Manitowoc MLC150-1 Manuals

Manuals and User Guides for Manitowoc MLC150-1. We have 3 Manitowoc MLC150-1 manuals available for free PDF download: Operator's Manual, Service Maintenance Manual, Lubrication Manual

Manitowoc MLC150-1 Service Maintenance Manual (206 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 13.49 MB

Table of Contents
5
Section 1
13
Continuous Innovation
13
Safety Messages
13
Safety Alert Symbol
13
Signal Words
13
Safe Maintenance Practices
14
Read this Manual
14
Authorized Repair Personnel Only
14
Basic Crane Maintenance Safety
14
Before Starting a Maintenance Procedure
14
Precautions While Working on the Crane
14
Stored Energy Safety Precautions
15
Chemical Handling Precautions
15
Fire Hazard Precautions
15
Welding Hazard Avoidance
15
Maintaining Structural Integrity of the Crane
15
Protection of the Environment
16
Identification and Location of Major Components
16
Returning the Crane to Service
16
Section 2
19
Hydraulic Schematic
21
Hydraulic System Overview
21
Hydraulic Pump Identification
21
OLA Pump
22
OLB Pump
23
Swing Pump
24
Fan Pump
25
Pilot Pump
26
Free Fall Pump
26
Hydraulic Motor Identification
27
Drum 1 and 2 Motors
27
Drum 3 Motor
28
Drum 4 Motor
29
Swing Motor
30
Travel Motors
31
Hydraulic Valve Identification
32
Main Control Valve
32
Low Pressure Accessory Control Valve
33
High Pressure Accessory Control Valve
34
Carbody Control Valve
35
Hydraulic System Maintenance
39
Safety
39
Storing and Handling Oil
39
Storing and Handling Parts
39
Disposing of Hydraulic Oil and Parts
39
Inspecting Hydraulic System
39
Taking Hydraulic Oil Sample
40
Inspecting and Replacing Hydraulic Hoses
41
Periodic Inspection
41
Periodic Replacement
41
Replacing Breather
42
Replacing Hydraulic Filters
42
Servicing Suction Strainer
44
Changing Hydraulic Oil
44
Servicing Pumps
45
Servicing Pressure Transducers
47
Testing a Pressure Transducer
47
Replacing a Pressure Transducer
47
Shop Procedures
48
Initial Hydraulic Oil Fill
48
Hydraulic Tests and Calibrations
49
Travel Speed Test
49
Swing Speed Test
49
Drum Speed Test
49
Disc Brake Operational Test
51
Free Fall Brake Operational Test
51
Accumulator Maintenance
52
Electrical Schematic
55
Electrical Power Sequence
55
Battery Power
55
Battery Power Disconnect
55
Crane Electrical Power Distribution
56
Electrical System Ground Points
57
Fuses and Circuit Breakers - Engine
58
Fuses and Circuit Breakers - Crane Cab
60
CAN Bus Control System
62
CAN Bus System Overview
62
CAN Bus System Diagram
63
Control Module Identification
64
Control Modules
64
Control Module Naming Conventions
64
Control Module Input/Output (I/O) Types
65
Safety Control Module (SCM)
65
Crane Control Module (CCM)
65
Input/Output-Large (IOL) Module
65
Input/Output-Small (IOS) Module
65
Control Module Devices
66
Pressure Transducers
66
Motor Speed Sensors
66
Limit Switches-Dual Contact
67
Limit Switches-Single Contact
67
Solenoids
67
Angle Sensors
67
Alarms
67
Load Link Sensors
67
Temperature Sensors
67
Fuel Level Sensor
67
Hydraulic Fluid Level Switch
67
Pressure and Vacuum Switches
67
Control Module Test Voltages
68
Relays
68
Hand Throttle
68
Foot Throttle
68
Travel and Free-Fall Brake Pedals
68
Pump Displacement Controls
68
RCL Beacon
68
Wind Speed Indicators
68
Proximity Sensors
68
Pump and Motor Voltages and Currents
