Manitowoc MLC165-1 Service Maintenance Manual
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Manitowoc MLC165-1 Service Maintenance Manual

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Manitowoc MLC165-1
Service/Maintenance Manual

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Summary of Contents for Manitowoc MLC165-1

  • Page 1 Manitowoc MLC165-1 Service/Maintenance Manual...
  • Page 3 NOTICE The serial number of the crane and applicable attachments (for example, luffing jib) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator cab and each attachment.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    MLC165-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1..........Introduction Continuous Innovation .
  • Page 6 TABLE OF CONTENTS MLC165-1 SERVICE/MAINTENANCE MANUAL Drum Identification ............. . . 3-1 Electrical Power Sequence .
  • Page 7 MLC165-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Removing Straps from Service ..........4-12 Inspection Checklist.
  • Page 8 TABLE OF CONTENTS MLC165-1 SERVICE/MAINTENANCE MANUAL SECTION 6 ..........Swing System Swing System Overview .
  • Page 9 MLC165-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Reverse Travel ............. . . 8-1 Travel Speed Selection .
  • Page 10 TABLE OF CONTENTS MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 05-26-17, Control # 238-02...
  • Page 11 Identification and Location of Components ..........1-5 Manitowoc...
  • Page 12 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 05-26-17, Control # 238-02...

  • Page 13: Section 1

    Due to continuing product innovation, the information in this CAUTION manual is subject to change without notice. If you are in doubt about any procedure, contact your Manitowoc dealer Used with the safety alert symbol, indicates a hazardous or the Manitowoc Crane Care Lattice Team.

  • Page 14: Safe Maintenance Practices

    Read This Manual constant verbal communication between the person at the controls and the person performing the To ensure safe and proper operation of Manitowoc cranes, maintenance or repair procedure. they must be maintained according to the instructions contained in this manual.

  • Page 15: Stored Energy Safety Precautions

    Avoid battery acid contact with skin and eyes. If contact • Unless authorized in writing by Manitowoc, do not alter occurs, flush the area with water and immediately t h e c r a n e i n a n y w a y t h a t a f f e c t s t h e c r a n e ’ s consult a doctor.

  • Page 16: Environmental Protection

    Dispose of waste properly! Improperly disposing of Air Conditioning Relay waste can cause environmental damage. Auto Lube Pump Potentially harmful waste used in Manitowoc cranes Alternator includes—but is not limited to—oil, fuel, grease, coolant, air Auxiliary conditioning refrigerant, filters, batteries, and cloths which Boom Hoist have come into contact with harmful substances.

  • Page 17: Identification And Location Of Components

    MLC165-1 SERVICE/MAINTENANCE MANUAL INTRODUCTION IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Lowerworks Upperworks Boom Butt Boom Stop (physical) Boom Butt Wire Rope Guide Drum 3 (luffing hoist or auxiliary) Insert: 6 m (19.7 ft) with Sheaves Guide Sheaves (in insert) Load Lines Insert: 3 m (9.8 ft)
  • Page 18 INTRODUCTION MLC165-1 SERVICE/MAINTENANCE MANUAL The legend is on next page. Figure 1-2. Right Side View Published 05-26-17, Control # 238-02...
  • Page 19 MLC165-1 SERVICE/MAINTENANCE MANUAL INTRODUCTION Legend for Figure 1-2 Item Description Rotating Bed Carbody Ladder (optional) Right Crawler Right Enclosure with Platform (see NOTE) Mast-Assist Cylinder (both sides) Mast-Assist Arm (both sides) Drum 4 (boom hoist) Generator (optional) Radiator and Coolers...
  • Page 20 INTRODUCTION MLC165-1 SERVICE/MAINTENANCE MANUAL The legend is on next page. Figure 1-3. Left Side Published 05-26-17, Control # 238-02...
  • Page 21 MLC165-1 SERVICE/MAINTENANCE MANUAL INTRODUCTION Legend for Figure 1-3 Item Description 1-10 Figure 1-2 Crane Counterweights Counterweight Handling Cylinder Boom Hoist Wire Rope Mast Self-Assembly Cylinder Engine Enclosure Left Enclosure with Platform (see NOTE) Handrail (optional both sides) Drum 2 (rear drum)
  • Page 22 INTRODUCTION MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-10 Published 05-26-17, Control # 238-02...

  • Page 23: Section 2

    Swing Brake Test............. 2-35 Manitowoc...
  • Page 24 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-26-17, Control # 238-02...

  • Page 25: Hydraulic System Overview

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OVERVIEW components to form working circuits be found in the appropriate functional sections of this manual. This section provides a physical description and general functional overview of the major hydraulic components. The...

  • Page 26: Main Pump

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Main Pump 304 and horsepower override solenoid HS-303, which are activated by node 3. The load-sensing override function is The main pump (Figure 2-2) is part of the open hydraulic not currently used. In horsepower override, software control system and contains two variable-displacement pumps.

  • Page 27: Swing Pump

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Swing Pump proportional solenoid valves at the swing pump. See Swing Pump Control on page 6-3 for a detailed description of the The swing pump (Figure 2-3) is part of a closed system swing pump and swing system control.

  • Page 28: Accessory Pump

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Accessory Pump Free Fall Cooling Pump T h e a c c e s s o r y p u m p ( F i g u r e 2 -4 ) i s a v a r i a b l e -...

  • Page 29: Fan Cooling Pump

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Fan Cooling Pump The fan cooling pump (Figure 2-6) is part of the open Item Description hydraulic system and is a variable-displacement pump that Outlet Port provides flow to the cooling fan motor. The displacement is L, L1 Case Drain Ports controlled by a solenoid valve HS-504, driven by node 5.

  • Page 30: Drum 1 And 2 Motors

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Drum 1 and 2 Motors Figure 2-7 illustrates the motor for each drum, 1 and 2. See Drum 1 and Drum 2 Motor on page 5-5 for a detailed operational description of the Drum 1 and 2 systems.

  • Page 31: Swing Motor

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Swing Motor Figure 2-9 illustrates the swing motor. See Swing System Overview on page 6-1 for a detailed operational description of the swing system. Item Description A, B Pressure Ports T1, T2 Case Drain Ports M100912 Figure 2-9.

  • Page 32: Travel Motors

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Travel Motors Figure 2-11 illustrates the travel motor. See Travel Overview on page 8-1 for a detailed operational description of the travel system. Item Description Item Description A, B Pressure Ports MA, MB Measuring Pressures for A & B...

  • Page 33: Main Control Valve Manifold

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Main Control Valve Manifold manifold. The solenoid valve shifts an on-off valve which connects the load sense and working pressure flows within The main control valve manifold (Figure 2-12) controls flow the two halves of the control valve manifold.

  • Page 34: Pilot Brake And Pawl Manifold

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Pilot Brake and Pawl Manifold The pilot brake and pawl manifold receives flow from the charge pump within the main pump. Solenoid valves in the manifold control flow to the brake and pawl functions listed in Figure 2-13.

  • Page 35: Accessory Manifold

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Accessory Manifold accessory valve, HS-502, of the manifold is driven by node 5. When the operator enables the manual valves from the The accessory manifold receives flow from the accessory main display screen, HS-502 opens, providing flow to the pump.

  • Page 36: Pilot Signal Manifold

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Pilot Signal Manifold Solenoid valves SV1–SV8 allow the control system to configure which handles control which drum functions. The pilot signal manifold (Figure 2-15) receives flow from Proportional solenoid valves PV1–P8 allow the control each hydraulic proportional control handle in the cab.

