Page 1 Manitowoc MLC650 Operator Manual...
Page 3 NOTICE The serial number of the crane and applicable attachments (i.e. luffing jib, VPC-MAX™) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH.
Page 5: Table Of Contents
Manitowoc Dealer........
Page 6 TABLE OF CONTENTS MLC650 OPERATOR MANUAL Boom Disassembly Safety ............2-23 General.
Page 7 MLC650 OPERATOR MANUAL TABLE OF CONTENTS VPC ............... 3-75 VPC-MAX .
Page 8 TABLE OF CONTENTS MLC650 OPERATOR MANUAL Install Operator Cab Ladder ........... . 4-25 Overview of Rotating Bed Platforms and Handrails .
Page 9 MLC650 OPERATOR MANUAL TABLE OF CONTENTS Raise Wire Rope ............4-117 Connect 4M Insert to Boom Butt .
Page 10 TABLE OF CONTENTS MLC650 OPERATOR MANUAL Removing Drum 3............4-181 Disconnecting Live Mast Hydraulics and Electrical Connectors.
Page 11 Manitowoc Dealer........
Page 12 MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 08-12-19, Control # 224-13...
Page 13: Section 1
• An arrow fabricated on the left-front top of the carbody, If you are the new owner of a Manitowoc crane, please as well as a yellow dot on the left-front face of the register it with the Manitowoc Crane Care Lattice Team so...
Page 14: Identification And Location Of Components
INTRODUCTION MLC650 OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Item Description Live Mast Sheaves Adapter Frame / Rotating Bed Pin Puller Self-Erect Cylinder (optional) Crawler Drive Live Mast Links/Straps Crawler Shoe Live Mast Hoist (Drum 4) Intermediate Roller...
Page 15 MLC650 OPERATOR MANUAL INTRODUCTION Item Description 30-35 Not Used Batteries (rear of rotating bed) DEF Exhaust System Air Intake Pump Drive and Hydraulic Pumps Hydraulic Tank Engine with Pump Drive Disconnect Cooler (coolant, hydraulic oil, charge air) Figure 1-3 continued...
Page 16: Vpc And Vpc-Max
INTRODUCTION MLC650 OPERATOR MANUAL VPC AND VPC-MAX 12 ft x 0.3048 = 3,6576 m VPC™ and VPC-MAX™ are registered trademarks. Inverse Conversion DIVIDE (÷) known value by conversion factor to obtain ENGLISH AND METRIC CONVERSIONS equivalent value in desired units. For example, 3,6576 m is...
Page 17 MLC650 OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By Cubic Inch Pump Displacement Cubic Centimeter 16.3871 VOLUME (LIQUID) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854...
Page 18 INTRODUCTION MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-12-19, Control # 224-13...
Page 19: Section 2
Personnel Handling Policy ............2-24 Manitowoc...
Page 20 MLC650 OPERATOR MANUAL Pedestal/Barge Mounted Cranes ........... 2-25 Pedestal Mounted Crane .
Page 21: Continuous Innovation
If you are in Used with the safety alert symbol, indicates a hazardous doubt about any procedure, contact your Manitowoc dealer situation which, if not avoided, could result in minor or or the Manitowoc Crane Care Lattice Team.
Page 22 SAFETY INFORMATION MLC650 OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards Hazard...
Page 23: Safety And Information Signs
MLC650 OPERATOR MANUAL SAFETY INFORMATION Table 2-1 Common Safety Symbols Emergency Cab Exit Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil Vent M100271 M100267 M100268 M100269 M100272 M100273 Pump Drive Oil...
Page 24 SAFETY INFORMATION MLC650 OPERATOR MANUAL Figure 2-1. Crane Access Points Published 08-12-19, Control # 224-13...
Page 25 MLC650 OPERATOR MANUAL SAFETY INFORMATION Item Description Operator’s Cab Platform with Handrails Carbody Platform (both ends and sides) Ladder (both crawlers) Left Front Ladders (2) Rotating Bed Platform with Handrails (both side) Engine Enclosure (non-skid) Rear Folding Ladder (both sides)
Page 26: Crane Access Points
Manitowoc has provided ladders and platforms at the When personnel use ladders to get on or off the crane, their locations shown in Figure 2-1 on page 2-4.
Page 27: Personal Fall-Protection
MLC650 OPERATOR MANUAL SAFETY INFORMATION PERSONAL FALL-PROTECTION Manitowoc has provided lifelines and anchors throughout the Item Description crane and attachment (see Figure 2-2.) to which workers can Lifeline attach their personal fall-protection equipment. Anchor WARNING Fall Hazard! To prevent falling from any height during crane assembly and disassembly, personnel shall wear fall-protection equipment.
Page 28: Operator Manual/Capacity Chart Storage
If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane or attachment, STORAGE contact your Manitowoc dealer for the proper manual or capacity charts. General Do not operate crane or attachment if proper Capacity Manitowoc provides the following manuals and other Chart is not in cab.
Page 29: Safe Operating Practices
(United States Federal Law), in ASME B30.5 American operation. Manitowoc cannot foresee all hazards that will National Standard, or in any other applicable federal, state, arise in the field. Therefore, safety remains responsibility or local laws.
Page 30 SAFETY INFORMATION MLC650 OPERATOR MANUAL 4. The operator shall be thoroughly familiar with operation 10. The operator shall verify that the Capacity Chart being of the crane and its proper care. If adjustments or repairs used is the correct one for the cranes configuration are necessary or if there are known defects that impair (boom length, load line reeving, counterweight, etc.).
Page 31: Handling Load
Do not operate the crane with a snow or ice covered NOTE Capacity charts for Manitowoc cranes show the boom. The extra weight may cause overload, tipping, or total weight of freely suspended loads for various structural damage.
Page 32: Lifting/Moving Load
SAFETY INFORMATION MLC650 OPERATOR MANUAL 2. Only use slings and other rigging that are in safe All personnel are clear of the swing radius of the operating condition and have a rating equal to or greater crane’s counterweight. than the load to be lifted.
Page 33: Multiple Load Line Operation
Engage the luffing hoist pawl when operating with Manitowoc authorizes multiple load line operation for those the luffing jib at a fixed radius. applications requiring it, provided the following steps are performed: 3.
Page 34: Signals
If communication is disrupted, load indicator(s). operator shall stop all crane movements. 6. Manitowoc recommends that each load line be equipped 2. Signals to the operator shall be in accordance with the with an anti two-block device. standard...
Page 35: Safety Devices
• Alternative measures are not permitted to be used for a faulty safety device. Manitowoc provides the following operational aids on its • Always tag-out any faulty safety device and place a cranes, either as standard equipment or optional equipment.
Page 36: Category 2 Operational Aids
SAFETY INFORMATION MLC650 OPERATOR MANUAL at a point that gives the signal person sufficient time Refer to the pendulum boom angle indicator on the to signal the operator and have the operator stop boom butt (visible from operator’s cab). the boom or jib within the minimum allowable radius.
Page 37: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines
WARNING dangerous. Electrocution Hazard! Set-Up and Operation Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, 1. During crane use, assume that every line is energized Table A clearances when the power lines are energized.
Page 38: Electrocution Hazard Devices
SAFETY INFORMATION MLC650 OPERATOR MANUAL source. This person should have no other duties while etc.). The insulating characteristics of these devices can the crane is working. be compromised if not kept clean, free of contamination, and undamaged. 6. Taglines should always be made of non-conductive materials.
Page 39: Refueling
Safety information in this publication is intended only as a for any evidence of damage and all damaged parts are guide to assist qualified maintenance personnel in safe repaired or replaced as authorized by Manitowoc or your maintenance. Manitowoc cannot foresee all hazards that Manitowoc dealer.
Page 40 SAFETY INFORMATION MLC650 OPERATOR MANUAL Place a warning sign at the start controls alerting 12. Avoid battery explosion: do not smoke while performing other personnel that the crane is being serviced and battery maintenance or short across battery terminals to the engine must not be started.
Page 41: Environmental Protection
33. Perform a function check to ensure proper operation at connecting bolts or pins are being removed. the completion of maintenance or repair. 28. Unless authorized in writing by Manitowoc, do not alter ENVIRONMENTAL PROTECTION the crane in any way that affects the crane’s...
Page 42 SAFETY INFORMATION MLC650 OPERATOR MANUAL View A WRONG – DANGEROUS! and there is No Blocking If Boom is off Ground Under Boom Sections... and Supported by Straps... Boom will COLLAPSE when Lower Pins are Removed! View B and Handling Slings WRONG –...
Page 43: Boom Disassembly Safety
MLC650 OPERATOR MANUAL SAFETY INFORMATION BOOM DISASSEMBLY SAFETY blocking, individual pin connections may still be under load. Pins can be ejected forcefully if the boom has any pressure NOTE The term “boom” used in the following instructions on it or if the boom is not supported properly.
Page 44: Personnel Handling Policy
50 percent of the rated capacity conditions. for the radius and configuration of the crane. Use of a Manitowoc crane to handle personnel is acceptable • The crane is uniformly level within one percent of level provided: grade and located on a firm footing.
Page 45: Pedestal/Barge Mounted Cranes
Manitowoc recommends that cranes be properly maintained, regularly inspected, and repaired as necessary. All safety WARNING signs must be in place and legible. We also urge Manitowoc The crane owner/user shall verify that the method used to crane owners to upgrade their cranes with rated capacity fasten or restrain the crane to the foundation, the barge, indicator/limiter systems for all lifting operations.
Page 46: Pedestal Mounted Crane
M a n i t o w o c d e a l e r f o r t h e NOTE Manitowoc does not permit traveling on a barge recommended bolt pattern and for the type and deck with load.
Page 47: Capacity Charts For Barge Mounted Crane
If the crane’s boom or structure is shock loaded during operation, or there is any indication of shock loading, all Manitowoc provides two types of Capacity Charts for a crane structural components of the crane must be inspected to mounted on a barge or other supporting structure under detect cracks and other damage.
Page 48: Barge Mount Definitions
1. Machine List, as defined by Manitowoc, is the crane’s required. Correct each defect found before placing the crane out-of-level condition — from side-to-side — as into service.
Page 49: Section 3
Cooling System ............. . 3-77 Manitowoc...
Page 50 MLC650 OPERATOR MANUAL Batteries ..............3-77 Engine Oil, Gear Oil, and Hydraulic Oil .
Page 51 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 08-12-19, Control # 224-13...
Page 52: Standard Hand Signals For Controlling Crane Operations
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1. Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124 M100125...
Page 53 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-1. Standard Hand Signals for Controlling Crane Operations Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles.
Page 54: Symbols Used On Control Consoles
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL SYMBOLS USED ON CONTROL CONSOLES The following symbols are used on the control consoles to identify the operating controls and their operation. Table 3-2. Symbol Identification — Control Consoles C y l i n d e r s , M a s t A s s i s t A r m s ,...
Page 55 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES DPF Regeneration (Tier 4) Light, Consoles M100284 M100165 Engine Run Light, Position M100159 M100291 Engine Start Light, Work (and camera) M100160 M100166 Engine Stop Lighter M100161 M100167 Lock and Unlock M100142 M100162a Heater...
