Maeda D3001 Operation Manual Download

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103ME-OM1903-00

Operation Manual

Mini-Crawler Crane

Serial No. D3001 and up

Summary of Contents for D3001

Page 1: ...103ME OM1903 00 Operation Manual Mini Crawler Crane Serial No D3001 and up...

Page 2: ...ad 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 manu...

Page 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 DI...

Page 4: ...Operation 4 15 Visible Checks 4 15 Checking before Starting Engine 4 15 Checking after Starting Engine 4 15 Normal Engine Start 4 15 Starting Engine in Cold Weather 4 16 Correction When Working at Hig...

Page 5: ...s to Be Performed upon Engine Stop 4 48 WORKING WITH CRANE 4 49 CRANE OPERATION 4 50 63B62BDos and Don ts During Crane Operations 4 50 64B63BBefore Crane Operations 4 52 65B64BCrane Operation Posture...

Page 6: ...orking Envelope Setting 4 72 Setting Working Envelope 4 73 Cancelling Working Envelope Setting 4 73 Moment Limiter Override Switch 4 74 REMOTE CONTROL SYSTEM INTRODUCTION 4 75 General 4 75 No Modifica...

Page 7: ...Main Switch 4 87 Monitor Display 4 87 Receptacle 4 87 Fuse in the Receiver 4 88 Removal of the Fuse 4 88 Insertion of a Fuse 4 89 MODE SETTING OF THE TRANSMITTER 4 89 A Mode 4 89 Opening A Mode Screen...

Page 8: ...4 122 Checking After Starting Electric Motor 4 122 Connecting Power Supply Cable 4 122 Operation and Checking After Power Connection 4 124 Machine Operation 4 126 Machine Stop and Checks after Stoppin...

Page 9: ...eep the Attachment Surface Clean 5 8 33BEmpty 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 N...

Page 10: ...ean Radiator and Oil Cooler Fins 5 32 Check Battery Charge Level 5 32 Post Start Inspection After Starting Engine 5 33 Check Horn 5 33 Check Working Lights 5 33 Check Fuse Box for Damage 5 33 Check Ou...

Page 11: ...nspection of Rubber Tracks 5 62 Replace Rubber Track 5 63 Checking After Starting Engine 5 64 Check Adjust Rubber Track Tension 5 64 Wire Rope 5 66 General Information and Precautions 5 66 Inspecting...

Page 12: ...Engine 5 80 Moment Limiter for Operation 850 kg Searcher Hook Mode 5 80 TROUBLESHOOTING 5 81 General 5 81 Machine Body 5 81 Engine 5 82 Electrical Components 5 83 Remote Control 5 84 Moment Limiter Er...

Page 13: ...3 2019 MC305C 3 1 1 Section 1 INTRODUCTION...

Page 14: ...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...

Page 15: ...3 2019 MC305C 3 2 1 Section 2 SAFETY...

Page 16: ...ion 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 an...

Page 17: ...oad 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 tota...

Page 18: ...ever 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 a...

Page 19: ...task at hand Explosion Hazard While the engine is running or the battery is charging hydrogen gas is being produced and can be easily ignited Keep the area around the battery well ventilated and keep...

Page 20: ...y to the machine before starting the engine Do not start the engine if any guards or covers are not properly installed on the machine Always turn the Starter Switch to the OFF position after operation...

Page 21: ...an elevated work surface Do not jump from the elevated work surface Do not climb on the boom outrigger or other machine surface The safety messages that follow have CAUTION level hazards Poor Lightin...

Page 22: ...e maintenance procedures or repairs Operating a machine with accumulated dirt and debris will cause premature wear of machine components Accumulated dirt and debris also hinders effective machine insp...

Page 23: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 9 SAFETY LABEL LOCATIONS Machine Body Fig 2 1...

Page 24: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 10 3 2019 MC305C 3 Fig 2 2...

Page 25: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 11 3 103 4762100 4 103 3439200...

Page 26: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 12 3 2019 MC305C 3 8 349 3195100 9 349 4420700 10 103 4762300 places 11 103 4762500 12 103 4551300 13 349 4421100...

Page 27: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 13 14 103 2214000...

Page 28: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 14 3 2019 MC305C 3 21 349 4421400 26 350 4539700 2 places 30 104 4550800 45 349 4426900 4 places 28 103 4559100 2 places 41 553 4267100...

Page 29: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 15 46 349 4427000 4 places 47 349 4427100 50 349 4427200 51 349 4527000 54 349 4421900 52 103 4576900 4 places...

Page 30: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 16 3 2019 MC305C 3 56 893 4239100 57 349 4427300 58 349 4427400 59 349 4427500 60 349 4427900 61 349 4526900...

Page 31: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 17 63 349 4427800 70 103 4551500 4 places 62 104 3327800 73 349 4422000...

Page 32: ...2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 18 3 2019 MC305C 3 83 103 4551700 75 553 4268000 2 places 76 553 4267500 2 places 77 553 4267400 2 places 78 585 4739200 80 103 3392900 81 103...

Page 33: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 19 84 349 4536600 87 353 4488600 95 553 4267700 88 103 4559200 2 places 89 350 4432100 93 103 4604800 94 103 4604900...

Page 34: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 20 3 2019 MC305C 3 Remote Control System Fig 2 3 Transmitter Receiver...

Page 35: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 21 1 349 4428500 23 104 4559300 68 300 4214000 92 104 4559400...

Page 36: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 22 3 2019 MC305C 3 Electric Motor Option Fig 2 4...

Page 37: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 23 70 103 4552100 4 places 100 553 4267300 2 places 26 350 4539700...

Page 38: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 24 3 2019 MC305C 3 850kg Searcher Hook Option Fig 2 5...

Page 39: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 3 2019 MC305C 3 2 25 9 103 4636300 2 places 5 102 4608500 2 places 1 102 4621200 2 places 4 103 4635500 2 103 3347900...

Page 40: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 26 3 2019 MC305C 3 B1 103 1213400...

Page 41: ...3 2019 MC305C 3 3 1 Section 3 SPECIFICATIONS TERMINOLOGY AND CAPACITY CHARTS...

Page 42: ...Two travelling lever operation enables not only direction changes among forward backward and right left but pivot turn and spin turn Crane An automatic slide outrigger is embedded in the crane to perm...

Page 43: ...n page 3 11 Fig 3 1 Rated Load A load derived by subtracting the mass weight of hoisting accessories hooks and slinging ropes from the rated total load Working Radius A horizontal distance between the...

Page 44: ...time 8 79m 26sec 8 79 m 39 6 sec Derrick system Method Direct push type hydraulic double acting cylinder 2 pieces With a hydraulic automatic locking device Boom angle time 0 to 80 deg 14 5sec 0 to 80...

Page 45: ...automatic stop device three winding stop alarm automatic stop device angle indicator hydraulic safety valve hydraulic automatic locking device slinging rope detachment protector alarm buzzer audio al...

