Page 1 Manitowoc MLC300 with Fixed Position Counterweight Service/Maintenance Manual...
Page 3 NOTICE 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
MLC300 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1..........Introduction Continuous Innovation .
Page 6 TABLE OF CONTENTS MLC300 SERVICE/MAINTENANCE MANUAL Crane Electrical System Ground Points ..........3-3 Circuit Breakers, Fuses, and Relays .
Page 7 MLC300 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Drum 3—Auxiliary Rear Hoist............5-10 Drum 3 Overview .
Page 8 TABLE OF CONTENTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 1 Minimum Bail Limit ............5-34 Pre-Adjustment.
Page 9 MLC300 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Swing Left Hydraulic Schematic ..........6-3 Swing Right Hydraulic Schematic .
Page 10 TABLE OF CONTENTS MLC300 SERVICE/MAINTENANCE MANUAL Quick-Drain Valve............7-16 Changing the Oil.
Page 11 MLC300 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Crawler Tread Slack Adjustment ........... . 8-18 Turntable Bearing Alignment .
Page 12 TABLE OF CONTENTS MLC300 SERVICE/MAINTENANCE MANUAL Cab Tilt Adjustment ............10-17 Cab Tilt Hydraulic Schematic .
Page 13 Solenoid Valve Identification ........... . . 1-8 Manitowoc...
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Page 15: Section 1
If you are in safety alert symbol and a signal word to identify the hazard’s doubt about any procedure, contact your Manitowoc Cranes degree of seriousness. dealer or the Manitowoc Crane Care Lattice Team.
Page 16: Safe Maintenance Practices
Read This Manual necessary. To ensure safe and proper operation of Manitowoc cranes, If the engine must be running while the crane is being they must be maintained according to the instructions serviced, observe the following: contained in this manual.
Page 17: Stored Energy Safety Precautions
• Do not smoke or allow open flames in the refueling area. • Unless authorized in writing by Manitowoc Cranes, do • not alter the crane in any way that affects the crane’s When using a fuel can, use a safety-type can with an performance (to include welding, cutting, or burning of automatic closing cap and flame arrestor.
Page 18: Protection Of The Environment
INTRODUCTION MLC300 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 MLC300 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Drum 0 (rigging winch) Drum 1 (main hoist) Drum 2 (aux hoist) Drum 3 (aux hoist) Drum 4 (boom hoist) Boom Butt Drum 6 (luffing or auxiliary hoist) Drum 7 (tagline) Upperworks Lowerworks Counterweight...
Page 20 INTRODUCTION MLC300 SERVICE/MAINTENANCE MANUAL Item Description Item Description Operator Cab Counterweight Tray Retainer (qty 2) Swing Drive (1 or 2 optional) Batteries (inboard right side) Crawler Fuel Tank Crawler Drive Mast Equalizer Intermediate Roller Load Pin (right side only) Turntable Bearing...
Page 21 MLC300 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Drum 2 (aux hoist) Mast-Assist Arm and Cylinder (qty 2) Drum 3 (aux hoist) Drum 4 (boom hoist) Hydraulic Tank Pump Drive with Pumps (under guards) Cooler Assembly (under guards) Engine (under guards) Exhaust Aftertreatment Components...
Page 22: Solenoid Valve Identification
INTRODUCTION MLC300 SERVICE/MAINTENANCE MANUAL Solenoid Valve Identification Table 1-1. Hydraulic Solenoid Identification Each hydraulic valve solenoid is assigned a solenoid number used in Manitowoc Cranes training classes (see Table 1-1). Solenoid Description The pin number corresponds to the control module...
Page 23 MLC300 SERVICE/MAINTENANCE MANUAL INTRODUCTION Solenoid Solenoid Description Description Number Number Number Number HSC30-03 Boom Pin Pusher Extend PC112-7 HSC34-11 Gantry Pin Puller Extend PC342-27 HSC30-04 Boom Pin Pusher Retract PC112-26 HSC34-13 Gantry Pin Puller Retract PC342-28 Left Mast Cylinder Directional...
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Page 25: Section 2
Accumulator Maintenance ..........2-34 Manitowoc...
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Page 27: Hydraulic System Overview
MLC300 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 eight hydraulic pumps driven by the engine. functional overview of the major hydraulic components. Figure 2-1...
Page 28: Pumps 1 And 2
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Pumps 1 and 2 P u m p s 1 a n d 2 ( F i g u r e 2 -2 ) a r e 1 6 5 c c , v a r i a b l e - displacement, axial piston pumps.
Page 29: Pumps 3 And 4
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pumps 3 and 4 P u m p s 3 a n d 4 ( F i g u r e 2 -3 ) a r e 1 4 5 c c , v a r i a b l e - displacement, axial piston pumps.
Page 30: Pump 5
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Pump 5 Pump 5 (Figure 2-4) is a 100cc, variable-displacement, axial piston pump. Pump direction and displacement are controlled by an electronic displacement control (EDC). The pump has a maximum operating pressure of 420 bar (6,090 psi).
Page 31: Pump 7
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump 6 Pump 6 (Figure 2-5) is a 45cc, variable-displacement, axial piston pump. It has a maximum operating pressure of 250 bar (3,600 PSI). Item Description Inlet Port S Outlet Port B Case Drain L...
Page 32 HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Pump 7 Pump 7 (Figure 2-6) is a 122cc, fixed-displacement, vane pump. Its pressure is limited to 25 bar (350 psi) by a relief valve. Item Description Inlet Port S Outlet Port P FIGURE 2-6...
Page 33 MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump 8 Pump 8 (Figure 2-7) is a 19.66cc, fixed-displacement, gear pump. Its pressure is limited to 9 bar (130 psi) by a relief valve. Item Description Outlet Port Inlet Port FIGURE 2-7 Manitowoc Published 11-22-17, Control # 257-02...
Page 34: Motor Locations
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Motor Locations Drum 1 Motor Drum 1 motor (Figure 2-8) is a bidirectional, variable- displacement motor. Motor displacement is controlled by an electronic motor controller. The motor has an external loop flushing circuit that continuously removes a small volume of oil from the motor loop to provide cooling and oil purification.
Page 35: Drums 2, 3, 4, And 6 Motors
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Drums 2, 3, 4, and 6 Motors Drums 2, 3, 4, and 6 motors (Figure 2-9) are bidirectional, variable-displacement motors. Motor displacements are controlled by electronic motor controllers. Item Description Case Drain Port L1 Gauge Port M5...
Page 36: Travel Motors
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Travel Motors The travel motors (Figure 2-10) are bidirectional, variable- displacement motors. Motor displacements are controlled by electronic motor controllers. Item Description Bearing Flushing U Measuring Pressure MA Measuring Stroking Chamber M1 System Pressure A...
Page 37: Swing Motors
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Swing Motors The swing motors (Figure 2-11) are bidirectional, fixed- displacement motors. Item Description Charge Pressure Gauge Port Loop Flush Relief Valve Case Outlet Loop Flushing Shuttle Valve System Port B System Port A Case Outlet...
Page 38: Rotating Bed Hydraulic Valves
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Rotating Bed Hydraulic Valves Item Description Gantry Equalizer Pin Puller Valve System A—Left Valve Manifold (from left to right): • Accessory System Valve • Drum 4 Valve • Drum 5 Valve (not used) • Left Travel Valve...
Page 39: Carbody Hydraulic Valves
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Carbody Hydraulic Valves Item Description Left Crawler Pin Puller Valve Jacking Cylinder Valves (from top to bottom): • Right Front Jack Raise/Lower Valve • Left Front Jack Raise/Lower Valve Jacking Cylinder Valves (from top to bottom): •...
Page 40: Drum Pawl And Brake Valve Locations
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Drum Pawl and Brake Valve Locations Drum 1 Drums 2 and 3 Typical for Drums 4 and 6 Item Description Brake Valve Solenoid Pawl Valve Solenoid FIGURE 2-14 2-14 Published 11-22-17, Control # 257-02...
Page 41 MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Table 2-1. Closed-Loop Circuit Hydraulic Specifications Pump Pump Charge Pressure Speed Pressure Function Number Port Bar (PSI) Bar (PSI) Drum 1 Hoist Up 42 to 46 Drum 1 Hoist Down 37 to 44 Drum 2 Hoist Up...
