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Manitowoc MLC150-1, Service Maintenance Manual

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Manitowoc MLC150-1 Service Maintenance Manual Download Page 95

Manitowoc

Published 03-21-2021, Control # 264-01

5-i

5

SECTION 5

HOISTS

TABLE OF CONTENTS

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drum Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
All Drums  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Speed Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Drums 1 and 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drum 2 Pawl  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Holding Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Lowering Load  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Pilot-Operated Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Raising Load   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Motor displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Drum 1 Hydraulic Diagram (without Free Fall)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drum 1 Electrical Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Drum 2 Hydraulic Diagram  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Drum 2 Electrical Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Drum 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Holding Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Lowering load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pilot-Operated Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Raising Load   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Motor displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Drum 3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Drum 3 Electrical Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Drum 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Drum 4 Pawl  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Holding Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Lowering and Holding a Load   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Pilot-Operated Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Raising a Load  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Drum 4 Hydraulic Diagram  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Drum 4 Electrical Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Drum 1 Hydraulic Diagram (with Free Fall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Drum 2 Hydraulic Diagram (with Free Fall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Free Fall System (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Drum Gearbox Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Gear Oil Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Oil Analysis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Periodic Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Initial Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Monthly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Quick-Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Drums 1, 2, and 4   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Drum 3  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Motor Shaft Oil Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

REFERENCE 

    

ONLY

Summary of Contents for MLC150-1

Page 1: ...Service Maintenance Manual Manitowoc MLC150 1 R E F E R E N C E O N L Y ...

Page 2: ...R E F E R E N C E O N L Y ...

Page 3: ...s or discussing service problems with your Manitowoc dealer or the Manitowoc Crane Care Lattice Team To prevent death or serious injury Avoid unsafe operation and maintenance Crane and attachments must be operated and maintained by trained and experienced personnel Manitowoc is not responsible for qualifying these personnel Do not operate or work on crane or attachments without first reading and u...

Page 4: ...THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH R E F E R E N C E O N L Y ...

Page 5: ...8 Drum 4 Motor 2 9 Swing Motor 2 10 Travel Motors 2 11 Hydraulic Valve Identification 2 12 Main Control Valve 2 12 Low Pressure Accessory Control Valve 2 13 High Pressure Accessory Control Valve 2 14 Carbody Control Valve 2 15 Hydraulic System Maintenance 2 19 Safety 2 19 Storing and Handling Oil 2 19 Storing and Handling Parts 2 19 Disposing of Hydraulic Oil and Parts 2 19 Inspecting Hydraulic Sy...

Page 6: ...n Due to Severe Environment 3 27 SECTION 4 Boom General Maintenance 4 1 Rotating Bed Level Sensor 4 1 Boom Angle Indicator 4 3 Automatic Boom Stop Assembly 4 5 Automatic Boom Stop Maintenance 4 5 Automatic Boom Stop Adjustment without Luffing Jib 4 5 Automatic Boom Stop Adjustment with Luffing Jib 4 7 Physical Boom Stop 4 9 Physical Boom Stop Angles 4 9 Physical Boom Stop Operation 4 9 Physical Bo...

Page 7: ...nt 5 23 Drum 2 Pawl 5 25 Operation 5 25 Maintenance 5 25 Spring Adjustment 5 25 Drum 1 and 2 Minimum Bail Limit 5 26 Non Free Fall Drum 5 26 Limit Switch Adjustment 5 26 Free Fall Drum 5 27 Limit Switch Adjustment 5 27 Drum 3 Minimum Bail Limit 5 29 Limit Switch Adjustment 5 29 Speed Sensor 5 31 Replacement 5 31 Speed Sensor Free Fall 5 33 Replacement 5 33 Pressure Rollers 5 35 Removing Pressure R...

Page 8: ...ulic Diagram 6 4 Swing Electrical Diagram 6 5 Swing Brake Manual Release 6 6 Swing Gearbox Oil Change 6 7 Gear Oil Specifications 6 7 Oil Analysis 6 7 Periodic Maintenance 6 7 Quick Drain Valve 6 7 Oil Change Procedure 6 7 SECTION 7 Power Train Battery Information 7 1 Battery Safety 7 1 Battery Gases Are Explosive 7 1 Jump Starting a Battery 7 1 Causes of Battery Failure 7 1 Overcharging 7 1 Under...

Page 9: ... Operation 8 2 Travel Cruise Operation 8 2 Forward Travel Operation 8 2 Reverse Travel Operation 8 2 No Travel 8 3 Travel Motor Cooling 8 3 Travel Hydraulic Diagram 8 4 8 4 Travel Electrical Diagram 8 5 Crawler Preventive Maintenance 8 6 Crawler Tread Slack Measurement 8 6 Crawler Tread Slack Adjustment 8 7 Intermediate Roller Bolt Torque 8 7 Crawler Hand Pump and Cylinder 8 8 Assembly 8 8 Mainten...

Page 10: ...Extend 10 1 Cab Tilt Operation 10 2 Neutral 10 2 Raise 10 2 Lower 10 2 Counterweight Pins 10 2 Counterweight Pins Overview 10 2 Engage extend 10 2 Disengage retract 10 2 Counterweight Limit Switch 10 3 Boom Hoist Operation 10 3 Hydraulic Cooling Fan Operation 10 3 Accessory Systems Hydraulic Diagram 10 4 Accessory Systems Electrical Diagram 10 5 R E F E R E N C E O N L Y ...

Page 11: ...el Only 1 2 Basic Crane Maintenance Safety 1 2 Before Starting a Maintenance Procedure 1 2 Precautions While Working on the Crane 1 2 Stored Energy Safety Precautions 1 3 Chemical Handling Precautions 1 3 Fire Hazard Precautions 1 3 Welding Hazard Avoidance 1 3 Maintaining Structural Integrity of the Crane 1 3 Returning the Crane to Service 1 4 Protection of the Environment 1 4 Identification and ...

Page 12: ...MLC150 1 SERVICE MAINTENANCE MANUAL 1 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 13: ... to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands a...

Page 14: ...rvice Wear clothing that is relatively tight and belted Wear appropriate eye protection and an approved hard hat Do not attempt to maintain or repair any part of the crane while the engine is running unless it is absolutely necessary If the engine must be running while the crane is being serviced observe the following Maintain constant verbal communication between the person at the controls and th...

Page 15: ...rea when filling hydraulic tanks Only use cleaning solvents which are nonvolatile and nonflammable Do not store flammable materials on the crane Use care while welding or torching on the crane Cover all hoses and components with nonflammable shields or blankets to prevent a fire and other damage Keep the crane clean Accumulations of dirt grease oil rags paper and other waste will not only interfer...

Page 16: ...ces Handle and dispose of waste according to local state and federal environmental regulations When filling and draining crane components do not pour waste fluids onto the ground down any drain or into any source of water Always drain waste fluids into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or a filling pump Immediately wipe up ...

Page 17: ...d Weight Ball 8 Load Block 9 Boom Top 10 Inserts 11 Wire Rope Guides 2 in butt 12 Boom Butt 13 Operator Cab 14 Upperworks 15 Lowerworks 16 Counterweight Carbody 17 Rotating Bed 18 Carbody 19 Crawler qty 2 20 Counterweight Crane 21 Load Cell 22 Counterweight Handling Links and Pendants 23 Gantry Backhitch qty 2 23 Gantry 25 Boom Stop Physical qty 2 26 Boom Hoist Wire Rope Reeving 27 Equalizer 28 St...

Page 18: ...m 2 Drive2 18 Pump Drive and Pump 8 Hydraulic Oil Cooler 19 Engine Air Cleaner 9 Drum 3 Drive2 20 Tier 4 DEF Tank 10 Generator Set 21 Hydraulic Tank 11 Crawler Drive inboard side both crawlers 3 1 Swing drive includes a planetary gearbox with swing pinion a spring applied brake and a motor 2 Each drum drive includes a drum a planetary gearbox a spring applied brake and a motor 3 Each crawler drive...

Page 19: ... Safety 2 19 Storing and Handling Oil 2 19 Storing and Handling Parts 2 19 Disposing of Hydraulic Oil and Parts 2 19 Inspecting Hydraulic System 2 19 Taking Hydraulic Oil Sample 2 20 Inspecting and Replacing Hydraulic Hoses 2 21 Periodic Inspection 2 21 Periodic Replacement 2 21 Replacing Breather 2 22 Replacing Hydraulic Filters 2 22 Servicing Suction Strainer 2 24 Changing Hydraulic Oil 2 24 Ser...

Page 20: ...MLC150 1 SERVICE MAINTENANCE MANUAL 2 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 21: ...tailed descriptions of the controls and operations using these components to form working circuits can be found in the appropriate sections of this manual HYDRAULIC PUMP IDENTIFICATION There are seven hydraulic pumps driven by the engine See Figure 2 1 Pump Supplies Oil To 1 Pump Drive 2 Open Loop B OLB Right Travel Drum 1 Drum 3 High Pressure Accessories Valve 3 Swing 4 Pilot OLA OLB and Low Pres...

Page 22: ... 03 21 2021 Control 264 01 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 FIGURE 2 2 R E F E R E N C E O N L Y ...

Page 23: ...ENANCE MANUAL HYDRAULIC SYSTEM 2 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 FIGURE 2 3 R E F E R E N C E O N L Y ...

Page 24: ...ed 03 21 2021 Control 264 01 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 R E F E R E N C E O N L Y ...

Page 25: ...AINTENANCE MANUAL HYDRAULIC SYSTEM 2 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 R E F E R E N C E O N L Y ...

