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OPERATORS MANUAL

MAEDA MINI CRANE

MC815

www.hird.co.uk

DISCLAIMER - ALL INSTRUCTIONS ARE SUPPLIED FROM MANUFACTURER AND WHERE CORRECT AT TIME OF PRINT

OM 1704-2

Northern

(Head Office)

Tel: +44 (0)1482 227333

Western

Tel: +44 (0)1384 900388

Southern

Tel: +44 (0)203 174 0658

Central

Tel: +44 (0)1302 341659

Содержание HIRD MC815

Страница 1: ...hird co uk DISCLAIMER ALL INSTRUCTIONS ARE SUPPLIED FROM MANUFACTURER AND WHERE CORRECT AT TIME OF PRINT OM 1704 2 Northern Head Office Tel 44 0 1482 227333 Western Tel 44 0 1384 900388 Southern Tel 44 0 203 174 0658 Central Tel 44 0 1302 341659 ...

Страница 2: ... 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 PRECAUTIONS ON HANDLING REMOTE CONTROL SYSTEM 27 3 PRECAUTIONS FOR USE OF ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 31 4 OPERATION RELATED PRECAUTIONS 32 4 1 BEFORE STARTING ENGINE 32 4 2 AFTER STARTING ENGIN...

Страница 3: ...VER 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 CONFIGURATION OF MOMENT LIMITER 115 1 5 2 FUNCTIONS OF MOMENT LIMITER 116 1 5 3 MOMENT LIMITER OPERATION 117 1 5 4 MOMENT LIMITER SETTINGS 119 1 5 5 MOMENT LIMITER FUNCTIONS 122 1 5 6 MOMENT LIMITER START CONDI...

Страница 4: ...53 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 UNWINDING 163 2 19 BOOM DERRICKING OPERATION 163 2 20 BOOM TELESCOPING OPERATION 164 2 21 SLEWING OPERATION 165 2 22 ACCELERATOR OPERATION 165 2 23 CRANE STOWAGE OPERATION 166 2 24 OUTRIGGER STOWAGE O...

Страница 5: ...SPENDED 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 3 12 EMERGENCYSTOP SWITCH OPERATION 205 3 13 LED LIGHT OPERATIONS 205 3 14 CHECKING AFTER CRANE OPERATION 206 3 14 1 CRANE STOWAGE OPERATION 206 3 14 2 STOPPING OPERATION BY RADIO CONTROL AND INSPEC...

Страница 6: ...ING 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 OF BATTERY 229 10 3 CHARGING METHOD OF BATTERY 230 11 TROUBLESHOOTING 232 11 1 ELECTRICAL COMPONENTS 232 11 2 MACHINE BODY 233 11 3 ENGINE 234 11 4 ELECTRIC MOTOR 235 11 5 BEFORE REMOTE CONTROLLER FA...

Страница 7: ... 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 5 INITIAL 250 HOURS MAINTENANCE 300 9 6 EVERY 50 HOURS MAINTENANCE 301 9 7 EVERY 100 HOURS MAINTENANCE 305 9 8 EVERY 250 HOURS MAINTENANCE 306 9 9 EVERY 500 HOURS MAINTENANCE 310 9 10 EVERY 1000 HOUR...

Страница 8: ...376 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 1 LIST OF ERROR CODE 379 7 2 WHEN THESE PHENOMENA HAPPEN 380 8 INSPECTION AND MAINTENANCE 381 8 1 PRE OPERATION INSPECTION 381 8 2 PERIODIC REPLACEMENT OF CRITICAL PARTS 383 8 3 CONSUMABLES 383 8 4 ...

Страница 9: ...R 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 HOOK MODE 405 5 1 2 CHANGING SEARCHER HOOK MODE 407 5 2 MOMENT LIMITER FUNCTIONS 408 5 3 RECOVERY OPERATION FROM AUTOMATIC STOP 408 6 OPERATION 409 6 1 CHANGING SEARCHER HOOK ANGLE 409 7 TROUBLESHOOTIN...

Страница 10: ...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 ...

Страница 11: ... 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 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 always accompany this machine upon transfe...

Страница 12: ...llowing 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 helpful information The operations inspections maintenance and safety precautions for this machine that are outlined in this manual are relevant to specified tasks It is impossible to anticipate all...

Страница 13: ...ving 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 front rear right and left of the machine are determined as viewed from the driver s seat in the traveling direction forward of the machine 2 Crane The boom slewing directions clockwise right and counter...

Страница 14: ... 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 when the crane and outriggers are stowed traveling posture which facilitates running in confined areas Use of the two operation levers enables not only travel direction changes forward backward rightwa...

Страница 15: ... 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 stipulated by laws and regulations applicable to the place of use are qualified to operate this machine Contact the relevant government office or our sales service agency for further information ...

Страница 16: ...he 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 between the boom primary pin and the sheave pin at the tip of the boom 5 DERRICKING ANGLE An angle which the boom forms with the horizon 6 LIFTING HEIGHT ABOVE GROUND A vertical distance between the...

Страница 17: ...nt 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 relationships between the working radius boom angle and lifting height at no load allowing for no deflection in the boom A deflection occurs in the boom when an object is hoisted which causes the working radi...

Страница 18: ...nded 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 accordance with the performance given in Booms 1 2 3 4 5 column If working radius exceeds the value of Working Radius column in the chart by any extent work should be performed within the rated total load ...

Страница 19: ...sent 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 should be performed in accordance with the performance of this column 3 Booms 1 2 3 Both of booms 4 and 5 are retracted with booms 2 and 3 fully extended If boom 3 is extended to some extent even on...

Страница 20: ...d 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 fully If more than half of the mark of boom 4 is exposed from boom 3 work should be performed in accordance with the performance of this column ...

Страница 21: ...h 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 machine to an unstable position Even if the total combined weight is within the rated total load reduce the working radius and traveling speed as much as possible and use sufficient care Outriggers extende...

Страница 22: ...ld 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 position Even if the total combined weight is within the rated total load reduce the working radius and traveling speed as much as possible and use sufficient care Outriggers extended to medium in Ra...

Страница 23: ...ension 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 expose the machine to an unstable position Even if the total combined weight is within the rated total load reduce the working radius and traveling speed as much as possible and use sufficient care Out...

Страница 24: ... 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 boom and is composed of a indicator and pointer scale as shown on the right The angle indicator should be used as follows Read the angle shown by the indicator This value is the boom angle at the tim...

Страница 25: ... 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 Machine so that remote operation of the Crane can be carried out 1 Left operation lever 2 Right operation lever 3 Remote controller power ON OFF switch 4 Engine Start Stop Switch 5 Operation mode select...

Страница 26: ... 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 the power of the remote control system is turned on manual operation cannot be performed ID data necessary for the operation of the transmitter is built in this remote control system If communicatio...

Страница 27: ...is 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 PM builds up on the filter inside the DPF the filter becomes clogged reducing the engine performance For that reason the regeneration process is necessary to burn remove the PM by raising the exhaust...

Страница 28: ... 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 stationary regeneration For the procedures for stationary regeneration refer to OPERATION 2 27 DPF STATIONARY REGENERATION METHOD section ...

Страница 29: ...20 This Page Intentionally Left Blank ...

Страница 30: ...PECIFICATIONS 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 defined in this manual should always be read and observed Failure to follow the safety precautions can cause serious personal injury or death ...

Страница 31: ...uitable 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 Machine COMMIT TO SAFE OPERATION Follow the instructions and signs given by the manager and work supervisor and observe safety first during work Follow the crane work basics during work Always make sure ...

Страница 32: ...operating 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 instructions and signs of the work supervisor and operate with caution When operating the crane the clearance between the boom and the carrier and also the gaps between the movable parts of the derrick cyli...

Страница 33: ...easures 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 designated position so that anyone can make the contact DO NOT RUSH AND BE CAREFUL WHEN OPERATING Do not attempt sudden lever operation or harsh driving When 2 or more cranes are within close proximity to eac...

Страница 34: ...oil 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 manual when replenishing fuel Cleanly wipe away fuel or oil that is spilled during replenishment HANDLING AT HIGH TEMPERATURE After stopping machine operations the engine and engine oil cooling water and...

Страница 35: ...site 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 your body to be caught Between the boom and the carrier Between the outrigger support and the ground contact surface Between the boom post and the derrick cylinder Between winch drum and wire rope Be...

Страница 36: ...od 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 clean the Transmitter and keep it unsoiled Oil or mud on surface may cause miss operation with slipping hands which may result in a serious hazard Never attempt to high pressure wash or wash with water...

Страница 37: ...s 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 of the Transmitter in a condition where the ambient temperature makes a sudden change or becomes extremely low 20 C or below or cold air is blowing directly to it Sudden change in temperature may caus...

Страница 38: ...ause 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 Doing so may cause electrolyte leakage and rupture of the battery Do not disassemble or modify the battery Doing so may cause electrolyte leakage heat generation and rupture of the battery Do not sol...

Страница 39: ... 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 REPAIR When performing welding repairs to the main body of the Machine weld in a location with good facility and only authorized personnel are permitted to weld Disconnect the battery terminals to prevent...

Страница 40: ...ker 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 inspection and maintenance of the electric system An electric shock may occur during work if disregarded In addition notify all personnel at the workplace that inspection and maintenance are being perfor...

Страница 41: ...ATER 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 the fuel oil leak accumulation of combustibles around the engine and battery systems and similar potential problems See OPERATION 2 1 PRE OPERATION INSPECTION Inspect the quantity of fuel cooling wat...

Страница 42: ... 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 and if there is any foreign matter such as a metal or paper in the case of the remote control system transmitter INSPECTION AFTER TURNING ON THE TRANSMITTER REMOTE CONTROL SYSTEM Check that the disp...

Страница 43: ...the 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 no one or no object is in the vicinity before starting to move Honk the horn for warning before starting to move Be sure to sit in the driver s seat during traveling operation of this Machine The Ma...

Страница 44: ...tacting 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 water depth no higher than center of idler 1 See OPERATION 2 12 2 ALLOWABLE WATER DEPTH Check the withstand ability against the Machine mass before crossing over a bridge or construction that is a priv...

