Maeda MC815C Bedienungsanleitung

106E-OM1805-01

OPERATION MANUAL

CRAWLER CRANE

Serial No. T0001 and up

Unsafe use of this machine may cause serious injury or death. Operators

must read this manual before operating this machine. This manual should

be kept near the machine for reference and periodically reviewed by all

personnel who will come into contact with it.

NOTICE

MAEDAhas Operation Manuals written in some other languages. If a

foreign language manual is necessary, contact your local distributor for

availability.

MC815C

CONTENTS

Item Page

INTRODUCTION 1

1. INTRODUCTION 2

2. FOR SAFE USE OF THE MACHINE 3

3. MACHINE OVERVIEW 4

3.1 SPECIFIED OPERATIONS 4

3.2 MACHINE STRUCTURE 4

3.3 MACHINE FUNCTIONS 5

4. QUALIFICATION FOR OPERATION 6

4.1 QUALIFICATION FOR CRANE OPERATION 6

5. TERMINOLOGY 7

5.1 TERMS AND DEFINITIONS 7

5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT 8

5.3 RATED TOTAL LOAD CHART 9

5.4 HOW TO LOOK AT THE ANGLE INDICATOR 15

6. OUTLINE OF REMOTE CONTROLLER 16

6.1 FEATURE 16

6.2 CONFIGURATION 16

6.2.1 CONFIGURATION OF REMOTE CONTROLLER 16

6.3 FUNCTIONS 17

6.3.1 FUNCTIONS OF REMOTE CONTROLLER 17

7. DPF OVERVIEW 18

7.1 DPF FUNCTION 18

7.2 DPF REGENERATION 18

SAFETY 21

1. BASIC PRECAUTIONS 22

2. PRECAUTIONS ON HANDLING REMOTE CONTROL SYSTEM 27

3. PRECAUTIONS FOR USE OF ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 31

4. OPERATION RELATED PRECAUTIONS 32

4.1 BEFORE STARTING ENGINE 32

4.2 AFTER STARTING ENGINE 34

4.3 DURING CRANE WORK 39

4.4 PRECAUTIONS FOR TERMINATING CRANE OPERATION (REMOTE CONTROL

SYSTEM) 50

5. TRANSPORT PRECAUTIONS 51

6. BATTERY HANDLING PRECAUTIONS 53

7. MAINTENANCE PRECAUTIONS 55

7.1 PRECAUTIONS BEFORE MAINTENANCE 55

7.2 PRECAUTIONS DURING MAINTENANCE 57

8. SAFETY LABEL LOCATIONS 62

Item Page

OPERATION 73

1. NAME OF EACH SECTION 74

1.1 MACHINE UNITS 74

1.2. DESCRIPTION OF CONTROLS 75

1.2.1. DESCRIPTION OF MONITOR 76

1.2.2. NAMES AND DESCRIPTION OF CONTROL LEVERS 98

1.2.3 NAMES AND DESCRIPTION OF OUTRIGGER OPERATION PANEL 103

1.2.4 EMERGENCY STOP SWITCH 104

1.2.5 STARTER SWITCH 104

1.2.6 LOCK LEVER 104

1.2.7 ACCELERATOR PEDAL 104

1.2.8 LIGHT SWITCH 105

1.2.9 DISCONNECT SWITCH 105

1.2.10 OVERRIDE SWITCH 106

1.2.11 FUSE BOX 107

1.2.12 CIGAR SOCKET 108

1.2.13 MAIN TENANCE USB PORT 108

1.3 NAMES AND DESCRIPTION OF REMOTE CONTROL PARTS 109

1.3.1. TRANSMITTER AND RECEIVER 109

1.3.2 DESCRIPTION OF REMOTE CONTROLLER ACCESSORIES 113

1.4. OUTRIGGER SAFETY DEVICE 114

1.4.1 FUNCTIONS OF OUTRIGGER SAFETY DEVICES 114

1.5 MOMENT LIMITER (OVERLOAD DETECTOR) 115

1.5.1 CONFIGURATION OF MOMENT LIMITER 115

1.5.2 FUNCTIONS OF MOMENT LIMITER 116

1.5.3 MOMENT LIMITER OPERATION 117

1.5.4 MOMENT LIMITER SETTINGS 119

1.5.5 MOMENT LIMITER FUNCTIONS 122

