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Maeda LC1385M-8BF Operating Manual

Crawler crane
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OPERATION MANUAL
CRAWLER CRANE
Serial No. 8009 and up
Unsafe use of this machine may cause serious injury or death. Operators
must read this manual before operating this machine. This manual should
be kept near the machine for reference and periodically reviewed by all
personnel who will come into contact with it.
MAEDA has Operation Manual written in some other languages. If a foreign
language manual is necessary, contact your local distributor for availability.
NOTICE
584E-OM0912-02

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Summary of Contents for Maeda LC1385M-8BF

  • Page 1 NOTICE MAEDA has Operation Manual written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.

  • Page 3: Table Of Contents

    CONTENTS ITEM Page INTRODUCTION 1- 1 1. INTRODUCTION 1- 2 2.FOR SAFE USE OF MACHINE 1- 3 3. MACHINE OVERVIEW 1- 4 3.1 SPECIFIED OPERATIONS 1- 4 3.2 MACHINE CONFIGURATION 1- 4 3.3 MACHINE FUNCTIONS 1- 5 4. QUALIFICATION FOR OPERATION 1- 6 4.1 QUALIFICATION FOR CRANE OPERATION 1- 6...

  • Page 4: Item Page

    ITEM Page 2.1.4 BASIC CHECK ITEMS 3-15 2.1.5 METER DISPLAY PORTION 3-16 2.1.6 MONITOR SWITCHES PORTION 3-22 2.1.7 HANDLING FUNCTION SWITCHES 3-28 2.2 SWITCHES 3-39 2.3 CONTROL LEVERS AND PEDALS 3-47 2.4 MOMENT LIMITER (OVERLOAD PROTECTOR) 3-51 2.4.1 MOMENT LIMITER CONFIGURATION 3-51 2.4.2 FUNCTION OF MOMENT LIMITER 3-52...
  • Page 5 ITEM Page 3. MACHINE OPERATIONS AND CONTROLS 3-99 3.1 CHECKING BEFORE OPERATION 3-99 3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) 3-99 3.1.2 CHECKING BEFORE STARTING ENGINE 3-102 3.1.3 CHECKING AFTER STARTING ENGINE 3-115 3.2 OPERATIONS BEFORE ENGINE STARTING 3-118 3.3 STARTING ENGINE 3-120 3.3.1 NORMAL STARTING ENGINE 3-120...
  • Page 6 ITEM Page 3.26 OPERATION OF PLADE 3-167 3.26.1 PRECAUTION OF BLADE OPERATION 3-167 3.26.2 OPERATION OF BLADE 3-168 3.26.3 WORKS WITH A BLADE 3-168 4. HANDLING WIRE ROPES 3-169 4.1 BENCH MARK FOR REPLACING WIRE ROPES 3-169 4.2 WINCH WIRE ROPE FALL MODE AND RATED TOTAL LOAD 3-170 4.3 What TO DO WITH TWISTED WINCH WIRE ROPE 3-171...
  • Page 7 ITEM Page 6. OTHER COMPONENTS 4-10 7. RECOMMENDED FUEL, COOLANT AND LUBRICANT 4-11 7.1 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT 4-11 TEMPERATURES 8. TIGHTENING TORQUE SPECIFICATIONS 4-13 8.1 STANDARD TIGHTENING TORQUE LIST 4-13 9. INSPECTION AND MAINTENANCE LIST 4-14 10.
  • Page 8 ITEM Page 7.3 SETTING OF OPERATING CONDITIONS 6-37 8. OPERATIONS 6-38 8.1 CAUTIONS FOR FLY-JIB OPERATION 6-38 9. INSPECTION AND MAINTENANCE 6-39 9.1 CHECKING BEFORE OPERATION 6-39 9.2 MAITENANCE EVERY 50 HOURS 6-41 10. SPECIFICATIONS 6-42 11. DIMENSIONS 6-42...

  • Page 9: Introduction

    INTRODUCTION 1. INTRODUCTION 1- 2 2. FOR SAFE USE OF MACHINE 1- 3 3. MACHINE OVERVIEW 1- 4 4. QUALIFICATION FOR OPERATION 1- 6 5. TERMINOLOGY 1- 7...

  • Page 10: Introduction

    • Keep this manual handy for reference when necessary. • Should you lose or damage this manual, contact Maeda or our sales service agency immediately for ordering a new manual.

  • Page 11: For Safe Use Of Machine

    2. FOR SAFE USE OF MACHINE This manual classifies the risks into the following three categories to present the details of the safety labels in easy-to-understand manner. This denotes that there is an imminent hazard which will cause serious personal injury or death. The method of hazard circumvention is stated.

  • Page 12: Machine Overview

    3. MACHINE OVERVIEW 3.1 SPECIFIED OPERATIONS This machine is to be used for operation listed below. • Crane operation • Pick & Carry operation This machine is a mobile crane which consists of a crawler type carrier and an upper structure of a boom equipped crane.

  • Page 13: Machine Functions

    This machine is composed of the units listed below. [1] UNDERCARRIAGE This is composed of a traveling gear and blade. [2] UPPER STRUCTURE (CRANE) This is composed of an engine, traveling operation unit, crane operation unit, telescoping system, derrick system, slewing system, hook block, and winch system. [3] SAFETY DEVICE This is composed of the following parts and devices: Over hoist detector/automatic stop device, three-winding stop alarm/automatic stop device, moment limiter (working envelope limited), slinging rope...

  • Page 14: Qualification For Operation

    4. QUALIFICATION FOR OPERATION • A high incidence of occupational accidents in crane operation has been reported. Be aware that experienced engineers are also no exception. • Warnings and precautions defined in this manual shall be observed for safety assurance during operation of the machine.

  • Page 15: Terminology

    5. TERMINOLOGY 5.1 DEFINITIONS OF TERMS [1] RATED TOTAL LOAD This is the maximum load that can be applied according to a boom length and angle. The load includes the mass (weight) of hoisting accessories (hooks) and slinging ropes. [2] RATED LOAD This is a load derived by subtracting the mass (weight) of hoisting accessories (hooks) and slinging ropes from the rated total load, which is a withstand load for hoisting.

  • Page 16: Diagram Of Working Radius And Lifting Height

    5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT • The diagram of working radius and lifting height shows the relationships the working radius of this machine, boom angle, and lifting height above the ground with no object hoisted. The diagram has been made allowing for no deflection in the boom. •...
  • Page 17 5.3 RATED TOTAL LOAD CHART • All the values provided in the rated total load chart are based on the assumption that the machine is placed on a level and firm surface. • The values in the rated total load chart are determined based on the working radius allowing for deflection that is developed when load is applied to the boom.
  • Page 18 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in parallel with the length of the boom. The loads are specified by working radius. [1] BOOM LENGTH The following figures illustrate the condition of the booms, “(1) 4.745m Boom”, “(2) 7.625m Boom”, “(3) 10.505m Boom”, “(4) 13.385m Boom”, and “(5) 16.265m Boom”...
  • Page 19 4. “(4) 13.385m Boom”: With booms (2) and (3) fully extended, booms (4) and (5) are extended midway (half of the “ mark” passes boom (3)). Boom (4) is to apply to crane operation with booms (4) and (5) extended even if only slightly. 5.
  • Page 20 1-12...

  • Page 21: Safety

    SAFETY 1. BASIC PRECAUTIONS 2- 2 2. DRIVING RELATED PRECAUTIONS 2- 8 3. TRANSPORT PRECAUTIONS 2-25 4. TOWING PRECAUTIONS 2-26 5. MAINTENANCE PRECAUTIONS 2-27 6. SAFETY LABEL LOCATIONS 2-34 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.

  • Page 22: Basic Precautions

    1. BASIC PRECAUTIONS Failure to operate or maintain this machine properly can lead to serious personal injury or death. Be sure to read this manual and each safety label thoroughly before performing operation or maintenance of this machine and observe the safety precautions. 1.1 PRECAUTIONS FOR BEFORE STARTING OPERATION OBSERVE THE MANUAL AND SAFETY LABELS •...

  • Page 23: Prepararations Of Safety Operation

    1.2 PREPARATIONS OF SAFETY OPERATION PROVIDE SAFETY DEVICES FOR SURE • Check that all guards, covers, mirrors and rear view camera are attached properly. Repair immediately if damaged. • Understand how to use the safety devices correctly and use properly. •...
  • Page 24 USE OF MACHINE THAT WAS RENTED OR PREVIOUSLY USED BY SOMEONE ELSE Check the following subjects in writing before using any Machine that was rented or previously used by someone else. In addition, check the inspection record table for the maintenance conditions such as the periodic inspections.

  • Page 25: Precautions For Fire Prevention

    1.3 PRECAUTIONS FOR FIRE PREVENTION ACTION IF FIRE OCCURS If a fire occurs, escape from the machine as follows. • Turn starter switch OFF to stop engine. • Use the handrails and steps to get off the machine. FIRE PREVENTION AND EXPLOSION PREVENTION •...

  • Page 26: Precautions When Getting On Or Off

    1.4 PRECAUTIONS WHEN GETTING ON OR OFF USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF To prevent personal injury caused by slipping or falling off the machine, always do as follows. •Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.

  • Page 27: Other Precautions

    Therefore contact our sales service agency for advice. • Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Maeda. • When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.

  • Page 28: Driving Related Precautions

    2. DRIVING RELATED PRECAUTIONS 2.1 PRECAUTIONS FOR JOBSITE SAFETY AT JOBSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. • When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
  • Page 29 BEWARE OF ELECTRICAL CABLE ABOVE • Do not let the Machine contact with electrical cables overhead. High voltage cables may inflict electrical shock by just approaching. • Persons who sling are likely to suffer electrical shocks. Always observe followings to prevent accidents. •...
  • Page 30 MEASURES WHEN CHARGE ACCIDENT OCCURS When an electrical charge accident occurred, do not panic and stay calm, apply the solution in the following sequence. １. Report Immediately report to the electricity company or related management company, and receive instructions for the power transmission stop, emergency procedures and related. 2.

  • Page 31: Precautions When Engine Starting

    2.2 PRECAUTIONS WHEN ENGINE STARTING PRECAUTIONS FOR WARNING TAG If there is a warning tag hanging from working equipment control lever, do not start the engine or touch the levers. Do NOT operate When this tag is not being used, keep it in the storage compartment.
  • Page 32 CAUTIONS UNDER COLD WEATHER • Remove snow from and defreeze the swing gear, boom and winch related parts, and check the movements before work. • Warm up enough. Attempting to operate the control levers and pedals without enough warm-up causes the Machine to react dull, and may result in unexpected accidents.

  • Page 33: Precautions When Starting To Move Machine

    2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE CHECKS BEFORE OPERATION Omitting the inspections after starting the engine results in delay to notice the Machine abnormalities, and may result in bodily accidents and Machine damages. Execute inspection in a wide location with no obstacle. In addition, be sure to prevent people from approaching nearby the Machine.
  • Page 34 CAUTIONS WHEN TRAVELING Always observe followings to prevent serious injuries and death accidents when the Machine is traveling. • Set the Machine to the traveling posture in the right diagram. See “Operation 3.7 Machine Traveling Posture” for details. • Do not attempt looking sideways or other dangerous act when driving.
  • Page 35 BE CAREFUL OF TIPPING ON UNSTABLE GROUND Always observe followings to prevent serious injuries and death accidents when traveling over an unstable ground for unavoidable reason. • Do not enter soft ground area. The Machine is difficult to evacuate from such area. •...

  • Page 36: Precautions When Working With Crane

    2.4 PRECAUTIONS WHEN WORKING WITH CRANE INSPECTION BEFORE STARTING WORK Check that the safety devices and crane operate properly. • Operate each of the operation levers, pedals and switches under no load, and check that operations take place without abnormality. Repair immediately if any abnormality exists.
  • Page 37 CAUTIONS UNDER COLD WEATHER • Remove snow from and defreeze the swing gear, boom and winch related parts, and check the movements before work. • Check the operation of winch brake. • Warm up enough. Attempting to operate the operation levers, pedals and switches without enough warm-up causes the Machine to react dull, and may result in unexpected accidents.
  • Page 38 PAY ATTENTION TO WEATHER INFORMATION • In case of thunderstorm, risk of lightning exists, so abort working with crane, immediately lower the load and contain the boom. • Exposing the hoisted load to wind causes the load to swing and causes the Machine to be unstable, thus is dangerous.
  • Page 39 CAUTIONS WHEN WORKING WITH CRANE • The stability of the crane is determined horizontally. Although the stability also increases diagonally, work exceeding the rated load causes the breakage of the boom or machine. The moment limiter (overload detector) must not be activated even in diagonal direction. •...
  • Page 40 CAUTIONS WHEN HANDLING MOMENT LIMITER • Use/store the moment limiter under the following ranges of ambient temperature. Temperature of use: -10 to 50 degrees C Storage temperature: -30 to 70 °C • Avoid direct sunlight so that the temperature of the moment limiter body does not exceed the above range.
  • Page 41 CAUTIONS WHEN HANDLING WIRE ROPE • The wire rope wears down as the time passes, so inspect every time before work, and replace immediately if at or beyond the replacement standard. At the same time, inspect the sheave at the tip of the boom and the sheave of the hook block.
  • Page 42 CAUTIONS WHEN OPERATING WINCH • Select the hook appropriate for the load weight and right number of wire rope falls. For details, see “Operation 5. Handling Wire Rope”. • Do not let persons enter below the hoisted load. • When hoisting a load, always stop once at the "takeoff" position where the hoisted load leaves the ground.
  • Page 43 CAUTIONS WHEN OPERATING BOOM • Be as slow as possible when operating the boom operation lever. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to swing and give large impact to the Machine, and thus may damage the crane or trip the Machine. •...
  • Page 44 WORKING AT THE SITE WITH UNDERGROUND LIFTING • Leave at least three loops of wire rope in the winch drum when winding down the wire rope in case of underground work or similar occasion. This Machine is equipped with three-winding stop alarm / automatic stop device as the safety device, but even then be very careful to prevent this safety device from activating.

