Maeda MC-305C-2 User manual

103E-SM0807-01
SERVICE MANUAL
MINI-CRAWLER CRANE
Serial No. D0001
001001
001 and up
and upand up
and up
The parts numbers and lists written in this service manual are th
e
references for the services such as disassembling and assembling.
Be sure to ALWAYS refer to the latest parts catalog (the lates
t
information) before ordering any part, since the parts and the model
numbers are subject to change during the endless improvements and
changes of our Machine.

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CONTENTS
ITEM Page
GENERAL 1- 1
1. SPECIFICATION DIMENSIONNAL DRAWING 1- 2
1.1 STANDARD SPECIFICATION 1- 2
1.2 ENGINE AND ELECTRIC MOTER SPECIFICATION 1- 3
2. DIMENSIONNAL DRAWING OF OUTRIGGER WIDTH 1- 4
3. PRINCIPLE SPECIFICATION LIST 1- 5
3.1 STANDARD SPECIFICATION 1- 5
3.2 ENGINE AND ELECTRIC MOTER SPECIFICATION 1- 6
4. WORKING RADIUS LIFTING HEIGHT 1- 8
5. TOTAL RATED LOAD CHART 1- 9
6. STANDARD PRESSURE AND OPERATING TIME CHART 1-12
6.1 OUTRIGGER 1-12
6.2 CRANE OPERATION (WHEN INCREASING SPEED) 1-12
6.3 TRAVELING OPERATION (WHEN INCREASING SPEED) 1-12
7. POWER TRAIN DRAWING 1-13
CONSTRUCTION & MAINTENANCE
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2- 1
1. HYDRAULIC CERCUIT DIAGRAM 2- 3
2. HYDRAULIC OIL PIPING 2- 6
2.1 CRANE ROTATE PORTION 2- 6
2.2 CRANE FIXED PORTION 2- 8
2.3 TRAVEL LINE 2- 10
2.4 OUTRIGGER LINE 2- 12
2.5 PUMP LINE (P LINE) 2- 16
2.6 TANK AND DRAIN LINE (T AND DR LINE) 2- 18
2.7 PILOT LINE 2- 20
2.8 ELECTRIC MOTOR LINE 2- 22
3. TANK 2- 24
3.1 HYDRAULIC TANK 2- 24
3.2 FUEL TANK 2- 25
4. RETURN MANI-BLOCK 2- 27
5. CHECK VALVE 2- 28
6. ENGINE ASSEMBLY 2- 30
6.1 ENGINE ASSEMBLY 2- 30
6.2 PRINCIPAL ENGINE SPECIFICATIONS 2- 31
6.3 EACH SECTION NAME 2- 32
6.4 LABELS 2- 33
6.5 DIESEL FUEL 2- 34
6.6 COOLANT 2- 37
6.7 LUBRICATING OIL 2- 38
6.8 PERIODIC MAINTENANCE SCHEDULE 2- 40
6.9 TROUBLE SHOOTING 2- 42
6.10 FUEL PIPING 2- 46
6.11 COOLANT PIPING 2- 48

