Manitowoc MLC650, Service Maintenance Manual

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Reference
Only
Manitowoc
Published 09-09-16, Control # 229-09
5-49
MLC650 SERVICE/MAINTENANCE MANUAL HOISTS
5
55
GEARBOXES
The drum gearboxes are filled with gear oil and are open to
the inside of the drum. Maintenance consists of periodically
checking the level and changing the oil.
Gear Oil Specifications
For gear oil specifications, see the Lubrication Guide
supplied with the crane.
Oil Analysis
An oil analysis program is the best way to determine the
optimal oil change interval and the condition of the drum
gearboxes.
Periodic Maintenance
Weekly
Check the gearbox oil level.
All drums have a level plug or level sight tube. For details,
refer to the Lubrication Guide supplied with the crane.
Monthly or 200 Hours
Check the oil level in the drum gearboxes every 200 hours of
operation or monthly, whichever occurs first. For details, see
the Lubrication Guide supplied with the crane.
Every 6 Months or 1,000 Hours
Drain and refill the gearboxes every 1,000 hours of operation
or every 6 months, whichever occurs first.
Quick-Drain Valve
Each drum gearbox is equipped with a quick-drain valve that
requires use of the quick-drain drainer assembly (see
Figure 5-25 ). The quick-drain drainer assembly is stored in
the parts box supplied with the crane.
Changing the Gearbox Oil
Drum 1 and Drum 2
See Figure 5-26 for the following procedures.
The gearboxes should be drained and refilled after every 200
hours of drum operation and thereafter every 1000 hours.
This interval may be adjusted according to the results of oil
analysis.
NOTE: It is better to change the oil when the gearbox is
warm (not hot).
To prevent harmful contaminants from entering the
gearbox, thoroughly clean components before
disconnecting or connecting them.
Only fill after the drum assembly is installed into the
boom butt.
The oil level sight glass on drum 1 will read the
correct oil level with the boom butt and 4M insert
installed and resting on the ground (approximately
-11° boom angle). The oil level can be checked at
any boom angle by removing the radial drain plug
from the gearbox when the boom is nearly
horizontal.
The oil level sight glass on the drum 2 will read the
correct oil level at 0° boom angle. The oil level can
be checked at any boom angle by removing the
radial drain plug from the gearbox when the boom
is nearly horizontal.
1. Lockout-tagout the crane.
2. Remove the breather plug (1) to vent the gearbox.
3. Remove the drum guard assembly (7) to access the
radial quick-drain valve (4b).
4. Remove the dust caps (3) from the quick-drain valves
(4a and 4b).
5. Place the non-fitting end of the quick-drain drainer
assembly hose (6) into an appropriate container for
collecting the drained oil.
6. Connect the quick-drain drainer assembly hose to the
quick-drain valve (4a, see View B).
7. When the draining is finished, disconnect the quick-drain
drainer assembly hose.
8. Connect the quick-drain hose to the radial quick-drain
valve (4b) to drain the remaining oil.
9. When the draining is finished, remove the quick-drain
hose.
10. Fasten the dust caps to the quick-drain valves.
FIGURE 5-25
Item Description
1 Quick-Drain Drainer
2 Hose Clamp
3 Hose: 19 mm (3/4 in) ID x 3,0 m (10 ft) length