Страница 45: ... 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 cold weather conditions check that the load before being hoisted is not frozen to the ground or other substance Attempt to hoist without knowing the load is frozen and stuck to the ground or other subst...

Страница 46: ... 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 battery fluid is frozen do not charge the battery or start the engine using other power source Such act may cause the battery to catch fire Defreeze the battery fluid and check for battery fluid leak be...

Страница 47: ...AND 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 with the mode selector switch 8 and switch to the crane mode with the Crane button on the monitor Operate the control lever and check that the crane operates properly When performing crane operations ...

Страница 48: ... 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 warning is issued even when the rated total load is approached Be sure to set the outriggers horizontally while checking the level When using the crane check that the boom angle and length and actua...

Страница 49: ... 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 Occasionally check the level gauge and make sure to keep the Machine level during the crane operation as well Always place the outriggers at its maximum extension If due to unavoidable reasons you need...

Страница 50: ...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 ...

Страница 51: ...re 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 and let him her watch so that the boom wire rope or Machine frame does not go near the electrical cable too much Before doing so decide the emergency signs and other necessities Ask the electricity ...

Страница 52: ...ine 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 location and after making sure the machine is not electrically charged take the affected personnel to the hospital 4 Measure after accident After the accident do not reuse as is Such attempt may cause unex...

Страница 53: ...ul 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 mentioned in the weathercast is mean wind velocity m s during 10 minutes at 10 m above the ground Force Wind Speed m s Effect On Land 0 Less than 0 3 Smoke rises vertically 1 0 3 below 1 6 Wind motion vis...

Страница 54: ...n 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 even if the total combined weight is within the rated total load Hoisting of lengthy load causes the load to lose balance and is dangerous In the case of such load hoist vertically by using a cramp or a...

Страница 55: ...s 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 When the view is bad because of bad weather rain fog snow etc stop the operation and wait until the weather recovers Do not use for purpose for instance raising a person using a crane other than the tr...

Страница 56: ...t 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 overwind the hook block Be careful to prevent 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 t...

Страница 57: ...he 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 prevent the boom from hitting the operator or the Machine Perform operation lever operation slowly Make sure to start smoothly slew at low speed and stop quietly Especially avoid sudden lever operatio...

Страница 58: ...ations 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 When lowering a wire rope in work underground leave at least 3 loops of wire rope on the winch drum This machine is equipped with an excessive unwind detector as a safety device Take care not to invi...

Страница 59: ...e 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 be ON unless the Crane is in operation Be sure to keep the power turned OFF Otherwise unexpected touching or contact of operation levers or buttons of the Transmitter with any other object may cause...

Страница 60: ...ravels 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 other substances from the footing to prevent the Machine from skidding over the ramps Remove the substances stuck on the ramps such as grease oil or ice and keep clean Be especially careful on the rainy ...

Страница 61: ...e 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 rotary parts The center of gravity of the machine is determined in the condition where the machine is in the traveling posture See OPERATION 2 5 MACHINE TRAVELLING POSTURE for details When transporting th...

Страница 62: ...urce 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 before charging the battery CAUTIONS WHEN STARTING UP USING BOOSTER CABLE Wrong booster cable connection method may result in fire so always observe the following Start the engine by two persons with one...

Страница 63: ...rse 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 Securely fix the charge clip of the charger to the terminal of the battery then securely fix the charge clip to terminal of the battery Set the charge current to no more than 1 10 of the rated capacity o...

Страница 64: ...which 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 system is dangerous and will cause faulty or improper operations TIDY UP WORKPLACE Always tidy away tools hammers and other things that obstruct the working area grease and oil should be wiped off im...

Страница 65: ...lieve 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 contacting the moving parts FIRE RISK PREVENTION Always observe the following during maintenance where the fuel oil battery or other substance that may catch fire is handled Keep the fuel oil and an...

Страница 66: ...earing 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 accidents do not attempt maintenance when the engine is running Always observe the following in case of maintaining with the engine running for unavoidable reason One person should sit at the driver s...

Страница 67: ...EN 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 engine when refilling Do not smoke when refilling Immediately wipe away spilt fuel or oil Securely tighten the fuel and oil caps Supply fuel oil at a location with good ventilation Do not leave the si...

Страница 68: ...monitor 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 electrical part to malfunction DISCONNECT BATTERY TERMINAL Disconnect terminal of the battery and stop the electrical flow before repairing the electrical system or starting an electrical weld See OPERAT...

Страница 69: ... 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 may puncture the skin or destroy eyesight upon contact If this happens wash away with flowing water and see the doctor as soon as possible CAUTIONS WHEN TEMPERATURE IS HIGH Parts such as the engine o...

Страница 70: ...e 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 maintained parts operate normally Check that issues such as an oil leak do not occur when load is applied to the oil pressure by increasing the engine rotation CAUTIONS WHEN TREATING WASTE To prevent en...

Страница 71: ...CATIONS 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 treated in the same way ...

Страница 72: ...63 3 Total load chart 106 2186300 ...

Страница 73: ...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 ...

Страница 74: ...65 9 Precautions when using 106 2186600 ...

Страница 75: ...66 ...

Страница 76: ...ing 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 CL000100000 4 places ...

Страница 77: ...er 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 prohibited CL000050000 ...

Страница 78: ...s 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 caution CL000090000 2 places 41 Cautions on override switch 585 4739200 ...

Страница 79: ...4 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 specifications 106 4718500 ...

Страница 80: ...places 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 Lifting height Pick Carry 106 4722000 64 Cautions when loading machine 106 4734900 ...

Страница 81: ...72 This Page Intentionally Left Blank ...

Страница 82: ... 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 BATTERY 224 10 HANDLING REMOTE CONTROLLER BATTERY 229 11 TROUBLESHOOTING 232 ...

Страница 83: ...lt 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 oil tank inside operation side cover 26 Fuel tank 27 Power supply box for machines with engine electric motor 28 Battery box 29 Over hoist detector 30 Idler 31 Track roller 32 Travelling motor and spro...

Страница 84: ...eration 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 Fuse box 13 Cigar socket 14 Maintenance USB port ...

Страница 85: ...Engine 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 regeneration request lamp 17 Exhaust temperature alarm lamp 18 DPF regeneration lamp 19 Failure 20 Emergency stop lamp 21 Light 22 Electricity on lamp 23 Mode selector switch travel outrigger crane 24 L...

Страница 86: ...or 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 with a bar indication 4 Fuel gauge Indicates the remaining amount of fuel contained in the tank when the starter switch is set to the ON position If the fuel level becomes low during operation immedi...

Страница 87: ...N 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 before implementing regeneration 7 Setting switch Use this switch to change the current screen to the User Initial Mode screen For details of the screen refer to OPERATION 1 2 1 5 MONITOR DISPLAY USER I...

Страница 88: ...s 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 engine oil pressure If the oil pressure is normal the monitor lights up when the starter switch is set to the ON position and goes out as engine speed increases after engine start If the monitor ligh...

Страница 89: ...n 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 with no load or operations with low load is repeated In this case the DPF regeneration request lamp on the monitor is lit If the DPF regeneration request lamp is lit carry out manual stationary regene...

Страница 90: ... 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 changed by either touching the displayed pop up selection switch upper side or lower side or by touching the Travel Outrigger Crane displayed on the screen 24 Levelling instrument Displays the incline co...

Страница 91: ...GLE 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 SIDE VIEW CAMERA MONITOR 12 Error codes 13 Pick Carry position ...

Страница 92: ...ngle 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 distance from the center of slewing of the crane to the center of the hook 4 SLEW ANGLE Shows the current slewing angle when operating the crane 5 RATED TOTAL LOAD Indicates the currently applicable ...

Страница 93: ...pacity 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 between Travelling Hi and Travelling Low with the pop up select switch up down or touchscreen operations 9 MODE SELECTOR SWITCH 3 Pick Carry Use this switch when travelling with suspended load Push ...

Страница 94: ...e 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 Pick Carry position Illuminates in yellow when the machine is in Pick Carry posture For conditions of Pick Carry posture read the section OPERATION 2 26 PICK CARRY OPERATION NOTES This may not illumi...

Страница 95: ...r 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 2 GROUND SET UP 19 Outrigger 3 GROUND SET UP 20 Outrigger 4 GROUND SET UP 21 Crane stow position 22 Pick Carry position 23 Mode selector switch 2 Extension Ground 24 Mode selector switch 3 Manual Aut...

Страница 96: ...ly 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 lamps light up individually to indicate that the corresponding outrigger is in the medium extended state second stage 13 Outrigger 1 maximum MAX 14 Outrigger 2 maximum MAX 15 Outrigger 3 maximum MAX...

Страница 97: ...can 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 operation mode for setting the outriggers on the ground between Manual with the outrigger operation panel and Auto Push to display a pop up screen When the pop up screen appears you can change the o...

Страница 98: ... 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 total load indication RATED TOTAL LOAD 16 Hook grounding indication GROUND CONTACT 17 Working radius indication WORKING RADIUS 18 Boom angle indication BOOM ANGLE 19 Slew angle indication 20 Mode selecto...

Страница 99: ...ing 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 the boom is limited due to workplace factors or other reasons these switches can be used to specify the working radius of the boom to a desired range To set the working radius of the boom move it to ...

Страница 100: ...utrigger 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 medium or maximum work within the range with boom position between those outriggers applies to rated total load of mid or max extension NOTES For safety the load is switched to the safe side of the ...

Страница 101: ...ated 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 up when the hook touches the ground 17 Working radius indication WORKING RADIUS Continually displays the current working radius during crane operations NOTES The working radius refers to the horizont...

Страница 102: ...een 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 Crane Hi Low Use this switch to change the winding speed of the crane Push to display a pop up screen When the pop up screen appears you can change the winding speed of the crane between Crane Hi and...

Страница 103: ... 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 25 Error code When a fault occurs in the machine the panel lets you know by displaying an error code on the display area If an error code is displayed please contact our company or our company s sale...

Страница 104: ...r 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 setting in SH mode ON OFF Only for machine with searcher hook ...

Страница 105: ...lected 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 Error history By touching the screen the screen transitions to the error history display screen where you can see the currently occurring errors errors that have occurred in the past For display detail...