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ITEM Page
7. HYDRAULIC OIL PUMP 2- 49
7.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 49
7.2 INNER PARTS 2- 50
7.3 BASICS OF FUNCTIONALITY 2- 51
7.4 TROUBLE SHOOTING 2- 52
8. TRAVEL CONTROL VALVE 2- 53
8.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 53
8.2 INNER PARTS 2- 54
8.3 INSPECTION AND ADJUSTMENT 2- 55
8.4 TROUBLE SHOOTING 2- 56
9. TRAVELING MOTOR 2- 57
9.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 57
9.2 INNER PARTS 2- 58
9.3 PRECAUTIONS FOR USE 2- 62
10. CRANE CONTROL VALVE 2- 64
10.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 64
10.2 HYDRAULIC CIRCUIT DIAGRAM 2- 65
10.3 RGB BLOCK 2- 66
10.4 ACCELERATOR BLOCK 2- 68
10.5 FUNCTION BLOCK (DERRICK, WINCH, TELESCOPIC, SLEWING) 2- 68
10.6 SOLENOID VALVE FUNCTIONING PRINCIPLE 2- 69
11. OUTRIGGER CONTROL VALVE 2- 72
11.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 72
11.2 INNER PARTS 2- 74
12. OUTRIGGER SELECT VALVE 2- 75
12.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 75
12.2 INNER PARTS 2- 76
13. CRANE CIRCUIT CONFLUENCE VALVE 2- 77
13.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 77
13.2 INNER PARTS 2- 78
13.3 INSPECTION AND ADJUSTMENT 2- 79
13.4 TROUBLE SHOOTING 2- 79
14. TRAVELING SPEED SELECT VALVE 2- 80
14.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 80
14.2 INSPECTION AND ADJUSTMENT 2- 81
14.3 TROUBLE SHOOTING 2- 81
15. ROTARY JOINT 2- 82
15.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 82
15.2 INNER PARTS 2- 83
16. HOOK BLOCK 2- 84
16.1 HOOK BLOCK INSPECTION 2- 86
17. BOOM 2- 88
18. TELESCOPIC AND DERRICK CYLINDER 2- 92
18.1 TELESCOPIC CYLINDER 2- 92
18.2 TELESCOPIC CYLINDER HYDRAULIC CIRCUIT SYSTEM 2- 94
18.3 COUNTER BALANCE VALVE (FOR TELESCOPIC AND DERRICK CYLINDER) 2- 95
18.4 SEQUENCE VALVE (FOR TELESCOPIC CYLINDER) 2- 97
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ITEM Page
18.5 MECHANICAL CHECK VALVE (FOR TELESCOPIC CYLINDER) 2- 98
18.6 LEFT SIDE DERRICK CYLINDER 2-100
18.7 RIGHT SIDE DERRICK CYLINDER 2-102
19. WINCH 2-104
19.1 WINCH UNIT 2-104
19.2 HYDRAULIC OIL MOTOR 2-106
19.3 HYDRAULIC OIL MOTOR INNER PARTS 2-108
19.4 TROUBLE SHOOTING 2-110
19.5 SAFETY PRECAUTIONS 2-111
20. SLEWING SYSTEM 2-114
20.1 EXTERIOR VIEW 2-114
20.2 SLEWING REDUCTION GEAR 2-116
20.3 HYDRAULIC OIL MOTOR INNER PARTS 2-117
20.4 SLEWING MOTOR TROUBLE SHOOTING 2-119
21. OUTRIGGER 2-120
21.1 FRONT OUTRIGGER 2-120
21.2 REAR OUTRIGGER 2-122
22.OUTRIGGER CYLINDER 2-124
22.1 OUTRIGGER SLIDE CYLINDER 2-124
22.2 SINGLE CHECK VALVE (FOR OUTRIGGER SLIDE CYLINDER) 2-126
22.3 FRONT OUTRIGGER CYLINDER 2-128
22.4 REAR OUTRIGGER CYLINDER 2-130
22.5 DOUBLE CHECK VALVE (FOR OUTRIGGER CYLINDER) 2-132
23. ASSEMBLY AND DISASSEMBLY OF BOOM 2-134
24. ELECTRIC CIRCUIT DIAGRAM 2-141
25. ELECTRIC SYSTEM DRAWING 2-142
26. ELECTRIC SYSTEM 2-144
26.1 ENGINE HARNESS 2-144
26.2 REMOTE CONTROL, VALVE AND ELECTRICAL PARTS HARNESS 2-146
26.3 MOMENT LIMITER HARNESS 2-148
26.4 ELECTRIC MOTOR HARNESS 2-150
26.5 OVER HOIST ALARM SYSTEM 2-152
26.6 CRANE INCLINATION ALARM SYSTEM 2-156
MOMENT LIMITER
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3- 1
1. MOMENT LIMITER RELATED 3- 2
1.1 DISPLAY UNIT AND CONVERTER 3- 2
1.2 FRONT OUTRIGGER EXTENSION DETECTOR 3- 4
1.3 REAR OUTRIGGER EXTENSION DETECTOR 3- 6
1.4 BOOM DISPLACEMENT DETECTOR 3- 8
1.5 LOAD DETECTOR 3-14
1.6 MOMENT LIMITER ACCESSORY 3-16
1.7 OVER UN-WINDING DETECTOR 3-18
2. OUTRIGGER SAFETY DEVICE 3-20
2.1 ROTARY POSITION DETECTOR 3-20
2.2 GROUND SETTING DETECTOR 3-22
2.3 BOOM STOWING POSITION DETECTOR 3-24
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ITEM Page
3. MOMENT LIMITER OVERVIEW AND FEATURES 3-27
4. EXTERNAL VIEW OF MOMENT LIMITER 3-28
4.1 DISPLAY UNIT 3-28
4.2 CONVERTER 3-29
5. BLOCK DIAGRAM 3-30
6. CONNECTOR DIAGRAM 3-31
7. CONNECTOR PIN ASSIGNMENT 3-32
7.1 CONVERTER CONNECTORS 3-32
7.2 DISPLAY UNIT CONNECTORS 3-33
8. INPUT/OUTPUT 3-34
8.1 CONVERTER 3-34
8.2 DISPLAY UNIT 3-35
9. DISPLAYS 3-38
10. SWITCHES 3-40
11. DISPLAY UNIT; DETAIL OF EACH SEGMENT 3-42
12. START–UP SEQUENCE 3-44
13. MOMENT LIMITER FUNCTIONS 3-44
14. DISPLAY OF SPECIFIC INDICATORS 3-45
15. OPERATION RANGE LIMITATION CONTROL 3-45
16. CALIBRATION PROCEDURE 3-46
16.1 LIST OF ITEMS 3-46
16.2 PROCEDURE 3-47
16.3 DISPLAY DETAILS AT CALIBRATION MODE 3-55
17. TEST MODE 3-56
17.1 CALL OUT OF TEST MODE 3-56
17.2 L01 (ROM/RAM TEST) 3-57
17.3 L02 (LED TEST) 3-58
17.4 L03 (SWITCH TEST) 3-59
17.5 L04 INPUT SIGNAL TEST 3-60
17.6 L05 OUTPUT SIGNAL TEST 3-61
17.7 L06 (LOAD FACTOR TEST) 3-62
17.8 L07 (VERIFICATION OF INPUT FROM CONVERTER) 3-62
17.9 L08 (TIME SETTING) 3-63
18. PC MODE 3-64
18.1 MOMENT LIMITER OPERATION LOG PICKING UP PROCEDURE 3-64
18.2 MOMENT LIMITER OPERATION LOG DELETING PROCEDURE 3-69
19. ERROR MESSAGES 3-71
20. TROUBLE SHOOTING 3-72
21. POINTS FOR INPUT VOLTAGE MEASUREMENT OF EACH SENSOR 3-74
REMOTE CONTROL 4- 1
1. INITIAL MODE SETTING PROCEDURE 4- 2
1.1 BUTTON ARRANGEMENT ON CONTROL PANEL 4- 2
1.2 ESTABLISHING INITIAL MODE 4- 3
1.3 INITIAL MODE FOR USER (A MODE) 4- 4
1.4 INITIAL MODE FOR SERVICE (B MODE) 4- 7
1.5 INITIAL MODE FOR MAKER (C MODE) 4-10
1.6 INITIAL MODE SETTING (For interactive remote controller) 4-16