  • Page 45: Transport Precautions

    3. TRANSPORT PRECAUTIONS CAUTIONS DURING TRANSPORT When transporting the machine on a trailer, do as follows. • The weight, transportation height, and overall length of the machine differ accroding to the crane. • When passing over bridges or structure on private land, check first that the structure is strong enough to support the weight of the machine.

  • Page 46: Towing Precautions

    4. TOWING PRECAUTIONS SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For details of towing, see “Operation 9.3 Lightweight Towing Hook”.

  • Page 47: Maintenance Precautions

    5. MAINTENANCE PRECAUTIONS 5.1 PRECAUTIONS BEFORE MAINTENANCE FAILURE REPORT Execution of a maintenance not described in our manual may cause unexpected failures. Ask us or our sales service agency for repair. PRECAUTIONS FOR WARNING TAG • Always attach the “Do NOT operate” warning tag to the work equipment control lever in the operator’s cab to alert others that you are performing service or maintenance on the machine.
  • Page 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE • Stop the machine on firm, level ground. Store the crane, and then stop the engine. • Turn the starter switch to the ON position. Operate the work equipment control lever back and forth. Left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then push up lock lever (1) to the LOCK position (L) and turn starter switch to the OFF position.
  • Page 49 USE APPROPRIATE TOOLS Use only tools suited to the task and be sure to use tools correctly. Using damaged, low quality, faulty, makeshift tools improper use of the tools could cause serious personal injury. PRECAUTIONS FOR ELEVATED WORK For elevated work, prepare an appropriate elevated work platform with steps. CAUTION WHEN WORKING UNDER THE MACHINE NAD CRANE •...

  • Page 50: Precautions During Maintenance

    5.2 PRECAUTIONS DURING MAINTENANCE CAUTIONS DURING WELDING REPAIR Welding operation must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
  • Page 51 CAUTIONS WHEN COOLANT TEMPERATURE IS HIGH To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
  • Page 52 SAFETY HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact us or our sales service agency.
  • Page 53 CAUTION FOR ACCUMULATOR AND GAS SPRING HANDLING The accumulator and gas springs are charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage. For this reason, always observe the following precautions. •...

  • Page 54: Safety Label Locations

    6. SAFETY LABEL LOCATIONS Keep these labels clean all the time. If lost, apply again or replace with new one. Labels other than the following safety labels exist, treat them the same. [SAFETY LABEL LOCATIONS IN CAB] 2-34...
  • Page 55 [SAFETY LABEL LOCATIONS ON CHASSIS] 2-35...
  • Page 56 (1) For your safe operation (556-3367900) (2) Working Range and Rated total load Chart (584-2198800) 2-36...
  • Page 57 (3) Moment Limiter Operation (584-2199400) (4) Warning for Operation, Inspection and Maintenance (584-3469700) (5) Warning for blade operation (556-4575300) 2-37...
  • Page 58 (6) Warning for Swinging and backing up (584-4588100) (7) Caution for Number of Parts Reeving Selector Switch (553-3181800) (8) Caution for Emergency switch (553-4266400) (9) Caution for Wash (300-4213900) (2 places) 2-38...
  • Page 59 (10) Warning for Window (20U-98-21910) (11) Warning for Front window (09803-03000) (12) Control Pattern (556-3368100) (13) Warning Tag (09963-03001) 2-39...
  • Page 60 (14) Warning for Lifting Eye (103-4576900) (2 places) (15) Do not Stand on here (584-4581700) (16) Warning for Hydraulic Oil (09653-03001) (17) Caution for fender (09805-03000) (18) Warning for Coolant (09668-03001) (19) Caution for Engine Hood (09805-13000) (20) Caution for Rotating portion (09667-03001) (21) Hoisting Load (584-4581600) (3 places) 2-40...
  • Page 61 (22) Warning (583-4268000) (2 places) (23) Loads on 2-rope machine hoisting (left) (584-4582200) (24) Loads on 2-rope machine hoisting (right) (584-4582100) (25) Warning for Lifting position (584-3437800) (26) Warning for winch (553-4267500) (27) Max. Working Radius and Overall Load at Max. Working Radius (584-3437700) (28) Connecting Position (09960-00802) (4 places) (29) Lifting Position (09960-00801) (4 places) 2-41...
  • Page 62 (30) Loads on 4-rope machine hoisting (front) (31) Warning for track tension adjusting (584-4581800) (2 places) (584-4588200) (2 places) (32) Loads on 4-rope machine hoisting (rear) (584-4581900) (2 places) (33) Keep off Swing Area (09133-23000) (34) Warning for Battery (09664-30011) (35) Rated Voltage, Current (556-4496600) 2-42...
  • Page 63 (36) Machine Weight (584-4582300) (37) Warning for battery cable (098808-03000) (38) Warning for Accumulator (09659-53000) (39) Warning for Hook Block (553-4267400) (40) WEEE DERECTIVE LABEL (104-4549500) (14 places) [LOCATIONS OF WEEE DIRECTIVE LABELS] (A) Top of relay box (B) Side of the moment limiter converter (C) Back side of the monitor display (D) Side of the moment limiter display (E) Top of the air conditioner controller...
  • Page 64 2-44...

  • Page 65: Operation

    OPERATION 1. MACHINE EACH SECTION 3- 2 2. EXPLANATION OF DEVICES 3- 6 3. MACHINE OPERATIONS AND CONTROLS 3-99 4. HANDLING WIRE ROPES 3-169 5. TRANSPORTATION 3-172 6. HANDLING IN COLD WEATHER 3-181 7. LONG-TERM STORAGE 3-183 8. TROUBLES AND ACTIONS 3-184...

  • Page 66: Machine Each Section

    1. MACHINE EACH SECTION 1.1 MACHINE EACH UNIT (1) Boom (9) Track (2) Working lamp (10) Blade cylinder (3) Boom derricking cylinder (11) Blade (4) Winch (12) Hook block (5) Head lamp (13) Over hoist detector (6) Sprocket and traveling motor (14) Working status lamp (7) Track frame (15) Rear view mirror...

  • Page 67: Operator's Compartment Equipment

    1.2 OPERATOR’S COMPARTMENT EQUIPMENT (1) Radio (13) Cigarette lighter (2) Level (14) Blade control lever (3) Engine emergency stop switch (15) Starter switch (4) Lock lever (16) Fuel control dial (5) Left work equipment control lever (17) Lamp switch (6) Travel pedals (18) Swing lock switch (7) Travel levers (19) Sun roof wiper switch...

  • Page 68: Machine Monitor

    1.2.1 MACHINE MONITOR AA: Standard screen BB: All lamps lit up screen CC: Maintenance interval warning screen (1) Wiper switch (15) Travel speed selector switch (2) Buzzer cancel switch (16) Window washer switch (3) Auto-deceleration switch (17) Air conditioner control switches (4) Engine coolant temperature monitor (18) Engine oil pressure monitor (5) Engine coolant temperature gauge...

  • Page 69: Momentolimiter Related Switch Box

    1.2.2 MOMENTOLIMITER RELATED SWITCH BOX (1) Moment limiter emergency stop cancel switch (2) Over-hoisting cancel switch (3) Winch speed selector switch...

  • Page 70: Explanation Of Devices

    2. EXPLANATION OF DEVICES The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safety, it is important to completely understand methods of operating the equipment, and the meanings of the displays. 2.1 MACHINE MONITOR AA: Standard screen BB: All lamps lit up screen...

  • Page 71: Basic Operation Of Machine Monitor

    2.1.1 BASIC OPERATION OF MACHINE MONITOR [1] STARTING ENGINE WHEN SITUATION IS NORMAL GG: Opening screen DD: Check before starting screen HH: Working mode/Travel mode display screen AA: Standard screen • When the starter switch is turned to the ON position, the Opening screen GG is displayed. •...
  • Page 72 [3] IF THERE IS ABNORMALITY WHEN STARTING ENGINE DD: Check before starting screen CC: Maintenance interval warning screen AA: Standard screen EE: Error screen FF: Warning screen • If there is any abnormality when starting the engine, the Check before starting screen DD changes to the Maintenance interval warning screen CC, Warning screen FF, or Error screen EE.
  • Page 73 [4] IF ANY ABNORMALITY OCCURS DURING OPERATION AA: Standard screen EE: Error screen FF-(1): Warning screen FF-(2): Warning screen • If any abnormality OCCURS DURING OPERATION, the Standard screen AA changes to the Warning screen FF-(1) or the Error screen EE. •...
  • Page 74 NOTES The colours lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows. AA: Standard screen BB: All lamps lit up screen CC: Maintenance interval warning screen Color when lit up Type of monitor At low When normal...

  • Page 75: Emergency Stop Items

    2.1.2 EMERGENCY STOP ITEMS If the monitor lights up red, Stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up and buzzer sounds, perform action immediately.
  • Page 76 [2] HYDRAULIC OIL TEMPERATURE MONITOR This monitor (2) warns operator that the hydraulic oil temperature has risen. If the hydraulic oil temperature becomes abnormally high, the monitor shows abnormal display (C). Stop operations and stop the engine or run it at low idling until monitor (2) change to normal display (B).

  • Page 77: Caution Items

    2.1.3 CAUTION ITEMS If the warning monitor lights up red, Stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running. If any abnormality occurs, the screen displays the item that needs immediate action.
  • Page 78 [2] HYDRAULIC OIL TEMPERATURE MONITOR If this monitor (2) shows low-temperature display (A), carry out the warm-up operation. For details, see “Operation 3.4.2 Hydraulic Equipment Warm Up”. This monitor (2) will show normal display (B), so carry out the warm-up operation for hydraulic equipment. •...

  • Page 79: Basic Check Items

    2.1.4 BASIC CHECK ITEMS These monitor do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly. Displays basic items among the check before starting items that must be checked before starting the engine.

  • Page 80: Meter Display Portion

    2.1.5 METER DISPLAY PORTION PILOT DISPLAY GAUGE AND METER (1) Engine pre-heating monitor (10) Engine coolant temperature gauge (2) Swing lock monitor (11) Hydraulic oil temperature gauge (3) Wiper monitor (12) Fuel level gauge (4) Auto-deceleration monitor (13) Service meter/Clock (5) Working mode monitor (14) ECO gauge (6) Travel speed monitor...
  • Page 81 [2] SWING LOCK MONITOR This monitor (2) informs the operator that the swing lock is being actuated. Actuated: Lights up When the swing lock switch is turned ON (Actuated), the monitor lights up. When the swing parking brake release switch is set to the FREE position, the monitor flashes.
  • Page 82 [6] TRAVEL SPEED MONITOR This monitor (6) shows the setting for the travel speed. The monitor display is as follows according to the operation of the travel speed selector switch. • Monitor Lo: Low-speed travel • Monitor Hi: High-speed travel For detail of positions of the travel speed selector switch, see “Operation 1.2 Operator`s Compartment Equipment”.
  • Page 83 [GAUGE AND METER] [10] ENGINE COOLANT TEMPERATURE GAUGE This meter (10) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator goes beyond red range (A) during operations, the overheat prevention system is actuated. •...
  • Page 84 [11] HYDRAULIC OIL TEMPERATURE GAUGE This meter (11) shows the hydraulic oil temperature. During normal operations, the indicator should be in the green range. If the indicator enters the red range (A) during operations, the hydraulic oil temperature is 102 degrees C or more. Run the engine at low idling or stop it and wait for the hydraulic oil temperature to go down.
  • Page 85 [13] SERVICE METER/CLOCK This meter (13) shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 1 for every hour that the machine is working, regardless of the engine speed.

  • Page 86: Monitor Switches Portion

    2.1.6 MONITOR SWITCHES PORTION (1) Working mode selector switch (5) Window washer switch (2) Auto-deceleration switch (6) Buzzer cancel switch (3) Travel speed selector switch (7) Function switch (4) Wiper switch (8) Air conditioner switch [1] WORK MODE SELECTOR SWITCH Use this switch (1) to set the movement or power of the crane.
  • Page 87 [PROCEDURE FOR OPERATION] 1. If working mode selector switch (1) is pressed, the working mode screen is displayed on the monitor. 2. Press function switches (F3) or (F4) at the bottom of the screen or working mode selector switch (1) to change the mode selection one at a time.
  • Page 88 [2] AUTO-DESELERATION SWITCH If the control levers are neutral, this switch (2) automatically lowers the engine speed and returns on the function to reduce fuel consumption. • Monitor ON: Auto-deceleration ON • Monitor OFF: Auto-deceleration OFF Each time the switch is pressed, the auto-deceleration is switched between ON and OFF.
  • Page 89 [3] TRAVEL SPEED SELECTOR SWITCH • When loading or unloading the machine on a trailer, always travel at low speed (set to Lo). Never operate the travel speed selector switch when traveling. • If the travel speed selector switch is operated when the machine is traveling, the machine may deviate to one side even when it is traveling in a straight line.
  • Page 90 [4] WIPER SWITCH This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON→INT→STOP (OFF). • Monitor INT: Wiper operates intermittently • Monitor ON: Wiper operates continuously • Monitor OFF: Wiper stops NOTES Each time wiper switch (4) is pressed, the mode is displyed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen.
  • Page 91 [6] BUZZER CANCEL SWITCH This switch (6) is pressed, the warning buzzer for the abnormal warning item stops. [7] FUNCTION SWITCHES Function switches (7) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen. When the monitor display shows the standard screen, the functions are displayed as follows.

