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.

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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

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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

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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

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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

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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

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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

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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

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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

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Pre-Start Inspection - Before Starting Engine ........................................................ 5-24
Check / Add Engine Coolant.............................................................................. 5-24
Check / Add Engine Oil...................................................................................... 5-25
Check / Add Fuel ............................................................................................... 5-26
Check / Clean Water Separator......................................................................... 5-26
Check / Add Hydraulic Oil.................................................................................. 5-27
Check / Add Slewing Motor Reduction Gear Case Oil ...................................... 5-28
Check / Add Travelling Motor Reduction Gear Case Oil ................................... 5-28
Check Dust Indicator ......................................................................................... 5-29
Check Battery Charge Level.............................................................................. 5-29
Check Horn........................................................................................................ 5-30
Check Working Light Operation......................................................................... 5-30
Check Fuse Box ................................................................................................ 5-30
Check Outrigger Display.................................................................................... 5-30
Adjust Operation Seat........................................................................................ 5-31
Post-Start Inspection - After Starting Engine.......................................................... 5-31
Check / Adjust Rubber Track Tension............................................................... 5-31
Check Rubber Tracks for Damage and Wear.................................................... 5-33
Check Outrigger Safety Device Operation......................................................... 5-33
Check Outrigger Operation................................................................................ 5-35
Check Crane Operation ..................................................................................... 5-36
Check Over Winding Detector Operation .......................................................... 5-37
Check Moment Limiter Operation ...................................................................... 5-37
Check Outrigger Extension Positions ................................................................ 5-38
Check Engine Exhaust Gas Colour, Noise and Vibration.................................. 5-38
PERIODIC MAINTENANCE............................................................................................. 5-39
Periodic Maintenance Schedule ............................................................................. 5-39
Periodic Maintenance Procedure ........................................................................... 5-40
Grease Machine Units ....................................................................................... 5-41
Check Oil Level and Refill Oil in Winch Reduction Gear Case.......................... 5-43
Radiator and Oil Cooler Fin Inspection/Cleaning............................................... 5-44
Check / Adjust Belt Tension............................................................................... 5-44
Check / Refill Oil in Travelling Motor Reduction Gear Case.............................. 5-45
Replace Engine Oil and Oil Filter....................................................................... 5-46
Replace Fuel Filter Cartridge............................................................................. 5-47
Replace Hydraulic Oil Return Filter ................................................................... 5-48
Replace Hydraulic Oil Suction Filter .................................................................. 5-49
Slew Ring Mounting Bolt Inspection .................................................................. 5-50
Replace Air Cleaner Element ............................................................................ 5-50
Replace Oil in Hydraulic Oil Tank...................................................................... 5-51
Replace Oil in Slewing Reduction Gear Case ................................................... 5-52
Replace Oil in Winch Reduction Gear Case...................................................... 5-53
Replace Oil in Travelling Motor Reduction Gearcase........................................ 5-54
Inspect / Adjust Inlet Valve and Exhaust Valve Clearance................................ 5-55
Inspect / Clean / Test Fuel Injector.................................................................... 5-55
Check Crankcase Breather................................................................................ 5-55
Check / Replace Engine Coolant....................................................................... 5-55
Inspect / Clean EGR Valve ................................................................................ 5-56

