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Maeda LC785M-8B Operation Manual

Crawler crane
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Table of Contents

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557E-OM1202-00
OPERATION MANUAL
CRAWLER CRANE
Serial No. 32024 and up
Unsafe use of this machine may cause serious injury or death. Operators
must read this manual before operating this machine. This manual should
be kept near the machine for reference and periodically reviewed by all
personnel who will come into contact with it.
NOTICE
MAEDA has Operation Manuals written in some other languages. If a
foreign language manual is necessary, contact your local distributor for
availability.

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Summary of Contents for Maeda LC785M-8B

  • 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 – 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 –...

  • Page 4: Item Page

    ITEM Page 2. EXPLANATION OF DEVICES 3 – 6 2.1 MACHINE MONITOR 3 – 6 2.1.1 BASIC OPERATION OF MACHINE MONITOR 3 – 7 2.1.2 EMERGENCY STOP ITEMS 3 – 10 2.1.3 CAUTION ITEMS 3 – 12 2.1.4 BASIC CHECK ITEMS 3 –...
  • Page 5 ITEM Page 2.20 OPERATION MANUAL STORAGE 3 – 106 2.21 CUP HOLDER 3 – 106 2.22 GREASE PUMP HOLDER 3 – 106 2.23 ASHTRAY 3 – 106 2.24 WIND-IN TYPE SEAT BELT 3 – 107 3. MACHINE OPERATIONS AND CONTROLS 3 –...
  • Page 6 ITEM Page 3.21.3 OPERATIONS DURING PICK & CARRY OPERATION 3 – 176 3.21.4 RELEASING PICK & CARRY OPERATION POSTURE 3 – 176 3.22 OPERATION OF BLADE 3 – 177 3.22.1 PRECAUTION OF BLADE OPERATION 3 – 177 3.22.2 OPERATION OF BLADE 3 –...
  • Page 7 ITEM Page 8.5.4 ELECTRONIC CONTROL SYSTEM 3 – 214 8.5.5 MOMENT LIMITER 3 – 215 8.5.6 OVER HOIST DETECTOR 3 – 216 INSPECTION AND MAINTENANCE 4 – 1 1. PRECAUTIONS REGARDING MAINTENANCE 4 – 2 2. BASIC MAINTENANCE 4 – 4 3.
  • Page 8 ITEM Page 6. FLY-JIB INSTALLATION AND STOWAGE 6 – 8 6.1 FLY-JIB INSTALLATION 6 – 9 6.2 EXTENDING NO.2 FLY-JIB 6 – 15 6.3 RETRACTIMG NO.2 FLY-JIB 6 – 15 6.4 FLY-JIB STOWAGE 6 – 16 7. HANDLING MOMENT LIMITER 6 –...
  • Page 9 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 • 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. • This manual should always accompany this machine upon transfer of the machine to the next owner.

  • 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 an 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: Machine Functions

    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...

  • Page 16: Diagram Of Working Radius And Lifting Height

    5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT • The diagram of working radius and lifting height shows the relationships the working radius of this machine, boom angle, and lifting height above the ground with no object hoisted. The diagram has been made allowing for no deflection in the boom. 1.

  • Page 17: Rated Total Load Chart

    5.3 RATED TOTAL LOAD CHART • All the values provided in the rated total load chart are based on the assumption that the machine is placed on a level and firm surface. • The values in the rated total load chart are determined based on the working radius allowing for deflection that is developed when load is applied to the boom.
  • Page 18 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in parallel with the length of the boom. The loads are specified by working radius. [1] BOOM LENGTH The following figures illustrate the condition of the booms, “(1) 4.63m Boom”, “(2) 7.38m Boom”, “(3) 10.13m Boom”, “(4) 12.88m Boom”, and “(5) 15.63m Boom”...
  • Page 19 4. “(4) 12.88m Boom”: With boom (2) fully extended, booms (3), (4), and (5) are extended 2/3 (half of the “ mark 2” passes boom (2)). Boom (4) is to apply to crane operation with half of the “ mark 1” on boom (3) passes boom (2). 5.

  • 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 bottom of operator cab. Information of EPA ・...
  • Page 21 Gauges and meters To be shown at service meter section on machine monitor. 1-13...
  • Page 22 1-14...

  • Page 23: Safety

    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.

  • 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 BEFORE STARTING OPERATION OBSERVE THE MANUAL AND SAFETY LABELS •...

  • Page 25: Preparations Of Safety Operation

    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: Precautions For Fire Prevention

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

  • Page 28: Precautions When Getting On Or Off

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

  • Page 29: Other Precautions

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

  • Page 30: Driving Related Precautions

    2. DRIVING RELATED PRECAUTIONS 2.1 PRECAUTIONS FOR JOB SITE 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: Precautions When Starting Engine

    2.2 PRECAUTIONS WHEN STARTING ENGINE 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: Precautions When Starting To Move Machine

    2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE CHECKS BEFORE OPERATION Omitting the inspections after starting the engine results in delay to notice the Machine abnormalities, and may result in bodily accidents and Machine damages. Execute inspection in a wide location with no obstacle. In addition, be sure to prevent people from approaching nearby the Machine.
  • Page 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: Precautions When Working With Crane

    2.4 PRECAUTIONS WHEN WORKING WITH CRANE INSPECTION BEFORE STARTING WORK Check that the safety devices and crane operate properly. • Operate each of the operation levers, pedals and switches under no load, and check that operations take place without abnormality. Repair immediately if any abnormality exists.
  • Page 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 an 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 according 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 ON position. Operate the work equipment control lever back and forth. Left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then push up lock lever (1) to the LOCK position (L) and turn starter switch to the OFF position.
  • Page 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: Precautions During Maintenance

    5.2 PRECAUTIONS DURING MAINTENANCE CAUTIONS DURING WELDING REPAIR Welding operation must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
  • Page 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 ACCUMULATOR AND GAS SPRING HANDLING The accumulator and gas springs are charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage. For this reason, always observe the following precautions.

  • Page 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 (557-2221400) (2) For your safe operation (556-3367900-2) 2-35...
  • Page 58 (3) Moment limiter operation (557-2221500) (4) Warning for operation, inspection and maintenance (584-3469700) 2-36...
  • Page 59 (5) Caution for number of parts reeving selector switch (553-3181800-1) (6) Caution for emergency switch (7) Warning for blade operation (553-4266400) (556-4575300) (8) Never water wash inside cabin (9) Caution for wash (300-4213900) (553-4266500) 2-37...
  • Page 60 (10) Control pattern (556-3368100) (11) Warning for Window (20U-98-21910) (12) Front window Lock (22P-00-11170) (13) Safety plate (09839-03000) 2-38...
  • Page 61 (14) Warning tag (09963-03001) (15) Portable Working range and rated total load chart (557-3488600) (16) Warning for track tension adjusting (09657-A0881) 2-39...

  • Page 62: (See Operation 3.1.1 Checking Before Starting Engine (Visible Checks))

    (17) Keep off swing area (09133-A1681) (18) Warning for winch (553-4267500) (19) Lifting Position (09960-00801) (4 places) (20) Warning (553-4268000) (2 places) (21) Machine Weight (557-4632300) (22) Do not Stand on here (584-4581700) 2-40...
  • Page 63 (23) Caution for filling hydraulic oil (09653-A0481) (24) Safety plate (09805-A0481) (2 places) (25) High temperature caution (349-4427800) (26) Falling Hazard (557-4632500) (27) Entanglement hazard (09667-A0481) (28) Shock hazard (09808-A0881) 2-41...
  • Page 64 (29) Safety plate (09659-A057B) (30) Warning for hook block (553-4267400) (2 places) 2-42...

  • Page 65: Operation

    OPERATION 1. MACHINE EACH SECTION 3 – 2 2. EXPLANATION OF DEVICES 3 – 6 3. MACHINE OPERATIONS AND CONTROLS 3 – 108 4. HANDLING WIRE ROPES 3 – 184 5. TRANSPORTATION 3 – 190 6. HANDLING IN COLD WEATHER 3 –...

  • Page 66: Machine Each Section

    1. MACHINE EACH SECTION 1.1 MACHINE EACH UNIT Boom Idler Working lamp Track Boom derricking cylinder (10) Blade cylinder Winch (11) Blade Head lamp (12) Hook block Sprocket and traveling motor (13) Over hoist detector Track frame (14) Working status lamp...

  • Page 67: Operator's Compartment Equipment

    1.2 OPERATOR’S COMPARTMENT EQUIPMENT Radio (13) Cigarette lighter Level (14) Blade control lever Engine emergency stop switch (15) Starter switch Lock lever (16) Fuel control dial Left work equipment control lever (17) Lamp switch Travel pedals (18) Sun roof wiper switch Travel levers (19) Room lamp switch Accelerator pedal...

  • Page 68: Machine Monitor

    1.2.1 MACHINE MONITOR AA: Standard screen BB: All lamps lit up screen CC: Maintenance interval warning screen Wiper switch (15) Travel speed selector switch Buzzer cancel switch (16) Window washer switch Auto-deceleration switch (17) Air conditioner control switches Engine coolant temperature monitor (18) Engine oil pressure monitor Engine coolant temperature gauge (19) Message monitor...

  • Page 69: Moment Limiter Related Switch Box

    1.2.2 MOMENT LIMITER RELATED SWITCH BOX (1) Moment limiter emergency stop cancel switch (2) Hook stowage switch (3) Winch speed selector switch...

  • Page 70: Explanation Of Devices

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

  • Page 71: Basic Operation Of Machine Monitor

    2.1.1 BASIC OPERATION OF MACHINE MONITOR STARTING ENGINE WHEN SITUATION IS NORMAL GG: Opening screen DD: Check before starting screen HH: Working mode/Travel mode display screen AA: Standard screen • When the starter switch is turned to the ON position, the Opening screen GG is displayed. •...
  • Page 72 IF THERE IS ABNORMALITY WHEN STARTING ENGINE DD: Check before starting screen CC: Maintenance interval warning screen AA: Standard screen EE: Error screen • If there is any abnormality when starting the engine, the Check before starting screen DD changes to the Maintenance interval warning screen CC, or Error screen EE.
  • Page 73 IF ANY ABNORMALITY OCCURS DURING OPERATION AA: Standard screen EE: Error screen • If any abnormality OCCURS DURING OPERATION, the Standard screen AA changes to the Error screen EE. NOTES The colours lighting up the monitors related to the emergency stop items, caution items, and basic check items are as follows.