Page 42 HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Past Current Item Description Hydraulic Tank Filter 1 (return oil) Power-Fill Coupling Oil Level Sight Gauge Schrader Valve Vent Valve (requires a mating coupler) Desiccant Breather Level Sensor Heater (if equipped) Access Cover (qty 3)
Page 43: Hydraulic System Maintenance
Clean the faucet or pump to remove oil from the drum, described in this section. The technicians shall read, also. understand, and comply with the instructions in this section and the instructions in the Manitowoc MLC300 Main Display • Only use clean transfer containers. Operation Manual.
Page 44: Inspecting The Hydraulic System
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Inspecting the Hydraulic System the system. Do not return leakage oil back to the hydraulic tank. The damaging effects of dirt, heat, air, and water in the Never check for hydraulic leaks with your hands. Check hydraulic system can only be prevented by regular, thorough for leaks with a piece of cardboard or wood.
Page 45: Inspecting And Replacing Hydraulic Hoses
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Inspecting and Replacing Hydraulic Hoses • Damaged or missing hose clamps, guards, or shields • Excessive dirt and debris around hose assemblies If any of these conditions exist, address them appropriately. CAUTION Periodic Replacement Burn Hazard! Table 2-3 for the following.
Page 46: Replacing The Desiccant Breather Cartridge
Replacing Hydraulic Filters CAUTION Avoid Hydraulic System Damage! Original Equipment Manufacturers’ filter elements, available from the Manitowoc Crane Care Lattice Team, must be used on this crane. Substituting with any other brand or type of filter element is not allowed. Item Description Non-OEM filter elements may collapse under pressure.
Page 47: Filter 1
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM 7. Remove the lock nuts and washers and remove the Filter 1 cover. 8. Remove the spring (6). Item Description Hydraulic Tank 9. Lift the filter element (7) out of the hydraulic tank using Guard...
Page 48: Filter 4 And 5
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL To replace Filter 2, proceed as follows (see Figure 2-18). Filter 3 (see Figure 2-19) filters the oil in the flushing circuit for each travel motor. 1. Stop the engine. On past production cranes, replace the filter element when 2.
Page 49: Servicing Suction Strainers
MLC300 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM 12. Start the engine and check for leaks. after the hydraulic oil warms up. 13. If needed, add oil to the hydraulic tank. On Left End of Free Fall Drums 2 and 3 Item Description...
Page 50: Changing Hydraulic Oil
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Changing Hydraulic Oil 13. Using a new seal, securely fasten the access cover to the hydraulic tank. Figure 2-15 for the following procedure. Drain and refill the hydraulic system every 1,000 hours or CAUTION semiannually, whichever comes first, unless an alternate...
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Page 52 HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Item Description Gauge Coupler with Dust Cap -18 UNF x -6 PRESSURE TRANSDUCER ID Swing Right Swing Left Accessory System 1 (see Main Display Operation Manual) Drum 4 Drum 5 (not used) Left Travel Typical Drum 4 or 6...
Page 53: Replacing Pressure Transducers
4. Place a suitable container under the faulty pressure Perform a pressure transducer calibration as instructed transducer to catch hydraulic oil leakage. in the MLC300 Main Display Operation Manual. 5. Disconnect the electrical connector from the pressure Stop the engine and turn the ignition switch to the RUN transducer.
Page 54: Shop Procedures
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL SHOP PROCEDURES CAUTION Initial Hydraulic Oil Fill Avoid Engine Clutch Damage! Figure 2-15 for the following procedure. Observe the following precautions for the engine clutch: The following procedure is used at the factory to fill the •...
Page 55: Initial Hydraulic System Startup
(see Figure 2-15). Calibrate the controls and perform the charge pressure and high pressure checks as instructed in the MLC300 Main Display Operation Manual. CAUTION Make sure the pressure reading for each pump is at Avoid Damage to the Hydraulic System! 30 bar (440 psi) standby pressure in the open-loop circuits.
Page 56: Hydraulic Tests And Calibrations
2-2. If the counted rotations are not understand, and comply with the instructions in this section within the specified range, contact the Manitowoc Crane and the instructions in the MLC300 Main Display Operation Care Lattice Team. Manual. Contact your Manitowoc Cranes dealer for an explanation of any procedure not fully understood.
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Page 58: Disc Brake Operational Test
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL DISC BRAKE OPERATIONAL TEST On Drum Frame (typical for Drums 2 - 6) In Boom Butt Inside Carbody Rear of Rotating Bed Item Description Electrical Connector BRAKE SOLENOID VALVE ID Drum 1 Drum 4 Travel...
Page 59: Free Fall Brake Operational Test
4. At the main display, navigate to the Control Information Turn on free fall for the drum being tested. See the Screen for the function being checked (see the MLC300 MLC300 Operator Manual for the procedure. Main Display Operation Manual).
Page 60: Accumulator Maintenance
HYDRAULIC SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL ACCUMULATOR MAINTENANCE Item Description Drum 1 (in boom butt) 2, 3 Drum 2 and 3 (in rotating bed) Drum 4 (in rotating bed) Drum 6 (in boom butt) Item Description Size Pre-Charge Max Pressure Purpose Accumulator: Diaphragm Type 0,5 L (0.13 gal)
Page 61 The accumulators are pre-charged with dry nitrogen gas. Do not tamper with the accumulators unless authorized and trained to do so. Contact the Manitowoc Crane Care Lattice Team for assistance if needed. The accumulators must be tested yearly to verify they have retained the specified pre-charge.
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Page 63 MLC300 SERVICE/MAINTENANCE MANUAL SECTION 3 ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical Drawings and Schematics ..........3-1 Electrical Power Sequence.
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Page 65: Electrical Drawings And Schematics
MLC300 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 66: Crane Electrical Power Distribution
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Crane Electrical Power Distribution ACM (via CB26) • Relay K5: When energized, relay K5 provides power When the battery disconnect switch is closed and battery from circuit breaker CB8 to terminal +UE on the power is available, turning the engine run switch S3 to the...
Page 67: Crane Electrical System Ground Points
MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Crane Electrical System Ground Points Cab Right Console Ground Points The cab ground points are at the following locations (see General Figure 3-1): The crane electrical system has several frame ground The cab right console (5) contains the following point ground connection (point) locations.
Page 68: Rotating Bed And Cab Mount /Arm Ground Points
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL • Rotating Bed and Cab Mount /Arm Ground Points Live Mast-to-Rotating Bed Ground Point (4)—Ensures an electrical path to ground for electrical components on Figure 3-2 for the following. the live mast frame. It electrically connects the left arm of the live mast to the rotating bed frame.
Page 69: Circuit Breakers, Fuses, And Relays
MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM CIRCUIT BREAKERS, FUSES, AND RELAYS Most circuit breakers, fuses, and relays are located in the DC load center junction box (see Figure 3-4). The following fuses and circuit breaker are not located in the DC load center (see...
Page 70 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL FIGURE 3-4 Relay Description Relay Description Starter Motor Relay (not shown) Diesel Exhaust Fluid (DEF) Hose Heater (Cummins) ECM Bus (time delay) Not Used ECM Bus Diesel Exhaust Fluid (DEF) Hose Heater (Cummins) Ignition Bus (time delay)
Page 71 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Circuit Circuit Amps Description of Item Protected Amps Description of Item Protected Breaker Breaker Does not leave the Junction Box CB36 IOLC31 (+UB input supply) ECM Start Relay (K7) CB37 IOLC31 (+UB input supply) Spare...
Page 72: Inspect Electrical Components
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL INSPECT ELECTRICAL COMPONENTS Visually inspect all Controller Area Network (CAN) nodes and electrical junction boxes for the following: • Damaged or loose connectors DANGER • Damaged or missing electrical clamps or tie straps Electric Shock Hazard! •...
Page 73: Can Bus Control System
MLC300 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 74: Can Bus System Chart
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL CAN Bus System Chart FIGURE 3-5 3-10 Published 11-22-17, Control # 257-02...
Page 75: Control Modules
MLC300 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 I/ Control modules perform several functions: O types used by the control modules. • Run the software control programs Table 3-3.
Page 76 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Safety Control Module (SCM) There are three SCMs on the crane (see Figure 3-6): • MWSCM-00 (1) (cab) SCMs are controllers that run the software programs to interface with the cab controls and to govern boom and jib •...
Page 77 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Crane Control Module (CCM) There are thre e CCM s m oun ted on th e c ran e (s ee Figure 3-7): CCMs are controllers that run the software programs • MWCCM-10 (1) (rotating bed—master) governing crane operations in the rotating bed and car body.
