10000a-1 T4F Com CTR250-01 01-28-16

OPERATOR MANUAL
This manual has been prepared for and is considered part of -
10000A-1
Model Number
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XXXXXRef
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Serial Number
This Manual is divided into the following sections:
IMPORTANT INFORMATION
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SECTION 1 SAFETY
SECTION 2 OPERATION
SECTION 3 LOAD SAFETY DEVICE
SECTION 4 ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY
SECTION 5 ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
SECTION 6 WIRE ROPE
SECTION 7
SECTION 8
SECTION 9
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MAINTENANCE
REFERENCE MATERIAL
DIAGRAM
NOTICE
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The serial number of the crane is the only method the Manitowoc Crane Care Lattice
Team has of providing you with correct parts and service information.
Always furnish serial number of crane when ordering parts or discussing service
problems with your Manitowoc distributor or the Manitowoc Crane Care Lattice Team.
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To prevent death or serious injury:

• Avoid unsafe operation and maintenance.
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Crane and attachments must be operated and maintained by trained

and experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
• Do not operate or work on crane or attachments without first reading
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and understanding instructions contained in Operator Information

Manual and Service Manual supplied with crane and applicable
attachments.
• Store Operator Information Manual and Service Manual in operator’s
cab.
If Operator Information Manual or Service Manual is missing from cab,
contact your Manitowoc distributor for a new one.
©2016 Manitowoc
Published 01-28-16, Control #250-01
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THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH
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TABLE OF CONTENTS
1. SAFETY
2. OPERATION
3. LOAD SAFETY DEVICE
4. ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY
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5. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
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6. WIRE ROPE
7. MAINTENANCE
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8. REFERENCE MATERIALS
9. DIAGRAM
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Published 01-28-16, Control #250-01 10000A-1

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10000A-1 Published 01-28-16, Control #250-01

[ TABLE OF CONTENTS ]
1. SAFETY
1.1 SAFETY INFORMATION ...................................................................................................... 1-1
1.2 EXPLANATION OF WARNING LABELS IN THE MACHINE ..................................... 1-2
1.2.1 HANDLING OF WARNING LABELS IN THE MACHINE ........................................ 1-2
1.2.2 LABEL LAYOUT.................................................................................................................. 1-3
1.2.3 DETAIL OF LABEL............................................................................................................. 1-10
1.3 SAFE OPERATING PRACTICES FOR MOBILE CRANES........................................ 1-19
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1.4 SAFETY AT INSPECTION AND MAINTENANCE WORK .......................................... 1-43
1.5 SAFETY DURING ASSEMBLY AND DISASSEMBLY WORK ................................... 1-46
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1.6 CAUTIONS IN HANDLING OIL AND PAINT ................................................................... 1-47
1.7 SAFETY EQUIPMENT (OPTION) ...................................................................................... 1-48
2. OPERATION
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2.1 TERMINOLOGY OF MACHINE EACH PART ................................................................ 2-1
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ........................................ 2-4
2.2.1 HANDING LEVER AND PEDAL .................................................................................... 2-5
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2.2.2 OPERATING SWITCHES ................................................................................................ 2-14
2.2.3 VARIOUS SETTING OF MONITOR ............................................................................. 2-42
2.2.4 ANEMOMETER INSTALLATION (OPTION) .............................................................. 2-51
2.2.5 AIR CONDITIONER .......................................................................................................... 2-52
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2.2.6 AIR CONDITIONER FOR AUTO-IDLE STOP (AIS AIR CONDITIONER)

(OPTION).............................................................................................................................. 2-58
2.2.7 AM/FM RADIO .................................................................................................................... 2-61
2.2.8 1WAY CALL (TRANSMITTER) ....................................................................................... 2-72
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2.2.9 MONITORING CAMERA (OPTION) ............................................................................. 2-73

2.3 CRANE OPERATION ............................................................................................................. 2-76
2.3.1 ADJUSTING THE OPERATOR’S SEAT ...................................................................... 2-76
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2.3.2 GETTING ON AND OFF FROM / TO OPERATOR’S CAB .................................... 2-78

2.3.3 STARTING AND STOPPING THE ENGINE............................................................... 2-79
2.3.4 EMISSION CONTROL DEVICE .................................................................................... 2-84
2.3.5 TIER4 FINAL INDUCEMENT CONTROL ................................................................... 2-100
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2.3.6 AUTO IDLE STOP FUNCTION ...................................................................................... 2-111

2.3.7 FUNCTION LOCK LEVER .............................................................................................. 2-114
2.3.8 TRAVELING OPERATION............................................................................................... 2-115
2.3.9 SWINGING OPERATION ................................................................................................ 2-118
2.3.10 BOOM RAISING/LOWERING OPERATION .............................................................. 2-123
2.3.11 HOOK HOISTING/LOWERING OPERATION ........................................................... 2-127
2.4 FREE FALL OPERATION ..................................................................................................... 2-136
2.5 CLAMSHELL OPERATION .................................................................................................. 2-142
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2.5.1 PREPARATION WORK..................................................................................................... 2-144

2.5.2 CLAMSHELL WORK.......................................................................................................... 2-148
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)........................................................ 2-149
2.7 HANDLING OF VIBRO HAMMER....................................................................................... 2-152
2.8 OPERATION IN WEATHER CHANGE AND SPECIAL CIRCUMSTANCE............. 2-155
2.8.1 CAUTION AGAINST WIND.............................................................................................. 2-155
2.8.2 CAUTION AGAINST ELECTRIC SHOCK.................................................................... 2-167
2.8.3 CAUTION AGAINST RADIO WAVE INTERFERENCE............................................ 2-169
2.8.4 CAUTION AGAINST LIGHTNING.................................................................................. 2-170
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2.8.5 COUNTERMEASURE AGAINST EARTHQUAKE..................................................... 2-170
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3.1 ARRANGEMENT OF EQUIPMENTS................................................................................. 3-3
3.2 TYPES AND FUNCTIONS OF EQUIPMENT.................................................................. 3-6
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3.3 CONNECTING PROCEDURE OF WIRING..................................................................... 3-12
3.3.1 CRANE ATTACHMENT..................................................................................................... 3-13
3.4 FUNCTION OF MONITOR.................................................................................................... 3-20
3.5 OPERATING PROCEDURE OF MONITOR.................................................................... 3-21
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3.5.1 SETTING OF CRANE CONFIGURATION................................................................... 3-26
3.5.2 SELECTION OF MAIN/AUXILIARY HOOK SELECTION....................................... 3-35
3.5.3 SETTING OF WORK AREA LIMIT VALUE.................................................................. 3-36
3.6 SWING LIMITATION DEVICE (OPTION).......................................................................... 3-41
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3.7 LOAD HISTORY (DATA LOGGER)..................................................................................... 3-53

3.8 FUNCTION OF GROUND INCLINE INDICATOR (OPTION)...................................... 3-54
3.9 WARNING AND AUTO-STOP.............................................................................................. 3-56
3.9.1 CONTENT OF WARNING AND AUTO-STOP............................................................ 3-56
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3.9.2 CONTENT OF AUTO-STOP............................................................................................ 3-57

3.9.3 RELEASING AUTO-STOP............................................................................................... 3-58
3.10 INSPECTION............................................................................................................................. 3-64
3.10.1 INSPECTION PROCEDURE WHEN ERECTING THE BOOM AFTER THE
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ATTACHMENT ASSEMBLY WORK IS COMPLETED............................................. 3-64

3.10.2 INSPECTION AFTER ERECTING ATTACHMENT................................................... 3-66
3.11 CAUTIONS IN HANDLING LOAD SAFETY DEVICE.................................................... 3-68
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3.12 ERROR CODE DISPLAY AND MESSAGE...................................................................... 3-69

3.13 WARNING CODE LIST AND CONDITION, ACTION.................................................... 3-82
3.14 CHECKING PROCEDURE OF LOAD SAFETY DEVICE............................................ 3-88

4.1 SWING AND TRAVEL STABILITY...................................................................................... 4-1
4.2 HANDLING THE REMOTE CONTROL SWITCH BOX................................................. 4-4
4.3 ASSEMBLING OF BASE MACHINE.................................................................................. 4-8
10000A-1
11000-1 2 Published 01-28-16, Control #250-01
4.3.1 CAB STEP EXTENSION.................................................................................................. 4-10

4.3.2 UNLOADING BASE MACHINE FROM TRAILER .................................................... 4-12
4.3.3 EXTENDING THE CRAWLER ....................................................................................... 4-13
4.3.4 INSTALLING OF LADDER FOR MACHINERY GUARD ........................................ 4-20
4.3.5 RAISING GANTRY ............................................................................................................ 4-21
4.3.6 INSTALLING THE BOOM TIP ........................................................................................ 4-26
4.3.7 INSTALLATION OF THE BASE GUY LINE ................................................................ 4-28
4.3.8 FRONT DRUM WIRE ROPE REEVING...................................................................... 4-30
4.3.9 CARBODY WEIGHT INSTALLATION (USING SELF REMOVAL DEVICE) ..... 4-35
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4.3.10 ASSEMBLING THE COUNTERWEIGHTS (USING SELF REMOVAL
DEVICE)................................................................................................................................ 4-50
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4.3.11 MOUNTING THE ASSEMBLED COUNTERWEIGHT TO BASE MACHINE
(USING SELF REMOVAL DEVICE) ............................................................................. 4-58
4.4 DISASSEMBLY OF BASE MACHINE ............................................................................... 4-67
4.4.1 REMOVE THE COUNTERWEIGHTS FROM THE MACHINE (USING
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SELF REMOVAL DEVICE) .............................................................................................. 4-69
4.4.2 DISASSEMBLY OF THE COUNTERWEIGHT .......................................................... 4-78
4.4.3 CARBODY WEIGHT REMOVAL (USING SELF REMOVAL DEVICE)............... 4-83
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4.4.4 WINDING UP THE FRONT DRUM WIRE ROPE ..................................................... 4-97
4.4.5 REMOVING THE BOOM GUY LINE ............................................................................ 4-99
4.4.6 DISASSEMBLING THE BOOM TIP .............................................................................. 4-101
4.4.7 LOWERING THE GANTRY............................................................................................. 4-103
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4.4.8 REMOVAL OF LADDER FOR MACHINERY GUARD ............................................ 4-108

4.4.9 RETRACTING THE CRAWLERS .................................................................................. 4-109
4.4.10 BASE MACHINERY LOADING ONTO TRAILER ..................................................... 4-115
4.4.11 STORE AND REMOVAL OF CAB STEP..................................................................... 4-118
4.5 TRANSPORTATION ............................................................................................................... 4-120
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4.6 INSTALLATION/REMOVAL OF BOOM BASE ................................................................ 4-121

4.6.1 BOOM BASE INSTALLATION ........................................................................................ 4-121
4.6.2 BACKSTOP INSTALLATION .......................................................................................... 4-123
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4.6.3 UPPER SPREADER INSTALLATION .......................................................................... 4-124

4.6.4 REEVING BOOM HOIST WIRE ROPE ....................................................................... 4-125
4.6.5 INSTALLATION OF BOOM HOIST WIRE ROPE TO THE DRUM ...................... 4-127
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4.6.6 WINDING UP OF BOOM HOIST WIRE ROPE TO THE DRUM .......................... 4-128
4.6.7 UPPER SPREADER REMOVAL ................................................................................... 4-130
4.6.8 BACKSTOP REMOVAL.................................................................................................... 4-131
4.6.9 REMOVAL OF BOOM BASE .......................................................................................... 4-132
4.7 CARBODY WEIGHT INSTALLATION (WHEN USING ASSIST CRANE) .............. 4-134
4.7.1 CARBODY WEIGHT INSTALLATION .......................................................................... 4-134
4.7.2 CARBODY WEIGHT REMOVAL ................................................................................... 4-138
4.8 SELF REMOVAL CYLINDER (OPTION) INSTALLATION/REMOVAL..................... 4-141

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4.9 SELF REMOVAL CYLINDER (OPTION) TAKEOUT/STORAGE............................... 4-145

4.9.1 TAKEOUT OF CYLINDER................................................................................................ 4-145
4.9.2 STORAGE OF CYLINDER............................................................................................... 4-149
4.10 CRAWLER INSTALLATION/REMOVAL (USING SELF REMOVAL CYLINDER
[OPTION])................................................................................................................................... 4-152
4.10.1 INSTALLATION OF CRAWLER...................................................................................... 4-152
4.10.2 REMOVAL OF CRAWLER................................................................................................ 4-169
4.11 CARBODY WEIGHT INSTALLATION/REMOVAL (USING SELF REMOVAL
CYLINDER [OPTION])............................................................................................................ 4-182
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4.11.1 CARBODY WEIGHT INSTALLATION........................................................................... 4-182
4.11.2 CARBODY WEIGHT REMOVAL.................................................................................... 4-192
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5.1 ASSEMBLING THE ATTACHMENT................................................................................... 5-5
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5.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE.............................................................. 5-6
5.1.2 BOOM AND GUY LINE ARRANGEMENT................................................................... 5-8
5.1.3 HANDLING OF SPREADER GUIDE............................................................................. 5-15
5.1.4 INSTALLING THE BOOM................................................................................................. 5-18
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5.1.5 CAUTION FOR CANTILEVER........................................................................................ 5-28
5.1.7 INSTALLING THE AUXILIARY SHEAVE...................................................................... 5-34
5.1.8 REAR DRUM WIRE ROPE REEVING TO AUXILIARY SHEAVE........................ 5-35
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5.1.9 ASSEMBLING THE FIXED JIB....................................................................................... 5-38

5.1.10 REAR DRUM WIRE ROPE REEVING TO THE FIXED JIB................................... 5-41
5.1.11 FUNCTION CHECK OF EACH LIMIT SWITCH......................................................... 5-44
5.2 ERECTING THE ATTACHMENT......................................................................................... 5-45
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5.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT............................... 5-45

5.2.2 ERECTING THE ATTACHMENT.................................................................................... 5-46
5.2.3 CONFIRMATION BEFORE LOWERING THE ATTACHMENT.............................. 5-49
5.2.4 LOWERING THE ATTACHMENT................................................................................... 5-50
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5.3 DISASSEMBLING THE ATTACHMENT............................................................................ 5-51

5.3.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING....................................... 5-52
5.3.2 WINDING UP THE FRONT/REAR DRUM WIRE ROPES...................................... 5-54
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5.3.3 DISASSEMBLING THE JIB.............................................................................................. 5-56

5.3.4 REMOVING THE AUXILIARY SHEAVE....................................................................... 5-59
5.3.5 DISASSEMBLING THE BOOM....................................................................................... 5-60
5.4 CAUTION WHEN TRANSPORTING BOOM.................................................................... 5-65
6. WIRE ROPE
6.1 HANDLING OF WIRE ROPE................................................................................................ 6-1
6.1.1 SPECIFICATION OF WIRE ROPE................................................................................ 6-2
10000A-1
6.1.2 WIRE ROPE LENGTH...................................................................................................... 6-5

6.1.3 CAUTIONS IN HANDLING WIRE ROPE .................................................................... 6-7
6.1.4 WINDING WIRE ROPE TO THE DRUM ..................................................................... 6-8
6.1.5 CORRECTING METHOD OF ENTANGLED WIRE ROPE .................................... 6-12
6.1.6 ROPE SOCKET INSTALLATION................................................................................... 6-14
6.1.7 REPLACEMENT STANDARDS FOR WIRE ROPE ................................................. 6-15
7. MAINTENANCE
7.1 INSPECTION INTERVAL ...................................................................................................... 7-9
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7.1.1 TABLE OF INSPECTION POINTS................................................................................ 7-9
7.1.2 TABLE OF OIL, GREASE AND WATER SUPPLY POINTS .................................. 7-11
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7.2 INSPECTION ............................................................................................................................ 7-13
7.2.1 INSPECTION OF UPPER MACHINERY .................................................................... 7-13
7.2.2 INSPECTION OF LOWER MACHINERY ................................................................... 7-20
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7.2.3 INSPECTION OF ATTACHMENT.................................................................................. 7-22
7.2.4 INSPECTION METHOD OF EACH POINT ................................................................ 7-24
7.3 INSPECTION AND OIL/GREASE AND WATER SUPPLY .......................................... 7-54
7.3.1 INSPECTION, OIL/GREASE AND WATER SUPPLY POINTS OF UPPER
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MACHINERY ....................................................................................................................... 7-56
7.3.2 LOWER LUBRICATION ................................................................................................... 7-60
7.3.3 ATTACHMENT LUBRICATION ...................................................................................... 7-62
7.3.4 INSPECTION, GREASING (WATER SUPPLY) ON EACH POINT ..................... 7-64
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7.4 REPLACEMENT AND CLEANING/WASHING FILTER ELEMENT AND

STRAINER ................................................................................................................................ 7-86
7.4.1 REPLACEMENT, CLEANING, WASHING POINTS OF FILTER ELEMENT
AND STRAINER ................................................................................................................. 7-86
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7.4.2 REPLACEMENT, CLEANING, WASHING METHODS OF FILTER

ELEMENT AND STRAINER............................................................................................ 7-88
7.5 BATTERY INSPECTION ....................................................................................................... 7-108
7.6 LOCATION AND USE OF FUSE ........................................................................................ 7-114
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7.7 OPERATION UNDER SEVERE CONDITIONS ............................................................. 7-116

7.8 HANDLING OF DIESEL PARTICULATE FILTER .......................................................... 7-120
7.9 MACHINE STORAGE ............................................................................................................ 7-123
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7.10 TIGHTENING TORQUE VALUES ...................................................................................... 7-124

7.11 PERIODICAL REPLACING SECURITY PARTS ............................................................ 7-129
7.12 ADJUSTMENT ......................................................................................................................... 7-131
7.12.1 ADJUSTMENT OF FRONT, REAR, THIRD (OPTION) DRUM LOCKS ............. 7-131
7.12.2 ADJUSTMENT OF BOOM DRUM LOCK ................................................................... 7-132
7.12.3 CRAWLER SHOES ADJUSTMENT ............................................................................. 7-133
7.13 CONSUMABLE PARTS LIST .............................................................................................. 7-134
7.14 MEASURES REQUIRED FOR FRONT, REAR WINCH MONITORING................. 7-142

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7.14.1 THEORETICAL SERVICE LIFE...................................................................................... 7-142

7.14.2 USED PROPORTION OF THEORETICAL SERVICE LIFE................................... 7-143
7.14.3 DETERMINING OF THE RESIDUAL THEORETICAL SERVICE LIFE............... 7-147
8.1 SPECIFICATION...................................................................................................................... 8-1
8.1.1 CRANE OUTSIDE DIMENSION..................................................................................... 8-2
8.1.2 CRANE SPECIFICATION, PERFORMANCE............................................................. 8-3
8.1.3 CRANE WORKING RANGES......................................................................................... 8-5
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8.2 DIMENSION, WEIGHT OF EACH COMPONENT......................................................... 8-8
8.2.1 BASE MACHINE................................................................................................................. 8-8
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8.2.2 COUNTERWEIGHT........................................................................................................... 8-10
8.2.3 ATTACHMENT..................................................................................................................... 8-11
8.3 CLAMSHELL RATED LOADS (OPTION).......................................................................... 8-13
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8.4 SWING AND TRAVEL STABILITY...................................................................................... 8-17
8.5 TRAVEL ALLOWABLE SLOPE ANGLE............................................................................. 8-20
8.5.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION...... 8-20
8.6 LOW GANTRY POSITION.................................................................................................... 8-26
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8.7 SAFETY DEVICE LIST (OPTION)...................................................................................... 8-27
9. DIAGRAM
9.1 HYDRAULIC DIAGRAM......................................................................................................... 9-1
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9.2 ELECTRIC SCHEMATIC....................................................................................................... 9-5

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10000A-1
[ IMPORTANT INFORMATION ]
Thank you for your purchasing Manitowoc crawler crane.
Full-hydraulically operated crawler crane is manufactured based on our many years of
experience and expertise.
11000-1. .
This manual describes the important information about the Model 10000A-1
Before operating the machine, be sure to thoroughly read this manual to use the
machine safely and efficiently.
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Do not operate or maintain this machine until you
read this manual and understand the instructions.
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Improper operation or maintenance of this
machine may cause accidents and could result in
a serious injury or loss of life.
Always keep this manual in the operators cab.
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If it is missing or damaged, place an order to a
Manitowoc authorize distributor for a replacement.
If the machine is to be sold to others, hand over
this manual together.
If you have any questions, please consult your
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Manitowoc authorize distributor.
This machine’s specification is based on Mobile crane ASME B30.5.

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As for class of utilization related to crane life, this crane is classified as [A1] of ISO 4301/2, FEM 1.001.
If there is any doubt if this crane conforms to the standard or regulation of your country, contact Manitowoc or your nearest
Manitowoc authorized distributor.
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11000-1
MACHINE SERIAL NUMBER AND HOUR METER
When you order repair parts and when you need repair or service of the machine,
always inform us the machine serial number stamped on the number plate and the total
number of hours indicated on the hour meter which is located in the left front stand.
HOUR METER
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J08EVV---------- No.GH05- 0 0 0 0 0
ENGINE NUMBER
MODEL CODE MACHINE SERIAL NUMBER
NUMBER PLATE
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MACHINE MACHINE
10000A-1
11000-1 GH05- ENGINE No. J08EVV-
MODEL SERIAL No.
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WARRANTY
The terms under which this machine is guaranteed are clearly defined in the
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accompanying WARRANTY.
Trouble and damage occurred during the terms of guarantee shall be repaired at no
cost to the purchaser according to the warrant description if the trouble or damage is
recognized to be our responsibility.
However, if you use the machine contrary to the instructions of this manual, the
WARRANTY does not cover any damage to the machine.
10000A-1
REPAIR PARTS
When servicing and repairing the machine, be sure to use genuine parts in order to
make the machine performance display sufficiently.
Since the important security parts are prepared to ensure safety and to protect the
machine from an serious accident, be sure to replace them on every specified period of
time.
The part number described in the operator’s manual is to be changed without prior
notice.
When place an order, please confirm the part number with the parts manual or the
engine hand book.
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MACHINE DIRECTION (FRONT, REAR, LEFT AND RIGHT)
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In this manual, idler wheel side is called “front” of the lower machinery and “front, rear,
left and right” of the upper machinery are called based on the operator’s view when he
sits down on the operator’s seat and facing front.
Left swing
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Front
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IDLER WHEEL
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OPERATOR CAB
Left Right
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TRAVEL MOTOR
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Rear

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10000A-1
[ 1. SAFETY ]
1. SAFETY
1.1 SAFETY INFORMATION ...................................................................................................... 1-1
1.2 EXPLANATION OF WARNING LABELS IN THE MACHINE ..................................... 1-2
1.2.1 HANDLING OF WARNING LABELS IN THE MACHINE ........................................ 1-2
1.2.2 LABEL LAYOUT.................................................................................................................. 1-3
1.2.3 DETAIL OF LABEL............................................................................................................. 1-10
1.3 SAFE OPERATING PRACTICES FOR MOBILE CRANES........................................ 1-19
1.4 SAFETY AT INSPECTION AND MAINTENANCE WORK .......................................... 1-43
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1.5 SAFETY DURING ASSEMBLY AND DISASSEMBLY WORK ................................... 1-46
1.6 CAUTIONS IN HANDLING OIL AND PAINT ................................................................... 1-47
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1.7 SAFETY EQUIPMENT (OPTION) ...................................................................................... 1-48
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11000-1
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[ 1. SAFETY ]
1. SAFETY
1.1 SAFETY INFORMATION
Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules.
Sufficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of
personnel.
Thus, precautionary measures, or notes, written in this manual should be read and understood by personnel before
starting each task.
Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority.
Messages of safety are indicated with caution marks.
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The safety information contained in this manual is intended only general safety information.
Messages of safety appear in this manual and on the machine.
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All messages of safety are identified by the words “DANGER”, “WARNING” and “CAUTION”.
These words mean the following :
Indicates an imminently hazardous situation which, if not avoided, will
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result in a loss of life or serious injuries.
Indicates a potentially hazardous situation which, if not avoided, could result

in a loss of life or serious injuries.
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Indicates a potentially hazardous situation which, if not avoided, may result
in a minor or moderate injuries.
It may also be used to alert against possible damage to the machine and
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its components.
Supplementary explanation.
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It is very difficult for us to forecast every danger that may occur during operation.
However, safety can be ensured by operating this machine according to methods recommended by Manitowoc.
While operating machine, be sure to perform work with great care, so as to not damage the machine, or let
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accidents occur.
Please continue studying this manual until proper operation is completely understood.
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Published 01-28-16, Control #250-01 1-1 10000A-1

11000-1
[ 1. SAFETY ]
1.2 EXPLANATION OF WARNING LABELS IN THE MACHINE

Since the warning labels are installed in the machine and indicated with the three stages in the same way as the
warning description, confirm the positions and contents of all warning labels first.
Put them to the practical use to secure safety when operating, checking and performing maintenance.
1.2.1 HANDLING OF WARNING LABELS IN THE MACHINE

1. When the warning label is damaged or stained, order it to the designated service shop.
2. Do not remove the warning labels.
3. When the surface of the warning label is soiled and difficult to be seen, wipe it cleanly.
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10000A-1
11000-1 1-2 Published 01-28-16, Control #250-01
[ 1. SAFETY ]
1.2.2 LABEL LAYOUT

* Numbers in the drawings correspond with those in the label explanation detail after “1.2.3 DETAIL OF LABEL”
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INSIDE VIEW (L/H)
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INSIDE VIEW (R/H)

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[ 1. SAFETY ]
17 17
19 19
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Machine front
CAB INSIDE VIEW (REAR)

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ACCUMULATOR
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10000A-1
[ 1. SAFETY ]
20 24
Machine front
Detail A (RADIATOR)
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[ 1. SAFETY ]
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Detail C (FUEL TANK) Detail D (DEF/AdBlue® TANK) Detail E (BATTERY)
18 16 7 23
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B C D
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View from B
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[ 1. SAFETY ]
22 25 22
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Section F-F (L/H) Section G-G (R/H) Section H-H

11000-1
[ 1. SAFETY ]
29 28 27
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BOOM
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28 27 29
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10000A-1
[ 1. SAFETY ]
27 27
BOOM INSERT
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JIB INSERT
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27 27
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11000-1
[ 1. SAFETY ]
1.2.3 DETAIL OF LABEL

1. Ensure to read the operators manual before
operation / handling / assembly / disassembly /
transportation / inspection / maintenance of the
machine.
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2. If the free fall speed select switch is in speed
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increase side and the brake is released and the
drum may rotate automatically to lowering side
even without lifting load and wire rope may be
paid out to lower the hook and rough spooling
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may be caused occur.
When paying out the wire rope from the drum,
ensure to set the free fall select switch to normal
side.
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3. The crane may turn over during work based on
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machine condition.
Install the proper amount of the counterweight
and secure them to make proper machine
configuration.
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10000A-1
[ 1. SAFETY ]
4. If machine swings or is assembled / disassembled

with crawler retracted, main machinery may turn
over to rear side.
Read the operator’s manual carefully and set
the crane to the proper configuration.
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5. If the brake pedal lock is not completely
engaged, lifting load or hook may be lowered
unexpectedly and is very dangerous.
When locking the brake pedal, press the brake
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pedal fully and confirm that the pedal is locked
completely.
6. During crane work if the boom comes to close

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to the tower or power lines, electric shock may
hit the crane.
Keep the boom away from the tower or power
lines for safety.
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7. When work is done on the upper surface of the

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guard or counterweight, person may fall off by

mistake.
Ensure to engage the safety hook on the
specified place.
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11000-1
[ 1. SAFETY ]
8. When the boom is assembled, disassembled,

boom self erection / self lowering or crane work
with the low gantry, the gantry or boom may be
damaged and may fall off.
Raise the gantry to the proper position for work.
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9. Free fall work of load may cause dropping the
load by mishandling.
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Use power lowering of load in the crane work.
(Even on neutral free side, power lowering is
possible by turning the lever to lowering side.)
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10. This machine contains alloy and heat treated
steels.
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Do not weld or apply heat without checking with

your authorized dealer.
Unauthorized modifications may weaken the
machine.
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11. Do not lift people with this crane.

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Failure to do so may cause serious injury.

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10000A-1
[ 1. SAFETY ]
12. Wrong handling of battery may cause burns,

blindness or explosion by inflammation.
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13. If accumulator is handled in wrong way, burns,
loss of eyesight, explosion may be caused.
Take extra care in handling accumulator.
(Do not weld, flame cut, dispose or disassemble.)
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14. The accumulator is charged with high pressure

nitrogen gas.
Charge the nitrogen gas within the specified
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pressure.
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15. Using the fuel other than the specified diesel

fuel may cause engine failure, fire or explosion.
Ensure to use the diesel fuel in the fuel tank.
Use ultra low sulfur diesel fuel only.
(S50 : sulfur content lower than 50 ppm)

11000-1
[ 1. SAFETY ]
16. After raising the gantry, ensure to insert the

gantry fixing pin.
Otherwise the gantry may come off and the
boom may drop off.
17. Handling the counterweight in wrong way is

very dangerous.
Never allow any person to enter under the lifting
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counterweight.
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18. When working on the upper surface of the
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guard, person may fall off the upper surface of
the guard.
During high place work on the upper surface of
the guard, do not come close to the guard side
face to prevent falling off.
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During work on the upper surface of the guard,
ensure to wear safety belt and hook the safety
belt on the upper machinery and firmly stand on
the guard.
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19. While the upper machinery is swinging, person

may be crushed with the upper machinery.
Never allow anybody to enter the swing range.
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10000A-1
[ 1. SAFETY ]
20. During engine running or straight after the

engine is stopped, hydraulic oil tank, engine and
muffler are hot.
Touching them may cause burns.
Do not touch the hot area.
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21. During engine running or right after the engine
is stopped, inside of the radiator becomes high
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pressure and hot.
Person may get burns by hot water blow out
when taking off the radiator cap.
Take extra care of opening or closing of the
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radiator cap.
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22. When inspection or work is done by removing
the drum flange cover, serious injuries may be
caused if the drum rotates unexpectedly.
Stop the crane and then remove the drum
cover.
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23. When the machine is transported with the low

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gantry, connect the tension bar to the revolving

frame or counterweight.

11000-1
[ 1. SAFETY ]
24. When working on the engine area for inspection

and maintenance, person may be entangled
with the fan belt and may get injured if the
engine is running.
Stop the engine when inspection or maintenance
work is done.
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25. There are some moving parts nearby.
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26. This is a connector cover of electrical wiring of
safety device.
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Do not step on and crush.

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27. Taking wrong procedure in boom assembly or

disassembly may cause boom falling off and
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person may get injured.

Do not allow any person to enter the inside
or under the boom during assembly or
disassembly.
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10000A-1
[ 1. SAFETY ]
28. Taking wrong method in using the spreader

guide installed on the boom base may damage
the spreader guide.
Set the spreader guide to the stowed position
except when the upper spreader is connected is
connected to the boom base.
29. Taking the wrong installing direction when the

rope sockets are installed to the boom tip and
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jib tip, may damage the boom or may break the
wire rope.
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Install the rope socket in the proper direction.
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30. Free fall work of load may cause dropping the

load by mishandling.
Use power lowering of load in the crane work.
(Even on neutral free side, power lowering is
possible by turning the lever to lowering side.)

11000-1
[ 1. SAFETY ]
31. When fill the water and/or diesel fuel etc. to this
tank is danger and may lead to the faults.
Fill the specified DEF/AdBlue® only.
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10000A-1
[ 1. SAFETY ]
1.3 SAFE OPERATING PRACTICES FOR MOBILE CRANES

INTRODUCTION
Because cranes have the ability to lift heavy loads to

great heights, they also have a potential for accidents
if safe operating practices are not followed.
This book will help you prevent accidents that could
result in a injury, death, or property damage.
General safe practices for working on machinery must

be followed as well as the safe operating practices
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recommended here.
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11000-1
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OPERATOR’S RESPONSIBILITY
The operator is the best safety feature in any crane.

Safety must always be the operator’s most important
concern.
He must refuse to operate when he knows it is unsafe
and consult his supervisor when safety is in doubt.
He must read and understand the Operator’s Manual

and see that the machine is in proper order before
operating.
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He must understand how to read the rating plate and
know that his machine can safely lift each load before
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attempting to lift it.
He must never lift a load without knowing the length of

the boom, the weight of the load, and the load radius
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or boom angle.
Never attempt to operate the crane at conditions

exceeding those shown on the rating chart.
Such operation can cause tipping or structural failure
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of the crane that can result in a damage, injury, or loss
of life.
He must be alert, physically fit, and free from the

influences of alcohol, drugs, or medications that might
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affect his eyesight, hearing, reactions, judgment.
He must see that unnecessary people, equipment,

and material are kept out of the work area.
The area around the machine should be properly
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barricaded.
When an operator’s vision is restricted or when operating

in hazardous places such as near electrical power lines
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or around people, a signalman must be used.

Because the operator is not always in the best position
to judge distances and can not see all parts of the job
site, a signalman may also be necessary at other times.
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Operators must understand standard crane signals

and take signals only from designated signalmen.
10000A-1
[ 1. SAFETY ]
SIGNALMAN’S RESPONSIBILITY
The primary duty of a signalman is to assist the

operator in safe and efficient operation.
Operators depend on designated signalmen to assist
them in making movements without endangering
people or property.
Signalmen must have a clear understanding of the

work to be done so that they can safely coordinate
each job with operators and other crew members.
Signalmen must place themselves where they can be
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clearly seen and where they can safely observe the
entire operation.
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Standard crane signals must be used unless other
methods of signaling, such as two way radios or flags
have been agreed upon.
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CREW MEMBER’S RESPONSIBILITY
Any unsafe condition or practice must be corrected or

reported to the job supervisor.
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Everyone who works around the crane, including
riggers and oilers, must obey all warning signs and
watch out for his own safety and the safety of others.
Crew members setting up machines or handling loads
are expected to know proper machine erection and
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rigging procedures.
Watch for hazards during operations and alert the

operator and signalmen of dangers such as power
lines, the unexpected presence of people, other
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equipment or unstable ground conditions.

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11000-1
[ 1. SAFETY ]
MANAGEMENT’S RESPONSIBILITY
See that operators are trained, competent, physically

fit and, if required, licensed.
Good vision is required, as are good judgment,
coordination and mental ability.
Any person who lacks any of these qualities must not
be allowed to operate a crane.
Signalmen must have good vision and sound

judgment, know standard crane signals and be able to
give signals clearly.
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They must have enough experience to be able to
recognize hazards and signal the operator to avoid
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them.
Riggers must be trained to determine weights and

distances and to select proper lifting tackle.
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Rigging is a complex subject far beyond the scope of
this manual.
It is management’s responsibility to employ qualified
riggers.
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Crew members must be given specific safety
responsibilities and instructed to report any unsafe
conditions to their supervisors.
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10000A-1
[ 1. SAFETY ]
PLANNING THE JOB
Most accidents can be avoided by careful job planning.

The person in charge must have a clear understanding
of the work to be done and equipment capabilities.
He must consider all dangers at the job site, develop a
plan to do the job safely, and then explain the plan to
all concerned.
Factors such as these should be considered :
• What crew members are needed and what

responsibilities will they be given?
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• What is the weight of the load to be lifted, the lift
radius, boom angle, and the rated capacity of
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the crane?
• How will the signalmen communicate with the
operator?
• What equipment is required to do the job safely?
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Is a crane the best equipment for the job?
• How can the equipment be safely transported to
the job site?
• Are there gas lines, electrical power lines or
structures that must be moved or avoided?
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• Is the surface strong enough to support the
machine and load?
• How will loads be rigged?
• What special safety precautions must be taken
if a crane must travel with a suspended load or
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if more than one crane is needed to lift a load?