  • Page 74: Emergency Stop Items

    2.1.2 EMERGENCY STOP ITEMS If the monitor lights up red, Stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up and buzzer sounds, perform action immediately.
  • Page 75 HYDRAULIC OIL TEMPERATURE MONITOR This monitor (2) warns operator that the hydraulic oil temperature has risen. If the hydraulic oil temperature becomes abnormally high, the monitor shows abnormal display (C). Stop operations and stop the engine or run it at low idling until monitor (2) change to normal display (B).

  • Page 76: Caution Items

    2.1.3 CAUTION ITEMS If the warning monitor lights up red, Stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. These are items that should be observed while the engine is running. If any abnormality occurs, the screen displays the item that needs immediate action.
  • Page 77 HYDRAULIC OIL TEMPERATURE MONITOR If this monitor (2) shows low-temperature display (A), carry out the warm-up operation. For details, see “Operation 3.3.2 Hydraulic Equipment Warm Up”. This monitor (2) will show normal display (B), so carry out the warm-up operation for hydraulic equipment. •...

  • Page 78: Basic Check Items

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

  • Page 79: Meter Display Portion

    2.1.5 METER DISPLAY PORTION PILOT DISPLAY GAUGE AND METER (1) Engine pre-heating monitor (10) Engine coolant temperature gauge (2) Swing lock monitor (11) Hydraulic oil temperature gauge (3) Wiper monitor (12) Fuel level gauge (4) Auto-deceleration monitor (13) Service meter/Clock (5) Working mode monitor (14) ECO gauge (6) Travel speed monitor...
  • Page 80 SWING LOCK MONITOR This monitor (2) does not operate. WIPER MONITOR This monitor (3) indicates operating status of the wiper. The monitor display when wiper switch is operated, as follows. • Monitor ON lights up: Wiper moves continuously • Monitor INT Lights up: Wiper moves intermittently •...
  • Page 81 TRAVEL SPEED MONITOR This monitor (6) shows the setting for the travel speed. The monitor display is as follows according to the operation of the travel speed selector switch. • Monitor Lo: Low-speed travel • Monitor Hi: High-speed travel For detail of positions of the travel speed selector switch, see “Operation 2.1.6 Monitor switches portion”.
  • Page 82 [GAUGE AND METER] ENGINE COOLANT TEMPERATURE GAUGE This meter (10) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator goes beyond red range (A) during operations, the overheat prevention system is actuated. •...
  • Page 83 HYDRAULIC OIL TEMPERATURE GAUGE This meter (11) shows the hydraulic oil temperature. The oil temperature should stay in range between (D) and (F) during operation. If the indicator enters the red range (A) during operations, the hydraulic oil temperature is 102 ° C or more. Run the engine at low idling or stop it and wait for the hydraulic oil temperature to go down.
  • Page 84 SERVICE METER/CLOCK This meter (13) shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 1 for every hour that the machine is working, regardless of the engine speed.

  • Page 85: Monitor Switches Portion

    2.1.6 MONITOR SWITCHES PORTION (1) Working mode selector switch (5) Window washer switch (2) Auto-deceleration switch (6) Buzzer cancel switch (3) Travel speed selector switch (7) Function switch (4) Wiper switch (8) Air conditioner switch WORK MODE SELECTOR SWITCH Use this switch (1) to set the movement or power of the crane. The operation becomes easier if the mode is selected to match the content of the operation.
  • Page 86 [PROCEDURE FOR OPERATION] 1. If working mode selector switch (1) is pressed, the working mode screen is displayed on the monitor. 2. Press function switches (F3) or (F4) at the bottom of the screen or working mode selector switch (1) to change the mode selection one at a time.
  • Page 87 AUTO-DESELERATION SWITCH If the control levers are neutral, this switch (2) automatically lowers the engine speed and returns on the function to reduce fuel consumption. • Monitor ON: Auto-deceleration ON • Monitor OFF: Auto-deceleration OFF Each time the switch is pressed, the auto-deceleration is switched between ON and OFF.
  • Page 88 TRAVEL SPEED SELECTOR SWITCH • When loading or unloading the machine on a trailer, always travel at low speed (set to Lo). Never operate the travel speed selector switch when traveling. • If the travel speed selector switch is operated when the machine is traveling, the machine may deviate to one side even when it is traveling in a straight line.
  • Page 89 WIPER SWITCH This switch (4) actuates the front window wiper. Each time the switch is pressed, it changes ON→INT→ STOP (OFF). • Monitor INT: Wiper operates intermittently • Monitor ON: Wiper operates continuously • Monitor OFF: Wiper stops NOTES Each time wiper switch (4) is pressed, the mode is displyed in the center of the monitor display, and after 2 seconds, the screen returns to the standard screen.
  • Page 90 BUZZER CANCEL SWITCH This switch (6) is pressed, the warning buzzer for the abnormal warning item stops. FUNCTION SWITCHES Function switches (7) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen.

  • Page 91: Handling Function Switches

    2.1.7 HANDLING FUNCTION SWITCHES • The function switches (A) at the bottom of the monitor display consist of 6 switches (F1 – F6). The function of each switch differs according to the content of each screen. • The function of switches (A) on each screen can be confirmed by guidance icons (B) displayed on top of each switch.
  • Page 92 SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH • On the standard screen, it is possible to press the function switch (F4) to switch the service meter and clock display at the top of the monitor display. • When the time is being displayed, press the function switch (F4) to switch to the service meter display.
  • Page 93 MAINTENANCE MODE SELECTOR SWITCH When function switch (F5) is pressed on the standard screen, the monitor display screen switches to the maintenance mode screen. The items on the maintenance display are as follows. Default maintenance Maintenance items interval settings (h) Engine oil change Engine oil filter change Fuel main filter change...
  • Page 94 [OPERATIONS ON MAINTENANCE LIST SCREEN] On the maintenance list screen, it is possible to carry out the following operations with function switches (F1 to F6). • Switch (F1): Displays next page. After the last page, it displays the first page. •...
  • Page 95 [OPERATIONS ON MAINTENANCE INTERVAL RESET SCREEN] On the maintenance list screen, if switch (F6) is kept pressed for at 1.5 seconds, the screen changes to the maintenance time reset screen. Reset the remaining time on this screen. 1. Press switch (F6) when the reset screen is in the condition shown in the diagram on the right.
  • Page 96 USER MODE SELECTOR SWITCH When the switch (F6) pressed, the monitor display screen switches to the setting mode screen for the machine. On the user menu screen, it is possible to carry out the following operations with function switches (F3 to F6). •...
  • Page 97 (c) Screen adjustment Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen. 1. On the standard screen, presses switch (F6). 2. Select screen adjustment on the user menu screen, then press switch (F6). The screen switches to the selection menu screen for screen adjustment.
  • Page 98 4. Use switches (F2 to F6) to adjust the brightness, contrast, and back light of the selected screen. (1) Adjusting standard screen • If the light switch is at night mode ON, and the standard screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode).
  • Page 99 (d) Clock Adjustment On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard screen. 1. On the standard screen, presses switch (F6). 2. Select “Clock Adjustment” on the user menu screen, then presses the switch (f6).
  • Page 100 3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches (F3 to F6). [Time] Adjust the hour setting. (1) If “Time” (a) is not highlighted in yellow, press switch (F6) to highlight “Time” (a) in yellow. When this is done, hour display (b) changes to orange.
  • Page 101 [Daylight Saving Time (Summer time)] (1) If “Daylight Saving Time” is turned ON (a), the clock display becomes 1 hour earlier. If “Daylight Saving Time” is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green. (2) Change the “Daylight Saving Time”...
  • Page 102 (e) Language selection On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. • apanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian, Thai.
  • Page 103 (f) Adjusting Economy Mode With this economy mode, the engine output can be adjusted to improve the fuel consumption in economy mode. 1. On the standard screen, press switch (F6). 2. Select “Economy Mode Adjustment” on the user menu screen, then press switch (F6). The screen switches to the “Economy Mode Adjustment”...

  • Page 104: Switches

    2.2 SWITCHES (1) Starter switch (9) Swing parking brake release switch (2) Fuel control dial (10) Moment limiter emergency stop cancel switch (3) Lamp switch (11) Hook stowage switch (4) Sun roof wiper switch (12) Winch speed selector switch (5) Horn switch (13) Level (6) Cigarette lighter (14) Battery disconnect switch...
  • Page 105 STARTER SWITCH Always turn the starter switch to the OFF position after completing the work. Starting switch (1) is used to start or stop the engine. • OFF position: The starter key can be inserted or withdrawn. Switches for the electrical system (except room lamp), are all turned off and the engine is stopped.
  • Page 106 FUEL CONTROL DIAL Use this dial (2) to control the engine rotating speed and output. • (a) Low idling (MIN): Turn dial fully to left • (b) Full speed (MAX): Turn dial fully to right NOTES On this machine, the engine is electronically controlled to give the optimum matching with the main pump.
  • Page 107 HORN SWITCH Use this switch (5) to sound the horn. Press the switch on the right work control lever to sound the horn. CIGARETTE LIGHTER CAUTION This cigarette lighter is for 24V. Do not use it as the power source for 12V equipment. This cigarette lighter (6) is used when lighting cigarettes.
  • Page 108 SWING PARKING BRAKE RELEASE SWITCH CAUTION This switch makes it possible to perform swing operations for a short time, even when there is a problem in the swing parking brake electric system. Do not use this switch except in emergencies. Repair the problem as soon as possible. This switch (9) is used to make it possible to carry out operation temporarily if any problem should occur in the swing parking brake system (when the display shows...
  • Page 109 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH The moment limiter emergency stop cancel switch will temporarily disable the moment limiter function. While this switch is turned to ON position (i.e. released), calculation of the rated total load is stopped, thus the machine is in a very risky condition. When lifting operation is continued in this condition, it may result in dropping of the hoisted load or damage to the boom, and cause serious accidents such as overturning of the machine resulting in death or serious injury.
  • Page 110 HOOK STOWAGE SWITCH • The Over-hoisting cancel switch cancels the auto-stop function of the over hoist detector. Operate the winch lever carefully when stowing the hook block. Pay sufficient attention not to let the hook block collide with the boom. •...
  • Page 111 WINCH SPEED SELECTOR SWITCH • High speed winch hoisting and lowering are allowed only in a condition that no load is hoisted. When any load is hoisted or lowered in high speed, it may cause an accident to the machine , overturning or damaging it, or the hoisted load may drop which results in a serious injury or death to personnel.
  • Page 112 LEVEL A crane operation on a slope condition could cause the machine to overturn. Prior to starting the operation, monitor the level and try to find a location which enables a level condition. Where an operation on a slope is un-avoidable, use supporting timber or build up ground with soil, so that the machine is level.