Page 46: ...trol unit voltage Power for the Crane DC 12V Control unit power consumption Approximately 70 watts maximum per single function Operating ambient temperature 10 C to 55 C Storage ambient temperature 20...

Page 47: ...019 MC305C 3 3 7 850 kg Searcher Hook Specifications System Item MC305C 3 Standard MC305C 3 Electric motor option Mass and dimensions Machine mass 3930 kg 4070 kg Stowed length width height 4435 1280...

Page 48: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 8 3 2019 MC305C 3 DIMENSIONAL DRAWINGS Machine Dimensional Drawing Fig 3 6...

Page 49: ...M A E D A Mini Crawler Crane Section 3 DIMENSIONAL DRAWINGS 3 2019 MC305C 3 3 9 850kg Searcher Hook Dimensional Drawing Fig 3 7...

Page 50: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 10 3 2019 MC305C 3 Outrigger Width Dimensional Drawing Fig 3 8...

Page 51: ...ed total load is a load including the mass of a hoisting accessory hook 30kg Operate using the value on the load chart corresponding to the MAX MID or MIN outrigger extension The rated lifting capacit...

Page 52: ...preceding boxes in the rated total load chart 1 Boom 1 All the booms are retracted Fig 3 10 2 Boom 1 2 With booms 3 4 and 5 retracted boom 2 is fully extended Boom 1 2 is to apply to crane operation...

Page 53: ...ded booms 4 and 5 are extended at the medium half of the mark passes boom 3 Boom 1 2 3 4 is to apply to crane operation with booms 4 and 5 extended even if only slightly Fig 3 13 5 Boom 1 2 3 4 5 All...

Page 54: ...load is lifted 3 Deductions from rated total loads must be made for the weight of hook block ball hook slings rigging or other suspended gear 4 The slewing range will be restricted if the outrigger a...

Page 55: ...Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total load kg 2 50 2980 2 70 2270 4 00 1060 4 50 780 3 00 2360 3 00 2090 4 50 950 5 00 650 3 50 1960 3...

Page 56: ...Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total load kg 2 50 1480 2 70 1480 4 00 1060 4 50 780 3 00 1480 3 00 1480 4 50 950 5 00 650 3 50 1480 3...

Page 57: ...oad kg Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total load kg 2 50 750 2 70 750 4 00 750 4 50 750 3 00 750 3 00 750 4 50 750 5 00 650 3 50 750 3...

Page 58: ...g 5 The capacity when using the searcher hook refers to the capacity with the crane hook detached 6 If boom 3 is extended to any extent work should be performed within the capacity for 26 7 ft Boom 7...

Page 59: ...M A E D A Mini Crawler Crane Section 3 RATED TOTAL LOAD CHARTS 3 2019 MC305C 3 3 19 OFFSET POSITION SH1 OFFSET POSITION SH2 OFFSET POSITION SH3...

Page 60: ...orking radius and lifting height shows the relationships the working radius of this machine boom angle and lifting height above the ground with no object hoisted The diagram has been made allowing for...

Page 61: ...radius and lifting height shows the relationships the working radius boom angle and lifting height at no load allowing for no deflection in the boom A deflection occurs in the boom when an object is...

Page 62: ...sing the searcher hook be sure to set searcher hook mode for moment limiter Fall mode and searcher hook offset position must be set as 850 kg searcher hook mode when 850 kg searcher hook is used Searc...

Page 63: ...M A E D A Mini Crawler Crane Section 3 WORKING RADIUS LIFTING HEIGHT 3 2019 MC305C 3 3 23 Fig 3 19 Fig 3 20...

Page 64: ...Section 3 WORKING RADIUS LIFTING HEIGHT Mini Crawler Crane M A E D A 3 24 3 2019 MC305C 3 This Page Intentionally Left Blank...

Page 65: ...3 2019 MC305C 3 4 1 Section 4 OPERATION...

Page 66: ...Outrigger extension cylinder Built in the box 10 Outrigger 11 Slewing device 12 Rubber track 13 Travel control 14 Crane control 15 Moment limiter display unit 16 Operation seat 17 Instrument panel 18...

Page 67: ...OUTRIGGER STOWING on page 4 45 Slewing device A device to slew the crane Rubber Tracks Travel Motor and Sprocket Track Roller Idler Carrier Roller Travel device for travelling Travel Control A part fo...

Page 68: ...ontrol Location Fig 4 2 1 Slewing lever 2 Boom telescoping lever 3 Winch lever 4 Boom lift lever 5 Outrigger un set warning lamp 6 Acceleration pedal 7 Level gauge 8 Travelling lock lever 9 Right trav...

Page 69: ...ever The lever returns to the Neutral position and the slewing stops Slew clockwise right Pull the lever toward you Right Boom Telescoping Lever Use this lever for telescoping the crane boom Fig 4 5 E...

Page 70: ...travelling levers are at the Neutral position Left Right Travelling Lever Use these levers to move the machine forward backward stop slew and to adjust the travelling speed Fig 4 9 Forward Push the l...

Page 71: ...king light switch 2 Crane high speed switch 3 Hook stowing switch 4 Travelling high speed switch 5 Boom stowing switch 6 Horn switch 7 Engine emergency stop switch EMO 8 Starter switch 9 Fuel gauge 10...

Page 72: ...es OFF Push the switch forward again and when the pilot lamp goes off the switch turns OFF and the crane operating speed returns to normal NOTICE Always set the work selector switch on the outrigger o...

Page 73: ...lly when stowing the boom Pay sufficient attention not to let the boom collide with the machine body Use the boom stowing switch only when stowing the boom Use this switch to stow the boom The pilot l...

Page 74: ...N position Emergency Stop Cancel Switch WARNING Do NOT set the emergency stop cancel switch to ON position during crane work Such attempt prevents automatic stop from occurring even under overwound co...

Page 75: ...22 Engine Water Temperature Monitor This monitor indicates errors with the engine coolant temperature The temperature is normal if this monitor is OFF during the operation If it lights up during the...

Page 76: ...error in the battery charge system Immediately stop the machine and check the tension of the alternator belt Fig 4 25 OPERATION SEAT Fig 4 26 1 Back seat 2 Seat 3 Slide adjusting lever 4 Reclining adj...

Page 77: ...ous injuries and death accidents when travelling over a snow covered ground or frozen road for unavoidable reason The snow covered grounds and frozen roads cause slips even when the inclination is sma...

Page 78: ...circuit by relieving the oil pressure let the pneumatic oil to escape to the hydraulic oil tank by raising to above the hydraulic circuit set pressure by using operation lever Doing so improves the M...

Page 79: ...ngine Start CAUTION If it is hard to start the engine due to low ambient temperature see Starting Engine in Cold Weather on page 4 16 for the engine starting operation Do not keep the starter turned f...

Page 80: ...1 Insert the key into the starter switch and turn the key to HEAT preheat position Keep the position until the preheat monitor goes off Release your hand and the key will automatically return to the...

