Maeda CC1485S-1 Operation Manuals Download Page 233

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225

INSPECTION AND

MAINTENANCE

1. PRECAUTIONS FOR MAINTENANCE

226

2. BASIC MAINTENANCE

228

3. LEGAL INSPECTION

232

4. PERIODIC REPLACEMENT OF CRITICAL PARTS

233

5. CONSUMABLES

234

6. OTHER REPLACEMENT PARTS

235

7. USE OF FUEL AND LUBRICATING OIL

236

8. STANDARD TIGHTENING TORQUE

238

9. LIST OF ITEMS FOR INSPECTION AND MAINTENANCE

239

10. MAINTENANCE PROCEDURES

241

11. AIR BLEEDING OF HYDRAULIC CIRCUITS

284

12. RELIEVING INTERNAL PRESSURE OF HYDRAULIC CIRCUIT

288

13. ATTACHING/DETACHING SINGLE-FALL HOOK

289

Summary of Contents for CC1485S-1

Page 1: ...ad this manual before operating this machine This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it NOTICE MAEDAhas Ope...

Page 2: ......

Page 3: ...FETY 13 1 BASIC PRECAUTIONS 14 1 1 PRECAUTIONS BEFORE STARTING WORK 14 1 2 PREPARING FOR SAFE OPERATION 15 1 3 PRECAUTIONS FOR FIRE PREVENTION 17 1 4 CAUTIONS IN GETTING ON AND OFF THE MACHINE 18 1 5...

Page 4: ...G PREVENTION DEVICE 104 2 6 AIR CONDITIONER HANDLING 105 2 6 1 COMPONENTS OF CONTROL PANEL 105 2 6 2 AIR CONDITIONER OPERATION METHOD 109 2 6 3 PRECAUTIONS IN AIR CONDITIONER USE 111 2 6 4 INSPECTION...

Page 5: ...ING 165 3 14 PRECAUTIONS BEFORE CRANE OPERATION 168 3 15 OPERATION BEFORE CRANE WORK 170 3 16 CRANE OPERATION POSTURE 172 3 17 HOISTING AND LOWERING OPERATION 173 3 17 1 NORMAL HOISTING AND LOWERING O...

Page 6: ...6 HANDLING WHEN COLD 206 6 1 PREPARING FOR LOW TEMPERATURE 206 7 LONG TERM STORAGE 208 7 1 BEFORE STORING MACHINE 208 7 2 DURING STORAGE 208 7 3 AFTER STORAGE 209 8 TROUBLESHOOTING 210 8 1 WHEN FUEL...

Page 7: ...ATION INSPECTION 241 10 3 IRREGULAR MAINTENANCE 242 10 4 MAINTENANCE EVERY 50 HOURS 258 10 5 MAINTENANCE EVERY 250 HOURS 260 10 6 MAINTENANCE EVERY 500 HOURS 264 10 7 MAINTENANCE EVERY 1000 HOURS 274...

Page 8: ...MONITOR DISPLAY 342 5 1 1 MONITOR DISPLAY IN FLY JIB MODE 342 5 1 2 MONITOR DISPLAY WHEN FLY JIB IS STOWED 344 5 2 MOMENT LIMITER FUNCTIONS 345 5 2 1 DISPLAY FOR FLY JIB MODE SWITCHING 346 5 3 SETTIN...

Page 9: ...1 INTRODUCTION 1 INTRODUCTION 2 2 FOR SAFE USE OF THE MACHINE 3 3 MACHINE OVERVIEW 4 4 QUALIFICATION FOR OPERATION 6 5 CRANE TERMINOLOGY 7...

Page 10: ...ghly Keep this manual at hand so that you can read it when necessary If you lose or damage this manual contact Maeda or our sales service agency immediately to order a new one This manual should alway...

Page 11: ...to avoid such hazard This manual also uses the following indications to provide other precautions for handling the machine and helpful information This denotes that failure to properly handle the mac...

Page 12: ...te and lifting an object weighing up to the rated total load 3 2 MACHINE STRUCTURE 1 Carrier 2 Upper slewing body 3 Safety device In this manual the front rear left and right directions are defined wi...

Page 13: ...er machine body inclination alarm leveling instrument working status lamp and the crane and travelling operation locking lever 3 3 MACHINE FUNCTIONS 1 CARRIER The carrier is of a crawler type which fa...

Page 14: ...defined in this manual shall be observed for safety assurance during operation of the machine 4 1 QUALIFICATION FOR CRANE OPERATION Only personnel that have obtained the required license or training...

Page 15: ...oisting accessories hooks and slinging ropes from the rated total load and can be hoisted 3 WORKING RADIUS A horizontal distance between the axis of slewing and the hook centre 4 BOOM LENGTH Refers to...

Page 16: ...ure at right indicates the boom angle and point B the lifting height above ground The working radius of points A and B are the same 2 The diagram of working radius and lifting height shows the relatio...

Page 17: ...extent perform the work within the capacity indicated in the column of boom 4 When more than one half of the mark of boom 4 is exposed from boom 3 perform the work within the capacity indicated in th...

Page 18: ...10 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects depending on boom length by working radius...

Page 19: ...1 4 745m boom 1 All the booms are retracted 2 7 625 m boom 2 Booms 3 4 and 5 are retracted while boom 2 alone is fully extended If boom 2 is extended even to a small extent perform the work in the ca...

Page 20: ...exposed half way from boom 3 If booms 4 and 5 are extended even to a small extent perform the work in the capacity indicated in this column 5 16 265 m boom 5 All the booms are fully extended When more...

Page 21: ...IONS 20 3 TRANSPORT PRECAUTIONS 37 4 MAINTENANCE PRECAUTIONS 39 5 SAFETY LABEL LOCATIONS 48 All the safety precautions defined in this manual should always be read and observed Failure to follow the s...

Page 22: ...mobile cranes all the time Also when performing a slinging operation always carry the completion certificate of skill training course for slinging operation The operators are requested to receive educ...

Page 23: ...ompletely before use The fuel for this Machine is diesel fuel Be especially careful for the presence of fuel leak Before leaving the Machine lower the hoisted load to the ground stop the engine and pu...

Page 24: ...ions If the Machine malfunctions it may behave unexpectedly resulting in serious injury CLEAN AND TIDY UP THE OPERATOR S CABIN Before getting in the cabin wipe off shoe soles to remove dirt oil and gr...

Page 25: ...to a safe place Fire due to deposition or adherence of combustibles If any of such combustibles as dead leaves chips paper litters and charcoal dust is deposited on or sticking to the peripheral area...

Page 26: ...treated with anti skidding coating Do not get on or off the machine while holding a tool in hand Do not jump on or off the Machine Also do not get on or off the moving Machine Even if the Machine une...

Page 27: ...units may give rise to safety and legal issues and thus the customer is kindly requested to consult with us or our sales service agency beforehand Depending on the combination of attachments and optio...

Page 28: ...d will be unstable The ground of an area near an earth fill or in the vicinity of a dug gutter may be collapsed by the mass and or vibration of the Machine resulting in the trip or fall of the Machine...

Page 29: ...safe distance shown in the following table between the boom Machine frame and electrical cables MEASURES WHEN CHARGE ACCIDENT OCCURS If a charge accident occurs react calmly and take measures in the...

Page 30: ...ch as the hook or wire exists BEWARE OF ASBESTOS DUST Inhalation of asbestos dust may result in lung cancer This Machine does not contain asbestos but asbestos may be found in the wall ceiling or othe...

Page 31: ...ge or abrasion Refer to the descriptions under OPERATION 3 1 2 11 ADJUSTING THE OPERATOR S SEAT Adjust the mirrors to the best position for commanding a good view of rear scene and the drum from the d...

Page 32: ...ches sensors or similar part If the infiltrated condensation and or similar substance freeze the Machine may operate improperly upon the next use and cause unexpected accidents CAUTIONS WHEN STARTING...

Page 33: ...ver and thus the Machine may move toward undesired direction resulting in serious bodily accidents Make sure the boom is fully lowered and retracted When moving the Machine for a short distance fix th...

Page 34: ...bstacle Travel as slowly as possible when moving over an obstacle for unavoidable reason Since the Machine tends to tumble more easily in the lateral direction rather than in the longitudinal directio...

Page 35: ...e Climbing the slope in the forward direction and going downhill in the reverse direction cause the Machine to be unstable giving rise to the risk of tumbling or lateral skidding When running on an in...

Page 36: ...tumbling or collision because of an invisible road shoulder or snow covered installations Be very careful Refrain from directly touching metal surface with your hands or fingers in cold and harsh wea...

Page 37: ...the crane is used with no correct indication given correct measurement results cannot be obtained causing serious physical injury due to tumbling or damage of the machine When using the moment limiter...

Page 38: ...slewing gear boom and around winch and ensure that their movements before starting work Check the brake of winch to ensure that it works properly Operating the Machine without sufficient engine warm u...

Page 39: ...cause the Machine to trip or damage the boom Be very careful during the work The higher the boom is derricked the higher the probability of tumbling backward is raised by wind blowing from ahead Thus...

