Maeda MC405C-3 User manual

Service Manual
Mini-Crawler Crane
104ME-SM1910-00
The parts numbers and lists written in this service manual are the
references for the services such as disassembling and assembling.
Be sure to ALWAYS refer to the latest parts catalog (the latest
information) before ordering any part, since the parts and the model
numbers are subject to change during the endless improvements and
changes of our Machine.

0-1
CONTENTS
Item
Page
GENERAL
1-1
1. SPECIFICATION DIMENSIONAL DRAWING
1-2
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH
1-3
3. PRINCIPLE SPECIFICATION LIST
1-4
3.1 STANDARD SPECIFICATION
1-4
3.2 ENGINES AND ELECTRIC MOTER SPECIFICATION
1-5
4. WORKING RADIUS AND LIFTING HEIGHT
1-7
5. WORKING RADIUS AND LIFTING HEIGHT (PICK & CARRY)
1-8
6. TOTAL RATED LOAD CHART
1-9
[1] TOTAL RATED LOAD CHART AT WIRE ROPE 4 FALLS
1-9
[2] TOTAL RATED LOAD CHART AT WIRE ROPE 2 FALLS
1-10
[3] TOTAL RATED LOAD CHART AT WIRE ROPE SINGLE FALL
1-11
7. CRANE STANDARD PRESSURE AND OPERATING TIMETABLE
1-12
7.1 OUTRIGGER
1-12
7.2 CRANE
1-12
7.3 TRAVELLING OPERATION
1-12
8. POWER TRAIN DRAWING
1-13
CONSTRUCTION & MAINTENANCE
2-1
1. HYDRAULIC CIRCUIT DIAGRAM
2-3
1.1 HYDRAULIC UNITS LAYOUT DIAGRAM
2-5
2. HYDRAULIC PIPING DIAGRAM
2-8
2.1 CRANE ROTATING PARTS (rotary joint - winch / derricking / telescopic cylinder)
2-8
2.2 CRANE FIXED PARTS (crane control valve - rotary joint / slewing motor)
2-10
2.3 TRAVEL LINE (travel control valve - terminal assembly - travel motor)
2-14
2.4 OUTRIGGER LINES
2-16
[1] Outrigger control valve –OR select valve –OR / Slide cylinder FR out (front right side out)
2-20
[2] Outrigger control valve –OR select valve –OR / Slide cylinder FR in (front right side in)
2-21
[3] Outrigger control valve –OR select valve –OR / Slide cylinder FL out (front left side out)
2-22
[4] Outrigger control valve –OR select valve –OR / Slide cylinder FL in (front left side in)
2-23
[5] Outrigger control valve –OR select valve –OR / Slide cylinder RR out (rear right side out)
2-24
[6] Outrigger control valve –OR select valve –OR / Slide cylinder RR in (rear right side in)
2-25
[7] Outrigger control valve –OR select valve –OR / Slide cylinder RL out (rear left side out)
2-26
[8] Outrigger control valve –OR select valve –OR / Slide cylinder RL in (rear left side in)
2-27
2.5 PUMP LINE
2-28
[1] Hydraulic oil tank - Pump
2-30
[2] Pump - Travel control valve
2-30
[3] Travel control valve –crane control valve / merge valve - OR control valve
2-31
2.6 TANK / DRAIN LINE
2-32
[1] Crane control valve - manifold block - oil cooler - tank (return filter)
2-34
[2] OR Control valve - travel control valve - manifold block
2-34
[3] Travel motor - terminal B - hydraulic oil tank
2-35
[4] Slewing motor - rotary joint - terminal B - hydraulic oil tank”
2-35
[5] Merge valve - speed increase valve - hydraulic oil tank
2-36
2.7 PILOT LINE
2-38
[1] Crane control valve - OR control valve - merge valve
2-40
[2] Travel valve - speed increase valve - travel motor
2-40