  • Page 37: Free Fall Manifold

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Free Fall Manifold Cooler Bypass Manifold The free fall manifold is illustrated in Figure 2-16. The hydraulic oil cooler bypass manifold is illustrated in Figure 2-17. Front of Right-Side Enclosure Under Rear of Rotating Bed Looking Rearward...
  • Page 38 HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-14 Published 05-26-17, Control # 238-02...

  • Page 39: Hydraulic System Specifications

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Hydraulic System Specifications Table 2-1 Hydraulic Specifications System System Valve/Pump Pilot Pressure Speed Function Direction Pressure 2 Pressure 1 Port psi (bar) psi (bar) psi (bar) Drum 1 Valve B6 5,076 (350) 507 (35) Down...

  • Page 40: Hydraulic System Maintenance

    MLC165-1 Main Display Operation manual. • When handling drums and transfer containers, use care to avoid damage which can cause leaks and entry of dirt Contact your Manitowoc dealer for an explanation of any or water into the oil. procedure not fully understood. •...

  • Page 41: Inspecting The Hydraulic System

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Inspecting the Hydraulic System • Check for external leaks. Leaks are not only unsafe, they also attract dirt, and in some cases, allow air and The damaging effects of dirt, heat, air, and water in the water to enter system.

  • Page 42: Inspecting And Replacing Hydraulic Hoses

    Hydraulic Component Damage At the same service interval, visually inspect all other Do not alter hydraulic system specifications given in this hydraulic components and valves for: section without approval of the Manitowoc Crane Care Lattice Team. • Leaking ports Damage to hydraulic components and improper operation •...

  • Page 43: Tightening Hydraulic Connections

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Tightening Hydraulic Connections • Be careful not to cut O-rings when assembling them onto fittings. Use a thimble as shown in Figure 2-18 • Make sure the fittings and O-rings being used are the when assembling O-ring over threads.
  • Page 44 HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Pipe Thread Connection Tighten SAE straight thread connections as follows: 1. Back up the jam nut and washer to the end of the 1. Apply sealant (Loctite 92 or equivalent) to male threads, smooth portion on the fitting as shown in...
  • Page 45 MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM ORS Connection Table 2-5 ORS Assembly Torque NOTE ORS is the registered trade mark for a face-type Nut Size Torque Fitting seal manufactured by Aeroquip Corporation. Across Flats Size In-Lb in (mm) 1. Lubricate and install the O-ring into the adapter groove 5/8 (15,9) 120 –...
  • Page 46 HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Split Flange Connection A Dimension Torque inch (mm) 1. Lubricate and install the O-ring in the shoulder groove (see Figure 2-22). Align the shoulder with the port and Flange assemble the flanges over the shoulder.
  • Page 47 MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Flare Connection 4. Misalignment of the marks will show how much the nut has been tightened, and best of all that it has been 1. Tighten the nut finger-tight until the sealing surfaces tightened.

  • Page 48: Replacing Desiccant Breather Cartridge

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Left-Side Enclosure Item Description Item Description Cover Hydraulic Tank Fill Plug Access Cover Return Filter (3) Breather Access Cover Filter Cap Air Vent Valves (2) Filter Body Breather Cartridge Filter Element Reusable Cap (do not discard)

  • Page 49: Replacing Return Filters

    Use care not to damage O-rings. Original Equipment Manufacturers’ filter elements— b. Twist and pull the filter elements (7c) to remove it available from Manitowoc—must be used on this crane. from the filter body (7b). Substituting with any other brand or type filter element is not allowed.

  • Page 50: Replacing Pilot Filter

    CAUTION Avoid Hydraulic System Damage Original equipment manufacturers’ filter elements— available from Manitowoc—must be used on this crane. Substituting with any other brand or type of filter element is not allowed. Filter elements made by other manufacturers may collapse under pressure.

  • Page 51: Replacing The Swing Filter

    Filter Element O-Ring CAUTION Avoid Hydraulic System Damage Original Equipment Manufacturers’ filter elements— available from Manitowoc—must be used on this crane. Substituting with any other brand or type filter element is not allowed. Filter elements made by other manufacturers may collapse under pressure.
  • Page 52 HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Item Description Cover Drain Pipe Air Vent Valves (2) Locking Pin (pull out to turn handle) Breather (see NOTE) Shut-off Handle Manual Fill Port Plug (see NOTE) Closed Position Return Filters (3) Opened Position...

  • Page 53: Changing The Hydraulic Oil

    19. Fill the tank to the Full Cold Level end of the hose into a suitable container to catch the symbol next to the oil level gauge hydraulic oil. See the MLC165-1 Lubrication Guide for (11). the hydraulic system capacity.

  • Page 54: Servicing The Pumps

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Servicing the Pumps 7. If testing a pilot pressure, actuate the function for the pressure being read. It is not necessary to drain the hydraulic tank when servicing 8. Verify the gauge pressure and the pressure displayed at the hydraulic pumps.

  • Page 55: Hydraulic Tests And Calibrations

    6. Travel the crane in reverse at full speed for one minute understand, and comply with the instructions in this section while the assistant walks along side the crane and and to the display screen instructions in the MLC165-1 Main counts the timing mark revolutions. Display Operation manual.

  • Page 56: Swing Speed Test

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Swing Speed Test 2. Start engine and run at high idle. 3. Move the swing handle fully left. NOTE Perform this check in an area where crane can be swung without interference. 4. At the Swing Diagnostic screen, verify the swing speed...

  • Page 57: Pressure Transducer Test

    MLC165-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pressure Transducer Test The pressure transducer test calculates the zero-pressure M100858 output level for each pressure transducer. It is only necessary to perform this procedure at the specified intervals or when necessary during troubleshooting. Perform this test whenever: •...

  • Page 58: Controls Calibration

    HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Controls Calibration A controls calibration calculates the pump threshold M100860 command level for the swing and accessory pump controls. Perform this calibration when: • A new swing pump, motor, or control coil is installed. •...

  • Page 59: Drum Brake Test

    4. At the display, navigate to the diagnostic screen for 4. Swing the crane by moving control handle in both function being checked (See the MLC165-1 Main directions and verify the rotating bed swings freely. Display Operation manual for display navigation instructions).
  • Page 60 HYDRAULIC SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-36 Published 05-26-17, Control # 238-02...
  • Page 61 Node 0 — Engine ............3-32 Manitowoc...
  • Page 62 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 05-26-17, Control # 238-02...

  • Page 63: Drum Identification

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM DRUM IDENTIFICATION • A/C and heater • Wiper motors The drum numbers given in Figure 3-1 are used to identify the drums in this section. • Panel lights • Work lights Front of Crane •...

  • Page 64: Master Node (Node 1)

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL M100791 Figure 3-2. CAN Bus Major Functions Master Node (Node 1) Micro- The microprocessor within the master node executes the processor main control program for crane operation and contains memory for lookup information such as load charts. Digital...

  • Page 65: Engine Node (Node 0)

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Engine Node (Node 0) Universal Nodes (Nodes 3–5) The microprocessor within the engine node communicates T h e m i c r o p r o c e s s o r s w i t h i n t h e u n i v e r s a l n o d e s with the engine control module (ECM).

  • Page 66: Motor Speed Sensors

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Motor Speed Sensors Limit Switches — Single Contact A universal node provides power to Hall-effect speed In the non-tripped state, a universal node provides power to sensors within the hydraulic motors that drive the drums and the normally closed contact.

  • Page 67: Mast Angle Sensors

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Mast Angle Sensors Hydraulic Fluid Level Sensor A universal node provides power to the mast angle sensor. A universal node provides power to the hydraulic level The sensor outputs an analog signal that is proportional to sensor.

