Maeda MC815C - 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 Contents3
Item Page4
Introduction11
Introduction12
For Safe Use of the Machine13
Machine Overview14
- Specified Operations14
- Machine Structure14
- Machine Functions15
Qualification for Operation16
- Qualification for Crane Operation16
Terminology17
- Terms and Definitions17
- Diagram of Working Radius and Lifting Height18
- Rated Total Load Chart19
- How to Look at the Angle Indicator25
Outline of Remote Controller26
- Feature26
- Configuration26
  - Configuration of Remote Controller26
- Functions27
  - Functions of Remote Controller27
Dpf Overview28
- Dpf Function28
- Dpf Regeneration28
Safety31
Basic Precautions32
Precautions on Handling Remote Control System37
Precautions for Use of Engine and Electric Motor Specifications41
Operation Related Precautions42
- Before Starting Engine42
- After Starting Engine44
- During Crane Work49
- Precautions for Terminating Crane Operation (Remote Control System)60
Transport Precautions61
Battery Handling Precautions63
Maintenance Precautions65
- Precautions before Maintenance65
- Precautions During Maintenance67
Safety Label Locations72
Operation83
Name of each Section84
- Machine Units84
- Description of Controls85
- Names and Description of Remote Control Parts119
  - Transmitter and Receiver119
  - Description of Remote Controller Accessories123
- Outrigger Safety Device124
  - Functions of Outrigger Safety Devices124
- Moment Limiter (Overload Detector)125
- Over Hoist Detector137
- Operator Seat138
- Radiator Cover140
- Radiator Grille141
- Engine Cover142
- Machinery Cover143
- Operation Side Cover144
- Power Unit145
Operation147
- Pre-Operation Inspection147
  - Visible Checks147
  - Checking before Starting Engine147
  - Inspection after Starting Engine147
- Starting Engine148
  - Normal Starting of Engine148
  - Starting Engine in Cold Environment149
- Operations and Checks after Starting Engine150
- Break-In Operation152
- Machine Travelling Posture152
- Start Moving Machine153
- Changing Machine Travelling Mode154
- Changing Direction of the Machine154
- Stopping/Parking the Machine156
- Stopping Engine157
- Inspection after Stopping Engine157
- Cautions in Driving158
- Outrigger/Crane Related Safety Devices160
- Outrigger Setting Operation163
  - Outrigger Components165
  - Outrigger Setup Operation165
- Cautions before Crane Operation170
- Operation before Crane Work171
- Crane Operation Posture172
- Winding and Unwinding173
- Boom Derricking Operation173
- Boom Telescoping Operation174
- Slewing Operation175
- Accelerator Operation175
- Crane Stowage Operation176
- Outrigger Stowage Operation179
- Prohibited Operations During Crane Work183
- Pick & Carry Operation185
  - Cautions During Pick & Carry Operation185
  - Pick & Carry Posture186
    - Change to Pick & Carry Posture from Travelling Posture186
    - Change to Pick & Carry Posture from Crane Mode Posture187
  - Pick & Carry Operations188
  - Canceling Pick & Carry Operation Posture189
    - How to Return to Travelling Posture189
    - How to Return to Crane Posture190
- Dpf Stationary Regeneration Method191
Operation by Remote Ccontrol192
- Cautions before Operation192
- Powering on193
- Indications of Display194
- Starting/Stopping the Engine198
- Operation after Engine Is Started198
  - Operation before Work198
  - Switching Operation Mode198
- Travel Operation199
- Outrigger Operation202
  - Outrigger Setting Operation203
  - Outrigger Stowage Operation206
- Crane Operation209
- Operating Speed Selector/Outrigger Select Switch214
- Operating Accelerator Control Switch214
- Operating Horm Switch214
- Emergencystop Switch Operation215
- Led Light Operations215
- Checking after Crane Operation216
  - Crane Stowage Operation216
  - Stopping Operation by Radio Control and Inspection216
Operating Machine with Engine & Electric Motor217
