Manitowoc MLC90A-1 Manuals

Manitowoc MLC90A-1 Manuals

Manuals and User Guides for Manitowoc MLC90A-1. We have 3 Manitowoc MLC90A-1 manuals available for free PDF download: Operator's Manual, Service And Maintenance Manual, Manual

Manitowoc MLC90A-1 Service And Maintenance Manual

Manitowoc MLC90A-1 Service And Maintenance Manual (188 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 8.78 MB

Table of Contents

See End of this Manual for Alphabetical Index

5
- Table of Contents
  5
- Section 1
  13
Section 2 Hydraulic System

19
- Section 2
  19
  - Hydraulic Schematic
    21
  - Hydraulic System Overview
    21
    
    Hydraulic Pump Locations
    21
    
    Pump 1
    22
    
    Pump 2
    22
    
    Pump 3
    23
    
    Pump 4
    23
    
    Pump 5
    24
    
    Drum 1 and 2 Motors
    25
    
    Drum 3 Motor
    25
    
    Motor Identification
    25
    
    Drum 4 Motor
    26
    
    Travel Motors
    27
    
    High Pressure Accessory Valve
    28
    
    Low Pressure Accessory Valve
    28
    
    Rotating Bed Hydraulic Valves
    28
    
    Swing Motors
    28
    
    Main Control Valve
    29
  - Hydraulic System Maintenance
    32
    
    Disposing of Hydraulic Oil and Parts
    32
    
    Safety
    32
    
    Storing and Handling Oil
    32
    
    Storing and Handling Parts
    32
    
    Inspecting the Hydraulic System
    33
    
    Inspecting and Replacing Hydraulic Hoses
    34
    
    Periodic Inspection
    34
    
    Periodic Replacement
    34
    
    Replacing Breather
    35
    
    Filter
    36
    
    Replacing Hydraulic Filters
    36
    
    Servicing Suction Strainer
    37
    
    Changing Hydraulic Oil
    39
    
    Servicing Pumps
    39
  - Replacing Pressure Transducers
    41
    
    Replacing a Pressure Transducer
    41
    
    Testing a Pressure Transducer
    41
  - Shop Procedures
    41
    
    Initial Hydraulic Oil Fill
    41
  - Hydraulic Tests and Calibrations
    43
    
    Charge Pressure Test
    43
    
    Controls Calibration
    43
    
    Drum Speed Test
    43
    
    High Pressure Test
    43
    
    Pressure Sender Calibration
    43
    
    Swing Speed Test
    43
    
    Travel Speed Test
    43
  - Disc Brake Operational Test
    45
    
    Free Fall Brake Operational Test
    45
  - Accumulator Maintenance
    46
Section 3 Electrical System

47
- Section 3
  47
  - Electrical Schematic
    49
  - Electrical Power Sequence
    49
    
    Battery Power
    49
    
    Battery Power Disconnect
    49
    
    Crane Electrical Power Distribution
    50
    
    Cab Right Console Ground Points
    51
    
    Crane Electrical System Ground Points
    51
    
    General
    51
    
    Rotating Bed and Cab Mount Ground Points
    52
  - Circuit Breakers, Fuses, and Relays
    53
  - Inspect Electrical Components
    56
    
    Degradation Due to Severe Environment
    56
    
    Every Month or 200 Hours
    56
  - CAN Bus Control System
    57
    
    CAN Bus System Overview
    57
    
    CAN Bus System Chart
    58
    
    Control Module Input/Output (I/O) Types
    59
    
    Control Module Naming Conventions
    59
    
    Control Modules
    59
    
    Crane Control Module (CCM)
    60
    
    Safety Control Module (SCM)
    60
    
    Input/Output-Large (IOL) Module
    61
    
    Input/Output-Small (IOS) Module
    61
    
    Control Module Devices
    62
    
    Motor Speed Sensors
    62
    
    Pressure Transducers
    62
    
    Alarms
    63
    
    Angle Sensors
    63
    
    Fuel Level Sensor
    63
    
    Hydraulic Fluid Level Switch
    63
    
    Limit Switches-Dual Contact
    63
    
    Limit Switches-Single Contact
    63
    
    Load Link Sensors
    63
    
    Pressure and Vacuum Switches
    63
    
    Solenoids
    63
    
    Temperature Sensors
    63
    
    Control Module Test Voltages
    64
    
    Foot Throttle
    64
    
    Hand Throttle
    64
    
    Proximity Sensors
    64
    
    Pump and Motor Voltages and Currents
    64
    
    Pump Displacement Controls
    64
    
    RCL Beacon
    64
    
    Relays
    64
    
    Travel and Free-Fall Brake Pedals
    64
    
    Wind Speed Indicators
    64
    
    Alphabetical Index of Controller Devices
    65
  - Solenoid Valve Identification
    66
  - Test Voltages
    67
Section 4 Boom

