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Service Manual 

Mini-Crawler Crane 

104ME-SM1910-00 

The parts numbers and lists written in this service manual are the 

references for the services such as disassembling and assembling. 

Be sure to ALWAYS refer to the latest parts catalog (the latest 

information) before ordering any part, since the parts and the model 

numbers are subject to change during the endless improvements and 

changes of our Machine.

 

Summary of Contents for MC405C-3

Page 1: ...e manual are the references for the services such as disassembling and assembling Be sure to ALWAYS refer to the latest parts catalog the latest information before ordering any part since the parts an...

Page 2: ......

Page 3: ...inder FR out front right side out 2 20 2 Outrigger control valve OR select valve OR Slide cylinder FR in front right side in 2 21 3 Outrigger control valve OR select valve OR Slide cylinder FL out fro...

Page 4: ...UATE COOLANT 2 60 6 6 3 ENGINE COOLANT SPECIFICATIONS 2 60 6 7 LUBRICATING OIL 2 61 6 7 1 LUBRICATING SYSTEM 2 61 6 7 2 USE OF ADEQUATE LUBRICANT 2 61 6 7 3 ENGINE OIL SPECIFICATIONS 2 62 6 8 PERIODIC...

Page 5: ...4 TROUBLE SHOOTING 2 104 14 TRAVELING SPEED SELECT VALVE 2 106 14 1 EXTERIOR VIEW AND SPECIFICATIONS 2 106 14 2 INSPECTION AND ADJUSTMENT 2 107 14 3 TROUBLE SHOOTING 2 107 15 ROTARY JOINT 2 108 15 1...

Page 6: ...22 5 DOUBLE CHECK VALVE FOR OUTRIGGER CYLINDER 2 162 23 ASSEMBLY AND DISASSEMBLY OF BOOM 2 164 24 ELECTRIC CIRCUIT DIAGRAM 2 171 25 ELECTRICAL WIRING SYSTEM DIAGRAM 2 173 26 ELECTRIC SYSTEM 2 176 26...

Page 7: ...E LIMITATION CONTROL 3 47 16 CALIBRATION PROCEDURE 3 48 16 1 LIST OF ITEMS 3 48 16 2 PROCEDURE 3 49 16 2 1 CALIBRATION WORK FLOW 3 49 16 2 2 CALL OUT OF CALIBRATION MODE 3 49 16 2 3 CALIBRATION OF BOO...

Page 8: ...23 2 3 CONNECTOR PIN ASSIGNMENT 4 24 2 4 VALVE NEUTRAL SETTING PROCEDURE 4 26 2 5 MONITOR DISPLAY MESSAGE 4 28 2 5 1 NORMAL OPERATION MESSAGE 4 28 2 6 FUSE IN THE RECEIVER 4 29 3 VOICE MESSAGES 4 31...

Page 9: ...RAWING OF OUTRIGGER WIDTH 1 3 3 PRINCIPLE SPECIFICATION LIST 1 4 4 WORKING RADIUS AND LIFTING HEIGHT 1 7 5 WORKING RADIUS AND LIFTING HEIGHT PICK CARRY 1 8 6 TOTAL RATED LOAD CHART 1 9 7 CRANE STANDAR...

Page 10: ...1 2 1 SPECIFICATION DIMENSIONAL DRAWING...

Page 11: ...1 3 2 DIMENSIONAL DRAWING OF OUTRIGGER WIDTH...

Page 12: ...od Extension ground Direct push type hydraulic cylinder With a hydraulic automatic locking device Overall width of extended outriggers Front 5118mm Right left 5786mm Rear 5520mm Travelling system Meth...

Page 13: ...hod Direct push type hydraulic double acting cylinder 2 pieces With a hydraulic automatic locking device Derrick angle time 0 to 80 deg 24 4 sec 3 28 deg sec Slewing system Method Slew bearing hydraul...

Page 14: ...inute consecutive no operation automatic power off in 30 minutes Safety device Over winding detector automatic stop device three winding stop alarm automatic stop device angle indicator hydraulic safe...

Page 15: ...1 7 4 WORKING RADIUS AND LIFTING HEIGHT...

Page 16: ...1 8 5 WORKING RADIUS AND LIFTING HEIGHT PICK CARRY...

Page 17: ...king radius m Total rated load kg Working radius m Total rated load kg Working radius m Total rated load kg 2 70 3830 3 50 3030 4 00 2230 5 00 1130 3 50 3030 4 00 2580 4 50 1830 5 50 980 4 00 2580 5 0...

Page 18: ...m Total rated load kg Working radius m Total rated load kg Working radius m Total rated load kg 2 70 1930 3 50 1930 4 00 1930 5 00 1130 3 50 1930 4 00 1930 4 50 1830 5 50 980 4 00 1930 5 00 1880 5 00...

Page 19: ...king radius m Total rated load kg Working radius m Total rated load kg Working radius m Total rated load kg 2 70 970 3 50 970 4 00 970 5 00 970 3 50 970 4 00 970 4 50 970 5 50 970 4 00 970 5 00 970 5...

Page 20: ...ATURE 30 to 50 C Accelerator full Operating pressure MPa at travel valve Operating time sec Engine Operating time sec Electric motor Boom derricking 0 to 80 Raising 11 5 to 14 0 18 3 28 3 Lowering 20...

Page 21: ...1 13 8 POWER TRAIN DRAWING 21 5MPa 220kgf cm2...

Page 22: ...1 14 This Page Intentionally Left Blank...

Page 23: ...8 11 OUTRIGGER CONTROL VALVE 2 96 12 OUTRIGGER SELECT VALVE 2 100 13 CRANE CIRCUIT CONFLUENCE VALVE 2 102 14 TRAVELING SPEED SELECT VALVE 2 106 15 ROTARY JOINT 2 108 16 HOOK BLOCK 2 110 17 BOOM 2 114...

Page 24: ...2 2 This Page Intentionally Left Blank...

Page 25: ...2 3 1 HYDRAULIC CIRCUIT DIAGRAM 21 5MPa 220kgf cm2 21 5MPa 220kgf cm2...

Page 26: ...2 4 This Page IntentionallyLeftBlank...

Page 27: ...2 5 1 1 HYDRAULIC UNITS LAYOUT DIAGRAM...

Page 28: ...2 6...

Page 29: ...2 7 This Page Intentionally Left Blank...

Page 30: ...2 8 2 HYDRAULIC PIPING DIAGRAM 2 1 CRANE ROTATING PARTS rotary joint winch derricking telescopic cylinder...

Page 31: ...Port Connection destination Action No Name No Label Name No Name Part No Part No Part No TA 3 TA TA hydraulic hose 2 Male 90 elbow with plate 22757V65172 N3000 06 1720L SC PF O ring SF PF 22611 11150...

Page 32: ...2 10 2 2 CRANE FIXED PARTS crane control valve rotary joint slewing motor...

Page 33: ...12 WB hydraulic hose up 1 KG06 C C 690L Part No 22782H85069 13 TA hydraulic hose up 1 KG06 C C 750L Part No 22782H85075 14 TB hydraulic hose up 1 KG06 C C 690L Part No 22782H85069 15 SA hydraulic hose...

Page 34: ...KG06 C C 690L A2 35 Male 45 elbow with plate 11 WA hydraulic hose up up Up 22611 11250 1072 06 HYDEX 22782H85075 KG06 C C 750L B2 12 WB hydraulic hose up down Down 22782H85069 KG06 C C 690L A3 35 Male...

Page 35: ...22782 85305 KG06 C C 3050L 22611 11050 1067 06 HYDEX Contract 4 TA TA hydraulic hose down contract 22 Male connector WB Contract 22782 85305 KG06 C C 3050L 22611 11050 1067 06 HYDEX Extend 5 TB TB hyd...

Page 36: ...2 14 2 3 TRAVEL LINE travel control valve terminal assembly travel motor...

Page 37: ...0001 A2 12 Flareless type joint 8 R pipe RA Right travelling forward Upper side of terminal assembly S104J3115 000 22511 07550 LLM UR 12 3 8 S104R4105000 B2 12 Flareless type joint 9 R pipe RB Right t...

Page 38: ...2 16 2 4 OUTRIGGER LINES...

Page 39: ...2 17...

Page 40: ...C C 700L with film Part No 22781HF3070 30 OR Extension FRB 1 KF04 C C 700L with film Part No 22781HF3070 31 OR Slide FRA 1 KF04 C C 1000L with film Part No 22781H83100 32 OR Slide FRB 1 KF04 C C 1000...

Page 41: ...t with washer 4 M6 1 0 25L Part No 21A12M06025 63 Hexagon head bolt with washer 5 M6 1 0 55L Part No 21A12M06055 64 Hexagon head bolt 2 M10 1 5 80L plated Part No 21012M10080 66 Spring washer 2 M10 Ty...

Page 42: ...78000 22511 07430 LLM UR 10 1 4 OR select valve FR 103S92100000 front right C3 51 Flareless type joint 4 OR pipe Extension FRB 22511 07430 LLM UR 10 1 4 S104R4047000 53 Flareless type joint 22511 5543...

