Page 1 NOTICE MAEDA has Operation Manuals 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. INTRODUCTION 2. FOR SAFE USE OF THE MACHINE 3. MACHINE OVERVIEW 3.1 SPECIFIED OPERATIONS 3.2 MACHINE STRUCTURE 3.3 MACHINE FUNCTIONS 4. QUALIFICATION FOR OPERATION 4.1 QUALIFICATION FOR CRANE OPERATION 5. CRANETERMINOLOGY 5.1 TERMS AND DEFINITIONS 5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT 5.3 RATED TOTAL LOAD CHART SAFETY...
Page 4: Item Page
Item Page OPERATION 1. NAME OF EACH SECTION 1.1 MACHINE UNITS 1.2 CRANE OPERATION UNITS 1.2.1 MACHINE MONITOR COMPONENTS 2. EXPLANATION OF ALL EQUIPMENT 2.1 MACHINE MONITOR 2.1.1 MONITOR BASIC ACTION AND DISPLAY 2.1.2 WARNING DISPLAY 2.2 SWITCHES 2.3 OPERATION LEVERS AND PEDALS 2.4 MOMENT LIMITER (OVERLOAD PREVENTIVE DEVICE) 2.4.1 CONFIGURATION OF MOMENT LIMITER 2.4.2 FUNCTIONS OF MOMENT LIMITER...
Page 5 Item Page 3. OPERATION 3.1 PRE-OPERATION INSPECTION 3.1.1 CHECKING BEFORE STARTING ENGINE 3.1.2 CHECKING BEFORE STARTING ENGINE 3.1.3 CHECKING AFTER STARTING ENGINE 3.2 OPERATIONS AND CHECKS BEFORE STARTING ENGINE 3.3 STARTING ENGINE 3.4 OPERATIONS AND CHECKS AFTER STARTING ENGINE 3.4.1 WARM-UP OPERATIONS FOR ENGINE 3.4.2 WARM-UP OPERATIONS FOR HYDRAULIC EQUIPMENT 3.5 STOPPING ENGINE 3.6 BREAK-IN OPERATION...
Page 6 Item Page 4. HANDLING OF WIRE ROPE 4.1 CRITERIA FOR WIRE ROPE REPLACEMENT 4.2 WINCH WIRE ROPE REEVING SYSTEM AND GROSS RATED LOAD 4.3 MEASURE TO TAKE WHEN WINCH WIRE ROPE IS TWISTED 5. TRANSPORTATION 5.1 LOADING/UNLOADING 5.1.1 LOADING 5.1.2 FIXING THE MACHINE 5.1.3 UNLOADING 5.2 HOISTING MACHINE 5.2.1 HOISTING MACHINE WITH BOOM LOWERED...
Page 7 Item Page INSPECTION AND MAINTENANCE 1. PRECAUTIONS FOR MAINTENANCE 2. BASIC MAINTENANCE 3. LEGAL INSPECTION 4. PERIODIC REPLACEMENT OF CRITICAL PARTS 5. CONSUMABLES 6. OTHER REPLACEMENT PARTS 7. USE OF FUEL AND LUBRICATING OIL 7.1 USE OF FUEL AND LUBRICATING OIL ACCORDING TO TEMPERATURES 8.
Page 8 Item Page FLY-JIB 1. PRECAUTIONS OF FLY-JIB OPERATION 2. SAFETY LABEL LOCATION 3. FLY-JIB EACH SECTION 4. FLY-JIB INSTALLATION AND STOWAGE 4.1 INSTALLATION OF FLY-JIB 4.2 CHANGING OF FLY-JIB TILT ANGLE 4.3 EXTENDING AND RETRACTING NO.2 FLY-JIB 4.3.1 EXTENDING NO.2 FLY-JIB CONFIGURED 0 DEGREE OR 20 DEGREES TILT ANGLE 4.3.2 EXTENDING NO.2 FLY-JIB CONFIGURED 40 DEGREES OR 60 DEGREES TILT ANGLE...
Page 9: Introduction
INTRODUCTION 1. INTRODUCTION 2. FOR SAFE USE OF THE MACHINE 3. MACHINE OVERVIEW 4. QUALIFICATION FOR OPERATION 5. CRANE TERMINOLOGY...
Page 10: Introduction
• Avoid operating this machine before understanding this manual thoroughly. • Keep this manual at hand so that you can read it when necessary. • If you lose or damage this manual, contact Maeda or our sales service agency immediately to order a new one.
Page 11: For Safe Use Of The Machine
2. FOR SAFE USE OF THE MACHINE This manual classifies the risks into the following categories for easy understanding of this manual and the safety labels attached to this machine. This denotes that there is an imminent hazard which will cause serious injury or death.
Page 12: Machine Overview
3. MACHINE OVERVIEW 3.1 SPECIFIED OPERATIONS This machine is to be used for the following operations: • Crane operation • Travelling suspension operation This machine is a mobile crane consisting of the upper swiveling body equipped with a boom type crane and the lower crawler type carrier. This self-propelled crane is capable of moving (travelling) in the worksite and lifting an object weighing up to the rated total load.
Page 13: Machine Functions
This machine is composed of the following units and systems: [1] CARRIER Consists of the traveling system. [2] CRANE Consists of the engine, travelling operation unit, crane operation unit, boom telescoping unit, boom derricking unit, slewing unit, hook block and winch system. [3] SAFTEY DEVICE Comprises the overwinding prevention device, over-unwinding prevention device, overload preventive device, slinging rope detachment protector, hydraulic safety valve, telescoping...
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. 4.1 QUALIFICATION FOR CRANE OPERATION Only personnel that have obtained the required license or training stipulated by laws and regulations applicable to the place of use are qualified to operate this machine.
Page 15: Craneterminology
5. CRANE TERMINOLOGY 5.1 TERMS AND DEFINITIONS [1] RATED TOTAL LOAD The maximum load that can be applied according to the boom length and angle. The load includes the mass (weight) of hoisting accessories (hooks) and slinging ropes. [2] RATED LOAD A load derived by subtracting the mass (weight) of hoisting accessories (hooks) and slinging ropes from the rated total load, and can be hoisted.
Page 16: Diagram Of Working Radius And Lifting Height
5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT • The working radius/lifting height shows relationship between working radius, boom angle and lifting height above ground of this machine with no load hoisted, and deflection of the boom is not included. •...
Page 17: Rated Total Load Chart
5.3 RATED TOTAL LOAD CHART • Rated total load chart is based on level, hard ground. • Values given in the rated total load chart are based on the working radius including the deflection of boom under actual load. • When boom (3) is extended even for a minimal extent, perform the work within the capacity indicated in the column of "boom (3)".
Page 18 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects depending on boom length by working radius.
Page 19 [1] BOOM LENGTH In the Rated Total Load Chart, the "4.745 m boom (1)", "7.625 m boom (2)", "10.505 m boom (3)", "13.385 m boom (4)" and "16.265 m boom (5)" given in columns on the top denote the respective states of the following figures: 1.
Page 20 4. "13.385 m boom (4)": Booms (2) and (3) are fully extended, while booms (4) and (5) are extended to an intermediate length ( mark) is exposed half way from boom (3). If booms (4) and (5) are extended even to a small extent, perform the work in the capacity indicated in this column.
Page 21: Safety
SAFETY 1. BASIC PRECAUTIONS 2. OPERATION RELATED PRECAUTIONS 3. TRANSPORT PRECAUTIONS 4. MAINTENANCE PRECAUTIONS 5. SAFETY LABEL LOCATIONS 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 Incorrect operation and servicing may result in serious bodily accidents. Before starting operation and servicing, read this manual and safety labels to observe their warnings and precautions. 1.1 PRECAUTIONS BEFORE STARTING WORK OBSERVE THE MANUAL AND SAFETY LABELS •...
Page 23: Preparing For Safe Operation
1.2 PREPARING FOR SAFE OPERATION PROVIDE SAFETY DEVICES FOR SURE • Check to ensure that all guards, covers, mirrors and rear-view camera are attached properly. Repair immediately if damaged. • Understand how to use the safety devices well 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 WHAT TO DO IF A FIRE OCCURS • Turn the starter switch OFF to stop the engine. • Get out of the Machine by using a handrail and steps. • Do not jump off the Machine. You may fall and get hurt. PREVENTING FIRE •...
Page 26: Cautions In Getting On And Off The Machine
1.4 CAUTIONS IN GETTING ON AND OFF THE MACHINE USE A HANDRAIL AND STEPS WHEN GETTING ON AND OFF THE MACHINE When getting on and off the Machine, be sure to observe the following precautions in order to prevent physical accidents such as slipping and falling or tumbling.
Page 27: Other Precautions
1.5 OTHER PRECAUTIONS CAUTION AGAINST BEING CAUGHT In the periphery of the upper slewing body and crane unit, the clearance varies with the motion of derricking cylinder and winch. If being caught in it, serious injury may occur. Keep persons away from all rotating and telescoping sections.
Page 28: Operation Related Precautions
2. OPERATION RELATED PRECAUTIONS 2.1 PRECAUTIONS ON WORK SITE SURVEY AND SAFETY ASSURANCE OF WORK SITE A number of risks that may cause serious injury are imbedded in a work site. Before starting work, check the following matters beforehand to ensure that no danger is present at the worksite: •...
Page 29 BEWARE OF ELECTRICAL CABLE ABOVE • Do not let the Machine touch the electrical cables above. High voltage cables may also inflict electrical shock by close proximity. • Slinging operators are likely to suffer electrical shocks. Always observe the following to prevent accidents. •...
Page 30 CAUTIONS WHEN OPERATING CRANE IN LOCATION WITH HIGH OUTPUT MICROWAVE EMISSION Operating the crane near high output microwave emission equipment such as a radar or TV/radio broadcast antenna causes the crane construction to be exposed to the microwave and generates induced current, therefore is very dangerous. In addition, the mechatronics may become haywire.
Page 31: Cautions When Starting Engine
2.2 CAUTIONS WHEN STARTING ENGINE PAY ATTENTION TO WARNING SIGNS When warning sign "DANGER. DO NOT OPERATE!" is put up, the Machine is being inspected and under maintenance. Do not start the engine and refrain from touching operating levers. Disregarding the warning sign to operate the Machine may give rise to the danger of involving the preparing personnel into the rotating parts or movable parts of the Machine, resulting in serious injury.
Page 32 CAUTIONS UNDER COLD WEATHER • Remove snow from and defrost the surface of the slewing gear, boom and around winch, and ensure that their movements before starting work. • Before starting the engine, ensure that the automatic glow lamp goes off. •...
Page 33: Precautions For Starting Carrier And Operating Crane
2.3 PRECAUTIONS FOR STARTING CARRIER AND OPERATING CRANE INSPECTION BEFORE STARTING OPERATION Omitting the inspections after starting the engine results in delay to discover the Machine abnormalities, and may result in accidents and Machine damages. Inspection should be carried out in a clear area. No unauthorized persons should be able to approach the Machine.
Page 34 CAUTIONS WHEN TRAVELLING Always observe the following to prevent serious injuries and accidental death when moving the Machine. • Set the Machine to the travelling posture in the right figure. Refer to the preceding subsection "CAUTIONS ON MACHINE FORWARDING/REVERSING AND SLEWING". •...
Page 35 BE CAREFUL WHEN TRAVELLING OVER SLOPE Always observe the following to prevent serious injuries and death accidents when travelling over a slope for unavoidable reason. • When running on a slope, be sure to store the hook block in the hook holder at the front end of the upper slewing body to form a running posture.Any simplified fixation of the hook at the tip of boom gives rise to the risk of loosening during running.
Page 36 BE CAREFUL OF TRIPPING ON UNSTABLE GROUND Always observe the following to prevent serious injuries and death accidents when travelling over an unstable ground for unavoidable reasons. • Do not enter soft ground area. The machine may get stuck. • The ground near cliff, roadside and deep gully is unstable, so avoid going near such ground as much as possible.
Page 37: Cautions During Crane Operation
2.4 CAUTIONS DURING CRANE OPERATION 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 any abnormality. Repair immediately if any abnormality exists.
Page 38 CAUTIONS WHEN WORKING ON A SLOPE When inevitably perform operation on a slope, provide an earth fill (B) to create a horizontal, solid and strong footing for installing the Machine in order to prevent it from tumbling. Attempting diagonal hoisting without ensuring horizontal installation of the Machine not only disturbs the...
Page 39 PAY ATTENTION TO WEATHER INFORMATION • A risk of lightning exists in case of a thunderstorm, so abort operating the crane, immediately lower the load and retract the boom. • Wind can cause the hoisted load to move back and forth, which could cause the machine to become unstable.
Page 40 CAUTIONS WHEN SLINGING • Check the following before hoisting a load. Attempt to hoist the load without checking may result in serious accidents by dropping the load or tripping. • Observe the values in the rated total load chart. • Hoist from the centre of gravity of the load. •...
Page 41 CAUTIONS WHEN OPERATING CRANE • Stability of a crane is decisively critical in the transverse direction of the carrier. In the diagonal direction, although stability is increased, exceeding the rated load may result in damage of the boom or Machine body. Do not turn the moment limiter (overload prevention device) off, even if operating in the diagonal direction.
Page 42 CAUTIONS ABOUT HIGH TEMPERATURE OIL WHEN OPERATING CRANE When hydraulic oil temperature exceeds 80°C, high pressure hoses and seals can be damaged by heat, and it may cause burning to skin from oil spray. If temperature of hydraulic oil exceeds 80°C, stop the operation and wait until the oil cools down.