• Are unusual weather conditions such as winds
or extreme cold expected?
• What steps will be taken to keep unnecessary
people and equipment safely away from the
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work area?
• How can the crane be positioned to use the
shortest boom and radius possible?
• Is “OFF LIMIT” sign posted in the swing radius
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area?
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11000-1
[ 1. SAFETY ]
OPERATOR’S CHECK LIST
The operator must make a safety check before starting

to work each day to see that the machine is in proper
order.
Some things to check are :
• Check the machine log book to see that periodic

maintenance and inspections have been
performed and all necessary repairs made.
• Check the operation of the boom hoist kickout,
boom angle indicator, back up alarms, and other
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safety devices.
• Carefully inspect load bearing parts such as wire
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rope, (load lines, boom hoist cable, suspension
lines), boom, outriggers, hooks, and rigging.
• Inspect the crane for any missing bolts, nuts or
pins and any cracked or broken components.
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• Be sure no unauthorized field modifications
have been made, such as counterweights
increased or decreased and booms that have
been improperly repaired.
• Check for fuel and hydraulic oil leaks.
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• After starting the engine, check all gauges for
proper readings.
• Test all controls for proper operation.
• Check brakes and clutches.
Test load brakes by lifting a load a few inches
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off the ground and holding it.

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10000A-1
[ 1. SAFETY ]
OPERATING PRECAUTIONS
The following recommendations represent our

experience in regard to the most likely causes of
personal injuries and damage to equipment.
Careful observance of the following recommendations
will prevent the majority of common accidents.
1. Mistakes in calculating lifting capacity can

cause accidents.
Several factors must be considered including :
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(1) Load radius (the distance between the center of
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the crane rotation to the center of the load).
Note that the radius will increase when the load
is lifted.
(2) Weight of the load, hook, and rigging.
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(3) Boom length, jib, parts of line, and operating
area (side, rear).
Use the next lower rated capacity when working
at boom length or radii between the figures on
the rating chart.
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It is dangerous to guess the capacity for boom
length or radii between those listed on the rating
plate.
Trying to lift a load without knowing whether it

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is within the rated capacity while expecting the

crane to start to tip to warn of an overload is
very dangerous and should never be done.
Cranes may suddenly tip over or collapse.
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Always operate within the rated capacity.

The operator must reduce the load under
adverse field conditions until, in his judgment,
the machine can safety handle the lift.
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(See operating precautions #3, 10, 16, 19, 27,

and 28.)
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11000-1
[ 1. SAFETY ]
2. Cranes may tip over or collapse if the operating

surface cannot support their weight.
Timber mats, steel plates or concrete rafts may
be needed under crawlers to distribute the load
under the crane so that the bearing strength of
the ground is not exceeded.
Determine the load bearing capacity of the
ground or other surface on which machines will
be operating.
Be sure cranes are adequately supported.
Avoid soft or unstable ground, sand, areas with
high water tables, and partially frozen ground.
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When machines are working near trenches, the
trenches should be shored or sloped to prevent
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cave-ins or slides.
3. The rated capacity of a crane is determined with

the crane leveled within ±0.5 degrees of grade
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(1 foot drop or rise in 100 foot distance).
Out of level more than ±0.5 degrees will
drastically reduce the lifting capacity.
Be sure cranes are level.
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4. People can be crushed by the scissors-like
action of the upper rotating on the lower.
Stay away from rotating cranes.
Erect barricades to keep people away.
Take the time to determine that these areas are
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clear before swinging.

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10000A-1
[ 1. SAFETY ]
5. People can be crushed by the rear

(counterweight) of the machine if there is not
enough room for it to swing.
Position machines so that people cannot be
trapped between the counterweight and other
obstructions.
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6. Many people have been injured when riding
crane hooks or loads.
They have no control over how they are handled
and no protection from impacts or falls.
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Small mistakes can be fatal.
Never permit anyone to ride loads, slings,

hooks, etc., for any reason.
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11000-1
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7. Power electrical lines have killed or serious

injured people working around cranes and
excavators.
These accidents can be avoided by following a
few simple rules.
Always determine whether there are power lines

in the area before starting any job, assembly
and disassembly.
OSHA regulations require at least 3.05 meter
(10 feet) of clearance from lines carrying 50,000
volts or less.
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Greater clearances are required for lines with
higher voltages.
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Some states require greater clearances than
OSHA.
Safety requires that you stay as far as possible
from power lines and never violate minimum
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clearances.
Always take these precautions if power lines

are present.
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10000A-1
[ 1. SAFETY ]
(1) Hold a job site meeting and make all people Operation near high voltage power lines
concerned aware of work procedure.
Normal voltage : kV Minimum required clearance
(2) For tagline work, ensure to use nonconductive
(Phase to Phase) : m (ft)
type tagline rope.
UP to 50 3.05 (10)
(3) Ensure to use swing angle limiter (if available).
Over 50 to 200 4.60 (15)
(4) Ensure to use visual signs such as an elevated
Over 200 to 350 6.10 (20)
warning line or barricade.
Over 350 to 500 7.62 (25)
(5) Ensure to use boom angle and work radius
Over 500 to 750 10.67 (35)
limiter.
Over 750 to 1,000 13.72 (45)
(6) Notify the electrical power company before
beginning work. Over 1,000 kV
(7) You and the power company must take specific As established by the utility owner/operator or registered
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precautions. professional engineer who is a qualified person with
These may include locating cranes and respect to electrical power transmission and distribution.
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materials away from electrical power lines, de- NOTE
energizing and grounding lines, rerouting lines, The value that follows “to” is up to and includes that value.
removing barricading lines, and insulating lines For example, over 50 to 200 means up to and including
with rubber sleeves. 200 kV.
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(8) Use a signalman to maintain a safe distance
between any part of the machine or load and
Operation in transit with
electrical power lines.
no load and boom or mast lowered.
The operator is not in the best position to judge
distances. Normal voltage : kV Minimum required clearance
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(9) Warn people to stay away from the machine (Phase to Phase) : m (ft)
and load at all times. Over UP to 0.75 1.22 (4)

If the load must be guided into place, ask the Over 0.75 to 50 1.83 (6)
power company about special precautions such Over 50 to 345 3.05 (10)
as insulated poles or hot sticks. Over 345 to 750 4.87 (16)
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(10) Slow down. Over 750 to 1,000 6.10 (20)

Give yourself time to react to problems and to (Extracted from ASME/ANSI Standard B30.5-2004)
double check the distance between electrical SAFE MAINTENANCE PRACTICES
power lines and any part of the machine or load. Required clearances for operation near high voltage power
lines
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11000-1
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Careful planning and supervision offer better

protection than any known hardware.
Insulated boom cages, proximity warning
devices, and insulating links have limitations
and can fail without warning.
Insulated boom cages and links only protect part
of the crane and can break down electrically if
contaminated with dust and water.
Operation of proximity warning devices can be
affected by different arrangements of power
lines, the movement of trucks, materials, and
the crane itself, and other influences.
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Relying on any of these devices could be
dangerous because users may think they are
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providing protection when in fact they are not.
If any part of the crane or rigging contacts a
high voltage line, the safest procedure for the
operator is to stay at his post until the contact is
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cleared, or the power has been shut off.
Do not allow anyone on the ground to touch the
machine.
If the operator must leave the machine, he
should jump off, rather than climb off.
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8. The load line can break if the hook block
contacts the end of the boom.
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This is called “two blocking”.

Two blocking, for example, can be caused by
hoisting the hook into the end of the boom or
lowering the boom without paying out load line.
Two blocking can pull jibs and lattice booms
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over backwards or cause structural damage at

boom or jib points.
Always keep space between the hook block and
boom point.
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Lower the hook when lowering the boom.

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10000A-1
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9. People can be injured if the hook, boom, load or

outriggers are moved when personnel are nearby.
Make sure everyone is clear before moving the
hook, boom, load or outriggers.
Do not move loads over people.
Do not allow the load to bump or catch on
anything.
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10. Rapid swings or sudden starts and stops can
cause the hook and attached load to swing out
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of control.
Always start and stop movements smoothly and
swing at speeds that will keep the load under
control.
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11000-1
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11. Dirty windows, darkness, bright sunlight, fog,

rain and other conditions can make it difficult for
the operator to see.
Keep windows clean.

Do not operate if you cannot see clearly enough
to operate safely. Replace cracked or broken
glass as soon as possible.
There are several specific safety signs on your

machine.
Their exact location and description of the
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hazard are reviewed in this section.
Please take the time to familiarize yourself with
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these safety signs.
Make sure that you can read all safety signs.

Clean or replace these if you cannot read the
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words or see the pictures.
When cleaning the labels use a cloth, water and
soap.
Do not use solvent, gasoline, etc.
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You must replace a label if it is damaged,missing
or cannot be read.
If a label is on a part that is replaced, make sure
a new label is installed on the replaced part.
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12. Even light winds can blow loads out of control,

collapse booms, or tip cranes.
Winds aloft can be much stronger than at
ground level.
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Do not lift loads if winds create a hazard.

Lower the boom if necessary.
Moderate winds may create a hazard for long

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booms or loads with large surface areas.

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10000A-1
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13. Carelessness in getting on and off equipment

can result in a serious injuries.
Always wait until the machine has stopped.
Do not jump on or off.
Always use both hands and make sure you
have good footing.
14. Slippery floors and steps, tools, trash, or other
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loose items can cause falls.
Keep the machine clean and dry.
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15. Damaged crane booms may collapse.
Lattice type booms will be weakened by damaged
chords, bent or missing lacings, or cracked
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welds. Inspect the crane boom daily for damage.
Do not use damaged booms.
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Due to the high strength steels used in boom and
jibs, special repair procedures are required.
Contact authorize Manitowoc distributor for repair.
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16. Crane booms can collapse if side loaded (pulled

sideways).
Typical causes of side loading are rapid starts and
stops while swinging, dragging a load sideways,
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winds, or lifting when the crane is not level.
Take care to avoid side loading.

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11000-1
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17. If the load strikes the boom or the boom hits a

building or other object, the boom may collapse.
Never let the load or any other object contact
the boom.
18. Boom suspension lines will stretch when the

load is lifted and contract when the load is
released.
At high boom angles this may be enough to pull
the boom backwards over the crane or collapse
the boom stops.
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When releasing loads be sure the boom never
tightens against the backstops.
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Release loads slowly booming out if necessary
while releasing.
19. The load will swing out of control if it is not
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directly beneath the boom point when lifted.
This can side load the boom and may cause the
crane to tip or collapse.
Always place the boom point directly above the

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load when lifting.
Make certain all personnel stand clear of the
load as it is lifted.
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20. Trying to lift a load which is stuck, frozen or

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attached to something else may result in a

tipping, boom collapse or other damage.
Be sure that loads are free before lifting.
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10000A-1
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21. If there is not enough wire rope on the drum the

rope can snap loose.
Keep at least 3 full turns
Keep at least 3 full turns of wire rope on drums of wire rope.
when operating.
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22. If foot brake pedals and locks are equipped on
the crane, always keep your feet on the pedals
while foot pedal brake locks are in use.
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23. Trying to repair or adjust equipment with a

suspended hook or load or with the boom
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raised could release machinery and let it move

unexpectedly.
Always lower the load to the ground and
the boom onto proper cribbing before doing
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maintenance or repair work.

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24. Pressure in hydraulic systems can be retained

for long periods of time.
If not properly released before maintenance
people attempt to work on the hydraulic
systems, this pressure can let machinery move
or cause hot oil and hose ends to shoot out at
high speed.
Release system pressure before attempting to
make adjustment or repairs.
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25. Pin-connected booms and jibs may fall if not
properly supported when removing pins.
Make sure both ends of each boom and jib
section are supported and the boom suspension
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lines completely slacked off before removing pins.
Never stand on, inside, or under booms or jibs
during assembly or disassembly.
26. As with all heavy equipment, care must be taken

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when cranes are driven (traveled), whether on
or off the job site.
Watch for people, electrical power lines, low or
narrow clearances, bridge or road load limits,
and steep hills or uneven terrain.
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Use a signalman in close quarters.

Know the height, width and weight of your
machine.
Set swing brake or lock before traveling.
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10000A-1
[ 1. SAFETY ]
27. Load ratings for cranes are based on the

machine being level and operated properly
so that dynamic effects of operation do not
increase the loadings on the crane.
Traveling a crane with a long boom or with
a load suspended involves special hazards
including the increased possibility of side
loading or tipping.
Because of the many variables involved in pick

and carry operations, the user must evaluate
conditions and take appropriate precautions
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such as these :
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• Follow the travel precautions listed in rule 26.
• Check the rating plate for limitations.
• Position the boom in line with the direction of
travel.
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• Reduce the maximum load while traveling to
reflect operating conditions.
The safe load will vary depending on speed,
crane, and other conditions.
• Travel slowly and avoid sudden stops and starts.
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• Do not steer.
Otherwise a lifting load may swing and lateral
load would be applied on the boom and would
be dangerous.
• Avoid backing away from the load.
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This could increase the radius and cause the

machine to tip over.
• Use tag lines to keep loads under control.
• Keep the load close to the ground.
• Use the shortest boom possible.
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28. Using two or more cranes to lift a load involves

many hazards not normally encounted in single
crane lifts.
Multi-crane lifts must be carefully engineered,
keeping the following points in mind.
• Since the load is not freely suspended, careful

engineering studies must be made to ensure
that the load carried by each machine is less
than its rated capacity.
• Make sure slings are arranged to divide the load
as planned.
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• Review the lifting plan with operators, signalmen
and other crew members before beginning the
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lift.
• Carefully coordinate crane movements through
every stage of the lift.
• Avoid boom side loading (see #16).
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29. Leaving a machine unattended can be very
dangerous.
Before leaving his seat, the operator must take
the following steps to prevent his machine from
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moving :
• Since the load is not freely suspended, careful

engineering studies must be made to ensure
that the load carried by each machine is less
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than its rated capacity.

• Lower the load or bucket to the ground.
Lower the boom when necessary.
• Set the swing brake or lock.
• Set all drum locks.
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• Set parking brakes.

• Set travel brakes or locks on crawler machines.
• Disengage the engine clutch or shut off the
engine.
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• Place the function lock lever in the shut down

position.
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10000A-1
[ 1. SAFETY ]
30. The operator or person in charge should see

that :
• Loads are well secured before being lifted.

• Slings are not kinked or damaged.
The load is well balanced, and the hook block is
adequate for the load to be lifted.
Slings are properly arranged on the hook.
• Sudden stops and starts are avoided.
• The hoist line is vertical before starting the lift.
• The crane hook is equipped with a properly
functioning retainer latch.
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• Crane loads, grapples, or buckets do not pass
over the heads of workmen nor in any way
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endanger their safety.
All loose objects must be removed from the
load.
Non-operating personnel should be warned, or
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told to leave the immediate area, when making
crane lifts.
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31. Always replace protective guards and panels

before operating the machine whenever they
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become dirty or damaged.

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11000-1
[ 1. SAFETY ]
32. Never wear loose clothing rings or other objects

which may become entangled in the moving
machinery.
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33. The operator should test the winch brakes when
a load is first lifted, and when the load is only a
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few inches above its starting position, to assure
the ability of the brakes to hold the load while it
is aloft.
34. When refueling, be careful not to smoke.

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Stop the engine, and keep metal funnels in
contact with the fuel tank filler pipe to prevent
static electrical sparks from igniting the fuel.
Turn off cab heater (if equipped) while refueling,
and avoid refueling near an open flame.
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• Use ultra-low sulfur diesel fuel only (S50 :

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sulfur content lower than 50 ppm).

(For the cold region, use suitable low sulfur
fuel in the area.)
Confirm again if it is the proper type of fuel
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before refilling.
Failure to observe this precaution may result
of adverse effect to the environmental and
white smoke.
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• If fuel other than specified one is used,

adverse effect may be caused to the engine
or exhaust gas recirculate combustion
devices and white smoke or failure may be
resulted.
• If the engine is started with the wrong fuel
filled, it is very dangerous because it may
cause fire disaster or damage to the engine.
10000A-1
[ 1. SAFETY ]
35. If an overheated condition necessitates an

engine shutdown, use extreme care when
checking the radiator, if possible, wait for
radiator to cool.
Use a heavy cloth and gloves to protect yourself
while slowly loosening the cap.
Wait until the sound and fluid flow stops.
Then remove the cap.
36. Be careful where you park your machine.

Do not leave it where there is a chance of a bank
caving in on it, or in a low spot where heavy rains
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may wash out the footing.
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37. When leaving the crane unattended, always
remove keys and lock all cab doors to prevent
unauthorized person from tampering with the
machine and possibly injuring themselves or
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others.
38. Other operating precautions
• Do not perform lifting work with the crawler

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retracted.
• Never work in over load condition.
• Avoid free fall work as much as possible.
• Be careful of slipping on slope road.
• Do not use the main and aux. hook
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simultaneously from the boom point.

• Take slow speed in landing of load on the
ground.
MEASURES FOR RADIO TRANSMITTERS

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When working in the vicinity of a transmitting antenna

for a broadcasting station, the boom could act as a
large antenna, and could become electrified.
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High voltage of electricity may be generated at the

hook end, and the hook could become heated.
If this happens, do not touch the hook.
Electrical shock, or burning could result.
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Ground personnel should be warned to stay away

from the machine.

11000-1
[ 1. SAFETY ]
MEASURES FOR LIGHTNING
1. When lightning storms are generated and

lightning bolts are anticipated, immediately take
the following steps :
(1) Stop the work, and lower the load onto the
ground.
When the boom (or tower) can be lowered,
lower it onto the ground.
(2) Engage the brakes and locks (winch and swing)
and stop the engine.
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Turn off the power source of the load safety
device and main switch.
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(3) Advise all personnel to stay away from the
surrounding area of the machine.
2. If a lightning strike occurs check the machine
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before operating it.
(1) Check for burns and damage.

(2) Check the electrical devices and load safety
device for performance.
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(3) Check each function for abnormality.
MEASURES FOR EARTHQUAKE
1. When earthquakes occur, immediately take the

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following step :
(1) Stop the work, and lower the load and hook
onto the ground.
When the boom (or tower) can be lowered,
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lower it onto the ground.

(2) Engage the brakes and locks (winch and swing),
stop the engine, and turn off the electrical power
of the main switch and load safety device.
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(3) Advise all personnel to stay away from the

surrounding area of the machine.
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2. After the earthquake is over, check the machine

before operating.
(1) Check each function for performance.

(2) Check the electrical devices and load safety
device for performance.
10000A-1
[ 1. SAFETY ]
1.4 SAFETY AT INSPECTION AND MAINTENANCE WORK

• Stop the engine during inspection and
maintenance work.
• Do not weld other object to the boom since it

may cause weakening the boom strength.
(Prohibiting modification)
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• Do not bring fire close during battery handling.
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• Disconnect the battery cables during inspection

and maintenance of electrical system.
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11000-1
[ 1. SAFETY ]
• When removing the radiator cap straight after

engine stop, take extra care about internal high
pressure and high temperature.
Slowly remove the radiator cap after the coolant
temperature becomes lowered to release
pressure.
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• Machine parts are hot straight after engine stop.
Do not touch them.
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• Perform the inspection and maintenance work
specified by law.
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• Keep machine always in order, tidy and clean.
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• Whenever any fault is found, repair immediately.

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UNDER
REPAIR
10000A-1
[ 1. SAFETY ]
• Ensure to use genuine wire rope, guy line or oil.
The warranty does not cover malfunctions caused

by the use of parts other than Manitowoc specified.
(Genuine oil, grease and filter).
• Do not use fuel other than specified one.
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fuel in the area.)
before refilling.
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white smoke.
or exhaust gas recirculate combustion
devices and white smoke or failure may be
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resulted.
• Use recommended engine oil.

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In order to keep good function of the emission

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control devices, it is recommended to use the

specified brand (recommended) engine oil.
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11000-1
[ 1. SAFETY ]
1.5 SAFETY DURING ASSEMBLY AND DISASSEMBLY WORK

• Ensure to wear safety belt and other protective
gear during high place work.
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• Ensure to secure the machine to the trailer
firmly during transportation.
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Strictly observe the road traffic regulation on
dimension and weight during transportation.
• Do not cause overloading on the trailer.

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10000A-1
[ 1. SAFETY ]
1.6 CAUTIONS IN HANDLING OIL AND PAINT

CAUTIONS IN HANDLING LUBRICATING OIL AND GREASE
1. Oil draining while they are hot may cause burns

and is dangerous.
Drain them after cool down.
2. Getting them into eyes may cause inflammation.
Wear safety glasses etc in handling to prevent
getting into eyes.
3. Getting them touched on skin may cause
inflammation.
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Wear protective gloves etc in handling to
prevent them touching on skin.
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4. Do not drink.
(Drinking them may cause diarrhea or vomiting.)
Keep them away from children to reach.
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CAUTIONS IN HANDLING PAINT
1. Do not handle in the place with fire.

2. Handling place should be equipped with the
localized exhaust system.
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3. During painting and drying, exhaust system
should work to prevent sucking steam.
4. During handling them, take care not to let them
touch on the skin.
Wear organic gas mask, supplied-air respirator,
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safety glasses, protective gloves, hood, long

sleeve work shirt, scarf etc as required.
5. If spilled, wipe off with cloths after scattering
sands.
Paint adhered cloths, paint dregs or spray dust
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should be handled by soaking in the water.

6. After handling, wash your face, your hand, rinse
your mouth and nasal well.
7. If paint adheres to your skin, wash out with
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soapy water. If painful or injured, see the doctor.

If painful or injured, see the doctor.
8. If paint get into your eyes, wash your eyes with
much water and see the doctor as soon as
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possible.
9. If you feel bad by sucking steam or gas, stay
calm in clean-air place and see the doctor as
required.
10. In case of fire, use CO 2 gas or foam fire
extinguisher.
11. Keep them with complete sealing and at the
specified place where children can not reach.
12. Dispose them as industrial wastes.
13. Do not use for purpose other than specified
(such as glue sniffing).

11000-1
[ 1. SAFETY ]
1.7 SAFETY EQUIPMENT (OPTION)

This machine is equipped with safety equipment as
option.
For the detail of the safety equipment (option), refer to
the article “8. REFERENCE MATERIALS”.
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10000A-1
[ 2. OPERATION ]
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART ................................................................ 2-1
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ........................................ 2-4
2.2.1 HANDING LEVER AND PEDAL .................................................................................... 2-5
2.2.2 OPERATING SWITCHES ................................................................................................ 2-14
2.2.3 VARIOUS SETTING OF MONITOR ............................................................................. 2-42
2.2.4 ANEMOMETER INSTALLATION (OPTION) .............................................................. 2-51
2.2.5 AIR CONDITIONER .......................................................................................................... 2-52
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(OPTION).............................................................................................................................. 2-58
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2.2.7 AM/FM RADIO .................................................................................................................... 2-61
2.2.8 1WAY CALL (TRANSMITTER) ....................................................................................... 2-72
2.2.9 MONITORING CAMERA (OPTION) ............................................................................. 2-73
2.3 CRANE OPERATION ............................................................................................................. 2-76
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2.3.1 ADJUSTING THE OPERATOR’S SEAT ...................................................................... 2-76
2.3.2 GETTING ON AND OFF FROM / TO OPERATOR’S CAB .................................... 2-78
2.3.3 STARTING AND STOPPING THE ENGINE............................................................... 2-79
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2.3.4 EMISSION CONTROL DEVICE .................................................................................... 2-84
2.3.5 TIER4 FINAL INDUCEMENT CONTROL ................................................................... 2-100
2.3.6 AUTO IDLE STOP FUNCTION ...................................................................................... 2-111
2.3.7 FUNCTION LOCK LEVER .............................................................................................. 2-114
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2.3.8 TRAVELING OPERATION............................................................................................... 2-115

2.3.9 SWINGING OPERATION ................................................................................................ 2-118
2.3.10 BOOM RAISING/LOWERING OPERATION .............................................................. 2-123
2.3.11 HOOK HOISTING/LOWERING OPERATION ........................................................... 2-127
2.4 FREE FALL OPERATION ..................................................................................................... 2-136
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2.5 CLAMSHELL OPERATION .................................................................................................. 2-142

2.5.1 PREPARATION WORK .................................................................................................... 2-144
2.5.2 CLAMSHELL WORK ......................................................................................................... 2-148
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2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)....................................................... 2-149

2.7 HANDLING OF VIBRO HAMMER...................................................................................... 2-152
2.8 OPERATION IN WEATHER CHANGE AND SPECIAL CIRCUMSTANCE ............ 2-155
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2.8.1 CAUTION AGAINST WIND ............................................................................................. 2-155

2.8.2 CAUTION AGAINST ELECTRIC SHOCK................................................................... 2-167
2.8.3 CAUTION AGAINST RADIO WAVE INTERFERENCE........................................... 2-169
2.8.4 CAUTION AGAINST LIGHTNING ................................................................................. 2-170
2.8.5 COUNTERMEASURE AGAINST EARTHQUAKE.................................................... 2-170

11000-1
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[ 2. OPERATION ]
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART
IDLER SHEAVE AUX. SHEAVE
POINT SHEAVE
BOOM GUY LINE
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AUX. HOOK
MAIN HOOK
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UPPER SPREADER BOOM TIP
BOOM HOIST WIRE ROPE
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BOOM INSERT
LOWER SPREADER
BOOM BACKSTOP
TRAVEL KIT
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GANTRY
TENSION BAR BOOM BASE

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COUNTERWEIGHT
UPPER ROLLER
TRAVEL MOTOR, IDLER
REDUCTION UNIT
LOWER ROLLER
SHOE SWING BEARING
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11000-1
[ 2. OPERATION ]
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BOOM DRUM
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THIRD DRUM (OPTION)
REAR DRUM
BOOM DRUM MOTOR,
FRONT DRUM REDUCTION UNIT
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THIRD DRUM MOTOR,
SWING MOTOR,
REDUCTION UNIT (OPTION)
REDUCTION UNIT
REAR DRUM MOTOR,
ACCUMULATOR REDUCTION UNIT
FRONT DRUM MOTOR,
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REDUCTION UNIT
TAGLINE MOTOR
SWIVEL JOINT
SWING BEARING
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10000A-1
[ 2. OPERATION ]
SCR
DPF
AIR CLEANER
ENGINE RADIATOR
POWER DIVIDER
OIL COOLER
HYDRAULIC PUMP
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HYDRAULIC OIL TANK BATTERY
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CONTROL VALVE
WASHER TANK (OPTION)
DEF/AdBlue® TANK
CONTROL VALVE
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CONTROL VALVE
FUEL TANK
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11000-1
[ 2. OPERATION ]
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS
RADIO CONTROL PANEL
REAR SWITCH PANEL

RIGHT SIDE SWITCH PANEL
LEFT SIDE SWITCH PANEL
LEVEL GAUGE
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A/C CONTROL PANEL
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MONITOR
DRUM CONTROL LEVER CONTROL PEDAL

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MONITOR STAND
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BYPASS SWITCH PANEL

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LEFT STAND
SWITCH PANEL
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LEFT LEVER STAND
RIGHT LEVER STAND
10000A-1
[ 2. OPERATION ]
2.2.1 HANDING LEVER AND PEDAL
23. BOOM DRUM CONTROL PEDAL

(OPTION)
20. FRONT DRUM BRAKE PEDAL
21. REAR DRUM BRAKE PEDAL
22. THIRD DRUM BRAKE PEDAL
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(OPTION) 24. ACCEL. CONTROL PEDAL
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12. THIRD DRUM ROTATION SENSING GRIP
(OPTION)
18. ACCEL. GRIP
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17. SWING CONTROL LEVER
4. THIRD DRUM CONTROL LEVER (OPTION)
8. THIRD DRUM LEVER LOCK (OPTION)
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1. FUNCTION LOCK LEVER
19. SWING LOCK
CONTROL LEVER
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14. RIGHT TRAVEL CONTROL LEVER

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15. LEFT TRAVEL CONTROL LEVER

16. TRAVEL CONTROL LEVER LOCK
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2. FRONT DRUM CONTROL LEVER 10. FRONT DRUM ROTATION SENSING GRIP
11. REAR DRUM ROTATION SENSING GRIP
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3. REAR DRUM CONTROL LEVER

13. BOOM DRUM ROTATION SENSING GRIP
(OPTION)
5. BOOM DRUM CONTROL LEVER
6. FRONT DRUM LEVER LOCK

7. REAR DRUM LEVER LOCK
9. BOOM DRUM LEVER LOCK

11000-1
[ 2. OPERATION ]
This article explains levers and pedals in the operator’s

cab.
Refer to the article “2.3 CRANE OPERATION” for the
explanation of control based on actual work.
1. FUNCTION LOCK LEVER
Near side : Far side :

The function lock lever is the safety device to Lock position Work position
make machine not to move even if the persons
body touches the control lever when getting ON
or OFF the operators seat. FUNCTION LOCK
LEVER
At lock position control of each drum, travel and
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swing can’t be performed.
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Pull to near side Lock position
Push to far side Work position
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Turn the function lock lever to “WORK” position
when the machine is to be operated.
Whenever leaving from the operator’s seat,
ensure to stop the engine and turn the function
lock lever to “LOCK” position.
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Ensure to turn the function lock lever to “LOCK”
position at work completion or at transportation
of machine.
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10000A-1
[ 2. OPERATION ]
DRUM CONTROL LEVER
2. FRONT DRUM CONTROL LEVER

3. REAR DRUM CONTROL LEVER
Far side :
4. THIRD DRUM CONTROL LEVER (OPTION) Unwinding side
5. BOOM DRUM CONTROL LEVER
These levers are to start, control and stop the

front, rear, third (option) and boom drum.
Near side :
Winding side
Pull to near side Winding
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Push to far side Unwinding
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Each lever drives and controls the drum such as
pulling backward to wind, neutral and pushing
forward to unwind. BOOM DRUM CONTROL LEVER
Each lever is held at the position due to detent REAR DRUM CONTROL LEVER
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provided. FRONT DRUM CONTROL LEVER
THIRD DRUM
CONTROL LEVER (OPTION)
* Detent : Function to prevent lever returning.
6. FRONT DRUM LEVER LOCK

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7. REAR DRUM LEVER LOCK
8. THIRD DRUM LEVER LOCK (OPTION)
THIRD DRUM
9. BOOM DRUM LEVER LOCK LEVER LOCK
(OPTION)
To lock the respective drum levers are provided

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FRONT DRUM LEVER LOCK

apart from the function lock lever. REAR DRUM LEVER LOCK
Engage each lever lock with the levers when BOOM DRUM LEVER LOCK
they are not in use at neutral position to prevent
unexpected movement of lever by touching the
operator’s body.
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Release position Lock position
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11000-1
[ 2. OPERATION ]
10. FRONT DRUM ROTATION SENSING GRIP Movable part

11. REAR DRUM ROTATION SENSING GRIP
12. THIRD DRUM ROTATION SENSING GRIP
Movable part
(OPTION)
13. BOOM DRUM ROTATION SENSING GRIP
(OPTION)
To sense the starting and the condition of each

drum rotation are provided.
When the “44. DRUM ROTATION SENSING
SWITCH (OPTION)” is turned to “ON” position,
operator can sense the each drum rotation by
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movable parts on the top face of each drum
control lever grip.
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* High speed rotation or free fall of the drum may
not be sensed.
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10000A-1
[ 2. OPERATION ]
TRAVEL CONTROL LEVER
14. RIGHT TRAVEL CONTROL LEVER

15. LEFT TRAVEL CONTROL LEVER
These levers are to control the traveling (drive,

Far side :
control and stop). Forward travel side
The pivot turn, spin turn and large radius turn Near side :
Backward travel side
can be done for direction change.
Pull to near side Backward travel side
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Push to far side Forward travel side
RIGHT TRAVEL
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Each lever is held at the position due to the CONTROL LEVER
detent provided. LEFT TRAVEL
CONTROL LEVER
* Special attention is required since the lever
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moving direction has to be reversed based on
TRAVEL CONTROL
the direction of lower machinery against the LEVER LOCK
upper.
16. TRAVEL CONTROL LEVER LOCK

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To lock travel control levers are provided apart Release position Lock position
from the function lock lever.
Engage each lever lock with the lever when
they are not in use at neutral position to prevent
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unexpected movement of lever by touching the

operator’s body.
Forward direction
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Pivot turn
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Spin turn
Normal turn

11000-1
[ 2. OPERATION ]
SWING CONTROL LEVER
17. SWING CONTROL LEVER Far side :

Left swing side
SWING CONTROL LEVER
This lever is to start, control and stop the left
and right swing motion of the upper machinery.
Near side :
Right swing side
Pull to near side Right swing side
Neutral position Stop (slowdown stop)
(Auto return) position
Push to far side Left swing side
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Lever returns automatically to neutral position
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when hand is released.
18. ACCEL. GRIP Speed decrease side
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The engine speed control is done with the ACCEL. GRIP
120 degrees
accel. grip installed on the swing lever.
Speed increase side
Accel. grip has 120 degrees control range and
can be set to any position.
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Clockwise Speed decrease side
Counterclockwise Speed increase side SWING CONTROL LEVER
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19. SWING LOCK CONTROL LEVER SWING LOCK CONTROL LEVER
This lever is to insert the lock pin from the Near side : Far side :
upper machinery to the pin catch on the lower
machinery to secure the upper machinery
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or release the pin to allow upper machinery

swinging.
Ensure to insert the swing lock pin at the work

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completion or at the transportation.
Pull to near side Release position

Push to far side Lock position
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10000A-1
[ 2. OPERATION ]
BRAKE PEDAL FOR FREE FALL
20. FRONT DRUM BRAKE PEDAL

21. REAR DRUM BRAKE PEDAL
22. THIRD DRUM BRAKE PEDAL (OPTION)
The pedal applies braking force to the

respective drums to control the free falling.
To control the lowering speed of lifting load

(bucket or the like) is to be adjusted by the
degree of pressing of the pedal.
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Pressing the pedal further, engage the pedal
lock and can be held the pedal with locked
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position. THIRD DRUM BRAKE PEDAL
(OPTION)
FRONT DRUM BRAKE PEDAL
While hoisting and power lowering, the brake
REAR DRUM BRAKE PEDAL
will not function even the brake pedal applied
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and function at free fall only.
* “22. THIRD DRUM BRAKE PEDAL (OPTION)”

and “23. BOOM DRUM CONTROL PEDAL
(OPTION)” can’t be equipped at same time.
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Pressing :
Engage side
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11000-1
[ 2. OPERATION ]
CONTROL PEDAL
23. BOOM DRUM CONTROL PEDAL (OPTION)
This pedal can control the boom drum instead

of the boom hoist control lever.
The boom raises with the control pedal pushed
heel side and the boom lowers with the control
pedal pushed toe side.
Press heel side Raising side
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Neutral position
Stop position
(Auto return)
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Press toe side Lowering side
BOOM CONTROL PEDAL (OPTION)

Pedal returns automatically to neutral position
when foot is released.
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* As for the boom drum control lever and boom
drum control pedal, whichever is used first over-
rides the other.
* “22. THIRD DRUM BRAKE PEDAL (OPTION)”
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and “23. BOOM DRUM CONTROL PEDAL
(OPTION)” can’t be equipped at same time.
Heel side :
Raising side Toe side :
Lowering side
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10000A-1
[ 2. OPERATION ]
24. ACCEL. CONTROL PEDAL
The pedal is for used instead of accel. grip for

adjusting the engine speed.
Pressing the control pedal to far side increase

the speed and the pedal returns automatically.
Leave the foot, the pedal returns to original

position.
* As for the accel. grip lever and accel. control
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pedal, whichever is used first over-rides the
other.
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ACCEL. CONTROL PEDAL
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Pressing :
Speed Increase side
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11000-1
[ 2. OPERATION ]
2.2.2 OPERATING SWITCHES
17. THIRD DRUM SPEED ADJUST TRIMMER (OPTION)
3. THIRD DRUM LOCK KNOB 15. FRONT DRUM

(OPTION) SPEED ADJUST
TRIMMER
1. FRONT DRUM LOCK KNOB
16. REAR DRUM
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4. BOOM DRUM LOCK KNOB SPEED ADJUST
TRIMMER
2. REAR DRUM LOCK KNOB
18. BOOM DRUM
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SPEED ADJUST
7. HOOK OVERHOIST RELEASE SWITCH TRIMMER
6. BOOM/JIB OVERHOIST RELEASE SWITCH

5. LOAD SAFETY DEVICE RELEASE SWITCH
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8. GANTRY CONTROL SWITCH
14. CIGARETTE
9. CRAWLER EXTEND/RETRACT SWITCH
LIGHTER
SPARE
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LEFT LEVER STAND RIGHT LEVER STAND
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10000A-1
[ 2. OPERATION ]
21. THIRD DRUM BRAKE

SELECT SWITCH (OPTION)
19. FRONT DRUM BRAKE

SELECT SWITCH
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20. REAR DRUM BRAKE
SELECT SWITCH
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22. FRONT DRUM G WINCH SWITCH
23. REAR DRUM G WINCH SWITCH
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DRUM CONTROL LEVER
12. KEY SWITCH

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11. HORN SWITCH
10. SWING BRAKE SWITCH

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13. HOUR METER

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11000-1
[ 2. OPERATION ]
42. G ENGINE SELECT SWITCH
41. AUTO IDLE STOP SWITCH
RADIO CONTROL PANEL 40. G WINCH MAIN SWITCH
44. DRUM ROTATION SENSING SWITCH (OPTION)
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SPARE
43. TRAVEL ALARM SWITCH (OPTION)
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REAR SWITCH PANEL
SPARE
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38. AUX. ACTUATOR SELECT SWITCH
SPARE
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SPARE
SPARE
39. TRAVEL SPEED SELECT SWITCH

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24. WIPER SWITCH (FRONT WINDOW) 29. THIRD DRUM FREE FALL SPEED
SELECT SWITCH (OPTION)
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25. WIPER SWITCH (ROOF WINDOW)

28. REAR DRUM FREE FALL SPEED
26. WASHER (ROOF, FRONT WINDOW) SELECT SWITCH
27. FRONT DRUM FREE FALL SPEED
SPARE
SELECT SWITCH
SPARE
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31. TAGLINE TENSION ADJUST

SPARE TRIMMER (OPTION)
30. ENGINE EMERGENCY STOP SWITCH

35. AUXILIARY ACCEL SWITCH 32. WORK LIGHT SWITCH
36. EMERGENCY STOP CHECK SWITCH 33. REAR WORK LIGHT SWITCH (OPTION)
37. SWING ALARM SELECT SWITCH 34. DRUM LIGHT SWITCH (OPTION)
10000A-1
[ 2. OPERATION ]
68. THIRD DRUM FREE FALL INDICATION LAMP (OPTION)

65. AUTO IDLE STOP INDICATION LAMP 66. FRONT DRUM FREE FALL INDICATION LAMP
64. G WINCH INDICATION LAMP 67. REAR DRUM FREE FALL INDICATION LAMP
63. G ENGINE INDICATION LAMP 69. INCHING SPEED LAMP
62. ENGINE WARNING LAMP
WIND SPEED INDICATOR (OPTION) 71. REMOTE CONTROL CONNECTION LAMP
0.0
10 . 0 f t 800
10021000000600120420
2015/05/10 10:00 72. HYDRAULIC OIL TEMPERATURE LAMP
4 1
73. EXHAUST SYSTEM COOLING CALL LAMP
100 . 3 f t
y
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
nl
× 1000
0. 0
70 . 0 deg
77. SOOT ACCUMULATION BAR GAUGE
76 DEF/AdBlue® BAR GAUGE
40 . 3 f t 50 . 0 f t
75. FUEL BAR GAUGE
O
74. ENGINE COOLANT TEMPERATURE GAUGE
L+S 0.3
RESET S
SET D 0.2
MONITOR SCREEN
51. SWING MODE SELECT ICON

ce
(BRAKE/LOW SPEED) (OPTION) 52. CAMERA SELECT ICON (OPTION)
(FREE/LOW SPEED) (OPTION) 53. WORK MODE SELECT ICON
(FREE/HIGH SPEED) (OPTION)
en
60. BOOM, JIB LOWERING ICON

54. MENU ICON 61. ASSY/DISASSY ICON
55. DPF REGENERATION START ICON

56. DPF REGENERATION CANCEL ICON 59. INCHING ICON
er
57. FINAL LIMIT RECOVERY ICON 58. ENGINE STOP ICON

Detail of menu icon
ef
47. MAIN CONTROLLER 1 BYPASS SWITCH

48. MAIN CONTROLLER 2 BYPASS SWITCH
R
46. FREE FALL LOCK MASTER KEY

45. RELEASE SWITCH MASTER KEY
BYPASS SWITCH PANEL

11000-1
[ 2. OPERATION ]
Explain for respective switches in this article.

