Tadano Faun TR-650XL-3 Rough Terrain Crane Operation & Maintenance Manual SN 545364 - PDF DOWNLOAD

Publication No. TR-650XL-3/O1(U)-2E

Operation and Maintenance Manual

Rough Terrain Crane Model

TR-650XL-3 Applicable Serial No. 545364〜

CAUTION: Read this manual before operating the crane. Save this manual for future reference.

H000410E

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

H000430E

WARRANTY Tadano Ltd. (herein referred to as TDN) warrants that each new Product manufactured by TDN shall be free from defects in material or workmanship under normal use and maintenance for a period of twelve (12) months or 1,000 hours, whichever occurs first, from the date of initial sale, lease or rental.

Within the United States, the distributor designated by TDN, shall repair and replace free of charge, including related labor, any such defective parts.

This warranty does not apply in the following cases, even when the occur during the warranty period: 1. Damage or defects caused by accident, misuse, negligence or natural calamity.

2. Damage or defects caused by using other than TDN genuine parts.

3. Damage or defects ascribed to repair work or modification, etc., being carried out at workshops other than those designated by TDN. 4. Damage or defects arising from the use of a product beyond the operating limitations specified by TDN. 5. Damage or defects caused by failure to operate, service or maintain products in accordance with the operation and maintenance manual or other instruction of TDN. 6. Loss of use, loss of time, inconvenience and other consequential damages such as expenses for fuel, telephone, travel, lodging, transportation, loss or damages to personal property or loss of revenues.

7. Slight defects that generally do not affect the integrity or reliability of product.

8. Corrosion or discoloration of plated surfaces caused by aging.

9. Consumable articles such as oil, fan belts, packings, gaskets, fuses, brake linings, fuel filters and other similar parts.

The present warranty is in lieu of any other warranties, expressed or implied, including any warranty of merchantability or fitness for a particular purpose.

TADANO LTD.

T002423E

Safety It is virtually impossible to anticipate every situation that might present a hazard. The safety precautions given in this manual and on the machine labels are not exhaustive.

It is important, therefore, to strictly follow the instructions in this manual and be sensitive to potential dangers in order to prevent bodily injury and damage to the machine.

Most accidents that occur during crane operation and maintenance are caused by failure to observe basic safety rules and precautions. Before operating your machine or performing maintenance, read and become familiar with all the safety precautions and recommendations given in this section. Remember that failure to observe even a single precaution could involve you and the people around the machine in a serious accident.

Remember that your most important duty is to ensure the safety of you, your co-workers and any other people in the area.

Foreseeing potential dangers is vital for preventing accidents. All personnel working with the machine, including the supervisor, crane operator and oiler, should be sensitive to potentially dangerous situations and take the necessary measures to prevent accidents.

Safety precautions and recommendations are outlined in this section and are also included in the operation and maintenance instructions given in subsequent sections. Warning labels are also provided on the machine.

The cautionary instructions in this manual are identified as “DANGER”, “WARNING”, “CAUTION” or “NOTICE”. These terms are defined as follows:

DANGER DANGER indicates an imminently hazardous situation, which, if not avoided, would result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation, which, if not avoided, may result in a minor or moderate injury. 【 NOTICE】 】 ◆NOTICE indicates an important operational or maintenance procedure or condition, which, if not strictly observed, can result in damage to machine components or deteriorated machine performance.

Safety

A-1

Safety

T011275E

Safety Rules Before Operation Use of improper or unauthorized method during operation or maintenance of this machine can be dangerous and could lead to serious injury or death. Read this manual thoroughly and be familiar with the proper operating and maintenance procedures before using the machine. Do not operate the machine or perform maintenance on it until you understand the instructions in this manual.

Qualifications of the Operator The operator must be fully trained and qualified.

The operator must be fully familiar with on-site safety rules, and national and local crane operation regulations.

Study the Operation and Maintenance Manual Improper operation, inspection or maintenance can damage the machine or cause injury or death.

Study the manual carefully. Become familiar with the proper procedures for operation, inspection and maintenance.

Keep the Operation and Maintenance Manual in the crane operator’s cab so that it is always readily accessible.

“Safety Rules” section describes the general instructions about operation with a hydraulic rough terrain crane. For more detailed instructions about your machine, see corresponding pages (white pages) of this manual.

The figures in this manual are for reference showing the important points. They may be different from an actual machine.

Before Operation・・・・・・・・・・・・・・・・・・・・・・・・・・A-2 Rules for Operation (Setting Outriggers) ・・・・・・・・・A-7 Rules for Operation (General) ・・・・・・・・・・・・・・・・A-8 Rules for Operation (Weather) ・・・・・・・・・・・・・・・A-17 Rules for Operation (Power Lines, Radio Waves)・・A-19 Rules for Operation (Operation without Extending Outriggers) ・・・・・・・・・・・・・・・・・・・・・・・・・A-20 Rules for Operation (Special Operation) ・・・・・・・・A-21 After Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・A-22 Rules for Road Travel ・・・・・・・・・・・・・・・・・・・・・A-23 Rules for Transportation and Towing ・・・・・・・・・・A-26 Rules for Parking・・・・・・・・・・・・・・・・・・・・・・・・・A-27 Rules for Inspection and Maintenance ・・・・・・・・・A-28

Safety Rules

Operation and Maintenance Manual

取り扱い説明書

T20001

Follow All Instructions and Warnings The Operation and Maintenance Manual and the warning labels on the machine contain instructions and must be followed to ensure safe operation.

Read and understand all DANGER, WARNING and CAUTION labels. Neglecting these instructions and warnings can result in injury or death.

If the manual is lost or any labels (decals) become illegible, order replacements from the nearest authorized TADANO distributor or dealer.

A-2

Safety Rules

T011275E

Avoid Overwork. Never Operate under the Influence of Alcohol or Drugs

Anticipate Accident Situations To deal with possible accidents or fires, equip the crane with a first-aid kit and fire extinguisher. Be aware of the locations of these safety items, and learn how to use them properly.

An emergency contact person and emergency liaison plan should be carefully prepared, and all personnel concerned must be made aware of the details.

If the operator is tired, lacking in sleep, or under the influence of medication or alcohol, the probability of an accident event is greatly increased since attentiveness and judgment are impaired. Maintain proper physical fitness for crane operation.

Wear Proper Clothing Sloppy clothing may result in sleeves or cuffs being caught and then cause an accident.

Observe Work-site Rules Neglecting work-site rules can result in accidents.

To ensure safe operation, observe all work-site rules covering prohibited practices, precautions and correct procedures.

Post a Signal Person Assign a signal person for all crane operations as necessary and always follow instructions especially when: • Working near power lines.

• The load is hidden from the crane operator’s view.

• Moving the carrier along narrow roads or when the operator’s vision is obscured.

The signal person and the operator should communicate with each other using mobile transceiver phones.

T20002

Wear Approved Protective Gear To ensure safety, always wear a hard hat and safety shoes. Also protective goggles, dust mask, earplugs, work gloves, safety belt, etc. must be worn as the situation requires. Check that all protective gear is in good condition before wearing it.

Safety Rules

A-3

Safety Rules

T011275E

Hold Work Site Meetings with Concerned All Personnel

Multi-Crane Operation In lift situations involving the coordination of two or more cranes, establish an agreed system for communications and assign a signal person. The crane operators must proceed cautiously, strictly observing all instructions of the signal person.

Lack of sufficient communications with concerned personnel can result in accidents.

Before starting the job, set up a liaison meeting with the site supervisor, rigging personnel, signal person, etc., to agree on the following details: • Weight of load, radius of load, lift height (based on rated lifting capacity table), locations of loading and unloading, work area of the machine, craning procedures, rigging methods, etc.

• Ground conditions of work area, use of blocks, pads, cribbing, etc. under outrigger floats, whether outrigger extension is required; presence of buried objects such as water and gas lines.

• Mutually agreed upon and OSHA approved signal conventions between rigging personnel and signal person.

• Designation of off-limit areas, provision of barricade.

• Work stations of all relevant workers.

• Emergency liaison plan and emergency contact person, as well as the safety/health organization.

Always Maintain Labels The warning labels on various parts of the machine provide important instructions for safe operation.

Always keep the labels (decals) clean and visible.

Should labels become lost or damaged, order replacements from the nearest authorized TADANO distributor or dealer.

Maintain Good Visibility Fouled window panels, lights or rearview mirrors can limit the operator’s visibility, impairing safe operation. Always keep the window panels and light lenses clean.

Position mirrors correctly as required by job conditions.

Night Operation Operation in the dark makes it difficult to ensure good footing, and to locate nearby persons or obstacles, increasing the probability of an accident.

When operating at night, turn on all working lamps.

Provide ancillary portable lighting equipment to illuminate the work area.

T20004

Always Study Work-site Conditions Carefully Pay due attention to surrounding conditions.

Before starting the job, inspect the work area, check routes to the work area, and monitor the presence of any obstacles and locations of other machinery.

Note changes in the surroundings or site conditions as crane operations are carried out.

Safety Rules

T00643

A-4

Safety Rules

T011275E

Keep the Engine Clean

Perform Pre-Operation Inspection

Dead leaves, paper dust and oil stains on and around the engine can catch fire. Remove all such debris before commencing operation.

Neglecting routine inspections and maintenance can shorten service life of the machine or even result in an accident.

Before starting operation (and before taking over a shift), perform the pre-operation inspection on the carrier and the upper structure to ensure that the machine is in proper condition and free from any problems.

Should any problem be found, report it to the responsible person, remedy it, and only then start operation.

Keep All Footings and Shoes Clean Oil, water or mud on soles of shoes, steps or decks can cause slip off and fall mishaps or cause accidental release of a control pedal. Always remove oil, mud, water or snow before operation and keep shoes and floor of the operator’s cab clean.

Do not leave any parts or tools on the operator’s cab floor or passageway.

Never Allow Anyone to Ride on the Machine, Except the Operator

Keep Unauthorized Personnel Away from the Work Area

If any persons other than the operator (in the operator’s seat) are on the machine, they must be stationed inside the operator’s cab.

Unauthorized personnel or vehicles in the work area can result in collision accidents, injury or death.

Before operation, make sure there are no unauthorized personnel or obstacles within the work area.

If the work area is situated near heavy traffic, post a control person to prevent vehicular accidents.

Barricade the work area with appropriate means either colored tape or rope.

Safely Climbing onto and Descending from the Machine Only climb onto or descend from the machine while it is completely at standstill. Use the handrails and steps, always support your hands and feet firmly (three point support); that is, one hand-two feet or two hands-one foot.

Never use the steering wheel or control levers as handrails.

DANGER STAY CLEAR

T01937E

T20528

Never Jump Onto or Off the Machine Do not jump onto or off the machine.

Do not climb onto or descend from the machine with objects in hand.

Safety Rules

A-5

Safety Rules

T011275E

Correctly Position the Seat

Check the Position of Controls before Starting the Engine

Incorrect positioning of the operator’s seat can result in mistakes or fatigue, possibly leading to an accident.

Before operating the machine, correctly position the seat so that the pedals and levers can be manipulated correctly.

If any control lever is in a position other than “neutral”, the machine may initiate some mechanical or hydraulic function as soon as the engine is turned over. This situation is very dangerous. Start the engine only when completely sure that all controls are in the proper neutral or inactive position.

Do Not Operate a Machine Being Inspected or Serviced Operating the machine while it is undergoing inspection or maintenance work can cause damage or an accident.

Post a “DO NOT OPERATE” sign on the operator’s cab door or any control lever. Do not attempt to operate the machine until the sign is removed by maintenance personnel.

Neutral

T01935E

Make Sure Work Area Is Safe before Starting the Engine Starting the engine without performing a thorough safety check of the work area may cause damage to the machine or injury or death.

Make sure there are no personnel or obstacles underneath or around the machine.

Before starting the engine, sound the horn to warn any nearby personnel.

WARNING DO NO T OP ER

AT E

T01938E

Safety Rules

A-6

Safety Rules

T011275E

Rules for Operation (Setting Outriggers)

Start the Engine from the Operator’s Cab Only If the engine is started from any location other than the crane operator’s cab, it can become impossible to avoid a dangerous hazard if some machine action is initiated when the engine turns over.

Start the engine only from the crane operator’s seat.

Set the Crane on Firm Level Ground The machine should not be located on soft ground, which can lead to sinking, sliding or overturning, nor on the edge of a pit, bank or slope.

If the ground conditions are doubtful, use blocks or steel plates of sufficient strength and size below the outrigger floats to disperse the load.

T01936

Inspection after Starting the Engine

T20617

Failure to perform a basic inspection after starting the engine can result in not detecting fault or abnormality with the machine.

Inspect the machine in a safe location that is free from obstacles and people other than maintenance personnel.

Allow the engine to warm up after it is started while the instrument readings and checking the machine components. Once the engine is properly warmed up, make a safety check of the work area, and run the machine without a load to check out condition of the controls, machine elements and safety devices.

Set the Crane Level If the crane is tilted, and the load is swung over the side, the working radius will increase, and the machine can overturn.

When setting the outriggers, level the machine carefully using a level.

Warm Up the Machine Failure to properly warm-up the engine, and various other machine components can result in decrease in service life of the machine, or malfunctions. In winter, run the engine for at least five minutes for proper warm-up.

Then, run the engine at low speed without a load to warm up the hydraulic oil and other machine components.

Safety Rules

A-7

Safety Rules

T011275E

Rules for Operation (General)

Fully Extend the Outriggers If the outriggers are not extended correctly, the crane may become unstable, causing the crane to overturn.

As a general rule, always extend the outriggers fully, even if the crane is rated for operation with the outriggers at middle extension. If it is absolutely necessary to use the outriggers at middle extension, make sure the machine is within the rated limits.

Observe Working Conditions Operating the crane under conditions (outrigger beam length, boom length, working radius, etc.) other than specified in the rated lifting capacity table can cause overturn even when not lifting a load.

Follow all instructions in the rated lifting capacity table.

Operate According to Signals If signals are not obeyed or if signals are improperly made, accidents can occur.

Follow instructions of the signal person. An emergency shut down signal must be acknowledged whoever gives it.

Do not Exceed Rated Lifting Capacity

T01939

Exceeding the rated lifting capacity will overload the machine. Damage or overturning can result from this practice.

Check the rated lifting capacity table before operating to ensure that the lift is safe. Load lifting capacity of the crane varies depending on boom length and working radius. Never exceed the lifting capacity in the table.

Check the Outrigger Setting Incorrect setting of the outriggers can decrease the load lifting capacity of the machine and result in overturning. To avoid crane instability, make sure: • The machine is absolutely level.

• All outrigger floats are stable and set firmly on the ground or blocks.

• All tires are clear of the ground.

• The outriggers are secured with lock pins (if lock pins are available).

Mass of hook block Rated lifting capacity

Lifting capacity T21566E

Safety Rules

A-8

Safety Rules

T011275E

Before Lifting a Load

Consider Boom Deflection before Lifting the Load

Make sure of the following before attempting to pick up a load: • The weight does not exceed the rated lifting capacity.

• The number of rope parts conforms to the standard in the rated lifting capacity table.

• A proper load handling device is used and the load is securely rigged.

• The hook block is located directly above the center of gravity of the load.

• The wire ropes runs are plumb so that the load can be lifted vertically.

• The safety latch on the hook is working properly.

• The wire rope has no entanglement or disorderly winding on the drum.

When a load is lifted, the boom will deflect downward, increasing the load radius. Swaying of the load also poses a hazard to the people around the crane, and may lead to overloading.

If the load starts to sway when lifted clear of the ground, lower the load back on the ground.

When lifting a heavy load or using the extended boom, anticipate the possible increase in the boom load radius.

Boom deflects

Rig the Load Securely Improper rigging procedure can result in the lifted load being dropped. Rig the load securely, paying special attention to the following points: • Know the weight, shape and center of gravity of the load, and use suitable load handling devices and rigging hardware.

• The load handling devices including wire ropes, chains and rigging hardware must have enough strength and be free from damage or excessive wear.

• Rig the load so that it is suspended at a point above its center of gravity. Otherwise, the load can overturn or come loose of the handling device when it is raised. Also, wire ropes and chains must not be crossed or twisted around each other.

• Do not rig the load with a single wire rope. Such rigging practice is very dangerous as the load can rotate, and untwist the wire rope, reducing its strength.

• When rigging a load with sharp corners, fit protective softeners at the load corners to protect the wire ropes and the load itself against damage.

Safety Rules

Load radius T20906E

Lift Single Loads Only Do not lift two or more loads simultaneously even if their total weight is within the rated lifting capacity; otherwise, the loads may loss balance. It is usually not possible to maintain complete attention to multiple loads.

A-9

Safety Rules

T011275E

Be Extremely Careful When Raising the Load Clear of the Ground

Operate the Crane from the Operator’s Cab Only

Stop lifting the load once the rigging is fully taut, check that the load is suspended at a point just above its center of gravity, and that the load is not stuck to the ground or interfering with a nearby body or structure.

Lift the load vertically. When the load clears the ground, stop lifting and suppress any swaying; then check that the rigging is secure, the load is in a stable position, and the crane is not overloaded.

Then, recommence the lift again.

Controlling the machine from outside the cab, through the cab window, is strictly forbidden and extremely dangerous.

Do Not Lift the Load Clear of the Ground

by Raising or Extending the Boom Raise a load clear of the ground by vertical hoisting only.

Raising or extending the boom to lift a load clear of the ground will cause the load to sway, posing a hazard.

If the boom is elevated to raise a load clear of the ground, the crane will not be automatically stopped even in case of an overload. An overloaded machine can overturn or be damaged.

Conduct a Safety Check within the Working Radius of the Crane before Starting Operation

Do Not Lift an Unknown Load Attempting to uproot a garden tree or raise an object buried or driven into the ground can severely overload various components of the machine, possibly causing the machine to overturn or be damaged. Do not attempt to pull up poles or piles driven into the ground, trees or any objects buried or frozen in mud or sand.

Only lift objects free from all restraining forces.

Any person located close to the crane may become caught between machine components or between the counterweight and a fixed obstacle. Before starting any swing motion, make sure that there is no one nearby. Sound the horn to warn all immediate personnel of crane startup.

During crane operations, fence off or barricade the work area to prevent unauthorized persons from approaching the machine.

Operate the Crane Carefully Operating the controls too abruptly can result in an accident: a swaying load can hit an object or damage the machine.

Operate all control levers and pedals smoothly and in a steady manner.

Move a Lifted Load Carefully When the crane state comes near the full rating, the AML gives an intermittent alarm. Operate the crane more carefully and slow the load-moving speed.

Take best care for over-loading in boom-lowering operation which enlarges the working radius.

T01941

Safety Rules

A-10

Safety Rules

T011275E

Swing the Crane Carefully If the swing speed is too high, substantial centrifugal force is applied to a load, resulting in an increased working radius. As a result, the machine may become overloaded and overturn.

Stopping a swing operation abruptly can cause a load to sway posing a hazard to nearby personnel and possibly leading to boom failure.

Swing all loads slowly. Carefully stop any swinging.

Be extremely cautious when working with an extended boom.

Wire Rope Must Be Properly Wound on the Drum Lifting a load with the wire rope improperly wound on the winch drum can lead to damage of the wire rope, not only decreasing service life of the rope but possibly breaking wires and strands which can lead to ultimate failure.

After reeving or replacement of the wire rope, make sure that the line is properly seated in the sheaves and on the winch drum.

Do Not Unwind the Wire Rope

T00648

If the entire rope is unwound from the winch drum, the frictional anchoring force will be insufficient to support a load. The rope will break or become damaged.

At least three winds of rope must always be left on the winch drum. This condition applies particularly when a load must be lowered below ground level such as a trench or excavation.

Be Careful during Complex Operations Actions of the crane will be slower during complex operations. When switching from a complex operation to a simple operation, action of the machine will become faster. When executing a complex operation, do not change speed immediately.

Do not attempt any complex operation until fully familiar with the crane operation.

Know of the Number of Wire Rope Parts If the number of the part lines is greater than specified for the boom length, the hoist line may become too short. As a result, the line can unwind off the winch drum causing the wire rope to be damaged or broken.

When lowering a very light load, or a bare hook block, the rope will unwind off the winch drum at a faster rate. The rope may then become improperly wound.

Use a number of part lines appropriate to the boom length.

Safety Rules

Use Safety Devices Correctly Improper use of safety devices including the overload cutout can lead to damage or overturn the crane.

Use all safety devices according to instructions in the manual.

A-11

Safety Rules

T011275E

Do Not Rely Exclusively on Safety Devices

Do Not Add Counterweights

A safety device is not a substitute for human skill and judgment.

The overload cutout, for example, does not warn the operator about conditions on the ground, effects of wind, improperly adjusted devices, load being pulled sideways, or other possibly hazardous situations.

All safety devices are merely auxiliary means to help the operator perform the task at hand. Safe crane work requires the qualities of a good operator, such as skill, experience, judgment, and safety awareness.

Installing a counterweight(s) other than those specified can damage the machine, or cause the machine to overturn to the rear owing to decreased rearward stability.

Never install or place a counterweight(s) or equivalent other than those specified.

Do Not Deactivate Any Safety Devices Avoid any action that impairs normal operation of the safety devices.

Intentionally deactivating any safety device may result in the inability to detect overloading or overwinding during operation, and lead to a serious accident.

Ensure that all safety devices are functioning correctly before starting any operation.

T01942

Do Not Anchor the Machine Do not attempt to hold down the crane frame or outrigger of the contrary side to the lifted load, using wire rope.

This practice might lead to crane damage and accidents.

Do Not Allow Anyone to Ride on the Machine Persons on the machine other than the operator (in the operator’s seat) may fall or be caught by a machine component or other objects. Other persons cause distraction and can disturb the attention and work of the operator.

Do Not Position Any Part of Your Body Out of the Window on the Boom Side Sticking any part of your body out from the window on the boom side can result in being caught between the moving boom and the window frame.

Serious injury or death can result from this dangerous practice.

If the window is equipped with a confining guard, do not remove it.

Safety Rules

A-12

Safety Rules

T011275E

Do Not Look Away from the Load While Operating the Crane

Use the Crane Only for Approved Applications

Looking away from the load, eating or performing any other action that can detract from awareness while operating the crane is very dangerous.

During operation, concentrate all attention on the load and the signal person.

The crane is designed to lift a freely suspended vertical load. Never attempt to lift persons, or push/pull a load with the boom.

Do Not Pull a Load Sideways, Do Not Lift a Load Obliquely, Do not Drag a Load Do Not Pass a Load over Any Person Passing a load over a person(s) is very dangerous and must be avoided.

Do not allow anyone to enter the area below the boom or the load.

Safety Rules

Pulling a load sideways, lifting a load obliquely or attempting to drag a load is very dangerous. Such actions can damage the boom, jib or swing mechanism, and lead to overturning of the crane.

Do not attempt to draw in a load that is located outside the working radius. To handle such a load, move the crane to the vicinity of the load, and lift it vertically.

A-13

Safety Rules

T011275E

Handle Wide Loads Carefully

Do Not Overwind the Hook Block

Be careful when lifting a wide load. The load can swing and hit a rigging person, the crane itself or a nearby structure.

Use tethers tied to either or both ends of the load to control the position and/or movement of the load.

When the boom is lowered or extended, the hook block is wound up.

Usually, overwinding the hook block will cause the overwind cutout device to trip and the winch automatically stops. However, if the device is damaged or the automatic stop function has been deactivated for some reason, the hook block can impact the boom head.

Always be aware of the position of the hook block. If the hook block approaches the boom head, wind off the wire rope to lower the hook block and avoid contact.

T00647

Do Not Leave a Load Suspended Do not leave a load in a hoisted position. If the machine is equipped with the drum lock device, actuate both the winch brake and the drum lock to hold the load safely. Use working procedures that minimize the duration a load is left suspended.

Do Not Leave the Operator’s Cab While a Load Is Suspended Before leaving the operator’s cab for any reason, be sure to: • Lower the load to the ground.

• Fully retract the boom and stow it.

• Actuate all brakes and the drum lock.

• Place all control levers in their neutral positions.

• Shut off the engine, and remove the starter key.

• Lock the crane operator’s cab door.

Safety Rules

A-14

Safety Rules

T011275E

Avoid Contact with Obstacles

Do Not Extend the Boom Excessively

While moving a load, be absolutely sure that the load or any part of the crane does not come into contact with nearby structures or other objects.

When working on a site where potential obstacles are present, post a signal person, and only move the load while following instructions.

An excessively extended boom decreases the rated lifting capacity and also can cause overswing of the load or lower working efficiency.

Keep the length of the boom as short as possible during operation.

Be Careful When the Boom Is at Maximum Permissible Angle When the boom is raised to its maximum permissible angle, there exists minimum horizontal clearance between the boom and the load. A swaying load may hit the boom or jib, and cause damage.

Handle the load carefully so that it does not strike the boom or jib.

T00644

Avoid Overloading Operate the Crane with Correct Boom Position When the boom configuration is irregular, for example, the top boom alone is extended for purpose of inspection or maintenance, never attempt to lift a load.

During crane operation, check that all the boom sections are telescoping in the correct sequence. The rated lifting capacity table has been developed based on assumption that the boom sections are telescoped in the correct sequence.

A load below the rated lifting capacity can still cause overloading of the crane if swaying occurs.

Do not trigger overloading while telescoping out or lowering the boom. These actions increase the working radius and are destabilizing.

When Overloading Occurs When overloading occurs, never attempt to raise or lower the boom rapidly. This situation is very dangerous as the machine can readily overturn.

Immediately set the load on the ground by carefully unwinding the wire rope off the winch drum.

Free Fall Operation (If Machine Is Equipped with Free Fall Device)

T01943

Safety Rules

Free fall operation with a lifted load can exert a shock on the machine, possibly damaging or overturning the machine. Allow free fall operation only when the hook block has no load.

For safe operation, it is recommended that loads be always lowered under crane power.

Actuate the winch drum brake smoothly during free fall operation to avoid a sudden shock.

A-15

Safety Rules

T011275E

Be Careful in Demolition Work It is very dangerous to lift parts or components of a structure undergoing demolition, if the weight and center of gravity are unknown. Before starting operation, ascertain the weight and center of gravity of the loads, and establish the lift procedure to be taken.

Do Not Push or Pull an Object with the Boom Never use the boom to push or pull an object. Do not use the boom to thrust up an object or force the boom into an object.

To move an object, use a machine designed for that purpose, such as a fork lift truck or carryall.

Do not use the crane in applications other than those specified.

T01944

Carefully Lift a Load in Water When handling a load submerged in water, it is important not to lift the load out “all at once” when it appears above the water’s surface. The load may be impregnated with water and heavier than expected.

Allow the load to drain while raising it slowly.

A load lifted out of water, even when fully drained, weighs more than it did when submerged because of buoyancy effects. Lift the load carefully so as not to cause overloading.

Caution while Using the Jib (1) Never attempt to lift separate loads on both the boom and the jib at the same time. Otherwise, the boom or the jib might be damaged, or the crane might overturn.

T50069

Safety Rules

A-16

Safety Rules

T011275E

Rules for Operation (Weather)

Caution while Using the Jib (2) Be sure to avoid the operation of the boom with the jib mounted, and the lifting operation for a single load via the concurrent use of the main winch and the auxiliary winch, as far as practicable.

If conditions require such a lift,observe the instructions given in the “AML” section of the manual and perform the operation with the utmost care and attention.

T50070

Mount and Stow the Jib Correctly Failure to observe the specified procedures for mounting and stowing the jib can damage the jib, or may cause the jib to drop.

Be sure to mount and stow the jib in the correct manner by referring to the “Jib” section in the manual.

Stop Operation When Visibility Becomes Poor During bad weather such as rain, snow or fog, stop operation and stow the machine. Wait until visibility improves before resuming operation.

Stop Operation When Strong Winds are Present Under strong winds, a lifted load will start swaying, posing a danger to working personnel and nearby structures and also possibly damaging the boom or overturning the machine.

The influence of cross wind on machine stability is directly proportional to length of the boom and size of the load.

When the maximum instantaneous (i.e. gust) wind speed exceeds 20 mph, stop crane operation and stow the boom.

When the boom is substantially extended or a largesized load is lifted, stop crane operation even if the wind speed is below 20 mph if there is any possible danger.

The table below lists wind speed ranges and the ground conditions for each range. Note that the wind speeds in the table are those at a point 30 ft above open level ground.

Wind speed (mph) 12 - 18

18 - 24

24 - 31 T00649

31 - 38

Safety Rules

A-17

Ground conditions Dust is raised, paper whirls up, and small branches sway.

Shrubs with leaves start swaying.

Wave crests are apparent in ponds or swamps.

Tree branches move. Power lines whistle. It is difficult to open an umbrella.

Whole trees sway. It is difficult to walk against the wind.

Safety Rules

T011275E

Cautions in Cold Weather

Stop All Operation If There is Any Likelihood of Lightning Lightning can not only damage the machine but also injure the operator and working personnel. If lightning is forecast or expected, stop operation, stow the boom, and leave the machine.

If the machine is struck by lightning: • Stay in the cab. Do not try to move out.

• Warn people around not to approach the machine.

• Afterward, inspect the entire crane carefully and have any damaged parts repaired.

Safety Rules

• Snow or ice on the crane should be removed before operation; it is especially important to eliminate any accumulation on the boom, as it could fall and injure someone when the boom is moved.

• Do not let bare skin come in contact with the machine’s metallic parts when the temperature is below freezing. Skin can freeze to the metallic surface, if any moisture is present.

• Warm up the machine sufficiently. Then, check that the machine is functioning correctly. Remove ice and dry machine components as required.

• After starting operation, run the machine slowly until oils fully circulates through all machine components.

• Before lifting, make sure that the load is not frozen to the ground or any other objects. Attempting to lift a load which is frozen to the ground can result in severe overloading and is very dangerous.

• If possible, stow the machine indoors so that the tires are not frozen to the ground. Remove mud from the undercarriage.

• Maintain the battery. Use oils and fuel rated for cold weather.

A-18

Safety Rules

T011275E

Rules for Operation (Power Lines, Radio Waves) Prevent Electric Shock Accidents Approaching too close to power lines can result in electric shock accidents. If conditions absolutely require operation near power lines or distribution lines, implement the following preventive measures: • Meet with the power company concerned to develop a relevant safety plan.

• Require that working personnel wear approved insulating shoes.

• Keep the crane and load beyond the required distance (stipulated by national or local laws and regulations) and away from power lines.

• Post a full-time signal person to ensure the machine or load does not approach power lines or unauthorized personnel do not enter the work area.

• Personnel on the ground must not directly touch the machine or load. When necessary to control the lifted load, use dry fiber ropes as tethers to prevent the load from rotating or swaying.

• Do not place a load below or near power lines.

• Operate the crane slowly with the utmost care and attention.

(The data shown below describes the required distance recommended by Japanese power companies.)

• The operator should stay calm and cautiously move the crane and load away from the power lines to the required stand-off distance, and only then leave the cab.

• Should the machine be damaged and/or disabled, stay in the operator’s seat until the power is cut off. If this is impossible, jump directly from the cab as far as possible. Do not touch any parts of the machine which may be electrified and can cause shock.

• After the accident, contact an authorized TADANO distributor or dealer to report the accident and discuss the measures, and inspection and repairs required.

T00651

Required stand-off distance

Voltage Required stand-off distance Low voltage 100 V, 200 V 2 meters High voltage 6,600 V 22,000 V 3 meters 66,000 V 4 meters Extra high 154,000 V 5 meters voltage 187,000 V 6 meters 275,000 V 7 meters 500,000 V 11 meters

T20762E

Should an electric shock accident occur, do not panic. Follow the instructions below: • Contact the power company to cut off the power and obtain instructions for emergency action.

• Direct all personnel around the machine to evacuate the site. Strictly control the site and keep everyone away from the electrified crane and load.

Safety Rules

A-19

Safety Rules

T011275E

Be Careful about High-Power Radio Waves In areas near sources of high-power radio or TV station transmitters, a current can be induced in the crane structure. Electrified crane components can then result. Also, electronic devices such as the overload cutout may be damaged.

If necessary, ground the hook block to discharge any induced voltage and only then start rigging.

Rules for Operation (Operation without Extending Outriggers) Be Very Careful When the Outriggers are Not Used If the crane is supported only on its tires, stability is decreased, and the machine is more prone to overturn. As a general rule, loads should always be lifted with the outriggers extended.

If operation without extending the outriggers is absolutely required, follow all instructions in the manual, and operate with utmost care.

T01945

T01946

Avoid Careless Swinging Carelessly swinging a load lifted from the over-front area to an over-side area, where crane stability is lower, may overturn the machine. Before swinging, be sure that weight of the load is less than the 360° capacity.

Carefully Swing a Load When swinging a load, the tilt of the machine may vary.

Listing of the machine is greatest when the load is lifted on an over-side area. As a result, the working radius will be higher, and the machine may become overloaded and overturn.

Swing the load cautiously while controlling the increase in working radius.

Safety Rules

A-20

Safety Rules

T011275E

Be Careful when Traveling with a Lifted Load Traveling with a lifted load can increase the possibility of overturn, and should be avoided.

If conditions absolutely require traveling with a lifted load, follow all instructions in the manual, and drive the machine with utmost care.

Do Not Operate the Crane When Traveling with a Lifted Load Operating the crane while traveling with a lifted load is very dangerous, and must be avoided. If the load must be moved, first stop traveling, and only then operate the crane.

Rules for Operation (Special Operation) Be Cautious in Multi-Crane Operation Lifting a load with two or more cranes can be dangerous. In these operations, loads are lifted at points other than directly above the center of gravity and there is possibility of the load falling, the machine being overturned, or the boom failing.

In multi-crane lifting operations, be absolutely careful, and adhere to the following instructions: • Meet with personnel to determine the proper working procedure and lift strategy.

• Assign a work leader, and follow instructions.

• Equip every person concerned with an appropriate communications device.

• Set each crane level on firm ground with the outriggers fully extended.

• The cranes used must have the same performance, characteristics and sufficient capacity for handling the load. Make sure that the cranes have the same settings for the boom length, boom angle, and number of rope parts.

• Lift the load so that the wire rope(s) of each crane are only subjected to vertical line pulls.

• Attempt to rig the load so that all the cranes are loaded equally.

• To move the load, use only the winches and booms. Swinging operations should be avoided.

Do not perform hoisting, elevating (or telescoping) of the boom or swinging at the same time.

• To protect against overloading, operate the separate cranes simultaneously.

T00650

Safety Rules

A-21

Safety Rules

T011275E

Cautions for Operating a Lifting Magnet If the power supply is disrupted, the load will fall.

When operating a lifting magnet, make sure that the following conditions are met: • Start and stop the power generator according to proper procedures.

• Before starting operation, make sure there is no person near the machine. Passing a load over any person is very dangerous and must be avoided.

Do not allow anyone to enter the area below the boom or the load.

• Operate the grab and release control levers correctly to lower the load to a specified location.

• Before leaving the crane operator’s cab, stow the magnet, and shut down the power supply.

• Inspect and maintain the electrical system of the lifting magnet to prevent electric shock under rainy conditions.

For further information, refer to the operation manual for the lifting magnet.

After Operation After Operation, Stow the Machine.

Leaving the machine unattended should be avoided.

Once operation is complete, stow the machine.

T02205

Drain the Air Tank Failure to drain the air tank can cause pneumatic equipment to fail and the machine to malfunction.

Drain the air tank every day.

In cold weather, drain the condensate in the air tank after operation to prevent freezing.

Cautions for Refilling the Fuel Fuel and other oils are highly flammable and dangerous.

Handle combustibles very carefully.

While refueling, observe the following instructions: • Stop the engine.

• Refuel the machine outdoors in a well-ventilated place.

• Keep sources of flames or sparks away from the fuel.

• Wear a protective mask.

• Do not refuel in excess of fuel tank capacity.

Safety Rules

A-22

Safety Rules

T011275E

Rules for Road Travel

Travel with Two-Wheel Steering

Observe All Vehicles Code Requirements for Travel on Public Roads Some national and local laws and rules exist regarding the travel of crane vehicles on public roads.

Before traveling on roads, study the requirements for road travel for the crane, and strictly obey all the regulations.

Check All Physical Limitations on the Planned Route Check road width, overhead clearance, load limits on bridges, etc.

Make sure the route is appropriate for traveling with the crane.

Driving Crane (Carrier) in Road Travel Configuration A swaying hook block or boom, or extended outriggers pose extreme hazards during crane road travel.

Before traveling, stow the hook block and boom in position, and lock the outrigger beams, etc., in position (if lock pins are available). Configure the machine for traveling by referring to the “Crane Travel Procedure” section in the manual.

Traveling on the highway in a special steering mode (four-wheel steering, four-wheel sideways steering, etc.) is very dangerous, and must be strictly avoided. Drive the machine in two-wheel steering mode only.

Special steering modes should only be used for low speed travel within work sites.

Pre-Travel Inspection Before crane travel, check the machine according to the “Pre-operational and Periodic Inspection” section in the manual. In particular, make sure to monitor the points listed below.

Should any irregularity be found, report it to a responsible person, remedy it, and only then start traveling on roads with the crane.

• Controls and instruments are functioning normally.

• Hydraulic and pneumatic pressures are correct.

There is no oil or air leakage.

• The fuel, cooling water, lubricant, hydraulic oil, and brake fluid levels are adequate.

• The tires are free from excessive wear, damage, and cracks. Tire pressure is at a normal level.

There are no loose wheel nuts.

• The braking devices including foot brake and parking brake are functioning normally.

• The lighting system and direction indicators illuminate correctly.

• The rearview mirrors are free from damage.

• Exhaust gas color is normal.

• There are no abnormal noises.

Observe the Riding Capacity T02205

Do Not Travel with Any Cargo on the Crane Carrying cargo on a traveling crane can result in a spill or fall. Use a vehicle designed specifically for cargo transport.

Safety Rules

Non-observance of the riding or passenger restriction not only often violates the law but can lead to an accident. If the operator’s cab is equipped with an auxiliary seat, the machine can accommodate two persons.

If an auxiliary seat is not provided, do not allow anyone other than the operator to ride in the cab.

A-23

Safety Rules

T011275E

Always Fasten the Seat Belt

Be Aware of Road-Surface Conditions

When traveling with the crane, always fasten the seat belt for safety. Be careful not to twist the belt.

Before Starting, Be Aware of Conditions Around the Machine Before starting travel, ensure that there are no personnel or obstacles in the immediate vicinity of the machine. Sound the horn to signal the start of travel.

Driving under poor road surface conditions can cause tires to lose traction or the loss of steering wheel control.

Be extremely careful and attentive when driving on snow-covered or frozen roads, or rough terrain or slope.

And use tire chains according to actual road surface conditions.

Be Aware of Overhead Obstacles Drive Safely Always keep a safe distance when following any vehicle. Drive at moderate speeds.

Turning the steering wheel too rapidly can overturn the crane.

Avoid abrupt driving practices such as speeding, sudden starts, extreme braking or sharp steering.

Pay attention to overhead clearance when passing under electric car wires, or highway or railway bridges, and when passing through a tunnel.

If the planned route necessitates travel below overhead railway lines or overhead bridges or through a tunnel, check the clearances in advance.

