Maeda CC1485S-1 - Inspection and Maintenance

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225

INSPECTION AND

MAINTENANCE

1. PRECAUTIONS FOR MAINTENANCE

226

2. BASIC MAINTENANCE 228

3. LEGAL INSPECTION 232

4. PERIODIC REPLACEMENT OF CRITICAL PARTS 233

5. CONSUMABLES

234

6. OTHER REPLACEMENT PARTS 235

7. USE OF FUEL AND LUBRICATING OIL 236

8. STANDARD TIGHTENING TORQUE

238

9. LIST OF ITEMS FOR INSPECTION AND MAINTENANCE 239

10. MAINTENANCE PROCEDURES 241

11. AIR BLEEDING OF HYDRAULIC CIRCUITS

284

12. RELIEVING INTERNAL PRESSURE OF HYDRAULIC CIRCUIT

288

13. ATTACHING/DETACHING SINGLE-FALL HOOK 289

Main Page

Table of Contents3
Item Page4
Introduction9
Introduction10
For Safe Use of the Machine11
Machine Overview12
- Specified Operations12
- Machine Structure12
- Machine Functions13
Qualification for Operation14
- Qualification for Crane Operation14
Crane Terminology15
- Terms and Definitions15
- Diagram of Working Radius and Lifting Height16
- Rated Total Load Chart17
Craneterminology15
Safety21
Basic Precautions22
- Precautions before Starting Work22
- Preparing for Safe Operation23
- Precautions for Fire Prevention25
- Cautions in Getting on and off the Machine26
- Other Precautions27
Operation Related Precautions28
- Precautions on Work Site28
- Cautions When Starting Engine31
- Precautions for Starting Carrier and Operating Crane33
- Cautions During Crane Operation37
Transport Precautions45
Maintenance Precautions47
- Precautions before Maintenance47
- Precautions During Maintenance51
Safety Label Locations56
Operation67
Name of each Section68
- Machine Units68
- Crane Operation Units69
  - Machine Monitor Components70
Explanation of All Equipment71
- Machine Monitor71
  - Monitor Basic Action and Display73
  - Warning Display80
- Switches83
- Operation Levers and Pedals93
- Moment Limiter (Overload Preventive Device)97
  - Configuration of Moment Limiter97
  - Functions of Moment Limiter98
  - Moment Limiter Operation and Canceling (Recovery)99
  - Moment Limiter Functions102
  - Moment Limiter Canceling Switch110
- Overwinding Prevention Device112
- Air Conditioner Handling113
  - Components of Control Panel113
  - Air Conditioner Operation Method117
  - Precautions in Air Conditioner Use119
  - Inspection and Maintenance of Air Conditioner Installed on the Machine119
- Car Radio Handling120
  - Explanation of the Equipment120
  - Car Radio Operation Method123
  - Precautions in Car Radio Use125
- Fuse126
- Fusible Link127
- Controller128
- Cab Front Window129
- Door131
- Hammer for Emergency Escape132
- Cap and Cover with Lock133
- Battery Room Door134
- Left Cover134
- Right Cover135
- Machinery Cover136
- Holder for Operation Manual136
- Grease Pump Holder137
- Cup Holder137
- Retractable Seat Belt Handling137
Operation138
- Pre-Operation Inspection138
  - Checking before Starting Engine138
  - Inspection Around Crane139
  - Inspection of Wire Rope139
  - Inspection of Hook Block139
  - Inspection Around Upper Slewing Body140
  - Inspection of Cabin140
  - Inspection Around Carrier140
  - Checking before Starting Engine141
  - Inspection before Starting Engine (Refer to Item "Operation 3.1.2".)141
  - Checking/Refilling Engine Coolant141
  - Checking/Refilling Oil Level in Engine Oil Pan141
  - Checking/Refueling Fuel Level in Fuel Tank143
  - Checking/Refilling Oil Level in Hydraulic Oil Tank144
  - Inspection of Dust Indicator145
  - Draining Contaminant Water/Deposits in Fuel Tank147
  - Inspecting Electric Wiring148
