Mounting and Dismounting Counterweights

Warning

To prevent accidents, never let anyone enter the area under the lifted load when lifting up the counterweights.

Do not step foot under the counterweight when they are lowered onto the frame.

Use the snap pins to secure the fixing pins (for counterweights No. 1, No. 2 and No. 3) and the counterweight cylinder fixing pins in position.

Components

◆ Mount the counterweight in numerical order shown in the figure below.

Counterweight control switch

Counterweight cylinder

COUNTERWEIGHT CONTROL

Counterweight cylinder fixing pin

Fixing pin (for counterweight No. 1)

Fixing pin (for counterweight No. 2)

Fixing pin (for counterweight No. 3)

Stowing bolt A

Counterweight No.1 (3,700 lbs.)

Counterweight No.2 (4,000 lbs.)

Counterweight No.3 (8,000 lbs.)

Counterweight No.1 or No.2

Stowage support

Front

Upper face of the carrier frame

Stowing bolt B

Counterweights No.1 + No.2 or Counterweight No.3

Stowage support

T30444E

Combination of Counterweights

Combination of counterweights is described below:

CombinationMass (lbs.)

None0

Counterweight No. 13,700

Counterweights No. 1 + No. 27,700

Counterweights No. 1 + No. 2 + No. 315,700

Dismounting the Counterweights

◆ Before dismounting the counterweights, set the crane as follows:

• Extend the outriggers and set the crane level.

• Retract the boom fully, swing it to over-rear, and insert the swing lock pin.

The following steps describe the dismounting procedure when counterweights No. 1+No. 2+No. 3 are mounted on the crane.

1. Operate the swing brake switch to the ON position.

2. Operate the counterweight control switch to “UP” to retract the counterweight cylinder. The clearance will be arranged in the pin hole. Then pull out the fixing pins (for counterweight No. 1).

3. Operate the counterweight control switch to “DOWN” to extend the counterweight cylinder. The counterweight will be lowered onto the stowage support.

4. Pull out the following pins corresponding to the counterweights to be dismounted:

• When dismounting counterweight No. 3: Pull out the fixing pins (for counterweight No. 3).

• When dismounting counterweights No. 2+No. 3: Pull out the fixing pins (for counterweight No. 2).

• When dismounting counterweights No. 1+No. 2 +No. 3: Pull out the counterweight cylinder fixing pins.

Counterweight cylinder fixing pin

Fixing pin (for counterweight No. 1)

Fixing pin (for counterweight No. 2)

Fixing pin (for counterweight No. 3)

WARNING

Do not stow the boom on the boom rest while the counterweights No. 1 + No. 2 + No. 3 or counterweights No. 2 + No. 3 are placed on the frame. The elevating cylinder will hit the counterweight and be damaged.

7. Release the swing lock and swing brake. Swing the boom to over-front and fix the dismounted counterweights to the carrier frame or unload them from the carrier frame.

◆ When the counterweights are fixed to the carrier frame, possible patterns of counterweight combination are as follows. Use the stowing bolt A or B depending on the counterweight combination.

• Counterweight No. 1 or No. 2: Use the stowing bolt A (short).

T30449E

5. Operate the counterweight control switch to “UP” to retract the counterweight cylinder fully.

◆ When all the counterweights No. 1, No. 2 and No. 3 are dismounted, skip the steps 5. and 6.

• Counterweights No. 1+No. 2 or No. 3: Use the stowing bolt B (long). COUNTERWEIGHT CONTROL T30450

6. Insert the fixing pins (for counterweight No. 1). Counterweight No. 1 or counterweights No. 1+No. 2 will be fixed.

Mounting the Counterweights [NOTICE]

◆ Before mounting the counterweights, extend the outriggers and set the crane level.

1. Place the counterweights on the carrier frame and connect them using the fixing pins.

◆ Use the provided sling to lift up or down the counterweight.

• When mounting the counterweights No. 2 + No. 3: Connect the counterweights No. 2 and No. 3 using the fixing pins for counterweight No. 3.

Fixing pin (for counterweight No. 3)

Counterweight No.3

T30452E

• When mounting the counterweight No. 3 only: Connecting is not necessary.

2. Swing the boom to over-rear and insert the swing lock pin.

3. Operate the swing brake switch to the ON position.

The mounting procedure varies depending on the patterns of the counterweight combination.

• When mounting the counterweights No. 1 + No. 2 + No. 3: Connect the counterweights No. 1, No. 2 and No. 3 using the fixing pins for counterweights No. 2 and No. 3.