1.5.6 MOMENT LIMITER START CONDITIONS 125

1.5.7 OVERRIDE SWITCH 126

1.5.8 TROUBLESHOOTING FOR MOMENT LIMITER 126

1.6 OVER HOIST DETECTOR 127

1.7 OPERATOR SEAT 128

1.8 RADIATOR COVER 130

1.9 RADIATOR GRILLE 131

1.10 ENGINE COVER 132

1.11 MACHINERY COVER 133

1.12 OPERATION SIDE COVER 134

1.13 POWER UNIT 135

1.13.1 NAMES OF POWER UNIT PARTS 135

1.13.2 NAMES OF POWER SUPPLY BOX PARTS 135

1.13.3 NAMES OF INVERTER PARTS 136

iii

Item Page

2. OPERATION 137

2.1 PRE-OPERATION INSPECTION 137

2.1.1 VISIBLE CHECKS 137

2.1.2 CHECKING BEFORE STARTING ENGINE 137

2.1.3 INSPECTION AFTER STARTING ENGINE 137

2.2 STARTING ENGINE 138

2.2.1 NORMAL STARTING OF ENGINE 138

2.2.2 STARTING ENGINE IN COLD ENVIRONMENT 139

2.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE 140

2.4 BREAK-IN OPERATION 142

2.5 MACHINE TRAVELLING POSTURE 142

2.6 START MOVING MACHINE 143

2.7 CHANGING MACHINE TRAVELLING MODE 144

2.8 CHANGING DIRECTION OF THE MACHINE 144

2.9 STOPPING/PARKING THE MACHINE 146

2.10 STOPPING ENGINE 147

2.11 INSPECTION AFTER STOPPING ENGINE 147

2.12 CAUTIONS IN DRIVING 148

2.13 OUTRIGGER/CRANE RELATED SAFETY DEVICES 150

2.14 OUTRIGGER SETTING OPERATION 153

2.14.1 OUTRIGGER COMPONENTS 155

2.14.2 OUTRIGGER SETUP OPERATION 155

2.15 CAUTIONS BEFORE CRANE OPERATION 160

2.16 OPERATION BEFORE CRANE WORK 161

2.17 CRANE OPERATION POSTURE 162

2.18 WINDING AND UNWINDING 163

2.19 BOOM DERRICKING OPERATION 163

2.20 BOOM TELESCOPING OPERATION 164

2.21 SLEWING OPERATION 165

2.22 ACCELERATOR OPERATION 165

2.23 CRANE STOWAGE OPERATION 166

2.24 OUTRIGGER STOWAGE OPERATION 169

2.25 PROHIBITED OPERATIONS DURING CRANE WORK 173

2.26 PICK & CARRY OPERATION 175

2.26.1 CAUTIONS DURING PICK & CARRY OPERATION 175

2.26.2 PICK & CARRY POSTURE 176

2.26.2.1 CHANGE TO PICK & CARRY POSTURE FROM TRAVELLING

POSTURE 176

2.26.2.2 CHANGE TO PICK & CARRY POSTURE FROM CRANE MODE

POSTURE 177

2.26.3 PICK & CARRY OPERATIONS 178

2.26.4 CANCELING PICK & CARRY OPERATION POSTURE 179

2.26.4.1 HOW TO RETURN TO TRAVELLING POSTURE 179

2.26.4.2 HOW TO RETURN TO CRANE POSTURE 180

2.27 DPF STATIONARY REGENERATION METHOD 181

Item Page

3. OPERATION BY REMOTE CCONTROL 182

3.1 CAUTIONS BEFORE OPERATION 182

3.2 POWERING ON 183

3.3 INDICATIONS OF DISPLAY 184

3.4 STARTING/STOPPING THE ENGINE 188

3.5 OPERATION AFTER ENGINE IS STARTED 188

3.5.1 OPERATION BEFORE WORK 188

3.5.2 SWITCHING OPERATION MODE 188

3.6 TRAVEL OPERATION 189

3.6.1 START MOVING MACHINE 189

3.6.2 CHANGING DIRECTION OF THE MACHINE 190

3.6.3 STOPPING/PARKING THE MACHINE 191

3.7 OUTRIGGER OPERATION 192

3.7.1 OUTRIGGER SETTING OPERATION 193

3.7.2 OUTRIGGER STOWAGE OPERATION 196

3.8 CRANE OPERATION 199

3.8.1 HOOK WINDING AND UNWINDING 200

3.8.2 BOOM DERRICKING OPERATION 200

3.8.3 BOOM TELESCOPING OPERATION 201

