Manitowoc MLC650 Service Maintenance Manual
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Manitowoc MLC650 Service Maintenance Manual

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Manitowoc MLC650
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Summary of Contents for Manitowoc MLC650

  • Page 1 Manitowoc MLC650 Service/Maintenance Manual...
  • Page 3 The serial number of the crane and applicable attachments (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

    MLC650 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1..........Introduction Continuous Innovation .
  • Page 6 TABLE OF CONTENTS MLC650 SERVICE/MAINTENANCE MANUAL Crane Electrical Power Distribution ..........3-2 Crane Electrical System Ground Points .
  • Page 7 MLC650 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Drum 2 Brake Overview............5-10 Drum 2 Brake Operation .
  • Page 8 TABLE OF CONTENTS MLC650 SERVICE/MAINTENANCE MANUAL Drum Motor Speed Sensor ............5-60 Speed Sensor Replacement.
  • Page 9 MLC650 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Battery Gases Are Explosive ........... . . 7-1 Jump-Starting a Battery .
  • Page 10 TABLE OF CONTENTS MLC650 SERVICE/MAINTENANCE MANUAL Carbody Manual Control............8-10 Setup Remote Control .
  • Page 11 MLC650 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS General ..............10-26 Setup Remote and Switch Control.
  • Page 12 TABLE OF CONTENTS MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-viii Published 09-09-16, Control # 229-09...
  • Page 13 Solenoid Valve Identification ........... . . 1-7 Manitowoc...
  • Page 14 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 09-09-16, Control # 229-09...

  • Page 15: Section 1

    If you are in This is the safety alert symbol. It is used to alert doubt about any procedure, contact your Manitowoc Cranes you to potential personal injury hazards. Obey all safety dealer or the Manitowoc Crane Care Lattice Team.

  • Page 16: Safe Maintenance Practices

    If the engine must be running while the crane is being Read This Manual serviced, observe the following: To ensure safe and proper operation of Manitowoc cranes, Maintain constant verbal communication between they must be maintained according to the instructions t h e p e r s o n a t t h e c o n t r o l s a n d t h e p e r s o n contained in this manual.

  • Page 17: Stored Energy Safety Precautions

    • Unless authorized in writing by Manitowoc, do not alter t h e c r a n e i n a n y w a y t h a t a f f e c t s t h e c r a n e ’ s •...

  • Page 18: Protection Of The Environment

    INTRODUCTION MLC650 SERVICE/MAINTENANCE MANUAL Returning Crane to Service Potentially harmful waste used in Manitowoc cranes includes—but is not limited to—oil, fuel, grease, coolant, air • Do not return the crane to service until: conditioning refrigerant, filters, batteries, and cloths that have come into contact with harmful substances.
  • Page 19 MLC650 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Upper Boom Point Lower Boom Point Boom Top Weight Ball Load Block Rope Guide 12M Heavy Insert Drum 2 (main hoist) (optional) Drum 6 (luffing hoist) Boom Butt Drum 0 (rigging winch) Operator Cab...
  • Page 20 INTRODUCTION MLC650 SERVICE/MAINTENANCE MANUAL Item Description Item Description Item Description Live Mast Sheaves Adapter Frame Inboard Tread Slack Adjustment Self-Assembly Cylinder Carbody/Crawler Pin Puller Outboard Tread Slack Adjustment Rotating Bed/Adapter Frame Pin Live Mast Links/Straps Boom Hinge Pin Puller Drum 4 (boom hoist/mast hoist)

  • Page 21: Solenoid Valve Identification

    MLC650 SERVICE/MAINTENANCE MANUAL INTRODUCTION Solenoid Valve Identification Table 1-1. Hydraulic Solenoid Identification Each hydraulic valve solenoid is assigned a solenoid number used in Manitowoc Cranes training classes (Table 1-1). The Solenoid Description pin number corresponds to the control module connector pin...
  • Page 22 INTRODUCTION MLC650 SERVICE/MAINTENANCE MANUAL Table 1-1. Hydraulic Solenoid Identification Table 1-1. Hydraulic Solenoid Identification Solenoid Solenoid Description Description Number Number Number Number HSC11-06 Drum 2 Left Brake Release PC112-15 HSC32-04 Drum 4 Right Brake Release PC322-6 HSC11-07 Drum 6 Pawls In...

  • Page 23: Section 2

    Hydraulic Tests and Calibrations ..........2-32 Manitowoc...
  • Page 24 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-ii Published 09-09-16, Control # 229-09...

  • Page 25: Hydraulic System Overview

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OVERVIEW Hydraulic Pump Locations This section provides a physical description and general There are nine hydraulic pumps driven by the engine. functional overview of the major hydraulic components. The...

  • Page 26: Hydraulic Pump Identification

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC PUMP IDENTIFICATION commanded by the control system. The EDC is driven by the IOLC32 control module. Pumps 1, 2, and 4 Pump two provides flow to either drum two or three. A diverter valve, driven by CCM—10, provides pump flow to...

  • Page 27: Pump 3

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump 3 motors, as commanded by the control system. Pump direction and displacement is controlled by an electronic Pump three (Figure 2-3) is a bidirectional variable- displacement control (EDC), driven by the IOLC32 control displacement pump providing flow to either drum one or the module.

  • Page 28: Pumps 5, 6, And 8

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Pumps 5, 6, and 8 Pump five provides flow to drum four. The EDC is driven by the IOLC33 control module. Pumps five, six, and eight (Figure 2-4) are bidirectional Pump six provides flow to drum five. The EDC is driven by variable-displacement pumps.

  • Page 29: Pump 7

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump 7 either the tray or beam motors, as commanded by the control system. Pump direction and displacement is controlled by an Pump seven (Figure 2-5) is a bidirectional variable- electronic displacement control (EDC), driven by the IOLC33 displacement pump providing flow to either the variable control module.

  • Page 30: Hydraulic Motor Identification

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC MOTOR IDENTIFICATION controlled by an electronic motor controller. Electronic control of drum motors one and two is provided by the Variable Displacement Motors CCMCII control module. Electronic control of the drum 4 motor is provided by the IOLC34 control module.
  • Page 31 MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM electronic motor controller. Electronic control of the drum five Drum 5 Motor—VPC-MAX Boom Hoist Motor motor is provided by the IOL30 control module. Drum five motor (Figure 2-9) is a bidirectional variable- displacement motor. Motor displacement is controlled by an...
  • Page 32 HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Travel Motor electronic motor controller. Electronic control of the travel motors is provided by the IOSB22 control module. The travel motors (Figure 2-10) are bidirectional variable- displacement motors. Motor displacement is controlled by an Item...

  • Page 33: Fixed Displacement Motors

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Fixed Displacement Motors The following motors (Figure 2-11) are bidirectional fixed displacement motors. • Swing Motor • Variable Position Counterweight (VPC) Tray Motor • VPC-MAX Trolley Actuator Motor Item Description A, B System Pressure Lines...

  • Page 34: Manifold Identification

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL MANIFOLD IDENTIFICATION Pressure Transducer and Accessories Manifold FIGURE 2-12 Accessory Valve Manifold Solenoids Pressure Transducer Manifold Item Description Rotating Bed Pin Puller—Retract Item Description Rotating Bed Pin Puller—Extend Left Travel/Drum 1 Up—Pump 3 Pressure Transducer Accessory Pressure Proportional Control Cab Tilt—Extend...

  • Page 35: Upperworks Jacking And Rigging Winch Valve Assembly

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Upperworks Jacking and Rigging Winch Valve Assembly Item Description Left Rear Jack—Extend Right Rear Jack—Extend Right Front Jack—Extend Left Front Jack—Extend Rigging Winch—Spool Out Rigging Winch—Spool In Left Front Jack—Retract Right Front Jack—Retract Right Rear Jack—Retract Left Rear Jack—Retract...

  • Page 36: Mast Assist And Self-Assembly Cylinder Valve Assembly

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Mast Assist and Self-Assembly Cylinder Valve Assembly Item Description Directional Control Lever Assembly Cylinder Mast Raise Cylinder A Coil B Coil FIGURE 2-14 2-12 Published 09-09-16, Control # 229-09...

  • Page 37: Drum Brakes Release Manifold And Solenoid Valves

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Drum Brakes Release Manifold and Solenoid Valves Drums 1, 2, 3, 4 and 6 Drum 3 shown. Other drums similar. Item Description Drum Brake Release Manifold Flow Control Poppet Solenoid Valve Sequence Valve Directional Control Solenoid...

  • Page 38: Pawl Control Manifold

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Pawl Control Manifold Drums 4, 5, and 6 Drum 5 shown. Other drums similar. Item Description Solenoid A—Retracts Pawl Assembly Cylinder Rod Pawl Control Manifold Solenoid B—Extends Pawl Assembly Cylinder Rod FIGURE 2-17 2-14 Published 09-09-16, Control # 229-09...

  • Page 39: Swing Brake, Travel Brake, And Front Adapter Pin Pusher Valve Assembly

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Swing Brake, Travel Brake, and Front Adapter Pin Pusher Valve Assembly Item Description Swing Brake Travel Brake Front Adapter Pin Pullers—Extend Front Adapter Pin Pullers—Retract FIGURE 2-18 Manitowoc 2-15 Published 09-09-16, Control # 229-09...

  • Page 40: Lower Accessories Valve Assembly (Without Jacking Valve)

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Lower Accessories Valve Assembly (Without Jacking Valve) Item Description Left Crawler Pin—Extend Right Crawler Pin—Extend Left Crawler Pin—Retract Right Crawler Pin—Retract FIGURE 2-19 2-16 Published 09-09-16, Control # 229-09...

  • Page 41: Lower Accessories Valve Assembly (With Jacking Valve)

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Lower Accessories Valve Assembly (With Jacking Valve) Item Description Left Rear Carbody Jack—Retract Left Front Carbody Jack—Retract Right Rear Carbody Jack—Retract Right Front Carbody Jack—Retract Left Crawler Pin—Extend Right Crawler Pin—Extend Right Crawler Pin—Retract Left Crawler Pin—Retract Right Front Carbody Jack—Extend...

  • Page 42: Hydraulic System Specifications

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SPECIFICATIONS Table 2-1 Hydraulic Specifications Pump Charge Pump Pump Speed Function Pressure Pressure 1 Number Port bar (psi) bar (psi) Drum 1 Hoist Up 39 to 44 Drum 1 Hoist Down 37 to 41...

  • Page 43: Hydraulic System Maintenance

    Storing and Handling Parts understand, and comply with the instructions in this section • Store new parts (valves, pumps, motors, hoses, tubes) and to the display screen instructions in the Manitowoc in a clean, dry indoor location. MLC650 Main Display Operation F2267. •...

  • Page 44: Inspecting And Replacing Hydraulic Hoses

    Do not alter hydraulic system specifications given in this • Check for external leaks using a piece of cardboard. section without approval of the Manitowoc Crane Care Leaks are not only unsafe, but they also attract dirt, and Lattice Team.
  • Page 45 MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM • Hard, stiff, heat cracked, or charred hose hose service life reduced by 40% to 50%. High duty circuits can include, but are not limited to, hoist(s), boom lift, swing, • Blistered, soft, degraded, or loose cover travel, pump suction and discharge to directional valves, and directional valve return to reservoir.

  • Page 46: Replacing The Desiccant Breather Cartridge

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Replacing the Desiccant Breather Cartridge 3. Remove the protective caps from the top and bottom of the new breather cartridge. Figure 2-21 for the following procedure. 4. Hand tighten the reusable cap to the new breather 1.

  • Page 47: Replacing The Return Filters

    CAUTION Avoid Hydraulic System Damage! Original equipment manufacturers’ filter elements— available from the Manitowoc Cranes dealer—must be used on this crane. Substituting with any other brand or type of filter element is not allowed. Filter elements made by other manufacturers may collapse under pressure.

  • Page 48: Changing The Hydraulic Oil

    Figure 2-23 for the following procedure. Drain and fill the hydraulic tank according to the interval WARNING specified in the MLC650 lube guide, unless an alternate interval has been established through an oil analysis Burn Hazard! program. Hydraulic oil may be under pressure and extremely hot 1.

  • Page 49: Servicing The Pumps

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM 4. Put the free end of a hose, with a quick drain coupler, 14. Fill the tank through the power fill coupling (6) or manual into a suitable container to catch the hydraulic oil. See...

  • Page 50: Replacing A Pressure Transducer

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL 4. Repeat the pressure transducer test. 5. Verify the output signal current at the transducer is 3.84 mA to 4.16 mA at 0 bar (0 psi). 6. Start the engine and run it at idle.

