Maeda MC815C Service Manual Download Page 227

5-23 

8.3 RATED TOTAL LOAD CHART

 

CAUTION 

The rated total load includes hook block mass (20 kg). 

When the fly jib is used, the available range and the rated total load vary depending on the 
outrigger extension, the fly jib angle and the number of boom sections. Check the available range 
in the rated total load chart before operating. 

Hoisting operation is not possible when the main boom angle is less than 50 degrees.

 

 
When outrigger is extended to the maximum 

Unit: kg 

 
At intermediate outrigger extension 

Unit: kg 

 
At minimum outrigger extension 

Unit: kg 

 

 The rated total load chart represents the load including the mass of hanging tools (mass of one hanger 

hook: 20 kg). 

 

Main boom 

Angle 

One jib section 

Two jib sections 

0°  20° 40° 60°  0°  20° 40° 60° 

80°  1520 820 720 620 1020 620 420 320 
70°  1020 620 520 420 820 420 320 220 
60° 420 

420 

320  320 

220 

120  

50° 170 

120  

 120  

 

 

Main boom 

Angle 

One jib section 

Two jib sections 

0°  20° 40° 60°  0°  20° 40° 60° 

80°  1520 820 720 620 1020 620 420 320 
70°  1020 620 520 420 820 320 120   
60° 120  

 

 

 

 

 

 

50° 

 

 

 

 

 

 

 

 

Main boom 

Angle 

One jib section 

Two jib sections 

0°  20° 40° 60°  0°  20° 40° 60° 

80°  1520 820 720 620 1020 620 420 320 
70° 720 

120  

 520  

 

 

60° 

 

 

 

 

 

 

 

 

50° 

 

 

 

 

 

 

 

 

Summary of Contents for MC815C

Page 1: ...list in the Service Manual are for use for servicing such as disassembling and assembling The parts and part numbers are subject to change without prior notice due to continuous machine improvement an...

Page 2: ......

Page 3: ...15 6 4 SINGLE FALL 1 18 7 WORKING RADIUS LIFTING HEIGHT 1 21 8 WORKING RADIUS AND HOISTING HEIGHT TRAVELLING WITH HOISTED LOAD 1 22 STRUCTURE AND MAINTENANCE PROCEDURE 2 1 1 ENGINE AND COOLING RELATED...

Page 4: ...RNAL VIEW 2 35 4 7 2 CRANE CONTROL VALVE CONNECTION DESTINATIONS 2 36 4 7 3 CRANE CONTROL VALVE CIRCUIT DIAGRAM 2 36 4 7 4 CRANE CONTROL VALVE LAYOUT 2 37 4 7 5 CRANE CONTROL VALVE SPECIFICATIONS 2 37...

Page 5: ...LY 2 61 4 16 1 SLIDE CYLINDER EXTERNAL VIEW 2 61 4 16 2 SLIDE CYLINDER CONNECTION DESTINATIONS 2 62 4 16 3 SLIDE CYLINDER SPECIFICATIONS 2 62 4 17 OR SELECT VALVE 2 63 4 18 OIL COOLER 2 64 4 19 RETURN...

Page 6: ...CABIN 2 126 8 4 1 LED LIGHT 2 126 8 4 2 SURVEILLANCE CAMERAS 2 127 8 5 SENSORS 2 128 8 5 1 PRESSURE AND OIL TEMPERATURE SENSORS 2 128 8 5 2 INCLINATION SENSOR 2 129 8 5 3 FUEL SENDER ASSEMBLY 2 130 8...

Page 7: ...2 REMOTE CONTROLLER 3 11 3 3 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER 3 12 3 4 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER 3 13 4 PRINCIPAL SPECIFICATIONS LIST 3 14 5 SERVICE LOCATIONS 3 15...

Page 8: ...D TRANSDUCER 5 14 5 2 LENGTH METER REEL FLY JIB MOUNTED 5 15 5 3 ANGLE DETECTOR FLY JIB MOUNTED 5 16 5 4 LENGTHGAUGEREEL MAINBOOMMOUNTED COMMONTOBOOMLIGHTSPECIFICATIONS 5 18 6 FLY JIB ELECTRICAL CIRCU...

Page 9: ...CHECKING ADJUSTING MAIN BOOM TELESCOPING WIRE ROPE 7 13 4 1 CHECKING THE BOOM TELESCOPING WIRE ROPE 7 13 4 2 ADJUSTING THE BOOM TELESCOPING WIRE ROPE 7 14 REFERENCE VALUES 8 1 1 TABLE OF ENGINE RELAT...

Page 10: ...0 8 This Page Intentionally Left Blank...

Page 11: ...DRAWING OF OUTRIGGER WIDTH 1 3 3 PRINCIPAL SPECIFICATIONS LIST 1 4 4 COMPONENT MASS LIST 1 7 5 OIL AND WATER QUANTITIES LIST 1 8 6 RATED TOTAL LOAD CHART 1 8 7 WORKING RADIUS LIFTING HEIGHT 1 21 8 WOR...

Page 12: ...1 2 1 EXTERNAL VIEW 1 1 STANDARD SPECIFICATIONS 1 2 SEARCHER HOOK SPECIFICATIONS...

Page 13: ...1 3 1 3 FLY JIB SPECIFICATIONS 2 DIMENSIONAL DRAWING OF OUTRIGGER WIDTH...

Page 14: ...m Type Swing bearing support hydraulic motor driven Reducer worm spur gear reduction Brake worm self lock Slewing angle Time 360 continuous 2 5 min 1 Outrigger system Type Extension grounding hydrauli...

Page 15: ...ime 360 continuous 2 5 min 1 Outrigger system Type Extension grounding hydraulic cylinder direct acting type with hydraulic automatic locking device Max extended width left to right Front 6300 mm Rear...

Page 16: ...wer OFF device Auto power off device Transmitter stop function when battery capacity decreases Alarm switch Transmitter voltage Battery BA405000 6 VDC 1500 mAh Receiver voltage Power of crane main bod...

Page 17: ...1 155 0 60 0 8 8 Rotary centre joint 47 4 Track frame assembly with track shoe Track frame Carrier roller Track roller Idler cushion assembly with recoil spring Idler assembly Sprocket Traveling motor...

Page 18: ...temperature Be sure to use our recommended abrasion resistant hydraulic oil for the hydraulic oil system ISO VG32 is used when the product was shipped For adjustment of antifreeze concentrations in co...

Page 19: ...90 3390 3 00 6390 6390 6390 6390 4690 4690 3390 3390 3 50 5490 5490 5490 5490 4690 4690 3390 3390 2390 2390 4 00 4790 4790 4790 4790 4690 4690 3390 3390 2390 2390 4 50 4190 4190 4190 4190 4090 4090 33...

Page 20: ...6290 4590 4590 3290 3290 3 00 6290 6290 6290 6290 4590 4590 3290 3290 3 50 5290 5290 5290 5290 4590 4590 3290 3290 2290 2290 4 00 4590 4590 4590 4590 4590 4590 3290 3290 2290 2290 4 50 3990 3990 3990...

Page 21: ...90 3090 3090 3 00 6190 6190 6190 6190 4590 4590 3090 3090 3 50 5290 5290 5290 5290 4590 4590 3090 3090 2190 2190 4 00 4590 4590 4590 4590 4590 4590 3090 3090 2190 2190 4 50 3990 3990 3990 3990 3990 39...

Page 22: ...390 3390 3 00 6090 6090 6090 6090 4690 4690 3390 3390 3 50 5490 5490 5490 5490 4690 4690 3390 3390 2390 2390 4 00 4790 4790 4790 4790 4690 4690 3390 3390 2390 2390 4 50 4190 4190 4190 4190 4090 4090 3...

Page 23: ...290 3290 3 00 6090 6090 6090 6090 4590 4590 3290 3290 3 50 5290 5290 5290 5290 4590 4590 3290 3290 2290 2290 4 00 4590 4590 4590 4590 4590 4590 3290 3290 2290 2290 4 50 3990 3990 3990 3990 3990 3990 3...

Page 24: ...90 3090 3090 3 00 6090 6090 6090 6090 4590 4590 3090 3090 3 50 5290 5290 5290 5290 4590 4590 3090 3090 2190 2190 4 00 4590 4590 4590 4590 4590 4590 3090 3090 2190 2190 4 50 3990 3990 3990 3990 3990 39...

Page 25: ...090 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2390 2390 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2390 2390 4 50 3090 3090 3090 3090 3090 3090 3...

Page 26: ...090 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2290 2290 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2290 2290 4 50 3090 3090 3090 3090 3090 3090 3...

Page 27: ...90 3090 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2190 2190 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2190 2190 4 50 3090 3090 3090 3090 3090 30...

Page 28: ...0 1520 1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 152...

Page 29: ...1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 1520 1520...

Page 30: ...1520 1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 1520...

Page 31: ...1 21 7 WORKING RADIUS LIFTING HEIGHT...

