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Operation Manual 

Mini-Crawler Crane 

102ME-OM1901-00 

Summary of Contents for MC285C-3

Page 1: ...Operation Manual Mini Crawler Crane 102ME OM1901 00...

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: ...efinitions 3 3 PRINCIPLE SPECIFICATIONS LIST 3 4 Standard and Electric Motor Option Specifications 3 4 Remote Control System Specifications 3 6 Searcher Hook Specifications 3 7 Auxiliary Winch Specifi...

Page 4: ...her Hook 3 25 Working Radius Lifting Height for Auxiliary Winch 3 28 Section 4 OPERATION MACHINE COMPONENTS 4 2 TRAVEL CONTROLS 4 4 Control Location 4 4 Switches 4 5 Accelerator Lever 4 5 L H Travel L...

Page 5: ...lerator Switch 4 16 54BHome Switch 4 16 55BDisplay Page Change 4 16 56BWarning Display 4 17 57BConsumables Display 4 18 58BAbnormality Display 4 18 62BEngine Oil Pressure Abnormality 4 18 63BEngine Co...

Page 6: ...s 4 37 34BOutrigger 1 and 4 2 and 3 Stowage Switches 4 37 35BOutrigger 1 and 4 2 and 3 Ground Set Up Switches 4 37 36BOutrigger Combined Stowage Switch 4 37 37BOutrigger Combined Ground Set Up Switch...

Page 7: ...61 Crane Stowing Operation 4 61 Safety Precautions 4 61 Stowing Procedure 4 61 MOMENT LIMITER OVERLOAD DETECTOR 4 63 Moment Limiter Features 4 63 Programmable Moment Limiter 4 64 During Setup 4 64 Mo...

Page 8: ...4 76 Setting Resetting Slewing Angle Limits 4 76 Moment Limiter Override Switch 4 77 REMOTE CONTROL SYSTEM INTRODUCTION 4 78 General 4 78 Modification 4 78 Holding 4 78 Washing 4 78 Foreign Objects 4...

Page 9: ...tion port 4 92 Antenna 4 92 REMOTE CONTROL SYSTEM VERIFICATIONS 4 93 Before Turning On Transmitter 4 93 After Turning On Transmitter 4 93 After Starting Engine 4 93 Checking Engine Start Operation 4 9...

Page 10: ...r Protective Cover 4 115 Inverter Unit 4 115 12V DC Power Switch 4 115 AC Circuit Power Switch 4 116 Power Light White 4 116 Trouble Light Red 4 116 ELECTRIC MOTOR OPERATION 4 116 Pre start Inspection...

Page 11: ...D DETACH BOOM HEAD 4 135 Installing Boom Head 4 135 Detaching Boom Head 4 139 AUXILIARY WINCH MACHINE TRAVELLING POSTURE AND HOISTING METHOD 4 139 Machine Travelling Posture 4 139 TRAILERING 4 140 Ram...

Page 12: ...f Undercarriage Travel motor control valve hydraulic oil tank and hose joint 5 18 Undercarriage rubber track track roller sprocket and idler 5 18 Outriggers 5 18 Outrigger Cylinder 5 18 Post 5 18 Derr...

Page 13: ...efill Oil in Winch Reduction Gearcase 5 37 Check Adjust Alternator Belt Tension 5 38 Check Refill Oil in Travelling Motor Reduction Gearcase 5 38 Replace Engine Oil 5 39 Replace Engine Oil Filter Cart...

Page 14: ...l 5 72 Engine Coolant 5 72 Battery 5 72 After Daily Operation 5 72 SEARCHER HOOK INSPECTION AND MAINTENANCE 5 73 Legal Inspection 5 73 Consumables 5 73 Inspection and Maintenance List 5 74 Pre Start a...

Page 15: ...Removal 5 80 Winch Wire Rope Installation 5 81 AUXILIARY WINCH PERIODIC MAINTENANCE 5 83 Periodic Maintenance Schedule 5 83 Periodic Maintenance Procedures 5 83 Grease Machine Units 5 83 Check Oil Lev...

Page 16: ...Table of Contents Mini Crawler Crane M A E D A xiv 1 2019 MC285C 3 This Page Intentionally Left Blank...

Page 17: ...1 2019 MC285C 3 1 1 Section 1 INTRODUCTION...

Page 18: ...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 19: ...1 2019 MC285C 3 2 1 Section 2 SAFETY...

Page 20: ...uation 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...

Page 21: ...d use rated total load chart Never try to hoist a load that exceeds the rated total load Rated total load is the mass of the load plus weight of the winch lines and the weight of the hook block Always...

Page 22: ...the load is stable Never hoist more than one load at a time When you hoist a long load such as pipes clamp the load vertically or secure it at both ends Slewing Hazard Never slew a load over anyone Al...

Page 23: ...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 24: ...machine guards and covers are attached properly 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 Star...

Page 25: ...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 26: ...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 27: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 9 SAFETY LABEL LOCATIONS Machine Body Fig 2 1...

Page 28: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 10 1 2019 MC285C 3 Fig 2 2...

Page 29: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 11 5 102 4748700 2 places 6 102 4749900 7 553 4267400 2 places 8 102 3324500 9 350 4539700 2 places 10 103 4592500...

Page 30: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 12 1 2019 MC285C 3 16 350 4432100 17 349 4427400 18 553 4268000...

Page 31: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 13 19 102 2205800...

Page 32: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 14 1 2019 MC285C 3 20 349 4427800 21 349 4427100 22 349 4421400 23 349 4427500 24 553 4267100 25 353 4488700 3 places 26 839 4239100...

Page 33: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 15 27 CL000200010 28 104 4550800 30 353 4488400 31 353 3235200 32 102 3427400 34 349 4422000...

Page 34: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 16 1 2019 MC285C 3 35 553 4267500 2 places 37 102 4750400 38 353 4488600 40 349 4427300 41 349 4427900 42 349 4421900...

Page 35: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 17 47 101 4593300 4 places 48 103 4526900 49 553 4267700 4 places...

Page 36: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 18 1 2019 MC285C 3 51 102 2205900...

Page 37: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 19 54 553 4267600 55 349 4427200 57 103 4604800 58 103 4604900 59 102 4619800 61 584 4581700 2 places...

Page 38: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 20 1 2019 MC285C 3 62 102 3425800 64 102 4749400 66 102 4750600...

Page 39: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 21 Electric Motor Option Fig 2 3...

Page 40: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 22 1 2019 MC285C 3 1 102 3427500 2 553 4267300 3 350 4539700 4 200 4652200...

Page 41: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 23 Searcher Hook Option Fig 2 4...

Page 42: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 24 1 2019 MC285C 3 1 102 4621200 2 places 2 102 3340000 4 102 4620300 2 places 5 102 4608500 2 places...

Page 43: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 25 10 102 2206800...

Page 44: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 26 1 2019 MC285C 3 Auxiliary Winch Option Fig 2 5...

Page 45: ...M A E D A Mini Crawler Crane Section 2 SAFETY LABEL LOCATIONS 1 2019 MC285C 3 2 27 1 102 2209700...

Page 46: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 28 1 2019 MC285C 3 5 584 3438600 7 553 4267500 places 8 104 3287200...

Page 47: ...1 2019 MC285C 3 3 1 Section 3 SPECIFICATIONS TERMINOLOGY AND CAPACITY CHARTS...

Page 48: ...n design in order to keep the overall width between the crane and outrigger minimised while housed in travelling position This compact design is ideal for work in confined areas Two travel lever opera...

Page 49: ...TS on page 3 13 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...

