10000a 1 - Com - CTR217 04 - 08 01 15
10000a 1 - Com - CTR217 04 - 08 01 15
10000a 1 - Com - CTR217 04 - 08 01 15
OPERATOR MANUAL
This manual has been prepared for and is considered part of -
10000A-1
Model Number
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1100Ref
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Serial Number
IMPORTANT INFORMATION
SECTION 1 SAFETY
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SECTION 2 OPERATION
SECTION 3 LOAD SAFETY DEVICE
SECTION 4 ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY
SECTION 5 ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
SECTION 6 WIRE ROPE
SECTION 7 MAINTENANCE
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SECTION 8 REFERENCE MATERIAL
NOTICE
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The serial number of the crane is the only method the Manitowoc Crane Care Lattice
Team has of providing you with correct parts and service information.
Always furnish serial number of crane when ordering parts or discussing service
problems with your Manitowoc distributor or the Manitowoc Crane Care Lattice Team.
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©2015 Manitowoc
Published 08-01-15, Control #217-04
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THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH
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TABLE OF CONTENTS
IMPORTANT INFORMATION
1. SAFETY
1.1 SAFETY INFORMATION ......................................................................................... 1-1
1.2 EXPLANATION OF WARNING LABELS IN THE MACHINE ................................... 1-2
1.2.1 HANDLING OF WARNING LABELS IN THE MACHINE................................... 1-2
1.2.2 LABEL LAYOUT ................................................................................................ 1-3
1.3 SAFE OPERATING PRACTICES FOR MOBILE CRANES ..................................... 1-20
1.4 SAFETY AT INSPECTION AND MAINTENANCE WORK ....................................... 1-44
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1.5 SAFETY DURING ASSEMBLY AND DISASSEMBLY WORK................................. 1-47
1.6 CAUTIONS IN HANDLING OIL AND PAINT............................................................ 1-48
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1.7 SAFETY EQUIPMENT (OPTION) ............................................................................ 1-50
2. OPERATION
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2.1 TERMINOLOGY OF MACHINE EACH PART.......................................................... 2-1
2.1.1 CRANE .............................................................................................................. 2-1
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ..................................... 2-2
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2.2.1 HANDING LEVER AND PEDAL ........................................................................ 2-3
2.2.2 OPERATING SWITCHES.................................................................................. 2-10
2.2.3 VARIOUS SETTING OF MONITOR .................................................................. 2-38
2.2.4 WIND SPEED SENSOR INSTALLATION (OPTION) ........................................ 2-49
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TABLE OF CONTENTS
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3. LOAD SAFETY DEVICE
3.1 ARRANGEMENT OF EQUIPMENTS....................................................................... 3-5
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3.2 TYPE AND FUNCTIONS OF EQUIPMENTS........................................................... 3-9
3.3 CONNECTING PROCEDURE OF WIRING............................................................. 3-18
3.3.1 CRANE ATTACHMENT .................................................................................... 3-18
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3.4 FUNCTION OF MONITOR....................................................................................... 3-25
3.5 OPERATING PROCEDURE OF MONITOR ............................................................ 3-26
3.5.1 SETTING OF CRANE CONFIGURATION ........................................................ 3-32
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3.5.2 SELECTION OF MAIN LIFTING / AUXILIARY LIFTING................................... 3-44
3.5.3 SETTING OF WORK AREA LIMIT VALUE ....................................................... 3-45
3.6 SWING LIMITATION DEVICE (OPTION) ................................................................ 3-51
3.7 FUNCTION OF GROUND INCLINE INDICATOR (OPTION)................................... 3-62
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TABLE OF CONTENTS
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4.2.11 INSTALLATION OF COUNTERWEIGHTS TO MACHINE ................................ 4-58
4.3 DISASSEMBLY OF MAIN MACHINERY.................................................................. 4-67
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4.3.1 REMOVE THE COUNTERWEIGHTS FROM THE MACHINE (USING SELF RE-
MOVAL DEVICE)4............................................................................................... -69
4.3.2 DISASSEMBLY OF THE COUNTERWEIGHT (USING SELF REMOVAL DEVICE)4
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4.3.3 CARBODY WEIGHT REMOVAL (USING SELF REMOVAL DEVICE) ............. 4-82
4.3.4 REMOVING THE BOOM GUY LINE ................................................................. 4-101
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4.3.5 DISASSEMBLING THE BOOM ......................................................................... 4-103
4.3.6 LOWERING THE GANTRY ............................................................................... 4-105
4.3.7 WINDING UP OF BOOM HOIST ROPE............................................................ 4-109
4.3.8 STOWING CAB STEP....................................................................................... 4-110
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TABLE OF CONTENTS
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5.1.11 INSTALLING THE AUXILIARY SHEAVE .......................................................... 5-46
5.1.12 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE .... 5-47
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5.1.13 PERFORMANCE CHECK OF EACH LIMIT SWITCH....................................... 5-49
5.2 ERECTING THE ATTACHMENT ............................................................................. 5-50
5.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT.......................... 5-50
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5.2.2 ERECTING THE ATTACHMENT ...................................................................... 5-51
5.3 LOWERING THE ATTACHMENT ............................................................................ 5-56
5.3.1 LOWERING THE ATTACHMENT ..................................................................... 5-57
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5.4 DISASSEMBLING THE ATTACHMENT .................................................................. 5-58
5.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING................................. 5-58
5.4.2 WINDING UP THE FRONT/REAR DRUM WIRE ROPES ................................ 5-61
5.4.3 DISASSEMBLING THE JIB............................................................................... 5-63
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6. WIRE ROPE
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7. MAINTENANCE
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TABLE OF CONTENTS
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7.3.1 UPPER LUBRICATION (INCL. WATER SUPPLY) ........................................... 7-52
7.3.2 LOWER LUBRICATION .................................................................................... 7-54
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7.3.3 ATTACHMENT LUBRICATION ......................................................................... 7-56
7.3.4 INSPECTION, GREASING (WATER SUPPLY) ON EACH POINT................... 7-58
7.4 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER ............. 7-76
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7.5 BATTERY INSPECTION .......................................................................................... 7-94
7.6 LOCATION AND USE OF FUSE.............................................................................. 7-98
7.7 OPERATION UNDER SEVERE CONDITIONS ....................................................... 7-100
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7.8 HANDLING OF DIESEL PARTICULATE FILTER .................................................... 7-102
7.9 MACHINE STORAGE .............................................................................................. 7-105
7.10 TIGHTENING TORQUE VALUES............................................................................ 7-106
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8. REFERENCE MATERIALS
8.1 SPECIFICATION ...................................................................................................... 8-1
8.1.1 CRANE OUTER DIMENSION ........................................................................... 8-2
8.1.2 CRANE SPECIFICATION, PERFORMANCE.................................................... 8-3
8.1.3 CRANE WORKING RANGES ........................................................................... 8-4
8.2 DIMENSION, WEIGHT OF EACH COMPONENT ................................................... 8-7
8.2.1 MAIN MACHINERY ........................................................................................... 8-7
8.2.2 COUNTERWEIGHT........................................................................................... 8-8
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TABLE OF CONTENTS
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IMPORTANT INFORMATION
IMPORTANT INFORMATION
Thank you for purchasing your Manitowoc crawler crane.
Full-hydraulically operated crawler crane is manufactured based on our many years of experience and expertise.
This manual describes the important information about the Model 10000A-1.
Before operating the machine, be sure to thoroughly read this manual to use the machine safely and efficiently.
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Improper operation or maintenance of this machine
may cause accidents and could result in serious in-
jury or loss of life.
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Always keep this manual in the operators cab. If it
is missing or damaged, place an order to a
Manitowoc authorized dealer for a replacement.
If the machine is to be sold to others, hand over this
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manual together.
If you have any questions, please consult your
Manitowoc authorized dealer.
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This machine's specification is based on Mobile crane ASME B30.5.
As for class of utilization related to crane life, this crane is classified as [A1] of ISO 4301/2, FEM 1.001.
If there is any doubt if this crane conforms to the standard or regulation of your country, contact Manitowoc or your
nearest Manitowoc authorized dealer.
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HOUR METER
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MACHINE SERIAL NUMBER
0 0 0 - 0 0 0 0 0
ENGINE NUMBER
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MACHINE MACHINE
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WARRANTY
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The terms under which this machine is guaranteed are clearly defined in the accompanying WARRANTY.
Trouble and damage occurred during the terms of guarantee shall be repaired at no cost to the purchaser accord-
ing to the warrant description if the trouble or damage is recognized to be our responsibility.
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However, if you use the machine contrary to the instructions of this manual, the WARRANTY does not cover any
damage to the machine.
REPAIR PARTS
When servicing and repairing the machine, be sure to use genuine parts in order to make the machine performance
display sufficiently.
Since the important security parts are prepared to ensure safety and to protect the machine from a serious accident,
be sure to replace them on every specified period of time.
The part number described in the operator manual is to be changed without prior notice.
When place an order, please confirm the part number with the parts manual or the engine hand book.
MACHINE DIRECTION
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FRONT
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IDLER WHEEL
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OPERATOR CAB
LEFT RIGHT
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PROPEL MOTOR
REAR
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1. SAFETY
1.1 SAFETY INFORMATION
Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Suf-
ficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of per-
sonnel.
Thus, precautionary measures, or notes, written in this manual should be read and understood by personnel before
starting each task.
Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority.
Messages of safety are indicated with caution marks. The safety information contained in this manual is intended
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only as general safety information.
Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words
“DANGER”, “WARNING” and “CAUTION”. These words mean the following:
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Indicates an imminently hazardous situation which, if not avoided, will result in loss of life or se-
rious injuries.
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Indicates a potentially hazardous situation which, if not avoided, could result in loss of life or se-
rious injuries.
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Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injuries. It may also be used to alert against possible damage to the machine and its compo-
nents.
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Supplementary explanation.
It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured
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by operating this machine according to methods recommended by Manitowoc. While operating machine, be sure to
perform work with great care, so as to not damage the machine, or let accidents occur.
Please continue studying this manual until proper operation is completely understood.
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2. If the free fall speed select switch is in speed in-
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crease side and the brake is released and the drum
may rotate automatically to lowering side even with-
out lifting load and wire rope may be paid out to low-
er the hook and rough spooling may be caused.
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When paying out the wire rope from the drum, en-
sure to set the free fall select switch to normal side.
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3. The crane may turn over during work based on ma-
chine condition.
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6. During crane work if the boom comes too close to
the tower or power lines, electric shock may hit the
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crane.
Keep the boom away from the tower or power lines
for safety.
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7. When work is done on the upper surface of the
guard or counterweight, person may fall off by mis-
take.
Ensure to engage the safety hook on the specified
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place.
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10. This machine contains alloy and heat treated
steels.
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Do not weld or apply heat without checking with
your authorized dealer.
Unauthorized modifications may weaken the ma-
chine.
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11. Do not lift people with this crane.
Failure to do so may cause serious injury.
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16. During raising the gantry, ensure to insert the gan-
try fixing pin.
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Otherwise the gantry may come off and the boom
may drop off.
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17. Handling the counterweight in wrong way is very
dangerous.
Never allow any person to enter under the lifting
counterweight.
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20. During engine running or straight after the engine is
stopped, hydraulic oil tank, engine and muffler are
hot.
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Touching them may cause burns.
Do not touch the hot area.
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23. When the machine is transported with the low gan-
try, connect the tension bar to the revolving frame
or counterweight.
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work is done.
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ty device.
Do not step on and crush.
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27. Taking wrong procedure in boom assembly or dis-
assembly may cause boom falling off and person
may get injured.
Do not allow any person to enter the inside or under
the boom during assembly or disassembly.
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spreader guide.
Set the spreader guide to the stowing position ex-
cept when the upper spreader is connected is con-
nected to the boom base.
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30. Free fall work of load may cause dropping the load
by mishandling.
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Use power lowering of load in the crane work.
(Even on neutral free side, power lowering is possi-
ble by turning the lever to lowering side.)
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CAUTION LABEL
• Keep the caution label in good condition to read.
• Whenever they become dirty, wash them with water
or detergent.
• Whenever they are damaged or missing, replace
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OPERATOR'S RESPONSIBILITY
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The operator is the best safety feature in any crane.
Safety must always be the operator's most important
concern. He must refuse to operate when he knows it
is unsafe and consult his supervisor when safety is in
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doubt.
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judge distances and can not see all parts of the job site,
a signalman may also be necessary at other times. Op-
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erators must understand standard crane signals and
take signals only from designated signalmen.
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SIGNALMAN'S RESPONSIBILITY
The primary duty of a signalman is to assist the opera-
tor in safe and efficient operation. Operators depend on
designated signalmen to assist them in making move-
ments without endangering people or property.
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Signalmen must have a clear understanding of the
work to be done so that they can safely coordinate each
job with operators and other crew members. Signalmen
must place themselves where they can be clearly seen
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erator and signalmen of dangers such as power
lines, the unexpected presence of people, other
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equipment or unstable ground conditions.
MANAGEMENT'S RESPONSIBILITY
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See that operators are trained, competent, physical-
ly fit and, if required, licensed. Good vision is re-
quired, as are good judgment, coordination and
mental ability. Any person who lacks any of these
qualities must not be allowed to operate a crane.
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Signalmen must have good vision and sound judg-
ment, know standard crane signals and be able to
give signals clearly. They must have enough experi-
ence to be able to recognize hazards and signal the
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• What is the weight of the load to be lifted, the lift
radius, boom angle, and the rated capacity of
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the crane?
• How will the signalmen communicate with the
operator?
• What equipment is required to do the job safely?
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Is a crane the best equipment for the job?
• How can the equipment be safely transported to
the job site?
• Are there gas lines, electrical power lines or
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structures that must be moved or avoided?
• Is the surface strong enough to support the ma-
chine and load?
• How will loads be rigged?
• What special safety precautions must be taken
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• Carefully inspect load bearing parts such as wire
rope, (load lines, boom hoist cable, suspension
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lines), boom, outriggers, hooks, and rigging.
• Inspect the crane for any missing bolts, nuts or pins
and any cracked or broken components.
• Be sure no unauthorized field modifications have
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been made, such as counterweights increased or
decreased and booms that have been improperly
repaired.
• Check for fuel and hydraulic oil leaks.
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• After starting the engine, check all gauges for prop-
er readings.
• Test all controls for proper operation.
• Check brakes and clutches. Test load brakes by lift-
ing a load a few inches off the ground and holding it.
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OPERATING PRECAUTIONS
The following recommendations represent our experi-
ence in regard to the most likely causes of personal in-
juries and damage to equipment.
Careful observance of the following recommendations
will prevent the majority of common accidents.
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Several factors must be considered including:
(1) Load radius (the distance between the center of the
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crane rotation to the center of the load).
Note that the radius will increase when the load is
lifted.
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(2) Weight of the load, hook, and rigging.
(3) Boom length, jib, parts of line, and operating area
(side, rear).
Use the next lower rated capacity when working at
boom length or radii between the figures on the rat-
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ing chart.
It is dangerous to guess the capacity for boom
length or radii between those listed on the rating
plate.
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When machines are working near trenches, the
trenches should be shored or sloped to prevent
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cave-ins or slides.
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or rise in 100 foot distance).
Out of level more than ± 0.5 deg. will drastically re-
duce the lifting capacity.
Be sure cranes are level.
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4. People can be crushed by the scissors-like action
of the upper rotating on the lower.
Stay away from rotating cranes.
Erect barricades to keep people away.
Take the time to determine that these areas are
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6. Many people have been injured when riding crane
hooks or loads or while being lifted in man baskets.
They have no control over how they are handled
and no protection from impacts or falls.
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Small mistakes can be fatal.
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Greater clearances are required for lines with high-
er voltages.
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Some states require greater clearances than OS-
HA.
Safety requires that you stay as far as possible from
power lines and never violate minimum clearances. Operation Near High Voltage Power Lines
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Normal Voltage, kV Minimum Required
Always take these precautions if power lines are (Phase to Phase) Clearance, m(ft)
present.
UP to 50 3.05 (10)
Over 50 to 200 4.60 (15)
(1) Hold a job site meeting and make all people con- Over 200 to 350 6.10 (20)
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Over 350 to 500 7.62 (25)
cerned aware of work procedure. Over 500 to 750 10.67 (35)
(2) For tagline work, ensure to use non-conductive Over 750 to 1000 13.72 (45)
type tagline rope. Over 1000 kV
(3) Ensure to use swing angle limiter (if available). As established by the utility owner/operator or
registered professional engineer who is a
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(7) You and the power company must take specific pre- For example, over 50 to 200 means up to and
including 200kV.
cautions.
These may include locating cranes and materials
away from electrical power lines, de-energizing and Operation in Transit With No Load and
Boom or Mast Lowered.
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they are providing protection when in fact they are
not. If any part of the crane or rigging contacts a
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high voltage line, the safest procedure for the oper-
ator is to stay at his post until the contact is cleared,
or the power has been shut off. Do not allow any-
one on the ground to touch the machine. If the op-
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erator must leave the machine, he should jump off,
rather than climb off.
jib points.
Always keep space between the hook block and
boom point. Lower the hook when lowering the
boom.
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10. Rapid swings or sudden starts and stops can cause
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the hook and attached load to swing out of control.
Always start and stop movements smoothly and
swing at speeds that will keep the load under con-
trol.
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Make sure that you can read all safety signs. Clean
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or replace these if you cannot read the words or see
the pictures. When cleaning the labels use a cloth,
water and soap. Do not use solvent, gasoline, etc.
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You must replace a label if it is damaged, missing
or cannot be read. If a label is on a part that is re-
placed, make sure a new label is installed on the re-
placed part.
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12. Even light winds can blow loads out of control, col-
lapse booms, or tip cranes.
Winds aloft can be much stronger than at ground
level.
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Due to the high strength steels used in booms and jibs,
special repair procedures are required.
Consult your local authorized Manitowoc authorized
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dealer for instructions.
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sideways).
Typical causes of side loading are rapid starts and
stops while swinging, dragging a load sideways,
winds, or lifting when the crane is not level.
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17. If the load strikes the boom or the boom hits a build-
ing or other object, the boom may collapse. Never
let the load or any other object contact the boom.
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Release loads slowly booming out if necessary
while releasing.
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19. The load will swing out of control if it is not directly
beneath the boom point when lifted. This can side
load the boom and may cause the crane to tip or
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collapse.
Keep at least 3 full turns of wire rope on drums Keep at least 3 full turns
of wire rope.
when operating.
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22. If foot brake pedals and locks are equipped on the
crane, always keep your feet on the pedals while
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foot pedal brake locks are in use.
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25. Pin-connected booms and jibs may fall if not prop-
erly supported when removing pins.
Make sure both ends of each boom and jib section
are supported and the boom suspension lines com-
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pletely slacked off before removing pins.
Never stand on, inside, or under booms or jibs
during assembly or disassembly.
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Because of the many variables involved in pick and car-
ry operations, the user must evaluate conditions and
take appropriate precautions such as these:
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• Follow the travel precautions listed in rule 26.
• Check the rating plate for limitations.
• Position the boom in line with the direction of travel.
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• Reduce the maximum load while traveling to reflect
operating conditions. The safe load will vary de-
pending on speed, crane, and other conditions.
• Travel slowly and avoid sudden stops and starts.
• Do not steer.
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over.
• Use taglines to keep loads under control.
• Keep the load close to the ground.
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• Review the lifting plan with operators, signalmen
and other crew members before beginning the lift.
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• Carefully coordinate crane movements through ev-
ery stage of the lift.
• Avoid boom side loading (see #16).
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29. Leaving a machine unattended can be very danger-
ous. Before leaving his seat, the operator must take
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the following steps to prevent his machine from
moving:
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• Crane loads, grapples, or buckets do not pass over
the heads of workmen nor in any way endanger
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their safety. All loose objects must be removed from
the load.
Non-operating personnel should be warned, or told
to leave the immediate area, when making crane
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lifts.
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33. The operator should test the winch brakes when a
load is first lifted, and when the load is only a few
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inches above its starting position, to assure the abil-
ity of the brakes to hold the load while it is aloft.
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If fuel other than the specified type is used or gas-
oline, kerosene and alcohol group fuels are sup-
plied or used after mixing them, it may cause
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malfunction due to the sliding defect on the fuel
sliding section in the injection pump and/or in the
injector, or it may adversely affect the engine and
result in damages.
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Check that the fuel is the specified product when
fueling to your vehicle. If a wrong product was sup-
plied, thoroughly drain it.
If the engine is started with the wrong fuel filled, it
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is very dangerous because it may cause fire disas-
ter or damage to the engine.
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• Be careful of slipping on slope road.
• Do not use the main and aux. hook simultaneously
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from the boom point.
• Take slow speed in landing of load on the ground.
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1. When lightning storms are generated and lightning
bolts are anticipated, immediately take the following
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steps:
(1) Stop work, and lower the load onto the ground.
When the boom (or tower) can be lowered, lower it
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onto the ground.
(2) Engage the brakes and locks (winch and swing)
and stop the engine. Turn off the power source of
the load safety device and main switch.
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(3) Advise all personnel to stay away from the sur-
rounding area of the machine.
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for performance.
(3) Check each function for abnormality.
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(1) Stop work, and lower the load and hook onto the
ground. When the boom (or tower) can be lowered,
lower it onto the ground.
(2) Engage the brakes and locks (winch and swing),
stop the engine, and turn off the electrical power of
the main switch and load safety device.
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(3) Advise all personnel to stay away from the sur-
rounding area of the machine.
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2. After the earthquake is over, check the machine be-
fore operating.
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• Do not bring fire close during battery handling.
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• Machine parts are hot straight after engine stop. Do
not touch them.
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• Perform the inspection and maintenance work
specified by law.
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• Keep machine always in order, tidy and clean.
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UNDER
REPAIR
Use Manitowoc
Warranty is voided if the failure is caused by use of genuine parts.
parts and components other than Manitowoc genuine
parts.
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• Do not use fuel other than specified one.
O
Use ultra low sulfur diesel fuel only (S50: sulfur
content lower than 50ppm).
If fuel other than specified one is used, adverse af-
ce
fect may be caused to the engine or diesel particu-
late filter and white smoke or failure may be
resulted.
en
y
nl
O
• Ensure to secure the machine to the trailer firmly
during transportation.
ce
Strictly observe the road traffic regulation on dimen-
sion and weight during transportation.
y
and grease touching skin.
4. Do not drink.
nl
(Drinking oil and grease may cause diarrhea or
vomiting.) Keep them away from children.
O
CAUTIONS IN HANDLING PAINT
1. Do not handle around fire.
2. Handling place should be equipped with the local-
ized exhaust system.
ce
3. During painting and drying, exhaust system should
work to prevent sucking steam.
4. During handling take care not to let paint touch the
skin. Wear organic gas mask, supplied-air respira-
tor, safety glasses, protective gloves, hood, long
en
y
nl
O
ce
en
er
ef
R
y
nl
O
ce
en
er
ef
R
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART
2.1.1 CRANE
AUX.
IDLER SHEAVE SHEAVE
y
BOOM HOIST WIRE ROPE
POINT
LOWER SPREADER SHEAVE
nl
AUX.
BOOM HOOK
BACKSTOP
GANTRY
TENSION BAR
BOOM TIP
O
COUNTER
WEIGHT
MAIN HOOK
BOOM BASE
UPPER ROLLER
ce
IDLER
SHOE
BOOM DRUM BATTERY REAR DRUM CONTROL VALVE FRONT DRUM SWIVEL JOINT
er
ef
SWING MOTOR
AND REDUCTION
UNIT
R
TAGLINE MOTOR
RIGHT SIDE
SWITCH PANEL
y
LEFT SIDE SWITCH PANEL
nl
O
LEFT FRONT MONITOR
BYPASS SWITCH
KEY SWITCH
CRANE CONTROL LEVER
ce
LEFT SIDE STAND PANEL ENGINE ABNORMAL
DETECT LAMP
AIR CON.
CONTROL PANEL
CRANE
LEVEL CONTROL PEDAL
en
GAUGE
er
ef
CRANE
CONTROL LEVER
R
DRUM SPEED
ADJUSTING TRIMMER BOX
2-(3).
THIRD DRUM CONTROL LEVER (OPTION)
4-(1).
SWING CONTROL LEVER
4-(2).
ACCEL GRIP
2-(7).
THIRD DRUM LEVER LOCK 5-(3).
(OPTION)
THIRD DRUM BRAKE PEDAL
y
(OPTION)
4-(3).
SWING LOCK 5-(1).
CONTROL LEVER FRONT DRUM BRAKE PEDAL
nl
5-(2).
REAR DRUM BRAKE PEDAL
6.
O
BOOM DRUM CONTROL
PEDAL (OPTION)
ce
7. ACCEL CONTROL PEDAL (LEFT)
en
3-(1).
LEFT PROPEL
CONTROL LEVER
3-(3).
PROPEL CONTROL
LEVER LOCK
er
3-(2).
RIGHT PROPEL 7. ACCEL CONTROL PEDAL (RIGHT)
CONTROL LEVER
IN CASE ACCEL CONTROL PEDAL (OPTION)
IS INSTALLED.
ef
2-(6). REAR DRUM LEVER LOCK 2-(8). BOOM DRUM LEVER LOCK
y
FUNCTION LOCK
WORK POSITION LEVER
nl
tion becomes operational.
O
Whenever leaving from the operator's seat, ensure
to stop the engine and turn the function lock lever to
“LOCK” position.
Ensure to turn the function lock lever to “LOCK” po-
sition at work completion or at transportation of ma-
ce
chine.
en
er
ef
R
y
rear third and boom drum.
nl
Each lever drives and controls the drum such as
pulling backward to raise, neutral and pushing for-
ward to lower.
Each lever is held at the position due to detent.
O
* Detent:
Function to prevent lever returning.
REAR DRUM FRONT DRUM
CONTROL LEVER CONTROL LEVER
(5) FRONT DRUM LEVER LOCK
ce
LOWER
(6) REAR DRUM LEVER LOCK RAISE
(7) THIRD DRUM LEVER LOCK (OPTION)
BOOM DRUM
(8) BOOM DRUM LEVER LOCK CONTROL LEVER
en
y
lever grip. High speed rotation or free fall of the
drum may not be sensed.
nl
3. PROPEL CONTROL LEVER
O
(1) LEFT PROPEL CONTROL LEVER
(Refer to P.2-90) LEFT PROPEL
Propelling
CONTROL LEVER
forward
(2) RIGHT PROPEL CONTROL LEVER
(Refer to P.2-90) Propelling
backward
ce
These levers are to drive, control and stop propel
forward or propel backward. Furthermore, pivot
turn, spin turn or normal turn can be done for direc-
tion change.
Each lever drives and controls the drum such as
en
(Refer to P.2-90)
Pivot turn
Spin turn
y
nl
O
(2) ACCEL GRIP
(Refer to P.2-74)
ce
SPEED INCREASE
SPEED DECREASE
The engine speed adjustment is done with the ac-
cel grip installed on the swing lever.
ACCEL GRIP
Accel grip has 120 degrees control range and can
en
SWING CONTROL
COUNTERCLOCKWISE (LEFT TURN): LEVER
Speed increase
CLOCKWISE (RIGHT TURN):
Speed decrease
er
CONTROL LEVER
This lever is to insert the lock pin from the upper
machinery to the pin catch on the lower machinery
to secure the upper machinery or release the pin to
make upper machinery swing freely.
R
y
Make free-fall, brake or stop while pressing the
brake pedal.
nl
REAR DRUM
BRAKE PEDAL
In order to hold the hook or lifting load during the
free-fall operation, press the brake pedal to engage
FRONT DRUM BRAKE PEDAL
the pedal lock.
O
THIRD DRUM BRAKE PEDAL
(OPTION)
Pressing the brake pedal during raising or power
lowering operation does not engage the brake.
Only during free fall operation, brake is engaged.
ce
6. BOOM DRUM CONTROL PEDAL
(OPTION)
This pedal can control the boom drum instead of
en
other.
Condition to install
RIGHT HAND INSTALLATION:
R
y
Condition to install
LEFT/RIGHT INSTALLATION:
In case of no third/boom pedal.
nl
RIGHT INSTALLATION:
In case of no boom drum pedal. RIGHT ACCEL
CONTROL PEDAL
LEFT INSTALLATION: (OPTION)
In case of no third drum pedal.
O
ce
en
er
ef
R
y
4. BOOM DRUM LOCK KNOB THIRD DRUM CONTROL LEVER
nl
SERECT SWITCH
(OPTION)
7. HOOK OVERHOIST
RELEASE SWITCH
6. BOOM/JIB OVERHOIST
O
RELEASE SWITCH
5. LOAD SAFETY DEVICE 49. ENGINE ABNORMAL
RELEASE SWITCH DETECT LAMP
8. GANTRY CONTROL
SWITCH 19. THIRD DRUM
9. CRAWLER EXTENSION SPEED ADJUST
SWITCH TRIMMER
ce
(OPTION)
10. SPARE
23. KEY
SWITCH
en
BRAKE SELECT
SWITCH
31. ENGINE
y
EMERGENCY
STOP SWITCH
nl
37. EMERGENCY STOP CHECK 34. REAR WORK LIGHT SWITCH (OPTION)
SWITCH
35. DRUM LIGHT SWITCH (OPTION)
38. SWING ALARM SELECT SWITCH
O
RIGHT SIDE SWITCH PANEL
SWITCH
POKP
0 m i n- 1 258 /%&
y
75. BATTERY LAMP (OPTION)
74. ELECTRIC OIL COOLER
WORK INDICATING LAMP
nl
73. INCHING SPEED LAMP
71. REAR DRUM FREE FALL
INDICATION LAMP
O
81. ENGINE COOLANT
TEMP. GAUGE
80. SOOT ACCUMULATION
GAUGE
79. FUEL GAUGE
78. HYD. OIL TEMP.
GAUGE
ce
57. CAMERA SELECT
ICON (OPTION)
58. HYD. OIL HEAT CIRCUIT
SELECT ICON (OPTION)
en
The following explains how to use each switch. Refer to article 2.3 CRANE OPERATION.
PANEL SWITCH
y
LOCK (ENGAGE)
knob when the drum is not used for long time.
To release, push the knob while pushing the button
RELEASE
nl
on the knob top. (DISENGAGE)
O
THIRD DRUM LOCK KNOB
(OPTION)
BOOM DRUM LOCK KNOB
ce
en
LOCK RELEASE
during lowering the lifting load or boom. Push down
(1 inch)
RELEASE
Only during the time when this switch is turned to
release side, auto stop function of the load safety
device can be released.
y
switch is hand released. RETURN
nl
LMI
RELEASE
O
RELEASE SWITCH
RELEASE
en
RETURN
switch is hand released. This switch is functional
only when 50. RELEASE SWITCH MASTER KEY
is turned to release side.
ef
RELEASE
RELEASE SWITCH
R
RELEASE
Only during the time when this switch is turned to
release side, auto stop function of the hook over-
preventive device can be released.
AUTO
RETURN
y
The switch can automatically return when the
switch is hand released. This switch is functional
only when 50. RELEASE SWITCH MASTER KEY
nl
is turned to release side.
RELEASE
O
RELEASE SWITCH
UP
NEUTRAL
When the gantry is raised or lowered, make sure that
ef
y
firm and level ground without counterweight, with
boom base and with boom angle of approx. 10 de-
grees. NEUTRAL
nl
Even without counterweight or without base boom,
crawler can be extended or retracted. CRAWLER
RET.
But in such case, swing the upper machinery to re-
O
duce the load applied on the retracting side axle. CRAWLER EXTENDING SWITCH
10. SPARE
ce
en
er
ef
R
y
This would cause large burden to the boom and swing
unit and is very dangerous.
nl
Apply the swing brake after the upper machinery is
completely stopped.
Due to the wind or ground slope main machinery may
start swing unexpectedly.
O
Take extra care when disengaging the swing brake.
If the engine is started with the swing brake disengaged
or if the function lock lever is turned to lock position with
the swing brake disengaged, the swing brake is kept
engaged.
ce
In such case, turn the swing brake to “engage” side
once and then turn to “disengage” side.
Failure to observe this precaution may result in serious
injuries or loss of life.
en
y
push the switch while pressing the brake pedal fully
REAR DRUM BRAKE
will make free fall mode. At the same time, free fall SELECT SWITCH
indication lamp lights up to advise free fall mode.
nl
(Brake turns into brake pedal control.) FORWARD
O
THIRD DRUM
pedal fully turns into the neutral brake mode. At the CONTROL LEVER
y
Drum speed is decreased.
nl
O
19. THIRD DRUM SPEED ADJUST TRIMMER
(OPTION)
ce
This trimmer adjusts the drum speed separately to
the drum speed control by the control lever. LOW HIGH
(This makes synchronous speed adjusting with oth-
er drum possible.)
en
FRONT DRUM
pushing this switch makes maximum speed raising FRONT DRUM CONTROL LEVER
G WINCH SWITCH
or lowering of each winch possible.
REAR DRUM
(Refer to P.2-104 for control detail.) CONTROL LEVER
R
INCHING SPEED:
Motion speed of the front drum, rear drum, boom
drum and propel becomes 1/4 of the normal speed.
NORMAL SPEED:
This is the normal motion speed.
INCHING SPEED SWITCH
(Installed on boom control lever.)
y
Selection of swing speed is done with swing mode
select switch.
(Refer to P.2-93)
nl
23. KEY SWITCH
O
This switch is to start, stop the engine and connect
OFF
its accessory circuit. ACC
ON
OFF:
Engine stop position.
ce
(Key insert position. Take out position.)
START
ACC:
Accessory circuit connected position.
ON:
Engine running position.
en
START:
Engine start position.
MC1-W01
er
y
nl
25. WIPER SWITCH (FRONT WINDOW)
26. WIPER SWITCH (SKY LIGHT)
O
Continuous operation. CONTINUOUS
CONTINUOUS
en
er
INTERMITTENT
ef
R
FRONT WINDOW
y
nl
28. FRONT DRUM FREE FALL SPEED
SELECT SWITCH
29. REAR DRUM FREE FALL SPEED SELECT
O
SWITCH
30. THIRD DRUM FREE FALL SPEED SELECT
SWITCH
(OPTION)
In order to make free fall of the hook or load effec-
ce
tive while the temperature is low, free fall speed can
be selected on each drum. SPEED
After 58. HYDRAULIC OIL HEAT CIRCUIT SELEC- INCREASE
NORMAL
SPEED INCREASE:
Free fall speed is increased.
er
NORMAL:
Free fall speed is normal.
ef
Do not use this switch when the heavy weight free fall
work is being done.
Do not release the brake pedal when the hook is
grounded with SPEED INCREASE.
