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MC815C
Maeda MC815C Service Manual
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106E
-SM
1804
-00
Service Manual
Crawler Crane
Serial No. T0001 an
d up
MC815C
Part numbers and parts list in the Service Manual
are for use fo
r
servicing such as disassembling and assembling.
The parts and part numbers are subjec
t to change without prior notice
due to continuous machine improvement and modification. When
ordering parts, make su
re to check the latest parts catalog (lates
t
information).
2
Table of Contents
Table of Contents
3
Overview
11
External View
12
Standard Specifications
12
Searcher Hook Specifications
12
Fly-Jib Specifications
13
Dimensional Drawing of Outrigger Width
13
Principal Specifications List
14
Standard Specifications
14
Engine and Electric Motor Specifications
15
Remote Control Specifications
16
Component Mass List
17
Oil and Water Quantities List
18
Rated Total Load Chart
18
Falls
19
Falls
22
Falls
25
Single Fall
28
Working Radius/Lifting Height
31
Working Radius and Hoisting Height (Travelling with Hoisted Load)
32
Structure and Maintenance Procedure
33
Engine and Cooling-Related Components
34
Engine Specifications
34
Engine Mount
36
Pto (Power Take-Off)
37
Cooling System
38
Fuel Line
40
Fuel Tank
41
Power Transmission Schematic Diagram
42
Hydraulic System Diagram (Mc815C)
42
Swing Circle
43
Undercarriage and Frame
44
Track Frame
44
Idler Cushion
46
Idler
47
Track Roller
48
Carrier Roller
49
Sprocket
50
Track Shoe
51
Shoe Plate
51
Adjusting Rubber Track Tension
52
Hydraulic Units
54
Hydraulic Units Layout Diagram
54
Hydraulic Circuit Diagram
56
Hydraulic Oil Tank and Filter
58
Hydraulic Pump
59
Hydraulic Pump External View
59
Hydraulic Pump Connection Destinations
60
Hydraulic Pump Specifications
60
Pump Hydraulic Circuit Diagram
60
Shuttle Manifold Block
61
Travel / Outrigger Control Valve
62
Travel / Outrigger Control Valve External View
62
Travel / Outrigger Control Valve (Upper) Connection Destinations
63
Travel / Outrigger Control Valve (Lower) Connection Destinations
63
Hydraulic Specifications
64
Solenoid Valve Specifications
64
Travel / Outrigger Control Valve Layout
64
Travel / Outrigger Control Valve Circuit Diagram
65
Check Valve (Joint)
66
Crane Control Valve
67
Crane Control Valve External View
67
Crane Control Valve Connection Destinations
68
Crane Control Valve Circuit Diagram
68
Crane Control Valve Specifications
69
Crane Control Valve Layout
69
Slewing Motor
70
Slewing Motor External View
70
Slewing Motor Connection Destinations
70
Slewing Motor Specifications
70
Slewing Motor Internal Structure Diagram
71
Travelling Motor
72
Travelling Motor External View
72
Travelling Motor Connection Destinations
72
Travelling Motor Specifications
72
Travelling Speed Switching Valve Appearance / Specifications
73
Winch Motor Connection Destinations
74
Winch Motor
74
Winch Motor External View
74
Winch Motor Specifications
75
Winch Venting
76
Rotary Joint
77
Rotary Joint External View
77
Rotary Joint Specifications
78
Rotary Joint Connection Destinations
78
Rotary Joint Structure
78
Derrick Cylinder
79
Derrick Cylinder External View
79
Derrick Cylinder Specifications
80
Derrick Cylinder Connection Destinations
80
Counterbalance Valve (Identification Stamp "D" for Derricking Cylinder)
81
Counter-Balance Valve Operating Diagram
82
Telescopic Cylinder Assembly
83
Telescopic Cylinder External View
83
Telescopic Cylinder Connection Destinations
84
Telescopic Cylinder Specifications
84
Telescopic Cylinder Cross-Sectional Drawing
85
Telescopic Cylinder Hydraulic System Diagram
86
Sequence Valve
87
Mechanical Check Valve
88
Counter Balance Valve (Identification Stamp "T" for Telescoping Cylinder)
89
Outrigger Cylinder Assembly
90
Outrigger Cylinder External View
90
Outrigger Cylinder Connection Destinations
91
Outrigger Cylinder Specifications
91
Double Pilot Check Valve
92
Slide Cylinder Assembly
93
Slide Cylinder External View
93
Slide Cylinder Connection Destinations
94
Slide Cylinder Specifications
94
Or Select Valve
95
Oil Cooler
96
Return Manifold Block
97
P Lines (Pump - Shuttle Manifold Block Line)
98
Hydraulic Piping Diagram
98
P Lines (Pump Lines - Shuttle Manifold Block - Check Joint) Hydraulic System Diagram
100