Fixing pin (for counterweight No. 2)

4. Operate the counterweight control switch to “UP” to retract the counterweight cylinder. The clearance will be arranged in the pin hole. Then pull out the fixing pins (for counterweight No. 1).

Fixing pin (for counterweight No. 3)

Fixing pin (for counterweight No. 1)

T24736E

◆ Take this step only when counterweight No. 1 or counterweights No. 1 + No. 2 are mounted on the revolving structure.

5. Operate the counterweight control switch to “DOWN” to extend the cylinder until its rod is aligned with the pin hole, and insert the fixing pin.

◆ Use the pin hole corresponding to the counterweight combination as follows:

･ When mounting the counterweights No. 1 + No. 2 + No. 3: Use the counterweight cylinder mounting pin hole for counterweight No. 1.

･ When mounting the counterweights No. 2 + No. 3: Use the fixing pin hole between counterweights No. 1 and No. 2.

･ When mounting the counterweight No. 3 only: Use the fixing pin hole between counterweights No. 2 and No. 3.

6. Operate the counterweight control switch to “UP” to lift up the counterweights.

7. After making sure that the fixing pins (for counterweight No. 1) are aligned with the pin hole, insert the fixing pins (for counterweight No. 1) to fix the counterweight to the revolving structure.

8. Release the swing brake and the swing lock.

Counterweight Mounting/Dismounting Position Indicator (Option)

This device provides an indication of the swing stop position where the counterweight should be placed on the revolving structure and the carrier frame.

1. Swing the boom to the over-rear until the indicator lamp lights up.

◆ The swing range where the indicator lamp is lit is extremely narrow. Swing the boom slowly.

Counterweight mounting/dismounting position indicator lamp

Dolly Traveling

Before Traveling

Warning

Prior to shifting the selector levers for swing motor, swing brake and elevating cylinder to the dolly position, make sure that the boom is surely mounted on the dolly. Shifting the levers while the boom is not surely supported on the dolly may make the boom swing or fall down. This is a very dangerous practice.

Before traveling with a dolly (trailer) coupled to the carrier, check that the selector levers for swing motor, swing brake and elevating cylinder are locked in place with the lock. Incorrect operation of the levers may cause a serious accident.

If the dolly travel failure warning buzzer in the carrier cab sounds while traveling with a hitched dolly (trailer), it indicates that the swing brake release pressure produced by the swing brake releasing hydraulic system is too low, a critical condition that may lead to a serious accident. Should this situation occur, stop the vehicle immediately. Reparation needs specialistic skills. Contact our distributor or dealer. Do not travel the dolly till reparation is accomplished. Traveling the dolly unrepaired is a very dangerous attempt.

To travel with a dolly hitched to the rear of the carrier, it is required that the hydraulic circuits for the boom elevating cylinder, swing motor and swing brake be free so that the boom can follow the movements of the dolly while traveling.

Follow the procedure below to set the hydraulic circuits for the boom elevating cylinder, swing motor and swing brake free.

1. Connect the dolly to the rear of the vehicle.

2. Mount the boom on the dolly and fix it.

3. 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.

[NOTICE]

◆ When setting the swing brake circuit free, release the swing brake and wait for a minute in order to increase hydraulic pressure enough to set the swing brake circuit free. If the increase does not reach the specified level, the swing circuit free-sustainable period will be shortened.

4. Turn the selector levers for the swing motor and swing brake in the direction indicated by the arrow to set the circuits free. Lock the levers with the lock after turning them.

After Traveling (Preparation for Crane Operation)

WARNING

Crane operation with wrong lever positions may cause serious accidents. Before crane operation, make sure that hydraulic circuits for the elevating cylinder, swing motor and swing brake have been shifted from free conditions for traveling to locked conditions for crane operation. Also confirm that the selector lever for swing brake is locked up at the correct position.

Before crane operation, hydraulic circuits for the elevating cylinder, swing motor and swing brake need to be locked. Follow the procedure as follows:

1. Adjust the carrier position so that the boom faces straight backward.

5. Turn the selector lever for elevating cylinder in the direction indicated by the arrow to set the circuit free. Lock the lever with the lock after turning it.

2. Turn the selector levers for swing motor and swing brake in the direction indicated by the arrow to lock the circuits. Lock the levers with the lock after turning them.

Now the preparation for traveling with a dolly is completed.

3. Turn the selector lever for elevating cylinder in the direction indicated by the arrow, and lock the circuit. Lock the lever with the lock after turning it.

For elevating cylinder

T30457E

WARNING

After locking each lever, make sure that the boom elevates and swings properly. Then start the crane operation.

4. Now the preparation for crane operation is completed. Separate the dolly from the carrier.