The drum rotates automatically to lowering direction
and the drum wire rope would be rough-spooled.
y
nl
32. TAGLINE TENSION ADJUST TRIMMER
(OPTION)
This knob is to adjust the tagline rope tension.
O
HIGH (RIGHT TURN):
Tagline rope tension becomes high.
LOW (LEFT TURN):
Tagline rope tension becomes low.
ce
When the tagline is not in use, set the knob to LOW
side.
The drum speed adjustment can not be done with
the adjusting knob.
en
er
ef
R
y
ON
nl
O
ce OFF
OFF
er
ef
R
MIDDLE SPEED:
Engine speed becomes approx. 1,500 min-1.
LOW SPEED:
Engine speed becomes approx. 800 min-1.
LOW
SPEED
y
Do not use the auxiliary accel switch when the accel
grip is normal.
nl
37. EMERGENCY STOP CHECK SWITCH
O
This switch can check the auto-stop function of the
boom and jib.
CHECK
CHK
CHECK:
Check of the auto-stop function can be done.
ce
Raising or lowering of the boom, raising of the jib or
lowering of the hook can not be done.
AUTO
RETURN
Switch returns automatically when hand is freed.
en
ALARM LIGHT
AND BUZZER
ALARM LIGHT
OFF Nothing occurs.
R
OFF
y
40. PROPEL SPEED SELECT SWITCH
nl
HIGH SPEED: Propel speed is increased.
LOW SPEED: Propel speed is decreased.
HIGH SPEED
O
Do not change the switch during propelling. It may
cause deflected propel.
LOW SPEED
ce
41. SPARE
en
er
ef
R
42. SPARE
y
This is the main switch to use G winch.
G winch is a function to realize maximum line speed
ON
nl
with low engine speed at no load condition.
(Refer to P.2-104 for detail of control.)
O
OFF
ce
44. AUTO IDLE STOP SWITCH
ON:
Auto idle stop function becomes effective.
ON
When auto idle stop conditions are filled, count-
en
STOP
down is indicated on the monitor and engine stops
at count zero.
OFF:
Auto idle function becomes ineffective.
Even when other auto idle stop conditions are filled, OFF
er
ON: G ENGINE
Max. engine speed becomes approx. 1,725 min-1
and G ENGINE operation becomes possible.
But in case of heavy load lifting, lifting speed be- OFF
comes lower than power mode.
y
OFF: POWER MODE
Max. engine speed becomes approx. 2,100 min-1
and lifting speed decrease is smaller than G EN-
nl
GINE and is suitable for heavy load lifting.
(Refer to P.2-107 for detail of control.)
O
46. PROPEL ALARM SWITCH (OPTION)
This is to select the propel alarm.
ON
ON: Buzzer voice alarm is issued.
ce
OFF: Nothing occurs.
OFF
en
er
ef
R
y
MOVABLE POINT
nl
O
ce
49. ENGINE ABNORMAL DETECT LAMP
This lamp lights up when the engine control unit
(ECU) detects engine abnormal.
Normally (in case of no abnormal) it lights up when
en
BYPASS SWITCH
(1) LOCK
Release of the auto-stop functions of the load safe-
ty device, boom over-hoist and hook over-hoist can
y
not be done.
(2) RELEASE
nl
When the key is turned to release side, the auto-
stop function of the load safety device, boom over-
hoist and hook over-hoist become possible.
O
The key can be pulled out at LOCK side.
ce
During work, the key must be kept and be controlled by
work responsible person.
en
er
ef
R
(1) LOCK
Free fall of the front, rear and third drum becomes
impossible.
(2) RELEASE
When the key is turned to RELEASE side, free fall
y
of the front, rear and third drum becomes possible.
nl
• When the switch is in LOCK side, free fall can not
be done even when the brake select switch is
turned to [FREE FALL] side. The key can be pulled
out at the LOCK position.
O
During work the key must be kept and be controlled by
ce
work responsible person.
NORMAL
becomes possible.
R
y
ICON (OPTION)
This select icon is to make free fall of the hook or
nl
load effective by heating up the hydraulic oil while
the temperature is low.
* Push for more than 1 second.
O
ON:
The device to heat up the hydraulic oil is actuated.
(Even with the icon ON, when the hydraulic oil tem-
perature becomes about 50° C (122° F) the device
becomes OFF and ON when cooled down to 40° C
ce
(104° F).)
Use this icon at winter time or morning time.
The icon turns to green when turned ON.
OFF:
en
HIGH SPEED:
Normal work
(Auto variable position)
LOW SPEED:
Special work
y
(front and rear drum are low speed fixed position)
The icon turns to green when low speed is selected.
nl
Select LOW SPEED when synchronization of front
and rear drum speed is difficult for heavy load such
as clamshell.
* Push for more than 1 second.
O
61. MENU ICON
This icon is used to indicate select item list.
ce
en
y
This icon becomes indicated when the mode select
becomes possible.
nl
* Push for more than 1 second.
O
This lamp lights up when G ENGINE is selected.
(When 45. G ENGINE SWITCH is turned ON.)
ce
67. G WINCH INDICATING LAMP
en
y
THIRD DRUM FRONT DRUM REAR DRUM
nl
73. INCHING SPEED LAMP
This lamp lights up when 22. INCHING SPEED
SWITCH is turned to [Inching speed] side.
O
ce
INDICATING LAMP
This lamp lights up when the electric oil cooler is
working.
en
Green:
Auto-idle stop possible
Yellow:
ef
y
50°C
(122°F)
nl
79. FUEL GAUGE
This indicates fuel level. Scale is divided into 15.
O
The highest division indicates 355 liter. (93.7 gal) 355 ltr.
(93.7 gal)
and the lowest division indicates less than 44 liter.
(11.6 gal).
44 ltr.
en
(11.6 gal)
The gauge color changes from white to red at high- 5°C (41°F) PITCH
er than 105° C (221° F).
y
70°C
(158°F)
nl
O
ce
en
er
ef
R
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
Push [A] in the indicated menu.
en
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
er
A
ef
R
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
en
er
ef
R
1. TIME SETTING
Time is set.
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
B
(2) Presently set year, month, day, time and minute are
indicated.
ce
Push the required item to change.
(A) Pushed item is highlighted.
(B) Under this condition, input numbers with the right
side number pad.
If there is other area to change, input numbers with
en
POKP
0 m i n- 1
ef
R
OK
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
C
ce
(2) Change the number with [↑] or [↓].
Number can be changed from 0 to 150.
The detent force becomes larger as number be-
comes higher.
en
Push [A].
er
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
ef
A
R
FR 70
RE 40
OK
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
UP
FR 70
y
DOWN
RE 40
nl
OK
O
(B) Setting of rear drum.
Push [B].
Change the number with [UP] or [DOWN].
ce
When changing number is completed, push [OK].
en
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
er
UP
FR 70
DOWN
RE 40
B
ef
OK
R
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
D
ce
(A) Pushed item is highlighted.
(B) Under this condition, input numbers with the right
side number pad.
en
OK
y
(1) Lift up or lower the main hook and stop the hook
nl
when the wire rope changes its layer
(2) Push [F] in the menu.
O
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
ce
en
F
er
ef
R
POKP
0 m i n- 1
y
nl
O
OK
VJ.C[GT
VJ.C[GT SETTING EXAMPLE
er
y
nl
O
ce
en
er
ef
R
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
G
O
ce
(A) By pushing the bar area, brightness varies. The
brightness becomes higher as bar goes toward
right (longer bar).
(B) When the required brightness is selected, push
en
[OK].
0 m i n- 1
er
POKP
11000100000500010200
2010/12/01 10:00
ef
R
y
(4) If height with winch raising, lowering, boom or jib
raising/lowering is higher than zero rest height, plus
indication appears and minus indication appears
nl
when lower.
O
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
ce
en
er
ef
R
In case of crane
Remove pin
at work.
y
(Work condition) (Transport condition)
nl
O
LOAD SAFETY
DEVICE WIND SPEED SENSOR
FOR CRANE ONLY
ce
MONITOR CN-11-1D
CN-11-5B
CN-590
5P
CRANE BOOM
11P TOP JUNCTION
BOX
en
CRANE CABLE
11P
ATTACHMENT CABLE REEL
JUNCTION PANEL CRANE CABLE
er
ELECTRICAL DIAGRAM
ef
R
AIR CON.
CONTROL PANEL
BLOW OUT
OPENING
y
BLOW OUT
OPENING
nl
BLOW OUT
OPENING
BLOW OUT
O
OPEN AIR OPENING
FILTER BLOW OUT
OPENING
IN-OUT AIR
SELECTOR SWITCH (5)
(a)
BLOW OUT OPENING TEMPERATURE AIR VOLUME
SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3)
y
(1) ON/OFF SWITCH
(POWER SWITCH)
nl
It turns ON or OFF the air conditioner. When this
switch is pushed, air conditioner starts with previ-
ous set mode.
When this switch is pushed at the first time, the air
O
conditioner starts on factory set mode.
LCD
tioner is running. DISPLAY
Pushing this switch changes temperature setting Pushing lowers temperature (blowing air temp.)
when the air conditioner is running.
Set temperature (d) is indicated on LCD display.
y
They are indicated as shown below.
nl
LCD display
Blow out opening Vent Bi level Foot
Upper rear Foot /
O
Blow out direction Upper rear and foot *windscreen
* Air blows from DEF too.
Blow volume is Foot > DEF.
ce
(7) DEFROSTER SWITCH
(DEF SWITCH)
(c) LCD display
Every time when this switch is pushed, blow out
opening changes to DEF and is indicated (c) on the Blow out opening DEF
LCD display.
en
This is to defog on the inner side of the front glass Blow out direction windscreen and *foot
or to defrost on the outer side of the front glass.
* Air also blows from DEF.
Blow volume is Foot < DEF.
er
ef
R
(d) (b)
IN-OUT AIR
SELECTOR SWITCH (5)
AIR CON. SWITCH (2)
y
(e)
BLOW OUT OPENING TEMPERATURE AIR VOLUME
SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3)
nl
(2) To cool:
O
(B) Push the TEMPERATURE CONTROL SWITCH (4)
to indicate on the LCD display.
(3) To warm:
(d) (b)
IN-OUT AIR
SELECTOR SWITCH (5)
AIR CON. SWITCH (2)
(e)
BLOW OUT OPENING TEMPERATURE AIR VOLUME
SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3)
y
(A) Push the TEMPERATURE CONTROL SWITCH (4)
to indicate on the LCD display.
nl
(d) TEMPERATURE CONTROL. INDICATION
(B) Push the AIR VOLUME SELECTOR SWITCH (3)
for required air volume.
O
(C) Push BLOW OUT OPENING SELECTOR SWITCH
(6) for FOOT position (e).
(Foot position is recommended in this case.)
(e) FOOT
IN-OUT AIR
SELECTOR SWITCH (5)
(a)
BLOW OUT OPENING TEMPERATURE AIR VOLUME
SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3)
y
(A) Push the TEMPERATURE CONTROL SWITCH (4)
to indicate (d) on the LCD display.
nl
(d) TEMPERATURE CONTROL. INDICATION
(B) Push the AIR VOLUME SELECTOR SWITCH (3)
for HIGH air volume.
O
(C) Push DEFROSTER SWITCH (7) to change the
blow out opening to DEF position (c).
(c) DEF
(D) By pushing IN-OUT AIR SELECTOR SWITCH (5),
ce
set the selector to internal air circulation (b).
pushed.
• If blow out opening is set to DEF, air bows to foot
too.
er
ef
R
IN-OUT AIR
SELECTOR SWITCH (5)
y
(A) Push the AIR VOLUME SELECTOR SWITCH (3)
for required air volume.
nl
(B) Push the DEFROSTER SWITCH (7) to change the
blow out opening to DEF position (c).
(c) DEF
O
(C) By pushing IN-OUT AIR SELECTOR SWITCH (5),
set the selector to out air take in.
SWITCH NAME
(b)
(f)
(c)
(e)
y
nl
O
(h) (a)
(g)
(d)
ce
CODE NAME FUNCTION
Tuning, Each control Select frequency, control step for sound control, adjust
(d)
button time.
ef
Sound control
(g) (balance/bass/treble) Control sound. (balance/bass/treble)
button
LCD DISPLAY
y
nl
(a) (b)
O
CODE NAME FUNCTION
1. Normal condition
From OFF condition, by pressing “power button”
the radio turns ON and receives presently selected
frequency.
y
nl
OFF CONDITION (CLOCK DISPLAY)
BUTTON BUTTON
O
ce
ON CONDITION (BAND NAME DISPLAY) FREQUENCY DISPLAY
( ST picto turns ON when stereo is reveiving.)
en
BUTTON
ef
BUTTON
2. Band select
From normal condition by pressing “AM/FM select”,
button, band is changed.
After band is selected, radio receives the last se-
lected frequency of the band.
Selecting sequence is FM1 → FM2 → AM → FM1.
BUTTON
y
ON CONDITION (BAND NAME DISPLAY) ON CONDITION (BAND NAME DISPLAY)
nl
BUTTON BUTTON
O
ce
ON CONDITION (BAND NAME DISPLAY)
en
er
ef
R
y
nl
FREQUENCY DISPLAY
( ST picto turns ON when stereo is reveiving.)
O
BUTTON BUTTON
ce
FREQUENCY DISPLAY FREQUENCY DISPLAY
( ST picto turns OFF when non-stereo is reveiving.) ( ST picto turns OFF when non-stereo is reveiving.)
en
FREQUENCY DISPLAY
ef
BUTTON BUTTON
R
y
BUTTON
nl
FREQUENCY DISPLAY FREQUENCY DISPLAY
( ST picto turns ON when stereo is reveiving.) ( ST picto turns OFF when non-stereo is reveiving.)
O
BUTTON (Press and hold.)
ce
SEARCHING
FOR FREQUENCY
BUTTON
ef
SEARCHING
FOR FREQUENCY
y
BUTTON (Press and hold.)
nl
O
FREQUENCY DISPLAY AUTO PRESET DISPLAY
( ST picto turns ON when stereo is reveiving.) ( ST picto turns OFF.)
FREQUENCY DISPLAY
( ST picto turns ON when stereo is reveiving.)
R
6. Preset call
From normal condition, by pressing “Preset” button
(1 to 6), memorized frequency on preset No. is
called and received.
Example when selected band is FM1 (76.0 MHz is pre-memorized in preset No.1).
BUTTON
(No.1)
y
FREQUENCY DISPLAY PRESET No. DISPLAY
( ST picto turns ON when stereo is reveiving.) P-X is displayed and held for 0.5 seconds
nl
(X : preset No.)
O
ce
FREQUENCY DISPLAY
( ST picto turns ON when stereo is reveiving.)
en
er
ef
R
y
nl
MICROPHONE
O
AMPLIFIER
ce
en
SPEAKER
2. OPERATION INSTRUCTION
er
(2) The operator's voice can be transmitted through the ELECTRET DYNAMIC
POWER
volume adjuster.
POWER
SWITCH
VOLUME ADJUSTER
MICROPHONE JACK
R
y
nl
The camera monitor can check the following locations:
O
ce
A Front drum
Rear drum
Third drum (Option)
B Boom hoist drum
en
CAMERA
CAMERA
y
nl
O
ce
“A” LOCATION “B” LOCATION
CAMERA
en
er
ef
R
“C” LOCATION
POKP
1000 m i n- 1 258 /%&
y
/'07
nl
CAMERA SELECT ICON
Selection of camera
O
Maximum 4 cameras can be connected.
When more than 2 cameras are connected, camera
60% 70% 80% 90% 100%
POKP
1000 m i n- 1 258 /%&
/'07
TOUCH
er
/'07
TOUCH
y
1. HEIGHT ADJUST/TILT LEVER
nl
HEAD REST
(1) When the lever is pulled up, rear portion of the seat
tilts up or down.
(Tilt on 5 steps)
ARM REST
O
(2) When the lever is pushed down, front area of seat
tilt up or down.
(Tilt on 5 steps)
(3) Seat height adjustment can be done by tilting of
seat front and rear alternately.
ce
HEIGHT
ADJUSTING LEVER
TILT LEVER
en
y
(Adjusting range: 160 mm (6-5/16 inch))
nl
4. SEAT FRONT AND REAR ADJUSTING HANDLE 1
(b)
Lift the handle (b) up and move the whole of seat
and control stand sliding back and forth.
O
(Adjusting range: 60 mm (2-3/8 inch))
SEAT FRONT AND SEAT FRONT AND
REAR ADJUSTING REAR ADJUSTING
HANDLE (a) HANDLE (b)
5. ARM REST
ce
The arm rest can be lifted up toward rear upper. ARM REST
In addition, by turning the lower control dial by ARM REST
hand, arm rest angle at normal position can be fine- 5
adjusted up or down.
en
5
er
ef
R
y
nl
STEP
O
ce
en
er
ef
R
(1) Front drum, rear drum, third drum (option), boom hoist, swing and propel control lever Neutral
(2) Function lock lever Lock position
(3) Swing brake switch Engaging side
(4) Front drum, rear drum, boom drum and third drum (option) lock knob Lock side
Front drum, rear drum and third drum (option) brake pedals
(5) Lock position
Release switch master key, free fall lock switch
y
nl
Ensure to set all the control levers to neutral posi-
tion before starting the engine to prevent unexpect-
ed movement of machinery when the engine is
O
started.
Even if each control lever of front drum, rear drum,
third drum (option) is not in neutral position, en-
gine can start.
However each motion cannot work without return-
ce
ing the control lever to neutral position once.
ENGAGE RELEASE
en
(1) NEUTRAL
er
(1) NEUTRAL
(1) NEUTRAL
Sound the signal horn to warn the surrounding per- HORN SWITCH
sonnel before starting the engine.
Failure to observe this precaution may result in se-
rious injury or loss of life.
y
(1) Turn the key switch 2 steps to the right (ON posi-
KEY SWITCH
tion).
nl
Confirm that the engine abnormal detect lamp lights OFF ENGINE STOP POSITION
up at this time.
ACCESSORY CIRCUIT
Confirm that the engine emergency stop switch is ACC
CONNECT POSITION
not ON too.
ON ENGINE RUN POSITION
O
START ENGINE START POSITION
ce
ENGINE EMERGENCY
STOP SWITCH
MONITOR
en
(2) By turning the key switch one step more to the right
(START position), the engine starts. OFF
ACC
After the engine starts, immediately release the
key. ON
y
the key and wait for more than 20 seconds, then start
the engine again.
nl
(3) After the engine starts, immediately check the mon-
OFF
itor for abnormality. ACC
O
ON
ately and seek for the cause.
START
ce
Desired control is available
(4) To adjust the engine speed, use the accelerator in the range of 120 degrees.
grip.
SPEED INCREASE
If the engine speed adjustment becomes impossi-
ble by the accel grip due to accelerator failure, use
en
y
nl
O
ce
2. STARTING ASSIST OF ENGINE AT COLD
ATMOSPHERE
When the ambient temperature is low (Approx.
10° C [50° F] or lower), place an engine key switch
to the ON position, the preheating function (Glow
en
4. ENGINE ABNORMAL
When engine abnormal occurs, the engine control
unit (ECU) detects it and engine abnormal detect
lamp (red) lights up on the monitor.
Immediately turn the key switch to OFF to atop en-
gine and contact the Manitowoc service shop.
If the engine must be stopped urgently, push the TURN RIGHT
engine emergency stop switch. PUSH
The switch is held at the pushed position and return
to original position when turned right.
y
ENGINE STOP RELEASE
nl
5. STOPPING THE ENGINE
Before stopping the engine, set the control levers
and switches as follows:
O
(A) Front drum, rear drum, third drum (option), boom hoist, swing and propel control lever Neutral
(B) Function lock lever Lock position
(C) Swing brake switch Engaging side
(D) Front drum, rear drum and third drum (option), boom drum lock knob Lock side
ce
(E) Front drum, rear drum and third drum (option) drum brake pedals Lock position
(2) Turn the key switch to the OFF position. After the
en
OFF
engine is stopped, the power will be cut after ACC
awhile.
ON
During this period, message will be indicated on the
monitor urging to engage the drum lock. START
If the emergency solenoid becomes actuated, the
er
y
unit when low idling or light load work continues for
long time, automatic refreshing occurs. (This is not
regeneration)
nl
(2) Auto regeneration mode
Burning (regenerating) the soot occurs automati-
O
cally and the lever control can be done even during
auto-regeneration.
<Procedure>
y
nl
Under refresh condition and engine speed exceed
1,100 min-1, this mode is canceled.
Since refresh again needs a few minutes to keep that
condition, once it is canceled, it must be started again.
O
When the refreshing is started, keep that condition as
long as possible and do not stop the engine or cancel
the refreshing.
ce
When non-combusted fuel is accumulated, white
smoke may come out of exhaust port and may cause
deterioration of DPF unit.
en
<Procedure>
y
3 to 4 bars
nl
O
• Auto regeneration becomes actuated when control
lever is not used and burning (regenerating) soot
start automatically.
ce
en
er
ef
R
y
• Lever control is possible during auto regeneration.
nl
During auto-regeneration, increasing the engine speed
may cause louder engine noise.
O
This is because the regeneration required control is
functioning and is not failure.
<Cancel>
CANCEL ICON
y
nl
• After canceled, when the control lever becomes
non-operational, auto regeneration mode starts
again.
O
• Cancel button is displayed by changing the setting.
Display the setting change screen with “Menu” icon
and select ON or OFF.
ce
en
er
ef
R
<Procedure>
5 to 8 bars
y
nl
O
• Make machine in idling condition and push the soot
burning (regenerating) icon.
ce
SOOT BURNING
(REGENERATING)
ICON
en
y
• During manual regeneration, lever control becomes
nl
impossible.
O
lation gauge is reset, manual regeneration is
completed.
ce
Manual regeneration work will be completed in about
15 to 20 minutes. (It varies depending on volume of
soot accumulation.)
Since soot burning (regeneration) work raises the tem-
perature in the diesel particulate filter to a certain level,
en
<Cancel>
CANCEL
Selecting cancel against request of regeneration is lim- ICON
Push the soot burning icon
ited.
When the soot accumulation gauge becomes 8 bars,
y
cancel icon will not be indicated.
Perform regeneration work as soon as possible.
nl
When canceled, burning (regenerating) soot would not
O
be completed. The soot accumulation gauge would not
be reset.
ce
• When machine operation becomes necessary even
during manual regeneration work, manual regener-
ation work can be suspended by pushing cancel
icon.
en
be reset.
y
nl
9 bars
When long time has elapsed under manual regenera-
tion request screen being indicated and accumulation
gauge becomes 9 bars, forcible soot regeneration will
occur to prevent failure of the diesel particulate filter.
O
Take extra care on this. In this case, maintain the con-
dition until the regeneration is completed.
ce
en
10 bars
y
ON
displayed.
STOP
nl
* In the event of occurrence of an error, this state is not
displayed, since priority is given to display of the error
message.
OFF
O
ce
10.0 POKP
8000 m i n- 1
11010100000400100110
2010/12/01 10:00
4 1
101.3
en
100
30.0
38.0
70.0
er
40.3
-0.3
0.2
ef
R
y
2 Engine rotational speed The engine rotational speed shall be 760 to 840 min-1.
nl
Remote control for transfer lifter/self installation and removal device shall
3 Remote control
not be connected yet.
O
Engine water
5 The engine water temperature shall be within the specified range.
temperature
8 AIS cancel It shall be at least 5 min after the AIS CANCEL icon is pushed.
9 Hydraulic oil temperature The hydraulic oil temperature shall be within the specified range.
en
Assembly/disassembly
11 LMI shall not be in the assembly/disassembly mode.
mode
er
y
During auto idle stop of the engine, the battery is con-
sumed. When you leave the operator seat, be sure to
nl
turn OFF the key switch.
O
ce
en
er
ef
R
y
FUNCTION LOCK
LEVER
nl
If the function lock lever is set to the “LOCK” position
while any of front drum, rear drum boom hoist drum and
propel control lever lock is operated, rotation of the
O
drum or propel is stopped.
Under this condition, even if the function lock lever is
turned to “WORK” position again, no motion becomes
operational.
After the control lever is returned to neutral position, the
ce
control becomes possible again.
y
RIGHT PROPEL
17. CONTROL LEVER
Use a signal person to direct operation. PROPEL LEVER LOCK
nl
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
ce
en
er
ef
R
High speed
Use this speed on good ground conditions.
LOW
Low speed
PROPEL SPEED
Use this speed when a tractive force is required on bad SELECT SWITCH
ground conditions.
y
nl
When the propel speed selector switch is placed in the
High speed position, pivot turn and spin turn due to
large propel resistance cannot be operated.
O
Turn the switch to Low speed position for pivot turn and
spin turn.
Since the machine may propel partially on rough ter-
rain, adjust propelling by the stroke of the propel control
levers.
ce
In order to identify front and rear of the lower machinery
easily, the crawler shoes have " " marks.
motor side.
When the cab positions to the propel motor side, use
PROPEL MOTOR IDLER
caution with propelling operation in reverse only.
FRONT
ARROW ARROW
er
ef
R
y
Do not perform sudden starts/stops/operation of
nl
the machine. Failure to observe this warning may
result in serious accidents due to collision or boom
Spin turn
windage.
If the front or rear drum is operated while propelling
O
the machine, it may cause danger because the pro-
pel speed changes or the direction slants. To oper-
ate these actions simultaneously, lower the
machine speed and slowly operate the drum.
ce
Large radius turn
tions of slope.
er
ef
R
y
nl
Swing speed is regulated by turning the accelerator
grip, and by proportionally pushing and pulling the
swing control lever.
O
with the swing alarm selector switch. SWING ALARM SELECT SWITCH
ALARM LIGHT
AND
BUZZER
ce
OFF
ALARM LIGHT
en
er
ef
R
y
When engine is started while the swing brake is re-
leased, or function lock lever is turned from LOCK po-
sition to WORK position, swing brake keeps engaged
nl
position.
In such case, turn the swing brake switch to engaged
position once and then to released position.
This would release the swing brake.
O
If the function lock lever is in LOCK position, swing
brake is engaged regardless of swing brake switch po-
sition.
ce
LOCK
RELEASE ENGAGE RELEASE
SWING LOCK
CONTROL LEVER
en
SWING BRAKE
SWITCH
BRAKE MODE
Slowly return the lever to the neutral position.
y
machinery may start swinging by itself.
Therefore engage the swing brake.
nl
For long time stop, engage the swing lock pin.
O
Swing to the right
Swing to the left
ce
en
er
y
nl
O
ce
en
er
ef
R
y
celerator grip and pressing or pulling up the boom op-
erating lever and the maximum speed of boom up and
nl
down motion can be also adjusted by operating the
drum speed adjusting knob.
O
Push
(1 inch)
25 mm
ce
en
y
nl
Operate the control lever slowly.
Abrupt control lever operation may create shock to
the main machinery or boom on load swinging and
O
is very dangerous. ce
3. Stopping
When the boom drum control lever is returned to
neutral, the drum brake actuates automatically and Raising
the boom is stopped and is held.
en
Lowering
y
nl
O
5. When the boom approaches the upper limit angle,
the hoisting speed is reduced. The angle to start the
speed reduction differs depending on the engine
ce
speed.
It reduces the speed approximately 10 degrees be-
fore the upper limit angle in the case of HIGH IDLE
and approximately 3 degrees before the upper limit
angle in the case of LOW IDLE.
en
y
ror.
Failure to observe this precaution may result in se-
nl
rious accident.
O
Do not actuate the drum lock while the hook is low-
ered.
Otherwise, the drum or drum lock may be dam-
aged.
ce
When making lifts, strictly follow the capacity
charts for determining the loads that can be han-
en
REAR DRUM
2. Release the drum lock by pushing the front, rear LOCK KNOB
and third hoist drum lock knob.
y
If not, move the switch to the NEUTRAL BRAKE Push
MODE.
nl (1 inch)
Failure to observe this precaution may result in se-
25 mm
rious injury or loss of life.
O
3. According to working condition, adjust the maximum
speed of the drum with the drum speed adjusting
knob.
ce
THIRD DRUM SPEED
ADJUSTING KNOB
en
y
raising side, then move to the lowering side again.
(3) STOPPING
When the drum control lever is returned to the neu-
nl
tral position, the automatic brake operates to stop
the load.
O
When returning the control lever to neutral, ensure that
the lever is surely returned to neutral position.
ce
THIRD DRUM
CONTROL LEVER
en
(OPTION) Lowering
THIRD DRUM BRAKE PEDAL
(OPTION)
Raising Lowering
REAR DRUM BRAKE PEDAL
er
Raising
ef
FRONT DRUM
FRONT DRUM BRAKE SELECT
CONTROL LEVER SWITCH
R
REAR DRUM
REAR DRUM BRAKE SELECT
CONTROL LEVER SWITCH
When the load is held in the air for a long time, engage
the drum lock.
To engage the drum lock, fully pull the knob up.
The pulling resistance may vary but pull it fully. Raising
Lowerin
y
nl
Even in case of neutral brake, engage the pedal
lock of the brake pedal.
O
In case of the brake with combination of brake pedal,
neutral brake mode does not function.
Whenever auto-stop occurs during hook raising or low-
ce
ering, immediately return the control lever to neutral.
When the lifting load is to be held in the air for long time,
engage the drum lock.
completely.
Although pull up resistance may change on its half way,
pull up to the end.
ef
G winch control
G winch is a function to realize maximum line speed
with low engine speed at no load condition. Control as
per the following procedure.
y
(1) Turn ON the G winch main switch on the upper area
nl
of the cab back face.
ON
After machine judges low idle and lever neutral con- * The symbol area lights up
dition, the yellow lamp in the monitor lights up. when the head light is turns on.
O
OFF
ce
G WINCH MODE INDICATING LAMP
en
60%
70%
80% MPH
90%
100%
m/ s
PO
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4 m i n- 1
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/12/01 258
/%
10:0
er
&
0
ef
y
Work condition of G winch individual select switch.
G WINCH MAIN SWITCH
(A) G winch main switch is ON.
OFF ON
nl
(B) Engine is low idling condition.
(C) There is no lifting load.
(D) The post processing unit is not in the soot burning
(regenerate) condition.
O
(Soot burning - regenerate lamp is OFF)
(E) The control lever is in neutral position. Yellow Yellow
(F) When condition (A) to (E) are met, push either front
drum or rear drum individual select switch.
When “individual select” is effective.
ce
The monitor symbol shown on right figure turns ON.
FRONT DRUM REAR DRUM
a: Front drum is in G winch mode
(a side: green light ON)
b: Rear drum is in G winch mode
(b side: green light ON)
en
y
switch] is missed before lever control, normal mode
is resumed.
nl
O
In the lowering control, initial speed may become slow-
er in certain times. This is caused by function of the
counterbalance valve and is not abnormal.
In case that the front and rear drum speed adjust knob
are not in maximum position, maximum speed cannot
ce
be obtained even under this function. Ensure to set
them to maximum position.
G ENGINE control
G ENGINE is a function to obtain maximum line speed
under no load with maximum engine speed being re-
stricted.
y
Under G ENGINE condition, enough energy for heavy
load work with high speed may not be obtained. Ensure
nl
to turn to power mode.
O
back face to ON side. ON㧔G ENGINE㧕
Green lamp in the main monitor lights up after lever * The symbol area lights up
when the head light is turns on.
neutral is detected.
ce
OFF㧔POWER MODE㧕
MPH
PO
KP
4 m i n- 1
1 2010
/12/01 258
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/%&
0
ef
R
y
Crane work with FREE FALL side may drop the load
by operation error.
nl
1. Set the “Free Fall Lock Switch” (with key in the left
side stand) to the “Release” position.
O
2. Set the control lever to the neutral position, and with
the brake pedal depressed fully, push the brake se-
lector switch at once.
The free fall indicator lamp in the monitor lights up
to indicate that the brake is in the free fall condition.
ce
At this condition, press the brake pedal at its heel
portion to disengage the pedal lock and gradually
release the brake pedal.
The lifting load starts lowering.
en
LOCK
RELEASE
RELEASE
ENGAGE
(PEDAL LOCK)
THIRD DRUM
BRAKE PEDAL
(OPTION)
FRONT DRUM
BRAKE PEDAL Pedal lock can be disengaged
by pressing the pedal heel portion.
REAR DRUM
BRAKE PEDAL
y
FRONT DRUM
nl
FRONT DRUM BRAKE SELECT
CONTROL LEVER SWITCH
REAR DRUM
REAR DRUM BRAKE SELECT
CONTROL LEVER SWITCH
O
ce
3. Free fall
RELEASE ENGAGE
(3) Slowly release the brake pedal to free fall the buck-
et.
(4) Lowering speed is adjusted by adjusting pressure
to the brake pedal.
er
PEDAL LOCK
ef
4. Raising
Pulling the drum control lever backward, raising is
possible even while the brake pedal remains de-
pressed.
6. Stopping
y
Depress the brake pedal, and return the drum con-
trol lever to the NEUTRAL position.
The drum is stopped.
nl
When the pressing amount is small, the brake ped-
al reacts with “knocking”.
Increase the pressing amount.
When the load is held in the air for a long time,
O
press the drum brake select switch again to turn
into the NEUTRAL BRAKE mode and engage the
drum lock.
Ensure that the free fall indication lamp goes out.
ce
When the control lever is returned to neutral, the lifting
load starts free falling.
en
In case of empty hook, if the free fall speed select FREE FALL SPEED
switch is turned to speed increase side, lowering speed INCREASE SELECT SWITCH
is increased. HIGH
y
In case of free-falling the heavy load, do not use free fall
speed select switch.
nl
A shock occurs at speed changing.
With the free falling, if auto-stop occurs due to load
safety device or over-hoist preventive device, press the
brake pedal first and then return the control lever to
O
neutral position.
If the control lever is return to neutral before pressing
the brake pedal, the lifting load may be dropped.
Take extra care on this.
Failure to observe these precautions may result in seri-
ce
ous accident.
en
er
ef
R
y
7. Switching from “FREE FALL MODE” to “BRAKE
MODE”
While the “FREE FALL MODE” is selected, set the
nl
drum control lever to the NEUTRAL position, and
fully depress the brake pedal.
Push the brake selector switch on the control lever
again.
O
The free fall indicator lamp in the monitor goes out
to indicate that the “BRAKE MODE” is selected.
y
the message indication disappeared.
If the messages as shown right are still indicated even
nl
if the engine has been restarted, stop the operation and
contact our designated service shop.
O
When the error message is indicated, do not stop
the engine with the sling load and hook held in the
air.
ce
If failed to observe this caution, the sling load or the
hook may fall.
en
er
ef
R
y
to the hoist drum or boom, pin wear or missing or loos-
ening bolts or missing occur.
Ensure to make pre-work or post work inspection sure-
nl
ly.
