MC-104CER MC-285CRM-E MC-305CRM-E

MC-104CER MC-285CRM-E MC-305CRM-E MINI-CRAWLER CRANE Electric Motor Driven SERVICE MANUAL

CONTENTS 1. OUTER DIMENSIONS...1 1.1 Outer Dimensions of Model MC-104CER...1 1.2 Outer Dimensions of Model MC-285CRM-E...2 1.3 Outer Dimensions of Model MC-305CRM-E...3 2. MAIN DATA AND SPECIFICATIONS...4 2.1 Main Data and Specifications of Model MC-104CER...4 2.2 Main Data and Specifications of Model MC-285CRM-E...5 2.3 Main Data and Specifications of Model MC-305CRM-E...6 3. NOMENCLATURE OF COMPONENTS...7 3.1 Model MC-104CER...7 3.1.1 Nomenclature of Components...7 3.1.2 Nomenclature of Travel Control Components...8 3.1.3 Nomenclature of Control Box...9 3.1.4 Switches...11 3.2 Model MC-285CRM-E...12 3.2.1 Nomenclature of Components...12 3.2.2 Operation Procedures...13 3.3 Model MC-305CRM-E...15 3.3.1 Nomenclature of Travel Control Components...15 3.3.2 Starting Electric Motor...16 3.3.3 Stopping Electric Motor...17 4. BLOCK DIAGRAM...18 4.1 Block Diagram of Model MC-104CER...18 4.2 Block Diagram of Model MC-285CRM-E...19 4.3 Block Diagram of Model MC-305CRM-E...20 5. HYDRAULIC CIRCUIT DIAGRAM...21 5.1 Hydraulic Circuit Diagram of Model MC-104CER...21 5.2 Hydraulic Circuit Diagram of Model MC-285CRM-E...22 5.3 Hydraulic Circuit Diagram of Model MC-305CRM-E...23 i

CONTENTS 6. HYDRAULIC PIPING FOR ELECTRIC MOTOR... 24 6.1 Hydraulic Piping Drawing of Model MC-104CER... 24 6.2 Hydraulic Piping Drawing of Model MC-285CRM-E... 26 6.3 Hydraulic Piping Drawing of Model MC-305CRM-E... 28 7. ELECTRICAL CIRCUIT DIAGRAM... 30 7.1 Model MC-104CER... 30 7.1.1 Electrical Circuit Diagram... 30 7.1.2 Wiring Harness Connection Drawing... 31 7.1.3 Electrical Circuit Diagram (Electric Motor Driven Partion) (1/2)... 32 7.1.4 Electrical Circuit Diagram (Electric Motor Driven Partion) (2/2)... 33 7.2 Model MC-285CRM-E... 34 7.2.1 Electrical Circuit Diagram (Electric Motor Driven Partion) (1/2)... 34 7.2.2 Electrical Circuit Diagram (Electric Motor Driven Partion) (2/2)... 35 7.2.3 Electrical Circuit Diagram (Engine Portion)... 36 7.2.4 Electrical Circuit Diagram (Moment Limiter Portion)... 37 7.3 Model MC-305CRM-E... 38 7.3.1 Electrical Circuit Diagram (Standard Portion)... 38 7.3.2 Electrical Circuit Diagram (Moment Limiter Portion)... 39 7.3.3 Electrical Circuit Diagram (Electric Motor Driven Partion)... 40 ii

1. OUTER DIMENSIONS 1.1 Outer Dimensions of Model MC-104CER a Above sketch represents the machine with the travel lever stowed for Transport Position. 1

