6. ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE

6.1 ACCESSORY TOOLS

The following tools come with this machine: No. Tool Remarks

1 Box wrench for spark plug Width across flat: 21 mm

2 Screw driver (Philips)

6.2 STANDARD TIGHTENING TORQUE LIST

Torque the metric bolts and nuts with no specific indication to the values shown in this table.

Adequate tightening torque is determined with respect to (a) width across flat (b) of a bolt or nut. [Table 1]

[1] Bolt marked with “8.8” (strength classification) on its head

[2] Bolt marked with “10.9” (strength classification) on its head

[3] Bolt marked with “12.9” (strength classification) on its head

[4] Other bolts

7. INSPECTION AND MAINTENANCE LIST

8. MAINTENANCE PROCEDURES

8.1 INITIAL 10 HOUR MAINTENANCE

The following maintenance should be performed after 10-hour operation, limited to the first maintenance of a new machine.

[1] GREASING MACHINE UNITS

See “Maintenance 8.7 Every 50 Hours” for maintenance items and procedure.

[2] GREASING BOOM UNITS

See “Maintenance 8.7 Every 50 Hours” for maintenance items and procedure.

8.2 INITIAL 25 HOUR MAINTENANCE

The following maintenance should be performed after 25-hour operation, limited to the first maintenance of a new machine.

[1] OIL REPLACEMENT IN ENGINE OIL PAN

See “Maintenance 8.7 Every 50 Hours” for maintenance items and procedure.

8.3 INITIAL 50 HOUR MAINTENANCE

The following maintenance should be performed after 50-hour operation, limited to the first maintenance of a new machine.

[1] OIL REPLACEMENT IN HYDRAULIC OIL TANK

See “Maintenance 8.11 Every 1000 Hours” for maintenance items and procedure.

[2] REPLACEMENT HYDRAULIC OIL RETURN FILTER AND SUCTION FILTER

See “Maintenance 8.10 Every 500 Hours” for maintenance items and procedure.

8.4 INITIAL 200 HOUR MAINTENANCE

The following maintenance should be performed after 250-hour operation, limited to the first maintenance of a new machine.

[1] OIL REPLACEMENT SLEWING REDUCTION GEAR CASE

See “Maintenance 8.11 Every 1000 Hours” for maintenance items and procedure.

[2] OIL REPLACEMENT WINCH REDUCTION GEAR CASE

See “Maintenance 8.11 Every 1000 Hours” for maintenance items and procedure.

[3] OIL REPLACEMENT TRAVELLING MOTOR REDUCTION GEAR CASE

See “Maintenance 8.11 Every 1000 Hours” for maintenance items and procedure.

8.5 CHECKS BEFORE OPERATION

Inspections specified in this section are required to be completed prior to starting an engine first of the day.

See “Maintenance 7. Inspection and Maintenance List” for the inspection and maintenance items

See “Operation 2.1 Checking before Operation” for before operation inspection items and procedure.

8.6 IRREGULAR MAINTENANCE [1] REPLACEMENT RUBBER TRACK

• The inside of the tension adjusting device of the rubber track is greased. Grease is under high pressure associated with the tension of the rubber track. Failure to follow precautions stated below when removing grease may lead to a serious accident due to the grease valve popping out.

• Only one full turn of the tension adjusting grease valve is allowed when loosening. The grease valve may pop out if disregarded.

• Always stand aside when conducting tension adjustment of the grease valve to circumvent potential dangers.

• Ensure that grease is completely removed from the inside of the rubber track before rotating the sprocket to remove the rubber track.

[REMOVAL RUBBER TRACK]

• Have a steel pipe available.

1. See “Operation 2.13 Outrigger Set Up Operation” to set up the outriggers and raise the rubber track for about 50mm from the ground.

2. Remove the 2 mounting bolts (2) and remove the inspection cover (1).

3. Loosen the grease valve (4) gradually and remove grease.

Notes

Provide only one full turn of the grease valve (1)

4. Insert the steel pipe between the idler and rubber track, as shown at right. Rotate the sprocket forward.

5. When the inserted steel pipe detaches the rubber track from the idler, slide the crawler in a lateral direction to remove it.