  • Page 68: Graphic Nodes

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Graphic Nodes Boom and Luffing Jib Remote Input Nodes Two graphic nodes reside on the CAN Bus. Each graphic The boom RIN contains digital inputs to read the block-up node contains a display module and graphic controller. The and jib angle limit switches.

  • Page 69: Solenoid Valve Identification

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SOLENOID VALVE IDENTIFICATION HS # Description Wire # HS-414 Swing Brake Each hydraulic solenoid valve (HS) is assigned a number (#) HS-415 Travel High Speed for troubleshooting. The wire number of each solenoid can be found in the electrical schematics.

  • Page 70: Circuit Breakers

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL CIRCUIT BREAKERS Engine Node Circuit breakers CB-1 through CB-9 are mounted in the Alternator Circuit engine node 0 (Figure 3-12). For the Tier 3 engine, a 120-amp circuit breaker (CB-0) is in the circuit between the alternator and the starter. The circuit...

  • Page 71: Operator Cab

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM operator cab Grid Heater Four circuit breakers and four fuses are mounted in the rear For the Tier 3 engine, a 120 amp circuit breaker (3) console behind the operator seat (Figure 3-13). (Figure 3-14) and one high power relay contactor (4) is located in the grid heater junction box (1) mounted in the left- front side of the engine compartment.

  • Page 72: Exhaust Aftertreatment System

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Exhaust Aftertreatment System 240 VAC Electric System For the Tier 4 engine, three circuit breakers and five relays The circuit breakers for the optional cold weather heater are located inside the exhaust aftertreatment junction box (1,...

  • Page 73: Checking And Replacing Electrical Components

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CHECKING AND REPLACING ELECTRICAL Loose junction box mounting hardware COMPONENTS I f a n y o f t h e s e c o n d i t i o n s e x i s t , a d d r e s s t h e m appropriately.

  • Page 74: Node Locations

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Node 0, Engine Node Node 1, Master Node Node 2, Side Console Node Node 3, Universal Node Node 4, Universal Node Node 5, Universal Node Figure 3-17. Node Locations 3-12 Published 05-26-17, Control # 238-02...

  • Page 75: Component To Node Identification

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Node Locations Component to Node Identification Figure 3-17 shows the locations of the nodes on the rotating Table 3-2. shows which major functions are connected to bed. Figure 3-18 shows the locations of the nodes in the each node.

  • Page 76: Pump And Motor Voltages And Currents

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Pump and Motor Voltages and Currents Abbreviations Table 3-3. shows the voltages and currents of the pumps, The following abbreviations are used in test voltage tables: hoists, and travel motors. Alternating Current Table 3-3. Pump and Motor Voltages and Currents...

  • Page 77: Checking Electrical Inputs/Outputs (Using The Test Box)

    Electrical Test Kit at universal nodes or Manitowoc Unit 2. Determine which signal contains the suspected fault. Tester at all nodes. The Electrical Test Kit or Manitowoc Unit 3. Disconnect the node cable (1) from the node connector Tester can be ordered from your Manitowoc dealer.

  • Page 78: Checking Electrical Inputs/Outputs (Using The Test Board)

    Electrical Test Kit at universal nodes or Manitowoc Unit 2. Determine which signal contains the suspected fault. Tester at all nodes. The Electrical Test Kit or Manitowoc Unit 3. Disconnect the node cable (1) from the node connector Tester can be ordered from your Manitowoc dealer.

  • Page 79: Test Voltages

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM TEST VOLTAGES — (Engine Node 0 only) indicates input to Receptacle/Pin No. receptacle number and pin number code (J2-1). Node Heading Descriptions Wire No. — (Engine Node 0 only) indicates wire to computer receptacle (0107) or wire number code (6C12A).

  • Page 80: Node 1 - Master

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Node 1 — Master See Electrical Schematic 81019880, Sheets 7 and 18 (at end of this section). Connector Function CAN Packet Description Test Voltages Number Type Number Receptacle Front Console – (Not Used Terminals are Omitted)
  • Page 81 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM P12-24 DI-22 Engine Run/Start 0 Volts Off; 24 Volts On CAN92-5-32 P12-25 DI-7 Travel Park Switch 0 Volts Off; 24 Volts On CAN92-3-64 P12-26 DI-17 Boom Hinge Pins Disengage 0 Volts Off; 24 Volts On...

  • Page 82: Node 2 - Alarms, Switches, And Gauge Panel

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Node 2 — Alarms, Switches, and Gauge Panel See Electrical Schematic 81019880, Sheets 7 through 9 and 19 (at end of this section). Connector Function CAN Packet Description Test Voltages Number Type Number Receptacle – Controls (Not Used Terminal are Omitted)
  • Page 83 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM P52-15 DO-1 RCI Beacon Light Green 0 Volts Off, 24 Volts On CAN20-1-1 P52-16 DO-22 System Operation Alarm 0 Volts Off, 24 Volts On CAN20-3-32 P52-17 DO-24 Rated Capacity Indicator/Limiter Fault Alarm 0 Volts Off, 24 Volts On...

  • Page 84: Node 3 - Drum Control And Limit Switches

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Node 3 — Drum Control and Limit Switches See Electrical Schematic 81019880, Sheets 10, 11, 20, and 21(at end of this section). Receptacle Function CAN Packet Description Test Voltages Number Type Number J1-WN10 I/O Cable — From Node 2 to Node 3...
  • Page 85 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM 1 Volt at 0 psi (0 bar), 33-p AI-7 Handle 2 (Drum 2) Up Pilot Pressure Sender CAN5-6 5 Volts at 870 psi (60 bar) 1 Volt at 0 psi (0 bar), 33-r AI-8 Handle 2 (Drum 2) Down Pilot Pressure Sensor...
  • Page 86 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL 36-C Ground Max Boom Angle Limit/Drum 2 Motor Control Ground 36-D DO-8 0 Volts Off; 24 Volts On Drum 2 Motor Control HS-308 CAN21-1-128 36-E Ground Handle 3 Up/Down Pilot Pressure Sensor Ground 36-F DO-9 0 Volts Off;...

  • Page 87: Node 4 - Swing Control, Drum Brake And Pawl Control

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Node 4 — Swing Control, Drum Brake and Pawl Control See Electrical Schematic 81019880, Sheets 12, 20, and 21 (at end of this section). Receptacle Function CAN Packet Description Test Voltages Number Type Number J7-WN18 I/O Cable —...
  • Page 88 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL J6/W46 Receptacle – Sensors, Pressure Senders, Alarms, and Auto Lube 46-A Ground Accessory Enable HS-407 Ground 46-B DO-7 Accessory Enable HS-407 0 Volts Off; 24 Volts On CAN23-1-64 46-C Ground Auto Grease Swing Ground 46-D Auto Grease Swing 0 Volts Off;...

  • Page 89: Node 5 - Accessories

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Node 5 — Accessories See Electrical Schematic 81019880, Sheets 13, 14, 20, and 22 (at end of this section). Receptacle Function CAN Packet Description Test Voltages Number Type Number J1-WN10 I/O Cable — From Engine Node J3/W53 Receptacle –...
  • Page 90 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL 54-D DO-12 Counterweight Pins Out HS-512 0 Volts Off; 24 Volts On CAN24-2-8 Ground 54-E Ground Counterweight Cylinder Left Up HS-513 54-F DO-13 Counterweight Cylinder Left Up HS-513 0 Volts Off; 24 Volts On CAN24-2-16...
  • Page 91 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM 56-f AI-14 Boom Hinge Pins Disengage 0 Volts Off; 24 Volts On CAN19-2-32 24 Volts Nominal 56-g 24 Volts Drum 2 Free Fall Flange Encoder 56-h AI-15 Mast Cylinders Extend (Remote) 0 Volts Off; 24 Volts On...

