Maeda MC815C User manual

106E-SM1804-00
Service Manual
Crawler Crane
Serial No. T0001 and up
MC815C
Part numbers and parts list in the Service Manual are for use fo
r
servicing such as disassembling and assembling.
The parts and part numbers are subject to change without prior notice
due to continuous machine improvement and modification. When
ordering parts, make sure to check the latest parts catalog (lates
t
information).

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CONTENTS
Item Page
OVERVIEW 1-1
1. EXTERNAL VIEW 1-2
1.1 STANDARD SPECIFICATIONS 1-2
1.2 SEARCHERHOOK SPECIFICATIONS 1-2
1.3 FLY-JIB SPECIFICATIONS 1-3
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 1-3
3. PRINCIPAL SPECIFICATIONS LIST 1-4
3.1 STANDARD SPECIFICATIONS 1-4
3.2 ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 1-5
3.3 REMOTE CONTROL SPECIFICATIONS 1- 6
4. COMPONENT MASS LIST 1- 7
5. OIL AND WATER QUANTITIES LIST 1- 8
6. RATED TOTAL LOAD CHART 1- 8
6.1 6 FALLS 1- 9
6.2 4 FALLS 1-12
6.3 2 FALLS 1-15
6.4 SINGLE FALL 1-18
7. WORKING RADIUS/LIFTING HEIGHT 1-21
8. WORKING RADIUS AND HOISTING HEIGHT (TRAVELLING WITH HOISTED LOAD) 1-22
STRUCTURE AND MAINTENANCE PROCEDURE 2-1
1. ENGINE AND COOLING-RELATED COMPONENTS 2-2
1.1 ENGINE SPECIFICATIONS 2-2
1.2 ENGINE MOUNT 2-4
1.3 PTO (POWER TAKE-OFF) 2-5
1.4 COOLING SYSTEM 2-6
1.5 FUEL LINE 2-8
1.6 FUEL TANK 2-9
2. POWER TRANSMISSIONSCHEMATIC DIAGRAM 2-10
2.1 HYDRAULIC SYSTEM DIAGRAM (MC815C) 2-10
2.2 SWING CIRCLE 2-11
3. UNDERCARRIAGE AND FRAME 2-12
3.1 TRACK FRAME 2-12
3.2 IDLER CUSHION 2-14
3.3 IDLER 2-15
3.4 TRACK ROLLER 2-16
3.5 CARRIER ROLLER 2-17
3.6 SPROCKET 2-18
3.7 TRACK SHOE 2-19
3.8 SHOE PLATE 2-19
3.9 ADJUSTING RUBBER TRACK TENSION 2-20

