Maeda MK1033C-1 User manual

200E-SM1608-02
SERVICE MANUAL
MINI-CRAWLER CRANE
Serial No. MK0003 and up
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.

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CONTENTS
Item Page
OVERVIEW 1-1
1. OUTSIDE DRAWING 1-2
1.1 STANDARD SPECIFICATIONS 1-2
1.2 ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 1-3
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 1-4
3. PRINCIPLE SPECIFICATION LIST 1-5
3.1 STANDARD SPECIFICATIONS 1-5
3.2 ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 1-7
4. WORKING RADIUS/LIFTING HEIGHT 1-9
5. RATED TOTAL LOAD CHART 1-18
6. CRANE STANDARD PRESSURE AND OPERATING TIME TABLE 1-19
6.1 OUTRIGGER 1-19
6.2 CRANE 1-19
6.3 TRAVELLING OPERATION 1-19
7. POWER TRANSMISSION SCHEMATIC DIAGRAM 1-20
STRUCTURE AND MAINTENANCE PROCEDURE 2-1
1. HYDRAULIC CIRCUIT DIAGRAM 2-5
2. HYDRAULIC PIPING DIAGRAM 2-7
2.1 CRANE ROTATING PART 2-7
2.1.1 HOSE GUIDE 2-8
2.2 CONTROL LINE A 2-13
2.3 CONTROL LINE B 2-15
2.4 TRAVEL LINE 2-17
2.5 OUTRIGGER LINE 2-19
2.6 PT LINE 2-21
2.7 ELECTRO-HYDRAULIC PIPING ON MACHINE BODY SIDE 2-25
2.8 RETURN MANIFOLD BLOCK 2-27
2.9 OIL COOLER 2-27
2.10 CHECK VALVE 2-28
3. HYDRAULIC TANK 2-29
3.1 AIR BREATHER ASSEMBLY 2-31
3.2 RETURN FILTER 2-32
4. ENGINE ASSEMBLY 2-33
4.1 ENGINE SPECIFICATIONS 2-33
4.2 ENGINE APPEARANCE 2-34
4.3 COMPONENTS OF ENGINE 2-36
4.4 FUEL 2-36
4.4.1 APPROPRIATE USE 2-36
4.4.2 DIESEL FUEL STANDARDS 2-37
4.4.3 BIODIESEL FUEL 2-37
4.4.4 FUEL FEED TO FUEL SYSTEM 2-38
4.5 MAINTENANCE AND INSPECTION 2-39
4.6 TROUBLE SHOOTING 2-40
4.7 FUEL PIPING 2-44
4.7.1 FUEL LINE 2-44
4.7.2 FUEL TANK ASSEMBLY 2-46
4.7.3 FUEL SENDER 2-47
4.8 ENGINE ACCESSORIES 2-48
5. HYDRAULIC PUMP 2-51
5.1 PUMP ASSEMBLY 2-51