- Power Supply Connection217
- Operation and Checking after Power Connection220
- Machine Operation222
- Machine Stop and Checks after Stopping Machine222
- Power Supply Separation223
Handling Wire Rope224
- Criteria for Wire Rope Replacement224
- Corretive Actions against Twisted Wire Rope225
Transportation227
- Loading/Unloading227
- Hoisting Machine228
- Cautions When Loading Machine229
- Cautions During Transportation229
Handling Machine in Cold Environment230
- Preparing for Low Temperature230
Long-Term Storage232
- Before Storing Machine232
- During Storage232
- After Storage233
Handling Battery234
- Cautions in Handling Battery234
- Removing/Installing Battery235
- Cautions in Charging Battery236
- Starting Engine with Booster Cable237
Handling Remote Controller Battery239
- Replacement Timing of Battery239
- Replacement Method of Battery239
- Charging Method of Battery240
Troubleshooting242
- Electrical Components242
- Machine Body243
- Engine244
- Electric Motor245
- Before Remote Controller Failure Disgnosis247
- Remote Controller248
- List of Error Codes249
Inspection and Maintenance255
Precautions for Maintenance256
Basic Maintenance258
Legal Inspection261
Periodic Replacement of Important Components262
Consumables263
Lubricating Oil264
- Use of Lubricating Oil According to Temperatures264
Accessory Tools and Standard Tightening Torque265
- List of Standard Tightening Torque265
- List of Hose Tightening Torque266
Inspection and Maintenance List267
Maintenance Procedures270
- Pre-Operation Inspection270
  - Inspection before Starting Engine (Patrol)270
  - Inspection Around Crane271
  - Inspection of Wire Rope271
  - Inspection of Hook Block271
  - Inspection Around Outrigger271
  - Inspection Around Safe Rubber Track272
  - Inspection Around Carrier272
  - Inspection Around Engine272
  - Inspection Around Carrier and Crane272
  - Inspection before Starting Engine273
  - Checking/Refilling Engine Coolant273
  - Checking Oil Level and Refilling Oil in Engine Oil Pan274
  - Checking Fuel Level and Refilling in Fuel Tank275
  - Checking/Cleaning Fuel Pre-Filter276
  - Checking Oil Level and Refilling Oil in Hydraulic Oil Tank277
  - Checking Oil Level and Refilling Oil in Slewing Reduction Gear Case278
  - Checking/Refilling Oil in Travelling Motor Reduction Gear Case279
  - Inspecting/Cleaning of Radiator and Oil Cooler Fins280
  - Inspecting/Refilling of Battery Electrolyte Level281
  - Checking Horn for Operation282
  - Checking Headlights for Operation282
  - Inspection of Fuse283
  - Inspection of Outrigger Display283
  - Adjusting Operator Seat284
  - Inspection before Starting Engine (Radio Control)285
  - Checking Prior to Turning on the Transmitter285
  - Checking after Turning on the Transmitter286
  - [3 ] Checking of Receiver287
  - Inspection after Starting Engine288
  - Inspection of Outrigger Safety Equipment Operation288
  - Checking Outrigger Operation291
  - Checking Crane Operations292
  - Inspection of over Hoist Detector293
  - Inspection of Moment Limiter293
  - Inspection of Outrigger Extension Position294
  - Checking Engine Exhaust Gas Colour, Noise and Vibration294
  - Inspection of Engine Start and Stop Operation (Radio Control)295
  - Inspection of Engine Start Operation295
  - Inspection of Engine Stop Operation295
  - Inspection of Outrigger Mode Operation296
  - Inspection of Crane Mode Operation297
- Irregular Maintenance299
- Inspection/Adjustment of Rubber Track Tension299
- Inspection/Adjustment of Rubber Track Shoe Bolt300
- Replacement of Winch Wire Rope301
- Inspection/Adjustment of Boom Telescoping Wire Rope305
- Replacement of Hydraulic Oil Suction Filter308
- Initial 10 Hour Maintenance310
- Initial 50 Hour Maintenance310
- Initial 250 Hours Maintenance310
- Greasing Machine Units310
- Oil Replacement in Hydraulic Oil Tank310