Page 43 CAUTIONS WHEN OPERATING BOOM • Perform boom operation lever operation as slowly as possible. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to waggle and give large impact to the Machine, and thus may damage the crane or trip the Machine.
Page 44 CAUTIONS FOR WORK AT WORKPLACE WHERE LIFT BELOW GROUND LEVEL IS PERFORMED • When lowering a wire rope in work underground, leave at least three loops of wire rope on the winch drum. • Make sure to give signals. • Perform crane operation with extra care. CAUTIONS ON TAVELING WITH HOISTED LOAD Hoisted load traveling operation is in principle forbidden, because it is extremely unstable and dangerous.
Page 45: Transport Precautions
3. TRANSPORT PRECAUTIONS CAUTIONS DURING TRANSPORT When transporting the Machine, there is a risk of inviting a serious bodily accident incurred by an accident during transportation. Strictly observe the following when transporting the Machine. • Depending on the type of crane installed, the mass, height and total length of the machine are varied, and thus check these details.
Page 46 CAUTIONS WHEN LOADING OR UNLOADING (CONTINUED) • Across the border of ramp and loading deck, the center of gravity of the Machine rapidly moves and thus the Machine becomes unstable. Accordingly, pass border particularly slowly. • When unloading the Machine and placing the load onto an earth fill or platform, secure sufficient width, strength and inclination of the ground or the platform.
Page 47: Maintenance Precautions
4. MAINTENANCE PRECAUTIONS 4.1 PRECAUTIONS BEFORE MAINTENANCE PUT UP A WARING SIGNBOARD DURING INSPECTION/MAINTENANCE • When warning sign "DANGER. DO NOT OPERATE!" is put Machine being inspected under maintenance. Do not start the engine and refrain from touching operating levers. Disregarding the warning sign to operate the Machine may give rise to the danger of involving the preparing personnel into the rotating parts or movable parts of the Machine, resulting in serious injury.
Page 48 KEEP ENGINE STANDING STILL DURING INSPECTION AND MAINTENANCE • Before starting inspection and maintenance servicing, be sure to retract the crane and stop the engine. • Turn the starter switch to ON position and move each of the left and right operating levers back and forth to the full stroke for 2 to 3 times so that the residual pressure in the hydraulic circuit is relieved.
Page 49 USE APPROPRIATE TOOLS Use proper tools and handle them in correct manners. Using a damaged or deformed tool and using it for any purpose other than its intended application may giving rise to a serious bodily accident. PRECAUTIONS FOR WORKING AT HIGH ELEVATION Secure scaffolding by using a workbench with the stairs when working at high elevation.
Page 50 CLEAN BEFORE INSPECTION OR MAINTENANCE • Before starting an inspection or maintenance, clean the Machine and prevent rubbish from entering the Machine and make sure the safety will be ensured during maintenance. • Attempt to inspect or maintain the Machine still dirty not only lessens chance of locating faulty part, but may cause rubbish or mud entering your eye, or slipping and tripping that result in injury.
Page 51: Precautions During Maintenance
4.2 PRECAUTIONS DURING MAINTENANCE CAUTIONS DURING WELDING REPAIR Conduct welding operation in a location with good facility, and, only authorized personnel are permitted to be engaged in the welding work. Unauthorized personnel are strictly prohibited since risks such as gas generation, fire and electrical shock are present when welding.
Page 52 BEWARE OF CHIPS WHEN WORKING WITH HAMMER Working with a hammer may cause a serious bodily accident because of springing off of a pin or littering of metallic chips. Strictly observe the following. • Hitting a pin or the like may give rise to shattering of broken chips to hurt people nearby.
Page 53 BEWARE OF FUEL UNDER HIGH INTERNAL PRESSURE In the engine fuel piping, an internal pressure is generated during engine operation. Before starting the inspection and maintenance servicing of fuel piping, wait until its internal pressure is relieved. After stopping the engine, wait for 30 seconds or more before starting the work. HANDLING HIGH PRESSURE HOSE AND PIPING If fuel leaks from a hose or piping, there occurs a risk of fire and malfunction leading to a serious bodily accident.
Page 54 NEVER DISASSEMBLE THE RECOIL SPRING Under no circumstances, refrain from disassembling the recoil spring assembly. In the recoil spring assembly that is intended for buffering the idler, a strong spring is installed. An inadvertent disassembling it causes the spring to jump out, inviting a serious bodily accident.
Page 55 SELECTING WINDOW WASHER SOLUTIONS Use the window washer based on ethyl alcohol. Do not use a washer solution based on methyl alcohol because it may hurt the eyes. PERIODIC REPLACEMENT OF CRITICAL PARTS • To assure the prolonged and safe use of the Machine, be sure to conduct the periodic replacement of parts that are particularly related to safety such parts as hoses and seat belts.
Page 56: Safety Label Locations
5. SAFETY LABEL LOCATIONS Keep safety labels clean and visible at all times. If lost, replace immediately or apply for a new one. There are other labels than safety labels shown below and treat them in the same manner. ［SAFETY LABEL LOCATIONS IN THE CABIN］...
Page 57 ［SAFETY LABEL LOCATIONS OUTSIDE OF THE CABIN］...
Page 58 ［SAFETY LABEL LOCATIONS IN THE ENGINE ROOM］...
Page 59 (1) Safe operation (557-3494500) (2) Working range diagram (585-2236900)
Page 60 (3) Washing caution (300-4213900) (4) Lever operating patterns (585-3555400) (5) Warning on switching numbers of falls (585-3555500)
Page 61 (6) Operating the moment limiter (585-2237000) (7) Warnings on operation, inspection and maintenance (584-3469700) (9) Cautions in repairing window (8) Operation prohibiting tag (585-4738300) breakage (585-4739300)
Page 62 (11) Cautions in opening/closing (10) Cautions in retracting the front the front window (585-4738400) window glass (CL000160010) (12) Cautions in slewing (15) Diesel fuel (585-4738600) (584-4588100) (13) Cautions for high temperatures of muffler (349-4427800)
Page 63 (16) Cautions against the risk of burns (18) Caution against rotating parts in (CL000170000) (2 spots) the engine room (CL000080000) (17) No entry within the slewing area (19) Cautions for plug popping out (CL000180013) (CL000190010) (20) Caution against suffering from electric shock by battery cable (CL000200000) (22) Warning on body hoisting positions (584-3437800) (2 spots)
Page 64 (23) Cautions on the fenders (24) Warning for winch (553-4267500) (CL000210000) (25) Caution against being entangled (26) Warning (553-4268000) by the hook block (553-4267400) (27) Body mass indication (28) Hoisting position (585-4738900) (585-4714800) (2 spots)
Page 65 (29) Tethering position indication (30) Warnings for the accumulator (585-4714200) (4 spots) (CL000220030) (31) Caution against rotation (32) Do not step on (557-4632500) (584-4581700) (2 spots) (34) Warning on boom hoisting (33) Cautions on disconnect switch Accessories (103-4576900) (585-4714100) (36) Cautions on override switch (37) Cautions against the risk of burns...
Page 66 (38) Hoisting machine / Fixing machine (585-3558800) (39) Caution air cleaner (585-4738700) (40) Caution pressure wash (CL000240110) (2 spots)
Page 67: Operation
OPERATION 1. NAME OF EACH SECTION 2. EXPLANATION OF ALL EQUIPMENT 3. OPERATION 4. HANDLING OF WIRE ROPE 5. TRANSPORTATION 6. HANDLING WHEN COLD 7. LONG-TERM STORAGE 8. TROUBLESHOOTING...
Page 68: Name Of Each Section
1. NAME OF EACH SECTION 1.1 MACHINE UNITS (1) Boom (9) Track Frame (2) Working lamp (10) Idler (3) Boom Derrick Cylinder (11) Crawler (4) Winch (12) Hook block (5) Head lamp (13) Overwinding detector (6) Wiper (Front window) (14) Rotating warning lamp (7) Wiper (Roof Window) (15) Rear view mirror (8) Sprocket, travel motor...
Page 69: Crane Operation Units
1.2 CRANE OPERATION UNITS (1) Maintenance switch (12) Lamp switch (2) Air conditioner operation unit (13) Front window wiper switch (3) Car radio (14) Roof window wiper switch (4) Lock lever (15) Buzzer canceling switch (5) Left work operation lever (Winch 2-speed (16) Accessory power supply selector switch on knob part) (17) Room lamp switch...
Page 70: Machine Monitor Components
1.2.1 MACHINE MONITOR COMPONENTS (1) Rear view camera selector switch (8) Fuel gauge (2) User mode switch (9) Warning display (3) Hook storage switch (10) Working mode display (4) Travel mode selector switch (11) Clock display (5) Travel 1st speed/2nd speed selector (12) Hour meter display switch (13) Moment limiter status display...
Page 71: Explanation Of All Equipment
2. EXPLANATION OF ALL EQUIPMENT The following is an explanation of equipment necessary for machine operation and work operation. It is most important that you to correctly understand the operation method of this equipment and the display content in order to perform correct, safe and comfortable work. 2.
Page 72 [2] TOP SCREEN (1) Rear view camera selector switch (7) Clock display (2) User mode switch (8) Hour meter display (3) Hook storage switch (9) Working mode display (4) Travel mode selector switch (10) Auto deceleration display (5) Travel 1st speed/2nd speed selector (11) Winch 1st speed/2nd speed display switch (12) Travel 1st speed/2nd speed display...
Page 73: Monitor Basic Action And Display
2.1.1 MONITOR BASIC ACTION AND DISPLAY [1] REAR VIEW CAMERA SELECTOR SWITCH When the rear view camera selector switch (1) is pressed on the top screen, the camera image is displayed on the monitor. When the home switch (HO) is pressed, the screen returns to the top screen.
Page 74 [2-1] AUTO DECELERATION ON/OFF CHANGE When the switch (2-1) is pressed, auto deceleration ON/OFF can be changed. • OFF: Maintains constant engine speed even if you do not operate the controls for the preset duration. • ON: Reduces engine speed if you do not operate the controls for the preset duration.
Page 75 [2-5] MONITOR BRIGHTNESS ADJUSTMENT When the switch (2-5) is pressed, the monitor brightness can be adjusted. Make adjustments with ◄ or ► of the adjustment switch (2-5B). The screen returns to the previous user mode screen with the home switch (2-5A). [2-6] TIME SETTING SCREEN When the switch (2-6) is pressed, time setting, 24/12 hour display and summer time ON/OFF can be changed.
Page 76 [2-7] LANGUAGE SETTING When the switch (2-7) is pressed, the language can be changed if there are alternatives of the display language. [2-8] ERROR HISTORY DISPLAY When the switch (2-8) is pressed, the error history can be viewed. If a fault occurs now, it is displayed in red characters. See "OPERATION 2.1.2 ‘’WARNING DISPLAY’’...
Page 77 NOTES We recommend setting the consumables icon display selector (2-9C) to "Always". The consumables icon display changes as follows when replacement time approaches when replacement time is exceeded based on the setting made. Always: The consumables icon is always displayed on the top screen.
Page 78 When the switch is released, the automatic stop function of the overwinding prevention device turns into an operating state. NOTES ･ While this switch is pressed, the red lamp of the rotating warning lamp illuminates. ･ When the winch is hoisted while this switch is pressed, the hoisting speed becomes slow, which is not a fault.
Page 79 The switch (5) changes the travel speed into two stages. Each time the switch is pressed, the speed changes from "1st speed" to "2nd speed" to "1st speed" repeatedly. Display of monitor "1": Low speed travel (1st speed) • Display of monitor "2": High speed travel (2nd speed) •...
Page 80: Warning Display
2.1.2 WARNING DISPLAY [1] WARNING DISPLAY AND ERROR CODE DISPLAY If the warning monitor illuminates in red, immediately stop the work and stop the engine or set it to low idle. Then, immediately inspect the applicable part and take the correct action. Emergency stop items are those to which you have to pay attention during engine running and when an abnormality occurs, items for which immediate action must be taken are displayed.
Page 81 [2] LIST OF ERROR CODES If the following error codes are displayed, see "Operation 8. Action in the case of abnormality”. If you think there is another reason, ask us or our sales service agency for repair.
Page 83: Switches
2.2 SWITCHES (1) Starter switch (10) Emergency accelerator driving switch (with (2) Fuel adjustment dial guard) (3) Lamp switch (11) Slewing parking brake emergency canceling (4) Front window wiper switch switch (with guard) (5) Roof window wiper switch (12) Emergency stop switch (6) Buzzer canceling switch (13) Maintenance switch (7) Accessory power supply...
Page 84 [1] STARTER SWITCH Always turn the starter switch to the “OFF” position at the end of work. Use this switch to start and stop the engine. • The key can be inserted and removed, the electrical system current is turned off except the room lamp and the engine stops.
Page 85 [3] LAMP SWITCH Use this switch to turn on the working lamp and headlamps. (a) ON position: The lamp turns on. • (b) OFF position: The lamp turns off. • [4] FRONT WINDOW WIPER SWITCH Use this switch to activate the wiper of the cab front window and window washer fluid.
Page 86 [7] ACCESSORY POWER SUPPLY CAUTION Accessory power supply is for 24V. Do not use this as power supply for equipment of 12V. This can be used as an accessory socket.（100W (24V x 5A)) [8] HORN SWITCH Use this switch to honk the horn. When the switch on the knob part of the right work equipment operation lever is pressed, the horn honks.