  • Page 113: Control Levers And Pedals

    2.3 CONTROL LEVERS AND PEDALS (1) Lock lever (4) Right work equipment control lever (2) Travel levers (With auto-deceleration system) (With pedal and auto-deceleration system) (5) Accelerator pedal (3) Left work equipment control lever (6) Blade control lever (With auto-deceleration system) LOCK LEVER •...
  • Page 114 TRAVEL LEVERS • Do not rest your foot on the pedal. If you carry out operations with your foot on the pedal, the machine may suddenly start if pressure is applied by mistake to the pedal, and this may lead to serious personal injury.
  • Page 115 WORK EQUIPMENT CONTROL LEVER • The control pattern of this machine is as indicated in the CONTROL PATTERN label, as below. When any user desires to change to any other pattern, please contact us, or our sales and service agency. •...
  • Page 116 ACCELERATOR PEDAL The accelerator pedal should only be used to control the crane operation while the machine is stationed. During traveling operation, use of this pedal is strictly prohibited; otherwise it may cause an accident due to an operation error which may lead to serious personal injury. During traveling operation, always adjust the engine speed only by turning the fuel control dial.

  • Page 117: Moment Limiter(Overload Detector)

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

  • Page 118: Function Moment Limiter

    2.4.2 FUNCTION OF MOMENT LIMITER • Do not remove, disassemble, or repair detectors. Do not move the detectors to another location from original position. • Should an object hit a detector or you find any damage on a detector, be sure to verify the actuation status of the auto stop.
  • Page 119 A - B Accuracy of the overload stop = X 100 < +10% Where: A: Total weight of the hoisted load, hook block and sling instruments B: Rated total load at the working radius (measured radius) of the overload error. DISPLAY OF THE MOMENT LIMITER ERROR MESSAGES The moment limiter performs self-diagnosis on the moment limiter display unit when an error is issued by the boom angle gauge, boom length gauge, pressure sensor, or when a circuit is opened or a connector...

  • Page 120: Moment Limiter Operations

    2.4.3 MOMENT LIMITER OPERATIONS The moment limiter is a device for unexpected events. Operations relying on the device may rather incur danger. Pay sufficient attention during the operation not to cause auto-stop of the crane. PROHIBITED ACTIONS AFTER AUTO STOP The following crane operations are prohibited after the crane has stopped automatically due to overloading.
  • Page 121 RECOVERY OPERATION FROM AUTO STOP The recovery operation from overloading should be the reverse operation of the crane operation that caused the auto stop. Perform one of the followings. (1) Lower the hook and put down the hoisted load on the ground. (2) Raise the boom.

  • Page 122: Names Of Moment Limiter Display Unit

    2.4.4 NAMES OF MOMENT LIMITER DISPLAY UNIT Load factor display (16) Cancel switch Actual load display (17) Overwind detection LED (Red) Rated total load display (18) 1 fall LED (Green) Boom angle display (19) 2 fall LED (Green) Actual working radius display (20) 4 fall LED (Green) Rated working radius display (21) Fly-jib length (1) LED (Orange)
  • Page 123 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 124 [CANCEL] With the upper limit value being set (LED ON), press the switch for 3 seconds or more. The current upper limit value setting will be cleared. At the same time, the LED goes off indicating that the upper limit value setting is cleared. NOTES The setting and canceling will not repeat even if you keep the switch pressed for more than three seconds.
  • Page 125 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.
  • Page 126 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 127 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 128 DESCRIPTIONS OF MOMENT LIMITER DISPLAY UNIT For LEDs not described in this section, see “Operation 2.4.4 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 129 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 130 LOAD FACTOR DISPLAY This display indicates the status of the moment limiter load factor by its illumination. • According to the change in the load capacity, particular "LEDs" are turned on or off to show the present load factor. • All the "LEDs" light up when the load factor is 110% or more.

  • Page 131: Moment Limiter Functions

    2.4.5 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 132 WORKING ENVELOPE RESTRICTION WARNING When the working envelope gets close to the set restriction value, a warning is issued to notify the operator and those around. The last status of the set value for the working envelope restriction is memorized even if the starter switch is turned to the OFF position.
  • Page 133 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 134 NUMBER OF WIRES ROPE FALL(S) SELECTOR SWITCH •Stop operating the crane when changing the number of wires by using the fall mode selector switch. Changing the number of wires while the crane is operating can cause unexpected accidents. •Always perform the crane operation after matching the number of wires displayed on the moment limiter with the actual number of wires.

  • Page 135: Moment Limiter Starting Status

    2.4.6 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 136: Pick & Carry / Staitionary Mode Select

    • 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 2.4.4 Names of Moment Limiter Display Unit (Descriptions of Switches on Moment Limiter Display Unit)"...

  • Page 137: Moment Limiter Error Causes And Actions To Taken

    2.4.9 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO BE TAKEN The moment limiter displays an error code at the “Rated radius” 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 138: Over Hoist Detector

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

  • Page 139: Air Conditioner Controls

    2.6 AIR CONDITIONER CONTROLS 2.6.1 AIR CONDITIONER CONTROL PANEL (1) OFF switch (6) FRESH/RECIRC selector switch (2) Fan switch (7) Display monitor (3) Temperature control switch (8) Air conditioner switch (4) Vent selector switch (9) Sunlight sensor (5) Auto switch OFF SWITCH This switch (1) is used to stop the fan and air conditioner.
  • Page 140 FAN SWITCH This switch (2) is used to adjust the air flow. The air flow can be adjusted to 6 levels. • Press the switch to increase the air flow, press the switch to decrease the air flow. • During auto operation, the air flow is automatically adjusted.
  • Page 141 VENT SELECTOR SWITCH This switch (4) is used to select the vents. • When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. • During automatic operation, the vents are automatically selected.
  • Page 142 FRESH/RECIRC SELECTOR SWITCH This switch (6) is used to switch the air source between recirculation of the air inside the cab and intake of fresh air from the outside. • During automatic operation, the selection of inside air (RECIRC) and outside air (FRESH) is performed automatically.

  • Page 143: Air Conditioner Operation Method

    2.6.2 AIR CONDITIONER OPERATION METHOD The air conditioner can be operated automatically or manually. Select the method of operation as desired. AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed. 2.
  • Page 144 MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and airflow (b) are displayed on monitor (7) 2. Turn air conditioner switch (8) ON. 3. Press temperature control switch (3) and adjusts temperature inside the cab.
  • Page 145 5. Press FRESH/RECIRC selector switch (6) and select recirculation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH). STOPPING MANUAL OPERATION Presses OFF switch (1). Operation stops. 3-81...
  • Page 146 OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7).
  • Page 147 DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and airflow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the below.
  • Page 148 5. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted.) NOTES When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON.

  • Page 149: Use Air Conditioner With Care

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

  • Page 150: Radio

    2.7 RADIO 2.7.1 CONTROL PANEL (1) Power switch, Volume control knob, balance (5) AS/PS button control knob (6) Preset station buttons (1.2.3.4.5.6) (2) SEL button (7) Display (3) FM/AM selection button (8) Tuning button (4) Display selection button (9) Time reset button POWER SWITCH, VOLUME CONTROL KNOB, BALANCE CONTROL KNOB Press the knob (1) to turn the power for the radio ON.
  • Page 151 DISPLAY SELECTION BUTTON (TIME) On this machine, priority is given to the frequency display. When the frequency is being displayed, press button (4) and the display will show the preset time for 5 seconds. After 5 seconds pass, the display returns automatically to the frequency display.

  • Page 152: Control Of Radio

    2.7.2 CONTROL OF RADIO METHOD OF SETTING WITH PRESS BUTTON 1 Press power switch (1) and display the frequency on display (7). 2. Use tuning button (9) to set to the desired frequency. There are two methods for tuning: auto tuning and manual tuning.
  • Page 153 METHOD OF OPERATING MODE • (BAS) Bass adjusting When button (2) is pressed, BAS is displayed on display (7). If knob (1) is turned clockwise within 5 seconds, the bass sound is emphasized. If the knob is turned counterclockwise, the bass sound is reduced.

  • Page 154: Use Radio With Care

    ANTENNA Before transporting the machine or putting it inside a building, stored the antenna to prevent any interference. Stow the antenna as flows. 1. Loosen antenna mounting bolt (1) and store the antenna at position (A). 2. After storing the antenna, tighten bolt (1). 2.7.3 USE RADIO WITH CARE •...

  • Page 155: Fuse

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

  • Page 156: Fusible Link

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

  • Page 157: Power Outlet

    24 V specification and that it has a capacity less than 240 W (equivalent to 10 A). When using a large capacity electrical component, contact us or our sales service agency. Use this power outlet connector for use of additional electric equipment other than Maeda brand. Left Connector NO: M10...