Page 32: ...the machine from overturning 1 Do not travel on slopes soft ground or ground that is not flat 2 Do not perform slewing operations Avoid performing sudden operations when stopping or starting 3 When t...

Page 33: ...LATED COMPONENTS 2 2 2 POWER TRANSMISSION SCHEMATIC DIAGRAM 2 10 3 UNDERCARRIAGE AND FRAME 2 12 4 HYDRAULIC UNITS 2 22 5 WORK EQUIPMENT 2 86 6 ELECTRIC CIRCUIT DIAGRAMS 1 3 3 3 2 91 7 ELECTRICAL EQUIP...

Page 34: ...2 2 1 ENGINE AND COOLING RELATED COMPONENTS 1 1 ENGINE SPECIFICATIONS 106 2187500...

Page 35: ...nders cylinder inside diameter stroke 4 88 90 mm Total displacement 2 189 L Rated output 30 5 KW 2 500 rpm Maximum torque 135 Nm Approx 1 600 rpm Fuel consumption rate at rated point 239 g KWh Maximum...

Page 36: ...2 4 1 2 ENGINE MOUNT 106 1186900...

Page 37: ...2 5 1 3 PTO Power Take Off 106 2179100...

Page 38: ...2 6 1 4 COOLING SYSTEM 106 1186900...

Page 39: ...2 7 106 1186900...

Page 40: ...2 8 1 5 FUEL LINE 106 2187400...

Page 41: ...2 9 1 6 FUEL TANK Specifications Tank capacity L 70 106 2186800...

Page 42: ...2 10 2 POWER TRANSMISSION SCHEMATIC DIAGRAM 2 1 HYDRAULIC SYSTEM DIAGRAM MC815C...

Page 43: ...ania EP2 Showa Shell Quantity of injected grease cc 360 Greasing swing circle Use a grease gun to inject grease through the grease plugs marked with arrows 7 in the right hand figure 106 1188300 Slewi...

Page 44: ...2 12 3 UNDERCARRIAGE AND FRAME 3 1 TRACK FRAME 106 1189300...

Page 45: ...2 13...

Page 46: ...DLER CUSHION Specifications Item Reference values L Grease application No 2 lithium grease P Quantity of grease cc 120 Spring mounting length mm 226 Mounting load kgf 5323 Spring free length mm 269 S1...

Page 47: ...2 15 3 3 IDLER Specifications Item Reference values Allowable limit Oil type 85W 90 Oil quantity cc 70 Outer diameter mm 374 Tread outside diameter mm 335 326 Tread width mm 75 70 S106W3555000...

Page 48: ...2 16 3 4 TRACK ROLLER Specifications Item Reference values Allowable limit Oil type 85W 90 Oil quantity cc 75 Outer diameter mm 119 Tread outside diameter mm 95 88 S106W3560000...

Page 49: ...2 17 3 5 CARRIER ROLLER Specifications Item Reference values Allowable limit Oil type 85W 90 Oil quantity cc 50 Tread outside diameter mm 70 64 Tread width mm 132 S106W3559000...

Page 50: ...2 18 3 6 SPROCKET Specifications Item Reference values Allowable limit No of teeth 19 Tooth tip diameter mm 424 416 Pitch circle diameter mm 415 77 Tooth root diameter mm 380 8 372 S106W3557000...

Page 51: ...2 19 3 7 TRACK SHOE Specifications Number of links 43 on one side 3 8 SHOE PLATE S106W3558000 1 2 S106W3558000 2 2...

Page 52: ...on between the upper plane of rubber track and the bottom surface of the square bar Reference value for amount of slack a 10 20 mm Adjustment If the result of test indicates that the tension differs f...

Page 53: ...our sales agency for repair 2 Screw in the plug 1 3 To ensure that the proper tension is applied keep the engine at low idling speed to advance a distance equal to the ground contact length and gradua...

Page 54: ...2 22 4 HYDRAULIC UNITS 4 1 HYDRAULIC UNITS LAYOUT DIAGRAM...

Page 55: ...2 23...

Page 56: ...2 24 4 1 1 HYDRAULIC CIRCUIT DIAGRAM...

Page 57: ...2 25 This Page Intentionally Left Blank...

Page 58: ...2 26 4 2 HYDRAULIC OIL TANK AND FILTER Specifications Consumption quantity in the tank L 157 Oil quantity in the tank L 170 106 1186700...

Page 59: ...2 27 4 3 HYDRAULIC PUMP 4 3 1 HYDRAULIC PUMP EXTERNAL VIEW 106 2179000 S1 port...

Page 60: ...Winch brake S1 Hydraulic oil tank Piston pump suction port R1 Air venting port 4 3 3 HYDRAULIC PUMP SPECIFICATIONS Pump port No A1 A2 A3 Pump type Variable capacity piston Variable capacity piston Gea...

Page 61: ...2 29 4 4 SHUTTLE MANIFOLD BLOCK S106J3645001...

Page 62: ...2 30 4 5 TRAVEL OUTRIGGER CONTROL VALVE 4 5 1 TRAVEL OUTRIGGER CONTROL VALVE EXTERNAL VIEW 106 2179000...

Page 63: ...T1 Via check joint Crane control valve P port G1 2 T3 Via return manifold block Hydraulic tank G1 2 4 5 3 TRAVEL OUTRIGGER CONTROL VALVE LOWER CONNECTION DESTINATIONS Port name Port destination Port s...

Page 64: ...SPECIFICATIONS 4 5 5 SOLENOID VALVE SPECIFICATIONS Item No S106G3573000 Rated pressure MPa High pressure circuit 24 5 Tank circuit 1 0 Service flow rate l min P1 T1 60 A B 45 4 5 6 TRAVEL OUTRIGGER C...

Page 65: ...2 33 4 5 7 TRAVEL OUTRIGGER CONTROL VALVE CIRCUIT DIAGRAM...

Page 66: ...2 34 4 6 CHECK VALVE JOINT 106 2179000...

Page 67: ...2 35 4 7 CRANE CONTROL VALVE 4 7 1 CRANE CONTROL VALVE EXTERNAL VIEW 106 2179000...

Page 68: ...inch A Winch raising port via rotary joint C port G3 4 B Winch lowering port via rotary joint D port G3 4 Telescoping A Telescope extension port via rotary joint E port G3 4 B Telescope retracting por...

Page 69: ...OL VALVE SPECIFICATIONS Item No S106G3572000 Rated pressure MPa High pressure circuit 20 6 Tank circuit 1 0 Allowable pressure MPa High pressure circuit 34 3 Tank circuit 1 0 Low pressure MPa Low pres...

Page 70: ...n Port size Note A Crane control valve slewing A port G3 8 Slewing rightward B Crane control valve slewing B port G3 8 Slewing leftward DR Hydraulic oil tank G1 4 4 8 3 SLEWING MOTOR SPECIFICATIONS Mo...

Page 71: ...5 Oil seal 1 6 O ring 1 Dimension 44 1 2 6 7 Thrust bearing race 1 8 Thrust bearing needle 1 9 Output shaft 1 10 Housing 1 13 Drive 1 14 O ring 4 Dimension 92 2 5 15 Spacer plate 1 16 Gerotor 1 17 En...

Page 72: ...eft motor Traveling switching G1 4 2 speed shift Right motor Traveling switching G1 4 2 speed shift DR 1 Left motor Drain G1 4 Tank DR2 Right motor Drain G1 4 Tank 4 9 3 TRAVELLING MOTOR SPECIFICATION...

Page 73: ...motor PP port PF1 4 T Drain PF1 4 No Name Qty No Name Qty No Name Qty 1 Plug 1 5 Solenoid 1 9 Rivet 2 2 Body 1 6 Name plate 1 10 O ring 1A P10 1 3 Compression spring 1 7 Missing number 11 O ring 1B P1...

Page 74: ...ONNECTION DESTINATIONS Port name Port destination Port size Note A Winch confluence valve B1 port PF1 Lifting B Winch confluence valve A1 port PF1 Lowering D Hydraulic oil tank PF1 2 E Winch brake rel...

Page 75: ...inuous MPa kgf cm2 Maximum 24 5 250 24 5 250 Revolution speed rpm Low speed High speed Maximum 3700 4000 2440 3600 Flow rate l min Maximum 155 135 2 speed switching pressure MPa kgf cm2 1 97 6 86 20 7...

Page 76: ...3 to 4 turns 3 While keeping the Machine without hoisting load perform the operation of slowly winding up the hook block stopping and winding down 4 If hydraulic oil is oozing out from air vent plug...

Page 77: ...2 45 4 12 ROTARY JOINT 4 12 1 ROTARY JOINT EXTERNAL VIEW 106 2178500 Rotary joint structure...

Page 78: ...peed up valve P port G1 4 A3 pump pressure DR Hydraulic oil tank via return manifold block G3 8 Drain Rotating section A Winch motor A port G3 4 Lifting B Winch motor B port G3 4 Lowering C Telescopic...

