Maeda MC815C Operation Manual Download Page 270

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9. MAINTENANCE PROCEDURES

9.1 PRE-OPERATION INSPECTION

9.1.1 INSPECTION BEFORE STARTING ENGINE (PATROL)

• This machine is equipped with a diesel engine.
If you smell fuel around the engine, it may be leaking. Carefully check for cracks on

the fuel 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.

Carefully check around these areas. If there is any abnormality, be sure to fix it or

contact us or our sales service agency.

Conduct patrol check of the followings in this section before starting the work every day.

(1) Around crane

(2) Wire rope

(3) Hook block

(4) Outrigger

(5) Around safe rubber track

(6) Carrier

(7) Engine

(8) Carrier and crane control

Summary of Contents for MC815C

Page 1: ...read 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 O...

Page 2: ......

Page 3: ...CONFIGURATION OF REMOTE CONTROLLER 16 6 3 FUNCTIONS 17 6 3 1 FUNCTIONS OF REMOTE CONTROLLER 17 7 DPF OVERVIEW 18 7 1 DPF FUNCTION 18 7 2 DPF REGENERATION 18 SAFETY 21 1 BASIC PRECAUTIONS 22 2 PRECAUTI...

Page 4: ...ER 109 1 3 2 DESCRIPTION OF REMOTE CONTROLLER ACCESSORIES 113 1 4 OUTRIGGER SAFETY DEVICE 114 1 4 1 FUNCTIONS OF OUTRIGGER SAFETY DEVICES 114 1 5 MOMENT LIMITER OVERLOAD DETECTOR 115 1 5 1 CONFIGURATI...

Page 5: ...3 2 14 1 OUTRIGGER COMPONENTS 155 2 14 2 OUTRIGGER SETUP OPERATION 155 2 15 CAUTIONS BEFORE CRANE OPERATION 160 2 16 OPERATION BEFORE CRANE WORK 161 2 17 CRANE OPERATION POSTURE 162 2 18 WINDING AND U...

Page 6: ...PENDED LOAD 203 3 8 6 FLY JIB DERRICKING TELESCOPING OPERATION 203 3 9 OPERATING SPEED SELECTOR OUTRIGGER SELECT SWITCH 204 3 10 OPERATING ACCELERATOR CONTROL SWITCH 204 3 11 OPERATING HORM SWITCH 204...

Page 7: ...NG BATTERY 225 9 3 CAUTIONS IN CHARGING BATTERY 226 9 4 STARTING ENGINE WITH BOOSTER CABLE 227 10 HANDLING REMOTE CONTROLLER BATTERY 229 10 1 REPLACEMENT TIMING OF BATTERY 229 10 2 REPLACEMENT METHOD...

Page 8: ...AFTER STARTING ENGINE 278 9 1 5 INSPECTION OF ENGINE START AND STOP OPERATION RADIO CONTROL 285 9 2 IRREGULAR MAINTENANCE 289 9 3 INITIAL 10 HOUR MAINTENANCE 300 9 4 INITIAL 50 HOUR MAINTENANCE 300 9...

Page 9: ...76 5 2 MOMENT LIMITER FUNCTIONS 377 5 3 RECOVERY OPERATION FROM AUTOMATIC STOP 377 6 OPERATION 378 6 1 FLY JIB DERRICKING OPERATION 378 6 2 FLY JIB RETRACT EXTEND OPERATION 378 7 TROUBLESHOOTING 379 7...

Page 10: ...HOOK SPECIFICATION 403 4 4 1 MOUNTING SEARCHER HOOK BOOM 403 4 4 2 ATTACHING BRACKET 404 5 HANDLING MONITOR AND MOMENT LIMITER 405 5 1 NAME OF MONITOR DISPLAY 405 5 1 1 MONITOR DISPLAY IN SEARCHER HO...

Page 11: ...1 INTRODUCTION 1 INTRODUCTION 2 2 FOR SAFE USE OF THE MACHINE 3 3 MACHINE OVERVIEW 4 4 QUALIFICATION FOR OPERATION 6 5 TERMINOLOGY 7 6 OUTLINE OF REMOTE CONTROLLER 16 7 DPF OVERVIEW 18...

Page 12: ...place so that all personnel that work on this machine will read it for reference periodically Avoid operating this machine before understanding this manual thoroughly Keep this manual at hand so that...

Page 13: ...lowing indications to provide other precautions for handling the machine and helpful information This denotes that failure to properly handle the machine may damage it or shorten its life This denotes...

Page 14: ...ing travelling in the worksite and lifting an object weighing up to the rated total load This crane is also equipped with a remote control system 3 2 MACHINE STRUCTURE 1 Carrier In this manual the fro...

Page 15: ...interlock crane interlock overload preventive device with working envelope specified and working status lamp 3 3 MACHINE FUNCTIONS 1 CARRIER This machine is designed to have a compact overall width wh...

Page 16: ...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 s...

Page 17: ...e mass weight of hoisting accessories hooks and slinging ropes from the rated total load 3 WORKING RADIUS A horizontal distance between the axis of slewing and the hook center 4 BOOM LENGTH A distance...

Page 18: ...t A denotes a boom angle and point B denotes a lifting height above ground The same working radius applies to point A and point B 2 The diagram of working radius and lifting height shows the relations...

Page 19: ...ded to some extent work should be performed in accordance with the performance given in the Booms 1 2 3 4 column If more than half of the mark is exposed from boom 3 work should be performed in accord...

Page 20: ...ent the conditions shown in the following figures 1 Boom 1 All the booms retracted 2 Booms 1 2 All of booms 3 4 and 5 are retracted with boom 2 fully extended If boom 2 is extended to some extent work...

Page 21: ...from boom 3 If booms 4 and 5 are extended to some extent even only slightly work should be performed in accordance with the performance of this column 5 Booms 1 2 3 4 5 All the main booms extended fu...

Page 22: ...a case work should be performed in accordance with values shown in the Use with outriggers extended to medium column of the Rated Total Load Chart Slewing 360 with a load lifted may expose the machin...

Page 23: ...d be performed in accordance with values shown in the Use with outriggers extended to minimum column of the Rated Total Load Chart Slewing 360 with a load lifted may expose the machine to an unstable...

Page 24: ...nsion a in the figure on the right is 50 mm In this state of extension do not operate the crane Otherwise the machine may tip over causing serious personal injury Slewing 360 with a load lifted may ex...

Page 25: ...hung Make sure that the total weight of the hoisting accessories baggage and slinging tools do not exceed that rated total load The angle indicator is attached to the left and right sides of the No 1...

Page 26: ...left operation lever 1 right operation lever 2 and emergency stop remote controller OFF switch 10 The Transmitter sends signals for crane operations to the Receiver mounted on the main body of the Mac...

Page 27: ...from stand by up to maximum speed In addition to handling the crane by remote control transmitter manual operation can be performed on the machine side depending on the type of operation required When...

Page 28: ...s the danger of carbon monoxide poisoning do not carry out DPF regeneration in places with poor ventilation As the exhaust gas is being cleaned the smell of the exhaust gas will differ from normal As...

Page 29: ...operations with low load is repeated the PM may not be regenerated In this case the DPF regeneration request lamp on the monitor is lit If the DPF regeneration request lamp is lit carry out manual sta...

Page 30: ...20 This Page Intentionally Left Blank...

Page 31: ...ECIFICATIONS 31 4 OPERATION RELATED PRECAUTIONS 32 5 TRANSPORT PRECAUTIONS 51 6 BATTERY HANDLING PRECAUTIONS 53 7 MAINTENANCE PRECAUTIONS 55 8 SAFETY LABEL LOCATIONS 62 All the safety precautions defi...

Page 32: ...itable for the relevant working condition Do not wear loose garments or accessories as these may get caught on an operation lever or any protrusions which could lead to unexpected movement of the Mach...

Page 33: ...perating the crane appoint a work supervisor and mutual signs beforehand and follow the work supervisor and signs during operation When operating at a driver s blind spot especially follow the instruc...

Page 34: ...asures to take upon an injury or fire accident Decide how to contact the emergency address for instance the emergency physician ambulance or fire department and put up the contact address at designate...

Page 35: ...il in a specified location and prohibit public access Do not leave the site when replenishing the fuel or oil Be especially careful to observe Safety when refilling fuel described earlier in this manu...

Page 36: ...ite that may contain asbestos dust Strictly observe the assigned rules related to the worksite and environmental standard CRANE INJURY PREVENTION To prevent serious accidents do not allow any part of...

Page 37: ...d such as a screwdriver etc It may make a hole in the Transmitter which allows water to enter inside the body causing problems or failures which may lead to a serious hazard NO WATER WASHING Always cl...

Page 38: ...service agency for repair Using a damaged Transmitter will result in miss operation and may cause an electrical shock or other serious hazard PRECAUTION FOR OPERATIONS IN COLD SEASONS Avoid the use o...

Page 39: ...use a failure of the inside devices of the transmitter and electrolyte leakage heat generation and rupture of the battery PRECAUTIONS IN HANDLING THE BATTERY Do not heat the battery or put it in fire...

Page 40: ...abnormality contents name and contact of the storage manager and the term of storage 2 Take out the battery 3 Never perform operation using a failed remote control system CAUTIONS DURING WELDING REPAI...

Page 41: ...er promptly in the event of a power failure during operation Otherwise the machine may inadvertantly operate upon energization Always turn OFF the power supply equipment breaker before performing insp...

Page 42: ...TER DEPTH INSPECTION BEFORE STARTING ENGINE Execute the following inspections before the first engine start up of the day Omitting these inspections may result in serious bodily accidents Inspect for...

Page 43: ...control levers and operation switches of the Transmitter Ensure that the control levers and operation switches of the Transmitter move smoothly and properly Check if the battery is correctly installed...

Page 44: ...he boom is fully lowered and retracted Fix the hook block at the stowage position Retract the outrigger See OPERATION 2 5 MACHINE TRAVELLING POSTURE for details Make sure to check around again so that...

Page 45: ...acting other machinery or object When travelling in the water or crossing over shallow water check the ground condition depth and water velocity beforehand and make sure not to exceed the allowable wa...

Page 46: ...likely to cause slips and thus dangerous Ground of the frozen road becomes soft when the air temperature rises and causes the Machine travels and other operations to be unstable Be very careful In col...

Page 47: ...escape to the hydraulic oil tank by raising to above the hydraulic circuit set pressure by using the operation lever Doing so improves the Machine reactions and prevents improper operations If the bat...

