Maeda MC285C-3 User manual

Service Manual
Mini-Crawler Crane
102ME-SM1906-00
The parts numbers and lists written in this service manual are the
references for the services suchas disassembling and assembling.
Be sure to ALWAYS refer to the latest parts catalog (the latest
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.

0-1
CONTENTS
Item
Page
OVERVIEW
1- 1
1. OUTSIDE DRAWING
1- 2
1.1. NON-ELECTRIC MOTOR MODEL
1- 2
1.2 ENGINE AND ELECTRIC MOTOR SPECIFICATIONS
1- 2
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH
1- 3
3. PRINCIPAL SPECIFICATIONS LIST
1- 4
4. COMPONENT MASS LIST
1- 6
5. LUBRICATING OIL
1- 7
6. WORKING RADIUS/LIFTING HEIGHT
1- 8
7. RATED TOTAL LOAD CHART
1- 9
[1] RATED TOTAL LOAD CHART FOR 4-FALL WIRE ROPE
1- 9
[2] RATED TOTAL LOAD CHART FOR 2-FALL WIRE ROPE
1- 10
[3] RATED TOTAL LOAD CHART FOR 1-FALL WIRE ROPE
1- 11
STRUCTURE AND MAINTENANCE PROCEDURE
2- 1
1. ENGINE ASSEMBLY
2- 3
1.1 ENGINE (DOMESTIC / CE) MODEL “YANMAR2TNV70-NMBA”
2- 3
1.1.1 COMPONENTS OF ENGINE
2- 3
1.1.2 ENGINE MODEL
2- 3
1.1.3 ENGINE ACCESSORIES
2- 4
1.1.4 FUEL PIPING
2- 6
1.2 ENGINE (U.S.) MODEL “SHIBAURA TYPE E672L-F-6701”
2- 7
1.2.1 COMPONENTS OF ENGINE
2- 7
1.2.2 ENGINE MODEL
2- 8
1.2.3 ENGINE ACCESSORIES
2- 9
1.2.4 FUEL PIPING
2- 11
1.3 FUEL TANK ASSEMBLY
2- 12
1.4 FUEL SENDER
2- 13
2. POWER TRANSMISSION SCHEMATIC DIAGRAM
2- 14
2.1 HYDRAULIC SYSTEM DIAGRAM
2- 14
2.2 SLEWING SYSTEM
2- 15
2.2.1. OUTSIDE DRAWING
2- 15
2.2.2 TOLERANCE OF LOOSENESS HEIGHT OF SLEWING BEARING
2- 16
3. UNDERCARRIAGE AND FRAME
2- 17
3.1 TRACK FRAME
2- 17
3.2 FRONT IDLER
2- 18
3.3 GREASE CYLINDER
2- 18
3.4 CARRIER ROLLER (UPPER ROLLING WHEEL)
2- 19
3.5 TRACK ROLLER
2- 19
3.6 TANDEM ROLLER
2- 20
3.7 SPROCKET
2- 20
3.8 RUBBER TRACKS
2- 21

0-2
Item
Page
4. HYDRAULIC UNITS
2- 22
4.1 HYDRAULIC UNITS LAYOUT DIAGRAM
2- 22
4.2 HYDRAULIC OIL TANK
2- 24
4.2.1 RETURN FILTER PART NO.: 329-3112700
2- 25
4.2.2 AIR BREATHER ASSEMBLY PART NO.: 353-4453000
2- 26
4.3 ROTARY JOINT
2- 27
4.3.1 APPEARANCE / MODEL PART NO.: 353S64700000
2- 27
4.3.2 INTERNAL STRUCTURE
2- 28
4.4 TRAVEL MOTOR
2- 29
4.4.1 APPEARANCE / MODEL PART NO.: 353S64800001