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GENERAL MACHINE MAINTENANCE ........................................................................... 5-56
Batteries.................................................................................................................. 5-56
Battery Precautions ........................................................................................... 5-56
Cautions In Handling Battery.................................................................................. 5-57
Remove / Install Battery..................................................................................... 5-58
Removal............................................................................................................. 5-58
Installation.......................................................................................................... 5-58
Cautions on Charging Battery............................................................................ 5-58
Starting Engine with Booster Cable ................................................................... 5-59
Rubber Tracks ........................................................................................................ 5-61
General Information and Precautions ................................................................ 5-61
Inspection of Rubber Tracks.............................................................................. 5-63
Replace Rubber Track....................................................................................... 5-64
Wire Rope............................................................................................................... 5-65
General Information and Precautions ................................................................ 5-65
Inspecting Wire Rope ........................................................................................ 5-66
Winch Wire Rope - Correcting Twisted Rope .................................................... 5-66
Winch Wire Rope - Removal ............................................................................. 5-67
Winch Wire Rope - Installation .......................................................................... 5-68
Checking / Adjusting Boom Telescoping Wire Rope ......................................... 5-70
Inspection, Cleaning and Replacement of Air Cleaner........................................... 5-72
Inspection .......................................................................................................... 5-72
Cleaning/Replacing the Element ....................................................................... 5-73
Cleaning Inside Engine Cooling System ................................................................ 5-74
Cleaning Method................................................................................................ 5-75
Draining Contaminant Water/Deposits in Fuel Tank .............................................. 5-76
Draining Contaminant Water/Deposits in Water Separator.................................... 5-76
LONG-TERM STORAGE ................................................................................................. 5-78
Before Storing Machine .......................................................................................... 5-78
During Storage........................................................................................................ 5-78
After Storage........................................................................................................... 5-78
For Electric Motor ................................................................................................... 5-78
COLD TEMPERATURE PREPARATION ........................................................................ 5-79
Lubrication .............................................................................................................. 5-79
Coolant .............................................................................................................. 5-79
Battery .................................................................................................................... 5-79
Cautions After Completing the Operation............................................................... 5-79
After the Cold Weather Is Gone ............................................................................. 5-79
850 kg SEARCHER HOOK INSPECTION AND MAINTENANCE ................................... 5-80
Legal Inspection...................................................................................................... 5-80
Consumables.......................................................................................................... 5-80
Inspection and Maintenance List ............................................................................ 5-81
Pre-Start and Post-Start Inspection Items ......................................................... 5-81
Pre-Start – Before Starting Engine ......................................................................... 5-82
E-Boom, Frame and Hook ................................................................................. 5-82
Greasing ............................................................................................................ 5-82
Searcher Hook Fix Bolts .................................................................................... 5-82
Position Pin and Lynch Pin ................................................................................ 5-82

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Pre-Start – After Starting Engine ............................................................................ 5-82
Moment Limiter for Operation (Searcher Hook Mode) ...................................... 5-82
FLY-JIB INSPECTION AND MAINTENANCE.................................................................. 5-83
Legal Inspection...................................................................................................... 5-83
Consumables.......................................................................................................... 5-83
Inspection and Maintenance List ............................................................................ 5-84
Pre-Start and Post-Start Inspection Items ......................................................... 5-84
Pre-Start – Before Starting Engine ......................................................................... 5-85
Boom and Frame ............................................................................................... 5-85
Wire Ropes ........................................................................................................ 5-85
Fly-jib Fix Bolts .................................................................................................. 5-85
Electrical Wiring (Fuse Box) .............................................................................. 5-85
Pre-Start – After Starting Engine ............................................................................ 5-85
Over Winding Detector ...................................................................................... 5-85
Winch and Boom ............................................................................................... 5-86
Moment Limiter for Operation (Fly-jib Mode) ..................................................... 5-86
Greasing Fly-Jib Foot Pin .................................................................................. 5-86
Irregular Maintenance............................................................................................. 5-86
Replacement Winch Wire Rope......................................................................... 5-86
Greasing Machine Units .................................................................................... 5-87
TROUBLESHOOTING ..................................................................................................... 5-88
General ................................................................................................................... 5-88
Machine Body......................................................................................................... 5-88
Engine..................................................................................................................... 5-88
Electrical Components............................................................................................ 5-89
Remote Control....................................................................................................... 5-90
Moment Limiter Error Causes and Actions to Be Taken ........................................ 5-93
Electric Motor.......................................................................................................... 5-94

