Manitowoc MLC150-1 Service Maintenance Manual
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Manitowoc MLC150-1 Service Maintenance Manual

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Summary of Contents for Manitowoc MLC150-1

  • Page 1 Manitowoc MLC150-1 Service/Maintenance Manual...
  • Page 3 SECTION 10 ACCESSORIES NOTICE The serial number of the 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

    MLC150-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1..........Introduction Continuous Innovation .
  • Page 6 TABLE OF CONTENTS MLC150-1 SERVICE/MAINTENANCE MANUAL SECTION 3 ......... . Electrical System Electrical Schematic .
  • Page 7 MLC150-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Holding Valve..............5-9 Motor displacement .
  • Page 8 TABLE OF CONTENTS MLC150-1 SERVICE/MAINTENANCE MANUAL Broken Rope Wires ............5-42 Rope That Has Been Idle a Month or More .
  • Page 9 MLC150-1 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Engine Cooling System ............7-8 Changing Coolant .
  • Page 10 TABLE OF CONTENTS MLC150-1 SERVICE/MAINTENANCE MANUAL Gantry Cylinders Overview........... . . 10-1 Neutral .
  • Page 11 Identification and Location of Major Components ........1-4 Manitowoc...
  • Page 12 MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 03-21-2021, Control # 264-01...

  • 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 MLC150-1 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 or Fixed Jib (not shown) Lower Boom Point Hook-and-Weight Ball Load Block Boom Top...
  • Page 18 INTRODUCTION MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Item Description Swing Drive High Pressure Accessory Valve Fuel Tank Drum 4 Drive A/C Condenser Counterweight Pins Battery Box Drum 1 Drive Low Pressure Accessory Valve Radiator Main Control Valve Engine Pump Drive and Pump...

  • Page 19: Section 2

    Accumulator Maintenance ..........2-32 Manitowoc...
  • Page 20 MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-ii Published 03-21-2021, Control # 264-01...

  • Page 21: Hydraulic Schematic

    MLC150-1 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: Ola Pump

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL OLA Pump The Open Loop A pump (Figure 2-2) is an axial piston, 130 cc/rev, variable-displacement pump with an electronic displacement control (EDC). The pump has a maximum operating pressure of 350 bar (5075 psi).

  • Page 23: Olb Pump

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM OLB Pump The Open Loop B pump (Figure 2-3) is an axial piston, 130 cc/rev, variable-displacement pump with an electronic displacement control (EDC). The pump has a maximum operating pressure of 350 bar (5075 psi).

  • Page 24: Swing Pump

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Swing Pump The Swing pump (Figure 2-4) is an axial piston, 56 cc/rev, variable-displacement pump with an electronic displacement control (EDC). The pump has a maximum operating pressure of 420 bar (6,096 psi). FIGURE 2-4...

  • Page 25: Fan Pump

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Fan Pump The Fan pump (Figure 2-4) is an axial piston, 18 cc/rev, variable-displacement pump with an electronic displacement control (EDC). The pump has a maximum operating pressure of 152 bar (2,200 psi). FIGURE 2-5...

  • Page 26: Pilot Pump

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Pilot Pump T he P i l o t pu m p ( F i g u re 2 -6) i s a 1 6 c c / r e v , fi x e d - displacement gear pump.

  • Page 27: Hydraulic Motor Identification

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM HYDRAULIC MOTOR IDENTIFICATION proportional displacement control. Displacement is 171,8 cc/ rev maximum and 36 cc/rev minimum Drum 1 and 2 Motors Each motor has an external loop flushing circuit that removes a small volume of oil from the motor loop to provide...

  • Page 28: Drum 3 Motor

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 3 Motor and 36 cc/rev minimum. The motor has an external loop flushing circuit that removes The Drum 3 motor (Figure 2-9) is a bidirectional, variable- a small volume of oil from the motor loop to provide cooling displacement, bent-axis piston motor.

  • Page 29: Drum 4 Motor

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Drum 4 Motor The Drum 4 motor (Figure 2-10) is an bidirectional, bent-axis fixed-displacement motor. Displacement is 107 cc/rev. Motor Shaft Rotation Flow Direction (viewed from shaft end) Port A Port B Drum Operation Clockwise...

  • Page 30: Swing Motor

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Swing Motor The swing motor (Figure 2-12) is a 56.1 cc/rev, bidirectional, fixed-displacement motor, bent-axis piston motor. Motor Shaft Rotation Flow Direction Crane Rotation (viewed from shaft end) (viewed from top) Port A Port B...

  • Page 31: Travel Motors

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Travel Motors Displacement is 142 cc/rev maximum and 68 cc/rev The travel motors (Figure 2-11) are bidirectional, variable- minimum. displacement, bent-axis piston motors. Motor displacement is controlled by a hydraulic two-speed signal and pressure override.

  • Page 32: Hydraulic Valve Identification

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC VALVE IDENTIFICATION Main Control Valve Right Side Enclosure Item Description Right Travel Reverse Right Travel Forward Drum 1 Lower Drum 1 Hoist Drum 3 Lower Drum 3 Hoist Drum 4 Lower Drum 4 Raise...

  • Page 33: Low Pressure Accessory Control Valve

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Low Pressure Accessory Control Valve Right Side Enclosure Item Description Swing Brake Solenoid Valve SB = To Swing Brake Travel High Speed Solenoid Valve THS = To Travel High Speed Motor Command Travel Brake Solenoid Valve...