Page 79: ...2 47 4 13 DERRICK CYLINDER 4 13 1 DERRICK CYLINDER EXTERNAL VIEW S106F356300...

Page 80: ...ng B Rotary joint D port G3 8 Lowering C Pressure sensor 1 bottom side port G3 8 Raising side D Pressure sensor 2 rod side port G3 8 Lowering side 4 13 3 DERRICK CYLINDER SPECIFICATIONS Size 160 90 14...

Page 81: ...1 kgf cm 2 Operating temperature range 10 80 C Troubleshooting and countermeasures Abnormal Phenomenon Cause Remedy During service the derrick cylinder is retracted the boom being lowered Defect in ch...

Page 82: ...2 50 4 13 5 COUNTER BALANCE VALVE OPERATING DIAGRAM 1 When neutral 2 When extending 3 When contracting...

Page 83: ...2 51 4 14 TELESCOPIC CYLINDER ASSEMBLY 4 14 1 TELESCOPIC CYLINDER EXTERNAL VIEW S106F3566001...

Page 84: ...TELESCOPIC CYLINDER SPECIFICATIONS Service pressure Extension side 20 6 MPa Retracting side 20 6 MPa No 1 cylinder size 95 80 3470 st Normal load When extended 146 0 KN When telescoping 42 5 KN No 2...

Page 85: ...2 53 4 14 4 TELESCOPIC CYLINDER CROSS SECTIONAL DRAWING...

Page 86: ...2 54 4 14 5 TELESCOPIC CYLINDER HYDRAULIC SYSTEM DIAGRAM...

Page 87: ...less pressurise 20 6 MPa 210 kgf cm 2 from port B Pilot pressure 1 18 0 3 MPa 12 3 kgf cm 2 at opening valve Check valve cracking pressure 2 45 MPa 25 kgf cm 2 Operating force 0 65 pressure 20 kg 6510...

Page 88: ...MECHANICAL CHECK VALVE 65100 02200V Specifications Rated flow rate 50 L min Pilot pressure 1 18 0 3 MPa 12 3 kgf cm 2 at opening valve Pressure loss B A 100 kgf cm 2 or less Cracking pressure 0 098 MP...

Page 89: ...f cm 2 Operating temperature range 10 80 C Troubleshooting and countermeasures Abnormal Phenomenon Cause Remedy During service the telescopic cylinder is retracted the boom is retracted Defect in chec...

Page 90: ...2 58 4 15 OUTRIGGER CYLINDER ASSEMBLY 4 15 1 OUTRIGGER CYLINDER EXTERNAL VIEW S106F3570001...

Page 91: ...ort size Note A OR select valve C3 port G1 4 Extension B OR select valve C2 port G1 4 Contraction 4 15 3 OUTRIGGER CYLINDER SPECIFICATIONS Size 140 80 302 st Service pressure Extension side 20 6 MPa R...

Page 92: ...re 41 2 MPa 420 kgf cm 2 Max flow rate 10 L min Allowable leak amount 0 05 cc min pressurizing 17 2 MPa 175 kgf cm 2 from A2 and B2 ports Check cracking pressure 0 49 MPa 5 kgf cm 2 Pilot area ratio 6...

Page 93: ...2 61 4 16 SLIDE CYLINDER ASSEMBLY 4 16 1 SLIDE CYLINDER EXTERNAL VIEW S106F3571001...

Page 94: ...Port size Note A OR select valve C4 port G1 4 Extension B OR select valve C1 port G1 4 Contraction 4 16 3 SLIDE CYLINDER SPECIFICATIONS Size 75 50 856 st Service pressure Extension side 20 6 MPa Retr...

Page 95: ...utrigger cylinder head Ground contact In PF1 4 C4 Outrigger slide cylinder head Extension In PF1 4 Specifications Specifications Maximum service pressure 25 MPa 250 kgf cm 2 Voltage 12 VDC Max flow ra...

Page 96: ...2 64 4 18 OIL COOLER Specifications No Name Specifications 1 Fan motor Voltage 12 VDC Current 11 8 A Output 0 14 KW Rotation 3000 RPM 2 Housing 3 Blanking plug M22 1 5 4 Radiator S106J3574000...

Page 97: ...2 65 4 19 RETURN MANIFOLD BLOCK Specifications Rated pressure 1 0 MPa Check cracking pressure 0 66 MPa Operating temperature range 20 to 100 C S106J3647001...

Page 98: ...2 66 4 20 Hydraulic Piping Diagram 4 20 1 P LINES PUMP SHUTTLE MANIFOLD BLOCK LINE 106 1190000 Pump...

Page 99: ...lbow with plate 10 Hose MP1SM 3 Male 90 elbow with plate H Shuttle manifold block 22611 11160 1071 08 HYDEX 106 4684700 01 PA2808C C 500L 22611 11160 1071 08 HYDEX A2 6 Male 90 elbow with plate 11 Hos...

Page 100: ...2 68 4 20 1 1 P LINES PUMP LINES SHUTTLE MANIFOLD BLOCK CHECK JOINT HYDRAULIC SYSTEM DIAGRAM...

Page 101: ...2 69 4 20 2 P LINES SHUTTLE MANIFOLD BLOCK TRAVELLING OUTRIGGER CONTROL VALVE LINES 106 1190000 Manifold block...

Page 102: ...0 PA2812C C 2650L 22611 15478 1071 16 12 102A HYDEX 7 Joint P Crane control valve 106 3377600 S106J3655000 G1ED M G1 JISF Shuttle manifold block S106J3645001 I 3 Male 90 elbow with plate 14 Hose SM2RV...

Page 103: ...2 71 4 20 3 T Dr LINES 106 1190200...

Page 104: ...block S106J3647001 22611 11180 1071 16 HYDEX 106 4689600 OKE08 C C 1840L BS 22611 11180 1071 16 HYDEX Return manifold block S106J3647001 9 Male 90 elbow with plate 16 Hose RMCC 10 Male connector Up p...

Page 105: ...2 73 4 20 4 TRAVELLING LINES 106 1190400...

Page 106: ...el motor S106H3567000 S106J3667000 G3 8ED M G3 8 30 seat M 106 4686600 PA2806C C 2390L BS 22611 11056 1067 08 06 HYDEX Track frame ass y 106 1189300 Speed up valve Travel speed switch valve 106 339640...

Page 107: ...2 75 4 20 5 OUTRIGGER LINES 106 1190500...

Page 108: ...2 76 106 1190500...

Page 109: ...2 77...

Page 110: ...2 78 4 20 6 HYDRAULIC PIPING CRANE FIXED PART ASSEMBLY 106 3378200...

Page 111: ...EX WB 6 Joint 4 WB1 hose 9 Male 90 elbow with plate B S106J3654000 G3 4ED M G3 4 30 seat M short 106 4673000 PA2112 C C 950L 22611 11170 1071 12 HYDEX TA 5 Joint 5 TA1 hose 10 Male 45 elbow with plate...

Page 112: ...elbow with long plate A Raising counterbalance 106 3394000 22611 11156 1071 08 06 HYDEX 106 4672200 KG06 C C 1070L 22611 12250 1071 0674A HYDEX D 7 Male 90 elbow with plate 2 DB2 hose 2 Mail 90 elbow...

Page 113: ...DEX 106 4672400 KG08 C C 1860L 22611 11165 1071 06 08 HYDEX 8 Long connector 3 8 A Extending counterbalance 106 1189800 106 4701700 Rotary joint 106 2178500 C 7 Male 90 elbow with plate 6 TB2 hose 10...

Page 114: ...HYDEX 106 4671900 PA2112 C C 1960L 14 WA pipe 42 Flareless type joint A Winch motor 106 1189100 106 3365700 22511 07A80 LLM UR 25 1 Rotary joint 106 2178500 B 9 Male 90 elbow with plate 4 WB2 hose 22...

Page 115: ...Rotary joint 106 2178500 DR 24 Single male threaded tee 22031 36500 2092 06 HYDEX 25 Male connector 10 WDR hose 22611 10150 1009 06 HYDEX 106 4671200 KF06 C C 1820L 16 W drain pipe 45 Flareless type j...

Page 116: ...2 84 4 20 11 HYDRAULIC PIPING ROTATING PART ASSEMBLY WINCH BRAKE RELEASE 2 SPEED SWITCHING LINES 106 1183000 Winch brake release 2 speed switching lines...

Page 117: ...C CR9 550L 22611 14830 9071 04 HYDEX Brake release valve 106 3396500 T Lower 12 SVT hose 4 Male 90 elbow with plate T Upper 2 speed switch valve 106 3396500 106 4691200 KF04 C CR9 290L 22611 11130 10...

Page 118: ...2 86 5 WORK EQUIPMENT 5 1 BOOM ASSEMBLY 106 1188400 02 1...

Page 119: ...2 87 106 1188400 02 2...

Page 120: ...2 88 5 2 HOOK BLOCK ASSEMBLY 5 2 1 HOOK BLOCK ASSEMBLY 106 1181000...