Page 78: Input/Output-Large (Iol) Module
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Input/Output—Large (IOL) Module There are five IOL modules mounted on the rotating bed (see Figure 3-8): 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 •...
Page 79: Input/Output-Small (Ios) Module
MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Input/Output—Small (IOS) Module There are two IOS modules on the crane (see Figure 3-9): • MWIOSB22 (1) (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 80: Control Module Devices
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Control Module Devices The control modules communicate with output devices to control crane movement and with input devices to read crane status. The following sections detail the operation of these devices. Pressure Transducers A controller provides power to a pressure transducer. The...
Page 81: Limit Switches-Dual Contact
MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Limit Switches—Dual Contact Solenoids In the non-tripped state, a controller provides power to the Solenoids are driven by controller digital outputs and activate normally closed contact and grounds the normally open hydraulic valves and provide control of the following contact.
Page 82: Temperature Sensors
ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Temperature Sensors Relays A controller digital output provides power to the temperature A controller digital output drives the relay coil. The coil sensor. energizes, creating a magnetic field that closes the relay contacts. Relays use a small control signal to control the flow The sensor produces an analog output voltage that is of a large current.
Page 83: Control Module Test Voltages
MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Control Module Test Voltages RCL Beacon A controller provides a digital output to each indicator in the Pump and Motor Voltages and Currents RCL beacon (red, amber, and green). Table 3-4 shows the voltages and currents of the pumps, Wind Speed Indicators hoists, and travel motor.
Page 84 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Alphabetical Index of Controller Devices Device Controller Find the device of interest and associated controller in Table Hydraulic Fluid Level and IOLC34 3-5, then refer to the applicable test voltage table for that Temperature Sensor controller.
Page 85 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-6. CCM-10 Test Voltages Function Voltages 0 to 24 V P1-1 OPH3A23 Pump 4 Travel System A 0 to 24 V P1-2 OPH3A28 Pump 1 Drum 2 FF 6% (low) to 70% (high) of 8.5 V...
Page 86 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-7. CCMB11 Test Voltages Function Voltages 0 or 24 V P1-1 OPH3A23 Carbody Left Front Jack Raise Solenoid 0 or 24 V P1-2 OPH3A28 Carbody Left Front Jack Lower Solenoid Open, 24 V Closed...
Page 87 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages Off, 24 V P2-6 ODH3A13 Crawler Right Tension Retract Solenoid 24 V P2-7 ODH3A15 Digital Output (not used) P2-10 Ground (from ground stud on rotating bed) 24 V P2-11 8C57 (+UB) Battery Power for Control Module Outputs...
Page 88 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-8. CCMC11 Test Voltages Function Voltages P1-1 OPH3A23 Drum 6 Valve—System B Valve Assembly—Side B 0 or 24 V P1-2 OPH3A28 Drum 4 Valve—System B Valve Assembly—Side A 0 or 24 V P1-3 ID21...
Page 89 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages 24 V Power to Rotating Bed Level Sensor 24 V P2-4 ODH3A08 Off, 24 V P2-5 ODH3A05 Drum 2 Park Brake Release Solenoid Off, 24 V P2-6 ODH3A13 Swing Brake Release Solenoid Off, 24 V...
Page 90 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-9. IOLC30 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
Page 91 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages P2-14 IACV20 Not Used 24 V Power to Max Boom Angle Limit Switch 24 V P2-15 ODH3A01 P2-16 ODH3A06 Not Used 24 V Power to Swing Encoder 24 V P2-17 ODH3A09 0 to 24 V...
Page 92 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-10. IOLC31 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
Page 93 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages Off, 24 V P2-25 ODH3A05 Free-Fall Enable 0 or 24 V P2-26 OPH3A08 Drum 2 Freefall Brake Hold Solenoid Off, 24 V P2-28 ODH3A13 ECM Start Relay 0 to 24 V P2-29 OPH3A15 Pump 5—Swing C1...
Page 94 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-11. IOLC32 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
Page 95 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Function Voltages Off, 24 V P2-24 ODH3A03 Cab Tilt Down Solenoid Off, 24 V P2-25 ODH3A05 Swing Bearing Auto Lube Off, 24 V P2-26 ODH3A08 Drums 1 and 6 Camera Lights Off, 24 V P2-27...
Page 96 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-12. IOLC33 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Control Module Ignition Power (from engine RUN switch) 0 V Open, 24 V Closed P1-2 KL15 Open, 24 V Closed...
Page 97 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-13. IOLC34 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) Open, 24 V Closed P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01...
Page 98 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Function Voltages 24 V Power to Hydraulic Vacuum Switches 2, 3, & 4 24 V P2-8 ODH3A10 P2-9 ODH3A12 Digital Output (not used) P2-10 OPH3A15 Digital Pulse Output (not used) 24 V P2-11 8C53 (+UB) Battery Power for Control Module Outputs (from CB53) 8.5 V...
Page 99 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-14. IOSA22 Test Voltages Function Voltages P1-1 Ground (from cab ground busbar) 24 V P1-2 KL15 Control Module Ignition Power (from engine RUN switch) Open, 24 V Closed P1-3 ID01 DPF Regen Initiate Open, 24 V...
Page 100 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-15. IOSB22 Test Voltages Function Voltages P1-1 Ground (from ground stud on rotating bed) 24 V P1-2 KL15 Control Module Ignition Power (from CB57) P1-3 ID01 Digital Input (not used) P1-4 ID02 Digital Input (not used)
Page 101 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-16. SCM-00 Test Voltages Function Voltages 24 V P1-1 8C45 (+UB) Battery Power for Control Module Outputs (from CB45) Off, 24 V P1-2 ODH1A17 RCL Light Amber Off, 24 V P1-3 ODH1A6 RCL Light Green...
Page 102 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Function Voltages 1.5 to 8.5 V P1-37 IACV14 Drum 3 Free-Fall Pedal Reverse 1.5 to 5.0 V P1-38 IACV16 Travel Pedal—Left 5 to 8.5 V Forward 1.5 to 5.0 V Reverse P1-39 IACV16 Travel Pedal—Right 5 to 8.5 V...
Page 103 MLC300 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-17. SCMD-01 Test Voltages Function Voltages 24 V P1-1 8C29 (+UB) Battery Power for Control Module Outputs (from CB29) 24 V P1-2 ODH1A7 Not Used 24 V Power Bus: • Jib Butt Angle Sensor...
Page 104 ELECTRICAL SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Table 3-18. SCMD-02 Test Voltages Function Voltages 24 V P1-1 6C8A (+UB) Battery Power for Control Module Outputs (from K5) 24 V Power to UBP Load Pin 24 V P1-3 ODH1A6 24 V Power to Lower/Upper Boom Point Slow Down...
Page 105: Section 4
Lattice Section Inspection and Lacing Replacement ........4-14 Manitowoc...
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Page 107: General Maintenance
MLC300 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM GENERAL MAINTENANCE Automatic Boom Stop Overview This section contains maintenance and adjustment Figure 4-2 for the following. instructions for the limit devices used with the boom and the The boom stop switch unit (1) automatically stops the boom luffing jib attachment.
Page 108: Maintenance
BOOM MLC300 SERVICE/MAINTENANCE MANUAL WARNING Falling Attachment Hazard! Do not operate the crane unless the automatic boom stop is properly adjusted and operational. Do not adjust the maximum operating angle higher than specified. The boom could be pulled over backward or collapse, causing death or serious injury.
Page 109: Adjusting The Automatic Boom Stop
ADJUSTMENT AND MAINTENANCE • If the boom stops before reaching the specified angle, go to step See the MLC300 Luffing Jib Operator Manual. • If the boom reaches the specified angle before it stops, go to step Manitowoc...
Page 110 BOOM MLC300 SERVICE/MAINTENANCE MANUAL View A SWITCH OPENED View B SWITCH CLOSED View D View C LIMIT SWITCH WIRING RIGHT SIDE OF BOOM BUTT Switch Digital Level Receptacle Function Maximum Switch Boom Angle Terminals Angle (16) Black Ground 84.5°—Boom with EUBP 76°...
Page 111: Boom Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL BOOM BOOM ELECTRICAL SCHEMATIC FIGURE 4-4 Manitowoc Published 11-22-17, Control # 257-02...