  • Page 34: High Pressure Accessory Control Valve

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL High Pressure Accessory Control Valve Inside Right-Rear Side of Rotating Bed Item Description Pressure Transducer Relief Valve Throttle Solenoid Valve Gantry RAISE Solenoid Valve B = To Gantry Cylinders EXTEND Ports Gantry LOWER Solenoid Valve...

  • Page 35: Carbody Control Valve

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Carbody Control Valve Item Description Front of Carbody Right Front Carbody Jack Extend Jack Retract Jack Right Rear Carbody Jack FIGURE 2-16 Extend Jack Retract Jack Right Crawler Pins Engage Pins Disengage Pins Left Crawler Pins...
  • Page 36 HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-16 Published 03-21-2021, Control # 264-01...
  • Page 37 MLC150-1 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 2.1 to 2.3 420 (6,096) 30 (435) Swing Right Figure 2-1 on page 1 for pump identification.
  • Page 38 HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Item Description Access Doors in Top of Enclosure Service Indicator Hydraulic Tank Oil Level Switch Oil Level Sight Gauge Oil Sample Valve Temperature Gauge Temperature Sensor Transmitter Hydraulic Filter (Qty 3) Shut-Off Valve...

  • Page 39: Hydraulic System Maintenance

    • Do not unpack parts or remove port plugs until the parts and the instructions in the Manitowoc MLC150-1 Main are needed. Display Operation Manual. •...

  • Page 40: Taking Hydraulic Oil Sample

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL • Fill the tank through the fill plug opening (7). Always filter NOTE: If the oil temperature in the tank rises the oil through an owner-supplied 10-micron filter. above 85°C (185°F), the fault alarm c o m e s o n a n d t h e H y d r a u l i c F l u i d •...

  • Page 41: Inspecting And Replacing Hydraulic Hoses

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM • Kinked, crushed, flattened, or twisted hose • Hard, stiff, heat-cracked, or charred hose WARNING • Blistered, soft, degraded, or loose cover • Cracked, damaged, or badly corroded fittings Burn Hazard! • Fitting slippage on the hose Oil in the hydraulic system is extremely hot.

  • Page 42: Replacing Breather

    Figure 2-19). CAUTION Avoid Hydraulic System Damage! Original equipment manufacturers’ filter elements, available from the Manitowoc Crane Care Lattice Team, Item Description must be used on this crane. Substituting with any other Vent Valve (requires mating coupler) brand or type of filter element is not allowed.
  • Page 43 MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Replace the filter elements when the fault alarm comes on and the Filter 1 icon appears in the Fault Bar of the main display. Also replace the filter elements at each oil change interval. NOTE: It is normal for the fault alarm to come on at startup when the oil is cold.

  • Page 44: Servicing Suction Strainer

    HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Figure 2-21 for the following procedure. 1. Stop the engine and allow the hydraulic oil to cool. View in Left Enclosure 2. Drain the hydraulic oil into a suitable container capable of holding 416 L (110 gal).

  • Page 45: Servicing Pumps

    MLC150-1 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM 17. Check that all pump and motor cases are filled with fresh oil filtered through an owner-supplied 10-micron filter. Quick-Drain Drainer 18. Fill the hydraulic tank to the Full Cold Level mark on the Clamp oil level sight gauge (3).
  • Page 46 HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Typical Drum Motor Main Control Valve Drum Motor Right Side Enclosure Typical All Drums in Right Side Enclosure Free Fall Control Valve Near Pumps in Left Side Enclosure High Pressure Control Valve FIGURE 2-23 Inside Right-Rear Side of Rotating Bed...

  • Page 47: Servicing Pressure Transducers

    T h e s t a t u s o f t h e p r e s s u r e t r a n s d u c e r s a n d t h e corresponding pressure readings can be monitored in the 4. Place a suitable container under the faulty pressure Control Information Screens in the MLC150-1 Main Display transducer to catch hydraulic oil leakage. Operation Manual.

  • Page 48: Shop Procedures

    CAUTION commands can be monitored in the Control Information Equipment Damage! Screens in the MLC150-1 Main Display Operation Manual. Check pump pressures during the first two minutes of Initial Hydraulic Oil Fill operation. If the pressure for any pump is not within the specified range, stop the engine immediately to prevent pump damage.

  • Page 49: Hydraulic Tests And Calibrations

    These procedures must be performed by field personnel Swing Speed Test when parts are replaced or when instructed by a Manitowoc NOTE: Perform this test in an area where the crane can be Dealer.
  • Page 50 HYDRAULIC SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Free Fall Control Valve Near Pumps in Left Side Enclosure Item Description Swing Brake Travel Brake Drum 2 Brake Drum 1 Brake Drum 4 Brake Drum 3 Brake Free Fall Enable Proportional Brake Command Drum 1...

  • Page 51: Disc Brake Operational Test

    1. Turn on free fall for the drum being tested. See the 4. At the main display, navigate to the Control Information MLC150-1 Operator Manual for the procedure. Screen for the function being checked (see the MLC150- 1 Main Display Operation Manual).

  • Page 52: Accumulator Maintenance

    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 assistance if needed. The accumulator must be tested yearly to verify it has retained the specified precharge.
  • Page 53 MLC150-1 SERVICE/MAINTENANCE MANUAL SECTION 3 ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical Schematic ............. . . 3-1 Electrical Power Sequence.
  • Page 54 MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 03-21-2021, Control # 264-01...