  • Page 51: Shop Procedures

    MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM With all control handles off, start and run the engine Remove the bleed line from the coupler at the at low idle. pressure transducer. d. When clear oil flows from the bleed lines (no air 10.
  • Page 52 HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL 2. Open the vent ports and remove the vent plugs from the Figure 2-25 for the remaining steps. suction manifold (Figure 2-27). 6. Open the air vent valve on top of the tank to release 3.
  • Page 53 MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 2-29 Published 09-09-16, Control # 229-09...

  • Page 54: Initial Hydraulic System Startup

    HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL INITIAL HYDRAULIC SYSTEM STARTUP Item Description Pressure Transducer Gauge Port Vent Plug—Right Side Suction Manifold Vent Plug—Top Left Side Suction Manifold FIGURE 2-27 2-30 Published 09-09-16, Control # 229-09...
  • Page 55 MLC650 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM The following procedure is used at the factory to start a new 8. Bleed the pressure transducers. crane engine for the first time. It is necessary to use this Observe the oil flowing from the bleed line at each procedure in the field only if the entire hydraulic system has pressure transducer.

  • Page 56: Hydraulic Tests And Calibrations

    The technicians shall read, understand, and comply with the instructions in this section and with the display screen instructions in the MLC650 Main Display Operation F2267. Contact your Manitowoc Cranes dealer for an explanation of any procedure not fully understood.
  • Page 57 2. Start and run the engine at high idle. screen and select the Pressure Transducer Test (Figure 2-30). See the MLC650 Main Display Operation 3. At the Main display, navigate to the Hydraulic Test F2267 for detailed instructions on how to navigate to the screen and start the Controls Calibration Test screen and run the test.
  • Page 58 3. At the Main display, navigate to the High Pressure Test screen and start the High Pressure Test (Figure 2-32). See the MLC650 Main Display Operation F2267 for detailed instructions on how to navigate to the screen and run the test. FIGURE 2-33 Charge pressure levels must be within a specified range during this test.
  • Page 59 4. At the display, navigate to the diagnostic screen for the 4. Swing the crane by moving the control handle in both function being checked (see the MLC650 Main Display directions and verify the rotating bed swings freely. Operation F2267 for display navigation instructions).
  • Page 60 HYDRAULIC SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Cab Tilt Adjustment To adjust the speed at which the cab tilts up and down, proceed as follows. Figure 2-34 for the following procedure. 1. Loosen the set screws (4). 2. Turn the adjusting knobs (3) fully clockwise to close the valves.

  • Page 61: Section 3

    Test Voltage Tables ............3-22 Manitowoc...
  • Page 62 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 09-09-16, Control # 229-09...

  • Page 63: Electrical Drawings And Schematics

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM ELECTRICAL DRAWINGS AND Battery Power Disconnect SCHEMATICS When in the OFF position (contacts open), the battery disconnect switch S1 disconnects the battery positive Electrical schematics are located at the end of this section.

  • Page 64: Crane Electrical Power Distribution

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Crane Electrical Power Distribution • Relay K5 provides power from circuit breaker CB8 to terminal +UE on the following control modules: When the battery disconnect switch is closed and battery power is available, turning the engine run switch S3 to the •...

  • Page 65: Crane Electrical System Ground Points

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Crane Electrical System Ground Points • Cab right console (5): Right console ground bus bar (1) Electrical system ground points are located in and under the cab, on the rotating bed, and on the engine block.

  • Page 66: Rotating Bed Ground Points

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Rotating Bed Ground Points carbody. A ground cable connects the battery negative (-) terminal to the ground stud. There are two major ground points on the rotating bed: The live mast-to-rotating bed ground point (2) provides a •...

  • Page 67: Circuit Breakers, Fuses, And Relays

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CIRCUIT BREAKERS, FUSES, AND RELAYS Item Description CB0—Alternator 150 A Circuit Breaker (Tier 3—Past Production) F0—Alternator 150 A Fuse (Tier 4 and Tier 3—Current Production) F5—TCU CraneStar 5 A Fuse FIGURE 3-3 For past production Tier 3 cranes, the alternator circuit...
  • Page 68 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL FIGURE 3-4 Relay Description Relay Description Left Starter Motor Relay (not shown) ECM Key (start) Right Starter Motor Relay (not shown) DEF Pressure Hose Heater ECM Bus (300 second TDO) DEF Supply Module ECM Bus...
  • Page 69 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Circuit Circuit Amps Description of Item Protected Amps Description of Item Protected Breaker Breaker Spare CB36 IOLC33 (+UB input supply) ECM Start Relay (K7) CB37 IOLC33 (+UB input supply) Spare CB38 IOLC33 (+UB input supply)

  • Page 70: Inspect Electrical Components

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL INSPECT ELECTRICAL COMPONENTS 2. Visually inspect all controller area network (CAN) control modules and electrical junction boxes for the following: • Damaged or loose connectors. • Damaged or missing electrical clamps or tie straps. DANGER •...

  • Page 71: Can Bus Control System

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CAN BUS CONTROL SYSTEM Control Modules—The CAN Bus control system contains control modules that use the CAN Bus to communicate with CAN Bus System Overview each other and with other CAN Bus devices. (For more...

  • Page 72: Can Bus System Chart

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL CAN Bus System Chart FIGURE 3-5 3-10 Published 09-09-16, Control # 229-09...

  • Page 73: Control Modules

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Control Modules Control Module Input/Output (I/O) Types Table 3-3 defines the terms used in the schematics for the Control modules perform several functions: I/O types used by the control modules. • Run the software control programs Table 3-3.
  • Page 74 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Safety Control Module (SCM) There are three SCMs on the crane (Figure 3-6): • MWSCMD01 (boom) SCMs are controllers that run the software programs to interface with the cab controls and to govern boom and jib •...
  • Page 75 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Item Description MWSCMD01 MWSCM-00 MWSCMD02 FIGURE 3-6 Manitowoc 3-13 Published 09-09-16, Control # 229-09...
  • Page 76 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Crane Control Module (CCM) There are three CCMs mounted on the crane (Figure 3-7): CCMs are controllers that run the software programs • MWCCMB11 (carbody) governing crane operations in the rotating bed and carbody. The software running in each CCM controls the I/O devices •...

  • Page 77: Input/Output-Large (Iol) Module

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Input/Output—Large (IOL) Module • MWIOLC30 • MWIOLC32 I O L s c o n t r o l t h e d e v i c e s c o n n e c t e d t o t h e m a n d communicate with CSMs or CCMs connected to their bus.

  • Page 78: Input/Output-Small (Ios) Module

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Input/Output—Small (IOS) Module There are two IOS modules on the crane (Figure 3-9): • MWIOSB22 (carbody) I O S s c o n t r o l t h e d e v i c e s c o n n e c t e d t o t h e m a n d communicate with CSMs or CCMs connected to their bus.

  • Page 79: Control Module Devices

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Control Module Devices A controller provides power to Hall-effect speed sensors located within the hydraulic motors that drive the drums The control modules communicate with output devices to rotating bed, VPC, and crawlers. A gear wheel within the...

  • Page 80: Solenoids

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Single contact limit switches are used for the following crane Alarms functions: A controller digital output drives the applicable alarm during • Lower boom point block-up limit various operational states: • Lower boom point block-up slow down •...

  • Page 81: Pressure And Vacuum Switches

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Pressure and Vacuum Switches Foot Throttle The pressure and vacuum switches are normally closed. The A controller provides a digital output to a potentiometer that switches open when the vacuum or pressure level exceeds is connected to the foot throttle. Power is applied across the the setting of the switch.

  • Page 82: Control Module Test Voltages

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Control Module Test Voltages 0 or 24 V nominal VPC Motors 0 or 600 mA nominal Pump and Motor Voltages and Currents Note 1: Resistance increases as the temperature rises on Table 3-4 shows the voltages and currents of the pumps, the pump or motor solenoid coil, resulting in decreased hoists, and travel motors.

  • Page 83: Alphabetical Index Of Controller Devices

    MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Alphabetical Index of Controller Devices Device Controller Find the device of interest and the associated controller in Hydraulic Fluid Level and IOLC32 Table 3-5, then refer to the applicable test voltage table for Temperature Sensor that controller.

  • Page 84: Test Voltage Tables

    ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Test Voltage Tables Table 3-6. SCM-00 Test Voltages I/O Network Function Voltages 24 V P1-1 Control Module Battery Power Off, 24 V P0-2 ODH1A7 RCL Beacon—Amber Off, 24V P0-3 ODH1A6 RCL Beacon—Green 24 V P1-4...
  • Page 85 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Open, 24 V Closed P1-28 Seat Safety Switch P1-29 Ground (from cab ground bus bar) P1-30 CAN1_L CAN Bus A Low Not Applicable P1-31 CAN1_H CAN Bus A High Not Applicable...
  • Page 86 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-7. SCMD01 (WBT1, Boom Top) Test Voltages I/O Network Function Voltages 24 V PD-1 Control Module Battery Power 24 V PD-2 ODH1A7 Power to Main Right Strut Collapse Solenoid Power Bus: • Jib Butt Angle Sensor •...
  • Page 87 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Lower Boom Point Block-Up Slow Down Switch and Open, 24 V Closed PD-21 Upper Boom Point Block-Up Slow Down Limit Switch 2 mA @ No Load PD-22 IACV11 Right Strap Load Link...
  • Page 88 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-8. SCMD01 (WWC1, Wind Cap) Test Voltages I/O Network Function Voltages 24 V PD-1 Battery Power for Control Module Outputs PD-2 No Connection Power Bus: 24 V PD-3 ODH1A6 • Left Strap Load Link •...
  • Page 89 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages PD-29 Ground (from load center) PD-30 CAN1_L CAN Bus D—Low Not Applicable PD-31 CAN1_H CAN Bus D—High Not Applicable PD-32 No Connection PD-33 No Connection PD-34 IMID2 Module Identifier Input (ground from load center)
  • Page 90 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-9. SCMD02 (WJT1, Jib CSM) Test Voltages I/O Network Function Voltages 24 V PD-1 Battery Power for Control Module Outputs PD-2 No Connection 24 V PD-3 ODH1A6 Power to Upper Boom Point Load Pin...
  • Page 91 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages PD-26 No Connection Open, 24 V Closed PD-27 KL15 Control Module Ignition Power (from relay K5) Not Installed, 24 V PD-28 Upper Boom Point Confirm Installed PD-29 Ground (from load center)
  • Page 92 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-10. CCM-10 Test Voltages I/O Network Signal Voltages Off, 24 V PC1-1 OPH3A23 Left Front Jack Extend Solenoid Off, 24 V PC1-2 OPH3A28 Left Rear Jack Retract Solenoid Open, 24 V Closed PC1-3 ID21...
  • Page 93 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Signal Voltages PC1-34 IMID2 Module Identifier Input (from ground stud on rotating bed) PC1-35 IDF02 VPC Actuator Left Motor Speed Sensor Not Applicable Input Voltage—0.5 V Over Tooth PC1-36 IDF07 VPC Right Motor Speed Sensor 0 to 0.5 V...
  • Page 94 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL I/O Network Signal Voltages Off, 24 V PC2-16 ODH3A14 Right Track Drum 2 Diverter Solenoid PC2-17 No Connection 24 V PC2-18 Battery Power for Control Module Outputs PC2-19 No Connection 24 V PC2-20 Battery Power for Control Module Outputs...
  • Page 95 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-11. CCMC11 Test Voltages I/O Network Function Voltages Open, 24 V Closed PC1-1 OPH3A23 Drum 1 Left Motor Control PC1-2 OPH3A28 Not Used—For Possible Future Expansion Open, 24 V Closed PC1-3 ID21 Drum 1 Minimum Bail Limit Switch...
  • Page 96 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL I/O Network Function Voltages PC1-29 Ground (from ground stud on rotating bed) PC1-30 CAN1_L CAN Bus C—Low Not Applicable PC1-31 CAN1_H CAN Bus C—High Not Applicable PC1-32 No Connection PC1-33 No Connection Module Identifier Input (from ground stud on rotating...
  • Page 97 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Open, 24 V Closed PC2-12 OPH3A24 Drum 1 Right Motor Control Power Bus: • Drums 1 and 2 Minimum Bail Normally Closed Limit 24 V PC2-13 ODH3A01 Switches • Boom Angle Sensor...
  • Page 98 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL I/O Network Function Voltages 55 to 85% of Input Voltage Over Tooth PB1-7 IDF01 Left Travel Motor Speed Sensor 2 to 10% of Input Voltage Over Gap 55 to 85% of Input Voltage Over Tooth...
  • Page 99 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages PB1-40 IACV12 Not Used—For Possible Future Expansion 8.5 V Power Bus: 8.5 V PB1-41 OS85H • Left Travel Motor Speed Sensor • Right Travel Motor Speed Sensor Off, 24 V PB1-42...
  • Page 100 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-13. IOSA22 Test Voltages I/O Network Function Voltages PA1-1 Ground from Cab Ground Bus Bar Open, 24 V Closed PA1-2 KL15 Control Module Ignition Power (from engine run switch) Open, 24 V Closed PA1-3...
  • Page 101 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-14. IOSB22 Test Voltages I/O Network Function Voltages PB1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PB1-2 KL15 Control Module Ignition Power (from relay K6) PB1-3 ID01 Not Used—For Possible Future Expansion...
  • Page 102 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-15. IOLC30 Test Voltages I/O Network Function Voltages PC1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PC1-2 KL15 Control Module Ignition Power (from engine run switch) 24 V PC1-3 ID01...
  • Page 103 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Not Installed, 24 V Installed PC2-2 ID13 Ambient Air Temperature Sensor Connected PC2-3 ID14 Not Used—For Possible Future Expansion PC2-4 IACV18 Not Used—For Possible Future Expansion Off, 24 V PC2-5 ODH3A02...
  • Page 104 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-16. IOLC31 Test Voltages I/O Network Function Voltages PC1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PC1-2 KL15 Control Module Ignition Power (from engine run switch) PC1-3 ID01 Not Used—For Possible Future Expansion...
  • Page 105 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages 24 V PC2-5 ODH3A02 Power to Right and Left VPC Actuator Motor Speed Sensors Off, 24 V PC2-6 ODH3A04 VPC Tray Diverter Solenoid Off, 24 V PC2-7 ODH3A07 VPC Alarm Off, 24 V...
  • Page 106 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-17. IOLC32 Test Voltages I/O Network Function Voltages PC1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PC1-2 KL15 Control Module Ignition Power (from engine run switch) Open, 24 V Closed...
  • Page 107 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Off, 24 V PC2-6 ODH3A04 Drum 4 Brake Release Solenoid Off, 24 V PC2-7 ODH3A07 Ether Start Off, 24 V PC2-8 ODH3A10 Air Conditioning Clutch PC2-9 ODH3A12 Not Used Off, 24 V...
  • Page 108 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-18. IOLC33 Test Voltages I/O Network Function Voltages PC1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PC1-2 KL15 Control Module Ignition Power (from engine run switch) PC1-3 No Connection PC1-4...
  • Page 109 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages PC2-3 No Connection PC2-4 No Connection Power Bus: • VPC Max Beam Maximum In Limit Switch • VPC Max Beam Maximum Out Limit Switch 24 V PC2-5 ODH3A02 • VPC Max Right Beam Up Limit Switch •...
  • Page 110 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Table 3-19. IOLC34 Test Voltages I/O Network Function Voltages PC1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed PC1-2 KL15 Control Module Ignition Power (from engine run switch) PC1-3 ID01 Not Used—For Possible Future Expansion...
  • Page 111 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages PC2-6 ODH3A04 Not Used—For Possible Future Expansion PC2-7 ODH3A07 Not Used—For Possible Future Expansion PC2-8 ODH3A10 Not Used—For Possible Future Expansion PC2-9 ODH3A12 Not Used—For Possible Future Expansion Open, 24 V...
  • Page 112 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL I/O Network Function Voltages PC1-9 No Connection PC1-10 CAN1_H CAN Bus C—High Not Applicable 24 V PC1-11 Supply Power for Control Module Outputs 24 V PC1-12 Control Module Battery Power Not Installed, 24 V Installed...
  • Page 113 MLC650 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM I/O Network Function Voltages Power Bus: • VPC-MAX Tray Maximum In Open, 24 V Closed PC2-15 ODH31A01 • VPC-MAX Tray Maximum Out • VPC-MAX Beam Level Sensor PC2-16 No Connection Off, 24 V PC2-17 ODH3A09...
  • Page 114 ELECTRICAL SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-52 Published 09-09-16, Control # 229-09...