  • Page 92: Handling Function Switches

    2.1.7 HANDLING FUNCTION SWITCHES • The function switches (A) at the bottom of the monitor display consist of 6 switches (F1 – F6). The function of each switch differs according to the content of each screen. • The function of switches (A) on each screen can be confirmed by guidance icons (B) displayed on top of each switch.
  • Page 93 • It is possible to change the working mode by pressing the working mode selector switch. When the working mode is changed, the screen returns automatically to the camera image display screen. When this happens, the pilot monitor display at the top centre of the monitor screen is highlighted in yellow for 2 seconds, then returns to blue.
  • Page 94 [ACTION WHEN WARNING IS GENERATED WHEN DISPLAYING CAMERA IMAGE] • If an error or alarm occurs while the camera image is being displayed, the error monitor or alarm monitor is displayed at the top left of the screen and flashes. •...
  • Page 95 [2] SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH • On the standard screen, it is possible to press the function switch (F4) to switch the service meter and clock display at the top of the monitor display. • When the time is being displayed, press the function switch (F4) to switch to the service meter display.
  • Page 96 [OPERATIONS ON MAINTENANCE LIST SCREEN] On the maintenance list screen, it is possible to carry out the following operations with function switches (F1 to F6). • Switch (F1): Displays next page. After the last page, it displays the first page. •...
  • Page 97 [4] USER MODE SELECTOR SWITCH When the switch (F6) pressed, the monitor display screen switches to the setting mode screen for the machine. On the user menu screen, it is possible to carry out the following operations with function switches (F3 to F6). •...
  • Page 98 (c) Adjusting screen Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen. 1. On the standard screen, presses switch (F6). 2. Select screen adjustment on the user menu screen, then press switch (F6). The screen switches to the selection menu screen for screen adjustment.
  • Page 99 (d) Clock Adjustment On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard screen. 1. On the standard screen, presses switch (F6). 2. Select “Clock Adjustment” on the user menu screen, then presses the switch (f6).
  • Page 100 (3) When minute display (c) is highlighted in orange, operate the switches as follows to adjust minute display (c). (4) If it is not necessary to change the minute setting, press switch (F6). If the time has been changed, always press switch (F6).
  • Page 101 (e) Language selection On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. • Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian, Thai.
  • Page 102 (f) Adjusting Economy Mode With this economy mode, the engine output can be adjusted to improve the fuel consumption in economy mode. 1. On the standard screen, press switch (F6). 2. Select “Economy Mode Adjustment” on the user menu screen, then press switch (F6).

  • Page 103: Switches

    2.2 SWITCHES (1) Starter switch (9) Emergency pump drive switch (2) Fuel control dial (10) Swing parking brake release switch (3) Lamp switch (11) Moment limiter emergency stop cancel switch (4) Swing lock switch (12) Over-hoisting cancel switch (5) Sun roof wiper switch (13) Winch speed selector switch (6) Horn switch (14) Engine emergency switch...
  • Page 104 [1] STARTER SWITCH Always turn the starter switch to the OFF position after completing the work. Starting switch (1) is used to start or stop the engine. • OFF position: The starter key can be inserted or withdrawn. Switches for the electrical system (except room lamp), are all turned off and the engine is stopped.
  • Page 105 [3] LAMP SWITCH This switch (3) is used to light up the working lamp and monitor lighting. • (a) Night position: Lamps light up and monitor illumination is set to night mode. • (b) Day position: Lamps light up and monitor illumination is set to day mode.
  • Page 106 [7] CIGARETTE LIGHTER CAUTION This cigarette lighter is for 24V. Do not use it as the power source for 12V equipment. This cigarette lighter (3) is used when lighting cigarettes. When the cigarette lighter is pushed in, it will return to it‟s original position after several seconds, so pull it out to use it.
  • Page 107 [10] SWING PARKING BRAKE RELEASE SWITCH CAUTION This switch makes it possible to perform swing operations for a short time, even when there is a problem in the swing parking brake electric system. Do not use this switch except in emergencies.
  • Page 108 [11] MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH The moment limiter emergency stop cancel switch will temporarily disable the moment limiter function. While this switch is turned to ON position (i.e. released), calculation of the rated total load is stopped, thus the machine is in a very risky condition. When lifting operation is continued in this condition, it may result in dropping of the hoisted load or damage to the boom, and cause serious accidents such as overturning of the machine resulting in death or serious injury.
  • Page 109 [12] OVER-HOISTING CANCEL SWITCH • The Over-hoisting cancel switch cancels the auto-stop function of the over hoist detector. Operate the winch lever carefully when stowing the hook block. Pay sufficient attention not to let the hook block collide with the boom. •...
  • Page 110 [14] ENGINE EMERGENCY STOP SWITCH Use this switch (14) in case of an error in the machine to stop the engine for emergency. • ON position: Press the switch. The engine stops. • OFF position: Turn the switch clockwise (direction of the arrow in the right figure) or pull up knob of this switch.

  • Page 111: Control Levers And Pedals

    2.3 CONTROL LEVERS AND PEDALS (1) Lock lever (4) Right work equipment control lever (2) Travel levers (With auto-deceleration system) (With pedal and auto-deceleration system) (5) Blade control lever (3) Left work equipment control lever (6) Accelerator pedal (With auto-deceleration system) [1] LOCK LEVER •...
  • Page 112 [2] TRAVEL LEVERS • Do not rest your foot on the pedal. If you carry out operations with your foot on the pedal, the machine may suddenly start if pressure is applied by mistake to the pedal, and this may lead to serious personal injury. Be extremely careful when using the pedal for travel and steering operations, and do not put your foot on the pedal when it is not necessary.
  • Page 113 [3] WORK EQUIPMENT CONTROL LEVER • The control pattern of this machine is as indicated in the CONTROL PATTERN label, as below. When any user desires to change to any other pattern, please contact us, or our sales and service agency. •...
  • Page 114 [5] ACCELERATOR PEDAL The accelerator pedal should only be used to control the crane operation while the machine is stationed. During traveling operation, use of this pedal is strictly prohibited; otherwise it may cause an accident due to an operation error which may lead to serious personal injury. During traveling operation, always adjust the engine speed only by turning the fuel control dial.

  • Page 115: Moment Limiter (Overload Protector)

    2.4 MOMENT LIMITER (OVERLOAD DETECTOR) 2.4.1 MOMENT LIMITER CONFIGURATION (1) Boom length gauge (Boom left side) (2) Boom angle gauge (Boom left side) (3) Pressure sensor (Derrick cylinder) (2 places) (4) Over hoist detector (Boon tip side) (5) Working status lamp (A) Red lamp (Warning lamp for load factor of 100% or more) (B) Yellow lamp (Pre-warning lamp for load factor of 90 to 100%) (C) Green lamp (Working lamp for load factor of less than 90%)

  • Page 116: Function Of Moment Limiter

    2.4.2 FUNCTION OF MOMENT LIMITER • Do not remove, disassemble, or repair detectors. Do not move the detectors to another location from original position. • Should an object hit a detector or you find any damage on a detector, be sure to verify the actuation status of the auto stop.
  • Page 117 [2] DISPLAY OF THE MOMENT LIMITER ERROR MESSAGES The moment limiter performs self-diagnosis on the moment limiter display unit when an error is issued by the boom angle gauge, boom length gauge, pressure sensor, or when a circuit is opened or a connector is disconnected.

  • Page 118: Moment Limiter Operations

    2.4.3 MOMENT LIMITER OPERATIONS The moment limiter is a device for unexpected events. Operations relying on the device may rather incur danger. Pay sufficient attention during the operation not to cause auto-stop of the crane. [1] PROHIBITED ACTIONS AFTER AUTO STOP The following crane operations are prohibited after the crane has stopped automatically due to overloading.
  • Page 119 4. Recovery Operation from Auto Stop The recovery operation from overloading should be the reverse operation of the crane operation that caused the auto stop. Perform one of the followings. (1) Lower the hook and put down the hoisted load on the ground. (2) Raise the boom.

  • Page 120: Names Of Moment Limiter Display Unit

    2.4.4 NAMES OF MOMENT LIMITER DISPLAY UNIT (1) Load capacity display (17) Overwind detection LED (Red) (2) Actual load display (18) 1 fall LED (Green) (3) Rated total load display (19) 2 falls LED (Green) (4) Boom angle display (20) 4 falls LED (green) (5) Working radius display (21) Fly-jib length (1) LED (Orange) (6) Rated radius display...
  • Page 121 [1] DESCRIPTIONS OF SWITCHES ON MOMENT LIMITER DISPLAY UNIT 1. WIRE ROPE FALL MODE SELECTOR SWITCH AND WIRE ROPE FALL DISPLAY LED (GREEN) When entering the number of wire rope falls, verify the actual number of wire rope falls and make sure to set up correctly.
  • Page 122 3. BOOM ANGLE LOWER LIMIT SWITCH AND LED (GREEN) Use this switch to set or cancel the boom angle lower limit. [SETUP] With no lower limit value being set, set the boom to the angle you would like, and press the switch for 3 seconds or more. The boom angle at this point is set as the lower limit.
  • Page 123 5. LIFTING HEIGHT UPPER LIMIT SWITCH AND LED (GREEN) Use this switch to set or cancel the lifting height upper limit. While the lifting height is restricted by detecting the height of the tip of the boom, the lifting height on the display panel shows the lifting height when the hook was raised to the over hoist detection status.
  • Page 124 7. CHECK SWITCH Use this switch to verify the values set in the section 2 to 5 above. Keep pressing the switch for 3 seconds or more; then each value being set will flash for 5 seconds in the respective display section. (1) “Boom angle upper limit value”...
  • Page 125 [2] DESCRIPTIONS OF MOMENT LIMITER DISPLAY UNIT For LEDs not described in this section, see “Operation 2.4.4 Names of moment limiter display unit”. 1. ACTUAL LOAD DISPLAY SECTION This section constantly displays the actual load of the hoisted load during the crane operation. The actual load indicates the total weight of the hoisted load and lifting accessories increasing the hook weight.
  • Page 126 6. LIFTING HEIGHT DISPLAY SECTION This section constantly displays the current lifting height during the crane operation. The lifting height is the vertical distance from the ground to the bottom of the hook. 7. BOOM ANGLE DISPLAY SECTION This section constantly displays the current boom angle during the crane operation.
  • Page 127 11. FLY-JIB ANGLE DISPLAY This section constantly displays the current fly-jib angle during the crane operation with the fly-jib configuration. The fly-jib angle is the angle that the fly-jib and the main boom form. NOTES Refer to the "FLY-JIB" for details of the fly-jib installation and it‟s angle setting.

  • Page 128: Moment Limiter Functions

    2.4.5 MOMENT LIMITER FUNCTIONS [1] OVERLOAD WARNING 1. SAFETY ZONE (“Actual load” is less than 90 % of the “rated total load”) • Green of the working status lamp lights up. • The LEDs lights up in green if the load factor is less than 80 %.
  • Page 129 [3] OVER HOIST DETECTOR CAUTION Pay attention to the distance between the hook and boom when raising the hook. Extending the boom also raises the hook. Always check the hook height when extending the boom. When you overwind the hook when raising the hook or extending the boom, •...

  • Page 130: Moment Limiter Starting Status

    2.4.6 MOMENT LIMITER STARTING STATUS The moment limiter checks it‟s function for approx. 3 seconds when the starter switch is turned to the ON position. Meanwhile, • All the working status lamps light up. • All the LEDs light up. Then, if the moment limiter and the sensors are normal upon the completion of the functional check of the moment limiter, the red and yellow of the working status lamp goes off and green of the working status lamp lights up indicating that the machine is ready for use.

  • Page 131: Pick & Carry/Staitionary Mode Select

    2.4.8 PICK & CARRY/STAITIONARY MODE SELECT Pick and carry operation is a very dangerous practice and prohibited, in genreal. Where such an operation is unavoidable, refer to "Operation 3.25 Pick & Carry Operation" and strictly observe rated total laod for pick and carry operation, correct practices and traveling posture.

  • Page 132: Moment Limiter Emergency Stop Cancel Switch

    2.4.9 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH The moment limiter emergency stop cancel switch will temporarily disable the moment limiter function. While this switch is turned to ON position (i.e. released), calculation of the rated total load is stopped, thus the machine is in a very risky condition. When lifting operation is continued in this condition, it may result in dropping of the hoisted load or damage to the boom, and cause serious accidents such as overturning of the machine resulting in death or serious injury.

  • Page 133: Moment Limiter Error Causes And Actions To Be Taken

    2.4.10 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO BE TAKEN The moment limiter displays an error code at the “rated total load” display section on the display panel to notify the error. If an error code shown in the table below was displayed, contact us or our sales service agency. Error Code Error Details Actions to Be Taken...

  • Page 134: Over Hoist Detector

    2.5 OVER HOIST DETECTOR CAUTION Pay attention to the distance between the hook block and the boom when raising the hook block. The hook block also raises when the boom is extended. Always check the height of the hook block when performing the boom extending operation. (1) Hook block (2) Over hoist detector (3) Weight...