Page 26: ... psi Free Fall Pump The Freefall pump Figure 2 6 is a fixed displacement dual gear pump Output 1 O1 displacement is 32 cc rev Output 2 O2 displacement is 22 5 cc rev The pump has a maximum operating pressure of O1 5 bar 73 psi O2 75 bar 1 090 psi FIGURE 2 6 Item Description O Output I Input from Tank FIGURE 2 7 Item Description O1 Output 1 Free Fall Cooling O2 Output 2 Free Fall Pilot I Input from...

Page 27: ...acement is controlled by an electric over hydraulic proportional displacement control Displacement is 171 8 cc rev maximum and 36 cc rev minimum Each motor has an external loop flushing circuit that removes a small volume of oil from the motor loop to provide cooling and oil purification FIGURE 2 8 Motor Shaft Rotation viewed from shaft end Flow Direction Port A Port B Drum Operation Clockwise IN ...

Page 28: ...ctric over hydraulic proportional displacement control Displacement is 107 cc rev maximum and 36 cc rev minimum The motor has an external loop flushing circuit that removes a small volume of oil from the motor loop to provide cooling and oil purification FIGURE 2 9 Motor Shaft Rotation viewed from shaft end Flow Direction Port A Port B Drum Operation Clockwise IN OUT Lower Load Counterclockwise OU...

Page 29: ...um 4 Motor The Drum 4 motor Figure 2 10 is an bidirectional bent axis fixed displacement motor Displacement is 107 cc rev FIGURE 2 10 Motor Shaft Rotation viewed from shaft end Flow Direction Port A Port B Drum Operation Clockwise IN OUT Lower Boom Counterclockwise OUT IN Raise Boom R E F E R E N C E O N L Y ...

Page 30: ...swing motor Figure 2 12 is a 56 1 cc rev bidirectional fixed displacement motor bent axis piston motor FIGURE 2 11 Motor Shaft Rotation viewed from shaft end Flow Direction Crane Rotation viewed from top Port A Port B Clockwise IN OUT Clockwise Counterclockwise OUT IN Counterclockwise R E F E R E N C E O N L Y ...

Page 31: ...aulic two speed signal and pressure override Displacement is 142 cc rev maximum and 68 cc rev minimum FIGURE 2 12 Left Crawler Motor Shaft Rotation viewed from shaft end Flow Direction Port A Port B Travel Direction Clockwise IN OUT Forward Counterclockwise OUT IN Reverse Right Crawler Motor Shaft Rotation viewed from shaft end Flow Direction Port A Port B Travel Direction Clockwise IN OUT Reverse...

Page 32: ...A Drum 3 Lower 3B Drum 3 Hoist 4A Drum 4 Lower 4B Drum 4 Raise 5A Drum 2 Lower 5B Drum 2 Hoist 6A Left Travel Reverse 6B Left Travel Forward 7 Gauge Coupler 8 OLB Pump Pressure Transducer 9 Right Travel Pressure Transducer 10 Drum 1 Pressure Transducer 11 Drum 3 Pressure Transducer 12 Drum 4 Pressure Transducer 13 Drum 2 Pressure Transducer 14 Left Travel Pressure Transducer 15 OLA Pump Pressure T...

Page 33: ... D1B To Drum 1 Brake 11 Drum 2 Pawl IN Solenoid Valve 12 D2PA To Drum 1 Pawl Cylinder IN Port 13 Drum 2 Pawl OUT Solenoid Valve 14 D2PB To Drum 1 Pawl Cylinder OUT Port 15 Drum 4 Brake Solenoid Valve 16 D4B To Drum 4 Brake 17 Drum 3 Brake Solenoid Valve 18 D3B To Drum 3 Brake 19 Drum 4 Pawl IN Solenoid Valve 20 D4PA To Drum 4 Pawl Cylinder IN Port 21 Drum 4 Pawl OUT Solenoid Valve 22 D4PB To Drum ...

Page 34: ...l Valve Item Description 1 Pressure Transducer 2 Relief Valve 3 Throttle Solenoid Valve 4 Gantry RAISE Solenoid Valve 5 B To Gantry Cylinders EXTEND Ports 6 Gantry LOWER Solenoid Valve 7 A To Gantry Cylinders RETRACT Ports 8 Lowerworks Enable Valve Inside Right Rear Side of Rotating Bed FIGURE 2 15 R E F E R E N C E O N L Y ...

Page 35: ...ract Jack 2 Right Rear Carbody Jack 2A Extend Jack 2B Retract Jack 3 Right Crawler Pins 3A Engage Pins 3B Disengage Pins 4 Left Crawler Pins 4A Engage Pins 4B Disengage Pins 5 Left Rear Carbody Jack 5A Extend Jack 5B Retract Jack 6 Left Front Carbody Jack 6A Extend Jack 6B Retract Jack P Pump Port T Tank Port A Working Port B Working Port Front of Carbody FIGURE 2 16 R E F E R E N C E O N L Y ...

Page 36: ...HYDRAULIC SYSTEM MLC150 1 SERVICE MAINTENANCE MANUAL 2 16 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 37: ...n each pump Function1 Speed2 RPM Valve Port Motor Port Pressure Bar PSI Drum 1 and 2 Hoist 42 to 49 B B Raising 350 5 075 Lowering 103 1 500 Drum 1 and 2 Lower See 3 A A Drum 3 Hoist 53 to 62 B B Raising 350 5 075 Lowering 180 2 600 Drum 3 Lower See 3 A A Drum 4 Hoist 18 to 22 A A Raising 350 5 075 Lowering 103 1 500 Drum 4 Lower See 3 B B Right Travel Reverse 10 8 to 12 7 at Tumbler A A 350 5 075...

Page 38: ...ture Gauge 5 Hydraulic Filter Qty 3 6 Hydraulic Tank Heater not shown 7 Fill Plug 8 Vent Valve requires a mating coupler 9 Schrader Valve 10 Desiccant Breather Item Description 11 Service Indicator 12 Oil Level Switch 13 Oil Sample Valve 14 Temperature Sensor Transmitter 15 Shut Off Valve 16 Locking Knob 17 OPEN Position 18 CLOSED Position 19 Access Cover Qty 2 20 Quick Drain Valve R E F E R E N C...

Page 39: ...the oil Before opening a drum carefully clean the top of it Clean the faucet or pump to remove oil from the drum Only use clean transfer containers Do not take oil from storage until the oil is needed If the oil cannot be used immediately keep the transfer container tightly covered Storing and Handling Parts Store new parts valves pumps motors hoses and tubes in a clean dry indoor location Do not ...

Page 40: ...dicate that air is being drawn into the pump or motor An air leak can be pinpointed by flooding the inlet fitting hose or tube with oil If there is an air leak the oil will cause a noticeable reduction in noise Correct the cause of any air leak or the pump or motor will be ruined NOTE A high pitched whine or scream from a pump can also indicate cavitation pump being starved of oil This condition m...

Page 41: ... missing hose clamps guards or shields Excessive dirt and debris around hose assemblies If any of these conditions exist address them appropriately Periodic Replacement See Table 2 3 for the following Hydraulic hose assemblies operating in Zone C should be replaced after 8 000 hours of service life Hydraulic hose assemblies operating in Zones A and B with high ambient temperatures and high duty ci...

Page 42: ...can escape when servicing components Allow the hydraulic system to cool before replacing the breather or the hydraulic filters Before opening the tank relieve any pressure from the tank using either vent valve 8 or 9 Figure 2 19 Item Description 1 Vent Valve requires mating coupler 2 Schrader Valve 3 Breather 4 Service Indicator 5 Indicator Coupling 6 Reset Button FIGURE 2 19 WARNING Burn Hazard T...

Page 43: ...Use a correct size wrench on the hexagon on the cover assembly 2 to loosen the cover assembly 7 Check that the O rings are not damaged If so replace 8 Remove filter element 7 and carefully inspect the surface for visible contamination Normally no dirt should show but visible dirt or particles can be an early warning of system component failure 9 Discard both the filter element and its O rings The ...

Page 44: ...lates and tighten with a pipe wrench 8 Reinstall the access cover 1 9 Fill the hydraulic tank with clean oil as instructed in step 18 on page 2 25 10 Start the engine and check for leaks Correct as needed Changing Hydraulic Oil Unless otherwise specified refer to Figure 2 17 page 18 for the following procedure Drain and refill the hydraulic system semiannually or every 1 000 hours of engine operat...

Page 45: ...ulic oil listed in the Lubrication Guide Fill the tank through the fill plug 7 opening Filter the oil through an owner supplied 10 micron filter 19 Close the Schrader valve 3 and the vent valve 4 20 Start the engine and allow the hydraulic system to reach its normal operating temperature 21 Check for leaks and correct them as required 22 Stop the engine 23 Check the hydraulic tank level and fill a...

Page 46: ...rol 264 01 FIGURE 2 23 Main Control Valve Right Side Enclosure Typical Drum Motor Free Fall Control Valve Near Pumps in Left Side Enclosure Drum Motor Typical All Drums in Right Side Enclosure High Pressure Control Valve Inside Right Rear Side of Rotating Bed R E F E R E N C E O N L Y ...

Page 47: ...to catch hydraulic oil leakage 5 Disconnect the electrical connector from the pressure transducer 6 Slowly loosen the pressure transducer only enough to relieve the pressure 7 Remove the pressure transducer and discard it and the oil leakage according to local environmental regulations 8 Install the new pressure transducer and connect the electrical connector 9 Bleed the pressure transducer circui...

Page 48: ...e pawl cylinders a total of 10 times 8 While running the engine at a low idle retract and extend the gantry cylinders to remove air from the cylinders in the following manner a Extend cylinders 50 out 229 mm 9 pause for 2 4 seconds before changing direction then fully retract Pause for 2 4 seconds Repeat b Extend cylinders 75 out 330 mm 13 pause for 2 4 seconds before changing direction then fully...