Post a Signal Person if Visibility Is Limited When traveling around a tight corner, narrow passage or a location where operator visibility is limited, or when backing up, always post a signal person to prevent any mishap.

T01947

Be Aware of Loss in Air Pressure

T00639

Safety Rules

Loss in air tank pressure will result in diminished braking power, and is very dangerous.

If the low air pressure alarm lamp lights or alarm buzzer sounds, immediately park and secure the machine in a safe place and then check the air system for any leakage.

Avoid stepping on the brake pedal repeatedly as this practice leads to loss in air pressure and sluggish brakes.

A-24

Safety Rules

T011275E

If the Engine Stops during Travel If the crane travels on grades with the engine cut (off), compressed air will not be accumulated in the air tank. Under this condition, frequent use of the brakes will deplete the air tank and result in inoperative brakes. If the engine stops during travel, immediately park and secure the machine in a safe place and attempt to restart the engine. Run the engine until the air supply and air pressure have been restored to proper level.

Stop the Machine with Enough Forward Clearance The boom point projects well ahead of the carrier front bumper. Be careful that the boom point does not exceed the limit line when stopping the machine.

If the Machine is Stuck in a Tunnel Immediately flash the hazard lamps. Place a danger sign behind the machine to warn other vehicles of the danger. Afterward, tow the machine to the outside of the tunnel.

Do not attempt to repair the machine inside the tunnel, as this can cause a traffic accident.

Do Not Allow the Machine to Roll in Neutral When the gearshift lever is put to the neutral position engine braking effectiveness will be lost, and may lead to damage of the transmission system.

Do not leave the gearshift lever in the neutral position while traveling.

Cautions for Traveling on Grades When traveling on a long downhill section of road, do not apply the brake pedal repeatedly or overrev the engine. Repeated use of the foot brake can lead to loss in braking power or even render the brakes inoperative. Overreving can damage the engine.

While on a downhill section, utilize engine braking by gearing down, and actuate exhaust braking. Use the foot brake intermittently to decelerate the machine quickly.

It may be necessary to make special considerations unique to the machine. Travel safely according to the instructions in the “Crane Travel Procedure” section in the manual.

Safety Rules

A-25

Safety Rules

T011275E

Rules for Transportation and Towing

Precautions for Transportation

Load and Unload the Machine Safely Improper loading and unloading procedures can displace the machine off a transporter. Observe the following instructions, and take extreme care in loading and unloading the crane on a transporter: • Secure a trailer of sufficient capacity for the machine’s weight so that it is not overloaded.

• Park the trailer on firm level ground, actuate the parking brake, and chock the tires.

• Use gangplanks of sufficient length, strength and width. Ensure that they provide a gentle slope from ground up to the trailer deck.

• If there is slippery object such as oil or mud on the trailer platform or gangplanks, remove it. On rainy days, the gangplanks can get very slippery.

Then, do not load or unload the machine to and from the trailer.

• Post a signal person, and follow all instructions for loading and unloading the machine.

• Turning the machine on the gangplanks is liable to result in a falling accident, and must be avoided.

To change direction, first descend to the ground, turn on the ground, and climb the gangplanks again.

• While loading or unloading the machine to or from the trailer, do not attempt any operation other than traveling.

Safety Rules

Prevent the crane from moving during transportation, as follows: • Apply the parking brake, chock the front and rear of each tire, and securely tie down the machine to the platform with chain binders.

• Ensure that the hook block and boom are stowed in position, and the upper structure and outriggers are locked.

• Remove the detachable outrigger floats and stow them securely.

T01948

Cautions for Transportation • Post a relevant caution sign according to applicable local and national laws and rules. Be guided by a lead car, if required.

• Check the planned route for road width, overhead clearances, load limits on bridges, and other conditions to make sure that the route is appropriate for transporting the crane.

• Speeding on curves can overturn the trailer or break the tie-down ropes, possibly causing the machine to fall off the trailer. Always drive carefully.

A-26

Safety Rules

T011275E

Rules for Parking

Cautions for Towing While towing, be extremely careful and observe the instructions given below and in the “Emergency Procedures” section in the manual.

• Employ a sufficiently strong tow bar or tow rope.

Check for any damages before use.

• The tow truck must be of equivalent or greater size than the towed crane.

• To prevent crane runaway on a downhill grade, take appropriate measures to maintain braking power during towing.

• Drive at moderate speed. Sharply pulling the crane or rapidly changing the towing speed could break the tow connection.

Park on Safe Level Ground As a rule, do not park the machine on a slope or grade.

Activate the parking brake.

Chock the Tires When Parking on a Slope Park along a slope rather than at an angle to it.

Actuate the parking brake and chock the tires to guard against the chance of a runaway accident.

T01950

T01949

Take Safety Measures When Parking on a Road Post warning signs or flags. Use a beacon lamp to make the machine clearly visible from passing vehicles at night.

Do not block the path of vehicles or pedestrians.

Before Leaving the Machine Do not leave the crane with the engine running or the key inserted in the starter switch.

• Park on level ground, and actuate the parking brake.

• Set all the brakes and locks, and place the gearshift lever in the neutral position.

• Shut down the engine, and remove the key from the starter switch.

• Lock all the doors and covers.

Safety Rules

A-27

Safety Rules

T011275E

Rules for Inspection and Maintenance

Become Familiar with Procedures for Inspection and Maintenance Improper inspection and maintenance procedures can lead to damage of the machine, and may cause injury or even death.

Read the “Inspection and Maintenance” section in the manual and become thoroughly familiar with all instructions given. Do not perform any inspection or maintenance work until the instructions are understood.

When inspection or maintenance work is more complicated, consult an authorized TADANO distributor or dealer.

Do Not Adjust or Disassemble the Hydraulic Equipment The hydraulic equipment including the safety valve and pneumatic equipment have been strictly inspected and carefully adjusted before shipment from the factory.

Disassembly or improper adjustment of the hydraulic or pneumatic equipment can cause failures in safety and functional features.

For disassembly or adjustment, contact an authorized TADANO distributor or dealer.

Wear Safe Clothing

Do Not Modify the Machine

Loose clothing may lead to sleeves or cuffs being caught by a projection or control lever on the machine.

Do not wear work clothing fouled with fuel or oil. It can readily catch fire.

Unauthorized modification may affect the performance, safety and strength of the crane and can lead to damage or overturning.

Never modify any part or aspect of the machine.

When an Irregularity is Detected

Wear Protective Gear

An irregularity which remains unremedied can cause a more serious failure or accident.

If an irregularity is found during inspection work, immediately determine the cause, then adjust and maintain the component in question to prevent a failure or accident.

Performing inspection or maintenance work without wearing the proper protective gear can result in burns, cuts, falling accidents, or eye injuries.

Always wear a hard hat, and safety shoes, also safety goggles, dust mask, earplugs, protective gloves, safety belt, etc., as the situation requires.

Inspect and Maintain at Regular Intervals Sloppy inspection or maintenance work makes it impossible to detect faults at an early stage.

Perform inspection and maintenance at specified intervals to ensure fault prevention and early detection of potential problems.

Safety Rules

A-28

Safety Rules

T011275E

Meet with Working Personnel

Fire Prevention

Working together with other persons on inspection or maintenance tasks without observing mutually agreed upon procedures can result in an accident.

Meet with all involved personnel to agree on the detailed tasks. Also, assign a work leader, and always follow his or her instructions.

Provide Effective Ventilation Performing inspection or maintenance work in a confined space without effective ventilation can lead to toxic poisoning.

Be very careful when handling fuel, wash oil, and paint.

When starting the engine in an enclosed space, provide a means of positive ventilation. Connect a hose from the exhaust to vent the fumes outdoors. Open doors and windows to allow fresh air circulation.

Install a ventilator as required.

To prevent the risk of fire during inspection and maintenance work requiring handling of potentially flammable substances, observe the following instructions.

• Use a non-flammable cleaning liquid to wash parts and components.

• Store fuel and oils away from fire.

• Do not allow sources of flames or sparks near any substance that is combustible.

• Do not smoke cigar or cigarette.

• Always carry a fire extinguisher in the operator’s cab.

• When checking fuel, oils, and battery liquid, use an explosion-proof lamp.

• When grinding or welding, keep flammable substances away from flying sparks or molten metal.

T01951

About Illumination Inspection or maintenance work in a poorly illuminated environment can lead to injury. Before starting the work, provide proper illumination.

Never use the exposed flame of a match or lighter for illumination, a fire accident may occur. The emitted gas from open lead storage batteries can explode, especially while they are being charged.

Safety Rules

A-29

Safety Rules

T011275E

Clean the Machine before Inspection or Maintenance

Labeling for Inspection or Maintenance Work

Dirt and debris on the machine not only prevents easy detection of faulty components or parts but also can be trapped in components or parts. Also, dust or mud can enter your eyes or cause you to slip and be injured.

Before starting general inspection or maintenance activities, wash the machine to ensure a safe work area.

If any unauthorized person starts the engine during inspection or maintenance work, the machine may be damaged or injury or even death may result.

When performing inspection or maintenance work, remove the starter key, and post a “DO NOT OPERATE” or “TAG OUT” sign on the door or control levers of the operator’s cab as a warning.

Also, post relevant warning signs at entry to the work area to prevent access of unauthorized personnel.

Cautions for Washing the Machine Wet footing can cause to slip and fall injuries.

Always wear non-slip shoes.

When washing the machine with high-pressure steam, the jet can penetrate skin or flying mud can cause eye damage. Always wear suitable protective gear during washing.

Do not direct water to electrical equipment, discharge and/or shortcircuits can result and lead to damage.

Inspect and Maintain the Machine on Level Ground It is difficult to inspect the machine properly if it is parked on a slope or grade. Also, the machine is liable to start moving if not parked properly.

Park the crane on firm flat ground, activate the parking brake, and chock the tires.

Keep the Work Area Clean and Tidy Performing inspection or maintenance work in a disorderly place can lead to personal injury or a falling accident.

Remove obstacles.

Start Inspection or Maintenance after the Machine Has Cooled Down When the crane is operated, various machine components become very hot and can cause burns.

These components include the engine, muffler, torque converter, transmission system, axles, engine cooling water, radiator, hydraulic oil, reducer, hydraulic equipment and hydraulic piping.

Allow these components and areas to cool down before starting inspection or maintenance work.

Do Not Dismount Nor Disassemble Hydraulic and Pneumatic Devices, Pipings and Couplings It is prohibited to attempt to dismount nor disassemble hydraulic and pneumatic devices, pipings and couplings. Some of them may have high pressure even when the engine is stopped. It may cause serious accidents to human body.

T01952

Safety Rules

A-30

Safety Rules

T011275E

Beware of High-Pressure Oils

Beware of Overhead Obstacles and Footing

High-pressure fuel or hydraulic oil that comes into contact with skin or eyes can cause serious injury.

To avoid this danger: • Release internal pressure, and only then, disconnect any piping.

• To check for leakage, wear protective goggles and gloves and use a piece of cardboard or wood as a monitor. Leaking high-pressure oil may be invisible.

Keep bare hands away from all leaking components.

• Immediately obtain medical attention when highpressure oil accidentally cuts into skin or affects the eyes.

Lack of awareness or loose footing can cause head impact with the hook block, boom, or jib or slip and falls off the machine.

Always be careful about overhead obstacles and footing. Walk on the non-slip strips if provided on the machine.

Inspect or Maintain Equipment with the Engine Shut Down

T01953

Performing inspection or maintenance work while the engine is running is very dangerous, and should be avoided. Unless otherwise necessary, be sure to shut down the engine before starting inspection or maintenance procedures.

Cautions for Working at Heights

Use Two Persons for Inspection or Maintenance with the Engine Running If for some reason it is necessary to perform an inspection or maintenance procedure with the engine running, post at least two persons—one in the operator’s cab to shut down the engine immediately when necessary, and the other(s) to perform maintenance. During the maintenance, ensure safety of all persons involved in the work.

Working at heights involves the possibility of falling.

To reduce this risk, remove all obstacles, and any spilled grease and oil. Keep all footing areas clean and tidy.

To climb onto and descend from a position of high elevation, face the machine directly. Use the handrails and steps, always be supported by at least three points of your hands and feet.

Be careful not to slip. When non-slip strips are provided on the machine, walk on them.

Use safety equipment such as safety belts ties, lanyards and platforms as the situation requires.

Cautions for Working Under the Machine Use Proper Tools Performing inspection or maintenance work without the proper tools not only decreases work efficiency but also can lead to damage to parts or even injury.

Do not use improper or damaged tools.

Safety Rules

When working under the crane with the jack cylinders extended, place supports and wood blocks beneath the outriggers to support the machine securely. Do not work under the crane unless the machine is securely and positively supported.

A-31

Safety Rules

T011275E

Do Not Stick Any Part of Your Body Out from the Window on the Boom Side

Beware of an Overheated Cooling System

Sticking any part of your body out from the window on the boom side can result in being caught between the moving boom and the window frame.

Serious injury or death can result from this dangerous practice.

If the window is equipped with a confining guard, do not remove it.

Do not unfasten the radiator cap while the engine cooling water is hot. Hot steam and water can spurt out, causing burns.

First allow the radiator to cool down. Then, loosen the cap very slowly while facing away to release the internal pressure.

Keep Away from Moving Parts Inadvertent motion of the machine, or contacting a moving part can cause personal injury and even death.

When necessary to inspect or maintain the machine while running, do not approach moving parts such as the boom, hoisting cylinder, winch, fan, fan belt, and propeller shaft, etc.

Keep hands and clothing away from moving parts.

Lock the Inspection Hole Covers An inspection hole cover that remains open can be closed abruptly by a gust, etc., causing hands or a leg to be caught and injured.

If an inspection hole cover or access door, or the operator’s cab door must remain open, secure in position.

Do Not Allow Tools and Parts to Drop When working through an inspection hole while facing down, be careful not to drop objects into the hole. Such mistakes can damage or lead to malfunction of the machine. Do not keep objects which are not needed for inspection in open pockets.

Recover any object or tool that has dropped into the machine.

Beware of Oil Smears Oil smears on the clutch, lining and brake disks can decrease braking effectiveness. Always keep these assemblies free from oil accumulation.

Safety Rules

A-32

Safety Rules

T011275E

Beware of Dust

Disconnect the Battery Cable before Inspecting or Maintaining the Electrical System

Be careful not to inhale dust during inspection or maintenance work. To inspect or maintain brakes and linings, remove dust using a vacuum cleaner.

Do not use compressed air because this action will scatter dust into the air.

About Starting the Engine with Jumper Cables Using improper jumper cables to start the engine can cause the battery to explode or damage the machine.

When starting the engine using jumper cables, wear protective goggles. This procedure requires two persons; one person must be seated in the operator’s cab. The procedure consists of: (1) Use an assist vehicle with a battery rated for 24 V. Do not use a 12 V or 48 V supply.

(2) Set the starter key to “OFF” position both for the dead vehicle and assist vehicle.

(3) Connect the jumper cables in the following order: 1. “+” terminal of the battery on the dead vehicle.

2. “+” terminal of the battery on the assist vehicle.

3. “-” terminal of the battery on the assist vehicle.

4. A portion of the frame or engine block of the dead vehicle, apart from its battery.

(4) Start the engine of the assist vehicle.

(5) Start the engine of the dead vehicle.

(6) Once the engine of the dead vehicle has successfully started, disconnect the jumper cables in the order of 4., 3., 2. and 1..

Be Cautious about Battery Fluid The battery fluid contains dilute sulfuric acid.

Battery fluid entering the eyes could cause blindness, and battery fluid on skin can cause burns.

When handling the battery, wear protective goggles, protective gloves, and long-sleeved clothing.

If battery fluid touches your eyes or skin, wash with a large amount of fresh water and seek medical attention immediately.

Prevent Explosion of the Battery The battery releases hydrogen gas. Do not light a match or lighter near the battery.

To check the battery fluid level, use a flash light.

If battery fluid is frozen in extreme freezing weather, do not charge the battery or start the engine with an alternative power supply.

Warm up the battery to 59°F (15°C) to avoid trouble.

1

Booster cable

2

Inspecting or maintaining the electrical system without disconnecting the battery cable can cause the wiring to be shortcircuited, possibly damaging the electrical and electronic systems.

Before inspecting or maintaining the electrical system, disconnect the battery cable from the minus terminal (ground side) of the battery.

3

Service vehicle battery

Disabled vehicle battery

Booster cable 4

Frame T21796E

Safety Rules

A-33

Safety Rules

T011275E

Careful Handling of Wire Ropes

Use Genuine Parts Only

Careless handling of wire ropes can shorten their service life, or cause them to break. Handle wire ropes properly by observing all instructions in the manual.

Use of non-factory approved parts can lead to failures in safety and functional systems.

To replace parts such as filters, etc., observe the parts list and use only the specified factory approved genuine items.

Cautions for Adjusting Tire Pressure When adjusting tire pressures, never stand facing the side of the tire. The tire may burst or wheel parts can fly off and cause injury or even death.

Place a tire cage over the wheel and stand behind the tire treads.

Use Specified Oils When replenishing or replacing oils, use recommended brands or grades of oils and greases.

Mixing different brands may change properties of the oil or grease owing to possible chemical reactions, and be detrimental to machine components.

When using oil or grease of a brand different from that in the machine, remove all existing oil or grease, and then refill with the new replacement oil or grease.

Verification after Maintenance

T00656

Assign Replacement or Maintenance Work of Tires to Trained Personnels Replacing or maintaining tires requires special facilities and skill. Inadequate procedures and tools can cause accidents.

For further information about replacement or maintenance of tires, contact an authorized TADANO distributor or dealer or other specialist.

Maintaining the Brake System An improperly maintained brake system can lead to a serious accident. Observe all instructions given in the manual.

Refill the brake system reservoir with approved brake fluid only.

Safety Rules

Verification of proper component or mechanism function after maintenance work is essential.

Be sure to check that the maintained areas are working correctly, that there is no oil leakage, and all bolts have been securely tightened.

Remember that all “maintenance work” should include positive verification of correct machine operation.

About Waste Disposal Waste oils, used filters, and other such petrochemical-related products, if disposed of thoughtlessly, will cause environmental contamination.

Obtain a proper-sized vessel before releasing waste oils from the machine. Never discharge waste oils on the ground or into rivers, lakes or marshes.

Follow all governing environmental rules and regulations when disposing of oils, fuels, cooling water, brake fluid, solvents, filters, batteries or any other damaging substances.

A-34

Safety Rules

T032610E

Warning Labels There are several warning labels affixed to your machine. These labels give important warnings and precautions which must be observed to ensure safety. This section reviews these warnings and precautions, and shows the location of the labels.

All the information on the labels is vital for preventing accidents; familiarize yourself thoroughly with it.

Make sure that the labels are not soiled. Clean them if words are illegible or pictures are unclear.

Replace a damaged or missing label. New labels are available from your nearest authorized TADANO distributor or dealer.

Warning Labels

A-35

Warning Labels

T032610E

Warning Labels - Location and Contents Upper structure 5 Jib Side 17

Right and Left

1 Right and Left 6 Right and Left

1 Right and Left 7

10

11 3

20 21 the reverse side of the cover

8

9

18

Jib head

2

15 2

4

36 12

13

Outside of Door

4

14

Inside the Cab 37 16

Oil Cooler

Glove Box

Warning Labels

T22863E

A-36

Warning Labels

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Lower structure (–545365)

22

22

25

25 26

27

29 23

2 24

34 26

24 26

26

27 33 38 23 2

25

25

22

22

A

B

35 27

2

6

31

C View A

6

2

30

View B

All the Outriggers 32

View C T21650E

Warning Labels

A-37

Warning Labels

T032610E

Lower structure (545366–) 27 23

22

22

25

25 26

29

2 24

34 26

24 26

26

27 33 38 23 2

25

25

22

22

A

B

35 27

2

6

31

C View A

6

2

30

View B

All the Outriggers 32

View C T22864E

Warning Labels

A-38

Warning Labels

T032610E

No.1

No.2

Warning Labels

A-39

Warning Labels

T032610E

No.3

No.4

No.7

No.5

No.8

No.6

No.9

Warning Labels

A-40

Warning Labels

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No.10

No.12

No.13

No.11

No.14

Warning Labels

A-41

Warning Labels

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No.15

No.17

No.18 No.16

Warning Labels

A-42

Warning Labels

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No.20

No.24

No.21 No.25

No.22

No.26

No.23

No.27

Warning Labels

A-43

Warning Labels

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No.29

No.33

No.30

No.34

No.31

No.35

No.32

Warning Labels

A-44

Warning Labels

T032610E

No.36

No.37

No.38

Warning Labels

A-45

Warning Labels

MEMO

A-46

T032621E

Contents Safety・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ A-1 Safety Rules・・・・・・・・・・・・・・・・・・・・・・・・・・ A-2 Before Operation ・・・・・・・・・・・・・・・・・・・・ A-3 Rules for Operation (Setting Outriggers) ・・・ A-7 Rules for Operation (General) ・・・・・・・・・・・ A-8 Rules for Operation (Weather)・・・・・・・・・・ A-17 Rules for Operation (Power Lines, Radio Waves) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・A-19 Rules for Operation (Operation without Extending Outriggers)・・・・・・・・・・・・・・・・・・・・・・ A-20 Rules for Operation (Special Operation)・・・ A-21 After Operation・・・・・・・・・・・・・・・・・・・・・ A-22 Rules for Road Travel ・・・・・・・・・・・・・・・・ A-23 Rules for Transportation and Towing ・・・・・ A-26 Rules for Parking ・・・・・・・・・・・・・・・・・・・ A-27 Rules for Inspection and Maintenance ・・・・ A-28 Warning Labels ・・・・・・・・・・・・・・・・・・・・・・ A-35 Warning Labels - Location and Contents ・・ A-36 Contents ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1 Preface ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 4 Servicing and Ordering Parts ・・・・・・・・・・・・・・ 5 Directional Terms ・・・・・・・・・・・・・・・・・・・・・・・ 6 Components ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 7 Layout of Controls ・・・・・・・・・・・・・・・・・・・・・・ 8 Travel Operation Controls ・・・・・・・・・・・・・・・ 8 Crane Operation Controls・・・・・・・・・・・・・・・ 10 Others・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 12 Terminology ・・・・・・・・・・・・・・・・・・・・・・・・・・ 13

How to Use the Starter Switch ・・・・・・・・・・・ 27 Pre-starting Checks ・・・・・・・・・・・・・・・・・・・ 28 Starting the Engine ・・・・・・・・・・・・・・・・・・・ 28 Stopping the Engine・・・・・・・・・・・・・・・・・・・ 29 Changing Drive Mode ・・・・・・・・・・・・・・・・・・・ 30 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 30 Changing Drive Mode ・・・・・・・・・・・・・・・・・ 30 Changing Speed Range ・・・・・・・・・・・・・・・・・・ 32 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 32 Changing Speed Range ・・・・・・・・・・・・・・・・ 32 Brakes ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34 Foot Brake ・・・・・・・・・・・・・・・・・・・・・・・・・ 34 Parking Brake ・・・・・・・・・・・・・・・・・・・・・・・ 34 Exhaust Brake ・・・・・・・・・・・・・・・・・・・・・・・ 35 Steering ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 36 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 36 Changing Steering Mode ・・・・・・・・・・・・・・・ 36 Lighting and Other Switches ・・・・・・・・・・・・・・ 38 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 38 Tires ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 40 Air Pressure ・・・・・・・・・・・・・・・・・・・・・・・・ 40 Restriction on Continuous Driving ・・・・・・・・・ 40 Equipment Inside the Cab ・・・・・・・・・・・・・・・・ 41 Control ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 41 Heater (option) ・・・・・・・・・・・・・・・・・・・・・・ 41 Other Equipment Inside the Cab ・・・・・・・・・・ 42 Equipment Outside the Cab・・・・・・・・・・・・・・・ 44 How to Use the Air Inflator (Option)・・・・・・・・ 44 Emergency Procedures ・・・・・・・・・・・・・・・・・・ 45 If Trouble Occurs ・・・・・・・・・・・・・・・・・・・・・ 45 If the Engine Stops while Traveling ・・・・・・・・ 45 If Shifting Gears is Impossible・・・・・・・・・・・・ 46 Towing the Crane ・・・・・・・・・・・・・・・・・・・・ 48

[TRAVELING] Traveling Procedure ・・・・・・・・・・・・・・・・・・・・ 15 Preparatory Steps ・・・・・・・・・・・・・・・・・・・・ 15 Starting ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 16 Traveling ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 17 Stopping ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 17 Parking ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 18 Crane Operator’s Cab ・・・・・・・・・・・・・・・・・・・ 19 Opening and Closing the Door ・・・・・・・・・・・ 19 Opening and Closing the Windows ・・・・・・・・ 20 Adjusting the Seat Position・・・・・・・・・・・・・・ 20 Control Levers Stowing ・・・・・・・・・・・・・・・・ 21 Adjusting the Steering Wheel ・・・・・・・・・・・・ 21 How to Read the Instrument Panel ・・・・・・・・・ 22 Meters and Gauges ・・・・・・・・・・・・・・・・・・・ 22 Indicator Lamps ・・・・・・・・・・・・・・・・・・・・・・ 24 Starting and Stopping the Engine ・・・・・・・・・・ 27 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 27 Contents

[OPERATION] Crane Operation Procedure – Summary ・・・・・ 51 On-outrigger Operation ・・・・・・・・・・・・・・・・ 51 How to Read the Performance Data Plate ・・・・ 53 WARNING AND OPERATING INSTRUCTIONS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 53 Load Radius/Lifting Height Chart ・・・・・・・・・ 56 Rated Lifting Capacity Table・・・・・・・・・・・・・ 57 Load Moment Indicator (AML-L) ・・・・・・・・・・・ 62 Configuration and Functions of the Load Moment Indicator System ・・・・・・・・・・・・・・・・・・・ 63 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 66

1

Contents

T032621E

Names and Functions of Load Moment Indicator Main Unit Parts ・・・・・・・・・・・・・・・・・・・・ 67 Selecting Operational Status ・・・・・・・・・・・・ 72 Load Moment Indicator Pre-operational Inspection ・・・・・・・・・・・・・・・・・・・・・・・・ 76 How to Use the Working Range Limit Function ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 78 Display Alteration・・・・・・・・・・・・・・・・・・・・・ 81 Recovery from a Stop ・・・・・・・・・・・・・・・・・ 82 Display and Disposition of Failure Messages ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 85 Disposition of System Trouble ・・・・・・・・・・・ 86 Other Safety Devices ・・・・・・・・・・・・・・・・・・・・ 87 Anti-twoblock Device ・・・・・・・・・・・・・・・・・・ 87 External Warning Lamps (Option) ・・・・・・・・・ 88 Operating the PTO and Warming Up the Machine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 89 Operating the PTO・・・・・・・・・・・・・・・・・・・・ 89 Warming Up the Machine ・・・・・・・・・・・・・・・ 89 Outriggers ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 90 Setting the Crane・・・・・・・・・・・・・・・・・・・・・ 90 Controls ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 90 Extending the Outriggers ・・・・・・・・・・・・・・・ 91 Level Adjustment ・・・・・・・・・・・・・・・・・・・・・ 93 Stowing the Outriggers・・・・・・・・・・・・・・・・・ 94 Adjusting Control Levers ・・・・・・・・・・・・・・・・ 96 Adjusting Neutral Position of Levers ・・・・・・・ 96 Adjusting Length of Control Levers ・・・・・・・・ 96 Hoisting ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 97 Controls (ISO recommended layout) ・・・・・・・ 97 Hoisting Up and Down ・・・・・・・・・・・・・・・・・ 97 Other Winch-related Controls and Devices ・・ 98 Telescoping the Boom・・・・・・・・・・・・・・・・・・・ 99 Controls (ISO recommended layout) ・・・・・・・ 99 Extending and Retracting the Boom ・・・・・・・ 99 Emergency Telescoping Procedure・・・・・・・ 101 Elevating the Boom ・・・・・・・・・・・・・・・・・・・・ 102 Controls (ISO recommended layout) ・・・・・・ 102 Raising and Lowering the Boom ・・・・・・・・・ 102 Swinging the Boom ・・・・・・・・・・・・・・・・・・・・ 103 Controls (ISO recommended layout) ・・・・・・ 103 Swinging the Boom ・・・・・・・・・・・・・・・・・・ 103 On-rubber Operation ・・・・・・・・・・・・・・・・・・・ 105 Stationary ・・・・・・・・・・・・・・・・・・・・・・・・・ 105 Traveling with a Load Lifted ・・・・・・・・・・・・ 106

Contents

Removing and Stowing the Main Hook Block ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 107 Removing the Main Hook Block ・・・・・・・・・ 107 Stowing the Main Hook Block ・・・・・・・・・・・ 108 Reeving Wire Rope ・・・・・・・・・・・・・・・・・・・・ 109 Standard Number of Parts of line ・・・・・・・・ 109 Reeving Procedure ・・・・・・・・・・・・・・・・・・ 111 Single Top ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 112 Components ・・・・・・・・・・・・・・・・・・・・・・・ 112 Single Top Lift ・・・・・・・・・・・・・・・・・・・・・・ 112 Mounting the Single Top・・・・・・・・・・・・・・・ 113 Stowing the Single Top ・・・・・・・・・・・・・・・ 115 Jib ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 117 Components ・・・・・・・・・・・・・・・・・・・・・・・ 117 Jib Lift ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 118 Mounting the jib ・・・・・・・・・・・・・・・・・・・・・ 120 Changing the jib Offset Angle ・・・・・・・・・・・ 125 Changing the Jib Length・・・・・・・・・・・・・・・ 126 Stowing the Jib ・・・・・・・・・・・・・・・・・・・・・ 131 Equipment Inside the Cab ・・・・・・・・・・・・・・・ 135 Equipment Outside the Cab・・・・・・・・・・・・・・ 136 Oil Cooler ・・・・・・・・・・・・・・・・・・・・・・・・・ 136 Winch Drum Monitor Mirror (Option) ・・・・・・ 136 [INSPECTION AND MAINTENANCE] Inspection and Maintenance ・・・・・・・・・・・・・ 137 Pre-Operational and Periodic Inspection ・・・・ 138 Safety Parts Requiring Regular Replacement ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 143 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 144 Maintenance Table ・・・・・・・・・・・・・・・・・・ 144 Greasing Chart ・・・・・・・・・・・・・・・・・・・・・ 145 Gear Oil ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 147 Maintenance Table ・・・・・・・・・・・・・・・・・・ 147 Winch Speed Reducer Oil Level Check ・・・・ 148 Winch Speed Reducer Oil Replacement ・・・ 148 Swing Speed Reducer Oil Level Check ・・・・ 149 Swing Speed Reducer Oil Replacement ・・・ 149 Axle (Carrier Axle) Oil Level Check ・・・・・・・ 150 Axle (Carrier Axle) Oil Replacement ・・・・・・ 150 Axle (Planetary Gear) Oil Level Check ・・・・ 151 Axle (Planetary Gear) Oil Replacement ・・・・ 151 Engine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 152 Maintenance Table ・・・・・・・・・・・・・・・・・・ 152 Air Cleaner Check ・・・・・・・・・・・・・・・・・・・ 152 Element Cleaning ・・・・・・・・・・・・・・・・・・・ 152 Element Replacement ・・・・・・・・・・・・・・・・ 154

2

Contents

T032621E

Engine Cooling System ・・・・・・・・・・・・・・・・・ 155 Maintenance Table ・・・・・・・・・・・・・・・・・・ 155 Cooling Water Level Check ・・・・・・・・・・・・ 155 Torque Converter System ・・・・・・・・・・・・・・・ 156 Maintenance Table ・・・・・・・・・・・・・・・・・・ 156 Oil Level Check ・・・・・・・・・・・・・・・・・・・・・ 156 Oil Replacement ・・・・・・・・・・・・・・・・・・・・ 156 Strainer Cleaning ・・・・・・・・・・・・・・・・・・・・ 158 Line Filter Element Replacement ・・・・・・・・ 158 Fuel System・・・・・・・・・・・・・・・・・・・・・・・・・・ 159 Maintenance Table ・・・・・・・・・・・・・・・・・・ 159 Fuel Tank Level Check・・・・・・・・・・・・・・・・ 159 Water Separator Water Level Check ・・・・・・ 159 Brake System ・・・・・・・・・・・・・・・・・・・・・・・・ 160 Maintenance Table ・・・・・・・・・・・・・・・・・・ 160 Brake Fluid Level Check・・・・・・・・・・・・・・・ 161 Brake Fluid Replacement ・・・・・・・・・・・・・・ 161 Disc Brake Pad Wear Check・・・・・・・・・・・・ 161 Air Dryer Function Check ・・・・・・・・・・・・・・ 163 Air Dryer Desiccating Agent Replacement ・・ 163 Parking Brake Pad Clearance Adjustment ・・ 163 Axle System・・・・・・・・・・・・・・・・・・・・・・・・・・ 165 Maintenance Table ・・・・・・・・・・・・・・・・・・ 165 Suspension Lock Cylinder Bleeding ・・・・・・ 165 Tires and Wheels ・・・・・・・・・・・・・・・・・・・・・・ 166 Maintenance Table ・・・・・・・・・・・・・・・・・・ 166 Tire Wear Check ・・・・・・・・・・・・・・・・・・・・ 166 Tire Replacement ・・・・・・・・・・・・・・・・・・・ 166 Loose Wheel Lug Nut Check ・・・・・・・・・・・ 167 Hydraulic System ・・・・・・・・・・・・・・・・・・・・・ 168 Maintenance Table ・・・・・・・・・・・・・・・・・・ 168 Oil Level Check (Hydraulic Oil Tank) ・・・・・・ 169 Oil Replacement (Hydraulic Oil Tank) ・・・・・ 169 Return Filter Replacement (Hydraulic Oil Tank) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 170 Air Breather Replacement (Hydraulic Oil Tank) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 171 Line Filter Replacement (Automatic Stop Circuit) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 171 Line Filter Replacement (Steering Circuit) ・・ 171 Line Filter Replacement (Winch Brake Circuit) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 171 Swing System ・・・・・・・・・・・・・・・・・・・・・・・・ 172 Maintenance Table ・・・・・・・・・・・・・・・・・・ 172 Swing Bearing Mounting Bolt Check ・・・・・・ 172 Electrical System・・・・・・・・・・・・・・・・・・・・・・ 173 Maintenance Table ・・・・・・・・・・・・・・・・・・ 173 Contents

Fuse Replacement・・・・・・・・・・・・・・・・・・・ 173 Battery Electrolyte Check ・・・・・・・・・・・・・・ 175 Wire Ropes ・・・・・・・・・・・・・・・・・・・・・・・・・・ 176 Proper Handling of Wire Ropes・・・・・・・・・・ 176 Wire Rope Replacement ・・・・・・・・・・・・・・ 177 [INFORMATION AND DATA] Major Specifications ・・・・・・・・・・・・・・・・・・・ 181 Conversion Table・・・・・・・・・・・・・・・・・・・・ 181 Crane Specifications ・・・・・・・・・・・・・・・・・ 183 Carrier Specifications ・・・・・・・・・・・・・・・・・ 183 Overall Dimensions ・・・・・・・・・・・・・・・・・・ 184 Mass・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 185 Relief Valve Pressure・・・・・・・・・・・・・・・・・ 185 Wire Rope Specifications ・・・・・・・・・・・・・・ 185 Other ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 185 Oils and Greases ・・・・・・・・・・・・・・・・・・・・・・ 186 Table ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 186 Recommended Oils and Greases ・・・・・・・・ 187 Consumable Parts ・・・・・・・・・・・・・・・・・・・・・ 190 Filters ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 190 Fuses ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 190 Hand Signals ・・・・・・・・・・・・・・・・・・・・・・・・・ 191

3

Contents

T032631E

Preface This manual is intended as a guide to help you operate and maintain the TADANO crane safely and correctly.

This manual covers cranes of the following specification numbers.

Specification numbers

Please note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual.

If there are any questions regarding the crane or this manual, contact the nearest TADANO distributor or dealer.

1. TR-650-3-00102

(Specification number of the crane is given on the nameplate as shown below.)

Nameplate: Located on the side of the crane operator's cab.

SPEC.

NO.

SERIAL.

NO.

MFG.DATE. KAGAWA, JAPAN

T200169

Please consult the separate engine and cab heater manuals for operation and maintenance of the engine and the cab heater.

The "TRAVELING" section of this manual describes the basic procedures for driving the vehicle. Read it carefully and become thoroughly familiar with the correct procedures for driving the vehicle.

The "OPERATION" section of this manual describes the basic procedures for operating the crane. Read it carefully and become thoroughly familiar with the correct procedures for operating the crane. Operating skill will improve as you gain knowledge of the crane and its capabilities.

The "INSPECTION AND MAINTENANCE" section covers the procedures for inspecting and servicing the crane. Proper inspection and servicing is essential for minimizing problems and obtaining optimum performance. Follow the instructions in this section to perform inspection and servicing properly.

Note that the illustrations in the manual may differ slightly from those on the machine. Also, some illustrations show the machine's components with their covers and guards removed to facilitate explanation.

If you transfer the machine, keep this manual together with it for the convenience of the next operator of this machine.

Preface

4

Preface

T011960E

Servicing and Ordering Parts When contacting the TADANO distributor or dealer for repairs or to order parts, please specify the following information: (1) Specification number (2) Production serial number (3) Year of production

(4) Details of the problem, or the listing, number and quantity of desired parts

Servicing and Ordering Parts

5

Servicing and Ordering Parts

T002461E

Directional Terms The directional terms (front, rear, right and left) used in this manual are defined with reference to the operator's position when the boom is centered toward the front of the carrier. The definitions remain the same even when the crane's upper structure is rotated.

Directional Terms

6

Directional Terms

T013641E

Components

◆These illustrations may be slightly different from the actual machine, due to designing alteration.