  • Page 135: Air Conditioner Controls

    2.6 AIR CONDITIONER CONTROLS 2.6.1 AIR CONDITIONER CONTROL PANEL (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch [1] OFF SWITCH This switch (1) is used to stop the fan and air conditioner.
  • Page 136 [2] FAN SWITCH This switch (2) is used to adjust the air flow. The air flow can be adjusted to 6 levels. • Press the switch to increase the air flow, press the switch to decrease the air flow. • During auto operation, the air flow is automatically adjusted. [Monitor display and air flow] Liquid crystal display Air flow...
  • Page 137 [4] VENT SELECTOR SWITCH This switch (4) is used to select the vents. • When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. • During automatic operation, the vents are automatically selected. •...
  • Page 138 [6] FRESH/RECIRC SELECTOR SWITCH This switch (6) is used to switch the air source between recirculation of the air inside the cab and intake of fresh air from the outside. • During automatic operation, the selection of inside air (RECIRC) and outside air (FRESH) is performed automatically.

  • Page 139: Air Conditioner Operation Method

    2.6.2 AIR CONDITIONER OPERATION METHOD The air conditioner can be operated automatically or manually. Select the method of operation as desired. [1] AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed. 2.
  • Page 140 [3] MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and airflow (b) are displayed on monitor (7) 2. Turn air conditioner switch (8) ON. 3. Press temperature control switch (3) and adjusts temperature inside the cab.
  • Page 141 [5] OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
  • Page 142 [6] DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and airflow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the below.

  • Page 143: Use Air Conditioner With Care

    2.6.3 USE AIR CONDITIONER WITH CARE CAUTION • When running the air conditioner, always start with the engine running at low speed. Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner.

  • Page 144: Radio

    2.7 RADIO 2.7.1 CONTROL PANEL (1) Power switch, Volume control knob, balance (5) AS/PS button control knob (6) Preset station buttons (1.2.3.4.5.6) (2) SEL button (7) Display (3) FM/AM selection button (8) Time reset button (4) Display selection button (9) Tuning button [1] POWER SWITCH, VOLUME CONTROL KNOB, BALANCE CONTROL KNOB Press the knob (1) to turn the power for the radio ON.
  • Page 145 [4] DISPLAY SELECTION BUTTON (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the preset time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.

  • Page 146: Control Of Radio

    2.7.2 CONTROL OF RADIO [1] METHOD OF SETTING WITH PRESS BUTTON 1. Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning. 3.
  • Page 147 [3] METHOD OF OPERATING MODE • (BAS) Bass adjusting When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.

  • Page 148: Use Radio With Care

    2.7.3 USE RADIO WITH CARE • To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation. • Take care for a risk that hearing impairment may appear after lengthy hearing the radio in a high volume. •...

  • Page 149: Fuse

    2.8 FUSE Be sure to turn the starter switch to the OFF position when checking or replacing a fuse. CAUTION Fuses protect electrical components and wires from being burnt out. • Fuses are blade fuses. If a fuse was corroded and shows white powder, be sure to change the fuse.

  • Page 150: Fusible Link

    2.9 FUSIBLE LINK Be sure to turn the starter switch to the OFF position when checking or replacing a fusIble link. CAUTION A fusible link refers to the large-sized fuse wiring installed in the high current flow portion of the circuit to protect electrical components and wiring from burning, in the same way as an ordinary fuse.

  • Page 151: Controllers

    2.10 CONTROLLERS CAUTION • Do not let water, mud, or any liquid spill on the controller. This will cause failures. • If any problem occurs in the controller, do not repair it yourself. Please contact us or our sales service agency. [1] CHASSIS CONTROLLER The chassis controller is installed inside the rear cover at the rear of the operator‟s cab.

  • Page 152: Windshield

    2.11 WINDSHIELD • When opening or closing the front winsow, bottom window, or door, always set the lock lever to the LOCK positon. If the lock lever is at the FREE positon and the control levers or control pedals are touched by mistake, this may lead to a serious accident. •...
  • Page 153 5. Hold lower knob (C) with your left hand from inside the operator‟s cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. 6.
  • Page 154 4. Grip handle (C) at the bottom of the front window with your left hand and handle (D) at the top with your right hand, push to the front, then lower slowly. 5. When the bottom of the window reaches the top of the lower window, push the top or the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock.
  • Page 155 [3] REMOVING LOWER WINDSHIELD 1. Open the front window, then hold grip (1), pull up, and remove the bottom window. 2. After removing the bottom window, store it at the rear of the operator‟s cab and lock it securely with lock (2). The procedure for stowing is as follows.

  • Page 156: Sliding Door

    2.12 SLIDING DOOR • Be sure to check that the sliding door is locked in position both when it is open and when it is closed. • Always stop the machine on level ground when operating or closing the door. If the door is opened or closed on a slope, there is danger that the operating effort will suddenly change.

  • Page 157: Cap With Lock

    2.14 CAP WITH LOCK • Use the starter switch key to open and close the locks on the caps and covers. • Insert the key as far as it will go to the shoulder (A). If the key is turned before it is inserted all the way, it may break. •...

  • Page 158: Engine Hood

    2.15 ENGINE HOOD • When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open. • Always keep the engine hood locked except when opening it. 1. Release lock (1) of the engine hood. For details, see “Operation 2.14 Cap with Lock [2] Opening and Closing Covers with Lock”.

  • Page 159: Pump Room Door

    2.17 PUMP ROOM DOOR • When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. • Always keep the door locked except when opening it. 1. Release lock (1) of the door. For details, see “Operation 2.14 Cap with Lock [2] Opening and Closing Covers with Lock”.

  • Page 160: Door At Front Of Tool Box

    2.19 DOOR AT FRONT OF TOOL BOX • When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. • Always keep the door locked except when opening it. 1. Release lock (1) of the door. For details, see “Operation 2.14 Cap with Lock [2] Opening and Closing Covers with Lock”.

  • Page 161: Grease Pump Holder

    2.22 GREASE PUMP HOLDER Open the door at the front of the tool box. The compartment is inside. Pass the nozzle through the hole at the end, and push the grease gun holder fully in store it. 2.23 CUP HOLDER This is on the left side of the operator‟s cab.

  • Page 162: Wind-In Type Seat Belt

    2.25 WIND-IN TYPE SEAT BELT • Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn of damaged, replace the seat belt. • Even if no problem can be seen in the belt, replace the seat belt every 3 years. The date of manufacture of the belt is shown on the back of the belt.

  • Page 163: Machine Operations And Controls

    3. MACHINE OPERATIONS AND CONTROLS 3.1 CHECKING BEFORE OPERATION 3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) • This machine has a diesel engine. If it smells of fuel around the engine, the fuel may be leaking. Carefully check for cracks on the fuel hose or fuel hose connections. •...
  • Page 164 [1] CHECKING AROUND CRANE • Look around and below the boom and boom mounting and look for any oil leak or similar. Be especially careful to check the derrick cylinder and lower part of the winch motor. If you find any abnormality, repair •...
  • Page 165 [4] CHECKING AROUND UPPER STRUCTURE • Check for fuel, oil or water leaking from the engine. If you find any abnormality, repair it. • Check the hot engine sections such as the engine muffler and around the battery for the buildup and deposit of combustibles such as dead leaves, paper wastes, dust, oil, and grease.

  • Page 166: Checking Before Starting Engine

    3.1.2 CHECKING BEFORE STARTING ENGINE Check the followings in this section without starting the engine and before starting the first work every day. [1] CHECKING/REFILLING ENGINE COOLANT • Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
  • Page 167 [2] CHECKING/REFILLING OIL LEVEL IN ENGINE OIL PAN Parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the oil temperature to go down before performing this operation. CAUTION • See “Maintenance 7.1 Use of Lubricating Oil According to Temperature” for which oil to be used.
  • Page 168 [3] CHECKING/REFUELING FUEL LEVEL IN FUEL TANK • Be extremely careful with fire such as cigarette. • Be sure to stop the engine when refueling. If refueling is done with the engine in operation, the fuel spilled on the section where it gets hot such as muffler can catch fire. •...
  • Page 169 [4] CHECKING/REFILLING OIL LEVEL IN HYDRAULIC OIL TANK • Parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the oil temperature to go down before performing this operation. • When removing the oil filler cap, turn it slowly to release the internal pressure, and then remove it.
  • Page 170 6. If the oil level is below the L line, remove the cover (1) at the top of the hydraulic oil tank, and then add oil through oil filler (F). CAUTION Do not add oil above the H line. This will damage the hydraulic circuit or cause the oil to spurt out.
  • Page 171 [6] CHECKING FOR WATER, SEDIMENT IN WATER SEPARATOR, DRAIN WATER • The water separator has fuel (diesel oil) inside. Be extremely careful of fire such as cigarette when cleaning the water separator transparent cap. • If the fuel spills when the water separator is removed, thoroughly wipe it off. CAUTION •...
  • Page 172 [Adjustment of Drain Valve] If drain valve (4) is stiff, coat the O-ring portion of the drain valve (4) with grease to make the movement smooth. 1. Set valve (5) at the side of fuel pre-filter cartridge (1) to the shut off position (S).
  • Page 173 [8] CHECKING ELECTRICAL WIRING • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask us or our sales service agency to locate the cause and make the repair. • Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
  • Page 174 [11] ADJUSTING OPERATOR’S SEAT • Adjust the operator’s seat position before starting operations or after changing the operator. • Adjust the operator’s seat so that the control levers, acelerator pedal, and switches can be operated freely and easily with the operator back against the backrest. •...
  • Page 175 [D] Adjusting Armrest Angle Armrest (4) can be made to spring up by hand approx. 90 degrees. In addition, by turning the dial (5) at bottom of armrest by hand it is possible to make fine vertical adjustment of the armrest angle. Armrest adjusting angle: 25 degrees NOTES If the seat back is tipped to the front without raising the armrest (4), the armrest will rise automatically.
  • Page 176 [Mirror (B)] Position of this mirror should be adjusted so that a person standing in the right-front end of the machine is visible. • Fix the mirror as shown in the figure in the right. Dimension (F): 454 mm • When fine adjustment of the mirror is not easy, loosen the bolt (4) for the mirror or bolt (5) for stay mount for easy movement.
  • Page 177 [Mirror (D)] Position of this mirror should be adjusted so that a person standing in the right side of the machine is visible. • Fix the mirror as shown in the figure in the right. • When fine adjustment of the mirror is not easy, loosen the bolt (8) for the mirror or bolt (9) for stay mount for easy movement.
  • Page 178 [14] ADJUSTING ANGLE OF REAR VIEW CAMERA If the image on the monitor is not aligned correctly, remove cover (1) and adjust the mounting angle (A) of the rear view camera. Amount of adjustment of angle (A): Within a range of 35 to 80 degrees 1.

  • Page 179: Checking After Starting Engine

    3.1.3 CHECKING AFTER STARTING ENGINE Check the followings in this section after starting the engine and before starting the first work every day. CAUTION The checkups described in this section should be carried out after starting the machine. Refer to "Operation 3.2 Operation and Checks After Starting Engine" and later to execute the engine startup, traveling operations, and crane operations.
  • Page 180 [4] CHECKING CRANE OPERATIONS Be sure to refer to the Operation sections between "3.15 Cautions before Crane Operation" and "3.23 Crane Stowing Operation", and strictly observe the methods described and cautions given when checking crane operations. 1. Verify that the boom rises smoothly when the right work equipment control lever is operated to "RAISE"...
  • Page 181 [5] CHECKING OVER HOIST DETECTOR FOR OPERATION Over hoist the hook block (1), and raise the hook with winch and extend the boom, and verify that the buzzer sounds intermittently, the hook raising operation and boom extending operation stop. If these events do not happen, the over hoist detector (2) may be faulty.

  • Page 182: Operations Before Engine Starting

    3.2 OPERATIONS BEFORE STARTING ENGINE When starting the engine, check that the lock lever is securely at the LOCK position. If the lock lever is not locked securely and the control levers or control pedals are touched when the engine is started, the machine may move unexpectedly, and this may lead to serious personal injury.
  • Page 183 (1) The buzzer sounds for approx. 2 seconds, and then the monitor or meter lights up for approx. 2 seconds. • Charging level monitor (4) • Engine oil pressure monitor (5) • Engine oil level monitor (6) • Engine oil temperature gauge (7) If any monitor does not light up or buzzer does not sound, there is probably a failure in the monitor, so please contact us or our sales service agency.

  • Page 184: Starting Engine

    3.3 STARTING ENGINE Never refuel (diesel oil) while the engine is in operation. Always stop the engine when refueling. 3.3.1 NORMAL STARTING ENGINE • Sit down in the operator’s seat before starting the engine. • Do not attempt to start the engine by short-circulating the engine starting circuit. Such an act may cause serious bodily injury or fire.
  • Page 185 4. When the engine starts, release the key in starter switch (3). The key will automatically return to ON position. 5. Keep the engine idle for the initial 15 seconds right after it has been started, and do not operate any control lever or the fuel control dial during that time.

  • Page 186: Starting Engine In Cold Weather

    3.3.2 STARTING ENGINE IN COLD WEATHER • Sit down in the operator’s seat before starting the engine. • Do not attempt to start the engine by short-circulating the engine starting circuit. Such an act may cause serious bodily injury or fire. •...
  • Page 187 5. When engine preheating monitor (4) goes OFF, turn the key in starter switch (3) to the START position to start the engine. 6. When the engine starts, release the key in starter switch (3). The key will automatically return to ON position. 7.