Page 49: ...ressure Test High Pressure Test Travel Speed Test See Figure 2 24 for the following procedure NOTE Perform this test in an area where the crane can be traveled without interference 1 Apply a timing mark 1 on the tumblers 2 2 Start the engine and run it at high idle 3 Using the travel speed selection switch select high speed travel 4 Travel the crane forward at full speed for one minute and count t...

Page 50: ...n 1 Swing Brake 2 Travel Brake 3 Drum 2 Brake 4 Drum 1 Brake 5 Drum 4 Brake 6 Drum 3 Brake 7 Free Fall Enable 8 Proportional Brake Command Drum 1 9 Proportional Brake Command Drum 2 Free Fall Control Valve Near Pumps in Left Side Enclosure Low Pressure Accessory Control Valve Right Side Enclosure R E F E R E N C E O N L Y ...

Page 51: ...Fall Brake Operational Test Perform this test in an area where the crane can be operated without interference 1 Turn on free fall for the drum being tested See the MLC150 1 Operator Manual for the procedure 2 Lift a single line pull load of 6 710 kg 14 800 lb approximately 305 mm 12 in off the ground 3 Apply the free fall brake pedal and watch the load for one minute 4 The load must not lower 5 If...

Page 52: ...ve the specified maximum pressure Stop the engine when reading the gauge to check the pressure The accumulator is not equipped with a gauge port The technician shall install test equipment in the fitting under the protective cap in the top of the accumulator The fitting size is M28 x 1 5 male thread FIGURE 2 26 Item Description 1 Accumulator Diaphragm Type 0 5 L 17 oz 21 7 bar 315 psi 2 Straight F...

Page 53: ... Large IOL Module 3 11 Input Output Small IOS Module 3 11 Control Module Devices 3 12 Pressure Transducers 3 12 Motor Speed Sensors 3 12 Limit Switches Dual Contact 3 13 Limit Switches Single Contact 3 13 Solenoids 3 13 Angle Sensors 3 13 Alarms 3 13 Load Link Sensors 3 13 Temperature Sensors 3 13 Fuel Level Sensor 3 13 Hydraulic Fluid Level Switch 3 13 Pressure and Vacuum Switches 3 13 Relays 3 1...

Page 54: ...MLC150 1 SERVICE MAINTENANCE MANUAL 3 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 55: ... systems The battery disconnect switch is turned to the OFF position for the following situations Whenever the electrical system is being serviced During extended downtime to help save battery life For security reasons The battery disconnect switch must be in the ON contacts closed position for machine operation When the switch is closed battery power becomes available to the following circuits an...

Page 56: ...les and the crane s CAN Bus control modules as follows Relay K4 When energized relay K4 provides power to the following Engine ECM via CB4 Relay K5 When energized relay K5 provides power from circuit breaker CB3 to terminal UE on the following control modules Relay K6 When energized relay K6 provides power to terminal UB on all crane CAN Bus control modules Relay K6 also provides power to terminal...

Page 57: ...LECTRICAL SYSTEM 3 ELECTRICAL SYSTEM GROUND POINTS See Figure 3 1 Item Description 1 Ground Strap between cab and rotating bed 2 Ground Distribution Post in compartment behind seat 3 Ground Strap between rotating bed and gantry 4 Ground Stud on engine FIGURE 3 1 R E F E R E N C E O N L Y ...

Page 58: ...nal 5 Battery Disconnect Relay Solenoid 6 Grid Heater Relay 7 Fuse 250A 8 K1 Start Relay 9 Ground Studs 10 Power Distribution Module PDM 11 Engine Harness Connector 12 Positive Power Stud 13 Fuse ECM 30A 14 Fuse Panel 15A 15 Fuse DEF Module 15A 16 Fuse AT 15A 17 Fuse Lines Heater 15A 18 Fuse Key 5A 19 Relay AT 20 Relay K8 DEF pressure hose 21 Relay K12 DEF return hose 22 Relay K13 DEF suction hose...

Page 59: ...Manitowoc Published 03 21 2021 Control 264 01 3 5 MLC150 1 SERVICE MAINTENANCE MANUAL ELECTRICAL SYSTEM 3 FIGURE 3 3 R E F E R E N C E O N L Y ...

Page 60: ...ELECTRICAL SYSTEM MLC150 1 SERVICE MAINTENANCE MANUAL 3 6 Published 03 21 2021 Control 264 01 FUSES AND CIRCUIT BREAKERS CRANE CAB See Figure 3 4 FIGURE 3 4 View Behind Seat R E F E R E N C E O N L Y ...

Page 61: ...0 Switch Back Lights 15A Circuit Breaker 8C35 21 J1939 Diagnostics 15A Circuit Breaker 8C37 22 Radio Illumination 15A Circuit Breaker 8C39 23 IOLC30 UB 15A Circuit Breaker 8C22 24 IOLC31 UB 15A Circuit Breaker 8C24 25 IOLC32 UB 15A Circuit Breaker 8C26 26 CCM10 UB 15A Circuit Breaker 8C28 27 CCM10 UB 15A Circuit Breaker 8C30 28 IOSA22 UB 15A Circuit Breaker 8C32 29 Wipers 15A Circuit Breaker 8C34 ...

Page 62: ...N Bus to communicate with each other and with other CAN Bus devices For more information see Control Modules on page 3 10 The control modules receive inputs from components such as switches sensors and transducers The control modules drive outputs to components such as motors relays and solenoids The control module components are hardwired separately to the control modules For more information see...

Page 63: ...Manitowoc Published 03 21 2021 Control 264 01 3 9 MLC150 1 SERVICE MAINTENANCE MANUAL ELECTRICAL SYSTEM 3 CAN Bus System Diagram FIGURE 3 5 R E F E R E N C E O N L Y ...

Page 64: ...s Communicate with each other over the CAN Bus Read input devices Command output devices Control Module Naming Conventions There are four types of control modules in the CAN Bus system Safety Control Module SCM Crane Control Module CCM Input Output Large IOL FIGURE 3 6 Item Description 1 SCM 00 2 IOSA22 3 IOLC30 4 CCM 10 5 IOLC31 6 IOLC32 Right Rear Corner of Operator Cab Right Enclosure Left Encl...

Page 65: ...rol the devices connected to them and communicate with the SCM or CCM connected to their bus IOLs have twice the device capacity as the input output small IOS modules There are three IOL modules mounted on the crane see Figure 3 6 IOLC30 IOLC31 and IOLC32 located in the right and left enclosures on the rotating bed Input Output Small IOS Module IOSs control the devices connected to them and commun...

Page 66: ...essure Accessory system pressure Track pressure Cooler fan pressure Motor Speed Sensors See Figure 3 7 for the following A controller provides power to Hall effect speed sensors within the hydraulic motors that drive the drums rotating bed and crawlers A gear wheel within the motor has teeth that move past the speed sensor as a motor shaft spins causing the sensor to produce two square wave signal...

Page 67: ... to measure the following items Gantry angle Boom angle Rotating bed pitch and roll Alarms A controller digital output drives the applicable alarm during various operational states Swing motion Travel motion Load approaching or exceeding capacity Load Link Sensors A controller digital output provides power to the load pin sensors A strain gauge within the load pin produces an analog output current...

Page 68: ...that actuate the solenoid valve in opposite directions As a PWM duty cycle increases at one coil more fluid is ported to the swashplate servo pistons through the solenoid valve increasing the swashplate angle in the direction commanded As the swashplate angle increases so does the piston stroke within the pump increasing the pump output volume RCL Beacon A controller provides a digital output to e...

Page 69: ... Drum 2 Components CCM 10 CCM S 10 IOLC31 Drum 3 Components CCM 10 CCM S 10 Drum 4 Components CCM 10 CCM S 10 ECM Start Relay IOLC32 Engine Components SCM 00 CCMC11 IOLC30 IOLC32 IOSA22 Free Fall Components SCM 00 IOLC32 IOSA22 Fuel Level Sensor IOLC30 Gantry Components IOLC30 Hydraulic Filter Alarm Switch IOLC32 Hydraulic Fluid Level and Temperature Sensor IOLC32 Hydraulic Pressure Accessory Enab...

Page 70: ...ence Designator 6 Connector Number 7 Pin Number HSC10 06 Drum 2 Brake Release PC102 15 HSC10 07 Drum 3 Brake Release PC102 14 HSC10 08 Drum 4 Brake Release PC102 04 HSC10 09 Drum 4 Pawl In PC102 03 HSC10 11 Drum 4 Pawl Out PC102 24 HSC10 12 Travel High Speed PC102 25 HSC10 13 Counterweight Pin Pullers PC102 06 HSC 10 15 Carbody Accessory Enable PC102 07 HSC10 23 Left Travel Side A PC101 01 HSC10 2...

Page 71: ...Manitowoc Published 03 21 2021 Control 264 01 3 17 MLC150 1 SERVICE MAINTENANCE MANUAL ELECTRICAL SYSTEM 3 R E F E R E N C E O N L Y ...

Page 72: ...losed P1 22 IACV11 Hand Throttle Input 0 5 VDC Low Idle 4 5 VDC High Idle P1 23 IACV12 Engine Foot Throttle Input 0 90 to 1 00 VDC High Idle 2 90 to 3 00 VDC Low Idle P1 24 IACV13 Drum 2 Free Fall Pedal Input 1 5 to 8 5 VDC P1 25 RTCN 3 6 VDC Real Time Clock Battery Power negative 0 VDC P1 26 0S85L 8 5 VDC Ground Bus Hand Throttle 8 5 VDC P1 27 KL15 Control Module Ignition Power from engine RUN sw...