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5.2 APPEARANCE AND SPECIFICATIONS (STANDARD PUMP) 2-52
5.3 INTERNAL STRUCTURE 2-53
5.4 OPERATING PRINCIPLES 2-54
5.5 FAILURE CAUSE AND COUNTERMEASURE 2-56
6. TRAVEL CONTROL VALVE 2-57
6.1 APPEARANCE AND SPECIFICATIONS 2-57
6.2 INTERNAL STRUCTURE 2-58
6.3 INSPECTION AND ADJUSTMENT 2-59
6.4 FAILURE CAUSE AND COUNTERMEASURE 2-60
7. TRAVELING MOTOR 2-61
7.1 APPEARANCE AND SPECIFICATIONS 2-61
7.2 INTERNAL STRUCTURE 2-62
7.3 OPERATING PRINCIPLES 2-63
7.4 OPERATING PRINCIPLES 2-64
7.4.1 REDUCER 2-64
7.4.2 HYDRAULIC MOTOR 2-65
7.4.3 HYDRAULIC VALVE (COUNTER-BALANCE VALVE) 2-66
7.4.4 PARKING BRAKE 2-67
7.5 PRECAUTIONS FOR USE 2-68
7.6 FAILURES AND COUNTERMEASURES 2-70
8. CRANE CONTROL VALVE 2-71
8.1 OUTSIDE DRAWING 2-71
8.2 OVERVIEW 2-72
8.3 HYDRAULIC CIRCUIT DIAGRAM 2-73
8.4 ACTIONS OF EACH SECTION 2-74
8.5 FAILURE CAUSE AND COUNTERMEASURE 2-81
9. OUTRIGGER SELECT VALVE 2-82
9.1 APPEARANCE AND SPECIFICATIONS 2-82
9.2 INTERNAL STRUCTURE 2-84
9.3 INSPECTION OF VALVES 2-85
9.4 METHODS FOR OPERATION ADJUSTMENT 2-86
9.5 OUTRIGGER CHANGE-OVER SWITCH 2-87
10. ROTARY JOINT 2-88
10.1 APPEARANCE AND SPECIFICATIONS 2-88
10.2 INTERNAL STRUCTURE 2-90
10.3 ROTARY BRUSH 2-91
11. HOOK 2-97
11.1 INSPECTION OF HOOK 2-97
12. BOOM 2-98
12.1 MAIN BOOM 2-98
12.2 JIB 2-101
12.3 JIB HEAD 2-103
13. TELESCOPIC AND DERRICK CYLINDERS 2-104
13.1 MAIN TELESCOPIC CYLINDER 2-104
13.2 JIB TELESCOPIC CYLINDER 2-106
13.2.1 JIB NO.1 TELESCOPIC CYLINDER 2-108
13.2.2 JIB NO.2 TELESCOPIC CYLINDER 2-110
13.3 JIB TELESCOPIC CYLINDER HYDRAULIC SCHEMATIC DIAGRAM 2-112
13.4 COUNTER BALANCE VALVE (FOR TELESCOPIC AND DERRICK CYLINDERS) 2-113
13.4.1 STRUCTURAL DRAWING 2-113
13.4.2 FAILURE CAUSE AND COUNTERMEASURE 2-113
13.4.3 WORKING DIAGRAM 2-114
13.5 SEQUENCE VALVE (FOR TELESCOPIC CYLINDER) 2-115
13.5.1 STRUCTURAL DRAWING 2-115

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13.5.2 WORKING DIAGRAM 2-115
13.6 MECHANICAL CHECK VALVE (FOR TELESCOPIC CYLINDER) 2-116
13.7 MAIN DERRICK CYLINDER ASSEMBLY 2-117
13.7.1 MAIN LEFT-HAND DERRICK CYLINDER 2-119
13.7.2 MAIN RIGHT-HAND DERRICK CYLINDER 2-121
13.8 JIB DERRICK CYLINDER ASSEMBLY 2-123
13.8.1 JIB DERRICK CYLINDER 2-124
14. SLEWING DEVICE 2-126
14.1 OUTSIDE DRAWING 2-126
14.1.1 TOLERANCE OF LOOSENESS HEIGHT OF SLEWING BEARING 2-127
14.2 INTERNAL STRUCTURE AND SPECIFICATIONS OF REDUCTION GEARS 2-128
14.3 APPEARANCE AND SPECIFICATIONS OF HYDRAULIC MOTOR 2-129
14.4 INTERNAL STRUCTURE OF HYDRAULIC MOTOR 2-130
14.5 FAILURE CAUSE AND COUNTERMEASURE OF SLEWING DEVICE 2-131
15. OUTRIGGER 2-132
15.1 APPEARANCE OF OUTRIGGER ON REAR RIGHT SIDE 2-132
15.2 APPEARANCE OF OUTRIGGER ON FRONT RIGHT SIDE 2-134
15.3 APPEARANCE OF OUTRIGGER ON FRONT LEFT SIDE 2-136
15.4 APPEARANCE OF OUTRIGGER ON REAR LEFT SIDE 2-138
16. OUTRIGGER CYLINDER 2-140
16.1 APPEARANCE AND SPECIFICATIONS 2-140
16.2 INTERNAL STRUCTURAL DRAWING 2-142
16.3 DOUBLE PILOT CHECK VALVE 2-144
17. ELECTRIC CIRCUIT DIAGRAM 2-145
18. ELECTRIC SYSTEM 2-146
18.1.1 WIRE HARNESS OF MACHINE BODY (1) 2-146
18.1.2 WIRE HARNESS OF MACHINE BODY (2) 2-148
18.2 CONTROL UNIT ASSEMBLY 2-149
19. CONTROL ASSEMBLY 2-151
19.1 CONTROLLER 2-151
19.2 MONITOR 2-156
19.2.1 STRUCTURE OF MONITOR SCREEN 2-156
19.2.2 USER MODE 2-169
19.2.3 SERVICE MODE 2-176
19.2.4 LIST OF DATA LOGGER DISPLAY CONTENTS 2-180
19.2.5 LIST OF CONTROLLER INPUT MONITORING 2-181
19.2.6 LIST OF CONTROLLER ANALOG INPUT / OUTPUT MONITORING 2-182
19.2.7 LIST OF ERROR CODES 2-183
20. PROCEDURE FOR DISASSEMBLING AND REASSEMBLING BOOM 2-184
20.1 REMOVING WIRE HARNESS CONNECTORS 2-184
20.2 REMOVING HYDRAULIC HOSES 2-185
20.3 PREPARING HOISTING ACCESSORIES 2-186
20.4 REMOVING THE ROD PIN AND FOOT PIN OF MAIN DERRICKING CYLINDER 2-187
20.5 REMOVING THE LINK ASSEMBLY 2-188
20.6 DISASSEMBLING THE MAIN BOOM 2-189
20.6.1 REMOVING THE MAIN BOOM NO. 1 2-189
20.6.2 REMOVING THE MAIN BOOM NO. 2 2-190
20.6.3 REMOVING THE TELESCOPIC CYLINDER 2-191
20.7 ASSEMBLING PROCEDURE FOR MAIN BOOM 2-192
20.7.1 ADJUSTING THE MAIN BOOM EXTENDING/CONTRACTING WIRE ROPES 2-192
20.8 DISASSEMBLING THE JIB 2-194
20.8.1 REMOVING THE JIB NO. 1 2-194
20.8.2 REMOVING THE JIB NO. 2 2-195
20.8.3 REMOVING THE TELESCOPIC CYLINDER 2-196