1. OUTER DIMENSIONS 1.2 Outer Dimensions of Model MC-285CRM-E 2

1. OUTER DIMENSIONS 1.3 Outer Dimensions of Model MC-305CRM-E 3

2. MAIN DATA AND SPECIFICATIONS 2.1 Main Data and Specifications of Model MC-104CER Mass and dimensions Performance Winch system Telescoping system Boom hoist system Swing system Outrigger system Travel syatem Hydraulic system Electric motor Safety systems Systems and Items Mass of the machine Overall length x overall width x overall height Distance between sprocket and drive shaft centers Track gauge Track width Minimum ground clearance Maximum rated total load x working radius Maximum working radius Maximum lifting height over ground level Type Hook hoist speed Hoist wire rope Type Type of boom Boom length Boom telescoping speed Type Hoist angle and time Type Swing angle and speed Type Maximum extended width Type Travel speed Grade ability Ground pressure Rated pressure Hydraulic pump Hydraulic oil tank capacity Type of electric motor Starting system MC-104CER 1,070 kg 2,180 mm x 600 mm x 1,305 mm 1,044 mm 420 mm 180 mm 120 mm 995 kg x 1.1 m 5.1 mm 5.5 mm Hydraulic motor driven, worm geared, worm cell block 3.2 m/min (4 part reeving) 6 x Fi (29) IWRC 0/0 single rope ø 6 x 39 m Hydraulic cylinder x 1 + wire rope type telescoping system x 2 Pentagonal, 4 stages (2 4 stages: Simultaneous telescoping) 1.85 m 3.00 m 4.15 m 5.30 m 3.45 m / 20 sec Hydraulic cylinder, direct acting X 1 0 75 / 11 sec Swing ring support, hydraulic motor driven, worm, spur gear reducer 360 degrees continuous / 1.3 min -1 {1.3 rpm} 1st stage with flexible stay damper 2nd stage manual pull-out, hydraulic cylinder direct acting (Front) 3,400 mm x (Lateral) 2,785 mm x (Rear) 3,300 mm Hydraulic motor driven, stepless speed changer, built-in brake Forward and reverse 0 1.9 km/h 20 28.4 kpa {0.29 kgf/cm 2 } Variable discharge piston pump (8.6 cc/rev x 2) 20.59 MPa {210 kgf/cm 2 } 20 l Totally-enclosed fan-cooled type 5.5 kw, 4P400V Direct system Over-hoist preventive device, load indicator, load meter, hydraulic safety valve, hydraulic, wire rope retainer, warning buzzer, leveling instrument and over loading preventive device (optional) Emergency engine stop switch 4

2. MAIN DATA AND SPECIFICATIONS 2.2 Main Data and Specifications of Model MC-285CRM-E Systems and Items Crane capacity Working radius upper limit Maximum lifting height from the ground Hoisting winch Telescopic device Hoisting device Winching system Hook winching speed Wire rope specification Telescopic system Boom system Boom length Boom expansion stroke / expansion time Hoisting system Boom angle / hoisting time MC-285CRM-E 2.82 t x 1.4 m 8.205 m x 0.15 t 8.7 m Driven by the hydraulic motor with internal brake, decelerated by planet gear, equipped with counterbalance (with internal drum) 8 m/min (three layers, four ropes) ø7 mm x 46 m Two hydraulic sequential telescopic cylinders and two wire rope telescopic devices Automatic pentagonal five-stage boom (the third to fifth stage expand/contract simultaneously) 2.535 m 4.075 m 5.575 m 7.075 m 8.575 m 6.04 m / 22 sec Two, directly pressed, double-acting hydraulic cylinders 0 80 / 14 sec Swing device Swing system Swing bearing support, trochoid motor drive worm, spur gear deceleration, and worm self-lock. Swing angle / swing time 360 successively / 35.5 sec Outrigger Travel device Outrigger system Maximum extending width With single-stage refracting stay damper, 2-stage manual stretch, and directly pressed hydraulic cylinder 4,580 mm (horizontal) x 4,530 mm (forward) x 3,810 mm (backward) Travel system Non-stage transmission hydraulic motor drive Travel speed 0 2.2 km/h Hill climbing ability 20 Crawler grounding length x width 975 mm x 200 mm Ground pressure 47.8 kpa {0.49 kg/cm 2 } Engine Motor Hydraulic system Radio controller Crawler tension adjustment Engine type Piston displacement Continuous rated horsepower Starting system Fuel tank capacity Motor type Starting system Hydraulic pump specification / tank capacity Radio controller type Creep speed mode Outrigger operation by radio controller Overall dimension (length x width x height) Overall weight Cylinder oil filler method Yanmar 2TNE68-MB 0.523 little {523 cc} 6.57 kw / 2,600 min 1 {9 PS / 2,600 rpm} Sel-motor system 12 little Totally enclosed fan-cooled motor 5.5 kw, 4P, 380V Inverter system (30 Hz 60 Hz) Variable piston pump 6 cc/rev x 2 (for engine) Variable piston pump 8.6 cc/rev x 2 (for motor) Tank capacity: 20 little Small-power type, 40-wave auto-scan Available Available (The engine and motor can be started and stopped also by radio controller.) 3,285mm x 750mm x 1,525mm 1,900 kg 5

