Manitowoc MLC80A-1 Service And Maintenance Manual
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Manitowoc MLC80A-1 Service And Maintenance Manual

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Manitowoc
MLC80A-1/MLC90A-1/
MLC100A-1/MLC100-1
Service/Maintenance Manual

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Summary of Contents for Manitowoc MLC80A-1

  • Page 1 Manitowoc MLC80A-1/MLC90A-1/ MLC100A-1/MLC100-1 Service/Maintenance Manual...
  • Page 3 SECTION 10 ACCESSORIES NOTICE The serial number of this crane 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’s cab.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1..........Introduction Continuous Innovation .
  • Page 6 TABLE OF CONTENTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Every Month or 200 Hours ............3-8 Degradation Due to Severe Environment.
  • Page 7 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Gear Oil Specifications ............5-21 Oil Analysis .
  • Page 8 TABLE OF CONTENTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Swing Hydraulic Diagram ............6-4 Swing Electrical Diagram .
  • Page 9 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS General............... . . 8-1 Hydraulic Travel System.
  • Page 10 TABLE OF CONTENTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Accessory Systems Electrical Diagram..........10-5...
  • Page 11 Identification and Location of Major Components ........1-4 Manitowoc...
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  • Page 13: Section 1

    If you are in safety alert symbol and a signal word to identify the hazard’s doubt about any procedure, contact your Manitowoc Cranes degree of seriousness. dealer or the Manitowoc Crane Care Lattice Team.

  • Page 14: Safe Maintenance Practices

    Read This Manual necessary. To ensure safe and proper operation of Manitowoc cranes, If the engine must be running while the crane is being they must be maintained according to the instructions serviced, observe the following: contained in this manual.

  • Page 15: Stored Energy Safety Precautions

    • Do not smoke or allow open flames in the refueling area. • Unless authorized in writing by Manitowoc Cranes, do not alter the crane in any way that affects the crane’s • When using a fuel can, use a safety-type can with an performance (to include welding, cutting, or burning of automatic closing cap and flame arrestor.

  • Page 16: Protection Of The Environment

    • Hydraulic motors • Transducers Potentially harmful waste used in Manitowoc cranes includes—but is not limited to—oil, fuel, grease, coolant, air • Hydraulic valve assemblies conditioning refrigerant, filters, batteries, and cloths that have come into contact with harmful substances.
  • Page 17 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Drum 1 (whip hoist) Drum 2 (main hoist) Drum 3 (optional aux hoist) Drum 4 (boom hoist) Upper Boom Point Lower Boom Point Hook-and-Weight Ball Load Block Boom Top Pin (Inserts not shown) Wire Rope Guide (three in the butt)
  • Page 18 INTRODUCTION MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Item Description Swing Drive Counterweight Pins (crane) Fuel Tank Drum 4 (boom hoist) (drive) Hydraulic Tank A/C Condenser Battery Box Hydraulic Oil Cooler Diesel Exhaust Fluid (DEF) Tank Drum 3 (optional aux hoist) (drive)

  • Page 19: Section 2

    Accumulator Maintenance ..........2-26 Manitowoc...
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  • Page 21: Hydraulic Schematic

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM HYDRAULIC SCHEMATIC Detailed descriptions of the controls and operations using these components to form working circuits can be found in The hydraulic schematic for this crane is located at the end the appropriate sections of this manual.

  • Page 22: Pump 1

    HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Pump 1 Pump 1 (Figure 2-2) is a dual 107 cc, variable-displacement pump. Dis pl ac ement is controlled by an electronic displacement control (EDC). Each pump has a maximum operating pressure of 350 bar (5075 psi).

  • Page 23: Pump 3

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump 2 Pump 2 (Figure 2-3) is a 56 cc, variable-displacement pump. The pump’s direction and displacement are controlled by an electronic displacement control (EDC). The pump has a maximum operating pressure of 320 bar (4640 psi).

  • Page 24: Pump 5

    HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Pump 3 Pump 3 (Figure 2-4) is a 18 cc, variable-displacement pump. Displacement is controlled by an electronic displacement control (EDC). The pump has a maximum operating pressure of 145 bar (2100 psi). Item Description...

  • Page 25: Motor Identification

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Motor Identification Each motor has an external loop flushing circuit that continuously removes a small volume of oil from the motor Drum 1 and 2 Motors loop to provide cooling and oil purification. Each drum 1 and 2 motor...

  • Page 26: Drum 4 Motor

    HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 4 Motor Drum 4 motor (Figure 2-8) is an 80 cc bidirectional, fixed- displacement motor. Item Description Pressure Port A Pressure Port B Tank Port Pilot Pressure Port S FIGURE 2-8 Published 10-09-2020, Control # 259-06...

  • Page 27: Travel Motors

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Travel Motors displacement is controlled by the two-speed signal and pressure override. The travel motors (Figure 2-9) are 160 cc (max), 70 cc (min) bidirectional, variable-displacement motors. Motor Item Description Tank Port T2 Pressure Port B...

  • Page 28: Rotating Bed Hydraulic Valves

    HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Swing Motors The swing motor (Figure 2-10) is a 56 cc, bidirectional, fixed- displacement motor. Item Description Tank Port T1 Pressure Port A Pressure Port B Tank Port T2 FIGURE 2-10 Rotating Bed Hydraulic Valves...