Page 43: ...79000 22511 07430 LLM UR 10 1 4 OR select valve FR 103S92100000 front right C2 51 Flareless type joint 3 OR pipe Extension FRA 22511 07430 LLM UR 10 1 4 S104R4046000 53 Flareless type joint 22511 5543...

Page 44: ...80000 22511 07430 LLM UR 10 1 4 OR select valve FL 103S92100000 front left C3 51 Flareless type joint 8 OR pipe Extension FLB 22511 07430 LLM UR 10 1 4 S104R4051000 53 Flareless type joint 22511 55430...

Page 45: ...1000 22511 07430 LLM UR 10 1 4 OR select valve FL 103S9210000 0 front left C2 51 Flareless type joint 7 OR pipe Extension FLA 22511 07430 LLM UR 10 1 4 S104R4050000 53 Flareless type joint 22511 55430...

Page 46: ...select valve RR 103S92100000 rear right C3 51 Flareless type joint 11 OR pipe Extension RRA 22511 07430 LLM UR 10 1 4 S104R4054000 53 Flareless type joint 22511 55430 LLM UGS 10 1 4 37 OR Extension RR...

Page 47: ...OR select valve RR 103S9210000 0 front right C2 51 Flareless type joint 12 OR pipe Extension RRB 22511 07430 LLM UR 10 1 4 S104R4055000 53 Flareless type joint 22511 55430 LLM UGS 10 1 4 38 OR Extensi...

Page 48: ...elect valve RL 103S9210000 0 rear left C3 51 Flareless type joint 15 OR pipe Extension RLA 22511 07430 LLM UR 10 1 4 S104R4058000 53 Flareless type joint 22511 55430 LLM UGS 10 1 4 41 OR Extension RLA...

Page 49: ...OR select valve RL 103S92100 000 rear left C2 51 Flareless type joint 16 OR pipe Extension RLB 22511 07430 LLM UR 10 1 4 S104R4059000 53 Flareless type joint 22511 55430 LLM UGS 10 1 4 42 OR Extensio...

Page 50: ...2 28 2 5 PUMP LINE P line...

Page 51: ...Part No 22718 86161 18 Hydraulic hose P2 1 PA2108 C C 1260L Part No 22718 86126 19 Male connector 1 1067 08 06 Part No 22611 11056 21 Male connector 1 1067 08 Part No 22611 11060 22 Hose adapter 3 7 8...

Page 52: ...k valve 9 Male 90 elbow To electric line 15 blanking plug 22031 07600 22031M39660 G1 2 Rc1 2 plated S576 G116200 Nishina Drawing No 01113 00000 22611 10460 1034 08 10 Male female connector IN 11 Femal...

Page 53: ...alve S104G3658000 22611 11060 1067 08 18 Terminal assembly S104J3115000 C01 27 Hydraulic hose CO1 22 Hose adapter B Merge valve 349S51400001 22782HF503538 KG06 C CE9 380L with film 22642 20165 7 8 14...

Page 54: ...2 32 2 6 TANK DRAIN LINE T Dr line...

Page 55: ...e 90 elbow 1 1034 16 Part No 22611 10480 22 Male 90 elbow with plate 5 1071 16 Part No 22611 11180 24 One side male tee 1 9051 08 Part No 22611 11360 25 Male connector 1 1009 12 08 Part No 22611 10167...

Page 56: ...103S95300001 B1 20 Male 90 elbow with plate 3 Return hose OC IN 21 Male 90 elbow with plate IN 4 4 Return filter 4380 13002 0 22611 11180 1071 16 22713S88055 PA0316 C C 550L wind full length spiral 22...

Page 57: ...S103J3114000 Travel upper side 11 Drain hose UR Hydraulic oil tank 104 2157300 22813 09065 OK excel 100 9 7 15 9 650L 4 Slewing motor rotary joint terminal B hydraulic oil tank Equipment name Port Jo...

Page 58: ...39 Barb fitting 14 Drain hose V 39 Barb fitting 33 Tee 22011 03300 22951 03105 10 5 PT1 4 22813 09030 OK excel 100 9 7 15 9 300L 22951 03105 10 5 PT1 4 33 Tee 22011 03300 41 Nipple 42 O ring boss fem...

Page 59: ...2 37 This Page Intentionally Left Blank...

Page 60: ...2 38 2 7 PILOT LINE...

Page 61: ...Rc1 4 Part No 22051 08303 10 Male 90 elbow with plate 1 1071 04 Part No 22611 11130 11 Male connector 3 1009 04 Part No 22611 10130 12 Male connector 2 1067 04 Part No 22611 11030 13 Nipple 1 2083 04...

Page 62: ...No Name No Name Part No Part No Part No Travel control valve 349s51300000 PP1 13 Nipple 22031 06300 66932 14 Female threaded tee 15 Sunk head plug 22031 34300 69854 22031 90031 2070 04 hexagon socket...

Page 63: ...2 41 This Page Intentionally Left Blank...

Page 64: ...2 42 2 8 ELECTRIC POWERED LINE...

Page 65: ...mp for electric operations 306S32500001 P1 7 Male connector 8 Male swivel 90 elbow IN 10 Check valve S576 G116200 Nishina Drawing No 01113 00000 22611 11060 1067 08 22611 13560 1060 08 10 Check valve...

Page 66: ...2 44 3 TANK 3 1 HYDRAULIC TANK...

Page 67: ...rt No 01024 80820 6 Band assembly 1 Part No 104 3340400 7 Heat insulator left 1 Part No 104 3267100 8 Trim seal 1 4100 B 3 16C 250L Part No 27822 01025 9 Packing 1 Part No 233 23171 0 10 Strainer 1 Pa...

Page 68: ...2 46 3 2 FUEL TANK...

Page 69: ...5 Cap assembly 1 Part No 4700 70000 6 Packing 1 Part No 353 4438700 7 Fuel sender assembly 1 Part No 103S93100000 8 Cross recessed head screw with captive washer 5 M5 0 8 10L with PW SW plated Part N...

Page 70: ...2 Die cast body 1 9 Spring washer 1 16 Spring washer 2 3 Skipped No 10 Contact bolt 1 17 Rvc wire 1 4 Tank wire 1 11 Plane washer 1 18 Rivet 1 5 Float 1 12 Washer 2 19 Insualted washer 2 6 Terminal 2...

Page 71: ...4 B1 Hydraulic tank outlet PF1 B2 Oil cooler outlet PF1 No Description Q ty Notice 1 System block 1 F 2460B 2 Check valve 1 DE CVA 00 0070 Specifications Max oil pressure 25 MPa 250 bar Max flow capa...

Page 72: ...Plunger 1 Maker Parts No 01113 10200 3 Compression spring 1 Maker Parts No 01113 10300 5 Plane washer 1 Maker Parts No 083007 02100 6 Snap ring 1 Maker Parts No 084300 01018 Specifications Rated flow...

Page 73: ...2 51 This Page Intentionally Left Blank...

Page 74: ...2 52 6 ENGINE ASSEMBLY 6 1 ENGINE ASSEMBLY 3TNV88F EPMB Yanmar...

Page 75: ...time 6 s Rotational fluctuation 22 min 1 Allowable inclination angle Continuous 30 degrees all sides momentary 35 degrees all sides Engine rotation direction Left rotation viewed from the flywheel si...

Page 76: ...2 54 6 3 NAME OF EACH SECTION...

Page 77: ...1 EMISSION CONTROL CERTIFICATION NAME PLATE Emission control is applied all over the world For this reason it is necessary to clarify which regulations each engine complies with The drawing on the rig...

Page 78: ...esidue of fuel into exhaust gas and corrosion of exhaust valve seats 2 Deposit to Piston Ring Grooves Deposit to piston ring grooves may cause blow back of combustion gas poor lubrication incomplete c...

Page 79: ...olume Less than 0 1 is preferred Total aromatics content should not exceed 35 by volume Less than 30 is preferred PAH polycyclic aromatic hydrocarbons content should be below 10 by volume Metal conten...

Page 80: ...uel system and or fuel storage containers may be necessary 6 The use of bio diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injec...

Page 81: ...2 59 This Page Intentionally Left Blank...

Page 82: ...nt LLC or an Extended Life Coolant ELC that meets or exceeds the following guideline and specifications Additional Technical Coolant Specifications JIS K2234 Japan ASTM D6210 D4985 US SAE J814C J1941...

Page 83: ...Protection of Engine components from deposit of sludges Grade of Lubricating Oil should be API Service Category CD or better Regarding Lubricating Oil change instruct users to follow the frequency as...

Page 84: ...hen the Total Base Number TBN has been reduced to 1 0 mgKOH g test method JIS K 201 5 2 2 HCI ASTM D4739 HCI Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient tempe...

Page 85: ...Valve Clearance Lap Intake Exhaust Valve Seats Electrical Equipment Check Engine Oil Level Check Battery Engine Oil Check Engine Oil Level Drain and Fill Engine Oil 1st time 2nd and after Replace Eng...