75
- Section 4
  75
Section 5 Hoists

85
- Section 5
  85
  - General
    87
  - Drum Identification
    87
  - All Drums
    88
    
    Brake Release
    88
    
    Drum Brake
    88
    
    Seat Switch
    88
    
    Speed Sensor
    88
  - Drums 1 and 2
    88
    
    Holding Valve
    88
    
    Lowering Load
    88
    
    Overview
    88
    
    Motor Displacement
    89
    
    Pilot-Operated Relief Valve
    89
    
    Raising Load
    89
    
    Drum 1 Hydraulic Diagram (Without Free Fall)
    90
    
    Drum 1 Electrical Diagram
    91
    
    Drum 2 Hydraulic Diagram (Without Free Fall)
    92
    
    Drum 2 Electrical Diagram
    93
  - Drum 3
    95
    
    Holding Valve
    95
    
    Lowering Load
    95
    
    Motor Displacement
    95
    
    Overview
    95
    
    Pilot-Operated Relief Valve
    95
    
    Raising Load
    95
    
    Drum 3 Hydraulic Schematic
    96
    
    Drum 3 Electrical Diagram
    97
  - Drum 4
    99
    
    Drum 4 Pawl
    99
    
    Holding Valve
    99
    
    Lowering and Holding a Load
    99
    
    Pilot-Operated Relief Valve
    99
    
    Raising a Load
    99
    
    Drum 4 Hydraulic Diagram
    100
    
    Drum 4 Electrical Diagram
    101
    
    Drum 1 Hydraulic Diagram
    102
    
    Drum 2 Hydraulic Diagram
    103
    
    Free Fall System (Optional)
    104
  - Drum Gearbox Oil Change
    107
    
    Gear Oil Specifications
    107
    
    Initial Operation
    107
    
    Monthly
    107
    
    Motor Shaft Oil Cavity
    107
    
    Oil Analysis
    107
    
    Oil Change Procedure
    107
    
    Periodic Maintenance
    107
    
    Quick-Drain Valve
    107
    
    Yearly
    107
  - Drum 4 Pawl
    109
    
    Daily
    109
    
    Drum 4 Parked
    109
    
    Drum 4 Un-Parked
    109
    
    Limit Switch Adjustment
    109
    
    Maintenance
    109
    
    Operation
    109
    
    Spring Adjustment
    109
    
    Weekly
    109
  - Drum 1 and 2 Minimum Bail Limit
    110
    
    Limit Switch Adjustment
    110
    
    Pre-Adjustment
    110
  - Speed Sensor-Hoist Motors
    111
    
    Replacement
    111
  - Speed Sensor-Free Fall
    113
    
    Replacement
    113
  - Anti Two Block (A2B) Switch
    114
    
    Locking
    114
    
    Unlocking
    114
    
    Cranes with Main Hoist Only
    115
    
    General
    115
    
    Two-Blocking Definition
    115
    
    Maintenance
    117
  - Wire Rope Inspection and Replacement
    117
    
    Maintain a Wire Rope Condition Report
    117
    
    Required Inspection Intervals
    117
    
    Wire Rope Care and Replacement Guidelines
    117
    
    Wire Rope Lubrication
    117
    
    Daily Inspection
    118
    
    Determining the Frequency of Inspection
    119
    
    Periodic Comprehensive Inspection
    119
    
    Broken Rope Wires
    120
    
    Reduction in the Rope Diameter
    120
    
    Replacement Criteria
    120
    
    Distributing Wire Rope Wear
    121
    
    Rope that Has Been Idle a Month or more
    121
  - Sheave, Roller, and Drum Inspection
    122
  - Load Block and Hook-And-Weight Ball Inspection
    124
    