  • Page 92: Boom Remote Input Node 30

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Boom Remote Input Node 30 See Electrical Schematic 81019880, Sheet 27 and 28 (at end of this section). Receptacle/ Wire No. Description Test Voltage RIN ID Receptacle – Input/Output 301A System Power 12 Volts Nominal...

  • Page 93: Luffing Jib Remote Input Node 31

    MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Luffing Jib Remote Input Node 31 See Electrical Schematic 81019880, Sheet 27 and 28 (at end of this section). Receptacle/ Wire No. Description Test Voltage RIN ID Receptacle – Input/Output 311A System Power 12 Volts Nominal...

  • Page 94: Node 0 - Engine

    ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Node 0 — Engine See Electrical Schematic 81019880, Sheet 16 (at end of this section). Receptacle/ Function Wire No. Description Pin No. Type Battery Power J1-A Ground Battery Ground J1-B 6 - 1 24 Volts...
  • Page 95 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM J7-2 RS232RX Signal RS232 Program Receive J7-3 RS232PE Signal RS232 Program Enable J7-4 RS232GND Ground RS232 Program Ground Boom Cable J8-A 12F2 24 Volts Boom Node Power J8-B 0126 DI Signal Boom Node Digital Input...
  • Page 96 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Table 3-4. Digital Input Reference Item Description CAN Packet Item Description CAN Packet Number (Node Number) Number (Node Number CAN36-1-1 Free Fall Safety Switch Left Pedal CAN92-3-8 Drum 0 Park Switch CAN36-1-2 Self Assembly Cylinder Retract...
  • Page 97 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-5. Digital Output Reference CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) CAN20-1-1 RCI Beacon Light Green CAN23-2-4 Travel Pilot HS-411 CAN20-1-128 Seat Safety Switch CAN23-2-64 Travel High Speed HS-415 CAN20-1-16 RCI Beacon –...
  • Page 98 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Table 3-6. Digital Output Disable Reference CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) CAN30-1-1 RCI Beacon Light Green CAN30-1-128 Seat Safety Switch CAN33-2-1 Swing Control Right HS-409 CAN30-1-16 RCI Beacon –...
  • Page 99 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-7. Bank Identifiers Manitowoc 3-37 Published 05-26-17, Control # 238-02...
  • Page 100 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Table 3-7. Bank Identifiers (continued) 3-38 Published 05-26-17, Control # 238-02...
  • Page 101 MLC165-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-7. Bank Identifiers (continued) Manitowoc 3-39 Published 05-26-17, Control # 238-02...
  • Page 102 ELECTRICAL SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Table 3-7. Bank Identifiers (continued) 3-40 Published 05-26-17, Control # 238-02...

  • Page 103: Section 4

    Lattice Section Inspection and Lacing Replacement ........4-15 Manitowoc...
  • Page 104 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-ii Published 05-26-17, Control # 238-02...

  • Page 105: Automatic Boom Stop

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP The automatic boom stop limit switch assembly (1, Figure 4-1) automatically stops the boom (2) and applies the boom hoist brake if the boom is raised to the maximum boom angle (3).
  • Page 106 BOOM MLC165-1 SERVICE/MAINTENANCE 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° Item...

  • Page 107: Automatic Boom Stop Adjustment

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM Automatic Boom Stop Adjustment Boom up slowly until the boom reaches the specified angle and stop. Figure 4-2 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 108 BOOM MLC165-1 SERVICE/MAINTENANCE 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 Boom Stop Pin...

  • Page 109: Physical Boom Stop

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP • Assist in preventing the boom rigging from pulling the boom back when traveling or setting loads with the Figure 4-3 boom at any angle above 80° • Assist in moving the boom forward when lowering the boom from any angle above 80°...

  • Page 110: Boom And Luffing Jib Angle Indicator

    BOOM MLC165-1 SERVICE/MAINTENANCE MANUAL 3.2° Notch Wire Color Wire ID Description FROM TO (see Note) Black ANGGND Ground Green ANGSIG Signal ANGPWR 5 VDC Item Description White Not Used Luffing Jib Top Controller NOTE Wires go to terminals on printed circuit Sensor board in bottom of controller.

  • Page 111: Mast Angle Sending Unit

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM 2. Place a digital protractor-level (1) on the left mast leg (2) and note the mast angle. M100695 3. Go to the mast angle readout (4) on the information screen of the main display. Note the mast angle.

  • Page 112: Strap Inspection And Maintenance

    Service Manual, contact your must be within all specifications identified in this dealer or the Manitowoc Crane Care Lattice Team. section. Any damage found must be recorded and a determination made as to whether continued use of strap is safe.

  • Page 113: Replacement Specifications

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM Replacement Specifications Any strap not within specifications listed in Table 4-1 must be replaced. WARNING View A I f d a m a g e t o s t r a p e x c e e d s t h a t a l l o w e d w i t h i n...

  • Page 114: Straightness

    BOOM MLC165-1 SERVICE/MAINTENANCE MANUAL Table 4-2 Strap Straightness Corrosion or Abrasion Strap Length Maximum Deviation P325 Allowed 1,5 to <3,0 m (5 to <10 ft) 1,5 mm (0.060 in) 3,0 to <6,1 m (10 to <20 ft) 3,2 mm (0.125 in) 6,1 to <9,1 m (20 to <30 ft)

  • Page 115: Storing Straps

    If dimension A is greater than 0,8 mm (0.030 in), reduction in thickness will exceed the maximum allowed. contact the Manitowoc Crane Care Lattice Team . A full periodic inspection is required for straps returned to service from storage.

  • Page 116: Removing Straps From Service

    BOOM MLC165-1 SERVICE/MAINTENANCE MANUAL Removing Straps from Service checklists may be required to verify warranty or product liability claims. Straps removed from service should be clearly marked to If no damage is found or damage is within specification, prevent accidental future use. Rendering the strap useless in ...
  • Page 117 MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date Length mm (ft) Part Number Corrosion Kinks Cracks Dents Breaks Straightness Elongated Holes Abrasion Length Flatness Other Length mm (ft) Part Number Corrosion Kinks Cracks Breaks Dents Abrasion Length...
  • Page 118 BOOM MLC165-1 SERVICE/MAINTENANCE MANUAL NOTES SKETCHES AND PHOTOGRAPHS 4-14 Published 05-26-17, Control # 238-02...

  • Page 119: Lattice Section Inspection And Lacing Replacement

    MLC165-1 SERVICE/MAINTENANCE MANUAL BOOM LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 1316 at the end of this section for lattice section inspection and lacing replacement instructions. Manitowoc 4-15 Published 05-26-17, Control # 238-02...
  • Page 120 BOOM MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-16 Published 05-26-17, Control # 238-02...

  • Page 121: Section 5

    Removal ..............5-37 Manitowoc...
  • Page 122 MLC165-1 SERVICE/MAINTENANCE MANUAL Installation ............. . 5-37 Adjustment .

  • Page 123: Hoist Theory Of Operation

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS HOIST THEORY OF OPERATION • control software governs operational characteristics differently for each hoist. This section will discuss the electrical and hydraulic control • A free fall option is available for hoists 1 and 2. See Free of the crane hoists.
  • Page 124 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL For drum 1 and 2 motor detail, Figure 5-3 on page 5-6. For drum 3 and 4 motor detail, see Figure 5-4 on page 5-7. M100832 Electrical Connection Working Flow Pilot or other non-working flow Figure 5-2. Hoist System Diagram...
  • Page 125 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Legend for Figure 5-2 on page 5-2. Item Description Item Description Accumulator Combined Flow Valve Pilot Pressure Unloading Valve Speed Switch Drum Brake Valve Load Sense Check Valve/Orifice Drum Pawl Valve (Drum 1 only) Double Main Pump...