0-2
Item
Page
2.8 ELECTRIC POWERED LINE
2-42
[1] Hydraulic pump for electric operations - hydraulic pump for engine / hydraulic oil tank
2-43
3. TANK
2-44
3.1 HYDRAULIC TANK
2-44
3.2 FUEL TANK
2-46
3.2.1 FUEL LEVEL SENSOR
2-48
4. RETURN MANI-BLOCK
2-49
5. CHECK VALVE
2-50
6. ENGINE ASSEMBLY
2-52
6.1 ENGINE ASSEMBLY 3TNV88F-EPMB Yanmar
2-52
6.2 ENGINE MODEL
2-53
6.3 NAME OF EACH SECTION
2-54
6.4 CERTIFICATION NAME PLATE
2-55
6.4.1 EMISSION CONTROL CERTIFICATION NAME PLATE
2-55
6.5 DIESEL FUEL
2-56
6.5.1 FUEL SYSTEM
2-56
6.5.2 USE OF ADEQUATE FUELS
2-56
6.5.3 DIESEL FUEL SPECIFICATIONS
2-57
6.5.4 BIO-DIESEL FUELS
2-57
6.5.5 PRIMING THE FUEL SYSTEM
2-58
6.6 COOLANT
2-60
6.6.1 COOLANT SYSTEM
2-60
6.6.2 USE OF ADEQUATE COOLANT
2-60
6.6.3 ENGINE COOLANT SPECIFICATIONS
2-60
6.7 LUBRICATING OIL
2-61
6.7.1 LUBRICATING SYSTEM
2-61
6.7.2 USE OF ADEQUATE LUBRICANT
2-61
6.7.3 ENGINE OIL SPECIFICATIONS
2-62
6.8 PERIODIC MAINTENANCE SCHEDULE
2-63
6.9 TROUBLE SHOOTING
2-64
6.10 FUEL PIPING
2-68
7. HYDRAULIC PUMP
2-70
7.1 HYDRAULIC PUMP FOR ENGINE
2-70
7.1.1 APPEARANCE AND SPECIFICATIONS
2-70
7.2 HYDRAULIC PUMP FOR ELECTRIC OPERATIONS
2-71
7.2.1 APPEARANCE AND SPECIFICATIONS
2-71
7.3 TROUBLE SHOOTING
2-72
8. TRAVEL CONTROL VALVE
2-74
8.1 EXTERIOR VIEW AND SPECIFICATIONS
2-74
8.2 INNER PARTS
2-75
8.3 INSPECTION AND ADJUSTMENT
2-76
8.4 TROUBLE SHOOTING
2-77
9.TRAVELING MOTOR
2-78
9.1 EXTERIOR VIEW AND SPECIFICATIONS
2-78
9.2 INNER PARTS
2-79
9.2.1 OUTLINE
2-79
9.2.2 BASICS OF FUNCTIONALITY
2-80
9.2.3 FUNCTION OF AUTOMATIC CONTROL VALVE
2-82
9.2.4 FUNCTION OF COUNTER BALANCE VALVE
2-84
9.2.5 FUNCTION OF PARKING BRAKE
2-85