Refer to the article “2.3 CRANE OPERATION” for the
explanation of control based on the actual work.
LEFT LEVER STAND
1. FRONT DRUM LOCK KNOB

2. REAR DRUM LOCK KNOB
3. THIRD DRUM LOCK KNOB (OPTION)
4. BOOM DRUM LOCK KNOB THIRD DRUM
LOCK KNOB
(OPTION)
These knobs are to lock the drum for safety
y
BOOM DRUM
LOCK KNOB
purpose.
nl
Engage the drum lock by pulling up the drum FRONT DRUM
LOCK KNOB
lock knob when the drum is not used for long
time. REAR DRUM
LOCK KNOB
To release, push the knob while pushing the
O
button on the knob top.
Pull up Lock position

25 mm (31/32″)
Push down Release position
ce
Pull up : Lock position Push down : Release position
Stopping the engine issues alarm sound to
expedite drum lock for 4 seconds.
en
Never engage the drum lock while lowering the

hook or the attachment.
The drum or drum lock pawl may be damaged.
er
Failure to observe this precaution may result of

damage the machine.
ef
R
10000A-1
[ 2. OPERATION ]
This switch is for release the over load prevention

function temporally.
This switch is to be used only in case of the
operation has to be made due to the emergency
case and/or maintenance work. Near side :
Release side
This switch is functional only when “45.

RELEASE SWITCH MASTER KEY” is turned to
release side.
y
Only while the switch is in release side, the auto
stop due to the over load can be released.
nl
Switch returns automatically to original position
O
This switch is for release the boom/jib overhoist

prevention function temporally.
ce
Release side

RELEASE SWITCH MASTER KEY” is turned to
en
release side.

stop due to boom/jib overhoist can be released.
er

ef
R

11000-1
[ 2. OPERATION ]
7. HOOK OVERHOIST RELEASE SWITCH
This switch is for release the hook overhoist

Release side

RELEASE SWITCH MASTER KEY” is turned to HOOK OVERHOIST RELEASE SWITCH
release side.
y
stop due to the hook overhoist can be released.
nl
O
8. GANTRY CONTROL SWITCH
This switch is to control the gantry raising or Far side :

Raising side
lowering motion.
ce
Press far side Raising side
Near side :
Neutral position Lowering side
Stop position
(Auto return)
Press near side Lowering side
GANTRY CONTROL SWITCH
en
Switch returns automatically to neutral position

er
When the gantry is raised or lowered, make sure

that there is no persons around the gantry area
ef
and observe the raising or lowering condition of

the gantry.
Failure to observe this precaution may result in a
serious injury or loss of life.
R
10000A-1
[ 2. OPERATION ]
9. CRAWLER EXTEND/RETRACT SWITCH
This switch is to extend or retract the crawler. Far side :

Extending side
Press far side Extending side

Neutral position
Stop position Near side :
(Auto return) Retracting side
Press near side Retracting side
CRAWLER EXTEND SWITCH

Switch returns automatically to neutral position
y
Crawler extension and retraction must be
nl
carried out on the firm and leveled ground
without the counterweights, with boom base and
the boom angle of approximate 10 degrees.
O
Even without counterweight and boom base,
crawler can be extended or retracted.
But in such case, swing the upper machinery to
reduce the load on the shifting side axle.
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
SWING CONTROL LEVER
10. SWING BRAKE SWITCH

Left : Right :
Engage side Disengage side
This is a brake to hold the upper machinery
stationary and not to swing.
SWING BRAKE SWITCH
Press Left side Engage side

Press Right side Disengage side
y
nl
Engage the swing brake and swing lock should
be performed when the upper machinery is
completely stopped.
Use of these to stop the swing motion creates
O
SWING CONTROL LEVER
huge burden to the swing mechanism and the
attachment and may lead to accident.
serious accident and loss of life.
ce
• Due to the wind or ground inclination the upper
machinery may start swing unexpectedly.
en
Take extra care when disengaging the swing

brake.
in a serious accident.
• If the engine is started with the swing brake
er
disengaged or if the function lock lever is

turned to lock position with the swing brake
disengaged, the swing brake is kept engaged.
In such case, turn the swing brake to
ef
“ENGAGE” side once and then turn to

“DISENGAGE” side to release the swing brake.
R
11. HORN SWITCH
This switch issues horn sound. Push the horn

HORN SWITCH
switch at stating the engine, swinging and
traveling to alarm personnel around. While the
switch is being pushed, the horn sounds.

SWING CONTROL LEVER
10000A-1
[ 2. OPERATION ]
OTHERS
12. KEY SWITCH
This switch is to start, stop the engine and

connect its accessory circuit.
Engine shut off position.

OFF KEY SWITCH
(Key insert / take out position.)
ACC Accessory ON position.
ON Engine running position.
y
START Engine start position.
nl
When starting the engine, make sure that the
O
function lock lever is in lock position and each OFF
ACC
control lever is in neutral position.
ON
START
ce
• There is no glow preheating switch but
engine control unit (ECU) automatically
preheating the intake air as required.
• Indicate an icon ( ) which is express
en
of under preheating in the monitor in the

operators cab.
• As to the starting assist of engine at cold
atmosphere, refer to the article “2.3.3
STARTING AND STOPPING THE ENGINE”.
er
13. HOUR METER

ef
Count of the machine operation time.

R
HOUR METER

11000-1
[ 2. OPERATION ]
14. CIGARETTE LIGHTER
When pushed in, lighter is held at its position

and when heated red, it is popped out.
Pull out for use.
CIGARETTE LIGHTER
If the lighter knob does not pop up within 30

seconds after it is pushed in, pull it out.
If it is kept pushed position, wiring may be
y
damaged and may cause fire. Normal position
nl
serious accident.
Heating position
O
15. FRONT DRUM SPEED ADJUST TRIMMER
16. REAR DRUM SPEED ADJUST TRIMMER
17. THIRD DRUM SPEED ADJUST TRIMMER
ce
(OPTION)
THIRD DRUM SPEED
18. BOOM DRUM SPEED ADJUST TRIMMER CONTROL TRIMMER
(OPTION)
This trimmer adjusts the drum speed apart from

the drum speed control by the control lever.
en
(This makes synchronous speed adjusting with

other drum possible.) FRONT DRUM
SPEED ADJUST TRIMMER
REAR DRUM
Turn right SPEED ADJUST TRIMMER
Speed increase side
(Clockwise) BOOM DRUM
er

Turn left
Speed decrease side
(Counterclockwise)
Left :
ef
Speed decrease side

Right :
Speed increase side
R
10000A-1
[ 2. OPERATION ]
HOIST CONTROL LEVER
19. FRONT DRUM BRAKE SELECT SWITCH THIRD DRUM BRAKE

20. REAR DRUM BRAKE SELECT SWITCH SELECT SWITCH (OPTION)
21. THIRD DRUM BRAKE SELECT SWITCH

(OPTION)
These switches are to select the required mode

either the free fall or neutral brake.
As for the detail of free fall operation, refer to
the article “2.4 FREE FALL OPERATION”.
y
FRONT DRUM BRAKE SELECT SWITCH
(1) Free fall mode REAR DRUM BRAKE SELECT SWITCH
Turns the free fall lock switch to release side
nl
and push the switch while pressing the brake
pedal fully will make free fall mode.
At the same time, free fall indication lamp lights
up to advise free fall mode.
O
(Brake turns into brake pedal control.)
(2) Neutral brake mode

Pushing the switch again while pressing the brake
pedal fully turns into the neutral brake mode.
ce
At the same time free fall indicating lamp goes
off. (Brake turns into auto brake.)
For safety it certainly turns to neutral brake
mode after the engine start.
en
22. FRONT DRUM G WINCH SWITCH

23. REAR DRUM G WINCH SWITCH
This switch is for changing these winches to G FRONT DRUM G WINCH SWITCH
winch mode. REAR DRUM G WINCH SWITCH
er
With “40. G WINCH MAIN SWITCH” turn

ON and push this switch, respective winches
change to G winch mode.
ef
As to the details of G winch mode, refer to “2.3.11

HOOK HOISTING/LOWERING OPERATION”
R

11000-1
[ 2. OPERATION ]
LEFT SIDE SWITCH PANEL Upper : Continuous operation side
24. WIPER SWITCH (FRONT WINDOW)

25. WIPER SWITCH (ROOF WINDOW)
These switch are to actuate each wiper.
Continuous operation.
Intermittent operation.
Lower : Intermittent operation side
y
26. WASHER (ROOF, FRONT WINDOW) Upper : Roof window side
nl
This switch is to discharge washer liquid to roof,
front window.
Washer liquid comes out to roof
O
window.
Washer liquid comes out to front
window.
Lower : Front window side

ce
Check the fluid level periodically and refill if
required.
en
Refer to the article “2.1 TERMINOLOGY OF MACHINE

EACH PART” for the location of the washer tank.
er
ef
R
10000A-1
[ 2. OPERATION ]
27. FRONT DRUM FREE FALL SPEED SELECT Upper : Speed increase side
SWITCH
28. REAR DRUM FREE FALL SPEED SELECT
SWITCH
29. THIRD DRUM FREE FALL SPEED SELECT
SWITCH (OPTION)
This switch is for making the free fall effective

when the ambient temperature is low.
Lower : Normal side

Free fall speed is increased.
Speed
y
This is suitable for light weight
increase
free falling work when ambient
side
temperature is low.
nl
Normal side Use normal free fall work.
O
• Do not free fall with heavy load.
The control of lifting load becomes difficult
by brake pedal if the free falling speed is fast.
ce
Perform free falling with lower speed as
slow as possible.
• When changing the free fall speed select
switch is in increase side, do not release the
brake pedal with the hook on the ground.
en
The drum automatically rotates to lowering

side and this may cause rough spooling.
30. ENGINE EMERGENCY STOP SWITCH

er
Push this switch to stop the engine in emergency.

The switch is held at the pushed position.
Turn the switch to right to return to the original
ef
position.
Push down : Engine stop Turn right : Release
R
The engine will not start when the switch is being

pushed in.

11000-1
[ 2. OPERATION ]
31. TAGLINE TENSION ADJUST TRIMMER

(OPTION)
This trimmer is to adjust the tagline rope tension.
Turn right Tagline rope tension

(Clockwise) becomes high.
Turn left Tagline rope tension
(Counterclockwise) becomes low.
When the tagline is not in use, set the trimmer
y
to “LOW” side.
nl
* The drum speed adjustment can not be done
with this adjusting trimmer.
32. WORK LIGHT SWITCH Upper : ON
O
33. REAR WORK LIGHT SWITCH (OPTION)
This switch is to select ON/OFF of the front,

rear lights.
ce
ON Light ON
OFF Light OFF
Lower : OFF
en
Ensure to turn the work light switch “OFF” when

the work is completed.
Failure to turn the switch off may cause of battery
er
discharge.
34. DRUM LIGHT SWITCH (OPTION) Upper : ON

ef
This switch is to select ON/OFF of the drum

lights.
R
ON Light ON
OFF Light OFF
Lower : OFF
10000A-1
[ 2. OPERATION ]
35. AUXILIARY ACCEL SWITCH Upper : Middle speed side
This switch is used when engine speed

adjustment can not be done due to failure of
accel grip. SLIDE LOCK
* This switch is equipped with the slide lock.

This switch can be operated only when the slide
lock is slid to upper side.
Lower : Low speed side

Middle Engine speed becomes approx.
y
speed side 1,500 to 1,600 min-1 (1,500 to 1,600 rpm).
Low speed Engine speed becomes
side approx. 800 min-1 (800 rpm).
nl
O
Do not use the auxiliary accelerator switch when
the accelerator grip is normal.
If in case of using the auxiliary accelerator switch
while the accelerator grip is in normal condition,
ce
the engine speed control by the grip can’t be made.
36. EMERGENCY STOP CHECK SWITCH Upper : Check side

en
This switch can check the auto-stop function of

the boom and jib.
The auto stop function is normal if the boom

raising, jib lowering and hook hoisting can’t be
er
done while this switch is kept in check side.

ef
37. SWING ALARM SELECT SWITCH Upper : Alarm light, buzzer side
This switch is to select swing alarm.

R
Buzzer sound and swing flasher

(Alarm light, buzzer) blinking.
Neutral position Nothing occurs.
Swing flasher blinking

(Alarm light) Lower : Alarm light side

11000-1
[ 2. OPERATION ]
38. AUX. ACTUATOR SELECT SWITCH Upper : ON
ON (Not use on this model)

Gantry, tagline (option) can be
OFF
controlled.
Normally use OFF position.
y
Lower : OFF
nl
39. TRAVEL SPEED SELECT SWITCH Upper : High speed side
High speed
Travel speed is fast.
side
O
Low speed
Travel speed is slow.
side
ce
Do not use the travel speed select switch during
traveling.
It may cause deflected travel.
en
er
ef
R
10000A-1
[ 2. OPERATION ]
REAR SWITCH PANEL
40. G WINCH MAIN SWITCH Upper : ON
This is the main switch to use G winch.
As to the detail of G winch mode is to be used,

refer to “2.3.11 HOOK HOISTING/LOWERING
OPERATION”
y
Lower : OFF
nl
41. AUTO IDLE STOP SWITCH Upper : ON
This switch is to use of the auto idle stop function.
O
As to the detail of auto idle stop function is
to be used, refer to “2.3.6 AUTO IDLE STOP
FUNCTION”
ce
Auto idle stop function becomes
ON
effective.
Lower : OFF
Auto idle stop function becomes
OFF
ineffective.
en
42. G ENGINE SELECT SWITCH Upper : Power mode side
This switch is to select the G engine mode or

power mode.
er
As to the detail of G engine mode, refer to “2.3.11

HOOK HOISTING/LOWERING OPERATION”
The max. engine speed becomes

ef
approximate 2,100 min-1 (2,100 rpm).

Lower : G engine mode side
Power mode This mode is suited to the heavy load
side lifting with less dropping the lifting
speed compared with the G engine
R
mode.
The max. engine speed becomes
G engine approximate 1,725 min-1 (1,725 rpm).
mode side Lifting light load with high speed can
be obtained.

11000-1
[ 2. OPERATION ]
43. TRAVEL ALARM SWITCH (OPTION) Upper : ON
This is to select the travel alarm.
ON Buzzer sound for warning of traveling.

OFF No buzzer sound.
Lower : OFF
y
44. DRUM ROTATION SENSING SWITCH (OPTION) Upper : ON
nl
This switch is to select the each drum rotation
sensing effective or not.
Move the movable part on grip
O
ON proportionally to the each drum rotating
speed.
OFF No movement.
Lower : OFF
ce
Movable part
Movable part
en
er
ef
R
10000A-1
[ 2. OPERATION ]
BYPASS SWITCH PANEL
45. RELEASE SWITCH MASTER KEY Left : Lock side Right : Release side
This is the master key to lock releasing the

load safety device, boom overhoist and hook
overhoist for safety.
Can’t be released the auto-stop

Lock side
functions.
Can be released the auto-stop
Release side
y
functions.
nl
The key can be taken off at the lock position.
O
During work bypass key must be kept and be
controlled by work responsible person.
ce
46. FREE FALL LOCK MASTER KEY Left : Lock side Right : Release side
This is the master key for lock the free fall

operation of the front, rear and third (option)
drum for safety purpose.
en
Lock side Can’t be made the free fall operation.

Release side Can be made the free fall operation.
er
When this key is in “LOCK” side, the free fall

operation can’t be made even the brake select
switch is turned to “FREE FALL” side.
ef

R
During work free fall lock key must be kept and be


11000-1
[ 2. OPERATION ]
47. MAIN CONTROLLER 1 BYPASS SWITCH Upper : Bypass side
When the main controller 1 failed, swing control

becomes possible.
48. MAIN CONTROLLER 2 BYPASS SWITCH Lower : Normal side
When the main controller 2 failed, each of front

drum, rear drum, third drum and boom hoist
control becomes possible.
y
nl
Do not use these switches for other than emergency
evacuation work due to failure of controller.
O
ce
en
er
ef
R
10000A-1
[ 2. OPERATION ]
SWITCHES IN THE MONITOR (TOUCH PANEL)
49. SWING MODE SELECT ICON (FREE/HIGH

SPEED) (OPTION)
50. SWING MODE SELECT ICON (FREE/LOW
SPEED) (OPTION)
51. SWING MODE SELECT ICON (BRAKE/LOW
FREE/HIGH SPEED BRAKE/LOW SPEED
SPEED) (OPTION)
FREE/LOW SPEED
This icon is to select the swing control and
swing speed based on work contents.
This icon is displayed on the monitor and
y
touching it can select the swing mode.
The selected mode icon is displayed in green.
nl
* Push for more than 1 second.
Mode Work content Movement
O
Free/high speed Crane, lifting magnet and clamshell work. With the lever neutral mode becomes swing free.
Free/low speed Long boom crane Select the swing speed based on the work.
With the lever neutral, swing brake is engaged.

Brake/low speed Long boom crane
(Hydraulic brake)
ce
* LOW SPEED At high idling about 50% of high speed.
At low idling about 70% of high speed.
At the long boom crane work, if the select icon is

kept to brake/low speed side, operation is easy
en
but hydraulic control is being applied to reduce

swing stop shock and swing power is lowered
and swing speed becomes slow.
er
In order to avoid damage on the base machine and

the hydraulic components, the swing mode select
ef
icon should be manipulated at the swing brake switch

is in the engage side with the engine at low idle.
Do not perform switching of swing mode while in
swing motion.
R
Failure to observe this precaution may lead to

parts damage.
This machine is only applicable to general crane works.

In case use of the lifting magnet and clamshell and
foundation works are required, consult authorized
Manitowoc distributor.

11000-1
[ 2. OPERATION ]
52. CAMERA SELECT ICON (OPTION)
This icon is to select camera indication / non

indication or to select the particular camera
when plural cameras are equipped.
* Press more than 1 second of this icon.
53. WORK MODE SELECT ICON
This select icon is to perform the work smoothly
y
based on work content.
nl
Normal crane work. (Auto variable

High speed
displacement position)
O
Special work. (Front, rear winch low
speed fixed position)
Low speed
The switch turns to green when low
speed is selected.
ce
Select “LOW SPEED” when synchronization of
front and rear drum speed is difficult for heavy
load such as clamshell.
en
54. MENU ICON
This icon is used to indicate select item list.

er

56. DPF REGENERATION CANCEL ICON DPF REGENERATION
START ICON
This icon is for stating or resume of the
ef
refreshing, manual and auto regeneration.

When under processing these task, the icon
transition to DPF regeneration cancel icon. DPF REGENERATION
CANCEL ICON
As to the detail of auto regeneration, refer to
R
“2.3.4 EMISSION CONTROL DEVICE”
57. FINAL LIMIT RECOVERY ICON
This icon is for resume the crane operation

temporary for evacuation purpose, when crane
operation becomes impossible due to the final
limit function of the inducement control.
As to the detail of inducement, refer to “2.3.5
TIER4 FINAL INDUCEMENT CONTROL”
10000A-1
[ 2. OPERATION ]
58. ENGINE STOP ICON
This icon is to stop the engine simply.

After stop the engine, the condition becomes
same as idling-stop condition.
To restating the engine, operate either the
acceleration grip or the foot acceleration.
59. INCHING ICON
This icon is to set the inching speeds of the

front, rear, third (option) and boom drum and
y
traveling speed.
Each speed will be 1/4 of normal speed when
nl
this icon turns ON.
O
This icon is used to lower the boom, jib to the

out of work area.
ce
61. ASSY/DISASSY ICON
This icon is used to select the assy/disassy

en
mode or the work mode.

er
This lamp light up in red color when functioning

the inducement control or the error code (P
code, U code)is appeared and light up in yellow
ef
when require the cooling to the exhaust system.
63. G ENGINE INDICATION LAMP

R
The lamp lights up when G engine mode is

selected.

11000-1
[ 2. OPERATION ]
64. G WINCH INDICATION LAMP
These lamps on the both sides lights up to

yellow when “40. G WINCH MAIN SWITCH” is Front drum side Rear drum side
turns ON.
When at the G WINCH mode, the lamp on the
corresponding drum side lights up to green.
65. AUTO IDLE STOP INDICATION LAMP
This lamp lights up when the engine is stopped

due to the auto idle stop function.
y
nl
66. FRONT DRUM FREE FALL INDICATION LAMP
67. REAR DRUM FREE FALL INDICATION LAMP
68. THIRD DRUM FREE FALL INDICATION LAMP
(OPTION)
O
This lamp lights up when drum becomes free
fall mode.
69. INCHING SPEED LAMP

ce
This lamp lights up when “59. INCHING ICON”
is turned to Inching speed side.
en
70. ELECTRIC OIL COOLER WORK INDICATING

LAMP
This lamp lights up when the electric oil cooler

is working.
er
71. REMOTE CONTROL CONNECTION LAMP
This lamp lights up when the remote control box

ef
is connected to the base machine.

As to the detail of the remote control switch
box, refer to “4.2 HANDLING THE REMOTE
CONTROL SWITCH BOX”.
R
10000A-1
[ 2. OPERATION ]
72. HYDRAULIC OIL TEMPERATURE LAMP
This lamp indicates the hydraulic oil temperature

by color.
Red 90 °C (194 °F) or higher.

Green 90 °C (194 °F) or lower.
* The red color indication remains until lower the
oil temperature to 80 °C (176 °F) after once
lights up to red.
y
nl
Indicate the necessity of cooling to exhaust
system by the lamp color.
Require the cooling
O
Yellow
(refer to following caution)
Green Normal condition
ce
Do not stop the engine when the exhaust system
cooling call lamp turns yellow.
Absolutely perform the cool down (keep the
en
engine running at low revolution with no load) and

must be stop the engine when the exhaust system
cooling call lamp turns green.
Stop the engine with exhaust system temperature
is high condition leads to adverse effect to the
er
parts life of the emission control device and also

if the related parts of emission control device
defects, the engine output will be limited step by
step.
ef
As to the output limitation, refer to the article “2.3.4

EMISSION CONTROL DEVICE” for the detail.
R

11000-1
[ 2. OPERATION ]

108 °C (226 °F)
This indicates the engine cooling water

100 °C (212 °F)
temperature.
The scale indicates is divided into 10.
60 °C (140 °F)
6 blocks 60 °C (140 °F) or higher to
White
or less less than 100 °C (212 °F)
7 to 9 100 °C (212 °F) or higher to
Yellow White Yellow Red
blocks less than 108 °C (226 °F)
Red 10 blocks 108 °C (226 °F)
y
nl
75. FUEL BAR GAUGE
355 L (93.7 gal)
This indicates the fuel level.

The scale indicates is divided into 10. 10 divisions
O
Max. Indication 355 L (93.7 gal)
44 L (11.6 gal)
Min. Indication 44 L (11.6 gal) or less
ce
The bar gauge color changes from white to red White Red
at lowest two blocks.
76. DEF/AdBlue® BAR GAUGE

en
60 L (15.8 gal)
This indicates the urea solution level
10
divisions
Max. Indication 60 L (15.8 gal)
er
Min. Indication EMPTY EMPTY
The bar gauge color changes from white to

yellow when reaches to 3 blocks and changes White Yellow Red
ef
to red when 2 blocks or less.

R
The warning and engine output limitation will be

issued depending on the remaining amount of the
DEF/AdBlue® when the level reaches lowest three
blocks.
As to the detail of output limitation, refer to “2.3.4
EMISSION CONTROL DEVICE”.
10000A-1
[ 2. OPERATION ]
77. SOOT ACCUMULATION BAR GAUGE
This bar gauge indicates guide of soot

accumulation in the DPF.
10 Blocks Red
5 Blocks or more Yellow to orange
3 Blocks or more White to yellow White Yellow Orange Red
y
nl
Depending on the accumulation of soot (number
of bar gauge), the soot burning (regeneration)
operation is to be required.
O
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.2.3 VARIOUS SETTING OF MONITOR

Screen setting, option setting etc are possible.
1. Display of set menu
(1) Press icon.
y
nl
(2) Press in the displayed menu.
O
ce
(3) List of setting items are displayed.
en
er
ef
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10000A-1
[ 2. OPERATION ]
2. Time setting
Carry out the time setting.
(1) Press in the setting items.
y
nl
(2) The current set year, month, day, time and
minute are indicated.
Push the item required changing, the item will 2015 05 10
be highlighted.
10 00
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(3) Under this condition, input numeral with the
right side numeric keypad.
If there are other areas to change, input
required numeral with same procedure.
(4) After input is completed, press .
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(5) The setting is completed.
(2) (3) (4)
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11000-1
[ 2. OPERATION ]
3. Lever detent force (holding force) setting
Set the middle points detent force (1st speed at

confluence circuit selected).
Set the detent force as required.
y
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(2) The current set detent forces are indicated. Rear drum setting area
(3) Can be set the detent force on the front and Front drum setting area
O
rear drum control lever individually.
The detent force becomes larger as corresponding
with the number indicated and the number can
50
be changed in between 0 and 150.
50
ce
(4) Front drum setting
Press front drum setting area.
Change the number by pressing of or .
(5) Rear drum setting

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Press rear drum setting area.

Change the number by pressing of or .

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10000A-1
[ 2. OPERATION ]
4. Wind velocity warning setting (option). WIND VELOCITY INDICATOR

(OPTION)
In case of anemometer (option) is equipped, set

0.0
the point of wind velocity to issue the warning.
y
nl
O
(2) Wind velocity measurement value and current
warning issuing set value are indicated.
When push the warning issuing set value, 0.0
pushed numeral part will be highlighted.
22 . 4
ce
(3) Under this condition, input numeral with the
When the wind velocity exceeds the set value,
en
the indication of wind velocity turns to red and

(2) (3) (4)
buzzer sound is issued.
er
ef
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11000-1
[ 2. OPERATION ]
5. Drum rope layer setting
To use load height meter properly, adjustment

of drum rope layer is require whenever the
drum has been turned freely during attachment
assembly or disassembly.
If the adjustment insufficient, height indication
would not vary or indicated value would become
deviate from actual.
Ensure to adjust.
The adjustment is required on front drum and
rear drum respectively.
y
The procedure is same for both drums.
Front drum adjustment is explained here as an
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example.
(1) Hoist or lower the main hook and suspend the

hook when the wire rope changes its layer.
O
ce
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10000A-1
[ 2. OPERATION ]
(3) Both front and rear drums layer are indicated.

When push the item where requires changing,
pushed numeral part will be highlighted.
(4) Under this condition, input numeral with the 1
In case of the border between 4th and 5th layer
1
for example, input “5”.
(3) (4) (5)
y
• The number of layer can be determined by the
distance from the drum flange circumference
nl
and the wire rope.
Refer to the figure below;
O
(4-11/32″)
(3-15/32″)
(2-19/32″)
(1-23/32″)
(5-3/16″)
132 mm
110 mm
88 mm
66 mm
44 mm
22 mm
(7/8″)
6th. layer
ce
5th. layer
4th. layer
3rd. layer
2nd. layer
1st. layer
en
Setting example wire rope wraps
1st. Layer 2nd. Layer = 2
2nd. Layer 3rd. Layer = 3
3rd. Layer 4th. Layer = 4

er
4th. Layer 5th. Layer = 5
5th. Layer 6th. Layer = 6

ef
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11000-1
[ 2. OPERATION ]
(6) Confirm the height indication varies as per

setting by referring to “7. handling of the height
meter” described in the next page.
(7) If there is any abnormality in height indication,

the sensor gap adjustment may be incorrect. Machine front
Perform the gap adjustment of the proximity
FRONT DRUM SIDE REAR DRUM SIDE
sensor. PROXIMITY SENSOR PROXIMITY SENSOR
• GAP ADJUSTMENT PROCEEDURE
Install the sensor as align with the center of fin
y
and adjust the clearance of 3 mm (1/8 in.) with
the drum.
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Allowance of gap : 2.5 to 5 mm [3/32 to 3/16 in.]
FRONT DRUM REAR DRUM
O
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SENSOR Sensor center
DRUM
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3 mm (1/8″)
er
(8) Setting is complete.

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In case still the indication abnormality is existed,

contact authorized Manitowoc distributor for
further inspection.
R
10000A-1
[ 2. OPERATION ]
6. Brightness setting of monitor
y
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(2) The current set monitor brightness is indicated.
By pushing the bar part, 8 steps of brightness
can be selected as longer bar is higher.
O
(5) The set monitor brightness will be reflected
when “32. WORK LIGHT SWITCH” is activated.
ce
(2) (3)
7. Handling of the height meter

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(1) Select the hook to be used. (3) (2) (1)

Press the figure area of the hook to be used.
Selected hook is indicated dark and non 10 . 0 f t
selected hook is indicated light.
er
(2) Check to see that the indicated number of

part line of the hoist rope matches with actual 4 1
condition.
100 . 3 f t
Use.
(3) Move the hook to certain height and press the Use.
ef
height indication area. 100 f t

Height value is reset and “0.0 m” is to be indicated. 30 . 0 POUNDS
× 1000
(4) When the hook is hoisting/lowering or boom/

jib raising/lowering is performed, the height
30 . 8 POUNDS
× 1000
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becomes plus indication if the height is higher

than the starting point of “0.0 m” and minus 70 . 0 deg
indication if lower.
40 . 3 f t 50 . 0 f t

11000-1
[ 2. OPERATION ]
8. Handling of the bypass switch when touch panel

of the monitor dose not functioning Upper : Bypass side
In case of abnormal phenomenon occurs on the MAIN CONTROLLER 2

monitor as no functioning of touch panel at the BYPASS SWITCH
boot up, the crane operation becomes possible

Lower : Normal side
by the following bypass processing.
(1) Remove a fuse F17 (5A) for not applying the

power to the monitor.
(2) Start the engine.
(3) The main controller-2 bypass switch located on
y
the bypass switch panel of the monitor stand
to bypass side once and return the switch to
nl
normal side immediately.
(4) Confirm each levers are ready for operation
after the function lock lever is shifted to work
BYPASS SWITCH PANEL
side.
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(5) If not obtain the crane operation after the step
(4) above has been carried out, repeat step
(3) again and reconfirm of the readiness for
operation.
ce
• Do not use these switches for other than
emergency evacuation work due to failure of
en
controller.
• Extra care to take an evacuation work due to
the indication is not available on the monitor.
er
• After the evacuation is completed, contact

an authorized Manitowoc distributor as soon
as possible.
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10000A-1
[ 2. OPERATION ]
2.2.4 ANEMOMETER INSTALLATION (OPTION)
Fix with pin

during transport.
Remove pin
at work.
(Work condition) (Transport condition)
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O
ce
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LOAD SAFETY DEVICE

MONITOR CN-11-1D
CN-11-5B
CN-590 ANEMOMETER FOR CRANE ONLY

5P
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11P
CRANE BOOM TOP JUNCTION BOX
CRANE CABLE
CABLE REEL
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11P
CRANE CABLE
ATTACHMENT JUNCTION PANEL
Electrical diagram

11000-1
[ 2. OPERATION ]
2.2.5 AIR CONDITIONER

NAME OF THE AIR CONDITIONER PARTS
A/C CONTROL PANEL
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INTERNAL AIR FILTER
OPEN AIR
O Air vent
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FILTER
AIR CONDITIONER UNIT

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NAME OF THE CONTROL PANEL
6. IN-EXT. AIR SELECTOR SWITCH
8. DEFROSTER SWITCH 1. LCD DISPLAY PANEL 3. AIR CONDITIONER

SWITCH
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7. AIR VENT SELECTOR SWITCH 5. TEMPERATURE CONTROL SWITCH 2. POWER SWITCH
4. AIR VOLUME SELECTOR SWITCH
10000A-1
[ 2. OPERATION ]
FUNCTION OF EACH CONTROL
1. LCD DISPLAY PANEL

(f) (c) (b) (d)
Air volume setting etc. are displayed.
(e) (a)
2. POWER SWITCH (ON/OFF SWITCH)
y
It turns ON or OFF the air conditioner.
When this switch is pushed at the first time, the
nl
air conditioner starts on factory set mode.
When this switch is pushed, air conditioner
starts with previous set mode.
O
3. AIR CONDITIONER SWITCH (A/C SWITCH)
Every time when this switch is pushed, the air

compressor alternates ON/OFF.
When the air conditioner is ON, lights up on
ce
the LCD display (a).
4. AIR VOLUME SELECTOR SWITCH

(FAN SWITCH)
en
Air volume can be changed by pushing this

switch when air conditioner is running.
Increase air volume.

er
Decrease air volume.
Set air volume is displayed on the LCD display (b).