1. Jib 2. Auxiliary winch wire rope 3. Cab 4. Boom 5. Elevating cylinder 6. Auxiliary winch 7. Main winch 8. Engine

Components

9. Rear outrigger 10. Rear axle 11. Hydraulic oil tank 12. Steps 13. Front axle 14. Front outrigger 15. Main winch wire rope

7

Components

T032641E

Layout of Controls Travel Operation Controls Inside the Cab 13

1

2

2 3

12

4

11

5 6

14 15

16

17

18 19 7

OFF Lo Hi

8

22

23 24

25

26

27

9

20

21 28

29

30

26

31

CPU ERROR

HYDRAULIC OIL

T/C OIL

39

BRAKE

BEAM

ENG OIL

CHG

4 WD

O/R SW

4 STEER

R/ S TEER CENTER

LOCK

AIR

LOW

LOCK UP

BRAKE

WORK LAMP

PTO

PTO

38

37

36 35 34 33 32

10 T22846

See page 1. Parking lamp switch ・・・・・・・・・・・・・・・・・・・・・ 38 2. Combination switch ・・・・・・・・・・・・・・・・・・ 34, 38 3. Service brake pedal ・・・・・・・・・・・・・・・・・・・・・ 34

18. Air pressure gauge・・・・・・・・・・・・・・・・・・・・・・ 22 19. Fuel gauge ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 22 20. Starter switch・・・・・・・・・・・・・・・・・・・・・・・・・・ 27 21. Fuel control knob ・・・・・・・・・・・・・・・・・・・・・・・ 27 22. Steering mode select switch ・・・・・・・・・・・・・・・ 36 23. Parking brake switch ・・・・・・・・・・・・・・・・・・・・ 34 24. MDT fault warning lamp ・・・・・・・・・・・・・・・・・・ 24 25. Torque converter oil pressure warning lamp・・・・ 24 26. Turn signal indicator lamp・・・・・・・・・・・・・・・・・ 24 27. Brake warning lamp ・・・・・・・・・・・・・・・・・・・・・ 24 28. High beam indicator lamp ・・・・・・・・・・・・・・・・・ 24 29. Engine oil pressure warning lamp ・・・・・・・・・・・ 24 30. Battery charging warning lamp ・・・・・・・・・・・・・ 24 31. Air pressure warning lamp ・・・・・・・・・・・・・・・・ 24 32. Suspension lock indicator lamp ・・・・・・・・・・・・・ 24 33. PTO/travel speed warning lamp ・・・・・・・・・・・・ 24 34. Rear steering center indicator lamp ・・・・・・・・・・ 24 35. Four-wheel steering indicator lamp ・・・・・・・・・・ 24

4. Accelerator pedal ・・・・・・・・・・・・・・・・・・・・・・・ 27 5. Gearshift lever ・・・・・・・・・・・・・・・・・・・・・・・・・ 32 6. Seat belt 7. Drive mode select switch ・・・・・・・・・・・・・・・・・ 30 8. Emergency transmission switch ・・・・・・・・・・・・ 46 9. Error number display ・・・・・・・・・・・・・・・・・・・・ 46 10. Multiplex data transmitter system check switch ・ 46 11. Seat ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 20 12. Steering wheel ・・・・・・・・・・・・・・・・・・・・・・・・・ 36 13. Hazard lamp switch ・・・・・・・・・・・・・・・・・・・・・ 38 14. Torque converter oil temperature gauge ・・・・・・ 22 15. Water temperature gauge ・・・・・・・・・・・・・・・・・ 22 16. Speedometer ・・・・・・・・・・・・・・・・・・・・・・・・・・ 22 17. Tachometer ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 22 Layout of Controls

8

Layout of Controls

T032641E

36. Exhaust brake indicator lamp ・・・・・・・・・・・・・・ 24 37. Lock up indicator lamp ・・・・・・・・・・・・・・・・・・・ 24 38. Low travel speed indicator lamp ・・・・・・・・・・・・ 24 39. Four-wheel drive indicator lamp ・・・・・・・・・・・・ 24

Layout of Controls

9

Layout of Controls

T032641E

Crane Operation Controls Inside the Cab (ISO recommended layout) 1

13 12

10 11 9

2 3

15

26

4

16

5 8

14

6 OFF Lo Hi

7 27 21

20

19 18 17

22

23

CPU ERROR

HYDRAULIC OIL

T/C OIL

BRAKE

BEAM

ENG OIL

CHG

4 WD

O/R SW

4 STEER

R/ S TEER CENTER

LOCK

AIR

LOW

LOCK UP

BRAKE

WORK LAMP

PTO

PTO

25

24

T22847

T22847 See page 1. Main hoist control lever・・・・・・・・・・・・・・・・・・・ 97 2. Boom elevating control lever ・・・・・・・・・・・・・・ 102

14. Anti-two block disable switch ・・・・・・・・・・・・ 87, 97 15. Override warning lamp ・・・・・・・・・・・・・・・・ 66, 86 16. Load moment indicator (AML-L) ・・・・・・・・・・・・ 62 17. PTO switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 89 18. Swing brake switch・・・・・・・・・・・・・・・・・・・・・ 103 19. Failure warning lamp ・・・・・・・・・・・・・・・・・・・・ 66 20. 2nd boom emergency telescoping switch・・・・・・ 99 21. 3rd/top boom emergency telescoping switch ・・・ 99 22. Hydraulic oil temperature warning lamp ・・・・・・ 136 23. Outrigger switch non-neutral position lamp・・・・・ 94 24. PTO lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 89 25. Flood lamp indicator lamp

3. Bubble level・・・・・・・・・・・・・・・・・・・・・・・・・・・ 90 4. Swing lock lever ・・・・・・・・・・・・・・・・・・・・・・・ 103 5. Outrigger control panel ・・・・・・・・・・・・・・・・・・・ 90 6. Swing free/lock select switch・・・・・・・・・・・・・・ 103 7. Flood lamp switch ・・・・・・・・・・・・・・・・・・・・・ 135 8. Swing control lever ・・・・・・・・・・・・・・・・・・・・・ 103 9. Auxiliary hoist control lever ・・・・・・・・・・・・・・・・ 97 10. Boom telescoping control pedal ・・・・・・・・・・・・ 99 11. Boom elevating control pedal ・・・・・・・・・・・・・ 102 12. 3rd/top boom extending switch ・・・・・・・・・・・・・ 99 13. Boom telescoping control lever ・・・・・・・・・・・・・ 99

Layout of Controls

26. Override push switch ・・・・・・・・・・・・・・・・・・・・ 66 27. Drum indicator switch (option) ・・・・・・・・・・・・・・ 97

10

Layout of Controls

T032641E

◆According to TADANO’s system, lever arrangement changes as follows: 1. Main hoist control lever →Auxiliary hoist control lever 2. Boom elevating control lever →Main hoist control lever 3. Auxiliary hoist control lever →Boom elevating control lever

Outside the Cab Elevating cylinder 1

T21645E

2

ON OVERRIDE OFF

T21646E

1. External warning lamps (option) ・・・・・・・・・・・・・ 88 2. Override key switch ・・・・・・・・・・・・・・・・・・・ 66, 86

Layout of Controls

11

Layout of Controls

T032641E

Others Inside the Cab 8

1 2

3 4 5 OFF Lo Hi

6 7

6

T22424

See page 1. Lighter・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 41 2. Roof washer switch ・・・・・・・・・・・・・・・・・・・・・ 135 3. Defroster switch (option)・・・・・・・・・・・・・・・・・・・ 41 4. Ashtray ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 41 5. Heater control panel (option)・・・・・・・・・・・・・・・・ 41 6. Cab lamp switch ・・・・・・・・・・・・・・・・・・・・・・・・ 41 7. Fan switch (option)・・・・・・・・・・・・・・・・・・・・・・・ 41 8. Roof wiper switch・・・・・・・・・・・・・・・・・・・・・・・ 135

Layout of Controls

12

Layout of Controls

T023181E

Terminology This section provides the meaning of some important terms used in this manual.

Jib Length, Jib Offset Angle "Jib length" refers to the center-to-center distance as illustrated in the figure below.

"Jib offset angle" refers to the angle formed by the centerline of an extended jib and the centerline of the boom.

Load radius, Lifting Height "Load radius" refers to the horizontal distance between the crane's center of rotation and the vertical center of the lifted load.

A "lifting height" is defined for each load radius and refers to the vertical distance between the ground and the bottom of the hook block raised to its uppermost position.

Jib offset angle

th

ng

b

Ji

le

T00050E

Lifting height

Rated Lifting Capacity "Rated lifting capacity" refers to the maximum allowable load for a particular boom length and load radius. The rated lifting capacity includes the mass of the hook block, rigging and load handling devices.

The mass of individual hook blocks are indicated in the "INFORMATION AND DATA" section at the end of this manual.

Load radius Center of rotation T20899E

Maximum Lifting Height "Maximum lifting height" refers to the maximum lifting height allowed.

Without Load Boom Length, Boom Angle

The phrase "without load" is used to indicate that no load is being lifted on the hook block.

"Boom length" refers to the distance from the pivot pin at the foot of the boom to the center axle of the sheave(s) at the boom head.

"Boom angle" refers to the angle formed by the boom's centerline and the horizontal.

Stability Section, Strength Section "Stability section" refers to the section of the rated lifting capacity table in which the major factor for determining lifting capacity is the stability of the crane.

"Strength section" refers to the section of the rated lifting capacity table in which the major factor for determining lifting capacity is the structural strength of the crane.

In the rated lifting capacity table, the values below the blue line are based on the stability of the crane.

The values above the blue line are based on the structural competence of the crane for on-outrigger operation, or of the tires for on-rubber operation.

gth

oom

len

B

Boom angle

T00667E

Terminology

13

Terminology

T023181E

Over-front

Maximum Extension Capacity, Middle Extension Capacity, Minimum Extension Capacity

"Over-front" refers to the forward working area of the carrier for which lifting capacities have been rated and listed in the rated lifting capacity table.

(1) Maximum extension capacity Lifting capacity when outriggers are maximally extended.

(2) Middle extension capacity Lifting capacity when outriggers are extended to middle.

(3) Minimum extension capacity Lifting capacity when outriggers are minimally extended.

Over-front

T00668E

On-outrigger Operation Over-front Capacity, 360-degree Capacity

"On-outrigger operation" refers to an operation performed with a crane that is supported on outriggers.

"Over-front capacity" refers to the rated lifting capacity that can be lifted in the over-front area.

"360-degree capacity" refers to the lifting capacities that remain the same regardless of the area in which the load is lifted.

On-rubber Operation "On-rubber operation" refers to an operation performed with a crane that is supported on the tires, and not on the outriggers.

Outrigger Extension Width Traveling with Load on Hook

“Outrigger extension width” refers to the horizontal distance between the right and left outrigger floats when outriggers are extended.

(1) Outrigger maximum extension width (L1) This refers to maximally extended outrigger extension width.

(2) Outrigger middle extension width (L2) This refers to designatedly-middle-extended outrigger extension width.

(3) Outrigger minimum extension width (L3) This refers to designatedly-minimum-extended outrigger extension width.

"Traveling with load on hook" refers to traveling with a suspended load. No crane operations are being performed during this activity.

Raising Load Just Clear of Ground “Raising load just clear of the ground” refers to clearing the load from the ground by hoisting up.

L3 L2 L1 T00053

Terminology

14

Terminology

H000440E

TRAVELING

T032651E

Traveling Procedure 6. Make sure that the control levers and switches are

WARNING

in the following positions: 1. Swing brake switch・・・・・・・・・・・・・・・・・・・・・"ON" 2. PTO switch ・・・・・・・・・・・・・・・・・・・・・・・・・"OFF" 3. Control levers (main winch, boom telescoping, and boom elevating levers) ・・・・・・・・・・・・・・・・Neutral 4. Gearshift lever ・・・・・・・・・・・・・・・・・・・・・・・・・"N" 5. Swing lock lever ・・・・・・・・・・・・・・・・・・・・・"LOCK" 6. Drive mode select switch ・・・・・・・・"2-WHEEL (Hi)" 7. Swing free/lock select switch・・・・・・・・・・・・"LOCK" 8. Control levers (auxiliary winch and boom elevating levers) ・・Leaned backward after locked in neutral positions 9. Parking brake switch ・・・・・・・・・・・・・・・・・"PARK" 10. Steering mode select switch ・・・・・・・・・"2-WHEEL"

This section describes briefly the essential steps for traveling the crane. For detailed information on the controls, refer to the appropriate pages in this section. Do not travel until you completely understand all the instructions and information given in this section.

The precautions to be observed when traveling are described in the "Safety" section at the beginning of this manual. Carefully read the section before traveling the crane.

If there is anything abnormal with the crane when traveling, stop immediately, check and locate the cause of trouble, and arrange to repair any faulty components. To prevent accidents, do not travel until the repairs have been completed.

10

Preparatory Steps

3

1 2

1. Perform pre-operational inspections.

3 4

9

2. Enter the cab and adjust the seat, control levers, steering wheel so that you can easily operate the levers and all other controls. Fasten the seat belt.

5 6

8 OFF

3. Perform pre-start checks and start the engine.

Lo Hi

7

4. Let the engine warm up. make sure that all meters and monitor displays are normal and that the engine is not making abnormal sounds.

T05212

◆Press in the knobs for hoist control levers, boom elevating control lever, boom telescoping control lever, and swing control lever, to their minimum lengths. Put lock pin in the auxiliary hoist control lever and swing control lever and lean them backward.

5. Set the crane in the following traveling style: (1)Stow the auxiliary hook block in its stowing position.

(2)Stow and lock the jib and single top in their stowing positions.

(3)Stow the main hook block in the front side of the frame.

(4)Fully retract the boom and place it over the front. Set the boom angle to its lowest angle.

(5)Lock the upper swing structure with the swing brake and swing lock pin.

(6)Fully retract and stow the outriggers. Lock the outrigger beams with the lock pins.

Lock pin T02987E

Traveling Procedure

15

Traveling Procedure

T032651E

7. Make sure that no warning and indicator lamps are

Starting

illuminated, except for the brake warning lamp. ◆At this point, the brake warning light is on as the parking brake is activated.

1. MDT fault warning lamp・・・・・・・・・・・・・・・・・・・Off 2. Torque converter oil temperature warning lamp・・Off 3. Brake warning lamp・・・・・・・・・・・・・・・・・・・・・・On 4. Engine oil pressure warning lamp・・・・・・・・・・・・Off 5. Battery charging warning lamp ・・・・・・・・・・・・・・Off 6. Air pressure warning lamp ・・・・・・・・・・・・・・・・・Off 7. Suspension lock indicator lamp ・・・・・・・・・・・・・Off 8. PTO/travel speed warning lamp ・・・・・・・・・・・・・Off 9. Four-wheel steer indicator lamp ・・・・・・・・・・・・・Off 10. Outrigger switch non-neutral position lamp ・・・・・Off

1. Depress the service brake pedal and hold it down.

1

2

3

4

5

T00699

2.

Set the parking brake switch to OFF. Make sure that the brake warning lamp goes out. ◆If the parking brake is switched to OFF when air pressure is below the specified level, an alarm buzzer sounds to alert that the air pressure is low.

6

CPU ERROR

HYDRAULIC OIL

T/C OIL

BRAKE

BEAM

ENG OIL

CHG

4 WD

O/R SW

4 STEER

R/ S TEER CENTER

LOCK

AIR

LOW

LOCK UP

BRAKE

WORK LAMP

PTO

PTO

11

10

9

8

3. Check the shift positions while operating the gearshift lever: (1)To go forward ・・・・・・・Drive, First, Second (2)To go backward・・・・・・Reverse ◆If the gearshift lever is operated without releasing the parking brake, the alarm buzzer will sound.

7 T20905

8. On rough or slippery roads, or on unpaved or soft ground, select a drive mode suitable for the terrain condition. When traveling in special steering modes depending on work site conditions, select steering and drive modes suitable for the operation.

T02989

4. Make sure the area completely around the vehicle is safe. Release the service brake pedal and start traveling by slowly depressing the accelerator pedal.

Traveling Procedure

16

Traveling Procedure

T032651E

Traveling

3. Also use the foot brake to slow down. Be sure to

Automatic Gear Shifting

slowly pump the foot brake to slow down more effectively.

Depressing the accelerator pedal with the gearshift lever in Drive automatically changes the transmission from first to third gear based on the traveling speed. This is the normal traveling mode. ◆When the drive mode select switch selects Lo speed, automatic gear shifting cannot be realized.

Manual Gear Shifting Shift into First gear to start forward motion then shift into Second and then Drive to increase speed.

When climbing a grade while manually shifting gears, choose the gear best suited to the the grade.

When accelerating, depress the accelerator pedal and then release it when the traveling speed reaches the next higher range. Then shift to the next higher gear.

When decelerating, slow down to the next slower range and then shift to the next lower gear.

T00699

Stopping 1. Release foot from the accelerator pedal and activate engine braking to slow down.

2. Depress the brake pedal to stop the vehicle.

3. Shift into Neutral.

Traveling on Grade

4. Switch the parking brake switch to PARK, then re-

1. When traveling down a grade, release the accelera-

lease foot from the brake pedal.

tor pedal and pull out the exhaust brake switch to activate engine braking.

Exhaust brake switch

Accelerator pedal

O IN FF T

T02990E

2. If the speed can not be controlled with the exhaust brake, shift down to activate stronger engine braking.

Before shifting down, slow down to the next slower range by depressing the foot brake.

Traveling Procedure

17

Traveling Procedure

T032651E

Parking ◆Parking the crane for long periods causes the portion of the tires that contact the ground to flatten. This effect may produce vibration until the tires return to their original shape with continued travel. To park for long periods, extend the outriggers and keep the tires off the ground.

1. Depress the brake pedal to stop the vehicle.

2. With the brake pedal held down, shift into Neutral and activate the parking brake.

PARK

OFF

PARKING BRAKE

T02991E

3. Release the brake pedal.

4. Turn off the heater and other equipment inside the cab.

5. If a special traveling mode has been selected, return the steering mode and drive mode to the normal modes (two-wheel steering mode and high-speed twowheel drive mode).

6. Close all the side windows and roof window in the cab.

7. Shut off the engine and remove the starter key.

8. Leave the cab and lock the door.

Traveling Procedure

18

Traveling Procedure

T029702E

Crane Operator’s Cab Leaving the Door Held Open

Opening and Closing the Door

To keep the door open during crane operation, open the door fully and press the lock lever forward with the door fully open.

Before closing the door, press the lock lever to the rear.

WARNING The door, if not completely shut, could open when the vehicle is traveling. Before traveling, be sure to close and lock the door.

CAUTION

Lock lever

Do not attempt to shut the door, holding it at the end. Your fingers may be pinched. When shutting the door, hold the door handle.

Door

Outer handle T00671E

Lock T21170E

Lock knob

Inner handle

T02992E

From Outside the Cab Pull the outer handle sideways to slide the door open or shut.

From Inside the Cab Pull the inner handle sideways to slide the door open or closed.

Locking and Unlocking Insert the door key in the lock, and rotate it clockwise to lock the door, or counterclockwise to unlock it. ◆Do not leave the crane with the key inserted in the lock.

Crane Operator's Cab

19

Crane Operator's Cab

T029702E

Opening and Closing the Windows

Adjusting the Seat Position

[NOTICE] ◆ Do not leave the windows open; Wet controls may cause problems. Be sure to shut the windows before leaving the cab.

WARNING Adjust the seat position before traveling or starting operation. Making adjustments while traveling or during operation could be dangerous.

Opening and Closing the Roof Window

The seat can be adjusted up or down, and forward or backward. The seatback angle is also adjustable. Adjust the seat to a position that allows you to easily operate the control levers and pedals.

[NOTICE] ◆ If the roof window is opened with water on it, the water will spill into the cab. Remove any water on the roof window before opening it.

Reclining lever

Pull the handle to open the roof window. To shut the window, push in the handle until it is locked. ◆Placing the starter switch in the OFF position with the

Slide adjustment lever

window open causes the alarm buzzer to sound for 10 seconds, warning that the window has been left open

Height adjustment knob

Handle

T22425E

Height Adjustment Turn the height adjustment knob until the seat is at the desired height. Turning the knob clockwise raises the seat and turning it counterclockwise lowers the seat.

T00672E

Forward/Backward Adjustment Hold the slide adjustment lever up, and adjust the seat forward or backward. The seat is locked in position when the lever is released. Try to move the seat back and forth to ensure that it is locked in place.

Opening and Closing the Door Windows Open or close the door windows by turning the handle in the cab.

Seatback Angle Adjustment

Handle

Pull the reclining lever forward and adjust the angle of the seatback. The seatback is locked in position when the lever is released.

T02993E

Crane Operator's Cab

20

Crane Operator's Cab

T029702E

Control Levers Stowing

Adjusting the Steering Wheel

WARNING

WARNING

Unintentional touch of control levers when entering the cab may cause the machine to move, which is very dangerous. When crane operation is over, lock the auxiliary hoist control lever and the swing control lever with the lock pin and lean them backward.

Be sure to adjust the steering wheel before traveling. Adjustment while traveling is dangerous.

The steering wheel is adjustable in height and angle.

Adjust it to a position that is comfortable.

1. Put in the lock pins.

2. Fully retract the control levers.

3. Push in the control levers to lean them backward.

Height adjustment knob

Angle adjustment knob T00677E

Height Adjustment Loosen the height adjustment knob and adjust the height of the steering wheel. ◆After adjustment, firmly tighten the height adjustment knob.

Lock pin T02987E

Angle Adjustment Loosen the angle adjustment knob and adjust the angle of the steering wheel. ◆After adjustment, firmly tighten the angle adjustment knob.

Crane Operator's Cab

21

Crane Operator's Cab

T012024E

How to Read the Instrument Panel Meters and Gauges 1

2

3

4

5

6

T21643

1. Torque converter oil temperature gauge 2. Water temperature gauge 3. Speedometer

4. Tachometer 5. Air pressure gauge 6. Fuel gauge

Torque Converter Oil Temperature Gauge

Water Temperature Gauge

[NOTICE] ◆ When the gauge needle reaches the yellow zone, decrease load and travel while paying attention to the oil pressure.

When the needle reaches the red zone, oil temperature is too high. Stop the vehicle in a safe location and idle the engine to lower the oil temperature.

[NOTICE] ◆ The engine may overheat if the gauge needle reaches the red zone. Stop the vehicle in a safe place and idle the engine to lower the water temperature.

However, if the radiator fan is not running, stop the engine immediately. After the engine has cooled down, examine and locate the cause of trouble.

This gauge indicates the temperature of the torque converter oil. When traveling, the needle should be in the green zone.

Green

This gauge indicates the temperature of the engine cooling water. When traveling, the gauge needle should be in the green or white zone.

Yellow Red

Green Red

White

VERTER CON OIL TEMP

ER TEM P WAT

T00679E T00680E

How to Read the Instrument Panel

22

How to Read the Instrument Panel

T012024E

Speedometer

Air Pressure Gauge WARNING

The speedometer indicates the travel speed.

A drop in air pressure for the air brakes, below the specified range, is dangerous as it reduces air brake performance. When the air pressure drops below the specified range, the air pressure warning lamp lights and the alarm buzzer sounds.

Immediately stop the vehicle in a safe location.

Shift into Neutral and rev the engine to increase air pressure.

20 30

10

0

MPH

40

This gauge indicates the air pressure in the air tank.

T02995E

Normal pressure range

80 to 140 psi (5.5 to 10.0 kgf/cm2)

Tachometer WARNING

Normal pressure range

If the pointer is in the red zone, the engine may overheat and an alarm buzzer may sound.

Immediately slow the vehicle down using the brake. When traveling down a long grade, pay special attention to the engine speed.

10 5

20 0

This meter indicates the number of engine revolutions per minute. The hour meter is built in the tachometer and counts 1 hour for each hour with an engine speed of 1,600 rpm. Perform inspection and maintenance work on the basis of the displayed hours.

0 0 0 0

AIR X10psi

T02996E

Fuel Gauge This gauge indicates the amount of fuel remaining in the fuel tank.

F ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・The tank is full.

E・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・Add fuel.

Red

hour

15

2 1 3 0

X1000rpm

E

FUEL

F

T00682E

T00684

How to Read the Instrument Panel

23

How to Read the Instrument Panel

T012024E

Indicator Lamps

1

14

13

2

3

4

5

1

BRAKE

BEAM

ENG OIL

CHG

4 WD

O/R SW

4 STEER

R/ S TEER CENTER

LOCK

AIR

LOW

LOCK UP

BRAKE

WORK LAMP

PTO

PTO

12 11

10 9

8

7

6

CPU ERROR

16

HYDRAULIC OIL

T/C OIL

15

T21644

1. Turn signal indicator lamp 2. Brake warning lamp 3. High beam indicator lamp 4. Engine oil pressure warning lamp 5. Battery charging warning lamp 6. Air pressure warning lamp 7. PTO/travel speed warning lamp 8. Suspension lock indicator lamp

9. Rear steering center indicator lamp 10. Exhaust brake indicator lamp 11. Four-wheel steering indicator lamp 12. Lock up indicator lamp 13. Low travel speed indicator lamp 14. Four-wheel drive indicator lamp 15. Torque converter oil pressure warning lamp 16. MDT fault warning lamp

Turn Signal Indicator Lamps

Brake Warning Lamp WARNING

The right or left turn signal indicator lamp flashes in sync with the exterior turn signal lamp. ◆The flashing interval is shorter if the turn signal lamp blows or a lamp with improper wattage is used. ◆Pressing the hazard switch causes the right and left indicator lamps to flash simultaneously.

If this lamp is illuminated when traveling, the brake fluid may be leaking or the disk brake lining may be worn out. Immediately stop in a safe location and check the brake fluid for leakage and the brake lining for wear.

This lamp comes on when the brake fluid level in the reservoir has dropped.

It also lights when the parking brake is activated.

High Beam Indicator Lamp This lamp is illuminated when the headlights are on high beam. This is off when the headlights are on low beam.

How to Read the Instrument Panel

24

How to Read the Instrument Panel

T012024E

Engine Oil Pressure Warning Lamp

PTO/Travel Speed Warning Lamp WARNING

[NOTICE] ◆ Continued traveling while this lamp is illuminated may cause the engine to overheat. If this lamp comes on when the engine is running, stop the engine and check the engine oil level. If the oil level is low, add oil.

If the oil level is O.K., there is some other problem.

Have the nearest TADANO distributor or dealer check the crane.

Traveling on roads with the PTO switch ON is dangerous, as the crane may start operating when a lever or switch is moved unexpectedly. When traveling on public roads, be sure that the PTO switch is OFF. This lamp flashes to alert the operator if the traveling speed has exceeded 2.5 mph (4 km/h) with the PTO switch ON.

This lamp comes on when engine oil pressure is low. ◆When starting the engine, this lamp comes on when the starter is turned to ON and goes out after the engine starts.

Suspension Lock Indicator Lamp This lamp comes on when the PTO switch is turned ON and also when the boom comes out of the over-front area with the PTO switch turned OFF.

Battery Charging Warning Lamp [NOTICE] ◆ Continued traveling while this lamp is illuminated will drain the battery. When this lamp comes on with the engine running, there is a failure in the battery charging system. Have the nearest TADANO distributor or dealer check the problem.

Rear Steering Center Indicator Lamp WARNING Attempting to travel on the public road under two-wheel steering mode while the rear steering center indicator lamp is on is a dangerous practice. Then the rear wheels are not in straight-running positions. Before performing two-wheel steering, make sure that this indicator is off and then lock the rear traveling wheels.

This lamp comes on when the battery is incorrectly charged. ◆When starting the engine, this lamp comes on when the starter is turned to ON and goes out when the engine starts.

This lamp comes on when the rear wheels are not in straight running position.

Air Pressure Warning Lamp

Exhaust Brake Indicator Lamp

This lamp comes on when the air pressure in the air tank drops below the specified range. At the same time, an alarm buzzer sounds to alert the operator.

this lamp comes on when the combination switch on the left side is pulled backward. The lamp goes out when the switch is restored.

Four-wheel steering Indicator Lamp This lamp comes on when the vehicle is in the fourwheel coordinated steering mode or crab steering mode, and goes out when it is in the normal two-wheel steering traveling mode. ◆When traveling on public roads using two-wheel steering, make sure that this lamp is not illuminated.

How to Read the Instrument Panel

25

How to Read the Instrument Panel

T012024E

Lock Up Indicator Lamp

MDT Fault Warning Lamp

This lamp comes on when torque converter lock-up is engaged.

In descending a slope, engine braking effect goes up if traveling with this lock up indicator lamp on by making proper shift changes in accordance with the road inclination. ◆When the drive mode select switch is in a Lo speed, the lock-up device will not be engaged.

[NOTICE] ◆ When the MDT fault warning lamp is on, automatic gear shifting cannot be performed. If this lamp lights in traveling, stop traveling and press the multiplex data transmitter system check switch. If failure code has not gone out from the display window, there are other trouble causes. Confirm the failure code and have the machine checked by the nearest TADANO authorized distributor or dealer. ◆ In order to drive the machine to a safe place for servicing, snap the emergency transmission switch on the multiplex data transmitter to the “ON” position. Shifting can then be done manually. See “If Shifting Gears is Impossible”, for details.

Low Travel Speed Indicator Lamp This lamp comes on when the low-speed four-wheel drive mode is set by placing the drive mode select switch in 4-WHEEL(Lo).

Four-wheel Drive Indicator Lamp

This lamp goes on when the multiplex data transmitter system has troubles on.

This lamp comes on when four-wheel drive mode is set by placing the drive mode select switch in 4-WHEEL(Lo) or 4-WHEEL(Hi).

Torque Converter Oil Pressure Warning Lamp [NOTICE] ◆ Traveling with the torque converter oil pressure warning lamp on will cause damage to the torque converter. If this lamp goes on while the engine is running, stop the engine and check for the quantity of torque converter oil. If short, add more. If the quantity is enough, there are some other causes.

Have the machine checked by the nearest TADANO authorized distributor or dealer.

This lamp goes on when the torque converter oil pressure goes below the specification. At the same time an alarm buzzer sounds.

How to Read the Instrument Panel

26

How to Read the Instrument Panel

T012033E

Starting and Stopping the Engine Controls

How to Use the Starter Switch [NOTICE] ◆ Do not leave the starter key in the “ON” position with the engine stopped. The battery will run down if the working lamps, fan, or other equipment is used for hours with the engine off and the starter switch turned to BATT or ON. If using electrical equipment for long periods of time, be sure to run the engine to maintain the battery charge.

1

2

BATT

OFF

ON

3 HEAT

T21642

START

1. Starter switch 2. Fuel control knob 3. Accelerator pedal T00689

"OFF" ・・・・・Shuts off the engine. The key can be inserted or removed in this position. Turning the switch back to OFF shuts off the engine.

"ON" ・・・・・・All electrical systems are activated.

"START" ・・・Starts the engine. Release the key after the engine has started. The switch will automatically return to ON. "BATT" ・・・・The fan, washer, wiper, horn, and flood lamps can be used with the engine off.

"HEAT" ・・・・Energizes the engine preheating circuit.

Use this position to start the engine in cold weather.

Releasing the key automatically returns the switch to BATT.

Starting and Stopping the Engine

27

Starting and Stopping the Engine

T012033E

Pre-starting Checks

Starting the Engine

Before starting the engine, perform the following inspection and checks:

[NOTICE] ◆ Do not hold the starter switch in the start position for more than 15 seconds, as this practice will overheat the starter motor. If the first attempt to start the engine fails, wait at least 30 seconds before trying again.

1. Perform the pre-operational inspections. ◆For an explanation of the engine pre-operational inspection procedure, see the "Engine Operation and Maintenance Manual".

Starting the Engine

2. Make sure that the controls are placed in the follow-

1. Depress the brake pedal and position the starter

ing positions: (1)Winch, boom telescoping, boom elevating and swing levers ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・Neutral (2)Parking brake switch ・・・・・・・・・・・・・・・・・"PARK" (3)Gearshift lever ・・・・・・・・・・・・・・・・・・・・・・・・・"N" (4)PTO switch・・・・・・・・・・・・・・・・・・・・・・・・・・"OFF"

switch at “START”. Release the key immediately once the engine has started. ◆In cold weather, turn the starter switch to HEAT and hold it for about 10 seconds to preheat the engine. Once the engine has been preheated, immediately turn the starter switch to START. ◆Do not step on the accelerator pedal if the PTO switch is on.

BATT HEAT

OFF

ON START

T00690

Warming Up the Machine

E

L H

FU

1. Once the engine has started, turn the fuel control knob toward "H" to increase the engine speed until it's running smoothly. Warm up the vehicle until the needle in the water temperature gauge begins to move.

L

T00691

Starting and Stopping the Engine

28

Starting and Stopping the Engine

T012033E

2. After warming up, turn the fuel control knob toward

Stopping the Engine

"L" to run the engine at idling speed (600 to 650 rpm).

[NOTICE] ◆ Stopping the engine when it is running at high speeds could damage the engine. Be sure to stop the engine when it is running at idling speeds. ◆ Stopping the engine immediately after traveling could affect it adversely. Before shutting off the engine, be sure to idle it for approximately 5 minutes to cool down the engine components.

Warm-up Checks During warm-up, check for abnormal exhaust gas color, sound and vibration. Also, check that the gauges and indicator lamps related to the engine display their normal reading as shown. If not, shut off the engine and have the nearest TADANO distributor or dealer check the problem. ◆When air pressure is low after draining water from the air tank or for other reasons, an alarm buzzer sounds to indicate low air pressure after the engine has started.

The alarm buzzer will stop once a sufficient amount of air is supplied.

1. Before stopping the engine, place the parking brake switch, gearshift lever and PTO switch in the following positions: (1)Parking brake switch ・・・・・・・・・・・・・・・・・ "PARK" (2)Gearshift lever ・・・・・・・・・・・・・・・・・・・・・・・・・ "N" (3)PTO switch ・・・・・・・・・・・・・・・・・・・・・・・・・ "OFF"

1. Torque converter oil Indicates green zone temperature gauge (after warm-up) 2. Water temperature gauge Indicates green or white zone (after warm-up) 3. Air pressure gauge 80 to 140 psi (5.5 to 10.0 kgf/cm2) 4. Fuel gauge Indicates green zone 5. Air pressure warning lamp Goes out 6. Battery charging warning Goes out lamp 7. Engine oil pressure Goes out warning lamp 8. Torque converter oil Goes out pressure warning lamp

1

2

3

4

0 0 0 0

20 10 VERTER CON OIL TEMP

2. Turn the starter switch to "OFF" to stop the engine.

hour

2 30

10

1

15

5

3

ER TEMP WAT

E

FUEL

F

20

0

MPH

40

0

0 x1000rpm

AIR X10psl

CPU ERROR

8

HYDRAULIC OIL

BRAKE

BEAM

ENG OIL

CHG

4 WD

O/R SW

4 STEER

R/ S TEER CENTER

LOCK

AIR

LOW

LOCK UP

BRAKE

WORK LAMP

PTO

PTO

T/C OIL

7

6 5

Starting and Stopping the Engine

T02999

29

Starting and Stopping the Engine

T029171E

Changing Drive Mode Drive Modes

Controls

Three drive modes can be set by operating the drive mode select switch.

Choose the drive mode suited to the road or working conditions.

(1)High-speed two-wheel drive mode Turning the drive mode select switch to 2-WHEEL(Hi) allows the crane to travel in the high-speed two-wheel drive (front wheels) mode.

Select this drive mode when traveling on public roads. ◆Lock the drive mode select switch lever with the stopper.

1

OFF Lo Hi

T05216

1. Drive mode select switch

DRIVE SELECT 4-WHEEL (Lo) 2-WHEEL (Hi) 4-WHEEL (Hi)

Changing Drive Mode [NOTICE] ◆ Operating the drive mode select switch when traveling or when the transmission is not in Neutral may damage the transmission or other components.

Before operating the switch, be sure to stop the vehicle and shift into Neutral. ◆ In four-wheel drive mode, a greater torque load is applied to the drive system than in two-wheel drive mode. Therefore, traveling in four-wheel drive mode for long periods of time can cause the tires to wear quickly and can damage the drive system.

If there is no reason to use four-wheel drive mode, return to two-wheel drive mode as soon as possible. ◆ Traveling with the indicator lamps which correspond to the actual condition of the drive mode select switch unlit will lead to damage to the transmission. ◆ Continuously driving the front wheels without driving the rear wheels damages the transmission bearings and other components.

If there is need to drive the wheels when the tires are off the ground while the outriggers are extended, do so in the four-wheel drive mode.

To perform this operation, position the tires straight ahead. Do not allow persons to come near the operating place.

Changing Drive Mode

T02930

(2)High-speed four-wheel drive mode Turning the drive mode select switch to 4-WHEEL(Hi) allows the crane to travel in the high-speed fourwheel drive mode.

Select this drive mode when traveling on slippery road surfaces such as rough or snow-covered roads. ◆When this drive mode is selected, the four-wheel drive indicator lamp is illuminated.

DRIVE SELECT 4-WHEEL (Lo) 2-WHEEL (Hi) 4-WHEEL (Hi)

4WD

T02931

30

Changing Drive Mode

T029171E

(3)Low-speed four-wheel drive mode Turning the drive mode select switch to 4-WHEEL(Lo) allows the crane to travel in the low-speed four-wheel drive mode.

Select this drive mode when traveling on unpaved roads, rough terrain, or traveling with a load on the hook block. ◆When this drive mode is selected, the four-wheel drive indicator lamp and the low travel speed indicator lamp are illuminated.

DRIVE SELECT 4-WHEEL (Lo) 2-WHEEL (Hi) 4-WHEEL (Hi)

4WD

LOW

T02932

Changing Drive Mode

1. Stop the vehicle on level ground.

2. Make sure that the transmission is in Neutral, then change the drive mode select switch to the desired drive mode.

3. Make sure that the corresponding indicator lamp comes on (goes off). ◆If the machine starts to travel while the indicator lamps corresponding to the actual condition of the drive mode select switch remain unlit, the alarm buzzer sounds (Applicable to the machines with Serial No.545415 or upward). If you continue traveling in this condition, the transmission will be damaged.

Changing Drive Mode

31

Changing Drive Mode

T012054E

Changing Speed Range "R"・・・Reverse. Enables the vehicle to move backwards.

"N"・・・Neutral. Select this position when starting the engine and stopping and parking, and during crane operations.

"D"・・・・Drive. Depressing the accelerator pedal automatically shifts the transmission from first gear to third gear based on the traveling speed. When the drive mode select switch selects Lo speed, the transmission is fixed to the third gear.

"2"・・・・Second. Used when traveling up a long grade or traveling down a grade with engine brakes. The transmission is fixed in second gear.

"1"・・・・First. Used when traveling up an extremely steep grade or when strong engine braking is required.

The transmission is fixed in first gear.

Controls

1

T21640

1. Gearshift lever

Changing Speed Range

◆The gearshift lever is so constituted to move as shown below to prevent misoperation. To unlock, press the unlock button situated by the knob side.

Gearshift Positions WARNING When the transmission is in first or second gear, gearshifts are not performed automatically based on the traveling speed. If the traveling speed exceeds the selected speed range of these gears, the engine will over-rev.

When the travel speed exceeds the selected speed range, traveling down a steep grade for example, slow down by slowly pumping the foot brake.

Free Lock

T02935E

The transmission speed range is selected with the gearshift lever.

Unlock button

T02934E

Changing Speed Range

32

Changing Speed Range

T012054E

Operating Gearshift Lever to Start Traveling

Operating Gearshift Lever while Traveling WARNING

WARNING

Do not travel with the gearshift in “N” position.

This will cause transmission seizure, excess speeding, etc. to cause a serious trouble.

Shifting into Drive, First, Second, or Reverse causes the vehicle to begin moving. When shifting gears from the standstall, be sure to depress the service brake pedal to prevent the vehicle from moving.

[NOTICE] ◆ Shifting from First, Second, or Drive into Reverse, or from Reverse into First, Second, or Drive while traveling may damage the transmission. Be sure to stop the vehicle before shifting into or out of Reverse.

1. Step on the service brake pedal by right foot and keep it depressed.

The gears can be shifted manually while traveling. Shift into First gear to start traveling and then change to Second gear and then Drive to speed up.

When ascending a grade while manually shifting gears, choose the proper gear to climb the grade.

When accelerating while manually shifting gears, accelerate until the traveling speed reaches the next higher range. Then shift to the next higher gear. When decelerating, slow down to the next slower range and then gear down. ◆Shifting into Second or First gear at high speeds activates the safety device for engine protection, which prevents the gear from shifting down until a safe traveling speed is reached. Before shifting to a lower gear, slow down using the foot brake.