Page 121: ...3 Check each mounting bolt of the sheave to ensure that it is securely mounted without any damage If it is loosened give it an additional tightening If it is damaged replace it 4 Check the hook nuts t...

Page 122: ...2 90 This Page Intentionally Left Blank...

Page 123: ...2 91 6 ELECTRIC CIRCUIT DIAGRAM 1 of 3 106 1178200...

Page 124: ...2 92 6 ELECTRIC CIRCUIT DIAGRAM 2 of 3 106 1178200...

Page 125: ...2 93 6 ELECTRIC CIRCUIT DIAGRAM 3 of 3 106 1178200...

Page 126: ...2 94 7 ELECTRICAL EQUIPMENT CONNECTION DIAGRAM 1 2 STANDARD SPECIFICATION 106 2180300...

Page 127: ...2 95 7 ELECTRICAL EQUIPMENT CONNECTION DIAGRAM 2 2 FLY JIB SPECIFICATION 106 2189100...

Page 128: ...2 96 This Page Intentionally Left Blank...

Page 129: ...PART 1 Outrigger operation panel 2 Left control lever 3 Right control lever 4 Monitor 5 Emergency stop switch 6 Starter switch 7 Lock lever 8 Accelerator pedal 9 Light switch 10 Disconnect switch 11 O...

Page 130: ...2 98 8 1 2 OUTRIGGER OPERATION PANEL Switch specifications 1 Outrigger 1 switch 2 Outrigger 2 switch 3 Outrigger 3 switch 4 Outrigger 4 switch...

Page 131: ...2 99 8 1 3 LEFT CONTROL LEVER...

Page 132: ...2 100...

Page 133: ...2 101 8 1 4 RIGHT CONTROL LEVER...

Page 134: ...2 102...

Page 135: ...2 103...

Page 136: ...and electric motor switch 9 Pop up select switch up 10 Pop up select switch down 11 Enter switch 12 Replacement reminder 13 Engine oil pressure 14 Engine coolant temperature 15 Charge 16 DPF regenerat...

Page 137: ...switch 2 Hook sling number change 3 Language setting 4 Error history display 5 Software version check 6 Monitor brightness adjustment 7 Time setting 8 Consumables display 9 Switch operation sound ON...

Page 138: ...C30 Inverter communication error Check CAN communication circuit harness Check inverter Input errors Error code Details of failure Check items when failure occurs EI01 Right joystick forward back star...

Page 139: ...Check the harness for the fuel sender circuit EV001 Battery voltage drop error Check if the battery voltage is at 11 V or below Check fuses Check harnesses for battery related circuits ES103 Slewing...

Page 140: ...or Check OR ground 3 solenoid Check harness for circuit relating to OR ground 3 solenoid EOS03H OR ground 3 SOL Lo error EOS04L OR ground 4 SOL Hi error Check OR ground 4 solenoid Check harness for ci...

Page 141: ...C03L Boom raising SOL Hi error Check boom raising solenoid Check harness for circuit relating to boom raising solenoid EOC03H Boom raising SOL Lo error EOC04L Boom lowering SOL Hi error Check boom low...

Page 142: ...r Check harness for circuit relating to boom light output EO107L Fly jib switching relay Lo error Check harness for circuit relating to fly jib switching relay EV10 Sensor power supply Lo error Check...

Page 143: ...hat require replacement will cause a hazardous situation or an adverse effect on the machine Be sure to immediately replace them The consumables included in the list appear on the screen are as follow...

Page 144: ...seat Inspect and replace fuses with the following procedure 1 Remove the mounting bolts 2 5 pieces from the small window cover 1 below the operation side cover to the left of the driver s seat then r...

Page 145: ...2 113 8 2 CONTROLLER 8 2 1 CONTROLLER LAYOUT...

Page 146: ...2 114...

Page 147: ...2 115 8 2 2 LOWER PART CONTROLLER PIN NUMBERS...

Page 148: ...2 116...

Page 149: ...2 117...

Page 150: ...2 118 8 2 3 IO UNIT PIN NUMBERS...

Page 151: ...2 119 8 3 HARNESS ASSEMBLY 8 3 1 HARNESS OVERVIEW FIGURE 8 3 2 HARNESS PRODUCT NAME NUMBER 106 2183600...

Page 152: ...2 120 8 3 3 OUTRIGGER SENSOR HARNESS 106 2183600 2...

Page 153: ...2 121 8 3 4 ENGINE HARNESS 106 2183600 3...

Page 154: ...2 122 8 3 5 CONSOLE HARNESS 106 2183600 3...

Page 155: ...2 123 8 3 6 VALVE HARNESS 106 2183600 4...

Page 156: ...2 124 8 3 7 DISPLAY HARNESS 106 2183600 4...

Page 157: ...2 125 8 3 8 BOOM HARNESS 106 2183600 4...

Page 158: ...TINGS OUTSIDE THE CABIN 8 4 1 LED LIGHT Specifications Model 927SWP Light source LED 9 Rated output For 24 VDC 27 W Operating voltage range 10 VDC 30 VDC Operating temperature range 30 C to 50 C witho...

Page 159: ...2 127 8 4 2 SURVEILLANCE CAMERAS S585L3318001...

Page 160: ...ge 5 V DC 10 Output type 1 0 to 5 0 V DC 3 wire system Mechanical accuracy 0 25 FS Overall value for non linearity hysteresis and reproducibility Mechanical stability 0 2 FS 10 000 000 cycles after fu...

Page 161: ...ion Unit Inclination angle Outrigger Parallel to the direction of vehicle travel degree 3 0 5 Perpendicular to the direction of vehicle travel 3 0 5 Crane Parallel to the direction of vehicle travel 3...

Page 162: ...2 130 8 5 3 FUEL SENDER ASSEMBLY 103S93100001 Performance Float position Full Empty Value of resistance 5 3 2 85 4 2...

Page 163: ...2 131 8 5 4 ROTARY BRUSH S106L3569000...

Page 164: ...2 132...

Page 165: ...dictor lamp for when load factor is from 90 up to but not including 100 C Green revolving working status lamp operation lamp for when load factor is less than 90 5 Boom length gauge inside the boom 6...

Page 166: ...NG 10 Hoist mode indication N mode P mode M mode 11 Boom length indication BOOM LENGTH 12 Number of wire falls indication 13 Over winding indication OVER WINDING 14 Actual load indication ACTUAL LOAD...

Page 167: ...2 135 9 3 SENSOR ASSEMBLY 9 3 1 LENGTH METER STANDARD SPECIFICATION S106L3577000 106 2183600 4...

Page 168: ...Approx 5 6 kg Potentiometer Resistance value 5000 250 Electrical rotation angle 350 1 5 Mechanical rotation angle 360 Boom light specifications Cord wire diameter 0 70 Cord length Main cord 21 m Strok...

Page 169: ...lack Across connectors 2 White and 3 Black at a boom angle of 0 degrees 1 800 0 055 V 4 619 0 139 V at a boom angle of 80 degrees Resistance value Across connectors 2 White and 3 Black at a boom angle...

Page 170: ...2 VDC 10 Output type 1 to 5 VDC 3 wire system Mechanical accuracy 0 25 FS Overall value for non linearity hysteresis and reproducibility Mechanical stability 0 2 FS 10 000 000 cycles after full scale...

Page 171: ...the wire rope actuating the over hoist detection switch The contact point of the over hoist detection switch opens sending a signal to operator unit which stops hook hoisting and jib extension At the...

Page 172: ...ered and length of wire rope in the winch drum becomes short The OVER UN WINDING lamp indication will flash in red When hook lowering operation is performed the alarm issues an intermittent sound peep...

Page 173: ...s from 90 to less than 100 of the rated total load The yellow colour of the tri colour revolving working status lamp turns on The alarm generates an intermittent buzzer sound peep peep 3 Limit alarm t...

Page 174: ...2 142 9 7 OUTRIGGER SAFETY DEVICES 9 7 1 OUTRIGGER POSITION DETECTION PARTS 106 1189700...

Page 175: ...2 143 9 7 2 OUTRIGGER GROUNDING DETECTION PARTS 106 2188000...

Page 176: ...2 144 9 7 3 OUTRIGGER ROTARY POSITION DETECTION PARTS 106 2187000...

Page 177: ...2 145 9 8 BOOM STOWING POSITION DETECTION PARTS 106 2183600 4...

Page 178: ...2 146 9 9 HOOK GROUNDING DETECTION PARTS Hook grounding indication GROUND CONTACT Lights up when the hook touches the ground 106 2184100...

Page 179: ...3 1 REMOTE CONTROL CONTENTS Item Page 1 COMPONENTS OF THE TRANSMITTER 3 2 2 HANDLING REMOTE CONTROLLER BATTERY 3 7 3 TROUBLESHOOTING 3 10 4 PRINCIPAL SPECIFICATIONS LIST 3 14 5 SERVICE LOCATIONS 3 15...