  • Page 115: Section 4

    Lattice Section Inspection and Lacing Replacement ........4-18 Manitowoc...
  • Page 116 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-ii Published 09-09-16, Control # 229-09...

  • Page 117: General Maintenance

    MLC650 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM GENERAL MAINTENANCE This section contains maintenance and adjustment instructions for the limit devices used with the boom and luffing jib attachment. It also contains maintenance and inspection of the following components: • Straps •...

  • Page 118: Automatic Boom Stop Overview

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL Automatic Boom Stop Overview When the maximum switch boom angle is reached, the fault alarm is activated and the Figure 4-2 for the following procedure. boom maximum up icon appears in the information screen of the main display.
  • Page 119 MLC650 SERVICE/MAINTENANCE MANUAL BOOM View A SWITCH OPENED View B SWITCH CLOSED 4 4 4 View C RIGHT SIDE OF BOOM BUTT Digital Level View D Maximum Switch Boom Angle Angle (16) LIMIT SWITCH WIRING 84.5° —Boom only with VPC-MAX 73.57°...

  • Page 120: Adjusting Automatic Boom Stop

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL Adjusting Automatic Boom Stop • If the boom reaches the specified angle before it stops, go to step If the boom stops before reaching the specified angle, perform the following: WARNING Loosen the jam nut (3).

  • Page 121: Physical Boom Stop

    MLC650 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP Figure 4-4 for the following procedure. Physical boom stops (1) serve the following purposes: • Assist in stopping the boom smoothly at any angle above 78° WARNING • Assists in preventing boom rigging from pulling the...

  • Page 122: Boom And Luffing Jib Angle Indicators

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL BOOM AND LUFFING JIB ANGLE Adjusting the Mast Angle INDICATORS Figure 4-5 for the following procedure. Angle indicators are mounted on the boom top and the luffing 1. Lower the mast to the transport position. j i b t o p. B o om an d l uf f i ng jib a n g le s a re ca li b r a te d 2.

  • Page 123: Fleeting Sheave Maintenance

    MLC650 SERVICE/MAINTENANCE MANUAL BOOM FLEETING SHEAVE MAINTENANCE The grease gun can be removed by hand. Turn the grease gun counterclockwise to remove from the fitting on the Figure 4-6 for the following. fleeting sheave assembly. Carefully thread the new grease gun clockwise onto the fleeting sheave fitting by hand.

  • Page 124: Boom Top Electrical Schematic

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL BOOM TOP ELECTRICAL SCHEMATIC FIGURE 4-7 Published 09-09-16, Control # 229-09...

  • Page 125: Luffing Jib Top Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL BOOM LUFFING JIB TOP ELECTRICAL SCHEMATIC 4 4 4 FIGURE 4-8 Manitowoc Published 09-09-16, Control # 229-09...

  • Page 126: Boom Wind Cap Electrical Schematic

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL BOOM WIND CAP ELECTRICAL SCHEMATIC FIGURE 4-9 4-10 Published 09-09-16, Control # 229-09...

  • Page 127: Strap Inspection And Maintenance

    Strap repairs are prohibited. Perform only the maintenance indicated in this section. For inspection procedures not Periodic Inspection covered in this manual, contact your dealer or the Manitowoc Periodic inspection must be performed at least monthly. Crane Care Lattice Team.

  • Page 128: Identifying Straps

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL Identifying Straps Table 4-1. Strap Specifications To aid in identification, the part number is stamped into both Allowable ends of each strap (Figure 4-10). Tolerance Condition Reference Corrective Action Part Number Deviation < 3% of strap Monitor condition.
  • Page 129 MLC650 SERVICE/MAINTENANCE MANUAL BOOM Corrosion or Abrasion Figure 4-12 for the following procedure. For quick identification by repair workers, clearly mark damaged areas with brightly colored tape. Sandblast to remove corrosion. Do not grind! View A Determine the reduction in the cross-sectional area.

  • Page 130: Straightness

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL Straightness 4. Verify that the line touches the top surface of the strap at all points along its length. Figure 4-13 for the following procedure. 5. If the string does not touch the strap, measure the 1.

  • Page 131: Storing Straps

    If dimension A is greater than 0,8 mm (0.030 in), contact the Inspect straps in storage for corrosion monthly. If necessary, Manitowoc Crane Care Lattice Team. sandblast to remove corrosion and repaint to maintain a continuous protective surface. If corrosion is not removed,...
  • Page 132 BOOM MLC650 SERVICE/MAINTENANCE MANUAL STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date mm (ft) Length Part Number Corrosion Kinks Cracks Dents Breaks Straightness Abrasion Length Flatness Elongated Holes Other mm (ft) Length Part Number Corrosion Kinks Cracks Dents Breaks Abrasion Length...
  • Page 133 MLC650 SERVICE/MAINTENANCE MANUAL BOOM NOTES 4 4 4 SKETCHES AND PHOTOGRAPHS Manitowoc 4-17 Published 09-09-16, Control # 229-09...

  • Page 134: Lattice Section Inspection And Lacing Replacement

    BOOM MLC650 SERVICE/MAINTENANCE MANUAL LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 2279 at the end of this section for lattice section inspection and lacing replacement instructions. 4-18 Published 09-09-16, Control # 229-09...

  • Page 135: Section 5

    Drum 5 Boom Hoist (VPC-MAX) ........... . 5-33 Manitowoc...
  • Page 136 MLC650 SERVICE/MAINTENANCE MANUAL Drum 5 Brake Overview ............5-33 Drum 5 Brake Operation.
  • Page 137 MLC650 SERVICE/MAINTENANCE MANUAL Pressure Roller..............5-72 Overview .
  • Page 138 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-iv Published 09-09-16, Control # 229-09...

  • Page 139: General

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS GENERAL Drum 1 Brake Operation This section provides the electrical and hydraulic crane hoist Figure 5-2 Figure 5-4. information. Electrical and hydraulic circuit schematics are The J2 joystick sends a 24 V output to the drum 1 park provided for each drum system.

  • Page 140: Drum 1 Motor Loop Flushing

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL When the CCMC11 control module receives the on-park During the drum 1 hoisting operation when the drum 6 park command from the J2 joystick, the CCMC11 control module switch and/or left travel park switch are in the ON position,...

  • Page 141: Drum 1 Lowering Operation

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Lowering Operation the PWM duty cycle decreases the swashplate angle in each motor, which increases the motor flow until the rotational Figure 5-3 Figure 5-4 for the following. speed is maximized based on the pump flow.

  • Page 142: Weekly Maintenance

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Installation 2. Make sure the return springs (12) have sufficient tension to hold the rollers firmly against the drum. 1. Connect the electrical wires to the new limit switch as If necessary, adjust spring tension as follows.
  • Page 143 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS 44 mm Jumper Wire View B View C View D 35 mm Item Description Lever Roller Capscrew Drum Jam Nut Adjusting Screw Screw (qty 4) Limit Switch Limit Switch Cover estraint Cable R Connector Three to Four Wraps...

  • Page 144: Drum 1 Hoisting Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 1 Hoisting Hydraulic Schematic Table 5-1.Legend for Figure 5-2 and Figure 5-3. FIGURE 5-2 Published 09-09-16, Control # 229-09...

  • Page 145: Drum 1 Lowering Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Lowering Hydraulic Schematic Table 5-1.Legend for Figure 5-2 and Figure 5-3. FIGURE 5-3 Manitowoc Published 09-09-16, Control # 229-09...
  • Page 146 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Table 5-1. Legend for Figure 5-2 Figure 5-3 Item Description Accessory Valve Manifold Left Travel/Drum 1 Selector Solenoid Valve Drum 1/Drum 6 Selector Solenoid Valve Pump 3 Charge Pressure Diverter Valve (directional control) Pump 3 Pressure Transducer (left track psi)

  • Page 147: Drum 1 Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Electrical Schematic FIGURE 5-4 Manitowoc Published 09-09-16, Control # 229-09...

  • Page 148: Drum 2 Main Hoist

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL DRUM 2 MAIN HOIST In the default state, the right travel/drum 2 selector solenoid valve (11) and the drum 2/drum 3 selector solenoid valve Drum 2 Brake Overview (12), located in the accessory valve manifold (1), are de- energized.

  • Page 149: Drum 2 Motor Loop Flushing

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Motor Loop Flushing The energized solenoid valve routes hydraulic fluid to the pilot control of the right travel/drum 2 diverter valve (5). The Figure 5-6 Figure 5-7 for the following. diverter valve shifts position, allowing the main hydraulic fluid...