  • Page 188: Operations After Starting Engine

    3.4 OPERATIONS AFTER STARTING ENGINE Never refuel (diesel oil) while the engine is in operation. Always stop the engine when refueling. • To stop the engine in emergencies or when the actuation of the engine is abnormal or there is any other trouble, turn the key in the starter switch to the OFF position.
  • Page 189 After the engine starts, do not start operating the machine immediately. First, carry out the following operations and checks. 1. Wait until the automatic warm-up operation is cancelled. If the engine water temperature goes above 30 degrees C or if the warm-up operation has been continued for more than 10 minutes, the automatic warm-up operation is cancelled and the engine speed drops to the normal low idling speed.

  • Page 190: Hydraulic Equipment Warm-Up

    3.4.2 HYDRAULIC EQUIPMENT WARM-UP • Before carrying out the warming-up operation for the hydraulic equipment, turn the swing lock switch ON, check on the monitor that the swing lock is actuated, then start the warming-up operation. • When warming up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation.
  • Page 191 4. Set lock lever (3) slowly to the FREE position (F). 5. For details of the before starting operation of the crane, see “Operation 3.16 Operation of Before Crane Operations” and “Operation 3.17 Crane Operation Posture”. 6. Turn fuel control dial „4) to a point midway between low idling (MIN) and full speed (MAX).
  • Page 192 12. Check that hydraulic oil temperature monitor (7) is displaying the correct temperature. • (A) Display when temperature is correct: Monitor background (C) is blue. • (B) Display when temperature is low: Monitor background (C) is white. If the hydraulic temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 7 to 11 until the display is the correct temperature.
  • Page 193 16. Turn fuel control dial (4) to the full speed (MAX) position, repeat Steps 7 to 10 for 3 to 5 minutes, then check again that the hydraulic oil temperature monitor is displaying the correct temperature. If it is not displaying the correct temperature, repeat Steps 7 to 10 for 3 to 5 minutes until hydraulic oil temperature monitor (7) displays the correct temperature.
  • Page 194 • Blade operation: LOWER (a) to/from RAISE (b) 19. Check that hydraulic oil temperature monitor (7) is displaying the correct temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 7 to 10 until the display is the correct temperature. •...

  • Page 195: Operation After Completion Of Warm-Up Operation

    3.4.3 OPERATION AFTER COMPLETION OF WARM-UP OPERATION 1. Check that hydraulic oil temperature monitor (7) displays the correct temperature. • (A) Display when temperature is correct: Monitor background (C) is blue. • (B) Display when temperature is low: Monitor background (C) is white.

  • Page 196: Stopping Engine

    3.5 STOPPING ENGINE CAUTION • If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do not stop the engine abruptly except in an emergency. • If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually, and then stop it.

  • Page 197: Breaking-In Machine

    3.6 BREAKING-IN MACHINE Perform breaking-in for the period of about the first 100 hours (hours displayed on the service meter). The life of the machine shortens if overloaded operation or task is performed before the various sections of the machine are used to the operation. During the period of normal collaboration, do not allow overload servicing or operation, otherwise, it may affect the performance or life of the machine.

  • Page 198: Machine Traveling Posture

    3.7 MACHINE TRAVELING POSTURE • When moving this machine self-propelled, take the “traveling posture” with which the boom and hook block are stowed. • Traveling or pick & carry with the boom extended is essentially prohibited. This will overturn the machine, causing serious injury accidents. •...

  • Page 199: Starting/Moving/Stopping Machine

    3.8 STARTING/MOVING/STOPPING MACHINE • Before operating the travel lever or travel pedal, check the direction that the track frame is facing. When the track frame is facing the rear (when the sprocket is at the front), the direction of operation of the travel lever and travel pedal is the opposite to the direction of movement of the machine (forward/reverse, left/right).
  • Page 200 [1] MOVING MACHINE FORWARD] 1. Set lock lever (4) to the FREE position (F). 2. Operate blade control lever toward you to raise the blade. 3. Operate right and left travel levers (5) or right and left travel pedals (6) as follows. •...
  • Page 201 [2] MOVING MACHINE BACKWARD] 1. Set lock lever (4) to the FREE position (F). 2. Operate blade control lever toward you to raise the blade. 3. Operate right and left travel levers (5) or right and left travel pedals (6) as follows. •...

  • Page 202: Steering Machine

    3.9 STEERING MACHINE Before operating the travel lever or travel pedal, check the direction that the track frame is facing. When the track frame is facing the rear (when the sprocket is at the front), the direction of operation of the travel lever and travel pedal is the opposite to the direction of movement of the machine (forward/reverse, left/right).
  • Page 203 [3] COUNTER-ROTATION TURN (SPIN TURN) When using counter-rotation (spin turn) to turn left, pull the left travel lever back and push the right travel lever forward. NOTES When using counter-rotation (spin turn) to turn right, pull the right travel lever back and push the left travel lever forward. 3-139...

  • Page 204: Swinging

    3.10 SWINGING • The rear of the machine extends outside the track width. Before swinging, check with the rear view monitor and mirror, and also check visually that the surrounding area is safe. • Before swinging the machine off, check that the area around the machine is safe, and sound the horn •...

  • Page 205: Parking Machine

    3.11 PARKING MACHINE • Parking the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the blade into the ground surface to stop the machine from moving. •...

  • Page 206: Machine Inspection After Daily Work

    3.12 MACHINE INSPECTION AFTER DAILY WORK 3.12.1 BEFORE STOPPING ENGINE Use the machine monitor to check engine coolant temperature (1), engine oil pressure (2), and fuel level (3). 3.12.2 AFTER STOPPING ENGINE 1. Walk around the machine and check the crane, machine exterior, and undercarriage, also check for any leakage of oil or coolant.

  • Page 207: Cautions In Traveling

    3.13 CAUTIONS IN TRAVELING Not observing these cautions in traveling will result in serious accidents. [1] CAUTIONS IN TRAVELING Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine.
  • Page 208 [4] CAUTIONS ON SLOPE TRAVELING • For slope traveling, take care of overturning or drifting. • At the leaning of 15 degrees or more of the machine in a slope, the incline detector actuates and it triggers a buzzer. When the buzzer sounds, stop traveling and change to a safer path.

  • Page 209: Working Mode Operation

    3.14 WORKING MODE OPERATION Use working mode selector switch (1) to select the working mode that matches the operating conditions or purpose. This will make it possible to carry out operations efficiently. Use the following procedure to select the most efficient working mode. When the starter switch is turned ON, the working mode is set to the mode that was in operation when the starter switch was last turned OFF.

  • Page 210: Cautions Before Crane Operation

    3.15 CAUTIONS BEFORE CRANE OPERATION Not observing these cautions before operation may result in serious accidents. • Always go for a level ground to station the machine for crane operations. Once the machine is stationed, check the level to secure the machine status. The moment limiter computes moment subject to the machine being correctly leveled.

  • Page 211: Operations Before Crane Operation

    3.16 OPERATIONS BEFORE CRANE OPERATION Boom extending or raising while the hook block is secured to the wire rope for stowage may damage the wire rope or the regular hook block stowage section in the front of the upper structure. Always lower the hook block at the same time, to avoid excessive tension to the stowage wire rope.
  • Page 212 6. Repeat the practices of 4. and 5. above alternately, so that the boom is slowly raised to the position where the hook block (4) comes perpendicular to the stowage position in the front of the crane upper structure. When the hook block is released from the stowage position before the boom is sufficiently raised to correct position, the hook block may swing badly and cause machine damage or serious injury to persons.

  • Page 213: Crane Operation Posture

    3.17 CRANE OPERATION POSTURE To start the crane operation, following "Operation 3.16 Preparation for Crane Operation", set to the crane operation posture as below: Operate the right work equipment control lever to HOOK RAISING position (pull backward) so that the hook block (4) is hoisted.

  • Page 214: Hook Raising/Lowering Operation

    3.18 HOOK RAISING /LOWERING OPERATION • With the boom deflection, the hoisted load slightly shifts forward. Notify the workers around such as slinging operators. • If the hook block was hoisted too much, the over hoisting will be detected. The alarm buzzer sounds will be heard.

  • Page 215: High Speed Hook Raising/Lowering Operation

    3.18.2 HIGH SPEED HOOK RAISING/LOWERING OPERATION • Use the high-speed winching only in the no-load condition where a hoisted load is not present. Raising/Lowering the hoisted load in the high-speed mode may cause machine damage or serious accidents such as overturning of the machine or dropping of the load, resulting in death or serious injury.

  • Page 216: Hook Raising/Lowering Operation By Over-Hoisting Cancel Switch

    3.18.3 HOOK RAISING/LOWERING OPERATION BY OVER-HOISTING CANCEL SWITCH • The Over-hoisting cancel switch cancels the auto-stop function of the over hoist detector. Operate the right work equipment control lever carefully when stowing the hook block. Pay sufficient attention not to let the hook block collide with the boom. •...

  • Page 217: Boom Derricking Operation

    3.19 BOOM DERRICKING OPERATION • Operate the right work equipment control lever as slowly as possible. Sudden lever operation especially while hoisting a load will cause the load to swing, giving a great impact to the machine, and thus may break the crane or overturn the machine.

  • Page 218: Boom Telescoping Operation

    3.20 BOOM TELESCOPING OPERATION • Operate the left working equipment control lever as slowly as possible. Sudden lever operation especially while hoisting a load will cause the load to swing, giving a great impact to the machine, and thus may break the crane or overturn the machine. •...

  • Page 219: Slewing Operation

    3.21 SLEWING OPERATION • Check the safety around and honk the horn before slewing. • Operate the left work equipment control lever as slowly as possible. Start smoothly, slew at low speed, and stop gently. Sudden lever operation especially while hoisting a load will cause the load to swing, causing the loss of stability in the machine, and thus may break the crane or overturn the machine.

  • Page 220: Acceleration Operation

    3.22 ACCELERATION OPERATION • It is a dangerous excercise to operate each crane functions un-necessarily fast. Regulate the operation to the adequate speed for each operation. • The accelerator pedal should only be used to control the crane operation while the machine is stationed.

  • Page 221: Stowage Operation Of Crane

    3.23 STOWAGE OPERATION OF CRANE 3.23.1 CRANE OPERATION FOR TEMPORARY HOOK BLOCK STOWAGE • The Over-hoisting cancel switch cancels the auto-stop function of the over hoist detector. Operate the right work equipment control lever carefully when stowing the hook block. Pay sufficient attention not to let the hook block collide with the hook block temporary stowage position in the boom.
  • Page 222 3. On each occasion that the hook block nearly reaches the ground as a result of practice in 3.1. and 2. above, operate the right work equipment control lever to HOOK RISING (pull backward) position and raise the hook block within an extent that over winding can be avoided.
  • Page 223 NOTES The figure in the right shows the correct condition where the hook block (4) is properly stowed below the boom tip. 3-159...

  • Page 224: Crane Operation For Regular Hook Block Stowage

    3.23.2 CRANE OPERATION FOR REGULAR HOOK BLOCK STOWAGE • For hook block stowage operation, use both the left and right work equipment control levers most carefully. Otherwise, the hook block may shake badly and damage objects around or cause serious accidents resulting in death or serious injury. •...
  • Page 225 5. Remove the wire rope (5) for the hook block stowage from the hanger (6). 6. Fasten the hook block (4) to wire rope (5) for the hook block stowage. 7. Operate the right work equipment control lever (2) to BOOM LOWERING (push outside) position and lower the boom until it stops.

  • Page 226: Dos And Don'ts During Operation

    3.24 DO’S AND DON’TS DURING OPERATION • Prior to the crane operation, always place the machine on level and solid ground. Use the level to ensure this. • In the event that a crane operation during traveling is un-avoidable, always stop traveling first, then carry out the crane operation.
  • Page 227 [6] DON’T USE FOR OTHER THAN MAIN APPLICATIONS Do not move people up/down with the crane. [7] DON’T PERFORM UNREASONABLE OPERATIONS Operations requiring more than the machine performance can cause accidents. Particularly, crane operations must be carried out according to the rated total load chart.

  • Page 228: Pick& Carry Operation

    3.25 PICK& CARRY OPERATION 3.25.1 SAFETY RRECAUTIONS FOR PICK & CARRY OPERATION Pick and carry operation is a very unstable and dangerous practice; it is prohibited, in genreal. Where such an operation is un-avoidable, strictly adhere the limits in the "Rated total load table for pick and carry operation"...

  • Page 229: Posture For Pick & Carry Operation

    3.25.2 POSTURE FOR PICK & CARRY OPERATION • During pick and carry operations, keep the machine in "posture for pick and carry operation" as below: • Retract the boom to "10.5 meters" (3 sections) or less. • Swing the upper structure to the front and fix the boom at the center position. •...

  • Page 230: Pick & Carry Operation

    3.25.3 PICK & CARRY OPERATION • Refer to "Operation 3.25.1 Safety Precautions for Pick and Carry Operation" and always take care for the safety operation as provided. • Crane operations during traveling are strictly prohibited. The machine may overturn. • Always be seated in the operator's compartment during a pick and carry operation and exercise it most carefully.