  • Page 55: Electrical Schematic

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM ELECTRICAL SCHEMATIC The battery disconnect switch is turned to the OFF position for the following situations: The electrical schematic for this crane is located at the end • Whenever the electrical system is being serviced of this section.

  • Page 56: Crane Electrical Power Distribution

    ELECTRICAL SYSTEM MLC150-1 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 57: Electrical System Ground Points

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM ELECTRICAL SYSTEM GROUND POINTS Figure 3-1 Item Description Ground Strap (between cab and rotating bed) Ground Distribution Post (in compartment behind seat) Ground Strap (between rotating bed and gantry) Ground Stud (on engine) FIGURE 3-1...

  • Page 58: Fuses And Circuit Breakers - Engine

    ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL FUSES AND CIRCUIT BREAKERS — ENGINE Figure 3-2 Figure 3-3. Item Description Fuse: 5A CraneSTAR Battery Disconnect Switch Battery Negative Terminal Battery Positive Terminal Battery Disconnect Relay Solenoid Grid Heater Relay View In Engine Fuse, 250A...
  • Page 59 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM FIGURE 3-3 Manitowoc Published 03-21-2021, Control # 264-01...

  • Page 60: Fuses And Circuit Breakers - Crane Cab

    ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL FUSES AND CIRCUIT BREAKERS — CRANE CAB Figure 3-4. View Behind Seat FIGURE 3-4 Published 03-21-2021, Control # 264-01...
  • Page 61 Relay Contactor — 28V, 120A Cab Switch Power • The circuit breaker numbers (for example, 6C1 and 8C21) correspond to the circuit breaker numbers in the MLC150-1 Electrical Schematic located at the end of this section. Manitowoc Published 03-21-2021, Control # 264-01...

  • Page 62: Can Bus Control System

    ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL 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 63: Can Bus System Diagram

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CAN Bus System Diagram FIGURE 3-5 Manitowoc Published 03-21-2021, Control # 264-01...

  • Page 64: Control Module Identification

    ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Control Module Identification Figure 3-6 Right-Rear Corner of Operator Cab Right Enclosure Left Enclosure Item Description SCM-00 IOSA22 IOLC30 CCM-10 FIGURE 3-6 IOLC31 IOLC32 Control Modules Control Module Naming Conventions There are four types of control modules in the CAN Bus...

  • Page 65: Control Module Input/Output (I/O) Types

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM • Input/Output—Small (IOS) Schematic Definition Term Control modules are named in the format MWXXXABC. Table 3-1 defines the variables used to build the name. PWM Output High Side, where “x” is the OPHxA current in Amps Table 3-1.

  • Page 66: Control Module Devices

    ELECTRICAL SYSTEM MLC150-1 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 67: Limit Switches-Dual Contact

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM • Gantry angle Limit Switches—Dual Contact • 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 68: Control Module Test Voltages

    ELECTRICAL SYSTEM MLC150-1 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 69: Alphabetical Index Of Controller Devices

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Alphabetical Index of Controller Devices Device Controller Find the device of interest and associated controller in Table SCM-00, Free Fall Components 3-4, then refer to the applicable test voltage table for that IOLC32, IOSA22 controller.

  • Page 70: Solenoid Valve Identification

    MLC150-1 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 3-5). HSC10-06 Drum 2 Brake Release PC102-15 The pin number corresponds to the control module...
  • Page 71 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Manitowoc 3-17 Published 03-21-2021, Control # 264-01...

  • Page 72: Test Voltages

    ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL TEST VOLTAGES Table 3-6. SCM-00 Test Voltages Function Voltages P1-1 8C31 (+UB) Battery Power for Control Module Outputs (from CB31) 24 VDC P1-4 ODH1A5 Seat Safety Switch 0 VDC Open, 24 VDC Closed 0 VDC Off, 24 VDC On...
  • Page 73 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-7. IOSA22 Test Voltages Function Voltages P1-1 Ground (from cab ground bus-bar) 0 VDC 24 VDC P1-2 KL15 Control Module Ignition Power (from engine RUN switch) P1-3 ID01 DPF Regen Initiate 0 VDC Open, 24 VDC Closed...
  • Page 74 ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Table 3-8. CCM-10 Test Voltages Function Voltages P1-1 OPH3A23 Left Travel Valve A 0 to 24 VDC P1-2 OPH3A28 Drum 4 Valve B 0 to 24 VDC P1-3 ID21 Drum 4 Pawl Limit Switch N.C.
  • Page 75 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages P2-17 OPLA3 Drum 3 Valve B 0 to 24 VDC P2-18 8C28 (+UB) Battery Power for Control Module Outputs 24 VDC P2-19 OPL3A Left Travel Valve B 0 to 24 VDC P2-20 8C29 (+UB) Battery Power for Control Module Outputs...
  • Page 76 ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Table 3-9. IOLC30 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) 0 VDC P1-2 KL15 Control Module Ignition Power (from engine RUN switch) 0 VDC Open, 24 VDC Closed P1-3 ID01...
  • Page 77 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages 0.15 VDC to 9.85 VDC P2-23 IACV22 Rotating Bed Level Sensor 24 VDC P2-28 ODH3A13 ECM Start Manitowoc 3-23 Published 03-21-2021, Control # 264-01...
  • Page 78 ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Table 3-10. IOLC31 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) 0 VDC P1-2 KL15 Control Module Ignition Power (from engine RUN switch) 0 VDC Open, 24 VDC Closed P1-3 ID01...
  • Page 79 MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-11. IOLC32 Test Voltages Function Voltages P1-1 Ground at Remote Battery Negative Terminal 0VDC P1-2 KL15 Control Module Ignition Power (from engine run switch) 0 VDC Open, 24 VDC Closed P1-3 ID01 Hydraulic Filter Switch...
  • Page 80 ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Function Voltages P2-21 OS85L Remote Control Drum 4 Pay Out/Haul In Switch 0 VDC Off, 24 VDC On P2-25 ODH3A05 A/C Compressor P2-23 IAVC22 Hydraulic Fluid Temperature Sender 4 to 20VDC P2-24 ODH3A03 Drum 1 and 2 Free Fall Brake Hydraulic PSI...