Страница 106: ...eplace 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 hours Replace engine oil 500 hours Replace engine oil filter 500 hours Replace fuel pre filter 500 hours Replace hydraulic oil tank air filter element 500 hours Replace fuel main filter 500 hours Air cl...

Страница 107: ...igger 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 10 11 12 13 14 Crane mode 1 Accelerator up down pop up up down 2 Horn 3 Pop up Enter 4 Mode selector switch Crane Hi Low 5 Mode selector switch Hook Fully automated stowage 6 Mode selector switch Tra...

Страница 108: ...selected 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 appears you can switch the travelling speed of the machine between Travelling Hi and Travelling Low with the up down select switch 1 Accelerator up down pop up up down 5 Mode selector switch Pick Car...

Страница 109: ...ard 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 directions opposite each other allows it to spin 11 Left travelling forward The crawler belt at the left side of the machine rotates in the forward direction To move the machine forward push the right ...

Страница 110: ...ou 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 described here 4 Mode selector switch Crane Hi Low Use this switch to change the winding speed of the crane Push to display a pop up screen When the pop up screen appears you can change the mode betw...

Страница 111: ...e 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 13 Boom clockwise slewing Slews the boom in the clockwise direction while the lever is pushed toward the right side 14 Boom counter clockwise slewing Slews the boom in the counter clockwise direction ...

Страница 112: ...selector 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 to the NEUTRAL position and the outrigger extending cylinder stops OUT Push the switch down The outrigger extending cylinder extends to allow the outrigger to extend In Ground mode IN Push the switc...

Страница 113: ...l 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 the warm up indicator lamp goes out in a cold environment without changing the switch position START Enables the engine or the electric motor to start When the engine or the electric motor has started...

Страница 114: ...NECT 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 maintenance Use this switch to turn off the battery power supply to prevent unexpected startup of electrical equipment during inspection and maintenance OFF The battery power supply is turned off and no elect...

Страница 115: ...the 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 operation may cause boom breakage and machine tipping Use the hook storage switch when stowing the hook If this switch is turned ON to perform hook hoisting operation automatic stop is not made in an over ...

Страница 116: ...r 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 hatch 2 Pull out the fuses in the fuse box and inspect them Replace if necessary Put back new or inspected fuses into their original places Fuse Capacities and Circuit Names Systems and capacities of...

Страница 117: ... 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 NOTES The maintenance USB port does not have battery charge function ...

Страница 118: ...r 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 light control panel M1 Left display M2 Right display N1 Display operation switch R1 Control box R2 Monitor LED R3 Connector connection port R4 Antenna For detailed operating procedures refer to OPERA...

Страница 119: ...n 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 cannot be changed when a fly jib is not mounted at the front end of the boom 8 Accelerator control switch Use this switch to control the engine speed 9 Horn switch The horn keeps blowing while this ...

Страница 120: ... 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 fire or a malfunction in the controller may result R2 Monitor LED The control box is equipped with monitor LEDs that show the operation status of the remote control system ...

Страница 121: ...d 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 the control box due to high voltage applied to it R4 Antenna Antenna that allows communication with the transmitter of the remote controller ...

Страница 122: ...t 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 controller Use the charging port appropriate for the specifications of respective devices ...

Страница 123: ...he 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 the crane interlock function is activated and the crane operation will be disabled To enable the setting operation and stowage operation of the outriggers stow the crane and set the mode selector sw...

Страница 124: ...p 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 indicator Both side faces at the rear end of the boom 7 Pressure sensor derricking cylinder section 2 pieces 8 Over winding alarm detector at the side surface of the boom front end 9 Outrigger position d...

Страница 125: ... 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 safety device for preventing accidents arising from overload such as dropping of a suspended load damage to the boom or an overturning accident of the machine Before starting crane operations be sur...

Страница 126: ...pped 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 lowering Boom raising Boom extension Hook winding Crane slewing 2 RECOVERY OPERATION FROM AUTOMATIC STOP 1 For a load capacity ratio Less than 90 The normal green revolving lights stays on as long as t...

Страница 127: ...his 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 NOTES Boom raising operation using boom lift by pass switch does not work by remote control To use this switch turn off the remote control and operate on the machine While using this switch machine co...

Страница 128: ...gle 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 setting turn the key switch to the OFF position and then turn it to the ON position again or lower the boom with the engine running so that the boom angle becomes smaller than the set value by at leas...

Страница 129: ...et 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 cannot be performed in a row even if the switch is touched and held for 2 seconds To perform these operations consecutively release your finger from the switch between each operation 4 WORKING RADIUS LI...

Страница 130: ...onds 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 To enable this setting turn the key switch to the OFF position and then turn it to the ON position again or move the boom with the engine running so that the lifting height becomes smaller than the se...

Страница 131: ...indicator 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 and held for 2 seconds To perform these operations consecutively release your finger from the switch between each operation 1 5 5 MOMENT LIMITER FUNCTIONS 1 OVERLOAD ALARM 1 Safety area the Actual Lo...

Страница 132: ...indicator 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 operation lever is operated Operation of the boom s danger side stops automatically 3 OVER HOIST DETECTOR CAUTION When winding the hook be careful of clearance between the hook and boom When the boom i...

Страница 133: ...onitor 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 remain memorized even after the starter switch is set to the OFF position 5 BOOM UPPER LIMIT DETECTION When the boom angle reaches approximately 77 degrees while the boom is raised up in a boom derri...

Страница 134: ...g 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 During the check The tricolor revolving light illuminates in red The horn sounds momentarily When the moment limiter function check is completed if the moment limiter and the sensors are found to be nor...

Страница 135: ...ion 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 perform hook hoisting operation automatic stop is not made in an over winding condition Use this switch only when the moment limiter fails or a load test of the crane is conducted ON Insert the key int...

Страница 136: ...f 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 time the winding of the hook block 1 and the extension of the boom 4 stop automatically When you hear the alarm buzzer sound immediately shift the right control lever to the UNWIND position or shift t...

Страница 137: ... 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 upward 2 After adjusting seat 2 position release your hand from the slide adjustment lever 3 The seat 2 will be fixed at that position 2 RECLINING ADJUSTMENT Use the reclining adjustment lever 4 to a...

Страница 138: ... 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 seatbelt 1 HOW TO WEAR SEATBELT Hold the grip 2 and pull out the seatbelt from the belt tensioner 1 Make sure that the seat belt is not twisted and securely insert the seat belt tongue 3 into the buckle 4 ...

Страница 139: ...or 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 INSTALLING RADIATOR COVER When you are finished with inspection maintenance inside the radiator cover install the radiator cover in the following procedure 1 Put back the radiator cover 1 into place 2 Secu...

Страница 140: ...RATION 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 the radiator grille 3 5 Remove the radiator grille 3 by pulling it backward 2 INSTALLING RADIATOR GRILLE When you are finished with inspection maintenance inside the radiator grille install the radia...

Страница 141: ...removed 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 10 bolts of the engine cover 1 2 Remove the engine cover 1 2 INSTALLING ENGINE COVER When you are finished with inspection maintenance inside the engine cover install the engine cover in the followi...

Страница 142: ... 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 front three on the top 2 for the joint fastening of the engine cover 2 for the joint fastening of the operation side cover and 4 2 each on the left and right sides of the machine 4 Pull the left side ma...

Страница 143: ...emove 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 side cover install the operation side cover with the following procedure 1 Put back the operation side cover 1 into position 2 Securely tighten the fixing bolts 2 10 bolts of the operation side cove...

Страница 144: ...OF 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 switch 6 Breaker switch block 7 Cover ...

Страница 145: ...r 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 fire or various parts to malfunction The breaker switch 1 automatically disconnects the power which is distributed from the inverter panel to the electric motor When an overcurrent or over voltage occ...

Страница 146: ...MAINTENANCE 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 INSPECTION AND MAINTENANCE 9 1 2 CHECKING BEFORE STARTING ENGINE 2 1 3 INSPECTION AFTER STARTING ENGINE Refer to INSPECTION AND MAINTENANCE 9 1 4 CHECKING AFTER STARTING ENGINE ...

Страница 147: ...Do 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 water separator pot is in the vertical position open before starting the engine Make sure that the remote control transmitter is in the OFF position 1 Insert the key into the starter switch and turn the...

Страница 148: ...rt 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 starter switch key is turned to the ON position the WARM UP MONITOR indicator lamp lights up to indicate that the engine is being warmed up When the engine has been warmed up the WARM UP MONITOR indicato...

Страница 149: ...potential 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 of the hydraulic oil to about 20 C Do not raise engine speed suddenly until the warm up operation is done When the engine has started check to see if the Battery charge monitor and Engine hydraulic mo...

Страница 150: ...air 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 control lever is shifted back to the NEUTRAL position and irregular winding does not occur in the winch drum Repair if any abnormality is found 9 Operate the left control lever 2 slowly back and for...

Страница 151: ... 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 it deteriorates the oil shortening the engine life 2 5 MACHINE TRAVELLING POSTURE In principle when you transport the machine on its own the machine must retain a travelling posture with its boom hook...

Страница 152: ...d 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 stop driving and check the safety for the travelling direction Assign a guide person if necessary depending on the worksite situation PREPARATION BEFORE STARTING 1 Slowly and surely shift the lock leve...

Страница 153: ... 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 turns at high speeds not only damages the crawler belt or hydraulic devices but also may result in a collision with other objects Stop the machine and then adjust the engine speed to low before perfor...

Страница 154: ...ockwise 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 MOVING BACKWARD While pushing the right control lever toward you move only the left control lever back to the NEUTRAL position RIGHT TURN WHILE MOVING FORWARD While pushing the left control lever forwa...

Страница 155: ...less 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 leaving the machine be sure to stop the engine remove the key from the starter switch and take it with you 1 Shift the left and right control levers into the NEUTRAL position at the same time The brake i...

Страница 156: ... 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 key 2 11 INSPECTION AFTER STOPPING ENGINE 1 Visibly check for oil leakage fuel leakage and water leakage and check around the crawlers crane and exterior of the machine If you find any leakage or abno...

Страница 157: ...ne 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 the front back or either side of the slope it may overturn Do not travel on a slope of more inclination When travelling on slopes always set the travelling speed selector switch to the OFF Traveling ...