Page 87 [10] EMERGENCY ACCELERATOR DRIVING SWITCH CAUTION Use this switch to increase the engine speed temporarily when accelerator revolution does not increase because of an abnormality in the electrical system. Use this switch to perform work temporarily when an abnormality occurs in the accelerator control system. (a) "Emergency"...
Page 88 [11] SLEWING PARKING BRAKE EMERGENCY CANCELING SWITCH CAUTION This enables slewing operation temporarily when the controller is abnormal. Do not use this switch except in the abnormal case. Promptly repair the abnormal area. Use this switch to perform slewing operation temporarily when an abnormality occurs.
Page 89 [12] EMERGENCY STOP SWITCH Use this switch to stop the engine urgently. ON: Press the switch. The engine stops. • "Emergency stop" is displayed on the upper right of the monitor. OFF: Turn the switch clockwise (in the arrow direction on the •...
Page 90 [15] WINCH 2 SPEED SELECTOR SWITCH Perform raising and lowering operation at high speed only under a no load condition and • without hoisting a load. Raising and lowering operation of a hoisted load at high speed may cause serious physical injury due to the machine tipping, breakage or dropping of a load.
Page 91 [16] DISCONNECT SWITCH CAUTION Be sure to place this switch in the "ＯＮ" position. Use this switch temporarily only in the case of preventing unexpected startup of electrical equipment during inspection and maintenance. Use this switch to turn off the battery power supply to prevent unexpected startup of electrical equipment during inspection and maintenance.
Page 92 Use this switch only when the moment limiter fails or a load test of the crane is conducted. ON: Insert the key into the switch. Turn the key clockwise • and then return it to the original position. The key automatically returns to the "OFF"...
Page 93: Operation Levers And Pedals
2.3 OPERATION LEVERS AND PEDALS (1) Lock lever (4) Right work equipment operation lever (with Travel lever (with auto deceleration auto deceleration mechanism) mechanism) (5) Accelerator pedal (3) Left work equipment operation lever (with auto deceleration mechanism) [1] LOCK LEVER When standing up from the driver seat, place the lock lever securely in the lock position •...
Page 94 Use this lever to lock crane operation, slewing and travel operation. (L) Lock: Pull up the lever. The machine does not move even • if each operation lever is operated. (F) Free: Push down the lever. The machine moves if •...
Page 95 [3] WORK EQUIPMENT OPERATION LEVER The operation pattern is set according to the standard operation method (ISO pattern). • If you desire to change the operation pattern, please request us or our sales service agency. When the operation pattern is changed, the operation nameplate needs to be replaced •...
Page 96 [4] ACCELERATOR PEDAL Use the accelerator pedal only when the machine stops and you operate the crane. Never use this pedal during travel operation. An operation mistake may be made, resulting in serious physical injury. Use the fuel adjustment dial to adjust engine speed during travel operation. Use this lever to adjust the engine speed or output during crane operation.
Page 97: Moment Limiter (Overload Preventive Device)
2.4 MOMENT LIMITER (OVERLOAD PREVENTIVE DEVICE) 2.4.1 CONFIGURATION OF MOMENT LIMITER (1) Boom length meter (left side of boom) (2) Boom angle meter (left side of boom) (3) Pressure sensor (derricking cylinder section) (2 pieces) (4) Overwinding detector (side of boom tip) (5) Rotating warning lamp (A) Rotating red lamp (warning lamp when load factor is 100% or more) (B) Rotating yellow lamp (prediction lamp when load factor is 90 - less than 100%)
Page 98: Functions Of Moment Limiter
2.4.2 FUNCTIONS OF MOMENT LIMITER Do not remove, disassemble, or repair the detector. In addition, do not reposition the • detector from the original location to another. When an object hits the detector or damage is found on it, be sure to check the operating •...
Page 99: Moment Limiter Operation And Canceling (Recovery)
[2] MOMENT LIMITER ABNORMALITY OCCURRENCE MESSAGE DISPLAY The moment limiter displays a fault code on the top screen of the monitor to notify the driver if an abnormality occurs in the boom angle meter, boom length meter or pressure sensor, or if wiring is cut or connectors come off.
Page 100 3. When load factor is "100% or more" If the hoisted load exceeds 90% (prediction alarm) of the rated total load and the hoisted load becomes 100% or more of the rated total load by further continuing crane operations, the rotating warning lamp changes from the yellow color to the red color, the alarm sounds continuously and subsequent crane action stops automatically.
Page 101 [When recovering by boom hoisting operation] In the case of an automatic stop, when hoisting of the boom is unavoidable, the boom hoist operation is possible only while keeping the maintenance switch in the “ON” position. To return to the “OFF” position, also return the boom hoisting lever.
Page 102: Moment Limiter Functions
2.4.4 MOMENT LIMITER FUNCTIONS [1] MONITOR DISPLAY OF MOMENT LIMITER (1) Load factor display (8) Boom angle lower limit display (2) Actual load display/Rated total load (9) Boom angle upper limit display display (10) Working radius upper limit display (3) Boom angle display (11) Lifting height upper limit display (4) Actual work radius display/rated work (12) Lifting height upper limit switch...
Page 103 [2] EXPLANATION OF MOMENT LIMITER DISPLAY 1. Rated total load display Continually displays the actual load of the hoisted load during crane operations. The actual load equals the total weight of the hook, hoisting attachment, and hoisted load. When no load is hoisted, it is normal that "0.0"...
Page 104 6. Lifting height display The current lifting height is continually displayed during crane operations. Lifting height refers to the vertical distance from the ground to the bottom of the hook. 7. Boom angle display The current boom angle is continually displayed during crane operations.
Page 105 [3] OVERLOAD ALARM A. Safety area ("Actual Load" is less than 90% of "Rated Total Load") The green color of the rotating warning lamp turns • B. Prediction alarm ("Actual Load" is 90 - less than 100% of "Rated Total Load") The yellow color of the rotating warning lamp turns •...
Page 106 The announcement is given and the alarm generates • continuous sound "peep". The alarm buzzer is activated only when the operation lever operated. • Operation of the boom’s danger side stops automatically. 1. Lifting height upper limit switch Use this switch to set or cancel the upper limit value of lifting height.
Page 107 NOTES Be sure to check, before actual work, that the boom automatically stops at the set angle. If the • boom does not automatically stop, reset the boom angle in the above steps. An alarm sounds intermittently when the boom, which is in the upper limit, is in the prediction zone or •...
Page 108 (2) Setting cancel Use this switch to cancel all the set values set in the above sections 1 - 3. Press and hold this switch. • All the set values set in the above sections 1 - 3 are canceled. [5] Over winding prevention device CAUTION When hoisting the hook, be careful of clearance between the hook and boom.
Page 109 For wire rope, safe load per rope fall is determined. Determine the number of falls according to the maximum hoisting load. Be sure to match the actual number of wire falls of the hook with the number of wire falls displayed on the monitor. This machine is equipped with a hook that serves for both 4 and 2 wire ropes as standard specifications.
Page 110: Moment Limiter Canceling Switch
2.4.5 OVERRIDE SWITCH Override switch has a function to disable the moment limiter. When this switch is turned ON, the crane does not automatically stop with the moment limiter and is very dangerous. Any crane operation in such conditions may result in dropping of hoisted load, breakage of crane boom, and/or machine tipping, and may cause a serious accident resulting in death or serious injury.
Page 111 NOTES You will notice the following when the operation stop function is cancelled. • The red lamp of the rotating warning lamp turns on. • The LED of the switch box lights up. • The buzzer sounds continuously. • The icon will be displayed on the monitor. [Overriding / Turn stater key off to reset] However, these behaviors are subject to change depending on the status of the Machine body.
Page 112: Overwinding Prevention Device
2.5 OVERWINDING PREVENTION DEVICE CAUTION When raising the hook block, be careful of clearance between the hook block and boom. Also, the hook block can be raised when the boom is extended. Perform boom extension operation while always checking the hook block height. (1) Hook block (2) Overwinding detector (3) Weight...
Page 113: Air Conditioner Handling
2.6 AIR CONDITIONER HANDLING 2.6.1 COMPONENTS OF CONTROL PANEL (1) ON/OFF switch (5) Defroster air flow switch (2) Fan switch (6) Fresh and recirculating air selector switch (3) Temperature setting switch (7) Display panel (4) Air outlet selector switch (8) A/C switch [1] ON/OFF SWITCH Use this switch to stop the operation of the fan and air conditioner.
Page 114 [2] FAN SWITCH Use this switch to adjust the amount of air flow. The amount of air flow can be adjusted in four stages. When the switch is pressed, the amount of air flow • increases, and when the switch is pressed, the amount of air flow decreases.
Page 115 [4] AIR OUTLET SELECTOR SWITCH Use this switch to change the air outlet. When the switch (4) is pressed, the air outlet is displayed on • the panel display section (7). Air outlet Air outlet (A): Rear air outlet (1 location) •...
Page 116 Liquid crystal Air outlet Air flow mode display Defroster air flow ○ Note: Air is blown from air outlets with ○ mark. [6] FRESH AND RECIRCULATING AIR SELECTOR SWITCH Use this to change between interior air recirculation and fresh air intake. The fresh air is shut and the interior air is Interior air recirculated.
Page 117: Air Conditioner Operation Method
2.6.2 AIR CONDITIONER OPERATION METHOD [1] OPERATION 1. Press the fan switch (2) to adjust the amount of air flow. Check, at this time, that the set temperature and the amount of air flow are displayed on the display panel. 2.
Page 118 [3] DEFROSTER OPERATION 1. Press the fan switch (2) to adjust the amount of air flow. Check, at this time, that the set temperature and the amount of air flow are displayed on the display panel. 2．Press the defroster air flow switch (5) and check that the air outlet is the defroster on the display panel.
Page 119: Precautions In Air Conditioner Use
2.6.3 PRECAUTIONS IN AIR CONDITIONER USE CAUTION Be sure to start the engine at low speed when breaking in the air conditioner. Never start • the air conditioner when the engine is running at high speed. Such may cause the air conditioner to malfunction.
Page 120: Car Radio Handling
2.7 CAR RADIO HANDLING 2.7.1 EXPLANATION OF THE EQUIPMENT Main body section (1) Power button (5) Preset button (2) AM/FM selector button (6) Display selector button (3) Volume control button (7) Sound quality adjustment button (4) Tuning button (8) Display Display part (a) Characters/numerical value information (d) This turns on at the time of balance...
Page 121 [1] POWER BUTTON (ON/OFF) The radio power turns on and the frequency is displayed on the display (8). When the button is pressed again, the power turns off. [2] AM / FM SELECTOR BUTTON (AM/FM) The sound quality adjustment of the desired band can be set. Each time the button is pressed, the indication of the display (8) changes "FM→AM→FM...".
Page 122 [8] DISPLAY This displays the reception band, frequency, preset number and time. [Antenna] Be sure to store the antenna to keep out of the way during transportation or when you take the machine in the garage. Take the following steps for storage. 1.
Page 123: Car Radio Operation Method
2.7.2 CAR RADIO OPERATION METHOD [1] TUNING METHOD 1. Press the power button (1). The frequency is displayed on the display (8). 2. Use the tuning button (4) to tune to the desired frequency. Tuning has two types: Auto tuning and manual tuning. Manual tuning •...
Page 124 [3] OPERATION METHOD OF EACH MODE To set each mode, operate the sound quality adjustment button (7) and tuning button (4). 1. Low sound (BAS) adjustment Press the button (7) to display "BAS" on the display (8). Operate the tuning button (4) to adjust low sound. button: Emphasize low sound •...
Page 125: Precautions In Car Radio Use
3. When the display selector button (6) is pressed, the "minute" part flashes. Operate the tuning button (4) to adjust "minute". button: Each time the button is pressed, time is advanced by one minute. • button: Each time the button is pressed, time is put back by one minute. •...
Page 126: 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 used here are blade fuses. If a fuse is corroded and shows white powder, be sure to change the fuse.
Page 127: 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 large fuse wiring installed in the circuit through which a large capacity current flows. As with a normal fuse, this protects electrical equipment and wiring from burning due to abnormal current.
Page 128: Controller
2.10 CONTROLLER CAUTION • Do not splash water, mud, juice and so on onto the controller. Doing so may cause a malfunction. • If an abnormality occurs in the controller, do not repair it by yourself but contact us or our sales service agency for inspection and repair.
Page 129: Cab Front Window
2.11 CAB FRONT WINDOW • When standing up from the driver seat, place the lock lever securely in the lock position. If the lock lever is in the free position and contacts the operation levers and operation pedals carelessly, serious physical injury may be caused. •...
Page 130 5. Check that the lever (B) is securely in a locked state. [2] WHEN CLOSING When closing the front window, slowly lower it to prevent your hand from being pinched. 1. Stop the machine on a level place and stop the engine. 2.
Page 131: Door
4. Hold the handles (A) of the front window with both hands, push them forward and gently lower them. 5. After moving the front window to the sash to align the position, push it forward and securely push it against the right and left locks (E) until "click"...
Page 132: Hammer For Emergency Escape
2.13 HAMMER FOR EMERGENCY ESCAPE • When striking the window glass with a hammer, be careful not to be injured by pieces of scattered broken glass. • When escaping, remove pieces of the glass from the sash to avoid injury by pieces of the glass.
Page 133: Cap And Cover With Lock
2.14 CAP AND COVER WITH LOCK • Use the starter switch key to open and close the cap and cover with lock. • Securely insert the key into the root (A) before turning. If the key is turned halfway, the key may be broken. •...
