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Maeda MC-305C-2 Service Manual

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SERVICE MANUAL
MINI-CRAWLER CRANE
Serial No. D0001
The parts numbers and lists written in this service manual are the
references for the services such as disassembling and assembling.
Be sure to ALWAYS refer to the latest parts catalog (the latest
information) before ordering any part, since the parts and the model
numbers are subject to change during the endless improvements and
changes of our Machine.
001 and up
001
001
and up
and up
and up
103E-SM0807-01

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  • Page 1 103E-SM0807-01 SERVICE MANUAL MINI-CRAWLER CRANE Serial No. D0001 001 and up and up and up and up The parts numbers and lists written in this service manual are the references for the services such as disassembling and assembling. Be sure to ALWAYS refer to the latest parts catalog (the latest information) before ordering any part, since the parts and the model numbers are subject to change during the endless improvements and changes of our Machine.

  • Page 3: Table Of Contents

    CONTENTS ITEM Page GENERAL 1- 1 1. SPECIFICATION DIMENSIONNAL DRAWING 1- 2 1.1 STANDARD SPECIFICATION 1- 2 1.2 ENGINE AND ELECTRIC MOTER SPECIFICATION 1- 3 2. DIMENSIONNAL DRAWING OF OUTRIGGER WIDTH 1- 4 3. PRINCIPLE SPECIFICATION LIST 1- 5 3.1 STANDARD SPECIFICATION 1- 5 3.2 ENGINE AND ELECTRIC MOTER SPECIFICATION 1- 6...

  • Page 4: Item Page

    ITEM Page 7. HYDRAULIC OIL PUMP 2- 49 7.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 49 7.2 INNER PARTS 2- 50 7.3 BASICS OF FUNCTIONALITY 2- 51 7.4 TROUBLE SHOOTING 2- 52 8. TRAVEL CONTROL VALVE 2- 53 8.1 EXTERIOR VIEW AND SPECIFICATIONS 2- 53 8.2 INNER PARTS 2- 54...
  • Page 5   ITEM Page 18.5 MECHANICAL CHECK VALVE (FOR TELESCOPIC CYLINDER) 2- 98 18.6 LEFT SIDE DERRICK CYLINDER 2-100 18.7 RIGHT SIDE DERRICK CYLINDER 2-102 19. WINCH 2-104 19.1 WINCH UNIT 2-104 19.2 HYDRAULIC OIL MOTOR 2-106 19.3 HYDRAULIC OIL MOTOR INNER PARTS 2-108 19.4 TROUBLE SHOOTING 2-110...
  • Page 6   ITEM Page 3. MOMENT LIMITER OVERVIEW AND FEATURES 3-27 4. EXTERNAL VIEW OF MOMENT LIMITER 3-28 4.1 DISPLAY UNIT 3-28 4.2 CONVERTER 3-29 5. BLOCK DIAGRAM 3-30 6. CONNECTOR DIAGRAM 3-31 7. CONNECTOR PIN ASSIGNMENT 3-32 7.1 CONVERTER CONNECTORS 3-32 7.2 DISPLAY UNIT CONNECTORS 3-33...
  • Page 7   ITEM Page 2. RECEIVER 4-18 2.1 STATUS DISPLAY 4-18 2.2 CONTROL PRINT CARD LACATIONS 4-20 2.3 CONNECTOR PIN ASSIGNMENT 4-24 2.4 VALVE NEUTRAL SETTING PROCEDURE 4-26 2.5 MONITOR DISPLAY MESSAGE 4-28 2.6 FUSE IN THE RECEIVER 4-29 3. VOICE MESSAGES 4-31 4.

  • Page 9: General

      GENERAL        1. SPECIFICATION DIMENSIONNAL DRAWING 1- 2 2. DIMENSIONNAL DRAWING OF OUTRIGGER WIDTH 1- 4 3. PRINCIPLE SPECIFICATION LIST 1- 5 4. WORKING RADIUS LIFTING HEIGHT 1- 8 5. TOTAL RATED LOAD CHART 1- 9 6. STANDARD PRESSURE AND OPERATING TIME CHART 1-12 7.

  • Page 10: Specification Dimensionnal Drawing

    1. SPECIFICATION DIMENSIONNAL DRAWING        1.1 STANDARD SPECIFICATION...

  • Page 11: Engine And Electric Moter Specification

    1.2 ENGINE AND ELECTRIC MOTER SPECIFICATION...

  • Page 12: Dimensionnal Drawing Of Outrigger Width

    2. DIMENSIONNAL DRAWING OF OUTRIGGER WIDTH       ...

  • Page 13: Principle Specification List

    3. PRINCIPLE SPECIFICATION LIST 3.1 STANDARD SPECIFICATION System / Item MC-305C-2 Machine mass 3900kg Overall length x width x height 4285mm x 1280mm x 1695mm Mass and Distance between idler and sprocket 1750mm dimensions Track gauge 980mm Track width 300mm Maximum rated total load x working 2.98t x 2.5m...

  • Page 14: Engine And Electric Moter Specification

    3.2 ENGINE AND ELECTRIC MOTER SPECIFICATION System / Item MC-305C-2 (Engine and Electric Motor Specifications) Machine mass 4040kg Overall length x width x height 4285mm x 1280mm x 1695mm Mass and Distance between idler and sprocket 1750mm dimensions Track gauge...
  • Page 15 System / Item MC-305C-2 (Engine and Electric Motor Specifications) Model Yanmar 3TNV76 Type Vertical in-line 3-cylinder, Water cooled, 4-cycle (special vortex) Engine Displacement 1.115L (1115cc) Rated output (continuous) 15.2kW/2500min (20.7PS/2500rpm) Fuel tank capacity Light oil/ 40L Battery Model 60B24R (DC12V x 1 piece) Motor specifications Three-phase induction motor: 5.5kW 4P 200.

  • Page 16: Working Radius Lifting Height

    4. WORKING RADIUS AND LIFTING HEIGHT                                        ...

  • Page 17: Total Rated Load Chart

    5. TOTAL RATED LOAD CHART [1] TOTAL RATED LOAD CHART AT WIRE ROPE 4 FALLS OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working Total rated Working Total rated Working Total rated Working Total rated radius (m) load (kg) radius (m) load (kg)
  • Page 18 [2] TOTAL RATED LOAD CHART AT WIRE ROPE 2 FALLS OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working Total rated Working Total rated Working Total rated Working Total rated radius (m) load (kg) radius (m) load (kg) radius (m) load (kg)
  • Page 19 [3] TOTAL RATED LOAD CHART AT WIRE ROPE 1 FALL OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working Total rated Working Total rated Working Total rated Working Total rated radius (m) load (kg) radius (m) load (kg) radius (m) load (kg)

  • Page 20: Standard Pressure And Operating Time Chart

    6. STANDARD PRESSURE AND OPERATING TIME CHART 6.1 OUTRIGGER (WHEN OIL TEMPERATURE 30 - 50 °C) WHEN FULL ACCELERATING Operating time (sec) Operating Pressure (MPa) (At Traveling control valve) Engine power Electric motor power Extend 10±2 14±2 Front Outrigger Slide (2-pieces) Retract 10±2...

  • Page 21: Power Train Drawing

    7. POWER TRAIN DRAWING                                                                           ...
  • Page 22     1-14...

  • Page 23: Construction & Maintenance

                      CONSTRUCTION & MAINTENANCE   1. HYDRAULIC CERCUIT DIAGRAM 2- 3 2. HYDRAULIC OIL PIPING 2- 6 3. TANK 2- 24 4. RETURN MANI-BLOCK 2- 27 5. CHECK VALVE 2- 28 6. ENGINE ASSEMBLY 2- 30 7.
  • Page 24        ...
  • Page 25 1. HYDRAULIC CERCUIT DIAGRAM...

  • Page 28: Hydraulic Oil Piping

    2. HYDRAULIC OIL PIPING 2.1 CRANE ROTATE PORTION...
  • Page 29 DESCRIPTION Q’TY NOTICE Long Connector (3/8) Parts No.: 349-4412500 Elbow (90 deg. With Seat) 1071-06 Hydraulic Oil Hose (TA) N3000-06 X 1480L SC- PF-06 (O-Ring) X SF- PF-06 Hydraulic Oil Hose (TB) N3000-06 X 1480L SC- PF-06 (O-Ring) X SF- PF-06 Elbow (45 deg.

  • Page 30: Crane Fixed Portion

    2.2 CRANE FIXED PORTION...
  • Page 31 DESCRIPTION Q’TY NOTICE Hydraulic Oil Hose (DA, Lower) KG06 C-C X 2550L Hydraulic Oil Hose (DB, Lower) KG06 C-C X 2550L Hydraulic Oil Hose (WA, Lower) KG06 C-C X 2550L Hydraulic Oil Hose (TA, Lower) KG06 C-C X 2550L Hydraulic Oil Hose (TB, Lower) KG06 C-C X 2550L Hydraulic Oil Hose (WB, Lower) KG06 C-C X 2600L...

  • Page 32: Travel Line

    2.3 TRAVEL LINE 2-10...
  • Page 33 DESCRIPTION Q’TY NOTICE Travel Hose (1) KG C-C X 2150L (With Protector) Travel Hose (2) KG C-C X 2150L (With Protector) Travel Hose (3) KG C-C X 2200L (With Protector) Travel Hose (4) KG C-C X 2200L (With Protector) Terminal (A) Parts No.: 103-3265400 Connector 1067-08-06...

  • Page 34: Outrigger Line

    2.4 OUTRIGGER LINE 2-12...
  • Page 35 DESCRIPTION Q’TY NOTICE OR Pipe (Extension) (FFRA) Parts No.:103-3266200 OR Pipe (Extension) (FFRB) Parts No.:103-3266300 OR Pipe (Grounding) (FRA) Parts No.:103-3266400 OR Pipe (Grounding) (FRB) Parts No.:103-3266500 OR Pipe (Extension) (FFLA) Parts No.:103-3266600 OR Pipe (Extension) (FFLB) Parts No.:103-3266700 OR Pipe (Grounding) (FLA) Parts No.:103-3266800 OR Pipe (Grounding) (FLB) Parts No.:103-3266900...
  • Page 36 DESCRIPTION Q’TY NOTICE Gall (40) Parts No.: 103-4531700 Gall (50) Parts No.: 103-4531800 Gall (3) Parts No.: 349-4400200 Gall (4) Parts No.: 103-4531900 Bolt (With Washer) M6 X 1.0 X 25L Bolt (With Washer) M6 X 1.0 X 25L Bolt M10 X 1.5 X 80L (Plating) Skipped No.
  • Page 37 2-15...

  • Page 38: Pump Line (P Line)

    2.5 PUMP LINE (P LINE) 2-16...
  • Page 39 DESCRIPTION Q’TY NOTICE Hose Nipple 40 X R1・1/2 Nipple R1・1/2 X 50L (Low Pressure Type) Nipple R1・1/2 X 75L (Low Pressure Type) Elbow RC1・1/2 (Low Pressure Type) RC1・1/2 (Low Pressure Type) Plug R1・1/2 (Low Pressure Type) Suction Hose 136-244-40 X 300L (S-Type) Hose Band ABA Hose Clamp 44-56 Elbow (90 deg.)