O
(FRONT DRUM)
(FRONT DRUM)
HOLDING ROPE DRUM SPEED
ADJUSTING KNOB (REAR DRUM)
ef
R
y
nl
O
ce
HOLDING ROPE
CLOSING ROPE
en
er
ef
In case of heavy load clamshell work, if the work mode WORK MODE
SELECT ICON
select icon is in “OFF” position, opening and closing
rope may not be able to synchronize.
y
nl
O
ce
en
er
ef
R
y
cating lamps. DRUM BRAKE PEDAL
HOLDING ROPE
DRUM BRAKE PEDAL
8. Adjust the engine speed with the accel grip.
nl
9. In case the clamshell work load safety device and
rated load is specified, load safety device will func-
O
tion.
DRUM BRAKE
SELECT SWITCH
ce
Take extra care not to cause overload in the clamshell
Depresses
work. Set the load about 60% to 70% of the clamshell (Pedal lock)
work rated load.
(Work at about 60% to 70% of the wire rope rated load.)
Do not shut off the load safety device at the clamshell
en
work.
Work with the overload condition may cause damage or
serious accident such as overturn of to the main ma-
chinery or boom. PEDAL LOCK
er
Setting example
Attachment type Clamshell
Boom length 18.3 m (60 ft)
Self removal
On Barge Clamshell mode
y
nl
A
O
Select [60 feet].
90 feet
100 feet
110 feet
120 feet
er
OK
Changed to green.
y
nl
OK
O
(5) Push [OK].
Setting is completed.
OK
er
ef
R
y
nl
CONTROL LEVER AND BRAKE PEDAL OPERATION IN CLAMSHELL WORK
O
Work Control condition
No. drum Front drum Rear drum drum
condition and Caution
control brake lever control lever brake
lever pedal
* Pedal Neutral Control the holding wire rope
Digging
ce
1 Hoist released (Free Half brake by rear drum brake and adjust
material
(Return) condition) the bucket bite.
Raise both closing wire rope
* Pedal * Pedal
and holding wire rope together
2 Hoist Hoist released Hoist released
to control not to allow one side
(Return) (Return)
en
loosening.
3 Stop Neutral Pedal pressed Neutral Pedal pressed Stop bucket raising motion.
4 Swing - - - -
* Pedal While swinging, release mate-
Releasing
5 Neutral released Neutral Pedal pressed rial and open bucket and keep
material
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(Return) opening.
Move bucket to digging posi-
6 Swing - - - -
tion by swinging.
Lowering (Half brake) (Half brake)
Lower bucket with half brake.
ef
2. Remove the lock bolt from the drum flange and lock
the bolt with nut.
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TAGLINE TENSION
ADJUST TRIMMER
nl
When starting the engine, ensure to turn the tagline CLAMP
tension adjust knob to minimum (turn left) and then
start the engine. MOTOR
FLANGE
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LOCK BOLT
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4. Set the other end of the wire rope to the bucket via
the guide sheave.
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or slackened when starting or stopping the engine.
Failure to observe this precaution may result in se-
nl
rious injuries or loss of life.
O
adjusting knob somewhat to the higher setting,
while tensioning the wire rope.
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When the tagline rope is slack, the winding motion
suddenly starts by operating the tension adjusting
switch. Keep clear of the drum and tag line rope.
Make sure to turn the adjusting switch to the weak-
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Winding speed decrease. (Flow decrease)
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Winding speed increase. (Flow increase)
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speed side).
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When not using the tagline:
Fully wind up the wire rope on the drum, and fix the wire
rope end.
Set the tension adjusting knob to the lowest setting (ful-
ly turn to the left).
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SPECIFICATION
HYD. Tagline
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Total load = (Hook weight + Pile weight + Vibro hammer weight + Centrifugal force [Vibration force] of vibro ham-
mer x 1/4)
nl
(2) Use of Lifting Wire Rope
Place a lifting wire rope in a way that vibration start-
ing force of the vibro hammer is not transmitted di-
rectly to the hook.
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2. CAUTIONS WHEN WORKING
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Do not turn the free fall speed select switch to speed in
crease side in vibro hammer work.
Otherwise the hoist rope may cause rough spooling.
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in the air (idling).
nl
In pile extracting work by the vibro hammer, while
checking the pile with the vibro and raising the load
O
to the extent that the machine rear is lifted up in-
tended to extract the pile with the machine lowering
reaction may lead to severe impact to the various
portion of the machine and serious accident.
Never operate such overload work in the vibro
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work.
Failure to observe this precaution may result in se-
rious accident.
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Check for looseness or missing of the counter-
weight nuts once every 5 months.
nl
O
The warranty does not cover any damage to the equip-
ment caused by failure to follow operating instructions
and cautions described above.
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to serious accident such as overturn of the ma-
chine.
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Strictly observe the following precautions to pre-
vent accident.
Failure to observe these precautions may lead to
serious accident, injuries or loss of life.
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1. INFLUENCE OF WIND
Influence of the wind on the machine becomes larg-
er in proportion to the size of a lifted load, lifting
ce
height, and boom length.
The following conditions are very dangerous, so ut-
most care is necessary for operation.
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ceeds 22 MPH stop the work.
nl
3. METHOD OF WIND SPEED MEASUREMENT
(1) If an instantaneous anemometer is provided in the
machine, measure the wind speed with the ane-
WORKING
mometer provided. POINT
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OF WIND
POINT
OF WIND
HEIGHT ABOVE
GROUND
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Height Wind speed 3 m/s (6.7 MPH) Wind speed 5 m/s (11.2 MPH) Wind speed 8 m/s (17.9 MPH) Wind speed 10 m/s (22.4 MPH)
above
Flat area City area Flat area City area Flat area City area Flat area City area
ground :
m (ft) Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst.
2.7 9.8 2.5 10.0 4.5 11.7 4.2 11.4 7.1 14.5 6.7 14.0 8.9 16.3 8.4 15.8
5 (17)
(6.0) (21.9) (5.6) (22.4) (10.0) (26.2) (9.4) (25.5) (15.9) (32.4) (15.0) (31.3) (19.9) (36.5) (18.8) (35.3)
3.0 10.2 3.0 10.2 5.0 12.3 5.0 12.3 8.0 15.4 8.0 15.4 10.0 17.5 10.0 17.5
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10 (33)
(6.7) (22.8) (6.7) (22.8) (11.2) (27.5) (11.2) (27.5) (17.9) (34.4) (17.9) (34.4) (22.4) (39.1) (22.4) (39.1)
3.2 10.4 3.3 10.5 5.4 12.7 5.6 12.9 8.6 16.0 8.9 16.3 10.7 18.2 11.1 18.7
15 (50)
(7.2) (23.3) (7.4) (23.5) (12.1) (28.4) (12.5) (28.9) (19.2) (35.8) (19.9) (36.5) (23.9) (40.7) (24.8) (41.8)
nl
3.4 10.5 3.6 10.8 5.6 12.9 6.0 13.3 9.0 16.5 9.5 17.0 11.2 18.8 11.9 19.5
20 (66)
(7.6) (23.5) (8.0) (24.2) (12.5) (28.9) (13.4) (29.8) (20.1) (36.9) (21.3) (38.0) (25.0) (42.1) (26.6) (43.6)
3.5 10.7 3.8 11.0 5.9 13.2 6.3 13.6 9.4 16.9 10.1 17.6 11.7 19.3 12.6 20.2
25 (82)
(7.8) (23.9) (8.5) (24.6) (13.2) (29.5) (14.1) (30.4) (21.0) (37.8) (22.6) (39.4) (26.2) (43.2) (28.2) (45.2)
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3.6 10.8 4.0 11.2 6.0 13.3 6.6 13.9 9.6 17.1 10.6 18.1 12.0 19.6 13.2 20.9
30 (99)
(8.0) (24.2) (8.9) (25.0) (13.4) (29.8) (14.8) (31.1) (21.5) (38.3) (23.7) (40.5) (26.8) (43.8) (29.5) (46.8)
3.8 11.0 4.2 11.5 6.3 13.6 7.1 14.5 10.1 17.6 11.3 18.9 12.6 20.2 14.1 21.8
40 (132)
(8.5) (24.6) (9.4) (25.7) (14.1) (30.4) (15.9) (32.4) (22.6) (39.4) (25.3) (42.3) (28.2) (45.2) (31.5) (48.8)
3.9 11.1 4.5 11.7 6.6 13.9 7.5 14.9 10.5 18.0 12.0 19.6 13.1 20.8 15.0 22.8
50 (164)
(8.7) (24.8) (10.0) (26.2) (14.8) (31.1) (16.8) (33.3) (23.5) (40.3) (26.8) (43.8) (29.3) (46.5) (33.6) (51.0)
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4.2 11.4 5.0 12.2 7.0 14.4 8.3 15.7 11.2 18.8 13.2 20.9 14.0 21.7 16.5 24.8
75 (260)
(9.4) (25.5) (11.2) (27.3) (15.7) (32.2) (18.6) (35.1) (25.0) (42.1) (29.5) (46.8) (31.3) (48.5) (36.9) (55.5)
4.4 11.6 5.3 12.6 7.4 14.8 8.9 16.3 11.8 19.4 14.2 21.9 14.7 22.4 17.8 26.7
100 (328)
(9.8) (25.9) (11.9) (28.2) (16.6) (33.1) (19.9) (36.5) (26.4) (43.4) (31.8) (49.0) (32.9) (50.1) (39.8) (59.7)
en
Note 1: Wind speed may be higher than the above value near tall buildings.
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R
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Larger tree branches moving, whistling in wires, hard to walk under an um-
10.8 (24.2) to less than 13.9 (31.1)
brella.
nl
13.9 (31.1) to less than 17.2 (38.5) Whole trees moving, resistance felt walking against wind.
17.2 (38.5) to less than 20.8 (46.5) Twigs broken, cannot walk against wind.
20.8 (46.5) to less than 24.5 (54.8) Slight structural damage occurs, chimney broken, slate blows off roofs.
Seldom experienced on land, trees broken or uprooted,
O
24.5 (54.8) to less than 28.5 (63.8)
and considerable structural damage.
28.5 (63.8) to less than 32.7 (73.1) Scarcely experienced, damages occur in wide areas.
32.7 (73.1) or more
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1. Lower the load on the ground and remove it from
the hook.
nl
2. Set the boom angle to approx. 60 degrees.
3. Swing the machine to receive the wind at the coun-
terweight side.
(Receive the wind at the back face of the boom.)
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4. Lock the winch and swing brake and stop the en-
gine.
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Approx.
60 degrees
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(4) Connect the hook to the anchor weight and apply
tension the hoist rope.
(5) Lock the winch and swing brake and stop the en-
nl
gine. Approx.
60 degrees ANCHOR WEIGHT
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CRANE ANCHOR WEIGHT
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Boom length Boom angle Anchor weight
m (ft) (degrees) t (lbs)
12.2
-
(40)
15.2 to 27.4 0.9
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ANCHOR WEIGHT (WITH JIB)
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Anchor weight
Jib length Boom length Boom angle t (lbs)
m (ft) m (ft) (degrees) Offset angle Offset angle
10 degrees 30 degrees
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24.4 to 36.6 1.8 1.3
(80 to 120) (4,000) (2,900)
9.1 and 12.2 39.6 to 45.7 2.8 2.2
(30 and 40) (130 to 150) (6,200) (4,900)
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48.8 to 51.8 4.8 3.7
60
(160 to 170) (10,600) (8,200)
24.4 to 42.7 2.4 1.6
15.2 and 18.3 (80 to 140) (5,300) (3,600)
(50 and 60) 45.7 to 51.8 4.8 3.2
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5. Lock the winch and swing brake and stop the engine.
JIB OFFSET
ANGLE
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Approx.
60 degrees
CRANE
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67
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60 BOOM LENGTH
12.2 m to 18.3 m
(40 ft to 60 ft)
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WIND SPEED (MPH)
50 BOOM LENGTH
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21.3 m to 27.4 m
(70 ft to 90 ft)
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40
BOOM LENGTH
30.5 m to 36.6 m
(100 ft to 120 ft)
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BOOM LENGTH
30 39.6 m to 54.9 m
(130 ft to 180 ft)
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BOOM LENGTH
57.9 m to 61.0 m
(190 ft to 200 ft)
20
60 65 70 75 80
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WITH 9.1 m (30 ft) JIB and 12.2 m (40 ft) JIB
67
60
BOOM LENGTH
24.4 m to 36.6 m
(80 ft to 120 ft)
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WIND SPEED (MPH)
50
O
40
BOOM LENGTH
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39.6 m to 45.7 m
(130 ft to 150 ft)
BOOM LENGTH
30 48.8 m to 51.8 m
(160 ft to 170 ft)
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20
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60 65 70 75 80
WITH 15.2 m (50 ft) JIB and 18.3 m (60 ft) JIB
67
60
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BOOM LENGTH
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24.4 m to 42.7 m
WIND SPEED (MPH)
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40
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BOOM LENGTH
45.7 m to 51.8 m
30 (150 ft to 170 ft)
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20
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60 65 70 75 80
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• Power supply cut to general homes and factory.
• Power supply cut to hospital affecting life of pa-
nl
tients.
• Affect to the traffics such as power cut to the
traffic signal etc.
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These may cause secondary accident.
Whenever crane work is to be done near the power
line, strictly observe the following precautions and
to prevent such accident.
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Failure to observe these precautions may result in
serious injuries.
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3. If coming close to the power line is unavoidable, ad-
vise the power company and obtain the protective
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insulated tube to prevent electric shock.
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machine holding a part of machine.
Operator would be electrocuted by getting off the
machine holding a part of machine.
nl
(3) Should someone be injured, immediately take
emergency treatment such as artificial respiration
or heart massage.
(4) If the power line is cut, do not allow any person to
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come close to the hanging power lines.
(5) Inspect the machine (specially on load safety de-
vice) for proper function before reuse.
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antenna and may be charged with electricity and the
high voltage may be induced at the end of the hook and
nl
may be heated.
Touching the hook may cause burns due to the electric
shock or heat.
The computer installed on the machine may loose prop-
O
er function. Take extra care in operating the machine.
Failure to observe these precautions may result in seri-
ous injuries or loss of life.
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PREVENTIVE MEASURE
1. Use insulating gloves.
2. Connect the grounding wire to the hook.
3. Wrap around the hook with insulating materials.
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(1) Stop the work and lower the lifting load on the
ground.
If the boom can be lowered, lower it on the ground.
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(2) Engage the brake/lock (hoist, swing) and stop the
engine and turn the key to OFF.
nl
(3) Get away from the machine and surrounding area.
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points:
(1) Is there any burning out or damage?
(2) Do all the electrical devices or load safety devices
work properly?
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(3) Does each function work properly?
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en materials.
3. Inspect the following points when re-starting the ma-
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chine.
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(3) Function of the machine.
vices and are controlled with the controller and are dis- Hook overhoist preventive device
(ޓCrane, aux. sheave, jib)
played with the monitor to prevent damage to the crane
Boom overhoist preventive device
or luffing tower due to overload, overhoist or to prevent (ޓBoom, tower)
overturning of crane. Ensure to use this device to oper-
ate the crane safely and inspect and maintain the de-
vice periodically.
If the device becomes failed, repair immediately before
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re-starting the work.
nl
• The load safety device is important to operate the
crane safely. Make sure that the device works prop-
erly and use this device surely during work.
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• If the load safety device is used improperly, re-
leased in undue way, or maintenance and repair
being neglected, machine may be damaged or may
face with serious accident such as turnover.
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• The load safety device is important device to work
in safe manner. Even if the load safety device func-
tions correctly, wind influence, ground collapsing or
incorrect adjustment of device may cause machine
damage or turnover.
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wire or boom limit striker and angle sensor of angle
of the load safety device since they are pre-adjust-
ed. The release master key must be kept following
nl
the instruction of work control person.
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HOOK OVERHOIST
RELEASE SWITCH
BOOM OVERHOIST
RELEASE SWITCH
LOAD SAFETY DEVICE
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RELEASE SWITCH
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10 . 0 POKP
0 m i n- 1 258 /%&
BATTERY LAMP
ELECTRIC OIL COOLER
WORK INDICATING LAMP
4 1 INCHING SPEED LAMP
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REAR DRUM FREE FALL
101.3
Use. INDICATION LAMP
Use. FRONT DRUM FREE FALL
100 INDICATION LAMP
30 . 0
nl
POUNDS
*1000 THIRD DRUM FREE FALL
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SOOT ACCUMULATION GAUGE
40 . 3 FUEL GAUGE
HYD. OIL TEMP. GAUGE
/'07
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WORK MODE SELECT ICON
ASSY / DISASSY ICON
BOOM / JIB LOWERING ICON
HYD. OIL HEAT CIRCUIT SELECT ICON
CAMERA SELECT ICON (OPTION)
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DIMMER ICON
MENU ICON
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MAIN CONTROLLER 1
BYPASS SWITCH
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RELEASE SWITCH
MASTER KEY
FREE FALL LOCK SWITCH
CRANE
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HOOK OVERHOIST
LIMIT SWITCH (8)
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JUNCTION CABLE (11)
(FOR HOOK OVERHOIST LIMIT SWITCH)
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CABLE REEL (12) (FOR CRANE)
BOOM ANGLE DETECTOR (3)
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MONITOR
(LOAD SAFETY DEVICE) (1)
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nl
JUNCTION PANEL (4)
(FOR ATTACHMENT CABLE)
FIXED JIB
HOOK OVERHOIST
LIMIT SWITCH (8)
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FIXED JIB ANGLE DETECTOR (3)
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AUXILIARY SHEAVE
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HOOK OVERHOIST
LIMIT SWITCH (8)
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HOOK OVERHOIST
RELEASE SWITCH
BOOM OVERHOIST
RELEASE SWITCH
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LOAD SAFETY DEVICE
RELEASE SWITCH
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LIMIT SWITCH
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CRANE
MACHINE
FRONT
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G ENGINE INDICATING LAMP G WINCH INDICATING LAMP
nl
(OPTION)
REMOTE CONTROL
CONNECTION LAMP
5 . 0 MPH
60% 70% 80% 90% 100%
10 . 0 0 m i n- 1 258 /%&
BATTERY LAMP
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POKP
ELECTRIC OIL COOLER
WORK INDICATING LAMP
4 1 INCHING SPEED LAMP
REAR DRUM FREE FALL
101.3
Use. INDICATION LAMP
Use. FRONT DRUM FREE FALL
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100 INDICATION LAMP
30 . 0 POUNDS
*1000 THIRD DRUM FREE FALL
/'07
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DIMMER ICON
MENU ICON
Crane
CLAMP
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ROPE SOCKET
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LINK
LOAD
DETECTOR
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BOOM HOIST DRUM
This device detects the angle of boom and jib. GUIDE MARK
(To be directed to boom, jib tip.)
gle detector to the boom, jib base after removing it for CONNECTOR
maintenance etc., the mark should be directed to the WATER
PROOF CAP
boom, jib tip. CABLE
able.
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GUIDE MARK
(To be directed to
boom, jib tip.)
From boom
angle detector.
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nl
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CABLE JUNCTION BOX (5)
This is the junction box for detector and limit switch.
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FOR CRANE BOOM TOP
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LIMIT SWITCH
STRIKER
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LIMIT SWITCH SIDE HARNESS SIDE
3P 3P
nl
O
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LIMIT SWITCH
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JUNCTION
CONNECTOR
nl
HARNESS SIDE LIMIT SWITCH SIDE
3P 3P
WIRE
O
MAIN HOOK (BOOM) BOOM, JIB, AUX. SHEAVE
AUX. HOOK (JIB) WEIGHT
AUX.HOOK (AUX. SHEAVE)
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RELEASE SWITCH (9)
This switch release auto-stop function.
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(Refer to P.3-68)
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HOOK OVERHOIST
RELEASE SWITCH
BOOM OVERHOIST
RELEASE SWITCH
LOAD SAFETY DEVICE
RELEASE SWITCH
CONNECTOR CONNECTOR
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CABLE
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WATER PROOF CAP WATER PROOF CAP
O
CABLE REEL (12) CABLE REEL
This is to wind up various cables.
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STOPPER
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• Load ratio higher than 100%: Red lamp light up
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Load ratio is less than 90% O
Load ratio ranges from 90 to 100% O O
Load ratio is 100% or more O O
O
Hook overhoist O
Boom overhoist (crane) O
Tower overhoist O
Tower jib overhoist O
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Tower jib over-lowering O O
Assembly configuration
O
(at assembly and disassembly)
While the overload release switch is actuated O O
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ROTATING TYPE
failed.
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LOAD SAFETY DEVICE
switch, indication, warning or auto-stop does not BYPASS CONFIGURATION
SELECT SWITCH
work.
nl
(Auto-stop function by overhoist preventive device
works.)
Repair or replace the controller immediately.
O
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MAIN KEY
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figuration can release each auto-stop function.
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JIB: Select when the luffing configuration is to be se-
lected. (Not used.) CONFIGURATION
SELECT SWITCH CR
CR: Select when the crane configuration is to be select-
ed.
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On this model, use the machine with this switch turning
to “CR” position.
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MAIN MACHINERY
CONTROLLER
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LOAD DETECTOR
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CABLE REEL
O
BOOM OVERHOIST LIMIT SWITCH
(FINAL STOP) MAIN HOOK OVERHOIST
LIMIT SWITCH
AUX. HOOK OVERHOIST
MONITOR LIMIT SWITCH
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5 . 0 MPH
60% 70% 80% 90% 100%
10 . 0 POKP
0 m i n- 1 258 /%&
38 . 0 POUNDS
*1000
/'07
RELEASE SWITCH
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2. CONNECTING PROCEDURE
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Before connecting the connectors, make sure that no
water remains in the connectors section of the connec-
nl
tor.
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(2) Connect the removed caps together.
(3) After disconnecting, install the cap securely.
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Overload preventive device may not work correctly if
water enters into connectors.
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CONTROLLER (1)
(C) (D), (E)
(B)
(A) (F)
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BOOM BASE
ANGLE DETECTOR
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CN-1062
CN-1061
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CABLE REEL
CN-1001 CN-1005 CN-1007
CN-1016
ATTACHMENT JUNCTION BOX
CN-1019 CN-1018
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CABLE REEL
CN-1027 CN-1042 CN-1043
BLOCK DIAGRAM
HANGER
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=#?
O
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JUNCTION PANEL
CABLE
To attachment
junction panel (4)
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WATER PROOF CAP
nl
To attachment
junction panel (4)
O
WATER PROOF CAP Connect to shortening cap
(Connect cap to cap.) installed on reel frame.
3P
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LIMIT SWITCH
(FOR AUX. SHEAVE)
nl
In case without the aux. sheave
MAIN HOOK OVERHOIST (A) Connect cable from the reel to junction box.
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LIMIT SWITCH WATER PROOF CAP (3P) (B) Connect the main hook limit switch connector.
(B)
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THIMBLE
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(A)
WATER PROOF CAP (3P)
MAIN HOOK OVERHOIST (A) Connect cable from the reel to junction box.
LIMIT SWITCH (B) Connect the main hook limit switch connector.
(MAIN) (C) Connect the aux. hook limit switch connector.
WATER PROOF CAP (3P)
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(B)
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THIMBLE
To To
junction box junction box
Connect to lower
angle detector.
To boom base
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cable reel
To main hook
overhoist limit switch
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VIEW FROM A ANGLE DETECTOR
HOOK OVERHOIST
LIMIT SWITCH
O
HOOK OVERHOIST
CABLE REEL (12) LIMIT SWITCH CABLE
A
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BOOM TOP SIDE BOOM BASE SIDE
3P 3P Hang thimble
on hook.
Connect conector.
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Connect connector.
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HOOK OVERHOIST
LIMIT SWITCH (8)
To jib foot
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5 . 0 MPH
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10 . 0 ft POKP
0 m i n- 1 258 /%&
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
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Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
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40 . 3 ft
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/'07
Classification of operation
Setting item Operation after changing
Daily operation Operation at initial erection
attachment
(1) Setting of crane configu-
X O O
ration
(2) Selection of main/aux.
O O
lifting
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(3) Setting of working area
limit value
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O: Necessary X: Unnecessary : If necessary
O
by stopping the engine and turning the power off, reset-
ting is not required.
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1. TURNING POWER ON
When the key switch is set to the ON position, pow-
er is automatically supplied to the monitor. If power
is not supplied to the monitor, check the fuse.
When power is supplied to the monitor, the follow-
ing screen is displayed on the monitor as follows.
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nl
Carefully read operator’ s manual
before operate the machine.
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1 Crane Boom 7 13
2 STD. 8 14
3 9 16 Use
1
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4
4 STD. Boom 10 17 Use
2 1
5 11 90 feet 18
would be required.
Push [A] icon and start re-setting referring to 3.5.1
SETTING OF CRANE CONFIGURATION.
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2. SCREEN EXAMPLE
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1 4
4 STD. Boom 10 17 Use
2 1
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5 11 90 feet 18
Boom type
6 STD. Weight 12 Aux. sheave
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Weight type
ft ft
deg deg
deg deg
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ft ft
POUNDS
x 1000
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POUNDS
x 1000
5 . 0 MPH
10 . 0 POKP
0 m i n- 1
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4 1
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101.3
Use.
Use.
100
30 . 0 POUNDS
*1000
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38 . 0 POUNDS
*1000
70 . 0 GHJ
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40 . 3
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MONITOR
LOAD RATIO WIND SPEED (OPTION)
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REAR DRUM
4 1 (No. of part line)
101.3 ft
Use. AUX. HOOK
POINT HEIGHT
Use. MAIN HOOK
100 ft
R
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000 ACTUAL LOAD
WORK RADIUS
LOAD SAFETY DEVICE INDICATION AREA
y
ANGLE INDICATION For fixed jib, indicate Indicate selected jib length.
selected angle. (Only for tower with fixed jib)
10 deg 40 feet
nl
POINT HEIGHT FRONT DRUM
INDICATION NO. OF PART LINE
Indicate boom or jib point Indicate input No. of front
height by 0.1 ft unit.
101.3 ft 4 hook rope No. part line.
O
WORK RADIUS REAR DRM
INDICATION NO. OF PART LINE Indicate input No. of rear
Indicate work radius by 0.1 ft
unit. hook rope part line.
40.3 ft 1
ce
ACTUAL LOAD MAIN HOOK
Indicate actual load by 0.1 klbs Indicate selected type of
unit. main hook.
30.0 POUNDS
*1000 Use
30.0 ft
ef
R
LOAD RATION Load ratio indication area lamp lights up from left
to right in order as load ratio increase.
INDICATION AREA
(Example)
y
Less than 60 %
nl
76 %
From 90 % to 100 %
O
105 %
ce
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R
y
1. SETTING PROCEDURE
nl
ed.
Menu screen is now indicated.
O
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
ce
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
40 . 3 ft
en
er
ef
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
R
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
40 . 3 ft
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
y
70 . 0 FGI
40 . 3 ft
nl
B
O
(3) After this, select items according to the screen in-
struction.
Selection items are type of attachment, boom
length, type of jib, jib offset angle, with/without aux.
ce
sheave, main hook/aux. hook and number of wire
rope part line.
en
er
ef
R
LUFFING
* BOOM ONLY COUNTERWEIGHT
or (WITHOUT HOOK) (VERTICAL 2)
TOWER
y
WITH AUX. SHEAVE COUNTERWEIGHT
HL CRANE
(WITH HOOK) (VERTICAL 1)
nl
*WITH AUX. SHEAVE
COUNTERWEIGHT
HL LUFFING (VERTICAL 2)
(WITHOUT HOOK)
CRAWLER RET.
O
FIXED JIB FULL COUNTERWEIGHT
SHL CRANE WITHOUT
(WITH HOOK)
CARBODY WEIGHT
* * ADD. COUNTERWEIGHT
CLAM SHELL JIB OFFSET ANGLE WITHOUT
CARBODY WEIGHT
*
en
ADD. COUNTERWEIGHT
DRAG LINE JIB LENGTH TWO
CARBODY WEIGHT
* FULL COUNTERWEIGHT
FLOATING CRANE BOOM LENGTH WITHOUT
CARBODY WEIGHT
er
SELF REMOVAL
* BOOM TOP
*
FULL COUNTERWEIGHT
(BOOM BASE) (STD) ONE
CARBODY WEIGHT
ef
* WITHOUT
HOOK 1 TOWER CRANE
COUNTERWEIGHT
y
DOUBLE DRUM
FRONT DRUM
WITHOUT MAST CONTROL
IN USE
THIRD DRUM
nl
REAR DRUM SELF REMOVAL MAST CONTROL (2)
IN USE (SHL MAST)
O
THIRD DRUM WITH SELF REMOVAL
IN USE POINT SHEAVE (CBWT)
WITHOUT
* SELF REMOVAL
SINGLE DRUM
ce
POINT SHEAVE (CWT PILE UP)
CLAM SHELL
ALARM
(NO SIDE WAY PULL)
er
WITH CRAWLER
HOOK POCKET FULL EXT.
ef
WITHOUT CRAWLER
HOOK POCKET MID EXT.
R
COUNTERWEIGHT
* FIXED JIB
(VERTICAL 4) CRANE
FULL COUNTERWEIGHT
ONE LUFFING CRANE
CARBODY WEIGHT
3. SETTING EXAMPLE
y
(1) Attachment select screen becomes indicated.
Select [C].
nl
Choose the mode of working or assembly.
O
Crane Boom Fixed Jib
Self removal
Clamshell C mode
ce
en
OPTION
With Without Without
carbody weight carbody weight carbody weight
y
nl
(4) Aux. sheave select screen becomes indicated.
O
Select [Aux. sheave].
y
nl
(6) Aux. hook select screen becomes indicated.
O
Select [Use.].
(A) Push [0] in the front drum number of part line set-
ting.
y
nl
O
OK
OK
ef
R
(C) Push [0] in the rear drum number of part line setting.
y
nl
OK
O
ce
en
OK
er
ef
R
y
nl
OK
O
(F) Data is searched.
ce
en
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Crane Boom
STD.
[a]
y
Use
nl
[b]
90 feet
A
STD. Weight Aux. sheave
O
ce
In case the selection is limited to only one choice, select
screen is neglected and only result is indicated.
(In the screen example, they are [a] to [b].)
en
er
ef
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SETTING CONFIRMATION
When all select and input are completed, the screen re-
turns automatically to main screen.
y
nl
There is no applicable data.
Push SET icon.
O
If error occurs, after all settings are completed. Corre-
sponding data reading starts by the monitor.
ce
If corresponding data is in correct, an error message
will be displayed and a buzzer sounds. Push [SET] icon
and reset.
Check for equipped attachment and start resetting.
en
If the data in the data card cannot be read out, the fol-
lowing screen will be displayed.
Contact the Manitowoc authorized service shop.
er
y
Push figure of actually used hook for work.
Selected hook is indicated brightly and non selected
nl
hook is indicated semi transparently.
O
101.3 Use.
Use.
101.3 Use.
Use.
100 100
POUNDS POUNDS
*1000 *1000
ce
POUNDS POUNDS
*1000 *1000
FGI FGI
40 . 3 40 . 3
en
y
When only stop point is set, pre-notice would be issued
on the specified point. (See table below)
When the boom comes closer to the pre-notice point,
nl
intermittent sound is issued and continuous sound is is-
sued to the stop point.
Operation toward danger side is auto-stopped.
As for intermittent and continuous sound are issued
O
only when operated toward danger side. Even when
the machine reaches to each limit value, the operation
lever is in neutral position (or toward safe side) sound
is not issued. With this setting, boom contacting acci-
dent due to careless mistake during work can be pre-
ce
vented.
1. SETTING
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
y
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
nl
70 . 0 FGI
40 . 3 ft
O
ce
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
en
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
40 . 3 ft
er
ef
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10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
y
40 . 3 ft
nl
F
O
(The screen example is crane case.)
Push the figure area if new setting is required.
ce
en
er
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R
y
nl
(4) SETTING METHOD
O
(Ex.) In case of boom upper limit angle
(Pre-notice point) setting
MESSAGE CODE
2 . 0 MPH
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
y
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
nl
70 . 0 FGI
40 . 3 ft
O
YELLOW INDICATION AREA
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
en
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
er
70 . 0 FGI
40 . 3 ft
ef
REVERSE INDICATION
y
Pushing the [BACK] icon returns the screen to the pre-
vious one and restart is possible.
nl
If this function is not used
If for each [0.0] is displayed, the item's limit function is
OFF.
Therefore set each item as [0.0] if the item function is
O
not to be used.
Place the cursor on [0.0] required item and push [CLR]
icon to indicate [0.0].
Then push [OK] icon.
ce
en
er
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y
This device assists the contact prevention from ob-
stacle and not to provide automatic stop function
without load swinging under any swing operation or
nl
swing speed.
Ensure to stop operation with your own operation
before reaching left (or right) limit position taking in-
dication and warning into account.
O
Since the crane may overrun the left (or right) limit
position by its inertia, set the limit position with
some allowance.
ce
Make sure to reduce the swing speed in order to
prevent the accident by attachment damage when
the left (or right) limit position comes closer.
Failure to observe this precaution may result in se-
en
rious accident.
POKP
0 m i n- 1
ef
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2. INDICATION AREA
GREEN
RIGHT LIMIT POSITION SET ICON
This icon is used to set the right
limit position.
YELLOW YELLOW
y
This is used to indicate swing limit
RED setting area on a circle.
GREEN…..Swing possible area.
YELLOW…Pre notice area
nl
RED….......Alarming (stop) area
O
L+S...Indication, alarming and stop
S.....Indication and alarming
D.....Indication only
3. MODE
The following three modes are provided in this de-
en
sound is issued.
In the yellow color area, intermittent sound pitch be-
comes higher as machine comes closer to red area
(danger side).
y
GREEN
nl
YELLOW YELLOW
O
RED
ce
L+S area turns to red.
en
y
Green color all around since the area
is not yet set and hatching indication
since the “limit” is not effective.
nl
GREEN
O
ce
(B) Swing the crane to the place just before the obsta-
cle on the left side and stop and push the icon
[LEFT LIMIT POSITION SET].
Since the crane may overrun the limit position by its
inertia, set the limit position with some allowance.
en
Push
YELLOW
ef
RED
R
GREEN GREEN
(C) Swing the crane to the place just before the obsta-
cle on the right side and stop and push the icon
[RIGHT LIMIT POSITION SET].
The crane figure swings to right. Push [RIGHT LIM-
IT POSITION SET] icon after stop.
The swing area is set. When the position setting
has to be adjusted more exactly after [RIGHT LIMIT
POSITION SET] icon is once pushed, swing to the
exact position and again push [RIGHT LIMIT POSI-
TION SET] icon.
Red and yellow indication area is renewed.
y
To determine the swing area, it is surely needed to set
nl
both sides.