  • Page 150: Drum 2 Lowering Operation

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 2 Lowering Operation Hydraulic fluid from the right travel/drum 2 selector solenoid valve also flows to the pilot control of the pump 4 charge Figure 5-7 Figure 5-8 for the following. pressure diverter valve (2), causing the valve to shift. When...

  • Page 151: Drum 2 Minimum Bail Limit

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Minimum Bail Limit b. Insert the wires of the electrical cable into the limit switch. Connect the cable wires and the jumper wire The optional minimum bail limit assembly on drum 2 is a...
  • Page 152 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL 44 mm Jumper Wire View B View C View D 35 mm 3 to 4 Wraps of Wire Rope Remaining on Drum Item Description Lever Roller Capscrew Drum Jam Nut Adjusting Screw Screw (qty 4) Limit Switch...

  • Page 153: Drum 2 Hoisting Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Hoisting Hydraulic Schematic Table 5-2.Legend for Figure 5-6 and Figure 5-7 FIGURE 5-6 Manitowoc 5-15 Published 09-09-16, Control # 229-09...

  • Page 154: Drum 2 Lowering Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 2 Lowering Hydraulic Schematic Table 5-2.Legend for Figure 5-6 and Figure 5-7 FIGURE 5-7 5-16 Published 09-09-16, Control # 229-09...
  • Page 155 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Table 5-2. Legend for Figure 5-6 Figure 5-7 Item Description Accessory Valve Manifold Pump 4 Charge Pressure Diverter Valve (directional control) Pump 4 Pressure Transducer (right travel psi) Shuttle Valve Right Travel/Drum 2 Diverter Valve (directional control)

  • Page 156: Drum 2 Electrical Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 2 Electrical Schematic FIGURE 5-8 5-18 Published 09-09-16, Control # 229-09...

  • Page 157: Drum 3 Whip Hoist

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 3 WHIP HOIST When energized, the solenoid valve routes hydraulic fluid to the pilot controls of the drum 2/drum 3 diverter valve (4) and Drum 3 Brake Overview the pump 2 charge pressure diverter valve (2). The diverter...

  • Page 158: Drum 3 Hoisting Operation

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 3 Hoisting Operation Drum 3 Lowering Operation Figure 5-10 Figure 5-12 for the following. Figure 5-11 Figure 5-12 for the following. To enable the control system to drive the drum 3 pump and To enable the control system to drive the drum 3 pump and...

  • Page 159: Drum 3 Minimum Bail Limit

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 Minimum Bail Limit Installation 1. Connect the electrical wires to the new switch as follows. Figure 5-9 for the following instructions. Remove the switch cover (2). The optional minimum bail limit assembly on drum 3 is a protective device that limits how much wire rope can be b.
  • Page 160 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Item Description Limit Switch Assembly Cover Fastener (qty 4) Cable Restraint Connector Capscrew (qty 6) Washer (qty 6) Drum Limit Switch Adjustment Screw FIGURE 5-9 5-22 Published 09-09-16, Control # 229-09...

  • Page 161: Drum 3 Hoisting Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 Hoisting Hydraulic Schematic FIGURE 5-10 Manitowoc 5-23 Published 09-09-16, Control # 229-09...

  • Page 162: Drum 3 Lowering Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 3 Lowering Hydraulic Schematic FIGURE 5-11 5-24 Published 09-09-16, Control # 229-09...

  • Page 163: Drum 3 Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 Electrical Schematic FIGURE 5-12 Manitowoc 5-25 Published 09-09-16, Control # 229-09...

  • Page 164: Drum 4 Boom Hoist Or Mast Hoist (Vpc-Max™)

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL DRUM 4 BOOM HOIST OR MAST HOIST Drum 4 Brake Operation (VPC-MAX™) Figure 5-14 Figure 5-16. Drum 4 Brake Overview The J2 joystick sends a 24 V output to the drum 4 park switch. The drum park switch is closed in the UN-PARK...

  • Page 165: Drum 4 Hoisting Operation

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 4 Hoisting Operation Drum 4 Lowering Operation Figure 5-14 Figure 5-16. Figure 5-15 Figure 5-16. To enable the control system to drive the drum 4 pump and To enable the control system to drive the drum 4 pump and...

  • Page 166: Drum 4 Pawl Operation

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 4 Pawl Operation Removal 1. Land the load from the drum being adjusted. 2. Lockout-tagout the crane. 3. Remove the screws (5) and the limit switch (1). WARNING 4. Remove the limit switch cover (7).

  • Page 167: Weekly Maintenance

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Weekly Maintenance 3. Make sure the electrical cables are clear of all moving parts and that cables are securely fastened with nylon Inspect and test the limit switch device weekly or every 40 straps. hours of operation as follows.

  • Page 168: Drum 4 Hoisting Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 4 Hoisting Hydraulic Schematic Item Description Pump 5 Pressure Transducer (drum 4 psi) Pawl Solenoid Valve Control Manifold Drum Pawl Actuator Drum Pawl Assembly Accumulator Drum 4 Right Hydraulic Motor (variable 160 cc) Drum Hoist Gearbox and Brake Assembly...

  • Page 169: Drum 4 Lowering Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 4 Lowering Hydraulic Schematic Item Description Pump 5 Pressure Transducer (drum 4 psi) Pawl Solenoid Valve Control Manifold Drum Pawl Actuator Drum Pawl Assembly Accumulator Drum 4 Right Hydraulic Motor (variable 160 cc) Drum Hoist Gearbox and Brake Assembly...

  • Page 170: Drum 4 Electrical Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 4 Electrical Schematic FIGURE 5-16 5-32 Published 09-09-16, Control # 229-09...

  • Page 171: Drum 5 Boom Hoist (Vpc-Max)

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 5 BOOM HOIST (VPC-MAX) When the drum brake switch is moved to the ON-PARK position, the drum park switch is open, sending a 0 V Drum 5 Brake Overview signal back to the J2 joystick. The J2 joystick communicates...

  • Page 172: Drum 5 Lowering Operation

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 5 Lowering Operation control units. The control algorithm uses this feedback to adjust the pump and motor flows while ramping up to, and Figure 5-19 Figure 5-20. maintaining, the speeds commanded by the joystick. To enable the control system to drive the drum 5 pump and...

  • Page 173: Drum 5 Pawl Limit Switch

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 5 Pawl Limit Switch Installation 1. Connect the electrical wires to the limit switch as follows. Remove the limit switch cover (7). b. Connect the wires, including the jumper wire, to the WARNING correct terminals in the limit switch (see View C).
  • Page 174 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Item Description Item Description Limit Switch Limit Switch Cover Limit Switch Arm Screw (qty 4) Drum Pawl Limit Switch Head Drum Screw Screw (qty 4) Limit Switch Shaft Cable Restraint Connector View C Jumper Wire After Adjustment...

  • Page 175: Drum 5 Hoisting Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 5 Hoisting Hydraulic Schematic Item Description Pump 6 Pressure Transducer (drum 5 psi) Charge Pressure Check Valve (0,35 bar [5 psi]) Charge and Brake Manifold Assembly Drum Pawl Actuator Drum Pawl Assembly Pawl Control Manifold...

  • Page 176: Drum 5 Lowering Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 5 Lowering Hydraulic Schematic Item Description Pump 6 Pressure Transducer (drum 5 psi) Charge Pressure Check Valve (0,35 bar [5 psi]) Charge and Brake Manifold Assembly Drum Pawl Actuator Drum Pawl Assembly Pawl Control Manifold...

  • Page 177: Drum 5 Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 5 Electrical Schematic FIGURE 5-20 Manitowoc 5-39 Published 09-09-16, Control # 229-09...

  • Page 178: Drum 6 Luffing Hoist

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL DRUM 6 LUFFING HOIST hydraulic fluid to the pilot controls of the pump 1 charge pressure pilot valve and drum 1/ drum 6 diverter pilot valve. Drum 6 Brake Overview The charge pressure and diverter pilot valves shift position,...

  • Page 179: Drum 6 Hoisting Operation

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 6 Hoisting Operation Drum 6 Lowering Operation Figure 5-22 Figure 5-24. Figure 5-23 Figure 5-24. To enable the control system to drive the drum 6 pump and To enable the control system to drive the drum 6 pump and...

  • Page 180: Drum 6 Pawl Operation

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 6 Pawl Operation Drum 6 Pawl Limit Switch Figure 5-22 Figure 5-24. The pawl is controlled by the park switch. WARNING When the drum park is turned on to engage the drum pawl, the CCMC11 control module sends a 24 V...

  • Page 181: Weekly Maintenance

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Installation Adjustment 1. Connect the electrical wires to the new limit switch (1). 1. Slowly turn the limit switch shaft (11) clockwise (as viewed from shaft end) until the limit switch clicks open, Remove the limit switch cover (7).
  • Page 182 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Item Description Limit Switch Limit Switch Arm Drum Pawl Drum Screw (qty 4) Cable Restraint Connector Limit Switch Cover Screw (qty 4) Limit Switch Head Screw Limit Switch Shaft Jumper Wire View C Before Adjustment After Adjustment...

  • Page 183: Drum 6 Hoisting Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 6 Hoisting Hydraulic Schematic Table 5-3.Legend for Figure 5-22 and Figure 5-23. FIGURE 5-22 Manitowoc 5-45 Published 09-09-16, Control # 229-09...

  • Page 184: Drum 6 Lowering Hydraulic Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 6 Lowering Hydraulic Schematic Table 5-3.Legend for Figure 5-22 and Figure 5-23. FIGURE 5-23 5-46 Published 09-09-16, Control # 229-09...
  • Page 185 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Table 5-3. Legend for Figure 5-22 Figure 5-23 Item Description Accessory Valve Manifold Pump 1 Charge Pressure Diverter Valve (directional control) Charge Pressure Check Valve (1,7 bar [25 psi]) Pump 1 Pressure Transducer (drum 1 psi)

  • Page 186: Drum 6 Electrical Schematic

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 6 Electrical Schematic FIGURE 5-24 5-48 Published 09-09-16, Control # 229-09...

  • Page 187: Gearboxes

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS GEARBOXES Changing the Gearbox Oil The drum gearboxes are filled with gear oil and are open to Drum 1 and Drum 2 the inside of the drum. Maintenance consists of periodically Figure 5-26 for the following procedures.
  • Page 188 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL 11. Fill the gearbox with specific oil as follows. d. Connect the quick-drain drainer assembly hose to the quick-drain valve. Make sure the fitting is all the Manual Fill Procedure (very slow process) way on, so that the poppet inside the valve opens.

  • Page 189: Drum 3

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Drum 2 View A Item Description Breather Plug Fill Port Dust Cap (qty 2) Quick-Drain Valve Quick-Drain Valve (radial location) Oil Level Sight Gauge Quick-Drain Drainer Assembly Hose Drum Guard Assembly View B FIGURE 5-26...

  • Page 190: Drum 5

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 3 8. Fill the gearbox with specific oil as follows. Manual Fill Procedure (very slow process) Figure 5-27 for the following procedures. The gearboxes should be drained and refilled after every 200 If not already done, remove the breather plug (1).

  • Page 191: Drum 6

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS View B View A Drum 3 View C Item Description Breather Plug Fill Port Dust Cap Quick-Drain Valve Oil Level Sight Gauge Quick-Drain Drainer Assembly Hose FIGURE 5-27 Manitowoc 5-53 Published 09-09-16, Control # 229-09...
  • Page 192 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 4 11. Fill the gearbox with specific oil as follows. Manual Fill Procedure (very slow process) Figure 5-28 for the following procedures. The gearboxes should be drained and refilled after every 200 If not already done, remove the breather plug (1).
  • Page 193 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS View B View A Item Description Breather Plug Fill Port Dust Cap (qty 2) Quick-Drain Valve Quick-Drain Valve (radial location) Oil Level Plug Quick-Drain Drainer Assembly Hose Drum Guard Assembly Drum 4 FIGURE 5-28 Manitowoc 5-55...
  • Page 194 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 5 9. Fasten the dust caps to the quick-drain valves. 10. Fill the gearbox with specific oil as follows. Figure 5-29 for the following procedures. The gearboxes should be drained and refilled after every 200 Manual Fill Procedure (very slow process) hours of drum operation and thereafter every 1000 hours.
  • Page 195 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS View B View A Drum 5 Item Description Breather Plug Fill Port Dust Cap (qty 2) Quick-Drain Valve Quick-Drain Valve (radial location) Oil Level Sight Gauge Quick-Drain Drainer Assembly Hose FIGURE 5-29 Manitowoc 5-57 Published 09-09-16, Control # 229-09...
  • Page 196 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Drum 6 7. When the draining is finished, disconnect the quick-drain drainer assembly hose. Figure 5-30 for the following procedures. 8. Connect the quick-drain drainer assembly hose to the The gearboxes should be drained and refilled after every 200 radial quick-drain valve (4b) to drain the remaining oil.
  • Page 197 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Slowly pump oil into the gearbox until the oil level is Install the breather plug. halfway up the oil level sight gauge (5). Do not 12. Check the oil level after operating the hoist. If necessary, overfill.

