INSPECTION AND MAINTENANCE

1. PRECAUTIONS FOR MAINTENANCE

Thorough understanding of the inspection and maintenance items is required to perform efficient inspection and maintenance that contributes to safe use of this machine.

• Do not perform any inspection or maintenance that is not described in this manual. Potential serious accidents or machine failures may occur if it is performed at the discretion of the individual.

In the event that a judgment on the severity of a failure or malfunction is unable to be made, contact us or our sales service agency to request repair.

• In the event that a failure or malfunction is encountered in machine operation or found in inspection, report it to your employer or supervisor immediately. Contact us or our sales service agency to request repair accordingly.

• Inspection and maintenance should be performed with the machine placed on a level and strong footing.

[1] CHECK THE SERVICE METERS

Read the service meters daily to check for any maintenance item that has reached the obligatory maintenance period.

[2] USE GENUINE PARTS FOR REPLACEMENT

Always use Maeda genuine parts as specified in the parts catalogue for part replacement.

[3] USE PURE GREASE

Always use Maeda pure grease. The viscosity of grease must conform to specifications according to ambient temperature.

[4] USE CLEAN OIL AND GREASE

Always use clean oil, grease, and container to keep impurities out of them.

[5] KEEP THE MACHINE CLEAN

Keep the machine clean to facilitate the detection of a malfunction. Especially keep the grease nipple, breather, and oil level gauge (oil access door) clean to prevent impurities from finding their way into the machine.

[6] HANDLE WATER AND OIL AT ADEQUATE TEMPERATURE

Drainage, drain oil, and exhaust filter will be at elevated temperatures immediately after the machine comes to a stop. Replace drainage, drain oil, and filter only after they drop in temperature for safety. If the oil is cold, raise the temperature of the oil to approx. 20 to 40°C.

[7] CHECK DRAIN OIL AND OIL FILTER

For replacement of oil and filter, check the drain oil and exhaust filter to make sure no a considerable amount of metal powder or foreign objects is present.

[8] CAUTIONS FOR LUBRICATION

Do not remove the strainer to lubricate if it is attached to the lubrication opening.

[9] PROTECT OIL FROM IMPURITIES

Avoid dust when inspecting and replacing the oil to keep impurities out of the oil.

[10] ATTACH A WARNING TAG

When draining coolant and oil, always attach a warning tag to the travelling operation unit for the prevention of accidental engine starting.

[11] FOLLOW SAFETY PRECAUTIONS

Safety precautions provided on the machine should always be followed when using the machine.

[12] CAUTIONS FOR WELDING REPAIRS

• Power off the machine. (Turn OFF the start switch)

• Do not continuously apply 200V or greater.

• Ground the machine within 1 meter from the welding point.

• Be sure to disconnect the connectors of the remote controller, moment limiting indicator, and moment limiting converter.

• Remove the negative terminal (-) of the battery.

• Make sure no sealing or bearing is present between the welding point and the grounding point. Potential damage to sealing may occur due to sparks if disregarded.

• Do not ground around the boom pin or the hydraulic cylinder. Potential damage to a plated section may occur due to sparks if disregarded.

[13]

Keep From Flame

Always clean the parts with noncombustible cleaning agent or light oil. Keep the machine from flames when using gasoline.

[14]

Keep The Attachment Surface Clean

Be sure to clean the attachment surface after removing a part to which the O-ring and gasket sealing are attached.

Replace the part with a new one with the O-ring and gasket reattached.

[15]

Empty YOUR POCKETS

Always empty your pockets before performing inspection and maintenance of the machine in a downward direction with the cover opened.

[16]

Assure Safe Rubber Track

When performing crane operation in a rocky location, make sure of no damage to the rubber track and no looseness, cracks, abrasion of bolts and nuts. Loosen the tension of the crawler tread more than usual.

[17]

Cautions For Machine Wash

• Do not direct a jet of steam to the electrical parts and connector.

• Keep the operation panel dry.

• Do not apply pressurized water directly to the recoil starter

• Wash the machine with clean cloth, rinsing off dirt and dust.

[18]

PRE- AND POST-WORK INSPECTION

Before performing crane operation in the muddy water, rain, snow and on the seashore, always check plugs and valves for looseness. Post-work inspection requires a check of all the units for cracks and damages and to check bolts and nuts for looseness and coming off, with the machine washed. Carry out early greasing. Grease the operating pins that enter muddy water on a daily basis.

[19]

Cautions For Working In A Dusty Site

The following precautions should be observed when working in a dusty site.

• Occasionally check the air cleaner for clogging.

• Clean and replace the fuel filter in a timely manner.

• Be sure to clean the electrical parts, especially the starter and flywheel magnet, to protect them from dust.

[20]

Do Not Mix Oil

Never use different types of oil together under any circumstance. Replace the oil entirely when replenishing a different type of oil. Always use Maeda genuine parts for part replacement.

2. BASIC MAINTENANCE

[1] OIL HANDLING

• Oil is used under extremely harsh conditions (high temperature, high pressure) in the engine and working device, which causes the oil to undergo deterioration with operating time. Always use oil that meets requirements such as grade and operating temperature defined in the operation manual. Be sure to perform periodic replacement of oil irrespective of contamination in the oil.

• Oil is equivalent to human blood. Exercise due caution to handle oil, keeping impurities (such as water, metal powder or dust) out of oil. Most mechanical failures are attributed to intrusion of impurities. Extra caution is required to prevent impurities from finding their way during machine storage and lubrication.

• Do not mix oil with another oil of a different grade or brand.

• Oil lubrication must conform to the designated quantity of oil. Failure to lubricate with an adequate quantity can lead to a machine failure.

• In the event that oil used in a working device turns cloudy, potential intrusion of moisture or air into the oil may be considered. Contact us or our sales service agency

• When replacing oil, always replace the relevant filter as well.

