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Operation Manual 

Mini-Crawler Crane 

104ME-OM1901-00 

Summary of Contents for MC405C-3

Page 1: ...Operation Manual Mini Crawler Crane 104ME 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: ...avelling Dolly 3 2 Crane 3 2 Safety Devices 3 2 CRANE TERMINOLOGY 3 3 Terms and Definitions 3 3 PRINCIPLE SPECIFICATIONS LIST 3 4 Standard and Electric Motor Option Specifications 3 4 Remote Control S...

Page 4: ...5 Boom Telescoping Lever 4 5 Winch Lever 4 5 Boom Derricking Lever 4 5 Travelling Lock Lever 4 6 Left Right Travelling Lever 4 6 Level Gauge 4 6 Outrigger Un Set Warning Lamp Yellow 4 6 INSTRUMENT PA...

Page 5: ...ESCRIPTION ON OUTRIGGER AND CRANE SAFETY DEVICES 4 29 Outrigger Safety Devices 4 29 Functions of Outrigger Safety Devices 4 29 Check Before Setting Outriggers 4 30 Outrigger Setting Operation 4 30 Cra...

Page 6: ...OVERLOAD DETECTOR 4 68 Moment Limiter Features 4 68 Function of Moment Limiter 4 69 Mechanism of Moment Limiter 4 69 Display of Moment Limiter Error Messages 4 69 Moment Limiter Operations 4 70 Prohi...

Page 7: ...on Worksite 4 84 Cautions on Operations 4 84 Pick Carry Posture 4 85 Pick Carry Operations 4 86 Cancelling Pick Carry Operation Posture 4 86 REMOTE CONTROL SYSTEM INTRODUCTION 4 87 General 4 87 Preca...

Page 8: ...Speed and Enhanced Speed Mode 4 124 Engine Stop and Emergency Stop Procedure 4 126 Engine Start and Reset Procedure 4 126 Checking After Crane Operation 4 127 ELECTRIC MOTOR OPTION 4 128 Instrument P...

Page 9: ...68 Operation Control by Moment Limiter 4 168 Restriction in Fly Jib Mode 4 168 Restriction for Boom Stowing Operation 4 170 Instruction for Fly Jib Operation 4 170 Moment Limiter Mode Change 4 170 Ins...

Page 10: ...g 5 10 Electrical Part Handling 5 11 Hydraulic Equipment Handling 5 11 BREAKING IN MACHINE 5 12 LEGAL INSPECTION 5 12 CONSUMABLES 5 13 LUBRICATING OIL 5 14 SPECIAL TOOLS AND STANDARD TIGHTENING TORQUE...

Page 11: ...tion 5 37 Check Outrigger Extension Positions 5 38 Check Engine Exhaust Gas Colour Noise and Vibration 5 38 PERIODIC MAINTENANCE 5 39 Periodic Maintenance Schedule 5 39 Periodic Maintenance Procedure...

Page 12: ...ection Cleaning and Replacement of Air Cleaner 5 72 Inspection 5 72 Cleaning Replacing the Element 5 73 Cleaning Inside Engine Cooling System 5 74 Cleaning Method 5 75 Draining Contaminant Water Depos...

Page 13: ...g Engine 5 85 Boom and Frame 5 85 Wire Ropes 5 85 Fly jib Fix Bolts 5 85 Electrical Wiring Fuse Box 5 85 Pre Start After Starting Engine 5 85 Over Winding Detector 5 85 Winch and Boom 5 86 Moment Limi...

Page 14: ...Table of Contents Mini Crawler Crane M A E D A xii 1 2019 MC405C 3 This Page Intentionally Left Blank...

Page 15: ...1 2019 MC405C 3 1 1 Section 1 INTRODUCTION...

Page 16: ...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 17: ...1 2019 MC405C 3 2 1 Section 2 SAFETY...

Page 18: ...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 19: ...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 20: ...you hoist a long load such as pipes clamp the load vertically or secure it at both ends Slewing Hazard Never slew a load over anyone Always slew the load as smoothly and slowly as possible Any sudden...

Page 21: ...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 22: ...y to the machine before starting the engine Do not start the engine if any guards or covers are not properly installed on the machine Always turn the Starter Switch to the OFF position after operation...

Page 23: ...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 24: ...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 25: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 9 SAFETY LABEL LOCATIONS Machine Body Fig 2 1...

Page 26: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 10 1 2019 MC405C 3 Fig 2 2...

Page 27: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 11 3 104 3279801...

Page 28: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 12 1 2019 MC405C 3 4 A 104 3433200 4 B 104 3433300 4 C 104 3433400...

Page 29: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 13 8 349 3195100 9 349 4420700 10 104 4753500 2 places 11 104 4760600 12 104 4548600 13 349 4421100...

Page 30: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 14 1 2019 MC405C 3 14 A 104 2209900...

Page 31: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 15 14 B 104 2210200...

Page 32: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 16 1 2019 MC405C 3 14 C 104 2210300...

Page 33: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 17 21 349 4421400 26 350 4539700 4 places 30 104 4550800 45 349 4426900 4 places...

Page 34: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 18 1 2019 MC405C 3 46 349 4427000 4 places 47 349 4427100 50 349 4427200 51 349 4527000 54 349 4421900 56 893 4239100...

Page 35: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 19 57 349 4427300 58 349 4427400 59 349 4427500 60 349 4427900 61 349 4526900 63 349 4427800 70 104 4549200 4 places...

Page 36: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 20 1 2019 MC405C 3 73 349 4422000 75 553 4268000 2 places 76 553 4267500 2 places 77 553 4267400 2 places 78 553 4266400...

Page 37: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 21 80 104 3393000 81 104 3287200 83 104 4752900 84 349 4536600 85 353 4488600 87 104 4549601 4 places...

Page 38: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 22 1 2019 MC405C 3 89 104 4569800 92 553 4267100 95 104 4557900 2 places 96 104 3327800...

Page 39: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 23 97 350 4432100 98 104 4558200 2 places 106 103 4604800 107 103 4604900 108 553 4267700...

Page 40: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 24 1 2019 MC405C 3 Remote Control System Fig 2 3 Transmitter Receiver...

Page 41: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 25 1 349 4428500 23 104 4559300 68 300 4214000 99 104 4559400...

Page 42: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 26 1 2019 MC405C 3 Electric Motor Option Fig 2 4 70 104 4552400 4 places 102 553 4267300 2 places...

Page 43: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 27 850kg Searcher Hook Option Fig 2 5...

Page 44: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 28 1 2019 MC405C 3 1 102 4608500 2 places 2 103 4635800 3 103 4635500 4 102 4621200 2 places...

Page 45: ...Mini Crawler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 29 S1 104 1165400...

Page 46: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 30 1 2019 MC405C 3 Fly Jib Option Fig 2 6...

Page 47: ...ler Crane M A E D A Section 2 SAFETY LABEL LOCATIONS 1 2019 MC405C 3 2 31 2 104 4568200 2 places 3 104 4568300 2 places 4 104 3300300 5 104 4572700 2 places 6 104 4572800 2 places 7 104 4579800 F1 104...

Page 48: ...Section 2 SAFETY LABEL LOCATIONS Mini Crawler Crane M A E D A 2 32 1 2019 MC405C 3 This Page Intentionally Left Blank...

Page 49: ...1 2019 MC405C 3 3 1 Section 3 SPECIFICATIONS TERMINOLOGY AND CAPACITY CHARTS...

Page 50: ...d in travelling position This compact design is ideal for work in confined areas Two travel lever operation enables direction changes forward backward and right left and also pivot and spin turns Cran...

Page 51: ...HARTS 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 betw...

Page 52: ...taneous telescoping Boom length 4 735m 7 695m 10 655m 13 565m 16 475m Boom telescoping stroke time 11 7 m 54 2 sec 0 22 m sec 11 7 m 61 6 sec 0 19 m sec Derrick system Method Direct push type hydrauli...

Page 53: ...rane mode 10 Hz operation after 5 minute consecutive no operation automatic power off in 30 minutes Safety device Over winding detector automatic stop device three winding stop alarm automatic stop de...