Page 86: ...ts Blow Seizure or breakage of Piston Rings Wearing of Piston Rings Pistons and Cylinders Seizure of Crank pin metals and Bearings Piston Ring Joint Clearance Error Reverse assembled Piston Ring Weari...

Page 87: ...lace gasket Replace Piston Ring Honing or replace to over sized components Repair or replace Re adjust Joint position Re assemble Measure and replace Tighten to designated torque Disassembly and repai...

Page 88: ...Injection Pump Timing too late Improper fuel Leakage of Water into Fuel System Fuel Filter Clogging Air Mixture in Fuel System Fuel Pipes Clogging or Crack In sufficient Fuel Flow to Injection Pump Fu...

Page 89: ...e too low Lower Pressure Higher Pressure Check and adjust Check and adjust Replace to adequate fuel Drain fuel filter Clean or replace Air bleed Clean or replace Check fuel filter and feed pump Check...

Page 90: ...2 68 6 10 FUEL PIPING...

Page 91: ...p 8 RS8006 Part No 22973 00600 5 Fuel hose 4 1 Yokohama fuel hose Nominal size 8 15 1300L Part No 22823 31300 6 Water separator 1 Part No 129242 55710 7 Solenoid feed pump 1 Part No 119225 52102 8 Bas...

Page 92: ...0 C Hydraulic fluid pollution level Within NAS level 11 Rotation Rated 2400 min 1 Suction strainer 150 mesh Maximum 2500 min 1 Line filter 10 m Variable control mechanism Fixed horsepower control P1 P...

Page 93: ...100 C Hydraulic fluid pollution level Within NAS level 11 Rotation Rated 2600 min 1 Suction strainer 150 mesh Maximum 2700 min 1 Line filter 10 m Variable control mechanism Fixed horsepower control Vi...

Page 94: ...tion rate Repair or replace cup ring Repair or replace pump Abnormal noise or vibration Cavitation Air or water mixture to hydraulic oil Clogged or choked suction pipe Damage to staking fit of piston...

Page 95: ...2 73 This Page Intentionally Left Blank...

Page 96: ...t PF3 8 B2 Right Travel Motor A Port Reverse PF3 8 CO2 Confluence Select Valve P Port PF3 8 Pressure Pick up Port Travel Speed Select Valve P Port PT1 4 Specifications Max Flow Capacity P1 P2 30 L min...

Page 97: ...ng holder 4 19 Plug 2 33 O ring 1B P8 1 6 Compression spring 2 20 Plunger housing 2 34 O ring 1B P9 2 7 Seal holder 4 21 Openspool 2 35 O ring 1B P10 2 8 Back up ring 4 22 Body 1 36 O ring 1B P12 2 9...

Page 98: ...mage such as rust corrosion deform and or breakage Replace Spool area Oil leakage to exterior Seal and Holder rust corrosion and or deform Repair or replace Repair or replace Main relief valve Port re...

Page 99: ...operation Overhaul of total circuit may be required as well as exchanging hydraulic oil Measure spool diameter and verify for replacing Measure roundness of spool and repair or replace as required Lo...

Page 100: ...x Output Torque 4766 N m 486 kgf m Max Output Revolution 35 0 57 8 min 1 Reduction Ratio 1 47 53 Specifications Of Hydraulic Motor Capacity 35 3 21 2 cm3 rev Max Common Use Pressure 21 0 MPa 214 kgf c...

Page 101: ...lve 6 Ball 15 Shaft 24 Counter balance valve 7 Housing 16 Swash plate 25 Check valve 8 Piston 17 Control piston 26 Autmatic speed changing valve 9 Cylinder 18 No 1 planetary gear 9 2 1 OUTLINE Swash p...

Page 102: ...1 is demagnetized Pressurized oil shall not flow from travel control valve to PP port since automatic control valve 2 is pressed downward by Spring 3 Swash plate 6 will be pressed rightward by tensio...

Page 103: ...uit to control chamber a Main pressurized oil which is regulated by travel lever enters into control chamber a from automatic control valve 2 through check valve 4 and actuates piston 5 to leftward Th...

Page 104: ...s generated by difference of size of pressurized areas of chamber a and chamber b a b The force together with tension ofspring 2 exceeds force F3 which is generated by pilot pressure PP F3 F1 F2 Then...

Page 105: ...Pc is reduced a force generated by pressure to actuate motor Pc together with tension of Spring 2 becomes smaller than force F3 which is generated by pilot pressure PP F3 F1 F2 Then automatic control...

Page 106: ...ch opens exit side of motor and makes it rotate 2 Function of Interrupt Mode When the travel lever is returned to neutral position pressurized oil from controlvalve is interrupted At the result spool...

Page 107: ...d Consequently pressure from spring 4 to plate 2 and disk 3 is reduced and allows plate 2 to release disk 3 2 Traveling in Neutral Mode When travel lever is returned to neutral position pressurized oi...

Page 108: ...ent is delivered to customers Please be careful for scales after welding or dusts and do not let them remain inside 3 Drain pipe G 14 is furnished with a plug to only one side of two bents When fittin...

Page 109: ...led when our crane is delivered ed to the customer When it is required refill as follows 1 Remove plug of refueling vent 2 Remove plug of check gauge vent 3 Fill lubricating oil to LEVEL 4 Restore plu...

Page 110: ...A Right PF3 8 B2 Winch Motor Port B Lower PF3 8 B4 Slewing Motor Port B Left PF3 8 Specifications Max Flow Capacity 70 L min Back Pressure Valve Setting Pressure 1 77 MPa 18 kgf cm2 Rated Flow Capaci...

Page 111: ...2 89 10 2 HYDRAULIC CIRCUIT DIAGRAM 21 5 MPa 220 kgf cm2...

Page 112: ...2 90 10 3 RGB BLOCK...

Page 113: ...unction switches of remote control transmitter is actuated in remote control mode 2 When operation lever of crane body is shifted from neutral position in Manual operation mode 6 Low Pressure Relief S...

Page 114: ...2 92 10 4 ACCELERATOR BLOCK 10 5 FUNCTION BLOCK DERRICK WINCH TELESCOPIC SLEWING...

Page 115: ...and SB for control valve are the same in their basics of functionality 1 Unmagnetized conditions 2 Magnetized conditions Circuit to control cylinder is interrupted Circuit to control cylinder is opene...

Page 116: ...agnetized and attached to tank Another solenoid is still magnetized and attached to pump In this condition oil flows from pump to control cylinder which actuates control cylinder Time of non conductin...

Page 117: ...2 95 This Page Intentionally Left Blank...

Page 118: ...2 A3 OR Selector valve 1 Port P1 Out PF3 8 T Return PF1 2 B3 OR Selector valve 1 Port P2 In PF3 8 A1 OR Selector valve 3 Port P1 Out PF3 8 A4 OR Selector valve 2 Port P1 Out PF3 8 B1 OR Selector valve...

Page 119: ...Capacity 50 L min Relief Setting Pressure 2 94 24 5 MPa 30 250 kgf cm2 Back Pressure Valve Setting Pressure 1 27 1 67 MPa 13 17 kgf cm2 Reducing Pressure Valve Setting Pressure 1 18 1 57 MPa 12 16 kgf...

Page 120: ...24 5 29 4 N m PF3 8 39 2 49 0 N m M18 39 2 49 0 N m M24 58 8 68 6 N m Hex Socket Head Plug GPM1 32 1 47 1 96 N m Coat Lock tight 242 NPT1 16 9 81 11 8 N m No DESCRIPTION Q TY 1 InletSection 1 2 Block...

Page 121: ...2 99 This Page Intentionally Left Blank...

Page 122: ...F1 4 C3 Outrigger Cylinder Head Grounding In PF1 4 C4 Outrigger Slide Cylinder Head Extension In PF1 4 Specifications COIL Specifications Max Common Use Pressure 25 MPa 250 kgf cm2 Voltage DC 12 V Max...

Page 123: ...2 101 12 2 INNER PARTS No Description Q ty 1 Solenoid block 1 2 Repair kit 1 3 Cap 1 4 O ring 14 00 1 5 O ring 29 87 1 6 Cap set 1 7 Main block 1...

Page 124: ...ve Port P1 Travel Control Valve CO1 7 8 14 UNF Pi Outrigger Control Valve Port GP Crane Control Valve Port PP1 9 16 18 UNF Dr Drain 9 16 18 UNF X No Connecting 9 16 18 UNF Specifications Max Common Us...

Page 125: ...spring 1 15 Rivet 2 2 Compression spring 1 9 Body 1 16 Steel ball 4 3 Sleeve 1 10 Spool 1 17 O ring 1A P16 1 4 Spool 1 11 Skipped No 18 O ring 1B P14 2 5 Solenoid 1 12 Flangeplug PF3 8 2 19 O ring AS5...

Page 126: ...SHOOTING Each Item shown in the table below indicates only individual problem however troubles may be caused by multiple problems in many cases It is advisable to check one by one for efficient troubl...

