NJAMD00400 Operation Manual - Maeda Mini Cranesmaedaminicranes.co.uk/pdf/lc785/LC785_Operation_Manual.pdfNJAMD00400 Operation Manual CRAWLER CRANE Applicable to No.31001 and later

NJAMD00400

Operation Manual

CRAWLER CRANE Applicable to No.31001 and later

WARNING Improper use of this machine can lead to serious accidents. The operators and maintenance personnel must carefully read this manual and sufficiently understand its contents before operating / inspecting / maintaining the machine. Keep this manual to hand at all times.

Introduction

Introduction INTRODUCTION

Introduction This manual describes the procedures of proper operation, inspection and maintenance of the machine and the items you have to observe for safety. Many accidents are caused by operation, inspection or maintenance of the machine that does not observe basic precautions. Being aware of the dangers to be expected in advance can also prevent accidents.

WARNING Operators and maintenance personnel must observe the following before operating, inspecting or maintaining the machine. • Read this manual carefully and thoroughly understand its contents. • Sufficiently understand the cautions given in this manual and the meanings of

safety signs. Keep this manual in the instruction manual holder shown below so that those involved can consult it at any time. Should you lose or damage this manual, contact our sales service agency immediately and purchase a new manual. When you transfer this machine, be sure to transfer this manual together with the machine. This machine is designed and manufactured in compliance with the safety regulations and standards in Japan and safety regulations and standards may differ overseas. Should you use this machine outside Japan, please contact our sales service agency beforehand. This manual expresses measurement units in the International System (SI) of units. For your reference, we have given the gravitational system of units previously used in { }. The storage location for the instruction manual is the magazine box on the left, inside the cab.

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INTRODUCTION Notes about Machine

For Safe Use of Machine For the safe use of the machine, we use the safety signs that appear in this manual and on the machine to indicate the dangers to be expected and how to avoid them. Warning signs The following warning signs notify users of a danger that can lead to injuries. This machine and this manual use the warning signs shown below according to the severity of the danger to be expected.

DANGER Indicates imminent danger that will cause death or serious injury.

WARNING Indicates potential danger that can cause death or serious injury.

CAUTION Indicates potential danger that may cause minor or moderate injury or serious damage to the machine.

Example of safety-related message using a warning sign

WARNING Ensure that the safety lock lever is in the lock position before standing up from the cab seat. Accidental contact with an unlocked operation lever can lead to serious injuries. Other warning signs Besides the warning signal words given above, the following indications are used to show what must be observed and what will be helpful for the proper functioning of the machine.

IMPORTANT Indicates that improper handling can damage the machine or shorten the life of the machine.

SUPPLEMENTAL Gives you helpful information.

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For Safe Use of Machine INTRODUCTION

• Safety signs To notify the persons involved of the existence of hazards accompanying operation and inspection/maintenance, safety signs are positioned at various locations of the machine. On this machine, safety signs comprise “safety signs by words” and “safety signs by pictograms”. Example of a safety sign by words

Example of a safety sign by pictograms Safety signs by pictograms indicate danger that requires signal words. These safety signs employ pictograms to allow operators and maintenance personnel to instantly understand the existence and the nature of a danger. Safety signs by pictograms show the nature of a danger at the top or on the left and how to avoid a danger at the bottom or on the right. The nature of the danger is indicated in the triangle. We cannot foresee every circumstance in which you will use this machine and thus, the cautions given in this manual and on this machine do not necessarily cover every safety-related issue.

Observe the following before moving the machine or implement to prevent serious injury and fatal accidents • Honk the horn to notify people

around. • Check that there is no-one on or

around the machine or within the swing range.

• Swing the top if necessary, to secure sufficient visibility in the traveling direction.

• Staff observer(s) when you have poor visibility.

Keep observing the above items even when the machine is equipped with a traveling alarm or mirrors.

Therefore, it is your own responsibility to consider and take necessary the safety actions when performing operation or inspection/maintenance in a situation that is not described in this manual. However, even in those cases, never attempt the works and operations this manual prohibits you from doing. The descriptions, numerical values and drawings given in this manual are based on the information we have at the time of writing this manual. The contents of this manual and the specification of this machine may partially differ due to constant improvement of the machine. Please contact our sales service agency for any question or comment.

The circled numbers in the drawings are given in parentheses in the text. (Ex: ① (1))

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Machine Overview Specified operations Use this product mainly in the following operations:

• Crane operation

• Traveling with a suspended load

Machine’s front, back, left and right This manual determines the front, back, left, and right of the machine, assuming that we see the traveling direction (front) of the machine from the cab seat and the sprockets are positioned in the back.

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Qualification for Operation INTRODUCTION

Qualification for Operation Qualification The personnel who operate and work with this machine should obey the crane operation license and related legal regulations applicable to the place of use.

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Notes about Machine Please give the following information to our sales service agency when asking for servicing or ordering parts.

Machine serial number nameplate location The nameplate is provided on the cab front.

Engine serial number nameplate location The nameplate is provided on the head cover.

Service meter location The service meter is provided on the machine monitor.

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Notes about Machine INTRODUCTION

Information on the serial number and your sales service agency Machine Serial Number Engine Serial Number

Agency Name Address Telephone Service Person in Charge

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Contents Introduction

INTRODUCTION ............................................................................................... 1-1 FOR SAFE USE OF MACHINE......................................................................... 1-2 MACHINE OVERVIEW ...................................................................................... 1-4

Specified operations.........................................................................................1-4 Machine’s front, back, left and right ...............................................................1-4

QUALIFICATION FOR OPERATION ................................................................ 1-5 Qualification ......................................................................................................1-5

NOTES ABOUT MACHINE ............................................................................... 1-6 Machine serial number nameplate location ...................................................1-6 Engine serial number nameplate location......................................................1-6 Service meter location......................................................................................1-6 Information on the serial number and your sales service agency ..............1-7

Safety SAFETY SIGNS ................................................................................................ 2-1 POSITION FOR ATTACHING SAFETY LABELS............................................. 2-2 BASIC PRECAUTIONS .................................................................................... 2-9 CAUTIONS ON OPERATIONS ....................................................................... 2-17

Starting engine ...............................................................................................2-17 Operations .......................................................................................................2-18 Cautions during crane operation ..................................................................2-23 Cautions in special crane operation .............................................................2-26 Transportation ................................................................................................2-27 Battery..............................................................................................................2-28 Towing/Being Towed .....................................................................................2-30

CAUTIONS ON MAINTENANCE .................................................................... 2-31

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Contents INTRODUCTION

Handling NAME OF EACH SECTION .............................................................................. 3-1

Machine overview .............................................................................................3-1 Controlling device overview ............................................................................3-2

DESCRIPTION OF EACH DEVICE .................................................................. 3-3 EMO SWITCH (EMERGENCY STOP SWITCH) ...............................................3-3 Machine monitor ...............................................................................................3-4 Caution items ....................................................................................................3-5 Emergency stop items .....................................................................................3-6 Meter indicator section ....................................................................................3-7 Monitor switch section ..................................................................................3-10 Switches...........................................................................................................3-12 Moment limiting device (Overload protector) .............................................3-20 Operation levers and pedals Safety lock lever ............................................3-23 Opening/Closing Cab Front Window ............................................................3-26 Sliding door .....................................................................................................3-32 Emergency escape hammer ..........................................................................3-32 Locked caps and covers ................................................................................3-33 Engine hood ....................................................................................................3-34 Battery inspection cover ...............................................................................3-35 Fuses ...............................................................................................................3-36 Fusible link ......................................................................................................3-37 Controller ........................................................................................................3-37 Handling air conditioner ................................................................................3-38 Handling vehicle radio....................................................................................3-43

Description of each system .................................................................3-43 Operations............................................................................................3-46

Manual holder .................................................................................................3-48 Grease pump holder .......................................................................................3-48 Ashtray ............................................................................................................3-48

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OPERATIONS ................................................................................................. 3-49 Check and adjustment before starting engine.............................................3-49

Walk-around check ..............................................................................3-49 Check before starting operation ..........................................................3-52 Adjustment ...........................................................................................3-60 Handling seat belt ................................................................................3-61 Operation and check before starting the engine .................................3-63

Starting the engine..........................................................................................3-65 Normal starting ....................................................................................3-65 Starting in the cold weather .................................................................3-67 Operation and check after starting the engine ....................................3-69

Stopping the engine........................................................................................3-72 Starting moving(forward/backward)/ ...........................................................3-73 Stopping the machine.....................................................................................3-73 Steering the machine .....................................................................................3-78 Swing the machine..........................................................................................3-80 Handling operation mode...............................................................................3-81 Cautions before crane operation...................................................................3-82 Crane operation overview .............................................................................3-83 Hoisting/Lowering operation .........................................................................3-85 Boom derricking operation ...........................................................................3-87 Boom extending/retracting operation ..........................................................3-88 Swing operation ..............................................................................................3-89 Operation posture ..........................................................................................3-90 Traveling hoist operation ..............................................................................3-91 Hook storing operation (simplified storing) ................................................3-92 Prohibited matters during operation.............................................................3-93 Cautions during operations ..........................................................................3-96 Parking the machine ......................................................................................3-99 Inspection and check after stopping the engine .......................................3-100 Inspection and check after completing the operation ..............................3-100 Locking ..........................................................................................................3-100 Handling wire ropes .....................................................................................3-101

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How to hook winch wire ropes and the rated load ............................3-101 Hooking winch wire ropes .................................................................3-102 Replacing wire ropes .........................................................................3-103 What to do with the twisted wire ropes ..............................................3-107

Inspection and adjustment of wire ropes for extending boom ...............3-108 Handling moment limiting device................................................................3-111

TRANSPORTATION...................................................................................... 3-124 Loading/Unloading the machine to/from trailer ........................................3-125 How to hoist the machine ............................................................................3-129

How to hoist the machine with the boom lowered .............................3-130 How to hoist the machine with the boom raised ................................3-131

HANDLING IN THE COLD WEATHER ........................................................ 3-132 Preparing for low temperature.....................................................................3-132

Fuel and lubricating oil ......................................................................3-132 Cooling water .....................................................................................3-132 Battery ...............................................................................................3-132 Cautions after completing the operation ...........................................3-133 When the cold weather is gone..........................................................3-133

LONG-TERM STORAGE............................................................................... 3-134 Before storing the machine .........................................................................3-134 During storage...............................................................................................3-134 After storage .................................................................................................3-134

TROUBLESHOOTING .................................................................................. 3-135 Non-failure phenomena ...............................................................................3-135 How to tow the machine ..............................................................................3-135 When the battery discharged.......................................................................3-136

Removing/Installing battery................................................................3-137 Cautions in charging the battery ........................................................3-137 Starting the engine with booster cable ..............................................3-138

Fault finding and remedial actions..............................................................3-140 Electrical components .......................................................................3-140 Machine body ....................................................................................3-141 Engine ...............................................................................................3-142 Electrical systems ..............................................................................3-143 Moment limiting device ......................................................................3-144

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Errors in overwinding protector .........................................................3-153

Inspection and Maintenance MAINTENANCE PRECAUTIONS ..................................................................... 4-1 BASIC MAINTENANCE CONTENTS ............................................................... 4-3

Oil/Fuel/Coolant Handling ...............................................................................4-3 Oil ..........................................................................................................4-3 Fuel ........................................................................................................4-3 Cooling water .........................................................................................4-4 Grease ...................................................................................................4-4 Stocking and Storage of Oils and Fuels ................................................4-4 Filter .......................................................................................................4-4

Handling Electricity Related Parts ..................................................................4-5 BOLT/NUT STANDARD TIGHTENING TORQUE ........................................... 4-6

Torque List Table ..............................................................................................4-6 INSPECTION AND MAINTENANCE LIST ........................................................ 4-7

Maintenance Cycle List ....................................................................................4-7 WORKING PROCEDURE ................................................................................ 4-9

Initial 50 Hour Maintenance (Only the First Maintenance of a New Car) ....4-9 Initial 250 Hour Maintenance (Only the First Maintenance of a New Car) ..4-9 Non-routine Maintenance ..............................................................................4-10

Inspection/Cleaning/Replacement of Air Cleaner ...............................4-10 Battery Fluid Level Inspection .............................................................4-12 Cooling System Internal Cleaning........................................................4-13 Water Separator Element Replacement .............................................4-15 Fuel Tank Internal Washing ................................................................4-16 Crawler Shoe Bolt Looseness Inspection/Retightening ......................4-17 Crawler Tension Inspection/Adjustment ..............................................4-18 Air Conditioner Inspection and Maintenance ......................................4-22 Slide Door Rail/Roller Inspection, .......................................................4-23 Cleanup and Grease Replenishment ..................................................4-23 Hydraulic Circuit Air Relief Procedure .................................................4-24

Check before starting operation....................................................................4-26 Maintenance Every 50 Hours ........................................................................4-27 Maintenance Every 100 Hours ......................................................................4-29

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Maintenance Every 250 Hours ......................................................................4-30 Maintenance Every 500 Hours ......................................................................4-34 Maintenance Every 1000 Hours ....................................................................4-40 Maintenance Every 2000 Hours ....................................................................4-47 Maintenance Every 4000 Hours ....................................................................4-48

Specifications SPECIFICATIONS ............................................................................................ 5-1 RATED TOTAL LOAD TABLE.......................................................................... 5-4

4 Rope Hook ......................................................................................................5-4 2 Rope Hook ......................................................................................................5-5 1 Rope Hook ......................................................................................................5-6

WORKING RADIUS AND LIFTING HEIGHT .................................................... 5-7 INDEX ................................................................................................................ 6-1

Replacement Parts PERIODIC REPLACEMENT OF IMPORTANT PARTS ................................... 7-1 CONSUMABLE PARTS .................................................................................... 7-2 MISCELLANEOUS PARTS .............................................................................. 7-3 AIR TEMPERATURE DEPENDENT FUEL AND LUBRICANT GREASE USE METHOD .................................................... 7-4

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Safety

WARNING Be familiar with the safety precautions given in this manual and on the machine. Observe these cautions when operating, inspecting or maintaining the machine.

Safety Signs SAFETY

Safety Signs The safety signs used on this machine are described below.

• Be sufficiently aware of the precise locations of the safety signs, the danger indicated on the signs and how to avoid the danger.

• Keep the safety signs clean so that the contents are visible and legible. Do not use organic solvent or gasoline when cleaning the safety signs, as they may peel.

• If a safety sign gets damaged, becomes illegible or is lost, replace the sign with a new one. Check the part number of the safety sign in this manual or with the actual sign and order new signs from our sales service agency.

• There are labels other than the safety signs on this machine. Handle these labels in the same way as the safety signs.

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SAFETY Position for attaching safety labels

Position for attaching safety labels

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Position for attaching safety labels SAFETY

(1) Precautions for emergency switch (553-4266400)

CAUTION

Turning the emergency switch clockwise and holding it there allows

you to disengage the auto-stop functionby the moment limiter. However, do not

use it except in emergencies.

(2) Precautions for safe operation (556-3367900) (3) Working radius and rated total load (556-2172400)

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(4) Precautions for moment limiter operation (553-2102200)

Configuration and how to use its function Moment limiter is a safety system installed for preventing accidents such as damage to or tipping over of the crane due to over-loading. For safer operation of your crane, be sure to fully utilize this system. 1) In addition to showing the lifting load and ratio of rated total load. It causes a pre-

warning (Intermittent sound) to go off at 90% of rated total load, warning (continuous sound) to go off at 100% causing actions of boom lowering, boom extending and hook hoisting to automatically stop, while safe actions such as boom hoisting and boom retracting and hook lowering continue to function.

2) Detects lifting load by means of pressure transmitter. Reads out the rated total load with the signal of the boom angle and length. Compares lifting load and rated total load for pre-warning, warning and stopping.

CAUTION 1. Swing mechanism does not stop automatically even when overloaded. Be careful. 2. Before starting operation of your crane, make sure you conduct a start up check. 3. Set the moment limiter so that LED's on it go on at proper working conditions. 4. Pay attention to the moment limiter display to avoid over-loading the crane at any

time. 5. If any unsafe operation (boom extend, boom lower or hook hoisting) automatically

comes to a stop, reset to a safe operation (boom retract, boom hoist or hook lowering).

6. For lifting a load off the ground, first hoist the hook until the load leaves the ground and stop it momentarily to check for safety. Never lift your load off the ground by hoisting the boom.

7. While in travel suspension mode, if the boom is extended to 4 or 5 stages, extension, lowering or hoisting functions will stop and EO7 will be displayed. But this is not abnormal. In travel suspension mode, use of the 4 or 5 stage boom is prohibited. Be sure to work with 3 or fewer stages.

MOMENT LIMITER OPERATION

(5) Precautions for changing the number of wire falls (553-3181800)

Before starting your work, be sure to check the number of part reeving and set the selector at 4 for 4 part reeving and 2 for 2 part reeving. If the number of part reeving and its selector switch does not coincide, the moment limiter will not work properly. It may result in a serious accident including the dropping or damaging of the load, or the machine tipping over.

Set the number of part reeving selector switch properly.

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(6) Cautions for operation, inspection, and maintenance (556-3368300)

To prevent SERIOUS INJURY or DEATH before moving the machine ALWAYS • sound the horn to alert

anybody nearby • ensure nobody is on or near

the machine, or in the swing area

• safety permitting, position thecab to maximize the view of the path of travel

• if your view is obstructed, obtain assistance

When opening, closing, removing or replacing the windows, in order to avoid accidents caused by inadvertent movement of the controls, before leaving the operator'sseat ALWAYS • ground any load • move the safety lock (to the left of the operator's seat) to the LOCK position. If the machine suddenly starts moving or acts in any unexpected way, serious injury or death may result.

Whenever you operate the machine, check the operation pattern shown with your intended action. When beginning any operation,start slowly, paying carefulattention to all your surroundings.

(7) Precautions when window goes out (8) Precautions for storing the front window (553-4266900) (09803-A0481)

For the operator's safety whenever the window goes out of place or is damaged, correct it immediately rather than continuing the work.

The stored front window might slide down and cause injury. Check the lock at the storage position.

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(9) Indication of maximum operating radius and rated load (556-3368500) (10) Precautions for high-temperature cooling (11) Prohibited to enter the range of swing water and hydraulic oil (553-4268500) (553-2102400)

Never remove the cap when the engine is at operating (high) temperatures. Stream or high temperature oil blowing up from the radiator or hydraulic tank, will cause personal injury and/or burns.

Never remove the radiator cap or hydraulic tank oil filler when cooling water or hydraulic oil is at high temperatures.

Your body can getpinched by the toprevolving superstructurewhen the machine turns.

Do not enter the turning range.

(12) Caution when opening or closing (13) Caution when checking and adjusting the the cover (553-4268600) track tension (553-4268700)

If a plug comes out of the track shoe tension adjustment device it will cause injury.

Read the operation and maintenance manual and carrying out the correct method when loosening the track tension.

There exists the hazard of being caught in the rotating parts of the machine causing injury.

Stop the rotating parts of the machine completely when carrying out inspection and maintenance.

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(14) Caution when handling cables (15) Load indication (With (09808-A0881) four/two wire falls)

(553-4267200)

Electrical shock hazard ispresent during cablehandling.

Read the instructionmanual for correcthandling.

(16) Precautions for hoisting a vehicle (17) Warnings for high temperature (556-3368600) hydraulic oil (203-00-61260)

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(18) Precautions for rotating parts (19) Precautions for rotating parts (553-4267400) (553-4267500)

There exists the hazard ofbeing caught in therotating parts as thewinch drum causes injury.

There exists the hazard ofbeing caught in the rotatingparts as the wire sheavecauses injury.

(20) Precautions for trapping (21) Precaution for burns (553-4267600) (553-4267700)

There are high temperature parts in thebonnet. These can

There exists the hazardof trapping a hand inthe bonnet.

(22) Caution (553-4268000)

When entering under machine, (grease up) pull out the starter key.

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Basic Precautions SAFETY

Basic Precautions Observing rules • Only those suitably trained and qualified can operate this machine.

• Observe all the safety precautions and procedures given in this manual when operating, inspecting or maintaining the machine.

• Do not operate the machine if you are in bad physical shape, after taking medicine (that makes you drowsy) or consuming alcohol or if you are mentally unstable.

• When you are working together with someone or use someone to guide you, thoroughly discuss the work details and work with specified signals.

If you notice any abnormality If you notice any abnormality of the machine (such as noise, vibration, smell, meter deviation, smoke, oil leakage or an error displayed on the warning devices or monitors), report this immediately to your supervisor for appropriate actions. Do not operate the machine until the abnormality is cleared. Proper clothing and wearing protective equipment • Loose clothing and accessories may get stuck in the operation

lever or protruding sections. Do not wear such clothing and accessories.

• Long hair that protrudes from a helmet may get entangled in the machine. Tie back your hair to prevent this.

• Always wear a helmet and safety shoes. Depending on the work you are carrying out, you also need to wear goggles, mask, gloves, ear protection devices and safety belt.

• Check the function of the protective equipment before use. Equipping fire extinguisher and first aid kit To be prepared for unexpected fire and serious injuries, observe the following:

• To be prepared for fire, check the location where the fire extinguisher is located and know how to use it.

• Regularly inspect and maintain the fire extinguisher. Determine where to store the first aid kit. Inspect the kit regularly and replenish the contents.

Cautions on safety-related devices • Check that all protective guards, covers and mirrors are installed properly. If you find them

damaged, repair them immediately.

• Be familiar with how to use the safety-related devices.

• Never remove safety-related devices. Maintain the safety-related devices for continuous, proper operation.

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SAFETY Basic Precautions

Keep the machine clean • Water getting into the electrical system will cause problems,

leading to malfunctions. Do not clean the electrical system (sensors and connectors) with water or steam.

• When the machine gets dirty with earth, sand or oil, you may slip or fall or some dirt may get into your eyes when getting on/off, inspecting or maintaining the machine. Always keep the machine clean.

Cautions for inside cab

• Clean dirt and oil from the soles of shoes before entering the cab. Operating pedals etc. with dirty or oily soles will cause slipping, resulting in an accident.

• Do not leave any parts and tools around the cab.

• Do not place suction cups on windows. Suction cups may function as lenses and cause fires.

• Do not use cellular phones in the cab while driving/working.

• Do not bring any dangerous goods such as inflammable materials or explosives into the cab. Cautions before standing up and leaving the cab seat • Always put down the implement on the ground, place the

safety lock lever (1) in the lock position and stop the engine when standing up from the cab seat to open/close the front window or skylight, installing/removing the bottom window or adjusting the cab seat. Accidental contact with an operation lever can cause sudden movement of the machine that can lead to serious injuries.

• Stow the implement, move the safety lock lever (1) to the lock position and stop the engine before leaving the machine. Turn off all the keys in locks. Be sure to remove and store the keys at specified locations.

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Use rails and steps for getting on/off the machine To prevent slips and falls leading to injuries, strictly observe the following:

• Use the rails and steps shown with arrows in the figure on the right to help you get on/off the machine.

• Always face the machine when getting on/off it. Using rails and steps, keep at least three of your limbs (two legs and one hand, or one leg and two hands) on the rails and steps (including crawler) to ensure that your body is supported.

• Do not grab an operation lever or safety lock lever for to get on/off the machine.

• Never get on the engine hood and cover where there is no antislip.

• Inspect the rails and steps (including crawler) before getting on/off the machine. If you find any oil and dirt, wipe them off to prevent slipping. Repair any damage and tighten the loosened bolts.

• Do not get on/off the machine with a tool in your hand. Do not jump on/off the machine • Do not jump on/off the machine. Do not get on/off the machine when in operation.

• Even if the machine starts moving while there is no one on the cab seat, do not attempt to jump into the machine to stop it.

Trapping hazard (risk of being squashed) The clearance area around the crane changes according to the pivot point(s). Being trapped in the clearance area will result in serious injury. Keep people away from any rotating and extending/retracting sections.

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Prevention of burns Hot cooling water • To prevent burns caused by blowout of hot water or steam,

check that the radiator cap is sufficiently cool for handling with bare hands before inspecting/draining the cooling water. Then slowly loosen the cap and release the internal pressure of the radiator before removing the cap.

Hot oil • To prevent burns caused by blowout of hot oil or by contact

with hot parts, check that the cap and plug are sufficiently cool for handling with bare hands before inspecting/draining the oil. Then slowly loosen the cap and plug and release the internal pressure before removing the cap and plug.

Prevention of fire • Fire caused by fuel and oil

If fire is close to fuel, oil, antifreeze or window washer fluid, it can catch fire. Strictly observe the following:

• Do not smoke or use fire nearby.

• Shut off the engine before refueling.

• Do not leave your position while refueling or refilling the oil.

• Securely tighten all fuel and oil caps.

• Do not spill fuel on the overheated surface or electrical system components.

• Store fuel and oil in well-ventilated areas.

• Store fuel and oil at specified locations to keep away people other than those involved.

• Wipe off spilled fuel and oil after refilling.

• Move inflammable materials to safe locations before grinding or welding on the machine.

• Use non-flammable wash oil for parts, not flammable oils such as gas oil and gasoline.

• Keep cloths with oil or other combustible materials in a safe container and store them at safe location.

• Do not weld or gas-cut pipes or tubes that may contain combustible solutions.

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• Fire caused by accumulation and adhesion of inflammable materials Should you find an accumulation or adhesion of dead leaves, chips, paper or coal dust near an

engine exhaust manifold, muffler, battery or cover, remove them.

• Fire from electrical wires Short circuit in the electrical system can cause a fire.

• Keep all the connections of electrical wires clean and secure them properly.

• Inspect wires daily for slack and damage. Re-tighten loose connectors and wire clamps and repair and replace damaged wires.

• Fires from piping Check that the clamps, guards and cushions of hoses and tubes are secured properly. Loosened clamps, guards or cushions will result in vibration of hoses/tubes during operation, leading to friction of hoses/tubes with other components and damage to hoses/tubes. Damaged hoses/tubes can result in blowout of high-pressure oil, leading to fire or injuries.

• Explosion with lighting equipment • Use explosion-proof lighting equipment when inspecting fuel, oil, battery or windscreen washer

fluid or cooling water. Not using explosion-proof lighting equipment can cause a fire, leading to serious injuries caused by explosions.

• Follow the instructions given in this manual to remove the power supply for the lighting equipment from the main unit of the machine.

In case of fire In case of fire, get out of the machine in the following way:

• Turn the starter switch to OFF position and stop the engine.

• Use rails and steps to exit from the machine. For window washing, use an ethanol-type washer fluid. Do not use a methanol-type washer fluid as this can hurt your eyes. Protection against falling objects, flying objects and intruding objects • Provide necessary equipment according to the working

conditions to protect workers from falling, flying or intruding objects that might enter the cab.

• Install a front guard and affix laminated sheet to the windshield when working at the site of demolition or breaker work.

• Install a protective structure against falling objects and a front guard and laminated sheet to the windshield when working where rocks may fall or be projected such as mines and stone-crushing sites.

• Always operate the machine with the windshield closed in the above situations. Check that there is no one other than the operator in the range where falling objects or objects might reach.

• The above situations assume standard works. Additional guards may need to be installed according to the work situation on site. Be sure to contact our sales service agency beforehand.

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Cautions with cab glass • If the cab glass on the implement side is damaged, the implement may directly contact with the

body of the operator. Stop the work immediately and replace the glass.

• The skylight using organic glass (polycarbonate) becomes fragile when damaged and can therefore lose its protective feature. Should you find scratches or cracks from fallen rocks or similar, replace the skylight with a new one.

Do not modify the machine Modifications may result in safety problems. Please consult our sales service agency before making any modifications.

• We assume no responsibility for injuries, failures and physical damage caused by modifications made without our consent.

Safety at working site Check the working site for any danger before starting work.

• Note that working near a thatched roof, dead leaves or dead grass can cause fires. Exercise caution when working in such conditions.

• Check the stratum and soil of the working site to determine safe working methods. Do not work where mudslides or rock falls may take place.

• Take necessary measures to prohibit people other than those involved from approaching the working site. Especially, work on streets requires guides or the installation of fences to ensure the safety of passing vehicles and pedestrians.

• Check the ground, terrain condition, depth and flow rate in advance when driving/working in shallow waters or on soft foundations.

Cautions against falling on unstable ground • Ground may have been softened near cliffs, shoulders and deep ditches. Do not drive or work in

these locations. The weight and vibration of the machine may cause the ground to give way, causing the machine to fall or overturn. Take extreme care after rain, blasting or earthquakes. The ground is more likely to give way in such conditions.

• The ground may give way with the weight and vibration of the machine on earth fill or near excavated holes. Take necessary measures to make the ground safe before working to prevent the machine from falling and turning over.

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Pay attention to electrical wires Do not drive or work near electrical wires as this can cause serious injuries. Strictly observe the following at sites where the machine may come into contact with electrical wires.

• Contact the power company, inform them you will be working near electrical wires and ask for necessary measures to be taken.

• Just approaching high voltage electrical wires can lead to electrical shocks. Secure the safety distance given on the right during work.

Power Line Voltage Safe Distance 100V/200V 2m or more Low

Voltage 6,600V 2m or more 22,000V 3m or more 66,000V 4m or more

154,000V 5m or more 187,000V 6m or more 275,000V 7m or more

Specially

High Voltage

500,000V 11m or more

• To be prepared for unexpected situations, wear rubber-soled shoes and rubber gloves and cover the cab seat with a rubber sheet. Parts of the body not protected with rubber should not contact the machine body.

• Use a guide to ensure the machine does not move too close to electrical wires.

• To prevent electrical shock, keep people other than those involved away from the machine when working near high-voltage electrical power lines.

• If the machine moves too close to or come into contact with electrical wires, do not stand up from the cab seat but remain seated until the power is shut off. This is to avoid the operator getting an electrical shock. Keep others away from the machine.

Securing visibility Carefully check the presence of people or obstacles around the machine and the situation of the site. Strictly observe the following so that you can work or drive safely:

• In dark locations, turn on the machine’s working light and headlight. If necessary, add some other lights in the operating area.

• Stop work when there is poor visibility due to fog, snow, rain or sandy dust. Cautions on indoor ventilation When starting the engine or handling fuel, wash oil or paint indoors or in badly ventilated locations, open the window and entrances/exits to improve ventilation.

Signs by guides and verification of signs • Set up signs so that people can identify soft shoulders and ground. When visibility is poor, guides

are needed. Operators should pay attention to signs and follow the instructions of guides.

• Only one guide should give signs.

• All workers must understand the meaning of all signals and signs.

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Emergency exit of the cab Should the cab door not open, use the hammer provided on the window to break the window. This serves as an emergency exit. See the section “Moment limiting device (Overload protector) (3-20)” in this manual.

• Remove glass from the window frame so that you will not get cut when exiting the machine via the window. Be careful not to slip on the broken glass pieces.

Asbestos dust caution Inhaling air containing asbestos dust can cause lung cancer. The asbestos inhalation hazard is present at the site of demolition work or handling industrial wastes. Strictly observe the following:

• Spray water so that the asbestos does not fly in all directions in the air. Do not use compressed air.

• When operating the machine at a site where the air might contain asbestos dust, the operator must work with the wind at his/her back. The operator must wear a particle mask.

• Keep third persons away during the work.

• Strictly observe the given rules regarding the working site and environmental standards.

Impure components present the risk of containing asbestos. Use our pure components. No asbestos has been used on this machine.

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Cautions on Operations SAFETY

Cautions on Operations Starting engine

Do NOT operate When this tag is not in use, keep it in the storagecompartment. If there is no storage compartment, keepit in the operation manual case.

0963-03001

When a warning tag has been attached to the operation lever of the implement, do not start the engine or touch levers. Inspection and adjustment before starting engine Inspect the following before starting the engine.

• Ensure the windows are clean.

• Clean the lens surface of the working light. Check the light for proper illumination.

• Check the cooling water level, fuel level, engine oil pan level, air cleaner and damage to electrical wires.

• Adjust the cab seat for comfortable working position and check the damage and wear on the seat belt and mounting brackets.

• Check the operation of gauges and check that the operation levers are in the neutral position.

• Check that the safety lock lever is at lock position before starting the engine.

• Adjust mirrors so that you can clearly see the bottom rear of the machine (where it is hidden behind the engine hood) from the cab seat.

Refer to “Adjusting mirrors (3-60)” for how to adjust mirrors.

• Check the presence of people or obstacles on under, or around the machine. Cautions in starting the engine • Always sit on the cab seat when starting the engine.

• Do not start the engine by creating a short circuit in the starter circuit. It can cause serious injuries or fire.

• For warning, honk the horn before starting the engine.

• Only the operator should be on board. Cautions in cold weather • Warm up the machine sufficiently. Operating the operation levers before the engine is warm may

slow the reaction of the machine or cause rapid change, leading to accidents.

• If the battery fluid is frozen, do not charge the battery or start the engine with another power supply. The battery may catch fire and explode.

When charging the battery or starting the engine with another power supply, unfreeze the battery fluid and check that there is no battery fluid leakage.

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SAFETY Cautions on Operations

Operations Checks before operation Check the machine in a large area with no obstacles, paying sufficient attention to around the machine, and operate slowly. Keep people away from the proximity of the machine.

• Make sure that you wear a seat belt.

• Check that the movement of the machine and the indication on the operation pattern card (a label stuck to the window, with operations and duty decals) agree.

If they do not agree, change the operation pattern card immediately to the one that agrees with the machine movement.

• Check operations such as crane, driving and turning.

• Check the machine noise, vibration, heat, smell, gauge abnormality, oil leakage and fuel leakage.

• Should you find any abnormality, be sure to fix the problem in question. Cautions in moving forward/backward and turning • Drive the machine with the sprockets in the back of the cab

seat. Note that if the sprockets are in front of the cab seat, the machine moves in the opposite direction (forward/backward and left/right steering) to the operating direction of the lever.

• Check that there are no people or obstacles around the machine one more time before starting to move the machine.

• Honk the horn before starting moving, to warn people around.

• Always remain seated on the cab seat when operating the machine.

• Do not let anyone on the machine except the operator.

• Whether they are open or closed, properly secure the doors and windows of the cab seat.

Make sure that they are closed on sites where flying or intruding objects may enter the cab seat.