Page 48: ...ND CAUTIONS DURING OPERATION REMOTE CONTRO LSYSTEM Before switching the operation mode to CRANE MODE make sure all the outriggers are extended and securely placed on the ground Set to the CRANE MODE w...

Page 49: ...LIMITER In the moment limiter the moment is calculated on the assumption that the machine is placed horizontally If crane work is performed without the machine being placed horizontally no forecast or...

Page 50: ...observe the following to prevent serious injuries and accidental death when placing the outriggers When placing the outriggers always keep the Machine sternly level while looking at the level gauge Oc...

Page 51: ...41 CAUTIONS WHEN PLACING OUTRIGGER Do not let people approach the machine when placing the outriggers Otherwise serious accidents such as feet being trapped may occur...

Page 52: ...e starting work Put on rubber soled shoes and rubber gloves and be careful that the body parts unprotected by rubber or other insulation do not contact the wire rope or the Machine frame Place a guide...

Page 53: ...ne is operational immediately move it to a safe location away from the cause of the electrical charge Take care not to break or disrupt the distribution power cable 2 Move the machine to a safe locati...

Page 54: ...l during the work When an earthquake occurs abort the operation and wait until it is over The following table indicates approximate relation between the wind speed and wind effect The wind speed menti...

Page 55: ...one load may cause the hoist bracket 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 2 load at a time eve...

Page 56: ...hoisted and the boom is deflected It is dangerous to operate the crane under bad weather or at places where the view is not clear Work lamps or other lighting devices should be used in dark places Wh...

Page 57: ...damaged Overwinding of the hook block may result in collision with the boom snipping the wire ropes and causing the hook block and load to fall and may lead to serious accidents Take care not to over...

Page 58: ...e boom is most lowered does not cause overloading CAUTIONS DURING SLEWING OPERATION Check the safety in the vicinity and honk the horn before slewing If the boom derrick angle is small be careful to p...

Page 59: ...tions to single operations as a rule and do not attempt any slewing operation Appoint 1 responsible sling operator who is most experienced Work at workplace where lift below ground level is performed...

Page 60: ...OUTRIGGER MODE and check that the mode is switched correctly When all the operation of the Transmitter is complete always turn OFF the power of the Transmitter Under no condition will the Transmitter...

Page 61: ...avels Use the ramps that have fully strong width length and thickness and that enable safe loading unloading Reinforce with blocks or other substances if the ramps deflect much Remove the mud and othe...

Page 62: ...on the right for the load applied to each wire rope When hoisting the machine be sure to set the machine to the traveling posture and securely insert the position pins 4 pieces to the outrigger rotar...

Page 63: ...rce Such act may cause the battery to catch fire Defrost the battery fluid and check for battery fluid leak before charging or starting the engine Always detach the battery from the Machine frame befo...

Page 64: ...se and prevents explosion Adjust the charger voltage to suit the voltage of the battery to charge Mistake in adjusting the voltage may cause explosions due to overheat and ignition of the charger Secu...

Page 65: ...hich causes skin laceration or mud or other substance to fly to eyes Do not directly spray water onto the electrical system sensors connector 1 receiving box and related Water entering the electrical...

Page 66: ...ieve the pressure remaining in the hydraulic circuits Apply pawls to prevent crawler from moving Persons in charge of the maintenance should pay attention to prevent parts of the body and clothes from...

Page 67: ...aring difficulty or deafness Use ear protection or ear plugs during long term noise exposure such as engine maintenance WORK BY AT LEAST TWO PERSONS DURING MAINTENANCE WITH ENGINE RUNNING To prevent a...

Page 68: ...N REPLENISHING FUEL OR OIL Attempt to let a fire approach the fuel or oil may result in catching fire Diesel fuel is used as the fuel and thus requires extra effort to observe the following Stop the e...

Page 69: ...onitor Wear protective equipment Always ventilate the area Keep combustibles away from the area and prepare a fire extinguisher Do not ground to a location near electrical part Such may cause the elec...

Page 70: ...piping hose itself or its vicinity or the ground is wet Crack or inflation of piping or hose is likely Contact us or our sales service agency for repair High pressure oil leaking through a small hole...

Page 71: ...engine is running Take special care when checking while the engine is running referring to Work by at least two persons during maintenance while engine is running section Check that the inspected mai...

Page 72: ...ATIONS These labels should be kept clean at all times If these labels come off re attach the label or replace with a new one As shown below there are labels other than safety labels which should be tr...

Page 73: ...63 3 Total load chart 106 2186300...

Page 74: ...64 6 Minimum hoisting weight 106 4711700 2 places 7 Fixing bracket positions during transportation 106 4713200 8 Caution when traveling on slope 349 4421100...

Page 75: ...65 9 Precautions when using 106 2186600...

Page 76: ...66...

Page 77: ...ng caution 350 4539700 3 places 15 Hydraulic oil caution 104 4550800 19 Lever patterns crane mode 106 3397300 21 Lever patterns travel mode 106 3397400 23 Do not insert fingers into the hole CL0001000...

Page 78: ...r mind your feet CL000110000 4 places 25 Outriggers extended CL000040000 29 Read the user manual CL000010000 30 Radiator caution 349 4427300 31 Exhaust gas caution CL000060010 32 Open flames prohibite...

Page 79: ...in the engine room CL000080010 35 Burn caution CL000070010 2 places 37 Do not enter under loads CL000020000 38 Electric shock caution 553 4267300 39 Warning 553 4268000 2 places 40 Winch entanglement...

Page 80: ...part hanging positions 106 4713500 51 Outrigger caution 104 4549601 4 places 53 Diesel fuel 585 4738600 54 Load for 6 4 2 wires hung 106 4714400 2 places 55 Main unit total weight standard specificat...

Page 81: ...laces 56 Load per single line of 4 part hanging engine with electric motor specification 106 4714000 4 places 57 Fire extinguisher caution 103 4604800 60 EPA regulation 114110 07761 61 Working radius...

Page 82: ...72 This Page Intentionally Left Blank...

Page 83: ...REMOTE CONTROL 182 4 OPERATING MACHINE WITH ENGINE ELECTRIC MOTOR 207 5 HANDLING WIRE ROPE 214 6 TRANSPORTATION 217 7 HANDLING MACHINE IN COLD ENVIRONMENT 220 8 LONG TERM STORAGE 222 9 HANDLING BATTER...

Page 84: ...t 15 Operating sections 16 Operator seat 17 Monitor 18 Machinery cover R 19 Machinery cover L 20 Radiator grille 21 Radiator cover 22 Operation side cover 23 Engine cover 24 Hook block 25 Hydraulic oi...

Page 85: ...ration panel 2 Left control lever 3 Right control lever 4 Monitor 5 Emergency stop switch 6 Starter switch 7 Lock lever 8 Accelerator pedal 9 Light switch 10 Disconnect switch 11 Override switch 12 Fu...

Page 86: ...ngine and electric motor switch 9 Pop up select switch up 10 Pop up select switch down 11 Enter switch 12 Replacement reminder 13 Engine oil pressure 14 Engine coolant temperature 15 Charge 16 DPF reg...

Page 87: ...r is not working The meter indication increments are 1 every one hour of machine operation regardless of the engine or motor speed 3 Engine Speed Indicates the number of engine revolutions per minute...

Page 88: ...2 27 DPF STATIONARY REGENERATION METHOD section CAUTION The machine cannot be operated at all during DPF stationary regeneration Regeneration takes about 25 to 30 minutes so complete preparations bef...

Page 89: ...when consumables have reached the time for replacement See OPERATION 1 2 1 5 MONITOR DISPLAY USER INITIAL MODE 8 Consumables for the details of consumables 13 Engine oil pressure Indicates a drop in...

Page 90: ...immediately and check the alternator belt for tension 16 DPF regeneration request lamp While the DPF will carry out automatic regeneration the filter may not be regenerated if the machine is idling w...

Page 91: ...Mode selector switch 1 travel outrigger crane Used for changing the machine mode A pop up screen is displayed when you press the switch When the pop up screen is displayed the machine mode can be chan...

Page 92: ...LE 3 WORKING RADIUS 4 SLEW ANGLE 5 RATED TOTAL LOAD 6 ACTUAL LOAD 7 LOAD CAPACITY 8 MODE SELECTOR SWITCH 2 Travelling Hi Low 9 MODE SELECTOR SWITCH 3 Pick Carry 10 FRONT VIEW CAMERA MONITOR 11 LEFT SI...

Page 93: ...gle refers to the angle between the boom and horizontal line 3 WORKING RADIUS Continually displays the current working radius during crane operations NOTES The working radius refers to the horizontal...

Page 94: ...acity ratio 8 MODE SELECTOR SWITCH 2 Travelling Hi Low Use this switch to change the travelling speed Push to display a pop up screen When the pop up screen appears you can switch the travelling speed...

Page 95: ...encounters an error an error code appears in this area If an error code appears contact us or our sales service agent For details about the error codes refer to OPERATION 11 7 LIST OF ERROR CODES 13...

Page 96: ...4 MIN 9 Outrigger 1 MID 10 Outrigger 2 MID 11 Outrigger 3 MID 12 Outrigger 4 MID 13 Outrigger 1 MAX 14 Outrigger 2 MAX 15 Outrigger 3 MAX 16 Outrigger 4 MAX 17 Outrigger 1 GROUND SET UP 18 Outrigger...

Page 97: ...y to indicate that the corresponding outrigger is in the minimum extended state first stage 9 Outrigger 1 middle MID 10 Outrigger 2 middle MID 11 Outrigger 3 middle MID 12 Outrigger 4 middle MID These...

Page 98: ...an change the outrigger operation mode between Extension and Ground with the pop up select switch up down or touch screen operations 24 Mode selector switch 3 Manual Auto Use this switch to change the...

Page 99: ...display N mode P mode M mode 11 Boom length indication BOOM LENGTH 12 Indication of the number of wire falls 13 Over winding indication OVER WINDING 14 Actual load indication ACTUAL LOAD 15 Rated tota...

Page 100: ...ng radius limiter switch 5 Boom angle upper limit switch 6 Boom angle lower limit switch 7 Clockwise slew angle limiter switch 8 Counter clockwise slew angle limiter switch When the working radius of...

Page 101: ...trigger mode When in N mode even if one outrigger is at minimum extension the rated total load chart applied will be for the minimum extension When in M mode if the adjacent outriggers are extended to...

Page 102: ...ted total load indication RATED TOTAL LOAD Indicates the currently applicable rated total load the total weight of the hook slings and hoisting load 16 Hook grounding indication GROUND CONTACT Lights...

