MC-285/305CRM

Moment Limiter TCL-139-1

SERVICE MANUAL
 CONTENTS

CONTENTS

1. OUTLINE DRAWING.........................................................................................................................1

2. SPECIFICATIONS.............................................................................................................................2

3. SYSTEM DIAGRAM ..........................................................................................................................3

4. SCHEMATIC......................................................................................................................................4

5. CONNECTION...................................................................................................................................5
5.1 Connector Allocation ...................................................................................................................5

6. INPUT AND OUTPUT........................................................................................................................7

6.1 Converter .....................................................................................................................................7
6.2 Display .........................................................................................................................................8

7. DISPLAY ............................................................................................................................................10

8. SWITCH.............................................................................................................................................12

9. DISPLAY DESCRIPTION..................................................................................................................14
9.1 Outrigger Extension Detection Inputs (4) ....................................................................................14
9.2 Over-winding Detection Input ......................................................................................................14
9.3 Boom Upper Limit Detection Input ..............................................................................................14
9.4 Boom Lower Limit Detection Input ..............................................................................................14
9.5 Triple-winding Stop Limit Switch Input (optional)........................................................................15
9.6 Fall Mode Selector Switch...........................................................................................................15
9.7 Operation at Power On................................................................................................................15
9.8 Moment Limiter Operation...........................................................................................................15
9.9 Readout in the Actual Load Display ............................................................................................16
9.10 Readout in the Rated Load Display ............................................................................................16
9.11 Readout in the Display ................................................................................................................16
9.12 Others ..........................................................................................................................................16

10. WORKING RANGE REGULATORY CONTROL ..............................................................................17

11. CALIBRATION PROCEDURE ..........................................................................................................18

11.1 Nomenclature of Each Part .........................................................................................................18
11.2 Calibration Procedure..................................................................................................................19

12. TEST MODE ......................................................................................................................................27

12.1 Entering the Test Mode ...............................................................................................................27
12.2 L01 (ROM/RAM test) ...................................................................................................................27
12.3 L02 (LED test)..............................................................................................................................27
12.4 L03 (Switch test) ..........................................................................................................................28
12.5 L04 (Test for input signals of outrigger extension/boom-hoisting operation) .............................29

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CONTENTS

12.6 L05 (Output signal test) ...............................................................................................................30

12.7 L06 (4 to 20 mA test) ...................................................................................................................31
12.8 L07 (Test for input voltage from each sensor) ............................................................................31
12.9 L08 (Loop back test)....................................................................................................................31

13. PRECAUTIONS ON DISASSEMBLING/ASSEMBLING THE DERRICK CYLINDER PIPING .......32

13.1 Disassembling .............................................................................................................................32
13.2 Assembling ..................................................................................................................................33

14. INSPECTING/REPLACING THE FUSE ON THE DISPLAY AND CONVERTER ...........................34

14.1 Inspecting/Replacing the Fuse on the Display............................................................................34
14.2 Inspecting/Replacing the Fuse on the Converter........................................................................35

15. ELECTRIC CIRCUIT DIAGRAM (1/2) (ENGINE PORTION) FOR MC-285C ..................................37

16. ELECTRIC CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-285C ................38

17. ELECTRIC CIRCUIT DIAGRAM (1/2) (STANDARD PORTION) FOR MC-305C............................39

18. ELECTRIC CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-305C ................40

ii
 1. OUTLINE DRAWING

1. OUTLINE DRAWING

FALL MODE L: BOOM LENGTH

OVER
LIFTING HEIGHT WINDING
UPPER LIMIT
H: LIFTING HEIGHT SETUP

CANCEL

LOAD
CAPACITY % BOOM ANGLE ACTUAL LOAD

160
173
186
BOOM ANGLE BOOM ANGLE RATED LOAD
UPPER LIMIT LOWER LIMIT
SETUP SETUP
CANCEL CHECK
CANCEL CANCEL

WORKING RADIUS
UPPER LIMIT
SETUP R: WORKING RADIUS
CANCEL

MAX MID MIN

50
146
160
93.1
90
40
20

XSM00010E

1
2. SPECIFICATIONS

2. SPECIFICATIONS
Item MC-285C MC-305C
(1) Crane type Travel type crane
(2) Moment limiter type Automatic stop type
(3) Crane rated load 0 to 2.82 t 0 to 2.93 t
2 2
(pressure range: 0 to 210 kfg/cm ) (pressure range: 0 to 210 kfg/cm )
(4) Power supply 12 VDC (10 V to 15 VDC)
(5) Current Display Maximum: 0.8 A when 12 VDC
consumption Converter Maximum: 0.2 A when 12 VDC
(6) Calibration Electrical calibration

2
 3. SYSTEM DIAGRAM

3. SYSTEM DIAGRAM

Pressure Pressure Over-winding Boom Boom

sensor 1 sensor 2 Length meter Angle meter limit upper limit lower limit

Moment Limiter converter

Moment Limiter display

Hoisting-lever LS

Lowering-lever LS

Radio controlled
receiver
Winching-lever LS

Extending-lever LS

* Substitute input signal

of differential
transformer for 305C.
Emergency stop valve Flow Accelerator

Low Crane control valve

Load factor 70% to 99% : Controls flow and accelerator

Load factor 100% : Emergency stop valve (unload valve) operation
(overload)