Page 134: Battery Room Door
2.15 BATTERY ROOM DOOR • When performing inspection and maintenance inside the door, be sure to fix the door in an open condition by using the stopper. 1. Insert your finger into the door pull (1) and open the door (2).
Page 135: Right Cover
2.17 RIGHT COVER • When performing inspection and maintenance inside the door, be sure to fix the door in an open condition by using the stopper. • Be sure to lock the door except when opening it. 1. Disengage the lock (1) of door locking. 2.
Page 136: Machinery Cover
2.18 MACHINERY COVER •Always use the designated place on the machinery cover, or you may slip and fall down. See "Safety 1.4 Cautions in getting on and off" for details. • When performing inspection and maintenance inside the machinery cover, be sure to fix the machinery cover in an open condition by using the machinery cover supporting rods.
Page 137: Grease Pump Holder
2．20 GREASE PUMP HOLDER This is located in the left door on the rear left. If you are not using the grease pump, hang it on this holder. 2．21 CUP HOLDER This is located on the left side in the cab. 2.22 RETRACTABLE SEAT BELT HANDLING ･...
Page 138: Operation
3. OPERATION 3.1 PRE-OPERATION INSPECTION 3. 1. 1 CHECKING BEFORE STARTING ENGINE • This machine is equipped with a diesel engine. If you smell fuel around the engine, it may be leaking. Carefully check for cracks on the fuel hose or fuel hose connections. •...
Page 139: Inspection Around Crane
[1] INSPECTION AROUND CRANE • Look around the surrounding area and lower parts of the boom and boom mounts to check for oil leaks. In particular, thoroughly inspect the derricking cylinder and the lower part of the winch motor around the mounts. Repair if any abnormality is found. •...
Page 140: Inspection Around Upper Slewing Body
[4] INSPECTION AROUND UPPER SLEWING BODY • Inspect if there are fuel leaks, oil leaks and water leaks from the engine. Repair if any abnormality is found. • Check for any accumulation or deposits of inflammable items including fallen leaves, wastepaper, dust, oil or grease in high temperature areas such as engine and muffler and around the battery.
Page 141: Checking Before Starting Engine
3. 1. 2 CHECKING BEFORE STARTING ENGINE Check the following in this section without starting the engine and before starting work every day. [1] CHECKING/REFILLING ENGINE COOLANT • Do not open the radiator cap when engine is hot. Inspect the coolant in the sub tank after the engine is cold.
Page 142 CAUTION • See “MAINTENANCE 7.1 USE OF FUEL AND LUBRICATING OIL ACCORDING TO TEMPERATURES” for the oil to be used. Using oil other than those specified may shorten the life of the engine. Be sure to refill with the specified oil. •...
Page 143: Checking/Refueling Fuel Level In Fuel Tank
[3] CHECKING FUEL LEVEL AND REFILLING FUEL IN FUEL TANK • Be extremely careful with fire such as cigarettes. • Always stop the engine before refilling fuel. Refilling the oil when engine is running may cause leaked fuel to draw fire from hot muffler or other hot areas. •...
Page 144: Checking/Refilling Oil Level In Hydraulic Oil Tank
[4] CHECKING OIL LEVEL AND REFILLING OIL IN HYDRAULIC OIL TANK • As parts and oil become hot immediately after the engine stops, you may suffer burns. Wait until the temperature drops, then start the work. • The oil may spurt out when the filler cap is removed. Turn the cap slowly to release the internal pressure before removing.
Page 145: Inspection Of Dust Indicator
6. If the oil level is below the "L" level, refill hydraulic oil from the filler opening (2). CAUTION When refilling, avoid the oil exceeding "H" of the level gauge. Otherwise, the hydraulic circuit may be damaged or the oil may spurt out. If the oil is refilled to the level exceeding "H", drain the excess oil in the following steps.
Page 146 [6] INSPECTING WATER SEPARATOR AND DRAINING CONTAMINANT WATER/DEPOSITS • The water separator has fuel (diesel fuel) inside. Be extremely careful of fire such as cigarettes when cleaning the transparent cap of the water separator. • If the fuel spills when water is drained from the water separator or the water separator is replaced, be sure to wipe it off.
Page 147: Draining Contaminant Water/Deposits In Fuel Tank
NOTES • If it is difficult to see the transparent cap (2) because it is dirty, clean the transparent cap (2) when replacing the fuel prefilter cartridge. 5. Close the right cover of the machine body. [Sub filter] 1. Inspect in the same steps as the main filter. ［7］...
Page 148: Inspecting Electric Wiring
[8] CHECKING ELECTRIC WIRING • When a fuse blows frequently or there is a trace of short circuit in the electric wiring, immediately request us or our sales service agency for the investigation of the cause and repair. • Keep the top face of the battery clean and inspect the vent hole of the battery cap. If it is clogged with mud, wash the battery cap with water to remove clogging.
Page 149: Adjusting The Operator's Seat
[11] ADJUSTING THE OPERATOR'S SEAT • Adjust the seat before operation or when a driver changes. • Adjust the seat with your back pushed against the seat back of the driver seat so that you can sufficiently operate the operation levers, switches and accelerator pedal. •...
Page 150: Adjustment Of Mirrors
[12] ADJUSTMENT OF MIRRORS Be sure to adjust the mirrors before operation. If the mirrors are poorly adjusted, the visibility can not be secured, resulting in disorder or serious physical injury. [MIRROR (A)] Adjust the mirror mounting so that a person at the rear left of the machine is in view.
Page 151: Adjusting Mirror For Checking Irregular Winding
[13] ADJUSTMENT OF MIRROR FOR CHECKING IRREGULAR WINDING Be sure to adjust the mirrors before operation. If the mirror is poorly adjusted, irregular winding caused by the winch drum cannot be checked. This not only damages the wire rope, but also shakes a hoisted load at the time of lowering, leading to instability and serious physical injury.
Page 152: Angle Adjustment Of Rear View Camera
[14] ANGLE ADJUSTMENT OF REAR VIEW CAMERA If images displayed on the monitor are not in the right position, remove the cover (1) and adjust the mounting angle (A) of the rear view camera. 1. Remove the bolt (2) (2 locations) to remove the cover. 2.
Page 153: Checking Battery Electrolyte Level
[15] CHECKING BATTERY ELECTROLYTE LEVEL Do not use the battery with its electrolyte level kept below "LOWER LEVEL " (minimum • electrolyte level line). The deterioration inside the battery is promoted, and not only is the battery life is shortened, but also the battery may burst (explode). •...
Page 154 3. After refilling, securely tighten all the caps (2). NOTES If purified water should be refilled above the highest electrolyte level line, use a syringe to extract it up to the highest electrolyte level line. For the extracted liquid, after neutralizing it with baking soda, wash it away with a lot of water.
Page 155: Checking After Starting Engine
3. 1. 3 CHECKING AFTER STARTING ENGINE Check the following in this section after starting the engine and before starting the work every day. CAUTION The checkups described in this section should be carried out after starting the machine. See "OPERATION 3.2 OPERATIONS AND CHECKS BEFORE STARTING ENGINE " and later to execute the engine start up, travelling operations and crane operations.
Page 156: Checking Crane Operations
[4] CHECKING CRANE OPERATIONS When performing an operation check of the crane, see "OPERATION 3.15 OPERATION BEFORE CRANE WORK" to "OPERATION 3.22 CRANE STOWAGE OPERATION" and observe the procedure and precautions. 1. Verify that the boom rises smoothly when the right work equipment operation lever is operated to "RAISE"...
Page 157 [5] CHECKING OVER HOIST PREVENTION DEVICE When performing the winch winding up operation and boom extending operation with the hook block (1) in a overwound state (a state in which the hook block (1) pushes up the weight (3)), check that the buzzer sounds intermittently and that the winch winding up operation and boom extending operation automatically stopped.
Page 158: Operations And Checks Before Starting Engine
3.2 OPERATIONS AND CHECKS BEFORE STARTING ENGINE When starting the engine, check that the lock lever is securely in the lock position. If you carelessly touch the operation levers and operation pedals at the same time as engine start, the machine may make an unexpected movement, causing serious physical injury.
Page 159: Starting Engine
3.3 STARTING ENGINE Never refuel (diesel fuel) while the engine is in operation. Always stop the engine before refilling fuel. Start the engine only when the operator is sitting on the operator's seat. • Do not start the engine by short-circuiting the starter circuit. Doing so may cause serious •...
Page 160 2. Insert the key into the starter switch (3) and turn the key to the "START" position. The engine starts. 3. When the engine has started, release your hand from the key. The key automatically returns to the "ON" position. 4.
Page 161: Operations And Checks After Starting Engine
3.4 OPERATIONS AND CHECKS AFTER STARTING ENGINE Never refuel (diesel fuel) while the engine is in operation. Always stop the engine before refilling fuel. When trouble such as emergency stop and abnormal action occurs, promptly turn the • starter switch to the "OFF" position and stop the engine. Do not perform work, sudden lever and pedal operations while the hydraulic oil •...
Page 162: Warm-Up Operations For Hydraulic Equipment
3.4.2 WARM-UP OPERATIONS FOR HYDRAULIC EQUIPMENT • Before performing warm-up operations for hydraulic equipment, make sure no personnel or impediments are close to the hydraulic equipment and honk the horn. • The warm-up operations for hydraulic equipment are necessary not only for the pump - cylinder circuits and pump-motor circuits but also for the operation circuits.
Page 163 7. Slowly operate the left work equipment operation lever (4) to the stroke end on the "Extend" side (push forward) and after the boom completely extends, hold the lever at that position for 30 seconds. At this time, operate the right work equipment operation lever (3) to the "Wind down"...
Page 164: Stopping Engine
3.5 STOPPING ENGINE CAUTION • Stopping the engine before it sufficiently cools down may shorten the life of engine units. Do not stop the engine suddenly except for an emergency. • When the engine is overheated, do not stop the engine suddenly.
Page 165: Break-In Operation
3.6 BREAK-IN OPERATION Perform break-in period for approximately the first "100 hours" (hours displayed on the service meter). The performance and life of the machine are adversely affected if overloaded operation or task is performed before the various sections of the machine are used to the operation. While this machine is shipped after thorough adjustment and inspection, immediate difficult tasks will quickly degrade the functions and shorten the life of the engine and crane.
Page 166: Starting (Forward And Backward)/Stopping The Machine
NOTES For details of stowage operation of the hook block, see "OPERATION 3.22 CRANE STOWAGE OPERATION". 3.8 STARTING (FORWARD AND BACKWARD)/STOPPING THE MACHINE • Check the direction of the track frame before operating the travelling lever. When the track frame faces backward (when the sprocket is in the front), the direction of the travelling lever operation is opposite to the direction of the machine movement.
Page 167 [1] MOVING FORWARD 1. Place the lock lever (4) at the "Free" position. 2. Operate the right and left travelling levers (5) as follows. • When the sprocket (A) is rearward of the machine body Push the travelling levers (5) slowly forward to start moving.
Page 168 [2] MOVING BACKWARD 1. Place the lock lever (4) at the "Free" position. 2. Operate the right and left travelling levers (5) as follows. • When the sprocket (A) is rearward of the machine body Pull the travelling levers (5) slowly toward you to start moving.
Page 169: Changing Direction Of The Machine
3.9 CHANGING DIRECTION OF THE MACHINE Check the direction of the track frame (position of the sprocket) before operating the travelling lever. When the sprocket is in the front, the direction of the travelling lever operation is opposite to the direction of the machine movement. Operate the travelling lever (1) to change the direction.
Page 170: Slewing The Machine
[3] MAKING PIVOT TURN (SPIN TURN) ON THE SPOT To make a pivot turn to the left, pull the left travelling lever toward you and push the right travelling lever forward. NOTES To make a pivot turn to the right, pull the right travelling lever toward you and push the left travelling lever forward.
Page 171: Parking The Machine
3.11 PARKING THE MACHINE • Choose a level and solid location for parking the machine. If it is necessary to park on a slope, provide some blocks so that the machine will not move. • Careless contact with the travelling lever(s) may result in sudden movement of the machine, leading to serious physical injury.
Page 172: Inspection And Check After Completing Work
3.12 INSPECTION AND CHECK AFTER COMPLETING WORK 3.12.1 AFTER STOPPING ENGINE 1. Check for oil and water leaks and conduct a walk-around check of the crane, exterior and undercarriage. If you find any leakage or abnormality, fix the problem. 2. Fill up the fuel tank to full. 3.
Page 173: Cautions In Driving
3.13 PRECAUTIONS IN TRAVELLING Unless these precautions in travelling are observed, serious physical injury may be caused. [1] PRECAUTIONS IN TRAVELLING Travelling over boulder stones or a stump can give a big impact to the machine (especially undercarriage), causing breakage. Avoid or remove the obstacles so as not to travel over it whenever possible.
Page 174 [3] ALLOWABLE WATER DEPTH If the climbing posture of sharp angle of "15 degrees" or more is taken, when the machine comes out of water, the revolving super structure may be submerged in water and the engine fan may stir up water, resulting in breakage of the fan.
Page 175 • When travelling on a steep downhill, keep down the speed using the travelling lever and fuel adjustment dial. When travelling downhill the inclination of which is 10 degrees or more, place the sprocket (A) at the downhill side and travel by decreasing the engine speed in the posture as shown in the right figure.
Page 176: Precautions Before Crane Operation
3.14 PRECAUTIONS BEFORE CRANE OPERATION Unless these precautions before work are observed, serious physical injury may be caused. • Be sure to select a level place and stop the machine there before performing work. After stopping the machine, check the level with a spirit level.