2. MAIN DATA AND SPECIFICATIONS 2.3 Main Data and Specifications of Model MC-305CRM-E Systems and Items Model MC-305C Model MC-305C-E Mass and dimensions Performance Winch system Telescoping system Boom hoist system Swing system Outrigger system Travel syatem Mass of the machine Overall length x overall width x overall height Distance between sprocket and drive shaft centers Track gauge Track width Minimum ground clearance Maximum rated total load x working radius Maximum working radius Maximum lifting height over ground level Type Hook hoist speed Hoist wire rope Type Type of boom Boom length Boom telescoping speed Type Hoist angle and time Type Swing angle and speed Type Maximum extended width Type Travel speed Grade ability Ground pressure (with shoe width: 300 mm) 5,700 kg 4,115 mm x 1,280 mm x 1,693 mm 1,750 mm 980 mm 300 mm 147.5 mm 2.93 t x 2.50 m 12.16 mm 12.66 mm Swash place axial piston motor, differential gear reducer, friction disk brake 15 m/min ø 8 x 73 m (4 part reeving) Sequential hydraulic cylinders x 3 + Wire rope telescoping system x 1 5 stage boom with pentagonal section 3.675 m 12.485 m 8.79 m / 25.5 sec Hydraulic cylinder, direct acting system x 2 0 80 / 14.5 sec Ball bearing support, hydraulic motor driven, worm spur gear reducer 360 degrees continuous / 26.5 rpm Extension: Hydraulic cylinder direct acting Setting up Hydraulic cylinder direct acting (Front) 4,504 mm x (Lateral) 4,887 mm x (Rear) 4,394 mm Hydraulic motor driven, stepless speed changer, built-in brake Forward and reverse 0 3 km/h 23.5 35.3 kpa {0.36 kgf/cm 2 } 3,825 kg 4,549 mm x 1,280 mm x 1,693 mm 1,750 mm 980 mm 300 mm 147.5 mm 2.93 t x 2.50 m 12.16 mm 12.66 mm Swash place axial piston motor, differential gear reducer, friction disk brake 4.3 m/min ø 8 x 73 m (4 part reeving) Sequential hydraulic cylinders x 3 + Wire rope telescoping system x 1 5 stage boom with pentagonal section 3.675 m 12.485 m 8.79 m / 38 sec Hydraulic cylinder, direct acting system x 2 0 80 / 21 sec Ball bearing support, hydraulic motor driven, worm spur gear reducer 3,600 continuous / 38 sec {1.7 rpm} Extension: Hydraulic cylinder direct acting Setting up Hydraulic cylinder direct acting (Front) 4,504 mm x (Lateral) 4,887 mm x (Rear) 4,394 mm Hydraulic motor driven, stepless speed changer, built-in brake Forward and reverse 0 1.3 km/h 23.5 35.3 kpa {0.36 kgf/cm 2 } Hydraulic system Engine / motor Rated pressure Hydraulic pump Hydraulic oil tank capacity Model Type Displacement Rated output (Continuous) Type of fuel and tank capacity 2 throw, variable capacity piston pump 13 cc/rev + 13 cc/rev / 44.1 l Travel: 20.6 MPa {210 kgf/cm 2 } Crane work: 19.1 MPa{195 kgf/cm 2 } 44 l (Complete with oil cooler) Yanmar 3TNE74-MB1 Water cooled. 4 cycle straight in-line, 4 cylinder, direct injection diesel 1,006 cc {1.006 l} 13.9 kw/2,530 min -1 {19 PS/2,530 rpm} Light oil / 57 l 2 throw, variable capacity piston pump 8.6 cc/rev + 8.6 cc/rev Travel: 20.6 MPa {210 kgf/cm 2 } Crane work: 19.1 MPa{195 kgf/cm 2 } 44 l (Complete with oil cooler) Selectable either an engine driven or an electric motor driven Electric Motor MITSUBISHI 5A EB434-01 Fully enclosed, outer from type Torque motor 5.5 kw 4P 400V Speed Control Inverter controlded meter rpm 1,130 1,750 min -1 Inverter, MITSUBISHI FR-A500-5.5k Battery Type 55B24R 55B24R Safety systems Over-hoist preventive device, load indicator, hydraulic safety valve, load meter, hydraulic automatic lock system, wire rope retainer, warning buzzer, leveling instrument and over loading preventive device (optional) Over-hoist preventive device, load indicator, hydraulic safety valve, load meter, hydraulic automatic lock system, wire rope retainer, warning buzzer, leveling instrument and over loading preventive device (optional) 6