Page 81: ...se in output due to an increase in altitude affects the maximum torque A decrease in the maximum torque is shown as below Altitude m 0 1000 2000 3000 Decrease in maximum torque 0 20 30 35 3 MISFIRE AT...

Page 82: ...If you find any abnormality during the crane operation check stop the machine immediately for emergency and repair Using the system in abnormal condition can result in serious accidents CAUTION The ap...

Page 83: ...the boom until it reaches the stroke end Check if there is any abnormality with the operation If there is any abnormality repair Fig 4 46 9 Operate the winch lever 3 slowly forward backward to check...

Page 84: ...ox unit is at the OFF position 1 Release your foot from the acceleration pedal 6 and change the engine speed to idling Continue the no load operation for about 5 minutes Fig 4 49 2 Turn the starter sw...

Page 85: ...TRIGGER STOWING on page 4 45 to stow the outriggers TRAVELLING CONTROLS AND OPERATION WARNING Not observing these cautions in travelling will result in serious accidents Cautions When Travelling When...

Page 86: ...es inclined for 15 degrees or more presents overturning hazard Do not travel on these slopes Be sure to switch the travelling high speed switch to the OFF low speed position when travelling on the slo...

Page 87: ...extremely careful when travelling forward If you cannot verify the safety because the travelling direction is the blind corner stop travelling and check the safety in the travelling direction Staff a...

Page 88: ...chine will be in the high speed travelling mode Push down the travelling high speed switch toward you The pilot lamp of the switch section goes off and the machine will be in the low speed travelling...

Page 89: ...spin turn Fig 4 62 Changing Path While Travelling Forward Backward Left Turn While Travelling Forward While tilting the right travelling lever forward return only the left travelling lever to the Neu...

Page 90: ...t with the travelling lever s during the engine operation may result in sudden movement of the machine leading to serious accidents Always set the travelling lock lever to the LOCK position when parki...

Page 91: ...tection switch inside the outrigger inner box to detect if the tray is seated properly through the detection pin installed between the tip of the inner box and the tray CAUTION Set the outriggers in t...

Page 92: ...splay and Warning Activation of Safety Devices Start the engine Travelling lock lever at LOCK position Check if the machine is in the posture of stowing the boom Fully retract the boom Boom horizontal...

Page 93: ...el flash Crane interlock device If any of the extension lamps and setting lamps total of eight goes off hook raising boom extending and boom lowering operation stop When the hook was raised excessivel...

Page 94: ...outriggers Outrigger extension switch ON Rotate Stow the outrigger rotary and secure at the specified position with position pin Stop the engine Extension lamps red on display panel flash Outrigger u...

Page 95: ...er Crane Section 4 OUTRIGGER COMPONENTS 3 2019 MC305C 3 4 31 OUTRIGGER COMPONENTS Fig 4 67 1 Position pin 2 Rotary 3 Outrigger setting cylinder 4 Outrigger extension cylinder 5 Outer box 6 Inner box 7...

Page 96: ...t and turns off when the tray 3 floats stow The conditions of the outrigger tray 3 are detected by the detection pin 1 at the tip of the inner box 2 and by the detection switch inside the inner box Fi...

Page 97: ...Boom Stowing Detection in Horizontal Direction The lamp turns on when the boom stops at the horizontal stowing position and turns off when the boom leaves the horizontal stowing position Boom movemen...

Page 98: ...elling lock lever is not at the LOCK position you can still travel the machine even if the work selector switch is operated to the Outrigger or Crane position The machine may move causing serious acci...

Page 99: ...e LOCK side restricts the travelling operation If the lever is not operated to the LOCK side the machine travels when a travelling lever is operated Note 2 The outrigger operation is enabled only when...

Page 100: ...ork Deteriorated pavement surface Areas where under the pavement surface is hollow due to water erosion and the top soil appears to be hard but soft in the ground Protecting Ground Place a sole plate...

Page 101: ...outriggers in a style that the rubber tracks are approximately 50 mm above the ground Fig 4 86 Make sure all of the outrigger position pins are securely fixed Do NOT let people approach nearby when pl...

Page 102: ...ly Suddenly raising two outriggers on one side will overturn the machine Reduce the engine speed to low speed when operating the outrigger switches At the high engine speed the outriggers operate sudd...

Page 103: ...between the outrigger bottom and crawler bottom should be obtained On ungraded ground or similar the width of extended outriggers decreases even when clearance a in the figure is 50 mm Do not perform...

Page 104: ...tary outward Fig 4 96 6 Insert the position pin 1 to the end at the position where the pin holes are aligned after rotating the rotary 2 outward Fig 4 97 NOTICE The position pin 1 has a wire to preven...

Page 105: ...side When the outrigger extension cylinder extends and the inner box extends to the desired position set the switch to the Neutral position Operate the remaining switches in the same way and extend th...

Page 106: ...t 50 mm above the ground Fig 4 105 7 When the machine was raised to about 50 mm above the ground operate the outrigger operation switches while checking the position of the bubble in the level to adju...

Page 107: ...igger is set at the positioning pin position 40 front 30 back 2 The inner box of all the outriggers is extended fully 3 All the outriggers are placed on a level surface 4 Approx 50mm is assured for cl...

Page 108: ...utrigger minimum extension is defined as that 1 The outrigger is set at the positioning pin position 40 front 30 back 2 The inner box of all the outriggers is minimised 3 All the outriggers are placed...

Page 109: ...put your hands or fingers around the gaps of movable areas when stowing the outriggers Your hands or fingers may get caught and it may lead to serious accidents Insert the position pin to the end whe...

Page 110: ...hen operating two outrigger grounding switches at the same time choose two front switches outrigger 1 and 4 or two rear switches outrigger 2 and 3 Operating two left or right switches at the same time...

Page 111: ...gger display are flashing in red Fig 4 122 NOTICE On the outrigger display the boom stowing lamp 1 green is illuminated and four outrigger extension lamps 2 and four outrigger grounding lamps 3 are fl...

Page 112: ...ing the rotary 2 inward Fig 4 127 NOTICE The position pin 1 has a wire to prevent the loss of the pin 3 Stow the other three outriggers in the same way NOTICE After stowing the outriggers verify that...

Page 113: ...ter body Such act may damage case and or panel sheet and may result in failures and improper operations Cautions When Setting Up Moment Limiter WARNING The moment limiter calculates the moments assumi...

Page 114: ...nforce the ground by laying a sufficiently large and strong base plate below each of all outrigger supports Fig 4 129 CRANE OPERATION 63B62BDos and Don ts During Crane Operations WARNING Always set th...

Page 115: ...iolently Do not operate the lever suddenly Especially the slewing boom lowering and hook lowering must be operated at low speed Fig 4 133 Do Not Access into Working Radius Do not let people access int...

Page 116: ...of the four outrigger extension lamps and four outrigger grounding lamps is flashing in red Set the travelling lock lever to the LOCK position when operating the operation levers of the crane system a...

