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Manitowoc MLC650, Service Maintenance Manual

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ELECTRICAL SYSTEM

MLC650 SERVICE/MAINTENANCE MANUAL

3-20

Published 09-09-16, Control # 229-09

Control Module Test Voltages

Pump and Motor Voltages and Currents

Table 3-4

 shows the voltages and currents of the pumps,

hoists, and travel motors.

Table 3-4. Pump and Motor Voltages and Currents

Pumps

1.6 or 8.8 V

DC 

nominal

200 to 600 mA 

1,2

Hoist Motors

4.5 to 10 V

DC

180 mA to 450 mA 

1,2

Travel Motors

0 or 24 V

DC

 nominal 

0 or 600 mA nominal

1

VPC Motors

0 or 24 V

DC

 nominal 

0 or 600 mA nominal 

1

Note 1

: Resistance increases as the temperature rises on 

the pump or motor solenoid coil, resulting in decreased 
current values when measured with a meter. The listing in 
the table is the current range for a 21°C (68.9°F) coil.

Note 2

: The node regulates displacement of the pump or 

motor with a PWM output. The values represent the 
beginning and end of the control range.

Summary of Contents for MLC650

Page 1: ...R e f e r e n c e O n l y Service Maintenance Manual Manitowoc MLC650 ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ...al for the exact location of the crane identification plate Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc dealer or the Manitowoc Crane Care Lattice Team To prevent death or serious injury Avoid unsafe operation and maintenance Crane and attachments must be operated and maintained by trained and experienced personne...

Page 4: ...R e f e r e n c e O n l y THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH ...

Page 5: ...pperworks Jacking and Rigging Winch Valve Assembly 2 11 Mast Assist and Self Assembly Cylinder Valve Assembly 2 12 Drum Brakes Release Manifold and Solenoid Valves 2 13 Pawl Control Manifold 2 14 Swing Brake Travel Brake and Front Adapter Pin Pusher Valve Assembly 2 15 Lower Accessories Valve Assembly Without Jacking Valve 2 16 Lower Accessories Valve Assembly With Jacking Valve 2 17 Hydraulic Sys...

Page 6: ...b Angle Indicators 4 6 Mast Angle Sending Unit 4 6 Adjusting the Mast Angle 4 6 Fleeting Sheave Maintenance 4 7 General 4 7 Specifications 4 7 Inspection 4 7 Replacement 4 7 Activation 4 7 Adjustment 4 7 Operation 4 7 Boom Top Electrical Schematic 4 8 Luffing Jib Top Electrical Schematic 4 9 Boom Wind Cap Electrical Schematic 4 10 Strap Inspection and Maintenance 4 11 Inspection 4 11 Identifying S...

Page 7: ...oop Flushing 5 26 Drum 4 Hoisting Operation 5 27 Drum 4 Lowering Operation 5 27 Drum 4 Pawl Operation 5 28 Drum 4 Pawl Limit Switch 5 28 Drum 4 Hoisting Hydraulic Schematic 5 30 Drum 4 Lowering Hydraulic Schematic 5 31 Drum 4 Electrical Schematic 5 32 Drum 5 Boom Hoist VPC MAX 5 33 Drum 5 Brake Overview 5 33 Drum 5 Brake Operation 5 33 Drum 5 Hoisting Operation 5 33 Drum 5 Lowering Operation 5 34 ...

Page 8: ...oller and Drum Inspection 5 79 Load Block and Hook and Weight Ball Inspection 5 82 Daily Inspection 5 82 Yearly Inspection 5 84 SECTION 6 Swing System General 6 1 Swing System Overview 6 1 Swing Brake Operation 6 1 Swing Park Switch Control 6 1 Momentary Swing Brake Control 6 1 Swing Operation 6 2 Swing Pump Control 6 2 Swing Left 6 2 Swing Right 6 2 Coasting 6 2 Swing Hydraulic Schematic 6 3 Swin...

Page 9: ... 11 Foot Throttle Control Assembly and Calibration 7 11 Engine Electrical Schematic 7 13 Tier 4 ECM Electrical Schematic Power and Ground Circuits 7 14 Tier 3 ECM Electrical Schematic Power and Ground Circuits 7 15 Engine Enclosure 7 16 Engine Belt Routing 7 17 Engine Radiator 7 17 Checking Coolant Level 7 18 Fill a Drained Cooling System 7 19 Diesel Particulate Filter 7 20 Regeneration 7 20 Maint...

Page 10: ...n Pullers Operation 10 1 Adapter Frame to Rotating Bed Front Pin Pullers Hydraulic Schematic 10 3 Adapter Frame to Rotating Bed Front Pin Pullers Electrical Schematic 10 4 Adapter Frame to Rotating Bed Rear Pin Pullers Operation 10 5 Adapter Frame to Rotating Bed Rear Pin Pullers Hydraulic Schematic 10 6 Adapter Frame to Rotating Bed Rear Pin Pullers Electrical Schematic 10 7 Rotating Bed Jack Cyl...

Page 11: ...stems 10 41 General 10 41 VPC Counterweight Tray Operation 10 42 VPC Counterweight Tray Hydraulic Schematic 10 45 VPC Electrical Schematic 10 46 VPC Counterweight Tray Motor Speed Sensor 10 47 VPC Counterweight Tray Absolute Encoder 10 48 VPC Counterweight Tray Limit Switches 10 49 VPC Counterweight Tray Roller Backlash Adjustment 10 50 Live Mast Limit Switch Adjustment 10 51 Gantry Limit Switch A...

Page 12: ...R e f e r e n c e O n l y TOC viii Published 09 09 16 Control 229 09 TABLE OF CONTENTS MLC650 SERVICE MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 13: ...pair Personnel Only 1 2 Basic Crane Maintenance Safety 1 2 Before Starting a Maintenance Procedure 1 2 Precautions While Working on the Crane 1 2 Stored Energy Safety Precautions 1 3 Chemical Handling Precautions 1 3 Fire Hazard Precautions 1 3 Welding Hazard Avoidance 1 3 Maintain Structural Integrity of the Crane 1 3 Returning Crane to Service 1 4 Protection of the Environment 1 4 Identification...

Page 14: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 1 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 15: ...are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Spark Arrestor Operation of this equipment may create sparks that can start fi...

Page 16: ...fe to return the crane to service Wear clothing that is relatively tight and belted Wear appropriate eye protection and an approved hard hat Do not attempt to maintain or repair any part of the crane while the engine is running unless it is absolutely necessary If the engine must be running while the crane is being serviced observe the following Maintain constant verbal communication between the p...

Page 17: ...or allow open flames in the area when filling hydraulic tanks Only use cleaning solvents which are nonvolatile and nonflammable Do not store flammable materials on the crane Use care while welding or burning on the crane Cover all hoses and components with nonflammable shields or blankets to prevent a fire or other damage Keep the crane clean Accumulations of dirt grease oil rags paper and other w...

Page 18: ...nces Handle and dispose of waste according to local state and federal environmental regulations When filling and draining crane components do not pour waste fluids onto the ground down any drain or into any source of water Observe the following Always drain waste fluids into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or a filling pu...

Page 19: ...ist 10 Boom Butt 11 Drum 0 rigging winch 12 Operator Cab 13 Swing Drive Carbody 14 Crawler Assembly 15 Upperworks 16 Lowerworks 17 Adapter Frame 18 Jacking Cylinder 19 Mast Assist Arms 20 VPC Tray 21 Rotating Bed 22 Gantry 23 Wire Rope 24 Live Mast 25 Self Assembly Cylinder 26 Counterweight Box as required 27 Drum 4 boom hoist mast hoist 28 Drum 3 whip hoist 29 Boom Stop 30 Drum 1 main hoist 31 Wi...

Page 20: ...0 Inboard Tread Slack Adjustment 11 Carbody Crawler Pin Puller 12 Boom Hinge Pin 13 Swing Drive Non VPC qty 2 VPC and VPC MAX qty 3 14 Adapter Frame Rotating Bed Pin Puller 15 Crawler Drive 16 Crawler 17 Intermediate Roller 18 Turntable Bearing Item Description 19 Adapter Frame 20 Outboard Tread Slack Adjustment 21 Rotating Bed Adapter Frame Pin Puller 22 Rotating Bed Jacking Cylinder 23 Gear Rack...

Page 21: ...ight Rear Carbody Jack Raise PB221 5 HSB22 02 Right Rear Carbody Jack Lower PB221 6 HSB11 04 Left Crawler Carbody Pin Puller Extend PB112 22 HSB11 05 Left Crawler Carbody Pin Puller Retract PB112 5 HSB11 06 Right Crawler Carbody Pin Puller Extend PB112 15 HSB11 07 Right Crawler Carbody Pin Puller Retract PB112 14 HSB11 15 Remote Manual Jacking Selector Valve PB112 7 HSB11 23 Left Front Carbody Jac...

Page 22: ...10 Left Cylinder Stowage Extend PC312 8 HSC31 11 Left Cylinder Stowage Retract PC312 27 HSC31 12 Right Cylinder Stowage Extend PC312 9 HSC31 13 Right Cylinder Stowage Retract PC312 28 HSC31 14 Right Rear Jack Extend PC312 18 HSC31 15 Right Rear Jack Retract PC312 10 HSC31 18 Rigging Winch Spool In PC311 5 HSC31 19 Rigging Winch Spool Out PC311 6 HSC32 02 Drum 4 Pawls Out PC322 5 HSC32 03 Drum 4 Pa...

Page 23: ... Release Manifold and Solenoid Valves 2 13 Pawl Control Manifold 2 14 Swing Brake Travel Brake and Front Adapter Pin Pusher Valve Assembly 2 15 Lower Accessories Valve Assembly Without Jacking Valve 2 16 Lower Accessories Valve Assembly With Jacking Valve 2 17 Hydraulic System Specifications 2 18 Hydraulic System Maintenance 2 19 Safety 2 19 Storing and Handling Oil 2 19 Storing and Handling Parts...

Page 24: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 2 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 25: ...riate functional sections of this manual Hydraulic Pump Locations There are nine hydraulic pumps driven by the engine Figure 2 1 illustrates the location of these pumps within the engine and pump assembly and the motors and cylinders that each drives Diverter valves allow some pumps to drive multiple functions as well as combine pump flows from multiple pumps to drive a single function FIGURE 2 1 ...

Page 26: ...C is driven by the IOLC32 control module Pump two provides flow to either drum two or three A diverter valve driven by CCM 10 provides pump flow to the drum commanded by the control system The EDC is driven by the IOLC32 control module Pump four provides flow to either drum two or the right travel motors A diverter valve driven by CCM 10 provides pump flow to either drum two or the right travel mo...

Page 27: ...otors A diverter valve driven by CCM 10 provides pump flow to either drum one or the left travel motors as commanded by the control system Pump direction and displacement is controlled by an electronic displacement control EDC driven by the IOLC32 control module FIGURE 2 3 Item Description A B Main Pressure Lines L1 L2 Case Drain Ports M1 Gauge Port A M2 Gauge Port B M3 Gauge Port Charge Pressure ...

Page 28: ... Pump five provides flow to drum four The EDC is driven by the IOLC33 control module Pump six provides flow to drum five The EDC is driven by the IOLC33 control module Pump eight provides flow to the swing motors Pump direction and displacement is controlled by an EDC driven by the IOLC33 control module Item Description A B Main Pressure Lines L1 L2 Case Drain Ports M1 Gauge Port A M2 Gauge Port B...

Page 29: ...m Pump direction and displacement is controlled by an electronic displacement control EDC driven by the IOLC33 control module Pump 9 Pump nine Figure 2 6 is a unidirectional variable displacement pump providing flow to the accessories The displacement is controlled by a proportional solenoid valve driven by the IOLC34 control module FIGURE 2 5 Item Description A B Main Pressure Lines L1 L2 Case Dr...

Page 30: ...tor is provided by the IOLC34 control module Drum 3 and 6 Motors Drum three and six motors Figure 2 8 are bidirectional variable displacement motors Motor displacement is controlled by an electronic motor controller Electronic control of drum motors three and six is provided by the following control modules IOLC30 Drum Three CCMCII Drum Six FIGURE 2 7 Item Description A B System Pressure Lines C1 ...

Page 31: ... motor Figure 2 9 is a bidirectional variable displacement motor Motor displacement is controlled by an electronic motor controller Electronic control of the drum five motor is provided by the IOL30 control module FIGURE 2 9 Item Description A B System Pressure Lines C1 Solenoid L1 L2 Drain Ports MA MB Gauge Ports System Pressure M4 M5 Gauge Ports Servo Pressure N Speed Sensor ...

Page 32: ...are bidirectional variable displacement motors Motor displacement is controlled by an electronic motor controller Electronic control of the travel motors is provided by the IOSB22 control module FIGURE 2 10 Item Description A B System Pressure Lines C1 Solenoid L1 L2 Drain Ports M4 M5 Gauge Port Servo Pressure MA MB Gauge Port System Pressure N Speed Sensor ...

Page 33: ...xed 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 FIGURE 2 11 Item Description A B System Pressure Lines L1 L2 Drain Ports M1 M2 Gauge Ports System Pressure M3 Charge Flush Port N Speed Sensor ...

Page 34: ...p Pump 2 Pressure Transducer H Swing Right Pump 8 Pressure Transducer I Swing Left Pump 8 Pressure Transducer J Accessory Pressure Pump 9 Pressure Transducer K Drum 5 Up Pump 6 Pressure Transducer L Right Travel Drum 2 Pump 4 Pressure Transducer Accessory Valve Manifold Solenoids Item Description 1 Rotating Bed Pin Puller Retract 2 Rotating Bed Pin Puller Extend 3 Accessory Pressure Proportional C...

Page 35: ...perworks Jacking and Rigging Winch Valve Assembly FIGURE 2 13 Item Description 1 Left Rear Jack Extend 2 Right Rear Jack Extend 3 Right Front Jack Extend 4 Left Front Jack Extend 5 Rigging Winch Spool Out 6 Rigging Winch Spool In 7 Left Front Jack Retract 8 Right Front Jack Retract 9 Right Rear Jack Retract 10 Left Rear Jack Retract ...

Page 36: ... MLC650 SERVICE MAINTENANCE MANUAL 2 12 Published 09 09 16 Control 229 09 Mast Assist and Self Assembly Cylinder Valve Assembly FIGURE 2 14 Item Description 1 Directional Control Lever 2 Assembly Cylinder 3 Mast Raise Cylinder 4 A Coil 5 B Coil ...

Page 37: ...rakes Release Manifold and Solenoid Valves Drums 1 2 3 4 and 6 Drum 5 Drum 3 shown Other drums similar FIGURE 2 15 Item Description 1 Drum Brake Release Manifold 2 Flow Control 3 Poppet Solenoid Valve 4 Sequence Valve 5 Directional Control Solenoid Item Description 1 Drum Brake Release Manifold 2 Directional Control Solenoid FIGURE 2 16 ...

Page 38: ...CE MANUAL 2 14 Published 09 09 16 Control 229 09 Pawl Control Manifold Drums 4 5 and 6 FIGURE 2 17 Item Description 1 Solenoid A Retracts Pawl Assembly Cylinder Rod 2 Pawl Control Manifold 3 Solenoid B Extends Pawl Assembly Cylinder Rod Drum 5 shown Other drums similar ...

Page 39: ...229 09 2 15 MLC650 SERVICE MAINTENANCE MANUAL HYDRAULIC SYSTEM 2 2 Swing Brake Travel Brake and Front Adapter Pin Pusher Valve Assembly FIGURE 2 18 Item Description 1 Swing Brake 2 Travel Brake 3 Front Adapter Pin Pullers Extend 4 Front Adapter Pin Pullers Retract ...

Page 40: ...VICE MAINTENANCE MANUAL 2 16 Published 09 09 16 Control 229 09 Lower Accessories Valve Assembly Without Jacking Valve FIGURE 2 19 Item Description 1 Left Crawler Pin Extend 2 Right Crawler Pin Extend 3 Left Crawler Pin Retract 4 Right Crawler Pin Retract ...

Page 41: ...tion 1 Left Rear Carbody Jack Retract 2 Left Front Carbody Jack Retract 3 Right Rear Carbody Jack Retract 4 Right Front Carbody Jack Retract 5 Left Crawler Pin Extend 6 Right Crawler Pin Extend 7 Right Crawler Pin Retract 8 Left Crawler Pin Retract 9 Right Front Carbody Jack Extend 10 Right Rear Carbody Jack Extend 11 Left Front Carbody Jack Extend 12 Left Rear Carbody Jack Extend FIGURE 2 20 ...

Page 42: ...4 Hoist Up 17 to 19 5 A Drum 4 Hoist Down 16 to 18 B Drum 5 Hoist Up 25 to 28 6 A Drum 5 Hoist Down 24 to 26 B Drum 6 Hoist Up 25 to 28 1 A Drum 6 Hoist Down 24 to 26 A Swing Left Liftcrane 1 3 8 A Swing Right Liftcrane B Swing Left VPC MAX 0 87 A Swing Right VPC MAX B VPC Tray Rearward N A 7 A VPC Tray Forward B VPC Beam Rearward A VPC Beam Forward B Right Travel Reverse 6 3 at tumbler 4 A Right ...

Page 43: ...m When handling drums and transfer containers use care to avoid damage that can cause leaks and entry of dirt or water into the oil Before opening a drum carefully clean the top of it Also clean the faucet or pump to remove oil from the drum Only use clean transfer containers Do not take oil from storage until the oil is needed If the oil cannot be used immediately keep the transfer container tigh...