  • Page 158: Controllers

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

  • Page 159: Windshield

    2.12 WINDSHIELD • When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK positon. If the lock lever is at the FREE positon and the control levers or control pedals are touched by mistake, this may lead to a serious accident. •...
  • Page 160 5. Hold lower knob (C) with your left hand from inside the operator’s cab, and with your right hand, grip top knob (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window. 6.
  • Page 161 CLOSING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, stow the crane completely, then stop the engine. 2. Set lock lever (1) securely to the LOCK position (L). 3.
  • Page 162 5. When the bottom of the window reaches the top of the lower window, push the top or the bottom window, push the top of the window to the front to push it against left and right lock catches (G) and engage the lock. 6.
  • Page 163 REMOVING LOWER WINDSHIELD 1. Open the front window, then hold grip (1), pull up, and remove the bottom window. 2. After removing the bottom window, store it at the rear of the operator’s cab and lock it securely with lock (2). The procedure for stowing is as follows.

  • Page 164: Sliding Door

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

  • Page 165: Cap With Lock

    2.15 CAP WITH LOCK • Use the starter switch key to open and close the locks on the caps and covers. • nsert 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 166 OPENING AND CLOSING COVERS WITH LOCK [Opening the Cover] 1. Insert the starter switch key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. Position (A): OPEN Position (B): LOCK [Locking the Cover] 1.

  • Page 167: Engine Hood

    2.16 ENGINE HOOD • Never get on engine hood except for the allowed area. It may cause you to fall by slipping. Refer to the section “1.4 PRECAUTIONS WHEN GETTING ON OR OFF” for detail. • When carrying out inspection and maintenance inside the engine hood, always use the hood support lever to hold the engine hood open.

  • Page 168: Maintenance Door On Rear Right

    2.17 MAINTENANCE DOOR ON REAR RIGHT • When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. 1. Insert fingers to door pull (1) and open door (2). 2. After door (2) is open, insert rod (3) into hitch to hold the door open.

  • Page 169: Battery Inspection Cover

    2.19 BATTERY INSPECTION COVER • When carrying out inspection and maintenance inside the door, always use the stopper to hold the door open. • Always keep the door locked except when opening it. 1. Remove stowage rope (3) from rope holder (4) 2.

  • Page 170: Operation Manual Storage

    2.20 OPERATION MANUAL STORAGE A magazine box is provided on the left side of the operator’s seat for safekeeping the operation and maintenance manual. Always keep the Operation and Maintenance Manual in this pocket so that it is possible to read it at any time. 2.21 CUP HOLDER This is on the left side of the operator’s cab.

  • Page 171: Wind-In Type Seat Belt

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

  • Page 172: Machine Operations And Controls

    3. MACHINE OPERATIONS AND CONTROLS 3.1 CHECKING BEFORE OPERATION 3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) • This machine has a diesel engine. If it smells of fuel around the engine, the fuel may be leaking. Carefully check for cracks on the fuel hose or fuel hose connections. •...

  • Page 173: Checking Wire Ropes

    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 174: Checking Around Upper Structure

    CHECKING AROUND UPPER STRUCTURE • Check for fuel, oil or water leaking from the engine. If you find any abnormality, repair it. • Check the hot engine sections such as the engine muffler and around the battery for the buildup and deposit of combustibles such as dead leaves, paper wastes, dust, oil, and grease.

  • Page 175: Checking Before Starting Engine

    3.1.2 CHECKING BEFORE STARTING ENGINE Check the followings in this section without starting the engine and before starting the first work every day. 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 176: Checking/Refilling Oil Level In Engine Oil Pan

    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 • See “Maintenance 7.1 Use of fuel coolant and lubricants according to ambient temperatures” for which oil to be used.

  • Page 177: Checking/Refueling Fuel Level In Fuel Tank

    CHECKING/REFUELING FUEL LEVEL IN FUEL TANK •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. •Be careful not to allow the fuel to overflow when refueling.

  • Page 178: Checking/Refilling Oil Level In Hydraulic Tank

    CHECKING/REFILLING OIL LEVEL IN HYDRAULIC TANK • Parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the oil temperature to go down before performing this operation. • When removing the oil filler cap, turn it slowly to release the internal pressure, and then remove it.
  • Page 179 6. If the oil level is below the L line, remove the cover (1) at the top of the hydraulic oil tank, and then add oil through oil filler (F). 7. Loosen bolt (2), remove upper plate (3) on oil filler (F), and take off cap of oil filler (F) to relieve inner pressure.

  • Page 180: Checking Dust Indicator

    CHECKING DUST INDICATOR 1. Open the maintenance door on right rear side and check that the red piston is not showing in the part of dust indicator (1). 2. If the red piston has appeared, clean or replace the air cleaner element immediately.

  • Page 181: Checking For Water, Sediment In Water Separator, Drain Water

    CHECKING FOR WATER, SEDIMENT IN WATER SEPARATOR, DRAIN WATER • The water separator has fuel (diesel oil) inside. Be extremely careful of fire such as cigarette when cleaning the water separator transparent cap. • If the fuel spills when the water separator is removed, thoroughly wipe it off. CAUTION •...

  • Page 182: Drain Water And Sediment From Fuel Tank

    [Adjustment of Drain Valve] If drain valve (4) is stiff, coat the O-ring portion of the drain valve (4) with grease to make the movement smooth. 1. Set valve (5) at the side of fuel pre-filter cartridge (1) to the shut off position (S). 2.

  • Page 183: Checking Electrical Wiring

    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 184: Adjusting Operator's Seat

    ADJUSTING OPERATOR’S SEAT • Adjust the operator’s seat position before starting operations or after changing the operator. • Adjust the operator’s seat so that the control levers, acelerator pedal, and switches can be operated freely and easily with the operator back against the backrest. •...

  • Page 185: Adjusting Mirrors

    ADJUSTING MIRRORS Always adjust mirrors before starting operations. When mirrors are improperly adjusted, correct view is not secured, which may result damage to the machine, or even a serious injury. [Mirror (A)] Position of this mirror should be adjusted so that a person standing in the left-rear end of the machine is visible.
  • Page 186 [Mirror (B)] Position of this mirror should be adjusted so that a person standing in the right-front end of the machine is visible. • Fix the mirror as shown in the figure in the right. Dimension (F): 1 m • When fine adjustment of the mirror is not easy, loosen the bolt (4) for the mirror or bolt (4) for stay mount for easy movement.

  • Page 187: Operations Before Starting Engine

    3.1.3 OPERATIONS 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 188 (1) The buzzer sounds for approx. 2 seconds, and then the monitor or meter lights up for approx. 2 seconds. • Charging level monitor (4) • Engine oil pressure monitor (5) • Engine oil temperature gauge (6) If any monitor does not light up or buzzer does not sound, there is probably a failure in the monitor, so please contact us or our sales service agency.

  • Page 189: Checking After Starting Engine

    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 190: Checking Crane Operations

    CHECKING CRANE OPERATIONS Be sure to refer to the Operation sections between "3.11 Cautions before Crane Operation" and "3.19 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 191: Checking Operation Of Over Hoist Detector

    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 192: Starting Engine

    3.2 STARTING ENGINE Never refuel (diesel oil) while the engine is in operation. Always stop the engine when refueling. 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 193 3. Turn the key in the starter switch (3) to START position. The engine starts. 4. When the engine starts, release the key in starter switch (3). The key will automatically return to ON position. 5. Keep the engine idle for the initial 15 seconds right after it has been started, and do not operate any control lever or the fuel control dial during that time.

  • Page 194: Starting Engine In Cold Weather

    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 195 3. Hold the key in starter switch (3) at HEAT position and check that preheating monitor (4) lights up. After approx. 30 seconds, preheating monitor (4) will flash for 10 seconds to inform the operator that the preheating has been completed. The key will automatically return to ON position.
  • Page 196 [Turbocharger Protect Function] The turbocharger protect function is a function to protect the turbocharger by keeping the engine speed at less than 1150 rpm immediately after the engine is started. • When the turbocharger protect function is actuated, the engine speed is held at less than 1150 rpm, regardless of the position of the fuel control dial.

  • Page 197: Operations After Starting Engine

    3.3 OPERATIONS AFTER STARTING ENGINE Never refuel (diesel oil) while the engine is in operation. Always stop the engine when refueling. • To stop the engine in emergencies or when the actuation of the engine is abnormal or there is any other trouble, turn the key in the starter switch to the OFF position.

  • Page 198: Engine Warm-Up

    3.3.1 ENGINE WARM-UP CAUTION • Do not accelerate the engine suddenly until the warm-up operation has completed. • Do not run the engine at low idling or high idling under no load for more than 20 minutes. This will have an adverse effect on the environment, and will also have an adverse effect on the internal structure of the engine.

  • Page 199: Hydraulic Equipment Warm-Up

    3.3.2 HYDRAULIC EQUIPMENT WARM-UP • When warming up the hydraulic equipment, check that there is no person or obstacle in the surrounding area, then sound the horn and start the operation •Carry out the warming-up operation for the hydraulic equipment until the hydraulic oil temperature monitor displays the correct temperature.
  • Page 200 3. Set lock lever (3) slowly to the FREE position (F). 4. For details of the before starting operation of the crane, see “Operation 3.12 Operation Before Operating The Crane” and “Operation 3.13 Crane Operation Posture”. 5. Turn fuel control dial (3) to a point midway between low idling (MIN) and full speed (MAX).
  • Page 201 9. Operate left work equipment control lever (5) slowly to RETRACT side (pull backward). Operate the lever to the stroke end and hold it in position for 30 seconds. During that task, operate the Right work equipment control lever (4) to WINDING (pull backward) position and raise the hook adequately so that it does not touch the ground.
  • Page 202 13.Check that the hydraulic oil temperature monitor and engine coolant temperature monitor are displaying the correct temperature, and then check that all the gauges and caution monitors on the machine monitor are in the following status. • Engine coolant temperature monitor (1): Displays correct temperature •...
  • Page 203 For both normal temperatures and cold temperatures, carry out the following operation. 16. Check that fuel control dial (3) is at a point midway between low idling (MIN) and full speed (MAX). If it is not at the midway position, set it to the midway position and run the engine at a mid-range speed before operating.
  • Page 204 18.Check that hydraulic oil temperature monitor (6) is displaying the correct temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 6 to 9 until the display is the correct temperature.