T00699

2. Snap the parking brake switch to OFF and make sure that the brake warning lamp goes out.

3. Operate the gearshift lever to check the position of each speed range: (1)To move forward ・・・・・Drive, First, Second (2)To move backward ・・・Reverse ◆The alarm buzzer will sound if the gearshift lever is operated without disengaging the parking brake.

Shift Transmission position gear

4. Make sure it is safe around the vehicle and then release the service brake pedal and slowly depress the accelerator pedal to start traveling.

“1”

First

“2”

Second

“D”

Third

“R”

First

Speed range Hi

Lo

0 to 6 MPH (0 to 10 km/h) 0 to 13 MPH (0 to 21 km/h) 0 to 25 MPH (0 to 40 km/h) 0 to 6 MPH (0 to 10 km/h)

0 to 2.5 MPH (0 to 4 km/h) 0 to 5 MPH (0 to 8 km/h) 0 to 10 MPH (0 to 16 km/h) 0 to 2.5 MPH (0 to 4 km/h)

◆While traveling in the Lo speed range (the low travel speed indicator lamps is on), carrier speed does not change automatically even if the gearshift lever is set to the “D” position. In low-speed traveling, perform gearshift lever operation manually without fail. Take care that the engine does not overrun.

Changing Speed Range

33

Changing Speed Range

T012064E

Brakes Controls

Parking Brake WARNING To park, activate the parking brake with the transmission in Neutral.

Avoid parking on a grade. To park on a steep grade, activate the parking brake and block the tires with chocks.

Except when in an emergency, do not use the parking brake while traveling.

3 1

2

Activate/release the parking brake with the parking brake switch. Use this switch when parking the vehicle.

"PARK" ・・・・Activates the parking brake.

"OFF" ・・・・・Releases the parking brake. ◆If the air pressure in the air tank is below the specified range, the parking brake will not release even the parking brake switch is turned OFF. Also, an alarm buzzer sounds when the switch is turned to OFF. ◆If an attempt to start traveling with the parking brake activated is made, an alarm buzzer will sound. ◆The brake warning lamp is illuminated when the parking brake is activated. ◆Do not apply parking brake before the carrier has come to a complete stop.

T21639

1. Service brake pedal 2. Parking brake switch 3. Combination switch (exhaust brake switch)

Foot Brake WARNING Before traveling down a long or steep grade, perform a brake test and make sure that the brake system functions normally.

Abrupt braking not only damages the tires and brake system, but also causes the vehicle to skid on a slippery road surface. Avoid abrupt braking.

Excessive use of the service brake pedal can overheat the brake discs and brake pads leading to a decrease in brake performance or "brake fade" which can cause the brake to become inoperable.

When traveling down a long grade, shift down to the proper speed range to activate engine braking and use the exhaust brake as supplement. Slowly pump the service brake pedal to effectively slow down.

When the brake warning lamp goes on during travel, there may be external leakage of brake fluid or wear of disc brake pad. Stop the carrier immediately and check for fluid leaks and pad wear.

PARK

OFF

BRAKE

PARKING BRAKE

T00701E

To stop the vehicle temporarily, depress the service brake pedal with the transmission in First, Second, Drive, or Reverse.

Depress the service brake pedal early, slowly pumping it.

Brakes

34

Brakes

T012064E

Exhaust Brake Activate the exhaust brake by pulling out the exhaust brake switch and releasing the accelerator pedal. The exhaust brake is released temporarily when the accelerator pedal is depressed.

Use the exhaust brake when strong engine braking is required, such as when traveling down a grade. If the speed can not be controlled with the exhaust brake, downshift to activate stronger engine braking. ◆The exhaust brake indicator lamp comes on when the exhaust brake switch is pulled backward.

O IN FF T

BRAKE

T01732

Brakes

35

Brakes

T029181E

Steering Steering Modes

Controls

2

(1)Two-wheel steering mode Steering is performed by the two front axle wheels only. Use this steering mode to travel on public roads.

(2)Four-wheel coordinated steering mode The front wheels and rear wheels turn in opposite directions. This steering mode is useful in a small work site, because it provides the smallest turning radius.

(3)Crab steering mode The front wheels and rear wheels turn in the same direction. This steering mode is useful to pull the vehicle over to the side of a road, because the vehicle travels obliquely.

1

OFF Lo Hi

T05217

1. Steering wheel 2. Steering mode select switch

Changing Steering Mode WARNING Two-wheel steering

Traveling on public roads in one of the special steering modes (four-wheel coordinated steering and crab steering) is dangerous. On public roads, never use special steering modes.

Use special steering modes at low speeds and within work sites or rough terrain only.

On public roads, travel in the two-wheel steering mode.

Four-wheel coordinated steering

Crab steering

T00705E

From Two-wheel to Four-wheel Coordinated/Crab Steering Mode

1. Stop the vehicle with the front wheels centered. ◆If the steering mode is changed with the front wheels turned even slightly, the steering angle will be different between the front wheels and rear wheels.

Choose from three steering modes using the steering mode select switch. The crane travels differently in each steering mode. Choose the steering mode best suited to the situation.

T00706

STEERING SELECT T02938

Steering

36

Steering

T029181E

2. Place the steering mode select switch in the "fourwheel coordinated steering" or "crab steering" position.

Make sure that the four-wheel steering indicator lamp comes on simultaneously.

Four-wheel coordinated steering

Crab steering

4 STEER

STEERING SELECT

STEERING SELECT

T02939

3. Move the steering wheel, and visually confirm the front and rear wheels show the same motion as the selected steering mode.

From Four-wheel Coordinated/Crab to Twowheel Steering Mode

1. Stop the carrier with the rear wheels directed straight so that the rear steering center indicator lamp goes out.

R/ S TEER CENTER

R/ S TEER CENTER

T05218

2. Return the steering mode select switch to "twowheel steering". Now the two-wheel steering mode has been set. ◆Lock the steering mode select switch lever with the stopper.

3. Try to turn the steering wheel and visually confirm that the rear wheels do not move.

Steering

37

Steering

T029193E

Lighting and Other Switches (1)Lighting switch Turning the lighting switch when the starter switch is ON activates the following lamps:

Controls

4

1

2

2

Switch position

Headlight

“OFF”

─

Clearance lamps, tail lamps, license plate lamps, instrument lamp, and boom top lamp ─

─

Lights

Lights

Lights

3

OFF Lo Hi

T05219

1. Parking lamp switch 2. Combination switch 3. Horn switch 4. Hazard lamp switch

OFF

T00719

Combination Switch

(2)Dimmer switch Holding the lever back when the headlights are on switches from low beams to high beams. Returning the lever switches back to low beams.

If you want to momentarily turn on the headlights, pull up the lever. The high beams will turn on regardless of the position of lighting switch. Releasing the lever returns it to its original position and the high beams turn off. ◆The beam indicator lamp is illuminated when the high beams are on.

The combination switch attached to the steering column activates the following functions:

Wiper switch Washer switch Exhaust brake switch

Lighting switch Dimmer switch Turn single switch

T02941E

BEAM

T00720

Lighting and Other Switches

38

Lighting and Other Switches

T029193E

(3)Turn signal switch Pushing the lever up or down causes the turn signal lamp to flash. ◆If the lever does not return automatically by recentering the steering wheel, return it by hand. ◆The right or left turn signal indicator lamp flashes in sync with the exterior turn signal lamp.

◆When the washer fluid runs out, refill the washer tank located outside on the right of the cab with the washer fluid.

Washer tank

L T50586E

R

Hazard Lamp Switch/Parking Lamp Switch [NOTICE] ◆ Illuminating the hazard/parking lamp for long periods when the engine is off causes the battery to run down.

T00721

(4)Washer switch and wiper switch [NOTICE] ◆ Do not use the wipers on dry glass; doing so will damage the glass. Wet glass by spraying the window with washer fluid before using the wipers. ◆ Never spray washer fluid continuously for more than 3 seconds and do not operate the washer switch when there is no window washer fluid. This practice may burnout the pump.

Pushing the hazard lamp switch causes both turn signal lamps to flash. Pulling the switch toward you causes the lamps to go out.

Use this switch when parking on the road side, to alert other drivers of a vehicle problem.

Pushing the parking lamp switch turns the parking lamps on. Pulling the switch toward you causes the lamps to go out.

Washer fluid can be sprayed on the windshield by pressing in the switch end knob.

Rotating the switch activates the wipers as follows: "OFF"・・・・・・・・・・・Stops the wipers.

"INT" ・・・・・・・・・・・Wipes once in 3 to 5 seconds.

"LO" ・・・・・・・・・・・・Wipes at low speed.

"HI" ・・・・・・・・・・・・Wipes at high speed.

Washer

Hazard lamp switch

Parking lamp switch P

T20900E

Wiper O IN FF T

Horn Switch Pressing the center of the steering wheel causes the horn to sound.

T02942E

Lighting and Other Switches

39

Lighting and Other Switches

T013662E

Tires Air Pressure WARNING Do not travel nor perform on-rubber operation if tire’s air pressure is below the values in the list below.

[NOTICE] ◆ When parking the crane for a long time, extend the jacks to stroke end and lift the wheels up from the ground. Otherwise, tires will get deformed.

Check for air pressure to the table below. Make this check every month when tires are cool.

Usage Travel On-rubber operation

Air pressure 50 psi (3.5 kgf/cm2) 60 psi (4.2 kgf/cm2)

Restriction on Continuous Driving To maintain the proper performance of the tires over their life, stop and cool them periodically while traveling.

Cooling time depends on atmospheric temperature.

Max. average speed Tires 29.5-25-22PR

Tires

Traveling cycle

19 mph (30 km/h) Ambient temp.

100°F (38°C) 122°F (50°C)

40

25 mph (40 km/h)

Travel time

Cooling time

Travel time

Cooling time

210 min.

90 min.

180 min.

240 min.

90 min.

60 min.

180 min.

240 min.

Tires

T029202E

Equipment Inside the Cab Controls

Heater (option) Operation DANGER 1

Do not turn the starter switch to “OFF” while the heater is in operation. This attempt may cause not only heater trouble but also fire and burn through overheating.

2 3

The heater is a combustion heater using kerosene. For operation, inspection and maintenance of the heater itself, refer to the separate heater operation and maintenance manual.

4 OFF Lo Hi

5

5 6

Heater Control Panel T05220

Heater operation is controlled from this panel. See the separate heater operation and maintenance manual for detailed instructions.

1. Lighter 2. Defroster switch (option) 3. Ashtray 4. Heater control panel (option) 5. Cab lamp switch 6. Fan switch (option)

MIKUNI

MY30

T21169

Equipment Inside the Cab

41

Equipment Inside the Cab

T029202E

Other Equipment Inside the Cab

Cab Lamp Switch

Ashtray

"DOOR" ・・・lamp turns on when the door is open and goes off when the door is closed "OFF" ・・・・・lamp stays off regardless of door position.

"O N " ・・・・・lamp stays on regardless of door position.

Close the lid after use. To clean, lift out the entire unit.

(DOOR) (OFF)

T00335

(ON ) T00727

Lighter Fan Switch (Option)

[NOTICE] ◆ Observe the following precautions to prevent a fault in the electrical system: • Do not let the lighter remain pushed in.

• Pull out the lighter by hand if it does not pop out within 15 to 20 seconds after it has been pushed in.

• Do not use power receptacle for anything other than a lighter.

• Do not allow the lighter to become deformed. A misshapen lighter will fail to come out. Replace a lighter that is malfunctioning.

The fan switch is used to turn the fan ON and OFF. "O N " ・・・・・fan comes on "OFF" ・・・・・fan goes off

F (ON) (OFF)

The lighter will pop out a few seconds after it has been pushed in. Pull out to use.

T00728

24V

T00336

Equipment Inside the Cab

42

Equipment Inside the Cab

T029202E

Defroster Switch (Option) The defroster switch is used when the windshield is fogged up. When the heater is used, hot air blows onto the windshield.

"OFF" ・・・・・the defroster stops "L" ・・・・・・・air blows weakly "H" ・・・・・・・air blows strongly

OFF

L

H

FAN

T02945

Equipment Inside the Cab

43

Equipment Inside the Cab

T014532E

Equipment Outside the Cab How to Use the Air Inflator (Option)

4. Check the approximate air pressure level with the air pressure gauge in the cab. Remove the air inflator from the tire at the proper inflation pressure.

WARNING Never stand facing the side of a tire when inflating it. The lock ring may fly off, causing serious injury or death. Use a tire guard to surround the tire and stand behind the tire treads to inflate it.

5. Check the tire air pressure level with an air pressure gauge. If the pressure exceeds the specified level, bleed air off. Check air pressure while the tires are not warm.

If the crane is equipped with an air inflator, the tires can be inflated directly from the pneumatic circuit of the crane as follows:

Usage Travel On-rubber operation

1. Remove the cap to the air-supply port. Connect the

Air pressure 29.5-25-22PR 50 psi (3.5 kgf/cm2) 60 psi (4.2 kgf/cm2)

air inflator to the air-supply port.

Air pressure gauge

Air-supply port

Air inflator

T00732E T00730E

6. After the tires have been inflated, remove the air in-

2. Remove the tire valve cap. Connect the other end

flator from the air-supply port. ◆Replace the caps on the crane air-supply port and the tire valves.

of the air inflator to the tire valve.

Air inflator

T00731E

3. Start the engine to drive the air compressor and inflate the tire. ◆The tire can be inflated more quickly if the engine speed is increased.

Equipment Outside the Cab

44

Equipment Outside the Cab

T029212E

Emergency Procedures If Trouble Occurs

If the Engine Stops while Traveling

WARNING

WARNING

If trouble occurs to the carrier while traveling, reduce the carrier speed. Remain calm and beware of the cars behind you. Stop the carrier at a safe place.

Working on a stopped carrier in a tunnel is very dangerous. Do not attempt to do this however simple the job may seem to be.

If the engine stops, steering can become extremely difficult if not impossible unless the crane is equipped with the emergency steering pump (option).

The emergency steering pump (optional) is connected directly to the transmission so steering can be continued even if the engine stops when traveling.

Pull the crane over to a safe location. After the vehicle stops, follow the appropriate troubleshooting procedures. ◆Power steering is not available when the engine is not running. ◆The emergency steering pump runs only when the vehicle is traveling. When the crane stops, steering can not be performed.

If trouble occurs to the carrier and the carrier cannot move, take necessary measures as follows: (1) When stalled on road • Light the hazard lamp to let the cars behind know the trouble of your carrier.

• Ask for help to transport the carrier to a safe place.

• Inform the nearest TADANO distributor or dealer.

(2) When stalled in railroad crossing • Press the emergency button provided in the crossing area to inform the coming train.

• If emergency button is not provided, position a person to make an approaching train know the trouble, considering the distance necessary for the train to stop.

• Ask for help to transport the carrier to a safe place.

• Inform the nearest TADANO distributor or dealer.

Indicate that this is a troubled car, first. Check the carrier for causes of trouble. If repairs are possible, perform repairs paying enough attention to the traffic.

Among many causes for carrier stall, there is one for shift inoperability. In this case see “If Shifting Gears is Impossible”.

Emergency Procedures

45

Emergency Procedures

T029212E

Emergency Gear Shifting Procedure (1)

If Shifting Gears is Impossible

WARNING

WARNING

When the emergency transmission switch is ON, the engine oil pressure gauge, water temperature gauge, and fuel gauge do not function. Be careful when traveling with the emergency transmission switch ON. When the emergency transmission switch is ON, the safety device for engine protection does not function. Gearing down without slowing the crane’s travel speed can cause the engine to overrev or damage the drive system.

Before gearing down, be sure to reduce the traveling speed to the next slower range.

Lock-up function is inactive, so that there is no engine braking effect. Take care of excessive foot brake application.

The following procedure is to be followed only for moving the crane to a service shop for repair.

Never use this procedure for other purposes.

Inspection with Check Switch Shifting gears on this crane is performed electrically using a multiplex data transmitter system. Therefore, if this system malfunctions, an error number is displayed and shifting gears becomes impossible.

Under this condition, press the multiplex data transmitter system check switch at the rear of the cab before attempting to shift gears. If error number disappears, the multiplex data transmitter system is again functioning normally. ◆If the multiplex data transmitter system cannot be restored, follow the "Emergency Gear Shifting Procedure (1)" in the next section.

1. Activate the parking brake. Shift into Neutral.

2. Snap the emergency transmission switch at the

OFF

Emergency transmission switch

Lo Hi

rear of the cab to ON. Operate the gearshift. Now the Drive position is set to third gear. Manually shift the gearshift lever into Second and First.

If shifting gears is possible, move the crane to a service shop. ◆After you have moved the crane, return the emergency transmission switch to OFF and lock it with the stopper. ◆If the above procedure is not effective, follow the "Emergency Gear Shifting Procedure (2)" in the next section.

Multiplex data transmitter system check switch

Error number display

T22849E

Multiple data transmitter system check switch

Emergency transmission switch

IPLEX TRANSR. CHECK

ON

OFF

EMERGENCY TRANSMISSION

T00740E T00741E

Emergency Procedures

46

Emergency Procedures

T029212E

Shift Transmission position gear

“1”

First

“2”

Second

“D”

Third

“R”

First

2. Loosen the lock nut beside the solenoid valve for

Speed range Hi

Lo

0 to 6 MPH (0 to 10 km/h) 0 to 13 MPH (0 to 21 km/h) 0 to 25 MPH (0 to 40 km/h) 0 to 6 MPH (0 to 10 km/h)

0 to 2.5 MPH (0 to 4 km/h) 0 to 5 MPH (0 to 8 km/h) 0 to 10 MPH (0 to 16 km/h) 0 to 2.5 MPH (0 to 4 km/h)

the transmission. Remove the hexagon bolt. Insert this hexagon bolt into the hole on the manual locking device of the corresponding solenoid valve. Turn it clockwise till it comes to an end. Lock it with the lock nut. The solenoid valve will be the same condition as energized to make the clutch operable. ◆Select solenoid valve to go forward or backward.

Forward Backward

Emergency Gear Shifting Procedure (2)

Solenoid valve 1.

Solenoid valve 2.

Solenoid valve 1

WARNING

Solenoid valve 2

A manual locking device for the solenoid valve is provided for moving the crane in case of emergency. Do not touch the locking device except in an emergency.

Before this operation, take the following safety precautions: • Stop the engine.

• Apply chocks to the wheels.

• Light the hazard lamp to let the cars behind know the trouble of your carrier.

If the solenoid valve is manually locked, the vehicle begins to move as soon as the engine starts.

Be sure to operate the parking brake and step on the service brake pedal, before starting the engine.

Be sure to stop the engine and return the lock bolt of the solenoid valve to the original position immediately after the travel of the vehicle.

Transmission Lock nut

T21172E

3. Depress the service brake pedal and start the engine.

4. Release the parking brake. Start traveling by letting off the service brake pedal slowly.When the crane must be towed in the event of engine failure, etc., follow the steps below:

1. Activate the parking brake. Shift into Neutral and stop the engine.

Emergency Procedures

47

Emergency Procedures

T029212E

Towing the Crane

WARNING If the plug is removed on the air-supply port with the air tank under pressure, the plug can fly off, resulting in an injury. Check the air pressure in the tank with the air pressure gauge. If the air pressure in the air tank remains high, open the drain cock on the air tank to release pressure, then remove the plug.

WARNING When the engine stops and the crane is at rest, steering is impossible unless the crane is equipped with the emergency steering pump (optional).

The steering wheel feels very heavy, because the engine is not running.

When a crane is towed, only the foot brake can be used. If a crane is towed on a long downward grade, it will be necessary to use the foot brake repeatedly, possibly overheating and damaging the brake. On a long downward grade, stop the carrier halfway to prevent brake overheating.

Use tow cables with sufficient tensile strength and firmly fastened to the crane. It is dangerous if the tow cable breaks or becomes disengaged.

Tow the crane at low speeds with minimum speed variation. Abrupt starting or braking is very dangerous.

1. Connect the air hose.

(1)Remove the plug on the air-supply port of the crane in order to supply compressed air to the brake.

(2)Connect the air hose from the towing vehicle to the air-supply port (PT 3/8) of the crane.

When the crane must be towed in the event of engine failure, etc., follow the steps below:

T00744

2. Attach a lengthy tow cable so that sufficient clearance is maintained between the towing vehicle and the vehicle in distress.

T00745

Emergency Procedures

48

Emergency Procedures

T029212E

[NOTICE] ◆ When a crane is towed, the transmission is not supplied with lubricating oil. Be sure to place the output shaft of the transmission in neutral before towing. Otherwise the transmission bearing of the towed vehicle may seize.

When towing is completed, remember to return the hexagonal head bolt to its original position.

3. Place the transmission output shaft in the neutral position.

(1)Remove the plug on the high/low changer of the transmission.

(2)Screw in the supplied hexagonal head bolt in place of the plug. This places the output shaft in neutral.

(3)Screw the plug in the hole for the hexagonal head bolt.

Hexagonal head bolt

Plug

Hexagonal head bolt T02948

4. Place the switches and levers in the following positions: (1)Gearshift lever ・・・・・・・・・・・"N" (2)Drive mode select switch ・・・・"2-WHEEL(Hi)" (3)Starter switch ・・・・・・・・・・・・"ON"

5. Make sure that the air pressure is as specified and release the parking brake. Start towing the crane.

Emergency Procedures

49

Emergency Procedures

MEMO

50

H000450E

OPERATION

T032661E

Crane Operation Procedure –Summary 5. Let the machine warm up. While it is warming up, check that all meter and monitor displays are normal and that the machine is not making any abnormal sounds.

This summary briefly describes the essential steps for crane operation from start to finish. For detailed information on the individual procedures, refer to the appropriate pages in this section of the manual. Do not operate the crane until you have a complete understanding of all the instructions given in this manual.

"Safety" section in this manual contains the precautions to be followed during the crane operation. Carefully read the section.

If you find anything abnormal with the crane during operation, stop the operation immediately, check and locate the cause, and repair any faulty components. To prevent accidents, do not operate the crane until repairs have been completed.

6. Fully extend the outriggers and level the crane.

7. Register the boom lift status and the maximum-extended outrigger status on the load moment indicator.

On-outrigger Operation T50092

Preparatory Steps

1. Enter the cab, and adjust the seat and the length of

8. Remove the main hook block from its stowed posi-

each lever so that the levers and all other controls can be operated easily.

tion.

2. Make sure that all the levers in the cab are in the following positions: 1. Swing brake switch ・・・・・・・・・・・・・・・・・・・・ “ON” 2. Main and auxiliary hoist levers, boom telescoping lever, boom elevating lever and swing lever ・・Neutral 3. Gearshift lever ・・・・・・・・・・・・・・・・・・・・・・・・・ "N" 4. Swing lock lever ・・・・・・・・・・・・・・・・・・・・・ "LOCK" 5. Parking brake switch ・・・・・・・・・・・・・・・・・ "PARK" 2

9. Reeve the wire rope around the main hook block sheaves as required for the operation.

1 2

5 3 OFF Lo

2

Hi

4 T05222

3. Start the engine.

4. Set the PTO switch ON.

Crane Operation Procedure – Summary

51

Crane Operation Procedure – Summary

T032661E

10. Mount the single top or jib as necessary.

3. Make sure that the levers in the cab are in the following positions: (1)Hoist, boom telescoping, boom elevating, and swing lever ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・Neutral (2)Swing brake switch ・・・・・・・・・・・・・・・・・・・・・“ON” (3)Swing lock lever ・・・・・・・・・・・・・・・・・・・・・"LOCK"

4. Retract the outriggers completely.

5. Set the PTO switch OFF. 6. Insert the lock pin to the auxiliary hoist control lever and the swing control lever, and set the hoist, boom telescoping, boom elevating and swing control levers to their shortest length. Rotate the auxiliary hoist control lever and swing control lever backward so that the levers do not hinder the operator from entering or exiting the cab.

11. Select the operational status on the AML. Crane Operation

1. Lift and move the load by using the hoisting, telescoping, elevating and swing operations.

Lock pin T02987E

T20050

At the End of Operation

7. Shut off the heater and all other equipment inside

1. Stow the single top or jib.

the cab.

8. Close all the cab windows including the roof win-

2. Stow the main hook block and the boom in the trav-

dow.

eling style.

9. Stop the engine and remove the key from the starter switch.

10. Exit of the cab and lock the door.

11. Perform the post-operational checks for the same points as for the pre-operational checks. If anything abnormal is found, have it repaired before operating the crane again.

Crane Operation Procedure – Summary

52

Crane Operation Procedure – Summary

T032671E

How to Read the Performance Data Plate 2. Rated lifting capacities do not exceed 85 % of the tipping load on outriggers fully extended as determined

by SAE J765 - Crane Stability Test Code.

Rated lifting capacities for partially extended outriggers are determined from the formula.

Rated lifting capacity = (Tipping Load - 0.1 x Tip Reaction) / 1.25.

3. Rated lifting capacities above blue lines in the chart are based on crane strength and those below, on its stability. They are based on actual load radius increased by boom deflection.

4. Rated lifting capacities include the mass of main hook block (1,320 lbs. for 65 t capacity), auxiliary hook block (330 lbs. for 6.2 t capacity), sling and auxiliary lifting devices and their masses shall be subtracted from the listed capacities to obtain the net load to be lifted.

5. Rated lifting capacities are based on freely suspended loads and make no allowance for such factors as the effect of wind, sudden stopping of loads, supporting surface conditions, inflation of tires, operating speeds, side loads, etc. Side pull on boom or jib is extremely dangerous.

6. Rated lifting capacities do not account for wind on lifted load or boom. Rated lifting capacities and boom length shall be appropriately reduced, when wind velocity is above 20 mph (9 m/sec).

7. Rated lifting capacities at load radius shall not be exceeded.

Do not tip the crane to determine allowable loads.

8. Do not operate at boom lengths, radii, or boom angle, where no capacities are shown. Crane may overturn without any load on the hook.

9. When boom length is between values listed, refer to the rated lifting capacities of the next longer and next shorter booms for the same radius. The lesser of the two rated lifting capacities shall be used.

10.When making lifts at a load radius not shown, use the next longer radius to determine allowable capacity.

11.Load per line should not exceed 11,900 lbs. (5,400 kg) for main winch and 12,300 lbs. (5,600 kg) for auxiliary winch.

WARNING AND OPERATING INSTRUCTIONS NOTES FOR LIFTING CAPACITIES GENERAL 1. RATED LIFTING CAPACITIES apply only to the machine as originally manufactured and normally equipped by TADANO LTD. Modifications to the machine or use of optional equipment other than that specified can result in a reduction of capacity.

2. Construction equipment can be hazardous if improperly operated or maintained. Operation and maintenance of this machine must be in compliance with information in the operation, safety and maintenance manual supplied with machine. If these manuals are missing, order replacement through the distributor.

3. The operator and other personnel associated with this machine shall fully acquaint themselves with the latest American National Standards Institute (ANSI) safety standards for cranes.

SET UP 1. Rated lifting capacities on the chart are the maximum allowable crane capacities and are based on the machine standing level on firm supporting surface under ideal job conditions. Depending on the nature of the supporting surface, it may be necessary to have structural supports under the outrigger floats or tires to spread the loads to a larger bearing surface.

2. For outrigger operation, outriggers shall be properly extended with tires free of supporting surface before operating crane.

OPERATION 1. Rated lifting capacities have been tested to and meet minimum requirements of SAE J1063 - Cantilevered Boom Crane Structures - Method of Test.

How to Read the Performance Data Plate

53

How to Read the Performance Data Plate

T032671E

12.Check the actual number of parts of line with LOAD MOMENT INDICATOR (AML-L) before operation.

Maximum lifting capacity is restricted by the number of parts of line of LOAD MOMENT INDICATOR (AML-L). Limited capacity is as determined from the formula, single line pull for main winch (11,900 lbs.) x number of parts of line.

13.The boom angle before loading should be greater to account for deflection.

14.The 36.1´ (11.0 m) boom length capacities are based on boom fully retracted. If not fully retracted [less than 49´ (14.9 m) boom length], use the rated lifting capacities for the 49´ (14.9 m) boom length.

15.Extension or retraction of the boom with loads may be attempted within the limits of the RATED LIFTING CAPACITIES. The ability to telescope loads is limited by hydraulic pressure, boom angle, boom length, crane maintenance, etc.

16.For lifting capacity of single top, reduce the rated lifting capacities of relevant boom by the mass of main hook block. Capacities of the single top shall not exceed 12,300 lbs. (5,600 kg) including main hook.

17.When erecting and stowing jib, be sure to retain it by hand or by other means to prevent its free movement.

18.6,200 lbs. (2,800 kg) shall be subtracted from the rated lifting capacities of the main boom, when jib is attached to main boom head. Jib mass is 2,200 lbs.

(1,000 kg).

19.Use “OVERWIND CUTOUT” disable switch when erecting and stowing jib and stowing hook block.

While the switch is pushed, the hoist does not stop, even when overwind condition occurs.

20.For boom length with 32.2´ (9.8 m) jib, rated lifting capacities are determined by loaded boom angle only in the column headed “114.8´ (35.0 m) boom + 32.2´ (9.8 m) jib”. For boom lengths with 56.1´ (17.1 m) jib, rated lifting capacities are determined by loaded boom angle only in the column headed “114.8´ (35.0 m) boom + 56.1´ (17.1 m) jib”. For angles not shown, use the next lower loaded boom angle to determine allowable capacity.

21.When lifting a load by using jib (aux. winch) and boom (main winch) simultaneously, do the following: • Enter the operation status as jib operation, not as boom operation.

• Before starting operation, make sure that mass of load is within rated lifting capacities for jib.

DEFINITIONS 1. Load Radius: Horizontal distance from a projection of the axis of rotation to supporting surface before loading to the center of the vertical hoist line or tackle with load applied.

2. Loaded Boom Angle: The angle between the boom base section and the horizontal, after lifting the rated lifting capacity at the load radius.

3. Working Area: Area measured in a circular arc about the centerline of rotation.

4. Freely Suspended Load: Load hanging free with no direct external force applied except by the hoist line.

5. Side Load: Horizontal side force applied to the lifted load either on the ground or in the air.

NOTES FOR ON RUBBER LIFTING CAPACITIES 1. Rated lifting capacities on rubber are in pounds and do not exceed 75 % of tipping loads as determined

by SAE J765 - Crane Stability Test Code.

2. Rated lifting capacities shown in the chart are based on condition that crane is set on firm level surfaces with axle oscillation lockout applied. Those above blue lines are based on tire capacity and those below, on crane stability. They are based on actual load radius increased by tire deformation and boom deflection.

3. If the axle oscillation lockout cylinders contain air, the axle will not be locked completely and rated lifting capacities may not be obtainable. Bleed the cylinders according to the operation, safety and maintenance manual.

4. Rated lifting capacities are based on proper tire inflation, capacity and condition. Damaged tires are hazardous to safe operation of crane.

5. Tire shall be inflated to correct air pressure.

Tires 29.5-25-22PR

How to Read the Performance Data Plate

54

Air Pressure 60 psi. (4.2 kgf/cm2)

How to Read the Performance Data Plate

T032671E

6. Over front operation shall be performed within 2 degrees in front of chassis.

7. On rubber lifting with “jib” is not permitted. Maximum permissible boom length is 89´ (27.1 m).

8. When making lift on rubber, stationary, set parking brake.

9. For creep operation, boom must be centered over front of machine, swing lock engaged, and load restrained from swinging. Travel slowly and keep the lifted load as close to the ground as possible, and especially avoid any abrupt steering, accelerating or braking.

10.Do not operate the crane while carrying the load.

11.Creep is motion for crane not to travel more than 200 ft. (60 m) in any 30 minute period and to travel at the speed of less than 1 mph (1.6 km/h).

12.For creep operation, set Drive select switch to “4WHEEL(Lo)” and set gear shift lever to “1”.

• Press the boom mode select key to register the boom mode. However, pay attention to the following.

(1) For stationary operation.

• The front capacities are attainable only when the over front position symbol comes on. When the boom is more than 2 degrees from centered over front of chassis, 360° capacities are in effect.

• When a load is lifted in the front position and then swung to the side area, make sure the value of the LOAD MOMENT INDICATOR (AML-L) is below the 360° lifting capacity.

(2) For creep operation.

• The creep capacities are attainable only when boom is in the straight forward position of chassis and the over front position symbol is on. If boom is not in the straight forward position of chassis, never lift load.

3. A swing does not automatically stop even if the crane becomes overloaded.

4. During crane operation, make sure that the displays on front panel are in accordance with actual operating conditions.

5. The displayed values of LOAD MOMENT INDICATOR (AML-L) are based on freely suspended loads and make no allowance for such factors as the effect of wind, sudden stopping of loads, supporting surface conditions, inflation of tire, operating speed, side loads, etc.

For safe operation, it is recommended when extending and lowering boom or swinging, lifting loads shall be appropriately reduced.

6. LOAD MOMENT INDICATOR (AML-L) is intended as an aid to the operator. Under no condition should it be relied upon to replace use of capacity charts and operating instruction. Sole reliance upon LOAD MOMENT INDICATOR (AML-L) aids in place of good operating practice can cause an accident. The operator must exercise caution to assure safety.

NOTES FOR LOAD MOMENT INDICATOR (AML-L) 1. When operating crane on outriggers: • Set P.T.O. switch to “ON”.

• Press the outrigger mode select key to register for the outrigger operation. Press the set key, then the outrigger mode indicative symbol changes from flickering to lighting.

• Press the boom mode select key to register the boom mode, then the boom mode indicative symbol changes from lighting to flickering. Each time the boom mode select key is pressed, the mode changes. Press the set key to select the status that corresponds to the actual state of the boom, then the boom mode indicative symbol changes from flickering to lighting.

• When erecting and stowing jib, select the status of jib set (Jib state indicative symbol flicker).

2. When operating crane on rubber: • Set P.T.O. switch to “ON”.

• Press the on-rubber mode select key. The on-rubber mode indicative symbol comes on. Each time the on-rubber mode select key is pressed, the mode changes. Select the creep operation, the onrubber mode indicative symbol flicker.

How to Read the Performance Data Plate

55

How to Read the Performance Data Plate

T032671E

Load Radius/Lifting Height Chart

◆The load radius/lifting height chart does not include the effect of boom deflection. The greater the mass of the load is, the more the boom deflects, causing the load radius to increase somewhat. Take this effect into consideration when reading the load radius/lifting height chart.

◆The following diagram is an example of the load radius/lifting height chart. The chart is located inside the cab.

The load radius/lifting height chart provides the load radii and lifting heights in relation to different boom lengths (jib lengths) and boom angles (jib offset angles). Use the chart in conjunction with the rated lifting capacities table when making an operation plan. ◆While points A and B in the figure are at the same load radius, point A denotes the boom angle (or jib offset angle), and point B the lifting height. θ°

A B

Lifting Height

(H)

Load Radius

(R) T20907E

How to Read the Performance Data Plate

56

How to Read the Performance Data Plate

T032671E

Rated lifting capacities tables are set up as shown below with the kind of job and the outrigger extension conditions. For actual values see the rated lifting capacity tables provided in the crane operator’s cab.

Rated Lifting Capacity Table WARNING The values shown in the rated lifting capacities table are based on ideal conditions where the crane is set level on a firm surface, there is no wind or side load, and the load is not swinging.

When operating the crane under these conditions is not possible, reduce the load as necessary according to the actual operating conditions.

Kind of job Outrigger extension 1. Outriggers extended Fully extended Boom lift 2.

Extended to mid (21´ 11 3/4˝) Single top lift 3.

Extended to mid (18´ 1/2˝) Jib lift Outriggers not extended (On-rubber) 4.

Boom lift Single top lift

─

Below are some examples of rated lifting capacities tables.

[Example 1:Outriggers fully extended]

How to Read the Performance Data Plate

57

How to Read the Performance Data Plate

T032671E

[Example 2:Outriggers extended to middle (21´ 11 3/4˝)]

[Example 3:Outriggers extended to middle (18´ 1/2˝)]

How to Read the Performance Data Plate

58

How to Read the Performance Data Plate

T032671E

[Example 4:Outriggers not extended (on-rubber)]

How to Read the Performance Data Plate

59

How to Read the Performance Data Plate

T032671E

Boom Lift when Outriggers are Extended

Jib Lift when Outriggers are Extended

See the rated lifting capacities table which conforms to the actual outrigger condition. Read the rated lifting capacities value W (lbs.) that corresponds to the boom length L (ft) and load radius R (ft).

See the rated lifting capacities table which conforms to the actual outrigger condition.Read the correct rated lifting capacity W (lbs.) for the jib length, jib offset angle, and boom angle θ .

Load Radius in Feet

R

Boom Length in Feet ……

……

L

W

……

……

Boom Length in Feet Boom Angle in Degree

…

…

θﾟ

◆Rated lifting capacities are based on the condition that the crane is installed level on the firm level ground.

They include the mass of both the lifted load and slings. ◆The values above the blue line are based on the crane strength and those below, on crane stability. ◆Rated lifting capacities do not include the effect of wind on the load or the boom. If wind speed is beyond 20 mph (9 m/sec), decrease loading or shorten the boom.

5ﾟﾟoffset

30ﾟﾟoffset

R

R

W

W

W

◆Rated lifting capacities are based on the condition that the crane is installed level on the firm level ground.

They include the mass of both the lifted load and slings. ◆The values above the blue line are based on the crane strength and those below, on crane stability. ◆For jib operation, rely only on the boom angle, regardless of boom length.

◆The rated lifting capacity values for boom lift assume a boom with jib and single top stowed. ◆The rated lifting capacity values for boom lift are based on the load radius. The load radii shown in the rated lifting capacities table include the deflection of the boom under the mass of a load. When determining capacity from the table, therefore, find the rated lifting capacity value based on the actual measured load radius. ◆When the actual boom length exceeds the length specified for a certain boom extension, compare the rated lifting capacity value for the specified length with that for one stage longer, and use the smaller of the two.

Single Top Lift when Outriggers are Extended For operations with the single top, use the boom lift and on-outriggers section of the rated lifting capacity table to find the allowable load. Find the rated lifting capacity value based on boom length and load radius. From that value, subtract the mass of main hook block. The resultant value is the rated lifting capacity for a single top lift.

However, remember that the maximum rated lifting capacity for a single top operation is 12,300 lbs. (5,600 kg). When the result of the above calculation (<table value> - the mass of main hook block) is over 12,300 lbs.

(5,600 kg), always regard the rated lifting capacity as 12,300 lbs. (5,600 kg).

(The value may be different from that indicated by the load moment indicator.)

How to Read the Performance Data Plate

114.8(35.0m)Boom+32.2(9.8m)jib

60

How to Read the Performance Data Plate

T032671E

Boom Lift when Outriggers are not Extended (On-rubber)

◆The “over-front area” in the table refers to an area indicated by the “over-front area” symbol in the load moment indicator display. This area lies in ±2° frontward of the carrier.

Choose “Stationary” or “Creep”. Choose “Over Front” or “360° rotation”. Select the boom length L (ft). And then read out the rated lifting capacity W (lbs.) from the load radius R (ft).