P Lines (Shuttle Manifold Block - Travelling / Outrigger Control Valve Lines)
101
T.dr Lines
103
Travelling Lines
105
Outrigger Lines
107
Hydraulic Piping Crane Fixed Part Assembly
110
Hydraulic Piping Rotating Part Assembly (Derricking Lines)
112
Hydraulic Piping Rotating Part Assembly (Telescoping Lines)
113
Hydraulic Piping Rotating Part Assembly (Winch Lines)
114
Hydraulic Piping Rotating Part Assembly (Winch Drain Line)
115
Hydraulic Piping Rotating Part Assembly (Winch Brake Release / 2 Speed Switching Lines)
116
Boom Assembly
118
Work Equipment
118
Hook Block Assembly
120
Inspection of Hook Block
121
Electrical Equipment Connection Diagram (1/2 - 2/2)
126
Electrical Units
129
Cabin Interior
129
Name of each Control Part
129
Outrigger Operation Panel
130
Left Control Lever
131
Right Control Lever
133
Monitor
136
List of Error Codes
138
Consumables Display
143
Fuse Box
144
Controller
145
Controller Layout
145
Lower Part Controller Pin Numbers
147
Io Unit Pin Numbers
150
Harness Assembly
151
Harness Overview Figure
151
Harness Product Name / Number
151
Outrigger Sensor Harness
152
Engine Harness
153
Console Harness
154
Valve Harness
155
Display Harness
156
Boom Harness
157
Electrical Fittings Outside the Cabin
158
Led Light
158
Surveillance Cameras
159
Sensors
160
Pressure and Oil Temperature Sensors
160
Inclination Sensor
161
Fuel Sender Assembly
162
Rotary Brush
163
Safety Device
165
Configuration of Moment Limiter
165
Moment Limiter - Names for Monitor Indicators (Crane Mode)
166
Sensor Assembly
167
Length Meter (Standard Specification)
167
Length Meter (Boom Light Specification)
168
Angle Detector
169
Pressure Sensor
170
Over-Hoisting Prevention Device
171
Over Un-Winding Detection Device
172
Tri-Colour Revolving Working Status Lamp
173
Outrigger Safety Devices
174
Outrigger Position Detection Parts
174
Outrigger Grounding Detection Parts
175
Outrigger Rotary Position Detection Parts
176
Boom Stowing Position Detection Parts
177
Hook Grounding Detection Parts
178
Remote Control
179
Item Page
179
Components of the Transmitter
180
Names and Description of Remote Control Parts
180
Transmitter and Receiver
180
Description of Remote Controller Accessories
184
Handling Remote Controller Battery
185
Replacement Method of Battery
185
Replacement Timing of Battery
185
Charging Method of Battery
186
Before Remote Controller Failure Diagnosis
188
Troubleshooting
188
Remote Controller
189
Electrical Wiring Diagram for Remote Controller
190
Electrical Wiring Diagram for Remote Controller
191
Principal Specifications List
192
Service Locations
193
Electric Motor
195
Electric Power Unit
196
Electric Power Unit Part Names
196
Power Supply Box
196
Inverter Part Names
197
Electric Power Unit Assembly
198
Electric Motor
199
Electric Line Assembly
200
Electric Circuit Diagram for Electric Motor Specifications
202
Inverter Harness (Wire Harness of the Electrical Motor)
202
Troubleshooting
203
Principal Specification List (Machines with Engine & Electric Motor)
204
Fly Jib
205
Name of each Section of Fly Jib
206
Fly Jib Hydraulic System
207
Solenoid Operated Directional Control Valve (Jib Switching Sol)
207
Hose Reel
208
Derricking Cylinder (for Fly Jib)
209
Telescoping Cylinder (for Fly Jib)
210
Selector Valve Block (Fly Jib Telescopic Cylinder Mounted)
211
Fly Jib
212
Fly Jib (Main Boom Side)
212
Fly Jib (Fly Jib Side)
213
Fly Jib Harness 4.1 Fly Jib Harness
215
Fly Jib Safety Device
218
Pin Type Load Cell (Load Transducer)
218
Length Meter Reel (Fly Jib Mounted)
219
Angle Detector (Fly Jib Mounted)
220
Fly Jib Electrical Circuit Diagram
223
List of Error Codes
224
Troubleshooting
224
When These Phenomena Happen
225
Specification Dimensional Drawing
226
Specification Table
226
Specifications
226
Rated Total Load Chart
227
Working Radius/Lifting Height
228
Searcher Hook
229
Names of Searcher Hook Parts
230
Searcher Hook Assembly
231
Changing Searcher Hook Angle
232
Changing to Searcher Hook Mode
233
Troubleshooting
234
Specification Dimensional Drawing
235
Specification Table
235
Specifications
235
Rated Total Load Chart
236
Working Radius/Lifting Height
237
Disassembling and Assembling
239
Item Page
239
Dismounting and Mounting the Boom Assembly
240
Connection Diagram for Boom Equipment
241
Dismounting the Boom
241
Mounting the Boom