• If the visibility is blocked on the back of the machine, use guides. Turn the machine slowly while paying sufficient attention not to cause any accidents.

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Cautions during operation • Speeding, sudden acceleration, sudden stops and sudden changes of direction are dangerous. Do

not operate the machine in this way.

• Drive the machine with the boom of the implement completely retracted and laid and with hook stored.

• Drive slowly to avoid turnover when driving on irregular ground. Avoid any sudden steering operation. The implement may touch the ground when doing so, leading to the loss of balance of the machine or damage to the machine or structures around.

• Avoid going over obstacles. If you absolutely have to go over an obstacle, keep the implement close to the ground and drive slowly. The machine tends to turn over to the side rather than front or back. Do not go over obstacles that will greatly affect the balance of the machine to one side.

• Keep appropriate distance during operation to avoid accidents with people, structures and other machines.

• If you have to pass over a bridge or structure, check if it can withstand the weight of the machine in advance. Contact the authorities concerned and follow their instructions when passing through public roads.

• When operating the machine at height-limited locations such as inside tunnels or buildings, under overpasses and electrical wires, pay attention so that the machine and implement do not come into contact with anything. Operate slowly.

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Cautions in driving on slopes Strictly observe the following to prevent turning over and side slip.

• When going up/down a slope of 10 degrees or more, keep the posture shown in the figure on the right while driving.

• Direct the cab seat to lower side of the slope for going up and down and check the ground while driving.

• Slow the engine speed and keep the drive lever close to the neutral position for low-speed drive when going down a slope.

• Drive straight along with the slope. Crossing the slope diagonally or horizontally is very dangerous.

• Do not steer the machine across the slope. If you need to change direction, move to a flat surface to make a detour.

• Drive as slow as possible on grass, dead leaves or wet steel plate. It is very slippery and dangerous on these surfaces, even with a gentle slope.

• Should the engine stop, move the operation levers back immediately to neutral position and start the engine.

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Cautions in working on a slope • Turning operation and implement operation on the slope will

result in the loss of balance of the machine, leading to possible turnover and serious injuries. Secure a stable location and work with sufficient care.

• If you absolutely have to work on a slope, provide some level earth fill to form solid ground to avoid turnover accidents.

Cautions against turnover on unstable ground • Do not go on soft ground. It will be difficult to get the machine out of the ground.

• Do not approach the ground near cliffs, shoulders and deep ditches. The weight and vibration of the machine may cause the ground to give way, causing the machine to turn over or fall. Take extreme care after rain, explosions or earthquakes. The ground is more likely to give way in such conditions.

• The ground may give way with the weight and vibration of the machine on earth fill or near excavated holes. Take necessary measures to make the ground safe before working to prevent the machine from turning over and falling.

Cautions when driving on snow-packed or icy land • The machine is likely to slip on snow-packed or icy land. Drive and operate carefully in such

conditions and avoid any sudden lever operations. Even gentle slopes can make the ground very slippery. Pay sufficient attention, especially on slopes.

• With rising temperatures, frozen ground can change to soft ground, causing the machine to turn over or get bogged down in the ground. Exercise caution in such situations.

• Going into deep snow may cause the machine to turn over or sink into the snow and is dangerous. Do not go beyond the shoulders or into snowdrifts.

• In snow-covered sites, turnover or collisions are possible because shoulders and installations are not visible under the snow. Be careful when driving in such conditions.

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Cautions in parking • Choose a location with level and solid ground.

• Choose a location where there is no hazard of landslide, rock fall or submersion.

• Drive the machine with the boom of the implement completely retracted and laid and the hook stored.

• Move the safety lock lever (1) to the lock position and stop the engine before leaving the machine.

• Be sure to close the cab door and turn all the keys in the lock. Make sure that you remove the keys and store them at specified locations so that others cannot operate the machine without asking.

• If you have to park on a slope, observe the followings

• Fully retract and lay the booms and store the hook before directing the boom to the lower side of the slope.

• Provide a block by the side of the crawler so that the machine does not move.

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Cautions during crane operation Inspection before starting crane operation Check that the operation of safety devices and crane is normal.

• Operate operation levers, pedals and switches with no load to check the normal operation of these devices. Should you find any abnormality, fix the problem immediately.

• Check that the moment limiting device (overload protector) functions properly. Cautions in selecting a location to install the crane Always install the crane on level, stable and solid ground. Installing the crane on the following locations is dangerous.

• Streets with a poor tarmac surface

• Streets with thin concrete or stone pavement

• Paved streets under which there is a cavity due to water erosion, which appears solid on the surface but is soft in the ground.

• Locations close to shoulders or holes for construction

• Slopes When working on a slope, level the ground before installing the crane. Hoisting without making the crane level not only prevents the accurate operation of the moment limiting device (overload protector) but also imposes unexpected force on the machine, leading to its damage or turnover. Cautions in cold weather • Wipe off any water, snow and dirt from the wire harness,

connector (1), switches and sensors after completing work and cover these devices.

If water enters the machine and freezes, the machine may malfunction when next used, resulting in accidents.

• Remove snow and unfreeze the swing circle and boom and around the winch and check their operation before starting work.

• Check the operation of the winch brake.

• Warm up the machine sufficiently. Operating the operation levers without sufficient warm-up may slow the reaction of the machine or cause rapid change, leading to accidents.

• Avoid increasing the engine speed right after starting the engine.

• Use the operation lever and release the hydraulic pressure (increase the hydraulic pressure to be higher than the set hydraulic circuit pressure to release the pressurized oil to the operating oil tank) to warm the oil in the hydraulic circuit. This improves the machine’s reaction and prevents malfunctions.

• If the battery fluid is frozen, do not charge it or start the engine with another power supply as the battery can catch fire.

When charging the battery or starting the engine with another power supply, unfreeze the battery fluid and check that there is no battery fluid leakage.

• Battery charging rate: See the section “Handling in cold weather (3-132)”.

• Accumulation of snow within the working range of the crane can cause problems; remove snow, if necessary, before starting operations.

• If the load to be hoisted is stuck to the ground because it is covered with snow or frozen, do not force the hoisting of the load. Thoroughly remove the snow or unfreeze before operating the crane.

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Pay attention to weather forecast • Stop the crane operation and stow the boom in case of thunderstorm.

• Stop the crane operation when the maximum sustained wind reaches 10 m/s. Retract the boom completely and bring the machine into the travel position.

• Note that the greater the load is, the higher the load is and the longer the boom is, the greater the influence of the wind will be even at the maximum sustained wind of 10 m/s or less.

• The winch wire rope with longer boom and electrical signal cables are also susceptible be gusts of wind.

Note that when working around tall buildings, the wind passing along the side of the buildings might have an even greater speed.

• When hoisting a load with a wide area where wind can hit, such as a steel plate, wind from front, back or side of the boom can turn over or damage the machine. Pay sufficient attention when working in such conditions.

• Wind from the boom front may cause turnover of the machine backward when no load has been hoisted. Pay sufficient attention when working in such conditions.

• In case of earthquakes, stop working. Wait until it calms down. Cautions in working • The stability of the crane is determined when the machine is on level ground. Although stability

increases diagonally (this refers to the position of the boom in relation to the crane, i.e. it is not pointing straight forwards or backwards but out over the tracks of the crane. In this position, the crane is more stable than when the boom is pointing fore or aft), work exceeding the rated load causes the breakage of the boom or machine. The moment limit device (overload protector) must not be activated, even in diagonal direction.

• Perform crane operation slowly until you are used to it.

• Do not perform any sudden operation of levers or acceleration.

• Pay attention to the indication and warning on the overload protector while working.

• Determine a work supervisor for hoisting work and always follow his/her instructions.

• Follow the instructions of the supervisor for work methods and procedures. Determine how to give signs and follow these signs.

• A long load is instable when hoisted and therefore dangerous. Attach a rope to both ends of the load to make it stable.

• The operating radius increases due to boom deflection when hoisting a load. Take this deflection into consideration when working.

• With temperature change, the volume of the cylinder operating oil changes. Leaving the crane while hoisting a load lowers the oil temperature over time, and the volume of the operating oil decreases. This will flat the boom derricking angle or shorten the boom length. When it happens, operate the boom operation lever to correct the situation.

• Do not use the crane for purposes other than the main uses, such as moving workers up/down.

• Check that the lever is at lock position before starting the crane operation.

• Do not leave the cab seat while hoisting a load. Put down the load when leaving the cab seat.

• Hoist the hook when not in use. Other workers around the load may run into the hook with no load.

• Work that goes beyond the machine performance will cause accidents and failures. Particularly, the crane operation must be performed based on the rated total load chart.

• Exercise caution not to let the wire come into contact with trees or steel beams. Should the wire be entangled around something, do not force wind the wire. Untangle it and then wind it up.

• Do not pull horizontally, vertically or pull in the wire. It is dangerous to do so.

• Work that hoists an attachment that generates some vibration such as vibros is forbidden. Vibration of the attachment may break the winch, etc.

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Handling wire ropes • The wire rope will wear out over time. Always check the wire rope before working. If the wire rope

needs replacing, change it immediately. Inspect the boom tip sheave and hook sheave at the same time. Damaged sheaves will accelerate damage to the wire rope.

• Use the wire rope specified.

• Wear leather gloves when handling wire ropes.

• When replacing a wire rope, in principle observe ISO 4309:1990 (E) as well as the legal restrictions applicable to the place where the crane is used.

Cautions in operating winch • Select the hook appropriate for the load weight and number of wire rope falls appropriate for the

boom length. How to hook wire ropes: See the section for “Handling wire ropes (3-101)”

• Do not allow any worker to go under the hung load.

• Pause the hoisting operation in the critical state where the load leaves the ground, check the safety and then continue the hoisting operation.

• Do not pull horizontally, pull towards you or hoist diagonally.

• Release the acceleration pedal to decrease the engine speed and slowly return the winch lever to decelerate from high-speed hoisting. Returning the winch lever quickly at high speed will result in a rapid deceleration shock in the hook, popping the hook and leading to irregular winding.

• Hoisting/Lowering in high-speed mode should be used to hoist/lower the hook alone. Hoisting/Lowering a hung load in high-speed mode can break the boom/frame or cause serious accidents in which the machine turns over.

• If the hook rotates due to the wire rope being twisted, untwist it before working. How to deal with twisted wire ropes: See the section for “What to do with twisted wire ropes

(3-107)”.

• At least three turns of the wire rope must remain on the drum when lowering. The standard number of wire rope falls may still be insufficient to put down a load at a place closer than the ground. In this case, check the remaining wire ropes on the drum while working.

Cautions in boom operation • Do not raise the boom beyond the height where the load reaches the height of the cab seat. If you

raise it higher, the load may fall onto the cab seat.

• Do not perform any sudden derricking or extending/retracting operation. Operate the levers gently.

• Pulling a load in or up with the boom derricking operation is forbidden.

• Check the winch operation when extending/retracting the boom. Limit the boom angle according to the following table. Boom length (m) Boom length (m) Boom angle (deg)

4.6-5.7 70o max 5.8-73 47 o max 7.4-9.2 78 o max

Cautions in turning operation • Perform turning operation at low speed, pay attention around the machine.

• Pulling a load in or up with the turning operation is forbidden.

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Cautions in special crane operation Cautions in double hoisting • In principle, double hoisting using two cranes is forbidden since this is highly dangerous and can

cause a machine to tip over due to center of gravity bias, fall of the hoisted load, machine breakage or another problem.

• You are permitted to carefully carry out double hoisting while observing the relevant safety and legal restrictions that apply to the place of use, if the legal restrictions that apply to the place where the cranes are used do not forbid double hoisting and double hoisting is unavoidable and the worker is ready to take responsibility for double hoisting with consideration to the working environment, conditions and all other factors.

Crane operation at the site with lift below ground level • At least three turns of the wire rope must remain on the drum when lowering.

• The signs must be thoroughly understood.

• Crane operation shall be conducted particularly carefully. Traveling with suspended load In principle, traveling with suspended load is forbidden since it is always unstable and involves risks. If you absolutely have to travel with a suspended load, observe the following cautions. Strictly avoid hung load operation if the restrictions that apply to the place where the crane is used forbid you to do so.

• Strictly observe cautions given in the instruction manual. Cautions: See the section for “Traveling with suspended load (3-91)”

• Hoist the load that the machine is sufficiently capable of and maintain height around ground level.

• Enforce work in a working posture specified in the instruction manual. See the section for “Working posture (3-90)”

• Staff guide(s) for driving operation.

• Remove any obstacles on the working path and keep workers away.

• Works exceeding the specified boom length are prohibited.

• The rated load is the maximum possible load. Work with an appropriately safe load for the situation.

• Keep the engine speed at low idling (low-speed rotation) and operate slowly while driving at LOW speed so that the load does not swing while driving with hung load. Do not accelerate or stop suddenly or change the speed to HIGH while traveling. Take appropriate measures against load swing and go slowly.

• Do not change traveling speed or perform turning/crane operations while driving with a hung load.

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Transportation This machine may need to be disassembled for transportation, depending on the legal restrictions that apply to the place of transportation. Consult our sales service agency for further information. Cautions in loading/unloading the machine • Improper handling of the machine during loading/unloading

will involve turnover and fall hazards. Operators must pay special attention to the following:

• Select a location with level and solid ground and avoid locations near shoulders and cliffs.

• Loading/unloading with the boom is dangerous and can cause turnover and fall. Never load/unload the machine using the boom.

• Put the implement in the stowing position and secure the hook block to the machine body with the wire rope.

• Always load backward.

• Always unload forward.

• Use a loading ramp with appropriate length and width and sufficient strength. Install the loading ramp so that it does not move or come off.

• Remove any deposits such as oil, snow and water from the ground, loading ramp and back of the vehicle to stop it from slipping. Also remove dirt around the legs of the machine. It is especially slippery on rainy days. Exercise caution in such a situation.

• Slow the engine to low speed and drive slowly.

• Do not operate anything other than the lever for traveling (forward/backward) while on the loading ramp.

• Never change the traveling direction on the loading ramp. If you need to change the direction, go back from the loading ramp and adjust your direction.

• The center of gravity moves suddenly at the edge between the loading ramp and the back of the vehicle.

Pass over the edge especially slowly since the machine will be unstable.

• When unloading the machine onto earth fill or platform, ensure sufficient width, strength and slope.

• The ground is unstable when turning the boom on the back of the vehicle. Retract the boom and operate slowly.

• Be sure to lock the door after loading the machine with cab. The door may open during transportation.

See the section for “Transportation (3-124).

• Place a square piece of timber between the machine and the back of the vehicle and secure the machine tightly using the wire rope etc. after loading the machine.

Cautions in transportation Strictly observe the following when transporting the machine:

• Carefully check the weight, total length and width of the implement and the transportation height.

• When passing over a bridge or a structure, you have to check if the bridge/structure can withstand the weight of the machine in advance. Contact and follow the instructions of the authorities that apply to the place when traveling on public roads.

• See the section for “Transportation (3-126)” in Handling chapter for how to transport the machine.

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Battery Handling batteries The battery generates inflammable hydrogen gas, which can cause explosion. The battery fluid also contains diluted sulfuric acid. Improper handling of the battery will cause injuries, explosions or fire. Strictly observe the following:

• Do not use or change the battery if the battery fluid level is lower than the minimum fluid level (LOWER LEVEL). Doing so will cause an explosion. Check the battery fluid level periodically and refill with the distilled water to the maximum fluid level (UPPER LEVEL).

• Always wear goggles and rubber gloves when handling the battery.

• Do not smoke or use fire near the battery.

• Should the battery fluid adhere to your clothes or skin, wash the affected area immediately with plenty of water.

• Should the battery fluid get in your eye, wash your eyes immediately with water and consult a physician.

• Inspect and handle the battery with the starter switch key turned to OFF position. Sparks can be generated. Observe the following:

• Do not allow any contact of metallic objects such as tools with either terminals of the battery. Do not leave tools around.

• When removing the battery terminal, always remove the earth (-) side first. Conversely, always install the (+) side first, before the earth side, when installing the battery. Make sure that the battery terminals are installed securely.

• Inflammable hydrogen gas is produced when charging the battery. Remove the battery from the machine and then move to a well-ventilated area to remove the battery cap before charging the battery.

• Securely tighten the battery cap.

• Secure the battery to the specified location without fail.

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Starting with booster cable Wrong connection with booster cable will lead to battery explosion. Strictly observe the following:

• Starting with booster cable should be performed with two people; one at the cab seat and another by the side of the battery.

• When starting the machine using another machine, take care not to allow the two machines to come into contact with each other.

• When connecting the booster cable, turn the starter switch key of both machines to the OFF position. When the power is supplied, the machine may start and if these switches are at the ON position, this will be hazardous.

• Always connect the booster cable to (+) terminal side first. Conversely, always disconnect (-) terminal (earth) side first.

• When disconnecting the booster cable, do not let the clips of the booster cable touch each other or the machine.

• Be sure to wear goggles and rubber gloves when starting the engine with booster cable.

• When using a second machine, both machines must have batteries of the same voltage.

See the section for “Starting with booster cable (3-138)” in the Handling section for the starting procedure with booster cable.

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Towing/Being Towed Cautions in towing/being towed Wrong selection of wire rope or wrong inspection method or towing method when towing/being towed will lead to serious injuries. See the section for “How to tow the machine (3-135)” for towing.

• Use leather gloves when handling wire ropes.

• Hook the wire ropes into the truck frame.

• Never go between the towing machine and towed machine during towing.

• Never tow the machine on a slope.

• Place a splint between the wire rope and the machine to prevent damage to the rope and the machine body.

• The wire ropes with broken wires (A), reduced diameter (B), and kink (C) can break. Never use such wire ropes.

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Cautions on Maintenance SAFETY

Cautions on Maintenance Post a warning tag during inspection/maintenance

Do NOT operate When this tag is not being used, keep it in thestorage compartment. If there is not storagecompartment, keep it in the operation manual case.

0963-03001

• Attach a “Do Not Operate” warning tag on an implement operation lever during inspection/maintenance. If necessary, post a tag also around the machine.

• Warning tag Part number: 09963-00101

• When this warning tag is not in use, store it in the toolbox. If there is no toolbox, store it in the manual holder.

If someone other than those involved start the engine or touch an implement operation lever during inspection/maintenance of the machine, this will lead to serious injuries. Organizing/Cleaning the work area • Clear the work area of tools and hammers and wipe away grease, oil etc. to provide a clean and

safe working environment. A cluttered workplace may result in falling or slipping, leading to injury.

• Use water and not organic solvents to clean the organic glass (polycarbonate) skylight. Using organic solvents such as benzene, toluene or methanol causes a chemical reaction that can damage the polycarbonate.

With instructions of supervisor when working in a team When repairing the machine or removing/installing the implement, determine a supervisor and everyone must follow his/her instructions. Note that during teamwork, miscommunication among workers can cause accidents. Stop the engine for inspection/maintenance • Select a level location with solid ground and stop the engine.

• Select a location where there will be no potential landslide, rockfall or submersion.

• Put down the implement on the ground and stop the engine.

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SAFETY Cautions on Maintenance

• Move the safety lock lever (1) to the lock position.

• Provide pawls to the crawlers so that they do not move. Maintenance on the operating engine by two people To prevent accidents, do not perform maintenance on the machine while the engine is in operation. If you absolutely have to perform maintenance while the engine is in operation, strictly observe the following:

• One should sit on the cab seat and be ready to stop the engine at any time. Communicate with each other.

• Move the safety lock lever (1) to the lock position.

• When working near rotating sections such as fans and belts, do not put your body or anything that can be entangled close to the rotating sections.

• Do not touch operation levers. If you absolutely have to operate an operation lever, always give a sign to your partner to leave to safe area.

• Dropping or inserting an object or a tool over the fans or belts will throw or cut the object/tool. Do not drop or insert an object or a tool.

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Use of appropriate tools Use appropriate tools properly. Using damaged or deformed tools or using tools for purposes other than intended can lead to serious injuries. Keep away unauthorized people Apart from essential workers, keep other personnel away from the machine during maintenance. Utilise observers as required. Cautions in working under machine or implement • If you have no choice but to go under the lifted machine or

implement to carry out inspection/maintenance tasks, hold the machine and implement securely with a solid block or support that can withstand the weight of the machine or implement.

Noise hazard If you will be exposed to noise for a long time because of tasks such as engine adjustment, wear ear covers or earplugs. Loud ambient noise may result in hearing loss or difficulty in hearing.

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Cautions against debris during work with hammer When using a hammer, pins can come out or metal debris may fly in all directions, leading to serious injuries. Strictly observe the following:

• When hammering hard metal parts such as pins, teeth, cutting edges or bearings, objects flying in all directions can result in serious injuries. Wear protective equipment such as goggles and gloves.

• When hammering pins or teeth, debris and other objects can fly in all directions and injure people around. Check that there is no one nearby before hammering these objects.

• Hammering out pins can result in the protruded pins injuring people around.

Cautions in weld repair Only qualified personnel shall perform welding at well-equipped facilities. During welding, gas can be generated and fire or electrical shock can take place. Unqualified personnel shall never attempt to perform weld repairs. Disconnecting battery terminal Disconnect the (-) terminal of the battery to stop the electrical current running when repairing the electrical system or performing electric welding. Cautions against high-pressure grease during adjustment of crawler tension • The grease inside the crawler adjustment device is at high

pressure. Making adjustments using an unspecified procedure can cause the grease drain plug to come out, leading to serious injuries.

• Loosen the grease drain plug (1) slowly. Do not loosen it by more than one turn when decreasing the tension of the crawler.

• Do not put your face, hands, feet or body close to the grease drain plug (1).

Do not disassemble recoil spring Never disassemble the recoil spring assembly. The recoil spring assembly to buffer the idler has a powerful spring built in. Careless disassembly will allow the spring to come out, leading to serious injuries. If you need to disassemble this assembly, please ask our sales service agency.

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High-pressure oil hazard The hydraulic system has constant internal pressure. Check the pressure in the circuit is released before inspecting/replacing pipes or hoses. Not checking this will result in serious injuries. Strictly observe the following:

• Release the pressure. Do not carry out inspection/replacement work with the pressure being applied.

• If there is oil leakage from pipes and hoses, the areas around them will be wet. Check the pipes and hoses for cracks and swell.

Wear protective equipment such as goggles and gloves when checking pipes and hoses.

• If high-pressure oil leaking from a small hole directly hits skin or eyes, it may cause a puncture in the skin or loss of sight. If your skin or eye becomes affected by high-pressure oil, wash the affected area with clear water and consult a physician as soon as possible.

Handling high-pressure hoses and pipes • Oil or fuel leaking from high-pressure hoses or pipes can lead to fire or serious injuries caused by

operation failures. Should you find any loosened connection on the hoses or pipes or oil/fuel leakage from the connections, stop work and re-tighten the connection with specified torque. Should you find any damage or deformation of the hoses or pipes, contact our sales service agency.

Hoses in the following state shall be replaced:

• Damaged or with deformed connector

• With covering scratched or cut or their wire-reinforcing layer exposed

• With covering partially expanded

• With twisted or crushed flexible sections

• With foreign objects buried in the covering Cautions in disposing of wastes To prevent environmental pollution, pay special attention to the disposal of waste.

• Always drain waste fluid into containers such as cans and tanks. Never release waste fluid into rivers, sewers, oceans, or lakes.

• Follow the applicable laws and regulations in disposing of harmful substances such as oil, fuel, cooling water, solvent, filters and batteries.

• When disposing of machinery with air conditioning, follow the Law Concerning Collection and Destruction of Chlorofluorocarbon and assign this task to suitably qualified technicians.

Maintaining air conditioner • If air-conditioning refrigerant gets into eyes it can cause blindness and frostbite can occur if it gets

onto skin. Never touch the refrigerant.

• Do not release refrigerant into the air when performing maintenance on the air conditioner. The discharge of refrigerant (R134a) into air is restricted since it causes global warming.

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Cautions against compressed air • Cleaning using compressed air can cause serious injuries with flying litter.

• Wear protective equipment such as goggles, particle mask and gloves when cleaning the filter element or radiator with compressed air.

Periodical replacement of important parts • For safe and long use of the machine, safety-related parts (especially hoses and seatbelts) must

be replaced periodically. Replacement of important parts: See the section for “Periodical replacement of important

parts (8-2)”

• Parts can deteriorate, be worn out or fatigue due to deterioration of material over time or through repeated use and can cause serious human or other problems. It is difficult to judge the remaining life of a part by how it operates and appears.

• Important parts should be replaced if they appear defective, even if they have not reached the normal replacement time.

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Handling

WARNING Read and understand the contents of the Safety before reading this chapter.

Name of Each Section HANDLING

Name of Each Section Machine overview Directions given in this manual indicate those shown with arrows in the figure below.

(1) Top boom (9) Track frame (2) Fourth boom (10) Idler (3) Third boom (11) Boom derricking cylinder (4) Second boom (12) Headlight (5) First boom (13) Hook (6) Working light (14) Overwinding detector (7) Sprocket (15) External indicator (8) Track shoe

3-1

HANDLING Name of Each Section

Controlling device overview

(1) Vehicle radio (21) Swing brake switch (2) Air conditioner control panel (22) Winch two-speed switch (3) Safety lock lever (23) Overwinding stop switch (4) Left implement control lever (24) Moment limiting device emergency switch (5) One-touch deceleration switch (25) Traveling speed selector switch (6) Traveling pedals (26) Operation mode selector switch (7) Traveling levers (27) Battery charge monitor (8) Acceleration pedal (28) Engine oil pressure monitor (9) Switch box (29) Engine coolant temperature gauge (10) Moment limiting device (30) Engine coolant temperature monitor (11) Ashtray (31) Display (For failures) (12) Level (32) Fuel level monitor (13) Machine monitor (33) Fuel gauge (14) Horn switch (34) Service meter (15) Right implement control lever (35) Warm-up monitor (16) Cigarette lighter (36) One-touch deceleration monitor (17) Starter switch (37) Wiper switch (18) Fuel adjustment dial (38) Windscreen washer switch (19) Lamp switch (39) EMO switch (20) Warning buzzer stop switch

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Description of Each Device HANDLING

Description of Each Device This is the description of devices necessary for the operation of the machine. The proper understanding of the operations and display details of these devices is critically important for proper, safe and comfortable operations. The following is an explanation of devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays.

EMO SWITCH (EMERGENCY STOP SWITCH)

WARNING • Emergency stop If a problem such as an abnormal operation occurs, press the EMO switch at the

top left of the operator’s seat to stop the engine. Then, switch the starting key to the OFF position to turn off the electric system and pull the key out. Then, set the safety lock lever to locked position.

• Abnormal operation If you have stopped the engine/machine because of an abnormal operation, explain

the problem to your Maeda agent and request repair. Keep the EMO switch depressed and the switch key pulled out. Do not start the engine again until the machine has been repaired.

When starting the engine again after stopping it with the EMO switch, firstly make sure the safety lock lever is in the locked position. Next, reset it by turning the switch clockwise. Make sure that the starting switch is in the OFF position, then start the engine.

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HANDLING Description of Each Device

Machine monitor A: Caution items C: Meter indicator section B: Emergency stop items D: Monitor switch section

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Caution items

CAUTION When the warning monitor flashes, check and maintain the relevant section as soon as possible. Leaving these sections as they are will cause failures. These are the items that call for your attention while the engine is in operation. These are the items that should be handled as soon as possible when an error is found. Upon detecting an error, the monitor of the relevant section flashes and a buzzer sounds. (1) Battery charge monitor (2) Fuel level monitor Battery charge monitor This monitor (1) flashes if the battery has not been charged properly while the engine is in operation. When the monitor flashes, check the slack of the v-belt. If any abnormality is found, see the section “What to do with this phenomenon (3-142)”. SUPPLEMENTAL This monitor illuminates when the starter switch is at ON position while the engine is being stopped. This is normal. The monitor may illuminate for a moment and the buzzer may sound when starting or stopping the engine. This is also normal. Fuel level monitor This monitor (2) warns of low fuel level in the fuel tank. The monitor flashes when the fuel level decreases to about 35 l. Refuel ahead of time.

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Emergency stop items

CAUTION When the monitor flashes, stop the engine or slow the engine immediately to low idling. Check and maintain the applicable section immediately. These are the items that should be monitored while the engine is in operation. Upon detection of an error, the relevant section monitor flashes and buzzer sounds. Take action immediately. (1) Engine coolant temperature monitor (2) Engine oil pressure monitor Engine coolant temperature monitor This monitor (1) warns of a rise in the engine coolant temperature. This monitor flashes when the engine coolant temperature rises abnormally. Stop work and keep the engine in low idling state until the engine coolant gauge returns to the green range. Engine oil pressure monitor This monitor (2) flashes when the engine lubricant pressure falls below the normal level. When it flashes, stop the engine and check the lubricant system and oil pan level. SUPPLEMENTAL • This monitor illuminates when the starter switch is at ON

position while the engine is being stopped. This is normal.

• The monitor may illuminate for a moment and the buzzer may sound when starting or stopping the engine. This is also normal.

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Meter indicator section Pilot lamp section Meter section (1) Warm-up monitor (3) Engine coolant temperature gauge (2) One-touch deceleration monitor (4) Fuel gauge

(5) Display (6) Service meter

Pilot lamp section These monitors illuminate when the displayed item is functioning while the starter switch is ON. Warm-up monitor This monitor (1) indicates the time required for warm-up when starting the engine at 0 deg C or lower. The monitor illuminates when the starter switch is moved to HEAT (warm-up) position and flashes in about 30 seconds, notifying that the warm-up has completed (the flashing ends in about 10 seconds).

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One-touch deceleration monitor This monitor (2) notifies that the one-touch deceleration function is being activated. Activated: ON Released: OFF Press the one-touch deceleration switch to illuminate the one-touch deceleration monitor. Press the switch again to turn off the monitor. SUPPLEMENTAL If the one-touch deceleration monitor is ON, the engine speed will still be in the low idling state even if you operate the fuel adjustment dial. Meter section Engine coolant temperature gauge This meter (3) indicates the temperature of the engine coolant. If the green range (A) is ON during operation, it is normal. If the red range (B) turns on during operation, decrease the engine speed to low idling and wait until the gauge returns to the green range (A). Perform warm-up operation after starting the engine until the gauge shows white range (C) up to green range (A). SUPPLEMENTAL As the segment (D) turns on, the engine coolant temperature monitor lamp (F) flashes. As the segment (E) turns on, the engine coolant temperature monitor lamp (F) flashes and the warning buzzer sounds. Fuel gauge This meter (4) indicates the fuel level in the fuel tank. If the green range (A) is ON during operation, it is normal. If only the red range (B) turns on during operation, the remaining fuel is 35 l or less. Check the level and refuel. The gauge may not show exact fuel level for a while after turning on the starter switch. This is normal. SUPPLEMENTAL As the red range (B) turns on, the fuel gauge monitor (C) flashes.

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Display This monitor shows failure details when an abnormality is detected. SUPPLEMENTAL If there is a machine failure, this monitor shows the failure details while the starter switch is ON. While flashing, it shows all the failure details one by one.

Monitor Indication

Failure Mode

EO3 Error in swivel braking system

EO5 Error in governor system

If the indication shown on the right is flashing, see the section “Electrical systems (3-145)”. Service meter This monitor (6) indicates the total running hours of the machine. Determine the periodical maintenance interval according to the indication on this monitor. If the engine is in operation, the service meter continues to advance even if the machine is not operating. When the machine runs for 1/10 hours, the meter advances for 1 regardless of the engine speed. Level This verifies whether the machine body is level or not. You can see how much the machine body is tilted and in which direction by the position of the bubbles. IMPORTANT Always use the level and work while keeping the vehicle body level in order to activate the moment limiting device properly.

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Monitor switch section (1) Operation mode selector switch (3) Wiper switch (2) Traveling speed selector switch (4) Windscreen washer switch Operation mode selector switch This switch (1) sets the movement and force of the implement. Select a mode appropriate for the work to facilitate the operation. E OFF: Active mode (For normal operation) (E = economical operation) E ON: E mode (For operation focusing on fuel consumption) You can switch the mode each time you press the switch. SUPPLEMENTAL This is set automatically to active mode (for normal operation) at the time of starting the engine.

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Traveling speed selector switch

WARNING • Always load/unload the machine to/from the trailer at low speed. Never switch the

traveling speed select switch while loading/unloading the machine. • Switching the traveling speed between Hi/Lo while traveling can change the

traveling direction even while going straight. Change the traveling speed after stopping the machine.

This switch (2) allows you to switch the traveling speed in two levels. Lo ON: Low speed traveling Hi ON: High speed traveling You can switch the speed each time you press the switch. SUPPLEMENTAL With a load of 0.5 t or more, changing the traveling speed selector switch to high speed traveling (Hi ON) does not switch the speed to high speed. For high speed traveling, decrease the load to 0.2 t or lower. Wiper switch This switch (3) can activate the wiper on the windshield. ON: Continuous wiper operation INT: Intermittent wiper operation OFF: Wiper stopped Each time you press the switch, you can switch the wiper operation sequentially to stopped intermittent continuous stopped. Window washer switch Keep pressing this switch (4) to release the window washer fluid onto the windshield. To stop fluid coming out, release your finger from the switch.

• If you keep pressing the switch (4) while the wiper is being stopped, window washer fluid comes out as the wiper operates continuously. The wiper stops after two continuous operations when you release the switch (4).

• When you keep pressing the switch (4) while the wiper is in intermittent operation, window washer fluid comes out at the same time and the wiper operates continuously. The wiper returns to intermittent operation after two continuous operations when you release the switch (4).

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Switches (1) Starter switch (7) Moment limiting device emergency switch (2) Fuel adjustment dial (8) Overwinding stop switch (3) One-touch deceleration switch (9) Winch two-speed switch (4) Horn switch (10) Swivel parking brake release switch (5) Lamp switch (11) Room lamp switch (6) Warning buzzer stop switch (12) Cigarette lighter Starter switch This switch (1) starts/stops the engine. OFF position You can insert/remove the starter switch key. All the switches for the electrical system except for room lamp and service meter turn off and the engine stops. ON position The electricity runs through the charge circuit and lamp circuit. Keep the switch at this position while the engine is in operation. START position This is the position to start the engine. Keep the switch at this position during cranking and release your hand from the switch right after the engine starts. The key returns to the ON position. HEAT position Turn the key to this position when starting the engine in cold weather. Turning the key to the HEAT position turns on the warm-up monitor. Keep the key in this position until the warm-up monitor flashes. When the warm-up monitor flashes, immediately release your hand from the key. The key returns to OFF position. Turn the key immediately to START to start the engine.