  • Page 29: Main Control Valve

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM High Pressure Accessory Valve Main Control Valve Item Valve Drum 1 Secondary Side A Drum 1 Secondary Side B Drum 2 Primary Side A Drum 2 Primary Side B Drum 3 Side A Drum 3 Side B...
  • Page 30 HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-10 Published 10-09-2020, Control # 259-06...
  • Page 31 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Table 2-1. Closed-Loop Circuit Hydraulic Specifications Pump Motor Charge Pressure Speed Pressure Function Port Port Bar (PSI) Bar (PSI) Swing Left 1.8 to 2 320 (4,640) 30 (435) Swing Right Figure 2-1 on page 1 for pump identification.

  • Page 32: Hydraulic System Maintenance

    Do not take oil from storage until the oil is needed. If the Operation Manual. oil cannot be used immediately, keep the transfer Contact your Manitowoc Cranes dealer for an explanation of container tightly covered. any procedure not fully understood.

  • Page 33: Inspecting The Hydraulic System

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Inspecting the Hydraulic System • Look for oil leaking from pump and motor shaft ends, from valve spool ends, and from cylinder shaft ends. Figure 2-12, page 15 for referenced item numbers. Replace the seal if leakage is found at any of these points.

  • Page 34: Inspecting And Replacing Hydraulic Hoses

    HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Inspecting and Replacing Hydraulic Hoses • Damaged or missing hose clamps, guards, or shields • Excessive dirt and debris around hose assemblies If any of these conditions exist, address them appropriately. CAUTION Periodic Replacement Burn Hazard! Table 2-3 for the following.

  • Page 35: Replacing Breather

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Replacing Breather Figure 2-12 for the following. Check the breather service indicator daily or every 8 hours of engine operation, whichever occurs first. WARNING 2. Replace the breather (2) when the red flag in the service Burn Hazard! indicator (3) rises to the top and locks in place.

  • Page 36: Replacing Hydraulic Filters

    Replace the filter element at each oil change Original equipment manufacturers’ filter elements, interval. available from the Manitowoc Crane Care Lattice Team, NOTE: It is normal for the fault alarm to come on at startup must be used on this crane. Substituting with any other when the oil is cold.

  • Page 37: Servicing Suction Strainer

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Servicing Suction Strainer 7. Either replace the strainer with a new one or (if the strainer is not damaged) clean it as follows: The suction line to the pumps is equipped with a suction Soak the suction strainer in a clean, nonflammable strainer located inside the hydraulic tank.
  • Page 38 HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Item Description Hydraulic Tank Shut-Off Valve Oil Level Sight Gauge Padlock Holes Schrader Valve Fill Plug Vent Valve (requires a mating coupler) Shut-Off Closed Position Desiccant Breather Shut-Off Open Position Level Sensor Locking Knob...

  • Page 39: Changing Hydraulic Oil

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Changing Hydraulic Oil Unless otherwise specified, refer to Figure 2-12 for the CAUTION following procedure. Contamination Hazard! Drain and refill the hydraulic system semiannually or every Do not fill the hydraulic tank through the breather opening.
  • Page 40 HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Swing Motor Typical Drum Motor High Pressure Accessory Valve Main Valve Main Valve Hoses Removed Item Description Gauge Coupler with Dust Cap-18 UNF x -6 PRESSURE TRANSDUCER ID Drum Motor (similar all drums) Swing Right...

  • Page 41: Replacing Pressure Transducers

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM REPLACING PRESSURE TRANSDUCERS 7. Remove the pressure transducer and discard it and the oil leakage according to local environmental regulations. Testing a Pressure Transducer 8. Install the new pressure transducer and connect the electrical connector.
  • Page 42 HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL NOTE: It is extremely important to perform the bleed NOTE: Remove the pin and support the cylinders to procedure described above in the field anytime the prevent them from striking anything during system is drained completely.

  • Page 43: Hydraulic Tests And Calibrations

    The calibration and test procedures described in this section were performed before the crane shipped from the factory. These procedures must be performed by field personnel only when parts are replaced or when instructed by a Manitowoc Cranes dealer. Pressure Sender Calibration See the Main Display Operation Manual.
  • Page 44 HYDRAULIC SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Located on Rotating Bed Right Side Enclosure above Pumps Free Fall Hydraulic Valve Low-Pressure Hydraulic Valve Item Description Drum 1 Brake Drum 2 Brake Drum 3 Brake Drum 4 Brake Swing Brake Travel Brake 2-Speed Travel...

  • Page 45: Disc Brake Operational Test

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM DISC BRAKE OPERATIONAL TEST 5. Slowly move the control handle for the brake being checked and verify the following: There is no physical way to check the disc brakes for any of • The specified system pressure is reached before the following: 50% pump command is reached.

  • Page 46: Accumulator Maintenance

    WARNING Explosion Hazard! The accumulator is precharged with dry nitrogen gas. Do not tamper with the accumulator unless authorized and trained to do so. Contact the Manitowoc Crane Care Lattice Team for Item Description FIGURE 2-20 assistance if needed. Protective Cap M28 x 1.5 Male Thread...