In case there is no obstacle on the right side, swing the
crane far enough to the position where automatic stop
does not disturb crane work and push [RIGHT LIMIT
O
POSITION SET].
Push
ce
GREEN GREEN
YELLOW
YELLOW
RED YELLOW
en
RED
GREEN
er
ef
R
GREEN
YELLOW YELLOW
y
RED
nl
The hatching on the [SET] icon
on the circle disappears and
a clear indication appears.
O
Push
ce
With the hatching indication just after engine start,
limit function does not work and swing motion is
en
free.
If the limit function is necessary, ensure to set the
limit area.
Failure to observe this precaution may result in se-
rious accident.
er
(A) [SET] icon and the circle with hatching are indicat-
ed.
GREEN
YELLOW YELLOW
y
RED
nl
O
(B) If resetting of set area is not necessary, push [SET]
icon.
[SET] icon and hatching on the circle disappear and
ce
setting is completed.
YELLOW
YELLOW
RED
y
nl
O
(B) To set again, push [RESET] icon. The screen re-
turns to the one shown right. Set again based on
new setting procedure (P.3-54).
ce
If the crane propels, positional relation with the obstacle
changes. GREEN
Ensure to set again.
en
y
5. FUNCTION
Function of L+S mode is explained here as an ex-
nl
ample.
(1) Figure below shows that the crane is in safe area af-
ter setting limit area.
O
ce GREEN
YELLOW YELLOW
RED
en
er
ef
R
y
sound becomes higher pitch as the crane comes
closer to red color area.
Intermittent warning area is 10 degrees.
nl
GREEN
O
YELLOW YELLOW
RED
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GREEN
YELLOW YELLOW
y
RED
nl
O
(5) After swing motion stops, swing left to returns the
crane to safe area (green area immediately.
ce
GREEN
YELLOW YELLOW
en
RED
er
ef
y
frame angle.
If the error becomes large, adjustment is neces-
sary.
nl
Contact Manitowoc service shop.
O
indication on its right lower part of the screen.
0 m i n- 1
ce
POKP
en
er
ef
2. INDICATOR
y
nl
Inclination on front-rear direction
Front lower...Minus figure
Rear lower...Plus figure
O
The above figure indicates example of condition
that right rear part is lower.
Either front or rear indication exceeds ±0.5 de-
grees, warning is indicated.
This function issues only indication and the crane
ce
will not stop.
Check the crane condition and push [OK] button.
Warning indication disappears.
en
POKP
0 m i n- 1
11000100000500010200
2010/12/0110:00
WARNING
er
ef
R
y
nl
O
ce
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CRANE
Indication, Stop
y
Color change in indicator Buzzer
Hazardous Code
Boom Load Actual Rated Work Back- display Overload Overhoist Auto-
conditions Hook Boom stop
angle ratio load load radius stop warning warning
**
nl
buzzer buzzer
(1) (2) (3) (4) (5) (6) (7) (8)
Load ration
- Yellow - - - - - - ME024 Intermittent - -
more than 90%
Load ration
- Red - - - - Red - ME005 Continuous - Stop
more than 100%
O
Main hook overhoist - - - - - Red - - ME017 - Continuous Stop
*
Aux. hook overhoist - - - - - Red - - ME017 - Continuous Stop
*
Boom overhoist Red - - - - - Red - ME008 - Continuous Stop
*
Boom overhoist
Red - - - Red - Red Red ME021 - Continuous Stop
(Limit)
ce
Boom overhoist
Red - - - Red - Red Red ME060 - Continuous Stop
(Backstop No.2)
Boom overlowering Red - --- 0.0 Red - Red - ME007 Continuous - Stop
** See P.3-89.
(2)
er
10 . 0 ft
(7)
4 1
ef
101.3 ft
Use.
(8)
Use.
(6)
100 ft
30 . 0 POUNDS
*1000 (3)
38 . 0 POUNDS
R
*1000 (4)
70 . 0 FGI
40 . 3 ft (1)
(5)
1. IN CASE OF CRANE
(1) Overload
y
nl
Hook raise
O
Boom lower
ce
(2) Hook overhoist
Boom over-lowering
Hook raise
en
er
Boom lower
ef
y
Normally when boom overhoist occurs, controller func-
nl
tions to stop automatically. If auto-stop function is being
released and operated, the final stop limit switch control
becomes actuated and machine auto-stops.
In this case, auto-stop cannot be released.
O
ce
en
er
ef
R
y
Never use the auto stop releasing switch other than
for maintenance purpose to avoid serious accident.
nl
Failure to observe this precaution may result in se-
rous accident.
O
1. AUTO-STOP RELEASING SWITCH
ce LEFT SIDE PANEL
en
HOOK OVERHOIST
RELEASE SWITCH
er
BOOM OVERHOIST
RELEASE SWITCH
LOAD SAFETY DEVICE
RELEASE SWITCH
ef
R
y
The key can be pulled out at [LOCK] position.
Auto-stop release function by the release switch Lock Release
nl
does not work at [LOCK] position and works only at
[RELEASE] position.
O
Follow the instruction of work controller for the release
master key control during work.
AUTO
RETURN
er
ef
LMI
RELEASE
RELEASE SWITCH
R
AUTO
RETURN
y
nl
RELEASE
RELEASE SWITCH
O
(4) HOOK OVERHOIST RELEASE SWITCH
This switch can release auto-stop function when
hook overhoist occurs.
By turning the switch to [RELEASE] side, auto-stop
can be released.
ce
When auto-stop function is to be released, hold the
AUTO
switch to release side with hand.
en
RETURN
When hand is freed, switch returns to neutral and auto
stop function resumes.
er
RELEASE
When the auto-stop function is to be released, ensure
to use the corresponding release switch.
RELEASE SWITCH
Using the other release switch can not release the re-
quired function.
ef
R
y
MASSAGE
ther, return the control lever to neutral once and ME007
Stop
push [Assy/disassy] icon for one time (1 second).
nl
Then the crane turns to Assy/disassy mode and
auto-stop due to hook overhoist is released and
boom lowering becomes possible.
O
Push [Assy/disassy] icon or [Boom/Jib] lowering icon
for more than 1 second.
Push Stop release
ce
MASSAGE
ME017
en
Stop
er
y
becomes only boom angle indication and caution
message indication.
nl
After assembly/disassembly work is completed and
boom is to be erected, push [Assy/disassy] icon
once again. Then the crane turns to work mode.
If the boom is erected without changing to work
O
mode, crane is turned to work mode automatically
when the boom angle exceed about 15 degrees (for
tower 40 degrees).
Therefore when the boom is erected, crane does
not turn to Assy/disassy mode even pushing the
ce
icon. Assy/disassy mode is canceled when the
power supply is cut.
Therefore ensure to push [Assy/disassy] icon again
whenever power is turned ON.
en
y
work configuration.
nl
When the machine becomes transportation mode,
the monitor of the load safety device displays mes-
sage requesting weight installation, detector con-
nection and angle display.
O
Under the transportation mode, front drum, rear
drum winch third drum become auto-stop condition
for both raising and lowering motion and only boom
drum becomes functional for raising and lowering.
ce
Machine can move to other mode either by lowering
boom angle to work mode range shown in “4.
AUTO-STOP RELEASING AT BOOM ASSEMBLY
OF DISASSEMBLY WORK” or by installing the re-
quired counterweight and connecting the detector.
en
tector.
R
3.10 INSPECTION
3.10.1 INSPECTION PROCEDURE WHEN BOOM IS RAISED AFTER ATTACHMENT ASSEMBLY WORK IS
COMPLETED
After attachment assembly work is completed, check
the function of safety related device and make sure that
there is no abnormality before raising the boom.
At checking work, limit switch may have already actuat-
ed. Pull the limit switch once and set it to safety condi-
tion and then inspect as follows.
y
CRANE ATTACHMENT
nl
O
BOOM OVERHOIST LIMIT SWITCH
(BOOM FOOT) HOOK OVERHOIST LIMIT SWITCH
ce
(MAIN HOOK) HOOK OVERHOIST LIMIT SWITCH
(AUX. HOOK)
ME021
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
ef
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
R
*1000
70 . 0 FGI
40 . 3 ft
ME017
y
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
nl
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
O
40 . 3 ft
ce
INSPECTION OF AUX. HOOK OVERHOIST LIMIT
SWITCH
Lift up the limit switch weight rope and check that the
hook figure in the display turns to red color and the
en
ME017
er
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
4 1
ef
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
R
40 . 3 ft
y
nl
O
ce
en
er
ef
R
10 . 0 ft POKP
0 m i n- 1
y
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
nl
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 FGI
O
ce 40 . 3 ft
G
en
10 . 0 ft POKP
0 m i n- 1
11000100000500010200
er
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
ef
*1000
70 . 0 FGI
40 . 3 ft
R
ME056
10 . 0 ft POKP
0 m i n- 1 56
ME056
11000100000500010200
2010/12/01 10:00
4 1
101.3 ft
Use.
Use.
100 ft
30 . 0 POUNDS
*1000
38 . 0 POUNDS
y
*1000
70 . 0 FGI
nl
40 . 3 ft
/'07
O
Check to see that hook raising or boom lowering can
not be done.
y
3. STATIC ELECTRICITY INTERFERENCE
If the monitor surface is rubbed strongly with dry ny-
nl
lon cloth etc. static electricity may be generated.
This static electricity has harmful effect to the mon-
itor function. Do not rub strongly.
O
ce
en
er
ef
R
y
nl
The table contains all the error codes.
There are some error codes which would not be
displayed depending on the model.
O
Code Message
P0045 VNT actuator failure.
P0047 VNT solenoid valve 1 low voltage
ce
P0048 VNT solenoid valve 1 high voltage
P0049 Turbo charger revolution overrun
P0087 Common rail pressure control failure.
P0088 Common rail pressure control failure.
P0096 Intake air temperature sensor (intake manifold) - rationality
en
P0097 Intake air temperature sensor (intake manifold) - out of range (Out of range low)
P0098 Intake air temperature sensor (intake manifold) - out of range (Out of range high)
P00AF VNT actuator failure.
P0102 Air-flow sensor failure (Low)
er
P0113 Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range high)
P0117 Engine coolant temperature sensor - rationality
P0118 Engine coolant temperature sensor - out of range (Out of range low)
P0122 Intake throttle valve-opening sensor 1 out of range (Out of range low)
R
P0123 Intake throttle valve position sensor 1 - out of range (Out of range high)
P0182 Fuel Temp. sensor failure (Low)
P0183 Fuel Temp. sensor failure (High)
P0187 Fuel Temp. sensor failure (Low)
P0188 Fuel Temp. sensor failure (High)
P0191 Common rail pressure sensor malfunction
P0192 Common rail pressure sensor (main) - out of range (Out of range low)
P0193 Common rail pressure sensor (main) - out of range (Out of range high)
P0197 Common rail pressure sensor (aux.) - out of range (Out of range low)
P0198 Common rail pressure sensor (aux.) - out of range (Out of range high)
P0200 Engine ECU failure.
Code Message
P0201 Fuel injector - disconnection (#1cyl)
P0202 Fuel injector - disconnection (#2cyl)
P0203 Fuel injector - disconnection (#3cyl)
P0204 Fuel injector - disconnection (#4cyl)
P0205 Fuel injector - disconnection (#5cyl)
P0206 Fuel injector - disconnection (#6cyl)
P0217 Overheat
P0219 Engine overrun
P0234 Turbocharger over boost
y
P0237 Boost pressure sensor - out of range (Out of range low)
P0263 Correction quantity of cylinders #1 error
nl
P0266 Correction quantity of cylinders #2 error
P0269 Correction quantity of cylinders #3 error
P0272 Correction quantity of cylinders #4 error
P0275 Correction quantity of cylinders #5 error
O
P0278 Correction quantity of cylinders #6 error
P0335 Crankshaft position sensor - disconnection
P0336 Crankshaft position sensor - rationality
P0340 Camshaft position sensor - disconnection
ce
P0341 Camshaft position sensor - rationality
P0401 EGR low flow
P0402 EGR high flow
P0404 EGR valve 1 stick
P0405 EGR lift sensor 1 circuit low input
en
Code Message
P0704 Clutch switch malfunction
P0850 Neutral switch malfunction
P1062 VNT solenoid valve 2 low voltage
P1063 VNT solenoid valve 2 high voltage
P1067 VNT solenoid valve 3 low voltage
P1068 VNT solenoid valve 3 high voltage
P1071 Turbo speed sensor failure (High)
P1072 Turbo speed sensor failure (Low)
P1132 Acceleration sensor circuit low voltage
y
P1133 Acceleration sensor circuit high voltage
P1142 Throttle control low voltage
nl
P1143 Throttle control high voltage
P119F Common rail pressure sensor - rationality
P1211 Fuel injector driver circuit 1 - circuit (Circuit low)
P1212 Fuel injector driver circuit 1 - circuit (Circuit high)
O
P1214 Fuel injector driver circuit 2 - circuit (Circuit low)
P1215 Fuel injector driver circuit 2 - circuit (Circuit high)
P1229 Excessive supply pump pressure
P1266 Insufficient Supply pump pressure
ce
P1401 EGR valve 2 stick
P1402 EGR solenoid 2 malfunction
P1403 EGR solenoid 2 malfunction
P1407 EGR solenoid 3 malfunction
P1408 EGR solenoid 3 malfunction
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Code Message
P2228 Barometric pressure sensor - out of range (out of range low)
P2229 Barometric pressure sensor - out of range (out of range high)
P244A DPF pressure difference (Low)
P244B DPF pressure difference (High)
P2458 DPF manual regeneration error
P2463 DPF regeneration operation error
P24A2 DPF fuel additive quantity too much
P2633 Fuel pump Magnetic valve2 failure (OPEN/GND short circuit)
P2634 Fuel pump Magnetic valve2 failure (+B short circuit)
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P2635 Fuel Pump A" Low Flow/Performance "
U0073 CAN Communication error (Engine)
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U1001 CAN communication error.(Mechatronics controller , Diag CAN)
U110A CAN communication disrupt (Mechatronics controller)
U1122 Communication error (EGR)
U1123 Communication error (VNT)
O
ME034 Crane configuration setting is wrong.
ME035 A moment real load exceeds minimum value.
ME036 The malfunction of the load cell for the boom(1).
ME037 The malfunction of the load cell for the boom(2).
ME038 The malfunction of the load cell for the jib(1).
ce
ME039 The malfunction of the load cell for the jib(2).
ME044 The malfunction of the boom base angle sensor.
ME045 The malfunction of the boom tip angle sensor.
ME046 The malfunction of the mast angle sensor.
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ME090 Time out error of synchronizing check during the MC2 start-up process.
ME092 Error No.1 of ML internal setting values abnormality. (Optional item setting)
ME093 Error No.2 of ML internal setting values abnormality. (Crane data)
ME094 Error No.3 of ML internal setting values abnormality. (Manufacturer adjustment data)
ME095 Error No.4 of ML internal setting values abnormality. (Temporary adjustment data)
ME096 Error No.5 of ML internal setting values abnormality. (Crane operation data)
ME097 Error No.6 of ML internal setting values abnormality. (Data for each case)
ME099 Error No.8 of ML internal setting values abnormality. (Failure history data)
ME100 Writing error of optional item setting.
ME101 Writing error of crane data.
Code Message
ME102 Writing error of manufacturer adjustment data.
ME103 Writing error of temporary adjustment data.
ME104 Writing error of crane operation data.
ME105 Writing error of the data of each case.
ME107 Writing error of failure history data.
ME108 Error of the MC crane model number unmatched.
ME109 Error of the MC optional item setting unmatched.
ME110 Communication error between touch panel monitor.
ME111 Time out error of MC1 & MC2 adjustment response.
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ME112 CAN communication error with MC1.
ME113 CAN communication error with MC2.
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ME114 CAN communication sending error with MC1 & MC2.
ME115 Error No.9 of ML internal setting values abnormality. (Failure history data of MC1)
ME116 Error No.10 of ML internal setting values abnormality. (Failure history data of MC2)
ME117 Writing error of failure history data for MC1.
O
ME118 Writing error of failure history data for MC2.
ME119 Error No.11 of ML internal setting values abnormality. (Operator identification ID and/or password)
ME120 Error No.12 of ML internal setting values abnormality. (WORKING AREA LIMIT values)
ME121 Access error to NOR flash memory in ML. Setting values can not be written.
ce
ME122 MC1 & MC2 reset is detected.
ME123 Writing error of system information for MC1 or MC2.
ME124 Writing error of optional item setting for MC1 or MC2.
ME125 Writing error of adjustment data for MC1 or MC2.
ME126 Writing error of crane operation data for MC1 or MC2.
en
Code Message
MC1-A21 Fr. drum clutch pressure sensor
MC1-A22 3rd. drum clutch pressure sensor
MC1-A23 Re. drum clutch pressure sensor
MC1-D01 Main pump power control proportional valve
MC1-D02 Boom pump power control proportional valve
MC1-D03 Swing speed control
MC1-D04 Swing reaction proportional valve
MC1-D05 Boom pump control proportional valve
MC1-D06 Fr. electromagnetic detent
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MC1-D07 Re. electromagnetic detent
MC1-D08 Main pump control proportional valve 1
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MC1-D09 Main pump control proportional valve 2
MC1-D10 Tagline proportional valve
MC1-D11 Left swing proportional valve
MC1-D12 Right swing proportional valve
O
MC1-C01 Fr. drum clutch CLM
MC1-C02 Fr. drum clutch ESM
MC1-C03 Re. drum clutch CLA
MC1-C04 Re. drum clutch ESA
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MC1-C05 3rd. drum clutch CLT
MC1-C06 3rd. drum clutch EST
MC1-C07 Not use
MC1-C08 Swing parking brake
MC1-C09 Adjustment mode
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Code Message
MC1-C32 E/G stop relay
MC1-C33 Swing voice alarm (not used)
MC1-C34 Re. / 3rd. drum change
MC1-C35 Not use
MC1-C36 3rd. drum turn detection grip
MC1-H01 Not use
MC1-H02 OVERLOAD AUTO STOP IS BEING RELEASED
MC1-H03 FLASH MEMORY DATA FAILURE
MC1-H04 MC ADJUSTMENT IS IRRELEVANT
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MC1-H05 RECEIVING ERROR FROM ML
MC1-H06 RECEIVING ERROR FROM MC2
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MC1-H07 Not use
MC1-H08 SYSTEM INFORMATION ABNORMAL (E10-4)
MC1-H09 OPTIONAL ITEM SETTING ABNORMAL 1 (E10-1)
MC1-H10 OPTIONAL ITEM SETTING ABNORMAL 2 (E10-2)
O
MC1-H11 OPTIONAL ITEM SETTING ABNORMAL 3 (E10-3)
MC1-H12 ADJUSTMENT DATA ABNORMAL (E10-5)
MC1-H13 CRANE OPERATION DATA ABNORMAL (E10-6)
MC1-H14 ERROR OF THE DISTINGUISHING SIGNAL BETWEEN MC1 AND MC2. (E10-7)
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MC1-H15 ERROR OF PREVIOUS MC1 OR MC2 START-UP MODE DISCREPANCY. (E10-8)
MC2-A01 Not use A/D
MC2-A02 Not use A/D
MC2-A03 Fr. motor pressure sensor
MC2-A04 Re. motor pressure sensor
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Code Message
MC2-D05 Re. drum hoisting speed control
MC2-D06 Re. drum lowering speed control
MC2-D07 3rd. drum hoisting speed control
MC2-D08 3rd drum lowering speed control
MC2-D09 Constant horse power
MC2-D10 Fr. drum motor control
MC2-D11 Re. drum motor control
MC2-D12 3rd drum motor control
MC2-C01 Not use
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MC2-C02 Not use
MC2-C03 Not use
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MC2-C04 Not use
MC2-C05 not use
MC2-C06 not use
MC2-C07 Not use
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MC2-C08 Not use
MC2-C09 Not use
MC2-C10 Not use
MC2-C11 Not use
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MC2-C12 Not use
MC2-C13 Not use
MC2-C14 Not use
MC2-C15 Fr. drum motor boost
MC2-C16 Oil cooler motor
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Code Message
MC2-H04 MC ADJUSTMENT IS IRRELEVANT
MC2-H05 RECEIVING ERROR FROM ML
MC2-H06 RECEIVING ERROR FROM MC1
MC2-H07 Not use
MC2-H08 SYSTEM INFORMATION ABNORMAL (E10-4)
MC2-H09 OPTIONAL ITEM SETTING ABNORMAL 1 (E10-1)
MC2-H10 OPTIONAL ITEM SETTING ABNORMAL 2 (E10-2)
MC2-H11 OPTIONAL ITEM SETTING ABNORMAL 3 (E10-3)
MC2-H12 ADJUSTMENT DATA ABNORMAL (E10-5)
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MC2-H13 CRANE OPERATION DATA ABNORMAL (E10-6)
MC2-H14 ERROR OF THE DISTINGUISHING SIGNAL BETWEEN MC1 AND MC2. (E10-7)
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MC2-H15 ERROR OF PREVIOUS MC1 OR MC2 START-UP MODE DISCREPANCY. (E10-8)
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When the angle detector is replaced, adjustment of the
load safety device becomes necessary. Contact
Manitowoc service shop for replacement or adjustment.
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Normally error is indicated by its code. By pushing the
indicated code area, detail can be indicated.
ME044
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10 . 0 POKP
0 m i n- 1 Touch the
error code area.
4 1
101.3
er
Use.
Use.
100
30 . 0 POUNDS
*1000
38 . 0 POUNDS
*1000
70 . 0 GHJ
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The table includes all codes.
There are no some codes which are not displayed
based on models.
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Code Message Condition, Action
The message is displayed when the engine cooling water tem-
MC1-W01 ENGINE PREHEAT
perature is 0 degrees or less with the key switch turned ON.
The message is displayed for 5 seconds after the operation is
MC1-W02 PREHEAT COMPLETED
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complete.
The charging circuit is malfunctioned. Consult with your
nearest Manitowoc authorized dealer.
MC1-W03 CHARGING PROBLEM
* Note: That it is not fault even this item is momentarily
displayed immediately after the engine is started.
en
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MC1-W14 If this item frequently appears during normal operations, con-
TEMPERATURE
sult with your nearest Manitowoc authorized dealer. At the
same time, inform the Manitowoc service of the details of the
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operation (lifting load, free fall distance, speed, and duration).
The winch cooling line filter is clogged. Replace the filter
cartridge.
MC1-W15 WINCH FILTER CLOGGED This item may appear during cold weather even when the filter
O
is not clogged. If the item disappear during warm-up, the
cartridge does not need to be replaced.
The front drum clutch emergency system is actuated. The free
fall of the front drum cannot be normally performed. Place a
load and the hook onto the ground, and turn the key switch to
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FRONT SAFETY ESM SOLENOID
MC1-W16 the OFF position.
VALVE IS ENERGIZED
Then, consult your nearest Manitowoc authorized dealer.
DO NOT operate the key switch with a load or the hook hung
in the air, since it may cause drop of the load or the hook.
The rear drum clutch emergency system is actuated. The free
en
in the air, since it may cause drop of the load or the hook.
The 3rd drum clutch emergency system is actuated. The free
fall of the front drum cannot be normally performed. Place a
load and the hook onto the ground, and turn the key switch to
3RD SAFETY EST SOLENOID VALVE
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FRONT DRUM NEGA BRAKE Front drum nega brake function may be abnormal.
MC2-W31
ABNORMAL Contact Manitowoc service shop.
REAR DRUM NEGA BRAKE Rear drum nega brake function may be abnormal.
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MC2-W32
ABNORMAL Contact Manitowoc service shop.
3RD. DRUM NEGA BRAKE 3rd. drum nega brake function may be abnormal.
MC2-W33
ABNORMAL Contact Manitowoc service shop.
Battery relay contact may be adhered.
O
MC1-W35 BATTERY RELAY ABNORMAL Inspect battery relay.
Replace if the deposited at the contact point of the relay.
Propel lever is kept ON. Pilot pressure is cut.
MC1-W36 PROPEL LEVER INTERLOCKED
Return propel lever back to neutral.
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Front drum is stopped since front drum lever is kept ON.
MC2-W37 FRONT DRUM LEVER INTERLOCKED
Return front drum lever back to neutral.
Rear drum is stopped since rear drum lever is kept ON.
MC2-W38 REAR DRUM LEVER INTERLOCKED
Return rear drum lever back to neutral.
3rd. drum is stopped since 3rd. drum lever is kept ON.
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MC1-W45 MC1, 2 INCHING SPEED SELECT Inching speed select signal differs on each MC.
MC2-W45 SIGNAL ABNORMAL Contact Manitowoc service shop.
Qmax cut solenoid relay contact is adhered at energize side.
Qmax CUT SOL OUTPUT OFF The engine revolution will be restricted not to raising the max-
R
MC1-W46
ABNORMAL imum revolution.
Contact Manitowoc service shop.
Qmax cut solenoid relay is not functioned.
Qmax CUT SOL OUTPUT ON The engine revolution will be restricted not to raising the max-
MC1-W47
ABNORMAL imum revolution.
Contact Manitowoc service shop.
Either front or rear winch motor is running over speed or en-
ACTUAL ROTATION IS HIGHER THAN
MC1-W48 gine speed is over.
NO LOAD ROTATION
Contact Manitowoc service shop.
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service shop.
Back up fuse (F-4) of each controller is blown off.
MC1-W51 BACK UP FUSE BLOWN OUT
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Replace with new one.
MC2 detects hook overhoist.
MC2-W52 HOOK OVERHOIST LS Check ML or hook overhoist signal and then contact
Manitowoc service shop.
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MC2 detects boom overhoist.
MC2-W53 BOOM OVERHOIST LS Check ML or boom overhoist signal and then contact
Manitowoc service shop.
MC2 detects jib overhoist.
MC2-W54 JIB OVERHOIST LS Check ML or jib overhoist signal and then contact Manitowoc
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service shop.
MC2 detects boom backstop No.1 overhoist.
MC2-W55 BOOM BACKSTOP No.1 LS Check ML or boom backstop No.1 overhoist signal and then
contact Manitowoc service shop.
MC2 detects boom backstop No.2 overhoist.
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MC2-W56 BOOM BACKSTOP No.2 LS Check ML or boom backstop No.2 overhoist signal and then
contact Manitowoc service shop.
ME001 Out of working angle. Out of capacity set range.
Hook over hoist release switch is
ME002 The hook overhoist automatic stop release switch is actuated.
operating.
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Detecting limit switch for high gantry The gantry is not raised for mast raising.
ME020
position has not been turned on. Raise the gantry.
The boom overhoist limit switch is actuated.
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ME021 Boom over hoist.
Lower the boom.
The jib overhoist limit switch is actuated.
ME022 Jib over hoist.
Lower the jib
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ME024 Overload precautions. Loading ratio is 90% or more.
Reached the load limitation value of Lifting load exceeds the lifting load limit value set by operator.
ME025
WORKING AREA LIMIT function. Lower the load or raise the jib or boom.
Reached 90% of the load limitation val- Lifting load exceeds 90% of the lifting load limit value set by
ME026
ue of WORKING AREA LIMIT function. operator.
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Boom angle reached upper limitation The boom reaches the boom angle upper limit point (stop
ME027 value of WORKING AREA LIMIT point) set by operator.
function. Lower the boom.
Boom angle reached lower limitation The boom reaches the boom angle lower limit point (stop
ME028 value of WORKING AREA LIMIT point) set by operator.
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ME030 by operator.
of WORKING AREA LIMIT function.
Raise the jib.
The boom reaches the working radius limit point (stop point)
Working radius reached limitation value
ME031 set by operator.
of WORKING AREA LIMIT function.
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detecting signal. proper counterweight selecting in the attachment setting.
ML crane configuration does not The input signal from the carbody weight detector does not
ME064 correspond to the carbody weight match the data. Check the counterweight detector or check for
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detecting signal. proper counterweight selecting in the attachment setting.
The jib connecting pin is not pulled out at lowering of maximum
Danger! The jib tip touches at the
ME066 tower length.
ground.
Pull out the pin. (Only 7200G)
O
Boom winch wire rope is abnormally
ME067 Loose the boom hoist rope before operate the mast.
tightened.
The front drum over pay out preventive device is actuated.
ME081 Front winch over pay out
Operate the front drum toward wind up direction.
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The rear drum over pay out preventive device is actuated.
ME082 Rear winch over pay out
Operate the rear drum toward wind up direction.
The third drum over pay out preventive device is actuated.
ME083 Third winch over pay out
Operate the third drum toward wind up direction.
Counterweights detection is not completed.
ME088 Connect the weight
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2. CHECK OF WORK RADIUS INDICATION
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(1) Lift a load weight which is exactly known in advance.
(2) Check if the load (lifting load + hook weight + sling
wire weight) matches exactly with the load indica-
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tion value.
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Counterweight
Attachment
ton (lbs) Crawler Crawler
Forward Backward
extend retract
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(Without)
8.31 (18,320) (No abrupt
Without attachment (No.1) lever control)
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(Base machine only) 19.81 (43,674) (No abrupt
(No.1 to No.2) lever control)
31.31 (69,028)
(No.1 to No.3)
0
(Without)
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8.31 (18,320)
With boom base (No.1)
(Boom angle
19.81 (43,674)
: 10 degrees or less (No.1 to No.2)
31.31 (69,028)
(No.1 to No.3)
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0
(Without)
8.31 (18,320)
With basic boom (No.1)
(Boom angle
: 30 degrees or less) 19.81 (43,674) (Slope:7 deg.
(No.1 to No.2) or less)
31.31 (69,028) (No abrupt (No abrupt
en
Propel motor
Traveling backward
Counterweight
Attachment
ton (lbs) Crawler Crawler
Forward Backward
extend retract
0
(Without) ۑ ۑ ۑ ۑ
8.31 (18,320)
ۑ ۑ ۑ ۑ
Without attachment (No.1)
(Base machine only) 19.81 (43,674) (Slope:8 deg.
(No.1 to No.2) ۑ or less) ۑ
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31.31 (69,028) (No abrupt (No abrupt
(No.1 to No.3) lever control) lever control)
0
ۑ ۑ ۑ ۑ
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(Without)
8.31 (18,320)
With boom base (No.1) ۑ ۑ ۑ ۑ
(Boom angle
19.81 (43,674) (Slope:12 deg.
: 10 degrees or less (No.1 to No.2) ۑ or less) ۑ
31.31 (69,028) (No abrupt (No abrupt
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(No.1 to No.3)
lever control) lever control)
0
(Without) ۑ ۑ ۑ ۑ
8.31 (18,320)
With basic boom (No.1) ۑ ۑ ۑ ۑ
(Boom angle
: 30 degrees or less) 19.81 (43,674) ۑ (No abrupt ۑ ۑ
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(No.1 to No.2) lever control)
31.31 (69,028) (Slope:3 deg.
(No.1 to No.3) ۑ or less) ۑ
: Able to be operated
: Able to be operated with conditions
: Unable to be operated
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Propel motor
Traveling backward
y
when aligning the holes or inserting/removing the
pins.
Failure to observe these precautions may result in
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serious injuries or loss of life.
O
The main machinery assembly place may receive a
large load. Place strong steel plates on the ground.
Provide enough capacity of an assisting crane,
sling rope or shackle to be used.
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Failure to observe these precautions may result in
serious accident.
2. SECURING PLACE
R
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4. CAUTIONS DURING ASSEMBLY WORK
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• During assembly work, install the waterproof cap on
the cable end of the hook over-hoist preventing de-
vice.
O
During crane work, wire the over-hoist cable prop-
erly and remove the waterproof cap.
• Refer to “8.2 DIMENSION, WEIGHT OF EACH
COMPONENT” for weight, dimension during as-
sembly.
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• The operator has to be informed if any person
moved to out of sight from the operator or at haz-
ardous location when equipment or machine part
moves.
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OPERATION
(1) Remove the lock pins and rotate the exhaust cover
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toward outer side before starting engine.
(2) Secure the exhaust cover with the lock pins.
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(3) Reverse order to put the cover back when transpor-
tation.
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(Rear side) (Front side)
A B
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WORKING TRANSPORTATION
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PIN
PIN
R
LOCK PIN
LOCK PIN
SECTION A SECTION B
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Watch your head when walking/moving on the platform.
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WIDTH OF THE MACHINE
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1,639 mm (5’ 5” ) 1,495 mm (4’ 11” )
(From center of the machine.) (From center of the machine.)
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WORKING TRANSPORTATION
y
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Do not raise the boom to higher than 10 degrees an-
gle when loading into trailer.
Main machinery may overturn backward.
Failure to observe this precaution may result in se-
O
rious injury or loss of life.
ce
Do not swing the upper machinery on the trailer to
prevent overturn of the main machinery.
Gravity center position may change suddenly on
the border of trailer and the loading plates.
Take constant and inching speed for propel to pre-
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• Without counterweight
• Boom.........Boom base
• Boom angle......approx. 10 degrees
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Prior to extending or retracting work, clean the axle ex-
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tension completely and apply grease (Molybdenum di-
sulfide grease) to the insertion area.
If the mud is adhered to, extension or retraction work
would not be done smoothly.
O
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with steel plates placed.
Extend the crawlers with all the counterweight, carbody
weight removed.
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PLATE “M”
PIN “L”
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(2) Pull out the pin “S” which secure the axle extension
and the crawler frame.
RETAINING
Remove the retaining pin before pulling the pin “S” PIN CRAWLER
out. FRAME
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(4 pieces on right and left)
en
PIN “S”
LOWER AXLE
ROLLER EXTENSION
(3) Turn all four axle extensions for 90 degrees toward AXLE
outside to make them parallel to the axles.
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Insert the pin “S” into the crawler frame bracket hole
and secure it with the retaining pin.
CRAWLER
RETAINING PIN FRAME
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PIN “S”
AXLE
EXTENSION
BRACKET “T”
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BRACKET “T”
(Note for
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bracket direction.)
BRACKET “T”
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crawler and the axle.
CRAWLER FRAME
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SHIM
AXLE
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EXTENDING EXTENDING
EXTENDING SIDE
CRAWLER
EXT.
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NEUTRAL
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CRAWLER
RET.
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(9) After extending the crawler for approx. 400 mm (1'
PIN “L”
4") (Ref: ext/ret stroke is 815 mm (2' 8")), stop the
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crawler ext/ret switch once and place the pin “L” on
PLATE “M”
extending/retracting side on the link.