  • Page 40: Tank And Drain Line (T And Dr Line)

    2.6 TANK AND DRAIN LINE (T AND DR LINE) 2-18...
  • Page 41 DESCRIPTION Q’TY NOTICE Return Hose (CV1) PA0312 C-CR9 X 1650L (With Spiral Sheets) Return Hose (CV2) PA0308 CR9-CR4 X 1660L (With Spiral Sheets) Return Hose (RF) PA0316 C-CR9 X 350L (With Spiral Sheets) Return Hose (OC IN) PA0316 C-C X 480L (With Spiral Sheets) Return Hose (OC OUT) PA0316 C-C X 430L (With Spiral Sheets) Return Hose (T)

  • Page 42: Pilot Line

    2.7 PILOT LINE 2-20...
  • Page 43 DESCRIPTION Q’TY NOTICE Hydraulic Oil Hose (PP1) SPL04 C-C X 1000L Hydraulic Oil Hose (PP2) SPL04 C-C X 880L Traveling Motor Hose (PLT) KP04 C-C X 1250L Traveling Motor Hose (PLT) KP04 C-C X 800L (With Protector) Connector (O-Ring Boss) 1068-04 Elbow (90 deg.) 1034-04...

  • Page 44: Electric Motor Line

    2.8 ELECTRIC MOTOR LINE 2-22...
  • Page 45 DESCRIPTION Q’TY NOTICE Hose Nipple 27 X R1 Bushing R1・1/2 X RC1 (Low Pressure Type) Elbow RC1・1/2 X R1・1/2 (Low Pressure Type) Suction Hose 25.4 X 34 X 1700L Hose Band ABA Hose Clamp 26-38 Skipped No. Connector 1067-06 Elbow (90 deg., Swivel) 1030-06 Connector 1009-06...

  • Page 46: Tank

    3. TANK 3.1 HYDRAULIC TANK DESCRIPTION Q’TY NOTICE (#D001 - D0020) Parts No.: 103S96200000 Hydraulic Tank Assembly (#D0021 -) Parts No.: 103S98700000 SEAL Washer (#D001 - D0020) W16 Parts No.: 103S96214000 1-14 O-Ring (#D0021 -) 1A-P14 (For G3/8) 1-15 Plug 1126-06 (G3/8) Suction Filter Assembly Parts No.: 103S94200000...

  • Page 47: Fuel Tank

    3.2 FUEL TANK DESCRIPTION Q’TY NOTICE FUEL Tank Assembly (#D001 - D0020) Parts No.: 103S98800000 (#D0021 -) Parts No.: 103S96300000 SEAL Washer (#D001 – D0020) W16 Parts No.: 103S96214000 1-13 O-Ring (#D0021 -) 1A-P14 (For G3/8) 1-15 Plug 1126-06 (G3/8) Fuel Level Sensor Assembly Parts No.: 103S93100000 Screw (With Washer)
  • Page 48 3.2.1 FUEL LEVEL SENSOR DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Mounting Plate Hex. Nut Philp head Screw Die Cast Body Spring Washer Spring Washer Skipped No. Contact Bolt RVC Wire Tank Wire Plane Washer Rivet Float Washer Insualted Washer Terminal Plane Washer Terminal Clip Extension Bracket...

  • Page 49: Return Mani-Block

    4. RETURN MANI-BLOCK Each Ports Connection Port Size Crane Control valve Port T1 Oil Cooler Inlet Outrigger Control valve Port V PF3/4 Travel Control valve Port T Hydraulic Tank Outlet Oil Cooler Outlet DESCRIPTION Q’TY NOTICE System Block F-2460B Check Valve DE-CVA-00-0070 SPECIFICATIONS Max.
  • Page 50 5. CHECK VALVE DESCRIPTION Q’TY NOTICE Body Maker Parts No.: 01113-10100 Port Thread Size: PT1/2 Plunger Maker Parts No.: 01113-10200 Compression Spring Maker Parts No.: 01113-10300 Skipped No. Plane Washer Maker Parts No.: 083007-02100 Snap Ring Maker Parts No.: 084300-01018 SPECIFICATIONS Rated Flow Capacity 70 L / min...
  • Page 51 2-29...

  • Page 52: Engine Assembly

    6. ENGINE ASSEMBLY 6.1 ENGINE ASSEMBLY DESCRIPTION Q’TY NOTICE ENGINE PARTS NO.: 103S89900000 OIL COOLER PARTS NO.: 103S90400000 2-30...

  • Page 53: Principal Engine Specifications

    6.2 PRINCIPAL ENGINE SPECIFICATIONS Engine Model 3TNV76-NMB Type Vertical In-line Diesel Engine Combustion System Ball-type Swift Chamber Aspiration Natural NO. Of Cylinder - Bore x Stroke 3 - 76 x 82 mm Displacement 1.115 L Continuous Rated Output 15.2 kW (20.7 PS) / 2500min Max.

  • Page 54: Each Section Name

    6.3 EACH SECTION NAME 2-32...

  • Page 55: Labels

    6.4 LABELS 6.4.1 EMISSION CONTROL LABELS Since emission control regulations are being issued on a global basis, it is necessary to identify which regulations a particular engine complies with. We have listed several different types of labels you might find on your engine.

  • Page 56: Diesel Fuel

    6.5 DIESEL FUEL 6.5.1 FUEL SYSTEM ( BALL-TYPE SWIRT CHAMBER 6.5.2 USE OF ADEQUATE FUELS Use poor quality fuels may cause defects as described below. Instruct users for use of adequate fuels. 1. Deposit to Exhaust Valves Deposit to exhaust valves may cause compression defect, incomplete combustion and/or poor fuel consumption efficiency, as well as, mixture of incineration residue of fuel into exhaust gas and corrosion of exhaust valve seats.
  • Page 57 6.5.3 DIESEL FUEL SPECIFICATIONS Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels Diesel Fuel Specification Location JIS K2204 Grade No. 2 Japan No.2-D, No.1-D, ASTM D975-94 EN590: 96 European Union ISO 8217 DM X International BS 2869-A1 or A2 United Kingdom...
  • Page 58 [Precautions and concerns regarding the use of bio-fuels] 1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components. 2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth. 3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization.

  • Page 59: Coolant

    6.6 COOLANT 6.6.1 COOLANT SYSTEM 6.6.2 USE OF ADEQUATE COOLANT Contaminants contained in coolant may deposit sludges to internal surface of engine and/or radiator or rust those. Further, that prevents correct heat conductivity or circulation of coolant, thus, poor cooling and engine overheat may result, Drain coolant and wash interior of cooling system with cleaning solution every 1,000 hours of operation or annually.

  • Page 60: Lubricating Oil

    6.7 LUBRICATING OIL 6.7.1 LUBRICATING SYSTEM 6.7.2 USE OF ADEQUATE LUBRICANT Use of adequate Lubrication Oil shall facilitate: 1. Reducing attrition of friction area in Engine. 2. Preventing rust and corrosion of Engine area. 3. Cooling of heat area in Engine. 4.
  • Page 61 6.7.3 ENGINE OIL SPECIFICATIONS Use an engine oil that meets or exceeds the following guidelines and classifications: [Service Categories] ･ API Service Categories CD or higher ･ ACEA Service Categories E-3, E-4, and E-5 ･ JASO Service Categories DH-1 [Definitions] ･...

  • Page 62: Periodic Maintenance Schedule

    6.8 PERIODIC MAINTENANCE SCHEDULE Instruct your users to follow schedule of Engine Periodic Maintenance as listed below: ○: Check ◇: replace ●: Contact your authorized Ynmar industrial engine dealer or distributor Periodic Maintenance Interval Every Every Every Every Every Every System Check Item Daily...
  • Page 63 2-41...

  • Page 64: Trouble Shooting

    6.9 TROUBLE SHOOTING This table is a summary of general disorders and causes. It is strongly advised to take adequate actions to prevent serious accidents whenever an indication of any disorder is detected: Disorders at Engine Power Exhaust Hunting Disorders Starting Down Engine stall...
  • Page 65 Lubricating Oil Intake Coolant Counter-action ○ ○ Adjust valve clearance ○ ○ ○ ○ Valve seat fitting ○ ○ ○ ○ Repair or replace intake and exhaust valve ○ ○ Replace gasket ○ ○ ○ ○ ○ ○ Replace Piston Ring ○...
  • Page 66 Disorders at Engine Power Exhaust Hunting Disorders Starting Down Engine stall Exhaust Gas Operat. Smoke Cause ○ ○ ○ Fuel Injection Pump Timing, too early ○ ○ ○ ○ Fuel Injection Pump Timing, too late ○ ○ ○ ○ ○ Improper fuel ○...
  • Page 67 Lubricating Oil Coolant Intake Counter-action ○ Check and adjust ○ ○ Check and adjust Replace to adequate fuel Drain fuel filter Clean or replace Air bleed Clean or replace Check fuel filter and feed pump ○ ○ Check and adjust ○...

  • Page 68: Fuel Piping

    6.10 FUEL PIPING 2-46...
  • Page 69 DESCRIPTION Q’TY NOTICE Fuel Hose (1) YOKOHAMA Fuel Hose 8 x 850L Fuel Hose (2) Parts No.: 103-4544800 Fuel Hose YOKOHAMA Fuel Hose 8 x 950L Corrugate Tube 15 x 19.5 x 15.2 x 770L Fuel Hose (3) YOKOHAMA Fuel Hose 8 x 420L Fuel Hose (4) YOKOHAMA Fuel Hose 8 x 300L Fuel Hose (5)

  • Page 70: Coolant Piping

    6.11 COOLANT PIPING DESCRIPTION Q’TY NOTICE Radiator Drain Hose KURARAY Fuel Hose 8 x 14 x 470L Radiator Drain Hose KURARAY Fuel Hose 8 x 14 x 250L Radiator Drain Hose KURARAY Fuel Hose 8 x 14 x 420L Radiator Drain Hose HI MID OIL 6 800L 2-48...

  • Page 71: Hydraulic Oil Pump

    7. HYDRAULIC OIL PUMP 7.1 EXTERIOR VIEW AND SPECIFICATIONS Specifications Pump Capacity P1 + P2: 13 + 13 cc / rev Recommended Oil ISO VG 32, 46, 68 Oil Temp. Scope -20 - 100 °C P1: 20.59 MPa Max. Oil Pressure P2: 20.59 MPa Permitted Contamination NAS1638 class 11 or better...

  • Page 72: Inner Parts

    7.2 INNER PARTS DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Body (S) Stopper Pin (A) Hex. Socket Head Plug Body (H) Stopper Pin (B) Skipped no. Shaft Skipped No. Plug Cylinder BARREL Skipped No. Spring Washer Valve Plate Skipped No. Skipped no. Piston Ball Bearing Skipped no.

  • Page 73: Basics Of Functionality

    7.3 BASICS OF FUNCTIONALITY Operation Principle 1. Outline This lightweight hydraulic pump can discharge two equal amounts of flow despite its compact size which requires only one conventional variable pump space. It provides with constant horsepower control characteristics which reduces discharge against increase of pump load to maintain constant load of the engine and to efficiently utilize its power.

  • Page 74: Trouble Shooting

    7.4 TROUBLE SHOOTING Disorders Cause Counter-action ･ Engine revolution rate is higher than the ･ Adjust to prescribed rate. prescription. ･ Adjust to prescribed rate. Engine, Over load ･ Pressure is higher than the prescription. ･ Repair or replace ･ Pump components, seizure or damage. Hydraulic oil discharge amount is ･...

  • Page 75: Travel Control Valve

    8. TRAVEL CONTROL VALVE 8.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Each Ports Connection Port Size Port Size Pump P2 Port PF1/2 Left Travel Motor A Port (Forward) PF3/8 Pump P1 Port PF1/2 Left Travel Motor B Port (Reverse) PF3/8 Return PF1/2...