Страница 158: ...ally 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 in a manner that the operator seat is always located on the higher part of the slope If the engine stops on a slope shift the control lever back into the NEUTRAL position and restart the engine ...

Страница 159: ...CK 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 position Boom is fully retracted Boom is in horizontal stow position Boom is in slewing stow position Crane stowage lamp lights up Tricolor revolving light red lights up Outrigger Interlock If the cr...

Страница 160: ...ed 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 outrigger grounding lamps goes out winding operation boom extension and boom lowering are suspended For winch over winding Alarm buzzer constantly sounds Over hoist detector activates Winch winding oper...

Страница 161: ...sion 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 lights up When the machine tilts at an angle of 3 degrees or more during outrigger stowage operation Alarm buzzer constantly sounds Machine tilt detection device activates 6 MACHINE TRAVELLING OPERATIO...

Страница 162: ...as 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 outriggers Check both the outrigger numbers indicated in the control panel of the switch and number labels attached to each outrigger If these are mistakenly operated it may cause a serious accident Whe...

Страница 163: ...e 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 on the soft ground to protect the ground If it is necessary to set the outriggers near the road shoulder make sure to take precautions to prevent the collapse of the road shoulder Before operating t...

Страница 164: ...er 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 only one OUTRIGGER 4 Repeat the same procedure for the other three outriggers 1 Shift the lock lever 1 into the lock L position 2 Turn the starter switch to the ON position ...

Страница 165: ...l 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 1 into the hole as far as it will go NOTES The positioning pin 1 is equipped with a wire to prevent it from being lost 8 Perform similar preparation work for the other 3 outriggers NOTES When you ar...

Страница 166: ...y 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 operated by checking the outrigger number shown on the operation nameplate attached to each outrigger switch on the outrigger operation panel 5 Set two outrigger switches individually or simultaneously to ...

Страница 167: ... 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 result in overturning of the machine 8 After all outrigger adapters have come into contact with the ground set two outrigger switches individually or simultaneously to the Extension position When a grou...

Страница 168: ... 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 monitor are lit in yellow NOTES All of the crane stowage lamp 1 the four outrigger extension lamps 2 and four outrigger grounding lamps 3 are lit in yellow CAUTION If any of the outrigger grounding lamps ...

Страница 169: ...tion 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 operation to a stop When the warning buzzer sounds immediately release your hand from the right control lever 2 and shift the lever into the NEUTRAL position to stop the boom extension operation und...

Страница 170: ...ilure 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 be damaged due to interference with peripheral devices Pay thorough attention around the hook block Perform the following operations before crane work 1 Shift the lock lever 1 into the free F position...

Страница 171: ...entioned 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 hook stowage wire remove the hook block from the stowage wire 2 Push the right control lever 1 to the left to raise the boom to a position where the hook block is not over wound and makes no contact wit...

Страница 172: ... 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 OPERATION Operate the right control lever as slowly as possible Especially avoid sudden lever operations when the load is hoisted which may cause the load to waggle and give a large impact to the Machine ...

Страница 173: ...he 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 CAUTION The hook block is wound or unwound while the boom is extended retracted Perform the winch operation at the same time to adjust the hook block height When the boom is extended for a long time th...

Страница 174: ...event 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 the left Neutral Release your hand from the lever The lever returns to the NEUTRAL position and the slewing stops Counter clockwise Push the lever to the right NOTES Control the crane slewing speed wi...

Страница 175: ...block 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 lit in yellow If the crane stowage lamp is not lit in yellow the outriggers cannot be stowed If the crane stowage lamp is not lit perform operations such as lowering the boom to its lowest position o...

Страница 176: ...hange 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 hook block simply to the boom head instead of stowing to the hook stowage wire 6 Make sure that the crane stowage lamp 1 on the monitor is lit in yellow NOTES If the crane stowage lamp 1 is not lit in ...

Страница 177: ...ke 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 is wound up until over winding is detected 2 The boom is fully retracted 3 The boom is raised to 30 degrees In case boom angle is below 30 degrees 4 The boom is slewed to a 2 degree slewing angle 5 ...

Страница 178: ...ches 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 operated at the same time two outriggers on one side may be abruptly activated causing the machine to overturn During outrigger switching operation always keep the engine at lower speed When the engine is ...

Страница 179: ...r 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 two outrigger switches at the same time only two on the front side outriggers 1 and 4 or two on the rear side outriggers 2 and 3 can be operated at the same time If two switches on either left or rig...

Страница 180: ...the 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 contact with the ground press and hold two outrigger switches individually or simultaneously to the Retract position When the grounding cylinder has been completely retracted and the top box is raised to t...

Страница 181: ...sitioning 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 The positioning pin 1 is equipped with a wire to prevent it from being lost 3 Repeat the above steps to stow the other three outriggers NOTES After the outriggers have been stowed make sure that each ...

Страница 182: ...g 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 DIAGONALLY Pulling the load sideways drawing it in or hoisting diagonally applies unreasonable force on the machine It not only damages the machine body but also is dangerous Never operate in this wa...

Страница 183: ...ng 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 rope over a tree or steel beam while working If it gets stuck on something do not forcibly wind the wire Untangle and then wind the wire 9 DON T OPERATE DURING PICK CARRY The load may swing or the mac...

Страница 184: ...roach 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 poor vision Slope soft ground such as swamps ground with many obstacles ground with distinct irregularity such as river beds Near deep gullies and road shoulders Under water shallow water snowy area f...

Страница 185: ...5 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 cannot be operated 5 When the Pick Carry position lamp lights in yellow pick carry can be operated If this is not lit check the machine condition NOTES Lighting condition of the Pick Carry position lamp ...

Страница 186: ...outrigger 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 to OPERATION 2 24 OUTRIGGER STOWAGE OPERATION in this manual and stow the outriggers NOTES Pick carry is possible even though the outriggers are not completely stowed However it is recommended to have...

Страница 187: ...ne 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 Carry mode now with the mode selector switch 3 Pick Carry on the monitor or with the left control lever Perform crane operation with this state For crane operation see OPERATION 2 18 WINDING AND UNWINDI...

Страница 188: ...ot 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 NOTES If hook block is raised too much overwind is detected and warning buzzer sounds and raising hook automatically stops 4 Slew the boom to 1 2 degree position using left control lever 2 by manipu...

Страница 189: ...rane 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 met the Pick Carry position lamp lights and outriggers can be operated 3 Change the mode to Outrigger with the mode selector switch 1 Travel Outrigger Crane on the monitor or with the left control le...

Страница 190: ...s 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 damage and fire If the DPF regeneration request lamp is lit on the monitor make sure to carry out manual stationary regeneration 1 Start the engine and put it in idling condition 2 Start regeneratio...

Страница 191: ...r 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 Transmitter from being accidentally dropped wear the waist belt 1 around your waist and attach the Transmitter to the waist belt 1 2 Be sure to perform inspections on the transmitter and the receiver in accord...

Страница 192: ...ontroller 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 ON OFF switch 3 will change the display indication and turn on the power CAUTION If the controller does not power on check the controller for the following Is the battery charged fully Is the emergenc...

Страница 193: ... 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 Detailed information about the error icons can be checked from the remote control menu in the configuration menu ...

Страница 194: ...de 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 monitor M1 always displays the engine speed Crane white RTL Displays the Rated Total Load AL Displays the Actual Load Outrigger F blue Outrigger R orange Travel red ...

Страница 195: ...ent 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 LED light front ON OFF 2 LED light operation panel ON OFF 3 Return to the Crane mode 4 To remote control menu ...

Страница 196: ...187 Remote control menu ...

Страница 197: ...low 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 controller set the lock lever 1 to free position F NOTES Crane operation is not possible unless the lock lever 1 is in free position F 3 5 2 SWITCHING OPERATION MODE Each press of the operation mode se...

Страница 198: ... 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 slowly at the same time and check the machine for the travelling speed Do not make a sudden start especially when you are going backward This could cause a serious accident If you cannot verify the ...

Страница 199: ...rward 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 right in the forward direction Pulling the left control lever 1 toward you causes the machine to turn right in the backward direction 2 SPIN TURNS LEFT SPIN TURN Pushing the right control lever 2 forwar...

Страница 200: ...r 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 level and solid location for parking the machine If it is necessary to park on a slope provide some blocks so that the machine will not move When parking the machine make sure to shift the lock lever in...

Страница 201: ...accident 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 serious accident such as overturning of the machine may result 1 Turn the starter switch on the machine to the ON position 2 Press the power ON OFF switch 3 for the remote control transmitter to sup...

Страница 202: ...4 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 and set the outriggers Repeat the above steps for the other two outriggers by operating the mode selector switch 5 Left lever outrigger 1 or 2 Right lever outrigger 4 or 3 ...

Страница 203: ...er 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 up from the ground release you hand from the switch Repeat the above steps to gradually raise the machine from the ground so that the crawler belts position about 50 mm from the ground 8 When the mach...

Страница 204: ...f 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 cover 7 of the outrigger adapters 6 part and check them for foreign materials being caught in the bend sections ...

Страница 205: ...the 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 1 and 4 Outrigger R operates outriggers 2 and 3 NOTES When operating by radio controller the 4 outriggers cannot be operated at the same time Nor can the front and rear outriggers 3 Make sure that th...

Страница 206: ...mpletely 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 top box is raised to the maximum height release your finger from the outrigger switch 7 Make sure that the four outrigger grounding lamps 3 on the outrigger indicator are blinking in red NOTES On the ...

Страница 207: ... 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 bring the outrigger inner boxes to the shortest position 10 Turn the starter switch to the OFF position The engine stops ...

Страница 208: ...the 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 operation to avoid abrupt movement Any abrupt acceleration or deceleration especially while a load is hoisted will make a large impact to the Crane and may result in a serious hazard such as Crane tipping or...

Страница 209: ...d 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 3 8 2 BOOM DERRICKING OPERATION Operate the right control lever as slowly as possible Especially avoid sudden lever operations when the load is hoisted which may cause the load to waggle and a give l...

Страница 210: ...ended 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 operation CAUTION The hook block is wound or unwound while the boom is extended retracted Perform the winch operation at the same time to adjust the hook block height When the boom is extended for a long ...