Page 44: ...the oil will cause a noticeable reduction in noise Correct the cause for any air leak or the pump or motor will be ruined NOTE A high pitched whine or scream from a pump can also indicate cavitation pump being starved of oil This condition is caused by Collapsed or plugged suction line Wrong oil viscosity too high Look for signs of overheating heat peeled parts burned and scorched oil odor and dar...

Page 45: ...ice life Hydraulic hose assemblies operating in zones A and B with high ambient temperatures and high duty circuits could see hose service life reduced by 40 to 50 High duty circuits can include but are not limited to hoist s boom lift swing travel pump suction and discharge to directional valves and directional valve return to reservoir Replace hoses operating in zones A and B after 4 000 to 5 00...

Page 46: ...ulic tank fitting 3 2 Unscrew the reusable cap 1 from the breather cartridge and dispose of the used breather cartridge properly Do not discard the cap 3 Remove the protective caps from the top and bottom of the new breather cartridge 4 Hand tighten the reusable cap to the new breather cartridge 5 Hand tighten the breather cartridge to the hydraulic tank fitting FIGURE 2 21 Item Description 1 Reus...

Page 47: ...aged O rings in the filter caps 7 Inspect and lubricate the O rings of the three filter caps with clean hydraulic oil 8 Install the three filter caps onto the filter housings and securely tighten 9 Start the engine and allow the hydraulic system to reach normal operating temperature 10 Check the filter caps and return lines for leaks and service as required 11 Stop the engine 12 Check the hydrauli...

Page 48: ... help prevent impurities from settling in the system 2 Stop the engine 3 Open the air vent valve 2 to allow air to enter into and escape from the hydraulic tank when draining and filling FIGURE 2 23 Item Description 1 Shut off Handle 2 Air Vent Valve qty 2 3 Access Cover qty 3 4 Quick Drain Valve 5 Strainer 6 Power Fill Coupling 7 Manual Fill Port 8 Sight Level Gauge WARNING Burn Hazard Hydraulic ...

Page 49: ...Replacing the Return Filters on page 2 23 14 Fill the tank through the power fill coupling 6 or manual fill port 7 to the Full Cold Level while watching hydraulic tank display on the information screen Use the proper hydraulic oil See Section 9 in this manual for hydraulic oil information NOTE Do not fill the tank to 100 Oil will flow out of the breather 15 Close the air vent valve 16 Start the en...

Page 50: ...ollowing procedure 1 Lower all loads to the ground 2 Move all control handles to OFF and park all crane functions 3 Shut off the engine 4 Place a suitable container under the faulty pressure transducers to catch the draining oil 5 Disconnect the electrical connector from the pressure transducer 6 Slowly loosen the pressure transducer only enough to relieve pressure 7 Remove the pressure transducer...

Page 51: ...2 25 and see Hydraulic Motor Identification on page 2 6 for the following procedure The following procedure is used at the factory to fill the hydraulic system on a new crane Use this procedure in the field only if the entire hydraulic system has been drained 1 Fill each motor case with clean oil to the level of the case drain port as follows a Disconnect the fittings at the case drain ports b Fil...

Page 52: ... to the Cold Full level on the hydraulic tank gauge 11 If required apply 0 20 to 0 34 bar 3 to 5 psi owner supplied air pressure to the air valve or coupler on the hydraulic tank The tank breather allows 0 21 bar 3 psi pressure to remain in the tank to force oil into the charge system 12 Observe bleed ports as the charge system fills Securely install vent caps when clear oil starts flowing from th...

Page 53: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 2 29 MLC650 SERVICE MAINTENANCE MANUAL HYDRAULIC SYSTEM 2 2 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 54: ...650 SERVICE MAINTENANCE MANUAL 2 30 Published 09 09 16 Control 229 09 INITIAL HYDRAULIC SYSTEM STARTUP FIGURE 2 27 Item Description 1 Pressure Transducer Gauge Port 2 Vent Plug Right Side Suction Manifold 3 Vent Plug Top Left Side Suction Manifold ...

Page 55: ...the faulty pressure and correct 10 Stop the engine 11 Remove the bleed lines from the gauge couplers at each pressure transducer 12 Start and run the engine at low idle 13 With the engine at low idle extend and retract all the cylinders three times gantry cylinders mast cylinders back hitch pins cab tilt boom hinge pin carbody jacks and crawler pins If the oil level drops to 53 a fault alarm will ...

Page 56: ...at high idle 3 Using the travel speed selection switch select high speed travel 4 Travel the crane forward at full speed for 1 minute while the assistant walks alongside the crane and counts the timing mark revolutions 5 Verify the counted revolutions are within the limits specified in Table 2 1 If the counted rotations are not within the specified range contact the Manitowoc Crane Care Lattice Te...

Page 57: ...ate to the screen and run the test 3 When the pressure transducer test completes verify no pressure transducer icons are highlighted in red If any pressure transducer icons appear in red troubleshoot the corresponding transducers to determine the fault cause NOTE The cause of a failed pressure transducer test or faulty display pressure reading may not be the pressure transducer The cause of the fa...

Page 58: ...ximum pressure levels must be reached within a specific pump command range during this test Any pump requiring a command in excess of this range or failing to generate maximum pressure is highlighted in red Troubleshoot the failed circuit to determine the cause of any failures Charge Pressure Test The charge pressure test checks the ability of all primary crane functions to build proper charge pre...

Page 59: ...ons in Table 2 1 1 Start and run the engine at low idle 2 Turn off the swing park switch 3 At the display navigate to the swing diagnostics screen and verify the swing park brake is released 4 Swing the crane by moving the control handle in both directions and verify the rotating bed swings freely 5 Move the control handle to the NEUTRAL position and allow the rotating bed to come to a complete st...

Page 60: ...ews 4 2 Turn the adjusting knobs 3 fully clockwise to close the valves 3 Open both valves slightly 4 Test the cab tilt operation with the switch on the control console in the cab 5 Repeat step 2 through step 4 until the cab tilt starts and stops smoothly in both directions 6 Securely tighten the set screws FIGURE 2 34 Near Cab On Left Side of Rotating Bed Item Description 1 Tilt Down Flow Control ...

Page 61: ...odule Input Output I O Types 3 11 Safety Control Module SCM 3 12 Crane Control Module CCM 3 14 Input Output Large IOL Module 3 15 Input Output Small IOS Module 3 16 Control Module Devices 3 17 Pressure Transducers 3 17 Motor Speed Sensors 3 17 Limit Switches Dual Contact 3 17 Limit Switches Single Contact 3 17 Solenoids 3 18 Angle Sensors 3 18 Alarms 3 18 Load Pin Sensors 3 18 Temperature Sensors ...

Page 62: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 3 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 63: ...sconnect When in the OFF position contacts open the battery disconnect switch S1 disconnects the battery positive terminal from the crane s electrical systems The switch is turned to the OFF position for the following situations Whenever the electrical system is being serviced During extended downtime to help save battery life For security reasons The battery disconnect switch must be in the ON co...

Page 64: ...3 energizes relay K4 which provides power to the engine ECM through the following circuit breakers CB15 and CB16 Tier 3 CB17 CB19 and CB20 Tier 4 Relay K5 provides power from circuit breaker CB8 to terminal UE on the following control modules When energized relay K6 provides power to terminal UB on all crane CAN Bus control modules K6 also provides power to terminals KL15 and UE on the following c...

Page 65: ... at the following locations Figure 3 1 Cab right console 5 Right console ground bus bar 1 Right console chassis ground stud 2 Right console chassis to cab ground strap 3 Right console chassis to rear panel ground strap 4 Cab frame ground straps 6 under cab frame 7 FIGURE 3 1 Item Description 1 Right Console Ground Bus Bar 2 Right Console Chassis Ground Stud 3 Right Console Chassis to Cab Ground St...

Page 66: ...int for the ground circuit of all the electrical devices located on the rotating bed and the carbody A ground cable connects the battery negative terminal to the ground stud The live mast to rotating bed ground point 2 provides a path to ground for electrical components on the live mast frame It electrically connects the left arm of the live mast to the rotating bed frame The ground cable cap asse...

Page 67: ... Tier 3 cranes the alternator fuse F0 2 is mounted on a panel left of the battery box Figure 3 3 The TCU CraneStar fuse F5 3 is mounted on the battery disconnect bracket All other circuit breakers and fuses are mounted in the junction box DC load center Figure 3 5 All relays are also mounted in the junction box DC load center Figure 3 5 Item Description 1 CB0 Alternator 150 A Circuit Breaker Tier ...

Page 68: ...ription Relay Description K1 Left Starter Motor Relay not shown K7 ECM Key start K2 Right Starter Motor Relay not shown K8 DEF Pressure Hose Heater K3 ECM Bus 300 second TDO K9 DEF Supply Module K4 ECM Bus K12 DEF Return Hose Heater K5 Ignition Bus 10 second TDO K13 DEF Suction Hose Heater K6 Crane Bus K14 Not Used FIGURE 3 4 ...

Page 69: ...meras and Work Lights CB16 10 ECM Tier 3 CB45 15 SCM 00 IOSA22 UB input supply CB17 30 ECM Tier 4 CB46 15 Joysticks Jog Dial Park Switches CB18 10 Spare CB47 15 Spare CB19 15 DEF Heater Relays K8 K12 K13 Cummins CB48 15 Diesel Heater CB20 15 Spare CB49 15 CCMC11 UB input supply CB21 15 IOLC31 UB input supply IOLC35 UB UE KL15 supply CB50 15 CCMC11 UB input supply CB22 15 IOLC31 UB input supply CB5...

Page 70: ... conditions exist address them appropriately Degradation Due to Severe Environment Table 3 1 Climate Zone Classification Zones A and B Replace harnesses and battery cables operating in this climate zone after 8 000 hours of service life Their electrical service life is reduced by 25 to 40 Zone C Replace harnesses and battery cables operating in this climate zone after 10 000 hours of service life ...

Page 71: ...odules that use the CAN Bus to communicate with each other and with other CAN Bus devices For more information see Control Modules on page 3 11 The control modules receive inputs from components such as switches sensors and transducers The control modules drive outputs to components such as motors relays and solenoids The control module components are hardwired separately to the control modules Fo...

Page 72: ...R e f e r e n c e O n l y ELECTRICAL SYSTEM MLC650 SERVICE MAINTENANCE MANUAL 3 10 Published 09 09 16 Control 229 09 CAN Bus System Chart FIGURE 3 5 ...

Page 73: ... used in the schematics for the I O types used by the control modules Table 3 3 Control Module I O Types Identifier Definition XXX Module Type SCM CCM IOL IOS A CAN Bus ID Multiple Buses A CAN Bus A B CAN Bus B C CAN Bus C D CAN Bus D J CAN Bus J H CAN Bus H B Module Hardware ID 0 SCM 1 CCM 2 IOS 3 IOL C Module Index Schematic Term Definition IAC Analog Current Input IACV Analog Current Voltage In...

Page 74: ... SCMs are controllers that run the software programs to interface with the cab controls and to govern boom and jib load safety The software running in each SCM controls the I O devices connected directly to the SCM and any I O modules connected on its bus There are three SCMs on the crane Figure 3 6 MWSCMD01 boom MWSCM 00 cab MWSCMD02 jib CSM ...

Page 75: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 3 13 MLC650 SERVICE MAINTENANCE MANUAL ELECTRICAL SYSTEM 3 FIGURE 3 6 Item Description 1 MWSCMD01 2 MWSCM 00 3 MWSCMD02 ...

Page 76: ... programs governing crane operations in the rotating bed and carbody The software running in each CCM controls the I O devices connected directly to the CCM and any I O modules connected to its bus There are three CCMs mounted on the crane Figure 3 7 MWCCMB11 carbody MWCCM 10 rotating bed master MWCCMC11 rotating bed slave FIGURE 3 7 Item Description 1 MWCCMB11 2 MWCCM 10 3 MWCCMC11 ...

Page 77: ...vices connected to them and communicate with CSMs or CCMs connected to their bus IOLs have twice the device capacity as input output small IOS modules There are six IOL modules mounted on the rotating bed Figure 3 8 MWIOLC30 MWIOLC32 MWIOLC33 MWIOLC34 MWIOLC31 MWIOLC35 VPC MAX FIGURE 3 8 Item Description 1 MWIOLC30 2 MWIOLC32 3 MWIOLC33 4 MWIOLC34 5 MWIOLC31 6 MWIOLC35 VPC MAX ...

Page 78: ... Output Small IOS Module IOSs control the devices connected to them and communicate with CSMs or CCMs connected to their bus IOSs have half the device capacity as input output large IOL modules There are two IOS modules on the crane Figure 3 9 MWIOSB22 carbody MWIOSA22 cab FIGURE 3 9 Item Description 1 MWIOSB22 2 MWIOSA22 ...

Page 79: ... speed The rotational direction is determined by which signals phase leads the other Software uses the square wave frequency and phase information to calculate the rotational speed and direction of the motor Limit Switches Dual Contact In the non tripped state a controller provides power to the normally closed contact and grounds the normally open contact A controller digital input reads the appli...

Page 80: ... output provides power to the load pin sensors A strain gauge within the load pin produces an analog output current that is proportional to the load A controller analog input reads this output current and the controller software determines the value of the load based upon the current level Load pin sensors monitor the following loads Mast strap Right and left strap links Upper boom point light fix...

Page 81: ... potentiometer windings The voltage provided at the wiper when referenced to ground is proportional to the foot throttle position and is sent to a controller analog input Travel and Free Fall Brake Pedals A controller digital output provides power to a potentiometer that is connected to the pedal Power is applied across the potentiometer windings to ground Moving the pedal moves a wiper across the...

Page 82: ...l 200 to 600 mA 1 2 Hoist Motors 4 5 to 10 VDC 180 mA to 450 mA 1 2 Travel Motors 0 or 24 VDC nominal 0 or 600 mA nominal1 VPC Motors 0 or 24 VDC nominal 0 or 600 mA nominal 1 Note 1 Resistance increases as the temperature rises on the pump or motor solenoid coil resulting in decreased current values when measured with a meter The listing in the table is the current range for a 21 C 68 9 F coil No...

Page 83: ...Components IOLC32 IOLC33 IOLC34 Drum 5 Components CCMC11 IOLC30 Drum 6 Components CCMC11 IOLC30 ECM Start Relay IOLC32 Engine Components IOLC32 IOLC34 Ether Start IOLC32 Fixed Jib Confirm SCMD01 Fuel Level Sensor CCMC11 Hydraulic Charge Filter Alarm Switch IOLC32 Hydraulic Fluid Level and Temperature Sensor IOLC32 Hydraulic Vacuum Switch IOLC32 Jacks Rotating Bed CCM 10 IOLC31 Jacks Carbody CCMB11...

Page 84: ...4 VDC Closed P1 11 IDF3 Mast Cylinder Extend Switch 0 VDC Open 24 VDC Closed P1 12 IDF4 Mast Cylinder Retract Switch 0 VDC Open 24 VDC Closed P1 13 ID5 A C Heater Switch 0 VDC Open 24 VDC Closed P1 14 UE Battery Power for Control Module Outputs 24 VDC P1 15 No Connection P1 16 CAN2_L CAN Bus D Low Not Applicable P1 17 CAN2_H CAN Bus D High Not Applicable P1 18 No Connection P1 19 No Connection P1 ...

Page 85: ...ction P1 34 IMID2 Module Identifier Input from cab ground bus bar 0 VDC P1 35 ID7 Engine Run Switch 0 VDC Open 24 VDC Closed P1 36 ID8 Travel Speed Switch 0 VDC Open 24 VDC Closed P1 37 No Connection P0 38 IACV15 Left Travel Pedal option 1 4 to 5 VDC Rev 5 to 8 6 VDC FWD P0 39 IACV16 Right Travel Pedal option 1 4 to 5 VDC Rev 5 to 8 6 VDC FWD P1 40 IB RTCp Real Time Clock Power Supply 3 6 VDC P0 4...

Page 86: ...nsor A Drum 2 Proximity Sensor B 24 VDC PD 6 ODH1A3 Power Bus Lower Boom Point Block Up Limit Switch Lower Boom Point Block Up Slow Down Switch 24 VDC PD 7 ODH1A2 Power to Main Left Strut Collapse Solenoid 24 VDC PD 8 ODH1A1 Power Bus Left Strap Load Link Right Strap Load Link 24 VDC PD 9 IDF1 Drum 2 Proximity Sensor A 0 VDC Open 22 VDC Closed PD 10 IDF2 Drum 2 Proximity Sensor B 0 VDC Open 22 VDC...

Page 87: ...nt Confirm 0 VDC Not Installed 24 VDC Installed PD 29 GND Ground from load center 0 VDC 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 0 VDC PD 35 ID7 Luffing Jib Maximum Angle Limit Switch 0 VDC Open 24 VDC Closed PD 36 ID8 Luffing Jib Minimum Angle Limit Switc...

Page 88: ...ble Future Expansion 0 VDC PD 10 IDF2 Not Used For Possible Future Expansion 0 VDC PD 11 IDF3 Not Used For Possible Future Expansion 0 VDC PD 12 IDF4 Not Used For Possible Future Expansion 0 VDC PD 13 ID5 Lower Boom Point Block Up Limit Switch 1 0 VDC Open 22 VDC Closed PD 14 UE Control Module Battery Power 24 VDC PD 15 No Connection PD 16 No Connection PD 17 No Connection PD 18 No Connection PD 1...