Page 117: ...the winch lever 3 to the Neutral position to stop raising the hook Then operate the winch lever 3 to DOWN push forward side to lower the hook block Fig 4 143 Extending the boom will hoist the hook bl...

Page 118: ...as slinging operators If the hook block was hoisted too much the over hoisting will be detected The alarm buzzer sounds and the audible message saying Hook over hoisted will be heard When the alarm bu...

Page 119: ...horizontally or pull in the load by telescoping the boom Extending the boom increases the working radius and the rated total load that can be hoisted decreases Be extremely careful so that the load w...

Page 120: ...igger Fig 4 153 Operate the slewing lever 1 as follows Fig 4 154 Slew counterclockwise left Push the lever forward to the LEFT side Neutral Release your hand from the lever The lever returns to the Ne...

Page 121: ...r interfere with the machine Stow the boom securely into the stowing position After stowing the boom verify that the boom stowing lamp on the outrigger display lights up in green If the boom stowing l...

Page 122: ...the detection of over hoist Then the alarm buzzer and audible message of Hook Over Hoist are heard and the hook raising operation automatically stops 6 With the hook stowing switch at the ON position...

Page 123: ...converter 4 Working status lamp A Red working status lamp Warning light for load factor of 100 or more B Yellow working status lamp Pre warning light for load factor of 90 to 100 C Green working statu...

Page 124: ...nts such as overturning of the machine resulting in death or serious injury If the Moment Limiter Override Switch is ON Override the Working Status Lamp will flash in red and an alarm buzzer will soun...

Page 125: ...ion Boom extending operation Hook raising operation Crane slewing operation Boom raising operation Recovery Operation after Auto Stop DANGER Be sure to switch the engine speed to low speed and perform...

Page 126: ...IMITER OVERLOAD DETECTOR Mini Crawler Crane M A E D A 4 62 3 2019 MC305C 3 The audible message of Peep overloading will be issued Furthermore the LED of 100 on the moment limiter load factor display l...

Page 127: ...operation In the case of an automatic stop when raising of the boom is unavoidable the boom raising operation is possible only while keeping the boom lift bypass switch in the ON position To return to...

Page 128: ...reen yellow and red 9 Over winding LED Red 10 Load capacity display Yellow 11 Actual load display 12 Rated total load display 13 Working radius display 14 Working radius upper limit switch 15 Working...

Page 129: ...nd LED Orange Use this switch to set or cancel the boom angle upper limit Fig 4 176 Setup With no upper limit value being set set the boom to the angle you would like and press the switch for 2 second...

Page 130: ...even if you keep the switch pressed for more than 2 seconds Let your hand go off the switch and press the switch again Working Radius Upper Limit Switch and LED Orange Use this switch to set or cance...

Page 131: ...tomatically stops at the set hook height before performing the actual operation If the boom does not stop automatically re set the hook height using the procedure above When the boom reaches the pre w...

Page 132: ...lay will be a blank for the item to which no value is set The display sections other than for the corresponding items will be blank Descriptions of Moment Limiter Display For LEDs not described in thi...

Page 133: ...y Section This section constantly displays the current boom angle during the crane operation The boom angle is the angle the boom and the horizontal line form Over Winding LED Red This LED flashes up...

Page 134: ...the number 50 and above are OFF Moment Limiter Functions Overload Warning Fig 4 191 Fig 4 192 1 Safety Zone Actual load is less than 90 of the rated total load Green of the working status lamp lights...

Page 135: ...ntinuously The hazardous operation of the boom stops automatically Fig 4 193 Over Winding Detector CAUTION Pay attention to the distance between the hook and boom when raising the hook Extending the b...

Page 136: ...tion stops automatically Outrigger Extension Detection The outrigger extension status is detected with the limit switch mounted to each of four outriggers lighting the appropriate LED blue of the MIN...

Page 137: ...ch to the OFF position and then turn again to the ON position to enable the restriction NOTICE The last status of the set value has been held in memory even if the starter switch is turned to the OFF...

Page 138: ...ilure of the Moment Limiter system and or machine maintenance service when any crane travel lifting operations are not being performed Do not store the override key permanently in the moment limiter o...

Page 139: ...ed by the forefinger Other fingers should grab the grip to hold the Transmitter Always manipulate levers and switches by fingers Do not attempt to pick them by a sharp edge or such for manipulation It...

Page 140: ...tremely low 14 F or below or cold air directly blows Sudden change in temperature may cause dew formation inside the Transmitter and which causes failure or malfunction and leads to a serious hazard I...

Page 141: ...ys proper indications when each lever and button is manipulated Further verify the each applicable value of load in the Transmitter is identical to that of the Moment limiter display Inspection Prior...

Page 142: ...cludes both Transmitter and Receiver which facilitate remote control of the Crane which is purchased with this device This Interactive Remote Control System provides an operation of the Crane at the m...

Page 143: ...limiter of the Crane are delivered to the Transmitter through the cable Fig 4 212 Functions of Remote Control System The Transmitter allows one hand operation which enables craning works such as holdi...

Page 144: ...2 Start Reset Button 3 Stop EMO Button 4 Speed Mode Button 5 Hook Stow Setting Button 6 Horn Button 7 Power Switch 8 Slewing No 1 Outrigger Operation Lever 9 Boom Telescoping No 2 Outrigger Operation...

Page 145: ...cy event where the Crane does not stop by normal operations or such this button provides the forced stop function Fig 4 215 Speed Mode Button This button also provides two usages as below During crane...

Page 146: ...on stowing of either only No 1 or all of the outriggers at once Retraction stowing Push the upper end of the lever Neutral Release your finger from the lever Extension installation Push the lower end...

Page 147: ...g Push the upper end of the lever Neutral Release your finger from the lever Extension installation Push the lower end of the lever 3 In the A MODE this lever is used as a cursor key by and Boom Lift...

Page 148: ...state of the engine when it is manipulated then the engine speeds up by further manipulation of it the crane operation turns to be faster accordingly The Accelerator lever does not control outriggers...

Page 149: ...Transmitter Before putting it into this case ensure that the power of the Transmitter is OFF Fig 4 228 Hook Belt During the operation this belt prevents the Transmitter from falling down to the groun...

Page 150: ...Section 4 REMOTE CONTROL SYSTEM COMPONENTS Mini Crawler Crane M A E D A 4 86 3 2019 MC305C 3 Receiver Components Fig 4 230 1 Control Box 2 Main Switch 3 Monitor Display 4 Receptacle...

Page 151: ...TION In the event that the monitor display 3 indicates an error code settle the error as follows 1 Push the Reset button of the Transmitter 2 When the practice as above 1 results another error code on...

Page 152: ...hows white rust or when a loose condition is recognised always replace it with a new one When the fuse is blown never fail to examine the circuit for the cause and repair it before replace the fuse Th...

Page 153: ...ass Type Grass tube fuse Rating 15A MODE SETTING OF THE TRANSMITTER This device provides the A MODE in which the initial values of the Transmitter are established the OUTRIGGER MODE in which the outri...