  • Page 205: Operation After Completion Of Warm-Up Operation

    3.3.3 OPERATION AFTER COMPLETION OF WARM-UP OPERATION 1. Check if hydraulic oil temperature monitor (6) is displaying indication of 20-102°, and also the hydraulic temperature meter indicates between (D)-(E). • (A) Display indication of 20-102°. Monitor background (C) is blue. •...

  • Page 206: Stopping Engine

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

  • Page 207: Breaking-In Machine

    3.5 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 208: Machine Travelling Posture

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

  • Page 209: Starting/Moving/Stopping Machine

    3.7 STARTING/MOVING/STOPPING MACHINE • Before operating the travel lever or travel pedal, check the direction that the track frame is facing. When the track frame is facing the rear (when the sprocket is at the front), the direction of operation of the travel lever and travel pedal is the opposite to the direction of movement of the machine (forward/reverse, left/right).
  • Page 210 MOVING MACHINE FORWARD 1. Set lock lever (2) to the FREE position (F). 2. Operate blade control lever toward you to raise the blade. 3. Operate right and left travel levers (3) or right and left travel pedals (4) as follows. •...
  • Page 211 MOVING MACHINE BACKWARD] 1. Set lock lever (2) to the FREE position (F). 2. Operate blade control lever toward you to raise the blade. 3. Operate right and left travel levers (3) or right and left travel pedals (4) as follows. •...
  • Page 212 STOPPING MACHINE Avoid stopping suddenly. Give yourself ample room when stopping. • Put the left and right travel levers (3) to the NEUTRAL position, and then stop the machine. 3-148...

  • Page 213: Steering Machine

    3.8 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 (1) to change direction. Avoid sudden changes of direction as much as possible.
  • Page 214 WHEN PERFORMING COUNTER-ROTATION TURN (SPIN TURN) When using counter-rotation (spin turn) to turn left, pull the left travel lever back and push the right travel lever forward. NOTES When using counter-rotation (spin turn) to turn right, pull the right travel lever back and push the left travel lever forward.
  • Page 215 3.9 SWINGING • The rear of the machine extends outside the track width. Before swinging, check with the rear view monitor and mirror, and also check visually that the surrounding area is safe. • Before swinging the machine off, check that the area around the machine is safe, and sound the horn •...

  • Page 216: Working Mode Operation

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

  • Page 217: Cautions Before Crane Operation

    3.11 CAUTIONS BEFORE CRANE OPERATION 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 218 • Use the horn switch and toot the horn to warn danger to persons nearby, when necessary, during crane operations. 3-154...

  • Page 219: Operations Before Operating The Crane

    3.12 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 220 4. Operate right working control lever (3) to BOOM RAISING side (pull toward you), raise the boom. NOTES During this operation, excessive tension between the hook block and the stowage wire rope (5) should be avoided. In such event of excessive tension, properly lower the hook block (4).

  • Page 221: Crane Operation Posture

    3.13 CRANE OPERATION POSTURE To start the crane operation, following "Operation 3.12 Operations Before Operating The Crane", set to the crane operation posture as below. 1. Operate the right work equipment control lever to HOOK RAISING position (pull backward) so that the hook block is hoisted.

  • Page 222: Hook Raising / Lowering Operation

    3.14 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 223: High Speed Hook Raising / Lowering Operation

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

  • Page 224: Hook Raising Operation By Hook Stowage Switch

    3.14.3 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 225: Boom Derricking Operation

    3.15 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 226: Boom Telescoping Operation

    3.16 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 227: Slewing Operation

    3.17 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 228: Acceleration Operation

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

  • Page 229: Stowage Operation Of Crane

    3.19 STOWAGE OPERATION OF CRANE 3.19.1 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 230 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 231 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. Keep the right-hand work equipment control lever in the HOOK RAISING position for about one second after the hook block is stowed in the boom tip.

  • Page 232: Crane Operation For Regular Hook Block Stowage

    3.19.2 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 233 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 the hook block (4) should be avoided. Otherwise, the loosened hook block (4) may damage other components around.
  • Page 234 7. 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 to raise hook block (4) up slowly and precisely to tension wire cable (5) NOTES During this operation, avoid over raising hook block (4).

  • Page 235: Do's And Don'ts During Operation

    3.20 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 236 DO NOT ALLOW ACCESS INTO WORKING RADIUS Do not let people enter the working radius area such as permitting an operator to go under the hoisted load. 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.
  • Page 237 NO OPERATIONS ON SLOPE Crane operation on a slope may cause the machine to turn over. Basically, do not carry out crane operations on a slope. If you absolutely have to do so, place some earth fill (B) on the slope to make the ground level and hard and to prevent the machine from turning over, then place the machine on the ground.

  • Page 238: Pick & Carry Operation

    3.21 PICK & CARRY OPERATION 3.21.1 SAFETY RRECAUTIONS FOR PICK & 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 239: Posture For Pick & Carry Operation

    3.21.2 POSTURE FOR PICK & CARRY OPERATION During pick and carry operation, retract the boom to "10.1 meters" (3 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.

  • Page 240: Operations During Pick & Carry Operation

    3.21.3 OPERATIONS DURING PICK & CARRY OPERATION • See "Operation 3.21.1 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 241: Operation Of Blade

    3.22 OPERATION OF BLADE 3.22.1 PRECAUTION OF BLADE OPERATION [BASIC POSTURE OF THE BLADE] •Always clear the Blade from the ground during the hoisting operation. Failure to do so may result a serious hazard including damaging the machine or it’s tipping over. •...

  • Page 242: Operation Of Blade

    3.22.2 OPERATION OF BLADE • Always clear the Blade from the ground during the hoisting operation. Failure to do so may result a serious hazard including damaging the machine or it’s tipping over. • Avoid ground leveling operations at the same time as hoisting operations. Otherwise, it may cause a serious hazard including damaging the machine or it’s tipping over.

  • Page 243: Parking Machine

    3.23 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 244: Machine Inspection After Daily Work

    3.24 MACHINE INSPECTION AFTER DAILY WORK 3.24.1 BEFORE STOPPING ENGINE Use the machine monitor to check engine coolant temperature (1), engine oil pressure (2), and fuel level (3). 3.24.2 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 245: Cautions In Travelling

    3.25 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. For this reason, always remove any obstacles or travel around them, or take other steps to avoid travelling over such obstacles as far as possible.
  • Page 246 PERMISSIBLE WATER DEPTH CAUTION When driving the machine out of water, if the angle of the machine exceeds 15 °, the rear of the upper structure will go under water, and water will be thrown up by the radiator fan. This may cause the fan to break.
  • Page 247 CAUTIONS FOR SLOPE TRAVELING • For slope travelling, take care of overturning or drifting. • At the angle of 15 ° 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 248: Handling Wire Cables

    4. HANDLING WIRE CABLES 4.1 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 249 3. The wire cable, corroded as below: (1) Wire surface has pitched or pitted. (2) Wires become slack due to internal corrosion. 4. Excessively deformed as below: Waviness width (1) The cable is twisted and has some kinks. (2) Waviness width is 4/3d or more in a distance within 25 times of nominal diameter d.

  • Page 250: Winch Wire Rope Fall Mode And Rated Total Load

    4.2 WINCH WIRE ROPE FALL MODE AND RATED TOTAL LOAD Number of wire rope falls of the hook block shall be determined based on the load to be hoisted, boom length and winching speed. The load to one wire rope fall must be within "1220 kg" . The table below shows the hook block types, wire rope falls and the rated total load in each condition.

  • Page 251: What To Do With Twisted Winch Wire Rope

    4.3 WHAT TO DO WITH TWISTED WINCH WIRE ROPE 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 252 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 253 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 254: Transportation

    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 255: Loading / Unloading

    5.1 LOADING / UNLOADING • See "Specifications 1 Specification List" in the Dimension for the dimensions and mass of the machine. • Select and use the ramp boards that satisfy the following conditions. • Has the length that when placed, the angle from the track is 15 °...

  • Page 256: Loading

    5.1.1 LOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks under the tires to prevent the trailer from moving. 3. Secure the ramp boards in a way that the center of the trailer and the machine match.
  • Page 257 9. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the center line of the machine matches that of the trailer. 10. Align the direction of travel with the ramps and travel slowly.

  • Page 258: Securing Machine

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

  • Page 259: Unloading

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

  • Page 260: Lifting Machine

    5.2 LIFTING MACHINE 5.2.1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE • See "Specifications 1 Specification List" 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 261 3. Set the lock lever securely to the LOCK position (L). 4. Stop engine, and remove key for starter switch. Confirm there is nothing left around operation seat, and get out from machine. 5. Close all of doors, windows, and covers. For doors, covers, and caps with lock, lock them all.

  • Page 262: Lifting Up The Machine In The Boom Raised Posture

    5.2.2 LIFTING UP THE MACHINE IN THE BOOM RAISED POSTURE • See "Specifications 1 Specification List" 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 263: Transportation Procedure

    4. Set the lock lever securely to the LOCK position (L). 5. Stop the engine, and then remove the key from the starter switch. 6. Close all doors, windows, and covers. Lock covers, caps, and doors fitted with locks. 7. Fix shackles to two brackets on the left and right sides of the boom, then attach the slinging wire cables.

  • Page 264: Handling In Cold Weather

    6. HANDLING IN COLD WEATHER 6.1 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 265 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 266: Long Term Storage

    7. LONG TERM STORAGE 7.1 BEFORE STORAGE 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 267: Troubles And Actions

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

  • Page 268: Method For Towing

    8.3 METHOD FOR TOWING Choosing wrong wire rope or wrong method for towing can cause serious accident. Confirm that the towing wire rope is sufficient in strength to bear towed mass. • Do not use wire rope with snipped wires (A), decreased width (B), and kink (C) as these may cause cutting of the wire rope.

  • Page 269: Discharged Battery

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

  • Page 270: Battery Removal And Installation

    8.4.2 BATTERY REMOVAL AND INSTALLATION CAUTION After securing the battery, check that it does not move. If it moves, tighten it again securely. [REMOVAL] 1. Take off stowage rope from rope holder. 2. Hold handle of battery inspection cover (1), and lift the cover (1) to open.