3. NOMENCLATURE OF COMPONENTS 3.1 Model MC-104CER 3.1.1 Nomenclature of Components 1. Boom 14. Hook hanger 2. Boom telescoping cylinder (inside the boom) 15. Crane control 3. Boom hoist cylinder 16. Outrigger mode indicator lamp 4. Load indicator 17. Hook block 5. Winch 18. Over-hoist alarm system 6. Post 20. Hydraulic oil tank 7. Travel Control 21. Rear idler 8. Outrigger 22. Track roller 9. Outrigger cylinder 23. Travel motor sprocket 10. Machinery cover 24. Emergency motor stop switch 11. Rubber track 25. Remote control cable 12. Motor 26. Remote control switch 13. Flood light (Rear) 7

3. NOMENCLATURE OF COMPONENTS 3.1.2 Nomenclature of Travel Control Components 2. Travel lever, left 8. Stop lamp 3. Travel lever, right 9. Flood light switch 4. Travel stand locking lever 10. Horn switch 5. Hour meter 11. Main starter switch 6. Fuse (5A) 12. Emergency motor stop switch 7. Fuse (15A) 13. Power supply cable connection box 8

3. NOMENCLATURE OF COMPONENTS 3.1.3 Nomenclature of Control Box 1. Power supply indicator lamp 4. DC12V circuit protector (15A) 2. Trouble indicator lamp 5. Wiring leak breaker 3. AC control circuit protector (3A) 9

3. NOMENCLATURE OF COMPONENTS (1) power supply indicator lamp: Goes on when power supply cable is connected to the power supply with all of AC control circuit protector, DC12V circuit protector and Leak breaker for wiring having been turned on. (2) Trouble indicator lamp: Goes on during crane operation if thermal tripping takes place due to overloading of electric motor or power supply being in opposite phase at the power on. If the trouble indicator goes on at power on, it may be because the power supply is in opposite phase. Check for proper connection. If the trouble indicator lamp goes on during crane, operation, it may be due to thermal tripping caused by overloading of electric motor. Turn OFF the switch once and wait for more than 10 minutes before turning ON the key switch again. If it goes off then, the system has been reset properly. (3) White mark appears due to tripping, when (4) AC control circuit protector (3A) and DC12V circuit protector (15A) are exposed to over-current. If the white mark appears, check for the cause of over-current and after correcting the situation, press the switch to reset (after waiting for more than 10 minutes after the white mark having appeared). (4) Wiring leak breaker At the time of over-loading or leakage, breaker lever returns to neutral and for the over-loading, red button and for the leakage, white button jumps out respectively. If the breaker has been actuated, check for the cause and take proper countermeasures. For resetting, turn OFF the lever before turning it On. [Note] As a part of daily inspection, before starting your work, press the leak breaker test button to see that the breaker works normally. Miscellaneous: Remote control Machinery cover is not provided with any hole for connecting remote control plug. After finishing your work, remove the remote controller at the portable switch side to stow it away separately. 10