Page 103: ...en appears you can select the retracting operation of the crane from Hook stowage or Fully automated stowage with the pop up select switch up down or touch screen operations 21 Mode selector switch 2...

Page 104: ...MODE Crane stow position indication Outrigger 1 to 4 Extension ANGLE SET UP Outrigger 1 to 4 Minimum MIN Outrigger 1 to 4 Medium MID Outrigger 1 to 4 Maximum MAX Outrigger 1 to 4 Ground GROUND SET UP...

Page 105: ...of falls 3 Language setting 4 Error history 5 Software version 6 Monitor brightness 7 Time setting 8 Consumables 9 Switch operation tone ON OFF 10 Switch hook ground detection ON OFF 11 Switch winch...

Page 106: ...ected monitor changes to the dedicated screen Please refer to the section of Searcher Hook in this manual for details 3 Language setting The display language can be changed by touching the screen 4 Er...

Page 107: ...place oil in winch reduction gear case First 250 1000 hours Oil replacement for slewing reduction gear case First 250 1000 hours Oil replacement for travel motor reduction gear case First 250 1000 hou...

Page 108: ...gger mode 1 Accelerator up down pop up up down 2 Horn 3 Pop up Enter 4 Mode selector switch Extension Ground 5 Mode selector switch Manual Auto 6 Mode selector switch Travelling Outrigger Crane 7 8 9...

Page 109: ...elected on the pop up screen that appears on the monitor 4 Mode selector switch Travelling Hi Low Use this switch to change the travelling speed Push to display a pop up screen When the pop up screen...

Page 110: ...rd direction To move the machine backward pull the right and left control levers toward you at the same time Operating only one lever allows the machine to rotate and controlling both levers in the di...

Page 111: ...u can change the outrigger operation mode between Manual and Auto with the up down select switch 1 Accelerator Up Down pop up up down Crane mode Only items different from those in the travel mode are...

Page 112: ...boom while the lever is pushed towards the left side 11 Boom extension Extends the boom while the lever is pushed forwards 12 Boom retraction Retracts the boom while the lever is pulled towards you 1...

Page 113: ...elector switch 2 In Extension mode IN Push the switch up The outrigger extending cylinder contracts so as to stow the outrigger inner box NEUTRAL Release your finger from the switch The switch returns...

Page 114: ...the switches in the electrical system are turned off and the engine or the electric motor stops ON Electricity runs through all the circuits When the engine is selected as a power source wait until t...

Page 115: ...ECT SWITCH CAUTION Be sure to place this switch in the ON position Use this switch temporarily only in the case of preventing unexpected startup of electrical equipment during inspection and maintenan...

Page 116: ...he operation do not perform hoisting operation boom lowering operation and boom extension operation while the operation stop function is cancelled by turning this switch to the ON position Such operat...

Page 117: ...at the left side of the operator seat Inspect and replace fuses in the following procedure 1 On the left side of the operator s seat below the operation side cover there is a hatch cover 1 Open this...

Page 118: ...battery for the radio controller The cigarette lighter port is below the fuse box 1 2 13 MAINTENANCE USB PORT This is only used at the time of maintenance The USB port is located under the fuse box NO...

Page 119: ...select switch 7 Load carrying Fly jib change switch 8 Accelerator control switch 9 Horn switch 10 Emergency stop Remote controller power OFF switch C1 Cable connection port L1 LED light front L2 LED...

Page 120: ...can be switched between extension retraction and extension stowage 7 Load carrying Fly jib change switch Only in crane operation the operation can be switched between boom and fly jib NOTES Operation...

Page 121: ...Use this switch to operate the display R1 Control box Contains the receiver devices and control devices Do not disassemble or modify the control box under any circumstances Otherwise an electric shock...

Page 122: ...Before performing electric welding due to repair work for the machine body or other reasons be sure to disconnect the wire Failure to do so may result in a machine failure caused by burn damage to th...

Page 123: ...when you operate the Transmitter Wear the waist belt around your waist Attach the Transmitter to the waist belt 2 BATTERY CHARGER FOR REMOTE CONTROLLER Battery charger for charging the remote control...

Page 124: ...e four outriggers fails to satisfy the outrigger setting detection conditions see 2 in the table above the tricolor revolving light red illuminates If two of the four outriggers are detected as un set...

Page 125: ...for a load capacity ratio between 90 and less than 100 C Green revolving light operation indicator lamp for a load capacity ratio of less than 90 5 Boom length gauge inside the boom 6 Boom angle indi...

Page 126: ...the boom at high speeds may result in a serious accident such as death or serious injury The boom may fail to stop at the predetermined position causing the machine to overturn The moment limiter is a...

Page 127: ...ped automatically due to overload the following crane operations are prohibited Disobeying this rule may cause critical danger due to tipping of the machine or breakage of the boom for example Boom lo...

Page 128: ...is switch for lifting a load from the ground in normal situation Using the boom lift by pass switch to lift a load from the ground may cause critical danger due to tipping or breakage of the machine N...

Page 129: ...le at this time will be set as an upper limit angle At the same time the illuminated blue indicator lamp on the switch turns orange to indicate that the upper limit angle has been set To enable this s...

Page 130: ...t At the same time the illuminated orange indicator lamp at the switch turns blue to indicate that the set value for the lower limit angle has been reset NOTES The setting and resetting operations can...

Page 131: ...nds The lifting height at this time will be set as an upper limit At the same time the illuminated blue indicator lamp on the switch turns orange to indicate that the upper limit height has been set T...

Page 132: ...ndicator lamp at the switch turns blue to indicate that the upper limit angle has been reset NOTES The setting and resetting operations cannot be performed consecutively even if the switch is pressed...

Page 133: ...ndicator lamps for the respective working ranges blink in orange The tricolor revolving light illuminates in yellow The alarm generates continuous sound peep The alarm buzzer operates only when the op...

Page 134: ...nitor agrees with the actual number To change the number of wires switch to the User Initial Mode screen by pressing the settings switch on the monitor The set value for the number of wires hung will...

Page 135: ...up operation 1 5 6 MOMENT LIMITER START CONDITIONS The moment limiter performs a check on the moment limiter functions for 2 seconds immediately after the starter switch is set to the ON position Dur...

Page 136: ...on is cancelled by turning this switch to the ON position Such operation may cause boom breakage and machine tipping Use the hook storage switch when stowing the hook If this switch is turned ON to pe...

Page 137: ...over winding with an intermittent buzzer sound while the hook block 1 is wound or the boom 4 is extended or when the weight 3 is pushed upward due to hook block 1 approaching the boom 4 At the same t...

Page 138: ...operator seat while driving the machine 1 SEAT FORE AND AFT ADJUSTMENTS Use the slide adjustment lever 3 to adjust the seat 1 Move the seat 2 back and forth while pulling the slide adjustment lever 3...

Page 139: ...when you drive or operate the machine Do not wear the seatbelt in a twisted state Since a seatbelt tensioner is incorporated into the seatbelt unit it is unnecessary to adjust the length of the seatbe...

Page 140: ...r cover with the following procedure when performing inspection maintenance inside the radiator cover 1 Remove the fixing bolts 2 4 bolts of the radiator cover 1 2 Remove the radiator cover 1 2 INSTAL...

Page 141: ...ATION 1 10 ENGINE COVER 2 Remove the front left camera 1 3 Remove the fixing bolts 2 bolts securing the operation side cover together with the radiator grille 3 4 Remove the fixing bolts 4 2 bolts of...

Page 142: ...emoved or installed by two or more people 1 ENGINE COVER Remove the engine cover with the following procedure when performing inspection maintenance inside the engine cover 1 Remove the fixing bolts 2...

Page 143: ...the rear outrigger 2 and outrigger 3 3 Remove the fixing bolts 3 12 bolts of the right side machinery cover 1 and left side machinery covers 2 NOTES The fixing bolts used are as follows one on the fro...

Page 144: ...move the 10 bolts 2 on the operation side cover 1 2 Remove the operation side cover 1 2 INSTALLING THE OPERATION SIDE COVER HATCH When you are finished with inspection maintenance inside the operation...

Page 145: ...F POWER UNIT PARTS 1 Electric motor 2 Coupling 3 Hydraulic pump 1 13 2 NAMES OF POWER SUPPLY BOX PARTS 1 Power supply box 2 Power supply box door 3 Power supply box handle 4 Cable gland 5 Breaker swit...

Page 146: ...our company s sales service shop Complete check repair before turning the breaker switch ON to return power to the machine If you return power to the machine without a check repair this may cause a f...

Page 147: ...AINTENANCE 8 MAINTENANCE AND INSPECTION LIST 2 1 1 VISIBLE CHECKS Refer to INSPECTION AND MAINTENANCE 9 1 1 CHECKING BEFORE STARTING ENGINE VISUAL CHECKS 2 1 2 CHECKING BEFORE STARTING ENGINE Refer to...

Page 148: ...o not keep the starter turned for more than 5 seconds Doing so will accelerate the battery discharge If the engine fail to start wait for 1 minute before retrying Verify that the fuel lever of the wat...

Page 149: ...t the engine as follows when it is cold 1 Insert the key into the starter switch turn and hold the key in the ON position and wait until the WARM UP MONITOR indicator lamp goes out NOTES When the star...

Page 150: ...otential serious accident may occur if disregarded CAUTION The appropriate temperature of the hydraulic oil is 50 to 80 C Even when operating at low temperature by necessity increase the temperature o...

Page 151: ...ir if any abnormality is found 8 Operate the right control lever 1 slowly back and forth to check the following the hook block is smoothly wound unwound the hook block immediately stops when the right...

Page 152: ...high speed operation Avoid sudden starting sudden acceleration unnecessary sudden stop or sudden steering The metal powder produced inside the engine through break in increases in the engine oil and i...

Page 153: ...spot exists at the front and the left corner of the machine be sure to check the monitor view while driving the machine If you cannot verify the safety because the driving direction is out of view st...

Page 154: ...2 Travelling Hi Low toggles the mode between Travelling Hi and Travelling Low and the monitor indication changes accordingly 2 8 CHANGING DIRECTION OF THE MACHINE Sudden steering or unnecessary spin t...

Page 155: ...ckwise 3 CHANGING DIRECTION WHILE MOVING LEFT TURN WHILE MOVING FORWARD While pushing the right control lever forward return only the left control lever back to the NEUTRAL position LEFT TURN WHILE MO...

Page 156: ...ess contact with a control lever may result in serious accidents caused by sudden movement of the machine When parking the machine be sure to shift the lock lever back into the Lock position When leav...