  • Page 47: Section 3

    Test Voltages ..............3-19 Manitowoc...
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  • Page 49: Electrical Schematic

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM ELECTRICAL SCHEMATIC Battery Power Disconnect The electrical schematic for this crane is located at the end When in the OFF position (contacts open), the battery disconnect switch disconnects the battery positive terminal of this section.

  • Page 50: Crane Electrical Power Distribution

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Crane Electrical Power Distribution • Relay K5: When energized, relay K5 provides power from circuit breaker CB3 to terminal +UE on the When the battery disconnect switch is closed and battery following control modules: power is available, turning the engine run switch S3 to the...

  • Page 51: Crane Electrical System Ground Points

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Crane Electrical System Ground Points Cab Right Console Ground Points The cab ground points are at the following locations (see General Figure 3-1): The crane electrical system has several frame ground The cab right console contains the following point ground connection (point) locations on the rotating bed.

  • Page 52: Rotating Bed And Cab Mount Ground Points

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Rotating Bed and Cab Mount Ground Points • Cab Arm-to-Cab Mount Ground Strap (3)—Ensures an electrical path to ground between the cab arm and the Figure 3-2 for the following items. cab mount. The rotating bed ground points are as follows: •...

  • Page 53: Circuit Breakers, Fuses, And Relays

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CIRCUIT BREAKERS, FUSES, AND RELAYS • TCU CraneStar® (if equipped) 5A fuse F5 is mounted on the battery disconnect switch bracket. Most circuit breakers, fuses, and relays are located in the • Alternator 250A fuse F0 (2) is mounted on a panel at the cab.
  • Page 54 ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL FIGURE 3-4 Published 10-09-2020, Control # 259-06...
  • Page 55 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Item Description Item Description Programing Plug Relay 24/12VDC, 30A J1939 Diagnostic Plug Battery, SCM 3.6V lithium AA Converter (24/12VDC) Time Delay Relay, SCM and CCM Backup—24V Main Fuse (CB41) Relay Contactor—28V Ground Bus Bar Circuit...

  • Page 56: Inspect Electrical Components

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL INSPECT ELECTRICAL COMPONENTS Visually inspect all Controller Area Network (CAN) nodes and electrical junction boxes for the following: • Damaged or loose connectors DANGER • Damaged or missing electrical clamps or tie straps Electric Shock Hazard! •...

  • Page 57: Can Bus Control System

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CAN BUS CONTROL SYSTEM Control Modules—The CAN Bus control system contains control modules that use the CAN Bus to communicate with CAN Bus System Overview each other and with other CAN Bus devices. (For more...

  • Page 58: Can Bus System Chart

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL CAN Bus System Chart FIGURE 3-5 3-10 Published 10-09-2020, Control # 259-06...

  • Page 59: Control Modules

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Control Modules Control Module Input/Output (I/O) Types Table 3-3 defines the terms used in the schematics for the I/ Control modules perform several functions: O types used by the control modules. • Run the software control programs Table 3-3.

  • Page 60: Safety Control Module (Scm)

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Safety Control Module (SCM) Crane Control Module (CCM) SCM is a controller that runs the software programs to CCM controllers run the software programs governing the interface with the cab controls and to govern boom and jib crane operations.

  • Page 61: Input/Output-Large (Iol) Module

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Input/Output—Large (IOL) Module Input/Output—Small (IOS) Module I O L s c o n t r o l t h e d e v i c e s c o n n e c t e d t o t h e m a n d...

  • Page 62: Control Module Devices

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Control Module Devices The control modules communicate with output devices to control crane movement and with input devices to read crane status. The following sections detail the operation of these devices. Pressure Transducers A controller provides power to a pressure transducer. The...

  • Page 63: Limit Switches-Dual Contact

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Limit Switches—Dual Contact • Gantry angle • Boom angle In the non-tripped state, a controller provides power to the normally closed contact and grounds the normally open • Rotating bed pitch and roll contact. A controller digital input reads the applied power...

  • Page 64: Control Module Test Voltages

    ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Relays Wind Speed Indicators A controller digital output drives the relay coil. The coil A controller digital output provides power to the wind speed energizes, creating a magnetic field that closes the relay sensor. The sensor outputs an analog signal that is contacts.

  • Page 65: Alphabetical Index Of Controller Devices

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Alphabetical Index of Controller Devices Device Controller Find the device of interest and associated controller in Table CCMC11, Gantry Components 3-5, then refer to the applicable test voltage table for that IOSA22 controller. Hydraulic-Charge Filter Alarm...

  • Page 66: Solenoid Valve Identification

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SOLENOID VALVE IDENTIFICATION Solenoid Description Number Number Each hydraulic valve solenoid is assigned a solenoid number used in Manitowoc Cranes training classes (see Table 3-6). HSC10-07 Drum 3 Brake Release PC102-14 The pin number corresponds to the control module...