Page 177 • When boom is excessively extended, the hook block is hoisted, the overwinding prevention device is activated, the warning buzzer sounds and the operation stops. When the warning buzzer sounds, release your hand immediately from the left work equipment operation lever and place it at the neutral position to stop the boom extension operation.
Page 178: Operation Before Crane Work
3.15 OPERATION BEFORE CRANE WORK If the boom extending and raising operations are performed with the hook block hung on the wire rope for stowage, the wire rope for stowage is broken and the vicinity of the normal stowage device in the front of the revolving super structure is damaged. Be sure to perform the hook lowering operation so that the wire rope for stowage is not tightened.
Page 179 4. Operate the right work equipment operation lever (3) to "RAISE" side (pull toward you) to raise the boom. NOTES At this time, be careful not to allow the hook block (4) and rope for stowage (5) to be overtightened. If the rope for stowage (5) is overtightened, lower the hook block (4).
Page 180: Crane Operation Posture
3.16 CRANE WORK POSTURE When moving to the crane work from the state of "Operation 3.15 Operation Before Crane Work", put the crane into the crane work posture in the following manner. 1. Operate the right work equipment operation lever (1) to the "HOIST"...
Page 181: Hoisting And Lowering Operation
3.17 HOISTING AND LOWERING OPERATION • With the boom deflection, the hoisted load slightly shifts forward. Notify the workers around such as slinging operators. • If the hook block is overhoisted, the overwinding prevention device detects overwinding and the warning buzzer sounds intermittently. When the buzzer sounds, immediately operate the right work equipment operation lever to the neutral position to stop the hoisting operation.
Page 182: Hoisting And Lowering Operation At High Speed
3.17.2 HOISTING AND LOWERING OPERATION AT HIGH SPEED • Perform high-speed winch operation only in a state of no load without lifting a load. The winch operation of a hoisted load at high speed may cause serious physical injury due to machine tipping and breakage or dropping of a load.
Page 183: Hoisting Operation With Hook Stowage Switch
3.17.3 HOISTING OPERATION WITH HOOK STOWAGE SWITCH • The hook storage switch cancels the automatic stop function of the overwinding prevention device. When storing the hook block, carefully operate the right work equipment operation lever and pay due attention not to allow the hook block to crash against the boom. •...
Page 184: Boom Derricking Operation
3.18 BOOM DERRICKING OPERATION • Perform the right work equipment operation lever operation as slowly as possible. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to waggle and give a large impact to the machine, and thus may damage the crane or tip the machine.
Page 185: Boom Telescoping Operation
3.19 BOOM TELESCOPING OPERATION • Perform the left work equipment operation lever operation as slowly as possible. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to waggle and give a large impact to the Machine, and thus may damage the crane or tip the Machine.
Page 186 CAUTION When the boom extends and the hook block (3) pushes up the weight (5) of the overwinding detector (4), the boom extension stops. In this state, the boom does not extend when the boom extending operation is performed. In such a case, lower the hook block by performing the retracting operation or the lowering operation of the boom.
Page 187: Slewing Operation
3.20 SLEWING OPERATION • Check for safety in the vicinity and honk the horn before slewing. • Perform the slewing operation as slowly as possible. Make sure to start smoothly, slew at low speed, and stop quietly. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to waggle and cause the machine to lose balance, and thus may damage the crane or tip the machine.
Page 188: Accelerator Operation
3.21 ACCELERATOR OPERATION • Accelerating the operation speed of the crane units more than necessary is dangerous. Adjust the speed to the proper working speed suitable to the work. • Use the accelerator pedal only when the machine stops and you operate the crane. Never use this pedal during travelling with a lifted load.
Page 189 • (a) Low idling: Release your foot from the pedal. The engine speed decreases and the working speed of the crane parts becomes slow. At this time, the speed turns to the minimum working speed adjusted by the fuel adjustment dial (1). •...
Page 190: Crane Stowage Operation
3.22 CRANE STOWAGE OPERATION 3.22.1 CRANE STOWAGE OPERATION AT THE TIME OF SIMPLE STOWAGE OF HOOK BLOCK • The hook storage switch cancels the automatic stop function of the overwinding prevention device. When storing the hook block, carefully operate the right work equipment operation lever and pay due attention not to allow the hook block to crash against the stowage position at the boom tip.
Page 191 1. Operate the left work equipment operation lever (2) to the "Retract" side (pull toward you) to retract the boom fully. NOTES The hook block lowers with the boom retracting operation. Perform the hoisting operation as appropriate and hoist the hook block.
Page 192 6. While pressing the hook stowage switch, operate the right work equipment operation lever (1) to the "Hoisting" side (pull toward you) again and slowly and carefully hoist the hook block (3) to store it in the lower part of the boom tip. NOTES When the hook stowage switch is pressed, the red lamp of •...
Page 193: Crane Stowage Operation At The Time Of Normal Stowage Of Hook Block
3.22.2 CRANE STOWAGE OPERATION AT THE TIME OF NORMAL STOWAGE OF HOOK BLOCK When storing the hook block, carefully operate the right and left work equipment operation • levers. Otherwise, the hook block may sway considerably, not only damaging the peripheral equipment but also causing serious physical injury.
Page 194 3. Operate the right work equipment operation lever (2) to the "Lower" side (push forward) and lower the hook block to near the normal stowage position. NOTES At this time, do not lower the hook block (3) excessively. If it is excessively lowered, the loosened hook block (3) may damage the peripheral equipment.
Page 195: Prohibited Operations During Crane Work
3.23 PROHIBITED OPERATIONS DURING CRANE WORK Always set the machine on level, solid ground when performing the crane operations. • Check the level state using a levelling instrument. Even when the crane must be unavoidably operated during travelling, be sure to stop the •...
Page 196 [5] DON'T ALLOW ACCESS INTO WORKING RADIUS Do not allow personnel to approach the working radius such as letting operators enter under a hoisted load. DON'T OTHER THAN MAIN APPLICATIONS Do not move people up/down with the crane. DON’T PERFORM UNREASONABLE OPERATIONS Operations requiring more than the machine performance...
Page 197: Operation During Travelling Hoist
3.24 OPERATION DURING TRAVELLING A HOISTED LOAD 3.24.1 PRECAUTIONS IN OPERATION DURING TRAVELLING A HOISTED LOAD Travel with a lifted load is in principle dangerous because it is very unstable. If travelling a hoisted load is unavoidably performed, strictly observe the range described in "List of gross rated load for travelling hoist"...
Page 198: Operation Posture During Travelling A Hoisted Load
3.24.2 OPERATION POSTURE DURING TRAVELLING A HOISTED LOAD When having this machine travel with a hoisted load, take the following "Travelling hoist • posture". Retract the boom to "10.5m" (three stage boom) or less. • Slew the boom to the front center position. •...
Page 199: Operation Of Travelling A Hoisted Load Work
3.24.3 OPERATION OF TRAVELLING A HOISTED LOAD WORK When performing travelling hoist work, see "OPERATION 3.24.1 PRECAUTIONS IN • OPERATION DURING TRAVELLING A HOISTED LOAD " and try to perform safety work. Do not perform any crane operation when travelling with a hoisted load. The machine may •...
Page 200: Handling Of Wire Rope
4. HANDLING OF WIRE ROPE 4.1 CRITERIA FOR WIRE ROPE REPLACEMENT CAUTION • The criteria for replacing wire ropes is common to all the wire ropes for winching, telescoping the boom, and slinging. • The diameter of the wire rope is measured at points where the wire repeatedly runs through the sheave.
Page 201 4. As a result of form collapsing, the following are observed: Undulation width (1) A strand that is kinked. (2) When the width of an undulation exceeds 4/3 d within a section that is 25 times of nominal diameter d. (3) When a wire rope is flattened by local crushing and the minimum diameter is 2/3 of the maximum diameter or less...
Page 202: Winch Wire Rope Reeving System And Gross Rated Load
4.2 WINCH WIRE ROPE REEVING SYSTEM AND GROSS RATED LOAD Use a wire rope so that the load per wire rope is "1500 kg" or more. The table below shows the type of a hook block, number of falls of a wire rope and the maximum gross rated load at that time.
Page 203: Measure To Take When Winch Wire Rope Is Twisted
4.3 MEASURE TO TAKE WHEN WINCH WIRE ROPE IS TWISTED Always put on thick leather work gloves when handling the wire rope. CAUTION Rewind the wire rope from time to time so that the hook block side and the winch drum side are opposite to each other.
Page 204 12. Repeat the above steps until the twist of the hook is eliminated. Replace the wire rope with a new one if the twist is not corrected by the above steps.
Page 205: Transportation
5. TRANSPORTATION Observe the related regulations and exercise safety during transport. 5.1 LOADING/UNLOADING See "SPECIFICATION 1. MAIN SPECIFICATION TABLE" for the dimensions and mass of • this machine. Select ramp boards to be used which satisfies the following conditions. • Length must be such that the setting angle onto a trailer is 15 degrees or less.
Page 206: Loading
Put the machine in the “travelling posture” and always use ramp boards or forwarding blocks when loading/unloading the machine. Follow the procedure below. 5.1.1 LOADING 1. Select a level and firm road surface for loading the machine. In addition, keep enough distance from the roadside. 2.
Page 207 8. Before getting on the ramp boards, check that the machine is positioned in a straight line to the ramp boards and that the center of the machine is aligned with the center of the trailer. 9. Fix the direction toward the ramp boards and slowly travel for loading.
Page 208: Fixing The Machine
5.1.2 FIXING THE MACHINE CAUTION Store the radio antenna. Re-assemble mirrors so that they are within the machine body width. After loading the machine to the specified position of the trailer, fix the machine in the following steps. 1. Place the lock lever (1) securely in the lock position (L). 2.
Page 209: Unloading
5.1.3 UNLOADING 1. Select a level and firm road surface for unloading the machine. In addition, keep enough distance from the roadside. 2. Brake the trailer securely. Place wheel blocks next to the wheels of the trailer to secure the trailer. 3.
Page 210: Hoisting Machine
5.2 HOISTING MACHINE 5.2.1 HOISTING MACHINE WITH BOOM LOWERED • See "SPECIFICATION 1. MAIN SPECIFICATION TABLE" for the dimensions and mass of this machine. • A person who uses the crane to perform hoisting operation must have the crane operation qualifications.
Page 211 5. Pass the wire rope for slinging through between the 1st and 2nd of the track crawler from the front of the machine and between the 1st and 2nd from the rear. 6. Put nailing strips between the wire rope and machine so that the wire rope and machine are not damaged.
Page 212: Hoisting Machine With Boom
5.2.2 HOISTING MACHINE WITH BOOM • See "SPECIFICATION 1. MAIN SPECIFICATION TABLE" for the dimensions and mass of this machine. • A person who uses the crane to perform hoisting operation must have the crane operation qualifications. • Do not perform hoisting operation with a worker placed on the machine. •...
Page 213: Cautions During Transportation
3. Place the lock lever (1) securely in the lock position (L). 4. Stop the engine and remove the starter switch key. Check that there is nothing around the driver seat and get off the machine. 5. Close all the doors, windows and covers. Lock the door, covers and caps with lock.
Page 214: Handling When Cold
6. HANDLING WHEN COLD 6.1 PREPARING FOR LOW TEMPERATURE In cold conditions, the machine starts to have some difficulty in starting. Take the following actions. [1] LUBRICATION Change the lubricating oil to one with a lower viscosity. See “MAINTENANCE 7.1 USE OF FUEL AND LUBRICATING OIL ACCORDING TO TEMPERATURE”...
Page 215 NOTES Measure the specific gravity of the battery fluid and convert it into the charging rate using the chart below. Fluid Temperature (°C) 1.28 1.29 1.30 1.31 Charging 1.26 1.27 1.28 1.29 Rate 1.24 1.25 1.26 1.27 1.23 1.24 1.25 1.26 [4] CAUTIONS AFTER COMPLETING THE OPERATION Observe the following to prevent the machine from not being able to function the next morning...
Page 216: Long-Term Storage
7. LONG-TERM STORAGE 7.1 BEFORE STORING MACHINE CAUTION Keep the machine in the "Travelling posture" shown in the figure on the right during long-term storage to protect the cylinder rod. See “Operation 3.7 Travelling Posture of Machine” for details. (To prevent rust on the cylinder rod) Store the machine as described below when storing it for one month or longer:...
Page 217: After Storage
7.3 AFTER STORAGE CAUTION If you did not perform antirust operation monthly during the long-term storage, contact us or our sales service agency before using the machine. Perform the following before using the machine after the long-term storage. • Remove the drain plug of the fuel tank, hydraulic oil tank, and engine oil pan to drain the water mixed in.
Page 218: Troubleshooting
8. TROUBLESHOOTING 8.1 WHEN FUEL RUNS OUT When starting the engine after fuel runs out, refill fuel and bleed air from the fuel system before starting the engine. [PROCEDURE FOR AIR BLEEDING] Start the engine and check if the fuel system leaks. A fuel leak causes a fire. •...
Page 219: Phenomenons That Are Not A Fault
11. Repeat the operation of the procedure 8 to 10 several times. 8.2 PHENOMENONS THAT ARE NOT A FAULT The following phenomena are not a fault. • A sound is generated from around the valve when the boom is retracted to the end and the telescopic cylinder is relieved on the retraction side.
