Greasing Chart

Upper Structure

Lower Structure

Gear Oil

[NOTICE]

◆ Using different brands of gear oil together can change the properties of the gear oil and have an adverse effect on the machine. When gear oil is added, be sure to use the same brand that is in the machine. If a different brand of oil must be used, remove all the remaining gear oil before adding the new oil.

◆ Clean the area around the plugs before removing them to prevent dust and other foreign matter from entering the oil tank.

◆ Clean the plugs and plug holes, and wrap sealing tape around the plugs. Install the plugs and tighten.

2. Remove the level plug and check the oil level. There is no need to add oil if the oil level comes to the bottom of the plug hole. If low, remove the filler plug and add oil through the filler plug hole.

◆ For the auxiliary winch, the plug layout is identical with the figure shown below.

The speed reducer is very hot immediately after operating. Let the speed reducer cool down until it can be touched with your bare hand before performing maintenance work on it.

1. Set the crane on a level surface.

3. Install and tighten the level and filler plugs.

Replacing Oil

1. Set the crane on a level surface.

2. Place an oil pan under the drain plug to catch the oil being changed.

3. Remove the drain, filler and level plugs, and drain the oil.

4. After all of the oil has drained out, install and tighten the drain plug.

5. Pour fresh gear oil through the filler plug hole until it begins to come out of the level plug hole.

6. Install and tighten the filler and level plugs.

Swing Speed Reducer Oil Level Check

Every 500 Hours or Every 6 Months

Swing Speed Reducer Oil Replacement

Every 1,000 Hours or Once a Year

Warning

Checking Oil Level

1. Set the crane as follows:

(1)Support the crane on extended outriggers in a level position.

(2)Raise the boom to an angle where it does not hinder maintenance work.

2. Remove the level plug and check the oil level. There is no need to add oil if the oil level comes to the bottom of the plug hole. If low, remove the filler plug and add oil through the filler plug hole.

The speed reducer is very hot immediately after operating. Let the speed reducer cool down until it can be touched with your bare hand before performing maintenance work on it. T02870E

3. Install and tighten the level and filler plug.

Replacing Oil

1. Set the crane as follows:

(1)Support the crane on extended outriggers in a level position.

(2)Raise the boom to an angle where it does not hinder the maintenance work.

2. Remove the drain plug and attach a hose to the vent. Remove the filler plug and drain the oil.

Axle (Carrier Axle) Oil Level Check

100 Hours or Once a Month

Axle (Carrier Axle) Oil Replacement

Every 1,000 Hours or Once a Year

The axle is very hot immediately after traveling. Let the axle cool down until you can touch it with your bare hand before starting maintenance work.

Checking Oil Level

1. Set the crane on level ground.

3. After all of the oil has drained out, remove the hose. Install and tighten the drain plug.

4. Pour fresh gear oil through the filler plug hole until the oil level comes to the bottom of the level plug hole in the reducer.

5. Install and tighten the filler plug.

2. Remove the filler/level plug and check the oil level. There is no need to add oil if the oil level is up to the bottom of the plug hole. If low, add oil through the filler/level plug hole.

3. Remount and tighten the filler/level plug.

Replacing Oil

1. Set the crane on level ground.

2. Place an oil pan under the drain plug.

3. Remove the drain plug and filler/level plug to drain the oil.

4. After all the oil has drained out, install and tighten the drain plug.

5. Pour fresh gear oil through the filler/level plug hole until the oil reaches the top of the plug hole.

6. Once the oil has been supplied, remount and tighten the filler/level plug.

Warning

The axle is very hot immediately after traveling. Let the axle cool down until you can touch it with your bare hand before starting maintenance work.

Checking Oil Level

1. Extend the outriggers and set the crane level.

2. Rotate the tire by hand until "OIL LEVEL" is positioned as shown. Wear protective gloves.

3. Remove the drain/level plug and check the oil level. There is no need to add oil if the oil level is up to the bottom of the plug hole. If low, remove the filler plug and add oil through the filler plug hole.