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
ITEM Page
2. RECEIVER 4-18
2.1 STATUS DISPLAY 4-18
2.2 CONTROL PRINT CARD LACATIONS 4-20
2.3 CONNECTOR PIN ASSIGNMENT 4-24
2.4 VALVE NEUTRAL SETTING PROCEDURE 4-26
2.5 MONITOR DISPLAY MESSAGE 4-28
2.6 FUSE IN THE RECEIVER 4-29
3. VOICE MESSAGES 4-31
4. TROUBLESHOOTING 4-32
ELECTRIC MOTOR 5- 1
1. POWER UNIT 5- 2
2. INVERTER UNIT 5- 4
2.1 GENERAL VIEW 5- 5
2.2 NAME AND FUNCTION 5- 6
2.3 TRIP INFORMATION AND REMEDIES 5- 8
2.4 INSPECTION AND MAINTENANCE 5-15
2.5 DISPOSAL OF THE INVERTER 5-17
3. POWER SUPPLY BOX 5-18
4. ELECTRIC CIRCUIT DIAGRAM 5-20

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1-1

GENERAL


1. SPECIFICATION DIMENSIONNAL DRAWING 1- 2
2. DIMENSIONNAL DRAWING OF OUTRIGGER WIDTH 1- 4
3. PRINCIPLE SPECIFICATION LIST 1- 5
4. WORKING RADIUS LIFTING HEIGHT 1- 8
5. TOTAL RATED LOAD CHART 1- 9
6. STANDARD PRESSURE AND OPERATING TIME CHART 1-12
7. POWER TRAIN DRAWING 1-13

1-2
1. SPECIFICATION DIMENSIONNAL DRAWING
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
1.1 STANDARD SPECIFICATION