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4. HYDRAULIC UNITS 2-22
4.1 HYDRAULIC UNITS LAYOUT DIAGRAM 2-22
4.1.1 HYDRAULIC CIRCUIT DIAGRAM 2-24
4.2 HYDRAULIC OIL TANK AND FILTER 2-26
4.3 HYDRAULIC PUMP 2-27
4.3.1 HYDRAULIC PUMP EXTERNAL VIEW 2-27
4.3.2 HYDRAULIC PUMP CONNECTION DESTINATIONS 2-28
4.3.3 HYDRAULIC PUMP SPECIFICATIONS 2-28
4.3.4 PUMP HYDRAULIC CIRCUIT DIAGRAM 2-28
4.4 SHUTTLE MANIFOLD BLOCK 2-29
4.5 TRAVEL / OUTRIGGERCONTROL VALVE 2-30
4.5.1 TRAVEL / OUTRIGGER CONTROL VALVE EXTERNAL VIEW 2-30
4.5.2 TRAVEL / OUTRIGGER CONTROL VALVE (UPPER) CONNECTION DESTINATIONS 2-31
4.5.3 TRAVEL / OUTRIGGER CONTROL VALVE (LOWER) CONNECTION DESTINATIONS 2-31
4.5.4 HYDRAULIC SPECIFICATIONS 2-32
4.5.5 SOLENOID VALVE SPECIFICATIONS 2-32
4.5.6 TRAVEL / OUTRIGGER CONTROL VALVE LAYOUT 2-32
4.5.7 TRAVEL / OUTRIGGER CONTROL VALVE CIRCUIT DIAGRAM 2-33
4.6 CHECK VALVE (JOINT) 2-34
4.7 CRANE CONTROL VALVE 2-35
4.7.1 CRANE CONTROL VALVE EXTERNAL VIEW 2-35
4.7.2 CRANE CONTROL VALVE CONNECTION DESTINATIONS 2-36
4.7.3 CRANE CONTROL VALVE CIRCUIT DIAGRAM 2-36
4.7.4 CRANE CONTROL VALVE LAYOUT 2-37
4.7.5 CRANE CONTROL VALVE SPECIFICATIONS 2-37
4.8 SLEWING MOTOR 2-38
4.8.1 SLEWING MOTOR EXTERNAL VIEW 2-38
4.8.2 SLEWING MOTORCONNECTION DESTINATIONS 2-38
4.8.3 SLEWING MOTOR SPECIFICATIONS 2-38
4.8.4 SLEWING MOTOR INTERNAL STRUCTUREDIAGRAM 2-39
4.9 TRAVELLING MOTOR 2-40
4.9.1 TRAVELLING MOTOREXTERNAL VIEW 2-40
4.9.2 TRAVELLING MOTOR CONNECTION DESTINATIONS 2-40
4.9.3 TRAVELLING MOTOR SPECIFICATIONS 2-40
4.10 TRAVELLINGSPEEDSWITCHINGVALVE (JOINT WINCH BRAKERELEASINGVALVE/ WINCH2SPEEDSWITCHINGVALVE) 2-41
4.10.1 TRAVELLING SPEED SWITCHING VALVE APPEARANCE / SPECIFICATIONS 2-41
4.11 WINCH MOTOR 2-42
4.11.1 WINCH MOTOR EXTERNAL VIEW 2-42
4.11.2 WINCH MOTOR CONNECTION DESTINATIONS 2-42
4.11.3 WINCH MOTOR SPECIFICATIONS 2-43
4.11.4 WINCH VENTING 2-44
4.12 ROTARY JOINT 2-45
4.12.1 ROTARY JOINT EXTERNAL VIEW 2-45
4.12.2 ROTARY JOINT SPECIFICATIONS 2-46
4.12.3 ROTARY JOINT CONNECTION DESTINATIONS 2-46
4.12.4 ROTARY JOINT STRUCTURE 2-46