Page 73: ...attery Power for Control Module Outputs from CB32 24 VDC P1 12 6C1A UE Control Module Battery Power from K5 24 VDC P1 13 ID03 Limit Bypass Switch 0 VDC Open 24 VDC Closed P1 14 ID04 Limit Bypass Switch 0 VDC Open 24 VDC Closed P1 15 ID05 RCL Override Switch 0 VDC Open 24 VDC Closed P1 16 ID06 RCL Override Switch 0 VDC Open 24 VDC Closed P1 17 IDF12 Drum 3 Un Park 0 VDC P1 19 CAN_A L CAN Bus A Low ...

Page 74: ...ion Power from engine RUN switch 0 VDC Open 24 VDC Closed P1 28 OPH3A27 Drum 4 Valve A 0 to 24 VDC P1 29 GND Ground from ground stud on rotating bed 0 VDC P1 35 IDF02 Drum 4 Motor Speed Sensor 6 low to 70 high of 8 5 VDC P1 36 IDF07 Drum 2 Flange Encoder 6 low to 70 high of 8 5 VDC P1 37 IDF08 Drum 2 Flange Encoder 6 low to 70 high of 8 5 VDC P1 38 IACV15 Drum 4 Motor PSI 4 to 20 mA P1 39 IACV13 D...

Page 75: ...4 VDC P2 21 ODH3A02 Drum 3 Motor Speed Sensor and Pressure 24 VDC P2 22 ODH3A04 Travel Brake Release 0 to 24 VDC P2 23 ODH3A10 Right Travel Pressure 0 to 24 VDC P2 24 ODH3A11 Drum 4 Pawl Extend 0 VDC Off 24 VDC On P2 25 ODH3A12 Travel High Speed 0 to 24 VDC P2 26 ODH3A16 Drum 2 Pawl Extend 0 VDC Off 24 VDC On P2 27 OPL3A21 Right Travel Valve B 0 to 24 VDC P2 28 OPL3A Drum 4 Valve B 0 to 24 VDC P2 ...

Page 76: ...1 16 ID06 Fixed Jib Connect 0 VDC Open 24 VDC Closed P1 17 IDF15 Drum 1 Flange Encoder EU 0 or 24 VDC P1 18 IMID2 GND NA P1 19 CAN1L CAN_C L NA P1 20 8C22 UB Battery Power for Control Module Outputs from CB21 24 VDC P1 21 ID07 Rotating Bed Level Sensor 0 VDC Disconnected 24 VDC Connected P1 26 IDF16 Drum 1 Flange Encoder EU 0 or 24 VDC P1 27 IACV17 Wind Speed Indicator 24 VDC P1 28 IMID3 GND NA P1...

Page 77: ...1 2021 Control 264 01 3 23 MLC150 1 SERVICE MAINTENANCE MANUAL ELECTRICAL SYSTEM 3 P2 23 IACV22 Rotating Bed Level Sensor 0 15 VDC to 9 85 VDC P2 28 ODH3A13 ECM Start 24 VDC Pin Net Function Voltages R E F E R E N C E O N L Y ...

Page 78: ... 5 VDC P1 20 8C36 UB Battery Power for Control Module Outputs from CB23 24 VDC P1 26 IDF16 Drum 1 Motor Speed Sensor 6 low to 70 high of 8 5 VDC P2 3 ID14 Boom Up Limit P2 4 IACV18 Drum 2 Motor PSI 4 to 20 mA P2 5 ODH3A02 Drum 2 and 3 Motor PSI 0 VDC Off 24 VDC On P2 6 ODH3A04 Alarm Switch Swing and Travel Limit 0 VDC Off 24 VDC On P2 7 ODH3A07 Pump 1 and Pump 2 Pressure P2 10 OPH3A15 25VDC Drum 2...

Page 79: ...Control Module Outputs from CB25 24VDC P1 21 ID07 Remote Control Gantry Cylinder Boom Hoist Sync Switch P1 22 ID08 Remote Control E Stop Switch P1 23 ID09 Remote Control Counterweight Pins Disengage Switch P1 24 ID10 Remote Control Gantry Cylinder Extend Switch P1 25 ID11 Remote Control Gantry Cylinder Retract Switch P1 26 IDF16 Drum 2 Free Fall Encoder EU P1 27 IACV17 Remote Control Drum 4 Pay Ou...

Page 80: ...ntrol Drum 4 Pay Out Haul In Switch P2 25 ODH3A05 A C Compressor 0 VDC Off 24 VDC On P2 23 IAVC22 Hydraulic Fluid Temperature Sender 4 to 20VDC P2 24 ODH3A03 Drum 1 and 2 Free Fall Brake Hydraulic PSI 4 to 20VDC P2 27 ODH3A11 Starter Motor Relay 0 VDC Off 24 VDC On Pin Net Function Voltages R E F E R E N C E O N L Y ...

Page 81: ...ddress them appropriately Degradation Due to Severe Environment Table 3 12 Climate Zone Classification Zones A and B Replace harnesses and battery cables operating in these climate zones after 8 000 hours of service life Their electrical service life is reduced by 25 to 40 Zone C Replace harnesses and battery cables operating in this climate zone after 10 000 hours of service life Zones D and E Co...

Page 82: ...ELECTRICAL SYSTEM MLC150 1 SERVICE MAINTENANCE MANUAL 3 28 Published 03 21 2021 Control 264 01 R E F E R E N C E O N L Y ...

Page 83: ... Assembly 4 5 Automatic Boom Stop Maintenance 4 5 Automatic Boom Stop Adjustment without Luffing Jib 4 5 Automatic Boom Stop Adjustment with Luffing Jib 4 7 Physical Boom Stop 4 9 Physical Boom Stop Angles 4 9 Physical Boom Stop Operation 4 9 Physical Boom Stop Adjustment 4 9 Lattice Section Inspection and Lacing Replacement 4 9 Boom Electrical Diagram 4 10 R E F E R E N C E O N L Y ...

Page 84: ...MLC150 1 SERVICE MAINTENANCE MANUAL 4 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 85: ...splay Working Screen View B To adjust the level sensor 1 Move the crane onto a level surface 2 Using a smart level measure the crane s roll and pitch at the turntable bearing 3 Securely fasten the level sensor 1 and the mounting plate 2 to the bracket 3 with the screws nuts and washers 4 Loosen the nuts 8 and adjust nuts 7 at location A so the roll and pitch shown in the main display match the rol...

Page 86: ...BOOM MLC150 1 SERVICE MAINTENANCE MANUAL 4 2 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 87: ...nd communicates the information to the crane s control system through the CCM S 10 control module The boom angle appears in the various screens of the RCL RCI Display For sensor installation and calibration instructions refer to the Performing Boom Calibration topic in the RCL RCI Operation Manual supplied with the crane FIGURE 4 2 Item Description 1 Angle Sensor 2 Boom Butt 3 RCL RCI Working Scre...

Page 88: ...d 6 Locking Screw Qty 2 7 Jam Nut Qty 2 8 Mounting Screw Qty 4 9 Roller 10 Limit Switch Boom 11 Limit Switch Luffing Jib Option X1 75 148 with Boom at 82 X2 81 648 With Boom at 88 5 FIGURE 4 3 GRN N O BLK GRD RED N C WHT 28VDC View B Limit Switch Wiring View B Right Side of Crane View A Right Inboard Side of Boom Butt Shown with Cover Removed R E F E R E N C E O N L Y ...

Page 89: ...e RCL RCI The following instructions assume that the RCL RCI is installed and properly calibrated During the following procedure the boom angle is monitored on the Working Screen of the RCL RCI Display Figure 4 2 on page 4 3 and on a smart level 4 View B Figure 4 3 Unless other wise indicated refer to View A Figure 4 3 for the following procedure 1 Park the crane on a firm level surface or level t...

Page 90: ...art Level 5 Actuator Rod 6 Locking Screw Qty 2 7 Jam Nut Qty 2 8 Mounting Screw Qty 4 9 Roller 10 Limit Switch Boom only 11 Limit Switch Luffing Jib Option X2 81 648 With Boom at 88 5 View B Limit Switch Wiring View B Right Side of Crane View A Right Inboard Side of Boom Butt FIGURE 4 4 GRN N O BLK GRD RED N C WHT 28VDC R E F E R E N C E O N L Y ...

Page 91: ...om does not stop at the specified angle proceed as follows a Remove the cover from the boom stop assembly b Lower the boom to approximately 80 c Loosen the jam nuts 7 the adjusting screws 6 and the mounting screws 8 d Slide the limit switch 11 rearward approximately 52 4 mm 1 in e Raise the boom to 88 5 and verify the boom angle with an accurate smart level 4 View B placed on the boom butt bottom ...

Page 92: ...MANUAL 4 8 Published 03 21 2021 Control 264 01 FIGURE 4 5 View B Physical Stop View A Start of Cushioning Item Description 1 Boom Butt 2 Physical Boom Stop 2 3A Springs fully relaxed 3B Springs fully compressed R E F E R E N C E O N L Y ...

Page 93: ...is raised to 59 1 the springs start to compress View A As the boom is raised higher spring compression increases to exert greater force against the boom If for any reason the boom is raised to 89 9 the springs fully compress to provide a physical stop View B Physical Boom Stop Adjustment The physical boom stops do not require adjustment LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Fo...