Page 40: ...ket to hit and damage the other hoisted load or the loads move and lose balance causing serious accidents such as tripping Do not hoist more than 1 piece of load even if the total combined weight is w...

Page 41: ...vent the wire rope and or hoisted load from contacting an obstacle such as a tree or steel when hoisting a load If caught by an obstacle do not forcibly wind up the hoist load but untangle the caught...

Page 42: ...d load from contacting an obstacle such as a tree or steel when hoisting a load If caught by an obstacle do not forcibly wind up the hoist load but untangle the caught part before winding up Do not us...

Page 43: ...the load is hoisted which may cause the load to waggle and cause the Machine to lose balance and thus may damage the crane or trip the Machine Attempts to pull the load towards the machine or let the...

Page 44: ...orking posture prescribed in the instruction manual Refer to the descriptions under OPERATION 3 24 2 OPERATION POSTURE DURING TRAVELLING HOIST As to the hoisted load limit its weight within an allowan...

Page 45: ...e In addition keep enough distance from the roadside Use the ramps under 15 or smaller angle In addition decide the clearance between ramps to meet the center of the crawler Use the ramps that have fu...

Page 46: ...f the ground or the platform Set the Machine to a traveling posture and be slow when operating to change the direction on the trailer platform where the footing is unstable After loading the Machine b...

Page 47: ...the instruction manual TIDY UP WORKPLACE Always tidy away tools hammers and other things that obstruct the working area grease and oil should be wiped off immediately after use to assure safe operatio...

Page 48: ...AINTENANCE WITH ENGINE RUNNING To prevent accidents do not attempt maintenance when the engine is running Always observe the following in case of maintaining with the engine running for unavoidable re...

Page 49: ...isk of bodily accidents caused by falling or stumbling due to slipping never step on a hood or cover When working on the engine hood use a safety belt CAUTIONS WHEN WORKING UNDER THE MACHINE AND CRANE...

Page 50: ...ering your eye or slipping and tripping that result in injury Always observe the following when washing the vehicle Use antis lip shoes to prevent slips and trips caused by wet foothold Put on protect...

Page 51: ...er available on the market to the UPPER LEVEL Do not smoke or use fire near the battery During recharging the battery it generates hydrogen gas that is flammable Before recharging it dismount if from...

Page 52: ...nd plug have been cooled down so that they can be touched by bare hand in order to prevent a burn injury because of the spewing hot oil or coming in contact with parts heated at high temperatures When...

Page 53: ...ally swollen Indication of twist or collapse on a movable part of hose Foreign object buried in coating BEWARE OF HIGH VOLTAGE During or at immediately after stopping an engine operation the inside of...

Page 54: ...ION OF AIR CONDITIONER If the refrigerant of air conditioner get into the eyes loss of sight may occur and if it comes into contact with skin it gives rise to a frostbite Never loosen parts of the coo...

Page 55: ...uch parts as hoses and seat belts Materials of these parts tend to change their properties with elapse of service time and will degrade abrade and show fatigue with repeated services and thus may caus...

Page 56: ...S Keep safety labels clean and visible at all times If lost replace immediately or apply for a new one There are other labels than safety labels shown below and treat them in the same manner SAFETY LA...

Page 57: ...49 SAFETY LABEL LOCATIONS OUTSIDE OF THE CABIN...

Page 58: ...50 SAFETY LABEL LOCATIONS IN THE ENGINE ROOM...

Page 59: ...51 1 Safe operation 557 3494500 2 Working range diagram 585 2236900...

Page 60: ...52 3 Washing caution 300 4213900 4 Lever operating patterns 585 3555400 5 Warning on switching numbers of falls 585 3555500...

Page 61: ...53 6 Operating the moment limiter 585 2237000 7 Warnings on operation inspection and maintenance 584 3469700 9 Cautions in repairing window breakage 585 4739300 8 Operation prohibiting tag 585 4738300...

Page 62: ...gh temperatures of muffler 349 4427800 11 Cautions in opening closing the front window 585 4738400 10 Cautions in retracting the front window glass CL000160010 12 Cautions in slewing 584 4588100 15 Di...

Page 63: ...nst the risk of burns CL000170000 2 spots 18 Caution against rotating parts in the engine room CL000080000 17 No entry within the slewing area CL000180013 19 Cautions for plug popping out CL000190010...

Page 64: ...e fenders CL000210000 24 Warning for winch 553 4267500 25 Caution against being entangled by the hook block 553 4267400 26 Warning 553 4268000 27 Body mass indication 585 4738900 28 Hoisting position...

Page 65: ...220030 34 Warning on boom hoisting Accessories 103 4576900 31 Caution against rotation 557 4632500 32 Do not step on 584 4581700 2 spots 36 Cautions on override switch 585 4739200 37 Cautions against...

Page 66: ...58 38 Hoisting machine Fixing machine 585 3558800 39 Caution air cleaner 585 4738700 40 Caution pressure wash CL000240110 2 spots...

Page 67: ...PERATION 1 NAME OF EACH SECTION 60 2 EXPLANATION OF ALL EQUIPMENT 63 3 OPERATION 130 4 HANDLING OF WIRE ROPE 192 5 TRANSPORTATION 197 6 HANDLING WHEN COLD 206 7 LONG TERM STORAGE 208 8 TROUBLESHOOTING...

Page 68: ...king lamp 3 Boom Derrick Cylinder 4 Winch 5 Head lamp 6 Wiper Front window 7 Wiper Roof Window 8 Sprocket travel motor 9 Track Frame 10 Idler 11 Crawler 12 Hook block 13 Overwinding detector 14 Rotati...

Page 69: ...itor 9 Right work operation lever Horn switch on knob part 10 Starter switch 11 Fuel adjustment dial 12 Lamp switch 13 Front window wiper switch 14 Roof window wiper switch 15 Buzzer canceling switch...

Page 70: ...switch 5 Travel 1st speed 2nd speed selector switch 6 Working range regulation setting and canceling switch 7 Working range regulation setting check all canceling switch 8 Fuel gauge 9 Warning display...

Page 71: ...rrect safe and comfortable work 2 1 MACHINE MONITOR 1 STARTING SCREEN When the starter switch is turned ON the starting screen is displayed After the starting screen is displayed the standby gauge is...

Page 72: ...switch 5 Travel 1st speed 2nd speed selector switch 6 Fuel gauge 7 Clock display 8 Hour meter display 9 Working mode display 10 Auto deceleration display 11 Winch 1st speed 2nd speed display 12 Travel...

Page 73: ...image adjust the camera angle 2 USER MODE SWITCH When the user mode switch 2 is pressed on the top screen the user mode is displayed 2 1 Auto deceleration ON OFF change 2 2 Working mode change 2 3 Hoo...

Page 74: ...ode display 9 on the top screen is changed 2 3 HOOK FALL NUMBER CHANGE When the switch 2 3 is pressed and held the hook fall number can be changed Four falls Two falls One fall When the fall number is...

Page 75: ...ate and time desired to be changed with or of the adjustment switch 2 6A and press the check mark 2 6B The part whose background is white is selected When the word color turns red editing becomes poss...

Page 76: ...he required page Once you ve selected a consumable item hold down the replacement switch 2 9B and update the replacement time Once updated the number of replacements is incremented by 1 while the rema...

Page 77: ...ort time pressing Returns one page Long time pressing Returns to the top screen 2 12 DISPLAY PAGE CHANGE Each time the switch is pressed the page changes 1 2 page to 2 2 page to 1 2 page 2 13 SOFTWARE...

Page 78: ...precautions in travelling with a lifted load are observed serious physical injury may be caused When the switch 4 is pressed the mode can be changed from the stationary mode to the travel mode enablin...

Page 79: ...cator comes near the red color of the meter check the fuel quantity in the fuel tank and replenish fuel NOTES Although the indicator may not point to the correct position for a while after the starter...

Page 80: ...which immediate action must be taken are displayed When an abnormality occurs the monitor of the abnormal part illuminates in red and the buzzer sounds 1 Abnormality display abnormality detected 2 En...

Page 81: ...73 2 LIST OF ERROR CODES If the following error codes are displayed see Operation 8 Action in the case of abnormality If you think there is another reason ask us or our sales service agency for repair...

Page 82: ...74...

Page 83: ...canceling switch 7 Accessory power supply 8 Horn switch 9 Room lamp switch 10 Emergency accelerator driving switch with guard 11 Slewing parking brake emergency canceling switch with guard 12 Emergen...

Page 84: ...ur hand from the key The key automatically returns to the ON position The engine of this machine has the automatic remaining heat function If the engine does not crank when it is cold AUTO GLOW lamp i...

Page 85: ...ps 5 ROOF WINDOW WIPER SWITCH Use this switch to activate the wiper of the cab roof window and window washer fluid a Wiper position The wiper operates b Washer position When the switch continues to be...

Page 86: ...on the knob part of the right work equipment operation lever is pressed the horn honks 9 ROOM LAMP SWITCH CAUTION Failure to turn off the switch causes the battery to be discharged Be sure to turn the...

Page 87: ...ncy position in the normal case the engine abnormality P0101 error is displayed on the monitor even if the switch is returned to the b Normal position However this is not a fault In this case take the...

