Page 1 NOTICE MAEDA has Operation Manual written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 3 CONTENTS ITEM Page INTRODUCTION １－１ 1. INTRODUCTION 1－２ 2.FOR SAFE USE OF MACHINE １－３ 3. MACHINE OVERVIEW １－４ 3.1 SPECIFIED OPERATIONS １－４ 3.2 MACHINE CONFIGURATION １－４ 3.3 MACHINE FUNCTIONS １－５ 4. QUALIFICATION FOR OPERATION １－...
Page 4 ITEM Page 2. EXPLANATION OF DEVICES ３－５ 2.1 MACHINE MONITOR ３－５ 2.1.1 EMERGENCY STOP ITEMS ３－６ 2.1.2 GAUGE AND METER ３－８ 2.1.3 PILOT DISPLAY ３－１０ 2.2 SWITCHES ３－１１ 2.3 MOMENT LIMITER (OVERLOAD DETECTOR ) ３－１４ 2.3.1 MOMENT LIMITER CONFIGURATION ３－１４...
Page 5 ITEM Page 3.7 STARTING/MOVING/STOPPING MACHINE ３－７２ 3.8 STEERING MACHINE ３－７６ 3.9 SWINGING ３－７８ 3.10 CAUTIONS BEFORE OPERATING THE CRANE ３－７9 3.11 OPERATIONS BEFORE OPERATING THE CRANE ３－８０ 3.12 CRANE OPERATION POSTURE ３－８２ 3.13 HOOK RAISING/LOWERING OPERATION ３－８３ 3.13.1 NORMAL HOOK RAISING/LOWERING OPERATION ３－８３...
Page 6 ITEM Page 5.2 LIFTING MACHINE ３－１１６ 5.2.1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE ３－１１６ 5.2.2 LIFTING THE MACHINE IN THE BOOM RAISED POSTURE ３－１１８ 6. HANDLING IN COLD WEATHER ３－１２０ 6.1 PREPARING FOR LOW TEMPERATURE ３－１２０ 7. LONG TERM STORAGE ３－１２３...
Page 7 ITEM Page 10. MAINTENANCE PROCEDURES ４－１６ 10.1 INITIAL 500 HOUR MAINTENANCE ４－１６ 10.2 CHECKING BEFORE OPERATION ４－１６ 10.3 IRREGULAR MAINTENANCE ４－１７ 10.4 MAINTENANCE EVERY 50 HOURS ４－３６ 10.5 MAINTENANCE EVERY 100 HOURS ４－３８ 10.6 MAINTENANCE EVERY 250 HOURS ４－３９ 10.7 MAINTENANCE EVERY 500 HOURS ４－４１...
Page 9: Table Of Contents
INTRODUCTION 1. INTRODUCTION 1- 2 2. FOR SAFE USE OF MACHINE 1- 3 3. MACHINE OVERVIEW 1- 4 4. QUALIFICATION FOR OPERATION 1- 6 5. TERMINOLOGY 1- 7 6. NECESSARY INFORMATION FOR SERVICE 1-12...
Page 10: Introduction
• Keep this manual handy for reference when necessary. • Should you lose or damage this manual, contact Maeda or our sales service agency immediately for ordering a new manual.
Page 11: For Safe Use Of Machine
2. FOR SAFE USE OF MACHINE This manual classifies the risks into the following three categories to present the details of the safety labels in a easy-to-understand manner. This denotes that there is an imminent hazard which will cause serious personal injury or death.
Page 12: Machine Overview
3. MACHINE OVERVIEW 3.1 SPECIFIED OPERATIONS This machine is for use with the operations listed below. • Crane operation • Pick & Carry operation This machine is a mobile crane which consists of a crawler type carrier and an upper structure of a boom type crane.
Page 13 This machine is comprised of the units listed below. [1] UNDERCARRIAGE This is comprised of a travelling gear and blade. [2] UPPER STRUCTURE (CRANE) This is comprised of an engine, travelling operation unit, crane operation unit, telescoping system, derrick system, slewing system, hook block, and winch system. [3] SAFETY DEVICE This is comprised of the following parts and devices: Over hoist detector/automatic stop device, three-winding stop alarm/automatic stop device, moment limiter (working envelope limited), slinging rope...
Page 14: Qualification For Operation
4. QUALIFICATION FOR OPERATION • A high incidence of occupational accidents during crane operation are reported. Be aware that experienced engineers are 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: Terminology
5. TERMINOLOGY 5.1 DEFINITIONS OF TERMS [1] RATED TOTAL LOAD This is the maximum load that can be applied according to boom length and angle. The load includes the mass (weight) of hoisting accessories (hooks) slings, chains and ropes etc. [2] LIFTED LOAD This is a load derived by subtracting the mass (weight) of hoisting accessories (hooks) and sling etc, from the rated total...
Page 16 5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT • The diagram of working radius and lifting height shows the relationships the working radius of this machine, boom angle, and lifting height above the ground with no object hoisted. The diagram has been made allowing for no deflection in the boom. •...
Page 17 1190 2.50 1200 1190 1190 1190 2.85 3.00 3.50 4.00 4.50 4.70 Maeda, Please check 8.71m Boom on above chart, it 5.00 5.50 should say Stationary and not Pick and Carry 6.00 6.54 7.00 7.50 8.00 8.38 Boom Angle(°) 0～42.9 0～64.2...
Page 18 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in parallel with the length of the boom. The loads are specified by working radius. [1] BOOM LENGTH The following figures illustrate the condition of the booms, “(1) 3.18m Boom”, “(2) 5.03m Boom”, “(3) 6.87m Boom”, and “(4) 8.71m Boom”...
Page 19 5. “(4) 8.71m Boom”: All the booms are fully extended. Boom (4) is to apply to crane operation with half of the “ mark” on boom (3) passes boom (2). 1-11...
Page 20: Necessary Information For Service
6. Necessary information for service The following information is required for us or our sales service agency at the time of requesting repair service or ordering spare parts. Machine serial number engraved on plate Located at the lower right part of canopy. Engine serial number engraved on plate Located on the top of engine cylinder head cover.
Page 21 Information of EPA EPA plate is located on radiator bracket. Gauges and meters Located at machine monitor. 1-13...
Page 22 1-14...
Page 23 SAFETY 1. BASIC PRECAUTIONS 2- 2 2. DRIVING RELATED PRECAUTIONS 2- 8 3. TRANSPORT PRECAUTIONS 2-24 4. TOWING PRECAUTIONS 2-25 5. MAINTENANCE PRECAUTIONS 2-26 6. SAFETY LABEL LOCATIONS 2-33 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 24: Basic Precautions
1. BASIC PRECAUTIONS Failure to operate or maintain this machine properly can lead to serious personal injury or death. Be sure to read this manual and each safety label thoroughly before performing any operation or maintenance of this machine and observe the safety precautions. 1.1 PRECAUTIONS FOR BEFORE STARTING OPERATION OBSERVE THE MANUAL AND SAFETY LABELS •...
Page 25 1.2 PREPARATIONS OF SAFETY OPERATION PROVIDE SAFETY DEVICES FOR SURE • Check that all guards, covers,and mirrors are attached properly. Repair immediately if damaged. • Understand how to use the safety devices correctly and use properly. • Do not detach any safety device under any circumstance. Keep control to achieve proper operation at all times.
Page 26 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 27 1.3 PRECAUTIONS FOR FIRE PREVENTION ACTION IF FIRE OCCURS If a fire occurs, escape from the machine as follows. • Turn starter switch OFF to stop engine. • Use the handrails and steps to get off the machine. FIRE PREVENTION AND EXPLOSION PREVENTION •...
Page 28 1.4 PRECAUTIONS WHEN GETTING ON OR OFF USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF To prevent personal injury caused by slipping or falling off the machine, always do as follows. • Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.
Page 29 Therefore contact our sales service agency for advice. • Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Maeda. • When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual.
Page 30: Driving Related Precautions
2. DRIVING RELATED PRECAUTIONS 2.1 PRECAUTIONS FOR JOBSITE SAFETY AT JOBSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. • When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 31 BEWARE OF ELECTRICAL CABLE ABOVE • Do not let the Machine come in contact with electrical cables overhead. High voltage cables may inflict electrical shock by just approaching. • Persons who sling are likely to suffer electrical shocks. Always observe followings to prevent accidents. •...
Page 32 MEASURES WHEN CHARGE ACCIDENT OCCURS If an electrical charge accident occurs, do not panic and stay calm, apply the solution in the following sequence. 1. Report Immediately report to the electricity company or related management company, and receive instructions to stop the power transmission, emergency procedures and any related procedures. 2.
Page 33 2.2 PRECAUTIONS WHEN ENGINE STARTING PRECAUTIONS FOR WARNING TAG If there is a warning tag hanging from working equipment control lever, do not start the engine or touch the levers. Do NOT operate When this tag is not being used, keep it in the storage compartment.
Page 34 CAUTIONS UNDER COLD WEATHER • Remove snow from and unfreeze the swing gear, boom and winch related parts, and check the movements before work. • Warm up the engine and hydraulics. Attempting to operate the control levers and pedals without enough warm up causes the Machine to react poorly, and may result in unexpected accidents.
Page 35 2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE CHECKS BEFORE OPERATION Omitting the inspections after starting the engine results in delay to notice the Machine abnormalities, and may result in bodily accidents and Machine damages. Execute inspection in a wide location with no obstacle. In addition, be sure to prevent people from approaching nearby the Machine.