2- 29
4.5 HYDRAULIC PUMP
2- 30
4.5.1 HYDRAULIC PUMP (DOMESTIC / CE): PART NO. 353S57600000
2- 30
4.5.2 HYDRAULIC PUMP (U.S.): PART NO. S102I3502001
2- 31
4.5.3 HYDRAULIC PUMP (WITH ELECTRIC MOTOR): PART NO. 329S33800002
2- 32
4.6 CRANE CONTROL VALVE
2- 33
4.6.1 OUTSIDE DRAWING: PART NO. S102G3946000
2- 33
4.6.2 OVERVIEW
2- 34
4.7 OUTRIGGER SELECT VALVE
2- 35
4.7.1 APPEARANCE / MODEL: PART NO. 353S67000000
2- 35
4.8 TRAVEL CONTROL VALVE
2- 37
4.8.1 APPEARANCE / MODEL PART NO.: 353S58800001
2- 37
4.9 SLEWING MOTOR
2- 38
4.9.1 APPEARANCE / MODEL PART NO.: 301S18600000
2- 38
4.10 WINCH MOTOR
2- 39
4.10.1 APPEARANCE / MODEL PART NO.: 344S44800000
2- 39
4.11 DERRICKING CYLINDER
2- 40
4.11.1 LEFT-SIDE DERRICKING CYLINDER PART NO.: 353S64500000
2- 40
4.11.2 RIGHT-SIDE DERRICKING CYLINDER PART NO.: 353S69700000
2- 42
4.12 TELESCOPING CYLINDER
2- 44
4.12.1 APPEARANCE / MODEL PART NO.: 353S61300002
2- 44
1 TELESCOPING CYLINDER HYDRAULIC SYSTEM DIAGRAM
2- 47
4.12.3 COUNTERBALANCE VALVE PART NO.: 353S61355002
2- 48
4.12.4 SEQUENCE VALVE PART NO.: 353S61356002
2- 49
4.12.5 MECHANICAL CHECK VALVE PART NO.: 353S61357002
2- 50
4.13 OUTRIGGER CYLINDER
2- 51
4.13.1 APPEARANCE / MODEL PART NO.: S102F2389000
2- 51
4.13.2 DOUBLE PILOT CHECK VALVE PART NO.: 103S92800000
2- 53
4.14 HYDRAULIC PIPING DIAGRAM
2- 54
4.14.1 SUCTION LINE (HYDRAULIC TANK - PUMP)
2- 54
1.14.2 PUMP LINE (PUMP - CHECK VALVE - MANIFOLD BLOCK1 - TRAVEL VALVE)
2- 55
4.14.3 TRAVEL VALVE P LINE
(TRAVEL VALVE - CRANE CONTROL VALVE - TRAVEL PRESSURE PORT)
2- 57
4.14.4 RETURN LINE 01 ( MANIFOLD BLOCK / SELECT VALVE - HYDRAULIC TANK)
2- 58
4.14.5 RETURN LINE 02 (TRAVEL / CRANE CONTROL VALVE / ROTARY JOINT - MANIFOLD BLOCK)
2- 60
4.14.6 ELECTRIC HYDRAULIC PIPING (WITHOUT ELECTRIC MOTOR)
2- 62
4.14.7 ELECTRIC HYDRAULIC PIPING (WITH ELECTRIC MOTOR)
2- 63
4.14.8 TRAVEL LINE (TRAVEL CONTROL VALVE - TRAVEL MOTOR)
2- 64

0-3
Item
Page
4.14.9 CONTROL A LINE (CRANE CONTROL VALVE - OR SELECT VALVE)
2- 66
4.14.10 CONTROL B LINE (OR SELECT VALVE - ROTARY JOINT / SLEWING MOTOR)
2- 68
4.14.11 OUTRIGGER LINE (OR SELECT VALVE - OUTRIGGER CYLINDER)
2- 70
