Maeda HIRD MC815 - Inspection and Maintenance

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245

INSPECTION AND

MAINTENANCE

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

7. ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE 255

8. INSPECTION AND MAINTENANCE LIST 257

9. MAINTENANCE PROCEDURES 260

Main Page

Table of Contents2
Item Page3
Introduction10
Introduction11
For Safe Use of the Machine12
Machine Overview13
Specified Operations13
Machine Structure13
Machine Functions14
Qualification for Operation15
Qualification for Crane Operation15
Terminology16
Terms and Definitions16
Diagram of Working Radius and Lifting Height17
Rated Total Load Chart18
How to Look at the Angle Indicator24
Outline of Remote Controller25
Feature25
Configuration25
Configuration of Remote Controller25
Functions26
Functions of Remote Controller26
Dpf Overview27
Dpf Function27
Dpf Regeneration27
Safety30
Basic Precautions31
Precautions on Handling Remote Control System36
Precautions for Use of Engine and Electric Motor Specifications40
Operation Related Precautions41
Before Starting Engine41
After Starting Engine43
During Crane Work48
Precautions for Terminating Crane Operation (Remote Control System)59
Transport Precautions60
Battery Handling Precautions62
Maintenance Precautions64
Precautions before Maintenance64
Precautions During Maintenance66
Safety Label Locations71
Operation82
Name of each Section83
Machine Units83
Description of Controls84
Description of Monitor85
Names and Description of Control Levers107
Names and Description of Outrigger Operation Panel112
Emergency Stop Switch113
Starter Switch113
Lock Lever113
Accelerator Pedal113
Light Switch114
Disconnect Switch114
Override Switch115
Fuse Box116
Cigar Socket117
Maintenance Usb Port117
Names and Description of Remote Control Parts118
Transmitter and Receiver118
Description of Remote Controller Accessories122
Outrigger Safety Device123
Functions of Outrigger Safety Devices123
Moment Limiter (Overload Detector)124
Configuration of Moment Limiter124
Functions of Moment Limiter125
Moment Limiter Operation126
Moment Limiter Settings128
Moment Limiter Functions131
Moment Limiter Start Conditions134
Override Switch135
Troubleshooting for Moment Limiter135
Over Hoist Detector136
Operator Seat137
Radiator Cover139
Radiator Grille140
Engine Cover141
Machinery Cover142
Operation Side Cover143
Power Unit144
Names of Power Unit Parts144
Names of Power Supply Box Parts144
Names of Inverter Parts145
Operation146
Pre-Operation Inspection146
Visible Checks146
Checking before Starting Engine146
Inspection after Starting Engine146
Starting Engine147
Normal Starting of Engine147
Starting Engine in Cold Environment148
Operations and Checks after Starting Engine149
Break-In Operation151
Machine Travelling Posture151
Start Moving Machine152
Changing Machine Travelling Mode153
Changing Direction of the Machine153
Stopping/Parking the Machine155
Stopping Engine156
Inspection after Stopping Engine156
Cautions in Driving157
Outrigger/Crane Related Safety Devices159
Outrigger Setting Operation162
Outrigger Components164
Outrigger Setup Operation164
Cautions before Crane Operation169
Operation before Crane Work170
Crane Operation Posture171
Winding and Unwinding172
Boom Derricking Operation172
Boom Telescoping Operation173
Slewing Operation174
Accelerator Operation174
Crane Stowage Operation175
Outrigger Stowage Operation178
Prohibited Operations During Crane Work182
Pick & Carry Operation184
Cautions During Pick & Carry Operation184
Pick & Carry Posture185
Change to Pick & Carry Posture from Travelling Posture185
Change to Pick & Carry Posture from Crane Mode Posture186
Pick & Carry Operations187
Canceling Pick & Carry Operation Posture188
How to Return to Travelling Posture188
How to Return to Crane Posture189
Dpf Stationary Regeneration Method190
Operation by Remote Ccontrol191
Cautions before Operation191
Powering on192
Indications of Display193
Starting/Stopping the Engine197
Operation after Engine Is Started197
Operation before Work197