  • Page 67: Test Voltages

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM TEST VOLTAGES Table 3-7. CCM-10 Test Voltages Function Voltages 0 to 24 V P1-1 OPH3A23 Left Travel Side A 0 to 24 V P1-2 OPH3A28 Drum 4 Side B Open, 24 V Closed P1-3 ID21 Drum 4 Pawl Limit Switch N.C.
  • Page 68 ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Function Voltages 24 V P2-18 8C32 (+UB) Battery Power for Control Module Outputs 24 V P2-20 8C33 (+UB) Battery Power for Control Module Outputs 24 V P2-21 ODH3A02 Drum 4 Motor Speed Sensor and Pressure...
  • Page 69 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-8. CCMC11 Test Voltages Function Voltages P1-1 OPH3A23 Swing Pump C1 0 or 24 V P1-2 OPH3A28 Drum 2 Free Fall Brake 0 or 24 V P1-3 ID21 Hydraulic Filter Alarm Open, 24 V...
  • Page 70 ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Table 3-9. IOLC30 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
  • Page 71 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-10. IOLC31 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
  • Page 72 ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Table 3-11. IOSA22 Test Voltages Function Voltages P1-1 Ground (from cab ground bus-bar) 24 V P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01 DPF Regen Initiate Open, 24 V...
  • Page 73 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-12. SCM-00 Test Voltages Function Voltages 24 V P1-1 8C45 (+UB) Battery Power for Control Module Outputs (from CB31) Off, 24 V P1-2 ODH1A17 RCL Light Amber Off, 24 V P1-3 ODH1A6 RCL Light Green...
  • Page 74 ELECTRICAL SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Function Voltages 8.5 V Power Bus Hand Throttle 8.5 V P1-41 0S85H P1-42 ID10 Not Used 3-26 Published 10-09-2020, Control # 259-06...

  • Page 75: Section 4

    Boom Electrical Diagram ............4-8 Manitowoc...
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  • Page 77: General Maintenance

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM GENERAL MAINTENANCE of the rotating bed and communicates the information to the crane’s control system through the IOLC30 control module. This section contains maintenance and adjustment The angles are viewable in the Crane Status Bar of the Main instructions for the limit devices used with the boom.
  • Page 78 BOOM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 10-09-2020, Control # 259-06...

  • Page 79: Boom Angle Indicator

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL BOOM BOOM ANGLE INDICATOR An BOOM angle sensor (see Figure 4-2) is located inside the boom butt. T h e s e n s o r m e a s u r e s t h e a n g l e o f t h e b o o m a n d communicates the information to the crane’s control system...
  • Page 80 BOOM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Limit Switch Limit Switch Wiring Boom Butt Switch Wire Color Function Terminals Actuator Green Maximum Angle Smart Level Black Ground Set Screw White 24 VDC Supply Lever Roller Shaft FIGURE 4-3 Published 10-09-2020, Control # 259-06...

  • Page 81: Automatic Boom Stop Limit Switch

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL BOOM AUTOMATIC BOOM STOP LIMIT SWITCH The limit switch for the automatic boom stop was set at the factory and should not require periodic adjustment. Figure 4-3. Adjustment is necessary when: The automatic boom stop limit switch (1) is mounted on the •...
  • Page 82 BOOM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL View B View A Physical Stop Start of Cushioning Item Description Boom Butt Physical Boom Stop (2) Springs (fully relaxed) Springs (fully compressed) FIGURE 4-4 Published 10-09-2020, Control # 259-06...

  • Page 83: Physical Boom Stop

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP • Assist in moving the boom forward when lowering the boom from any angle above 59° Figure 4-5 • Provide a physical stop at 84° Physical Boom Stop Operation WARNING • When the boom is raised to 59°, the springs start to compress (View A).

  • Page 84: Boom Electrical Diagram

    BOOM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL BOOM ELECTRICAL DIAGRAM A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 4-5 Published 10-09-2020, Control # 259-06...

  • Page 85: Section 5

    Drum 4 Pawl ..............5-23 Manitowoc...
  • Page 86 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Operation ..............5-23 Drum 4 Parked .

  • Page 87: General

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS GENERAL DRUM IDENTIFICATION This section provides operational information for the Hoist Systems (Drums 1-4). Additional component information for the Hoist Systems can be found in the following sections of this Service Manual: •...

  • Page 88: All Drums

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL DRUMS 1 AND 2 NOTE: In the following instructions, CCS stands for Crane Control System. Figure 5-2 through Figure 5-5. ALL DRUMS Overview Figure 5-2 through Figure 5-9. Drums 1 and 2 are identically constructed. The hydraulic...

  • Page 89: Motor Displacement

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS which begins to shift to the unchecked position to allow Raising Load motor outflow. When the control handle is moved toward When system flow is in the up direction, the holding valve center, the holding valve begins to close, slowing the load. At...

  • Page 90: Drum 1 Hydraulic Diagram (Without Free Fall)

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 1 Hydraulic Diagram (without Free Fall) A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Motor (Command 0=max displacement, 100%= min Item Drum 1 Components displacement) Handle (Command -100 to 100%) Brake + number = raise, –...

  • Page 91: Drum 1 Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 5-3 Manitowoc Published 10-09-2020, Control # 259-06...

  • Page 92: Drum 2 Hydraulic Diagram (Without Free Fall)

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 2 Hydraulic Diagram (without Free Fall) A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Motor (Command 0=max displacement, 100%= min Item Drum 2 Components displacement) Handle (Command -100 to 100%) Brake + number = raise, –...