Page 88: ...ler is abnormal Do not use this switch except in the abnormal case Promptly repair the abnormal area Use this switch to perform slewing operation temporarily when an abnormality occurs a Release posit...

Page 89: ...H This switch is not used for crane operations It is a maintenance switch for servicing 14 LEVELLING INSTRUMENT If crane operation is performed with the machine tilted it may cause tripping Find a pla...

Page 90: ...uch operation may cause serious physical injury due to machine tipping breakage or dropping of a load Therefore avoid such operation as much as possible Use this switch when changing the speed at the...

Page 91: ...n death or serious injury Use this switch only when the moment limiter which detects the crane conditions fails or a load test of the crane is conducted Key for the switch must be detached during norm...

Page 92: ...D of the switch box lights up The buzzer sounds continuously The icon will be displayed on the monitor Overriding Turn stater key off to reset The above statuses will change as follows 30 seconds befo...

Page 93: ...hen standing up from the driver seat place the lock lever securely in the lock position L If the lock lever is in the free position F and contacts the operation levers and operation pedals carelessly...

Page 94: ...When the track frame faces rearward the direction of travel lever operation is opposite to the direction of machine movement forward and rearward movement right and left movement direction When opera...

Page 95: ...ht direction b Left slewing Push the lever in the left direction Extension and retraction operation of boom c Retraction of boom Pull the lever rearward d Extension of boom Push the lever forward N Ne...

Page 96: ...lever to adjust the engine speed or output during crane operation a Low idling Release your foot from the pedal b Full revolution Depress the pedal fully NOTES As a priority is given to the engine sp...

Page 97: ...cking cylinder section 2 pieces 4 Overwinding detector side of boom tip 5 Rotating warning lamp A Rotating red lamp warning lamp when load factor is 100 or more B Rotating yellow lamp prediction lamp...

Page 98: ...ct operation of the moment limiter to make sure that there is no abnormality 1 MECHANISM OF MOMENT LIMITER The moment limiter knows the current posture by the boom angle meter and boom length meter an...

Page 99: ...boom for example Boom lowering operation Boom hoisting operation Boom extending operation Hook hoisting operation 2 RECOVERY OPERATION FROM AUTOMATIC STOP If an automatic stop occurs you will not be a...

Page 100: ...ing action Boom lowering action Boom hoisting action In addition audible warning Peep overload is issued 4 RECOVERY OPERATION FROM AUTOMATIC STOP To perform recovery operation from overload perform ei...

Page 101: ...er Only use this switch when an automatic stop has occurred through entry into the overload region while lowering or extending the boom Do not use under normal conditions or when lifting clear from th...

Page 102: ...work radius display 5 Boom length display 6 Lifting height display 7 Number of wire falls display 8 Boom angle lower limit display 9 Boom angle upper limit display 10 Working radius upper limit displ...

Page 103: ...ed total load i e total weight of hook hoisting attachment and hoisted load which the crane can currently hoist is displayed It is calculated according to the conditions including the number of wire f...

Page 104: ...ing warning and automatically stops hook hoisting and boom extension actions During hook storage operation the mark flashes in red in a hook stored state However this is not an abnormality 9 Overlower...

Page 105: ...erations see OPERATIONS 2 4 3 2 RECOVERY OPERATION FROM AUTOMATIC STOP 4 WORKING RANGE LIMIT DEVICE When the set value of the working range limit is neared an alarm is issued to notify the driver and...

Page 106: ...upper limit stop state an alarm sounds intermittently only if lowering operation or extension operation is performed The set value is memorized when the starter switch is turned to the OFF position Wh...

Page 107: ...the upper limit value of the working radius Setting Set the boom to the desired working radius in a condition in which no upper limit value is set and press and hold the switch The upper limit value o...

Page 108: ...recover from the stop For recovery operation perform hook lowering operation and boom retraction operation 6 Overlowering prevention device When the hook is lowered and length of wire rope in the win...

Page 109: ...a lifted load is in principle not advisable because it is very unstable and involves danger If travel with a lifted load is unavoidably performed see OPERATION 3 24 OPERATION DURING TRAVELLING HOIST a...

Page 110: ...oad boom breakage and machine tipping due to cutting of the winch wire rope After the moment limiter detects that the rated total load is exceeded during crane operation and automatically stops the op...

Page 111: ...inuously The icon will be displayed on the monitor Overriding Turn stater key off to reset However these behaviors are subject to change depending on the status of the Machine body Although the boom l...

Page 112: ...the boom 4 automatically stops hook block 1 hoisting and boom 4 extension actions and prevents any further action if the hook block 1 nears the boom 4 tip and pushes up the weight 3 At the same time o...

Page 113: ...OFF switch 2 Fan switch 3 Temperature setting switch 4 Air outlet selector switch 5 Defroster air flow switch 6 Fresh and recirculating air selector switch 7 Display panel 8 A C switch 1 ON OFF SWITC...

Page 114: ...unt of air flow decreases Monitor display and amount of air blow Monitor display Amount of air blow Air flow Weak Air flow Medium 1 Air flow Medium 2 Air flow Strong 3 TEMPERATURE SETTING SWITCH Use t...

Page 115: ...n Air outlet D Front windshield air outlet 1 location Liquid crystal display Air flow mode Air outlet A B C D Front air flow Front and rear air flow Front and rear foot air flow Foot air flow Foot air...

Page 116: ...lass 7 DISPLAY MONITOR This display monitor 7 displays the state of the temperature setting a amount of air flow b and air outlets c When the OFF switch 1 is pressed the display of temperature setting...

Page 117: ...turn it to ON 3 Press the temperature setting switch 3 to adjust the temperature to the desired one 4 Press the air outlet selector switch 4 to select the desired air outlet At this time the display...

Page 118: ...tlet is the defroster on the display panel 3 Press the fresh and recirculating air selector switch 6 to take in fresh air 4 Press the temperature setting switch 3 to set the set temperature display of...

Page 119: ...ling The cooling temperature is said to be optimal for the health if you feel a little cool difference from outside temperature 5 6 C the moment you enter the cab Pay due attention to temperature adju...

Page 120: ...Characters numerical value information such as the band name frequency and clock is displayed b The frequency at the time of FM 50kHz step is displayed c This turns on at the time of stereo reception...

Page 121: ...s of 1 6 memorize the frequency of broadcasting stations and select the station with one touch Six stations each of AM and FM can be memorized See OPERATION 2 7 2 CAR RADIO OPERATION METHOD for the pr...

Page 122: ...sure to store the antenna to keep out of the way during transportation or when you take the machine in the garage Take the following steps for storage 1 Loosen the antenna mounting bolt 1 and store th...

Page 123: ...station with the lower frequency is automatically selected button A station with the higher frequency is automatically selected When this button is pressed again during auto tuning auto tuning is canc...

Page 124: ...nd emphasized its volume button This selects the left speaker and emphasized its volume BAL0 is a state in which the right and left are balanced Default value NOTES In all modes the display returns au...

Page 125: ...PRECAUTIONS IN CAR RADIO USE For your safety use the volume control to the extent that you can hear sound outside the machine during operation Listening at a high volume for long hours may cause hear...

Page 126: ...city and circuit name Systems and capacities of fuses are as follows No Capacity Connection table 1 10A Operation switch 2 5A Operation switch 3 30A Controller I O power supply 4 5A Controller K15 Mon...

Page 127: ...e link is located on the left side in the battery room If the following phenomena occur a fusible link is considered to be broken Open the battery room and inspect and replace the fusible link If the...

Page 128: ...occurs in the controller do not repair it by yourself but contact us or our sales service agency for inspection and repair 1 MACHINE CONTROLLER AND MOMENT LIMITER CONTROLLER The controllers are instal...

Page 129: ...h When closing the front window hold the handle securely with both hands to close The upper side front window can be stored in the interior ceiling pull up 1 WHEN OPENING 1 Stop the machine on a level...

Page 130: ...ing the front window slowly lower it to prevent your hand from being pinched 1 Stop the machine on a level place and stop the engine 2 Place the lock lever 1 securely in the lock position L 3 While ho...

Page 131: ...it is opened and closed on a slope operating force may change suddenly which is dangerous Be sure to hold the door handle 1 when performing opening and closing operation of the door Be careful not to...

Page 132: ...move pieces of the glass from the sash to avoid injury by pieces of the glass Pay also due attention so that you will not slip on pieces of the broken glass A hammer 1 is provided in the left rear pil...

Page 133: ...cap and cover with lock 1 Machinery cover 2 Cab door 3 A C filter 4 Left cover 5 Right cover Method of opening and closing the cover with lock for cover with lock When opening when locked 1 Insert the...

Page 134: ...rod 3 to remove it from the groove and close the door 2 16 LEFT COVER When performing inspection and maintenance inside the door be sure to fix the door in an open condition by using the stopper Be su...

Page 135: ...sing the stopper Be sure to lock the door except when opening it 1 Disengage the lock 1 of door locking 2 Insert your finger into the door pull 2 and open the door 3 3 After opening the door 3 put the...