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20.9 DISASSEMBLING PROCEDURE FOR THE MACHINE WITH OPTIONAL WINCH 2-197
20.9.1 REMOVING THE WINCH WIRE 2-198
20.9.2 REMOVING THE WINCH HYDRAULIC HOSE 2-199
21. PROCEDURE FOR DISASSEMBLING THE VEHICLE BODY 2-200
21.1 PROCEDURE FOR DISASSEMBLING THE OUTRIGGER TOP AND INNER BOXES 2-200
21.2 REMOVAL OF ELECTRIC MOTOR UNIT 2-202
21.3 HOW TO REMOVE AND MOUNT A COUNTERWEIGHT 2-206
21.3.1 REMOVING THE COUNTERWEIGHT 2-206
21.3.2 MOUNTING THE COUNTERWEIGHT 2-208
SAFETY DEVICE 3-1
1. MOMENT LIMITER 3-2
1.1 CONFIGURATION OF MOMENT LIMITER 3-2
1.2 BOOM DISPLACEMENT DETECTION 3-3
1.2.1 TOTAL LENGTH REEL 3-5
1.2.2 ANGLE DETECTOR 3-7
1.2.3 ANGLE METER (360°) 3-9
1.3 LOAD DETECTION 3-11
1.3.1 PRESSURE AND OIL TEMPERATURE SENSOR 3-12
1.4 LEVER DETECTION 3-14
1.5. COMPONENTS OF MONITOR 3-15
1.6 MOMENT LIMITER CALIBRATION PROCEDURE 3-16
1.7 SLEW ANGLE CALIBRATION PROCEDURE 3-22
2. OUTRIGGER SAFETY DEVICE 3-24
2.1 SETTING DETECTION 3-24
2.1.1 SETTING DETECTION ASSEMBLY 3-24
2.1.2 WORKING OF SETTING DETECTION 3-25
2.2 OR STOWAGE DETECTION 3-26
2.2.1 OR STOWAGE DETECTION ASSEMBLY 3-26
2.2.2 WORKING OF OR STOWAGE DETECTION DEVICE 3-27
2.3 OR POSITION DETECTION 3-28
2.3.1 OR POSITION DETECTION ASSEMBLY 3-28
2.3.2 WORKING OF OR POSITION DETECTION DEVICE 3-29
2.4 OR OPEN DETECTION 3-30
2.4.1 OR OPEN DETECTION ASSEMBLY 3-30
2.4.2 WORKING OF OR OPEN DETECTOR 3-31
2.5 OR EXTENSION DETECTION 3-32
2.5.1 OR EXTENSION DETECTION ASSEMBLY 3-32
2.5.2 WORKING OF OR EXTENSION DETECTION DEVICE 3-33
2.6 SLEWING DIRECTION DETECTION 3-34
2.6.1 SLEWING DIRECTION DETECTION ASSEMBLY 3-34
2.6.2 WORKING OF SLEWING DIRECTION DETECTION 3-35
3. TIP-OVER WARNING DEVICE 3-36
3.1 INSTALLATION POSITION 3-36
3.2 APPEARANCE AND SPECIFICATION OF DEVICE 3-37
REMOTE CONTROL 4-1
1. COMPONENTS OF THE TRANSMITTER 4-2
1.1 UPPER PART COMPONENTS OF THE TRANSMITTER 4-2
1.2 LOWER PART COMPONENTS OF THE TRANSMITTER 4-2
1.3 DESCRIPTION OF COMPONENTS OF THE TRANSMITTER 4-3
1.4 DIAGNOSIS OF THE TRANSMITTER STATUS LED (D1) 4-5
2. COMPONENTS OF THE RECEIVER 4-8
2.1 COMPONENTS OF THE RECEIVER 4-8
2.2 INSPECTION AFTER TURNING ON THE TRANSMITTER 4-10
2.3 INSPECTION OF RECEIVER 4-10

