Maeda MC405C-3 User manual

Operation Manual
Mini-Crawler Crane
104ME-OM1901-00

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.

Mini-Crawler Crane M A E D A Table of Contents
1/2019 MC405C-3 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 ......................................................................................... 2-24
Electric Motor (Option)............................................................................................ 2-26
850kg Searcher Hook (Option)............................................................................... 2-27
Fly-Jib (Option) ....................................................................................................... 2-30
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
Fly-Jib Specifications................................................................................................ 3-8
DIMENSIONAL DRAWINGS.............................................................................................. 3-9
Machine Dimensional Drawing ................................................................................. 3-9
850 kg Searcher Hook Dimensonal Drawing.......................................................... 3-10
Fly-Jib Dimensonal Drawing................................................................................... 3-11
Outrigger Width Dimensional Drawing ................................................................... 3-12
RATED TOTAL LOAD CHARTS ...................................................................................... 3-13
Programmable Moment Limiter .............................................................................. 3-13
Reading the Angle Indicator .............................................................................. 3-13
Boom Length .......................................................................................................... 3-14
Rated Total Load Chart for Standard Specification ................................................ 3-16

Table of Contents Mini-Crawler Crane M A E D A
ii 1/2019 MC405C-3
Rated Total Load Chart - 4 Falls ............................................................................ 3-17
Rated Total Load Chart - 2 Falls ............................................................................ 3-18
Rated Total Load Chart - Single Fall ...................................................................... 3-19
Rated Total Load Chart for 850 kg Searcher Hook ................................................ 3-20
Rated Total Load Chart for Fly-Jib ......................................................................... 3-22
WORKING RADIUS/LIFTING HEIGHT............................................................................ 3-23
Standard ................................................................................................................. 3-23
During Pick & Carry ................................................................................................ 3-25
Working Radius/Lifting Height for 850 kg Searcher Hook ...................................... 3-26
Working Radius/Lifting Height for Fly-jib ................................................................ 3-28
Section 4 OPERATION
MACHINE COMPONENTS ................................................................................................ 4-2
TRAVEL AND CRANE CONTROLS .................................................................................. 4-4
Control Location........................................................................................................ 4-4
Acceleration Pedal............................................................................................... 4-5
Slewing Lever ...................................................................................................... 4-5
Boom Telescoping Lever ..................................................................................... 4-5
Winch Lever......................................................................................................... 4-5
Boom Derricking Lever ........................................................................................ 4-5
Travelling Lock Lever........................................................................................... 4-6
Left/Right Travelling Lever................................................................................... 4-6
Level Gauge ........................................................................................................ 4-6
Outrigger Un-Set Warning Lamp (Yellow) ........................................................... 4-6
INSTRUMENT PANEL SECTIONS.................................................................................... 4-7
Switches ................................................................................................................... 4-8
Monitors .................................................................................................................. 4-11
OPERATION SEAT.......................................................................................................... 4-13
Seat Forward/Backward Slide Adjustment ............................................................. 4-13
Reclining Adjustment.............................................................................................. 4-13
OPERATION RELATED PRECAUTIONS........................................................................ 4-14
Before Starting Engine ........................................................................................... 4-14
After Starting Engine............................................................................................... 4-15
COLD WEATHER OPERATION ...................................................................................... 4-16
Cautions When Snow Covered or Frozen.............................................................. 4-16
Cautions under Cold Weather ................................................................................ 4-17
STARTING ENGINE ........................................................................................................ 4-18
Checking Before Operation .................................................................................... 4-18
Visible Checks ................................................................................................... 4-18
Checking Before Starting Engine....................................................................... 4-18
Checking After Starting Engine.......................................................................... 4-18
Normal Engine Start ............................................................................................... 4-18
Starting Engine in Cold Weather ............................................................................ 4-19
OPERATIONS AND CHECKS AFTER STARTING ENGINE .......................................... 4-20