Page 136: ...ob 1 to make it an open state 2 After pulling out the key open the machinery cover 2 while pushing the machinery cover open knob 1 3 After opening the machinery cover fix the machinery cover supportin...

Page 137: ...nufacture is woven in the back of the belt Be sure to wear the seat belt during operation Do not wear the seat belt in a twisted condition As this seat belt has a retractable device it is not necessar...

Page 138: ...el hose or fuel hose connections Build up of combustibles and oil leakage around the hot engine section such as engine and muffler and around the battery can cause fire in the machine Make a thorough...

Page 139: ...is found Check the working lamp for breakage noticeable deformation or contamination Repair if any abnormality is found Clean if there is any contamination Check the electric wiring for slackness con...

Page 140: ...nd Clean if there is any contamination 5 INSPECTION OF CABIN Inspect if windows have come off or broken and if window glasses are cracked or broken Repair if any abnormality is found Check the seat be...

Page 141: ...e on a level surface 2 Open the machinery cover 3 Inspect the sub tank 1 level and check that the coolant is between FULL and LOW 4 If the coolant level is lower than the LOW level use the following p...

Page 142: ...to the filler opening when refilling the oil 1 Place the machine on a level surface 2 Open the machinery cover 3 Pull the oil level gauge 1 out and wipe the oil with a disposable cloth 4 Insert the oi...

Page 143: ...RES for the fuel to be used Be careful not to let any foreign substance go into the filler opening when refueling 1 Place the machine on a level surface 2 Turn the starter switch to the ON position an...

Page 144: ...n checking the oil level Checking the oil level in the working position will cause overfilling since the oil in the cylinders has not returned to the tank See OPERATION 3 7 MACHINE TRAVELLING POSTURE...

Page 145: ...of the tank is located between the right and left crawlers 2 Stop the engine and wait until the hydraulic oil cools down 3 Remove the drain plug 3 to drain the oil 4 Inspect the oil level again 5 INS...

Page 146: ...eezes check that frozen water melts completely before draining water Water draining The water separator is integral with the fuel filter and inspect the water separator of the main filter 1 and sub fi...

Page 147: ...N FUEL TANK Prepare a container to receive drained water 1 Slew the revolving super structure so that the drain valve 1 on the bottom of the tank is located between the right and left crawlers 2 Stop...

Page 148: ...ls are loosened If loosened retighten them In particular inspect the wiring of Battery Starter and Alternator Be sure to inspect if combustibles accumulate around the battery and remove them 9 CHECKIN...

Page 149: ...2 upward adjust the seat back to the easy to operate position and release your hand from the lever 2 Bring your back into intimate contact with the seat back for adjustment The seat back may suddenly...

Page 150: ...ror stay 1 with the mirror position extended to the maximum If the mirror movement is stiff during adjustment loosen the mirror bolt 2 and mirror mounting bolt 3 to adjust Tightening torque of bolt 2...

Page 151: ...ng caused by the winch drum cannot be checked This not only damages the wire rope but also shakes a hoisted load at the time of lowering leading to instability and serious physical injury Adjust the m...

Page 152: ...osition remove the cover 1 and adjust the mounting angle A of the rear view camera 1 Remove the bolt 2 2 locations to remove the cover 2 Loosen the camera mounting bolt 3 on both sides and adjust the...

Page 153: ...water example commercial battery replenisher should be refilled before starting work the next day to avoid freezing Be sure to perform a battery electrolyte level check at least once a month according...

Page 154: ...lling opening 3 to check 3 If the electrolyte level does not reach the sleeve 4 be sure to refill purified water up to the bottom highest electrolyte level of the sleeve 4 A Proper amount As the elect...

Page 155: ...vice agency to request inspection in good time 2 CHECKING LOW SPEED AND ACCELERATION STATE OF ENGINE Check if variations in engine rotation occur or the engine suddenly stops when the machine stops in...

Page 156: ...r is operated to RETRACT side pulled backward At this time check if abnormal noise is generated from various parts of the boom or boom telescopic cylinder Repair if any abnormality is found 3 Verify t...

Page 157: ...conds the green rotating warning lamp illuminates 3 Start the engine and operate the crane as follows Then check if the display of the moment limiter is correct Crane operation and display item Displa...

Page 158: ...ver is in the Neutral position Unless each operation lever is not touched it is in the Neutral position 3 Insert the key into the starter switch 2 turn the key to the ON position and check the followi...

Page 159: ...enclosed place pay due attention to ventilation CAUTION If it is difficult to start the engine because the temperature is low perform the cold climate engine starting operation Do not start the engine...

Page 160: ...w idling position MIN 2 Turn the fuel adjustment dial 2 to position between the low idling position MIN and full rotation position MAX 3 Insert the key into the starter switch 3 turn the key to the ON...

Page 161: ...nd the other for hydraulic equipment The method of warming up operations differs depending on the environmental condition Perform warm up operations according to the respective descriptions The warm u...

Page 162: ...rane Work and Operation 3 16 Crane Operation Position and prepare for crane operation 4 Turn the fuel adjustment dial 2 to position between the low idling position MIN and full rotation position MAX 5...

Page 163: ...wound 8 Slowly operate the left work equipment operation lever 4 to the stroke end on the Retract side pull backward and after the boom completely retracts hold the lever at that position for 30 secon...

Page 164: ...When the engine is overheated do not stop the engine suddenly Change the engine speed to low and gradually cool down the engine before stopping 1 Turn the fuel adjustment dial 2 to the low idling pos...

Page 165: ...udden acceleration unnecessary sudden stop or sudden steering 3 7 MACHINE TRAVELLING POSTURE When moving this machine self propelled take the travelling posture with which the boom and hook block are...

Page 166: ...the rear of the machine body with a rear view camera before performing backward travel operation Be careful that when the travelling lever is operated during auto decel operation engine speed suddenly...

Page 167: ...Check that the travelling alarm sounds properly during travelling If the travelling alarm does not sound contact us or our sales service agency for repair When the machine does not travel at proper s...

Page 168: ...larm does not sound contact us or our sales service agency for repair When the machine does not travel at proper speed at low temperature perform sufficient warm up operation When the machine does not...

Page 169: ...urning to the left push the right travelling lever forward to turn to the left in forward movement When pulling the lever toward you the machine turns to the left in the backward movement A Left turn...

Page 170: ...e rear end of the machine protrudes from the crawler width Check for safety in the vicinity with the rear view camera mirrors and visual inspection before slewing Check for safety in the vicinity of t...

Page 171: ...o serious physical injury Be sure to place the lock lever securely at the lock position before leaving the driver seat 1 Stop the machine See OPERATION 3 8 STARTING FORWARD AND BACKWARD STOPPING THE M...

Page 172: ...terior and undercarriage If you find any leakage or abnormality fix the problem 2 Fill up the fuel tank to full 3 Remove paper and dead leaves in the engine compartment and around the battery because...

Page 173: ...and reduce the travelling speed as much as possible so that the machine will go over the obstacles at the centre of the crawlers NOTES See OPERATION 3 7 MACHINE TRAVELLING POSTURE for the travelling...

Page 174: ...ling on a hill be sure to take the travelling posture in which the hook block is stowed in the normal stowage position in the front of the revolving super structure The hook block which is stowed in t...

Page 175: ...e neutral position the brake becomes effective automatically WHEN ENGINE STOPS When the engine stops during uphill travelling place the travelling lever at the neutral position and stop the machine Th...

Page 176: ...the boom may be damaged leading to serious physical injury Example of erroneous settings Number of wire rope falls in actual work Two falls Number of wire rope falls in set switch Four falls If the se...

Page 177: ...zer sounds release your hand immediately from the left work equipment operation lever and place it at the neutral position to stop the boom extension operation After that operate the left work equipme...

Page 178: ...s in irregular winding of the winch drum When the hook block is loosened from the normal stowage position the hook block may sway interfering with and damaging the peripheral equipment Pay due attenti...

Page 179: ...wly raise the boom until the hook block 4 is placed at the position where it is perpendicular to the stowage section in the front of the revolving super structure If the hook block 4 is removed from t...

Page 180: ...ide pull toward you to hoist the hook block At this time do not overhoist the hook block If overhoisted the hook block is in a state of being overwound 2 Operate the right work equipment operation lev...

Page 181: ...er the hook block excessively so that the hook block does not fall sideways on the ground Doing so results in irregular winding of the winch drum When stopping the winch operation do not suddenly retu...

Page 182: ...wered the numerical value of an actual load of the moment limiter changes slightly due to a change of pressure of the derrick cylinder If the numerical value of an actual load of the moment limiter is...

Page 183: ...e storage section of the boom tip At this time the lamp of the switch part turns on Automatic Release your finger from the switch The switch returns to the original position and the automatic stop fun...

Page 184: ...ecreases When operating by derricking the boom pay extra attention so that the mass weight of the load at the time the boom is most lowered does not cause overloading Operate the right work equipment...

Page 185: ...peration return the boom telescoping lever immediately to the neutral position and stop the boom extending operation CAUTION When the boom is extended retracted the hook block is in a raised or lowere...

Page 186: ...he weight 5 of the overwinding detector 4 the boom extension stops In this state the boom does not extend when the boom extending operation is performed In such a case lower the hook block by performi...