68
Alphabetical Index of Controller Devices
69
Solenoid Valve Identification
70
Test Voltages
72
Inspect Electrical Components
81
Every Month or 200 Hours
81
Degradation Due to Severe Environment
81
Section 4
83
General Maintenance
85
Rotating Bed Level Sensor
85
Boom Angle Indicator
87
Automatic Boom Stop Assembly
89
Automatic Boom Stop Maintenance
89
Automatic Boom Stop Adjustment - Without Luffing Jib
89
Automatic Boom Stop Adjustment - with Luffing Jib
91
Physical Boom Stop
93
Physical Boom Stop Angles
93
Physical Boom Stop Operation
93
Physical Boom Stop Adjustment
93
Lattice Section Inspection and Lacing Replacement
93
Boom Electrical Diagram
94
Section 5
95
General
99
Drum Identification
99
All Drums
100
Seat Switch
100
Drum Brake
100
Brake Release
100
Speed Sensor
100
Drums 1 and 2
100
Overview
100
Drum 2 Pawl
100
Holding Valve
100
Lowering Load
100
Motor Displacement
101
Pilot-Operated Relief Valve
101
Raising Load
101
Drum 1 Hydraulic Diagram (Without Free Fall)
102
Drum 1 Electrical Diagram
103
Drum 2 Hydraulic Diagram
104
Drum 2 Electrical Diagram
105
Drum 3
107
Overview
107
Holding Valve
107
Motor Displacement
107
Lowering Load
107
Pilot-Operated Relief Valve
107
Raising Load
107
Drum 3 Hydraulic Schematic
108
Drum 3 Electrical Diagram
109
Drum 4
111
Drum 4 Pawl
111
Holding Valve
111
Lowering and Holding a Load
111
Pilot-Operated Relief Valve
111
Raising a Load
111
Drum 4 Hydraulic Diagram
112
Drum 4 Electrical Diagram
113
Drum 1 Hydraulic Diagram (with Free Fall)
114
Drum 2 Hydraulic Diagram (with Free Fall)
115
Free Fall System (Optional)
116
Drum Gearbox Oil Change
119
Gear Oil Specifications
119
Oil Analysis
119
Periodic Maintenance
119
Quick-Drain Valve
119
Oil Change Procedure
119
Motor Shaft Oil Cavity
119
Initial Operation
119
Monthly
119
Yearly
119
Drum 4 Pawl
121
Operation
121
Maintenance
121
Spring Adjustment
121
Limit Switch Head Orientation
121
Limit Switch Adjustment
121
Drum 4 Parked
121
Drum 4 Un-Parked
121
Daily
121
Weekly
121
Drum 2 Pawl
123
Operation
123
Maintenance
123
Spring Adjustment
123
Drum 2 Un-Parked
123
Drum 2 Parked
123
Daily
123
Weekly
123
Drum 1 and 2 Minimum Bail Limit
124
Non-Free Fall Drum
124
Limit Switch Adjustment
124
Free Fall Drum
125
Limit Switch Adjustment
125
Drum 3 Minimum Bail Limit
127
Limit Switch Adjustment
127
Speed Sensor
129
Replacement
129
Drum 4 (View B)
129
Drum 1, 2, or 3 (View A)
129
Speed Sensor - Free Fall
131
Replacement
131
Pressure Rollers
133
Removing Pressure Roller Assembly
133
Installing Pressure Roller Assembly
133
Block-Up Limit Device
135
General
135
Locking/Unlocking Block-Up Limit Switch
135
Locking a Block-Up Limit Switch
135
Unlocking a Block-Up Limit Switch
135
Maintenance
136
Wire Rope Inspection and Replacement
137
Wire Rope Lubrication
137
Maintain a Wire Rope Condition Report
137
Required Inspection Intervals
137
Wire Rope Care and Replacement Guidelines
137
Daily Inspection
138
Periodic Comprehensive Inspection
139
Determining the Frequency of Inspection
139
Replacement Criteria
140
Reduction in the Rope Diameter
140
Broken Rope Wires
140
Rope that Has Been Idle a Month or more
141
Distributing Wire Rope Wear
141
Seizing and Cutting Wire Rope
142
Sheave, Roller, and Drum Inspection
142
Load Block and Hook-And-Weight Ball Inspection
146
Daily Inspection