ON RUBBER

Over-front

Stationary Load Radius in Feet

Over Front

360ﾟﾟRotation

Boom Length in Feet

Boom Length in Feet

……

……

L

……

……

T00668E

R

W

……

……

Single Top Lift When Outriggers are not Extended (On-rubber) For operations with the single top mounted, use the boom lift and on-rubber section of the rated lifting capacity table to find the allowable load. Find the rated lifting capacity value based on boom length and load radius.

From that value, subtract the mass of main hook block.

The resultant value is the rated lifting capacity for a single top lift. However, remember that the maximum rated lifting capacity for a single top operation is 12,300 lbs.

(5,600 kg). When the result of the above calculation (<table value> - the mass of main hook block) is over 12,300 lbs. (5,600 kg), always regard the rated lifting capacity as 12,300 lbs. (5,600 kg).

◆The rated lifting capacity include the mass of the slings and the hook block. ◆The values above the blue line are based on crane strength and those below, on crane stability. ◆The load radii shown in the rated lifting capacity table include the deflection of the boom and the tires under the mass of a load. When determining capacity from the table, therefore, find the rated lifting capacity value based on the actual measured load radius. ◆The rated lifting capacity values for on-rubber operation assume that the tires are at the specified air pressure and that the crane is set on firm and level ground with the suspensions locked. ◆Do not perform jib lift. Do not perform boom lift with the boom length exceeding 89 ft (27.1 m). ◆“Creep” during on-rubber operation refers to traveling at a speed of 1 mph (1.6 km/h) or less and less than 200 feet (60 meters) in 30 minutes. ◆Before traveling with load on hook, position the boom to the front and insert the swing lock pin. ◆Do not operate the crane during traveling with a load on hook. ◆For traveling with load on hook, shift the drive mode select switch to “4-WHEEL (Lo)”. Keep the gearshift lever to the first.

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61

How to Read the Performance Data Plate

T032681E

Load Moment Indicator (AML-L) • Swinging will not stop automatically even if overloading occurs. When lifting a load on rubber, note that the 360-degree capacity is less than the over-front capacity.

When having a load lifted up in the over-front area, swing it toward the over-side area, be extremely careful not to overload the crane. If, when swinging a load toward the over-side area, the moment ratio indication on the load moment indicator exceeds 100% and the alarm buzzer sounds, stop swinging immediately. Then lower the load or swing the boom back.

The load moment indicator (AML-L) is intended as an aid to the operator. Under no condition should it be relied upon to replace use of Rated Lifting Capacity Table and Operating Instructions.

Sole reliance upon the load moment indicator aids in place of good operating practice can cause an accident. The operator must exercise caution to assure safety.

The load moment indicator operates properly only when it is used exactly as instructed in this manual. If you do not follow the specified load moment indicator and crane operating procedures, the crane could overturn or be damaged, causing a serious accident. Be sure to observe the following precautions for safe operation.

Over-front

• Never perform any operation with the load moment indicator deactivated.

• Place the crane on firm and level ground with the outriggers extended and adjust the crane so that it is level (when outriggers extended).

• Before operating on rubber, check that the tires have the specified air pressure (when outriggers not exteded).

• Before starting operation, perform pre-operational checks on the load moment indicator to ensure that it is operating properly.

T00668E

• When the load moment indicator exceeds the specified value, the alarm will sound intermittently. Slow the crane operation and take great care. (For the specified value, see the "Configuration and Functions of the Load Moment Indicator System" section.)

• Do not lift a load on the boom with the jib mounted. If this must be done by unavoidable reasons, a boom lift status, and not a jib lift status, should be selected on the load moment indicator. This kind of operation can be dangerous if the moment ratio exceeds 90%. Watch the bar-type moment ratio indicator carefully, and make sure that it stays within the green zone during the operation.

Green 90%

T02881E

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Configuration and Functions of the Load Moment Indicator System

• When lifting a single load using both the boom and jib, a jib lift status, and not a boom lift status, should be selected on the load moment indicator. (The figure shows a 5° offset angle with the first jib section extended.) Make sure that the mass of the load (including the mass of the load handling devices) is less than the specified rated lifting capacity for the jib. If the load is left held up only by the auxiliary winch wire rope when the main winch wire rope is loosened, the load's center of gravity moves to give an increased figure in moment display.

Take care to overloading.

The load moment indicator (AML-L) system is a safety device provided to prevent overloading of the crane which may cause it to overturn or be damaged.

The load moment indicator unit stores the operation mode selected by the operator and the signals from various sensors. Based on the data stored in its memory, the load moment indicator calculates the working and limit moment values and constantly compares the two.

When the load moment indicator recognizes that the working moment ratio is approaching or has reached the limit value, it either sets off an alarm or stops any further movement of the crane toward the critical condition.

The configuration and functions of the load moment indicator system are described in the following chart and tables.

deg

T02882

• When the crane is automatically stopped during a critical operation (hoisting up, boom extension or boom lowering), operate the appropriate controls to move toward the non-critical condition (hoist down, retract boom or raise boom).

• Do not elevate the boom to raise the load clear of the ground. Doing so is dangerous because the crane will not stop automatically even when it is overloaded. Hoist up the load to raise it clear of the ground. Once the load has cleared the ground, stop hoisting and check for safety.

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Load Moment Indicator System Configuration

Boom length signal

Boom angle signal

Over-front area signal

Moment ratio signal

Crane control position signal

L θ

Outrigger status Operator selection

Outrigger extension width detector

L

Boom status

Working range limits

Number of part-lines of rope Load moment indicator unit

External warning lamps(option)

Alarm buzzer

Display panel

Stop output when:

Moment ratio exceeds 100% Twoblocking occurs Load moment indicator system error occurs

Rearward stability control activated Working range limit signal output

Boom extension halted

Boom lowering halted

Hoisting up halted

Boom raising halted

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

θu H θL R

T21758E

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Stop Functions Causes of stop

Operation

• Two-blocking • Moment ration

•Boom lift

exceeds 100 % • Load moment indicator system error occurs Rearward stability control

• Single top lift

Halted movement

• Hoisting-up •Boom lowering • Boom extending

• Jib lift • Boom raising

Alarm Functions Condition Operated to critical side when twoblock has

Alarm Moment display: Displays [Warning:0024].

Buzzer: Sounds continuously.

occurred When antiMoment display: twoblock device Displays [Warning:0015]. is deactivated Moment ratio is Moment display: Yellow segment is lit.

90 % or more, but Buzzer: Sounds intermittently. less than 100%.

Operated to crit- Moment display: ical side when Displays [Warning:0023]. moment ratio is Buzzer: Sounds continuously.

100 % or more.

Load moment indi- Moment display: cator system error Displays failure messages.

Operated to crit- Moment display: ical side when Displays [Warning:0025]. rearward stability Buzzer: 3 seconds. control activated Working range limit Associated limit lamp flashes. function activated Buzzer: Sounds continuously.

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Controls

1

5

4

2

ON OVERRIDE

3

OFF

T21634

1. Load moment indicator unit and display panel 2. Override warning lamp 3. Failure warning lamp

4. Override key switch 5. Override push switch

Override Key Switch,Override Warning Lamp, Override Push Switch

Failure Warning Lamp The failure warning lamp comes on to warn that the operator is attempting an operation toward a critical condition (hoisting, boom extending, or boom lowering) while the load moment indicator detects overloading or overhoisting of the hook block.

When this lamp is illuminated, the operation is automatically halted. Shift the operation toward the noncritical condition.

While the override key switch is ON, the override warning lamp will light.

The load moment indicator stop function will be cancelled while the lamp is lit and the override push switch is pressed.

Take great care of crane operation while pressing the push switch.

OV ER R ID E WA R N IN G L A M P

FA ILU R E T3010E T00749E

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Names and Functions of Load Moment Indicator Main Unit Parts Bargraph display

Display panel 1

Display panel 2

Control

T50095E

Bargraph Display

1

3

4

2 T02885

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1. Moment ratio mark The moment ratios on the bargraph are color coded as follows: safe (green), notice(yellow) and limit (red).

2. Moment display Normally displays a moment ratio on a bargraph.

Displays the main-circuit oil pressure and torque converter oil pressure when the display alteration key is held down.

Also displays error messages when the load moment indicator or any of its associated devices fail(s).

90〜99

0〜89

Each frame representing 10％ Usually on

100〜 109

110 or more than that

Each frame representing 2.5％

Each frame representing 2.5％ T21182E

3. Scroll-up key Used to see the previous lines of message displayed on the moment display.

4. Scroll-down key Used to see the next lines of messages displayed on the moment display.

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Display Panel 1 1

2

3

17

20

5

m deg

15 14

16 21

6

18

13

％ deg

7 19

17

12 8

11

10

9 T21760

1. Jib angle display When jib lift is selected, the jib angle offset is displayed.

When the upper boom angle restriction function is registered, the registered upper boom angle restricted value is displayed as long as the register key is pressed on.

9. Load radius limit restriction indicative symbol Comes on to indicate that the value shown in the load radius display 11. represents the load radius limit. Note that the load radius indicative symbol * is also displayed at the same time.

2. Number of part-lines of indicative symbol This symbol shoes that the jib angle display (1) indicates the number of part-lines of rope

10. load radius indicative symbol Indicates that the value shown in the load radius display 11. represents the load radius.

3. Boom length indicative symbol This symbol, while marked up, means the value in the boom length display ‑ is a boom length value.

11. Load radius display Normally displays the crane's load radius.

When the load radius limit restriction function is activated, the load radius limit restriction value is displayed while the register key is held down.

4. ─ 5. Jib angle indicative symbol Comes on to indicate that the value shown in the jib angle display 1. represents the offset angle.

12. ─ 13. Boom length display Usually displays boom length.

Displays the lifting height while the display alteration key is pressed.

When the lifting height restriction function is effective, this displays lifting height restriction value, while the register key is being pressed.

6. Jib state indicative symbol Lights when the jib lift (32.2 ft or 56.1 ft) is selected.

7. Real load display Displays the real load.

8. Rated lifting capacity display Displays the rated lifting capacity.

Load Moment Indicator (AML-L)

14. Lifting height indicative symbol This symbol, while marked up, means the value in the boom length display 13. is a lifting height.

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15. Lifting height restriction symbol This symbol, while marked up, means the value in the boom length display 13. is a lifting height restriction value.The lifting height symbol 14. is marked up simultaneously.

18. Lower boom angle limit restriction symbol Indicates that the boom angle display 19. displays the registered lower boom angle restricted value.

19. Boom angle display Normally displays the boom angle.

Displays the moment % when the display alteration key is held down. When the restriction function is activated, the lower boom angle limit restriction value is displayed while the register key is held down.

16. Upper boom angle limit restriction symbol Indicates that the jib angle display 1. displays the registered boom angle upper restricted value.

17. Boom angle indicative symbol Indicates that the boom angle display 19. displays the boom angle.

20. Boom state indicative symbol Lights when the boom lift is selected.

21. Single-top state indicative symbol Lights when the single-top lift is selected.

Controls 5

4

6

7 8

3

9

2 1

10

18

11 12

17

16

15

14

1. Increase key Used to increase the selected value.

T50097

5. Upper boom angle limit restriction indicator lamp Lights up when the upper most boom angle limiting function activated.

2. Decrease key Used to decrease the selected value.

6. Lower boom angle limit restriction indicator lamp Lights up when the lower most boom angle limiting function is activated.

3. Lifting height restriction key Used to activate and release the lifting height limiting function.

7. Upper boom angle limit restriction key Used to activate and release the upper most boom angle limiting function.

4. Lifting height restriction indicator lamp Lights up when lifting height limiting function is activated.

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8. Lower boom angle limit restriction key Used to activate and release the lower most boom angle limiting function.

13. Check key Used to check the load moment indicator system functions.

9. Load radius restriction indicator lamp Lights up when the load radius limiting function is activated.

14. Boom mode select key Used to select the lift status.

15. On-rubber mode (Outriggers-not-in-use mode) select key Used to select the on-rubber operation mode.

10. Load radius restriction key Use to activate and release the load radius limiting function.

16. Right outrigger mode select key Used to select the right outrigger operation mode.

11. Display alteration key Used to alternate the displays on display panel 1.

17. Left outrigger mode select key Used to select the left outrigger operation mode.

12. Register key Used to register a selected state.

18. Number of part-lines of rope select key Used to resister a number of part-lines of rope.

Display Panel 2 1 3 2 4

2

2

3

3

2 3

T02888

1. Over-front position symbol Indicates that the boom is swung into the over-front position.

3. "On-rubber" (Outrigger-not-in-use) state indicative symbol Indicates that the on-rubber operation (non-outrigger operation) is selected.

Lit when the stationary on-rubber operation is selected, and flashes when the traveling on-rubber (creep) operation is selected.

2. Outrigger state indicative symbol Displays the way the outriggers are extended.Lights when the outrigger conditions are registered.

4. Suspension lock state indicative symbol Displays that the suspensions are locked up.

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Selecting Operational Status

◆The outrigger status automatically changes to a onrubber stationary status, when an operation is made for stowing the outrigger after the registration of the outrigger status. Be sure to again register the outrigger status, when necessary.

Should the operational status be incorrectly registered, the crane might overturn or be damaged, leading to a serious accident. Prior to every operation, check that the registered status corresponds to the actual status of the crane.

Selecting Outrigger Status ◆The "on-rubber stationary" status is the default status and is automatically selected when the power supply is turned on (the PTO switch is placed in the "ON" position). ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

Register key Right outrigger Left outrigger mode select key mode select key On-rubber mode select key T50098E-1

Fully extended

Register the outrigger state, as follows:

Mid extended

(1) When outriggers are extended Press either right outrigger mode select key or left outrigger mode select key. The outrigger state indicative symbol flashes in accordance with the status that load moment indicator detects on. Make sure this conforms to the actual crane conditions. If it does, press the register key. If the outrigger state indicative symbol change to continuous lighting, this means correct registration of this state.

(2) When outriggers are not extended Press on the on-rubber mode select key to make display the on-rubber state indicative symbol to show up. ◆After selecting the intended outrigger status, press the register key to register the status. The following symbols will stop flashing and become marked up: • Segment(s) of the moment display • Outrigger state indicative symbol that has been shown up before the register key is pressed (If the "on-rubber" state indicative symbol has been shown up, it will not change.)

Load Moment Indicator (AML-L)

Mid extended

T20911E

On rubber creep operation

On rubber stationary operation

T02891E

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Selecting Lift Status ◆The boom lift status is the default status and is automatically selected (the boom indicator lamp lights) when the power supply is turned on (the PTO switch is placed in the ON position). ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power has been last turned off, enter the settings all over again.

Use the boom mode select key to register the lift status.

Each time the boom mode select key is pressed, the mode changes in numerical sequence, from (1) to (7).

The display returns to (1) if you press the switch while the status (7) is displayed on the screen. Select the status that corresponds to the actual state of the boom. ◆After selecting the intended lift status, press the register key to register the status.The following symbols will stop flashing and become marked up: • Segment(s) of the moment display • Boom state indicative symbol, single-top state indicative symbol or jib state indicative symbol that has been shown up before the register key is pressed.

(When the jib set status is selected, the jib state indicative symbol will remain flashing.) ◆Select the boom lift status when lifting a load on the boom with the jib mounted. ◆Select a jib lift status when lifting a single load using both the boom and jib.

Boom mode select key T50099E

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Type of lift

Display (1) Boom lift

(2) Single top lift

Flicker

(3) Jib set(mounting or stowage)

(4) Jib lift : 32.2ft(9.8m) jib,5°offset

deg

(5) Jib lift : 32.2ft(9.8m) jib,30°offset

deg

(6) Jib lift : 56.1ft(17.1m) jib,5°offset

deg

(7) Jib lift : 56.1ft(17.1m) jib,30°offset

deg

T02893E

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Selecting Number of Part-lines of Rope

2. Press the increase or the decrease key to set the number of part-lines of rope at a desired value. ◆When the increase or the decrease key is pressed, a numeral showing the number of rope changes from flashing to lighting, showing a fixed value for the increase or decrease. ◆When the increase or the decrease key is kept pressed, the number of rope continuously increases or decreases.

◆When the power supply is turned on (i.e. PTO switch ON), the number of part-lines of rope corresponding to the last work condition is selected. ◆When the type of lift is single top lift status or jib lift status, register the number of part-line of auxiliary winch rope. ◆Even if the power supply is turned off (i.e. PTO switch OFF), the load moment indicator still saves the changed number of part-lines of rope.

3. Once the intended number of part-lines of rope is set, press the register key and register the number.

Then, the number of part-lines of rope symbol is turned off and the jib angle display returns to a normal status. ◆The number of part-lines of rope can be confirmed by pressing the display alteration key.

Register the number of part-lines of rope by use of the number of part-lines of rope select key, as follows:

1. Press the number of part-lines of rope select key.

The number of part-lines of rope symbol flashes, and the number of part-lines of rope is shown on the jib angle display in a flashing mode.

Number of part-lines of rope indicative symbol Number of part-lines of rope

Increase key Decrease key Number of part-lines of rope select key

Register key

T50100E

[NOTICE] ◆ If the registered number of part-lines of rope is smaller than the standard number, a maximum allowable lifting load is limited, depending on the registered number. In case the number is registered as ‘0’, however, a process takes place as if the standard number were registered. ◆ Similarly, a process takes place on the basis of the standard number of part-lines of rope if the registered number is larger than the standard number.

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Load Moment Indicator Pre-operational Inspection Before starting operation, check the load moment indicator system according to the instructions given on the "Load moment indicator check" plate.

Operating the crane with a malfunctioning load moment indicator could cause the crane to overturn or be damaged. Be sure to perform the pre-operational inspection on the load moment indicator system and start the crane only after ensuring that the system is operating properly.

Load moment indicator check plate

1. Arrange the crane in the way as follows:

3. Press the set key. On the moment display a mes-

(1) Extend the outriggers to middle or fully. And install the crane level.

(2) Stow the jib or the single top.

(3) Stow the auxiliary hook.

(4) Mount a 1,320 lbs (65 t) hook.

sage will appear as follows: Boom L 36.1 ± 0.3 ft

4. Retract the boom fully.

5. Read out the boom length value and make sure the

2. Press in the check key to make sure:

displayed value is within the standard in above step 3. ◆If the value obtained is not within the standard value, have your machine checked and repaired at your nearest TADANO distributor or dealer.

(1) all the segments on the display panel 1 and 2 and on the moment display light; (2) all the lamps on the control light; (3) the buzzer sounds continuously; and (4) hoisting up, boom extension, and boom lowering operation become impossible.

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6. Press in the register key. The moment display will

11. When the boom angle comes in the 50° ± 0.3°

give the following message.

range, the moment display shows both the standard and detected values from the moment detector. Make sure the detected value is within the standard value range. ◆If the value obtained is not within the standard value, have your machine checked and repaired at your nearest TADANO distributor or dealer.

Boom A 10 ± 0.3 °

7. Elevate the boom to the boom angle of 10°.

8. When the boom angle comes in the 10° ± 0.3° range, the moment display shows both the standard and detected values from the moment detector. Make sure the detected value is within the standard value range. ◆If the value obtained is not within the standard value, have your machine checked and repaired at your nearest TADANO distributor or dealer.

12. Checking is over. Press in the register key for the ordinary state. ◆Press the display alteration key or the check key from any state steps No. 1 through 12. The preoperational inspection will end for the ordinary state.

9. Press in the register key. The moment display will give the following message.

Boom A 50 ± 0.3°

10. Elevate the boom to the boom angle of 50°.

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Boom Angle Limit

How to Use the Working Range Limit Function

Raise or lower the boom to the desired angle, and press the upper or lower boom angle limit restriction key. The corresponding limit restriction indicator lamp flashes and the buzzer sounds continuously, indicating that the limit boom angle has been stored in the memory. When the boom is moved back to an angle within the set limit, the limit restriction indicator lamp stops flashing and stays illuminated and the buzzer stops.

Thereafter, the upper or lower boom angle limit restriction indicator lamp flashes and the buzzer sounds continuously whenever the upper or lower limit previously registered is reached.

To cancel the boom angle limit function, press the boom angle limit restriction key again. The corresponding boom angle limit restriction indicator lamp goes off.

[NOTICE] ◆ If the selected working range limits allow the crane to approach too close to an obstruction, the crane may be contacted or hit, depending on the operational status and the manner in which the load is handled. When selecting limits, allow sufficient clearance. ◆ If working range limit function is active, the machine does not stop automatically. Take care.

The working range limit function allows the operator to restrict the boom angles (upper and lower), boom height and load radius, beyond the point where buzzer sounds and the movement of the boom should be automatically stopped.

The function is useful for handling a load in a confined place because it defines the area in which the boom can operate. ◆Turning the power off (PTO switch: OFF) automatically erases all the previous settings stored in memory after approximately 2 hours. To resume the operation more than 2 hours after the power was last turned off, enter the settings all over again.

Upper boom angle limit restriction indicator lamp Lower boom angle limit restriction indicator lamp

Lower boom angle limit restriction key Upper boom angle limit restriction key T50101E

Upper boom angle restricted Lower boom angle restricted

Lifting height restricted

Load radius restricted

θu H θL

R T20912E

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Lifting Height Limit

Load Radius Limit

Move the boom to the desired height, and press the lifting height restriction key. The lifting height restriction indicator lamp flashes and the buzzer sounds continuously, indicating that the limit height has been stored in the memory. When the boom is moved back to a height within the set limit, the lifting height restriction indicator lamp stops flashing and stays illuminated and the buzzer stops.

Thereafter, the lifting height restriction indicator lamp flashes and the buzzer sounds continuously whenever the height limit previously registered is reached.

To cancel the height limit function, press the lifting height restriction key again. The corresponding lifting height restriction indicator lamp goes off.

Move the boom to the desired load radius, and press the load radius restriction key. The load radius restriction indicator lamp flashes and the buzzer sounds continuously, indicating that the limit load radius has been stored in the memory. When the boom is moved back toward the non-critical side, the load radius restriction indicator lamp stops flashing, and stays illuminated and the buzzer stops.

The load radius restriction indicator lamp flashes and the buzzer sounds continuously whenever the limit previously registered is reached.

To cancel the load radius limit function, press the load radius restriction key again. The corresponding load radius restriction indicator lamp goes off.

Lifting height restriction indicator lamp

Load radius restriction indicator lamp

Lifting height restriction key

Load radius restriction key T50103E

T50102E

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Display of Working Range Restriction Values Press in the register key while working range restricting functions are registered.

While the key is being pressed in, the registered working range restriction values are displayed. On the moment display will be displayed a message “Working range”. ◆This display is not available when preoperational load moment indicator check is made and when working state is registered. ◆When working range restricting functions are not registered, the message “---” will be displayed.

Upper boom angle limit restriction values Working range

Lifting height restriction values

Lower boom angle limit restriction values deg

Load radius restriction values deg

Register key

T50104E

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Display Alteration Displays on the moment display and the display panel 1 can be altered, as shown below in the figures, while the display alteration key is being pushed. The indicative symbols are displayed, too.

Moment Display

Display Panel 1 ◆Displays on the real load display and the rated load display do not alter even when the display alteration key is pressed in.

Number of part-lines of rope M＊＊＊＊ T/C＊＊＊ PSi

Lifting height

Moment ratio Real load

％

Rated lifting capacity

Display alteration key T50105E

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Recovery from a Stop Restore the crane operation according to the following steps.

(1) When moment is more than 100 % • Moment display: [Warning:0023] • Buzzer sounds continuously.

Set the load on the ground.

Warning:0023

Retract the boom slowly.

Buzz

Raise the boom slowly.

T50106E

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(2) Two-blocking • Moment display: [Warning:0024] • Buzzer sounds intermittently.

Hoist down the winch.

Warning:0024

Buzz Retract the boom slowly.

T50107E

(3) When rear stability control function works • Moment display: [Warning:0025]

Warning:0025

Lower the boom slowly.

T50108E

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(4) When working range limit function works ◆If working range limit function is active, the machine does not stop automatically.

(1)When upper boom angle restriction function works: • Moment display: [Warning:0026] in shown.

• Buzzer: Continuous • Upper boom angle limit restriction indicator lamp flashes.

(2)When lower boom angle restriction function works: • Moment display: [Warning:0027] in shown.

• Buzzer: Continuous • Lower boom angle limit restriction indicator lamp flashes.

Buzz

(3)When lifting height restriction function works: • Moment display: [Warning:0028] is shown.

• Buzzer: Continuous • Lifting height restriction indicator lamp flashes.

Buzz

(4)When load radius restriction function works: • Moment display: [Warning:0029] is shown.

• Buzzer: Continuous • Load radius restriction indicator lamp flashes.

Buzz

Buzz

Warning：0026

Warning：0027

Warning：0028

Warning：0029

ft

ft

ft

ft

Lower the boom slowly.

Raise the boom slowly.

Retract the boom slowly.

Release working range restriction function.

T31683E

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Display and Disposition of Failure Messages

Displays a failure message

When failure messages are shown on the load moment indicator moment display, a buzzer sounds. Stop working and take appropriate action.

T50109E

Messages

[Warning:0001] [Warning:0002] [Warning:0003] [Warning:0004] [Warning:0012]

Meanings R.F. outrigger retracts R.R. outrigger retracts L.F. outrigger retracts L.R. outrigger retracts Over-rear tipping area

Causes Outrigger beam retracts and extended width decreases.

Swing rearward into over-rear stability excess area.

[Warning:0015] Stoppage due to twoMain (or auxiliary) winch is blocking (with anti-twoblock wound excessively. function deactivated) [Warning:0024] Stops by overwinding [Error:0016] Operation state not Wrong registration of operation applied <case 1> state (boom lift, jib lift, single top [Error:0017] Operation state not lift, outrigger) applied <case 2> [Warning:0023] Stops at moment ratio 100% Moment ratio beyond 100 %

Solutions Re-extend outrigger.

Lower boom angle.

Extend outrigger widths.

Hoist down the main (or auxiliary) winch.

Register operation state again.

Hoist down winch.

Raise boom angle. Retract boom.

Lower boom angle. Extend boom.

Extend outrigger widths.

Register operation state again.

[Warning:0025] Stops due to rearward Out of rearward stability area. stability.

[Warning:0046] Unexpected outrigger Switch is touched in wrong time retraction. to cause outrigger retraction.

[Warning:0057] R.F. outrigger state change Outrigger state change as to Re-extend outrigger.

[Warning:0058] R.R. outrigger state change decrease extension.

Register working state again.

[Warning:0059] L.F. outrigger state change Crane performance shifted to that [Warning:0060] L.R. outrigger state change with smaller outrigger extension.

Load moment indicator main body Check or repair required. Contact or detector defective nearest TADANO distributor or Others ─ dealer. For crane stowing, see “Disposition of System Troubles”.

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T032681E

Disposition of System Troubles How to Use Override Key Switch Keeping the override key switch in the ON position and pressing the override push switch cancels the load moment indicator's safety feature, the stop function. Using this switch during normal operation is extremely dangerous. Do not use this switch during normal operation. Use the switch only when operation has been disabled due to failure of the load moment indicator system. Be sure to set the load on the ground and retract the boom before using the switch. Use the elevating and/or swing functions to stow the boom.

If restoring operations after a failure message appears does not normalize crane operations, the load moment indicator is in trouble. When the system is out of order, crane operation becomes impossible.

The override key switch is only intended for use to stow the boom. Insert the key into the key hole and turn the switch to ON to operate the crane. The override warning lamp will light. While the lamp is lit and the override push switch is pressed, the crane operation will be available.

Override key switch

Override warning lamp

ON OVERRIDE

OFF

OVERRIDE WARNING LAMP T21573E

◆The key should be kept by a person who takes care of the crane, or a person responsible for job-site works.

Load Moment Indicator (AML-L)

86

Load Moment Indicator (AML-L)

T012153E

Other Safety Devices Deactivation of the Anti-twoblock Function

Anti-twoblock Device

WARNING

The anti-twoblock device prevents damage to the crane that would be caused by pulling the hook block into the boom head. When the hook block approaches the boom head, single top or jib, the anti-twoblock device sends a signal to the AML, which then stops any further crane action toward the critical condition.

When overwinding is detected, the crane will be set in the following status: (1) Any operation involving action toward the critical state (hoisting up, extending or lowering the boom) is halted.

(2) If a critical-state operation is attempted, the alarm buzzer sounds and the failure warning lamp illuminates to alert the operator.

When the crane is automatically stopped because the anti-twoblock device has been activated, retract the boom or hoist down to move the hook block away from the boom head, single top or jib. ◆The anti-twoblock device for the jib can also be used for the single top. ◆When the jib or single top is mounted, be sure to connect the leads of the anti-twoblock device correctly. If the leads are not connected, the load moment indicator assumes a two-blocking condition, and all actions toward the critical conditions are automatically stopped. ◆Once two-blocking has occurred, the alarm buzzer keeps sounding until the hook block is lowered.

Boom

Jib

When the anti-twoblock function is deactivated, the stop function will not operate even if the hook block is overhoisted. Be careful not to two-block the crane when deactivating the anti-twoblock function is unavoidable or specifically required.

Use the anti-twoblock disable switch to deactivate the anti-twoblock function. The anti-twoblock function may hinder stowing the main hook block and mounting or stowing the jib. If this happens, deactivate the function temporarily by pressing the anti-twoblock disable switch.

While the switch is held down, the anti-twoblock function is deactivated.

Anti-two block disable switch

OVER WIND CUT-OUT T02952E-1

Single top

Two blocking detection switch T02951

Other Safety Devices

87

Other Safety Devices

T012153E

External Warning Lamps (Option) WARNING When the external warning lamp in red lights, crane operation to the critical side stops. Do not release load moment indicator stop function to continue crane operation. Operate the crane toward safety side at once. Restart the work after lamp lighting has changed from red to orange, or lamp has gone off.

The external warning lamps are to inform the people engaged in work around the crane of load moment indicator conditions.

Red

Orange T00750E

Color Not lighted Orange Red

Crane (or load moment indicator) conditions Safe • Moment ratio: less than 90 % Not in danger, but attention needed • Moment ratio: between 90 % and 100 % In danger (Motion to critical side stops) • Moment ratio: more than 100 % • Anti-twoblock disable switch: pressed • Override switch: ON

Other Safety Devices

88

Other Safety Devices

T012162E

Operating the PTO and Warming Up the Machine Operating the PTO

Warming Up the Machine

When the PTO gears are engaged (PTO is ON) after starting the engine, the hydraulic pump is driven, and hydraulic pressure is made available for operating the crane. The hydraulic pump stops when the PTO is disengaged (PTO is OFF) and power from the engine is interrupted.

[NOTICE] ◆ Be sure to allow the machine to warm up before the start of any operation. This practice is especially important in cold weather when the engine and hydraulic oil viscosities are high. If an operation is started without sufficiently warming up the engine and machine, highly viscous oils may cause damage to the engine and hydraulic system.

Engaging the PTO

1. Make sure that every crane operation lever (hoist,

1. Let the engine warm up at idling speed for approxi-

elevation, telescoping, and swing) is in the neutral position.

mately five minutes after engaging the PTO. When it is very cold, extend the warmup time as necessary, according to the ambient temperature.

2. Start the engine and turn the PTO switch to the ON 2. Increase the engine speed to between 800 and

position. The PTO lamp will illuminate and the load indicator system will be energized. At the same time the suspension will be locked and the suspension lock indicator lamp will illuminate. ◆Register the operational status on the AML before crane operation. ◆Keep the engine at idle when turning the PTO switch ON.

1,000 min-1 [rpm] and operate the crane without a load for approximately five to ten minutes. When it is very cold, extend the operating time according to the ambient temperature. ◆Check the engine, hydraulic pumps, hydraulic motors, swing bearing and each pivot pin for any unusual sound.

If any are found, stop operation immediately and contact the nearest TADANO distributor or dealer.

3.

OFF

Only start a lift operation after the machine has been sufficiently warmed up without a load.

ON

PTO

P.T.O. T02953

Disengaging the PTO

1. Turn the PTO switch to the OFF position. The PTO lamp will go out and the AML will be de-energized. At the same time the suspension lock will be released and the suspension lock indicator lamp will go out. ◆After crane operation, turn the PTO switch to OFF to protect the battery.

Operating the PTO and Warming up the Machine

89

Operating the PTO and Warming Up the Machine

T029411E

Outriggers Setting the Crane WARNING If the crane is set on inappropriate ground, it is possible that the crane could overturn. Always set the crane on firm ground.

Preparing the Ground When setting the crane on soft ground or on ground that cannot bear the weight of the crane , carry out the following procedures: (1) Grade a slope or rough surface so that the crane can be set in a level position.

(2) Place steel plates or wood blocks on the surfaces where the outrigger floats are to be located, in order to distribute the ground bearing pressure over a larger area. The steel plates and wood blocks must be sufficiently strong and large in area and also appropriate for the ground condition. The outrigger floats must be set at the center of the plates or blocks.

Controls

3

2

4

5

OUTRIGGER CONTROL RIGHT FRONT

EXT.

1

RIGHT REAR

N RET. ENG

SLIDER

ALL

N LEFT FRONT

JACK

LEFT REAR

OFF Lo Hi

8

1. Bubble level 2. Extend/retract selector switch 3. Collective control button 4. Individual control button (right front)

Outriggers

7

6

T05223

5. Individual control button (right rear) 6. Individual control button (left rear) 7. Individual control button (left front) 8. Slide/jack selector switch

90

Outriggers

T029411E

[NOTICE] ◆ After outriggers’ extension and retraction, set the switches to neutral: • Extend/retract selector switch • Slide/jack selector switch Unless the extend/retract selector switch is situated at neutral, the outrigger switch non-neutral position lamp flashes.

Extending the Outriggers WARNING Outriggers with improperly extended beams cannot assure safety. Fully extend the beams at all times.

The machine can sometimes remain level even when it is supported on only three jacks.

Operating the machine in such a condition is very dangerous. After extending the outriggers, make sure that all outrigger floats are in contact with the ground. Any unseated float must be lowered so that it is in firm contact with the ground.

If the crane is not level on the ground, the load radius will increase when the load is swung toward the lower side. In the worst case, this could cause the crane to overturn. Always use the bubble levels to make sure that the crane is level after extending the outriggers.

Operating on outriggers when any tires are in contact with the ground will reduce machine stability due to the reaction force of the tires. Extend jacks and, if necessary, place blocking under the outrigger floats to raise the tires clear of the ground.

The outrigger beams may accidentally retract during operation if they are not properly locked with the lock pins. Be sure to secure the outrigger beams with the lock pins whenever they are extended.

The outrigger switches can be activated regardless of the PTO switch position.

After extending or retracting the outriggers, be sure to return the extend/retract selector switch and slider/jack selector switch to their neutral positions. This action prevents unexpected extension or retraction of the outriggers if the switches are touched inadvertently.

Unless the gearshift lever is set to other than the “N” position, neither extension nor retraction of outriggers can be performed. Make sure of the gearshift lever “N” position, beforehand.

Outriggers

O/R SW

T101122

◆ When outrigger stowing operation is made, data on outrigger extension width is cleared. After resetting the outriggers, register the extension widths again.

Full Extension Procedure

1. Remove all four lock pins.

Lock pin

T02903E

91

Outriggers

T029411E

2. Flick the slider/jack selector switch to the SLIDER

6. Use the bubble levels to make sure that the crane

position. Keeping the extend/retract selector switch pressed to the EXT. position, press the collective control button to extend all the outrigger beams fully. ◆Adjust the operation speed by pressing down the accelerator pedal. ◆See the outrigger extension width by the full extended mark.

is level. If the crane is not level, refer to the "Level Adjustment" section for detailed instructions on leveling the crane.

Bubble level

Bubble

Marking line Marking line OUTRIGGER

CONTROL RIGHT FRONT

EXT.

T05224E

RIGHT REAR

N

SLIDER

Middle Extension Procedure

Full extended mark

RET.

ALL

N LEFT FRONT

JACK

1. By the same procedure with the outriggers’ full ex-

LEFT REAR

T02904E

tension procedure, extend outrigger beans to the middle extension marks (21´ 11 3/4˝ or 18´ 1/2˝).

3. Insert all four lock pins in the outrigger pin holes to lock the outrigger beams in place.

4. Flick the slider/jack selector switch to the JACK position. Keeping the extend/retract selector switch pressed to the EXT. position, press the collective control button to extend all the jack cylinders fully.

Mid extended mark 21 11 3/4 Mid extended mark 18 1/2 T02906E

2. Insert all four lock pins in the outrigger pin holes to OUTRIGGER

RIGHT FRONT

EXT.

lock the outrigger beams in place.

CONTROL RIGHT REAR

N

3. By the same procedure with the outriggers’ full ex-

RET. SLIDER

ALL

tension procedure, extend all the jack cylinders.

N JACK

LEFT FRONT

LEFT REAR

T02905

5. After all four jack cylinders are fully extended, return the slider/jack selector switch and the extend/retract selector switch to the neutral position.

Outriggers

92

Outriggers

T029411E

Level Adjustment

2. If the bubbles in the level glass are between the marking lines, the crane is considered to be level.

Return the slider/jack selector switch and extend/retract selector switch to the neutral position.

Using the Bubble Level When the crane is set level, the bubbles in the level glass are between the marking line. If a bubble is offcenter, it means that the crane is not level, and the side of the crane in the direction of the bubble is higher.

—Example — A bubble in the level glass is off-center and to the right. = The crane is listing to the left.

Bubble level

Bubble

Marking line Marking line

Bubble level

T05224E

3. Make sure that all four outrigger floats are in con-

Marking line

tact with the ground. Any unseated outrigger floats must be lowered until they are in firm contact with the ground.

T05225E-1

Adjustment The crane should be adjusted to a level position by retracting (extending) the jack cylinders located on the higher (lower) side of the crane. The following explanation assumes that the right side of the crane is higher (lower).

1. Flick the slider/jack selector switch to the JACK position. Keeping the extend/retract selector switch pressed to the RET. (EXT.) position, press the right front and right rear individual control buttons (buttons corresponding to the higher [lower]side of the crane) repeatedly to retract (extend) the jack cylinders on the right side of the crane a little at a time.

OUTRIGGER EXT.

CONTROL RIGHT FRONT

RIGHT REAR

LEFT FRONT

LEFT REAR

N RET. SLIDER

ALL

N JACK

T02907

Outriggers

93

Outriggers

T029411E

Stowing the Outriggers

1. Flick the jack/slider selector switch to the JACK position. Keeping the extend/retract selector switch pressed to the RET. position, press the collective control button and retract the jack cylinders fully.

WARNING If the outriggers are retracted with the boom extended, the crane may overturn. Fully retract the boom and stow in the traveling configuration before retracting the outriggers.

Traveling with the crane without first securing the retracted outriggers with the lock pins is dangerous. The outrigger beams could accidentally extend during travel. Be sure to securely pin the outrigger beams whenever they are stowed.

Unless the gearshift lever is set to other than the “N” position, neither extension nor retraction of outriggers can be performed. Make sure of the gearshift lever “N” position, beforehand.

OUTRIGGER EXT.

CONTROL RIGHT FRONT

RIGHT REAR

LEFT FRONT

LEFT REAR

N RET. SLIDER

ALL

N JACK

T02908

2. Remove all four lock pins.

[NOTICE] ◆ After outriggers’ extension and retraction, set the switches to neutral: • Extend/retract selector switch • Slide/jack selector switch Unless the extend/retract selector switch is situated at neutral, the outrigger switch non-neutral position lamp flashes.