Page 56 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Park On Travel Forward—Right Crawler M100172 M100193 Speed, Fast Travel Reverse—Left Crawler M100183 M100194 Speed, Slow Travel Reverse—Right Crawler M100184 M100195 Stop, Emergency Travel Speed M100185 M100196a Swing Winch, Tagline (Drum 7) M100186...
Page 57: Symbols Used On Remote Control
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SYMBOLS USED ON REMOTE CONTROL The following symbols are used on the remote control to identify the operating controls and their operation. Table 3-3. Symbol Identification — Remote Control Data, Confirm Alert M100146...
Page 58 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Jack, Carbody Jack, Carbody (individual) Left Front and Right Front M102430 M102443 Jack, Carbody Jack, Rotating Bed (all) Right Front M102442 M102754 Jack, Carbody Jack, Rotating Bed (individual) Right Front and Right Rear...
Page 59 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Jack, Rotating Bed Pin, Adapter Frame to Rotating Bed, Left Rear and Left Front Front M102764 M102756 Jack, Rotating Bed Pin, Adapter Frame to Rotating Bed, Left Front Rear M102765 M102757 Jack, Rotating Bed...
Page 60 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Trolley, Beam Mounted (In/Out) M102439 Winch, Rigging M101687 Winch, Rigging (Pay Out/Haul In) M101687b 3-10 Published 08-12-19, Control # 224-13...
Page 61 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-11 Published 08-12-19, Control # 224-13...
Page 62: Operating Controls
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL OPERATING CONTROLS Figure 3-1. Cab Controls and Indicators 3-12 Published 08-12-19, Control # 224-13...
Page 63 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-4. Cab Controls and Indicators Item Name Description Louvers Vents to circulate air in the operator’s cab. Travel Foot Pedals page 3-28 for more information. Not Used Front Windshield Wiper page 3-23 for more information.
Page 64 Self-acting latch that secures the door closed. The door latch can be Door Latch locked with the provided key. GPS/GSM Antenna Contact your Manitowoc dealer for CraneSTAR information. Turn the knob CLOCKWISE to CONNECT the battery circuit. Turn the knob COUNTERCLOCKWISE to DISCONNECT the battery circuit for the following reasons: •...
Page 65 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES page 3-31 for more information. Boom Angle Indicator Manitowoc 3-15 Published 08-12-19, Control # 224-13...
Page 66: Left Console
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Left Console Table 3-5. Left Console Item Name Description Maximum current draw is 10A. For fuse location, see Section 3 of the Service 12VDC Power Source Manual. Seat Riser Control Item Description Engage switch in this location to raise or lower the rear riser.
Page 67 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-5. Left Console • Move the handle FORWARD to DECREASE the engine speed. • Move the handle BACK to INCREASE the engine speed. Hand Throttle Engine speed must be fast enough to provide sufficient power for the work being done.
Page 68: Right Console
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Right Console Table 3-6. Right Console 3-18 Published 08-12-19, Control # 224-13...
Page 69 Rated Capacity Indicator and Displays load lifting information and alerts the operator to overload conditions. Rated Capacity Limiter Display See the MLC650 RCL/RCI Operation Manual at the end of this section for (RCL/RCI) detailed information. This key bypasses the limits described in...
Page 70 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Table 3-6. Right Console • Press and hold the TOP of the rocker to tilt the front of the cab UP to a maximum of 21° above horizontal. • Release the rocker CENTER to LOCK the cab in the desired position.
Page 71 The regeneration/inhibit switch is a three-position rocker switch. The top position is momentary. The center and bottom positions are maintained. For more information on this switch, see Section 7 of the MLC650 Service Manual. Active Position The active center position is for normal engine operation. The position does not require operator assistance under normal conditions.
Page 72 The switch will remain depressed. The amber LED in the rocker will glow. To re-enable active regeneration, manually return the switch to the active position. Do not use the Inhibit switch unless specifically instructed by a Manitowoc or Cummins technical advisor. Engine Regeneration/Inhibit...
Page 73 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6. Right Console Travel Operation on page 3-72. The following directions of travel are with the front of the rotating bed and the front of carbody facing the same direction. The swing and travel alarm beeps to warn personnel when the crane is traveled.
Page 74 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Table 3-6. Right Console • Press the TOP of rocker to TURN ON the panel switch backlights. • Press the BOTTOM of rocker to TURN OFF the panel switch Panel Lights backlights. • Press the TOP of rocker to TURN ON the dome light.
Page 75 • RELEASE to TURN OFF the horn. Before swinging or traveling, sound the horn to alert nearby personnel. Used in conjunction with the Crane Control System (CCS). See the MLC650 Jog Dial Main Display Operation Manual and the RCL/RCI Operation Manual for more information.
Page 76 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-26 Published 08-12-19, Control # 224-13...
Page 77: Operation Of Diverting Circuits
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operation of Diverting Circuits Diverting Circuit 1 Diverting Circuit 2 Condition Drum 1 Left Crawler Drum 6 Condition Drum 2 Right Crawler Drum 3 Full Parked Parked Full Parked Parked Parked Full Parked...
Page 78: Foot Pedals
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Foot Pedals Table 3-7. Foot Pedals Item Name Description • Press DOWN on the foot throttle to INCREASE engine speed above the hand throttle setting. Engine Foot Throttle • RELEASE the foot throttle to DECREASE engine speed to idle or to the hand throttle setting.
Page 79: Seat Controls
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Seat Controls Table 3-8. Seat Controls Item Name Description Seat Riser on Left Console page 3-16 for operating instructions. • Push the lever to the LEFT to UNLOCK the seat. Fore-Aft Control • Use body weight to slide the seat to the desired position.
Page 80: Climate Control Keypad
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Climate Control Keypad Table 3-9. Climate Control Keypad Item Name Description Temperature Set Switches Adjusts the desired cab temperature UP or DOWN. Turns the fan on and opens the fresh air door to bring in air from outside the Windshield Defrost cab.
Page 81: Other Operator Aids
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Other Operator Aids • Amber Beacon ON = Crane’s rated capacity is approaching the maximum level. Boom Angle Indicator • Red Beacon ON = Crane’s rated capacity has been The boom angle indicator...
Page 82 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL The circular level (Figure 3-4) indicates crane levelness from front-to-rear and from side-to-side using four concentric rings (2). • The crane is level when the bubble (1) is centered in the 0° ring of the glass.
Page 83 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-33 Published 08-12-19, Control # 224-13...
Page 84: Crane Cameras
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Crane Cameras Table 3-10. Crane Camera Locations Item Name Camera Points at DRUM 1 and DRUM 6 if equipped (reposition camera to view both drums) Camera Points at DRUM 2 Camera Points at DRUM 3...
Page 85: Crane Camera Monitor
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Crane Camera Monitor Table 3-11. Camera Monitor Operating Controls NOTE For detailed information about the camera monitors, refer to the camera manual that is supplied with the crane. Item Name Description To change the label (“DRUM 3” in this case), refer to the vendor Camera label manual.
Page 86: Motion Warning Lights And Alarms
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL MOTION WARNING LIGHTS AND ALARMS Table 3-12. Motion Warning Lights and Alarms 3-36 Published 08-12-19, Control # 224-13...
Page 87 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-12. Motion Warning Lights and Alarms Item Name Description Dual-tone, interrupted alarm that sounds when the swing or Swing and Travel Alarm either travel control handle is moved in either direction from off.
Page 88: Service Lights
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL SERVICE LIGHTS Table 3-13. Service Light Components Drum Description Service Work Light (2) On-Off Switch Load Center Receptacle (6) 3-38 Published 08-12-19, Control # 224-13...
Page 89 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-13. Service Light Components Item Name Description This crane is equipped with two portable service lights (1) stored in the lockable storage compartment on the left side of the operator cab. Each light has an...
Page 90: Remote Control Activation
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL REMOTE CONTROL ACTIVATION Table 3-14. Remote Control Components Item Description Remote Control Electric Cable: 20 m (66 ft) Transceiver Receptacle (2) Battery Charger External Engine Switch DC Load Center 3-40 Published 08-12-19, Control # 224-13...
Page 91 3-43) for approximately one second and release it to re-establish communication. NOTE The remote control can also be turned on in the Remote Control Selection Screen in the Main Display (see MLC650 Main Display Operation Manual). To start the engine using the remote control: 1.
Page 92: Remote Control Operation
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL REMOTE CONTROL OPERATION Table 3-15. Identification and Operation of Remote Controls NOTE See Section 4 in this manual for Assembly and Disassembly procedures using the remote control. 3-42 Published 08-12-19, Control # 224-13...
Page 93 The remote control can be operated without an electric cable (wireless) if job site conditions allow transmission of a wireless signal. If you are unable to get a wireless signal, the electric cable (A) supplied by Manitowoc can be connected between the remote control receptacle (4) and the transceiver receptacle (B). Receptacle Not Used Rotate CLOCKWISE to INCREASE engine speed (high).
Page 94 If the signal is lost, troubleshoot the system (dead battery or connection, faulty electric cable, faulty electric cable connection). Glows RED to indicate that an operating limit has been reached. See MLC650 Operating Limit Light Main Display Operation Manual.
Page 95 Each remote control has a unique identification number (A) on the side of the unit. This number must be entered in the Main Display when turning on the remote control in the Remote Control Selection Screen. See MLC650 Main Display Operation Manual for instructions.
Page 96 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Table 3-15. Identification and Operation of Remote Controls • Select and confirm item 15. All Rotating Carbody Jacks (at same • Move the control handle I either in direction to energize the function.
Page 97 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-15. Identification and Operation of Remote Controls • Select and confirm item 25. • Move the control handle I in either direction to energize the function. VPC-MAX Beam Rear Pins, Upper • Move the control handle II FORWARD to ENGAGE the upper pins or move the control handle II REARWARD to DISENGAGE the upper pins.
Page 98: Operating Limits Identification And Operation
3-54. 2 Cranes meeting European requirements (CE) are equipped with an RCI/RCL External Override Switch located outside the operator’s cab. See MLC650 Rated Capacity Indicator/Limiter Operation Manual. 3 CE = Cranes that comply with 2010 European requirements. 4 Only if boom or luffing jib is below allowable angle given in capacity chart (while raising or lowering boom and luffing jib from or to ground level).
Page 99 Do not hoist the load above the minimum block clearance given in the Reeving Diagrams (see Section 4 of the MLC650 Operator Manual). Do not use the limit bypass switch to lower the boom or the luffing jib after the block-up limit is contacted, or two-blocking could occur.
Page 100 Do not operate the live mast or the boom until the gantry is properly raised and pinned. Structural damage could result, possibly causing the boom and luffing jib to collapse. See Section 4 of the MLC650 Operator Manual for gantry raising instructions. Inactive Control Station This limit applies only to cranes meeting CE requirements.
Page 101 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operating Limit Icon Luffing Jib Maximum Down 2 (minimum angle) A limit switch stops the luffing jib before the boom-to-luffing jib angle is 68.5°. • This limit cannot be bypassed. • If this limit is contacted on cranes meeting CE requirements, the luffing jib cannot be raised until the limit is reset.
Page 102 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Operating Limit Icon Mast Arms Down With the Setup Mode ON, this limit stops the boom hoist if you attempt to raise the live mast when the mast arms are down. WARNING Falling Mast/Boom Hazard!