147
Yearly Inspection
148
General
151
Swing System Overview
151
Swing Brake Operation
151
Park Switch Control
151
Holding Brake Switch Control
151
Swing Operation
151
Swing Pump Control
151
Swing Left
153
Cross Port Orifice
153
Swing Right
153
Coasting
153
Swing Alarm
153
Swing Hydraulic Diagram
154
Swing Electrical Diagram
155
Swing Brake Manual Release
156
Swing Gearbox Oil Change
157
Gear Oil Specifications
157
Oil Analysis
157
Periodic Maintenance
157
Quick-Drain Valve
157
Oil Change Procedure
157
Oil Level Interval
157
Initial Drain Interval
157
Breather Cleaning Interval
157
Oil Change Interval
157
Section 7
159
Battery Information
161
Battery Safety
161
Battery Gases Are Explosive
161
Jump-Starting a Battery
161
Causes of Battery Failure
161
Overcharging
161
Undercharging
161
Lack of Water
161
Loose Hold-Down Plate
161
Overloads
161
Multiple Battery System
163
Checking Battery State of Charge
163
Troubleshooting-Slow Cranking
164
Charging
164
Storage
164
Battery Maintenance
164
Battery Disconnect Switch
165
Engine Operation
165
Engine Maintenance
166
Engine Belt Routing
166
Air Cleaner Maintenance
166
Daily Inspection
166
Monthly Inspection
166
Changing the Air Cleaner Filters
166
Engine Cooling System
168
Changing Coolant
168
Draining
168
Flushing
169
Filling
169
Adjusting the Engine Throttle
171
Hand Throttle Control
171
Foot Throttle Control
171
Exhaust Aftertreatment System
173
Engine Regeneration and Inhibit
173
Tier 4/Euro Stage 5 Main Display Icons
173
DEF Tank
173
DEF Supply Module
173
Coolant Control Valve
174
DOC/DPF Module
174
DEF Dosing Module
174
SCR Module
174
Decomposition Reaction Module
174
Engine Electrical Schematic
174
Excessive Nox Warning System
174
Aps
174
General
177
Hydraulic Travel System
177
Travel System Overview
177
Travel Brake Operation
177
Hydraulic Pump
177
Directional Control Valves
177
Travel Motors
177
Joystick Control
177
Travel Park Brake Released
177
Travel Park Brake Engaged
177
Travel 2-Speed Operation
178
Travel Cruise Operation
178
Forward Travel Operation
178
Reverse Travel Operation
178
No Travel
179
Travel Motor Cooling
179
Travel Hydraulic Diagram
180
Travel Electrical Diagram
181
Crawler Preventive Maintenance
182
Crawler Tread Slack Measurement
182
Crawler Tread Slack Adjustment
183
Intermediate Roller Bolt Torque
183
Crawler Hand Pump and Cylinder
183
Crawler Hand Pump and Cylinder
184
Assembly
184
Maintenance
184
Air Removal
184
Operation
185
Crawler Gearbox Oil Change
187
Gear Oil Specifications
187
Oil Analysis
187
Periodic Maintenance
187
Oil Change Procedure
187
Initial Operation
187
Weekly
187
Semi-Annually
187
Slewing Ring Alignment
189
Slewing Ring Bolt
189
After First 50 Hours of Operation
189
Annually or Every 2,000 Hours of Operation (Whichever Comes First)
189
Replacing Slewing Ring Bolts
189
Section 9
191
Lubrication
191
Section 10
195
Gantry Cylinders Operation
197
Gantry Cylinders Overview
197
Neutral
197
Retract
197
Load Holding
197
Extend
197
Cab Tilt Operation
198
Neutral
198
Raise
198
Lower
198
Counterweight Pins
198
Counterweight Pins Overview
198
Engage (Extend)
198
Disengage (Retract)
198
Counterweight Limit Switch
199
Boom Hoist Operation
199
Hydraulic Cooling Fan Operation
199
Accessory Systems Hydraulic Diagram
200
Accessory Systems Electrical Diagram
201