Page 54: ...ot received 5 Danger defective safety device 6 Danger defective remote control 7 Danger set outriggers 8 Danger overload Control unit voltage Power for the Crane DC 12V Control unit power consumption...

Page 55: ...019 MC405C 3 3 7 850 kg Searcher Hook Specifications System Item MC405C 3 Standard MC405C 3 Electric motor option Mass and dimensions Machine mass 5630 kg 5780 kg Stowed length width height 5210 1380...

Page 56: ...ATIONS LIST Mini Crawler Crane M A E D A 3 8 1 2019 MC405C 3 Fly Jib Specifications System Item MC405C 3 Standard MC405C 3 Electric motor option Mass and dimensions Machine mass 5750 kg 5900 kg Perfor...

Page 57: ...Mini Crawler Crane M A E D A Section 3 DIMENSIONAL DRAWINGS 1 2019 MC405C 3 3 9 DIMENSIONAL DRAWINGS Machine Dimensional Drawing Fig 3 6...

Page 58: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 10 1 2019 MC405C 3 850 kg Searcher Hook Dimensonal Drawing Fig 3 7...

Page 59: ...Mini Crawler Crane M A E D A Section 3 DIMENSIONAL DRAWINGS 1 2019 MC405C 3 3 11 Fly Jib Dimensonal Drawing Fig 3 8...

Page 60: ...Section 3 DIMENSIONAL DRAWINGS Mini Crawler Crane M A E D A 3 12 1 2019 MC405C 3 Outrigger Width Dimensional Drawing Fig 3 9...

Page 61: ...hoisting accessory hook 50kg When the crane is used with the outriggers extended other than at the maximum crane operation should proceed with respect to the values specified in the rated total load c...

Page 62: ...preceding boxes in the rated total load chart 1 Boom 1 All the booms are retracted Fig 3 11 2 Boom 1 2 With booms 3 4 and 5 retracted boom 2 is fully extended Boom 1 2 is to apply to crane operation...

Page 63: ...ded booms 4 and 5 are extended at the medium half of the mark passes boom 3 Boom 1 2 3 4 is to apply to crane operation with booms 4 and 5 extended even if only slightly Fig 3 14 5 Boom 1 2 3 4 5 All...

Page 64: ...load is lifted 3 Deductions from rated total loads must be made for the weight of hook block ball hook slings rigging or other suspended gear 4 The slewing range will be restricted if the outrigger a...

Page 65: ...total load kg Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total 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...

Page 66: ...total load kg Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total 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...

Page 67: ...m Rated total load kg Working radius m Rated total load kg Working radius m Rated total load kg Working radius m Rated total 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...

Page 68: ...r boom deflection as the load is lifted 4 Deductions from Searcher Hook Rated Total Load must be made for the weight of 850 kg searcher hook 30 kg block ball and all rigging 5 The capacity when using...

Page 69: ...Mini Crawler Crane M A E D A Section 3 RATED TOTAL LOAD CHARTS 1 2019 MC405C 3 3 21 OFFSET POSITION SH1 Fig 3 16 OFFSET POSITION SH2 Fig 3 17 OFFSET POSITION SH3 Fig 3 18...

Page 70: ...A 3 22 1 2019 MC405C 3 Rated Total Load Chart for Fly Jib CAUTION The rated total load is a load including the mass of a hoisting accessory hook 20kg Rated total load chart Boom angle deg Rated total...

Page 71: ...orking radius and lifting height shows the relationships the working radius of this machine boom angle and lifting height above the ground with no object hoisted The diagram has been made allowing for...

Page 72: ...ius and lifting height shows the relationships the working radius boom angle and lifting height at no load allowing for no deflection in the boom A deflection occurs in the boom when an object is hois...

Page 73: ...k Carry duties follow these rules to prevent machine from tipping over 1 Do not travel on a slope soft ground or uneven ground 2 Do not slew Avoid any sharp movements when stopping or starting 3 When...

Page 74: ...g 850 kg searcher hook be sure to set searcher hook mode for moment limiter Number of falls mode and searcher hook offset position must be set as 850 kg searcher hook mode when 850 kg searcher hook is...

Page 75: ...Mini Crawler Crane M A E D A Section 3 WORKING RADIUS LIFTING HEIGHT 1 2019 MC405C 3 3 27 Fig 3 24 Fig 3 25...

Page 76: ...g Radius Lifting Height for Fly jib WARNING The diagram of working radius and lifting height shows the relationships the working radius of this machine boom angle and lifting height above the ground w...

Page 77: ...1 2019 MC405C 3 4 1 Section 4 OPERATION...

Page 78: ...r 9 Outrigger extension cylinder Built in the box 10 Outrigger 11 Slewing device 12 Working status lamp 13 Rubber track 14 Travel control 15 Crane control 16 Moment limiter display unit 17 Operation s...

Page 79: ...UTRIGGER STOWING on page 4 49 Slewing device A device to slew the crane Rubber Tracks Travel Motor and Sprocket Track Roller Idler Carrier Roller Travel device for travelling Travel Control A part for...

Page 80: ...rol Location Fig 4 2 1 Slewing lever 2 Boom telescoping lever 3 Winch lever 4 Boom derricking lever 5 Outrigger un set warning lamp 6 Acceleration pedal 7 Level 8 Travelling lock lever 9 Right travell...

Page 81: ...g Lever Use this lever for telescoping the crane boom Fig 4 5 Extend Push the lever forward Extend Neutral Release your hand from the lever The lever returns to the Neutral position and the boom teles...

Page 82: ...d from the right lever and operate the left lever forward or backward Spin turn Operate the left and right levers to the opposite direction The left and right crawlers turn to the opposite direction a...

Page 83: ...e high speed switch 3 Hook stowing switch 4 Travelling high speed switch 5 Boom stowing switch 6 Horn switch 7 Engine emergency stop switch EMO 8 Starter switch 9 Pick Carry switch 10 Fuel gauge 11 Ho...

Page 84: ...s OFF Push the switch forward again and when the pilot lamp goes off the switch turns OFF and the crane operating speed returns to normal NOTICE Always set the work selector switch on the outrigger op...

Page 85: ...he boom lowering operation Operate the boom derricking lever carefully when stowing the boom Pay sufficient attention not to let the boom collide with the machine body Use the boom stowing switch only...

Page 86: ...e will be very unstable and it accompanies the risk of overturning If you have to perform Pick Carry by necessity strictly observe the following cautions Strictly maintain the Pick Carry posture and o...

Page 87: ...or flashes during the work stop the operation immediately and check adjust or repair the relevant section Fuel Gauge This gauge indicates the remaining amount of the fuel in the fuel tank Turn the sta...

Page 88: ...leakage from the radiator clogging in the radiator core and damage and tension of the alternator belt Fig 4 27 Engine Oil Pressure Monitor This monitor indicates the drop in the engine oil pressure I...

Page 89: ...ward Slide Adjustment Use the slide adjusting lever 3 to make adjustment Fig 4 31 1 While pushing the slide adjusting lever 3 leftward move the seat 2 forward backward 2 After adjusting the seat 2 rel...

Page 90: ...hallow water check the ground condition depth and water velocity beforehand and make sure not to exceed the allowable water depth no higher than centre of idler 1 Inspection Before Starting Engine Fig...

Page 91: ...hook block is not contained Make the boom fully lowered and retracted Fix the hook block to the containment position Make the outrigger contained For more information see TRAVELLING POSITION on page 4...

Page 92: ...he frozen road becomes soft when the air temperature rises and causes the Machine travels and other operations to be unstable Be very careful Under cold weather check that the load to be hoisted is no...

Page 93: ...e hydraulic oil tank by raising to above the hydraulic circuit set pressure by using operation lever Doing so improves the Machine reactions and prevents improper operations If the battery fluid is fr...

Page 94: ...ine Normal Engine Start CAUTION If it is hard to start the engine due to low ambient temperature see Starting Engine in Cold Weather on page 4 19 for the engine starting operation Do not keep the star...

Page 95: ...key into the starter switch and turn the key to HEAT preheat position Keep the position until the preheat monitor goes off Release your hand and the key will automatically return to the ON position Fi...

