Manitowoc MLC165 Operator's Manual
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Manitowoc MLC165 Operator's Manual

Luffing jib
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Manitowoc
MLC165/MLC165-1
Luffing Jib
Operator Manual

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Summary of Contents for Manitowoc MLC165

  • Page 1 Manitowoc MLC165/MLC165-1 Luffing Jib Operator Manual...
  • Page 3 The serial number of the crane and applicable attachments (for example, a luffing jib or MAX-ER ) is the only method a Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing the correct parts and service information.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    Manitowoc Dealer ........
  • Page 6 TABLE OF CONTENTS MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Lower Boom ..............4-7 Prepare Boom for Jib .
  • Page 7 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL TABLE OF CONTENTS Physical Boom Stop Operation ........... 6-7 Physical Boom Stop Adjustment .
  • Page 8 TABLE OF CONTENTS MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-iv Published 05-25-17, Control # 221-05...
  • Page 9 Manitowoc Dealer ........
  • Page 10 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 05-25-17, Control # 221-05...

  • Page 11: Section 1

    FIGURE 1-1 LEFT RIGHT CHANGE OF OWNERSHIP REGISTRATION If you are the new owner of a Manitowoc crane, please register it with the Manitowoc Crane Care Lattice Team so we can contact you if the need arises. Go to www.manitowoccranes.com Go to Service >...
  • Page 12 INTRODUCTION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...

  • Page 13: Identification And Location Of Components

    Wire Rope Guide Jib Stop Winch Jib Point with Roller Load Block (1 or 2 Sheaves) Hook and Weight Ball NOTE See MLC165 Crane Operator Manual for identification of crane and boom components. M100430 FIGURE 1-3 Manitowoc Published 05-25-17, Control # 221-05...

  • Page 14: English And Metric Conversions

    INTRODUCTION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL ENGLISH AND METRIC CONVERSIONS Inverse Conversion DIVIDE (÷) known value by conversion factor to obtain Direct Conversion equivalent value in desired units. For example, 3,6576 m is MULTIPLY (x) known value by conversion factor to obtain converted to feet as follows: equivalent value in desired units.
  • Page 15 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854 WEIGHT Pound Unit/Component Kilogram 0.4536...
  • Page 16 INTRODUCTION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...

  • Page 17: Section 2

    Safety ................2-1 Manitowoc...
  • Page 18 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-ii Published 05-25-17, Control # 221-05...

  • Page 19: Safety

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION SAFETY Read and become thoroughly familiar with the safety information in Section 2 of the MLC165 Crane Operator Manual. Manitowoc Published 05-25-17, Control # 221-05...
  • Page 20 SAFETY INFORMATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...
  • Page 21 Wind Conditions ..............3-10 Manitowoc...
  • Page 22 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 05-25-17, Control # 221-05...
  • Page 23 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 05-25-17, Control # 221-05...

  • Page 24: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124...
  • Page 25 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles. USE MAIN HOIST—Tap fist on head. Then use regular signals.
  • Page 26 OPERATING CONTROLS AND PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Front Console M100497 Left Side of Boom Butt M100497 Side Consoles Left Side of Rotating Bed M100449 Item Description RCL Display Main Display 2a – Information Screen 2b – Fault Screens...
  • Page 27 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES LUFFING JIB MODE Boom Butt with Drum 3 Option (Optional) Front of Rotating Bed (Optional) Crane Has No Function LUFFING JIB MODE without Drum 3 Option DRUM IDENTIFICATION Drum Description Front Load Drum or Luffing Hoist...

  • Page 28: General Operation

    OPERATING CONTROLS AND PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL • To familiarize qualified operators with the location of the controls used for luffing jib operation. • To alert operators to important safety information. WARNING Prevent Death or Serious Injury to Personnel!

  • Page 29: 2B - Main Display-Fault Screens

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES with the Main Display Manual (F2260) provided with your Block-Up Limit crane. The manual is stored in the operator cab. This limit stops the boom and luffing hoists in the down direction and the load hoists in the...

  • Page 30: Jib Max Down 1 Limit

    OPERATING CONTROLS AND PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Jib Max Down 1 Limit Jib Max Down 2 Limit This limit turns on the fault alarm to alert the This limit stops the luffing jib when the boom operator that the jib is near the Jib Max Down to luffing jib angle is 57°...

  • Page 31: Limit Bypass Switch

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 3 – Limit Bypass Switch The limits will remain bypassed for 9-10 seconds after the control handle(s) is returned to off. The Limit Bypass Switch bypasses preset limits (Table 3-2). NOTE...