Page 89: ... PD 34 IMID2 Module Identifier Input ground from load center 0 VDC PD 35 ID7 EUBP Block Up Limit Switch 1 0 VDC Open 24 VDC Closed PD 36 ID8 EUBP Block Up Limit Switch 2 0 VDC Open 24 VDC Closed PD 37 IACV14 EUBP Wind Speed Sensor 0 to 20 mA PD 38 IACV15 Lower Boom Point Load Link 0 VDC Open 24 VDC Closed PD 39 IACV16 Not Used For Possible Future Expansion 0 VDC PD 40 No Connection PD 41 No Connec...

Page 90: ...9 IDF1 Drum 2 Proximity Sensor A 0 VDC Open 22 VDC Closed PD 10 IDF2 Drum 2 Proximity Sensor B 0 VDC Open 22 VDC Closed PD 11 IDF3 Drum 1 Proximity Sensor A 0 VDC Open 22 VDC Closed PD 12 IDF4 Drum 1 Proximity Sensor B 0 VDC Open 22 VDC Closed PD 13 ID5 Upper and Lower Boom Point Block Up Limit Switches 0 VDC Open 22 VDC Closed PD 14 UE Control Module Battery Power 24 VDC PD 15 ODH2A8 Power Bus Wi...

Page 91: ...Installed PD 29 GND Ground from load center 0 VDC 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 No Connection PD 35 No Connection PD 36 No Connection PD 37 IACV14 Wind Speed Sensor 0 to 20 mA PD 38 IACV15 Upper Boom Point Load Pin 0 VDC Open 24 VDC Closed PD 39 IACV16 Not Used For Possible Future Expansion 0 VDC P...

Page 92: ...e Expansion 0 VDC PC1 14 UE Control Module Battery Power 24 VDC PC1 15 OPH3A25 Right Front Jack Extend Solenoid 0 VDC Off 24 VDC On PC1 16 CAN2_L CAN Bus C Low Not Applicable PC1 17 CAN2_H CAN Bus C High Not Applicable PC1 18 CAN4_L CAN Bus J Low Not Applicable PC1 19 CAN4 H CAN Bus J High Not Applicable PC1 20 IMID1 Module Identifier Input from ground stud on rotating bed 0 VDC PC1 21 IDF03 VPC L...

Page 93: ...2 1 PGND1 Ground from ground stud on rotating bed 0 VDC PC2 2 ODH3A03 Rear Frame Pusher Pin Extend Solenoid 0 VDC Off 24 VDC On PC2 3 No Connection PC2 4 ODH3A08 Power Bus Mast Arm NC Limit Switch VPC Actuator Extend Pressure Transducer Accessory Systems Pressure Transducer 24 VDC PC2 5 ODH3A05 Not Used For Possible Future Expansion 0 VDC PC2 6 ODH3A13 Left Track Drum 1 Diverter Solenoid 0 VDC Off...

Page 94: ...y Power for Control Module Outputs 24 VDC PC2 21 ODH3A02 Not Used For Possible Future Expansion 0 VDC PC2 22 ODH3A04 Rear Frame Pin Pusher Retract Solenoid 0 VDC Off 24 VDC On PC2 23 No Connection PC2 24 ODH3A11 Cab Tilt Up Solenoid 0 VDC Off 24 VDC On PC2 25 ODH3A12 Cab Tilt Down Solenoid 0 VDC Off 24 VDC On PC2 26 ODH3A16 Drum 3 Drum 2 Diverter Solenoid 0 VDC Off 24 VDC On PC2 27 No Connection P...

Page 95: ...to 85 of Input Voltage Over Tooth 2 to 10 of Input Voltage Over Gap PC1 10 IACV20 Ambient Air Temperature Sensor optional 0 to 10 VDC PC1 11 IACV16 Boom Angle Sensor 2 to 20 mA 90 µA PC1 12 IACV18 Not Used For Possible Future Expansion 0 VDC PC1 13 IACV14 Live Mast Angle Sensor 2 to 20 mA 90 µA PC1 14 UE Control Module Battery Power 24 VDC PC1 15 OPH3A25 Drum 2 Left Motor Control 0 VDC Open 24 VDC...

Page 96: ...nsor 5 025 VDC 0 1 005 VDC Offset PC1 40 IACV12 Rotating Bed Level Sensor 5 025VDC 0 1 005VDC Offset PC1 41 OS85H 8 5 VDC Power to Drums 3 and 5 Motor Speed Sensors 8 5 VDC PC1 42 OPH3A26 Drum 2 Right Motor Control 0 VDC Open 24 VDC Closed PC2 1 PGND1 Ground from rotating bed ground stud 0 VDC PC2 2 ODH3A03 Drums 1 and 2 6 Camera Lights 0 VDC Off 24 VDC On PC2 3 ODH3A09 Drum 6 Right Brake Release ...

Page 97: ... Future Expansion 0 VDC PC2 23 ODH3A10 Power Bus Drum 5 Minimum Bail Normally Closed Limit Switch Mast Position Limit Switch Fixed Mast Cylinder System Pressure Transducer Drum 5 Pawl Normally Open Limit Switch 24 VDC PC2 24 ODH3A11 Diesel Heater 0 VDC Off 24 VDC On PC2 25 ODH3A12 Drum 5 Pawls In Solenoid 0 VDC Off 24 VDC On PC2 26 ODH3A16 Power Bus Rotating Bed Level Sensor Drum 3 Minimum Bail No...

Page 98: ...r 55 to 85 of Input Voltage Over Tooth 2 to 10 of Input Voltage Over Gap PB1 22 No Connection PB1 23 No Connection PB1 24 No Connection PB1 25 IACV11 Not Used For Possible Future Expansion 0 VDC PB1 26 OS85L Left and Right Travel Motor Speed Sensors Ground 0 VDC PB1 27 KL15 Control Module Ignition Power from relay K6 0 VDC Open 24 VDC Closed PB1 28 OPH3A27 Left Rear Carbody Jack Raise Solenoid 0 V...

Page 99: ...DC PB2 12 OPH3A24 Left Front Carbody Jack Lower Solenoid 0 VDC Off 24 VDC On PB2 13 ODH3A01 Power Bus Right Crawler Grease Pressure Switch Left Crawler Grease Pressure Switch 24 VDC PB2 14 ODH3A07 Right Crawler Carbody Pin Puller Retract Solenoid 0 VDC Off 24 VDC On PB2 15 ODH3A06 Right Crawler Carbody Pin Puller Extend Solenoid 0 VDC Off 24 VDC On PB2 16 ODH3A14 Not Used For Possible Future Expan...

Page 100: ...10 CAN1 H CAN Bus A High Not Applicable PA1 11 UB Supply Power for Control Module Outputs 24 VDC PA1 12 UE Control Module Battery Power 24 VDC PA1 13 ID03 Limit Bypass Switch 0 VDC Open 24 VDC Closed PA1 14 ID04 Cab Tilt Up Switch 0 VDC Open 24 VDC Closed PA1 15 ID05 Cab Tilt Down Switch 0 VDC Open 24 VDC Closed PA1 16 ID06 Camera Light Switch 0 VDC Open 24 VDC Closed PA1 17 No Connection PA1 18 N...

Page 101: ...8 OPH6A04 Right Front and Rear Travel Motors Control 0 VDC Off 24 VDC On PB1 9 IMID1 Module Identifier Input from ground stud on rotating bed 0 VDC PB1 10 CAN1 H CAN Bus B High No Connection PB1 11 UB Supply Power for Control Module Outputs 24 VDC PB1 12 UE Control Module Battery Power 24 VDC PB1 13 ID03 Not Used For Possible Future Expansion 0 VDC PB1 14 ID04 Not Used For Possible Future Expansio...

Page 102: ...D04 Drum 6 Minimum Bail Limit Switch 0 VDC Open 24 VDC Closed PC1 15 ID05 APU Connected 0 VDC Not Installed 24 VDC Installed PC1 16 ID06 Swing Grease Pressure Switch 0 VDC Open 24 VDC Closed PC1 17 IDF15 Swing Motor Speed Sensor 55 to 85 of Input Voltage Over Tooth 2 to 10 of Input Voltage Over Gap PC1 18 IMID2 Module Identifier Input from ground stud on rotating bed 0 VDC PC1 19 CAN1_L CAN Bus C ...

Page 103: ...PC2 14 IACV20 Not Used For Possible Future Expansion 0 VDC PC2 15 ODH3A01 Front Swing Travel LMI Alarm 0 VDC Off 24 VDC On PC2 16 ODH3A06 Not Used For Possible Future Expansion 0 VDC PC2 17 ODH3A09 Swing Bearing Auto Lube 0 VDC Off 24 VDC On PC2 18 OPH3A14 Drum 3 Right Side Motor Control 55 to 85 of Input Voltage Over Tooth 2 to 10 of Input Voltage Over Gap PC2 19 OPH3A17 Right Mast Cylinder Press...

Page 104: ...ot Used For Possible Future Expansion 0 VDC PC1 15 ID05 Not Used For Possible Future Expansion 0 VDC PC1 16 ID06 Not Used For Possible Future Expansion 0 VDC PC1 17 IDF15 Not Used For Possible Future Expansion 0 VDC PC1 18 IMID2 Module Identifier Input from ground stud on rotating bed 0 VDC PC1 19 CAN1_L CAN Bus C Low Not Applicable PC1 20 UB Supply Power for Control Module Outputs 24 VDC PC1 21 I...

Page 105: ...00 psi PC2 15 ODH3A01 Power Bus Drums 1 3 4 and 5 Pressure Transducers VPC Actuator Retract Pressure Transducer 24 VDC PC2 16 ODH3A06 VPC Alarm 0 VDC Off 24 VDC On PC2 17 ODH3A09 VPC Rear Warning Lights 0 VDC Off 24 VDC On PC2 18 OPH3A14 Right Rear Jack Extend Solenoid 0 VDC Off 24 VDC On PC2 19 OPH3A17 Not Used For Possible Future Expansion 0 VDC PC2 20 UB Supply Power for Control Module Outputs ...

Page 106: ...Connection PC1 15 No Connection PC1 16 ID06 VPC Tray Max In Switch 0 VDC Open 24 VDC Closed PC1 17 IDF15 Not Used For Possible Future Expansion 0 VDC PC1 18 No Connection PC1 19 CAN1_L CAN Bus C Low Not Applicable PC1 20 UB Supply Power for Control Module Outputs 24 VDC PC1 21 ID07 Hydraulic Vacuum Switch 0 VDC Open 24 VDC Closed PC1 22 ID08 Drum 4 Pawl Limit Switch 0 VDC Open 24 VDC Closed PC1 23...

Page 107: ...Filter Alarm Switch Hydraulic Fluid Level Sensor VPC Tray Max In Limit Switch VPC Tray Max Out Limit Switch Gantry Limit Switch 24 VDC PC2 16 ODH3A06 Power Bus Hydraulic Vacuum Switch Cooler Fan Pressure Transducer 24 VDC PC2 17 ODH3A09 Front Swing Travel LMI Alarm 0 VDC Off 24 VDC On PC2 18 OPH3A14 Drum 1 6 Pump 1 0 VDC Off 24 VDC On PC2 19 OPH3A17 Left Travel Drum 1 Pump 3 0 VDC Off 24 VDC On PC...

Page 108: ...s 24 VDC PC1 12 UE Control Module Batter Power 24 VDC PC1 13 No Connection PC1 14 ID04 Gantry Limit Switch 0 VDC Open 24 VDC Closed PC1 15 ID05 VPC Tray Max Out Limit Switch 0 VDC Open 24 VDC Closed PC1 16 No Connection PC1 17 IDF15 Drum 4 Motor Speed Sensor 55 to 85 of Input Voltage Over Tooth 2 to 10 of Input Voltage Over Gap PC1 18 No Connection PC1 19 CAN1_L CAN Bus C Low Not Applicable PC1 20...

Page 109: ...4 VDC PC2 12 OS85H 8 5 VDC Power to Drum 4 Motor Speed Sensor 8 5 VDC PC2 13 No Connection PC2 14 No Connection PC2 15 ODH3A01 Not Used For Possible Future Expansion 0 VDC PC2 16 ODH3A06 Not Used For Possible Future Expansion 0 VDC PC2 17 ODH3A09 Engine AC Heat Relay 0 VDC Off 24 VDC On PC2 18 OPH3A14 Drum 4 Pump 5 0 VDC Off 24 VDC On PC2 19 OPH3A17 Drum 5 Pump 6 0 VDC Off 24 VDC On PC2 20 UB Supp...

Page 110: ...ible Future Expansion 0 VDC PC1 14 ID04 Not Used For Possible Future Expansion 0 VDC PC1 15 ID05 Not Used For Possible Future Expansion 0 VDC PC1 16 No Connection PC1 17 IDF15 Not Used For Possible Future Expansion 0 VDC PC1 18 IMID2 Module Identifier Input from ground stud on rotating bed 0 VDC PC1 19 CAN1_L CAN Bus C Low Not Applicable PC1 20 UB Supply Power for Control Module Outputs 24 VDC PC1...

Page 111: ...ump Solenoid 0 VDC Off 24 VDC On PC2 20 UB Supply Power for Control Module Outputs 24 VDC PC2 21 OS85L Not Used For Possible Future Expansion 0 VDC PC2 22 IACV21 VPC MAX Beam Max Out 24 VDC PC2 23 IACV22 Not Used For Possible Future Expansion 0 VDC PC2 24 ODH3A03 Not Used For Possible Future Expansion 0 VDC PC2 25 ODH3A05 Not Used For Possible Future Expansion 0 VDC PC2 26 ODH3A08 Not Used For Pos...

Page 112: ...C PC1 23 ID09 Not Used For Possible Future Expansion 0 VDC PC1 24 ID10 Not Used For Possible Future Expansion 0 VDC PC1 25 No Connection PC1 26 No Connection PC1 27 No Connection PC1 28 IMID4 Module Identifier Input from ground stud on rotating bed 0 VDC PC1 29 No Connection PC2 1 ID12 Not Used For Possible Future Expansion 0 VDC PC2 2 ID13 Not Used For Possible Future Expansion 0 VDC PC2 3 ID14 N...

Page 113: ...d For Possible Future Expansion 0 VDC PC2 20 UB Supply Power for Control Module Outputs 24 VDC PC2 21 No Connection PC2 22 IACV21 VPC MAX Beam Level Sensor pitch 5 025 VDC 0 1 005 VDC Offset PC2 23 IACV22 VPC MAX Beam Level Sensor roll 5 025 VDC 0 1 005 VDC Offset PC2 24 ODH3A03 VPC Actuator Pin Retract 0 VDC Off 24 VDC On PC2 25 No Connection PC2 26 ODH3A08 VPC MAX Actuator Encoder 0 VDC Off 24 V...

Page 114: ...R e f e r e n c e O n l y ELECTRICAL SYSTEM MLC650 SERVICE MAINTENANCE MANUAL 3 52 Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 115: ...he Mast Angle 4 6 Fleeting Sheave Maintenance 4 7 General 4 7 Specifications 4 7 Inspection 4 7 Replacement 4 7 Activation 4 7 Adjustment 4 7 Operation 4 7 Boom Top Electrical Schematic 4 8 Luffing Jib Top Electrical Schematic 4 9 Boom Wind Cap Electrical Schematic 4 10 Strap Inspection and Maintenance 4 11 Inspection 4 11 Frequent Inspection 4 11 Periodic Inspection 4 11 Cranes Not in Regular Use...

Page 116: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 4 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 117: ...ity Indicator RCL RCI display and do not require adjustment BOOM STOP LIMIT SWITCH When the boom is at a position other than the maximum allowable angle the limit switch in the boom stop switch unit 1 Figure 4 2 is closed providing a continuous 24 VDC signal to the ID07 input on the IOLC30 control module If the boom reaches the maximum allowable angle for your boom jib configuration the limit swit...

Page 118: ...imum switch boom angle is reached the fault alarm is activated and the boom maximum up icon appears in the information screen of the main display To correct the fault once it is activated lower the boom The fault cannot be bypassed Maintenance At least once weekly verify that the automatic boom stop stops the boom at the specified maximum switch boom angle If it does not replace any worn or damage...

Page 119: ...t Bottom Chord 7 Spring Washer 16 Digital Level Angle 8 Spring 17 Blue Jumper Wire View D LIMIT SWITCH WIRING Receptacle Switch Terminals Function Black 13 Ground Green 14 Maximum Angle White 21 24 VDC Supply Blue 14 22 Jumper View C RIGHT SIDE OF BOOM BUTT Maximum Switch Boom Angle Digital Level Angle 16 84 5 Boom only with VPC MAX 73 57 86 4 Boom with Luffing Jib and without VPC MAX 75 47 86 4 B...

Page 120: ...tops before reaching the specified angle perform the following a Loosen the jam nut 3 b Turn the adjusting rod 2a or 2b all the way into the coupling 4 c Boom up slowly until the boom reaches the specified angle d Turn the adjusting rod out against the stop plate on the boom butt 1 until the limit switch 5 clicks open e Tighten the jam nut 7 If the boom reaches the specified angle before it stops ...

Page 121: ...en the boom is raised to 78 the boom stop spring 4 in the boom stop tube 5 begins to compress see View A 2 As the boom is raised higher spring compression increases to exert greater force against the boom 3 If the boom is raised to 88 the boom stop spring becomes fully compressed and the boom stop tube provides a physical stop see View B NOTE Struts 3 do not require adjustment WARNING Falling Atta...