Page 96: ...y for emergency and repair Using the system in abnormal condition can result in serious accidents CAUTION The appropriate temperature of the hydraulic oil is 50 to 80 C Even when operating at low temp...

Page 97: ...t the boom until it reaches the stroke end Check if there is any abnormality with the operation If there is any abnormality repair Fig 4 54 9 Operate the winch lever 3 slowly forward backward to check...

Page 98: ...ol system is at the OFF position 1 Release your foot from the acceleration pedal 6 and change the engine speed to idling Continue the no load operation for about 5 minutes Fig 4 57 2 Turn the starter...

Page 99: ...UTRIGGER STOWING on page 4 49 to stow the outriggers TRAVELLING CONTROLS AND OPERATION WARNING Not observing these cautions in travelling will result in serious accidents Cautions When Travelling When...

Page 100: ...lopes Be sure to switch the travelling high speed switch to the OFF low speed position when travelling on the slope The machine may overrun Never change the direction on the slope or cut the slope hor...

Page 101: ...e extremely careful when travelling forward If you cannot verify the safety because the travelling direction is the blind corner stop travelling and check the safety in the travelling direction Staff...

Page 102: ...machine will be in the high speed travelling mode Push down the travelling high speed switch toward you The pilot lamp of the switch section goes off and the machine will be in the low speed travelli...

Page 103: ...spin turn Fig 4 70 Changing Path While Travelling Forward Backward Left Turn While Travelling Forward While tilting the right travelling lever forward return only the left travelling lever to the Neu...

Page 104: ...with the travelling lever s during the engine operation may result in sudden movement of the machine leading to serious accidents Always set the travelling lock lever to the LOCK position when parkin...

Page 105: ...xtension position Install a detection switch inside the outrigger inner box to detect if the tray is seated properly through the detection pin installed between the tip of the inner box and the tray C...

Page 106: ...engine Travelling lock lever at LOCK position Check if the machine is in the posture of stowing the boom Fully retract the boom Boom horizontal stowing position Boom slewing stowing position Boom stow...

Page 107: ...s go up in the air during crane operation Setting lamps red on display panel flash Crane interlock device If any of the extension lamps and setting lamps total of eight goes off hook raising boom exte...

Page 108: ...outriggers Outrigger extension switch ON Rotate Stow the outrigger rotary and secure at the specified position with position pin Stop the engine Extension lamps red on display panel flash Outrigger u...

Page 109: ...esulted error and its action Check Before Setting Outriggers Standard Operation Sequence Machine Status Display and Warning Activation of Safety Devices Start the engine Travelling lock lever at LOCK...

Page 110: ...ndard Operation Sequence Machine Status Display and Warning Activation of Safety Devices Perform crane operations Work selector switch Crane Operate crane operation levers Boom stowing lamp on display...

Page 111: ...Operation Standard Operation Sequence Machine Status Display and Warning Activation of Safety Devices Operate the machine to take the boom stowing posture Fully retract the boom Boom horizontal stowi...

Page 112: ...rd Operation Sequence Machine Status Display and Warning Activation of Safety Devices Travel the machine Travelling lock lever at TRAVEL position Start the engine Operate the travelling levers When th...

Page 113: ...E D A Section 4 OUTRIGGER COMPONENTS 1 2019 MC405C 3 4 37 OUTRIGGER COMPONENTS Fig 4 75 1 Position pin 2 Rotary 3 Outrigger setting cylinder 4 Outrigger extension cylinder 5 Outer box 6 Inner box 7 O...

Page 114: ...t and turns off when the tray 3 floats stow The conditions of the outrigger tray 3 are detected by the detection pin 1 at the tip of the inner box 2 and by the detection switch inside the inner box Fi...

Page 115: ...Boom Stowing Detection in Horizontal Direction The lamp turns on when the boom stops at the horizontal stowing position and turns off when the boom leaves the horizontal stowing position Boom movemen...

Page 116: ...OCK position you can still travel the machine even if the work selector switch is operated to the Outrigger or Crane position Be careful not to let your hand or body touch the travelling levers The ma...

Page 117: ...e LOCK side restricts the travelling operation If the lever is not operated to the LOCK side the machine travels when a travelling lever is operated Note 2 The outrigger operation is enabled only when...

Page 118: ...t pavement low cost asphalt or thin concrete Surface with paving stones Area reclaimed after excavation work Landfill Road shoulders or area close to hole such as excavation work Deteriorated pavement...

Page 119: ...o keep the machine level during the crane works as well Fig 4 94 Place the outriggers at a maximum extension condition as the basic rule If it is not possible to extend the outriggers to their maximum...

Page 120: ...en when clearance a in the figure is 50 mm Fig 4 98 Crane operation should proceed with respect to the values specified in When the crane is used with the outriggers extended at the minimum in the rat...

Page 121: ...of the rotary 2 and rotate the rotary outward Fig 4 105 6 Insert the position pin 1 to the end at the position where the pin holes are aligned after rotating the rotary 2 outward Fig 4 106 NOTICE The...

Page 122: ...not sound 1 See STARTING ENGINE on page 4 18 and start the engine 2 Release your foot from the acceleration pedal 6 and change the engine speed to idling Fig 4 108 3 Check the number on the operation...

Page 123: ...t the switch to the Neutral position Operate the remaining switches in the same way so that the four outriggers are raised to the same height Set the switch to the Neutral position Repeat this operati...

Page 124: ...at 1 The outrigger is set at the positioning pin position 40 front 30 back 2 The inner box of all the outriggers is extended fully 3 All the outriggers are placed on a level surface 4 Approx 50mm is a...

Page 125: ...e is any object under the rubber tracks the machine may overturn and serious accidents may occur when stowing the outriggers Stop the engine for operation except for extending setting the outrigger cy...

Page 126: ...three outriggers in the same way Fig 4 124 1 Operate the travelling lock lever 8 to the LOCK position Fig 4 125 2 See STARTING ENGINE on page 4 18 and start the engine 3 Release your foot from the acc...

Page 127: ...are completely set on the ground push down again an outrigger grounding switch or two of them at the same time to the IN upward side When the setting cylinder completely retracts and the top box goes...

Page 128: ...pin holes are aligned after rotating the rotary 2 inward Fig 4 136 NOTICE The position pin 1 has a wire to prevent the loss of the pin 3 Stow the other three outriggers in the same way NOTICE After s...

Page 129: ...chine is not level warnings and alarms are not issued even when the rated total load is near Always set the outrigger horizontally to the ground while looking at the level gauge Before using the crane...

Page 130: ...lectrical Cable Minimum Safe Distance Low voltage Distribution line 100 200V 2m 6 600V 2m Special Transmission line 22 000V 3m 66 000V 4m 154 000V 5m 187 000V 6m 275 000V 7m 500 000V 11m Measures When...

Page 131: ...diately lower the load and contain the boom Even when the maximum instantaneous wind speed is below 10 m s bigger the hoisted load higher the hoisted load position and longer the boom the wind effect...

Page 132: ...position before operating the crane Do not attempt the crane operation when the moment limiter override switch is at ON position The moment limiter override switch is permitted to be at ON position on...

Page 133: ...use Otherwise person near the load may collide the hook block without load The operator must always ensure that no one is ever underneath a hoisted load To ensure safety any lifting carried out over...

Page 134: ...ases and the rated total load that can be hoisted decreases When working with extending retracting the boom pay extra attention so that the mass weight of the load at the time the boom is most lowered...

Page 135: ...o not attempt any slewing operation Appoint one responsible slinger who is most experienced Working at the Site with Underground Lifting Leave at least three loops of wire rope in the winch drum when...

Page 136: ...ohibited Fig 4 147 Do Not Operate with Derricking Force Drawing in or lifting the load with boom derricking operation is prohibited Fig 4 148 Do Not Pull Sideward Draw in and Hoist Diagonally Pulling...

Page 137: ...cidents Particularly the crane operations must be carried out according to the rated total load chart Fig 4 153 Do Not Wind by Force Be careful not to hook the wire rope over a tree or steel beam whil...

Page 138: ...on the winch drum When loosening the stowing of the hook block the hook block may slew and interfere with the peripheral devices resulting breakage of the devices Pay sufficient attention around the h...