  • Page 198: Drum Motor Speed Sensor

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL DRUM MOTOR SPEED SENSOR Fill the motor with filtered hydraulic oil of the correct type. A speed sensor is installed in each motor. The sensor sends d. Make sure that the fill plug is clean, then install the r o t a t i o n a l s p e e d a n d d i r e c t i o n i n f o r m a t i o n t o t h e fill plug.

  • Page 199: Block Level

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS BLOCK LEVEL 7. Connect the electrical cable to the proximity sensor. 8. Insert the bracket into the rectangular slot of the guide Operation wire rope assembly (4). The block level sensors ensure that the load block remains 9.

  • Page 200: Block-Up Limit Switch

    For service of the block-up limit components in the luffing jib, Make sure the cables are securely fastened to the see the MLC650 Luffing Jib Operator Manual supplied with boom (and the jib, if equipped) with nylon straps. the luffing jib.

  • Page 201: Switch Adjustment And Replacement

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS 4. Test the block-up limit devices for proper operation using either of the following two methods: CAUTION • Boom Lowered Method Avoid Sheave Damage! While the boom is lowered and with the engine running: Do not lengthen or shorten the chains that hold the block limit weights.
  • Page 202 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Location of components at boom top is shown Location of components at boom cap, EUBP, and luffing jib top is similar Item Description Item Description Upper Boom Point Weight Lower Boom Point Weight Block-Up Limit Switch Enclosure...

  • Page 203: Main Boom Lower Point Block-Up Limit Switch

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Main Boom Lower Point Block-Up Limit Switch Replacement Adjustment Figure 5-34 for the following procedure. 1. Remove the block-up limit assembly cover (7). Figure 5-34 for the following procedure. 2. Remove four mounting screws on the limit switch (8).
  • Page 204 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Dim. C = 24,1 mm Dim. B = 22,6 mm Dim. A = 26,4 mm Item Description Spring Spring Eyebolt (qty 2) Setscrew Limit Switch Shaft Limit Switch Actuator Arm Actuating Lever Block-Up Limit Assembly Cover...

  • Page 205: Main Boom Upper Point Block-Up Limit Switch

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Main Boom Upper Point Block-Up Limit Switch Replacement Adjustment Figure 5-35 for the following procedure. 1. Remove the block-up limit assembly cover (6). Figure 5-35 for the following procedure. 2. Remove four mounting screws on the limit switch (7).

  • Page 206: Main Boom Lower Point 1M Boom Cap Block-Up Limit Switch

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Main Boom Lower Point 1M Boom Cap Block-Up Replacement Limit Switch Figure 5-36 for the following procedure. Adjustment 1. Remove the block-up limit assembly cover (8). Figure 5-36 for the following procedure. 2. Remove four mounting screws on the limit switch (9).

  • Page 207: Eubp Limit 1 Block-Up Limit Switch

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS EUBP Limit 1 Block-Up Limit Switch Replacement Adjustment Figure 5-37 for the following procedure. 1. Remove the block-up limit assembly cover (6). Figure 5-37 for the following procedure. 2. Remove four mounting screws on the limit switch (7).

  • Page 208: Eubp Limit 2 Block-Up Limit Switch

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL EUBP Limit 2 Block-Up Limit Switch Replacement Adjustment Figure 5-38 for the following procedure. 1. Remove the block-up limit assembly cover (6). Figure 5-38 for the following procedure. 2. Remove four mounting screws on the limit switch (7).

  • Page 209: Luffing Jib Lower Boom Point #682 Top Block-Up Limit Switch

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Luffing Jib Lower Boom Point #682 Top Block-Up Replacement Limit Switch Figure 5-39 for the following procedure. Adjustment 1. Remove the block-up limit assembly cover (8). Figure 5-39 for the following procedure. 2. Remove four mounting screws on the limit switch (9).

  • Page 210: Pressure Roller

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL PRESSURE ROLLER of wire rope on the drum—from the first layer to the last layer. Overview 2. If necessary, increase the tension of the springs by tightening the lock nut (7a). The pressure roller is a protective device that prevents the...

  • Page 211: Drum 5

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS 9. Tighten the lock nuts (7b) against the plates until Spring Replacement components can be assembled. 1. Attach lifting slings from a hoist to the pressure roller 10. Attach lifting slings from a hoist to the pressure roller assembly.
  • Page 212 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Marks Dim. B = 11 mm View A View C Item Description Drum Pressure Roller Spring Dim. A = 289 mm Spring Retainer Bar Roller Acting on Roller Acting on Cotter Pin Rope Layer Barrel Lock Nut...

  • Page 213: Wire Rope Inspection And Replacement

    The following information is from various wire rope use only pre-assembled lengths of wire rope as supplied manufacturers and includes inspection, replacement, and from Manitowoc Cranes. Do not build lengths from maintenance guidelines for wire rope as established by individual components.
  • Page 214 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL Loss of rope diameter (see Reduction in the Rope Diameter on page 5-77) Broken wires—Record the number, distribution and type of broken wires (see Broken Rope Wires on page 5-78). Internal wear or broken wires for ropes operating on synthetic sheaves.

  • Page 215: Periodic Comprehensive Inspection

    MLC650 SERVICE/MAINTENANCE MANUAL HOISTS Periodic Comprehensive Inspection • Expected rope life as determined by experience on the particular installation or similar installations The comprehensive inspection must be done by a qualified • Size, nature, and frequency of lifts person. The inspection must include pulling all the rope off the drum and carefully inspecting the entire length.

  • Page 216: Broken Rope Wires

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL diameter can be caused by loss of core support, internal or • Running ropes—six randomly broken wires in one lay external corrosion, or wear of the outside wires. length or three broken wires in one strand in one lay...

  • Page 217: Distributing Wire Rope Wear

    Replace the sheaves that have oversized or undersized grooves. Replacement wire rope can break if it does not meet Manitowoc Cranes specifications given in the following • Replace any grooved drums that allow one wrap of the publications supplied with your crane: wire rope to contact the next wrap as the rope spools •...
  • Page 218 HOISTS MLC650 SERVICE/MAINTENANCE MANUAL • Inspect the nylon sheaves to verify they have not separated and “walked off” the steel inserts or the Observe the groove to see if the contour of the gauge bearings (Figure 5-48). matches the contour at the bottom of the sheave groove.
  • Page 219 MLC650 SERVICE/MAINTENANCE MANUAL HOISTS B = tread diameter, new sheave E = tread diameter, used sheave PLASTIC SHEAVE DATA B minus E = total wear Sheav If total wear is 5 mm (3/16 in) or more, Outside Tread Rope the sheave should be replaced.

  • Page 220: Load Block And Hook-And-Weight Ball Inspection

    Item Description Working Load Limit (ton [US and metric]) FIGURE 5-51 Wire Rope Diameter (mm and inch) Block Weight (kg and lb) Block Serial Number Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-50 5-82 Published 09-09-16, Control # 229-09...
  • Page 221 Do not weld on any load-bearing component unless proper welding methods are used (contact the Manitowoc The groove must be larger than the wire rope, and Crane Care Lattice Team for material and welding the groove must be free of rough edges and burrs.

  • Page 222: Yearly Inspection

    HOISTS MLC650 SERVICE/MAINTENANCE MANUAL WARNING Falling Load Hazard! To prevent the load from dropping, make sure that, under slack conditions, the hook latch retains the slings or other rigging in the hook. The hook latch is not intended as an anti-fouling device.
  • Page 223 Weekly Periodic Maintenance ........... 6-10 Manitowoc...
  • Page 224 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 09-09-16, Control # 229-09...

  • Page 225: General

    0 V output voltage to the screen on the main display (see the MLC650 Main Display swing brake release solenoid valve, de-energizing the Operation F2267).

  • Page 226: Swing Operation

    SWING SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL SWING OPERATION Swing Right When the J1 joystick is moved to the right, the joystick sends Swing Pump Control a swing right command to the IOLC33 control module via the The swing pump is controlled by an electronic displacement CAN Bus.

  • Page 227: Swing Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Hydraulic Schematic Item Description Variable-Displacement Hydraulic Pump 100 cc Pump 8 Port A Pressure Transducer (swing left psi) Suction Manifold Triple Swing Manifold Adapter Frame Valve Assembly Swing Brake Solenoid Valve Fixed-Displacement Hydraulic Motor 75 cc...

  • Page 228: Swing Electrical Schematic

    SWING SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL Swing Electrical Schematic FIGURE 6-2 Published 09-09-16, Control # 229-09...

  • Page 229: Swing Drive System

    MLC650 SERVICE/MAINTENANCE MANUAL SWING SYSTEM SWING DRIVE SYSTEM Swing Adapter Frame The planetary swing drives are mounted to the adapter Planetary Swing Drive frame. The ring gear is mounted to the carbody. The planetary swing drive pinion gear drives the ring gear, causing the adapter frame assembly to rotate relative to the carbody.

  • Page 230: Planetary Swing Drive Gear Oil

    SWING SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL PLANETARY SWING DRIVE GEAR OIL The planetary swing drive gearbox is filled with gear oil. Maintenance consists of periodically checking the level and changing the oil. Gear Oil Specifications Item Description For gear oil specifications, see the Lubrication Guide Quick-Drain Drainer supplied with the crane.

  • Page 231: Vpc Planetary Swing Drives

    MLC650 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Power Fill Procedure (recommended) VPC Planetary Swing Drives If not already done, remove the breather plug (1). Figure 6-7 for the following procedure. b. Remove the dust cap (3) from the quick-drain NOTE: It is better to change the oil when the planetary valve (4).

  • Page 232: Vpc-Max Planetary Swing Drives

    SWING SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Planetary Swing Drives 8. Fill the planetary drive with specific oil as follows. Remove the plug from the fill port (2). Figure 6-8 for the following procedures. NOTE: It is better to change the oil when the gearbox is b.

  • Page 233: Manual Release Of Swing Brake

    MLC650 SERVICE/MAINTENANCE MANUAL SWING SYSTEM MANUAL RELEASE OF SWING BRAKE 3. Using the hand pump, pressurize the brake to 18 bar (261 psi). Figure 6-9 for the following procedure. 4. To apply the swing brake, relieve hydraulic pressure to When removing or installing a planetary drive, the swing the brake.

  • Page 234: Swing Motor Speed Sensor

    SWING SYSTEM MLC650 SERVICE/MAINTENANCE MANUAL SWING MOTOR SPEED SENSOR 5. The final sensor position should be between 1/2 turn (180°) and 1/4 turn (90°) counterclockwise from the point A speed sensor is installed in each swing motor. The sensor where the sensor contacts the speed ring.

  • Page 235: Section 7

    Installation ............. . 7-21 Manitowoc...
  • Page 236 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7-ii Published 09-09-16, Control # 229-09...

  • Page 237: Batteries

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERIES Causes of Battery Failure A battery should never be left in a discharged state. When Battery Safety discharged, it rapidly sulfates and, unless recharged within hours, will permanently lose capacity.

  • Page 238: Loose Hold-Downs

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Front of Crane Item Description Cover Hold-Down Bolt (qty 4) Battery (qty 2) Battery Cover with Latches FIGURE 7-1 Loose Hold-Downs Battery Maintenance Loose hold-downs will allow the battery to vibrate in the CAUTION holder. This can cause cracks or wear in the container and Potential Electronic Control Module Malfunction! cause the acid to leak.

  • Page 239: Troubleshooting-Slow Cranking

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN NOTE: Do not use this test method if the battery has been When cranking, a voltage drop of more than 0.2 volts recently charged by a charger or alternator. Recent between the starting motor cable and ground can cause hard charging places a high surface charge voltage, starting regardless of a battery’s condition.

  • Page 240: Storage

    To prevent batteries from discharging when the ENGINE CONTROLS crane is stored for extended periods of time See the engine start procedure in Section 3 of the MLC650 To prevent the crane from being started by Operator Manual for engine startup. See the Cummins unauthorized personnel engine manual for detailed engine instructions.