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SUPPLEMENTAL The engine will not start if the safety lock lever is not in the lock position. Check that the safety lock lever is at lock position before operating the starter switch. Fuel adjustment dial This dial (2) adjusts the rotating speed and output of the engine. (a) Low idling: where the dial is turned fully leftward

(counterclockwise). (b) High gear: where the dial is turned fully rightward (clockwise). SUPPLEMENTAL If the one-touch deceleration monitor is ON, the engine speed will remain at low idling even if you operate the fuel adjustment dial. To restore the engine speed, press the one-touch deceleration switch at the center of the left implement operation lever to cancel the deceleration function. One-touch deceleration switch

WARNING Operate the one-touch deceleration switch after switching the implement and traveling levers to the neutral position. Operating the switch while the lever is in operation will make a sudden change in the implement moving and traveling speeds. This switch (3) decreases the engine speed and activates the device to lower the fuel consumption when the engine output is not necessary such as when traveling levers, implement operation levers, and pedals are in the neutral position. Press the switch at the center of the left implement operation lever to turn on the one-touch deceleration monitor and the engine speed reduces to low idling. Press the switch again to turn off the one-touch deceleration monitor and the engine speed returns to the speed set by the fuel adjustment dial. SUPPLEMENTAL • Even if you press this switch when the fuel adjustment dial is at low idling, the engine speed will

not decrease further.

• When the engine speed does not increase, this switch may be ON. Check the switch state with the one-touch deceleration monitor.

• If you turn the starter switch to the OFF position while the one-touch deceleration switch is ON, the deceleration function is canceled.

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Horn switch Press the switch (4) at the center of the right implement operation lever to honk the horn. Lamp switch This switch (5) turns on the working light and monitor illumination. Warning buzzer stop switch This switch (6) stops the warning buzzer sound for the warning item error while the engine is in operation.

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Moment limiting device (overload protector) emergency switch

WARNING There is turnover hazard and overwinding hazard during operation. Do not use the switch during operation. Use this switch (7) before inspection, service or maintenance or to cancel the auto stop function of the moment limiting device as required. Releasing your hand from this switch will automatically return the key to the ON (automatic) position. OFF (automatic) position: You can insert/remove the key for the moment limiting device emergency switch and the moment limiting device is activated. ON (cancel) position: The auto stop function of the moment limiting device is canceled. The auto stop function remains canceled while the key is maintained at this position. SUPPLEMENTAL Turning the moment limiting device emergency switch to ON (cancel) position turns on the red lamp of the external indicator.

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Overwinding stop switch Use this switch (8) to store the hook. If you hoist the hook to store it, the overwinding alarm sensor is activated and auto stop is applied. At this point, keep pressing this switch and perform hoisting operation with the right operation lever. While the switch is being pressed, the hoisting operation is enabled and the hook store lamp turns on.

SUPPLEMENTAL • Stop the overwinding only when the overwinding alarm is

issued.

• Auto stop cannot be canceled against the overload limit alarm and operation range restriction limit alarm.

• When hoisting the winch by pressing the overwinding stop cancel switch, the flow rate automatically decreases and the hoisting speed slows. This is not a failure.

• Pressing the overwinding stop switch turns on the red lamp of the external indicator.

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Winch two-speed switch Use this switch (9) during hoisting/lowering operation with right operation lever.

Press the winch high-speed switch (9) for high-speed winching and then the winch high-speed switch lamp illuminates. Press the winch high-speed switch again to return to low speed and the winch high-speed switch lamp goes off. IMPORTANT High-speed hoisting/lowering of the winch can be performed only with no load (no hoisted load). High-speed hoisting/lowering with a hoisted load causes failures or accidents. SUPPLEMENTAL • High-speed hoisting/lowering of the winch should be

performed only with no load.

• With a load of 0.5 t or more, changing the winch two-speed switch to high speed position does not switch the speed to high speed. For high-speed hoisting/lowering, decrease the load to 0.2 t or lower.

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Swing brake switch IMPORTANT • This switch temporarily enables the swing operation when the swing braking system has a

problem, and thus is not permanent. Repair the abnormal section as soon as possible.

• If you accidentally change this switch to “cancel” position and work while the machine is in normal state, “E03” will be displayed.

• When “E03” is displayed during the work, check if the switch is in “auto” position or not. This swing (10) temporary enables the swing operation when the swivel parking braking system has a problem (“E03” displayed). (a) Cancel: Abnormal (Switched to top) (b) Auto: Normal (Switched to bottom) Switch this switch to top when “E03” is displayed to enable the operation.

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Room lamp switch IMPORTANT Failing to turn off the switch will result in a dead battery. Be sure to change the switch to OFF position after using the room lamp. This switch (11) turns on the room lamp. ON: ON OFF: OFF SUPPLEMENTAL This switch turns on even if the starter switch is at OFF position. Do not forget to switch it off. Cigarette lighter Use this lighter (12) to light a cigarette. Push in this cigarette lighter and it returns to its original position in a few seconds. Pull out the lighter and use. With the cigarette lighter removed, this can be used as a power supply. IMPORTANT This cigarette lighter uses 24 V. Do not use this as a power supply for 12-V devices. Doing so will cause the device to fail. The power of the cigarette lighter is 85 W (24 V x 3.5 A).

3-19


Moment limiting device (Overload protector) (1) Moment ratio LED (16) Check Setting button (2) Actual load display (17) Cancel Setting button (3) Rated total load display (18) Overwinding detection LED (Red) (4) Boom angle display (19) One wire fall hooking LED (Green) (5) Actual working radius display (20) Two wire falls hooking LED (Green) (6) Rated working radius display (21) Four wire falls hooking LED (Green) (7) Boom length display (22) Sub-boom 1 selection LED (Orange) (8) Lifting height display (23) Sub-boom 2 selection LED (Orange) (9) Number of wire falls selector button (24) Boom angle upper limit LED (Green) (10) Sub-boom selection button (25) Boom angle lower limit LED (Green) (11) Still/Travel mode switch button (26) Operating radius upper limit LED (Green) (12) Boom angle upper limit setting button (27) Lifting height upper limit LED (Green) (13) Boom angle lower limit setting button (28) Travel mode selection LED (Red) (14) Working radius upper limit setting button (29) Still mode switching LED (Orange) (15) Lifting height upper limit setting button (30) Moment ratio indicator (External indicator) The switch No. 10 and lamps (LEDs) No. 22 and 23 are not used.

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Functions of moment limiting device

WARNING • Do not remove the detector to install it at another location or disassemble it for

repair. • If you hit or notice damage to a detector, check the operation state of the auto stop. • Do not change the moment limiting device emergency switch to cancel side except

when there is an abnormal condition or when inspecting/servicing the detectors. • Note that the swivel operation does not stop automatically, even when overloaded. • When the boom operation is at high speed, the boom may go beyond the specified

stop position, leading to the serious accidents such as turnover of the vehicle. Always operate the boom at low speed when you approach the stop position.

The moment limiting device (overload protector) is installed to prevent the hoisted load from falling, the boom from breaking and the vehicle turning over due to overloading. Always check the operation of the moment limiting device for any abnormality before starting the crane operation. SUPPLEMENTAL • The hoisted load is detected by the derrick cylinder pressure via the pressure sensor converter.

Read the rated load with the boom angle and length. Compare the hoisted load and the rated load for pre-warning and auto stop.

• When derricking the boom, the actual load value changes slightly due to change in the derricking cylinder pressure.

Moment limiting device error message display When an error occurs in the angle detector, length detector or load detector, or when an open circuit takes place in a wire or a connector is disconnected, the self-diagnosis is carried out at the moment limiting device operation section in the cab. The result appears as an error code on the rated load indicator at the moment limiting device display, and the buzzer sounds to notify the operator of the error. Stop using the vehicle when an error code is displayed.

E1L, E1H Error in load detector 1 E2L, E2H Error in load detector 2 E3L, E3H Error in angle detector E4L, E4H Error in length detector

: See the section "What to do in this phenomenon (3-1140)" for other displays and error details.

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Activating the moment limiting device The moment limiting device is an emergency device. The operation relying on this device will be potentially hazardous. Exercise caution in operating so that the crane does not stop automatically. Overload

WARNING When hoisting a load after auto stop, check that indication is 100% or lower. Then, slowly hoist the load until the load leaves the ground. Do not raise the boom suddenly to hoist a load. Recovery operation from overloading When the hoisted load gets closer to 90% of the rated load (pre-warning), the buzzer sounds intermittently to notify the operator of the fact that the hoisted load is close to the rated load. At this time, the moment ratio LED indication changes from green to orange. Change the working condition by lowering or retracting the hook or raising the boom. If you continue the operation and the hoisted load reaches overload level (100%), the buzzer sounds continuously and hook hoisting, boom extension and boom lowering automatically stop. At this time, the moment ratio LED changes from orange to red. SUPPLEMENTAL The external indicator illuminates blue when the load rate is below 90%, yellow between 90% and 100% and red at 100% or more. When the boom angle falls below the limit value When the boom angle becomes 0 degrees while lowering the extended boom, the boom lowering operation stops automatically. SUPPLEMENTAL When all the booms are stored, the operation does not stop automatically even if the boom angle became 0 degrees.

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Control levers and pedals Safety lock lever (1) Left implement control lever (3) Traveling levers (with pedals) (2) Right implement control lever (4) Acceleration pedal Safety lock lever

WARNING • Ensure that the safety lock lever is locked before standing up from the cab seat.

Accidental contact with an operation lever when the safety lock lever is not locked can cause serious accidents.

• Check that the safety lock lever is at the position shown in the figure. If the safety lock lever is not fully locked, serious accidents can arise.

• Be careful not to touch an implement operation lever when engaging or releasing the safety lock lever.

This lever (1) locks operations such as implement, swivel, travel and attachment. Pulling up the lever locks the operation. This safety lock lever uses a hydraulic system to lock the operations. While the operation levers and pedals still work even if the lever is moved to lock position, the implement and the machine body does not move. SUPPLEMENTAL The engine will not start if the safety lock lever is not in the lock position. Check that the safety lock lever is in the lock position before operating the starter switch.

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Implement control levers

WARNING • If you need to change the operation pattern, ask our

sales service agency. • When changing the operation pattern, you also

need to change the operation nameplate so that it agrees with the machine movement.

Extend/Retract the top revolving superstructure and boom using the left implement operation lever (2). Boom extend/retract operation: (a) Extension

(b) Retraction Swivel operation: (c) Clockwise swing

(d) Counter-clockwise swing

N (Neutral): The top revolving superstructure and the boom are retained stopped at that position. When extending the boom, lower the hook sufficiently to prevent overwinding. Use the right implement operation lever (3) to operate the winch and boom derricking.

Winch operation: (a) Hoisting

(b) Lowering Boom-derricking operation: (c) Lower

(d) Raise N (Neutral): The winch and the boom are retained stopped at that position.

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Traveling levers

WARNING • Check that the safety lock lever is at the position

shown in the figure. If you have your foot on a pedal while working, you may accidentally tread on it, causing sudden traveling of the machine which can lead to serious accidents.

• When the track frame is facing backward, the traveling operation (forward/backward) is inverted.

• Check whether the track frame is facing forward or backward when operating a traveling lever.

(The track frame is facing forward when the drive sprocket (A) is at the back.)

• Exercise sufficient caution when traveling/operating using pedals.

Use these levers (4) to drive the machine. (a) Forward: Lever pushed forward (b) Backward: Lever pulled backward N (Neutral): The vehicle stops. SUPPLEMENTAL When the traveling lever is operated (tilted) forward/backward, the rated load of the moment limiting device automatically switches to traveling mode and you will hear a “Bleep” (see the section “Handling moment limiting device (3-111)”.) Acceleration pedal This pedal (5) adjusts the engine speed and output. (a) Low speed: Position where your foot is released from the

pedal (b) High speed: Position where you fully stepped on the pedal SUPPLEMENTAL Turning the fuel adjustment dial clockwise will rev up the engine to high speed. Because the engine speed set by the fuel adjustment dial has priority, the engine speed does not fall below the speed set by the dial even if the operator’s foot is released from the acceleration pedal. Turn the fuel adjustment dial counterclockwise to decrease the engine speed.

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Opening/Closing Cab Front Window

WARNING • Always move the safety lock lever to the lock

position when opening/closing the front or bottom window or door.

Accidental contact with an operation lever can cause serious injuries.

• Put down the implement on level ground and stop the engine before opening/closing the front window.

• To open the front window, hold the handles firmly with both hands and pull the handles up. Do not release until the handles are locked by the auto lock catch.

• Close the front window by firmly holding the handles with both hands.

The front window (upper section) can be stored (pulled up) in the cab ceiling. To open 1. Put down the implement on level ground and stop the engine. 2. Make sure that the safety lock lever is set in the lock position. 3. Check that the wiper blade is stored in the right support. 4. While holding the handles (A) on the left and right at the

upper section of the front window, unlock the upper section by pulling the lock lever (B) toward you. The upper section of the front window is disengaged.

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5. Hold the lower handle (C) with your left hand and upper handle (D) with your right hand in the operator cab and pull them up. Press them firmly against the lock catches (E) in the back of the cab to lock the handles.

6. Check that the lock lever (B) is surely locked.

• If the arrow on the lock case (F) and the arrow position on the lock lever (B) line up, the handles are locked. Check this visually.

• If the arrow on the lock case (F) and the arrow position on the lock lever (B) do not line up, they are not locked. Repeat the operation in 5. to lock the handles.

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To close

WARNING Lower the window slowly so as not to pinch your hands when closing the window. 1. Put down the implement on level ground and stop the engine. 2. Make sure that the safety lock lever is set in the lock position. 3. While holding the left and right handles (A), pull down the lock

lever (B) to unlock the handles. 4. Hold firmly the front window lower handle (C) with your left

hand and upper handle (D) with your right hand, push them forward and slowly lower the window.

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5. When the bottom of the window reaches the top of the lower window, push the upper section of the window forward and against the lock catches (G) on the left and right to lock the window.

6. Check that the lock lever (B) is securely locked.

• If the arrow on the lock case (F) and the arrow on the lock lever (B) line up, the handles are locked. Check the lock state visually.

• If the arrow on the lock case (F) and the arrow on the lock lever (B) do not line up, they are not locked. Repeat the operation in 5. to lock the handles.

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Removing front window (bottom) 1. While the front window is open, pull up the knobs (A) to

remove the bottom window. 2. Store the removed bottom window inside the left of the

operation cab and lock the window securely with the lock lever (B). Store the window with the following procedure:

3. Hold the window with the glass notch facing forward and the

knob (A) protrusions inside, insert the window between the magazine box inside the left of the operation cab and the left switch lever box.

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4. After inserting the window into the bottom frame rubber groove (D) and back frame rubber (E), press the bottom window against the lock base (C).

IMPORTANT Using force to lock the window while glass is on the lock base (C) or not touching the lock lever (B) can break the glass. Check these before locking the window. 5. Lock (Close) the lock lever (B).

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Sliding door

CAUTION • Check that the sliding door is locked before

opening/closing the door. • Always open/close the sliding door when the crane

is standing on level ground. • Avoid opening/closing the sliding door on a slope

since the force of gravity can change suddenly. • Always open/close the sliding door by holding door

handles (1) and (2). • Be careful not to get your hand pinched between

the door and the front or center pillar. • If there is someone in the cab, talk to him/her first

before opening/closing the sliding door. Door lock Pull the door handle (1) backward first to release the lock (3), and then pull the door forward to close the door.

Emergency escape hammer

CAUTION • When hammering a window, beware of scattered glass fragments. • When exiting a window, remove any glass fragments from the window frame so as

not to cut or hurt yourself. Watch your step so as not to slip on the glass fragments.

A hammer (A) is equipped so that you can use it to escape from the cab in emergency such as the cab door not opening. Break the window with the hammer (A) to escape and climb out through it.

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Locked caps and covers Use the starter switch key to open/close the locked caps and covers. See the section “Locking (3-100)” for the location of locked caps and covers. Fully insert the key and turn. Turning a half-inserted key can break it. How to open/close the locked cap (For fuel tank filler cap) To open 1. Insert the key into the key slot. 2. Turn the key clockwise and align the mark on the key slot and

cap to open the cap. To lock 1. Screw in the cap and insert the key into the key slot. 2. Turn the key counterclockwise and then remove it. How to open/close the locked cover To open (When locked) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and pull the cover handle to

open the cover. To lock 1. Close the cover and insert the key into the key slot. 2. Turn the key clockwise and then remove it.

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Engine hood

WARNING Always use the hood support lever to keep the engine hood open when inspecting/maintaining the hood. IMPORTANT Always lock the hood when it is closed. You can check whether the hood is locked by looking at the key slot direction of the opening knob. 1. Unlock (1) the engine hood (See the section “How to open/close the locked cover (For

locked cover) (3-33)”.) 2. While pressing the engine hood opening knob (1), open the

hood (2). 3. After opening the hood, secure the hood support lever (3) at

its securing position. 4. To close the hood (2), remove the hood support lever (3) and

secure the lever in the lever lock. To lock the hood, lower the hood gently and press it down.

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Battery inspection cover 1. Lift the cover handle (1). 2. While lifting the cover (2), pull the cover toward you and then

lower it. 3. Close the cover (2) so that the spring clip at the end of the

cover (2) is fastened.

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Fuses IMPORTANT • Always turn off the power (starter switch to OFF position) before replacing a fuse. Fuses protect electrical components and wires from burning out. Replace the fuse if a fuse is corroded and covered with white powder, or if there is some slack between a fuse and the fuse holder. Replace a fuse with the one of same capacity.

• The fuse box is provided on the back of the left console box.

Fuse Capacity and Circuit Name No. Capacity Circuit Name (1) 10A Controller (2) 10A Pump Solenoid Cancel (3) 10A Crane Solenoid, Revolving Light (4) 10A Windscreen Washer

Cigarette Lighter (5) 5A Horn (6) 15A Working Light (7) 10A Radio (8) 25A Air Conditioner, Heater (9) 15A Fuel Governor Control (10) 5A Swing Parking Brake, Moment

Limiting Device, Relay Cancel (11) 10A Deceleration Switch Controller (12) 10A Spare (13) 10A Monitor Panel (14) 10A PPC Hydraulic Solenoid (15) 15A Key Stop Solenoid (16) 5A Radio Backup (17) 10A Air Conditioner Backup (18) 10A Monitor (Constant Power Supply) (19) 5A Room Lamp (20) 30A Starter Switch (B)

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Fusible link If the power does not turn on even if the starter switch is turned to the ON position, the fusible link (1) may have an open circuit. Open the engine hood on the right of the machine body to check/replace the fusible link. SUPPLEMENTAL The fusible link is a large fuse wire mounted on the circuit where high power current runs through. As is the case with fuses, this protects electrical components and wires from being burned out by abnormal currents.

Controller IMPORTANT • Do not spill water, dirt or juice on the controller. This will

cause failures.

• Should you find any abnormality in the controller, do not repair it by yourself but ask our sales service agency to repair it.

The controller is positioned behind the operator seat.

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Handling air conditioner Name of each section of the control panel (1) Air outlet selector switches (5) Air conditioner switch (2) Inside/Outside air selector switch (6) Off switch (3) Temperature control switches (7) Defroster switch lever (4) Airflow selector switches Air outlet selector switch (sends air towards upper body) Press this switch (1) to send air from the air conditioner to the upper body. This is suitable for cool air in the summer.

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Air outlet selector switch (sends air towards upper body and feet) Press this switch (1) to send air from the air conditioner towards upper body and feet. Air outlet selector switch (sends air towards feet) Press this switch (1) to send air from the air conditioner towards the feet. This is suitable for warm air in winter.

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Inside/Outside air selector switch (for outside air) Press this switch (2) to take air from outside the cab for cooling/heating. Use this switch to take in clean air from outside the cab or to defog the cab window. Inside/Outside air selector switch (internal air circulation) When this switch (2) is OFF, it only circulates air in the cab. Use this switch to quickly cool/heat the cab or when the outside air is dirty. Temperature control switch (Low temperature) The closer the range illumination is to “C”, the lower the temperature is. The closer the range illumination is to “H”, the higher temperature is. There are 11 ranges and each range is further divided into countless other ranges. This switch (3) lowers the temperature. Press this switch to lower the temperature of the air coming out of the air conditioner outlet. The closer the range illumination is to “C”, the lower the temperature will be.

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Temperature control switch (High temperature) This switch (3) increases the temperature. Press this switch to raise the temperature of the air coming out of the air conditioner air outlet. The closer the range illumination is to “H”, the higher the temperature will be. Airflow selector switches

There are four ranges. The closer the range is to LO (rear of the machine), the lower the airflow will be. The closer the range is to HI (front of the machine), the higher the airflow will be. Airflow selector switch (LO) This switch (4) lowers the outlet airflow from the air conditioner. Press this switch to lower the outlet airflow. The closer the range is to LO (rear of the machine), the lower the outlet airflow will be. Airflow selector switch (HI) This switch (4) increases the outlet airflow from the air conditioner. Press this switch to increase the outlet airflow. The closer the range is to HI (front of the machine), the higher the outlet airflow will be.

3-41


Air conditioner switch Use this switch (5) to turn on/off the air conditioner. Off switch Use this switch (6) to stop the fan. Defroster switch lever This switch (7) defrosts the mist formed on the windshield in winter and rain. Switch lever forward: To defroster (Open) Switch lever backward: Close The defroster can be used when the air outlet selector switch is set to upper body, or to upper body and feet. Cautions when using air conditioner Occasional ventilation during air-conditioning You may get sore eyes if you smoke while air-conditioning is on. In this case, open the window for temporary ventilation and extract the smoke. When air-conditioning is on for long period, ventilate once an hour. Be careful of overcooling The healthiest temperature is one which feels a bit cool when we enter the vehicle (5 to 6 deg C of difference compared to the outside temperature). Pay sufficient attention to temperature control. Inspection/Maintenance of vehicles with air conditioner When inspecting/maintaining a vehicle with air conditioning, see the section “Maintenance for the first 250 hours (only the first maintenance for new vehicles) (4-10)” and carry out inspection/maintenance according to the list.

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Handling vehicle radio Description of each system The vehicle radio may be unusable depending on the area where the crane is used. (1) Power switch, volume control knob, (5) Manual tuning buttons balance control knob (6) Pre-set buttons (2) Tone control knob (7) Display (3) FM/AM selector button (8) Time adjustment buttons (4) Display switch button (9) Stereo indicator Power switch, volume control knob (SW-VOLUME), balance control knob (Pull BAL) Press this knob (1) to turn on the radio and display the frequency on the display (7). Press it again to turn it off. Turn the knob clockwise to increase the volume and counterclockwise to lower it. Pull this knob until it is locked and turn to adjust the balance of the speakers on the left and right. Turn the knob clockwise to enhance the sound on the right, and counterclockwise on the left. When you have finished with balance adjustment, lightly press the knob to return to the original state. (You cannot adjust the volume if the knob is pulled out).

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Tone control knob (TONE) Turning this knob (2) clockwise from the middle position enhances the treble and counterclockwise reduces it. FM/AM selector button (AM/FM) Press this button (3) to select a desired band. It changes between AM and FM each time you press the button. Display switch button (TIME) This button puts priority on frequency display. Press the button (4) when frequency is being displayed to show the current time for 5 seconds. After 5 seconds, the display automatically shows frequency again. Pressing a button other than TIME SET (H, M, SET) returns the display to show frequency. Manual tuning buttons (TUNING) Press the up arrow of button (5) to increase frequency and the down arrow to decrease the frequency. Keep pressing the button continuously, until you find the station you want.

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Pre-set buttons (1, 2, 3, 4, 5 and 6) (PRESET STATION) Pre-setting a desired station to this button (6) then allows you to select the station with a touch of the button. See the section “How to adjust pre-set buttons (3-46)” for how to pre-set a station and detailed description. Display This display (7) shows the reception band, frequency, pre-set no. and time. Time adjustment buttons Use these buttons (8) to adjust the time. H: Hour, M: Minute SET: 00 minute adjustment Stereo indicator (ST) This indicator (9) illuminates when the radio is receiving stereo broadcasting whilst on an FM station.

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Operations How to adjust pre-set buttons 1. Press the power switch (1). The frequency appears on the

display (7). 2. Use the tuning buttons (5) (manual, auto) to find the desired

frequency. 3. When you would like to store a frequency, press a pre-set

button for 1.5 seconds or more. Although the sound you were hearing will be lost, it will return once the frequency has been stored. At the same time, the pre-set no. is shown on the display (7) to notify that the frequency has been stored. Once the frequency has been stored, press the pre-set button (6) for 1.5 seconds or less and release your finger to receive the station that is memorized to that button number. You can memorize 1 AM station and 1 FM station per pre-set button.

Manual tuning Press the tuning buttons (5) and find desired frequency. The frequency changes by 9 kHz in AM and 0.1 MHz in FM each time you press the button. Down triangle button: Moves to lower frequency Up triangle button: Moves to higher frequency

• When the frequency reaches the upper or lower limit, the frequency automatically changes from upper to lower limit or lower to upper limit.

Automatic tuning Press a tuning button (5) for 0.5 seconds or more. The tuning automatically stops when the radio finds a station. Press the tuning button (5) again for 0.5 seconds or more to find the next station. Down triangle button: Automatically selects a station of lower frequency Up triangle button: Automatically selects a station of higher frequency

• Press this button during the auto tuning to cancel auto tuning and receive the set frequency before making the cancellation.

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Description of Each Device HANDLING How to adjust the time 1. Press the display switch button (4) to display the time.

The display returns to frequency after 5 seconds, and you cannot adjust the time. Press the display switch button (4) again to adjust the time.

2. Press the time adjustment buttons (8) to set the Hour and Minute.

H button: Sets the hour (advances one hour each time the button is pressed) M button: Sets the minute (advances one minute each time the button is pressed) SET button: Press the SET button to reset as follows;

Reset to 00 minutes 00 seconds if the time was between 00 min. and 05 min. Reset to 00 minutes 00 seconds by advancing one hour if the time was between 55 min and 59 min. Cannot be reset if the time was between 06 min. and 54 min.

Ex. 10:05 10:00 10:59 11:00 10:26 10:26 Press the H, M, or SET button to set the desired time. Antenna IMPORTANT Always lay down the antenna before transportation or before putting the machine into the garage, to avoid any breakage of the antenna. Put the antenna up if the receiving sensitivity is low or if you hear noise. Cautions in using the radio • For safety reasons, use your radio at a volume at which you can still hear sound outside the

machine during operation.

• Water going into the speaker case or vehicle radio (auto tuning) will cause unexpected failures. Be careful not to allow water to get into these devices.

• Do not wipe meters and buttons with solvent such as benzine and thinner. Use a dry soft cloth (soaked in alcohol for heavy soil).

• When a battery is changed, all the memories in the pre-set buttons will be lost. Set them again.

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Manual holder There is a pocket to store the instruction manual and oil chart on the left inside the cab. Keep the instruction manual in this pocket for necessary reference at any time.

Grease pump holder This is located inside the cover on the right of the machine body. Hook the grease pump in this holder when not in use.

Ashtray Located on the right front of the cab seat. Be sure to put out a cigarette before closing the cover.

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Operations HANDLING

Operations Check and adjustment before starting the engine Walk-around check Look around and under the machine to check for loosened bolts and nuts, leakage of oil, fuel, and cooling water, and the state of the operation system and hydraulic system before starting the engine. Also check for slack and electrical wires, and accumulation of dust at the section where it becomes hot.

WARNING • Open the hood or cover completely and be sure to secure the hood/cover with the

stopper for checking and maintenance inside the engine hood. • Remove the accumulation of inflammable materials immediately around the hot

engine section, such as the engine muffler and around the battery. Fuel leakage and oil leakage will cause fire in the machine. Check thoroughly for leakage. If you find any abnormality, repair immediately or contact our sales service agency.

If the machine is tilted at the time of inspection, level the machine first before inspection. Perform the following checks and cleaning before starting the engine for the first time each day. 1. Check sensor section for breakage Check the sensor section for any breakage. If you find any abnormality, ask us or our sales service

agency for inspection and repair. 2. Check implement, cylinder, linkage, and hoses for breakage, wear, and gaps Check the implement, cylinder, linkage, and hoses for cracks, excessive wear, and gaps. If you

find any abnormality, repair. 3. Remove dust around the engine, battery, and on the radiator

Check around the engine and radiator for accumulation of dust. Check the hot section of the engine, such as the engine muffler and around the battery for accumulation of inflammable materials (such as dead leaves and branches). If you find any dust or inflammable materials, remove them.

Check especially carefully between the muffler (1) and muffler cover (2) for dust.

4. Check around the engine for water leakage and oil leakage Check the engine for oil leakage and water leakage from the cooling water system. If you find any

abnormality, repair it. 5. Check hydraulic devices, operating oil tank, hoses, and joints for oil leakage Check these components for oil leakage. If you find any abnormality, repair the section where the

oil is leaking. 6. Check around the feet (crawlers, sprockets, idlers, and guards) for abnormality, wear, loose bolts,

and roller oil leakage.

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HANDLING Operations If you find any abnormality, repair it. 7. Check rails and steps for abnormality and loose bolts. If you find any abnormality, repair it. Re-tighten loose bolts. 8. Check gauges and monitors Check the gauges and monitors for any breakage and if you find any abnormality, change the

gauge/monitor. Clean the surface of gauges and monitors. 9. Check windows for fitting and breakage Check that the windows fit properly and are not broken. If you find a broken window, repair the

section. If a window disengages or breaks during operation, stop the work and repair the window immediately.

10. Check and clean rear view mirror Check the rear view mirror for any abnormality. If you find any breakage, repair the section. Clean

the surface of the mirrors and adjust the mirror angle so that the operator can see the bottom of the back of the machine (where it is hidden behind the engine hood) from the operator seat.

11. Check the seat belt and mounting brackets Check the seat belt and mounting brackets for any abnormality. If you find any damage, change

the part for a new one. 12. Crane 1) Frame • Cracks, warps and damage • Slack at mounting section 2) Derrick cylinder • Operation (Abnormal noise) • Oil leakage • Natural.lowering (i.e. without influence from the control levers)

• Wear and damage on the support point pin

• Slack of support point pin retaining plate bolt • Slack at pipe connections and oil leakage 3) Booms • Cracks, warps and damage • Wear and damage on the support point pin • Slack of support point pin retaining plate bolt • Damage and greasing condition at sliding sections 4) Telescopic cylinder • Operation (Abnormal noise) • Oil leakage • Natural lowering (i.e. without influence from the control levers) • Slack at pipe connections and oil leakage 5) Wire ropes

• Damage, deformation, wear, twist, kink and corrosion • Greasing condition • Tension 6) Moment limiting device • Operation 7) Overwinding protector

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Operations HANDLING • Operation

• Damage to the wire rope that is holding the overhoisting detector 8) Hydraulic motor

• Operation (Abnormal noise)

• Oil leakage

• Slack at mounting section

• Slack at pipe connections and oil leakage 9) Drum

• Cracks and damage

• Irregular winding 10) Hook

• Rotation of hook sheave

• Cracks and damage on the hook sheave

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HANDLING Operations Check before starting operation Perform the following checks once, before starting the engine for the first time each day. Inspection and replenishing of cooling water

WARNING • Normally, do not open the radiator cap. Check the cooling water with the sub tank

while the engine is cold. • The cooling water is hot right after the engine was stopped. Pressure is built up

inside the radiator. Opening the cap in that condition will cause burns. Turn the cap slowly and release the pressure after the engine has cooled down.

1. Open the engine hood and check if the cooling water level in

the sub tank (1) (figure on the right) is within the range between FULL and LOW. If the level is lower than this range, supply the sub tank (1) with water from the feed opening to the FULL level.

2. Tighten the cap securely after supplying water. 3. If the sub tank is empty, water leakage is suspected. Check the sub tank and if you find any abnormality, repair the

section. If you find no abnormality, check the water level in the radiator. If the water level is low, supply the radiator with water first and then the sub tank.

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Operations HANDLING Inspection and replenishing of oil in the engine oil pan

WARNING The parts and oil are hot right after the engine was stopped. Touching these sections can cause burns. Start working when the temperature has gone down. 1. Open the engine hood. 2. Pull out the oil level gauge (G) and wipe off the oil with a

waste cloth. 3. Insert the oil level gauge (G) into the observation pipe again as far as it goes and pull it out. 4. If the oil is found between the mark H and L on the oil level

gauge (G), the oil level is appropriate. If the oil is found below L, replenish the oil from the filler opening (F).

5. If the oil is found above H, drain the excess engine oil through

the drain hole, after removing the drain plug (P) and check the oil level again.

6. If the oil level is found to be appropriate, securely tighten the filler cap and close the engine hood.

SUPPLEMENTAL • If the machine is tilted at the time of inspection, level the machine first before inspecting the above

items.

• Check the oil level before starting the engine or 15 minutes or more after stopping the engine.

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HANDLING Operations Inspection and replenishing of fuel

WARNING Pay attention not to spill fuel when refueling. Spilled fuel can cause a fire. Thoroughly wipe off the spilled fuel. If there is sand and earth at the section where the fuel spilled, remove the sand and earth as well. The fuel is highly combustible and dangerous. Do not allow fire anywhere near to the fuel. 1. Insert the key into the starter switch (1) and turn the key to

the ON position to turn on the monitor (2). 2. Check the remaining fuel on the fuel gauge (3). 3. If the fuel is insufficient, refuel from the filler opening (F)

while looking at the sight gauge (G). Fuel tank capacity: 141 l

Securely tighten the cap after refueling.