Page 139: ...slinging operators If the hook block was hoisted too much over winding will be detected The alarm buzzer sounds and the audible message saying Hook over hoisted will be heard When the alarm buzzer and...

Page 140: ...thus may break the crane or overturn the machine Do not pull the load horizontally or pull in the load by telescoping the boom Extending the boom increases the working radius and the rated total load...

Page 141: ...te the slewing lever 1 as follows Fig 4 167 Slew counterclockwise left Push the lever forward to the LEFT side Neutral Release your hand from the lever The lever returns to the Neutral position and th...

Page 142: ...he boom securely into the stowing position After stowing the boom verify that the boom stowing lamp on the outrigger display lights up in green If the boom stowing lamp does not light up the outrigger...

Page 143: ...n automatically stops 6 With the hook stowing switch at the ON position operate the winch lever 3 to the UP pull toward you side again and slowly raise the hook block 4 to stow the block at the bottom...

Page 144: ...king status lamp A Red working status lamp Warning lamp for load factor of 100 or more B Yellow working status lamp Pre warning lamp for load factor of 90 to 100 C Green working status lamp Working la...

Page 145: ...high speed boom operation the boom may overrun the specified stop position causing serious accidents such as overturning of the machine resulting in death or serious injury Fig 4 178 The moment limit...

Page 146: ...op DANGER Be sure to switch the engine speed to low speed and perform crane operation carefully if the moment limiter load factor is 90 or higher Performing crane operation at high engine speed will s...

Page 147: ...operation In the case of an automatic stop when raising of the boom is unavoidable the boom raising operation is possible only while keeping the boom lift bypass switch in the ON position To return to...

Page 148: ...anges to green yellow and red 9 Over winding LED Red 10 Load capacity display Yellow 11 Actual load display 12 Rated total load display 13 Working radius display 14 Working radius upper limit switch 1...

Page 149: ...ith no upper limit value being set set the boom to the angle you would like and press the switch for 2 seconds The boom angle at this point is set as the upper limit At the same time the LED lights up...

Page 150: ...even if you keep the switch pressed for more than 2 seconds Let your hand go off the switch and press the switch again Working Radius Upper Limit Switch and LED Orange Use this switch to set or cance...

Page 151: ...the boom automatically stops at the set lifting height before performing the actual operation If the boom does not stop automatically re set the lifting height using the procedure above When the boom...

Page 152: ...lay The display will be a blank for the item to which no value is set The display sections other than for the corresponding items will be blank Descriptions of Moment Limiter Display For LEDs not desc...

Page 153: ...ay Section This section constantly displays the current boom angle during the crane operation The boom angle is the angle the boom and the horizontal line form Over Winding LED Red This LED flashes up...

Page 154: ...factor is 90 to less than 100 The LED lights up in red if the load factor is 100 or higher Load Factor Display Yellow This display indicates the status of the moment limiter load factor by its illumin...

Page 155: ...op If the system stops automatically promptly perform the recovery operation caused by overloading For more information on recovery operations see Recovery Operation After Auto Stop on page 4 70 Worki...

Page 156: ...continuously The hook raising and boom extending operation stop automatically The voice saying hook is overwinded is heard In case of auto stop immediately perform the recovery operation Perform hook...

Page 157: ...mit Detection When the boom is raised and the boom angle reaches about 77 degrees the boom raising operation stops automatically Boom Lower Limit Detection When the boom is lowered and the boom angle...

Page 158: ...degrees or more for boom upper limit Set value 7 degrees or more for boom lower limit Set value 1 3 m or less for working radius upper limit Set value 1 3 m or less for lifting height With Lower or R...

Page 159: ...ilure of the Moment Limiter system and or machine maintenance service when any crane travel lifting operations are not being performed Do not store the override key permanently in the moment limiter o...

Page 160: ...present the machine overturning hazard Do not approach those locations or perform Pick Carry at those locations Check the condition of the road surface and ground in advance and place someone to guid...

Page 161: ...ise the boom to about 65 degrees 3 See Slewing Operation on page 4 65 to slew the boom to the centre position in front Fig 4 217 4 Operate the Pick Carry switch to the ON position NOTICE If the machin...

Page 162: ...iately The machine may topple over Strictly observe the values in the Hoisted load rated total load during the crane operation Avoid slope and obstacles while travelling 1 Operate the work selector sw...

Page 163: ...refinger Other fingers should grab the grip to hold the Transmitter Fig 4 224 Always manipulate levers and switches by fingers Do not attempt to pick them by a sharp edge or such for manipulation It m...

Page 164: ...cold air directly blows Sudden change in temperature may cause dew formation inside the Transmitter and which causes failure or malfunction and leads to a serious hazard Fig 4 229 In the winter times...

Page 165: ...roper indications when each lever and button is manipulated Further verify the each applicable value of load in the Transmitter is identical to that of the Moment limiter display Inspection Prior to T...

Page 166: ...udes both Transmitter and Receiver which facilitate remote control of the Crane which is purchased with this device This Interactive Remote Control System provides an operation of the Crane at the mos...

Page 167: ...limiter of the Crane are delivered to the Transmitter through the cable Fig 4 233 Functions of Remote Control System The Transmitter allows one hand operation which enables craning works such as holdi...

Page 168: ...ng No 2 Outrigger Operation Lever 10 Hook Raising and Lowering No 3 Outrigger Operation Lever 11 Boom derricking No 4 Outrigger Operation Lever 12 Accelerator Lever 13 Grip 14 Connection Cable LCD Scr...

Page 169: ...ode will be displayed in the LCD screen Fig 4 237 Hook Stow Setting Button This button also serves two usages as below To push this button automatically stows the hook For each of the setting of the m...

Page 170: ...lever controls extension setting and retraction stowing of either only No 2 or all of the outriggers at once Retraction stowing Push the upper end of the lever Neutral Release your finger from the le...

Page 171: ...lower end of the lever Accelerator Lever The Accelerator lever controls the flow rate of the control valves and the engine speed or output Fig 4 245 Low idling Release your finger from the Accelerator...

Page 172: ...nsmitter and Receiver Before and after the operation always check this connection cable for any crack or damage or bent In addition check the receptacle for any damage Fig 4 248 Storage Case The Stora...

Page 173: ...ain Switch The Main switch is a toggle switch to power ON or OFF the Receiver Fig 4 252 ON Turn the toggle to ON to start the Receiver OFF Turn the toggle to OFF to terminate the Receiver CAUTION Befo...

Page 174: ...eceptacle 4 is incompetent Always keep the water proof cap attached Fuse in the Receiver CAUTION For any tests or replacement of a fuse always turn OFF the Main switch of the Control box before removi...

Page 175: ...A to pull out the fuse 8 from its clips then examine it Fig 4 257 6 Insert a new fuse or the examined fuse to where the one was Insertion of a Fuse After the fuse is examined or replaced restore the...

Page 176: ...result a serious accident due to entry of values in the other mode by mistake Opening A Mode Screen Push the Speed Mode button and Power switch jointly for 2 seconds A message as A MODE appears in the...

Page 177: ...w Setting button The condition obtained in above 1 will be fixed and the display returns to the A MODE screen Loudness Control Available Only for Units with Optional Voice Message Adjust the volume of...

Page 178: ...me in above 1 will be fixed and the display returns to the A MODE screen Low Idling Up CAUTION The low idling rate regulated by this idling up function is valid only during crane operation levers are...

Page 179: ...o the A MODE screen 2 Shift the cursor or using the Hook raising and lowering lever and select EXIT 3 Push the Hook stow Setting button which will terminate the A MODE and turn the mode to the CRANE M...

Page 180: ...ormal signal detector automatically starts first Please allow it for 3 to 4 seconds without using any levers buttons and the Accelerator lever NOTICE For changes between the modes always turn OFF the...

Page 181: ...CD screen for 2 seconds around NOTICE In case that the power is already ON once turn OFF and then push the Power button again for power ON Fig 4 277 Fig 4 278 2 While the Crane mark is shown in the LC...

Page 182: ...of the crane structure In the event where any failure is revealed in such checking repair it or contact us or our sales service agency Checking Before Turning on the Transmitter WARNING For the Check...