Страница 211: ...when 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 the machine Exercise caution to prevent the suspended load from hitting outriggers If someone is sitting in the operator s seat be careful so that the boom does not hit this person when slewing Operat...

Страница 212: ...rmality 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 stop of the engine investigate the cause for the abnormality and repair the fault location The emergency stop switch can also be used for turning OFF the power to the remote control transmitter or fo...

Страница 213: ...e 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 to control the maximum rpm of the engine The maximum rpm value appears on the left side monitor M1 when the crane menu is displayed Increases maximum rpm Decreases maximum rpm 3 11 OPERATING HORM SWI...

Страница 214: ...pping 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 Transmitter turns OFF and the engine stops To cancel the emergency stop turn the Emergency stop Remote controller power OFF switch 10 to the right The switch returns to the original position NOTES To enable m...

Страница 215: ...st 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 it is required to turn ON the Transmitter for the purpose of inspection or such ensure that the engine is not running 1 Press the Emergency stop switch Remote controller power OFF switch 10 on the t...

Страница 216: ...place 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 snagged on a protrusion and become damaged or broken To connect the cabtire cable to the breaker switch block in the power supply box torque the screw to the specified value A potential fire or electri...

Страница 217: ... 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 length of a cabtire cable varies with cable specifications Any cable length should conform to values listed below Be sure to connect the grounding cable 8 of the cabtire cable to the ground point As to th...

Страница 218: ...over 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 supply box breaker switch 1 to the ON position ...

Страница 219: ...ales 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 to avoid contact between the boom the operator and any personnel whilst slewing it If crane operational check detects an abnormal event make an emergency stop promptly and repair any relevant part A p...

Страница 220: ... 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 present in or around the power unit 1 Turn the starter switch key to the OFF position to stop the electric motor 2 To remove the cover see OPERATION 1 11 MACHINERY COVER 3 Check the mounting bolts securing ...

Страница 221: ...ACHINE 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 the machine If you find any leakage or abnormality fix the problem 4 Clean off the crawlers and outriggers removing mud 5 Keep the area around the inverter unit free of dead leaves and paper waste A po...

Страница 222: ...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 ...

Страница 223: ...for extending boom No 5 IWRC 6 Fi 29 0 0 ø9 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 in the wire rope 10 or more of strands except a filler wire in 1 twist 6 crests of a wire rope are broken NOTES When 9 strands or more for the winch or 13 strands or more for the telescoping boom has...

Страница 224: ...shift 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 the starter switch to the OFF position to stop the engine 4 Remove the fixing pin 1 securing the wedge socket and remove the wedge socket 2 5 Hold the end of the wire rope and forcibly twist it in t...

Страница 225: ...ion 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 close together on the winch drum with tensioned wraps 10 Repeat the above steps to minimize the twists in the wire rope If the above steps do not solve the problem replace the twisted wire rope with ...

Страница 226: ...to 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 driver is requested always to be positioned on the load carrying platform of a truck Be especially careful when loading or unloading the Machine because of the risks mentioned above Select a locatio...

Страница 227: ...e 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 The center of gravity of the machine is determined when the machine is in the travelling posture See OPERATION 2 5 MACHINE TRAVELLING POSTURE for details When hoisting the machine perform the followi...

Страница 228: ...chains 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 Even if it cannot be fixed directly to the truck deck be sure to take measures to prevent the boom from slewing NOTES If you fix the hook block to the truck deck fix the hook block vertically to the...

Страница 229: ...acement 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 substance Keep it away from your eyes and skin Should it come into the contact with eyes or skin wash the affected area with plenty of water and consult a physician immediately The battery capacity drops whe...

Страница 230: ... 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 ability remarkably drops at low temperature Cover the battery or remove the battery from the machine and keep it in a warm place to be installed next morning If the electrolyte level is low refill with...

Страница 231: ...h 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 electric motor they need to be operated at no load for about 5 minutes once in every 3 months 8 2 DURING STORAGE If you have to perform antirust operation indoors open the window and entrance for b...

Страница 232: ...and 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 the side first Remove the drain plug of the fuel tank hydraulic oil tank and engine oil pan to drain any water ingress Carefully perform these checks before starting operation and perform warm up op...

Страница 233: ...cts 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 installing the terminals Secure the battery when changing it to prevent it from being displaced If it is not secured the terminals will slacken causing sparks Be sure not to confuse between the terminal a...

Страница 234: ...ve 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 Remove the wing nuts 10 2 pieces and battery fixing brackets 11 and then remove the battery 12 2 INSTALLATION Install the battery in the reverse order of removal NOTES Connect the terminal 8 on the ...

Страница 235: ...e 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 of battery 2 Decrease in the battery fluid 3 Failures in battery When connecting battery cables do not reverse the polarity terminal and terminal Doing so can cause damage to the alternator Remove the...

Страница 236: ...other 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 of the same capacity Check that the cable and clips have no breakage or corrosion Connect the clips securely Verify that the operation levers of both the slave machine and machine in failure are in t...

Страница 237: ...gine 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 started disconnect the booster cable in the reverse order of connecting the booster cable 1 Disconnect the clip of the booster cable B connected to the engine block of the machine in failure 2 Disconnec...

Страница 238: ...LACEMENT 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 10 will turn OFF the power 2 Lift the battery upward while pushing it The battery comes off 3 Insert a charged battery into the Transmitter while pushing it 4 Make sure that the power turns ON when ...

Страница 239: ...he 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 be stored for a long period of time Keep the battery at room temperature Use the supplied protective cap to store the battery Never short out the battery When the battery is correctly used it can be c...

Страница 240: ...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 ...

Страница 241: ...tive 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 wiring Insufficient battery charge Inspection and repair Charge the battery Starter pinion going out and in repeatedly struggling Insufficient battery charge Charge the battery Starter key turning s...

Страница 242: ...t 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 temperature too high Insufficient hydraulic oil Dust build up on cooling fins Refill with hydraulic oil to the specified oil level referring to the section Check before operation Cleaning Crawler belt comes ...

Страница 243: ...e 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 parts Clean Inspection and replacement Engine water temperature monitor illuminates while the engine is in operation Insufficient coolant Water leakage from the cooling line Slackened or broken fan bel...

Страница 244: ...ction 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 source of power supply equipment voltage and phase interruption Inspect connection with the motor Terminal block Inspection repair replacement The cabtire cable rises in temperature Considerable volt...

Страница 245: ...inspection 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 Inverter unit main breaker is tripped High humidity Presence of water droplets Poor grounding A break in stator winding Make sure the power unit is complying with the environmental specifications At...

Страница 246: ... 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 operate troubleshoot the machine body Is power supplied with transmitter and machine engine key set to ON position If the power is not turned ON turn it ON Does the emergency stop switch remain ON Se...

Страница 247: ...onnection 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 Connection to machine is interrupted Check connection cable to receiver for disconnection If the problem is not solved after applying the suggested remedies above contact us or our sal es service agent or...

Страница 248: ... 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 check Check each joy stick Check harnesses of each input circuit EI01 Right joystick left right start position error EI02 Left joystick front rear start position error EI02 Left joystick left right s...

Страница 249: ...Battery 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 position LS circuit ES14 Slew angle input error Check slew potentiometer Check harness of slew angle circuit ES05L Boom angle sensor input Lo error Check angle sensor Check harness of angle sensor circ...

Страница 250: ...R 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 4 solenoid circuit EOS04H OR grounding 4 SOL Lo error EOT03L Right front SOL Hi error Check right front solenoid Check harness of right front solenoid circuit EOT03H Right front SOL Lo error EOT04L ...

Страница 251: ... 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 error Check boom lower solenoid Check harness of boom lower solenoid circuit EOC04H Boom lower SOL Lo error EOC05L Winch up SOL Hi error Check winch up solenoid Check harness of winch up solenoid circ...

Страница 252: ...or 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 of TTC36X sensor power circuit EV11 Rotary lamp power Lo error Check harness of rotary lamp power circuit EOF02H Fly jib derrick telescopic shift SOL Hi error Check harness of fly jib derrick telesc...

Страница 253: ...244 This Page Intentionally Left Blank ...

Страница 254: ... 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 INSPECTION AND MAINTENANCE LIST 257 9 MAINTENANCE PROCEDURES 260 ...

Страница 255: ...must 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 MACHINE CLEAN Wash the machine clean to facilitate the detection of a malfunction Especially keep the grease nipple breather and oil level gauge oil access door clean to prevent impurities from entering...

Страница 256: ...opened 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 tension of the crawler tread more than usual 17 CAUTIONS FOR MACHINE WASH Do not direct a jet of steam to the electrical parts and connector Keep the operation panel dry Wash the machine with a clean cloth...

Страница 257: ...r 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 remaining in piping and cylinders does not cause problems even when mixed with other oil 2 FUEL HANDLING The fuel pump is precision equipment that becomes inoperative if fuel containing moisture or ...

Страница 258: ...ure 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 used Do not reuse any washed filters cartridge typed ones under any circumstances After replacing an oil filter check the used filter for any metal powder If metal powder is found on the used filter c...

Страница 259: ...ic 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 at elevated temperatures and high pressure immediately after equipment comes to a stop Perform inspection and maintenance only after the oil drop in temperature for safety An internal pressure may be...

Страница 260: ...he 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 flaw is detected 6 Check the structural parts including the boom for cracks and deformations 7 Check for loose or missing mounting bolts and joints 8 Check if the booms perform proper operation and s...

Страница 261: ...unctionality 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 deteriorations of O rings are found please replace them LIST OF IMPORTANT COMPONENTS No Parts to be replaced regularly Q ty Replacement cycle 1 Fuel hose fuel tank pre filter pump filter 3 Every 2 years or every...

Страница 262: ...ear 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 replacement Every 500 hours Fuel pre filter replacement Every 500 hours Hydraulic oil tank air filter replacement Every 500 hours Fuel main filter replacement Every 500 hours Air cleaner Every 500 hours Hydr...

Страница 263: ... 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 recommended abrasion resistant hydraulic oil for the hydraulic oil system ISO VG32 is used when the product was shipped For adjustment of antifreeze concentrations in coolant with temperature at 10 C or b...