  • Page 241: Air Cleaner-Tier 4

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN AIR CLEANER—TIER 4 Monthly Complete the following checks monthly: Figure 7-4 for location of components. • Inspect the rubber reducer and the elbows between the The air filter requires periodic maintenance. Use the service air cleaner and the engine for cracks or other damage indicator to determine when to change the filter element.

  • Page 242: Changing The Filters

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Changing the Filters 6. Clean the inside of the outlet tube. Carefully wipe the inside of the outlet tube using a clean Figure 7-4 for the following procedure. cloth, while being careful not to damage the sealing area The air cleaner has two primary filters (1c) and two of the tube.
  • Page 243 MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description Item Description Air Cleaner Housing Straight Adapter Service Cover Rubber Elbow (qty 2) Clamp (qty 8) Air Intake Primary Filter (qty 2) Mounting Lugs Secondary Filter (qty 2) Service Indicator Inner Housing Service Window...

  • Page 244: Air Cleaner-Tier 3

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL AIR CLEANER—TIER 3 Monthly Complete the following actions monthly: Figure 7-5 for location of components. • Inspect the rubber reducer and the elbow between the The air filter requires periodic maintenance. Use the service air cleaner and the engine for cracks or other damage indicator to determine when to change the filter element.

  • Page 245: Changing The Filters

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN Changing the Filters 5. Clean the inside of the outlet tube. Carefully wipe the inside of the outlet tube using a clean Figure 7-5 for the following procedure. cloth, while being careful not to damage the sealing area The air cleaner has one primary filter (1d) and one of the tube.
  • Page 246 POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Item Description Air Cleaner Assembly Service Cover Clamp (qty 3) Cover Seal Primary Filter Secondary Filter Air Cleaner Housing Steel Tube Clamp (qty 5) Straight Adapter Fitting Rubber Elbow Air Intake Mounting Bracket Capscrews Service Indicator...

  • Page 247: Engine Throttle Adjustment

    With a supply voltage of 25 V to 26 V available replace it or send the unit to Manitowoc Cranes for repair. at the white wire, 0 V should be present at the However, if field disassembly was done, use the following potentiometer output (green wire) lead.
  • Page 248 POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Potentiometer (Electrical Schematic) Supply (White) 5 Watt Signal (Green) Zener Ground (Black) Diode Surface X Flat on the Head of the Shaft These holes should aligned when initially inserting the shaft and spring into the housing.

  • Page 249: Engine Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE ELECTRICAL SCHEMATIC FIGURE 7-7 Manitowoc 7-13 Published 09-09-16, Control # 229-09...

  • Page 250: Tier 4 Ecm Electrical Schematic-Power And Ground Circuits

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL TIER 4 ECM ELECTRICAL SCHEMATIC— POWER AND GROUND CIRCUITS FIGURE 7-8 7-14 Published 09-09-16, Control # 229-09...

  • Page 251: Tier 3 Ecm Electrical Schematic-Power And Ground Circuits

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN TIER 3 ECM ELECTRICAL SCHEMATIC— POWER AND GROUND CIRCUITS FIGURE 7-9 Manitowoc 7-15 Published 09-09-16, Control # 229-09...

  • Page 252: Engine Enclosure

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL ENGINE ENCLOSURE Figure 7-10 for location of components. WARNING The engine enclosure consists of seven cover panels that Personal Injury Hazard—Heavy Objects! can be removed to allow access for engine service. The panels over each DPF weigh approximately Do not operate the crane without the cover panels in place 9 kg (20 lb).

  • Page 253: Engine Belt Routing

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE BELT ROUTING ENGINE RADIATOR Figure 7-11 for engine belt routing. WARNING Burn Hazard! Do not remove the radiator fill cap from a hot engine. Allow the engine to cool below 50°C (120°F) before adding the coolant.

  • Page 254: Checking Coolant Level

    POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Checking Coolant Level 3. Wait for all pressure to escape. 4. When the hissing stops, depress the radiator reservoir For any service other than this periodic checking of the cap, and turn it counterclockwise to remove.

  • Page 255: Fill A Drained Cooling System

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN Fill a Drained Cooling System NOTE: The capacity of the Tier 4 cooling system is approximately 106 liters (28 gallons). CAUTION The capacity of the Tier 3 cooling system is approximately 91 liters (24 gallons).

  • Page 256: Diesel Particulate Filter

    Regeneration Inhibit and replaced (see DPF Replacement on page 7-21). Do not use the inhibit switch unless specifically instructed to do so by the Manitowoc Crane Care Lattice Team. Regeneration NOTE: The inhibit switch is only for special circumstances Regeneration is the process of converting soot collected in i n w h i c h i t i s d e s i r a b l e t o d i s a b l e a c t i v e the DPF into carbon dioxide.

  • Page 257: Dpf Replacement

    MLC650 SERVICE/MAINTENANCE MANUAL POWER TRAIN DPF Replacement CAUTION WARNING Avoid Damage to the DPF! Hot Exhaust Surfaces and Inhalation Hazards! The oxidation catalyst elements of the diesel particulate filter are made of brittle material. Do not drop or strike the Extremely hot surfaces and exhaust gasses side of the DPF.
  • Page 258 POWER TRAIN MLC650 SERVICE/MAINTENANCE MANUAL Item Description Exhaust Clamp w/ Gasket DPF Assembly DPF Exhaust Mounting Bracket (qty 2) Wire Connectors Lifting Tabs Exhaust Clamp w/ Gasket Exhaust Mounting Bracket Capscrew (qty 4) Torque—7,3 Nm (5.3 lb-ft) Torque—20 Nm (14.5 lb-ft)
  • Page 259 Crawler Tread Slack Adjustment ........... . 8-27 Manitowoc...
  • Page 260 MLC650 SERVICE/MAINTENANCE MANUAL Crawler Tensioning Assembly and Hydraulic Hand Pump ....... . 8-28 Operating the Hand Pump .

  • Page 261: General

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE GENERAL Travel Brake Operation This section provides operational information and electrical Figure 8-1 Figure 8-3 for the following information. and hydraulic schematics for the following systems: The travel brakes are a spring-applied, hydraulically •...

  • Page 262: Travel Speed Selection

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Travel Speed Selection Travel Operation The travel speed switch, located on the right console, Figure 8-1 Figure 8-3 for the following information. provides low-speed and high-speed travel selections. Travel To enable the control system, the switches listed below must...

  • Page 263: Left Reverse Travel Control

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Left Reverse Travel Control proportion to the speed commanded by the travel control handle. Increasing the PWM duty cycle increases the pump Figure 8-2 Figure 8-3 for the following information. swashplate angle, which increases the hydraulic flow from the B-side of the pump.

  • Page 264: Forward Travel (High Speed) Hydraulic Schematic

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Forward Travel (High Speed) Hydraulic Schematic Table 8-1.Legend for Figure 8-1 and Figure 8-2 FIGURE 8-1 Published 09-09-16, Control # 229-09...

  • Page 265: Reverse Travel (Low Speed) Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Reverse Travel (Low Speed) Hydraulic Schematic Table 8-1.Legend for Figure 8-1 and Figure 8-2 FIGURE 8-2 Manitowoc Published 09-09-16, Control # 229-09...
  • Page 266 UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Table 8-1. Legend for Figure 8-1 Figure 8-2 Item Description Pump 3 (left travel / drum 1) (130 cc) Pump 9 (accessory) (45 cc) Pump 3 Pressure Transducer (left track psi) Pump 9 Pressure Transducer (acc systems psi)

  • Page 267: Travel Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Travel Electrical Schematic FIGURE 8-3 Manitowoc Published 09-09-16, Control # 229-09...

  • Page 268: Turntable Bearing Alignment

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL TURNTABLE BEARING ALIGNMENT Two dowel pins (A) are installed in the inner ring (D) to locate the inner ring on the rotating bed. The outer ring (C, Figure 8-4) can be installed in any position with relation to the carbody.

  • Page 269: Turntable Bearing Bolt Periodic Tightening

    WARNING follows: Bolt Failure! • Lubricate the crawlers as instructed in the MLC650 Loose or improperly tightened bolts can cause bolts or the Lubrication Guide. turntable bearing to fail, possibly allowing the upperworks to break away from the carbody.

  • Page 270: Carbody Jack Cylinders And Carbody/Crawler Pin Pullers

    NOTE: For instructions on operating and connecting the HPU, refer to the folio F2283—MLC650 Hydraulic Power Unit Operation and Maintenance Manual. 8-10 Published 09-09-16, Control # 229-09...
  • Page 271 MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Item Description B1 Right Front Carbody Jack Extend B2 Right Rear Carbody Jack Extend B3 Right Crawler Carbody Pin Puller Extend B4 Left Crawler Carbody Pin Puller Extend B5 Left Rear Carbody Jack Extend B6 Left Front Carbody Jack Extend...

  • Page 272: Extend Carbody Jacks Using Manual Control

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Extend Carbody Jacks Using Manual Control Retract Carbody Jacks Using Manual Control Figure 8-9 for the following. Figure 8-9 for the following. NOTE: The following describes the operation to extend NOTE: The following describes the operation to retract one one carbody jack cylinder.

  • Page 273: Setup Remote Control

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Setup Remote Control Neutral Position Using Setup Remote Figure 8-7 Figure 8-10 for the following. Setup Remote Overview When the crane control system is on, the selector solenoid NOTE: The setup remote is covered in section 4 of the valve (1) is energized.

  • Page 274: Retract Carbody Jacks Using Setup Remote

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Retract Carbody Jacks Using Setup Remote corresponding jack cylinder counterbalance valve (4), via the orifice with bypass check valve (3). Figure 8-8 Figure 8-10 for the following. NOTE: The orifice decreases the maximum flow during the...

  • Page 275: Carbody Jacks Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Carbody Jacks Hydraulic Schematic The hydraulic schematic is shown with the remote in the neutral state. FIGURE 8-7 Manitowoc 8-15 Published 09-09-16, Control # 229-09...

  • Page 276: Carbody Jacks Hydraulic Schematic (Remote Control)

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Carbody Jacks Hydraulic Schematic (Remote Control) FIGURE 8-8 8-16 Published 09-09-16, Control # 229-09...

  • Page 277: Carbody Jacks Hydraulic Schematic (Manual Control)

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Carbody Jacks Hydraulic Schematic (Manual Control) FIGURE 8-9 Manitowoc 8-17 Published 09-09-16, Control # 229-09...

  • Page 278: Carbody Jacks Electrical Schematic

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Carbody Jacks Electrical Schematic FIGURE 8-10 8-18 Published 09-09-16, Control # 229-09...

  • Page 279: Crawler/Carbody Pin Pullers Control

    NOTE: For instructions on operating and connecting the carbody manual control manifold (3) for controlling HPU, refer to the folio F2283—MLC650 Hydraulic movement of the crawler/carbody pin puller cylinders. It does Power Unit Operation and Maintenance Manual. this by sending a command to the CCM-10 control module.

  • Page 280: Neutral Position Using Setup Remote

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Neutral Position Using Setup Remote the corresponding cylinder extend solenoid in the six-section lower accessory valve assembly. The solenoid valve routes Figure 8-11 Figure 8-14 for the following. pilot hydraulic fluid through a shuttle valve, then to the corresponding valve spool.

  • Page 281: Crawler/Carbody Pin Pullers Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Crawler/Carbody Pin Pullers Hydraulic Schematic The schematic is shown with the remote in the neutral state. FIGURE 8-11 Manitowoc 8-21 Published 09-09-16, Control # 229-09...

  • Page 282: Crawler/Carbody Pin Pullers Hydraulic Schematic (Remote Control)

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Crawler/Carbody Pin Pullers Hydraulic Schematic (Remote Control) FIGURE 8-12 8-22 Published 09-09-16, Control # 229-09...

  • Page 283: Crawler/Carbody Pin Pullers Hydraulic Schematic (Manual Control)

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Crawler/Carbody Pin Pullers Hydraulic Schematic (Manual Control) FIGURE 8-13 Manitowoc 8-23 Published 09-09-16, Control # 229-09...

  • Page 284: Crawler/Carbody Pin Pullers Electrical Schematic

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL Crawler/Carbody Pin Pullers Electrical Schematic FIGURE 8-14 8-24 Published 09-09-16, Control # 229-09...

  • Page 285: Crawler Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Crawler Electrical Schematic FIGURE 8-15 Manitowoc 8-25 Published 09-09-16, Control # 229-09...