Page 112: Luffing Jib Electrical Schematic
BOOM MLC300 SERVICE/MAINTENANCE MANUAL LUFFING JIB ELECTRICAL SCHEMATIC FIGURE 4-5 Published 11-22-17, Control # 257-02...
Page 113: Strap Inspection And Maintenance
For inspection procedures not all dirt, grease, oil, etc., so a thorough inspection can be covered in this manual, contact your dealer or the Manitowoc made. Closely examine those areas where paint is chipped, Crane Care Lattice Team.
Page 114: Replacement Specifications
BOOM MLC300 SERVICE/MAINTENANCE MANUAL Replacement Specifications Any strap not within specifications listed Table 4-1 in must be replaced. View A WARNING Falling Attachment Hazard! Depth If damage to the strap exceeds that allowed within of Dent specification, do not operate the crane until the strap has Dent been replaced.
Page 115: Straightness
MLC300 SERVICE/MAINTENANCE MANUAL BOOM Table 4-2. Strap Straightness Corrosion or Abrasion Strap Length Maximum Deviation P325 Allowed 1,5 to <3,0 m (5 to <10 ft) 1,5 mm (0.060 in) 3,0 to <6,1 m (10 to <20 ft) 3,2 mm (0.125 in) 6,1 to <9,1 m (20 to <30 ft)
Page 116: Storing The Straps
If dimension B is not half of A, the hole is elongated. Distance between Line Remove the strap from service. Line and Strap If dimension A is greater than 0,8 mm (0.030 in), contact the Manitowoc Crane Care Lattice Team. A1086 Elongated Holes FIGURE 4-10 Table 4-3 Strap Flatness...
Page 117: Removing The Straps From Service
MLC300 SERVICE/MAINTENANCE MANUAL BOOM Removing the Straps from Service Straps removed from service should be clearly marked to prevent accidental future use. Rendering the strap useless in some way, such as cutting off an end, is recommended. Inspection Checklist The Strap Inspection Checklist is provided at the end of this section.
Page 118 BOOM MLC300 SERVICE/MAINTENANCE MANUAL STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date Length mm (ft) Part Number Corrosion Dents Kinks Cracks Breaks Abrasion Length Straightness Flatness Elongated Holes Other Length mm (ft) Part Number Corrosion Dents Kinks Cracks Breaks Straightness Elongated Holes...
Page 119 MLC300 SERVICE/MAINTENANCE MANUAL BOOM NOTES SKETCHES AND PHOTOGRAPHS Manitowoc 4-13 Published 11-22-17, Control # 257-02...
Page 120: Lattice Section Inspection And Lacing Replacement
BOOM MLC300 SERVICE/MAINTENANCE MANUAL LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 1316 at the end of this section for lattice section inspection and lacing replacement instructions. 4-14 Published 11-22-17, Control # 257-02...
Page 121: Section 5
Drum 4 Hoisting Operation ........... . . 5-15 Manitowoc...
Page 122 MLC300 SERVICE/MAINTENANCE MANUAL Neutral ..............5-16 Drum 4 Lowering Operation .
Page 123 MLC300 SERVICE/MAINTENANCE MANUAL Pre-Adjustment ............. . 5-34 Spring Adjustment .
Page 124 MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-iv Published 11-22-17, Control # 257-02...
Page 125: General
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS GENERAL DRUM IDENTIFICATION This section provides the electrical and hydraulic crane hoist information. Electrical and hydraulic circuit schematics are provided for each drum system. Details of individual components are covered later in this section.
Page 126: Drum 1-Main Hoist
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 1—MAIN HOIST The drum brake remains engaged until drum 1 joystick J3 is moved in either direction to hoist or lower a load. When Figure 5-2 Figure 5-3 for the following descriptions. moved, joystick J3 communicates this information to the CCM-10 control module via the CAN Bus.
Page 127: Drum 1 Hoisting Operation
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS When the drum 1/3 selector solenoid valve is de-energized, solenoid valve is de-energized. The de-energized solenoid the following occurs: valve vents hydraulic brake pressure back to the tank, allowing spring force to apply the drum brake.
Page 128: Drum 1 Hydraulic Schematic-Hoisting
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 1 Hydraulic Schematic—Hoisting FIGURE 5-2 Published 11-22-17, Control # 257-02...
Page 129: Drum 1 Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 1 Electrical Schematic FIGURE 5-3 Manitowoc Published 11-22-17, Control # 257-02...
Page 130: Drum 2-Auxiliary Front Hoist
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 2—AUXILIARY FRONT HOIST Drum 2 Brake Operation Figure 5-4 Figure 5-5 for the following descriptions. UN-PARK Operation Drum 2 Overview Joystick J2 sends 24 V to the drum 2 park switch. The park switch is closed in the UN-PARK position, causing the...
Page 131: Drum 2 Hoisting Operation
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Hoisting Operation Drum 2 Lowering Operation The following conditions must be met to operate drum 2: The following conditions must be met to operate drum 2: • • Seat safety switch must be closed Seat safety switch must be closed •...
Page 132: Drum 2 Hydraulic Schematic-Hoisting
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 2 Hydraulic Schematic—Hoisting FIGURE 5-4 Published 11-22-17, Control # 257-02...
Page 133: Drum 2 Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 2 Electrical Schematic FIGURE 5-5 Manitowoc Published 11-22-17, Control # 257-02...
Page 134: Drum 3-Auxiliary Rear Hoist
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 3—AUXILIARY REAR HOIST The drum brake remains engaged until drum 3 joystick J5 is moved in either direction to hoist or lower a load. Figure 5-6 Figure 5-7 for the following descriptions. When moved, joystick J5 communicates this information to Drum 3 Overview the CCM-10 control module via the CAN Bus.
Page 135: Drum 3 Hoisting Operation
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS When the drum 1/3 selector solenoid valve is energized, the is then de-energized. The de-energized solenoid valve vents following occurs: hydraulic brake pressure back to tank, allowing spring force to apply the drum brake. • The drum 1/3 selector solenoid valve routes hydraulic...
Page 136: Drum 3 Hydraulic Schematic-Hoisting
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 3 Hydraulic Schematic—Hoisting FIGURE 5-6 5-12 Published 11-22-17, Control # 257-02...
Page 137: Drum 3 Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 3 Electrical Schematic FIGURE 5-7 Manitowoc 5-13 Published 11-22-17, Control # 257-02...
Page 138: Drum 4-Boom Hoist
J1 on the left console or by joystick J5 on the right command to the IOLC31 control module via the CAN Bus. console. For more information, see Drum and Control Handle Identification in Section 3 of the MLC300 Operator Upon receiving the un-park command, the IOLC31 control Manual.
Page 139: Drum 4 Pawl Control
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 4 Pawl Control At the same time, the CCM-10 control module sends a pulse- w i d t h m o d u l a t e d ( P W M ) s i g n a l t o t h e e l e c t r o n i c Pawl Disengagement displacement controls (EDC) on pumps 3 and 4 (3 and 4).
Page 140: Neutral
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Neutral The oil flows through the check valve in the sequence valve to the A port of the hydraulic motor, causing the motor to When drum 4 joystick J1 is moved back to neutral, the pump attempt to turn the drum.
Page 141: Brake Defeat Valve
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Brake Defeat Valve High Pressure Protection When the hydraulic system is operating properly, the The relief valve (10) protects the hydraulic pump (3) and pressure on the A side of the motor should always be above motor (18) from a pressure spike such as might occur when 5 bar (73 psi).
Page 142: Drum 4 Hydraulic Schematic-Hoisting
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 4 Hydraulic Schematic—Hoisting Item Description Engine Pump Drive Pump 3 (inboard C) (left/system B) Pump 4 (inboard D) (right/system A) Pump 3 Pressure Transducer Pump 1 Charge Pump (inboard A) Check Valve Drum 4 System A Control Valve...
Page 143: Drum 4 Hydraulic Schematic-Lowering
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 4 Hydraulic Schematic—Lowering Item Description Engine Pump Drive Pump 3 (inboard C) (left/system B) Pump 4 (inboard D) (right/system A) Pump 3 Pressure Transducer Pump 1 Charge Pump (inboard A) Check Valve Drum 4 System A Control Valve...
Page 144: Drum 4 Electrical Schematic
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 4 Electrical Schematic FIGURE 5-10 5-20 Published 11-22-17, Control # 257-02...