Page 36 CAUTIONS WHEN TRAVELLING Always observe the following to prevent serious injuries and fatal accidents when the Machine is travelling. • Set the Machine to the travelling posture shown in the right diagram. See “Operation 3.6 Machine Travelling Posture” for details. •...
Page 37 BE CAREFUL OF TIPPING ON UNSTABLE GROUND Always observe the followings to prevent serious injuries and fatal accidents when travelling over unstable ground for any reason. • Do not enter any soft ground area. The Machine is difficult to remove from this type of ground. •...
Page 38 2.4 PRECAUTIONS WHEN WORKING WITH CRANE INSPECTION BEFORE STARTING WORK Check that the safety devices and crane operate properly. • Operate each of the operation levers, pedals and switches under no load, and check that operations take place without abnormality. Repair immediately if any abnormality exists.
Page 39 PRECAUTIONS FOR CRANE OPERATION ON A SLOPE Where a crane operation on a slope is un-avoidable, firstly fill some soil (B) to prepare a level and solid platform, and then place the machine on it, so that overturning is prevented. Unless this is done the crane is not placed level and attempting to hoist will mean that the moment limiter (over-load detector) will not work accurately, as well as a un-foreseeable force to the machine...
Page 40 PAY ATTENTION TO WEATHER INFORMATION • During a thunderstorm, risk of lightning exists, so abort working with the crane, immediately lower the load and contain the boom. • Exposing the hoisted load to wind causes the load to swing and the Machine to become unstable, this is dangerous.
Page 41 CAUTIONS WHEN SLINGING • Check the following before hoisting a load. Attempting to hoist the load without checking may result in serious bodily accidents by dropping of the load or tipping of the crane. • Observe the values in the rated total load chart. •...
Page 42 CAUTIONS WHEN WORKING WITH CRANE • The stability of the crane is determined horizontally. Although the stability also increases diagonally, work exceeding the rated load causes the breakage of the boom or machine. The moment limiter (overload detector) must not be activated even in diagonal direction. •...
Page 43 CAUTIONS HIGH TEMPERATURE OIL WHEN WORKING WITH CRANE When the hydraulic oil temperature exceeds 80 degrees, high pressure hoses and seals can be damaged by heat. It may cause a burn from spouting oil. If the temperature of hydraulic oil becomes over 80 degrees, stop operation and wait until the oil cools down.
Page 44 CAUTIONS WHEN OPERATING BOOM • Be as slow as possible when operating the boom operation lever. Especially avoid sudden lever operations when the load is hoisted, which may cause the load to swing and give a large impact to the Machine, and thus may damage the crane or tip the Machine.
Page 45 WORKING AT A SITE WITH BELOW GROUND LIFTING • Leave at least three loops of wire rope in the winch drum when winding down the wire rope in the case of underground work or similar. This Machine is equipped with three-winding stop alarm / automatic stop device as the safety device, but even then be very careful to prevent this safety device from activating.
Page 46: Transport Precautions
3. TRANSPORT PRECAUTIONS CAUTIONS DURING TRANSPORT When transporting the machine on a trailer, do as follows. • The weight, transportation height, and overall length of the machine differ accroding to the crane. • When passing over bridges or structure on private land, check first that the structure is strong enough to support the weight of the machine.
Page 47: Towing Precautions
4. TOWING PRECAUTIONS SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For details of towing, see “Operation 8.3 How to tow the machine”. •...
Page 48: Maintenance Precautions
5. MAINTENANCE PRECAUTIONS 5.1 PRECAUTIONS BEFORE MAINTENANCE FAILURE REPORT Execution of any maintenance not described in our manual may cause unexpected failures. Ask us or our sales service agency for repair. PRECAUTIONS FOR WARNING TAG • Always attach the “Do NOT operate” warning tag to the work equipment control lever in the operator’s cab to alert others that you are performing service or maintenance on the machine.
Page 49 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE • Stop the machine on firm, level ground. Store the crane, and then stop the engine. • Turn the starter switch to the OFF position, and push up lock lever (1) to the LOCK position (L). •...
Page 50 USE APPROPRIATE TOOLS Use only tools suited to the task and be sure to use tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury. PRECAUTIONS FOR ELEVATED WORK For elevated work, prepare an appropriate elevated work platform with steps. CAUTION WHEN WORKING UNDER THE MACHINE AND CRANE •...
Page 51 5.2 PRECAUTIONS DURING MAINTENANCE CAUTIONS DURING WELDING REPAIR Welding operation must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
Page 52 CAUTIONS WHEN COOLANT TEMPERATURE IS HIGH To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 53 SAFETY HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact us or our sales service agency.
Page 54 CAUTION FOR COMPRESSED AIR • When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. • When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.
Page 55: Safety Label Locations
6. SAFETY LABEL LOCATIONS Keep these labels clean all the time. If lost, apply again or replace with new one. Labels other than the following safety labels exist, treat them the same. [SAFETY LABEL LOCATIONS IN CAB] 2-33...
Page 56 [SAFETY LABEL LOCATIONS ON CHASSIS] 2-34...
Page 57 (1) Working range and rated total load chart (541-3470600) (2) For your safe operation (556-3367900-2) 2-35...
Page 58 (3) Moment limiter operation (541-2214000) (4) Warning for operation, inspection and maintenance (584-3469700) 2-36...
Page 59 (5) Warning for blade operation (556-4575300) (6) Caution for emergency switch (553-4266400) (7) Control pattern (556-3368100) (8) Caution for number of parts reeving selector switch (553-3181800) 2-37...
Page 60 (9) Keep off swing area (09133-23000) (10) Caution for rotating portion (09667-03001) (11) Caution for engine hood (09805-13000) (12) Warning for winch (553-4267500) (13) Warning for track tension adjusting (584-4588200) (2 places) 2-38...
Page 61 (14) Warning for lifting position (584-3437800) (15) Caution for lifting machine (541-3472400) 2-39...
Page 62 (16) Warning tag (09963-03001) (17) Warning (541-4614900) (18) Caution for wash (300-4213900) (3 places) (19) Warning for hook block (553-4267400) (2 places) 2-40...
Page 63 (20) Machine weight (541-4614800) (21) Warning for radiator cap (09653-A0361) (22) Warning for hydraulic oil (09653-03001) 2-41...
Page 64 (23) Working range and rated total load chart for searcher hook (541-3470700) (Optional) (24) Do not stand on here (584-4581700) 2-42...
Page 65 OPERATION 1. MACHINE EACH SECTION 3- 2 2. EXPLANATION OF DEVICES 3- 5 3. MACHINE OPERATIONS AND CONTROLS 3- 46 4. HANDLING WIRE CABLES 3-104 5. TRANSPORTATION 3-110 6. HANDLING IN COLD WEATHER 3-120 7. LONG TERM STORAGE 3-123 8. TROUBLES AND ACTIONS 3-124...
Page 66 1. MACHINE EACH SECTION MACHINE EACH UNIT Hook Sprocket Hook block Track frame Wire cable (10) Idler Boom (11) Blade cylinder Derricking cylinder (12) Blade Winch (13) Working status lamp Track...
Page 67 OPERATOR’S COMPARTMENT EQUIPMENT Operator's seat (14) Speed-up pedal Lamp switch (15) Travel lock lever Lock lever (16) Service meter Left-hand work equipment control lever (17) Engine coolant temperature gauge Travel lever (18) Fuel gauge Accelerator pedal (19) Engine pre-heating monitor Horn switch (20) Engine oil pressure monitor Right-hand work equipment control lever...
Page 68 MOMENT LIMITER RELATED SWITCH BOX Moment limiter emergency stop cancel switch Hook stowage switch...
Page 69 2. EXPLANATION OF DEVICES The following is an explanation of devices that are required to operate the machine. To perform suitable operations correctly and safety, it is important to have a complete understanding of equipment operating methods, and the displays. MACHINE MONITOR Emergency stop items Pilot display...
Page 70 2.1.1 EMERGENCY STOP ITEMS If the monitor flashes or the buzzer sounds, stop the engine immediately or run at a low idle, check applicable location, then perform necessary actions. These are items that should be observed while the engine is running. If any abnormality occurs, the abnormal section monitor flashes and the buzzer sounds.
Page 71 CHARGE LEVEL MONITOR If the battery is not charged normally while the engine is running, this monitor (2) flashes and the buzzer sounds. If this monitor flashes, stop the engine and check the V-belt tension. If the V-belt is abnormal, see "Operation 8.5 Other Trouble".
Page 72 2.1.2 GAUGE AND METER Engine coolant temperature gauge Service meter Fuel gauge ENGINE COOLANT TEMPERATURE GAUGE This meter (1) shows the engine coolant temperature. If the pointer is in range (A) while the machine is operating, the coolant temperature is normal. If the pointer enters red range (B) while the machine is operating, pilot lamp (C) flashes and the buzzer sounds.
Page 73 FUEL LEVEL GAUGE This gauge (2) shows the amount of fuel remaining in the fuel tank. The letter F indicates that the tank is Full. The letter E indicates that only a small amount of fuel remains. If the amount of remaining oil drops below 6 liters, the pointer enters red range (A) and pilot lamp (B) flashes.
Page 74 2.1.3 PILOT DISPLAY Engine pre-heating monitor Travel speed-up monitor (Does not function for this machine) ENGINE PRE-HEATING MONITOR This monitor (1) flashes when the starter switch is turned to the HEAT position. After approximately 18 seconds, the buzzer sounds and this monitor goes out. 3-10...