Lock pin

T02909E

3. Flick the jack/slider selector switch to the SLIDER position. Keeping the extend/retract selector switch pressed to the RET. position, press the collective control button to retract the outrigger beams fully.

O/R SW

T101122

OUTRIGGER EXT.

CONTROL RIGHT FRONT

RIGHT REAR

LEFT FRONT

LEFT REAR

N RET. SLIDER

ALL

N JACK

T02910

Outriggers

94

Outriggers

T029411E

4. After all four outrigger beams have been fully retracted, return the jack/slider selector switch and the extend/retract selector switch to the neutral positions.

5.

Install all four lock pins in the outrigger beam pin holes to lock the outrigger beams in place.

Lock pin

T02911E

Outriggers

95

Outriggers

T012181E

Adjusting Control Levers Adjusting Neutral Position of Levers

4. Pull out the lock pins. ◆After operating the crane, set the auxiliary hoist and swing control levers backward as shown so that the levers do not hinder the operator from entering or leaving the crane.

WARNING Unintended touch of control levers while ascending or descending the cab or while the carrier is traveling makes the crane move suddenly and unexpectedly. After crane operation, lock the auxiliary hoist and swing control levers by lock pins.

Then retract all the control levers, and lean the auxiliary hoist and swing control levers backward.

For each of the control levers, the operator can choose the neutral position from three positions. Before starting crane operations, set the levers to their most comfortable position(s).

Lock pin T02987E

1. Raise the control levers.

Adjusting Length of Control Levers

2. Push on the lever knob. While keeping the lever de-

The length of all the control levers is adjustable. Adjust each lever to the desired length as follows: ◆After crane operations, push in the knob to shorten the length of each lever.

(1)Loosen the lock nut by turning it counterclockwise.

(2)Move the knob in or out to adjust the length.

(3)Lock the knob by turning the lock nut clockwise.

pressed, move it to the desired neutral position, and release it. Then, move the lever forward and backward slightly. The clicking sound means the lever is now locked in Neutral.

Lock pin Knob Lock nut

T00675E

T02954

3. Adjust the control lever lengths.

Adjusting Control Levers

T02954

96

Adjusting Control Levers

T029251E

Hoisting Perform the hoist-up or hoist-down operation by using the appropriate hoist control lever.

Obtain the desired hoisting speed by changing the amount the hoist control lever is moved and also by using the accelerator.

Since the main and auxiliary winch systems are independent of each other, both winches can be used simultaneously.

Controls (ISO recommended layout) ◆The arrangement of the levers shown here is based on the ISO layout. The arrangement on machines adopting the TADANO recommended layout is different from the one shown.

Push(hoist down) 3

1

2

Neutral(stop) Hoist control lever

4

Pull(hoist up)

OFF Lo Hi

T20916E T05226

Main Hoist

1. Main hoist control lever 2. Auxiliary hoist control lever 3. Anti two block disable switch 4. Drum indicator switch (option)

Operate the main hoist control lever to hoist up or hoist down the load.

To hoist up : Pull the lever rearward.

To hoist down : Push the lever forward.

To stop : Return the lever to the neutral position.

Hoisting Up and Down ı

Auxiliary Hoist WARNING

Operate the auxiliary hoist by following the same procedure for the main hoist operation.

See the “Main Hoist” section and substitute “auxiliary hoist” for “main hoist”.

Moving the control levers abruptly is dangerous because it causes the load to bounce and swing. This practice could result in damaging the crane, and injury or death. Be sure to operate the levers slowly and carefully.

Never attempt to pull a load sideways or inward by operating the winch. Doing so may not only cause the boom failure but also overturn the crane.

When a load is lifted, the boom deflects and the load radius increases, possibly exceeding the allowable limit. This result causes an overload condition. Stop lifting when the load just clears the ground, and check the condition of the load, as well as for any sign of overloading, before continuing.

Hoisting

97

Hoisting

T029251E

Other Winch-related Controls and Devices Winch Drum Indicator (option) The hoist control lever knob has a function of detecting the rotating status of the winch drum. Turn ON the drum indicator switch and, then, operate the hoist control lever. When you lightly touch the knob by your thumb, you will feel the pulsation sound of knocks. ◆The indicator functions only when the winch drum is rotating at low speed. The indicator becomes inoperable, when the winch is rotating at high speed. ◆Normally keep the drum indicator switch at the ON position, and turn OFF the switch only when it is not used.

DRUM INDICATOR OFF

ON

T50111E

Hoisting

98

Hoisting

T032691E

Telescoping the Boom [NOTICE] ◆ The extended boom retracts, though slightly, in course of time, due to hydraulic oil temperature change. For example, 15 ft (5 m) extended boom retract by approx. 1.6 in (40 mm) along with lowering of temperature by 50°F (10°C). Besides temperature, the boom’s telescoping conditions, boom angle, lubrication, etc. affect the amount of retraction.

For boom retraction prevention, use the following precautions: • Do not extend the boom when the hydraulic oil is extremely high.

• Manipulate the telescoping control lever slightly to the EXTEND direction to mitigate the oil effect.

• Fully extend the 2nd boom section for working with this section.

Controls (ISO recommended layout) 4

5

3

2 1 OFF Lo Hi

T05227

The boom consists of four sections. The telescoping of these boom sections is controlled by using the boom telescoping control lever, the boom telescoping control pedal and the 3rd/top boom extending switch.

The telescoping speed can be controlled by changing the amount the boom telescoping control lever and the boom telescoping control pedal are moved and by using the accelerator pedal.

To extend: Push the lever forward.

To retract: Pull the lever rearward.

To stop: Return the lever to neutral position.

1. Boom telescoping control pedal 2. 2nd boom emergency telescoping switch 3. 3rd/top boom emergency telescoping switch 4. 3rd/top boom extending switch 5. Boom telescoping control lever

Extending and Retracting the Boom WARNING Moving the control levers abruptly is dangerous because it causes the load to bounce and swing. Operate levers slowly and carefully.

When the boom is extended, the working radius increases. Be alert to any sign of overloading when extending the boom.

A boom telescoped incorrectly can collapse if a lift is made in this condition. Watch out for any error in the boom section telescoping sequence while operating the crane.

Do not push or pull the load by telescoping the boom. This practice can damage the crane and lead to an accident.

Telescoping the Boom

Push（to extend）

Boom telescoping control lever

Neutral(stop)

Pull（to retract）

3rd／top boom extending switch T20917E

99

Telescoping the Boom

T032691E

The boom lengths and boom telescoping sequence are shown below.

Extension

Retraction

36.1ft.

(Full retracted) 49ft.

62.3ft.

(2nd boom section full extended) 75ft.

89ft.

102ft.

114.8ft.

(Full extended) T21101E

Extension

Boom Telescoping Control Pedal

1. Push the boom telescoping control lever forward.

This pedal is for extending and retracting the boom. It is linked with the boom telescoping control lever in motion.

The 2nd boom section will extend.

2. After the 2nd boom section has fully extended, press the 3rd/top boom extending switch. The 3rd and the top boom sections go extending simultaneously.

Keep the lever pushed in this while. ◆When the 3rd boom section begins to extend, release the switch.

To extend To stop To retract Boom telescoping control pedal

3. Once the boom has extended to the desired length, return the boom telescoping control lever to the neutral position.

T20918E

Retraction

1. Pull the boom telescoping control lever rearward.

The boom will begin to retract. When retracting a fully extended boom, first the 3rd and top boom sections will retract simultaneously. After the 3rd and top boom sections have completely retracted, the 2nd section will retract.

2. Once the boom has retracted to the desired length, return the boom telescoping control lever to the neutral position.

Telescoping the Boom

100

Telescoping the Boom

T032691E

3rd/Top Boom Sections

Emergency Telescoping Procedure

While pressing the 3rd/top boom emergency telescoping switch, operate the boom telescoping control lever. The 3rd and top boom sections will extend or retract regardless of the status of the 2nd boom section.

WARNING When the boom is extended or retracted using the emergency telescoping procedure, it is no longer in a normal operating condition. The strength of a boom extended to any length by this method will be considerably less than when extended normally to the same length. When the emergency telescoping procedure must be used, remove the load from the hook. Never hoist any load until the boom has been returned to its normal operating condition.

Emergency telescoping switches work only when the override switch stays ON. This method of telescoping the boom should be used to stow the boom when the boom cannot be extended or retracted for some reason, such as a malfunctioning boom length sensor.

Use this procedure also when you need to extend or retract a boom section in a sequence other than the normal sequence, for inspection or maintenance purposes.

The controls used in the emergency telescoping procedure are the boom telescoping control lever, 2nd boom emergency telescoping switch, and 3rd/top boom emergency telescoping switch.

3rd/top boom emergency telescoping switch 2nd boom emergency telescoping switch

3rd, Top

2nd

EMERGENCY TELESCOPING T02957

T02957 2nd Boom Section While pressing the 2nd boom emergency telescoping switch, operate the boom telescoping control lever. The 2nd boom section will extend or retract regardless of the status of the 3rd and top boom sections.

Telescoping the Boom

101

Telescoping the Boom

T012213E

Elevating the Boom [NOTICE] ◆ When the boom angle is raised to a very high angle with the hook block is positioned near the boom top, abrupt boom elevating operation will cause the hook block or the lifted load to hit the elevating cylinder or the boom at the lower face. The cylinder or the boom may be damaged.

Controls (ISO recommended layout) ◆The arrangement of the levers shown here is based on the ISO layout. The arrangement on machines adopting the TADANO recommended layout is different from the one shown.

The boom elevating control lever (or boom elevating control pedal) is used to raise or lower the boom.

Control the elevating speed by changing the amount you

2

move the boom elevating control lever and by using the accelerator pedal.

To raise: Pull the lever rearward.

To lower: Push the lever forward.

To stop: Return the lever to neutral position.

1

T21648

Push (to lower)

1. Boom elevating control lever 2. Boom elevating control pedal Neutral (stop)

Raising and Lowering the Boom DANGER

Pull (to raise)

Do not stick your hand or head out of the window during crane operation. Serious injury or death can result from this practice.

T20919E

Boom Elevating Control Pedal This pedal is for raising and lowering the boom. It is linked with the boom elevating control lever in motion.

WARNING Moving the control levers abruptly is dangerous because it causes the load to bounce and swing. Be sure to operate the levers slowly and carefully.

The machine is not automatically stopped even if the boom is elevated to raise a dangerously heavy load clear of the ground. An overloaded machine could overturn or be damaged. Use only the hoist-up operation to raise the load clear of the ground.

When the boom is lowered, the working radius increases. Be alert to any sign of overloading when lowering the boom.

Do not try to pull the load inward by raising the boom. This practice can damage the crane, leading to an accident.

Elevating the Boom

Boom elevating control lever

To lower To stop To raise Boom elevating control pedal T20920E

102

Elevating the Boom

T029271E

Swinging the Boom Use the swing control lever to swing the crane. The swing speed can be controlled by changing the amount you move the swing control lever and by using the accelerator pedal. ◆When the swing free/lock select switch is in the FREE position, be sure to take into account the effect of inertia on the swing when you stop the swing. ◆Be sure to set the swing brake switch “ON” after a swing operation. ◆When leaving the cab, center the boom to the front and position the swing lock lever in the LOCK position.

Controls (ISO recommended layout)

1

4 2 3 OFF Lo Hi

T05231

1. Swing brake switch 2. Swing lock lever 3. Swing free/lock select switch 4. Swing control lever

SWING SELECT LOCK

Swing free/lock select switch

FREE

Swinging the Boom T02960

WARNING Swing lock lever

Be sure to move the swing control lever slowly and carefully. Moving the lever abruptly is dangerous because it causes the load to bounce and swing. This practice could result in injury or death and may also damage the crane.

During a swing operation, the crane will not be stopped even if it is in an overload condition.

When swinging a load from the over-front area to an over-side area during on-rubber operation, be extremely careful not to have the crane become overloaded.

Do not try to pull the load inward or sideways by swinging the boom. This practice can damage the crane, leading to an accident.

Before swinging the load, make sure that the work area is clear of obstructions which the boom or jib could hit.

Before swinging the load, press the horn switch to alert people in the work area around the crane.

Swinging the Boom

CK E G LO RELEAS SWIN LOCK

T02961

ON OFF

SWING BRAKE T02962

103

Swinging the Boom

T029271E

1. Set the swing brake switch OFF to release the swing brake. Pinch the knob up to operate the switch.

2. If the swing lock pin is engaged, position the swing lock lever in the RELEASE position to extract the swing lock pin. ◆When the swing lock pin is too heavy to come out, move the swing control lever slightly to and fro.

3. Operate the swing control lever as follows: To swing left: Pull the lever rearward.

To swing right: Push the lever forward.

To stop: Return the lever to the neutral position. ◆Be sure to set the swing brake switch ON after a swing operation. ◆Do not set the swing lock lever to “LOCK” during swing operation. ◆Shift the swing free/lock select switch when the boom is not being swung.

Push (to swing right)

Neutral (stop) Swing control lever

Pull (to swing left) T20921E

Swinging the Boom

104

Swinging the Boom

T013703E

On-rubber Operation 1. Set the PTO switch ON.

WARNING Do not use the jib. Do not perform boom lift nor single top lift when the boom length exceeds 89 ft (27.1 m).

Do not operate the crane unless tire’s air pressure is at the specified value. (On-rubber operation is allowed assuming the tires are pressurized as specified.)

Do not swing the boom free. Set the swing free/lock select switch to LOCK.

OFF

ON

PTO

P.T.O. T02953

[NOTICE] ◆ Rated lifting capacities for on-rubber operation are values when the crane is installed on the firm level ground. Inclined ground or soft ground do not satisfy the rated lifting capacity values. Always take the ground conditions into account for operation.

2. Set the parking brake switch to PARK.

PARK

Stationary

OFF

BRAKE

PARKING BRAKE

WARNING The only case for over-front performance is when shown on the load moment indicator by the over-front position symbol. Otherwise the crane is under all 360° performance control.

Do not lift up a load in over-front area and swing it sideways unless the load is under the 360° performance.

T00701E

3. Register “On rubber stationary operation” on the load moment indicator.

[NOTICE] ◆ Register “on rubber stationary operation” on the load moment indicator. ◆ Pay attention to the moment display on the load moment indicator during operation.

The crane is supported only by the tires. When overloading conditions occurs, the crane operation stops. But the inertia makes the crane to oscillate to and fro, or right and left.

T22853

4. Operate the crane (hoist, boom telescoping, boom elevation, and swing).

On-rubber Operation

105

On-rubber Operation

T013703E

Traveling with a Load Lifted WARNING Do not travel at a speed exceeding 1 mph (1.6 km/h).

Do not lift the load high. Keep it near the ground. For safety do not fail to hold it with an auxiliary rope.

Do not shift into “D” or “2” position, but keep the gearshift lever positioned at “1”. Avoid abrupt motion: start, stop and steering. Otherwise the lifted load is given oscillation.

Do not operate the crane while traveling.

Before traveling, extend the outrigger beams and extend the jacks until the outrigger floats are slightly clear of the ground.

[NOTICE] ◆ Do not travel with the PTO switch set OFF and with a load on.

1. Register “On rubber creep operation” on the load moment indicator.

T22854

2. Set the drive mode select switch to “4-WHEEL (Lo)”.

3. Perform steps 1 and 2 of the “Stationary”.

4. Set the swing brake switch to ON and apply swing brake. Set the swing lock lever to “LOCK” and insert the swing lock pin.

5. Set the parking brake switch to OFF and start to travel slowly.

On-rubber Operation

106

On-rubber Operation

T012240E

Removing and Stowing the Main Hook Block

3. Detach the hook holding rope from the main hook

WARNING

block.

When the anti-twoblock function is deactivated, a hoisting operation is not stopped even if the hook block is overhoisted. Two-blocking damages the wire rope and crane and can result in serious personal injury or death due to a falling hook block. Always be careful not to two-block when the anti-twoblock function is deactivated.

[NOTICE] ◆ Operating the winch with no tension on the wire rope causes the rope to wind improperly. Perform the hoist-down operation by always maintaining the tension provided by the weight of the hook block.

T00798

◆When the main hook block is being taken out or stowed, the anti-twoblock device may be activated, making any further operation impossible. You can avoid this condition by pressing the anti-twoblock disable switch to deactivate the anti-twoblock function. While the switch is held down, the anti-twoblock function will be deactivated.

Removing the Main Hook Block 1. Extend the outriggers and set the crane in a level position.

2. Hoist down with the main winch to slacken the main winch wire rope, and, at the same time, raise the boom to a position where the hook holding rope can be released. ◆Raise the boom, taking care not to apply too much tension to the wire rope and being sure that the wire rope winds properly around the drum.

T00797

Removing and Stowing the Main Hook Block

107

Removing and Stowing the Main Hook Block

T012240E

Stowing the Main Hook Block 1. Fully retract the boom.

2. Move the main hook block to its stowing position.

T00799

3. Attach the hook holding rope to the main hook block.

T00800

4. Lower the boom while hoisting up with the main winch, and stow the boom in the traveling configuration. ◆After the boom has been stowed, take in the rope until it is somewhat taut.

T00801

Removing and Stowing the Main Hook Block

108

Removing and Stowing the Main Hook Block

T033121E

Reeving Wire Rope Standard Number of Parts of Line WARNING If the wire rope is reeved in a number of parts of line greater than the standard and the boom is raised to a large angle, the extra wraps of rope that should be left on the drum will be unwound before the hook block reaches the ground, causing damage to the wire rope and its anchor at the winch drum. Even with the standard number of parts of line, this problem will arise if the load is lowered below ground level. When the number of parts of line is greater than the standard or the load is being handled on a site that has a significant elevation differences, ensure that more than three wraps of rope will remain on the winch drum while the load is lowered.

When the number of parts of line is less than the standard, be sure not to exceed the allowable load for one part of line (see the "INFORMATION AND DATA" section).

Reeving Wire Rope

109

Reeving Wire Rope

T033121E

The following table shows the standard number of parts of line for different boom lengths. Select the number of parts of line that ensures the most efficient operation, taking into consideration boom length, load mass, hoisting speed and other conditions such as winch drum wire rope capacity.

36.1ft (11.0m)

36.1ft to 62.3ft (11.0m to 19.0m)

62.3ft to 114.8ft (19.0m to 35.0m)

12

8

4

Jib,single top

1

2

1

Use single top.

3

6.2 t

65 t

4

5

1,320 lbs.(600 kg)

330 lbs.(150 kg) T22845E

1. Boom length 2. Number of parts of line 3. Reeving pattern 4. Hook block 5. Hook block mass

Reeving Wire Rope

110

Reeving Wire Rope

T033121E

Reeving Procedure

CAUTION

1. Extend the outriggers and set the boom in the desired direction.

Secure the rope socket fixing pin installing bolt using a wrench.

2. Lower the boom all the way down and set the hook

7. After reeving the rope, install the rope socket on the

block on the ground.

boom if the number of parts of line is even, or on the hook if the number is odd. ◆Have the rope socket facing in the direction shown when it is installed on the boom.

3. Remove the weight for the anti-twoblock device from the wire rope.

T00223

T101163

4. Remove the two rope guide pins from the boom

8. Install the weight for the anti-twoblock device on the

head.

rope. ◆Where the weight should be installed depends on the number of parts of line. When the number of parts of line is even, install the weight on the last part of line. When the number is odd, install the weight on the second to last part of line.

5. Remove the three bolts from the main hook block.

Bolt Washer

Even number of parts

Odd number of parts

Rope socket Weight Weight

T00804E

Rope socket

6. Reeve the wire rope according the "Standard

T00227E

Number of Parts of Line" table. ◆Pull the rope out by hand while hoisting down with the winch in order to prevent improper winding. Wear protective gloves.

9. Reinstall the two rope guide pins at the the boom head. Reinstall the three bolts on the hook block.

10. Raise the boom and hoist up with the winch to wind the rope around the drum. ◆The rope is often wound improperly when the wire rope is reeved without suitable tension on the line.

Rewind the ropes if necessary.

Reeving Wire Rope

111

Reeving Wire Rope

T029302E

Single Top Components

Single Top Lift WARNING The rated lifting capacity for a single top lift is determined by subtracting the mass of main hook block from the rated lifting capacity for a boom lift.

The maximum load permitted for the single top, however, is limited to 12,300 lbs (5,600 kg). If the load obtained from the above calculation is over 12,300 lbs (5,600 kg), 12,300 lbs (5,600 kg) must be taken as the rated lifting capacity.

7 6

1

In stowed configuration

2

The single top is mounted on the the boom head and used for lifting relatively light loads. Although the load that the single top can handle is limited in weight, the single top utilizes a single rope arrangement which significantly shortens hoisting time.

Usually the single top is used with the auxiliary winch, auxiliary winch wire rope and auxiliary hook block. ◆Prior to lifting a load with the single top, select the single top lift status on the load moment indicator.

3 4

5 T02965

1. Connecting pin 2. Single top 3. Rope guide pin 4. Weight for anti-twoblock device 5. Auxiliary hook block 6. Auxiliary winch wire rope 7. Stowing pin

T22855

Single Top

112

Single Top

T029302E

Mounting the Single Top

4. Insert the connecting pin to secure the single top in position.

WARNING When working at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Mount the single top securely. Use the attached bolts, cotter pins and rings to ensure that the stowing pin, connecting pins, rope guide pins, and hook mounting pins do not slip out of position.

Connecting pin

T00503E

1. Fully extend the outriggers and set the crane in a level position.

5. Remove the anti-twoblock device from the jib and

2. Lower the boom all the way down.

remount it on the single top.

T00501

T00504

3. Remove the stowing pin and swing the single top forward. Replace the stowing pin in its original position.

6. Connect the leads of the anti-twoblock device as shown.

Stowing pin

T21223 T02966

T02966

Single Top

113

Single Top

T029302E

7. Return the stowed auxiliary winch wire rope over

CAUTION

the upper side of the boom.

Secure the rope socket fixing pin installing bolt using a wrench.

Auxiliary winch wire rope

10. Install the rope socket in the auxiliary hook block.

Rope socket

Rope arresters

Anchor Auxiliary hook block

T20922E

8. Remove the lock pin to detach the auxiliary winch

T00509E

wire rope socket from the anchor on the jib.

11. Hoist up the hook block to remove it from its stowLock pin

ing position.

Rope socket

12. Select the single top lift status on the load moment indicator.

T03017E

T03017E

9. Reeve the auxiliary winch wire rope around the sheaves of the top boom section (boom head) and single top. Set the rope guide pins back in their original position.

T22855

13. Raise the auxiliary hook block and make sure that the anti-twoblock device is operating normally.

Rope guide pin

T02967

T02967

Single Top

114

Single Top

T029302E

Stowing the Single Top

5. Reeve the auxiliary winch wire rope through the rope arresters.

WARNING When working at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Stow the single top securely. Use the attached bolts, cotter pins and rings to ensure that the stowing pin, connecting pins, rope guide pins, and hook mounting pins do not slip out of position.

Auxiliary winch wire rope

Rope arresters

Anchor

1. Stow the auxiliary hook block in its stowing position.

T20923E

2. Take the rope socket out from the auxiliary hook

6. Attach the rope socket to the anchor on the jib.

block.

Lock pin Rope socket Rope socket

Auxiliary hook block T03017E

T00510E

[NOTICE] ◆ Operate the auxiliary winch carefully. If the wire rope is wound too tight, the anchor will be broken.

7. Wind the auxiliary winch wire rope, leaving it slightly slack.

3. Lower the boom all the way down.

4. Remove the weight for the anti-twoblock device and remove the auxiliary winch wire rope from the sheaves of the boom head and single top. ◆Place the rope guide pin on the original position.

8. Connect and disconnect the leads of the antitwoblock device as shown.

Rope guide pin

T03019E T21229

T03019E

Single Top

115

Single Top

T029302E

9. Remove the anti-twoblock device and return it to its

12. Select the boom lift status on the load moment indi-

stowing position at the head of the jib.

cator.

T22856

T02918

10. Remove the connecting pin and swing the single top back to its stowing position.

13. Raise the main hook block and make sure that the anti-twoblock device is operating normally.

Connecting pin

T00516E

11. Insert the stowing pin to secure the single top.

Stowing pin

T02919E

Single Top

116

Single Top

T012273E

Jib Components 10 1

2

11

9 8

7

12

3 6

5

13 14

4

T02964

1. Rope guide pin 2. Top jib section 3. Connecting pin 4. Pivot pin 5. Offset pin 6. Base jib section 7. Weight for anti-twoblock device 8. Rope socket 9. Rope guide pin 10. Center support 11. Set pin 12. Stowing pin 13. Stowing bracket 14. Jib handle

Jib

117

Jib

T012273E

Jib Lift WARNING Install the crane on firm ground and level extending the outriggers.

Extend the outriggers as far as possible.

Do not fail to make sure the auxiliary winch wire rope is not wound disorderly on the drum.

Before jib operation, register jib operation on the load moment indicator.

[NOTICE] ◆ When you mount or stow the jib with the antitwoblock function deactivated, operation will not be stopped even if the hook block is overwound. Twoblocking damages the crane and can cause serious personal injury or death. Be sure not to overwind when mounting or stowing the jib. ◆ The jib will be damaged if it is mounted or stowed in an incorrect sequence. To mount and stow the jib, follow the procedure given in the chart below.

Mounting Jib Stowing Jib 1. Mount the jib.

1. Retract the jib.

2. Change the jib offset 2. Return the jib offset angle. angle to 5°.

3. Extend the jib.

3. Stow the jib.

The jib is mounted on the boom head and is used for lifting a relatively light load to a higher location. Two jib offset angles (5° and 30°) are available, depending on the operation to be performed.

Use of the jib is limited to hoisting operations with the auxiliary hoist, auxiliary winch wire rope and auxiliary hook block.

Jib

118

Jib

T012273E

How to Use the Jib Handle Use the jib handle for the following purposes when mounting or stowing the jib.

(1)Mounting and removing the pivot pin and connecting pin (2)Setting and removing the set pin (3)Reeving wire rope Pivot pin and connecting pin

Set pin

Reeving wire rope

T00805E

Jib

119

Jib

T012273E

Mounting the Jib

1. Set the crane on fully extended outriggers in a location large enough for mounting the jib.

WARNING Do not lower the boom to an angle below 0°.

This action could cause the jib to disengage and drop off.

Always make sure that both the stowing pin and pivot pin are in position before starting any operation. Without these pins in position, the jib will drop off when an operation is started.

T00753

2. Take the auxiliary hook block out of stowage, and place it below the expected position of the jib tip.

T00649-1

Take the necessary precautions to ensure that nobody enters the area over which the jib will swing. Anyone standing in this area could be injured. Also check the adjacent work area for any structure or other obstruction that may present a problem when operating the jib.

T00518

The load moment indicator's control functions and the automatic stop function are deactivated when the jib set status is selected on the load moment indicator. Mount the jib carefully with no load on the crane.

3. Select the jib set status on the load moment indicator.

When working at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Use the attached bolts and cotter pins to secure the lock pin, rope guide pins, and stowing pin in position.

T22857

Jib

120

Jib

T012273E

WARNING

WARNING

Do not lower the boom below 0°. This action could cause the jib to disengage and drop off.

Always make sure that either the stowing pin or pivot pin is in position before starting any crane operation. Without these pins in position, the jib will fall off the boom when an operation is started.

4. Fully retract the boom, and lower the boom to a 0° angle.

8. Remove the stowing pin and swing the jib out away from the boom until it hits the stopper.

Stowing pin

Stopper T00501 T00519E

5. Return the stowed auxiliary wire rope over the upper side of the boom.

9. After making sure that the pivot pin is aligned with the pin holes in the base jib section, use the jib handle to insert the pivot pin in the pin holes. ◆Insert the pivot pin properly; the red tape on the threaded portion should be exposed.

Auxiliary winch wire rope

Pivot pin Rope arresters

Red tape

Anchor T20922E

6. Remove the lock pin and remove the rope socket from the support on the jib.

T00520E

Lock pin

Rope socket

T03017E

7. Hoist down with the auxiliary winch and pull the wire rope close to the jib head. ◆To prevent the wire from being improperly wound, pull the wire rope by hand. Wear protective gloves.

Jib

121

Jib

T012273E

10. Free the set pin so that the jib can be locked by the

13. Hold the guide rope, and swing the jib forward.

set pin when the jib is swung forward.

T00523 T00806

14. Reeve the auxiliary winch wire rope around the 11. Attach the guide rope to the jib head.

sheaves on the upper side of the top boom section and jib, and set the rope guide pin in position.

Rope guide pin

T02922 T02923E

12. Extend the boom until the jib is disengaged from 15. Take the donut weight for the anti-twoblock device

the stowing bracket. ◆When the jib is disengaged from the stowing bracket, it starts to swing forward. Prevent this motion by holding the jib in place with the guide rope.

out of stowage.

Jib

Stowing bracket T02924 T00522E

Jib

122

Jib

T012273E

[NOTICE] ◆ If the boom is extended or lowered in place of hoisting up by the auxiliary winch, the jib could be damaged. Use the auxiliary winch only.

18. Take in the rope slowly by operating the auxiliary winch until the connecting pin is aligned with the pin hole in the base jib section.

16. Reeve the auxiliary winch wire rope through the jib head sheave and insert the rope guide pin.

Rope guide pin T05234E

[NOTICE] ◆ Take care to the rope socket position when attaching it to the bracket. (See the enlarged portion

T00807

of the figure.)

If positioned inversely, the rope socket hits the jib at the lower face when the auxiliary winch is operated, and the socket will be damaged.

17. Attach the rope socket to the underside jib bracket with the lock pin.

19. After making sure that the connecting pin and the pin holes in the base jib section are aligned, use the jib handle to insert the connecting pin in the pin holes. ◆Insert the connecting pin properly; the red tape on the threaded portion should be exposed.

Connecting pin

Red tape

Rope socket Lock pin Jib handle

T00528E

T00808E

Jib

123

Jib

T012273E

20. Hoist down with the auxiliary winch until the wire

23. Select the status for 32.2 ft (9.8 m) jib, 5° offset on

rope becomes slightly slack. Then remove the rope socket from the jib bracket and reeve it through the weight for the anti-two block device.

the load moment indicator.

deg

T22858

24. Overwind the auxiliary hook block and make sure that the anti-twoblock device is operating properly.

21. Hoist down with the auxiliary winch to let out the 25. The jib is now mounted at 32.2 ft (9.8 m) with a 5°

auxiliary winch wire rope. Then mount the rope socket on the auxiliary hook block. ◆To prevent the wire rope from being improperly wound, pull the wire rope by hand. Wear protective gloves.

offset angle. ◆To change the offset angle or to extend the top jib section, see the "Changing Jib Offset Angle" and "Changing Jib Length" sections.

22. Connect the leads of the anti-twoblock device.

T05235

Jib

124

Jib

T012273E

[NOTICE] ◆ Take care to the rope socket position when attaching it to the bracket. (See the enlarged portion of the figure.)

If positioned inversely, the rope socket hits the jib at the lower face when the auxiliary winch is operated, and the socket will be damaged.

2. Remove the auxiliary hook block and secure the rope socket to the bracket on the jib using the fixing pin.

Changing the Jib Offset Angle WARNING When working on a part at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Secure the offset pin in place by using the attached cotter pin.

[NOTICE] ◆ The jib will be damaged if the jib offset angle is changed with the top jib section extended. Make sure that the jib is fully retracted whenever the jib offset angle is changed. ◆ Do not extend or lower the boom to bring the jib to a desired angle. This could damage the jib. Use the hoist operation to raise or lower the jib.

Rope socket Lock pin T00528E

1. Select the jib set status on the load moment indicator.

3. Raise the jib to a point where the offset pin can be removed by hoisting up with the auxiliary winch. ◆The jib needs to be raised only slightly to remove the offset pin. ◆When the jib offset angle is to be reduced, raise the jib slightly above the desired offset angle.

T22857

T21040

Jib

125

Jib

T012273E

4. Reinsert the offset pin in the pin hole of the desired

Changing the Jib Length

offset angle.

WARNING When working on a part at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Secure the jib lock pin in place by using the attached cotter pin.

30° Offset pin

[NOTICE] ◆ The jib could be damaged if the boom is raised or lowered with the jib at a 5° offset angle and the auxiliary hook block in contact with the jib head. Use the hoist operation to change the jib length.

5° T20938E

5. Slowly lower the jib by hoisting down with the auxiliary winch until the jib is held in place by the offset pin. ◆When increasing the offset angle, raise the boom as necessary while lowering the jib to prevent the jib head from hitting against the ground.

Extending the Top Jib Section

1. Select the jib set status on the load moment indicator.

T21041 T22857

6. Select the jib offset angle on the load moment indi-

2. Disconnect the anti-twoblock device leads at the jib

cator corresponding to the actual angle.

32.2 ft (9.8 m) jib 5° offset

head.

32.2 ft (9.8 m) jib 30° offset

deg

deg

5° 30° T02969 T02970

Jib

126

Jib

T012273E

(4) Extend the outrigger jack cylinder to set the crane level.

3-1.

Jib offset angle at 5° (1) To draw out the jib easily, retract the outrigger jack cylinder on the boom facing side until the jib head is approximately 3 feet (1 meter) above the ground.

3ft (1m)

T00540

3-2.

T02971

Jib offset angle at 30° [NOTICE] ◆ Take care to the rope socket position when attaching it to the bracket. (See the enlarged portion of the figure.)

If positioned inversely, the rope socket hits the jib at the lower face when the auxiliary winch is operated, and the socket will be damaged.

(1) Remove the auxiliary hook block and secure the rope socket to the bracket on the jib using the fixing pin.

T02971 (2) Hoist down with the auxiliary winch to let out the wire rope approx. 25 feet (8 meters). ◆To prevent the wire rope from being improperly wound, pull on the rope by hand. Wear protective gloves.

T00538

Rope socket Lock pin

WARNING

T00528E

The top jib section may extend suddenly. Do not stand in the path of an extending jib.

(2) Hoist up the auxiliary winch slightly and remove the jib lock pin.

(3) Remove the jib lock pin and slide out the top jib section.

Base jib

Jib lock pin

Jib lock pin Top jib

T00542E T00539E

Jib

127

Jib

T012273E

(3) Slowly hoist down the auxiliary winch. The top jib section will extend under its own weight. ◆While lowering the auxiliary winch, raise the boom as necessary to prevent the jib head from hitting against the ground.

6. Reconnect the anti-twoblock device leads.

T02972

7. Select the status on the load moment indicator that T00543

corresponds to the actual state of the jib.

WARNING 56.1 ft (17.1 m) jib 5° offset

The top jib section may extend suddenly. Do not stand in the path of an extending jib.

56.1 ft (17.1 m) jib 30° offset deg

deg

(4) If the top jib section does not extend all the way, draw it out by hand. Wear protective gloves.

5°

4. After the top jib section has extended completely,

30° T02973

insert the jib lock pin.

8. Operate the auxiliary winch to overwind the hook block, and make sure that the anti-twoblock device is operating properly.

Top jib

Retracting the Top Jib Section Jib lock pin

1. Select the jib set status on the load moment indicator.

T00544E

5. Remove the rope socket from the bracket on the jib and attach the rope to the auxiliary hook block.

T22857

Jib

128

Jib

T012273E

[NOTICE] ◆ Take care to the rope socket position when attaching it to the bracket. (See the enlarged portion of the figure.)

If positioned inversely, the rope socket hits the jib at the lower face when the auxiliary winch is operated, and the socket will be damaged.

5. Remove the auxiliary hook block and secure the rope socket to the bracket on the jib using the fixing pin.

2. To make handling the job easier, lower the boom until the jib head is approximately 3 feet (1 meter) above the ground.

3ft (1m)

T02974

T02974

3. Disconnect the anti-twoblock device leads.

Rope socket Lock pin T00528E

6. Slowly hoist up using the auxiliary winch to retract the top jib section until about 3 feet (1 meter) remains extended.

T02975

4. Remove the jib lock pin.

3ft（1m）

T21042

Jib lock pin T00548E

Jib

129

Jib

T012273E

7. Lower the boom until the jib head is approximately

11. Select the status on the load moment indicator that

3 feet (1 meter) above the ground.

Hoist up again with the auxiliary winch until the top jib section is fully retracted.

corresponds to the actual length of the jib.

32.2 ft (9.8 m) jib 5° offset

32.2 ft (9.8 m) jib 30° offset

deg

deg

3ft（1m）

5° 30° T02969 T21043

12. Operate the auxiliary winch to overhoist the hook block, and make sure that the anti-twoblock device is operating properly.

8. Insert the jib lock pin.

After the jib lock pin has been inserted, hoist down the auxiliary winch.

Jib lock pin

T20924E

9. Remove the rope socket from the bracket on the jib and attach the rope to the auxiliary hook block.

10. Reconnect the anti-twoblock device leads.

T02978

Jib

130

Jib

T012273E

Stowing the Jib

1. Select the jib set status on the load moment indicator.

WARNING Do not lower the boom to an angle below 0°.

The jib could become disengaged and drop off.

Always make sure that either the stowing pin or pivot pin is in position before starting any crane operation. Without these pins in position, the jib will drop off when an operation is started.

T22857

2. Place the auxiliary hook block in its stowing position.

3. Extend the boom until the yellow mark on the side

T00649-1

of the 2nd boom section comes out of the base boom section.

Take the necessary precautions to ensure that nobody enters the work area over which the jib will swing. Anyone standing in this vicinity could be injured. Also check the adjacent area for any structure or other obstruction that may present a problem when operating the jib.

The load moment indicator's control functions and the automatic stop function are deactivated when the jib set status is selected on the load moment indicator. Stow the jib carefully with no load on the crane.

When working at an elevated position, use a platform or scissor lift to prevent falling and ensure safety.

Use the attached bolts and cotter pins to secure the lock pin, rope guide pins, and stowing pin in position.

Yellow mark

T00553E

4. Lower the boom to a 0° angle. Connect the antitwoblock device leads to the connector on the boom.

◆When the offset angle and length of the jib is changed, return the jib to the 32.2 feet (9.8 m) jib, 5° offset status before stowing it.

T05236

Jib

131

Jib

T012273E

[NOTICE] ◆ Take care to the rope socket position when attaching it to the bracket. (See the enlarged portion of the figure.)

If positioned inversely, the rope socket hits the jib at the lower face when the auxiliary winch is operated, and the socket will be damaged.

5. Attach the rope socket to the jib bracket with the lock pin.

7. Use the jib handle to remove the connecting pin.

Connecting pin

Jib handle T00811E

8. Hoist down with the auxiliary winch until the wire rope becomes slack. Remove the rope socket from the jib bracket.

Rope socket Lock pin T00528E

[NOTICE] ◆ If the boom is extended or lowered to raise the jib, the jib could be damaged. Use the auxiliary winch only.

6. Hoist up with the auxiliary winch to raise the jib to a position where the connecting pin can be easily removed.

9. Remove the auxiliary winch wire rope from the antitwoblock device weight and the boom and jib sheaves.

Replace the rope guide pins and the set pins back in their original position.

Connecting pin

T00555E

T20925

Jib

132

Jib

T012273E

[NOTICE] ◆ Do not stand under the swinging jib.