Page 154: ...ersion information of the Transmitter firmware To switch the function item to another or to change the setting value of the function use the Hook raising and lowering lever Then to fix the value in th...

Page 155: ...obtained push the Hook stow Setting button The value obtained in above 1 will be fixed and the display returns to the A MODE screen LCD Backlight Adjust the time to the auto cut of the LCD backlight...

Page 156: ...o speed mode Fig 4 247 1 Shift the cursor or using the Hook raising and lowering lever and select N or Y To reset select Y otherwise select N to preserve 2 Whether reset or not is fixed push the Hook...

Page 157: ...ook raising and lowering lever so that the cursor comes to the side of 10 minutes then push the Hook stow Setting button Now the OFF timer setting is 10 minutes Fig 4 250 4 Shift the cursor or using t...

Page 158: ...to continue the operation in the previous mode call the appropriate mode again Call Out Crane Mode 1 Push the Power button to turn ON the Transmitter The Crane mark is displayed in the LCD screen for...

Page 159: ...utton when the cursor points out the OUTRIGGER Fig 4 260 Fig 4 261 4 The operation mode is already switched to the OUTRIGGER MODE thus the Outrigger mark is exhibited Soon after it enters into Ground...

Page 160: ...the vicinity of the control levers and or acceleration lever they may disturb correct operations and cause un expected motion of the Crane which results a serious accident Check for any cracks and or...

Page 161: ...at each indication in the LCD screen is correct 3 Verify that START is correctly displayed in the LCD screen when the Start Reset button is pushed Fig 4 269 4 Also verify that STOP is correctly displa...

Page 162: ...trigger mark is exhibited then it enters into the Ground setting mode soon after Fig 4 276 Fig 4 277 5 To shift to Extension mode push the Speed Mode button while the LCD screen shows the Ground setti...

Page 163: ...iver then cause a serious hazard Check the Main switch 2 and Receptacle 4 for the loose conditions or damages Repair immediately when such loose conditions or damages are found Such loose conditions o...

Page 164: ...ath The Crane is inoperable in such event where the LCD screen in the Transmitter shows an error message or the Monitor display in the Receiver shows an error code Without fail examine the cause of th...

Page 165: ...e them stowed Otherwise the Transmitter operation may cause damages to the boom or outriggers or tipping the Crane that results serious injury or death The Crane is inoperable in such event where the...

Page 166: ...ower and Retract upper area and check that the No 1 outrigger follows the lever operation Fig 4 292 Fig 4 293 8 During the control lever manipulation slowly pull and release the Accelerator lever and...

Page 167: ...WARNING Ensure that all the outriggers are securely settled before starting crane operations Any crane operations where outriggers are improperly used cause the tip of the Crane or other serious accid...

Page 168: ...m lift lever pushing to the Raise upper area Fig 4 304 8 During the Hook raising and lowering lever manipulation to the Raise upper and Lower lower area respectively pull the Accelerator lever and che...

Page 169: ...each control lever manipulation of 6 through 12 above slowly pull and release the Accelerator lever and confirm that the speed of each action follows the acceleration ratio Fig 4 310 14 During each co...

Page 170: ...ble when the remote control is active Prior to start the remote control operations always conduct inspections of both the Transmitter and Receiver in accordance with REMOTE CONTROL SYSTEM VERIFICATION...

Page 171: ...such as tipping of the Crane For the outrigger operations always ensure that the position pin of each outrigger is securely inserted In the event where the pins are missing the Crane may be tipped and...

Page 172: ...4 321 3 Turn one of the outrigger operation levers to Extend lower and pull the Accelerator lever slowly Fig 4 322 4 When the outrigger is extended to the proper position slowly release the accelerat...

Page 173: ...1 In accordance with Procedure in the Operation Mode on page 4 94 enter into the OUTRIGGER MODE Fig 4 326 Fig 4 327 2 Turn one of the outrigger operation levers to Retract upper and pull the Accelerat...

Page 174: ...o not attempt to push more otherwise it may damage the Transmitter and cause its fault it may result a serious accident To toggle each operation lever to the opposite side or to use another lever alwa...

Page 175: ...celeration especially while a load is hung will make a large impact to the Crane and may result a serious hazard such as Crane tipping or damage Fig 4 335 Slew Clockwise Right Push the Slewing No 1 ou...

Page 176: ...owered by the boom telescoping or boom lift as well The same attention must be paid as the hook raising and lowering by the winch operation Fig 4 337 Hook Raising Push the Hook raising and lowering No...

Page 177: ...rator lever slowly The hook 4 will be raised to the proper stow position Fig 4 341 NOTICE This hook stowage operation is performed under the engine idling condition regardless of the Accelerator lever...

Page 178: ...seconds Indication of 2 in the LCD screen is high lighted and it enters into the Micro speed mode setting screen NOTICE The Micro speed mode setting is available while the 2 in the LCD screen is high...

Page 179: ...engine Such cases include that the crane operation does not stop though you release your fingers from any of the operation levers or Accelerator lever or the Crane starts the operation despite that n...

Page 180: ...Receiver power In no occasions except the Crane operations power of the Transmitter shall not be turned ON That may cause an un expected motion of the Crane and result a serious hazard such that the C...

Page 181: ...eaker before performing inspection and maintenance of the electric system Potential electric shock may occur during work if disregarded Before inspection and maintenance inform all personnel to alert...

Page 182: ...ive when the electrical motor is the output source Fuel gauge pre heat monitor engine water temperature monitor engine oil pressure monitor battery charge monitor Engine and Electric Motor Switch CAUT...

Page 183: ...C MOTOR OPTION 3 2019 MC305C 3 4 119 Power Unit Fig 4 353 1 Power unit cover 2 Electric motor 3 Coupling 4 Hydraulic pump Power Supply Box Fig 4 354 1 Power supply box 2 Power supply box door 3 Door h...

Page 184: ...TOR OPTION Mini Crawler Crane M A E D A 4 120 3 2019 MC305C 3 Inverter Unit Fig 4 355 1 Rear cover 2 Protective cover 3 Inverter unit 4 DC12V power switch 5 AC circuit power switch 6 Power light white...

Page 185: ...in the upper figure and the DC12V power switch is illustrated in the lower figure Power Light White The power light is designed to indicate the presence of energization to this machine from power supp...

Page 186: ...wer supply equipment and this machine Be sure to supply the machine specifications compliant power AC 380 400V to this machine Power supply voltage Power current Power supply frequency 380 400 V 11 5...

Page 187: ...bottom of the power supply box to connect it to the terminal block 5 CAUTION The ground cable 8 of the cabtyre cable must be properly connected to the ground terminal 15 in the power supply box Invert...

Page 188: ...heck is necessary after motor warm up Keep the hook block away from the boom to avoid interference and collision Exercise caution to keep the boom from contact with an operator and this machine when s...

Page 189: ...ough the access protective cover of the Inverter unit that the trouble lamp remains OFF Fig 4 368 CAUTION An error occurs in the Inverter unit which causes the trouble lamp to come ON in red Contact u...