Page 75 SWITCHES Starter switch Hook stowage switch Horn switch Moment limiter emergency stop cancel Lamp switch switch Engine emergency stop switch STARTER SWITCH This switch (1) is used to start or stop the engine. (A): OFF position The starter key can be inserted or withdrawn. All switches for the electrical system are turned off and the engine is not running.
Page 76 HORN SWITCH Press this switch (2) at the center of the right-hand work control lever to sound the horn. LAMP SWITCH Use this switch (3) to light up the working lamps and the lamp inside the instruments. Position 1: The lamp inside the instruments lights up. Position 2: The lamp inside the instruments and the working lamps light up.
Page 77 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH The moment limiter emergency stop cancel switch will temporarily disable the moment limiter function. While this switch is turned to the ON position (i.e. released), the moment limiter calculation of the rated total load is disabled, and the machine will be in a very risky condition. When lifting operations are continued under these conditions, it may cause the hoisted load to fall, damage to the boom, or a serious accident such as the machine rolling over, which may result in death or serious injury.
Page 78 MOMENT LIMITER (OVERLOAD DETECTOR) 2.3.1 MOMENT LIMITER CONFIGURATION Boom length sensor (Boom left side) Boom angle sensor (Boom left side) Pressure sensor (Derrick cylinder) (2 places) Over hoist detector (Boon tip side) Working status lamp Red lamp (Warning lamp for load factor of 100% or more) Yellow (ON with load factor of 90 to less than 100%) (C) Green (On with load factor of less than 90%) Moment limiter display unit...
Page 79 2.3.2 FUNCTION OF MOMENT LIMITER • Do not remove, disassemble, or repair detectors. Do not move the detectors to another location from original position. • Should an object hit a detector or you find any damage on a detector, be sure to verify the actuation status of the auto stop.
Page 80 DISPLAY OF THE MOMENT LIMITER ERROR MESSAGES The moment limiter performs self-diagnosis on the moment limiter display unit when an error is issued from the boom angle, boom length, or pressure sensors, when a circuit is opened or a connector is disconnected.
Page 81 2.3.3 MOMENT LIMITER OPERATIONS The moment limiter is a device for emergency situations. Operations relying on the device may involve danger. Pay sufficient attention during operations not to cause the crane to auto-stop. PROHIBITED ACTIONS AFTER AUTO STOP • The following crane operations are prohibited after the crane has stopped automatically due to overloading.
Page 82 RECOVERY OPERATION FROM AUTO STOP The recovery operation from overloading should be the reverse operation of the crane operation that caused the auto stop. Perform one of the following. (1) Lower the hook and put down the hoisted load on the ground. (2) Raise the boom.
Page 83 2.3.4 NAMES OF MOMENT LIMITER DISPLAY UNIT Load factor display (16) Cancel switch Actual load display (17) Searcher hook mode selector switch Rated total load display (18) Over winding detection LED (Red) Boom angle display (19) 1-fall LED (Green) Actual working radius display (20) 2-fall LED (Green) Rated working radius display (21) 4-fall LED (Green)
Page 84 DESCRIPTIONS OF SWITCHES ON MOMENT LIMITER DISPLAY UNIT FALL MODE SELECTOR SWITCH AND WIRE ROPE DISPLAY LED (GREEN) When entering the number of wire rope falls, verify the actual number of wires and make sure you set them up correctly. Failure to set the correct wire rope fall(s) may cause the winch wire rope to break and lead to a serious accident.
Page 85 BOOM ANGLE LOWER LIMIT SWITCH AND LED (GREEN) Use this switch to set or cancel the boom angle lower limit. [SETUP] With no lower limit value set, position the boom to the angle you would like, and press the switch for three or more seconds. The boom angle at this point is set as the lower limit.
Page 86 WORKING RADIUS UPPER LIMIT SWITCH AND LED (ORANGE) Use this switch to set or cancel the working radius upper limit. [SETUP] With no upper limit value set, set the boom to the working radius you would like, and press the switch for three or more seconds. The working radius at this point is set as the upper limit.
Page 87 LIFTING HEIGHT UPPER LIMIT SWITCH AND LED (GREEN) Use this switch to set or cancel the lifting height upper limit. While the lifting height is restricted by detecting the height of the tip of the boom, the lifting height on the display panel shows the lifting height when the hook was raised to the over hoist detection status.
Page 88 CHECK SWITCH Use this switch to check the set values. Keep pressing the switch for three or more seconds. Each set value flashes for approximately five seconds in the display section. (1) "Boom angle upper limit value" is displayed at the boom length display section.
Page 89 DESCRIPTIONS OF MOMENT LIMITER DISPLAY UNIT For LED’s not described in this section, see "Operation 2.3.4 Names of Moment Limiter Display Unit". ACTUAL LOAD DISPLAY SECTION This section constantly displays the actual load of the hoisted load while the crane is operating. The actual load indicates the total weight of the hoisted load and lifting accessories increasing the hook weight.
Page 90 BOOM LENGTH DISPLAY SECTION This section constantly displays the current boom length while the crane is operating. The boom length is the distance from the boom foot pin to the sheave pin at the end of the boom. LIFTING HEIGHT DISPLAY SECTION This section constantly displays the current lifting height while the crane is operating.
Page 91 OVER UN-WINDING LED (RED) When the hook reaches over un-winding condition while the crane is operating, the over un-winding LED flashes for warning and hook un-winding is automatically interrupted. LOAD FACTOR DISPLAY This display indicates the status of the moment limiter load factor...
Page 92 2.3.5 MOMENT LIMITER FUNCTIONS OVERLOAD WARNING 1. SAFETY ZONE ("Actual load" is less than 90% of the "rated total load") (Load factor is less than 90%) • The green working status lamp lights up. • The LEDs lights up in green if the load factor is less than 80%.
Page 93 OVER HOIST DETECTOR CAUTION Pay attention to the distance between the hook and boom when raising the hook. Extending the boom also raises the hook. Always check the hook height when extending the boom. When you overwind the hook when raising the hook or extending the boom, •...
Page 94 2.3.6 MOMENT LIMITER STARTING STATUS The moment limiter checks its function for approximately three seconds when the starter switch is turned to the ON position. Meanwhile, • All the working status lamps light up. • All the LED’s light up. Then, if the moment limiter and the sensors are normal upon the completion of the functional check of the moment limiter, the red and yellow working status lamps turn off and the green working status lamp lights up indicating that the machine is ready for use.
Page 95 • Press the SETUP/CANCEL switch of the motion for which restriction you would like to cancel for three or more seconds. The set value of only the selected item can be canceled. At the same time, the LED above the switch goes off to complete the cancellation of the setting. NOTES See "Operation 2.3.4 Names of Moment Limiter Display Unit (Descriptions of Switches on Moment Limiter Display Unit)"...
Page 96 2.3.9 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH The moment limiter emergency stop cancel switch will temporarily disable the moment limiter function. While this switch is turned to the ON position (i.e. activated), calculation of the rated total load is disabled, thus the machine is in a very risky situation. When lifting operations are continued under these conditions, it may cause the hoisted load to fall, damage to the boom , or cause a serious accident such as the machine rolling over, which could result in death or serious injury.
Page 97 2.3.10 MOMENT LIMITER CAUSES OF ERRORS AND ACTIONS TO BE TAKEN The moment limiter displays an error code at the “rated total load” display section on the display panel to notify the error. If an error code shown in the table below was displayed, contact us or our sales service agency. Error Code Error Details Actions to Be Taken...
Page 98 OVER HOIST DETECTOR CAUTION Pay attention to the distance between the hook block and the boom when raising the hook block. The hook block also raises when the boom is extended. Always check the height of the hook block when performing boom extension operations. (1) Hook block (2) Over hoist detector (3) Weight...
Page 99 CONTROL LEVERS AND PEDALS Lock lever Travel lever Left-hand work equipment control lever Travel speed-up pedal Right-hand work equipment control lever Travel lock bar Accelerator pedal Level Blade lever LOCK LEVER (FOR LEFT-HAND AND RIGHT-HAND WORK EQUIPMENT CONTROL LEVERS) • When standing up from or leaving the operator's seat, set the lock lever to the LOCK position.
Page 100 WORK EQUIPMENT CONTROL LEVER • The control pattern of this machine is as indicated in the CONTROL PATTERN label, shown below. When any user desires to change to any other pattern, please contact us or our sales and service agency. •...
Page 101 ACCELERATOR PEDAL Use this pedal (4) to control the engine rotating speed and output. You can control the engine speed freely from low idle to full speed. BLADE CONTROL LEVER CAUTION • This operation lever is not locked even if the lock lever is set to the LOCK position. Accordingly, do not touch this lever while you are not operating the blade.
Page 102 TRAVEL LEVERS When the track frame is facing the rear, the direction of operation is opposite to the direction of movement of the machine. When operating the travel lever, check if the track frame is facing the front or the rear. (When the sprocket (a) is at the rear, the track frame is facing the front.) Use these levers (6) to travel the machine.
Page 103 TRAVEL LOCK BAR This bar (8) is used to "LOCK" the travel lever to prevent the machine from moving. • LOCK (L): Turn the bar to the left to engage it in the groove. • TRAVEL (F): Turn the bar to the right. LEVEL Operating the crane on a slope may cause the machine to roll over.
Page 104 COVERS WITH LOCK The dust cover, engine hood, and tool box cover are equipped with locks. Open or close the covers using the starter key. OPENING AND CLOSING COVERS WITH LOCK Insert the key as far as it will go to the shoulder (A). If the key is turned before it is inserted all the way, it may break.