Manitowoc MLC150-1 Operator's Manual (254 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 16.6 MB

Table of Contents
5
Section 1

13
- Crane Data
  13
- Crane Weights
  13
- Outline Dimensions
  13
- Crane Identification
  13
- Change of Ownership Registration
  13
- Manitowoc Dealer
  13
- Crane Orientation
  13
- Identification and Location of Components
  14
- English and Metric Conversions
  16
  - Direct Conversion
    16
  - Inverse Conversion
    16
Section 2

19
- Continuous Innovation
  21
- Nameplates and Decals
  21
- Safety Messages
  21
  - General
    21
  - Safety Alert Symbol
    21
  - Signal Words
    21
  - Symbol Identification
    21
- Safety and Information Signs
  23
  - Maintaining Signs
    23
  - Ordering Signs
    23
- Crane Access Points
  25
  - General
    25
- Getting on or off Crane
  25
- Personal Fall-Protection
  25
- Operator Manual/Capacity Chart Storage
  26
  - General
    26
  - Storing Manuals
    26
- Safe Operating Practices
  27
  - General
    27
  - Read Operator Manual
    27
  - Operator Qualifications
    27
  - Operator Conduct
    27
  - Handling Load
    29
  - Size of Load
    29
  - Attaching Load
    29
  - Lifting/Moving Load
    30
  - Multiple Load Line Operation
    31
- Signals
  32
- Holding Load
  32
- Safety Devices
  33
- Operational Aids
  33
  - Category 1 Operational Aids
    33
  - Category 2 Operational Aids
    34
- Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
  35
  - Electrocution Hazard
    35
  - Set-Up and Operation
    35
  - Electrocution Hazard Devices
    36
  - Electrical Contact
    36
- Refueling
  37
- Fire Extinguishers
  37
- Accidents
  37
- Safe Maintenance
  37
  - Maintenance Instructions
    37
  - Safe Maintenance Practices
    37
- Environmental Protection
  39
- Boom Disassembly Safety
  41
- General
  41
- Location
  41
- Pin Removal
  41
- Disassembly Precaution
  41
- Personnel Handling Policy
  42
- Pedestal/Barge Mounted Cranes
  43
  - Pedestal Mounted Crane
    44
  - Barge Mounted Crane
    44
  - Definition
    44
  - Examples
    44
  - Capacity Charts for Barge Mounted Crane
    45
  - Shock Loading Caused by Barge Dynamics
    45
  - Operation on Barge
    45
  - Barge Mount Definitions
    46
  - Inspection of Barge-Mounted Crane
    46
  - Transporting Crane on Barge
    46
Section 3

47
- Standard Hand Signals for Controlling Crane Operations
  50
- Symbols Used on Control Consoles
  52
- Operating Controls
  56
  - Left Console
    60
  - Right Console
    62
  - Overhead Console
    69
  - Foot Pedals
    73
  - Seat Controls
    74
  - Other Operating Aids and Controls
    75
  - Boom Angle Indicator
    75
  - Crane Capacity Beacon (Optional)
    75
  - Crane Levels
    75
  - Swing and Travel Alarm
    75
  - Battery Disconnect Switch
    76
  - Crane Cameras
    78
  - Crane Camera Monitor
    79
- Remote Control
  80
- Carbody Controls
  82
- Operating Limits Identification
  83
- Cab Window Operation
  87
  - Opening Windows for Ventilation
    87
  - Exiting Cab in Emergency
    87
- Operating in Wind
  87
- Crawler Blocking
  87
- Preparing Crane for Operation
  88
- Startup Procedures
  88
- Operating Procedures
  90
- Shutdown Procedure or Leaving the Crane Unattended
  102
- Cold Weather Operation
  104
  - Crane Limitations
    104
  - Wire Rope
    104
  - Cold Weather Starting Aid
    104
  - Cooling System
    104
  - Batteries
    104
  - Engine Oil, Gear Oil, and Hydraulic Oil
    104
- AC Power Supply
  106
  - Turning AC Power on
    106
  - Turning AC Power off
    106
- Work Lights
  106
  - Cold Weather Heaters
    108
  - Fuses and Circuit Breakers
    110
  - Boom and Jib Assembly Drawings
    115
  - Liftcrane Boom Butt Capacities
    115
  - Crane Orientation
    115
  - Accessing Parts
    115
  - Assembly and Disassembly Notes
    115
  - Assembly and Disassembly Area
    116
  - Handling Components
    116
  - Retaining Connecting Pins
    116
  - Crane Weights and Shipping Data
    116
  - Parts Storage
    116
    