Page 127: ...2 105 This Page Intentionally Left Blank...

Page 128: ...cription Q ty No Description Q ty 1 Plug 1 5 Solenoid 1 9 Rivet 2 2 Body 1 6 Nameplate 1 10 O ring 1A P10 1 3 Compression spring 1 7 Skipped No 11 O ring 1B P16 1 4 Spool 1 8 Hex socket headbolt M5 10...

Page 129: ...SHOOTING Each Item shown in the table below indicates only individual problem however troubles may be caused by multiple problems in many cases It is advisable to check one by one for efficient troubl...

Page 130: ...2 108 15 ROTARY JOINT 15 1 EXTERIOR VIEW AND SPECIFICATIONS...

Page 131: ...ed Flow Capacity 50 L min Max Common Use Pressure TA TB WA WB DA DB 20 6 MPa 210 kgf cm2 WDR 2 9 MPa 30 kgf cm2 Withstand Pressure TA TB WA WB DA DB 30 9 MPa 315 kgf cm2 WDR 3 5 MPa 36 kgf cm2 Operati...

Page 132: ...2 110 16 HOOK BLOCK...

Page 133: ...51206 12 Spring pin 1 5 45 L 13 Hex socket headbutton bolt 6 M10 22L Plating 8 8T 14 Spring washer 6 M10 Plating 15 Hex socket headbolt 4 M10 20L Plating 8 8T 16 Plane washer 4 M10 Plating 17 Wire ro...

Page 134: ...hook nut and make sure that the mounting is secure and that no damage exists Retighten if loose Replace if the hook nut is worn or damaged 5 Check that the wire rope latch works properly If the work i...

Page 135: ...2 113 This Page Intentionally Left Blank...

Page 136: ...2 114 17 BOOM...

Page 137: ...n pin 4 27 Sheave pin forboom extend 1 28 Pointpin 1 29 Wire pin forboom extend 2 30 Snap sheave pin 1 31 Telescopic guide rollerpin 1 32 Wedge socketpin 1 33 Sheave assembly 2 34 Sheave for boom exte...

Page 138: ...athead bolt withhex Hole 2 M12 1 75 30L 70 Button bolt withhex Hole 38 M10 1 5 15L Plating 8 8T 71 Button bolt withhex Hole 2 M10 1 5 20L Plating 8 8T 72 Nut 4 M12 1 75 Plating 73 Spring washer 60 M10...

Page 139: ...2 117 This Page Intentionally Left Blank...

Page 140: ...2 118 18 TELESCOPIC AND DERRICK CYLINDER 18 1 TELESCOPIC CYLINDER...

Page 141: ...n At 195 kgf cm2 Test Pressure When extended 28 9 MPa 295 kgf cm2 When retracted 28 9 MPa 295 kgf cm2 No 2 TELESCOPIC Cylinder Specifications Cylinder Bore x Rod O D Stroke 70 mm 50 mm 2960 mm Normal...

Page 142: ...2 120 18 2 TELESCOPIC CYLINDER HYDRAULIC CIRCUIT SYSTEM...

Page 143: ...l Stroked Check Valve Cracking Pressure 0 098 MPa 1 kgf cm2 Operating Temperature Range 10 80 C 18 3 2 TROUBLE SHOOTING Disorders Cause Counter action Telescopic derrick cylinders retract while hoisti...

Page 144: ...2 122 18 3 3 FUNCTION 1 When Neutral 2 When Extended 3 When Retracted...

Page 145: ...akage Capacity Less than 0 05 L min Apply 20 6 MPa 210 kgf cm2 From Port B Pilot Pressure 1 18 0 3 MPa 12 3 kgf cm2 At Valve Opened Check Valve Cracking Pressure 2 45 MPa 25 kgf cm2 Operating Force 0...

Page 146: ...IC CYLINDER Specifications Rated Flow Capacity 50 L min Pilot Pressure 1 18 0 3 MPa 12 3 kgf cm2 At Valve Opened Pressure Loss B to A Less than 9 8 MPa 100 kgf cm2 Check Valve Cracking Pressure 2 45 M...

Page 147: ...2 125 This Page Intentionally Left Blank...

Page 148: ...2 126 18 6 LEFT SIDE DERRICK CYLINDER...

Page 149: ...Paint Protection Specifications Cylinder Bore x Rod O D Stroke 90 mm 60 mm 1164 mm Normal Load When extended 131 0 kN At 20 6 MPa 72 8 ton At 210 kgf cm2 When retracted 72 8 kN At 20 6 MPa 7 4 ton At...

Page 150: ...2 128 18 7 RIGHT SIDE DERRICK CYLINDER...

Page 151: ...Paint Protection Specifications Cylinder Bore x Rod O D Stroke 90 mm 60 mm 1164 mm Normal Load When extended 131 0 kN At 20 6 MPa 72 8 ton At 210 kgf cm2 When retracted 72 8 kN At 20 6 MPa 7 4 ton At...

Page 152: ...2 130 19 WINCH 19 1 WINCH EXTERIOR VIEW...

Page 153: ...15L 16 Plane washer 2 M6 Plating 17 Snap pin 2 10 Plating 18 Bolt 12 M12 1 75 25L Plating 10 9TTighteningTorque 65 N m or 55 N m Coat Lock tight 262 19 Bolt 6 M12 1 75 35L Plating 10 9TTighteningTorqu...

Page 154: ...t 55 L min Drum Brake Torque 1 55 kN m At Back Pressure 0 MPa Blake Release Pressure Min 2 MPa Allowable Pressure 5 MPa Winding Rotation Direction when viewed from Motor Counterclockwise with intake t...

Page 155: ...the Unit 2 Trouble Shooting Disorder Cause and Counter action Drum does not rotate Measure pressure of Winch circuit In case that pressure is insufficient check Pump Circuit Relief Valve Control Valve...

Page 156: ...dlebearing 38 Plunger 5 Cam plate 22 Snapring 39 Spacer 6 Collar 23 Piston 40 O ring 7 Return plate 24 Teflon ring 41 Spring 8 Spring 25 Balanceplate 42 Piston 9 Piston assembly 26 O ring 43 Cap 10 Ex...

Page 157: ...rightward When pressure increases and its force exceeds tension of spring 29 of piston 33 which presses brake press force to friction board 35 is lost and mechanical brake is released Then motor start...

Page 158: ...valve 48 closes prevents motor from reverse rotation 19 3 4 TROUBLE SHOOTING Disorders Cause Counter action Abnormal Noise and or Vibration Air remains within circuit and or Motor Cavitation Condition...

Page 159: ...2 137 This Page Intentionally Left Blank...

Page 160: ...19 Thrustplate 2 Snap ring 11 Shaft 2 20 Coupling 3 End plate 12 Spring pin 21 Gear 4 4 O ring 13 O ring 22 Spring 5 Holder 1 BAS 14 Ball bearing 23 Spacer 6 Holder 2 BAS 15 Oil seal 24 Sun gear 7 Ho...

Page 161: ...e the winch slowly to a point where the oil inspection Plug G and drain Plug P come in sight 1 Stop the winch at a point where the oil inspection Plug G can be seen through the post side inspection ho...

Page 162: ...xudes from the oil inspection Plug 12 Put in the oil inspection Plug G and secure it upon completion of oil replenishment NOTES Perform a proper break in with no object hoisted for 5 minutes after oil...

Page 163: ...2 141 This Page Intentionally Left Blank...

Page 164: ...w the wire rope 5 through the weight of the over hoist 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 2 Draw the wire rope 5 through the atta...

Page 165: ...oom with the wedge socket pin 1 and tighten the wedge socket fixing bolt 2 8 Place the boom derricking lever in the Raise position pull it toward you or the boom telescoping lever in the Extend positi...

Page 166: ...2 144 20 SLEWING SYSTEM 20 1 EXTERIOR VIEW...

Page 167: ...after slewing reduction gear and hydraulic oil motorareinstalled 20 1 1 SLEWING BEARING WOBBLE LIMIT TOLERANCE In case the clearance is excessive when the bearing receives the momentum load the oscul...

Page 168: ...Oil Corporation BONNOCM320 tothe center of oil Level gauge Slewing Reduction Gear Specifications Reduction ratio 1 35 Input shaft revolution 800 min 1 Output shaft revolution 22 86 min 1 Output shaft...

Page 169: ...NF 73 22 Name plate 1 23 Rivet 2 24 Key 1 30 Brake pin 1 31 Brake housing 1 32 Spring 1 33 Plug 2 NPTF1 16 Motor RotationDirection Viewed from Power Shaft Clockwise Slewing Whenpressurizedoil is fed t...

Page 170: ...ystem Re align Shaft Drain air from circuit completely Run no load operation until bubbles in tank is completely purged Negative Pressure is generated when Motor rotates in heavy inertia condition and...

Page 171: ...2 149 This Page Intentionally Left Blank...

Page 172: ...2 150 21 OUTRIGGER 21 1 FRONT OUTRIGGER...