4.14.12 HYDRAULIC PIPING (ROTATING PARTS) LINE
(ROTARY JOINT - WINCH / DERRICKING / TELESCOPIC CYLINDER)
2- 72
4.15 RETURN MANIFOLD BLOCK (P/T LINE ASSEMBLY PART NO.20)
2- 74
4.16 OIL COOLER (P, T LINE ASSEMBLY PART NO.5)
2- 74
4.17 CHECK VALVE
(ELCTRIC MOTOR P/U ASSEMBLY PART NO.49 / P / T LINE ASSEMBLY PART NO.29)
2- 75
4.18 MANIFOLD BLOCK (P / T LINE ASSEMBLY PART NO.6)
2- 75
5. WORK EQUIPMENT
2- 76
5.1 BOOM ASSEMBLY DIAGRAM
2- 76
5.1.1 BOOM TELESCOPING MECHANISM
2- 78
5.2 HOOK ASSEMBLY DIAGRAM
2- 79
5.3 INSPECTION OF HOOK BLOCK
2- 80
5.4 WINCH ASSEMBLY
2- 81
5.5 OUTRIGGER
2- 82
5.5.1 APPEARANCE OF OUTRIGGER 1
2- 82
5.5.2 APPEARANCE OF OUTRIGGER 2
2- 83
5.5.3 APPEARANCE OF OUTRIGGER 3
2- 84
5.5.4 APPEARANCE OF OUTRIGGER 4
2- 85
5.6 TRAVEL CONTROL
2- 86
5.6.1 TRAVEL CONTROL ASSEMBLY
2- 86
5.6.2 TRAVEL CONTROL ASSEMBLY DETAILS
2- 87
6. ELECTRICAL UNITS
2- 88
6.1 ELECTRICAL UNITS LAYOUT DIAGRAM
2- 88
6.2 MONITOR
2- 89
[1] STARTING SCREEN
2- 89
[2] HOME SCREEN
2- 90
[3] OUTRIGGER MODE SCREEN
2- 91
[4] USER MODE SWITCH
2- 92
[5] CONSUMABLES DISPLAY
2- 93
[6] WARNING DISPLAY AND ERROR CODE DISPLAY
2- 94
[7] LIST OF ERROR CODES
2- 95
6.3 OUTRIGGER SAFETY DEVICES
2- 97
6.3.1 FUNCTIONS OF OUTRIGGER SAFETY DEVICES
2- 97
6.4 FUSE
2- 98
6.5 VEHICLE BODY WIRE HARNESS (DOMESTIC / CE / YANMAR ENGINE)
2- 99
6.5.1 GENERAL DRAWING
2- 99
6.5.2 VALVE STAND PART
2- 100
6.5.3 ENGINE ELECTRIC BOX PART
2- 101
6.5.4 MONITOR CASE PART
2- 102
6.5.5 TRAVEL LEVER PART
2- 103
6.5.6 OUTRIGGER PART
2- 104
6.6 VEHICLE BODY WIRE HARNESS (U.S. / SHIBAURAENGINE)
2- 105
6.6.1 GENERAL DRAWING
2- 105
6.6.2 ENGINE ELECTRIC BOX PART
2- 106
6.6.3 TRAVEL LEVER PART
2- 107

0-4
Item
Page
6.7 SENSORS
2- 108
6.7.1 INCLINATION SENSOR PART NO.: S102M3958000
2- 108
6.7.2 TIP-OVER WARNING DEVICE
2- 108
6.8 LED LAMPS
2- 109
7. MOMENT LIMITER
2- 110
7.1 CONFIGURATION OF MOMENT LIMITER
2- 110
7.2 MONITOR DISPLAY OF MOMENT LIMITER
2- 111
7.3 ML ASSEMBLY
2- 112
7.3.1 LDC CONTROLLER
2- 112
7.3.2 MAIN CONTROLLER TTC60
2- 113
7.3.3 LOWER CONTROLLER TTC36X
2- 114
7.3.4 UPPER CONTROLLER TTC30XH
2- 115
7.3.5 TRI-COLOUR LIGHTS
2- 116
7.3.5.1 TRI-COLOUR LIGHTS MODEL PART NO.: S102M3974000