[INSTALLATION RUBBER TRACK]

• Have a grease gun available.

• Have a steel pipe available.

1. See “Operation 2.13 Outrigger Set Up Operation” to set up the outriggers and raise the rubber track again for about 50mm from the ground.

2. With the rubber track engaged with the sprocket, put the crawler on the idler.

3. With the sprocket rotating forward, push the rubber track in to stop rotation.

4. Insert the steel pipe between the idler and rubber track again, and re-rotate the sprocket to put the crawler on the idler properly.

5. Stop rotation, and ensure that the rubber track is on the sprocket and idler properly.

6. Make a tension adjustment to the rubber track according to “Operation 2.1.3 Checks After Starting The Engine [1] Checking/ adjustment Rubber Track Tension” in the Operation.

7. Ensure that adequate engagement and tension of the rubber track, sprocket, and idler are obtained.

8. See “Operation 2.23 Outrigger Stowing Operation” to stow the outriggers and lower the machine on the ground.

[2] REPLACEMENT WINCH WIRE ROPE [BENCHMARK FOR REPLACING WIRE ROPES]

Always wear work leather gloves when replacing the wire rope.

Caution

• The benchmark for replacing wire ropes is common to all the wire ropes for winching, telescoping the boom, and slinging.

• Measure the wire rope diameter at the section where the rope repeatedly passes through the sheave. Measure from three directions and average the value.

• Do not use the old wire ropes even if they had not been used.

• See “Maintenance 8.6 [2] Replacement Winch Wire Ropes” for how to replace the wire rope.

• Contact us or our sales service agency for replacing/repairing the wire ropes.

[WIRE ROPE NOMINAL DIMENSION]

• Wire rope for winching : IWRC 6 x Ws (29) 0/0 φ6 x 35 m

• No. 4 wire rope for extending boom: IWRC 6 x Fi (29) 0/0 φ8 x 3.73 m

• No. 4 wire rope for retracting boom: IWRC 6 x Fi (29) 0/0 φ6 x 6.19 m

[BENCHMARK FOR REPLACING WIRE ROPES]

Wire ropes fatigue as time goes by. Change the wire ropes when they show the following signs.

• In one twist (6 crests), 10％ or more of the wires (excluding the filler wires) are broken.

Notes

Change winching/boom telescoping wire rope when 13 or more wires are broken.

• The diameter of the wire rope is worn at 7 % or more of the nominal diameter.

Notes

• Change the 8-mm diameter wire rope when it is reduced to 7.5 mm.

• Change the 6-mm diameter wire rope when it is reduced to 5.6 mm.

• The rope is twisted and has some kinks.

• The rope shows remarkable deformation or corrosion.

• The rope shows some abnormality at the ends.

[REMOVAL WINCH WIRE ROPE]

Use the following procedure to remove the wire rope.

1. Place the machine on a level and solid surface.

2. Place the boom telescoping lever in the “Extend” position (push forward) to extend the boom slightly.

3. Place the winch lever in the “Down” position (push forward) to lower down the hook block to the ground.

4. Undo the wedge socket fixing bolt (2) and remove the wedge socket (3).

5. Remove the wire clip (4)

6. Pull the wire rope (5) out of the wedge socket (3), following the procedure provided below.

(1) Bring a 4 to 6mm round bar (6) into contact with the rope wedge (7)

(2) Remove the rope wedge (7), lightly tapping the round bar (6) with a hammer in the direction indicated by the arrow (a).

7. Place the winch lever in the “Down” position (push forward) to wind up the wire rope (5) from the winch drum.

8. With the wire rope wound off from the winch drum, detach the end of the wire rope (5) from the winch drum (8) by following the procedure provided below.

(1) Bring a 4 to 6mm round bar (6) into contact with the rope wedge (9).

(2) Remove the rope wedge (9), lightly tapping the round bar (6) with a hammer in the direction indicated by the arrow (b).

9. Wind off the remaining wire rope (5) completely.

Removal of the winch wire rope is completed.