Page 173: ...ating 14 Skipped no 15 Bolt 5 M10 18L Plating 8 8T 16 Bolt 2 M10 25L Plating 8 8T 17 Bolt 3 M12 25L Plating 8 8T 18 Plane spring 4 M6 2L Plating 19 Spring washer 7 M10 Plating 20 Spring washer 3 M12 P...

Page 174: ...2 152 21 2 REAR OUTRIGGER...

Page 175: ...lt withhex hole 4 M6 16L Plating 14 Skipped no 15 Bolt 5 M10 18L Plating 8 8T 16 Bolt 2 M10 25L Plating 8 8T 17 Bolt 3 M12 25L Plating 8 8T 18 Plane spring 4 M6 2L Plating 19 Spring washer 7 M10 Plati...

Page 176: ...2 154 22 OUTRIGGER CYLINDER 22 1 OUTRIGGER SLIDE CYLINDER...

Page 177: ...ons Cylinder Bore x Rod O D Stroke 60 mm 35 mm 700 2 0 mm Pressure When extended 58 2 kN At 20 6MPa 5 9 ton At 210 kgf cm2 When retracted 38 4 N At 20 6MPa 3 9 ton At 210 kgf cm2 Test Pressure 30 9 MP...

Page 178: ...2 156 22 2 SINGLE CHECK VALVE FOR OUTRIGGER SLIDE CYLINDER...

Page 179: ...m 4 Piston 1 5 O ring 1 P7 6 Plug 2 7 O ring 2 P11 8 O ring 2 P8 Specifications Rated Pressure 20 6 MPa 210 kgf cm2 Resisting Pressure 30 9 MPa 315 kgf cm2 Rated Flow Capacity 10 L min Allowable Leaka...

Page 180: ...2 158 22 3 FRONT OUTRIGGER CYLINDER...

Page 181: ...2701 Cylinder Specifications Cylinder Bore x Rod O D Stroke 110 mm 70 mm 393 5 2 0 mm Pressure When extended 195 7 kN At 20 6 MPa 19 9 T At 210 kgf cm2 When retracted 116 4 kN At 20 6 MPa 11 8 T At 21...

Page 182: ...2 160 22 4 REAR OUTRIGGER CYLINDER...

Page 183: ...01 Cylinder Specifications Cylinder Bore x Rod O D Stroke 110 mm 70 mm 248 5 2 0 mm Pressure When extended 195 7 kN At 20 6 MPa 19 9 ton At 210 kgf cm2 When retracted 116 4 kN At 20 6 MPa 11 8 ton At...

Page 184: ...Resisting Pressure 41 2 MPa 420 kgf cm2 Max Flow Capacity 10 L min Allowable Leakage Level Less than 0 05 L min Apply 17 2 MPa 175 kgf cm2 From Port A2 and B2 Check Valve Cracking Pressure 0 49 MPa 5...

Page 185: ...2 163 This Page Intentionally Left Blank...

Page 186: ...2 164 23 ASSEMBLY AND DISASSEMBLY OF BOOM...

Page 187: ...t and it for support 6 Remove 2 telescopic cylinder hoses and dismantle 2 elbows 16 and 2 long connectors 17 7 Take off 2 snap rings 18 and extract telescopic cylinder head pin 19 You may hammer the p...

Page 188: ...36 16 Unscrew 8 hexagon socket head button bolts 38 M10 15L and remove 8 spring washers 39 on both left and right side then remove 4 side plate stopper plate 40 and side slide plates 41 respectively o...

Page 189: ...vely on both left and right side 22 Unscrew 2 hexagon socket head button bolts 54 M10 15L and remove 2 spring washers 55 then pull out No 3 4 and 5 booms and telescopic cylinder assembly from No 2 boo...

Page 190: ...tively on both left and right side 27 Unscrew 2 hexagon socket head button bolts 66 M10 15L and remove 2 spring washers 67 then pull out No 4 and 5 booms and telescopic cylinder assembly from No 3 boo...

Page 191: ...8 spring washers 75 on both left and right side then remove 4 side plate stopper plate 76 and side plates 77 respectively on both left and right side 32 Unscrew 2 hexagon socket head button bolts 78...

Page 192: ...y be used Screw the bolt to M6 tapped hole of trunnion pin 83 and pinch the bolt by a plier to pull out 36 Pull out the telescopic cylinder boom retraction wire 80 and boom extension wire 85 assembled...

Page 193: ...2 171 24 ELECTRIC CIRCUIT DIAGRAM 1 2...

Page 194: ...2 172 ELECTRIC CIRCUIT DIAGRAM ENGINE 2 2...

Page 195: ...2 173 25 ELECTRICAL WIRING SYSTEM DIAGRAM...

Page 196: ...2 174 This Page IntentionallyLeftBlank...

Page 197: ...2 175 This Page Intentionally Left Blank...

Page 198: ...2 176 26 ELECTRIC SYSTEM 26 1 ENGINE HARNESS 104 1212200...

Page 199: ...istor assembly 1 2 4 CN5 3A 1 1 2 5 CN5 3B 1 1 2 6 CN5 4 1 1 2 7 Slow blow fuse 1 2 8 Slow blow fuse 1 2 9 Slow blow fuse 1 2 10 Charge relay 1 2 11 Glow lamp relay 1 2 12 Main relay 1 2 13 Actuator r...

Page 200: ...r bracket S1 1 Part No 103 4544400 16 Washer assembling bolt 2 17 Battery relay cover 1 Part No 103 4547300 18 Hexagon head bolt 2 M8 1 25 30L plated 19 Plain washer 2 M8 1 25 30L plated 20 Spring was...

Page 201: ...2 179 This Page Intentionally Left Blank...

Page 202: ...2 180 26 2 REMOTE CONTROLLER VALVE ELECTRIC HARNESS 104 1212300...

Page 203: ...sor Moment limiter vehiclebody MC05 6 P yellow Slew andstowsensor Moment limiter vehiclebody CN7 1 4 P grey Moment limiter powersupply Vehiclebody Momentlimiter CM13 2 4 P blue OR 2 3 Outriggerselect...

Page 204: ...2 182 26 3 MOMENT LIMITER HARNESS 104 1212500...

Page 205: ...N13 1 4 Pyellow OR 1 4 Outriggerselect Operatingbox vehiclebody RC05 4 Pyellow Outrigger selectoperationoutput remote control Remotecontroller Operatingbox No Name Qty Note 1 Metal connectorharness as...

Page 206: ...2 184 26 4 ELECTRIC HARNESS 104 2213400...

Page 207: ...electrically powered Starting engineNOT available lever operation Electric Operatingbox Inverterpanel CN3 4 6 P grey When electrically powered Meter unit OFF Operatingbox Inverterpanel CN5 2 4 P blue...

Page 208: ...2 186 26 5 OVER WINDING DETECTOR 104 2111400...

Page 209: ...7 1713 000 9 Cable tie 3 SG 100 PartNo 737 1722 000 10 Guide roller 2 Part No 104 4534400 11 Guide rollerPIN 2 Part No 104 4534500 12 Snap ring 4 ForshaftC shape 10 Part No 21911 01002 13 Detectorcove...

Page 210: ...itch Thecontact of the over hoist detectorswitch opens and thesignal thereof enters the moment limiter computer andcauses the hook raising and boom extension operations to stop At thesame time the lam...

Page 211: ...2 189 This Page Intentionally Left Blank...

Page 212: ...2 190 26 6 TIP OVER WARNING DEVICE 104 3436600 Unit No 16 or after...

Page 213: ...S104M4076000 2 Cross recessedheadmachinescrew 2 M4 0 7 20LSW PW assembly plated Part No 2187AM04020 3 Buzzer 1 B221G Kernel wired Part No S803 M1803000 4 Hexagon headbolt 1 M8 1 25 25L Part No 21012M...

Page 214: ...2 192 This Page Intentionally Left Blank...

Page 215: ...SSIGNMENT 3 34 8 INPUT OUTPUT 3 36 9 DISPLAYS 3 40 10 SWITCHES 3 42 11 DISPLAY UNIT DETAIL OF EACH SEGMENT 3 44 12 START UP SEQUENCE 3 46 13 MOMENT LIMITER FUNCTIONS 3 46 14 DISPLAY OF SPECIFIC INDICA...

Page 216: ...3 2 1 MOMENT LIMITER RELATED 1 1 DISPLAY UNIT AND CONVERTER...

Page 217: ...ter Display Unit 1 2 Moment Limiter Display UnitBracket 1 3 Nut 4 M6 Plating 4 Spring Washer 4 M6 Plating 5 Bolt 2 M8X15L Plating 6 Spring Washer 2 M8 Plating 7 Moment Limiter Converter 1 8 Screw 4 M1...

Page 218: ...3 4 1 2 FRONT OUTRIGGER EXTENSION DETECTOR...

Page 219: ...rigger Mid Extension LimitSwitch 1 3 Extension LimitSwitch Cover 1 4 Tie Band Stay 4 5 Screw 4 M6X6L Plating 6 Tie Band 4 7 Hex Socket Head Bolt 4 M8X0 8X25L Plating 8 Spring Washer 4 M5 Plating 9 Pla...