  • Page 76: Inner Parts

    8.2 INNER PARTS DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Compression Spring Spring Cover Screw (M10 X 14) Needle Valve Tie Rod Nut (M8) Cap Nut Inlet Housing Rivet Gasket Inlet Housing O-Ring (1A-P12) Spring Holder Plug O-Ring (1B-P8) Compression Spring Plunger Housing O-Ring (1B-P9) Seal Holder...

  • Page 77: Inspection And Adjustment

    8.3 INSPECTION AND ADJUSTMENT [1] PARTS INSPECTION Assembly Criteria Counter-action ･ Scratch, rust and/or corrosion in spool sliding area. ･ Replace ･ Scratch, rust and/or corrosion in seal pocket of spool insertion. ･ Replace ･ Housing ･ Scratch, rust and/or corrosion in port seal area next to O-ring . ･...

  • Page 78: Trouble Shooting

    8.4 TROUBLE SHOOTING Each Item shown in the table below indicates only individual problem, however, troubles may be caused by multiple problems, in many cases. It is advisable to check one by one for efficient trouble shooting. Disorders Cause Counter-action ･...

  • Page 79: Traveling Motor

    9. TRAVELING MOTOR 9.1 EXTERIOR VIEW AND SPECIFICATIONS Right Traveling Motor Left Traveling Motor A Port Reverse B Port Reverse B Port Forward A Port Forward Specifications Specifications Of Reduction Gear Max. Output Torque 3461 N・m (353 kgf・m) Max. Output Revolution 25.1 / 42.9 min Reduction Ratio 1 / 52.73...

  • Page 80: Inner Parts

    9.2 INNER PARTS 9.2.1 REDUCTION GEAR 2-58...
  • Page 81 DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Body Thrust Collar O-Ring (AS568-263-70) Cover Slide Ring O-Ring (1B-P14) Skipped No. Floating Seal 2set O-Ring (1B-P8) ・O-Ring Carrier Plug Skipped No. Bearing Plug Gear (B1) Needle Hydraulic Oil Motor Gear (B2) Needle Skipped No. Gear (S1) Thrust Washer Skipped No.
  • Page 82 9.2.2 HYDRAULIC OIL MOTOR 2-60...
  • Page 83 DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Body Assembly (1) Ball Spool Body (2) Snap Ring (28) Shuttle Spool Shaft Screw (M10X25) Spring (V 1) Cylinder Barrel Spring Pin (5X12) Spring (V 2) Valve Plate Spring (V 3) Piston Disk Plate Plug Shoe Steel Plate...

  • Page 84: Precautions For Use

    9.3 PRECAUTIONS FOR USE 9.3.1 INSTALLATION 1. Fitting Area (Ref. Figure, right) Fitting A to Sprocket: 210h8 (0 / -0.072) Fitting B to Body: 165h8 (0 / -0.063) 2. To install Motor to Body and/or to install Sprocket to Motor, use mount bolts and fix them mildly, but avoid tapping by hammers.
  • Page 85 9.3.3 LUBRICATING OIL FOR GEARS 1. Use diesel oil class “SAE30-CD” or equivalent for lubricating oil. (Apollo Diesel Motive S-330 of Idemitsu Kosan is used at delivery of our cranes.) 2. It is user’s option to select lubricating oil from any other recommended products; however it is not advisable to mix different brands 3.

  • Page 86: Crane Control Valve

    10. CRANE CONTROL VALVE 10.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Port Size Each Ports Connection Port Size Travel Control Valve (CO1) PF1/2 Return PF1/2 Derrick Cylinder Bottom (Boom Raise) PF3/8 Telescopic Cylinder Head (Boom Retract) PF3/8 Derrick Cylinder Head (Boom Lower) PF3/8 Telescopic Cylinder Bottom (Boom Extend) PF3/8...

  • Page 87: Hydraulic Circuit Diagram

    10.2 HYDRAULIC CIRCUIT DIAGRAM 2-65...

  • Page 88: Rgb Block

    10.3 RGB BLOCK 2-66...
  • Page 89 1. Back Pressure Valve Back pressure valve secures minimum pressure rate of hydraulic oil to actuate control cylinder. 2. Reducing Valve Reducing valve reduces pressure rate of hydraulic oil to control cylinder to proper level. 3. Main Relief Valve Main relief valve regulates maximum pressure of pump circuit. 4.

  • Page 90: Accelerator Block

    10.4 ACCELERATOR BLOCK 10.5 FUNCTION BLOCK (DERRICK, WINCH, TELESCOPIC, SLEWING) 2-68...

  • Page 91: Solenoid Valve Functioning Principle

    10.6 SOLENOID VALVE FUNCTIONING PRINCIPLE These figures are for the purpose to illustrate basics of functionality of solenoid valves. Solenoid valves SA and SB for control valve are the same in their basics of functionality. 1. Unmagnetized conditions 2. Magnetized conditions Circuit to control cylinder is interrupted.
  • Page 92 Computation of Deviations and Pulse Width Hydraulic unit is controlled as follows: 1. When control is out, a transistor in the receiver is “OFF” and solenoid valves are attached to a tank. In this condition control cylinder is held in neutral position by spring tension.
  • Page 93 2-71...

  • Page 94: Outrigger Control Valve

    11. OUTRIGGER CONTROL VALVE 11.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Port Size Each Ports Connection Port Size Confluence Select Valve Port A PF1/2 OR Selector valve (1) Port P1 (Out) PF3/8 Return PF1/2 OR Selector valve (1) Port P2 (In) PF3/8 OR Selector valve (3) Port P1 (Out) PF3/8...
  • Page 95 Circuit Diagram Specifications Max. Common Use Pressure 20.6MPa (210 kgf / cm Rated Flow Capacity 50 L / min Relief Setting Pressure 2.94 - 24.5 MPa (30 - 250 kgf / cm Back Pressure Valve Setting Pressure 1.27 - 1.67 MPa (13 - 17 kgf / cm Reducing Pressure Valve Setting Pressure 1.18 - 1.57 MPa (12 - 16 kgf / cm Allowable Back Pressure for Port T...

  • Page 96: Inner Parts

    11.2 INNER PARTS Tightening Torque Table DESCRIPTION Q’TY Portion Tightening Torque Thread Size Inlet Section Mounting Bolt 19.6±0.98 N・m Block (Outrigger 1, 3, 4) Spool (Outrigger 1, 3, 4) 18.6±0.98 N・m Spool End and Connecting End Block (Outrigger 2) Coat Lock-tight #242 Spool (Outrigger 2) Solenoid Mounting Bolt 2.45 - 3.43N・m...

  • Page 97: Outrigger Select Valve

    12. OUTRIGGER SELECT VALVE 12.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Port Size Outrigger Control Valve Port A PF1/4 Outrigger Control Valve Port B PF1/4 Outrigger Slide Cylinder Bottom (Extension Out) PF1/4 Outrigger Cylinder Bottom (Grounding Out) PF1/4 Outrigger Cylinder Head (Grounding In) PF1/4 Outrigger Slide Cylinder Head (Extension In) PF1/4...

  • Page 98: Inner Parts

    12.2 INNER PARTS DESCRIPTION Q’TY Solenoid Block Repair Kit ・Cap ・O-Ring (14.00) ・O-Ring (29.87) Cap Set Main Block 2-76...

  • Page 99: Crane Circuit Confluence Valve

    13. CRANE CIRCUIT CONFLUENCE VALVE 13.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Port Size Travel Control Valve (CO2) 7/8-14 UNF Outrigger Control Valve Port P 7/8-14 UNF Crane Control Valve Port P1 7/8-14 UNF Travel Control Valve (CO1) Outrigger Control Valve Port GP 9/16-18 UNF Crane Control Valve Port PP1 Drain...

  • Page 100: Inner Parts

    13.2 INNER PARTS DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Plug Compression Spring Rivet Compression Spring Body Steel Ball Sleeve Spool O-Ring (1A-P16) Spool Skipped No. O-Ring (1B-P14) Solenoid Flange Plug (PF3/8) O-Ring (AS568-906) Name Plate Hex. Socket Head Bolt (M5X10) Plug (NPTF1/16) Stopper Plane Washer (M5)

  • Page 101: Inspection And Adjustment

    13.3 INSPECTION AND ADJUSTMENT [1] PARTS INSPECTION Assembly Criteria Counter-action ･ Damage to solenoids, including short-circuit and wire breakage. ･ Replace ･ Coil Assembly ･ Short-circuit and wire breakage. ･ Replace ･ Scratch, rust and/or corrosion in spool sliding area. ･...

  • Page 102: Traveling Speed Select Valve

    14. TRAVELING SPEED SELECT VALVE 14.1 EXTERIOR VIEW AND SPECIFICATIONS Each Ports Connection Port Size Travel Control Valve Pressure Pick-up Port PF1/4 Left and Right Traveling Motors Port PP PF1/4 Drain PF1/4 DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Plug Solenoid Rivet Body Name Plate...

  • Page 103: Inspection And Adjustment

    14.2 INSPECTION AND ADJUSTMENT [1] PARTS INSPECTION Assembly Criteria Counter-action ･ Damage to solenoids, including short-circuit and wire breakage. ･ Replace ･ Coil Assembly ･ Short-circuit and wire breakage. ･ Replace ･ Scratch, rust and/or corrosion in spool sliding area. ･...

  • Page 104: Rotary Joint

    15. ROTARY JOINT 15.1 EXTERIOR VIEW AND SPECIFICATIONS 2-82...

  • Page 105: Inner Parts

    Rotary Joint Connection Table Thread Thread Stamp Upper Side Connecting Hose Stamp Lower Side Connecting Hose Size Size (Boom Retract) PF3/8 TB Hose (Crane Valve Port A3) PF3/8 TB Hose (Telescopic Cylinder Head Port) TA Hose (Telescopic Cylinder Bottom Port) (Boom Extend) PF3/8 TA Hose (Crane Valve Port B3) PF3/8...

  • Page 106: Hook Block

    16. HOOK BLOCK 2-84...
  • Page 107 DESCRIPTION Q’TY NOTICE Hook Block Sheave Pin Hook Hook Nut Sheave Sheave Collar (N) Sheave Collar Stopper aPlate Top Guard Top Plate Thrust Bearing 51206 Spring Pin 5 X 45L Hex. Socket Head Button Bolt M10X22L (Plating) 8.8T Spring Washer M10 (Plating) Hex.

  • Page 108: Hook Block Inspection

    16.1 HOOK BLOCK INSPECTION The hook block is one of the important maintenance parts. Check by the following procedure and be sure to always use under safe condition. Repair or replace immediately whenever any defect is found as result of the inspection. Replacement requires a modification inspection prior.
  • Page 109 2-87...

  • Page 110: Boom

    17. BOOM 2-88...
  • Page 111 DESCRIPTION Q’TY NOTICE No.1 Boom No.2 Boom No.3 Boom No.4 Boom No.5 Boom Wire Rope Wire Rope (For Boom Extend) Wire Rope (For Boom Retract) Wire Clip Assembly Wedge Wedge Socket Slide Plate (B2 Upper) Slide Plate (B3 Upper) Slide Plate (Boom Lower) Side Slide Plate Slide Plate (S) Side Stopper Plate...
  • Page 112 DESCRIPTION Q’TY NOTICE Bolt M10X1.5X20L (Plating) 4.6T Bolt M10X1.5X16L (Plating) 8.8T Bolt M8X1.25X20L (Plating) 12.9T Bolt M8X1.25X12L (Plating) 12.9T Bolt M6X1.0X15L (Plating) 4.6T Bolt M6X1.0X10L (Plating) 4.6T Flat Head Bolt (With Hex. Hole) M6X1.0X8L Flat Head Bolt (With Hex. Hole) M12X1.75X30L Flat Head Bolt (With Hex.
  • Page 113 2-91...