Page 145: Drum 6-Auxiliary Hoist
IOLC33 control module via the CAN Bus. console. For more information, see Drum and Control Upon receiving the un-park command, the IOLC33 control Handle Identification in Section 3 of the MLC300 Operator module sends 24 V to the drum 6 brake release solenoid Manual.
Page 146: Drum 6 Pawl Control
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 6 Pawl Control The CCM-10 control module then sends a pulse-width modulated (PWM) signal to the electronic displacement Pawl Disengagement control (EDC) on pump 3 (3). The PWM signal is in proportion to the speed commanded by the joystick.
Page 147: Neutral
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Neutral system B control valve. This allows the drum to turn in the direction that lowers the luffing jib. When drum 6 joystick J1 is moved back to neutral, the pump The CCM-10 control module then sends a signal to the...
Page 148: Drum 6 Hydraulic Schematic-Hoisting
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 6 Hydraulic Schematic—Hoisting Item Description Engine Pump Drive Pump 3 (inboard C) (right/system B) Pump 3 Pressure Transducer Pump 1 Charge Pump (inboard A) Check Valve (cracking pressure = 0,34 bar [5 psi]) Drum 6 System B Control Valve Relief Valve (370—375 bar [5,366—5,439 psi])
Page 149: Drum 6 Hydraulic Schematic-Lowering
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Drum 6 Hydraulic Schematic—Lowering Item Description Engine Pump Drive Pump 3 (inboard C) (right/system B) Pump 3 Pressure Transducer Pump 1 Charge Pump (inboard A) Check Valve (cracking pressure = 0,34 bar [5 psi]) Drum 6 System B Control Valve Relief Valve (370—375 bar [5,366—5,439 psi])
Page 150: Drum 6 Electrical Schematic
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Drum 6 Electrical Schematic FIGURE 5-13 5-26 Published 11-22-17, Control # 257-02...
Page 151: Drum Gearbox Oil Change
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS DRUM GEARBOX OIL CHANGE Fill each drum gearbox through the fill port (3) to the middle of the sight gauge (5). Drum gearbox maintenance consists of periodically checking Every 6 Months or 1,000 Hours the level and changing the oil in the gearboxes for drums 1, 2, 3, 4, 5, and 6.
Page 152: Oil Change Procedure
NOTE: Additional quick-drain drainer assemblies can be so that the poppet inside the valve opens and allows the purchased from your Manitowoc Cranes dealer. oil to drain from the gearbox. d. Connect the quick-drain drainer assembly hose to 6. Once the gearbox has finished draining, remove the the quick-drain valve.
Page 153 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Breather Plug Fill Port (elbow opening) Quick-Drain Valve Sight Gauge Drum 4 Shown All Other Drums Similar FIGURE 5-15 Manitowoc 5-29 Published 11-22-17, Control # 257-02...
Page 154: Drum 4 Pawl
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 4 PAWL NOTE: In some cases, the pawl may come to rest on the top of a ratchet tooth. There must be enough spring Figure 5-16 for the following procedures. tension to pull the pawl into the root of a ratchet tooth if the drum starts to turn in the down direction.
Page 155 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS View A—Engaged View B—Disengaged Item Description Hydraulic Cylinder Pawl Spring Adjusting Nut (qty 2) Eyebolt Ratchet Limit Switch Setscrew Limit Switch Shaft Limit Switch Lever View C Limit Switch Wiring Switch Wire Color Function Terminals Black...
Page 156: Drum 6 Pawl
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 6 PAWL Spring Adjustment Figure 5-17 for the following procedures. If the spring tension becomes insufficient, perform the following procedure. Operation 1. Visually check the position of the pawl and make sure it The pawl is controlled by the drum 6 park switch in the is fully engaged with the ratchet.
Page 157 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS View A — Engaged View B — Disengaged Item Description Hydraulic Cylinder Pawl Spring Adjusting Nut (qty 2) Eyebolt Ratchet Limit Switch Setscrew Limit Switch Shaft Limit Switch Lever View C Limit Switch Wiring Switch Wire Color...
Page 158: Drum 1 Minimum Bail Limit
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 1 MINIMUM BAIL LIMIT Pre-Adjustment 1. Pay out the wire rope from drum 1 until there are three to Figure 5-18 for the following procedures. four wraps of wire rope on the first layer of the drum and The minimum bail limit stops drum 1 from lowering when the rollers (2) are against the bare drum barrel.
Page 159 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Limit Switch Rollers Jam Nut Bolt Dimension: 44 mm (1.7 in) Eyebolt (qty 3) Jam Nut (qty 6) Dimension: 35 mm (1.4 in) Shorting Plug Limit Switch Wiring Switch Wire Color Function Terminals Black...
Page 160: Drum 2/3 Minimum Bail Limit (Non-Free Fall Drum)
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 2/3 MINIMUM BAIL LIMIT (NON-FREE Pre-Adjustment FALL DRUM) 1. Pay out the wire rope from the desired drum 2 or drum 3 until there are three to four wraps of rope on the first Figure 5-19 for the following procedures.
Page 161: Drum 2/3 Minimum Bail Limit (Free Fall Drum)
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS DRUM 2/3 MINIMUM BAIL LIMIT (FREE FALL Pre-Adjustment DRUM) 1. Pay out the wire rope from the desired Drum 2 or 3 until there are three to four wraps of rope on the first layer of Figure 5-20 for the following procedures.
Page 162: Drum 6 Minimum Bail Limit
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL DRUM 6 MINIMUM BAIL LIMIT Pre-Adjustment 1. Pay out the wire rope from drum 6 until there are three to Figure 5-21 for the following procedures. four wraps of rope on the first layer of the drum and the The minimum bail limit stops drum 6 from lowering when rollers (2) are against the bare drum barrel.
Page 163: Speed Sensor-Hoist Motors
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS SPEED SENSOR—HOIST MOTORS 1. Lockout-tagout the crane. 2. Disconnect the electrical cable (3) from the speed Figure 5-22 for the following procedure. sensor (1). For non-free-fall drums only, a speed sensor (1) is installed 3. Thoroughly clean the area around the speed sensor to in the drum motor (2) for each drum, 1 through 6.
Page 164: Block Level
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL BLOCK LEVEL 8. Install the mounting bracket and shim (if used with old sensor). Secure with the nuts (12), washers (13 and 14), Proximity Sensor Operation and bolts (17). 9. Check the clearance between sensors and the drum 2 The block level proximity sensors ensure that the load block sheave (8).
Page 165 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS View A Item Description Item Description Shim (5 mm [0.2 in]) (as necessary) Drum 2 Proximity Sensor B Bolt (qty 2) Drum 2 Proximity Sensor A Lock Washer (qty 2) Nut (qty 2) Mounting Bracket Lock Washer...
Page 166: Block-Up Limit Installation And Adjustment
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL BLOCK-UP LIMIT INSTALLATION AND Two-Blocking Definition ADJUSTMENT Two-blocking is the unsafe condition in which the load block or the weight ball contacts the sheave assembly from which either is suspended. Two-blocking can result in failure of the sheaves and the wire WARNING rope, possibly causing the load to fall.
Page 167 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS 1-Part Line 2-Part Line Item Description Position Indicator Light Wind Speed Indicator Limit Switch (lower and upper jib point) Chain Weight with 2-Chain Attachments Lift Plate Hook-and-Weight Ball Weight with 1-Chain Attachment Lift Block Load Block...
Page 168: Maintenance
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Maintenance 2. Test the block-up limit controls for proper operation with the engine running using either of the following methods: • Boom and Jib Lowered: Manually lift each weight— CAUTION one at a time. The corresponding load drum must...
Page 169 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS A1050 Item Description Limit Switch Spring Eyebolt and Nuts Setscrew Shaft Roller Actuating Lever Limit Switch Lever Cover Bracket Dimension A Jumper Wire (blue) 26 mm (1.04 in) Typical for Upper and Lower Jib Points Limit Switch Wiring...
Page 170: Wire Rope Inspection And Replacement
Prevent Wire Rope Damage! use only pre-assembled lengths of wire rope as supplied from Manitowoc Cranes. Do not build lengths from Do not use grease to lubricate the wire rope. Grease will individual components.
Page 171: Daily Inspection
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS Daily Inspection • Throughout the day, observe the wire rope during operation, particularly the following: Wire rope should be inspected in accordance with ANSI/ Pick-up Points—Sections of the wire rope that are ASME B30.5 and OSHA 29 CFR 1926.1413. A running...