0-3
Item
Page
9.3 PRECAUTIONS FOR USE
2-86
9.3.1 INSTALLATION
2-86
9.3.2 PIPING
2-86
9.3.3 LUBRICATING OIL FOR GEARS
2-87
9.3.4 GENERAL PRECAUTIONS
2-87
10. CRANE CONTROL VALVE
2-88
10.1 EXTERIOR VIEW AND SPECIFICATIONS
2-88
10.2 HYDRAULIC CIRCUIT DIAGRAM
2-89
10.3 RGB BLOCK
2-90
10.4 ACCELERATOR BLOCK
2-92
10.5 FUNCTION BLOCK (DERRICK, WINCH, TELESCOPIC, SLEWING)
2-92
10.6 SOLENOID VALVE FUNCTIONING PRINCIPLE
2-93
11. OUTRIGGER CONTROL VALVE
2-96
11.1 EXTERIOR VIEW AND SPECIFICATIONS
2-96
11.2 INNER PARTS
2-98
12. OUTRIGGER SELECT VALVE
2-100
12.1 EXTERIOR VIEW AND SPECIFICATIONS
2-100
12.2 INNER PARTS
2-101
13. CRANE CIRCUIT CONFLUENCE VALVE
2-102
13.1 EXTERIOR VIEW and SPECIFICATIONS
2-102
13.2 INNER PARTS
2-103
13.3 INSPECTION AND ADJUSTMENT
2-104
13.4 TROUBLE SHOOTING
2-104
14. TRAVELING SPEED SELECT VALVE
2-106
14.1 EXTERIOR VIEW AND SPECIFICATIONS
2-106
14.2 INSPECTION AND ADJUSTMENT
2-107
14.3 TROUBLE SHOOTING
2-107
15. ROTARY JOINT
2-108
15.1 EXTERIOR VIEW AND SPECIFICATIONS
2-108
15.2 INNER PARTS
2-109
16. HOOK BLOCK
2-110
16.1 HOOK BLOCK INSPECTION
2-112
17. BOOM
2-114
18. TELESCOPIC AND DERRICK CYLINDER
2-118
18.1 TELESCOPIC CYLINDER
2-118
18.2 TELESCOPIC CYLINDER HYDRAULIC CIRCUIT SYSTEM
2-120
18.3 COUNTER BALANCE VALVE (FOR TELESCOPIC AND DERRICK CYLINDER)
2-121
18.3.1 STRUCTURE
2-121
18.3.2 TROUBLE SHOOTING
2-121
18.3.3 FUNCTION
2-122
18.4 SEQUENCE VALVE (FOR TELESCOPIC CYLINDER)
2-123
18.4.1 FUNCTION
2-123
18.5 MECHANICAL CHECK VALVE (FOR TELESCOPIC CYLINDER)
2-124
18.6 LEFT SIDE DERRICK CYLINDER
2-126
18.7 RIGHT SIDE DERRICK CYLINDER
2-128
19. WINCH
2-130
19.1 WINCH EXTERIOR VIEW
2-130
19.2 WINCH UNIT EXTERIOR VIEW
2-132
19.2.1 OUTLINE OF WINCH UNIT
2-133
19.3 HYDRAULIC OIL MOTOR
2-134

0-4
Item
Page
19.3.1 INNER PARTS
2-134
19.3.2 OPERATIONAL TEST
2-135
19.3.3 BASICS OF FUNCTIONALITY
2-135
19.3.4 TROUBLE SHOOTING
2-136
19.4 WINCH REDUCTION GEAR
2-138
19.5 OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE
2-139
19.6 REPLACEMENT WINCH WIRE ROPE
2-142
20. SLEWING SYSTEM
2-144
20.1 EXTERIOR VIEW
2-144
20.1.1 SLEWING BEARING WOBBLE LIMIT TOLERANCE
2-145
20.2 SLEWING REDUCTION GEAR
2-146
20.3 HYDRAULIC OIL MOTOR INNER PARTS
2-147
20.4 SLEWING MOTOR TROUBLE SHOOTING
2-148
21. OUTRIGGER
2-150
21.1 FRONT OUTRIGGER
2-150
21.2 REAR OUTRIGGER
2-154
22. OUTRIGGER CYLINDER
2-154
22.1 OUTRIGGER SLIDE CYLINDER
2-154
22.2 SINGLE CHECK VALVE (FOR OUTRIGGER SLIDE CYLINDER)
2-156
22.3 FRONT OUTRIGGER CYLINDER
2-158
22.4 REAR OUTRIGGER CYLINDER
2-160
22.5 DOUBLE CHECK VALVE (FOR OUTRIGGER CYLINDER)
2-162
23. ASSEMBLY AND DISASSEMBLY OF BOOM
2-164
24. ELECTRIC CIRCUIT DIAGRAM
2-171
25. ELECTRICAL WIRING SYSTEM DIAGRAM
2-173
26. ELECTRIC SYSTEM
2-176
26.1 ENGINE HARNESS
2-176
26.2 REMOTE CONTROLLER, VALVE, ELECTRIC HARNESS
2-180
26.3 MOMENT LIMITER HARNESS
2-182
26.4 ELECTRIC HARNESS
2-184
26.5 OVER-WINDING DETECTOR
2-186
26.5.1 OPERATION PRINCIPLE
2-188
26.6 TIP-OVER WARNING DEVICE
2-190
MOMENT LIMITER
3-1
1. MOMENT LIMITER RELATED
3-2
1.1 DISPLAY UNIT AND CONVERTER
3-2
1.2 FRONT OUTRIGGER EXTENSION DETECTOR
3-4
1.3 REAR OUTRIGGER EXTENSION DETECTOR
3-6
1.4 BOOM DISPLACEMENT DETECTOR
3-8
1.4.1 ANGLE SENSOR
3-10
1.4.2 LENGTH SENSOR CODE REEL
3-12
1.5 LOAD DETECTOR
3-14
1. 5.1 PRESSURE SENSORS
3-15
1.6 MOMENT LIMITER ACCESSORY
3-16
1.7 OVER UN-WINDING DETECTOR
3-18
1.8 PICK AND CARRY RELATED
3-20
2. OUTRIGGER SAFETY DEVICE
3-22
2.1 ROTARY POSITION DETECTOR
3-22
2.2 GROUND SETTING DETECTOR
3-24