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3. SAFETY DEVICE OF REMOTE CONTROLLER 4-11
4. HANDLING BATTERY 4-12
4.1 REPLACEMENT TIMING OF BATTERY 4-12
4.2 REPLACEMENT METHOD OF BATTERY 4-12
4.3 CHARGING METHOD OF BATTERY 4-13
5. TROUBLESHOOTING 4-14
5.1 BEFORE TROUBLESHOOTING 4-14
5.2 ERRORS IN THE REMOTE CONTROLLER 4-15
6. ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER 4-17
7. PRINCIPLE SPECIFICATION LIST 4-18
8. SERVICE LOCATIONS 4-19
ELECTRIC MOTO
R
5-1
1. ELECTRICAL MOTOR UNIT ASSEMBLY 5-2
1.1 POWER UNIT 5-5
1.2 EXTERNAL APPEARANCE / SPECIFICATION OF THE PUMP 5-6
2. CONTROL PANEL ASSEMBLY (CE SPECIFICATION 380V) 5-7
2.1 INVERTER PANEL 5-8
2.2. EXTERNAL APPEARANCE AND NAME OF EACH SECTION 5-9
2.3 NAME AND CONTENT OF THE DIGITAL OPERATOR 5-9
2.4 DETAIL OF INVERTER SET ITEMS 5-10
2.5 ALARM DISPLAY AND COUNTERMEASURE 5-13
2.6 LIST OF ALARM CODES 5-15
2.7 TROUBLESHOOTING 5-19
2.8 MAINTENANCE AND INSPECTION 5-25
2.9 NOTE ABOUT DISPOSAL 5-28
3. POWER SUPPLY BOX 5-29
4. ELECTRIC DIAGRAM 5-31
5. ELECTRIC MOTOR BOX HARNESS 5-33
OPTIONAL WINCH 6-1
1. OPTIONAL WINCH 6-1
1.1 WINCH MACHINE SECTION 6-2
1.2 WINCH ACCESSORIES 6-3
1.3 WINCH UNIT 6-5
1.3.1 APPEARANCE AND SPECIFICATION OF WINCH MOTOR 6-7
1.3.2 INTERNAL STRUCTURE OF WINCH MOTOR 6-8
1.3.3 FAILURE CAUSE AND COUNTERMEASURE 6-10
1.3.4 PRECAUTIONS IN WINCH MOTOR 6-10
1.4 OVER LOWERING DETECTION DEVICE 6-12
1.5 IRREGULAR WINDING PREVENTION ROLLER 6-12
2. OVER-HOISTING PREVENTION DEVICE ASSEMBLY 6-13
2.1 OVER-HOISTING PREVENTION DEVICE 6-14
3. INSTALLATION OF WIRE ROPE 6-15
4. WORKING RADIUS/LIFTING HEIGHT OF ONE FALL WINCH 6-17
5. SPECIFICATIONS OF OPTIONAL WINCH 6-18

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1-1
OVERVIEW
1. OUTSIDE DRAWING 1-2
2. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 1-4
3. PRINCIPLE SPECIFICATION LIST 1-5
4. WORKING RADIUS/LIFTING HEIGHT 1-9
5. RATED TOTAL LOAD CHART 1-18
6. CRANE STANDARD PRESSURE AND OPERATING TIME TABLE 1-19
7. POWER TRANSMISSION SCHEMATIC DIAGRAM 1-20

1-2
1. OUTSIDE DRAWING
1.1 STANDARD SPECIFICATIONS
Standard specifications
Standard specifications with winch attached