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LCD
display
Air Max.
Low Medium High
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volume high

11000-1
[ 2. OPERATION ]
5. TEMPERATURE CONTROL SWITCH

(AIR CONDITIONER TEMP. SET)
Pushing this switch changes temperature

setting when the air conditioner is running.
Rises temperature (blowing air temp.)
Lowers temperature (blowing air temp.)
Set temperature is displayed on LCD

display (c).
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6. IN-EXT. AIR SELECTOR SWITCH
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(R/F SWITCH)
Every time when this switch is pushed, internal

air / external air alternate.
O
Internal air circulation
External air take in

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Setting is displayed on LCD display (d).
7. AIR VENT SELECTOR SWITCH

(MODE SWITCH)
en
Every time when this switch is pushed, blow out

opening changes on in sequence.
LCD display
er
Blow out opening Face Vent Bi level Foot

Front / upper rear and
Blow out direction Front Front / upper rear Foot *
foot
* Air blows from defroster also.
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Setting is displayed on LCD display (e).
8. DEFROSTER SWITCH (DEF SWITCH)

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Every time when this switch is pushed, blow out

opening changes to defroster.
Blow out opening Defroster

Blow out direction Front windscreen*
* Air blows from foot too.
is displayed on LCD display (f).
10000A-1
[ 2. OPERATION ]
AIR CONDITIONER CONTROL
1. To start or stop air conditioner
Push (Power switch).
2. To cool (5) (1)
y
(1) Push (Air conditioner switch).
nl
(2) Push (Temperature control switch) to
indicate temperature display.
(3) Push the air volume selector switch for required
air volume setting.
O
(4) (2) (3)
(4) Push (Air vent selector switch) for
(Vent) position.
(The above is recommended position and can
be chosen as desired.)
(5) By pushing (In-ext. air selector switch), set
ce
the selector to (Internal air circulation).
If the A/C cools down too low, adjust the temp.
or air volume by (2), (3).
en
• (Air conditioner switch) is not pushed, the

A/C does not cool but only air flows.
• While defrosting the windows, do not set the
temperature too low.
er
• Cold air may make windows foggy from outside

ef
R

11000-1
[ 2. OPERATION ]
3. To warm (5) (1)

air volume setting.
(4) (2) (3)
(4) Push (Air vent selector switch) for (Foot
position.
y
nl
If the A/C warms up too high, adjust the temp.
or air volume by (2), (3).
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• If (Air conditioner switch) is pushed, the A/
C operates on dry air warming.
• If blow out opening is set to “Foot”, small
amount for air bows from defroster also.
ce
en
er
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10000A-1
[ 2. OPERATION ]
4. To defrost on the windows (4) (5) (1)

(3) Push the air volume selector switch for “Max,
high” air volume.
(2) (3)
(4) Push (Defroster switch) to change the
blow out opening to (Defroster) position.
y
• By pushing (Air vent selector switch) blow
out opening return to previous one before
nl
(Defroster switch) is pushed.
• When blow out opening is set to “Defroster”,
small amount of air comes out from foot also.
O
5. To defog on the windows (3) (4) (1)

air volume setting.
ce
(3) Push (Defroster switch) to change the
blow out opening to (Defroster) position.
(2)
the selector to (External air take in).
en
• If quick defogging is required, set the air volume

to “Max, high” by (2).
• By pushing (Air vent selector switch) blow
out opening return to previous one before
(Defroster switch) is pushed.
er
• When blow out opening is set to “Defroster”,

small amount of air comes out from foot also.
ef
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11000-1
[ 2. OPERATION ]

(OPTION)
• AIS air conditioner is to work as an auxiliary air
conditioner when the engine stops due to auto
idle stop function.
This is not to keep the temperature in the
operator’s cabin comfortably.
• Can be adjust the blowing direction by change
the air vent.
• Avoid to use of AIS air conditioner long period
due to power consumption is large.
y
If has been used long period, the next auto idle
stop interval become longer according to the
nl
degree of battery discharge.
• When the filter clogging, the performance of an
air conditioner is drops.
Clean the filter periodically.
O
The filter can be pulling out forward to the above.
• Should be use the AIS air conditioner with the
filter otherwise lead to damage the internal
parts.
ce
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10000A-1
[ 2. OPERATION ]
NAME OF THE AIS AIR CONDITIONER PARTS
AIS AIR CONDITIONER PANEL Air vent
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Air vent
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AIR CONDITIONER UNIT (ROOM UNIT)
FILTER
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en

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6. COOLING LAMP 7. HEATING LAMP 2. POWER LAMP

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1. POWER SWITCH 3. TEMPERATURE 4. AIR VOLUME 5. MODE SELECT SWITCH

CONTROL CONTROL
TRIMMER TRIMMER

11000-1
[ 2. OPERATION ]
FUNCTION OF EACH CONTROL
1. POWER SWITCH (ON/OFF SWITCH)
It turns ON or OFF the AIS air conditioner.

When the switch is in ON position, the AIS air
conditioner starts when the engine stops due to
the auto idle stop function.
(Even the switch is ON position, AIS air
conditioner will not start other than the auto idle
stop is functioning.)
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2. POWER LAMP
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The lamp lights up while the AIS air conditioner
is in working.
3. TEMPERATURE CONTROL TRIMMER
O
Control the AIS air conditioner temperature.
Rotate clockwise, the temperature rise and
counterclockwise is lower.
ce
4. AIR VOLUME CONTROL TRIMMER
Control the AIS air conditioner air volume.

en
Rotate clockwise, the air volume increase and

counterclockwise is decrease.
er
5. MODE SELECT SWITCH
Switching the AIS air conditioner to cooling or

heating.
ef
Cooling operation
Heating operation
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6. COOLING LAMP
The lamp lights up while in cooling operation.
7. HEATING LAMP
The lamp lights up while in heating operation.
10000A-1
[ 2. OPERATION ]
2.2.7 AM/FM RADIO

6. DISPLAY SELECT BUTTON 5. PRESET BUTTON 3. VOLUME BUTTON

2. AM/FM SELECT BUTTON
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1. POWER BUTTON
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8. LCD DISPLAY 7. SOUND CONTROL BUTTON
4. TUNING BUTTON
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FUNCTION OF EACH AREA
1. POWER BUTTON
Turn radio ON / OFF.
ce
2. AM/FM SELECT BUTTON
Select band.
(AM / FM1 / FM2)
en
3. VOLUME BUTTON
Control volume.
4. TUNING BUTTON
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Select frequency, control step for sound control,

adjust time.
5. PRESET BUTTON
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Call preset frequency and register.
6. DISPLAY SELECT BUTTON

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Select display.
(Frequency / Time)
7. SOUND CONTROL BUTTON

Control sound.
(Balance / Bass / Treble)
8. LCD DISPLAY
Display frequency, time etc.

11000-1
[ 2. OPERATION ]
DETAIL OF LCD DISPLAY
3. ST PICTO 4. BAL PICTO 5. TRE PICTO 6. BAS PICTO
y
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1. SEGMENT (LARGE) 2. SEGMENT (SMALL)
1. SEGMENT (LARGE)
O
To display band name, frequency, time, word/
number.
2. SEGMENT (SMALL)
To display frequency for FM 50 kHz step
ce
system.
3. ST PICTO
Lights up when stereo is received at FM1/FM2.
en
4. BAL PICTO
Lights up when balance is selected at sound
control.
er
5. TRE PICTO
Lights up when treble is selected at sound
control.
ef
6. BAS PICTO
Lights up when bass is selected at sound
control.
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10000A-1
[ 2. OPERATION ]
FUNCTION AND DISPLAY
Function and LCD display of this machine is explained

here.
1. Normal condition
From OFF condition, by pressing “POWER

BUTTON” the radio turns ON and receives
presently selected frequency.
y
nl
OFF condition : Time display
POWER BUTTON
O
POWER BUTTON ce
ON condition : Band name display Frequency display
(ST picto turns ON when stereo is reveiving.)
en
Under this condition, by pressing “DISPLAY

SELECT BUTTON” (frequency/time), frequency
display and time display alternates.
(When display is changed from time display →
frequency display, band name is displayed for
er
1.0 seconds and then changed to frequency

displayed.)
ef
Frequency display
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After 1.0 seconds.
DISPLAY
SELECT BUTTON
Time display DISPLAY SELECT BUTTON Band name display

11000-1
[ 2. OPERATION ]
2. Band select
From normal condition by pressing “AM/FM

SELECT BUTTON”, band is changed.
After band is selected, radio receives the last
selected frequency of the band.
Selecting sequence is FM1 → FM2 → AM → FM1.
y
Band name display
nl
AM/FM SELECT BUTTON
AM/FM SELECT BUTTON
O
ce
Band name display AM/FM SELECT BUTTON Band name display
en
er
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10000A-1
[ 2. OPERATION ]
3. Frequency control (1 step up or 1 step down)
From normal condition, by pressing up side of

“TUNING BUTTON”, frequency goes 1 step up.
By pressing down side, frequency goes 1 step
down.
(At FM receiving, frequency is controlled by 0.2
MHz per 1 step and at AM receiving, by 10 kHz
per 1 step.)
• When selected band is FM1, FM2.
y
nl
Frequency display
O
TUNING BUTTON TUNING BUTTON
ce
en
Frequency display Frequency display

(ST picto turns OFF when non-stereo is reveiving.) (ST picto turns OFF when non-stereo is reveiving.)
• When selected band is AM.

er
Frequency display
ef
(ST picto always turns OFF when AM is receiving.)

R

(ST picto always turns OFF when AM is receiving.) (ST picto always turns OFF when AM is receiving.)

11000-1
[ 2. OPERATION ]
4. Frequency control (auto seek)
From normal condition, by press-holding up side

of “TUNING BUTTON”, frequency goes up by 1
step for continuously.
By press-holding down side, frequency goes
down by 1 step for continuously.
By searching for good receiving frequency,
auto seeking function stops and radio turns to
receiving condition.
• Example when selected band is FM1.
y
TUNING BUTTON
nl
O
(ST picto turns ON when stereo is reveiving.) (ST picto turns OFF when non-stereo is reveiving.)
ce
TUNING BUTTON㸦Press and hold㸧
en
Auto seek condition : Frequency changes continuously Auto seek stop : Frequency display
㸦6T picto turns ON when stereo is reveiving.㸧
er
TUNING BUTTON
ef

(ST picto turns ON when stereo is reveiving.) (ST picto turns OFF when non-stereo is reveiving.)
R
TUNING BUTTON㸦Press and hold㸧
Auto seek condition : Frequency changes continuously Auto seek stop : Frequency display
㸦6T picto turns ON when stereo is reveiving.㸧
10000A-1
[ 2. OPERATION ]
5. Frequency control (auto preset)
From normal condition, by press-holding

“SOUND CONTROL BUTTON” good receiving
frequency is automatically detected and
memorized to the preset memory 1 to 6 (auto-
preset function).
During auto preset, auto preset display as
shown below is displayed (“A” display changes
a certain interval) and this display ends with
2 beep sounds and preset 1 memorized
frequency is received.
y
• Example when selected band is FM1.
nl
SOUND CONTROL BUTTON
(Press and hold)
O
ce
Frequency display Auto preset display
(ST picto turns ON when stereo is reveiving.) (ST picto turns OFF)
en
er
Auto preset display Auto preset display

(ST picto turns OFF) (ST picto turns OFF)
ef
Auto preset ends

R
Frequency display

11000-1
[ 2. OPERATION ]
6. Preset call / Registration
From normal condition, by pressing “PRESET

BUTTON (1 to 6)”, memorized frequency on
preset No. is called and received.
During the radio reception, by press-holding the
“PRESET BUTTON (1 to 6)” presently receiving
frequency will be registered.
• Example when selected band is FM1

(89.5 MHz is pre-memorized in preset No.1).
y
nl
Frequency display
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PRESET BUTTON (No.1)
ce
After 0.5 seconds.
en
Preset No. display Frequency display

(Preset No. is displayed and held for 0.5 seconds.) 㸦Reception of frequency registered in No.1.㸧
er
ef
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10000A-1
[ 2. OPERATION ]
7. Time setting
When at OFF condition, press-holding a “DISPLAY

SELECT BUTTON”, enter to time setting mode.
Indication of “Time” becomes blinking and adjust
with the “TUNING BUTTON” and by pressing
the “DISPLAY SELECT BUTTON”, shift the
adjustment object of “time” → “minute” and the
indication of “minute” becomes blinking then adjust
with the tuning button and adjustment is complete,
press the “DISPLAY SELECT BUTTON”.
The time setting mode will be released and
y
display time indication.
(From this point, start counting a second
nl
internally.)
O
(Colon blinking)
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DISPLAY SELECT BUTTON (Press-holding)

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DISPLAY SELECT BUTTON

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DISPLAY SELECT BUTTON

(Colon blinking)

11000-1
[ 2. OPERATION ]
8. Area setting
There is a possibility that the radio reception

may be poor due to the replacement of radio or
the machine moved out to other territory.
When the radio reception is poor, confirm the
present area setting and resetting of area
selection if required.
(1) Confirmation method of setting area
With at OFF condition, press the DOWN side of
y
“TUNING BUTTON” and the “PRESET BUTTON
4” at the same time, display the present set
nl
area code.
In case no area code is displayed even perform
the above, contact with authorized Manitowoc
distributor.
O
ce
PRESET
BUTTON 4 Press at the
same time
en
TUNING
BUTTON
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Area display : Australia and Europe Area display : North America Area display : Japan
ef
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10000A-1
[ 2. OPERATION ]
(2) Changing method of area setting
With at OFF condition, press-holding the “AM/

FM SELECT BUTTON” and the + side of
“VOLUME BUTTON” at the same time for 5
seconds or more, display the changing area
setting mode.
Select the area with “TUNING BUTTON” and
finalize and initialize the memory and reset
when press the “SOUND CONTROL BUTTON”.
When not handling of any buttons for 10
seconds or when ACC power becomes ON, the
y
area setting mode will be released.
nl
O
AM/FM SELECT BUTTON

Press-holding for
5 seconds or more
ce
SOUND CONTROL BUTTON TUNING BUTTON
en

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Area display : Australia and Europe Area display : North America Area display : Japan

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TUNING BUTTON
SOUND CONTROL BUTTON

11000-1
[ 2. OPERATION ]
2.2.8 1WAY CALL (TRANSMITTER)

1. Configuration of 1way call
T h e 1 w a y c a l l c o m p r i s e s t h e a m p l i f i e r,
microphone, and external speaker.
y
nl
O
ce
AMPLIFIER MICROPHONE
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SPEAKER
2. Operation instruction
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(1) Set the power switch to the “ON” position. VOLUME ADJUSTER
(2) The operator ’s voice can be transmitted
through the outside speaker by talking to the
ef
microphone. MIC 1 MIC 1

ELECTRET DYNAMIC
(3) The volume of the speaker can be adjusted with POWER
the volume adjuster.

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MICROPHONE JACK POWER SWITCH
10000A-1
[ 2. OPERATION ]
2.2.9 MONITORING CAMERA (OPTION)

It can check each drum wire rope winding condition or
rear area of base machinery in the operator’s cab.
MONITOR
The camera monitor can check the following location.
Front drum
Hoist drum monitoring
Rear drum
camera
Third drum (option)
Boom drum monitoring
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Boom hoist drum
camera
Machine rear monitoring
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Machine rear side
camera
O
ce
The monitor can be displayed by the selection of
monitoring camera equipped at respective locations.
Hoist drum monitoring camera Boom drum monitoring camera Machine rear monitoring camera
en
MONITORING
CAMERA
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MONITORING CAMERA
Inside of gantry MONITORING CAMERA
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11000-1
[ 2. OPERATION ]
1. Image indicating of monitor camera 0.0
10 . 0 f t 800
Push the (Camera select icon) in the monitor. 10021000000600120420
Camera image is indicated on right lower of the

2015/05/10 10:00
4 1
monitor.
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t CAMERA IMAGE (LOWER)
y
L+S 0.3
RESET S
SET D 0.2
nl
2. Selection of camera 0.0
O
10 . 0 f t 800
Maximum 4 cameras can be connected. 10021000000600120420
When more than 2 cameras are connected,

2015/05/10 10:00
4 1
camera can be selected in order by touching
100 . 3 f t
Use.
the camera image indicating area. Use.
100 f t
Select the required camera. 30 . 0 POUNDS
ce
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg

en
L+S 0.3
RESET S
SET D 0.2
3. Change of camera indicating position 0.0

er
10 . 0 f t 800
When the machine inclination (option) or swing 10021000000600120420
angle are indicated on right lower area of

2015/05/10 10:00
4 1
monitor, camera image can be indicated on right
100 . 3 f t
Use.
ef
upper of the monitor. Use. CAMERA IMAGE (UPPER)

100 f t
When the camera image is indicated on right 30 . 0 POUNDS
× 1000
lower, push (Camera select icon) can change 30 . 8 POUNDS

× 1000
0. 0
the image indicating position to right upper. 70 . 0 deg
R
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2
10000A-1
[ 2. OPERATION ]
4. Indication of plural images 0.0
10 . 0 f t 800
In the condition of the image displayed on right 10021000000600120420
upper, press (Camera select icon) one more

2015/05/10 10:00
4 1
time, the camera monitor images are displayed
100 . 3 f t
Use.
respectively on upper and lower. Use. CAMERA IMAGE (UPPER)

100 f t
30 . 0 POUNDS
× 1000
Ex) In case of 4 cameras are equipped (camera 30 . 8 POUNDS

× 1000
0. 0
1 to 4) and displaying the camera 1 image on 70 . 0 deg
the right upper, every press to the lower part

of camera image indication area, display the 40 . 3 f t 50 . 0 f t CAMERA IMAGE (LOWER)
image of camera 2 → 3 → 4 → 2 in order.
y
L+S 0.3
RESET S
SET D 0.2
* Not possible to display same camera image on
nl
upper and lower.
5. Warning indication WARNING CODE
0.0
O
When the camera image is displaying on the
10 . 0 f t 800
upper part, warning buzzer sound is issued if 10021000000600120420
warning occurs.
2015/05/10 10:00
4 1
Change the screen manually and confirm

100 . 3 f t
Use.
contents of the warning and then take Use.

ce
100 f t
appropriate action. 30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg

en
L+S 0.3
RESET S
SET D 0.2
6. Switching of camera image zoom in or out 0.0

er
10 . 0 f t 800
The camera image on both upper and lower 10021000000600120420
parts can be zoomed in.

2015/05/10 10:00
4 1
By every touching the right upper corner of
100 . 3 f t
Use.
screen, switching the image normal size from/to Use. CAMERA IMAGE (UPPER)
100 f t
ef
zoom in. 30 . 0 POUNDS

× 1000
The zoom in display is to be enlarged center 30 . 8 POUNDS

× 1000
0. 0
part of indication. 70 . 0 deg
40 . 3 f t
R
50 . 0 f t CAMERA IMAGE (LOWER)
L+S 0.3
RESET S
SET D 0.2
When the display is zoom in, power off of base
machine, switching the camera image display and
switching the camera, the indication will be back
to normal display.

11000-1
[ 2. OPERATION ]
2.3 CRANE OPERATION

2.3.1 ADJUSTING THE OPERATOR’S SEAT
Adjust the operator seat to the position where the

brake pedal can be firmly depressed.
During the seat adjustment, stop the engine and
be sure not to move the control levers.
If the control lever moves, return it to the neutral
y
position.
nl
NAME OF EACH MOVABLE PORTION
O
HEAD REST
2
5. ARM REST
5
ce
3
1 4
en
1. HEIGHT ADJUSTING LEVER, TILT LEVER 4. STAND FRONT REAR ADJUSTING BAR
2. RECLINING ADJUSTING LEVER 3. SEAT FRONT REAR ADJUSTING BAR
er
ADJUSTING OF EACH PORTION
1. HEIGHT ADJUST, TILT LEVER

ef
(1) When the lever is pulled up, rear portion of the

seat tilts up or down. (Tilt on 5 steps)
(2) When the lever is pushed down, front portion of
R
seat tilt up or down. (Tilt on 5 steps)

(3) Seat height adjustment can be done by tilting of
seat front and rear alternately.
2. RECLINING ADJUSTING LEVER
Adjust the seat back to the required angle by

pulling up the lever.
After adjusting, release the lever to fix.
10000A-1
[ 2. OPERATION ]
3. SEAT FRONT AND REAR ADJUSTING LEVER
Lift the lever up and move the seat by sliding

back and forth.
After adjusting to the required position, release
the handle and make sure that the seat is firmly
locked.
(Adjusting range : 160 mm [6-5/16 in.])
4. STAND FRONT AND REAR ADJUSTING LEVER
Lift the lever up and move the whole seat and
y
control stand sliding back and forth.
(Adjusting range : 60 mm [2-3/8 in.])
nl
5. ARM REST
The arm rest can be lifted up toward rear.
O
In addition, by turning the lower control dial by
hand, arm rest angle at normal position can be
fine-adjusted up or down.
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.3.2 GETTING ON AND OFF FROM / TO OPERATOR’S CAB

Use the step on the lower part of cab deck to get on
and off from/to operator’s cab.
• The door secures at fully closed and fully

opened position by the door catch.
• The door may slide open and close movement
unexpectedly if the position in between due to
the wind and ground inclination effect.
• The door should be fully open and secured
by door catch when getting on and off to the
y
operator’s cab in order to prevent catch the
body and/or hands in a door.
nl
• When close the door, make sure the door be
completely closed until hold by the door catch.
STEP
O
• Take extra care not to have your hand caught
during opening or closing the operator’s cab
door.
ce
in a serious injury.
• Take extra care not to fall from the step
during getting on or off the operator’s cab.
en
• When leaving from the operator’s cab, stop
the engine and the function lock lever turn
to lock position.
er
ef
R
10000A-1
[ 2. OPERATION ]
2.3.3 STARTING AND STOPPING THE ENGINE

1. Starting the engine
(1) Before starting the engine, set the control levers

and switches as follows.
(A) Front, rear, third (option) and boom drum control lever
Neutral position
Swing, travel control lever
(B) Function lock lever Lock position
(C) Swing brake switch Engage side
y
(D) Front, rear, third (option) and boom drum lock knob Lock position
(E) Front, rear drum brake pedal Pedal lock position (pressing)
nl
(F) Release switch master key Lock side
(G) Free fall lock master key Lock side
O
Position all control levers to the neutral and check
safety around the machine before starting the
ce
engine.
Even if each control levers are not in neutral
position, the engine can start.
However each motion can’t work without positioning
the control lever to neutral once.
en
(6) RELEASE SWITCH MASTER KEY : Lock side

(7) FREE FALL LOCK MASTER KEY : Lock side
(1) EACH CONTROL LEVER : Neutral position

er
Left : Engage side
(5) EACH BRAKE PEDAL :

Pedal lock position (pressing)
ef
(3) SWING BRAKE SWITCH
(1) EACH CONTROL LEVER :

Neutral position
Pull up : Lock position
R
25 mm (2) FUNCTION LOCK LEVER :

(31/32″) Lock position
(4) EACH DRUM LOCK KNOB
(1) EACH CONTROL LEVER :

Neutral position

11000-1
[ 2. OPERATION ]
HORN SWITCH
Sound the signal horn to warn the surrounding
personnel before starting the engine.
SWING CONTROL LEVER
y
(2) Confirm that the engine emergency stop switch
is release position.
nl
O
Push down : Engine stop Turn right : Release
ENGINE EMERGENCY STOP SWITCH

ce
(3) Turn the key switch 2 steps to the right (ON

en
position).
Engine shut off position

OFF
(Key insert / Take out position)
er
ACC Accessory ON position KEY SWITCH

ON Engine run position
START Engine start position
ef
R
OFF
ACC
ON
START
10000A-1
[ 2. OPERATION ]
(4) By turning the key switch one step more to the OFF
right (START position), the engine starts. ACC
After the engine starts, immediately release the ON

key.
The key returns to the ON position automatically. START
OFF
Do not allow the starter to run more than 15
ACC
seconds continuously.
If the engine does not start within 15 seconds, ON
y
release the key and wait for more than 20 seconds,
then start the engine again. START
nl
(5) After the engine starts, immediately check the
monitor for abnormality.
O
If there is any abnormality, stop the engine
immediately and seek for the cause.
(6) To adjust the engine speed, use the accelerator

Speed decrease side
grip.
ce
If the engine speed adjustment becomes ACCEL GRIP
impossible by the accel grip due to accelerator 120 degrees
failure, use the auxiliary accel switch. Speed increase side
* This switch is equipped with the slide lock.

en
This switch can be operated only when the slide

lock is slid to upper side.
SWING CONTROL LEVER

er
Upper : Middle speed side

Do not use the auxiliary accelerator switch when
the accelerator grip is normal.
If in case of using the auxiliary accelerator switch
ef
while the accelerator grip is in normal condition, SLIDE LOCK

the engine speed control by the grip can’t be made. AUXILIARY ACCEL
SWITCH
R

11000-1
[ 2. OPERATION ]
2. Engine starting assist at cold
The preheating function will start automatically

when the key turns to ON position at the cooling
water temperature is low (approximate 10 °C [50
°F] or less).
Indicate in the monitor while preheating
and the buzzer issues sound upon completion
of preheating (approximate 5 seconds after)
then the indication will be disappeared.
The engine starting would be easier with the
engine key turns to start position right after the
y
preheating is completed.
In addition to the above, the starting efficiency
nl
will increase when the engine starting with the
acceleration grip turns more than 60% of its
rotation which is enters into the cold starting
mode.
O
At this time, the engine speed rise up to approx.
1,500 min -1 and this is to avoid the engine
stalling and is not failure.
3. Engine warming up (At the engine starting)

ce
(1) At normal ambient temperature, run the engine Warmup!
to modulate speed 1,000 min-1 or less for 5 to
10 minutes without load.
(2) At cold ambient temperature, run the engine to
en
modulate speed 1,000 min-1 or less for 10 to 20

minutes without load.
er
If the crane is operated without warming up the

engine, the engine and the hydraulic components
will be worn out earlier than usual or will be
ef
damaged.
R
Depending on the machine operating condition or

low atmosphere temperature due to the cold region
or in winter, there is a case of auto regeneration
may not be started or completed.
This is not the failure but perform the soot burning
(regeneration) manually.
10000A-1
[ 2. OPERATION ]
4. Shutting off the engine
(1) Before stopping the engine, set the control

levers and switches as follows :
(A) Front, rear, third (option) and boom drum control lever
Neutral position
Swing, travel control lever
(B) Function lock lever Lock position
(C) Swing brake switch Engage side
(D) Front, rear, third (option) and boom drum lock knob Lock position
y
Pedal lock position
(E) Front, rear drum brake pedal
(pressing)
nl
(2) Allow the engine to run at low speed for approx. EXHAUST SYSTEM
COOLING CALL LAMP
5 minutes with no load before shutting off the
engine.
Do not stop the engine when the exhaust system
O
ce
cooling call lamp turns yellow.
Absolutely perform the cool down (keep the
engine running at low revolution with no load) and
must be stop the engine when the exhaust system
cooling call lamp turns green.
en
Stop the engine with exhaust system temperature

is high condition leads to adverse effect to the
parts life of the emission control device and also
if the related parts of emission control device
defects, the engine output will be limited step by
er
step.
As to the output limitation, refer to the article “2.3.4
EMISSION CONTROL DEVICE” for the detail.
ef
(3) Turn the key switch to the OFF position. OFF

After the engine is stopped, the power will be ACC
cut after awhile. ON

R
During this period, message will be indicated on

the monitor urging to engage the drum lock. START
If the emergency solenoid becomes actuated,
the power will be cut after about 90 seconds.

11000-1
[ 2. OPERATION ]
2.3.4 EMISSION CONTROL DEVICE

When the certain amount of the soot accumulated in
the DPF, regeneration will function.
Burn the accumulated soot (regeneration) in the DPF
by rise the exhaust temperature.
There are two modes of burning (regeneration) the
soot which are an automatic regeneration mode and a
manual.
Soot accumulation
Mode Contents
y
bar gauge
Since the non-combusted fuel and the film which deteriorates the catalyst
are accumulated in the emission control device when low idling or light load
nl
Refresh mode 0 to 8
work continues for long time, therefore, rise the exhaust gas temperature and
automatic refreshing occurs. (This is not regeneration)
Since the non-combusted fuel and the film which deteriorates the catalyst are
O
accumulated in the SCR catalyst when light load work continues for long time,
SCR refresh mode 0 to 8
therefore, rise the exhaust gas temperature and automatic refreshing occurs.
(This is not regeneration)
Auto-regeneration Burning (Regeneration) the soot occurs automatically.

3 to 4
mode The lever control is possible even during automatic regeneration.
ce
Manual regeneration Burning (Regeneration) the soot occurs manually.
5 to 8
mode The lever control is not possible during manual regeneration processing.
en
When the soot accumulation gauge icon starts

blinking gray and yellow automatically, the load valve
er
is working to rise the exhaust system temperature.

The blinking occurs when the refresh mode or the
auto regeneration mode is on.
In such case, avoid stopping the engine and or
ef
cancelation of load valve working as much as possible.

Once the load valve is stopped, fuel so far used to
rise the exhaust temperature becomes wasted and
parts deterioration may be resulted.
R
Under the G engine mode, when start the manual

or auto regeneration the mode is to be changed to
power mode automatically and is not abnormal.
When complete respective processing, return to G
engine mode.
10000A-1
[ 2. OPERATION ]
REFRESH MODE
When low idling, light load work or low exhaust

temperature condition continue for one hour, refresh
start for emission control device.
Refresh mode functions regardless of the soot
accumulation bar gauge.
1. Sequence
(1) When starting the refresh mode, automatically

the engine speed increase gradually up to
y
1,000 min-1 and start function of the load valve.
nl
O
(2) Rise the exhaust gas temperature and perform
the refresh of emission control device.
(Approx. 10 to 15 minutes)
ce
en
(3) When the refresh of emission control device

is completed, automatically the engine speed
decrease to 800 min-1 and returns to normal
er
operation.
ef
• Under the refresh mode, if the engine speed

exceed 1,100 min -1, refresh mode will be
cancelled automatically and keep the cancel
R
condition until the key switch turns OFF.

• The key switch turns OFF once, the cancel
condition to be released.

11000-1
[ 2. OPERATION ]
2. Cancelation of refresh mode
Due to some reasons of crane work, to

avoid entering the refresh mode, press DPF
regeneration cancel icon in the monitor.
DPF REGENERATION
CANCEL ICON
• When press the DPF regeneration cancel

icon, refresh mode and auto-regeneration
will becomes cancel condition and refresh
y
and auto regeneration being unable to do
while in this period.
nl
O
• If cancel the refreshing, there is a possibility
of white smoke poured out of which contents
ce
unburned fuel.
• When accumulate the unburned fuel may
cause in deterioration of the emission control
system.
• The refresh mode is differ from the auto
en
regeneration, therefore the soot accumulation

gauge level will not be reduced.
er
ef
R
10000A-1
[ 2. OPERATION ]
AUTOMATIC REGENERATION MODE

(CRANE OPERATION POSSIBLE)
When the soot accumulation bar gauge reaches to

3 blocks
the 3 blocks, automatically start the soot burning
(regeneration).
Under the auto-regeneration, the crane can be able to
operate.
During auto-regeneration,
an icon blinking to yellow.
y
There is a possibility of not starting/completion of
auto regeneration when the ambient temperature
nl
is low at cold region or in winter season.
And also there is a case of not starting/completion
of auto regeneration depend on the condition of
operation.
O
Unable to do the starting/completion, this is not a
fault, refer to the “MANUAL REGENERATION MODE”
describe later, perform burning (regeneration) the
soot manually.
ce
en

engine mode.
er
1. Selection of automatic regeneration mode
Depend on the situation, can be selected the

ef
control of the automatic regeneration from out

of 3 controls.
At shipping the machine from manufacture, the
control 1 has been set.
R
(1) Press menu icon in the monitor.

11000-1
[ 2. OPERATION ]
(2) From the displayed screen, press in the

monitor.
(3) Setting items are display, press .
y
nl
O
ce
(4) Press and display the automatic regeneration
select screen.
en
er
(5) Select one of the automatic regeneration

controls from out of 3 icons.
These controls are selected the engine speed
behavior and the function timing of load valve at
ef
the automatic regeneration.

(As to the details of each control. Refer to next
page.)
R
* When use of camera select switch (option),

select only either control 1 or 2.
Control 1 (Sweep up control)

Control 2 (Quick up control)
Control 3 (Semi-manual up control)
10000A-1
[ 2. OPERATION ]
2. Details of each control
(1) Control 1 (Sweep up control)

This control is that the automatically increase
the engine speed gradually and when the
burning (regeneration) of soot is completed
automatically the engine speed decrease
gradually.
Engine speed
1,000 min-1
y
Functioning
nl
800 min-1 Engine speed
Stop Stop
Load valve
Time
Starting of automatic regeneration Completion of automatic regeneration
O
(A) When automatic regeneration is started, the
starting icon will be displayed on the monitor,
after the alarm sound is issued, increase the
engine speed up to 1,000 min-1 gradually.
ce
(B) Start function the load valve when the engine
speed reaches 1,000 min-1.
en
(C) Rise the exhaust temperature and perform the MINIMIZE BUTTON
soot burning (regeneration) (Approx. 10 to 20
minutes)
(D) Under the automatic regeneration, display time
er
bar gauge which shows the estimate time to

completion.
Automatic regeneration screen can be switched
either display / non display by minimize button.
ef
TIME BAR GAUGE

R
AUTOMATIC REGENERATION SCREEN

11000-1
[ 2. OPERATION ]
(E) W h e n b u r n i n g ( r e g e n e r a t i o n ) o f s o o t i s
completed, display the completion message
and after the alarm sound is issued, stop the
function of load valve.
(F) Automatically the engine speed decrease to
800 min-1 and returns to normal operation.
(G) After the automatic regeneration is completed, EXHAUST SYSTEM COOLING CALL LAMP
require the exhaust system cooling to decrease
y
the exhaust temperature. 800
(H) The message will be displayed in the monitor, 10021000000600120420
10:00
nl
2015/05/10
don’t stop the engine until the exhaust system
cooling call lamp turns to green color.
O
0. 0
ce
en
L+S 0.3
RESET S
SET D 0.2
TIME BAR GAUGE MINIMIZE BUTTON
EXHAUST SYSTEM COOLING SCREEN

er
ef
R
10000A-1
[ 2. OPERATION ]
(2) Control 2 (Quick up control)

This control is that the automatically increase
the engine speed and while the burning
(regeneration) of soot automatically the engine
speed decrease.
Engine speed
900 min-1
Functioning
y
800 min-1 Engine speed
Stop Stop
Load valve
Time
nl
Starting of automatic regeneration Completion of automatic regeneration
(A) When automatic regeneration is started, after

the alarm sound is issued, increase the engine
O
speed up to 900 min-1 quickly and start the load
valve function.
(B) Rise the exhaust temperature and perform the MINIMIZE BUTTON
minutes)
ce
(C) Under the automatic regeneration, display time
completion.
(D) W h e n b u r n i n g ( r e g e n e r a t i o n ) o f s o o t i s
proceeding, after the alarm sound is issued,
en
automatically the engine speed decrease to

800 min-1 quickly.
(E) The burning (regeneration) of soot is completed,
TIME BAR GAUGE
stop the load valve function and returns to
normal operation. AUTOMATIC REGENERATION SCREEN
er
ef
R

11000-1
[ 2. OPERATION ]
(F) After the automatic regeneration is completed, EXHAUST SYSTEM COOLING CALL LAMP
(G) The message will be displayed in the monitor, 10021000000600120420
2015/05/10 10:00
y
0. 0
nl
O
L+S 0.3
RESET S
SET D 0.2

ce
en
er
ef
R
10000A-1
[ 2. OPERATION ]
(3) Control 3 (Semi-manual up control)

This control is that the manually increase
the engine speed to 1,000 min-1 or more and
perform the burning (regeneration) of soot.
* When use of camera select switch (option),

select only either control 1 or 2.
Engine speed Under the auto regeneration,

Manually increase keep the engine speed Returns to normal operation
exceed 1,000 min-1
1,000 min -1
y
Functioning
Engine speed
nl
800 min-1
Stop Stop
Load valve
Time
Starting of Increase to Completion of
automatic regeneration 1,000 min-1 or more automatic regeneration
O
(A) When automatic regeneration is started, after
the alarm sound is issued and start the load
valve function.
(B) The request message will displayed, therefore
ce
increase the engine speed to 1,000 min-1 or
more.
en
(C) Rise the exhaust temperature and perform the MINIMIZE BUTTON
minutes).
(D) Under the automatic regeneration, display time
er

completion.
Automatic regeneration screen can be switched
either display / non display by minimize button.
ef
TIME BAR GAUGE

R
Under the auto regeneration, unless keep the AUTOMATIC REGENERATION SCREEN
engine speed exceed 1,000 min-1, the soot burning

(regeneration) may not be completed.
(E) W h e n b u r n i n g ( r e g e n e r a t i o n ) o f s o o t i s
completed, after the alarm sound is issued, stop
the function of load valve.
(F) Leave the acceleration as is position, returns to
normal operation.