Mini-Crawler Crane M A E D A Table of Contents
1/2019 MC405C-3 iii
STOPPING ENGINE ........................................................................................................ 4-22
INSPECTION AFTER STOPPING ENGINE .................................................................... 4-22
TRAVELLING POSITION................................................................................................. 4-23
TRAVELLING CONTROLS AND OPERATION ............................................................... 4-23
Cautions When Travelling ...................................................................................... 4-23
Allowable Water Depth ........................................................................................... 4-23
Cautions on Upward/Downward Slope................................................................... 4-24
STARTING TRAVELLING MACHINE .............................................................................. 4-25
Preparation Before Starting Travelling ................................................................... 4-25
Travelling Forward.................................................................................................. 4-25
Travelling Backward ............................................................................................... 4-25
CHANGING MACHINE TRAVELLING MODE ................................................................. 4-26
Changing Travelling Speed Mode .......................................................................... 4-26
DIRECTIONAL CONTROLS ............................................................................................ 4-26
Changing the Machine Direction While Being Stopped.......................................... 4-26
Spin Turns ......................................................................................................... 4-27
Changing Path While Travelling Forward/Backward .............................................. 4-27
STOPPING/PARKING MACHINE .................................................................................... 4-28
DESCRIPTION ON OUTRIGGER AND CRANE SAFETY DEVICES ............................. 4-29
Outrigger Safety Devices........................................................................................ 4-29
Functions of Outrigger Safety Devices .............................................................. 4-29
Check Before Setting Outriggers ....................................................................... 4-30
Outrigger Setting Operation............................................................................... 4-30
Crane Operations .............................................................................................. 4-31
Crane Stowing Operation .................................................................................. 4-31
Outrigger Stowing Operation ............................................................................. 4-32
Machine Travelling Operation............................................................................ 4-32
Description of Pick & Carry Safety Devices............................................................ 4-33
Check Before Setting Outriggers ....................................................................... 4-33
Outrigger Setting Operation............................................................................... 4-33
Crane Operations .............................................................................................. 4-34
Pick & Carry Operation ...................................................................................... 4-34
Outrigger Setting Operation............................................................................... 4-35
Crane Stowing Operation .................................................................................. 4-35
Outrigger Stowing Operation ............................................................................. 4-35
Machine Travelling Operation............................................................................ 4-36
OUTRIGGER COMPONENTS......................................................................................... 4-37
OUTRIGGER DISPLAY ................................................................................................... 4-38
OUTRIGGER UN-SET WARNING LAMP (YELLOW)...................................................... 4-39
OUTRIGGER OPERATION PANEL................................................................................. 4-40
Work Selector Switch (Travel, Outrigger, Crane) .............................................. 4-40
Outrigger Grounding Switches........................................................................... 4-41
Outrigger Extension Switch ............................................................................... 4-41
OUTRIGGER SETTING ................................................................................................... 4-42