  • Page 286: Crawler Tread Slack Measurement

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL CRAWLER TREAD SLACK MEASUREMENT 1. Place a straightedge (13, Figure 8-16) on top of the tread. Measure the gap (14) between the straightedge Check the tread slack at the tumbler end of each crawler. and the top of the tread at the lowest point.

  • Page 287: Crawler Tread Slack Adjustment

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE CRAWLER TREAD SLACK ADJUSTMENT 6. Add or remove an equal thickness of shims (6) on both sides of the crawler frame. Shim thicknesses are as Adjust the treads tighter when operating on firm ground and follows: looser when operating on soft ground (mud or sand).

  • Page 288: Crawler Tensioning Assembly And Hydraulic Hand Pump

    UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL CRAWLER TENSIONING ASSEMBLY AND Operating the Hand Pump HYDRAULIC HAND PUMP Figure 8-17 for the following procedure. 1. Before using the hand pump: • Check that all fittings are tight and leak free. WARNING • Check the oil level.

  • Page 289: Maintenance

    MLC650 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Item Description Jack Cylinder (qty 2) Hose Fill Cap Hand Pump Clockwise (to pressurize) Counterclockwise (to depressurize) FIGURE 8-17 Maintenance Remove Air from the Crawler Tensioning Assembly Figure 8-17 for the following procedure. Figure 8-17 for the following procedure.
  • Page 290 UNDERCARRIAGE MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 8-30 Published 09-09-16, Control # 229-09...

  • Page 291: Lubrication

    Lubrication ..............9-1 Manitowoc...
  • Page 292 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9-ii Published 09-09-16, Control # 229-09...
  • Page 293 MLC650 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2271 at the end of this section. Manitowoc Published 09-09-16, Control # 229-09...
  • Page 294 LUBRICATION MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 09-09-16, Control # 229-09...

  • Page 295: Section 10

    Rigging Winch (Drum 0) Hydraulic Schematic ........10-22 Manitowoc...
  • Page 296 MLC650 SERVICE/MAINTENANCE MANUAL Rigging Winch (Drum 0) Hydraulic Schematic (Remote Control) ....10-23 Rigging Winch (Drum 0) Hydraulic Schematic (Manual Control)....10-24 Rigging Winch (Drum 0) Electrical Schematic .
  • Page 297 MLC650 SERVICE/MAINTENANCE MANUAL Trolley Retraction ........... . 10-53 Trolley Motor Brakes .
  • Page 298 MLC650 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-iv Published 09-09-16, Control # 229-09...

  • Page 299: Adapter Frame-To-Rotating Bed Pin Pullers

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES SECTION 10 ACCESSORIES ADAPTER FRAME-TO-ROTATING BED PIN Adapter Frame-to-Rotating Bed Front Pin PULLERS Pullers Operation The adapter frame-to-rotating bed front pin pullers are General controlled by the setup remote. This part of Section 10 provides operational information and Figure 10-1 for an illustration of the front pin pullers.

  • Page 300: Neutral Position Using Setup Remote

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Neutral Position Using Setup Remote hydraulic fluid from the accessory pump to flow to the piston end of the cylinders. This causes the cylinder rods to extend, Figure 10-2 for the following information. engaging the pins. At the same time, hydraulic fluid in the rod side of the cylinders is pushed out and back to the tank.

  • Page 301: Adapter Frame-To-Rotating Bed Front Pin Pullers Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Adapter Frame-to-Rotating Bed Front Pin Pullers Hydraulic Schematic Item Description Adapter Frame Valve Assembly Valve Spool (front adapter pin puller) Extend Solenoid Retract Solenoid FIGURE 10-2 Manitowoc 10-3 Published 09-09-16, Control # 229-09...

  • Page 302: Adapter Frame-To-Rotating Bed Front Pin Pullers Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Adapter Frame-to-Rotating Bed Front Pin Pullers Electrical Schematic FIGURE 10-3 10-4 Published 09-09-16, Control # 229-09...

  • Page 303: Adapter Frame-To-Rotating Bed Rear Pin Pullers Operation

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Adapter Frame-to-Rotating Bed Rear Pin by the return springs. When in neutral, both sides of the pin puller cylinders are connected to the tank via the valve Pullers Operation spool. The adapter frame-to-rotating bed rear pin pullers are Extend Pin Pullers Using Setup Remote controlled by the setup remote.

  • Page 304: Adapter Frame-To-Rotating Bed Rear Pin Pullers Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Adapter Frame-to-Rotating Bed Rear Pin Pullers Hydraulic Schematic Item Description Accessory Valve Manifold Valve Spool (rear adapter pin puller) Proportional Pressure Relief Valve (operating pressure = 350 bar [5076 psi]) Extend Solenoid Retract Solenoid FIGURE 10-5...

  • Page 305: Adapter Frame-To-Rotating Bed Rear Pin Pullers Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Adapter Frame-to-Rotating Bed Rear Pin Pullers Electrical Schematic FIGURE 10-6 Manitowoc 10-7 Published 09-09-16, Control # 229-09...

  • Page 306: Rotating Bed Jack Cylinders

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL ROTATING BED JACK CYLINDERS The rotating bed jack cylinders are controlled by the following methods: General • Setup remote control This part of Section 10 provides operational information and • Manual control levers on the upperworks jacking and...

  • Page 307: Setup Remote Control

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Setup Remote Control Within the counterbalance valves, flow and control is as follows: Setup Remote Overview • The rod side counterbalance valve is piloted open by the NOTE: The setup remote is covered in Section 4 of the rod side pressure and the accessory pressure from the Operator Manual.

  • Page 308: Manual Control

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Manual Control Retract Jack Cylinder Using Manual Control NOTE: Manual control is only used for troubleshooting the Extend Jack Cylinder Using Manual Control rotating bed jacks. NOTE: Manual control is only used for troubleshooting the When a manual control lever (1,...

  • Page 309: Upperworks Jacking And Rigging Winch Valve Assembly

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Upperworks Jacking and Rigging Winch Valve Assembly Item Description Manual Control Lever (qty 5) Right Front Rotating Bed Jack Control Valve Right Rear Rotating Bed Jack Control Valve Left Front Rotating Bed Jack Control Valve Left Rear Rotating Bed Jack Control Valve...

  • Page 310: Rotating Bed Jacks Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Rotating Bed Jacks Hydraulic Schematic The hydraulic schematic is shown in the neutral state. FIGURE 10-9 10-12 Published 09-09-16, Control # 229-09...

  • Page 311: Rotating Bed Jacks Hydraulic Schematic (Remote Control)

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rotating Bed Jacks Hydraulic Schematic (Remote Control) FIGURE 10-10 Manitowoc 10-13 Published 09-09-16, Control # 229-09...

  • Page 312: Rotating Bed Jacks Hydraulic Schematic (Manual Control)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Rotating Bed Jacks Hydraulic Schematic (Manual Control) FIGURE 10-11 10-14 Published 09-09-16, Control # 229-09...

  • Page 313: Rotating Bed Jacks Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rotating Bed Jacks Electrical Schematic FIGURE 10-12 Manitowoc 10-15 Published 09-09-16, Control # 229-09...

  • Page 314: Rotating Bed Jack Stowage Cylinder

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL ROTATING BED JACK STOWAGE The rotating bed jack stowage cylinders are controlled by the setup remote. CYLINDER NOTE: The rotating bed jacks stowage is covered in General Section 4: Store Rotating Bed Jacking Cylinders of the Operator Manual.

  • Page 315: Rotating Bed Jack Stowage Cylinder Operation

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rotating Bed Jack Stowage Cylinder to flow through a check valve that bypasses the holding valve (2). Operation This causes the cylinder rods to extend, pivoting the jack Setup Remote Overview cylinders into the stowed position. At the same time,...

  • Page 316: Rotating Bed Jack Stowage Cylinders Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Rotating Bed Jack Stowage Cylinders Hydraulic Schematic Item Description Accessory Valve Manifold Right Stowage Cylinders Holding Valve (set at 3600 psi) Valve Spool (right stowage cylinders) Left Stowage Cylinders Holding Valve (set at 3600 psi) Valve Spool (left stowage cylinders)

  • Page 317: Rotating Bed Jack Stowage Cylinder Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rotating Bed Jack Stowage Cylinder Electrical Schematic FIGURE 10-15 Manitowoc 10-19 Published 09-09-16, Control # 229-09...

  • Page 318: Rigging Winch (Drum 0)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL RIGGING WINCH (DRUM 0) When in the neutral position, the rigging winch valve spool prevents the accessory pump hydraulic fluid from flowing to General the drum motor and brake. The counterbalance valve (3) is closed during this time, keeping the motor and drum from This part of Section 10 provides operational information and spooling out.

  • Page 319: Manual Control

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Manual Control Spool Out Using Manual Control Figure 10-18 for the following. NOTE: Manual control is used only for troubleshooting the rigging winch and is not used for normal operation. When the manual control lever for the rigging winch (6,...

  • Page 320: Rigging Winch (Drum 0) Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Rigging Winch (Drum 0) Hydraulic Schematic The hydraulic schematic is shown in the neutral state. FIGURE 10-16 10-22 Published 09-09-16, Control # 229-09...

  • Page 321: Rigging Winch (Drum 0) Hydraulic Schematic (Remote Control)

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rigging Winch (Drum 0) Hydraulic Schematic (Remote Control) FIGURE 10-17 Manitowoc 10-23 Published 09-09-16, Control # 229-09...

  • Page 322: Rigging Winch (Drum 0) Hydraulic Schematic (Manual Control)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Rigging Winch (Drum 0) Hydraulic Schematic (Manual Control) FIGURE 10-18 10-24 Published 09-09-16, Control # 229-09...

  • Page 323: Rigging Winch (Drum 0) Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rigging Winch (Drum 0) Electrical Schematic FIGURE 10-19 Manitowoc 10-25 Published 09-09-16, Control # 229-09...

  • Page 324: Mast Assist Cylinders

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL MAST ASSIST CYLINDERS The live mast assist cylinders are controlled by the following methods: General • Setup remote control This part of Section 10 provides operational information and • Mast assist arm switch (located on the right console...

  • Page 325: Setup Remote And Switch Control

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Setup Remote and Switch Control end of the cylinders is forced out and back to the tank, via the counterbalance valves. Setup Remote Overview NOTE: During operation, the sequence valves within the NOTE: The setup remote is covered in Section 4 of the cylinder counterbalance valves remain open.

  • Page 326: Mast Assist And Self-Assembly Cylinders Valve Assembly

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Mast Assist and Self-Assembly Cylinders Valve Assembly Item Description Manual Control Lever Self-Assembly Cylinder Control Valve Mast Raise Cylinder Control Valve Retract Solenoid (qty 2) Extend Solenoid (qty 2) Extend Position Neutral Position Retract Position FIGURE 10-21...

  • Page 327: Mast Assist Cylinders Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Mast Assist Cylinders Hydraulic Schematic The hydraulic schematic is shown in the neutral state. Item Description Mast Assist and Self-Assembly Valve Assembly Load-Hold Counterbalance Valve (set at 275 bar [4000 psi]) Cylinder Counterbalance Valve (set at 248 bar [3600 psi]) (qty 4)

  • Page 328: Mast Assist Cylinders Hydraulic Schematic (Setup Remote And Switch Control)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Mast Assist Cylinders Hydraulic Schematic (Setup Remote and Switch Control) FIGURE 10-23 10-30 Published 09-09-16, Control # 229-09...

  • Page 329: Mast Assist Cylinders Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Mast Assist Cylinders Electrical Schematic FIGURE 10-24 Manitowoc 10-31 Published 09-09-16, Control # 229-09...

  • Page 330: Self-Assembly Cylinder (Optional)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL SELF-ASSEMBLY CYLINDER (OPTIONAL) The self-assembly cylinder is controlled by the following methods: General • Setup remote control This part of Section 10 provides operational information and • J4 joystick (located on the right console in the cab) electrical and hydraulic schematics for the self-assembly •...

  • Page 331: Setup Remote And J4 Joystick Control

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Setup Remote and J4 Joystick Control Extend Cylinder Using Setup Remote or J4 Joystick Figure 10-27 for the following. Setup Remote Overview When the setup remote or J4 joystick sends an extend NOTE: The setup remote is covered in Section 4 of the command, the IOLC30 control module energizes the self- Operator Manual.

  • Page 332: Self-Assembly Cylinder Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Self-Assembly Cylinder Hydraulic Schematic The hydraulic schematic is shown in the neutral state. Item Description Mast Assist and Self-Assembly Cylinder Valve Assembly Load-Hold Valve (set at 269 bar [3900 psi]) FIGURE 10-26 10-34 Published 09-09-16, Control # 229-09...