  • Page 231: Precaution Of Blade Operation

    3.26 OPERATION OF BLADE 3.26.1 PRECAUTION OF BLADE OPERATION [BASIC POSTURE OF THE BLADE] • Always clear the Blade from the ground during the hoisting operation. Failure to do so may result a serious hazard including damaging the machine or it’s tipping over. •...
  • Page 232 3.26.2 OPERATION OF BLADE • Always clear the Blade from the ground during the hoisting operation. Failure to do so may result a serious hazard including damaging the machine or it’s tipping over. • Avoid ground leveling operations at the same time as hoisting operations. Otherwise, it may cause a serious hazard including damaging the machine or it’s tipping over.

  • Page 233: Handling Wire Ropes

    4. HANDLING WIRE ROPES 4.1 BENCHMARK FOR REPLACING WIRE ROPES CAUTION • The benchmark for replacing wire ropes is common to all the wire ropes for winching, telescoping the boom, and slinging. • Measure the wire rope diameter at the section where the rope repeatedly passes through the sheave.

  • Page 234: Winch Wire Rope Fall Mode And Rated Total Load

    4.2 WINCH WIRE ROPE FALL MODE AND RATED TOTAL LOAD Number of wire rope falls of the hook block shall be determined based on the load to be hoisted, boom length and winching speed. The load to one wire rope fall must be within "1500 kg" . The table below shows the hook block types, wire rope falls and the rated total load in each condition: For 2 or 4 Falls For 2 or 4 Falls...

  • Page 235: What To Do With Twisted Winch Wire Rope

    4.3 What TO DO WITH TWISTED WINCH WIRE ROPE Be sure to wear a pair of thick leather working gloves when handling wire ropes. CAUTION Change the hooking direction of the wire rope (reverse the hook block side and winch drum side) from time to time to extend the life of the wire rope.

  • Page 236: Transportation

    5. TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. 5.1 LOADING/UNLOADING • See "Specifications 1.1 Specification List " in the Dimension for the dimensions and mass of the machine. • Select and use the ramp boards that satisfy the following conditions. •...

  • Page 237: Loading

    5.1.1 LOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks under the tires to prevent the trailer from moving. 3. Secure the ramp boards in a way that the center of the trailer and the machine match. NOTES •...
  • Page 238 10. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer. 11. Align the direction of travel with the ramps and travel slowly. When on the ramps, operate only the travel.

  • Page 239: Securing Machine

    5.1.2 SECURING MACHINE CAUTION Stow the radio antenna. Reassemble the mirrors so that they are within the width of the machine. After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1. Operate blade control lever to lower the blade. 2.

  • Page 240: Unloading

    5.1.3 UNLOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks under the tires to prevent the trailer from moving. 3. Secure the ramp boards in a way that the center of the trailer and the machine match. NOTES •...

  • Page 241: Lifting Machine

    5.2 LIFTING MACHINE 5.2.1 LIFTING UP THE MACHINE IN THE BOOM LOWERED POSTURE • See "Specifications 1.1 Specification List " in the Dimension for the dimensions and mass of the machine. • The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
  • Page 242 6. Pass wire ropes between the 1st and 2nd track rollers from the front and between the 1st and 2nd track rollers from the rear. 7. Put blocks between the wire rope and the machine to prevent damage to the rope or machine. 8.

  • Page 243: Lifting Up The Machine In The Boom Raised Posture

    5.2.2 LIFTING UP THE MACHINE IN THE BOOM RAISED POSTURE • See "Specifications 1.1 Specification List " in the Dimension for the dimensions and mass of the machine. • The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.

  • Page 244: Transportation Procedure

    7. Fix shackles to 2 brackets in the left and right sides of the crane frame, then attach the slinging wire ropes. NOTES Apply appropriate pads to the locations in which the slinging wire rope may touch the machine, prior to lifting up. 8.

  • Page 245: Handling In Cold Weather

    6. HANDLING IN COLD WEATHER 6.1 PREPARING FOR LOW TEMPERATURE When the temperature goes down, the machine may start to have some difficulty in starting. Take the following actions. [1] LUBRICATION Change the oil to one with a low viscosity. See “Maintenance 7.1 Use of Lubricating Oil According to Temperature”...
  • Page 246 [3] BATTERY • The battery generates flammable gas. Do not bring fire or sparks near the battery. • Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. •...

  • Page 247: Long-Term Storage

    7. LONG TERM STORAGE 7.1 BEFORE STORAGE MACHINE CAUTION The machine shall take the posture shown in the figure on the right during the long-term storage to protect the cylinder rod. See “Operation 3.7 Machine Traveling Posture” for traveling posture. (To prevent rust on the cylinder rod) The custody practice for one month or longer, shall be as follows: •...

  • Page 248: Troubles And Actions

    8. TROUBLES AND ACTIONS 8.1 RUNNING OUT FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. [PROCEDURE FOR BLEEDING AIR] 1. Loosen the knob (1) of feed pump, pull it out, and then pump it in and out until the movement becomes heavy.

  • Page 249: Discharged Battery

    8.4 DISCHARGED BATTERY 8.4.1 CAUTIONS IN BATTERY HANDLING • It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. • When checking or handling the battery, stop the engine and turn the starter switch key to the OFF position.

  • Page 250: Battery Removal And Installation

    8.4.2 BATTERY REMOVAL AND INSTALLATION CAUTION After securing the battery, check that it does not move. If it moves, tighten it again securely. [REMOVAL] 1. Open the battery room door, then move vinyl cover (1) (installed on top of the battery). 2.

  • Page 251: Cautions In Battery Charging

    8.4.3 CAUTIONS IN BATTERY CHARGING When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of “Operation 8.4.1 Cautions In Battery Handling" and the instruction manual accompanying the charger, and do as follows. •...

  • Page 252: Starting Engine With Booster Cable

    8.4.4 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows. [1] PRECAUTIONS FOR CONNECTING AND DISCONNECTING BOOSTER CABLE • When connecting the cables, never contact the positive (+) and negative (-) terminals. • When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
  • Page 253 [3] STARTING ENGINE Always check that the lock lever is set to the LOCK position, regardless of whether the machineisworking normal or has failed. Check also that all the control levers are at the HOLD or NEUTRAL position. 1. Make sure the clips are firmly connected to the battery terminals. 2.

  • Page 254: Other Trouble

    8.5 OTHER TROUBLE 8.5.1 ELECTRICAL SYSTEM • : Always contact us or our sales service agency when dealing with these items. • In causes of problems or causes which are not listed blow, contact us or our sales service agency for repairs.

  • Page 255: Chassis

    8.5.2 CHASSIS • : Always contact us or our sales service agency when dealing with these items. • In causes of problems or causes which are not listed blow, contact us or our sales service agency for repairs. Problem Main causes Remedy •...

  • Page 256: Engine

    8.5.3 ENGINE • : Always contact us or our sales service agency when dealing with these items. • In causes of problems or causes which are not listed blow, contact us or our sales service agency for repairs. Problem Main causes Remedy •...
  • Page 257 Problem Main causes Remedy • Low grade fuel being used • Change to specified fuel • Overheating • See “Engine water temperature Abnormal noise generated gauge indicator is in red range” (combustion or mechanical) above • Damage inside muffler Replace muffler •...

  • Page 258: Electronic Control System

    8.5.4 ELECTRONIC CONTROL SYSTEM When the user code is shown on the display portion of the machine monitor, take the respective measure shown in the self-diagnosis chart below. [MACHINE MONITORING SYSTEM] Monitor Failure mode Action display When emergency pump drive switch is at the up (emergency) position, normal operations become Pump control system error possible,...

  • Page 259: Moment Limiter

    8.5.5 MOMENT LIMITER • : Always contact us or our sales service agency when dealing with these items. • In causes of problems or causes which are not listed blow, contact us or our sales service agency for repairs. NOTES When an error code is displayed on the moment limiter display unit, refer to “Operation 2.4.10 Moment Limiter Error Causes and Actions to be Taken”.
  • Page 260 3-196...

  • Page 261: Inspection And Maintenance

    INSPECTION AND MAINTENANCE 1. PRECAUTIONS FOR MAINTENANCE 4- 2 2. BASIC MAINTENANCE 4- 4 3. LEGAL INSPECTION 4- 7 4. SAFETY CRITICAL PARTS 4- 8 5. CONSUMABLES 4- 9 6. OTHER COMPONENTS 4-10 7. RECOMMENDED FUEL, COOLANT AND LUBRICANT 4-11 8.

  • Page 262: Precautions For Maintenance

    [2] USE GENUINE PARTS FOR REPLACEMENT Always use Maeda genuine parts as specified in the parts catalogue for part replacement. [3] USE PURE GREASE Always use recommended pure grease. The viscosity of grease must conform to specifications according to ambient temperature.
  • Page 263 • Be sure to clean the electrical parts, especially the starter and alternator, to protect them from dust. [21] DO NOT MIX OIL Never use together with different types of oil under any circumstance. Replace the oil completely when replenishing with a different type of oil. Always use Maeda genuine parts for part replacement.

  • Page 264: Basic Maintenance

    2. BASIC MAINTENANCE [1] OIL HANDLING • Oil is used under extremely harsh conditions (high temperature, high pressure) in the engine and working device, which causes the oil to undergo deterioration with operating time. Always use oil that meets requirements such as grade and operating temperature defined in the operation manual.
  • Page 265 • As to a replacement filter, always unpack it immediately prior to its use. • Always use Maeda genuine filters. [6] COOLANT HANDLING • River water contains a large amount of calcium and impurities. Use of the river water results in accumulation of water sludge in the engine and radiator, which causes heat exchange error leading to overheating.
  • Page 266 [8] HYDRAULIC EQUIPMENT HANDLING • Hydraulic equipment will be at elevated temperatures during and immediately after operation. Hydraulic equipment operates under high pressure. The following precautions should be observed when performing inspection and maintenance of hydraulic equipment. • Place the machine in travel position on a level surface to reduce the application of pressure to the cylinder circuit.

  • Page 267: Legal Inspection

    3. LEGAL INSPECTION If periodic inspection for machine safety assurance is stipulated by laws and regulations of your country, perform inspection complying with the inspection items listed below. 1. Make sure no abnormal event is present in the safety devices. 2.

  • Page 268: Safety Critical Parts

    4. SAFETY CRITICAL PARTS For using the machine safely for an extended period of time, you must periodically replace the safety critical and fire prevention-related parts listed in the table of important parts. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.

  • Page 269: Consumables

    Consumables such as a filter element and wire rope are to be replaced 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.

  • Page 270: Other Components

    6. OTHER COMPONENTS Item numbers of components are subject to change for ongoing product improvements. Prior to ordering spare parts, please contact our service agency and advice your machine number to confirm the correct item number of parts. №. №. Parts No.

  • Page 271: Recommended Fuel, Coolant And Lubricant

    • Commercially available lubricant additives may be good for the machine, but they may also cause harm. Maeda does not recommend any commercially available lubricant additive. • Use the oil recommended according to the ambient temperature in the chart below.
  • Page 272 . Note.1: HTHS (High-Temperature High-Shear Viscosity 150 degrees C), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Maeda SAE 0W30 and SAE 5W40 are the most suitable oils.

  • Page 273: Tightening Torque Specifications

    8. TIGHTENING TORQUE SPECIFICATIONS 8.1 STANDARD TIGHTENING TORQUE LIST Torque the metric bolts and nuts with no specific indication to a values shown in this table. Adequate tightening torque is determined with respect to a width across flat (b) of a bolt or nut. Width Tightening torque Thread...

  • Page 274: Inspection And Maintenance List

    9. INSPECTION AND MAINTENANCE LIST Inspection and maintenance item Page 10.1 CHECKING BEFORE OPERATION 4-16 10.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) 3-98 (See Operation 3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS)) [1] CHECKING AROUND CRANE 3-99 [2] CHECKING WIRE ROPES 3-99 [3] CHECKING HOOK BLOCK 3-99...
  • Page 275 Inspection and maintenance item Page 10.3 MAINTENANCE EVERY 50 HOURS 4-35 [1] GREASING MACHINE UNITS 4-35 10.4 MAINTENANCE EVERY 100 HOURS 4-37 [1] CHECKING/REFILLING OIL IN SWING MACHINERY CASE 4-37 10.5 MAINTENANCE EVERY 250 HOURS 4-38 [1] CHECKING/REFILLING OIL IN TRAVEL MOTOR REDUCTION GEAR CASE 4-38 [2] CHECKING/REFILLING OIL IN WINCH MOTOR REDUCTION GEAR CASE 4-39...

  • Page 276: Maintenance Procedures

    10. MAINTENANCE PROCEDURES 10.1 CHECKING BEFORE OPERATION Inspections specified in this section are required to be completed prior to starting an engine first of the day. See “Maintenance 9. Inspection and Maintenance List” for the inspection and maintenance items See “Operation 3.1 Checking before Operation” for before operation inspection items and procedure. 4-16...