  • Page 81: Inspect Electrical Components

    MLC150-1 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM 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 82 ELECTRICAL SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL 3-28 Published 03-21-2021, Control # 264-01...

  • Page 83: Section 4

    Boom Electrical Diagram ............4-10 Manitowoc...
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  • Page 85: General Maintenance

    MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM GENERAL MAINTENANCE crane’s control system through the IOLC30 control module. The angles are viewable in the Crane Status Bar of the Main This section contains maintenance and adjustment Display Working Screen (View B).
  • Page 86 BOOM MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 03-21-2021, Control # 264-01...

  • Page 87: Boom Angle Indicator

    MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM BOOM ANGLE INDICATOR An boom angle sensor (Figure 4-2) is located on the right inboard side 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 88 BOOM MLC150-1 SERVICE/MAINTENANCE MANUAL Shown with Cover Removed BLK (GRD) GRN (N/O) WHT (28VDC) RED (N/C View A Right Inboard Side of Boom Butt View B – Limit Switch Wiring Item Description Boom Stop Assembly Actuator Boom Butt Smart Level...

  • Page 89: Automatic Boom Stop Assembly

    MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM AUTOMATIC BOOM STOP ASSEMBLY only or boom with fixed jib was set at the factory and should not require periodic adjustment. Adjustment is necessary Figure 4-3. when: The automatic boom stop assembly (1, View A and C) is •...
  • Page 90 BOOM MLC150-1 SERVICE/MAINTENANCE MANUAL BLK (GRD) GRN (N/O) WHT (28VDC) RED (N/C View A Right Inboard Side of Boom Butt View B – Limit Switch Wiring Item Description Boom Stop Assembly Actuator Boom Butt Smart Level Actuator Rod Locking Screw (Qty 2)

  • Page 91: Automatic Boom Stop Adjustment - With Luffing Jib

    MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM Automatic Boom Stop Adjustment — with Loosen the jam nuts (7), the adjusting screws (6), and the mounting screws (8). Luffing Jib d. Slide the limit switch (11) rearward approximately Unless other wise indicated, refer to View A, Figure 4-4 52,4 mm (1 in).
  • Page 92 BOOM MLC150-1 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 4-5 Published 03-21-2021, Control # 264-01...

  • Page 93: Physical Boom Stop

    MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP Figure 4-5 WARNING Collapsing Boom Hazard! Physical boom stops must be installed for all crane operations. Physical boom stops do not automatically stop boom at maximum operating angle. Automatic boom stop must be installed and properly adjusted.

  • Page 94: Boom Electrical Diagram

    BOOM MLC150-1 SERVICE/MAINTENANCE MANUAL BOOM ELECTRICAL DIAGRAM A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. THIS PAGE INTENTIONALLY LEFT BLANK 4-10 Published 03-21-2021, Control # 264-01...

  • Page 95: Section 5

    Motor Shaft Oil Cavity ............5-21 Manitowoc...
  • Page 96 MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 4 Pawl ..............5-23 Operation .
  • Page 97 MLC150-1 SERVICE/MAINTENANCE MANUAL Yearly Inspection ............. 5-50...
  • Page 98 MLC150-1 SERVICE/MAINTENANCE MANUAL 5-iv Published 03-21-2021, Control # 264-01...

  • Page 99: General

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS GENERAL This section contains maintenance and adjustment procedures for the hoists, wire rope, and rigging. Additional component information for the Hoist Systems can be found in the following sections of this Service Manual: •...

  • Page 100: All Drums

    HOISTS MLC150-1 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. The hydraulic circuit for each drum consist of an open loop...

  • Page 101: Motor Displacement

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Motor displacement center, the holding valve begins to close, slowing the load. At center, the check valve is again closed, preventing motor Each motor contains an electronic displacement control. The outflow and downward movement of the load. An orifice in...

  • Page 102: Drum 1 Hydraulic Diagram (Without Free Fall)

    HOISTS MLC150-1 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. For Free Fall, see Figure 5-10 on page 5-16 Drum 1 Components Handle (command -100 to 100%: + number = raise, Load Holding Valve –...

  • Page 103: Drum 1 Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...

  • Page 104: Drum 2 Hydraulic Diagram

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 2 Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. For Free Fall, see Figure 5-11 on page 5-17 Drum 2 Components Handle (command -100 to 100%: + number = raise, Motor Pressure Transducer –...

  • Page 105: Drum 2 Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...
  • Page 106 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 03-21-2021, Control # 264-01...