Страница 264: ...Tolerance 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 45 0 61 0 4 6 6 21 12 19 65 5 6 70 57 0 75 3 5 85 7 70 93 0 9 5 79 0 107 8 10 10 9 14 22 104 10 6 90 4 120 9 2 12 2 148 15 1 126 170 12 8 17 4 16 24 163 16 6 142 187 14 4 19 1 231 23 5 196 266 20 0 2...

Страница 265: ... 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 36 915 93 3 778 1050 79 3 107 211 21 5 183 243 18 7 24 7 27 41 1340 136 1140 1540 116 156 309 31 4 269 355 27 3 36 1 30 46 1820 185 1550 2090 157 213 419 42 6 364 482 37 0 49 0 33 50 2470 252 2100 2...

Страница 266: ...OTOR 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 FOR OPERATION 272 12 INSPECTION OF FUSE 273 13 INSPECTION OF OUTRIGGER DISPLAY 273 14 ADJUSTING OPERATOR SEAT 274 9 1 3 INSPECTION BEFORE STARTING ENGINE RADIO CONTROL 275 1 CHECKING PRIOR TO TURNING...

Страница 267: ...ONTAMINANT 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 HOURS MAINTENANCE 306 1 INSPECTION CLEANING OF AIR CLEANER 306 2 INSPECTION ADJUSTMENT OF ALTERNATOR BELT TENSION 308 3 CHECKING REFILLING OIL IN TRAVELLING MOTOR REDUCTION GEAR CASE 309 9 9 EVERY 5...

Страница 268: ...VALVE 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 CLEANING OF EGR COOLER CLEANING OF WATER SIDE EXHAUST PASSAGE BLOWER 327 4 INSPECTION OF DPF DOC 327 5 INSPECTION OF INLET THROTTLE VALVE OPERATION 327 6 INSPECTION OF EXHAUST THROTTLE VALVE OPERATION 327...

Страница 269: ...p 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 O...

Страница 270: ...ION 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 connection of wire rope ends Replace if any loose wire rope ends are found Check for any irregular winding of wire rope winch drum part If you find irregular winding rewind it 3 INSPECTION OF HOOK BLOCK Chec...

Страница 271: ...ng 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 abnormality is found 7 INSPECTION AROUND ENGINE Check for fuel oil or water leakage from the engine Repair if any abnormality is found Check for any accumulation or deposits of inflammable items including fall...

Страница 272: ...ve 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 below 1 See OPERATION 1 10 ENGINE COVER and remove the engine cover 2 Remove the radiator cap 3 and check the coolant level in the radiator 3 If the coolant level in the radiator was low check the radiat...

Страница 273: ...e 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 3 Pull the oil level gauge G out and wipe the oil with a disposable cloth 4 Insert the oil level gauge G into the gauge guide and pull it out 5 If the oil level is between the H mark and L mark on th...

Страница 274: ...upper 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 the fuel is filled to almost full around F 3 If there is not enough fuel left pull up the lock lever 1 to open the console box R 2 Remember to set the lock bar 3 so that the console box R 2 does not f...

Страница 275: ... 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 pre filter 1 coming up indicates that the water has mixed in 4 If there is water accumulated in the fuel pre filter 1 remove it using the following procedure 1 Connect a hose A to the outlet of the va...

Страница 276: ...e 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 side of the operation side cover and ensure that the oil level is between H and L 3 If there is not sufficient oil refill the hydraulic oil according to the following procedure 1 Turn ON release the ...

Страница 277: ...o 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 outrigger rotary of outrigger 1 and outrigger 4 to outward 2 Remove the mounting bolts 2 4 bolts and then remove covers 3 and 5 on the post 3 Remove the filler plug F on the rear part of the post and refill ...

Страница 278: ...k 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 check if the oil comes out of the plug hole 3 If the oil level is low remove the upper drain plug P and refill the gear oil from the plug hole NOTES Pour in the gear oil until the oil comes out of the...

Страница 279: ...om 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 bolts 2 4 bolts and then remove the radiator cover 1 3 Apply the compressed air less than 0 19 MPa 1 9 kg cm to the oil cooler 3 and radiator 4 to remove the mud and dust clogged in the fins 4 After clea...

Страница 280: ...r 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 can see through the side of the battery case from the inspection hole of the machinery cover NOTES Wipe the battery case clean if it is dirty 4 Verify that the surface of the electrolyte is at the max...

Страница 281: ...3 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 switch to verify that the horn sounds If not the horn may be faulty or the circuit may be open Ask us or our sales service agency for repair 11 CHECKING HEADLIGHTS FOR OPERATION 1 Turn ON the starter swi...

Страница 282: ...es 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 each lamp turns on and off in the order described below 1 All of crane stowage position lamp 1 extension lamp 2 and contact lamp 3 turn on then turn off 2 The crane stowage position lamp 1 turns on ...

Страница 283: ...the 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 Adjusting reclining CAUTION When you recline the back seat adjust the angle while paying attention to the back space 1 Set the back seat to the appropriate angle while pressing forward the reclining a...

Страница 284: ...d 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 or impairment to the rubber cover of the control levers and operation switches If cracks or damage is found repair immediately Cracks or damage to the transmitter may allow water to enter inside caus...

Страница 285: ...ons 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 position Check that the power is turned on and the display is functioning properly ...

Страница 286: ...nd 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 power of the Receiver is turned ON or OFF LED ON yellow on the uppermost part of the monitor LED 2 comes ON When pressing theremote controller power ON OFF switch 3 of the transmitter twice and operat...

Страница 287: ...SPECTION 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 mode 3 Check that only the crane stowage position lamp 1 of the monitor is eventually lit in green 4 Insert the position pins 4 securely by rotating outward the outrigger rotary of all four outriggers...

Страница 288: ... 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 outriggers outrigger contact switch 7 to On position to move the tray of outrigger above the ground 9 Press the mode switch of the monitor or touch the screen to enter the crane mode 10 Move the opera...

Страница 289: ...til 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 the screen to enter the contact mode 6 Press the mode switch 6 of the monitor or touch the screen to enter the manual mode 7 Turn the outrigger contact switch 7 on the outrigger control panel to In po...

Страница 290: ...d 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 Repair if any abnormality is found 2 Move the outrigger contact switch to Out position and see whether the outrigger lowers smoothly Also move the outrigger contact switch to In position and see whether t...

Страница 291: ... 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 the boom or boom telescoping cylinder Repair if any abnormality is found 3 Push the operation lever on the right forward and check that the hook is unwound smoothly Also pull the operation lever on the...

Страница 292: ...status 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 engine and operate the crane as follows Then check if the monitor display of the moment limiter is correct Crane operation and display item Monitor display value of moment limiter Displayed value of boom...

Страница 293: ...gger 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 the engine is kept in no load operation for 5 minutes 2 Verify that the engine exhaust gas color is either transparent or slightly blue Also check for abnormal noises and vibrations Repair if any abno...

Страница 294: ...RT 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 the horn sounds 4 Push down the Engine start stop switch 4 to the start side and check that the engine starts 2 INSPECTION OF ENGINE STOP OPERATION 1 After the engine has started as above 1 push down ...

Страница 295: ...p 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 levers 1 2 up and down and check that the outrigger operates at a speed responding to an operation amount of the operation levers 6 Press the speed outrigger switch 5 to change from the outrigger retra...

Страница 296: ...s 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 crane perform the steps from 1 to 4 above and be sure to check that the crane mode is set 5 Move the operation lever 2 to LOWER and RAISE side and check that the boom follows the lever operation 6 Mov...

Страница 297: ...peed 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 engine speed increases also NOTES When the Acceleration adjustment switch 9 is set to the maximum and each operation lever is pushed down to the maximum the crane speed becomes the maximum engine spe...

Страница 298: ...between 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 tension Have a grease pump ready 1 Inject grease from the grease nipple 1 using grease pump 2 Set the engine to the low idling mode and forward by the contact length and stop slowly to check that the ten...

Страница 299: ...bove 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 appropriate 4 Check the tension of rubber track again If the tension is not appropriate make another adjustment 2 INSPECTION ADJUSTMENT OF RUBBER TRACK SHOE BOLT If you use the loose rubber track sho...

Страница 300: ...rope 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 broken NOTES 9 strands or greater for winch Replace the boom telescoping wire rope when 13 or more wires are broken Wear equivalent to 7 or more of a nominal diameter occurred in the wire rope diamet...

Страница 301: ...w 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 right operation lever forward to wind up the wire rope 5 from the winch drum 8 After winding up the wire rope from the winch drum detach the end of the wire rope 5 fixed to the winch drum 8 by follo...

Страница 302: ...e 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 bracket 14 and slide sheave 15 2 Draw the wire rope 5 through the rope attachment hole of the winch drum 9 Secure the wire rope 5 to the winch drum 9 following the procedure provided below 1 Draw the s...

Страница 303: ...nk 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 the boom with the wire socket pin 2 and tighten the wire socket pin mounting bolt 1 9 Pull the right operation lever inward or push down the left operation lever forward to raise the hook block NOTES ...

Страница 304: ...olt 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 the adjusting bolt 9 is turned If the No 5 boom is not extended refer to the section Adjustment of Wire Rope and adjust it 4 Check for a 5 mm or more gap between booms No 4 and 5 when the booms are fu...

Страница 305: ...lowing 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 wire rope 8 3 Remove the mounting bolts 1 3 bolts on the boom tip and then remove the cover 2 When it sags refer to the section Adjustment of Wire Rope 4 Adjustment of No 5 boom retracting wire rope 5 1...

Страница 306: ...se 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 wire rope 5 with the lock nut 3 4 Fix the adjustment bolts 9 of the No 5 boom extending wire rope 8 with the lock bolt 6 6 Install the cover 2 on the boom tip with the mounting bolts 1 3 bolts after...

Страница 307: ...aulic 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 it may spout out from the air breather during traveling or crane operation Be careful not to let any foreign substance go into the filler opening when refilling the oil 1 Place the machine on a level...

Страница 308: ...10 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 cylinder to the stroke end stop them at a position approximately 100 mm before the stroke end Repeat this 4 to 5 times 3 See OPERATION 2 14 OUTRIGGER SETTING OPERATION and make the outrigger cylinder telesc...