Table of Contents Mini-Crawler Crane M A E D A
iv 1/2019 MC405C-3
Outrigger Setting Precautions ................................................................................ 4-42
Tasks to Be Performed upon Engine Stop ............................................................. 4-44
Tasks to Be Performed after Starting Engine ......................................................... 4-46
Outrigger Extension Modes .................................................................................... 4-48
Outrigger Maximum Extension .......................................................................... 4-48
Outrigger Medium Extension ............................................................................. 4-48
Outrigger Minimum Extension ........................................................................... 4-49
OUTRIGGER STOWING ................................................................................................. 4-49
Tasks to Be Performed after Starting Engine ......................................................... 4-50
Tasks to Be Performed upon Engine Stop ............................................................. 4-52
WORKING WITH CRANE ................................................................................................ 4-53
CRANE OPERATION....................................................................................................... 4-60
Dos and Don’ts During Crane Operations .............................................................. 4-60
Before Crane Operations........................................................................................ 4-62
Crane Operation Posture........................................................................................ 4-63
Hook Raising/Lowering Operation.......................................................................... 4-63
Boom Derricking Operation .................................................................................... 4-64
Boom Telescoping Operation ................................................................................. 4-64
Slewing Operation .................................................................................................. 4-65
Acceleration Operation ........................................................................................... 4-65
Crane Stowing Operation ....................................................................................... 4-66
MOMENT LIMITER (OVERLOAD DETECTOR) .............................................................. 4-68
Moment Limiter Features........................................................................................ 4-68
Function of Moment Limiter .................................................................................... 4-69
Mechanism of Moment Limiter........................................................................... 4-69
Display of Moment Limiter Error Messages....................................................... 4-69
Moment Limiter Operations .................................................................................... 4-70
Prohibited Actions After Auto Stop .................................................................... 4-70
Recovery Operation After Auto Stop ................................................................. 4-70
Moment Limiter Display .......................................................................................... 4-72
Descriptions of Switches on Moment Limiter Display............................................. 4-73
Wire Falls Selector Switch and Wire Falls Display LED (Blue) ......................... 4-73
Boom Angle Upper Limit Switch and LED (Orange).......................................... 4-73
Boom Angle Lower Limit Switch and LED (Orange).......................................... 4-74
Working Radius Upper Limit Switch and LED (Orange).................................... 4-74
Lifting Height Upper Limit Switch and LED (Orange) ........................................ 4-75
Cancel Switch .................................................................................................... 4-75
Check Switch ..................................................................................................... 4-75
Descriptions of Moment Limiter Display ................................................................. 4-76
Actual Load Display Section .............................................................................. 4-76
Rated Total Load Display Section ..................................................................... 4-76
Working Radius Display Section........................................................................ 4-77
Boom Length Display Section............................................................................ 4-77
Lifting Height Display Section ............................................................................ 4-77
Boom Angle Display Section ............................................................................. 4-77
Over Winding LED (Red) ................................................................................... 4-77
Outrigger Extension LED (Blue) ........................................................................ 4-77

Mini-Crawler Crane M A E D A Table of Contents
1/2019 MC405C-3 v
Load Factor LED (Changes to Green/Yellow/Red) ........................................... 4-78
Load Factor Display (Yellow)............................................................................. 4-78
Moment Limiter Functions ...................................................................................... 4-79
Overload Warning.............................................................................................. 4-79
Working Envelope Restriction Warning ............................................................. 4-79
Over Winding Detector ...................................................................................... 4-80
Number of Wires Selector Switch...................................................................... 4-81
Boom Upper Limit Detection.............................................................................. 4-81
Boom Lower Limit Detection.............................................................................. 4-81
Outrigger Extension Detection........................................................................... 4-81
Moment Limiter Starting Status .............................................................................. 4-81
Moment Limiter Working Envelope Setting ............................................................ 4-82
Setting Working Envelope ................................................................................. 4-82
Cancelling Working Envelope Setting................................................................ 4-82
Moment Limiter Override Switch ............................................................................ 4-83
Pick & Carry Operation........................................................................................... 4-84
Cautions During Pick & Carry Operation ........................................................... 4-84
Rated Total Load and Working Range Caution During Pick & Carry ................ 4-84
Cautions on Worksite......................................................................................... 4-84
Cautions on Operations ..................................................................................... 4-84
Pick & Carry Posture ......................................................................................... 4-85
Pick & Carry Operations .................................................................................... 4-86
Cancelling Pick & Carry Operation Posture....................................................... 4-86
REMOTE CONTROL SYSTEM INTRODUCTION........................................................... 4-87
General ................................................................................................................... 4-87
Precautions for Crane Operation - before Starting Engine..................................... 4-89
Precautions for Crane Operation - after Starting Engine........................................ 4-89
Precautions for Crane Operation - Terminating the Operation............................... 4-90
REMOTE CONTROL SYSTEM FEATURES ................................................................... 4-90
Transmitter.............................................................................................................. 4-91
Receiver.................................................................................................................. 4-91
Functions of Remote Control System..................................................................... 4-91
REMOTE CONTROL SYSTEM COMPONENTS............................................................. 4-92
Transmitter.............................................................................................................. 4-92
Receiver Components ............................................................................................ 4-97
Fuse in the Receiver............................................................................................... 4-98
Removal of the Fuse.......................................................................................... 4-98
Insertion of a Fuse ............................................................................................. 4-99
MODE SETTING OF THE TRANSMITTER ................................................................... 4-100
A Mode ................................................................................................................. 4-100
Opening A Mode Screen ................................................................................. 4-100
Messages in the A Mode Screen..................................................................... 4-100
An Example for Setting in the A Mode............................................................. 4-103
Procedure in the Operation Mode ........................................................................ 4-104
Call Out Crane Mode ....................................................................................... 4-104
Call Out Outrigger Mode.................................................................................. 4-105
REMOTE CONTROL SYSTEM VERIFICATIONS ......................................................... 4-106