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4.13 DERRICK CYLINDER 2-47
4.13.1 DERRICK CYLINDER EXTERNAL VIEW 2-47
4.13.2 DERRICK CYLINDER CONNECTION DESTINATIONS 2-48
4.13.3 DERRICK CYLINDER SPECIFICATIONS 2-48
4.13.4 COUNTERBALANCE VALVE (IDENTIFICATION STAMP “D” FORDERRICKING CYLINDER) 2-49
4.13.5 COUNTER-BALANCE VALVE OPERATING DIAGRAM 2-50
4.14 TELESCOPIC CYLINDER ASSEMBLY 2-51
4.14.1 TELESCOPIC CYLINDER EXTERNAL VIEW 2-51
4.14.2 TELESCOPIC CYLINDER CONNECTION DESTINATIONS 2-52
4.14.3 TELESCOPIC CYLINDER SPECIFICATIONS 2-52
4.14.4 TELESCOPIC CYLINDER CROSS-SECTIONAL DRAWING 2-53
4.14.5 TELESCOPIC CYLINDER HYDRAULIC SYSTEMDIAGRAM 2-54
4.14.6 SEQUENCE VALVE 2-55
4.14.7 MECHANICAL CHECK VALVE 2-56
4.14.8 COUNTER BALANCE VALVE (IDENTIFICATION STAMP “T” FOR TELESCOPING CYLINDER) 2-57
4.15 OUTRIGGER CYLINDER ASSEMBLY 2-58
4.15.1 OUTRIGGER CYLINDER EXTERNAL VIEW 2-58
4.15.2 OUTRIGGER CYLINDER CONNECTION DESTINATIONS 2-59
4.15.3 OUTRIGGER CYLINDER SPECIFICATIONS 2-59
4.15.4 DOUBLE PILOT CHECK VALVE 2-60
4.16 SLIDE CYLINDER ASSEMBLY 2-61
4.16.1 SLIDE CYLINDER EXTERNAL VIEW 2-61
4.16.2 SLIDE CYLINDER CONNECTION DESTINATIONS 2-62
4.16.3 SLIDE CYLINDER SPECIFICATIONS 2-62
4.17 OR SELECT VALVE 2-63
4.18 OIL COOLER 2-64
4.19 RETURN MANIFOLD BLOCK 2-65
4.20 HYDRAULIC PIPING DIAGRAM 2-66
4.20.1 P LINES (PUMP - SHUTTLE MANIFOLD BLOCK LINE) 2-66
4.20.1.1 P LINES (PUMP LINES- SHUTTLE MANIFOLD BLOCK - CHECK JOINT) HYDRAULIC SYSTEM DIAGRAM 2-68
4.20.2 P LINES (SHUTTLE MANIFOLD BLOCK -TRAVELLING / OUTRIGGER CONTROL VALVE LINES) 2-69
4.20.3 T.DR LINES 2-71
4.20.4 TRAVELLING LINES 2-73
4.20.5 OUTRIGGER LINES 2-75
4.20.6 HYDRAULIC PIPING CRANE FIXED PART ASSEMBLY 2-78
4.20.7 HYDRAULIC PIPING ROTATING PART ASSEMBLY (DERRICKING LINES) 2-80
4.20.8 HYDRAULIC PIPING ROTATING PART ASSEMBLY (TELESCOPING LINES) 2-81
4.20.9 HYDRAULIC PIPING ROTATING PART ASSEMBLY (WINCH LINES) 2-82
4.20.10 HYDRAULIC PIPING ROTATING PART ASSEMBLY (WINCHDRAIN LINE) 2-83
4.20.11 HYDRAULICPIPING ROTATINGPARTASSEMBLY (WINCH BRAKERELEASE/2 SPEEDSWITCHINGLINES) 2-84
5. WORK EQUIPMENT 2-86
5.1 BOOM ASSEMBLY 2-86
5.2 HOOK BLOCK ASSEMBLY 2-88
5.2.1 HOOK BLOCK ASSEMBLY 2-88
5.2.2 INSPECTION OF HOOK BLOCK 2-89
6. ELECTRIC CIRCUIT DIAGRAMS (1/3 - 3/3) 2-91
7. ELECTRICAL EQUIPMENT CONNECTION DIAGRAM (1/2 - 2/2) 2-94

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8. ELECTRICAL UNITS 2-97
8.1 CABIN INTERIOR 2-97
8.1.1 NAME OF EACH CONTROL PART 2-97
8.1.2 OUTRIGGER OPERATION PANEL 2-98
8.1.3 LEFT CONTROL LEVER 2-98
8.1.4 RIGHT CONTROL LEVER 2-101
8.1.5 MONITOR 2-104
8.1.6 LIST OF ERROR CODES 2-106
8.1.7 CONSUMABLES DISPLAY 2-111
8.1.8 FUSE BOX 2-112
8.2 CONTROLLER 2-113
8.2.1 CONTROLLER LAYOUT 2-113
8.2.2 LOWER PART CONTROLLER PIN NUMBERS 2-115
8.2.3 IO UNIT PIN NUMBERS 2-118
8.3 HARNESS ASSEMBLY 2-119
8.3.1 HARNESS OVERVIEW FIGURE 2-119
8.3.2 HARNESS PRODUCT NAME / NUMBER 2-119
8.3.3 OUTRIGGER SENSOR HARNESS 2-120
8.3.4 ENGINE HARNESS 2-121
8.3.5 CONSOLE HARNESS 2-122
8.3.6 VALVE HARNESS 2-123
8.3.7 DISPLAY HARNESS 2-124
8.3.8 BOOM HARNESS 2-125
8.4 ELECTRICAL FITTINGS OUTSIDE THE CABIN 2-126
8.4.1 LED LIGHT 2-126
8.4.2 SURVEILLANCE CAMERAS 2-127
8.5 SENSORS 2-128
8.5.1 PRESSURE AND OIL TEMPERATURE SENSORS 2-128
8.5.2 INCLINATION SENSOR 2-129
8.5.3 FUEL SENDER ASSEMBLY 2-130
8.5.4 ROTARY BRUSH 2-131
9. SAFETY DEVICE 2-133
9.1 CONFIGURATION OF MOMENT LIMITER 2-133
9.2 MOMENT LIMITER - NAMES FOR MONITOR INDICATORS (CRANE MODE) 2-134
9.3 SENSOR ASSEMBLY 2-135
9.3.1 LENGTH METER (STANDARD SPECIFICATION) 2-135
9.3.2 LENGTH METER (BOOM LIGHT SPECIFICATION) 2-136
9.3.3 ANGLE DETECTOR 2-137
9.3.4 PRESSURE SENSOR 2-138
9.4 OVER-HOISTING PREVENTION DEVICE 2-139
9.5 OVER UN-WINDING DETECTION DEVICE 2-140
9.6 TRI-COLOUR REVOLVING WORKING STATUS LAMP 2-141
9.7 OUTRIGGER SAFETY DEVICES 2-142
9.7.1 OUTRIGGER POSITION DETECTION PARTS 2-142
9.7.2 OUTRIGGER GROUNDING DETECTION PARTS 2-143
9.7.3 OUTRIGGER ROTARY POSITION DETECTION PARTS 2-144
9.8 BOOM STOWING POSITION DETECTION PARTS 2-145
9.9 HOOK GROUNDING DETECTION PARTS 2-146