Page 183: ...serious hazard Check the connection cable for any cracks damages and or bents or loose connection or damage in the connector section Repair or replace to a new cable where such cracks damages or loose...

Page 184: ...ansmitter Fig 4 292 2 Push the Power switch again to turn ON the Transmitter The Crane mark is displayed in the LCD screen for 2 seconds around Fig 4 293 3 While the Crane mark is shown in the LCD scr...

Page 185: ...in the LCD screen is correct Fig 4 300 Fig 4 301 6 To shift to Extension mode push the Speed Mode button while the LCD screen shows the Ground setting mode Here confirm that the Outrigger Extension mo...

Page 186: ...iver then cause a serious hazard Check the Main switch 2 and Receptacle 4 for the loose conditions or damages Repair immediately when such loose conditions or damages are found Such loose conditions o...

Page 187: ...in such event where the LCD screen in the Transmitter shows an error message or the Monitor display in the Receiver shows an error code Without fail examine the cause of the error and perform appropri...

Page 188: ...sh the Power switch of the Transmitter to power ON 3 Turn ON the Main switch of the Receiver 4 Switch the operation mode to the OUTRIGGER MODE and confirm that Ground setting mode is indicated in the...

Page 189: ...l the outrigger operation levers to Extend lower 10 Use the Speed Mode button to switch to the Ground setting mode Fig 4 319 Fig 4 320 11 Use the Slewing No 1 Outrigger operation lever to the both Ext...

Page 190: ...ch of the Crane 2 See Before Crane Operations on page 4 62 and Crane Operation Posture on page 4 63 to configure the Crane as shown in the figure Fig 4 324 3 Push the Power switch of the Transmitter t...

Page 191: ...area respectively pull the Accelerator lever and check that the Crane follows the lever operation In addition practice a slew around 360 degrees or more to check any abnormal conditions Fig 4 333 13...

Page 192: ...n page 4 106 Cautions Before Operation 1 So that dropping the Transmitter is prevented hook one end of the hook belt 16 to the Transmitter and attach another end to the operator s waist belt or such F...

Page 193: ...For the installation of outriggers always extend them first in the Extension mode then switch the mode to Ground setting mode Lift each outrigger equally and gradually until the Crane is properly elev...

Page 194: ...g 4 345 3 Turn one of the outrigger operation levers to Extend lower and pull the Accelerator lever slowly Fig 4 346 4 When the outrigger is extended to the proper position slowly release the accelera...

Page 195: ...1 In accordance with Procedure in the Operation Mode on page 4 104 enter into the OUTRIGGER MODE Fig 4 350 Fig 4 351 2 Turn one of the outrigger operation levers to Retract upper and pull the Accelera...

Page 196: ...d do not attempt to push more otherwise it may damage the Transmitter and cause its fault it may result a serious accident To toggle each operation lever to the opposite side or to use another lever a...

Page 197: ...on actuate the Accelerator lever carefully and always keep in low speed Also actuate the Accelerator lever slowly and delicately to avoide abrupt slewing Such abrupt acceleration or deceleration espec...

Page 198: ...ached the ground the random wind of the wire rope will happen This may damage the wire rope or shorten its life badly Further there is some risk that the wire rope may bite itself which prevents any m...

Page 199: ...the Hook raising and lowering No 2 outrigger operation lever to Raise upper then pull the Accelerator lever Keep raising the hook until it touches to the over winding detector weight and automatically...

Page 200: ...Contrary when it is required to enhance the maximum speed of the Crane operation the ENHANCED SPEED MODE is also available NOTICE MICRO SPEED MODE is valid only in the CRANE MODE Setting the Micro or...

Page 201: ...able while the 2 in the LCD screen is high lighted Fig 4 369 3 Push the operation lever to be adjusted and pull the Accelerator lever slowly When the operation speed reaches the desired maximum speed...

Page 202: ...mitter or in case of emergency The engine stops Fig 4 372 Engine Start and Reset Procedure Engine Start Procedure CAUTION For the practice of the engine start from the Transmitter Start Reset button t...

Page 203: ...the CRANE MODE of the Transmitter operation mode 2 Use the operation levers and retract the boom to its shortest condition and lower it to the base position then stow the hook 3 Enter into the OUTRIG...

Page 204: ...er before performing inspection and maintenance of the electric system Potential electric shock may occur during work if disregarded Before inspection and maintenance inform all personnel to alert the...

Page 205: ...are not active when the electrical motor is the output source Fuel gauge pre heat monitor engine water temperature monitor engine oil pressure monitor battery charge monitor Engine and Electric Motor...

Page 206: ...r Crane M A E D A 4 130 1 2019 MC405C 3 Power Unit Fig 4 379 1 Rear cover 2 Electric motor 3 Coupling 4 Hydraulic pump Power Supply Box Fig 4 380 1 Power supply box 2 Power supply box door 3 Door hand...

Page 207: ...ELECTRIC MOTOR OPTION 1 2019 MC405C 3 4 131 Inverter Unit Fig 4 381 1 Rear cover 2 Protective cover 3 Inverter unit 4 Main breaker with a leak detector 5 DC12V power switch 6 AC circuit power switch...

Page 208: ...y of power to the electric motor and Inverter unit ON Power is supplied OFF No power is supplied The overvoltage ground fault indication button 2 on the cover is designed to eject in the event of an o...

Page 209: ...White The power lamp is designed to indicate the presence of energisation to this machine from power supply equipment Fig 4 385 ON This machine is deriving power from power supply equipment OFF This...

Page 210: ...this machine Power supply voltage V Power current A Power supply frequency Hz 380 400 15 50 A cabtyre cable must adhere to the specifications of this machine AC 380 400V Motor voltage V Cable spec sq...

Page 211: ...he cabtyre cable must be properly connected to the PE terminal on the terminal block Inverter driven three cables 9 other than the ground cable are capable of being connected to any of L1 L2 and L3 te...

Page 212: ...eck is necessary after motor warm up Keep the hook block away from the boom to avoid interference and collision Exercise caution to keep the boom from contact with an operator and this machine when sl...

Page 213: ...p to come ON in red Contact us or our sales service agency 6 Use the following procedure for checking the power unit if an abnormal noise odour or vibration is present in and around the power unit Fig...

Page 214: ...crews 11 and remove the protective cover 10 Fig 4 400 3 Turn OFF the main breaker 1 Fig 4 401 4 Replace the protective cover 10 to the original position and securely tighten four mounting screws 11 5...

Page 215: ...unting bolts using the specified torque to keep the searcher hook from falling when it is being attached Keep fingers out of the pin holes at all times The position pins must always be secured using l...

Page 216: ...EARCHER HOOK COMPONENTS OPTION Fig 4 404 1 E Boom 2 Bracket 3 Bracket 1 4 Bracket 2 5 Pin 6 Position pin 7 Lynch pin 8 Hook 9 Shackle 10 Hexagonal bolt with washer strength 10 9 11 Hexagonal bolt with...

Page 217: ...g LED Red 10 Load capacity display Yellow 11 Actual load display 12 Rated total load display 13 Working radius display 14 Working radius upper limit switch Setup cancel 15 Working radius upper limit L...

Page 218: ...actual searcher hook offset position and display of boom length windows do not match Without setting moment limiter to the actual searcher hook offset position moment limiter may not work properly an...

Page 219: ...Mini Crawler Crane M A E D A Section 4 850 kg SEARCHER HOOK MOMENT LIMITER DISPLAY 1 2019 MC405C 3 4 143 Searcher Hook offset position and mode display in boom length window Fig 4 409...

Page 220: ...lts to the designated tightening torque To install searcher hook always use new genuine Maeda bolts nuts and washers 3 Using fall mode option selector switch 24 set moment limiter to 850 kg searcher h...

Page 221: ...ove lynch pin 11 from the tip of position pin 10 and remove the position pin 10 Fig 4 416 8 Move E boom 7 to the required angle for the work and line the holes 1 in the E boom 7 Fig 4 417 DANGER E boo...

Page 222: ...achine tipping and could cause a serious accident 11 Attach the load securely to the hook 12 and start operations Fig 4 421 DANGER When hoisting a load in 850 kg searcher hook mode raise boom to hoist...