  • Page 93: Drum 2 Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 5-5 Manitowoc Published 10-09-2020, Control # 259-06...
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  • Page 95: Drum 3

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 3 When there is no working pressure (handle in center), a check valve stops hydraulic flow in the return side of the Figure 5-6 Figure 5-7. down circuit. This prevents the hoist motor from turning in the down direction.

  • Page 96: Drum 3 Hydraulic Schematic

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 3 Hydraulic Schematic A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Drum 3 Components Brake Handle (Command -100 to 100%) Load Holding Valve + number = raise, – number = lower...

  • Page 97: Drum 3 Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 5-7 Manitowoc 5-11 Published 10-09-2020, Control # 259-06...
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  • Page 99: Drum 4

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 4 Lowering and Holding a Load When flow is in the lowering direction, the holding valve Figure 5-8 Figure 5-9. functions as a hydraulically operated proportional spool The hydraulic circuit for Drum 4 consists of an independently...

  • Page 100: Drum 4 Hydraulic Diagram

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 4 Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Drum 4 Components Load Holding Valve Handle (Command -100 to 100%) Motor Pressure Sensor + number = raise, – number = lower...

  • Page 101: Drum 4 Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 4 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 5-9 Manitowoc 5-15 Published 10-09-2020, Control # 259-06...

  • Page 102: Drum 1 Hydraulic Diagram

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum 1 Hydraulic Diagram (with Free Fall A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Drum 1 Components Handle (Command -100 to 100%) Brake Valve (motor end) + number = raise, –...

  • Page 103: Drum 2 Hydraulic Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Hydraulic Diagram (with Free Fall A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Drum 1 Components Handle (Command -100 to 100%) Brake Valve (motor end) + number = raise, –...

  • Page 104: Free Fall System (Optional)

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Free Fall System (Optional) (Figure 5-18 on page 5-25) or from the free fall speed sensor (Figure 5-19 on page 5-26). Figure 5-10 Figure 5-11. The speed sensor sends a signal to the rotation indicator Drum 1, Drum 2, or both drums can be equipped with the (thumper solenoid) in the control handle.
  • Page 105 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Free Fall Selector Valves Free Fall Brake (Drum 2 shown) Free Fall Speed Senor Cooling Flow In Cooling Flow Out Brake Release Pressure FIGURE 5-13 When the brake pedal is latched down, flow from the free fall...
  • Page 106 HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Drum Description Breather Fill Port Sight Gauge Quick-Drain Valve Upper Hose Fill Plug Level Plug Drain Plug Fill Plug – Motor Shaft Oil Cavity Drums 1 and 2 (similar) Drum 3 Drum 4 FIGURE 5-14 Item Description...

  • Page 107: Drum Gearbox Oil Change

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM GEARBOX OIL CHANGE into an suitable container for collecting the drained oil. Refer to the Lubrication Guide for oil capacities. Drum gearbox maintenance consists of periodically checking 4. Thread the quick-drain drainer assembly to the quick- the level and changing the oil in each drum gearbox.
  • Page 108 HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL View C View A—Engaged View B—Disengaged Item Description Hydraulic Cylinder Pawl Spring Limit Switch Wiring Switch Adjusting Nut (qty 2) Wire Color Function Terminals Eyebolt Black Normally Open Ratchet Green Input Limit Switch White Normally Closed...

  • Page 109: Drum 4 Pawl

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 4 PAWL b. Check the pawl again and make sure it is fully engaged with the ratchet. Figure 5-16 for the following procedures. NOTE: In some cases, the pawl may come to rest on the Operation top of a ratchet tooth.

  • Page 110: Drum 1 And 2 Minimum Bail Limit

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL DRUM 1 AND 2 MINIMUM BAIL LIMIT Pre-Adjustment Figure 5-17 for the following procedures. 1. Pay out the wire rope from the desired Drum 1 or Drum 2 until there are three to four wraps of rope on the first The minimum bail limit stops the corresponding drum from layer of the drum.

  • Page 111: Speed Sensor-Hoist Motors

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS SPEED SENSOR—HOIST MOTORS 1. Lockout-tagout the crane. 2. Disconnect the electrical cable (3A) from the electric Figure 5-18 for the following procedure. cable (3B). A speed sensor (1) is installed in the drum motor (2) for each 3.
  • Page 112 HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Speed Sensor Electrical Cable Hex Cap Screw (Qty 6) Cover Driver Driver Studs (Qty 3) Bearing Housing Set Screw Phillips Head Screw, Flat Washer and Nut (Qty 4) FIGURE 5-19 Drive Pinion 5-26 Published 10-09-2020, Control # 259-06...

  • Page 113: Speed Sensor-Free Fall

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS SPEED SENSOR—FREE FALL 6. Loosen the set screw (8) and remove the driver (5) with drive studs (6) from the speed sensor shaft. Figure 5-19 for the following procedure. 7. Note the orientation of the speed sensor (1) on the cover A speed sensor (1) is installed on the right end of each free (4).

  • Page 114: Anti Two Block (A2B) Switch

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ANTI TWO BLOCK (A2B) SWITCH 1. Remove A2B weight. 2. (A) Remove the cap (1) from switch. If a hoist rope has been reeved and two A2B switches are installed, the unused A2B switch must be locked (disabled) 3.