  • Page 114: Telescopic And Derrick Cylinder

    18. TELESCOPIC AND DERRICK CYLINDER 18.1 TELESCOPIC CYLINDER 2-92...
  • Page 115 DESCRIPTION Q’TY NOTICE No.1 Telescopic Cylinder Assembly 1-27 Counter Balance Valve Parts No.: 300S09200000 Tightening Torque: 88.2 - 98.0 N・m 1-28 Sequence Valve Parts No.: 300S09000000 Tightening Torque: 98.0 - 117.6 N・m 1-29 Mechanical Check Valve Parts No.: 300S09100000 Tightening Torque: 68.6 - 78.4 N・m No.2 Telescopic Cylinder Assembly 2-30 Bolt...

  • Page 116: Telescopic Cylinder Hydraulic Circuit System

    18.2 TELESCOPIC CYLINDER HYDRAULIC CIRCUIT SYSTEM 2-94...

  • Page 117: Counter Balance Valve (For Telescopic And Derrick Cylinder)

    18.3 COUNTER BALANCE VALVE (FOR TELESCOPIC AND DERRICK CYLINDER) 18.3.1 STRUCTURE Specifications Max. Common Use Pressure 20.6 MPa (210 kgf / cm Resiting Pressure 30.9 MPa (315 kgf / cm Max. Flow Capacity 50 L / min Rated Flow Capacity 40 L / min Allowable Leakage Capacity Less than 0.05 L / min (Apply 20.6 MPa [210 kgf / cm...
  • Page 118 18.3.3 FUNCTION 1. When Neutral 2. When Extended 3. When Retracted 2-96...

  • Page 119: Sequence Valve (For Telescopic Cylinder)

    18.4 SEQUENCE VALVE (FOR TELESCOPIC CYLINDER) Specifications Rated Flow Capacity 40 L / min Allowable Leakage Capacity Less than 0.05 L / min [Apply 20.6 MPa (210 kgf / cm From Port B] ＋ ＋ Pilot Pressure 1.18 MPa (12 kgf / cm ) At Valve Opened Check Valve Cracking Pressure...

  • Page 120: Mechanical Check Valve (For Telescopic Cylinder)

    18.5 MECHANICAL CHECK VALVE (FOR TELESCOPIC CYLINDER) Specifications Rated Flow Capacity 50 L / min ＋ ＋ Pilot Pressure 1.18 MPa (12 kgf / cm ) At Valve Opened Pressure Loss (B to A) Less than 9.8 MPa (100 kgf/cm Check Valve Cracking Pressure 2.45 MPa (25 kgf / cm 0.65 x Pressure + ２０...
  • Page 121 2-99...

  • Page 122: Left Side Derrick Cylinder

    18.6 LEFT SIDE DERRICK CYLINDER 2-100...
  • Page 123 DESCRIPTION Q’TY NOTICE Cylinder Piston Rod Cylinder Head Bushing LFB-5030 Rod Packing GNY-50 Back-up Ring TC-GNY-50 Dust Seal SCB-50 Snap Ring AR62 O-Ring 1B-G75 Back-up Ring T3-G75 O-Ring 1B-G80 Piston Piston Ring SPGW 65, 80, 10.5 Wear Ring 75, 80, 20 O-Ring 1B-P38 Set Screw...

  • Page 124: Right Side Derrick Cylinder

    18.7 RIGHT SIDE DERRICK CYLINDER 2-102...
  • Page 125 DESCRIPTION Q’TY NOTICE Cylinder Piston Rod Cylinder Head Bushing LFB-5030 Rod Packing GNY-50 Back-up Ring TC-GNY-50 Dust Seal SCB-50 Snap Ring AR62 O-Ring 1B-G75 Back-up Ring T3-G75 O-Ring 1B-G80 Piston Piston Ring SPGW 65, 80, 10.5 Wear Ring 75, 80, 20 O-Ring 1B-P38 Set Screw...

  • Page 126: Winch

    19. WINCH 19.1 WINCH UNIT 2-104...
  • Page 127 DESCRIPTION Q’TY NOTICE Winch Unit Assembly Winch Case Winch Cover Wire Supporting Roller (A) Wire Supporting Roller (B) Roller Arm Roller Pin Spring Spring Adjusting Bolt BEARING #6000ZZ Roller Arm Pin Hex. Head Socket Bolt M6X1.0X15L Tightening Torque: 11.1 - 15.0 N・m (Coat Lock-tight #262) Snap Pin 10 (Plating) Plane Washer...

  • Page 128: Hydraulic Oil Motor

    19.2 HYDRAULIC OIL MOTOR Specifications Specifications of Reduction Gear Reduction Ratio 28.7 Max. Output Torque 1030 N・m (105 kgf・m) Max. Output Revolution 123 min Specifications of Hydraulic Oil Motor Capacity per Stroke 17.3 cm / rev Max. Common Use Pressure 20.6 MPa (210 kgf / cm Max.
  • Page 129 2-107...

  • Page 130: Hydraulic Oil Motor Inner Parts

    19.3 HYDRAULIC OIL MOTOR INNER PARTS 2-108...
  • Page 131 DESCRIPTION Q’TY DESCRIPTION Q’TY DESCRIPTION Q’TY Drum Snap Ring (For Hole) Spring Spindle Kit Snap Ring (For Shaft) Friction Plate ・Spindle Assembly Snap Ring (For Shaft) Plate ・・Spindle O-Ring O-Ring ・・Hold Flange O-Ring O-Ring ・Parallel Pin Plug O-Ring ・Hex. Head Socket Bolt Orifice O-Ring RV Gear Assembly...

  • Page 132: Trouble Shooting

    19.4 TROUBLE SHOOTING [1] Seal Parts Seal parts (i.e. O-rings and oil seals) should be replaced to new ones when the assembly is once overhauled, regardless of part has no damage. [2] Criteria for replacement of wear and tear 1. Replace all the parts which show visible serious damage. 2.

  • Page 133: Safety Precautions

    19.5 SAFETY PRECAUTIONS ･ All the services must be performed by personnel who is practiced to Hydraulic Wiinch operations. ･ Always wear Protective Gear such as Safety Footwear and Hard Cap for services. 1. Installation Q’ty Dimensions Applicable Bolt Recommended Tightening Torque Holes for Bolts M12 (P = 1.75) M12 (P = 1.75)
  • Page 134 3. Hydraulic Oil Hydraulic oil is removed from motor casing when delivered to customers. Assure to fill motor casing with hydraulic oil before start the operation. 4. Check and Exchange of Hydraulic Oil Frequency of exchanging oil depends on specific operation conditions; as general, change at frequency as stated below; ･...
  • Page 135 6. Procedure for Gear Oil Exchange: Gear Oil for exchange should be the same type and brand. Do not mix different oil. (1) Lower hook as well as any load to the ground. (2) Set face of refuel port and drain port perpendicular to horizontal level. (Refer to a figure below) (3) Suspend hydraulic pump.

  • Page 136: Slewing System

    20. SLEWING SYSTEM 20.1 EXTERIOR VIEW (SERIAL NO.D0001 – D0132)   2-114...
  • Page 137   DESCRIPTION Q’TY NOTICE Slewing Bearing Slewing Gear Box Assembly Hydraulic Oil Motor O-Ring AS568-152 Slewing Gear Cover (A) Slewing Gear Cover (B) Grease Nipple A-PT1/8 Bolt M20X2.5X80L Tightening Torque: 450 – 608 N・m (Coat Lock-tight #262) Bolt M18X2.5X45L Tightening Torque: 317 – 429 N・m (Coat Lock-tight #262) Bolt M14X2.0X40L Tightening Torque: 127.5 N・m (Coat Lock-tight #262) Hex.
  • Page 138 20.1 EXTERIOR VIEW (SERIAL NO.D0133 and up)   2-116 2-115-1...
  • Page 139   DESCRIPTION Q’TY NOTICE Slewing Bearing Slewing Gear Box Assembly Hydraulic Oil Motor O-Ring AS568-152 Slewing Gear Cover (A) Slewing Gear Cover (B) Grease Nipple A-PT1/8 Bolt M20X2.5X80L Tightening Torque: 450 – 608 N・m (Coat Lock-tight #262) Bolt M18X2.5X45L Tightening Torque: 317 – 429 N・m (Coat Lock-tight #262) Bolt M14X2.0X40L Tightening Torque: 127.5 N・m (Coat Lock-tight #262) Hex.

  • Page 140: Slewing Reduction Gear

    20.2 SLEWING REDUCTION GEAR     Caution for un-installation and installation ・Secure post and frame by a rope or such to prevent superstructure from accidental slewing when slewing reduction gear is un-installed. ・ Fill gear oil ( ) to the Nippon Oil Corporation BONNOC M320 center of oil Level gauge.

  • Page 141: Hydraulic Oil Motor Inner Parts

    20.3 HYDRAULIC OIL MOTOR INNER PARTS (SERIAL NO.D0001 – D0132) DESCRIPTION Q’TY NOTICE Screw Geroller Drive Back-up Ring Spacer Plate Flange HS Shaft S High Pressure Housing Back-up Ring Housing Screw Oil Seal Dust Seal O-Ring D.m. : 91.6 X 1.8 Name Plate Rivet Seal Washer...
  • Page 142 20.3 HYDRAULIC OIL MOTOR INNER PARTS (SERIAL NO.D0133 and up) DESCRIPTION Q’TY NOTICE Screw 5/16UNF X 22 Flange Dust Seal Back-up Ring Oil Seal O-Ring D.m. : 44.1 X 2.6 Thrust Bearing Race Thrust Bearing Needle Output Shaft Housing Drive O-Ring D.m.

  • Page 143: Slewing Motor Trouble Shooting

    20.4 SLEWING MOTOR TROUBLE SHOOTING Disorders Cause Counter-action ･ Seizure of shaft and housing due to ・Test by slewing in no-load condition and contamination, poor condition of oil or excess check pressure level. of radial load. In case that applying pressure to level of 2.94 MPa [30 kgf / cm ] does not provide Motor does not rotate...

  • Page 144: Outrigger

    21. OUTRIGGER 21.1 FRONT OUTRIGGER 2-120 2-120...
  • Page 145 DESCRIPTION Q’TY NOTICE Rotary Rotary Shaft Rotary Shaft Stopper Plate Outrigger Cylinder Head Pin Outer Box Outer Box Pin Outer Box Pin Stopper Plate Outrigger Cylinder Rod Pin Inner Box Rigger Adapter Rigger Adapter Pin Rigger Adapter End Plate Position Pin Button Bolt (With Hex.

  • Page 146: Rear Outrigger

    21.2 REAR OUTRIGGER 2-122...
  • Page 147 DESCRIPTION Q’TY NOTICE Rotary Rotary Shaft Rotary Shaft Stopper Plate Outrigger Cylinder Head Pin Outer Box Outer Box Pin Outer Box Pin Stopper Plate Outrigger Cylinder Rod Pin Inner Box Rigger Adapter Rigger Adapter Pin Rigger Adapter End Plate Position Pin Button Bolt (With Hex.

  • Page 148: Outrigger Cylinder

    22.OUTRIGGER CYLINDER 22.1 OUTRIGGER SLIDE CYLINDER 2-124...
  • Page 149 DESCRIPTION Q’TY NOTICE Cylinder Tube Assembly Piston Rod Assembly Cylinder Head Tightening Torque: 294N・m Bushing U-Ring Back-up Ring Dust Seal O-Ring Back-up Ring For G55 Endless Type O-Ring Piston Tightening Torque:262N・m Packing Back-up Ring Wear Ring U-Ring Holder O-Ring Steel Ball Set Screw Tightening Torque: 6.8N・m Orifice Plug...