  • Page 107: Drum 3

    MLC150-1 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 108: Drum 3 Hydraulic Schematic

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 3 Hydraulic Schematic A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Drum 3 Components Handle (command -100 to 100%: + number = raise, Load Holding Valve – number = lower)

  • Page 109: Drum 3 Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...
  • Page 110 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-12 Published 03-21-2021, Control # 264-01...

  • Page 111: Drum 4

    MLC150-1 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 consist of an open loop...

  • Page 112: Drum 4 Hydraulic Diagram

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 4 Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Drum 4 Components Handle (command -100 to 100%: + number = raise, Motor Pressure Transducer – number = lower)

  • Page 113: Drum 4 Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...

  • Page 114: Drum 1 Hydraulic Diagram (With Free Fall)

    HOISTS MLC150-1 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. Drum 1 Components Handle (command -100 to 100%: + number = raise, Brake (motor end) –...

  • Page 115: Drum 2 Hydraulic Diagram (With Free Fall)

    MLC150-1 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. Drum 1 Components Handle (command -100 to 100%: + number = raise, Brake Valve –...

  • Page 116: Free Fall System (Optional)

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Free Fall System (Optional) (Figure 5-20 on page 5-30) or from the free fall speed sensor (Figure 5-21 on page 5-32). 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 117 MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Free Fall Selector Valves Free Fall Brake (Drum 1 shown) Free Fall Speed Senor Cooling Flow In View in Left Enclosure Near Pump Drive Cooling Flow Out Brake Release Pressure FIGURE 5-13 Typical View Left End of Drums 1 and 2 For the remaining instructions, operation applies only to the selected drum.
  • Page 118 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Drums 1 and 2 (similar) Drum 3 Drum Description Breather Fill Port Sight Gauge Quick-Drain Valve Upper Hose Motor Shaft Oil Cavity Fill Plug Fill Plug Level Plug Drain Plug Quick-Drain Drainer Hose Clamp Hose: 3/4 in (19 mm) Inside Diameter by 10 ft (3.0 m) Long...

  • Page 119: Drum Gearbox Oil Change

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM GEARBOX OIL CHANGE 4. Remove the breather (1) and fill plug for faster draining. 5. Thread the quick-drain drainer assembly to the quick- Drum gearbox maintenance consists of periodically checking drain valve. The poppet inside the valve will open the level and changing the oil in each drum gearbox.
  • Page 120 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL View D View C View A—Engaged View B—Disengaged Limit Switch Wiring Item Description Item Description Wire Switch Function Color Terminals Hydraulic Cylinder Screw (Qty 4) Black Normally Open Head Green Input Pawl Setscrew White Normally Closed...

  • Page 121: Drum 4 Pawl

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 4 PAWL NOTE: In some cases, the pawl may come to rest on the top of a ratchet tooth. There must be enough spring tension to pull the pawl into the root of a ratchet tooth if the drum starts to turn in the down direction.
  • Page 122 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL View A—Disengaged View B—Engaged FIGURE 5-16 Item Description Item Description Ratchet Eye Bolt Pawl Adjusting Nut (qty 2) Hydraulic Cylinder 35 mm (1-3/8 in) 211 mm (8-5/16 in) Spring 182 mm (7-5/32 in) 5-24 Published 03-21-2021, Control # 264-01...

  • Page 123: Drum 2 Pawl

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 2 PAWL Weekly Apply open gear lube to the sliding surfaces between the Figure 5-16 for the following procedures. cam (4) and pawl (2). Operation Spring Adjustment The pawl is controlled by the Drum 2 park switch in the If the spring tension becomes insufficient, perform the operator cab.

  • Page 124: Drum 1 And 2 Minimum Bail Limit

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL DRUM 1 AND 2 MINIMUM BAIL LIMIT • The drum can be operated in the hoist direction after the limit is contacted. • The limit can only be bypassed by disconnecting the electric cable (5) from the electric cable (6) and...

  • Page 125: Free Fall Drum

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Free Fall Drum Limit Switch Adjustment Figure 5-18 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 1 or 2 layer of the drum.
  • Page 126 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL View D View B Item Description Item Description Drum 3 Limit Switch Roller (bail and pressure) Electric Cable from Limit Switch Actuator Electric Cable from Wire Harness Lock Nut Shorting Plug View C Adjusting Screw FIGURE 5-19...

  • Page 127: Drum 3 Minimum Bail Limit

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 3 MINIMUM BAIL LIMIT When the fault is activated, the drum stops lowering and the fault icon appears in the fault bar of the Main Display Working Screen. • The drum can be operated in the hoist WARNING direction after the limit is contacted.
  • Page 128 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL View B Drum 4 View A Drum 1 Shown Drums 2 and 3 Similar Item Description Item Description Drum 4 Drum 1 Speed Sensor Speed Sensor Electric Cable from Sensor Electric Cable from Sensor Electric Cable WRR1-P23 from Harness...

  • Page 129: Speed Sensor

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS SPEED SENSOR 7. Remove the speed sensor (2) mounting screws and the faulty speed sensor. Figure 5-20 for the following procedure. 8. Clean the mating surfaces and install the new speed A speed sensor (2 or 6) is installed in the motor of each sensor (2) and O-Ring (9).
  • Page 130 HOISTS MLC150-1 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) Drive Pinion Drum 2 Shown Drum 1 Similar...