Page 180: ...Operation mode selector switch 6 Speed selector outrigger select switch 7 Load carrying Fly jib change switch 8 Accelerator control switch 9 Horn switch 10 Emergency stop Remote controller power OFF s...

Page 181: ...tion can be switched between extension and extension stowage 7 Load carrying Fly jib change switch Only in crane operation the operation can be switched between boom and fly jib NOTES Operation cannot...

Page 182: ...Use this switch to operate the display R1 Control box Contains the receiver devices and control devices Do not disassemble or modify the control box under any circumstances Otherwise an electric shock...

Page 183: ...Before performing electric welding due to repair work for the machine body or other reasons be sure to disconnect the wire Failure to do so may result in a machine failure caused by burn damage to th...

Page 184: ...ACCESSORIES 1 Waist belt 1 Wear the belt when you operate the transmitter Wear the waist belt around your waist Attach the transmitter to the waist belt 2 Battery charger for remote controller Battery...

Page 185: ...ENT METHOD OF BATTERY Replace the battery of the transmitter in the procedure described below 1 Turn OFF the power of the transmitter Pressing the Emergency stop Remote controller power OFF switch 10...

Page 186: ...er battery status bar illuminates in red followed by a signal alarm sound immediately charge the battery It is ideal to store the battery in a 30 to 50 charged condition if it is going to be stored fo...

Page 187: ...3 9 The radio control battery can be charged using the vehicle s cigarette lighter socket Install the remote control battery charging case B5 at the bottom of the override switch...

Page 188: ...eration on the machine body side If the crane operates there is an abnormality in this equipment If the crane does not operate troubleshoot the machine body Is power supplied with transmitter and mach...

Page 189: ...or disconnection Check functionality with LED in receiver control light field Individual commands cannot be executed Receiver has failed Connection to machine is interrupted Check connection cable to...

Page 190: ...3 12 3 3 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER...

Page 191: ...3 13 3 4 ELECTRICAL WIRING DIAGRAM FOR REMOTE CONTROLLER...

Page 192: ...wer OFF device Auto power off device Transmitter stop function when battery capacity decreases Alarm switch Transmitter voltage Battery BA405000 6 VDC 1500 mAh Receiver voltage Power of crane main bod...

Page 193: ...3 15 5 SERVICE LOCATIONS...

Page 194: ...3 16...

Page 195: ...T ASSEMBLY 4 4 3 ELECTRIC MOTOR 4 5 4 ELECTRIC LINE ASSEMBLY 4 6 5 INVERTER HARNESS WIRE HARNESS OF THE ELECTRICAL MOTOR 4 8 6 ELECTRIC CIRCUIT DIAGRAM FOR ELECTRIC MOTOR SPECIFICATIONS 4 8 7 TROUBLES...

Page 196: ...ELECTRIC POWER UNIT PART NAMES 1 Electric motor 2 Coupling 3 Hydraulic pump 1 2 POWER SUPPLY BOX 1 Power supply box 2 Power supply box door 3 Power supply box handle 4 Cable gland 5 Breaker switch 6...

Page 197: ...e sure to locate failures and check for burning smell and faulty parts The breaker switch 1 is designed to provide automatic shutoff of the power supplied by the inverter panel to the electric motor t...

Page 198: ...4 4 2 ELECTRIC POWER UNIT ASSEMBLY 106 2187300...

Page 199: ...4 5 3 ELECTRIC MOTOR Specifications Rated output 15 KW Rated voltage 380 V Rated current 30 2 A Rated torque 97 8 N m Rated speed 1465 rpm Frequency 50 Hz No of poles 4 Ambient temperature 20 to 40 C...

Page 200: ...4 6 4 ELECTRIC LINE ASSEMBLY 106 1190700...

Page 201: ...late 1 Hose EP1SM 3 Male 90 elbow with plate G Shuttle manifold block 22611 11160 1071 08 HYDEX 106 4685000 02 PA2808C C 850L 22611 11160 1071 08 HYDEX A2 6 Male 90 elbow with plate 2 Hose EP2SM 3 Mal...

Page 202: ...4 8 5 INVERTER HARNESS WIRE HARNESS OF THE ELECTRICAL MOTOR 6 ELECTRIC CIRCUIT DIAGRAM FOR ELECTRIC MOTOR SPECIFICATIONS 106 1178200 1 3 106 2183600 2 4...

Page 203: ...a specified value 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 Loose fixing bol...

Page 204: ...wing angle Time 360 continuous 2 5 min 1 Outrigger system Type Extension grounding hydraulic cylinder direct acting type with hydraulic automatic locking device Max extended width left to right Front...

Page 205: ...Page 1 NAME OF EACH SECTION OF FLY JIB 5 2 2 FLY JIB HYDRAULIC SYSTEM 5 3 3 FLY JIB 5 8 4 FLY JIB HARNESS 5 11 5 FLY JIB SAFETY DEVICE 5 14 6 FLY JIB ELECTRICAL CIRCUIT DIAGRAM 5 19 7 TROUBLESHOOTING...

Page 206: ...detector weight 10 Single hook 11 Snap sheave 12 Wire rope 13 Wire 14 Guide sheave 15 Derricking wire rope 16 Derricking sheave 21 Stowage bracket A 22 Stowage bracket B 56 Fly jib switching valve 81...

Page 207: ...JIB SWITCHING SOL Specifications Maximum service 24 5 MPa Maximum service flow rate 60 L min Allowable temperature range 10 to 80 C Solenoid operated directional control valve Electrical specification...

Page 208: ...REEL Specifications Service hose N3000 04 Nitta Moore Service pressure 20 6 MPa Hose length Stroke 14 m Mounting length 4 0 m Dead turns 1 5 m Operating temperature range 30 to 80 C Mass Approx 65 kg...

Page 209: ...2 3 DERRICKING CYLINDER FOR FLY JIB Specifications Size 90 60 350 st Service pressure Raising side 20 6 MPa Lowering side 20 6 MPa Normal load When extended 131 1 KN When retracted 72 8 KN S106F37190...

Page 210: ...2 4 TELESCOPING CYLINDER FOR FLY JIB Specifications Size 55 40 2200 st Service pressure Raising side 20 6 MPa Lowering side 20 6 MPa Normal load When extended 48 9 KN When retracted 23 1 KN S106F3720...

Page 211: ...20 6 MPa Maximum service flow rate 45 L min Allowable temperature range 10 to 90 C Solenoid operated directional control valve Electrical specifications Rated voltage 12 VDC Continuous rating Holding...

Page 212: ...5 8 3 FLY JIB 3 1 FLY JIB MAIN BOOM SIDE 106 1192600...

Page 213: ...5 9 3 2 FLY JIB FLY JIB SIDE 1 2 106 1192700 1 2...

Page 214: ...5 10 3 3 FLY JIB FLY JIB SIDE 2 2 106 1192700 2 2...

Page 215: ...5 11 4 FLY JIB HARNESS 4 1 FLY JIB HARNESS 1 3 106 1192800 1 3...

Page 216: ...5 12 4 2 FLY JIB HARNESS 2 3 106 1192800 2 3...

Page 217: ...5 13 4 3 FLY JIB HARNESS 3 3 106 1192800 3 3...

Page 218: ...overload 150 R C Rated output 1 5 mV V 0 3 mV V Temperature compensation range 20 to 60 C Electrical characteristics Recommended applied voltage 10 V or less Maximum applied voltage 12 V Input resist...

Page 219: ...METER REEL FLY JIB MOUNTED Note When replacing the total length reel do not allow the yellow tape of the main cord to enter the drum If the main cord enters the drum the potentiometer will malfunctio...

Page 220: ...5 16 5 3 ANGLE DETECTOR FLY JIB MOUNTED 103S9720000...

Page 221: ...t to CP 2F Effective electrical angle 340 2 3 Total resistance value 1 k 20 Index point Adjust the output in this illustration 0 to 15 3 Insulation resistance 200 M or more 500 VDC Withstand voltage 5...

Page 222: ...wire diameter 0 70 Cord length Main cord 21 m Stroke 14 m Machine body external length 5 5 m Dead turns 1 5 m Sub cord 0 40 m Operating temperature range 30 to 70 C Mass Approx 7 kg Potentiometer Resi...

Page 223: ...5 19 6 FLY JIB ELECTRICAL CIRCUIT DIAGRAM 106 1178200 2 3...

Page 224: ...uit ES17 Load cell input error Check load cell Check load cell amplifier Check harness of load cell related circuit EV20 Fly jib power supply voltage error Check converter 24V 12V Check power supply r...

Page 225: ...d wire and repair Fly jib length and fly jib angle is shown Boom Fly jib operation selector switch is shown 3 When fly jib is attached to vehicle body and extended fly jib mode Abnormal Phenomenon Maj...

Page 226: ...for the fly jib specification different from standard specification are described For other specifications see Specification section Equipment Item MC815C FLY JIB Weight and dimensions Body mass 9950...

