Maeda MC305C-3 User manual

103ME-OM1903-00
Operation Manual
Mini-Crawler Crane
Serial No. D3001 and up

Improper use of this machine can lead to
serious injury.
The operators and maintenance personnel
must carefully read this manual and
sufficiently understand its contents before
operation / inspecting / maintaining the
machine.
Keep this manual at hand to read it over
anytime.

i
Table of Contents
Section 1 INTRODUCTION
INTRODUCTION................................................................................................................1-2
Section 2 SAFETY
SAFETY DEFINITIONS .....................................................................................................2-2
SAFETY PRECAUTIONS ..................................................................................................2-2
SAFETY LABEL LOCATIONS ...........................................................................................2-9
Machine Body...........................................................................................................2-9
Remote Control System .........................................................................................2-20
Electric Motor (Option)............................................................................................2-22
850kg Searcher Hook (Option)...............................................................................2-24
Section 3 SPECIFICATIONS, TERMINOLOGY AND
CAPACITY CHARTS
MACHINE FEATURES ......................................................................................................3-2
Main Features ..........................................................................................................3-2
Travelling Dolly ....................................................................................................3-2
Crane...................................................................................................................3-2
Safety Devices.....................................................................................................3-2
CRANE TERMINOLOGY ...................................................................................................3-3
Terms and Definitions...............................................................................................3-3
PRINCIPLE SPECIFICATIONS LIST.................................................................................3-4
Standard and Electric Motor Option Specifications ..................................................3-4
Remote Control System Specifications ....................................................................3-6
850 kg Searcher Hook Specifications.......................................................................3-7
DIMENSIONAL DRAWINGS..............................................................................................3-8
Machine Dimensional Drawing .................................................................................3-8
850kg Searcher Hook Dimensional Drawing ............................................................3-9
Outrigger Width Dimensional Drawing....................................................................3-10
RATED TOTAL LOAD CHARTS ......................................................................................3-11
Programmable Moment Limiter ..............................................................................3-11
Reading the Angle Indicator ..............................................................................3-11
Boom Length ..........................................................................................................3-12
Rated Total Load Chart for Standard Specification ................................................3-14
Rated Total Load Chart–4 Falls..............................................................................3-15
Rated Total Load Chart-2 Falls ..............................................................................3-16
Rated Total Load Chart-Single Fall ........................................................................3-17

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Rated Total Load Chart for 850 kg Searcher Hook ................................................3-18
WORKING RADIUS/LIFTING HEIGHT............................................................................3-20
Standard.................................................................................................................3-20
Working Radius/Lifting Height for Searcher Hook ..................................................3-22
Section 4 OPERATION
MACHINE COMPONENTS................................................................................................4-2
TRAVEL AND CRANE CONTROLS ..................................................................................4-4
38B37BControl Location .......................................................................................................4-4
INSTRUMENT PANEL SECTIONS....................................................................................4-7
Switches ...................................................................................................................4-8
Monitors..................................................................................................................4-10
OPERATION SEAT..........................................................................................................4-12
Seat Forward/Backward Slide Adjustment .............................................................4-13
Reclining Adjustment..............................................................................................4-13
COLD WEATHER OPERATION ......................................................................................4-13
Cautions When Snow Covered or Frozen ..............................................................4-13
Cautions under Cold Weather ................................................................................4-14
STARTING ENGINE ........................................................................................................4-15
Checking before Operation.....................................................................................4-15
Visible Checks ...................................................................................................4-15
Checking before Starting Engine .......................................................................4-15
Checking after Starting Engine ..........................................................................4-15
Normal Engine Start ...............................................................................................4-15
Starting Engine in Cold Weather ............................................................................4-16
Correction When Working at High Altitude .............................................................4-17
OPERATIONS AND CHECKS AFTER STARTING ENGINE...........................................4-18
STOPPING ENGINE........................................................................................................4-20
INSPECTION AFTER STOPPING ENGINE ....................................................................4-20
TRAVELLING POSITION.................................................................................................4-21
TRAVELLING CONTROLS AND OPERATION ...............................................................4-21
Cautions When Travelling ......................................................................................4-21
Allowable Water Depth ...........................................................................................4-22
Cautions on Upward/Downward Slope ...................................................................4-22
STARTING TRAVELLING MACHINE ..............................................................................4-23
Preparation before Starting Travelling ....................................................................4-23
Travelling Forward..................................................................................................4-23
Travelling Backward ...............................................................................................4-23
CHANGING MACHINE TRAVELLING MODE .................................................................4-24
DIRECTIONAL CONTROLS ............................................................................................4-24
Changing the Machine Direction While Being Stopped ..........................................4-24
Spin Turns .........................................................................................................4-25