Switching Operation Mode197
Travel Operation198
Start Moving Machine198
Changing Direction of the Machine199
Stopping/Parking the Machine200
Outrigger Operation201
Outrigger Setting Operation202
Outrigger Stowage Operation205
Crane Operation208
Hook Winding and Unwinding209
Boom Derricking Operation209
Boom Telescoping Operation210
Slewing Operation211
Operation While Traveling with a Suspended Load212
Fly Jib Derricking/Telescoping Operation212
Operating Speed Selector/Outrigger Select Switch213
Operating Accelerator Control Switch213
Operating Horm Switch213
Emergencystop Switch Operation214
Led Light Operations214
Checking after Crane Operation215
Crane Stowage Operation215
Stopping Operation by Radio Control and Inspection215
Operating Machine with Engine & Electric Motor216
Power Supply Connection216
Operation and Checking after Power Connection219
Machine Operation221
Machine Stop and Checks after Stopping Machine221
Power Supply Separation222
Handling Wire Rope223
Criteria for Wire Rope Replacement223
Corretive Actions against Twisted Wire Rope224
Transportation226
Loading/Unloading226
Hoisting Machine227
Cautions When Loading Machine228
Cautions During Transportation228
Handling Machine in Cold Environment229
Preparing for Low Temperature229
Long-Term Storage231
Before Storing Machine231
During Storage231
After Storage232
Handling Battery233
Cautions in Handling Battery233
Removing/Installing Battery234
Cautions in Charging Battery235
Starting Engine with Booster Cable236
Handling Remote Controller Battery238
Replacement Timing of Battery238
Replacement Method of Battery238
Charging Method of Battery239
Troubleshooting241
Electrical Components241
Machine Body242
Engine243
Electric Motor244
Before Remote Controller Failure Disgnosis246
Remote Controller247
List of Error Codes248
Inspection and Maintenance254
Precautions for Maintenance255
Basic Maintenance257
Legal Inspection260
Periodic Replacement of Important Components261
Consumables262
Lubricating Oil263
Use of Lubricating Oil According to Temperatures263
Accessory Tools and Standard Tightening Torque264
List of Standard Tightening Torque264
List of Hose Tightening Torque265
Inspection and Maintenance List266
Maintenance Procedures269
Pre-Operation Inspection269
Inspection before Starting Engine (Patrol)269
Inspection Around Crane270
Inspection of Wire Rope270
Inspection of Hook Block270
Inspection Around Outrigger270
Inspection Around Safe Rubber Track271
Inspection Around Carrier271
Inspection Around Engine271
Inspection Around Carrier and Crane271
Inspection before Starting Engine272
Checking/Refilling Engine Coolant272
Checking Oil Level and Refilling Oil in Engine Oil Pan273
Checking Fuel Level and Refilling in Fuel Tank274
Checking/Cleaning Fuel Pre-Filter275
Checking Oil Level and Refilling Oil in Hydraulic Oil Tank276
Checking Oil Level and Refilling Oil in Slewing Reduction Gear Case277
Checking/Refilling Oil in Travelling Motor Reduction Gear Case278
Inspecting/Cleaning of Radiator and Oil Cooler Fins279
Inspecting/Refilling of Battery Electrolyte Level280
Checking Horn for Operation281
Checking Headlights for Operation281
Inspection of Fuse282
Inspection of Outrigger Display282
Adjusting Operator Seat283
Inspection before Starting Engine (Radio Control)284
Checking Prior to Turning on the Transmitter284
Checking after Turning on the Transmitter285
[3 ] Checking of Receiver286
Inspection after Starting Engine287
Inspection of Outrigger Safety Equipment Operation287
Checking Outrigger Operation290
Checking Crane Operations291
Inspection of over Hoist Detector292
Inspection of Moment Limiter292
Inspection of Outrigger Extension Position293
Checking Engine Exhaust Gas Colour, Noise and Vibration293
Inspection of Engine Start and Stop Operation (Radio Control)294
Inspection of Engine Start Operation294
Inspection of Engine Stop Operation294
Inspection of Outrigger Mode Operation295
Inspection of Crane Mode Operation296
Irregular Maintenance298
Inspection/Adjustment of Rubber Track Tension298