Table of Contents Mini-Crawler Crane M A E D A
vi 1/2019 MC405C-3
Checking Before Starting Engine ......................................................................... 4-106
Checking Before Turning on the Transmitter................................................... 4-106
Checking After Turning on the Transmitter...................................................... 4-107
Checking Receiver........................................................................................... 4-110
Checking After Starting Engine ............................................................................ 4-111
Verification for the Engine Start and Stop........................................................ 4-111
Checking "Outrigger Mode" Operation ............................................................ 4-112
Checking "Crane Mode" Operation.................................................................. 4-114
REMOTE CONTROL OPERATION ............................................................................... 4-116
Cautions Before Operation ................................................................................... 4-116
Operation in Outrigger Mode ................................................................................ 4-116
Outrigger Setting.............................................................................................. 4-118
Outrigger Stowage........................................................................................... 4-119
Operation in Crane Mode ..................................................................................... 4-120
Slewing Operation ........................................................................................... 4-121
Boom Telescoping ........................................................................................... 4-122
Hook Raising and Lowering Operation ............................................................ 4-122
Boom Derricking Operation ............................................................................. 4-122
Automatic Hook Stow Function........................................................................ 4-123
Set-Up/Cancel Micro Speed and Enhanced Speed Mode .............................. 4-124
Engine Stop and Emergency Stop Procedure................................................. 4-126
Engine Start and Reset Procedure.................................................................. 4-126
Checking After Crane Operation .......................................................................... 4-127
ELECTRIC MOTOR (OPTION) ...................................................................................... 4-128
Instrument Panel Sections.................................................................................... 4-129
Engine and Electric Motor Switch .................................................................... 4-129
Power Unit ............................................................................................................ 4-130
Power Supply Box ................................................................................................ 4-130
Inverter Unit .......................................................................................................... 4-131
Main Breaker (with a Leak Detector) ............................................................... 4-132
DC12V Power Switch ...................................................................................... 4-132
AC Circuit Power Switch.................................................................................. 4-133
Power Lamp (White) ........................................................................................ 4-133
Trouble Lamp (Red)......................................................................................... 4-133
ELECTRIC MOTOR OPERATION ................................................................................. 4-134
Pre-start Inspection............................................................................................... 4-134
Pre-start Visible Checks .................................................................................. 4-134
Checking Before Starting Electric Motor.......................................................... 4-134
Checking After Starting Electric Motor............................................................. 4-134
Connecting Power Supply Cable.......................................................................... 4-134
Operation and Checking After Power Connection................................................ 4-136
Machine Operation ............................................................................................... 4-137
Machine Stop and Checks After Stopping Machine ............................................. 4-138
Disconnecting Power Supply Cable ..................................................................... 4-138
SEARCHER HOOK SAFETY PRECAUTIONS.............................................................. 4-139
Handling Precautions ........................................................................................... 4-139
Operating Precautions.......................................................................................... 4-139