Page 157: ...Take your foot off the accelerator pedal 6 let the engine idle for about 5 minutes with no load applied 2 Turn the starter switch key to the OFF position The engine stops 3 Remove the starter switch k...

Page 158: ...e 2 ALLOWABLE WATER DEPTH Keep water level below the center of the idler 1 3 CAUTIONS ON UPWARD DOWNWARD SLOPE While the machine is travelling if it tilts at an angle of 15 degrees or greater towards...

Page 159: ...lly brakes the machine however driving down a slope at high speed may cause the machine to overrun When travelling on a slope orient the machine so as to be square to the slope and operate the machine...

Page 160: ...K OUTRIGGER PLACEMENT CONDITION Standard operating procedures Machine conditions Indication and Alarm Operation of safety devices Starting engine Lock lever position Lock Check if the boom is in stow...

Page 161: ...d Even if only one out of four outriggers leaves the ground during crane operation Outrigger grounding lamp red blinks Crane Interlock Even if only one out of 8 lamps outrigger extension lamps and out...

Page 162: ...ion stowage Outrigger extension switch ON Slewing stowing outrigger rotaries and securing them with positioning pins Engine shutdown Outrigger extension lamp red blinks Tricolor revolving light red li...

Page 163: ...s it will go Do not set the outriggers with the outrigger rotaries stowed There are 4 outriggers Each outrigger has its own switch Be careful not to confuse the outrigger switches when setting the out...

Page 164: ...to water erosion and the top soil appears to be hard but soft in the ground Slope PROTECTING GROUND Place a sole plate of sufficient size with sufficient strength under the tray of all the outriggers...

Page 165: ...r adapter plate 2 14 2 OUTRIGGER SETUP OPERATION 1 TASKS TO BE PERFORMED BEFORE STARTING THE ENGINE There are 4 outriggers installed on the machine The following explains the setting procedure for onl...

Page 166: ...the position pin 1 out of the outrigger rotary 2 and rotate the outrigger rotary outward 7 Rotate the outrigger rotary 2 outwards so that it can align with the pin hole and insert the positioning pin...

Page 167: ...shift the lock lever 1 into a free F position 3 Select the Extension mode with the mode select switch 2 Extension Ground on the monitor or the left control lever 4 Identify the outrigger to be operat...

Page 168: ...be operated at the same time Simultaneous operation of the two switches for the outriggers on either left or right side will cause the outriggers on one side to leave the ground abruptly This will res...

Page 169: ...is in horizontal condition 10 When you are finished setting all outriggers set all outrigger switches to the NEUTRAL position 11 Make sure that all of the four outrigger grounding lamps 3 on the monit...

Page 170: ...ion Then push the right control lever 1 forward to lower the hook block When the boom is extended the hook block is wound and the over winding detector triggers the warning buzzer bringing the ongoing...

Page 171: ...lure to observe this may result in an irregular winding of the wire rope in the winch drum When loosening the wire rope for the stowed hook block there is a danger that the swinging hook block could b...

Page 172: ...ntioned below 1 Push the right control lever 1 forward to unwind the wire rope to an extent that the hook block does not come into contact with the ground NOTES If the hook block is secured to the hoo...

Page 173: ...block stops Winding Pull the lever backwards NOTES Control the winding unwinding speed of the winch drum with the right control lever and the stroke of the accelerator pedal 2 19 BOOM DERRICKING OPERA...

Page 174: ...e hook block is wound If the over winding detector generates an alarm buzzer while the boom is extended immediately shift the left control lever into the NEUTRAL position to stop the boom operation CA...

Page 175: ...vent it from hitting the operators However 360 degrees slewing can be operated with radio control regardless of the boom angle Operate the left control lever 2 as follows Clockwise Push the lever to t...

Page 176: ...lock will not touch the ground or interfere with the machine Be sure to stow the boom in the designated position After the boom has been stowed make sure that the crane stowage lamp on the monitor is...

Page 177: ...ange the mode change switch 3 to Hook stowage on the monitor The hook is wound automatically stowing the hook 4 NOTES In case of temporary stowage or short distance self travelling you can stow the ho...

Page 178: ...e sure there is no obstacle around the boom will be displayed 2 Pressing the fully automated stowage switch once more starts the automatic stowage operation according to the following procedure 1 Hook...

Page 179: ...hes at one time only the two switches for the front outriggers 1 and 4 or the two for the rear outriggers 2 and 3 can be operated simultaneously If two switches on either left or right side are operat...

Page 180: ...5 Make sure that the crane stowage lamp 1 on the monitor is lit in yellow 6 Select the Manual mode with the mode selector switch 3 Manual Auto on the monitor or the left control lever When operating...

Page 181: ...he NEUTRAL position temporarily Repeat this operation to gradually lower the machine until the crawler belts are completely grounded 10 After the right and left crawler belts come into complete contac...

Page 182: ...itioning pin 1 out of the outrigger rotary 2 and rotate the outrigger rotary inwards 2 When the outrigger rotary 2 is aligned with the pin hole fully insert the positioning pin 1 into the hole NOTES T...

Page 183: ...the load with slewing operation is prohibited 2 DON T OPERATE WITH DERRICKING FORCE Drawing in or lifting the load with boom derricking operation is prohibited 3 DON T PULL SIDEWARD DRAW IN OR HOIST...

Page 184: ...g more than the machine performance can cause accidents Crane operations must always be carried out according to the rated total load chart 8 DON T WIND WIRE BY FORCE Be careful not to hook the wire r...

Page 185: ...oach those locations or perform pick carry at those locations Check the condition of the road surface and ground in advance and have someone to guide you at the hazardous location or a location with p...

Page 186: ...degrees NOTES Slewing operation is possible only when the boom is fully retracted boom angle is more than 70 degrees and there is no load hoisted While operating the slewing other crane function cann...

Page 187: ...utrigger cannot be operated so check the machine condition 3 Change the mode to Outrigger with the mode selector switch 1 Travel Outrigger Crane on the monitor or with the left control lever 4 Refer t...

Page 188: ...e operation Avoid slopes and obstacles while travelling If the machine is inclined more than 2 degrees travelling cannot be operated 1 To perform crane operation confirm if the mode is set to Pick Car...

Page 189: ...t met slewing operation is not possible other than the 180 5 degrees area 3 Raise the hook block with right lever 1 by manipulating to your side until hook block automatically stops overwind condition...

Page 190: ...ane into no load condition 2 Set the crane into below conditions Boom is fully retracted Boom angle is more than 60 degrees Slewing angle is within 180 5 degrees No load NOTES If above conditions are...

Page 191: ...when regeneration begins in order to raise the exhaust gas temperature and is not a fault If the machine is operated with the regeneration request lamp still lit on the monitor there is a risk of DPF...

Page 192: ...be sure to perform inspections on the transmitter and the receiver in accordance with INSPECTION AND MAINTENANCE 9 1 PRE OPERATION INSPECTION 3 1 CAUTIONS BEFORE OPERATION 1 To prevent the Transmitte...

Page 193: ...ntroller power ON OFF switch 3 is pressed The controller has been left un operated for 5 second or longer 2 When the controller is ready for power on pressing and holding the remote controller power O...

Page 194: ...2 Battery status bar Indicates the remaining battery levels as follows 3 Radio wave status bar The intensity of radio waves are as follows 4 Error icon An icon appears when an error is detected Detail...

Page 195: ...e the setting menu Crane menu Pressing the operation mode selector switch 5 will automatically display the screen on the right side monitor M2 according to the operation to be performed The left side...

Page 196: ...nt menu to the settings menu Turning the display operation switch N1 allows you to select a desired menu Select a menu on the display and press the display operation switch N1 to determine the menu 1...

Page 197: ...187 Remote control menu...

Page 198: ...ow the engine to stop CAUTION To stop the engine press and hold the engine start stop switch 4 until it stops 3 5 OPERATION AFTER ENGINE IS STARTED 3 5 1 OPERATION BEFORE WORK Before operating with co...

Page 199: ...Check for safety in the vicinity of the machine and honk the horn before starting to move the machine To start the machine control the engine at low speeds manipulate the left and right control levers...

Page 200: ...ward direction Pulling the right control lever 2 toward you causes the machine to turn left in the backward direction RIGHT TURN Pushing the left control lever 1 forward causes the machine to turn rig...

Page 201: ...1 toward you move only the right control lever 2 back to the NEUTRAL position 3 6 3 STOPPING PARKING THE MACHINE Avoid sudden stops and try to stop with a safety margin whenever possible Choose a lev...

Page 202: ...ccident such as tipping of the Crane When operating the outriggers always ensure that the position pin of each outrigger is securely inserted If any of the positioning pins come out during operation a...

Page 203: ...STARTING STOPPING THE ENGINE to start the engine 2 Change the mode to Extension with the Transmitter speed selector Outrigger select switch 6 on the transmitter 3 Operate the control levers to extend...

Page 204: ...r 1 or 2 Right lever outrigger 4 or 3 7 After all outrigger adapters have been grounded when the grounding cylinders are extended by manipulating the control lever and the machine is slightly raised u...

Page 205: ...the crane stowage lamp 1 the four outrigger extension lamps 2 and four outrigger grounding lamps 3 are lit in green CAUTION If any of the outrigger grounding lamps 3 are blinking in red remove the co...

Page 206: ...he other three outriggers 1 See OPERATION 3 4 STARTING STOPPING THE ENGINE to start the engine 2 Set the mode selector switch 5 for the transmitter to Outrigger F or R Outrigger F operates outriggers...

Page 207: ...pletely grounded 6 After the right and left crawler belts come to complete contact with the ground further operate the control lever When the grounding cylinder has been completely retracted and the t...

Page 208: ...When the extension cylinder has been completely retracted and the inner box reaches the shortest position release your finger from the operation lever Repeat the above step for other outriggers to bri...

Page 209: ...he Outrigger mode the outrigger operates unexpectedly which is very dangerous Always actuate the operation lever with caution Make adjustments to achieve the optimal operation speed for crane operatio...

Page 210: ...the winding unwinding of the hook block stops Winding Pull the lever backwards NOTES Control the winding unwinding speed of the winch drum with the right control lever and accelerator control switch...

Page 211: ...nded the hook block is wound If the over winding detector generates an alarm buzzer while the boom is extended immediately shift the left control lever into the NEUTRAL position to stop the boom opera...

Page 212: ...hen slewing the boom with a suspended load In some cases depending on the configuration of the outriggers the suspended load may hit the outriggers resulting in damage to the crane or overturning of t...