Page 172: Periodic Comprehensive Inspection
HOISTS MLC300 SERVICE/MAINTENANCE MANUAL Periodic Comprehensive Inspection • Size, nature, and frequency of lifts • Rope maintenance practices The comprehensive inspection must be done by a qualified person. The inspection must include pulling all the rope off • Severity of the environment, such as the following: the drum and carefully inspecting the entire length.
Page 173: Broken Rope Wires
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS • New Wire Rope—After initial loading, measure and record Standing Ropes (pendants)—More than two broken the diameter of any new wire rope for comparison to future wires in one lay length in sections beyond the end...
Page 174: Rope That Has Been Idle A Month Or More
The above problems indicate bearing damage. If found, NOTE: Wire rope may be purchased through Manitowoc the corresponding sheave, roller, or drum should be Crane Care Lattice Team. disassembled for further inspection. New bearings should be installed.
Page 175 MLC300 SERVICE/MAINTENANCE MANUAL HOISTS • Inspect the nylon sheaves to verify they have not Observe the groove to see if contour of gauge separated and “walked off” the steel inserts or the matches contour at bottom of sheave groove. bearings (see Figure 5-32).
Page 176 HOISTS MLC300 SERVICE/MAINTENANCE MANUAL B = tread diameter, new sheave E = tread diameter, used sheave PLASTIC SHEAVE DATA B minus E = total wear If total wear is 5 mm (3/16 in) or more, Outside Tread Rope Sheave the sheave should be replaced.
Page 177: Load Block And Hook-And-Weight Ball Inspection
Item Description Working Load Limit in Tons (US and metric) Wire Rope Diameter (in and mm) Block Weight (lb and kg) Block Serial Number Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-34 Manitowoc 5-53 Published 11-22-17, Control # 257-02...
Page 178 Do not weld on any load-bearing component unless and sheave. proper welding methods are used (contact 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 179: Yearly Inspection
MLC300 SERVICE/MAINTENANCE MANUAL HOISTS 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 180 HOISTS MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-56 Published 11-22-17, Control # 257-02...
Page 181 Weekly Periodic Maintenance ........... . 6-9 Manitowoc...
Page 182 MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 11-22-17, Control # 257-02...
Page 183: General
Speed and Torque Settings joystick J1 sends a brake command to CCMC11 control Screen of the main display (see the MLC300 Main Display module via the CAN Bus. The CCMC11 control module then Operation Manual).
Page 184: Swing Operation
SWING SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL SWING OPERATION Swing Right Swing Pump Control When joystick J1 is moved to the right, the joystick sends a swing right command to CCM-10 control module via CAN Swing pump 5 is controlled by an electronic displacement Bus A.
Page 185: Swing Left Hydraulic Schematic
MLC300 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Left Hydraulic Schematic FIGURE 6-1 Manitowoc Published 11-22-17, Control # 257-02...
Page 186: Swing Right Hydraulic Schematic
SWING SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL Swing Right Hydraulic Schematic FIGURE 6-2 Published 11-22-17, Control # 257-02...
Page 187: Swing Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Swing Electrical Schematic FIGURE 6-3 Manitowoc Published 11-22-17, Control # 257-02...
Page 188: Swing Brake Manual Release
SWING SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL SWING BRAKE MANUAL RELEASE 4. Service the swing drive as required. 5. At the completion of servicing, perform the following Figure 6-4 for the following procedure. procedure. Depending on your options, the crane has either one or two Apply the swing brake by relieving the pressure with swing drives.
Page 189: Swing Gearbox Oil Change
MLC300 SERVICE/MAINTENANCE MANUAL SWING SYSTEM Item Description Fill Cap/Breather Fill Port (expansion tank) Sight Gauge Quick-Drain Valve FIGURE 6-5 SWING GEARBOX OIL CHANGE Fill each swing gearbox through the fill cap/breather (1) opening to the level indicated on the decal next to the sight Figure 6-5 for the following procedures.
Page 190: Oil Change Procedure
2. Remove the fill cap/breather (1) to vent the swing NOTE: Additional quick-drain drainer assemblies can be gearbox. purchased from your Manitowoc Cranes dealer. 3. Remove the dust cap from the quick-drain valve (4). d. Thread the quick-drain drainer assembly all the way 4.
Page 191: Swing Motor Speed Sensor
MLC300 SERVICE/MAINTENANCE MANUAL SWING SYSTEM SWING MOTOR SPEED SENSOR 5. Hold the sensor in the position with a 1/2 in hex wrench while tightening the lock nut to 13 Nm (10 ft-lb). The speed sensor sends rotational speed and direction information to the corresponding control module to be used by the crane control functions.
Page 192 SWING SYSTEM MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-10 Published 11-22-17, Control # 257-02...
Page 193: Section 7
Adjusting the Engine Throttle ............7-19 Manitowoc...
Page 194 MLC300 SERVICE/MAINTENANCE MANUAL Hand Throttle Control ............7-19 Foot Throttle Control.
Page 195: Batteries
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERIES Causes of Battery Failure Battery Safety A battery should never be left in a discharged state. When discharged, it rapidly sulfates and, unless recharged within hours, will permanently lose capacity.
Page 196: Loose Hold-Downs
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL Item Description Hold-Down Screw with Nuts and Washers (qty 4) Hold-Down Tubes Battery Cover Hold-Down Knobs Rubber Strip (qty 10) Located in Rotating Bed Battery: 12V, 1,375 CCA, Size 8D (qty 2) on Right Side of Engine...
Page 197: Troubleshooting-Slow Cranking
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN • Clean the posts and terminals. The posts can be lightly coated with petroleum jelly to prevent corrosion. • Make sure that the hold-downs are in good condition. Replace any faulty parts. • Replace frayed, broken, or corroded cables.
Page 198: Battery Disconnect Switch
10 KW, continuous duty, 60 HZ AC generator and a DC Turn the switch handle clockwise to turn on (connect) the charging system is available from Manitowoc Cranes for the batteries to the electrical control system. following operations when the crane engine is off: •...
Page 199: Engine Controls
The speed of the crane motors and actuating cylinders depends on engine speed and equipment control handle See the engine start procedure in Section 3 of the MLC300 movement. Engine speed is controlled with the hand or foot Operator Manual for engine startup. See the Cummins throttle.
Page 200: Engine Enclosure
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL ENGINE ENCLOSURE The engine enclosure consists of cover panels that can be WARNING removed to allow access for engine service. Personal Injury Hazard—Heavy Objects! Engine cover panel weights are listed in the table for WARNING Figure 7-5.
Page 201: Engine Component Identification
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE COMPONENT IDENTIFICATION Item Description Item Description Item Description Fuel Tank Exhaust Aftertreatment Assembly Pump Drive Assembly Radiator and Coolers Engine Clutch Disconnect Lever Engine Clutch Coolant Expansion Tank DEF Treatment System Batteries Cummins QSG12 Engine...
Page 202: Engine Belt Routing
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL ENGINE BELT ROUTING Cummins Engine MTU Engine Item Description Fan Pulley Tensioner Item Description Alternator Belt 1 Idler A/C Compressor Belt Harmonic Balancer Water Pump Tensioner Idler Water Pump Harmonic Balancer Belt 2 Alternator Tensioner...
Page 203: Air Cleaner Maintenance
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN AIR CLEANER MAINTENANCE CAUTION Figure 7-9 for the following procedure. Avoid Engine Damage! The air cleaner requires periodic maintenance due to the following: • Stop the engine before servicing the air cleaner. • Otherwise, unfiltered air will be drawn directly into the Clogged air cleaner filters prevent adequate air flow to engine.
Page 204 POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL 9. Carefully install new secondary filters (2b, View E), if Never use the latches on the cover to force the filters into the air cleaner. It is tempting to assume that the required, and gently push them into the back of the housing.
Page 205: Replacing The Fuel Filter-Mtu
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN REPLACING THE FUEL FILTER—MTU 5. Using the collar wrench (8a), loosen and remove the collar (9) from the cover. Overview Loosen the collar two half-twists with the collar wrench (8b). Figure 7-10 for the following procedure.
Page 206 POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL View A Item Description Drain Valve Vent Cap View B Cover Housing Filter Housing Fuel Inlet Port Fuel Outlet Port Collar Wrench Applying Collar Wrench to Collar Collar Label with Black Bar Spring View C...