13. Carefully fold the jib in toward the boom by pulling the guide rope.

10. Place the weight for the anti-twoblock device in its stowing position.

T02979 T00558

11. Attach the guide rope to the jib head.

14. Slowly retract the boom completely. The jib head will be fitted on the stowing bracket. ◆Make sure that the boom is fully retracted and the jib is fitted to the center support and the stowing bracket.

Center support

Stowing bracket

T02922

12. Use the jib handle to pull the set pin down. Lock the set pin in place by turning clockwise.

T00559E

T00813

Jib

133

Jib

T012273E

18. Attach the rope socket to the rope bracket on the

WARNING

swing table.

Always make sure that either the stowing pin or pivot pin is in place. Never start any crane operation until the jib head stowing pin has been inserted as instructed in Step 16.

After removing the pivot pin, proceed to Step 16 immediately.

Lock pin

Rope socket

15. Use the jib handle to remove the pivot pin.

T03017E

Pivot pin

[NOTICE] ◆ Operate the auxiliary winch carefully. If the wire rope is wound too far, the bracket mounting bolts will be broken.

19. Take in the auxiliary winch wire rope, leaving it slightly slack.

T00560E

20. Select the boom lift status on the AML.

16. Move the jib head close to the boom and insert the stowing pin.

Stowing pin

T22856 T00541E

21. Operate the main winch to overhoist the hook block and make sure that the anti-twoblock device is operating properly.

17. Reeve the auxiliary winch wire rope through the rope arrester.

Auxiliary winch wire rope

Rope arresters

Anchor T20923E

Jib

134

Jib

T029331E

Equipment Inside the Cab Roof Wiper Switch

2

The roof wiper switch is used to turn the roof wiper ON and OFF. “ON” ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ wiper starts “OFF” ・・・・・・・・・・・・・・・・・・・・・・・・・・・ wiper stops 3

1 O N OFF Lo Hi

OFF

T02130

T05241-1

1. Flood lamp switch 2. Roof wiper switch 3. Roof washer switch

Roof Washer Switch [NOTICE] ◆ Do not use the wipers on dry glass; doing so will damage the glass. Wet glass by spraying the window with washer fluid before using the wipers. ◆ Never spray washer fluid continuously for more than 3 seconds and do not operate the washer switch when there is no window washer fluid. This practice may burn out the pump.

Flood Lamp Switch When the flood lamp switch is turned ON, the flood lamps (one on the side of the boom, one on the front face of the swing table and one on the front face of the cab) will illuminate. ◆Never turn ON the flood lamps when traveling.

"ON"・・・・・・・・・・・・・・・・・・・・・・・・・・lamps come on "OFF"・・・・・・・・・・・・・・・・・・・・・・・・・・・lamps go out

Washer fluid can be sprayed on the roof glass by pressing this switch.

WORKING LAMP OFF

ROOF WASHER

ON T00815E

Equipment Inside the Cab

T21083

135

Equipment Inside the Cab

T029342E

Equipment Outside the Cab Oil Cooler When the hydraulic oil temperature goes beyond 122°F (50°C), the oil cooler begins to work. When the temperature gets higher than 185°F (85°C), the temperature warning lamp comes on. If the lamp lights, stop the crane operation immediately. Wait till the lamp goes off and resume operation.

CPU ERROR

HYDRAULIC OIL

T/C OIL

T03022E

Winch Drum Monitor Mirror (Option) [NOTICE] ◆ Lifting a load with a wire rope disorderly wound on a winch drum will damage the wire rope the shorten the life of the wire rope. Do not lift a load with a wire rope disorderly wound.

Use the mirror to check the wire rope condition on the winch drum. ◆To look at the mirror, turn to the rear of the crane operator`s cab.

T05242

Equipment Outside the Cab

136

Equipment Outside the Cab

H000460E

INSPECTION AND MAINTENANCE

T025770E

Inspection and Maintenance Proper inspection and maintenance helps ensure safety and prolongs the life of your crane. To keep your crane in peak condition and maintain optimum performance, inspect and service it at the recommended intervals. In this way, you can prevent failures and detect problems in their early stages.

Two recommended inspection and maintenance intervals are provided; one based on the hourmeter reading and the other on calendar months; perform inspections and maintenance according to whichever comes first. ◆The inspection intervals are based on the assumption that the crane is used under normal operating conditions. If it is used under severe or unusual conditions, shorten the intervals accordingly. ◆If you are unable to perform any inspection or maintenance work yourself, contact your nearest TADANO distributor or dealer for assistance.

100 hours or 1 month 250 hours or 3 months 500 hours or 6 months 1,000 hours or 1 year 2,000 hours or

Perform before start of each day’s operation.

Perform every 100 hours or once a month.

Perform every 250 hours or every 3 months.

Perform every 500 hours or every 6 months.

Perform every 1,000 hours or once a year.

Perform every 2,000 hours

2 years 4,000 hours or 4 years

or every 2 years.

Perform every 4,000 hours or every 4 years

Inspection and maintenance intervals

Pre-operational inspection

Inspection and Maintenance

137

Inspection and Maintenance

T012332E

Pre-Operational and Periodic Inspection WARNING If pre-operational and periodic inspections are neglected, it will not be possible to detect problems in their early stages or prevent consequent accidents. Make it a habit to perform the recommended pre-operational and periodic inspections.

If any abnormality is found, take corrective action immediately.

System/Component

Power PTO transmission system Propeller shaft

Hydraulic pump Hydraulic system

Swing system

Hydraulic oil tank Swing table (including swing bearing) Swing motor, speed reducer Rotary joint

Boom elevating system

Boom telescoping system

Boom elevating cylinder

Boom

Jib and single top

Check Point External appearance Operation (abnormal sounds, overheating), oil leaks External appearance run out, worn splines External appearance Operation (abnormal sounds, overheating, trapped air, etc.), oil leaks External appearance Oil level, contamination, oil leaks Clean tanks, and air breathers External appearance (cracks, deformation, etc.)

Swing motion (abnormal sounds, high pressure in swing circuit) External appearance Operation, oil level, oil leaks External appearance Operation, oil leaks External appearance Operation, oil leaks Spontaneous retraction External appearance Operation, oil leaks Worn slide plates Spontaneous retraction External appearance Operation

PrePeriodic Inspection operational 100 hrs Inspection 1 month ● ● ● ● ● ● ● ●

●

● ●

● ● ● ●

●

●

● ● ● ● ● ●

● ●

● ● ● ● ● ● ● ● ● ● ● ● ●

*1: Every 250 hrs or every 3 months *2: Every 500 hrs *3: Every 1,000 hrs or once a year

Pre-Operational and Periodic Inspection

138

Pre-Operational and Periodic Inspection

T012332E

System/Component

Check Point

Winch motor, speed reducer

Hoisting system

Crane control system

Safety Device

Crane supporting and positioning devices

Electrical system

External appearance Operation, oil quantity, oil leaks, abnormal sounds External appearance Hook blocks, Operation wire ropes, Condition of wire rope (rope socket, wedge) sheaves Condition of safety latch Wire rope reeving Disorderly winding External appearance prevention device Operation Operating Movement of each lever/pedal controls Movement of accelerator External appearance Selector valves Operation, oil leaks Relief valve pressure setting, condition of seal External appearance Angle meter Operation External appearance Load moment Functions (check button, stop) indicator Operation (lamps, buzzers, etc.)

External appearance of boom length detector Anti two block External appearance device Operation, electrical leads and connections Working area External appearance control devices Operation Other safety devices Operation External appearance Outriggers, Operation, oil leaks jack cylinders Jack cylinder spontaneous retraction External appearance Bubble levels Condition of bubbles External appearance Lamps Operation External appearance Switches Operation External appearance Wipers Operation Worn or damaged blades

PrePeriodic Inspection operational 100 hrs Inspection 1 month ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

*1: Every 250 hrs or every 3 months *2: Every 500 hrs *3: Every 1,000 hrs or once a year

Pre-Operational and Periodic Inspection

139

Pre-Operational and Periodic Inspection

T012332E

System/Component

Piping, hoses

Crane operator’s cab Other Heater Components Oil cooler Lubrication Chassis frame Indication plates Starter Electrical system

Alternator Battery Electrical wiring

Main unit

Lubrication unit Engine Fuel unit

Cooling unit

Check Point Oil leaks Obstructions, twists, damage, worn hose, etc.

Loose support, couplings, fittings External appearance Door lock function Condition of seat adjusting mechanism External appearance Operation External appearance Operation Apply grease to each grease nipple Apply grease to wire ropes, sheaves and slide plates External appearance (rust, cracks, deformation, twists, etc.)

External appearance External appearance Engaging pinion Operation Fluid level, specific gravity of electrolyte Loose wiring connections Start-up, abnormality Idling, acceleration Operation of fuel control knob Exhaust condition Air cleaner element condition Engine oil level, oil leaks Replace oil filter Oil pressure Fuel leaks Fuel filter, strainer Check injection nozzle Water level, water leaks Radiator cap mounting condition, function Looseness of fan belt, damage Clean radiator fins

PrePeriodic Inspection operational 100 hrs Inspection 1 month ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

●

● ● ● ● ● ● ● ● ● ● ● ●

●

● ● ●

*2 ● ●

● ●

● ● ● ● ● ● ● ●

*1: Every 250 hrs or every 3 months *2: Every 500 hrs *3: Every 1,000 hrs or once a year

Pre-Operational and Periodic Inspection

140

Pre-Operational and Periodic Inspection

T012332E

System/Component

Steering system

Brake system

Check Point

Operation (play, looseness, vibration, etc.)

Steering wheel External appearance Orbitrol oil leaks Steering system Oil leaks and damage to hydraulic circuit hydraulic circuit Steering shift function Steering pump, External appearance steering cylinder Oil leaks Tie rod Bending, binding Emergency steering pump Function Play, clearance between pedal and floor plate when Service brake depressed pedal Operation of stop lamp Performance and function of brake Hose, piping Oil leaks, damage, deterioration, loosened support Fluid level, air and oil leaks Brake Check pads for wear External appearance Air tank Check for condensation External appearance Operation, brake condition Parking brake Clearance between disc and pads Check strokes of chamber Function of brake fluid level warning device Function of low air pressure warning device Oil leaks Axle Clean air breather Air pressure in tires Rips, damage, unusual wear on tires Wheel Loosened wheel nuts Damaged rim side rings and wheels Loosened wheel bearings Mounting/joint portion Loosened axle mounting, damage Operation, oil leaks Suspension External appearance lock unit Eject air from cylinders Air pressure gauge warning device

Traveling system

Shock absorber

PrePeriodic Inspection operational 100 hrs Inspection 1 month ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

● ● ●

● ● ● ● *1

● ●

● ● ● ● *3 *3

● ●

● ●

● ● ● ● ● ● *1 ● ● ● ● ● ●

*1: Every 250 hrs or every 3 months *2: Every 500 hrs *3: Every 1,000 hrs or once a year

Pre-Operational and Periodic Inspection

141

Pre-Operational and Periodic Inspection

T012332E

System/Component

Power transmission system

Torque converter, transmission

Propeller shaft Differential, planetary gear Lighting device Horn, wiper, turn signal

Other Rearview mirror, Components reflector Meter and gauges Exhaust piping, muffler Lubrication

Check Point Operation, oil level, oil leaks External appearance Clutch pressure, operation Clean air breather, strainer and filter Shifting between drive mode select gears External appearance Runout, worn spline Oil level, oil leaks Clean air breather Operation External appearance Operation External appearance Worn blade

PrePeriodic Inspection operational 100 hrs Inspection 1 month ● ● ● ● *3 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

Mirror condition External appearance Operation External appearance Muffler function Lubricate each grease nipple

●

●

● ● ● ● ● ●

*1: Every 250 hrs or every 3 months *2: Every 500 hrs *3: Every 1,000 hrs or once a year

Pre-Operational and Periodic Inspection

142

Pre-Operational and Periodic Inspection

T002776E

Safety Parts Requiring Regular Replacement WARNING Be sure to replace safety parts regularly.

Neglecting to replace the safety parts regularly can cause accidents.

Some components of your machine use parts which wear with time. It is not always easy to determine when they should be replaced, even if the periodic inspection is performed as recommended. For safety, such parts must be replaced regularly.The following table gives the replacement intervals for the major safety parts. Contact your nearest TADANO distributor or dealer to have these parts replaced at the regular intervals.

Crane Safety parts requiring regular replacement Boom telescoping wire ropes

Interval 4 years

Carrier Safety parts requiring regular replacement

Interval

Seals, O-rings and cups for brake valve Packing, O-rings and cups for air booster Piston seals and dust seals for brake caliper

1 year

Brake fluid Brake hoses Rubbers and packing in pneumatic equipment for brake, excepting above Hoses for steering system

2 years

Packing and O-rings for steering cylinder Packing and O-rings for steering system hydraulic circuit Hydraulic hoses for traveling system

Safety Parts Requiring Regular Replacement

4 years

143

Safety Parts Requiring Regular Replacement

T033131E

Greasing [NOTICE] ◆ Using different brands of lubrication grease together can change the properties of the grease and have an adverse effect on the machine. When grease is added, use the same brand that is already in the machine.

If a different brand of grease must be used, remove all remaining grease before adding the new grease. ◆ Dust and especially debris particles in the grease causes premature wear of sliding surfaces, and consequently, shortens the life of the lubricated machinery. Always clean grease nipples and other surfaces which require lubrication before applying grease.

The wire ropes should be cleaned before they are greased.

◆ Lubricating wire ropes with an improper gear oil, cup grease or waste oil only shortens their life. Use rope grease or other grease that has properties suitable for wire ropes. ◆ In addition to the areas listed in the "Maintenance Table", the following areas should also be lubricated with grease to protect them from rusting and ensure smooth movement.

• Hydraulic cylinder rod portions (boom elevating cylinder, jack cylinder, etc.) that are exposed to air when the cylinder is in a fully retracted position • Links and sliding sections that were coated with grease before shipment from the factory

Maintenance Table

Lower structure

Upper structure

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 25 26 27

Number

Grease Points and Method Side surfaces of boom Slide plates (top surface of boom) Slide plates (bottom surface of boom) Wire rope (for winch) Wire rope (for extending boom) Swing bearing Swing gear Rotary joint Jib connecting pin boss Pin (for jib head sheave) Elevating cylinder lower pivot pin Boom pivot pin Main hook block (*1) Auxiliary hook block (*1) Outrigger floats Propeller shaft Axle oscillation lock cylinder King pin Steering cylinder Tierod end Rear axle oscillation center pin

of Points Coat Inject Inject Coat Coat Inject Coat Inject Inject Inject Inject Inject Inject Inject Inject Inject Inject Inject Inject Inject Inject

3 points 6 points 6 points 2 points 2 points 4 points 1 point 3 points 4 points 1 point 1 point 1 point 1 point 1 point 4 points 9 points 4 points 8 points 8 points 4 points 2 points

1 day

1 week

Check interval 100 hrs 1 month ●

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

(*1): Option

Greasing

144

Greasing

T033131E

Greasing Chart Upper structure 1

2

3

6

7

8

9

5

1

4

5

Every 100hrs (Once a month)

10 11 2 12

Once a week

3

Once a week

4

Every 100hrs(Once a month)

9

10

14 (＊1)

＊1：Option

11

13 14

6

12

7

8 13 (＊1)

T22852E

Greasing

145

Greasing

T033131E

Lower structure

Once a week Every 100hrs (Once a month)

21 24 22

26

21

22

23

25

26

27

27 23 25 24

T20926E

Greasing

146

Greasing

T013733E

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.

Maintenance Table

No.

Component and Required Operation

1

Winch speed reducer

2

Swing speed reducer

3

Axle (carrier axle)

4

Axle (planetary gear)

Check oil level Replace oil Check oil level Replace oil Check oil level Replace oil Check oil level Replace oil

Number of Points/Quantity 1 week

Check interval 100 hrs

250 hrs

500 hrs 1000 hrs 2000 hrs

1 month 3 months 6 months

2 points

1 year

●

1.06 gal.(4.0 lit.) × 2

●

◎ ●

1 point 0.85 gal.(3.2 lit.)

◎

2 points

●

6.3 gal.(24 lit.) × 2

◎

4 points

●

1.32 gal.(5.0 lit.) × 4

◎

● ● ● ◎：First replacement only

Gear Oil

147

Gear Oil

T013733E

Winch Speed Reducer Oil Level Check ・・・・・・・・・Every 500 Hours or Every 6 Months Winch Speed Reducer Oil Replacement ・・・Every 1,000 Hours or Once a Year

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.

WARNING 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.

Checking Oil Level

1. Set the crane on a level surface.

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 symmetrical to the figure shown below.

Filler plug Level plug

Drain plug

T02869E

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.

Gear Oil

148

Gear Oil

T013733E

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

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

Filler plug

Level plug Vent

WARNING 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.

Drain plug

T02871E

3. After all of the oil has drained out, remove the hose.

Install and tighten the drain plug.

Checking Oil Level

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.

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.

5. Install and tighten the filler plug.

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.

Filler plug

Level plug

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.

Gear Oil

149

Gear Oil

T013733E

Axle (Carrier Axle) Oil Level Check ・・・・・・・・・・・・・・Every 100 Hours or Once a Month Axle (Carrier Axle) Oil Replacement ・・・・・・・・・・・・・Every 2,000 Hours or Every 2 Years

5. Pour fresh gear oil through the air breather hole until the oil reaches the bottom of the level plug hole.

6. Once the oil has been supplied, remount and tighten the level plug and the air breather.

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. Set the crane on level ground.

2. Remove the 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 air breather hole.

Level plug

Drain plug T102370E

3. Remount and tighten the 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 level plug to drain the oil.

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

Gear Oil

150

Gear Oil

T013733E

Axle (Planetary Gear) Oil Level Check ・・・・・・・・・・・・・・Every 100 Hours or Once a Month Axle (Planetary Gear) Oil Replacement ・・・Every 2,000 Hours or Every 2 Years

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

DRAIN

FILL

Drain/level plug

TA DA NO OIL LEVEL

Filler 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.

T20224E

3. Place an oil pan under the drain plug.

Checking Oil Level

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

1. Extend the outriggers and set the crane level.

the oil.

2. Rotate the tire by hand until "OIL LEVEL" is posi-

5. After all the oil has drained out, rotate the tire by

tioned as shown. Wear protective gloves.

hand until "OIL LEVEL" is right-side up and horizontal.

Filler plug

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

Drain/level plug

FILL

TA

7. Once the oil has been supplied, install and tighten

DA

OIL LEVEL DRAIN

NO

the filler plug and drain/level plug.

T20223E

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.

Gear Oil

151

Gear Oil

T013754E

Engine [NOTICE] ◆ 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.

Ambient temperature Over 86°F(30℃) 23°F(-5℃) to 104°F(40℃) 5°F(-15℃) to 59°F(15℃) 32°F(0℃) or below

SAE viscosity index SAE40 SAE 30 SAE20W-20 SAE10W-30

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

No.

Component and Required Operation Check oil level

1

Engine

Replace oil

Number of

Check interval

Points/Quantity

1 day

1 point

●

4.23 gal.(16 lit.)

Replace oil filter Air cleaner

100 hrs

250 hrs

◎

500 hrs

1000 hrs

●

1 point

●

Check 2

60 hrs

●

Clean element

1 point

● ● (*1)

Replace element (*1): Once a year or after flushing 6 times

Element Cleaning ・・・・・・・・・・・・Every 250 Hours or

Air Cleaner Check ・・・・・・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.

Dust indicator

◎：First replacement only

When the Red Indicator is Visible [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.

Air cleaner

Reset button

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

Red indicator T00595E

Engine

152

Engine

T013754E

2. Remove the wing nut fastening the element.

7. Clean the gasket attached to the groove on the pe-

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.

riphery 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.

Cap nut Element

Wing Nut

Body

Cover

T20715E

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 kgf/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

153

Engine

T013754E

Element Replacement ・・・・・・Once a Year or after Cleaning 6 Times For element replacement procedures, refer to the previous section, "Element Cleaning".

Engine

154

Engine

T013764E

Engine Cooling System [NOTICE] ◆ For cooling water, use soft water or tap water (water which soap lathers well). Do not use water from wells or rivers. ◆ 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.

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.

Minimum Temperature 14°F (-10°C) 5°F (-15°C) -4°F (-20°C) -13°F (-25°C) -22°F (-30°C) -31°F (-35°C) -40°F (-45°C)

LLC Mixture Ratio 30 % 35 % 40 % 45 % 50 % 55 % 60 %

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

No.

Component and Required Operation Check water level

1 Coolant

Check interval

Number of Points/ 1 day

Quantity 1 point

100 hrs

250 hrs

500 hrs

1000 hrs

2000 hrs

1 month

3 months 6 months

1 year

2 years

●

9.51 gal.(36 lit.)

Replace (when using long life coolant) 4.28 gal.(16.2 lit.) (*2) (*1)

(*1):Total water volume

●

(*2):Necessary volume of long-life coolant when mixing ratio is 45 %

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.

Engine Cooling System

155

Engine Cooling System

T013776E

Torque Converter System ◆ Dust, foreign material or water in the torque converter could cause a failure. Be especially careful when adding or replacing torque converter oil to prevent any foreign substances from entering the torque converter.

[NOTICE] ◆ Using different brands of torque converter oil together can change the properties of the oil and may have an adverse effect on the system. If torque converter oil must be added, be sure to use the same brand of oil as that is already in the machine. If another brand of torque converter oil must be used, drain all the remaining torque converter oil before adding new oil.

Maintenance Table Number of No.

Component and Required Operation

Points/

1 week

Quantity 1

Torque converter,

Check oil level

Check interval

1 point

100 hrs

250 hrs

500 hrs

1000 hrs

2000 hrs

1 month

3 months 6 months

1 year

2 years

●

transmission

Replace oil

7.93 gal.(30 lit.)

◎

●

2

Transmission

Clean strainer

1 point

◎

●

3

Line filter

Replace element

1 point

◎

●

(*1)

(*1): Whole amount

Oil Level Check ・・・・Every 100 Hours or Once a Month Oil Replacement ・・Every 1,000 Hours or Once a Year

◎: First replacement only

3. Idle the engine for a few minutes to raise the oil temperature to approximately 122°F (50°C).

（50°C） 122 ゜ F

WARNING

Torque converter oil temperature gauge

VERTER CON OIL TEMP

The torque converter and transmission are very hot immediately after traveling. Let the torque converter and transmission cool down until you can touch them with your bare hand before starting maintenance work.

T20927E

[NOTICE] ◆ An excessively low or high oil level can cause the transmission to fail or overheat. Make sure that the oil level is within the specified range.

Checking Oil Level

1. Set the crane in the traveling configuration on level ground.

2. Switch the PTO switch to OFF. Shift into Neutral and start the engine.

Torque Converter System

156

Torque Converter System

T013776E

Replacing Oil

4. After making sure that the level in the oil gauge on the transmission does not sink any more, check the oil level. If the oil level is in the middle of "H" and "L", the oil level is ok. If the oil level is low, add oil through the filler port of the torque converter.

◆Clean the area around the plug before removing it to prevent dust and other foreign materials from entering the torque converter system. ◆When replacing the oil, also clean the strainer and replace the oil filter.

Transmission (rear)

1. Set the crane in the traveling configuration on level ground.

Oil level gauge Proper range

2. Remove the drain plug at the lower part of the transmission to completely drain the oil.

H L

Transmission (front) T03001E

Torque converter

Filler port Drain plug

T03003E

3. Clean the drain plug. Install the drain plug and tighten it.

T21178E

4. With the engine shut off, add oil through the torque converter filler port until the level reaches the "H" mark of the transmission oil level gauge.

5. Switch the PTO switch to OFF and shift into Neutral. Start the engine and let it idle.

6. The oil level drops gradually because the oil is passing through the torque converter, pipes, oil-cooler, filter, etc.

Add oil little by little to compensate for the drop in oil level. Keep the engine idling for approximately 5 minutes and continue to add oil until the indicator bar in the transmission oil level gauge remains in the specified range with the oil at a temperature of 122°F (50°C).

Torque Converter System

157

Torque Converter System

T013776E

Strainer Cleaning ・・・・・・Every 1,000 Hours or Once a Year

Line Filter Element Replacement ・・・・・・・・・・・・・Every 1,000 Hours or Once a Year

1. Drain oil first.

◆Mounting position: at front right side of transmission

2. Remove the strainer from the lower part of the transmission.

Remove the case and replace the filter element.

3. Clean the bottom face of the transmission case through the strainer mounting hole.

4. Wash the strainer as follows:

O-ring

(1) Wash the strainer on the surface with a soft nylon brush immersed in thinner or kerosine.

(2) Pass 43–57 psi (3–4 kgf/cm2) compressed air from the inside of the strainer.

(3) Dry out the strainer.

Filter element

Case T00602E

Remove the line filter case in the transmission and replace the filter element.

Bolt (54.7 N•m) Seal washer Filter case Spring Washer T01928J

Rubber washer Filter element

5. Remount it.

O-ring T24449E

Transmission(rear) Strainer

T03004E

6. Refill the transmission with oil.

Torque Converter System

158

Torque Converter System

T013782E

Fuel System [NOTICE] ◆Use fuel that meets the standards shown below:

WARNING Fuel leakage could cause a fire. If an oil leak is discovered, immediately repair it. After replacing the filter element or bleeding air, wipe away all spilled fuel.

Using diesel fuel mixed with gasoline or alcohol is dangerous. This practice could cause a fire or explosion, resulting in serious injury or death, or damage to the machine. Use standard diesel fuel only. Do not mix diesel fuel with gasoline or alcohol.

Ambient Temperature Over 10°F (-12°C) 10°F (-12°C) or below

Standard ASTM/D-975 Grade 2-D ASTM/D-975 Grade 1-D

ASTM is an acronym for the American Society for Testing Materials which recommends fuel containing 0.5% or less sulfur content.

Note that a sulfur content exceeding 0.5% reduces time between engine oil changes by 50%.

Maintenance Table ◆For fuel filter element replacement procedures, refer to the "Engine" operation manual.

No.

Component and Required Operation

Number of Points/

Check interval

Quantity

1 day

1 Fuel tank

Check oil level

79.26 gal.(300 lit.) (*1)

●

2 Fuel filter

Replace element

1 point

3 Water separator

Check water level

1 point

100 hrs

250 hrs

500 hrs 1000 hrs ●

● (*1)：Tank capacity

Fuel Tank Level Check ・・Once a Day

Water Separator Water Level Check ・・・・・・・・・・・・・・Every 100 Hours

Check the fuel level with the fuel gauge in the instrument panel.

◆When the water level reaches the red line on the water separator, drain the water regardless of the check interval.

1. Loosen the drain plug to drain water.

2. After the water has drained, tighten the drain plug.

3. Check that there is no fuel leakage.

Fuel tank

Water separator

Red line

Drain plug

Fuel System

159

T02872E

Fuel System

T013794E

Brake System WARNING Using different brands of brake fluid together can change the properties of the fluid and may have an adverse effect on the brake system. For brake fluid, use "TADANO Genuine Brake Fluid". If another recommended brand must be used, drain all of the remaining brake fluid before adding new fluid.

"TADANO Genuine Brake Fluid" and other recommended brake fluids are all glycol-based. If a silicon- or mineral-based brake fluid is used, it will permeate the packing causing the brakes to become ineffective. Therefore, always use glycol-based brake fluid.

Some low-grade glycol-based brake fluids have a low boiling point. Using a low-grade brake fluid is dangerous because it could result in vapor lock.

Use only "TADANO Genuine Brake Fluid" or another recommended brand.

Over time, brake fluid gradually absorbs moisture from the air, which lowers its boiling point.

This behavior could result in vapor lock. Be sure to replace the brake fluid regularly.

Maintenance Table

No.

Component and Required Operation

1 Brake fluid reservoir 2 Disc brake pad 3 Air dryer 4 Parking brake pad

Brake System

Number of Points/ Quantity

Check fluid level

2 points

Replace brake fluid

0.45 gal.(1.7 lit.)

1 day

Check interval 100 hrs 250 hrs 500 hrs 1000 hrs 1 month 3 month 6 month 1 year

● ●

Check wear

4 points

●

Check function

1 point

●

Replace desiccating agent

1 point

●

Adjust clearance

1 point

●

160

Brake System

T013794E

・・・Every Disc Brake Pad Wear Check・ 250 Hours or Every 3 Months

Brake Fluid Level Check ・・・・・・・・・・・・・・・・・・Once a Day

WARNING

WARNING

Using the brakes when the pads are at or near their wear limit will not only damage the disc plates but also cause the brakes to quit working altogether, an extremely dangerous condition.

If an inspection reveals that the pads are near their wear limit, have the nearest TADANO distributor or dealer replace the pads immediately.

Brake pads whose thickness is within working specifications can still be carbonized by heat build-up, worn unevenly or scratched. If scratching, abnormal wear or rust is discovered on the disc plates during inspection, the pads must be removed and inspected. If the condition is severe, the disc plates or pads may have to be replaced.

Have the nearest TADANO distributor or dealer inspect them immediately.

If the brake fluid is leaking, the brakes will cease to function, an extremely dangerous condition. If the fluid level is low, check the brake system for leaks. If there are no leaks but the fluid level has lowered, the disc brake pads may be worn. Inspect the pads for excessive wear.

[NOTICE] ◆ We recommend that you use only brand new brake fluid for replenishment or replacement.

Make sure the fluid level is between H and L. If the level is low, remove the cap and add fluid. ◆There are 2 brake fluid reservoirs located in the center right side of the carrier. ◆Fasten the cap where the match marks meet on the cap and the tank.

H H L

L

T20226

Brake Fluid Replacement ・・・・Every 1,000 Hours or Once a Year For brake fluid replacement, contact the nearest TADANO distributor or dealer.

Brake System

161

Brake System

T013794E

[NOTICE] ◆ You need to remove the pads for closer inspection or can use an check gauge shown below for less closer checks.

If the pads are not undergoing rapid wear, only the outer pad may be worn. At this time, remove the pad for a closer check. ◆ Pad wear inspection should be carried out for all wheels. If, as a result of inspection, even one pad is worn to near its wear limit, replace all pads, or pairs of pads together; the left and right front pads or the left and right rear pads.

2. Check the wear of the pads by inserting the check gauge (included) into the caliper check holes. ◆The check gauge cannot be inserted at some points, depending on the orientation of the tire. If so, turn the steering wheel as far as possible and then reinspect. ◆There are three check holes for each front wheel and two for each rear wheel.

Caliper

Check hole

Caliper

Check hole

Pad Clearance

Disc plate

Check gauge Front wheel

Rear wheel T20929E

3. If an inspection shows that there is no clearance between the caliper and the check gauge, the brake pad is at its wear limit.

T00605E

0.39in(10mm)

New pad

0in(0mm)

Wear limit T20928E

1. Support the crane by fully extending the outriggers.

Brake System

162

Brake System

T013794E

・・・・・Every Air Dryer Function Check・ 250 Hours or Every 3 Months Air Dryer Desiccating Agent Replacement ・・・Every 1,000 Hours or Once a Year

Parking Brake Pad Clearance Adjustment ・・・・Every 1,000 Hours or Once a Year WARNING The parking brake pads come to use limit when their remaining thickness becomes as small as 0.15 in. (3.8 mm) at any point on the circumference. They must be replaced with new ones, then.

After parking brake has been used as emergency brake, the pads stay remarkably worn out.

Check them soon. If you fail to check the pads for wear after such brake application, the pad wear may cause system failure.

[NOTICE] ◆ If the compressor air dryer performance is poor, vapor contained in the compressed air will condense into water, adversely affecting the equipment.

Regularly check and replace the desiccating agent. ◆The air dryer is installed near the rear of the air tank (right side of the carrier).

1. Release parking brake to bring the brake chamber

Air dryer

into the extension side stroke end.

Brake chamber Jam nut Link

Hand brake bolt Disk plate

Front axle T002874E

Performance Inspection T20930E

Open the drain cock on the air tank and check whether any water drains out. If drainage occurs during normal operation, the desiccating agent may have become permeated with oil, etc., lowering its ability to absorb moisture. If so, have the nearest TADANO distributor or dealer check the air dryer.

2. Screw the hand brake bolt in accordance with the pad wear, until the clearance between the pad and the disc plate becomes approx. 0.006 in. (0.15 mm) per side.

Disc plate

Desiccating Agent Replacement For replacement of the desiccating agent, contact the nearest TADANO distributor or dealer.

Lever

Brake System

163

Pad 0.006in. （0.15mm）

T21179E-1

Brake System

T013794E

3. When it becomes impossible to adjust the clearance by hand brake bolt, readjust the brake as follows: (1) Move the lever to release the parking brake and bring the brake chamber to the extension stroke end (2) Connect the link to the lever by adjusting its position.

(3) Check the clearance between the pad and the disc plate. It must be approx. 0.006 in. (0.15 mm) per side. If the clearance is correct, lock it with the jam nut.

Brake System

164

Brake System

T013802E

Axle System Maintenance Table No.

Number of Points/ 1 day Quantity

Component and Required Operation

1 Suspension lock cylinder

Bleed air

4 points

Check Interval 100hrs 250hrs 500hrs 1000hrs 1 month 3 months 6 months 1 year

2000hrs

2 years

●

Suspension Lock Cylinder Bleeding ・・・・・・・・・・ Every 100 Hours or Once a Month

5. After air-bleeding is over, fasten the bleeder screw and remove the hose.

1. Set the crane in the traveling configuration on level

connector in the inside-cab relay box.

6. Turn off the starter switch and connect the on/off

ground. （22 A）G

2. Keep the starter switch to OFF, open the door of the inside-cab relay box, and disconnect the on/off connector.

ON/OFF connector

（22 A）G

ON/OFF connector

（22 ）G

T20933E

7. Turn on the starter switch. Turn the PTO switch on.

Make sure then the suspension lock indicator lamp lights. （22 ）G

T20933E

3. Start the engine, turn the PTO switch on, and raise the engine speed to approx. 2,150 min-1 {rpm}.

4. Attach a hose to the bleeder screw (A). And loosen the bleeder screw. In this condition, bleed air for approx. one minute. ◆Bleed air in the order of bleeder screws, (A), (B), (C) and (D).

C

A

B

D

T20932E

Axle System

165

Axle System

T013813E

Tires and Wheels WARNING Tires replaced and remounted in an improper way may burst, causing serious injury or death.

Have specially trained tire technicians or the nearest TADANO dealer or distributor replace or remount the tires.

Maintenance Table No.

1 2

Component and Required Operation

Tire Wheel nut

Check interval

Number of Points/Quantity

1 day

Check wear

4 points

●

Replace

4 points

Check tightness

4 points

Tire Wear Check ・・・・・・・Once a Day

100 hrs

250 hrs

500 hrs 1000 hrs

1 month 3 months 6 months

1 year ●

●

Tire Replacement ・・・・・・Every 1,000 Hours or Once a Year

WARNING

[NOTICE] ◆As the number of traveled kilometers increases, tires may start to wear unevenly. Periodically rotate the tires so that they wear evenly.

Using tires that are ripped or damaged or whose treads are worn out is dangerous and may cause the tires to skid, go flat or blow out. If a wear check reveals that the tire has reached its wear limit, replace it with a new tire.

1. Slightly loosen the wheel lug nuts with the tires in contact with the ground.

Check the following points: (1) Are there any rips or damage on the tire tread or side walls?

(2) Is there excessive wear of the tire tread?

(3) Have the treads reached their wear limit? ◆The amount of wear or damage that a tire can tolerate depends on the tire manufacture. Contact the nearest TADANO distributor or dealer for detailed information.

2. Extend the outriggers to raise the tires off the ground.

3. Remove the wheel lug nuts to remove the tire.

4. Thoroughly clean the threads of the wheel lug nuts and wheel bolts and the wheel mounting surface. Dirt on the nuts may cause them to loosen. ◆Replace the wheel lug nuts and wheel bolts whose threads are damaged. Also replace deformed or cracked wheels.

Tires and Wheels

166

Tires and Wheels

T013813E

Loose Wheel Lug Nut Check ・・Every 250 Hours or Every 3 Months

5. Mount the tires with the wheel bolts aligned to the wheel bolt holes. ◆When performing tire rotation, change the tire positions as shown.

Front wheel

WARNING Loose or excessively tight wheel lug nuts can cause the wheel to come off or damage the wheel bolts. Check them regularly and tighten them as necessary with the specified torque.

Rear wheel

Check for loose wheel nuts. Re-tighten if a loose wheel nut is found.

T00609E

6. Apply light weight grease to the spherical areas of the wheel nuts and the threaded sections of the bolts.

7. Loosely tighten the wheel lug nuts.

8. Stow the outriggers and lower the tires to the ground gently.

9. Tighten the wheel lug nuts to the specified tightening torque.

Tightening torque

360 to 435 ft-lb (50 to 60 kgf.m)

9 5 1 13 5 20 17 9 16 21 12 LL FI 3 8 TADANO 7 11 7 4 15 22 19 18 23 2 6 10 14 L VE LE IN IL A O DR

T20227E

◆Tighten the wheel lug nuts diagonally as shown.

10. After replacing tires, check for loose wheel lug nuts after approximately 30 miles (50 km) travel. Re-tighten if a loose nut is found.

Tires and Wheels

167

Tires and Wheels

T013835E

Hydraulic System ◆ If the crane is operated for a long time with the hydraulic oil at a high temperature, the oil will rapidly deteriorate, shortening the life of the hydraulic components.

Take enough care of oil temperature. ◆ The hydraulic oil is more viscous when its temperature is low. If, in cold weather, the crane is operated with a heavy load at high speed without allowing it to warm up, the hydraulic components could be damaged. When the ambient temperature is low, do not start crane operation right away.

Instead, let the crane warm up sufficiently; until the oil temperature rises to approximately 68°F (20°C). ◆ Be sure to handle the hydraulic pipes carefully.

Handling these pipes incorrectly can cause oil leaks or the hydraulic components to malfunction.

WARNING The hydraulic oil and hydraulic equipment become very hot immediately after an operation. Let them cool down before starting maintenance work.

Even when the engine is not running, some hydraulic components remain under high pressure.

Careless dismounting or disassembling will cause serious accidents to the human body. Do not attempt to dismount or disassemble hydraulic components, pipings and couplings.

[NOTICE] ◆ Using different brands of hydraulic oil together can change the properties of the oil and have an adverse effect on the machine. When hydraulic oil is

Whenever a pipe has to be removed, be sure to consult the nearest TADANO distributor or dealer. ◆ Dust, foreign matter, water, etc. in the hydraulic oil tank or pipes could cause a machine failure.

Keep these parts free of dust when working on them.

added, be sure to use the brand that is in the machine. If a different brand of oil must be used, be sure to take out all the remaining hydraulic oil before adding the new oil.

Maintenance Table ◆Contact the nearest TADANO distributor or dealer for the replacement of line filter from 4 to 6 in the list below.

No.

Component and Required Operation Check oil level

1 Hydraulic oil tank

Replace oil

Check interval

Number of Points/Quantity

1 day

1 point

●

195 gal.(740 lit.)