Page 220: When Battery Has Discharged
8.3 WHEN BATTERY HAS DISCHARGED 8.3.1 BATTERY HANDLING PRECAUTIONS • It is dangerous to charge the battery in an installed condition. Be sure to remove it from the machine and charge it separately. • Stop the engine and turn the starter switch to the “OFF” position when checking/handling the battery.
Page 221: Removing/Installing Battery
8.3.2 REMOVING/INSTALLING BATTERY CAUTION Verify that the battery does not move after securing the battery. If it moves, secure it again. [1] REMOVAL 1. Open the battery room door and turn up the vinyl cover installed on the battery. 2. First, remove the cable (2) on the (-) terminal side (ground side) of the right-hand battery.
Page 222: Cautions In Charging Battery
8.3.3 CAUTIONS IN CHARGING BATTERY If you make a handling mistake during battery charging, the battery may explode. Strictly observe the following according to "Operation 8.3.1 Precautions in Handling Battery" and the instruction manual attached to the charger. • Adjust the charger voltage to suit the voltage of the battery to charge.
Page 223: Starting Engine With Booster Cable
8.3.4 STARTING ENGINE WITH BOOSTER CABLE Start the engine with booster cable as described below. [1] CAUTIONS IN CONNECTING/DISCONNECTING BOOSTER CABLE • Never let the (+) terminal come into contact with the (-) terminal when connecting the cable. • Wear goggles and rubber gloves when starting the engine with the booster cable.
Page 224 [3] STARTING ENGINE Verify that the lock lever of both the normal machine and failed machine is at the lock position. In addition, verify that each operation lever is at the neutral position. 1. Verify that the clips are securely connected to the battery terminals. 2.
Page 225: When Such A Phenomenon Occurs
8.4 WHEN SUCH A PHENOMENON OCCURS 8.4.1 ELECTRICAL COMPONENTS • Make sure that you contact us or our sales service agency for the actions marked with in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or cause than those given below.
Page 226 Abnormal Phenomenon Major cause(s) Remedy • Defective wiring Check and repair looseness, pullout and Travelling alarm does not sound break of connector when travelling lever is operated. • Defective alarm Replacement • Defective PPC pressure Replacement sensor • Defective wiring Check and repair looseness, pullout and Rear view camera shows...
Page 227: Machine Body Components
8.4.2 MACHINE BODY COMPONENTS • Make sure that you contact us or our sales service agency for the actions marked with in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or causes than those given below.
Page 228: Engine Components
8.4.3 ENGINE COMPONENTS • Make sure that you contact us or our sales service agency for the actions marked with in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or causes than those given below.
Page 229 Abnormal Phenomenon Major cause(s) Remedy • Insufficient fuel • See “Check before operation” and refuel • Mixing of air in fuel system • See "Periodical Maintenance" to repair the area where air is mixed • Defective fuel pump and Replace pump or nozzle Engine does not start even after nozzle the starter key is turned...
Page 230: Moment Limiter Components
8.4.4 MOMENT LIMITER COMPONENTS • Make sure that you contact us or our sales service agency for the actions marked with in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or causes than those given below.
Page 231: Overwinding Prevention Device
8.4.5 OVERWINDING PREVENTION DEVICE • Make sure that you contact us or our sales service agency for the actions marked with in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or causes than those given below.
Page 232 This Page Intentionally Left Blank.
Page 233: Inspection And Maintenance
INSPECTION AND MAINTENANCE 1. PRECAUTIONS FOR MAINTENANCE 2. BASIC MAINTENANCE 3. LEGAL INSPECTION 4. PERIODIC REPLACEMENT OF CRITICAL PARTS 5. CONSUMABLES 6. OTHER REPLACEMENT PARTS 7. USE OF FUEL AND LUBRICATING OIL 8. STANDARD TIGHTENING TORQUE 9. LIST OF ITEMS FOR INSPECTION AND MAINTENANCE 10.
Page 234: Precautions For Maintenance
[2] USE GENUINE PARTS FOR REPLACEMENT Always use Maeda genuine parts as specified in the parts catalog for part replacement. [3] USE PURE GREASE Always use Maeda pure grease. The viscosity of grease must conform to specifications according to ambient temperature.
Page 235 [21] DO NOT MIX DIFFERENT BRANDS OF OIL Never mix oil of different brands and different types under any circumstance. Replace the oil entirely when replenishing a different type of oil. Always use Maeda genuine parts for part replacement.
Page 236: 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 237 If metal powder is found on the used filter, contact us or our sales service agent. • Always unpack the replacement filter prior to its use. • Always use Maeda genuine filters. [6] COOLANT HANDLING • The river water contains a large amount of calcium and impurities. Use of the river water results in accumulation of water stain in the engine and radiator, which causes heat exchange error leading to overheating.
Page 238 [7] ELECTRICAL PARTS HANDLING • A current leakage is developed if the electrical parts are wet or have a damaged coating, which causes the machine to become out of order and malfunction. • Inspection and maintenance include the checking of belt tension, belt damage, and battery electrolyte level.
Page 239 Check Item • Abnormal vibration and abnormal operation noise of the compressor • Oil oozing out on and around the compressor • Scratches, corrosion, rust and other blemishes on the compressor • Frosting of air-conditioner heat-exchanger in the cabin Storage of inspection and maintenance servicing history Keep the records of administrator's name, location of the machine, initial amount of Freon filled, and dates of inspection, repair, refrigerant recovery, and refrigerant filling until the machine is disposed of.
Page 240: 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 241: Periodic Replacement Of Critical Parts
4. PERIODIC REPLACEMENT OF CRITICAL PARTS To assure prolonged and safe use of the Machine, be sure to conduct the periodic replacement of parts listed on the table of critical parts especially related to safety and fire. Since these parts are prone to degradation of material by aging and abrasion and the extent of the degradation and deterioration cannot be determined, it is required to replace them even if no abnormality is found in order to maintain their correct functions all the time.
Page 242: Consumables
Replace consumables such as a filter element and wire rope upon periodic maintenance or prior to the wear limit. Proper replacement of consumables delivers increased economy in machine use. Always use Maeda genuine parts for part replacement. See the parts catalogue for part numbers when ordering parts. [LIST OF CONSUMABLES]...
Page 243: Other Replacement Parts
6. OTHER REPLACEMENT PARTS Since part numbers may be changed as a consequence of product improvement, check with us or our sales agency for the latest part number by referring to the machine number. Part Name Q'ty Part Name Q'ty Glass Mirror Glass...
Page 244: Use Of Fuel And Lubricating Oil
7. USE OF FUEL AND LUBRICATING OIL • To keep the Machine in the best possible condition for a long period of time, we recommend the use of our specified oil, grease and coolant as given in this instruction manual. •...
Page 245 Oiling Area Specified oil quantity (l) Replacement oil quantity (l) Engine oil 11.0 10.0 Travelling motor reducer casings (1 left and 1 right) Hydraulic oil system Winch motor reducer casing Cooling system 12.0 Fuel tank CAUTION Always use diesel fuel. For the engine of this Machine, an electronically controlled high pressure injection unit is used to obtain good fuel consumption and exhaust gas characteristics.
Page 246: Standard Tightening Torque
8. STANDARD TIGHTENING TORQUE 8.1 STANDARD TIGHTENING TORQUE LIST CAUTION Tightening at a torque beyond the specified range will cause damage to tightened parts or loosening, resulting in failure and malfunction of the Machine. Pay adequate attention to the tightening operation. Torque the metric bolts and nuts that have no specific indication, to the values shown in this table.
Page 247: List Of Items For Inspection And Maintenance
9. LIST OF ITEMS FOR INSPECTION AND MAINTENANCE Inspection and maintenance items Page 10.1 INITIAL 500-HOUR MAINTENANCE (Only the 1st maintenance of a new machine) [1] OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE 10.2 PRE-OPERATION INSPECTION 10.2.1 Inspection before starting engine (visual inspection) (Refer to item "Operation 3.1.1".) [1] INSPECTION AROUND CRANE [2] INSPECTION OF WIRE ROPE...
Page 248 Inspection and maintenance items Page [10] LEVELLING INSTRUMENT 10.4 MAINTENANCE EVERY 50 HOURS [1] GREASING MACHINE UNITS 10.5 MAINTENANCE EVERY 250 HOURS [1] CHECKING/REFILLING OIL LEVEL IN TRAVELLING MOTOR REDUCTION GEAR CASE [2] OIL LEVEL CHECK AND REFILLING IN WINCH REDUCTION GEAR CASE [3] CHECKING/ADJUSTING FAN BELT TENSION [4] CHECKING/ADJUSTING AIR-COMPRESSOR BELT TENSION 10.6 MAINTENANCE EVERY 500 HOURS...
Page 249: Maintenance Procedures
10. MAINTENANCE PROCEDURE 10.1 INITIAL 500 HOUR MAINTENANCE The following maintenance should be performed after 500hours of operation for the 1st maintenance servicing only, of a new machine. [1] OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE See "10.7 MAINTENANCE EVERY 1000 HOURS " for maintenance places and procedure. 10.2 PRE-OPERATION INSPECTION Inspections described in this section should be conducted before the first engine start-up of the day.
Page 250: Irregular Maintenance
10.3 IRREGULAR MAINTENANCE [1] REPLACEMENT OF WINCH WIRE ROPE Always put on thick leather work gloves when replacing the wire rope. CAUTION • The diameter of the wire rope is measured at points where the wire repeatedly runs through the sheave. A mean value needs to be determined through 3 way measurement.
Page 251 (8) One or more strand is loosened. (9) Wires that are noticeably sticking out. 5. An end socket that is found faulty. [REMOVAL OF WINCH WIRE ROPE] Always put on thick leather work gloves when handling the wire rope. CAUTION After lowering the hook block on the ground, an attempt of further unwinding give rise to the irregular winding of wire rope on the winch drum.
Page 252 6. Pull the wire rope (5) out of the wire socket (3), following the procedure provided below. (1) Bring a 6 to 10mm round bar (A) into contact with the rope wedge (6). (2) Remove the rope wedge (6) by lightly tapping the round bar (A) with a hammer in the direction indicated by the arrow (a).
Page 253 [INSTALLATION OF WINCH WIRE ROPE] • Always put on thick leather work gloves when replacing the wire rope. • Be sure to attach the rope wedge properly to secure the wire rope. Serious accidents may occur if the wire rope is detached during crane operations. CAUTION •...
Page 254 4. Depending on the number of falls of wire rope, pass the wire rope through the load sheave and hook block sheave as illustrated in the following sketches: 4 fall 2 fall Single fall 5. Pass the wire rope (5) through the weight of over-winding prevention unit.
Page 255: Checking/Adjusting Main Boom Telescoping Wire Rope
[2] CHECKING/ADJUSTING MAIN BOOM TELESCOPING WIRE ROPE ・ Always put on thick leather work gloves when replacing the wire rope. ・ Do not fail to follow the procedure to adjust securely the for boom telescoping wire rope. Omitting procedural steps or leaving faulty adjustment increases the risk of fall of the boom or load.
Page 256: Checking/Cleaning/Replacing Air Cleaner
[3] CHECKING/CLEANING/REPLACING AIR CLEANER • Do not clean and replace the air cleaner when the engine is in rotation. Such action may cause damage to the engine. • When using the compressed air, watch out for dust scattering, which may cause bodily accidents.
Page 257 6. Shine a light bulb into the element after cleaning for inspection. If inspection finds a pore or thining part, replace the element. CAUTION • Do not tap and bump the element while cleaning it. • Avoid using the element if the groove, gasket, or sealing is damaged.
Page 258: Cleaning Engine Cooling System
[4] CLEANING ENGINE COOLING SYSTEM • Coolant temperature remains high immediately after stopping the engine and the pressure is accumulated in the radiator. Removing the cap in this stage for discharging water may cause burns. Allow it to cool down, and then slowly turn the cap to relieve the pressure.
Page 259 CAUTION • Always use tap water for coolant. Contact us or our sales service agent if river water, well water, or water through the small water-supply system is necessarily substituted for tap water. • The mixing proportion of coolant is recommended to be controlled by using the coolant concentration meter.
Page 260 [FEEDING WATER] 1. Pour tap water and the coolant through the water inlet until the liquid level reaches the lip of the inlet. For the mixing proportion of water and the Super Coolant, refer to the "Table of mixing proportion of water and undiluted coolant".
Page 261: Checking And Re-Tightening Rubber Track Bolts
[5] CHECKING AND RE-TIGHTENING RUBBER TRACK BOLTS Using the Machine while its rubber track bolts (1) are left loosened will cause the bolts to break, fasten each of the loosened bolts. [METHOD FOR RETIGHTENING BOLTS] 1. After tightening the bolts with a tightening torque of 196 +/-19.6N·m [20+/-2kgf·m] first, ensure that the nuts and shoes are a tight fit to the link mating surface.
Page 262 [ADJUSTMENT] • Do not loosen plug (1) for more than one turn. Loosening for more than one turn gives rise to the risk of plug (1) flying out because of the grease inside at a high pressure. In this stage, do not loosen any parts except the plug (1).
Page 263: Checking/Replenishing Window Washer Solution
[LOOSENING THE TENSION] Discharging grease without using the following procedure is extremely dangerous. If the rubber track is not loosened, request us or our sales service agency for repair. 1. Slowly loosen the plug (1) to discharge the grease. When loosening the plug (1), loosen it for only one turn at the most.