Page 190: ...y leakage or abnormality fix the problem 4 Clean off the crawlers and outriggers removing mud 5 Keep the periphery of the inverter unit free of dead leaves and paper waste Potential fire may occur if...

Page 191: ...e If the crane is operated in a mode other than 850 kg searcher hook mode the moment limiter will not operate correctly posing risk of machine damage toppling or other serious accidents Precautions Wh...

Page 192: ...EARCHER HOOK COMPONENTS OPTION Fig 4 374 1 E Boom 2 Bracket 3 Bracket 1 4 Bracket 2 5 Pin 6 Position pin 7 Lynch pin 8 Hook 9 Shackle 10 Hexagonal bolt with washer strength 10 9 11 Hexagonal bolt with...

Page 193: ...g LED Red 10 Load capacity display Yellow 11 Actual load display 12 Rated total load display 13 Working radius display 14 Working radius upper limit switch Setup cancel 15 Working radius upper limit L...

Page 194: ...ot use 850 kg searcher hook if actual searcher hook position and display of boom length window do not match Without setting moment limiter to the actual searcher hook offset position moment limiter ma...

Page 195: ...M A E D A Mini Crawler Crane Section 4 850 kg SEARCHER HOOK MOMENT LIMITER DISPLAY 3 2019 MC305C 3 4 131 Searcher Hook offset position and mode display in boom length display Fig 4 378...

Page 196: ...htening torque To install searcher hook always use new genuine Maeda bolts nuts and washers 3 Using the fall mode selector switch 23 set moment limiter to 850 kg searcher hook mode all LED flashes Als...

Page 197: ...ED AREA on Rated Total Load chart and it may cause a serious accident Always adjust boom angle to proper position for the work 9 Insert the position pin 10 through the hole of bracket and secure with...

Page 198: ...r load value than actual load Sudden lever operation increases error in reading load When operating boom derricking lever move the lever slowly 12 When operation is auto stopped by reaching overload d...

Page 199: ...al Load chart Do not exceed 30 degrees of boom angle when E boom offset position is in SH1 Fig 4 393 TRANSPORTATION Observe the related laws and regulations and transport the machine safely Transport...

Page 200: ...ur Do NOT change direction over a gangplank Temporarily leave the gangplank before correcting the direction Be slow when operating to change the direction on the truck platform where the footing is un...

Page 201: ...mensions and mass of the machine see PRINCIPLE SPECIFICATIONS LIST on page 3 4 Select and use the ramp boards that satisfy the following conditions Has the length that when placed the angle from the t...

Page 202: ...he ramp boards and load unload the machine in a way that the boom does not hit the trailer Move backward to load the machine and forward to unload the machine 5 Do not operate any other lever than tra...

Page 203: ...ION on page 4 21 and put the machine in the travelling posture 2 Verify that the position pins four are securely inserted in the rotary joint of the outrigger 3 Install a shackle 1 to the holes 4 loca...

Page 204: ...ve the key of the starter switch 2 Provide a square timber in front and back of the rubber tracks to prevent the machine from moving during transportation Secure the machine with chain or wire cable S...

Page 205: ...3 2019 MC305C 3 5 1 Section 5 MAINTENANCE AND INSPECTION...

Page 206: ...rubbish from entering the machine and make sure the safety will be ensured during maintenance Attempt to inspect or maintain with the maintenance machine still dirty not only lessens chance of locati...

Page 207: ...t and lower the boom and stop the engine Operate each of the crane operation levers forward backward several times to relief the pressure remaining in the hydraulic circuits Apply pawls to so that the...

Page 208: ...ne maintenance Work by at Least Two Persons during Maintenance with Engine Running Fig 5 8 To prevent accidents do not attempt maintenance when the engine is running Always observe the followings in c...

Page 209: ...d a helmet on and insert a copper bar or similar object between the hammer and the target when hitting Giving impact to a hard metal part such as a pin or a bearing may cause the broken chip to enter...

Page 210: ...k us or our sales service agency for a repair Replacement of high pressure hose requires experienced skill In addition the tightening torques are decided by the horse types and size Customers are proh...

Page 211: ...peration of the maintained part may cause an unexpected fault which may result in bodily accidents Always observe the followings Checks with engine stopped Check for unexecuted inspection maintenance...

Page 212: ...ainer to lubricate if it is attached to the lubrication opening 27BProtect Oil from Impurities Avoid dust when inspecting and replacing the oil to keep impurities out of the oil 28BAttach a Warning Ta...

Page 213: ...different type of oil Always use Maeda genuine parts for part replacement BASIC MAINTENANCE Oil Handling Oil is used under extremely harsh conditions high temperature high pressure in the engine and...

Page 214: ...d in the Periodic Maintenance chapter is used for overhauls which requires no grease replenishment Grease the nipple if a long term use hinders its smoothness Wipe off old grease squeezed out after gr...

Page 215: ...utions should be observed when performing inspection and maintenance of hydraulic equipment Place the machine in travel position on a level surface to inhibit the application of pressure to the cylind...

Page 216: ...op or sudden steering When the breaking in period reaches 50 hours do not fail to change the engine oil See Replace Engine Oil and Oil Filter on page 5 41 The metal powder produced inside the engine t...

Page 217: ...r part numbers when ordering parts List of Consumables Item Replacement cycle Engine oil filter Every 250 hrs initial 50 hrs Hydraulic oil return filter Every 500 hrs Hydraulic oil suction filter Ever...

Page 218: ...E 5W 30 SAE 15W 40 SAE 30 Fig 5 20 A specified oil quantity is defined as a total quantity of oil including that for unit piping and a replacement oil quantity is defined as a quantity of oil to be re...

Page 219: ...espect to the width across the flat b of the bolt or nut Fig 5 21 Bolts Marked with 8 8 Strength Classification on Head Nominal Size Mark a Width Across Flat Mark b Target Value Tolerance mm mm N m kg...

Page 220: ...661 895 67 4 91 2 27 41 1130 116 961 1300 98 6 133 30 46 1540 158 1310 1770 134 182 33 50 2100 214 1790 2410 182 246 36 55 2700 275 2300 3100 234 316 Bolts Marked with 12 9 Strength Classification on...

Page 221: ...32 166 16 9 144 191 14 7 19 4 24 36 211 21 5 183 243 18 7 24 7 27 41 309 31 4 269 355 27 3 36 1 30 46 419 42 6 364 482 37 0 49 0 33 50 570 58 0 495 656 50 4 66 7 36 55 732 74 5 636 842 64 8 85 7 Hose...

Page 222: ...left hand machinery cover 1 and right hand machinery cover 2 Fig 5 23 Four retaining bolts at the top and six at the sides three each on the left and right are used to tighten with the machinery cove...

Page 223: ...on or maintenance inside the rear cover 1 Remove the eight retaining bolts 2 from the rear cover 1 2 Remove the rear cover 1 52BInstalling Rear Cover Once inspection and maintenance inside the rear co...