  • Page 150: Single Check Valve (For Outrigger Slide Cylinder)

    22.2 SINGLE CHECK VALVE (FOR OUTRIGGER SLIDE CYLINDER) 2-126...
  • Page 151 DESCRIPTION Q’TY NOTICE Body Check Valve Spring Tightening torque: 294N･m Piston O-Ring Plug O-Ring O-Ring Specifications Rated Pressure 20.6 MPa [210 kgf / cm Resisting Pressure 30.9 MPa [315 kgf / cm Rated Flow Capacity 10 L / min Allowable Leakage Capacity 0.05 L / min Check Valve Cracking Pressure 0.59 MPa [6 kgf / cm...

  • Page 152: Front Outrigger Cylinder

    22.3 FRONT OUTRIGGER CYLINDER 2-128...
  • Page 153 DESCRIPTION Q’TY NOTICE Cylinder Tube Assembly Piston Rod Assembly Cylinder Head Tightening Torque: 392 N・m Bushing LFB6525 U-Ring 1D165 Back-up Ring Dust Seal SCB65 Snap Ring O-Ring Back-up Ring For G95 Endless Type O-Ring G100 Piston Tightening Torque: 1843N・m Packing RQU100 Slide Ring PWL100...

  • Page 154: Rear Outrigger Cylinder

    22.4 REAR OUTRIGGER CYLINDER 2-130...
  • Page 155 DESCRIPTION Q’TY NOTICE Cylinder Tube Assembly Piston Rod Assembly Cylinder Head Tightening Torque: 392 N・m Bushing LFB6525 U-Ring 1D165 Back-up Ring Dust Seal SCB65 Snap Ring O-RING Back-up Ring For G95 Endless Type O-Ring G100 Piston Tightening Torque: 1843N・m Packing RQU100 Slide Ring PWL100...

  • Page 156: Double Check Valve (For Outrigger Cylinder)

    22.5 DOUBLE CHECK VALVE (FOR OUTRIGGER CYLINDER) Specifications Rated Pressure 20.6 MPa (210 kgf / cm Resisting Pressure 41.2 MPa (420 kgf / cm Max. Flow Capacity 10 L / min Allowable Leakage Level Less than 0.05 L / min (Apply 17.2 MPa [175 kgf / cm ] From Port A2 and B2) Check Valve Cracking Pressure 0.49 MPa (5 kgf / cm...
  • Page 157 2-133...

  • Page 158: Assembly And Disassembly Of Boom

    23. ASSEMBLY AND DISASSEMBLY OF BOOM 2-134...
  • Page 159 [Procedure for Overhaul] 1. Start engine and lower hook block (1) to the ground. Winch wire rope should be properly slack. Take care not to cause random wound caused by over unwinding. 2. Stop engine. Unscrew bolt (2) (M8 X 12L) and remove spring washer (3), extract wedge socket pin (4) and take off edge socket (5).
  • Page 160 12. Unscrew 2 bolts (28) (M6 X 10L), and remove 2 spring washers (29), then take off boom tail cover (30) so that code reel is revealed 13. Unscrew 3 bolts (31) (M6 X 10L), and remove 3 spring washers (32), then take off boom head cover (33) 14.
  • Page 161 20. Unscrew 4 bolts (46) (M10 X 16L), and remove 4 spring washers (47), then take off 2 stopper plates (48). 21. Unscrew 8 hexagon socket head button bolts (50) (M10 X 15L), and remove 8 spring washers (51) on both left and right side, then remove 4 side plate stopper plate (52) and side slide plates (53) respectively, on both left and right side.
  • Page 162 25. Unscrew 4 bolts (58) (M10 X 16L), and remove 4 spring washers (59), then take off 2 stopper plates (60). 26. Unscrew 8 hexagon socket head button bolts (62) (M10 X 15L), and remove 8 spring washers (63) on both left and right side, then remove 4 side plate stopper plate (64) and side slide plates (65) respectively, on both left and right side.
  • Page 163 30. Unscrew 4 bolts (70) (M10 X 16L), and remove 4 spring washers (71), then take off 2 stopper plates (72). 31. Unscrew 8 hexagon socket head button bolts (74) (M10 X 15L), and remove 8 spring washers (75) on both left and right side, then remove 4 side plate stopper plate (76) and side plates (77) respectively on both left and right side.
  • Page 164 34.Remove the hexagon nuts (81) (M12) one by one from the one nearest to the wire tip first while holding down the tip of the boom retraction wire (80) with a 8 mm spanner, then remove the boom retraction wire from the No. 5 boom. 35.

  • Page 165: Electric Circuit Diagram

    Note: A version of this electrical circuit diagram enlarged to A2 size is prepared as an appendix. Refer to the separate A2 size circuit diagram for details. 24. ELECTRIC CIRCUIT DIAGRAM 2-141...

  • Page 166: Electric System Drawing

    25. ELECTRIC SYSTEM DRAWING   2-142...
  • Page 167   2-143...

  • Page 168: Electric System

    26. ELECTRIC SYSTEM 26.1 ENGINE HARNESS 2-144...
  • Page 169 A View on Arrow for Connector Details Connector No. Pin No. & Color Details CN5-3 3P・Gray Power Source +12V Electrical Box to/from Operating Box CN5-4 12P・Gray Engine Electrical Related Electrical Box to/from Operating Box CN5-1 8P・Gray When Electric Motor: Failure Engine Start, Lever Operating Electrical and Operating Box to Inverter Unit 6P・Gray CN3-4 When Electric Motor: Meter Unit OFF...

  • Page 170: Remote Control, Valve And Electrical Parts Harness

    26.2 REMOTE CONTROL, VALVE AND ELECTRICAL PARTS HARNESS 2-146...
  • Page 171 View on Arrow for Connector Details Connector No. Pin No. & Color Details CN6-2 4P・Brown Emergency Stop Cancel, Pick and Carry, Hook Stow Operating Box to/from Moment Limiter CN6-1 6P・Brown Send / receive, Hook Stow, Increase Speed, Horn, Start, Stop Operating Box to/from Remote Control RC04 8P・Gray...

  • Page 172: Moment Limiter Harness

    26.3 MOMENT LIMITER HARNESS 2-148...
  • Page 173 View on Arrow for Connector Details Connector No. Pin No. & Color Details CN6-2 4P・Brown Emergency Stop Cancel, Pick and Carry, Hook Stow Operating Box to/from Moment Limiter CN6-1 6P・Brown Send/receive, Hook Stow, Increase Speed, Horn, Start, Stop Operating Box to/from Remote Control RC04 8P・Gray OR Valve Operating Output (Remote Control)

  • Page 174: Electric Motor Harness

    26.4 ELECTRIC MOTOR HARNESS 2-150...
  • Page 175 A View on Arrow for Connector Details Connector No. Pin No. & Color Details CN5-3 3P・Gray Power Source +12V Electrical Box to/from Operating Box CN5-4 12P・Gray Engine Electrical Related Electrical Box to/from Operating Box CN5-1 8P・Gray When Electric Motor: Failure Engine Start, Lever Operating Electrical and Operating Box to Inverter Unit 6P・Gray CN3-4 When Electric Motor: Meter Unit OFF...

  • Page 176: Over Hoist Alarm System

    26.5 OVER HOIST ALARM SYSTEM 2-152...
  • Page 177 DESCRIPTION Q’TY NOTICE Protect Weight Protective Rope Ring Over Hoist Detector Length Sensor Reel Bolt M6X1.0X15L (Plating) Spring Washer M6 (Plating) Grommet NG-79-F Tie Band SG-100 CR Sheave CR Sheave Pin Snap Ring For Shaft C-10 Over Hoist Detector Cover Bolt M6X1.0X55L (Plating) Grommet...
  • Page 178 26.5.1 OPERATION PRINCIPLE When the hook is raised too much, the weight hoisted through the wire rope is pushed up by the hook, and activates the over hoist detector switch. The contact of the over hoist detector switch opens, and the signal thereof enters the moment limiter computer, and causes the hook raising and boom extension operations to stop.
  • Page 179 2-155...

  • Page 180: Crane Inclination Alarm System

    26.6 CRANE INCLINATION ALARM SYSTEM 2-156...
  • Page 181 DESCRIPTION Q’TY NOTICE Incarnation Sensor Bolt M6X1.0X30L Spring Washer Buzzer Bolt M8X1.25X12L Spring Washer 2-157...
  • Page 182 2-158...

  • Page 183: Moment Limiter

      MOMENT LIMITER   1. MOMENT LIMITER RELATED 3- 2 2. OUTRIGGER SAFETY DEVICE 3-20 3. MOMENT LIMITER OVERVIEW AND FEATURES 3-27 4. EXTERNAL VIEW OF MOMENT LIMITER 3-28 5. BLOCK DIAGRAM 3-30 6. CONNECTOR DIAGRAM 3-31 7. CONNECTOR PIN ASSIGNMENT 3-32 8.

  • Page 184: Moment Limiter Related

    1. MOMENT LIMITER RELATED 1.1 DISPLAY UNIT AND CONVERTER  ...
  • Page 185 DESCRIPTION Q’TY NOTICE Moment Limiter Display Unit Moment Limiter Display Unit Bracket M6 (Plating) Spring Washer M6 (Plating) Bolt M8X15L (Plating) Spring Washer M8 (Plating) Moment Limiter Converter Screw M14X15L (Plating) Spring Washer M14 (Plating)

  • Page 186: Front Outrigger Extension Detector

    1.2 FRONT OUTRIGGER EXTENSION DETECTOR...
  • Page 187 DESCRIPTION Q’TY NOTICE Outrigger Max. Extension Limit Switch Outrigger Mid. Extension Limit Switch Extension Limit Switch Cover Tie Band Stay Screw M6X6L (Plating) Tie Band Hex. Socket Head Bolt M8X0.8X25L (Plating) Spring Washer M5 (Plating) Plane Washer M5 (Plating) Bolt (With Washer) M6X1.0X16L (Plating)

  • Page 188: Rear Outrigger Extension Detector

    1.3 REAR OUTRIGGER EXTENSION DETECTOR...
  • Page 189 DESCRIPTION Q’TY NOTICE Outrigger Max. Extension Limit Switch Outrigger Mid. Extension Limit Switch Extension Limit Switch Cover Tie Band Stay Screw M6X6L (Plating) Tie Band Hex. Socket Head Bolt M8X0.8X25L (Plating) Spring Washer M5 (Plating) Plane Washer M5 (Plating) Bolt (With Washer) M6X1.0X16L (Plating)

  • Page 190: Boom Displacement Detector

    1.4 BOOM DISPLACEMENT DETECTOR...
  • Page 191 DESCRIPTION Q’TY NOTICE Angle Sensor Bolt M6X1.0X15L (Plating) Spring Washer M6 (Plating) Boom Angle Detection Limit Switch Hex. Socket Head Bolt M8X0.8X25L (Plating) Spring Washer M5 (Plating) Plane Washer M5 (Plating) M5X0.5 (Plating) Angle Sensor Cover Bolt (With Washer) M6X1.0X16L (Plating)
  • Page 192 1.4.1 ANGLE SENSOR     3-10...
  • Page 193 Specifications 110°, min. Inclination Angle (98°, min. to plus range and 12°, min. to minus range, based on 0°of the chart above.) Total Accuracy ±1% under vibrating conditions (Including linearity and hysteresis). Approx. 1 second at Inclination angle 90° Response (Adequate under operation temperature conditions) Potentiometer (CP-2 or equivalent) Significant Electrical Angle...
  • Page 194 1.4.2 LENGTH SENSOR CODE REEL   3-12...
  • Page 195 Description Q’ty Remarks Base Plate Case Drum Assembly Contact Cylinder Assembly Contact Assembly Potentiometer Case Packing O-ring Bracket Potentiometer NIPOSEAL, Seal Connector Gear Fasten Terminal (male) Sleeve Fasten Terminal (female) Sleeve Cable Guide Microphone Code Assembly Super lock Cable Stopper Caution Label 3-13...