  • Page 32: 10 - Wind Speed Transmitter

    OPERATING CONTROLS AND PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL 10 – Wind Speed Transmitter • Do not operate, to include raising the boom and luffing jib from ground level, if the wind exceeds the allowable Figure 3-1 limits. Contact your local weather station for wind velocity.

  • Page 33: Section 4

    Anchoring Wire Rope to Button Socket ....... . . 4-35 Manitowoc...
  • Page 34 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Breaking in Wire Rope..........4-37 Pad Eye Usage for Wire Rope Reeving .

  • Page 35: General Setup And Installation

    SETUP AND INSTALLATION GENERAL SETUP AND INSTALLATION This section contains installation and removal instructions for the #135 Luffing Jib on the Model MLC165 Crane. WARNING The luffing jib must be installed, operated, and removed by Avoid Death or Serious injury!

  • Page 36: Accessing Parts

    Optional boom ladders (stored in boom butt) are available section. The boom and luffing jib components (butts, inserts, from Manitowoc. If your crane has ladders see Section 4 of tops, pendants, straps) must be assembled in proper the Crane Operator Manual for instructions.

  • Page 37: Pin And Connecting Hole Cleanliness

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION PIN AND CONNECTING HOLE CLEANLINESS Item Description To prevent dirt from damaging closely machined surfaces of Boom or Jib Chord pins and connecting holes: Boom or Jib Number • Thoroughly clean all pins and connecting holes.
  • Page 38 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...

  • Page 39: Shipping Crane Components

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION SHIPPING CRANE COMPONENTS P2498 It is the owner/user’s responsibility to ensure: • That all trailer loads comply with local, state, and federal transportation requirements. • That all crane components are properly blocked and secured so they cannot shift or fall off trailers.
  • Page 40 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL NOTE The Model MLC165 boom top wire rope guide shown. The Model MLC165-1 boom top wire rope guide has holes in the shafts to which the clamps are fastened. 2.36 in (60,0 mm)

  • Page 41: Preparing Crane For Luffing Jib

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION PREPARING CRANE FOR LUFFING JIB Prepare Boom for Jib The instructions in this section assume that the crane and Figure 4-3 the boom are already fully assembled. Disconnect the required load lines and remove and store...
  • Page 42 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL M100436 View A 14LOM4107 View C M100435 View B Item Description M100437 Jib Stop Strut Assembly Boom Top Lug (2) Lug (2) Pin with Cotter Pins (2) Pin with Snap Pins (2) Pendant—7 ft 9-1/2 in (2,37 m) (2)

  • Page 43: Installing Luffing Jib

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION INSTALLING LUFFING JIB Install Jib Butt Figure 4-4 Install Jib Stop Strut Assembly NOTE The jib butt, jib adapter, and jib strut are shipped as Figure 4-4, View A an assembled unit.
  • Page 44 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Item Description Jib Butt 14LOM4108 Jib Insert—20 ft (6,1 m) Shown Jib Adapter (ships attached to jib butt) Pin with Cotter Pins Jib Top View B M100435 View A 14LOM4162 View C...

  • Page 45: Install Jib Inserts And Top

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Install Jib Inserts and Top Connect Jib Stop Control Cable Figure 4-5 Figure 4-6 Determine the jib length required for the lift to be made. Pay out control cable (4, View A) from hand winch (2) on the jib top.
  • Page 46 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Item Description Basic Jib Pendants Pendant Link Main Strut Jib Strut Not Used Strut Support (erecting) Strut Support (stored) Strut Support Pins Jib Insert Pendant (install with jib inserts) Jib Insert Pendant Link...

  • Page 47: Install Main Strut

    NOTE backstay pendants shipped from (6a, View A). Manitowoc in the coiled position and attached to fork-lift pallets. Install Jib Pendants If desired at disassembly, the backstay pendants Figure 4-7 can be disconnected and left on top of the boom sections for shipping.
  • Page 48 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL 14LOM4161 Item Description Luffing Hoist Wire Rope Wire Rope Guide (boom top) Main Strut Sheaves Jib Strut Sheaves Main Strut Dead-End Link (left side) Terminator Socket and Wedge View A From Luffing Hoist...