0-5
Item
Page
2.3 BOOM STOWING POSITION DETECTOR
3-26
3. MOMENT LIMITER OVERVIEW AND FEATURES
3-28
4. EXTERNAL VIEW OF MOMENT LIMITER
3-30
4.1 DISPLAY UNIT
3-30
4.2 CONVERTER
3-31
5. BLOCK DIAGRAM
3-32
6. CONNECTOR DIAGRAM
3-33
7. CONNECTOR PIN ASSIGNMENT
3-34
7.1 CONVERTER CONNECTORS
3-34
7.2 DISPLAY UNIT CONNECTORS
3-35
7.2.1 DISPLAY UNIT CONNECTORS (M1)
3-35
7.2.2 DISPLAY UNIT CONNECTORS (M2)
3-35
8. INPUT/OUTPUT
3-36
8.1 CONVERTER
3-36
8.2 DISPLAY UNIT
3-37
8.2.1 DISPLAY UNIT INPUT
3-37
8.2.2 DISPLAY UNIT OUTPUT
3-38
9. DISPLAYS
3-40
10. SWITCHES
3-42
11. DISPLAY UNIT; DETAIL OF EACH SEGMENT
3-44
12. START–UP SEQUENCE
3-46
13. MOMENT LIMITER FUNCTIONS
3-46
14. DISPLAY OF SPECIFIC INDICATORS
3-47
15. OPERATION RANGE LIMITATION CONTROL
3-47
16. CALIBRATION PROCEDURE
3-48
16.1 LIST OF ITEMS
3-48
16.2 PROCEDURE
3-49
16.2.1 CALIBRATION WORK FLOW
3-49
16.2.2 CALL OUT OF CALIBRATION MODE
3-49
16.2.3 CALIBRATION OF BOOM LENGTH
3-50
16.2.4 CALIBRATION OF BOOM ANGLE
3-52
16.2.5 CALIBRATION OF WEIGHING
3-54
16.3 DISPLAY DETAILS AT CALIBRATION MODE
3-57
17. TEST MODE
3-58
17.1 CALL OUT OF TEST MODE
3-58
17.2 L01 (ROM/RAM TEST)
3-59
17.3 L02 (LED TEST)
3-59
17.4 L03 (SWITCH TEST)
3-60
17.5 L04 INPUT SIGNAL TEST
3-61
17.6 L05 OUTPUT SIGNAL TEST
3-62
17.7 L06 (LOAD FACTOR TEST)
3-63
17.8 L07 (VERIFICATION OF INPUT FROM CONVERTER)
3-63
17.9 L08 (TIME SETTING)
3-64
17.10 L09 (DISPLAY OF THE TIME TO REPLACE BUTTERIES)
3-65
18. PC MODE
3-66
18.1 MOMENT LIMITER OPERATION LOG PICKING UP PROCEDURE
3-66
18.2 MOMENT LIMITER OPERATION LOG DELETING PROCEDURE
3-71
18.3 READ MOMENT LIMITER HISTORY
3-73
19. ERROR MESSAGES
3-74
20. TROUBLE SHOOTING
3-76