Page 103 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operating Limit Icon Pawl Engaged This limit prevents the drum from lowering until the pawl is disengaged from the ratchet. It may be necessary to hoist slightly to fully disengage the pawl. M102794 Rated Capacity Limiter This fault is activated for the following conditions.
Page 104: Bypassing Limits In Luffing Jib Setup Mode
Display (Figure 3-5). The limits will remain bypassed for 10 seconds after the See the MLC650 Main Display Operation Manual for control handle(s) is returned to off. detailed instructions. Turn the luffing jib setup mode OFF (4) for normal Turn the luffing jib setup mode ON (2).
Page 105: Resetting Luffing Jib Limits
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Resetting Luffing Jib Limits When either prompt appears: 1. Release the control handle to off. This procedure applies only to cranes meeting CE requirements. See Figure 3-6. 2. Press either select button (3) to reset the limit.
Page 106: Drum And Control Handle Identification
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL DRUM AND CONTROL HANDLE IDENTIFICATION Drum Numbers Change to T Appears if TANDEM Drums Match Selected Configuration are Configured and Both Drums are Unparked Drum Description Main Hoist Main Hoist (optional) Whip Hoist...
Page 107 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES HANDLE A HANDLE C HANDLE D HANDLE B Configuration Controls Drum Controls Drum Controls Drum Controls Drum With Live Mast (without fixed mast) Live Mast Handling (crane assembly) 3 or 2 or 5...
Page 108: Right Cab Window Operation
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL RIGHT CAB WINDOW OPERATION Figure 3-8 for the following procedure. Closing Window Rotate the window latch handle DOWN to the position shown in View A. Opening Window For Ventilation Rotate the window latch handle UP to the position shown in View B.
Page 109: Cab Tilt Adjustment
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 5. Repeat the steps until the cab tilt starts and stops smoothly in both directions. Item Description 6. Securely tighten the set screws. Tilt DOWN Flow Control Valve Tilt UP Flow Control Valve...
Page 110: Crawler Blocking
See the appropriate instructions given in the capacity charts, in Section 4 of Liftcrane Boom or Jib Capacities chart for blocked crawler the MLC650 Operator Manual, and in Section 4 of the requirements. MLC650 Luffing Jib Manual.
Page 111: Startup Procedures
NOTE Manitowoc recommends the use of the Cold Weather Package to aid startup when the ambient temperature will be 0°C (32°F) and below. Figure 3-11. Hydraulic Tank Shut-Off Valves...
Page 112 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL 5. For Cummins engine only, make sure the fuel system shut-off valves (1, Figure 3-12) are open as shown. Through Access Cover on Top of Engine Item Description Engage Disengage View at Engine Figure 3-13.
Page 113 12. Configure the crane and select the appropriate capacity Screen. The faults should go away as soon as the chart in the RCL/RCI Display. See the MLC650 RCL/ engine oil pressure and hydraulic oil temperature rise to RCI Operation Manual.
Page 114 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL YELLOW = Indicates reduced drum speed. The shorter the bar, the slower the drum speed. Speed can be so slow that it appears the drums are not turning. GREEN = Up to Full Drum Speed...
Page 115: Operating Procedures
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPERATING PROCEDURES of the crane, operations increasing load moment — hoisting up, booming down, or luffing down — will be limited. VPC Operation Drum speed and VPC movement can be monitored in the...
Page 116: Boom Hoist Operation
3. Make sure the automatic boom stop is set at the proper brake will apply to hold the boom in position. angle. For detailed instructions, see the Automatic Boom Stop Adjustment topic in Section 4 of the MLC650 NOTE Besides the boom maximum up limit, a physical Service Manual.
Page 117: Luffing Hoist Operation
3. Make sure the automatic boom stop is set at the proper angle. For detailed instructions, see the Automatic Boom Stop Adjustment topic in Section 4 of MLC650 Service Manual. 4. Make sure the automatic jib stops are set at the proper angles.
Page 118: Swing Operation
RCL/RCI Display. For detailed instructions, speed. see the MLC650 RCL/RCI Operation Manual. Then, move the control handle to off to stop the luffing jib 2. Swing speed and torque can be adjusted between 25% when it reaches the desired angle.
Page 119 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-69 Published 08-12-19, Control # 224-13...
Page 120 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Use this Handle for TANDEM Drums when Both Drums are Unparked T Appears if TANDEM Drums are Configured and Both Drums are Unparked Figure 3-19. Load Drum Control Handles Item Description Lower Boom Point Sheaves...
Page 121: Load Drum Operation
RCL/RCI Display. For detailed instructions, boom point sheaves is parked, the left handle on see the MLC650 RCL/RCI Operation Manual. the right console controls the drum for the left side 2. Load drum speed can be adjusted between 25% and...
Page 122: Travel Operation
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Travel Operation CAUTION Boom Damage WARNING Abrupt travel operation could result in shock loading the boom and rigging. To avoid this, perform all travel Tipping Hazard functions—starting, turning, stopping—slowly and The travel surface must be firm and uniformly supporting.
Page 123 MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 4. For travel on grade, the VPC Lockout Key Switch NOTE The following directions of travel are with the front of (page 3-22) must be in the LOCK position (not the rotating bed and the front of carbody facing the same direction.
Page 124: Shutdown Procedure Or Leaving The Crane Unattended
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL 10. To make a SHARP RIGHT TURN, reverse step 7. 16. When finished traveling, turn on the travel park switch. 11. To make a GRADUAL LEFT TURN (Figure 3-24), move SHUTDOWN PROCEDURE OR LEAVING both crawler handles to front from the neutral position.
Page 125: Changing Counterweight With Boom/Jib In Air
MLC650 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CHANGING COUNTERWEIGHT WITH BOOM/ The suspended load under the boom and jib points must be as small as permitted by the capacity chart. JIB IN AIR 2. Make sure the current boom length, luffing jib length (if...
Page 126 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-76 Published 08-12-19, Control # 224-13...
Page 127: Cold Weather Operation
The static load-carrying limitations of the steels used in off, leaving rope without lubrication. Manitowoc cranes are not affected by cold weather. Manitowoc’s capacity charts are acceptable for use in cold Consult your wire rope supplier for recommended cold– weather.
Page 128 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL See the Legend on page 3-79. View E View C View D View F View A View B Figure 3-26. Cold Weather Heaters 3-78 Published 08-12-19, Control # 224-13...
Page 129: Cold Weather Heater Package
(1) on the crane and to the receptacle on the Package is available. The package contains the following generator (APU). 240VAC heaters: 5. Start the generator (APU) engine. The Manitowoc Figure 3-26 supplied APU can be started from inside the operator’s •...
Page 130 OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Item Description APU (auxiliary power unit) Locking Pin with Hair-Pin Cotter (2) Hook (2) Fixed Pin (2) Adjusting Bolt with Nuts (2) Air Conditioner Hose (2) Fuel Hose (2) Electric Cable (DC, WAC1)
Page 131: Ac Operation
Match the identification numbers on the hoses with the 60 HZ AC generator and a DC charging system is available identification numbers on the quick couplers for proper from Manitowoc to power the following operations when the connection. crane engine is off: 10.
Page 132: Removing Apu
OPERATING CONTROLS AND PROCEDURES MLC650 OPERATOR MANUAL Removing APU interlock switch (12, View A) on the rotating bed. Store the cable in the job box. 1. If the air conditioner hoses (6, View C) are connected, 5. Disconnect the electric cable (9, View C) from the...
Page 133 MLC650 OPERATOR MANUAL SECTION 4 SET-UP AND INSTALLATION TABLE OF CONTENTS Boom and Jib Assembly Drawings ........... . 4-1 Liftcrane Mast Handling Capacities .
Page 134 MLC650 OPERATOR MANUAL Raise Live Mast to Operating Position ..........4-46 Deploy the Self-Erect Cylinder .
Page 135 MLC650 OPERATOR MANUAL Install the Boom Block-Up Limit Components ........4-133 Prepare Intermediate Suspension Pendants .
Page 136 MLC650 OPERATOR MANUAL Installing Cab Window Covers (If Equipped) ........4-200 Wire Rope Installation .
Page 137: Boom And Jib Assembly Drawings
Contact your Manitowoc dealer for assistance if needed. Manitowoc Published 08-12-19, Control # 224-13_v2...
Page 138: Assembly And Disassembly Area
CRANE WEIGHTS AND SHIPPING DATA See the Crane Weights topic at the end of Section 1 of this manual for the weights of individual crane components. See the MLC650 Product Guide in Section 1 of this manual FIGURE 4-1 for outline and shipping dimensions.
Page 139: Personal Fall-Protection
• Do not use anchors for lifting or pulling loads. Number of Manitowoc has provided anchors (2) and lifelines (1) Lifting Points throughout the crane and attachments (see examples in Figure 4-2) to which workers can attach their personnel fall- protection equipment.
Page 140 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Live Mast Live Mast Links/Straps Self-Erect Cylinder Cylinder Rod End Shackle (qty 2) Synthetic Lifting Sling (not shown) Operator Cab Crawler (qty 2) Carbody Jacking Cylinders (qty 4) Carbody Outrigger Pads (4)
Page 141: Crane Assembly Components
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION CRANE ASSEMBLY COMPONENTS The MLC650 crane can be equipped with the following self- erect components, as shown in Figure 4-5. • Self-erect cylinder (3) for lifting major parts. The cylinder is attached to the top of the live mast (1).
Page 142 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Sling # Part # m (ft) mm (in) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) SL 1 (2) 3,30 70,00 45 360 39 281 32 069 22 680 90 718...
Page 143 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION LIFTING POINTS WITHOUT LIVE MAST 4- SH 3-SHACKLES-40 t (44.00 USt) 4- SL 6-SLINGS-5,00 m (16.40 ft) - 31 751kg (70,000 lb) Item Rotating Bed 43 800 76,600 Jacks 6 000 13,200 Drum 5 700...
Page 144: Swing Limits
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SWING LIMITS Reference Table 4-2 Table 4-3 for swing data during crane assembly and disassembly. Table 4-2 Crane Configurations on Pedestals Crane Configuration Swing Capacity Radius • Crane on pedestals (rotating bed, adapter frame, and carbody) •...
Page 145 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Table 4-3 Crane Configurations on Carbody Jacks Crane Configuration Swing Max Capacity Max Radius • Crane on four carbody jacks (rotating bed, adapter 7,5 m (26ft) 54 430 kg frame, and carbody) 120, 000 lb when handling loads •...
Page 146: Hydraulic Hose Identification
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL HYDRAULIC HOSE IDENTIFICATION HOSE AND CABLE CLEANLINESS Where necessary, the hydraulic hoses and corresponding To prevent dirt from entering the hydraulic systems or from couplers have identification tags (5) as shown in Figure 4-10.
Page 147 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION All plugs, regardless of location, must be fully screwed together into their corresponding caps until there is metal to metal contact during crane assembly. Examples of locations of caps and plugs: • hanging lanyards •...
Page 148: Remote Control
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Remote Control Electric Cable: 20 m (66 ft) Transceiver Receptacle (qty 2) Battery Charger External Engine Switch DC Load Center FIGURE 4-12 Remote Control The remote control can be operated without the electric...
Page 149: Activating The Remote Control
STOP position or the remote control is deactivated in the instructions. Remote Control Selection Screen in the Main Display (see MLC650 Main Display Operation Manual). This step allows the boom control handle to raise and lower the live mast and the center drum control handle to The remote control will “go to sleep”...