Page 224: ...g one The fuse box is provided at the lower section of the instrument panel Check and replace a fuse using the procedure below 1 Remove the buckle 2 of the cover 1 at the bottom of the instrument pane...

Page 225: ...arator See Check Clean Water Separator on page 5 28 Check Clean Fuel Filter Pot See Check Clean Fuel Filter Pot on page 5 29 Check Add Hydraulic Oil See Check Add Hydraulic Oil on page 5 30 Check Refi...

Page 226: ...e fuel hose or fuel hose connections Buildup of combustibles and oil leakage around the hot engine section such as engine and muffler and around the battery can cause fire in the machine Carefully che...

Page 227: ...electrical wire loosened connection and trace of burns If you find any abnormality repair Check if the boom angle limit switch works properly or not If any abnormality is found repair Wire Ropes For m...

Page 228: ...or If you find any abnormality repair Look around and below the Machine and check for breakage excessive deformation contamination and similar of lights such as the outrigger unset lamps and working s...

Page 229: ...ll with tap water 1 Remove the cap 2 of the reserve tank 1 and fill water from the filler opening to the level FULL 2 After refilling with coolant securely install the cap 2 of the reserve tank 1 6 If...

Page 230: ...efilling with the oil 1 Stop the machine at levelled location 2 See OUTRIGGER SETTING on page 4 36 and rotate the Outrigger 1 and Outrigger 2 outrigger rotaries outward 3 Open the access hatch in the...

Page 231: ...than the specified upper limit level If the fuel spills be sure to thoroughly wipe it off Be careful not to let any foreign substance go into the filler opening when refuelling Be sure to close the t...

Page 232: ...hand machinery cover 4 Check the water separator pot 1 for any water or dust in the pot and verify if the red float 2 in the pot has not come up from the bottom The red float 2 in the pot 1 coming up...

Page 233: ...in the right hand machinery cover 4 Inspect the fuel filter pot 1 and check for water or dust accumulated inside the pot and also for the dust or similar object blocking the element Fig 5 40 5 If wat...

Page 234: ...l level in the working posture will cause overfilling since the oil in the cylinders has not returned to the tank Be careful not to let dust go in from the filler opening when refilling with oil 1 Sto...

Page 235: ...from the filler opening Fig 5 45 3 After refilling with the oil install the filler plug F and securely tighten the plug 4 See OUTRIGGER STOWING on page 4 45 and rotate the rotary of the outrigger 2 in...

Page 236: ...he machinery cover 6 See OUTRIGGER STOWING on page 4 45 and rotate the outriggers inward to stow them Check Battery Charge Level WARNING The electrolyte generates combustible gas and presents explosio...

Page 237: ...ion and check the followings Fig 5 51 2 Push the working light switch in the back and verify that the pilot lamp of the switch section and the working light on front of the machine lights up Fig 5 52...

Page 238: ...at the outrigger un set warning lamp flashes and the red of the working status lamp lights up Adjust Operation Seat WARNING Adjust the operation seat before operation or when the operator changes Pres...

Page 239: ...for 2 seconds and then the green lights up 3 Check the moment limiter display unit Verify that no error code is displayed at the RATED TOTAL LOAD display on the display panel 4 Start the engine and o...

Page 240: ...reduction gearcase X X Winch Gearcase Replace oil in winch reduction gearcase X X Travel Gearcase Replace oil in travelling motor reduction gearcase X X X Check Refill oil in travelling motor reductio...

Page 241: ...eplace Oil in Hydraulic Oil Tank on page 5 51 Replacement Hydraulic Oil Return Filter See Replace Hydraulic Oil Return Filter on page 5 46 Replacement Hydraulic Oil Suction Filter See Replace Hydrauli...

Page 242: ...ry cover 4 Set the fuel lever 3 on the water separator pot 1 to a horizontal position Close position to stop fuel supply 5 Turn the retaining ring 4 counterclockwise left to loosen it and remove the w...

Page 243: ...od 4 places 7 Greasing of the slewing gear 1 place 8 Greasing of the hook block 1 place 9 Greasing of the boom slide plate 8 places Neo grease grease for boom 10 Greasing of both sides and bottom of a...

Page 244: ...Section 5 PERIODIC MAINTENANCE Mini Crawler Crane M A E D A 5 40 3 2019 MC305C 3 Fig 5 61...

Page 245: ...e Failure to use proper oil may cause the engine to shorten its useful life Always use the specified oil for replenishment The engine oil must be maintained at a proper amount The complete draining of...

Page 246: ...gauge G and filler cap F properly upon completion of oil replacement 16 Start the engine and idle it for 5 minutes Stop the engine 17 Make sure again the oil level is in the range H to L marked on th...

Page 247: ...oil to be used Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil 1 Move the machine forward and backward to position it...

Page 248: ...36 and rotate the outriggers outward 2 See Removing Machinery Cover on page 5 18 and remove the machinery cover 3 Disengage the two clamps 1 and remove the dust pan 2 Fig 5 70 4 Pull out the element 3...

Page 249: ...d Always put in the fuel tank drain plug and secure it after draining fuel Fuel drain pan A 1 L container 1 Place the machine on a level surface 2 See OUTRIGGER SETTING on page 4 36 and rotate the out...

Page 250: ...ter WARNING All the parts will be at elevated temperatures immediately after engine operation which urges you not to replace the filter Always perform replacement with the engine cold Potential gush o...

Page 251: ...he filter Always perform replacement with the engine cold Potential gush of oil may occur upon removing the filler cap of the hydraulic oil tank Be sure to relieve internal pressure by slowly rotating...

Page 252: ...ow idle for 10 minutes 2 Move the cylinders and winch motor slowly with a crane control lever at low idle speed Always stop the boom lift cylinder and telescoping cylinder approx 100mm back from the s...

Page 253: ...adiator coolant is hot Potential gush of boiling water may occur if disregarded Cap removal is allowed when the water drops in temperature Be sure to relieve internal pressure by slowly rotating the f...

Page 254: ...antifreeze mixed water Fig 5 86 7 Open the drain valve 8 to drain coolant Close the drain valve 8 upon completion of draining 8 Supply tap water to the radiator through the radiator supply port The r...

Page 255: ...rt to FULL Install the cap 2 properly 20 See Installing Machinery Cover on page 5 18 and install the machinery cover 21 See OUTRIGGER STOWING on page 4 45 and rotate the outriggers inward to stow them...

Page 256: ...rt the engine with piping and hydraulic equipment filled with oil Make sure the engine runs at low idle for 10 minutes 2 Move the cylinders and winch motor slowly with a crane control lever at low idl...

Page 257: ...l Fig 5 94 5 Remove the drain plug P slowly to drain the oil keeping from contact with draining oil 6 Check the drained oil If check finds a considerable amount of metal powder and foreign objects con...

Page 258: ...Reduction Gearcase CAUTION See LUBRICATING OIL on page 5 14 for which oil to be used Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilli...