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Operations HANDLING Inspection and replenishing of oil in the operation oil tank

WARNING • The parts and oil are hot right after the engine was stopped. Touching these

sections can cause burns. Start working when the temperature has gone down. • The oil may blow out when you remove the filler cap. Turn the cap slowly with care

while releasing the pressure, and then remove the cap. 1. Check the level of the oil in the operation oil tank when the

machine is in the following state. 1) When checking the oil level in the state shown in the

figure on the right, start the engine, and at low engine speed, put the boom into traveling posture and stop the engine.

2. Check the sight gauge (G) on the left of the vehicle. The oil

level between the line H and L is appropriate.

IMPORTANT Do not refill oil to a level higher than the line H. Doing so will damage the hydraulic circuit or cause blowout of the oil. If you refilled the oil to a level higher than the line H, turn the top revolving superstructure so that the drain plug (P) at the bottom of the tank comes between the left and right crawlers. Stop the engine. After the operation oil has cooled down, drain the excessive oil through the drain hole, after removing the drain plug (P).

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HANDLING Operations 3. When the oil level is below line L, loosen the four bolts to

remove the operation oil tank top cover (I) and refill from the filler opening (F).

SUPPLEMENTAL The oil level changes with the oil temperature. Keep the following in mind when checking the oil level.

• If it is around level L before operation (Oil temperature: 10 to 30 deg C)

• If it is around level H after normal operation (Oil temperature: 50 to 80 deg C)

3-56

Operations HANDLING Inspection of dust indicator 1. Open the engine hood and check if the red piston in the

transparent section of the dust indicator (1) is coming out. 2. If the red piston is coming out, immediately clean or change

the element. See the section “Inspection, cleaning, and replacement of air cleaner (4-10)” for how to clean the element. 3. After checking/cleaning/replacing the element, press in the

knob of the dust indicator (1) to push back the red piston to the original position.

Inspection of water separator If the red ring (5) of the water separator is sunk to the bottom of the element cup (4), there is no water mixed in. If the red ring (5) is floating, water has come in upto under the ring. Drain the mixed water using the following procedure.

• Have a filter wrench for the water separator ready at hand. 1. Open the engine hood and turn the filter handle (2) inside to

the “Closed” position (a). 2. Using the filter wrench, loosen the ring (3) and remove the

element cup (4) to drain the water inside. 3. Fill the element cup (4) with fuel and install the cup to the

filter block. Tighten the ring (3). 4. Turn the handle (2) to the “Open” position (b). 5. Drain the mixed water and sediment from the fuel tank,

referring to the section “Draining mixed water and sediment in the fuel tank (4-27)”.

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HANDLING Operations Inspection of electrical wires

WARNING • If many fuses were blown or if you find a trace of short circuit in the electrical

wiring, check the causes immediately. Repair the section or contact our sales service agency.

• Keep the top surface of the battery clean and check the battery cap ventilation hole. If you find any clogging with dirt, wash the battery cap with water to unclog the hole.

Check fuses for damage and use of specified capacity, electrical wiring for trace of open/short circuits, and covering for damage. Check the terminals for any slack. Tighten the terminals additionally if any slack is observed. Check wiring for battery, starter, and alternator especially carefully. Always check around the battery for accumulation of inflammable materials. Remove the materials if you find any. Inspection of horn and headlight functions 1. Turn the starter switch to the ON position. 2. Press the horn button to check that the horn works

instantly. If the horn does not honk, ask our sales service agency for

repair. 3. Press the lamp switch to check if the main unit headlight,

boom headlight, and monitor illumination turns on. If it does not turn on, the bulb may be blown or there may be an open circuit. Ask us or our sales service agency for repair.

Inspection of boom frame for cracks, deformation and damage Check the boom frame for cracks, deformation and damage. If you find any abnormality, repair the section. Inspection of wire ropes for deformation, damage and wear Check the securing section at the rope end, the rewinding state, and the contact between ropes. Check and inspect the wire ropes at the time of winching or extending/retracting boom, referring to the section “Handling wire ropes (3-101)”.

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Operations HANDLING Inspection of winch and boom operations 1. Check that winch-hoisting/lowering, and boom-derricking,

extending/retracting, and swing operations agree with their operation position on the operation levers.

2. While checking the operation described in item 1, check the crane sections such as booms and hydraulic motor for any abnormal noise.

3. Operate the crane with no load to check any bolts and nuts loosened or lost.

4. Check the hook for deformation, the bearing for abnormal noise, and the wire rope retainer for proper function.

Inspection of moment limiting device

WARNING Should any abnormality be found on the moment limiting device, contact us or our sales service agency immediately. ALWAYS check the safety devices before starting crane operation. 1. Operate and check the moment limiting device, referring to

the section “Operation and verification before starting the engine (3-63)”.

2. Turn the starter switch key to the START position to start the engine.

3. Check that the moment limiting device display is correct.

• Check that the boom length display is “4.6 m” with the shortest boom length.

• Check that the boom length display is “15.6 m” with the boom extended to its maximum.

• Set the boom so that the boom length is “7.8 m” and the boom angle is “0 degree”. Check that the operating radius display is “6.7 m” at this point.

Prepare a load whose weight is known. Hang the weight and check that the “weight + 0.09 t (hook block weight)” and the current load display agree (with hook for two or four wire rope falls).

Note that the load display may cause a slight error depending on the boom conditions. The load display changes depending on the setting of the “Still/Travel mode switch button” and of “The number of wire falls switch button”. Make the operating conditions and the setting of the working conditions (see the section “Setting working state” (3-115)) agree.

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HANDLING Operations Adjustment

WARNING • Make adjustments before operation or when an operator changes. • Adjust the seat so that the operation levers and switches can be operated freely

while your back rests on the backrest of the cab seat. Adjustment of cab seat (A) Forward/Backward adjustment of the seat Pull the lever (1) upward to adjust the seat to a desired position. Release the lever. Forward/Backward adjustment volume: 50 mm (B) Adjustment of seat reclining SUPPLEMENTAL The seat reclines a lot when the seat is moved forward, and will recline less and less as you move the seat backward. When you move the seat backward, return the backrest to the original position. Pull the lever (2) upward to adjust the backrest to the position where it is easier for you to operate the machine. Release the lever. Adjust the reclining while pressing your back closely against the backrest. The backrest can return suddenly if your back is not resting on the backrest. (C) Adjustment of armrest angle The armrest (3) can flip up manually to about 90 degrees. You can make fine upward/downward adjustments by turning the dial (4) at the bottom of the armrest with your hand. Armrest adjustment angle: 25 degrees SUPPLEMENTAL If you tilt the backrest forward without raising the armrest (3), the armrest will automatically raise. (D) Forward/Backward adjustment of entire seat Pull the lever (5) to the right to adjust the seat to a desired position. Release the lever (5). In this case, operator seat, left/right levers, and safety lock lever slide all together. Forward/Backward adjustment volume: 100 mm Adjustment of mirrors Adjust the angle so that the bottom of the back of the machine (where it is hidden beyond the counter weight) can be clearly seen from the cab seat.

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Operations HANDLING Handling seatbelt

WARNING • Check the belt mounting brackets and mounting belt for any abnormality before

wearing the seat belt. Change the bracket/belt if they are worn out or damaged. • Even if the belt appears to be in working order, change the seatbelt every three

years. The date of manufacture is textured onto the back of the belt. • Adjust and wear the seatbelt before operation. • Always use the seatbelt during operation. • Do not use the seatbelt twisted. Check the mounting bracket bolts installed to the machine body for any looseness. If you find any loosened bolt, tighten it additionally. Tightening torque: 24.5 ± 4.9 N• m {2.5 ± 0.5 kg• m} If you find any scratch or blanket-like fluffing on the belt or breakage or deformation on the brackets, change the seatbelt. Fastening/Unfastening seatbelt 1. Sit on the seat and adjust the seat so that you are in a

comfortable position to operate and that your back sticks firmly to the backrest of the seat.

2. Sit on the seat after adjusting the seat position. Hold the buckle (1) and insert the metal fitting (2) in your left and right hands. Insert the metal fitting (2) into the buckle (1). Pull the belt to check that the belt is securely locked.

3. Press the red button on the buckle (1) to unfasten the belt. The belt should not be twisted and should fit the body. Adjust the length of the belt on the insert metal fitting side.

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HANDLING Operations Adjustment of seatbelt length To make it shorter Pull the free end of the belt on the insert metal fitting side. To make it longer Pull the fixed side of the belt on the insert metal fitting side perpendicular to the metal fitting.

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Operations HANDLING Operation and check before starting the engine

WARNING Always move the safety lock lever to the lock position before standing up from the cab seat, whether the engine is in operation or being stopped. 1. Check that the safety lock lever (1) is at the lock position. SUPPLEMENTAL The engine does not start if the safety lock lever is not at the lock position. 2. Check that the levers are at the neutral position. 3. Insert the key into the starter switch (2) and turn the key to

the ON position. Then, check the following. 1) The buzzer sounds for about 1 second and the following monitors and meters illuminate for about 3 seconds.

• Battery charge monitor (3)

• Engine oil pressure monitor (4)

• Engine coolant temperature gauge (5)

• Engine coolant temperature monitor (6)

• Fuel level monitor (7)

• Fuel gauge (8)

• One-touch deceleration monitor (9)

• Warm-up monitor (10) If these monitors and meters do not illuminate or if the buzzer does not sound, the monitor bulb may be blown or there may be an open circuit. Ask our sales service agency for repair. In about 3 seconds, only the following monitors and meters remain illuminated and the others go off.

• Battery charge monitor (3)

• Engine oil pressure monitor (4)

• Engine coolant temperature gauge (5)

• Fuel gauge (8)

3-63

HANDLING Operations 2) Press the horn switch (11) to check that the horn honks. 3) Change over the lamp switch (12) to ON position and check

that the working light illuminates. If it does not, the bulb may be burned out or there may be an

open circuit. Ask our sales service agency for repair.

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Operations HANDLING

Starting the engine Normal starting

WARNING • Always start the engine while sitting on the cab seat. • Do not start the engine by shorting the starter circuit. This can cause serious

injury, accidents or fire. • Check that there is no one and no obstacle around the machine. Honk the horn

before starting the engine. • The exhaust gas is harmful. Pay sufficient attention to ventilation when starting the

engine in a small, enclosed location. IMPORTANT • Do not start the engine with the fuel adjustment dial near the

full speed position. This may damage engine components.

• Do not turn the starter for more than 20 seconds. If you failed to start the engine, wait for around 2 minutes and

restart the engine. 1. Check that the safety lock lever is at the lock position. If the

safety lock lever (1) is at the free position, the engine does not start.

2. Turn the fuel adjustment dial (2) to the low idling position.

3-65

HANDLING Operations 3. Turn the starter switch (3) key to the START position. The

engine starts. 4. Release your hand from the starter switch (3) key when the

engine starts. The key returns to the ON position by itself. 5. Continue idling for 15 seconds after starting the engine. Do

not operate the operation levers or the fuel adjustment dial during that period.

6. Check that the battery charge monitor (4) and engine oil pressure monitor (5) are OFF.

3-66

Operations HANDLING Starting in cold weather

WARNING • Always start the engine while sitting on the cab seat. • Do not start the engine by shorting the starter circuit. This can cause serious

injury, accidents or fire. • Check that there is no one and no obstacle around the machine. Honk the horn

before starting the engine. • Starting the engine by using the starting aid fluid can cause an explosion. Never

use such fluid. • The exhaust gas is harmful. Pay sufficient attention to ventilation when starting the

engine in a small, enclosed location. IMPORTANT • Do not start the engine with the fuel adjustment dial near

the full speed position. This may damage engine components.

• Do not turn the starter for more than 20 seconds. If you failed to start the engine, wait for around 2 minutes

and restart the engine. Start the engine as follows when the ambient temperature is low. 1. Check that the safety lock lever is at the lock position. If the

safety lock lever (1) is at the free position, the engine does not start.

2. Check that the fuel adjustment dial (2) is at the low idling

position before starting the engine.

3-67

HANDLING Operations 3. Turn the fuel adjustment dial so that it is between the low

idling and full speed. 4. Keep the starter switch (3) key at the HEAT position and

check that the warm-up monitor (4) turns on. In about 30 seconds, the warm-up monitor (4) flashes for 10 seconds to notify the completion of the warming up. SUPPLEMENTAL At the warm-up position, the monitors and gauges also illuminate. This is normal. 5. When the warm-up monitor (4) goes off, turn the starter

switch (3) key to the START position to start the engine. 6. Release your hand from the starter switch (3) key when the

engine starts. The key returns to the ON position by itself. 7. Continue idling for 15 seconds after starting the engine. Do

not operate the operation levers or the fuel adjustment dial during that period.

8. Check that the battery charge monitor (5) and engine oil

pressure monitor (6) are OFF.

3-68

Operations HANDLING Operation and check after starting the engine

WARNING • Should a problem such as emergency stop or abnormal operation occur, turn the

starter switch key to the OFF position. • Operating the implement without sufficient warm-up operation will result in slow

reaction of the implement to the operation levers and the implement may not perform in the way the operator intended. Always perform the warm-up operation, especially in the cold weather.

Running-in

CAUTION This machine is shipped after sufficient adjustment and inspection. However, forcing the machine too much from the beginning will degrade its functions fast and shorten its life. For the first 100 hours (hours displayed on the service meter), perform some run-in. Pay attention especially to the following points in performing the run-in.

• Idle the engine for 5 minutes after starting, then perform the warm-up operation.

• Avoid operation with heavy load or at high speed.

• Avoid sudden acceleration, unnecessary stops and sudden steering.

3-69

HANDLING Operations Warm-up operation IMPORTANT • Do not work or perform sudden lever operations while the operating oil is at a low

temperature. Always perform the warm-up operation. This will also extend the life of the machine.

• Avoid sudden engine acceleration until the warm-up operation is complete. Do not perform low idling or high idling for more than 20 minutes with no load (oil down). Apply some load from time to time or change to medium engine speed when you need some idling.

Do not move on to the machine operation right after starting the engine. Perform the following operations and checks. 1. Turn the fuel adjustment dial (1) to be between the low idling

and full speed to keep the engine at medium speed. Run the machine for about 5 minutes with no load.

2. Move the safety lock lever (2) to the free position. 3. Operate the right operation lever slowly leftward (boom-

raising operation) to move the derricking cylinder to the end of the stroke.

4. Operate the right operation lever left and right (boom-

derricking operation) for a full 5 minutes.

IMPORTANT • Exercise caution so that the hook does not interfere with

the machine body or ground when you lower the hook.

3-70

Operations HANDLING 5. Check that the machine monitor (5) is in the following state

after the warm-up operation.

• Engine coolant temperature gauge (6): In green range

• Fuel gauge (4): In green range

• Engine coolant temperature monitor (5): OFF

• Engine oil pressure monitor (6): OFF

• Battery charge monitor (7): OFF

• Fuel level monitor (8): OFF

• Warm-up monitor (9): OFF

• Display (10): OFF 6. Check that there is no abnormality observed in exhaust color,

sound and vibration. If you find any abnormality, contact our sales service agency.

7. Move the safety lock lever (2) to the lock position and check

that the implement and machine body do not move, even when you operate operation levers and pedals.

8. Switch to the operation mode you are going to use with the

operation mode changeover switch (14) on the machine monitor (5).

Lamp (E) ON: E mode (For works focusing on fuel consumption) Lamp (E) OFF: Active mode (For normal works)

3-71

HANDLING Operations

Stopping the engine IMPORTANT Stopping the engine all of a sudden can shorten the life of various engine components. Do not stop the engine suddenly except in emergency. Should the engine get overheated, do not stop it right away. Keep the engine at medium speed and cool the engine gradually and stop. 1. Operate the engine at low idling speed for about 5 minutes to

gradually cool the engine. 2. Turn the starter switch (1) key to the OFF position and stop

the engine. 3. Remove the starter switch (1) key. Inspection and check after stopping the engine 1. Check for oil/water leakage and perform a walk-around check around the implement, exterior, and

around the feet. If you find any leakage or abnormality, repair the section. 2. Remove papers and waste in the engine room and around the battery. They can catch fire. 3. Remove the dirt, etc. stuck around the feet of the machine.

3-72

Operations HANDLING

Starting to move (forward/backward)/ Stopping the machine

WARNING • Check the direction of the track frame before operating a traveling lever. • If the sprocket is in front, the traveling lever operation is inverted. • Check safety around the machine and honk the horn before starting to move the

vehicle. • Keep people away from the machine. • Clear the traveling path of obstacles. • Because the back of the machine will be out of your line of vision, pay special

attention when you move backward. IMPORTANT • Always make the boom flat for storage. Storing the hook

with raised boom will damage the rubber on the top of the hook.

• Do not raise the boom when the hook is stored. Doing so will damage the rubber on the top of the hook. Lower the hook so that it stays positioned below the weight of the overwinding protector whilst the boom is being raised. See the section “Hook storing operation (simplified storing) (3-92)” for the procedure for storing the hook.

1. Move the safety lock lever (2) to the free position and hoist

the hook with the winch hoisting operation using the right operation lever (5).

2. After the hoisting is stopped with auto stop, press the

overwinding stop cancel switch (6) to perform the hoisting operation and store the hook. If the hook is not stored well, increase the engine speed and perform the hook storing operation.

3-73

HANDLING Operations Preparing to start moving 1. Set the safety lock lever to the lock position. The machine

cannot travel if the safety lock lever is at the free position. 2. Turn the fuel adjustment dial (1) to the full speed direction to

increase the engine speed. SUPPLEMENTAL If the engine speed does not go up, the one-touch deceleration switch may be ON. Check the status of the switch on the one-touch deceleration monitor. See the section “One-touch deceleration switch (3-13)” for the operation of the one-touch deceleration switch.

3-74

Operations HANDLING Moving forward 1. Operate the left and right traveling levers (3) or left and right

traveling pedals (4) as described below.

• When the sprocket (A) is in the back of the machine body. Push the lever (3) slowly forward or slowly press down on the front of the pedal (4) to move the machine forward.

• When the sprocket (A) is in front of the machine body. Pull the lever (3) slowly toward you or slowly press down on

the back of the pedal (4) to move the machine forward. SUPPLEMENTAL • The machine cannot travel unless the safety lock lever is at the lock position.

• The hook store may get loosened due to vibration during traveling. In this case, perform the hook-storing operation again.

3-75

HANDLING Operations Moving backward 1. Operate the left and right traveling levers (3) or left and right

traveling pedals (4) as described below.

• When the sprocket (A) is in the back of the machine body. Pull the lever (3) slowly toward you or slowly press down on

the back of the pedal (4) to move the machine forward.

• When the sprocket (A) is in front of the machine body. Push the lever (3) slowly forward or slowly press down on the

front of the pedal (4) to move the machine forward. SUPPLEMENTAL • The machine cannot travel unless the safety lock lever is at the lock position.

• The hook store may get loosened due to vibration during traveling. In this case, perform the hook-storing operation again.

3-76

Operations HANDLING Stopping

WARNING Avoid sudden stops. Try to stop well in advance whenever possible. Move the left and right traveling levers (1) to the N (neutral) position. The machine will stop.

3-77

HANDLING Operations

Steering the machine Steering (Changing direction)

WARNING Check the track frame direction (sprocket position) before operating the traveling levers. If the sprocket is in front of the machine, the direction of traveling levers you operated and the direction the machine moves are the other way around. Operate the traveling levers to change the direction. Avoid sudden direction change whenever possible. In particular, spin turns shall be carried out after the machine stopped moving. Operate two traveling levers (1) as described below. Changing machine direction when being stopped Push the right traveling lever forward to turn to the left while moving forward. Pull the lever backward to turn to the left while moving backward. SUPPLEMENTAL Operate the left traveling lever in the same way to turn to the right.

3-78

Operations HANDLING When changing direction to left/right while driving straight Return the left driving lever to the neutral position to turn to the left.

SUPPLEMENTAL Operate the right traveling lever in the same way to turn to the right. Spin-turning on the spot Pull the left traveling lever toward you and push the right traveling lever forward to spin-turn to the left. SUPPLEMENTAL Pull the right traveling lever toward you and push the left traveling lever forward to spin-turn to the right.

3-79

HANDLING Operations

Swing the machine

WARNING • Check safety around before swinging. • Honk the horn to give the signal before swinging. • Operate the levers gently. Sudden lever operation while hoisting a load is

especially dangerous, causing horizontal swing of the load. 1. Operate the left implement operation lever (1) to swing. 2. Keep the left implement operation lever (1) at N (neutral)

position when not swinging. This will apply the swing brake.

3-80

Operations HANDLING

Handling operation mode Using the operation mode changeover switch, you can switch the operation mode to the one appropriate for the operation conditions or purpose for efficient operation. Follow the procedure below for effective use of the operation mode. Each time you press the operation mode switch, the mode switches between active mode (for normal works) and E mode (for works focusing on fuel consumption). SUPPLEMENTAL The mode is set automatically to active mode (for normal works) when the engine is started.

Operation Mode Lamp (E) Appropriate Work Set Rotating Speed During Work* (rpm)

Active mode (For normal works)

OFF Normal crane operation 2,020 + 50

E mode (For works focusing on fuel consumption)

ON Normal crane operation (when focusing on fuel

consumption)

1,850 + 100

* : The set rotating speed is the one given with the fuel adjustment dial at the full speed position with

no load. SUPPLEMENTAL Setting the fuel adjustment dial to the full speed position and switching to E mode (for works focusing on fuel consumption) will slightly lower the engine speed. This is normal.

3-81

HANDLING Operations

Cautions before crane operation

WARNING Set the moment limiting device accurately according to the crane operation to be conducted. The moment limiting device calculates the moment based on the switches set. Setting differently from the actual operation will cause failures given below. Exercise caution when setting the switches. Example. • Number of wire rope falls in actual operation: 2 • Number of wire rope falls on the setting switches: 4

(the switch for 2 canceled) Setting as shown above will result in the moment

limiting device calculating the load for “four wire rope falls” state. Therefore, even if the load is getting close to overloading in reality, there will be no pre-warning or warning.

In addition, exceeding the rated load can break the wire ropes. Be very careful in setting switches.

• Always keep the vehicle leveled in performing the operation.

• The moment limiting device calculates the moment assuming that the vehicle is leveled. Operating with the vehicle not leveled will result in no pre-warning and warning issued even if the operation is getting close to the hazardous range.

3-82

Operations HANDLING

Crane operation overview This section describes the issues regarding crane operation. The relationship between operation levers and implement is shown in the figure on the right. See the details given in the order shown below. (1) Left implement control lever (2) Right implement control lever (3) Winch two-speed switch (4) Horn switch (5) Acceleration pedal (5) Fuel adjustment dial (6) Safety lock lever Description order • Hoisting/Lowering operation: See the section

“Hoisting/Lowering operation (3-85)”.

• Boom derricking operation: See the section “Boom derricking operation (3-87)”.

• Boom extending/retracting operation: See the section “Boom extending/retracting operation (3-88)”.

3-83

HANDLING Operations • Swing operation: See the section “Swing operation (3-89)”.

• Operation speed adjustment: See the section “Adjustment of operation speed (3-89)”.

• Traveling hoist operation: See the section “Traveling with suspended load operation (3-91)”.

• Hook storing operation: See the section “Hook storing operation (simplified storage) (3-92)”.

3-84

Operations HANDLING

Hoisting/Lowering operation

WARNING • Note that when hoisting a load, the load moves

slightly forward due to flexure of the boom. • When lowering the hook for long distance due to

underground operation, etc., be sure to keep 3 turns or more of wire ropes on the winch drum.

IMPORTANT • Do not let the hook touch the ground. This will cause

loose and irregular winding of the wire ropes.

• Do not return the lever suddenly to the N (neutral) position when stopping the hoisting/lowering operation. This will cause loose and irregular winding of the wire ropes.

Normal hoisting/lowering operation Operate with the right operation lever (2) as follows;

• Hoisting: Pull the lever toward you.

• Stop: Return the lever to the neutral position (Release your hand slowly from the lever)

• Lowering: Push the lever gradually forward. Adjust the hoisting/lowering speed with the stroke of the right

operation lever (2) and pressing on the acceleration pedal (5). SUPPLEMENTAL • When hoisting the winch by canceling the overwinding

warning, the pump flow rate automatically drops and the winch hoisting speed slows. This is not a failure.

• When the overwinding stop switch is pressed, the red lamp of the external indicator illuminates.

3-85

HANDLING Operations High-speed hoisting/lowering operation While carrying out normal hoisting/lowering operation, operate the winch two-speed switch (3) on the switch box as described below.

• Press the winch two-speed switch (3). The winch operates at high speed and the switch lamp illuminates.

• Press the winch two-speed switch (3) again. The winch operation returns to low speed and the switch lamp goes off.

SUPPLEMENTAL • Winch high-speed hoisting/lowering operation should be carried out only with no load. With the hoisted load of 0.5 t or more, switching the winch two-speed switch to high-speed position

does not change the operation speed to high speed. Decrease the hoisted load to 0.2 t or lower in order to perform high-speed hoisting/lowering operation.

• When derricking the boom, the moment limiting device actual load value slightly changes due to pressure change in the derricking cylinder.

With the moment limiting device actual load value of 0.5 t or more, switching the winch two-speed switch to high-speed position does not change the operation speed to high speed.

3-86

Operations HANDLING

Boom derricking operation

WARNING • Do not lower the boom to exceed the dangerous angle given in the rated total load

chart. The machine may turn over. • Pulling in or pulling up a load using the boom raising operation is prohibited.

Always hoist a load using the hook hoisting operation. IMPORTANT • Note that lowering the boom with a load hoisted will

result in overloading due to load swing.

• When lowering the boom, operate the lever gently. Operate the right operation lever (2) as follows;

• Raise the boom: Pull the lever rightward (inward).

• Stop: Return the lever to neutral position (Release the hand slowly from the lever).

• Lower the boom: Push the lever leftward (outward).

3-87

HANDLING Operations

Boom extending/retracting operation

WARNING Operational precautions • Do not pull a load from the side or pull in a load. • The hook will be hoisted/lowered during the boom extending/retracting operation.

Perform winch operation at the same time to adjust the hook height. • If the boom is left extended for a long time, the boom slightly retracts due to

change in operating oil temperature. In this case, extend the boom appropriately. IMPORTANT • When extending/retracting the boom with a hoisted load,

operate the levers gently whether the load is large or small.

• Extending the boom hoists the hook at the same time. Pay attention to overwinding.

• The boom can be extended as long as the hoisted load does not exceed the rated total load at the operating radius. Extending the boom with a hoisted load is likely to result in overloading. Pay close attention to the overloading.

Operate with the left operation lever (1) as described below.

• Extending: Push the lever forward.

• Stop: Return the lever to the neutral position (release your hand slowly from the lever).

• Retracting: Pull the lever toward you. SUPPLEMENTAL • When the boom extends, the second boom extends first, and

then the third, fourth and fifth boom all extend at the same time.

• When the boom retracts, it retracts in the reverse order of extending the boom.

• As the boom extends and the hook hoists the weight of the overwinding protector, the boom extension stops. When the hook has hoisted the weight of the overwinding protector, performing the extending operation does not extend the boom. In this case, lower the hook.

3-88

Operations HANDLING

Swing operation

WARNING • Honk the horn to give a signal before swinging. • Operate the levers gently. Sudden lever operation,

especially with a hoisted load, is dangerous, causing side swing of the load.

Operate with the left operation lever (1) as described below.

• Left swing: Push the lever leftward (outward).

• Stop: Return the lever to the neutral position (release your hand slowly from the lever).

• Right swing: Pull the lever rightward (inward). SUPPLEMENTAL • There is a horn switch (4) at the center of the right operation

lever knob. Use this horn to give a signal for swing operation.

• The rated load is the same in all directions regardless of the swing stop position.

Adjustment of operation speed

WARNING Increasing the speed of the implement more than necessary is dangerous. Adjust the operation speed using both the fuel adjustment dial (6) and acceleration pedal (5). SUPPLEMENTAL Perform operations at reasonable speed such as slowing the speed near the end of each operation or changing the speed between low-speed and high-speed depending on the load.

3-89

HANDLING Operations

Operation posture Adopt the operation posture as described below when changing from the traveling posture to operation. 1. Push the right operation lever forward and lower the winch

but do not let the hook touch the ground. 2. Pull the right operation lever inward to raise the boom up to

the angle at which the hook does not issue overwinding and the hook does not touch the ground.

3-90

Operations HANDLING

Traveling with suspended load operation

WARNING When traveling with a hoisted load, observe the following. • As a rule, traveling with a hoisted load is prohibited since it is very unstable and

comes with some danger. If you absolutely have to perform traveling with a hoisted load, perform the

operation with the rated total load for traveling hoist. • Do not perform the crane operation when traveling with a hoisted load. • The rated total load for traveling hoist is the value of the load the machine can

travel with on the leveled solid ground after hoisting the load while still. Never perform traveling hoist on the slope or on the soft ground.

• Check the ground state, the situation around, and the operation state before driving.

• Do not change the speed while traveling. • Switch the traveling speed switch to Low (low-speed traveling) and slow the engine

speed. Drive slowly, maintaining the load near the ground to avoid load swing. • Do not perform sudden accelerations, sudden stops and sudden steering. The load

will swing and it is very dangerous. 1. Press the still/travel mode switch on the moment limiting

device and check that the red indicator is ON. SUPPLEMENTAL • As soon as the machine starts traveling, the machine is

automatically set to the "traveling hoist" mode and the indicator turns on.

• The traveling speed does not change to high speed even by switching the traveling speed switch to high speed if the hoisted load weighs 0.5 t or more. Decrease the weight of the load to 0.2 t or less for high-speed traveling. Note that even in this condition, the Hi lamp is illuminated.

2. Switch the traveling speed switch to LOW (low-speed traveling).

3. Check that the high-speed traveling lamp is OFF.

3-91

HANDLING Operations

Hook storing operation (simplified storing)

CAUTION • Always lower the boom to store the hook. Storing

the hook with the boom raised will damage the rubber on the top of the hook.

• Do not derrick the boom when the hook is stored. This will damage the rubber on the top of the hook.

• Do not perform the hook storing operation with the emergency switch ON. This will not switch the machine to hook storing mode and the rubber on the top of the hook, boom and wire ropes can be damaged.

IMPORTANT • Put the boom in the traveling posture (boom fully

retracted and lowered) before operating the overwinding stop switch.

• Stop the swing of the hook before hoisting the winch and storing the hook.

• Perform the hoist operation slowly. Do not store the hook with the winch hoisting operation at high-speed

1. Fully retract the boom. 2. Hoist the hook (1) to just below the weight for detecting

overwinding (2). 3. Fully lower the boom and press on the acceleration pedal. 4. Hoist the winch while pressing on the overwinding stop

cancel switch to store the hook at the specified position. SUPPLEMENTAL • Press the overwinding stop switch only when an overwinding

alarm is issued. You cannot cancel the auto stop when the overload limit

warning or operation range restriction limit warning is issued.

• When hoisting the winch after pressing the overwinding stop switch, the flow rate automatically drops and the hoisting speed slows down. This is not a failure.

• Pressing the overwinding stop switch turns on the red lamp of the external indicator.

3-92

Operations HANDLING

Things not allowed during operation

WARNING • If you have to operate the left or right operation

lever during traveling, pause traveling and then operate the operation lever. This machine is designed not to perform the crane operation even if an operation lever is used during traveling.

See the section of precautions in the Safety chapter. No operation using swing force Pulling in or pulling up a load with swing operation is prohibited. No operation using derricking force Pulling in or pulling up a load with boom-derricking operation is prohibited. No pulling from the side, pulling toward you or hoisting diagonally Pulling from the side, pulling toward you, and diagonal hoisting applies unreasonable force on the vehicle. This not only damages the vehicle, but also is dangerous. Never operate the machine for these purposes. Keep the hook right over the center of the gravity of the hoisted load.

3-93

HANDLING Operations No rough handling during operation Do not perform sudden lever operations. Perform swing especially at low speed. No entry within the operating radius Keep people away from the operating radius, such as prohibiting workers from going under the hoisted load. No usage of the machine for other purposes than major applications. Do not move workers up/down with the crane. No unreasonable operations Operations that exceed the performance of the machine will cause accidents. In particular, the crane operation must be carried out according to the rated load chart.

3-94

Operations HANDLING No wire windup by force Exercise caution not to hook the wires on trees or steel beams during operation. If the wires get entangled around something, do not wind up the wire by force. Untangle the hooked wire and then wind up the wire. No operations during traveling hoist The load may swing and the machine can turn over during traveling hoist. Do not change the traveling speed or perform swing operation or crane operation during traveling hoist. No sudden lever operations during high-speed traveling • Do not carry out any sudden lever operations that will cause

sudden acceleration.

• Do not carry out any sudden lever operations from forward to backward (or from backward to forward).

• Do not carry out any sudden lever operations (sudden release of the hand from the levers) that will cause a sudden stop from nearly maximum speed.

3-95

HANDLING Operations

Cautions during operations Cautions during traveling Traveling by going over an obstacle such as a fallen rock or stump will impose a great shock on the vehicle body (especially around the feet), leading to some breakage in the machine. Avoid or remove the obstacles so that you will not have to go over them, as much as possible. If you have to go over an obstacle, take the traveling posture (boom lowered and hook stored) and keep the center of gravity as low as possible. Decrease the traveling speed to as low as possible and go over the obstacle at the center of the crawlers. Cautions during high-speed traveling Slow the speed to low-speed traveling (Lo illuminated) when driving on uneven roadbeds with base rocks or uneven tracks with loose stones. Direct the idler wheel to the traveling direction when traveling at high speed (Hi illuminated). Permitted water depth

CAUTION • Adopting climbing posture for an acute angle of

more than 15 degrees when getting out of water can submerge the back of the top revolving superstructure. This will result in the radiator fans scooping water, and the fan can break while doing so.

Exercise caution when getting out of water. In the posture shown in the figure on the right, the

machine can turn over. Always direct the boom to the lower side when climbing/going down the slope.

Use the machine in the water at the depth that covers the machine up to the center of the upper tracker roller (1) or lower. Grease thoroughly the section submerged in the water for a long time until the old grease comes out of the bearing.