Page 150: Identification And Location Of Components
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Item Description Boom Hinge Pin Live Mast Sheaves Swing Drive Self-Erect Cylinder (optional) Adapter Frame/Rot Bed Pin Puller Live Mast Links/Straps Crawler Drive Live Mast Hoist (Drum 4)
Page 151: Crane Assembly
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION CRANE ASSEMBLY If equipped, remove and store the cab window covers. The cab covers are secured with hair-pin cotters attached to the Remove Cab Window Covers covers with lanyards. Remove hair-pin cotters to remove covers.
Page 152 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Electrical Plugs Electrical Disconnect Switch (left rear on rotating bed) CAN D Terminator (left front inside rotating bed) Dust Cap CAN Terminator (right front outside rotating bed) CURRENT PAST FIGURE 4-15 4-16...
Page 153: Perform Pre-Start Checks
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Perform Pre-Start Checks Make the following checks before proceeding to assemble Item Description the crane or starting the engine. See Section 3 for starting Hydraulic Tank Shut-Off Valve (closed) instructions. Hydraulic Tank Shut-Off Valve (open)
Page 154 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING POSITION SETUP POSITION Item Description Safety Pin (qty 2) Handrail Lanyard Pin (qty 3) Cab Handrail Quick Release Pin (qty 2) FIGURE 4-17 4-18 Published 08-12-19, Control # 224-13_v2...
Page 155: Deploy Operator Cab Platform
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploy Operator Cab Platform Reference the Start Up Procedure found in Section 3 of this manual. NOTE: Identification labels are provided on the handrails Perform the pre-start checks given on page 4-17. and platforms for ease of installation.
Page 156 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING POSITION Item Description Pins and Safety Pin (qty 3) Strut (shipping position) Strut (set up position) Strut (working position) Rotating Bed Operator Cab Support SETUP POSITION FIGURE 4-18 4-20 Published 08-12-19, Control # 224-13_v2...
Page 157 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploy Operator Cab Figure 4-18 for the following procedure: Remove the strut (2a) from the shipping position. Remove the pins and safety pins (1) from the shipping position that secure the operator cab support (4) to the rotating bed (3).
Page 158 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A- Stored Position View B–Set-Up Position View C–Set-Up Position Item Description Alignment Pendants Adapter Frame Pins and Safety Pins Rotating Bed Rotating Bed Lug (working and stored positions) Outrigger Strut Outrigger Beam Assembly...
Page 159: Remove Rotating Bed From Trailer
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Remove Rotating Bed from Trailer Install the pin and wire locking pin (9, View C) to secure the rotating bed jacking cylinder. Figure 4-19 for the following procedure: Repeat steps 1-8 for each rotating bed jack assembly.
Page 160: Install Operator Cab Rear Platform
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Install Operator Cab Rear Platform NOTE: The rear cab platform (1) must be installed using an assist crane or forklift. CAUTION The pins (4) secure the platform to the crane and must be Attach four lifting slings to the lifting lugs and raise the installed to avoid injury and /or property damage.
Page 161: Install Operator Cab Ladder
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install Operator Cab Ladder Remove pins and pivot the two struts (2) from the shipping position to the working position. Figure 4-22 for the following procedure: Install the pins into the strut brackets (3) to secure the...
Page 162 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-26 Published 08-12-19, Control # 224-13_v2...
Page 163: Overview Of Rotating Bed Platforms And Handrails
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Overview of Rotating Bed Platforms and Handrails Item Description Front Platform and Handrail - Operator Cab Side Platform and Handrail - Operator Cab Side/Rear Platform and Handrail - Operator Cab Rear Handrail - Operator Cab...
Page 164 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Safety Pin Platform Brace Hitch Pin Storage Bracket Hinge Bracket Quick Release Pin and Location Quick Release Pin and Location Lanyard Pin SHIPPING POSITION FIGURE 4-24 4-28 Published 08-12-19, Control # 224-13_v2...
Page 165: Deploy Rotating Bed Platforms
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploy Rotating Bed Platforms Remove safety pin (1) from the storage bracket (4). Swing platform up (upper rear platforms swing down). The rotating bed platforms are attached to the rotating bed and must be flipped up or down to the working position. Each Remove the safety pin (1) from the hitch pin (3) and platform includes hinged platform braces for quick assembly.
Page 166 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Platform Rotating Bed Brackets Quick Release Pins Ladder Pins Handrails FIGURE 4-25 4-30 Published 08-12-19, Control # 224-13_v2...
Page 167: Install Platforms, Ladders And Handrails
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install Platforms, Ladders and Handrails bed brackets (2), and secure with pins and quick release pins(3). NOTE: Identification labels are provided on platforms and Platform and ladder combined weight is approximately handrails for ease of installation.
Page 168 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A WORKING POSITION STORED POSITION Item Description Drum 3 Assembly 4-SL 4 - Slings - 3,80 m (12.5 ft) - 11 340 kg (25,000 lb) Lifting Lug (4) 4-SH 2 - Shackles - 17 t (18.70 USt)
Page 169: Install Drum 3
View A) from the lifting lugs (3) on the drum assembly. area. 11. Disconnect the four hydraulic hoses (10, stored position) Attach the Manitowoc supplied lifting slings (2, View A) from the rotating bed and connect them to the four to the hook of the assist crane.
Page 170: Activate Auxiliary Hydraulic System
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL FIRST MENU SCREEN AUXILIARY HYDRAULICS NOT ACTIVATED FIGURE 4-27 AUXILIARY HYDRAULICS ACTIVATED Activate Auxiliary Hydraulic System Start from the first menu screen and use either the jog dial on the right console, or the scroll keys on the display Before using the hand-held pin puller the auxiliary hydraulic to select the auxiliary hydraulics icon.
Page 171 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-35 Published 08-12-19, Control # 224-13_v2...
Page 172 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL PAST Item Description Hand-Held Pin Puller Insert Coupler Cylinder Rod End CURRENT Control Knob Item Description Pull to Extend Rotating Bed Push to Retract Hydraulic Connections Control Knob Right to Extend Left to Retract...
Page 173: Connect Hand-Held Pin Puller
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Hand-Held Pin Puller b. The cylinder rod end (3) is used to push or pull pins and the insert coupler (2) is used to align the pin Use the hand-held pin puller to assist in the installation and puller during insert pin installation or removal.
Page 174: Install The Live Mast
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A View C View B Item Description Live Mast Lifting Points 4-SL 4 - Slings - 3,8 m (12.50 ft) - 11 340 kg (25,000 lb) 4-SH 2 - Shackles -17 t (18.70 USt)
Page 175 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Not Used Live Mast Hinge Keeper Pin (stored position) Backhitch/Gantry Operating Pins Gantry Pin Retention Bracket Keeper Pin Keeper Plate Hoist Drum Operating Pin Pin Puller Cage Pin Puller Cage Backhitch Link Pin...
Page 176 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL HANDLING POSITION Item Description Backhitch Assembly Backhitch Link Pin (working position) Backhitch Link Pin (shipping position) Pin (shipping position) Pin (stored position) Gantry Assembly Pin (stored position) Pin (shipping position) Shipping Pin (stored position)
Page 177: Secure The Backhitch/Gantry Assemblies
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Secure the Backhitch/Gantry Assemblies Remove the gantry pin retention brackets (9a) and place them in the stored position (9b). With the assist crane still attached to the live mast assembly, Install the operating pins (8) to the working position...
Page 178 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING WORKING View C View A View B View C Item Description Pin (stored position) Pin (shipping position) Shim Safety Pin Alignment Pin Pin Puller Cage Operating Pin Keeper Pin Keeper Bar Drum Hoist Frame...
Page 179: Secure The Live Mast Hoist Drum
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Secure the Live Mast Hoist Drum NOTE: This shim reduces the amount the mast can shift relative to the drum assembly during shipping and is not used during crane operation. CAUTION Install the operating pins (7, View C) using the pin puller...
Page 180 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Drum 4 Pawl Hydraulic Connections (qty 2) Drum 4 Hydraulic Connections (qty 4) Stored Drum 4 Hydraulic Hoses (qty 4) Working Drum 4 Electrical Connection Live Mast Hydraulic Connections (qty 2) Stored...
Page 181: Connect The Live Mast Hydraulic And Electrical
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect the Live Mast Hydraulic and Connect the drum 4 electrical connector (3) to the second plug connector from the top of the receptacle Electrical bracket. Figure 4-36 for the following procedure: Remove the two hydraulic connections (4a) from the Connect the two, drum 4 pawl hydraulic connections (1).
Page 182: Activate Setup Mode
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Live Mast Gantry Backhitch Pin - Stored Position Pin - Working Position Pin - Stored Position Pin - Working Position Pin - Stored Position Pin - Working Position Backhitch Pin Mast Roller...
Page 183 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Check the boom hoist wire rope between the sheaves in If the pin holes do not align, extend the live mast assist the end of the live mast (1) and the gantry (2). If the wire cylinders (7) to tighten the ropes and align the pin holes.
Page 184 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Self-Erect Cylinder Rod End Bracket STORED POSITION WORKING POSITION Spring Retention Bracket FIGURE 4-39 CAUTION WARNING Mast Damage! Falling Mast Hazard! Make sure mast angle indicator is properly installed and Prevent the mast from falling over backwards or forward: adjusted prior to raising the mast (see Section 4 of MLC650 Service Manual).
Page 185: Deploy The Self-Erect Cylinder
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploy the Self-Erect Cylinder • The hazard warning symbol and MAST TOO FAR FORWARD icon will appear in the system Figure 4-39 for the following procedure: fault bar on the information screen. Raise the live mast to 85° (7).
Page 186 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL VIEW A Item Description Trailer Adapter Frame Carbody Rotating Bed Rotating Bed Jacking Cylinder (qty 4) Alignment Pendant (qty 4) Alignment Pendant Lug (qty 8) VIEW B FIGURE 4-40 4-50 Published 08-12-19, Control # 224-13_v2...
Page 187: Aligning Rotating Bed To Carbody
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Aligning Rotating Bed to Carbody Raise the rotating bed jacking cylinders so the adapter frame and carbody are not resting on the trailer, allowing Figure 4-40 for the following procedure: the adapter frame to self align to the rotating bed.
Page 188 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Rotating Bed Pin (stored position) (qty 2) Rotating Bed Pin (working position) (qty 2) Collar (stored position) (qty 4) Collar (working position) (qty 4) Adapter Frame Pin (stored position) (qty 2) Adapter Frame Pin (working position) (qty 2)
Page 189: Attaching Rotating Bed To Adapter Frame
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Attaching Rotating Bed to Adapter Frame Figure 4-42 for the following procedure: Confirm the alignment of the pin holes on the rotating bed and the adapter frame. Engage the front adapter frame pins (3a) to the rotating bed.
Page 190 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING POSITION Item Description Rotating Bed Jacking Cylinder (qty 4) Carbody Carbody Jacking Cylinder (qty 4) Outrigger Pad (qty 4) Strut (qty 4) Safety Pin and Pin (qty 8) Jack Lug (qty 4) Carbody Lug (qty 4)
Page 191: Deploying Carbody Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploying Carbody Jacking Cylinders Using the remote control, extend the carbody jacking cylinder (3, View C) until the cylinder rod engages the Figure 4-44 for the following procedure: outrigger pad. Repeat steps 1 – 6 for each carbody jacking cylinder...