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Changing Path While Travelling Forward/Backward ..............................................4-25
STOPPING/PARKING MACHINE ....................................................................................4-26
DESCRIPTION ON OUTRIGGER AND CRANE SAFETY DEVICES ..............................4-27
Outrigger Safety Devices........................................................................................4-27
Functions of Outrigger Safety Device ................................................................4-27
OUTRIGGER COMPONENTS.........................................................................................4-31
OUTRIGGER DISPLAY ...................................................................................................4-32
OUTRIGGER UN-SET WARNING LAMP (RED) .............................................................4-33
OUTRIGGER OPERATION PANEL.................................................................................4-34
OUTRIGGER SETTING...................................................................................................4-36
57B56BOutrigger Setting Precautions ................................................................................4-36
Cautions When Placing Outrigger .....................................................................4-37
58B57BTasks to Be Performed upon Engine Stop .............................................................4-39
59B58BTasks to Be Performed after Starting Engine .........................................................4-41
60B59BOutrigger Extension Modes ....................................................................................4-43
Outrigger Maximum Extension ..........................................................................4-43
Outrigger Midium Extension ..............................................................................4-43
Outrigger Minimum Extension ...........................................................................4-44
OUTRIGGER STOWING .................................................................................................4-45
61B60BTasks to Be Performed after Starting Engine .........................................................4-46
62B61BTasks to Be Performed upon Engine Stop .............................................................4-48
WORKING WITH CRANE................................................................................................4-49
CRANE OPERATION ......................................................................................................4-50
63B62BDos and Don’ts During Crane Operations ..............................................................4-50
64B63BBefore Crane Operations........................................................................................4-52
65B64BCrane Operation Posture........................................................................................4-54
66B65BHook Raising/Lowering Operation..........................................................................4-54
67B66BBoom Derricking Operation ....................................................................................4-55
68B67BBoom Telescoping Operation .................................................................................4-55
69B68BSlewing Operation ..................................................................................................4-56
70B69BAcceleration Operation ...........................................................................................4-56
71B70BCrane Stowing Operation .......................................................................................4-57
MOMENT LIMITER (OVERLOAD DETECTOR) ..............................................................4-59
72B71BMoment Limiter Features........................................................................................4-59
Function of Moment Limiter ....................................................................................4-60
Mechanism of Moment Limiter...........................................................................4-60
Display of Moment Limiter Error Messages .......................................................4-61
Moment Limiter Operations ....................................................................................4-61
Prohibited Actions after Auto Stop.....................................................................4-61
Recovery Operation after Auto Stop..................................................................4-61
Moment Limiter Display ..........................................................................................4-64
Descriptions of Switches on Moment Limiter Display .............................................4-65
Fall Mode Selector Switch and Fall Mode Display LED (Blue) ..........................4-65
Boom Angle Upper Limit Switch and LED (Orange) ..........................................4-65
Boom Angle Lower Limit Switch and LED (Orange) ..........................................4-66