    Daily Inspection
    124
    
    Yearly Inspection
    126
Section 6 Swing System

127
- General
  129
- Swing Brake Operation
  129
  - Park Switch Control
    129
  - Holding Brake Switch Control
    129
- Swing Operation
  129
  - Swing Pump Control
    129
  - Swing Left
    131
  - Cross Port Orifice
    131
  - Swing Right
    131
  - Coasting
    131
  - Swing Alarm
    131
  - Swing Hydraulic Diagram
    132
  - Swing Electrical Diagram
    133
- Swing System Overview
  129
- Swing Brake Manual Release
  134
- Swing Gearbox Oil Change
  135
  - Gear Oil Specifications
    135
  - Oil Analysis
    135
  - Periodic Maintenance
    135
  - Quick-Drain Valve
    135
  - Oil Change Procedure
    135
    
    Initial Drain Interval
    135
    
    Oil Change Interval
    135
    
    Oil Level Interval
    135
Section 7 Power Train

137
- Section 7
  137
  - Battery Information
    139
    
    Battery Gases Are Explosive
    139
    
    Battery Safety
    139
    
    Causes of Battery Failure
    139
    
    Jump-Starting a Battery
    139
    
    Lack of Water
    139
    
    Overcharging
    139
    
    Undercharging
    139
    
    Checking Battery State of Charge
    140
    
    Loose Hold-Downs
    140
    
    Multiple Battery System
    140
    
    Overloads
    140
    
    Charging
    141
    
    Storage
    141
    
    Troubleshooting-Slow Cranking
    141
  - Battery Maintenance
    142
  - Battery Disconnect Switch
    142
  - Battery Charger (Optional)
    142
  - Engine Controls
    144
  - Engine Access Panels
    144
  - Engine Component Identification
    145
  - Engine Maintenance
    146
  - Engine Belt Routing
    146
  - Air Cleaner Maintenance
    146
    
    Changing the Air Cleaner Filters
    146
    
    Daily Inspection
    146
    
    Monthly Inspection
    146
  - Engine Radiator
    148
    
    Changing Coolant
    148
    
    Draining
    148
    
    Filling
    148
    
    Flushing
    148
  - Adjusting the Engine Throttle
    150
    
    Foot Throttle Control
    150
    
    Foot Throttle Control Assembly and Calibration
    150
    
    Hand Throttle Control
    150
  - Engine Electrical Schematic
    152
  - Exhaust Aftertreatment System
    153
    
    DEF Supply Module
    153
    
    DEF Tank
    153
    
    Engine Regeneration and Inhibit
    153
    
    Tier 4 Main Display Icons
    153
    
    Aps
    154
    
    Coolant Control Valve
    154
    
    DEF Dosing Module
    154
    
    DOC/DPF Module
    154
    
    Drp
    154
    
    Excessive Nox Warning System
    154
    
    SCR Module
    154
Section 8 Undercarriage

157
- General
  159
- Hydraulic Travel System
  159
  - Travel System Overview
    159
  - Travel Brake Operation
    159
    
    Directional Control Valves
    159
    
    Hydraulic Pump
    159
    
    Joystick Control
    159
    
    Travel Motors
    159
    
    Travel Park Brake Engaged
    159
    
    Travel Park Brake Released
    159
  - Travel 2-Speed Operation
    160
  - Travel Cruise Operation
    160
  - Forward Travel Operation
    160
  - Reverse Travel Operation
    160
  - No Travel
    161
  - Travel Motor Flushing
    161
  - Travel Hydraulic Diagram
    162
  - Travel Electrical Diagram
    163
- Crawler Preventive Maintenance
  165
- Crawler Tread Slack Adjustment
  165
- Crawler Tread Slack Measurement
  165
- Crawler Hand Pump and Cylinder
  166
  - Assembly
    167
  - Maintenance
    167
  - Air Removal
    167
  - Operation
    167
- Intermediate Roller Bolt Torque
  166
- Turntable Bearing Alignment
  168
- Replacing Turntable Bolts
  169
- Tightening Turntable Bearing Bolt
  169
  - After First 50 Hours of Operation
    169
  - Annually or Every 2,000 Hours of Operation (Whichever Comes First)
    169
- Crawler Gearbox Oil Change
  171
  - Gear Oil Specifications
    171
  - Oil Analysis
    171
  - Periodic Maintenance
    171
  - Oil Change Procedure
    171
  - Motor Shaft Oil Cavity
    171
    
    Initial Operation
    171
    
    Weekly
    171
- Section 9
  173
  - Lubrication
    173
Manitowoc 10-I

177
- Section 10
  177
  - Counterweight Pins
    179
    
    Counterweight Limit Switch
    179
    
    Counterweight Pins Overview
    179
    
    Disengage (Retract)
    179
    
    Engage (Extend)
    179
  - Gantry Cylinder Operation
    180
    
    Extend
    180
    
    Gantry Cylinders Overview
    180
    
    Load Holding
    180
    
    Neutral
    180
    
    Retract
    180
  - Boom Hoist Operation
    180
  - Crawler Positioning Cylinders Operation
    181
    