Page 187: ...hook hoisting operation to lift a load Operate the left work equipment operation lever 1 as follows Left slewing Push the lever outside left side Neutral Release your hand from the lever The lever ret...

Page 188: ...f the fuel adjustment dial even if you release your foot from the accelerator pedal When performing work using the accelerator pedal operate the fuel adjustment dial in advance to set the necessary mi...

Page 189: ...ecomes slow At this time the speed turns to the minimum working speed adjusted by the fuel adjustment dial 1 b Full revolution Depress the pedal The engine speed increases and the working speed of the...

Page 190: ...ored with the boom raised up the rubber on the upper part of the hook block can be broken Do not raise or lower the boom with the hook stored The rubber on the upper part of the hook block can be brok...

Page 191: ...e hook block to the extent that it is not overwound NOTES If the hook block is overhoisted overwinding is detected the warning buzzer sounds and the hoisting operation stops automatically 4 Operate th...

Page 192: ...block 3 to store it in the lower part of the boom tip NOTES When the hook stowage switch is pressed the red lamp of the rotating warning lamp turns on When the winch is hoisted while the hook stowage...

Page 193: ...k block in the simple stowage position Be careful not to lower the hook block excessively so that the hook block does not fall sideways on the ground Doing so results in irregular winding of the winch...

Page 194: ...work equipment operation lever 2 to Lower side push outside to lower the boom to the end NOTES At this time hoist the hook block 3 occasionally to reduce slack in the wire rope At this time be careful...

Page 195: ...sides the do s and don ts in this section 1 DON T OPERATE USING SLEWING FORCE Drawing in or lifting the load with slewing operation is prohibited 2 DON T OPERATE USING DERRICKING FORCE Drawing in or l...

Page 196: ...orce it Untangle the rope and then wind it 9 DON T OPERATE DURING TRAVELLING A LOAD Operation during travelling a hoisted load may result in the swing of load and tipping over This is in principle is...

Page 197: ...ver on the following grounds and places do not approach them or perform travelling a hoisted load Check the condition of the road surface and ground Arrange a traffic guide for a dangerous place or a...

Page 198: ...gth to 10 5m three stage boom or less 2 See OPERATION 3 17 HOISTING AND LOWERING OPERATION and lower the hoisted load as near to the ground as possible 3 Press and hold the travelling mode selector sw...

Page 199: ...hat the hoisted load or machine does not crash against another machine or structure 1 When travelling the machine see OPERATION 3 8 STARTING FORWARD AND BACKWARD STOPPING THE MACHINE and OPERATION 3 9...

Page 200: ...pulling in boom IWRC 6 x Fi 29 0 0 8 2 CRITERIA FOR WIRE ROPE REPLACEMENT A wire rope undergoes wear and tear over time Prompt replacement is required if any of the following appears in the wire rope...

Page 201: ...er d 3 When a wire rope is flattened by local crushing and the minimum diameter is 2 3 of the maximum diameter or less 4 A rope of which core wires or rope core is exposed 5 A rope extremely bent 6 A...

Page 202: ...ype of a hook block number of falls of a wire rope and the maximum gross rated load at that time Hook type Hook used for both 2 falls and 4 falls Hook used for both 2 falls and 4 falls Hook exclusive...

Page 203: ...Lower push outside side and lower the hook block to the ground and lower the boom to the maximum 5 Operate the starter switch to the OFF position to stop the engine After that place the lock lever at...

Page 204: ...196 12 Repeat the above steps until the twist of the hook is eliminated Replace the wire rope with a new one if the twist is not corrected by the above steps...

Page 205: ...turn ON Operation the machine may make a sudden start Be sure to set the travelling speed to the low speed range LO and load and unload the machine with engine speed set to low speed Always move back...

Page 206: ...ft ramp boards in paralell at the same distance for the right and left with respect to the center of the trailer The installation angle of the ramp boards must be 15 degrees or less Securely hang the...

Page 207: ...the ramp boards and slowly travel for loading At this time do not operate any other lever than travelling levers on the ramp boards 10 The machine becomes unstable when it gets over rear wheels of the...

Page 208: ...ngine and remove the starter switch key 3 Close all the doors windows and covers Lock the door covers and caps with lock 4 Put blocks of wood in front and back of the crawler to prevent the machine fr...

Page 209: ...urely hang the hooks of the ramp boards on the hooks of the trailer If the ramp boards are bent by the machine weight place a block such as lumber under the ramp boards to prevent bending 4 Remove the...

Page 210: ...er from the front of the machine and between the 1st and 2nd from the rear If the machine necessarily needs to be lifted in other manner consult us or our sales service agency CAUTION When lifting the...

Page 211: ...e 1st and 2nd from the rear 6 Put nailing strips between the wire rope and machine so that the wire rope and machine are not damaged 7 Set the slinging angle of the wire rope for slinging to 20 30 deg...

Page 212: ...the machine only in the following procedure and at the sling installation position right and left bracket hole position of the boom at two locations If the machine necessarily needs to be lifted in ot...

Page 213: ...ely 3 degrees The inclination angle changes slightly depending on the boom angle and remaining quantity of fuel 5 3 CAUTIONS DURING TRANSPORTATION Take road width height and weight into consideration...

Page 214: ...t into a ditch or spray it on the ground CAUTION Never use antifreezing fluid with methanol ethanol and propanol See Maintenance 10 3 Irregular Maintenance 4 Cleaning Engine Cooling System for the coo...

Page 215: ...ne on This prevents the ground and around the tracks of the machine from freezing and allows the machine to start moving quickly next morning Open the drain valve of the fuel tank to drain the water i...

Page 216: ...posed section of the piston rod of the hydraulic cylinder Disconnect the negative terminal of the battery and put on a cover or dismount the battery from the machine for storage If the temperature dro...

Page 217: ...ngine oil pan to drain the water mixed in Refuel grease and change the oil without fail Wipe off grease applied to the exposed section of the piston rod of the hydraulic cylinder Remove the cover over...

Page 218: ...fuel filter and push the priming pump 4 with your hand to operate until the fuel comes out 3 Loosen the air vent plug 2 and operate the priming pump 4 at least 10 times until the fuel filter is fille...

Page 219: ...fault A sound is generated from around the valve when the boom is retracted to the end and the telescopic cylinder is relieved on the retraction side A sound is generated from the brake valve at the b...

Page 220: ...onnect the terminal first to install the battery cable Objects such as tools coming between terminal and the machine body will cause sparks which is dangerous Slackened battery terminals can cause spa...

Page 221: ...ry 4 Remove the connection cable 4 5 Remove the mounting bolt 5 at two locations and remove the mounting bracket 6 and vinyl cover 1 6 Take the battery outside of the machine body 2 INSTALLATION 1 Set...

Page 222: ...charger to the terminal of the battery Set the charge current to 1 10 or less of the battery rated capacity In the case of boost charge set the charge current to the value of rated capacity or less E...

Page 223: ...onnecting the booster cable CAUTION Use booster cable and clips of appropriate size for the battery size The battery in the donor machine and machine in failure should be of the same capacity The star...

Page 224: ...more than 2 minutes before next attempting to start NOTES See Operation 3 3 Starting Engine for how to start the engine 4 DISCONNECTING BOOSTER CABLE When the engine has started disconnect the booste...

Page 225: ...e starter Insufficient battery charge Inspection and repair Replacement Charge the battery Starter pinion going out and in repeatedly struggling Insufficient battery charge Defective safety relay Char...

Page 226: ...Defective wiring Defective alarm Defective PPC pressure sensor Check and repair looseness pullout and break of connector Replacement Replacement Rear view camera shows nothing Defective wiring Defect...

Page 227: ...o the specified oil level referring to the section Check before operation Abnormal noise from pump Air suction Clogging in the hydraulic oil tank strainer and element lack of oil See Periodic check an...

Page 228: ...just oil level to appropriate one See Periodical Maintenance to check or replace Inspection and repair Replacement Replacement Steam spouts out from the upper part pressure valve of radiator Lack of c...

Page 229: ...Change to specified fuel Exhaust gas color sometimes turns into black Air cleaner element clogged Defective nozzle Defective compression Defective turbocharger See Irregular Maintenance for cleaning o...

Page 230: ...even in an overload state Defective communication defective controller Inspection of communication circuit replacement of controller Defective cancel switch Inspection and replacement of cancel switch...

Page 231: ...overwinding detector When extension or hoisting does not operate even when not in an overwinding state Abnormal Phenomenon Major cause s Remedy When extending or hoisting operation is performed the bu...

Page 232: ...224 This Page Intentionally Left Blank...

Page 233: ...RTS 233 5 CONSUMABLES 234 6 OTHER REPLACEMENT PARTS 235 7 USE OF FUEL AND LUBRICATING OIL 236 8 STANDARD TIGHTENING TORQUE 238 9 LIST OF ITEMS FOR INSPECTION AND MAINTENANCE 239 10 MAINTENANCE PROCEDU...

Page 234: ...oil or grease and keep in a secure container to reduce contact with impurities 5 USING CLEAN WINDOW WASHER LIQUID Use the window washer liquid for automobiles and keep it free from any contamination...