  - Checking Working Lamp148
  - Checking Horn for Operation148
  - Adjusting the Operator's Seat149
  - Adjustment of Mirrors150
  - Adjusting Mirror for Checking Irregular Winding151
  - Angle Adjustment of Rear View Camera152
  - Checking Battery Electrolyte Level153
  - Checking after Starting Engine155
  - Inspection before Starting Engine (Refer to Item "Operation 3.1.3".)155
  - Checking Ease of Engine Cranking and Abnormal Noise155
  - Checking Low Speed and Acceleration State of Engine155
  - Checking Engine Exhaust Gas Colour, Abnormal Noise and Vibration155
  - Checking Crane Operations156
  - Checking over Hoist Prevention Device156
  - Inspection of Moment Limiter156
- Operations and Checks before Starting Engine158
- Starting Engine159
- Operations and Checks after Starting Engine161
  - Warm-Up Operations for Engine161
  - Warm-Up Operations for Hydraulic Equipment162
- Stopping Engine164
- Break-In Operation165
- Machine Travelling Posture165
- Starting (Forward and Backward)/Stopping the Machine166
- Changing Direction of the Machine169
- Slewing the Machine170
- Parking the Machine171
- Inspection and Check after Completing Work172
  - After Stopping Engine172
  - Locking172
- Cautions in Driving173
- Precautions before Crane Operation176
- Operation before Crane Work178
- Crane Operation Posture180
- Hoisting and Lowering Operation181
  - Normal Hoisting and Lowering Operation181
  - Hoisting and Lowering Operation at High Speed182
  - Hoisting Operation with Hook Stowage Switch183
- Boom Derricking Operation184
- Boom Telescoping Operation185
- Slewing Operation187
- Accelerator Operation188
- Crane Stowage Operation190
  - Crane Stowage Operation at the Time of Simple Stowage of Hook Block190
  - Crane Stowage Operation at the Time of Normal Stowage of Hook Block193
- Prohibited Operations During Crane Work195
- Operation During Travelling Hoist197
  - Precautions in Operation During Travelling Hoist197
  - Operation Posture During Travelling a Hoisted Load198
  - Operation of Travelling a Hoisted Load Work199
  - Cancel Operation of Travelling Hoist Operation Posture199
Handling of Wire Rope200
- Criteria for Wire Rope Replacement200
- Winch Wire Rope Reeving System and Gross Rated Load202
- Measure to Take When Winch Wire Rope Is Twisted203
Transportation205
- Loading/Unloading205
- Hoisting Machine210
  - Hoisting Machine with Boom Lowered210
  - Hoisting Machine with Boom212
- Cautions During Transportation213
Handling When Cold214
- Preparing for Low Temperature214
Long-Term Storage216
- Before Storing Machine216
- During Storage216
- After Storage217
Troubleshooting218
- When Fuel Runs out218
- Phenomenons that Are Not a Fault219
- When Battery Has Discharged220
- When such a Phenomenon Occurs225
Inspection and Maintenance233
Precautions for Maintenance234
Basic Maintenance236
Legal Inspection240
Periodic Replacement of Critical Parts241
Consumables242
Other Replacement Parts243
Use of Fuel and Lubricating Oil244
- Use of Fuel and Lubricating Oil According to Temperatures244
Standard Tightening Torque246
- Standard Tightening Torque List246
List of Items for Inspection and Maintenance247
Maintenance Procedures249
- Initial 500 Hour Maintenance249
- Initial 500-Hour Maintenance249
- Pre-Operation Inspection249
- Oil Replacement in Winch Reduction Gear Case249
- Irregular Maintenance250
- Replacement of Winch Wire Rope250
- Checking/Adjusting Main Boom Telescoping Wire Rope255
- Checking/Cleaning/Replacing Air Cleaner256