- Replacement of Hydraulic Oil Return Filter310
- Checking/Adjustment Alternator Belt Tension310
- Oil Replacement in Slewing Reduction Gear Case310
- Oil Replacement Oil in Winch Reduction Gear Case310
- Oil Replacement Oil in Travelling Motor Reduction Gear Case310
- Every 50 Hours Maintenance311
- Draining of Contaminant Water/Deposits in Fuel Tank311
- Draining of Contaminant Water/Deposits in Fuel Pre-Filter312
- Greasing of Machine Units313
- Every 100 Hours Maintenance315
- Inspecting/Refilling of Oil Level in Slewing Reduction Gear Case315
- Every 250 Hours Maintenance316
- Inspection/Cleaning of Air Cleaner316
- Inspection/Adjustment of Alternator Belt Tension318
- Checking/Refilling Oil in Travelling Motor Reduction Gear Case319
- Every 500 Hours Maintenance320
- Replacement Engine Oil and Engine Oil Filter Cartridge320
- Replacement of Air Cleaner322
- Replacement of Fuel Pre-Filter323
- Replacement of Fuel Filter Cartridge324
- Replacement Hydraulic Oil Return Filter Cartridge325
- Replacement of Hydraulic Oil Tank Air Filter326
- Inspection of Slewing Ring Mounting Bolt327
- Every 1000 Hours Maintenance328
- Cleaning of Engine Cooling System328
- Oil Replacement in Hydraulic Oil Tank331
- Oil Replacement in Slewing Reduction Gear Case333
- Oil Replacement in Winch Reduction Gear Case334
- Oil Replacement in Travelling Motor Reduction Gear Case335
- Inspection/Adjustment Engine Valve Clearance335
- Every 1500 Hours Maintenance336
- Every 2000 Hours Maintenance336
- Every 3000 Hours Maintenance337
Specifications339
Principal Specifications List340
Specification Dimensional Drawing343
Dimensional Drawing of Outrigger Width344
Rated Total Load Chart345
- Fall Hook345
- Fall Hook348
- Fall Hook351
- Single Fall Hook354
Working Radius/Lifting Height357
Working Radius and Lifting Height (During Pick & Carry)358
- Item Page359
Fly Jib359
Cautions in Using Fly Jib360
Mount Position of Fly Jib Safety Labels361
Name of each Section of Fly Jib365
Mounting and Storing Fly Jib366
- Mounting and Stowing Fly Jib366
- Mounting Fly Jib367
- Stowing Fly Jib375
Handling Monitor and Moment Limiter383
- Name of Monitor Display383
  - Monitor Display in Fly Jib Mode383
  - Monitor Display in Fly Jib Stowage Mode386
- Moment Limiter Functions387
- Recovery Operation from Automatic Stop387
Operation388
- Fly Jib Derricking Operation388
- Fly Jib Retract/Extend Operation388
Troubleshooting389
- List of Error Code389
- When These Phenomena Happen390
Inspection and Maintenance391
- Pre-Operation Inspection391
- Periodic Replacement of Critical Parts393
- Consumables393
- Maintenance Every 50 Hours394
Specification395
- Specification Table395
- Specification Dimensional Drawing395
- Rated Total Load Chart396
- Working Radius/Lifting Height397
  - Item Page399
Searcher Hook399
Cautions in Using Searcher Hook400
Searcher Hook Safety Label Locations401
Names of Searcher Hook Parts404
Mounting and Stowing Searcher Hook405
- Mounting Searcher Hook406
- Stowing Searcher Hook409
- Removing Searcher Hook (Changing to Standard Specification)411
  - Removing Searcher Hook Boom411
  - Removing Bracket412
- Mounting Searcher Hook (Changing to Searcher Hook Specification)413
  - Mounting Searcher Hook Boom413
  - Attaching Bracket414
Handling Monitor and Moment Limiter415
- Name of Monitor Display415
  - Monitor Display in Searcher Hook Mode415
  - Changing Searcher Hook Mode417
- Moment Limiter Functions418
- Recovery Operation from Automatic Stop418
Operation419
- Changing Searcher Hook Angle419
Troubleshooting420
Inspection and Maintenance421
- Pre-Operation Inspection421
Specification422
- Specification Table422
- Specification Dimensional Drawing422
- Rated Total Load Chart423
- Working Radius/Lifting Height424

Maeda MC815C - Inspection and Maintenance

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