3.8.4 SLEWING OPERATION 202

3.8.5 OPERATION WHILE TRAVELING WITH A SUSPENDED LOAD 203

3.8.6 FLY JIB DERRICKING/TELESCOPING OPERATION 203

3.9 OPERATING SPEED SELECTOR/OUTRIGGER SELECT SWITCH 204

3.10 OPERATING ACCELERATOR CONTROL SWITCH 204

3.11 OPERATING HORM SWITCH 204

3.12 EMERGENCYSTOP SWITCH OPERATION 205

3.13 LED LIGHT OPERATIONS 205

3.14 CHECKING AFTER CRANE OPERATION 206

3.14.1 CRANE STOWAGE OPERATION 206

3.14.2 STOPPING OPERATION BY RADIO CONTROL AND INSPECTION 206

4. OPERATING MACHINE WITH ENGINE & ELECTRIC MOTOR 207

4.1 POWER SUPPLY CONNECTION 207

4.2 OPERATION AND CHECKING AFTER POWER CONNECTION 210

4.3 MACHINE OPERATION 212

4.4 MACHINE STOP AND CHECKS AFTER STOPPING MACHINE 212

4.5 POWER SUPPLY SEPARATION 213

5. HANDLING WIRE ROPE 214

5.1 CRITERIA FOR WIRE ROPE REPLACEMENT 214

5.2 CORRETIVE ACTIONS AGAINST TWISTED WIRE ROPE 215

6. TRANSPORTATION 217

6.1 LOADING/UNLOADING 217

6.2 HOISTING MACHINE 218

6.3 CAUTIONS WHEN LOADING MACHINE 219

6.4 CAUTIONS DURING TRANSPORTATION 219

Item Page

7. HANDLING MACHINE IN COLD ENVIRONMENT 220

7.1 PREPARING FOR LOW TEMPERATURE 220

8. LONG-TERM STORAGE 222

8.1 BEFORE STORING MACHINE 222

8.2 DURING STORAGE 222

8.3 AFTER STORAGE 223

9. HANDLING BATTERY 224

9.1 CAUTIONS IN HANDLING BATTERY 224

9.2 REMOVING/INSTALLING BATTERY 225

9.3 CAUTIONS IN CHARGING BATTERY 226

9.4 STARTING ENGINE WITH BOOSTER CABLE 227

10. HANDLING REMOTE CONTROLLER BATTERY 229

10.1 REPLACEMENT TIMING OF BATTERY 229

10.2 REPLACEMENT METHOD OF BATTERY 229

10.3 CHARGING METHOD OF BATTERY 230

11. TROUBLESHOOTING 232

11.1 ELECTRICAL COMPONENTS 232

11.2 MACHINE BODY 233

11.3 ENGINE 234

11.4 ELECTRIC MOTOR 235

11.5 BEFORE REMOTE CONTROLLER FAILURE DISGNOSIS 237

11.6 REMOTE CONTROLLER 238

11.7 LIST OF ERROR CODES 239

Item Page

INSPECTION AND MAINTENANCE 245

1. PRECAUTIONS FOR MAINTENANCE 246

2. BASIC MAINTENANCE 248

3. LEGAL INSPECTION 251

4. PERIODIC REPLACEMENT OF IMPORTANT COMPONENTS 252

5. CONSUMABLES 253

6. LUBRICATING OIL 254

6.1 USE OF LUBRICATING OIL ACCORDING TO TEMPERATURES 254

7. ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE 255

7.1 LIST OF STANDARD TIGHTENING TORQUE 255

7.2 LIST OF HOSE TIGHTENING TORQUE 256

8. INSPECTION AND MAINTENANCE LIST 257

9. MAINTENANCE PROCEDURES 260

9.1 PRE-OPERATION INSPECTION 260

9.1.1 INSPECTION BEFORE STARTING ENGINE (PATROL) 260

9.1.2 INSPECTION BEFORE STARTING ENGINE 263

9.1.3 INSPECTION BEFORE STARTING ENGINE (RADIO CONTROL) 275

9.1.4 INSPECTION AFTER STARTING ENGINE 278

9.1.5 INSPECTION OF ENGINE START AND STOP OPERATION(RADIO CONTROL) 285

9.2 IRREGULAR MAINTENANCE 289

9.3 INITIAL 10 HOUR MAINTENANCE 300

9.4 INITIAL 50 HOUR MAINTENANCE 300

9.5 INITIAL 250 HOURS MAINTENANCE 300

9.6 EVERY 50 HOURS MAINTENANCE 301