  • Page 271: Cautions In Battery Charging

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

  • Page 272: Starting Engine With Booster Cable

    8.4.4 STARTING ENGINE WITH 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 273 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 274: Other Trouble

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

  • Page 275: Chassis

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

  • Page 276: Engine

    8.5.3 ENGINE • : Always contact us or our sales service agency when dealing with these items. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services. Problem Main causes Remedy •...
  • Page 277 Problem Main causes Remedy • Clogging air cleaner element • Clean or replace, see Irregular Maintenance Exhaust gas sometime become • Defective nozzle Replace nozzle black • Defective compression Adjust valve clearance (Defective valve clearance) • Defective turbocharger Clean or replace turbocharger Combustion noise occasionally •...

  • Page 278: Electronic Control System

    8.5.4 ELECTRONIC CONTROL SYSTEM When the user code is shown on the display portion of the machine monitor, take the respective measure shown in the self-diagnosis chart below. [MACHINE MONITORING SYSTEM] Monitor Failure mode Action display Pump control system error Have inspection carried out immediately.

  • Page 279: Moment Limiter

    8.5.5 MOMENT LIMITER • : Always contact us or our sales service agency when dealing with these items. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services. NOTES When an error code is displayed on the moment limiter display unit, refer to “Operation 2.4.9 Moment Limiter Error Causes and Actions to be Taken”.

  • Page 280: Over Hoist Detector

    8.5.6 OVER HOIST DETECTOR • : Always contact us or our sales service agency when dealing with these items. • For causes of problems or causes that are not listed blow, contact us or our sales service agency for repair services. ★Boom extending or hook hoisting operation does not stop even when over hoisted Problem Main causes...
  • Page 281 INSPECTION AND MAINTENANCE 1. PRECAUTIONS FOR MAINTENANCE 4 – 2 2. BASIC MAINTENANCE 4 – 4 3. LEGAL INSPECTION 4 – 7 4. SAFETY CRITICAL PARTS 4 – 8 5. CONSUMABLES 4 – 9 6. OTHER COMPONENTS 4 – 10 7.

  • Page 282: 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 283 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 284: 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 285 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 286 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 287: 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 288: Safety Critical Parts

    4. 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 289: 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 290: Other Components

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

  • Page 291: 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 292 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.

  • Page 293: Tightening Torque Specifications

    8. TIGHTENING TORQUE SPECIFICATIONS 8.1 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.

  • Page 294: Inspection And Maintenance List

    9. INSPECTION AND MAINTENANCE LIST INITIAL 500-HOUR MAINTENANCE (ONLY FOR FIRST TIME MAINTENANCE OF A NEW MACHINE) • REPLACING OIL IN WINCH MOTOR REDUCTION GEAR CASE······································ 4 – 17 CHECKING BEFORE OPERATION (See Operation 3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS))········· 3 – 108 •...
  • Page 295 IRREGULAR MAINTENANCE • REPLACEMENT WINCH WIRE ROPE ··············································································· 4 – 18 • CHECKING/ADJUSTING BOOM TELESCOPING WIRE ROPE ········································· 4 – 24 • CHECKING, CLEANING AND REPLACING AIR CLEANER ELEMENT······························ 4 – 27 • CLEANING INSIDE OF COOLING SYSTEM ······································································ 4 – 31 •...
  • Page 296 MAINTENANCE EVERY 2000 HOURS • CHECKING ALTERNATOR AND STARTER MOTOR·························································· 4 – 71 • CHECKING/ADJUSTING ENGINE VALVE CLEARANCE ··················································· 4 – 71 MAINTENANCE EVERY 4000 HOURS • CHECKING WATER PUMP ································································································· 4 – 72 • REPLACEMENT ACCUMULATOR (FOR CONTROL CIRCUIT) ········································· 4 – 72 MAINTENANCE EVERY 5000 HOURS •...

  • Page 297: 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. •...

  • Page 298: Irregular Maintenance

    • Do not use the old wire rope regardless of the frequency of use. • Always use Maeda genuine wire rope. [CRITERIA FOR WINCH WIRE ROPE REPLACEMENT] A wire rope undergoes wear and tear over time.
  • Page 299 [REMOVAL WINCH WIRE ROPE] Always wear thick leather working gloves for handling of wire ropes. CAUTION Stop un-winding the hook block when it reaches the ground, otherwise, it may result in irregular winding of the wire rope to the drum. Once the hook block reaches the ground, avoid un-winding any more.
  • Page 300 6. Pull out the wire rope (5) of the wire socket (3), following the procedure provided below. (1) Bring a 6 to 10 mm round bar (A) into contact with the rope wedge (6). (2) Remove the rope wedge (6), lightly tapping the round bar (A) with a hammer in the direction indicated by the arrow (a).
  • Page 301 [INSTALLATION WINCH WIRE ROPE] • Always wear thick leather working gloves for handling of wire ropes. • The rope wedge to secure the wire rope must be fastened correctly and firmly. Otherwise, the wire rope may slip out and result in a serious accident. CAUTION •...
  • Page 302 4. In response to the number of falls, draw the wire rope through the load sheave at the boom end and hook block sheave. 1-falls 4-falls 2-falls 5. Draw the end of the wire rope (5) through the weight of the over hoist detector.
  • Page 303 9. Place the right work equipment control lever in the BOOM RAISING position (pull it toward you) or the left work equipment control lever in the BOOM EXTENDING position (pull it forward) to raise the hook block. NOTES Winch operation is allowed only after the hook block is raised.

  • Page 304: Checking/Adjusting Boom Telescoping Wire Rope

    CHECKING/ADJUSTING BOOM TELESCOPING WIRE ROPE • Always wear thick leather working gloves for handling of wire ropes. • To adjust the boom telescopic wire rope, strictly adhere to the procedure as specified below. Any ommission or falure to follow the procedure may cause a hazard with the boom or hoisting load dropping.
  • Page 305 [ADJUSTMENT OF BOOM TELESCOPING WIRE ROPE] CAUTION • Four wire ropes are used for boom extending. There is an adjusting sequence for these four wire ropes, so always follow the sequence when adjusting these wire ropes. • When adjusting each wire rope, be careful not to have too much tension. 1.
  • Page 306 5. Adjusting extending wire rope (7) for boom (4) (1) Loosen lock nut (12), and tighten adjusting nut (13) to the direction extending wire rope (7) for boom (4) tensions, until just before the boom (4) starts to extend, evenly on both left and right side. (2) Retighten both adjusting nuts (11) on right and left side of retracting wire rope (6) of boom (4) for one turn.

  • Page 307: Checking, Cleaning And Replacing Air Cleaner Element

    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 carry out this work after the engine is stopped.
  • Page 308 5. Blow dry compressed air (Max. 0.69 MPa{7 kg/cm2}) 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. CAUTION The inner element must not be used again even after cleaning.
  • Page 309 [REPLACEMENT ELEMENT] 1. Open maintenance door on right rear side, and set rod into hitch to hold the door open. 2. Remove 3 clips (2), and then take out cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4.
  • Page 310 8. Press the button of dust indicator to return the red piston to its original position. 4-30...

  • Page 311: Cleaning Inside Of Cooling System

    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 312 CAUTION • Always use tap water for coolant. Contact Maeda or our sales service agency if river water, well water, or water through the small water-supply system is necessarily substituted for tap water.
  • Page 313 8. After draining the water, close drain valve (2) and tighten drain plug (3). Fill with clean tap water. 9. When the radiator is full, start the engine, and run it at low idle. Keep the engine running at low idle for 10 minutes until the water temperature reaches more than 90 degrees C.

  • Page 314: Checking Level Of Battery Electrolyte

    CHECKING LEVEL OF BATTERY ELECTROLYTE • 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 315 5. After refilling, close cap (1) tightly. NOTES If distilled water is added to above the bottom tip of the sleeve, use a syringe to remove electrolyte. Neutralize the removed fluid with sodium bicarbonate, then flush it away with a large amount of water. Or, contact us, our sales service agency or the battery manufacturer.

  • Page 316: Checking/Tightening Track Shoe Bolts

    CHECKING/TIGHTENING TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. [TIGHTENING] 1. First tighten to a tightening torque of 117 ± 19.6 Nm (12 ± 2 kgfm) then check that the nut and shoe are in close contact with the link contact surface.
  • Page 317 [ADJUSTING] Do not loosen plug (1) more than one turn. If you loosen it more than one turn, plug (1) may jump out due to the high internal pressure of the grease. When doing this, do not loosen any part other than plug (1).

  • Page 318: Checking Window Washer Fluid Level, Adding Fluid

    [LOOSENING TRACK TENSION] It is extremely dangerous to discharge the grease using any method except the procedure given below. If track tension is not relieved by this procedure, contact us or our sales service agency for repair services. 1. Loosen plug (1) gradually to discharge grease. When loosening plug (1), turn it a maximum of one turn.

  • Page 319: Checking/Maintenance Air Conditioner

    CHECKING/MAINTENANCE AIR CONDITIONER [CHECKING LEVEL OF REFRIGERANT (GAS)] • If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause lose of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.

  • Page 320: Checking/Cleaning/Greasing Cab Slide Door Rail And Roller

    CHECKING/CLEANING/GREASING CAB SLIDE DOOR RAIL AND ROLLER [CHECKING] When opening or closing the slide door, it may sometimes not slide smoothly due to mud stuck to the rail. In that case clean and lubricate slide door rail (1) and roller (2) at the 3 points.

  • Page 321: Checking Gas Spring

    • Do not open holes, weld, or cut by fusing. • Do not cause an impact by hitting or rolling it. • Before discarding it, enclosed gas must be released. Request Maeda service agency for releasing the gas. Gas spring is located in left console (one location).

  • Page 322: Maintenance Every 50 Hours

    10.4 MAINTENANCE EVERY 50 HOURS GREASING MACHINE UNITS 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 323 4-43...

  • Page 324: Maintenance Every 100 Hours

    10.5 MAINTENANCE EVERY 100 HOURS Perform this maintenance in tandem with maintenance every 50 hours. CHECKING/REFILLING OIL IN SWING MACHINERY CASE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION •...
  • Page 325 4. Remove dipstick (G) and wipe the oil from the dipstick with a cloth. 5. Fully insert dipstick (G) into the filler pipe. 6. When dipstick (G) is pulled out If oil level is between the H and L marks of the gauge, oil level is correct. 7.