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4. SCHEMATIC

4. SCHEMATIC

Over-winding B-contact
detection
A-contact
Pressure Boom upper limit
sensor-1 Input A-contact
Boom lower limit
Serial
communication

Pressure +12V
Input
sensor-1
0V
A-contact
Winch drum
triple-winding
stop limit
Angle Input
sensor

Converter
Length Input
sensor

Shield

Slip link

Display device
A-contact Moment ratio 4 to 20 mA output
Outrigger extension input maximum RR
A-contact Moment ratio 4 to 20 mA output common
Outrigger extension input maximum FR
A-contact Winch drum triple-winding stop output
Outrigger extension input maximum RL
A-contact
Outrigger extension input maximum FL For future
A-contact expansion RS232C input data (from converter)
Outrigger extension input middle RR (RS232C)
A-contact
Outrigger extension input middle FR
A-contact
Outrigger extension input middle RL
A-contact
Outrigger extension input middle FL
A-contact
Boom-hoisting lever input For future expansion

Buzzer output Photo-coupler input

Red lamp output Voltage output

Yellow lamp output B-contact output

Green lamp output A-contact output

Moment ratio 100% or higher output A-contact output

Over-winding output Open-collector output

Boom hoist output Open-collector output

Boom extension output Open-collector output
Boom lower output Open-collector output
Alarm forecast output
Open-collector output
Boom lower lever output A-contact
Photo-coupler input

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 5. CONNECTION

5. CONNECTION

5.1 Connector Allocation

The converter and display are provided with 2 connectors each.
Allocation (pin number and signal name) of each connector is shown below:

1. [Power Control] Connector (converter)

Model: RM15WTR-8P (Hirose) (Adaptable plug: RM15WTP-8S-0 Hirose)
Pin No. Signal Name Pin No. Signal Name
1 Over-winding detection input (1b contact) 5 +12 V
Lifting height upper limit detection input
2 6 +0 V
(1a contact)
Lifting height lower limit detection input
3 7 Triple-winding stop LS input (optional)
(1a contact)
4 Serial communication output 8 Not used

2. [Sensor] Connector (converter)

Model: RM21WTR-15S (Hirose) (Adaptable plug: RM21WTP-15P0 Hirose)
Pin No. Signal Name Pin No. Signal Name
1 Pressure sensor 1 + 12 V 9 Angle sensor GND
2 Pressure sensor 1 input 10 Length sensor + 12 V
3 Pressure sensor 1 GND 11 Length sensor input
4 Pressure sensor 2 + 12 V 12 Length sensor GND
5 Pressure sensor 2 input 13 Shield (common)
6 Pressure sensor 2 GND 14 Not used
7 Angle sensor + 12 V 15 Not used
8 Angle sensor input

3. [Power Control] Connector (display)

Model: RM15WTR-8P (Hirose) (Adaptable plug: RM15WTP-8S-0 Hirose)
Pin No. Signal Name Pin No. Signal Name
1 Moment ratio 4 to 20 mA output (+ side) 5 Not used
2 Moment ratio 4 to 20 mA output (− side) 6 Serial communication input
3 Triple-winding stop output (optional) 7 +12 V
4 Not used 8 +0 V

5
5. CONNECTION

4. [Input/Output] Connector
Model: RM21WTR-20S (Hirose) (Adaptable plug: RM21WTP-20P0 Hirose)
Pin No. Signal Name Pin No. Signal Name
1 Outrigger ① maximum extension input 11 Red lamp output
2 Outrigger ② maximum extension input 12 Yellow lamp output
3 Outrigger ③ maximum extension input 13 Green lamp output
4 Outrigger ④ maximum extension input 14 Mom ent ratio over 100% output
5 Not used 15 Over-winding output
6 Not used 16 Boom hoist output
7 Not used 17 Boom extension output
8 Not used 18 Boom lower output
9 Boom-hoisting lever input 19 Alarm forecast area output
10 Buzzer output 20 Boom-lowering lever input

6
 6. INPUT AND OUTPUT

6. INPUT AND OUTPUT

6.1 Converter
I/O Configuration Q’ty Specification
2
Pressure sensor 1 1 Analog input: 1 to 2.4 V/0 to 210 kgf/cm
2
Pressure sensor 2 1 Analog input: 1 to 2.4 V/0 to 210 kgf/cm
Angle sensor 1 Analog input: 1.8 V to 2.8 V/0 to 80°
Length sensor 1 Analog input: 0.72 V to 3.07 V/0 m to 4.5 m
Input
Lifting height upper limit detection 1 Photo-coupler input (Note)
Lifting height lower limit detection 1 Photo-coupler input (Note)
Over-winding detection 1 Photo-coupler input (Note)
Winch triple-winding stop input 1 Photo-coupler input (Note)
Output RS232C output 1 Data of each detector