    Parts Box
    116
    
    Position Light and Anemometer Option
    117
  - Chain Lifting Sling
    119
  - Shipping Configuration
    120
  - Self-Erect Configuration
    120
  - Self-Erect Controls
    123
  - Pin and Connecting Hole Cleanliness
    124
  - Hose and Cable Cleanliness
    124
  - Connecting/Disconnecting Hydraulic Hoses and Electric Cables
    124
  - Pre-Start Checks
    124
    
    Deploy the Crane Platforms as Necessary to Gain Access to Components
    124
    
    Engine
    124
    
    Gear Boxes
    124
    
    Hydraulic System
    124
  - Operating Limits for Assembly and Disassembly
    125
  - Crane Assembly
    127
    
    Prepare Trailer for Unloading
    127
    
    Deploy Crane Platforms
    127
    
    Prepare Cab
    129
    
    Raise Handrails
    131
    
    Start Engine
    131
    
    Configure RCL/RCI for Crane Setup
    131
    
    Deploy Carbody Jacks
    133
    
    Raise Gantry
    135
    
    Remove Trailer
    136
    
    Install Self-Erect Hook Block
    136
    
    Install Chain Lifting Sling
    137
    
    Install Crawlers - Preliminary Steps
    139
    
    Install First Crawler
    139
    
    Install Second Crawler
    142
    
    Deploy Crawler Steps
    143
    
    Store Carbody Jacks
    143
    
    Connect Crawler Hydraulic Hoses
    145
    
    Raise Handrails
    145
    
    Unload Trailers
    149
    
    Assemble Boom and Jib
    151
    
    Install Carbody Counterweight
    151
    
    Assemble Crane Counterweight
    153
    
    Enable Remote Control
    155
    
    Install Crane Counterweight
    155
    
    Install Crane Counterweight (Continued)
    157
  - Block under Last Insert
    161
  - Remove Self-Erect Hook Block
    161
  - Connect Boom Butt to Boom
    161
  - Connect Boom Straps to Equalizer
    163
  - Close Boom
    163
  - Disconnect Equalizer from Boom Butt
    163
  - Configure RCL/RCI for Crane Operation
    163
  - Connect Boom Butt to Boom Top Electric Cables
    165
  - Install Boom Top Position Light and Wind Speed Indicator (Option)
    167
  - Install Boom Top Camera (Option)
    167
  - Install Boom Block-Up Limit Components
    167
  - Install Jib Top Position Light and Wind Speed Indicator (Option)
    169
  - Install Jib Top Camera (Option)
    169
  - Connect Jib Extension Cable
    169
  - Install Jib Block-Up Limit Components
    169
  - Deactivating/Activating a Block-Up Limit Switch
    171
  - Install Load Lines
    173
Section 4