3-96

Operations HANDLING Cautions on going uphill/downhill

WARNING • A slope of 15 degrees or more involves a turnover

hazard. Do not drive on such a slope. • Store the hook by hooking it over the hooking wire

of the vehicle when traveling on the slope. Do not go backward to go down the slope or go

forward to go up the slope if the slope is more than 10 degrees.

• Lower the boom and drive slowly when going over the obstacles.

• Never change the direction on, or drive across, the slope. Go down to flat land and go around for safe driving.

• When operating on the slope, the moment limiting device does not function properly. Never swivel or operate the implement on the slope. The machine may lose balance and turn over. If you absolutely have to do it, place some earth fill to keep the machine as level as possible.

• Operate and drive in a condition in which you can stop safely anytime the machine slips or becomes unstable.

SUPPLEMENTAL If the vehicle leans for more than 15 degrees with the slope, the slope alarm is activated and the buzzer sounds to notify the driver of the condition. If the traveling direction has a sharp inclination, do not travel further.

3-97

HANDLING Operations When going down a steep slope, use the traveling levers, fuel adjustment dial and acceleration pedal to keep the traveling speed at low speed. When climbing/going down a slope of 10 degrees or more, adopt the posture shown in the figure on the right and slow the engine speed for driving. Braking while going down the slope Returning the traveling lever to the neutral position automatically puts on the brake. If the engine stops If the engine stops while climbing up, return the traveling lever to the neutral position before re-starting the engine. Cautions on the slope • On the slope, the swing operation with the left implement operation lever may actually swing the

implement with its own weight even if the engine is being stopped. Never attempt to perform the swing operation.

• Do not open/close the sliding door during the operation or traveling on the slope. The operation force can suddenly change.

Always keep the sliding door locked.

• Pay sufficient attention when opening/closing the sliding door while the machine is being stopped. The door can open/close suddenly with the door weight.

3-98

Operations HANDLING

Parking the machine

WARNING • Park the machine on a solid, level location. Avoid

parking the machine on a slope. If you absolutely have to park on a slope, provide a

wheel block to prevent the machine from moving, and sink the implement into the ground.

• Careless contact with an operation lever can result in sudden movement of the implement or machine, leading to serious injuries. Always move the safety lock lever to the lock position without fail before standing up from the cab seat.

1. Release your foot from the acceleration pedal (5). 2. Return the left and right traveling levers to the N (neutral)

position. 3. Turn the fuel adjustment dial (6) to the low idling position and

decrease the engine speed. 4. Move the safety lock lever (4) to the lock position.

3-99

HANDLING Operations

Inspection and check after stopping the engine Check the engine coolant temperature (1), engine oil pressure light (2) and remaining fuel level (3) on the machine monitor.

Inspection and check after completing the operation (1) Check for oil/water leakage and perform a walk-around check around the implement, the exterior,

and around the feet. If you find any leakage or abnormality, repair the section. (2) Fill up the tank with fuel. (3) Remove papers and waste in the engine room and around the battery. They can catch fire. (4) Remove the dirt, etc. stuck around the under carriage of the machine.

Locking Always lock the following locations. (1) Operation cab door section (2) Fuel tank filler opening (3) Engine hood SUPPLEMENTAL The starter switch key is used to lock all of these sections.

3-100

Operations HANDLING

Handling wire ropes How to hook winch wire ropes and the rated load

• Determine the number of hook wire rope falls according to the load to be hoisted, boom length and hoisting speed.

• Use the machine in such a way that the load per wire rope fall is 1.25 t or lower.

Hook Type Hook for 2 or 4 Wire Rope Falls Hook for 4 Wire Rope Falls Number of Wire Rope Falls 4 4

Hook Method

Rated Load 4.9 t 4.9 t Hook Weight 90 kg 60 kg

Hook Type Hook for 2 or 4 Wire Rope Falls Hook for 1 Wire Rope Fall Number of Wire Rope Falls 2 1 Hook Method

Rated Load 2.45 t 1.22 t Hook Weight 90 kg 20 kg

3-101

HANDLING Operations Hooking winch wire ropes

WARNING Always wear thick leather gloves when removing or hooking wire ropes. IMPORTANT • Pay attention to irregular winding of wire ropes.

• Lowering the hook onto the ground with the lowering operation after the hook has reached the ground will result in irregular winding of the wire ropes in the winch drum.

Remove wire ropes with the following procedure. 1. Install the vehicle on solid, level ground. Fully retract the

boom to have a boom angle of about 20 degrees. 2. From the state described in 1., “lower” the winch so that the

hook almost touches the ground. 3. Lower the hook onto the ground with the boom-lowering

operation. 4. Loosen the bolt (3) and remove the wedge socket pin (2) to

remove the wire socket (1) from the boom. 5. Remove the wire clip (4). 6. Remove the wire rope (9) from the wire socket (1) as

described below.

• Have a round rod with a length of 6 to 10 mm (8) ready. Put the rod onto the rope wedge (5), and hammer the rod lightly in the direction of the arrow (a). Remove the rope wedge (5).

7. Remove the wire rope (9) from the hook. 8. Remove the wire rope (9) from the weight (10) of the

overwinding protector. 9. See the section “Removing wire ropes (3-115)” for how to

remove the wire ropes. 10. See the wire-rope hooking method to hook the wire rope.

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Operations HANDLING Replacing wire ropes The wire rope fatigues over time. Replace the wire rope when the following symptoms are observed. Wire rope replacement indication IMPORTANT • In principle, observe ISO 4309:1990 (E) as well as the legal restrictions applicable to the

place where the crane is used, such as the criteria when replacing a wire rope.

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HANDLING Operations Removing wire ropes IMPORTANT • Pay attention to irregular winding of wire ropes.

• Lowering the hook onto the ground with the lowering operation after the hook has reached the ground will result in irregular winding of the wire ropes in the winch drum.

Remove the wire rope with the following procedure. 1. Install the vehicle on solid, level ground. Fully retract the

boom to have a boom angle of about 20 degrees. 2. From the state described in 1., “lower” the winch so that the

hook almost touches the ground. 3. Lower the hook onto the ground with the boom-lowering

operation. 4. Loosen the bolt (3) and remove the wedge socket pin (2) to

remove the wire socket (1) from the boom. 5. Remove the wire clip (4). 6. Remove the wire rope (9) from the wire socket (1) as

described below.

• Have a round rod with a length of 6 to 10 mm (8) ready. Put the rod onto the rope wedge (5), and hammer the

rod lightly in the direction of the arrow (a). Remove the rope wedge (5).

7. Remove the wire rope (9) from the hook. 8. Remove the wire rope (9) from the weight (10) of the

overwinding protector. 9. After rewinding the wire rope (9) from the drum (6), then

finally remove the wire rope (9) secured on the drum (6) as follows.

• Put the round rod (8) onto the rope wedge (7), and hammer the rod lightly in the direction of the arrow (b). Remove the rope wedge (7)

10. Remove all the remaining wire rope (9), and this completes the removal of the wire rope.

3-104

Operations HANDLING Installing wire ropes

WARNING • Install the wire rope and rope wedges properly. • Be careful not to cause irregular winding. IMPORTANT Right after installing a new rope, extend and raise the boom to its maximum and hoist a load of about 1000 kg, and repeat the hook hoisting and lowering operation several times to condition the rope. Install a wire rope with the following procedure. 1. Hold a rope end and pass the wire rope (9) through the

sheave at the end of the boom (left sheave when seen from the boom end), boom guide sheaves, roller sheave and slide sheave.

2. Pass the wire rope (9) through the rope-mounting hole on the

drum (6) and secure the wire rope (9) to the drum (6).

• Loosen the wire rope (9) and pass the rope into the drum (6). Insert the rope wedge (7) into the position (a) and hook the wire rope (9). Tug the rope in the direction of the arrow.

3. While applying some tension to the wire rope, slowly hoist the

winch and rewind the wire rope (9) onto the drum.

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HANDLING Operations 4. Pass the wire rope (9) through the sheave at the end of the

boom and hook sheaves according to the number of wire rope falls.

5. Secure the end of the wire rope (9) to the wire socket (1) as

described below. • Pass the wire rope through the wire socket (1) as shown

in the figure on the right, and insert the rope wedge (5) into the position (a). Tug the wire rope (9) in the direction of the arrow.

6. Install the rope clip (4) to the wire rope (9). 7. Extend and raise the boom to its maximum. 8. With some tension applied to the wire rope (9), hoist the

winch to rewind the wire rope (9).

3-106

Operations HANDLING What to do with twisted wire ropes When the wire rope gets twisted, straighten the twist with the following procedure. 1. With the hook in working condition, check the twisting

direction and how many times the rope is twisted. 2. Fully retract the boom to have a boom angle of about 20

degrees, and lower the hook so that the hook almost touches the ground. Lower the boom to put the hook on the ground.

If you cannot lower the hook, lower or retract the boom to lower the hook.

3. Move the safety lock lever (1) to the lock position and stop the engine.

4. Remove the wire rope socket. 5. Forceably twist the end of the wire rope in the hook twisting

direction you checked in 1. for n (the number of wire rope falls) times of the number hook is twisted for and install the wire rope.

6. With the longest boom length and the maximum boom-derricking angle, repeat the hoisting/lowering operation of the hook several times.

7. Tidily spool up the wire rope into the winch drum with some

tension applied to the rope. 8. Repeat the procedure above until there is no twist to the

hook. If the twist cannot be straightened after performing the procedure above, change the wire rope to a new one. SUPPLEMENTAL Change the hooking direction of the wire rope (inverse the hook side and winch drum side) from time to time to extend the life of the wire rope.

3-107

HANDLING Operations

Inspection and adjustment of wire ropes for extending boom Make adjustments if the wire ropes for extending the boom are in the state shown in the figure below. Inspection of wire ropes 1. Make the boom flat. Check if the wire ropes for extending booms hang down 30 mm or more at the

center during the boom-retracting operation. If a wire rope hangs 30 mm or more, see the section “Adjusting wire ropes” to adjust the wire rope. 2. Make the boom flat and then fully retract the boom.

Check if the gap between the boom (3) and (4) (gap a in the figure on the right) and boom (4) and (5) (gap b in the figure on the right) is 5 mm or more.

If the gap is 5 mm or more, see the section “Adjusting wire ropes” to adjust the wire rope.

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Operations HANDLING Adjusting wire ropes There are four wire ropes for extending the booms. There is an adjustment order among these four wire ropes. Always follow the adjustment order given below to make adjustments. IMPORTANT Be careful not to apply too much tension to the wire ropes when adjusting them. 1. Fully retract the boom and make the boom flat. Extend the booms that extend/retract at the same

time for about 3 m. 2. Retract the boom slowly to the stowing position. In this condition, measure the dimension of gap a and gap b and make the adjustment described below.

• If gap a is 5 mm or more, adjust the wire rope (6) for retracting boom (4).

• If gap a is 0, make adjustments starting at “Adjusting the wire rope (7) for extending boom (4)” in 4.

3-109

HANDLING Operations 3. Adjusting the wire rope (6) for retracting the boom (4) 1) Loosen the lock nut (10) and tighten the adjustment nut

(11) evenly between left and right, in the tension direction of the wire rope (6) for retracting, until gap a becomes 0.

2) If gap a is 5 mm or more, even after operations and measurements of 1., 2., and 3. of the procedure, make adjustments again.

4. Adjusting the wire rope (7) for extending the boom (4)

1) Loosen the lock nut (12) and tighten the adjustment nut (13) evenly between left and right, in the tension direction of the wire rope (7) for extending the boom (4), until right before the boom (4) starts to extend.

2) Turn the left and right adjustment nuts (11) for the wire rope (6) for the retracting boom (4) for just one turn to apply additional tightening.

3) Secure the adjustment nuts (11) and (13) of the wire ropes (6) and (7) for retracting/extending the boom with the lock nuts (10) and (12) respectively.

4) If gap b is 0 after operations and measurements of 1., 2., and 3. of the procedure, make adjustments described in 6. “Adjusting wire rope (9) for extending boom (5)”.

5. Adjusting the wire rope (8) for retracting the boom (5) 1) Loosen the lock nut (14) and tighten the adjustment nut

(15) evenly between left and right, in the tension direction of the wire rope (8) for retracting, until gap b becomes 0.

2) If gap b is 5 mm or more even after operations and measurements of 1., 2., and 3. of the procedure, make adjustments again.

6. Adjusting the wire rope (9) for extending the boom (5) 1) Loosen the lock nut (16) and tighten the adjustment nut

(17) evenly between left and right, in the tension direction of the wire rope (9) for extending the boom (5), until right before the boom (5) starts to extend.

2) Turn the left and right adjustment nuts (15) for the wire rope (8) for retracting the boom (5) for just one turn to apply additional tightening.

3) Secure the adjustment nuts (15) and (17) of the wire ropes (8) and (9) for retracting/extending the boom (5) with the lock nuts (14) and (16) respectively.

3-110

Operations HANDLING

Handling the moment limiting device

WARNING Do not turn off the power to the moment limiting device and do not fix the emergency switch to the OFF position while working. Doing so will cause the hoisted load to fall, breakage of the boom, or the vehicle to turn over due to overloading, leading to serious injuries which could result in death. IMPORTANT Be careful not to allow any water for washing, or rain, to splash over the operation section and display section of the moment limiting device. Moment limiting device display section (1) Moment ratio LED (16) Check Setting button (2) Actual load display (17) Cancel Setting button (3) Rated total load display (18) Overwinding detection LED (Red) (4) Boom angle display (19) One wire fall LED (Green) (5) Actual working radius display (20) Two wire falls LED (Green) (6) Rated working radius display (21) Four wire falls LED (Green) (7) Boom length display (22) Sub-boom 1 selection LED (Orange) (8) Lifting height display (23) Sub-boom 2 selection LED (Orange) (9) Number of wire falls switch button (24) Boom angle upper limit LED (Green) (10) Sub-boom selection button (25) Boom angle lower limit LED (Green) (11) Still/Travel mode switch button (26) Operating radius upper limit LED (Green) (12) Boom angle upper limit setting button (27) Lifting height upper limit LED (Green) (13) Boom angle lower limit setting button (28) Travel mode LED (Red) (14) Working radius upper limit setting button (29) Still mode LED (Orange) (15) Lifting height upper limit setting button (30) Moment ratio indicator (External indicator) Switch No. 10 and lamps (LEDs) No. 22, and 23 are not used.

3-111

HANDLING Operations Cautions before operating the moment limiting device

WARNING • Set the moment limiting device accurately

according to the crane operation to be conducted. The moment limiting device calculates the moment based on the switches set.

Setting differently from the actual operation will cause failures given below. Exercise caution when setting the switches.

Ex) • Number of wire rope falls in actual operation: 2 • Number of wire rope falls on the setting switches: 4

(the switch for 2 canceled) Setting as shown above will result in the moment

limiting device calculating the load for “four wire rope falls” state. Therefore, even if the load is getting close to overloading in reality, there will be no pre-warning or warning.

In addition, exceeding the rated total load can break wire ropes. Be very careful in setting switches.

• Always keep the vehicle leveled in performing the operation.

• The moment limiting device calculates the moment assuming that the vehicle is leveled. Operating with the vehicle not leveled will result in no pre-warning and warning issued even if the operation is getting close to the hazardous range.

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Operations HANDLING Moment limiting device functions Overload alarm 1. Pre-alarm

When the actual load value reaches 90 % or more of the rated load value, a pre-alarm is issued.

• “Load Ratio” 90 % LED (orange) illuminates.

• Alarm buzzer intermittently sounds, “peep, peep”. 2. Limit alarm

When the actual load value reaches 100 % or more of the rated load value, a limit alarm is issued.

• You will hear “Peep, overloaded.”

• Alarm buzzer sounds continuously.

• Machine automatically stops. (See the section Auto stop) 3. Canceling the limit alarm auto stop

The auto stop caused by an overload limit alarm issued is canceled when the cancel input (emergency switch) is turned on.

SUPPLEMENTAL • The external indicator illuminates the blue lamp when the load ratio is lower than 90 %, the yellow

lamp between 90 % to 100 %, and the red lamp at 100 % or more.

• Moving the moment limiting device emergency switch to ON (clear) position illuminates the red lamp of the external indicator.

Operation range restriction alarm 1. Limit alarm

When the value reaches the stored set value for the operation range restriction, a limit alarm is issued.

• The applicable “Operation range restriction” LED illuminates.

• Alarm buzzer sounds intermittently.

• The yellow lamp of the external indicator illuminates.

• Machine automatically stops. (See the section Auto stop) Overwinding alarm 1. Overwinding state

When the machine enters the overwinding state (overwinding input is OFF), an overwinding alarm is issued.

• The “Overwinding” LED flashes.

• The alarm buzzer intermittently sounds “peep, peep” when extending or hoisting the boom.

• Machine automatically stops. (See the section Auto stop)

3-113

HANDLING Operations Auto stop

Operation Restriction Range

Overload Alarm

Overwinding Alarm Max. Lifting

Height Max.

Working Height

Max. Boom Angle

Min. Boom Angle

Hoist Raise Lower Extend

Operations that are disabled

upon auto stop

Auto How to cancel the auto stop Turn on the

moment limiting device

emergency switch

Press the overwinding stop switch

Press the applicable setting button for more than 1 second. (For each registered value)

Press the Check Setting button and Cancel Setting button simultaneously for more than 5 seconds. (For all the

registered values)

Still/Travel mode switch display 1. Travel mode

The rated total load is changed to the one for travel mode when the still/travel mode switch button is switched to travel.

• The “Travel” LED illuminates. 2. Still mode

The rated total load is changed to the one for still mode when the still/travel mode switch button is switched to still.

• The “Still” LED illuminates. Number of wire falls switch display 1. Single wire fall

The rated load is changed to the one for single wire fall when the number of the wire falls switch button is switched to 1.

• The “1” LED illuminates. 2. Two wire falls

The rated load is changed to the one for two wire falls when the number of the wire falls switch button is switched to 2.

• The “2” LED illuminates. 3. Four wire falls

The rated load is changed to the one for four wire falls when the number of the wire falls switch button is switched to 4.

• The “4” LED illuminates.

3-114

Operations HANDLING Setting operation state

WARNING • Do not perform sudden reclining of the boom. The machine can turn over. • When swinging with hoisted load or when hoisting the load to leave the ground,

the operating radius becomes greater due to flexure of the vehicle and booms. Pay sufficient attention to this.

• Hoisted load The hoisted load does not include hook weight and hooking metal weight. Hook weight: 90 kg

• Number of wire falls Refer to the rated load chart in “Dimensions (5-2)” to determine the number of wire falls on the hook. Operate the wire falls switch button to set the number of wire falls.

• Actual load and rated total load display When the moment limiting device functional check is completed after turning the starter switch to the ON position, the moment limiting device operation part makes a diagnosis and displays the values. The actual load and rated load values displayed include the hook weight. Actual load display Displays the weight of the hoisted load. This section displays the hook weight if no load has been hoisted. SUPPLEMENTAL If the hook has four wire rope falls and is hoisting no load, 0.1 t, which is the hook weight (0.0 t depending on the boom conditions), appears on the display. Rated total load display The rated total load that can be hoisted appears on the display, considering the hook wire rope falls, boom length, operating radius, and conditions such as traveling hoist or still hoist.

3-115

HANDLING Operations Lifting height and boom length display

Lifting height display The maximum height from the ground to the bottom of the hook is given on the display.

Boom length display The length from the boom foot pin to the sheave pin at the end of the boom is given on the display.

3-116

Operations HANDLING Boom angle, actual working radius, and rated working radius display Boom angle display The boom angle is given on the display.

Actual operating radius display The horizontal distance from the center of the swing to the center of the hook is given on the display.

Rated operating radius display The rated working radius given by the actual load and boom length is displayed.

3-117

HANDLING Operations Crane operation at the site with restricted operation range

WARNING Even if the operation range is set with the registration setting, the values may exceed the set values depending on the operation speed of the boom. Always keep a distance from obstacles and operate at low speed when setting values. When the operation range of the boom is restricted due to operation site conditions, you can set the operation range of the boom to the range you want. During registration setting, press the Check Setting button for 3 seconds or more to display the set value registered on the display. When the boom position reaches the set position registered, the LED (indicator) illuminates and the buzzer sounds to notify the operator, and the crane operation automatically stops. IMPORTANT Be sure to check that the boom stops at the set position after setting the operation range of the boom. Setting boom angle upper limit Move the boom to have the angle you would like to set, and press the boom angle upper limit-setting button for more than 3 seconds. The boom angle upper limit LED illuminates and the value is registered. When the boom angle reaches the registered angle during operation, the boom angle upper limit LED illuminates and the buzzer sounds. Press the boom angle upper limit setting button for more than 1 second to cancel the alarm. Setting boom angle lower limit Move the boom to have the angle you would like to set, and press the boom angle lower limit-setting button for more than 3 seconds. The boom angle lower limit LED illuminates and the value is registered. When the boom angle reaches the registered angle during operation, the boom angle lower limit LED illuminates and the buzzer sounds. Press the boom angle lower limit setting button for more than 1 second to cancel the alarm.

3-118

Operations HANDLING Setting working radius upper limit Move the boom to have the working radius you would like to set, and press the working radius upper limit-setting button for more than 3 seconds. The working radius restriction indicator illuminates and the value is registered. When the working radius reaches the value set in this setting through boom lowering or boom extension during operation, the restriction indicator illuminates and the buzzer sounds. Press the working radius upper limit-setting button for more than 1 second to cancel the alarm. Setting lifting height upper limit Move the boom to have the working radius you would like to set, and press the lifting height upper limit-setting button for more than 3 seconds. The lifting height restriction indicator illuminates and the value is set. When the lifting height reaches the value set in this setting through boom raising or boom extension during operation, the restriction indicator illuminates and the buzzer sounds. Press the lifting height upper limit setting button for more than 1 second to cancel the alarm. Canceling all settings Press the Check Setting button and Cancel Setting button simultaneously for more than 5 seconds to cancel all the settings.

3-119

HANDLING Operations Setting operation conditions

WARNING Set the mode properly. Setting a wrong mode will prevent the moment limiting device from functioning properly. If the moment limiting device does not function, this can cause overloading, resulting in serious accidents due to hoisted loads falling, boom breakage, or vehicle turnover. The rated total load given on the display of the moment limiting device changes depending on the selection of the still/travel mode switch button and the number of wire falls switch button. The load to be hoisted is determined by the pressure in the derricking cylinder and changes depending on the number of wire rope falls on the hook.

• Moment limiting device display

• Still/Travel mode switch button

• Number of wire falls switch button

3-120

Operations HANDLING Switching still/travel mode

WARNING When the Still mode lamp is ON, do not use the traveling hoist. Doing so will result in serious accidents such as vehicle turnover or breakage of the hoisted load. Select the still/travel mode switch button according to the operating conditions. See the section “Traveling hoist operation (3-91)” when performing the traveling hoist operation. 1. When you do not need to travel with a hoisted load, press the

button to switch to Still mode. The Still mode selection lamp illuminates.

SUPPLEMENTAL Switching the still/travel mode switch button to Travel mode or operating a traveling lever while the boom length is 10.2 m or more sounds the buzzer, and an error code “E-07” is given on the rated operating radius display. In this case, shorten the boom length to 10.1 m or less. The error code disappears and the crane operation is enabled again. 2. When traveling with a hoisted load, press the button to switch

to Travel mode before hoisting the load. The Travel mode selection lamp illuminates.

3-121

HANDLING Operations Switching the number of wire falls The wire ropes have an established safety load per rope. Determine the number of wire rope falls according to the maximum load to be hoisted. The standard specification is the hook that can be used for 2 wire rope falls and 4 wire rope falls. SUPPLEMENTAL Because the hoisting force is normally greater than the braking force, aggressive hoisting may not allow you to brake. The hoisting force per wire rope is determined by the safety factor of the rope and the braking force. Match the number of wire rope falls and the number of wire rope falls on the moment limiting device reading. Press the number of wire rope falls switch button on the moment limiting device display for more than 3 seconds to set the number of wire rope falls that agrees with the number of wire rope falls on the hook. 1: Hook position for single wire rope fall 2: Hook position for two and four wire rope falls 4: Hook position for four wire rope falls or for two and four wire

rope falls Moment limiting device emergency switch

WARNING • Do not hoist a load while the moment limiting device emergency switch is ON

(boom auto stop function canceled). • Do not leave the emergency switch key on the machine. The owner should always

manage and store the key. You can cancel the auto stop function of the moment limiting device as required for inspection and maintenance of the machine. Insert the moment limiting device emergency switch key into the emergency switch and turn the key to the ON side to cancel the function. Releasing your hand from the key automatically returns the key to the OFF side, activating the auto stop function. Should you lose the moment limiting device emergency switch key, contact us or our sales service agency. SUPPLEMENTAL Turning the key on the moment limiting device emergency switch to the ON (canceled) position illuminates the red lamp of the external indicator.

3-122

Operations HANDLING Overwinding protector When the hook hoists the weight on the wire rope for detecting overwinding upon the hook hoist or boom extension, the buzzer intermittently sounds to notify the operator of the overwinding. At the same time, the hook hoist and boom extension automatically stops and the overwinding lamp on the moment limiting device display flashes. Perform the recovery operation promptly when the operation stops automatically. SUPPLEMENTAL The buzzer sounds only when the hoisting operation is performed with the right operation lever and extending operation with the left operation lever. The buzzer does not sound when the left or right operation lever is moved to other positions or returned to N (neutral) position. SUPPLEMENTAL When hoisting the hook, pay attention to the clearance between the hook and boom. Extending the boom also hoists the hook. Always check the hook height while carrying out the boom-extending operation. Recovery operation from auto stop Lower the hook or retract the boom to lower the hook. Overwinding down protection device If the wire rope remaining in the winch drum shortens to five turns when winding down the hook, the limit switch activates, and the hook winding down operation automatically stops. Promptly execute the recovery operation when this automatic stop happens.

3-123

HANDLING Transportation Cautions during use

WARNING • Setting the operating condition wrongly can result in the machine breaking or

turning over. Set the switches properly and always check the setting when using these switches.

• Do not handle this machine in any way other than those specified in this instruction manual. This system model has been approved by the Japan Crane Association. Do not change the system configuration such as by modification.

• Do not touch the moment limiting device other than the display.

• Keep the moment limiting device display clean. Wipe off dirt and oil immediately with a soft cloth.

• The moment limiting device display is an electrical product installed in the cabin. Do not splash water directly on the display or expose the display to wind and rain.

• Always use your fingers to operate the push-button switches on the moment limiting device display.

• Do not apply excessive shock on the moment limiting device display and detector (sensor). Do not leave the display for a long time at locations where there will be direct sunlight, or hot or humid locations.

• If the power voltage falls below DC 22 V, this may prevent the system from functioning properly. Check the battery regularly without fail.

Transportation When transporting, observe the relevant legal restrictions that apply to the place of transportation.

3-124

Transportation HANDLING

Loading/Unloading the machine to/from trailer

WARNING • Load/Unload the machine to/from the trailer always

at low speed. Do not change the traveling speed during loading/unloading.

• Keep the engine at low speed and operate slowly while loading/unloading the machine.

• Select flat and solid ground for loading/unloading the machine.

Keep sufficient distance from the shoulders. • Use loading ramps with sufficient width, length,

thickness and strength, and install them securely with a slope of 15 degrees or less.

If you use earth fill, thoroughly compact the earth fill so that the slope does not collapse.

• Remove dirt around the feet to prevent any side slip of the machine on the loading ramps.

Remove any materials on the loading ramps such as water, snow, ice, grease and oil.

• Never change direction on the loading ramps. The machine can turn over.

Go back to the road or to the back of the truck and change direction.

• Do not perform any operation on the loading ramps except traveling.

• The center of gravity moves suddenly at the edge between the loading ramp and the trailer, and the machine may lose balance. Pass over the edge slowly.

• The lorry platform is too unstable to swing the crane on it. Fold the boom and swivel slowly.

• Check that the cab sliding door is always locked, whether you are closing or opening the door. Avoid opening/closing the door on the loading ramp. Doing so can cause a sudden shift in the centre of gravity.

• Direct the sprockets and counterweight to the trailer and load the machine from the back.

Always use loading ramps or forwarding blocks when loading/unloading the machine with the following procedure.

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HANDLING Transportation Loading 1. Load the machine on level, solid ground. Keep sufficient

distance from the shoulders. 2. Brake the trailer securely. Place wheel blocks to the wheels

of the trailer to secure the trailer. Keep the slope of the loading ramps to 15 degrees or lower. 3. Hang the hook over the hooking wire of the vehicle for

storage. 4. Switch the traveling speed changeover switch to low traveling

(Lo illuminates). 5. Decrease the engine speed to low. 6. Direct the sprocket and counterweight side to the trailer side. 7. Check that the machine is positioned straight toward the

loading ramps and that the center line of the machine and that of the trailer are in line before getting the machine on the loading ramps.

Determine the direction toward the loading ramps and drive slowly.

Do not operate any levers other than traveling levers on the loading ramps.

8. Stop the machine at the specified position on the trailer.

3-126

Transportation HANDLING Cautions in loading

WARNING Select flat and solid ground to load the machine. Keep sufficient distance from the shoulders. Load the machine to the specified position and secure the machine with the following procedure. 1. Store the hook in the specified position. 2. Stop the engine and remove the starter switch key. 3. Lock the operation levers without fail with the safety lock

lever. 4. Provide a square timber in front and back of the track shoes

to prevent the machine from moving. Secure the machine with chain or wire rope of appropriate strength. Secure it strongly, especially so as not to let it slip to the side.

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HANDLING Transportation Unloading 1. Unload the machine onto the flat and solid ground. Keep

sufficient distance from the shoulders. 2. Brake the trailer securely. Place wheel blocks to the wheels

of the trailer to secure the trailer. Keep the slope of the loading ramps at 15 degrees or lower. 3. Remove the chain or wire rope that secures the machine. 4. Start the engine. Perform a sufficient warm-up operation when it is cold. 5. Move the safety lock lever to the free position. 6. Change the engine speed to low speed. 7. Switch the traveling speed switch to low traveling (Lo

illuminates). 8. With the counterweight in the back, determine the direction

toward the loading ramps and drive slowly. Do not operate any levers other than traveling levers on the loading ramps.

3-128

Transportation HANDLING

How to hoist the machine Only those who have obtained applicable local and national authorization are permitted to hoist using a crane.

WARNING • Do not perform the hoisting operation with a worker on the vehicle. • The wire rope used in hoisting must be sufficiently strong for the weight of this

machine. • Do not hoist the vehicle in a posture other than those described in the following

procedure. The vehicle may lose its balance. • Do not hoist the vehicle with the bottom of the vehicle swiveled. • Use shackles as hoisting brackets to hook the wire rope securely. • Pay attention to the position of the center of gravity while hoisting, to balance the

machine. Hoist the vehicle on solid and flat ground using the following procedure. IMPORTANT • Refer to the section “Dimensions (5-1)” for the weight of the machine.

• The dimensions are for standard specifications. The hoisting method varies depending on the attachments and options mounted. In that case, contact us or our sales service agency.

3-129

HANDLING Transportation How to hoist the machine with the boom lowered • Use four hoisting wire ropes of the same standard.

• Breaking force: 18.7 t or more

• Use four shackles of the same standard.

• Working load: 3.0 t or more IMPORTANT When the machine is hoisted with the hook stored at the end of the boom, the boom will raise due to the vehicle weight, preventing the machine from being hoisted. When hoisting the machine with the boom lowered, always secure the hook and boom to the vehicle main body using the hooking wire rope. 1. Hang the hook over the hooking wire rope and move the

boom so that it adopts the posture shown in the figure on the right. Secure the hook and boom to the vehicle main body.

2. Lock the levers securely with the safety lock lever. 3. Install shackles at four locations (A and B) on the crane

boom. Using the hoisting hook, install the wire rope so that the wire rope hoisting angle is 60 degrees or less. The hoisting hook should come to the center of gravity at this point.

4. Check that there is no posture change caused by leakage from the hydraulic circuit on the derricking cylinder head side when the machine is hoisted.

5. After the machine has left the ground, check the hook condition and hoisting posture. Then slowly hoist the machine.

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Transportation HANDLING How to hoist the machine with the boom raised

• Use two hoisting wire ropes of the same standard.

• Breaking force: 36.0 t or more

• Use two shackles of the same standard.

• Working load: 7.0 t or more 1. Retract all the booms and raise the boom to 80 degrees.

Store the hook block. See the section “Hook storing operation (simplified storing)

(3-92)”. 2. Swing so that the sprockets are positioned in the back of the

vehicle. 3. Securely lock the safety lock lever. 4. Install shackles at two locations on the crane frame to hook

the hoisting wire rope. Before hoisting the machine, place some cushion where the hoisting wire rope and the vehicle come into contact.

5. Check that there is no posture change caused by leakage from the hydraulic circuit on the derricking cylinder head side when the machine is hoisted.

6. After the machine has left the ground, check the hook condition and hoisting posture. Then slowly hoist the machine.

SUPPLEMENTAL The machine will tilt forward for about 8 degrees when hoisted with the boom raised.

3-131

HANDLING Handling in the Cold Weather

Handling in Cold Weather Preparing for low temperatures When the temperature goes down, the machine starts to have some difficulty in starting and the cooling water may freeze. Take the following actions. Fuel and lubricating oil Change the oil to one with low viscosity. See the section “How to use fuel and lubricating oil according to temperature (7-4)” for specified viscosity. Cooling water

WARNING • Antifreezing fluid is harmful. Exercise caution not to have the fluid come into

contact with your eyes and skin. Should it come into contact with your eyes or skin, wash the affected area well with clean water and consult a physician immediately.

• Ask a specialized company or contact our sales service agency to dispose of the cooling water (to which antifreezing fluid is added) drained at the time of the cooling water replacement or radiator repair. Antifreezing fluid is harmful. Do not release it into a drain or sprinkle it on the ground.

• Antifreezing fluid is inflammable. Do not put the fluid close to fire and do not smoke while handling the fluid.

IMPORTANT Never use antifreezing fluid with methanol, ethanol, or propanol. See the section “Cleaning inside the cooling water system (4-13)” for the cooling water replacement period and the mixing rate of antifreezing fluid. Battery

WARNING • The battery produces combustible gas. Do not put fire close to the battery. • Battery fluid is a harmful substance. Keep it away from your eyes and skin. Should

it come into contact with your eyes or skin, wash the affected area with plenty of water and consult a physician immediately.