Page 220: ...3 6 1 3 REAR OUTRIGGER EXTENSION DETECTOR...

Page 221: ...rigger Mid Extension LimitSwitch 1 3 Extension LimitSwitch Cover 1 4 Tie Band Stay 4 5 Screw 4 M6X6L Plating 6 Tie Band 4 7 Hex Socket Head Bolt 4 M8X0 8X25L Plating 8 Spring Washer 4 M5 Plating 9 Pla...

Page 222: ...3 8 1 4 BOOM DISPLACEMENT DETECTOR...

Page 223: ...5L Plating 3 Spring Washer 2 M6 Plating 4 Boom Angle Detection Limit Switch 2 5 Hex Socket Head Bolt 4 M8X0 8X25L Plating 6 Spring Washer 4 M5 Plating 7 Plane Washer 4 M5 Plating 8 Nut 4 M5X0 5 Platin...

Page 224: ...3 10 1 4 1 ANGLE SENSOR...

Page 225: ...ectrical Angle 340 2 3 Total Resistance 1 k ohm 20 Index Point Output to calibrate to 15 3 at the condition of above chart 0 Insulation Resistance 200 M ohm minimum DC 500 V Withstand Voltage AC500V 1...

Page 226: ...3 12 1 4 2 LENGTH SENSOR CODE REEL...

Page 227: ...tact Assembly 1 6 Potentiometer Case 1 7 Packing 1 8 O ring 1 9 Bracket 1 10 Potentiometer 1 11 NIPOSEAL Seal Connector 1 12 Gear 1 13 Fasten Terminal male 1 14 Sleeve 1 15 Fasten Terminal female 1 16...

Page 228: ...3 14 1 5 LOAD DETECTOR NO DESCRIPTION Q TY NOTICE 1 Pressure Sensor 2 2 Pressure SensorCover 1 3 Bolt With Washer 2 M8X1 25X15L Plating...

Page 229: ...emperature Coefficient origin 0 1 F S C Temperature Coefficient span 0 1 F S C Temperature Compensation Range 20 to 70 C Operation Temperature Range 20 to 70 C Stand by Temperature Range 20 to 80 C Vi...

Page 230: ...3 16 1 6 MOMENT LIMITER ACCESSORY...

Page 231: ...7 Bolt 2 M10X25L Plating 8 Spring Washer 2 M10 Plating 9 Working Status Lamp Guard 1 10 Nut 4 M6 Plating 11 Spring Washer 4 M6 Plating 12 Working Status Lamp 1 12 1 Nut 3 M5 Plating 12 2 Spring Washe...

Page 232: ...3 18 1 7 OVER UN WINDING DETECTOR...

Page 233: ...Washer 2 M8 Plating 12 Hex Socket Head Bolt 2 M6X1 0X15L 13 Plane Washer 2 M6 Plating 14 Spring Washer 2 M6 Plating 15 Snap Ring 2 ForShaft C 10 16 Over Un Winding Limit Switch 1 17 Bolt 2 M4X0 7X25L...

Page 234: ...3 20 1 8 PICK AND CARRY RELATED...

Page 235: ...triction detection limit switch bracket 1 3 Pick and Carry detectivelimit Switch 1 4 Outrigger Mid And Over Un Winding Limit Switch 3 5 Bolt 4 M8X20L Plating 6 Spring Washer 4 M8 Plating 7 Plane Washe...

Page 236: ...3 22 2 OUTRIGGER SAFETY DEVICE 2 1 ROTARY POSITION DETECTOR...

Page 237: ...ertion Limit Switch 1 1 2 Pin Insertion Limit Switch 2 1 3 Hex Socket Head Bolt 8 M8X0 8X25L Plating 4 Spring Washer 8 M5 Plating 5 Plane Washer 8 M5 Plating 6 Nut 8 M5X0 5 Plating 7 Limit switch Cove...

Page 238: ...3 24 2 2 GROUND SETTING DETECTOR...

Page 239: ...g 1 6 Nut 1 M8X1 25 Plating 7 Hex Socket Head Bolt 4 M6X1 0X15L Plating 8 Spring Washer 4 M6 Plating 9 Grease Nipple 1 C PT1 8 10 Limit Switch 1 11 Bolt 2 M4X0 7X30L Plating 12 Nut 2 M4X0 7 Plating 13...

Page 240: ...3 26 2 3 BOOM STOWING POSITION DETECTOR...

Page 241: ...te 1 2 Boom Stowing Limit SwitchBracket 1 3 Outrigger Mid And Over Un Winding Limit Switch 1 4 Bolt 2 M8X1 25X20L Plating 5 Spring Washer 2 M8 Plating 6 Plane Washer 2 M8 Plating 7 Screw With Washer 2...

Page 242: ...C 405C Type of Moment Limiter Automatic Cut Out Crane Rated Load 0 to 3 83 ton Pressure Range 0 to 225kg cm2 Power Supply DC 12V DC 10V 15V Max Power Dissipation Display Panel 0 8 A at DC 12V Converte...

Page 243: ...3 29 This Page Intentionally Left Blank...

Page 244: ...3 30 4 EXTERNAL VIEW OF MOMENT LIMITER 4 1 DISPLAY UNIT...

Page 245: ...3 31 4 2 CONVERTER...

Page 246: ...3 32 5 BLOCK DIAGRAM contact...

Page 247: ...3 33 6 CONNECTOR DIAGRAM Outrigger 1 contact input Outrigger 4 contact input Outrigger 2 contact input Outrigger 3 contact input...

Page 248: ...Switch M Angle Sensor 0V B Length Sensor input O Pressure Sensor 1 12V C Angle Sensor input P Pressure Sensor 1 0D D Pressure Sensor 1 input Q Pressure Sensor 2 12V E Pressure Sensor 2 input R Pressur...

Page 249: ...ntake M1 15 RS422RA input A extensional M1 31 Data Delete Checker PC Cancel Record intake M1 16 RS422RB input B extensional 7 2 2 DISPLAY UNIT CONNECTORS M2 Model HD34 24 31PN for Japan Germany Corres...

Page 250: ...or 1 Analog input 0 3 to 10 3V 0 to 11 7m Angle Sensor 1 Analog input 1 8 to 2 8V 0 to 80 Boom Angle Upper Limit 1 Photo Coupler input See Note 1 Boom Angle Lower Limit 1 Photo Coupler input See Note...

Page 251: ...t 1 Photo Coupler input See Note 1 Slewing Counter Clockwise Limit input 1 Photo Coupler input See Note 1 Pick and Carry Detector input 1 Photo Coupler input See Note 1 Boom Raising Lever input 1 Phot...

Page 252: ...Transistor Spec DC12V 50mA Max See Note 2 Slewing Counter Clockwise Limit output 1 Open Collector output Transistor Spec DC12V 50mA Max See Note 2 Outrigger Stowing output 1 Open Collector output Tran...

Page 253: ...5 6 7 8 9 Data D W1 W2 C1 C2 R1 SW SUM CR Header Actual Load Rated Total Load Load Factor Status Word Check sum Terminator Status Word SW Bit assignment 7bit 6bit 5bit 4bit 3bit 2bit 1bit 0bit Reserve...

Page 254: ...3 40 9 DISPLAYS...

Page 255: ...when the Radius reaches the limit 18 Outriggers Extension Min 5mm LED Blue LED lights when one or more Detectors input output for Outriggers Extension Max or Mid are OFF 19 Outriggers Extension Mid 5m...

Page 256: ...Upper Limit Push the Switch and hold for two seconds or more shall set the current angle as the upper limit Push the Switch and hold for five seconds or more shall cancel the current value One push fo...

Page 257: ...er limits shall be canceled when this Cancel Switch and Check Switch are push and held for five seconds or more simultaneously 7 Check Switch Each one push of this Switches shall indicate values of sp...

Page 258: ...shall be OFF Open 4 Boom Angle Upper Limit Detector input Controls as below shall be active when Boom Angle Upper Limit Detector input is ON Boom Angle Upper Limit Detector output shall be OFF Open 5...

Page 259: ...iggerAngleSet Up GreenLEDshall light Controls as belowshall beactivewhen Outriggers PinInserted Detector input is OFF Each OutriggerAngleSet Up Red LEDshall flash 3 Boom Angle LowerLimit Detector inpu...

Page 260: ...tatus Lamp Yellow shall start 4 Controls as below shall be active when the Load Factor exceeds 100 Continuity to Working Status Lamp Red shall start Moment 100 output shall be ON 5 Load Factor 0 to 10...

Page 261: ...shall flash Prediction Alarm output RS422 shall be ON Boom Angle Upper Limit output shall be ON Working Status Red Light output shall be ON Boom Angle Lower Limit At Boom Angle Lower Limit 7 Boom Ang...

Page 262: ...S Switches 1 Fall Mode Selector Switch 2 Lifting Height Upper Limit Switch 3 Boom Angle Upper Limit Switch 4 Boom Angle Lower Limit Switch 5 Check Switch LED Indicators 6 Wire Fall LED 7 Outriggers St...