  • Page 196: Load Detector

    1.5 LOAD DETECTOR DESCRIPTION Q’TY NOTICE Pressure Sensor Pressure Sensor Cover Bolt (With Washer) M8X1.25X15L (Plating) 3-14...
  • Page 197 1. 5.1 PRESSURE SENSORS Specifications/Capacity Working range 0 to 35 MPa Permissible pressure 52.5 MPa Power Supply Voltage 12V DC ±10% Power Form 1 to 5 DC 3 wires Load Resistance 10 K-ohm, min. ±0.1% F.S. Accuracy (Including linearity, hysteresis and repeatability at 23±2°C) Temperature ±0.1%F.S./ °C...

  • Page 198: Moment Limiter Accessory

    1.6 MOMENT LIMITER ACCESSORY 3-16...
  • Page 199 DESCRIPTION Q’TY NOTICE Moment Limiter Converter Cover Bolt (With Washer) M6X16L (Plating) Connector Bracket Bolt M6X75L (Plating) Spring Washer M6 (Plating) Working Status Lamp Bracket Bolt M10X25L (Plating) Spring Washer M10 (Plating) Working Status Lamp Guard M6 (Plating) Spring Washer M6 (Plating) Working Status Lamp 12-1...

  • Page 200: Over Un-Winding Detector

    1.7 OVER UN-WINDING DETECTOR 3-18...
  • Page 201 DESCRIPTION Q’TY NOTICE Over Un-Winding Detector Bracket Wire Holding Roller (A) #6000ZZ ・Bearing Skipped Number Roller Pin Arm Pin Spring Collar Bolt M8X1.25X30L (Plating) Spring Washer M8 (Plating) M8X1.25 (Plating) Hex. Socket Head Bolt M6X1.0X15L Plane Washer M6 (Plating) Spring Washer M6 (Plating) Snap Ring For Shaft C-10...

  • Page 202: Outrigger Safety Device

    2. OUTRIGGER SAFETY DEVICE 2.1 ROTARY POSITION DETECTOR 3-20...
  • Page 203 DESCRIPTION Q’TY NOTICE Pin Insertion Limit Switch (1) Pin Insertion Limit Switch (2) Hex. Socket Head Bolt M8X0.8X25L (Plating) Spring Washer M5 (Plating) Plane Washer M5 (Plating) M5X0.5 (Plating) Limit switch Cover Bolt (With Washer) M6X12L (Plating) 3-21...

  • Page 204: Ground Setting Detector

    2.2 GROUND SETTING DETECTOR 3-22...
  • Page 205 DESCRIPTION Q’TY NOTICE Pin Case Washer Spring M8X1.25 (Plating) Hex. Socket Head Bolt M6X1.0X15L (Plating) Spring Washer M6 (Plating) Grease Nipple C-PT1/8 Limit Switch Bolt M4X0.7X30L (Plating) M4X0.7 (Plating) Plane Washer M4 (Plating) Spring Washer M14 (Plating) Tie Band SG-200 3-23...

  • Page 206: Boom Stowing Position Detector

    2.3 BOOM STOWING POSITION DETECTOR 3-24...
  • Page 207 DESCRIPTION Q’TY NOTICE Limit Switch Mounting Plate Boom Stowing Limit Switch Bracket Outrigger Mid. And Over Un-Winding Limit Switch Bolt M8X1.25X20L (Plating) Spring Washer M8 (Plating) Plane Washer M8 (Plating) Screw (With Washer) M4X0.7X25L (Plating) Bolt (With Washer) M6X1.0X12L (Plating) 3-25...
  • Page 208 3-26...

  • Page 209: Moment Limiter Overview And Features

    3. MOMENT LIMITER OVERVIEW AND FEATURES Items MC-305C-2 Type of Moment Limiter Automatic Cut Out Crane Rated Load 0 to 2.98 ton [Pressure Range: 0 to 20.6 MPa (0 to 210kg/cm Power Supply DC 12V (DC 10V – 15V) Display Panel 0.8 A (at DC 12V)

  • Page 210: External View Of Moment Limiter

    4. EXTERNAL VIEW OF MOMENT LIMITER 4.1 DISPLAY UNIT 3-28...

  • Page 211: Converter

    4.2 CONVERTER 3-29...

  • Page 212: Block Diagram

    5. BLOCK DIAGRAM 3-30...

  • Page 213: Connector Diagram

    6. CONNECTOR DIAGRAM 3-31...

  • Page 214: Connector Pin Assignment

    7. CONNECTOR PIN ASSIGNMENT The Converter has one connector and the DISPLAY UNIT has two Connectors. Pin assignment of each Connector are as listed below: 7.1 CONVERTER CONNECTORS Model: HD34-24-23PN (for Japan/Germany) [Corresponding Plug (Harness side): HD36-24-23SN-059 for Japan/Germany] Pin No. Signal Pin No.

  • Page 215: Display Unit Connectors

    7.2 DISPLAY UNIT CONNECTORS 7.2.1 DISPLAY UNIT CONNECTORS (M1) Model: HD34-24-31SN (for Japan/Germany) [Corresponding Plug (Harness side): HD36-24-31PE-059 for Japan/Germany] Pin No. Signal Pin No. Signal M1-1 Moment 100% output M1-17 Working Status Lamp COM M1-2 Over Un-Winding output M1-18 Working Status Lamp output for Green Lamp M1-3 Over Hoist output...

  • Page 216: Input/Output

    8. INPUT/OUTPUT 8.1 CONVERTER Direction Description Q’ty Specifications Pressure Sensor 1 Analog input [1 to 2.4V / 0 to 20.6 MPa (0 to 210kgf/cm ２ Pressure Sensor 2 Analog input [1 to 2.4V / 0 to 20.6 MPa (0 to 210kgf/cm ２...

  • Page 217: Display Unit

    8.2 DISPLAY UNIT 8.2.1 DISPLAY UNIT INPUT Direction Description Q’ty Specifications Serial Communication Input Data from Converter Outrigger Extending Detector input Photo Coupler input (See Note 1) (Max. X 4, Mid. X 4) Outrigger Pin Insertion Detector input Photo Coupler input (See Note 1) Outrigger Ground Setting Detector input Photo Coupler input (See Note 1) Boom Stowing Position Detector...
  • Page 218 8.2.2 DISPLAY UNIT OUTPUT Direction Description Q’ty Specifications Open Collector output Moment 100% output Transistor Spec. (DC12V 50mA Max.) (See Note 2) Open Collector output Over Un-Winding output Transistor Spec. (DC12V 50mA Max.) (See Note 2) Open Collector output Over Hoist output Transistor Spec.
  • Page 219   Note 3: Relay output (別紙参照 ) Note 4: Voltage output (別紙参照 ) Note 5: RS422 output Baud Rate 9600bps ･ Output Data № “D” “CR” Data Load Status Header Actual Load Rated Total Load Check-sum Terminator Factor Word ･ Status Word (SW ) Bit assignment 7bit 6bit...

  • Page 220: Displays

    9. DISPLAYS 3-38...
  • Page 221 Item Type Remarks 10 Segments Bar Each Segment indicates 10% of Load Factors, i.e. indicating 0 to Load Factor (Yellow) 100%. Actual Load 7 Segments (Green) Permanent Indication (Letter height 10mm) Rated Total Load 7 Segments (Red) Permanent Indication (Letter height 8mm) Boom Length 7 Segments (Blue) Permanent Indication (Letter height 8mm)

  • Page 222: Switches

    10. SWITCHES Function Remarks Push the “Fall Mode” Switch to switch for another Wire Fall configuration. Push the Switch and hold for two seconds or more shall activate configuration change “Fall Mode” Switch function. One push for more seconds shall not proceed continuously. Another push and hold shall switch to the further configuration.
  • Page 223 Function Remarks Push the “Working Radius Upper Limit” Switch to set or cancel the Working Radius Upper Limit. Push the Switch and hold for two seconds or more shall set the current radius as the Set and Cancel Switch for upper limit.

  • Page 224: Display Unit; Detail Of Each Segment

    11. DISPLAY UNIT; DETAIL OF EACH SEGMENT [1] Outriggers Extending Detector input (4 sets) 1. Controls as below shall be active when all of four Outrigger Extending Detectors input for maximum is “ON”: ･ “Outriggers Extension Max.” LED shall light. ･...
  • Page 225 [9] Outriggers Section 1. Outriggers Ground Setting Detector input [4 sets, (1) to (4)]. Controls as below shall be active when Outriggers Ground Setting Detector input is “ON”: ･ Each “Outrigger Ground Setting” Green LED shall light. Controls as below shall be active when Outriggers Ground Setting Detector input is “OFF”: ･...

  • Page 226: Start-Up Sequence

    12. START–UP SEQUENCE 1. All LEDs shall light approximately for 2 seconds. Only Green of Green/Red combination LEDs shall light. 2. All the switches activation shall be checked. 3. Input from external devices shall be checked. 4. Status of output is as shown in the table below: Signals Output Signals...

  • Page 227: Display Of Specific Indicators

    14. DISPLAY OF SPECIFIC INDICATORS   [1] Working Radius Indicator Working Radius shall be displayed in unit of “Meter” after so converted and rounded off to one decimal place. (XX.X) [2] Lifting Height Indicator Lifting Height shall be displayed in unit of “Meter” after so converted and rounded off to one decimal place. (XX.X) [3] Boom Angle Indicator Value of angle θshall be displayed after rounded off to one decimal place.

  • Page 228: Calibration Procedure

    16. CALIBRATION PROCEDURE 16.1 LIST OF ITEMS [LED Indicators] Switches] (1) Fall Mode Selector Switch (6) Wire Fall LED (2) Lifting Height Upper Limit Switch (7) Outriggers Status LED (3) Boom Angle Upper Limit Switch (8) Over Un-Winding LED (4) Boom Angle Lower Limit Switch (9) Boom Angle LED (5) Check Switch 3-46...