• Battery fluid melts paints. Wash the affected area immediately with water, should the fluid come into contact with the machine.

• Do not charge the battery or start the engine with another power supply when the battery fluid is frozen. The fluid may explode.

• Battery fluid is harmful. Do not release it into a drain or sprinkle it on the ground. The battery capacity drops when the temperature goes down. In this condition, the battery fluid can freeze at a low battery charging rate. Keep the charging rate as close as possible to 100 %. Keep the battery warm in order to start the engine next morning.

3-132

Handling in the Cold Weather HANDLING SUPPLEMENTAL Measure the specific gravity of the battery fluid and convert it into the charging rate using the chart below. Fluid Temperature (°C) Charging Rate (%)

20

0

-10

-20

100 1.28 1.29 1.30 1.31 90 1.26 1.27 1.28 1.29 80 1.24 1.25 1.26 1.27 75 1.23 1.24 1.25 1.26

• The battery capacity falls dramatically when it is cold. Cover the battery or remove the battery from the machine and leave it somewhere warm. Then, reinstall the battery the next morning.

• If the battery fluid level is low, refill with distilled water before starting the operation next morning. To prevent freezing during the night, do not refill with distilled water after operation.

Cautions after completing the operation

WARNING Crawlers in an idle running state is dangerous. Do not approach crawlers. Observe the following to prevent the machine from not being able to function the next morning due to deposits such as dirt and water and materials frozen around under carriage.

• Remove any dirt and water on the machine. Keep the hydraulic cylinder rod especially clean to prevent the seal from being damaged by dirt coming into the seal and also by waterdrops on the rod.

• Park the machine on solid, dry ground. If there is no such place to park, place a board on the ground to park the machine on the board.

This prevents the freezing of the ground and around the under carriage of the machine, to allow the machine to start moving next morning.

• Open the drain cock to drain the water in the fuel system to prevent the water from freezing.

• After any operation that has submerged the machine in water or dirt, drain the water around the feet in order to extend the life of the components around the feet.

When the cold weather is over When the season changes and it starts to get warm, take the following action.

• Change the oil in the system to one with specified viscosity, according to the section “How to use fuel and lubricating oil according to the temperature (7-4)”.

3-133

HANDLING Long-Term Storage

Long-Term Storage Before storing the machine IMPORTANT The machine should adopt the posture shown in the figure on the right during storage, to protect the piston rod of the hydraulic cylinder. (To prevent rust on the piston rod of the cylinder) Store the machine as described below for long-term storage (1 month or more).

• Wash and clean each section of the machine and store it indoors. If you absolutely have to leave it outdoors, select a flat location and cover the machine, for example with some sheeting.

• Fill up the fuel tank. This prevents the accumulation of moisture.

• Refuel, grease and change the oil without fail.

• Apply some grease to the exposed section of the hydraulic cylinder piston rod.

• Disconnect the negative terminal of the battery and cover, or dismount the battery from the machine for storage.

• Lock the operation levers with the safety lock lever.

During storage

WARNING If you have to perform the antirust operation indoors, open the window and the entrance for better ventilation, in order to prevent gas poisoning.

• Be sure to operate the machine once a month during storage and prevent lack of oil film at the lubricating section. Also charge the battery at the same time.

• Wipe off the grease applied to the hydraulic cylinder rod when operating the implement.

• For vehicles with air conditioning, be sure to operate the air conditioning once a month for 3 to 5 minutes at low idling speed to keep the oil lubricating the air conditioner compressor section. Also check the coolant gas level twice a year.

After storage IMPORTANT Contact our sales service agency when using a machine on which you have not performed a monthly antirust procedure. Perform the following procedure and then use the machine after long-term storage.

• Wipe off the grease applied to the hydraulic cylinder piston rod.

• Make sure that fuel and oil are provided to the refueling and refilling section.

• The moisture in the air mixes into the oil during long-term storage. Check the oil at each section before and after starting the engine. If water is mixed in the oil, change all the oil.

3-134

Troubleshooting HANDLING

Troubleshooting Non-failure phenomena The following phenomena are not failures.

• Some noise from the braking valve in the beginning and at the end of the swing operation.

• Some noise from the traveling motors when going down the sharp slope at low speed.

• Some noise from around the valves when the boom-derricking cylinder is released at a lowered position.

How to tow the machine

WARNING Use a wire rope with sufficient strength to tow the weight of the machine. When the machine gets stuck in the mud and cannot get out of it, or when towing a heavy object use the wire rope as shown in the figure on the right to tow the object. Place a splint between the wire rope and the vehicle body to prevent damage by the rope to the vehicle body. Do not use the hook equipped on the truck frame for this.

3-135

HANDLING Troubleshooting

When the battery is discharged

WARNING • Charging the battery while the battery is on the

vehicle is dangerous. Always remove the battery before charging.

• Stop the engine and turn the starter switch key to the OFF position when checking/handling the battery.

• The battery produces hydrogen gas, involving an explosion hazard. Do not put fire such as cigarettes close to the battery and do not do anything that could cause sparks.

• The battery fluid is diluted sulfuric acid. This corrodes clothes and skin. Should the battery fluid come into contact with your clothes or skin, wash the affected area immediately with plenty of water.

Should it go into your eye, wash your eye immediately with clean water and consult a physician.

• Wear goggles and rubber gloves when handling the battery.

• Disconnect the ground side (normally - terminal) first to remove the battery, and conversely, connect the + terminal first to install the battery.

Objects such as tools coming between the + terminal and the machine body will cause sparks. Be very careful.

• A slackened terminal can cause sparks with poor contact, involving an explosion hazard.

Install terminals securely. • Check the + terminal and - terminal when

removing/installing the battery.

3-136

Troubleshooting HANDLING Removing/Installing the battery IMPORTANT Check that the battery does not move after securing it. If it moves, secure it again.

• Hold the battery check cover (1) handle and lift the cover up to open the cover.

• Remove the battery by disconnecting the ground side (normally - terminal) first.

Note that objects such as tools coming between the + terminal and the machine body will cause sparks.

• Connect the ground side last when installing the battery.

• Securely fix the battery unit with the battery mounting metals (2) when replacing the battery.

The tightening torque of the mounting nuts (3): 3.92 to 5.88 N• m {0.5 to 0.6 kgf• m}

SUPPLEMENTAL Depending on the battery type, a low battery fluid level and low battery charge indicator may be equipped with the battery. If so, take action according to the readings on the indicators given below.

• Blue (A): Normal. The battery should always show this color.

• Red (B): The fluid level may be low. See the section “Checking battery fluid level (4-12)” to refill the battery with water.

• White (C): The battery charge may be insufficient. See the section “Cautions in charging the battery (3-137)” to charge the battery.

Cautions in charging the battery Wrong handling while charging the battery can cause the battery to explode. Follow the section “What to do with this phenomenon (3-140)” and the instruction manual provided with the charger, and observe the following.

• Adjust the voltage of the charger according to the voltage of the battery to be charged. Setting the wrong voltage can cause the charger to be overheated and catch fire, leading to an explosion.

• Secure the (+) charging clip of the charger to the (+) terminal of the battery, and then the (-) charging clip to the (-) terminal of the battery, without fail.

• The charging current should be set to 1/10 or lower of the battery rated capacity. With the quick charger, set the charging current to the battery rated capacity or lower.

3-137

HANDLING Troubleshooting • An excessive charging current can result in fire and explosion, due to fluid leakage or lack of fluid.

• Do not charge the battery or start the engine with another power supply when the battery fluid is frozen.

The battery fluid can catch fire and explode.

• Do not use or charge the battery when the battery fluid level is at lowest (LOWER LEVEL) or lower.

Doing so can cause an explosion. Regularly check the battery fluid level and refill the battery with distilled water up to the highest level (UPPER LEVEL).

Starting the engine with the booster cable

Start the engine with the booster cable as described below.

Cautions in connecting/disconnecting the booster cable

WARNING • Never connect the (+) terminal and (-) terminal when

connecting the cable. • Wear goggles and rubber gloves when starting the

engine with the booster cable. • Do not let the machine which is working normally

and the machine which is failing to come into contact with each other.

Because the battery produces hydrogen gas, sparks around the battery can cause an explosion.

• Do not make mistakes in connecting the booster cable. Note that there will be some sparks when making the last connection (the connection to the top revolving superstructure frame). Make this connection at the location as far as possible from the battery. (However, avoid the implement, since it is difficult to obtain continuity.)

• Do not let the booster cable clips make contact with each other or with the machine when disconnecting the booster cable.

IMPORTANT • Use the booster cable and clips of appropriate size for the battery size.

• Use the battery of the same capacity in the machine which is working normally and the machine which is failing.

The starting system of the machine which is failing uses 24 V. Use 24 V in the machine which is working normally also.

• Check that the cable and clips are not broken or corroded.

• Connect the clips securely.

• Check that the safety lock lever and parking brake lever are at the lock position in both of the machines.

• Check that the levers are at the neutral position.

3-138

Troubleshooting HANDLING Connecting the booster cable Turn the starter switch of both of the machine which is working normally and the machine which is failing to the OFF position. Connect the booster cable in the numerical order shown in the figure. 1. Connect a clip of the booster cable (A) to the (+) terminal of

the machine which is failing. 2. Connect the other clip of the booster cable (A) to the (+)

terminal of the machine which is working normally. 3. Connect a clip of the booster cable (B) to the (-) terminal of

the machine which is working normally. 4. Connect the other clip of the booster cable to the top

revolving superstructure frame of the machine which is failing. Starting the engine

WARNING Check that the safety lock lever is at the lock position in both the machine which is working normally and the machine which is failing. Also check that the levers are at the neutral position. 1. Check that the clips are securely connected to the battery terminals. 2. Start the engine of the machine which is working normally and keep the engine at full speed

(highest speed). 3. Turn the starter switch of the machine which is failing to START to start the engine.

If the engine does not start, wait more than 2 minutes before re-starting. Disconnecting the booster cable When the engine starts, disconnect the booster cable in reverse order of connecting it. 1. Disconnect the clip of the booster cable (B) connected to the

top revolving superstructure frame of the machine which is failing.

2. Disconnect the clip of the booster cable (B) connected to the (-) terminal of the machine which is working normally.

3. Disconnect the clip of the booster cable (A) connected to the (+) terminal of the machine which is working normally.

4. Disconnect the clip of the booster cable (A) connected to the (+) terminal of the machine which is failing.

3-139


What to do with this phenomenon Electrical components

• Make sure that you contact our sales service agency for the actions indicated in parentheses in the Actions field.

• Ask our sales service agency for repair if you suspect any other abnormality or causes other than those given below.

Abnormal Phenomenon Major Cause(s) Actions Dark light even at highest engine speed Light blinks during engine operation

• Defective wiring • Improper fan belt tension

adjustment

• (Check and repair slackened terminals and open circuits)

• Adjust fan belt tension, referring to the section "Maintenance for every 250 hours"

Battery charge monitor remains illuminated even after the engine starts

• Defective alternator • Defective wiring

• (Replace) • (Check and repair)

Abnormal noise from alternator • Defective alternator • (Replace) Starter not rotating even after the starter switch is turned to START

• Defective wiring • Insufficient battery charge

• (Check and repair) • Charge the battery

Starter piston going out and in repeatedly (struggling)

• Insufficient battery charge • Charge the battery

Starter key turning slowly • Insufficient battery charge • Defective starter

• Charge the battery • (Replace)

Starter disengaged before the engine starts

• Defective wiring • Insufficient battery charge


Warm-up monitor not illuminating • Defective wiring • Defective monitor


Engine oil pressure monitor not illuminating even while the engine is stopped (With starter switch at ON position)

• Defective monitor • Defective hydraulic switch

• (Replace) • (Replace)

While the deceleration monitor is not ON, the fuel adjustment dial doesn’t work

• Defective relay • Defective acceleration motor • Defective controller

• (Replace) • (Replace) • (Replace)

Engine speed not decreasing/increasing even after pressing the deceleration switch

• Defective wiring • Fuse blown

• (Check and repair) • (Check and repair)

3-140

Troubleshooting HANDLING Machine body



Abnormal Phenomenon Major Cause(s) Actions Crane operation not working • Defective travelling pressure

switch • Defective solenoid valve • Defective safety lever limit switch

• Replace the switch • Replace the valve • Adjust/Replace the switch

Slow travelling, swing, boom, or hook speed Abnormal noise from pump

• Insufficient operating oil • Operating oil return filter or

suction filter clogged

• Refill to the specified oil level, referring to the section "Check before operation"

• Clean and replace the filter by referring to the section "Maintenance for every 250 hours and 1000 hours"

Operating oil temperature too high

• Dirty oil cooler • Slackened fan belt • Insufficient operating oil

• Clean • Refill to the specified oil level,

referring to the section "Check before operation"

Crawlers running off Abnormal wear on the sprockets

• Too much slack on the crawlers • Adjust the tension by referring to the section "Irregular maintenance"

3-141

HANDLING Troubleshooting Engine



Abnormal Phenomenon Major Cause(s) Actions Engine oil pressure monitor illuminating

• Insufficient oil level in the oil pan (air suctioned)

• Oil filter cartridge clogged • Oil leakage due to improper tightening or

breakage of oil pipe or pipe joint • Defective monitor

• Refill to the specified oil level, referring to the section "Check before operation"

• Replace the cartridge by referring to the maintenance for every 500 hours

• (Check and repair) • (Replace)

Steam blowing out of the top of the radiator (pressure valve)

Engine coolant temperature gauge red zone illuminating

• Insufficient cooling water, water leakage • Slackened fan belt • Accumulation of dust and water scale in

the cooling water system • Clogged radiator fin or fin fallen • Defective thermostat • Loose radiator filler cap (for operation on

highway) • Defective water level sensor

• Check refill cooling water, and repair referring to the check before operation

• Adjust the fan belt tension by referring to the maintenance for every 250 hours

• Change the cooling water and clean inside the cooling water system by referring to the maintenance for every 500 hours

• (Replace the thermostat) • Tighten the cap or change the

packing • (Replace the sensor)

Engine coolant temperature white range illuminating even after long hours of operation

• Defective thermostat • (Replace the thermostat)

Engine does not start even after the starter key is turned

• Insufficient fuel • Air mixed into the fuel system • Defective fuel jet pump or nozzle • Starter key turned too slowly • Warm-up monitor not illuminating • Improper compression • Improper valve clearance

• Refuel by referring to inspection • Repair air-mixed section by

referring to the maintenance for every 500 hours

• (Replace the pump or nozzle) • See the table for Electrical

components • See the table for Electrical

components • (Adjust valve clearance)

White or bluish exhaust • Excess oil in the oil pan • Improper fuel • Sudden acceleration right after starting in

the cold weather

• Refill to the specified oil level, referring to the check before operation

• Change to the specified fuel • Avoid sudden acceleration until

the warm-up operation is complete Exhaust occasionally becoming black

• Air cleaner element clogged • Defective nozzle • Improper compression

• Clean or replace by referring to irregular maintenance

• (Replace the nozzle) • (See the section of "Improper

compression" above The engine occasionally misfires

• Defective nozzle • (Replace the nozzle)

Abnormal noise (Exhaust silencer or mechanical)

• Use of inferior fuel • Overheating • Breakage inside the muffler • Excess valve clearance

• Change to the specified fuel • See the section for "Engine

coolant temperature gauge red zone illuminating" above

• Replace the muffler • (Adjust valve clearance)

Engine stops during operation • Feed pump pre-filter clogged • Defective engine and combustion circuit

• Replace the filter cartridge • (Check and repair)

3-142

Troubleshooting HANDLING Electrical systems When an error code is displayed on the mechanical monitor display section (1), follow the table for self-diagnosis below. Actions for self-diagnosis Monitor Display Failure Mode Actions EO3 Error in swivel braking

system Turn on the swing parking brake cancel switch to cancel braking. Depending on the cause of the failure, the braking may not be cancelled. In any case, check the system immediately. (*)

EO5 The fuel adjustment dial is not working. Depending on the cause of failure, acceleration, deceleration or both of these operations may not be performed. In any case, check the system immediately.

Implement or swing operation not working, but no error code displayed

Check the system immediately.

(*) See the section “Switches (3-12)” for handling the swivel parking brake cancel switch.

3-143

HANDLING Troubleshooting Moment limiting device Error code on display Error Code Error details Actions Output activated E1L Pressure sensor 1 input lower

than the specified value E1H Pressure sensor 1 input higher

than the specified value

Check the installation of pressure sensor 1

E2L Pressure sensor 2 input lower than the specified value

E2H Pressure sensor 2 input higher than the specified value

Check the installation of pressure sensor 2

E3L Angle sensor input lower than the specified value

E3H Angle sensor input higher than the specified value

Check the installation of angle sensor

E4L Length sensor input lower than the specified value

E4H Length sensor input higher than the specified value

Check the installation of length sensor

E6L Internal reference voltage lower than the specified value

E6H Internal reference voltage higher than the specified value

Replace the part

E04 Error in memory for calibration Turn off the main switch and then turn it on again. If the error is displayed again, replace the part.

E05 Analogue/Digital converter stopped. Pressure, angle and length data cannot be computed.

Turn off the main switch and then turn it on again. If the error is displayed again, replace the part.

• Buzzer output • Red lamp output • Boom-raising, -lowering, -extending, and -hoisting operation stops

E06 Sub-boom selection operation despite the "Sub-boom presence switch" being at the OFF position.

Cancel the "Sub-boom selection"

E07 Travel mode selected in the travel mode prohibited area.

Cancel the selection of Travel mode or retract the booms so that the area accepts Travel mode.

(*) There is no option setting for sub-boom on this machine.

3-144

Troubleshooting HANDLING Activation errors When the moment limiting device display is normal Abnormal Phenomenon Major Cause(s) Actions

Defective relay circuit on the CPU card

Replace the part

Defective emergency switch on the instrument panel

Check and replace the emergency switch

Defective 5 port electromagnetic valve spool

Disassemble, repair or replace the 5 port electromagnetic valve

Operation does not stop even when overloaded

Short circuit in the emergency power supply circuit

Check, repair, or replace the wire harness between the part and the 5 port electromagnetic valve

Defective wire harness between the part and the 5 port electromagnetic valve

Extending, hoisting and lowering operations not activated, even when not overloaded.

Defective 5 port electromagnetic coil or spool

Disassemble, repair, or replace the 5 port electromagnetic valve

3-145

HANDLING Troubleshooting Troubleshooting (Failure diagnosis) If there is any operational error while using the moment limiting device, follow the procedure below to check the error. If there is no applicable item, or taking action to sort out the error does not correct the problem, replace the part with a working part. Ask us or our sales service agency to repair defective parts. Executing troubleshooting

WARNING If you changed a part or a sensor during troubleshooting, be sure to calibrate the part or sensor. Without calibration, you may not be able to obtain the correct measurement results or it may cause some malfunctions, leading to breakage of the peripheral devices and serious accidents.

Turn on the main switchagain

Start operation

n

Normal operation

Faulty operation

N.G.

O.K.

Turn on the main switchagain

Operatio

3-146


Execute troubleshooting

Turn on the main switch again

Display

Tm

2

NO

NO

YES

3-147

urn on the ain switch

Turn on the main switch

NO

YES

No open circuit in wires

1

Repair the open circuits YES


3-148

1

Power supplied

Fuse blown

Cable connection between controller

and display is normal

Supply power

Replace the fuse, referring to the section for how to

replace the fuse

Connect cable properly

(1) If there is no problem with the cable connection, change the connection cable. (2) If the problem is not corrected even after changing the connection cable, replace

the display section with a display section which is in working order. (3) If the problem is not corrected even after changing the display section, replace the

controller with a controller which is in working order.

NO

NO

NO

YES

YES

YES


2

Error code displayed

d

3

NO

YES

YES
'E1L' or 'E1H' displaye
3-1

'

NO

YES
'E2L' or 'E2H'displayed
'

YES

NO

'E3L' or 'E3H'displayed

YES

NO

E3L' or 'E3H' displayed

YES

NO


4

'YES

NO


9

4

NO

Check the connection cable of the pressure sensor 1. (1) If there is no problem with the cable, change the pressure sensor. (2) If the error code is not cleared even after changing the pressure sensor, replace the controller with a controller which is in working order.


Check the connection cable of the boom angle sensor. (1) If there is no problem with the cable, change the pressure sensor. (2) If the error code is not cleared even after changing the pressure sensor, replacethe controller with a controller which is in working order.

Re


Check the connection cable of the length sensor. (1) If there is no problem with the cable, change the pressure sensor. (2) If the error code is not cleared even after changing the pressure sensor, replace the controller with a controller which is in working order.

place the controller part with a controller which is in working order.


2

'E04' displayed

'E05' displayed

'E06' displayed

'E07' displayed

Normal

YES

YES

YES

YES

NO

NO

NO

NO

Replace the controller with a controller which is in working order.

Replace the controller with a controller which is in working order.
Check that the "Sub-boom 1 input" and "Sub-boom 2 input"are not connected. (1) If they are connected, disconnect them. (2) If not, or if the error code is not cleared even by disconnecting them, replace the controller with a controller which is in working order.
3-150

Check that the machine is in Travel mode and the boom length is within the Travel mode prohibited area. (1) If in the prohibited area, retract the boom so that it is out of the prohibited area or select Still mode. (2) if the machine cannot move out of the prohibited area even by retracting the booms, perform "Boom length display calibration". (3) If Still mode cannot be selected, check the connection of "Signal input during travelling". (4) If the error code is not cleared even after performing (1) to (3), replace the controller with a controller which is in working order..


3-151

YES

YES

YES

YES

NO

NO

NO

NO

3

Boom length display changes when

extending/retracting the boom

Wrong boom length

display

The working radius display changes

when derricking the boom

Wrong working radius

display

5

Check the cable of the length sensor for open circuit and disconnection. (1) If there is no problem with the cable and connectors, change the length

sensor. (2) If the problem is not corrected even after changing the length gauge,

replace the controller with a controller which is in working order.

(1)

(2

C(1)

(2

Ca

(1) I

(2)

Calibrate the boom length according to the calibration of boom length reading.

If the problem is not corrected even after calibration, replace the lengthsensor with a length sensor which is in working order.

) If the problem is not corrected even after changing the length gauge, replace the controller with a controller that is in working order.

heck the cable of the angle sensor for open circuit and disconnection. If there is no problem with the cable and connectors, change the angle

sensor. ) If the problem is not corrected even after changing the angle sensor,


librate the operating radius according to the calibration of the boom length and boom angle.

f the problem is not corrected even after calibration, replace the angle sensor with an angle sensor which is in working order.

If the problem is not corrected even after changing the angle sensor, replace the controller with a controller which is in working order.


3-152

Start operation

5

Correct control

outputs

Wrong overwinding

detection

Wrong actual load

display

Actual load display changes when the

load is hoisted

Check the connection cable of the control outputs for any abnormality. • If there is no problem with the cable, replace the controller with a

controller which is in working order. Calibrate the controller after replacement

Check the cable of the overwinding detector for open circuits, and the switch operation for any abnormality.

• If there is no problem with the cable, replace the controller with a controller which is in working order.

Calibrate the actual load according to the calibration of the actual load display.(1) If the problem is not corrected even after calibration, replace the pressure

sensor 1 with a pressure sensor which is in working order. (2) If the problem is not corrected even after changing the pressure sensor 1,

replace the pressure sensor 2 with a pressure sensor which is in working order.(3) If the problem is not corrected even after changing the pressure sensor 2,


Check that the monitor display of the pressure sensor 1 and 2 changes when a load is hoisted. Then, check the cable of any pressure sensor

whose display does not change for open circuit and disconnection. (1) If there is no problem with the cable and connectors, change the

pressure sensor whose reading did not change. (2) If the problem is not corrected even after changing the pressure

sensor, replace the controller with a controller which is in working order.

YES

YES

YES

YES

NO

NO

NO

NO


Errors in overwinding protector Abnormal Phenomenon Major Cause(s) Actions Operation does not stop even when overloaded

Short circuit in emergency power supply circuit

Check and replace the wire harness connecting the 5-spool-solenoid valve

1. Buzzer sounds (during boom extension/hoisting operation)

Defective overwinding cancel switch

Check and replace the overwinding cancel switch

2. Buzzer does not sound (during boom extension/hoisting operation)

Defective overwinding protector

Check and replace the overwinding protector

Extension/Hoisting operation not activated even when not overwound Defective overwinding detector

Check and replace the overwinding detector

Overwinding detector wire is broken or entangled

Check, repair or replace the wire for overwinding detection

Loss of overwinding weight Check and replace the overwinding detector weight

1. Buzzer sounds (during boom extension/hoisting operation)

Defective wire harness between the overwinding detector and controller

Check the wire harness between the detector and controller

Defective 5-spool solenoid valve coil or spool

Disassemble, repair or replace the 5-spool solenoid valve

2. Buzzer does not sound (during boom extension/hoisting operation)

Defective wire harness from the controller to the 5-spool solenoid valve

Check the wire harness between the controller and the 5-spool solenoid valve

3-153

Inspection and Maintenance

WARNING Read and understand the Safety chapter before reading this chapter.

Maintenance Precautions Inspection and Maintenance

Maintenance Precautions Do NOT perform any inspection or maintenance that is not described in this book. Check service meters Read the service meters every day, and check for any maintenance item that has reached the obligatory maintenance period. Replacement part When replacing, use Maeda genuine products as specified in the parts book. Grease to be used Use the greases specified in the descriptions of this manual. Use clean washer liquid Use a window washer liquid intended for use with automobiles, and be careful to prevent contamination by dust or anything else. Use pure oils and greases Use pure oils and greases, and use a clean container and prevent dust contamination. Check old oil and filter After replacing oil, check the old oil and existing filter before replacing the filter or doing related work, and if an excessive amount of metal powder or a foreign object is found, inform the personnel responsible and take appropriate measures. Cautions during oil fill Do NOT remove the filler strainer before filling. Cautions during welding repair • Shut down the power. (Turn off the start switch)

• Do NOT continuously apply 200V or greater voltage.

• Set the grounding within one (1) meter from the welding point. As an additional caution, grounding at a point near a meter/connector may result in a meter/gauge malfunction.

• Be sure to prevent a seal or bearing being inserted between the welding point and the grounding point. A seal or similar object may cause sparks that cause damage.

• Do NOT set the grounding near the boom pin or the hydraulic cylinder. Setting in this way may damage the plated section or elsewhere due to sparks.

Do NOT drop any object into the cab • Do NOT drop a bolt, nut or tool into the machine during inspection when the inspection

port or filler opening of the tank is open. A dropped object may cause the machine to be damaged or to malfunction, and may result in an accident. Make sure that you pick up anything that you drop.

• Keep anything which is not needed for the inspection out of your pockets when you are working.

4-1

Inspection and Maintenance Maintenance Precautions

Dusty site Be careful of the following when working in a dusty site.

• Occasionally check for air cleaner clogging using a dust indicator.

• Clean the radiator core beforehand to prevent clogging.

• Clean/replace the fuel filter beforehand.

• Make sure you clean the electrical parts, especially the starter and alternator, to prevent accumulation of dust.

• To prevent intrusion of dust, move the machine to a dustless location before the oil inspection/replacement.

Do NOT mix oils! Do NOT mix and use different types of oil under any circumstances. Replace the oil entirely when refilling with a different type of oil. Inspection cover lock Securely lock with a lockbar (securing bar) or other means before doing any maintenance with the inspection cover open. If you try to do any maintenance without locking, the inspection cover may abruptly close due to a gust of wind or any other reason, and may cause injury. Air release from hydraulic circuit Air inside the applicable circuit should be released after repairing/replacing any hydraulic device, and after disconnecting any hydraulic piping. Refer to "Hydraulic Circuit Air Release Procedure (4-24)" section for air release. Cautions when jointing hydraulic hose • After disjointing a section with seal material (O-ring or gasket) in, clean the joint surface

and replace with new material. Be sure to assemble the O-ring/gasket at this point.

• Do NOT bend the hose or joint to a radius that is too small. Otherwise the hose may be damaged and fail prematurely.

Checkup after inspection/maintenance Failure to check the inspection/maintenance causes unexpected defects that may result in personal injury, therefore be sure to observe the following.

• Post-work check (with engine stopped)

• Is there any inspection/maintenance that has not been carried out?

• Was inspection/maintenance work carried out without error?

• Was any tool or other part dropped? Any object inserted inside the lever related link mechanism is extremely hazardous.

• Is there any water leak, oil leak or a bolt that was not tightened?

• Checkup with the engine running

• Refer to "Maintenance on the operating engine by two people (2-32)" section when checking the operating engine, and pay full attention to safety.

• Is the inspection/maintenance target operating normally?

• Increase the engine idling, and check for fuel leaks and oil leaks. Fuel and lubricant types switched depending on air temperature The fuel and lubricant types should be switched depending on the air temperature. Refer to the "Air Temperature Dependent Fuel and Lubricant Use Method (7-4)" section for details.

4-2

Basic Maintenance Contents Inspection and Maintenance

Basic Maintenance Contents Oil/Fuel/Coolant Handling Oil • ALWAYS replace the oil after a fixed period, even if the oil is not dirty.

• Oils are used under extremely harsh conditions (high temperature, high pressure) of the engine or working device; therefore they degrade as the time of use goes on.

• ALWAYS use an oil that matches the grade and temperature of use written in the handling manual.

• Do NOT mix the oil with any other oil of different grade or brand.

• ISO VG32 is used as the hydraulic oil system oil at the factory shipment. Replace the standard oil quantity (100% of the capacity) before using ISO VG46 hydraulic

oil. Do NOT use any hydraulic oil that is not recommended by us, otherwise the filter may

clog. The small amount of oil remaining in the piping and cylinders does not cause a problem

even if mixed with other oil.

• The oils are equivalent to blood in the case of humans, so be careful to handle them without any impurities getting in (such as water, metal powder or dust).

Be especially careful to prevent impurities getting in during storage and oil fill. Most machine failures are caused by impurities getting in.

• Use the designated quantity of oil. Both excessive and insufficient oil causes failures.

• When replacing oil, ALWAYS replace the relevant filters as well.

• If a working device oil is cloudy, it is possible that air or water has gotten into the oil circuit. Consult our sales service agency.

Fuel • The fuel pump is a precision device, and becomes unable to operate when fuel containing

water or rubbish is used.

• Be careful to prevent impurities getting in during storage or when filling fuel.

• ALWAYS use the fuel written in the operation manual. The fuel is prone to coagulate under certain temperature of use (especially cold

temperature below -15 °C); therefore it should be changed to a fuel that matches the temperature.

• Fill the fuel tank to full each time you finish your daily work, to prevent condensation of the humid air inside the fuel tank that will result in moisture getting in.

• Release the condensation and water out of the fuel tank before starting the engine and also approximately 10 minutes after refilling the fuel.

• The air inside the circuit should be released when fuel becomes empty, and also after replacing a filter.

• Wash the tank and fuel system if any foreign object enters the fuel tank.

4-3

Inspection and Maintenance Basic Maintenance Contents

Cooling water • Insufficient cooling water can cause overheating, as well as corrosion and problems with

the cooling circuit due to air influx.

• River water contains large amounts of calcium and impurities. If used, river water results in the accumulation of substances in the engine and radiator, leading to heat exchange and other problems and possible overheating.

• Do NOT use any water that is not potable.

• Our vehicles are delivered with our specified antifreeze fluid. This antifreeze fluid effectively prevents corrosion of the cooling system parts and is

effective for two (2) years or 4,000 hours. Therefore, do not change the antifreeze fluid even when it is not winter.

• When using antifreeze fluid, observe cautions in the operation manual. Antifreeze fluids are flammable, so be fully careful with flames. The mixing ratio of the antifreeze fluid differs depending on temperature of the external atmosphere. Refer to "Cooling System Internal Cleaning (4-13)" for mixing ratio.

Grease • Grease prevents seizures of connections and other parts and prevents noise.

• The nipple not mentioned in the periodical maintenance chapter is the nipple used during overhauls, and does not require grease refilling.

Add grease when used or when grating noises are heard after long-term use.

• Wipe off the old grease that was pushed out after refilling grease. Be especially careful to wipe away grease mixed with sand or dust, as this accelerates

wear of moving parts.

Stocking and Storage of Oils and Fuels • Stock/store indoors to prevent impurities such as moisture or dust getting in.

• To store the drums long-term, place the drums horizontally, making sure that the drum bungs are below the liquid surface (to prevent humidity entering). When outdoor storage is unavoidable, take precautions such as covering with a waterproof sheet.

• To prevent degrading quality by long-term storage, use the oldest stored drums first.

Filter • Filters are extremely important safety valves that prevent failures caused by the intrusion

of a fuel or air circuit impurities. Periodically replace filters in accordance with the operation manual.

However, you should shorten the replacement period under certain harsh running conditions leading to oil or fuel (sulfur composition) being used up.

• Do NOT wash and reuse any (cartridge type) filter under any circumstances.

• After replacing an oil filter, check for any metal powder or similar stuck to the used filter. If it is, consult our sales service agency.

• Do NOT unpack the replacement filter until just before the use.

• Be sure to ALWAYS use genuine Maeda filters.

4-4

Basic Maintenance Contents Inspection and Maintenance

Handling Electric Parts • Electrical parts are extremely hazardous if wet or if the insulation is damaged as this can

cause operation problems due to leaking currents. Do NOT wash the inside of the cab with water and be sure to prevent water affecting the electrics when washing the chassis.

• Inspections and maintenance include belt tension inspection, belt damage checkup and battery fluid quantity inspection.

• Do NOT install any electric parts that are not made by Maeda.

• External disturbance via radio waves may cause the control system controller to malfunction, therefore contact our sales service agency before installing a radio or similar equipment in the vehicle.

• When working near a beach, treat the electrics well to prevent corrosion.

• Do NOT connect any nonstandard electrical part to a fuse, starter switch, battery relay or elsewhere.