Page 227: ...At intermediate outrigger extension Unit kg At minimum outrigger extension Unit kg The rated total load chart represents the load including the mass of hanging tools mass of one hanger hook 20 kg Main...

Page 228: ...5 24 8 4 WORKING RADIUS LIFTING HEIGHT...

Page 229: ...CHER HOOK CONTENTS Item Page 1 NAMES OF SEARCHER HOOK PARTS 6 2 2 SEARCHER HOOK ASSEMBLY 6 3 3 CHANGING SEARCHER HOOK ANGLE 6 4 4 CHANGING TO SEARCHER HOOK MODE 6 5 5 TROUBLESHOOTING 6 6 6 SPECIFICATI...

Page 230: ...NAMES OF SEARCHER HOOK PARTS 1 Searcher hook boom 2 Swivel hook 3 Shackle 4 Searcher hook bracket 5 Point pin 6 Collar 7 Plate 8 Nut 9 Pin A 10 Pin B 11 Stowage bracket A 12 Stowage bracket B 13 Head...

Page 231: ...6 3 2 SEARCHER HOOK ASSEMBLY 106 2189500...

Page 232: ...g the mode damage to or overturn of the machine might occur causing a serious accident To change the searcher hook angle follow the procedure below The following procedure assumes the starting point i...

Page 233: ...the User Initial Mode screen opens the Searcher Hook Display enabling selection and switching NOTES When you select the number of wire falls it goes back to the standard crane mode from the searcher...

Page 234: ...Abnormal Phenomenon Major cause s Remedy Indication on monitor changes to searcher hook mode OFFSET POSITION is shown Searcher hook mode is selected in user mode Change to searcher hook mode 3 When s...

Page 235: ...ok specification different from the standard specification is described For other specifications see Specification section Equipment Item MC815C SEARCHER HOOK Weight and dimensions Body mass 9520 kg O...

Page 236: ...rigger extension the number of main boom sections and the working radius Check the available range in the rated total load chart before operating Hoisting operation is not possible when the boom angle...

Page 237: ...6 9 6 4 WORKING RADIUS LIFTING HEIGHT...

Page 238: ...6 10 This Page Intentionally Left Blank...

Page 239: ...LING THE NO 2 BOOM 7 5 2 3 DISASSEMBLING THE NO 3 BOOM 7 6 2 4 DISASSEMBLING THE NO 4 BOOM 7 7 2 5 DISASSEMBLING THE TELESCOPIC CYLINDER FROM THE NO 5 BOOM 7 8 3 DISMOUNTING AND MOUNTING THE WINCH WIR...

Page 240: ...7 2 1 DISMOUNTING AND MOUNTING THE BOOM ASSEMBLY...

Page 241: ...S ANG CN41 S LEN LS RS and arrange them in the post assembly area 9 Remove the overwinding LS connector CN42 the cord on the top surface of the boom and wind it up onto the cord reel In this step be c...

Page 242: ...and lower left and upper and lower right parts of the No 1 boom tip 4 Loosen two hexagon socket set screws on the upper part of the No 1 boom tip 5 Remove the two stopper plates from the lower part o...

Page 243: ...two stopper plates from the lower part of the No 2 boom tip 4 Pull out the No 3 No 4 No 5 booms and telescopic assembly in their assembled state from the No 2 boom At this time also remove the slide...

Page 244: ...the two stopper plates from the lower part of the No 3 boom tip 4 Pull out the No 4 No 5 booms and telescopic assembly in their assembled state from the No 3 boom At this time also remove the slide pl...

Page 245: ...No 4 boom tip 2 Loosen two hexagon socket set screws on the upper part of the No 4 boom tip 3 Remove two stopper plates from the lower part of the No 4 boom tip 4 Pull out the No 5 boom and telescopi...

Page 246: ...he No 5 boom At this time hold down the metal fitting at the end of the contracting wire rope with a spanner loosen the M16 nut and remove it 3 Pull out the telescopic cylinder contracting wire rope a...

Page 247: ...procedure provided below 1 Bring a 4 to 6 mm round bar 6 into contact with the rope wedge 7 2 Remove the rope wedge 7 by lightly tapping the round bar 6 with a hammer in the direction indicated by th...

Page 248: ...evention unit load sheave 11 at the end of load sheave 11 wire guide 12 of boom Nos 2 3 and 4 roller sheave 13 sheave 14 inside the boom derricking cylinder mounting bracket and slide sheave 15 2 Draw...

Page 249: ...ull the wire rope 5 strongly in the direction indicated by the arrow 7 Fix a rope clip 4 to the wire rope 5 according to the dimensions specified in the figure on the right 8 Affix the wire socket 3 t...

Page 250: ...4 Remove the fixing pin 1 securing the wedge socket and remove the wedge socket 2 5 Install the wire rope end forcibly making a number of twists calculated by n number of falls of wire rope multiplie...

Page 251: ...on the tip of extension cylinder inside the boom and turn the boom extending wire adjusting bolt 9 clockwise The tension of the boom extending wire 8 is normal if the No 5 boom is extended when the a...

Page 252: ...following for proper adjustment If the clearance a is 5 mm or more adjust the No 5 boom retracting wire rope 5 If the clearance a is 0 zero adjust according to step 5 Adjustment of No 5 boom extendin...

Page 253: ...gins to extend 2 Further tighten both the right and left adjusting nuts 4 for the No 5 boom retracting wire rope 5 by two turns 3 Fix the adjustment nuts 4 of the No 5 boom retracting wire rope 5 with...

Page 254: ...7 16 This Page Intentionally Left Blank...

Page 255: ...8 1 REFERENCE VALUES CONTENTS Item Page 1 TABLE OF ENGINE RELATED REFERENCE VALUES 8 2 2 TABLE OF MACHINE RELATED REFERENCE VALUES 8 3 3 TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES 8 6...

Page 256: ...ngine lubricating oil pressure Rated speed MPa 0 32 0 47 3 3 4 8 Kgf cm 2 Low idling 0 06 or more 0 6 Kgf cm 2 or more Allowable temperature for engine lubricating oil Entire revolution area inside oi...

Page 257: ...on Operation mode Name Unit New Vehicle Reference Left control lever Left Right Crane mode N Left Right slewing N m 0 97 0 2 2 5 0 5 Up Down N Extend Retract 0 98 0 2 2 7 0 54 Travel mode N Left Forwa...

Page 258: ...y Hydraulic oil temperature 30 to 50 C Engine in a high revolution idling Boom stowed Fully retracted to fully extended sec 20 2 Fully extended to fully retracted 24 2 Rear side outrigger slide speed...

Page 259: ...essure at the same time mm 200 or less Fig 1 Travel deviation Inclination sensor Mode Vehicle body inclination direction Unit Inclination angle Outrigger Parallel to the direction of vehicle travel de...

Page 260: ...t total load 4 09 t 4 0 4 3 Alarm signal operation check Boom fully extended boom length 19 40 m Total load 0 90 t lifted load 0 81 t hook 0 09 t Lowering operation at slow speed Short cycle sound at...

Page 261: ...IAL SETTING S 9 6 CRANE CALIBRATION S 11 6 1 LEVEL CALIBRATION S 11 6 2 POTENTIOMETER CALIBRATION S 12 6 3 BOOM LENGTH CALIBRATION S 13 6 4 BOOM ANGLE CALIBRATION S 13 6 5 LOAD CALIBRATION S 14 6 6 FL...

Page 262: ...please enter 2435 to the password entry field and press the enter button on the screen It will shift to the service mode screen If the screen does not shift to the service mode check the password aga...

Page 263: ...t value and ON OFF state of each sensor can be confirmed Press the Input Output Engine buttons displayed at the bottom of the screen to change the screen To return to the previous screen push the home...

Page 264: ...s are replaced Select the replaced consumables with the up and down pop up select switches highlighted in white and press the replace consumables button A confirmation screen will be displayed If you...

Page 265: ...d Item C pages Also if the history number is large you can change the page with the pop up selection switch up down By pressing the Item A Item B Item C page and Item D page you can change the display...

Page 266: ...During regeneration of DPF DR Moment Record the state at the moment entered to service mode Continuously record if inclination exceeds 2 deg during P C mode Record the state at the moment DPF regenera...

Page 267: ...d state when Y if input during recording 23 Mode select MS C F CL SH FJ OR TR PC C Calibration F Function CL Crane mode SH SH mode FJ FJ mode OR OR mode TR Travelling mode PC P C mode Others Value and...

Page 268: ...when recorded Max load factor during recording 49 Outrigger 2 operation OR2O O2E O2R O2U O2L O2E OR2Extend O2R OR2Retract O2U OR2Raise O2L OR2Lower Value and state when recorded Max load factor durin...

Page 269: ...measures which are shown in the white font If an error is currently occurring it will be displayed in red In this case it is not possible to erase the error so please delete it after completing the er...

Page 270: ...e start up password Please enter the 4 digit numbers you want to set and touch the enter button Initialize the start up password You can initialize the set password Keep pressing the YES button to ini...