Page 213: ...mality mentioned above includes continuation of crane operations even after the release of control levers or unexpected crane movements before the control levers are used In the event of an emergency...

Page 214: ...can be switched between Extension and Extension stowage by pressing the Speed selector Outrigger select switch 6 3 10 OPERATING ACCELERATOR CONTROL SWITCH The accelerator control switch 8 allows you...

Page 215: ...ping the engine Press the Emergency stop Remote controller power OFF switch 10 when turning off the power to the transmitter or in case of an abnormality in crane operations The power of the Transmitt...

Page 216: ...t the power of the Transmitter be turned ON This could cause unexpected movement of the Crane resulting in a serious hazard such that the Crane hitting someone or an object or the Crane could tip When...

Page 217: ...lace a damaged cabtire cable with a new one Ensure that no sharp protrusion is present at an area where the cabtire cable is routed Failure to follow the above precaution may cause the cable to get sn...

Page 218: ...the breaker switch pedestal 5 5 Insert the applicable cabtire cable A into the cable hole of the cable gland 7 under the power supply box and connect it to the breaker switch block 5 CAUTION The lengt...

Page 219: ...ver 6 of the breaker switch block 5 into place and close the door 3 of the power supply box 2 7 Attach the box 3 The box is attached using 4 bolts 4 inside 8 Connect power plug 2 9 Turn the power supp...

Page 220: ...les service agency to request inspection or repair Crane operational check is necessary after motor warm up Keep the hook block away from the boom to avoid interference or collision Exercise caution t...

Page 221: ...further 30 minutes To restart the engine turn the starter switch to the START position again 6 Use the following procedure for checking the power unit if an abnormal noise odor or vibration is presen...

Page 222: ...CHINE 1 Turn the starter switch key to the OFF position The electric motor stops 2 Remove the starter switch key 3 Visually check for oil leakage and check around the crawlers crane and exterior of th...

Page 223: ...213 4 5 POWER SUPPLY SEPARATION 1 Turn OFF the power supply equipment breaker 2 Turn the breaker switch 1 of the power supply box to the OFF position 3 Remove the power plug 2...

Page 224: ...for extending boom No 5 IWRC 6 Fi 29 0 0 9 mm 17 04 m 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...

Page 225: ...hift the right control lever into the Lower side push it to the right to lower the boom or shift the left control lever into the Retraction side pull it toward you to retract and lower the boom 3 Turn...

Page 226: ...on side push it forward to fully extend the boom 8 Shift the right control lever into the Up or Down side and repeat winding and unwinding the hook block several times 9 Spool the wire rope tight and...

Page 227: ...o be positioned on the load carrying platform of a truck Be sure to unload the machine from the truck by driving the machine forward Unloading by driving in reverse may cause the machine to overturn A...

Page 228: ...of lifting the mass weight of the machine Before lifting the machine be sure to bring it into the travelling posture and securely insert the positioning pins 4 into the respective outrigger rotaries...

Page 229: ...hains or wire ropes Especially making sure it is properly secured so that it cannot move from side to side 3 Please make sure if the hook block is secured to the hook stowage wire or to the truck deck...

Page 230: ...cement period and mixing rate of the antifreeze fluid 3 BATTERY The battery produces combustible gas and can be explosive Do not put fire close to the battery The battery fluid is a hazardous substanc...

Page 231: ...from freezing and allows the machine to start moving quickly next morning Remove the drain plug of the fuel tank to drain the water in the fuel system to prevent the water from freezing The battery ab...

Page 232: ...engine electric motor cover the electric motor and the hydraulic pump in the power unit with a sheet together with a dehumidifying agent to keep the machine as dry as possible For machines with engine...

Page 233: ...nd change the oil without fail Remove the battery cover install the battery if it is removed from the machine and check the electrolyte level and specific gravity and then connect the battery cable at...

Page 234: ...ts such as tools coming between terminal and the machine body will cause sparks Slackened battery terminals can cause sparks due to poor contact causing an explosion hazard Tighten securely when insta...

Page 235: ...e the battery cover 3 3 Remove the 2 bolts 6 and open the driver s seat floor cover 7 4 To remove the battery cable disconnect it from the terminal 8 first and then disconnect it from the terminal 9 5...

Page 236: ...battery becomes overheated fluid temperature exceeded 45 C Stop charging promptly once the charging is completed Continuing to charge after reaching the fully charged state will cause 1 Overheating o...

Page 237: ...ther or the machine when disconnecting the booster cable CAUTION Use booster cable and clips of appropriate size for the battery size The battery in the slave machine and machine in failure should be...

Page 238: ...ine If the engine does not start wait for more than 2 minutes before re trying NOTES See OPERATION 2 2 STARTING ENGINE for how to start the engine 4 DISCONNECTING BOOSTER CABLE When the engine has sta...

Page 239: ...ACEMENT METHOD OF BATTERY Replace the battery of the Transmitter in the procedure described below 1 Turn OFF the power of the Transmitter Pressing the Emergency stop Remote controller power OFF switch...

Page 240: ...e transmitter battery status bar illuminates in red followed by a signal alarm sound immediately charge the battery It is ideal to store the battery in a 30 to 50 charged condition if it is going to b...

Page 241: ...231 The radio controller battery can be charged using the cigarette lighter port of the vehicle Set the charger case B5 for radio controller battery under the override switch...

Page 242: ...ive alternator Defective wiring Replacement Inspection and repair Abnormal noise from alternator Defective alternator Replacement Starter not rotating even after the starter switch is turned Defective...

Page 243: ...Refill with hydraulic oil to the specified oil level referring to the section Check before operation Clean and replace the strainer and element according to periodic inspection Hydraulic oil temperat...

Page 244: ...does not start Engine power is low or the power gradually drops Air cleaner element clogged Radiator fin clogged Insufficient compression See Regular Maintenance for cleaning or replacement of the pa...

Page 245: ...tion repair replacement The power output of the motor reaches zero or undergoes gradual decrease Phase interruption in the power source of power supply equipment Slack in motor wiring Check the power...

Page 246: ...nspection and cleaning according to Engine Electric Motor Spec Operation Replace the cabtire cable with one adhering to specifications Reduce loads Reduce the number of starts The leak detector of the...

Page 247: ...of the Transmitter Check item Cause and Action Does the crane operate with the operation on the machine body side If the crane operates there is an abnormality in this equipment If the crane does not...

Page 248: ...nnection for wireless communication Check receiver cable for disconnection Check functionality with LED in receiver control light field Individual commands cannot be executed Receiver has failed Conne...

Page 249: ...Items to check EI01 Right joystick front rear start position error If error occurs when you start with lever control in input condition set the lever control to no input condition and start again and...

Page 250: ...ttery pressure low error Check if battery pressure is lower than 11V Check fuse Check harness of battery related circuit ES103 Stow position LS input error Check limit switch Check harness of stow pos...

Page 251: ...grounding 3 solenoid Check harness of OR grounding 3 solenoid circuit EOS03H OR grounding 3 SOL Lo error EOS04L OR grounding 4 SOL Hi error Check OR grounding 4 solenoid Check harness of OR grounding...

Page 252: ...circuit EOC02H Boom retract SOL Lo error EOC03L Boom raise SOL Hi error Check boom raise solenoid Check harness of boom raise solenoid circuit EOC03H Boom raise SOL Lo error EOC04L Boom lower SOL Hi e...

Page 253: ...r EO106L Boom light output Lo error Check harness of boom light output circuit EO107L Fly jib shift relay Lo error Check harness of fly jib shift relay circuit EV10 Sensor power Lo error Check harness...

Page 254: ...244 This Page Intentionally Left Blank...

Page 255: ...246 2 BASIC MAINTENANCE 248 3 LEGAL INSPECTION 251 4 PERIODIC REPLACEMENT OF IMPORTANT COMPONENTS 252 5 CONSUMABLES 253 6 LUBRICATING OIL 254 7 ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE 255 8 INS...

Page 256: ...ust conform to specifications according to ambient temperature 4 USE CLEAN OIL AND GREASE Always use clean oil or grease and keep in a secure container to reduce contact with impurities 5 KEEP THE MAC...

Page 257: ...pened 16 ASSURE SAFE RUBBER TRACK When performing crane operation in a rocky location make sure of no damage to the rubber track and no looseness cracks or abrasion of bolts and nuts Loosen the tensio...

Page 258: ...a hydraulic oil system as factory default Do not use any other hydraulic oil that is not recommended by us Failure to follow the instruction may cause the filters to get clogged A small amount of oil...

Page 259: ...re Periodic replacement of the filter is required in accordance with the Operation Manual The replacement period should be shortened in responses to harsh operating environments or the amount of oil u...

Page 260: ...c equipment Place the machine in travel position on a level surface to inhibit the application of pressure to the cylinder circuit Be sure to stop the engine Hydraulic oil and lubricating oil will be...

Page 261: ...e winch wire rope end and wire clip for breakage 4 If wire rope is damaged replace immediately 5 Check the hydraulic hose for oil leaks and friction flaws on the surface Replace the hose if a surface...

Page 262: ...nctionality These parts need repair or replacement when any abnormality is detected even before the exchange time comes For the hose part if any distortions or cracks in the hose clamp or deterioratio...

Page 263: ...ar case oil replacement Initial 250 hrs every 1000 hrs Travel motor reduction gear case oil replacement Initial 250 hrs every 1000 hrs Engine oil replacement Every 500 hours Engine oil filter replacem...

Page 264: ...replaced at inspection and maintenance Always use SAE10W CD SAE10W 30CD or SAE10W 40CD to start the engine with temperature at 0 C or below despite rise in diurnal temperature Be sure to use our recom...

Page 265: ...olerance Target value Tolerance 6 10 7 8 0 80 6 8 9 0 0 70 0 92 11 0 1 1 9 4 12 7 0 93 1 26 8 13 19 0 1 95 16 5 21 9 1 70 2 24 27 0 2 7 23 0 31 1 2 3 3 10 10 17 37 5 3 85 32 6 43 1 3 35 4 43 53 0 5 4...

Page 266: ...71 9 5 55 7 35 18 27 373 38 1 317 429 32 4 43 8 86 0 8 75 74 8 98 9 7 60 10 0 20 30 529 54 0 450 608 45 9 62 1 122 12 4 106 140 10 8 14 3 22 32 720 73 4 612 828 62 4 84 4 166 16 9 144 191 14 7 19 4 24...