  • Page 126: Working And Pilot Flow Components

    The proportional flow valves are used to limit the motor hoist drum from lowering. speed by a percentage. This percentage is set by the operator in the crane control screens (see the MLC165-1 Main Display Operation manual for instructions). Published 05-26-17, Control # 238-02...

  • Page 127: Drum Pawl

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum Pawl Pressure Compensation Override (PCOR) The PCOR ensures that the motor delivers sufficient torque The drum pawls are controlled by node 4 voltage, the drum when required. When working pressure (a reflection of load) pawl directional control valves, and the park switches in the reaches 4,000 psi (275 bar), the PCOR begins shifting the cab.For pawl operation see:...
  • Page 128 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Test Meter Port P o r t M 1 i s i n t h e P C O R o u t p u t p i l o t c i r c u i t t o t h e displacement control hydraulic cylinder.

  • Page 129: Drum 3 And Drum 4 Motor

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 and Drum 4 Motor Test Meter Ports Ports MA and MB are for connecting a pressure test meter to Figure 5-4. the respective work flow circuit. The fixed axial piston motors for hoists 3 and 4 are identical.

  • Page 130: Free Fall System (Optional)

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Free Fall System (Optional) not have a speed sensor. Drum speed is taken from an external speed sensor assembly (See Speed Sensor—Free Drum 1, Drum 2, or both drums can be equipped with the Fall Drum on page 5-11).
  • Page 131 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Electrical Connection Working Flow Pilot or other non-working flow M100862 Item Description Free Fall Manifold For the remainder of the hoist hydraulic Free Fall Enable Solenoid system diagram, see Hoist System Diagram on page 5-2 Check Valve...
  • Page 132 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL To release the free fall brake, three conditions must be met: • The hydraulic valve (5, Figure 5-6 on page 5-9) is in the open (on) position. • The clutch/brake pedal is all the way down until it latches.

  • Page 133: Electrical Diagrams

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Speed Sensor—Free Fall Drum When the drum rotates, an encoder on the speed sensor assembly (Figure 5-25 on page 5-35) sends a 24 volt direction and speed signal to the control system. The control system sends a 24 volt output to a rotation indicator (thumper solenoid) in the control handle.
  • Page 134 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL M100837 Figure 5-9. Electrical Controls—Drum 1 (Front Main Hoist) 5-12 Published 05-26-17, Control # 238-02...
  • Page 135 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS M100865 Figure 5-10. Electrical Controls—Drum 2 (Rear Main Hoist) Manitowoc 5-13 Published 05-26-17, Control # 238-02...
  • Page 136 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL M100867 Figure 5-11. Electrical Controls—Drum 3 (Auxiliary or Luffing Hoist) 5-14 Published 05-26-17, Control # 238-02...
  • Page 137 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS M100864 Figure 5-12. Electrical Controls—Drum 4 (Boom Hoist) Manitowoc 5-15 Published 05-26-17, Control # 238-02...
  • Page 138 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL M100866 Figure 5-13. Electrical Controls—Drum 1 with Free Fall 5-16 Published 05-26-17, Control # 238-02...
  • Page 139 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS M100868 Figure 5-14. Electrical Controls—Drum 2 with Free Fall Manitowoc 5-17 Published 05-26-17, Control # 238-02...
  • Page 140 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-18 Published 05-26-17, Control # 238-02...

  • Page 141: Drum Gearboxes

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM GEARBOXES Quick-Drain Valve Each drum gearbox is filled with gear oil and is not open to Each drum gearbox is equipped with a quick-drain valve the inside of the drum. Only the gearbox itself contains oil.

  • Page 142: Drums 1 And 2 Gearbox With Free Fall Option

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Drums 1 and 2 Gearbox with Free Fall Option d. Thread the quick-drain drainer assembly all the way onto the quick-drain valve (6). The poppet inside the Figure 5-16 for the following instructions. valve will open.

  • Page 143: Drums 1 And 2 Gearbox Without Free Fall Option

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Drums 1 and 2 Gearbox without Free Fall Option Connect the hose from the quick-drain drainer assembly to a portable pump, either hydraulically Figure 5-17 for the following instructions. powered or hand powered. NOTE To prevent harmful contaminants from entering the...

  • Page 144: Drum 3 Gearbox

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Drum 3 Gearbox 2. If necessary, remove the plug (1) and add oil through the fill port (2a). 3. Reinstall the plug (1). WARNING Boom butt at 87° (View B): Falling Boom Hazard 1. Remove plug (1).
  • Page 145 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS View A Left Side of Boom Butt at 0° View B Left Side of Boom Butt at 87° View C Left Side of Boom Butt at 25° to 70° Item Description Plug Fill Port (0-70°) Level Port (87°)
  • Page 146 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL View A Left Side of Boom Butt at 0° View B Left Side of Boom Butt at 87° Item Description Plug Fill Port (0°) Level Port (87°) Sight Glass Dust Cap Quick-Drain Valve (0°) Quick-Drain Valve (87°) Not Used Fill Port (87°)
  • Page 147 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS d. Thread the quick-drain drainer assembly all the way 8. Fill the gearbox with specified oil: onto the quick-drain valve (5a). The poppet inside MANUAL FILL PROCEDURE the valve will open. If not already done, remove the sight glass (3).

  • Page 148: Drum 4 Gearbox

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Drum 4 Gearbox Slowly pump oil into the gearbox until the oil level is halfway up the sight glass (3). Do not overfill. Figure 5-20 for the following procedure. Once the gearbox is filled, remove the quick-drain...
  • Page 149 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 5-27 Published 05-26-17, Control # 238-02...
  • Page 150 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Drum Ratchet Pawl Apply grease to this area Spring Eyebolt Hydraulic Cylinder View at Front of Rotating Bed 19/32 in (15 mm) to 1-1/16 in (27 mm) Bracket Broken View A View B Away for Clarity Figure 5-21.

  • Page 151: Drum 1 Pawl

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 1 PAWL It may be necessary to hoist slightly to fully disengage the pawl from the drum ratchet. Maintenance WARNING Daily Falling Boom Hazard Before performing the steps in this section, land the loads Visually check the pawl for proper operation according to the and lower the boom onto blocking at ground level.
  • Page 152 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Drum Ratchet Pawl Apply grease to this area Spring Eyebolt Hydraulic Cylinder View at Boom Hoist Drum on Top of Rotating Bed Bracket Broken Away for Clarity 5-29/32 in 5-7/64 in (150mm) (130mm) View A...

  • Page 153: Drum 4 Pawl

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 4 PAWL It may be necessary to boom up slightly to fully disengage the pawl from the drum ratchet. Maintenance WARNING Daily Falling Boom Hazard Before performing the steps in this section, land the loads Visually check the pawl for proper operation according to the and lower the boom onto blocking at ground level.

  • Page 154: Drum 3 Pawl

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL DRUM 3 PAWL Operation WARNING WARNING Falling Boom Hazard Falling Boom Hazard Before performing the steps in this section, land the loads Before performing the steps in this section, land the loads and lower the boom onto blocking at the ground level.

  • Page 155: Speed Sensor-Hoist Motors

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Replacement Item Description Speed Sensor (with O-ring) WARNING Screw (2) Burn Hazard Hoist Motor Sensor Cable Oil will drain from the port when the sensor is removed. Wait for the hydraulic oil to cool before removing the...
  • Page 156 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-34 Published 05-26-17, Control # 238-02...