  • Page 49: Install Luffing Hoist Wire Rope

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Install Luffing Hoist Wire Rope Anchor the free end of luffing hoist wire rope (1, View C) to left side dead-end link (5) on the main strut with Figure 4-8 socket and wedge (6).
  • Page 50 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL 14LOM4115 View A View B 14LOM4116 Left Side of Main Strut 14LOM4113 View G at Boom Butt 14LOM4117a View C Lowered Position Haul in Load Line to Raise Main Strut While Paying Out Luffing Hoist Wire Rope...

  • Page 51: Raise Main Strut And Connect Backstay Pendants

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raise Main Strut and Connect Backstay Slowly haul in the load line while paying out the luffing hoist wire rope to raise the main strut. Pendants Figure 4-9 CAUTION Jib Strut Damage!
  • Page 52 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Stored M100446 View B Stop Tubes View A M100445 Operating Position 14LOM4108 Working Shipping M100447 View C View D Jib Pendant Connecting Position Item Description Main Strut Stop Tubes Stop Pin Lower Stop Tube...

  • Page 53: Connect Jib Pendants To Jib Strut

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-10, View B Store hold down pins (10) in the hold-down lugs on adapter (11). 18. Slowly haul in the luffing hoist wire rope until the holes in both middle stop tubes (5) line up with the upper holes in Lower pendant links (12, View C) from the shipping both lower stop tubes (4).

  • Page 54: Install Jib Load Line

    SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL INSTALL BOOM LOAD LINE Determine the parts of load line required for the job and size the load block accordingly (see the Wire Rope Depending on boom and jib length, it may be possible to...

  • Page 55: Pre-Raising Checks

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION PRE-RAISING CHECKS  All blocking, tools, and other items removed from boom and jib. Make the following checks and correct any defects before  All blocking, tools, and other items removed from jib raising the attachment.
  • Page 56 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Item Description Jib Stop Beam 7 ft 9.5 in (2,37 m) Jib Stop Pendants 14LOM4125 Jib Stop Strut (stored) Boom Top Lug Pins Pin Storage Hole Quick-Release Pin (installed) 14LOM4124 View D...

  • Page 57: Raising Boom And Jib

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION RAISING BOOM AND JIB Lower the jib stop strut to the operating position (View B). Store pins (6, View A) in boom top lugs (5). Slowly boom up until the ends of jib stop inner strut (9,...
  • Page 58 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Numbered Step Correspond to Raising Procedure Steps 6 to 12 in (152 to 305 mm) M100484 View A M100480 M100477a View B View C M100482 View E M100481 View D M100483 M100478a...

  • Page 59: Raising Procedure

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raising Procedure The jib and backstay pendants will tighten as the boom and jib rise. The item numbers in Figure 4-12 correspond to the Operator: watch the backstay pendants along the left numbered steps in the following procedure.
  • Page 60 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Item Numbers Correspond to Lowering Procedure Steps M100488 M100485 View A View B 6 to 12 in (152 to 305 mm) M100484 M100489a View C View D M100490 View F M100487a View E...

  • Page 61: Lowering Boom And Jib

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION LOWERING BOOM AND JIB balls onto the ground. Then swing the boom and jib in- line with the crawlers and apply the swing brake. WARNING WARNING Falling Boom And Jib Hazard! Tipping Crane Hazard!

  • Page 62: Final Lowering Procedure

    SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Disengage the jib stop strut pins with the hand winch on left side of jib top (Figure 4-6, View A). NOTE The outer end of the jib stop strut pins are painted...

  • Page 63: Removing Jib

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Remove hold-down pins (10, View D) from the stored 21. Tighten the load line as the main strut nears vertical so position in the hold-down lugs on the jib adapter. the strut moves smoothly forward past vertical.

  • Page 64: Wire Rope Installation

    SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL WIRE ROPE INSTALLATION NOTE The wire rope manufacturer’s recommendations take precedence over the information in this Reel section. Wire Rope Storage Drum Brake Store the wire rope in coils or on reels off the ground or floor in a clean and dry indoor location.

  • Page 65: Anchoring Wire Rope To Drum

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Loosely fasten the keeper plates to the drum flange. NOTE Apply Loctite™ 271 to the bolt threads. Seizings Wire Rope Type Required Route the wire rope from the drum through the hole in Preformed the drum flange.