Page 267: ...TOR REDUCTION GEAR CASE 269 8 INSPECTING CLEANING OF RADIATOR AND OIL COOLER FINS 270 9 INSPECTING REFILLING OF BATTERY ELECTROLYTE LEVEL 271 10 CHECKING HORN FOR OPERATION 272 11 CHECKING HEADLIGHTS...

Page 268: ...NTAMINANT WATER DEPOSITS IN FUEL PRE FILTER 302 3 GREASING OF MACHINE UNITS 303 9 7 EVERY 100 HOURS MAINTENANCE 305 1 INSPECTING REFILLING OF OIL LEVEL IN SLEWING REDUCTION GEAR CASE 305 9 8 EVERY 250...

Page 269: ...ALVE SEAT 326 2 CHECKING ALTERNATOR AND STARTER 326 9 13 EVERY 3000 HOURS MAINTENANCE 327 1 INSPECTION OF ECU AND RELATED SENSOR AND ACTUATOR 327 2 INSPECTION CLEANING TESTING OF EGR VALVE 327 3 CLEAN...

Page 270: ...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 Carefully check around these areas If there is any abnorm...

Page 271: ...ON OF WIRE ROPE See OPERATION 5 HANDLING WIRE ROPE for details on wire rope Check wire ropes for damage deformation wear twist kink and corrosion Replace if any abnormality is found Check the connecti...

Page 272: ...g loose connections or any trace of burning Repair if any abnormality is found Check for any cracks significant deformation or dirt in the frame machinery cover or engine hood Repair if any abnormalit...

Page 273: ...e tank 1 and fill the water from the filler opening to the level FULL 2 After refilling coolant securely re install the cap 2 of the reserve tank 1 When the reserve tank is empty Follow the steps belo...

Page 274: ...careful not to let any foreign substance go into the filler opening when refilling the oil Checking oil level 1 Place the machine on a level surface 2 Open the inspection cover 1 of the engine cover...

Page 275: ...pper limit level Always wipe away cleanly whenever the fuel spills Securely close the tank cap after refuelling 1 Turn ON the starter switch 2 Looking at the fuel gauge on the monitor panel check if t...

Page 276: ...the radiator cover 3 Check the fuel pre filter 1 for any water or dust that is accumulated inside and verify if the red float 2 in the pot has not come up from the bottom The red float 2 in the fuel p...

Page 277: ...oil level in the working position will cause overfilling since the oil in the cylinders has not returned to the tank 1 Place the machine on a level surface 2 Check the oil level gauge G in the front...

Page 278: ...the center point of the sight gauge G 3 If there is not sufficient oil refill the gear oil according to the following procedure 1 See OPERATION 2 14 OUTRIGGER SETTING OPERATION to rotate the outrigge...

Page 279: ...and forth so that one of two drain plugs P of the traveling motor reduction gear case will come directly underneath 2 Remove the oil level check plug G of the traveling motor reduction gear case to c...

Page 280: ...m the fins Damage on the fins will cause water leakage or overheating At a dusty worksite check the fins every day and clean as needed 1 Place the machine on a level surface 2 Remove the mounting bolt...

Page 281: ...should be refilled before starting the work next day to avoid freezing Electrolyte level inspection 1 Place the machine on a level surface 2 Open the inspection cover 1 3 Verify the electrolyte you c...

Page 282: ...back into their original positions and securely tighten the 4 attachment bolts 4 10 CHECKING HORN FOR OPERATION 1 Turn ON the starter switch and conduct the following inspection 2 Press the horn swit...

Page 283: ...s service agency for repair 13 INSPECTION OF OUTRIGGER DISPLAY 1 Turn ON the starter switch 2 Press the mode switch 1 of the monitor or touch the screen to enter the outrigger mode 3 Check to see that...

Page 284: ...he seat to the appropriate position while lifting up the slide adjustment lever 1 2 Release your hand from the lever 1 NOTES The fine tuning range by back forth slide is 160 mm and can be adjustable A...

Page 285: ...or operation switches they may disturb correct operations causing unexpected movement of the Crane and resulting in a serious accident Check for any cracks and or damage to the transmitter enclosure...

Page 286: ...ns while the transmitter power is ON CHECKING DISPLAY AFTER TURNING THE POWER ON Press the remote controller power ON OFF switch 3 twice when the control lever of the transmitter is in the neutral pos...

Page 287: ...d repair immediately Cracks or damage to the Receiver may allow water to enter inside causing a malfunction and creating a serious hazard Operate ON OFF of the main starter switch and check that the p...

Page 288: ...PECTION OF OUTRIGGER SAFETY EQUIPMENT OPERATION Checking operation of crane interlock 1 Turn ON the starter switch 2 Press the mode switch 1 of the monitor or touch the screen to enter the outrigger m...

Page 289: ...the monitor are lit CAUTION If any of the contact lamps 3 is flashing in red check any foreign objects in the bending part by removing the cover 9 of the outrigger tray 8 part 8 Turn one of the four o...

Page 290: ...il the crane stowage position lamp 1 of the monitor turns off 4 Press the mode switch of the monitor or touch the screen to enter the outrigger mode 5 Press the mode switch 5 of the monitor or touch t...

Page 291: ...see whether the outrigger inner box retracts smoothly At this time check if abnormal noise is generated from various parts of the outriggers Continue to check other switches for their operation Repai...

Page 292: ...check that the boom extends smoothly Also pull the operation lever on the left backward and check that the boom retracts smoothly At this time check if abnormal noise is generated from the parts of th...

Page 293: ...tatus lamp should be lit for three seconds and then the green rotating light is lit 3 Check that there is no error code displayed on the Rated total load in the moment limiter monitor 4 Start the engi...

Page 294: ...ger extension check the sticker medium maximum on the top side of inner box 7 CHECKING ENGINE EXHAUST GAS COLOUR NOISE AND VIBRATION 1 Release the acceleration pedal 6 to low idling position so that t...

Page 295: ...T OPERATION 1 Turn ON the main starter switch on the machine side 2 Press the start stop radio control button 3 of the transmitter twice to turn the power ON 3 Press the horn switch 7 and check that t...

Page 296: ...switch 4 to start the engine 5 Operate the operating levers 1 2 to the Extend side and Retract side and check that the outrigger corresponds to the operation levers NOTES Slowly push the operation le...

Page 297: ...the start stop radio control button 3 of the transmitter twice to turn the power ON 4 Using the mode selector switch 8 of the transmitter set the operation mode to the Crane mode When operating the c...

Page 298: ...eed to any position The maximum engine speed can be set to increase on the side Check that when each operation lever is pushed down the crane speed increases according to the operation amount and the...

Page 299: ...etween the upper side of the rubber track and the lower side of the lumber Standard slack a 10 20 mm Adjustment If the result was lower than standard tension make adjustments as below To increase tens...

Page 300: ...ove ask us or our sales service agency for repair 2 Tighten the plug 1 3 Set the engine to the low idling mode and forward by the contact length and stop slowly to check that the tension condition is...

Page 301: ...ope undergoes wear and tear over time Prompt replacement is required if any of the following appears in the wire rope 10 or more of strands except a filler wire in 1 twist of a wire rope 6 crests are...

Page 302: ...1 Bring a 4 to 6 mm round bar 6 into contact with the rope wedge 7 2 Remove the rope wedge 7 by lightly tapping the round bar 6 with a hammer in the direction indicated by the arrow a 7 Push down the...

Page 303: ...wire rope 5 through the weight of the over hoist detector 11 load sheave 11 at the jib end wire guide 12 of booms Nos 2 3 and 4 roller sheave 13 sheave inside the boom derricking cylinder mounting br...

Page 304: ...k at the wire rope 5 in the direction indicated by the arrow 7 Attach the wire clip 4 to the wire rope 5 according to the dimension described in the figure to the right 8 Secure the wire socket 3 to t...

Page 305: ...lt 6 on the tip of extension cylinder inside the boom and turn the boom extending wire adjusting bolt 9 clockwise The tension of the boom extending wire 8 is normal if the No 5 boom is extended when t...

Page 306: ...owing for proper adjustment If the clearance a is 5 mm or more adjust the No 5 boom retracting wire rope 5 If the clearance a is 0 zero adjust according to step 5 Adjustment of No 5 boom extending wir...

Page 307: ...e until just before the No 5 boom begins to extend 2 Re tighten both the right and left adjusting nuts 4 of the No 5 boom retracting wire rope 5 3 Fix the adjustment nuts 4 of the No 5 boom retracting...

Page 308: ...ulic oil do not start the engine for a while until piping and hydraulic equipment are filled with the oil Do not refill oil exceeding the level gauge H upper limit When the oil goes beyond this level...

Page 309: ...0 minutes 2 While keeping the engine speed low slightly operate each control lever to operate each cylinder and winch motor slowly Do not operate the boom hoisting cylinder and telescopic boom cylinde...

Page 310: ...See 9 9 EVERY 500 HOURS MAINTENANCE for details on the place and method of maintenance 3 CHECKING ADJUSTING ALTERNATOR BELT TENSION See 9 8 EVERY 250 HOURS MAINTENANCE for details on the place and met...

Page 311: ...he ground so you can go under the machine If the machine is unstable and sways place supports stands under the front and rear sides of the machine to stabilize it Fuel drain pan Prepare a container of...

Page 312: ...the fuel pre filter 1 to the left to loosen and drain the fuel until the red float 2 inside the fuel pre filter 1 sinks to the bottom 6 When draining is finished turn the valve 3 at the bottom of the...

Page 313: ...f the sheave 1 place 9 Greasing of the hook block 1 place 10 Greasing of the boom top slide plate 8 places Neo grease grease for boom 11 Greasing of the boom bottom slide plate 8 places 12 Greasing of...

Page 314: ...304...

Page 315: ...to be used Use seal tape etc at the thread of the oil level check plug to stop the oil leak and securely tighten the plug after checking refilling the oil Prepare a container to drain the oil Have an...

Page 316: ...m initial use Always use Maeda genuine elements 1 See OPERATION 1 9 RADIATOR GRILL and remove the radiator grill See OPERATION 1 12 OPERATION SIDE COVER and remove the operator side cover 2 Disengage...

Page 317: ...loth or tape from the air connector at the back of the air cleaner body 4 10 Insert the cleaned element 3 into the air cleaner body 4 11 Mount the dust pan 2 by matching the arrow to the mating mark o...

Page 318: ...ly check if the V belt is touching the bottom of the V groove and if it is replace the belt Standard slack of belt in use mm A B C 10 14 7 10 9 13 NOTES Belt in use refers to the belt attached to the...