iv
Working Radius Upper Limit Switch and LED (Orange) ....................................4-66
Lifting Height Upper Limit Switch and LED (Orange).........................................4-67
Cancel Switch....................................................................................................4-67
Check Switch.....................................................................................................4-67
Descriptions of Moment Limiter Display .................................................................4-68
Actual Load Display Section ..............................................................................4-68
Rated Total Load Display Section .....................................................................4-68
Working Radius Display Section........................................................................4-69
Boom Length Display Section............................................................................4-69
Lifting Height Display Section ............................................................................4-69
Boom Angle Display Section .............................................................................4-69
Over Winding LED (Red) ...................................................................................4-69
Outrigger Extension LED (Blue) ........................................................................4-69
Load Factor LED (Changes to Green/ Yellow/Red)...........................................4-70
Load Factor Display (Yellow).............................................................................4-70
Moment Limiter Functions ......................................................................................4-70
Overload Warning..............................................................................................4-70
Working Envelope Restriction Warning .............................................................4-71
Over Winding Detector ......................................................................................4-71
Number of Wires Selector Switch ......................................................................4-72
Boom Upper Limit Detection..............................................................................4-72
Boom Lower Limit Detection..............................................................................4-72
Outrigger Extension Detection...........................................................................4-72
Moment Limiter Starting Status ..............................................................................4-72
Moment Limiter Working Envelope Setting.............................................................4-72
Setting Working Envelope .................................................................................4-73
Cancelling Working Envelope Setting................................................................4-73
Moment Limiter Override Switch ............................................................................4-74
REMOTE CONTROL SYSTEM INTRODUCTION ...........................................................4-75
General...................................................................................................................4-75
No Modification..................................................................................................4-75
No Water Washing ............................................................................................4-75
No Shock to the Transmitter ..............................................................................4-76
Precaution for Operations in Cold Seasons.......................................................4-76
Precautions for Handling of Connection Cable ..................................................4-76
Precautions for Crane Operation - before Starting Engine .....................................4-77
Inspection Prior to Starting Engine ....................................................................4-77
Safety Measures for Starting Engine .................................................................4-77
Inspection Prior to Turn on the Transmitter .......................................................4-77
Inspection after Turning on the Transmitter .......................................................4-77
Inspection Prior to Turn on the Receiver ...........................................................4-77
Precautions for Crane Operation - after Starting Engine ........................................4-77
Function Check of Outrigger Mode by the Transmitter, and Notices for Operation ........4-77
Function Check of Crane Mode by the Transmitter and Notices for Operation ..............4-77
Precautions for Crane Operation - Terminating the Operation ...............................4-78
Precautions for Terminating the Operation by the Transmitter ..........................4-78
REMOTE CONTROL SYSTEM FEATURES ...................................................................4-78
Transmitter .............................................................................................................4-79

v
Receiver .................................................................................................................4-79
Functions of Remote Control System .....................................................................4-79
REMOTE CONTROL SYSTEM COMPONENTS .............................................................4-80
Transmitter .............................................................................................................4-80
LCD Screen .......................................................................................................4-81
Start/Reset Button .............................................................................................4-81
Stop/EMO Button...............................................................................................4-81
Speed/Mode Button...........................................................................................4-81
Hook Stow/Setting Button..................................................................................4-81
Horn Button .......................................................................................................4-81
Power Switch.....................................................................................................4-82
Slewing/No.1 Outrigger Operation Lever ...........................................................4-82
Boom Telescoping/No.2 Outrigger Operation Lever..........................................4-82
Hook Raising and Lowering/No.3 Outrigger Operation Lever............................4-83
Boom Lift/No.4 Outrigger Operation Lever ........................................................4-83
Accelerator Lever ..............................................................................................4-84
Grip....................................................................................................................4-84
Connection Cable ..............................................................................................4-84
Storage Case.....................................................................................................4-85
Hook Belt ...........................................................................................................4-85
Receiver Components ............................................................................................4-86
Control Box........................................................................................................4-87
Main Switch .......................................................................................................4-87
Monitor Display..................................................................................................4-87
Receptacle.........................................................................................................4-87
Fuse in the Receiver...............................................................................................4-88
Removal of the Fuse..........................................................................................4-88
Insertion of a Fuse.............................................................................................4-89
MODE SETTING OF THE TRANSMITTER .....................................................................4-89
A Mode ...................................................................................................................4-89
Opening A Mode Screen ...................................................................................4-89
Messages in the A Mode Screen.......................................................................4-90
An Example for Setting in the A Mode...............................................................4-93
Procedure in the Operation Mode ..........................................................................4-94
Call Out Crane Mode.........................................................................................4-94
Call Out Outrigger Mode....................................................................................4-94
REMOTE CONTROL SYSTEM VERIFICATIONS ...........................................................4-96
Checking Before Starting Engine ...........................................................................4-96
Checking before Turning ON the Transmitter.........................................................4-96
Checking after Turning on the Transmitter ........................................................4-96
Checking Receiver ............................................................................................4-99
Checking after Starting Engine.............................................................................4-100
Verification for the Engine Start and Stop........................................................4-100
Checking "Outrigger Mode" Operation.............................................................4-101
Checking "Crane Mode" Operation..................................................................4-103
REMOTE CONTROL OPERATION ...............................................................................4-106
Cautions Before Operation ...................................................................................4-106