Page 105 ENGINE HOOD When carrying out inspection and maintenance of the engine compartment, fully open the engine hood and be sure to keep it open using the stopper. CAUTION Always keep the engine hood locked except when opening it. You can check whether the engine hood is locked by checking the direction of the key slot of the opening knob.
Page 106 2. Push up hood (2) fully. Stopper (3) operates to fix hood (2). 3. When closing engine hood (2), pull stopper (3) to the free position (F) and lower the hood slowly, and then press it to the lock position (L). 3-42...
Page 107 FUSES CAUTION Be sure to turn the starter switch to the OFF position when replacing a fuse. Fuses protect electrical components and wires from burning out. If a fuse has corroded and is surrounded by white powder or there is play between it and its holder, be sure to change the fuse.
Page 108 FUSIBLE LINK If the starter motor does not turn even when the starter switch is turned to the START position, there is probably a disconnection in the fusible link (1). Open the cover on the right side of the machine and check and replace the fusible link.
Page 109 2.12 POWER SUPPLY FOR OPTIONS CAUTION When using an electrical component that has not been manufactured by us, confirm that it is of 12 V specification and that it has a capacity less than 240 W (equivalent to 20 A). When using a large capacity electrical component, contact us or our sales service agency.
Page 110 3. MACHINE OPERATIONS AND CONTROLS CHECKING/ADJUSTING BEFORE STARTING ENGINE 3.1.1 VISIBLE CHECKS Look around and below the machine before starting the engine, and check the status of working equipment and the hydraulic system such as tightness of nuts and bolts, and leakage of oil, fuel and coolant.
Page 111 CHECKING AROUND CRANE • Look around and below the boom, boom mounting and look for any leaking oil or other substances. Be especially careful to check the derrick cylinder and lower part of the winch motor. If you find any abnormalities, repair them.
Page 112 CHECKING AROUND UPPER STRUCTURE • Check for any fuel, oil or water leaks from the engine, and check for damages hoses and tubes. If you find any abnormalities, repair them. • Check the hot engine sections such as the engine muffler and around the battery for the buildup and deposit of combustibles such as dead leaves, paper wastes, dust, oil, and grease.
Page 113 3.1.2 CHECKING BEFORE STARTING (CHECKING BEFORE OPERATION) Checks specified in this section are required to be completed once prior to starting the engine for the first time every day. CHECKING/REFILLING ENGINE COOLANT • Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 114 CHECKING/REFILLING OIL LEVEL IN ENGINE OIL PAN Parts and oil will still be very hot immediately after the engine is stopped, and may cause burns. Wait for the temperature of these components to drop before performing this operation. CAUTION • If the machine is on an angle, place the machine on a level surface and start the inspection. •...
Page 115 CHECKING FUEL LEVEL • Be extremely careful with fire, such as that from cigarettes. • Be sure to stop the engine when refueling. If refueling is carried out while the engine is operating, any fuel that spills on a section that gets hot such as a muffler may catch fire. •...
Page 116 CHECKING/REFILLING OIL LEVEL IN WINCH MOTOR REDUCTION GEAR CASE The parts and oil will still be very hot immediately after the engine is stopped. Wait for the oil temperature to drop; do not try to remove the plug of the port immediately. CAUTION •...
Page 117 CHECKING/REFILLING OIL LEVEL IN HYDRAULIC TANK When removing the cap of oil filter port, turn it slowly to release the internal pressure. Otherwise, it may gush out. 1. If the machine is not in the condition as shown on the right, start the engine and run it at low speed.
Page 118 CHECKING DUST INDICATOR 1. Open the engine hood and check that the red piston is not showing in the transparent part of dust indicator (1). 2. If the red piston has appeared, clean or replace the air cleaner element immediately. See "Inspection and Maintenance 10.3 Irregular Maintenance (Checking/Cleaning/Replacement...
Page 119 CHECKING ELECTRICAL WIRING • If fuses frequently blow or if there are traces of short-circuiting on the electrical wiring, promptly ask us or our sales service agency to locate the cause and carry out repairs. • Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 120 ADJUSTING When adjusting the operator's seat position, always set the lock lever to the LOCK position. This will prevent an operation error if the control lever is touched accidentally. ADJUSTING OPERATOR’S SEAT The seat can slide in the forward or backward direction. Pull up lever (1) to set the seat to the desired position, then release the lever.
Page 121 HANDLING SEAT BELT • Before fitting the seat belt, check that there are no problems with the belt mounting brackets. If the seat belt is worn or damaged, replace it. • Even if the seat belt does not appear to have any abnormalities, replace it every three years. The date of manufacture of the belt is shown on the back of the belt.
Page 122 ADJUSTING THE SEAT BELT LENGTH To shorten the belt: Pull the belt end from the flap. To lengthen the belt: Pull the belt toward the buckle at a right angle. ADJUSTING MIRRORS Always adjust the mirrors before starting operations. If mirrors are not adjusted correctly, you will not be able to obtain a sufficient view of your surroundings, which may result in damage to the machine, or serious injury.
Page 123 3.1.3 OPERATIONS/CHECKING BEFORE STARTING ENGINE When starting the engine, check that the lock lever is securely in the LOCK position. If the lock lever is not locked securely and the control levers or control pedals are touched when the engine is started, the machine may move unexpectedly, which may lead to serious personal injury.
Page 124 2) Operate lamp switch and check that working lamps light up. If any lamp does not light up, the bulb has likely blown or there may be a disconnection. In such a case, ask us or our sales service agency for repair services.
Page 125 3.1.4 CHECKING AFTER STARTING ENGINE Check the followings in this section after starting the engine and before starting work for the first time every day. CAUTION The checkups described in this section should be carried out after starting the machine. See "Operation 3.1.3 Operations Before Starting Engine"...
Page 126 CHECKING CRANE OPERATIONS Be sure to refer to the Operation sections between "3.10 Cautions before Operating the Crane" and "3.17 Stowage Operation of Crane", and strictly observe the methods described and cautions given when checking crane operations. 1. Verify that the boom rises smoothly when the right-hand work equipment control lever is moved to the RAISE position (pull toward you).
Page 127 CHECKING OPERATION OF OVER HOIST DETECTOR Over hoist hook block (1), and raise the hook using the winch and extend the boom, and verify that the buzzer sounds intermittently, and that the hook raising and boom extension operations stop. If these operations do not stop, the over hoist detector (2) may be faulty.
Page 128 STARTING ENGINE 3.2.1 NORMAL STARTING ENGINE • Sit down in the operator’s seat before starting the engine. • Do not attempt to start the engine by short-circulating the engine starting circuit. Such an act may cause serious bodily injury or fire. •...
Page 129 3.2.2 STARTING ENGINE IN COLD WEATHER • Sit down in the operator’s seat before starting the engine. • Do not attempt to start the engine by short-circulating the engine starting circuit. Such an act may cause serious bodily injury or fire. •...
Page 130 4. Release the key of starter switch (2) when engine has started. The key returns to ON position (B) automatically. NOTES If the ambient temperature is below 0C, press the accelerator pedal for one fourth of its stroke and warm up the engine.
Page 131 OPERATIONS AFTER STARTING ENGINE • If you experience any problems such as an emergency stop or an abnormal machine operation, return the starter switch key to the OFF position. • If the warm-up operation for the hydraulic equipment is not carried out thoroughly, and the machine is operated, the response to the movement of the control levers will be slow and the machine’s movement may not be what the operator expects.
Page 132 3. Using right-hand work equipment control lever (3) carefully, lower the boom to its stop position and hold it there for five minutes. While carrying out this task, move the right-hand work equipment control lever (3) to the HOOK RAISING position (pull backward) and raise the hook adequately so that it does not touch the ground.
Page 133 STOPPING ENGINE CAUTION Do not stop the engine quickly except in an emergency, as it can reduce the service life of engine and the engine parts. If the engine has overheated, do not stop it quickly but cool down the engine by rotating it at an intermediate speed.
Page 134 BREAKING-IN MACHINE Perform breaking-in for the period of about the first 100 hours (hours displayed on the service meter). The life of the machine shortens if overloaded operation or task is performed before the various sections of the machine are used to the operation. While this machine is shipped after undergoing a thorough adjustment and inspection process, forcing the machine from the beginning will quickly degrade the functions of the engine and crane, shortening their life.
Page 135 MACHINE TRAVELLING POSTURE • When moving this machine under its own power, take the "travelling posture" with which the boom and hook block are stowed. • Travelling or performing pick and carry operations with the boom extended is essentially prohibited. Doing so will cause the machine to roll over, and may result in a serious accident.
Page 136 STARTING/MOVING/STOPPING MACHINE • Before operating the travel lever or travel pedal, check the direction that the track frame is facing. When the sprocket is at the front, the operation direction of the travel lever is opposite to the direction of movement of the machine. •...
Page 137 MOVING MACHINE FORWARD 1. Set lock lever (2) to FREE position (F) and keep the machine in the travelling posture. NOTES See "Operation 3.6 Machine Travelling Posture" for details. 2. Raise the blade. 3. Push travel lock lever (5) to travel position (F). 4.
Page 138 MOVING MACHINE BACKWARD 1. Set lock lever (2) to FREE position (F) and keep the machine in the travelling posture. NOTES See "Operation 3.6 Machine Travelling Posture" for details. 2. Raise the blade. 3. Push travel lock bar (5) to travel position (F). 4.