Page 122: ...uld not require periodic adjustment Adjustment is required if parts are replaced Adjusting the Mast Angle See Figure 4 5 for the following procedure 1 Lower the mast to the transport position 2 Place a digital protractor level 1 on the left mast leg 2 and note the mast angle 3 Note the mast angle on the main display Information screen 4 Verify the angles noted in step 2 and step 3 are within 1 of ...

Page 123: ...the new grease gun clockwise onto the fleeting sheave fitting by hand Do not overtighten the grease gun Damage to the grease gun can occur when excessive tightening force is applied to the plastic canister Activation To activate the grease gun turn the dial on the grease gun canister head to a minimum of 1 and to a maximum of 12 Adjustment The dial indicator on the top of the grease gun can be set...

Page 124: ...R e f e r e n c e O n l y BOOM MLC650 SERVICE MAINTENANCE MANUAL 4 8 Published 09 09 16 Control 229 09 BOOM TOP ELECTRICAL SCHEMATIC FIGURE 4 7 ...

Page 125: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 4 9 MLC650 SERVICE MAINTENANCE MANUAL BOOM 4 4 4 4 4 LUFFING JIB TOP ELECTRICAL SCHEMATIC FIGURE 4 8 ...

Page 126: ...R e f e r e n c e O n l y BOOM MLC650 SERVICE MAINTENANCE MANUAL 4 10 Published 09 09 16 Control 229 09 BOOM WIND CAP ELECTRICAL SCHEMATIC FIGURE 4 9 ...

Page 127: ...curred If the boom and or jib has come into contact with another object for example power lines building another crane If the boom or jib has been struck by lightning Frequent Inspection Visually inspect all straps once each work shift for obvious damage that poses an immediate hazard Pay particular attention to areas where wear and other damage is likely to occur Look for straps that are disconne...

Page 128: ...ition Reference Allowable Tolerance or Deviation Corrective Action Dent Figure 4 11 View A 3 of strap thickness Monitor condition 3 of strap thickness Remove strap from service Crack or Break Figure 4 11 View B None Remove strap from service Kink Figure 4 11 View C None Remove strap from service Corrosion or Abrasion Figure 4 12 3 of strap cross sectional area Sandblast and paint to maintain conti...

Page 129: ...he strap s cross sectional area paint the strap to maintain a continuous protective coating If the reduction is 3 or more of the strap s cross sectional area remove the strap from service Dent Depth of Dent Kink Do not straighten or bend into alignment Remove from service Crack or Break Do not weld Strap cannot be repaired Remove from service View A View B View C FIGURE 4 11 Not Acceptable Abrasio...

Page 130: ...If the deviation from flat is greater than the maximum allowed in Table 4 3 remove the strap from service 6 Remove the line Turn the strap over 7 Repeat step 1 through step 5 above Table 4 3 Strap Flatness Strap Length L Maximum Deviation 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 6 4 mm 0 250 in 9 1 to 12 2 m 30 to 40 ft 9 5 m...

Page 131: ...chemicals salt water spray etc Inspect straps in storage for corrosion monthly If necessary sandblast to remove corrosion and repaint to maintain a continuous protective surface If corrosion is not removed the strap will need to be removed from service because the reduction in thickness will exceed the maximum allowed A full periodic inspection is required for straps returned to service from stora...

Page 132: ... Dents Length Part Number Length Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flatness Other mm ft Straightness Dents Length Part Number Length Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flatness Other mm ft Straightness Dents Length Part Number Length Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flatness Other mm ft Straightness Dents Length Part Number Length Kink...

Page 133: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 4 17 MLC650 SERVICE MAINTENANCE MANUAL BOOM 4 4 4 4 4 NOTES SKETCHES AND PHOTOGRAPHS ...

Page 134: ...C650 SERVICE MAINTENANCE MANUAL 4 18 Published 09 09 16 Control 229 09 LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 2279 at the end of this section for lattice section inspection and lacing replacement instructions ...

Page 135: ...rum 2 Hoisting Hydraulic Schematic 5 15 Drum 2 Lowering Hydraulic Schematic 5 16 Drum 2 Electrical Schematic 5 18 Drum 3 Whip Hoist 5 19 Drum 3 Brake Overview 5 19 Drum 3 Brake Operation 5 19 Drum 3 Motor Loop Flushing 5 19 Drum 3 Hoisting Operation 5 20 Drum 3 Lowering Operation 5 20 Drum 3 Minimum Bail Limit 5 21 Lowering Limit Switch Replacement 5 21 Weekly Maintenance 5 21 Drum 3 Hoisting Hydr...

Page 136: ...ydraulic Schematic 5 46 Drum 6 Electrical Schematic 5 48 Gearboxes 5 49 Gear Oil Specifications 5 49 Oil Analysis 5 49 Periodic Maintenance 5 49 Weekly 5 49 Monthly or 200 Hours 5 49 Every 6 Months or 1 000 Hours 5 49 Quick Drain Valve 5 49 Changing the Gearbox Oil 5 49 Drum 1 and Drum 2 5 49 Drum 3 5 52 Drum 4 5 54 Drum 5 5 56 Drum 6 5 58 Drum Motor Speed Sensor 5 60 Speed Sensor Replacement 5 60...

Page 137: ...Rope Lubrication 5 75 Maintain a Wire Rope Condition Report 5 75 Required Inspection Intervals 5 75 Wire Rope Care and Replacement Guidelines 5 75 Daily Inspection 5 75 Periodic Comprehensive Inspection 5 77 Determining the Frequency of Inspection 5 77 Replacement Criteria 5 77 Reduction in the Rope Diameter 5 77 Broken Rope Wires 5 78 Rope That Has Been Idle a Month or More 5 79 Distributing Wire...

Page 138: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 5 iv Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 139: ... 1 selector solenoid valve 2 and the drum 1 drum 6 selector solenoid valve 3 located in the accessory valve manifold 1 are de energized The drum 6 park switch must be in the ON position for this to occur With the selector solenoid valves 2 and 3 de energized the pumps 1 and 3 charge pressure diverter valves 4 and 8 are in the default position allowing charge pressure from pumps 1 and 3 to be prese...

Page 140: ... located in the accessory valve manifold The energized solenoid valve routes hydraulic fluid to the pilot control of the left travel drum 1 diverter valve 9 The diverter valve shifts position allowing the main hydraulic fluid from pump 3 to flow to the double manifold where it combines with the fluid from pump 1 The combined fluid then flows to the left and right hydraulic motors Hydraulic fluid f...

Page 141: ...ide solenoids of pumps 1 and or 3 EDCs The PWM signal is in proportion to the speed commanded by the joystick Increasing the PWM duty cycle increases the pump swashplate angle which increases the hydraulic flow from the B side of the pump s From the pump s the flow is routed through the diverter valves 9 and 10 the double manifold 11 and then into the A side of the right hydraulic motor 16 and the...

Page 142: ... remaining on the first layer e Repeat the adjustment procedure if necessary 2 Make sure the return springs 12 have sufficient tension to hold the rollers firmly against the drum If necessary adjust spring tension as follows a Adjust the eyebolt 13 of each spring to the 35 mm 1 4 in dimension see View D b Tighten the two eyebolt jam nuts 14 to lock adjustment 3 Adjust the lever kickstand as follow...

Page 143: ...er 2 Roller 3 Capscrew 4 Drum 5 Jam Nut 6 Adjusting Screw 7 Screw qty 4 8 Limit Switch 9 Limit Switch Cover 10 Cable Restraint Connector 11 Mounting Tab 12 Return Spring qty 3 13 Eyebolt qty 3 14 Eyebolt Jam Nut qty 6 15 Cotter Pin 16 Nut 17 Nylon Tube Three to Four Wraps of Wire Rope Remaining on Drum View D View B View C 35 mm 44 mm View A Jumper Wire ...

Page 144: ...R e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 6 Published 09 09 16 Control 229 09 Drum 1 Hoisting Hydraulic Schematic FIGURE 5 2 See Table 5 1 Legend for Figure 5 2 and Figure 5 3 ...

Page 145: ...r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 7 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 1 Lowering Hydraulic Schematic FIGURE 5 3 See Table 5 1 Legend for Figure 5 2 and Figure 5 3 ...

Page 146: ... Diverter Valve directional control 9 Left Travel Drum 1 Diverter Valve directional control 10 Drum 1 Drum 6 Diverter Valve directional control 11 Double Manifold for diverter control 12 Drum Hoist Gearbox and Brake Assembly 13 Charge Pressure Check Valve 1 7 bar 25 psi 14 Drum 1 Left Hydraulic Motor variable 160 cc 15 Drum 1 Brake Pressurized disengaged 16 Drum 1 Right Hydraulic Motor variable 16...

Page 147: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 9 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 1 Electrical Schematic FIGURE 5 4 ...

Page 148: ...ps 2 and 4 to be present at the drum brake release solenoid valve 18 During drum 1 operation the CCM 10 control module energizes the right travel drum 2 selector solenoid valve The right travel park switch must be in the ON position for this to occur When energized the solenoid valve routes hydraulic fluid to the pilot control of the right travel drum 2 diverter valve 5 and the pump 4 charge press...

Page 149: ...draulic fluid from pump 4 to flow to the double manifold where it combines with the fluid from pump 2 The combined fluid then flows to the left and right hydraulic motors Hydraulic fluid from the right travel drum 2 selector solenoid valve also flows to the pilot control of the pump 4 charge pressure diverter valve 2 causing the valve to shift When in this position charge pressure from pump 4 is p...

Page 150: ...the right travel drum 2 selector solenoid valve also flows to the pilot control of the pump 4 charge pressure diverter valve 2 causing the valve to shift When in this position charge pressure from pump 4 is present at the charge pressure check valve 10 If the main pump pressure drops to less than 0 35 bar 5 psi of the charge pressure the check valve opens allowing the pumps 2 and 4 charge pressure...

Page 151: ... connector 10 to the limit switch d Install the limit switch cover 2 Using the screws 7 install the limit switch Adjustment NOTE The limit switch 8 must stop the drum 4 when a minimum of three to four wraps of rope remain on the first layer 1 Adjust the limit switch as follows a Make sure the rollers 2 contact the drum see Views A and D b Turn the adjusting screw 6 until the 44 mm 1 7 in dimension...

Page 152: ...cription 1 Lever 2 Roller 3 Capscrew 4 Drum 5 Jam Nut 6 Adjusting Screw 7 Screw qty 4 8 Limit Switch 9 Limit Switch Cover 10 Cable Restraint Connector 11 Mounting Tab 12 Return Spring qty 3 13 Eyebolt qty 3 14 Eyebolt Jam Nut qty 6 3 to 4 Wraps of Wire Rope Remaining on Drum View D View B View C 35 mm 44 mm View A Jumper Wire ...

Page 153: ... e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 15 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 2 Hoisting Hydraulic Schematic FIGURE 5 6 See Table 5 2 Legend for Figure 5 6 and Figure 5 7 ...

Page 154: ... e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 16 Published 09 09 16 Control 229 09 Drum 2 Lowering Hydraulic Schematic FIGURE 5 7 See Table 5 2 Legend for Figure 5 6 and Figure 5 7 ...

Page 155: ...um 3 psi 8 Drum 2 Drum 3 Diverter Valve directional control 9 Double Manifold for Diverter Control 10 Charge Pressure Check Valve 1 7 bar 25 psi 11 Right Travel Drum 2 Selector Solenoid Valve 12 Drum 2 Drum 3 Selector Solenoid Valve 13 Drum Hoist Gearbox and Brake Assembly 14 Drum 2 Left Hydraulic Motor variable 160 cc 15 Drum 2 Brake Pressurized disengaged 16 Drum 2 Right Hydraulic Motor variable...

Page 156: ...R e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 18 Published 09 09 16 Control 229 09 Drum 2 Electrical Schematic FIGURE 5 8 ...

Page 157: ...ssure present at the charge pressure check valve 5 If the main pump pressure drops to less than 0 35 bar 5 psi of the charge pressure the check valve opens allowing the pump 2 charge pressure fluid to flow to the brake release solenoid valve When the IOLC30 control module receives the un park command from the J2 joystick the IOLC30 control module sends a 24 VDC output to the drum brake release sol...

Page 158: ...osed loop feedback to the control modules The control algorithm uses this feedback to adjust the pump and motor flows while ramping up to and maintaining the speed commanded by the joystick input Drum 3 Lowering Operation See Figure 5 11 and Figure 5 12 for the following To enable the control system to drive the drum 3 pump and motor the switches listed below must be in the stated positions Seat s...

Page 159: ...al wires to the new switch as follows a Remove the switch cover 2 b Connect the electrical wires and tighten the cable restraint connector 4 onto the switch cover c Install the switch cover 2 Using capscrews 5 and washers 6 install the limit switch assembly 1 Adjustment 1 Adjust the rope so that there are three wraps on the first layer of the drum 7 2 Remove the cover 2 from the limit switch assem...

Page 160: ...SERVICE MAINTENANCE MANUAL 5 22 Published 09 09 16 Control 229 09 FIGURE 5 9 Item Description 1 Limit Switch Assembly 2 Cover 3 Fastener qty 4 4 Cable Restraint Connector 5 Capscrew qty 6 6 Washer qty 6 7 Drum 8 Limit Switch Adjustment Screw ...

Page 161: ...m 2 Drum3 Diverter Valve directional control 5 Charge Pressure Check Valve 0 35 bar 5 psi 6 Drum 3 Gearbox and Brake Assembly 7 Hydraulic Motor variable 160 cc 8 Pilot Operated Sequence Valve balanced piston 9 Manually Operated Service Valve 2 position 2 way poppet control 10 Flow Control Valve 6 GPM 11 Loop Flushing Valve 6 GPM at 200 psi 12 Drum Brake Release Solenoid Valve 2 position 4 way dire...

Page 162: ... Drum 2 Drum3 Diverter Valve directional control 5 Charge Pressure Check Valve 0 35 bar 5 psi 6 Drum 3 Gearbox and Brake Assembly 7 Hydraulic Motor variable 160 cc 8 Pilot Operated Sequence Valve balanced piston 9 Manually Operated Service Valve 2 position 2 way poppet control 10 Flow Control Valve 6 GPM 11 Loop Flushing Valve 6 GPM at 200 psi 12 Drum Brake Release Solenoid Valve 2 position 4 way ...

Page 163: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 25 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 3 Electrical Schematic FIGURE 5 12 ...

Page 164: ...tick IOLC32 control module sends a 24 VDC output to the drum brake release solenoid valve energizing the solenoid The solenoid valve shifts position routing hydraulic fluid from the pump 5 to the drum brake piston releasing the brake When the drum brake switch is moved to the ON PARK position the drum park switch is open sending a 0 VDC signal back to the J2 joystick The J2 joystick communicates t...

Page 165: ...ide closed loop feedback to the control modules The control algorithm uses this feedback to adjust the pump and motor flows while ramping up to and maintaining the speeds commanded by the joystick Input Drum 4 Lowering Operation See Figure 5 15 and Figure 5 16 To enable the control system to drive the drum 4 pump and motors the switches listed below must be in the stated positions Seat safety swit...

Page 166: ...the limit switch see View C 6 Remove the cable restraint connector 6 and carefully pull the electrical cable and wires from the limit switch 7 Loosen the screws 10 and remove the limit switch arm 2 from the limit switch shaft 11 Installation 1 Connect the electrical wires to the new limit switch as follows a Remove the limit switch cover 7 b Connect the wires including the jumper wire to the corre...

Page 167: ...e 3 Make sure the electrical cables are clear of all moving parts and that cables are securely fastened with nylon straps 4 Make sure that all plugs are securely fastened Item Description 1 Limit Switch 2 Limit Switch Arm 3 Drum Pawl 4 Drum 5 Screw qty 4 6 Cable Restraint Connector 7 Limit Switch Cover 8 Screw qty 4 9 Limit Switch Head 10 Screw 11 Limit Switch Shaft View A View B View C CABLE NAME...

Page 168: ...or 6 Drum 4 Right Hydraulic Motor variable 160 cc 7 Drum Hoist Gearbox and Brake Assembly 8 Check Valve 0 35 bar 5 psi 9 Loop Flushing Valve 6 GPM at 200 psi 10 Pilot Operated Sequence Valve balanced piston 11 Manually Operated Service Valve 2 position 2 way poppet control 12 Flow Control Valve 6 GPM 13 Drum Brake Release Solenoid Valve 2 position 4 way directional control 14 Drum Brake Pressurize...

Page 169: ...ccumulator 6 Drum 4 Right Hydraulic Motor variable 160 cc 7 Drum Hoist Gearbox and Brake Assembly 8 Check Valve 0 35 bar 5 psi 9 Loop Flushing Valve 6 GPM at 200 psi 10 Pilot Operated Sequence Valve balanced piston 11 Manually Operated Service Valve 2 position 2 way poppet control 12 Flow Control Valve 6 GPM 13 Drum Brake Release Solenoid Valve 2 position 4 way directional control 14 Drum Brake Pr...

Page 170: ...R e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 32 Published 09 09 16 Control 229 09 Drum 4 Electrical Schematic FIGURE 5 16 ...

Page 171: ...odule via the CAN Bus When the CCMC11 control module receives the on park command from the J2 joystick the CCMC11 control module sends a 0 VDC output voltage to the drum brake solenoid valve de energizing the solenoid This causes the brake release valve to return to the default position allowing the fluid in the brake piston to flow through the brake release solenoid valve and back to the tank The...