Page 271: ...functions are cancelled during the calibration be cautious of the risk of falling or damage of the machine Be sure to observe the monitor display or manual descriptions and refrain from lifting loads...

Page 272: ...in starting at around 20 degrees 6 2 2 Counterclockwise calibration CCW Starting from an angle of 20 degrees to the left as viewed from the monitor side begin a counterclockwise slew and press the inp...

Page 273: ...gth sensor 6 4 BOOM ANGLE CALIBRATION Attach an angle meter to the boom Calibrating the horizontal state of boom angle Set the boom angle to horizontal Input the value which is indicated on the angle...

Page 274: ...nothing is suspended adjust the boom length and angle by operating the boom in the following conditions Boom length 8 99m 2 stage boom Boom angle 60 0 1 Adjust by lowering operation Stop the swaying...

Page 275: ...jib angle to horizontal Set an angle meter on main boom and on jib and make sure these are horizontal Input the value which is indicated on the angle meter and when input voltage is stabilized press...

Page 276: ...0 40 30 20 and 10 respectively and check if displayed load value is between 0 62t 0 72t at each angle at stationary state If the displayed load value is not between 0 62 0 72t change setting of the fa...

Page 277: ...t the button indicates Without Fly Jib Always set to a condition that matches actual machine condition Searcher hook setting When searcher hook is mounted set so that the button indicates With Searche...

Page 278: ...e item you want to check output with the pop up select switch up down and left right switch item changes to red and press ON Note Boom Light Audio Power and Audio 1 to 4 in the item are not currently...

Page 279: ...0 1900mV With fly jib Load No load 0 10t Sensor 1 1325mV 10 0m 60 Sensor 2 1030mV With a weight 4 10t Sensor 1 2100mV 10 0m 60 Sensor 2 1030mV Potentiometer CW CPU1 3370mV CPU2 830mV CCW CPU1 3370mV C...

Page 280: ...S 20 This Page Intentionally Left Blank...

Page 281: ...LATED TO ELECTRIC LIST OF ERROR CODES T 301 1 2 TROUBLESHOOTING MATTERS OTHER THAN ERROR CODE DISPLAY T 401 1 2 1 TROUBLESHOOTING OF THE ENGINE UNIT T 403 1 2 2 TROUBLESHOOTING OF THE ELECTRICAL SYSTE...

Page 282: ...T 2 This Page Intentionally Left Blank...

Page 283: ...joystick left right input error T 311 El01 Right joystick accelerator lever input error T 311 El02 Left joystick forward back start position error T 311 El02 Left joystick left right start position e...

Page 284: ...28 EOC03H Boom raising SOL Lo error T 329 EOC03L Boom raising SOL Hi error T 329 EOC04H Boom lowering SOL Lo error T 329 EOC04L Boom lowering SOL Hi error T 329 EOC05H Winch wind up SOL Lo error T 330...

Page 285: ...41 EOP01L Pilot SOL Hi error T 341 EOS01H OR ground 1 SOL Lo error T 342 EOS01L OR ground 1 SOL Hi error T 342 EOS02H OR ground 2 SOL Lo error T 342 EOS02L OR ground 2 SOL Hi error T 342 EOS03H OR gro...

Page 286: ...r fly jib T 357 EV001 Battery voltage drop error T 359 EV10 Derrick pressure sensor power supply Lo error T 361 EV11 Revolving lamp power supply Lo error T 361 EV20 Fly jib power supply voltage error...

Page 287: ...Communication error with I O unit 1 TTC36X Error code EC02 Details of failure Communication error with I O unit TTC36X Failure determining conditions Communication error detected in the CAN communica...

Page 288: ...ontroller TTC 540 Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Fault of CAN communication circuit Check the inverter CAN communication circuit harness 2 Inverte...

Page 289: ...T 307 Relevant electric circuits Standard...

Page 290: ...T 308 Location information Standard...

Page 291: ...T 309 Relevant electric circuits Fly jib...

Page 292: ...T 310 Location information Fly jib...

Page 293: ...operating and for an input voltage of 5 V 0 5 V the output voltage strayed outside of the ranges of 90 2 4 5 V 0 1 V or 10 2 0 5 V 0 1 V of the input Assumed cause and diagnostic method Cause Diagnos...

Page 294: ...f the range of 50 4 of the input 2 5 V 0 2 V Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Input voltage error Monitor the voltage at neutral Check the power sup...

Page 295: ...umed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Input voltage error Monitor the voltage when operating Check the signal circuit harness for the lower controller TTC54...

Page 296: ...cause and diagnostic method Cause Diagnostic method and action to be taken 1 Input voltage error Monitor the voltage at neutral Check the power supply circuit harness for the lower controller TTC540...

Page 297: ...T 315 Related electric circuits...

Page 298: ...T 316 Location...

Page 299: ...its for any short circuit to ground 2 Travelling 2 speed SOL fault Check if the solenoid functions normally Error code EO05L Travelling 2 speed SOL travelling speed switching valve Hi error Error code...

Page 300: ...rcuits for any short circuit to ground 2 Winch high speed SOL fault Check if the solenoid functions normally Error code EO08L Winch high speed SOL winch 2 speed switching valve Hi error Error code EO0...

Page 301: ...lay fault Check if the relay functions properly Error code EO100L Fan stop output Lo error Error code EO100L Details of failure Fan stop output Lo error Failure determining conditions Relay resistance...

Page 302: ...t inverter panel fault Replace the inverter panel Error code EO101L Electric stop electric OFF output Lo error Error code EO101L Details of failure Electric stop output Lo error Failure determining co...

Page 303: ...the inverter panel Additional information Refer to T 319 320 for relay parts and locations Error code EO102L Motive power stop output Lo error Error code EO102L Details of failure Motive power stop o...

Page 304: ...ons Short circuit to power supply line detected when output is OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Harness short circuit to power supply line Check...

Page 305: ...ditions Short circuit to power supply line detected when output is OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Harness short circuit to power supply line C...

Page 306: ...when output is OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Harness short circuit to power supply line Check the related circuits for any short circuit to g...

Page 307: ...power supply line detected when output is OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Harness short circuit to power supply line Check the related circuit...

Page 308: ...power supply line detected when output is OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Harness short circuit to power supply line Check the related circuit...

Page 309: ...s for any short circuit to ground 2 Winch brake release SOL fault Check if the solenoid functions normally Error code EO13L Winch brake release SOL Hi error Error code EO13L Details of failure Winch b...

Page 310: ...functions normally Additional information Refer to T 333 for relevant electric circuit and location Error code EOC02H Boom retraction SOL Lo error Error code EOC02H Details of failure Boom retraction...

Page 311: ...functions normally Additional information Refer to T 333 for relevant electric circuit and location Error code EOC04H Boom lowering SOL Lo error Error code EOC04H Details of failure Boom lowering SOL...

Page 312: ...tions normally Additional information Refer to T 333 for relevant electric circuit and location Error code EOC06H Winch wind down SOL Lo error Error code EOC06H Details of failure Winch wind down SOL...

Page 313: ...fault Check if the solenoid functions normally Additional information Refer to T 333 for relevant electric circuit and location Error code EOC08H Clockwise slewing SOL Lo error Error code EOC08H Detai...

Page 314: ...e SOL fault Check if the solenoid functions normally Additional information Refer to T 333 for relevant electric circuit and location Error code EOC10L Low pressure SOL Hi error Error code EOC10L Deta...

Page 315: ...T 333 Related electric circuits Location information...

Page 316: ...c circuit and location Error code EOF02H Fly jib derricking telescoping switch SOL Hi error Error code EOF02H Details of failure Fly jib derricking telescoping switch SOL Hi error Failure determining...

Page 317: ...T 335 Additional information Refer to T 326 for fly jib switching relay location Related electric circuits Location information...

Page 318: ...ation Refer to T 346 for relevant electric circuit and T 347 for location Error code EOH01L Crane high speed SOL Lo error Error code EOH01L Details of failure Crane high speed SOL Lo error Failure det...

Page 319: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOO02H OR1 out SOL Lo error Error code EOO02H Details of failure OR1 out SOL Lo error Fai...

Page 320: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOO04H OR2 out SOL Lo error Error code EOO04H Details of failure OR2 out SOL Lo error Fai...

Page 321: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOO06H OR3 out SOL Lo error Error code EOO06H Details of failure OR3 out SOL Lo error Fai...

Page 322: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOO08H OR4 out SOL Lo error Error code EOO08H Details of failure OR4 out SOL Lo error Fai...

Page 323: ...fault Check if the solenoid functions normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOP01L Pilot SOL Hi error Error code EOP01L Details...

Page 324: ...ns normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOS02H OR ground 2 SOL Lo error Error code EOS02H Details of failure OR ground 2 SOL L...

Page 325: ...ns normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOS04H OR ground 4 SOL Lo error Error code EOS04H Details of failure OR ground 4 SOL L...