Страница 309: ... 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 method of maintenance 9 5 INITIAL 250 HOURS MAINTENANCE The following maintenance should be performed after 250 hours of operation limited to the 1st maintenance of a new machine 1 OIL REPLACEMENT IN SL...

Страница 310: ...the 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 sufficient size according to the amount of residual fuel 1 Place the machine on a level surface 2 Place a container to collect the drained fuel directly underneath the drain plug P of the fuel tank ...

Страница 311: ...f 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 fuel pre filter 1 to the right to close 7 Disconnect the hose A connected to the valve 3 drainage 8 Turn the fuel lever 4 to the vertical position open NOTES Wipe off the oil spills completely 9 Ble...

Страница 312: ...of 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 both sides and underside of the boom Each boom 13 Greasing of the boom extending and retracting wire ropes 2 pieces Rope oil 14 Greasing of the winch wire rope 1 piece 1 Using the grease gun inject ...

Страница 313: ...304 ...

Страница 314: ...l 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 Allen key ready 1 Place the machine on a level and firm surface and raise the boom to approx 80 degrees 2 Remove the oil level check plug G using the Allen key It is normal if the oil flows out of t...

Страница 315: ...om 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 the clamps 1 3 places and remove the dust pan 2 3 Pull out the outer element 3 only NOTES The inner element 5 should be removed only when the element clogging occurs soon after replacing the outer el...

Страница 316: ...cloth 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 on the air cleaner body 4 12 Secure the clamps 1 3 places 13 See OPERATION 1 9 RADIATOR GRILL and install the radiator grill See OPERATION 1 12 OPERATION SIDE COVER and install the operation side cove...

Страница 317: ...lly 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 engine and operated for more than five minutes 3 If the belt 3 slack is not within the range of standard slack adjust the slack tension of the belt 3 by referring to the Tension adjustment section TE...

Страница 318: ... 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 checking and refilling the oil Prepare a container to drain the oil Have an Allen key ready 1 Move the machine back and forth so that the drain plug P comes directly underneath 2 Place a container to...

Страница 319: ...ife 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 engine is warmed up just to the extent that it can be touched by hands Be careful not to let any foreign substance go into the filler opening when refilling the oil Oil drain pan Prepare a container for ...

Страница 320: ... 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 spilled oil 12 After replacing the filter cartridge 3 feed engine oil through filler port F to the specified level 13 Pull the oil level gauge G out and wipe the oil with a disposable cloth 14 Insert th...

Страница 321: ...ogging 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 located at the back of the air cleaner body 4 with a clean cloth or tape to keep impurities out of the duct entrance 6 Clean inside the air cleaner body 4 7 Clean inside the dust pan 2 and the rubbe...

Страница 322: ...taminants 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 condition of the Oring 9 and replace if necessary 10 Set the float 7 inside the cup 5 and attach the Oring 9 and new element 8 NOTES Tightening torque of the cup 5 is as below Tightening torque 1 0 2 0 ...

Страница 323: ...o 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 specified tightening torque Tightening torque 19 6 23 5 N m 2 0 2 4 kgf m 7 Bleed the air from the fuel system according to the following sequence 1 Turn the starter switch to ON position and wait for 10 ...

Страница 324: ...mit 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 the oil 1 Place the machine on a level surface 2 See OPERATION 1 10 ENGINE COVER and remove the engine cover 3 Remove the air filter F to relieve internal pressure 4 Using a filter wrench turn the filt...

Страница 325: ...ilter 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 1 Place the machine on a level surface 2 Remove 2 pieces of mounting bolts 2 and remove the inspection cover 1 3 Remove the air filter F and replace with new one NOTES The air filter F is cap integra...

Страница 326: ...cedure 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 comes to the center of the inspection opening A and check all the mounting bolts 2 for loosening loss or damage 3 If any loose bolts are found re tighten with the tightening torque in the above table If ...

Страница 327: ...ater 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 year A mixing ratio of antifreeze is recommended to be controlled by the antifreeze concentration meter Cooling system cleaning and antifreeze replacement should conform to the cycles specified in t...

Страница 328: ...e 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 radiator is to retain a high water level during cleaning with running water Adjust the quantities of water supplied and drained as necessary Ensure that the water filling hose stays connected to the rad...

Страница 329: ...or 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 with the radiator cap 3 removed and ensure that the engine runs at low idle for 5 minutes Release air from the cooling system with the engine at high idle for another 5 minutes 17 Wait for approx 3 ...

Страница 330: ... 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 limit 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...

Страница 331: ...wage 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 run the engine at low idle for 10 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 cylin...

Страница 332: ...enter 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 the ground and the crawler to prevent the machine from lowering 3 Remove the slewing ring cover 4 Remove the filler plug F of slewing reduction gear case 5 Go under the machine and place a drain pan...

Страница 333: ... 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 and firm surface and raise the boom to approx 80 degrees 2 Place a container to collect the drained fuel underneath the drain plug P 3 Remove the filler plug F oil level checking plug G and drain plu...

Страница 334: ... 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 Remove the filler plug F oil level checking plug G and drain plug P using an Allen key and drain the oil 4 Install and tighten the drain plug P securely after draining 5 Refill the oil of the exchange a...

Страница 335: ...ls 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 REPAIR OF VALVE SEAT Inspection and repair of valve seat require special tools Contact us or our sales service agent to request inspection and repair 2 CHECKING ALTERNATOR AND STARTER CAUTION Inspect...

Страница 336: ...er 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 special tools Contact us or our sales service agent to request inspection and repair 5 INSPECTION OF INLET THROTTLE VALVE OPERATION Testing of inlet throttle valve requires special tools Contact us or our ...

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Страница 338: ... 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 LIFTING HEIGHT DURING PICK CARRY 348 ...

Страница 339: ...draulic 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 with automated hydraulic locking device Max extended width left to right Front 6300 mm Rear 6520 mm Max extended width front to rear 6770 mm Travelling system Type 2 speed hydraulic motor driven Ste...

Страница 340: ...rigger 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 to rear 6770 mm Travelling system Type 2 speed hydraulic motor driven Step less speed changer built in brake Travel speed Forward reverse 0 to 3 2 km h Grade ability 23 degrees Ground pressure 53 kP...

Страница 341: ... 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 Continuous operating hours of Transmitter Approximately 20 hours Changes depending on usage environment Ambient operating temperature 20 C to 70 C Transmitter mass Approx 1 8 kg including battery Operation i...

Страница 342: ...333 2 SPECIFICATION DIMENSIONAL DRAWING ...

Страница 343: ...334 3 DIMENSIONAL DRAWING OF OUTRIGGER WIDTH ...

Страница 344: ...390 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 4190 4090 4090 3390 3390 2390 2390 4 92 3790 3790 3790 3790 3690 3690 3390 3390 2390 2390 5 00 3790 3790 3690 3690 3390 3390 2390 2390 6 00 3190 3190 3090 3090 2790 2790 2390 2390 7 00 2690 2690 2590 2...

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Страница 355: ... 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 1520 1520 1520 1520 1520 4 92 1520 1520 1520 1520 1520 1520 1520 1520 1520 1520 5 00 1520 1520 1520 1520 1520 1520 1520 1520 6 00 1520 1520 1520 1520 1520 1520 1520 1520 7 00 1420 1520 1420 1520 1420...

Страница 356: ...347 5 WORKING RADIUS LIFTING HEIGHT ...

Страница 357: ...these 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 keep it low to the ground as possible 4 If the load swings stop traveling until the load is still ...

Страница 358: ...0 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 8 INSPECTION AND MAINTENANCE 381 9 SPECIFICATION 385 ...

Страница 359: ...omes 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 boom side beforehand If the wires are not connected correctly the moment limiter or over hoist detector will not function properly causing a serious accident This manual assumes that a fly jib is attac...

Страница 360: ...on 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 become damaged lost or unreadable please replace them with new ones There are other labels than safety labels shown below and treat them in the same manner ...

Страница 361: ...352 1 Diagram of fly jib working range chart 106 2189200 ...

Страница 362: ...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 ...

Страница 363: ...00 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 rated total load 106 4719500 2 locations ...

Страница 364: ... 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 Hose reel A1 Position pin A1 A2 Position pin A2 B1 Position pin B1 B2 Position pin B2 C1 Position pin C1 C2 Position pin C2 L1 Linchpin L2 Shaft lock pin ...

Страница 365: ...t 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 electric wires from the over hoist detector on the main boom side and reconnect them to the fly jib side If the wires are not connected correctly the moment limiter or over hoist detector will not fu...

Страница 366: ...ate 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 fly jib mounting bracket 6 can be attached The collar 29 will not be used so please keep it and do not lose it 3 Attach the fly jib mounting bracket 6 and insert the point pin 30 to fix it 4 Put back t...

Страница 367: ...on 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 position pin B2 of the stowage bracket A 21 as a pivot point pull out the fly jib base 4 to the main boom tip side by holding its handle H4 and align the holes A B of the right section of the fly jib moun...

Страница 368: ...m 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 fly jib and the main boom might be seriously damaged 10 Attach the lever block 23 to the No 1 fly jib 2 and the fly jib base 4 to prevent the fly jib from falling NOTES The lever block 23 should be ...

Страница 369: ...ase 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 not to damage any electric wires in the vicinity 17 Align the positions of the hole C on the left side of the fly jib mounting bracket 27 and the hole of the fly jib base 4 using the lever block and in...

Страница 370: ...y 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 procedure below 1 Remove the cap of the couplers 1 F1 and 2 F2 2 Disconnect the coupler 3 F3 of the hydraulic hose A F5 stowed in the fly jib side and reconnect it to the coupler 2 F2 on the main boo...

Страница 371: ...ove 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 direction indicated by the arrow a 7 Pull out the wire rope 12 from the hook 8 Pull the wire rope 12 out of the weight 42 of the over hoist detector 9 Pull out all the wire ropes 12 from three sheaves o...

Страница 372: ...ht 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 indicated by the arrow 26 Attach the rope clip 40 to the wire rope 12 See the figure on the right for the position to attach the rope clip 40 27 Hold the wire socket 37 and insert it so that the pin ho...

Страница 373: ...y 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 the fly jib is mounted Refer to Fly jib 5 Handling monitor and moment limiter section for details on monitor display ...