Page 172: ...p flow The drum 5 motor speed sensor and pump 6 pressure transducer drum 5 psi provide closed loop feedback to the control units The control algorithm uses this feedback to adjust the pump and motor flows while ramping up to and maintaining the speeds commanded by the joystick Drum 5 Pawl Operation See Figure 5 18 and Figure 5 20 The pawl is controlled by the park switch When the drum park is turn...

Page 173: ...to the position shown see View B c Install the screws 8 3 Install the limit switch arm 2 onto the limit switch shaft 11 Do not tighten the screw 10 at this time see View A 4 Using the screws 5 install the limit switch 1 Adjustment 1 Slowly turn the limit switch shaft 11 clockwise as viewed from shaft end until the limit switch clicks open then hold the shaft 2 Adjust the limit switch arm 2 54 from...

Page 174: ...iew C Jumper Wire N O N C CABLE NAME FROM PLUG TO TERMINAL WIRE COLOR SYSTEM I D W1 J1 21 J2 A WHITE N C W1 J1 13 J2 C BLACK N O W1 J1 14 J2 B GREEN INPUT Item Description Item Description 1 Limit Switch 7 Limit Switch Cover 2 Limit Switch Arm 8 Screw qty 4 3 Drum Pawl 9 Limit Switch Head 4 Drum 10 Screw 5 Screw qty 4 11 Limit Switch Shaft 6 Cable Restraint Connector ...

Page 175: ...ump 6 Pressure Transducer drum 5 psi 2 Charge Pressure Check Valve 0 35 bar 5 psi 3 Charge and Brake Manifold Assembly 4 Drum Pawl Actuator 5 Drum Pawl Assembly 6 Pawl Control Manifold 7 Accumulator 8 Hydraulic Motor variable 160 cc 9 Drum Hoist Gearbox and Brake Assembly 10 Drum Brake Pressurized disengaged 11 Pump 9 Pressure Transducer acc systems psi 12 Drum Brake Release Solenoid Valve ...

Page 176: ...essure Transducer drum 5 psi 2 Charge Pressure Check Valve 0 35 bar 5 psi 3 Charge and Brake Manifold Assembly 4 Drum Pawl Actuator 5 Drum Pawl Assembly 6 Pawl Control Manifold 7 Accumulator 8 Hydraulic Motor variable 160 cc 9 Drum Hoist Gearbox and Brake Assembly 10 Drum Brake Pressurized disengaged 11 Pump 9 Pressure Transducer acc systems psi 12 Drum Brake Release Solenoid Valve ...

Page 177: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 39 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 5 Electrical Schematic FIGURE 5 20 ...

Page 178: ...ent at the drum brake release solenoid valve The charge pressure check valve only allows flow from the charge pump when main pump pressure is not present When the CCMC11 control module receives the un park command from the J2 joystick the CCMC11 control module sends a 24 VDC output to the drum brake release solenoid valve energizing the solenoid This causes the solenoid valve to shift position rou...

Page 179: ...ure transducer drum 1 psi provide closed loop feedback The control algorithm uses this feedback to adjust the pump and motor flows while ramping up to and maintaining the speed commanded by the joystick Drum 6 Lowering Operation See Figure 5 23 and Figure 5 24 To enable the control system to drive the drum 6 pump and motor the switches listed below must be in the stated positions Seat safety switc...

Page 180: ... rod retracts moving the drum pawl to the disengaged position When the control system is not powered the drum pawl solenoid valve moves to the center position allowing hydraulic fluid at both ends of the pawl cylinder to return to the tank Spring force holds the pawl in the engaged position Drum 6 Pawl Limit Switch See Figure 5 21 for the following procedures Limit Switch Replacement Removal 1 Lan...

Page 181: ...rew 10 at this time see View A 4 Using the screws 5 install the limit switch 1 Adjustment 1 Slowly turn the limit switch shaft 11 clockwise as viewed from shaft end until the limit switch clicks open then hold the shaft 2 Adjust the limit switch arm 2 40 from the horizontal position see View B 3 Adjust the limit switch position so that it will trip when the pawl is fully disengaged from the drum 4...

Page 182: ... View A CABLE NAME FROM PLUG TO TERMINAL WIRE COLOR SYSTEM I D W1 J1 21 J2 A WHITE N C W1 J1 13 J2 C BLACK N O W1 J1 14 J2 B GREEN INPUT View C Item Description 1 Limit Switch 2 Limit Switch Arm 3 Drum Pawl 4 Drum 5 Screw qty 4 6 Cable Restraint Connector 7 Limit Switch Cover 8 Screw qty 4 9 Limit Switch Head 10 Screw 11 Limit Switch Shaft Jumper Wire N O N C ...

Page 183: ...e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 5 45 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 6 Hoisting Hydraulic Schematic FIGURE 5 22 See Table 5 3 Legend for Figure 5 22 and Figure 5 23 ...

Page 184: ...e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 46 Published 09 09 16 Control 229 09 Drum 6 Lowering Hydraulic Schematic FIGURE 5 23 See Table 5 3 Legend for Figure 5 22 and Figure 5 23 ...

Page 185: ...Diverter Valve directional control 6 Accumulator 7 Drum Pawl Actuator 8 Drum Pawl Assembly 9 Drum Pawl Control Manifold 10 Loop Flushing Valve 6 GPM at 200 psi 11 Drum Brake Release Solenoid Valve 2 position 4 way directional control 12 Pilot Operated Sequence Valve balanced piston 13 Manually Operated Service Valve 2 position 2 way poppet control 14 Flow Control Valve 6 GPM 15 Hydraulic Pump vari...

Page 186: ...R e f e r e n c e O n l y HOISTS MLC650 SERVICE MAINTENANCE MANUAL 5 48 Published 09 09 16 Control 229 09 Drum 6 Electrical Schematic FIGURE 5 24 ...

Page 187: ...val may be adjusted according to the results of oil analysis NOTE It is better to change the oil when the gearbox is warm not hot To prevent harmful contaminants from entering the gearbox thoroughly clean components before disconnecting or connecting them Only fill after the drum assembly is installed into the boom butt The oil level sight glass on drum 1 will read the correct oil level with the b...

Page 188: ...n the inside of the quick drain drainer assembly hose 6 d Connect the quick drain drainer assembly hose to the quick drain valve Make sure the fitting is all the way on so that the poppet inside the valve opens e Connect the quick drain drainer assembly hose to a portable pump either hydraulically powered or hand powered f Slowly pump oil into the gearbox until the oil level is halfway up the oil ...

Page 189: ... SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Drum 1 Item Description 1 Breather Plug 2 Fill Port 3 Dust Cap qty 2 4a Quick Drain Valve 4b Quick Drain Valve radial location 5 Oil Level Sight Gauge 6 Quick Drain Drainer Assembly Hose 7 Drum Guard Assembly Drum 2 View A View B FIGURE 5 26 ...

Page 190: ...the dust cap to the quick drain valve 8 Fill the gearbox with specific oil as follows Manual Fill Procedure very slow process a If not already done remove the breather plug 1 b Add oil through the fill port 2 using an appropriate funnel until the oil level is halfway up the oil level sight gauge 5 Do not overfill c Install the breather plug Power Fill Procedure recommended a If not already done re...

Page 191: ... 09 16 Control 229 09 5 53 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Item Description 1 Breather Plug 2 Fill Port 3 Dust Cap 4 Quick Drain Valve 5 Oil Level Sight Gauge 6 Quick Drain Drainer Assembly Hose Drum 3 View A View B View C FIGURE 5 27 ...

Page 192: ...alve 4b to drain the remaining oil 9 When the draining is finished remove the quick drain drainer assembly hose 10 Fasten the dust caps to the quick drain valves 11 Fill the gearbox with specific oil as follows Manual Fill Procedure very slow process a If not already done remove the breather plug 1 b Add oil through the fill port 2 using an appropriate funnel until the oil level is halfway up the ...

Page 193: ... MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Item Description 1 Breather Plug 2 Fill Port 3 Dust Cap qty 2 4a Quick Drain Valve 4b Quick Drain Valve radial location 5 Oil Level Plug 6 Quick Drain Drainer Assembly Hose 7 Drum Guard Assembly Drum 4 View A View B FIGURE 5 28 ...

Page 194: ...r assembly 6 7 Connect the quick drain drainer assembly 6 to the radial quick drain valve 4b to drain the remaining oil 8 When the draining is finished disconnect the quick drain drainer assembly hose 9 Fasten the dust caps to the quick drain valves 10 Fill the gearbox with specific oil as follows Manual Fill Procedure very slow process a If not already done remove the breather plug 1 b Add oil th...

Page 195: ... 09 5 57 MLC650 SERVICE MAINTENANCE MANUAL HOISTS 5 5 5 Item Description 1 Breather Plug 2 Fill Port 3 Dust Cap qty 2 4a Quick Drain Valve 4b Quick Drain Valve radial location 5 Oil Level Sight Gauge 6 Quick Drain Drainer Assembly Hose Drum 5 View A View B FIGURE 5 29 ...

Page 196: ...drain drainer assembly hose to the quick drain valve 4a see View B 7 When the draining is finished disconnect the quick drain drainer assembly hose 8 Connect the quick drain drainer assembly hose to the radial quick drain valve 4b to drain the remaining oil 9 When the draining is finished remove the quick drain drainer assembly hose 10 Fasten the dust caps to the quick drain valves 11 Fill the gea...

Page 197: ...lfway up the oil level sight gauge 5 Do not overfill g When the gearbox is filled remove the quick drain drainer assembly hose h Fasten the dust cap to the quick drain valve i Install the breather plug 12 Check the oil level after operating the hoist If necessary add oil through the fill port 2 13 Thoroughly clean the quick drain drainer assembly hose and store it in the parts box ...

Page 198: ...rness 10 On motors positioned so that the sensor is located on the underside of the motor perform the following a Make sure that the drain plug is clean then install the drain plug b Thoroughly clean all around the fill plug then remove the fill plug c Fill the motor with filtered hydraulic oil of the correct type d Make sure that the fill plug is clean then install the fill plug 11 Operate the ho...

Page 199: ...tall the new proximity sensor Secure the new proximity sensor with the jam nut 7 Connect the electrical cable to the proximity sensor 8 Insert the bracket into the rectangular slot of the guide wire rope assembly 4 9 Install the cover with the bolts and washers on the bracket Adjustment 1 Loosen the jam nut 5 securing the proximity sensor 1 to the bracket 6 2 Turn the proximity sensor in or out as...

Page 200: ...t plates spring force rotates the actuating lever against the limit switch lever This causes the corresponding limit switch to open the hoist control handle electrical circuits The load drum and the boom mast hoist pumps will stroke to off At the same time the load drum and the boom park brakes apply to stop the load drum from hoisting and the boom from lowering Weekly Maintenance Inspect and test...

Page 201: ...acement Overview The spring should have sufficient strength and stiffness to lift the weight of the chain to force the actuator lever to rotate against the limit switch arm activating the limit switch The switch then sends a signal to a control module which sends a corresponding signal to the appropriate cab display NOTE The spring eyebolt distance and the limit switch arm are preset at the factor...

Page 202: ...ents at boom top is shown Location of components at boom cap EUBP and luffing jib top is similar Item Description Item Description 1 Upper Boom Point 7 Weight 2 Lower Boom Point 8 Weight 3 Block Up Limit Switch Enclosure 9 Lift Plate 4 Block Up Limit Switch Enclosure 10 Weight Ball 5 Chain 11 Load Block 6 Chain 12 Chain Shackle and Pin ...

Page 203: ... adjustment steps until the limit switch operates properly 12 Install the block up limit assembly cover when testing is complete Replacement See Figure 5 34 for the following procedure 1 Remove the block up limit assembly cover 7 2 Remove four mounting screws on the limit switch 8 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the...

Page 204: ... 66 Published 09 09 16 Control 229 09 Item Description 1a Spring 1b Spring 2 Eyebolt qty 2 3 Setscrew 4 Limit Switch Shaft 5 Limit Switch Actuator Arm 6 Actuating Lever 7 Block Up Limit Assembly Cover 8 Limit Switch FIGURE 5 34 Dim C 24 1 mm Dim A 26 4 mm Dim B 22 6 mm ...

Page 205: ...s until the limit switch operates properly 10 Install the block up limit assembly cover when testing is complete Replacement See Figure 5 35 for the following procedure 1 Remove the block up limit assembly cover 6 2 Remove four mounting screws on the limit switch 7 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the limit switch 5 ...

Page 206: ...ng is complete Replacement See Figure 5 36 for the following procedure 1 Remove the block up limit assembly cover 8 2 Remove four mounting screws on the limit switch 9 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the limit switch 5 Remove the cable restraint nut and carefully pull the electrical cable and wires from the limit sw...

Page 207: ...s until the limit switch operates properly 10 Install the block up limit assembly cover when testing is complete Replacement See Figure 5 37 for the following procedure 1 Remove the block up limit assembly cover 6 2 Remove four mounting screws on the limit switch 7 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the limit switch 5 ...

Page 208: ...ntil the limit switch operates properly 10 Install the block up limit assembly cover when testing is complete Replacement See Figure 5 38 for the following procedure 1 Remove the block up limit assembly cover 6 2 Remove four mounting screws on the limit switch 7 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the limit switch 5 Rem...

Page 209: ...hen testing is complete Replacement See Figure 5 39 for the following procedure 1 Remove the block up limit assembly cover 8 2 Remove four mounting screws on the limit switch 9 3 Remove the limit switch cover to expose the internal wiring connections 4 Disconnect the electrical wires inside the limit switch 5 Remove the cable restraint nut and carefully pull the electrical cable and wires from the...

Page 210: ...ller assembly weighs 123 7 kg 272 73 lb 2 Remove the spring load from the pressure roller by tightening the lock nuts 7b against the plates 11 3 Remove the cotter pins 5 and 9 Remove the pins 6 and 10 and the washers 8 4 Remove the pressure roller assembly from the drum assembly 5 Unload the springs by loosening and removing the lock nuts 7b 6 Remove the spring retainer bars 4 7 Remove the old spr...

Page 211: ...ase the tension of the springs by tightening the lock nut 7a Spring Replacement 1 Attach lifting slings from a hoist to the pressure roller assembly The pressure roller assembly weighs 185 7 kg 409 4 lb 2 Remove the spring load from the pressure roller by tightening the lock nuts 7b against the plates 11 3 Remove the cotter pins 5 and 9 Remove the pins 6 and 10 and the washers 8 4 Remove the press...

Page 212: ... 229 09 Item Description 1 Drum 2 Pressure Roller 3 Spring 4 Spring Retainer Bar 5 Cotter Pin 6 Pin 7a Lock Nut 7b Lock Nut 8 Washer 9 Cotter Pin 10 Pin 11 Plate 12 Pressure Roller Arm View A FIGURE 5 41 View B View C Roller Acting on Barrel Roller Acting on Rope Layer Dim B 11 mm Dim A 289 mm Marks ...

Page 213: ... pre assembled lengths of wire rope as supplied from Manitowoc Cranes Do not build lengths from individual components Replace an entire wire rope assembly Do not attempt to rework damaged wire rope or wire rope ends Never electroplate a wire rope assembly Do not weld any wire rope assembly or component unless welding is recommended by the wire rope manufacturer Welding spatter must never be allowe...

Page 214: ...nts and the repetitive pickup points on drums Take special care to observe the boom hoist ropes and rotation resistant ropes for evidence of core failure or other deterioration remove from service Internal deterioration of rotation resistant ropes may not be readily observable Throughout the day observe the wire rope during operation particularly the following Pick up points Sections of the wire r...

Page 215: ...ifts Rope maintenance practices Severity of the environment such as Variation in the temperature Continuous excessive moisture levels Exposure to corrosive chemicals or vapors Subjecting the wire rope to abrasive material Power line contact Exposure to abuse and shock loads such as High velocity movement such as hoisting or swinging a load followed by abrupt stops Suspending loads while traveling ...

Page 216: ...The wire rope must be taken out of service when it has the following number of broken wires See Figure 5 45 for an explanation of lay length Running ropes six randomly broken wires in one lay length or three broken wires in one strand in one lay length Standing ropes pendants more than two broken wires in one lay length in sections beyond the end attachment or more than one broken wire at the end ...

Page 217: ...t water may have entered bearing Grease leaks indicating a faulty seal or water in grease The above problems indicate bearing damage If found the corresponding sheave roller or drum should be disassembled for further inspection New bearings should be installed For sheaves not equipped with grease fittings be sure to pack the new bearings with grease at assembly For steel sheaves check the depth wi...

Page 218: ...but are packed with grease at assembly Repack the bearings of these sheaves with CraneLUBE EP 2 grease when the sheaves are overhauled Due to application and design variations it is not possible to give specific grease repacking intervals or the life expectancy of the components Make sure the sheaves drums and rollers are properly lubricated according to the instructions in the lubrication guide p...

Page 219: ... 63 50 8 1 94 16 5 8 631055 500 1 19 69 447 17 60 47 1 85 22 7 8 631067 500 1 19 69 450 9 17 75 50 1 97 19 3 4 631529 508 20 431 8 17 00 76 2 3 25 1 631519 584 2 23 511 20 13 57 2 2 25 22 7 8 631520 631084 584 2 23 511 20 13 63 5 2 50 22 7 8 A00083 631102 584 2 23 511 20 13 63 5 2 50 25 1 631082 27 00 685 8 23 00 584 2 3 00 76 2 1 25 631103 A00051 631096 27 00 685 8 23 00 584 2 3 00 76 2 1 18 28 A...