11000-1
[ 2. OPERATION ]
(G) After the automatic regeneration is completed, EXHAUST SYSTEM COOLING CALL LAMP
(H) The message will be displayed in the monitor, 10021000000600120420
2015/05/10 10:00
y
0. 0
nl
O
L+S 0.3
RESET S
SET D 0.2

ce
en
er
ef
R
10000A-1
[ 2. OPERATION ]
3. Cancellation of auto regeneration
(1) Due to some reasons of crane work, to avoid

entering the automatic regeneration mode,
press DPF regeneration cancel icon in the
DPF REGENERATION
monitor. CANCEL ICON
(2) After the automatic regeneration is cancelled,
automatic regeneration will be restarted when
the soot accumulation bar gauge is reached
to the 4 blocks with the restating message is
displayed on the monitor.
y
nl
When cancelled, soot burning (regenerating) is not
completed.
The soot accumulation gauge will not be reset.
O
ce
• When press the DPF regeneration cancel
icon, refresh mode and auto-regeneration
will becomes cancel condition and refresh
and auto regeneration being unable to do
while in this period.
en

(3) After the automatic regeneration is cancelled,

er
automatic regeneration can be restarted

at arbitrary time with pressing the DPF
regeneration start icon at the soot accumulation
bar gauge is located in between 3 to 4 blocks.
ef
DPF REGENERATION
START ICON
R

11000-1
[ 2. OPERATION ]
MANUAL REGENERATION MODE

(CRANE OPERATION IMPOSSIBLE)
5 to 8 blocks
The soot accumulated further and accumulation bar

gauge is reached to 5 blocks, the manual regeneration
can become possible.
When the soot accumulation bar gauge is become the
range of 5 to 8 blocks, pop up the manual regeneration
request in the monitor.
During manual-regeneration,
Under the manual regeneration, the crane operation is an icon blinking to yellow.
not possible.
y
1. Sequence (b)
nl
0.0
(1) Press DPF starting icon at the engine idling and
all the levers are in neutral position. 10 . 0 f t 800
10021000000600120420
The manual regeneration icons are to be shown 2015/05/10 10:00
4 1
on 2 places (a) and (b).
O
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
ce
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2
(a)
en
(2) W h e n s t a t i n g t h e m a n u a l r e g e n e r a t i o n ,
automatically the engine speed rise to 1,000 min-1
quickly and start the load valve function.
On the monitor screen, indicate the manual
er
regeneration display and the estimate time to

completion with the time bar gauge.
(3) Rise the exhaust temperature and perform the
ef
minutes).
TIME BAR GAUGE
MANUAL REGENERATION SCREEN

R
10000A-1
[ 2. OPERATION ]
(4) W h e n b u r n i n g ( r e g e n e r a t i o n ) o f s o o t i s
completed, automatically the engine speed
decrease to 800 min-1 quickly and stop the load
valve function then returns to normal operation.
(5) Depend on the operating condition, soot burning
(regeneration) may be cancelled and soot
accumulation bar gauge may not be reset.
In this case, regeneration request screen will not
displayed until the soot accumulation bar gauge
increase by one block however the regeneration
can be possible to perform at any time.
Perform the manual regeneration as soon as
y
become ready.
nl
• The burning of soot (regeneration) is rise
O
the temperature in the emission control
system to certain revel therefore the
higher temperature at starting is faster to
completion.
Thus, perform the regeneration is started
ce
under or just after the high load operation, is
the high degrees of efficiency.
• In case of the engine is cool, the burning
(regeneration) of soot will be performed
after warming up, thus, takes longer time to
en
completion.
Therefore, if the manual regeneration
performed under the high temperature
situation of engine is higher efficiency.
(Confirm the cooling water temperature is
er
raised sufficiently if in case the ambient

temperature is extreme low.)
ef

R

engine mode.

11000-1
[ 2. OPERATION ]
2. Cancellation
Cancellation of the manual regeneration request

and manual regeneration has a limitation.
When the soot accumulation gauge reaches 8
bars, DPF regeneration cancel icon will not be
indicated.
Manual regeneration should be performed as soon
as possible.
y
nl
When cancelled, soot burning (regenerating) is not
O
completed.
The soot accumulation gauge will not be reset.
(1) Even indicate the manual regeneration request,

ce
the cancellation can be selected if in case of the
process can’t be performed immediately.
en
er
ef
(2) Indicate the DPF regeneration cancel icon

during the manual regeneration is processing.
(3) W h e n t h e m a c h i n e o p e r a t i o n b e c o m e s
necessary while manual regeneration is in
R
progress by pressing the DPF regeneration

DPF REGENERATION
cancel icon. CANCEL ICON
(4) After canceled, regeneration request will not

be displayed until the bar gauge is become
increase by one block.
However, the regeneration can be performed at
any time.
DPF REGENERATION
Perform regeneration (burn the soot) whenever START ICON
preparation is ready.
10000A-1
[ 2. OPERATION ]
9 blocks
When no action taken for long time after the

manual regeneration request is displayed and soot
accumulation bar gauge reaches 9 blocks, the
forced regeneration will be performed to prevent
failure of emission control device.
Halt operation and wait until the regeneration is Orange
completed.
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10 blocks
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When the soot accumulation gauge reaches
10 blocks, the emission control device could
malfunction and error would be indicated in the
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main monitor.
Contact the nearest Manitowoc service shop and
request of replacing the emission control device
Red
and error reset.
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Do not wash the engine area with high pressure
en
water.
During engine running especially during the
emission control device is under burning
(regeneration) work, if the high pressure water hit
the diesel throttle etc. water may enter into the diesel
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throttle and may cause malfunction of the system.

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• The burning (regeneration) of soot becomes

unable to do when enter the engine output
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limitation situation due to inducement

control.
• When enter the output limitation situation,
stop the engine and recover normally as
soon as possible.
• The details of inducement control, refer to
the article “2.3.5 TIER4 FINAL INDUCEMENT
CONTROL”.

11000-1
[ 2. OPERATION ]
2.3.5 TIER4 FINAL INDUCEMENT CONTROL

WHAT IS INDUCEMENT CONTROL
An inducement control is to be issued a warning

display, alarming and decreasing machine output
when the emission control is not functioned properly
or possibility of malfunction.
And this control system urges to return to the normal
condition.
The engine output decreases depending on the
contents of occurrence and become difficult to operate
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as normal work.
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The engine output will be limited by the inducement
control when faced following conditions.
• DEF/AdBlue® level becomes lower.
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• DEF/AdBlue® quality becomes deteriorated.
• Parts of SCR system failure.
The engine output varies depending on the respective

conditions.
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10000A-1
[ 2. OPERATION ]
WHAT IS DEF/AdBlue®
Under the DEF/AdBlue ® SCR system is use urea

solution use as a medium to create ammonia of which
is required to purify NOx.
DEF/AdBlue® is the created solution of 67.5% purified
water and 32.5% urea.
When DEF/AdBlue ® injected exhaust gas in the
muffler, DEF/AdBlue® is to be hydrolyzed and create
ammonia.
This ammonia deoxidize with NOx which contents of
the exhaust gas and resolute into nitrogen (N2) and
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water (H2O).
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• DEF/AdBlue® becomes crystallized and white
powder when it is dried.
When find crystallized DEF/AdBlue ® on the
surface of the DEF/AdBlue ® tank, wipe out
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thoroughly with clean cloth.
• Do not smell and come closer the face when
open the filter cap of the DEF/AdBlue® tank.
DEF/AdBlue® may be smell if it warmed.
• DEF/AdBlue® froze -11°C (12°F) below zero.
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Don’t apply any heat to the DEF/AdBlue® tank
when it is frozen.
This machine equipped defrosting device and
DEF/AdBlue® will melt while in operation.
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Dispose the DEF/AdBlue® as industrial wastes and

strictly follow the regulations/provisions specified
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by regional authority.
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Use the DEF/AdBlue® only for reducing the NOx

emission.
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If operated this machine without use of DEF/

AdBlue® may subject to punishment.

11000-1
[ 2. OPERATION ]
• The pot life of DEF/AdBlue® is differ with stored Stored Temperature

temperature. Pot Life
°C (°F)
Keep in the cool and dark place as much as
0 (32) ∞
possible.
10 (50) 75 years
20 (68) 11 years
30 (86) 23 months
40 (104) 4 months
50 (122) 1 month
60 (140) 1 week
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10000A-1
[ 2. OPERATION ]
DEF/AdBlue® REMAINING QUANTITY
1. The engine output limitation will be limited step

by step as follows.
(DEF/AdBlue® tank capacity : Approx. 60 L)
(1) Caution remaining DEF/AdBlue® bar gauge Change DEF/AdBlue® bar gauge color to yellow.
amount 3 blocks (No engine output limitation)
Change DEF/AdBlue® bar gauge color to red.
(2) Remaining amount DEF/AdBlue® bar gauge
Display RL1 and issue intermit sound.
warning 1 2 blocks
(No engine output limitation)
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(3) Remaining amount DEF/AdBlue® bar gauge Display RL2 and issue intermit sound.
warning 2 2 blocks (No engine output limitation)
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(4) Remaining amount DEF/AdBlue® bar gauge Display RL3 and change intermit sound.
output limit 1 1 blocks (Engine max. speed and output become half)
(5) Remaining amount final DEF/AdBlue® bar gauge Display RL4 and change continuous sound.
limit 0 blocks (Engine speed 800 min-1 limit and lever control limitation)
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Replenish the DEF/AdBlue ® immediately when
warning of remaining quantity has issued.
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The burning (regeneration) of soot will not enable

to do when enter to the engine output limitation
situation due to inducement control.
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Pay attention to the number of blocks on soot

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• Under the final limitation, the crane operation

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is not possible.
Perform the respective treatments according to
the warning before enter to the final limitation.
• There is a possibility of not restating the engine
if stop the engine under the final limitation.

11000-1
[ 2. OPERATION ]
2. Measure against remaining quantity warning

“RL1” and “RL2”
When indicate the warning of “RL1” or “RL2”,

take action as follow.
(1) Turn a key switch to OFF position.

(2) Replenish the DEF/AdBlue® (20 L or more)
(3) Turn the key to ON position and confirm if the
warning has been released.
* To release the warning after replenish the DEF/
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AdBlue®, It may take 6 to 10 minutes.
In case the warning is not released, confirm the
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DEF/AdBlue® gauge level if 4 blocks or more
and repeat step (1) to (3) above.
3. Measure against output limitation 1 and
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remaining quantity final limitation
When indicate the warning of “RL3” or “RL4”,

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(2) Replenish the DEF/AdBlue® (20 L or more)
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* To release the warning after replenish the DEF/

In case the warning is not released, confirm the
DEF/AdBlue® gauge level if 4 blocks or more
and repeat step (1) to (3) above.
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OFF
(4) Turn the key to OFF again. ACC
(5) Confirm the acceleration grip is in low idle and
ON
control levers are in neutral position.
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If in case of the G engine mode is selected, START

change to power mode.
(The details of the G engine mode, refer to “G
ENGINE CONTROL” in this chapter “2.3.11 KEY SWITCH
R
HOOK HOISTING/LOWERING OPERATION”.)

(6) Start the engine and confirm if the engine speed
rise to 2,100 min-1 with the acceleration grip.
* If the engine output limitation is not released,

repeat the step (4) and (6) above.
10000A-1
[ 2. OPERATION ]
DETERIORATE THE DEF/AdBlue® QUALITY
1. When detect the DEF/AdBlue ® quality is

abnormal, the engine output limitation will be
limited step by step according to elapse of time
as follows.
Display RQ1 and issue intermit sound.

(1) Quality warning 1 Quality abnormal detect
(No engine output limit.)
60 minutes after Display RQ3 and change intermit sound.
(2) Quality output limit 1
detect quality abnormal (Max engine speed and output become half.)
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210 minutes after Display RQ4 and change intermit sound.
(3) Quality final limit
detect quality abnormal (Engine speed 800 min-1 limit and lever control limitation)
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Replace with new DEF/AdBlue® specified immediately
when warning of quality has issued.
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is not possible.
Perform the respective treatments according to
the warning before enter to the final limitation.
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• Enter to the final limit within 30 minutes when
detect the abnormal again within 40 hours (hour
R
meter) after rectify to the normal condition.
Use the DEF/AdBlue® only otherwise not only facing

the above limitations but also lead to damage the
internal parts of engine and other components.

11000-1
[ 2. OPERATION ]
2. Measure against quality warning “RQ1”
When indicate the warning of “RQ1”, take action

as follow.

(2) Drain the DEF/AdBlue® from the tank and fill
new specified DEF/AdBlue® (20 L or more)
* To release the warning after replace the DEF/
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In case of the warning is not released, repeat
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step (1) to (3) above.
* Even after performed the above repetition,
still the warning is remain, contact authorized
Manitowoc distributor for clean the DEF/AdBlue®
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sensor and tank.
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10000A-1
[ 2. OPERATION ]
3. Measure against quality output limitation

and final limitation
When indicate the warning of “RQ3” or “RQ4”,


(2) Drain the DEF/AdBlue® from the tank and fill
new specified DEF/AdBlue® (20 L or more)
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* To release the warning after replace the DEF/
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In case of the warning is not released, repeat
step (1) to (3) above.
* Even after performed the above repetition, OFF
ACC
still the warning is remain, contact authorized
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Manitowoc distributor for clean the DEF/AdBlue® ON
sensor and tank.
START
(4) Turn the key to OFF again.
(5) Confirm the acceleration grip is in low idle and
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KEY SWITCH
control levers are in neutral position.
If in case of the G engine mode is selected,
change to power mode.
(The details of the G engine mode, refer to “G
ENGINE CONTROL” in this chapter “2.3.11
en
HOOK HOISTING/LOWERING OPERATION”.)

(6) Start the engine and confirm if the engine speed
rise to 2,100 min-1 with the acceleration grip.
* If the engine output limitation is not released,

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repeat the step (4) and (6) above.

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11000-1
[ 2. OPERATION ]
SCR SYSTEM PARTS FAILURE
1. When detect the SCR related parts failure, the

engine output limitation will be limited step by
step according to elapse of time as follows.
(1) SCR parts failure Display TF2 in the monitor and issue intermit sound.
Detect parts failure
output limit 1 Engine output is limited to 75%
(2) SCR parts failure 60 minutes after Display TF3 in the monitor and change intermit sound.
output limit 2 detect parts failure Engine speed and output is limited to half.
(3) SCR parts failure final 210 minutes after Display TF4 in the monitor and change intermit sound.
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limit detect parts failure Engine speed 800 min-1 limit and lever control limitation
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10000A-1
[ 2. OPERATION ]
2. Measure against scr parts failur output

limitation 1, 2 and final limitation
When indicate the warning of “TF2” “TF3” or

“TF4”, contact authorized Manitowoc distributor
immediately.

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nl
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is not possible.
Before entering to the final limitation,
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contact authorized Manitowoc distributor.
• Enter to the final limit within 30 minutes when
detect the failure again within 40 hours (hour
en
meter) after rectify to the normal condition.

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If operated the machine continuously with the

warning of inducement control indicated may
result in the engine or related component damage.
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11000-1
[ 2. OPERATION ]
FINAL LIMITATION RECOVERY MODE
Under the final limitation, the crane operation is not

possible.
Display following warning and enter to the final FINAL LIMIT RECOVERY ICON
limitation and “FINAL LIMIT RECOVERY ICON” is pop

up.
When press this icon, the crane can be able to operate
temporally for evacuation purpose.
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Residual quantity final limit (RL4) DFE/AdBlue® bar gauge 0 block
Quality final limit (RQ4) 210 minutes after quality abnormal detect
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SCR system parts final limit (TF4) 210 minutes after SCR parts failure detect
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• The final limit recovery icon use only at the
evacuation purpose.
• The crane can be able to operate temporally
but the motion is very slow.
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• The crane operation may be difficult depending
on the work load.
• There is a possibility of stalling the engine
at evacuation when perform the combined
controls.
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is not possible.
Before entering to the final limitation, contact
authorized Manitowoc distributor.
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• If operated the machine continuously with the

warning of inducement control indicated may
result in the engine or related component
damage.
• Perform the action to normal return as soon
as possible after evacuation.
10000A-1
[ 2. OPERATION ]
2.3.6 AUTO IDLE STOP FUNCTION

This function is designed to stop the engine while no
operation of the crane is made to save the fuel.
1. When the auto idle stop switch is turned ON

Upper : ON
located on the rear switch panel, this function
becomes effective.
In case of this switch is in OFF position, the
engine can be stopped manually at only when
the stop switch is displayed
AUTO IDLE
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STOP SWITCH
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Lower : OFF
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REAR SWITCH PANEL
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11000-1
[ 2. OPERATION ]
2. When the auto idle stop switch turns ON, the

engine stop conditions are displayed on the
monitor.
The item is met the requirement to stop lights
up in green color.
* If the machine has an error, the stop condition

display will not be shown, since the priority is
given to display the error message.
Indication area for conditions to stop the engine
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CONDITIONS TO STOP THE ENGINE
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Condition to stop Icon Details of condition
(1) Swing brake The swing brake is engage side.
(2) Engine speed The engine speed is 760 to 840 min-1 (760 to 840 rpm).
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(3) Remote control switch box Not connected remote control cable to base machine.
(4) Soot burning (regeneration) DPF regeneration is not in progress.
(5) Engine coolant temperature The engine coolant temperature is within the specified range.
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(6) Control lever All control levers are in the neutral position.
(7) Boom/Jib lowering mode LMI shall not be in the Boom/Jib lowering mode.
(8) AIS cancel At least 5 min is passed after the AIS cancel.
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(9) Hydraulic oil temperature The hydraulic oil temperature is within the specified range.
(10) Exhaust system temperature The exhaust system temperature is within the specified range.
(11) Winch mode All winches are neutral brake mode.

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(12) Assy/disassy mode LMI shall not be in the assy/disassy mode.
(13) Battery The battery residual shall be above the specified level.
The lifting load is lower than the specified.

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(14) Lifting load * However this condition does not need to become to start the
countdown. (May require longer time)
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10000A-1
[ 2. OPERATION ]
3. When the conditions are satisfied, the STOP COUNTDOWN

countdown message is displayed.
When the numeric number reaches to zero, the
engine becomes stop.
When the stop icon is pressed, the engine can

be stopped even if the countdown is on the way.
When the cancel icon is pressed, the countdown
is cancelled, however as far as the stop icon is
indicated, the engine can be stopped manually.
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The countdown will start from “10” if in case that
the lifting load is within specified value however
the lifting load is exceeding specified value,
starting from “100”.
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(May be started from “99” depending on the
communication condition.)
STOP ICON CANCEL ICON
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The indication of countdown will disappear, even if
one of the conditions to stop engine becomes invalid.
When all conditions satisfied again, countdown
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will resume from beginning.
4. When the engine is stopped either by auto idle Speed decrease side
stop function or manual stop, the engine can be
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restated by turning the accelerator grip. ACCEL. GRIP

Turn the accelerator grip by approximate 1/4
once return the accelerator back in the low idle Speed increase side
position.
ef
Once the key switch turn to the OFF position,

the engine can be restated as normal starting
procedure.
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SWING CONTROL LEVER
During auto idle stop of the engine, the battery

power is used.
When you leave the operator’s seat, be sure to
turn OFF the key and take all safety measure.

11000-1
[ 2. OPERATION ]
2.3.7 FUNCTION LOCK LEVER

The function lock lever is the safety device to make
machine not to move even if the persons body
touches the control lever when getting ON or OFF the Lock position Work position
operators seat.
At lock position control of each drum, travel and swing
can’t be performed. FUNCTION LOCK
LEVER
Pull to near side Lock position

Push to far side Work position
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Turn the function lock lever to “WORK” position when
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the machine is to be operated.
Whenever leaving from the operator’s seat, ensure
to stop the engine and turn the function lock lever to
“LOCK” position.
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Ensure to turn the function lock lever to “LOCK”
position at work completion or at transportation of
machine.
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If the function lock lever is set to the “LOCK”
position while any of control levers is operated,
rotation of the drum or travel is kept stopped.
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Under this condition, even if the function lock

lever is returned to “WORK” position, no motion
becomes operational.
After the control lever is returned to the neutral
position, the control becomes possible again.
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Do not set the function lock lever to the “LOCK”

position during operation.
Otherwise, all the operation functions are
R
suddenly stopped, causing extreme danger.

10000A-1
[ 2. OPERATION ]
2.3.8 TRAVELING OPERATION
• Assign the signalman at visible place from

Far side :
the operator. Forward travel side
Near side :
• Confirm that people and obstacles are kept Backward travel side
out of the traveling area.
• Sound the horn to warn the surrounding
people before traveling.
• Be ensuring the machine stability especially
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when the boom is long, boom angle is high
and the ground condition is doubtful and RIGHT TRAVEL
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perform safe traveling. CONTROL LEVER
LEFT TRAVEL
CONTROL LEVER
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TRAVEL CONTROL
LEVER LOCK
As to the stability in swing and traveling to avoid
the machine turnover, refer to the article “8.4
SWING AND TRAVEL STABILITY”.
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Failure to observe this precaution may result in a Near side : Far side :
serious injury or loss of life. Release position Lock position
The travel speed is controlled by turning the

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accelerator grip and the adjusting of the control lever

stroke to forward and backward.
By selection of the travel speed select switch, select
Upper : High speed side
high/low speed.
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High speed Use this speed on good ground condition.
Use this speed when more traction force is TRAVEL SPEED

Low speed SELECT SWITCH
required on bad ground condition.
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Adjust the right/left travel control lever stroke on the

rough terrain where may deflect the traveling. Lower : Low speed side
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11000-1
[ 2. OPERATION ]
TRAVELING DIRECTION
• Traveling forward means that the machine

moving to the idler direction and traveling
backward is toward to the travel motor direction.
Forward direction
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TRAVEL MOTOR IDLER
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• In order to identify front and rear of the lower Forward direction
machinery, the crawler shoes have “ ” marks.
When the cab positions to the travel motor side,
use caution with traveling operation in reverse
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only.
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10000A-1
[ 2. OPERATION ]
OPERATION METHOD
1. Release the travel control lever lock. Forward direction
2. Select high or low speed by the travel speed

select switch according to the requirement of
traveling.
3. When the travel speed selector switch is placed

in the high speed position, pivot turn and spin Pivot turn
turn due to large travel resistance cannot be
operated.
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Turn the switch to Low speed position for pivot
turn and spin turn.
nl
4. Engage the control lever lock when not to travel
the machine. Spin turn
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• Operate the control lever slowly.
Normal turn
Abrupt control lever operation is very
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dangerous, and may create the unexpected
loads to the base machinery and the
attachment or load swinging.
• If the front or rear drum is operated while
traveling the machine, it will cause of danger
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such as the traveling speed/direction changes.

To perform such simultaneous operation,
slow down the travel speed and slowly
operate the drum.
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Do not use the travel speed select switch during

traveling.
It may cause deflected travel.
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When the machine has travel on a slope, improve

the slope gradually change at starting and
stopping parts so that the machine may not be
sudden inclination and turnover.
serious accident.

11000-1
[ 2. OPERATION ]
2.3.9 SWINGING OPERATION
• Ensure no personnel and obstacles are

within the rear end radius of swing and
beneath the attachment.
• S o u n d h o r n s i g n a l w a r n p e r s o n n e l
surroundings.
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in a serious injury or loss of life.
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• As to the stability in swing and traveling
to avoid the machine turnover, refer to
t h e a r t i c l e “ 8 . 4 S W I N G A N D T R AV E L
STABILITY”.
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The swing speed is controlled by turning the accelerator

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grip and the adjusting of the control lever stroke.
1. Kind of alarm can be selected by the swing

Upper : Alarm light, buzzer side
alarm select switch.
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SWING ALARM
SELECT SWITCH
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Lower : Alarm light side

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10000A-1
[ 2. OPERATION ]
2. Select free (high/low) speed or brake (low) by

swing mode select icon based on work content.
At the brake mode (low) or free (low), swing
max. speed becomes lowered.
FREE/HIGH SPEED BRAKE/LOW SPEED
FREE/LOW SPEED
Operate the control lever slowly.

Abrupt control lever operation is very dangerous,
and may create the unexpected loads to the base
machinery and the attachment or load swinging.
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Mode Work content Movement
Free/high speed Crane, lifting magnet and clamshell work. With the lever neutral mode becomes swing free.
Free/low speed Long boom crane Select the swing speed based on the work.
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With the lever neutral, swing brake is engaged.
Brake/low speed Long boom crane
(Hydraulic brake)
* LOW SPEED At high idling about 50% of high speed.
At low idling about 70% of high speed.
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At the long boom crane work, if the select icon is
kept to brake/low speed side, operation is easy
but hydraulic control is being applied to reduce
swing stop shock and swing power is lowered
and swing speed becomes slow.
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In order to avoid damage on the base machine and

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the hydraulic components, the swing mode select

icon should be manipulated at the swing brake switch
is in the engage side with the engine at low idle.
Do not perform switching of swing mode while in
ef
swing motion.
parts damage.
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11000-1
[ 2. OPERATION ]
3. Release the swing lock operation lever so that SWING LOCK CONTROL LEVER
the swing lock pin is disengaged and the swing
brake switch turn to disengage side so that Near side : Far side :
release the swing brake.

completely stopped.
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huge burden to the swing mechanism and the Left : Right :
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SWING BRAKE SWITCH
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• Due to the wind or ground inclination the upper
machinery may start swing unexpectedly.
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Take extra care when disengaging the swing
brake.
SWING CONTROL LEVER
• If the engine is started with the swing brake
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disengaged or if the function lock lever is

turned to lock position with the swing brake
disengaged, the swing brake is kept engaged.
In such case, turn the swing brake to “ENGAGE”
side once and then turn to “DISENGAGE” side
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to release the swing brake.

• If the function lock lever is in “LOCK”
position, swing brake is engaged regardless
of swing brake switch position.
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10000A-1
[ 2. OPERATION ]
4. Pulling the lever backward is the upper Far side :

machinery to swing right and pushing forward to Left swing side
SWING CONTROL LEVER
swing left
Near side :
To stop the swing motion
Right swing side
At swing Move the lever slowly to the counter
free mode direction of swing.
At swing Return the lever slowly to the neutral
brake mode position.
In case of strong wind or on the slope, the
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upper machinery may start swinging by itself.
Therefore engage the swing brake.
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Right swing side
Left swing side
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completely stopped.
huge burden to the swing mechanism and the
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Never do abrupt acceleration or deceleration of

swing control which may cause side loading at
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swinging.
These may damage to the attachment and is very
dangerous.
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11000-1
[ 2. OPERATION ]
5. When pause the work, apply swing lock at the

upper machinery align to the swing lock position
(upper machinery is facing parallel or right angle
to the crawler).
• Only when upper machinery is at swing lock

position (upper machinery is facing parallel or
right angle to the crawler), swing lock can be
applied.
• After engaging the swing lock, lightly swing to
both directions to confirm surely engaged.
• In the above condition, if the swing can be
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made, the swing lock position is incorrect.
• Release the swing lock and swing the upper
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machinery to the correct place and engage
swing lock again.
Swing lock is engaged correctly if both direction
of swing can’t be made.
The machine may damage when swinging with the
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swing lock engaged other than the lock position.
Failure to observe this precaution may result in
serious damage of the machine.
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10000A-1
[ 2. OPERATION ]
2.3.10 BOOM RAISING/LOWERING OPERATION
Ensure that there are no personnel and obstacles

within the attachment work range.
The boom raising/lowering speed is controlled by
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turning the accelerator grip and the adjusting of the
control lever stroke and can also be adjusted by the
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drum speed adjusting trimmer.
1. To release the drum lock by pushing down the

boom drum lock knob.
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* In case of the drum lock can’t be released, may
be the pawl is bit with the drum ratchet.
In this case, raise the boom drum a bit and BOOM DRUM
LOCK KNOB
perform the releasing by the knob again.
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25 mm (31/32″)
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11000-1
[ 2. OPERATION ]
2. Push the boom drum control lever forward to

Far side :
lower the boom, and pull the lever backward to BOOM DRUM CONTROL LEVER
Lowering side
raise the boom.
Near side :
Raising side

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Raising side
While lowering the boom, do not make the boom,

jib to come close to the hook.
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When the hook contacts the attachment, the
attachment and their wire rope may be damaged.
Lowering side
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damage the machine.
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10000A-1
[ 2. OPERATION ]
3. When the boom drum control lever is returned to

the neutral, the drum brake actuates automatically
and the boom is stopped and is held.
When returning the control lever to the neutral,

ensure that it is returned surely to the neutral
position.
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nl
While lowering the boom, do not make the boom,
jib to come close to the hook.
When the hook contacts the attachment, the
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attachment and their wire rope may be damaged.
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damage the machine.
4. Adjust the drum speed by the drum speed

adjust trimmer based on the work condition.
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BOOM DRUM
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Left :
Speed decrease side
Right :
Speed increase side

11000-1
[ 2. OPERATION ]
5. When the boom approaches the upper limit

angle, the raising speed is reduced.
The starting angle for speed reducing differs
depending on the engine speed and the position
of drum speed trimmer.
When the engine is at high idle and the drum
speed adjusting trimmer is at maximum position,
the speed reducing starts 10 degrees before
limited angle.
6. Be sure to stop the engine, and engage the

drum lock before leaving the operator’s seat.
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To engage the drum lock, push and hold the
nl
button, and then fully pull the knob up.
Fully pull it up, although the resistance against
pulling may be altered halfway.
Check to see if the boom control lever is
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returned to the neutral and then engage the
lever lock.
Turn the function lock lever to “LOCK” position.
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10000A-1
[ 2. OPERATION ]
2.3.11 HOOK HOISTING/LOWERING OPERATION
Ensure that there are no obstacles or personnel

within and hanging the hook or load moving area.
serious injury.
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Perform the crane work with “NEUTRAL
BRAKE”mode.
Crane work with “FREE FALL” mode may drop the
load by operation error.
O
ce
damage the machine.
en
er
When making lifts, strictly follow the capacity

charts for determining the loads that can be
handled as supplied by the manufacturer.
Follow good operating practice and procedures as
ef
outlined in this manual.

R

11000-1
[ 2. OPERATION ]
NORMAL OPERATION
Hoisting and lowering speed is controlled by turning

the accelerator grip and the drum control lever stroke
and can also be adjusted by the drum speed adjusting
trimmer.
1. Ensure that the free fall indication lamp is OFF.
2. Release the drum locks by pushing down the

each drum lock knob. THIRD DRUM
LOCK KNOB
y
(OPTION)
* In case of the drum lock can’t be released, may
be the pawl is bit with the drum ratchet.
nl
In this case, hoist the respective drum a bit and
perform the releasing by the knob again. FRONT DRUM
LOCK KNOB
REAR DRUM
LOCK KNOB
O
• When releasing the drum lock, ensure
that the drum brake mode is in “NEUTRAL
25 mm (31/32″)
BRAKE MODE” to prevent from dropping the
ce
lifting load.
Failure to observe this precaution may result Pull up : Lock position Push down : Release position
• Brake pedal should be engaged with the
pedal lock even in the neutral brake mode
en
for safety.
er
ef
R
10000A-1
[ 2. OPERATION ]
3. Pushing the each drum control lever to forward

THIRD DRUM
to lower the hook and pulling the lever backward CONTROL LEVER
(OPTION) Far side :
is to hoist the hook. Lowering side
Near side :
When lowering a hook, place a foot on the brake Hoisting side
pedal and maintain the action to apply braking at
FRONT DRUM
any time. CONTROL LEVER
Failure to observe this precaution may result in a REAR DRUM
serious accident. CONTROL LEVER
y
nl
Hoisting side
O
Lowering side
ce
en

damage the machine.
er
The braking by the brake pedal while hoisting/

ef
lowering does not function if the neutral brake

mode is selected.
Whenever auto-stop occurs during hook hoisting/
lowering, immediately return the control lever to
R
neutral.

11000-1
[ 2. OPERATION ]
4. When the drum control lever is returned to the

neutral, auto-brake actuates and the hook stops.
When the lifting load is to be held in the air for

long time, engage the drum lock.
When the drum lock is to be engaged, pull the

knob up completely.
Although pull up resistance may change on its
half way, pull up to the end.
y
nl
When returning the control lever to the neutral,
ensure that it is returned surely to the neutral
position.
Brake pedal should be engaged with the pedal
O
ce
lock even in the neutral brake mode for safety.
serious accident.
en
Simultaneous operation of the front drum with 1st

speed and the rear drum with 2nd speed cannot
er
be done due to hydraulic system.

ef
R
10000A-1
[ 2. OPERATION ]
5. According to working condition, adjust the

speed of the drum with the drum speed adjust
trimmer.
THIRD DRUM SPEED

ADJUST TRIMMER
(OPTION)
FRONT DRUM
REAR DRUM
y
nl
Left :
Speed decrease side
O
Right :
ce Speed increase side
en
er
ef
R

11000-1
[ 2. OPERATION ]
G WINCH CONTROL
Upper : ON
G winch is a function to bring maximum line speed

with low engine speed at no load condition.
Control as per the following procedure.
G WINCH
MAIN SWITCH
G winch mode is not available with a load

condition to prevent damage to the machine. Lower : OFF
y
damage parts.
nl
1. Turn ON the G winch main switch located at the REAR SWITCH PANEL
rear switch panel of the cab.