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Section 1
INTRODUCTION

Section 1 – INTRODUCTION Mini-Crawler Crane M A E D A
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INTRODUCTION
Thank you for purchasing the Maeda Mini
Crawler Crane model MC405C-3.
This manual is intended as a guide for the safe
and effective use of this machine. This manual
describes the procedures for proper operation
and maintenance of the machine.
This manual is available in other languages. If a
different language manual is necessary, contact
your local Maeda distributor for availability.
Save this manual in a designated safe place for
future reference. Should this manual be lost or
damaged, contact Maeda or a Maeda sales
service agency immediately to order a new
manual. This manual should remain with this
machine upon transfer of the machine to a new
owner.
This manual contains information that was
available at the time of print.
The contents of this manual, including
maintenance specifications, tightening torques,
pressure, measuring methods, adjustment values
and illustrations, are subject to change upon
refinement of the machine, without notice.
Machine maintenance procedures may be
updated by Maeda at any time. Always obtain the
latest information from Maeda or a Maeda sales
service agency before performing maintenance
on this machine.
Installation and operation of this machine must
comply with all laws and regulations where
operated.
Only personnel who have obtained a licence
stipulated by the laws and regulations from the
place of use are qualified to operate this
machine, establish the power connection of the
power supply equipment, and inspect and repair
the electric system.
Disclaimers:
All information, illustrations and specifications in
this manual are based on the latest information
available at the time of publishing. The
illustrations used in this manual are intended as
representative reference views only. Moreover,
because of our continuous product improvement
policy, we may modify information, illustrations
and/or specifications to explain and/or exemplify
a product, service or maintenance improvement.
We reserve the right to make any change at any
time without notice.
Maeda is a registered trademark of Maeda
Seisakusho Co., Ltd. in Japan, the United States
and/or other countries.
All Rights Reserved:
No part of this publication may be reproduced or
used in any form by any means - graphic,
electronic or mechanical, including photocopying,
recording, taping, or information storage and
retrieval systems - without the written permission
of Maeda Seisakusho Co., Ltd.
© 2019 Maeda Seisakusho Co., Ltd.
1/2019

1/2019 MC405C-3 2-1
Section 2
SAFETY

Section 2 – SAFETY DEFINITIONS Mini-Crawler CraneM A E D A
2-2 1/2019 MC405C-3
SAFETY DEFINITIONS
Maeda is concerned for your safety and the
condition of your mini-crawler crane. Safety
statements are one of the primary ways to call
your attention to the potential hazards associated
with Maeda mini-crawler cranes. Follow the
precautions listed throughout the manual before
operation, during operation and during periodic
maintenance procedures for your safety, the
safety of others and to protect the performance of
your mini-crawler crane. Keep the labels from
becoming dirty or torn and replace them if they
are lost or damaged. Also, if a part needs to be
replaced that has a label attached to it, make
sure to order the new part and label at the same
time.
This safety alert symbol appears
with most safety statements. It
means attention, become alert, your
safety is involved! Please read and
abide by the message that follows
the safety alert symbol.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Indicates a situation which can cause damage to
the mini-crawler crane, personal property and/or
the environment, or cause the equipment to
operate improperly.
SAFETY PRECAUTIONS
There is no substitute for common sense and
careful practices. Improper practices or
carelessness can cause burns, cuts, mutilation,
asphyxiation, other bodily injury or death. This
information contains general safety precautions
and guidelines that must be followed to reduce
risk to personal safety. Special safety
precautions are listed in specific procedures.
Read and understand all of the safety
precautions before operating or performing
repairs or maintenance. This safety section
cannot cover every situation that may occur that
is incidental to the use of the machine. Use
common sense if you encounter a situation that
is not covered to help avoid a hazardous
situation.
The safety messages that follow have
CAUTION level hazards.
Pre-Operation Hazard
・
Never permit anyone to install or
operate the machine without
proper training.
・Read and understand this Operation Manual
before operating or servicing the crane to
ensure that safe operating practices and
maintenance procedures are followed.
・Safety signs and labels are additional
reminders for safe operating and maintenance
techniques.
・Contact us or our sales service agency for
additional training.
・Make sure you are aware of licences, laws and
regulations that may be required or in effect
where the machine is operated.
NOTICE