Note: Photo-coupler input

Internal
circuit
Input

(Toshiba)
Converter

7
6. INPUT AND OUTPUT

6.2 Display
I/O Configuration Q’ty Specification
RS232C 1 Data received from the converter
Input Outrigger extension detection input 4 Photo-coupler input (Note 1)
Boom-hoisting lever input 1 Photo-coupler input (Note 1)
Voltage output: Transistor specification
Buzzer output 1
(12 VDC, 50 mA MAX) (Note 2)
B contact output: Relay output
Red lamp output 1
(contact capacity + 12 V, 0.5 A MAX) (Note 3)
A contact output: Relay output
Yellow lamp output 1
(contact capacity + 12 V, 0.5 A MAX) (Note 3)
A contact output: Relay output
Green lamp output 1
(contact capacity + 12 V, 0.5 A MAX) (Note 3)
Open-collector output: Transistor specification
Moment over 100% output 1
(12 VDC, 50 mA MAX) (Note 4)
Output Open-collector output: Transistor specification
Over-winding output 1
(12 VDC, 50 mA MAX) (Note 4)
Moment ratio 1 Analog output: 4 to 20 mA
Open-collector output: Transistor specification
Boom hoist output 1
(12 VDC, 50 mA MAX) (Note 4)
Open-collector output: Transistor specification
Boom extension output 1
(12 VDC, 50 mA MAX) (Note 4)
Open-collector output: Transistor specification
Boom lower output 1
(12 VDC, 50 mA MAX) (Note 4)
Open-collector output: Transistor specification
Forecast output 1
(12 VDC, 50 mA MAX) (Note 4)
Input Boom-lowering lever input 1 Photo-coupler input (Note 1)
Open-collector output: Transistor specification
Output Winch triple-winding stop output 1
(12 VDC, 50 mA MAX) (Note 4)

Note 1: Photo-coupler input

Internal
circuit
Input

(Toshiba)
Converter

8
 6. INPUT AND OUTPUT

Note 2: Voltage output

Internal
circuit

Output

(Toshiba)
Display

Note 3: Relay output

Used for relay: G5V-1-5V (Omron)

Output

Internal
circuit (Omron)

Display

Note 4: Open-collector output

Display

Internal
circuit
Output

(Toshiba)

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7. DISPLAY

7. DISPLAY

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 7. DISPLAY

No. Item Type Remarks

① Actual load display 7 segment Constantly displayed (character height: 10 mm)
② Rated total load display 7 segment Constantly displayed (character height: 8 mm)
③ Working radius display 7 segment Constantly displayed (character height: 10 mm)
④ Lifting height display 7 segment Constantly displayed (character height: 8 mm)
⑤ Boom angle display 7 segment Constantly displayed (character height: 8 mm)
⑥ Boom length display 7 segment Constantly displayed (character height: 8 mm)
Blinks when over-winding detection input is ON
⑦ Over-winding detection LED LED (Red)
(open)
Outrigger less than maximum
Blinks if any of the outrigger extension detection
extension LED
inputs are OFF (Applicable to MC-285C)
(Applicable to MC-285C)
⑧ LED (Amber)
Lights up when 3 or fewer middle extension inputs
Outrigger minimum extension
among the outrigger extension detection inputs are
LED (Applicable to MC-305C)
ON (Applicable to MC-305C)
Not used (Applicable to MC-285C)

Outrigger middle extension When 3 or fewer maximum extension inputs and 4

⑨ LED (Amber) middle extension inputs among the outrigger
LED
extension detection inputs are ON
(Applicable to MC-305C)
Lights up when all the outrigger extension detection
inputs are ON (Applicable to MC-285C)
Outrigger maximum extension
⑩ LED (Amber) Lights up when 4 maximum extension inputs among
LED
the outrigger extension detection inputs are ON
(Applicable to MC-305C)
Load capacity less than 70%
⑪ LED (Amber) Lights up when load capacity is less than 70%.
LED
Load capacity 70% or more Lights up when load capacity is 70% or more and less
⑫ LED (Amber)
and less than 100% LED than 100%.
Load capacity 100% or more
⑬ LED (Amber) Lights up when load capacity is100% or more.
LED
⑭ One-Hanged wire count LED LED (Amber) Press the switch for 2 seconds or longer to switch the
wire count LED. Continuously holding down the
⑮ Two-Hanged wire count LED LED (Amber)
switch switches sequentially through the wire count
⑯ Four-Hanged wire count LED LED (Amber) LEDs in 1-second intervals. The lit wire count is
substituted in the boom movement calculation.
Lights up when setting [Boom angle upper limit], and
⑰ Boom angle upper limit LED LED (Red)
blinks when the upper limit is reached.
Lights up when setting [Boom angle lower limit], and
⑱ Boom angle lower limit LED LED (Red)
blinks when the lower limit is reached.
Working radius upper limit Lights up when setting [Working radius upper limit],
⑲ LED (Red)
LED and blinks when the upper limit is reached.
Lights up when setting [Lifting height upper limit], and
⑳ Lifting height upper limit LED LED (Red)
blinks when the upper limit is reached.