The G winch indication lamp in the monitor OFF ON
O
becomes yellow light and the standby condition
of G winch mode.
2. While in the standby condition of G winch, turn Light up yellow

to the G winch mode when pressing the G
ce
G WINCH INDICATION LAMP
winch switch on the front/rear control lever with
the following conditions are satisfy.
• Low idling.
• No lifting load.
en
• Not the regeneration (soot burning) is in

progress.
• Each control levers are in neutral position.
* Under the G winch mode, if one of the above

er
becomes out of condition, the G winch mode

will released and the G winch indication lamp is
turned back to standby condition (yellow).
ef
R
10000A-1
[ 2. OPERATION ]
3. The G winch mode can be selected either the

front or rear drum individually.
The selected winch indication lamp becomes
FRONT DRUM
light up in green. G WINCH SWITCH
* As for the loaded or not is to be determined with REAR DRUM

G WINCH SWITCH
the displayed load in the monitor.
The hook uses for G winch mode is to be
selected (Either front or rear drum) and use the
G winch mode.
* Under the green light is ON condition, pressing
the switch again can cancel the G winch mode.
y
Front drum side Rear drum side
nl
Light up green Light up green
When switching to the G winch mode, the engine
speed become limited as shown following table, G WINCH INDICATION LAMP
O
but it is not abnormal.
G engine mode 900 min-1 (900 rpm)

ce
Power mode 1,000 min-1 (1,000 rpm)
* At power mode, the engine speed can be
controlled between 800 to 1,000 min-1.
en
er
ef
R

11000-1
[ 2. OPERATION ]
4. Operate the lever while in the G winch mode,

can be obtained the high speed hoisting and
lowering.
After selection the G winch mode individually,

only ONE operation is possible for high speed
motion.
When the lever is returned to the neutral
position, this function is cancelled and returns to
standby condition.
If this function has to be used again, push the
y
either front or rear G winch switch when the
lever is in neutral.
nl
O
In the lowering control, the initial speed may be
slower in certain times.
This is caused by function of the counterbalance
valve and is normal.
In case the front and rear drum speed adjusting
ce
trimmer are not in maximum position, maximum
speed can not be obtained even under this function.
Ensure to the set them to maximum position.
en
5. When the following warning is issued, this

function can not be used.
Actual rotation is higher than no load

W-48
rotation.
er
* When the above warning is issued, safety lower

the lifting load and turn OFF the key switch.
ef
If the warning does not disappear after restart of

the engine, contact Manitowoc service shop.
R
10000A-1
[ 2. OPERATION ]
G ENGINE CONTROL
“G ENGINE” is a function to obtain the maximum line

speed under no load at lower engine speed .
This is effective to save fuel consumption which
otherwise is caused by unnecessary engine high
speed.
Under G engine mode, enough energy for heavy
y
load work with high speed may not be obtained.
Ensure to turn to power mode.
nl
O
ce
engine mode.
1. Turn ON the G engine switch located at the rear

Upper : Power mode side
switch panel of the cab.
en
The G engine indication lamp in the monitor is

lit in green while each lever is in neutral.
2. When any of the following warnings are issued,

G ENGINE
this function can not be used. SELECT SWITCH
er
The engine returns to power mode automatically.
Qmax cut solenoid output OFF

W-46
abnormal. Lower : G engine mode side
ef
Qmax cut solenoid output ON

W-47
abnormal.
Actual rotation is higher than no load
W-48
R
rotation. REAR SWITCH PANEL
* When the above warning is issued, safely lower OFF ON

the lifting load and turn OFF the key switch.
If the warning does not disappear after restart of
the engine, contact Manitowoc service shop.
Light up green
G ENGINE INDICATION LAMP

11000-1
[ 2. OPERATION ]
2.4 FREE FALL OPERATION

This section explains free fall operation.
The free fall operation must be limited to use of
excavation works with the bucket or the like.
Perform the crane work with “NEUTRAL BRAKE”

mode.
Crane work with “FREE FALL” mode may drop the
y
load by operation error.
nl
O
With the free fall mode, if auto-stop occurs due to
over loading or overhoist, press the brake pedal
first and then return the control lever to neutral
position.
If the control lever is return to neutral before pressing
ce
the brake pedal, the lifting load may be dropped.
serious injuries or lose of life.
en
er
ef
R
10000A-1
[ 2. OPERATION ]
• When the hydraulic oil has been replaced, the

feeling of brake operation may change from the
experience in the past.
In this case, contact to authorized Manitowoc
distributor.
• When the messages as shown right are indicated MC1-W16

on the monitor during the operation, the free fall
function will be disabled. MC1-W17
Lower the lifting load and hook to the ground

MC1-W18
and turn OFF the key switch.
y
Power supply will be shut off about 90 seconds
later.
nl
Then, restart the engine and start the operation
when the message indication disappeared.
If the messages as shown right are still
indicated even if the engine has been restarted,
O
stop the operation and contact authorized
ce
When the error message is indicated, do not stop
the engine with the load and hook held in the air.
Failure to observe this precaution, the load or the
hook may fall.
en

serious injuries or lose of life.
er
ef
R

11000-1
[ 2. OPERATION ]
1. Mode change (Neutral brake → Free fall)
(1) Turn the “FREE FALL LOCK MASTER KEY”

located in the monitor stand bypass switch Left : Lock side Right : Release side
panel to release side.
FREE FALL LOCK MASTER KEY
y
nl
O
BYPASS SWITCH PANEL
ce
(2) Set the control lever to the neutral position and
depress the brake pedal fully.
Lock position
The pedal will be locked with its lock and is held
at depressed position.
en
PEDAL LOCK
er
(3) Push the “DRUM BRAKE SELECT SWITCH” on THIRD DRUM BRAKE
the drum control lever. SELECT SWITCH (OPTION)
The free fall indication lamp in the monitor lights

ef
up to indicate that entering to the free fall mode.

R
FRONT DRUM BRAKE SELECT SWITCH
REAR DRUM BRAKE SELECT SWITCH
10000A-1
[ 2. OPERATION ]
2. Free fall operation
(1) Press the brake pedal at its heel portion to

disengage the pedal lock.
PEDAL LOCK
(2) Release the brake pedal gradually.
y
The lifting load will starts free falling.
nl
O
(3) Adjust the lowering speed by the amount of
pressing brake pedal.
ce
* When the brake pedal is depressed slightly, feel
the pedal vibrates slightly and from this point
depressing the pedal further will start works the
brake.
en

er

damage the machine.
ef
R
• Do not free fall with heavy load.

The control of lifting load becomes difficult
by brake pedal if the free falling speed is fast.
Perform free falling with lower speed as
slow as possible.
• Do not apply abrupt brake during free falling.
And also do not handle the drum brake
select switch and each control levers.

11000-1
[ 2. OPERATION ]
3. Hoisting operation
(1) Depress the brake pedal fully and confirm the

free falling is over and stop.
* When the brake pedal is depressed slightly, feel

the pedal vibrates slightly and from this point
depressing the pedal further will start works the
brake.
(2) Pull the drum control lever backward, start

hoisting motion even with the brake pedal is
y
remain depressing.
(3) Return the drum control lever to the neutral
nl
position, the hoisting motion stops.
* The hoisting speed will not be affected even

with the brake pedal is kept in depress position.
O
In order to avoid the unexpected free falling just
after the stop hoisting, operate with the brake
pedal kept depressing.
4. Power lowering
ce
(1) With the brake pedal is depressing, push the
drum control lever forward, lowering motion
starts as the power lowering.
(2) Return the drum control lever to the neutral
en
position, the lowering motion stops.
* The power lowering speed will not be affected

even with the brake pedal is kept in depress
position.
er
In order to avoid the unexpected free falling just

after the stop lowering, operate with the brake
pedal kept depressing.
ef
5. Mode change (Free fall → Neutral brake )
(1) Depress the brake pedal fully and return the

drum control lever to the neutral position.
R
(2) Push the “DRUM BRAKE SELECT SWITCH” on

the drum control lever.
The free fall indication lamp in the monitor goes
off to indicate that entering to the neutral brake
mode.
(3) In case of the lifting load is to be suspended in
the air long of time, apply the drum lock as well.
10000A-1
[ 2. OPERATION ]
6. Handling at cold situation

Upper : Speed increase side
In case of free fall speed is slow due to the

ambient temperature is low, by select the “FREE
FALL SPEED SELECT SWITCH” in the left side
switch panel to increase speed side, speed is to
be increased.
Lower : Normal side

• When changing the free fall speed select
y
switch is in increase side, do not release the
brake pedal with the hook on the ground.
nl
The drum automatically rotates to lowering
side and this may cause rough spooling. LEFT SIDE SWITCH PANEL
• While the heavy load is free falling, do not
change the free fall speed select switch.
O
A shock occurs at speed changing.
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.5 CLAMSHELL OPERATION

In clamshell operation, the control levers and brake
pedals are called with the designations shown in the
following figure.
The basic control is as same as the crane operation.
CLOSING DRUM
BRAKE PADEAL
HOLDING DRUM
BRAKE PADEAL
y
nl
O
CLOSING DRUM LOCK KNOB CLOSING DRUM CONTROL LEVER
HOLDING DRUM LOCK KNOB HOLDING DRUM CONTROL LEVER
BOOM DRUM LOCK KNOB
ce
BOOM DRUM CONTROL LEVER
en
CLOSING DRUM SPEED ADJUST TRIMMER
HOLDING DRUM SPEED ADJUST TRIMMER

er
BOOM DRUM SPEED ADJUST TRIMMER

ef
CLOSING DRUM BRAKE

SELECT SWITCH
R
HOLDING DRUM BRAKE

HOLDING ROPE CLOSING ROPE SELECT SWITCH
10000A-1
[ 2. OPERATION ]
After the work is completed, lower the bucket on

the ground and press the closing and holding rope
brake pedals and engage the pedal locks, turn to
the brake mode and engage each drum lock, and
then engage the rotation lock on tagline drum after
engine is stopped.
y
nl
Since the clamshell needs repeating of bucket
closing, hoisting, lowering or swing operation, it is
likely that the damage to the hoist drum or boom,
pin wear or missing or loosening bolts or missing
O
may occur.
Ensure to make pre operation or after work
inspection absolutely.
serious accident.
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.5.1 PREPARATION WORK

1. Select the capacity of the clamshell bucket to
meet the machine specification.
(Rated load, bucket size, digging material weight)
2. Set the hydraulic tag line rope for bucket swing

prevention to the bucket and check for its proper
tension.
3. Set the drum speed adjusting trimmer to

maximum.
y
CLOSING DRUM
HOLDING DRUM
nl
BOOM DRUM
As for the drum speed adjusting trimmer, closing
rope and holding rope would not be synchronized
O
other than at maximum speed position. Left :
Speed decrease side
Right :
Speed increase side
ce
4. Turn the “WORK MODE SELECT ICON” in the
monitor to ON.
en
In case of heavy load clamshell work, if the

work mode select icon is in “OFF” (High speed)
position, holding and closing rope may not be able
to synchronize.
er
5. In case of bucket lowering of clamshell work with

free fall mode, change to free fall mode refer to
ef
the article “2.4 FREE FALL OPERATION”.
6. Adjust the engine speed with the accel grip.

R
10000A-1
[ 2. OPERATION ]
7. If the clamshell rated load is programmed in the

load safety device, it will function.
Take extra care not to cause overload in the

clamshell work.
Set the load about 60% to 70% of the clamshell
work rated load. (Work at about 60% to 70% of the
wire rope rated load.)
Do not shut off the load safety device at the
y
clamshell work.
Work with the overload condition may cause
nl
damage on the boom or serious accident such as
overturn of to the machine.
O
8. Setting of the controller of the load safety device.
• In case clamshell lifting capacity is specified.
This machine specifies clamshell lifting capacity.

ce
When clamshell work has to be done, set it on
the monitor screen as follows.
Select the item according to the indication of the

monitor screen.
en
In case of set contents are made mistake, press

on the right bottom corner to return the
previous display.
SETTING EXAMPLE
er
Attachment type Clamshell

Boom length 18.3 m (60 ft)
ef
(1) Push the of the monitor and select .

Refer to the chapter “3.5.1 SETTING OF
CRANE COFIGURATION”
(2) Attachment select screen is displayed.
R
Select .

11000-1
[ 2. OPERATION ]
(3) Boom length select screen is displayed.

Select “60 ft.”.
y
nl
(4) Press “0” in the number of part line setting.
O
ce
en
(5) Press “1” by the numeric keypad. Highlighting

er
0
ef
R
10000A-1
[ 2. OPERATION ]
(6) Setting is completed.

Press .
y
nl
O
ce
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.5.2 CLAMSHELL WORK
Never do abrupt acceleration or deceleration of

swing control which may cause side loading at
swinging.
These may damage to the boom or guy line and is
very dangerous.
y
nl
Total weight of bucket and materials should not
O
exceed the rated load.
The rated load is determined by the machine
stability and boom strength.
ce
CONTROL LEVER AND BRAKE PEDAL OPERATION IN CLAMSHELL WORK
Closing rope Holding rope
en
Work condition Closing drum Closing drum Holding drum Holding drum Control condition and caution
control lever brake pedal control lever brake pedal
Control the holding wire rope by
Pedal released Neutral
1. Digging material Hoist Half brake rear drum brake and adjust the
(Return)* (Free condition)
bucket to bite into material.
er
Hoist both closing wire rope and

Pedal released Pedal released
2. Hoist Hoist Hoist holding wire rope together to control
(Return)* (Return)*
not to allow one side loosening.
3. Stop Neutral Pedal pressed Neutral Pedal pressed Stop bucket hoisting motion.
ef
4. Swing
Pedal released While swinging, release material
5. Releasing material Neutral Neutral Pedal pressed
(Return) and open bucket and keep opening.
R
Move bucket to digging position

6. Swing
by swinging.
7. Lowering Half brake or Half brake or Lower bucket with half brake.
Neutral Neutral
(Prepare for digging) Pedal released Pedal released Take care not to twist rope.
* Even brake pedal is pressed, hoisting motion is possible.
The above is one example of clamshell work.

According to the work condition, combination work is
possible such as swinging with hoisting bucket and
releasing material.
10000A-1
[ 2. OPERATION ]
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)

SPECIFICATION
Relief pressure 13.7 MPa (140 kgf/cm2)
Wire rope type FC 6 W (19) C/O
Breaking strength 57.9 kN (5.91 tf)
Wire rope dia. Φ10 mm
Wire rope length 45 m
Wire rope tension 1.67 kN (170 kgf)
y
1. Stop the engine, and set the tagline tension
adjusting trimmer to the lowest setting (fully turn
nl
to the left).
2. Remove the lock bolt from the drum flange and

lock the bolt with nut.
O
3. Reeve the wire rope end through the outside of
the drum flange, and fix it with a clamp. TAGLINE TENSION ADJUST TRIMMER
ce
CLAMP
en
FLANGE
MOTOR
er
LOCK BOLT
ef
R

11000-1
[ 2. OPERATION ]
4. Set the other end of the wire rope to the bucket

via the guide sheave.
5. Confirm that the tagline tension adjusting

trimmer is at the lowest setting (fully turned to
the left), and then start and idle the engine.
GUIDE SHEAVE
• Do not stand close to the drum or tagline
wire rope since the tagline rope may be
y
suddenly tensioned or slackened when
starting or stopping the engine.
nl
in a serious injuries or loss of life.
• Before starting the engine, ensure to turn
the tagline tension adjust trimmer to the
O
minimum tension (turn counterclockwise
fully) and then start the engine.
ce
6. To wind up the rope on the drum, turn the
tagline adjusting knob trimmer somewhat to the
higher setting, while tensioning the wire rope.
en
When the tag line rope is slacken, the winding

TAGLINE TENSION ADJUST TRIMMER
motion suddenly starts by operating the tension
er
adjusting switch.
Keep clear of the drum and tag line rope.
Make sure to turn the adjusting switch to the
minimum tension position (turn counterclockwise
ef
fully) when you come close to the drum and tag

line rope.
serious injury.
R
7. Adjust the wire rope tension with the tagline

adjusting knob trimmer carefully.
Turn right Tagline rope tension

(Clockwise) becomes high.
Turn left Tagline rope tension
(Counterclockwise) becomes low.
10000A-1
[ 2. OPERATION ]
8. Turn the flow adjusting knob in case of winding

speed needs to be changed.
Remove the swing motor cover to access the
adjusting knob.
Close the valve and oil flow

Turn right
decrease thus winding speed
(Clockwise)
becomes decrease.
Open the valve and oil flow
Turn left
increase thus winding speed
(Counterclockwise)
becomes increase.
y
* At the time of shipment, the flow adjusting
handle set up at fully counterclockwise position
nl
(high speed side).
FLOW ADJUSTING KNOB
O
When not using the tagline : Fully wind up the
wire rope on the drum and secure the wire rope
end and set the tension adjusting trimmer to the
minimum setting (fully turn to the left).
ce
Secure the drum flange with the lock bolt.
en
er
ef
R

11000-1
[ 2. OPERATION ]
2.7 HANDLING OF VIBRO HAMMER

1. Cautions when using
(1) Be sure to use a vibro hammer within the rated

load.
Total load indicated below must be within the
crane rated load.
When
Hook weight + Pile weight + Vibro
driving a
hammer weight
y
pile
When Hook weight + Pile weight + Vibro hammer
extracting weight + Centrifugal force (Vibratory force)
nl
a pile of vibro hammer × 1/4
(2) Use of lifting wire rope
O
Place a lifting wire rope between hock and vibro
hammer so that the vibratory force of the vibro
hammer is not transmitted directly to the hook.
2. Cautions when working

ce
Do not turn the free fall speed select switch to
en
speed increase side in vibro hammer work.

Otherwise the hoist rope may cause rough
spooling.
er
(1) When starting operation

Place the vibro hammer on the head of the pile,
and start with the winch wire rope loosened.
ef
R
10000A-1
[ 2. OPERATION ]
(2) While operating
If the buffer spring is compressed completely,

vibration of the vibro hammer would be
transmitted directly to the boom through the wire
rope and hook and damage may be caused.
Adjust the hook lowering speed so that the
y
buffer springs is not tight compressed.
Do not operate the vibro hammer without a pile
nl
or pile lifted in the air.
O
While extracting the pile with the vibro and
hoisting the load to the extent that the machine
rear is lifted up intended to extract the pile with the
machine rear lowering reaction may lead to severe
ce
impact to the various portion of the machine.
Never attempt to operate such overload work in
the vibro work.
serious accident.
en
(3) When stopping operation

In order to minimize resonance generated when
stopping, place the vibro hammer on the head
er
of the pile, and stop operation.

ef
R

11000-1
[ 2. OPERATION ]
3. Check and maintenance Dye penetrant check

for damage, crack.
Since larger loads and vibrations are generated

repeatedly in a short time in vibro hammer
operation and damage to the boom, hook, and
frame etc. and looseness of screws are likely to
occur.
Be sure to check carefully before and after Dye penetrant check
operation. for damage, crack.
If any abnormality is found, immediately repair

or replace.
Consult the authorized Manitowoc distributor
y
for disassembly inspection of the hook (Dye
penetrant check).
nl
Check for looseness or missing of the
counterweight nuts every 5 months. Check for loose nut.
O
The warranty does not cover any damage to
the equipment caused by failure to observe the
operating instructions and cautions described.
ce
en
er
ef
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10000A-1
[ 2. OPERATION ]
2.8 OPERATION IN WEATHER CHANGE AND SPECIAL

CIRCUMSTANCE
This article explains countermeasures in operation
when strong wind, lightning, electric shock or radio
wave interference occurs.
2.8.1 CAUTION AGAINST WIND
y
Lifting load swinging due to strong wind may
nl
lead to serious accident such as overturn of the
machine.
Strictly observe the following precautions to
prevent accident.
O
Failure to observe these precautions may lead to a
serious accident, injury or loss of life.
INFLUENCE OF WIND
ce
Influence of the wind on the machine becomes larger
in proportion to the size of a lifted load, lifting height,
and boom length.
Utmost care is necessary for operation.
en
er
CAUTIONS FOR WIND

ef
1. When performing crane operation in strong

wind, utmost cautions are required according to
the wind speed, machine condition and working
environment.
R

11000-1
[ 2. OPERATION ]
2. Especially following conditions are very

dangerous, so, utmost care is necessary for
operation.
(1) When lifting a load of with large surface area,

against which the wind blows hard, the wind
could cause the overturn of the machine and
damage to the boom.
(2) The wind could also blow the load against the
boom, and could cause damage.
(3) When the boom is fully raised without a load,
the wind could blow the boom backward
y
resulting in an overturn of the machine.
nl
3. The wind speed is different on the ground than
in the high air.
It is also different on open area and populated
area.
O
Always consider these conditions and take
proper measures to meet the situation.
The wind speed mentioned here means the
instantaneous wind speed.
ce
When the wind speed exceeds 9.8 m/s (22
MPH) stop the work.
METHOD OF WIND SPEED MEASUREMENT Crane

en
:A
1. If an instantaneous anemometer is provided in

gth
the machine, measure the wind speed with the Working point of wind
len
om
anemometer provided.
×A
Bo
0.6
2. I f a n i n s t a n t a n e o u s a n e m o m e t e r i s n o t Height above ground

er
provided in the machine, the wind speed given

by a weather report can be converted to the
instantaneous wind speed based on convention
table in next page.
Fixed jib :B
ef
gth
en
Jibl
3. T h e i n s t a n t a n e o u s w i n d s p e e d c a n b e
approximated by the Beaufort chart in next page.
:A
The position where the wind works against the

gth
R
machine is the height above the ground as Working point of wind

B)
len
A+
shown right figures.

om
×(
Bo
0.6
Height above ground
10000A-1
[ 2. OPERATION ]
Wind speed in the weather report is average wind

speed in 10 minutes.
This must be converted into instantaneous wind
speed.
CONVERSION TABLE OF WIND SPEED Unit : m/s (MPH)

Height Wind speed Wind speed Wind speed Wind speed
above 3 m/s (6.7 MPH) 5 m/s (11.2 MPH) 8 m/s (17.9 MPH) 10 m/s (22.4 MPH)
ground Flat area City area Flat area City area Flat area City area Flat area City area
: m (ft.) Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst.
2.7 9.8 2.5 10.0 4.5 11.7 4.2 11.4 7.1 14.5 6.7 14.0 8.9 16.3 8.4 15.8
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5 (17)
(6.0) (21.9) (5.6) (22.4) (10.0) (26.2) (9.4) (25.5) (15.9) (32.4) (15.0) (31.3) (19.9) (36.5) (18.8) (35.3)
3.0 10.2 3.0 10.2 5.0 12.3 5.0 12.3 8.0 15.4 8.0 15.4 10.0 17.5 10.0 17.5
10 (33)
(6.7) (22.8) (6.7) (22.8) (11.2) (27.5) (11.2) (27.5) (17.9) (34.4) (17.9) (34.4) (22.4) (39.1) (22.4) (39.1)
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3.2 10.4 3.3 10.5 5.4 12.7 5.6 12.9 8.6 16.0 8.9 16.3 10.7 18.2 11.1 18.7
15 (50)
(7.2) (23.3) (7.4) (23.5) (12.1) (28.4) (12.5) (28.9) (19.2) (35.8) (19.9) (36.5) (23.9) (40.7) (24.8) (41.8)
3.4 10.5 3.6 10.8 5.6 12.9 6.0 13.3 9.0 16.5 9.5 17.0 11.2 18.8 11.9 19.5
20 (66)
(7.6) (23.5) (8.0) (24.2) (12.5) (28.9) (13.4) (29.8) (20.1) (36.9) (21.3) (38.0) (25.0) (42.1) (26.6) (43.6)
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3.5 10.7 3.8 11.0 5.9 13.2 6.3 13.6 9.4 16.9 10.1 17.6 11.7 19.3 12.6 20.2
25 (82)
(7.8) (23.9) (8.5) (24.6) (13.2) (29.5) (14.1) (30.4) (21.0) (37.8) (22.6) (39.4) (26.2) (43.2) (28.2) (45.2)
3.6 10.8 4.0 11.2 6.0 13.3 6.6 13.9 9.6 17.1 10.6 18.1 12.0 19.6 13.2 20.9
30 (99)
(8.0) (24.2) (8.9) (25.0) (13.4) (29.8) (14.8) (31.1) (21.5) (38.3) (23.7) (40.5) (26.8) (43.8) (29.5) (46.8)
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40 3.8 11.0 4.2 11.5 6.3 13.6 7.1 14.5 10.1 17.6 11.3 18.9 12.6 20.2 14.1 21.8
(132) (8.5) (24.6) (9.4) (25.7) (14.1) (30.4) (15.9) (32.4) (22.6) (39.4) (25.3) (42.3) (28.2) (45.2) (31.5) (48.8)
50 3.9 11.1 4.5 11.7 6.6 13.9 7.5 14.9 10.5 18.0 12.0 19.6 13.1 20.8 15.0 22.8
(164) (8.7) (24.8) (10.0) (26.2) (14.8) (31.1) (16.8) (33.3) (23.5) (40.3) (26.8) (43.8) (29.3) (46.5) (33.6) (51.0)
75 4.2 11.4 5.0 12.2 7.0 14.4 8.3 15.7 11.2 18.8 13.2 20.9 14.0 21.7 16.5 24.8
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(260) (9.4) (25.5) (11.2) (27.3) (15.7) (32.2) (18.6) (35.1) (25.0) (42.1) (29.5) (46.8) (31.3) (48.5) (36.9) (55.5)
100 4.4 11.6 5.3 12.6 7.4 14.8 8.9 16.3 11.8 19.4 14.2 21.9 14.7 22.4 17.8 26.7
(328) (9.8) (25.9) (11.9) (28.2) (16.6) (33.1) (19.9) (36.5) (26.4) (43.4) (31.8) (49.0) (32.9) (50.1) (39.8) (59.7)
* Wind speed may be higher than the above value near tall buildings.
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BEAUFORT WIND SCALE CHART

Approximate wind speed at 10 m (33 ft) height
Details
from the open and flat ground : m/s (MPH)
Less than 0.3 (0.7) Calm, smoke rises vertically.
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0.3 (0.7) to less than 1.6 (3.6) Smoke drift indicates wind direction, still wind vanes.
1.6 (3.6) to less than 3.4 (7.6) Wind felt on face, leaves rustle, vanes begin to move.
3.4 (7.6) to less than 5.5 (12.3) Leaves and small twigs constantly moving, light flags extended.
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5.5 (12.3) to less than 8.0 (17.9) Dust, leaves, and loose paper lifted, twigs move.
8.0 (17.9) to less than 10.8 (24.2) Many whitecaps, leaf in small trees begin to sway.
10.8 (24.2) to less than 13.9 (31.1) Larger tree branches moving, whistling in wires, hard to walk under an umbrella.
13.9 (31.1) to less than 17.2 (38.5) Whole trees moving, resistance felt walking against wind.
17.2 (38.5) to less than 20.8 (46.5) Twigs broken, cannot walk against wind.
20.8 (46.5) to less than 24.5 (54.8) Slight structural damage occurs, chimney broken, slate blows off roofs.
Seldom experienced on land, trees broken or uprooted,
24.5 (54.8) to less than 28.5 (63.8)
and considerable structural damage.
28.5 (63.8) to less than 32.7 (73.1) Scarcely experienced, damages occur in wide areas.
32.7 (73.1) or more

11000-1
[ 2. OPERATION ]
COUNTERMEASURE AGAINST WIND

(CRANE)
Take the following actions based on wind speed at

work area.
Take the same action in case the strong wind is
expected after work.
The wind speed here means “Instantaneous wind
speed”.
1. In case the wind speed is 9.8 to 15.6 m/s (22

to 35 MPH)
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Stop the work and take the following actions.
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(1) Lower the load on the ground and remove it
from the hook.
(2) Set the boom angle to approx. 60 degrees.
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(3) Swing the machine to receive the wind at the
counterweight side. Approx. 60 degrees
(Receive the wind at the back face of the

boom.)
(4) Lock the winches, apply swing brake, and stop
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the engine.
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10000A-1
[ 2. OPERATION ]
2. In case the wind speed is 15.6 to 30 m/s (35

to 67 MPH)

(Prepare the anchor weight by referring with the
following table)
• In case the attachment can be lowered on the

ground.

from the hook.
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(2) Lower the boom on the ground.
If swing is necessary, swing with approx. 60
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degrees boom angle.
the engine.
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• In case the attachment can’t be lowered on the
ground.

from the hook.
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counterweight side.
Approx.
boom.) 60 degrees
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(4) Connect the anchor weight to the hook and give

the tension to hoist rope with the anchor weight
kept remains on the ground.
ANCHOR WEIGHT
the engine.
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ANCHOR WEIGHT (CRANE)

Boom length : m (ft.) Boom angle : degrees Anchor weight : t (lbs)
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12.2 (40)
15.2 to 27.4 (50 to 90) 0.9 (2,000)
60
30.5 to 54.9 (100 to 180) 4.2 (9,300)
57.9 to 61.0 (190 to 200) 5.3 (11,700)
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11000-1
[ 2. OPERATION ]
3. In case wind speed is higher than 30.0 m/s

(67 MPH).
Ensure to lower the attachment on the ground

by following procedure.

from the hook.
degrees boom angle.
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the engine.
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10000A-1
[ 2. OPERATION ]
4. Wind speed effect graph (crane)
This shows the wind speed increase when

raising the boom.
Wind effect becomes larger with longer boom
length or higher boom angle.
CRANE
67
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BOOM LENGTH
60 12.2 m to 18.3 m
(40 ft to 60 ft)
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WIND SPEED (MPH)
BOOM LENGTH
50 21.3 m to 27.4 m
(70 ft to 90 ft)
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40
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BOOM LENGTH
30.5 m to 36.6 m
(100 ft to 120 ft)
BOOM LENGTH
39.6 m to 54.9 m
30 (130 ft to 180 ft)
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BOOM LENGTH
57.9 m to 61.0 m
(190 ft to 200 ft)
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20 60 65 70 75 80
BOOM ANGLE (degrees)

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11000-1
[ 2. OPERATION ]
COUNTERMEASURE AGAINST WIND (WITH

JIB)
Take the following actions based on wind speed at

work area.
Take the same action in case the strong wind is
expected after work.
The wind speed here means “Instantaneous wind
speed”.
1. In case the wind speed is 9.8 to 15.6 m/s (22

to 35 MPH)
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from the hook.
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counterweight side.
boom.)
Approx. 60 degrees
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the engine.
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10000A-1
[ 2. OPERATION ]
2. In case the wind speed is 15.6 to 30 m/s (35

to 67 MPH)

(Prepare the anchor weight by referring with the
following table)
• In case the attachment can be lowered on the

ground.

from the hook.
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degrees boom angle.
the engine.
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• In case the attachment can’t be lowered on the Jib offset angle
ground.

from the hook.
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counterweight side.
boom.)
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(4) Connect the anchor weight to the hook and give

the tension to hoist rope with the anchor weight
kept remains on the ground.
(5) Lock the winches, apply swing brake, and stop Approx. 60 degrees
the engine.
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ANCHOR WEIGHT
ANCHOR WEIGHT (WITH JIB)

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Boom angle : Anchor weight : t (lbs)

Jib length : m (ft.) Boom length : m (ft.)
degrees Offset angle 10 degrees Offset angle 30 degrees
24.4 to 36.6 (80 to 120) 1.8 (4,000) 1.3 (2,900)
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9.1 to 12.2
39.6 to 45.7 (130 to 150) 2.8 (6,200) 2.2 (4,900)
(30 to 40)
48.8 to 51.8 (160 to 180) 60 degrees 4.8 (10,600) 3.7 (8,200)
15.2 to 18.3 24.4 to 42.7 (80 to 140) 2.4 (5,300) 1.6 (3,600)
(50 to 60) 45.7 to 51.8 (150 to 170) 4.8 (10,600) 3.2 (7,100)

11000-1
[ 2. OPERATION ]
3. In case wind speed is higher than 30.0 m/s

(67 MPH).
Ensure to lower the attachment on the ground

by following procedure.

from the hook.
degrees boom angle.
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the engine.
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10000A-1
[ 2. OPERATION ]
4. Wind speed effect graph (with jib)
This shows the wind speed increase when

raising the boom.
Wind effect becomes larger with longer boom
length or larger boom angle.
9.1 m (30 ft.) and 12.2 m (40 ft.) jib
67
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60 BOOM LENGTH
24.4 m to 36.6 m
(80 ft to 120 ft)
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50
WIND SPEED (MPH)
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40
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BOOM LENGTH
39.6 m to 45.7 m
(130 ft to 150 ft)
BOOM LENGTH
48.8 m to 51.8 m
30 (160 ft to 170 ft)
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OFFSET ANGLE 10 degrees

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20 60 65 70 75 80

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11000-1
[ 2. OPERATION ]
15.2 m (50 ft.) and 18.3 m (60 ft.) jib
67
60
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BOOM LENGTH
24.4 m to 42.7 m
(80 ft to 140 ft)
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50
WIND SPEED (MPH)
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40
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BOOM LENGTH
45.7 m to 51.8 m
(150 ft to 170 ft)
30

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60 65 70 75 80
20
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10000A-1
[ 2. OPERATION ]
2.8.2 CAUTION AGAINST ELECTRIC SHOCK

If the machine or load comes close to the power lines,
danger of electric shock becomes possible.
Follow local rules and regulations.
There is a possibility of serious accident such as

injuries or loss of life of personnel when the crane
boom or lifting load comes close to or contact
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with power line.
Furthermore, an accident can be extended to :
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• Power supply cut to homes and factories.
• Power supply cut to hospital affecting life of
patients.
• Affect to the traffics such as power cut to
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the traffic signal etc.
These may cause secondary accident.
Whenever crane work is to be done near the power
line, strictly observe the following measures and
to prevent such accident.
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Failure to observe these precautions may result in
an accident and a serious injury or loss of life.
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11000-1
[ 2. OPERATION ]
MEASURE AT WORK
1. Hold a meeting with the power company to

understand the dangerous location in advance.
2. Place a signal person and keep safe distance

between the machine, lifting load and the power
line.
Refer to the article “1. SAFETY”.
3. If coming close to the power line is unavoidable,

advise the power company and obtain the
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protective insulated tube to prevent electric
shock.
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ACTION IN CASE ACCIDENT OCCURS
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Should an accident occur, take the following actions
immediately to minimize damage.
(1) Advise the nearest power company office.

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(2) Operator without getting panic, should remove
the boom or lifting load from the power line.
If removing is not possible, it is safer to stay on
the machine.
Operator would be electrocuted by getting off
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the machine holding a part of machine.

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While the boom or lifting load is touching the

power line, do not get off the machine. If person
get off the machine while holding a part of
machine, person will be electrocuted.
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Never hold any part of machine when get off.

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(3) Should someone be injured, immediately

take emergency treatment such as artificial
respiration or heart massage.
(4) If the power line is cut, do not allow any person
to come close to the loose power lines.
(5) Inspect the machine (specially on load safety
device) for proper function before reuse.
10000A-1
[ 2. OPERATION ]
2.8.3 CAUTION AGAINST RADIO WAVE INTERFERENCE

If the machine is operated near the radio or TV
transmitting station, boom, wire rope or hook may be
charged with electricity.
If charged it may lead to the danger such as trouble in
slinging to the hook or damage to the safety device.
When working near the transmitting station’s
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antenna, the boom or wire rope may function as
an extra large antenna and may be charged with
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electricity and the high voltage may be induced at
the end of the hook and may be heated.
Touching the hook may cause burns due to the
electric shock or heat.
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The computer installed on the machine may
malfunction.
Take extra care in operating the machine.
an accident and a serious injury or loss of life.
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PREVENTIVE MEASURE
• Use insulating gloves.

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• Connect the grounding wire to the hook.

• Wrap around the hook with insulating materials.
• Use nylon rope (belt type) for sling.
* Consult Manitowoc service shop if electrical

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component installed on the machine is failed.

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11000-1
[ 2. OPERATION ]
2.8.4 CAUTION AGAINST LIGHTNING

When the machine is struck by lightning, fatal accident
is likely to the operator or surrounding personnel.
Various portion of machine may also be damaged.
1. Take the following actions immediately when

the thunder cloud appears and lightning is
expected.
(1) Stop the work and lower the lifting load on the
ground.
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If the boom can be lowered, lower it on the
ground.
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(2) Engage the brake/lock (hoist, swing) and stop
the engine and turn the key to OFF.
(3) Get away from the machine and surrounding
area.
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2. If the machine was struck by lightning, check
the following points.
(1) Is there any burning out or damage?

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(2) Do all the electrical devices or load safety
devices work properly?
(3) Does each function work properly?
2.8.5 COUNTERMEASURE AGAINST EARTHQUAKE

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Earthquake is unpredictable for its time or size.

It is essential to prepare always against earthquake.
1. Preparation against earthquake.

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Lower the boom on the ground after completion

of daily work.
2. Action when earthquake occurs.

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Stop work immediately and stop the machine

and turn the engine key to OFF position.
Evacuate to the safety place taking care about
fallen materials.
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3. Inspect the following points when re-starting the

machine.
• Ground condition of the machine placed.