4-5

Inspection and Maintenance Bolt/Nut Standard Tightening Torque

Bolt/Nut Standard Tightening Torque Torque List Table

WARNING Tightening by a non-standard torque can lead to loosening, breakage, mechanical failure and/or operational defects. Be careful when tightening. Tighten the metric bolts and nuts (that are without special markings) by the torques shown in this table. Whenever a bolt or nut needs to be replaced, ALWAYS use an identical, genuine Maeda product. Tighten the hoses by the torques in the following table.

Tightening Torque (N●m{kg●m}) Thread Outer

Diameter a (mm)

Width Across b (mm)

Target Value Tolerance

6 8 13

113{11.5} 172{17.5}

10 12 14

10

17 19 22

13.2{1.35} 31{3.2} 66{6.7}

11.8-14.7{1.2 to 1.5} 27-34{2.8 to 3.5} 59-74{6.0 to 7.5}

98-123{10.0 to 12.5} 153-190{15.5 to 19.5}

16 18

22

27 510{52.3} 688{70.3}

20

24

24

30 32 36

260{26.5} 360{37.0}

883{90.0}

235-285{23.5 to 29.5} 320-400{33.0 to 41.0} 455-565{46.5 to 58.0} 610-765{62.5 to 78.0}

785-980{80.0 to 100.0} 27 30 33 36 39

41 46 50 55 60

1295{132.5} 1720{175.0} 2210{225.0} 2750{280.0} 3280{335.0}

1150-1440{118.0 to 147.0} 1520-1910{155.0 to 195.0} 1960-2450{200.0 to 250.0} 2450-3040{250.0 to 310.0} 2890-3630{295.0 to 370.0}

4-6

Inspection and Maintenance List Inspection and Maintenance

Inspection and Maintenance List Maintenance Cycle List Initial 50 Hour Maintenance (Only the First Maintenance of a New Vehicle)........................ 4-9 • Hydraulic oil Filter Element Replacement .................................................................................. 4-9 Initial 250 Hour Maintenance (Only the First Maintenance of a New Vehicle)...................... 4-9 • Fuel Filter Cartridge Replacement ............................................................................................. 4-9 • Engine Oil Pan Oil Replacement and Engine Oil Filter Cartridge Replacement........................ 4-9 Non-routine Maintenance ........................................................................................................ 4-10 Inspection/Cleaning/Replacement of Air Cleaner....................................................................... 4-10 Battery Fluid Level Inspection .................................................................................................... 4-12 Cooling System Internal Cleaning .............................................................................................. 4-13 Water Separator Element Replacement..................................................................................... 4-15 Fuel Tank Internal Washing........................................................................................................ 4-16 Crawler Shoe Bolt Looseness Inspection/Retightening ............................................................. 4-17 Crawler Tension Inspection/Adjustment..................................................................................... 4-18 Air Conditioner Inspection and Maintenance.............................................................................. 4-22 Slide Door Rail/Roller Inspection,............................................................................................... 4-23 Cleaning and Grease Refilling.................................................................................................... 4-23 Hydraulic Circuit Air Relief Procedure ........................................................................................ 4-24 Check before starting operation ............................................................................................. 4-26 Maintenance Every 50 Hours................................................................................................... 4-27 Draining of Intruded Water/Sediment in Fuel Tank .................................................................... 4-27 Maintenance Every 100 Hours................................................................................................. 4-29 Swing Carry Case Oil Quantity Inspection and Refilling ............................................................ 4-29 Maintenance Every 250 Hours................................................................................................. 4-30 Final Drive Case Oil Quantity Inspection and Refilling............................................................... 4-30 Fan Belt Tension Inspection and Adjustment............................................................................. 4-31 Air Conditioner Compressor Belt Tension Inspection and Adjustment ...................................... 4-33 Maintenance Every 500 Hours................................................................................................. 4-34 Fuel Filter Cartridge Replacement.............................................................................................. 4-34 Engine Oil Pan Oil Replacement and Engine Oil Filter Cartridge Replacement........................ 4-35 Air Conditioner Internal/External Air Filter Cleaning................................................................... 4-36 Radiator Fin/Oil Cooler Fin/Condenser Fin Inspection and Cleaning ........................................ 4-38 Swing Circle Greasing ................................................................................................................ 4-39 Swing Pinion Grease Quantity Inspection and Refilling ............................................................. 4-39 Maintenance Every 1000 Hours............................................................................................... 4-40 Winch Reduction Gear Case Oil Replacement .......................................................................... 4-40

4-7

Inspection and Maintenance Inspection and Maintenance List

Hydraulic oil Return Filter Element Replacement....................................................................... 4-41 Hydraulic oil Line Filter Element Replacement........................................................................... 4-42 Swing Carry Case Oil Replacement ........................................................................................... 4-43 Final Drive Case Oil Replacement ............................................................................................. 4-44 Hydraulic oil Tank Oil Replacement and Suction Filter Cartridge Replacement........................ 4-45 Maintenance Every 2000 Hours............................................................................................... 4-47 Turbocharger Cleaning and Inspection ...................................................................................... 4-47 Alternator/Starter Inspection....................................................................................................... 4-47 Engine Valve Clearance Inspection and Adjustment ................................................................. 4-47 Maintenance Every 4000 Hours............................................................................................... 4-48 Water Pump Inspection .............................................................................................................. 4-48

4-8

Working Procedure Inspection and Maintenance

Working Procedures

Perform following maintenance after 250 hours operation, limited to the first maintenance of a new vehicle.

Initial 50-Hour Maintenance (Only the First Maintenance of a New Vehicle) Perform the following maintenance after 50 hours operation, limited to the first maintenance of a new vehicle. • Hydraulic oil Filter Element Replacement Refer to 250 Hour Maintenance for the maintenance method.

Initial 250-Hour Maintenance (Only the First Maintenance of a New Vehicle)

• Fuel Filter Cartridge Replacement • Engine Oil Pan Oil Replacement and Engine Oil Filter Cartridge Replacement Refer to 500 Hour Maintenance for the maintenance method.

4-9

Inspection and Maintenance Working Procedure

Non-routine Maintenance Inspection/Cleaning/Replacement of Air Cleaner

WARNING If you attempt to inspect/clean/maintain the engine when it is rotating, dust enters and damages the engine. Stop the engine before such work. When using compressed air, litter may become airborne and cause personal injury. Wear protective equipment such as goggles and a dust-resistant mask. Inspection If the red piston is indicated in the transparent section of the dust indicator (1), clean the air cleaner element.

Cleaning/Replacement of Element

IMPORTANT • Do NOT clean the element before the red piston is

indicated in the transparent section of the dust indicator (1).

If you frequently clean the element before the red piston is indicated, the air cleaner will not work fully and the washing efficiency will degrade.

1. Open the engine hood, remove three clips (2) and then remove the cover (3).

2. Take out the element (4), then cover the air connector side at

end of the air cleaner body with a clean cloth/tape to prevent dust intrusion.

3. Clean the air cleaner body inner side, cover (3) and actuator

valve (5).

4-10


4. Blow dry compressed air (0.69 MPa {7kgf/cm2} or lower) from inside the element along the folds, then blow from the outside along the folds, then blow again from the inside. 1) Replace an element after six (6) cleanings or when one

year has passed since its first use. 2) If the dust indicator indicated red soon after cleaning,

replace the element even if it has cleaned fewer than six times.

5. After cleaning, inspect the element inner side while

illuminating with a light bulb and replace it if any pore or thinned part is found.

IMPORTANT • When cleaning an element, do NOT damage it or hit an

object it. Do NOT use any element whose fold, gasket or seal is damaged.

Keep the unused elements packed and stored in a dry location.

6. Remove the cloth or tape cover that was attached to the air

connector at the end of the air cleaner body. 7. Install the new/cleaned element (4). 8. Install the cover (3) to the air cleaner body with the arrow on

the cover (3) facing upward, then secure with the clip (2). 9. Return the red piston to its previous condition by pushing the

dust indicator (1) button.

4-11


Battery Fluid Level Inspection Execute this operation before starting the vehicle.

WARNING • Do NOT attempt to use when the battery fluid level is at the LOWER LEVEL

(minimum fluid level line) or lower. If you do, the battery will degrade more quickly and which will shorten its life and may result in a rupture (explosion).

• Keep flames away from batteries as they generate combustible gas and there is a risk of explosions.

• Battery fluid is a hazardous substance. Avoid contact with your eye or skin and, if it makes contact, wash off with large amounts of water then seek medical advice.

• Do NOT refill the battery fluid level beyond upper fluid level limit (UPPER LEVEL). If you do, the fluid may leak out and damage painted surfaces and/or corrode parts.

IMPORTANT When there is a risk of freezing, refill the purified water (for example: commercially sold battery top-up fluid) before starting tomorrow's work, to prevent freezing. Inspect the battery fluid level at least once every month by the following regime: Fluid Level Inspection Method 1. Grasp handhold of the battery inspection cover (1),

then lift the cover (1) upward. 2. Remove the cap at the top of the battery, then check

the fluid level by peeking into the fluid inspection port. If the fluid level is below the sleeve, ALWAYS refill the purified water (for example: commercially sold battery top-up fluid) up to the lower end of the sleeve (maximum level: UPPER LEVEL).

3. Securely tighten cap (2) after refilling. SUPPLEMENTAL • If you fill beyond the lower end of the sleeve, extract using a pipette or similar tool until the

correct level is reached. To treat the extracted fluid, neutralize with baking sodium (sodium bicarbonate) or other agent then wash away with large amounts of water, or ask our sales service agency or the battery manufacturer.

When Fluid Level is Checkable by Indicator or Other Means If the fluid level can be checked by looking at an indicator or similar, follow the corresponding instructions.

4-12


Cooling System Internal Cleaning

WARNING • Cooling water is hot and pressure accumulates inside the radiator after

stopping the engine. Attempting to remove the cap may result in burns. Wait until the temperature lowers then relieve the pressure by slowly turning the cap.

• Start the engine before cleaning. Set the safety lock lever to the lock position before standing up from or leaving the driving seat.

• For engine startup, refer to "Check and adjustment before starting engine (3-49)" and "Starting the engine (3-69)" in the driving operation description of the Operation chapter.

• The engine is running during cleaning, therefore you are in danger if you are standing behind the machine when it starts working. Do NOT approach the rear of the machine when the engine is running.

Observe the following table for cooling system internal cleaning and antifreeze fluid replacement. Antifreeze Fluid Type Cooling System Cleaning and

Antifreeze fluid Replacement Supercoolant AF-ACL antifreeze fluid (Corrosion resistant all season type)

Every two years (biannual) or 4000 hours, whichever is earlier

AF-NAL antifreeze fluid (All season type)

Every year or 2000 hours, whichever is earlier

SUPPLEMENTAL • The genuine Maeda Supercoolant (AF-NAC) is not only prevents freezing but also

corrosion.

• Each antifreeze fluid has different additive mixed, therefore do not use when mixed together.

Clean/replace while the machine is stopped on level ground. The mixture ratio, that differs depending on the air temperature, needs to be at least 30% of the capacity. Decide the mixing ratio between the antifreeze fluid and water in conformance to the following mixing ratio table after checking the lowest air temperature known in the past. As guidance, set a temperature approximately 10 degrees centigrade lower than the lowest temperature. Water-Antifreeze Fluid Mixing Ratio Table

Lowest Air Temperature (Centigrade) -15 -20 -25 -30 -10 or

above Antifreeze fluid quantity

3.2 3.8 4.3 4.8 5.3 Mixing quantity (liters)

Water quantity

7.3 6.7 6.2 5.7 5.2

4-13


WARNING Antifreeze fluids are flammable, so be careful with flames. Antifreeze fluids are toxic. Be careful to avoid being splashed by water mixed with antifreeze fluid when you are removing the drain plug. If any antifreeze fluid enters your eye, wash it with plenty of water immediately, then seek a medical advice. Use tap water or equivalent soft water as the dilution water. Consult our sales service agency when using water from rivers, wells or private supplies is unavoidable. Management of the mixing ratio by an antifreeze fluid concentration gauge is recommended.

• Obtain an antifreeze/water container with a capacity of at least 11 liters.

• Obtain a water fill hose.

5. Put a coolant/water mix container beneath the drain cock (2) and the drain plug (3).

11. Continue low idling for five minutes, then change to high idling for five minutes to eject the air from the cooling water (keep the cooling water cap off during this procedure.)

1. Stop the engine. 2. Open the engine hood. 3. Check if the radiator cap surface temperature is low

enough to be touched with bare hands and if OK, vent the pressure by slowly turning the radiator cap (1) as far as the stopper.

4. Remove the radiator cap (1) by turning further as far as the stopper while keeping the radiator cap (1) pushed down.

6. Finish draining the water, then close the drain cock (2) and drain plug (3) and turn off the tap water. Once the radiator is filled with water, start up and keep the engine at a low idle, raising the water temperature to at least 90 °C, then continue to run for approximately 10 minutes.

7. Stop the engine, then drain the water by opening the drain cock (2) and drain plug (3).

8. Finish draining the water, then wash using detergent. 9. Close the drain cock (2), then close the drain plug (3) by

wrapping it in sealing tape. 10. Refill the Supercoolant and tap water from the water refilling port until it reaches the port

opening. Refer to "Water-Supercoolant Mixing Ratio Table" for the mixing ratio.

4-14


12. Drain the cooling water out of the subtank (4), wash the subtank internally, then refill the cooling water to halfway between FULL and LOW.

13. Stop the engine, wait for approximately three minutes, then fill with tap water up to near the water fill port, then tighten the cap.

Water Separator Element Replacement

WARNING Keep away from flames.

• Obtain a water separator filter wrench. 1. Open the engine hood, then set the filter handle (2)

inside to the "close" position (a). 2. Loosen the ring (3) using the filter wrench, remove the

element cup (4) then extract the element (5). Be sure not to lose the red ring (6) inside the case. 3. Wash the element cup (4) with light oil or cleaning oil. 4. Install a new element (5). 5. Put the red ring (6) inside the element cup (4), fill with

fuel, install the element cup (4) to the filter mount then tighten the ring (3).

6. Set the handle (2) to the "open" position (b). 7. After replacing the element replacement, let out the air. Refer to the "Air Relief Procedure (4-34)" section for air

expulsion procedure.

4-15


Fuel Tank Internal Washing IMPORTANT • Do NOT use trichlene when washing inside the tank. 1. Drain the fuel from the tank internally by referring to

the "Draining of Intruded Water/Sediment in Fuel Tank (4-27)" section.

2. Remove the filler opening (F).

3. Wash the tank internally. 4. Finish washing, then close the drain cock (1).

4-16


Crawler Shoe Bolt Inspection/Retightening (iron shoe model) The crawler shoe bolt (1) fractures if used when loose, therefore be sure to tighten it if it becomes loose. Iron Shoe Retightening Method 1. Initially tighten to torque of 117±19.6 N-m (12±2kg-m), then

make sure both the nut and shoe are firmly in contact with the linking surface.

2. Check the tightening, then retighten the nut/bolt to the specified torque, then retighten it by a 1/4 turn approximately (90 degrees).

Retightening Order Tighten the bolts by the order shown in the figure right. After tightening, make sure both the nut and shoe are firmly contacting the linking surface.

4-17


Crawler Tension Inspection/Adjustment (iron shoe model) Wear condition of the drive related pins and bushes differs depending on the working condition and soil quality, therefore inspect the crawler tension occasionally to maintain the standard tension. Choose a level and hard ground as inspection/adjustment location. Inspection 1. Set the engine to low idle, drive forward by the length of the

contact between ground and crawler then stop slowly. 2. Place a square timber (3) that reaches from the idler (1) to

the upper pulley (2) above the crawler. 3. Measure the maximum slack between the crawler upper

surface and the square timber lower surface.

• Slack standard Normal range of slack is between 10 and 30mm.

Adjust as follows if the tension is not correct. Adjustment

WARNING Do NOT loosen the plug (4) a full turn or greater. If you do, the high-pressure grease inside may eject the plug (4). Do NOT loosen any part other than the plug (4) during this procedure. Furthermore, do not face towards the installation direction of the plug (4). If the procedure described here does not loosen the crawler, ask our sales service agency for a repair. To strengthen tension Obtain a grease pump. 1. Inject grease through the grease fitting (5) from the grease

pump. 2. To check the proper tension, drive forward for the ground

contact length with the engine at low idle, then stop slowly. 3. Re-inspect the crawler tension and, if it is incorrect, adjust

again. 4. You can inject grease until S becomes 0mm, but if the

tension is loose even then, the pins and bushes will wear excessively so they need to be reversed or replaced. Ask our sales service agency for a repair.

4-18


To loosen tension

WARNING Grease poses extreme danger if procedures for ejection are not followed. Ask our sales service agency for a repair if you cannot loosen the crawler. 1. Eject grease by slowly loosening the plug (4). 2. Do NOT loosen the plug (4) by more than one full turn. 3. If the grease ejection is not smooth, slightly move the

machine forward and backward. 4. Tighten the plug (4) fully. 5. To check the proper tension condition, drive forward for

the ground contact length with the engine at low idle, then stop slowly.

6. Re-inspect the crawler tension and, if it is incorrect, re-adjust.

4-19


Track Floating Method (to lift/jack up a track) Wire Cable Hoisting Method

WARNING ALWAYS work on level, hard ground. Only personnel who are authorized locally/nationally are permitted to hoist with a crane. 1. Swing the boom 90 degrees. 2. Hang the hook onto the hook hanging wire rope, then secure

the hook. 3. Wrap the wire rope around the boom, then hoist it. Insert a piece of square timber between the cable and the

boom, to prevent damaging the boom.

4. Insert a piece of square timber or similar object for good stability between the ground and the lower surface of the truck frame.

5. The square timber should be approximately 450mm high.

Jack-up Method

WARNING ALWAYS work on level, hard ground. Apply two 10-metric ton or stronger jacks onto the lower surface of the track frame, then lift until the crawler leaves the ground.

4-20


Window Washer Liquid Inspection and Refilling If air is found mixed with window washer liquid, check the liquid level in the window washer tank (1) and refill if necessary. When refilling, be careful not to allow dust to enter. Mixture Ratio between Washer Liquid Concentrate and Water Depending on the air temperature, use one of the following washer liquid/water mix ratios:

Region and Season of Use

Mixture Ratio Lowest Temperature

Standard 1/3 concentrate and 2/3 water

-10oC

Cold region winter ½ concentrate and ½ water -20oC Arctic region

winter Concentrate only -30oC

Select the mixture ratio according to the lowest temperatures, regions and seasons.

4-21


Air Conditioner Inspection and Maintenance Coolant (Gas) Quantity Inspection

WARNING If coolant liquid enters your eye or spills on your hand, you will be blinded or suffer frostbite. Coolant should NEVER touch the skin. Do NOT loosen any part of the coolant circuit. Ban flames from any location where coolant gas is leaking. Insufficient coolant (gas) affects cooling. Check the condition of the coolant gas (non-CFC R134a) in the coolant circuit by looking through the sight glass (inspection port) of the receiver while running the cooler at high speed when the engine is rotating fully.

• No bubbles are present in the flow: Proper

• Bubbles are present in the flow: Insufficient (Bubbles are passing continuously)

• Colorless and transparent: Empty

SUPPLEMENTAL The presence of bubbles indicates insufficient gas, so immediately refill with gas from the sales depot. If you continue running with insufficient gas, the compressor may be damaged. Off Season Inspection

Approximate

Maintenance Interval

To prevent the destruction of oils in various part of the compressor, run the air conditioner for 3 to 5 minutes once a month, even during the off-season. Table of Cooler Inspection and Maintenance Items

Inspection/Maintenance Item

Inspection/Maintenance Contents

Coolant (gas) Filled quantity Spring and fall, twice a year

Condenser Fin section blockage Every 500 hours Compressor Operating condition Every 4000 hours

V belt Damages and tension Every 250 hours Blower motor and fan Operating condition

(abnormal noise absent or not)

Non-routine

Control mechanism Operating condition (properly functioning or

not)

Non-routine

Each piping installation Installation condition, tightening section,

loosening at connection section, gas leak, damage

Non-routine

4-22


Slide Door Rail/Roller Inspection, Cleaning and Grease Refilling Inspection

1. Remove residual dust from the rail (1) using a brush or similar tool, while opening and closing the door.

IMPORTANT Do NOT use highly viscous lubricant. Manufacturer's recommendation: PANDO - 18C from ThreeBond Co. Ltd.

If the slide door cannot be opened/closed due to mud or other substances, clean it and replace grease on the slide door rail (1) and roller (2) at three sections shown in the diagram (right):

Door Rail Cleaning Method

2. Remove the rail (1) contamination using a waste cloth. Door Rail and Roller Grease Refilling Method

1. Spray sufficient lubricant onto the rail (1) and roller (2). 2. After replacing the grease, slide the door and check whether it opens/closes smoothly. If

not, consult our sales service agency.

4-23


Hydraulic Circuit Air Relief Procedure Refer to the "Starting the engine (3-65)" section for engine startup. Refer to the engine startup, machine start/steering/stop sections in the Operation chapter as necessary. 1. Pump air expulsion IMPORTANT If you run the pump without filling the inside of the pump case with hydraulic oil, it may heat up abnormally and be damaged. Be sure to securely expel the air.

1) Loosen the air breather (1) installed to the drain port and check that the oil oozes out (which means the air expulsion is complete).

2) After having done this, tighten the air breather.

If you set the engine idling to high speed from the beginning or operate the cylinder to the stroke end, the piston packing or other part may be damaged due to air entering the cylinder.

1) Set the engine to the middle idle speed (1650 rpm) and extend-then-retract each of the cylinders four to five times without reaching the stroke end (but approximately 100mm before the stroke end).

2) Next, operate each of the cylinders three to four times up to the stroke end. 3) In addition, operate each of the cylinders four to five times up to the stroke end until the

air is fully expelled. SUPPLEMENTAL Turn on the moment limiter emergency switch before an operation up to the stroke end, because the derrick cylinder stops by effect of the limit switch at stub of the boom.

2. Air Expulsion between Pump and Hydraulic oil Tank IMPORTANT If you set the engine idling to high speed without expelling the air between the pump and the hydraulic oil tank, the pump may heat up abnormally and be damaged.

1) Start the engine by referring to the "Starting the engine (3-65)" section, then keep the engine idling at the middle speed (1650 rpm).

2) Expel the air by operating the implement for approximately five (5) minutes. 3. Cylinder air expulsion IMPORTANT

4-24


4. Swing Motor Air Expulsion (execute only after draining the oil inside the swing motor case)

If you do not expel the air from the idling motor, the motor bearing may break.

2) Float the wheels by referring to the "Wheel Floating Method (4-20)" section.

• After completing the air expulsion, stop the engine once and keep it stopped for at least five minutes, then operate the engine again. Doing so, purges air bubbles from the tank oil.

IMPORTANT

1) Set the engine to low idle, loosen the hose (3) and once the oil leaks out, tighten the hose (3). Do NOT execute any swing operation during this procedure.

2) Set the engine to low idle, then swing evenly clockwise and anticlockwise, at least two idlings each.

5. Traveling Motor Air Expulsion (execute only after draining the oil inside the traveling motor case) 1) Set the engine to low idle, loosen the D port hose (5)

and once the oil leaks out, tighten the D port hose (5).

3) Run the crawler without touching the ground for two minutes, repeat this procedure for both right and left crawler.

IMPORTANT

• Check for any oil leak and wipe off any dripped oil.

4-25


Check before starting operation For the following items, refer to the "Check before starting operation (3-52)" section in Handling Chapter.

• Inspection of water separator

• Inspection of electrical wires

• Inspection and refilling of cooling water

• Inspection and refilling of oil in the engine oil pan

• Inspection and refilling of fuel

• Inspection and refilling of oil in the hydraulic oil tank

• Inspection of dust indicator

• Inspection of horn and headlight functions

• Inspection of winch and boom operations

• Inspection of moment limiting device

4-26


Maintenance Every 50 Hours Draining of Intruded Water/Sediment in Fuel Tank 1. Carry out this procedure before running the vehicle. 2. Get a container for the drained fuel.

3. Open the drain cock at the bottom of the tank, then drain out the sediment that has accumulated at the bottom and any intruded water, together with the fuel. Be careful to avoid being sprayed by fuel spill during this procedure.

4. Close the drain cock when only clean fuel comes out.

Greasing Grease every 10 hours until a new machine has been operated for 100 hours, as after this time the machine is worn in. Use a grease type in the following table, depending on the greasing point. No. Greasing Point Grease Type 1 Derrick cylinder foot pin greasing 1pt 2 Derrick cylinder rod end greasing 1pt 3 Guide sheave greasing 1pt 4 Boom foot pin greasing 1pt 5 Wire retainer roller pin greasing 1pt

Lithium grease

6 Boom slide plate (upper) greasing 8pts 7 Boom slide plate (lower) greasing 8pts

Molybdenum grease

8 Boom side surface/lower surface greasing

Every boom Boom grease

9 Boom extension wire rope greasing Hoisting wire rope greasing

Five ropes

10 Hook block greasing 1pt

Rope oil

Apply red rope grease to prevent wearing and rust of the wire ropes. Before applying, remove any contamination from the rope surface then apply using a brush. 1. Stop the engine. 2. Grease with a grease pump up to the arrow. 3. Wipe off the old grease that was expelled after greasing. Boom Side Surface/Lower Surface Greasing • To prevent jerking during boom extension/retraction, apply

our genuine boom grease (spray type) to the side and lower surfaces of the boom.

• To lubricate a large area, fold the nozzle and push the button at the top.

4-27


4-28


Maintenance Every 100 Hours Execute this maintenance along with the 50-hour maintenance procedures. Swing Carry Case Oil Quantity Inspection and Refilling

WARNING Parts and oils stay hot for some time after stopping operation and may inflict burns. Wait until temperatures drop before starting work. 1. Remove the oil level gauge (G) then wipe off the oil with a

waste cloth. 2. Fully insert the oil level gauge (G) into the guide. 3. Remove the level gauge (G) and check the oil level; the

proper level is between the H and L indicated on the gauge. 4. If the oil level is less than the L indicated on the oil level gauge

(G), refill the engine oil through the gauge insertion port (F). Remove the air relief plug (1) before refilling. IMPORTANT Refer to the "Air Temperature Dependent Fuel and Lubricant Grease Use Method (7-4)" section for the correct oil. 5. If the oil level is above the H indicated on the oil gauge,

loosen the drain plug (P) and drain out the excess oil. 6. After inspecting/refilling the oil, insert the level gauge into the

insertion port then attach the air relief plug (1).

4-29


Maintenance Every 250 Hours Execute this maintenance along with the 50-hour maintenance procedures.

Final Drive Case Oil Quantity Inspection and Refilling

WARNING • Parts and oils stay hot for some time after stopping operation and may

inflict burns. Wait until temperatures drop before starting work. • Oil or plug may gush out if pressure remains inside the case. Relieve the

pressure by slowly loosening the plug.

• Obtain a drained oil container and a hex wrench. 1. Let the plug (P) face the ground perpendicularly. 2. Place the oil container below the plug (P). 3. Remove the plug (G) using the hex wrench and check

the oil level; the proper level is near the lower extremity of the plug (G) hole.

4. If the oil level is low, remove the plug (F) using the hex wrench then refill with oil through the plug (F) hole. Continue refilling until oil drips out of the plug (G) hole.

5. After the inspection, attach plug (F) and plug (G).

4-30


Fan Belt Tension Inspection and Adjustment Inspection Push (approximately 58.8 N-m {6kg}) the middle point between the alternator pulley and the fan pulley, the tension is correct if the sag distance a is approximately 8mm.

4-31


Adjustment

Piece of wood

• Obtain a crowbar and a piece of wood.

4. Push the alternator (2) to the front of the chassis by using the crowbar and tighten the adjustment bolt (4) until the belt tension indicates approximately 8mm (approximately 58.8 N-m {6kgf}).

6. Install the fan guard (1).

1. Remove the fan guard (1). 2. Fix the alternator (2) by inserting the crowbar between the

alternator (2) and the cylinder block. When fixing, insert the piece of wood between the crowbar and the alternator (2) to protect it from being damaged.

3. Loosen the alternator installation bolt (3) and adjustment bolt (4).

5. Tighten the installation bolt (3). IMPORTANT • Check for any pulley breakage, V groove wear and V-belt

wear. Be especially careful to make sure that the V-belt is not hitting the bottom of the V-groove.

• If the belt is too slack to achieve the correct adjustment length or if the belt makes a sliding or creaking noise due it being cut or ripped, ask our sales service agency for a replacement.

4-32


Air Conditioner Compressor Belt Tension Inspection and Adjustment Inspection Push (approximately 58.8 N-m {6kgf}) the middle point between the fan pulley and the compressor. The tension is correct if the sag length a is between 10 and 12mm.

2. Loosen the nut (3), then gradually tighten the bolt (4) until the belt sag length is between 10 and 12mm (approximately 58.8 N-m {6kgf}).

Adjustment 1. Loosen the bolts (1) and (2).

3. Fix the compressor by tightening bolts (1) and (2). 4. Loosen bolt (4) by two or three turns, then fix bolt (4) by

tightening the nut (3).

IMPORTANT • Check for any pulley breakage, V groove wear or V-belt wear. Be especially careful

to make sure that the V-belt is not hitting the bottom of the V-groove.

• If the belt is too slack to achieve the correct adjustment length or if the belt makes a sliding or creaking noise due it being cut or ripped, ask our sales service agency for a replacement.

• After replacing the V-belt, continue running for one hour, then readjust.

4-33


Maintenance Every 500 Hours Execute this maintenance at the same time as the 50-hour, 100-hour and 250-hour maintenance procedures. Fuel Filter Cartridge Replacement

WARNING • Do NOT start replacing the filter immediately after stopping the engine,

when various parts are still hot. Wait until all parts are cool before starting work.

• Keep away from flames.

• Obtain a filter wrench 1. Place a waste cloth below the filter cartridge. 2. Turn clockwise and remove the filter cartridge (1) by using the

filter wrench. 3. Clean the filter holder, fill the new filter cartridge with clean

fuel, apply engine oil over the packing surface then install the new filter cartridge to the filter holder.

4. To install, let the packing surface come into contact with the filter holder seal surface, then tighten by approximately two to three turns.

IMPORTANT Be sure to observe the proper tightening angles. If you excessively tighten the filter cartridge, the packing may be damaged and a fuel leak may occur. If you insufficiently tighten it, fuel will leak through the packing gap. 5. After the fuel filter cartridge replacement, expel the air. Refer to the "Air Relief Procedure (4-44)" section to expel the air. 6. After expelling the air, start the engine and check for oil leakage from the filter seal

surface. If any oil is leaking, check the tightness of the filter cartridge. If it is correct but oil is leaking, remove the filter cartridge by procedures 1. and 2., then check the packing surface to inspect for damage or foreign objects.

If the packing is damaged or a foreign object is found, replace the packing with a new one and repeat procedures 3. to 6.

Air Relief Procedure 1. Fill the fuel to full. 2. Loosen the air relief plug (1) and joint bolt (2). 3. Loosen the feed pump (3) knob and move it up and down so

that fuel overflows and no more bubbles come out of the joint bolt (2).

4. Tighten the joint bolt (2) and air relief plug (1). SUPPLEMENTAL You can also use this method to expel air when you have run out of fuel.

4-34


Engine Oil Pan Oil Replacement and Engine Oil Filter Cartridge Replacement

WARNING Parts and oils stay hot for some time after stopping the engine and may cause burns. Wait until temperatures drop before starting work.

• Oil pan replacement oil - quantity 7 liters

• Obtain a filter wrench.

3. Inspect the drained oil and if it contains excessive metal powder or foreign objects, report to our sales service agency.

4. Put back the drain plug (P). 5. Open the engine hood, then turn the filter cartridge (1)

counterclockwise using the filter wrench until the filter cartridge (1) is removed.

6. Clean the filter holder, apply clean oil (alternatively, you can

thinly apply grease) to the packing section and threadsection of a new filter cartridge, then install the filtercartridge.

1. Place a drained oil container right below the drain plug (P) located to the lower side of the chassis.

2. Slowly remove the drain plug (P) while being careful to avoid being sprayed by spilled oil then drain the oil.

SUPPLEMENTAL Place a cloth under the filter housing to catch any spilt oil.

SUPPLEMENTAL Make sure that the old packing is not stuck to the filter holder. If the old packing is stuck, oil leakage may occur.

7. To install, let the packing surface come into contact with the filter holder seal surface, then tighten by 1/2 turn or more.

8. After replacing the filter cartridge, fill oil through the filler opening (F) to a level between H and L on the level gauge (G).

9. Run the engine idle for some time, then stop the engine and check if the oil quantity is properly between H and L on the level gauge by referring to the "Inspection and refilling of oil in the engine oil pan (3-53)" section.

4-35


Air Conditioner Internal/External Air Filter Cleaning

WARNING When using compressed air, litter may fly about which can cause personal injuries. Wear protective equipment such as goggles and a dust mask. IMPORTANT • 500 hours cleaning cycle is the conventional rule of thumb, but shorten the

maintenance interval when, for instance, the workplace is dusty.

• Be sure to avoid being sprayed by water spillage when washing the floor.

SUPPLEMENTAL

Internal Air Filter Cleaning 1. Roll up the floor mat (1) at lower leftward front of the driving

seat, then open the cover (2). 2. Take out the internal air filter (3). 3. Clean the filter (3) with compressed air. If the filter (3) has oil deposition or is excessively dirty,

wash it with water and a neutral detergent. Dry sufficiently before use.

If a filter blockage cannot be removed by the air or by washing with water, replace with a new filter. 4. Put back the cleaned filter (3) to its original location, close the

cover (2) then replace the floor mat (1).

4-36


External Air Filter Cleaning 1. Pull the popup rivet (4) of the external air introduction

duct at the rear left of the driving seat. Doing so allows the cover (5) to be removed.

If a filter blockage cannot be removed by the air or by washing with water, replace with a new filter.

2. Pull out the external air filter (6). 3. Clean the external air filter (6) with compressed air. If the external air filter (6) has oil deposition or is

excessively dirty, wash it with water and a neutral detergent. Dry sufficiently before use.

SUPPLEMENTAL

4. Replace the cleaned filter (6) to its original location then

replace the cover (5).

IMPORTANT Ensure a filter (6) is the right way round when replacing it.