  • Page 131: Speed Sensor - Free Fall

    MLC150-1 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 5-21 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 132 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Drum 1 or 2 without Free Fall Drum 1 or 2 with Free Fall Item Description Drum 1 Pressure Roller Assembly without Free Fall — 40 kg (88 lb) Mounting Screws with Washers (Qty 4) M10 x 12 mm or Longer Socket Head Screw (Qty 4)(Owner Furnished) Pressure Roller Assembly with Free Fall —...

  • Page 133: Pressure Rollers

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS PRESSURE ROLLERS 3. Support the pressure roller assembly so it cannot fall and remove the mounting screws (3 or 6). Optional pressure rollers (Figure 5-22) are available to assist 4. Remove the pressure roller assembly from the drum and in maintaining proper wire rope spooling on the Drums 1 and store it for future use.
  • Page 134 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL View A View B View C View D FIGURE 5-23 5-36 Published 03-21-2021, Control # 264-01...

  • Page 135: Block-Up Limit Device

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS The block-up limit device consists of the components shown Figure 5-24 on page 5-38): WARNING Locking/Unlocking Block-Up Limit Switch Two-Blocking Hazard See. Figure 5-23 for the following procedures. Two-blocking is the condition in which the load block or...

  • Page 136: Maintenance

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Limit Switch Actuator Cable Chain with Shackles and Pins Weight with Chain and Links Lower Boom Point Shown. Typical at: • Lower Boom Point 2nd A2B • FIGURE 5-24 Upper Boom Point Maintenance 1. Lower the boom (and the jib, if equipped) onto blocking at ground level.

  • Page 137: Wire Rope Inspection And Replacement

    If replacement is needed, replace with the same length, as pendants) having permanently attached end fittings, size, and material specified in the Parts Manual. use only pre-assembled lengths of wire rope as supplied from Manitowoc Cranes. Do not build lengths from WIRE ROPE INSPECTION AND individual components. REPLACEMENT •...

  • Page 138: Daily Inspection

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL • Do not paint or coat wire ropes with any substance except approved lubricants. Daily Inspection Wire rope should be inspected in accordance with ANSI/ ASME B30.5 and OSHA 29 CFR 1926.1413. A running record of the condition of each wire rope should be noted in the equipment inspection log.

  • Page 139: Periodic Comprehensive Inspection

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Take special care to observe the boom hoist ropes • Inspection of the boom sheaves, hook block sheaves, and rotation-resistant ropes for evidence of core gantry/mast sheaves, boom extension/jib sheaves, jib failure or other deterioration (remove from service)

  • Page 140: Replacement Criteria

    Replacement Criteria WARNING Falling Load Hazard! Replacement wire rope can break if it does not meet Manitowoc Cranes specifications given in the following publications supplied with your crane: • Wire Rope Specifications Chart located in the Capacity Chart Manual (for load lines) •...

  • Page 141: Rope That Has Been Idle A Month Or More

    NOTE: Wire rope may be purchased through Manitowoc • Standing Ropes (pendants)—More than two broken Crane Care Lattice Team. wires in one lay length in sections beyond the end...

  • Page 142: Seizing And Cutting Wire Rope

    HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL Seizing and Cutting Wire Rope • Check the drum clutches and the brakes for proper adjustment. Apply tight seizings of annealed wire to the ends of all wire • Check all sheaves, rollers, and drums for the following rope.
  • Page 143 MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Observe the groove to see if contour of gauge matches contour at bottom of sheave groove. “Corrugated” steel sheave, roller, or drum will cause wire rope to wear rapidly. Groove Too Small Groove Too Large Proper fitting sheave groove should support FIGURE 5-31 wire rope or 135–150°...
  • Page 144 HOISTS MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-46 Published 03-21-2021, Control # 264-01...
  • Page 145 MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS • Measure the nylon sheaves identified in Figure 5-32 Nylon sheaves cannot be accurately inspected excessive tread wear: using conventional methods such as sheave gauges. 80103997 in gantry and equalizer Due to the characteristics of nylon sheaves, the...

  • Page 146: Load Block And Hook-And-Weight Ball Inspection

    Working Load Limit in Tons (US and metric) Hook Wire Rope Diameter (in and mm) Block Weight (lb and kg) Block Serial Number Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-33 FIGURE 5-35 5-48 Published 03-21-2021, Control # 264-01...

  • Page 147: Daily Inspection

    MLC150-1 SERVICE/MAINTENANCE MANUAL HOISTS Daily Inspection • Check the swivel of the hook-and-weight ball for the following conditions: The operating condition of the load block and the hook-and- Overloading—Spin the swivel by hand. If the motion weight ball can change daily with use and therefore must be is rough or has a ratchet-like effect, the swivel inspected daily (at start of each shift).

  • Page 148: Yearly Inspection

    Do not weld on any load-bearing component unless proper welding methods are used (contact Manitowoc Crane Care Lattice Team for material and welding specifications). •...
  • Page 149 Oil Change Procedure ............6-7 Manitowoc...
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  • Page 151: General

    EDC. The PWM output generates a control current within of work being performed in the Speed and Torque Settings the range of 200-600 mA. Screen of the main display (see the MLC150-1 Main Display Operation Manual). The PWM signal is proportional to the speed commanded by the position of joystick J1.
  • Page 152 SWING SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK Published 03-21-2021, Control # 264-01...

  • Page 153: Swing Left

    MLC150-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Left The swing pump sends hydraulic fluid out port A on the pump to port A on the motor. Hydraulic fluid then flows from port B When joystick J1 is moved to the left, the joystick sends a on the motor to port B on the pump to complete the closed- swing left command to the CCS.