  • Page 326: Maintenance Every 250 Hours

    10.6 MAINTENANCE EVERY 250 HOURS Perform this maintenance in tandem with maintenance every 50 hours. CHECKING/REFILLING OIL IN TRAVEL MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.

  • Page 327: Checking/Refilling Oil In Winch Motor Reduction Gear Case

    CHECKING/REFILLING OIL IN WINCH MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. • If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.

  • Page 328: Checking/Adjusting Cooling Fan Belt Tension

    CHECKING/ADJUSTING COOLING FAN BELT TENSION [CHECKING] 1. Open engine hood. 2. Loosen 2 bolts and remove guard (1). 3. Deflection (A) should be 9 to 13 mm when the belt is pressed with the thumb with a force of approx. 58.8 N (6 kg) at a point midway between the alternator pulley and crank pulley.
  • Page 329 [ADJUSTMENT] 1. Set boom to fully retracted and fully derricked position. 2. Shift lock lever to lock (L) position, and stop engine. Loosen 7 bolts and remove cover (1) and cover (7). 4. Loosen mounting bolt (3) of alternator (2). 5.

  • Page 330: Checking/Adjusting Air Compressor Belt Tension

    CHECKING/ADJUSTING AIR COMPRESSOR BELT TENSION [CHECKING] 1. Open engine hood, and surely lock to hold the door with hood support bar. 2. Deflection (A) should be 12 to 15 mm when the belt is pressed with the thumb with a force of approx. 58.8 N (6 kg) at a point midway between the compressor pulley (2) and crank pulley (3).

  • Page 331: Maintenance Every 500 Hours

    10.7 MAINTENANCE EVERY 500 HOURS Perform this maintenance in tandem with maintenance every 50/100/250 hours. REPLACEMENT OF ENGINE LUBRICATING OIL AND OIL FILTER CARTRIDGE The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.
  • Page 332 6. Clean the filter holder, fill the new filter cartridge with clean oil, coating the thread and packing portion of the new filter cartridge with oil (or coat thinly with grease), then install. NOTES • Check that there is no old packing stuck to the holder. If there is any old packing stuck to the filter, it will cause leakage of oil.

  • Page 333: Replacement Fuel Pre-Filter Cartridge

    • Do not bring any fire or flame close. CAUTION • Genuine Maeda fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Maeda parts. • The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle.
  • Page 334 NOTES If the transparent cap is tightened too much, the O-ring will be damaged and this will cause leakage of fuel; if it is not tightened enough, fuel will leak through the gap at the O-ring. To prevent these problems, always tighten securely to the fixed tightening angle.

  • Page 335: Checking Swing Pinion Grease Level, Adding Grease

    CHECKING SWING PINION GREASE LEVEL, ADDING GREASE • Prepare a scale. 1. Remove fixing bolts (2) (2 parts) of floor mat, and remove floor mat. 2. Loosen 2 bolts and remove cover (1). 3. Remove rubber cap (3) on upper side of frame. 4.

  • Page 336: Cleaning/Checking Radiator Fins, Oil Cooler Fins, Fuel Cooler

    CLEANING/CHECKING RADIATOR FINS, OIL COOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.

  • Page 337: Cleaning Air Conditioner Fresh/Recirc Filters

    CLEANING AIR CONDITIONER FRESH/RECIRC FILTERS • When using compressed air, there is danger of dirt flying and causing personal injury. Always wear protective glasses, dust mask, and other protective equipment. • Always check that the slide door is locked at the open or closed position before cleaning the FRESH or RECIRC filter.
  • Page 338 [CLEANING FRESH AIR FILTER] 1. Use starter key to unlock cover (1) at the rear left of the operator’s cab. 2. Open cover (1) by hands, secure it in position with cover support lever (3), then remove filter (2) from the inside. 3.

  • Page 339: Replacement Breather Element In Hydraulic Tank

    REPLACEMENT BREATHER ELEMENT IN HYDRAULIC TANK • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. • When removing the oil filter cap, turn it slowly to release the internal pressure, then remove it. 1.

  • Page 340: Maintenance Every 1000 Hours

    10.8 MAINTENANCE EVERY 1000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500 hours. REPLACEMENT OIL IN SWING MACHINERY CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. CAUTION •...
  • Page 341 7. Loosen 4 bolts and remove cover (1). 8. Remove dipstick (G) and fill the oil through the gauge insertion port (F) by the replacement oil quantity. 9. Wipe off the oil on the dipstick (G) with a cloth. 10. Fully insert dipstick (G) into gauge guide, then remove 11.

  • Page 342: Greasing Swing Machinery Bearing

    GREASING SWING MACHINERY BEARING • Prepare a grease pump 1. Set boom to fully retracted and fully derricked position. 2. Set the lock lever to the LOCK position (L) and stop the engine. 3. Loosen 4 bolts and remove cover (1). 4.

  • Page 343: Replacement Oil In Travel Motor Reduction Gear Case

    REPLACEMENT OIL IN TRAVEL MOTOR REDUCTION GEAR CASE • The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. • If internal pressure is present inside the case, the oil plug might spring out. Loosen the plug slowly to release the internal pressure.

  • Page 344: Replacement Oil In Winch Motor Reduction Gear Case

    REPLACEMENT 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 345 4. Using a hexagon wrench and remove plugs (F), (G) and (P), then drain oil. 5. After draining oil, install drain plug (P) securely. 6. Add the replacement amount of oil through the hole of plug (F). 7. After the oil flows out of the hole for plug (G), install plugs (G) and (F) securely.

  • Page 346: Hydraulic Oil Return Filter Cartridge Replacement

    HYDRAULIC OIL RETURN FILTER CARTRIDGE REPLACEMENT • 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 347 4. Open maintenance door on left rear side, and set rod into hitch to hold the door open. 5. Using filter wrench, turn filter (4) to left and remove. 6. Clean the filter holder. coat the packing surface of the new filter cartridge thinly with oil, then install the filter cartridge to the filter holder.

  • Page 348: Hydraulic Line Filter Element Replacement

    HYDRAULIC LINE FILTER ELEMENT REPLACEMENT • 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 349: Replacement Fuel Main Filter Cartridge

    • Do not bring any fire or flame close. CAUTION • Genuine Maeda fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Maeda parts. • The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle.

  • Page 350: Checking All Tightening Points Of Engine Air Intake Pipe Clamps

    CAUTION • Do not fill the new filter cartridge with fuel. • Remove cap (B) and install the filter cartridge. 7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. NOTES If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel.

  • Page 351: Maintenance Every 2000 Hours

    10.9 MAINTENANCE EVERY 2000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000 hours. CHECKING ALTERNATOR AND STARTER MOTOR The brushes may be worn or the bearing may have run out of grease, contact us or our sales service agency for inspection and repairs.

  • Page 352: Maintenance Every 4000 Hours

    10.10 MAINTENANCE EVERY 4000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000/2000 hours. CHECKING WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any problem is found, please contact us or our sales service agency for repairs or replacement.

  • Page 353: Maintenance Every 5000 Hours

    10.11 MAINTENANCE EVERY 5000 HOURS Perform this maintenance in tandem with maintenance every 50/100/250/500/1000 hours. REPLACING HYDRAULIC TANK OIL AND CLEANING STRAINER • Parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the oil temperature to go down before performing this operation. •...
  • Page 354 5. Remove the cap (F) from oil filler, and release the internal pressure. 6. Set a container to catch the oil under the drain plug under the machine. 7. Using a handle, remove drain plug (P) and drain the oil. NOTES Take care not to get oil on yourself when you remove drain plug (P).
  • Page 355 14. Add the replacement amount of oil through oil filler (F). Check that the oil level is between the H and L lines on the sight gauge. For details of oil level check, See Operation 3.1.2 Checking Before Starting Engine Checking/refilling Oil Level in Hydraulic Tank”.

  • Page 356: Bleeding Air From Hydraulic System

    11. BLEEDING AIR FROM HYDRAULIC SYSTEM NOTES For details, see “Operation 3.2 Starting Engine”. If it is necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see “Operation 3.8 Starting/moving/stopping Machine” and “3.9 Steering Machine”. CAUTION •...
  • Page 357 BLEEDING AIR FROM SWING MOTOR CAUTION • Carry out only if the oil inside the swing motor case has been drained. • If the air is not bleed from the swing motor, the motor bearings may be damaged. 1. Set the engine to low idle, loosen the hose (3), and once the oil leaks out, tighten the hose (3).
  • Page 358 PROCEDURE TO RAISE THE UNDERCARRIAGE USING A CRANE • Always exercise this practice only on level and solid ground. • Refer to "Specifications 1. Main Specifications" for dimension and mass of this machine. • The operator who operates the crane to lift this machine up must be licensed or trained for crane operation.
  • Page 359 BLEEDING AIR FROM WINCH MOTOR To loosen or tighten the bleeder plug of the winch motor, always practice it when the hook block is lowered to touch the ground and the equipment control levers are positioned to NEUTRAL. Otherwise, the plug or oil may come out due to the internal pressure. CAUTION •...
  • Page 360 12. METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equipment, do not stand in the direction that the oil spurts out when caring out the operation. In addition, loosen the bolts slowly when carrying out the operation. CAUTION Carry out the following procedure to operate the blade control lever fully to the front and rear within 15 seconds of stopping the engine.

  • Page 361: Specifications

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

  • Page 362: Specification List

    1. SPECIFICATION LIST System / Item LC785M-8B / LC785M-8BF Machine mass 10,250kg / 10,420kg Overall length  width  5,020mm  2,360mm  2,795mm height Distance between idler and Mass and 2,235mm sprocket dimension Track gauge 1,870mm Track width 450mm...
  • Page 363 Model KOMATSU SAA4D95LE-5 Vertical in-line, Water cooled, 4-cycle, Direct fuel injection Type type with turbo charger Engine Displacement 3.26 liters (3260cc) Rated output (continuous) 41.0kW / 1,950min-1 (55PS / 1950rpm) Fuel tank capacity Light oil / 140liters Overwind protections, moment limiter (with working envelope restriction), wire rope latch, Safety hydraulic safety valve, alarm buzzer, machine body inclination alarm, working status lamp, device...