Page 94: ...NANCE MANUAL 4 10 Published 03 21 2021 Control 264 01 BOOM ELECTRICAL DIAGRAM A detailed electrical schematic is provided at the end of Section 3 in this Service Manual THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 95: ... load 5 9 Pilot Operated Relief Valve 5 9 Raising Load 5 9 Motor displacement 5 9 Drum 3 Hydraulic Schematic 5 10 Drum 3 Electrical Diagram 5 11 Drum 4 5 13 Drum 4 Pawl 5 13 Holding Valve 5 13 Lowering and Holding a Load 5 13 Pilot Operated Relief Valve 5 13 Raising a Load 5 13 Drum 4 Hydraulic Diagram 5 14 Drum 4 Electrical Diagram 5 15 Drum 1 Hydraulic Diagram with Free Fall 5 16 Drum 2 Hydrauli...

Page 96: ...ement 5 33 Pressure Rollers 5 35 Removing Pressure Roller Assembly 5 35 Installing Pressure Roller Assembly 5 35 Block Up Limit Device 5 37 General 5 37 Locking Unlocking Block Up Limit Switch 5 37 Locking a Block Up Limit Switch 5 37 Unlocking a Block Up Limit Switch 5 37 Maintenance 5 38 Wire Rope Inspection and Replacement 5 39 Wire Rope Lubrication 5 39 Maintain a Wire Rope Condition Report 5 ...

Page 97: ...MLC150 1 SERVICE MAINTENANCE MANUAL Manitowoc Published 03 21 2021 Control 264 01 5 iii 5 Yearly Inspection 5 50 R E F E R E N C E O N L Y ...

Page 98: ...MLC150 1 SERVICE MAINTENANCE MANUAL 5 iv Published 03 21 2021 Control 264 01 R E F E R E N C E O N L Y ...

Page 99: ...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 Section 2 Hydraulics Section 3 Electrical DRUM IDENTIFICATION See Figure 5 1 Drum Description 1 Front Drum main hoist 2 Rear Drum whip or luffing hoist 3 Auxiliary Drum optional 4 Boom Hoist FIGURE 5 1 R E F E R E N C E O N L Y ...

Page 100: ...ol handle The rotation indicator pulsates with a varying frequency to indicate drum rotational speed The direction of rotation is also displayed on the main display via an arrow on the corresponding drum icon DRUMS 1 AND 2 See Figure 5 2 through Figure 5 5 Overview The hydraulic circuit for each drum consist of an open loop pump which contains a 130 cc rotary group an electrically operated directi...

Page 101: ...uick stop when lowering Raising Load When system flow is in the up direction the holding valve remains in the unchecked position and has no effect on operation Motor displacement Each motor contains an electronic displacement control The motor will stay at maximum displacement until the drum begins to turn The motor will shift towards minimum displacement in proportion to the position of the contr...

Page 102: ...1 Handle command 100 to 100 number raise number lower 7 Load Holding Valve 2 Open Loop B Pump command 0 to 100 8 Motor Pressure Transducer 3 Open Loop B Pump Pressure Transducer 9 Pilot Pump 4 Control Valve command 100 to 100 number raise number lower 10 Brake Valve 5 System Pressure Transducer 11 Brake motor end 6 Motor command 0 max displacement 100 min displacement 12 Drum For Free Fall see Fig...

Page 103: ...21 2021 Control 264 01 5 5 MLC150 1 SERVICE MAINTENANCE MANUAL HOISTS 5 Drum 1 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 5 3 R E F E R E N C E O N L Y ...

Page 104: ... 100 to 100 number raise number lower 8 Motor Pressure Transducer 2 Open Loop A Pump command 0 to 100 9 Pilot Pump 3 Open Loop A Pump Pressure Transducer 10 Pawl Valve 4 Control Valve command 100 to 100 number raise number lower 11 Brake Valve 5 System Pressure Transducer 12 Brake motor end 6 Motor command 0 max displacement 100 min displacement 13 Drum 7 Load Holding Valve For Free Fall see Figur...

Page 105: ...21 2021 Control 264 01 5 7 MLC150 1 SERVICE MAINTENANCE MANUAL HOISTS 5 Drum 2 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 5 5 R E F E R E N C E O N L Y ...

Page 106: ...HOISTS MLC150 1 SERVICE MAINTENANCE MANUAL 5 8 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 107: ...turn side of the down circuit This prevents the hoist motor from turning in the down direction As the control handle is moved off center in the down direction the working pressure begins to act on the valve which begins to shift to the unchecked position to allow motor outflow When the control handle is moved toward center the holding valve begins to close slowing the load At center the check valv...

Page 108: ... Drum 3 Components 1 Handle command 100 to 100 number raise number lower 7 Load Holding Valve 2 Open Loop B Pump command 0 to 100 8 Motor Pressure Transducer 3 Open Loop B Pump Pressure Transducer 9 Pilot Pump 4 Control Valve command 100 to 100 number raise number lower 10 Brake Valve 5 System Pressure Transducer 11 Brake 6 Motor command 0 max displacement 100 min displacement 12 Drum R E F E R E ...

Page 109: ...1 2021 Control 264 01 5 11 MLC150 1 SERVICE MAINTENANCE MANUAL HOISTS 5 Drum 3 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 5 7 R E F E R E N C E O N L Y ...

Page 110: ...HOISTS MLC150 1 SERVICE MAINTENANCE MANUAL 5 12 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 111: ...motor outflow in one position and in the other position allows motor outflow When there is no working pressure handle in center a check valve halts hydraulic flow in the return side of the down circuit This prevents the hoist motor from turning in the down direction As the control handle is moved off center in the down direction the working pressure begins to act on the valve which begins to shift...

Page 112: ...Components 1 Handle command 100 to 100 number raise number lower 8 Motor Pressure Transducer 2 Open Loop A Pump command 0 to 100 9 Pilot Pump 3 Open Loop A Pump Pressure Transducer 10 Pawl Valve 4 Control Valve command 100 to 100 number raise number lower 11 Brake Valve 5 System Pressure Transducer 12 Brake 6 Motor command 0 max displacement 100 min displacement 13 Drum 7 Load Holding Valve R E F ...

Page 113: ...1 2021 Control 264 01 5 15 MLC150 1 SERVICE MAINTENANCE MANUAL HOISTS 5 Drum 4 Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 5 9 R E F E R E N C E O N L Y ...

Page 114: ...n Loop B Pump Pressure Transducer 13 Free Fall Brake Pedal command 0 to 100 0 pedal down 100 pedal up 4 Control Valve command 100 to 100 number raise number lower 14 Free Fall Pilot Pump 5 System Pressure Transducer 15 Free Fall System Enable Valve 6 Motor command 0 max displacement 100 min displacement 16 Free Fall Brake Valve command 0 to 100 0 pedal down 100 pedal up 7 Load Holding Valve 17 Fre...

Page 115: ... 3 Open Loop A Pump Pressure Transducer 13 Drum 4 Control Valve command 100 to 100 number raise number lower 14 Free Fall Brake Pedal command 0 to 100 0 pedal down 100 pedal up 5 System Pressure Transducer 15 Free Fall Pilot Pump 6 Motor command 0 max displacement 100 min displacement 16 Free Fall System Enable Valve 7 Load Holding Valve 17 Free Fall Brake Valve command 0 to 100 0 pedal down 100 p...

Page 116: ...ndle The rotation indicator pulsates with a varying frequency to indicate drum rotational speed The direction of rotation is also displayed on the main display via an arrow on the corresponding drum icon Cooling oil flow through the brake is continuous whether or not the free fall mode is enabled Cooling oil flow at 5 bar 73 psi is provided by the free fall cooling pump which is dedicated for this...

Page 117: ...nk and then increase brake release pressure proportionally to the brake pedal position via the free fall brake valve The free fall brake will release and the load will lower Full brake release occurs at 60 bar 870 psi Adjusting the slip setting in the main display will limit the maximum pressure available to the brake from the free fall pump When free fall is enabled the drum control handle will o...

Page 118: ...ription 1 Breather 2 Fill Port 3 Sight Gauge 4 Quick Drain Valve 5 Upper Hose 6 Motor Shaft Oil Cavity Fill Plug 7 Fill Plug 8 Level Plug 9 Drain Plug 10 Quick Drain Drainer 11 Hose Clamp 12 Hose 3 4 in 19 mm Inside Diameter by 10 ft 3 0 m Long Drums 1 and 2 similar Drum 4 Drum 3 R E F E R E N C E O N L Y ...

Page 119: ...m the quick drain drainer assembly into a 23 L 6 gal container under the drum 4 Remove the breather 1 and fill plug for faster draining 5 Thread the quick drain drainer assembly to the quick drain valve The poppet inside the valve will open allowing the oil to drain from the gearbox 6 Once the gearbox has finished draining remove the quick drain drainer assembly 7 Fasten the dust cap to the quick ...

Page 120: ...ite 21 Normally Closed Blue 14 22 Jumper Item Description Item Description 1 Hydraulic Cylinder 8A Screw Qty 4 2 Cam 8B Head 3 Pawl 9 Setscrew 4 Spring 10 Limit Switch Shaft 5 Adjusting Nut qty 2 11 Limit Switch Lever 6 Eye Bolt A 11 20 mm 7 16 25 32 in 7 Ratchet B 150 mm 5 29 32 in 8 Limit Switch View A Engaged View B Disengaged View C FIGURE 5 15 View D R E F E R E N C E O N L Y ...

Page 121: ...to engage the pawl 4 When new at the factory the spring is adjusted to Dimension B 5 Start the engine and check the pawl for proper operation and engagement Limit Switch Head Orientation If a new limit switch is being installed orient the head 8B View D as follows 1 Remove the screws 8A 2 Rotate the head 8B 90 counterclockwise 3 Install and securely tighten the screws 8A 4 Install the lever 11 Lim...