Page 220: ...to structural failure of load block or hook and weight ball Only use a load block or a hook and weight ball that has a capacity equal to or greater than the load to be handled Do not remove or deface the nameplate Figure 5 50 that is attached to the load blocks and hook and weight balls See Section 4 of the Operator Manual for recommended sling angles and capacity restrictions when the load block ...

Page 221: ...bearings are damaged Side loading This can cause the swivel to turn freely in one spot and to lockup in another This condition can also be checked by checking the gap 4c Figure 5 51 between the barrel and shank To check the swivel must be removed from the weight ball If the gap is wide on one side and closed on the other side damage is present NOTE The gap between the barrel and the shank is norma...

Page 222: ...ing one or more of the following methods Dye penetrant test MAG particle test Ultrasonic test X ray WARNING Falling Load Hazard To prevent the load from dropping 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 Make sure that the hook latch does not support any part of the load Make sure th...

Page 223: ... 6 4 Swing Drive System 6 5 Planetary Swing Drive 6 5 Swing Adapter Frame 6 5 Planetary Swing Drive Gear Oil 6 6 Gear Oil Specifications 6 6 Oil Analysis 6 6 Periodic Maintenance 6 6 Weekly 6 6 Monthly or 200 Hours 6 6 Every 6 Months or 1 000 Hours 6 6 Quick Drain Valve 6 6 Changing the Planetary Swing Drive Oil 6 6 Non VPC and Non VPC Max Planetary Swing Drives 6 6 VPC Planetary Swing Drives 6 7 ...

Page 224: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 6 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 225: ...ake is a spring applied hydraulically released brake system located between each swing motor and its corresponding planetary drive If the brake hydraulic pressure or electrical control is lost the brake is applied by spring force The swing brake release system uses charge pressure from the swing pump supplied to the swing brake solenoid valve The brake release pressure must be at least 18 bar 261 ...

Page 226: ... pressure transducer swing left psi provide closed loop feedback to the control modules CCM 10 and IOLC30 Swing Right When the J1 joystick is moved to the right the joystick sends a swing right command to the IOLC33 control module via the CAN Bus The IOLC33 control module then ramps up the PWM duty cycle to the proportional solenoid B in the swing pump EDC to move the pump swashplate to a position...

Page 227: ... FIGURE 6 1 Item Description 1 Variable Displacement Hydraulic Pump 100 cc 2 Pump 8 Port A Pressure Transducer swing left psi 3 Suction Manifold 4 Triple Swing Manifold 5 Adapter Frame Valve Assembly 6 Swing Brake Solenoid Valve 7 Fixed Displacement Hydraulic Motor 75 cc 8 Gearbox and Brake Assembly 9 Pump 8 Port B Pressure Transducer swing right psi ...

Page 228: ...R e f e r e n c e O n l y SWING SYSTEM MLC650 SERVICE MAINTENANCE MANUAL 6 4 Published 09 09 16 Control 229 09 Swing Electrical Schematic FIGURE 6 2 ...

Page 229: ...gear causing the adapter frame assembly to rotate relative to the carbody See Figure 6 4 for the following Cranes without VPC MAX option 1 have two planetary swing drives mounted to the adapter frame Cranes with VPC MAX option 2 have three planetary swing drives mounted to the adapter frame FIGURE 6 3 Item Description 1 Oil Level Sight Gauge 2 Breather Filler Cap 3 Oil Expansion Tank 4 Oil Filler ...

Page 230: ...tary swing drive gearbox is equipped with a quick drain valve that requires use of the quick drain drainer assembly see Figure 6 5 The quick drain drainer assembly is stored in the parts box supplied with the crane Changing the Planetary Swing Drive Oil Non VPC and Non VPC Max Planetary Swing Drives See Figure 6 5 and Figure 6 6 for the following procedure NOTE It is better to change the oil when ...

Page 231: ...ee Figure 6 7 for the following procedure NOTE It is better to change the oil when the planetary drive is warm not hot To prevent harmful contaminants from entering the planetary drive thoroughly clean components before disconnecting or connecting them Lock out tag out the crane 1 Lockout tagout the crane 2 Remove the dust cap 2 from the quick drain valve 3 3 Place the non fitting end of the quick...

Page 232: ...4 4 Place the non fitting end of the quick drain drainer assembly hose into an appropriate container for collecting the drained oil 5 Connect the quick drain drainer assembly hose to the quick drain valve 6 When the planetary drive has finished draining remove the quick drain drainer assembly 7 Fasten the dust cap to quick drain valve 8 Fill the planetary drive with specific oil as follows a Remov...

Page 233: ...mp pressurize the brake to 18 bar 261 psi 4 To apply the swing brake relieve hydraulic pressure to the brake 5 Disconnect the hand pump hose from the brake release port fitting 6 Connect the swing brake hose to the brake release port fitting WARNING Unexpected Crane Movement Avoid possible injury When the swing brake is released the crane can suddenly swing Before releasing the swing brake secure ...

Page 234: ...s follows 1 Loosen the sensor lock nut with an 1 1 16 in hex wrench 2 Turn the sensor clockwise by hand until it contacts the speed ring 3 Turn the sensor counterclockwise 1 2 turn 180 to establish the nominal gap of 0 71 mm 0 028 in 4 Turn the sensor clockwise until the wrench flats on the sensor body are positioned at a 22 angle to the pump shaft centerline 5 The final sensor position should be ...

Page 235: ... 7 5 Inspection 7 5 Daily 7 5 Monthly 7 5 Changing the Filters 7 6 Air Cleaner Tier 3 7 8 Inspection 7 8 Daily 7 8 Monthly 7 8 Changing the Filters 7 9 Engine Throttle Adjustment 7 11 Hand Throttle Control 7 11 Foot Throttle Control 7 11 Foot Throttle Control Assembly and Calibration 7 11 Engine Electrical Schematic 7 13 Tier 4 ECM Electrical Schematic Power and Ground Circuits 7 14 Tier 3 ECM Ele...

Page 236: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 7 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 237: ...xcessive heat is a result of overcharging Overheating causes the plates to warp which can damage the separators and cause a short circuit within a cell This bubbling and gassing of the electrolyte can wash the active material from the plates reducing the battery s capacity or causing an internal short Undercharging or Discharged Undercharging can cause a type of sulfate to develop on the plates Th...

Page 238: ... crane s electrical system voltage regulator and or alternator Battery Maintenance Checking Battery State of Charge Special equipment is required to properly determine the condition of a battery that has been in service However a voltmeter can be used to determine a battery s state of charge by checking the voltage between the battery terminals see Figure 7 2 and Table 7 2 This open circuit test i...

Page 239: ...e 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 faulty parts Replace frayed broken or corroded cables Replace the batteries if their containers are cracked or worn to the point that they leak Ensure a good tight contact between the clamp terminals and the battery posts Make sure the hold dow...

Page 240: ...ng when the crane is stored for extended periods of time To prevent the crane from being started by unauthorized personnel The handle of the battery disconnect switch can be padlocked to prevent unauthorized use ENGINE CONTROLS See the engine start procedure in Section 3 of the MLC650 Operator Manual for engine startup See the Cummins engine manual for detailed engine instructions The engine is st...

Page 241: ... the yellow indicator reaches the red zone at the end of the indicator The yellow flag remains locked in place after the engine is stopped The indicator reset button on the top of the indicator can be pressed at any time When the engine is running the indicator will return to the proper reading Monthly Complete the following checks monthly Inspect the rubber reducer and the elbows between the air ...

Page 242: ... 8 Inspect the new filters especially the sealing area Never install damaged filters 9 Install the new filters in a timely manner to shorten the amount of time the opened air cleaner is exposed to the environment 10 Carefully install each new secondary filter by gently pushing the filter element into the housing Apply pressure to all four corners to make sure the filter is completely seated in the...

Page 243: ...escription Item Description 1 Air Cleaner Housing 4 Straight Adapter 1a Service Cover 5 Rubber Elbow qty 2 1b Clamp qty 8 6 Air Intake 1c Primary Filter qty 2 7 Mounting Lugs 1d Secondary Filter qty 2 8 Service Indicator 1e Inner Housing 8a Service Window 1f Removal Tab 8b Reset Button 2 Steel Tube qty 2 9 Service Instruction 3 Clamp qty 6 ...

Page 244: ...he yellow flag remains locked in place after the engine is stopped The indicator reset button on the top of the indicator can be pressed at any time When the engine is running the indicator will return to the proper reading Monthly Complete the following actions monthly Inspect the rubber reducer and the elbow between the air cleaner and the engine for cracks or other damage that might allow unfil...

Page 245: ...the clean side of a filter is a telltale sign Remove any cause of leaks before installing a new filter 7 Inspect the new filters especially the sealing area Never install damaged filters 8 Install the new filters in a timely manner to shorten the amount of time the opened air cleaner is exposed to the environment 9 Carefully install the new secondary filter if required and gently push it into the ...

Page 246: ...Description 1 Air Cleaner Assembly 1a Service Cover 1b Clamp qty 3 1c Cover Seal 1d Primary Filter 1e Secondary Filter 1f Air Cleaner Housing 2 Steel Tube 3 Clamp qty 5 4 Straight Adapter Fitting 5 Rubber Elbow 6 Air Intake 7 Mounting Bracket Capscrews 8 Service Indicator 8a Service Window 8b Reset Button FIGURE 7 5 ...

Page 247: ... foot pedal shaft 4 into the cavity in the bottom of the foot pedal housing through the roller bearing and into the foot pedal 4 Rotate the foot pedal as needed and install the roll pins 10 through the holes in the foot pedal and the foot pedal shafts see Pedal Position A 5 Install the setscrew 17 only partway into the threaded hole Do not allow the setscrew to contact the right foot pedal shaft a...

Page 248: ...11 Receptacle Control Wires 12 Black Wire ground 13 Green Wire signal 14 White Wire supply 15 Resistor 16 Flat Head Brass Screw qty 2 17 Setscrew 3 4 in 18 Setscrew 3 16 in FIGURE 7 6 Surface X Potentiometer Electrical Schematic Flat on the Head of the Shaft These two holes should be aligned when initially inserting the shaft and spring into the housing Supply White Signal Green Ground Black 22 VD...

Page 249: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 7 13 MLC650 SERVICE MAINTENANCE MANUAL POWER TRAIN 7 ENGINE ELECTRICAL SCHEMATIC FIGURE 7 7 ...

Page 250: ...R e f e r e n c e O n l y POWER TRAIN MLC650 SERVICE MAINTENANCE MANUAL 7 14 Published 09 09 16 Control 229 09 TIER 4 ECM ELECTRICAL SCHEMATIC POWER AND GROUND CIRCUITS FIGURE 7 8 ...

Page 251: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 7 15 MLC650 SERVICE MAINTENANCE MANUAL POWER TRAIN 7 TIER 3 ECM ELECTRICAL SCHEMATIC POWER AND GROUND CIRCUITS FIGURE 7 9 ...

Page 252: ...ace and properly fastened See the engine enclosure assembly drawing for the location of enclosure components WARNING Personal Injury Hazard Heavy Objects The panels over each DPF weigh approximately 9 kg 20 lb The panel over the engine weighs approximately 25 kg 55 lb To prevent serious injury use the appropriate lifting equipment when lifting or removing these objects Item Description 1 Engine En...

Page 253: ... 4 Tensioner 5 Water Pump 6 Tensioner 7 Harmonic Balancer FIGURE 7 11 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 Material Hazard Coolant is toxic Do not ingest If not reused dispose in accordance with all local and other applicable environmental regulations CAUTION Avoid Engine Damage The required co...

Page 254: ...or reservoir cap 3 then turn do not depress the cap counterclockwise until the cap stops at the safety detent 3 Wait for all pressure to escape 4 When the hissing stops depress the radiator reservoir cap and turn it counterclockwise to remove 5 Add coolant to the radiator reservoir stopping at times to prevent overflow and to allow the coolant to flow into the engine and all portions of the radiat...

Page 255: ...le in the sight glass 4 wait 1 to 2 minutes then add coolant again as needed 9 Start the engine and run until the thermostat opens 10 Reduce engine speed to low idle for two minutes to cool down engine components then stop the engine 11 When the engine has cooled add coolant until it is visible in the sight glass Install the radiator reservoir cap and close the access hatch CAUTION Maintain Coolan...

Page 256: ...ly in cranes operated at light or no load Active regeneration will be transparent to the operator except there may be an increase in turbocharger noise and exhaust temperature The High Exhaust Temperature icon should be on during regeneration and remain on until regeneration cycle is completed and the exhaust temperatures return to normal Manual Regeneration Manual regeneration is active regenerat...

Page 257: ...ng the removal procedure in reverse 2 Install the engine enclosure components and connect the batteries positive cable first and negative cable last WARNING Hot Exhaust Surfaces and Inhalation Hazards Extremely hot surfaces and exhaust gasses can cause death or serious injury When the HEST icon is illuminated make sure that people stay at least 1 5 m 5 ft away from the exhaust pipe and that the pi...

Page 258: ...hed 09 09 16 Control 229 09 Item Description 1 Exhaust Clamp w Gasket 2 DPF Assembly 3 DPF Exhaust Mounting Bracket qty 2 4 Wire Connectors 5 Lifting Tabs 6 Exhaust Clamp w Gasket 7 Exhaust Mounting Bracket Capscrew qty 4 A Torque 7 3 Nm 5 3 lb ft B Torque 20 Nm 14 5 lb ft FIGURE 7 14 ...

Page 259: ...al Control 8 12 Retract Carbody Jacks Using Manual Control 8 12 Setup Remote Control 8 13 Setup Remote Overview 8 13 Neutral Position Using Setup Remote 8 13 Extend Carbody Jacks Using Setup Remote 8 13 Retract Carbody Jacks Using Setup Remote 8 14 Carbody Jacks Hydraulic Schematic 8 15 Carbody Jacks Hydraulic Schematic Remote Control 8 16 Carbody Jacks Hydraulic Schematic Manual Control 8 17 Carb...

Page 260: ...MLC650 SERVICE MAINTENANCE MANUAL 8 ii Published 09 09 16 Control 229 09 Crawler Tensioning Assembly and Hydraulic Hand Pump 8 28 Operating the Hand Pump 8 28 Maintenance 8 29 Remove Air from the Crawler Tensioning Assembly 8 29 ...

Page 261: ...d its corresponding planetary drive If the brake hydraulic pressure or electrical control is lost the brake is applied by spring force The travel brake release system uses charge pressure from the swing pump supplied to the travel brake cylinders via the travel brake release solenoid valve The brake release pressure must be at least 16 bar 232 psi to fully release the brakes If the pressure is les...

Page 262: ...rs This causes the angle of each motor s swashplate to increase which increases motor displacement The motors rotate at a slower speed but with more torque Travel Operation See Figure 8 1 and Figure 8 3 for the following information To enable the control system the switches listed below must be in the stated positions Seat safety switch closed Travel park switch in the UN PARK position In the defa...

Page 263: ... signal to the IOLC32 and IOSB22 control modules via the CAN Bus The IOLC32 begins to ramp up the PWM duty cycle to the B side solenoid of the pump 4 EDC The PWM signal is in proportion to the speed commanded by the travel control handle Increasing the PWM duty cycle increases the pump swashplate angle which increases the hydraulic flow from the B side of the pump From the pump the flow is routed ...

Page 264: ... e n c e O n l y UNDERCARRIAGE MLC650 SERVICE MAINTENANCE MANUAL 8 4 Published 09 09 16 Control 229 09 Forward Travel High Speed Hydraulic Schematic FIGURE 8 1 See Table 8 1 Legend for Figure 8 1 and Figure 8 2 ...

Page 265: ... e O n l y Manitowoc Published 09 09 16 Control 229 09 8 5 MLC650 SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Reverse Travel Low Speed Hydraulic Schematic FIGURE 8 2 See Table 8 1 Legend for Figure 8 1 and Figure 8 2 ...

Page 266: ... Left Travel Drum 1 Diverter Pilot Valve directional control 6 Right Travel Drum 2 Diverter Pilot Valve directional control 7 Pump 4 Pressure Transducer right travel psi 8 Pump 8 swing 100 cc 9 Pump 4 right travel drum 2 130 cc 10 Suction Manifold 11 Adapter Frame Valve 12 Travel Brake Release Solenoid Valve 13 Gearbox and Brake Assembly qty 4 14 Travel Motor variable displacement 160 cc qty 4 15 ...

Page 267: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 8 7 MLC650 SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Travel Electrical Schematic FIGURE 8 3 ...

Page 268: ... ring C Figure 8 4 can be installed in any position with relation to the carbody Two dowel pins A are installed in the inner ring D to locate the inner ring on the rotating bed FIGURE 8 4 Item Description A Dowel Pin Two Places B M52 X 5 X 380 LG Special Grade Bolt With Flat Washer 84 Places Outer Ring 84 Places Inner Ring C Outer Ring D Inner Ring ...

Page 269: ...hree at a time in the numbered sequence see Figure 8 4 to a final torque of 6960 Nm 5 120 ft lb CRAWLER PREVENTIVE MAINTENANCE Crawler wear cannot be eliminated but the rate of wear can be reduced through regular preventive maintenance as follows Lubricate the crawlers as instructed in the MLC650 Lubrication Guide Keep the crawlers clean and avoid dirt buildup when cutting Keep all mounting bolts ...