Page 50: ...Hoisting rope IWRC 6 x Fi 29 7 mm x 48 m Boom Telescoping System Type Two sequential hydraulic cylinders with two wire rope telescoping systems Boom type Fully automatic 5 section pentagonal telescopi...

Page 51: ...duction motor 5 5kW 4P 380V 50Hz Starting method Inverter controlled 30 to 60 Hz Safety Device Over winding detector over unwinding stop device angle indicator hydraulic safety valve wire rope latch l...

Page 52: ...function during interruption of remote control Automatic power OFF device Auto power off device Transmitter stop function when battery capacity decreases Alarm switch Transmitter voltage Battery BA40...

Page 53: ...Hook Specifications System Item MC285C 3 Standard MC285C 3 Electric motor option Mass and dimensions Machine mass 2012 kg 2182 kg Stowed length width height 3000 750 1470 mm 3485 750 1470 mm Performa...

Page 54: ...750 mm 1670 mm 3515 mm 750 mm 1670 mm Performance Crane capacity 0 9 t 2 0 mm Maximum working radius 8 5 m Maximum lifting height above ground 8 3 m Maximum lifting height below ground 100 m Winch sy...

Page 55: ...A E D A Mini Crawler Crane Section 3 DIMENSIONAL DRAWINGS 1 2019 MC285C 3 3 9 DIMENSIONAL DRAWINGS Machine Dimensional Drawing Standard Fig 3 6 Machine Dimensional Drawing Electric Motor Option Fig 3...

Page 56: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 10 1 2019 MC285C 3 Searcher Hook Dimensional Drawing Standard Fig 3 8 Searcher Hook Dimensional Drawing Electric Motor Option Fig 3 9...

Page 57: ...A E D A Mini Crawler Crane Section 3 DIMENSIONAL DRAWINGS 1 2019 MC285C 3 3 11 Auxiliary Winch Dimensional Drawing Standard Fig 3 10 Auxiliary Winch Dimensional Drawing Electric Motor Option Fig 3 11...

Page 58: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 12 1 2019 MC285C 3 Outrigger Width Dimensional Drawing Fig 3 12...

Page 59: ...in the table even slightly crane operation should proceed with respect to the rated total load corresponding to the working radius The rated total load includes the mass of the hoisting accessory rig...

Page 60: ...2 540 4 075 m Boom 4 080 5 575 m Boom 5 580 7 075 m Boom 7 080 8 575 m Boom 1 2 535 m Boom All the booms are retracted Fig 3 14 2 2 540 4 075 m Boom When boom begins to extend until boom is fully exte...

Page 61: ...285C 3 3 15 4 5 580 7 075 m Boom When boom begins to extend past the first mark until the boom extends until the second mark is visible at the end of boom Fig 3 17 5 7 080 8 575 m Boom When boom begin...

Page 62: ...d 41 2 kN Rated Total Load Chart 4 Falls Rated Total load Chart 4 falls The unit of loads kg 2 535 m Boom 2 536 4 075 m Boom 4 076 5 575 m Boom 5 576 7 075 m Boom 7 076 8 575 m Boom Load radius m Load...

Page 63: ...0 130 6 5 7 0 31 5 200 100 7 0 7 5 24 0 180 80 7 5 8 0 13 0 150 70 8 0 Hook block mass weight 30 kg standard supplied Maeda hook block or ball Rated Total Load Chart Single Fall Rated Total load Chart...

Page 64: ...ensate for boom deflection as the load is lifted 4 Deductions from Searcher Hook Rated Total Load must be made for the weight of the searcher hook 22 kg as well as block ball and all rigging 5 All cap...

Page 65: ...han MAX MAX Other than MAX MAX Other than MAX MAX Other than MAX MAX Other than MAX 50 0 or more Prohibited 50 0 or more Prohibited 50 0 or more Prohibited 50 0 or more Prohibited 50 0 or more Prohibi...

Page 66: ...e Prohibited 75 0 or more Prohibited 50 0 or more Prohibited 50 0 or more Prohibited 50 0 or more Prohibited 1 5 59 5 850 850 70 5 850 850 1 5 2 0 47 5 850 820 63 5 850 820 2 0 2 5 31 0 850 740 56 5 8...

Page 67: ...r than MAX MAX Other than MAX MAX Other than MAX 1 5 60 0 850 850 71 5 850 850 1 5 2 0 46 5 850 820 64 5 850 820 2 0 2 5 25 0 850 740 56 5 850 740 2 5 2 6 2 0 850 700 49 5 850 580 2 6 3 0 47 5 850 540...

Page 68: ...and specification 9 Standard wire rope specification 6xWs 26 IWRC 8 mm diameter 108 m Specified breaking load 48 1 kN Rated Total load Chart Searcher Hook Position SH3 The unit of loads kg 2 535 m Boo...

Page 69: ...d lifting height above the ground with no object hoisted The diagram indicates that there is no deflection in the boom The diagram is based on the assumptions that the operation is performed without l...

Page 70: ...on page 3 23 shows the relationships between the working radius boom angle and lifting height at no load with no deflection in the boom A deflection occurs in the boom when an object is hoisted which...

Page 71: ...Lifting Height for Searcher Hook DANGER When using the searcher hook be sure to set searcher hook mode for moment limiter When using the searcher hook the searcher hook position must always be switche...

Page 72: ...Section 3 WORKING RADIUS LIFTING HEIGHT Mini Crawler Crane M A E D A 3 26 1 2019 MC285C 3 Fig 3 25 2...

Page 73: ...M A E D A Mini Crawler Crane Section 3 WORKING RADIUS LIFTING HEIGHT 1 2019 MC285C 3 3 27 Fig 3 25 3...

Page 74: ...relationship between the working radius of this machine boom angle and lifting height above the ground with no object hoisted Deflection in the boom is not indicated When using auxiliary winch always...

Page 75: ...1 2019 MC285C 3 4 1 Section 4 OPERATION...

Page 76: ...Indicator 6 Winch 7 Post 8 Travel Control 9 Outrigger 10 Outrigger Cylinder 11 Machinery Cover 12 Rubber Track 13 Fuel Tank under the engine 14 Hook Hanger 15 Over Winding Alarm Buzzer 16 Crane Contro...

Page 77: ...towage see OUTRIGGER STOWING on page 4 48 Outrigger Cylinder A cylinder for extending the outrigger Machinery Cover A left right splitting machinery cover Rubber Tracks Rubber tracks for travelling Fo...

Page 78: ...A 4 4 1 2019 MC285C 3 TRAVEL CONTROLS Control Location Fig 4 2 1 Accelerator Lever 2 L H Travel Lever Locking lever 3 R H Travel Lever Locking lever 4 Starter Switch 5 Emergency Engine Stop Switch EMO...

Page 79: ...Travel Pull up the lever while releasing the lock to allow travel operations Crane Outrigger Push in and stow the lever while releasing the lock to allow crane outrigger operations Fig 4 5 NOTICE The...

Page 80: ...orking Light Switch is used to turn on the working light on the front of the machine ON Push the switch upward to turn the Working Light on OFF Push the switch downward to turn the Working Light off F...

Page 81: ...OM CONTROLS 1 2019 MC285C 3 4 7 CRANE AND BOOM CONTROLS Control Location Fig 4 10 1 Accelerator Lever 2 Slewing Lever 3 Boom Telescoping Lever 4 Winch Lever 5 Boom Lift Lever 6 Emergency Engine Stop S...

Page 82: ...om Lift Lever The boom lift lever is used to raise and lower the boom of the crane Emergency Engine Stop Switch EMO The Emergency Engine Stop Switch EMO is used to stop the engine in the event of an a...