  • Page 157: Speed Sensor-Free Fall Drums

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Optical Encoder Drum Flange Indicator Wheel and Shaft Assembly Bearings (2) Spring Eyebolt Pin and Cotter Pin Figure 5-25. Speed Sensor Assembly SPEED SENSOR—FREE FALL DRUMS 2. Check that the indicator wheel is centered on the drum flange and firmly in contact.
  • Page 158 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL M100749 View A Item Description Auxiliary Drum Bail Limit Rollers Lever Limit Switch Arm Limit Switch Spring (2) Eyebolt (2) Screw (4) Limit Switch Head Limit Switch Cover Limit Switch Shaft Screw (9/64 in socket) Screw and Washer (4)

  • Page 159: Minimum Bail Limit (Drum 3)

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS MINIMUM BAIL LIMIT (DRUM 3) 2. If needed, re-orient the limit switch head (9, View B): Remove the screws (8). Figure 5-26 for the following procedure. b. Rotate the limit switch head (9) to the position The OPTIONAL minimum bail limit is a protective device shown in View B.
  • Page 160 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Drum 3 Pressure Rollers Spring (2) Compression Rod (threaded)(2) Hex Nut (4) View A Flat Washer (2) Hex Nut (4) STORED Screw with Washer and Nut (4) Bracket View of Pressure Roller Assembly Installed...

  • Page 161: Pressure Roller (Drum 3)

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Pressure Roller (Drum 3) rollers (2) are pulled away from the wire rope on the drum. Figure 5-27 for the following procedure. 5. Attach lifting slings from a hoist to the pressure roller Daily Maintenance assembly. It weighs 66 lb (30 kg).

  • Page 162: Minimum Bail Limits And Pressure Rollers (Drums 1 And 2)

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL MINIMUM BAIL LIMITS AND PRESSURE ROLLERS (DRUMS 1 AND 2) The optional minimum bail limits and pressure rollers for the front and rear drums are identified in Figure 5-28. Item Description Note Drum 1 (front drum) Bail Limit Minimum Bail Limit (Drum 1 and 2) on page 5-43.
  • Page 163 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 5-41 Published 05-26-17, Control # 238-02...
  • Page 164 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL View A Item Description Bail Limit Rollers Cap Screw (2) Drum Lever Actuator Spring (2) Eyebolt (2) Limit Switch Arm Limit Switch Screw, Nut, and Lock Washer (2) Cable Connector Front Drum Shown Screw (4) Rear Drum Similar...

  • Page 165: Minimum Bail Limit (Drum 1 And 2)

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS MINIMUM BAIL LIMIT (DRUM 1 AND 2) d. Install the limit switch cover (16). 2. If needed, re-orient the limit switch head (13, View B): Figure 5-29 for the following instructions. Remove the screws (12). The minimum bail limit for the front drum is shown. The minimum bail limit for the rear drum is similar.
  • Page 166 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Rear Drum Pressure Rollers Lever Spring (2) Eyebolt (2) Figure 5-30. Pressure Roller (Drum 2) Item Description Front Drum Pressure Rollers Spring (2) Mounting Plate (2) Cap Screw with Flat Washer (4) Pressure Roller Bracket...

  • Page 167: Pressure Roller (Drum 1 And 2)

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS PRESSURE ROLLER (DRUM 1 AND 2) Spring Replacement 1. Land the load on the drum and stop the engine. The OPTIONAL pressure roller is a protective device which pre ve nt s th e w i r e r op e fro m j um pi ng w r ap s on t he 2.

  • Page 168: Block-Up Limit Switch

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Location of Components at Boom Top Shown Location of Components at Jib Tops is Similar M100767a • Upper Boom Point (1 or 2-part) • Fixed Jib Point (1-part) 2-Part Reeving Item Description Lower Boom Point Upper Boom Point...

  • Page 169: Theory Of Operation

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS • A weight (5 or 8) freely suspended by a chain (4) from Inspect the entire length of each electric cable for each limit switch actuating lever (weight encircles load damage. line as shown). d. Check that the electric cables are clear of all moving •...
  • Page 170 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Black Wire to Limit Switch Terminal #21 White Wire to Limit Switch Terminal #22 Item Description M100766 Enclosure Electric Cable Spring Eyebolt Setscrew Limit Switch Shaft Limit Switch Lever Actuating Lever Enclosure Cover Limit Switch Dimension A...

  • Page 171: Adjustment

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Adjustment 4. Manually lift the weight to allow the actuating lever (8) to rotate up. Figure 5-33 for the following procedure. 5. Hold the actuating lever (8) at the Dimension A. Lower the boom and jib onto blocking at ground level and 6.
  • Page 172 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Right End of Either Load Drum in Right Side Enclosure Item Description Swivel Fitting in SUPPLY Port Cover Supply Hose Case Drain Hose Brake Housing Bolt: 18 each M10 x 8,8 Threads x 35 mm long Figure 5-34.

  • Page 173: Free Fall Brake

    (5) so the cover can be reinstalled in the same position. The free fall brakes must be serviced by factory trained personnel. For assistance, contact the Manitowoc Crane 8. Remove two bolts (6), 180° apart — at locations marked Care Lattice Team.

  • Page 174: Wire Rope Inspection And Replacement

    Maintain a Wire Rope Condition Report from Manitowoc Cranes. Do not build lengths from individual components. Always keep on file a signed and dated periodic inspection report of the wire rope’s condition.

  • Page 175: Daily Inspection

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS Daily Inspection 2. Throughout the day, observe wire rope during operation, particularly: Wire rope should be inspected in accordance with ANSI/ Pick-up Points—Sections of wire rope that are ASME B30.5 and OSHA 29 CFR 1926.1413. A running...

  • Page 176: Periodic Comprehensive Inspection

    HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL Periodic Comprehensive Inspection • Size, nature, and frequency of lifts. • Rope maintenance practices. The comprehensive inspection must be done by a qualified person. The inspection must include pulling all the rope off • Severity of environment, such as: the drum and carefully inspecting the entire length.

  • Page 177: Broken Rope Wires

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS New Wire Rope—After initial loading, measure and record attachment, or more than one broken wire at the end the diameter of any new wire rope for comparison to future attachment (see Figure 5-37). inspections. See Maintain a Wire Rope Condition Report on •...

  • Page 178: Distributing Wire Rope Wear

    Wire Rope Specifications Chart located in Capacity Chart Manual (for load lines). Item Description • Boom or jib assembly drawings located in MLC165-1 Lay Length: distance in which one strand makes one Operator Manual (for boom or luffing hoist). complete revolution around core.

  • Page 179: Sheave, Roller, And Drum Inspection (Weekly)

    MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS SHEAVE, ROLLER, AND DRUM INSPECTION Observe groove to see if contour of gauge (WEEKLY) matches contour at bottom of sheave groove. Perform the following inspections weekly. 1. Check the drum clutches and brakes for proper adjustment.
  • Page 180 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL 8. Inspect nylon sheaves to verify they have not separated and “walked off” steel inserts or bearings as shown in Item Description Figure 5-41. Maximum sideways displacement is 1/8 in Nylon Sheave (3 mm). Replace worn or damaged sheaves.
  • Page 181 MLC165-1 SERVICE/MAINTENANCE MANUAL HOISTS PLASTIC SHEAVE DATA Outside Sheave E = Replacement dimension Tread Diameter Width Rope Diameter Part No. Diameter E = B – 3/16 in (5 mm) (maximum) inch inch inch inch If tread print exists in root of sheave 912738 13.19...