Page 270: ...uit when using the carbody manual control Movement of the carbody jacks is controlled by one of the following methods Setup remote control Carbody manual control manifold Carbody Manual Control The carbody jacks can be manually controlled using the hydraulic power unit HPU and the carbody manual control manifold located on the front of the carbody From this location the carbody jack cylinders can ...

Page 271: ... 12 Valve handles that control crawler carbody pins extend B3 right crawler carbody pin puller extend 3 B4 left crawler carbody pin puller extend 4 Valve handles that control crawler carbody pins retract A3 right crawler carbody pin puller retract 9 A4 left crawler carbody pin puller retract 10 Item Description 1 B1 Right Front Carbody Jack Extend 2 B2 Right Rear Carbody Jack Extend 3 B3 Right Cra...

Page 272: ...s through the counterbalance bypass check valve 3 then into the piston side of the cylinder Retract Carbody Jacks Using Manual Control See Figure 8 9 for the following NOTE The following describes the operation to retract one carbody jack cylinder The operation is the same for all carbody jack cylinders When the HPU is connected the selector solenoid valve 1 is de energized causing the valve to sh...

Page 273: ...rgized The energized selector valve routes hydraulic fluid to the six section lower accessory valve assembly 2 When no signal is sent to any of the jack cylinder solenoids in the six section lower accessory valve assembly all the valve spools are held in the neutral position by the return springs Each jack cylinder is held in position by its corresponding counterbalance valve which closes and stop...

Page 274: ...ssory valve assembly The retract solenoid valve routes pilot hydraulic fluid through an internal shuttle valve then to the corresponding valve spool This causes the valve spool to shift to a position that allows hydraulic fluid from the accessory pump to flow to the corresponding jack cylinder counterbalance valve 4 via the orifice with bypass check valve 3 NOTE The orifice decreases the maximum f...

Page 275: ...draulic Schematic The hydraulic schematic is shown with the remote in the neutral state Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Orifice With Bypass Check Valve 4 Counterbalance Valve 5 Carbody Manual Control Manifold Cylinder Pressures Extend 240 Bar 3500 psi Retract 69 Bar 1000 psi FIGURE 8 7 ...

Page 276: ... 16 Published 09 09 16 Control 229 09 Carbody Jacks Hydraulic Schematic Remote Control FIGURE 8 8 Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Orifice With Bypass Check Valve 4 Counterbalance Valve 5 Carbody Manual Control Manifold ...

Page 277: ...SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Carbody Jacks Hydraulic Schematic Manual Control FIGURE 8 9 Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Orifice With Bypass Check Valve 4 Counterbalance Valve 5 Carbody Manual Control Manifold ...

Page 278: ...R e f e r e n c e O n l y UNDERCARRIAGE MLC650 SERVICE MAINTENANCE MANUAL 8 18 Published 09 09 16 Control 229 09 Carbody Jacks Electrical Schematic FIGURE 8 10 ...

Page 279: ... end of the cylinder is forced out and back to the tank This causes the rod to extend engaging the pins Retract Pin Pullers Using Manual Control See Figure 8 13 for the following When the HPU is connected the selector solenoid valve 1 is de energized causing the valve to shift to the default position When in the default position the selector valve routes the flow to the carbody manual control mani...

Page 280: ...itiated on the setup remote transmitter the CCMB11 control module energizes the corresponding cylinder extend solenoid in the six section lower accessory valve assembly The solenoid valve routes pilot hydraulic fluid through a shuttle valve then to the corresponding valve spool This causes the valve spool to shift to a position that allows hydraulic fluid from the accessory pump to flow to the pis...

Page 281: ...ERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Crawler Carbody Pin Pullers Hydraulic Schematic The schematic is shown with the remote in the neutral state FIGURE 8 11 Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Carbody Manual Control Manifold ...

Page 282: ... MAINTENANCE MANUAL 8 22 Published 09 09 16 Control 229 09 Crawler Carbody Pin Pullers Hydraulic Schematic Remote Control Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Carbody Manual Control Manifold FIGURE 8 12 ...

Page 283: ...l 229 09 8 23 MLC650 SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Crawler Carbody Pin Pullers Hydraulic Schematic Manual Control FIGURE 8 13 Item Description 1 Selector Solenoid Valve 2 Six Section Lower Accessory Valve Assembly 3 Carbody Manual Control Manifold ...

Page 284: ...R e f e r e n c e O n l y UNDERCARRIAGE MLC650 SERVICE MAINTENANCE MANUAL 8 24 Published 09 09 16 Control 229 09 Crawler Carbody Pin Pullers Electrical Schematic FIGURE 8 14 ...

Page 285: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 8 25 MLC650 SERVICE MAINTENANCE MANUAL UNDERCARRIAGE 8 8 Crawler Electrical Schematic FIGURE 8 15 ...

Page 286: ...ge 13 Figure 8 16 on top of the tread Measure the gap 14 between the straightedge and the top of the tread at the lowest point Tight limit gap 38 1 mm 1 5 in Loose limit gap 76 2 mm 3 in 2 If the gap exceeds the tight or loose limits adjust the crawler tread slack see Crawler Tread Slack Adjustment on page 8 27 FIGURE 8 16 Item Description 1 Nut 2 Cover 3 Quick Connect Fitting 4 Crawler Jack Cylin...

Page 287: ...6 on both sides of the crawler frame Shim thicknesses are as follows 06 mm 0 24 in 12 mm 0 47 in 25 mm 0 98 in 7 Relieve the pressure in the crawler tensioning assembly and remove the hand pump 8 Travel the crane forward or reverse to tighten the shims 9 Check for correct crawler tread slack see Crawler Tread Slack Measurement on page 8 26 Readjust as required by performing step 4 through step 8 1...

Page 288: ... Erratic operation indicates air in the system To bleed the jack cylinders see Remove Air from the Crawler Tensioning Assembly on page 8 29 3 To depressurize the crawler tensioning assembly push the pump handle down fully then open the valve by turning it counterclockwise 6 WARNING Personal Injury Hazard Serious personal injury may occur due to contact with hydraulic oil that is under pressure Be ...

Page 289: ...ee Remove Air from the Crawler Tensioning Assembly on page 8 29 g Recheck the oil level after removing the air Remove Air from the Crawler Tensioning Assembly See Figure 8 17 for the following procedure NOTE The crawler tensioning assembly consists of two jack cylinders one on the outside of the crawler frame and the other on the inside 1 Close the valve on the hand pump 4 by rotating it clockwise...

Page 290: ...R e f e r e n c e O n l y UNDERCARRIAGE MLC650 SERVICE MAINTENANCE MANUAL 8 30 Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 291: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 9 i 9 SECTION 9 LUBRICATION TABLE OF CONTENTS Lubrication 9 1 ...

Page 292: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 9 ii Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 293: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 9 1 MLC650 SERVICE MAINTENANCE MANUAL LUBRICATION 9 SECTION 9 LUBRICATION LUBRICATION See F2271 at the end of this section ...

Page 294: ...R e f e r e n c e O n l y LUBRICATION MLC650 SERVICE MAINTENANCE MANUAL 9 2 Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 295: ...ote 10 9 Retract Jack Cylinder Using Setup Remote 10 9 Manual Control 10 10 Extend Jack Cylinder Using Manual Control 10 10 Retract Jack Cylinder Using Manual Control 10 10 Upperworks Jacking and Rigging Winch Valve Assembly 10 11 Rotating Bed Jacks Hydraulic Schematic 10 12 Rotating Bed Jacks Hydraulic Schematic Remote Control 10 13 Rotating Bed Jacks Hydraulic Schematic Manual Control 10 14 Rota...

Page 296: ...Cylinder Hydraulic Schematic Setup Remote and J4 Joystick Control 10 35 Self Assembly Cylinder Electrical Schematic 10 36 Cab Tilt 10 37 Cab Tilt in Neutral 10 37 Cab Tilt Up Using the Cab Tilt Switch 10 37 Cab Tilt Down Using the Cab Tilt Switch 10 37 Cab Tilt Cylinder Hydraulic Schematic Neutral 10 38 Cab Tilt Cylinder Hydraulic Schematic Tilt Up and Tilt Down 10 39 Cab Tilt Electrical Schematic...

Page 297: ... Neutral Position Using Setup Remote 10 60 Extend Pin Puller Cylinders Using Setup Remote 10 60 Retract Pin Puller Cylinders Using Setup Remote 10 60 VPC MAX Frame Assembly Auxiliary Member to VPC MAX Beam Assembly 10 61 VPC MAX Beam Pin Puller Hydraulic Schematic 10 62 VPC MAX Beam Electrical Schematic 10 63 VPC MAX Beam Switch Adjustments 10 64 Maximum Tray In Switch Adjustment 10 64 Maximum Tra...

Page 298: ...R e f e r e n c e O n l y MLC650 SERVICE MAINTENANCE MANUAL 10 iv Published 09 09 16 Control 229 09 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 299: ...Frame to Rotating Bed Front Pin Pullers Operation The adapter frame to rotating bed front pin pullers are controlled by the setup remote See Figure 10 1 for an illustration of the front pin pullers See Figure 10 2 for the hydraulic schematic of the front pin pullers circuit See Figure 10 3 for the electrical schematic of the front pin pullers circuit Setup Remote Overview NOTE The setup remote is ...

Page 300: ...he extend solenoid 3 With the extend solenoid energized the valve spool shifts to a position that allows hydraulic fluid from the accessory pump to flow to the piston end of the cylinders This causes the cylinder rods to extend engaging the pins At the same time hydraulic fluid in the rod side of the cylinders is pushed out and back to the tank Retract Pin Pullers Using Setup Remote See Figure 10 ...

Page 301: ...29 09 10 3 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Adapter Frame to Rotating Bed Front Pin Pullers Hydraulic Schematic Item Description 1 Adapter Frame Valve Assembly 2 Valve Spool front adapter pin puller 3 Extend Solenoid 4 Retract Solenoid FIGURE 10 2 ...

Page 302: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 4 Published 09 09 16 Control 229 09 Adapter Frame to Rotating Bed Front Pin Pullers Electrical Schematic FIGURE 10 3 ...

Page 303: ...prings When in neutral both sides of the pin puller cylinders are connected to the tank via the valve spool Extend Pin Pullers Using Setup Remote When the setup remote sends an extend command for the rear adapter frame pin puller the CCM 10 control module energizes the extend solenoid 4 With the cylinder extend solenoid energized the valve spool shifts to a position that allows hydraulic fluid fro...

Page 304: ...09 16 Control 229 09 Adapter Frame to Rotating Bed Rear Pin Pullers Hydraulic Schematic Item Description 1 Accessory Valve Manifold 2 Valve Spool rear adapter pin puller 3 Proportional Pressure Relief Valve operating pressure 350 bar 5076 psi 4 Extend Solenoid 5 Retract Solenoid FIGURE 10 5 ...

Page 305: ...e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 7 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Adapter Frame to Rotating Bed Rear Pin Pullers Electrical Schematic FIGURE 10 6 ...

Page 306: ...linders are controlled by the following methods Setup remote control Manual control levers on the upperworks jacking and rigging winch valve assembly see Figure 10 8 NOTE The rotating bed jacks deployment is covered in Section 4 Deploy Rotating Bed Jacking Cylinders of the Operator Manual See Figure 10 7 for an illustration of the rotating bed jack cylinders in the working position See Figure 10 9...

Page 307: ... causes the valve spool to shift to a position that allows hydraulic fluid from the accessory pump to flow to the corresponding jack cylinder counterbalance valves 2 Within the counterbalance valves flow and control is as follows The rod side counterbalance valve is piloted open by the rod side pressure and the accessory pressure from the valve spool on the extend side Once open the oil on the rod...

Page 308: ...on side counterbalance valve has an integral bypass check valve that allows the accessory pressure to enter the piston side of the cylinder extending the cylinder Retract Jack Cylinder Using Manual Control NOTE Manual control is only used for troubleshooting the rotating bed jacks When a manual control lever 1 Figure 10 8 on the upperworks jacking and rigging winch valve assembly is moved to the r...

Page 309: ... 2 Right Front Rotating Bed Jack Control Valve 3 Right Rear Rotating Bed Jack Control Valve 4 Left Front Rotating Bed Jack Control Valve 5 Left Rear Rotating Bed Jack Control Valve 6 Rigging Winch Control Valve 7 Retract Solenoid qty 5 8 Extend Solenoid qty 5 9 Extend Position 10 Neutral Position 11 Retract Position FIGURE 10 8 The manual control lever positions for the rigging winch 6 are as foll...

Page 310: ...AL 10 12 Published 09 09 16 Control 229 09 Rotating Bed Jacks Hydraulic Schematic The hydraulic schematic is shown in the neutral state FIGURE 10 9 Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Counterbalance Valve qty 4 set at 248 bar 3600 psi ...

Page 311: ...trol 229 09 10 13 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Rotating Bed Jacks Hydraulic Schematic Remote Control FIGURE 10 10 Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Counterbalance Valve qty 4 set at 248 bar 3600 psi ...

Page 312: ...CE MAINTENANCE MANUAL 10 14 Published 09 09 16 Control 229 09 Rotating Bed Jacks Hydraulic Schematic Manual Control FIGURE 10 11 Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Counterbalance Valve qty 4 set at 248 bar 3600 psi ...

Page 313: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 15 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Rotating Bed Jacks Electrical Schematic FIGURE 10 12 ...

Page 314: ...ection 3 Electrical The rotating bed jack stowage cylinders are controlled by the setup remote NOTE The rotating bed jacks stowage is covered in Section 4 Store Rotating Bed Jacking Cylinders of the Operator Manual See Figure 10 13 for an illustration of the jack cylinder in the stowed position The right front jack cylinder is shown See Figure 10 14 for the hydraulic schematic of the rotating bed ...

Page 315: ...e valve spool 3 shifts to a position that allows hydraulic fluid from the accessory pump to flow through a check valve that bypasses the holding valve 2 This causes the cylinder rods to extend pivoting the jack cylinders into the stowed position At the same time hydraulic fluid in the rod side of the cylinders is pushed out and back to the tank After extending the stowage cylinder a pin is used to...

Page 316: ...n 1 Accessory Valve Manifold 2 Right Stowage Cylinders Holding Valve set at 3600 psi 3 Valve Spool right stowage cylinders 4 Left Stowage Cylinders Holding Valve set at 3600 psi 5 Valve Spool left stowage cylinders 6 Proportional Pressure Relief Valve operating pressure 300 bar 5076 psi 7 Extend Solenoid right stowage cylinders 8 Retract Solenoid left stowage cylinders FIGURE 10 14 ...

Page 317: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 19 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Rotating Bed Jack Stowage Cylinder Electrical Schematic FIGURE 10 15 ...

Page 318: ...pooling out The brake shuttle valve 2 provides a return path for hydraulic fluid in the drum brake 4 to flow back to the tank The drum brake is applied by spring force Spool In Using Setup Remote or J1 Joystick See Figure 10 17 for the following When a spool in command is received from the setup remote or the J1 joystick the IOLC31 control module energizes the spool in solenoid located on the uppe...

Page 319: ... the brake shuttle valve 2 to the drum brake 4 releasing the brakes From the opposite side of the motor the hydraulic fluid returns to the tank Spool Out Using Manual Control See Figure 10 18 for the following When the manual control lever for the rigging winch 6 Figure 10 8 on the upperworks jacking and rigging winch valve assembly is moved to the spool out position 11 Figure 10 8 the correspondi...

Page 320: ...0 22 Published 09 09 16 Control 229 09 Rigging Winch Drum 0 Hydraulic Schematic The hydraulic schematic is shown in the neutral state Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Brake Shuttle Valve 3 Counterbalance Valve 4 Drum Brake FIGURE 10 16 ...

Page 321: ...ENANCE MANUAL ACCESSORIES 10 10 Rigging Winch Drum 0 Hydraulic Schematic Remote Control FIGURE 10 17 Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Brake Shuttle Valve 3 Spool Out Lower Side 4 Drum Brake 5 Spool In Raise Side 6 Function Check Valve 7 Counterbalance Valve ...

Page 322: ...09 09 16 Control 229 09 Rigging Winch Drum 0 Hydraulic Schematic Manual Control FIGURE 10 18 Item Description 1 Upperworks Jacking and Rigging Winch Valve Assembly 2 Brake Shuttle Valve 3 Spool Out Lower Side 4 Drum Brake 5 Spool In Raise Side 6 Function Check Valve 7 Counterbalance Valve ...

Page 323: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 25 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Rigging Winch Drum 0 Electrical Schematic FIGURE 10 19 ...

Page 324: ...n 3 Electrical The live mast assist cylinders are controlled by the following methods Setup remote control Mast assist arm switch located on the right console in the cab Manual control lever located on mast assist and self assembly cylinders valve assembly manual control is only used for troubleshooting see Figure 10 21 See Figure 10 20 for an illustration of the mast assist cylinders See Figure 1...

Page 325: ... the piston end of the cylinders causing the rods to extend and raise the mast At the same time hydraulic fluid in the rod end of the cylinders is forced out and back to the tank via the counterbalance valves NOTE During operation the sequence valves within the cylinder counterbalance valves remain open The counterbalance valves close only when a sudden loss of hydraulic pressure occurs such as wh...

Page 326: ...ntrol 229 09 Mast Assist and Self Assembly Cylinders Valve Assembly Item Description 1 Manual Control Lever 2 Self Assembly Cylinder Control Valve 3 Mast Raise Cylinder Control Valve 4 Retract Solenoid qty 2 5 Extend Solenoid qty 2 6 Extend Position 7 Neutral Position 8 Retract Position FIGURE 10 21 ...