- Cleaning Engine Cooling System258
- Checking and Re-Tightening Rubber Track Bolts261
- Checking/Adjusting Rubber Track Tension261
- Checking/Replenishing Window Washer Solution263
- Checking and Servicing Air-Conditoner264
- Checking/Cleaning/Greasing Door Rails and Rollers265
- Maintenance Every 50 Hours [1] Greasing Machine Units266
- Levelling Instrument266
- Maintenance Every 250 Hours268
- Checking/Refilling Oil Level in Travelling Motor Reduction Gear Case268
- Oil Level Check and Refilling in Winch Reduction Gear Case269
- Checking/Adjusting Fan Belt Tension270
- Checking/Adjusting Air-Compressor Belt Tension271
- Maintenance Every 500 Hours272
- Replacing Oil in Engine Oil Pan and Replacing Engine Oil Filter Cartridge272
- Checking/Refilling Swing Pinion Grease Amount274
- Greasing Swing Circle274
- Checking/Cleaning Radiator Fins, Oil Cooler Fins, after Cooler Fins and Air-Condenser Fins275
- Filters276
- Replacement of Hydraulic Oil Tank Breather Element277
- Oil Replacement in Winch Reduction Gear Case (for the First Time Only)278
- Replacing the Fuel Pre-Filter Cartridge279
- Replacing the Main Fuel Filter Cartridge280
- Replacing the Fuel Feed Pump Filter281
- Maintenance Every 1000 Hours282
- Oil Replacement in Travelling Motor Reduction Gear Case282
- Oil Replacement in Winch Reduction Gear Case283
- Replacement of Hydraulic Oil Return Filter Cartridge284
- Replacement of Hydraulic Oil Line Filter Element286
- Maintenance Every 1500 Hours [1] Cleaning Egr Cooler287
- Maintenance Every 3000 Hours [1] Checking/Cleaning Egr Valve287
- Checking Alternator and Starter287
- Inspection/Adjusting Engine Valve Clearance287
- Measuring Compression Pressure287
- Maintenance Every 4000 Hours288
- Inspection of Water Pump288
- Replacement of Accumulator288
- Maintenance Every 5000 Hours289
- Replacing Oil in Hydraulic Oil Tank and Cleaning Strainers289
Venting Air in Hydraulic Circuits292
- Air Bleeding of Hydraulic Circuits292
Relieving Internal Pressure of Hydraulic Circuit296
Attaching/Detaching Single-Fall Hook297
- Attaching Single-Fall Hook297
- Detaching Single-Fall Hook300
Specifications303
Principle Specification List304
Specification Dimensional Drawing305
Rated Total Load Chart306
Working Radius/Lifting Height309
- Item Page311
Fly-Jib311
Precautions of Fly-Jib Operation312
Safety Label Location314
Fly-Jib each Section317
Fly-Jib Installation and Stowage318
- Installation of Fly-Jib319
- Changing of Fly-Jib Tilt Angle327
- Extending and Retracting No.2 Fly-Jib329
- Stowage of Fly-Jib333
- Removal of Fly-Jib338
- Installation of Fly-Jib343
Handling Monitor and Moment Limiter350
- Names of Monitor Display350
  - Monitor Display in Fly-Jib Mode350
  - Monitor Display When Fly-Jib Is Stowed352
- Moment Limiter Functions353
  - Display for Fly-Jib Mode Switching354
- Setting of Operating Conditions355
Operations356
- Cautions for Fly-Jib Operation356
Troubleshooting357
- List of Error Codes357
- When such a Phenomenon Occurs358
Inspection and Maintenance359
- Checking before Operation359
- Maintenance Every 50 Hours361
Specifications362
- Specification Table362
- Specification Dimensional Drawing363
- Rated Total Load Chart364
- Working Radius/Lifting Height365
  - Working Radius/Lifting Height (When Fly-Jib Angle Is 0 Degrees and 20 Degrees)365
  - Working Radius/Lifting Height (When Fly-Jib Angle Is 40 Degrees and 60 Degrees)366

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Table of Contents

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