Page 139 STOPPING MACHINE Avoid stopping suddenly. Give yourself ample room when stopping. 1. Set left and right travel levers (1) to the Neutral position (N). The machine is braked and stopped. 2. Push travel lock bar (2) to the LOCK position (L) and locate it in the groove.
Page 140 STEERING MACHINE Before operating the travel levers, check the sprocket position. When the sprocket is at the front, the operation direction of travel lever is opposite to the direction of movement of the machine. Use the travel levers to change direction. Avoid sudden changes of direction as much as possible.
Page 141 WHEN OPERATING LEVERS DURING TRAVELLING (WITH THE LEFT AND RIGHT TRAVEL LEVERS SHIFTED TO THE SAME DIRECTION) When turning to the left, return the left travel lever to the neutral position. The machine turns to the left. (A): Forward left turn (B): Reverse left turn NOTES...
Page 142 SWINGING • The rear of the machine extends outside the track width. Before swinging, check with the mirror, and also check visually that the surrounding area is safe. • Before swinging the machine, check that the area around the machine is safe, and sound the horn 1.
Page 143 3.10 CAUTIONS BEFORE OPERATING THE CRANE Not observing these cautions before operation may result in serious accidents. • Always position the machine on level ground before operating the crane. Once the machine is stationed, check it is level. The moment limiter computes the moment subject to the machine being correctly leveled.
Page 144 3.11 OPERATIONS BEFORE OPERATING THE CRANE Boom extending or raising while the hook block is secured to the wire cable for stowage may damage the wire cable or the regular hook block stowage section in the front of the upper structure.
Page 145 5. Move right working control lever (3) to the RAISE position (pull toward you) to raise the boom. NOTES During this operation, excessive tension between hook block (4) and stowage wire cable (5) should be avoided. If storage wire cable (5) is under excessive tension, lower hook block (4).
Page 146 3.12 CRANE OPERATION POSTURE To start the crane operation, following "Operation 3.11 Operations before Operating the Crane", set to the crane operation posture as below: 1. Move right-hand work equipment control lever (1) to the HOOK RAISING position (pull backward) so that the hook block is hoisted.
Page 147 3.13 HOOK RAISING /LOWERING OPERATION • With the boom deflection, the hoisted load slightly shifts forward. Notify workers around you such as slinging operators. • If the hook block was hoisted too far, over hoisting will be detected. The alarm buzzer sounds intermittently.
Page 148 3.13.2 HOOK RAISING OPERATION BY HOOK STOWAGE SWITCH • The hook stowage switch cancels the auto-stop function of the over hoist detector and reduces the hook raising ability. Move the right-hand work equipment control lever carefully (very slowly without moving to the stroke end) when stowing the hook block.
Page 149 3.14 BOOM DERRICKING OPERATION • Move the right-hand work equipment control lever as slowly as possible. Sudden operation of the lever especially while hoisting a load will cause the load to swing, which may adversely impact the machine and result in damage or the machine rolling over. •...
Page 150 3.15 BOOM TELESCOPING OPERATION • Move the left-hand working equipment control lever as slowly as possible. Sudden operation of the lever, in particular when hoisting a load, will cause the load to swing, which may adversely impact the machine and result in damage or the machine rolling over.
Page 151 3.16 SWING OPERATION • Check the safety of the surrounding area and sound the horn before swinging. • Swing the crane as slowly as possible. Start smoothly, swing at a low speed, and stop gently. Sudden operation of the lever, in particular when hoisting a load, will cause the load to swing, causing the machine to lose stability, and thus may break the crane or overturn the machine.
Page 152 3.17 STOWAGE OPERATION OF CRANE 3.17.1 CRANE OPERATION FOR TEMPORARY HOOK BLOCK STOWAGE • The hook stowage switch cancels the auto-stop function of the over hoist detector and reduces the hook raising ability. Move the right-hand work equipment control lever carefully (very slowly without moving to the stroke end) when stowing the hook block.
Page 153 3. On each occasion that the hook block nearly reaches the ground as a result of practice in Steps 1 and 2 above, move right-hand work equipment control lever (1) to the HOOK RISING (pull backward) position and raise the hook block within an extent that over winding can be avoided.
Page 154 6. Keep pressing hook block stowage switch (3) (at the ON position) and move right-hand work equipment control lever (1) to the HOOK RAISING (pull backward) position again to raise hook block (4) up slowly and precisely to stow the hook block below the tip of the boom.
Page 155 3.17.2 CRANE OPERATION FOR REGULAR HOOK BLOCK STOWAGE • For hook block stowage operation, use both the left and right-hand work equipment control levers most carefully (slowly without moving at full stroke). Otherwise, the hook block may shake badly and damage objects around or cause serious accidents resulting in death or serious injury.
Page 156 3. Move right-hand work equipment control lever (1) to the HOOK LOWERING (push forward) position and lower the hook block until it reaches close to the regular stowage position. NOTES During this operation, over lowering hook block (4) should be avoided. Otherwise, loosened hook block (4) may damage other components around.
Page 157 3.18 DO’S AND DON’TS DURING OPERATION • Prior to operating the crane, always place the machine on level and solid ground. Use the level to ensure this. • In the event that operating the crane while travelling is unavoidable, always stop travelling first, then carry out the crane operation.
Page 158 DON’T USE FOR OTHER THAN MAIN APPLICATIONS Do not lift people up/down with the crane, unless using a safety cage designed for this purpose. For details, follow laws and regulations applicable to the place of use machine. DON’T PERFORM UNREASONABLE OPERATIONS Operations requiring more than the machine’s level of performance can cause accidents.
Page 159 3.19 PICK AND CARRY OPERATION 3.19.1 SAFETY PRECAUTIONS FOR PICK AND CARRY OPERATION • Pick and carry operation is a very unstable and dangerous practice and extreme care must be taken during this operation. Where such an operation is unavoidable, strictly adhere the limits in the "Rated total load table for pick and carry operation"...
Page 160 3.19.2 POSTURE FOR PICK AND CARRY OPERATION During pick and carry operation, retract the boom to "5.0 meters" (second section) or less, and carry out operations within the range of "Rated total load table for pick and carry operation" and the specified pick and carry travelling posture. If the operation posture is changed during travelling, this will overturn the machine, causing serious injury accidents.
Page 161 3.19.3 OPERATIONS DURING PICK AND CARRY OPERATION • See "Operation 3.19.1 Safety Precautions for Pick and Carry Operation" and always observe safe operation procedures as required. • Do not operate the crane during the pick and carry operation. The machine may overturn. •...
Page 162 3.20 OPERATION OF BLADE 3.20.1 PRECAUTION OF BLADE OPERATION [BASIC POSTURE OF THE BLADE] • Always clear the Blade from the ground during the hoisting operation. Failure to do so may result a serious hazard including damaging the machine or tipping it over. •...
Page 163 3.20.2 OPERATION OF BLADE • Always clear the Blade from the ground during the hoisting operation. Failure to do so may result in a serious hazard including damaging the machine or tipping it over. • Avoid ground leveling operations at the same time as hoisting operations. Otherwise, it may cause a serious hazard including damaging the machine or tipping it over.
Page 164 3.21 PARKING MACHINE • Parking the machine on the firm, level ground. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the blade into the ground surface to stop the machine from moving. •...
Page 165 3.22 MACHINE INSPECTION AFTER DAILY WORK 3.22.1 BEFORE STOPPING ENGINE Use the machine monitor to check engine coolant temperature (1), engine oil pressure (2), and fuel level (3). 3.22.2 AFTER STOPPING ENGINE 1. Walk around the machine and check the crane, machine exterior, and undercarriage, also check for any leakage of oil or coolant.
Page 166 3.23 CAUTIONS IN TRAVELLING Not observing these cautions before operating the crane will result in a serious accident. CAUTIONS IN TRAVELLING Travelling over boulders, tree stumps, or other obstacles will cause a significant amount of shock to the chassis (and in particular to the tracks), and this will cause damage to the machine.
Page 167 CAUTIONS FOR SLOPE TRAVELING • For slope travelling, take care of overturning or drifting. • At the angle of 15 degrees or more, when the machine is on a slope, the incline detector actuates and it triggers a buzzer. When the buzzer sounds, stop travelling and change to a safer path.
Page 168 4. HANDLING WIRE CABLES BENCHMARK FOR REPLACING WIRE CABLES CAUTION • The benchmark for replacing wire cables is common to all the wire cables for winching, telescoping the boom, and slinging. • Measure the diameter of the wire cable at the section where the wire cable repeatedly passes through the sheave.
Page 169 4. Excessively deformed as below: (1) The cable is twisted and has some kinks. Waviness width (2) Waviness width is 4/3d or more in a distance within 25 times of nominal diameter d. (3) The minimum diameter is 2/3 or less of the maximum diameter due to local pressure and being flattened.
Page 170 WINCH WIRE CABLE FALL MODE AND RATED TOTAL LOAD Number of wire cable falls of the hook block shall be determined based on the load to be hoisted, boom length and winching speed. The load to one wire cable fall must be within "750 kg". The table below shows the hook block types, wire cable falls and the rated total load in each condition: For 2 or 4 falls For 2 or 4 falls...
Page 171 WHAT TO DO WITH TWISTED WINCH WIRE CABLE Always wear thick leather working gloves when handling wire cables. CAUTION Change the hooking direction of the wire cable (reverse the hook block side and winch drum side) from time to time. Doing so can extend the service life of the wire cable.
Page 172 5. Turn the starter switch to the (A) (OFF) position to stop the engine. Then, set the lock lever to the LOCK position. 6. Remove securing bolt (1) to remove wedge socket pin (2), and then remove wedge socket (3). 7.