    Crawler Positioning Cylinders Overview
    181
    
    Extend
    181
    
    Neutral
    181
    
    Retract
    181
  - Hydraulic Cooling Fan Operation
    181
  - Accessory Systems Hydraulic Diagram
    182
  - Accessory Systems Electrical Diagram
    183

Advertisement

Manitowoc MLC90A-1 Operator's Manual

Manitowoc MLC90A-1 Operator's Manual (218 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 45.93 MB

Table of Contents

Table of Contents
5
Section 1

13
- Crane Data
  13
- Crane Weights
  13
- Outline Dimensions
  13
- Change of Ownership Registration
  13
- Manitowoc Dealer
  13
- Crane Identification
  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
    68
  - Foot Pedals
    71
  - Seat Controls
    72
  - Other Operation Aids
    73
  - Boom Angle Indicator
    73
  - Crane Capacity Beacon (Optional)
    73
  - Crane Level
    73
  - Swing and Travel Alarm
    73
  - Battery Disconnect Switch
    74
  - Crane Cameras
    75
  - Crane Camera Monitor
    76
- Remote Control
  77
- Operating Limits Identification
  79
- Cab Window Operation
  81
  - Opening Windows for Ventilation
    81
  - Exiting Cab in Emergency
    81
- Operating in Wind
  81
- Crawler Blocking
  82
- Preparing Crane for Operation
  82
- Startup Procedures
  83
- Operating Procedures
  85
- Shutdown Procedure or Leaving the Crane Unattended
  94
- Low Clearance Travel Option
  94
- Cold Weather Operation
  100
  - Crane Limitations
    100
  - Wire Rope
    100
  - Cold Weather Starting Aid
    100
  - Cooling System
    100
  - Batteries
    100
    
    Engine Oil, Gear Oil, and Hydraulic Oil
    100
  - AC Power Supply
    102
    
    Generator Installation/Removal
    102
    
    Turning AC Power on
    102
    
    Turning AC Power off
    102
  - Work Lights
    102
  - Cold Weather Heaters
    104
  - Fuses and Circuit Breakers
    106
  - Boom and Jib Assembly Drawings
    111
  - Liftcrane Boom Butt Capacities
    111
  - Crane Orientation
    111
  - Accessing Parts
    111
  - Assembly and Disassembly Notes
    111
  - Assembly and Disassembly Area
    112
  - Handling Components
    112
  - Retaining Connecting Pins
    112
  - Crane Weights and Shipping Data
    112
  - Parts Storage
    112
    
    Parts Box
    112
    
    Position Light and Anemometer Option
    112
  - Lifting Sling
    113
  - Shipping Configuration
    115
  - Self-Erect Components
    115
  - Self-Erect Controls
    116
  - Pin and Connecting Hole Cleanliness
    117
  - Electric Cable Cleanliness
    117
  - Connecting/Disconnecting Hydraulic Hoses and Electric Cables
    117
  - Pre-Start Checks
    117
    
    Deploy the Crane Platforms as Necessary to Gain Access to Components
    117
    
    Engine
    117
    
    Gear Boxes
    117
    
    Hydraulic System
    117
  - Crane Assembly
    119
    
    Prepare Trailer for Unloading
    119
    
    Deploy Crawler Steps
    119
    
    Deploy Crane Platforms
    119
    
    Prepare Cab
    121
    
    Raise Handrails
    123
    
    Start Engine
    125
    
    Configure RCL/RCI for Crane Setup
    125
    
    Raise Gantry
    125
    
    Travel Crane off Trailer
    125
    
    Extend Crawlers
    127
    
    Install Hook-And-Weight Ball
    129
    
    Unload Trailers
    129
    
    Assemble Boom and Jib
    133
    
    Install Carbody Counterweight
    133
    
    Assemble Crane Counterweight
    135
    
    Activate Remote Control
    137
    
    Install Crane Counterweight
    137
    
    Install Crane Counterweight (Continued)
    139
    
    Remove Hook-And-Weight Ball
    143
    
    Connect Boom Butt to Boom
    143
    
    Connect Boom Pendants to Equalizer
    145
  - Disconnect Equalizer from Boom Butt
    145
  - Configure RCL/RCI for Crane Operation
    145
  - Connect Boom Butt to Boom Top Electric Cables
    147
  - Install Boom Top Position Light and Wind Speed Indicator (Option)
    149
  - Install Boom Top Camera (Option)
    149
  - Install Boom Block-Up Limit Components
    149
  - Install Jib Top Position Light and Wind Speed Indicator (Option)
    151
  - Install Jib Top Camera (Option)
    151
  - Connect Jib Extension Cable
    151
  - Install Jib Block-Up Limit Components
    151
  - Deactivating/Activating a Block-Up Limit Switch
    153
  - Install Load Lines
    155
Section 4