Page 264: Checking And Servicing Air-Conditoner
[8] CHECKING AND SERVICING AIR-CONDITONER [INSPECTING THE AIR-CONDITIONING UNITS] Users (possessors) of the Machine are obligated to conduct periodic inspections by the Fluorocarbon Refrigerants Emission Regulating Act. Inspect once every three months. Even when the air-conditioner is not used during off season, the inspection is required.
Page 265: Checking/Cleaning/Greasing Door Rails And Rollers
[ACT ON RATIONAL USE AND PROPER MANAGEMENT OF FLUOROCARBONS] The Act on Rational Use and Proper Management of Fluorocarbons (Fluorocarbon Refrigerants Emission Regulating Act) stipulates that the operating entity (possessor) of air-conditioners shall endeavor to suppress the emission of fluorocarbons that cause the global warming and ozone layer destruction.
Page 266: Maintenance Every 50 Hours [1] Greasing Machine Units
[10] LEVELLING INSTRUMENT If crane operation is performed with the machine tilted, tipping may occur. Search for a place, while looking at the levelling instrument, where the machine body is in a level state before starting crane operation. If work is unavoidably performed on a slope, place planking or lay earth on the ground to make the ground level.
Page 268: Maintenance Every 250 Hours
10.5 MAINTENANCE EVERY 250 HOURS Perform this maintenance in tandem with maintenance every 50 hours. [1] CHECKING/REFILLING OIL IN TRAVELLING MOTOR REDUCTION GEAR CASE • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not check oil level immediately. Wait until the oil is cooled. •...
Page 269: Oil Level Check And Refilling In Winch Reduction Gear Case
[2] OIL LEVEL CHECK AND REFILLING IN WINCH REDUCTION GEAR CASE • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not check oil level immediately. Wait until the oil is cooled. • If there remains a residual internal pressure of the case, the oil and the plug may jump out.
Page 270: Checking/Adjusting Fan Belt Tension
[3] CHECKING/ADJUSTING FAN BELT TENSION [TENSION CHECK] 1. Open the machinery cover (1). 2. Push the middle portion of the belt between alternator pulley (2) and fan pulley (3) with thumb (approximately 98N·m [10kgf·m]) to ensure that the deflection (a) is in the standard range of 8.3 to 9.3mm.
Page 271: Checking/Adjusting Air-Compressor Belt Tension
[4] CHECKING/ADJUSTING AIR-COMPRESSOR BELT TENSION [TENSION CHECK] 1. Open the machinery cover (1). 2. Press down on the middle of the belt (A) between the crank pulley (2) and the compressor pulley (3) with your thumb (approximately 17.7 N [1.8 kgf]) and confirm that the deflection is the standard value of 4 [TENSION ADJUSTMENT] 1.
Page 272: Maintenance Every 500 Hours
10.6 MAINTENANCE EVERY 500 HOURS Perform this maintenance in tandem with maintenance every 50 and 250 hours. [1] REPLACING OIL IN ENGINE OIL PAN AND REPLACING ENGINE OIL FILTER CARTRIDGE Various parts are at elevated temperatures immediately after stopping engine operation. Do not proceed with oil or filter cartridge replacement immediately, but wait for the engine to cool so that you can touch it with your hand.
Page 273 6. After replacing the filter cartridge, fill the oil through the oil inlet (F) to the level within the range "H-L" marked on the level gauge (G). 7. After starting the engine and allow it to run at an idling revolution speed for a while, stop the engine to ensure that the oil level remains within the range "H-L"...
Page 274: Checking/Refilling Swing Pinion Grease Amount
[2] CHECKING/REFILLING SWING PINION GREASE AMOUNT • Have a scale (rule) available. 1. Remove bolts of tank cover (1) and post cover (2) to take off the cover. 2. Remove the rubber plug (3) on the top of the frame. 3.
Page 275: Checking/Cleaning Radiator Fins, Oil Cooler Fins, After Cooler Fins And Air-Condenser Fins
[4] CHECKING/CLEANING RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS AND AIR-CONDENSER FINS There is a risk to the human body if directly subjected to compressed air, pressurized water or steam and the use of them may cause scattering of dust, resulting in a accident.
Page 276: Filters
[5] CLEANING AIR-CONDITIONER OUTDOOR/INDOOR AIR FILTERS There is a risk to the human body if directly subjected to compressed air, pressurized • water or steam and the use of them may cause scattering of dust, resulting in a accident. Wear goggles, dust mask and other protective equipment Check the slide door to ensure that it is always locked when opened or closed, and •...
Page 277: Replacement Of Hydraulic Oil Tank Breather Element
[6] REPLACEMENT OF HYDRAULIC OIL TANK BREATHER ELEMENT • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not replace the elements immediately. Wait until the oil is cooled. • When removing the oil inlet cap, turn it slowly to relieve the internal pressure in order to prevent the oil from spurting out.
Page 278: Oil Replacement In Winch Reduction Gear Case (For The First Time Only)
[7] OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE Perform the replacement in the initial servicing for the new Machine. Afterwards conduct the replacement every 1000 hours. Refer to the description under "10.7 MAINTENANCE EVERY 1000 HOURS" for maintenance places and procedure.
Page 279: Replacing The Fuel Pre-Filter Cartridge
CAUTION • The genuine fuel filter cartridge employs a special filter having a high-efficiency filtering characteristic. Always use Maeda genuine filters for the replacement. • The common rail type fuel injection system employed in the Machine consists of parts that are higher precision than that of conventional injection pumps and nozzles.
Page 280: Replacing The Main Fuel Filter Cartridge
CAUTION The genuine fuel filter cartridge employs a special filter having a high-efficiency • filtering characteristic. Always use Maeda genuine filters for the replacement. The common rail type fuel injection system employed in the Machine consists of parts • that have higher precision than that of conventional injection pumps and nozzles.
Page 281: Replacing The Fuel Feed Pump Filter
[10] REPLACING THE FUEL FEED PUMP FILTER Since the pump has residual fuel, receive the fuel in a pan before removing it, while • paying attention not to allow the fuel to splash on the engine. Also, be cautious of any fire.
Page 282: Maintenance Every 1000 Hours
10.7 MAINTENANCE EVERY 1000 HOURS Perform this maintenance in tandem with maintenance every 50, 250 and 500 hours. [1] OIL REPLACEMENT IN TRAVELLING MOTOR REDUCTION GEAR CASE • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not change the oil immediately. Wait until the oil has cooled. •...
Page 283: Oil Replacement In Winch Reduction Gear Case
[2] OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not check oil level immediately. Wait until the oil is cooled. • If there remains a residual internal pressure in the case, the oil and the plug may jump out.
Page 284: Replacement Of Hydraulic Oil Return Filter Cartridge
[3] REPLACEMENT OF HYDRAULIC OIL RETURN FILTER CARTRIDGE • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not replace the elements immediately. Wait until the oil is cooled. • The oil may spurt out when the filler cap of the hydraulic oil tank is removed. To relieve the internal pressure, slowly turn the oil inlet cap.
Page 285 6. Clean the filter base, thinly apply oil on the gasket face of the new filter and refit it on the filter base. 7. When reinstalling the filter cartridge, tighten it for 3/4 of a turn after the gasket face comes in contact with the sealing face of the filter base.
Page 286: Replacement Of Hydraulic Oil Line Filter Element
[4] REPLACING THE HYDRAULIC OIL LINE FILTER ELEMENT • Various parts are at elevated temperatures immediately after stopping the engine operation. Do not replace the filter immediately. Wait until the oil is cooled. • The oil may spurt out when the filler cap of the hydraulic oil tank is removed. To relieve the internal pressure, slowly turn the oil inlet cap.
Page 287: Maintenance Every 1500 Hours [1] Cleaning Egr Cooler
[5] CHECKING ALTERNATOR AND STARTER The brushes may wear down or a loss of grease in a bearing. Contact us or our sales service agency to request for inspection and repair. [6] INSPECTION/ADJUSTING ENGINE VALVE CLEARANCE Since special tools are required for the inspection and adjustment, request us or our sales agency for the servicing.
Page 288: Maintenance Every 4000 Hours
10.10 MAINTENANCE EVERY 4000 HOURS Perform this maintenance in tandem with maintenance every 50, 250, 500 and 1000 hours. [1] INSPECTION OF WATER PUMP Check the pulleys for play, oil leakage, water leakage and drain hole clogging. If any fault is found, request us or our sales agency for the dismounting and repair.
Page 289: Maintenance Every 5000 Hours
10.11 MAINTENANCE EVERY 5000 HOURS Perform this maintenance in tandem with maintenance every 50, 250, 500 and 1000 hours. [1] REPLACING OIL IN HYDRAULIC OIL TANK AND CLEANING STRAINERS • Various parts are at elevated temperatures immediately after stopping the engine operation.
Page 290 5. Remove the cap of oil inlet (F) to relieve the internal pressure. 6. Set a container to receive spent oil beneath the drain plug on the bottom side of the Machine body. 7. Remove the drain plug (P) slowly to avoid splashing oil on yourself, and drain the oil.
Page 291 15. Set the boom in the completely retracted and fully raised state, fit the oil feed cap and pressurize the tank. CAUTION Omitting pressurization of the hydraulic tank causes the pump to suck air, resulting in adverse effect on the units. 16.
Page 292: Venting Air In Hydraulic Circuits
11. VENTING AIR IN HYDRAULIC CIRCUITS NOTES For details of starting engine, refer to the description under "OPERATION 3.3 STARTING ENGINE". Refer to the description under the section of starting, stopping and changing direction of the Machine in the Operation volume as required. CAUTION After completion of air venting, stop the engine once to allow it to be standing still for •...
Page 293 [3] VENTING AIR IN WINCH MOTOR Before loosening and tightening the air venting plug of winch motor, be sure to allow the hook block to touch the ground and set the work machine operation lever to "NEUTRAL" position. Otherwise, the internal pressure may force the plug or oil to spurt out.
Page 294 [4] VENTING AIR IN TRAVELLING MOTOR NOTES Conduct the air venting only when the oil in the travelling motor is drained. 1. Start the engine and run it at a low idling revolution speed. 2. Remove the hose of port C (3), and if oil is flowing out, tighten it.
Page 295 3. Apply a wire rope (A) to the boom and hoist the crane slowly. NOTES In this step, to prevent the boom from being damaged, insert a pad (B) between the crane wire rope (A) and the boom. 4. Insert the packing block (C) that has been prepared between the floating track frame and the ground.
Page 296: Relieving Internal Pressure Of Hydraulic Circuit
12. RELIEVING INTERNAL PRESSURE OF HYDRAULIC CIRCUIT The pressure in the hydraulic circuit cannot be completely relieved. When removing a • hydraulic unit, stay away from the oil flow direction. Also, loosen the screw slowly. CAUTION Complete this procedure. After stopping the engine move the machine work ration lever back and forth as well as leftward and rightward using its full stroke for 15 seconds.
Page 297: Attaching/Detaching Single-Fall Hook
13. ATTACHING/DETACHING SINGLE-FALL HOOK The rope wedge used to secure the wire rope must be correctly attached. Improper • attachment may result in the wire rope coming loose and falling out during crane work and serious accidents. • Be sure to mount the overwinding prevention device securely. If the device does not function correctly, the hook or load may fall resulting in serious accidents.
Page 298 5. Attach protective wire ropes (22) to both the overwinding prevention device (9) and the bar (15). Set the protective wire rope (22) sandwiched between two washers (19) to the bolt (18) inserted into the overwinding prevention device (9) or bar (15), then secure with the nut (20), followed by the U nut (21).
Page 299 9. Secure the end of the wire rope (12) to the wire socket (37) as follows: (1) Draw the wire rope (12) through the wire socket (37) as shown in the diagram on the right. (2) Insert the rope wedge (41) at position (a), then firmly pull the wire rope (12) in the direction indicated by the arrow.
Page 300: Detaching Single-Fall Hook
13.2 DETACHING SINGLE-FALL HOOK 1. Stop the machine on level solid ground, fully retract the boom, and set the boom angle to approximately 20 degrees. 2. Unwind the winch from the state described in step 1 above to unwind the hook block until it is almost touching the ground.
Page 301 8. Alter the attachment position of the overwinding prevention device (9). First, detach the connector of the harness from the device, remove the two clips (11) from the extension harness (23), then remove the extension harness (23). Connect the harness on the vehicle side to the connector on the device.
Page 302 This Page Intentionally Left Blank.
Page 303: Specifications
SPECIFICATIONS 1. PRINCIPLE SPECIFICATION LIST 2. SPECIFICATION DIMENSIONAL DRAWING 3. RATED TOTAL LOAD CHART 4. WORKING RADIUS/LIFTING HEIGHT...
Page 304: Principle Specification List
1. PRINCIPLE SPECIFICATION LIST Equipment/Item CC1485S-1 Machine mass 14,400kg Overall length x width x height 6,560mm x 2,490mm x 2,865mm Distance between center 2,880mm idler and sprocket Weight and dimensions Track gauge 1,990mm Width of crawler 500mm Slewing radius at rear end of...
Page 305: Specification Dimensional Drawing
2. SPECIFICATION DIMENSIONAL DRAWING...
Page 306: Rated Total Load Chart
3. RATED TOTAL LOAD CHART [1] RATED TOTAL LOAD CHART FOR 4-FALL WIRE ROPE 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...
Page 307 [2] RATED TOTAL LOAD CHART FOR 2-FALL WIRE ROPE 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 3000...
Page 308 [3] RATED TOTAL LOAD CHART FOR SINGLE-FALL WIRE ROPE 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 1500...
Page 309: Working Radius/Lifting Height
4. WORKING RADIUS/LIFTING HEIGHT...
Page 310 This Page Intentionally Left Blank.