Page 263: ...f specific load Span weighing value Complete Note Calibration Mode shall turn output unconditionally ON of Outriggers Setting Outriggers Stowing Over Un Winding Over Hoist and Working Status Red Lamp...

Page 264: ...ght Indicator display LEn and oFF respectively Set the figures in the Boom Angle Indicator to the value of Boom length at fully retracted condition by pushing Boom Angle Upper Limit Switch 3 and or Bo...

Page 265: ...Extension condition by pushing Boom Angle Upper Limit Switch 3 and or Boom Angle Lower Limit Switch 4 A value of two decimal places may be acquired by pushing and holding Check Switch 5 Note Boom leng...

Page 266: ...ngle value 1 Push Lifting Height Upper Limit Switch 2 and ensure that Boom Length Indicator and Lifting Height Indicator display Ang and oFF respectively Set the figures in the Boom Angle Indicator to...

Page 267: ...et the figures in the Boom Angle Indicator to 80 for 80 degree when the Boom is fully raised by pushing Boom Angle Upper Limit Switch 3 and or Boom Angle Lower Limit Switch 4 2 Operate crane and raise...

Page 268: ...ure that Boom Length Indicator and Lifting Height Indicator display ton and Par respectively Weighing parameters shall be calibrated to the conditions as listed below Boom length 10 7m with 3 sections...

Page 269: ...he Boom Angle Indicator to 0 05 for zero load lifting weight 0 05 tons of Hook weight by pushing Boom Angle Upper Limit Switch 3 and or Boom Angle Lower Limit Switch 4 2 Keep the boom configuration as...

Page 270: ...3 and or Boom Angle Lower Limit Switch 4 2 Lift up a test weight of 2 00 ton with the Boom configuration as identical to above 2 Register of zero load also identical to previous 1 Register of Weighing...

Page 271: ...DE Indicator Calibration Items Boom Length Calibration Items Lifting Height Calibration Items Boom Angle Calibration Items Offset Length Span Length Offset Angle Span Angle Length and Angle at Weighin...

Page 272: ...lues are canceled Outriggers must be fully Extension and any hazardous operations such as overload and or haste must be absolutely avoided 17 1 CALL OUT OF TEST MODE 1 Turn Power ON Key switch ON whil...

Page 273: ...XX 000 NormalEnd Err Error 17 3 L02 LED TEST 1 Procedure 1 Ensure that Boom Length Indicator displays L02 When any other Test Item is on push Cancel Switch to switch to L02 2 When you push Check Swit...

Page 274: ...h Cancel Switch again to switch to subsequent Test Item 2 Result Indication Display Boom Length Lifting Height Boom Angle Actual Load Rated Total Load Working Radius Load Factor ShowTest Item ShowTest...

Page 275: ...ing Lever 1 for Raising Position 2 for Lowering Position Neutral Position has no result indication Three digits Numbers displayed at Boom Angle Indicator Digit 100 10 1 Functions Boom Upper Lower Limi...

Page 276: ...ShowTest Item Numbers displayed for each output signal ON OFF Status Data L05 1 Per pushing each Switch 20 ON OFF 3 Reference of each Output Signal and indicated number Output Signal Indicated number...

Page 277: ...ator displays L07 When any other Test Item is on push Cancel Switch to switch to L07 2 When you push Check Switch Tests shall start Each function shall be verified by actual processes of Switches 3 Pu...

Page 278: ...g press the reset switch to determine the time 4 To move to the next item press the reset switch Caution After setting the time determine the time by pressing the reset switch The setting will not be...

Page 279: ...lifting height upper limit switch and the boom angle upper limit switch simultaneously for two seconds 2 Check if the date on the display is updated to the current date Display contents As an example...

Page 280: ...this software Note Microsoft WINDOWS EXCEL and Word are registered trademarks of Microsoft Corporation in the United States and other countries Note The personal computer is required to have at least...

Page 281: ...ber connected to Moment Limiter May differ per computers 2 Baud Rate Set to 9600 3 Parity Set N 4 Length Set 8 5 Stop Bit Set 1 6 Terminator Set CR 7 MANUAL Repeat Clear the check Indicator of Repeat...

Page 282: ...imiter Working Radius Indicator shall display O u t and two dots shall flash alternately each other while operation log is transferred When data transfer is completed Working Radius Indicator shall tu...

Page 283: ...7 Click Save Switch 9 of RsCom to save acquired data into the personal computer Save the data to appropriate area and with an appropriate file name accompanied by csv extension Data may be read by Ex...

Page 284: ...ear Switch 10 of RsCom Otherwise data which remains in buffer may cause a mass of data to handle 9 PC Mode sahll be out when main power of Moment Limiter is turned OFF Key switch OFF RsCom on the pers...

Page 285: ...le inside Remove a cap from a connector when the cable is ready 2 Connect PC Clear Cable Parts No 103 4560800 included in attached accessories kit to PC Cable 3 Turn main power ON while pushing both B...

Page 286: ...eted operation log cannot be restored Operation log should be saved as back up data in accordance with 16 1 Moment Limiter Operation Log Picking up Procedure then it shall be deleted Note Internal com...

Page 287: ...Date Overload Time Load factor 4 D Selection Date Selection Time Number of hooks after selection 5 Note 1 The top row of data displays the date when the history was deleted 2 If the starter key is tur...

Page 288: ...llation and configuration D5 Angle Sensor input is over criteria D6 Length Sensor input is under criteria Check Length Sensor installation and configuration D7 Length Sensor input is over criteria D8...

Page 289: ...Description Counter Measure Criticality Output to be ON Time is not set Set time TEST MODE L08 This error code is displayed in Hook Height Indicator Error Code Description Counter Measure Criticality...

Page 290: ...3 76 20 TROUBLE SHOOTING In the event of malfunction check each device in accordance with the Flow Chart below...

Page 291: ...3 77...

Page 292: ...E MEASUREMENT OF EACH SENSOR The drawing above is the mother board for Converter From top to bottom NF8 Angle Sensor NF9 Length Sensor NF7 Pressure Sensor 2 NF6 Pressure Sensor 1 Measure voltage betwe...

Page 293: ...L MODE FOR SERVICE B MODE 4 7 1 5 INITIAL MODE FOR MAKER C MODE 4 10 1 6 INITIAL MODE SETTING For interactive remote controller 4 16 2 RECEIVER 4 18 2 1 STATUS DISPLAY 4 18 2 2 CONTROL PRINT CARD LACA...

Page 294: ...4 2 1 INITIAL MODE SETTING PROCEDURE 1 1 BUTTON ARRANGEMENT ON CONTROL PANEL Alphabetical character on each button corresponds to the button name that appears in the following discussion...

Page 295: ...n will become that for setting the OFF timer 3 Use K and L buttons until cursor comes to the side of 10M before pushing the D button That change the OFF timer to show 10M 4 To exit from the initial mo...

Page 296: ...he screen for initial mode for user With the system power remaining turned OFF while holding C button pressed continue to press F button until the screen of initial mode for user appears For about 2 s...

Page 297: ...f accelerator lever Setting the maximum amount At the time of factory shipment this is set at 100 4 Light For selection of backlight OFF as will as how many seconds the backlight remains on after rele...

Page 298: ...Reset Micro Speed For resetting user s Micro Speed rate to the initial value N Not reset setting value of the item to default Y Reset setting value of the item to default 8 Version Version will be dis...

Page 299: ...g turned OFF while holding H and N buttons pressed continue to press F button until the screen of initial mode for user appears For about 2 seconds After MAEDA RADIO REMOTE CONTROL having showed up B...

Page 300: ...et it besides HI for reasons of the structure of the valve 3 Boom Raising and Lowering For change the gain in boom raising and lowering There are 3 selections of HI MID and LOW HI Increase the gain MI...

Page 301: ...e 2 4 Valve Neutral Setting Procedure 7 Serial Number Serial number will be displayed At the time of factory shipment serial number of your transmitter has been entered Make sure that it coincides wit...

Page 302: ...d continue to press F button until the screen of initial mode for maker appears For about 2 seconds After MAEDA RADIO REMOTE CONTROL having showed up C MODE Initial Mode for Maker appears before the p...

Page 303: ...he error may be displayed the time of manufacture and since it is alike and is displayed with the operation check at the time of shipment etc If it is operating normally now it does not have a problem...

Page 304: ...ADJ for details 9 FLOW ADJ Flow control For setting maximum flow rate point i e lever actuating distance in proportion to triggering ratio Use G and H buttons to change the value of this control At th...

Page 305: ...of VR ON Accelerator ON position Available range 0 to 100 Value at the time of factory shipment 40 Result When this value is increased the timing of the accelerator to be ON position shall become late...

Page 306: ...at the time of factory shipment 120 Result When this value is increased the timing of the flow rate lever to be maximum point shall become late against triggering ratio Caution Due to dispersion of ea...