Page 173 10. Move the right-hand work equipment control lever to repeat RAISING/LOWERING (forward/backward) the hook block for several times. 11. Tidily spool up the wire cable into the winch drum with some tension applied to the cable. 12. Repeat the above procedure until the hook is no longer twisted.
Page 174 5. TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to ensure safety. OBSERVATION OF ROAD TRANSPORTATION ACTS If there are applicable local laws and regulations, observe these laws and regulations for safe transportation. If not, contact us or our sales service agency. TRANSPORTATION MEASURE Take road width, height, and weight into consideration in determining the transportation route.
Page 175 LOADING/UNLOADING • See "Specifications 1. Main Specification Table" for dimensions and weights related to this machine. • Select and use the ramp boards that satisfy the following conditions. • Has a length that when placed, the angle from the track is 15 degrees or less. •...
Page 176 5.1.1 LOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks under the tires to prevent the trailer from moving. 3. Secure the ramp boards in a way that the center of the trailer and the machine match.
Page 177 9. Align the direction of travel with the ramps and travel slowly. When on the ramps, operate only the travel. 10. When the machine travels over the rear wheels of the trailer, it becomes unstable, so drive slowly and carefully. Never operate the steering. 11.
Page 178 5.1.2 SECURING MACHINE After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1. Lower the blade. 2. Stop the engine, and remove the key from the starter switch. 3. Set the lock lever securely to the LOCK position (L). CAUTION Do not use the fixing hole at the rear of the track frame for towing or lifting the machine.
Page 179 5.1.3 UNLOADING 1. Unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks under the tires to prevent the trailer from moving. 3. Secure the ramp boards in a way that the center of the trailer and the machine match.
Page 180 LIFTING MACHINE 5.2.1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE • See "Specifications 1. Main Specification Table" for dimension and weights related to this machine. • The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
Page 181 2. Set the lock lever securely to the LOCK position (L). 3. Stop the engine, and remove the key from the starter switch. Then check that there is nothing around the operator’s compartment and get off the machine. 4. Lock the covers and caps fitted with locks. 5.
Page 182 5.2.2 LIFTING THE MACHINE IN THE BOOM RAISED POSTURE • See "Specifications 1. Main Specification Table" for dimension and weights related to this machine. • The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
Page 183 3. Stop the engine, and remove the key from the starter switch. Then check that there is nothing around the operator’s compartment and get off the machine. 4. Set the lock lever securely to the LOCK position (L). 5. Lock the lock cover and cap. 6.
Page 184 6. HANDLING IN COLD WEATHER PREPARING FOR LOW TEMPERATURE In low temperatures, the machine may start to have some difficulty and the coolant may freeze. In this case, take the following actions. FUEL AND LUBRICANTS Change the fuel and oil to ones with low viscosity. See "Inspection and Maintenance 7.1 Use of Fuel, Coolant and Lubricants According to Ambient Temperature"...
Page 185 BATTERY • The battery generates flammable gas. Do not bring fire or sparks near the battery. • Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. •...
Page 186 AFTER THE DAYS WORK IS COMPLETED To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. • Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud, dirt, or drops of water from getting inside the seal.
Page 187 7. LONG TERM STORAGE BEFORE STORING IT MACHINE CAUTION The machine should take the posture shown in the figure on the right during any long-term storage to protect the cylinder rod. See "Operation 3.6 Machine Travelling Posture" for travelling posture, (to prevent rust on the cylinder rod) The correct practice for one month or longer, is as follows: •...
Page 188 8. TROUBLES AND ACTIONS RUNNING OUT FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. PROCEDURE FOR BLEEDING AIR 1. Completely fill the fuel tank with fuel. 2.
Page 189 TOWING THE MACHINE • Wire cables used for towing the machine must be sufficiently durable for the towing weight of the machine. • Do not apply any sudden load to the wire cable. If pulling the machine out when it is stuck in mud or when towing a heavy object with the machine, pass wire cables for towing lengthwise through the track frame as shown in the figure on the right.
Page 190 8.4.2 BATTERY REMOVAL AND INSTALLATION CAUTION After securing the battery, check that it does not move. If it moves, tighten it again securely. • When removing the battery, first disconnect the cable from the ground (normally the negative (-) terminal). If a tool touches the positive terminal (+) and the chassis, there is danger that it will cause a spark, so be extremely careful.
Page 191 8.4.3 CAUTIONS IN BATTERY CHARGING When charging the battery, if the battery is not handled correctly, there is a hazard that the battery may explode. Always follow the instructions of "Operation 8.4.1 Cautions in Battery Handling" and the instruction manual accompanying the charger, and do the following.
Page 192 8.4.4 STARTING ENGINE WITH A BOOSTER CABLE When starting the engine using a booster cable, do the following. PRECAUTIONS FOR CONNECTING AND DISCONNECTING BOOSTER CABLE • When connecting the cables, never contact the positive (+) and negative () terminals. • When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
Page 193 8.4.5 STARTING ENGINE Check that the lock levers of the normal machine and problem machine are set to the LOCK positions. Also check that each control lever is in the NEUTRAL position. 1. Make sure the clips are firmly connected to the battery terminals. 2.
Page 194 OTHER TROUBLE 8.5.1 ELECTRICAL COMPONENTS • Always contact us or our sales service agency when dealing with the items in parentheses in the "Actions to be Taken" column. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services.
Page 195 8.5.3 ENGINE • Always contact us or our sales service agency when dealing with the items in parentheses in the "Actions to be Taken" column. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services.
Page 196 8.5.4 MOMENT LIMITER • Always contact us or our sales service agency when dealing with the items marked with ★ in the "Actions to be Taken" column. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services.
Page 197 ★ Boom extending or hook hoisting operation not activated even when not over hoisted Problem Main Causes Actions to be Taken Boom extending or hook Defective over hoist detector ★ Check, replace over hoist hoisting operation not detector activated even when not over Breakage of over hoist detector ★...
Page 198 3-134...
Page 199 INSPECTION AND MAINTENANCE 1. PRECAUTIONS REGARDING MAINTENANCE 4- 2 2. BASIC MAINTENANCE 4- 4 3. LEGAL INSPECTION 4- 7 4. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 8 5. CONSUMABLES 4- 9 6. OTHER COMPONENTS 4-10 7. USE OF FUEL, COOLANT AND LUBRICANT 4-11 8.
Page 200: Precautions Regarding Maintenance
Read the service meters daily to check for any maintenance items that have reached the obligatory maintenance period. USE GENUINE PARTS FOR REPLACEMENT Always use genuine Maeda parts as specified in the parts catalogue when replacing parts. USE GENUINE GREASE Always use genuine recommended grease. The viscosity of the grease must conform to specifications according to ambient temperature.
Page 201 DO NOT MIX OILS Never use or mix different types of oil from different manufacturers together under any circumstances. When replacing the currently used oil, be sure to replace all of it with new oil. Always use genuine Maeda parts when replacing parts.
Page 202: Basic Maintenance
2. BASIC MAINTENANCE HANDLING OIL • Oil is used under extremely harsh conditions (high temperature, high pressure) in the engine and working devices, which causes the oil to deteriorate over time. Always use oil that meets the requirements stated in the operating manual, such as those for grade and operating temperature.
Page 203 If any metal powder is discovered on the used filter, contact us or our sales service agency. • Regarding the replacement filter, always unpack it immediately before using it. • Always use genuine Maeda filters. HANDLING COOLANT • River water contains a large amount of calcium and impurities. Use of river water will result in water sludge accumulating in the engine and radiator, which will cause a heat exchange error and lead to overheating.
Page 204 HANDLING HYDRAULIC EQUIPMENT • Hydraulic equipment will be very hot during and immediately after operation. Hydraulic equipment operates under high pressure. The following precautions should be observed when carrying out inspection and maintenance tasks on hydraulic equipment. • Place the machine in the travelling position on a level surface to reduce the pressure on the cylinder circuit.
Page 205: 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 all safety devices are operating correctly. 2. Check the hoisting accessories including the hook block for any abnormalities. 3.
Page 206: Periodic Replacement Of Safety Critical Parts
4. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To use the machine safely for an extended period of time, you must periodically replace the safety critical and fire prevention-related parts listed in the table of important parts. The quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration when periodic maintenance checks are carried out.
Page 207: Consumables
Correct replacement of consumables delivers increased economy of machine use. Always use genuine Maeda parts when replacing parts. See the parts catalogue for part numbers when ordering parts. LIST OF CONSUMABLES...
Page 208: Other Components
6. OTHER COMPONENTS When ordering parts, please inform us or our service agency of your machine number to confirm the correct part numbers. LIST OF OTHER PARTS (1) Clear plate (4) Fuse (2) Working lamp assembly (5) Fusible link (45A) (3) Mirror (6) Fan belt 4-10...
Page 209: Use Of Fuel, Coolant And Lubricant
Failure to use recommended oil(s) may result in reduced life or excess wear of the engine, power train and cooling system. • Commercially available lubricant additives may degrade oil performance. Maeda does not recommend any commercially available lubricant additive. •...
Page 210 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Maeda machines are supplied with Supercoolant AF-NAC. Supercoolant AF-NAC has excellent anticorrosion, antifreeze, and cooling properties and can be used continuously for 2 years or 4000 hours. Supercoolant AF-NAC is strongly recommended whenever available.