Replace

1 point

3 Air breather (hydraulic oil tank)

Replace

1 point

4 Line filter (automatic stop circuit) Replace

2 points

5 Line filter (steering circuit)

Replace

1 point

6 Line filter (winch brake circuit)

Replace

1 point

3 months 6 months

1 year

2 years 4 years

(*1)

260 gal.(985 lit.) (*2)

2 Return filter (hydraulic oil tank)

250 hrs 500 hrs 1000 hrs 2000 hrs 4000 hrs

◎ ◎

● (*3) ● ● ●

◎

● ●

(*1): Tank capacity (*2): Total capacity ◎: First replacement only (*3): When the hydraulic oil other than TADANO Hydraulic Oil LL is used, replace the oil every 2,000 hours or 2 years.

Hydraulic System

168

Hydraulic System

T013835E

Oil Level Check (Hydraulic Oil Tank) ・・・・・・・・・・・・・・・・・・Once a Day Oil Replacement (Hydraulic Oil Tank) ・・・・・・・・Every 4,000 Hours or Every 4 Years ・・・・・・・・・・・・・Every 2,000 Hours or Every 2 Years

2. Check the oil level with the oil level gauge. The oil level gauge is marked taking into account the effect of oil temperature. Check whether the oil level is between the 32°F (0°C) mark and the mark corresponding to the current oil temperature.

If the oil is low, remove the cap on the hydraulic oil tank and add oil through the filler port.

- Example When the current oil temperature is 68°F (20°C), there is sufficient oil in the tank if the oil level is between the 32°F (0°C) and 68°F (20°C) marks. ◆When the oil temperature is 32°F (0°C) or lower, regard the 32°F (0°C) mark as the proper level.

[NOTICE] ◆ After the hydraulic oil has been replaced, the hydraulic pump must be bled since air may be present in the suction side of the pump. The hydraulic pump could experience failure if it is operated without first bleeding it. The hydraulic pump must not be operated after replacing the hydraulic oil unless it has been properly bled. For instructions on how to bleed the hydraulic pump, contact the nearest TADANO distributor or dealer. ◆ Replace the oil within 250 hours or 3 months after the machine has been delivered (whichever comes earlier): • Replace it every 4,000 hours or 4 years after that.

(Applicable to TADANO Hydraulic Oil LL.) • Replace it every 2,000 hours or 2 years after that.

(Applicable to other than TADANO Hydraulic Oil LL.) ◆ Replace the oil filters described in this chapter at designated intervals.

Cap Oil level gauge

40°C

20°C

0°C

T02875E

Replacing Oil ◆When replacing the hydraulic oil, also replace the return filter.

1. Stow the crane in the traveling configuration on level ground.

Checking Oil Level

2. Remove the cover from the filler port and use an oil

1. Stow the crane in the traveling configuration on lev-

pump to pump the hydraulic oil from the tank into an oil drum or other suitable container.

el ground.

Cover

Hydraulic oil tank

Drain plug T02876E

Hydraulic System

169

Hydraulic System

T013835E

3. Remove the drain plugs at the bottom of the tank to

Return Filter Replacement (Hydraulic Oil Tank) ・・・・・・・Every 500 Hours or Every 6 Months

release any remaining hydraulic oil.

4. Check the inside of the tank and clean if any dust or foreign matter is found.

1. Remove the top cover on the hydraulic oil tank and take out the return filter.

5. Clean the drain plug and wrap sealing tape around it, then reinsert and tighten.

Cover

6. While watching the oil level on the level gauge, add

Return filter

new hydraulic oil into the tank.

7. Remount the cover on the hydraulic oil tank.

8. Bleed the hydraulic pump.

T02877E

9. Check the oil level again. If low, add more hydraulic oil.

2. Remove the snap pin and then the nut from the return filter.

Snap pin Nut Hold down spring

Center bolt

Housing assembly Filter element T20934E

3. Replace the filter element with a new one and reassemble the return filter.

4. Install the return filter in the tank and remount the cover.

Hydraulic System

170

Hydraulic System

T013835E

Air Breather Replacement (Hydraulic Oil Tank) ・・・・・・・Every 500 Hours or Every 6 Months

Line Filter Replacement (Steering Circuit) ・・・・・・・Every 2,000 Hours or Every 2 Years

Unlock the air breather cap to remove it.

Remove the two bolts, then use a wrench (spanner) as shown in the figure to remove the element holder.

Replace the element with a new one.

Filter Rotary joint

Flow control valve

Cap

Element

Element holder

T04513E

Bolt

Line Filter Replacement (Winch Brake Circuit) ・・Every 2,000 Hours or Every 2 Years

Packing T00618E

Filter

Element retainer

T00619 T04514E

Line Filter Replacement (Automatic Stop Circuit) ・・・Every 2,000 Hours or Every 2 Years Filter element Plug Sleeve

T21180E

Hydraulic System

171

Hydraulic System

T013843E

Swing System Maintenance Table Number of No.

Component and Required Operation

1 Swing bearing mounting bolt

Check

points/ Quantity 1 point

Check Interval 1 week

100 hrs 250 hrs 500 hrs 1 month 3 months 6 months ●

Swing Bearing Mounting Bolt Check ・・・・・・・・・・・・・・Every 500 Hours or Every 6 Months WARNING If the mounting bolts come loose and/or break, the crane's upper and lower structures will be separated, resulting in a serious accident. Check the bolts at regular intervals. If they are loose, have the nearest TADANO distributor or dealer retighten them. The bolts should be checked at least once a year by a TADANO distributor or dealer.

Tightening torque (bearing inner ring bolts) 904 ±36 ft-lb (125 ±5 kgf.m) Tightening torque (bearing outer ring bolts) 904 ±36 ft-lb (125 ±5 kgf.m)

Swing System

172

Swing System

T033171E

Electrical System Maintenance Table Check Interval No.

Component and Required Operation

1

Fuse/Replace

2

Battery electrolyte/Check

Number of points

1 week

100 hrs

250 hrs

500 hrs

1 month

3 months 6 months

When fuse blows 2 points

●

Fuse Replacement ・・・・・・・・・・・・When a Fuse Blows [NOTICE] ◆ Be sure to turn OFF the starter switch to prevent a short circuit and disconnect the negative (–) terminal of the designated battery when replacing a fuse. ◆ Using a fuse with a larger capacity than the rated capacity may cause the wiring or electrical devices to be burned in the event of a short circuit. Always replace a fuse with a fuse of the specified capacity.

F1 F2 F3 F4 F5 F6 F7

Load moment indicator

OFF Lo Hi

Fuse box

Adjustment cover

T22850E

Electrical System

173

Electrical System

T033171E

Fuses are installed on the inside of the adjustment cover of the load moment indicator. When a fuse is burnt out, check for the cause, remove the cause and replace the fuse.

Symbol Name Rating Circuits F1 MAIN 3A Main fuse F2 RLY 1,2 3A For relay output 1,2 F3 RLY 3,4 3A For relay output 3,4 F4 RLY 5,6 3A For relay output 5,6 F5 RLY 7,8 3A For relay output 7,8 F6 SIF 2 2A Fuse to SIF2SRC power source output terminal F7 SIF 1 2A Fuse to SIF1SRC power source output terminal (Fuse box) PTO SWITCH 470 1 BATTERY 1 BATTERY

1 BATTERY

1 BATTERY

POSITION CAPACITY No. COLOR OBJECT A 5A 344 WB DRUM INDICATOR(Opt.) B 5A - YR RESERVE C 15A 156 LR MONITOR LAMPS,POWER SOURCE FOR CRANE D 10A 154 LgB PTO SWITCH E 15A - YG RESERVE F 10A 148 LO COMBINATION SWITCH G 10A 144 LG PARKING BRAKE MULTIPLEX TRANSMITTER UNIT SHIFT SELECT,STEERING SELECT H 10A 157 Y T/M DRIVE SELECT,SYSTEM CHECK OUTRIGGER CONTROL I 10A 160 RW DCーDC CONVERTOR J 15A 151 LW CIGAR LIGHTER K 15A ー L RESERVE X 5A ー ー SPARE Y 10A ー ー SPARE Z 15A ー ー SPARE POSITION CAPACITY No. COLOR OBJECT A 5A ー WB RESERVE B 5A ー YR RESERVE C 15A 454 LR FAN・DEFROSTER(Opt.) D 10A 159 LgB EXTERNAL WARNING LAMP,DRUM INDICATOR(Opt.) E 15A ー YG RESERVE F 10A ー LO RESERVE G 10A 153 LG STARTER SWITCH H 10A 152 Y WORKING LAMP I 10A 155 RW COMBINATION SWITCH,EMERGENCY T/M SWITCH,AIR HORN,BUZZER J 15A 150 LW FRONT WINDSHIELD WIPER K 15A 158 L WASHER,ROOF WINDSHIELD WIPER X 5A ー ー SPARE Y 10A ー ー SPARE Z 15A ー ー SPARE

1 BATTERY 1 BATTERY 1 BATTERY 1 BATTERY 1 BATTERY

343-941-91271-0

POSITION CAPACITY No. COLOR

1 BATTERY

1 BATTERY

1 BATTERY

1 BATTERY

OBJECT

POSITION CAPACITY No. COLOR

A B C D E F G

5A 5A 5A 5A 5A 5A 5A

- RB RESERVE POWER SOURCE 1 96 RW FOR MISSION BATTERY 87 L B OUTRIGGER CONTROL AIR HEATER 79 Gr EXHAUST BRAKE 1 90 GR OUTRIGGER CONTROL BATTERY 88 GY T/C LOCK UP HEAD LAMP･PTO･LIMITER 95 RL CLEARANCE LAMP

H

5A

94

I

5A

LAMP 93 GW HEAD SUSPENSION LOCK

J K X Y Z

5A 5A 5A 5A 5A

92 91 -

G

STEERING SELECT SOURCE

100

BATTERY

GL STEERING SELECT 1 GO DRIVE SELECT BATTERY - SPARE - SPARE - SPARE

A B C D E F G

10A 15A 10A 10A 15A 10A 10A

H

20A

OBJECT

- RG RESERVE 125 RL HEAD LAMP LAMP 124 R STOP CLEARANCE LAMP - WR RESERVE 141 L R BACK UP LAMP DATA 105 W MULTIPLEX TRANSMITTER UNIT STARTER SWITCH 17 GO BATTERY RELAY

I

10A

-

RY

ROOM LAMP HEATER(Opt.) HAZARD LAMP TURN SIGNAL RESERVE

J

5A 123

P

REAR STEERING CONDITION

K X Y Z

5A 569 YL 10A 15A 20A -

6

O

HOUR METER (Opt.) SPARE SPARE SPARE 343-941-92060-0

65A

ALTERNATOR

BATTERIES (+24V)

T22848

◆It is prohibited to connect new wiring to fuses other than reserve fuses.

Electrical System

174

Electrical System

T033171E

Battery Electrolyte Check ・・・・Every 250 Hours or Every 3 Months WARNING Using or charging the battery with its fluid level below the "LOWER LEVEL" line indicated on its side may cause an explosion of the battery.

Always take care of the battery fluid level.

The hydrogen gas released from the battery is explosive. Never use a cigarette lighter or other open flame near the battery, particularly at the battery vent openings. Use a flashlight for illumination when checking battery fluid level.

If battery fluid gets in your eyes, it may cause blindness. Should this happen, immediately flush your eyes with a large amount of water and seek medical attention.

When removing batteries, set the starter switch OFF; remove them from the ground side terminals (-- ). To connect the terminals, begin with the plus + ) side . Take care to the terminal positions. (+ The fluid level should be between the "UPPER LEVEL" and "LOWER LEVEL" lines. If the fluid level is low, add battery fluid or distilled water to the "UPPER LEVEL" line.

UPPER LEVEL LOWER LEVEL

T00636E

Standard specific gravity of the battery fluid is 1.27 1.29 (68°F or 20°C).

Recharge the battery if it is smaller than 1.21.

Electrical System

175

Electrical System

T022624E

Wire Ropes Disentangling Wire Rope Parts

Proper Handling of Wire Ropes

If new wire rope is used with a long boom and the line parts are few in number, a coiling effect may be created, causing the rope to become tangled. This condition is dangerous because it will cause the hook block or load to rotate. Disentangle the rope as follows:

CAUTION Do not handle wire ropes with your bare hands.

Always wear protective gloves when handling the wire ropes.

Always handle wire ropes carefully and correctly. The life of wire ropes can be maximized if they are handled correctly. If handled improperly, wire ropes become deformed or lose their original strength, and must be replaced prematurely.

1. Let out the wire rope until only a few wraps of rope are left on the winch drum, and check the direction and number of twists.

2. Remove the rope socket from the boom or hook block, and eliminate the twists as described below.

(1) If the rope is twisted in a clockwise direction, twist the rope further (i.e., turn it in the same direction as the twist).

(2) If the rope is twisted in a counterclockwise direction, untwist the rope (i.e., turn it in the opposite direction of the twist). ◆If there are many twists, correct the rope in stages.

Do not twist or untwist the rope more than four turns at a time.

How to Unwind Wire Rope Wire rope is wound in a coil or around a wooden spool when supplied. Unwind the wire rope by rolling the coil, or pull out the rope while rotating the spool.

If the wire rope is unwound improperly, it may become twisted or have kinks, rendering it unusable. Even a slight added twist may cause the wire rope to become tangled.

(1) Rope twisted in a clockwise direction

(2) Rope twisted in a counterclockwise direction

T00058-1 T00060E

T00059

Wire Ropes

176

Wire Ropes

T022624E

3. Hoist the hook block up and down several times to

Wire Rope Replacement

distribute any remaining twists evenly throughout the rope. If, after this action, twists still remain, correct again.

Criteria for Replacing Wire Ropes WARNING If a wire rope breaks during operation, a serious accident could occur. Check the wire ropes at regular intervals. Wire ropes that do not meet even one of the criteria given below should be replaced immediately.

Perform routine and periodic (monthly) inspections of the wire ropes for breaks, wear, corrosion, deformation, arcing or heat effects, oil coat condition, and rope end condition. If any of the following conditions 1 through 5 exist, replace the wire rope. ◆If the end of wire rope is not in proper condition, repair or cut.

1. In running ropes: six randomly distributed broken wires in one lay, or three broken wires in one strand in one lay.

2. Wear of one-third of the original diameter of outside individual wires. Evidence of kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure.

3. Evidence of any heat damage from any cause.

4. Reductions from nominal diameter of more than: 1/64 inch for diameters up to and including 5/16 inch 1/32 inch for diameters 3/8 to 1/2 inch inclusive 3/64 inch for diameters 9/16 to 3/4 inch inclusive 1/16 inch for diameters 7/8 to 1-1/8 inches inclusive 3/32 inch for diameters 1-1/4 to 1-1/2 inches inclusive 5. In standing ropes: more than two broken wires in one lay in sections beyond end connections, or more than one broken wire at an end connection.

T00061

Correcting the Torsion of the Wire Rope 【 NOTICE】 】 ◆ Wire ropes may lose its structural elongation and be untwisted with use. Using such wire ropes for a long time can lead torsions to gather at the rope ends, damaging the wire ropes.

To settle twisting condition of the wire rope, rereeve the wire ropes regularly to remove the torsions on the rope ends. It is essential for a while after the wire rope has been replaced.

Removing Wire Rope

1. Extend the outriggers and place the boom in the over-rear or an over-side area.

Wire Ropes

177

Wire Ropes

T022624E

2. Fully lower the boom and lay the hook block on the

6. Wind the wire rope around a wooden spool while

ground.

hoisting down with the winch. ◆Pull on the wire rope as it is let out to prevent improper winding. Wear protective gloves.

T00067

3. Remove the rope socket from the hook block or

T00069

boom head.

7. When there is no wire rope left on the winch drum, 4. Detach the wire rope from the rope socket by removing the rope clip, then hammering the wedge out of its stuck position.

Rope clip

hammer the wedge out of the winch drum and wind up all the remaining wire rope.

Drum

Wedge

Wire rope Wedge

Wire rope

Hammer Steel rod

T00070E

Rope socket T21585E-2

5. Pull the wire rope out of the hook block and weight for the anti-twoblock device.

Wire Ropes

178

Wire Ropes

T022624E

Installing Wire Rope

3. Operate the winch to wind the rope around the drum leaving enough rope for attaching it to the hook block. ◆Wind the rope slowly while applying tension to prevent improper winding. ◆Pay attention to the following when winding the rope: (1) The first wrap must be wound along the guide at the end of the drum. (See Fig. 1.)

(2) In the first layer of wraps, the rope should be fitted in the grooves made on the drum.

(3) When winding over a layer of wraps, the rope should be set in the valleys between the wraps. (See Fig. 2.)

◆When a wire rope is cut or treatment is applied to the ends, wrap the cut or treated ends with sheathing to prevent the strands from coming loose. Use an annealed low carbon steel wire covered with zinc plating. Wrap it around the wire rope.

The width of the sheathing should be two or three times the diameter of the rope.

Wire rope diameter (mm) Sheathing wire diameter (mm)

Less than 12 12 or more but less than 18 18 or more but less than 30 30 or more but less than 50

0.8 1.0 2.0 2.5

Fig. 1

Sheathing

Guide

T00073E

T20769E

Fig. 2

1. Reeve a new wire rope from the boom head or jib head to the winch drum. ◆Be sure to route the rope correctly.

2.

Flange projection

Secure the end of the wire rope to the winch drum with the wedge. ◆The wedge must be oriented correctly. Make sure that the end of the wire rope does not extend beyond the edge of the winch drum spool (lagging).

T00074E

4. After passing the rope through the weight for the anti-twoblock device, reeve it through the boom and hook block sheaves in the pattern appropriate to the number of parts of line. ◆For information on how to reeve the crane, see the "Reeving Wire Ropes" section.

Wedge T00072E

Wire Ropes

179

Wire Ropes

T022624E

5. Pass the rope through the rope socket and secure it to the socket with the rope clip. ◆Be sure to insert the wedge and attach the rope clip in the proper orientations. (D: wire rope diameter) ＊1: Cut the wire rope in 10D length.

Wire rope (＊1)

Wire rope

5D

Rope clip

5D

Wedge

Rope socket T21586E-2

6. Secure the rope socket to the hook block or boom head.

After Replacing Wire Rope ◆A new wire rope is prone to improper winding. Check the rope on the winch drum from time to time. If it is improperly wound, rewind it neatly. ◆When first using a new wire rope, lift light loads at low speeds in order to settle the strands. This practice helps prolong the life of the wire rope.

When the wire rope is replaced, the new wire rope wound around the winch drum will not have the proper tension. If a load is hoisted with the rope at improper tension, the wraps in an outer rope layer will become wedged between the wraps in an inner layer, possibly deforming the wire rope, or causing improper winding, broken wires, etc. Before actually lifting a load, apply the proper tension to the wire rope and rewind as follows:

1. Extend the boom, and unwind the wire rope until about three wraps are left on the winch drum.

2. Suspend a load to provide tension to the wire rope and then wind the rope tightly and slowly around the winch drum. Use a load weight obtained by the following equation: [Load weight] =[Allowable load per line]x0.3x[Number of parts of line] (For the allowable load per wire rope, see the "INFORMATION AND DATA" part.)

Wire Ropes

180

Wire Ropes

H000470E

INFORMATION AND DATA

T033141E

Major Specifications Conversion Table NOTE: Units (length, volume, mass, etc.): Both the US system (main) and the metric system (supplementary) are used, with corresponding values for the latter system given in ( ). For reference, conversion tables are provided.

Length conversion table millimeter, mm

centimeter, cm

meter, m

inch, in, "

foot, ft, '

1 10 1000 25.40 304.8

0.1 1 100 2.540 30.48

0.001 0.01 1 0.0254 0.3048

0.03937 0.3937 39.37 1 12

0.00328 0.03281 3.281 0.08333 1

mile, mi

kilometer, km

1 0.6214

1.6093 1

square meter, m2

square inch, in2

square foot, ft2

0.000001 0.0001 1 0.000645 0.09290

0.00155 0.155 1550 1 144

0.001076 10.764 0.006944 1

Area Conversion Table square millimeter, mm2 1 100 1000000 645.2 92903.0

square centimeter, cm2 0.01 1 10000 6.452 929.03

Volume Conversion Table cubic centimeter, cm3, cc

cubic meter, m3

cubic inch, in3

cubic foot, ft3

gallon, gal

cubic inch, in3

liter, lit,

1 1000000 16.39 28320

0.000001 1 0.0000164 0.02832

0.0610 61024 1 1728

0.0000353 35.31 0.000579 1

1 0.004329 0.2642

231 1 61.02

3.785 0.01639 1

Major Specifications

181

L

Major Specifications

T033141E

Mass Conversion Table gram, g

kilogram, kg

ounce, oz

pound, lb

metric ton, ton, t

1 1000 28.349 453.592 1000000 907185

0.001 1 0.02835 0.4536 1000 907.2

0.03527 35.27 1 16 35274 32000

0.0022 2.205 0.0625 1 2205 2000

0.001 0.00002835 0.0004536 1 0.9072

short ton, s. t

0.001102 0.00003125 0.0005 1.102 1

Pressure Conversion Table bar

kgf/cm2

1 0.9807 0.06895

lb/in2, psi

1.0197 1 0.07031

14.50 14.22 1

Work, Energy Conversion Table kgf.m

kgf.cm 1 100 13.83 1.1525

foot-pound, ft-lb

0.01 1 0.1383 0.01153

inch-pound, in-lb 0.8681 86.81 12 1

0.0723 7.233 1 0.08333

Centigrade-Fahrenheit Conversion Table °F

°C

°F

°C

°F

°C

°F

°C

-450 -400 -350 -300 -250

-267.78 -240.00 -212.22 -184.44 -156.67

-200 -150 -100 -50 0

-128.89 -101.11 -73.33 -45.56 -17.78

5 10 15 20 25

-15.00 -12.22 -9.44 -6.67 -3.89

30 35 40 45 50

-1.11 1.67 4.44 7.22 10.00

°F

°C

°F

°C

°F

°C

°F

°C

55 60 65 70 75

12.78 15.56 18.33 21.11 23.89

80 85 90 95 100

26.67 29.44 32.22 35.00 37.78

150 200 250 300 350

65.56 93.33 121.11 148.89 176.67

400 450 500 550 600

204.44 232.22 260.00 287.78 315.56

Major Specifications

182

Major Specifications

T033141E

Crane Specifications

Carrier Specifications

Maximum Total Rated Load (number of parts of line given in parentheses)

Engine ・・・・・・・・・・・・・・・ Model:Mitsubishi 6D16-TLEA Engine displacement ・・・・・460 in3 (7.545 liters) Tires ・・・・・・・・・・・・・・・・・ Front wheel: 29.5-25-22PR(OR) Rear wheel: 29.5-25-22PR(OR) Maximum traveling speed・・25 mph (40 km/h)

36.1 ft (11.0 m) boom ・・・・・・・130,000 lbs. x 10 ft (12) 49 ft (14.9 m) boom ・・・・・・・・・・91,000 lbs. x15 ft (8) 62.3 ft (19.0 m) boom ・・・・・・・・82,000 lbs. x12 ft (8) 75 ft (22.9 m) boom ・・・・・・・・・・47,400 lbs. x20 ft (4) 89 ft (27.1 m) boom ・・・・・・・・・・47,400 lbs. x15 ft (4) 102 ft (31.1 m) boom ・・・・・・・・・34,700 lbs. x20 ft (4) 114.8 ft (35.0 m) boom ・・・・・・・28,800 lbs. x25 ft (4) 32.2 ft (9.8 m) jib (5° offset)・・・12,300 lbs. X 80° (1) 32.2 ft (9.8 m) jib (30° offset) ・・・6,100 lbs. X 80° (1) 56.1 ft (17.1 m) jib (5° offset) ・・・6,100 lbs. X 80° (1) 56.1 ft (17.1 m) jib(30° offset) ・・・2,400 lbs. X 80° (1) Single top ・・・・・・・・・・・・・・・・・12,300 lbs.

(1)

Lifting Height, Boom Length, Boom Angle and Speeds Maximum lifting height ・・・・Boom: 117.8 ft (35.9 m) Jib: 172.3 ft (52.5 m) Maximum load radius ・・・・・Boom: 108 ft (32.9 m) Jib: 145 ft (44.2 m) Boom length・・・・・・・・・・・・36.1´ to 114.8´ (11.0 m to 35.0 m) Boom extension speed ・・・・78.7´ (24 m)/153 sec.

Jib length ・・・・・・・・・・・・・・32.2´ (9.8 m), 56.1´ (17.1 m) Main winch line speed ・・・・469 fpm (143 m/min) (at the 4th layer) Auxiliary winch line speed ・・404 fpm (123 m/min) (at the 2nd layer) Boom elevation angle ・・・・・-1.5° to 80° Elevation speed ・・・・・・・・・-1.5° to 80°/68 sec.

Swing angle ・・・・・・・・・・・・360° continuous Swing speed ・・・・・・・・・・・2.4 min-1｛rpm｝

Major Specifications

183

Major Specifications

T033141E

Overall Dimensions No. Dimension 1. ・・・・・・・・・・・・・・・・・・・ 11´ 5 5/8˝ (3,367 mm) 2. ・・・・・・・・・・・・・・・・・・・ 12´ 6 15/16˝ (3,833 mm) Max. extension width・・・ 23´ 7 1/2˝ (7,200 mm) 3. Mid. extension width ・・・ 21´ 11 3/4˝ (6,700 mm) Mid. extension width ・・・ 18´ 1/2˝ (5,500 mm) 4. ・・・・・・・・・・・・・・・・・・ φ1´ 7 2/3˝ (500 mm) 5. ・・・・・・・・・・・・・・・・・・・ 11´ 7 11/16˝ (3,548 mm) 6. ・・・・・・・・・・・・・・・・・・・ 11´ 11 13/16˝(3,652 mm) 7. Overall width・・・・・・・・・ 10´ 10 1/2˝ (3,315 mm) 8. ・・・・・・・・・・・・・・・・・・・ 13´ 6 1/4˝ (4,120 mm) 9. Departure angle・・・・・・・ 14.6° 10. ・・・・・・・・・・・・・・・・・・ 7´ 4 3/8˝ (2,245 mm) 11. Wheel base・・・・・・・・・ 12´ 11 1/2˝ (3,950 mm) 12. ・・・・・・・・・・・・・・・・・・ 6´ 4 1/4˝ (1,937 mm) 13. Approach angle ・・・・・・ 18.6° 14. ・・・・・・・・・・・・・・・・・ 24´ 4 5/16˝ (7,435 mm) 15. Overall length ・・・・・・・ 44´ 8 2/3˝ (13,630 mm) 16. Overall height ・・・・・・・ 12´ 4 3/4˝ (3,780 mm)

1

2 8

7

3

4 6

5

16

13

9 12

11

10

14 15 T03008

Major Specifications

184

Major Specifications

T033141E

Mass

Wire Rope Specifications

Carrier Mass Gross vehicle mass Front axle load Rear axle load

Configuration :7 x 7 + 6 x WS(31)o/o Allowable load :11,900 lbs (5,400 kg) Ultimate :27.3 short tons Wire rope for (failure) load (24.8 tons) main winch Diameter :3/4˝ (19.0 mm) Length :672´ (205 m)

:93,100 lbs (42,200 kg) :46,550 lbs (21,100 kg) :46,550 lbs (21,100 kg)

Hook Block Mass

mass :1.07 lbs/ft (1.59 kg/m) Configuration :7 x 7 + 6 x WS(31)o/o Allowable load :12,300 lbs (5,600 kg) Ultimate :27.3 short tons Wire rope for (failure) load (24.8 tons) auxiliary winch Diameter :3/4˝ (19.0 mm) Length :380´ (116 m) mass :1.07 lbs/ft (1.59 kg/m)

Main hook block mass (65 short tons) :1,320 lbs (600 kg) Auxiliary hook block mass (6.2 short tons) :330 lbs (150 kg) Main hook block

Auxiliary hook block

Other Maximum vertical load capacity of outrigger ・・・・・・・・・・・・・・・・・・・・・・・・・・97,000 lbs (44,000 kg) Tire air pressure T00637E

29.5-25-22PR Travel 50 psi (3.5 kgf/cm2) On-rubber operation 60 psi (4.2 kgf/cm2)

Relief Valve Pressure Winch hoist up circuit :3980 ± 70 psi (280 ± 5 kgf/cm2) Winch hoist down circuit:1280 ± 70 psi (90 ± 5 kgf/cm2) Boom raising circuit :2990 ± 70 psi (210 ± 5 kgf/cm2) Boom lowering circuit : 710 + 700 psi (50 + 50 kgf/cm2) Boom extending circuit :3130 ± 70 psi (220 ± 5 kgf/cm2) Boom retracting circuit :2770 ± 70 psi (195 ± 5 kgf/cm2) Swing circuit :2840 + 700 psi (200 + 50 kgf/cm2)

Major Specifications

185

Major Specifications

T025091E

Oils and Greases Table The oils and greases listed below are used in new cranes at time of shipment from the factory.

Component Brand (manufacturer) 1 Side and bottom surfaces of boom 2 Slide plates (top surface of boom) TNR (TADANO Genuine Grease) 3 Slide plates (bottom surface of boom) 4 Wire rope (for winch) Mobilarma 798 (Mobil) 5 Wire rope (for extending boom) 6 Swing bearing 7 Swing gear 8 Rotary joint 9 Jib connecting pin boss 10 Pin (for jib to sheave) 11 Pin (for elevating cylinder lower pivot) Daphne Colonex Grease EP No. 2 12 Boom pivot pin (Idemitsu) (*1) 13 Main hook block

Upper structure

Oil or grease No.

Lower structure

Grease

Gear oil

14 Auxiliary hook block (*1) 21 Outrigger floats 22 Propeller shaft 23 Axle oscillation lock cylinder 24 King pin 25 Steering cylinder 26 Tierod end 27 Axle oscillation center pin 1 Winch speed reducer 2 Swing speed reducer 3 Axle (carrier axle) 4 Axle (planetary gear)

Hydraulic 1 oil Engine oil 1 Torque 1 converter oil Brake fluid 1

Hydraulic oil tank Engine Torque converter Brake fluid reservoir

Capacity/Quantity

As required

Molybdenum Grease No.2 (Cosmo oil) Daphne Colonex Grease EP No. 2 (Idemitsu)

Molybdenum Grease No.2 (Cosmo oil) Daphne Colonex Grease EP No. 2 (Idemitsu)

Mobilgear 632 (Mobil) Cosmo Gear GL-5 90 (Cosmo oil) TADANO Hydraulic Oil LL (TADANO Genuine Hydraulic Oil) Mobil Delvac 1330 (Mobil) TADANO Genuine Torque Converter Oil TADANO Genuine Brake Fluid DOT 5.1

Coolant

1 Radiator

TADANO Genuine Long-life Coolant

Fuel

1 Fuel tank

ASTM/D-975 Grade 2-d

1.06 gal (4.0 lit.) x 2 0.85 gal (3.2 lit.)

6.3 gal (24 lit.) x 2 1.32 gal (5.0 lit.) x 4 195 gal (740 lit.) (*2) 260 gal (985 lit.) (*3) 4.23 gal (16 lit.)

7.93 gal (30 lit.) (*3) 0.45 gal (1.7 lit.)

9.51 gal (36 lit.) (*4) 4.28 gal (16.2 lit.) (*5) 79.26 gal (300 lit.) (*2)

*1: Option *2: Tank capacity *3: Total capacity *4: Total water volume *5: Necessary volume of Long-life coolant when mixing ratio is 45 %

Oils and Greases

186

Oils and Greases

T025091E

Recommended Oils and Greases Greases ■: Greases used in new cranes Component

Boom

Wire rope

Ambient temperature TADANO Genuine

Other

King pin, tierod end

-4°F to 104°F (-20°C to 40°C) -22°F to 86°F (-30°C to 30°C) ■TNR

Grease Idemitsu Japan Energy

■Daphne Colonex

Daphne Grease XLA

Grease EP No. 2

No. 2

JOMO Lesonix Grease

JOMO LT Grease No. 2

EP-2 Nippon Oil

Epnoc Grease AP2

Epnoc Grease LT2

Shell

Alvania EP Grease 2

Alvania Grease RA

Esso

Lithtan EP2

Beacon 325

Mobilux EP2

Mobilgrease 22

■Mobilarma 798

Mobil

■Molybdenum

Cosmo Oil

Grease No.2

Gear Oils ■: Oils used in new cranes Axle

Component

Winch speed reducer, swing speed reducer ISO VG 320

Type

API Service Class GL-4

API Service Class GL-5

Idemitsu

Apolloil Gear HE90

Apolloil Gear HE-S90

Daphne Super Gear Oil 320

Japan Energy

JOMO Gear 4 90

JOMO Gear 5 90

JOMO Reductus 320

Gearlub EHD90

Bonnoc SP 320

Nippon Oil Shell

Spirax EP90

Esso

Esso Gear Oil GP 80W-90 Standard Super Gear Oil 90 Spartan EP 320

Mobil

Pegasus Gear Oil 90

Cosmo Oil

Oils and Greases

Omala Oil 320 Mobilube HD 80W-90

■Mobilgear 632

■Cosmo Gear GL-5 90

187

Oils and Greases

T025091E

Hydraulic Oils ■: Oils used in new cranes Component Type ISO VG 68 Ambient temperature 32°F to 95°F (0℃ to 35℃) Operating temperature range 41°F to 176°F (5℃ to 80℃) Allowable temperature range 32°F to 194°F (0℃ to 90℃) TADANO Genuine Hydraulic oil Idemitsu Japan Energy Nippon Oil Shell Esso Mobil

─

Hydraulic oil tank ISO VG 46 ISO VG 32 23°F to 77°F (-5℃ to 25℃) 14°F to 59°F (-10℃ to 15℃) 32°F to 158°F (0℃ to 70℃) 23°F to 140°F (-5℃ to 60℃) 23°F to 176°F (-5℃ to 80℃) 14°F to 158°F (-10℃ to 70℃) ■TADANO Hydraulic Oil LL

Daphne Super Hydraulic Fluid 68 JOMO Hydlux 68 Super Hyrando 68 Tellus Oil 68 Nuto H 68 Mobil DTE 26

Daphne Super Hydraulic Fluid 46 JOMO Hydlux 46 Super Hyrando 46 Tellus Oil 46 ─ Mobil DTE 25

Daphne Super Hydraulic Fluid 32 JOMO Hydlux 32 Super Hyrando 32 Tellus Oil 32 Nuto H 32 Mobil DTE 24

◆If a hydraulic oil rather than TADANO Genuine "TADANO Hydraulic Oil LL" is used, reduce the replacement interval to the half for "TADANO Hydraulic Oil LL".

Engine Oils ■: Oils used in new cranes Component Type Ambient temperature SAE viscosity index Idemitsu Japan Energy Nippon Oil Shell Esso Mobil Cosmo Oil

Oils and Greases

Over 86°F (30℃) SAE 40

Engine API Service Class CD 23°F to 104°F (-5℃ to 40℃) 5°F to 59°F (-15℃ to 15℃) SAE 30 SAE 20W-20

32°F (0℃) or below SAE 10W-30

■Mobil Delvac 1330

188

Oils and Greases

T025091E

Torque Converter Oils ■: Oils used in new cranes Component

Torque Converter, Transmission

Type

GM Dexlon II or Ford M2C33F

Ambient Temperature Over 86°F (30°C) TADANO Genuine

■TADANO Genuine Torque Converter Oil

Idemitsu

Apolloil Dexlon

Japan Energy

JOMO ATF Special

Nippon Oil Shell

Dexlon II

Esso

Esso ATF

Mobil

Mobil ATF220

Brake Fluids ■: Oils used in new cranes Component

Brake fluid reservoir

TADANO Genuine

■TADANO Genuine Brake Fluid DOT5.1

British Petroleum

BP Brake Super DOT 4

PENTOSIN

PENTOSIN Super DOT 4

TEXTAR

TEXTAR Super DOT 4

Ate

Ate Super DOT 4

M.Benz

DOT 4 PLUS

Oils and Greases

189

Oils and Greases

T029402E

Consumable Parts Filters ◆For locations and instructions on how to replace the filters, see the "Hydraulic System" section. ◆Engine filters are shown in the engine parts catalog.

No. 1 2 Hydraulic 3 system 4 5 Engine 1 1 Torque converter system 2

Filter (location) Return filter (hydraulic oil tank) Air breather (hydraulic oil tank) Line filter (automatic stop circuit) Line filter (steering circuit) Line filter (winch brake circuit) Air cleaner Line filter Line filter (transmission)

Consumable part Filter element Element Filter element Filter element Filter element Element Element Element

Part No. 366-707-50010 336-600-07510 366-455-45010 366-725-30000 366-037-65010 347-804-37540 366-712-75010 363-504-65380

Fuses ◆For instructions on how to replace fuses, see the "Electrical System" section.

OFF

3A（361-167-95080） 2A（361-167-95090）

Lo Hi

5A（821-000-01837） 10A（821-000-01839） 15A（821-000-01840）

5A（821-000-01837） 10A（821-000-01839） 15A（821-000-01840） 20A（821-000-01841） 65A（821-741-03527）

Consumable Parts

190

T05248

Consumable Parts

T005541E

Hand Signals Hand signals shown are an excerpt from ASME B30.-5-1994.

T101542E

T101543E

T101544E

HOIST. With forearm vertical, fore- LOWER. With arm extended down- USE MAIN HOIST. Tap fist on head; then use regular signals. finger pointing up, move hand in ward, forefinger pointing down, small horizontal cicle. move hand in small horizontal circle.

T101545E

T101546E

USE WHIPLINE(Auxiliary Hoist).

RAISE BOOM. Arm extended, Tap elbow with one hand: then use fingers closed, thumb pointing regular signals. upward.

T101547E

LOWER BOOM. Arm extended, fingers closed, thumb pointing downward.

T101548E

T10154E

T101550E

MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal.

(Hoist slowly shown as example.)

RAISE THE BOOM AND LOWER THE LOAD. With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired.

LOWER THE BOOM AND RAISE THE LOAD. With arm extended, thumb pointing down, flex fingers in and out as long as load movement is desired.

Hand Signals

191

Hand Signals

T005541E

T101551E

SWING. Arm extended, point with finger in direction of boom.

T101552E

T101553E

STOP. Arm extended, palm down, EMERGENCY STOP. Both arms move arm back and forth extended, palms down, move arms horizontally. back and forth horizontally.

T101556E

T101554E

TRAVEL. Arm extended forward, hand open and sligtly raised, make pushing motion in direction of travel.

T101555E

DOG EVERYTHING. Clasp hands in front of body.

TRAVEL(Both Tracks). Use both fists in front of body, making a circular motion about each other, indicating direction of travel, forward or backward.

(For land cranes only.)

T101557E

TRAVEL(One Track). Lock the track T101558E on side indicated by raised fist.

EXTEND BOOM(Telescoping Travel opposide track in direction Booms). Both fists in front of body indicated by circufar motion of other fist, rotated vertically in front with thumbs pointing outward. of body. (For land cranes only.)

Hand Signals

192

T101559E

RETRACT BOOM(telescoping Booms). Both fists in front of body with thumbs pointing toward each other.

Hand Signals

T005541E

T101560E

T101561E

EXTEND BOOM (Telescoping Boom).

One Hand Signal. One fist in front of chest with thumb tapping chest.

RETRACT BOOM (Telescoping Boom). One Hand Signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest.

Hand Signals

193

Hand Signals

MEMO

194

H490E

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2001 PRINTED IN JAPAN 0112 E