Page 192: Storing Rotating Bed Jacking Cylinders
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED on Rotating STORED POSITION STORED on Crawler Item Description U-shaped Locking Pin (stored position) (qty 4) U-shaped Locking Pin (working position) (qty 4) Outrigger Pad Locking Pin (qty 4) Outrigger Pad (stored position) (qty 4)
Page 193: Installing Hydraulic Connections
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing Hydraulic Connections NOTE: There are four hydraulic hose connections on the left side of the crane and five hydraulic hose Figure 4-47 for the following procedure. connections on the right side of the crane.
Page 194 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-58 Published 08-12-19, Control # 224-13_v2...
Page 195 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION WORKING POSITION Item Description Alignment Pendant (qty 4) Adapter Frame Rotating Bed Safety Pin and Pin (qty 8) STORED POSITION FIGURE 4-48 Removing and Storing Alignment Pendants Install the alignment pendants on the adapter frame in the stored position.
Page 196: Deploying Operator Cab (Working Position)
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Deploying Operator Cab (Working Position) Rotate the operator cab to the working position. Install the strut (2c) using the locking pin and pins to Figure 4-49 for the following procedure: secure the operator cab in the working position.
Page 197: Installing Crawlers
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing Crawlers The crane must be in the following configuration to install the crawlers: WARNING • Mast arms fully raised. Tipping Hazard! Parts Damage! • Crane SETUP mode selected and confirmed. • Do not exceed 54 430 kg (120,000 lb) capacity at •...
Page 198 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description SH 1 Shackle – 55 t (60.60 USt) (qty 2) SL 5 Sling – 2,60 m (8.50 ft), 56 700 kg (125,000 lb) SL 1 Sling – 3,30 m (10.83 ft), 45 360 kg (100,000 lb) SL 2 Sling –...
Page 199 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing the First Crawler 12. Retract the self-erect cylinder to lift the crawler from the trailer. The crawlers may be installed using the live mast or an assist NOTE: There will be approximately 8° of tilt toward the crane.
Page 200 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Collar (stored position) (qty 2) Collar (working position) (qty 2) Retaining Pin (stored position) (qty 2) Retaining Pin (working position) (qty 2) Hair-Pin Cotter or Safety Pin (stored position) Hair-Pin Cotter or Safety Pin (working position)
Page 201 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing the First Crawler (continued) 14. Slowly lower the crawler, mast up, and swing to engage the crawler hooks (5) with the carbody pins (6). Figure 4-52 for the following procedure: 15. Stop lowering when the crawler hooks are fully engaged Figure shown without lifting jack cylinders for clarity.
Page 202 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A Item Description Carbody Jacking Cylinders (qty 4) Crawler 1 Crawler 2 Rotating Bed View B FIGURE 4-54 Installing the Second Crawler Position the trailer carrying crawler 2 (3) alongside the first crawler (View A).
Page 203: Storing Carbody Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION WORKING POSITION STORED POSITION View B View C View A Item Description Carbody Jack (qty 4) Outrigger Pad (qty 4) Strut (qty 4) Safety Pin and Pin (qty 8) Jack Lug (qty 4) Carbody Lug (qty 4)
Page 204: Installing Carbody Cavity Platform
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Quick Release Pin (qty 4) Carbody Cavity Platform (removed) (qty 2) Carbody Cavity Platform (working position) (qty 2) FIGURE 4-56 Installing Carbody Cavity Platform Slide the quick release pins (1) through the lugs to secure.
Page 205 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-69 Published 08-12-19, Control # 224-13_v2...
Page 206 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Lock Nut and Bolt (qty 8) Drive Shaft Flange Locking Pin Latch Crawler Drive Shaft Storage Bracket Companion Flange Collar Locking Pin (qty 2) SHIPPING POSITION Drive Shaft Guard (qty 2) Drive Shaft Lever...
Page 207: Installing Crawler Drive Shafts
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing Crawler Drive Shafts Remove the lock nuts and bolts (1) from the drive shaft flange (2) in the shipping position and set them aside. Figure 4-57 for the following procedure: In the shipping position, remove the locking pin (3), raise the latch (4), and lift the crawler drive shaft (5) from the storage bracket (6).
Page 208: Installing Carbody Platforms
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING POSITION WORKING POSITION Item Description Item Description Wire Locking Pin (qty 2) Platform Bracket (qty 3) Safety Pin (qty 2) Carbody Platform Bracket (qty 3) Hitch Pin (qty 2) Hitch Pin with Safety Pin (qty 2)
Page 209: Installing Carbody Ladders And Handrails
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Ladder Assembly Ladder Support Adjustment Screw Ladder Bracket Handrail Front of Carbody Arrow FIGURE 4-59 Installing Carbody Ladders and Handrails Install the handrail into the ladder assembly and secure with pins. Figure 4-59...
Page 210 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Carbody Ladder and Handrail Carbody Front and Rear Platform Operator Cab (working position) FIGURE 4-60 4-74 Published 08-12-19, Control # 224-13_v2...
Page 211: Installing Front Platforms, Ladders, And Handrails From Rotating Bed And Cab
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Installing Front Platforms, Ladders, and Install the upper cab-to-bed ladder (3) by sliding the tubes at the top of the ladder through sleeves on the Handrails from Rotating Bed and Cab underside of the platform.
Page 212 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Plates Pendants Counterweight Tray Tag Line Lugs Lifting Ring FIGURE 4-62 4-76 Published 08-12-19, Control # 224-13_v2...
Page 213: Installing Counterweight Tray
For ease of counterweight tray handling and lifting, NOTE: The counterweight tray must be installed with an Manitowoc provides four pendants (2) and two plates (1). assist crane. Damage may occur if the tray is lifted The pendants and plates are stored in the counterweight too high.
Page 214 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Plates Pendants Counterweight Tray Tag Line Rotating Bed Front Vertical Rollers Front Horizontal Rollers Large Stop Blocks (qty 2) Small Stop Blocks (qty 2) Rotating Bed Counterweight Tray Rack FIGURE 4-63 4-78...
Page 215 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Continued from the previous page. Slowly position the counterweight tray (3) using the assist crane toward the front of the crane and position Figure 4-63 for the following: the counterweight tray onto the rotating bed (5) to a point...
Page 216 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Hydraulic Hoses (stored position) Counterweight Tray Hydraulic Hoses (working position) Connecting Link (stored position) Connecting Link (working position) Rotating Bed Electrical Cable (WVB-1) connects to (WVT1-P1) Rotating Bed Electrical Cable (WVB-2) connects to (WVT2-P1)
Page 217: Installation Of The Hydraulic Hoses
Speed control is variable for the counterweight tray. Disconnect the assist crane from the counterweight tray. Align the Counterweight Tray to the Pinions See the MLC650 Main Display Operation manual for Figure 4-65 for the following procedure: counterweight tray calibration instructions.
Page 218 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Rotating Bed Physical Stop on Tray (1 each side) Physical Stop on Bed (1 each side) FIGURE 4-66 4-82 Published 08-12-19, Control # 224-13_v2...
Page 219: Remove Counterweight Boxes From Trailer
The crane will tip. If the MLC650 will be used to assemble the boom and jib, To prevent the counterweight boxes from falling and install the counterweight boxes after the boom and jib are crushing personnel: assembled.
Page 220 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Tray at the minimum working position Counterweight Chain Assembly 2-SL 4 Slings - 3,80 m (12.50 ft) - 11 340 kg (25,000 lb) Counterweight Box Alignment Lug Counterweight Tray Alignment Lug Counterweight Tray Lug...
Page 221 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION around counterweight tray (6). 13. Tighten the turnbuckles until the counterweight chain counterweight chain assemblies (2) are designed to assemblies around the lugs are snug. minimize counterweight movement during travel and NOTE: The ratchet on the turnbuckle must be flipped in...
Page 222 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Upper Boom Point Lower Point Sheaves Boom Top Assembly Weight Ball Block Luffing Jib Wire Rope Guides Insert w/Sheaves Drum 2 Main Hoist (optional) Drum 6 Luffing Hoist (optional) Butt Assembly Drum 0 Rigging Winch...
Page 223 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-87 Published 08-12-19, Control # 224-13_v2...
Page 224: Boom And Jib Rigging-General
See the Crane • Mast-assist arms (2) fully raised. Weights topic in Section 1 of the MLC650 Operator Manual • Shackles (7) and lifting slings (8) attached to the self- for the weights of the boom and jib components.
Page 225: Blocked Crawlers
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Blocked Crawlers To prevent the crane from tipping, some boom and jib Item Description lengths must be raised and lowered over the end of blocked c r a w l e r s . S e e c a pa c i t y c h a r ts f o r b l o c k e d c ra w l e r...
Page 226 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Boom Section (typical) Boom links (stored) Lifting Lug (4) (if equipped, for shackles of lifting sling hooks) Lifting Lug (4) (synthetic lifting sling posts) Boom Straps and Luffing Jib Backstay (stored) FIGURE 4-71...
Page 227: Handling Boom And Jib Sections
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Handling Boom and Jib Sections CAUTION Handle the boom and jib sections with care to avoid Lacing Damage damaging the lacings and chords. Ensure the boom straps and links (Figure 4-71) and the jib...
Page 228 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED POSITION WORKING POSITION Item Description 12M Insert W/Sheaves Ladders Ladder Mounting Bracket without Latch Ladder Mounting Bracket with Latch Rubber Latch Lower Pad FIGURE 4-72 4-92 Published 08-12-19, Control # 224-13_v2...
Page 229: Boom Ladders
Installing Ladders on Boom Inserts • Avoid improper use. Ladder is intended for use only on Manitowoc #680 boom inserts. Any other use is Lift ladder (2) to desired outside location on insert so ladder prohibited. is securely hooked over backside of upper chord and lower pad (6) is firm against lower chord (see working position).
Page 230 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Installed or Removed Mast-Assist Arms Mast in Operating Range Self-Erect Cylinder Live Mast Straps Rod End 2-SH 1 Shackle - 55 t (60.60 USt) 4-SL 4 Slings - 3,80 m (12.50 ft) - 11 340 kg (25,000 lb)
Page 231: Boom Assembly
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION BOOM ASSEMBLY provided in a separate publication at the end of this section or at the end of Section 4 in the MLC650 VPC-MAX Operator Manual. NOTE: To lift inserts, use shackles and lifting slings WARNING attached to the self-erect cylinder rod end.
Page 232 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL VIEW A VIEW D VIEW E Item Description Fixed Horizontal Pin (2 each section) Hooked Connector (2 each section) Safety Pin (2 each section) Hand-held Pin Puller Pin (shipping position) VIEW B Pin (working position)
Page 233 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Figure 4-74, for the following steps: Install Intermediate Suspension Insert at proper location (see "Prepare Intermediate Suspension Lift the next insert into position and engage the fixed Pendants" on page 4-135) horizontal pins (1, View A) with the hooked connectors (2) on the adjacent insert.
Page 234 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Intermediate Wire Rope Guide Pin and Safety Pin (2) Wear Pad (2) Insert Safety Pin (2) Pendant Pin with Cotter Pin (2) Intermediate Suspension Pendant (2) 35 mm (1-3/8 in) Diameter x 1,8 m (5 ft 10 in) Long...