Page 122: ...021 Control 264 01 Item Description Item Description 1 Ratchet 6 Eye Bolt 2 Pawl 7 Adjusting Nut qty 2 3 Hydraulic Cylinder A 35 mm 1 3 8 in 4 Cam B1 211 mm 8 5 16 in 5 Spring B2 182 mm 7 5 32 in FIGURE 5 16 View B Engaged View A Disengaged R E F E R E N C E O N L Y ...

Page 123: ...tion as described under Operation Weekly Apply open gear lube to the sliding surfaces between the cam 4 and pawl 2 Spring Adjustment If the spring tension becomes insufficient perform the following steps 1 Visually check the position of the pawl and make sure it is fully engaged with the ratchet If the pawl is not fully engaged perform the following a Start the engine and operate the drum slightly...

Page 124: ... Drum 2 until there are three to four wraps of rope on the first layer of the drum 2 Remove the cover 3 3 Turn either adjusting screw 4 counterclockwise until you hear the switch click Repeat this step for the other adjusting screw 4 4 Operate the drum to make sure it stops with three to four wraps of wire rope on the first layer of the drum 5 Readjust the limit switch as needed 6 Install the cove...

Page 125: ... electric cable 6 Limit Switch Adjustment 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 layer of the drum 2 Remove the cover 3 3 Turn either WHITE adjusting screw 4 counterclockwise until you hear the switch click Repeat this step for the other WHITE adjusting screw 4 The black adjusting screw has no function for this application...

Page 126: ...264 01 FIGURE 5 19 Item Description Item Description 1 Drum 3 4 Limit Switch 2 Roller bail and pressure 5 Electric Cable from Limit Switch 3 Actuator 6 Electric Cable from Wire Harness 3A Lock Nut 7 Shorting Plug 3B Adjusting Screw View B View D View C R E F E R E N C E O N L Y ...

Page 127: ...e Main Display Working Screen 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 View C from the electric cable 6 and connecting the supplied shorting plug 7 to the electric cable 6 Limit Switch Adjustment 1 Pay out the wire rope from Drum 3 until there are three to four wraps of rope on the first layer ...

Page 128: ...Description Item Description 1 Drum 4 5 Drum 1 2 Speed Sensor 6 Speed Sensor 3 Electric Cable from Sensor 7 Electric Cable from Sensor 4 Electric Cable WRR1 P23 from Harness 8 Electric Cable WRR1 P2 from Harness 9 O Ring View A Drum 1 Shown Drums 2 and 3 Similar View B Drum 4 R E F E R E N C E O N L Y ...

Page 129: ...aces and install the new speed sensor 2 and O Ring 9 9 Install the mounting screws and tighten them to 10 Nm 7 4 ft lb 10 Connect the electrical cables 3 and 4 11 Operate the drum and check for a steady drum speed rpm and direction signal in the corresponding drum s Control Information Screen in the main display 12 Make sure there is no oil leakage Drum 1 2 or 3 View A 1 Stop the engine and lockou...

Page 130: ... 264 01 FIGURE 5 21 Item Description 1 Speed Sensor 2 Electrical Cable 3 Hex Cap Screw Qty 6 4 Cover 5 Driver 6 Driver Studs Qty 3 7 Bearing Housing 8 Set Screw 9 Phillips Head Screw Flat Washer and Nut Qty 4 10 Drive Pinion Drum 2 Shown Drum 1 Similar R E F E R E N C E O N L Y ...

Page 131: ...bled unit 6 Loosen the set screw 8 and remove the driver 5 with drive studs 6 from the speed sensor shaft 7 Note the orientation of the speed sensor 1 on the cover 4 8 Disassemble the speed sensor 1 from the cover 4 and discard the speed sensor 9 Assemble the new speed sensor 1 in the original orientation to the cover 4 with the phillips head screws flat washers and nuts 9 Apply Loctite 222 to the...

Page 132: ...r Assembly without Free Fall 40 kg 88 lb 3 Mounting Screws with Washers Qty 4 4 M10 x 12 mm or Longer Socket Head Screw Qty 4 Owner Furnished 5 Pressure Roller Assembly with Free Fall 27 kg 60 lb 6 Mounting Screws with Washers Qty 4 Drum 1 or 2 without Free Fall Drum 1 or 2 with Free Fall FIGURE 5 22 R E F E R E N C E O N L Y ...

Page 133: ...e on the drum 2 If necessary pre load the pressure roller 2 or 5 by pulling the roller rearward as far as it will go and securely holding it in place 3 Install the M10 socket head screws 4 in the fours holes indicated This step will hold the pressure roller in the pre loaded position 4 Lift the pressure roller assembly 2 or 5 into position at the rear of the drum 5 Apply Loctite 243 to the mountin...

Page 134: ...HOISTS MLC150 1 SERVICE MAINTENANCE MANUAL 5 36 Published 03 21 2021 Control 264 01 FIGURE 5 23 View A View B View C View D R E F E R E N C E O N L Y ...

Page 135: ...ot used it must be locked disabled to allow all hoist operations Locking a Block Up Limit Switch 1 Remove the block up limit chains and weight from the limit switch lanyard 2 View A 2 Remove the cap 1 View A from limit switch 3 Pull the lanyard 2 down 4 Install the cap 1 View B to secure the lanyard 2 in the locked disabled position Unlocking a Block Up Limit Switch 1 Attach the block up limit cha...

Page 136: ...each weight chain shackle and connecting pin for excessive or abnormal wear Make sure the cotter pins for the shackles are installed and spread c Inspect the entire length of each electric cable for damage FIGURE 5 24 Item Description 1 Limit Switch 2 Actuator Cable 3 Chain with Shackles and Pins 4 Weight with Chain and Links Lower Boom Point Shown Typical at Lower Boom Point 2nd A2B Upper Boom Po...

Page 137: ...rope should be replaced After initial loading of a new rope measure and record its diameter for comparison with future inspections Measure the rope s diameter across the crowns of the strands so the true diameter is measured see Figure 5 26 Wire rope removed from service should be examined and a corresponding report kept This information can be used to establish a relationship between visual inspe...

Page 138: ...ameter see Reduction in the Rope Diameter on page 5 42 Distortion to the uniform structure of the rope Broken wires Record the number distribution and type of broken wires see Broken Rope Wires on page 5 42 Internal wear or broken wires for ropes operating on synthetic sheaves Common indicators of internal deterioration include localized reduction in the rope diameter corrosion between the strands...

Page 139: ...ows Sections in contact with the saddles equalizer sheaves or other sheaves where the wire rope travel is limited Sections of the wire rope at or near the terminal ends where corroded or broken wires may protrude Inspection of the boom sheaves hook block sheaves gantry mast sheaves boom extension jib sheaves jib strut sheaves and hoist drums for wear NOTE Damaged sheaves or hoist drums can acceler...

Page 140: ...e inspections see Maintain a Wire Rope Condition Report on page 5 39 The wire rope must be taken out of service when the reduction from its nominal diameter is more than 5 percent Broken Rope Wires When conducting the periodic comprehensive inspection thoroughly clean the wire rope so breaks can be seen Relax the rope move it off pick up points and flex it as much as possible to uncover damage Use...

Page 141: ... replace the rope or cut off the affected area and reattach the fitting Rope That Has Been Idle a Month or More Wire rope must be given a complete inspection if it has been idle for a month or more The inspection must be performed by a qualified inspector looking for the damage identified under both daily and periodic comprehensive inspection NOTE Wire rope may be purchased through Manitowoc Crane...

Page 142: ...e installed Many current production sheaves are not equipped with grease fittings but are packed with grease at assembly Repack the bearings of these sheaves with CraneLUBE EP 2 grease when the sheaves are overhauled Due to application and design variations it is not possible to give specific grease repacking intervals or the life expectancy of the components Make sure the sheaves drums and roller...

Page 143: ...contour of the gauge matches the contour at the bottom of the sheave groove Proper fitting sheave groove should support the wire rope or 135 150 of rope circumference Groove Too Small Groove Too Large FIGURE 5 30 Corrugated steel sheave roller or drum will cause the wire rope to wear rapidly FIGURE 5 31 R E F E R E N C E O N L Y ...

Page 144: ...HOISTS MLC150 1 SERVICE MAINTENANCE MANUAL 5 46 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 145: ...sing conventional methods such as sheave gauges Due to the characteristics of nylon sheaves the nylon material will actually move to better support the wire rope as the sheave wears normally Nylon sheave properties can be degraded in temperatures above 60 C 140 F E replacement dimension E B minus 5 mm 3 16 in maximum If a tread print exists in the root of the sheave groove measure to the maximum t...

Page 146: ...rator Manual for recommended sling angles and capacity restrictions when the load block has a duplex or a quadruplex hook Item Description 1 Working Load Limit in Tons US and metric 2 Wire Rope Diameter in and mm 3 Block Weight lb and kg 4 Block Serial Number 5 Block Part Number OEM and Manitowoc 6 Design Factor FIGURE 5 33 Item Description Item Description 1 Dead End Clip 4c Check Gap Here 2 Sock...

Page 147: ... groove must be larger than the wire rope and the groove must be free of rough edges and burrs Check that the hook the trunnion and the swivel rotate freely without excessive play Faulty operation indicates faulty bushings or bearings or inadequate lubrication Check the swivel of the hook and weight ball for the following conditions Overloading Spin the swivel by hand If the motion is rough or has...