Page 311: Item Page
FLY-JIB Item Page 1. PRECAUTIONS OF FLY-JIB OPERATION 2. SAFETY LABEL LOCATION 3. FLY-JIB EACH SECTION 4. FLY-JIB INSTALLATION AND STOWAGE 5. HANDLING MONITOR AND MOMENT LIMITER 6. OPERATIONS 7. TROUBLESHOOTING 8. INSPECTION AND MAINTENANCE 9. SPECIFICATIONS...
Page 312: Precautions Of Fly-Jib Operation
1. PRECAUTIONS OF FLY-JIB OPERATION • The Fly-jib is installed to the Main boom with four 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 313 CAUTION • The machine weight depends on the machine configuration. The weight table on the right shows the weight of the standard vehicle and additional weight of respective accessory units. • The Fly-jib tilt angle is adjustable to four (4) positions (0, 20, 40 and 60 degrees). During the Fly-jib operations, always keep the boom angle in the range as specified below: [At the Fly-jib angle in 0 or 20 degrees] Perform the crane operation within the boom angle range of “45 degrees”...
Page 314: 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 315 (1) Work range chart for fly-jib (585-2237900) (2) Over-hoist detection wiring instruction (585-3558600) (4) Warning for fly-jib installation (585-2238200)
Page 316 (5) Warning for fly-jib stowage (585-2238300) (2 places) (6) Fly-jib detection wiring instruction (585-3558100) (7) Pin hole caution (349-4426900) (7 places) (8) Caution for hole (556-4580700) (10) Explanation of split pin (585-3558700)
Page 317: Fly-Jib Each Section
3. FLY-JIB EACH SECTION (1) Main boom (18) Harness connection part (2) No.1 Fly-jib (For over hoist detection) (Main boom side) (3) No.2 Fly-jib (19) Harness connection part (4) Position pin (For fly-jib detection) (Fly-jib side) (5) Outer rod (For fly-jib angle adjusting) (20) Harness connection part (6) Inner rod (For fly-jib angle adjusting) (For fly-jib detection) (Main boom side)
Page 318: Fly-Jib Installation And Stowage
4. FLY-JIB INSTALLATION AND STOWAGE • It is recommended that two operators perform the installation and stowage work of the Fly-jib. 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 319: Installation Of Fly-Jib
4.1 INSTALLATION OF FLY-JIB Practice installing the Fly-jib to the Main boom from the stowed position from the right side as shown below: Always avoid standing on crawlers for installation work. You may miss your footing and fall resulting in serious injury. For elevated work, always prepare a strongly-built work platform.
Page 320 1. Pull the linchpin of the position pin (B1) of the stowage bracket A (21) and pull out the position pin (B1). Insert the pulled out position pin (B1) into the hole for pin stowage at the back of the stowage bracket A (21). Securely lock with the linchpin after insertion.
Page 321 5. Once the connection hole of the No.1 Fly-jib (2) and the holes (A, B) of the bracket (26) on the right side of the Main boom tip are aligned, insert the position pins (C1, C2) to the hole then secure it with the linchpin.
Page 322 9. Fit the connection hole of the No.1 Fly-jib (2) to the hole (C, D) of bracket (27) on the left side of the Main boom tip. 10. Once the connection hole of the No.1 Fly-jib (2) and the hole (C, D) of the bracket (27) on the left side of the Main boom tip are adjusted, insert the position pins (A1, A2) to the hole then secure it with the linchpin.
Page 323 (3) Connect the dummy plug (30) disconnected in Section (1) After harness exchange; to the connector (31). 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 324 (3) Connect the wiring connector (34) disconnected in Section After harness exchange; (1) to the wiring connector (36). In the same way, connect the Main boom side: the connector for stowage (33) disconnected in Section (1) to the connector for stowage (35). NOTES Arrange the harness connector (34) to pass through the notch hole under the harness connection part (20: Main boom side)
Page 325 14. Start the engine and wind up the removed wire rope (12) in accordance with 13, above by winch operation. CAUTION • Take care to avoid the wire rope winding randomly. • The wire rope should not be wound to the end, so stop winding to allowing 7 m to 8 m excess from sheave (44) of the boom tip.
Page 326 18. 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) firmly to the direction of the arrow. 19. Install the rope clip (40) to the wire rope (12). Refer to the Figure on the right for the rope clip position.
Page 327: Changing Of Fly-Jib Tilt Angle
4.2 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 328 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 329: Extending And Retracting No.2 Fly-Jib
4.3 EXTENDING AND RETRACTING NO.2 FLY-JIB 4.3.1 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 330: Extending No.2 Fly-Jib Configured 40 Degrees Or 60 Degrees Tilt Angle
4.3.2 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 331 [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.~ 4. as above. In this posture, the signal indicating that Fly-jib length is two stages is transmitted to the moment limiter and the display of the number of the Fly-jib stage of the monitor is...
Page 332: Retracting Of No.2 Fly-Jib
4.3.3 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 333: Stowage Of Fly-Jib
4.4 STOWAGE OF FLY-JIB NOTES When the No.2 Fly-jib (3) is extended, refer to section; “FLY-JIB, 4.3 Extending and Retracting No.2 Fly-jib” and retract the No.2 Fly-jib (3) correctly. 1. Hang the hook (10) for Fly-jib to the hook stowing wire (13) on the underside of the Fly-jib (2).
Page 334 3. Swap the harness connection part (17) and (18) as shown below to switch and connect over-hoist detector. Before harness exchange; (1) Open the cover of the harness connection part (17: Fly-jib Fly-jib side: side) and extract the harness plug (32) in the connector (29).
Page 335 4. Remove linchpins of the position pins (A1, A2) installed in the holes (C, D) of the bracket (27) on the left side of the main boom tip and pull out the position pins (A1, A2) from the holes of the bracket (27). NOTES ･...
Page 336 8. When the hole of the No. 1 Fly-jib (2) connection is aligned with the hole of the Fly-jib stowage bracket A (21), insert the position pin (B2) into the hole and insert the linchpin. At this time, be sure to turn over the ring to lock securely. •...
Page 337 12. Pull the No. 1 Fly-jib (2) toward the tip side. 13. Push the No.1 Fly-jib (2) into the Fly-jib bracket B (22), then insert the position pin (A1) into the hole of the Fly-jib bracket B (22). Use the linchpin to secure the position pin. The position pin (A1) must always be inserted downward from the upper side.
Page 338: Removal Of Fly-Jib
4.5 REMOVAL OF FLY-JIB NOTES This section explains a method of removing the whole Fly-jib from the main body of the machine. Fully retract the main boom and set it to horizontal before using the crane to remove the Fly-jib. •...
Page 339 1. Pull the linchpin of the position pin (B1) of the stowage bracket A (21) and pull out the position pin (B1). Insert the removed position pin (B1) into the hole for pin stowage at the back of the stowage bracket A (21). Securely lock with the linchpin after insertion.
Page 340 5. Once the connection hole of the No.1 Fly-jib (2) and the holes (A, B) of the bracket (26) on the right side of the Main boom tip are aligned, insert the position pins (C1, C2) to the hole then secure it with the linchpin.
Page 341 9. Hang wire rope for lifting on the No. 1 Fly-jib (2) and sling it temporarily. 10. Pull out the linchpins of the position pins (C1, C2) and draw out the position pins (C1, C2). 11. Operate the crane and lift the No. 1 Fly-jib (2) to remove. 12.
Page 342 16. Detach the counterweight upper cover (60). 17. Disconnect the bottommost harness (65) connector on the cab and attach the short connector (61) provided. Connector: CN-BM5 18. Remove all harness clips (62) and bands (63). 19. Remove the connector cover (64), disconnect the connector inside, and remove the harness (65).
Page 343: Installation Of Fly-Jib
4.6 INSTALLATION OF FLY-JIB NOTES This section explains a method of installing the whole Fly-jib to the main body of the machine. Fully retract the main boom and set it to horizontal before using the crane to install the Fly-jib. •...
Page 344 4. Pull the cable (68) out from the cable reel (67). Secure with the nut (66) with washers (69) and (70) inserted in between. Finally, connect the connector to the harness connection part (20) at the end of the boom head. 5.
Page 345 8. Set the Fly-jib stowage bracket B (22) on the mounting position of the main boom (1) and lightly tighten it with 4 mounting bolts (56). 9. Connect the wiring connector (55) of the Fly-jib stowage detection limit switch at the side of the Fly-jib stowage bracket B (22).
Page 346 13. Insert the lifted No. 1 Fly-jib (2) into the brackets (26), (27) and align the holes (A, B) of the bracket (26) with the holes of the No. 1 Fly-jib (2) connection. 14. When the holes (A, B) of the bracket (26) on the right side of the main boom tip is aligned with the holes of the No.
Page 347 18. Align the hole of the No. 1 Fly-jib (2) connection with the hole of the Fly-jib stowage bracket A (21). 19. Insert the position pin (A2) into the bracket (27) on the left side of the Main boom tip. At this time, be sure to turn over the ring of the linchpin to lock securely.
Page 348 23. Insert the position pins (C1, C2) into the bracket (26) on the right side of the Main boom tip. At this time, be sure to turn over the ring of the linchpin to lock securely. 24. Pull the No. 1 Fly-jib (2) toward the tip side. 25.
Page 349 CAUTION In the case of the Fly-jib mode with the Fly-jib in a stowage condition, the monitor display is as shown on the right figure. Either switch to the main boom mode or install the Fly-jib. For the detailed operation method, see “5.1.2 Monitor display when Fly-jib is stowed”.
Page 350: Handling Monitor And Moment Limiter
5. HANDLING MONITOR AND MOMENT LIMITER Do not perform work with the override switch left “ON”. Doing so may cause the hoisted load to fall, breakage of the boom, or overturning of machine due to overloading, leading to serious injury or even resulting in death. CAUTION In this section, the devices indicated are exclusive for The Fly-jib model but different from that of a standard model.
Page 351 CAUTION When the Fly-jib is installed on the main boom tip, the mode is automatically switched to the Fly-jib mode. [1] Explanation of each display of monitor 1. Fly-jib angle display (7) The Fly-jib angle display indicates current Fly-jib angle continuously, during the crane operation.
Page 352: Monitor Display When Fly-Jib Is Stowed
5.1.2 MONITOR DISPLAY WHEN FLY-JIB IS STOWED When the Fly-jib is stowed just after it is used, the monitor changes to the following main boom work selection screen. Rear view camera selector switch Travel 1st speed/2nd speed selector switch Hook stowage switch Check switch NOTES When the Fly-jib is stowed, CAUTION is displayed on the monitor.
Page 353: Moment Limiter Functions
5.2 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 354: Display For Fly-Jib Mode Switching
5.2.1 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 355: Setting Of Operating Conditions
5.3 SETTING OF OPERATING CONDITIONS CAUTION When the Fly-jib is installed to the main boom tip, the machine turns into the following operation state. • The rated total load value displayed on the monitor is switched to the one for the Fly-jib. •...
Page 356: Operations
6. 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 3. Machine Operation”. 6.1 CAUTIONS FOR FLY-JIB OPERATION •...
Page 357: Troubleshooting
7. TROUBLESHOOTING 7.1 LIST OF ERROR CODES Fly-jib related errors displayed on the monitor are as follows. If the following error codes are displayed, see “FLY-JIB 7.2 When such a phenomenon occurs”. If the error codes other than the below are displayed, a cause other than a Fly-jib related cause is conceivable.
Page 358: When Such A Phenomenon Occurs
7.2 WHEN SUCH A PHENOMENON OCCURS • Make sure that you contact us or our sales service agency for the actions marked with ★ in the table. • Ask us or our sales service agency for repair if you suspect any other abnormalities or causes than those given below.
Page 359: Inspection And Maintenance
8. INSPECTION AND MAINTENANCE 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: “INSPECTION AND MAINTENANCE”. 8.1 CHECKING BEFORE OPERATION Check the followings in this section before first starting work every day after installing fly-jib.
Page 360 [3] 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 first, then only the green light remains lit. 3.
Page 361: Maintenance Every 50 Hours
8.2 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 362: 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”. System / Item CC1485S-1 FLY-JIB Machine mass 14,700 kg Overall length x width x height 6,560 mm ×...
Page 363: Specification Dimensional Drawing
9.2 SPECIFICATION DIMENSIONAL DRAWING...
Page 364: Rated Total Load Chart
9.3 RATED TOTAL LOAD CHART CAUTION • The rated total load is a load including the weight of the hook block (20 kg). • 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”.
Page 365: Working Radius/Lifting Height
9.4 WORKING RADIUS/LIFTING HEIGHT 9.4.1 WORKING RADIUS/LIFTING HEIGHT (WHEN FLY-JIB ANGLE IS 0 DEGREES AND 20 DEGREES)
Page 366: Working Radius/Lifting Height (When Fly-Jib Angle Is 40 Degrees And 60 Degrees)
9.4.2 WORKING RADIUS/LIFTING HEIGHT (WHEN FLY-JIB ANGLE IS 40 DEGREES AND 60 DEGREES)
Page 367 OPERATION MANUAL for MAEDA CRAWLER CRANE CC1485S-1 Document Number 585E-OM1712-02 First edition November 30, 2015 Third edition December 25, 2017 Issued by MAEDA SEISAKUSHO CO., LTD. 1095, Onbegawa, Shinonoi, Nagano City, Nagano Prefecture, 388-8522 Japan Any reproduction or reprinting without permission is prohibited.

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