Page 235 Refer to the rope routing diagrams in the Extended (1) to the lugs on the male connectors of the insert (4). Upper Boom Point publication at the end of this section or at the end of Section 4 in the MLC650 Disconnect the lifting slings. VPC-MAX Operator Manual.
Page 236 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View D View C View E View F View B Item Description Lifting Lug (2) Socket (2) Insert (closest to butt) Connecting Pin (2) Adjacent Insert Pin Puller Bracket with Pin (2) Strap Links (4)
Page 237 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install Drop-Down Suspension b. Remove the strap links (7, View D) from both sides of the insert and store them in the parts box. Place If the drop-down suspension is required per the Boom the pins with collars (8) to the side for use later.
Page 238 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Installed or Removed Mast-Assist Arms Mast in Operating Range Self-Erect Cylinder Live Mast Straps Rod End 2-SH 1 Shackles - 55 t (60.60 USt) 4-SL 4 Slings - 3,80 m (12.50 ft) -...
Page 239 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Assemble Top to Boom Inserts If the boom top is in Shipping Configuration A, the lower boom points (and wire rope guide) will rotate down to the The boom top can be shipped in either of the configurations...
Page 240 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL VIEW A Item Description Wire Rope Guide Pins and Safety Pins Struts (shipping position) Struts (shipping position) VIEW B FIGURE 4-81 4-104 Published 08-12-19, Control # 224-13_v2...
Page 241: Raise Boom Top Wire Rope Guide
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Raise Boom Top Wire Rope Guide Raise the wire rope guide (1, View B) to the working position. Figure 4-81, for the following procedure. Raise the struts (3b, View B) and pin them to the wire Rig two slings using shackles through the wire rope rope guide.
Page 242 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View C View A Boom Only or Boom View D View B Boom Only with Luffing Jib Boom Only Boom with Luffing Jib View D SHIPPING View E WORKING Item Description Boom Top Connecting Pin with Safety Pin (2-4)
Page 243: Install/Remove Lower Boom Point
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install the links (slotted ends toward boom top) between the lower boom points and the boom top using the appropriate long and short pins as shown in View E. WARNING Secure the pins and links with safety pins.
Page 244 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Hair-Pin Cotter Position Light (stored position) Position Light (working position) Boom Top Camera (optional) Hair-Pin Cotter Block-Up Limit Switch Position Light Block Level Indicators Wind Speed Indicator Electric Cable (WBT1-P8 Position Light)
Page 245: Install Position Light And Wind Speed Indicator
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install Position Light and Wind Speed Insert the position light and wind speed indicator bracket (2b) into the tube on the right side of the boom top and Indicator install a safety pin (8).
Page 246 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Strap Link Pin with Cotter Pins Pin Storage Bracket Pin with Collar, Retaining Pin, and Cotter Pins Pin with hair-Pin Cotter Strap Bracket View B View A FIGURE 4-84 4-110 Published 08-12-19, Control # 224-13_v2...
Page 247: Connect Boom Straps
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Boom Straps If required per the capacity chart, remove the luffing jib straps, links, and connecting hardware from the boom Figure 4-84 for the following procedure: sections. The boom straps and, if equipped, the luffing jib straps are To connect boom straps, start at the boom top and proceed shipped on the boom sections as shown in View A.
Page 248 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A Item Description Upper Boom Point View B Lifting Lug (if equipped) Pins with Safety Pins (qty 2) Anti-Two Block Lug Pins with Safety Pins (qty 2) Electric Cable (WBU1-P1 connects to WBT1-J2)
Page 249: Install Upper Boom Point
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install Upper Boom Point Disconnect the lifting slings. Connect the electric cable (5) from the upper boom point to the receptacle (6) in the boom top (View A). The electric cable is stored on the brackets on the left WARNING side of the upper boom point.
Page 250 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Installed or Removed Mast-Assist Arms Mast in Operating Range Self-Erect Cylinder Live Mast Straps Rod End View A 2-SH 1 - Shackle 55 t (60.60 USt) 4-SL 4 - Sling - 3,80 m (12.50 ft) - 11 340 kg...
Page 251 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Prepare Boom Butt Attach the four nylon lifting slings to the four lifting lugs on the boom butt (View A). Figure 4-86 for the following steps: Lift the boom butt from the trailer and position boom butt...
Page 252 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Installed or Removed Mast-Assist Arms Mast in Operating Range Self-Erect Cylinder Live Mast Straps Rod End 2-SH 1 - Shackle 55 t (60.60 USt) 4-SL 4 - Sling - 3,80 m (12.50 ft) - 11 340 kg (25,000 lb)
Page 253: Prepare 4M Insert
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Prepare 4M Insert Raise Wire Rope Figure 4-87, for the following steps: Figure 4-88, for the following steps: NOTE: To lift inserts, use shackles and lifting slings Connect two nylon slings to the wire rope guide lifting attached to the self-erect cylinder rod end.
Page 254 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Working Position Stored Position Item Description Hand-Held Pin Puller Hair-Pin Cotter Hydraulic Hoses (stored) Hydraulic Hoses (working) Hydraulic Piping (boom butt) WBB3 Electric Cable WBB2 Receptacle WN15500T Electric Cable (connects to WN145000) WBB1 Electric Cable...
Page 255: Connect 4M Insert To Boom Butt
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect 4M Insert to Boom Butt Remove the hitch pins (3) from the struts (2). d. Lower the carbody platform assembly until the holes Figure 4-89, for the following steps: in the struts (2) align and insert the hitch pins (3).
Page 256 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Self-Erect Cylinder Live Mast Straps Rod End 2-SH 1 - Shackles - 55 t (60.60 USt) 2-SL 1 - Slings - 3,30 m (10.83 ft) - 45 360 kg (100,000 lb) 2-SL 2 - Slings - 3,10 m (10.30 ft) - 18 144 kg (40,000 lb) 2-SH 3 - Shackles - 40 t (44 USt) 2-SH 2 - Shackles - 17 t (18.70 USt)
Page 257: Connect Boom Butt To Crane
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Boom Butt to Crane Lift the boom butt and 4M insert to align with the adapter frame mounting holes. Figure 4-91, for the following steps: Install the pin puller cage (2) for installing the boom butt Rig the lifting slings (5 and 7) to the self erect cylinder hinge pin (3).
Page 258 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Self-Erect Cylinder Live Mast Straps Rod End 2-SH 1 - Shackles - 55 t (60.60 USt) 2-SL 2 - Slings - 3,30 m (10.83 ft) - 45 360 kg (100,000 lb) 2-SL 2 - Slings - 3,10 m (10.30 ft) - 18 144 kg (40,000 lb) °...
Page 259: Lower Boom Butt And 4M Insert
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Lower Boom Butt and 4M Insert Raise the carbody platform to the working position. Insert the hitch pins (3). Figure 4-93, for the following procedure: Insert the hitch pins and safety pins (5). Confirm that the mast assist arms (9) are fully raised before proceeding.
Page 260 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Hydraulic Hoses (stored) Hydraulic Piping (boom butt) Electric Cable - CAN D CAN TERMINATOR WBB2 Cable Connects to WFR2 WBB1 Cable Connects to WRL2 FIGURE 4-95 4-124 Published 08-12-19, Control # 224-13_v2...
Page 261: Connect Hydraulic Hoses From Crane To Boom Butt
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Hydraulic Hoses from Crane to Remove the cotter (1) and hitch pins (2) from the hose storage brackets (4). Boom Butt Flip the hose storage brackets (4) up, slide them down, Figure 4-95, for the following procedure:...
Page 262 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED Item Description Fixed Horizontal Pin Hooked Connector Safety Pins Pins Live Mast Straps 4-Bushings (stored position) 4-Bushings (working position) 2-SH 3 - Shackles - 40 t (44 USt) 1-SL 3 - Spreader Sling - 1,60 m (5.25 ft) - 9 072 kg (20,000 lb) 2-SL 1 - Slings - 3,30 m (10.83 ft) - 45 360 kg (100,000 lb)
Page 263: Connect 4M To Boom
Slowly travel in reverse several feet. Boom down to attach the live mast straps (5) to the 4M d. Place the required blocking on the ground at the closing lugs using the Manitowoc supplied shackles and points marked in step 8a. slings.
Page 264 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View B View A View C View D Item Description ° Mast Angle (maximum) Live Mast Link Hole “A” Hole “B” Hole “C” Strap Link 4M Strap Pin and Safety Pin Pin, Collar, Cotter Pin...
Page 265: Connect Mast Straps To Boom Straps
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Mast Straps to Boom Straps for the necessary live mast adjustment hole identification (3a, 3b, or 3c, View B). Figure 4-98, for the following procedure: Using the switch on the remote control or on the right...
Page 266 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View C View A View B View D Item Description Camera (Optional) View E Camera Shaft Bracket Hair-Pin Cotter Electric Cable CCTV (WJT3 connects to WBR3) Cable Clip WBT1-P3 (connects to the A2B lower point slow)
Page 267: Connect Camera And Electric Cables
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Camera and Electric Cables Disconnect the CAN terminator (8, View E) from the CAN NET IN electric cable (8). SeeFigure 4-99, for the following procedure: Connect WN145000 electric cable (15, View E) to the Pay out the electric cables (10, 13, and 16, View B) from CAN NET IN electric cable (8).
Page 268 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Position Indicator Light Wind Speed Indicator Limit Switch (lower and upper boom point) Chain Weight with 2-Chain Attachments Lift Plate Hook-and-Weight Ball Weight with 1-Chain Attachment Lift Block Load Block Shackle Weight and Chain Storage...
Page 269: Install The Boom Load Lines
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Install the Boom Load Lines Read the following topics: • "Wire Rope Installation" on page 4-201. Route the load lines up the boom. See Figure 4-164 on page 4-210. • "Load Line Reeving" on page 4-211.
Page 270 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View D View A WORKING View B View C View F SHIPPING View E See Legend on Following Page FIGURE 4-102 4-134 Published 08-12-19, Control # 224-13_v2...
Page 271: Prepare Intermediate Suspension Pendants
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Prepare Intermediate Suspension Pendants (1). The pendants (1a) are stored on the intermediate wire rope guide shown in Figure 4-76 on page 4-98. Legend for Figure 4-102 Pin the intermediate suspension pendants (1, View A) or...
Page 272: Raise Boom
 Left-rear rotating bed ladder is folded in stored position or removed. NOTE: Refer to the MLC650 Luffing Jib Operator Manual  All tools and other items are removed from boom and jib. for the pre-raising checks and raising procedure when equipped with a luffing jib.
Page 273: Shipping Crane Components
FIGURE 4-104 b. Check all safety devices for proper operation (see It is the owner/user’s responsibility to ensure the following: Section 3 of the MLC650 Operator Manual). • All trailer loads comply with local, state, and federal Check that the boom stop is adjusted for the proper transportation requirements.
Page 274: Crane Disassembly
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL CRANE DISASSEMBLY Removing Block-Up Limit Components Read all of the topics on page 4-1 through page 4-10 before Remove the block-up limit weights and chains (see proceeding. Figure 4-101 on page 4-132) and store them as shown.