Page 259: ...NSE Batteries Battery Precautions Observe the followings when handling the battery WARNING Stop the engine and turn the main starter switch to the OFF position when checking handling the battery Wipe...

Page 260: ...If you have swallowed the battery fluid by mishap immediately drink huge quantity of water milk raw egg or vegetable oil and see the doctor as soon as possible Wipe with a wet clean cloth when cleanin...

Page 261: ...ndling when charging the battery may cause the battery to explode Follow the manuals attached to the machine and the charger and always observe the followings Adjust the charger voltage to suit the vo...

Page 262: ...Connecting Disconnecting Booster Cable WARNING Never let the terminal and terminal come into contact with the other when connecting the cable Fig 5 106 Wear goggles and rubber gloves when starting th...

Page 263: ...lock lever is at the lock position 1 Verify that the clips are securely connected to the battery terminals 2 Start the engine of the normal machine and increase the engine speed to full speed highest...

Page 264: ...the rubber blocks such as steel plates U shaped gutters corners of bricks corners of sheer broken stones and rocks reinforcing steels and iron scraps are not covered by warranty Dos and Don ts The fol...

Page 265: ...the rubber tracks coming off Fig 5 115 The rubber tracks slip very easily on a wet steep plate or snowed and frozen surface Be especially careful not to slip when operating on the slope Fig 5 116 Avoi...

Page 266: ...Contact us or our sales service agency for determining whether to replace repair or keep the rubber track The following condition requires the repair or replacement of the rubber track Contact us or o...

Page 267: ...n adjustment of the grease valve to circumvent potential dangers Ensure that grease is completely removed from the inside of the rubber track before rotating the sprocket to remove the rubber track Re...

Page 268: ...ter to execute the engine startup travelling operations outrigger operations and crane operations Check Adjust Rubber Track Tension CAUTION Set the outriggers and raise the rubber track for about 50 m...

Page 269: ...ber track found the tension lower than standard tension of the rubber track make adjustments as described below Working with the loose rubber track the tension of the rubber track at 15 mm or more wil...

Page 270: ...in for about 50 mm from the ground 3 Tighten the grease valve 1 4 Perform the tension check of the rubber track If the tension is not appropriate make another adjustment 5 See OUTRIGGER STOWING on pag...

Page 271: ...y either moving the boom lifting lever to LOWER push forward to lower the boom or by moving the boom telescoping lever to RETRACT pull toward you to retract the boom 3 Turn the starter switch to the O...

Page 272: ...lescoping lever to RETRACT pull toward you to retract the boom 4 Undo the wedge socket fixing bolt 2 Remove the wedge socket pin 1 and remove the wedge socket 3 5 Remove the wire clip 4 Fig 5 142 6 Pu...

Page 273: ...h the end of the wire rope held draw the wire rope 5 through the weight of the over winding detector load sheave 1 at the boom end wire guide 2 of No 2 3 and 4 boom snap sheave 3 and idler sheave 4 Fi...

Page 274: ...h the rope clip 4 to the dead end of the wire rope 5 Fig 5 152 7 Secure the wedge socket 3 to the boom with the wedge socket pin 1 and tighten the wedge socket fixing bolt 2 8 Place the boom derrickin...

Page 275: ...ylinder top and turn adjustment bolt 9 of the boom extending wire clockwise right The boom extending wire rope 8 is adjusted to the correct tension if boom No 5 extends upon rotating the adjusting bol...

Page 276: ...With the booms retracted in a horizontal position extend the telescoping booms approx 2m Fig 5 156 2 Retract the booms completely Slow boom stowing is required Measure clearance a to check the followi...

Page 277: ...159 5 Adjustment of boom No 5 extending wire rope 8 1 Remove the lock bolt 6 Turn the adjusting bolt 9 in the direction that the extending wire rope 8 of boom No 5 becomes tight clockwise right to pro...

Page 278: ...t the same time 65BAfter Storage WARNING If you did not perform antirust operation monthly during the long term storage contact us or our sales service agency before using the machine Perform the foll...

Page 279: ...ing fluid see Coolant Replacement and Internal Cleaning on page 5 49 Battery WARNING The battery produces combustible gas and can be explosive Do not put fire close to the battery The battery fluid is...

Page 280: ...hine and keep it at warm place to be installed next morning If the electrolyte level is low refill with distilled water next morning before starting the operation Do not refill after the operation in...

Page 281: ...e for correct part number for parts request List of Consumables Item Replacement cycle Searcher hook fix bolt M12x35L strength 10 9 8pcs Every 6 months or when damage crack or squash is found Searcher...

Page 282: ...ection Item Reference Pre Start Visible Checks See Pre Start Visible Checks on page 5 22 Pre Start Before Starting Engine Check E Boom Frame and Hook See E Boom Frame And Hook on page 5 79 Check Greas...

Page 283: ...h part of the E Boom frame and Hook for cracks excessive deformation and contamination etc In addition check bolts nuts and pins for any looseness drop and damage etc If you find any abnormality repai...

Page 284: ...operate the crane as follows to verify if the moment limiter properly displays the value Crane Operation and Displayed Parameter Value Displayed on Moment Limiter Displayed boom length with the boom l...

Page 285: ...eck Add Hydraulic Oil on page 5 30 and refill with hydraulic oil to the specified oil level See Periodic Maintenance Procedure on page 5 37 and clean or replace the filter Hydraulic oil temperature to...

Page 286: ...ent compression See Inspect Clean Replace Air Cleaner on page 5 44 and clean or replace the parts Clean Check and replace Engine water temperature monitor illuminates while the engine is in operation...

Page 287: ...the engine starts Defective alternator Defective wiring Replace Check and repair Abnormal noise from alternator Defective alternator Replace Starter not rotating even after the starter switch is turne...

Page 288: ...ontrol device has a failure Otherwise when the Crane does not operate perform the diagnosis of the Crane itself Power of the Transmitter and Receiver is ON Turn ON the power when not The fuse in the R...

Page 289: ...er ON again the Transmitter and Receiver Shut down the electrical power of the Crane then ON again Maintenance replace The Transmitter is in emergency stop Use the Reset button to release the emergenc...

Page 290: ...reaking of wire for telescopic control Maintenance replace Breaking of wire for hoisting control Maintenance replace Breaking of wire for derricking control Maintenance replace Breaking of wire for sl...

Page 291: ...detector E3H The input to angle detector is higher than the specified value E4L The input to length detector is lower than the specified value Check the installation of the length detector E4H The in...

Page 292: ...Replace the cabtyre cable with one adhering to specifications An abnormal noise and vibration are present in the power unit during operation A break in motor winding Looseness in the motor and pump fi...

Page 293: ...05C 3 OPERATION MANUAL Document No 103ME OM1903 00 First edition March 1st 2019 Maeda Seisakusho Co Ltd 1095 Onbegawa Shinonoi Nagano Nagano 388 8522 Japan No part of this manual can be reproduced in...

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Maeda D3001, Operation Manual

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