  • Page 229: Procedure

    16.2 PROCEDURE 16.2.1 CALIBRATION WORK FLOW [1] Call out of Calibration Mode ↓ ↓ ↓ ↓         2] Calibration of Boom Length 1. Register of fully retracted length (Offset length value) 2. Resister of fully Extension length (Span length value) ↓...
  • Page 230 16.2.3 CALIBRATION OF BOOM LENGTH Note: When this Boom length calibration is not required, skip the operations below by pushing “Lifting Height Upper Limit Switch (2)” twice. Refer to subsequent “14.2.4 Calibration of Boom Angle “ when Boom Length Indicator turns to “Ang” and Lifting Height Indicator to “oFF”.
  • Page 231 [2] Register of fully Extension length (Span length value) 1. Push “Lifting Height Upper Limit Switch (2)” and ensure that Boom Length Indicator and Lifting Height Indicator display “LEn” and “SPA” respectively. Set the figures in the Boom Angle Indicator to the value of Boom length at fully Extension condition by pushing “Boom Angle Upper Limit Switch (3)”...
  • Page 232 16.2.4 CALIBRATION OF BOOM ANGLE Note: When this Boom angle calibration is not required, skip the operations below by pushing “Lifting Height Upper Limit Switch (2)” twice. Refer to subsequent “14.2.5 Calibration of Weighing” when Boom Length Indicator turns to “ton” and Lifting Height Indicator to “PAr”.
  • Page 233 2] Resister of fully raised angle (Span angle value) 1. Push “Lifting Height Upper Limit Switch (2)” and ensure that Boom Length Indicator and Lifting Height Indicator display “Ang” and “SPA” respectively. Set the figures in the Boom Angle Indicator to “80” (for 80 degree when the Boom is fully raised) by pushing “Boom Angle Upper Limit Switch (3)”...
  • Page 234 16.2.5 CALIBRATION OF WEIGHING Note: When this weighing calibration is not required, skip the operations below by pushing “Lifting Height Upper Limit Switch (2)” three times. Calibrating operation shall terminate and displays of all indicators resume to normal conditions. [1] Register of Weighing Calibration Parameters 1.
  • Page 235 [2] Register of zero load (Offset weighing value)        1. Push “Lifting Height Upper Limit Switch (2)” and ensure that Boom Length Indicator and Lifting Height Indicator display “ton” and “oFF” respectively. Set the figures in the Boom Angle Indicator to “0.03” (for zero load lifting weight, 0.03 tons of Hook weight) by pushing “Boom Angle Upper Limit Switch (3)”...
  • Page 236 [3] Register of specific load (Span weighing value)        1. Push “Lifting Height Upper Limit Switch (2)” and ensure that Boom Length Indicator and Lifting Height Indicator display “ton” and “SPA” respectively. Set the figures in the Boom Angle Indicator to “1.03” (for test lifting load weight 1.00 plus 0.03 tons of Hook weight) by pushing “Boom Angle Upper Limit Switch (3)”...

  • Page 237: Display Details At Calibration Mode

    16.3 DISPLAY DETAILS AT CALIBRATION MODE Indicator Boom Length Lifting Height Boom Angle (Calibration Items) (Calibration Items) (Calibration Items) Calibration Items Offset Length Span Length Offset Angle   Span Angle Length and Angle at Weighing Calibration Offset Weighing Span Weighing 3-55...

  • Page 238: Test Mode

    17. TEST MODE   Test Mode is provided with this Moment Limiter for the verification of operations and/or signals input/out of each of module. Test Mode can be called out by a procedure as mentioned below. Once the Test Mode starts, power should be turned off for resuming Normal Mode.

  • Page 239: L01 (Rom/Ram Test)

    17.2 L01 (ROM/RAM TEST) [1] Procedure: 1. Ensure that Boom Length Indicator displays “L01”. When any other Test Item is on, push “Cancel Switch” to switch to “L01”. 2. When you push “Check Switch”, the Test proceeds automatically then version shall be shown when a test cycle is complete.

  • Page 240: L02 (Led Test)

    17.3 L02 (LED TEST) [1] Procedure: 1. Ensure that Boom Length Indicator displays “L02”. When any other Test Item is on, push “Cancel Switch” to switch to “L02”. 2. When you push “Check Switch”, each of LED tests shall start and proceed. Another push of “Check Switch”...

  • Page 241: L03 (Switch Test)

    17.4 L03 (SWITCH TEST) [1] Procedure 1. Ensure that Boom Length Indicator displays “L03”. When any other Test Item is on, push “Cancel Switch” to switch to “L03”. 2. When you push “Check Switch”, Switch tests shall start and proceed. Each push of “Switches”...

  • Page 242: L04 Input Signal Test

    17.5 L04 INPUT SIGNAL TEST [1] Procedure: 1. Ensure that Boom Length Indicator displays “L04”. When any other Test Item is on, push “Cancel Switch” to switch to “L04”. 2. When you push “Check Switch”, Tests shall start. Each function shall be verified by actual processes of “Switches”.

  • Page 243: L05 Output Signal Test

    17.6 L05 OUTPUT SIGNAL TEST [1] Procedure: 1. Ensure that Boom Length Indicator displays “L05”. When any other Test Item is on, push “Cancel Switch” to switch to “L05”. 2. When you push “Check Switch”, Tests shall start. Additional push of “Check Switch” shall switch test subject; when specific test subject is displayed, push “Lifting Height Switch”...

  • Page 244: L06 (Load Factor Test)

    17.7 L06 (LOAD FACTOR TEST) [1] Procedure: 1. Ensure that Boom Length Indicator displays “L06”. When any other Test Item is on, push “Cancel Switch” to switch to “L06”. 2. Push “Check Switch”, start automatic test cycle. 3. Push “Check Switch” again to switch to subsequent Test Item. [2] Result Indication ...

  • Page 245: L08 (Time Setting)

    17.9 L08 (TIME SETTING) [1] Procedure: 1. Ensure that Boom Length Indicator displays “L08”. When any other Test Item is on, push “Cancel Switch” to switch to “L08”. 2. Each push of “Lifting Height Upper Limit Switch” shall move flashing Indicators; each of them shows “Hour (hh)”, “Minute (mm)”, “Year (yy)”, Month (mm)”...

  • Page 246: Pc Mode

    As well, appropriate application software, such as Microsoft Excel is required. MAEDA SEUSAKUSHO CO., LTD is not responsible for any troubles caused by the use of this software. Note: Microsoft®, WINDOWS®, , EXCEL® and Word®, are registered trademarks of Microsoft Corporation in the United States and other countries.
  • Page 247 3. Instruction for Screen and Operation Start “RsCom” of “WinCT” in a personal computer which was installed beforehand. A window as shown comes out to the screen. (1) Port: Com Input or select the port number connected to Moment Limiter. (May differ per computers) (2) Baud Rate Set to “9600”...
  • Page 248 5. Assure the indication of “PC” above then click “START” Switch (8) of RsCom screen, which will turn to “Command” for standby. 6. Push “Fall Mode Selector Switch (1)” on Display Panel of Moment Limiter. “Working Radius Indicator” shall display “O.u.t.” and two dots shall flash alternately each other while operation log is transferred. When data transfer is completed, “Working Radius Indicator”...
  • Page 249 7. Click “Save”Switch (9) of “RsCom” to save acquired data into the personal computer. Save the data to appropriate area and with an appropriate file name accompanied by “.csv” extension. Data may be read by Excel.     3-67...
  • Page 250   8. When it is required to read out repeatedly, it is advisable to start from the initial process by clicking “Clear” Switch (10) of “RsCom”. Otherwise, data which remains in buffer may cause a mass of data to handle.  ...

  • Page 251: Moment Limiter Operation Log Deleting Procedure

    18.2 MOMENT LIMITER OPERATION LOG DELETING PROCEDURE 1. Open the fuse-box lid in the left side to Instrument Panel of Crane main-body and pull out a PC Cable inside. Remove a cap from a connector when the cable is ready.  ...
  • Page 252 4. Push both “Wire Fall Switch (1)” and “Check Switch (5)” and hold for three seconds. Then “Working Radius Indicator” shall display “CLr” and operation log deleting shall start and “Working Radius Indicator” displays “C.Lr.”; two dots starts flashing alternately each other while operation log is being deleted.

  • Page 253: Error Messages

    19. ERROR MESSAGES Any detectable errors cause “Rated Total Load Indicator” to display error codes. Criticality of errors shall be rated as A, B, C, D, or E, where A is most critical and gradually being reduced. Error Code Description Counter Measure Criticality Output to be “ON”...

  • Page 254: Trouble Shooting

    20. TROUBLE SHOOTING In the event of malfunction, check each device in accordance with the Flow-Chart below:     3-72...
  • Page 255   3-73...

  • Page 256: Points For Input Voltage Measurement Of Each Sensor

    21. POINTS FOR INPUT VOLTAGE MEASUREMENT OF EACH SENSOR The drawing above is the motherboard for Converter. From top to bottom NF8: Angle Sensor NF9: Length Sensor NF7: Pressure Sensor 2 NF6: Pressure Sensor 1 Measure voltage between each of above points and GND.  3-74...

  • Page 257: Remote Control

    INTERACTIVE REMOTE CONTROL   1. INITIAL MODE SETTING PROCEDURE 4- 2 2. RECEIVER 4-18 3. VOICE MESSAGES 4-31 4. TROUBLESHOOTING 4-32...

  • Page 258: Initial Mode Setting Procedure

    1. INITIAL MODE SETTING PROCEDURE 1.1 BUTTON ARRANGEMENT ON CONTROL PANEL *Alphabetical character on each button corresponds to the button name that appears in the following discussion.  ...

  • Page 259: Establishing Initial Mode

    1.2 ESTABLISHING INITIAL MODE: Example: Changing the setting of OFF timer from 5M to 10M. Retrieving the screen for initial mode 1. Use K and L buttons a few times so that cursor ▲ or ▼ comes to the side of item you desire to set.

  • Page 260: Initial Mode For User (A Mode)

    F button until the screen of initial mode for user appears (For about 2 seconds). After “MAEDA RADIO REMOTE CONTROL” having appeared. Note: ･ Be sure to turn OFF the main switch at receiver before starting to operate the initial mode.
  • Page 261 2. Items for establishing the initial mode for user: (1) Contrast of LCD For adjusting the contrast of LCD. ･ To make the contrast stronger: Press K button ･ To make the contrast weaker: Press L button *At the time of factory shipment, the contrast is set to be optimum for in door use. (2) Voice Volume For adjusting the volume of voice message.
  • Page 262 (7) Reset Micro Speed For resetting user’s Micro Speed rate to the initial value. N: Not reset setting value of the item to default. Y: Reset setting value of the item to default. (8) Version Version will be displayed.

  • Page 263: Initial Mode For Service (B Mode)

    N buttons pressed, continue to press F button until the screen of initial mode for user appears (For about 2 seconds). After “MAEDA RADIO REMOTE CONTROL” having showed up. ”B MODE” appears, before the prompt for password “PASS WORD 0000”...
  • Page 264 2. Items for setting the initial mode for service: (1) Pattern Allow you to change the operating pattern. There are 3 patterns of STD, OPT or US patterns. ＊At the time of factory shipment, this is set as STD.   OPT pattern US pattern STD pattern...
  • Page 265 (5) Tow block limit switch For selection of contacts A and B of over-hoisting limit switch. For the contact A (NO), set it at ON. For the contact B (NC), set it at OFF. If your crane is not provided with hook stowing function, select this OFF. ＊At the time of factory shipment, this is set at ON.

  • Page 266: Initial Mode For Maker (C Mode)

    F button until the screen of initial mode for maker appears (For about 2 seconds). After “MAEDA RADIO REMOTE CONTROL” having showed up. ”C MODE (Initial Mode for Maker)” appears, before the prompt for password “PASS WORD 0000” comes up.
  • Page 267 (1) Model For selection of model. ･ CAB: Track crane ･ MIN 1: MC-104C, MC-235C, MC-285C ･ MIN 1A: Not used. ･ MIN 2: MC-305C, MC-305C-2, MC-405C ･ MIN 2A: MC-583CF ･ LC: Not used. (2) Valve For selection of valve.
  • Page 268 (6) ID Code Not used. (7) Gain A setup of the revolution mentioned above, the gain value (Slew, Boom raising and lowering) “MID” and “LOW” can be performed. *Keep the value as “0” for reasons of the structure of the valve. (8) VR ON (Accelerator ON position) For setting of Accelerator ON position, in propotion to triggering ratio.
  • Page 269 3. Adjustment of (8) VR ON and (9) FLOW ADJ Actuation range of the Accelerator may be changed, by adjusting (8) VR ON (Accelerator ON position) and (9) FLOW ADJ (Flow-control) as described above (1) Outline of VR ON (Accelerator ON position) Available range: 0 to 100 Value at the time of factory shipment: 40 Result...
  • Page 270 (2) Outline of FLOW ADJ (Flow-control) The graph below shows the correlation with triggering ratio: Available range: 1 to 254 Value at the time of factory shipment: 120 Result When this value is increased, the timing of the flow rate (lever) to be maximum point shall become late, against triggering ratio Caution: Due to dispersion of each valve or power transformer, it may miss-function when the value is set to “0”.
  • Page 271 (3) Adjustment of VR ON (Accelerator ON position) and FLOW ADJ (Flow-control) standard setting The graph below shows the correlation with triggering ratio: Comment: At first, when it is started triggered, only the flow rate (lever actuating ratio) increases. Just before the flow rate (lever actuating ratio) reaches its maximum point, the accelerator is started to be ON.