9.7 EVERY 100 HOURS MAINTENANCE 305

9.8 EVERY 250 HOURS MAINTENANCE 306

9.9 EVERY 500 HOURS MAINTENANCE 310

9.10 EVERY 1000 HOURS MAINTENANCE 318

9.11 EVERY 1500 HOURS MAINTENANCE 326

9.12 EVERY 2000 HOURS MAINTENANCE 326

9.13 EVERY 3000 HOURS MAINTENANCE 327

SPECIFICATIONS 329

1. PRINCIPAL SPECIFICATIONS LIST 330

2. SPECIFICATION DIMENSIONAL DRAWING 333

3. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 334

4. RATED TOTAL LOAD CHART 335

4.1 6 FALL HOOK 335

4.2 4 FALL HOOK 338

4.3 2 FALL HOOK 341

4.4 SINGLE FALL HOOK 344

5. WORKING RADIUS/LIFTING HEIGHT 347

6. WORKING RADIUS AND LIFTING HEIGHT (DURING PICK & CARRY) 348

vii

Item Page

FLY JIB 349

1. CAUTIONS IN USING FLY JIB 350

2. MOUNT POSITION OF FLY JIB SAFETY LABELS 351

3. NAME OF EACH SECTION OF FLY JIB 355

4. MOUNTING AND STORING FLY JIB 356

4.1 MOUNTING FLY JIB 357

4.2 STOWING FLY JIB 365

5. HANDLING MONITOR AND MOMENT LIMITER 373

5.1 NAME OF MONITOR DISPLAY 373

5.1.1 MONITOR DISPLAY IN FLY JIB MODE 373

5.1.2 MONITOR DISPLAY IN FLY JIB STOWAGE MODE 376

5.2 MOMENT LIMITER FUNCTIONS 377

5.3 RECOVERY OPERATION FROM AUTOMATIC STOP 377

6. OPERATION 378

6.1 FLY JIB DERRICKING OPERATION 378

6.2 FLY JIB RETRACT/EXTEND OPERATION 378

7. TROUBLESHOOTING 379

7.1 LIST OF ERROR CODE 379

7.2 WHEN THESE PHENOMENA HAPPEN 380

8. INSPECTION AND MAINTENANCE 381

8.1 PRE-OPERATION INSPECTION 381

8.2 PERIODIC REPLACEMENT OF CRITICAL PARTS 383

8.3 CONSUMABLES 383

8.4 MAINTENANCE EVERY 50 HOURS 384

9. SPECIFICATION 385

9.1 SPECIFICATION TABLE 385

9.2 SPECIFICATION DIMENSIONAL DRAWING 385

9.3 RATED TOTAL LOAD CHART 386

9.4 WORKING RADIUS/LIFTING HEIGHT 387

viii

Item Page

SEARCHER HOOK 389

1. CAUTIONS IN USING SEARCHER HOOK 390

2. SEARCHER HOOK SAFETY LABEL LOCATIONS 391

3. NAMES OF SEARCHER HOOK PARTS 394

4. MOUNTING AND STOWING SEARCHER HOOK 395

4.1 MOUNTING SEARCHER HOOK 396

4.2 STOWING SEARCHER HOOK 399

4.3 REMOVING SEARCHER HOOK (CHANGING TO STANDARD SPECIFICATION) 401

4.3.1 REMOVING SEARCHER HOOK BOOM 401

4.3.2 REMOVING BRACKET 402

4.4 MOUNTING SEARCHER HOOK (CHANGING TO SEARCHER HOOK SPECIFICATION) 403

4.4.1 MOUNTING SEARCHER HOOK BOOM 403

4.4.2 ATTACHING BRACKET 404

5. HANDLING MONITOR AND MOMENT LIMITER 405

5.1 NAME OF MONITOR DISPLAY 405

5.1.1 MONITOR DISPLAY IN SEARCHERHOOK MODE 405

5.1.2 CHANGING SEARCHER HOOK MODE 407

5.2 MOMENT LIMITER FUNCTIONS 408

5.3 RECOVERY OPERATION FROM AUTOMATIC STOP 408

6. OPERATION 409

6.1 CHANGING SEARCHER HOOK ANGLE 409

7. TROUBLESHOOTING 410

8. INSPECTION AND MAINTENANCE 411

8.1 PRE-OPERATION INSPECTION 411

9. SPECIFICATION 412

9.1 SPECIFICATION TABLE 412

9.2 SPECIFICATION DIMENSIONAL DRAWING 412

9.3 RATED TOTAL LOAD CHART 413

9.4 WORKING RADIUS/LIFTING HEIGHT 414

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