2- 116
7.3.5.2 TRI-COLOUR LIGHTS CONDITIONS
2- 117
7.3.5.3 MOMENT LIMITER TRI-COLOUR LIGHTS CONDITIONS
2- 117
7.3.5.4 OUTRIGGER NOT INSTALLED WARNING
2- 118
7.3.6 OVERRIDE SWITCH
2- 118
7.4 OR POSITION DETECTION ASSEMBLY
2- 119
7.5 OR OPEN DETECTION ASSEMBLY
2- 120
7.6 OR EXTENSION DETECTION ASSEMBLY
2- 120
7.7 BOOM DISPLACEMENT DETECTION ASSEMBLY
2- 121
7.7.1 TOTAL LENGTH REEL
2- 121
7.7.2 ANGLE DETECTOR
2- 123
7.8 LOAD DETECTION ASSEMBLY
2- 124
7.8.1 PRESSURE AND OIL TEMPERATURE SENSOR
2- 125
7.9 LEVER DETECTION ASSEMBLY
2- 127
7.10 OVER-UNWINDING PREVENTION DEVICE
2- 127
7.11 GROUND DETECTION ASSEMBLY
2- 128
7.12. SLEWING DETECTION ASSEMBLY
2- 129
7.12.1 DIGITAL MAGNETIC REVOLUTION SENSOR PART NO.: S102M395900
2- 129
7.13 OVER-HOISTING PREVENTION DEVICE ASSEMBLY
2- 130
7.14 MOMENT LIMITER OVERVIEW AND MODEL
2- 131
7.14.1 OVERVIEW
2- 131
7.14.2 MODEL
2- 131
7.15 CALIBRATION OF MOMENT LIMITER
2- 131

0-5
Item Page
REMOTE CONTROL (OVERSEAS) F3- 1
1. COMPONENTS OF THETRANSMITTER F3- 2
1.1 NAMES AND DESCRIPTION OF REMOTE CONTROL PARTS F3- 2
1.2 NAME AND DESCRIPTION OF THE TRANSMITTER DISPLAY F3- 5
1.2.1 DESCRIPTION OF THE DISPLAY INDICATION SCREEN F3- 5
1.2.2 STATUS INDICATION FOR THE DISPLAY F3- 8
1.3 NAME AND DESCRIPTION OF THE RECEIVER F3- 9
1.4 DESCRIPTION OF REMOTE CONTROLLER ACCESSORIES F3- 11
2. HANDLING REMOTE CONTROLLER BATTERY F3- 12
2.1 TIME TO REPLACE THE BUTTERIES F3- 12
2.2 REPLACEMENT METHOD OF BATTERY F3- 12
2.3 HOW TO CHARGE THE BUTTERIES F3- 13
3. TROUBLESHOOTING F3-14
3.1 BEFORE REMOTE CONTROLLER FAILURE DIAGNOSIS F3-14
3.2 REMOTE CONTROLLER F3-15
3.3 ELECTRICAL WIRING FORREMOTE CONTROLLER F3-16
3.4 ELECTRICAL WIRING FOR REMOTE CONTROLLER DIAGRAM F3-17
4. PRINCIPAL SPECIFICATIONS LIST F3-18
5. LIST OF SERVICE LOCATIONS F3-19

0-6
Item Page
INSPECTION AND ADJUSTMENT 4- 1
1. INSPECTING/ADJUSTING THE FAN BELT TENSION 4- 2
2. INSPECTING/ADJUSTING THE RUBBER TRACK TENSION 4- 3
3. INSPECTING RUBBER TRACKS FOR DAMAGE ANDWEAR 4- 6
4. REPLACING WIREROPES 4- 7
5. INSPECTING/ADJUSTING THE TELESCOPING WIREROPE 4-10
DISASSEMBLING AND ASSEMBLING 5-1
1. PROCEDURE FOR DISASSEMBLING AND ASSEMBLING THE BOOM 5-2