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8. SWITCH

8. SWITCH

12
 8. SWITCH

No. Configuration Remarks

Press the switch for 2 seconds or longer to switch the wire count.
① Fall mode selector switch Then, as you press the switch, the wire count switches as follows:
1→2→4→1→….
Press when setting/canceling the boom angle lower limit value.
Pressing the switch for 2 seconds without any preset value sets the
current angle.
② Boom angle upper limit switch Pressing the switch for 5 seconds with a preset value cancels the current
setting.
Pressing the switch for 2 seconds or longer will not repeat set/cancel.
(To set or cancel, release the switch once.)
Press when setting/canceling the boom angle lower limit value.
Pressing the switch for 2 seconds without any preset value sets the
Boom angle lower limit switch current angle.
③ Pressing the switch for 5 seconds with a preset value cancels the current
setting.
Pressing the switch for 2 seconds or longer will not repeat set/cancel.
(To set or cancel, release the switch once.)
Press when setting/canceling the upper limit value of the working radius.
Pressing the switch for 2 seconds without any preset value sets the
current angle.
Working radius upper limit
④ Pressing the switch for 5 seconds with a preset value cancels the current
switch
setting.
Pressing the switch for 2 seconds or longer will not repeat set/cancel.
(To set or cancel, release the switch once.)
Press when setting/canceling the upper limit value of the lifting height.
Pressing the switch for 2 seconds without any preset value sets the
current lifting height.
⑤ Lifting height upper limit switch Pressing the switch for 5 seconds with a preset value cancels the current
setting.
Pressing the switch for 2 seconds or longer will not repeat set/cancel.
(To set or cancel, release the switch once.)
Press this switch together with the Setting value check switch for 5
⑥ Setting cancel switch
seconds or longer to cancel all the upper and lower limit value settings.
Each setting value can be checked upon pressing the switch.
When the switch is pressed, the following set values are repeatedly
displayed in the following order:
① [Boom angle upper limit value] in the boom angle display (the [Boom
angle upper limit] LED blinks)
② [Boom angle lower limit value] in the boom angle display (the [Boom
angle lower limit] LED blinks)
⑦ Setting value check switch ③ [Working radius upper limit value] in the working radius display (the
[Working radius upper limit] LED blinks)
④ [Lifting height upper limit value] in the lifting height display (the [Lifting
height upper limit] LED blinks)
⑤ Returns to the first display.
The display of items, excluding the above, remains blank.
Return to the first display by not pressing the switch for 5 seconds or
by pressing another switch during the setting displayed state.
An item without a set value preset remains blank.

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9. DISPLAY DESCRIPTION

9. DISPLAY DESCRIPTION

9.1 Outrigger Extension Detection Inputs (4)

★ Applicable to MC-285C
1. When all 4 outrigger extension detection inputs are ON:
• Lights up [Outrigger maximum extension] LED
• Uses "constant for rated total load calculation" for "outrigger maximum extension" time

2. When any of the 4 outrigger extension detection inputs is OFF:

• Lights up [Outrigger minimum extension] LED
• Uses "constant for rated total load calculation" for "outrigger middle/minimum extension" time

★ Applicable to MC-305C
1. When 4 maximum extension inputs among the outrigger extension detection inputs are ON:
• Lights up [Outrigger maximum extension] LED
• Uses "constant for rated total load calculation" for "outrigger standard extension" time

2. When 3 or fewer maximum extension inputs and 4 middle extension inputs among the outrigger
extension detection inputs are ON:
• Lights up [Outrigger middle extension] LED
• Uses "constant for rated total load calculation" for "outrigger middle extension" time

3. When 3 or fewer middle extension inputs among the outrigger extension detection inputs are ON:
• Lights up [Outrigger minimum extension] LED
• Uses "constant for rated total load calculation" for "outrigger minimum extension" time

9.2 Over-winding Detection Input

When input is ON:
• Blinks [Over-winding] LED (0.5 Hz cycle)
• Turns ON [Over-winding output]

9.3 Boom Upper Limit Detection Input

When input is ON:
• Turns ON [Boom hoist output]

9.4 Boom Lower Limit Detection Input

When input is ON:
• Turns ON [Boom lower output]

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 9. DISPLAY DESCRIPTION

9.5 Triple-winding Stop Limit Switch Input (optional)

When input is ON:
• Turns ON [Triple-winding stop output]

9.6 Fall Mode Selector Switch

Press the switch for 2 seconds or longer to switch the wire count LED. Continue pressing to sequentially
switch through the wire count LEDs in 1-second intervals. The blinking wire count is substituted in the
boom moment calculation. When you turn the power OFF, the final state of the wire count is saved.

9.7 Operation at Power On

1. Lights up all LEDs for 1 second
2. Switch input is restricted
3. External input is restricted
4. The output state is shown below:

Signal Name Output

Buzzer output OFF
Red lamp output ON (indicates continuity)
Yellow lamp output OFF
Blue lamp output OFF
Moment ratio over 100% output ON
Over-winding output OFF
Boom hoist output OFF
Boom extension output OFF
Boom lower output OFF
Alarm forecast area output 8 OFF
Moment ratio 4 to 20 Ma 20 mA
Triple-winding stop output OFF

9.8 Moment Limiter Operation

1. When load capacity is less than 70%:
• Lights up the [Load capacity less than 70%] LED
• Indicates continuity with the [Green lamp output]