Page 235: ...or abrasion of bolts and nuts Loosen the tension of the crawler tread more than usual 18 CAUTIONS FOR MACHINE WASH Do not direct a jet of steam to the electrical parts and connector Keep the operatio...

Page 236: ...low the instruction may cause the filters to get clogged A small amount of oil remaining in piping and cylinders does not cause problems even when mixed with other oil 2 FUEL HANDLING CAUTION For the...

Page 237: ...ailure Periodic replacement of the filter is required in accordance with the Operation Manual The replacement period should be shortened if commensurate with harsh operating environments or the amount...

Page 238: ...lugs screws and hose joints stand aside and provide gradual loosening to decompress Be sure to release the pressure by removing the air from the hydraulic oil tank before performing inspection and mai...

Page 239: ...d other blemishes on the compressor Frosting of air conditioner heat exchanger in the cabin Storage of inspection and maintenance servicing history Keep the records of administrator s name location of...

Page 240: ...the winch wire rope end and wire clip for damage 4 Replace the wire rope promptly if it is damaged 5 Check the hydraulic hose for oil leaks and friction flaws on the surface Replace the hose if a sur...

Page 241: ...indicated in the following table conduct the inspection of hydraulic hoses and fuel hoses Classification of Inspection Check Item Daily Checkup before starting work Oil leakage from the joint and cau...

Page 242: ...500 hrs Hydraulic oil tank breather Every 500 hrs Fuel feed pump filter Every 500 hrs Main fuel filter Every 500 hrs Hydraulic oil return filter Every 1000 hrs Hydraulic oil line filter Every 1000 hr...

Page 243: ...ss 1 12 Mirror 1 2 Glass 1 13 Mirror 1 3 Glass 1 14 Winch mirror 1 4 Glass 1 15 Fuse 30A 1 5 Glass 1 Fuse 20A 2 6 Glass 1 Fuse 15A 1 7 Glass 1 Fuse 10A 7 8 Glass assembly 1 Fuse 5A 7 Glass 1 16 Fusibl...

Page 244: ...ding that for unit piping and a replacement oil quantity is defined as a quantity of oil to be replaced at inspection and maintenance When starting the engine at temperatures of 0 C or lower always us...

Page 245: ...ales service agency Note 2 On the coolant 1 The coolant is required to perform important functions such as an anticorrosion agent as well as an antifreezing agent for a cooling system Thus use this co...

Page 246: ...0 6 0 to 7 5 12 19 113 11 5 98 0 to 123 10 0 to 12 5 14 22 172 17 5 153 to 190 15 5 to 19 5 16 24 260 26 5 235 to 285 23 5 to 29 5 18 27 360 37 0 320 to 400 33 0 to 41 0 20 30 510 52 3 455 to 565 46...

Page 247: ...SITS IN FUEL TANK 139 8 INSPECTING ELECTRIC WIRING 140 9 CHECKING WORKING LAMP 140 10 CHECKING HORN FOR OPERATION 140 11 ADJUSTING THE OPERATOR S SEAT 141 12 ADJUSTMENT OF MIRRORS 142 13 ADJUSTING MIR...

Page 248: ...HYDRAULIC OIL TANK BREATHER ELEMENT 269 7 OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE FOR THE FIRST TIME ONLY 270 8 REPLACING THE FUEL PRE FILTER CARTRIDGE 271 9 REPLACING THE MAIN FUEL FILTER CARTR...

Page 249: ...CTION GEAR CASE See 10 7 MAINTENANCE EVERY 1000 HOURS for maintenance places and procedure 10 2 PRE OPERATION INSPECTION Inspections described in this section should be conducted before the first engi...

Page 250: ...r than the following ratio 1 10 or more of a single twist of rope Nevertheless when breakage occurs in a single strand only the ratio should be 5 or more 2 20 or more of 5 twists of rope 2 A rope of w...

Page 251: ...he hook block has been lowered on the ground never try to unwind the rope Use the following procedure to remove the wire rope 1 Stop the Machine on solid ground fully retract the boom and set the boom...

Page 252: ...nd from hook block 7 8 Operate the right machine operation lever to DOWN push it forward to wind up the wire rope 5 from the winch drum 9 9 After winding up the wire rope 5 on winch drum 9 release the...

Page 253: ...it load sheave 11 at the end of load sheave 11 wire guide 12 of boom Nos 2 3 and 4 roller sheave 13 sheave 14 inside the boom derricking cylinder mounting bracket and slide sheave 15 2 Draw the wire r...

Page 254: ...rding to the dimensions specified in the sketch at right 8 Apply a wire socket 3 to the boom by using a wire socket pin 2 and tighten the wire socket pin fixing bolt 1 9 Operate the right machine oper...

Page 255: ...ting the main boom extending contracting wire ropes When the gap a exceeds 4mm adjustment of the boom telescoping cylinder is needed Thus consult with us or our sales agency ADJUSTING THE BOOM TELESCO...

Page 256: ...air cleaner element CAUTION Until the transparent window of dust indicator 1 shows a red piston do not clean the air cleaner element If the element is frequently cleaned before the red piston appears...

Page 257: ...sealing is damaged Pack the unused elements and store them in a dry place 7 Set the cleaned element inside the body attach cover 3 and fix it with clips 2 When attaching the cover 3 check the O ring...

Page 258: ...ing is not needed use the coolant at a minimum proportion of 30 to prevent corrosion of cooling system The mixing proportion between water and the coolant is to be determined with respect to past mini...

Page 259: ...utts with the the stopper to relieve the internal pressure 5 Then remove the radiator cap 2 6 Open the drain valve 3 underneath the radiator to drain the water 7 Remove the drain plug 4 of the cylinde...

Page 260: ...s been lowered fill the cooling water to the lip of the radiator water inlet 8 Securely mount the radiator cap 2 start the engine and warm up the engine at an idling speed When the radiator is equippe...

Page 261: ...surface 6 CHECKING ADJUSTING RUBBER TRACK TENSION The pins and bushings around the footage of the Machine shows varied states of abrasion depending on the working conditions and soil quality Check the...

Page 262: ...it in the following manner STRENGTHENING THE TENSION Have a grease pump available 1 By using the grease gun inject the grease through the grease plug 2 opening 2 To ensure that a proper tension is ap...

Page 263: ...SHING WINDOW WASHER SOLUTION If air is entrapped in the window washer solution check the level of solution in the window washer tank 1 and if it is not enough replenish with window washer solution for...

Page 264: ...ork must be consigned to a Class 1 fluorocarbon refrigerants filling and recovering contractor registered by the competent authorities in accordance with the Fluorocarbon Refrigerants Emission Regulat...

Page 265: ...nded servicing interval Refrigerant gas Replenished quantity Every 3 months Condenser of air conditioner Clogging of fins Compressor Operating condition V belt Extent of damage and state of tension Bl...

Page 266: ...on Use proper grease specified below according to the greasing points No Greasing point Grease type 1 Greasing of the boom mounting pin 1 places Lithium grease 2 Greasing of the derrick cylinder botto...

Page 267: ...259...

Page 268: ...to the thread of the oil level check plug to stop oil leaks and securely tighten the plug after checking refilling the oil Prepare a container to receive spent oil Have a hexagonal wrench available 1...

Page 269: ...check plug to stop oil leaks and securely tighten the plug after checking refilling the oil Prepare a container to receive spent oil Have a hexagonal wrench available 1 Stop the Machine on flat and s...

Page 270: ...Turn the adjuster bolt 7 of alternator 2 toward the loosening direction to adjust the belt tension so that it shows a sagging deflection of 8 3 to 9 3mm approximately 98N m 10kgf m 4 Tighten the moun...

Page 271: ...kgf Adjust the adjustment bracket 6 position to ensure that the deflection A is 4 mm NOTES Tightening bolt 5 increases the belt tension Loosening the bolt decreases the belt tension 3 Tighten bolts 4...

Page 272: ...t it can be touched by hand Be careful not to let any foreign substance go into the filler opening when refilling the oil Volume of replaced oil in the oil pan 10 liters Oil drain pan Prepare a contai...

Page 273: ...the level gauge G 7 After starting the engine and allow it to run at an idling revolution speed for a while stop the engine to ensure that the oil level remains within the range H L marked on the lev...

Page 274: ...f 4mm or more If it is not enough refill the grease 4 Ensure that the grease is not contaminated or white If any white or contamination is detected the grease must be replaced Contact us or our sales...

Page 275: ...ew 1 4 spots and remove nets 2 3 and 4 3 Inspect the front and back sides of oil cooler fins 5 radiator fins 6 after cooler fins 7 and air conditioner fins 8 and if any dirt dust or tree leaves are st...

Page 276: ...ut the indoor filter 1 2 Clean the indoor filter 1 with compressed air If the indoor filter 1 is smeared with oil or heavily contaminated clean it with neutral detergent After water cleaning dry it th...

Page 277: ...oil is cooled When removing the oil inlet cap turn it slowly to relieve the internal pressure in order to prevent the oil from spurting out 1 Loosen the bolts to remove the cover 1 on top of the hydra...