  • Page 277: Irregular Maintenance

    • Do not use the old wire rope regardless of the frequency of use. • Always use Maeda genuine wire rope. [CRITERIA FOR WINCH WIRE ROPE REPLACEMENT] A wire rope undergoes wear and tear over time.
  • Page 278 [REMOVAL WINCH WIRE ROPE] Always wear thick leather working gloves for handling of wire ropes. CAUTION Stop un-winding the hook block when it reaches the ground, otherwise, it may result in irregular winding of the wire rope to the drum. Once the hook block reaches the ground, avoid un-winding any more.
  • Page 279 9. With the wire rope (5) wound off of the winch drum (9), remove the end of the wire rope (5) from the winch drum (9) by following the procedure provided below. (1) Bring a 6 to 10 mm round bar (A) into contact with the rope wedge (10).
  • Page 280 [INSTALLATION WINCH WIRE ROPE] • Always wear thick leather working gloves for handling of wire ropes. • The rope wedge to secure the wire rope must be fastened correctly and firmly. Otherwise, the wire rope may slip out and result in a serious accident. CAUTION •...
  • Page 281 4. In response to the number of falls, draw the wire rope through the load sheave at the boom end and hook block sheave. 2-falls 1-fall 4-falls 5. Draw the end of the wire rope (5) through the weight of the over hoist detector.
  • Page 282 [2] CHECKING/ADJUSTING BOOM TELESCOPING WIRE ROPE • Always wear thick leather working gloves for handling of wire ropes. • To adjust the boom telescopic wire rope, strictly adhere to the procedure as specified below. Any ommission or falure to follow the procedure may cause a hazard with the boom or hoisting load dropping.
  • Page 283 [3] CHECKING/CLEANING/REPLACEMENT AIR CLEANER ELEMENT • If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. • When using compressed air, there is danger that dirt may be blown around and cause serious injuly.
  • Page 284 5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm ) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. CAUTION The inner element must not be used again even after cleaning.
  • Page 285 [REPLACEMENT ELEMENT] 1. Open the battery room door on the left side of the machine. 2. Remove 3 clips (2), and then take out cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4.
  • Page 286 The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the area where freezing is not an issue, the use of antifreeze coolant is essential. Maeda machine are supplied with Supercoolant (AF-NAC). Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
  • Page 287 CAUTION • Always use tap water for coolant. Contact Maeda or our sales service agency if river water, well water, or water through the small water-supply system is necessarily substituted for tap water. • A mixing ratio of antifreeze is to be controlled by the concentration meter.
  • Page 288 7. Remove drain plug (5) in the engine cylinder block and drain the water. 8. After draining the water, close drain valve (4) and tighten drain plug (5). 9. Fill with city water. 10. When the radiator is full, start the engine, and run it at low idle. 11.
  • Page 289 [6] CHECKING/ADJUSTING TRACK TENSION The wear of the pins and bushings on the undercarriage will differ with the working conditions and type of soil, so inspect the track tension frequently in order to maintain the standard tension. Stop the machine on firm, level ground when carrying out the inspection and maintenance. [CHECKING] 1.
  • Page 290 [LOOSENING TRACK TENSION] It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact us or our sales service agency for repairs. 1. Loosen plug (1) gradually to release the grease. When loosening plug (1), turn it a maximum of one turn.
  • Page 291 [8] CHECKING/MAINTENANCE AIR CONDITIONER [CHECKING LEVEL OF REFRIGERANT (GAS)] • If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause lose of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
  • Page 292 [9] CHECKING/CLEANING/GREASING CAB SLIDE DOOR RAIL AND ROLLER [CHECKING] When opening or closing the slide door, it may sometimes not slide smoothly due to mud stuck to the rail. In that case clean and lubricate slide door rail (1) and roller (2) at the 3 points. [CLEANING DOOR RAIL] 1.
  • Page 293 [10] WASHING WASHABLE FLOOR • When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the operation. • If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a serious accident.
  • Page 294 [PROCEDURE TO MAKE THE MACHINE LEAN AT AN ANGLE) • Always exercise this practice only on a level and solid ground. • Refer to "Specifications 1. Main Specifications" for dimension and mass of this machine. • The operator who operates the crane to lift this machine up must be licensed or trained for crane operation.

  • Page 295: Maintenance Every 50 Hours

    10.3 MAINTENANCE EVERY 50 HOURS [1] GREASING MACHINE UNITS CAUTION • Grease type varies with greasing points. Failure to grease properly may cause the machine to shorten its useful life. See the following table for grease types. • Greasing a new machine is required once every 10 hours until the machine attains the first 100 hours of operation, this is the running in period.
  • Page 296 4-36...

  • Page 297: Maintenance Every 100 Hours

    10.4 MAINTENANCE EVERY 100 HOURS Perform this maintenance in tandem with maintenance every 50 hours. [1] CHECKING/REFILLING OIL IN SWING MACHINERY CASE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION •...

  • Page 298: Maintenance Every 250 Hours

    10.5 MAINTENANCE EVERY 250 HOURS Perform this maintenance in tandem with maintenance every 50/100 hours. [1] CHECKING/REFILLING OIL IN TRAVEL MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.
  • Page 299 [2] CHECKING/REFILLING OIL IN WINCH MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. •...
  • Page 300 [3] CHECKING LEVEL OF BATTERY ELECTROLYTE • Do not use battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
  • Page 301 [WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY] If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows. 1.
  • Page 302 [4] CHECKING/ADJUSTING COOLING FAN BELT TENSION [CHECKING] 1. Open the engine hood (1) and remove step (7). 2. Deflection (a) should be 7 to 10 mm when the belt is pressed with the thumb with a force of approx. 58.8 N (6 kg) at a point midway between the alternator pulley and fan pulley.
  • Page 303 [5] CHECKING/ADJUSTING AIR COMPRESSOR BELT TENSION [CHECKING] 1. Open the engine hood (1) and remove step (7). 2. Deflection (A) should be 5 to 8 mm when the belt is pressed with the thumb with a force of approx. 58.8 N (6 kg) at a point midway between the compressor pulley (3) and fan pulley (4).

  • Page 304: Maintenance Every 500 Hours

    10.6 MAINTENANCE EVERY 500 HOURS Perform this maintenance in tandem with maintenance every 50/100/250 hours. [1] GREASING EACH BLEAD SECTION CAUTION • Grease type is lithium grease. Failure to grease properly may cause the machine to shorten its useful life. •...
  • Page 305 [2] REPLACEMENT OF ENGINE LUBRICATING OIL AND OIL FILTER CARTRIDGE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION •...
  • Page 306 • Do not bring any fire or flame close. CAUTION • Genuine Maeda fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Maeda parts. • The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle.
  • Page 307 9. Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with oil, then install to the filter holder. CAUTION • When adding fuel, do not remove cap (B). Always add fuel from the 8 small holes (A) on the dirty side. •...
  • Page 308 [4] CHECKING SWING PINION GREASE LEVEL, ADDING GREASE • Prepare a scale. 1. Remove 2 bolts (1) on the top of the upper structure and remove cover (2). 2. Insert a scale into the grease and check that the height of the grease in the portion where the pinion passes is at least 4 mm.
  • Page 309 [6] CLEANING/CHECKING RADIATOR FINS, OIL COOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
  • Page 310 [7] CLEANING AIR CONDITIONER FRESH/RECIRC FILTERS • When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, and other protective equipment. • Always check that the slide door is locked at the open or closed position before cleaning the FRESH or RECIRC filter.
  • Page 311 [8] REPLACEMENT BREATHER ELEMENT IN HYDRAULIC TANK • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. • When removing the oil filter cap, turn it slowly to release the internal pressure, then remove it. 1.
  • Page 312 [9] REPLACEMENT OIL IN WINCH MOTOR REDUCTION GEAR CASE The following maintenance should be performed after 500 hours operation, limited to the first maintenance of a new machine. • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.

  • Page 313: Maintenance Every 1000 Hours

    10.7 MAINTENANCE EVERY 1000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500 hours. [1] REPLACEMENT OIL IN SWING MACHINERY CASE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION •...
  • Page 314 [2] REPLACEMENT OIL IN TRAVEL MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. •...
  • Page 315 [3] REPLACEMENT OIL IN WINCH MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. •...
  • Page 316 [4] REPLACEMENT HYDRAULIC OIL FILTER ELEMENT • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. • When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. CAUTION •...
  • Page 317 • Do not bring any fire or flame close. CAUTION • Genuine Maeda fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Maeda parts. • The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle.
  • Page 318 8. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. NOTES If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
  • Page 319 [6] CHECKING/REFILLING OIL IN PTO GEAR CASE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION For details of using oil specified, see “Maintenance 7.1 Use of Fuel, Coolant and Lubricants According to Ambient Temperature”.

  • Page 320: Maintenance Every 2000 Hours

    10.8 MAINTENANCE EVERY 2000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000 hours. [1] CLEANING HYDRAULIC TANK STRAINER • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. •...
  • Page 321 [4] CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the accumulator, always do as follows. •...
  • Page 322 5. Set the lock lever to the FREE position (F). 6. Operate the blade control lever fully to the LOWER position. 7. Check that the blade goes down to the ground under its own weight. This completes the inspection. CAUTION If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.

  • Page 323: Maintenance Every 4000 Hours

    10.9 MAINTENANCE EVERY 4000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000/2000 hours. [1] CHECKING WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any problem is found, please contact us or our sales service agency for repairs or replacement.
  • Page 324 [4] CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER The fuel spray prevention 10 caps on the fuel injection piping and both ends of the high-pressure piping act to prevent the fuel from coming into contact with high-pressure parts of the engine and causing a fire if the fuel should leak or spray out.

  • Page 325: Maintenance Every 5000 Hours

    10.10 MAINTENANCE EVERY 5000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000 hours. [1] REPLACEMENT OIL IN HYDRAULIC TANK • Parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the oil temperature to go down before performing this operation. •...

  • Page 326: Maintenance Every 8000 Hours

    5. Set a container to catch the oil under the drain plug under the machine. 6. Using a handle, remove drain plug (P) and drain the oil. NOTES Take care not to get oil on yourself when you remove drain plug (P).

  • Page 327: Bleeding Air From Hydraulic System

    11. BLEEDING AIR FROM HYDRAULIC SYSTEM NOTES For details, see “Operation 3.3 Starting Engine”. If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see “Operation 3.8 Starting/moving/stopping Machine” and “3.9 Steering Machine”. [1] BLEEDING AIR FROM PUMP CAUTION If the pump is operated without filling the pump case with hydraulic oil, there is danger that the...
  • Page 328 [3] BLEEDING AIR FROM SWING MOTOR CAUTION • Carry out only if the oil inside the swing motor case has been drained. • If the air is not bleed from the swing motor, the motor bearings may be damaged. 1. Remove 2 covers (1) between the hydraulic tank and the operator’s cab 2.
  • Page 329 [4] BLEEDING AIR FROM WINCH MOTOR To loosen or tighten the bleeder plug of the winch motor, always practice it when the hook block is lowered to touch the ground and the equipment control levers are positioned to NEUTRAL. Otherwise, the plug or oil may come out due to the internal pressure. CAUTION •...
  • Page 330 [5] BLEEDING AIR FROM TRAVEL MOTOR NOTES Only when oil inside travel motor case has been drained. 1. Start the engine, and then run the engine at low idle. 2. Remove hose (3) from “port C”, then when the oil has flowed out, tighten it again.

  • Page 331: Method For Releasing Pressure In Hydraulic Circuit

    12. METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the direction that the oil spurts out when caring out the operation. In addition, loose the bolts slowly when carrying out the operation. NOTES Refer to "Operation 3.3 Starting Engine"...
  • Page 332 4-72...

  • Page 333: Specifications

    SPECIFICATIONS 1. SPECIFICATION LIST 5- 2 2. SPECIFICATION DIMENSIONAL DRAWING 5- 4 3. RATED TOTAL LOAD CHART 5- 5 4. WORKING RADIUS AND LIFTING HEIGHT 5- 8...

  • Page 334: Specification List

    1. SPECIFICATION LIST System / Item LC1385M-8B Machine mass 15640kg Overall length  width  height 6545mm x 2490mm x 2965mm Distance between idler 2880mm Mass and sprocket dimensions Track gauge 1990mm Track width 500mm 1600mm Swing radius at machine rear end Maximum rated total load ...
  • Page 335 System / Item LC1385M-8B Model Komatsu SAA4D95LE-5 Vertical in-line 4-cylinder, Water cooled, 4-cycle, Type Direct fuel injection type, With turbocharger Engine Displacement 3.26 liters (3260cc) Rated output (continuous) 68.4kW/2200min (93PS/2200rpm) Fuel tank capacity Light oil/195 liters Over hoist detector, three-winding stop device, moment limiter (working envelope limited), slinging rope detachment protector, hydraulic safety valve, telescoping Safety cylinder hydraulic automatic locking device, derricking cylinder hydraulic automatic...

  • Page 336: Specification Dimensional Drawing

    2. SPECIFICATION DIMENSIONAL DRAWING...

  • Page 337: Rated Total Load Chart

    3. RATED TOTAL LOAD CHART [1] RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS Unit: kg 13.385m 16.265m Working 4.745m Boom 7.625m Boom 10.505m Boom Boom Boom radius Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry...
  • Page 338 [2] RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS Unit: kg 13.385m 16.265m Working 4.745m Boom 7.625m Boom 10.505m Boom Boom Boom radius Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry 2.00 3000 1000 3000 1000...
  • Page 339 [3] RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL Unit: kg 13.385m 16.265m Working 4.745m Boom 7.625m Boom 10.505m Boom Boom Boom radius Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry 2.00 1500 1500 1500 2.50...

  • Page 340: Working Radius And Lifting Height

    4. WORKING RADIUS AND LIFTING HEIGHT...

  • Page 341: Fly-Jib

    FLY-JIB 1. PRECAUTIONS OF FLY-JIB OPERATION 6- 2 2. SAFETY LABEL LOCATION 6- 4 3. WORKING RANGE CHART 6- 7 4. RATED TOTAL LOAD CHART 6- 8 5. FLY-JIB EACH SECTION 6- 9 6. FLY-JIB INSTALLATION AND STOWAGE 6-10 7. HANDLING MOMENT LIMITER 6-33 8.