Page 207: Replacing The Fuel Filter-Cummins Qsg12 Engine
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN REPLACING THE FUEL FILTER—CUMMINS 5. Connect a 19 mm (3/4 in) I.D. hose to the drain valve to QSG12 ENGINE direct the fuel to an approved container with a minimum capacity of 3,8 L (1 gal). Use a hose clamp if needed.
Page 208: Engine Radiator
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL ENGINE RADIATOR CAUTION Avoid Engine Damage! WARNING The required supplemental coolant additive (SCA) Burn Hazard! concentration must be maintained to prevent engine damage. Hot and pressurized coolant can burn, causing serious injury. Do not remove the coolant fill cap while the coolant SCA must be added to the cooling system to prevent liner is hot.
Page 209 MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN 4. Attach the quick-drain drainer to the quick-drain valve (7). The fluid will drain. WARNING 5. Once the cooling system has completely drained, refill it. 6. Dispose of the drained coolant according to local Chemical and Burn Hazard! environmental regulations.
Page 210: Changing The Pump Drive Oil
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL CHANGING THE PUMP DRIVE OIL Every 6 Months or 1,000 Hours Drain and refill the pump drive every 1,000 hours of Gear Oil Specifications operation or every 6 months, whichever occurs first, unless an alternate interval has been established through an oil For gear oil specifications and gearbox capacities, see the analysis program.
Page 211: Changing The Oil
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN Changing the Oil 5. Thread the quick-drain drainer assembly all the way onto the quick-drain valve (4). The poppet inside the Figure 7-15 for the following procedure. valve will open, allowing the oil to drain from the gearbox.
Page 212: Engine Clutch Maintenance
POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL ENGINE CLUTCH MAINTENANCE 2. At least once each month, park all crane functions and disengage and engage the clutch several times with the A disc-type, manually operated clutch (see Figure 7-16) is engine running. This practice cleans the disc surfaces mounted between the engine and the pump drive.
Page 213: Adjusting The Engine Throttle
If there is a problem with the foot throttle, it is best to either With a supply voltage of 25 V to 26 V available replace it or send the unit to the Manitowoc Crane Care at the white wire, 0 V should be present at the Lattice Team for repair.
Page 214 POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL Potentiometer (Elect. Schematic) Low Idle Supply (white) Signal (green) Ground (black) High Idle Surface X Flat on the Head of the Shaft These two holes should be aligned when initially inserting the shaft and spring into the housing.
Page 215: Engine Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE ELECTRICAL SCHEMATIC FIGURE 7-18 Manitowoc 7-21 Published 11-22-17, Control # 257-02...
Page 216: Exhaust Aftertreatment System
EXHAUST AFTERTREATMENT SYSTEM Engine Regeneration and Inhibit Figure 7-19 for the following instructions. See Section 3 of the MLC300 Operator Manual for operation of the Engine Regeneration/Inhibit switch in the operator Table 7-3. Abbreviations cab. Tier 4 Main Display Icons...
Page 217: Def Supply Module
MLC300 SERVICE/MAINTENANCE MANUAL POWER TRAIN DEF Supply Module NOTE: DPF cleaning requires special tools and equipment and should not be attempted by field service The DEF supply module (2) is an electronically operated personnel. pump and metering system controlled by the ECM. The...
Page 218 POWER TRAIN MLC300 SERVICE/MAINTENANCE MANUAL Item Description DEF Tank Fill Cap Fill Height—343 mm (13.5 in) Drain Plug DEF Supply Module Coolant Control Valve DOC/DPF Module DEF Dosing Module SCR Module FIGURE 7-19 7-24 Published 11-22-17, Control # 257-02...
Page 219 Gear Oil Specifications ............8-21 Manitowoc...
Page 220 MLC300 SERVICE/MAINTENANCE MANUAL Oil Analysis..............8-21 Periodic Maintenance .
Page 221: General
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE GENERAL Directional Control Valves The directional control valve is an electronically controlled This section provides operational information and electrical proportional valve. Each directional control valve contains and hydraulic schematics for the following systems: two solenoids.
Page 222: Travel Brake Operation
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Travel Brake Operation Travel Speed Selection Figure 8-1 Figure 8-2 for the following information. Figure 8-1 Figure 8-2 for the following information. The travel brakes are a spring-applied, hydraulically Low Travel Speed released brake system located between each travel motor...
Page 223: Forward Travel Operation
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Forward Travel Operation • If the left joystick handle is moved forward, the IOLC33 control module energizes the left travel control valve, Figure 8-1 Figure 8-2 for the following information. shifting the valve to the position that allows hydraulic fluid to flow to the left travel motor for forward travel.
Page 224: Reverse Travel Operation
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Reverse Travel Operation • If the right joystick handle is moved rearward, the CCMC11 control module energizes the right travel Figure 8-1 Figure 8-2 for the following information. control valve, shifting the valve to the position that allows...
Page 225: Travel Hydraulic Schematic
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Travel Hydraulic Schematic Figure 8-1 shows the travel circuit in the neutral position. FIGURE 8-1 Manitowoc Published 11-22-17, Control # 257-02...
Page 226: Travel Electrical Schematic
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Travel Electrical Schematic FIGURE 8-2 Published 11-22-17, Control # 257-02...
Page 227: Travel Motor Case Flushing
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE TRAVEL MOTOR CASE FLUSHING The hydraulic fluid exits from the outlet port (CF) of the valve manifold, then flows through the swivel (5), and enters the Figure 8-3 for the following descriptions. inlet of the flow divider (6) in the carbody.
Page 228: Travel Motor Case Flushing Hydraulic Schematic
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Travel Motor Case Flushing Hydraulic Schematic Item Description Valve Manifold Relief Valve (setting = 15 bar [218 psi]) Pump 8 (fixed displacement, gear type) Pressure-Reducing Valve (setting = 13 bar [190 psi]) Swivel (between rotating bed and carbody)
Page 229: Carbody Jacks
To operate the setup remote, it must be turned on as As hydraulic fluid fills the rod end of the jack cylinder, the instructed in the MLC300 Operator Manual. rod retracts. This action forces hydraulic fluid out of the barrel end of the jack cylinder, through the open valve, Neutral and back to the tank.
Page 230: Carbody Jacks Hydraulic Schematic
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Carbody Jacks Hydraulic Schematic FIGURE 8-4 8-10 Published 11-22-17, Control # 257-02...
Page 231: Carbody Jacks Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Carbody Jacks Electrical Schematic FIGURE 8-5 Manitowoc 8-11 Published 11-22-17, Control # 257-02...
Page 232: Crawler Pins
To operate the setup remote, it must be turned on as Engage (extend pins) instructed in the MLC300 Operator Manual. Neutral When an engage (extend pins) command is initiated by the...
Page 233: Crawler Pins, Auto Lube, And Track Tension Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Crawler Pins, Auto Lube, and Track Tension Electrical Schematic FIGURE 8-6 Manitowoc 8-13 Published 11-22-17, Control # 257-02...
Page 234: Crawler Pins Hydraulic Schematic
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Crawler Pins Hydraulic Schematic FIGURE 8-7 8-14 Published 11-22-17, Control # 257-02...
Page 235: Carbody Track Tension Cylinders
To operate the setup remote, it must be turned on as through the open counterbalance valve, and back to the instructed in the MLC300 Operator Manual. tank. Neutral Extend...
Page 236: Carbody Track Tension Hydraulic Schematic
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL Carbody Track Tension Hydraulic Schematic FIGURE 8-8 8-16 Published 11-22-17, Control # 257-02...
Page 237: Crawler Preventive Maintenance
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Typical View Both Crawlers Item Description Item Description Drive Tumbler Shim Storage Compartment Tread Slack Dimension Shim • 38,1 mm (1.5 in)—Tight Limit • 12,7 mm (0.5 in) • 76,2mm (3.0 in)—Loose Limit • 25,4 mm (1.0 in)
Page 238: Crawler Tread Slack Adjustment
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL CRAWLER TREAD SLACK ADJUSTMENT CAUTION Figure 8-9 for the following procedure. Avoid Parts Wear! Tighten the treads when operating on firm ground. Parts will wear rapidly if an equal thickness of shims is not Loosen the treads when operating on soft ground (mud or installed on both sides of the crawler frame.
Page 239: Turntable Bearing Alignment
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE TURNTABLE BEARING ALIGNMENT The S stamped in each side of the inner ring must be centered on the left and right sides of the rotating bed. Figure 8-10 for the following. Two dowel pins (A) are installed in the carbody to locate the The outer ring (C) can be installed in any position with inner ring with the carbody.