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PIN “L”
LOCK PIN
RETAINING PIN
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LOCK PIN
PIN “L”
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CRAWLER FRAME
R
SHIM
AXLE
CAB STEP
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STOWED
CONDITION
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(M10)
EXTENDED
CONDITION
FIXING PIN
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CAB STEP
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ADJUSTING BOLT
EXTENSION
1. Remove the fixing pin and lift up the outer end of the
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STOWED
3. Secure one side of each step with the fixing pin to CONDITION
EXTENDED
CONDITION
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Ensure to perform the gantry raising work with the
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boom placed on the wooden block of approx. 100 mm
(4") in height.
Take extra care on slack or tension of the boom hoist
wire rope.
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1. Place the boom base on the block.
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Do not lower the boom base tip to the level lower
than ground level. Otherwise some components
may be damaged with the boom or the backstop,
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winch valve.
Approx. 100 mm (4” )
(1) Pull out the pin “W” fixing the travel kit and remove
the travel kit from the upper frame.
(Pin “W” is fixed with the spring pins.)
(2) Start the engine and set the speed to
approx. 1000 min-1.
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TRAVEL KIT
(OPTION)
O PIN “W”
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SPRING PIN
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NEUTRAL
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DOWN
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(4) When the gantry comes to WORK position, insert
the pin “W” into the travel kit and fix it to the stopper.
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Never raise the gantry using the boom hoist wire rope
or using the assisting crane. SPRING
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PIN
Otherwise the gantry raise cylinder would be damaged. PIN “W”
STOPPER
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(5) Insert the pin “Y” into the gantry and retain with the
spring pins.
SPRING PIN
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PIN “Y”
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PIN “Y”
STOWED POSITION
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(6) Wind up the wire rope slowly until the slack is taken
up.
In this case, wind up the wire rope to the drum neat-
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rious accident.
SPRING PIN
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CONNECTING PIN
(With flange)
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2. Raise the boom base until the lower pin holes are
aligned with each other. Then tap the connecting
pins (double tapered pin) in, and insert the spring
pins into the both ends of the connecting pin.
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SPRING PIN
SPRING PIN
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CONNECTING PIN
(Double tapered pin)
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R
y
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Stowing position
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SPLIT PIN
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Insert the
pin from
inner side.
Insert the
pin from
er
inner side.
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BASIC GUY LINE
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1. Prepare the hook, overhoist limit switch, weight and
socket, etc. to be used near the tip end of the boom.
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2. Turn the front drum control lever to the lowering
side to feed out the wire rope to the tip end of the HOIST WIRE ROPE
boom and pass it through the right idler sheave and
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IDLER SHEAVE
pass it to the right of the boom point.
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LIMIT SWITCH
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SHACKLE
WIRE ROPE
R
WEIGHT
IDLER SHEAVE
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BOOM POINT
SHEAVE
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AUX. SHEAVE
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8 Parts HOOK SHEAVE 7 Parts 6 Parts
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en
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Open the split pin to
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approx. 60 degrees.
ROPE SOCKET
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(A) Secure the junction cables or limit switch wiring to
the boom with the hanger.
(B) Connect the attachment wiring to the main machin- LOAD
DETECTOR
ery junction panel.
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(C) Check the connection of load detector connector.
(boom hoist winch plate area)
(D) Connect the cable reel wiring to the boom tip junc-
tion box.
(E) Connect the hook overhoist cable reel connector.
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If the jib and the aux. sheave are not installed, connect
the hook overhoist limit switch wiring at this time.
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LOAD DETECTOR
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CONTROLLER
(D)
(F)
(E)
R
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84.5 degrees to
Limit switch (against machine angle)
85.5 degrees
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EACH WEIGHT
Carbody weight Weight
No.1 WEIGHT (1) 7.2 t (15,873 lbs)
No.2 WEIGHT (2) 7.2 t (15,873 lbs)
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1. PREPARATION OF CARBODY WEIGHT
INSTALLATION No.1 WEIGHT
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• Basic boom configuration / 35 ton hook (2 part line)
• The gantry is in WORK position.
• Main machinery is placed on firm and level ground.
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• The crawler is extended to the extended position.
No.2 WEIGHT
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[TOOL]
• Sling wire rope (Approx. 5 m X 2 pieces)
• Shackle
(5.4 ton)
X 4 pieces
• Chain block (6.3 ton) X 2 pieces
y
BOOM BASE
nl
CHAIN
BLOCK
Max.
Approx.
O
84 degrees
ce
CARBODY WEIGHT
en
er
ef
R
y
Be extremely careful of the chain block operation.
nl
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
(1) Setting of LMI
When removing or attaching the counterweights,
set up the LMI as shown below.
ce
The machine may be stopped by the automatic stop
function, leading to impossibility of work, unless you
carry out this setting.
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
c. Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
e. Finally the part line number input screen becomes in-
dicated.
Input [2] into Hook 1.
ce
f. Push [0] of Hook 1.
en
er
OK
ef
R
g. Push [2].
Changed to green.
y
nl
O
h. Push [OK]. ce
en
er
ef
R
i. Data is searched.
y
nl
O
j. When data is searched, result of selection becomes
indicated. Check if the selected items are correct. If
correct, push [OK]. The screen returns to main
screen.
If not correct, push [A]. Then screen returns to “a.”
ce
and start re-input.
Self removal
mode
en
C/W removal
mode
2
er
A
ef
R
y
nl
O
HOOK
70 degrees
ce
Approx. 5 to 6 m (16.4 to 19.7 ft)
en
er
ef
R
y
HOOK
nl
O
70 degrees
ce
Approx. 3.9 m (12.8 ft)
en
er
ef
R
y
time (1 second).
Then the crane turns to Assy/disassy mode and
nl
auto-stop due to hook overhoist is released and
boom lowering becomes possible.
O
Push [Assy/disassy] icon or [Boom/Jib] lowering icon
Push Stop release
for more than 1 second.
ce
MASSAGE
ME017
en
Stop
er
(5) Set the rope chain block for the carbody weight.
y
Approx. 3.9 m (12.8 ft)
nl
O
ce
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
c. Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
e. Finally the part line number input screen becomes in-
dicated.
Input [2] into Hook 1.
ce
f. Push [0] of Hook 1.
en
er
OK
ef
R
g. Push [2].
Changed to green.
y
nl
O
h. Push [OK]. ce
en
er
ef
R
i. Data is searched.
y
nl
O
j. When data is searched, result of selection becomes
indicated. Check if the selected items are correct. If
correct, push [OK].
The screen returns to main screen.
If not correct, push [A]. Then screen returns to “a.”
ce
and start re-input.
Self removal
mode
en
CB/W removal
mode
2
er
A
ef
R
4.5 degrees
y
nl
(9) Raise the boom to bring the carbody weight closer.
(10) Align the carbody weight pin with the top of the car-
O
body side installation bracket.
ce
en
SHACKLE
83.8
degrees
ef
CHAIN BLOCK
R
SHACKLE
y
nl
83.8 degrees
O
ce
Approx. 1.3 m (4.3 ft)
en
(12) Install the “a” area of the carbody weight to the “b”
area of the carbody.
er
“a”
ef
“b”
R
CARBODY WEIGHT
CARBODY
y
nl
O
ce
en
WEIGHT.
ef
R
y
nl
O
ce
FRONT SIDE
en
EACH
CH WEIG
WEIGHT
Counterweight Weight WEIGHT (5)
WEIGHT (1) 8.31 t (18,300 lbs)
WEIGHT (3)
WEIGHT (2) (4) 5.75 t (12,680 lbs)
WEIGHT (3) (5) 5.75 t (12,680 lbs) WEIGHT (4)
WEIGHT (2)
WEIGHT (1)
1. SETTING OF LMI
y
When removing or attaching the counterweights,
set up the LMI as shown below.
nl
The machine may be stopped by the automatic stop
O
function, leading to impossibility of work, unless you
carry out this setting.
ce
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
(3) Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
(5) Finally the part line number input screen becomes
indicated.
Input [2] into Hook 1.
ce
(6) Push [0] of Hook 1.
en
er
ef
OK
R
Changed to green.
y
nl
O
(8) Push [OK]. ce
en
er
ef
R
y
nl
O
(10) When data is searched, result of selection be-
comes indicated.
Check if the selected items are correct. If correct,
push [OK].
The screen returns to main screen. If not correct,
ce
push [A].
Then screen returns to (1) and start re-input.
en
Self removal
mode
C/W removal
mode
2
er
A
ef
R
y
Counterweight of this machine is composed of 5 piec-
es.
nl
Remove these pieces at the transportation.
Never use the counterweight other than specified one.
Firmly tighten the counterweight installation bolts to
prevent them from becoming loose during work.
O
• The following conditions must be satisfied for coun-
terweight mounting firm horizontal ground.
• Select the site of assembly for assembling and
ce
hoisting up the WEIGHT (1). Lay on underlay for
the WEIGHT (1).
The base plate's underlay eases connecting the
counterweight links.
en
er
ef
R
18,300 lbs
WEIGHT (1)
8,310 kg
Detail “A”
“A1”
y
2. Raise the links then fix the links with spring pins and
lock pins.
nl
O WEIGHT (1)
ce
en
WEIGHT (1)
er
4. Lift up right and left WEIGHTS (2), (3) with the ma-
chinery and place them on WEIGHT (1).
y
nl
O
WEIGHT (2)
WEIGHT (3)
ce
WEIGHT (1)
en
WEIGHT (4)
WEIGHT (2)
WEIGHT (5)
WEIGHT (3)
WEIGHT (1)
y
nl
7. Propel the crane to the position where the counter-
weight link and the base machine counterweight
link can be connected.
O
ce
en
er
ef
R
y
nl
O
ce
VIEW FROM Y
LINK
en
SPRING PIN
LOCK PIN
er
ef
R
y
Perform the work with engine speed lower than 1000
rpm.
nl
If the engine speed exceeds 1000 rpm, cylinder speed
would become higher and unexpected force would be
applied on the cylinder at start or stop.
This may result cylinder rod damage by bending.
O
1. Installation of counterweight lifting link
ce
(1) Propel the machine to the position that the counter-
weight lifting links can be connected to the counter-
weight lifting section.
en
y
ous injury or loss of life.
nl
O
ce
BLOCK
BLOCK
R
BLOCK
SPRING PIN
y
nl
LOCK PIN
O
ce
en
LINK
er
SPRING PIN
ef
R
(1) Open the guard and connect the remote control ca-
ble to the receptacle.
y
RECEPTACLE
nl
O c. ENGINE EMERGENCY STOP SWITCH
ce
b. HORN SWITCH d. ENGINE SPEED CONTROL SWITCH
f. COUNTERWEIGHT REMOVAL
CYLINDER CONTROL SWITCH
a. Power switch
b. Horn switch
Pushing this switch sounds horn.
y
c. Engine emergency stop switch
nl
Push this switch to stop engine in emergency case.
Switch stays at pushed position. Turning switch to
right or pulling switch returns to original position.
O
d. Engine speed control switch
occurs.
When this lamp is ON, check the detail of abnor-
mality by the cab monitor and take appropriate ac-
tion.
er
y
tions of the right and the left cylinders to keep hor-
izontally.
nl
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
ce
EXTENSION BAR
en
er
ef
EXTENSION
BAR
R
ROTATE
y
nl
O
ce
LOCK PIN
SPRING PIN
en
y
nl
(10) If the counterweight quantity detect unit is
O
ce
equipped, connect the detect harnesses installed
on all of the counterweights and the main machin-
ery harness.
Connect the cap to cap also.
After connection of connectors, secure the har-
en
HARNESS CLAMP
CN-863
ef
CN-861 CN-861
OPTION
With Without Without
carbody weight carbody weight carbody weight
y
nl
O
ce
IN CASE OF WEIGHT REDUCED
SPECIFICATION
In case of the weight reduced specification, if the
counterweight quantity is small, connect the main
en
y
when aligning the holes or inserting/removing the
pins.
Failure to observe these precautions may result in
nl
serious injuries or loss of life.
O
The main machinery disassembly place may re-
ceive a large load. Place strong steel plates on the
ground.
Provide enough capacity of an assisting crane,
ce
sling rope or shackle to be used.
Failure to observe these precautions may result in
serious accident.
en
2. SECURING PLACE
y
4. CAUTIONS DURING TRANSPORTATION WORK
nl
• During transportation work, install the waterproof
cap on the cable end of the hook over-hoist pre-
O
venting device.
During crane work, wire the over-hoist cable prop-
erly and remove the waterproof cap.
• In case of machine transportation on the trailer, the
permit issued by the related authority may be re-
ce
quired.
Follow the related regulation regarding the weight
and dimension for transportation.
Refer to “8.2 DIMENSION, WEIGHT OF EACH
COMPONENT” for weight, dimension during disas-
en
sembly.
er
ef
R
4.3.1 REMOVE THE COUNTERWEIGHTS FROM THE MACHINE (USING SELF REMOVAL DEVICE)
1. If the counterweight quantity detect unit is
equipped, disconnect the detect harnesses in-
stalled on all of the counterweights from the main
machinery harness.
After disconnection, put the water proof caps on CN-863
CN-862
y
CN-861
nl
O
ce
en
er
y
nl
4. Go up onto WEIGHT (1) using the ladder.
O
ce
5. Pull out the lock pin and spring pin.
en
er
ef
R
LOCK PIN
SPRING PIN
y
EXTENSION BAR
nl
O
ce
EXTENSION
BAR
en
ROTATE
er
y
When lower the counterweights, equalize the mo-
tions of the right and the left cylinders to keep hor-
nl
izontally.
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
ce
en
er
COUNTERWEIGHT REMOVAL
CYLINDER CONTROL SWITCH
SPRING PIN
LOCK PIN
y
nl
O
ce
LINK
SPRING PIN
en
er
ef
R
y
nl
O
ce
en
y
(1) Push [MENU] icon while the main screen is indicat-
ed.
nl
Menu screen is now indicated.
MPH
O
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
ce
en
er
MPH
POKP
0 m i n- 1
11000100000500010200
ef
2010/12/01 10:00
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
(3) Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
(5) Finally the part line number input screen becomes
indicated.
Input [2] into Hook 1.
ce
(6) Push [0] of Hook 1.
en
er
OK
ef
R
Changed to green.
y
nl
O
(8) Push [OK]. ce
en
er
ef
R
y
nl
O
(10) When data is searched, result of selection be-
comes indicated. Check if the selected items are
correct. If correct, push [OK].
The screen returns to main screen.
If not correct, push [A]. Then screen returns to (1)
ce
and start re-input.
Self removal
mode
en
C/W removal
mode
2
er
A
ef
R
WEIGHT (4)
Do not lift more than three weights at a time. Lifting WEIGHT (2)
brackets may break.
Failure to observe this precaution may result in se-
WEIGHT (5)
rious injury or loss of life.
WEIGHT (3)
y
WEIGHT (1)
nl
brackets may break.
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
ce
WEIGHT (5)
en
er
ef
R
WEIGHT (1)
y
nl
O
WEIGHT (1)
ce
en
er
ef
R
y
BOOM BASE
nl
CHAIN
BLOCK
O
Max.
Approx.
84 degrees
ce
CARBODY WEIGHT
en
er
ef
R
1. SETTING OF LMI
When removing or attaching the counterweights,
set up the LMI as shown below.
y
ed.
Menu screen is now indicated.
nl
MPH
O
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
ce
en
er
MPH
POKP
0 m i n- 1
11000100000500010200
ef
2010/12/01 10:00
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
(3) Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
(5) Finally the part line number input screen becomes
indicated.
Input [2] into Hook 1.
ce
(6) Push [0] of Hook 1.
en
er
OK
ef
R
Changed to green.
y
nl
O
(8) Push [OK]. ce
en
er
ef
R
y
nl
O
(10) When data is searched, result of selection be-
comes indicated. Check if the selected items are
correct. If correct, push [OK].
The screen returns to main screen.
If not correct, push [A]. Then screen returns to (1)
ce
and start re-input.
Self removal
mode
en
CB/W removal
mode
2
er
A
ef
R
4.5 degrees
y
nl
O
ce
83.8 degrees
en
er
Approx. 1.3 m
ef
R
3. Take out the lock pin “B” and remove the carbody
weight installation pin “A”. INSTALLATION PIN “A”
y
nl
O
ce
en
er
ef
R
y
nl
O
ce
FRONT SIDE
en
er
ef
R
y
nl
“a”
O
ce “b”
CARBODY WEIGHT
CARBODY
en
er
ef
R
y
nl
O
ce
8. Remove No.2 carbody weight from the carbody in
the same way as No.1 carbody weight.
en
y
time (1 second).
Then the crane turns to Assy/disassy mode and
nl
auto-stop due to hook overhoist is released and
boom lowering becomes possible.
O
Push [Assy/disassy] icon or [Boom/Jib] lowering icon
Push Stop release
for more than 1 second.
ce
MASSAGE
ME017
en
Stop
er
y
Remove
nl
O
ce
en
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
O
ce
MPH
POKP
0 m i n- 1
11000100000500010200
en
2010/12/01 10:00
er
ef
R
MPH
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
y
nl
B
O
(3) Crane attachment select screen becomes indicated.
Select [D].
ce
Choose the mode of working or assembly.
Crane Boom Fixed Jib
en
Self removal
On Barge Clamshell mode
D
er
ef
R
y
nl
O
(5) Finally the part line number input screen becomes
indicated.
Input [2] into Hook 1.
ce
(6) Push [0] of Hook 1.
en
er
ef
OK
R
Changed to green.
y
nl
O
(8) Push [OK]. ce
en
er
ef
R
y
nl
O
(10) When data is searched, result of selection be-
comes indicated. Check if the selected items are
correct. If correct, push [OK].
The screen returns to main screen.
If not correct, push [A]. Then screen returns to (1)
ce
and start re-input.
Self removal
mode
en
C/W removal
mode
2
er
A
ef
R
y
nl
O
ce
en
er
ef
R
y
nl
SPREADER GUIDE
O
ce
Assembly/disassembly position
UPPER SPREADER
er
GUY LINE
CONNECTING
PIN
y
UPPER SPREADER BASE GUY LINE
GUY LINE
CONNECTING
nl
PIN
O
ce
en
y
boom hoist wire rope to remove load from the bot-
tom connector section, then draw out the bottom
nl
connecting pins (with a suitable tool).
O
structure when removing the connecting pins.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
ce
en
er
CONNECTING PIN
(Double tapered pin)
SPRING PIN
SPRING PIN
ef
R
y
nl
SPRING PIN
O
CONNECTING PIN
ce (With flange)
en
er
ef
R
y
Perform the gantry lowering work with boom placed on
the ground wooden block of approx. 100 mm (4") in
nl
height.
Take extra care on slack or tension of the boom hoist
rope.
O
1. Start the engine and set the speed to LOW (800
min-1).
ce
en
y
nl
4. Take out the spring pin and pull out the pin “Y” from
the gantry and stow to the stowing location.
O
ce
SPRING PIN
en
PIN “Y”
er
PIN “Y”
STOWED POSITION
ef
R
5. Pull out the pin “W” from the travel kit and remove
the travel kit from the stopper.
SPRING
PIN
PIN “W”
STOPPER
y
nl
6. Set the engine speed to 1,000 min-1.
O
At this time, pay out the boom hoist rope to prevent
the boom base from coming afloat.
ce
UP
Do not enter under the gantry to avoid accident of
being caught due to sudden drop of the gantry.
Failure to observe these precautions may result in
NEUTRAL
serious accident.
en
DOWN
8. Connect the travel kit and upper frame with pin “W”
and retain with the spring pin.
y
nl
TRAVEL KIT
(OPTION)
O
ce
PIN “W”
en
SPRING PIN
er
ef
R
y
nl
(1) Confirm that the upper spreader is fixed to the boom
LOWER SPREADER
base top bracket with pin.
UPPER SPREADER
O
ce
en
er
ef
R
CAB STEP
y
nl
STOWED
CONDITION
O
(M10)
EXTENDED
CONDITION
FIXING PIN
ce
CAB STEP
en
ADJUSTING BOLT
STOWED
CONDITION
EXTENDED
move all side steps completely. CONDITION
y
grease on the inserting area.
If the mud is adhered to, extension or retraction work
nl
may not be preformed easily.
O
Perform the crawler retraction work on the flat place
with the steel plate placed.
Retract the crawler with all the counterweight removed.
ce
en
er
(1) Take out the lock pins and retaining pins and re-
move the pin “L” which connect the crawler and the
axle and rotate the plate “M” and place it on the
plate “M”.
PLATE “M”
y
nl
Apply grease on the sliding surface between the car-
O
ce
body and crawler prior to work. (4 locations)
en
CRAWLER FRAME
SHIM
R
AXLE
y
nl
RETRACTING SIDE
O
er retracting side. Turn the crawler ext/ret control
switch to [RET] side to retract the crawler.
If the crawler can not be retracted smoothly, repeat
extending and retracting motions or propel forward
or backward of the retracting side crawler slightly
ce
while retracting.
CRAWLER
er
RET.
PIN “L”
ef
PLATE “M”
R
PLATE “M”
RETAINING
PIN
y
LOCK PIN
nl
O
ce
(8) Swing the upper machinery for 180 degrees and re-
tract the other side of the crawler in the same way.
en
(9) Remove the retaining bracket “T” from the axle ex-
tension root area and move to the stowing position.
BRACKET “T”
er
ef
BRACKET “T”
R
(10) Rotate all four axle extensions for 90 degrees to- AXLE
ward inside to make them right angle with axles.
AXLE
y
EXTENSION
nl
(11) Secure the axle extension and crawler frame with
CRAWLER FRAME
the pin “S” and insert the retaining pin.
RETAINING PIN
O
PIN “S”
ce
CRAWLER FRAME
en
RETAING PIN
PIN “S”
y
responsibility.
nl
3. PRE-WORK INSPECTION
Conduct the pre-work inspection.
O
require the permit issued by authorities concerned.
Refer to P.8-7 for weight and dimensions during dis-
assembly.
Prepare large enough trailer for the machinery
weight.
ce
5. Set the boom angle from 5 degrees to 10 degrees
range.
Adjust the angle so that the front portion of trailer
and the boom do not interfere during loading to the
en
trailer.
Boom angle also must be adjusted to fit within the
allowable trailer height.
er
6. LOADING TO TRAILER
(1) Swing the upper machinery to make the upper ma-
chinery and the crawler parallel and engage the
swing brake and swing lock.
(2) Load the machinery onto the trailer using the load-
ing plate and with the drive tumbler on rear side.
y
avoid overturn of the machine.
The gravity center may move rapidly on the border
of loading plate and the trailer.
nl
Turn the speed select switch into inching speed
and propel with slow and constant speed to avoid
overturn of the machine.
O
ce
en
4.4 TRANSPORTATION
In case of transportation of the machine or attachment
with the trailer or truck, there is various combination of
different weight, type of trailer or truck and the transpor-
tation configuration differ.
y
sary document to the related authority office to obtain
the permit.
For detail, refer to the related traffic regulation.
nl
Refer to P.8-7 for disassembly dimension and weight.
O
Do not exceed weight limit or dimension limit.
Do not perform unreasonable transportation since
it may lead to accident involving person or proper-
ce
ty.
Failure to observe these precautions may result in
serious injuries or loss of life.
en
y
1. Machine must be placed on firm and level ground.
2. The crawlers are extended and fixing pins are in-
stalled to the crawlers and the shims are inserted
nl
on the axles.
O
Do not allow any person to enter under or inside of
the boom during boom connecting work to prevent
accident of being crushed due to falling of the
boom.
Failure to observe this precaution may result in se-
ce
rious injuries or loss of life.
(1) Lift up the boom base with the assisting crane and
en
(2) Paste grease on the boom foot pin and pin hole ar-
ea. BOOM BASE
BOOM
FOOT PIN
(3) Align the boom foot pin hole on both side and insert
the right hand pin from inside then insert the left
hand pin.
RETAINING
Insert the lock pins from top to bottom and fix them PIN
with the retaining pins. LOCK PIN
UPPER FRAME
(INSIDE)
y
Do not put your finger or hand into pin hole when
inserting or pulling out the pins.
nl
Failure to observe this precaution may result in se-
rious injury.
O
(4) Place the boom base connector area on the wooden
block and remove the sling wire rope.
ce
Do not lower the boom base tip to the level lower
than ground level. Otherwise some components
may be damaged with the boom or the backstop,
winch valve.
Approx. 100 mm (4” )
en
GREASE FITTING
R
(6) Connect the cable reel and angle detector wiring re-
ferring to “3. LOAD SAFETY DEVICE”.
(7) Apply grease from the left and right boom foot pins.
y
FRAME
Failure to observe this precaution may result in se-
rious injury.
nl
Do not stand on backstop pulling out direction to
O
prevent accident of collision.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
ce
Insert pin from inside.
en
er
ef
R
SHACKLE
y
UPPER
nl
SPREADER
BOOM BASE
TOP BRACKET
y
caught accident.
Failure to observe these precautions may result in
nl
serious injuries or loss of life.
O
(1) Turn the boom drum control lever to lowering side to UPPER SPREADER
feed out the wire rope from the boom drum.
(2) Reeve the wire rope through the upper spreader 2
and the lower spreader preventing the wire rope 11
10
from twisting, twining or coming out of sheave.
ce
7 9
5
3
4
6
8
Do not fail to follow the reeving order when passing the
en
LOWER SPREADER
er
(3) Fix the wire rope end to the winch bracket using the
socket, wedge and clamp.
CLAMP
y
nl
LINK
LOAD
DETECTOR
O
BOOM HOIST DRUM
ce
en
er
ef
R
y
Do not touch the wire rope with bare hands. Use
leather groves.
nl
Pay extra attention to the running rope to prevent
caught accident.
Failure to observe these precautions may result in
serious injuries or loss of life.
O
(1) Secure the wire rope end to the boom hoist drum
with the wedge.
(2) Wind up the wire rope to the boom drum.
ce
Reverse installation Protruding
en
er
ef
y
FIXING PIN POSITION
nl
SHACKLE
UPPER
SPREADER
O
BOOM BASE
TOP BRACKET
ce
FIXING PIN POSITION
en
rious injury.
ef
y
nl
Do not put your finger or hand into pin hole.
Failure to observe this precaution may result in se-
rious injury.
O
Do not stand on the area on the direction where the
backstop is to be pulled out.
ce
3. While holding the backstop with the assisting
crane, secure the backstop to the boom base with BACKSTOP
WIRE ROPE
(both right and left hand)
BOOM BASE
er
ef
R
y
nl
Do not stand under or inside the boom to avoid ac-
cident of being crushed due to falling off of the
boom during boom connecting work.
O
1. Remove the wiring of the cable reel and the angle
detector referring to “3. LOAD SAFETY DEVICE”.
ce
2. Take out the boom foot shim.
BOOM FOOT AREA
SHIM
en
er
BOOM
FOOT PIN
R
RETAINING
PIN
LOCK PIN
UPPER FRAME
(INSIDE)
y
5. Propel the machine backward slightly and lower the
boom base to the ground with the assisting crane.
nl
O
ce
en
er
ef
R
EACH WEIGHT
y
Carbody weight Weight
No.1 WEIGHT (1) 7.2 t (15,873 lbs)
nl
No.2 WEIGHT (2) 7.2 t (15,873 lbs)
O
Before installing the carbody weight, check that the
machine is in the following conditions.
as listed below.
ef
R
[TOOL]
• Attached tool set
• Assisting crane (25,000 kg class or larger)
• Sling wire rope 25 mm X 8 m (1" X 26' 3") 2 pieces
• Light weight shackle Nominal 10,000 kg 2 pieces
(Attached tool)
y
Do not stand under lifted carbody weight or be-
nl
tween carbody weight and the basic machine to
avoid accident of drop or being caught. Failure to
observe this precaution may result in serious injury
or loss of life.
O
Lift the carbody weights with the assisting crane, and
install them by hooking them with the carbody brackets.
When removing them, lift them with the assisting crane
ce
in a similar manner.
en
er
ef
R
y
main machinery to prevent accident of falling or be-
ing caught.
nl
Failure to observe this precaution may result in se-
rious injuries.
O
(B) Install the “a” area of the carbody weight to the “b”
area of the carbody.
“a”
er
“b”
ef
CARBODY WEIGHT
R
CARBODY
(3) Insert the carbody weight installation pin “A” and se-
cure it with the lock pin “B”. INSTALLATION PIN “A”
y
nl
O
ce
en
er
ef
R
y
nl
O
ce
FRONT SIDE
en
y
LOCK PIN “B”
nl
O
ce
en
er
ef
R
y
nl
O
ce
FRONT SIDE
en
er
ef
R
y
nl
O
“a”
ce
“b”
en
CARBODY WEIGHT
CARBODY
y
nl
O
ce
en
er
ef
R
y
• The boom hoist rope has been roved through the up-
per and lower spreader and the gantry is in work po-
sition (high gantry).
nl
• The base boom is attached to the main machinery.
• The crane backstop has been installed.
O
ce
en
y
3. PREOPERATION CHECKS
Perform the pre-operation checks of the basic ma-
nl
chine.
O
Do not allow any person to enter under, inside of
the boom, jib during assembly, disassembly.
Failure to observe these precautions may result in
serious injuries or loss of life.
ce
Do not apply slings directly to a sharp edge part to
prevent the slings from cutting.
en
Wear the safety belt during the high place work and
prepare the foot hold for work on the boom.
Failure to observe these precautions may result in
ef
y
or wire rope attached directly to main chords or lacings.
Use soft material sling.
nl
4. CAUTIONS DURING ASSEMBLY WORK
Refer to P.8-7 for weight and dimension during as-
sembly.
O
Pay attention on center of gravity and stability of
parts and machine.
The operator has to be informed if any person
moved to out of sight from the operator or at haz-
ce
ardous location when equipment or machine part
moves.
y
• Hand cable winch (3 t)
nl
sy/disassy” icon. Then, the load safety device enters
the Assy/disassy mode, and the automatic stop is can-
celed.
/'07
O
ASSY/DISASSY
ICON
ce
en
er
y
ignated service shop.
nl
The boom length in which the 24.4 m to 57.9 m
jib can be installed (80 ft to 190 ft)
The boom length in which the 12.2 m to 57.9 m
aux. sheave can be installed (40 ft to 190 ft)
O
ce
booms may collapse and cause serious injuries or
loss of life.
Failure to observe this precaution may result in se-
rious accident.
en
STEEL BLOCKING
PLATE
y
2. BOOM AND GUY LINE ARRANGEMENT
nl
Depending on the purchased configuration of boom,
boom may not be able to arrange as shown on the
chart.
O
The boom arrangement with the " " is the preferred
configuration. Using the " " arrangement will allow any
shorter boom length to be assembled. Shown below
the " " configurations are acceptable arrangement if
ce
required due to boom that was purchased.
en
er
ef
R
Front Rear
drum drum
Boom
Boom
Boom and guy line configuration chart With self
length aux. With jib Max. Max. erecting
1/3 Number Number
sheave of parts of parts at side
m (ft)
line line direction
12.2
8 1
(40)
y
15.2
nl
8 1
(50)
O
18.3
8 1
(60)
ce
21.3
6 1
(70)
en
24.4
6 1
(80)
er
ef
27.4
5 1
(90)
R
30.5
5 1
(100)
Front Rear
drum drum
Boom
Boom
Boom and guy line configuration chart With self
length aux. With jib Max. Max. erecting
2/3 Number Number at side
sheave
m (ft) of parts of parts
line line direction
33.5
4 1
(110)
y
nl
36.6
4 1
(120)
O
ce
39.6
4 1
(130)
en
42.7
er
4 1
(140)
ef
45.7
4 1
(150)
R
48.8
2 1
(160)
Front Rear
drum drum
51.8
2 1
(170)
y
nl
54.9
2 1
(180)
57.9
O
ce
2 1
(190)
61.0
2
(200)
en
mark shows the boom insert with lugs attached and the guy line installing position when the jib is used.
er
mark shows the standard boom arrangement which make the boom arrangement of less than the each
boom length possible.
mark shows the installing of the cable roller for the insert boom.
ef
In the following case, one of 12.2 m (40 ft) boom insert with lugs attached is required.
(2) When assembling the boom without the use of the as-
sisting crane.
y
Guy line dimension
Connector type
Symbol Diameter mm Remarks [m(ft)]
Length m (ft)
(in)
nl
A 30 (1–3/16) 6.17 (20.2) Boom tip
B 30 (1–3/16) 3.05 (10) 3.0 (10) Boom insert
C 30 (1–3/16) 6.10 (20) 6.1 (20) Boom insert
D 30 (1–3/16) 12.20 (40) 12.2 (40) Boom insert
O
ce
en
er
ef
R
10 degrees 10 degrees
E (or 30 degrees) E F TIP (or 30 degrees)
TIP 10 ft
BASE BASE
TIP TIP
H H
y
40 ft 40 ft
nl
(J) BOOM INSERT WITH LUGS (J) BOOM INSERT WITH LUGS
O
F
TIP
E TIP 10 degrees E G 10 degrees
G (or 30 degrees) 10 ft (or 30 degrees)
ce
20 ft 20 ft
BASE BASE
TIP TIP
en
H H
40 ft 40 ft
(J) BOOM INSERT WITH LUGS (J) BOOM INSERT WITH LUGS
er
10 degrees H
30 degrees H+J
y
42.7 (140) O O O O O
45.7 (150) O O O O O
nl
48.8 (160) O O O O O
51.8 (170) O O O O O
54.9 (180) O O O O X
57.9 (190) O O O O X
O
O: Installation possible
X: Installation not possible
ce
Kind of jib insert
Symbol Jib length Specification
SPRING PIN
y
CONNECTING PIN
(With flange)
nl
O
ce
en
er
ef
R
2. Raise the boom base until the lower pin holes are
aligned with each other. Then tap the connecting
pins (both end tapered) in, and insert the spring
pins into the both ends of the connecting pin.
y
nl
O
ce
SPRING PIN
SPRING PIN
en
CONNECTING PIN
(Double tapered pin)
er
ef
R
y
nl
O
Stowing position
ce
SPLIT PIN
en
Insert the
pin from
inner side.
Insert the
pin from
er
inner side.
y
nl
BASIC GUY LINE
O
ce
en
er
ef
R
y
6.1 m (20 ft) -
12.2 m (40 ft) 12.2 m (40 ft)
nl
Although the special boom insert (with bracket) is basi-
cally used for the tower, it can be also used for the
crane by removing the guide sheave for tower crane.
O
The case that the boom insert with the lugs attached is
as follows.
y
Keep hands and clothing clear of the rotating drum and
running wire rope.
nl
Failure to observe this precaution may result in serious
injury or loss of life.