3. NOMENCLATURE OF COMPONENTS 3.1.4 Switches (1) Main starter switch CAUTION When you finish your work, be sure to turn the main starter switch to OFF position. Used for starting and stopping the motor. OFF: At this position, key can be inserted or removed and switches of all the electric systems go off and motor comes to stop. ON: Power flows to all the circuits. Start: At this position, motor starts. Once the motor starts. take you hand off the key. The key will automatically return to ON position. (2) Emergency motor stop Use this switch to stop the motor with trouble having developed on the machine. Switch ON: Pressing the switch causes engine to stop. Switch OFF:Turn the switch to right, It will return to original position. (3) Flood light switch This switch is to be used for turning on the flood light at the machine front. Turning ON:Pull out the switch. Turning OFF:Push in the switch. a When the starter switch is at OFF position, the flood light will not go on even if the switch is pulled out. a The flood light itself has a switch as well. Normally leave the switch on the flood light at its ON position. (4) Horn switch Used to sound horn. To sound the horn: Press the switch. a Horn sound stops as you take your finger off the switch. a Horn switch is provided on the crane operating side as well. 11

3. NOMENCLATURE OF COMPONENTS 3.2 Model MC-285CRM-E 3.2.1 Nomenclature of Components Motor unit Traveling stand 12

3. NOMENCLATURE OF COMPONENTS 3.2.2 Operation Procedures Preparation (1) Turn the engine/motor selector switch to the motor side. (2) Turn OFF the main power supply ground-fault circuit interrupters of the equipment and vehicle, then connect the wire to the power supply box. (3) Turn ON the ground-fault circuit interrupters of the equipment and vehicle, confirm that the indicator lamp lights on. Then, press the test switches of the ground-fault circuit interrupters and check to see that they operate normally. (4) After confirming that they operate normally, turn OFF the main power supply ground-fault circuit interrupters once, then ON again. CAUTION (ADVICE) After you have performed steps (1) to (4), you can use the motor first. Otherwise (when you perform them imperfectly), even if the engine/motor selector switch is switched to the motor side, the engine will be started. 13

3. NOMENCLATURE OF COMPONENTS Starting the motor (1) Turn the key switch to the "START" position to start the motor. (2) Operate the crane according to the operating manual Stopping the motor (1) Turn the key switch to "OFF". (2) Turn OFF the main power supply ground-fault circuit interrupters of the facility and vehicle. (3) Disconnect the wire from the power supply box. 14

3. NOMENCLATURE OF COMPONENTS 3.3 Model MC-305CRM-E 3.3.1 Nomenclature of Travel Control Components (1) Position of the selector switch 1. Swing lever 12. Crane work high speed selector switch 2. Boom telescoping lever 13. Hook stowing switch 3. Hook hoist lever 14. Horn switch 4. Boom hoist lever 15. Emergency stop switch 5. Level instrument 16. Travel high speed selector switch 6. Acceleration pedal 17. Outrigger control switch 7. Travel lock lever 18. Emergency stop cancel switch 8. Travel lever, right 19. Work selector switch 9. Travel lever, left (travel, outrigger, crane work) 10. Flood light (Rear) 20. Starter switch 11. Flood light switch (Front) 21. Meter panel 22. Engine/elect. motor selector switch 15

3. NOMENCLATURE OF COMPONENTS (2) The selector switch (Engine Elec. Motor) You can select [Engine] driven or [Elec. Motor] driven by the selector switch. For engine driven: Set the selector switch at Engine position. For elect. motor driven: Set the selector switch at Elect. Motor position. Make sure the Starter Switch is off when switching to electric motor driven, and stop the engine stop, if in use. 3.3.2 Starting Electric Motor WARNING Before starting the electric motor, make sure that there is no person or other obstacle around and sound the horn. OUR ADVICE Before starting the electric motor, make sure that the inverter breaker has been turned ON. Make sure that power connection has been made properly. 1. Switch the power selector to Electric Motor side. 2. Insert the key into starter switch and turn it to START position. 3. As soon as the electric motor has started, release the key. It will return automatically to ON position. 16

3. NOMENCLATURE OF COMPONENTS 3.3.3 Stopping Electric Motor 1. Take your foot off the accelerator pedal to reduce the motor speed. 2. Turn the key in starter switch to OFF position. The motor will stop. 3. Remove the key of starter switch. 4. After finishing your work by means of electric motor, be sure to return the selector switch to ENGINE side. 17