• Damage of the machine.
• Function of the machine.
Do not operate the machine until the damage is

repaired.
10000A-1
[ 3. LOAD SAFETY DEVICE ]

3.1 ARRANGEMENT OF EQUIPMENTS................................................................................ 3-3
3.2 TYPES AND FUNCTIONS OF EQUIPMENT ................................................................. 3-6
3.3 CONNECTING PROCEDURE OF WIRING .................................................................... 3-12
3.3.1 CRANE ATTACHMENT .................................................................................................... 3-13
3.4 FUNCTION OF MONITOR ................................................................................................... 3-20
3.5 OPERATING PROCEDURE OF MONITOR.................................................................... 3-21
3.5.1 SETTING OF CRANE CONFIGURATION .................................................................. 3-26
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3.5.2 SELECTION OF MAIN/AUXILIARY HOOK SELECTION ...................................... 3-35
3.5.3 SETTING OF WORK AREA LIMIT VALUE ................................................................. 3-36
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3.6 SWING LIMITATION DEVICE (OPTION) ......................................................................... 3-41
3.7 LOAD HISTORY (DATA LOGGER) .................................................................................... 3-53
3.8 FUNCTION OF GROUND INCLINE INDICATOR (OPTION) ..................................... 3-54
3.9 WARNING AND AUTO-STOP ............................................................................................. 3-56
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3.9.1 CONTENT OF WARNING AND AUTO-STOP ........................................................... 3-56
3.9.2 CONTENT OF AUTO-STOP ........................................................................................... 3-57
3.9.3 RELEASING AUTO-STOP .............................................................................................. 3-58
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3.10 INSPECTION ............................................................................................................................ 3-64
3.10.1 INSPECTION PROCEDURE WHEN ERECTING THE BOOM AFTER THE
ATTACHMENT ASSEMBLY WORK IS COMPLETED ............................................ 3-64
3.10.2 INSPECTION AFTER ERECTING ATTACHMENT .................................................. 3-66
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3.11 CAUTIONS IN HANDLING LOAD SAFETY DEVICE................................................... 3-68

3.12 ERROR CODE DISPLAY AND MESSAGE ..................................................................... 3-69
3.13 WARNING CODE LIST AND CONDITION, ACTION.................................................... 3-82
3.14 CHECKING PROCEDURE OF LOAD SAFETY DEVICE ........................................... 3-88
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11000-1
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This machine is provided with various safety devices
to operate the machine safely.
The machine conditions are detected with various
devices and are controlled with the controller and are
displayed with the monitor to prevent damage to the
attachment due to overload, overhoist or to prevent
overturning of the crane.
Ensure to use this device to operate the crane safely
and inspect and maintain the device periodically.
If the device becomes inoperable, repair immediately
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before restarting the work.
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SAFETY DEVICE OF THIS MACHINE
Load safety device
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Hook overhoist preventive device
(Crane, aux. sheave, jib)
Boom overhoist preventive device
(Boom, luffing jib)
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Never operate the crane with respective auto-
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stop release switches and its master keys in the

“RELEASE” position.
These switches and keys must be used for the
case of emergency evacuation when failure of
safety device or maintenance purpose.
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serious accident.
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11000-1
• The load safety device is important to operate

the crane safely.
Make sure that the device works properly and
use this device surely during work.
• Do not use the load safety device improperly,
released in unsafe way, or maintenance and
repair being neglected, machine may be
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damaged or may serious accident such as
overturning.
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• Even if the load safety device functions
correctly, wind influence, ground collapsing
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or incorrect adjustment of the device may
cause machine damage or overturning.
• Adequate caution required against electric
shock or radio wave interference during work.
If there is a possibility of strong wind,
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earthquake or lightening, stop work
immediately.
• Never adjust the length of hook overhoist
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weight wire or the limit striker and the angle

sensor of load safety device since they are
pre-adjusted.
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10000A-1
3.1 ARRANGEMENT OF EQUIPMENTS

The part name and the item number in the figures
of arrangement of equipments correspond to the
description in the section 3.2.
CRANE
12. AUX. HOOK OVERHOIST LIMIT SWITCH

11. MAIN HOOK OVERHOIST LIMIT SWITCH
8. BOOM TIP JUNCTION PANEL
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4. CABLE REEL
2. BOOM ANGLE DETECTOR

9. JUNCTION CABLE
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10. BOOM OVERHOIST LIMIT SWITCH (FINAL STOP)

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6. LOAD DETECTOR

11000-1
FIXED JIB
9. JUNCTION CABLE
4. CABLE REEL
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3. JIB ANGLE DETECTOR
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7. BASE MACHINE JUNCTION PANEL
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BYPASS SWITCH MAIN KEY
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17. LOAD SAFETY DEVICE BYPASS

CONFIGURATION SELECT SWITCH
5. OVERLOAD ALARM LAMP (OPTION)

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10000A-1
DETAIL OF OPERATOR CAB LEFT SIDE STAND

PANEL
1. MONITOR
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MAIN CONTROLLER 1
BYPASS SWITCH
MAIN CONTROLLER 2
BYPASS SWITCH
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FREE FALL LOCK

MASTER KEY
RELEASE SWITCH
MASTER KEY
LEFT SIDE PANEL BYPASS SWITCH PANEL

11000-1
3.2 TYPES AND FUNCTIONS OF EQUIPMENT

1. MONITOR
Indicate the machine condition on the touch

panel type monitor, and issues the signal for the
alarms and stop as required.
All values in the monitor displays are for reference
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only.
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68. THIRD DRUM FREE FALL INDICATION LAMP (OPTION)
65. AUTO IDLE STOP INDICATION LAMP 66. FRONT DRUM FREE FALL INDICATION LAMP
64. G WINCH INDICATION LAMP 67. REAR DRUM FREE FALL INDICATION LAMP
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63. G ENGINE INDICATION LAMP 69. INCHING SPEED LAMP
WIND SPEED INDICATOR (OPTION) 71. REMOTE CONTROL CONNECTION LAMP
0.0
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10 . 0 f t 800
10021000000600120420
2015/05/10 10:00 72. HYDRAULIC OIL TEMPERATURE LAMP
4 1
100 . 3 f t
Use.
Use.
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100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg 77. SOOT ACCUMULATION BAR GAUGE

®
76. DEF/AdBlue BAR GAUGE
40 . 3 f t 50 . 0 f t
75. FUEL BAR GAUGE
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L+S 0.3
RESET S
SET D 0.2
MONITOR SCREEN
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(BRAKE/LOW SPEED) (OPTION) 52. CAMERA SELECT ICON (OPTION)
(FREE/LOW SPEED) (OPTION) 53. WORK MODE SELECT ICON
(FREE/HIGH SPEED) (OPTION)
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54. MENU ICON 61. ASSY/DISASSY ICON

56. DPF REGENERATION CANCEL ICON 59. INCHING ICON
57. FINAL LIMIT RECOVERY ICON 58. ENGINE STOP ICON

Detail of menu icon
10000A-1
2. BOOM ANGLE DETECTOR

SENSOR
3. JIB ANGLE DETECTOR
This device detects the angle of boom and jib.
CONNECTOR
CABLE
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WATER PROOF CAP
4. CABLE REEL CABLE REEL
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This is to store electrical cables.
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STOPPER
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5. OVERLOAD ALARM LAMP (OPTION)
Issue respective warnings and indicates load

ratio in operation with 3 color lamps.
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CONTENT OF 3 COLOR LAMP INDICATION

Indicated status Red Yellow Green Buzzer
Load ratio is less than 90%
Load ratio ranges from 90 to 100%

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Load ratio is 100% or more
Hook overhoist
Boom overhoist (crane)

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Assembly configuration (at assembly and disassembly)
While the overload release switch is actuated

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Red
Yellow
Do not operate crane while red lamp is ON.
Do not modify the overload alarm lamp circuit. Green
serious accident.
OVERLOAD ALARM LAMP

11000-1
6. LOAD DETECTOR
This pin detects load.

CLAMP
WEDGE
ROPE SOCKET
LINK
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LODE
DETECTOR
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BOOM DRUM
7. BASE MACHINE JUNCTION PANEL
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Relay the cables from “CONTROLLER” to “BOOM
ANGLE DETECTOR” and “CABLE REEL”.
From
boomangle detector.
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From cable reel.
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8. BOOM TIP JUNCTION PANEL
Relay the cables from “CABLE REEL” to “JIB

ANGLE DETECTOR” (When equipped with
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fixed jib) and respective hook overhoist limit

switches.
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WIND SPEED SENSOR JUNCTION CABLE CONNECTOR

HOOK OVERHOIST LIMIT SWITCH CRANE JIB BASE ANGLE DETECTOR
10000A-1
9. JUNCTION CABLE
Relay each electric component.
CONNECTOR CONNECTOR
CABLE
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WATER PROOF CAP WATER PROOF CAP
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10. BOOM OVERHOIST LIMIT SWITCH (FINAL LIMIT SWITCH
STOP)
STRIKER
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This prevents the boom from overhoisting.
This is the final stop limit switch.
When crane is stopped due to this limit switch
actuated, auto-stop can not be released. BOOM BASE
ce
SWING FRAME
3P 3P
en
Limit switch side Harness side

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ef
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11000-1
11. MAIN HOOK OVERHOIST LIMIT SWITCH

These switches prevent the hook from overhoisting.
LIMIT SWITCH
y
JIB HARNESS SHACKLE
JUNCTION CONNECTOR
nl
Harness side Limit switch side
O
3P 3P WIRE
MAIN HOOK (BOOM) BOOM, JIB, AUX. SHEAVE

AUX. HOOK (JIB) WEIGHT
AUX.HOOK (AUX. SHEAVE)
ce
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These switches release auto-stop function.

Refer to the article “3.9.3 RELEASING AUTO-
STOP”.
er
HOOK OVERHOIST RELEASE SWITCH
BOOM/JIB OVERHOIST RELEASE SWITCH

ef
LOAD SAFETY DEVICE RELEASE SWITCH

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LEFT SIDE PANEL
10000A-1
CONTROLLER (LOAD SAFETY DEVICE)

BYPASS SWITCH
This switch is used to release the auto-stop function

when the controller (load safety device) becomes
inoperable.
LOAD SAFETY DEVICE
BYPASS SWITCH
MAIN KEY
LOAD SAFETY DEVICE

When the controller is functioning properly, BYPASS CONFIGURATION
bypass function will not work even when the SELECT SWITCH
y
bypass switch is released.
During the crane work with using the bypass switch,
nl
indication, warning or auto-stop does not work.
(Auto-stop function by overhoist preventive device
works.)
Repair or replace the controller immediately.
O
16. LOAD SAFETY DEVICE BYPASS SWITCH
Left : OFF Right : ON
MAIN KEY
ce
In case of load safety device failure, the
following configuration select switch becomes
effective by turning the main key to ON.
17. LOAD SAFETY DEVICE BYPASS

en
Upper : Jib side

CONFIGURATION SELECT SWITCH
While the main key is turned ON, selecting

the configuration can release each auto-stop
function.
er
On this model, use the machine with this switch

turning to “Crane side”. Lower : Crane side
Select when the luffing configuration

ef
Jib side
is to be selected. (Not used.)
Select when the crane configuration
Crane side
is to be selected.
R

11000-1
3.3 CONNECTING PROCEDURE OF WIRING
The cable should be handled with care in order to

avoid damage.
Do not pull or fasten.
When assembling the basic machine and attachment,

make the connections as follows.
y
When disassembling, disconnect the connectors in the
reverse order.
nl
Before connecting the connectors, make sure that no
foreign objects, water is in the connectors section of
the connector.
O
• Insert the connector tightly and tighten firmly.
• Connect the removed caps together.
• After disconnecting, install the cap securely.
ce
Overload preventive device may not work correctly
if water is in the connectors.
en
er
Ensure to turn the key switch OFF to avoid any

adverse effect to the electric devices when the
connectors are in the process of connecting or
disconnecting.
ef

KEY (5 Places)
damage parts.
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PULG RECEPTACLE
Ensure to match the key position of the plug and
receptacle when connecting the connector to
avoid damage to the connector. KEY (1 Place)
PULG RECEPTACLE
10000A-1
3.3.1 CRANE ATTACHMENT

1. Diagram of system
BOOM ANGLE
DETECTOR
BASE MACHINE
JUNCTION PANEL CABLE REEL
FIXED JIB
ANGLE DETECTOR
y
LOAD DETECTOR
nl
BOOM TIP MAIN HOOK OVERHOIST
JUNCTION PANEL LIMIT SWITCH
CONTROLLER
AUX. HOOK OVERHOIST

LIMIT SWITCH
O
CABLE REEL
BOOM OVERHOIST
LIMIT SWITCH
(FINAL STOP)
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AUX. HOOK OVERHOIST
LIMIT SWITCH
(Only for fixed jib)
0.0
10 . 0 f t 800
10021000000600120420
2015/05/10 10:00
4 1
100 . 3 f t Use.
Use.
OVERLOAD ALARM LAMP
100 f t
(LOAD SAFETY DEVICE OUTSIDE
en
30 . 0 POUNDS
× 1000
30 . 8
INDICATION LAMP OPTION)
POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2
MONITOR
RESPECTIVE RELEASE SWITCHES
er
ef
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11000-1
2. Connecting points of respective wiring
LOAD DETECTOR
CONTROLLER
(3) (4), (5)
(2)
(1) (6)
y
BOOM BASE
ANGLE DETECTOR
nl
CN-1062
O
CN-1061
CABLE REEL
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CN-1001 CN-1005 CN-1007
BASE MACHINE
JUNCTION PANEL CN-1019 CN-1016
JIB BASE
ANGLE DETECTOR CN-1018
en
BOOM TIP
JUNCTION PANEL
CABLE REEL
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JIB HOOK OVERHOIST

LIMIT SWITCHMAIN
CN-1042 CN-1043
AUX. SHEAVE HOOK OVERHOIST

ef
LIMIT SWITCHMAIN
CN-1022 CN-1027
MAIN HOOK OVERHOIST

LIMIT SWITCHMAIN
CN-1021 CN-1026
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BLOCK DIAGRAM
10000A-1
3. Connecting procedure
(1) Secure the junction cable and the limit switch HANGER
cable to the boom or jib with hangers.
(2) Connections at the base machine junction panel
y
(A) Connect the cable (1) from the boom angle
detector.
nl
(B) Connect the cable (2) from the cable reel. (A)
O
(B)
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Detail of junction panel
en
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11000-1
(3) Connections at the cable reel
(A) At crane work
• The method of cable pays out.

When pay out the cable from cable reel, turn
the cable reel with hold a thimble.
THIMBLE
To cable junction box

Connect this (boom tip)
y
connector.
nl
To base machine
junction panel
WATER PROOF CAP (Connect both cap.)
O
When pay out the cable, pay out with holding the
thimble.
ce
If pay out the cable with holding the connector,
the thimble part receives the load and may lead to
break the internal cable.
en
Do not operate crane while the water proof caps

are connected to the cable.
er
The auto-stop and alarming will not be issued

even when hook overhoist occurs.
serious accident.
ef
(B) At transportation
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WATER PROOF CAP WATER PROOF CAP
To base machine
junction panel
WATER PROOF CAP (Connect cap to cap.) Connect to shortening cap installed on reel frame
10000A-1
(4) Installation of thimble

Ensure to hang the thimble on the cable hook
provided on the boom tip area.
Otherwise unreasonable force would be applied
to the connector for the hook overhoist limit CABLE HOOK
switch and may cause of damage.
THIMBLE
y
nl
O
ce
en
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11000-1
(5) Connection of hook overhoist limit switch area

(Crane work with aux. sheave)
3P
HARNESS SIDE MAIN HOOK OVERHOIST LIMIT SWITCH
3P
HARNESS SIDE AUX. HOOK OVERHOIST LIMIT SWITCH
• In case without the aux. sheave
(A) Connect cable from the reel to junction panel.
y
(B) Connect the main hook limit switch connector.
nl
WATER PROOF CAP (3P)
(B)
MAIN HOOK OVERHOIST
LIMIT SWITCH
O
(A)
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• In case with the aux. sheave

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(A) Connect cable from the reel to junction panel.

(B) Connect the main hook limit switch connector.
(C) Connect the aux. hook limit switch connector.
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MAIN HOOK OVERHOIST WATER PROOF CAP (3P)

LIMIT SWITCH (B)
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(A)
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AUX. HOOK OVERHOIST

(C)
LIMIT SWITCH
10000A-1
(6) Connection of jib area (in case with fixed jib)
Wiring procedure at A area.
From boom base cable reel
To fixed jib angle detector (Only for fixed jib)
To main hook overhoist limit switch
y
SPARE To aux. hook overhoist limit switch
(Not used)
nl
3P 3P
BOOM TIP JUNCTION PANEL
O
Boom tip side Jib base side
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B
en
A
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Wiring procedure at B area. Hang thimble on hook.
CABLE REEL AUX. HOOK

ef
ATTACHMENT OVERHOIST
JUNCTION CABLE LIMIT SWITCH
R
To jib foot
Connect conector.
3P 3P
WEIGHT
Harness side Limit switch side

11000-1
3.4 FUNCTION OF MONITOR

Change the screen protector if it is dirty or damaged.
Do not press the touch panel screen with sharp

object such as tool or handle with excessive force
to avoid monitor failure.
y
nl
0.0
10 . 0 f t 800
10021000000600120420
2015/05/10 10:00
O
4 1
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0
ce
deg
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2
en
er

only.
ef
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10000A-1
3.5 OPERATING PROCEDURE OF MONITOR

Referring to the setting items (following), perform
necessary setting.
Set timing category

Setting item Operation after changing
Daily operation Operation at initial erection
attachment
(1) Setting of crane configuration
(2) Selection of front/rear drum lifting
y
(3) Setting of working area limit value
: Necessary : Unnecessary : If necessary
nl
The Input data are memorized and retained in the
controller even by stopping the engine or turning the
power off.
O
1. Turning power on
When the key switch is turned to the ON position,

power will be supplied to the monitor.
ce
If power is not supplied to the monitor, check
the fuse.
en
It may take several seconds to boot-up the monitor

and display.
Do not operate the crane while this period.
er
ef
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11000-1
2. Crane configuration screen
When power is supplied to the monitor, the

following screen is displayed on the monitor.
The crane configuration is indicated on the
screen.
Check to see that this configuration matches
with the actual crane configuration.
If so, press icon.
If different, re-setting required.
Press icon and start setting.
Referring to “3.5.1 SETTING OF CRANE
y
CONFIGURATION”.
nl
O
Mode of working or assembly
Type of operation Jib offset angle

(Only for fixed jib)
Main hook type
Main hook No. of part line
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Boom type Aux. hook type
Aux. hook No. of part line
Weight type
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Jib length / aux. sheave Boom length

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The optional items or custom specifications are to

be indicated in the blank on the monitor.
ef
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10000A-1
3. Work area limit screen
Then setting condition of work area limit is

displayed.
After checking the content, press icon.
By pressing icon, setting can be changed.
Refer to “3.5.1 SETTING OF CRANE
CONFIGURATION”.
y
nl
O
ce
en
er
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11000-1
4. Main screen
Main screen is displayed and the crane is ready

to operate.
As for the detail of message display area,
refer to “3.13 WARNING CODE LIST AND
CONDITION, ACTION”.
y
only.
nl
• EXAMPLE DISPLAY OF MAIN SCREEN.
Data code (for service) Message indication area
O
0.0
10 . 0 f t 800
10021000000600120420
2015/05/10 10:00
4 1
100 . 3 f t
Use.
ce
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t
en
L+S 0.3
RESET S
SET D 0.2
er
LOAD RATIO 0.0 WIND SPEED (OPTION)
LOAD HEIGHT 10 . 0 f t FRONT DRUM (No. of part line)
REAR DRUM (No. of part line)

ef
4 1
100 . 3 f t
Use. AUX. HOOK
POINT HEIGHT
Use. MAIN HOOK
R
BOOM LENGTH 100 f t

30 . 0 POUNDS
× 1000 ACTUAL LOAD
30 . 8 POUNDS
× 1000
70 . 0 deg BOOM ANGLE
WORK RADIUS 40 . 3 f t 50 . 0 f t MAX. WORK RADIUS
Load safety device indication area
10000A-1
5. How to read load safety device indication
(1) Each data display (Example of indication)
Name Display ex. Content
Boom angle indication Indicate boom angle by 0.1 degrees unit.
Jib offset angle indication For fixed jib, indicate selected angle.
Point height indication Indicate boom or jib point height by 0.1 ft. unit
Work radius indication Indicate work radius by 0.1 ft. unit.
y
Max. radius indication Indicate max. work radius by 0.1 ft. unit.
nl
Actual load Indicate actual load by 0.1 klbs unit.
Rated load Indicate rated load by 0.1 klbs unit.
O
Load height indication Indicate hook position from zero reset position by 0.1 ft. unit.
Boom length Indicate selected boom length.
Jib length Indicate selected jib length. (Only for fixed jib)
ce
Front drum No. of part line Indicate input number of lines on front drum.
Rear drum No. of part line Indicate input number of lines on rear drum.
Main hook Indicate Use when selected main hook.

en
Aux. hook Indicate Use when selected aux. hook.
Wind speed indication (option) Indicate wind speed by 0.1 MPH.
(2) Load ratio display (Example of indication)

er
Load ratio display lamp lights up from left to

right in order as load ratio increase.
Load ratio Display

ef
Less than 60 %
R
76 %
From 90 % to 100 %
105 %

11000-1
3.5.1 SETTING OF CRANE CONFIGURATION
Input the crane configuration properly to prevent

machine overturning or damage.
serious accident.
Crane configuration setting is required on the type of
y
attachment, boom length, with/without aux. sheave
and type of hook.
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SETTING PROCEDURE
1. Press icon while the main screen is
O
indicated.
Menu screen is now displayed.
ce
2. On the selected screen, select the mark
and press icon.
en
er
3. After this, select the items to set and follow

ef
according to the screen instruction.
SELECTION ITEMS
Type of attachment
R
Boom length
Type of jib
Jib offset angle
With/without Aux. sheave
With/without Main hook
With/without Aux. hook
Number of part line
10000A-1
4. List of ML monitor symbol at configuration setting
The symbols used on this machine are shaded.
1 16 31
Boom only CWT
Crane
(With hook) (Vertical 3)
2 17 32
Boom only CWT
Luffing or tower
(Without hook) (Vertical 2)
3 18 33
y
With aux. sheave CWT
HL crane
(With hook) (Vertical 1)
nl
4 19 34
With aux. sheave CWT (vertical 2)
HL luffing
(Without hook) Crawler ret.
5 20 35
O
Fixed jib Full CWT
SHL crane
(With hook) Without CBWT
6 21 36
With fixed jib Less CWT
SHL luffing
(Without hook) Without CBWT
ce
7 22 37
Add. CWT
Clam shell Jib offset angle
Without CBWT
8 23 38
en
Add. CWT
Drag line Jib length
Two CBWT
9 24 39
Full CWT
Floating crane Boom length
Two CBWT
10 25 40
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Self removal Full CWT

Boom top (STD)
(Boom base) One CBWT
11 26 41
ef
Self removal Boom top SHL weight

(Mast) (Luffing 1) (Large)
12 27 42
Self removal Boom top SHL weight
(CWT) (Long) (Middle)
R
13 28 43
Boom top SHL weight
Pick and carry
(Luffing 2) (Small)
14 29 44
Boom top Self removal
Simultaneous hoist
(Light) (Boom base 2)
15 30 45
Boom top Self removal
Pile driver
(Heavy) (Mast 2)

11000-1
46 61 76
Hook 1 Without CWT Tower crane
47 62 77
Hook 2 Without third drum SHL mast radius
48 63 78
Double drum with Less CWT
Hook 3
third drum One CBWT
49 64 79
Double drum
y
Front drum in use Mast control (1)
without third drum
50 65 80
nl
Self removal
Rear drum in use Mast control (2)
(SHL mast)
51 66 81
Self removal
Third drum in use With point sheave
O
(CBWT)
52 67 82
Without point Self removal
Single drum
sheave (CWT pile up)
53 68 83
ce
Jib Self removal
Double drum
(With aux. sheave) (Mast 3)
54 69 84
Clam shell (Side Self removal
Stop
en
way pull possible) (Boom base 3)

55 70 85
Clam shell
Alarm
(No side way pull)
56 71 86
er
With hook pocket Crawler full ext.
57 72 87
Without hook
Crawler mid ext.
pocket
ef
58 73 88
SHL weight radius Crawler full ret.

R
59 74 89
CWT (vertical 4) Fixed jib crane
60 75 90
Full CWT
Luffing crane
One CBWT
10000A-1
SETTING EXAMPLE
Attachment type Crane
Boom length 90 feet
Jib type Aux. sheave
Main hook = Use

Main, Aux. hook
Aux. hook = Use
Main hook = 4
Number of part of line
Aux. hook = 1
y
Setting procedure of the above items is as follows;
If input item is in error, press icon to return to the
nl
previous screen.
1. Attachment select screen is displayed.
O
Select “2 (Crane Boom)”.
ce
en
2. Counterweight select screen is displayed. STD Reduced

(Indicate only in the case of reduced
er
counterweight specification is equipped)

Select “2 (STD Weight)”.
Counterweight No.1 to No.5

ef
STD
With carbody weight
Counterweight No.1 to No.3
Reduced
Without carbody weight
R

11000-1
3. Boom length select screen is displayed.

Select “90 feet”.
y
nl
4. Aux. sheave select screen is displayed.
Select “Aux. sheave”.
O
ce
en
5. Main hook select screen is displayed.

Select “Use”.
er
ef
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10000A-1
6. Aux. hook select screen is displayed.

Select “Use”.
y
nl
7. Finally number of part of line input screen is
displayed.
Input “4” into Main and “1” into Aux.
O
NUMERIC INPUT METHOD
(1) Press “0” in the front drum number of part of

line.
The numeric keypad is displayed.
ce
en
er
(2) Press “4”.

Highlighting
ef
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11000-1
(3) Press “0” in the rear drum number of part of

line.
y
nl
(4) Press “1” by the number pad.
O
ce
en
(5) Press .
er
ef
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10000A-1
8. When all the settings are completed, data is

being searching.
y
nl
• NO ERROR CASE
In case of the data could searched, the result of

selected items are displayed.
O
Check if the selected items are correct.
If correct, press .
The screen returns to main screen.
If not correct, press .
Then screen returns to “attachment select
ce
screen” and start re-input.
en
• ERROR CASE
In case of the data could not searched, the error

message is displayed with buzzer sounding.
Press and confirm the machine configuration
er
and conduct resetting.

ef
In case the selection is limited to only one choice,

select screen is to be neglected and indicates only
the result.
R

11000-1
• READING ERROR OF CF CARD
If the data in the data card can not be read out,

the following screen will be displayed.
Contact the Manitowoc authorized service shop.
y
nl
O
ce
en
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10000A-1
3.5.2 SELECTION OF MAIN/AUXILIARY HOOK SELECTION

serious accident.
In case both of main hook (front drum) and auxiliary
y
hook (rear drum) are equipped, ensure to select main
lifting (front drum) or auxiliary lifting (rear drum) based
nl
on actual hook being used to change capacity.
Selecting procedure is as follows.
[SELECT PROCEDURE]
O
Press figure of actually used hook for work for 3
seconds or more.
Selected hook is indicated brightly and non selected
hook is indicated semi transparently.
ce
10 . 0 f t 10 . 0 f t
4 1 4 1
en
100 . 3 f t 100 . 3 f t
Use. Use.
Use. Use.
100 f t 100 f t
30 . 0 POUNDS
× 1000 30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000 30 . 8 POUNDS
× 1000
er
70 . 0 deg 70 . 0 deg
40 . 3 f t 50 . 0 f t 40 . 3 f t 50 . 0 f t
ef
Main lifting selection Aux. lifting selection

R

11000-1
3.5.3 SETTING OF WORK AREA LIMIT VALUE

In case of work requiring area limitations as work within Pre-notice point stop point
the building or narrow area, the extent of machine
moving range can be set arbitrary in addition to the
rated area limited with overload preventive device. 0.0 deg 0.0 deg
The following items (A) to (E) are able to set. A

0.0 deg 0.0 deg
“The lifting load limit” can be set only at stop point and
0.0 deg 0.0 deg
other items can be set at both pre-notice point and B

0.0 deg 0.0 deg
stop point individually.

0.0 POUNDS
× 1000 C
When only stop point is set, pre-notice would be issued
on the specified point as shown the table below.
y
Respective operation exceed the pre-notice point,
0 . 0 ft 0 . 0 ft D
issue intermittent warning sound is issued and issued
nl
continuous sound are issued when the machine
reaches to the stop point and toward to danger side
0 . 0 ft 0 . 0 ft E
operation will automatically stops.
As for intermittent and continuous sound are issued
O
only when operated toward to danger side, even
when the machine reaches to each limited values, the
control lever is in neutral position or toward to safe
side sound is not issued.
ce
TABLE OF WORK AREA LIMIT VALUES
Limit item Setting unit Pre-notice point
5 degrees before stop point

(A) Boom upper/lower angle limit value Set with 0.1 degrees unit
(In case pre-notice point is not set)
en
5 degrees before stop point

(B) Jib upper/lower angle limit Set with 0.1 degrees unit
(C) Lifting load limit value 90 % of stop value
Set with 100 lbs unit
(front and rear. drum) (Pre-notice point would not be set)
er
(D) Work area limit value 1 m before stop point

Set with 0.1 ft. unit
(front and rear drum) (In case pre-notice point is not set)
1 m before stop point
(E) Max. height limit value Set with 0.1 ft. unit
ef
(A) to (E) above can be set at the same time (multiple

setting).
Set value is memorized until changed even if the
R
power is cut.
10000A-1
SETTING
1. With the main screen being on the indication

area, press icon.
Menu screen is displayed.
2. Press in the menu.
y
nl
O
ce
en
er
ef
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11000-1
3. Work area limit setting screen is displayed.

(The screen example is crane case.)
0.0 0.0
Press the figure area if new setting is required.
deg deg
Numeric keypad is displayed on right part of the 0.0 deg 0.0 deg
screen. 0.0 deg 0.0 deg
0.0 deg 0.0 deg
0.0 POUNDS
× 1000
0 . 0 ft 0 . 0 ft
y
0 . 0 ft 0 . 0 ft
nl
0.0 deg 0.0 deg
O
0.0 deg 0.0 deg
0.0 deg 0.0 deg
0.0 deg 0.0 deg
0.0 POUNDS
× 1000
ce
0 . 0 ft 0 . 0 ft
0 . 0 ft 0 . 0 ft
en
er
ef
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10000A-1
4. Setting method
0.0 0.0
Ex) In case of pre-notice point setting of boom
deg deg
upper limit angle. 0.0 deg 0.0 deg
0.0 deg 0.0 deg
(1) Raise the boom to the angle where pre-notice is 0.0 deg 0.0 deg
required to issue. 0.0 POUNDS

× 1000
(2) Press the figure area of the boom upper limit

angle (pre-notice point).
(3) Indicated value of the present boom angle. 0 . 0 ft 0 . 0 ft
(4) If fine adjustment is required, input value with
the numeric keypad.
y
(5) When value is decided, press icon. 0 . 0 ft 0 . 0 ft
This is to complete the work area setting.
nl
• Pre-notice point and alarming point
(stop point)
On the item with both pre-notice and alarming
O
points are possible to be set, pre-notice point
must be set to more safety side than the
alarming point.
If this rule is not followed, caution message is
indicated and setting will not be accepted.
ce
Re-setting is necessary in such case.
• If cancelling becomes required during input

work
Cancelling is possible right after placing the
en
cursor on setting required item and pressing the

icon.
Pressing the icon returns the screen to the
previous one and restart is possible.
er
• IF THIS FUNCTION IS NOT USED

If for each “0.0” is displayed, the item’s limit
function is OFF.
Therefore set each item as “0.0” if the item
ef
function is not to be used.

Place the cursor on “0.0” required item and
press “CLR” icon to indicate “0.0”.
Then press icon.
R
5. If other item needs to be changed, set the other

items in the same way before pressing .

11000-1
6. On items where the area limit setting is Message code

completed, figure area becomes yellow 0.0
highlighted when the crane enters into the pre-
10 . 0 f t 800
notice zone and corresponding message code 10021000000600120420
is indicated.
2015/05/10 10:00
4 1
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t
y
L+S 0.3
RESET S
SET D 0.2
nl
Yellow hightlighted area
7. When the load limit is input, the rated load MESSAGE CODE
indication area becomes reverse indication 0.0
O
(green background/black letters).
10 . 0 f t 800
10021000000600120420
• Max height can not be set individually for main

2015/05/10 10:00
4 1
lifting and aux. lifting.
100 . 3 f t
Use.
• In the main lifting mode, limit function becomes Use.

ce
100 f t
actuated when the boom point reaches to the 30 . 0 POUNDS
× 1000
set point. 30 . 8 POUNDS

× 1000
0. 0
In the aux. lifting mode, limit function becomes 70 . 0 deg
actuated when the jib point (or aux. sheave)

reaches to the set point. 40 . 3 f t 50 . 0 f t
en
• Input of the load limit value is to be done with

L+S 0.3
input of variation of value only. RESET
SET S
D 0.2
REVERSE INDICATION
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10000A-1
3.6 SWING LIMITATION DEVICE (OPTION)

1. Introduction 0.0
Swing limitation device (option) is a device that 10 . 0 f t 800

10021000000600120420
allows the operator to stop the upper machinery at 2015/05/10 10:00

4 1
any preset limit position (right and left).
100 . 3 f t
Use.
When machine reaches either preset limit position, Use.
100 f t
the controller automatically stops the swing 30 . 0 POUNDS
× 1000
motion of upper machinery and prevents upper 30 . 8 POUNDS

× 1000
0. 0
machinery from passing the swing limit position. 70 . 0 deg
The operator may swing the upper machinery in
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the opposite direction. 40 . 3 f t 50 . 0 f t
This device assists contact prevention from
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obstacle and may not provide automatic stop RESET
SET
L+S
S
D
0.3
0.2
function without load swing.
Ensure to stop operation with your own operation SWING LIMITATION INDICATOR
before reaching left (or right) limit position while
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taking indication and warning into account.
Since the crane may overrun the left (or right) limit
position by its inertia, set the limit position with
some allowance.
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Machine equipped with this option has the
monitor indication on its right lower part of
screen.
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Make sure to reduce the swing speed when the left

(or right) limit position comes closer in order to
prevent the accident by attachment damage.
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11000-1
2. Detail of indicator
(a) SWING ANGLE
Green : Safe area INDICATOR
(b) LEFT LIMIT POSITION SET ICON

344. 3 (c) RIGHT LIMIT POSITION SET ICON
Yellow : Warning area Green : Safe area

Yellow : Warning area
(d) SWING AREA SETTING INDICATION
Red : Dangerous area
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L+S
(e) RESET ICON RESET S (g) MODE SELECT ICON
SET
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D
(f) SET ICON
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TABLE OF SWING AREA LIMIT FUNCTION DISPLAY
This indicates the present swing position by the angle.
(a) SWING ANGLE INDICATOR
The front is 0 degrees and figure increases as crane swing left.
(b) LEFT LIMIT POSITION SET ICON This icon is used to set the left limit position.
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(c) RIGHT LIMIT POSITION SET ICON This icon is used to set the right limit position.
Swing areas setting indication displays in color by green, yellow and red
on the circumference.
(d) SWING AREA SETTING INDICATION • Red : Dangerous area
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• Yellow : Warning area

• Green : Safe area
(e) RESET ICON This icon is used to reset the swing area.
This icon is used to select USE or NOT USE of swing limitation device.
This icon lights up in color based on the selected mode.
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(f) SET ICON • Red : L+S mode

• Yellow : S mode
• Green : D mode
This icon is used to select trom three modes.
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(g) MODE SELECT ICON • L+S mode : Indication, alarm and stop
• S mode : Indication and alarm
• D mode : Indication only
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10000A-1
3. Mode
The following three modes are available in this

344. 3
device.
Select mode based on the needs.
Use mode select icon for selecting a mode.
The color of the set icon can tell the current set
mode.
Each mode differs as explained below (1) to (3)
but setting method of limit area, resetting and
function are the same to all modes.
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L+S
(1) L+S mode RESET S
SET D
The swing speed is reduced about 1/3 of the
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normal speed. MODE SELECT ICON
When enters into warning area (Yellow) SET ICON
Red : L+S mode
intermittent buzzer sound is issued and the Yellow : S mode
buzzer sound becomes higher pitch when Green : D mode
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comes closer to the dangerous area (Red).
When enters into the dangerous area (Red)
continuous buzzer sound is issued and the
swing to the dangerous direction would not be
able to operated.
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(2) S mode
When enters into warning area (Yellow)
intermittent buzzer sound is issued and the
buzzer sound becomes higher pitch when
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comes closer to the dangerous area (Red).