Page 83: ...d screen will display Next a standby screen appears before switching to the home screen NOTICE When the engine is started the battery voltage can suddenly decrease depending on the temperature and bat...

Page 84: ...e Switch 3 Hook Stowage Boom Stowage Switch 4 Boom Lift Bypass Switch 5 Level Gauge 6 Time Display 7 Hour Meter Display 8 Fuel Gauge 9 Engine Electric Motor Drive Display 10 Remote Control System Conn...

Page 85: ...n for hook stowage and boom stowage Fig 4 17 The hook or boom can be stowed by pressing each switch Boom stowage Switch 3 1 Hook stowage Switch 3 2 For more information on stowage procedures see Crane...

Page 86: ...e remote control system is not connected Fig 4 23 28BOutrigger Status Display Displays the current outrigger status For more information on display content see OUTRIGGER INDICATORS on page 4 33 29BMom...

Page 87: ...e User Mode is displayed Fig 4 26 2 1 Number of Falls Change 2 2 Not in use 2 3 Error History Display 2 4 Consumables Display 2 5 Monitor Brightness Adjustment 2 6 Time Setting 2 7 Language Change 2 8...

Page 88: ...cted hold down the replacement switch 2 4B to update the replacement time Updating increments the number of replacements by 1 and resets the time remaining Fig 4 30 If Always or At start is selected f...

Page 89: ...s possible Make adjustments with or of the adjustment switch in this condition When the check mark is finally pressed editing is completed Fig 4 33 24 12 Hour Display Change When the switch 2 6C is pr...

Page 90: ...emote control system operation lever Set the desired value using or on the adjustment switch 2 10A Fig 4 39 NOTICE For example if set to 60 the acceleration value will be 60 and not 100 when the remot...

Page 91: ...display on the monitor illuminates in red and an alarm buzzer sounds at the same time Fig 4 40 1 Consumables Display 2 Abnormality Display abnormality detected 3 Engine Oil Pressure Abnormality 4 Eng...

Page 92: ...ality A warning is displayed if an abnormality occurs in the recharging circuit 65BError Code Display Displays an error code for the current error If multiple errors occur simultaneously check the err...

Page 93: ...n ground surfaces become soft when air temperature rises The load that is to be hoisted could be stuck to the ground NOTICE When cold always perform the warm up operation Sufficient warm up operation...

Page 94: ...contact the travelling levers while starting or operating the machine Only operate the correct controls per the operation Always turn the Starter Switch to the OFF position after operation is complete...

Page 95: ...tically return to the ON position Fig 4 51 2 Pull the acceleration lever upward to operate the engine at medium speed lever stroke about midway Fig 4 52 3 When the preheat lamp goes off turn the key t...

Page 96: ...tch to the OFF position to stop power to the electrical system Remove the key from the Starter Switch Be sure to correct the problem before operating the machine NOTICE Do not leave the engine at low...

Page 97: ...unction is normal If not correct it as necessary Fig 4 62 8 Slowly operate the boom telescope cylinder back and forth so that the boom extends or retracts to its stroke end to check that its function...

Page 98: ...ch key to OFF to stop the engine Fig 4 66 4 Remove the Starter Switch key Emergency Stopping 61BEmergency Engine Stop Switch EMO The Emergency Engine Stop Switch EMO is used to stop the engine in the...

Page 99: ...lly or boom Do not allow a person to sit or stand on the travelling dolly or boom while moving the machine Do not travel with a load placed on the travelling dolly or boom Never make sudden directiona...

Page 100: ...es Only change the direction of the machine on solid ground away from obstacles WARNING The following safety message addresses a potential Tip Hazard while the machine is travelling over unstable grou...

Page 101: ...same time to check the travelling speed of the machine Fig 4 75 Travelling Forward Push the left and right travelling levers slowly at the same time to move forward Fig 4 76 Travelling in Reverse Pul...

Page 102: ...levers in the opposite directions Left Spin Turn Push the right travelling lever forward while pulling the left travelling lever toward you to rotate the left and right rubber tracks in the opposite d...

Page 103: ...safety precautions Always provide safety precautions such as clearly placed flags protection barriers lighting and caution notices that do not interfere with traffic Avoid parking the machine on unst...

Page 104: ...n Check if the machine is in the BOOM STOWING position Fully retract the boom Boom horizontal stowing position Boom slewing stowing position Boom Stowing Light on the monitor green on Working Status L...

Page 105: ...Standard Operation Sequence Machine Status Display and Warning Activation of Safety Devices Stow the outriggers 1 Set and stow the outriggers Ground Set Up Lights red on the monitor flash Working Stat...

Page 106: ...85C 3 OUTRIGGER COMPONENTS Fig 4 84 1 Linkage Bracket 2 Outrigger Cylinder 3 Rotary 4 Rotary Positioning Pin 5 Outrigger Base Box 6 Stay of damper type 7 Outrigger Top Positioning Pin 8 Inner Box Posi...

Page 107: ...Fig 4 85 1 Outrigger Ground Set Up Light 1 2 Outrigger Ground Set Up Light 2 3 Outrigger Ground Set Up Light 3 4 Outrigger Ground Set Up Light 4 5 Outrigger Angle Setting Light 1 6 Outrigger Angle Set...

Page 108: ...ground The conditions of the outrigger pad are detected by the detection switch 1 at the bottom of the outrigger cylinder There is a detection switch at the bottom of all four outrigger cylinders Fig...

Page 109: ...ed once both detection positions are simultaneously detected and the Boom Stowing Light illuminates in green Fig 4 90 Boom Slewing Stowage Position Determined as stowed once the boom stops at the slew...

Page 110: ...ch 1 4 Outrigger 2 Ground Set Up Switch 1 5 Outrigger 3 Stowage Switch 1 6 Outrigger 3 Ground Set Up Switch 1 7 Outrigger 4 Stowage Switch 1 8 Outrigger 4 Ground Set Up Switch 1 9 Outrigger 1 and 4 St...

Page 111: ...triggers to be brought into contact with the ground Fig 4 95 34BOutrigger 1 and 4 2 and 3 Stowage Switches Allow front and rear outriggers to be stowed Front outrigger 1 and 4 simultaneous operation R...

Page 112: ...o the next page OUTRIGGER SETTING Support Plates When used on soft ground place a single plate of sufficient size with sufficient strength under the pad of each outrigger to add support and protect th...

Page 113: ...ople away from the machine when placing the outriggers Do not allow people around the working area until the outriggers are placed Setting Outriggers Normal Outrigger State This machine has four outri...

Page 114: ...s by inserting the pin into any hole other than the one with a sticker Extended to maximum at the pin of the coupled bracket operate the machine in accordance with the rated total load for the Other t...

Page 115: ...r used Fig 4 116 5 Press one or two Outrigger Ground Set Up Switches The outrigger cylinders will extend Release the switch es once the outrigger pads make contact with the ground Operate the other sw...

Page 116: ...the standard angle outrigger state Even when all four outriggers are extended at the standard angles the situation in which the Outrigger Angle Setting Lights are not all lit in green or yellow is ref...

Page 117: ...for the Other than MAX outrigger position in RATED TOTAL LOAD CHARTS on page 3 14 when the outriggers are not fully extended For proper operation of the machine do not exceed these guidelines WARNING...

Page 118: ...triggers are set at the Other than MAX outrigger position on uneven ground do not use the machine Fig 4 126 The Other than MAX outrigger position occurs when 1 The outrigger is set with the position p...

Page 119: ...ited zones diagonally shaded zones in the illustration below causes the machine to tip over leading to serious personal injury Never perform crane operation in the shaded zones below At least two of t...