•”ISO VG32” is adopted for a hydraulic oil system as factory default. Do not use any other hydraulic oil that is not recommended by us. Failure to follow the instruction may cause the filters to get clogged. A small amount of oil remaining in piping and cylinders does not cause problems even if mixed with another oil.

[2] FUEL HANDLING

• Do not remove the strainer when replenishing fuel.

• Always use fuel that meets requirements such as grade and operating temperature defined in the operation manual.

• Ensure that the fuel tank is filled up after finishing daily work to prevent condensation of the humid air inside the fuel tank that will result in intrusion of moisture.

• Drain deposits and water out of the fuel tank before starting the engine or approximately 10 minutes after fuel replenishment.

• The air should be released from the circuit when the machine runs out of fuel or fuel filter replacement is performed.

• Clean the tank and fuel system if any foreign objects enter the fuel tank.

[3] STOCKING AND STORAGE OF OIL AND FUEL

• Stock and store oil and fuel indoors to keep impurities such as moisture or dust out of them.

• When storing oil and fuel in drums for a long time, line the drums horizontally aligning the drum bungs sideways (to store them away from moisture). Be sure to cover the drums with a waterproof sheet if storing them outside.

• To prevent deterioration of oil and fuel resulting from long-term storage, employthe first-in first-out for using oil and fuel.

[4] GREASE HANDLING

• Grease is designed to prevent the joint from rattling and making a noise.

• A nipple that is not described in the Periodic Maintenance chapter is used for overhauls, which requires no grease replenishment. Grease the nipple if long-term use hinders its smoothness.

• Wipe off old grease squeezed out after greasing. Extra care is required to wipe the parts where the adhesion of sand and dust accelerates the wearing away of the rotating part.

[5] FILTER HANDLING

• A filter is an extremely important part that keeps major equipment free from impurities in oil, fuel, and the air circuit, which prevents an associated failure. Periodic replacement of the filter is required in accordance with the Operation Manual. The replacement period should be shortened in responses to harsh operating environments or the oil used.

• Do not reuse any washed filters (cartridge type one) under any circumstances.

• After replacing an oil filter, check the used filter for any metal powder. If check finds metal powder on the used filter, contact us or our sales service agency

• As to a replacement filter, always unpack it immediately prior to its use.

• Always use Maeda genuine filters.

[6] ELECTRICAL PART HANDLING

• The electrical parts are susceptible to water damage and damaged coating. A current leakage is developed if the electrical parts are wet or have damaged coating, which causes the machine to go out of order and malfunction. Exercise due caution when handling the electrical parts.

• Inspection and maintenance include the checking of fuse damage, and battery electrolyte level.

• Never remove and disassemble equipment (electrical parts) from the machine.

• Only optional electrical parts that accompany the machine can be installed.

• Keep the electrical parts away from water when the machine is washed and used in the rain.

• When using the machine at the seashore, keep the electrical parts free of water and impurities to prevent corrosion.

[8] HYDRAULIC EQUIPMENT HANDLING

• Hydraulic equipment will be at elevated temperatures during and immediately after operation. Hydraulic equipment operates under high pressure. The following precautions should be observed when performing inspection and maintenance of hydraulic equipment.

• Place the machine in travel position on a level surface to inhibit the application of pressure to the cylinder circuit.

• Be sure to stop the engine.

• Hydraulic oil and lubricating oil will be at elevated temperatures and high pressure immediately after equipment comes to a stop. Perform inspection and maintenance only after the oil drops in temperature for safety. An internal pressure may be exerted despite temperature drop. When removing the plugs, screws and hose joints, stand aside and gradually loosen to decompress.

• Be sure to remove the pressure releasing air from the hydraulic oil tank before performing inspection and maintenance of the hydraulic circuit.

• Inspection and maintenance include hydraulic oil level check and replacement of the filters and hydraulic oil.

• Check the O-ring for scratches when removing the high-pressure hose. If check finds scratches, replace the O-ring.

• Air bleed of the hydraulic circuit is required after the following tasks are performed: replacement and cleaning of the hydraulic oil filter element and strainer, repair and replacement of hydraulic equipment, and hydraulic piping replacement.

3. LEGAL INSPECTION

If periodic inspection for machine safety assurance is stipulated by laws and regulations of your country, perform inspection complying with the inspection items listed below.

1. Make sure no abnormal event is present in the safety devices.

2. Check the hoisting accessories including a hook block for any abnormalities.

3. Check the winch wire rope end and wire clip for breakage.

4. Replace the wire rope promptly if it is damaged.

5. Check the hydraulic hose for oil leaks and friction flaws on the surface. Replace the hose if a surface flaw is detected.

6. Check the structural part including the boom for cracks and deformations.

7. Check the mounting bolts and joints for looseness and falling off.

8. Check if the booms perform proper operation and stop in extending, retracting, raising, lowering, and slewing.

If check finds a malfunction, contact us or our sales service agency

4. CONSUMABLES

Consumables such as a filter element and wire rope are to be replaced upon periodic maintenance or prior to the wear limit. Proper replacement of consumables delivers increased economy in machine use. Always use Maeda genuine parts for part replacement.

See the parts catalogue for part numbers when ordering parts.

[LIST OF CONSUMABLES]

Part

Hydraulic oil return filter, suction filter

Replacement cycle

Every 500 hrs

Cylinder gasket 3 yrs

Boom slide plate

Winch wire rope

Boom extending wire rope

Boom retracting wire rope

Engine fuel pipe

Every 3 yrs

Every 3 yrs

Every 3 yrs

Every 3 yrs

Every 3 yrs

The cycles marked with a star “ ” in Replacement cycle include a halt period. Contact us or our sales service agency for part replacement.