Page 275 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Figure 4-105 for the following procedure: Hold onto the mounting plug (2) and remove the locking Item Description pin (4). Mounting Bracket Disconnect the hose coupler (3) from its working Mounting Plug position and screw the mounting plug into the hose Hose Coupler coupler.
Page 276 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View B View A View C View D Item Description Live Mast Angle (maximum) Live Mast Link Hole A Hole B Hole C Strap Link Strap Locking Pin and Pin Retaining Pin FIGURE 4-107...
Page 277: Activating Setup Mode
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Activating Setup Mode Using an assist crane and slings or a forklift, slightly raise the platform to relieve pressure from hitch pins (3 Perform the steps under Setup Mode on page 4-13. and 4).
Page 278 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Fixed Horizontal Pin (qty 2) Hooked Connector Safety Pin (qty 2) Lower Connecting Pin (qty 2) Live Mast Strap (qty 2) Bushing (stored position) (qty 4) Bushing (working position) (qty 4) SH 3 Shackle – 40 t (44 USt) (qty 2) SL 3 Spreader Sling –...
Page 279: Disconnecting Boom From 4M Insert
WARNING Attach the live mast straps (5) to the 4M lugs using the Manitowoc supplied shackles and slings. Crushing Injury Hazard! Stand outside the boom to prevent serious crushing injury, Remove the bushings (6a) from the stored position and do not stand inside the boom sections when removing the place the bushings (6b) into the live mast straps.
Page 280: Removing Boom Butt And 4M
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Self-Erect Cylinder Live Mast Strap Rod End SH 1 Shackle – 55 t (60.60 USt) (qty 2) SL 1 Sling – 3, 30 m (10.83 ft), 45 360 kg (100,000 lb) (qty 2) SL 2 Sling –...
Page 281 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Use the hand-held pin pullers to remove the boom butt hinge pins (3). Remove the boom butt hinge pins. WARNING 10. Retract the self-erect cylinder to lift the boom butt and Moving Load Hazard! 4M to clear the pin holes in the adapter frame.
Page 282 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED POSITION WORKING POSITION Item Description Support Pedestal (qty 2) Fixed Pin (qty 4) SL 2 Sling – 3,10 m (10.30 ft), 18 144 kg (40,000 lb) (qty 4) Hydraulic Hose (stored position) (qty 6)
Page 283: Separating 4M Insert From Boom Butt
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Separating 4M Insert from Boom Butt Remove the safety pins (12) from the lower connecting pins (13). Figure 4-113 for the following procedure: 10. Either install the hand-held pin puller and remove both of...
Page 284: Loading Boom Butt
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description SL 4 Sling – 3,80 m (12.50 ft), 11 340 kg (25,000 lb) (qty 4) Rod End SH 1 Shackle – 55 t (60.60 USt) (qty 2) Lifting Lug (qty 4) Boom Butt...
Page 285: Disassembling Boom
See "Personal Fall- Protection" on page 4-3. If the MLC650 will be used to disassemble the boom, remove the counterweight boxes and tray before proceeding. Refer to the following bulleted procedures: • "Install Counterweight Boxes" on page 4-83.
Page 286: Removing Counterweight Boxes
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Counterweight Tray Rotating Bed Physical Stop on Tray (1 each side) Physical Stop on Bed (1 each side) FIGURE 4-117 Removing Counterweight Boxes tray (3, Figure 4-117) contacts the physical stop on the bed (4).
Page 287 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION b. Remove two counterweight boxes from the other Attach slings (3) around the lifting lugs on the SL 4 side of the tray. counterweight boxes. Two counterweight boxes may be lifted at one time.
Page 288: Preparing Counterweight Tray For Removal
NOTE: For ease of counterweight tray handling and lifting, Manitowoc provides four lifting pendants (2) and Hoist with the assist crane so the lifting slings are taut. two lifting plates (1), and two lifting lugs on each side of the tray.
Page 289: Disconnecting Counterweight Tray Hydraulics And Electrical Wiring
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Hydraulic Hose (stored position) (qty 4) Hydraulic Hose (working position) (qty 4) Connecting Link (stored position) Connecting Link (working position) Rotating Bed Electrical Connector WVB-1 (connects to WVT1-P1) Rotating Bed Electrical Connector WVB-2 (connects to (WVT2-P1)
Page 290 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Lifting Plates Lifting Pendant (qty 4) Counterweight Tray Tag Line Rotating Bed Front Vertical Rollers Front Horizontal Rollers Large Stop Block (qty 2) Small Stop Block (qty 2) Rotating Bed Counterweight Tray Rack...
Page 291: Removing Counterweight Tray
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Removing Counterweight Tray Store the counterweight chain assemblies in the storage pockets in the counterweight tray. Figure 4-121 for the following procedure: Remove the hair pin cotter from the two large stop blocks (8) and set aside.
Page 292 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SHIPPING POSITION WORKING POSITION Item Description Locking Pin (qty 2) Safety Pin (qty 2) Hitch Pin (qty 2) Strut (qty 2) Platform Bracket Carbody Platform Bracket Hitch Pin (qty 2) Adjuster FIGURE 4-122 4-156...
Page 293: Removing Carbody Platforms
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Removing Carbody Platforms Figure 4-122 for the following procedure: NOTE: An assist crane or forklift must be used to remove the carbody platform. Lift and remove the ladder assembly from the carbody platform. Use an assist crane or forklift to slightly lift the carbody platform to remove weight from the pins.
Page 294 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View A View B View C View D Item Description Locking Pin (qty 2) Outer Drive Shaft Guard Drive Shaft Lever Forked Bracket Collar Locking Pin Lock Nut and Bolt (qty 8) Drive Shaft Flange...
Page 295: Disconnecting And Storing Drive Shafts
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Disconnecting and Storing Drive Shafts Remove the bottom lock nuts and bolts (7) attaching the drive shaft flange (8, View D) and the companion flange Figure 4-124 for the following procedure: (9, View D) first, leaving one bolt attached on the top.
Page 296 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED POSITION Item Description Rotating Bed Crawler Carbody Jacking Cylinder (qty 4) Outrigger Pad (qty 4) Strut (qty 4) Safety Pin and Pin (qty 2) Jack Lug Carbody Lug Locking Pin View A View C...
Page 297: Deploying Carbody Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploying Carbody Jacking Cylinders Remove the locking pin (9) securing the outrigger pad (4) in the stored position and place the outrigger pad on Figure 4-125 for the following procedure: the ground below the jack rod (View C). Return the locking pin to the stored position.
Page 298 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL View B View A Item Description SH 1 Shackle – 55 t (60.60 USt) (qty 2) SL 5 Sling – 2,60 m (8.50 ft), 56 700 kg (125,000 lb) SL 1 Sling – 3,30 m (10.83 ft), 45 360 kg (100,000 lb) SL 2 Sling –...
Page 299: Removing First Crawler
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Removing First Crawler Using the remote control extend the carbody jacking cylinder on the side of the crawler to be removed high Figure 4-126 for the following procedure: enough for the crawler pads to clear the ground.
Page 300: Removing First Crawler (Continued)
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Collar (stored position) Collar (working position) Retaining Pin (stored position) Retaining Pin (working position) Hair Pin Cotter or Safety Pin (stored position) Hair Pin Cotter or Safety Pin (working position) Crawler Pin (qty 2)
Page 301 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-165 Published 08-12-19, Control # 224-13_v2...
Page 302 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Rotating Bed Sling (qty 3) Crawler (qty 2) Carbody Jacking Cylinder (qty 4) Carbody Distance FIGURE 4-129 4-166 Published 08-12-19, Control # 224-13_v2...
Page 303: Removing Second Crawler
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Removing Second Crawler Extend the carbody jacking cylinder (4) so the carbody distance (5) is high enough for the crawler pads to clear Figure 4-129 for the following procedure: the ground and the crane is level.
Page 304 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL STORED POSITION Item Description Clevis Pin (qty 4) Outrigger Strut (qty 4) Clevis Pin (qty 4) Rotating Bed Lug (qty 4) Outrigger Beam Assembly (qty 4) Jacking Cylinder Pin (qty 4) Jacking Cylinder Pin (qty 4)
Page 305: Deploying Rotating Bed Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Deploying Rotating Bed Jacking Cylinders Using the remote control, lower the rotating bed jacking cylinder (8) to the working position. Figure 4-130 for the following procedure: Install the jacking cylinder pin and safety pin removed in...
Page 306 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Carbody Jacking Cylinders (qty 4) Outrigger Pad (qty 4) Carbody Cavity (qty 4) S Hook Strap (qty 4) Safety Pin and Pin (qty 4) Strut (qty 4) Carbody Lug (qty 4) Jack Lug (qty 4)
Page 307: Storing Carbody Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Storing Carbody Jacking Cylinders Figure 4-131 for the following procedure: Using the remote control, retract the carbody jacking cylinders (1) completely. Place the outrigger pads (2) from the carbody jacking cylinders in the shipping position in the carbody cavity and attach the S hook straps (4).
Page 308 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Adapter Frame Pin (stored position) (qty 2) Adapter Frame Pin (working position) (qty 2) Collar (stored position) (qty 2) Collar (working position) (qty 2) Adapter Frame Pin (stored position) (qty 2) Adapter Frame Pin (working position) (qty 2) Rotating Bed Jacking Cylinder (qty 4) Maximum Trailer Height –1168 mm (46 in)
Page 309: Disconnecting Carbody From Rotating Bed
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Disconnecting Carbody from Rotating Bed Back the trailer under the carbody, being careful not to hit the rotating bed jacking cylinders. Figure 4-133 for the following procedure: Lower the crane onto the trailer until the trailer deck just...
Page 310: Disconnecting Hydraulic Hoses
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL RIGHT SIDE OF CRANE LEFT SIDE OF CRANE WORKING POSITION Item Description Adapter Frame Electrical Cable (WFC1 connects to WRF2-J5) Hydraulic Hose (qty 5) FIGURE 4-134 Disconnecting Hydraulic Hoses Disconnect the adapter frame electrical cable (1).
Page 311: Removing Carbody And Adapter Frame From Rotating Bed
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Trailer Adapter Frame Carbody Rotating Bed FIGURE 4-135 Removing Carbody and Adapter Frame from Remove the trailer (1). Use extreme care not to hit the rotating bed jacking cylinders with the trailer. Have a Rotating Bed signal person provide instructions to the truck driver.
Page 312 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Rotating Bed Jacking Cylinder (qty 4) Self-Erect Cylinder Live Mast 85° Angle Retention Bracket FIGURE 4-136 4-176 Published 08-12-19, Control # 224-13_v2...
Page 313: Storing Self-Erect Cylinder
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Storing Self-Erect Cylinder Position the live mast (3) at approximately 85° angle (4) so the self-erect cylinder rests on the wear pad. Figure 4-136 for the following procedure: Retract the self-erect cylinder until the pin (5) fully Lower the rotating bed jacking cylinders (1) completely.
Page 314 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Backhitch Assembly Backhitch Link Pin (working position) (qty 2) Backhitch Link Pin (shipping position) (qty 2) Locking Pin Storage Bracket Locking Pin (shipping position) Gantry Assembly Gantry Link Pin (stored position) (qty 2)
Page 315: Securing Live Mast, Gantry, And Backhitch
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Securing Live Mast, Gantry, and Backhitch NOTE: As the live mast approaches the horizontal position, the gantry assembly may contact the mast Figure 4-137 for the following procedure: roller. This is acceptable. Boom up and lower the live mast to 40°.