241
Disassembling and Assembling the Boom Assembly
242
Disassembling the No.1 Boom
242
Disassembling the No.2 Boom
243
Disassembling the No.3 Boom
244
Disassembling the No.4 Boom
245
Disassembling the Telescopic Cylinder from the No. 5 Boom
246
Dismounting and Mounting the Winch Wire Rope
247
Removal of Winch Wire Rope
247
Installation of Winch Wire Rope
248
Actions to Take When the Winch Wire Rope Is Twisted
250
Checking the Boom Telescoping Wire Rope
251
Checking/Adjusting Main Boom Telescoping Wire Rope
251
Adjusting the Boom Telescoping Wire Rope
252
Reference Values
255
Table of Engine Related Reference Values
256
Table of Machine Related Reference Values
257
Table of Moment Limiter Related Reference Values
260
Service Mode
261
Consumables
262
Crane Calibration
262
Error History
262
Function
262
Initial Setting
262
Ml Setting
262
Monitoring
262
Service Mode
262
Work History
262
Consumables
264
Work History
265
Error History
269
Initial Setting
269
Crane Calibration
271
Level Calibration
271
Potentiometer Calibration
272
Boom Angle Calibration
273
Boom Length Calibration
273
Load Calibration
274
Fly-Jib Angle Calibration
275
Fly-Jib Length Calibration
275
Fly-Jib Load Calibration
276
Ml Setting
277
Function
278
Table of Contents
284
Eo101H
302
Eo101L
302
Eo102H
303
Eo102L
303
Eo103L
304
Eo104L
305
Eo105L
306
Eo106L
307
Eo107L
308
Eo13H
309
Eo13L
309
Eoc01H
310
Eoc01L
310
Eoc02H
310
Eoc02L
310
Eoc03H
311
Eoc03L
311
Eoc04H
311
Eoc04L
311
Eoc05H
312
Eoc05L
312
Eoc06H
312
Eoc06L
312
Eoc07H
313
Eoc07L
313
Eoc08H
313
Eoc08L
313
Eoc10H
314
Eoc10L
314
Eof01H
316
Eof01L
316
Eof02H
316
Eof02L
316
Eoh01H
318
Eoh01L
318
Eoo01H
319
Eoo01L
319
Eoo02H
319
Eoo02L
319
Eoo03H
320
Eoo03L
320
Eoo04H
320
Eoo04L
320
Eoo05H
321
Eoo05L
321
Eoo06H
321
Eoo06L
321
Eoo07H
322
Eoo07L
322
Eoo08H
322
Eoo08L
322
Eop01H
323
Eop01L
323
Eos01H
324
Eos01L
324
Eos02H
324
Eos02L
324
Eos03H
325
Eos03L
325
Eos04H
325
Eos04L
325
Eot01H
326
Eot01L
326
Eot02H
326
Eot02L
326
Eot03H
327
Eot03L
327
Eot04H
327
Eot04L
327
Troubleshooting (Matters Other than Error Code Display)
347
Engine Start Fault
349
Engine Stall
350
Engine Hunting
351
Engine Output Shortage
352
Much Black Smoke in Exhaust Gas
353
Much White Smoke in Exhaust Gas
353
Abnormal Noise from Engine
354
Significant Fuel Consumption
354
Significant Oil Consumption
354
Monitor Displays Nothing
355
Troubleshooting of the Electrical Systems
355
Moment Limiter Indication Values on Monitor Are Questionable
356
Monitor Frozen and Inoperable
356
Monitor Switches Inoperable (Except for Being Frozen
356
Fuel Gauge Fails to Indicate Normally
357
Monitor Does Not Display Partially
357
Glow Lamp Does Not Function
359
Headlights Do Not Turn on Normally
359
Tri-Colour Revolving Working Status Lamp Does Not Come on
359
Travelling Speed Cannot be Changed
360
High Speed Operation of Winch Wind-Up/Down Cannot be Performed
361
Wind-Up Cannot be Performed with Hook Stowage Operation
361
None of All the Working Machines and the Slewing/Travelling Works
364
Abnormal Sound or Vibration Is Generated from Winch Motor or Its Periphery
367
Wind-Down Cannot be Performed
367
Wind-Up Cannot be Performed
367
Boom Telescoping Is Slow or Weak
368
Gear Positions 1 and 2 of Winch Cannot be Shifted
368
Boom Extending/Retracting Order Is Disturbed
369
Crane Cannot be Operated Discretely
369
Either Boom No. 2 or 3 Fails to Retract
369
Hunting Occurs During Boom Retraction
369
Time Lag of Crane Is Significant
370
Sway in Travelling Is Observed
371
Travelling Speed Is Slow
371
Steering Is Difficult or Weak
372
Travelling Rubber Track Fails to Move (One Side Only
372
Travelling Speed Cannot be Changed, or Travelling Speed Is Slow/High
372
Does Not Slew
373
Slewing Acceleration Is Unsatisfactory, or Slewing Speed Is Slow
374
Overrun after Stop of Slewing Is Significant
375
Abnormal Sound Generated at a Stop of Slewing Is Loud
376
Impact at a Stop of Slewing Is Significant
376
Natural Descending Amount at Slewing Is Significant
376
Other manuals for Maeda MC815C
Operation Manual
426 pages
Quick Operation Guide
24 pages
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Maeda MC815C Specifications
General
Brand
Maeda
Model
MC815C
Category
Construction Equipment
Language
English
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