Page 148: ...ection Check each hook and shackle at least yearly for cracks using one or more of the following methods Dye penetrant test MAG particle test Ultrasonic test X ray WARNING Falling Load Hazard To prevent the load from dropping due to a hook or shackle failure do not attempt to repair any cracks in hooks and shackles by welding Do not weld on any load bearing component unless proper welding methods ...

Page 149: ...l 6 1 Swing Left 6 3 Cross Port Orifice 6 3 Swing Right 6 3 Coasting 6 3 Swing Alarm 6 3 Swing Hydraulic Diagram 6 4 Swing Electrical Diagram 6 5 Swing Brake Manual Release 6 6 Swing Gearbox Oil Change 6 7 Gear Oil Specifications 6 7 Oil Analysis 6 7 Periodic Maintenance 6 7 Oil Level Interval 6 7 Initial Drain Interval 6 7 Breather Cleaning Interval 6 7 Oil Change Interval 6 7 Quick Drain Valve 6...

Page 150: ...MLC150 1 SERVICE MAINTENANCE MANUAL 6 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 151: ...OPERATION The swing brake is a spring applied hydraulically released disc brake located between the swing motor and the planetary swing drive The swing brake release system uses pilot pressure from the pilot pump supplied to the swing brake via the swing brake solenoid valve The brake release pressure must be at least 23 bar 334 psi to fully release the brake If brake hydraulic pressure or electri...

Page 152: ...SWING SYSTEM MLC150 1 SERVICE MAINTENANCE MANUAL 6 2 Published 03 21 2021 Control 264 01 THIS PAGE LEFT INTENTIONALLY BLANK R E F E R E N C E O N L Y ...

Page 153: ...the pump swashplate to a position that meets the direction and speed commanded by the joystick position 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 on the motor to port B on the pump to complete the closed loop circuit The swing encoder and swing right psi pressure sensor provide closed loop feedback to the CCS Coasting ...

Page 154: ... provided at the end of Section 2 in this Service Manual FIGURE 6 1 Swing Components 1 Control Handle command 100 to 100 number swing right number swing left 5 Motor 2 Pump command 100 to 100 number swing right number swing left 6 Pilot Pump 3 Pressure Sensor Right Swing 7 Brake Valve 4 Pressure Sensor Right Left 8 Brake R E F E R E N C E O N L Y ...

Page 155: ...2021 Control 264 01 6 5 MLC150 1 SERVICE MAINTENANCE MANUAL SWING SYSTEM 6 Swing Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 6 2 R E F E R E N C E O N L Y ...

Page 156: ... At the completion of servicing perform the following procedure a Apply the swing brake by relieving the pressure with the hand pump b Disconnect the hand pump hose from the elbow 2 in the brake release port 4 c Connect the brake release hose 1 to the elbow 2 7 Clean up any spilled oil Item Description 1 Swing Brake Release Hose 2 06 ORFS x M12 Elbow 3 Swing Motor 4 M12 Swing Brake Release Port 5 ...

Page 157: ...lowing it thoroughly dry with compressed air Oil Change Interval Drain and refill the swing gearbox semiannually or every 200 hours of swing operation or every 1000 hours of engine operation whichever occurs first unless an alternate interval has been established through an oil analysis program Quick Drain Valve The swing gearbox is equipped with a quick drain valve 4 which requires use of the qui...

Page 158: ... cap 2 in the fill port Power Fill Procedure a Remove the dust cap from the quick drain valve 4 b Thoroughly clean the inside of the hose for the existing quick drain drainer assembly c Thread the quick drain drainer assembly all the way onto the quick drain valve The poppet inside the valve will open d Connect the hose from the quick drain drainer assembly to a portable pump either hydraulically ...

Page 159: ...on 7 5 Engine Maintenance 7 6 Engine Belt Routing 7 6 Air Cleaner Maintenance 7 6 Daily Inspection 7 6 Monthly Inspection 7 6 Changing the Air Cleaner Filters 7 6 Engine Cooling System 7 8 Changing Coolant 7 8 Draining 7 8 Flushing 7 9 Filling 7 9 Adjusting the Engine Throttle 7 11 Hand Throttle Control 7 11 Foot Throttle Control 7 11 Exhaust Aftertreatment System 7 13 Engine Regeneration and Inhi...

Page 160: ...MLC150 1 SERVICE MAINTENANCE MANUAL 7 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 161: ...al short Undercharging Undercharging can cause a type of sulfate to develop on the plates The sulfate reduces the battery capacity and causes strains in the positive plates which cause plate buckling Buckled plates can pinch the separators and cause a short circuit An undercharged battery is not only unable to deliver power but also may freeze see Table 7 1 Table 7 1 Battery Freeze Points Lack of ...

Page 162: ...POWER TRAIN MLC150 1 SERVICE MAINTENANCE MANUAL 7 2 Published 03 21 2021 Control 264 01 FIGURE 7 1 R E F E R E N C E O N L Y ...

Page 163: ...ibility of cell contamination and electrolyte spillage NOTE Do not use this test method if the battery has been recently charged by a charger or alternator Recent charging places a high surface charge voltage on the battery which is not a true indication of actual battery voltage Item Description 1 Fuel Tank 2 Battery Compartment Cover 3 Lockable Access Door coolant fill cap and sight gauge 4 Cool...

Page 164: ...hours maximum Charge until a 2 hour period results in no increase in voltage or decrease in current NOTE Overcharging shortens a battery s life If the battery becomes hot to the touch or if it gases violently temporarily halt charging or reduce the charging current Storage When the crane is left idle for prolonged periods the batteries should be periodically charged When storing batteries make sur...

Page 165: ... key switch The emergency stop button must be pulled up before the engine can be started When this button is depressed the crane engine shuts off the brakes apply and the currently operated crane functions come to a complete stop For normal engine shut down use the engine ignition switch An engine hand throttle is located on the left control console in the operator cab and a foot throttle is provi...

Page 166: ...reading Monthly Inspection Monthly or Every 200 Hours of Engine Operation whichever occurs first Inspect the rubber reducers the reducing elbows and the tubing between the air cleaner and the engine for cracks or other damage that might allow unfiltered air to enter the engine Replace worn or damaged parts Check for loose clamps Tighten as required Check the air intake housing 1 the pre cleaner ho...

Page 167: ...f removed carefully install the new secondary filter 8 O ring side first with the plastic rings and gently push it into the back of the housing Apply pressure to all four corners to make sure the filter is completely secure in the housing 9 Carefully install the new primary filters 7 O ring side first using the handles Make sure all surfaces are sealed inside the housing 10 Make sure the seal is i...

Page 168: ... hissing sound c Wait for the pressure to escape completely d Turn the fill cap fully counterclockwise and remove it 6 Slowly add a 50 50 coolant mixture of water and ethylene glycol until the coolant is at the middle of the sight gauge 3 7 Securely install the fill cap 4 8 Close and lock the access door 2 Changing Coolant Every Other Year or Every 2000 Hours of Engine Operation whichever occurs f...

Page 169: ...commendations 3 Once coolant is visible in the middle of the sight gauge 3 wait 2 to 3 minutes before starting the engine to allow the system to naturally purge entrained air and to allow the coolant level to stabilize 4 Add a 50 50 coolant mixture to bring the coolant to the middle the sight gauge 2 5 Check that both cab heater valves on the engine are open 6 In the cab place the heat control to ...

Page 170: ...e Control Wires 12 Black Wire ground 13 Green Wire signal 14 White Wire supply 15 Resistor 16 Flat Head Brass Screw qty 2 17 Setscrew 3 4 in 18 Setscrew 3 16 in Potentiometer Elect Schematic Supply white Signal green Ground black Low Idle High Idle Surface X These two holes should be aligned when initially inserting the shaft and spring into the housing Pedal Position A Low Idle High Idle Pedal Po...

Page 171: ...ll the roll pins 10 through the holes in the foot pedal and the foot pedal shafts see Pedal Position A 5 Install the setscrew 17 only partway into the threaded hole Do not allow the setscrew to contact the right foot pedal shaft at this time 6 Rotate the foot pedal approximately 40 to Pedal Position B low idle The flat on the head of the right foot pedal shaft should be parallel with the surface X...

Page 172: ...2 Published 03 21 2021 Control 264 01 Item Description 1 DEF Tank 1A Fill Cap 1B Drain Plug 2 DEF Supply Module 3 Coolant Control Valve 4 SCR Module 5 DEF Dosing Module 6 Decomposition Reactor Module 7 DOC DPF Module FIGURE 7 9 R E F E R E N C E O N L Y ...

Page 173: ...ded in case the tank needs to be emptied of poor quality DEF NOTE Do not store DEF for long periods of time DEF deteriorates relative to time and temperature Low quality DEF may require the tank to be drained and the system purged DEF Supply Module The DEF supply module 2 is an electronically operated pump and metering system controlled by the ECM The Abbreviation Description APS Aftertreatment Pr...

Page 174: ...ough the dosing module also keeps it cool and operable SCR Module The SCR module 4 incorporates a catalyst a temperature sensor and an NOx sensor The SCR module utilizes DEF urea and deionized water to reduce NOx content in the exhaust gas to nitrogen The SCR module does not require maintenance Excessive NOx Warning System If an excessive NOx warning is issued check anything that might cause an el...

Page 175: ...l Hydraulic Diagram 8 4 8 4 Travel Electrical Diagram 8 5 Crawler Preventive Maintenance 8 6 Crawler Tread Slack Measurement 8 6 Crawler Tread Slack Adjustment 8 7 Intermediate Roller Bolt Torque 8 7 Crawler Hand Pump and Cylinder 8 8 Assembly 8 8 Maintenance 8 8 Air Removal 8 8 Operation 8 9 Crawler Gearbox Oil Change 8 11 Gear Oil Specifications 8 11 Oil Analysis 8 11 Periodic Maintenance 8 11 I...