  • Page 272: Initial Mode Setting (For Interactive Remote Controller)

    1.6 INITIAL MODE SETTING (For interactive remote controller) *High-light in “Selective Modes and Values” are the initial values. Selective Modes and Mode Setting Items Remarks Values LCD Contrast Optimum For indoors operation Voice Volume Accelerator 100% Bar chart indicator A MODE Light (For User) OFF Timer...
  • Page 273 *High-light in “Selective Modes and Values” are the initial values. Selective Modes and Mode Setting Items Remarks Values MIN1 MIN1A Model MIN2 MIN2A NSS50 Micro Speed：1→0  This value is not effective. SSC3A VALVE Valve 2→0 NACHI 3→0 ERROR Error Indication, only C MODE COUNT Operation Time Number...

  • Page 274: Receiver

    2. RECEIVER 2.1 STATUS DISPLAY The Receiver has a status LED monitor display which indicates INPUT/OUTPUT status. Message by each LED is as listed in a chart in the next page: 4-18...
  • Page 275 Chart 1 4-19...

  • Page 276: Control Print Card Lacations

    2.2 CONTROL PRINT CARD LACATIONS 2.2.1 MAIN PRINT CARD (UPPER SIDE) (MC9141-A) 4-20...
  • Page 277 2.2.2 MAIN PRINT CARD LED DISPLAY (UPPER SIDE) (MC9141-A) 4-21...
  • Page 278 2.2.3 SUB PRINT CARD (LOWER SIDE) (MC9143-A) 4-22...
  • Page 279 2.2.4 SUB PRINT CARD LED DISPLAY (LOWER SIDE) (MC9143-A) 4-23...

  • Page 280: Connector Pin Assignment

    2.3 CONNECTOR PIN ASSIGNMENT Receiver has two connectors for Input/Output. 4-24...
  • Page 281 1. CONNECTOR R1 Description Description Emergency Stop Right Slewing Left Slewing SV GND OR Stowing OR Setting +12V Boom Raising Sol. Operation IN Boom Lowering Sol. Operation (Travel OFF) Boom Lower output Engine Start Boom Raising output Engine Stop Horn Low Pressure SV OR1 OUT RS422 A...

  • Page 282: Valve Neutral Setting Procedure

    2.4 VALVE NEUTRAL SETTING PROCEDURE 1. Start the engine of the crane. 2. Turn the main switch to “ON” of the receiver. ３. While holding Slewing lever (H side) and Boom derricking lever (N side) pressed to down side, continue to press F buttons for about 2 seconds until the screen of “INITIAL MODE FOR SERVICE (B MODE)”...
  • Page 283 6. Operate winch control lever up and down to select “VALVE ON”, and press D setting button. After operate winch control lever to enter “VALVE ON” and push D button, “Signal not received” will be announced. Go to the next step, after voice message will be announced.

  • Page 284: Monitor Display Message

    2.5 MONITOR DISPLAY MESSAGE 2.5.1 NORMAL OPERATION MESSAGE 2.5.2 ERROR MESSAGE Code Details [1] Receive status Error Code Details Display Emergency stop Receiving (A dot blinks alternately) Signal receiving error [2] Function display Code Details Display Breaking of wire within transmitter Boom extending Volume position error at resetting Boom retracting...

  • Page 285: Fuse In The Receiver

    2.6 FUSE IN THE RECEIVER CAUTION        • For any tests or replacement of a fuse, always turn OFF the Main switch of the Control box, before removing it. • The fuse must be replaced with the same type of grass tube fuses, and of the same rating. CAUTION A fuse is inserted in the (+) line of the main power supply of the Receiver as a protective circuit of internal devices and prevents circuits from burnt.
  • Page 286 5. With a jeweler’s driver (A) to pull out the fuse (8) from its clips, then examine it. 6. Insert a new fuse or the examined fuse to where the one was. [2] INSERTION OF A FUSE After the fuse is examined or replaced, restore the Receiver in the reverse practice of the removal. CAUTION •...

  • Page 287: Voice Messages

    3. VOICE MESSAGES Voice message Condition Extending or raising operation by radio control or manual control, when over Danger, rope over-hoisting hoist limit switch is at work. Hook stowing operated. No voice message of “Danger, rope over-hoisting” Do not store hook until boom is in travel mode when stowing hook.

  • Page 288: Troubleshooting

    4. TROUBLESHOOTING While crane operates perfectly under manual control, it do not at all under remote control. (When crane is displayed, in case of manual operation.) Error display Remedy Main cause Transmitter Receiver Remedy 1 Remedy 2 Nothing Receiver printed circuit (PC) input displayed voltage dropped ･Relay PC defective.
  • Page 289 Error display Remedy Main cause Transmitter Receiver Remedy 1 Remedy 2 Telescopic line wire harness or power transformer defective. ･Telescopic line wire harness ･ Check, repair or replace the breakage Telescopic line wire harness. ･Power transformer defective. ･ Check or replace the Power transformer.
  • Page 290 4-34...
  • Page 291   ELECTRIC MOTOR   1. POWER UNIT 5- 2 2. INVERTER UNIT 5- 4 3. POWER SUPPLY BOX 5-18 4. ELECTRIC CIRCUIT DIAGRAM 5-20...

  • Page 292: Power Unit

    1. POWER UNIT     (1) Power unit cover (2) Electric motor (3) Coupling (4) Hydraulic pump...

  • Page 294: Inverter Unit

    2. INVERTER UNIT (1) Inverter unit cover (5) DC12V power switch (2) Protective cover (6) AC circuit power switch (3) Inverter unit (7) Power lamp (white) (4) Main breaker (with a leak detector) (8) Trouble lamp (red)

  • Page 295: General View

    2.1 GENERAL VIEW...

  • Page 296: Name And Function

    2.2 NAME AND FUNCTION   (1) Run lamp (11) STOP key (2) PRG lamp (12) Built-in potentiometer (3) MON lamp (13) Enter key (4) Percent (%) lamp (14) MODE key (5) Hertz (Hz) lamp (15) Built-in potentiometer lamp (6) Up key (16) Charge lamp (7) Up/Down key lamp (17) Front panel...
  • Page 297 (1) Run lamp Lights when an ON command is issued but no frequency signal is sent out it blinks when operation is started. (2) PRG lamp Lights when the inverter is in parameter setting mode. Blinks when the inverter is placed in AUH Gr. U mode. (3) MON lamp Lights when the inverter is in monitor mode.

  • Page 298: Trip Information And Remedies

    2.3 TRIP INFORMATION AND REMEDIES 2.3.1 TRIP CAUSES/WARNINGS AND REMEDIES When a problem arises, diagnose it in accordance with the following table. If it is found that replacement of parts is required or the problem cannot be solved by any remedy described in the table, contact your Toshiba dealer.
  • Page 299 (Continued) Failure Error code Problem Possible cause Remedies code 000A Over-voltage ･The input voltage fluctuates abnormally. ･Insert a suitable input reactor. during acceleration (1) The power supply has a capacity of 200kVA or more. (2) A power factor improvement capacitor is opened or dosed.
  • Page 300 (Continued) Failure Error code Problem Possible cause Remedies code 002E External thermal trip ･An external thermal trip is input. ･Check the external thermal input. 0011 Emergency stop ･ During automatic operation or remote ･Reset the inverter. operation, a stop command is entered from the operation panel or a remote input device.
  • Page 301 [ALARM INFORMATION] Each message in the table is displayed to give warning but does not cause the inverter to trip. Error code Problem Possible cause Remedies ST terminal OFF ･ The ST-CC circuit is opened. ･Close the ST-CC circuit. Under-voltage in main ･The supply voltage between R, S and T is ･Measure the main circuit supply voltage.
  • Page 302 2.3.2 RESTORING THE INVERTER FROM A TRIP Do not reset the inverter when tripped because of a failure or error before eliminating the cause. Resetting the tripped inverter before eliminating the problem causes it to trip again. The inverter can be restored from a trip by any of the following operations: (1) By turning off the power (Keep the inverter off until the LED turns off.) (2) By means of an external signal (Short circuit between RES and CC on terminal board →...
  • Page 303 2.3.3 IF THE MOTOR DOES NOT RUN WHILE NO TRIP MESSAGE IS DISPLAYED… If the motor does not run while no trip is displayed, follow these steps to track down the cause. The motor does not run. YES: NO : Is the 7-segment LED extinguished? Check the power supply and the MCCB.
  • Page 304 2.3.4 HOW TO DETERMINE THE CAUSES OF OTHER PROBLEMS The following table provides a listing of other problems, their possible causes and remedies. Problems Causes and remedies The motor runs in the wrong ･Inverter the phases of the output terminals U, V and W. direction.

  • Page 305: Inspection And Maintenance

    2.4 INSPECTION AND MAINTENANCE • The equipment must be inspected every day. If the equipment is not inspected and maintained, error and malfunctions may not be discovered which could lead to accidents. •Before inspection, perform the following steps. (1) Shut off all input power to the inverter. (2) Wait at least ten minutes and check to make sure that the change lamp is no longer lit.
  • Page 306 2.4.2 PERIODICAL INSPECTION Make a periodical inspection at intervals 3 or 6 months depending on the operating conditions. •Before inspection, perform the following steps. (1) Shut off all input power to the inverter. (2) Wait at least ten minutes and check to make sure that the change lamp is no longer lit. (3) Use a tester that can measure DC voltages (800V DC or more), and check that the voltage to the DC Mandatory main circuits (across PA-PC) does not exceed 45V.

  • Page 307: Disposal Of The Inverter

    Note: The operation time is helpful for roughly determining the time of replacement. For the replacement of parts, contact your nearest Maeda distributor. For safety’s sake, never replace any part on your own. (Parts replacement alarms can be known by monitor and alarm output, if it is set.) ■...

  • Page 308: Power Supply Box

    3. POWER SUPPLY BOX (1) Power supply box (4) Terminal block (2) Power supply box door (5) Cable inserting hole (3) Door handle 5-18...
  • Page 309 5-19...

  • Page 310: Electric Circuit Diagram

    4. ELECTRIC CIRCUIT DIAGRAM 5-20...
  • Page 311 5-21...
  • Page 312 MARK DESCRIPTION Q’TY PARTS NO. MODEL ELB1 Circuit Breaker EG53C AC440V 3P 50AF/20AT 100mA F1, F2 Current limiting plug fuse AfaC-5 AC600V 5A F1, F2 Fuse cover CG-30 F1, F2 Fusible link BLA005 Circuit protector C60N-1P-2A AC277V 1P2A Single phase insulated transformer HEC-300UL74 P: 380 S: 200V 300VA Operation...
  • Page 314 MAEDA MINI-CRAWLER CRANE MC-305C-2 SERVICE MANUAL Document No: 103E-SM0807-01 Second edition: July 20 2008 Issued by Maeda Seisakusyo Co., Ltd. 1095 Onbegawa, Shinonoi Nagano, Nagano 388-8522, Japan No part of this manual can be reproduced in any from without permission...

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