  • Page 182: Load Block And Hook-And-Weight Ball Inspection

    • Do not remove or deface nameplate attached to load blocks and hook-and-weight balls. • See Section 4 of the MLC165-1 Operator Manual for Item Description Item Description recommended sling angles and capacity restrictions Dead-End Clip Check Gap Here when load block has duplex or quadruplex hook.
  • Page 183 Do not weld on any load bearing Check that Hook is Not Twisted component unless proper welding methods are used Check for Cracks and Twisting (contact the Manitowoc Crane Care Lattice Team for Check for Wear and Cracks Figure 5-46. material and welding specifications).
  • Page 184 HOISTS MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-62 Published 05-26-17, Control # 238-02...
  • Page 185 Oil Change Procedure ............6-7 Manitowoc...
  • Page 186 THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 6-ii Published 05-26-17, Control # 238-02...

  • Page 187: Swing System Overview

    Function Mode screen controlled variable hydraulic pump drives a fixed hydraulic (see the MLC165-1 Main Display Operation manual). motor. Swing motor speed is proportional to the output flow volume of the swing pump. The swing motor drives a M100836 Figure 6-1.

  • Page 188: Swing Brake

    SWING SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL M100831 Figure 6-2. Swing Brake When the swing brake switch is moved to the ON- PARK position, the swing park switch is open, sending a 0Vdc The swing planetary drive has a spring-applied, hydraulically signal back to node 1. Node 4 controller sends a 0Vdc output released brake at the input of the planetary drive after the voltage to the swing brake valve solenoid, de-energizing it.

  • Page 189: Swing Handle Command

    MLC165-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Handle Command Swinging Right The swing control system receives operator commands via a When swinging right, node 4 sends a PWM signal to proportional hydraulic control handle. Left or right control proportional solenoid A in the swing pump EDC, energizing handle movement ports pilot pressure to the corresponding it.
  • Page 190 SWING SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Swing Motor Swing Brake Swing Gearbox Brake Release Hose Brake Release Fitting (04 ORFS) Figure 6-3. Swing Drive Published 05-26-17, Control # 238-02...

  • Page 191: Manual Release Of Swing Brake

    MLC165-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM MANUAL RELEASE OF SWING BRAKE 1. At the brake (2) disconnect the brake release hose (4) from the brake release fitting (5). When removing or installing the swing drive, the swing brake 2. Connect the hand pump hose to the brake release fitting must be released to allow alignment of the pinion gear and (5).

  • Page 192: Swing Gearbox

    SWING SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Sight Glass Breather Fill Port Dust Cap Quick-Drain Valve (access under rotating bed) Figure 6-4. Swing Drive SWING GEARBOX middle of the sight glass (1). If necessary add oil through the fill port (3).

  • Page 193: Quick-Drain Valve

    MLC165-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Quick-Drain Valve 4. Thread the quick-drain drainer assembly all the way onto the quick-drain valve (5). The poppet inside the The swing gearbox is equipped with a quick-drain valve valve will open, allowing the oil to drain from the which requires use of the quick-drain drainer assembly gearbox.
  • Page 194 SWING SYSTEM MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-26-17, Control # 238-02...

  • Page 195: Section 7

    DEF Heating and Cooling System ..........7-17 Manitowoc...
  • Page 196 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7-ii Published 05-26-17, Control # 238-02...

  • Page 197: Batteries

    MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERIES Causes of Battery Failure A battery should never be left in a discharged state. When Safety discharged, it rapidly sulfates and, unless recharged within hours, will permanently lose capacity. WARNING...

  • Page 198: Maintenance

    POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Battery Hold-Down 12V Batteries (connected parallel) Battery Cover with Latches M100704 M100706 Figure 7-1. Batteries Maintenance Loose Hold-Downs Loose hold-downs will allow the battery to vibrate in the CAUTION holder. This can cause cracks or wear in the container and cause the acid to leak.

  • Page 199: Charging

    MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Quarterly Maintenance Item Description • Thoroughly clean the batteries and the holder with a Test Leads on Battery Terminals baking soda/water solution. Voltmeter • If provided, make sure the drain holes are open in the holder.

  • Page 200: Storage

    ENGINE CONTROLS See the engine start procedure in Section 3 of the MLC165-1 Operator Manual for engine startup. See the Cummins engine manual for detailed engine instructions. The engine is started and stopped with the engine key switch.
  • Page 201 MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description 7.5 kW Generator with Power Supply Cord Load Center 50A Main Circuit Breaker 15A Circuit Breaker: Rotating Bed Work Lights 15A Circuit Breaker: Boom Work Lights 15A Circuit Breaker: Engine Oil Heater, Battery...

  • Page 202: Air Cleaner

    POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL unfiltered air to enter the engine. Replace the worn or damaged parts. CAUTION • Check the housing (2) for dents or other damage that Avoid Engine Damage may allow unfiltered air to enter the engine. Replace the housing if damaged.
  • Page 203 MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN 10. Install the service cover (4), making sure the O-ring is in cover will do the job of sealing the filter, but it will not. place. Fasten the latches. The cover should go on Using latches to push filters in could damage the without extra force.

  • Page 204: Engine Throttle Adjustment

    (6) shaft fully CCW as viewed from the shaft end (zero volts out). If there is a problem with the foot throttle, it is best to either replace it or send the unit to the Manitowoc Crane Care With pedal...
  • Page 205 MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN 11b 11c Surface X RTV-162 Flat on Head of Shaft These two holes should be aligned when initially inserting shaft and spring into housing. Pedal Position A Item Description Foot Pedal Housing Foot Pedal Foot Pedal Shaft (right)

  • Page 206: Engine Enclosure

    POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL ENGINE ENCLOSURE ENGINE BELT ROUTING The engine components can be accessed from the doors, Engine belt routing is shown in Figure 7-8 to help the service panels, and grating shown in Figure 7-7 personnel when installing new belts on the engine.

  • Page 207: Engine Radiator

    MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Checking Coolant Level CAUTION Maintain Coolant Additive The required Supplemental Coolant Additive (SCA) concentration must be maintained to prevent engine damage. Check the SCA concentration according to the schedule in the engine manufacturer’s manual and per the manufacturer’s warnings, cautions, and instructions.

  • Page 208: Draining And Filling Cooling System

    POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL Draining and Filling Cooling System Drain the cooling system every 1,000 hours of operation or semi-annually (whichever occurs first). The radiator is equipped with a quick-drain valve (2) which requires use of the quick-drain drainer assembly shown in Figure 7-10.
  • Page 209 MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN 12. Once coolant is visible at the full cold mark on the decal 13. Start the engine and run it until the thermostat opens at a next to the sight glass (Figure 7-9, page 7-11), wait 2-3 coolant temperature of 181-199°F (83-93°C).
  • Page 210 POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL Item Description Components DEF Tank Coolant Flow Control Solenoid Valve Coolant Manifold Air Bleed Valves DEF Supply Module SCR Module DRT Module DEF Dosing Module DOC Module Coolant Hoses (BLUE) From Coolant Manifold to DEF Tank...

  • Page 211: Exhaust Aftertreatment System

    MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN EXHAUST AFTERTREATMENT SYSTEM Figure 7-11, page 7-14 for the following instructions. Item Description DEF Tank Fill Cap Abbreviation Description DEF Return Port DEF Coolant OUT Port Aftertreatment Protection System DEF Coolant IN Port Diesel Exhaust Fluid...

  • Page 212: Coolant Solenoid Valve

    POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL CAUTION CAUTION Use Only Approved Replacement Parts! Loss of Power or Engine Shutdown Hazard! The DEF system components are designed to withstand freezing and to be compatible with DEF fluid and the other If poor-quality DEF or a low-level condition is sensed, an unique characteristics of the system.