Page 211: Tightening Torque Specifications
8. TIGHTENING TORQUE SPECIFICATIONS STANDARD TIGHTENING TORQUE LIST Tightening by using an unspecified torque may cause damage or a tightened item to become loose, which may lead to problems or a malfunction. Be extremely careful when tightening any item. Torque the metric nuts and bolts to the values shown in the following table. Adequate tightening torque is determined with respect to the width across flat (b) of the bolt or nut.
Page 212: Inspection And Maintenance List
9. INSPECTION AND MAINTENANCE LIST Inspection and maintenance item Page INITIAL 500-HOUR MAINTENANCE (ONLY FOR FIRST TIME MAINTENANCE OF A NEW MACHINE) REPLACING OIL IN WINCH MOTOR REDUCTION GEAR CASE 4-16 CHECKING/ADJUSTING BEFORE STARTING ENGINE (VISIBLE CHECKS) 3-46 (See Operation 3.1.1) CHECKING AROUND CRANE 3-47 CHECKING WIRE CABLES...
Page 213 Inspection and maintenance item Page MAINTENANCE EVERY 50 HOURS GREASING 4-36 MAINTENANCE EVERY 100 HOURS GREASING 4-38 MAINTENANCE EVERY 250 HOURS REPLACING HYDRAULIC OIL FILTER ELEMENT 4-39 CHECKING/REFILLING OIL LEVEL IN WINCH MOTOR REDUCTION GEAR CASE 4-40 MAINTENANCE EVERY 500 HOURS REPLACING OIL IN ENGINE OIL PAN AND ENGINE OIL FILTER CARTRIDGE 4-41 REPLACING FUEL FILTER CARTRIDGE...
Page 214: Maintenance Procedures
10 MAINTENANCE PROCEDURES 10.1 INITIAL 500-HOUR MAINTENANCE (ONLY FOR FIRST TIME MAINTENANCE OF A NEW MACHINE) Carry out the following maintenance tasks when performing maintenance on a new machine for the first time after operating it for 500 hours. • REPLACING OIL IN WINCH MOTOR REDUCTION GEAR CASE For the maintenance procedure, see maintenance every 1000 hours.
Page 215 10.3 IRREGULAR MAINTENANCE CHECKING, CLEANING AND REPLACING AIR CLEANER ELEMENT • Checking and cleaning the air cleaner while the engine is running may allow dirt and dust to enter the engine, and subsequently cause damage. Be sure to work after the engine is stopped.
Page 216 5. Blow dry compressed air (Max. 0.69 MPa{7 kg/cm from the inside of the outer element along its folds. Then, blow the compressed air from the outside along the folds, and blow it again from the inside. 1) Replace the element after it has been cleaned five times or used for one year.
Page 217 Even in the area where freezing is not an issue, the use of antifreeze coolant is essential. Maeda machine are supplied with Supercoolant (AF-NAC). Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 218 CAUTION Use genuine Maeda Supercoolant (AF-NAC) for the coolant. In principle, any coolant other than genuine Maeda Supercoolant AF-NAC is not recommended. Use tap water as a diluting liquid. Contact us or our sales service agency if you have to use river water, well water, or water from a private water supply system.
Page 219 8. Stop the engine, and open drain valve (3) and remove drain plug (4) to drain the water. 9. After draining the water, clean the inside using detergent. Follow the cleaning procedure provided on the detergent used. 10. Close drain valve (3), and wrap drain plug (4) with sealing tape and close it, too.
Page 220 CHECKING LEVEL OF BATTERY ELECTROLYTE Check the level before operating the machine. • Do not use the battery if the battery electrolyte level is below the LOWER LEVEL (minimum electrolyte level). Using the battery in the above condition will not only shorten its life by accelerating internal deterioration but also increase the risk of it exploding.
Page 221 WHEN UNABLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is not possible to check the electrolyte level from the side of the battery, or if there is no indication of UPPER LEVEL on the side face of the battery, check the level as follows. 1.
Page 222 CLEANING WATER SEPARATOR ELEMENT Keep this part away from open flames. • Prepare a filter wrench. • Prepare a container to receive drained fuel. 1. Open the engine hood. 2. Set handle (1) of the water separator to the Close position (A).
Page 223 DRAINING WATER AND SEDIMENT FROM FUEL TANK CAUTION Do not use trichloroethylene for cleaning inside of the tank. 1. Draining them before operating the machine. 2. Prepare a container to receive drained fuel. 3. Open cover (1) on the right side of the machine body. 4.
Page 224 CHECKING/ADJUSTING TRACK TENSION The wearing speed of the pins and bushings on the undercarriage varies depending on the working conditions and type of soil, so you must check the track tension frequently to maintain the standard tension. Stop the machine on firm level ground when carrying out the inspection and maintenance tasks. INSPECTION 1.
Page 225 INCREASING TRACK TENSION Prepare a grease gun. 1. Inject grease from the grease gun into the grease fitting (2). 2. To check that the track tension is correct, run the engine at a low idle, move the machine forward by the ground contact length and then stop the machine.
Page 226 BLEEDING AIR FROM HYDRAULIC SYSTEM CAUTION Operating the pump without filling the pump case with hydraulic oil can produce abnormal heat and damage the pump prematurely. Be sure to bleed the air completely. 1. Bleeding air from the piston pump 1) Remove the oil filler cap from the hydraulic tank.
Page 227 (A measurement should be performed at several points, with spacing between the points.) • Do not use an old wire rope even when it has not been used before. • Always use Maeda genuine wire rope. BENCHMARK FOR REPLACING WIRE ROPES A wire cable undergoes wear and tear over time.
Page 228 REMOVING WINCH WIRE ROPE Use the following procedure to remove the wire rope. 1. Set the machine on level and solid ground. 2. Operate the right work equipment control lever to the BOOM RAISING position (pull it toward the left) to raise the boom a little.
Page 229 INSTALLING WINCH WIRE ROPE The rope wedge to secure the wire rope must be fastened correctly and firmly. Otherwise, the wire rope may slip out, which may cause a serious accident. CAUTION • Ensure the wire rope winds normally onto the winch drum. •...
Page 230 4. Depending on the given number of falls, reeve the wire rope through the load sheave (10) at the boom end, hook block sheave (13), weight of the over hoist detector (14) and guide sheave (15) as shown in the figure below. 4-fall 2-fall 1-fall...
Page 231 CHECKING/ADJUSTING BOOM TELESCOPING WIRE ROPE Prompt adjustment is required if the following event appears in the boom extending wire rope. 1. Fully retract the boom. 2. Remove three mounting bolts (1) in the boom end and remove cover (2). 3. Remove lock bolt (6) in the end of the telescoping cylinder in the boom, and turn the adjustment bolt (9) for the boom extending wire clockwise.
Page 232 ADJUSTING BOOM TELESCOPING WIRE ROPE CAUTION When adjusting wire ropes, be careful not to apply excessive tension to them. A single wire rope is used for each of boom extending and boom retracting respectively. The following adjustment procedure is prepared for these wire ropes. Be sure to follow it. 1.
Page 233 4. Adjusting No. 4 boom retracting wire rope (5) 1) Loosen lock nut (3), and then tighten left and right adjustment nuts (4) evenly in the direction that tensions retracting wire rope (5) (clockwise direction) until clearance (a) becomes "0 (zero)". 2) If it is found after the operation and measurement of Steps 1 and 2 that the retracting wire rope is loosened or clearance (a) is 5 mm or greater, you...
Page 234: Maintenance Every 50 Hours Greasing
10.4 MAINTENANCE EVERY 50 HOURS GREASING CAUTION • Type of grease used varies with greasing points. Failure to grease properly may shorten the machine life. • For a new machine that requires an initial running-in, grease it once every 10 hours until it has been operated for up to 100 hours.
Page 235 4-37...
Page 236: Maintenance Every 100 Hours Greasing
10.5 MAINTENANCE EVERY 100 HOURS GREASING Carry out this maintenance in tandem with the maintenance tasks that are performed every 50 hours. When greasing the swing circle and swing pinion, exercise care not to swing them while greasing them. CAUTION •...
Page 237: Maintenance Every 250 Hours
10.6 MAINTENANCE EVERY 250 HOURS Carry out this maintenance in tandem with the maintenance tasks that are performed every 50 and 100 hours. REPLACING HYDRAULIC OIL FILTER ELEMENT • Parts and oil will still be very hot immediately after the engine is stopped, and have the potential to cause burns.
Page 238: Checking/Refilling Oil Level In Winch Motor Reduction Gear Case
CHECKING/REFILLING OIL LEVEL IN WINCH MOTOR REDUCTION GEAR CASE The parts and oil will still be very hot immediately after the engine is stopped. Wait for the oil temperature to drop and do not try to remove the plug of the port immediately. CAUTION •...
Page 239: Maintenance Every 500 Hours
10.7 MAINTENANCE EVERY 500 HOURS Carry out this maintenance in tandem with the maintenance tasks that are performed every 50, 100 and 250 hours. REPLACING OIL IN ENGINE OIL PAN AND ENGINE OIL FILTER CARTRIDGE Parts and oil will still be very hot immediately after the engine is stopped, and have the potential to cause burns.
Page 240: Replacing Fuel Filter Cartridge
REPLACING FUEL FILTER CARTRIDGE • Since each part will still be very hot immediately after the engine is stopped, do not try to replace the filter immediately. Be sure to proceed with the work after they have cooled down. • Keep this part away from open flames. •...
Page 241: Checking/Refilling Oil Level In Final Drive
CHECKING/REFILLING OIL LEVEL IN FINAL DRIVE • Parts and oil will still be very hot immediately after the engine is stopped, and have the potential to cause burns. Wait for the temperatures of these components to drop before performing this operation. •...