111
- Boom and Jib Rigging - General
  156
  - Blocked Crawlers
    156
  - Boom Handling
    156
  - Rigging Drawings
    156
  - Identifying Boom and Jib Components
    156
  - Handling Boom and Jib Sections
    157
- Boom #290 Assembly
  159
  - Assemble Boom Inserts
    159
  - Connect Boom Top to Inserts
    159
  - Install Boom Pendants
    160
  - Install Intermediate Suspension Pendants
    161
  - Install Upper Boom Point
    161
  - Install Optional Rope Guard
    163
  - Install Tagline
    163
  - Complete Boom/Crane Assembly
    163
- Jib #117 Assembly
  165
  - Prepare Boom
    165
  - Install Jib Bottom
    165
  - Install Jib Inserts
    165
  - Install Jib Top
    165
  - Install Jib/Backstay Pendants
    167
  - Prepare to Raise Jib Strut
    167
  - Deploy Strut Raising Arm
    167
  - Raise Jib Strut
    169
  - Deploy Strut Stops
    169
  - Complete Jib Rigging
    169
- Raise Boom
  170
  - Pre-Raising Checks
    170
  - Boom Raising Procedure
    170
- Shipping Crane Components
  171
- Crane Disassembly
  173
  - Prepare Crane
    173
  - Lower Boom
    173
  - Store Load Lines
    173
  - Remove Boom/Jib Point Electronics
    173
  - Store Strut Stops
    175
  - Deploy Strut Raising Arm
    175
  - Lower Jib Strut
    175
  - Connect Equalizer to Boom Butt
    177
  - Open Boom
    179
  - Disconnect Boom Pendants from Equalizer
    181
  - Disconnect Boom Butt from Boom
    181
  - Install Hook-And-Weight Ball
    181
  - Configure RCL/RCI for Crane Setup
    181
  - Remove Crane Counterweight
    183
    
    Remove Crane Counterweight (Continued)
    185
    
    Disassemble Crane Counterweight
    185
    
    Remove Carbody Counterweight
    187
    
    Disassemble Jib and Boom
    187
    
    Load Trailers
    189
    
    Remove Hook-And-Weight Ball
    189
    
    Retract Crawlers
    191
    
    Prepare Trailer for Loading
    193
    
    Travel Crane Onto Trailer
    193
    
    Lower Gantry
    193
    
    Secure Operator Cab
    194
    
    Lower Handrails
    194
    
    Store Crane Platforms
    194
    
    Store Crawler Steps
    194
    
    Prepare Trailer for Travel
    194
  - Boom #290 Disassembly
    194
  - Jib #117 Disassembly
    195
  - Wire Rope Installation
    196
    
    Wire Rope Specifications
    196
    
    Wire Rope Storage
    196
    
    Seizing and Cutting Wire Rope
    196
    
    Anchoring Wire Rope to Drum
    196
    
    Winding Wire Rope Onto Drum
    198
    
    Anchoring Wire Rope to Wedge Socket
    201
    
    Anchoring Wire Rope to Button Socket
    203
    
    Pad Eye Usage for Wire Rope Reeving
    203
    
    Breaking in Wire Rope
    203
  - Load Line Reeving
    205
    
    Guide Sheaves and Drums
    205
    
    Dead End Location
    205
    
    Load Block Identification
    205
    
    Wire Rope Specifications
    205
    
    Load Block Reeving
    205
  - Load Block Tieback
    206
    
    General
    206
    
    Specifications
    206
Section 5

207
- Lubrication
  207
- Lube and Coolant Product Guide
  209
Section 6

213
- Inspection and Maintenance Checklist
  213
- Fiberglass Maintenance
  213

Manitowoc MLC90A-1 Manual

Manitowoc MLC90A-1 Manual (22 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 8.53 MB

Table of Contents

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Construction Equipment Ice Maker Accessories Commercial Food Equipment Dispenser

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