Page 120: ...e following conditions are met No load Boom fully retracted Boom angle of at least 50 degrees The boom can be lowered to an angle at or below 50 degrees only when the slewing angle is within the 340 d...

Page 121: ...fully retracted Boom not fully retracted Maximum Maximum Other than maximum Multi 340 to 160 20 to 160 Maximum Maximum Multi Other than maximum 340 to 160 20 to 160 Maximum Maximum Multi Multi 340 to...

Page 122: ...t stowed completely 1 Start the engine See Starting the Engine on page 4 20 After starting set the accelerator lever to low speed 2 Push in the travel lever while unlocking the lever to enable operati...

Page 123: ...it with the snap pin 13 at its end Fig 4 138 4 After removing the snap pin 12 at the end of the position pin 7 of the linkage bracket 1 pull out the position pin Fig 4 139 5 Lower the top box 9 and al...

Page 124: ...knobs at the top of the monitor case and open the cover toward you Fig 4 143 2 Switch the Moment Limiter Override Switch to ON Fig 4 144 3 Turn on the Emergency Outrigger Operation Selection switch in...

Page 125: ...feature Immediately repair any problems with the auto stop feature before operating the crane Review understand and follow the following operation sequences warning alarms and stopping procedures when...

Page 126: ...se of each outrigger cylinder which detects whether the outrigger is in contact with the ground based on the load on the cylinder If an abnormality occurs during operation check the detection switch o...

Page 127: ...ring operations stop When one of the outriggers goes up in the air during crane operation Ground Set Up Lights red on the monitor flash When two or more adjacent outriggers lift up during crane operat...

Page 128: ...safety messages address a potential Crush Hazard while operating the crane and boom Verify there are no people within the working radius of the crane and boom before operating the crane and boom Blow...

Page 129: ...erating the crane or boom Do not work if visually impaired due to worksite location or weather Always use adequate lighting when working in dark areas WARNING The following safety messages address a p...

Page 130: ...ng on the winch drum Perform the following operations before operating the crane 1 Verify that the Moment Limiter Override Switch is at the OFF position The safety device operation will not stop if at...

Page 131: ...tor lever on the side of the travel levers also affects engine speed Set the lever to low idle when operating the crane For more information see Accelerator Lever on page 4 5 Fig 4 161 Hook Raising Lo...

Page 132: ...ty messages address a potential Unsafe Operation Hazard while hoisting or lowering a load Do not continue to hoist a load if the overwind alarm detector sounds Stop the operation immediately and retur...

Page 133: ...windings of the wire rope cable remain on the winch drum the alarm sounds and the Over Unwinding Stop Display flashes in red Boom Lifting Operation Safety Precautions WARNING Tip Hazard Always move t...

Page 134: ...tion and boom telescoping stops Retract Pull the lever toward you to RETRACT Adjust the boom telescoping speed with the boom telescoping lever and the stroke of the accelerator levers Slewing Operatio...

Page 135: ...owing the crane Keep the hook block from slewing while stowing the crane Do not allow the hook block to contact the boom while stowing the crane While retracting the boom or lowering the boom the hook...

Page 136: ...1 Steady green Boom stowed Steady yellow Only stowed at slewing position Flashing red Not yet stowed in slewing position or boom fully lowered position 7 Adjust the hook position by raising or lowerin...

Page 137: ...p A Working Status Lamp red Warning Light for load factor of 100 or more B Working Status Lamp yellow Pre warning Light for load factor of 90 to 100 C Working Status Lamp green Working Light for load...

Page 138: ...ON The following safety messages address a potential Equipment Damage Hazard concerning the moment limiter Avoid direct sunlight Do not allow the temperature of the moment limiter body to exceed the s...

Page 139: ...lculated in the current figure Then it issues an alarm if the result is as follows Actual load Rated total load 90 to 100 If the calculation result is Actual load Rated total load 100 or more the mome...

Page 140: ...low colour of the Working Status Lamp flashes Operation of the applicable crane motion stops automatically Fig 4 178 Over Winding Detector CAUTION When hoisting the hook be careful of clearance betwee...

Page 141: ...ted by limit switches mounted on each of the four outriggers The rated total load changes based on outrigger extension Moment Limiter Error Display When an error is sensed by the boom angle sensor boo...

Page 142: ...or of less than 90 Working Status Lamp green Switch the engine speed to low speed and operate the crane with caution if the moment limiter load factor is 90 or higher WARNING Tip Hazard Always operate...

Page 143: ...und Fig 4 185 b Retract the boom Fig 4 186 5 Recovery operation using boom raising If the boom was stopped automatically note that you can raise it only while depressing the Boom Lift Bypass Switch Fi...

Page 144: ...y 9 Boom Section Display 10 Number of Falls Display 11 Over Winding Display 12 Over Unwinding Stop Display 13 Lifting Height Upper Limit Switch 14 Boom Angle Upper Limit Lower Limit Switch 15 Working...

Page 145: ...n a numerical value of actual load display changes when the boom is raised and lowered Although the numerical value of the actual load changes on a higher side when boom raising operation is performed...

Page 146: ...e hook has been raised to the over winding position detection Working Radius Display The current working radius is continually displayed during crane operations The working radius refers to the horizo...

Page 147: ...r Limit Display Boom Angle Upper Limit Lower Limit Switch Boom Angle Upper Limit Lower Limit Switch Working Radius Upper Limit Display Working Radius Upper Limit Switch Slewing Angle Limit Switch Cloc...

Page 148: ...boom telescoping level to RETRACT to lower the hook block For more information on control during stoppage caused by over winding see Over Winding Detector on page 4 66 Moment Limiter Working Envelope...

Page 149: ...ion zone or upper limit stop position in a condition in which the boom angle upper limit or lower limit is set the monitor display illuminates in orange Fig 4 205 Setup Set the boom to the desired ang...

Page 150: ...in which the slewing angle limit is set the monitor display illuminates in orange Fig 4 207 Setup Slew the boom to the desired angle in a condition in which no slewing angle limit is set and press the...

Page 151: ...travel lifting operations are not being performed Do not store the override key permanently in the moment limiter override switch box Fig 4 208 Fig 4 209 To Override the Moment Limiter System The mom...

Page 152: ...4 211 Always manipulate levers and switches with your fingers WARNING Electrical Shock Hazard Do not use sharp objects or tools to operate the transmitter A sharp object or tool may damage the transmi...

Page 153: ...e the battery from the transmitter and return the transmitter to us or our sales service agency for service WARNING Sudden Movement Hazard Do not use the transmitter if its case is damaged A damaged t...

Page 154: ...he battery Fig 4 221 Do not solder directly to the battery Doing so may cause electrolyte leakage heat generation and rupture of the battery Fig 4 222 If leaked electrolyte contacts your eyes immediat...

Page 155: ...UTRIGGER Mode Using Transmitter Switch the transmitter mode selector switch to OUTRIGGER Confirm that the display also switches to the outrigger display Operate the levers and check the outrigger exte...

Page 156: ...ludes both transmitter and receiver which facilitate remote control system of the crane This is a wireless remote control system the Crane can be operated at the most convenient place away from it wit...

Page 157: ...handling the crane by transmitter manual operation can be performed on the machine side depending on the type of operation required When the power of the remote control system is turned on manual ope...

Page 158: ...witch 5 Boom Lift Bypass Switch 6 Micro Speed Switch 7 Emergency Engine Stop EMO Remote Control System Power OFF Switch 8 Cable Connection Port Not used 9 No 1 Outrigger Slewing Operation Lever 10 No...

Page 159: ...le this switch is pressed following an overload stop Micro Speed Switch Used to operate the crane at slow speed when operating the crane Emergency Engine Stop EMO Remote Control System Power OFF Switc...