Page 316 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Drum Assembly SL 4 Sling – 3,80 m (12.5 ft), 11 340 kg (25,000 lb) (qty 4) Lifting Lug (qty 4) SH 2 Shackle – 17 t (18.70 USt) (qty 4) Rear Pin (qty 2)
Page 317: Removing Drum 3
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Removing Drum 3 An assist crane is required to lift the drum from the rotating Figure 4-138 for the following procedure: bed. Disconnect the electrical cable (8) from the drum NOTE: The assist crane must be capable of lifting 6 000 kg assembly (1) and store the cable.
Page 318 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Drum 4 Pawl Hydraulic Connector (qty 2) Drum 4 Hydraulic Hose (stored position) (qty 4) Drum 4 Hydraulic Hose (working position) (qty 4) Drum 4 Electrical Connector Live Mast Hydraulic Hose (stored position) (qty 2)
Page 319: Disconnecting Live Mast Hydraulics And Electrical Connectors
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Locking Pin Hole Bracket Hole Locking Pin Shim FIGURE 4-141 Disconnecting Live Mast Hydraulics and Removing Live Mast Electrical Connectors NOTE: The procedure shown is the same for both sides. Figure 4-140...
Page 320 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL FIGURE 4-142 4-184 Published 08-12-19, Control # 224-13_v2...
Page 321 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Legend for Figure 4-142 Remove the keeper pins or plates (10a or 10b). Item Description Install the pin puller cage (12) and disengage the two hoist drum operating pins (11) using the hand-held pin Live Mast Lift Point (qty 4) puller.
Page 322 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Operator Cab Folding Front Handrail Operator Cab Front Handrail Operator Cab Rear Handrail Operator Cab Back Handrail Operator Cab Ladder Handrail Lower Front Rotating Bed Handrail Upper Front Rotating Bed Handrail Front Left Rotating Bed Handrail...
Page 323: Removing Rotating Bed Handrails And Rear Platform
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Platform Platform Mounting Bracket Quick Release Pin (qty 2) Ladder (raised position) Ladder (shipping position) Pin (qty 2) FIGURE 4-144 Removing Rotating Bed Handrails and Rear Figure 4-144 for the following rear platform removal...
Page 324: Removing Front Platform And Ladders From Rotating Bed And Cab
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Platform Cotter Pin and Pin (qty 2) Upper Cab to Bed Ladder Lower Cab to Bed Ladder Quick Release Pin (qty 4) FIGURE 4-145 Removing Front Platform and Ladders From Slide the ladders off the sleeves of the platforms and set aside.
Page 325 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-189 Published 08-12-19, Control # 224-13_v2...
Page 326: Storing Rotating Bed Platforms
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Pin and Safety Pin Platform Brace WORKING POSITION FIGURE 4-146 Storing Rotating Bed Platforms Swing the platform brace into the platform and secure with the hitch pin (3). The rotating bed platforms are attached to the rotating bed Swing the platforms down (upper rear platforms swing and must be flipped up or down to the stored position.
Page 327 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description SHIPPING POSITION Pin and Safety Pin Platform Brace Hitch Pin Platform Storage Brace Pin Position Hole Locking Pin Platform Storage Bracket FIGURE 4-147 Manitowoc 4-191 Published 08-12-19, Control # 224-13_v2...
Page 328: Moving Operator Cab (Shipping Position)
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL WORKING POSITION WORKING POSITION Item Description Pin and Hair-Pin Cotter Strut Rotating Bed Operator Cab Support SETUP POSITION FIGURE 4-148 Moving Operator Cab (Shipping Position) Figure 4-148 for the following procedure: Remove the pin and safety pin (1) from the strut (2)
Page 329: Removing Operator Cab Ladder
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Ladder Strut (qty 2) Strut Bracket (qty 2) Ladder Bracket (qty 2) FIGURE 4-149 Removing Operator Cab Ladder Disconnect the struts (2) from the strut brackets. Pivot the struts to the stored position and secure with...
Page 330: Removing Operator Cab Rear Platform
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Operator Cab Rear Platform Fixed Pin (qty 2) Hooded Bracket Locking Pin (qty 2) FIGURE 4-150 Removing Operator Cab Rear Platform Attach four lifting slings to the lifting lugs and raise the operator cab rear platform from the fixed pins (2).
Page 331: Storing Operator Cab Front Platform
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION VIEW B VIEW A Item Description Safety Pin (qty 2) Cab Pivoting Handrail Quick-Release Pin (qty 2) FIGURE 4-151 Storing Operator Cab Front Platform Remove the safety pins (1, View A) from the platform bracket.
Page 332: Securing Operator Cab
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL SETUP POSITION Item Description Pins and Hair-Pin Cotter (qty 3) Strut Rotating Bed Operator Cab Support Bracket Operator Cab Support Lug Clamp Handle RCL Light SHIPPING POSITION FIGURE 4-152 Securing Operator Cab Place the strut (2) in the shipping position and install the pins and safety pins (1).
Page 333: Extending Rotating Bed Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Rotating Bed Jacking Cylinder (qty 4) Trailer Rotating Bed FIGURE 4-153 Extending Rotating Bed Jacking Cylinders Figure 4-153 for the following procedure: Slowly back the trailer under the rotating bed until the beam on the rotating bed is close to the drop deck of the Align the trailer (2) with the rotating bed (3).
Page 334 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL VIEW A Item Description Rotating Bed Jacking Cylinder (qty 4) U-Shaped Locking Pin Outrigger Pad Rotating Bed Rotating Bed Lug Outrigger Strut (qty 4) Outrigger Beam Assembly Jacking Cylinder Pin Locking Pin Outrigger Pad Locking Pin...
Page 335: Lowering Rotating Bed Jacking Cylinders
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Lowering Rotating Bed Jacking Cylinders For shipping, all four outrigger pads should be stored on the rotating bed so the pads are available Figure 4-154 for the following procedure: when the crane arrives at the new job site.
Page 336: Installing Cab Window Covers (If Equipped)
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Window Cover Top Cover Front Cover Right Side Rear Cover Right Side Front Cover Left Cover Back Cover Hair-Pin Cotter Stud FIGURE 4-155 Installing Cab Window Covers (If Equipped) Figure 4-155 for the following procedure: Install the window cover (1) on the appropriate windows aligning the hole in the cover with the stud (3).
Page 337: Wire Rope Installation
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION WIRE ROPE INSTALLATION NOTE: The wire rope manufacturer’s recommendations Seizings Wire Rope Type takes precedence over the following information. Required Preformed Wire Rope Specifications Non-preformed See the Wire Rope Specifications Chart in the Capacity...
Page 338: Anchoring Wire Rope To Drum
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Don’t Allow End of Wire Rope to Extend Out of Socket Opening Item Description Wire Rope Pocket in Drum Barrel Straight Wedge Seizing FIGURE 4-157 Anchoring Wire Rope to Drum Item Description Item Description...
Page 339 MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION d. Avoid dragging the wire rope in the dirt or around objects that can scrape, nick, cut, or crush the wire rope. Carefully inspect the drums and all rope guides, rollers, and sheaves for defects that can cause the wire rope to wear or be cut.
Page 340 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL T (Rope Clip Nut Torque) Item Description Wire Rope Clip Size Seizing 22,23 25,4 28,58 31,75 Dead End Live End in Straight Line with Socket (inch) (7/8) (1-1/8) (1-1/4) Socket Torque Wedge kN/m 0,30...
Page 341: Anchoring Wire Rope To Wedge Socket
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION Anchoring Wire Rope to Wedge Socket end. Right Method C is only for use with a Terminator wedge socket. After the socket is pinned in place, hoist the load slowly so the wedge seats tightly. Do not shock load the socket and wedge.
Page 342 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Rigging Line No. 1.5 Pad Eye Item Inch Connector Approximate Capacity 553 kg (1220 lb) 16,00 Wire Rope with Button 6,35 Pad Eye 25,40 Wire Rope without Button 11,18 7/16 28,70 1-1/8...
Page 343: Pad Eye Usage For Wire Rope Reeving
This slackening is caused by the normal stretch that occurs in a new wire rope under tension Some rotation-resistant wire rope supplied by Manitowoc is and periodically throughout the wire rope’s life from release equipped with a pad eye welded to the leading end of the of the load.
Page 344: Rigging Winch Operation
FIGURE 4-163 RIGGING WINCH OPERATION Scroll to the rigging winch selection screen (5) in the main display. See MLC650 Main Display Operation If your crane is equipped with the optional rigging winch Manual for instructions. (Drum 0), see the Rigging Winch Assembly drawing at the Use either the jog dial on the right console or the scroll end of this section for wire rope routing and anchoring.
Page 345: Operating Rigging Winch
Scroll to the rigging winch selection screen (5) in the crane’s programmable controller. main display. See MLC650 Main Display Operation Manual for instructions. CAUTION Use either the jog dial on the right console or the scroll...
Page 346 SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Item Description Wire Rope from Drum 1 Wire Rope from Drum 2 Item Description Wire Rope from Drum 3 Drum 1 (Main Hoist) Wire Rope Guide on 4 m Insert Drum 2 (Main Hoist Optional)
Page 347: Load Line Reeving
MLC650 OPERATOR MANUAL SET-UP AND INSTALLATION LOAD LINE REEVING NOTE: The boom top can be reeved in various configurations. See the reeving diagrams included WARNING at the end of this section for each reeving option. Avoid Death or Serious Injury! Exercise care when block is standing in vertical position, as the potential for tipping exists.
Page 348: Wire Rope Specifications
SET-UP AND INSTALLATION MLC650 OPERATOR MANUAL Wire Rope Specifications Upper Boom Point Multiple Parts of Line Refer to the Wire Rope Specifications chart in the Capacity Chart Manual for: Parts of the line required to handle desired load Wire rope length required for various boom lengths and parts...
Page 349: Section 5
Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
Page 350 MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-ii Published 08-12-19, Control # 224-13...
Page 351: Lube And Coolant Product Guide
MLC650 OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION LUBE AND COOLANT PRODUCT GUIDE See F2271 at the end of this section. See the publication at the end of this section. Manitowoc Published 08-12-19, Control # 224-13...
Page 352 LUBRICATION MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-12-19, Control # 224-13...
Page 353 Fiberglass Maintenance ............6-1 Manitowoc...
Page 354 MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 08-12-19, Control # 224-13...
Page 355: Inspection And Maintenance Checklist
MLC650 OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST INSPECTION AND MAINTENANCE FIBERGLASS MAINTENANCE CHECKLIST See Bulletin W04-009 at the end of this section. See F2273 at the end of this section. Manitowoc Published 08-12-19, Control # 224-13...
Page 356 MAINTENANCE CHECKLIST MLC650 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-12-19, Control # 224-13...
Page 357 Manitowoc Dealer........
Page 358 MLC650 OPERATOR MANUAL Motion Warning Lights and Alarms ..........3-36 Nameplates and Decals .

Manitowoc MLC650 Operator's Manual

Section 1

Section 2

Section 3

Section 4

Quick Links

Related Manuals for Manitowoc MLC650

Summary of Contents for Manitowoc MLC650