Page 327: ... ACCESSORIES 10 10 Mast Assist Cylinders Hydraulic Schematic The hydraulic schematic is shown in the neutral state Item Description 1 Mast Assist and Self Assembly Valve Assembly 2 Load Hold Counterbalance Valve set at 275 bar 4000 psi 3 Cylinder Counterbalance Valve set at 248 bar 3600 psi qty 4 FIGURE 10 22 ...

Page 328: ... 09 16 Control 229 09 Mast Assist Cylinders Hydraulic Schematic Setup Remote and Switch Control FIGURE 10 23 Item Description 1 Mast Assist and Self Assembly Valve Assembly 2 Load Hold Counterbalance Valve set at 275 bar 4000 psi 3 Cylinder Counterbalance Valve set at 248 bar 3600 psi qty 4 ...

Page 329: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 31 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Mast Assist Cylinders Electrical Schematic FIGURE 10 24 ...

Page 330: ...mbly cylinder is controlled by the following methods Setup remote control J4 joystick located on the right console in the cab Manual control lever located on mast assist and self assembly cylinders valve assembly manual control is only used for troubleshooting see Figure 10 21 See Figure 10 25 for the stored and working positions of the self assembly cylinder See Figure 10 26 for the hydraulic sch...

Page 331: ...ule energizes the self assembly cylinder extend solenoid on the mast assist and self assembly cylinder valve assembly 1 The extend solenoid valve routes pilot hydraulic fluid to the corresponding valve spool This causes the valve spool to shift to a position that allows hydraulic fluid from the accessory pump to flow to the piston end of the cylinder It also provides pilot pressure to the load hol...

Page 332: ...NUAL 10 34 Published 09 09 16 Control 229 09 Self Assembly Cylinder Hydraulic Schematic The hydraulic schematic is shown in the neutral state Item Description 1 Mast Assist and Self Assembly Cylinder Valve Assembly 2 Load Hold Valve set at 269 bar 3900 psi FIGURE 10 26 ...

Page 333: ...09 10 35 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 Self Assembly Cylinder Hydraulic Schematic Setup Remote and J4 Joystick Control FIGURE 10 27 Item Description 1 Mast Assist and Self Assembly Cylinder Valve Assembly 2 Load Hold Valve set at 269 bar 3900 psi ...

Page 334: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 36 Published 09 09 16 Control 229 09 Self Assembly Cylinder Electrical Schematic FIGURE 10 28 ...

Page 335: ...the flow control valves 3 Within the counterbalance valves flow and control is as follows The rod side counterbalance valve is piloted open by the rod side pressure and the accessory pressure from the valve spool on the extend side Once open the hydraulic fluid on the rod side is allowed to exit the cylinder and return to tank via the bypass check valve on the flow control valve The piston side co...

Page 336: ...9 09 16 Control 229 09 Cab Tilt Cylinder Hydraulic Schematic Neutral Item Description 1 Accessory Valve Manifold 2 Proportional Pressure Relief Valve operating pressure 350 bar 5076 psi 3 Flow Control Valves 4 Counterbalance Valve set at 275 bar 4000 psi 5 Cab Tilt Valve Spool FIGURE 10 29 ...

Page 337: ...ilt Cylinder Hydraulic Schematic Tilt Up and Tilt Down Item Description 1 Accessory Valve Manifold 2 Proportional Pressure Relief Valve operating pressure 350 bar 5076 psi 3 Flow Control Valves 4 Counterbalance Valve set at 275 bar 4000 psi 5 Cab Tilt Up Solenoid cylinder extend 6 Cab Tilt Down Solenoid cylinder retract FIGURE 10 30 ...

Page 338: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 40 Published 09 09 16 Control 229 09 Cab Tilt Electrical Schematic FIGURE 10 31 ...

Page 339: ...C MAX Trolley see Figure 10 41 VPC MAX Beam see Figure 10 41 See Figure 10 32 for an illustration of the VPC and VPC MAX counterweight system Information and adjustment procedures are provided for the following Speed sensors Absolute encoders Limit switches Roller backlash Additional component information for this system can be found in the following sections of the Service Manual Section 2 Hydrau...

Page 340: ...See Figure 10 34 for the hydraulic schematic of the VPC counterweight tray motor circuit See Figure 10 35 for the electrical schematic of the VPC counterweight tray motor circuit Setup Remote Overview NOTE The setup remote is covered in Section 4 of the Operator Manual The setup remote control communicates with the CCM 10 control module using the controller area network bus CAN Bus The crane contr...

Page 341: ...33 control module to ramp down the PWM duty cycle to the pump 7 EDC stopping all flow to the tray motors When the tray movement is stopped the VPC warning lights and alarms are deactivated VPC Counterweight Tray Retraction See Figure 10 34 for the following When the CCM 10 control module receives a retract tray command either from the setup remote or from the on board computer control the CCM 10 c...

Page 342: ...must be at least 16 bar 232 psi to fully release the brakes If the pressure is less than 16 bar 232 psi the brakes could remain partially applied which could damage the brake system To disengage the tray motor brakes the IOLC31 control module sends a 24 VDC output voltage to the brake release solenoid valve energizing the solenoid The energized solenoid valve routes hydraulic fluid to the brake pi...

Page 343: ...ght Tray Hydraulic Schematic Item Description 1 Hot Oil Shuttle Valve VPC MAX only 2 VPC 1 VPC 2 Diverter Pilot Valve VPC MAX only 3 Pressure Reducing Relief Valve set at 21 bar 300 psi 4 Right VPC Counterweight Tray Motor 55 cc fixed 5 Left VPC Counterweight Tray Motor 55 cc fixed 6 Brake Assembly 7 Brake Release Solenoid Valve FIGURE 10 34 ...

Page 344: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 46 Published 09 09 16 Control 229 09 VPC Electrical Schematic FIGURE 10 35 ...

Page 345: ... a motor be careful to contain the hydraulic fluid that will drain from the motor 1 Loosen the sensor lock nut with an 1 1 16 inch hex wrench and remove the sensor 2 Install and adjust the new sensor See Speed Sensor Adjustment on page 10 47 3 Before starting the engine add clean hydraulic oil of the correct type to the motor s top case drain port Speed Sensor Adjustment The speed sensor is set at...

Page 346: ...presents a unique binary code When a program looks at the binary code it determines the absolute position of the tray The relationship between the encoder value and the physical position of the tray is set at assembly The system does not need to return to a calibration point to maintain position accuracy Absolute Encoder Backlash Adjustment 1 Loosen the encoder mounting capscrews Position the enco...

Page 347: ...s 408 mm 16 1 in between the physical stop on the VPC counterweight tray 3 and the physical stop on the rotating bed 6 Rear Limit Switch Adjustment See Figure 10 38 for the following The rear limit switch 2 is used to stop the VPC counterweight tray 3 before it reaches the rear physical stop 1 With the rear stop installed adjust the rear limit switch so that it trips when the counterweight tray is...

Page 348: ... 1 for the permissible front and rear adjustment combinations and resulting change in backlash To decrease backlash rotate the shaft counter clockwise To increase backlash rotate the shaft clockwise and a corresponding increase in backlash will result Adjust equally side to side Table 10 1 Shaft Angle Decrease in Backlash Item Description 1 VPC Counterweight Tray 2 Roller Assembly FIGURE 10 39 Fro...

Page 349: ...e tripped when the live mast is down in the shipping position Gantry Limit Switch Adjustment Adjust the gantry limit switch 1 Figure 10 40 to trip as the gantry comes down to the shipping position When the gantry is in the working position the limit switch is closed Item Description 1a Gantry Limit Switch current production 1b Gantry Limit Switch past production 2 Live Mast Limit Switch 3 Rotating...

Page 350: ...etup remote See Figure 10 41 for an illustration of the VPC MAX trolley and beam See Figure 10 42 for the hydraulic schematic of the VPC MAX trolley motor circuit See Figure 10 43 for the electrical schematic of the VPC MAX trolley motor circuit Setup Remote Overview NOTE The setup remote is covered in Section 4 of the Operator Manual The setup remote control communicates with the CCM 10 control m...

Page 351: ...ntrol module to ramp down the PWM duty cycle to the pump 7 EDC stopping all flow to the trolley motors When the trolley movement has stopped the VPC warning lights and alarms are deactivated Trolley Retraction See Figure 10 42 for the following When the CCM 10 control module receives a retract trolley command either from the setup remote or from the on board computer control the CCM 10 control mod...

Page 352: ...n to the default position allowing the hydraulic fluid in the brake cylinders to flow through the brake release solenoid valve then back to the tank The reduced hydraulic pressure allows spring force to apply the trolley motor brakes VPC MAX Trolley Pin Pullers Extend Trolley Pin Pullers Using Setup Remote See Figure 10 42 for the following When a command to extend the VPC MAX trolley pin puller c...

Page 353: ... Description 1 Trolley Pin Puller Cylinder qty 2 2 Left Trolley Motor 100 cc fixed 3 Pin Pullers Retract Solenoid 4 Pin Pullers Extend Solenoid 5 VPC MAX Actuator Valve 6 VPC 1 VPC 2 Diverter Solenoid Valve 7 Brake Release Solenoid Valve 8 Hot Oil Shuttle Valve 9 VPC 1 VPC 2 Diverter Pilot Valve 10 Right Trolley Motor 100 cc fixed 11 Brake Assembly qty 2 FIGURE 10 42 ...

Page 354: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 56 Published 09 09 16 Control 229 09 VPC MAX Trolley Electrical Schematic FIGURE 10 43 ...

Page 355: ...ed sensor 1 from a motor be careful to contain the hydraulic fluid that will drain from the motor 1 Loosen the sensor lock nut with an 1 1 16 inch hex wrench and remove the sensor 2 Install and adjust the new sensor See Speed Sensor Adjustment on page 10 57 3 Before starting the engine add clean hydraulic oil of the correct type to the motor s top case drain port Speed Sensor Adjustment The speed ...

Page 356: ...When a program looks at the binary code it determines the absolute position of the VPC MAX trolley The relationship between the encoder value and the physical position of the trolley is set at assembly The system does not need to return to a calibration point to maintain position accuracy Absolute Encoder Backlash Adjustment See Figure 10 45 for the following procedures 1 Loosen the encoder mounti...

Page 357: ...the shaft in the bore See Table 10 2 for the permissible front and rear adjustment combinations and resulting change in backlash To decrease backlash rotate the shaft counter clockwise To increase backlash rotate the shaft clockwise Adjust equally side to side Table 10 2 Shaft Angle Decrease in Backlash Item Description 1 VPC MAX Trolley 2 Roller Assembly FIGURE 10 46 Front Shaft Rotation Angle CC...

Page 358: ...inders 1 and 2 to the tank Extend Pin Puller Cylinders Using Setup Remote See Figure 10 49 for the following When a command to extend the VPC MAX beam pin puller cylinders is initiated on the setup remote the CCM 10 control module sends the command to the IOLC35 control module The IOLC35 control module then sends a 24 VDC output voltage to the upper and lower pin puller extend solenoids 5 and 6 en...

Page 359: ...lished 09 09 16 Control 229 09 10 61 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 VPC MAX Frame Assembly Auxiliary Member to VPC MAX Beam Assembly Item Description 1 Frame Assembly Auxiliary Member 2 VPC MAX Beam Assembly FIGURE 10 48 ...

Page 360: ...Hydraulic Schematic FIGURE 10 49 Item Description Item Description 1 Upper Pin Puller Cylinder qty 2 5 Upper Pin Puller Extend Solenoid 2 Lower Pin Puller Cylinder qty 2 6 Lower Pin Puller Extend Solenoid 3 Upper Pin Puller Valve Spool 7 Upper Pin Puller Retract Solenoid 4 Lower Pin Puller Valve Spool 8 Lower Pin Puller Retract Solenoid ...

Page 361: ...R e f e r e n c e O n l y Manitowoc Published 09 09 16 Control 229 09 10 63 MLC650 SERVICE MAINTENANCE MANUAL ACCESSORIES 10 10 VPC MAX Beam Electrical Schematic FIGURE 10 50 ...

Page 362: ...ust the forward limit switch position so that it will trip the limit switch when the counterweight tray reaches a position that is 409 mm 16 1 in away from the forward physical stop Maximum Tray Out Switch Adjustment See Figure 10 51 for the following Adjust the rear limit switch position so that it will trip the limit switch when the counterweight tray reaches a position that is 466 mm 18 3 in aw...

Page 363: ...ment See Figure 10 52 for the following procedure 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 opening is 10 mm 0 39 in away from contacting the bottom of the hook pin on the rotating bed At this point the rack teeth at the end of the rotating bed should be approximately 15 mm 0 59 in from the top of the beam FIGURE 10 52 Item Des...

Page 364: ...for the following 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 in away from contacting the pin on the rear of the rotating bed 3 The free state of the adjustable arm 4 is 60 and the tripped state of the arm is 34 Item Description 1 Beam Up Limit Switch 2 VPC MAX Beam 3 Rotating Bed 4 On Hook Limit Switch Adjustable Arm 5 Switch Mount ...

Page 365: ...rcuit The AFMS system consists of two fixed mast stops each containing an integral hydraulic cylinder The AFMS system controls the pressure within the mast stop cylinders over the operational range of the cylinder as well as adapts to current crane conditions Each mast stop cylinder contains the following internal components Hydraulic accumulator Pressure relief valve with bypass check valve Ruptu...

Page 366: ... of the cylinder decreases When hydraulic pressure in the bore side of the cylinder decreases below the regulated supply pressure the check valve 6 opens and allows hydraulic fluid to flow into the bore side until the pressure in the cylinder and the regulated supply pressure equalize When this happens the check valve closes FIGURE 10 55 Cylinder Extension Item Description 1 Mast Stop Cylinder 2 R...

Page 367: ...t cylinder pressure reducing solenoid valve 5 At the same time the IOLC30 control module sends a pulse width modulation PWM signal to this solenoid modulating the solenoid valve to allow the high pressure oil to flow back to the hydraulic tank This reduces the pressure in the cylinder bore until the target pressure is obtained NOTE When the mast cylinder pressure reducing solenoid valve is de ener...

Page 368: ...e reaches 221 bar 3200 psi the relief valve 2 opens allowing the hydraulic fluid to flow from the cylinder bore to the integrated cylinder accumulator 3 charging the accumulator A small portion of the hydraulic fluid stored in the accumulator flows through the relief valve 4 and back to the tank High Load Compression Item Description 1 Mast Stop Cylinder 2 Relief Valve set at 221 bar 3200 psi 3 In...

Page 369: ...draulic fluid from the system supply circuit also flows to the cylinder bore via the check valve 6 Once the system pressure has stabilized the excess oil in the accumulator will bleed off through the relief valve 4 and return to the tank Item Description 1 Mast Stop Cylinder 2 Relief Valve set at 221 bar 3200 psi 3 Integrated Cylinder Accumulator 4 Relief Valve set at 16 6 bar 240 psi 5 Mast Cylin...

Page 370: ...cumulator 3 charging the accumulator If the cylinder bore pressure reaches 310 bar 4500 psi the pressure differential across the relief valve will cause the rupture disc 8 to burst allowing an additional flow path from the cylinder bore to the accumulator NOTE Whenever a rupture disc bursts it must be replaced and the whole cylinder fully inspected including the seals and rod prior to the cylinder...

Page 371: ...ted Cylinder Accumulator qty 2 4 Relief Valve set at 16 6 bar 240 psi qty 2 5 Mast Cylinder Pressure Reducing Solenoid Valve qty 2 6 Check Valve qty 2 7 Mast Cylinder Directional Control Solenoid Valve qty 2 8 Rupture Disc qty 2 9 Bypass Check Valve qty 2 10 Left Mast Cylinder Pressure Transducer 11 Mast Cylinder System Pressure Reducing Valve set at 31 bar 450 psi 12 Mast Cylinder System Pressure...

Page 372: ...R e f e r e n c e O n l y ACCESSORIES MLC650 SERVICE MAINTENANCE MANUAL 10 74 Published 09 09 16 Control 229 09 Active Fixed Mast Stop Electrical Schematic FIGURE 10 61 ...

Page 373: ...ing Assembly and Hydraulic Hand Pump 8 28 Crawler Tread Slack Adjustment 8 27 Crawler Tread Slack Measurement 8 26 Crawler Carbody Pin Pullers Control 8 19 Diesel Particulate Filter 7 20 Drum 1 Main Hoist 5 1 Drum 2 Main Hoist 5 10 Drum 3 Whip Hoist 5 19 Drum 4 Boom Hoist or Mast Hoist VPC MAX 5 26 Drum 5 Boom Hoist VPC MAX 5 33 Drum 6 Luffing Hoist 5 40 Drum Motor Speed Sensor 5 60 Electrical Dra...

Page 374: ...ion of the Environment 1 4 Replacing Turntable Bolts 8 9 Rigging Winch Drum 0 10 20 Rotating Bed Jack Cylinders 10 8 Rotating Bed Jack Stowage Cylinder 10 16 Safe Maintenance Practices 1 2 Safety Messages 1 1 Self Assembly Cylinder Optional 10 32 Sheave Roller and Drum Inspection 5 79 Shop Procedures 2 27 Strap Inspection and Maintenance 4 11 Swing Brake Operation 6 1 Swing Drive System 6 5 Swing ...

Page 375: ...R e f e r e n c e O n l y ...

Page 376: ...R e f e r e n c e O n l y ...

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