Page 223: ...by entering overload area by boom lowering or boom extending operation recover from the overload area by retracting boom or lifting boom by keeping the boom lift bypass switch to ON side NOTICE When w...

Page 224: ...over winding detector of the fly jib is operational before starting work In the event that the over winding detector mis functions it may cause the hook or hoisted load to drop resulting in a serious...

Page 225: ...etector 7 Sheave 8 Protective rope 9 Protective Weight 10 Single fall hook block 11 Wire rope 12 Hook holder 13 Cord real 14 Hoot pin 15 Jib bracket 16 Stowing bar 17 Position pin 150L 18 Position pin...

Page 226: ...may cause the fly jib to drop resulting in a serious hazard Whenever Fly jib is installed always extend the jib to second stage The working radius and lifting height indication of fly jib mode moment...

Page 227: ...cedures to remove wire rope connected to hook block CAUTION Take care to avoid the wire rope winding randomly Avoid unwinding after the hook is grounded otherwise it will make the wire rope wind rando...

Page 228: ...Lift up No 1 Fly jib 4 tip to take it out from stow stay then slew it around the position pin 17 length 150mm on the right side of the head of main boom Fig 4 435 10 Lace the wire rope 11 which pulled...

Page 229: ...36 out from position pin 21 which fixing two supporting rods 3 then pull out position pin 21 length 135mm Fig 4 441 NOTICE The position pin 21 which you pulled out will be used later to connect suppor...

Page 230: ...4 446 22 Slide the storage bar 16 to the back edge side of the main boom Fig 4 447 NOTICE Slide storage bar 16 until stopper 30 of storage bar 16 hit the bar guide B 24 and put the hole of stopper 30...

Page 231: ...ck 12 on the bottom of No 1 Fly jib 4 or guide sheave 7 on the head of No 2 Fly jib 5 Fig 4 452 2 Use shackle 46 to attach two over winding detector ropes 8 length 700mm and weight 9 to over winding d...

Page 232: ...ted extension cord 43 please confirm that wiring is not strained If wiring is strained strongly it will cause wiring to snap Before crane operation regularly raise hook to confirm whether hook will st...

Page 233: ...CE Insert storage bar 16 into the head of No 1 Fly jib bracket 38 and put position of the hole on the head of storage bar 16 and bracket 38 together 9 Insert position pin 17 length 150mm into the hole...

Page 234: ...sert position pin 20 length 135mm into the hole on the upside of No 1 Fly jib bracket 15 and lock position pin 20 firmly by lynch pin 36 NOTICE Supporting rod 3 is composed of two rods Move the rod on...

Page 235: ...direction of the head of No 1 Fly jib 4 put the hole of the stopper 30 on the storage bar 16 and No 1 Fly jib 4 together 24 Insert position pin 18 into the hole of stopper 30 on the storage bar 16 the...

Page 236: ...ng connection of wiring over winding detector will not work and may drop the hook or load and result in a serious hazard Before crane operation always raise hook to confirm whether hook will stop auto...

Page 237: ...is to attach the wire rope to 4 fall hook block Fig 4 481 1 Take up wire rope to winch operation 2 Accommodate the type of hook block single to 4 fall hook lace wire rope to load sheave hook block she...

Page 238: ...t from position pin 18 inserted at storage bar 16 then pull out position pin 18 length 55mm Fig 4 485 2 Move No 1 Fly jib 4 and storage bar 16 to the direction of head of the main boom Fig 4 486 NOTIC...

Page 239: ...sher on each bar guide and between main booms Installation of Fly Jib Assembly NOTICE This section is an explanation of Fly jib attachment to the machine Use crane to attach Fly jib WARNING Always sto...

Page 240: ...firmly until bar guide C 25 is attached 4 Set bar guide C 25 into bar guide A 23 and tighten it by four attachment bolts 61 and plural washers 62 5 Set bar guide D 26 into bar guide B 24 and tighten...

Page 241: ...497 9 Tighten two attachment bolts 63 and plural washers 64 on bar guide A 23 10 Insert storage bar 16 into bracket 38 to put the hole position together 11 Insert position pin 17 into bracket 38 then...

Page 242: ...17 Slide No 1 Fly jib 4 and storage bar 16 to the head of No 1 Fly jib 4 then put the hole on stopper 30 of storage bar 16 and No 1 Fly jib 4 together 18 Insert position pin 18 into the hole on the s...

Page 243: ...h 6 Boom angle lower limit LED Orange 7 Boom angle lower limit switch 8 Load factor LED Changes to green yellow and red 9 Over winding detection LED Red 10 Load capacity display Yellow 11 Actual load...

Page 244: ...eration under conditions that moment limiter s load capacity display indicates 90 or higher must only be practiced carefully in decelerated mode with low engine revolutions If engine is in high revolu...

Page 245: ...le is within this range indicator below on moment limiter display will flash Boom angle lower limit LED 6 At the same time the warning buzzer beeps to warn the operator and others that the boom is rea...

Page 246: ...nd Rated load display 12 as it indicates in case of boom angle lower limit range Fig 4 507 DANGER For stowing fly jib main boom could be lowered to the angle less than 55 and extended under the condit...

Page 247: ...ed Both manual operation lever and remote control are available also as normal operation However main boom angle and length is restricted for fly jib operation Rated total load for fly jib operation i...

Page 248: ...ng in such a configuration is prohibited because Rated load display 2 of moment limiter only indicates E J TRANSPORTATION Observe the related laws and regulations and transport the machine safely Tran...

Page 249: ...he ramp before correcting the direction Be slow when operating to change the direction on the truck platform where the footing is unstable After loading the machine apply the wood blocks so that the m...

Page 250: ...when placed the angle from the track is 15 degrees or less Has the width no narrower than the rubber tracks Has the thickness and strength that can fully withstand the mass of the machine Be sure to...

Page 251: ...hments such as wire rope and shackle used in hoisting shall be sufficiently strong for the weight of this machine When hoisting the machine always put the machine in the travelling posture and securel...

Page 252: ...icking cylinder 4 when the machine is hoisted Fig 4 526 NOTICE Recommended hoisting attachments Wire ropes two in front breaking force of 9 0 t or more Wire ropes two in back breaking force of 9 0 t o...

Page 253: ...1 2019 MC405C 3 5 1 Section 5 MAINTENANCE AND INSPECTION...

Page 254: ...chine and prevent rubbish from entering the machine and make sure the safety will be ensured during maintenance Attempt to inspect or maintain with the maintenance machine still dirty not only lessens...

Page 255: ...nd fully retract and lower the boom and stop the engine Operate each of the crane operation levers forward backward several times to relief the pressure remaining in the hydraulic circuits Apply pawls...

Page 256: ...instance an engine maintenance Work by at Least Two Persons during Maintenance with Engine Running Fig 5 8 To prevent accidents do not attempt maintenance when the engine is running Always observe th...

Page 257: ...d a helmet on and insert a copper bar or similar object between the hammer and the target when hitting Giving impact to a hard metal part such as a pin or a bearing may cause the broken chip to enter...

Page 258: ...a damaged hose or loosened bolt is found abort working and ask us or our sales service agency for a repair Replacement of high pressure hose requires experienced skill In addition the tightening torqu...

Page 259: ...ection maintenance item or failure to check the function and operation of the maintained part may cause an unexpected fault which may result in bodily accidents Always observe the followings Checks wi...

Page 260: ...iner to lubricate if it is attached to the lubrication opening Protect Oil from Impurities Avoid dust when inspecting and replacing the oil to keep impurities out of the oil Attach a Warning Tag When...

Page 261: ...different type of oil Always use Maeda genuine parts for part replacement BASIC MAINTENANCE Oil Handling Oil is used under extremely harsh conditions high temperature high pressure in the engine and...

Page 262: ...bed in the Periodic Maintenance chapter is used for overhauls which requires no grease replenishment Grease the nipple if a long term use hinders its smoothness Wipe off old grease squeezed out after...

Page 263: ...utions should be observed when performing inspection and maintenance of hydraulic equipment Place the machine in travel position on a level surface to inhibit the application of pressure to the cylind...