1.1 REMOVING THE WINCH WIRES 5-2
1.2 REMOVING THE ROD PIN AND FOOT PIN FROM THE HYDRAULIC FITTING AND DERRICKING
CYLINDER 5-3
1.3 DISASSEMBLING THE BOOM 5- 4
1.3.1 REMOVING THE NO.1 BOOM 5- 4
1.3.2 REMOVING THE NO.2 BOOM 5- 5
1.3.3 REMOVING THE NO.3 BOOM 5- 6
1.3.4 REMOVING THE TELESCOPIC CYLINDER 5- 7
1.3.5 REMOVING THE NO.4 BOOM 5- 9
1.4 ASSEMBLING PROCEDURE FOR BOOMS 5- 10
1.4.1 ASSEMBLING THE TELESCOPIC CYLINDER 5- 10
1.4.2 ADJUSTING THE BOOM TELESCOPING WIRE ROPES 5-11
HYDRAULIC AND ELECTRIC CIRCUIT DIAGRAMS 6- 1
MC285C-3 HYDRAULIC CIRCUIT DIAGRAM 6- 1
MC285C-3 ELECTRICAL DIAGRAM (YANMAR ENGINE) 6- 2

0-7
Item
Page
ELECTRIC MOTOR
7- 1
PRINCIPAL ENGINE AND ELECTRIC MOTOR SPECIFICATIONS - COMPARISON TABLES
7- 1
1. ELECTRIC MOTOR UNIT ASSEMBLY
7- 2
1.1 POWER UNIT
7- 4
1.2 HYDRAULIC PUMP (MOTORIZED) - APPEARANCE AND SPECIFICATIONS
7- 5
2. ELECTRIC MOTOR WIRE HARNESS ASSEMBLY
7- 6
2.1 COMPONENTS OF POWER SUPPLY BOX
7- 7
2.2 INVERTER PANEL
7- 10
2.3 POWER SUPPLY CONNECTION
7- 11
2.4 MAINTENANCE AND INSPECTION
7- 12
2.4.1 DAILY INSPECTION
7- 12
2.4.2 PERIODIC INSPECTIONS
7- 13
2.5 NOTES REGARDING DISPOSAL
7- 15
3. INSTALLING ELECTRIC MOTOR UNIT
7- 16
3.1 REMOVING ELECTRIC MOTOR UNIT
7- 16
3.2 MOUNTING ELECTRIC MOTOR UNIT
7- 18
4. ELECTRIC MOTOR TROUBLESHOOTING
7- 19
5. ELECTRICAL WIRING DIAGRAM
7- 20
SEARCHER HOOK
8- 1
1. NAMES OF SEARCHER HOOK PARTS
8- 2
2. CHANGING SEARCHER HOOK ANGLE
8- 3
3. CHANGING TO THE SEARCHER HOOK MODE
8- 5
4. SEARCHER HOOK POSITION SETTINGS
8- 7
5. TROUBLESHOOTING
8- 8
6. WORKING RADIUS AND RATED TOTAL LOAD
8- 9
6.1 WORKING RADIUS / LIFTING HEIGHT DIAGRAM FOR SEARCHER HOOK
8- 9
6.2 RATED TOTAL LOAD TABLE FOR SEARCHER HOOK
8-10
AUXILIARY WINCH
9- 1
1. COMPONENTS OF AUXILIARY WINCH
9- 2
2. MONITOR
9- 3
2.1 DESCRIPTION OF HOME SCREEN
9- 3
2.2 DESCRIPTION OF USER MODE
9- 4
3. METHOD FOR REMOVING AND INSTALLING BOOM HEAD
9- 5
3.1 INSTALLING BOOM HEAD
9- 5
3.2 REMOVING BOOM HEAD
9- 10
4. AUXILIARY WINCH ASSEMBLY
9- 11
5. AUXILIARY WINCH ACCESSORIES ASSEMBLY
9- 12
5.1 AUXILIARY WINCH ACCESSORIES
9- 12
5.2 OVER-HOISTING PREVENTION DEVICE
9- 13
5.3 AUXILIARY WINCH THREE-WIND STOP