  • Page 115: General

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS Two-Blocking Definition Two-blocking is the unsafe condition in which the load block or the weight ball contacts the sheave assembly from which WARNING either is suspended. Two-Blocking Hazard! Two-blocking can result in failure of the sheaves and the wire The block-up limit control is a protective device designed rope, possibly causing the load to fall.
  • Page 116 HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Limit Switch (Qty 1-3) Actuator Cable (Qty 1-3) Chain with Shackles and Pins (Qty 1-3) Weight with Chain and Link (Qty 1-3) FIGURE 5-20 5-30 Published 10-09-2020, Control # 259-06...

  • Page 117: Maintenance

    A high-quality wire rope lubricant is available from d. Inspect the entire length of the electric cables for Manitowoc Crane Care Lattice Team. Otherwise, consult damage. your wire rope supplier. Make sure that the electric cables are clear of all...

  • Page 118: Daily Inspection

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL use only pre-assembled lengths of wire rope as supplied Distortion to the uniform structure of the rope from Manitowoc Cranes. Do not build lengths from Broken wires—Record the number, distribution, and individual components. type of broken wires (see Broken Rope Wires on •...

  • Page 119: Periodic Comprehensive Inspection

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS • Comprehensive examination for broken wires (see Broken Rope Wires on page 5-34) • End connections. Check for broken wires or severely corroded, cracked, bent, worn, or improperly applied end connections • Areas subjected to rapid deterioration are as follows:...

  • Page 120: Replacement Criteria

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Power line contact • Exposure to abuse and shock loads, such as: High-velocity movement, such as hoisting or swinging a load followed by abrupt stops Suspending loads while traveling over irregular surfaces such as railroad tracks, potholes, and...

  • Page 121: Rope That Has Been Idle A Month Or More

    NOTE: Wire rope may be purchased through Manitowoc Crane Care Lattice Team. WARNING Falling Load Hazard!

  • Page 122: Sheave, Roller, And Drum Inspection

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL • Check all sheaves, rollers, and drums for the following Observe the groove to see if contour of gauge conditions: matches contour at bottom of sheave groove. Unusual noises Freedom of movement—Must turn freely by hand.
  • Page 123 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL HOISTS B = tread diameter, new sheave E = tread diameter, used sheave B minus E = total wear If total wear is 5 mm (3/16 in) or more, sheave should be replaced. If a tread print exists in root of sheave groove, measure to maximum tread diameter.

  • Page 124: Load Block And Hook-And-Weight Ball Inspection

    Item Description Working Load Limit in Tons (US and metric) Wire Rope Diameter (in and mm) Block Weight (lb and kg) Block Serial Number Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-28 5-38 Published 10-09-2020, Control # 259-06...
  • Page 125 Do not weld on any load-bearing component unless and sheave. proper welding methods are used (contact Manitowoc The groove must be larger than the wire rope, and Crane Care Lattice Team for material and welding the groove must be free of rough edges and burrs.

  • Page 126: Yearly Inspection

    HOISTS MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL • Inspect each hook and shackle for damage (see Figure 5-31). • See the ASME B30-10 Standard for specific hook replacement guidelines. The standards are available as follows: Mail—ASME, 22 Law Drive, Fairfield, New Jersey, 07004-2900 Toll-free phone—US &...
  • Page 127 Oil Change Procedure ............6-7 Manitowoc...
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  • Page 129: General

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM GENERAL The swing brake release system uses pilot pressure from the accessory pump supplied to the swing brake via the swing This section provides operational information for the Swing brake solenoid valve. The brake release pressure must be at System.
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  • Page 131: Swing Left

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Left The swing pump sends hydraulic fluid out port B on the pump to port B on the motor. Hydraulic fluid then flows from port A When joystick J1 is moved to the left, the joystick sends a on the motor to port A on the pump to complete the closed- swing left command to the CCS.

  • Page 132: Swing Hydraulic Diagram

    SWING SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Swing Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Swing Components Item Swing Components Control Handle (Command -100 to 100%) Motor + number = swing right, – number = swing left...

  • Page 133: Swing Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 6-2 Manitowoc Published 10-09-2020, Control # 259-06...

  • Page 134: Swing Brake Manual Release

    SWING SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SWING BRAKE MANUAL RELEASE Figure 6-3 for the following procedure. The crane has one swing drive. When removing or installing the swing drive, the swing brake must be released to allow alignment of the swing pinion with the slewing ring gear.

  • Page 135: Swing Gearbox Oil Change

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Oil Analysis An oil analysis program is the best way to determine the best oil change interval and the condition of the swing gearbox. Periodic Maintenance Initial Drain Interval Drain and refill the swing gearbox after the first 200 hours of engine operation.
  • Page 136 SWING SYSTEM MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL 3. Place the hose from the quick-drain drainer assembly b. Thoroughly clean the inside of the hose for the (Figure 6-5) into an suitable container for collecting the existing quick-drain drainer assembly. drained oil: 5 L (1.3 gal) of oil is required to fill a dry Thread the quick-drain drainer assembly all the way gearbox.