  • Page 154: Swing Hydraulic Diagram

    SWING SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL Swing Hydraulic Diagram A detailed hydraulic schematic is provided at the end of Section 2 in this Service Manual. Swing Components Control Handle (command -100 to 100%: + number = Motor swing right, – number = swing left Pump (command -100 to 100%;...

  • Page 155: Swing Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...

  • Page 156: Swing Brake Manual Release

    SWING SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL WARNING Unexpected Crane Movement! When the swing brake is released, the crane can suddenly swing. Before releasing the swing brake, secure the crane by lowering the boom onto blocking at ground level to prevent sudden uncontrolled swinging.

  • Page 157: Swing Gearbox Oil Change

    MLC150-1 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Remove the fill cap (2) and fill the swing gearbox through the fill port to middle of the sight gauge (1). Initial Drain Interval Drain and refill the swing gearbox after the first 200 hours of engine operation.
  • Page 158 SWING SYSTEM MLC150-1 SERVICE/MAINTENANCE MANUAL 4. Thread the quick-drain drainer assembly hose to the b. Thoroughly clean the inside of the hose for the quick-drain valve. The poppet inside the valve will open existing quick-drain drainer assembly. allowing the oil to drain from the gearbox.

  • Page 159: Section 7

    Engine Electrical Schematic ............7-14 Manitowoc...
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  • Page 161: Battery Information

    MLC150-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY INFORMATION Overcharging Overcharging is one cause of battery failure and is most Battery Safety often caused by a malfunctioning voltage regulator. Excessive heat is the result of overcharging. Overheating causes the plates to warp, which can damage the separators WARNING and cause a short circuit within a cell.
  • Page 162 POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL FIGURE 7-1 Published 03-21-2021, Control # 264-01...

  • Page 163: Multiple Battery System

    MLC150-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN Multiple Battery System Legend for Figure 7-1 Item Description The crane’s 24 V system is powered by two 12 V batteries Fuel Tank connected in series (see Figure 7-2). Battery Compartment Cover Lockable Access Door (coolant fill cap and sight gauge) Connect the battery cables as indicated.

  • Page 164: Troubleshooting-Slow Cranking

    POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL Table 7-2. Open Circuit Voltage bring the level just to the top of the plates. Use a clean funnel. Re-check the electrolyte level after charging. Approximate • The maximum charge rate in amperes should be no...

  • Page 165: Battery Disconnect Switch

    ENGINE OPERATION For detailed engine startup and shutdown instructions, refer to Section 3 of the MLC150-1 Operator Manual and to Cummins Owner’s Manual supplied with the crane. The engine is started and stopped with the engine key switch...

  • Page 166: Engine Maintenance

    POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL ENGINE MAINTENANCE when the yellow stem reaches the red zone of the window. The yellow stem remains locked in place when the engine is For detailed engine maintenance and service instructions stopped. The reset button (1B) on the top of the indicator can refer to the Cummins Owner’s Manual supplied with the...
  • Page 167 MLC150-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN There will be some initial resistance, similar to breaking 8. If removed, carefully install the new secondary filter (8) – the seal on a jar. Using the handle (7A) on each filter, O-ring side first – with the plastic rings and gently push it move the end of the filter back and forth to break the into the back of the housing.

  • Page 168: Engine Cooling System

    POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Radiator Lockable Access Door Sight Gauge Fill Cap—1.03 bar (15 PSI) Drain Valve FIGURE 7-7 ENGINE COOLING SYSTEM 4. To prevent engine damage, stop the engine and wait until the coolant temperature is below 50°C (122°F).

  • Page 169: Flushing

    MLC150-1 SERVICE/MAINTENANCE MANUAL POWER TRAIN can hold 30 L (8 gal) of coolant. allow the system to naturally purge entrained air and to allow the coolant level to stabilize. 3. Take care to prevent being burned by hot coolant as follows.
  • Page 170 POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL 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 171: 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 your Manitowoc Dealer for at the white wire, 0 V should be present at the repair.
  • Page 172 POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL FIGURE 7-9 Item Description DEF Tank Fill Cap Drain Plug DEF Supply Module Coolant Control Valve SCR Module DEF Dosing Module Decomposition Reactor Module DOC/DPF Module 7-12 Published 03-21-2021, Control # 264-01...

  • Page 173: Exhaust Aftertreatment System

    NO and NO2 (nitric oxide and The DEF level can be monitored in the Crane Systems nitrogen dioxide). They are produced Status Bar of the main display. See the MLC150-1 Main from the reaction of nitrogen and oxygen Display Operator Manual.

  • Page 174: Coolant Control Valve

    POWER TRAIN MLC150-1 SERVICE/MAINTENANCE MANUAL DEF Dosing Module module pumps DEF to the dosing module (5), which is mounted on the decomposition reactor module (6). The DEF dosing module (5) injects a liquid mixture of urea At engine shutdown, the DEF supply module enters a purge...
  • Page 175 Replacing Slewing Ring Bolts............8-13 Manitowoc...
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  • Page 177: General

    MLC150-1 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 178: Travel 2-Speed Operation

    UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL Travel 2-Speed Operation • If the left control handle is moved forward, the CCS energizes the left travel proportional control valve, The travel motors are variable displacement and shift shifting the valve to the position that allows hydraulic oil...