4. Install and tighten the filler plug and the drain/level plug.

Replacing Oil

1. Extend the outriggers and set the crane level.

2. Rotate the tire by hand to move the drain/level plug to the lowest position as shown. Wear protective gloves.

3. Place an oil pan under the drain plug.

4. Remove the drain/level plug and filler plug to drain the oil.

5. After all the oil has drained out, rotate the tire by hand until "OIL LEVEL" is right-side up and horizontal.

6. Pour new gear oil through the filler plug hole until the oil reaches the top of the drain/level plug hole.

7. Once the oil has been supplied, install and tighten the filler plug and drain/level plug.

◆ Using different brands of engine oil together can change the properties of the oil and may have an adverse effect. When adding engine oil, be sure to use only the same brand as that already in the crane. To use a different brand of oil, drain out all the remaining engine oil before adding the new oil.

◆ Use engine oil suited to the ambient operating temperature.

Maintenance

◆ For engine oil and oil filter replacement procedures, refer to the "Engine" operation manual.

(*1): When replacing oil filter(*2): Once a year or after flushing 6 times

Once a Day

Check the air cleaner with the dust indicator. If the red indicator is visible in the window, clean the element. After cleaning or replacing the element, press the reset button to cancel the red indication.

[NOTICE]

◆ Be sure to stop the engine before cleaning the element.

◆ Handle the element with care. The element will become damaged if hit, knocked, or dropped.

1. Unscrew the cap nut to remove the cover. If dust has accumulated on the cover, clean the dust off.

2. Remove the wing nut fastening the element. Carefully draw out the element while holding the end of the element with both hands. If the element seems to be stuck, slightly shake it up and down, and right and left.

◆ Be careful that dust does not enter the intake of the engine.

7. Clean the gasket attached to the groove on the periphery of the cover. Then, assemble the cover on the body and tighten the cap nut.

◆ Replace the gasket in one or two years. A damaged gasket allows water to soak in.

Element Replacement

a Year or after Cleaning 6 Times

For element replacement procedures, refer to the previous section, "Cleaning Element".

3. Clean the element.

(1)For dry dust

Spray dry and clean compressed air from inside the element, along the filter folds, while moving the air nozzle up and down. Wear eye protection goggles.

◆ Air pressure should not exceed 71 psi (5 kg/cm2). Keep proper clearance between the nozzle and filter element.

(2)For carbonic and oily materials

Soak the element in water with synthetic detergent for approximately 10 minutes and rinse it. Then, rinse it again with clean water and let it dry.

◆ Avoid using water higher than 122 °F (50°C).

◆ Clean the element taking care that dust does not get caught inside the element.

4. After cleaning, check the filter for internal damage with a flashlight. If a pin hole or crack of any size is found in the filter, or the gasket is damaged, replace it with a new element.

5. Clean the faces of the gasket on the element and the body with a clean cloth.

6. Insert the element into the body and place it in position. Fasten the element with the wing nut (attached with a gasket).

Engine Cooling System WARNING

The cooling water is very hot immediately after traveling. Opening the radiator cap when cooling water is hot may cause boiling water, capable of scalding, to spray out. Let the water cool before starting maintenance work.

When using long life coolant (LLC), keep in mind the following:

• LLC is toxic. Should you accidentally ingest LLC, immediately vomit and seek medical attention. Should LLC get in your eyes, immediately flush with clean water and seek medical attention.

• Keep LLC away from fire. LLC is flammable.

[NOTICE]

◆ For cooling water, use soft water or tap water (water which soap lathers well). Do not use water from wells or rivers.

Maintenance Table

◆ For procedures related to replacing the cooling water and flushing the coolant tank, refer to the "Engine" operation manual.

◆ Only add cooling water that has the correct ratio of LLC added. Do not mix different brands of LLC together. If another brand of LLC must be used, drain all the remaining cooling water before adding new cooling water.

◆ The ratio of LLC to water must be determined on the basis of the minimum temperature of the region where the crane is to be used, as shown below.

Cooling Water Level Check

Once a Day

Check the reserve tank for water volume. If the water level stays within the scale on the tank, the volume is appropriate. If the level has come below L on the scale, replenish the water.