  • Page 333: Self-Assembly Cylinder Hydraulic Schematic (Setup Remote And J4 Joystick Control)

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Self-Assembly Cylinder Hydraulic Schematic (Setup Remote and J4 Joystick Control) FIGURE 10-27 Manitowoc 10-35 Published 09-09-16, Control # 229-09...

  • Page 334: Self-Assembly Cylinder Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Self-Assembly Cylinder Electrical Schematic FIGURE 10-28 10-36 Published 09-09-16, Control # 229-09...

  • Page 335: Cab Tilt

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES CAB TILT Within the counterbalance valves, flow and control is as follows: The cab tilt cylinders are controlled by the cab tilt switch on • The rod side counterbalance valve is piloted open by the the right side console in the operator cab.

  • Page 336: Cab Tilt Cylinder Hydraulic Schematic (Neutral)

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Cab Tilt Cylinder Hydraulic Schematic (Neutral) Item Description Accessory Valve Manifold Proportional Pressure Relief Valve (operating pressure = 350 bar [5076 psi]) Flow Control Valves Counterbalance Valve (set at 275 bar [4000 psi]) Cab Tilt Valve Spool...

  • Page 337: Cab Tilt Cylinder Hydraulic Schematic (Tilt Up And Tilt Down)

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Cab Tilt Cylinder Hydraulic Schematic (Tilt Up and Tilt Down) Item Description Accessory Valve Manifold Proportional Pressure Relief Valve (operating pressure = 350 bar [5076 psi]) Flow Control Valves Counterbalance Valve (set at 275 bar [4000 psi])

  • Page 338: Cab Tilt Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Cab Tilt Electrical Schematic FIGURE 10-31 10-40 Published 09-09-16, Control # 229-09...

  • Page 339: Vpc And Vpc-Max Systems

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC AND VPC-MAX SYSTEMS Information and adjustment procedures are provided for the following: General • Speed sensors This part of Section 10 provides the electrical and hydraulic • Absolute encoders control of the VPC and VPC-MAX counterweight system.

  • Page 340: Vpc Counterweight Tray Operation

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC Counterweight Tray Operation Setup Remote Overview NOTE: The setup remote is covered in Section 4 of the The VPC counterweight tray movement is controlled by the Operator Manual. following methods: The setup remote control communicates with the CCM-10 •...

  • Page 341: Vpc Counterweight Tray Extension

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC Counterweight Tray Extension VPC Counterweight Tray Retraction Figure 10-34 for the following. Figure 10-34 for the following. When the CCM-10 control module receives an extend tray When the CCM-10 control module receives a retract tray...

  • Page 342: Vpc Counterweight Tray Motor Brakes

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC Counterweight Tray Motor Brakes To disengage the tray motor brakes, the IOLC31 control module sends a 24 V output voltage to the brake release Figure 10-34 for the following. solenoid valve, energizing the solenoid. The energized...

  • Page 343: Vpc Counterweight Tray Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC Counterweight Tray Hydraulic Schematic Item Description Hot Oil Shuttle Valve (VPC-MAX only) VPC 1/VPC 2 Diverter Pilot Valve (VPC-MAX only) Pressure Reducing / Relief Valve (set at 21 bar [300 psi]) Right VPC Counterweight Tray Motor (55 cc fixed)

  • Page 344: Vpc Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC Electrical Schematic FIGURE 10-35 10-46 Published 09-09-16, Control # 229-09...

  • Page 345: Vpc Counterweight Tray Motor Speed Sensor

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC Counterweight Tray Motor Speed Speed Sensor Adjustment Sensor The speed sensor is set at the factory and should not need adjustment, unless replaced. When installing or adjusting the Speed Sensor Overview speed sensor on the motor, it must be set at a specific distance from the target ring on the unit’s rotating cylinder.

  • Page 346: Vpc Counterweight Tray Absolute Encoder

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC Counterweight Tray Absolute Encoder Absolute Encoder Backlash Adjustment 1. Loosen the encoder mounting capscrews. Position the Absolute Encoder Overview encoder so that it is tightly meshed with the pinion gear. The absolute encoder determines its position using a static Do not apply radial load to the encoder shaft.

  • Page 347: Vpc Counterweight Tray Limit Switches

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC Counterweight Tray Limit Switches Rear Limit Switch Adjustment Figure 10-38 for the following. Forward Limit Switch Adjustment T h e r e a r l i m i t s w i t c h ( 2 ) i s u s e d t o s t o p t h e V P C Figure 10-38 for the following.

  • Page 348: Vpc Counterweight Tray Roller Backlash Adjustment

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC Counterweight Tray Roller Backlash Table 10-1 for the permissible front and rear adjustment combinations and resulting change in backlash. Adjustment • To decrease backlash, rotate the shaft counter- Initially position the roller assembly so that the slot is clockwise.

  • Page 349: Live Mast Limit Switch Adjustment

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Live Mast Limit Switch Adjustment Gantry Limit Switch Adjustment Adjust the live mast limit switch (2, Figure 10-40) to be Adjust the gantry limit switch (1, Figure 10-40) to trip as the tripped when the live mast is down in the shipping position.

  • Page 350: Vpc-Max Trolley Operation

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Trolley Operation Setup Remote Overview NOTE: The setup remote is covered in Section 4 of the The VPC-MAX trolley is attached to the VPC-MAX beam by Operator Manual. two hydraulically actuated pins controlled by the setup remote.

  • Page 351: Trolley Extension

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Trolley Extension Trolley Retraction Figure 10-42 for the following. Figure 10-42 for the following. When the CCM-10 control module receives an extend trolley When the CCM-10 control module receives a retract trolley command (either from the setup remote or from the on-board...

  • Page 352: Vpc-Max Trolley Pin Pullers

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Trolley Pin Pullers Trolley Motor Brakes Figure 10-42 for the following. Extend Trolley Pin Pullers Using Setup Remote The VPC trolley motor brakes are a spring-applied, Figure 10-42 for the following. hydraulically released brake system. Each of the trolley...

  • Page 353: Vpc-Max Trolley Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Trolley Hydraulic Schematic Item Description Trolley Pin Puller Cylinder (qty 2) Left Trolley Motor (100 cc fixed) Pin Pullers Retract Solenoid Pin Pullers Extend Solenoid VPC-MAX Actuator Valve VPC 1/VPC 2 Diverter Solenoid Valve Brake Release Solenoid Valve...

  • Page 354: Vpc-Max Trolley Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Trolley Electrical Schematic FIGURE 10-43 10-56 Published 09-09-16, Control # 229-09...

  • Page 355: Vpc-Max Trolley Motor Speed Sensor

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Trolley Motor Speed Sensor Speed Sensor Adjustment The speed sensor is set at the factory and should not need Speed Sensor Overview adjustment, unless replaced. When installing or adjusting the The VPC-MAX trolley is driven by two hydraulic motors.

  • Page 356: Vpc-Max Trolley Absolute Encoder

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Trolley Absolute Encoder Absolute Encoder Backlash Adjustment Figure 10-45 for the following procedures. Absolute Encoder Overview 1. Loosen the encoder mounting capscrews. Position the The absolute encoder determines its position using a static encoder so that it is tightly meshed with the pinion gear.

  • Page 357: Vpc-Max Trolley Roller Backlash Adjustment

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Trolley Roller Backlash Table 10-2 for the permissible front and rear adjustment combinations and resulting change in backlash. Adjustment • To decrease backlash, rotate the shaft counter- Initially position the roller assembly so that the slot is clockwise.

  • Page 358: Vpc-Max Beam Pin Pullers

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Beam Pin Pullers Extend Pin Puller Cylinders Using Setup Remote Figure 10-49 for the following. The VPC-MAX frame assembly auxiliary member attaches to the VPC-MAX beam assembly using four hydraulically When a command to extend the VPC-MAX beam pin puller actuated pins.

  • Page 359: Vpc-Max Frame Assembly Auxiliary Member To Vpc-Max Beam Assembly

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Frame Assembly Auxiliary Member to VPC-MAX Beam Assembly Item Description Frame Assembly Auxiliary Member VPC-MAX Beam Assembly FIGURE 10-48 Manitowoc 10-61 Published 09-09-16, Control # 229-09...

  • Page 360: Vpc-Max Beam Pin Puller Hydraulic Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Beam Pin Puller Hydraulic Schematic Item Description Item Description Upper Pin Puller Cylinder (qty 2) Upper Pin Puller Extend Solenoid Lower Pin Puller Cylinder (qty 2) Lower Pin Puller Extend Solenoid Upper Pin Puller Valve Spool...

  • Page 361: Vpc-Max Beam Electrical Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Beam Electrical Schematic FIGURE 10-50 Manitowoc 10-63 Published 09-09-16, Control # 229-09...

  • Page 362: Vpc-Max Beam Switch Adjustments

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX Beam Switch Adjustments Maximum Tray Out Switch Adjustment Figure 10-51 for the following. The VPC-MAX beam maximum tray in and maximum tray out switches require adjustment. Adjust the rear limit switch position so that it will trip the limit...

  • Page 363: Vpc-Max Beam Up Limit Switch Adjustment

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES VPC-MAX Beam Up Limit Switch Adjustment 1. Set the adjustable limit switch arm to 32 mm (1.26 in). 2. Set the switch to trip when the bottom of the beam hook The VPC-MAX beam up limit switches require adjustment.

  • Page 364: Vpc-Max On Hook Limit Switch Adjustment

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL VPC-MAX On Hook Limit Switch Adjustment 1. Set the adjustable limit switch arm to 56 mm (2 in). 2. Set the switch to trip when the beam hook is 6 mm (0.24 The VPC-MAX on hook limit switches require adjustment.

  • Page 365: Active Fixed Mast Stop System

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES ACTIVE FIXED MAST STOP SYSTEM The AFMS system consists of two fixed mast stops, each containing an integral hydraulic cylinder. The AFMS system General controls the pressure within the mast stop cylinders over the operational range of the cylinder as well as adapts to current This part of Section 10 provides the electrical and hydraulic crane conditions.

  • Page 366: Active Fixed Mast Stop Operation

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Active Fixed Mast Stop Operation Hydraulic Supply Figure 10-55 for the following. The hydraulic supply for the active fixed mast stop (AFMS) system is provided by the accessory pump. The mast cylinder system pressure-reducing valve (11) decreases the accessory pump pressure to the cylinder operating pressure of 31 bar (450 psi).

  • Page 367: Normal Operation-Cylinder Retraction

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Normal Operation—Cylinder Retraction Figure 10-56 for the following. When the load on the mast stop cylinder increases during cylinder retraction, the pressure on the bore side of the cylinder increases. The mast cylinder pressure transducer (10), located on each cylinder, detects this pressure and provides a feedback signal to the IOLC30 control module.

  • Page 368: High Load Operation-Compression

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL High Load Operation—Compression Figure 10-57 for the following. When the active fixed mast stop (AFMS) system needs a higher load capability from the mast stop cylinder, the mast cylinder directional control solenoid valve (7) and the mast cylinder pressure-reducing solenoid valve (5) are de- energized.

  • Page 369: High Load Operation-Extension

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES High Load Operation—Extension Figure 10-58 for the following. After a high load event and when the mast stop cylinder starts to extend, a lower pressure is created in the cylinder bore versus the stored accumulator pressure. The higher...

  • Page 370: Loss Of Load Operation

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Loss of Load Operation Figure 10-59 for the following. During normal cylinder retraction, the mast cylinder pressure-reducing solenoid valve (5) regulates the cylinder bore pressure. But during a load loss situation, the mast stop cylinders rapidly compress, causing a pressure spike. When...

  • Page 371: Active Fixed Mast Stop Hydraulic Schematic

    MLC650 SERVICE/MAINTENANCE MANUAL ACCESSORIES Active Fixed Mast Stop Hydraulic Schematic Item Description Left Mast Stop Cylinder Relief Valve (set at 221 bar [3200 psi]) (qty 2) Integrated Cylinder Accumulator (qty 2) Relief Valve (set at 16,6 bar [240 psi]) (qty 2)

  • Page 372: Active Fixed Mast Stop Electrical Schematic

    ACCESSORIES MLC650 SERVICE/MAINTENANCE MANUAL Active Fixed Mast Stop Electrical Schematic FIGURE 10-61 10-74 Published 09-09-16, Control # 229-09...
  • Page 373 Identification and Location of Major Components ........1-4 Manitowoc...
  • Page 374 MLC650 SERVICE/MAINTENANCE MANUAL Initial Hydraulic System Startup ........... . 2-30 Inspect Electrical Components .

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