Page 240: Tightening Turntable Bearing Bolt
UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL TIGHTENING TURNTABLE BEARING BOLT After First 50 Hours of Operation Figure 8-10 for the following procedures. Tighten all bolts, three at a time, in the numbered sequence given to 3 525 Nm (2,600 ft-lb). Annually or Every 2,000 Hours of Operation...
Page 241: Crawler Gearbox Oil Change
MLC300 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE CRAWLER GEARBOX OIL CHANGE 1. Travel the crawlers until the plugs are positioned as shown. 2. Lockout-tagout the crane. 3. Thoroughly clean the area around the plugs to prevent dirt from entering the gearboxes. 4. Remove the fill plug (1) and the level plug (2) from the gearbox.
Page 242 UNDERCARRIAGE MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 8-22 Published 11-22-17, Control # 257-02...
Page 243: Lubrication
Lubrication ..............9-1 Manitowoc...
Page 244 MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9-ii Published 11-22-17, Control # 257-02...
Page 245 MLC300 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2280 at the end of this section. Manitowoc Published 11-22-17, Control # 257-02...
Page 246 LUBRICATION MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 11-22-17, Control # 257-02...
Page 247 Rigging Winch (Drum 0) Hydraulic Schematic........10-20 Manitowoc...
Page 248 MLC300 SERVICE/MAINTENANCE MANUAL Rigging Winch (Drum 0) Electrical Schematic ........10-21 Boom Butt Pin Pullers .
Page 249: Warming Circuit
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES SECTION 10 ACCESSORIES WARMING CIRCUIT When no accessory circuit is active, the hydraulic fluid is dead headed, causing the hydraulic pressure in the F i g ur e 1 0 -1 an d F i gu re 1 0-2 f o r th e f o ll o w i ng accessory circuit to increase.
Page 250: Warming Circuit Hydraulic Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Warming Circuit Hydraulic Schematic Item Description Engine Pump Drive (inboard pad D) Hydraulic Main Pump 4 Charge Pump Isolation A PSI Pressure Transducer Temperature Sensor Hydraulic Tank To Accessory Circuits: • Live Mast Pin Pullers •...
Page 251: Warming Circuit Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Warming Circuit Electrical Schematic FIGURE 10-2 Manitowoc 10-3 Published 11-22-17, Control # 257-02...
Page 252: Live Mast Pin Pullers
IOLC32 and IOLC33 control modules via CAN Bus C. To operate the setup remote, it must be turned on as instructed in the MLC300 Operator Manual. The following then occurs: •...
Page 253: Live Mast Pin Pullers Hydraulic Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Live Mast Pin Pullers Hydraulic Schematic FIGURE 10-3 Manitowoc 10-5 Published 11-22-17, Control # 257-02...
Page 254: Live Mast Pin Pullers Electrical Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Live Mast Pin Pullers Electrical Schematic FIGURE 10-4 10-6 Published 11-22-17, Control # 257-02...
Page 255: Gantry Equalizer Pin Pullers
IOLC33 and IOLC34 control modules via CAN Bus C. To operate the setup remote, it must be turned on as instructed in the MLC300 Operator Manual. The following then occurs: •...
Page 256: Gantry Equalizer Pin Puller Hydraulic Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Gantry Equalizer Pin Puller Hydraulic Schematic FIGURE 10-5 10-8 Published 11-22-17, Control # 257-02...
Page 257: Gantry Equalizer Pin Puller Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Gantry Equalizer Pin Puller Electrical Schematic FIGURE 10-6 Manitowoc 10-9 Published 11-22-17, Control # 257-02...
Page 258: Live Mast Assist Arms
The live mast assist arms (and cylinders) are also controlled Extend (Raise) automatically during live mast raising and lowering (see Section 4 of the MLC300 Crane Operator Manual). Figure 10-8 Figure 10-10 for the following.
Page 259: Retract (Lower)
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Retract (Lower) • The IOLC32 control module then sends 24 V to the corresponding solenoid on the live mast assist arms Figure 10-9 Figure 10-10 for the following. valve, energizing the solenoid. The valve shifts to route...
Page 260: Live Mast Assist Arms Hydraulic Schematic-Neutral
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Live Mast Assist Arms Hydraulic Schematic—Neutral FIGURE 10-7 10-12 Published 11-22-17, Control # 257-02...
Page 261: Live Mast Assist Arms Hydraulic Schematic-Extend Cylinders
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Live Mast Assist Arms Hydraulic Schematic—Extend Cylinders FIGURE 10-8 Manitowoc 10-13 Published 11-22-17, Control # 257-02...
Page 262: Live Mast Assist Arms Hydraulic Schematic-Retract Cylinders
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Live Mast Assist Arms Hydraulic Schematic—Retract Cylinders FIGURE 10-9 10-14 Published 11-22-17, Control # 257-02...
Page 263: Live Mast Assist Arms Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Live Mast Assist Arms Electrical Schematic FIGURE 10-10 Manitowoc 10-15 Published 11-22-17, Control # 257-02...
Page 264: Cab Tilt Cylinder
To operate the setup remote, it must be turned on as Load Holding instructed in the MLC300 Operator Manual. S23 Cab Tilt Switch Control If system pressure is lost, the check valve closes and the load holding valve locks the cab tilt cylinder in position.
Page 265: Cab Tilt Adjustment
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Cab Tilt Adjustment 1. Loosen the set screw (2). 2. Turn the adjusting knob (3) clockwise to close the valve. The cab tilt circuit contains a pressure-compensated flow control valve (1) that allows adjustment of the cab tilt speed.
Page 266: Cab Tilt Electrical Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Cab Tilt Electrical Schematic FIGURE 10-13 10-18 Published 11-22-17, Control # 257-02...
Page 267: Rigging Winch (Drum 0)
CCM-10 control module. The CCM-10 control module To operate the setup remote, it must be turned on as then communicates the pay out command to the CCMC11 instructed in the MLC300 Operator Manual. and IOLC30 control modules via CAN Bus C. Figure 10-14...
Page 268: Rigging Winch (Drum 0) Hydraulic Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Rigging Winch (Drum 0) Hydraulic Schematic FIGURE 10-14 10-20 Published 11-22-17, Control # 257-02...
Page 269: Rigging Winch (Drum 0) Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Rigging Winch (Drum 0) Electrical Schematic FIGURE 10-15 Manitowoc 10-21 Published 11-22-17, Control # 257-02...
Page 270: Boom Butt Pin Pullers
To operate the setup remote, it must be turned on as When a pin puller disengage command is initiated by the instructed in the MLC300 Operator Manual. setup remote, the setup remote receiver sends the The mast must be configured for setup by using the RCL/RCI command to CCM-10 control module.
Page 271: Boom Butt Pin Pullers Hydraulic Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Boom Butt Pin Pullers Hydraulic Schematic FIGURE 10-16 Manitowoc 10-23 Published 11-22-17, Control # 257-02...
Page 272: Boom Butt Pin Pullers Electrical Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Boom Butt Pin Pullers Electrical Schematic FIGURE 10-17 10-24 Published 11-22-17, Control # 257-02...
Page 273: Self-Erect Cylinder
Lower (extend) To operate the self-erect cylinder, the setup mode must be turned on as instructed in the MLC300 Operator Manual. When a lower command is sent by joystick J4 to CCM-10 control module, the CCM-10 control module communicates...
Page 274: Self-Erect Cylinder Hydraulic Schematic
ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL Self-Erect Cylinder Hydraulic Schematic FIGURE 10-18 10-26 Published 11-22-17, Control # 257-02...
Page 275: Self-Erect Cylinder Electrical Schematic
MLC300 SERVICE/MAINTENANCE MANUAL ACCESSORIES Self-Erect Cylinder Electrical Schematic FIGURE 10-19 Manitowoc 10-27 Published 11-22-17, Control # 257-02...
Page 276 ACCESSORIES MLC300 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-28 Published 11-22-17, Control # 257-02...
Page 277 General............... . . 5-1 Manitowoc...
Page 278 MLC300 SERVICE/MAINTENANCE MANUAL General ............... . 6-1 General .

Manitowoc MLC300 Service And Maintenance Manual

See End of this Manual for Alphabetical Index

Section 2 Hydraulic System

Section 3 Electrical System

Section 4 Boom

Section 5 Hoists

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Summary of Contents for Manitowoc MLC300