  • Page 66: Winding Wire Rope Onto Drum

    SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Winding Wire Rope onto Drum Wraps of First Layer Tight Against Figure 4-18 Wedge Drum and Against Each Other. P448 See the Drum and Lagging Chart in the Capacity Chart Manual for the correct size of drum laggings, if used.
  • Page 67 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-33 Published 05-25-17, Control # 221-05...
  • Page 68 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL T (Rope Clip Nut Torque) Wire Rope/Clip Size TL (Tail Length) inch 1-1/8 1-1/4 Standard 6 to 8 Strand Wire Rope (mm) (22,23) (25,4) (28,58) (31,75) Minimum of 6 rope diameters, Torque but not less than 6 in (152 mm).

  • Page 69: Anchoring Wire Rope To Wedge Socket

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Anchoring Wire Rope to Wedge Socket will aid in preventing the wire rope from being pulled out of the socket. NOTE Use Right Method A only if the wire rope clip is...
  • Page 70 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL M100461 M100462 M100463 Rope Clips Pull Rigging Line with Winch or Fork-Lift Truck Rigging Line Wire Rope Wire from Drum Rope P1519 Boom Point Sheaves Load Block Sheaves Wire Rope EXAMPLE without Button...

  • Page 71: Breaking In Wire Rope

    General Some rotation-resistant wire rope supplied by Manitowoc is equipped with a No. 1.5 pad eye welded to the leading end of the wire rope or to the button on the end of the wire rope.
  • Page 72 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL 14LOM4145 Single Part Line Two Part Line Two Part Line with Dead End Multiple Part with Dead End at Line Center Shaft at Anchor Joint WARNING Avoid Death or Serious Injury! If you are using a load block that can be stood up vertically for reeving, exercise care, as the potential for tipping exists.

  • Page 73: Load Line Reeving

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION LOAD LINE REEVING • Anchoring wire rope to drums See Wire Rope Lubrication in Section 5. Dead End Locations WARNING See Figure 4-22 for the dead end locations. Falling Load Hazard! Guide Sheaves and Drums Use only a load block or hook and weight ball with a capacity equal to or greater than load to be handled.
  • Page 74 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Wire Rope Routing WITH DRUM 3 Option • Drum 3 to Luffing Jib Struts (see Luffing Jib Assembly Drawing for Reeving) • Front Drum to Luffing Jib Point • Rear Drum to Lower Boom Point OR Not Used...
  • Page 75 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Wire Rope Routing WITH DRUM 3 Option • Drum 3 to Luffing Jib Struts (see Luffing Jib Assembly Drawing for Reeving) • Front Drum Not Used • Rear Drum to Luffing Jib Point (over luffing jib strut UPPER guide sheave)
  • Page 76 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Wire Rope Routing WITH DRUM 3 Option • Drum 3 to Luffing Jib Struts (see Luffing Jib Assembly Drawing for Reeving) • Front Drum Not Used • Rear Drum to Luffing Jib Point (over luffing jib strut LOWER guide sheave)
  • Page 77 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Wire Rope Routing WITHOUT DRUM 3 Option • Front Drum to Luffing Jib Struts (see Luffing Jib Assembly Drawing for Reeving) • Rear Drum to Luffing Jib Point Not Used Figure 4-22...
  • Page 78 SETUP AND INSTALLATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-44 Published 05-25-17, Control # 221-05...

  • Page 79: Section 5

    Lube and Coolant Product Guide ......... . 5-1 Manitowoc...
  • Page 80 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-ii Published 05-25-17, Control # 221-05...

  • Page 81: Lube And Coolant Product Guide

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2261 at the end of this section. LUBE AND COOLANT PRODUCT GUIDE See the publication at the end of this section. Manitowoc Published 05-25-17, Control # 221-05...
  • Page 82 LUBRICATION MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...
  • Page 83 Block-Up Limit Adjustment ......... . . 6-17 Manitowoc...
  • Page 84 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 05-25-17, Control # 221-05...

  • Page 85: General Maintenance

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES SECTION 6 MAINTENANCE PROCEDURES GENERAL MAINTENANCE BOOM AND LUFFING JIB ANGLE INDICATOR This section contains maintenance and adjustment instructions for the limit devices used with the luffing jib Figure 6-1 attachment. An angle sensor (3) is located inside the controller (2) F o r m a i n t e n a n c e a n d i n s p e c t i o n o f t h e f o l l o w i n g mounted on the boom top and on the luffing jib top (1).
  • Page 86 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-25-17, Control # 221-05...