  • Page 137: Section 7

    DRP ............... 7-16 Manitowoc...
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  • Page 139: Battery Information

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY INFORMATION 3. Connect the remaining cable to the frame or block of the starting vehicle. Never connect it to the grounded Battery Safety terminal of the starting vehicle. Causes of Battery Failure A battery should never be left in a discharged state.

  • Page 140: Loose Hold-Downs

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Item Description Cover Mounting Cap Screws, Nuts, and Washers (4 places) Cover Hold-Down Plates with Cap Screws and Washers (Qty 4) Battery Box Battery: 12V, 1,375 CCA, Size 8D (Qty 2) Retaining Bar (Qty 4, past)

  • Page 141: Troubleshooting-Slow Cranking

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN This open-circuit test is the simplest test, but not as accurate post. Also, poor start-switch contacts and frayed, broken, or in determining a battery’s condition as a hydrometer test. corroded cables can be the cause.

  • Page 142: Battery Maintenance

    Disconnect battery cables at 5 KW, continuous duty, 60 HZ AC generator and a DC batteries before welding. charging system is available from Manitowoc Cranes for the following operations when the crane engine is off: The battery disconnect switch...
  • Page 143 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description Item Description Item Description Generator (5 kw,120/240VAC) Circuit Breaker — 50A Main Circuit Breaker — 15A, 2000W Lifting Ring (Qty 4) Circuit Breaker — 15A, 300W Hydraulic Tank Heater Rotating Bed Lights Circuit Breaker — 15A, 1500W...

  • Page 144: Engine Controls

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ENGINE CONTROLS The grating over the radiator and the covers over the exhaust aftertreatment assembly can also be removed. See the engine start procedure in Section 3 of the Operator Manual for engine startup. See the Cummins engine manual for detailed engine instructions.

  • Page 145: Engine Component Identification

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE COMPONENT IDENTIFICATION Item Description Air Cleaner Assembly DEF Tank Battery Box Fuel Tank Exhaust Aftertreatment Assembly Radiator Cummins QSB6.7 Engine Engine Oil Dipstick Engine Oil Fill Cap Engine Oil Drain Valve Fuel Filter Fuel Pre-Filter/Water Separator with Drain Valve...

  • Page 146: Engine Maintenance

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ENGINE MAINTENANCE Check the service indicator (1) with the engine running. The indicator gives a visual indication when it is time to change Refer to the Engine Manufacturer’s Manual supplied with the the air cleaner filters.
  • Page 147 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN move the end of the filter back and forth to break the 8. If removed, carefully install the new secondary filter (6) – seal. O-ring side first – with the tabs and gently push it into the back of the housing.

  • Page 148: Engine Radiator

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ENGINE RADIATOR d. Turn the fill cap fully counterclockwise and remove 5. Slowly add a 50/50 coolant mixture of water and ethylene glycol until the coolant is at the middle of the WARNING sight gauge (2).
  • Page 149 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN 2. Slowly add supplemental coolant additive (SCA) and a • Start the engine and operate it a low idle for 2-3 50-50 coolant mixture to the radiator through the fill cap minutes. opening. Refer to the Engine Manufacturer’s Manual for •...

  • Page 150: Adjusting The Engine Throttle

    If there is a problem with the foot throttle, it is best to either With a supply voltage of 25 V to 26 V available replace it or send the unit to the Manitowoc Crane Care at the white wire, 0 V should be present at the Lattice Team for repair.
  • Page 151 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Potentiometer (Elect. Schematic) Low Idle Supply (white) Signal (green) Ground (black) High Idle Surface X Flat on the Head of the Shaft These two holes should be aligned when initially inserting the shaft and spring into the housing.

  • Page 152: Engine Electrical Schematic

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ENGINE ELECTRICAL SCHEMATIC FIGURE 7-11 7-14 Published 10-09-2020, Control # 259-06...

  • Page 153: Exhaust Aftertreatment System

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN EXHAUST AFTERTREATMENT SYSTEM Tier 4 Main Display Icons Figure 7-12 for the following instructions. Refer to Main Display Operation Manual for identification of the tier 4 icons that appear in the Crane Systems Status Bar Table 7-3.

  • Page 154: Coolant Control Valve

    POWER TRAIN MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL The DEF supply module is heated electrically and with ahead of the inlet to the SCR module (6). The flow of DEF engine coolant. It has a 10-micron filter that requires periodic through the dosing module also keeps it cool and operable.
  • Page 155 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description DEF Tank DEF Supply Module Coolant Control Valve DOC/DPF Module DEF Dosing Module SCR Module Fill Cap Drain Plug Coolant Tee Blocks FIGURE 7-12 Manitowoc 7-17 Published 10-09-2020, Control # 259-06...
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  • Page 157 Motor Shaft Oil Cavity ............8-13 Manitowoc...
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  • Page 159: General

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE GENERAL The speed and direction of the travel motors depends on the output flow volume of the travel pumps, the position of the This section provides operational information for the Travel proportional control valves, and the position of the travel System.

  • Page 160: Travel 2-Speed Operation

    UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL The reduced hydraulic pressure allows spring force to apply • Travel park switch in the UN-PARK position the travel brakes. When either control handle is moved to the forward position, the joystick (J2) communicates the travel command to the Travel 2-Speed Operation CCS.