Page 278: ...ION GEAR CASE Perform the replacement in the initial servicing for the new Machine Afterwards conduct the replacement every 1000 hours Refer to the description under 10 7 MAINTENANCE EVERY 1000 HOURS...

Page 279: ...fuel system Never use any substitutes When conducting the inspection and maintenance services of the fuel system pay more attention to the inclusion of foreign matters than that paid for conventional...

Page 280: ...uel system Never use any substitutes When conducting the inspection and maintenance services of the fuel system pay more attention to the inclusion of foreign matters than that paid for conventional p...

Page 281: ...ed pump 1 3 Use a spanner to turn the cover 3 and take it off 4 Remove the filter 4 and gasket 5 and replace them For the paper type replace with new filter 4 and gasket 5 For the steel mesh type wash...

Page 282: ...tape etc on the thread of each plug to stop the oil leaking and securely tighten the plugs Volume of replaced oil 2 1 liters each for left and right tanks Prepare a container to receive spent oil Have...

Page 283: ...each plug to stop the oil leaking and securely tighten the plugs Volume of replaced oil 1 8 liters Prepare a container to receive spent oil Have a hexagonal wrench available 1 Stop the Machine on flat...

Page 284: ...r the oil to be used After replacing the filter elements of hydraulic oil do not start the engine for a while until piping and hydraulic equipment are filled with the oil Prepare a container to receiv...

Page 285: ...use fuel leakage around the gasket Always observe the tightening angle When using a filter wrench for the tightening pay adequate attention not to generate scratches and dents on the filter 8 Attach t...

Page 286: ...elling posture as shown in the sketch on the right 2 Open the engine hood and securely lock it with the hood support lever 3 Set a container to receive spent oil under the filter element 4 Turn the fi...

Page 287: ...our sales agency for the servicing 7 MEASURING COMPRESSION PRESSURE Since special tools are required for the measurement request us or our sales agency for the servicing 10 8 MAINTENANCE EVERY 1500 HO...

Page 288: ...bserve the following for handling The pressure in the hydraulic circuit cannot be totally relieved When removing a hydraulic unit stay away from the escaping oil direction Also loosen screws slowly Ne...

Page 289: ...sure to put the machine in the travelling posture when checking the oil level If you check the oil level in the working posture you judge the oil level to be low and feed the oil excessively After rep...

Page 290: ...emoving the bolts 11 Lift up the upper end of rod 7 from above to take out the spring 6 and strainer 8 Remove dust stuck to strainer 8 and wash it with clean diesel fuel or washing oil If any damage i...

Page 291: ...ulic tank causes the pump to suck air resulting in adverse effect on the units 16 Attach the cover 1 on top of the hydraulic oil tank 17 After replacing cleaning the hydraulic oil filter element and s...

Page 292: ...th hydraulic will oil cause early damage of pump after giving off abnormal noise Be sure to exercise the air venting 1 Loosen the fitting 1 of port D of the pump to check if oil is oozing out through...

Page 293: ...mechanical brake for 3 to 4 turns 3 Without hoisting a load repeat the operation of slowly winding up the hook block stopping and winding down 4 If hydraulic oil is oozing out from air vent plug 1 of...

Page 294: ...right tracks METHOD FOR FLOATING THE FOOTING BY USING THE CRANE Conduct the operations on a flat and solid ground For the dimensions and mass of this Machine refer to the descriptions under SPECIFICA...

Page 295: ...t a pad B between the crane wire rope A and the boom 4 Insert the packing block C that has been prepared between the floating track frame and the ground Make sure it is well balanced 5 Slowly lower th...

Page 296: ...Since the accumulator pressure gradually decreases after stopping the engine the pressure can only be relieved immediately after stopping it 1 Place the machine on horizontal and solid ground surface...

Page 297: ...block 2 Attach the single fall hook bracket 7 to the end of the boom Attach the bracket 7 by first removing the four bolts 8 already attached 3 Alter the mounting position of the overwinding preventi...

Page 298: ...roximately 2 mm on either side of the protective wire rope 22 between the washers 19 so that it can move smoothly 6 Use the shackles 14 to attach the overwinding prevention device weight 13 to the two...

Page 299: ...11 Insert the wire socket 37 into the connection part a inside the hook 10 align with the hole b and insert the pin 49 then secure from both sides at positions c and d using the bolt 50 with the washe...

Page 300: ...e bolt 1 and washer 2 to pull out the pin 3 Remove the wedge socket from the hook block 5 Remove the wire rope 5 from the wire socket 3 as follows 1 Press a 6 mm to 10 mm round bar A against the rope...

Page 301: ...ce 9 as they are The removed extension harness 23 and clips 11 will not be reused 9 Remove the single fall hook bracket 7 from the end of the boom Attach the four bolts 8 at the location of the remove...

Page 302: ...294 This Page Intentionally Left Blank...

Page 303: ...295 SPECIFICATIONS 1 PRINCIPLE SPECIFICATION LIST 296 2 SPECIFICATION DIMENSIONAL DRAWING 297 3 RATED TOTAL LOAD CHART 298 4 WORKING RADIUS LIFTING HEIGHT 301...

Page 304: ...505m 13 385m 16 265m Telescoping stroke Extending time 11 52m 33 sec Boom hoist system Type Double acting hydraulic cylinder direct thrusting system Derricking angle Time 4 to 80deg 19sec Slewing syst...

Page 305: ...297 2 SPECIFICATION DIMENSIONAL DRAWING...

Page 306: ...640 2600 5 50 2520 1260 2400 1200 2340 2320 6 00 2210 1105 2140 1070 2100 2080 6 50 1950 975 1920 960 1890 1880 7 00 1720 860 1720 860 1710 1710 7 46 1530 765 1570 785 1570 1580 7 50 1550 775 1560 156...

Page 307: ...2520 1000 2400 1000 2340 2320 6 00 2210 1000 2140 1000 2100 2080 6 50 1950 975 1920 960 1890 1880 7 00 1720 860 1720 860 1710 1710 7 46 1530 765 1570 785 1570 1580 7 50 1550 775 1560 1560 8 00 1400 7...

Page 308: ...00 500 1500 1500 6 00 1500 500 1500 500 1500 1500 6 50 1500 500 1500 500 1500 1500 7 00 1500 500 1500 500 1500 1500 7 50 1500 500 1500 500 1500 1500 7 56 1500 500 1500 500 1500 1500 8 00 1400 500 1430...

Page 309: ...301 4 WORKING RADIUS LIFTING HEIGHT...

Page 310: ...302 This Page Intentionally Left Blank...

Page 311: ...B OPERATION 304 2 SAFETY LABEL LOCATION 306 3 FLY JIB EACH SECTION 309 4 FLY JIB INSTALLATION AND STOWAGE 310 5 HANDLING MONITOR AND MOMENT LIMITER 342 6 OPERATIONS 348 7 TROUBLESHOOTING 349 8 INSPECT...

Page 312: ...ted in low speed Sudden lever operation may produce excessive load to the Fly jib which may cause damage to the Fly jib resulting in a serious accident When the Fly jib is installed any error in crane...

Page 313: ...owerring operations automatically stop However when the boom length is less than 5 3 m the moment limiter does not emit a warning signal In a condition where the boom angle is less than 45 degrees boo...

Page 314: ...tandard model For labels other than these refer to the section Safety 5 Safety Label Location Keep these safety labels clean and legible at all times When a safety label is degraded missing or illegib...

Page 315: ...307 1 Work range chart for fly jib 585 2237900 2 Over hoist detection wiring instruction 585 3558600 4 Warning for fly jib installation 585 2238200...

Page 316: ...rning for fly jib stowage 585 2238300 2 places 6 Fly jib detection wiring instruction 585 3558100 7 Pin hole caution 349 4426900 7 places 8 Caution for hole 556 4580700 10 Explanation of split pin 585...

Page 317: ...stowing wire 14 Sheave 17 Harness connection part For over hoist detection Fly jib side 18 Harness connection part For over hoist detection Main boom side 19 Harness connection part For fly jib detect...

Page 318: ...ntial to re connect the over hoist detector harness from the Main boom detector to the Fly jib detector Always ensure the over hoist detector of the Fly jib is working correctly before starting operat...

Page 319: ...b to the Main boom from the stowed position from the right side as shown below Always avoid standing on crawlers for installation work You may miss your footing and fall resulting in serious injury Fo...

Page 320: ...the lower part on the left of the Main boom tip 3 Pull out the position pins C1 C2 from the bracket 26 on the right side of the main boom tip NOTES The removed position pins C1 C2 will be required fo...

Page 321: ...position pins B2 C1 C2 are fitted into both holes of the bracket 26 on the right side of the Main boom tip and Fly jib bracket A 21 Main boom telescoping must not be operated This operation will criti...

Page 322: ...de the position pin could easily drop down to cause the Fly jib to collapse causing a serious hazard 11 Swap the harness connection part 17 and 18 as shown below to switch and connect over hoist detec...

Page 323: ...switch and connect fly jib angle and length detector 1 Disconnect the wiring connector 34 including the clip connected to the connector for stowage 33 of the harness connection 19 on the Fly jib side...