2. When load capacity is more than 70% and less than 100%:
• Lights up the [Load capacity 70% or more and less than 100%] LED
• Indicates continuity with the [Yellow lamp output]
• Turns ON [Buzzer output] intermittently (0.5 Hz)

15
9. DISPLAY DESCRIPTION

3. When load capacity is 100% or more:

• Lights up the [Load capacity 100% or more] LED
• Indicates continuity with the [Red lamp output]
• Turns ON [Buzzer output] successively
• Turns ON [Moment 100% or more output]

4. Moment ratio output (4 to 20 mA)

• Moment ratio 70%: 4 mA to moment ratio 99%: 20 mA; outputs linear current
• Fixed to 4 mA when moment ratio is 70% or less
• Fixed to 20 mA when moment ratio is 99% or more
• Fixed to 20 mA upon error occurrence

9.9 Readout in the Actual Load Display

When calculating the actual load, correct the load with [Boom-hoisting lever input] and [Boom-lowering
lever input]. Readout is converted to and given in "tons" and rounded off to the first decimal place. (XX.X)
No negative readout.
However, when calibrating, round off to the 2nd decimal place. (X.XX)

9.10 Readout in the Rated Load Display

Readout is converted to and given in "tons" and rounded off to the first decimal place. (XX.X)
No negative readout.

9.11 Readout in the Display

1. WORKING RADIUS display
Readout is converted to and given in "meters" and rounded off to the first decimal place. (XX.X)
2. LIFTING HEIGHT display
Readout is converted to and given in "meters" and rounded off to the first decimal place. (XX.X)
3. BOOM ANGLE display
θ value is rounded off to the 1st decimal place. (XX.X)
4. BOOM LENGTH display
Readout is converted to and given in "meters" and rounded off to the first decimal place. (XX.X)

9.12 Others
1. The [Red lamp] shall be B contact output and keep the continuity between the contacts when the
machine stalls. Therefore, the [Red lamp] is lit at machine downtime.
During normal operation, while each relay maintains continuity, electricity to the [Red lamp] is turned off
due to the ON condition.
2. The input/output response speed in the display and converter shall be as quick as possible.

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 10. WORKING RANGE REGULATORY CONTROL

10. WORKING RANGE REGULATORY CONTROL

Limit Limit
Value Description of Control Value Description of Control
Name Name
Boom When (boom angle upper limit value −10 Working When (working radius upper limit value −1.3 m)
angle degrees) > boom angle: (Safety area) radius > working radius: (Safety area)
upper limit • Lights up [Boom angle upper limit] LED upper limit • Lights up [Working radius upper limit] LED
value value
When (boom angle upper limit value −7 When (working radius upper limit value −0.6 m)
degrees) > boom angle ≧ (boom angle upper > working radius ≧ (working radius upper limit
limit value −10 degrees): −1.3 m):
• Blinks [Boom angle upper limit] LED • Blinks [Working radius upper limit] LED
• Turns ON [Alarm forecast area output] • Turns ON [Alarm forecast area output]
• Turns on [Buzzer output] intermittently • Turns ON [Buzzer output] intermittently
When boom angle ≧ (boom angle upper limit When working radius ≧ (working radius upper
value −7 degrees) : limit value −0.6 m):
• Blinks [Boom angle upper limit] LED • Blinks [Working radius upper limit] LED
• Turns ON [Alarm forecast area output] • Turns ON [Alarm forecast area output]
• Turns ON [Boom hoist output] • Turns ON [Boom extension output]
• Turns ON [Yellow lamp output] • Turns ON [Boom lower output]
• Turns ON [Buzzer output] successively • Turns ON [Yellow lamp output]
• Turns ON Buzzer output] successively
Boom When (boom angle lower limit value +7 degrees) Lifting When (lifting height upper limit value −1.3 m)
angle < boom angle: (Safety area) height > lifting height: (Safety area)
lower limit • Lights up [Boom angle lower limit] LED upper limit • Lights up [Lifting height upper limit] LED
value value
When (boom angle lower limit value +4 degrees) When (lifting height upper limit value −0.45 m)
< boom angle ≦ (boom angle lower limit value > lifting height ≧ (lifting height upper limit value
7 degrees): −1.3 m):
• Blinks [Boom angle lower limit] LED • Blinks [Lifting height upper limit] LED
• Turns ON [Alarm forecast area output] • Turns ON [Alarm forecast area output]
• Turns ON [Buzzer output] intermittently • Turns ON [Buzzer output] intermittently
When boom angle ≦ (boom angle lower limit When lifting height ≧ (lifting height upper limit
value +4 degrees) : value −0.45 m):
• Blinks [Boom angle lower limit] LED • Blinks [Lifting height upper limit] LED
• Turns ON [Alarm forecast area output] • Turns ON [Alarm forecast area output]
• Turns ON [Boom lower output] • Turns ON [Boom extension output]
• Turns ON [Yellow lamp output] • Turns ON [Boom hoist output]
• Turns ON [Buzzer output] successively • Turns ON [Yellow lamp output]
• Turns ON [Buzzer output] successively

Note:
• When no set value is set (due to default setting or canceling the setting), the following LEDs will remain
turned off: [Boom upper limit], [Boom lower limit], [Working radius upper limit], and [Lifting height upper
limit].
• After setting, return to the safety area once to make each output effective. The alarm will not
immediately come on even when the set value is set within the alarm area during setting.
• The final state of the set value is saved even when the power is turned OFF.