  • Page 342: Precautions Of Fly-Jib Operation

    1. PRECAUTIONS OF FLY-JIB OPERATION • The Fly-jib is installed to the Main boom with two position pins. The Fly-jib tilt angle is adujusted by extending or retracting of the angle adjuster rod, then the Fly-jib is fixed to the angle by one position pin.
  • Page 343 Model names in the Table right represent the respective machine configurations: • LC1385M-8B stands for a Blade model. • LC1385M-8BF stands for a Blade and Fly- Jib model. • The Fly-jib tilt angle is adjustable to four (4) positions (0, 20, 40 and 60 degrees).

  • Page 344: Safety Label Location

    2. SAFETY LABEL LOCATION CAUTION In this section, the safety labels indicated are exclusive for The Fly-jib model but different from those of a standard model. For labels other than these, refer to the section: “Safety 5. Safety Label Location”. Keep these safety labels clean and legible at all times.
  • Page 345 (1) Work range chart for fly-jib (584-2198900) (2) Over-hoist detection wiring instruction (584-3438200) (3) Fly-jib minimum hoisting load (584-3438300) (4) Warning for fly-jib installation (584-3438400)
  • Page 346 (5) Warning for fly-jib stowage (584-3438500) (2 places) (6) Fly-jib detection wiring instruction (584-3438700) (7) Pin hole caution (349-4426900) (7 places) (8) Caution for hole (556-4580700) (9) Rated voltage and current (556-4496600)

  • Page 347: Working Range Chart

    3. WORKING RANGE CHART...

  • Page 348: Rated Total Load Chart

    4. RATED TOTAL LOAD CHART CAUTION • The rated total load is a load including the weight of the hook block (20kg). • During the Fly-jib operations, the boom angle range must be kept at "45 degrees" or more when the Fly-jib tilt angle is "0 or 20 degrees". Or, the boom angle range must be kept at "65 degrees"...

  • Page 349: Fly-Jib Each Section

    5. FLY-JIB EACH SECTION (1) Main boom (14) Sheave (2) No.1 Fly-jib (15) Position pin A (3) No.2 Fly-jib (16) Position pin B (4) Position pin (17) Harness connection part (5) Outer rod (For fly-jib angle adjusting) (For over hoist detection) (Fly-jib side) (6) Inner rod (For fly-jib angle adjusting) (18) Harness connection part (7) Position pin...

  • Page 350: Fly-Jib Installation And Stowage

    6. FLY-JIB INSTALLATION AND STOWAGE • Fly-jib installation and stowage will require two people. Prior to operation, discuss each person’s duties in detail and follow the agreed signals during the operation. If signals are not clearly understood, it may cause an accident resulting in injury or death. •...

  • Page 351: Installation Of Fly-Jib

    6.1 INSTALLATION OF FLY-JIB Practice installing the Fly-jib to the Main boom from the stowed position from the right side as shown below: CAUTION The lever block (23) included in the accessories shall be set to the bracket between the tilt angle adjuster outer rod and inner rod, for the purpose to match the holes in the Main boom and No.1 Fly-jib or changing the Fly-jib tilt angle.
  • Page 352 Always avoid standing on crawlers or blade for installation work. You may miss your footing and fall resulting in serious injury. For elevated work, always prepare a strongly-built work platform. NOTES Slew the upper strucure 90 degrees so that it comes perpendicular to crawlers.
  • Page 353 3. Once the connection hole of the No.1 Fly-jib (2) and the hole (A) of the bracket (26) on the right side of the Main boom tip are aligned, insert the position pin (15) to the hole then secure it with the linchpin (25).
  • Page 354 7. Pull the linchpin (25) out from the position pin (16) in the Fly-jib bracket A (21) to pull out the position pin (16). NOTES • When you find it difficult to extract the position pin (16), use the lever block (23) again to make a clearance between the bracket of No.1 Fly-jib (2) and the stowage bracket (21).
  • Page 355 10. Once the connection hole of the No.1 Fly-jib (2) and the hole (B) of the bracket (27) on the left side of the Main boom tip are adjusted, insert the position pin (16) to the hole then secure it with the linchpin (25).
  • Page 356 (3) Connect the dummy plug (30), as extracted in (1) above, to After harness exchange; the connector (31) and then close the cover. the Main boom side: Don’t forget to install the dummy plug (30) into the connector (31) in the harness connection part (18: Main boom side).
  • Page 357 (3) Connect the harness connector (34), as extracted in (1) above, to the harness connector (36) and After harness exchange; then close the cover. the Main boom side: NOTES • Arrange the harness connector (34) to pass through the notch hole under the harness connection part (20: Main boom side) after removing it from harness connection part (Fly-jib side).
  • Page 358 15. Stop the engine then take the wire rope off from the wire rope holder at the boom tip. Arrange the wire rope to go straight through the sheave of the main boom tip to the Fly-jib. 16. Detach the over-hoist detector weight (9) from the weight hanger (46) on the right side of the Fly-jib (2).
  • Page 359 19. Put the wire rope (12) through the wire socket (37), as removed in 13 above, and set the rope wedge (41) to position (a). Pull the wire rope (12) intensely to the direction of the arrow. 20. Install the rope clip (40) to the wire rope (12). Refer to the Figure on the right for the rope clip position.

  • Page 360: Changing Of Fly-Jib Tilt Angle

    6.2 CHANGING OF FLY-JIB TILT ANGLE Changing of the Fly-jib tilt angle should be always practiced without any hoisted load and only with the No.1 Fly-jib. Avoid changing the Fly-jib tilt angle with a hoisted load and/or using No.2 Fly-jib, otherwise excess load is applied to the lever block which may damage it. CAUTION •...
  • Page 361 4. When the hole of the inner rod (6) for 0 degree angled Fly-jib and the hole of the outer rod (5) match, insert the position pin (7) to the holes and insert the linchpin (25). When inserted, ensure the ring is turned to lock it. 5.

  • Page 362: Changing Of Fly-Jib Tilt Angle To Stowage Position

    6.2.2 CHANGING OF FLY-JIB TILT ANGLE TO STOWAGE POSITION To return the Fly-jib to the stowage position, follow the instructions below: 1. Set the attached lever block (23) between the tilt angle adjuster outer rod (5) and inner rod (6). NOTES Lever block (23) handling will be easier, when you set the lever side to the outer rod side (5).

  • Page 363: Extending And Retracting No.2 Fly-Jib

    6.3 EXTENDING AND RETRACTING NO.2 FLY-JIB 6.3.1 EXTENDING NO.2 FLY-JIB CONFIGURED 0 DEGREE OR 20 DEGREES TILT ANGLE To extend the No.2 Fly-jib configured 0 or 20 degrees, follow the instructions below: 1. Lower the main boom to the lowest angle. 2.

  • Page 364: Tilt Angle

    6.3.2 EXTENDING NO.2 FLY-JIB CONFIGURED 40 DEGREES OR 60 DEGREES TILT ANGLE • When the Fly-jib angle is set higher, No.2 Fly-jib may rapidly slide out when the position pin which fixes it is extracted and it may cause a serious accident resulting in death or serious injury.
  • Page 365 [Posture of the 60 degrees angled Fly-jib] CAUTION The posture in the figure on the right shows that the No.2 Fly-jib is extended in accor- dance with the procedure 1. to 4. as above. Once configured to this length, the No.2 Fly-jib length data is transmitted to the moment limiter, then the Fly-jib length (2) LED of moment limiter will turn on.

  • Page 366: Retracting Of No.2 Fly-Jib

    6.3.3 RETRACTING OF No.2 FLY-JIB • When the Fly-jib angle is set higher, No.2 Fly-jib may rapidly slide out when the position pin which fixes it is extracted, which may cause a serious accident resulting in death or serious injury. Before you extract the position pin, always wind up the hook close to the Fly-jib tip to prevent No.2 Fly-jib from rushing out.

  • Page 367: Stowage Of Fly-Jib

    6.4 STOWAGE OF FLY-JIB NOTES •When the No.2 Fly-jib (3) is extended, refer to section; “FLY-JIB, 6.3 Extending and Retracting No.2 Fly-jib” and retract the No.2 Fly-jib (3) correctly. • Refer to "Fly-jib 6.2.2 Changing of Fly-jib Tilt Angle to Stowage Position" for details to return the Fly-jib (3) to its stowage position.
  • Page 368 (2) Connect the harness connector (36), as extracted in (1) After harness exchange; above, to the storage connector (35) and the close the cover. Main boom side: (3) Open the cover of the harness connection part (19: Fly-jib Before harness exchange; side).
  • Page 369 (2) Open the cover of the harness connection part (18: Main Before harness exchange; boom side) and extract the dummy plug (30) in the connector Main boom side: (31). NOTES The removed dummy plug (30) will be later connected into a connector in the harness connection part (17: Fly-jib side).
  • Page 370 8. Start the engine again to raise the boom level, then stop the engine. Now pull out the position pin (16) completely. NOTES • To make the boom level, ensure that the boom angle display of the moment limiter indicates "0". In addition, visually check the boom is level.
  • Page 371 • Do not remove the position pin (15) from the bracket (26) until the position pin (16) is fully inserted into the hole of the fly-jib bracket A (21). Incorrect fitting order may cause a serious hazard. • The position pin (16) must always be inserted downward from the upper side. Otherwise, where it is inserted upward from the underside, the position pin could easily drop down to cause the Fly-jib to collapse and may cause a serious hazard.
  • Page 372 15. Keep pressing the over-winding cancel switch and wind the winch slowly, to reduce the wire rope slack. Never attempt hook stowage using the moment limiter emergency stop cancel switch. The hook stowage mode is not available and may result in damage to the bracket for the hook stowage wire rope (13), main boom, or wire rope (12).

  • Page 373: Handling Moment Limiter

    7. HANDLING MOMENT LIMITER Do not turn off the power to the moment limiter and do not set the emergency switch to the OFF position during working. Doing so may cause the hoisted load to fall, breakage of the boom, or turnover of machine due to overloading, leading to serious injury or even resulting in death.
  • Page 374 (1) Load capacity display (17) Overwind detection LED (Red) (2) Actual load display (18) 1 fall LED (Green) (3) Rated total load display (19) 2 falls LED (Green) (4) Boom angle display (20) 4 falls LED (green) (5) Working radius display (21) Fly-jib length (1) LED (Orange) (6) Rated radius display (22) Fly-jib length (2) LED (Orange)

  • Page 375: Moment Limiter Functions

    7.2 MOMENT LIMITER FUNCTIONS CAUTION During the Fly-jib operations, always keep the boom angle in the range as specified below: [At a Fly-jib angle in 0 or 20 degrees] Perform the crane operation in the boom angle range of "45 degrees" or more. When a load is hoisted in a condition that the boom angle is less than "45 degrees"...
  • Page 376 7.2.1 DISPLAY FOR FLY-JIB MODE SWITCHING 1. Fly-jib angle at 0 degree: When the Fly-jib tilt angle is set to 0 degree, the Rated total load display, Working radius display, Fly-jib angle display and Lifting height display are switched to Fly-jib tilt angle 0 degree mode. •...

  • Page 377: Setting Of Operating Conditions

    7.3 SETTING OF OPERATING CONDITIONS CAUTION When the Fly-jib is installed to the boom tip and its tilt angle is set to 0 degree or more from its stowage position, the machine is configured to the following operating conditions: • The rated total load value is switched to the Fly-jib mode in the Moment limiter. •...

  • Page 378: Operations

    8. OPERATIONS CAUTION In this section, the devices indicated are exclusive to a Fly-jib model but different from those of a standard model. For devices other than these, refer to the section: “Operation”. 8.1 CAUTIONS FOR FLY-JIB OPERATION • Whenever the Fly-jib is installed, always keep the engine speed in low idling so that the machine is operated in low speed.

  • Page 379: Inspection And Maintenance

    9. INSPECTION AND MAINTENANCE CAUTION In this section, the devices indicated are exclusive to a Fly-jib model but different from those of For devices other than these, refer to the section: “Inspection and a standard model. Maintenance”. 9.1 CHECKING BEFORE OPERATION Check the followings in this section before starting the first work every day after installing fly-jib.
  • Page 380 [4] CHECKING MOMENT LIMITER FOR OPERATION If you find any abnormality with the moment limiter, immediately contact us or our sales service agency. 1. Turn the starter switch to the ON position. 2. Check the working status lamp. All 3 colors light for approximately 3 seconds first, then only the green light remains lit.
  • Page 381 9.2 MAINTENANCE EVERY 50 HOURS [1] GREASING CAUTION • Grease a new machine regularly until it has been operated for 100 hours, that is the time when the machine will have settled down and may be considered as run-in. • Any unusual noise at greasing points requires immediate greasing regardless of the maintenance period.

  • Page 382: Specifications

    In this section, the data indicated is exclusive for the Fly-jib model but different from those of a standard model. For data other than this, refer to the section: “SPECIFICATIONS” of the LC1385 operation manual. System / Item LC1385M-8BF Machine mass 15,850kg Overall length x width x height 6,545mm x 2,490mm x 2,965mm...
  • Page 384 MAEDA CRAWLER CRANE LC1385M-8 OPERATION MANUAL Document No: 584E-OM0912-02 Third edition: December 15, 2009 Issued by Maeda Seisakusyo Co., Ltd. 1095 Onbegawa, Shinonoi Nagano, Nagano 388-8522, Japan No part of this manual can be reproduced in any from without permission...

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