  • Page 161: No Travel

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE • Simultaneously, the travel brakes are released to allow The purpose of the travel motor flushing circuit is to provide a travel. continuous flow of flushing oil to the case of both travel motors while the crane is traveling.

  • Page 162: Travel Hydraulic Diagram

    UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Travel Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item RIGHT Crawler Components Item LEFT Crawler Components Control Handle (Command -100 to 100%) Control Handle (Command -100 to 100%) + number = forward, –...

  • Page 163: Travel Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Travel Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 8-3 Manitowoc Published 10-09-2020, Control # 259-06...
  • Page 164 UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL View B View A 4 Places Quantities are for Both Crawler Item Description Item Description Drive Tumbler Shim: Qty 18, 6.4 mm (0.25 in) thick Gearbox Shim: Qty 2, 3.4 mm (0.134 in) thick Tread Adjusting Rod...

  • Page 165: Crawler Preventive Maintenance

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE CRAWLER PREVENTIVE MAINTENANCE CRAWLER TREAD SLACK ADJUSTMENT Weekly or Every 40 Hours of Engine Operation Figure 8-4. • Tighten the treads when operating on firm ground. Figure 8-4. • Lubricate the crawlers as instructed in the Lubrication •...

  • Page 166: Intermediate Roller Bolt Torque

    UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL • Clean threads with solvent/degreaser as needed Item Description • Apply LOCTITE™ 263 to threads Intermediate Roller (qty 11 each crawler) • Torque bolts to 895 Nm (660 ft-lb) Bolt with Flat Washer (qty 4 each roller...

  • Page 167: Assembly

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Assembly Test pump operation and remove air from system, if required. Recheck oil level after removing the air. 1. Connect the hose from the pump outlet port to the cylinder inlet (Figure 8-6). Air Removal Figure 8-6.

  • Page 168: Turntable Bearing Alignment

    UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL TURNTABLE BEARING ALIGNMENT Two shear pins (A) are installed in the rotating bed to locate the outer ring (C) with the rotating bed. Figure 8-7 for the following. Verify the S stamp in the outer ring (C) is toward the side of Install the inner ring (D) so the S stamp is towards the side of the rotating bed.

  • Page 169: Tightening Turntable Bearing Bolt

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE TIGHTENING TURNTABLE BEARING BOLT After First 50 Hours of Operation Figure 8-7 for the following procedures. Tighten all bolts, two at a time, in the numbered sequence given to 1 763 Nm (1300 ft-lb). Annually or Every 2,000 Hours of Operation...
  • Page 170 UNDERCARRIAGE MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL View A View B Item Description Level Plug Fill Plug – Gear Box Drain Plug Fill Plug – Motor Shaft Oil Cavity FIGURE 8-8 8-12 Published 10-09-2020, Control # 259-06...

  • Page 171: Crawler Gearbox Oil Change

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE CRAWLER GEARBOX OIL CHANGE engine operation, whichever occurs first, unless an alternate interval has been established through an oil analysis Figure 8-8. program. Gear Oil Specifications Oil Change Procedure For gear oil specifications and the crawler gearbox capacity, Change the oil when the crawler gearboxes are warm.
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  • Page 173: Section 9

    Lubrication ..............9-1 Manitowoc...
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  • Page 175 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2314 at the end of this section. Manitowoc Published 10-09-2020, Control # 259-06...
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  • Page 177: Section 10

    Accessory Systems Electrical Diagram ..........10-5 Manitowoc...
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  • Page 179: Counterweight Pins

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES SECTION 10 ACCESSORIES This section provides operational information for the crane’s • The solenoid on the counterweight pins control valve is accessory hydraulic systems. deenergized. Additional component information for this system can be • A spring shifts the control valve to the engage position.

  • Page 180: Gantry Cylinder Operation

    ACCESSORIES MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL GANTRY CYLINDER OPERATION • At the same time, the retract solenoid on the gantry cylinders control valve is energized by 24 V from the Figure 10-1 Figure 10-2 CCS. Gantry Cylinders Overview • The energized solenoid shifts the valve spool to the...

  • Page 181: Crawler Positioning Cylinders Operation

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES CRAWLER POSITIONING CYLINDERS • At the same time, the retract solenoid on the crawler positioning control valve is energized by 24 V from OPERATION the CCS. Crawler Positioning Cylinders Overview • The energized solenoid shifts the valve spool to the...

  • Page 182: Accessory Systems Hydraulic Diagram

    ACCESSORIES MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ACCESSORY SYSTEMS HYDRAULIC DIAGRAM A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Item Accessory Systems Components Item Accessory Systems Components Pump A (Command (0 to 100%) Accessory System Pump (low pressure)

  • Page 183: Accessory Systems Electrical Diagram

    MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES ACCESSORY SYSTEMS ELECTRICAL DIAGRAM A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 10-2 Manitowoc 10-5 Published 10-09-2020, Control # 259-06...
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  • Page 185 Hydraulic Tests and Calibrations ........... . 2-23 Manitowoc...
  • Page 186 MLC80A-1/MLC90A-1/MLC100A-1/MLC100-1 SERVICE/MAINTENANCE MANUAL Hydraulic Travel System ............8-1 Identification and Location of Major Components .

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