Page 326: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOT02H Travelling backward left SOL Lo error Error code EOT02H Details of failure Backwar...

Page 327: ...normally Additional information Refer to T 346 for relevant electric circuit and T 347 for location Error code EOT04H Travelling backward right SOL Lo error Error code EOT04H Details of failure Backwa...

Page 328: ...T 346 Related electric circuits...

Page 329: ...T 347 Location information...

Page 330: ...essure sensor 1 fault Additional information Refer to T 350 for relevant electric circuit and location Error code ES03 Derrick pressure sensor 2 input error Error code ES03 Details of failure Derrick...

Page 331: ...7 89 V longest Replace the boom length meter sensor Additional information Refer to T 350 for relevant electric circuit and location Error code ES05H Boom angle sensor Hi error Error code ES05H Detail...

Page 332: ...T 350 Related electric circuits Location information...

Page 333: ...sor Additional information Refer to T 352 for relevant electric circuit and location Error code ES101 P1 oil temperature sensor pressure sensor 3 input error Error code ES101 Details of failure P1 oil...

Page 334: ...T 352 Related electric circuits Location information...

Page 335: ...use and diagnostic method Cause Diagnostic method and action to be taken 1 Fault of a circuit related to accelerator Check the circuits related to accelerator 2 Fault of accelerator potentiometer Moni...

Page 336: ...T 354 Related electric circuits Location information...

Page 337: ...stance exceeded 300 for 60 seconds Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Fault in circuit related to fuel sender Check the circuits related to fuel sende...

Page 338: ...95 V Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Fault in circuits relating to the slewing angle sensor CUP1 CUP2 potentiometers Check circuits relating to the...

Page 339: ...gth sensor voltage exceeded 4 95 V Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Fault in circuit related to fly jib length sensor Check circuits related to fly...

Page 340: ...T 358 Related electric circuits Location information...

Page 341: ...ngine ON Battery voltage undershot 11 V with engine OFF Assumed cause and diagnostic method Cause Diagnostic method and action to be taken 1 Open or short circuit of battery circuit Check the battery...

Page 342: ...T 360 Location information...

Page 343: ...circuits related to pressure sensor 2 Pressure sensor fault Replace the pressure sensor Error code EV11 Revolving lamp power supply Lo error Error code EV11 Details of failure Revolving lamp power su...

Page 344: ...T 362 Location information...

Page 345: ...ace the fly jib 24 V 12 V converter Additional information Refer to T 358 for relevant electric circuit and location Error code EV21 Fly jib sensor power supply Lo error Error code EV21 Details of fai...

Page 346: ...T 364 This Page Intentionally Left Blank...

Page 347: ...frozen T 410 E 4 Moment limiter indication values on monitor are questionable T 410 E 5 Fuel gauge fails to indicate normally T 411 E 6 Monitor does not display partially T 411 E 7 Screen does not swi...

Page 348: ...4 Hunting occurs during boom retraction T 423 H 15 Either boom No 2 or 3 fails to retract T 423 H 16 Crane cannot be operated discretely T 423 H 17 Natural descending amount of crane is significant T...

Page 349: ...for any clogging Check to make sure the fuel pump is running 3 Battery capacity shortage Check if battery voltage has dropped Voltage 1 item 12 V or more Specific gravity 1 item 1 26 or more 4 Intake...

Page 350: ...l piping and filter Check fuel line for any air inclusion Check fuel filter for any clogging Check to make sure the fuel pump is running 3 Intake system fault Check air cleaner for any clogging Check...

Page 351: ...t 5 Electrical wiring fault Check engine and fuel circuit 6 Hydraulic unit fault Check to ensure that hydraulic pump functions properly and there is no abnormality that may cause engine overload 7 Sup...

Page 352: ...unning 3 Intake system fault Check air cleaner for any clogging Check air intake piping for any fault 4 Fault in exhaust system Check the exhaust system including muffler and exhaust pipe for any abno...

Page 353: ...ormation Note on the use of unauthorized fuels Use of a low viscosity fuel such as kerosene may cause an injection fault due to an abnormal abrasion of injector seat resulting in generation of white s...

Page 354: ...e pending Check each item to ensure that replacement of engine oil engine oil filter air cleaner element and fuel filter is executed periodically 3 Electrical wiring fault Check engine and fuel circui...

Page 355: ...2 V or more Specific gravity 1 item 1 26 or more 3 Fuse blown off Check if fuse has been blown off If so ground fault may have occurred and thus check the circuit Fuse F8 F9 4 Open circuit failure of...

Page 356: ...newest version The internal fault prevents the diagnosis to be executed 2 Monitor fault Switch fault If the phenomenon appears again after the system is restarted a switch fault or monitor fault shoul...

Page 357: ...nitor fault should be suspected The internal fault prevents the diagnosis to be executed E 6 Monitor does not display partially Content Monitor screen does not display partially Assumed cause and acti...

Page 358: ...ause and action to be taken Cause Diagnostic method and action to be taken 1 Battery capacity shortage Check if battery voltage has dropped Voltage 1 item 12 V or more Specific gravity 1 item 1 26 or...

Page 359: ...If the filament of bulb is not burnt out failure of lamp body should be suspected E 11 Tri colour revolving working status lamp does not come ON Content All tri colour revolving working status lamp do...

Page 360: ...ver signal circuit for open circuits 3 Harness short circuit fault Contact with grounding circuit Check that there are no short circuits to ground in the locking lever signal circuit 4 Is the emergenc...

Page 361: ...it is not replace the I O unit TTC36X 7 Monitor fault When no problem is diagnosed in steps 1 6 it is likely that the monitor is defective 8 Lower controller fault If there is still no problem diagno...

Page 362: ...the circuit Fuse F2 10 A 2 There is emergency stop switch fault or perhaps the emergency stop switch is operating Check if the emergency stop switch functions properly 3 Override unit fault Check if...

Page 363: ...0 6 0 5 0 MPa 210 5 0 kg cm 2 2 Piston pump fault When none of the above written problems are found performance degradation malfunctions internal faults etc for the piston pump are possible H 2 Engine...

Page 364: ...nosis at a high engine idling speed Operation lever at neutral Output pressure 0 Mpa 0 kg cm 2 When using operation lever Pilot pressure 3 1 Mpa 32 kg cm 2 or more 2 Piston pump fault Piston pump A3 p...

Page 365: ...rectly 4 Clogging of hydraulic oil tank suction filter Since the hydraulic oil tank suction filter resulting in a negative pressure of the suction circuit is conceivable inspect directly 5 Piston pump...

Page 366: ...Check for winch 2 speed switch valve operation faults 3 Crane control valve winch operation valve spool operation fault Check for crane control valve winch operation valve spool operation faults 4 Cr...

Page 367: ...ation faults 3 Winch brake cancelation valve operation fault Check for winch brake release valve operation faults 4 Winch motor brake operation fault Check for winch motor brake operation faults 5 Win...

Page 368: ...the 2 speed shift hose joint and vent the air H 11 Boom telescoping is slow or weak Content Boom telescoping is slow or weak Assumed cause and action to be taken Cause Diagnostic method and action to...

Page 369: ...alfunction H 14 Hunting occurs during boom retraction Content Hunting occurs during boom retraction Assumed cause and action to be taken Cause Diagnostic method and action to be taken 1 Counterbalanci...

Page 370: ...nder leakage rate 10 cc 10 min 2 Counter balance valve leakage Check for leakage from the counter balance valve seat parts 3 Sequence valve mechanical check valve leakage Check for leakage from sequen...

Page 371: ...ravelling motor leakage amount 1 65 L min Assess by presence of abnormal sounds or heating metal powder contamination in drain oil etc H 20 Travelling speed is slow Content Travelling speed is slow As...

Page 372: ...to be taken 1 Travelling 2 speed switching solenoid malfunction Stop engine to perform preparations and conduct diagnosis at a high engine idling speed Travelling speed travel lever Lo position 1 or a...

Page 373: ...alfunctions May be assessed by presence of abnormal sounds or heating metal powder contamination in lubricating oil etc Content Only one side fails to slew Assumed cause and action to be taken Cause D...

Page 374: ...bricating oil etc Content Slewing acceleration is unsatisfactory or slewing speed is slow for only one side Assumed cause and action to be taken Cause Diagnostic method and action to be taken 1 Crane...

Page 375: ...ing reducer malfunctions May be assessed by presence of abnormal sounds or heating metal powder contamination in lubricating oil etc Content Overrun after stop of slewing is significant for only one s...

Page 376: ...wing reducer fault Check for slewing reducer malfunctions May be assessed by presence of abnormal sounds or heating metal powder contamination in lubricating oil etc 3 Slewing bearing fault Check for...

Page 377: ...ocument number 106E SM1804 00 First edition April 27 2018 Published by Maeda Seisakusho Co Ltd 1095 Onbegawa Shinonoi Nagano City Nagano Pref 388 8522 Japan http www maesei co jp Any reproduction or r...

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