115
- Boom and Jib Rigging - General
  174
  - Rigging Drawings
    174
  - Blocked Crawlers
    174
  - Identifying Boom and Jib Components
    174
  - Boom Handling with Equalizer
    175
  - Handling Boom and Jib Sections
    175
- Boom #350 Assembly
  177
  - Assemble Boom Inserts
    177
  - Connect Boom Top/Cap to Inserts
    177
  - Raise Boom Cap Wire Rope Guide
    177
  - Connect Boom Straps
    179
  - Install Intermediate Suspension Pendants
    179
  - Install Upper Boom Point
    179
  - Install Optional Tagline
    180
  - Complete Boom/Crane Assembly
    180
- Jib #134 Assembly
  183
  - Prepare Boom
    183
  - Install Jib Package
    183
  - Deploy Backstay Spreader
    183
  - Install Jib Inserts
    183
  - Install Jib Top
    185
  - Install Jib Pendants
    185
  - Prepare Backstay Pendants
    185
  - Connect Backstay Pendants to Boom
    187
  - Install the Jib Stop
    189
  - Complete Jib Rigging
    189
- Raise Boom
  190
  - Pre-Raising Checks
    190
  - Boom Raising Procedure
    190
- Shipping Crane Components
  191
- Crane Disassembly
  193
  - Prepare Crane
    193
  - Lower Boom
    193
  - Store Load Lines
    193
  - Store Block-Up Limit Components
    193
  - Remove Boom/Jib Point Electronics
    193
  - Connect Equalizer to Boom Butt
    195
  - Open Boom
    197
  - Disconnect Boom Straps from Equalizer
    199
  - Disconnect Boom Butt from Boom
    199
    
    Install Self-Erect Hook Block
    201
    
    Configure RCL/RCI for Crane Setup
    201
    
    Remove Blocking from under Last Insert
    201
    
    Install Chain Lifting Sling
    201
    
    Remove Crane Counterweight
    203
    
    Remove Crane Counterweight (Continued)
    205
    
    Disassemble Crane Counterweight
    205
    
    Store Handrails
    205
    
    Remove Carbody Counterweight
    207
    
    Disassemble Boom and Jib
    209
    
    Deploy Carbody Jacks
    211
    
    Store Crawler Steps
    213
    
    Disconnect Crawler Hydraulic Hoses
    213
    
    Remove First Crawler
    213
    
    Remove Second Crawler
    215
    
    Remove Chain Lifting Sling
    217
    
    Remove Self-Erect Hook Block
    217
    
    Install Trailer under Crane
    219
    
    Lower the Boom Butt and Gantry
    219
    
    Store Carbody Jacks
    221
    
    Secure Operator Cab
    221
    
    Lower Handrails
    221
    
    Store Crane Platforms
    221
  - Boom #350 Disassembly
    223
  - Jib #134 Disassembly
    225
    
    Lower Boom and Jib
    225
    
    Prepare Jib for Shipping
    225
    
    Store Jib Stop
    225
    
    Lower Jib Strut
    227
    
    Remove Jib Pendants
    227
    
    Remove Jib Top
    229
    
    Remove Jib Inserts
    229
    
    Install Jib Top on Jib Butt
    229
    
    Store Backstay Spreader and Pendants
    229
    
    Remove Jib Package
    229
  - Wire Rope Installation
    230
    
    Wire Rope Specifications
    230
    
    Wire Rope Storage
    230
    
    Seizing and Cutting Wire Rope
    230
    
    Anchoring Wire Rope to Drum
    230
    
    Winding Wire Rope Onto Drum
    232
    
    Anchoring Wire Rope to Wedge Socket
    235
    
    Anchoring Wire Rope to Button Socket
    237
    
    Pad Eye Usage for Wire Rope Reeving
    237
    
    Breaking in Wire Rope
    237
  - Load Line Reeving
    239
    
    Guide Sheaves and Drums
    239
    
    Dead End Location
    239
    
    Load Block Identification
    240
    
    Wire Rope Specifications
    240
    
    Load Block Reeving
    240
  - Load Block Tieback
    241
    
    General
    241
    
    Specifications
    241

Manitowoc MLC150-1 Lubrication Manual (22 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 6.03 MB

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Manitowoc MLC150-1 Operator's Manual (254 pages)

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Manitowoc MLC150-1 Lubrication Manual (22 pages)

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