O
3. REMOVING THE BOOM TIP SECTION
(1) Lower the boom and install the upper spreader onto
the top of the boom base with the use of spreader
guide.
ce
How to use spreader guide is shown in the next
page.
en
GUY LINE
er
ef
GUY LINE
R
PIN “A”
PIN “A”
SPREADER GUIDE
y
Stowing position Assembly/disassembly position
nl
O
(B) Lower the boom. After the tip end of the boom has
been grounded, slowly loosen the boom hoist wire
rope more. The spreader is lowered along the
spreader guide. When the hole of the spreader is
aligned with the pin hole of the bracket on the boom
ce
base section, insert pin “B” to connect the spreader
to the base boom bracket.
en
PIN “B”
er
ef
R
y
nl
When the gantry is in the lowered condition, be sure to
set the guide in the stowing position. If the guide is left
in the assembly/disassembly position, the guide could
O
be damaged by boom raising.
When the gantry is lowered and the upper spreader is
connected to the boom base section, set the guide in
the stowing position. At this time, do not raise the boom
to higher than 20 degrees. If the boom is raised to high-
ce
er than 20 degrees, the winch wire rope has possibility
to be damaged.
en
CLEARANCE
PIN “A”
er
Stowing position
ef
y
PIN “B”
nl
O
(E) Return the spreader guide to the stowing position.
ce
(F) When setting the spreader guide to the assembly/
disassembly position, after the boom connection is
finished, tighten the boom hoist wire rope, and set
the spreader guide to the assembly/disassembly
position.
en
PIN “A”
PIN “A” SPREADER GUIDE
er
GUY LINE
CONNECTING
PIN
y
nl
PIN “B”
O
boom hoist wire rope to remove load from the bot-
tom connector section, then draw out the bottom
connecting pins (with a suitable tool).
ce
Do not stand or work under, inside or on the boom
structure when removing the connecting pins.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
en
er
ef
CONNECTING PIN
(Double tapered pin)
R
SPRING PIN
SPRING PIN
y
nl
SPRING PIN
O
CONNECTING PIN
ce (With flange)
en
er
ef
R
CORRECT
y
Bottom
nl
Top
WRONG
O
Bottom
LUG
ce
en
er
ef
(2) Align the top connecting pin holes of the boom base
and insert the right and left connecting pins (pin
with flange) with the lock pinholes facing up and
down. Insert the spring pins to fix the connecting
pins.
y
nl
SPRING PIN
O
CONNECTING PIN
(With flange)
ce
en
er
ef
R
y
rious injuries or loss of life.
nl
O
ce
en
SPRING PIN
er
SPRING PIN
ef
CONNECTING PIN
(Double tapered pin)
R
SPRING PIN
y
nl
CONNECTING PIN
(With flange)
O
ce
SPRING PIN
en
CONNECTING PIN
(With flange)
er
ef
R
SPRING PIN
CONNECTING PIN
(With flange)
y
nl
O
SPRING PIN
ce
CONNECTING PIN
(With flange)
en
y
CABLE ROLLER
nl
SPACER
CABLE ROLLER
O
CABLE ROLLER
BOOM INSERT
ce
en
er
ef
R
y
CONNECTING PIN
nl
2. Connect the prepared guy lines from the boom tip
side to the basic machine side one by one.
O
do not make the guy lines slacken.
If the guy lines slacken much, then guy lines may
not reach to the upper spreader.
ce
en
er
ef
UPPER SPREADER
PIN “B”
SPLIT PIN
Insert the
y
pin from
inner side.
nl
Insert the
pin from
Open the split pin to inner side.
approx. 60 degrees.
O
SPLIT PIN
ce
en
5. Use the spreader guide to remove the pin “B”. SPREADER GUIDE
PIN “B”
er
ef
y
nl
O
Be sure to confirm that gantry is set in high gantry con-
ce
dition.
Do not exceed the length of cantilever mentioned be-
low.
Operate crane at the slowest speed possible.
en
er
y
nl
12.2 m (40 ft) or less
O
ce
the boom is supported with the cantilever.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
en
er
ef
R
y
socket, etc. to be used near the tip end of the boom.
nl
side to feed out the wire rope to the tip end of the HOIST WIRE ROPE
boom and pass it through the right idler sheave and IDLER SHEAVE
pass it to the right of the boom point. (Right side from the rear)
O
ce
BOOM POINT SHEAVE
en
LIMIT SWITCH
SHACKLE
ef
WIRE ROPE
R
WEIGHT
4. Pass the front drum wire rope through the hook (s)
and boom point sheave (s) in order.
Fix the wire rope end to the boom point for even
number part reeving and to the hook for odd num-
ber part reeving with the rope socket.
IDLER SHEAVE
BOOM POINT
SHEAVE
y
AUX. SHEAVE
nl
O
8 Parts HOOK SHEAVE 7 Parts 6 Parts
ce
en
y
Open the split pin to
nl
approx. 60 degrees.
ROPE SOCKET
O
5. LOAD SAFETY DEVICE CONNECTION
(A) Secure the junction cables or limit switch wiring to
the boom with the hanger.
(B) Connect the attachment wiring to the main machin- LOAD
DETECTOR
ery junction panel.
ce
(C) Check the connection of load detector connector.
(boom hoist winch plate area)
(D) Connect the cable reel wiring to the boom tip junc-
tion box.
en
If the jib and the aux. sheave are not installed, connect
er
LOAD DETECTOR
CONTROLLER
R
Self removal
On Barge Clamshell mode
y
nl
Input the crane configuration properly to prevent
O
machine overturn or damage.
Failure to observe this precaution may result in se-
rious accident.
ce
Type Type of overhoist Type of stop Auto-stop angle
82 degrees to
Controller (against ground angle)
82.5 degrees
Crane Boom overhoist
84.5 degrees to
Limit switch (against machine angle)
85.5 degrees
en
er
ef
R
JIB
STRUT
y
JIB GUY LINE
㧔BOOM SIDE㧕 12.2 m (40 ft) BOOM INSERT
nl
LINK
BOOM INSERT WITH LUG
O
ce
Do not stand or work under, inside or on the jib
structure when assembling jib.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
en
33.5 (110) O O O O
36.6 (120) O O O O
39.6 (130) O O O O
42.7 (140) O O O O
R
45.7 (150) O O O O
48.8 (160) O O O O
51.8 (170) O O O O
54.9 (180) O O O O
57.9 (190) O O O O
O: can be installed
X: cannot be installed
SPRING PIN
CONNECTING PIN
(With flange)
y
nl
O
SPRING PIN
ce
CONNECTING PIN
(With flange)
en
3. Prepare the jib guy lines (the jib side and boom
side).
OFFSET ANGLE
• The length of the jib guy line of the jib side varies (10 degreesor 30 degrees)
according to the jib length.
• The length of the jib guy line of the boom side varies
according to the jib offset angle (10 degrees or 30
degrees) and the boom insert length (6.1 m or 9.1
y
m) connected to the boom tip.
nl
O
ce
4. Temporarily remove the equalizer sheave of the jib
strut, and pass the jib guy line through the sheave.
Only then, reinstall the sheave back to the original
en
EQUALIZER SHEAVE
R
5. Connect both ends of the jib guy line to the top end
of the jib.
y
nl
Insert the pin from out side.
6. Install the jib guy line link to the boom insert with
lug, referring to the “Boom and guy line configura-
O
tion chart”.
GUY LINE
ce
PIN SPLIT PIN
Open the split pin to
en
approx. 60 degrees.
(Boom inside)
er
ef
R
STRUT
STRUT BACKSTOP
y
nl
O
ce
8. By holding the jib strut, connect both ends of the
boom side jib guy line to the link on the boom insert.
en
(BOOM SIDE)
Connect
BOOM INSERT
WITH LUG
ef
R
y
1. Place the hook block near the tip end of the jib.
nl
2. Turn the rear drum control lever to the lowering side
to feed out the rear drum wire rope to the tip end of
the jib, and pass it through the jib point sheave.
O
ce
en
LIMIT SWITCH
R
WEIGHT
4. Pass the wire rope end through the weight for the
limit switch, and secure the end to the hook rope
socket with the bolt, nut and split pin.
y
nl
O
Open the split pin to
approx. 60 degrees.
ce
5. Referring to chapter “3. LOAD SAFETY DEVICE”,
en
tem.
y
LOAD DETECTOR
nl
CONTROLLER CABLE REEL
O
7. Referring to chapter “3. LOAD SAFETY DEVICE”,
input the crane configuration data in the load safety
ce
Choose the mode of working or assembly.
device. Crane Boom Fixed Jib
Self removal
en
Monitor indication
ef
y
nl
Install the auxiliary sheave installation position at the
boom top, and fix it with the pin.
O
ce
en
er
SPRING PIN
ef
PIN
R
5.1.12 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE
y
1. Place the hook block near the tip of the auxiliary
sheave.
nl
2. Control the rear drum control lever to the lowering
position to pay out the wire rope up to the tip end of
the boom, and pass the wire rope through the idler
sheave and auxiliary sheave in this order.
O
3. Install the overhoist limit switch and weight to the
auxiliary sheave.
4. Pass the wire rope end through the weight for the
ce
limit switch, and fix the end to the ball hook with the
use of the rope socket, bolt, nut and split pin.
en
y
Self removal
nl
On Barge Clamshell mode
O
ce
Ensure to input the “Auxiliary sheave configura-
tion” properly to prevent overturning of the ma-
chine.
en
y
2. Check the performance of the limit switch of the
main hook overhoist, aux. hook overhoist and
boom overhoist.
nl
As for the detail of the checking method, refer to the
article “3. LOAD SAFETY DEVICE” (P.3-74).
If any part of the boom overhoist limit switch or strik-
O
er shows damage, deformation, loose bolt etc and
angle setting becomes deviated or parts replaced,
re-adjustment of angle is necessary.
In such case, contact the Manitowoc service shop.
ce
en
er
ef
R
y
6. Is the off-limiting step to the surrounding area of the attachment taken?
7. Are the wirings for the boom, main and auxiliary hook overhoist limit switches correctly connected?
nl
8. Does each limit switch properly work?
9. Is the load safety device correctly wired?
10. Is the crane configuration data properly set in the controller (load safety device)?
Is the mode (Front/Rear) properly selected?
O
11. Is the propel motor set to rear side?
12. For the combination of the boom of 57.9 m (190 ft) length and the jib of any length, place blocking steel plates
between the ends of the crawlers and the ground.
ce
2, 4, 5, 7
10
12
1, 8, 9
en
11 3 12
6 6 6
6 6
er
y
To prevent possible serious injuries or loss of life
from being dragged or struck by suddenly moving
nl
hook, keep clear from the area near the hook when
the attachment is erected.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
O
1. CAUTIONS WHEN ERECTING
attached.
HOOK
hoisting /
lowering
y
nl
O
ce
en
er
ef
R
y
nl
O
ce
Approx. 82 degrees
en
er
ef
R
y
nl
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
O
ce
A
en
er
POKP
0 m i n- 1
11000100000500010200
2010/12/01 10:00
R
ME056
POKP
0 m i n- 1 56
ME056
11000100000500010200
2010/12/01 10:00
y
nl
O
/'07
ce
Check to see that hook raising or boom lowering
cannot be done.
y
51.8 m (170 ft) length or more, place the hook on
600 mm (23.6 inch)
the ground until the boom angle reaches approxi-
nl
mately 30 degrees.)
50 mm
(2 inch)
3. Operation must be performed at a low speed.
Sudden start and stop must be avoided.
O
450 mm (17.7 inch)
4. Prevent the wire rope from catching and kink in the STEEL BLOCKING PLATE
tip end of the boom and jib.
ce
5. For the combination of the boom of 57.9 m (190 ft)
length and the jib of any length, place floor plates
between the ends of the crawlers and the ground.
en
y
will be released. Lower the boom further.
nl
O
5. By lowering the boom further, the hook overhoist
limit switch operates when the weight of the hook
overhoist limit switch is placed on the ground, and
the boom lowering is automatically stopped again.
ce
Press and hold the “Assy/disassy” icon one time for
approx. 1 second and it becomes the Assy/disassy
mode, and the boom can be lowered. Be careful be-
cause the hook overhoist automatic stop does not
function in the Assy/disassy mode.
en
er
ef
R
ASSY/DISASSY
ICON
y
nl
O
ce
Press “Assy/disassy” icon 1 second or more.
boom is raised.
When the boom is raised after the assembly is complet-
ed, the Assy/disassy mode is released.
er
[TOOL]
y
nl
HOOK OVERHOIST LIMIT SWITCH
O
Remove the thimble
ce from the hook.
To jib foot
Disconnect the connector. Disconnect the connector.
en
falling off.
Failure to observe this precaution may result in se-
rious injuries or loss of life.
ef
R
y
nl
Remove the thimble
from the hook.
O
WATER PROOF CAP (3P) CONNECT WATER PROOF CAP (3P)
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SPLIT PIN
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LIMIT SWITCH
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WEIGHT
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may suddenly jump and cause injuries.
Keep hands and clothing clear of the rotating drum and
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running wire rope.
Failure to observe these precautions may result in seri-
ous injuries or loss of life.
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4. Fix the wire rope end to the drum outer layer with a
steel wire after winding up.
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Disconnect
BOOM INSERT
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WITH LUG
STRUT
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GUY LINE
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3. Take off the jib guy line from the jib tip end.
SPLIT PIN
4. Take off the strut equalizer sheave and jib guy line.
Re-install the removed equalizer sheave back to
the original position.
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EQUALIZER SHEAVE
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JIB GUY LINE JIB GUY LINE
(BOOM SIDE) (JIB SIDE)
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5. With the jib being held with the assisting crane, de-
tach the jib from the boom.
Place the jib on wooden blocking.
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1. Remove the bolt, nut and split pin first and then re-
move the rope socket from the ball hook.
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3. Wind up the rear drum rope slowly.
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BALL HOOK WEIGHT
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SPLIT PIN
PIN
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SPREADER GUIDE
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Assembly/disassembly position
UPPER SPREADER
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GUY LINE
CONNECTING
PIN
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UPPER SPREADER BASE GUY LINE
GUY LINE
CONNECTING
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PIN
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ground.
At this time, be careful not to damage the boom.
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CABLE ROLLER
SPACER
CABLE ROLLER
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BOOM TIP BOOM TIP
CABLE ROLLER
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BOOM INSERT
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draw out the bottom side connecting pins.
Then, draw out the top side connecting pins, and
disconnect the boom tip.
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Remove the boom tip with using the assisting
crane.
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SPRING PIN
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CONNECTING PIN
(With flange)
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SPRING PIN
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CONNECTING PIN
(With flange)
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(1) Lift up the connecting point of the boom base and
the boom insert and take out the spring pins in the
lower connecting pins (double tapered pin) and
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then draw out the pins from outside to inside.
Draw out the pin for only one side and insert the
crowbar in this hole to prevent moving.
(2) Draw out the pin on the other side of lower connect-
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ing pin hole.
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SPRING PIN
SPRING PIN
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CONNECTING PIN
(Double tapered pin)
SPRING PIN
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CONNECTING PIN
(With flange)
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SPRING PIN
CONNECTING PIN
(With flange)
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SPRING PIN
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CONNECTING PIN
(With flange)
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LATTICE
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Do not transport the boom with the lattice pipe fixed.
Lattice pipe may be damaged.
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2. Place wooden block under both ends of the boom.
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becomes high.
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BOOM INSERT
WITH LUG
6. WIRE ROPE
6.1 HANDLING OF WIRE ROPE
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cross winding or biting may occur.
Use of proper rope length based on crane operating
nl
conditions (length of boom or jib, number of part lines
of rope, lifting height) is recommended.
(Refer to the table in 6.1.2 WIRE ROPE LENGTH.)
The hook has been removed at the factory delivery.
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Winding of rope may be loose and rope biting may oc-
cur.
If wire rope is loose, rewind the wire rope applying
some tension.
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If rope diameter is not correct, biting or rough spooling
may occur.
Use genuine wire rope.
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Breaking
Rope length
Use Rope spec. strength Rope dia. mm Part No.
m (ft)
kN (lbs)
IWRC 6 X Fi (29) 534
235 (771)
Right-hand Regular lay (120,048)
Front drum 26
U3 X SeS (48) 601
240 (787)
O/O Special (135,110)
IWRC 6 X Fi (29) 534
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160 (525)
Right-hand Regular lay (120,048)
Rear drum 26
U3 X SeS (48) 601
165 (541)
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O/O Special (135,110)
IWRC 6 X P•WS (31) 210
Boom hoist drum 16 150 (492)
Right-hand Regular lay (47,210)
Third drum IWRC 6 X Fi (29) 363
22 145 (476)
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(Option) Right-hand Regular lay (81,606)
Breaking
Rope length
Use Rope spec. strength Rope dia. mm Part No.
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m (ft)
kN (lbs)
FC 6 X W (19) 58
Hydraulic tagline 10 45 (148)
Right-hand Regular lay (13,039)
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Breaking
Rope length
Use Rope spec. strength Rope dia. mm Part No.
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m (ft)
kN (lbs)
FC 6 X W (19) 37
Reeving winch 8 260 (853)
Right-hand Regular lay (8,318)
Drum winding capacity on min. Pcd with 26 mm dia. rope. Drum winding capacity on min. Pcd with 22 mm dia. rope.
Winding L on Winding L on
Layer lane Min Pcd each layer Total winding Layer lane Min Pcd each layer
Total winding
m (ft) m (ft) length m (ft) m (ft) length m (ft)
m (ft)
1 22 0.614 (2.014) 42.4 (139) 42.4 (139) 1 23 0.550 (1.805) 39.7 (130) 39.7 (130)
2 22 0.658 (2.159) 45.5 (149) 87.9 (288) 2 23 0.587 (1.926) 42.5 (139) 82.2 (270)
3 22 0.702 (2.303) 48.6 (159) 136.5 (448) 3 23 0.624 (2.047) 45.1 (148) 127.3 (418)
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4 22 0.747 (2.451) 51.6 (169) 188.1 (617) 4 23 0.662 (2.172) 47.9 (157) 175.2 (575)
5 22 0.791 (2.595) 54.6 (179) 242.7 (796) 5 23 0.700 (2.297) 50.5 (166) 225.7 (740)
6 22 0.835 (2.740) 57.7 (189) 300.4 (986) 6 23 0.737 (2.418) 53.3 (175) 279.0 (915)
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7 22 0.879 (2.884) 60.8 (199) 361.2 (1,185) 7 23 0.774 (2.539) 55.9 (183) 334.9 (1,098)
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Min Pcd means theoretical value Min Pcd means theoretical value
calculated from the right figure 26 calculated from the right figure 22
on 2nd or higher layer. on 2nd or higher layer.
Min Pcd
Min Pcd
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(0.7)
(0.9)
18.7
22.1
27.4 23.2
Unit : mm (inch) (1.1) Unit : mm (inch) (0.9)
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(0.5)
13.6
16.9
Unit : mm (inch) (0.6)
MAIN WORK CONTENT AND ITS RECOMMENDED HOIST WIRE ROPE TYPE
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• Crane, Tower Even non-rotating type has
U4 X SeS (39)
• Jib, Aux. sheave rotating property.
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• Rope number of parts line 1 to 2
General crane work
• Work with boom shorter than half of
longest boom.
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Work cycle is comparatively low. IWRC 6 X Fi (29)
• Assisting crane work to
foundation work
• Clamshell work
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Large load, High cycle work
• Block lifting / transposition work
IWRC 6 X Fi (29)
• Port loading / unloading work
(Grab bucket work)
Large load, High cycle work
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Unit : m (ft)
Boom Length 1 Part 2 Part 4 Part 5 Part 6 Part 7 Part 8 Part
12.2 (40) 28 (92) 40 (131) 65 (213) 78 (256) 90 (295) 103 (338) 115 (377)
15.2 (50) 34 (112) 49 (161) 80 (262) 96 (315) 111 (364) 127 (417) 142 (466)
18.3 (60) 40 (131) 58 (190) 95 (312) 114 (374) 132 (433) 151 (495) 169 (554)
21.3 (70) 46 (151) 67 (220) 110 (361) 132 (433) 153 (502)
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24.4 (80) 52 (171) 76 (249) 125 (410) 150 (492) 174 (571)
27.4 (90) 58 (190) 85 (279) 140 (459) 168 (551)
30.5 (100) 64 (210) 95 (312) 156 (512) 186 (610)
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33.5 (110) 70 (230) 104 (341) 171 (561)
36.6 (120) 76 (249) 113 (371) 186 (610)
39.6 (130) 82 (269) 122 (400) 201 (659)
42.7 (140) 88 (289) 131 (430) 216 (709)
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45.7 (150) 94 (308) 140 (459) 231 (759)
48.8 (160) 100 (328) 149 (489)
51.8 (170) 106 (348) 158 (518)
54.9 (180) 112 (367) 167 (548)
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57.9 (190) 118 (387) 176 (577)
61.0 (200) 124 (407) 185 (607)
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2. AUXILIARY
Unit : m (ft)
Jib Length
Boom Length
9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60)
24.4 (80) 72 (236) 78 (256) 83 (272) 89 (292)
27.4 (90) 78 (256) 84 (276) 90 (295) 95 (312)
30.5 (100) 84 (276) 90 (295) 96 (315) 101 (331)
33.5 (110) 90 (295) 96 (315) 102 (335) 108 (354)
36.6 (120) 96 (315) 102 (335) 108 (354) 114 (374)
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39.6 (130) 102 (335) 108 (354) 114 (374) 120 (394)
42.7 (140) 108 (354) 114 (374) 120 (394) 126 (413)
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45.7 (150) 114 (374) 120 (394) 126 (413) 132 (433)
48.8 (160) 120 (394) 126 (413) 132 (433) 138 (453)
51.8 (170) 126 (413) 132 (433) 138 (453) 144 (472)
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54.9 (180) 132 (433) 138 (453) 144 (472) 150 (492)
57.9 (190) 138 (453) 144 (472) 150 (492) 156 (512)
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This table indicates the required rope length in case
that the hook height is about boom foot.
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2. Cautions in storing
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• Store the wire rope in dry atmosphere.
In case of outdoor storage, ensure to put the cover
to protect from rain.
• Do not place the wire rope directly on the ground
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but place them approx. 200 to 300 mm above the
ground with wooden sleepers.
To drum
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not to cause laying or kink.
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Wire ropes are simply wound on the drum and not tight
under tension at the factory delivery.
Lifting the large load without tension on the base layer
may cause upper layer to penetrate into lower layer and
may cause rope deformation, rope upsetting or prema-
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ture strand cut.
Ensure to feed out all of the wire rope from the drum pri-
or to actual crane work and properly wind the dead
turns to the drum applying tension based on the work
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content.
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(1) Pass the wire rope end through the inside of the
drum flange and fix it to the drum flange by pressing
with two mounting plates.
Do not allow the rope end to protrude from the drum
flange.
Paint the wire rope here
in “WHITE”.
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Rope end should come out
(2 X 2 - M20 X 65 of mounting plate end but
Tightening Torque : not to protrude from drum
333 to 407 N-m) flange out dia.
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If the rope end is not firmly fixed, rope may slip out
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(2) Pull the wire rope manually and wind up on the drum
groove while guiding the rope along the drum end
guide.
Make sure that minimum 3 turns remain on the
drum even wire rope is fed out to maximum. FLANGE
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Tap Lightly
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If more than 3 turns do not remain on the drum, wire
rope may slip out and lifting load may drop off.
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Ensure to have minimum 3 turns remained on the
drum.
Failure to observe this precaution may result in se-
rious accident.
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(3) Then apply the required tension on the wire rope
and wind up to the drum.
Refer to the chapter “Applying tension on the rope”
and its figure.
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(1) Do not allow the wire rope end to come out of drum
wedge hole.
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Tension side rope should come to the straight face WIRE ROPE
Do not allow wire rope
side of socket. to come out of wedge end.
Install the wedge firmly on the drum.
WEDGE
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(2) Pull the boom hoist wire rope manually and tap light-
Pull Pull Pull
ly on the wire rope to align and wind the wire rope
slowly.
Apply tension on the wire rope by boom weight and
slowly wind on the drum.
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Lightly tap Lightly Twist Lightly tap
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WINDING OF WIRE ROPE
(In case of boom hoist wire rope)
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Take extra care on running wire rope to prevent ac-
cident of being crushed or being entangled.
Failure to observe these precautions may result in
serious injuries or loss of life.
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(3) Make sure that minimum 3 turns remain on the drum
even wire rope is fed out to maximum.
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PARALLEL -
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LOWER LAYER
FLANGE
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PROTRUSION
CROSS - OVER
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PARALLEL
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FLANGE PROTRUSION
CLEARANCE
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rope rotating property, correct them as per the following
procedure.
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(1) Type of wire rope lay There are two types of wire
rope lay, Right hand lay and Left hand lay.
Be careful about the type of lay.
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RIGHT HAND LAY LEFT HAND LAY
rope completely.
Turn the rope socket side end forcibly by repeating
hook hoisting or lowering in such way that the ap-
plied lay portion will move toward drum side se-
quentially.
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hand twisting
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Since it would be difficult to correct evenly through-
out the entire length by one trial, limit the rope rota-
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tions to 4 to 5 on one trial.
Repeat the correcting for several times based on
the conditions.
• The cause of entanglement may vary based on the
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timing of entanglement occurrence.
Be careful on this point.
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2. Insert the wedge and pull the wire rope loop with
WEDGE
the wedge strongly to fix.
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4. Install the socket to the boom or hook and apply the ROPE CLAMP
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load to the wire rope to pull in the wedge to the final
position.
When installing the rope socket to the boom point,
make sure to install in the proper direction.
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CLAMP
LOAD LINE DEAD END
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PULL
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Insert the rope socket mounting bolt from boom in-
ner side and fix it with the nut and split pin at the
outer side.
If fixed with nut at the inner side, the wire rope and
the split pin would interfere and the nut would be-
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come loose and fall off.
Failure to observe this precaution may result in se-
rious accident.
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Items (6) onwards should be replaced with new one
as soon as possible according to the degree of
damage.
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TYPE OF WIRE ROPE
• HOOK HOIST WIRE ROPE
• BOOM HOIST WIRE ROPE
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• THIRD DRUM WIRE ROPE (OPTION)
• GUY LINE
• TAGLINE WIRE ROPE (OPTION)
• REEVING WINCH WIRE ROPE (OPTION)
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(1) 10% or more steel wires are broken excepting filler
Length of one lay. (one pitch)
wires in one lay of wires. Inspection of internal
1 2 3 4 5 6
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(2) Wire rope of more than 7% (or 5%, under OSHA Method of measuring rope diameter.
1926.1413) reduction of diameter from the nominal
diameter, caused by abrasion.
Correct Wrong
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STRAND
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ELEMENT WIRE
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Be careful on this point.
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(B) Diameter
Diameter of wire rope will be reduced by wear.
Diameter also is reduced by applying overload.
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Therefore, it is necessary to keep measuring its di-
ameter for safety.
a
6 strand
a+b+c
d=
3
Even number
strand In the same cross sections, measure on almost
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㩷 90 degree angle and take average of those.
a
a
Others
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a+b
d= b
2
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to 1 layer length and its known thickness t at 3 position
a
and take measurement as shown and deduct t from
3 strand its average value.
t
a+b+c
d= -t
3
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Odd number
strand In the same cross section, place the plate with 1/2
to 1 layer length and its known thickness t at 3 position
and take measurement as shown and deduct t from
a
Others its average value.
t
a+b
d= -t
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(4) Due to upper layer wire rope with load penetrated
into lower layer wire rope and lower wire rope is ex-
nl
cessively deformed.
(5) Excessive deformation or corrosion is observed on
the wire rope.
(6) Excessive elongation is observed due to overload-
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ing or derailment from sheaves.
(7) A short circuit has been formed electrically.
(8) Those wire ropes that are subject to fire or spark by
electric current or by gas welding as well as subject
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to high temperature.
from the inside in the boom guy line, replacement Normal crane work 6 years
time cannot be judged from the appearance. Both crane and clamshell work, or
4 years
If the guy line is broken by progressing of internal frequent crane work such as landing work
damage and/or corrosion, there is possibility to Lifting magnet or clamshell work only 2 years
cause an serious accident.
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WEIGHT ROPE
(VINYL TUBE)
WEIGHT
7. MAINTENANCE
In order to use this machine always safely in the best
condition, preventive maintenance is required.
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Failure to observe this precaution may result in se-
rious injury or loss of life.
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1. PRECAUTIONS WHEN PERFORMING CHECK
AND MAINTENANCE
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• Carry out check and maintenance with a suitable
working clothes on.
• Be sure to set the machine on a firm and level
ground, and post a notice board showing “Under
Check and Inspection”.
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• Check and maintenance in a place of higher than
two meters are elevation work.
Be sure to use a working scaffold and safety belt.
• When moving to perform check and maintenance,
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2. INSPECTION TABLE
3. MAINTENANCE
• Maintenance
When replacement of parts and readjustment are
required by check, immediately replace or adjust.
If repair is necessary, consult the service shop des-
ignated by Manitowoc.
• Parts
Use the Manitowoc genuine parts for replacement
parts and lubricant to be used in order to keep per-
formance of the machine.
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The parts of consumption such as elements, etc.
must be replaced somewhat early in order to pre-
nl
vent deterioration of performance due to delay of
replacement.
For doubtful point regarding check and mainte-
nance, consult the service shop designated by
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Manitowoc.
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Use Manitowoc
genuine parts.
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The warranty does not cover malfunctions caused by
the use of parts other than Manitowoc genuine parts
(genuine oil, grease and filter).
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• Clean carrier.
Cleanly wash the carrier to make finding of oil leak,
crack, loosening and other wrong condition easy.
Especially, clean grease fittings, breathers and oil
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level gauge parts (window for check of oil), and
avoid entering of dust.
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• Disposal of spilled oil.
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Doὐᬌਛ
notUVCTV
WPFGTEJGEMKPI
ᆎേߔࠆߥ
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• The lighting of fires prohibited!
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Wastes with oil adhered and combustibles should
be stored in a safe place without fire.
Confirm the storage position and using method of
fire extinguisher for emergency.
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• Check the drained oil and filter.
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When replacing oil or filter, check the drained oil
and oil filter to see if the significant amount of metal
powder or foreign material are included.
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• Pay attention to internal pressure.
When removing hydraulic system, air system, fuel
system or pipings and connectors of cooling sys-
tem and other related parts which have internal
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pressure, bleed internal pressure beforehand.
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troller, remove them to prevent damage.
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• Treatment of discarded oil.
Be sure to drain discarded oil into a container such
as oil can, and treat it as industrial discharges.
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troller etc.).
Failures due to unauthorized modification, unau-
thorized parts installation or wrong handling of com-
ponents would not be covered by WARRANTY.
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2 Engine O
3 Hose, piping, connector O
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4 Swing brake O
5 Swing lock O
6 Control lever, brake pedal O
O
7 Gantry O
8 Horn, head light, wiper O
9 Air cleaner O
10 Pin, link, cotter pin O
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11 Bolt, nut O
12 Hook overhoist preventive device O
13 Boom overhoist preventive device O
14 Load safety device, monitor O
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15 Drum lock O
Upper 16 Window glass, step, handle, guard O
machinery 17 Front, rear drum brake disk O
18 Fuel pre-filter O
19 Fan belt O
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26 Gantry cylinder O
27 Drum lock O
Fuel supply pump, hose
28 O
(Option)
29 Swing alarm lamp O
30 Accumulator O
31 Frame O
* The item numbers in the above table correspond to the numbers in the following description.
* The item numbers, 3, 10, 11 are not indicated in the drawing.
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machinery 38 Swivel joint O
39 Slewing bearing O
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40 Crawler shoe O
Drive tumbler, idler wheel,
41 O
upper and lower roller
42 Slewing bearing mounting bolt O
O
43 Frame O
44 Upper spreader, lower spreader O
45 Hook, latch O
46 Cable roller, Guide roller O
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47 Sheave O
48 Boom, jib O
49 Pin, link, cotter pin O
Attachment
50 Bolt, nut O
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51 Boom backstop O
52 Strut O
53 Wire rope, guy line O
54 Load detector rope socket pin, bolt, nut O
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* The item numbers in the above table correspond to numbers in the following description.
* The item numbers 33, 34, 49 and 50 are not indicated in the drawing.
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2 Engine O
3 Radiator O
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4 Hydraulic oil tank O
Drum lock
5 O
(Front, rear, third, boom)
O
6 Hydraulic oil tank O
7 Swing reduction unit O
8 Power divider O
9 Drum shaft bearing O
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Reduction unit
10 O
(Front, rear, third drum (Option))
Upper
Reduction unit
machinery 11 O
(Boom drum)
12 Engine (Engine oil) *2 O
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13 Fuel tank O
14 Radiator O
15 Reduction unit-swing O
Reduction unit
16 O
(Front, rear, third drum (Option))
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Reduction unit
17 O
(Boom drum)
18 Power divider O
19 Fuel tank O
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20 Washer tank O
21 Swing bearing O
22 Reduction unit-propel O
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36 Boom point sheave O *6 O *5
37 Idler sheave O *6 O *5
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38 Auxiliary sheave O *6 O *5
39 Upper spreader sheave (Boom hoist) O *6 O *5
40 Lower spreader sheave (Boom hoist) O *6 O *5
O
41 Gantry peak sheave O *6 O *5
Attachment
42 Strut sheave O *5
43 Strut equalizer sheave O *5
44 Jib point sheave O *5
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45 Rear guide sheave O *5
46 Blank
47 Blank
48 Front, rear wire rope *7
49 Boom hoist wire rope *7
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*3 Replace item 23 every week or every 50 hours operation in case of clamshell or lifting magnet work.
*4 Replace item 27 to 29 at the overhaul time, unless any abnormality such as oil leak is noted.
*5 Item 36 to 45 are grease sealed type.
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7.2 INSPECTION
7.2.1 INSPECTION OF UPPER MACHINERY
31 23
30
15,27
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24
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28
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23
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24
25
22
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15,27
18
21
23
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1
17
24
2
15,27
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23
19
15,27
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17
20
6
14 (MONITOR)
4
8
6
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5
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6
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14 (CONTROLLER)
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12
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7 13
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26
O
16
29
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16
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Check Reference
No. Identification Check item Check method
interval page
1 Fuel and hydraulic lines Damage Visual check 7-24
Starting,
Starting, leak,
2 Engine check by 7-24
unusual noise
hearing
3 Hose, piping, connector Oil leak Visual check 7-24
4 Swing brake Effectiveness Operation 7-24
5 Swing lock Performance Operation 7-25
Operation,
6 Control lever, Brake pedal Play, deformation 7-25
visual check
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Daily or 7 Gantry Deformation, crack Visual check 7-25
every Operation,
8 Horn, head light, wiper Performance 7-25
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8 hours visual check
(Every shift) 9 Air cleaner Clogging (indicator) Visual check 7-26
10 Pin, link, cotter pin Damage, falling off Visual check 7-26
11 Bolt, nut Looseness, falling off Visual check 7-26
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12 Hook overhoist preventive device Performance Operation 7-26
13 Boom overhoist preventive device Performance Operation 7-26
14 Load safety device, monitor Performance Operation 7-26
15 Drum lock Performance Operation 7-27
Damage, crack,
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16 Window glass, step, handle, guard Visual check 7-27
falling off
17 Front, rear drum brake disk Wear (indicator) Visual check 7-28
Weekly or
every 18 Fuel pre-filter Water level Visual check 7-29
50 hours
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* The item numbers in the above table correspond to the numbers in the following description.