4-37


Radiator Fin/Oil Cooler Fin/Condenser Fin Inspection and Cleaning

WARNING Injuries may occur if bodies come into direct contact with compressed air/pressurized water/steam or if debris is splattered around the workplace. Wear protective equipment such as goggles and dust masks. IMPORTANT Use compressed air from a distant location to prevent damaging the fin. Blow against the core perpendicularly as much as possible. Water leakage and overheating may occur if the fin is damaged. If the workplace is dusty, inspect daily, ignoring the maintenance cycle. 1. Open the engine hood. 2. Remove mud, dust and leaves stuck in the radiator

fin (1) with the compressed air.

4-38


Swing Circle Greasing (two points) 1. Fold the crane. 2. Inject grease using the grease pump through the grease

fittings indicated by arrows. 3. Wipe off old grease that was expelled after refilling the

grease. Swing Pinion Grease Quantity Inspection and Refilling • Obtain a scale. 1. Swing counterclockwise (approximately 60 degrees) until the

revolving frame lower cover gets to an easily removable position.

2. Remove eight bolts (4), then remove the revolving frame lower cover (3).

Do NOT remove the two bolts shown by a "*" in the right diagram, but only loosen these two bolts, then remove the lower cover (3) whilst propping it up with these two bolts.

3. Remove the rubber plug (1) from the revolving frame top surface below the driving seat.

4. Insert the scale (2) into the grease and measure the grease level. The proper quantity is at least 4mm. Refill if insufficient.

5. Check if the grease is misty. If it is, the grease needs to be replaced, so ask our sales service agency for the replacement. Full grease capacity is 5.5 liters (5.0 kg)

6. Replace the rubber plug (1). 7. Fit the lower cover (3) snugly with two bolts remaining at

lower part of the revolving frame, then tighten eight bolts (4).

4-39


Maintenance Every 1000 Hours

Winch Reduction Gear Case Oil Replacement

• Replacement oil quantity: 1.4 liter 1. Raise the boom to approximately 60 degrees to let the

plug (F) face perpendicularly upward. 2. Set the oil drainage container below the plug (P). 3. Remove the plug (F). 4. Remove the plug (P) and drain the oil. After draining the

oil, tighten the plug (P). 5. Remove the plug (G), then refill the gear oil through the

plug (F) hole. Continue refilling until oil drips out of the plug (G) hole.

6. After inspecting/refilling the oil, install the plugs (F) and (G) by wrapping sealing tape around the thread section of each plug.

Execute this maintenance at the same time as the 50-hour, 100-hour, 250-hour and 500-hour maintenance procedures.

• Oil drainage container with 1.4 liter or more capacity

4-40


Hydraulic oil Return Filter Element Replacement

WARNING • Parts and oils stay hot for some time after stopping the engine, and may

inflict burns. Wait until the temperatures drop before starting work. • When removing the filler cap, be careful to turn it slowly to relieve the inner

pressure, since oil may gush out. 1. If the machine is not in the condition shown in the right

diagram, start the engine, set the engine to low speed idling, then stop the engine when the boom is in the travel position.

2. Loosen four bolts, then remove the hydraulic oil tank

upper cover (1). 3. Slowly turn and remove the filler opening (F) and relieve

the inner pressure. 4. Remove two filters (2) using the filter wrench. 5. Wash the filter holder, apply clean oil (alternatively, you

can thinly apply grease) to the seal surface of a new filter then install the filter.

6. Check for any oil leaks and wipe off any spilt oil. 7. Replace the filler opening (F). 8. Replace the hydraulic oil tank upper cover (1) then

tighten four bolts.

4-41


Hydraulic oil Line Filter Element Replacement

WARNING • Parts and oils stay hot for some time after stopping the engine, and may

inflict burns. Wait until temperatures drop before starting work. • When removing the filler cap, be careful to turn it slowly to relieve the inner

pressure, since oil may gush out.

2. Open the engine hood.

• Obtain a drained oil container. 1. If the machine is not in the condition shown in the right

diagram, start the engine, set the engine to low idling, then stop the engine when the boom is in the travel position.

3. Position the oil drainage container filter element under the

filter element. 4. Remove the filter case (1) by turning it counterclockwise,

then remove the element (2) and O-ring (3) from the filter holder (4).

5. Clean the filter holder (4) and filter case (1), apply clean hydraulic oil over the packing of a new element (2) then install the packing and also the O-ring (3) to the filter holder (4).

6. Fill the filter case (1) with clean hydraulic oil, then install the filter case (1) to the filter holder (4).

To install, position the filter case (1) in the filter holder (4), then tighten by 1/2 of a turn.

IMPORTANT Make sure that the old O-ring is not stuck to the filter holder. If the old O-ring is stuck, oil leaks may occur.

4-42


Swing Carry Case Oil Replacement

WARNING Oil stays hot for some time after ceasing operations and may inflict burns. Wait until the temperature drops before starting work.

• Oil drainage container with 1.5 liter or more capacity

• Replacement oil quantity: 1.5 liter 1. Position the oil drainage container under the drain plug (P). 2. Remove the drain plug (P), drain the oil and after draining the

oil, tighten the drain plug (P). The tightening torque for the drain plug (P) is between 44 and 93 N.m {4.5 and 9.5 kgf.m}

3. Remove the oil level gauge (G) and air relief plug (1), then fill the engine oil through the gauge insertion port with the correct quantity.

4. Wipe off oil from the oil level gauge (G) with a waste cloth. 5. Reinsert the oil level gauge (G) to the full length of the oil

check tube, then pull it out. 6. The correct oil level is between the H and L indicated on the

level gauge (G). If the oil level is below L, refill the engine oil through the

filler opening (F). 7. If the oil level is above H, release the excess oil out of the

drain plug (P), then recheck the oil level.

SUPPLEMENTAL After stopping the engine, wait at least 15 minutes before starting the oil quantity inspection. If the machine is tilted, set it to a level position before inspecting.

4-43


Final Drive Case Oil Replacement

WARNING • Oil stays hot for some time after stopping operations and may inflict burns.

Wait until the temperature drops before starting work. • Oil or the plug may gush out if pressure remains inside the case. Relieve the

pressure by slowly loosening the plug.

• Replacement oil quantity: 1.3 liter each to right/left

2. Place the oil container below the plug (P). 3. Remove plugs (P), (G) and (F) using the hex wrench, then

drain the oil. 4. Tighten the plug (P). 5. Pour the right quantity of oil through the plug (F) hole.

• Obtain a hex wrench. 1. Let the plug (P) face the ground perpendicularly.

6. If oil starts coming out of the plug (G) hole, replace the plug (G) and (F).

4-44


Hydraulic oil Tank Oil Replacement and Suction Filter Cartridge Replacement

WARNING • Parts and oils stay hot for some time after stopping the engine and may

inflict burns. Wait until the temperatures drop before starting work. • When removing the filler cap, take care while slowly turning it to relieve the

internal pressure since oil may gush out. 1. If the machine is not in the position illustrated in the right

diagram, start the engine, set it to low idling then stop it whenthe boom is in the travel position.

2. Swing counterclockwise (approximately 60 degrees) until the drain plug below the hydraulic oil tank reaches the midpoint between the right and left crawlers.

3. Set the safety lock lever to the lock position and stop the engine.

4. Loosen four bolts then remove the hydraulic oil tank upper

cover (1).

5. Slowly turn and remove the filler cap (F) and relieve the inner pressure.

4-45


6. Place an oil container below the drain plug below the vehicle. 7. Remove the drain plug (P), then drain the oil. Be careful to

avoid being sprayed by oil when you remove the drain plug (P). Check up the O-ring attached to the drain plug (P), and if any damage is found, replace it. After draining all the oil, tighten the drain plug (P). The tightening torque for the drain plug (P) is 68.6±9.81N-m (7±1 kg-m).

8. Loosen eight bolts (4) then remove the lower cover (3). Do

NOT remove the two bolts shown by a "*" in the right diagram, but only loosen these two bolts, then remove the lower cover (3) whilst propping it up with these two bolts.

10. Wash the filter holder, apply clean oil (alternatively, you can thinly apply grease) to the seal surface of a new filter, then install the filter.

IMPORTANT

14. After replacing the hydraulic oil and filter element, expel the air from inside the circuit. To expel air from the hydraulic circuit, refer to the "Hydraulic Circuit Air Relief Procedure

(4-24)" section.

9. Remove the filter (5) using the filter wrench.

ALWAYS fully drain the oil out of the hydraulic oil tank before removing the filter. 11. Install the lower cover (3) with the bolts (4). 12. Inject the correct quantity of hydraulic oil through the filler opening (F). Check that the oil level is between the H and L on the sight gauge. For the oil quantity inspection method, refer to the "Inspection and refilling of oil in the

operation oil tank (3-55)" section. 13. Replace the filler opening (F).

15. After expelling the air, set the boom to the travel position. Check whether the hydraulic oil sight gauge is showing a level between H and L. If lower

than L, refill with hydraulic oil. 16. Install the hydraulic oil tank upper cover (1), then tighten four bolts.

4-46


Maintenance Every 2000 Hours Execute this maintenance as well as the 50-hour, 100-hour, 250-hour, 500-hour and 1000-hour maintenances procedures. Turbocharger Cleaning and Inspection Ask our sales service agency for a cleaning and inspection. Alternator/Starter Inspection Ask our sales service agency for a cleaning and inspection, since the brush might be worn and the bearing grease might be empty. Ask for an inspection every 1000 hours if your engine startup frequency is high. Engine Valve Clearance Inspection and Adjustment Ask our sales service agency for a cleaning and inspection, as these require special tools.

4-47


Maintenance Every 4000 Hours Execute this maintenance as well as the 50-hour, 100-hour, 250-hour, 500-hour, 1000-hour and 2000-hour maintenance procedures. Water Pump Inspection Check for play in pulleys, oil leaks, water leaks and weep hole (drain hole) blockages, and if any fault is found, ask our sales service agency for a disassembly repair or replacement.

4-48

Specifications

Specifications SPECIFICATIONS

Specifications

System/Item City Pad with Iron Shoe Model Main body mass 9,700kg

Overall length x width x height 5,005mm x 2,350mm x 2,685mm Mass and dimensions

Distance between idler and sprocket 2,235mm Track gauge 1,870mm Track width 450mm

Lowest height from ground 360mm Maximum rated total load x working

radius 4,900kg x 2.1m

Maximum working radius 14.52m

Capacity

Maximum lifting height 16.35m Method 2-speed hydraulic motor with built

in automatic brake, differential planet reduction gear, grooved

drum Rope falls 4 ropes (2 ropes, 1 rope)

Low 27.0m/min (4th drum layer) Winding speed .0m/min (4th drum layer) High 39

Winch system

Hook capacity; mass 4,810kg;90kg Method Sequentially telescopic two-double

acting cylinder + simultaneous wire rope telescopic device, 2

Telescoping system

Boom length 4,630mm - 15,630mm (minimum-maximum)

Boom type Pentagonal section 5 stage telescopic boom (hydraulic

automatic extension) Boom telescoping system stroke; time 11.0m;24.5 sec

Method Direct push with hydraulic cylinder Derrick system Boom derrick angle and raise time -2 to 80 degrees/12.5 sec

Method Hydraulic motor drive, fixed displacement piston (with safety

valve and pivot brake)

Swing system

Swing angle; swing speed 360 degrees continuously; 2.4 rpm Method Variable displacement piston type

(with brake valve and parking valve)

Travel system

Low Forward-backward 2.5km/h Travel speed High Forward-backward 3..8km/h

Gradeability 20 % Ground pressure (shoe width) 46.8kpa/cm2 (0.48kg/cm2)(450mm)

5-1

SPECIFICATIONS Specifications

System/Item City Pad with Iron Shoe Model Hydraulic pump Variable piston pump + dual gear pump

(for winch/right travel/telescoping and winch/derrick/left travel, swing, and control

valve) Relief set pressure 210 kgf/cm2 (telescoping, derrick), 250

kgf/cm2 (winch, travel) 195 kgf/cm2 (swing), 32 kgf/cm2 (control)

Hydraulic system

Hydraulic oil tank capacity 126 l Model Komatsu S4D95LE-3-A Type Water cooled, 4-cycle, in line, 4-cylinder,

direct injection diesel

Engine

Displacement 3,2600 cc Rated output 40.5kw(55PS) / 1,850rpm

Fuel Tank capacity 141 l Safety device Overwinding protection, overload protection, sling rope detachment

protector, hydraulic safety valve, telescoping cylinder hydraulic lock device, derrick cylinder hydraulic lock device, alarm buzzer, machine body

inclination alarm, level gauge Hoisting rope Single rope

6Xfi (29) IWRC 0/0 Ø10 -72.9 kN (115m) Wire rope

No.4 boom extending rope 6xFi (29) IWRC type C Ø14 -144 kN No. 5 boom extending rope 6xFi (29) IWRC type B Ø10 -67.7 kN No. 4 boom retracting rope 6xFi (29) IWRC type B Ø8 -43.3 kN No. 5 boom retracting rope 6xFi (29) IWRC type B Ø6 -24.4kN

Drum Hoisting rope Pitch diameter/rope ratio

Ø220/22.0

Boom Ø162/16.2 Hoisting rope Pitch diameter/rope ratio Hook Ø228/22.8

Sheave

No.4 Ø224/16.0 Hoisting rope Pitch diameter/rope ratio No.5 Ø162/16.2

No.4 Ø200/25.0 Hoisting rope Pitch diameter/rope ratio No.5 Ø95/16.0

5-2

Specifications SPECIFICATIONS

5-3

SPECIFICATIONS Rated Total Load Table

Rated Total Load Table 4 Rope Hook

1) 4.63m boom 2) 7.38m boom 3) 10.13m boom 4) 12.88m boom 5) 15.63m boom Boom Length Working radius

Stationary Rated Total

Load (kg)

Travelling Rated Total

Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)

2.00 4900 2000 4900 2000 2600 1400 2000 2. 4900 4830 2000 2000 2600 1400 2000 10 2. 3800 2000 50 3760 2000 2600 1400 2000 1400 2.70 3310 1950 3410 1940 2520 1400 2000 1400 3.00 2900 1670 2980 1700 2310 1360 2000 1400 3.15 2640 2220 1400 1550 2800 1590 1300 2000 3.50 2290 2010 1400 1330 2420 1380 1170 1890 3.52 2270 1320 2400 1370 2000 1400 1170 1880 4.00 2000 1140 1750 1020 1650 1400 4.50 1670 960 1530 890 1450 1320 5.00 1400 810 1340 770 1280 1200 5.50 1180 690 1170 680 1130 1090 6.00 1000 590 1030 590 1010 990 6.27 910 Unusable 540 950 550 940 940 6.50 510 890 900 900 7.00 780 440 800 820 7.50 670 380 710 750 8.00 580 320 630 680 Unusable 8.50 490 270 560 610 9.00 410 230 500 560 9.02 410 230 500 560 9.50 440 500 10.00 450 390 10.50 340 400 11.00 300 360 11.50 260 320 11.77 260 300 12.00 280 12.50 240 13.00 210 13.50 200 14.00 200 14.52 200

Boom Angle Range (Deg)

0 to 56.6 0 to 70.4 0 to 76.0 0 to 79.0 - 0 to 79.1 -

Hook mass 90kg 4.63m boom Boom retracted minimum Rated total load limit per number of wires 7.38m boom Boom length more than 4.63m less than 7.38m 4 wires Up to 4900 kg 10.13m boom Boom length more than 7.38m less than 10.13m

2 wires Up to 2450 kg 12.88m boom Boom length more than 10.13m less than 12.88m 1 wire Up to 1220 kg 15.63m boom Boom length 12.88m or more

5-4

Rated Total Load Table SPECIFICATIONS

2 Rope Hook



Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)

2.00 2450 or less

2000 2450 or less

2000 2450 or less

1400 2000

2.10 2450 or less

2000 2450 or less

2000 2450 or less

1400 2000

2.50 2450 or less

2000 2450 or less

2000 2450 or less

1400 2000 1400

2.70 2450 or less

1950 2450 or less

1940 2450 or less

1400 2000 1400

3.00 2450 or less

1670 2450 or less

1700 2310 1360 2000 1400

3.15 2450 or less

1550 2450 or less

1590 2220 1300 2000 1400

3.50 2290 1330 2420 1380 2010 1170 1890 1400 3.52 2270 1320 2400 1370 2000 1170 1880 1400 4.00 2000 1140 1750 1020 1650 1400 4.50 1670 960 1530 890 1450 1320 5.00 1400 810 1340 770 1280 1200 5.50 1180 690 1170 680 1130 1090 6. 00 1000 590 1030 590 1010 990 6.27 910 540 950 550 940 Unusable 940 6.50 890 510 900 900 7.00 780 440 800 820 7.50 670 380 710 750 8.00 630 580 320 680 Unusable 8.50 490 270 560 610 9.00 410 230 500 560 9.02 410 230 500 560 9.50 440 500 10.00 390 450 10.50 340 400 11.00 300 360 11.50 260 320 11.77 260 300 12.00 280 12.50 240 13.00 210 13.50 200 14.00 200 14.52 200


0 to 56.6 0 to 70.4 0 to 76.0 0 to 79.0 - 0 to 79.1 -

Hook mass 90kg 4.63m boom Boom retracted minimum Rated total load limit per number of wires 7.38m boom Boom length more than 4.63m less than 7.38m 4 wires Up to 4900 kg 10.13m boom Boom length more than 7.38m less than 10.13m

2 wires Up to 2450 kg 12.88m boom Boom length more than 10.13m less than 12.88m 15.63m boom Boom length 12.88m or more

5-5

SPECIFICATIONS Rated Total Load Table

1 Rope Hook



Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)


Load (kg)

2.00 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

2.10 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

2.50 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

2.70 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

3.00 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

3.15 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

3.50 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1170 1220 or less

1220 or less

3.52 1220 or less

1220 or less

1220 or less

1220 or less

1220 or less

1170 1220 or less

1220 or less

4.00 1220 or less

1140 1220 or less

1020 1220 or less

1220 or less

4.50 1220 or less

1220 or less

960 1220 or less

890 1220 or less

5.00 1220 or less

810 1220 or less

770 1220 or less

1200

5.50 1180 690 1170 680 1130 1090 6.00 1000 590 1030 590 1010 990 6.27 910 540 950 550 940 Unusable 940 6.50 890 510 900 900 7.00 780 440 800 820 7.50 670 380 710 750 8.00 580 320 630 680 Unusable 8.50 490 270 560 610 9.00 410 230 500 560 9.02 410 230 500 560 9.50 440 500 10.00 450 390 10.50 400 340 11.00 300 360 11.50 260 320 11.77 260 300 12.00 280 12.50 240 13.00 210 13.50 200 14.00 200 14.52 200


0 to 56.6 0 to 70.4 0 to 76.0 0 to 79.0 - 0 to 79.1 -

Hook mass 20 kg 4.63m boom Boom retracted minimum Rated total load limit per number of wires 7.38m boom Boom length more than 4.63m less than 7.38m 10.13m boom Boom length more than 7.38m less than 10.13m

12.88m boom Boom length more than 10.13m less than 12.88m 1 wire Up to 1220kg 15.63m boom Boom length 12.88m or more

5-6

Working Radius and Lifting Height SPECIFICATIONS

Working Radius and Lifting Height

5-7

A - Ins INDEX

6-1

Grease pump holder.....................................3-48

Cautions during crane operation .................. 2-23 Handling moment limiting device ................3-111

Cautions on Operations ............................... 2-17

Hoisting/Lowering operation .........................3-85

Consumable Parts ......................................... 7-2

Description of each system.......................... 3-43

Initial 250 Hour Maintenance (Only the First Maintenance of a New Vehicle) ......................4-9

Electrical systems ...................................... 3-143 Maintenance of a New Vehicle) ......................4-9 Emergency escape hammer ........................ 3-32 Inspection and Maintenance List ....................4-7

INDEX[A] Engine ........................................................3-142 Engine hood .................................................3-34 Air Temperature Dependent Fuel and Lubricant Grease Use Method....................................... 7-4

Engine serial number nameplate location.......1-6

Ashtray......................................................... 3-48 Errors in overwinding protector...................3-153 [B] [F] Basic Maintenance Contents ......................... 4-3 Filter ...............................................................4-4 Basic Precautions .......................................... 2-9 For Safe Use of Machine................................1-2 Battery ......................................................... 2-28 Fuses............................................................3-36 Battery Fluid Level Inspection ...................... 4-12 Fusible link ...................................................3-37 Battery inspection cover............................... 3-35 [G] Bolt/Nut Standard Tightening Torque............. 4-6 Boom derricking operation ........................... 3-87 [H] Boom extending/retracting operation ........... 3-88 Handling Electricity Related Parts ..................4-5 [C] Handling air conditioner................................3-38 Caution items ................................................. 3-5 Handling vehicle radio ..................................3-43 Cautions before crane operation.................. 3-82 Handling in the Cold Weather.....................3-132

Cautions during operations .......................... 3-96 Handling operation mode .............................3-81 Cautions in charging the battery ................ 3-137 Handling wire ropes....................................3-101 Cautions in special crane operation ............. 2-26 How to hook winch wire ropes Cautions on Maintenance ............................ 2-31 and the rated load.......................................3-101

Hooking winch wire ropes...........................3-102 Check and adjustment before starting engine.......................................................................... 3-49

Replacing wire ropes ..................................3-103

What to do with the twisted wire ropes .......3-107 Adjustment ................................................... 3-60 Check before starting operation ................... 3-52 Handling seat belt ........................................ 3-61 Hook storing operation (simplified storing) ...3-92 Operation and check before starting the engine ...................................................................... 3-63

How to hoist the machine ...........................3-129

Walk-around check ...................................... 3-49 How to hoist the machine with the boom lowered................................3-130

Controller ..................................................... 3-37 How to hoist the machine Controlling device overall view....................... 3-2 with the boom raised ..................................3-131 Crane operation overview ............................ 3-83 How to tow the machine .............................3-135 [D] Hydraulic Circuit Air Relief Procedure ..........4-24 Description of Each Device ............................ 3-4 [I]

Information on the serial number and [E] your sales service agency ..............................1-7 EMO SWITCH (EMERGENCY STOP SWITCH)....................................................................... 3-3 Electrical components................................ 3-140 Initial 50 Hour Maintenance (Only the First

Emergency stop items ................................... 3-6 Inspection and adjustment of wire ropes for

INDEX Ins-Saf

extending boom ......................................... 3-108

Oil/Fuel/Coolant Handling...............................4-3

Machine overall view...................................... 3-1

Machine's front, back, left, and right............... 1-4

Maintenance Every 2000 Hours................... 4-47 [P]

Cooling water .............................................3-132

Non-failure phenomena ............................. 3-135

Air Conditioner Inspection

Cooling System Internal Cleaning................ 4-13 Crawler Shoe Bolt Looseness Inspection/Retightening ............................... 4-17 Safety Signs ...................................................2-1

Crawler Tension Inspection/Adjustment .......4-18 Inspection and check after completing the operation .................................................... 3-100

Fuel Tank Internal Washing..........................4-16

Inspection and check after stopping the engine .................................................................... 3-100

Hydraulic Circuit Air Relief Procedure ..........4-24

Introduction .................................................... 1-1 Inspection/Cleaning/Replacement Slide Door Rail/Roller Inspection ..................4-23

[L] Water Separator Element Loading/Unloading the machine Replacement ................................................4-15 to/from the trailer........................................ 3-125 Of Air Cleaner...............................................4-10 Locked caps and covers .............................. 3-33 Notes about Machine......................................1-6 Locking ...................................................... 3-100 [O] Long-term Storage ..................................... 3-134 Before storing the machine ........................ 3-134 Cooling water .................................................4-4 During storage ........................................... 3-134 Filter ...............................................................4-4 After storage .............................................. 3-134 Fuel ................................................................4-3 [M] Grease............................................................4-4 Machine overview .......................................... 1-4 Oil ...................................................................4-3 Machine body............................................. 3-141 Stocking and Storage of Oils and Fuels .........4-4 Machine monitor ............................................ 3-4 Opening/closing Cab Front Window .............3-26

Operation levers and pedals Safety lock lever .........................................................................3-23

Machine serial number nameplate location.... 1-6 Operation posture.........................................3-90

Maintenance Cycle List .................................. 4-7 Checks before operation ..............................2-18 Maintenance Every 100 Hours..................... 4-29 Operation of the radio...................................3-46 Maintenance Every 1000 Hours.................. 4--40 Operation of the machine .............................3-49

Maintenance Every 250 Hours..................... 4-30 Parking the machine.....................................3-99 Maintenance Every 4000 Hours................... 4-48 Periodic Replacement of Maintenance Every 50 Hours....................... 4-27 Important Parts ...............................................7-1 Maintenance Every 500 Hours..................... 4-34 Position for attaching safety labels .................2-2 Maintenance Precautions .............................. 4-1 Preparing for low temperature ....................3-132 Manual holder .............................................. 3-48 Fuel and lubricating oil................................3-132 Meter indicator section................................... 3-7 Miscellaneous Parts....................................... 7-3 Battery ........................................................3-132 Moment limiting device ............................. 3-144 Cautions after completing the operation .....3-133 Moment limiting device (Overload protector) ........................................................................... 3-20

When the cold weather is gone ..................3-133

Monitor switch section.................................. 3-10 Prohibited matters during operation..............3-93 [N] [Q] Name of Each Section ................................... 3-1 Qualification....................................................1-5

Qualification for Operation..............................1-5 Non-routine maintenance............................. 4-10 [R]

Rated Total Load Table ..................................5-4 and Maintenance ......................................... 4-22 1 Rope Hook ..................................................5-6 Battery Fluid Level Inspection ...................... 4-12 2 Rope Hook ..................................................5-5 Cleaning and Grease Refilling ..................... 4-23 4 Rope Hook ..................................................5-4

Removing/installing battery ........................3-137 [S]

6-2

Ser-W INDEX

Service meter location ................................... 1-6

Specifications ................................................ 5-1

Starting the engine....................................... 3-65 Normal starting............................................ 3-65

Swing the machine ...................................... 3-80 Switches ...................................................... 3-12

Working radius and lifting height.................. 5-7

Sliding door ................................................. 3-32

Specified operations ...................................... 1-4 Starting engine............................................. 2-17 Starting moving (forward/backward) .......... 3-73

Starting in the cold weather ......................... 3-67 Operation and check after starting the engine ......................................................................... 3-69

Starting the engine with booster cable....... 3-138 Steering the machine ................................... 3-78 Stocking and storage of oils and fuels ........... 4-4 Stopping the engine ..................................... 3-72 Stopping the machine .................................. 3-73 Swing operation........................................... 3-89

[T] Torque list table............................................. 4-6 Towing/being towed.................................... 2-30 Transportation of the machine..................... 2-27 Transportation - legal provisions............... 3-124 Travelling hoist operation............................ 3-91 [W] What to do with abnormal condition ......... 3-135 What to do with this phenomenon............. 3-140 When the battery is discharged.................. 3-136 Working procedure........................................ 4-9

6-3

Replacement Parts

Periodic Replacement of Important Parts REPLACEMENT PARTS

Periodic Replacement of Important Parts For safe and long-term use of the machine, please be especially careful to periodically replace parts in the important parts list table. These parts, as time passes, are prone to deteriorate likely to be affected by wearing and degrading, but the seriousness of such problems cannot be easily judged by periodic maintenance, therefore full functionality should be preserved at all times by replacing such parts with new ones after they have been used for certain time, even if no particular abnormality is noticeable. Even before their replacement is due, these parts need to be repaired/replaced if any abnormality is found. When a deformation or split is found in the clamp of a hose section, replace the clamp together with the hose. Also inspect hydraulic hoses that do not have to be periodically replaced and, if any abnormality is noticed, retighten or replace them.

Inspection Item

When replacing a hose, replace the relevant O-rings and gaskets at the same time. Ask our sales service agency for replacements of an important part. When carrying out one of the following periodic inspections, also inspect the hydraulic and fuel hoses.

Inspection Class Pre-start inspection Oil leak from fuel/hydraulic hose connection or caulked section Monthly inspection Oil leak form fuel/hydraulic hose connection or caulked section

Fuel/hydraulic hose damage (split, wear, nipping) Yearly inspection Oil leak from fuel/hydraulic hose connection or caulked section

Fuel/hydraulic hose mutual interference, crush, aging, twist, damage (split, wear, nipping)

Important Parts List Table No. Periodic Replacement Part Qty Replacement Cycle 1 Fuel hose (between fuel tank and water separator) 1 2 Fuel hose (between water separator and feed pump prefilter) 1 3 Fuel hose (feed pump prefilter and fuel filter) 1 4 Fuel hose (fuel filter and injection pump) 1 5 Fuel return hose (between fuel filter and union tee) 1 6 Fuel return hose (between nozzle and union tee) 1 7 Fuel return hose (between union tee and fuel tank) 1 8 Spill hose (between nozzle and filler opening hose) 1 9 Hydraulic hose (between pump outlet and operation valve) 1 10 Hydraulic hose (telescopic cylinder inlet) 1 11 Hydraulic hose (derrick cylinder inlet) 1 12 Hydraulic hose (winch motor inlet) 1 13 Hydraulic hose (swivel motor inlet) 1 14 Hydraulic hose (main pump suction) 1 15 Hydraulic hose (gear pump suction) 1 16 Heater hose 1 17 Water separator (case, plug, O-ring) 1 each

2 years or 4000 hours, whichever is earlier

18 Seatbelt 1 Replace every 3 years

7-1

REPLACEMENT PARTS Consumable Parts

Consumable Parts Replace consumable parts such as the filter element, air cleaner element or wire ropes when carrying out periodic maintenance and before the wear limit arrives. Replace consumable parts securely to use this machine more economically. Use genuine Maeda products when replacing a part. Part numbers may change due to product upgrades, so when you order a part, tell the serial number of your machine to our sales service agency and confirm the latest part number. Consumable Parts List Table

Item Part Number Part Name Qty Replacement Cycle Engine oil filter 600-211-2110 Cartridge 1 Every 500 hours

Fuel filter 600-311-7460 Cartridge Every 500 hours 1 Hydraulic oil filter

Return MHS553-J078502 Cartridge 2 Every 250 hours

Hydraulic oil filter Suction

MHS553-J078602 Cartridge 1 Every 1000 hours

Hydraulic oil filter Line

MHS551-2012400 Element ass'y 1 Every 25 hours

Air cleaner MHS556-W153802 Element ass'y 1 - Wire rope Winch MHS553-P081400 Wire rope

ø10 X 155m 1 -

Wire rope No. 4 boom extending

MHS551-3032900 Wire rope Ø14 X 8.8m

2 -

Wire rope No. 5 boom extending

MHS551-3032800 Wire rope Ø10 X 8.5m

2 -

Wire rope No. 4 boom retracting

MHS551-3032700 Wire rope Ø 8 X 14.8m

2 -

Wire rope No. 5 boom retracting

MHS551-3032600 Wire rope Ø 6 X 14.2m

2 -

• Replace the packing and seal of each cylinder, and also the boom slide plate every 3 (3) years.

7-2

Miscellaneous Parts REPLACEMENT PARTS

Miscellaneous Parts

Part Number

Part numbers may change due to product upgrades, so when you order a part, tell the serial number of your machine to our sales service agency and confirm the latest part number.

Miscellaneous Parts List Table No. Part Name Qty 1 22B-54-15811 Part Name 1 2 21B-54-17931 Window glass 1 3 22W-54-46910 Window glass 1 4 22B54-15221 Clear plate 1 5 1 22B54-15350 Window glass 6 22B-54-15211 Window glass 1 7 21W-54-46220 Window glass 1 8 22B-54-16150 Window glass 1 9 568-06-15910 Mirror 1 10 22B-54-17211

08116-02410 Interior roof lamp - Bulb (10W) 1

11 MHS551-4040600 Working light ass'y (boom) 1 12 MHS552-W014700 Working light ass'y (chassis) 1 13 08041-00500

08041-01000 08041-01500 08041-02500 08041-03000

Fuse (5A) Fuse (10A) Fuse (15A) Fuse (25A)

11 3 1 1 Fuse (30A)

4

14 2 S556-M162200 Fusible link 15 04120-21747 Fan belt 1 16 04120-21743 Air conditioner belt 1

7-3

REPLACEMENT PARTS Air Temperature Dependent Fuel and Lubricant Grease Use Method

Air Temperature Dependent Fuel and Lubricant Grease Use Method Fuel, Oil and Cooling Water Use selectively as follows, depending on the air temperature. The standard oil quantities indicate the total oil quantities that include oil within the pipes of devices, while the replacement oil quantities indicate quantities of the oil to be replaced at the time of inspection or maintenance. In case the engine is to be started in a less than 0 °C or lower air temperature, ALWAYS use SAE10W, SAE10W-30 or SAW15W-40 even if the daytime air temperature is as high as 10 °C. * Use our recommended, wear-resistant hydraulic oils (ISO VG32, VG46).

Air Temperature Dependent Usage Oil Fill Section Oil Type -30 –20 -10 0 10 20 30 40 50

Engine oil pan

Swing machinery case Final drive case

Engine oil

Winch reductions gear

Gear oil

Hydraulic oil system

Wear resistant hydraulic oil

Fuel tank

Diesel oil

Cooling system Coolant Add antifreeze

S

S

S

S

S

S

I

I

ASTM D975 No. 1

Engine oil

pan Swing

machinery case

Final drive case

Winch reduction

gear

Hydraulioil system

Standard oil quantity (liters)

7.5 2.0 1.3 to both right and left

1.4 127

Replacement oil quantity

(liters)

7.0 2.0 1.3 to both right and left

1.4 120

AE30CD

AE10WCD
AE10W-30CD AE15W-40CD AE30CD AE 90 SO VG46 (-10 TO 80Oc) SO VG432 (-15 TO 70Oc) ASTM D975 No.2
c

Fuel tank Cooling system

141 10.5

- -

7-4

Documents

NJAMD00400 Operation Manual - Maeda Mini Cranesmaedaminicranes.co.uk/pdf/lc785/LC785_Operation_Manual.pdfNJAMD00400 Operation Manual CRAWLER CRANE Applicable to No.31001 and later