  • Page 213: Def Dosing Module

    MLC165-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN DEF Dosing Module delivers coolant to the DEF dosing module (8) to keep it from overheating. The DEF dosing module (8, Figure 7-11, page 7-14) injects The coolant solenoid valve (2) adjusts coolant flow according a liquid mixture of urea and deionized water (called DEF) into to the temperature of the DEF in the DEF tank.
  • Page 214 POWER TRAIN MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7-18 Published 05-26-17, Control # 238-02...
  • Page 215 Operation ..............8-9 Manitowoc...
  • Page 216 THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 8-ii Published 05-26-17, Control # 238-02...

  • Page 217: Travel Overview

    MLC165-1 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TRAVEL OVERVIEW the motor, rotating it. Fluid flows from the motor, back through the open motor valve P1 connection, through the Figure 8-1 Figure 8-2 open control valve B4 connection, and back to tank.
  • Page 218 UNDER CARRIAGE MLC165-1 SERVICE/MAINTENANCE MANUAL M100847 Figure 8-1. Travel Control (Left Crawler) Published 05-26-17, Control # 238-02...
  • Page 219 MLC165-1 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE M100851 Figure 8-2. Travel Electrical Diagram Manitowoc Published 05-26-17, Control # 238-02...
  • Page 220 UNDER CARRIAGE MLC165-1 SERVICE/MAINTENANCE MANUAL 31/32 in (50 mm) Front of Rotating Bed and Front of Carbody Item Description Dowel Pin (2 places) 1-1/2 in 6 UNC x 8 in Long Grade 8 Bolt with Flat Steel Washers 56 Places Outer Ring...

  • Page 221: Turntable Bearing Maintenance

    MLC165-1 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE TURNTABLE BEARING MAINTENANCE Lubrication Figure 8-3 on the previous page. Before installing the turntable bearing bolts (B, View B-B), lubricate the threads of each bolt and both sides of the washers with "Never-Seez" or equivalent anti-seizing lubricant.
  • Page 222 UNDER CARRIAGE MLC165-1 SERVICE/MAINTENANCE MANUAL See View B for items 12 and 13. Item Description Bolt and Nut Cover Jack Cylinder Support Shim - 0.134 in (3,4 mm) Shim 0.250 in (6,4 mm) Tread Front Crawler Roller Hand Pump Center Punch A...

  • Page 223: Crawler Preventative Maintenance

    MLC165-1 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE CRAWLER PREVENTATIVE MAINTENANCE CRAWLER TREAD SLACK ADJUSTMENT Crawler wear cannot be eliminated, but the rate of wear can Figure 8-4 for the following procedure. be reduced through regular preventive maintenance. Repair Adjust the treads tighter when operating on firm ground and or replace damaged parts immediately to prevent further looser when operating on soft ground (mud or sand).

  • Page 224: Crawler Hand Pump And Jacking Cylinder

    UNDER CARRIAGE MLC165-1 SERVICE/MAINTENANCE MANUAL CRAWLER HAND PUMP AND JACKING CYLINDER M100737 WARNING Hand Pump Explosion The hand pump and cylinder is provided for crawler adjustment only, any other use is neither intended nor approved. Wear safety glasses and other personal protective gear when operating the hand pump.

  • Page 225: Air Removal

    MLC165-1 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE Air Removal Operation Figure 8-5 for the following procedure. 1. Before using the pump: • Check that all fittings are tight and leak free. 1. Rotate the valve (5) clockwise until finger tight. • Check the oil level.
  • Page 226 UNDER CARRIAGE MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 8-10 Published 05-26-17, Control # 238-02...

  • Page 227: Section 9

    Lube and Coolant Product Guide ........... . . 9-1 Manitowoc...
  • Page 228 MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9-ii Published 05-26-17, Control # 238-02...

  • Page 229: Lube And Coolant Product Guide

    MLC165-1 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2278 at the end of this section. LUBE AND COOLANT PRODUCT GUIDE See the publication at the end of this section. Manitowoc Published 05-26-17, Control # 238-02...
  • Page 230 LUBRICATION MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-26-17, Control # 238-02...
  • Page 231 Lower ............. . 10-9 Manitowoc...
  • Page 232 THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 10-ii Published 05-26-17, Control # 238-02...

  • Page 233: Accessory System Pressure

    MLC165-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES SECTION 10 ACCESSORIES ACCESSORY SYSTEM PRESSURE user interface, node 5 sends a 24Vdc signal to the lower accessory valve solenoid, energizing it. The valve moves to All of the accessory system functions are operated at 3,400...

  • Page 234: Jack Cylinders

    ACCESSORIES MLC165-1 SERVICE/MAINTENANCE MANUAL Jack Cylinders Pin Pullers M100841 Figure 10-3. Car Body Pin Puller Control M100844 Neutral Figure 10-2. Jack Cylinder Control The valve spool is centered by the return springs in the neutral position. The center valve position is closed, so no Neutral fluid flows to the cylinder.

  • Page 235: Rotating Bed Cylinders

    MLC165-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES ROTATING BED CYLINDERS M100834 Figure 10-4. Rotating Bed Accessories Electrical Diagram—Part 1 Manitowoc 10-3 Published 05-26-17, Control # 238-02...
  • Page 236 ACCESSORIES MLC165-1 SERVICE/MAINTENANCE MANUAL M100835 Figure 10-5. Rotating Bed Accessories Electrical Diagram—Part 2 10-4 Published 05-26-17, Control # 238-02...

  • Page 237: Mast

    MLC165-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES Mast Raise When either of the mast cylinders extend/retract switches are toggled to the extend position, the extend contact closes a n d s e n d s t h e 2 4 V d c s u p p l y s i g n a l b a c k t o t h e corresponding node.

  • Page 238: Assembly Cylinder (Optional)

    ACCESSORIES MLC165-1 SERVICE/MAINTENANCE MANUAL Assembly Cylinder (Optional) drum 3/4 pilot pressure transducer. Node 5 then sends a 24Vdc signal to the assembly cylinder extend solenoid, energizing it. The valve spool moves to the open position. Fluid flows from the pressure port, through the valve, and on to the holding valve.

  • Page 239: Boom Butt Pin Pullers

    MLC165-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES Boom Butt Pin Pullers Counterweight Cylinders M100839 Figure 10-8. Boom Butt Pin Puller Control M100843 Neutral Figure 10-9. Counterweight Cylinder Control Node 1 sends 24Vdc to the boom pins disengage switch pole Neutral in cab. Node 5 sends 24Vdc to the boom hinge pins engage/ disengage switch in the remote set up controller.

  • Page 240: Counterweight Pin Pullers

    ACCESSORIES MLC165-1 SERVICE/MAINTENANCE MANUAL Counterweight Pin Pullers Node 5 then sends a 24Vdc signal to the left or right counterweight down solenoid, energizing it. The valve spool moves to the reversing position. Fluid flows from the pressure port, through the valve, and on to the holding valve.

  • Page 241: Cab Tilt

    MLC165-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES Cab Tilt so no fluid can flow from the rod or barrel end of the cylinder if a load on the cylinder is producing pressure. Raise When the cab tilt up/down switch is toggled to the up position, the up contact closes and sends the 24Vdc supply signal back to node 2.
  • Page 242 ACCESSORIES MLC165-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-10 Published 05-26-17, Control # 238-02...
  • Page 243 Sheave, Roller, and Drum Inspection (Weekly) ......... 5-57 Manitowoc...
  • Page 244 MLC165-1 SERVICE/MAINTENANCE MANUAL Solenoid Valve Identification ............3-7 Speed Sensor—Free Fall Drums .

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