Page 319: ...See INSPECTION AND MAINTENANCE 6 1 USE OF LUBRICATING OIL ACCORDING TO TEMPERATURES for the oil to be used Tighten the plug securely paying attention to the engagement of the O ring of the plug after...

Page 320: ...fe of the engine Be sure to refill the specified oil Keep the engine oil at an appropriate level When the engine is cold oil cannot be drained completely Drain the oil in a condition in which the engi...

Page 321: ...the mounting surface tighten with a filter wrench to the specified tightening torque Tightening torque 19 6 23 5 N m 2 0 2 4 kgf m 11 Check around the filter cartridge 3 for oil leaks and wipe off spi...

Page 322: ...gging occurs soon after replacing the outer element 3 with a new one The inner element 5 is for backup to prevent engine troubles caused by missing or damaged outer element 3 5 Cover the duct entrance...

Page 323: ...aminants 5 Remove the cup 5 by turning to left NOTES Wipe off the oil spills completely 6 Remove the float 7 from the cup 5 7 Remove the element 8 8 Wash inside the cup 5 with new fuel oil 9 Check con...

Page 324: ...install the filter cartridge 1 tighten it with your hand until the seat surface hits the mounting surface After the seat surface touches the mounting surface tighten with a filter wrench to the speci...

Page 325: ...it When the oil goes beyond this level it may spout out from the air filter during traveling or crane operation Be careful not to let any foreign substance go into the filler opening when refilling th...

Page 326: ...lter to relieve internal pressure by slowly rotating it first Securely close the air filter after refilling If the air filter falls during the operation hot oil may spout out of the pan causing burns...

Page 327: ...edure below 1 Remove the mounting bolts 4 2 bolts and then remove the inspection cover 3 on the right of rotating post 2 Rotate the post so that the mounting bolt 2 on the bearing inner ring side come...

Page 328: ...ter through the small water supply system is necessarily substituted for tap water Use a lubricant compliant to one of the SAE J814 SAE J1034 ASTM D3306 or JIS K2234 standard Replace the coolant every...

Page 329: ...radiator needs to be filled up to the supply port 8 Start the engine with the drain valve 8 open and ensure the engine runs at low idle Conduct a 10 minute cleaning with running water CAUTION The rad...

Page 330: ...r needs to be filled up to the supply port NOTES See the above mentioned table Mixing ratio between water and antifreeze for the mixing ratio of antifreeze and tap water soft water 16 Start the engine...

Page 331: ...oil excessively After replacing the hydraulic oil do not start the engine for a while until piping and hydraulic equipment are filled with the oil Do not refill oil exceeding the level gauge H upper l...

Page 332: ...age position and stop the engine 14 Bleed the air according to the following sequence 1 Start the engine only after piping and hydraulic equipment are filled with oil After engine start continue to ru...

Page 333: ...nter under the machine Using a level check to make sure that the machine is installed on a level surface When using the outriggers place them at their maximum extension Then place a firm block between...

Page 334: ...securely tighten the plug after changing the oil Volume of oil actually to be replaced in the oil pan 1 8 L Prepare a container to drain the oil Have an Allen key ready 1 Place the machine on a level...

Page 335: ...key ready 1 Move the machine back and forth so that the filler plug F and drain plug P are perpendicular to the ground 2 Place a container to collect the drained fuel underneath the drain plug P 3 Rem...

Page 336: ...s Contact us or our sales service agent to request inspection and repair 9 12 EVERY 2000 HOURS MAINTENANCE Perform this maintenance along with maintenance every 50 100 250 500 1000 hours 1 INSPECTION...

Page 337: ...r cleaning water side exhaust passage blower requires special tools Contact us or our sales service agent to request inspection and repair 4 INSPECTION OF DPF DOC Inspection of DPF DOC requires specia...

Page 338: ...328 This Page Intentionally Left Blank...

Page 339: ...SPECIFICATIONS LIST 330 2 SPECIFICATION DIMENSIONAL DRAWING 333 3 DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 334 4 RATED TOTAL LOAD CHART 335 5 WORKING RADIUS LIFTING HEIGHT 347 6 WORKING RADIUS and LIFTI...

Page 340: ...raulic motor driven Reducer worm spur gear reduction Brake worm self lock Slewing angle 360 degrees continuous 2 5 min 1 Outrigger System Type Extension grounding hydraulic cylinder direct acting type...

Page 341: ...igger System Type Extension grounding hydraulic cylinder direct acting type with automated hydraulic locking device Max extended width left to right Front 6300 mm Rear 6520 mm Max extended width front...

Page 342: ...power off device Transmitter stop function when battery capacity decreases Alarm switch Transmitter voltage Battery BA405000 6 VDC at 1500 mAh Receiver voltage Power of crane main body 12 VDC Continuo...

Page 343: ...333 2 SPECIFICATION DIMENSIONAL DRAWING...

Page 344: ...334 3 DIMENSIONAL DRAWING OF OUTRIGGER WIDTH...

Page 345: ...90 4690 4690 3390 3390 3 00 6390 6390 6390 6390 4690 4690 3390 3390 3 50 5490 5490 5490 5490 4690 4690 3390 3390 2390 2390 4 00 4790 4790 4790 4790 4690 4690 3390 3390 2390 2390 4 50 4190 4190 4190 41...

Page 346: ...290 4590 4590 3290 3290 3 00 6290 6290 6290 6290 4590 4590 3290 3290 3 50 5290 5290 5290 5290 4590 4590 3290 3290 2290 2290 4 00 4590 4590 4590 4590 4590 4590 3290 3290 2290 2290 4 50 3990 3990 3990 3...

Page 347: ...0 3090 3090 3 00 6190 6190 6190 6190 4590 4590 3090 3090 3 50 5290 5290 5290 5290 4590 4590 3090 3090 2190 2190 4 00 4590 4590 4590 4590 4590 4590 3090 3090 2190 2190 4 50 3990 3990 3990 3990 3990 399...

Page 348: ...3390 3390 3 00 6090 6090 6090 6090 4690 4690 3390 3390 3 50 5490 5490 5490 5490 4690 4690 3390 3390 2390 2390 4 00 4790 4790 4790 4790 4690 4690 3390 3390 2390 2390 4 50 4190 4190 4190 4190 4090 4090...

Page 349: ...90 3290 3 00 6090 6090 6090 6090 4590 4590 3290 3290 3 50 5290 5290 5290 5290 4590 4590 3290 3290 2290 2290 4 00 4590 4590 4590 4590 4590 4590 3290 3290 2290 2290 4 50 3990 3990 3990 3990 3990 3990 32...

Page 350: ...0 3090 3090 3 00 6090 6090 6090 6090 4590 4590 3090 3090 3 50 5290 5290 5290 5290 4590 4590 3090 3090 2190 2190 4 00 4590 4590 4590 4590 4590 4590 3090 3090 2190 2190 4 50 3990 3990 3990 3990 3990 399...

Page 351: ...3090 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2390 2390 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2390 2390 4 50 3090 3090 3090 3090 3090 3090...

Page 352: ...90 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2290 2290 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2290 2290 4 50 3090 3090 3090 3090 3090 3090 30...

Page 353: ...0 3090 3090 3 00 3090 3090 3090 3090 3090 3090 3090 3090 3 50 3090 3090 3090 3090 3090 3090 3090 3090 2190 2190 4 00 3090 3090 3090 3090 3090 3090 3090 3090 2190 2190 4 50 3090 3090 3090 3090 3090 309...

Page 354: ...520 1520 1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 1...

Page 355: ...1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 1520 1520...

Page 356: ...1520 1520 1520 3 00 1520 1520 1520 1520 1520 1520 1520 1520 3 50 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 00 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 4 50 1520 1520 1520 1520 1520...

Page 357: ...347 5 WORKING RADIUS LIFTING HEIGHT...

Page 358: ...hese rules to prevent machine from tipping over 1 Do not travel on a slope soft grond or uneven ground 2 Do not slew Avoid any sharp movements when stopping or starting 3 When traveling with a load ke...

Page 359: ...2 MOUNT POSITION OF FLY JIB SAFETY LABELS 351 3 NAME OF EACH SECTION OF FLY JIB 355 4 MOUNTING AND STOWING FLY JIB 356 5 HANDLING MONITOR AND MOMENT LIMITER 373 6 OPERATION 378 7 TROUBLESHOOTING 379...

Page 360: ...mes off the fly jib may fall causing a serious accident When stowing a fly jib be sure to disconnect the electric wires on the fly jib side and reconnect them to the over hoist detector on the main bo...

Page 361: ...n are described See Safety Safety Label Locations for the safety labels that are not described in this section Please keep these safety labels clean so you can read them correctly If any safety labels...

Page 362: ...352 1 Diagram of fly jib working range chart 106 2189200...

Page 363: ...353 2 Notice on mounting fly jib 106 3401300 3 Notice on stowing fly jib 106 3401400 4 Notice on exchanging fly jib harness 106 3401000 5 Notice on exchanging fly jib hydraulic hose 106 3401100...

Page 364: ...0 7 Division pin description 585 3558700 8 Notice for pin holes CL000100001 2 locations 9 Caution against being caught CL000120011 2 locations 10 Hoisting position 585 4714800 2 locations 11 Maximum r...

Page 365: ...detector weight 10 Single hook 11 Snap sheave 12 Wire rope 13 Wire 14 Guide sheave 15 Derricking wire rope 16 Derricking sheave 21 Stowage bracket A 22 Stowage bracket B 56 Fly jib switching valve 81...

Page 366: ...positions and tighten them securely with a linchpin and shaft lock pin If the position pin comes off the fly jib may fall causing a serious accident When mounting a fly jib be sure to disconnect the...

Page 367: ...te 31 and the collar 29 and pull out the head pin 28 completely so that the fly jib mounting bracket 6 can be inserted NOTES The head pin 28 does not need to be pulled out completely as long as the fl...

Page 368: ...n of the fly jib mounting bracket 26 NOTES You need these position pins C1 C2 you have just pulled out to connect the fly jib and the right section of the fly jib mounting bracket 26 8 Using the posit...

Page 369: ...extend retract operation with the position pins B2 C1 C2 inserted into both the holes on the right section of the fly jib mounting bracket 26 and the stowage bracket A 21 If you perform the above the...

Page 370: ...se 4 to prevent the fly jib from falling 16 Attach the wire 13 and the lever block 23 to the main boom and the fly jib base 4 CAUTION When attaching the wire 13 and the lever block 23 pay attention no...

