Boom Stop Adjustment
81
Automatic Boom Stop Maintenance
81
Physical Boom Stop
83
Physical Boom Stop Adjustment
83
Physical Boom Stop Angles
83
Physical Boom Stop Operation
83
Lattice Section Inspection and Lacing Replacement
83
Boom Electrical Diagram
84
Section 5 Hoists
85
Section 5
85
General
87
Drum Identification
87
All Drums
88
Brake Release
88
Drum Brake
88
Seat Switch
88
Speed Sensor
88
Drums 1 and 2
88
Holding Valve
88
Lowering Load
88
Overview
88
Motor Displacement
89
Pilot-Operated Relief Valve
89
Raising Load
89
Drum 1 Hydraulic Diagram (Without Free Fall)
90
Drum 1 Electrical Diagram
91
Drum 2 Hydraulic Diagram (Without Free Fall)
92
Drum 2 Electrical Diagram
93
Drum 3
95
Holding Valve
95
Lowering Load
95
Motor Displacement
95
Overview
95
Pilot-Operated Relief Valve
95
Raising Load
95
Drum 3 Hydraulic Schematic
96
Drum 3 Electrical Diagram
97
Drum 4
99
Drum 4 Pawl
99
Holding Valve
99
Lowering and Holding a Load
99
Pilot-Operated Relief Valve
99
Raising a Load
99
Drum 4 Hydraulic Diagram
100
Drum 4 Electrical Diagram
101
Drum 1 Hydraulic Diagram
102
Drum 2 Hydraulic Diagram
103
Free Fall System (Optional)
104
Drum Gearbox Oil Change
107
Gear Oil Specifications
107
Initial Operation
107
Monthly
107
Motor Shaft Oil Cavity
107
Oil Analysis
107
Oil Change Procedure
107
Periodic Maintenance
107
Quick-Drain Valve
107
Yearly
107
Drum 4 Pawl
109
Daily
109
Drum 4 Parked
109
Drum 4 Un-Parked
109
Limit Switch Adjustment
109
Maintenance
109
Operation
109
Spring Adjustment
109
Weekly
109
Drum 1 and 2 Minimum Bail Limit
110
Limit Switch Adjustment
110
Pre-Adjustment
110
Speed Sensor-Hoist Motors
111
Replacement
111
Speed Sensor-Free Fall
113
Replacement
113
Anti Two Block (A2B) Switch
114
Locking
114
Unlocking
114
Cranes with Main Hoist Only
115
General
115
Two-Blocking Definition
115
Maintenance
117
Wire Rope Inspection and Replacement
117
Maintain a Wire Rope Condition Report
117
Required Inspection Intervals
117
Wire Rope Care and Replacement Guidelines
117
Wire Rope Lubrication
117
Daily Inspection
118
Determining the Frequency of Inspection
119
Periodic Comprehensive Inspection
119
Broken Rope Wires
120
Reduction in the Rope Diameter
120
Replacement Criteria
120
Distributing Wire Rope Wear
121
Rope that Has Been Idle a Month or more
121
Sheave, Roller, and Drum Inspection
122
Load Block and Hook-And-Weight Ball Inspection
124
Daily Inspection
124
Yearly Inspection
126
Section 6 Swing System
127
General
129
Swing Brake Operation
129
Park Switch Control
129
Holding Brake Switch Control
129
Swing Operation
129
Swing Pump Control
129
Swing Left
131
Cross Port Orifice
131
Swing Right
131
Coasting
131
Swing Alarm
131
Swing Hydraulic Diagram
132
Swing Electrical Diagram
133
Swing System Overview
129
Swing Brake Manual Release
134
Swing Gearbox Oil Change
135
Gear Oil Specifications
135
Oil Analysis
135
Periodic Maintenance
135
Quick-Drain Valve
135
Oil Change Procedure
135
Initial Drain Interval
135
Oil Change Interval
135
Oil Level Interval
135
Section 7 Power Train
137
Section 7
137
Battery Information
139
Battery Gases Are Explosive
139
Battery Safety
139
Causes of Battery Failure
139
Jump-Starting a Battery
139
Lack of Water
139
Overcharging
139
Undercharging
139
Checking Battery State of Charge
140
Loose Hold-Downs
140
Multiple Battery System
140
Overloads
140
Charging
141
Storage
141
Troubleshooting-Slow Cranking
141
Battery Maintenance
142
Battery Disconnect Switch
142
Battery Charger (Optional)
142
Engine Controls
144
Engine Access Panels
144
Engine Component Identification
145
Engine Maintenance
146
Engine Belt Routing
146
Air Cleaner Maintenance
146
Changing the Air Cleaner Filters
146
Daily Inspection
146
Monthly Inspection
146
Engine Radiator
148
Changing Coolant
148
Draining
148
Filling
148
Flushing
148
Adjusting the Engine Throttle
150
Foot Throttle Control
150
Foot Throttle Control Assembly and Calibration
150
Hand Throttle Control
150
Engine Electrical Schematic
152
Exhaust Aftertreatment System
153
DEF Supply Module
153
DEF Tank
153
Engine Regeneration and Inhibit
153
Tier 4 Main Display Icons
153
Aps
154
Coolant Control Valve
154
DEF Dosing Module
154
DOC/DPF Module
154
Drp
154
Excessive Nox Warning System
154
SCR Module
154
Section 8 Undercarriage
157
General
159
Hydraulic Travel System
159
Travel System Overview
159
Travel Brake Operation
159
Directional Control Valves
159
Hydraulic Pump
159
Joystick Control
159
Travel Motors
159
Travel Park Brake Engaged
159
Travel Park Brake Released
159
Travel 2-Speed Operation
160
Travel Cruise Operation
160
Forward Travel Operation
160
Reverse Travel Operation
160
No Travel
161
Travel Motor Flushing
161
Travel Hydraulic Diagram
162
Travel Electrical Diagram
163
Crawler Preventive Maintenance
165
Crawler Tread Slack Adjustment
165
Crawler Tread Slack Measurement
165
Crawler Hand Pump and Cylinder
166
Assembly
167
Maintenance
167
Air Removal
167
Operation
167
Intermediate Roller Bolt Torque
166
Turntable Bearing Alignment
168
Replacing Turntable Bolts
169
Tightening Turntable Bearing Bolt
169
After First 50 Hours of Operation
169
Annually or Every 2,000 Hours of Operation (Whichever Comes First)
169
Crawler Gearbox Oil Change
171
Gear Oil Specifications
171
Oil Analysis
171
Periodic Maintenance
171
Oil Change Procedure
171
Motor Shaft Oil Cavity
171
Initial Operation
171
Weekly
171
Section 9
173
Lubrication
173
Manitowoc 10-I
177
Section 10
177
Counterweight Pins
179
Counterweight Limit Switch
179
Counterweight Pins Overview
179
Disengage (Retract)
179
Engage (Extend)
179
Gantry Cylinder Operation
180
Extend
180
Gantry Cylinders Overview
180
Load Holding
180
Neutral
180
Retract
180
Boom Hoist Operation
180
Crawler Positioning Cylinders Operation
181
Crawler Positioning Cylinders Overview
181
Extend
181
Neutral
181
Retract
181
Hydraulic Cooling Fan Operation
181
Accessory Systems Hydraulic Diagram
182
Accessory Systems Electrical Diagram
183
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Manitowoc MLC80A-1 Specifications
General
Engine Power
300 hp
Main Boom Length
12.7 m to 54.9 m
Fixed Jib Length
40 ft
Boom Length
12.7 m to 54.9 m
Travel Speed
1.6 km/h
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