Mini-Crawler Crane M A E D A Table of Contents
1/2019 MC405C-3 vii
850 kg SEARCHER HOOK COMPONENTS (OPTION) ................................................ 4-140
850 kg SEARCHER HOOK MOMENT LIMITER DISPLAY............................................ 4-141
Wire Falls Selector Switch and Wire Falls Display LED (Blue) ....................... 4-142
Cancel Switch .................................................................................................. 4-142
SEARCHER HOOK OPERATION.................................................................................. 4-144
FLY-JIB SAFETY PRECAUTIONS ................................................................................ 4-148
FLY-JIB COMPONENTS (OPTION) .............................................................................. 4-149
FLY-JIB INSTALLATION AND STOWAGE.................................................................... 4-150
Fly-Jib Installation................................................................................................. 4-151
Fly-Jib Stowage (Single Fall Hook Mode) ............................................................ 4-156
Change to Single Fall Hook from Main-Boom Hook Block ................................... 4-160
Removal of Fly-Jib Assembly ............................................................................... 4-162
Installation of Fly-Jib Assembly ............................................................................ 4-163
FLY-JIB MOMENT LIMITER CONTROL........................................................................ 4-167
Moment Limiter Display ........................................................................................ 4-167
Items of Moment Limiter Restriction for Operation ............................................... 4-168
Operation Control by Moment Limiter.............................................................. 4-168
Restriction in Fly-Jib Mode .............................................................................. 4-168
Restriction for Boom Stowing Operation.......................................................... 4-170
Instruction for Fly-Jib Operation ........................................................................... 4-170
Moment Limiter Mode Change ........................................................................ 4-170
Instruction for Operation .................................................................................. 4-171
Operation for Boom Retraction........................................................................ 4-172
TRANSPORTATION ...................................................................................................... 4-172
Transport Precautions .......................................................................................... 4-172
Loading/Unloading................................................................................................ 4-174
Hoisting Machine .................................................................................................. 4-175
Cautions on Loading Machine .............................................................................. 4-176
Cautions During Transportation............................................................................ 4-176
Section 5 MAINTENANCE AND INSPECTION
GENERAL MAINTENANCE INFORMATION AND PRECAUTIONS ................................. 5-2
Precautions Before Maintenance ............................................................................. 5-2
Precautions During Maintenance ............................................................................. 5-4
Check the Service Meters ........................................................................................ 5-8
Use Genuine Parts for Replacement........................................................................ 5-8
Use Pure Grease...................................................................................................... 5-8
Use Clean Oil and Grease........................................................................................ 5-8
Keep the Machine Clean .......................................................................................... 5-8
Handle Water and Oil at Adequate Temperature ..................................................... 5-8
Check Drain Oil and Oil Filter ................................................................................... 5-8
Cautions for Lubrication............................................................................................ 5-8
Protect Oil from Impurities ........................................................................................ 5-8
Attach a Warning Tag............................................................................................... 5-8

Table of Contents Mini-Crawler Crane M A E D A
viii 1/2019 MC405C-3
Follow Safety Precautions ........................................................................................ 5-8
Cautions for Weld Repair ......................................................................................... 5-8
Keep from Flame ...................................................................................................... 5-8
Keep the Attachment Surface Clean ........................................................................ 5-8
Empty 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
Accessory Tools ..................................................................................................... 5-15
Standard Tightening Torque List ............................................................................ 5-15
Bolt and Nut Tightening Torque......................................................................... 5-15
Hose Connector Tightening Torque................................................................... 5-17
MACHINERY COVER ...................................................................................................... 5-18
Removing Machinery Cover ................................................................................... 5-18
Installing Machinery Cover ..................................................................................... 5-18
REAR COVER.................................................................................................................. 5-19
Removing Rear Cover ............................................................................................ 5-19
Installing 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 .......................................................................................................... 5-23
Tracks and Frame.............................................................................................. 5-24
Engine................................................................................................................ 5-24
Travel and Crane Controls................................................................................. 5-24