Страница 374: ...rregularly 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 fully retracted and make sure the main boom angle is approx 20 degrees 2 Operate the winch lever to lower the single hook 10 so that it is barely touching the ground 3 Lower the single hook 10 to the gr...

Страница 375: ...e 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 according to the dimensions specified in the sketch at the right 6 Secure the wedge socket 37 to the boom with the wedge socket pin 38 and tighten the wedge socket pin 38 and the bolt 39 NOTES When lifti...

Страница 376: ...y 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 dummy connector E3 and reconnect the connector B E5 to the connector E2 on the main boom side 4 Connect the plug to the dummy connector E3 CAUTION The machine will not function unless you reconnect the...

Страница 377: ...upler 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 position using the lever block 23 Pull out the shaft lock pins of the position pins A1 A2 on the left section of the fly jib mounting bracket 27 and pull out the position pin A2 first then A1 from the ...

Страница 378: ... 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 pins C1 C2 from the right section of the fly jib mounting bracket 26 until the position pin B2 is securely inserted into the hole of stowage bracket A 21 and the fly jib is fixed If you remove it ma...

Страница 379: ...1 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 the right section of the fly jib mounting bracket 26 16 Insert the position pins C1 C2 to the right section of the fly jib mounting bracket 26 When doing so be sure to turn the ring of the linchpin b...

Страница 380: ...o 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 mounting bracket 6 and remove the nut 32 and the plate 31 and pull out the head pin 28 from the fly jib mounting bracket 6 completely NOTES The head pin 28 does not need to be pulled out completely as...

Страница 381: ...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 ...

Страница 382: ...e 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 JIB MODE 1 Load capacity ratio display 2 Number of fly jib boom section display 3 Fly jib length display 4 Fly jib angle display 5 Boom length display 6 Boom angle display 7 Actual load display 8 Rat...

Страница 383: ...d 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 fly jib angle during crane operations The angle of the fly jib is 0 degree when it is parallel to the main boom As the fly jib is lowered the degree increases NOTES The angle of the fly jib indicates...

Страница 384: ...s 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 total load display The rated total load of the fly jib is shown when you touch RTL on the monitor display Touch again to return to the original display ...

Страница 385: ...crane 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 position of each status indication is adjusted Boom fly jib operation selector switch changes to the mode selector switch ...

Страница 386: ... 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 table below unless the main boom length is less than 6 0 m and with no load Outrigger extension Main boom angle Maximum More than 0 degree and less than 50 degrees Medium More than 0 degree and less th...

Страница 387: ...r 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 EXTEND OPERATION Operate the left control lever 2 as follows Extension Push the lever forward Neutral Release your hand from the lever The lever returns to the NEUTRAL position and the fly jib telescop...

Страница 388: ...sor 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 related circuit EV20 Fly jib power supply voltage error Check converter 24V 12V Check power supply related circuit EOF02H Fly jib derricking Extend retract switching SOL Hi error Check switch valve Check h...

Страница 389: ...function 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 is shown 3 When fly jib is attached to vehicle body and extended fly jib mode Abnormal Phenomenon Major cause s Remedy R is shown as the number of fly jib boom sections instead of 1 or 2 Out of place...

Страница 390: ...jib 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 the code reel cables and make sure they operate smoothly Repair if any abnormality is found Check for slack wiring lose connections and any trace of burning Repair if any abnormality is found 2 INSPEC...

Страница 391: ...play 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 retracted 1 Number of fly jib boom sections display when fly jib is fully extended 2 Fly jib angle display when fly jib is fully raised 0 Fly jib angle display when fly jib is fully lowered 60 5 Start the ...

Страница 392: ...4000 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 consumables delivers increased economy in machine use Always use Maeda genuine parts for part replacement See the parts catalogue for part numbers when ordering parts LIST OF CONSUMABLES Item Replacement cycl...

Страница 393: ...ction 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 place 4 No 2 fly jib slide plate touching surface Both sides Boom grease 5 Lower side 6 No 1 fly jib slide roller touching surface Each part 1 Grease the grease fittings using a grease pump 2 Wipe o...

Страница 394: ... 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 kg Overall length width height 6200 mm 1740 mm 2490 mm 9 2 SPECIFICATION DIMENSIONAL DRAWING ...

Страница 395: ... 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 820 720 620 1020 620 420 320 70 degrees 1020 620 520 420 820 420 320 220 60 degrees 420 420 320 320 220 120 50 degrees 170 120 120 Main boom Angle One jib section Two jib sections 0 degree 20 degree...

Страница 396: ...387 9 4 WORKING RADIUS LIFTING HEIGHT ...

Страница 397: ...388 This Page Intentionally Left Blank ...

Страница 398: ...OOK 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 TROUBLESHOOTING 410 8 INSPECTION AND MAINTENANCE 411 9 SPECIFICATION 412 ...

Страница 399: ...Remember 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 hole It may cause a serious accident When changing the angle of the searcher hook change the displayed angle on the monitor according to the actual angle If you use the machine without changing the mod...

Страница 400: ...tion 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 become damaged lost or unreadable please replace them with new ones There are other labels than safety labels shown below and treat them in the same manner ...

Страница 401: ...392 1 Searcher hook working range diagram 106 2189200 ...

Страница 402: ...393 6 Maximum rated total load 106 4716100 2 locations 7 Notice on pin holes CL000100001 2 locations ...

Страница 403: ...3 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 pin ...

Страница 404: ...ain 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 accident Never put your fingers into the pin hole A searcher hook is attached and stowed to the left section of the main boom with two position pins Insert the position pins for fixing in the correct p...

Страница 405: ... 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 the tip side of the point pin 5 5 Tighten the nut 8 you loosened in step 2 6 Pull out the stowed pin A 9 7 Pull out the pin B 10 from the stowage bracket B 12 and slide the searcher hook boom 1 hori...

Страница 406: ...cket 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 retaining pin NOTES The pin A 9 and the pin B 10 are the same parts so either of them can be inserted ...

Страница 407: ...t 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 the wire clip 40 6 Remove the rope wedge 41 by preparing a cylindrical rod of 6 to 8 mm and lightly tapping the rope wedge 41 with a hammer in the direction indicated by the arrow a 7 Pull out the wir...

Страница 408: ...need 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 A 11 on the left section of the main boom NOTES Position the searcher hook boom 1 according to the guide line on the stowage bracket A 11 3 Align the searcher hook boom 1 with the stowage bracket B ...

Страница 409: ...racket 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 remove by pulling it out toward you 8 Tighten the nut 8 you loosened in step 6 9 Secure the searcher hook bracket 4 you have removed with the eye bolt 15 and the washer 16 to the stowage bracket 14 on th...

Страница 410: ...orizontally 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 is mounted 1 Pull out the pin B 10 and the pin A 9 in that order from the searcher hook bracket 4 to remove the searcher hook boom 1 The searcher hook boom 1 will fall when the pin A 9 is pulled out...

Страница 411: ...and 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 NOTES The searcher hook bracket 4 should be hung from the head pin 13 by its design remove by pulling it out toward you 3 Tighten the nut 8 you loosened in step 1 Removing stowage bracket 1 Loosen two ...

Страница 412: ... 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 pin A 9 and the pin B 10 are the same parts so either of them can be inserted To attach to searcher hook bracket 1 Align the hole H1 of the searcher hook boom 1 with the hole H2 of the searcher hook br...

Страница 413: ...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 3 Attach the collar 6 the plate 7 and the nut 8 to the tip side of the point pin 5 4 Tighten the nut 8 you loosened in step 1 Attaching stowage bracket 1 Fasten the stowage bracket A 11 with two bolts to the left section of the main boom 2 Fasten the stowage bracket B 12 with tw...

Страница 414: ...fferent 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 DISPLAY IN SEARCHER HOOK MODE 1 Load capacity ratio display 2 Actual load display 3 Rated total load display 4 Offset position display 5 Boom length display 6 Boom angle display 7 Working radius disp...

Страница 415: ... 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 main boom cannot be lowered when Offset Position 60 or 80 degrees are selected 11 Setting switch user mode The setting procedure for the user mode is the same as the standard specification To change ...

Страница 416: ...er 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 Winch settings in searcher hook mode Winch movement in searcher hook mode can be switched SH Mode Winch ON Winch can be controlled in searcher hook mode SH Mode Winch OFF Winch cannot be controlled in...

Страница 417: ...hown 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 the general banned operations The winch operation is prohibited 5 3 RECOVERY OPERATION FROM AUTOMATIC STOP Refer to the OPERATION 1 5 3 2 RECOVERY OPERATION FROM AUTOMATIC STOP for more information abo...

Страница 418: ...serious 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 searcher hook change OFFSET POSITION on the monitor according to the actual angle If you use the machine without changing the mode damage to or overturn of the machine might occur causing a serious acc...

Страница 419: ...hook 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 OFFSET POSITION is shown Searcher hook mode is selected in user mode Change away from searcher hook mode 3 When searcher hook is mounted to vehicle and extended Abnormal Phenomenon Major cause s Remedy I...

Страница 420: ...m 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 noise coming from bearings and the hook latch S functions correctly Also check the shackle 3 attaching the swivel hook 2 3 Inspection of moment limiter searcher hook mode CAUTION In this section only th...

Страница 421: ...ook 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 Overall length width height 6550 mm 1670 mm 2490 mm 9 2 SPECIFICATION DIMENSIONAL DRAWING ...

Страница 422: ...trigger 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 is less than 30 degrees in the 5th stage of the main boom The rated total load chart indicates the load including the mass of hoisting accessories searcher hook mass 60 kg ...

Страница 423: ...414 9 4 WORKING RADIUS LIFTING HEIGHT ...

Страница 424: ...l 8 Gauges and switches 9 Electrical components wiring connectors 10 Hydraulic hoses 11 Nut bolts other fasteners 12 Tracks 13 Outriggers 14 Outrigger Pads 15 Winch Cable serviceable 16 Drivers cabin in servicable condition 17 Horn 18 Audible Visual warnings Alarms Beacons 19 Controls Buttons Joysticks Remote Control 20 Boom sections free from defects or debris 21 Fly Jib free from defects where a...

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