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REMOTE CONTROL 3-1
1. COMPONENTS OF THE TRANSMITTER 3-2
1.1 NAMES AND DESCRIPTION OF REMOTE CONTROL PARTS 3-2
1.1.1 TRANSMITTER AND RECEIVER 3-2
1.1.2 DESCRIPTION OF REMOTECONTROLLER ACCESSORIES 3-6
2. HANDLING REMOTE CONTROLLER BATTERY 3-7
2.1 REPLACEMENT TIMING OF BATTERY 3-7
2.2 REPLACEMENT METHOD OF BATTERY 3-7
2.3 CHARGING METHOD OF BATTERY 3-8
3. TROUBLESHOOTING 3-10
3.1 BEFORE REMOTE CONTROLLER FAILURE DIAGNOSIS 3-10
3.2 REMOTE CONTROLLER 3-11
3.3 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER 3-12
3.4 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER 3- 13
4. PRINCIPAL SPECIFICATIONS LIST 3-14
5. SERVICE LOCATIONS 3-15
ELECTRIC MOTOR 4-1
1. ELECTRIC POWER UNIT 4-2
1.1 ELECTRIC POWER UNIT PART NAMES 4-2
1.2 POWER SUPPLY BOX 4-2
1.3 INVERTER PART NAMES 4-3
2. ELECTRIC POWER UNIT ASSEMBLY 4-4
3. ELECTRIC MOTOR 4-5
4. ELECTRIC LINE ASSEMBLY 4-6
5. INVERTER HARNESS (WIRE HARNESS OF THE ELECTRICAL MOTOR) 4-8
6. ELECTRIC CIRCUIT DIAGRAM FOR ELECTRIC MOTOR SPECIFICATIONS 4-8
7. TROUBLESHOOTING 4-9
8. PRINCIPAL SPECIFICATION LIST (MACHINES WITH ENGINE & ELECTRIC MOTOR) 4-10