Page 160: ...rated using levers Crane Allows the crane to be operated using levers LED Light Front LED Light Control Panel Turns on the LED lights to illuminate the surrounding area For more information on turning...

Page 161: ...M A E D A Mini Crawler Crane Section 4 REMOTE CONTROL SYSTEM COMPONENTS 1 2019 MC285C 3 4 87 Transmitter Display Components Fig 4 233...

Page 162: ...e lever is moved The right display varies as follows for each of the screens Fig 4 234 Crane Screen The crane symbol is displayed The rated total load and actual load are also displayed RTL Indicates...

Page 163: ...M A E D A Mini Crawler Crane Section 4 REMOTE CONTROL SYSTEM COMPONENTS 1 2019 MC285C 3 4 89 Remote control menu list Fig 4 237...

Page 164: ...Icon Battery Icon Blinks in green when the power supply is in normal condition Battery Status Icon Indicates the remaining battery levels as follows Fig 4 239 Radio Wave Status Bar The intensity of r...

Page 165: ...NTROL SYSTEM COMPONENTS 1 2019 MC285C 3 4 91 Receiver Components Fig 4 241 R1 Control Box R2 Monitor LED R3 Connector Connection Port R4 Antenna Control Box The control box contains the receiver and c...

Page 166: ...ing connector to allow communication with the controller on the machine The wire must be kept connected WARNING Before performing electric welding due to repair work for the machine body or other reas...

Page 167: ...Hazard Do not operate the transmitter if its case the rubber covers operation levers or operation switches are damaged Damage to these items may cause internal component damage and or electrical fail...

Page 168: ...t start the engine using the Starter Switch of the machine 2 Push the Horn Switch 4 and confirm that the horn sounds Fig 4 243 3 Press the Engine Start Stop Switch 2 while the engine is stopped and co...

Page 169: ...the operation mode selector switch on the transmitter to Crane Fig 4 247 2 Move the operation lever 9 to the clockwise right and counterclockwise left side and verify that the result corresponds to t...

Page 170: ...or electrical failure WARNING Sudden Movement Hazard Do not use the transmitter if its case is damaged A damaged transmitter case may cause operator error WARNING Sudden Movement Hazard Do not use bo...

Page 171: ...changes 3 To enable crane operations press the Transmitter Power Switch once again with power to the remote control system turned on CAUTION You must press the Transmitter Power Switch a total of thre...

Page 172: ...ne speed is too high Only operate the outriggers when the engine speed is set to low The engine must be set to low speed to properly operate the outriggers During outrigger operations position the cra...

Page 173: ...gage and prevent outrigger operations 3 Switch the operation mode selector switch to Outrigger Fig 4 264 4 Use the levers to extend all four outriggers until they are in contact with the ground Stop o...

Page 174: ...n see Crane Stowing Operation on page 4 61 Operations after Starting Engine 1 Start the engine See Starting the Engine on page 4 97 2 Push in the travel lever on the machine main unit while unlocking...

Page 175: ...rcing a transmitter lever against its stop could result in damage to the transmitter Check for smooth and free movement of each operation lever on the transmitter Levers must return to the NEUTRAL pos...

Page 176: ...ring speed of the boom by moving the lever forward or backward Boom Telescoping Operation WARNING Operate the lever as slowly as possible WARNING Do not pull the load horizontally or pull in the load...

Page 177: ...d load from hitting outriggers Move the operation lever 9 as follows Clockwise right Push the lever forward Neutral Release your hand from the lever The lever returns to the Neutral position and the s...

Page 178: ...he right The switch returns to the original position Fig 4 280 Horn Switch Operation The horn keeps blowing while this switch is pressed and held Fig 4 281 Boom Lift Bypass Switch Operations If you ca...

Page 179: ...wage operations see Crane Stowing Operation on page 4 61 Stopping Operation by Remote Control System WARNING When the operation is finished be sure to press the Emergency Engine Stop EMO Remote Contro...

Page 180: ...ight high temperatures and high humidity HANDLING TRANSMITTER BATTERY NOTICE The battery used for the transmitter is an exclusive battery Replacement Timing of Battery If the battery runs low recharge...

Page 181: ...rd stop using it at once Do not modify or change the battery charger or cord CAUTION The battery capacity depends on the number of years used and ambient temperature The capacity decreases when the ba...

Page 182: ...atus LED indicator B4 on the charger starts blinking to indicate the charging has started Fig 4 293 4 When the battery becomes fully charged the LED indicator B4 is lit in green 5 After charging is co...

Page 183: ...voltmeter to verify no voltage is present at the power supply box Alert all personnel of your actions before performing inspection and maintenance on the electric system Attach a DO NOT TOUCH warning...

Page 184: ...g 4 294 1 Start Switch 2 Accelerator Lever NOTICE This section describes only switches that have different functions when using an electric motor as the power source i e as opposed to using the engine...

Page 185: ...ctric motor stops Pre heating Not used ON Electric circuits of the inverter unit are on START When the electric motor starts release the key The key automatically returns to the ON position Fig 4 295...

Page 186: ...tion 4 ELECTRIC MOTOR COMPONENTS Mini Crawler Crane M A E D A 4 112 1 2019 MC285C 3 Power Unit Fig 4 297 1 Power Unit Cover 2 Electric Unit Transport Casters 3 Electric Motor 4 Coupling 5 Hydraulic Pu...

Page 187: ...4 ELECTRIC MOTOR COMPONENTS 1 2019 MC285C 3 4 113 Power Supply Box Fig 4 298 1 Power Supply Box 2 Power Supply Box Door 3 Door Handle 4 Main Breaker Switch 5 Terminal Block 6 Ground Connection Termina...

Page 188: ...ray The breaker 1 is designed to provide automatic shutoff of the power that is supplied from the Inverter unit to the electric motor in the event of an error including overvoltage to prevent fire and...

Page 189: ...pections or maintenance Note risk of serious accidents due to electric shock or entanglement in rotating parts Inverter Unit This is the control unit for the electric unit WARNING Do not disassemble o...

Page 190: ...quipment and machine check the power supply on the power supply equipment Trouble Light Red NOTICE If the Trouble Light is illuminated an error has occurred in the inverter unit Contact us or our sale...

Page 191: ...e to follow the above precaution may cause the cable to get snagged on the protrusion and becoming damaged or broken To connect the cabtyre cable to the terminal block in the power supply box torque t...

Page 192: ...supply equipment breaker accordingly to shut off the supply source Check the Inverter unit and electric motor surrounding items and electric wiring for burning smells or damaged parts Promptly contact...

Page 193: ...r or vibration is present in and around the power unit 1 Turn the starter switch key to the OFF position The electric motor comes to a stop 2 Remove the four mounting bolts 2 securing the bottom of th...

Page 194: ...regarded Disconnecting Power Supply 1 Turn OFF the power supply equipment breaker 2 Unlock the door 3 of the power supply box 2 by pulling the handle 4 toward you to open it Fig 4 316 3 Turn OFF the m...

Page 195: ...it securely to the drop prevention hook on the frame of the main unit Serious accidents may result if the hook comes off and the electric unit falls Make sure the electric unit transport casters are i...

Page 196: ...lower cover 5 Remove the cover 5 Fig 4 322 5 Detach the three hydraulic hoses 7 from the couplers Fig 4 323 NOTICE Check the position of the couplers They can be removed only when the ball and groove...

Page 197: ...tension is too low the machine may fall when you remove the electric unit Fig 4 329 10 Remove the four bolts 16 connecting the electric unit to the machine main unit Fig 4 330 11 Gradually lower the e...