Page 264: ...stop or sudden steering When the breaking in period reaches 50 hours do not fail to change the engine oil For more information see Initial 50 Hour Maintenance on page 5 40 The metal powder produced i...

Page 265: ...bers when ordering parts List of Consumables Item Replacement cycle Engine oil filter Every 500 hrs initial 50 hrs Fuel filter Every 500 hrs Hydraulic oil return filter Every 500 hrs initial 50 hrs Hy...

Page 266: ...engine with temperature at 0 C or below despite rise in diurnal temperature to approx 10 C Be sure to use our recommended abrasion resistant hydraulic oil for the hydraulic oil system ISO VG46 and VG...

Page 267: ...4 43 12 19 65 5 6 70 57 0 75 3 5 85 7 70 14 22 104 10 6 90 4 120 9 2 12 2 16 24 163 16 6 142 187 14 4 19 1 18 27 224 22 8 195 258 19 8 26 2 20 30 318 32 4 277 366 28 2 37 3 22 32 432 44 0 376 497 38 3...

Page 268: ...4 84 4 24 36 915 93 3 778 1050 79 3 107 27 41 1340 136 1140 1540 116 156 30 46 1820 185 1550 2090 157 213 33 50 2470 252 2100 2840 214 290 36 55 3180 324 2700 3660 275 373 Other Bolts Nominal Size Mar...

Page 269: ...torque values shown in the following table Determine the appropriate tightening torque based on the hose connector width across flats a Fig 5 22 Hose No Width Across Flat Mark a Target value Tolerance...

Page 270: ...iggers to an angle to allow removal of the machinery covers 2 Remove the 11 retaining bolts 3 from the left hand machinery cover 1 and right hand machinery cover 2 Fig 5 23 NOTICE One retaining bolt a...

Page 271: ...ntenance inside the rear cover 1 Remove the eight retaining bolts 2 from the rear cover 1 Fig 5 24 2 Remove the rear cover 1 Installing Rear Cover Once inspection and maintenance inside the rear cover...

Page 272: ...ne The fuse box is provided at the lower section of the instrument panel Check and replace a fuse using the procedure below 1 Remove the buckle 2 of the cover 1 at the bottom of the instrument panel t...

Page 273: ...se Box on page 5 30 Check Outrigger Display Operation See Check Outrigger Display on page 5 30 Adjust Operation Seat See Adjust Operation Seat on page 5 31 Post Start After Starting Engine Check Adjus...

Page 274: ...e fuel hose or fuel hose connections Buildup of combustibles and oil leakage around the hot engine section such as engine and muffler and around the battery can cause fire in the machine Carefully che...

Page 275: ...Check the wire ropes for damage deformation wear twists kinks corrosion etc If you find any abnormality replace Check the bound condition of the wire rope ends If you find any loosened wire rope end r...

Page 276: ...around the battery for the buildup and deposit of combustibles such as dead leaves paper wastes dust oil and grease If there is any remove them Check the starter alternator around battery and similar...

Page 277: ...causing burns CAUTION For more information on the which oil to be used see LUBRICATING OIL on page 5 14 Using other oil than those specified may shorten the life of the engine Be sure to refill with t...

Page 278: ...full around F Fig 5 36 3 If the fuel level is low remove the tank cap F on the top of the fuel tank and refuel from the filler opening while watching the fuel gauge Fig 5 37 4 After refuelling turn t...

Page 279: ...ulic Oil WARNING The oil may spout out when the cap of the hydraulic oil tank is removed Turn the cap slowly to let the inner pressure escape before removing Do not refill with the oil to the level hi...

Page 280: ...illed up to the centre of the site gauge G Fig 5 42 3 If there is not sufficient oil refill with the gear oil using the following procedure Fig 5 43 1 See OUTRIGGER SETTING on page 4 42 to rotate the...

Page 281: ...he knob on the dust indicator 1 to return the red piston to its original position Fig 5 46 5 Reattach the machinery cover as described in Installing Machinery Cover on page 5 18 Check Battery Charge L...

Page 282: ...ilot lamp of the switch section and the working light on front of the machine lights up Fig 5 51 Check Fuse Box WARNING If fuses are brown frequently or if you find the trace of a short circuit create...

Page 283: ...adjusting the angle when reclining the backseat backward 1 While pushing the reclining adjusting lever 2 forward set the backseat to the desired angle 2 Release your hand from the reclining adjusting...

Page 284: ...ibed below Working with the loose rubber track the tension of the rubber track at 15 mm or more will cause run off or early wear of the core metal Loose Tension Increase Tension Have a grease gun pump...

Page 285: ...rawlers again for about 50mm from the ground 3 Tighten the grease valve 1 4 Perform the tension check of the rubber track If the tension is not appropriate make another adjustment 5 See OUTRIGGER STOW...

Page 286: ...the cover 7 of the outrigger tray 6 and check if there is any foreign object engaged in the bending section Fig 5 66 6 Operate one of the four outrigger grounding switches 5 to ON position and raise...

Page 287: ...trigger extension switch is pushed down to the OUT position Also verify that the inner box retracts smoothly when the outrigger extension switch is pushed down to the IN position Fig 5 71 Fig 5 72 Whe...

Page 288: ...4 is operated to LOWER side push forward When doing the above check for any abnormal sound emitted by part of the boom or from the boom derrick cylinder If there is any abnormality repair Fig 5 76 3...

Page 289: ...the moment limiter immediately contact us or our sales service agency 1 Turn the starter switch to the ON position 2 Check with the working status lamp The red of the lamp lights up for 2 seconds and...

Page 290: ...81 NOTICE Look to the sticker MID MAX affixed to the top of the inner box when adjusting the outrigger extension Fig 5 82 Fig 5 83 Check Engine Exhaust Gas Colour Noise and Vibration 1 Leave your foot...

Page 291: ...case 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 Replace oil in travelling motor reduction gearcase X X...

Page 292: ...eplace Oil in Hydraulic Oil Tank on page 5 51 Replacement Hydraulic Oil Return Filter See Replace Hydraulic Oil Return Filter on page 5 48 Replacement Hydraulic Oil Suction Filter See Replace Hydrauli...

Page 293: ...ng cylinder rod 4 places 7 Greasing of the slewing gear 2 places 8 Greasing of the hook block 1 place 9 Greasing of the boom slide plate 8 places Neo grease grease for boom 10 Greasing of both sides a...

Page 294: ...Section 5 PERIODIC MAINTENANCE Mini Crawler Crane M A E D A 5 42 1 2019 MC405C 3 Fig 5 85...

Page 295: ...ecurely tighten the plug after refilling with the oil Hexagonal wrench for plug removal 8mm 1 Place the machine on a level surface 2 See OUTRIGGER SETTING on page 4 42 to rotate the rotary of the outr...

Page 296: ...ging the fins Fig 5 89 4 After cleaning reattach the machinery cover as described in Installing Machinery Cover on page 5 18 Check Adjust Belt Tension Tension Check 1 Remove the machinery cover as des...

Page 297: ...Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil 1 Move the machine forward and backward to position it immediately a...

Page 298: ...ays use the specified oil for replenishment The engine oil must be maintained at a proper amount The complete draining of oil is disabled if the engine becomes cold completely Oil draining is allowed...

Page 299: ...G Fig 5 97 16 Attach the oil level gauge G and filler cap F properly upon completion of oil replacement 17 Start the engine and idle it for 5 minutes Stop the engine 18 Make sure again the oil level...

Page 300: ...filter Oil replenished should remain below H upper limit on the level gauge Excessive oil replenishment may cause the oil to gush from the air breather during machine travelling and crane operation wh...

Page 301: ...it on the level gauge Excessive oil replenishment may cause the oil to gush from the air breather during machine travelling and crane operation which could result in burns Keep impurities out of the f...

Page 302: ...ring side M20 25 363 to 392 Nm 2 Bearing outer ring side M18 10 235 to 265 Nm Fig 5 102 Inspect the inner ring mounting bolts 2 as follows 1 Remove the two mounting bolts 4 and remove the inspection...

Page 303: ...be supplied at excessive amount The engine must be at halt until piping and hydraulic equipment is filled with oil after replacement of the hydraulic oil filter Oil replenished should remain below H...