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Item Page
FLY JIB 5-1
1. NAME OF EACH SECTION OF FLY JIB 5-2
2. FLY JIB HYDRAULIC SYSTEM 5-3
2.1 SOLENOID OPERATED DIRECTIONAL CONTROL VALVE (JIB SWITCHING SOL) 5-3
2.2 HOSE REEL 5-4
2.3 DERRICKING CYLINDER (FOR FLY JIB) 5-5
2.4 TELESCOPING CYLINDER (FOR FLY JIB) 5-6
2.5 SELECTOR VALVE BLOCK (FLY JIB TELESCOPIC CYLINDER MOUNTED) 5-7
3. FLY JIB 5-8
3.1 FLY JIB (MAIN BOOM SIDE) 5-8
3.2 FLY JIB (FLY JIB SIDE) 1/2 5-9
3.3 FLY JIB (FLY JIB SIDE)2/2 5-10
4. FLY JIB HARNESS 5-11
4.1 FLY JIB HARNESS 1/3 5-11
4.2 FLY JIB HARNESS 2/3 5-12
4.3 FLY JIB HARNESS 3/3 5-13
5. FLY JIB SAFETY DEVICE 5-14
5.1 PIN TYPE LOAD CELL (LOAD TRANSDUCER) 5-14
5.2 LENGTH METER REEL (FLY JIB MOUNTED) 5-15
5.3 ANGLE DETECTOR (FLYJIB MOUNTED) 5-16
5.4 LENGTH GAUGE REEL(MAIN BOOM MOUNTED (COMMONTO BOOM LIGHT SPECIFICATIONS) ) 5-18
6. FLY JIB ELECTRICAL CIRCUIT DIAGRAM 5-19
7. TROUBLESHOOTING 5-20
7.1 LIST OF ERROR CODES 5-20
7.2 WHEN THESE PHENOMENA HAPPEN 5-21
8. SPECIFICATIONS 5-22
8.1 SPECIFICATION TABLE 5-22
8.2 SPECIFICATION DIMENSIONAL DRAWING 5-22
8.3 RATED TOTAL LOAD CHART 5-23
8.4 WORKING RADIUS/LIFTING HEIGHT 5-24
SEARCHER HOOK 6-1
1. NAMES OF SEARCHER HOOK PARTS 6-2
2. SEARCHER HOOK ASSEMBLY 6-3
3. CHANGING SEARCHER HOOK ANGLE 6-4
4. CHANGING TO SEARCHER HOOK MODE 6-5
5. TROUBLESHOOTING 6-6
6. SPECIFICATIONS 6-7
6.1 SPECIFICATION TABLE 6-7
6.2 SPECIFICATION DIMENSIONAL DRAWING 6-7
6.3 RATED TOTAL LOAD CHART 6-8
6.4 WORKING RADIUS/LIFTING HEIGHT 6-9

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DISASSEMBLING AND ASSEMBLING 7-1
1. DISMOUNTING AND MOUNTING THE BOOM ASSEMBLY 7-2
1.1 DISMOUNTING THE BOOM 7-3
1.2 MOUNTING THE BOOM 7-3
1.3 CONNECTION DIAGRAM FOR BOOM EQUIPMENT 7-3
2. DISASSEMBLING AND ASSEMBLING THE BOOM ASSEMBLY 7-4
2.1 DISASSEMBLING THE NO.1 BOOM 7-4
2.2 DISASSEMBLING THE NO.2 BOOM 7-5
2.3 DISASSEMBLING THE NO.3 BOOM 7-6
2.4 DISASSEMBLING THE NO.4 BOOM 7-7
2.5 DISASSEMBLING THETELESCOPIC CYLINDER FROM THE NO. 5 BOOM 7-8
3. DISMOUNTING AND MOUNTING THE WINCH WIRE ROPE 7-9
3.1 REMOVAL OF WINCH WIRE ROPE 7-9
3.2 INSTALLATION OF WINCH WIRE ROPE 7-10
3.3 ACTIONS TO TAKE WHEN THE WINCH WIRE ROPE IS TWISTED 7-12
4. CHECKING/ADJUSTING MAIN BOOM TELESCOPING WIRE ROPE 7-13
4.1 CHECKING THE BOOM TELESCOPING WIRE ROPE 7-13
4.2 ADJUSTING THE BOOMTELESCOPING WIREROPE 7-14
REFERENCE VALUES 8-1
1. TABLE OF ENGINE RELATED REFERENCE VALUES 8-2
2. TABLE OF MACHINE RELATED REFERENCE VALUES 8-3
3. TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES 8-6
SERVICE MODE S-1
1. MONITORING S-3
2. CONSUMABLES S-4
3. WORK HISTORY S-5
4. ERROR HISTORY S-9
5. INITIAL SETTING S-9
6. CRANE CALIBRATION S-11
7. ML SETTING S-17
8. FUNCTION S-18
TROUBLESHOOTING T-1
1. TROUBLESHOOTING T-301
1.1 TROUBLESHOOTING (RELATED TO ELECTRIC; LIST OF ERROR CODES) T-301
1.2 TROUBLESHOOTING (MATTERS OTHER THAN ERROR CODE DISPLAY) T-401
1.2.1 TROUBLESHOOTING OF THE ENGINE UNIT T-403
1.2.2 TROUBLESHOOTING OF THE ELECTRICAL SYSTEMS T-409
1.2.3 TROUBLESHOOTING OF THE HYDRAULIC PRESSURE AND MECHANICAL SYSTEMS T-417

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