Page 198: ...correctly and there is a risk of serious injury through the machine becoming damaged or overturning There may be no display for the searcher hook selector switch due to retrofit etc of the searcher ho...

Page 199: ...5C 3 4 125 SEARCHER HOOK COMPONENTS OPTION Fig 4 333 1 E Boom 2 Bracket1 3 Bracket 2 4 Position pin 5 Lynch pin 6 pin 7 Hexagonal bolt with washer 8 Hexagonal bolt with washer M12 35L strength 10 9 9...

Page 200: ...ion see Home Screen on page 4 10 Boom Lift Bypass Switch If it becomes necessary to raise the boom while automatically stopped the boom can be raised only while the Boom Lift Bypass Switch is depresse...

Page 201: ...and operations that differ from normal use when using a searcher hook For more information on indications and switch operations not described in this section see User Mode on page 4 13 Hook Hanging Nu...

Page 202: ...to main boom and install bracket 2 using M8 bolts with washers strength 10 9 to main boom Using torque wrench tighten M12 bolts at 93 N m 14 N m and M8 bolts at 27 N m 8 N m Fig 4 340 DANGER Crash Ha...

Page 203: ...of 50 when the E boom position is SH1 or a boom angle of 75 when the E boom position is SH2 Fig 4 346 8 Insert the position pin 8 through the hole of bracket and secure with lynch pin 9 to the tip of...

Page 204: ...oom stops automatically on entering the overload area while being lowered or extended retract the boom and move to a safe area before lowering the boom to lower the load If it becomes necessary to rai...

Page 205: ...ices such as the moment limiter outrigger safety device and over winding detector automatic stop device activate properly Cautions during Operation Be careful for tipping by swaying load underground l...

Page 206: ...PTION Fig 4 353 1 Winch Unit Auxiliary Winch 2 Wire Rope Auxiliary Winch 3 Snap Sheave Bracket 4 Idler Bracket 5 Boom Head 6 Bullet Connector 7 Over Winding Detector Auxiliary Winch 8 Protect Weight A...

Page 207: ...ch Display NOTICE This section describes only indications and operations that differ from normal use when using an auxiliary winch For more information on indications and switch operations not describ...

Page 208: ...ce NOTICE This section describes only those indications and operations that differ from normal use when using an auxiliary winch For more information on indications and switch operations not described...

Page 209: ...and secure with lynch pin If position pin comes off it causes boom head to fall off leading to a serious accident When boom head is installed change electrical wiring from boom side of over winding d...

Page 210: ...provided below Fig 4 361 a Draw the wire rope through the wedge socket as shown in the figure b With the rope wedge 6 in position a pull the wire rope in direction indicated by the arrow 8 Attach the...

Page 211: ...m regular side to auxiliary winch side Fig 4 367 NOTICE If valve is not shifted main winch activates causing random winding 9 Hold wire rope end and operate hook lowering Holding with hand pass the ru...

Page 212: ...9 to bullet connector relay harness 31 on boom head side Fig 4 372 14 Disconnect hook lowering stop harness 32 from harness 33 on machine body side and connect to harness 34 for auxiliary winch Fig 4...

Page 213: ...and 3 Fig 4 376 AUXILIARY WINCH MACHINE TRAVELLING POSTURE AND HOISTING METHOD Machine Travelling Posture WARNING When moving this machine self propelled take the travelling posture with which the boo...

Page 214: ...dditional information on transporting the machine NOTICE Always follow all local laws and regulations when trailering the machine on public roads NOTICE Always position the machine in travelling posit...

Page 215: ...direction Loading Unloading Procedure WARNING Overturn Hazard Always load the machine moving backward onto the trailer Moving forward onto the trailer could result in an unstable condition 1 Place whe...

Page 216: ...quipment is installed See the nameplate attached to the machine for weight specifications The total machine weight is for a standard machine configuration 1990 kg The total machine weight for a machin...

Page 217: ...1 2019 MC285C 3 5 1 Section 5 MAINTENANCE AND INSPECTION...

Page 218: ...he parts catalogue Cleaning Parts Clean parts with a noncombustible cleaning agent Be sure to clean mating surfaces after removing a part to which an O ring or gasket is attached When you replace the...

Page 219: ...NG Burn Hazard Always wear welding gloves to protect your hands and a welding face mask to protect your eyes and face when welding NOTICE When welding Never weld using 200V or greater Do not place wel...

Page 220: ...NOTICE Do not mix oil with other oil of different grades or brands Secure the oil fill and drain plugs after oil replacement Use seal tape on the threads to prevent leaks To assist in oil draining oi...

Page 221: ...operation manual Fill the fuel tank after daily operation to prevent condensation and moisture contamination inside the tank Drain water deposits from the fuel tank before starting the engine and app...

Page 222: ...sales service agency for recommendations when using water other than clean fresh potable water Place the machine on a flat level surface in the TRAVEL position to check coolant level Do not start the...

Page 223: ...from the tank during machine operation For oil type and usage specifications see LUBRICATING OIL on page 5 10 Secure the hydraulic oil fill and drain plugs after oil replacement Use seal tape on the...

Page 224: ...r tracks a minimum of 80 mm off the ground 5 Place square blocks underneath the tracks at both the front and back of machine 6 Use the outriggers and slowly lower the tracks until they rest firmly on...

Page 225: ...periodic maintenance intervals or prior to reaching their wear limit Proper replacement of consumables ensures increased machine performance and efficiency Always use Maeda genuine parts for part rep...

Page 226: ...es Oil quantity is defined as the total quantity of oil in the system and replacement oil quantity is defined as the quantity of oil to be replaced during maintenance Always refer to the engine operat...

Page 227: ...pect to the width across the flat b of the bolt or nut Fig 5 3 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 kgf m...

Page 228: ...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 229: ...2 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 Hos...

Page 230: ...rom the left side machinery cover 1 Fig 5 5 NOTICE The mounting bolts 2 are positioned with 3 at the top 3 at the rear and 1 at the front left lower side 2 Remove 2 mounting bolts 4 from the right sid...

Page 231: ...rroded replace the fuse If a fuse blows inspect and repair the cause before replacing the fuse Always use a fuse of the same type and capacity when replacing Fig 5 7 No Capacity Circuit name F1 2 A Ov...

Page 232: ...an Radiator and Oil Cooler Fins See Check Clean Radiator and Oil Cooler Fins on page 5 24 Check Add Battery Electrolyte See Check Add Battery Electrolyte on page 5 53 Check Horn Operation See Check Ho...

Page 233: ...Undercarriage on page 5 18 4 Outriggers See Outriggers on page 5 18 5 Outrigger Cylinder See Outrigger Cylinder on page 5 18 6 Post See Post on page 5 18 7 Derrick Cylinder See Derrick Cylinder on pa...

Page 234: ...swing system speed reducer mounting bolts loose pipe connections or oil leakage Repair any abnormality detected Derrick Cylinder Check for loose pipe connections oil leakage wear or damage of support...

Page 235: ...e the machine on a level surface 2 Check the coolant level in the reserve tank 1 through the inspection window A located at the front side of the left machinery cover It must be between LOW and FULL F...

Page 236: ...If the oil level is too high high oil consumption and increased oil temperature will deteriorate the oil faster If the oil level is too low the engine may be damaged 4 Insert the oil level gauge G int...

Page 237: ...f the fuel tank and add fuel through the filler opening while watching the fuel gauge Fig 5 16 4 After refuelling securely close the tank cap Fill the fuel tank after daily operation is completed Chec...

Page 238: ...of fire such as cigarettes when replacing the fuel filter pot WARNING If the fuel spills when the fuel filter pot is removed thoroughly wipe it off CAUTION Water or dust accumulated inside the fuel fi...