  • Page 364: Specification Dimensional Drawing

    2. SPECIFICATION DIMENSIONAL DRAWING...

  • Page 365: Rated Total Load Chart

    3. RATED TOTAL LOAD CHART RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS Unit: kg 12.88m 15.63m 4.63m Boom 7.38m Boom 10.13m Boom Boom Boom Working radius (m) Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry...
  • Page 366 RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS Unit: kg 12.88m 15.63m 4.63m Boom 7.38m Boom 10.13m Boom Boom Boom Working radius (m) Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry 2.00 2450 2000 2450 2000...
  • Page 367 RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL Unit: kg 12.88m 15.63m 4.63m Boom 7.38m Boom 10.13m Boom Boom Boom Working radius (m) Pick & Pick & Pick & Stationary Stationary Stationary Stationary Stationary Carry Carry Carry 2.00 1220 1220 1220 1220...

  • Page 368: Working Radius And Lifting Height

    4. WORKING RADIUS AND LIFTING HEIGHT WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 4 FALLS...
  • Page 369 WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 2 FALLS...
  • Page 370 WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 1 FALLS 5-10...

  • Page 371: Fly-Jib

    FLY-JIB 1. PRECAUTIONS OF FLY-JIB OPERATION 6 – 2 2. SAFETY LABEL LOCATION 6 – 4 3. WORKING RANGE CHART 6 – 5 4. TOTAL RATED LOAD CHART 6 – 6 5. FLY-JIB EACH SECTION 6 – 7 6. FLY-JIB INSTALLATION AND STOWAGE 6 –...

  • Page 372: Precautions Of Fly-Jib Operation

    1. PRECAUTIONS OF FLY-JIB OPERATION • The Fly-jib is installed to the Main boom with two position pins. The Fly-jib consists of two sections and another position pin fixes the 1st and 2nd section. Prior to starting operation, always ensure these three position pins are inserted in the correct positions and secured by the linchpins.
  • Page 373 • The machine weight depends on the machine configuration. Model names of the Table above represent the respective machine configurations: • LC785M-8B stands for a Blade model. • LC785M-8BF stands for a Blade and Fly-Jib model. • Fly-jib operations are limited to the boom angle range, “55 degrees or more”.

  • Page 374: 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. Keep these safety labels clean and legible at all times. When a safety label is degraded, missing or illegible, replace with a new label. In addition to the safety labels shown below, some other labels are required used.

  • Page 375: Working Range Chart

    3. WORKING RANGE CHART...

  • Page 376: Total Rated Load Chart

    4. TOTAL RATED LOAD CHART CAUTION The total rated load is a load including the mass of a hook block (20kg). Total rated load (kg) Boom angle (deg) Jib length 1 section: 3.0m Jib length 2 section: 4.7m...

  • Page 377: Fly-Jib Each Section

    5. FLY-JIB EACH SECTION Main boom (11) Hook No.1 Fly-jib (12) Position pin No.2 Fly-jib (13) Hook stowing bracket Wire guide A (14) Position pin Wire guide B (15) Position pin Sheave (16) Harness connection part (Fly-jib side) Sheave (17) Harness connection part (Main boom side) Wire rope (18) Fly-jib bracket A Sheave...

  • Page 378: Fly-Jib Installation And Stowage

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

  • Page 379: Fly-Jib Installation

    6.1 FLY-JIB INSTALLATION Practice installing the Fly-jib to the Main boom from the stowed position from the right side as shown below: 1. Pull the linchpin (20) out from the position pin (14) in the Fly-jib bracket B (19) to pull out the position pin (14).
  • Page 380 2. Slide the No.1 Fly-jib (2) forward through the position pin (15) in the Fly-jib bracket A (18) as a point of support, then fit the connection hole of the No.1 Fly-jib (2) to the hole (A) of the bracket (21) in the right side of the Main boom tip.
  • Page 381 4. Pull the linchpin (20) out from the position pin (15) in the Fly-jib bracket A (18) to pull out the position pin (15). NOTES • Move up and down or right and left the D portion of the No.1 Fly-jib (2) to ease the extraction of the position pin (15) when difficult.
  • Page 382 8. Swap the harness connection part (16) and (17) as shown below to switch and connect over-hoist detector. (1) Open the cover of the harness connection part Before harness exchange; (16: Fly-jib side) and extract the dummy plug (24) the Fly-jib side: from the connector (23).
  • Page 383 (4) Open the cover of the harness connection part After harness exchange; (16: Fly-jib side) and insert the harness plug (26), the Fly-jib side: as extracted in (2) above, to the connector (23). 9. Detach the wire rope from the hook block as shown below: CAUTION •...
  • Page 384 10. Pull out the wire rope (8) as detailed in 9. above to a sheave in the Main boom tip, then put it through inside wire rope guides (4) and (5). 11. Set the wire rope (8) under the sheave (6) and over the sheave (7) and (9) respectively, then put if through a ring of the weight (10), after is put through wire rope guides (4) and (5).

  • Page 385: Extending No.2 Fly-Jib

    6.2 EXTENDING NO.2 FLY-JIB Extending No.2 Fly-jib is as shown below: 1. Pull the linchpin (20) out from the position pin (12) in the tip of No.1 Fly-jib (2) to extract the position pin (12). NOTES Removed position pin (12) will be necessary for the later operation to secure the extended No.2 Fly-jib (3).

  • Page 386: Fly-Jib Stowage

    6.4 FLY-JIB STOWAGE NOTES Where the No.2 Fly-jib (3) is extended, refer to section; “FLY-JIB, 6.3 RETRACTING NO.2 FLY-JIB” and retract the No.2 Fly-jib (3) correctly. 1. Hang the hook (11) for Fly-jib to the hook stowing bracket (13) on the underside of the Fly-jib (2). NOTES Allow the wire rope (8) to be adequately slack.
  • Page 387 (3) Insert the harness plug (26), as extracted in (1) After harness exchange; above, to the connector (25). the Main boom side: NOTES Ensure that wires of the harness plug (26) and connector (25) are guided out of the connector box through the cut hole in the bottom left.
  • Page 388 5. Adjust the connection hole of No.1 Fly-jib (2) and hole (C) of Fly-jib bracket A (18) . NOTES When the connection hole of the No.1 Fly-jib (2) and hole (C) of Fly-jib bracket A (18) do not correctly fit, telescope the Main boom slowly to allow a correct fit 6.
  • Page 389 8. Push the No.1 Fly-jib (2) into the Fly-jib bracket B (19), then insert the position pin (14) into the hole of the Fly-jib bracket B (19). Use the linchpin (20) to secure the position pin. The position pin (14) must always be inserted downward from the upper side.

  • Page 390: Handling Moment Limiter

    7. HANDLING MOMENT LIMITER Do not turn off the power to the moment limiter and do not set the emergency switch to the OFF position during working. Doing so may cause the hoisted load to fall, breakage of the boom, or turnover of machine due to overloading, leading to serious injury or even resulting in death.
  • Page 391 Load factor display (16) Cancel switch Actual load display (17) Overwind detection LED (Red) Rated total load display (18) 1 fall LED (Green) Boom angle display (19) 2 fall LED (Green) Actual working radius display (20) 4 fall LED (Green) Rated working radius display (21) Fly-jib length (1) LED (Orange) Boom length display...

  • Page 392: Prior To Use Moment Limiter, Safety Precautions

    7.2 PRIOR TO USE MOMENT LIMITER, SAFETY PRECAUTIONS Set the Moment limiter correctly to comply with The Fly-jib operation of a crane. The moment limiter computes applicable moments in condition of the switch setting. A failure to provide a correct setting to the actual operation will result an error.

  • Page 393: Moment Limiter Functions

    7.3 MOMENT LIMITER FUNCTIONS 7.3.1 FLY-JIB MODE SWITCH DISPLAY 1. No.1 Fly jib mode: When the “1” is [ON] in the Fly jib mode selection button, rated load, actual working radius and lifting height are switched to the “Fly-jib 1” condition. •...

  • Page 394: Setting Of Operating Conditions

    7.4 SETTING OF OPERATING CONDITIONS 7.4.1 FLY-JIB MODE SWITCH (FLY-JIB OPERATION) Push the Fly jib mode selection button to obtain a correct mode, suitable for the actual condition of its sections in use. Keep the Fly jib mode selection button pushed in for 3 seconds or longer until the LED indicates the same number as the actual section (s).

  • Page 395: Operations

    8. OPERATIONS CAUTION Refer to “Operation 3 MACHINE OPERATIONS AND CONTROLS” section for operation of Fly-jib model. 9. TRANSPORTATIONS CAUTION Refer to “Operation 5 TRANSPORTAION” section for transporting the Fly-jib model. To lift the Fly-jib model, lower the boom to the minimum and always use four hooking wire ropes.

  • Page 396: Inspection And Maintenance

    10. 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. Refer to “INSPECTION AND MAINTENANCE” section for other inspections and maintenances guide not listed in this section. 10.1 MAINTENANCE EVERY 50 HOURS GREASING CAUTION...

  • Page 397: Specifications

    Refer to “SPECIFICATION” section for other cautions not listed in this section. 11.1 SPECIFICATIONS System / Item LC785M-8B / LC785M-8BF Machine mass 10,250kg / 10,420kg Overall length x width x height 5,020mm x 2,360mm x 2,795mm...
  • Page 399 MAEDA CRAWLER CRANE LC785M-8 OPERATION MANUAL Document No: 557E-OM1202-00 First edition: February 23, 2012 Issued by Maeda Seisakusyo Co., Ltd. 1095 Onbegawa, Shinonoi Nagano, Nagano 388-8522, Japan No part of this manual can be reproduced in any from without permission...

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