Page 176: ...MLC150 1 SERVICE MAINTENANCE MANUAL 8 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 177: ...w volume of the travel pumps the position of the proportional control valves and the position of the travel motor servos Joystick Control The pumps and proportional control valves are electronically controlled by the position of the corresponding travel control handle joystick J2 and the travel speed switch located on the right console The joystick communicates with the crane control system via th...

Page 178: ...enable the travel control system the operator must be seated seat safety switch closed and the travel brakes must be in the UN PARKED state When either control handle is moved to the forward position the joystick J2 communicates the travel command to the CCS At the same time the CCS communicates the forward travel command to the solenoid at the corresponding proportional control valve If the left ...

Page 179: ... left and right travel proportional control valves remain in the center position blocking hydraulic flow from the pumps to the travel motors The travel brake solenoid is deenergized allowing spring force to apply the travel brakes Travel Motor Cooling The purpose of the travel motor cooling circuit is to provide a continuous flow of oil to the case of both travel motors The flow comes from the low...

Page 180: ... 100 number forward number reverse 7 Control Handle command 100 to 100 number forward number reverse 2 Open Loop B Pump command 0 to 100 8 Open Loop A Pump command 0 to 100 3 Proportional Control Valve command 100 to100 number forward number reverse 9 Proportional Control Valve command 100 to100 number forward number reverse 4 Pressure Transducer 10 Pressure Transducer 5 Motor 11 Motor 6 Brake 12 ...

Page 181: ...021 Control 264 01 8 5 MLC150 1 SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 Travel Electrical Diagram A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 8 2 R E F E R E N C E O N L Y ...

Page 182: ... each crawler Maintain equal tread slack at both crawlers 1 Travel forward or reverse on a firm level surface until all tread slack is in the top treads at the drive tumbler end of the crawlers 2 Place a straightedge 13 on top of the treads 3 The straightedge must span from the top of the rear guide bars 12 to the top of the drive tumbler 1 3 Measure the tread slack between the straightedge and th...

Page 183: ...rawler frame 12 Repeat the procedure for the other crawler NOTE The extreme limit of tread adjustment occurs when the bolts are tight against the front end of the slots in the crawler frame One crawler tread can be removed when this limit is reached 13 Store the hand pump the cylinder and any extra shims in the parts box INTERMEDIATE ROLLER BOLT TORQUE See Figure 8 4 Annually Every 2000 Hours of E...

Page 184: ... handle 6 up and down to fully extend the jacking cylinder 1 rod 4 Rotate the valve 5 counterclockwise push the jacking handle 6 all the way down and fully retract the jacking WARNING Hand Pump Explosion The hand pump and cylinder is provided for crawler adjustment only any other use is neither intended nor approved Wear safety glasses and other personal protective gear when operating the hand pum...

Page 185: ...ressurize the jacking cylinder 1 and extend the rod close the valve 5 by turning it clockwise until finger tight Pump the jacking handle 6 up and down Pressure is maintained until the valve is opened To reduce the handle effort at high pressure use short strokes maximum leverage is obtained in last five degrees of stroke 3 To de pressurize the jacking cylinder 1 push the jacking handle down fully ...

Page 186: ...UNDERCARRIAGE MLC150 1 SERVICE MAINTENANCE MANUAL 8 10 Published 03 21 2021 Control 264 01 Item Description 1 Level Plug 2 Fill Plug 3 Drain Plug FIGURE 8 6 View A R E F E R E N C E O N L Y ...

Page 187: ...opening 7 Install the fill and level plugs 8 Repeat the procedure for the other crawler gearbox Semi Annually Drain and refill both crawler gearboxes semi annually or every 200 hours of function operation or every 1000 hours of engine operation whichever occurs first unless an alternate interval has been established through an oil analysis program Oil Change Procedure Change the oil when the crawl...

Page 188: ...cription 1 Slewing Ring Inner Ring 2 Slewing Ring Outer Ring 3 1 1 2 in 6 UNC x 8 in Long Grade 8 Bolt 48 Places Outer Ring 48 Places Inner Ring 4 Washer 5 Shear Pin 2 places 6 Access Slots to Inner Ring Bolts 7 Carbody 8 Rotating Bed C C B B Front of Rotating Bed A A Front of Carbody R E F E R E N C E O N L Y ...

Page 189: ...shers 4 for the corresponding ring Replace all of the bolts 3 and washers 4 anytime a new slewing ring is installed REPLACING SLEWING RING BOLTS 1 Apply Never Seez or an equivalent anti seizing lubricant to Bolt threads Underside of bolt heads Both sides of all washers 2 Install and tighten the bolts 3 two at a time in the numbered sequence to an initial torque of 814 Nm 600 ft lb 3 Tighten the bo...

Page 190: ...UNDERCARRIAGE MLC150 1 SERVICE MAINTENANCE MANUAL 8 14 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 191: ...Manitowoc Published 03 21 2021 Control 264 01 9 i 9 SECTION 9 LUBRICATION TABLE OF CONTENTS Lubrication 9 1 R E F E R E N C E O N L Y ...

Page 192: ...MLC150 1 SERVICE MAINTENANCE MANUAL 9 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 193: ...Manitowoc Published 03 21 2021 Control 264 01 9 1 MLC150 1 SERVICE MAINTENANCE MANUAL LUBRICATION 9 SECTION 9 LUBRICATION LUBRICATION See F2321 at the end of this section R E F E R E N C E O N L Y ...

Page 194: ...LUBRICATION MLC150 1 SERVICE MAINTENANCE MANUAL 9 2 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 195: ...d Holding 10 1 Extend 10 1 Cab Tilt Operation 10 2 Neutral 10 2 Raise 10 2 Lower 10 2 Counterweight Pins 10 2 Counterweight Pins Overview 10 2 Engage extend 10 2 Disengage retract 10 2 Counterweight Limit Switch 10 3 Boom Hoist Operation 10 3 Hydraulic Cooling Fan Operation 10 3 Accessory Systems Hydraulic Diagram 10 4 Accessory Systems Electrical Diagram 10 5 R E F E R E N C E O N L Y ...

Page 196: ...MLC150 1 SERVICE MAINTENANCE MANUAL 10 ii Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 197: ... on the gantry cylinders control valve are deenergized and springs shift the valve to the neutral position The gantry cylinders are held in their last position by the holding valve on each cylinder Retract When a retract command is sent by either gantry cylinders switch the following occurs The proportional solenoid on the accessory enable valve is energized by a PWM pulse width modulation signal ...

Page 198: ...rod end of the cab tilt cylinder Pressure from the rod end of the cylinder pilots open the load holding valve allowing the oil from the barrel end of the cylinder to flow back to tank via the high pressure accessory valve The cylinder retracts to lower the gantry COUNTERWEIGHT PINS See Figure 10 1 and Figure 10 2 Counterweight Pins Overview The counterweight pins are controlled by a switch on the ...

Page 199: ...w along with the gantry when the boom hoist thumbwheel is used to raise and lower the gantry during counterweight installation and removal HYDRAULIC COOLING FAN OPERATION See Figure 10 1 and Figure 10 2 The system consists of the fan pump the hydraulic oil cooler and motor and the hydraulic oil temperature sensor The hydraulic cooling fan is proportionally controlled by the temperature of the hydr...

Page 200: ...ystems Components Item Accessory Systems Components 1 Open Loop A Pump command 0 to 100 6 Cab Tilt Control Valve 2 Open Loop A Pump Pressure Transducer 7 Accessory System Pump low pressure 3 Accessory System Enable Valve command 0 to 100 8 Counterweight Pins Control Valve 4 Accessory System Pressure Transducer 9 Hydraulic Cooler Fan Pump command 0 or 100 5 Gantry Cylinders Control Valve 10 Hydraul...

Page 201: ...ntrol 264 01 10 5 MLC150 1 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 ACCESSORY SYSTEMS ELECTRICAL DIAGRAM A detailed electrical schematic is provided at the end of Section 3 in this Service Manual FIGURE 10 2 R E F E R E N C E O N L Y ...

Page 202: ...ACCESSORIES MLC150 1 SERVICE MAINTENANCE MANUAL 10 6 Published 03 21 2021 Control 264 01 THIS PAGE INTENTIONALLY LEFT BLANK R E F E R E N C E O N L Y ...

Page 203: ...wler Preventive Maintenance 8 6 Crawler Tread Slack Adjustment 8 7 Crawler Tread Slack Measurement 8 6 Disc Brake Operational Test 2 31 Drum 1 and 2 Minimum Bail Limit 5 26 Drum 2 Pawl 5 25 Drum 3 Minimum Bail Limit 5 29 Drum 4 Pawl 5 23 Drum 4 5 13 Drum Gearbox Oil Change 5 21 Drum Identification 5 1 Electrical Power Sequence 3 1 Electrical Schematic 3 1 Electrical System Ground Points 3 3 Engine...

Page 204: ...ion 9 1 Physical Boom Stop 4 9 Pressure Rollers 5 35 Protection of the Environment 1 4 Replacing Slewing Ring Bolts 8 13 Rotating Bed Level Sensor 4 1 Safe Maintenance Practices 1 2 Safety Messages 1 1 Servicing Pressure Transducers 2 27 Sheave Roller and Drum Inspection 5 44 Shop Procedures 2 28 Slewing Ring Alignment 8 13 Slewing Ring Bolt 8 13 Solenoid Valve Identification 3 16 Speed Sensor Fre...

Page 205: ...R E F E R E N C E O N L Y ...

Page 206: ...R E F E R E N C E O N L Y ...

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