  • Page 87: Automatic Boom Stop

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES AUTOMATIC BOOM STOP The automatic boom stop limit switch assembly (1, Figure 6-2) automatically stops the boom (2) and applies the boom hoist brake if the boom is raised to the maximum boom angle (3).
  • Page 88 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL View A SWITCH OPENED STORED View B SWITCH OPENED View C Left Side of Boom Butt Digital Level Maximum Boom Angle Angle (14) 82.7° Boom without Luffing Jib 74.34° 88.0° Boom with Luffing Jib 79.64°...

  • Page 89: Automatic Boom Stop Adjustment

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES Automatic Boom Stop Adjustment Boom up slowly until the boom reaches the specified angle and stop. Figure 6-3 for the following procedure. d. Turn the adjusting rod (2a or 2b) out against the The limit switch for the automatic boom stop was set at the boom butt (1) until the limit switch (10) “CLICKS”...
  • Page 90 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL M100470 • 80.0° - Start of Spring Cushioning—see View B • 89.5° - Physical Stop (springs solid)—see View C Item Description Boom Butt Physical Boom Stop (2) Strut Outer Tube Inner Tube Rod End...

  • Page 91: Physical Boom Stop

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES PHYSICAL BOOM STOP • Assist in preventing the boom rigging from pulling the boom back when traveling or setting loads with the Figure 6-4 boom at any angle above 80°. • Assist in moving the boom forward when lowering the boom from any angle above 80°.
  • Page 92 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Deactivated Activated Item Description Edge of Actuator Rod to Edge of 15.18 in (385,6 mm) 14.91 in (378,7 mm) Limit Switch Housing Edge of Actuator Rod to Front Edge 6.07 in (154,2 mm) 5.84 in (148,4 mm)

  • Page 93: Jib Stop

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES JIB STOP • The luffing jib angles must be properly calibrated. See the RCL/RCI Operation Manual for instructions. Figure 6-5 Jib Max Up 2 Limit Check Perform the following steps with the boom and luffing jib on...

  • Page 94: Jib Stop Actuator Rod Replacement

    MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Turn the limit bypass key switch clockwise to bypass the 15. The luffing hoist must stop and be inoperable in down Jib Max Up 1 angle. direction when boom to luffing jib angle is 57°.
  • Page 95 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES View B Switch Activated Circuit Opened or 3b Roller Over-Travel View A Switch Deactivated Circuit Closed M100472 Item Description View A Adjusting Rod Switch Deactivated Circuit Closed Lock Nut Actuator Rod (Jib Max Up 2 Limit Switch)
  • Page 96 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL M100473 Far Side 1-Part Line View B Near Side 3 or Dead-End Load Line or 4-Part Line Slowest Live Line 2-Part Line View C See Load Block Reeving Diagrams for Suggested Location of Weight...

  • Page 97: Block-Up Limit

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES BLOCK-UP LIMIT Two-blocking can result in failure of sheaves and wire rope, possibly causing load to fall. The block-up limit system consists of the following components (Figure 6-7): WARNING • Jib top controller Two-Blocking Hazard! •...
  • Page 98 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MLC165-1 M100474 MLC165 Boom Luffing Jib FIGURE 6-8 6-14 Published 05-25-17, Control # 221-05...

  • Page 99: Disconnecting Block-Up Limit Switches

    (C2). used. Disconnect electric cable (WWLJ) from wind speed Disconnecting Wind Speed Controller controller (C3) for the MLC165 or from electric cable (WJT2) for the MLC165-1. Figure 6-8 Connect sealing caps to the ends of all disconnected Connect terminating plug (TP) to receptacle (J2) if electric cables and receptacles.
  • Page 100 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL A1007 Limit Switch Wiring Switch Wire Terminals Black White Item Description Limit Switch Cover Shaft Limit Switch Lever Dimension A Roller 1.04 in (26 mm) Actuating Lever Grease Fitting Adjusting Screw Enclosure Spring...

  • Page 101: Block-Up Limit Maintenance

    MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL MAINTENANCE PROCEDURES Block-Up Limit Maintenance CAUTION CAUTION Avoid Sheave Damage! Prevent Damage! Use extreme care when testing block-up limit controls when boom and jib are raised. To prevent two-blocking from occurring, do not operate crane until cause for improper operation and all If block-up limit control fails to stop load, immediately stop hazardous conditions have been found and corrected.
  • Page 102 MAINTENANCE PROCEDURES MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-18 Published 05-25-17, Control # 221-05...
  • Page 103 Manitowoc Dealer ........
  • Page 104 MLC165/MLC165-1 LUFFING JIB OPERATOR MANUAL Wind Conditions ..............3-10 Wire Rope Installation .

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Mlc165-1

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