4. BLOCK DIAGRAM 4.1 Block Diagram of Model MC-104CER 18

4. BLOCK DIAGRAM 4.2 Block Diagram of Model MC-285CRM-E 19

4. BLOCK DIAGRAM 4.3 Block Diagram of Model MC-305CRM-E 20

5. HYDRAULIC CIRCUIT DIAGRAM 5.1 Hydraulic Circuit Diagram of Model MC-104CER 21

5. HYDRAULIC CIRCUIT DIAGRAM 5.2 Hydraulic Circuit Diagram of Model MC-285CRM-E 22

5. HYDRAULIC CIRCUIT DIAGRAM 5.3 Hydraulic Circuit Diagram of Model MC-305CRM-E 23

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 6.1 Hydraulic Piping Drawing of Model MC-104CER 24

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 1. Suction block 2. Bushing 3. Suction hose 4. P hose 5. Co hose 6. Return hose 1 7. Return hose 2 8. Accelerator drain hose 9. PP drain hose 10. Male 90-degree seated connector 11. Male 90-degree seated connector 12. Male 90-degree hose connector 13. Low pressure joint 14. Connector 15. Low pressure joint 16. Jubilee band 17. Jubilee band 18. O-ring 19. O-ring boss female connector 20. Jubilee band 21. O-ring 22. Hexagon bolt 23. Spring washer 24. Male 90-degree elbow 25. O-ring boss male 90-degree elbow 25

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 6.2 Hydraulic Piping Drawing of Model MC-285CRM-E 26

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 1. Suction block (1) 2. Suction block (2) 3. Check valve 4. P hose (1) 5. P hose (2) 6. P hose (3) 7. P hose (4) 8. P hose (5) 9. P hose (6) 10. Suction hose 11. Male connector 12. Male 90-degree elbow 13. Male 45-degree elbow 14. O-ring boss male 90-degree elbow 15. Nipple 16. Female tapped tee 17. O-ring 18. Jubilee band 19. Hexagon socket head bolt 20. Belleville spring 21. Spiral tube 22. Spiral tube 23. Male 90-degree elbow 24. O-ring boss female connector 27

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 6.3 Hydraulic Piping Drawing of Model MC-305CRM-E 28

6. HYDRAULIC PIPING FOR ELECTRIC MOTOR 1. Female/male elbow 2. Female/male tee 3. Bushing 4. Connector 5. Suction hose 6. Hose band 7. Bushing 8. Male/female elbow 9. Flange kit 10. Missing number 11. Male connector 12. Male swivel 90-degree elbow 13. Male connector 14. Hydraulic hose 15. Male 45-degree elbow 16. Female tapped tee 17. Male 45-degree elbow 18. Male 90-degree elbow 19. Nipple with O-ring 20. Check valve 21. Check valve 29

7. ELECTRICAL CIRCUIT DIAGRAM 7.1 Model MC-104CER 7.1.1 Electrical Circuit Diagram 30

7. ELECTRICAL CIRCUIT DIAGRAM 7.1.2 Wiring Harness Connection Drawing 31

7. ELECTRICAL CIRCUIT DIAGRAM 7.1.3 Electrical Circuit Diagram (Electric Motor Driven Partion) (1/2) 32

7. ELECTRICAL CIRCUIT DIAGRAM 7.1.4 Electrical Circuit Diagram (Electric Motor Driven Partion) (2/2) 33

7. ELECTRICAL CIRCUIT DIAGRAM 7.2 Model MC-285CRM-E 7.2.1 Electrical Circuit Diagram (Electric Motor Driven Partion) (1/2) 34

7. ELECTRICAL CIRCUIT DIAGRAM 7.2.2 Electrical Circuit Diagram (Electric Motor Driven Partion) (2/2) 35

7. ELECTRICAL CIRCUIT DIAGRAM 7.2.3 Electrical Circuit Diagram (Engine Portion) 36

7. ELECTRICAL CIRCUIT DIAGRAM 7.2.4 Electrical Circuit Diagram (Moment Limiter Portion) 37

7. ELECTRICAL CIRCUIT DIAGRAM 7.3 Model MC-305CRM-E 7.3.1 Electrical Circuit Diagram (Standard Portion) 38

7.3.2 Electrical Circuit Diagram (Moment Limiter Portion) 7. ELECTRICAL CIRCUIT DIAGRAM 39

7. ELECTRICAL CIRCUIT DIAGRAM 7.3.3 Electrical Circuit Diagram (Electric Motor Driven Partion) 40