Page 239: ...ng the hydraulic oil tank do not fill above the upper limit on the level gauge Overfilling may cause oil to gush from the tank during machine operation 1 Stop the machine on a level location 2 Rotate...

Page 240: ...ver Check Clean Radiator and Oil Cooler Fins WARNING Exposure Hazard Always wear appropriate eye protection to prevent the risk of eye injury when using compressed air NOTICE Avoid damaging cooling fi...

Page 241: ...rope take up condition and contact between the ropes For the check and inspection of wire rope while winch and boom telescoping See Wire Rope on page 5 63 Post Start Inspection Precautions Perform th...

Page 242: ...standard angle positions and insert the position pins 5 Confirm that the Outrigger Angle Setting Light is lit in green on the monitor Fig 5 32 6 Set the outriggers to maximum extension Start the engin...

Page 243: ...inner boxes Fig 5 35 Fig 5 36 2 See Starting the Engine on page 4 20 and start the engine 3 Verify that the outrigger descends smoothly when the Outrigger Extend Switch is pressed Also verify that th...

Page 244: ...om telescoping lever 3 is moved to EXTEND push forward Fig 5 41 7 Verify the boom retracts smoothly when the boom telescoping lever is moved to RETRACT pull toward you 8 Check for any abnormal sounds...

Page 245: ...rrectly contact us or our sales service agency immediately Do not operate the machine until the problem has been corrected 1 Turn the Starter Switch to ON 2 Verify the Working Status Lamp flashes in r...

Page 246: ...E When restarting the engine after emergency stop be sure to turn the Emergency Engine Stop Switch EMO to the OFF position before starting the engine The engine does not start when it is ON Fig 5 45 C...

Page 247: ...Slewing Gearcase Replace oil in slewing reduction gearcase X X Winch Gearcase Replace oil in winch reduction gearcase X X Check oil level and refill oil in winch reduction gearcase X Travel Gearcase R...

Page 248: ...first 250 hours of operation Replace Oil in Slewing Reduction Gearcase See Replace Oil in Slewing Reduction Gearcase on page 5 48 Replace Oil in Winch Reduction Gearcase See Replace Oil in Winch Redu...

Page 249: ...g the grooves and re blow the air on the inside Fig 5 49 NOTICE Always replace the element with a new one after 5 cleanings or a lapse of 1 year from initial use 7 Shine a light bulb into the element...

Page 250: ...and drain fuel NOTE Remove the fuel tank cap if normal or smooth fuel draining fails 5 After draining the fuel install and tighten the drain plug securely 6 See OUTRIGGER STOWING on page 4 48 to stow...

Page 251: ...g the outrigger cylinders 4 Place the boom derricking lever in the Raise position pull it toward you to raise the boom slightly for greasing the derricking cylinder mounting pin and slide plate that i...

Page 252: ...Section 5 PERIODIC MAINTENANCE Mini Crawler Crane M A E D A 5 36 1 2019 MC285C 3 Fig 5 55...

Page 253: ...tape etc at the thread of the oil inspection plug to stop the oil leak and securely tighten the plug after checking refilling the oil Allen key to remove a plug 5 mm 1 Place the machine on a level su...

Page 254: ...e belt is not in contact with the bottom of V groove 6 If the belt has elongated to the extent that the adjusting allowance is lost or it has scar or crack on it replace it with a new one 7 When the b...

Page 255: ...f the engine Be sure to refill the specified oil CAUTION Keep the engine oil at an appropriate level CAUTION When the engine is cold oil cannot be drained completely Drain the oil in a condition in wh...

Page 256: ...e engine oil pan is mounted at the cover under the control lever When draining engine oil use outriggers to raise the machine approximately 80 mm Always place timbers beneath right and left crawlers a...

Page 257: ...eplacing the filter cartridge 3 feed engine oil through filler port F to the specified level 12 Pull the oil level gauge G out and wipe the oil with a disposable cloth 13 Insert the oil level gauge in...

Page 258: ...lic oil tank is removed Loosen the filler cap mounting bolts so that the filler cap is raised a little to allow the release of inner pressure then remove the mounting bolts and the filler cap WARNING...

Page 259: ...pe away cleanly whenever the oil spills 11 See Installing Machinery Cover on page 5 14 and install the machinery cover 12 Bleed the air according to the following sequence a Start the engine only afte...

Page 260: ...connector at the back of the air cleaner body 7 Insert a new element into the air cleaner body 8 Connect cover and air cleaner body aligning the marks 5 and securely fasten with the latch Fig 5 78 9...

Page 261: ...Mixed quantity L 15 20 24 29 Antifreeze 0 6 0 7 0 8 0 9 Water 1 5 1 4 1 3 1 2 Antifreeze mixed water drain pan A 3 litre container Have a water filling hose available 1 See Removing Machinery Cover on...

Page 262: ...g with running water 13 Once clean water has flowed out stop the engine and water supply and drain tap water Close the drain valve 4 upon completion of draining 14 Supply coolant mixed of antifreeze a...

Page 263: ...ng the level point red point of the level gauge When the oil goes beyond the correct level it may spout out from the air breather during travelling or crane operation Be careful not to let any foreign...

Page 264: ...ine To drain oil use outriggers to raise the rubber track about 80 mm allowing access under the machine If the machine becomes unstable and wobbles insert supports under the front and back of the mach...

Page 265: ...ures immediately after engine operation Do not remove the plug of the inspection port or drain port immediately Wait until the oil cools down CAUTION See LUBRICATING OIL on page 5 10 for the oil to be...

Page 266: ...in plug 7 Place a container H to collect the drained oil just below the elbow 8 With the Allen key C turn and remove the oil inspection plug G Gear oil in the reduction gearcase is drained Fig 5 90 9...

Page 267: ...lug to receive drained oil 4 Remove the oil inspection plug G 5 Turn the drain plug slowly to avoid splashing oil on yourself and drain oil 6 Check the drained oil and if it contains an unacceptable a...

Page 268: ...andling or servicing the battery If contact with the skin and or eyes should occur seek immediate medical treatment and flush continuously with water until medical treatment is obtained Fig 5 96 NOTIC...

Page 269: ...Install the battery in the reverse order of removal NOTICE Before connecting the battery cables to the battery make sure the polarity is correct Always connect the positive cable first when installing...

Page 270: ...ety messages address a potential Explosion and Fire Hazard Batteries produce flammable hydrogen gas when charging Do not smoke near a battery and never expose the battery to fire or sources of high he...

Page 271: ...precautions and the Battery Precautions on page 5 52 WARNING The following safety messages address a potential Fire and Explosion Hazard The battery produces hydrogen gas The gas will ignite if spark...

Page 272: ...engine of the working machine and increase the engine speed to full speed 4 Turn the Starter Switch of the failed machine to the START position to start the engine If the engine does not start wait a...

Page 273: ...tracks Remove and clean any oil and chemical solvents immediately Do not travel over road surfaces covered in oil Fig 5 106 Do not operate on a fire or on hot surfaces such as steel plates left in th...

Page 274: ...hly with water after use on the following materials Material crushed and yielding oil such as soy beans corns and rapeseed Ammonium sulfate potassium chloride or concentrated super phosphate These are...

Page 275: ...more than two links Fig 5 117 Broken Steel Cords More than half of the steel cord layer is broken on one side Fig 5 118 Fallen Core Metal Core metal of the rubber track has fallen out of more than on...

Page 276: ...it Installation of Rubber Tracks A grease gun and steel pipe are required for the following procedure 1 Set the outriggers and raise the tracks approximately 50 mm from the ground See OUTRIGGER SETTI...