Page 371: ...inserted Use plugs on the unconnected ends to protect connectors 19 Reconnect the hydraulic hoses on the right section of the main boom tip and on the right section of the fly jib base following the...

Page 372: ...ve the wedge socket 37 from the main boom 5 Remove the wire clip 40 6 Remove the rope wedge 41 by preparing a cylindrical rod A of 6 to 8 mm and lightly tapping the rope wedge with a hammer in the dir...

Page 373: ...t 9 25 Pull the wire rope 12 through the wire socket 37 removed in step 20 as shown in the figure on the right and put the rope wedge 41 in the position a and yank the wire rope 12 in the direction in...

Page 374: ...the fly jib body the lever block 23 or the wire 13 might be damaged when the main boom is extended with the lever block 23 mounted 29 The monitor display changes for the fly jib automatically when th...

Page 375: ...regularly Do not unwind after the hook block touches the ground since the wire ropes are wound irregularly inside the winch drum when the hook is lowered further to the ground 1 Make the main boom ful...

Page 376: ...wire rope 12 through the wedge socket 37 4 The rope wedge 41 should be in position a and yank at the wire rope 12 in the direction indicated by the arrow 5 Fix a wire clip 40 to the wire rope 12 acco...

Page 377: ...jib side 2 Disconnect the connector A E4 from the connector E2 on the main boom side and connect the connector B E5 to the connector E3 on the fly jib side 3 Disconnect the connector B E5 from the du...

Page 378: ...pler after cleaning it The coupler cap should be attached to prevent foreign objects to be mixed in 8 Attach the lever block 23 and the wire 13 to the main boom and the fly jib base 4 to adjust the po...

Page 379: ...section with the hole on the fly jib stowage bracket A 21 insert the position pin B2 into the hole and insert the linchpin Remember to turn the ring back to lock it securely Do not remove the position...

Page 380: ...C2 remove the lever block 23 NOTES Stow the position pins C1 C2 you have just pulled out later 15 Slide the fly jib horizontally while holding the handle H4 of the fly jib base 4 to separate it from...

Page 381: ...lock it securely CAUTION The monitor display changes as the figure below when the fly jib is stowed Remove the fly jib mounting bracket as necessary 20 Hang a sling on the upper part of the fly jib m...

Page 382: ...372 23 Secure the fly jib mounting bracket 6 you have removed in step 21 with the eye bolt 34 and the washer 35 to the stowage bracket 33 at the front of vehicle and stow it...

Page 383: ...standard specification is described See Operation 1 5 Moment limiter overload detector for the devices that are not described in this section 5 1 NAME OF MONITOR DISPLAY 5 1 1 MONITOR DISPLAY IN FLY...

Page 384: ...1 is shown When the fly jib is extended 2 is shown 3 Fly jib length display Continually shows the current fly jib length during crane operations 4 Fly jib angle display Continually shows the current...

Page 385: ...NOTES If you are switched to the fly jib operation you cannot perform the extend retract operation and the derrick operation at the same time Either of the preceding operation is executed 13 Rated to...

Page 386: ...rane mode NOTES When the fly jib is stowed the monitor display changes as follows The number of fly jib boom sections is shown as R The fly jib length is not shown The fly jib angle is not shown The p...

Page 387: ...not be lower than the level to the ground The fly jib and crane operation are disabled when the main boom angle is in the range shown in the table below Also the angle cannot be in the range in the ta...

Page 388: ...Push the lever forward Neutral Release your hand from the lever The lever returns to the NEUTRAL position and the fly jib derricking stops Raise Pull the lever to the rear side 6 2 FLY JIB RETRACT EX...

Page 389: ...or input error Check fly jib length sensor Check harness of fly jib length sensor related circuit ES17 Load cell input error Check load cell Check load cell amplifier Check harness of load cell relate...

Page 390: ...unction of stowage limit switch Defective wiring Check limit switch and replace Check for disconnected wire and repair Fly jib length and fly jib angle is shown Boom fly jib operation selector switch...

Page 391: ...ib tip for any significant damage or deformation Repair if any abnormality is found Check code reel on the left side of fly jib for any significant damage or deformation Also check for any damage on t...

Page 392: ...lay is correct Posture of fly jib and display item Monitor display Number of fly jib boom sections display when fly jib is stowed R Number of fly jib boom sections display when fly jib is fully retrac...

Page 393: ...000 hours whichever falls first 2 Fly jib hose switch valve 2 8 3 CONSUMABLES Replace consumables such as wire rope upon periodic maintenance or prior to the wear limit Proper replacement of consumabl...

Page 394: ...tion and maintenance time Use proper grease specified below according to the greasing points No Greasing point Grease type 1 Greasing hook block 2 places Lithium grease 2 3 Greasing fly jib foot pin 1...

Page 395: ...for the fly jib specification different from standard specification are described For other specifications see Specification section Equipment Item MC815C FLY JIB Weight and dimensions Body mass 9950...

Page 396: ...mass of hanging tools mass of one hanger hook 20 kg Main boom Angle One jib section Two jib sections 0 degree 20 degrees 40 degrees 60 degrees 0 degree 20 degrees 40 degrees 60 degrees 80 degrees 1520...

Page 397: ...387 9 4 WORKING RADIUS LIFTING HEIGHT...

Page 398: ...388 This Page Intentionally Left Blank...

Page 399: ...OK 390 2 SEARCHER HOOK SAFETY LABEL LOCATIONS 391 3 NAMES OF SEARCHER HOOK PARTS 394 4 MOUNTING AND STOWING SEARCHER HOOK 395 5 HANDLING MONITOR AND MOMENT LIMITER 405 6 OPERATION 409 7 TROUBLESHOOTIN...

Page 400: ...emember to check each part of a searcher hook and make sure there are no deformation or cracks on the welded section When changing the angle of the searcher hook never put your fingers into the pin ho...

Page 401: ...ion are described See Safety Safety Label Locations for the safety labels that are not described in this section Please keep these safety labels clean so you can read them correctly If any safety labe...

Page 402: ...392 1 Searcher hook working range diagram 106 2189200...

Page 403: ...393 6 Maximum rated total load 106 4716100 2 locations 7 Notice on pin holes CL000100001 2 locations...

Page 404: ...NAMES OF SEARCHER HOOK PARTS 1 Searcher hook boom 2 Swivel hook 3 Shackle 4 Searcher hook bracket 5 Point pin 6 Collar 7 Plate 8 Nut 9 Pin A 10 Pin B 11 Stowage bracket A 12 Stowage bracket B 13 Head...

Page 405: ...in boom with two position pins Insert two position pins in the correct positions and tighten them securely with a linchpin If the position pin comes off the searcher hook may fall causing a serious ac...

Page 406: ...the point pin 5 to secure it NOTES The searcher hook bracket 4 should be hung from the head pin 13 by its design slide in from the front to attach it 4 Attach the collar 6 the plate 7 and the nut 8 to...

Page 407: ...ket 4 on the main boom tip 9 Insert the pin A 9 to the aligned hole from the left side and attach the retaining pin 10 In the same manner insert the pin B 10 from the left side and attach the retainin...

Page 408: ...is barely touching the ground 3 Lower the hook to the ground by lowering the boom 4 Remove the bolt 39 and pull out the wedge socket pin 38 to remove the wedge socket 37 from the main boom 5 Remove t...

Page 409: ...eed these pins you have just pulled out pin A 9 and pin B 10 to attach the searcher hook boom 1 to the stowage bracket 2 Align the searcher hook boom 1 with the stowage position of the stowage bracket...

Page 410: ...acket 4 will fall when the point pin 5 is pulled out be sure to support the bracket and pull the pin out slowly NOTES The searcher hook bracket 4 should be hung from the head pin 13 by its design remo...

Page 411: ...rizontally to remove it from the stowage bracket A 11 The searcher hook boom 1 will fall when the pin B 10 is pulled out be sure to support the boom and pull the pin out slowly When searcher hook boom...

Page 412: ...nd pull out the point pin 5 to remove the searcher hook bracket 4 The searcher hook bracket 4 will fall when the point pin 5 is pulled out be sure to support the bracket and pull the pin out slowly NO...

Page 413: ...the stowage bracket A 11 2 Align the searcher hook boom 1 with the stowage bracket B 12 and insert the pin B 10 to attach the retaining pin 3 Stow the pin A 9 and attach the retaining pin NOTES The pi...

Page 414: ...OTES The searcher hook bracket 4 should be hung from the head pin 13 by its design slide in from the front to attach it 3 Attach the collar 6 the plate 7 and the nut 8 to the tip side of the point pin...

Page 415: ...ferent from the standard specification is described See Operation 1 5 Moment limiter overload detector for the devices that are not described in this section 5 1 NAME OF MONITOR DISPLAY 5 1 1 MONITOR...

Page 416: ...except for winding up the hook When the winch settings are turned OFF in searcher hook mode the winch will not move during full automatic stowage In addition hook stowage cannot be selected NOTES The...

Page 417: ...r hook You can change it by touching the monitor screen to show the searcher hook NOTES When you select the number of wire falls it goes back to the standard crane mode from the searcher hook mode 2 W...

Page 418: ...own in the monitor is changed to the value for a searcher hook The main boom angle cannot be 60 or more when Offset Position is 14 When overloaded the raising operation is prohibited in addition to th...

Page 419: ...erious bodily accident When changing the angle the searcher hook boom might fall suddenly after pin is pulled out so be sure to support the boom before changing pins After changing the angle of the se...

Page 420: ...ook mode Incorrect setting change Change setting 2 When searcher hook is mounted to vehicle and stowed Abnormal Phenomenon Major cause s Remedy Indication on monitor changes to searcher hook mode OFFS...

Page 421: ...and bracket Also check for loose missing or damaged check pins Repair or replace if any abnormality is found 2 Inspection of swivel hook Check that there is no deformation of the swivel hook 2 or noi...

Page 422: ...ok specification different from the standard specification is described For other specifications see Specification section Equipment Item MC815C SEARCHER HOOK Weight and dimensions Body mass 9520 kg O...

Page 423: ...rigger extension the number of main boom sections and the working radius Check the available range in the rated total load chart before operating Hoisting operation is not possible when the boom angle...

Page 424: ...414 9 4 WORKING RADIUS LIFTING HEIGHT...

Page 425: ...cument Number 106E OM1805 01 First edition March 31 2017 Second edition May 31 2018 Issued by MAEDA SEISAKUSHO CO LTD 1095 Onbegawa Shinonoi Nagano City Nagano Prefecture 388 8522 Japan Any reproducti...

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