Page 242: Cleaning/Checking Radiator Fins, Oil Cooler Fins And Fuel Cooler Fins
CLEANING/CHECKING RADIATOR FINS, OIL COOLER FINS AND FUEL COOLER FINS Note that your body may be directly hit by compressed air, compressed water or steam in this operation, which may scatter litter and cause a personal injury. Always use protective glasses, a dust mask, and other protective equipment.
Page 243: Checking/Adjusting Fan Belt Tension
CHECKING/ADJUSTING FAN BELT TENSION Special tools are required for this inspection and adjustment. Before starting the inspection or replacement, contact us or our sales service agency. INSPECTION Press at a midway point between the alternator pulley and fan pulley, the fan belt tension is normal if it deflects approximately 5 to 6 mm (approximately 58.5N {6 Kgf}).
Page 244: Maintenance Every 1000 Hours
10.8 MAINTENANCE EVERY 1000 HOURS Carry out this maintenance in tandem with the maintenance tasks that are performed every 50, 100, 250 and 500 hours. REPLACING OIL IN FINAL DRIVE CASE • Parts and oil will still be very hot immediately after the engine is stopped, and have the potential to cause burns.
Page 245: Replacing Oil In Winch Motor Reduction Gear Case
REPLACING OIL IN WINCH MOTOR REDUCTION GEAR CASE • The oil is at high temperature immediately after the engine is stopped. Wait for the oil temperature to drop and do not try to remove the plug of the port immediately. •...
Page 246: Maintenance Every 1500 Hours
10.9 MAINTENANCE EVERY 1500 HOURS Carry out this maintenance in tandem with the maintenance tasks that are performed every 50, 100, 250 and 500 hours. CHECKING/CLEANING FUEL INJECTION DEVICE The fuel injection valve must operate normally in order to secure an optimum engine performance. Check and clean the fuel injection valve.
Page 247: Maintenance Every 2000 Hours
10.10 MAINTENANCE EVERY 2000 HOURS Carry out this maintenance in tandem with the maintenance tasks that are performed every 50, 100, 250, 500 and 1000 hours. REPLACING OIL IN HYDRAULIC TANK AND CLEANING STRAINER • Parts and oil will still be very hot immediately after the engine is stopped, and have the potential to cause burns.
Page 248 4. Open dust cover (1) on the right side of the machine body and remove cap of oil filler port (F) to release the internal pressure. 5. Open inspection cover (2) on the right side of the machine body and set a container for receiving oil at the bottom of drain plug (P).
Page 249: Checking Alternator And Starter Motor
10. As shown in the figure to the right, retract the boom to the minimum length and raise it fully, lower the blade to the ground, attach the oil filler cap and then pressurize the inside of the tank. 11. After refilling the oil, set each control lever to the neutral position and run the engine at a low idle for two to three minutes before starting the operation.
Page 250 4-52...
Page 251 SPECIFICATIONS 1. SPECIFICATION LIST 5- 2 2. SPECIFICATION DIMENSIONAL DRAWING 5- 3 3. RATED TOTAL LOAD CHART 5- 4 4. WORKING RADIUS AND LIFTING HEIGHT 5- 7...
Page 252 1. SPECIFICATION LIST System / Item LC383M-5 Machine mass 4,400kg Overall length  width  height 4,020mm x 1,740mm x 2,500mm Distance between idler 1,650mm Mass and sprocket dimensions Track gauge 1,440mm Track width 300mm 980mm Swing radius at machine rear end Maximum rated total load ...
Page 253 2. SPECIFICATION DIMENSIONAL DRAWING...
Page 254 3. RATED TOTAL LOAD CHART [1] RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS Unit: kg Working 3.18m Boom 5.03m Boom 6.87m Boom 8.71m Boom radius Pick & Pick & Stationary Stationary Stationary Stationary Carry Carry 1.50 2930 1465 2930 1465 1870...
Page 255 [2] RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS Unit: kg Working 3.18m Boom 5.03m Boom 6.87m Boom 8.71m Boom radius Pick & Pick & Stationary Stationary Stationary Stationary Carry Carry 1.50 1480 1480 1480 1190 2.00 1480 1480 1480 1190 2.50...
Page 256 [3] RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL Unit: kg Working 3.18m Boom 5.03m Boom 6.87m Boom 8.71m Boom radius Pick & Pick & Stationary Stationary Stationary Stationary Carry Carry 1.50 2.00 2.50 2.85 3.00 3.50 4.00 4.50 4.70 5.00 5.50...
Page 257 4. WORKING RADIUS AND LIFTING HEIGHT [1] WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 4 FALLS...
Page 258 [2] WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 2 FALLS...
Page 259 SEARCHER HOOK 1. SEARCHER HOOK EACH SECTION 6- 2 2. MOMENT LIMITER DISPLAY UNIT 6- 3 3. OPERATION 6- 5 4. INSPECTION AND MAINTENANCE 6- 8 5. WORKING RADIUS AND RATED TOTAL LOAD 6-11...
Page 260: Searcher Hook Each Section
1. SEARCHER HOOK EACH SECTION (1) Hook (5) Snap pin (2) E-Boom (6) Hex. head bolt (3) Bracket (7) Hex. head nut (4) Position pin (8) High tension washer...
Page 261: Moment Limiter Display Unit
2. MOMENT LIMITER DISPLAY UNIT (1) Load capacity display (16) Cancel switch (2) Actual load display (17) Searcher hook mode switch (3) Rated total load display (18) Overwind detection LED (Red) (4) Boom angle display (19) 1 fall LED (Green) (5) Working radius display (20) 2 falls LED (Green) (6) Rated radius display...
Page 262 [1] DESCRIPTIONS OF SWITCHES ON MOMENT LIMITER DISPLAY UNIT CAUTION For general operation, see “OPERATION 2.3 MORMENT LIMITER”. 1. Searcher hook mode switch ・Searcher hook mode must be set when operating searcher hook. Otherwise moment limiter would not work correctly and thus may result in serious accidents. ・Travel lock bar must be in lock position when operating searcher hook.
Page 263: Operation
3. OPERATION ・Do not use searcher hook other than in searcher hook mode. It cause moment limiter to function incorrectly, and thus may cause serious accident. ・Main hook block must not be used in searcher hook mode. ・When operate searcher hook, surely set travel lock bar to lock position. Pick and carry operation is prohibited.
Page 264 5. Press searcher hook mode switch (17) for 3 seconds. Do not operate searcher hook other than in the searcher hook mode. Moment limiter would not work correctly and thus may result in serious accidents. 6. Make sure the searcher hook LED (29) is turned on, and fall mode LEDs (19) ~ (21) are turned off.
Page 265 9. Insert the position pin (4) through the hole of bracket (3), and ＸＡＭ２９０５０新規 secure it with the snap pin (5) to the tip of position pin (4). Always secure the position pin (4) with the snap pin (5). If the snap pin falls out during operations, serious injury or damage to the machine may result.
Page 266: Inspection And Maintenance
4. INSPECTION AND MAINTENANCE 4.1 LEGAL INSPECTION In the event that federal or local law or regulation requires regular inspection to maintain safe operation of machine, check items below: 1. Check disorder of safety devices. 2. Check disorder of lifting equipment such as hook. 3.
Page 267 4.4 MAINTENANCE PROCEDURES 4.4.1 INSPECTION OF BEFORE OPERATION [CHECKING BEFORE STARTING ENGINE] Check the followings in this section without starting the engine and before starting work every day. [1] CHECKING BOOM AND FRAME • Check each part of the boom and frame for cracks, excessive deformation and contamination etc. In addition, check bolts, nuts and pins for any looseness, drop, or damage etc.
Page 268 [CHECKING AFTER STARTING ENGINE] Check the followings in this section after starting the engine and before starting work every day. CAUTION The checks described in this section should be carried out after starting the machine. Refer to "Operation 3.2 Starting Engine" and later to execute the engine startup, travelling and crane operations.
Page 269: Working Radius And Rated Total Load
5. WORKING RADIUS AND RATED TOTAL LOAD • The diagram of working radius and lifting height shows the relationships the working radius of this machine, boom angle, and lifting height above the ground with no object hoisted. The diagram has been made allowing for no deflection in the boom. •...
Page 270 5.2 RATED TOTAL LOAD CHART FOR SEARCHER HOOK Unit：Kg 3.18m boom 5.03m boom 6.87m boom 8.71m boom Working radius Stationary Stationary Stationary Stationary 1.50 2.00 2.50 2.85 3.00 3.50 4.00 4.50 4.70 5.00 5.50 6.00 6.54 7.00 7.50 8.00 8.38 ★...
Page 271 MAEDA CRAWLER CRANE LC383M-5 OPERATION MANUAL Document No: 541E-OM1010-00 First edition: October 12, 2010 Issued by Maeda Seisakusyo Co., Ltd. 1095 Onbegawa, Shinonoi Nagano, Nagano 388-8522, Japan No part of this manual can be reproduced in any from without permission...

Maeda LC383M-5 Operation Manual

Introduction

Safety

Inspection and Maintenance

Table of Contents

Maintenance Every 50 Hours Greasing

Maintenance Every 100 Hours Greasing

Maintenance Every 250 Hours

Maintenance Every 500 Hours

Maintenance Every 1000 Hours

Maintenance Every 1500 Hours

Maintenance Every 2000 Hours

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