Page 304: ...n to be placed under the machine for draining oil If the machine becomes unstable and wobbles insert supports under the front and back of the machine to gain stability CAUTION For more information on...

Page 305: ...o be used see LUBRICATING OIL on page 5 14 Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil Oil drain pan A 1 litre co...

Page 306: ...ATING OIL on page 5 14 Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil Oil drain pan A 1 litre container Quantity of...

Page 307: ...hat the surface temperature of the radiator cap 5 is as low as can be touched with a bare hand and slowly turn it until it comes into contact with the stopper to relieve the internal pressure Fig 5 11...

Page 308: ...he explosion hazard Do not put fire such as cigarettes close to the battery or take any actions that can cause sparks The battery fluid is diluted sulfuric acid which corrodes clothes and skin Should...

Page 309: ...as soon as possible Wipe with a wet clean cloth when cleaning the battery upper surface or related part Do not use organic solvent or detergent for instance gasoline or paint thinner If the battery f...

Page 310: ...e to suit the voltage of the battery to charge Mistake in adjusting the voltage may cause explosions due to overheat and ignition of the charger Securely fix the charge clip of the charger to the term...

Page 311: ...achine when disconnecting the booster cable Fig 5 125 Fig 5 126 WARNING Start the engine by two persons with one standing on the operation position in the travel operation panel side When starting usi...

Page 312: ...ever is at the lock position 1 Verify that the clips are securely connected to the battery terminals 2 Start the engine of the normal machine and increase the engine speed to full speed highest speed...

Page 313: ...the rubber blocks such as steel plates U shaped gutters corners of bricks corners of sheer broken stones and rocks reinforcing steels and iron scraps are not covered by warranty Dos and Don ts The fol...

Page 314: ...chine perpendicular to the step when going over it Going over the step diagonally may result in the rubber tracks coming off Fig 5 136 The rubber tracks slip very easily on a wet steep plate or snowed...

Page 315: ...se tension will allow the rubber tracks to come off Fig 5 141 Inspection of Rubber Tracks CAUTION Contact us or our sales service agency for determining whether to replace repair or keep the rubber tr...

Page 316: ...urn of the tension adjusting grease valve is allowed to loosen The grease valve may pop out if disregarded Always stand aside when conducting tension adjustment of the grease valve to circumvent poten...

Page 317: ...Tension on page 5 31 7 Ensure that adequate engagement and tension of the rubber track sprocket and idler are obtained 8 See OUTRIGGER STOWING on page 4 49 to stow the outriggers and lower the machin...

Page 318: ...e deformation or corrosion is developed A faulty end socket is used Winch Wire Rope Correcting Twisted Rope WARNING Be sure to wear a pair of thick leather working gloves when handling wire ropes CAUT...

Page 319: ...pe into the winch drum with some tension applied to the rope 10 Repeat the above procedure until the hook is no more twisted If the wire rope is still twisted after performing the procedure above chan...

Page 320: ...lly immediately after attaching a new rope Repeat raising and lowering the hook several times until the new rope conforms The wire rope is coiled Exercise caution not to form a kink in the rope when w...

Page 321: ...wedge socket 3 2 With the rope wedge 7 in position a yank at the wire rope 5 in the direction indicated by the arrow 6 Attach the rope clip 4 to the wire rope 5 7 Secure the wedge socket 3 to the boom...

Page 322: ...elescoping cylinder top and turn adjustment bolt 9 of the boom extending wire clockwise right The boom extending wire rope 8 is adjusted to the correct tension if boom No 5 extends upon rotating the a...

Page 323: ...s retracted in a horizontal position extend the telescoping booms approx 2m Fig 5 176 2 Retract the booms completely Boom stowing is required Measure clearance a to check the following for proper adju...

Page 324: ...4 Provide retightening to both adjusting bolt 9 of the boom No 5 extending wire rope 8 and secure it with the lock bolt 6 Fig 5 180 6 Install the cover 2 to the boom end with the three mounting bolts...

Page 325: ...ong the fold Blow compressed air on the outside of the element along the grooves and re blow the air on the inside Fig 5 185 7 Check the inside of the element by illuminating with a light bulb and if...

Page 326: ...varies with temperature a volumetric proportion of 30 at a minimum is required Even in areas where anti freezing is not needed use the super coolant at a minimum proportion of 30 to prevent corrosion...

Page 327: ...ant 6 After draining close the drain plug 4 and inject tap water when the radiator is filled with water start the engine put it in low idling state raise the water temperature to 90 C and run it for a...

Page 328: ...to drain fuel keeping from contact with draining fuel Fig 5 193 NOTICE Remove the fuel tank cap F if normal or smooth fuel draining fails Fig 5 194 5 Put in the drain plug P and secure it upon comple...

Page 329: ...5 clockwise right to tighten it 7 Set the fuel lever 4 to a vertical position Open position NOTICE Wipe off fuel completely if spilled 8 Use the following procedure for air bleed of the fuel system 1...

Page 330: ...rge the battery at the same time After Storage WARNING If you did not perform antirust operation monthly during the long term storage contact us or our sales service agency before using the machine Pe...

Page 331: ...down In this condition the battery fluid can freeze with low battery charging rate Keep the charging rate as close to as 100 Keep the battery warm in order to start the engine next morning Cautions Af...

Page 332: ...ng raising lowering and slewing the boom Contact us or a our sales service agency to request inspection and repair service as needed Consumables Parts for mounting searcher hook are consumable items R...

Page 333: ...ry 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 82 Check Greasing See...

Page 334: ...on bolt If any abnormality is found change the bolt for a new one even it is earlier than expected bolt life Position Pin and Lynch Pin Check if position pin is surely secured with lynch pin Pre Start...

Page 335: ...hine does not auto stop by overloading immediately stop the operation and perform recovery operation caused by overloading NOTICE When measuring actual working radius measure from hook offset position...

Page 336: ...efore Starting Engine Check Boom and Frame See Boom and Frame on page 5 85 Check Wire Ropes See Wire Ropes on Page 5 85 Check Fly jib Fix Bolts See Fly jib Fix Bolts on page 5 85 Check Electrical Wiri...

Page 337: ...ing Fuse Box WARNING If fuses are brown frequently or if you find the trace of a short circuit created in the electrical wiring be sure to find the cause and fix the problem Check the fuse at the lowe...

Page 338: ...iter Crane motion and moment limiter indication Value of moment limiter Boom is extended to 13 0m or longer then lowered Check boom angle indication when rated load display shows E J 55 Boom is extend...

Page 339: ...250 Hours Greasing Machine Units CAUTION Grease type varies with greasing points Failure to grease properly may cause the machine to shorten its useful life See the following table for grease types Gr...

Page 340: ...ied oil level Clean Rubber tracks coming off Abnormal wear on the sprockets Rubber tracks too loose See Check Adjust Rubber Track Tension on page 5 31 and adjust the tension Outriggers cannot operate...

Page 341: ...change the filter Check and repair Electrical Components Problem Major Cause s Actions Dark light even at highest engine speed Defective wiring Check and repair slackened terminals and open circuits...

Page 342: ...trol system has a failure Otherwise when the Crane does not operate perform the diagnosis of the Crane itself Power of the Transmitter and Receiver is ON Turn ON the power when not The fuse in the Rec...

Page 343: ...error Relay PCB in the Crane side defective Wiring failure between the communication PCB and the Moment limiter display panel The Moment limiter display panel defective Power ON again the Transmitter...

Page 344: ...ers and push the Reset button Maintenance replace The Transmitter internal Devices defective Data error in the memory Power on the Transmitter again Maintenance replace Breaking of wire for telescopic...

Page 345: ...is lower than the specified value Check the installation of the length detector E4H The input to length detector is higher than the specified value EAD The AD converter at the converter section is no...

Page 346: ...Replace the cabtyre cable with one adhering to specifications An abnormal noise and vibration are present in the power unit during operation A break in motor winding Looseness in the motor and pump fi...

Page 347: ...3 OPERATION MANUAL Document No 104ME OM1901 00 First edition January 7 2019 Maeda Seisakusho Co Ltd 1095 Onbegawa Shinonoi Nagano Nagano 388 8522 Japan No part of this manual can be reproduced in any...

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