  • Page 179: No Travel

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE The control system uses this feedback to adjust the pump The travel brake solenoid is deenergized, allowing spring and proportional control valves to maintain the speeds force to apply the travel brakes. commanded by the handles.

  • Page 180: Travel Hydraulic Diagram

    UNDERCARRIAGE MLC150-1 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%: + number = Control Handle (command -100 to 100%: + number = forward, –...

  • Page 181: Travel Electrical Diagram

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Travel Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual. FIGURE 8-2 Manitowoc Published 03-21-2021, Control # 264-01...

  • Page 182: Crawler Preventive Maintenance

    UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL Quantities are for Each Crawler Item Description Item Description Drive Tumbler Cover (shown removed) (qty 2) Gearbox Shim: 10 mm (0.39 in) (qty 1 each side) Tread Shim: 6.4 mm (0.25 in) thick (qty as required) Shim: 3.4 mm (0.134 in) thick (qty as required)

  • Page 183: Crawler Tread Slack Adjustment

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE 4. If the slack exceeds the tight or loose limit, adjust 8. Travel the crane forward and/or in reverse to tighten the crawler tread slack. shims. 9. Check for proper tread slack. CAUTION 10. Tighten the nuts (8) to 2712-4067 Nm (2000-4000 ft-lb).

  • Page 184: Crawler Hand Pump And Cylinder

    UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL CAUTION Hand Pump Damage Do not apply sealant to the first complete thread to ensure the sealant does not shed into the hydraulic system and cause malfunctioning or damage. 2. Apply 1-1/2 wraps of a high-grade thread sealant (Teflon tape) to the fittings.

  • Page 185: Operation

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE cylinder (1) rod to force oil and trapped air back into the 2. To pressurize the jacking cylinder (1) and extend the pump. rod, close the valve (5) by turning it clockwise until finger tight. Pump the jacking handle (6) up and down.
  • Page 186 UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Level Plug Fill Plug Drain Plug View A FIGURE 8-6 8-10 Published 03-21-2021, Control # 264-01...

  • Page 187: Crawler Gearbox Oil Change

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE CRAWLER GEARBOX OIL CHANGE 8. Repeat the procedure for the other crawler gearbox. Figure 8-6. Semi-Annually Drain and refill both crawler gearboxes semi-annually or Gear Oil Specifications every 200 hours of function operation or every 1000 hours of...
  • Page 188 UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL Item Description Slewing Ring — Inner Ring Slewing Ring — Outer Ring 1-1/2 in—6 UNC x 8 in Long Grade 8 Bolt • 48 Places Outer Ring • 48 Places Inner Ring Washer Shear Pin (2 places)

  • Page 189: Slewing Ring Alignment

    MLC150-1 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE SLEWING RING ALIGNMENT After First 50 Hours of Operation Figure 8-7 for the following. Tighten all bolts (3), two at a time, in the numbered sequence given to 2 847 Nm (2,100 ft-lb). Install the inner ring (1) so the S stamp is towards the side of the carbody (7).
  • Page 190 UNDERCARRIAGE MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 8-14 Published 03-21-2021, Control # 264-01...

  • Page 191: Section 9

    Lubrication ..............9-1 Manitowoc...
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  • Page 193 MLC150-1 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2321 at the end of this section. Manitowoc Published 03-21-2021, Control # 264-01...
  • Page 194 LUBRICATION MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 03-21-2021, Control # 264-01...

  • Page 195: Section 10

    Accessory Systems Electrical Diagram ..........10-5 Manitowoc...
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  • Page 197: Gantry Cylinders Operation

    MLC150-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES SECTION 10 ACCESSORIES This section provides operational information for the crane’s • The gantry cylinders are held in their last position by the accessory hydraulic systems. holding valve on each cylinder. Additional component information for this system can be...

  • Page 198: Cab Tilt Operation

    ACCESSORIES MLC150-1 SERVICE/MAINTENANCE MANUAL CAB TILT OPERATION • The cylinder retracts to lower the gantry. Figure 10-1 Figure 10-2 COUNTERWEIGHT PINS The system consists of the OLB pump, a 2-position, Figure 10-1 Figure 10-2 proportional solenoid-operated accessory enable control valve, a 3-position, solenoid-operated control valve, and a Counterweight Pins Overview double-acting hydraulic cylinder with holding valve.

  • Page 199: Counterweight Limit Switch

    MLC150-1 SERVICE/MAINTENANCE MANUAL ACCESSORIES Counterweight Limit Switch HYDRAULIC COOLING FAN OPERATION The counterweight limit switch stops the boom hoist and the Figure 10-1 Figure 10-2 gantry from raising the crane counterweights too high during The system consists of the fan pump, the hydraulic oil cooler counterweight installation.

  • Page 200: Accessory Systems Hydraulic Diagram

    ACCESSORIES MLC150-1 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 Open Loop A Pump (command (0 to 100%)

  • Page 201: Accessory Systems Electrical Diagram

    MLC150-1 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 03-21-2021, Control # 264-01...
  • Page 202 ACCESSORIES MLC150-1 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-6 Published 03-21-2021, Control # 264-01...
  • Page 203 Hydraulic Schematic............. . . 2-1 Manitowoc...
  • Page 204 MLC150-1 SERVICE/MAINTENANCE MANUAL Hydraulic System Maintenance........... . . 2-19 Hydraulic System Overview .

Table of Contents