0-6
Item
Page
21. POINTS FOR INPUT VOLTAGE MEASUREMENT OF EACH SENSOR
3-78
INTERACTIVE REMOTE CONTROL
4-1
1. INITIAL MODE SETTING PROCEDURE
4-2
1.1 BUTTON ARRANGEMENT ON CONTROL PANEL
4-2
1.2 ESTABLISHING INITIAL MODE:
4-3
1.3 INITIAL MODE FOR USER (A MODE)
4-4
1.4 INITIAL MODE FOR SERVICE (B MODE)
4-7
1.5 INITIAL MODE FOR MAKER (C MODE)
4-10
1.6 INITIAL MODE SETTING
4-16
2. RECEIVER
4-18
2.1 STATUS DISPLAY
4-18
2.2 CONTROL PRINT CARD LACATIONS
4-20
2.2.1 MAIN PRINT CARD (UPPER SIDE) (MC9141-A)
4-20
2.2.2 MAIN PRINT CARD LCD DISPLAY (UPPER SIDE) (MC9141-A)
4-21
2.2.3 SUB PRINT CARD (LOWER SIDE) (MC9143-A)
4-22
2.2.4 SUB PRINT CARD LCD DISPLAY (LOWER SIDE) (MC9143-A)
4-23
2.3 CONNECTOR PIN ASSIGNMENT
4-24
2.4 VALVE NEUTRAL SETTING PROCEDURE
4-26
2.5 MONITOR DISPLAY MESSAGE
4-28
2.5.1 NORMAL OPERATION MESSAGE
4-28
2.6 FUSE IN THE RECEIVER
4-29
3. VOICE MESSAGES
4-31
4. TROUBLESHOOTING
4-32
ELECTRIC MOTOR
5-1
1. ELECTRIC MOTOR
5-2
2. INVERTER PANEL
5-3
2.1 STRUCTURAL DRAWING
5-4
2.2 EXTERNAL APPEARANCE AND NAME OF EACH SECTION
5-6
2.3 NAME AND CONTENT OF THE DIGITAL OPERATOR
5-7
2.4 DETAIL OF INVERTER SET ITEMS
5-9
2.5 ALARM DISPLAY AND COUNTERMEASURE
5-10
2.5.1 ALARM DISPLAY
5-10
2.5.2 FAULT MONITOR DISPLAY
5-10
2.5.3 METHOD FOR RELEASING (RESETTING) THE TRIP STATUS
5-11
2.6 LIST OF ALARM CODES
5-12
2.7 TROUBLESHOOTING
5-16
2.8 INSPECTION AND MAINTENANCE
5-22
2.8.1 REGULAR INSPECTION
5-22
2.8.2 PERIODICAL INSPECTION
5-23
2.9 DISPOSAL OF THE INVERTER
5-25
3. POWER SUPPLY BOX
5-26
4. ELECTRIC CIRCUIT DIAGRAM
5-28

1-1
GENERAL
1. SPECIFICATION DIMENSIONAL DRAWING
1-2
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH
1-3
3. PRINCIPLE SPECIFICATION LIST
1-4
4. WORKING RADIUS AND LIFTING HEIGHT
1-7
5. WORKING RADIUS AND LIFTING HEIGHT (PICK & CARRY)
1-8
6. TOTAL RATED LOAD CHART
1-9
7. CRANE STANDARD PRESSURE AND OPERATING TIMETABLE
1-12
8. POWER TRAIN DRAWING
1-13

1-2
1. SPECIFICATION DIMENSIONAL DRAWING