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11. CALIBRATION PROCEDURE

11. CALIBRATION PROCEDURE

11.1 Nomenclature of Each Part

① Boom angle display

② Boom lifting upper limit switch
③ Boom angle lower limit switch
④ Boom angle upper limit switch
⑤ Outrigger pendent condition
⑥ Setting value check switch
⑦ Load capacity display LED
⑧ Hanged wire count display LED
⑨ Fall mode selector switch

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 11. CALIBRATION PROCEDURE

11.2 Calibration Procedure

11.2.1 Preparation

1. Press the Lifting height upper limit switch ②, Boom angle upper limit switch ④, and Fall mode selector
switch ⑨ simultaneously for about 3 seconds.

2. The Display panel will display as in the diagram.

11.2.2 Length Calibration

1. Setting the boom to full retraction (length offset

value)

(1) Use the Boom angle upper limit switch ④and

the Boom angle lower limit switch ③, and set
the numerical value of the Boom angle display
① as shown below:
Set the second decimal places while pressing
the Setting value check switch ⑥.
★ Applicable to MC-285C: 2.54
(Length of the fully retracted boom: 2.535 m)
★ Applicable to MC-305C: 3.70
(Length of the fully retracted boom: 3.695 m)

19
11. CALIBRATION PROCEDURE

(2) Operate the crane and fully retract the boom.

(3) Press the Fall mode selector switch ⑨ to set the boom to
full retraction.
The [Four-hanged wire count] LED lights up when properly
set.

★ When not setting the boom to full retraction (length offset

value), skip the above and go to the next procedure.

2. Setting the boom to full extension

(length span value)

(1) Press the Lifting height upper limit switch ②.

The readouts in the display switch to [LEn]
and [SPA].

(2) Use the Boom angle upper limit switch ④ and the Boom angle lower limit switch ③, and set the
numerical value of the Boom angle display ① as shown below:
Set the second decimal places while pressing the Setting value check switch ⑥.
★ Applicable to MC-285C: 8.58 (Length of the fully retracted boom: 8.575 m)
★ Applicable to MC-305C: 12.49 (Length of the fully retracted boom: 12.485 m)

20
 11. CALIBRATION PROCEDURE

(3) Operate the crane and fully extend the boom.

(4) Press the Fall mode selector switch ⑨ to set the boom to
full extension. The [Two-hanged wire count] LED lights up
when properly set.

★ When not setting the boom in full extension (length span

value), skip the above procedure and go to the next.

11.2.3 Angle Calibration

1. Setting the boom to its fully lowered state

(angle offset value)

(1) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to [Ang]
and [oFF].

(2) Use the Boom angle upper limit switch ④ and the Boom angle lower limit switch ③, and set the
numerical value of the Boom angle display ① to 0 (Angle of fully lowered boom: 0°).

21
11. CALIBRATION PROCEDURE

(3) Operate the crane and fully lower the boom (boom angle:
0°).

(4) Press the Fall mode selector switch ⑨ to set the boom to
its fully lowered state.
The [One-hanged wire count] LED lights up when properly
set.

★ When not setting the boom to its fully lowered state (angle
offset value), skip the above procedure and go to the next.

2. Setting the boom to its fully hoisted state

(angle span value)

(1) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to [Ang]
and [SPA].

(2) Use the Boom angle upper limit switch ④ and the Boom angle lower limit switch ③, and set the
numerical value of the Boom angle display ① to 80 (Angle of fully hoisted boom: 80°).

22
 11. CALIBRATION PROCEDURE

(3) Operate the crane and fully hoist the boom (boom angle:
80°).

(4) Press the Fall mode selector switch ⑨ to set the boom to
its fully hoisted state. The [Load capacity 100%] LED
lights up when properly set.

★ When not setting the boom in its fully hoisted state (angle
span value), skip the above procedure and go to the next.

11.2.4 Weight Calibration

1. Setting the Weight Calibration Conditions

★ Calibrate the weight with either one of the following conditions, according to the weight you have.
MC-285C MC-305C
509 m
Working Radius Rated Total Load Boom Length
(Boom 2nd Stage)
3.0 m 1,220 kg Boom Angle 40°
3.5 m 970 kg Weight 1,000 kg
4.0 m 780 kg

★ The following procedure is an example for MC-285C with a working radius of 3.5 m and a rated total
load of 970 kg.

(1) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to [ton]
and [PAr].

23
11. CALIBRATION PROCEDURE

(2) Operate the crane and set the working radius to 3.5 m.

(3) Press the Fall mode selector switch ⑨ and set the
working radius for weight calibration.
The [Load capacity 70% or more and less than 100%] LED
lights up when properly set.

★ When not setting the weight calibration condition, skip the

above procedure and go to the next.

2. Setting to the No-load State (Weight Offset Value)

(1) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to [ton]
and [oFF].

(2) Use the Boom angle upper limit switch ④ and the Boom angle lower limit switch ③, and set the
numerical value of the Boom angle display ① to 0.02 (hoisting load during no load: 0.02 t (hook
weight)).