* The item numbers 3, 10, 11 are not indicated in the drawing.
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Check Reference
No. Identification Check item Check method
interval page
Push with
19 Fan belt Looseness, damage finger, 7-30
visual check
20 Radiator, oil cooler Oil leak, damage Visual check 7-32
Engine mounting bolt, Visual check,
21 Looseness, damage 7-32
rubber mount test hammer
Oil leak, Visual check,
22 Power divider 7-32
unusual noise check by hearing
Monthly or Oil leak, Visual check,
23 Hydraulic motor, Reduction unit 7-33
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every unusual noise check by hearing
100 hours 24 Valve, etc. Oil leak Visual check 7-33
Oil leak,
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Visual check,
25 Hydraulic pump 7-34
unusual noise check by hearing
26 Gantry cylinder Oil leak, damage Visual check 7-34
27 Drum lock Wear, damage Visual check 7-34
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Performance, Operation,
28 Fuel supply pump, hose (Option) 7-35
damage visual check
Alarm sound, Operation,
29 Swing alarm 7-35
Filament is gone visual check
Semi-annually 30 Accumulator Oil leak, damage Visual check 7-36
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or every
31 Frame Damage, crack Visual check 7-37
500 hours
* The item numbers in the above table correspond to the numbers in the following description.
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36
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42
37
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43
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32
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35
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41 43 39 38 42 40 41
R
41
Check Reference
No. Identification Check item Check method
interval page
Daily or 32 Hose, piping, connector Oil leak, damage Visual check 7-38
every 33 Pin, link, cotter pin Damage, falling off Visual check 7-38
8 hours
34 Bolt, nut Looseness, falling off Visual check 7-38
(Every shift)
Oil leak,
35 Hydraulic motor, reduction unit Visual check 7-38
unusual noise
36 Valve, etc. Oil leak Visual check 7-38
Weekly or
37 Crawler extend/retract cylinder Oil leak, damage Visual check 7-38
every
38 Swivel joint Oil leak Visual check 7-39
50 hours
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39 Slewing bearing Unusual noise Check by hearing 7-39
Extension, damage,
40 Crawler shoe Visual check 7-39
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wear
Quarterly Drive tumbler, idler wheel,
41 Oil leak, damage Visual check 7-40
or every upper and lower roller
250 hours 42 Slewing bearing mounting bolt Looseness, falling off Visual check 7-40
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Semi-annually
or every 43 Frame Damage, crack Visual check 7-41
500 hours
* The item numbers in the above table correspond to numbers in the following description.
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* The item numbers 33, 34 are not indicated in the drawing.
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47
47
53
44
53
53
46
44 45
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47 51
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48
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55
54
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53
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47
52
53
47
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51
45
Check Reference
No. Identification Check item Check method
interval page
44 Upper spreader, lower spreader Deformation, crack Visual check 7-42
45 Hook, latch Damage, looseness Visual check 7-42
Damage,
46 Cable roller, Guide roller Visual check 7-42
deformation, wear
Damage,
47 Sheave Visual check 7-43
deformation, wear
Daily or 48 Boom, jib Damage, deformation Visual check 7-43
every 49 Pin, link, cotter pin Damage, falling off Visual check 7-43
8 hours 50 Bolt, nut Looseness, falling off Visual check 7-43
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(Every shift) 51 Backstop (Boom, jib) Damage, deformation Visual check 7-44
52 Strut Damage, deformation Visual check 7-44
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Damage,
53 Wire rope, guy line Visual check 7-45
deformation, wear
Load detector rope socket pin,
54 Looseness, falling off Visual check 7-45
bolt, nut
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55 Hoist wire rope clamp bolt Looseness, falling off Visual check 7-46
* The item numbers in the above table correspond to numbers in the following description.
* The item numbers 49, 50 are not indicated in the drawing.
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If fuel leak is observed, repair leak and remove ex-
cess fuel immediately.
Failure to observe this precaution may result in se-
rious accident.
O
2. ENGINE
Start the engine to confirm proper starting condition
and listen for unusual noise.
ce
3. HOSE, PIPING AND CONNECTOR, ETC.
Check the hose, piping and connector, etc. for oil
leaks and for damage.
en
4. SWING BRAKE
Confirm that the swing brake is functioning proper-
ly.
SWING BRAKE
With the swing brake switch placed in the ON posi- SWITCH
tion, operate the swing control lever to confirm that
er
5. SWING LOCK
Confirm that the swing lock pin is inserted smoothly
and can be held being pulled out. Check the lock
pin and rod for deformation.
y
SWING LOCK
CONTROL LEVER
nl
6. CONTROL LEVER, BRAKE PEDAL
Check the control lever and brake pedal for unusual
play and for damage. CONTROL LEVER
O
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BRAKE PEDAL
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7. GANTRY
Check the gantry for damage.
GANTRY
er
9. AIR CLEANER
Use the sensor to determine if the air cleaner is
clogged.
When the air cleaner is clogged the error code will
be indicated on the monitor as below.
y
nl
AIR CLEANER
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SENSOR
Check the pin, link and cotter pin for damage and
to determine if they are loose or missing.
loose or missing.
operates normally.
(Refer to chapter 3. LOAD SAFETY DEVICE)
THIRD DRUM
LOCK KNOB
(OPTION)
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BOOM DRUM
LOCK KNOB DRUM LOCK
nl
FRONT DRUM
LOCK KNOB
REAR DRUM
LOCK KNOB
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16. WINDOW GLASS, STEP, HANDLE AND GUARD
Always clean the window glass, step, handle and
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guard, etc.
Immediately remove any grease and oil.
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(RIGHT SIDE VIEW)
nl
Be sure to lower the hook block onto the ground to Protruded length during
free fall mode (Approx. 21 mm (13/16 inch))
prevent it from dropping abruptly.
Failure to observe this precaution may result in se- Normal protruded length
(Approx. 8 mm (5/16 inch))
O
rious accident. (When pushed in after engine is stopped.)
ce
INDICATOR
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(2) Loosen the water draining plug (C) of the fuel pre- (B)
nl
fuel pre-filter case. (A)
(3) Tighten the water draining plug (C). (C) (Referenced tightening torque :
2 to 3 N-m [1.5 to 2.2 lbs-ft])
(4) Actuate the priming pump and bleed air from the
fuel system.
O
Drained water contains fuel, therefore, follow the pro-
cessing regulation specified in each region, when dis-
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posing of it.
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FAN BELT FAN BELT
(Alternator side) (Compressor side)
nl
O
ce
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The ultrasonic tension meter reads the belt fre-
quency and indicates it.
nl
(6) Repeat the above actions (5) for about five times
and confirm that the average value is within the
specified value range.
O
Specified tension value: 1,324 to 1,422 N
(135 to 145 kgf)
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the rubber mount for damage.
nl
O
BOLT
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RUBBER
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POWER DIVIDER
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SWING MOTOR AND REDUCTION UNIT
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MOTOR
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REDUCTION UNIT
REDUCTION UNIT
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MOTOR
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24. VALVE
Check each valve for oil leak.
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HYDRAULIC PUMP
O
ce GANTRY CYLINDER
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PUMP
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SWITCH
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29. SWING ALARM
Make sure that the swing alarm and swing flasher
on left and right rear of main machinery function
properly while operating machine swing.
ce
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30. ACCUMULATOR
Check the accumulator for oil leak.
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Do not remove valve cap except when charging or
discharging gas.
Do not step on or place heavy material on the accu-
nl
mulator installed on the machine.
Check the accumulator for gas pressure every two
years.
Ask Manitowoc authorized dealer to charge the
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gas.
Do not disassemble the accumulator.
ACCUMULATOR
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31. FRAME
UPPER
Check the frame for crack and deformation. FRAME
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Check the pin, link and cotter pin for damage, and
for falling off.
nl
34. BOLT AND NUT
Check the bolt and nut for looseness and for falling
off.
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CHECK OF LOWER MACHINERY, MONTHLY OR EVERY 100 HOURS
36. VALVE
Check the valve, etc. for oil leak.
CRAWLER
Check the crawler extend/retract cylinder for oil EXTEND/RETRACT CYLINDER
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SLEWING
BEARING
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40. CRAWLER SHOE SHOE
Check the crawler shoes for looseness and for
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damage and wear.
If the crawler tension is too high, the shoes wear
quickly and a connection part of shoes could
break.
On the other hand, if the crawler tension is too
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loose, the shoes may ride off the drive tumbler or SLACK
idler wheel during propelling. 10 to 20 mm
(3/8 to 13/16 inch)
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42. SLEWING BEARING MOUNTING BOLT
Check the slewing bearing mounting bolt for loose-
ness and falling off.
nl
Remove the upper and lower covers of the revolv-
ing frame for the inner bolt checking.
If the bolt is loose, remove and check it.
And if it is damaged, replace it with new one.
O
If the removed bolt is not damaged, clean and coat
it with LOCTITE #242 or equivalent, then securely
tighten it.
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Tightening torque:
• Outer Bolt = 2,780 N-m (2,050 lbs-ft)
BOLT (OUTER)
• Inner Bolt = 2,780 N-m (2,050 lbs-ft)
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BOLT (INNER)
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UPPER COVER
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LOWER COVER
Inspection bole
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BOLT (INNER)
UPPER FRAME
43. FRAME
Check the carbody and crawler frame for crack and
damage.
CRAWLER FRAME
(L.H.)
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CARBODY
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CRAWLER FRAME
(R.H.)
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CHECK OF ATTACHMENT
(Refer to P.7-22 to 7-23)
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Do not touch a wire rope directly with bare hands.
If wires protrude, you could be injured.
nl
Working gloves are recommended.
Failure to observe this precaution may result in se-
rious injury or loss of life.
O
Before climbing on machine make certain that the
guard and walk ways are clean and dry, and use
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safety belt in order to prevent falls due to slippery
surface.
Failure to observe this precaution may result in se-
rious injury or loss of life.
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BEARING
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LATCH
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47. SHEAVE
• Boom point sheave
• Idler sheave
• Auxiliary sheave
• Jib point sheave
• Strut sheave
• Gantry peak sheave
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48. BOOM AND JIB
Check the boom and jib for damage and deforma-
nl
tion. Do not use the damaged and/or deformed
boom and jib.
Be sure to replace the damaged boom and jib with
new ones, or repair.
O
Due to the high strength steels used in boom and jibs,
BOOM
special repair procedures are required.
ce
Consult your local Manitowoc authorized dealer for in-
struction.
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JIB
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Consult your local Manitowoc authorized dealer for in-
struction.
JIB STRUT STRUT
nl
BACKSTOP
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52. STRUT
Check the jib strut for damage, deformities and
usual play.
en
53. WIRE ROPE AND GUYLINE BOOM HOIST BOOM GUY LINE
WIRE ROPE
Check the wire rope and guy line for damage and
deformation and wear.
Signs are; Kink, Crushing, Unstranding, Birdcage,
Core Failure / Protrusion, Significant corrosion,
Electric arc damage.
Also inspect socket and end conditions.
Do not use the wire rope and guy line sustaining
HOIST WIRE ROPE
damages beyond regulations described.
Refer to the article 6. WIRE ROPE.
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JIB GUY LINE HOIST WIRE ROPE
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54. LOAD DETECTOR ROPE SOCKET PIN,
BOLT, NUT PIN
Check for the looseness and missing of pin, bolt,
LINK
nut.
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BOLT
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Tightening torque :
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373 N-m (275 ft-lbs)
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SHEAVES
The operating condition of main and aux. hook can
change daily with use; therefore, they must be inspect-
SHEAVE PIN
ed daily (at start of each shift) and observed during op-
eration for any defects which could affect their safe
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TIE BOLT
operation. Correct all defects before using the hook
GREASE
block or ball hook. FITTING
HOOK PIN
Daily inspection and maintenance will include the fol- THRUST
BEARING
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lowing points.
LATCH
(1) Clean the hook block or the ball hook. SIDE PLATE
(5) Check the fit of the wire rope in the groove of each
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(6) Check that the hook, the trunnion, and the swivel ro-
tate freely without excessive play.
Faulty operation indicates faulty bushings or bear-
ings or inadequate lubrication.
(7) Check the swivel of the hook for the following con-
ditions:
Overloading: Spin the swivel by hand; if the motion
is rough or has a ratchet-like effect, the swivel bear-
ings are damaged.
(8) Check the main hook for signs of overloading:
spread side plates, elongated holes, bent or elon-
y
gated tie-bolts, and cracks.
(9) Check the wire rope for wear and broken wires at
nl
the point the wire rope enters the dead-end socket. SOCKET
Check the socket for cracks. Tighten the wire-rope
clips at the dead end of the wire rope.
(10) Check that each hook is equipped with a hook
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latch and that the latch operates properly. The latch
must not be wired open or removed.
WEDGE
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The latch must retain slings or other rigging in hook un- PULL
der slack conditions. The latch is not intended as anti-
fouling device, and caution must be taken to prevent
hook latch from supporting any part of load. Slings or CHECK FOR WEAR
AND DEFORMATION
other rigging must be seated in hook when handling
en
AND DEFORMATION
Do not attempt to repair cracks in hooks and shackles
by welding. Furthermore, do not weld on any load bear-
ing component unless proper welding methods are CHECK FOR WEAR
AND STRAIGHTNESS
used. Contact Service Department at factory for mate-
rial and welding specifications.
CHECK FOR
“OPENING UP”
SHACKLE
STANDARD OIL (WATER) SUPPLY CAPACITY TABLE (NOT INCLUDING GREASING POINT)
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ULTRA LOW SULFUR FUEL.
Fuel tank - 400 (105.6)
Sulfur contained 50 ppm or less.
#46
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Hydraulic oil tank Hydraulic oil HO 380 (100.3)
#32 (OPTION)
Upper Power divider Gear oil #90 GO 10.7 (2.8)
Front, rear drum
Gear oil #80W-90 GO 22/each (5.8/each)
reduction unit
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Boom hoist drum
Gear oil #90 GO 5 (1.3)
reduction unit
Swing reduction unit Gear oil #90 GO 16.5 (4.3)
Propel reduction unit Gear oil #90 GO 18 (4.8)
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Idler wheel Gear oil #140 GO 0.25/each (0.07/each)
Lower
Lower roller Gear oil #140 GO 0.13/each (0.03/each)
Upper roller Gear oil #140 GO 0.06/each (0.02/each)
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#90
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Gear oil GO
#80W-90
#140
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SAE #10W-30
Engine oil MO
(DH-2, CJ-4, E-6)
LUBRICATION CHART
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EPG Multipurpose grease
Grease
NLGI No.2 Lithium base grease EP type
nl
GL NLGI No.1 Lithium base with Mo52 grease
Above 40 °C 40 °C to - 0 °C 40 °C to -30 °C
Engine Oil MO (Above 104°F) (104°F to 32°F) (104°F to -22°F)
SAE40 SAE30 SAE10W-30
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RECOMMENDED HYDRAULIC OIL
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VG32 VG32 VG46 VG68
KW32S KW32 KW46 KW68
NUTO NUTO NUTO
ESSO -
H32 H46 H68
DTE DTE DTE DTE
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MOBIL
13 24 25 26
RANDO RANDO RANDO
CALTEX -
HD32 HD46 HD68
TELLUS TELLUS TELLUS
SHELL -
32 46 68
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This page is blank for editing convenience.
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5 7,15
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1,13 20
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4,6,19
9
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10,16
8,18
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2,12
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3,14
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11,17 5
Check and
Item Required Kind Amount Reference
lubrication Check and lubrication place
No. service of lubricant ltr. (gal) page
interval
1 Fuel tank *1 Supply fuel Diesel fuel 400 (105.6) 7-58 to 7-59
Daily or
2 Engine (Engine oil) Check oil level MO 7-59
every
Check
8 hours 3 Radiator LLC 7-60
coolant level
(Every shift)
4 Hydraulic oil tank Check oil level HO 7-61
Weekly or Drum lock
5 Grease EPG 7-62
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every (Front, rear, third, boom drums)
50 hours 6 Hydraulic oil tank Drain 7-62
Monthly or 7 Swing reduction unit Check oil level GO 7-63
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every
8 Power divider Check oil level GO 7-63
100 hours
9 Drum shaft bearing Grease EPG 7-64
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Quarterly Winch reduction unit
10 Check oil level GO 7-64
or every (Front, rear, third drum (Option))
250 hours 11 Winch reduction unit (Boom drum) Check oil level GO 7-64
12 Engine *2 Replace oil MO 28.5 (7.5) 7-65
Half years
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13 Fuel tank Drain 7-65
or 500 hours
Replace
14 Radiator Soft water 34 (9.0) 7-66
coolant
Annually or 15 Swing reduction unit Replace oil GO 16.5 (4.4) 7-67
every Winch reduction unit 22/1 pc
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23
21
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24
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21 28
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22,26 27 24 29
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Check and
Item Required Kind Amount Reference
lubrication Check and lubrication place
No. service of lubricant ltr. (gal) page
interval
Weekly or
every 21 Slewing bearing Grease EPG 7-71
50 hours
22 Propel reduction unit Check oil level GO 7-71
Quarterly
23 Slewing ring gear *3 Grease GL 7-72
or every
24 Axle extension Grease EPG 7-72
250 hours
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25 Blank
Annually or
18/pc
every 26 Propel reduction unit Change oil GO 7-73
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(4.8/pc)
1,000 hours
Change oil 0.13/pc
27 Lower roller GO 7-73
leak (0.03/pc)
0.06/pc
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*4 28 Upper roller Check oil leak GO 7-73
(0.02/pc)
0.25/pc
29 Idler wheel Check oil leak GO 7-73
(0.06/pc)
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*3 Replace item 23 every week or every 50 hours operation in case of clamshell or lifting magnet work.
*4 Item 27 to 29, replace them at the overhaul time if there is no abnormality such as oil leak is noted.
37 38
50 36
39 48
49
32
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33
40
41
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31
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30
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43
51
44
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51 45
48
42
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34
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Check and
Item Required Kind of Reference
lubrication Check and lubrication place
No. service lubricant page
interval
Daily or 30 Boom foot pin Grease EPG 7-74
every
8 hours 31 Gantry link Grease EPG 7-74
(Every shift)
Weekly or 32 Hook sheave Grease EPG 7-75
every 33 Hook bearing Grease EPG 7-75
50 hours 34 Ball hook bearing Grease EPG 7-75
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36 Boom point sheave Grease EPG
37 Idler sheave Grease EPG
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38 Auxiliary sheave Grease EPG
39 Upper spreader sheave (For boom hoist) Grease EPG
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every 41 Gantry peak sheave Grease EPG
1,000 hours 42 Strut sheave Grease EPG
*5 43 Strut equalizer sheave Grease EPG
44 Jib point sheave Grease EPG
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45 Rear guide sheave Grease EPG
46 Blank
47 Blank
48 Front and rear hoist wire rope Lubricate WO
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1. ADDING FUEL
After daily work is finished, fill the fuel tank as full as
possible in order to minimize condensation.
y
Never run the fuel pump empty.
nl
Do not use fuel other than those specified.
Check for proper type of fuel again before refilling.
When fuel is to be refilled, ensure to stop the en-
O
gine.
Do not overfill the fuel. Otherwise it may cause fire. Bottom of tank
DRAIN COCK
Ensure to wipe off spilled fuel completely.
Do not bring fire close.
ce
Failure to observe these precautions may result in
serious injuries or loss of life.
en
resulted.
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SWITCH
Refer to P.7-65 for fuel tank drain.
OIL FILL
PORT
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2. ENGINE OIL LEVEL CHECK
Ensure to check the engine oil level prior to work.
Wipe the level gauge clean once and then insert the
level gauge.
en
PROPER
OIL LEVEL
MESH
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Failure to observe this precaution may result in se-
rious injury or loss of life.
nl
The long life coolant (LLC) is flammable and it is
O
harmful for human body.
Keep away from flame when it is replaced. Ensure
no to splash the long life coolant (LLC) to the eyes
and the skin.
In case the LLC contacts the eyes and skin, imme-
ce
diately wash thoroughly with clear water and con-
sult with doctor.
Failure to observe this precaution may result in se-
rious injury.
en
y
Refer to P.7-70 for replacing hydraulic oil.
nl
O
ce
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Label
specified
R
range
OIL
SURFACE
LEVEL GAUGE
HYDRAULIC
OIL TANK
5. DRUM LOCK
Supply grease to the drum lock of the front, rear
and third drum (option) from the grease fittings pro-
vided on the front face of the swing frame.
(2 or 3 for with third drum)
y
GREASE FITTING
nl
grease fitting provided under the swing frame.
O
ce
BOOM DRUM
LOCK
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GREASE FITTING
tions).
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DRAIN PLUG
R
Bottom of tank
DRAIN PLUG
LEVEL GAUGE
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DRAIN COCK
MESH ce
PROPER OIL LEVEL
DRAIN COCK
R
LEVEL GAUGE
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10. OIL LEVEL CHECK OF REDUCTION UNIT
(FRONT, REAR, THIRD DRUM (OPTION))
nl
More than 30 minutes of operation stop, check the
oil level. If the oil level is up to red mark on the oil
level meter, it is normal in case of front drum and
rear drum.
O
Refer to P.7-68 for oil change of reduction unit
(front, rear and third drum (option)).
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OIL FILL
PORT
LEVEL GAUGE
en
DRAIN COCK
normal.
y
the use of parts other than Manitowoc genuine parts
(genuine oil, grease and filter).
nl
OIL FILTER
(1) Prepare the container about 30 liter (7.9 gal).
DRAIN COCK
(2) Loosen the drain plug and drain the oil to the pre-
pared container.
O
(3) Tighten the drain plug.
(4) After checking if there is no metal powder mixed in
the oil, pour the new oil to the fill port.
When changing oil, replace the oil filter too.
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(5) When the filter element and the total quantity of the
oil are changed, pour the oil using the guidepost
position of oil pouring.
(Do not start the engine.)
Drive the engine for a few minutes.
PROPER
Stop the engine for about 30 minutes.
en
OIL LEVEL
Then confirm that the oil level is in the proper level. Guidepost position
of oil pouring.
MESH
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DRAIN COCK
Bottom of tank
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(2) Combine soft water (tap water) and Long life cool-
ant, and fill the radiator up to the foot of the water Bottom of radiator
supply port.
nl
In order to prevent air from entering, slowly pour
water. After water pouring, confirm that the water
level does not lower, then tighten the radiator cap.
O
(3) Start and run the engine for about 1 minute. Stop
the engine, and check water level. If insufficient,
add water.
COOLANT BLENDING
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Blend the coolant (long lift coolant) based on ambi-
ent temperature. Refer to P.7-100 for blending.
WATER JACKET
water and consult with doctor. PLUG
Failure to observe this precaution may result in se-
rious injury.
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LEVEL GAUGE
y
nl
DRAIN COCK
MESH
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PROPER OIL LEVEL
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Do not drain the oil when it is hot. The hot oil may
spout out which could result in personal injury. Af-
ter the oil has cooled, drain the oil.
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OIL FILL
Do not drain the oil when it is hot. The hot oil may PORT
nl
spout out which could result in personal injury. Af-
ter the oil has cooled, drain the oil. DRAIN COCK
LEVEL GAUGE
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17. OIL CHANGE OF BOOM HOIST DRUM OIL FILL PORT
REDUCTION UNIT
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Prepare a container of approx. 5 liter (1.3 gal) of
capacity.
Rotate the drum to make the level gauge in hori-
zontal position.
With the level plug removed, remove the drain plug
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y
DRAIN COCK
Do not drain the oil when it is hot. The hot oil may
spout out which could result in personal injury. Af-
nl
ter the oil has cooled, drain the oil.
Failure to observe this precaution may result in se-
rious injury or loss of life.
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LEVEL GAUGE
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Extra care must be taken to ensure that all the hydraulic
tank is completely filled with oil before the engine is re-
nl
started.
Failure to properly prime the hydraulic pumps could re-
sult in a catastrophic failure of the pumps.
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It is standard to replace hydraulic oil every 2,000
hours of the hour meter, but if the oil is remarkably
contaminated or deteriorated, replace the oil re-
gardless of operating hours.
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(1) Prepare a container of approx. 400 liter (105.6 gal).
(2) Remove the cap of the filler port and filter cover.
(3) Loosen the drain plug and drain the hydraulic oil
into the prepared container.
en
(4) Replace the drain plug, fill the tank with the speci-
fied hydraulic oil through the filler port up to the
specified level.
(5) Reinstall the filter cover and oil supply cap.
(6) Check the oil level again.
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DRAIN PLUG
R
Bottom of tank
DRAIN PLUG
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GREASE FITTING
UNIT
Check the oil level more than 30 minutes after the
operation is stopped.
With the drain plug positioned at the right bottom,
remove the level plug. If the oil level is up to the
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DRAIN PLUG
R
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UPPER COVER
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LOWER COVER
SLEWING
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RING GEAR
UPPER COVER
UPPER FRAME
en
(4 locations).
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GREASE FITTING
R
DRAIN PLUG
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Do not drain the oil when it is hot. The hot oil may
spout out which could result in personal injury. Af-
nl
ter the oil has cooled, drain the oil.
Failure to observe this precaution may result in se-
rious injury or loss of life.
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27. OIL CHANGE OF LOWER ROLLER
Remove the both end plugs to drain the oil. Supply
PLUG
the specified oil of specified amount. PLUG
To change oil, consult the local Manitowoc autho-
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rized dealer.
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rized dealer.
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oil.
Supply the specified oil of specified amount.
To change oil, consult the local Manitowoc autho-
rized dealer.
GREASE
FITTING
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31. GANTRY LINK
Grease through the grease fitting provided on the
front member. GREASE
FITTING
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GREASE
FITTING
GREASE
FITTING
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34. BALL HOOK BEARING
GREASE FITTING
Grease from the grease fitting provided on the
bearing cap.
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10-1 6 3
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1,11
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8-2
15 12 13
9
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4
5
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10-2
14 7 8-1
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or every Fuel tank fill port
6 Wash 1 7-80
250 hours strainer
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HINO MOTORS
7 Engine oil element Replace 1 7-81
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hours 8-2 Fuel pre-filter (Element, O-ring, gasket) 1 7-85
Return filter
9 Replace (Repair kit) 1 7-86 to 7-88
(in hydraulic tank)
Filter
Annually 10-1 1 7-89
Wash • O-ring
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or every Line filter
Replace Filter
1,000 hours 10-2 1 7-89
O-ring
NIPPON-DONALDSON
11 Air element Replace 1 7-89
Suction filter
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12 Replace 1 7-90
(in hydraulic tank) Element
Every 2
Fill port strainer
years or 13 Wash 1 7-90
(in hydraulic tank)
2,000 hours
HINO MOTORS
14 Fuel filter (On engine) Replace 1 7-91
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ELEMENT
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(OPEN AIR FILTER)
The clogged air conditioner filter causes air volume
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to decrease and poor air conditioner performance.
Clean the filter according to the check and mainte-
nance list.
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AIR CON.
CONTROL PANEL
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INTERNAL AIR FILTER
BLOW OUT
OPENING
BLOW OUT
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OPENING
BLOW OUT
OPENING
BLOW OUT
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Installation:
Take the reverse way of the installation.
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Cleaning
(1) Cleaning of the internal air filter (once a month)
• Remove the inspection window in rear of the oper-
ator seat.
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• Draw out the filter upward.
• Remove any dirt including dusts from the filter with
compressed air.
If the filter is excessively dirty or clogged, immerse
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it in lukewarm water with a neutral detergent dis-
solved, and wash it by moving it up, down, right.
Then, rinse it with clean water, and let it dry com-
pletely.
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DRAIN FILTER
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LINE FILTER FOR
BRAKE COOLING
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6. WASHING FUEL TANK FILL PORT
STRAINER
Remove the cap, take out the strainer and suffi- OIL FILL
PORT
ciently wash it with washing liquid.
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STRAINER
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Failure to observe this precaution may result in se-
rious injuries or loss of life.
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(3) Remove the dirt or mud adhered to the seal face of
the oil filter body.
(4) Paste the engine oil on the gasket of the new ele-
ment and rotate it lightly to right until it touches the
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body seal face.
O-RING
Ensure to use the new gasket supplied as element kit.
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When installing it, take extra care not to damage the
gasket due to twisting. ELEMENT
Do not reuse the element.
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filter wrench or the pipe wrench.
Filter wrench
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Pipe wrench
(Accessory of machine too: Refer to P.7-119)
The ball to be reused, therefore, it is not damaged
or throw it away.
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AIR BLEEDER PLUG (a)
ELEMENT (c)
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*1
O-RING (f)
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BALL (d)
*1
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Do not re-use the element (c).
Use the new element supplied as element kit. Take ex-
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tra care not to damage the O-ring (f) by twisting.
Make sure that the O-ring (f) touches firmly on the seal
face.
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(C) After the O-ring (f) of the ball (d) contacts the ele-
ment (c), rotate it further for about 1/2 to 3/4 turns
to install the element (c).
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(Referenced tightening torque: 9 to 11.3 N-m
[6.6 to 8.3 lbs-ft])
* Do not use tools. Hand-tighten.
(D) Install further 1/2 turn after contacting the O-ring (e)
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After work, wipe off the leaked fuel and start the engine
and make sure that there is no more oil leak.
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der the drain valve.
BALL
(B) Loosen the air bleeder plug and the drain valve of
the fuel filter to drain water gathered at the inside of
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the fuel filter.
DRAIN VALVE
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Drained water contains fuel, therefore, follow the dis-
posing regulation specified in each region, when dis-
posing of it.
(C) Tighten the water drain valve and air bleeder plug.
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(D) Bleed air from the system.
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(6) Apply light oil to new O-rings (D), (F) thinly, set it to
case (C) and replace it with new element (E). FUEL
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PRE-FILTER
(STANDARD)
(7) Fit case (C) to filter head by hand securely and tight-
en it with filter wrench.
(Referenced tightening torque: 28 to 32 N-m
[20.7 to 23.6 lbs-ft])
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AIR BLEED
(8) Tighten air bleeder plug (A) (Referenced tightening PLUG (A)
torque: 8 to 12 N-m [5.9 to 8.9 lbs-ft]) and *1
ELEMENT (E)
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PROCEDURE OF REPLACING THE RETURN
FILTER
Remove the filter cover and replace the element
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and O-ring with new ones.
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COVER
O-RING
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SPRING
VALVE
O-RING
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ELEMENT
PACKING
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(2) Hold the top mold plate and loosen the grip.
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(3) Pull out the grip assembly.
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(4) Turn over the filter.
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LINE FILTER
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CONTROL
LINE FILTER
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O-RING
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FILTER
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ELEMENT
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COVER
O-RING
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FILTER
O-RING
(FILTER)
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STRAINER
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* Clean the area around the fuel filter before the start
of work.
Otherwise dirt may enter.
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(2) After loosening the drain plug, loosen the air bleed-
er plug and drain the fuel from the drain pipe.
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DRAIN PLUG
* At this time, drain all fuel from the filter. When the
element is replaced without draining all of the fuel,
DRAIN PIPE
unfiltered fuel may remain inside the filter and later
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fl ow to the engine.
(3) Confirm that no more fuel flows from the drain pipe
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Tightening torque
Drain plug 4.9 to 8.9 N-m (3.6 to 6.6 lbs-ft)
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Loosen the center bolt, remove the cap, and then ELEMENT
remove the element.
Tightening torque
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Center bolt 24.5 to 34.3 N-m (18.1 to 25.3 lbs-ft)
Air bleeder plug 4.9 to 8.9 N-m (3.6 to 6.6 lbs-ft)
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* Replace the gasket by the new gasket included in
the element kit.
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(2) After installation, bleed the air from the fuel system.
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If the battery electrolyte level is up to 10 mm (3/8
inch) above the plates, it is normal. If insufficient,
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add distilled water.
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(1) Checking the battery electrolyte level from the side
level line:
(2) When you cannot check the battery electrolyte level OIL FILL PORT SLEEVE
from the side level line, or no level lines are provid-
ed on the side of the battery:
Detach the plug at the top of the battery, and check UPPER LEVEL
the battery electrolyte level from the filling port.
LOWER LEVEL
If the electrolyte level is lower than the sleeve, add
battery electrolyte to the bottom of the sleeve.
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• Never smoke cigarettes while checking electro- Sufficiently
replenished
lyte level. This could cause the battery electro-
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lyte to ignite and cause property damage, injury
When the electrolyte level does not reach
to personnel or loss of life. the bottom of the sleeve, the pole plates
seen to be straight.
Insufficiently
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replenished
3. CHANGING BATTERY
BATTERY
(1) Place the machinery on the horizontal place and
stop the engine.
(2) When changing to new battery, make sure to
change two batteries as one set.
(3) When removing the battery cable, make sure to re-
move the earth side cable {(-) side terminal} first.
(4) After installed, put the red and black battery terminal
covers.
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4. USING BOOSTER CABLES
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Battery generates flammable hydrogen gas.
Do not use fire or spark near the battery.
Do not use or charge the battery when the battery fluid
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(C) Connect one end of the other booster cable (2)
(black) to the battery (-) terminal of the booster ma-
chine and the other end to the upper frame of this
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Booster machine battery This machine battery
machine. Since at the last connection, sparking will
(BLACK)
occur, connect it separating from the battery as
To upper frame of this machine.
much as possible.
2
(D) Make sure for connection and then start the booster
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machine engine.
BOOSTER CABLE CONNECTION
(E) Start this machine engine.
(F) After the engine is started, remove the booster ca-
ble (2) and (1) in this order in the following proce-
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dure which is reverse way to the connection.
(RED)
(B) Remove the booster cable (2) (black) which is con-
nected to the (-) terminal of the booster machine.
(C) Remove the booster cable (1) (red) which is con-
nected to (+) terminal of the booster machine.
(D) Remove the booster cable (1) (red) which is con-
er
nected to (+) terminal of this machine. Booster machine battery This machine battery
(E) Put the red and black battery terminal covers as the (BLACK)
last step. To upper frame of this machine.
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2 Remove first.
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COVER FUSE BOX
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Lower
Upper
FUSE PULLING
TOOL SOCKET
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Fuse No.