Page 307: ...ty may become poor when the balance is lost by changing it Advise 1 In case that VR ON Accelerator ON position is set to 0 the crane speed is picked up in proportion to engine rev which results poor m...

Page 308: ...FF 1 2 3 4 MAX Accelerator 100 Barchartindicator Light OFF 1S 3S 5S OFF Timer 5M 10M 15M IdleUp 0 Barchartindicator ResetMicroSpeed N Y VERSION Version V 3 41B JUL242007 B MODE For Service PTN Pattern...

Page 309: ...MIN1 MIN1A LC MIN2 MIN2A VALVE Valve NSS50 Micro Speed 1 0 This valueis noteffective 2 0 3 0 SSC3A NACHI ERROR Error Indication only COUNT Operation TimeNumber Indication only HOUR Operation Time Ind...

Page 310: ...4 18 2 RECEIVER 2 1 STATUS DISPLAY The Receiver has a status LED monitor display which indicates INPUT OUTPUT status Message by each LED is as listed in a chart in the next page...

Page 311: ...4 19 Chart 1...

Page 312: ...4 20 2 2 CONTROL PRINT CARD LACATIONS 2 2 1 MAIN PRINT CARD UPPER SIDE MC9141 A...

Page 313: ...4 21 2 2 2 MAIN PRINT CARD LCD DISPLAY UPPER SIDE MC9141 A...

Page 314: ...4 22 2 2 3 SUB PRINT CARD LOWER SIDE MC9143 A...

Page 315: ...4 23 2 2 4 SUB PRINT CARD LCD DISPLAY LOWER SIDE MC9143 A...

Page 316: ...4 24 2 3 CONNECTOR PIN ASSIGNMENT Receiver has two connectors for Input Output...

Page 317: ...CC Sol 22 Differential transformer 3 Boom Raising Sol 23 Differential transformer 4 Boom Lowering Sol 24 Telescopic Differential transformer 5 Sol GND 25 Differential transformer 6 Sol GND 26 Differen...

Page 318: ...screen will be showed up after release your hold of control button of transmitter Press each control buttons to enter 2435 and press D setting button 5 Operate winch control lever up and down to selec...

Page 319: ...button And INITIAL MODE FOR SERVICE B MODE will finish Make sure that indication of E2 on receiver monitor display is out and nothing is displayed If receiver status appears as dot blinking the settin...

Page 320: ...ion if over hoisted from the start Indication appears when over hoisted after released once Hook stowing 2 5 2 ERROR MESSAGE Error Code Details Emergency stop Signal receiving error Breaking of wire w...

Page 321: ...a new one When the fuse is blown never fail to examine the circuit for the cause and repair it before replace the fuse The fuse must be replaced with the same type of grass tube fuses and of the same...

Page 322: ...SE After the fuse is examined or replaced restore the Receiver in the reverse practice of the removal CAUTION When the three connectors 6 of the first PCB 5 is inserted again secure them and avoid any...

Page 323: ...nd scanning frequency is completed 4 Signal not received Signal cannotbe received E2 displayed on receiver monitor display No voice message when main switchis OFF whenmanually shifted 5 Danger defecti...

Page 324: ...Wiring failure of the remote control cable Check that the transmitter has been powered up Check repair or replace the transmitter Check repair or replace the remotecontrol cable Receiver defective PC...

Page 325: ...ormerdefective Slewing line wire harness breakage Powertransformerdefective Check repair or replace the Slewing line wire harness Check or replace the Power transformer Accelerator line wire harness o...

Page 326: ...4 34 This Page Intentionally Left Blank...

Page 327: ...EACH SECTION 5 6 2 3 NAME AND CONTENT OF THE DIGITAL OPERATOR 5 7 2 4 DETAIL OF INVERTER SET ITEMS 5 9 2 5 ALARM DISPLAY AND COUNTERMEASURE 5 10 2 6 LIST OF ALARM CODES 5 12 2 7 TROUBLESHOOTING 5 16 2...

Page 328: ...5 2 1 ELECTRIC MOTOR 1 Power unit 2 Electric motor 3 Coupling 4 Hydraulic pump...

Page 329: ...ER PANEL 1 Inverter panel cover 2 Protective cover 3 Inverter panel 4 Main breaker with a ground fault detector 5 DC 12 V power supply switch 6 AC circuit power supply switch 7 Power lamp white 8 Trou...

Page 330: ...5 4 2 1 STRUCTURAL DRAWING...

Page 331: ...P2RF 05 E TLR2 Timer Front connection socket 1 1 H3RN 11 DC12 P2RF 05 E Y0 Power relay W metal fittings 1 1 G7L 2A2B B DC12 R99 04 FOR G5F F1 F2 End contact fuse Live part protective cover Fuse link s...

Page 332: ...5 6 2 2 EXTERNAL APPEARANCE AND NAME OF EACH SECTION 3G3MX2 A4055 V1 1 Cooling fan cover 2 Cooling fan 3 Cooling fin 4 Main unit case 5 Terminal block cover 6 Option cover 7 Electric wire drawer panel...

Page 333: ...celeration after the run command OFF Monitor LED Hz Lights up in green when the data displayed in the display part is frequency Monitor LED A Lights up in green when the data displayed in the display...

Page 334: ...ut mode confirms the blinking line and moves the blinking line to the right Increment key Adds parameter or setting data Accelerates if long pressed Enters the individual input mode where each line ca...

Page 335: ...81 Selection of first AVR 01 Normally OFF A082 Selection of first motor receiving voltage 400 Default value setting not necessary b001 Selection of restart during momentary power interruption and unde...

Page 336: ...current and past alarms can be observed in the fault monitor 1 to 6 d081 to d086 The latest alarm is displayed in the fault monitor 1 d081 Precautions The inverter status at the time of alarm may be d...

Page 337: ...gital operator The trip status can be reset if 00 enable or 02 enable only reset is set for the stop key selection b087 Enter reset input from the control circuit terminal block Set 18 RS reset in one...

Page 338: ...ct Adjust so that it is correct Overload protection of the limiting resistor Trips when the activity ratio of the regenerative braking exceeds the activity ratio configured in b090 E06 Are there any s...

Page 339: ...being turned ON If residual voltage exists in the motor this function will not operate E14 Are there any ground faults Check the output line and motor Are there any faults in the inverter itself Remo...

Page 340: ...eration Check the brake Is the b124 setting short Make the b124 long Is the brake check signal being inputted Check the wirings Emergency cutoff 3 Trips when the safety input of GS1 or GS2 has been in...

Page 341: ...he encoder is below the start frequency b082 continues consecutively for more than the encoder breakage detection time P077 0 when the output frequency is above the creep speed setting P015 E80 Breaka...

Page 342: ...tput frequency setting monitor F001 if the primary frequency command selection A001 is 02 operator Input the frequency according to the setting value of the primary frequency command selection A001 th...

Page 343: ...urn OFF the corresponding terminal 84 ROK run OK signal is assigned to the multi function input terminal and it is in OFF state Turn ON the assigned terminal There is a breakage in the wiring from the...

Page 344: ...motor The 3 wire input function is used and the non inversed rotation inversed rotation logic is incorrect Check the 22 F R 3 wire non inversed inversed logic of the multi function input terminal The...

Page 345: ...tion overcurrent restriction function selection b130 enabled The value in the deceleration overcurrent restriction ratio gain b133 deceleration overcurrent restriction reset time b134 is inappropriate...

Page 346: ...on is being used check that the setting is correct and fix accordingly The circuit breaker activates when running the inverter The leakage current of the inverter is large Reduce the carrier frequency...

Page 347: ...g function selection P200 to 00 standard Modbus address Overload protection E05 occurs on brake control Inverter is running in brake restrain state Release the run command of the inverter in brake res...

Page 348: ...pection procedure Criteria for judgment Inspection item Inspection cycle Inspection method 1 Indoor environment 1 Dust temperature and gas 2 Drop of water or other liquid 3 Room temperature Occasional...

Page 349: ...trolytic capacitor declines When leaving the inverter unused for a long time supply it with electricity once every two years for 5 hours or more each to recover the performance of the large capacity e...

Page 350: ...e replaced together with the circuit board Criteria for appearance check Absence of liquid leak Safety valve In the depressed position Measurement of electrostatic capacitance and insulation resistanc...

Page 351: ...trial waste product collectors and transporters or industrial waste disposal persons If the collection transport and disposal of industrial waste is done by someone who is not licensed for that job it...

Page 352: ...5 26 3 POWER SUPPLY BOX 1 Power supply box 2 Power supply box door 3 Door handle 4 Terminal block 5 Cable inserting hole...

Page 353: ...5 27...

Page 354: ...5 28 4 ELECTRIC CIRCUIT DIAGRAM...

Page 355: ...5 29...

Page 356: ...5 30 This Page Intentionally Left Blank...

Page 357: ...3 SERVICE MANUAL Document No 104ME SM1910 00 First edition October 31 2019 Issued by Maeda Seisakusho Co Ltd 1095 Onbegawa Shinonoi Nagano Nagano 388 8522 Japan No part of this manual can be reproduce...

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