Mini-Crawler Crane M A E D A Section 2 – SAFETY PRECAUTIONS
1/2019 MC405C-3 2-3
The safety messages that follow have
DANGER level hazards.
Electrocution Hazard
Contact with, or proximity to, an electrically
charged power line will result in death or serious
injury:
・This unit will not provide protection from
contact with, or proximity to, an electrically
charged power line when the components at
the boom tip are in contact with, or in proximity
to, another power line, ground or pole.
・All metal and fiberglass components at the
boom tip may become energised.
・Operators must follow safe electrical work
practices in accordance with their employers’
work rules and applicable government
regulations including:
・Maintain minimum approach distances
from electrical power lines.
・Allow for boom, electric line and load
sway.
・If any part of the unit is elevated within the
minimum approach distance of an energised
conductor, all unauthorised personnel must
KEEP CLEAR.
The safety messages that follow have
WARNING level hazards.
Tip / Boom Failure Hazard
Overloading the crane may cause it to tip over or
the boom to fail:
・Before you try to hoist a load, it is essential
that you know:
・Boom angle (use boom angle indicator)
・Working radius (use operating range
chart)
・Boom length (use rated total load chart)
・Rated total load (use rated total load
chart)
・Never try to hoist a load that exceeds the rated
total load. Rated total load is the mass of the
load plus weight of the winch lines and the
weight of the hook block.
・Always calculate the total load using the rated
total load chart before you attempt to hoist the
load. Never rely on the moment limiter as the
primary means to determine whether a load is
safe to lift.
・All the values provided on the rated total load
chart assume that the machine is located on a
level and firm surface. Always use outrigger
pads when you deploy the outriggers on soft or
unpaved surfaces.
・The values shown in the operating range chart
do not account for boom deflection when the
load is raised. Boom deflection will widen the
working radius. Use the next largest radius on
the operating range chart to account for this.
・Always extend outriggers before lifting load. If
the terrain is not completely level and you must
adjust the outrigger position to compensate,
you must derate the rated total load by the
amount indicated for outriggers other than
maximum in "RATED TOTAL LOAD CHARTS"
on page 3-13. All outrigger monitor lights, other
than the boom stowing lamp, must be on.
・Always look at the level gauge when setting
the outriggers. Look at the level gauge when
making adjustments during operation. Always
keep the machine body level when operating.
・Sudden or jerky movement of the travel, crane
or outrigger controls can cause the machine to
tip over. Always operate these controls
smoothly.

Section 2 – SAFETY PRECAUTIONS Mini-Crawler CraneM A E D A
2-4 1/2019 MC405C-3
The safety messages that follow have
WARNING level hazards.
Crush Hazard
・
Keep bystanders away from
work area before and during
operation.
・Keep all body parts clear of machine
components during operation, especially
between the boom/post and the boom cylinder,
the winch drum and the winch line, the
sheaves and the winch line, and between the
tracks and the ground.
・Never commence work unless you have clear
view of the jobsite or you have a helper to
guide you.
・Always lower the load fully to the ground
before you leave the operator’s position.
Rigging Hazard
・Pay attention to the distance between the hook
block and the boom when you raise the hook
block or when you extend the boom (as the
boom extends, the hook block automatically
raises). If the hook block strikes the boom, it
could cause the load to fall.
・Never overload the winch line.
・When you are lowering the hook block, make
sure there are more than three turns of winch
line left on the winch drum when the hook
block reaches the final working height.
・Before you hoist the load, make sure the hook
block is securely attached to the winch line.
・Make sure the winch line is perpendicular to
the ground as you hoist a load to avoid tipping
the machine over.
・When you are hoisting a load off the ground,
stop hoisting the load momentarily as the load
clears the ground to make sure the load is
stable.
・Never hoist more than one load at a time.
・When you hoist a long load, such as pipes,
clamp the load vertically or secure it at both
ends.
Slewing Hazard
・Never slew a load over anyone.
・Always slew the load as smoothly and slowly
as possible. Any sudden movement could
cause the load to sway and the machine to tip
over.
・Keep away from other cranes working in the
area to avoid accidental contact.
・Never slew the load over the operator.
・If you need to slew the boom counterclockwise
(left), make sure it is raised sufficiently to clear
the operator’s seat and operator.
Wind Speed Hazard
・If the maximum instantaneous wind speed is
19 to 24 mph (8.5 to 10.7 m/s) or greater, abort
the job you are performing and immediately
lower the load and secure the boom. This wind
speed is called a “fresh wind” on the Beaufort
Scale. At that speed, small trees in leaf sway
slightly and wavelets form on ponds and lakes.
・Even if the maximum instantaneous wind
speed is below 19 to 24 mph (8.5 to 10.7 m/s),
be aware that loads with more mass, loads that
are hoisted high off the ground and booms that
are extended all magnify the effect of the wind
on the machine. Stay aware of changing
weather conditions.
・If a load is hoisted that has a large surface
area, such as a metal plate, the wind can
cause the load to sway and subsequently
cause the machine to tip over.
High Hydraulic Oil temperature
If hydraulic oil temperature exceeds 80°C
hydraulic hoses and seals can be damaged and
leak. The leaking hydraulic oil can cause burns.
Continuous hook raising and lowering at high
speeds and high lifting heights can cause the
hydraulic oil to heat up faster.
If hydraulic oil temperature exceeds 80°C stop
crane operation and allow the hydraulic oil to
cool.