24
 11. CALIBRATION PROCEDURE

(3) Press the Fall mode selector switch ⑨ to set to the no

load state. The [Load capacity less than 70%] LED lights
up when properly set.

★ When not setting to the no-load state (weight offset value),

skip the above procedure and go to the next.

3. Setting to the Under Load State (Weight Span Value)

(1) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to [ton]
and [SPA].

(2) Use the Boom angle upper limit switch ④ and the Boom angle lower limit switch ③, and set the
numerical value of the Boom angle display ① to 0.97 (hoisting load during under load: 0.95 t
(weight weight) +0.02 t (hook weight)).

25
11. CALIBRATION PROCEDURE

(3) Hoist a 0.95 t weight in the working radius of 3.5 m set

above.

(4) Press the Fall mode selector switch ⑨ to set to the no

load state. The [Load capacity less than 70%] LED lights
up when properly set.

★ When not setting to the under load state (weight span

value), skip the above procedure and go to the next.

(5) Press the Lifting height upper limit switch ②.

The readouts in the displays switch to normal display.

26
 12. TEST MODE

12. TEST MODE

This machine has a test mode function to confirm the machine operation and output/input signals of the
machine.

12.1 Entering the Test Mode

1. Turn ON the power while pressing the Setting cancel switch
and the Setting value check switch.

2. [L01] appears in the Boom length display.

3. Press the Setting cancel switch to change the test items by

sequentially scrolling through [L01] to [L08].

Test Item Configuration

L01 ROM/RAM test
L02 LED test
L03 Switch test
L04 Test for Input signals of outrigger extension/boom-hoisting operation
L05 Output signal test
L06 4 to 20 mA test
L07 Test for input voltage value from each sensor
L08 Loop back test

12.2 L01 (ROM/RAM test)

Use is restricted.

12.3 L02 (LED test)

BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Test item LED
Readout L02 888 888 888 888 888

Note: All LEDs light up.

Testing method:
1. Check to see if [L02] is displayed in the Boom
length display.

2. Press the Setting value check switch to

automatically light up each display.

27
12. TEST MODE

12.4 L03 (Switch test)

BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Testing
Test item Switch
section
1
Readout L03 (Each switch
number)

Testing method:
1. Check to see if [L03] is displayed in the Boom length display.

2. Press the Setting value check switch to enable testing.

3. Pressing each panel switch displays the following switch

numbers:

Switches on the Panel Display No. Remarks

Setting check 1
Setting cancel 2 Successively press the button twice to proceed to the next test.
Lifting height upper limit 3
Working range upper limit 4
Angle upper limit 5
Angle lower limit 6

28
 12. TEST MODE

12.5 L04 (Test for Input signals of outrigger extension/boom-hoisting

operation)
BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Input signals
of outrigger
Testing
Test item extension/
section
boom-hoisting
operation
Readout L04 Example: 20F

Testing method:
1. Check to see if [L04] is displayed in the Boom length display.

2. Press the Setting value check switch to light up the Lifting

height display.

3. In the Lifting height display, the detection signal of each

outrigger extension and input signal of the boom-hoisting lever
will be displayed in 3 digits.

3 digits displayed in the [LIFTING HEIGHT] display

Place Hundred's place Ten's place One's place
Testing Boom hoisting Outrigger middle extension Outrigger maximum extension
section
Readout Moving the boom-hoisting MC-285C displays 0 for no Represents 4 detection signals
lever towards "hoist" displays 1 setting; MC-305C displays the in 4 numerical values (Refer to
and moving it towards "lower" numerical value as calculated the table below) and displays
displays 2. in the right column for the the total in hexadecimals
"one's place."

Contrast Table of Outrigger Number and Input Signal

Outrigger Number Input Signal Number
① 1
② 2
③ 4
④ 8

Contrast Table of Decimal Number and Hexadecimal Number

Decimal number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Hexadecimal number 1 2 3 4 5 6 7 8 9 A B C D E F G

For example, when fully extending ③ and ④ outriggers only:

4 (③) + 8 (④) = 12 (decimal number) → C (hexadecimal number)

29
12. TEST MODE

12.6 L05 (Output signal test)

BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Testing Turning on/off
Test item Output signal
section output signal
1
Readout L05 (Each output ON/OFF
number)

Testing method:
1. Check to see if [L05] is displayed in the Boom length display.
2. Press the Setting value check switch to light up the Lifting
height display.

3. Pressing each panel switch displays the following switch

numbers:

Output signal Display No. Remarks

Boom hoist 1
Boom extension 2
Boom lower 3
Extra wire layer on winch drum 4
Buzzer 5
Red lamp 6 Output signal is turned ON in default.
Yellow lamp 7
Green lamp 8
Moment ratio 100% 9 Output signal is turned ON in default.
Hook over winding 10
Forecast alarm 11

4. Set the output signal to be checked, press the Lifting height

upper limit switch, and switch the output signal ON.

5. Actually operate the boom to check that each output signal is

sent.

30
 12. TEST MODE

12.7 L06 (4 to 20 mA test)

BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Test item 4 to 20 mA mA
4.0→8.0→
Readout L06 12.0→16.0→
20.0

Testing method:
1. Check to see if [L06] is displayed in the Boom length display.