Upper
F A F A F A F A
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1 20 20A 11 10 21 5 10A 31 10
2 5 12 10 22 10 32 20
× ×
3 5 13 5 23 10 33 10
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4 5 2 14 20 24 15 5 34 5
5 10 15 10 25 20 35 10
6 5 15A 16 10 26 15 5A 36 10
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7 10 17 5 27 20 37 10
× ×
8 10 18 15 28 20 38 5
9 10 1 19 10 29 10 4 39 10
10 20 20 10 30 5 40 10
Lower
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F10 20A 2F - 20 Output power (MC1)
F11 10A 2F - 21 Auto-stop
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F12 10A 2F - 22 Engine condition
F13 5A 52 - 23 Radio, One-way call
F14 20A 2G - 24 Wiper
F15 10A 2G - 25 Function lock
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F16 10A 2G - 26 Remo-con
F17 5A 2G - 27 Monitor
F18 15A 2E - 28 Air conditioner
F19 10A 2E - 29 Air conditioner2
F20 10A 2E - 30 Fun motor
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Auto motive
F21 5A mini fuse 51 - 31 Generation detect Fuse box
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In order to keep good function of the diesel
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particulate filter, it is recommended to use the
specified brand (recommended) engine oil.
Fuel
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Ambient temp. Type
-5° C (23° F) or more JIS 2 light oil
-5° C to -15° C (23° F to 5° F) JIS 3 light oil
-15° C (5° F) or less JIS 3 special light oil
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Use fuel, suitable to the atmospheric temperature.
Before starting work, drain water. After the work is finished,
fill the tank as full as possible.
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Coolant Combine antigreeze (long life coolant) according to the atomospheric temperature. Sometimes,
combination rate
(Capacity of Coolant : 30 ltr. (7.9 gal)) may be different
Atmospheric Volume of Volume of depending upon
temperature (° C (° F)) Cooling water (ltr. (gal)) antifreeze (ltr. (gal)) brands.
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Battery Sufficiently chage the battery. (Maintain the specific gravity more 1.22.) After distilled water
has been added,
start and run the
engine to mix water
and electrolyte.
The electrolyte in a fully charged battery will resist freezing at
lower temperatures better than a battery that is not fully charged.
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In order to keep good function of the diesel
particulate filter, it is recommended to use the
specified brand (recommended) engine oil.
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Coolant Use of long life coolant compounding ratio of 30%.
Battery Always maintain the electrolyte level 10mm (3/8inch)
above the plates.
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3. OPERATION IN DUSTY PLACE
4. OPERATION IN SEASIDE
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Basic machine
wash salt off.
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particulate filter reaches a certain level, the unit starts
burning process (regeneration).
With this, it is avoided that soot would accumulate to
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abnormal level and cleaning capacity of the diesel par-
ticulate filter is kept to a satisfactory level.
In addition, with using the high performance catalyst
and common-rail fuel injection system, it becomes pos-
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sible to burn (regenerate) soot during the crane work.
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Do not park the crane near the place where dry grass
or inflammable objects are there.
Directly after the work or during cleaning mode, ex-
haust pipe area, muffler and exhaust gas become hot.
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Inflammable object may cause fire. Hot exhaust gas
may also cause burns to personnel.
Failure to observe these precautions may result in seri-
ous injuries or loss of life.
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When the diesel particulate filter is working, take care
of the following points:
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work. Lever work becomes impossible.
• If the low exhaust air temperature continues for
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long time (such as longer than 1 hour idling), regen-
eration motion may be interrupted once when the
lever is turned on to work.
This regeneration may resume whenever lever
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control is finished within a certain period of time.
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• Clean, sufficiently dry, and then carefully lubricate
the entire machine.
• Sufficiently grease the slewing ring gear.
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• Replace the reduction unit gear oil and hydraulic oil
with fresh oil.
• Replace all filters with new ones.
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• Remove the battery and store it in a cold, dark
place.
• Apply thin coat of oil to places that are prone to rust.
• Completely drain coolant and post a “No Water”
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sign.
• Cover the entire machine to protect it from dust.
Nominal Tightening torque N-m (lbs-ft) Tightening torque N-m (lbs-ft) 2 face
width
Dry Lubricated Dry Lubricated mm
(inch)
4.6 to 5.6 3.9 to 4.7 10 to 12.2 8.4 to 10.2 10
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M6
(0.47 to 0.57) (0.40 to 0.48) (1.02 to 1.24) (0.85 to 1.05) (3/8)
11.1 to 12.2 10.3 to 10.5 24.4 to 30.1 20.2 to 24.8 13
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M8
(8.1 to 9.9) (6.9 to 8.5) (18.2 to 22.2) (14.9 to 18.3) (1/2)
22 to 27 18.5 to 22.7 47.6 to 58.2 40.6 to 49.6 17
M10
(16.3 to 19.9) (13.7 to 16.7) (35.1 to 42.9) (29.9 to 36.5) (11/16)
37.1 to 45.3 32.7 to 39.9 81.0 to 99.2 68.8 to 84.0 19
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M12
(27.3 to 33.3) (24 to 29.4) (59.8 to 73) (50.7 to 61.9) (3/4)
59.1 to 72.3 50.2 to 61.5 129 to 157 109 to 133 22
M14
(43.6 to 53.2) (37.1 to 45.3) (94.5 to 115.5) (79.9 to 97.7) (7/8)
90 to 110 75.9 to 92.7 194 to 238 163 to 199 24
M16
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(66.2 to 81) (55.9 to 68.3) (143 to 175) (121 to 147) (15/16)
123 to 151 105 to 129 274 to 334 229 to 281 27
M18
(91 to 111) (77.3 to 94.5) (202 to 246) (169 to 207) (1-1/16)
174 to 212 146 to 178 379 to 463 318 to 388 30
M20
(128 to 156) (107 to 131) (279 to 341) (234 to 286) (1-3/16)
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M27
(319 to 389) (260 to 318) (696 to 850) (579 to 707) (1-5/8)
591 to 723 494 to 604 1279 to 1563 1075 to 1315 46
M30
(436 to 532) (364 to 444) (942 to 1152) (793 to 969) (1-13/16)
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Nominal Tightening torque N-m (lbs-ft) Tightening torque N-m (lbs-ft) 2 face
width
Dry Lubricated Dry Lubricated mm
(inch)
11.6 to 14.2 9.8 to 12 25.6 to 31.2 21.1 to 25.9 13
8
(8.6 to 10.4) (7.2 to 8.8) (18.8 to 23) (15.6 to 19) (1/2)
22.9 to 28.1 19.4 to 23.8 49.4 to 60.4 42.7 to 51.7 17
M10
(16.9 to 20.7) (14.3 to 17.5) (36.4 to 44.4) (31.2 to 38.2) (11/16)
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40.6 to 49.6 34.4 to 42 87.3 to 106.7 73.2 to 89.4 19
M12
(29.9 to 36.5) (25.4 to 31.6) (64.3 to 78.7) (53.9 to 65.9) (3/4)
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94 to 116 79.4 to 97 202 to 248 172 to 210 24
M16
(69.6 to 85) (58.5 to 71.5) (149 to 183) (127 to 155) (15/16)
185 to 227 157 to 191 406 to 496 335 to 409 30
M20
(137 to 27) (116 to 142) (299 to 365) (247 to 301) (1-3/16)
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318 to 388 265 to 323 688 to 840 573 to 701 36
M24
(234 to 286) (195 to 239) (507 to 619) (422 to 516) (1-7/16)
635 to 777 529 to 647 1393 to 1703 1156 to 1412 46
M30
(468 to 572) (390 to 476) (1027 to 1255) (851 to 1103) (1-13/16)
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1058 to 1294 882 to 1078 2311 to 2825 1922 to 2350 55
M36
(779 to 953) (650 to 794) (1703 to 2081) (1417 to 1731) (2-3/16)
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2. Tightening torque of bolt, nut with special specification are listed below.
Tightening torque shall be within ±10% of the value in the list.
2,780 N-m
(2,050 lbs-ft)
ENGINE
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121 N-m
(89 lbs-ft)
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290 N-m
(214 lbs-ft)
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400 N-m 560 N-m
310 N-m
(295 lbs-ft) (413 lbs-ft)
(229 lbs-ft)
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PUMP ASSEMBLY PROPEL REDUCTION UNIT ASSEMBLY
161 N-m 560 N-m
(119 lbs-ft) (413 lbs-ft)
25 N-m
(18 lbs-ft)
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1,150 N-m
310 N-m (848 lbs-ft)
(229 lbs-ft)
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FRONT AND REAR DRUM ASSEMBLY (OUTER) FRONT AND REAR WINCH ASSEMBLY (INNER)
39 N-m
(29 lbs-ft)
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560 N-m
(413 lbs-ft)
BOOM DRUM ASSEMBLY
Apply Loctite #242 or equivalence to the bolts and nuts.
For maintenance, contact your Manitowoc authorize distributor.
39 N-m
(29 lbs-ft)
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or visual inspection.
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spection maintenance time, replace these parts with
new ones even before periodic replacement time as
shown here.
Contact Manitowoc service shop for part replacement.
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REPLACEMENT
No. HOSE RELATED PERIODICAL REPLACING PART INTERVAL
(RECOMMENDED)
Front drum nega. Posi-clutch main hose
Front drum CLM GG20H01053DC
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Front drum ESM GG20H01054DC
1 Rear drum CLA GG20H01053DH
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Rear drum ESA GG20H01054DB
Third drum CLT GG20H01053DD
Third drum EST GG20H01054DD
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Foot brake control hose
Front drum FBM ZX23M06190
2
Rear drum FBA ZX23M06190
Third drum FBT ZX23M06330
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Pressure control hose
3 (Pump to Line filter)
2 years
Relief valve ZX33M08082
Pressure control hose
4 (Line filter to Accumulator)
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Water immersion
If the internal damage or corrosion is progressed,
guy line may be broken and may cause serious ac-
cident. Make sure to replace periodically based on
work content.
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1 Geneal crane work. 6 years
Crane work main with clamshell and bucket work as
2 4 years
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sub.
3 Only for lifting magnet, clamshell and hammer grab. 2 years
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䞉CRANE GUY LINE
Boom guy line chart
Guy line dimension
Connector type
Symbol Diameter mm Remarks [m(ft)]
Length m (ft)
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(in)
A 30 (1–3/16) 6.17 (20.2) Boom tip
B 30 (1–3/16) 3.05 (10) 3.0 (10) Boom insert
C 30 (1–3/16) 6.10 (20) 6.1 (20) Boom insert
D 30 (1–3/16) 12.20 (40) 12.2 (40) Boom insert
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7.12 ADJUSTMENT
7.12.1 ADJUSTMENT OF FRONT, REAR, THIRD DRUM LOCKS
20 (13/16) or more
Do not adjust the drum locks until the boom, hook
block, and load have been lowered to the ground. LOCK
(ENGAGED)
Failure to observe this precaution may result in se-
RELEASE
rious injury or loss of life. (DISENGAGED)
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check to see that the pawl is engaged in the bottom PAWL
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et, adjust the spring length to allow the pawl to be 58 (2-5/16)
109
engaged. (4-5/16) 126 (5)
Lock opened Lock opened
2. With the RELEASE position, adjust the respective Control cable Spring
set length set length
dimension as shown in the figure to the right.
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3. Push the drum lock knob in the RELEASE position FRONT, REAR, THIRD DRUM LOCKS
and check to see that the pawl is clear of the ratchet
by at least 20 mm (13/16 inch).
4. Operate the knob to the LOCK position, and to the
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RELEASE position and confirm that the pawl
moves smoothly.
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If the pawl is not engaged in the bottom of the ratch-
et, adjust the spring dimension to allow the pawl to
be engaged.
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2. With the RELEASE position, adjust the respective
dimension as shown in the figure to the right.
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Unit : mm (inch)
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LOCK (ENGAGED)
LOCK (DISENGAGED)
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PAWL
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LATCHET
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slackening to be 10 to 20 mm (3/8 to 7/8 inch).
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1. Propel the machine forward about one crawler SHIM PACK (A)
length so that the slackening in the crawler shoes SHIM PACK (B)
Machine
appear on the top of the crawler. outside
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3. Position the hydraulic jack between the bracket and
block of the side frame.
Operate the jack to push the idler wheel and re-
Machine
move the slackening in the shoes. inside
COVER (D)
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4. Insert the shims removed from pack (A) in step (2) SPACER
into the vacant room of pack (B). (In the tool box)
JACK BLOCK
IDLER
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BRACKET IN WHEEL
CRAWLER FRAME
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For the recommended fuse, refer to the chart on
page 7-98.
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4. WIRE ROPE
For the recommended wire rope, refer to the of
Chapter 6. WIRE ROPE.
5. LIGHT AND MIRROR
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6. BATTERY
Lens
Lens
Mirror
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Blue
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Spotlight
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WIPER BLADE
RUBBER
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GLASS GLASS SASH ASSY GLASS
WIRE ROPE
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WIRE ROPE
WIRE ROPE
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WEIGHT
WEIGHT
SPLIT PIN
SHACKLE
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PIN
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9. CABLE REEL
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For crane-hook overhoist
For crane jib-hook overhoist
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10. KEY
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ENGINE
DOOR
GUARD
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11. TOOL
(24 mm)
2421R397
(1-15/16 inch)
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(44 mm)
(2-3/4 inch)
HAMMER (+) DRAIVER (-) DRAIVER ADAPTOR
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(When adjustment of shoe)
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(5.5 mm)
(3/16 inch)
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JACK RATCHET HANDLE EXTENSION BAR SPANNER
(When adjustment of shoe)
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(For wrench)
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(B) (PT1/4)
2408R587D2 (19 mm)
(3/4 inch) (C) (PT1/8)
2408R587D3 (22 mm)
(7/8 inch)
2408R587D4 (24 mm)
(15/16 inch)
ZT32A30000 (30 mm)
(1-3/16 inch)
ZT32A55000 (55 mm)
(2-3/16 inch)
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X2
(For 10.0 t)
X4
(For 5.0 t)
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PIPE WRENCH SCREW KEY CHAIN FUEL FILTER (HINO MADE)
(For gantry cylinder) WRENCH
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FUEL FILTER
FUEL PRE-FILTER FUEL FILTER WRENCH ENGINE OIL FILTER
(MOUNTED ON ENGINE)
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dimensioning the winches of this crane.
The winches of this crane are classified as follows.
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(ISO 4301/1, FEM 1.001, DIN Calculating code for
power unit)
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Load spectrum : Q 1 (L 1)
Load spectrum factor : Km = 0.125
Theoretical service life : D = 3,200 h
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The theoretical service life is not the same as the real
(actual) service life of a winch.
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6. Leaks which were ignored.
7. Improper adjustment of safety devices.
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8. Concealed damage caused by accidents.
Extreme low or high temperatures.
9. Extreme environmental conditions: Severe climate condition.
Dust and dirt.
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The operator is responsible for proper documentation
in the crane logbook.
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DETERMINING THE OPERATING CONDITIONS
(LOAD SPECTRUM)
The load spectrum of the crane is divided into groups:
(also refer to ISO 430/1, JIS 8822-2)
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When establishing the load spectrum, the existing wire
cable condition is used as a standard, i.e. under certain
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circumstances, the crane can be supporting a heavy
load, whereby the winch is actually supporting a light
load.
Therefore, the following graphic representation of the
load spectrum refers to the winch's wire cables.
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erating conditions (collective load)”
Ti = Effective operating hours in the testing interval “i” according to section “Determining the actual op-
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erating hours Ti”
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If the remaining theoretical service life is not sufficient
for the next operating period, then a general overhaul
of the winch must be performed.
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If theoretical service life D has been reached (7.14.1),
the winch must not be operated until after a general
overhaul has been performed.
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tive.
The results are to be entered in the crane logbook.
years.
ALTERNATIVE PROVISION
If, after ten years, the theoretical service life has not
been used up, the winch can continue to be operated
without a general overhaul under the following condi-
tions.
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As a minimum, this includes:
• a visual inspection of the exterior
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(for leaks, damage, malformation etc.)
• an oil inspection (especially for metallic residue)
• a load inspection with minimum and maximum rope
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pull and each with maximum possible speed.
At least one position is to be wound.
Pay attention to any unusual noises during the load
inspection.
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This inspection must be confirmed in the crane test
book by the crane expert and there must be a declara-
tion of continued operation for the winch.
The next inspection takes place before the 12th year of
operation and must be repeated every year thereafter.
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10000A-1
Crane model : 10000A-1
Work number :
Commissioned on :
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Serial number of the winch in accordance with the type plate :
7. MAINTENANCE
7-126
0(*) 10. 6. 11 0 0 3,200
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1 5. 6. 12 L1 0.125 800 800 160 160 3,040
(20% of 800)
CAUTION : Si = Used proportion of theoretical service life since the last inspection
A general overhaul is to be performed every 10 years. Di = Remaining theoretical service life
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Di-1 = Remaining theoretical service life after the previous inspection
Alternative provision, refer to [ALTERNATIVE PROVISION] in chapter “10.11.2 ” . Km = Load spectrum factor established during winch calculation.
This factor is given in the operating instructions.
Kmi = Load spectrum factor in the inspection interval “i” .
Ti = Effective working hours in the inspection interval “i” .
Last general overhaul performed on .............................. (*) Copy last line of the previous page to the following pages.
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7.14.3 EXAMPLE
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i.e. Km1 = 0.125.
The operating hour counter reads 800 h. The winch
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was operated 20% of the time,
i.e. T1 = 160 h.
The used proportion S1 of theoretical service life af-
ter the first inspection is therefore:
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0.125
Si = 160 h = 160 h
0.125
ble.
(see table example P. 7-126)
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0.5
Si = 480 h = 1,920 h
0.125
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Remaining theoretical service life:
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D2 = 3,040 h 1,920 h = 1,120 h
this period:
3,000 h - 2,000 h = 1,000 h (2,000 h were used
during the first two years).
The winch was operated 30% of the time,
i.e. T 3 = 300 h.
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0.25
Si = 300 h = 600 h
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0.125
.
8. REFERENCE MATERIALS
8.1 SPECIFICATION
This crane is designed for normal work of lifting hook.
Classification of this crane is as follows. (ISO 4301/2, FEM 1.001)
Class of utilization: U1
State of loading: Q2
Group Classification as crane: A1
In case of severer work condition such as bucket etc, components life may be lowered.
In case of severer work condition, perform work referring to manufacturer's recommended condition.
As for Front or Rear winch, calculate service life of component referring to Article 7.14 MEASURES REQUIRED
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FOR WINCH MONITORING and perform maintenance work under appropriate interval.
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4,430 (14’ 6” )
914 (3’ )
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1,100
ce 5,140 (16’ 10” ) (3’ 7” )
6,190 (20’ 4” )
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3,310 (10’ 10” )
(6’ 8” )
2,030
(5’ 10” )
1,770
(3’ 8” )
1,120
390 (1’ 3” )
R
5,244 (17’ 2” )
(CRAWLER EXTENDED)
16 mm
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Boom lowering rope speed 70 to 2 m/min (230 to 6.6 ft/min)
Third hoisting rope speed (Option) 120 to 3 m/min (390 to 10 ft/min)
22 mm
Third lowering rope speed (Option) 120 to 3 m/min (390 to 10 ft/min)
Swing speed 4.0 min-1 (4.0 rpm)
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Propel speed 1.7/1.1 km/h (1.1/0.72 mph)
Gradability 40%
Working weight *1 90.0 t (198,000 lbs)
Average ground pressure *1 88.9 kPa (12.9 psi)
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Engine
OUTSIDE DIMENSIONS
Unit : mm (ft-in)
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Unit : m (ft)
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54.9 (180) BOOM
55 (180)
51.8 (170) BOOM
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45°
48.8 (160) BOOM
50 (164)
45.7 (150) BOOM
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42.7 (140) BOOM 45 (148)
40°
39.6 (130) BOOM
40 (131)
36.6 (120) BOOM
35°
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33.5 (110) BOOM
35 (115)
30.5 (100) BOOM
30°
27.4 (90) BOOM 30 (98)
25 (82)
21.3 (70) BOOM
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10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
Radius from center of rotation
R
Center of
rotation
1.10 (3.6)
Unit : m (ft)
80 (263)
57.9 (190) Boom 10°
+ 18.3 (60) Jib 80°
57.9 (190) Boom 75 (246)
+ 15.2 (50) Jib
57.9 (190) Boom
+ 12.2 (40) Jib
57.9 (190) Boom 70 (230)
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+ 9.1 (30) Jib
65 (213)
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60 (197)
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55 (180)
50 (164)
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24.4 (80) Boom 45 (148)
+ 18.3 (60) Jib
24.4 (80) Boom
+ 15.2 (50) Jib
40 (131)
24.4 (80) Boom
+ 12.2 (40) Jib
24.4 (80) Boom
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30 (98)
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25 (82)
20 (66)
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10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
Radius from center of rotation
Center of
rotation
1.10 (3.6)
Unit : m (ft)
80 (263)
80° 30°
57.9 (190) Boom
+ 18.3 (60) Jib 75 (246)
57.9 (190) Boom
+ 15.2 (50) Jib
57.9 (190) Boom
+ 12.2 (40) Jib 70 (230)
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57.9 (190) Boom
+ 9.1 (30) Jib
65 (213)
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60 (197)
55 (180)
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50 (164)
45 (148)
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24.4 (80) Boom
+ 18.3 (60) Jib
24.4 (80) Boom
40 (131)
+ 15.2 (50) Jib
24.4 (80) Boom
+ 12.2 (40) Jib
24.4 (80) Boom 35 (115)
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30 (98)
25 (82)
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20 (66)
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10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
Radius from center of rotation
Center of
rotation
1.10 (3.6)
Weight
Name Dimension mm (ft-in)
kg (lbs)
• Crawler
3,350
3,320
(11’)
43,150
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• Wire rope (95,128)
(Front / rear /
boom hoist)
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3,610 (11’ 10”)
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• Wire rope
(10’ 11”)
41,090
3,350
3,320
(11’)
(Front / rear / (90,586)
boom hoist)
• Without boom base
3,610 (11’ 10”)
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Base Machine 8,210 (26’ 11”)
• Gantry
• Crawler
(10’ 11”)
3,350
(11’)
• Wire rope
2,960
er (9’ 8”)
2,930
Crawler 7,640
(16,843)
8.2.2 COUNTERWEIGHT
Weight
Name Dimension mm (ft-in)
kg (lbs)
(3’ 11”)
1.190
No.1 8,310
Counterweight (18,300)
4,430 (14’ 6”)
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(2’ 9”)
830
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880 1,450
(2’ 11”) (4’ 9”)
5,750 /
No.2, No.3
1 piece
Counterweight (R)
(3’ 10”)
1,170 (12,680)
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1,450 880
(4’ 9”) (2’ 11”)
5,750 /
No.2, No.3
1 piece
Counterweight (L)
(3’ 10”)
(12,680)
1,170
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(5’ 8”)
1,720
R
7,240
Carbody weight
(15,960)
1,970
(6’ 6”)
620
(2’)
Weight
Name Dimension mm (ft-in)
kg (lbs)
870
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8.2.3 ATTACHMENT
Weight
Name Dimension mm (ft-in)
kg (lbs)
(4’ 10”)
(4’ 4”)
1,310
1,480
1,170
Boom tip
(2,580)
1,510
(4’ 11”) 6,910 (22’ 8”)
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(5’ 7”)
1,700
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1,475
Boom base
(3,252)
5,970 (19’ 7”) 1,490
(4’ 11”)
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1,310
3.0m (10ft) 310
Boom insert (685)
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1,490
3,160 (10’ 4”) (4’ 11”)
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(4’ 4”)
1,310
(4’ 4”)
1,310
(4’ 4”)
1,310
Weight
Name Dimension mm (ft-in)
kg (lbs)
270
Backstop (595)
5,130 (16’ 10”)
(2’ 8“)
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800
280
Jib tip (617)
790
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(2’ 7”) 5,000 (16’ 5”)
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(2’ 8“)
800
200
Jib base
(440)
800
4,810 (15’ 9”) (2’ 8”)
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(2’ 8“)
800
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(2’ 8“)
800
800
6,160 (20’ 3”) (2’ 8”)
R
(1’ 1“)
340
(2’ 9“)
840
Weight
Name Dimension mm (ft-in)
kg (lbs)
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480
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870 (2’ 10”) (1’ 7”)
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pendulum action, jerking or sudden stopping of
loads, inexperience of personnel, multiple machine
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lifts, and traveling with a load).
2. Rated loads do not exceed 66% of minimum tipping
loads.
Rated loads based on factors other than machine
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stability such as structural competence are shown
by asterisk * in the charts.
3. The machine must be reeved and set-up as stated
in the operation manual and all the instruction man-
uals.
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If these manuals are missing, obtain replacements.
• Boom backstops are required for all boom lengths.
• Gantry must be fully raised position for all opera-
tions.
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weight.
4. Do not attempt to lift where no radius on load is list-
ed as crane may tip or collapse.
5. Attempting to lift more than rated loads may cause
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• 43,700 lbs Counterweight
• Without carbody counterweight.
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(2) (3)
(1)
Counterweights
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Carbody weights
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26.0 57.1 22,000 30.0 59.0 22,000 34.0 60.3 21,400
28.0 53.5 22,000 32.0 56.3 22,000 36.0 58.1 20,200
30.0 49.8 22,000 34.0 53.5 21,400 38.0 55.8 19,200
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32.0 45.9 22,000 36.0 50.5 20,200 40.0 53.4 18,200
34.0 41.7 21,400 38.0 47.4 19,200 42.0 51.0 17,300
36.0 37.0 20,200 40.0 44.2 18,200 44.0 48.4 16,500
38.0 31.8 19,200 42.0 40.7 17,300 46.0 45.8 15,800
40.0 25.7 18,200 44.0 37.0 16,500 48.0 43.0 15,200
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46.0 32.9 15,800 50.0 40.1 14,600
48.0 28.3 15,200 52.0 37.0 14,000
54.0 33.6 13,500
56.0 29.9 13,000
58.0 25.7 12,500
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70' Boom 80' Boom 90' Boom
Load Boom 360° Load Boom 360° Load Boom 360°
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Radius Angle Rated Load Radius Angle Rated Load Radius Angle Rated Load
(ft) (deg.) (lbs) (ft) (deg.) (lbs) (ft) (deg.) (lbs)
34.0 64.9 21,400 38.0 65.1 19,200 42.0 65.2 17,300
36.0 63.1 20,200 40.0 63.5 18,200 44.0 63.8 16,500
38.0 61.2 19,200 42.0 61.9 17,300 46.0 62.4 15,800
18,200 16,500 15,200
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50.0 62.8 14,600 60.0 59.6 11,600 60.0 62.3 11,200
52.0 61.5 14,000 62.0 58.3 11,300 62.0 61.3 11,000
54.0 60.2 13,500 64.0 57.1 11,100 64.0 60.2 10,800
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56.0 58.8 13,000 66.0 55.8 10,800 66.0 59.0 10,600
58.0 57.5 12,500 68.0 54.6 10,400 68.0 57.9 10,200
60.0 56.1 12,100 70.0 53.3 10,100 70.0 56.8 9,900
62.0 54.7 11,700 72.0 52.0 9,700 72.0 55.6 9,500
64.0 53.3 11,400 74.0 50.6 9,300 74.0 54.5 9,100
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66.0 51.8 11,000 76.0 49.2 8,900 76.0 53.3 8,800
68.0 50.4 10,700 78.0 47.8 8,500 78.0 52.1 8,400
70.0 48.8 10,300 80.0 46.4 8,200 80.0 50.8 8,100
72.0 47.3 9,900 82.0 45.0 7,900 82.0 49.6 7,700
74.0 45.7 9,400 84.0 43.4 7,500 84.0 48.3 7,400
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76.0 44.1 9,000 86.0 41.9 7,200 86.0 47.0 7,100
78.0 42.4 8,800 88.0 40.3 7,000 88.0 45.7 6,800
80.0 40.6 8,300 90.0 38.6 6,800 90.0 44.3 6,600
82.0 38.8 8,100 92.0 36.9 6,600 92.0 42.9 6,400
84.0 36.9 7,700 94.0 35.1 6,400 94.0 41.5 6,200
86.0 35.0 7,400 96.0 33.3 6,200 96.0 40.0 6,000
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Counterweight
Attachment
ton (lbs) Crawler Crawler
Forward Backward
extend retract
0
(Without)
8.31 (18,320) (No abrupt
Without attachment (No.1) lever control)
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(Base machine only) 19.81 (43,674) (No abrupt
(No.1 to No.2) lever control)
31.31 (69,028)
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(No.1 to No.3)
0
(Without)
8.31 (18,320)
With boom base (No.1)
(Boom angle
19.81 (43,674)
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: 10 degrees or less (No.1 to No.2)
31.31 (69,028)
(No.1 to No.3)
0
(Without)
8.31 (18,320)
With basic boom
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(No.1)
(Boom angle
: 30 degrees or less) 19.81 (43,674) (Slope:7 deg.
(No.1 to No.2) or less)
31.31 (69,028) (No abrupt (No abrupt
(No.1 to No.3) lever control) lever control)
: Able to be operated
: Able to be operated with conditions
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: Unable to be operated
Propel motor
Traveling backward
Counterweight
Attachment
ton (lbs) Crawler Crawler
Forward Backward
extend retract
0
(Without) ۑ ۑ ۑ ۑ
8.31 (18,320)
ۑ ۑ ۑ ۑ
Without attachment (No.1)
(Base machine only) 19.81 (43,674) (Slope:8 deg.
(No.1 to No.2) ۑ or less) ۑ
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31.31 (69,028) (No abrupt (No abrupt
(No.1 to No.3) lever control) lever control)
0
ۑ ۑ ۑ ۑ
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(Without)
8.31 (18,320)
With boom base (No.1) ۑ ۑ ۑ ۑ
(Boom angle
19.81 (43,674) (Slope:12 deg.
: 10 degrees or less (No.1 to No.2) ۑ or less) ۑ
31.31 (69,028) (No abrupt (No abrupt
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(No.1 to No.3)
lever control) lever control)
0
(Without) ۑ ۑ ۑ ۑ
8.31 (18,320)
With basic boom (No.1) ۑ ۑ ۑ ۑ
(Boom angle
: 30 degrees or less) 19.81 (43,674) ۑ (No abrupt ۑ ۑ
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(No.1 to No.2) lever control)
31.31 (69,028) (Slope:3 deg.
(No.1 to No.3) ۑ or less) ۑ
: Able to be operated
: Able to be operated with conditions
: Unable to be operated
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Propel motor
Traveling backward
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the following points.
• Do not propel with a load lifted.
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• Propel with low speed and gently.
• Propel on flat and firm ground.
• Ensure to check the ground condition and propel on
the slope angle smaller than shown in the chart.
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• Propel straight against slope.
• Provide gentle slope at the beginning and end po-
sitions of slope.
Propel upward downward on slope
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( : allowable angle)
FORWARD BACKWARD
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BOOM
ANGLE
BOOM
ANGLE
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(Unit : Degree)
Forward Backward
Boom length m (ft) Boom angle Boom angle
35 40 50 40 50 60
12.2 (40) 5 5 4 8 8 8
15.2 (50) 7 6 5 8 8 8
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18.3 (60) 8 8 6 8 8 8
21.3 (70) 8 8 6 8 8 8
24.4 (80) 8 8 7 8 8 8
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27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 7 8 8
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51.8 (170) 8 8 8 5 6 8
54.9 (180) 8 8 8 3 4 6
57.9 (190) 8 8 8 1 2 5
61.0 (200) 8 8 8 - 1 3
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(Unit : Degree)
Forward Backward
er
18.3 (60) 8 8 6 8 8 8
21.3 (70) 8 8 6 8 8 8
24.4 (80) 8 8 7 8 8 8
27.4 (90) 8 8 8 8 8 8
R
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 7 8 8
51.8 (170) 8 8 8 5 6 8
54.9 (180) 8 8 8 3 4 6
57.9 (190) 8 8 8 1 2 5
(Unit : Degree)
Jib length m (ft) 9.1 (30)
Offset angle 10
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
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27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
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33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
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45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 6 8 8
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57.9 (190) 8 8 8 2 6 8
(Unit : Degree)
Jib length m (ft) 9.1 (30)
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Offset angle 30
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
er
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
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36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
R
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 7 8 8
57.9 (190) 8 8 8 2 6 8
(Unit : Degree)
Jib length m (ft) 12.2 (40)
Offset angle 10
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
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33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
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48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 4 8 8
57.9 (190) 8 8 8 - 4 8
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(Unit : Degree)
Jib length m (ft) 12.2 (40)
Offset angle 30
Configuration Forward Backward
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30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
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42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
R
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 4 8 8
57.9 (190) 8 8 8 - 4 8
(Unit : Degree)
Jib length m (ft) 15.2 (50)
Offset angle 10
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
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33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
O
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 7 8 8
54.9 (180) 8 8 8 2 6 8
57.9 (190) 8 8 8 - 2 7
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(Unit : Degree)
Jib length m (ft) 15.2 (50)
Offset angle 30
Configuration Forward Backward
en
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
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42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
R
51.8 (170) 8 8 8 7 8 8
54.9 (180) 8 8 8 2 6 8
57.9 (190) 8 8 8 - 2 7
(Unit : Degree)
Jib length m (ft) 18.3 (60)
Offset angle 10
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
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30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
O
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 5 8 8
54.9 (180) 8 8 8 - 4 8
57.9 (190) 8 8 8 - 1 6
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(Unit : Degree)
Jib length m (ft) 18.3 (60)
Offset angle 30
Configuration Forward Backward
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30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
ef
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
R
51.8 (170) 8 8 8 5 8 8
54.9 (180) 8 8 8 - 4 8
57.9 (190) 8 8 8 - 1 5
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Ensure to see that there is enough clearance be-
tween the machine height / boom height and the
low overhead place.
nl
Make low gantry propel distance as short as possi-
ble and slowly.
O
CONDITIONS
• The crawlers are fully extended.
• All counterweight are equipped and secured firmly
with bolts.
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• Install the travel kit to the counterweight firmly.
• Propel on level ground with low speed.
• The boom angle is horizontal or slightly up.
• Guy cable with proper length is connected on the
boom tip.
en
TRAVEL KIT
(OPTION)
y
3 AUXILIARY PLATFORM
Stowing type step on the both side of machine deck. ( width : 300mm) GG40C00045F1
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4 LOAD SAFETY DEVICE OUTER INDICATING LIGHT
Indication of load condition by square type 3 color light to outside ( gr, ye. Re) GG53E00022F1
O
5 PROPEL WARNING DEVICE
Warning at propel by buzzer intermittent sound. GG53E00019F1
6 EXTINGUISHER
ABC powder type extinguisher GG71M00002F1 (For EU)
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GG71M00005F1