9- 14
5.3.1 OVER UN-WINDING DETECTOR
9- 15
5.3.2 IRREGULAR WINDING PREVENTION ROLLER
9- 15
6. APPEARANCE AND MODEL OF AUXILIARY WINCH MOTOR
9- 16
7. HYDRAULIC PIPING FOR AUXILIARY WINCH
9- 17
8.TROUBLESHOOTING AND COUNTERMEASURES
9- 19
8.1 WINCH MOTOR PROBLEMS
9- 19

0-8
Item
Page
8.2 WINCH MOTOR PRECAUTIONS
9- 20
8.3. OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE
9- 21
9. INSTALLATION OF WIRE ROPE
9- 22
10. PRINCIPAL SPECIFICATIONS LIST OF AUXILIARY WINCH
9- 24
10.1 PRINCIPAL SPECIFICATIONS TABLE FOR AUXILIARY WINCH
9- 24
10.2 DIMENSIONAL SPECIFICATION DIAGRAM
9- 25
10.3 WORKING RADIUS / LIFTING HEIGHT DIAGRAMS AND RATED TOTAL LOAD CHARTS
9- 26
10.3.1 WORKING RADIUS / LIFTING HEIGHT DIAGRAM FOR AUXILIARY WINCH
9- 26
10.3.2 RATED TOTAL LOAD CHART FOR AUXILIARY WINCH
9- 27
REFERENCE VALUES
10- 1
1. TABLE OF ENGINE RELATED REFERENCE VALUES
10- 2
1.1 YANMAR 2TNV70-NMBA (DOMESTIC [JAPANESE] / CE MODEL)
10- 2
1.2 SHIBAURA MODEL E672L-F-6701 (US MODEL)
10- 2
2. TABLE OF MACHINE RELATED REFERENCE VALUES
10- 3
3. TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES
10- 5
SERVICE MODE
S-1
SERVICE MODE
S-2
1. MONITORING
S-3
2. FUNCTIONS
S-4
2.1 CONTROL OUTPUT CHECK
S-4
2.1.1 CONTROL OUTPUT CHECK / NUMERICAL VALUE SELECTION SCREEN
S-5
2.2 CHECK CALIBRATION VALUE
S-6
2.3 INITIALIZE CALIBRATION
S-7
3. WORK HISTORY
S-8
4. ERROR HISTORY
S-11
5. INITIAL SETTING
S-12
5.1 SELECT WHETHER TO USE START PASSWORD
S-12
5.2 PASSWORD CHANGE AT START
S-12
5.3 PASSWORD INITIALIZE AT START
S-13
6. CRANE CALIBRATION
S-14
6.1 LEVEL CALIBRATION
S-15
6.2 BOOM SLEWING POSITION CALIBRATION
S-16
6.3 BOOM LENGTH CALIBRATION
S-17
6.4 BOOM ANGLE CALIBRATION.4 BOOM ANGLE CALIBRATION
S-18
6.5 LOAD CALIBRATION
S-19
7. ML SETTING
S-22
7.1 SETTING OF FALL FIXED
S-22
7.2 SETTING SEARCHER HOOK PRESENT / ABSENT
S-22
7.3 SETTING AUXILIARY WINCH PRESENT / ABSENT
S-22
8. SETTING AND RESETTING HBC REMOTE CONTROL SLOW SPEEDS
S-23
8.1 HBC REMOTE CONTROL SLOW SPEED ③- SETTING
S-23
8.2 HBC REMOTE CONTROL SLOW SPEED ①- SETTING
S-23
8.3 HBC REMOTE CONTROL SLOW SPEED ②- SETTING
S-23
8.4 HBC REMOTE CONTROL SLOW SPEED - RESET
S-24