Page 324: ...e rope wind randomly around the winch drum 1 Retract the boom fully and set the boom angle to approx 20 degrees 2 Lower the hook so that it almost touches the ground 3 Lower the boom to allow the hook...

Page 325: ...rope 12 off from the wire rope holder 45 at the boom tip Arrange the wire rope to go straight through the sheave of the main boom tip to the Fly jib 16 Detach the over hoist detector weight 9 from th...

Page 326: ...19 Install the rope clip 40 to the wire rope 12 Refer to the Figure on the right for the rope clip position 20 Insert the wire socket 37 into connection base a inside the hook 10 Adjust the holes a b...

Page 327: ...jib follow the instructions below 1 Set the attached lever block 23 between the tilt angle adjuster outer rod 5 and inner rod 6 and take up the slack NOTES Lever block 23 handling will be easier when...

Page 328: ...e boom derricking operation and the procedure specified in 3 above un winding the lever block alternately to allow the Fly jib angle to be gradually adjusted 2 Match the hole of the outer rod and the...

Page 329: ...winding operation and take hold of handles in the both left and right side in the tip of No 2 Fly jib 3 and pull the No 2 Fly jib 3 out 4 When the No 2 Fly jib 3 is extended adjust both side holes of...

Page 330: ...until it lightly touches the No 2 Fly jib 3 tip 2 Pull the linchpin 25 out from the position pin 4 in the tip of No 1 Fly jib 2 to extract the position pin 4 NOTES Removed position pin 4 will be neces...

Page 331: ...right shows that the No 2 Fly jib is extended in accor dance with the procedure 1 4 as above In this posture the signal indicating that Fly jib length is two stages is transmitted to the moment limit...

Page 332: ...in the tip of No 1 Fly jib 2 to extract the position pin 4 NOTES Removed position pin 4 will be necessary for the later operation to secure the retracted No 2 Fly jib 3 3 Keep pressing the hook stowa...

Page 333: ...or for stowage 35 Then disconnect the wiring connector 34 including the clip connected to the wiring connector 36 NOTES Removed storage connector 33 and harness connector 34 will be later connected in...

Page 334: ...17 Fly jib side 3 Connect the wiring connector 32 disconnected in Section 1 to the connector 31 NOTES Ensure that wires of the harness plug 32 and connector 31 are guided out of the connector box thr...

Page 335: ...ly jib tip is shaken up and down When removing the handle H1 be sure to fasten it to the main body of the pins to the specified torque Tightening torque 27 0 34 0 N m 5 Turn the No 1 Fly jib 2 around...

Page 336: ...tion pin could easily drop down to cause the Fly jib to collapse and may cause a serious hazard CAUTION When the position pins B2 C1 C2 are fitted in both holes of the bracket 26 on the right side of...

Page 337: ...closest to the front and insert the linchpin At this time be sure to turn over the ring to lock securely 15 Hang the single hook 10 on the hook stowage rope 13 While pressing the hook stowage switch p...

Page 338: ...he crawler You may miss your footing and fall down causing serious physical injury Be sure to set a stable workbench when working above ground level When work is performed on the main boom with the Fl...

Page 339: ...jib bracket B 22 to pull out the position pin A1 3 Pull out the position pins C1 C2 from the bracket 26 on the right side of the main boom tip 4 Holding the handle H4 of the No 1 Fly jib 2 with the p...

Page 340: ...allowing the Fly jib to collapse causing a serious hazard CAUTION When the position pins B2 C1 C2 are fitted into both holes of the bracket 26 on the right side of the Main boom tip and Fly jib brack...

Page 341: ...en the nut 53 of the Fly jib stowage bracket A 21 and turn the adjusting bolt 52 counterclockwise to loosen 13 Remove the Fly jib stowage bracket A 21 from the main boom 1 by unscrewing 4 mounting bol...

Page 342: ...ands 63 19 Remove the connector cover 64 disconnect the connector inside and remove the harness 65 20 Remove the nut 66 and remove the cable 68 Disconnect the connector from the harness connection par...

Page 343: ...ifting the Fly jib Never perform work while stepping on the crawler You may miss your footing and fall down causing serious physical injury Be sure to set a stable workbench when working above ground...

Page 344: ...the connector to the harness connection part 20 at the end of the boom head 5 Connect the harness 65 to the cable reel 67 connector and attach the connector cover 64 6 Attach the harness clips 62 and...

Page 345: ...10 Set the Fly jib stowage bracket A 21 on the mounting position of the main boom 1 and lightly tighten it with 4 mounting bolts 54 11 Tighten the adjusting bolt 52 with the nut 53 attached of the Fly...

Page 346: ...on the No 1 Fly jib 2 16 Using the position pins C1 C2 on the right side of the main boom tip as a fulcrum rotate the No 1 Fly jib 2 and place it in the Fly jib stowage bracket A 21 on the side of the...

Page 347: ...ed into the stowage bracket A 21 hole and the Fly jib is fixed This could cause a serious accident Be sure to insert the position pin B2 in a downward direction from the above If they are inserted in...

Page 348: ...rd direction from the lower part the position pins could fall off and the Fly jib could drop causing a serious accident 26 Insert the position pin B1 into the hole closest to the front of the Fly jib...

Page 349: ...mode with the Fly jib in a stowage condition the monitor display is as shown on the right figure Either switch to the main boom mode or install the Fly jib For the detailed operation method see 5 1 2...

Page 350: ...exclusive for The Fly jib model but different from that of a standard model For devices other than these refer to the section OPERATION 2 4 Moment Limiter 5 1 NAMES OF MONITOR DISPLAY 5 1 1 MONITOR D...

Page 351: ...angle continuously during the crane operation Fly jib angle means the angle between the Fly jib and the main boom The Fly jib angle is adjustable to four 4 positions 0 20 40 and 60 degrees 2 Display...

Page 352: ...e main boom press the check switch 4 The mode exits from the Fly jib mode and the screen moves to the top screen of the main boom mode Do not perform work in the main boom mode by pressing the check s...

Page 353: ...emit a warning signal In a condition where the boom angle is less than 45 degrees boom lowering operation is not available unless the boom length is less than 5 3 m At a Fly jib angle in 40 or 60 degr...

Page 354: ...ly jib tilt angle 20 degrees mode Lifting height display indicates the value for Fly jib tilt angle 20 degrees mode 3 Fly jib angle at 40 degrees When the Fly jib tilt angle is set to 40 degrees the R...

Page 355: ...d hoisting operation is not available where the boom angle is 45 degrees or less The moment limiter emits an over load warning When the Fly jib tilt angle is set to 40 or 60 degrees load hoisting oper...

Page 356: ...ing operations automatically stop However when the boom length is less than 5 3 m the moment limiter does not emit a warning signal In a condition where the boom angle is less than 45 degrees boom low...

Page 357: ...played a cause other than a Fly jib related cause is conceivable See Operation 2 1 2 Warning display Monitor display Warning buzzer Description Error code Item EFJ01 FlyJib Error 1 Fly jib is detected...

Page 358: ...rmed Rewire wires connected to Fly jib Error code EFJ03 is displayed Fly jib is not stowed properly Defective stowage limit switch Stow Fly jib until contact is made with the stowage limit switch Insp...

Page 359: ...e of the position pins If you find any abnormality repair Check for excessive damage and deformity of the over hoist weight wire rope of the over winding alarm device at the tip of the fly jib If ther...

Page 360: ...display indication when the Fly jib tilt angle is set to 60 60 5 Start the engine and operate the crane as follows to verify if the moment limiter is acting properly for each function Crane operation...

Page 361: ...gardless of the maintenance period Use a grease type in the following table depending on the greasing point No Greasing Point Grease Type 1 Hook block greasing 2 Places Lithium grease 2 3 Fly jib angl...

Page 362: ...but different from those of a standard model For data other than this refer to the section SPECIFICATIONS System Item CC1485S 1 FLY JIB Mass and dimensions Machine mass 14 700 kg Overall length x widt...

Page 363: ...355 9 2 SPECIFICATION DIMENSIONAL DRAWING...

Page 364: ...jib tilt angle is 40 or 60 degrees Unit kg Boom angle deg Jib tilt angle 0 deg 20 deg 40 deg 60 deg 80 820 820 620 620 75 820 820 620 620 70 720 720 520 520 65 620 620 420 420 60 520 520 Prohibited un...

Page 365: ...357 9 4 WORKING RADIUS LIFTING HEIGHT 9 4 1 WORKING RADIUS LIFTING HEIGHT WHEN FLY JIB ANGLE IS 0 DEGREES AND 20 DEGREES...

Page 366: ...358 9 4 2 WORKING RADIUS LIFTING HEIGHT WHEN FLY JIB ANGLE IS 40 DEGREES AND 60 DEGREES...

Page 367: ...ment Number 585E OM1712 02 First edition November 30 2015 Third edition December 25 2017 Issued by MAEDA SEISAKUSHO CO LTD 1095 Onbegawa Shinonoi Nagano City Nagano Prefecture 388 8522 Japan Any repro...

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Summary of Contents for CC1485S-1

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