2. Press the Setting value check switch to automatically conduct

the test.

12.8 L07 (Test for input voltage value from each sensor)
BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Input voltage Pressure Pressure
Angle meter Length meter
Test item value from the sensor 1 sensor 2
[V] [V]
sensors [V] [V]
Readout for
L07 1 to 2.4 1 to 2.4 1.8 to 2.8 0.72 to 3.07
MC-285C
Readout for
MC-305C

Testing method:
1. Check to see if [L07] is displayed in the Boom length display.

2. Press the Setting value check switch to automatically conduct

the test.

12.9 L08 (Loop back test)

BOOM LIFTING BOOM ACTUAL RATED WORKING
Display
LENGTH HEIGHT ANGLE LOAD LOAD RADIUS
Test item Loop back
Readout L07 Err

This test is not necessary. (Displays "Err" in the Lifting height display.)

31
13. PRECAUTIONS ON DISASSEMBLING/ASSEMBLING THE DERRICK CYLINDER PIPING

13. PRECAUTIONS ON DISASSEMBLING/ASSEMBLING THE

DERRICK CYLINDER PIPING
When disassembling the derrick cylinder piping, disassemble the pipe, connecting the counterbalance
valves on the left and right derrick cylinders (bottom connect pipe) by completely depressurizing the
internal pressure of the counterbalance valve using the method below.
As shown in Fig. 1, the bottom connection piping is a closed circuit with the left and right derrick cylinders
and counterbalance valves, and its internal pressure does not depressurize even when you operate the
boom-hoisting lever up and down. Therefore, it is very dangerous if the bottom connection piping is
disassembled without having the internal pressure of the counterbalance valve completely depressurized
since the hydraulic oil will spew out. Operate with due caution.

Bottom connection pipe

Derrick cylinder (R) Derrick cylinder (L)

Fig. 1 Derrick Cylinder Hydraulic System Diagram

13.1 Disassembling
1. Before disassembling, lower the boom horizontally. The boom needs to be lowered horizontally to
prevent it from falling when you remove the counterbalance in the next step.
2. Move the boom-hoisting lever up and down several times and depressurize the circuit pressure.
3. Remove the hose mouth ring in the A section of the derrick cylinder (right) (refer to Fig. 2).
4. Loosen the counterbalance valve of the derrick cylinder (right) (refer to Fig. 2).
Loosen (about 10 mm) until the pressure is completely removed from the joint in section A (Fig. 2).
5. Pull out the counterbalance valve of the derrick cylinder (left) (refer to Fig. 2).
Release the pressure in the block.
6. Slowly remove the piping connecting the bottom connection section.

32
 13. PRECAUTIONS ON DISASSEMBLING/ASSEMBLING THE DERRICK CYLINDER PIPING

13.2 Assembling
Assemble in reverse order to the above disassembling order. Here, assemble the counterbalance valve
with a tightening torque of 88.3 Nm (9 kgf･m) to 98.1 Nm (10 kgf･m) to prevent damage to the O ring of the
counterbalance valve.

Dcyl (L)
Bottom connection pipe Counterbalance valve

Dcyl (F)
Counterbalance valve

Fig. 2 Derrick Cylinder Top View

33
14. INSPECTING/REPLACING THE FUSE ON THE DISPLAY AND CONVERTER

14. INSPECTING/REPLACING THE FUSE ON THE DISPLAY AND

CONVERTER

14.1 Inspecting/Replacing the Fuse on the Display

1. Remove the top and bottom covers ① (hatched

area) of the display.
Remove the cover ① and find the 4 screws ②.
2. Remove the 4 screws ② with the plus
screwdriver.
3. Lift up the display ③ and separate it from the
body ④.
When lifting the display ③, be careful not to
damage the wiring harness.
4. Inspect or replace the fuse (3A) ⑤ in the body.

34
 14. INSPECTING/REPLACING THE FUSE ON THE DISPLAY AND CONVERTER

14.2 Inspecting/Replacing the Fuse on the Converter

1. Remove the top and bottom covers ① (hatched

area) of the converter.
Remove the cover ① and find the 4 screws ②.
2. Remove the 4 screws ② with the plus
screwdriver.
3. Lift up the converter cover ③ and separate it
from the body ④.
4. Inspect or replace the fuse (3A) ⑤ in the body.

35
36
 15. ELECTRICAL CIRCUIT DIAGRAM (1/2) (ENGINE PORTION) FOR MC-285C

15. ELECTRICAL CIRCUIT DIAGRAM (1/2) (ENGINE PORTION) FOR MC-285C

only

37
 16. ELECTRICAL CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-285C

16. ELECTRICAL CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-285C

38
 17. ELECTRICAL CIRCUIT DIAGRAM (1/2) (STANDARD PORTION) FOR MC-305C

17. ELECTRICAL CIRCUIT DIAGRAM (1/2) (STANDARD PORTION) FOR MC-305C

M/L specifications

39
 18. ELECTRICAL CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-305C

18. ELECTRICAL CIRCUIT DIAGRAM (2/2) (MOMENT LIMITER PORTION) FOR MC-305C

Electrically specifications

40