Inspection/Adjustment of Rubber Track Shoe Bolt299
Replacement of Winch Wire Rope300
Inspection/Adjustment of Boom Telescoping Wire Rope304
Replacement of Hydraulic Oil Suction Filter307
Initial 10 Hour Maintenance309
Initial 50 Hour Maintenance309
Initial 250 Hours Maintenance309
Greasing Machine Units309
Oil Replacement in Hydraulic Oil Tank309
Replacement of Hydraulic Oil Return Filter309
Checking/Adjustment Alternator Belt Tension309
Oil Replacement in Slewing Reduction Gear Case309
Oil Replacement Oil in Winch Reduction Gear Case309
Oil Replacement Oil in Travelling Motor Reduction Gear Case309
Every 50 Hours Maintenance310
Draining of Contaminant Water/Deposits in Fuel Tank310
Draining of Contaminant Water/Deposits in Fuel Pre-Filter311
Greasing of Machine Units312
Every 100 Hours Maintenance314
Inspecting/Refilling of Oil Level in Slewing Reduction Gear Case314
Every 250 Hours Maintenance315
Inspection/Cleaning of Air Cleaner315
Inspection/Adjustment of Alternator Belt Tension317
Checking/Refilling Oil in Travelling Motor Reduction Gear Case318
Every 500 Hours Maintenance319
Replacement Engine Oil and Engine Oil Filter Cartridge319
Replacement of Air Cleaner321
Replacement of Fuel Pre-Filter322
Replacement of Fuel Filter Cartridge323
Replacement Hydraulic Oil Return Filter Cartridge324
Replacement of Hydraulic Oil Tank Air Filter325
Inspection of Slewing Ring Mounting Bolt326
Every 1000 Hours Maintenance327
Cleaning of Engine Cooling System327
Oil Replacement in Hydraulic Oil Tank330
Oil Replacement in Slewing Reduction Gear Case332
Oil Replacement in Winch Reduction Gear Case333
Oil Replacement in Travelling Motor Reduction Gear Case334
Inspection/Adjustment Engine Valve Clearance334
Every 1500 Hours Maintenance335
Every 2000 Hours Maintenance335
Every 3000 Hours Maintenance336
Specifications338
Principal Specifications List339
Specification Dimensional Drawing342
Dimensional Drawing of Outrigger Width343
Rated Total Load Chart344
Fall Hook344
Fall Hook347
Fall Hook350
Single Fall Hook353
Working Radius/Lifting Height356
Working Radius and Lifting Height (During Pick & Carry)357
Item Page358
Fly Jib358
Cautions in Using Fly Jib359
Mount Position of Fly Jib Safety Labels360
Name of each Section of Fly Jib364
Mounting and Storing Fly Jib365
Mounting and Stowing Fly Jib365
Mounting Fly Jib366
Stowing Fly Jib374
Handling Monitor and Moment Limiter382
Name of Monitor Display382
Monitor Display in Fly Jib Mode382
Monitor Display in Fly Jib Stowage Mode385
Moment Limiter Functions386
Recovery Operation from Automatic Stop386
Operation387
Fly Jib Derricking Operation387
Fly Jib Retract/Extend Operation387
Troubleshooting388
List of Error Code388
When These Phenomena Happen389
Inspection and Maintenance390
Pre-Operation Inspection390
Periodic Replacement of Critical Parts392
Consumables392
Maintenance Every 50 Hours393
Specification394
Specification Table394
Specification Dimensional Drawing394
Rated Total Load Chart395
Working Radius/Lifting Height396
Item Page398
Searcher Hook398
Cautions in Using Searcher Hook399
Searcher Hook Safety Label Locations400
Names of Searcher Hook Parts403
Mounting and Stowing Searcher Hook404
Mounting Searcher Hook405
Stowing Searcher Hook408
Removing Searcher Hook (Changing to Standard Specification)410
Removing Searcher Hook Boom410
Removing Bracket411
Mounting Searcher Hook (Changing to Searcher Hook Specification)412
Mounting Searcher Hook Boom412
Attaching Bracket413
Handling Monitor and Moment Limiter414
Name of Monitor Display414
Monitor Display in Searcher Hook Mode414
Changing Searcher Hook Mode416
Moment Limiter Functions417
Recovery Operation from Automatic Stop417
Operation418
Changing Searcher Hook Angle418
Troubleshooting419
Inspection and Maintenance420
Pre-Operation Inspection420
Specification421
Specification Table421
Specification Dimensional Drawing421
Rated Total Load Chart422
Working Radius/Lifting Height423

Maeda HIRD MC815 - Inspection and Maintenance

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