Page 277: ...der of the rubber track 4 Standard tension of the rubber track is 5 to 10 mm clearance between the wheel tread of the centre of the track roller and the shoulder of the rubber track Fig 5 129 5 If the...

Page 278: ...page 4 48 In case the tension is strong to reduce tension 1 With two mounting bolts 2 removed remove the inspection cover 1 Fig 5 132 2 Loosen grease valve 3 slowly to let the grease come out Fig 5 13...

Page 279: ...or beyond the replacement standard The benchmark for replacing wire ropes is common to all wire ropes for winching telescoping the boom and slinging Wire rope fatigues with normal use Change wire rope...

Page 280: ...direction and number of twists Fig 5 137 2 Move the winch lever to LOWER push forward to lower the hook block until just before it makes contact with the ground Lower the hook block by either moving t...

Page 281: ...wire rope from winch drum 8 When you have removed the wire rope remove the end of the wire rope that was attached to the winch drum 8 using the following procedure Have a piece of round bar 6 with a...

Page 282: ...through the winch drum with the rope loose b The rope wedge 9 should be in position a Pass the wire rope around the rope wedge and pull the rope in the direction indicated by the arrow Adjust the len...

Page 283: ...1 9 Secure the wedge socket 3 to the boom with the wedge socket pin 1 and tighten the wedge socket pin fixing bolt 2 10 Place the boom lift lever in the RAISE position pull it toward you or place the...

Page 284: ...rope is slackened at its midway If it is slacked down see Boom Telescope Wire Rope Adjustment on page 5 69 and make the adjustment Fig 5 152 2 With the boom positioned horizontally and all the booms r...

Page 285: ...tally retracted and positioned horizontally extend the boom which telescopes approximately 2 m Fig 5 154 2 Retract boom slowly to stowed position In this position measure the clearance a and b and mak...

Page 286: ...earance b is zero make the adjustment in accordance with Step 6 Fig 5 158 5 Adjust no 5 boom pull in wire rope 7 Fig 5 159 a Loosen the lock nut 13 then tighten the right and left side adjustment nuts...

Page 287: ...RAVELLING POSITION on page 4 24 Fig 5 162 When storing the machine for long periods follow these procedures Wash and clean each section of the machine and store inside If the machine is to be stored o...

Page 288: ...PERATURE PREPARATION To avoid difficulty when starting during low temperatures perform the following procedures Engine Oil Change the engine oil to a low viscosity type See the engine operation manual...

Page 289: ...ur sales service agency to request inspection and repair service as needed Consumables Parts for mounting searcher hook are consumables Replace them at periodic inspection or before they reach abrasio...

Page 290: ...try and region Pre Start and Post Start Inspection Items Inspection Item Reference Pre Start Before Starting Engine Check E Boom Frame and Hook See E Boom Frame and Hook on page 5 75 Check Greasing Se...

Page 291: ...ring and correct function of wire rope latch 1 Fig 5 163 Greasing Wipe off and clean old grease from contact point 3 of shackle 2 and E boom hole and contact point 4 of hook 1 and shackle 2 then apply...

Page 292: ...on and Displayed Parameter Value Displayed on Moment Limiter Displayed boom length with the boom length at minimum 2 5 m Displayed boom length with the boom length at maximum 8 6 m Displayed working r...

Page 293: ...rates properly by stopping extending retracting raising lowering and slewing the boom Contact us or our sales service agency to request inspection and repair service as needed Consumables Wire ropes i...

Page 294: ...Frame and Hook on page 5 79 Installation Check of Position Pin and Lynch Pin See Position Pin and Lynch Pin on page 5 79 Check Wire Rope See Wire Rope on page 5 79 Check Over Winding Detector See Ove...

Page 295: ...e and repair it as necessary Check hoisting wire rope for disorderly winding and repair it as necessary Post Start After Starting Engine CAUTION The checkups described in this section should be carrie...

Page 296: ...ment limiter display indicates the boom length is 4 4 m and boom angle is 29 2 degrees then measure the boom angle and working radius If the measured value s differ from the moment limiter display val...

Page 297: ...lly immediately after attaching a new rope Repeat raising and lowering the hook several times until the new rope conforms Do not kink the rope when winding up Always unwind by the rope by pulling it o...

Page 298: ...align hole of wedge socket pin 25 and hole of wedge socket 26 then secure with spring washer 27 and bolt 28 Fig 5 173 7 Place the boom lift lever in the RAISE position pull it toward you or place the...

Page 299: ...ne Units See Grease Machine Units on page 5 83 Maintenance Every 50 Hours Grease Machine Units CAUTION Grease type varies with greasing points Failure to grease properly may cause the machine to short...

Page 300: ...readed part of oil inspection plug with sealer tape and securely tighten it Plug removal Allen key 8mm 1 Place the machine on a level surface 2 See OUTRIGGER SETTING on page 4 38 to rotate the rotary...

Page 301: ...ch slowly to a point where the oil inspection plug G and drain plug P come in sight Fig 5 179 1 Stop the winch at a point where the oil inspection plug can be seen through the post side inspection hol...

Page 302: ...the oil inspection plug and secure it upon completion of oil replenishment NOTICE Perform a proper break in with no object hoisted for 5 minutes after oil replacement Wipe off the oil completely if s...

Page 303: ...oil level Fill hydraulic oil to specified level See Check Add Hydraulic Oil on page 5 23 Hydraulic oil tank strainer and element clogged Clean and replace filter See Replace Hydraulic Oil Return Filte...

Page 304: ...wer low or power gradually drops Air cleaner element clogged Replace air cleaner See Replace Air Cleaner Element on page 5 44 Radiator fins clogged Clean Insufficient compression Check and replace Eng...

Page 305: ...motor not rotating when Starter Switch is turned to START Defective wiring Check and repair Insufficient battery charge Charge the battery Starter motor pinion moves in and out repeatedly struggling I...

Page 306: ...or damaged Where the transmitter is deformed or damaged repair or replace it Each operation lever of the transmitter is in its NEUTRAL position In the event of operation lever or control button failur...

Page 307: ...Inspect repair replace The cabtyre cable rises in temperature Considerable voltage drop Ensure that the power supply voltage of power supply equipment is at the specified value Replace the cabtyre cab...

Page 308: ...Crawler Crane M A E D A 5 92 1 2019 MC285C 3 Problem Major Cause s Actions The trouble light red of the inverter unit comes on Failure in the inverter unit Inspect repair replace Trips Battery deteri...

Page 309: ...be used EO03H Retract SOL Short circuit The remote control system cannot be used EO04L Extend SOL Disconnected The remote control system cannot be used EO04H Extend SOL Short circuit The remote contr...

Page 310: ...4L Pressure sensor 2 Lo ES04H Pressure sensor 2 Hi EO18H Working Status Lamp Green Overload EO19H Working Status Lamp Yellow Overload EO20L Working Status Lamp Red Disconnected EO20H1 Working Status L...

Page 311: ...Fig 5 184 NOTICE You do not need to stow the boom here Only the boom slewing position is being aligned 3 Once the alignment marks are aligned press the check mark to calibrate the position Fig 5 185...

Page 312: ...Section 5 TROUBLESHOOTING Mini Crawler Crane M A E D A 5 96 1 2019 MC285C 3 This Page Intentionally Left Blank...

Page 313: ...C285C 3 OPERATION MANUAL Document No 102ME OM1901 00 First edition Jan 12 2019 Maeda Seisakusho Co Ltd 1095 Onbegawa Shinonoi Nagano Nagano 388 8522 Japan No part of this manual can be reproduced in a...

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