vi
Operation in Outrigger Mode ................................................................................4-107
Outrigger Setting .............................................................................................4-108
Outrigger Stowage...........................................................................................4-109
Operation in Crane Mode .....................................................................................4-110
Slewing Operation ...........................................................................................4-111
Boom Telescoping Operation ..........................................................................4-111
Hook Raising and Lowering Operation ............................................................4-112
Boom Derricking Operation .............................................................................4-112
Automatic Hook Stow Function........................................................................4-113
Set-Up/Cancel Micro Speed and Enhanced Speed Mode ...............................4-113
Engine Stop and Emergency Stop Procedure .................................................4-115
Engine Start and Reset Procedure ..................................................................4-116
Checking after Crane Operation...........................................................................4-116
ELECTRIC MOTOR (OPTION) ......................................................................................4-117
Instrument Panel Sections....................................................................................4-118
Power Unit............................................................................................................4-119
Power Supply Box ................................................................................................4-119
Inverter Unit..........................................................................................................4-120
ELECTRIC MOTOR OPERATION .................................................................................4-122
Pre-start Inspection ..............................................................................................4-122
Pre-start Visible Checks ..................................................................................4-122
Checking Before Starting Electric Motor ..........................................................4-122
Checking After Starting Electric Motor.............................................................4-122
Connecting Power Supply Cable..........................................................................4-122
Operation and Checking After Power Connection ................................................4-124
Machine Operation ...............................................................................................4-126
Machine Stop and Checks after Stopping Machine..............................................4-126
Disconnecting Power Supply Cable .....................................................................4-126
SEARCHER HOOK SAFETY PRECAUTIONS..............................................................4-127
Handling Precautions ...........................................................................................4-127
Moment Limiter Settings Check.......................................................................4-127
Precautions When Attaching/Removing Main Unit or Altering Position ...........4-127
Operating Precautions..........................................................................................4-127
Precautions Using Boom Raising ....................................................................4-127
850 kg SEARCHER HOOK COMPONENTS (OPTION) ................................................4-128
850 kg SEARCHER HOOK MOMENT LIMITER DISPLAY............................................4-129
SEARCHER HOOK OPERATION..................................................................................4-132
TRANSPORTATION ......................................................................................................4-135
Transport Precautions ..........................................................................................4-135
Cautions When Loading or Unloading .............................................................4-135
Cautions During Transport...............................................................................4-136
Cautions When Loading/Unloading with Crane ...............................................4-136
Loading/Unloading................................................................................................4-137
Hoisting Machine..................................................................................................4-138
Cautions on Loading Machine ..............................................................................4-140
Cautions During Transportation............................................................................4-140

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Section 5 MAINTENANCE AND INSPECTION
GENERAL MAINTENANCE INFORMATION AND PRECAUTIONS..................................5-2
17BPrecautions Before Maintenance .............................................................................5-2
18BPrecautions During Maintenance .............................................................................5-4
19BCheck the Service Meters ........................................................................................5-8
20BUse Genuine Parts for Replacement........................................................................5-8
21BUse Pure Grease......................................................................................................5-8
22BUse Clean Oil and Grease........................................................................................5-8
23BKeep the Machine Clean ..........................................................................................5-8
24BHandle Water and Oil at Adequate Temperature .....................................................5-8
25BCheck Drain Oil and Oil Filter ...................................................................................5-8
26BCautions for Lubrication............................................................................................5-8
27BProtect Oil from Impurities ........................................................................................5-8
28BAttach a Warning Tag...............................................................................................5-8
29BFollow Safety Precautions ........................................................................................5-8
30BCautions for Weld Repair .........................................................................................5-8
31BKeep from Flame......................................................................................................5-8
32BKeep the Attachment Surface Clean ........................................................................5-8
33BEmpty Your Pockets .................................................................................................5-8
Assure Safe Rubber Track .......................................................................................5-9
Cautions for Machine Wash .....................................................................................5-9
Pre- and Post-Work Inspection.................................................................................5-9
Cautions for Working in a Dusty Site........................................................................5-9
Do Not Mix Oil ..........................................................................................................5-9
BASIC MAINTENANCE .....................................................................................................5-9
Oil Handling..............................................................................................................5-9
Fuel Handling .........................................................................................................5-10
Stocking and Storage of Oil and Fuel.....................................................................5-10
Grease Handling ....................................................................................................5-10
Filter Handling ........................................................................................................5-10
Coolant Handling....................................................................................................5-10
Electrical Part Handling ..........................................................................................5-11
Hydraulic Equipment Handling ...............................................................................5-11
BREAKING-IN MACHINE ................................................................................................5-12
LEGAL INSPECTION.......................................................................................................5-12
CONSUMABLES..............................................................................................................5-13
LUBRICATING OIL ..........................................................................................................5-14
SPECIAL TOOLS AND STANDARD TIGHTENING TORQUE ........................................5-15
47BAccessory Tools .....................................................................................................5-15
48BStandard Tightening Torque List ............................................................................5-15
Bolt and Nut Tightening Torque.........................................................................5-15
Hose Connector Tightening Torque...................................................................5-17
MACHINERY COVER......................................................................................................5-18
49BRemoving Machinery Cover ...................................................................................5-18
50BInstalling Machinery Cover .....................................................................................5-18

viii
REAR COVER .................................................................................................................5-19
51BRemoving Rear Cover ............................................................................................5-19
52BInstalling Rear Cover ..............................................................................................5-19
FUSES .............................................................................................................................5-20
INSPECTION ...................................................................................................................5-21
Pre-Start and Post-Start Inspection Items ..............................................................5-21
Pre-Start Visible Checks.........................................................................................5-22
Crane.................................................................................................................5-23
Wire Ropes........................................................................................................5-23
Hook Block ........................................................................................................5-23
Outriggers..........................................................................................................5-24
Undercarriage Parts...........................................................................................5-24
Travelling Dolly ..................................................................................................5-24
Engine ...............................................................................................................5-24
Travel and Crane Operation Section .................................................................5-24
Pre-Start Inspection - Before Starting Engine.........................................................5-25
Check / Refill Engine Coolant ............................................................................5-25
Check / Add Engine Oil......................................................................................5-26
Check / Add Fuel ...............................................................................................5-27
Check / Clean Water Separator.........................................................................5-28
Check / Clean Fuel Filter Pot.............................................................................5-29
Check / Add Hydraulic Oil..................................................................................5-30
Check / Refill Oil Level in Slewing Reduction Gear Case ..................................5-31
Check / Refill Oil Level in Travelling Motor Reduction Gear Case.....................5-31
Check / Clean Radiator and Oil Cooler Fins......................................................5-32
Check Battery Charge Level..............................................................................5-32
Post-Start Inspection - After Starting Engine ..........................................................5-33
Check Horn........................................................................................................5-33
Check Working Lights........................................................................................5-33
Check Fuse Box for Damage.............................................................................5-33
Check Outrigger Display....................................................................................5-34
Check Over Winding Detector Operation...........................................................5-35
Check Moment Limiter Operation ......................................................................5-35
PERIODIC MAINTENANCE.............................................................................................5-36
Periodic Maintenance Schedule .............................................................................5-36
Periodic Maintenance Procedure ...........................................................................5-37
Drain Contaminant Water/Deposits in Water Separator ....................................5-38
Grease Machine Units .......................................................................................5-39
Replace Engine Oil and Oil Filter.......................................................................5-41
Check / Adjust Belt Tension...............................................................................5-42
Check / Refill Oil in Travelling Motor Reduction Gear Case ..............................5-43
Inspect / Clean / Replace Air Cleaner................................................................5-44
Drain Contaminant Water/Deposits in Fuel Tank...............................................5-45
Replace Fuel Filter Cartridge.............................................................................5-46
Replace Hydraulic Oil Return Filter ...................................................................5-46
Replace Hydraulic Oil Suction Filter ..................................................................5-47
Replace Air Cleaner Element ............................................................................5-48
Coolant Replacement and Internal Cleaning .....................................................5-49