When enters into the dangerous area (Red)
continuous buzzer sound is issued.
(3) D mode
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Indicate only display and not performed warning

and auto stop functions.
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11000-1
EEx) When swing right, to the red area, right swing Green :
stops. Safe area Green :
Safe area
In 5 seconds after entering into red area, swing
283 . 0
parking brake also actuates automatically. Yellow :
The swing parking brake will only be released Warning area
during operation toward safety side (left side in Yellow :
the example below) or when the crane comes Warning area
out of red area.
Red :
Dangerous
area
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L+S
Check the selected mode before starting the work. RESET S
SET D
If the wrong mode is selected, alarming or stopping
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does not function properly.
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If the mode is changed after the limit area is set, only
the mode (function) is changed while limit area setting
is the same.
Therefore limit area re-setting is not required.
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10000A-1
4. Limit area setting method
(1) Initial setting
(A) When engine is started, screen indicates as Green :

Hatching indication
shown bellows.
The swing area setting indication will be green
358 . 2
hatching indication on whole circumference
appears due to the limit setting is not made and
limit function is not effective yet.
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L+S
RESET S
SET D
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(B) Swing the crane left to the safe place just before Green :
Hatching indication
the obstacle on the left side and stop.
Press the (Left limit position set icon).
51 . 6
Since the crane may overrun the limit position
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by its inertia, set the limit position with some
allowance.
The boom facing area changes its color to red
and right next to this area to yellow.
When the position has to be adjusted after
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(Left limit position set icon) is once pressed,

swing to the exact position and again press
(Left limit position set icon). L+S
Red and yellow indication area are renewed. RESET S
SET D
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Yellow :
Warning area
51 . 6
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Red :
Dangerous
area
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Green :
Hatching
indication
L+S
RESET S
SET D

11000-1
(C) Swing the crane right to the safe place just Yellow :
before the obstacle on the right side and stop. Hatching
indication
283 . 0
Press the icon (Right limit position set icon).
The swing area is set. Red :
Hatching
When the position has to be adjusted after indication
(Right limit position set icon) is once pressed,
swing to the new position and press (Right
Green :
limit position set icon). Hatching
Red and yellow indication area will be renewed. indication
L+S
RESET S
SET
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D
Green :
To set the swing area, both side swing limit Hatching
indication Green :
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positions are needed to be set. Hatching
indication
In case there is no obstacle on the right side, Yellow : 283 . 0
swing the crane far enough to the position where Hatching
indication
automatic stop does not disturb crane work and
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press (Right limit position set icon). Yellow :
Hatching
indication
Red :
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Hatching
indication
L+S
RESET S
SET D
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10000A-1
(D) After changing the swing mode to the brake Green :

Safe area Green :
mode, press (Set icon). Safe area
The swing areas setting indication and (Set 344. 3
icon) disappears hatching indication and setting Yellow :
is now completed. Warning area
The mode selected becomes effective Yellow :

(Indication, alarming and stopping). Warning area
Red :
Dangerous
area
With the hatching indication just after engine start,
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L+S
limit function does not work and swing motion is free. RESET S
SET D
If the limit function is necessary, ensure to set the
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limit area.
serious accident.
It is also possible to set the limit position from the
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right side first and to the left side.
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Even press (Set icon) without changing the

swing mode to the brake mode, mode setting
cannot be made.
Ensure to change to the brake mode and then press
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(Set icon) again.

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11000-1
(2) In case of restart of the engine after setting

completed
(A) Swing area setting indication and (Set Green :

Hatching
icon) with hatching are displayed. indication Green :
Hatching
indication
Yellow : 344 . 3
Hatching
indication
Yellow :
Hatching
indication
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Red :
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Hatching
indication
L+S
RESET S
SET D
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(B) If adjustment of area is not necessary, press Green :
(Set icon). Hatching indication
The swing areas setting indication and (Set

358 . 2
icon) disappears hatching indication and setting
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is now completed.
(C) To reset the area again, press (Reset icon).
(D) The swing area setting indication will be green
appears due to the limit setting is not made and
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limit function is not effective yet.

(E) Set swing areas as same method as initial
setting. L+S
RESET S
SET D
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With the hatching indication just after engine start,

limit function does not work and swing motion is free.
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If the limit function is necessary, press the

(Set icon).
serious accident.
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10000A-1
(3) In case crane traveled
(A) The swing area limit function will be released Green :

Hatching
at the moment when the travel control lever is indication Green :
operated and the swing areas setting indication Hatching
indication
and (Set icon) appears hatching indication. Yellow : 344 . 3
Hatching
indication
Yellow :
Hatching
indication
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Red :
Hatching
indication
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L+S
RESET S
SET D
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(B) To resetting, press (Reset icon). Green :
(C) The swing area setting indication will be green Hatching indication

358 . 2
appears due to the limit setting is not made.
(D) Set swing areas as same method as initial
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setting.
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If the crane travels, relative positions with obstacle

are changed. L+S
Be sure to set again. RESET S
SET D
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11000-1
(4) To temporary cancel the limits Green :

Safe area Green :
Safe area
(A) When press the (Set icon) once, the swing
344. 3
areas setting indication and (Set icon) Yellow :
appears hatching indication. Warning area
In this condition, the swing motion can be Yellow :
operated freely due to the swing area limit Warning area
function becomes ineffective.

(B) In order to resume swing area limit function,
press (Set icon) once again.
Red :
The swing areas setting indication and (Set Dangerous
area
icon) disappears hatching indication and swing
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L+S
area limit function becomes effective. RESET S
SET D
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Green :
Hatching
indication
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Yellow : 344 . 3
Hatching
indication
Yellow :
Hatching
indication
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Red :
Hatching
indication
L+S
S
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RESET
SET D
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10000A-1
5. Function
Function of L+S mode is explained here as an

example.
(1) Figure right shows that the crane is in safe area Green :
after setting a limit area. Safe area Green :
Safe area
344. 3
Yellow :
Warning area
Yellow :
Warning area
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Red :
Dangerous
area
L+S
RESET S
SET D
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(2) From this condition, if the crane swings to the
304. 3
right, crane figure turns right.
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* Only in case of L+S mode, swing speed is
reduced to 1/3 of normal speed to reduce shock
at the time of stop.
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L+S
RESET S
SET D
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(3) Swing to right direction further and the tip of Green :

Safe area Green :
boom in the swing area limit indication enters Safe area
into warning area (Yellow), intermittent buzzer 293 . 0
sound is issued. Yellow :
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In this situation, reduce the swing speed by Warning area
taking with reducing engine speed and/or

adjusting control lever.
Yellow :
The intermittent buzzer sound becomes higher Warning area
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pitch when comes closer to the dangerous area

(Red). Red :
The warning area (Yellow) is the range of 10 Dangerous
area
degrees before entering the dangerous area L+S
(Red). RESET S
SET D

11000-1
(4) Swing to right direction further and the tip of Green :

boom in the swing area limit indication enters Safe area Green :
Safe area
into dangerous area (Red), continuous buzzer
283 . 0
sound is issued and the swing motion stops. Yellow :
Warning area
Yellow :
Warning area
Red :
Dangerous
area
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L+S
RESET S
SET D
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(5) After swing motion stops, swing to safe direction Green :
Safe area Green :
(left) and the tip of boom returns to safe area Safe area
(Green). 344. 3
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Yellow :
Warning area
Yellow :
Warning area
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Red :
Dangerous
area
L+S
RESET S
SET
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(6) If the crane swing to left, directions (1) to (5)

become opposite.
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* Caution on indication
Issuing timing of intermittent and continuous
buzzer (auto stop) sounds may slightly shift
from the appearance of timing when the color
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on circumference changes, therefore, swinging

is to be performed with sufficient time.
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10000A-1
3.7 LOAD HISTORY (DATA LOGGER)

This machine is provided with the recording function of
the machine condition in order to make investigation
when necessary.
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11000-1
3.8 FUNCTION OF GROUND INCLINE INDICATOR (OPTION)

1. Introduction 0.0
10 . 0 f t 800
This device is to detect inclination of the crane 10021000000600120420
against the ground to indicate and issue

2015/05/10 10:00
4 1
warning.
100 . 3 f t
Use.
Improve ground condition enough for crane Use.
100 f t
work so that warning from this device will not be 30 . 0 POUNDS
× 1000
issued. 30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
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40 . 3 f t 50 . 0 f t
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L+S 0.3
Periodical check should be performed to confirm RESET
SET S
D 0.2
error between actual indicated value and the level
gauge at crane lower frame. GROUND INCLINE
INDICATOR
If the error becomes large, adjustment is necessary.
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Contact authorized Manitowoc distributor.
Machine equipped with this option has the

monitor indication on its right lower part of the
screen.
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2. Indicator
The above figure indicates example of condition

that Left rear side is lower.
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(A) Inclination condition indication

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0.3 (B) Inclination on lateral direction

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0.2 (C) Inclination on front-rear direction
The same display as the bubble position of

(A) Inclination condition indication
the a level.
Right lower : Minus figure
(B) Inclination on lateral direction
Left lower : Plus figure
Front lower : Minus figure
(C) Inclination on front-rear direction
Rear lower : Plus figure
10000A-1
3. Display and action at danger WARNING
0.0
The above figure indicates example of condition
that right rear part is lower. 10 . 0 f t 800
10021000000600120420
Any of front/rear or right/left indication exceeds 2015/05/10 10:00

4 1
±0.5 degrees, warning is indicated.
100 . 3 f t
Use.
-0 . 4
This function issues only indication and the Use.
100 f t 0.8
crane work will not stop. 30 . 0 POUNDS
× 1000
Check the crane condition and press button. 30 . 8 POUNDS

× 1000
0. 0
Warning indication disappears. 70 . 0 deg
If indication appears before starting work or

without load lifting, ground improvement is 40 . 3 f t 50 . 0 f t
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recommend.
-0 . 4
Improve the ground so that the indication
L+S
RESET S
SET 0.8
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D
becomes within ±0.5 degrees at any condition.

Corresponding angle
indication turns to red.
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11000-1
3.9 WARNING AND AUTO-STOP

3.9.1 CONTENT OF WARNING AND AUTO-STOP
When the machine condition becomes closer to
danger situation, alarm is issued and machine stops
automatically. (See table below)
When the machine stops automatically, operate the
machine toward safety side immediately.
CRANE
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Color change in indicator Buzzer
Code
Hazardous (1) (2) (3) (4) (5) (6) (7) (8) Overload Overhoist Auto-
display
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conditions Boom Load Actual Rated Work Back- warning warning stop
Hook Boom *2
angle ratio load load radius stop buzzer buzzer
Load ratio
Yellow ME024 Intermittent
more than 90%
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Load ratio
Red Red ME005 Continuous Stop
more than 100%
Main hook ME017 Continuous
Red Stop
overhoist *3 *1
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ME018 Continuous
Aux. hook overhoist Red Stop
*3 *1
Continuous
Boom overhoist Red Red ME008 Stop
*1
Boom overhoist
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Red Red Red Red ME021 Continuous Stop

(Limit)
Boom overhoist
Red Red Red Red ME060 Continuous Stop
(Backstop No.2)
Boom overlowering Red 0.0 Red Red ME007 Continuous Stop
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*1 Only when operated toward danger side.

*2 See this article “3.13 WARNING CODE LIST AND CONDITION, ACTION” detail of display code.
*3 The message “ME017” and “ME018” change places depending on the attachments configuration.
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(2) Load ratio 0.0
10 . 0 f t
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(7) Boom
4 1
100 . 3 f t
Use.
(6) Hook
Use.
100 f t
30 . 0 POUNDS
× 1000
(3) Actual load
(8) Boom back stop 30 . 8 POUNDS

× 1000
(4) Rated load
70 . 0 deg
(1) Boom angle
(5) Work radius 40 . 3 f t 50 . 0 f t
10000A-1
3.9.2 CONTENT OF AUTO-STOP

When the machine stops on each danger condition,
machine does not move to “ ” direction on the
following figures.
Direction without “ ” mark is safety side and machine
moves without handling the release switch.
1. IN CASE OF CRANE
(1) Overload
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Hook hoist
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Boom lower
(2) Hook overhoist

Boom overlowering
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Hook hoist
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Boom lower
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(3) Boom overhoist

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Boom raise
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(4) Boom overhoist

(Final stop limit switch control)
Hook hoist
Normally when boom overhoist occurs,
controller functions to stop automatically.
Boom raise
If auto-stop function is being released and
operated, the final stop limit switch control
becomes actuated and machine auto-stops.
In this case, auto-stop can not be released.

11000-1
3.9.3 RELEASING AUTO-STOP
Never operate the crane with respective auto-

stop release switches and its master keys in the
“RELEASE” position.
These switches and keys must be used for the
case of emergency evacuation when failure of
safety device or maintenance purpose.
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serious accident.
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1. Auto-stop release switch
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HOOK OVERHOIST RELEASE SWITCH
BOOM/JIB OVERHOIST RELEASE SWITCH

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LOAD SAFETY DEVICE RELEASE SWITCH

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LEFT SIDE PANEL

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10000A-1
2. Handling procedure of auto-stop release switch
Use this switch only when auto-stop function

must be released at the case of emergency or
maintenance work.
Each release switches would not be released
unless otherwise “RELEASE SWITCH MASTER
KEY” is in release position.
(1) RELEASE SWITCH MASTER KEY Left : Lock side Right : Release side
This is the master key to lock releasing the
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load safety device, boom overhoist and hook
overhoist for safety.
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Can’t be released the auto-stop
Lock side
functions.
Can be released the auto-stop
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Release side
functions.

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(2) LOAD SAFETY DEVICE RELEASE SWITCH
This switch is for release the over load prevention

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function temporally.
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Release side
This switch is functional only when “RELEASE

SWITCH MASTER KEY” is turned to release side.
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stop due to the over load and exceeding the
work radius can be released.


11000-1
(3) BOOM, JIB OVERHOIST RELEASE SWITCH
This switch is for release the boom/jib overhoist

Release side

SWITCH MASTER KEY” is turned to release side.
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(4) HOOK OVERHOIST RELEASE SWITCH
This switch is for release the hook overhoist

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Release side

SWITCH MASTER KEY” is turned to release side. HOOK OVERHOIST RELEASE SWITCH
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When release the auto-stop function, hold the

switch by hand at release side.
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When leave the hand, the switch returns original

position and auto-stop function resumes.
When the auto-stop function is to be released,

ensure to use the corresponding release switch.
10000A-1
3. Handling at boom stowing
(1) Lower the boom until auto-stop occurs. Auto stop

When the boom automatically stops, indicate ME007
warning code [ME007] on the monitor display.
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(2) When the crane auto-stops, press (Boom,
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jib lowering icon) in the monitor for more than 1
second.
The crane is turned to boom lowering mode
and auto-stop is released and boom lowering
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becomes possible.
Auto stop is released

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Press (assy/disassy icon), (boom, jib
lowering icon) for more than 1 second.
(3) However when the weight of hook overhoist limit Auto stop
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switch contacts the ground, auto-stop occurs ME017

due to hook overhoist preventive device.
When the boom automatically stops, indicate
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WEIGHT
(4) To lower the boom further, return the control

lever to neutral once and press (assy/
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disassy icon) for one time (1 second).

Then the crane turns to assy/disassy mode and
auto-stop due to hook overhoist is released and
boom lowering becomes possible.
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11000-1
4. Auto-stop releasing at boom assembly or

disassembly work 0.0ft
When load safety device, angle detector or hook

overhoist limit switch are not connected such
as base machinery or attachment assembly or
disassembly work, auto-stop due to load safety
device or hook overhoist preventive device
occurs or alarm is issued.
By pressing icon, load safety device turns

to assy/disassy mode and auto-stop and alarm
11 . 7
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deg
sound are released.
When crane turns to assy/ disassy mode,
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load safety device indication becomes only
boom angle indication and caution message
indication.
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After assembly/disassembly work is completed
and boom is to be erected, press icon once
again.
Then the crane turns to work mode.
If the boom is erected without changing to
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work mode, crane is turned to work mode
automatically when the boom angle exceed
about 15 degrees (for tower 40 degrees).
Therefore when the boom is erected, crane
does not turn to assy/disassy mode even
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pressing the icon.

Assy/disassy mode is cancelled when the main
key switch is turned to “OFF” position.
Therefore ensure to press icon again
whenever the main key switch is turned ON.
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When the boom angle is being high or the load is

detecting by the load cell, the assy/disassy mode
cannot be set.
When the boom is raised after the assembly, assy/
disassy mode will be released.
10000A-1
5. Stop release mode when transportation with

boom base attached. 0.0ft
(Only machine with reduced weight specification)
For machine with the reduced weight specification,

counterweight is not installed during transportation.
Therefore the machine becomes transportation
mode unless the machine is out of the work
mode applicable range shown in “4. Auto-stop
releasing at boom assembly or disassembly
work” and crane work configuration, tower work
configuration.
11 . 7
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deg
When the machine becomes transportation
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mode, the monitor of the load safety device
displays message requesting weight installation,
detector connection and angle display.
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Under the transportation mode, front drum, rear
drum and third drum winches become auto-stop
condition for both hoisting and lowering motion
and only boom drum becomes functional for
raising and lowering.
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Machine can move to other mode either by
lowering boom angle to work mode range
shown in “4. Auto-stop releasing at boom
assembly or disassembly work” or by installing
the required counterweight and connecting the
en
detector.
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If the counterweight detector is removed under

the crane work configuration (or under luffing
work configuration), the machine becomes all stop
condition rather than transportation mode.
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When the machine becomes under all stop

condition, install the weight detector once again
and when machine becomes safe disassembling
condition then remove the weight detector.
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11000-1
3.10 INSPECTION
3.10.1 INSPECTION PROCEDURE WHEN ERECTING THE BOOM AFTER
THE ATTACHMENT ASSEMBLY WORK IS COMPLETED
After the attachment assembly work is completed,

check the function of safety related devices and make
sure that there is no abnormality before erecting the
boom.
At the inspection, limit switch may have already been
actuated.
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Pull the limit switch once and set it to safe condition
and then inspect as follows;
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CRANE ATTACHMENT
BOOM OVERHOIST LIMIT SWITCH (BOOM FOOT)
HOOK OVERHOIST LIMIT SWITCH (MAIN HOOK)
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HOOK OVERHOIST LIMIT SWITCH (AUX. HOOK)
1. Inspection of boom overhoist limit switch
(1) Press the limit switch (final stop) roller located

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on the right hand boom foot by hand.

(2) Confirm if the indication of boom angle, work
radius, boom and backstop figures turns to red
color and display “ME021” warning message
on the load safety device display area in the ME021
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monitor. 0.0
10 . 0 f t 800
10021000000600120420
2015/05/10 10:00
4 1
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100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
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70 . 0 deg
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2
10000A-1
2. Inspection of main hook overhoist limit switch
(1) Lift up the limit switch weight hanging rope.

(2) Confirm if the indication of main hook figure
turns to red color and display “ME017” warning
message on the load safety device display area Lift up
in the monitor.
(3) After that pull the hanging rope and confirm the
warning message will be disappeared.
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ME017
0.0
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10 . 0 f t 800
10021000000600120420
2015/05/10 10:00
4 1
100 . 3 f t
Use.
Use.
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100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t
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L+S 0.3
RESET S
SET D 0.2
3. Inspection of auxiliary hook overhoist limit

switch
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(1) Lift up the limit switch weight hanging rope.

(2) Confirm if the indication of auxiliary hook figure
turns to red color and display “ME017” warning Lift up
message on the load safety device display area
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in the monitor.
(3) After that pull the hanging rope and confirm the
warning message will be disappeared.
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ME017
0.0
10 . 0 f t 800
10021000000600120420
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2015/05/10 10:00
4 1
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
0. 0
70 . 0 deg
40 . 3 f t 50 . 0 f t
L+S 0.3
RESET S
SET D 0.2

11000-1
3.10.2 INSPECTION AFTER ERECTING ATTACHMENT

Check to see that there is no abnormality of auto-stop,
alarming functions and display indication.
Auto-stop angle on boom overhoist side is as shown
on the table below.
Auto-stop angle on boom overlowering side (work
radius exceeding) varies depending on boom length.
Attachment Type of overhoist Stop type Auto-stop angle

Controller (angle against ground) 82 degrees to 82.5 degrees
y
Crane Boom overhoist
Limit switch (angle against machine) 84.5 degrees to 85.5 degrees
nl
INSPECTION OF OVERLOAD (LOAD SAFETY
DEVICE) WITH THE MONITOR
If it is difficult to test auto-stop function due to overload
O
by lifting the actual load, check can be done in the
display.
Perform this test in “WORK” position.
The test will not work in assembly/disassembly mode.
ce
(1) Press icon to indicate menu and press .
en
er
(2) Press icon.

ef
R
10000A-1
(3) The crane turns to the simulated overload

condition and auto-stop occurs.
(Overload check mode)
Check to see that hook hoisting or boom
lowering can not be done.
During check mode, message “ME056” appears

in the message area.
(4) After motion check, press icon. Check mode
y
is completed.
nl
O
ce
en
er
ef
R

11000-1
3.11 CAUTIONS IN HANDLING LOAD SAFETY DEVICE

1. Welding work
When welding to machine, stop the engine and

turns the key switch to OFF.
For further, disconnect all the connectors on the
backside of the monitor and controller.
2. Radio wave interference
If the radio wave interference is received from
y
the near radio station, contact Manitowoc
service shop.
nl
3. Static electricity interference
If the monitor surface is rubbed strongly with
O
dry nylon cloth etc. static electricity may be
generated.
This static electricity has harmful effect to the
monitor function.
Do not rub strongly.
ce
en
er
ef
R
10000A-1
3.12 ERROR CODE DISPLAY AND MESSAGE

Explain the error codes and message when
Error code
abnormality occurs here in after.
• When abnormality occurs, its error code is

indicated in the message indication area and
buzzer sounds.
Buzzer can be stopped by pressing the buzzer
stop icon in the message indication area.
In addition when error code of the load detector
or angle detector appears, the machine stop
y
automatically.
• Whenever indicate the error code (error
nl
message) in the monitor display, contact with an
O
When the angle detector is replaced, adjustment
of the load safety device becomes necessary.
Contact authorized Manitowoc distributor for
ce
replacement or adjustment.
• Normally error is indicated by its code.

By pressing the indicated code area, detail can
en
be displayed.
In the message indication area can be displayed
up to 12 error codes and if more than 12 error
are existing, additional errors can be seen by
pressing “ ” or “ ” (display switching).
er
Return to
table indication
Error detailed display
ef
Following code list shown all of codes and some

of codes would not be indicated depending on the
model.
R
INDICATION SELECT ICON

11000-1
ERROR CODE (ERROR MESSAGE) LIST

Code Message
B2799 Immobilizer communication abnormal
B279A Immobilizer communication abnormal
B279C This engine ECU is not support for immobilizer system
P0006 Fuel cut valve failure (GND short circuit)
P0007 Fuel cut valve failure (Open/+B short circuit)
P0016 Crankshaft position sensor and cam-shaft position sensor - rationality
P0045 VNT actuator failure.
P0049 Turbo charger revolution overrun
y
P007B Intake air temperature sensor (inter-cooler outlet) - rationality
P007C Intake air temperature sensor (inter-cooler outlet) - out of range (Out of range low)
nl
P007D Intake air temperature sensor (inter-cooler outlet) - out of range (Out of range high)
P0087 Common rail pressure control failure.
P0088 Common rail pressure control failure.
O
P0093 Fuel leakage
P0096 Intake air temperature sensor (intake manifold) - rationality
P0097 Intake air temperature sensor (intake manifold) - out of range (Out of range low)
P0098 Intake air temperature sensor (intake manifold) - out of range (Out of range high)
ce
P00AF VNT actuator failure.
P0101 Air flow sensor - rationality
P0102 Air-flow sensor failure (Low)
P0103 Air-flow sensor failure (High)
en
P0104 Air flow sensor - out of range

P0106 Boost pressure sensor - rationality
P0108 Boost pressure sensor - out of range (Out of range high)
P0112 Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range low)
er
P0113 Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range high)
P0116 Engine coolant temperature sensor - rationality
P0117 Engine coolant temperature sensor - out of range (Out of range low)
P0118 Engine coolant temperature sensor - out of range (Out of range high)
ef
P011C Intake air temperature sensor (air flow sensor built-in) - rationality
P0122 Intake throttle valve-opening sensor 1 out of range (Out of range low)
P0123 Intake throttle valve position sensor 1 - out of range (Out of range high)
R
P0128 Thermostat - The coolant temperature does not reach a warmed-up temperature
P0130 O2 sensor (SCR inlet) failure
P0136 O2 sensor (SCR outlet) failure
P0182 Fuel Temp. sensor failure (Low)
P0183 Fuel Temp. sensor failure (High)
P0187 Fuel Temp. sensor failure (Low)
P0188 Fuel Temp. sensor failure (High)
P0191 Common rail pressure sensor malfunction
P0192 Common rail pressure sensor (main) - out of range (Out of range low)
10000A-1

Code Message
P0193 Common rail pressure sensor (main) - out of range (Out of range high)
P0200 Engine ECU failure.
P0201 Fuel injector - disconnection (#1cyl)
y
P0217 Overheat
P0219 Engine overrun.
nl
P0222 Intake throttle valve position sensor 2 - out of range (Out of range low)
P0223 Intake throttle valve position sensor 2 - out of range (Out of range high)
P0234 Over boost
O
P0237 Boost pressure sensor - out of range (Out of range low)
P0263 Correction quantity of cylinders #1 error
ce
P0299 Turbo under boost
en
P0301 Continuously misfiring (#1cyl)

er

P0335 Crankshaft position sensor - disconnection
P0336 Crankshaft position sensor - rationality
ef
P0340 Camshaft position sensor - rationality

P0341 Camshaft position sensor - rationality
P0381 Glow lamp (wait-to-start lamp) - circuit
R
P0401 EGR low flow

P0402 EGR high flow
P0404 EGR valve 1 stick
P0405 EGR lift sensor 1 circuit low input
P0406 EGR lift sensor 1 circuit high input
P0407 EGR lift sensor 2 circuit low input
P0408 EGR lift sensor 2 circuit high input
P041B EGR gas temperature sensor - characteristic failure
P041C EGR gas temperature sensor - out of range (Out of range low)

11000-1

Code Message
P041D EGR gas temperature sensor - out of range (Out of range high)
P0420 Catalyst located downstream of PM filter
P0489 EGR solenoid 1 malfunction
P0500 Vehicle speed sensor - low
P0501 Vehicle speed sensor - high
P0504 Brake switch correlation
P0510 Idle SW malfunction.
y
P0519 Idle speed control system
P0524 Engine oil pressure Too Low
nl
P0540 Preheat circuit malfunction
P0545 Exhaust temp. sensor failure (Upper stream) (Low)
P0546 Exhaust temp. sensor failure (Upper stream) (High)
O
P0562 Sensor supply voltage - out of range (out of range low)
P0563 Sensor supply voltage - out of range (out of range high)
P05F1 Crankcase ventilation system abnormal
P0605 ECU failure
ce
P0606 ECU failure
P0607 ECU failure
P0610 VIN data error
P0611 ECU failure
en
P0617 Starter switch - rationality

P0628 Suction control valve for fuel supply pump - circuit (Circuit low)
P0629 Suction control valve for fuel supply pump - circuit (Circuit high)
P0642 ECU sensor supply 1 failure (Low)
er
P0643 ECU sensor supply 1 failure (High)

P064C Glow control unit malfunction
P0652 ECU sensor supply 2 failure (Low)
P0653 ECU sensor supply 2 failure (High)
ef
P0671 Glow plug 1 failure.

R
P0674 Glow Plug 6 failure.

Glow controller - Battery for glow controller open, GND short glow controller - glow control signal glow controller
P0683
- Diagnosis signal
P0686 Main relay malfunction
P06D3 Air flow sensor power supply failure short to GND
P06D4 Air flow sensor power supply failure (High)
P0704 Clutch SW malfunction
P073D Information abnormal from transmission ECU.
P081A Starter disable circuit Low
10000A-1

Code Message
P081B Starter disable circuit High
P0850 Neutral SW failure (MT)
P1062 VNT solenoid valve 2 low voltage
P1063 VNT solenoid valve 2 high voltage
P1067 VNT solenoid valve 3 low voltage
P1068 VNT solenoid valve 3 high voltage
P1071 Turbo speed sensor failure (High)
P1072 Turbo speed sensor failure (Low)
y
P1132 Acceleration sensor circuit low voltage
P1133 PTO accelerator sensor (Hi)
nl
P1142 Throttle control low voltage
P1143 Throttle control high voltage
P1197 Common rail pressure sensor (sub) - out of range (Out of range low)
O
P1198 Common rail pressure sensor (sub) - out of range (Out of range high)
P119F Common rail pressure sensor - rationality
P1211 Fuel injector driver circuit 1 - circuit (Circuit low)
P1212 Fuel injector driver circuit 1 - circuit (Circuit high)
ce
P1214 Fuel injector driver circuit 2 - circuit (Circuit low)
P1215 Fuel injector driver circuit 2 - circuit (Circuit high)
P1229 Excessive supply pump pressure
P1266 Insufficient supply pump pressure
en
P1401 EGR valve 2 stick

er

P1412 Pulse EGR solenoid malfunction
P1413 Pulse EGR solenoid malfunction
P1416 EGR cooler overheat.
ef
P1417 EGR cooler water temp. sensor failure (Low)

P1418 EGR cooler water temp. sensor failure (High)
P141F Burner system malfunction
R
P1426 Differential pressure sensor - rationality

P1427 Differential pressure sensor - out of range (Out of range low)
P1428 Differential pressure sensor - out of range (Out of range high)
P1458 EGR actuator malfunction (Slight)
P1459 EGR actuator malfunction (Tertiary)
P1462 Engine retarder1 failure (Open/GND short circuit)
P1463 Engine retarder1 failure (+B short circuit)
P1467 Engine retarder2 failure (Open/GND short circuit)
P1468 Engine retarder2 failure (+B short circuit)

11000-1

Code Message
P1472 Transmission retarder relay malfunction
P1473 Transmission retarder relay malfunction
P1477 Scanning cruise retarder relay malfunction
P1478 Scanning cruise retarder relay malfunction
P1515 Charge air under coding
P1530 Engine stop switch malfunction
P1565 Cruise switch malfunction
P1601 Fuel injector adjustment data abnormal
y
P1676 Fuel cut relay failure.
P1681 Exhaust control valve magnetic valve failure.
nl
P1682 Exhaust control valve magnetic valve failure.
P2002 DPR system malfunction
P200C DPF over temperature
O
P2032 Exhaust temp. sensor failure (2nd from upper stream) (Low)
P2033 Exhaust temp. sensor failure (2nd from upper stream) (High)
P203F Urea tank level warning
P204F Urea SCR system failure
ce
P207F Urea quality error
P2080 Exhaust temp. sensor failure (Upper stream) - rationality
P2084 Exhaust temp. sensor failure (2nd from upper stream) - rationality
P20CD Fuel additives valve failure (Low)
en
P20CE Fuel additives valve failure (High)

P20CF Fuel additives valve characteristic abnormal
P20EE NOx converting catalyst conversion efficiency
P2100 Intake throttle valve DC motor failure.
er
P2101 Intake throttle valve - functional

P2103 Intake throttle valve DC motor failure.
P2120 Throttle/Pedal Position Sensor/Switch D “Circuit”
P2121 Accelerator sensor 1 voltage abnormal
ef
P2122 Accelerator pedal position sensor 1 -out of range (Out of range low)
P2123 Accelerator pedal position sensor 1 -out of range (Out of range high)
P2126 Accelerator sensor 2 voltage abnormal
R
P2127 Accelerator pedal position sensor 2 -out of range (Out of range low)
P2128 Accelerator pedal position sensor 2 -out of range (Out of range high)
P2135 Intake throttle valve position sensor - rationality
P2138 Accelerator pedal position sensor - rationality
P2200 NOX sensor (SCR inlet) failure
P2205 NOX sensor (SCR inlet) heater failure
P2213 NOX sensor (SCR outlet) failure
P2214 SCR outlet NOX sensor characteristic abnormal
P2215 NOX sensor (SCR outlet) Heater failure
10000A-1

Code Message
P2227 Barometric pressure sensor - rationality
P2228 Barometric pressure sensor - out of range (out of range low)
P2229 Barometric pressure sensor - out of range (out of range high)
P2269 Water in fuel condition warning
P226C VGT slow response
P240F EGR flow slow response
P2428 ATC over heat
P242B Exhaust temp. sensor failure (3rd from upper stream) - rationality
y
P242C Exhaust temp. sensor failure (3rd from upper stream) (Low)
P242D Exhaust temp. sensor failure (3rd from upper stream) (High)
nl
P244A DPR pressure difference (Low)
P244B DPR pressure difference (High)
P244F DOC Temp. failure
O
P2457 EGR cooler performance down
P2458 DPR manual regeneration error
P2459 DPR regeneration frequency abnormal
P2463 DPR regeneration operation error
ce
P246F Exhaust gas temperature sensor (DOC outlet) - rationality
P2470 Exhaust gas temperature sensor (DOC outlet) - out of range (Out of range low)
P2471 Exhaust gas temperature sensor (DOC outlet) - out of range (Out of range high)
P2481 Exhaust temp. sensor failure (4th from upper stream) (Low)
en
P2482 Exhaust temp. sensor failure (4th from upper stream) (High)
P2483 Exhaust temp. sensor failure (4th from upper stream) - rationality
P24A2 DPR fuel additive quantity too much
P2633 Fuel pump Magnetic valve 2 failure (OPEN/GND short circuit)
er
P2634 Fuel pump Magnetic valve 2 failure (+B short circuit)

P2635 Fuel pump A “Low Flow/Performance”
P2674 Supply pump specification learning unfinished
U0073 CAN communication error. (Engine)
ef
U0101 CAN communication disrupt. (Transmission)

U0104 CAN communication error. (Scanning cruise)
U010E CAN communication disrupt. (DCU)
R
U0121 CAN communication disrupt. (ABS)

U0132 CAN communication error. (Air suspension)
U0155 CAN communication disrupt. (Meter)
U029D CAN communication disrupt. (SCR upstream NOx sensor)
U029E CAN communication disrupt. (SCR downstream NOx sensor)
U1001 CAN communication error. (Mechatronics controller , Diag CAN)
U110A CAN communication disrupt. (Mechatronics controller)
U111E CAN communication disrupt. (BCU)
U1122 CAN communication disrupt. (EGR controller)

11000-1

Code Message
U1123 CAN communication disrupt. (VNT controller)
ME034 Crane configuration setting is wrong.
ME035 A moment real load exceeds minimum value.
ME036 The malfunction of the load cell for the boom (1).
ME037 The malfunction of the load cell for the boom (2).
ME038 The malfunction of the load cell for the jib (1).
ME039 The malfunction of the load cell for the jib (2).
ME044 The malfunction of the boom base angle sensor.
y
ME045 The malfunction of the boom tip angle sensor.
ME046 The malfunction of the mast angle sensor.
nl
ME047 The malfunction of the jib base angle sensor.
ME048 The malfunction of the jib tip angle sensor.
ME049 CEN Option Setting Error
O
ME050 ML test mode
ME051 Data un-match of civil engineering mode
ME052 Options un-match of civil engineering mode
ME053 Transmission or ML failure.
ce
ME054 DPF Regeneration control not possible.
ME055 Between ECU-ML transmission abnormal.
ME068 Writing error of operator identification ID and/or password.
ME069 Writing error of WORKING AREA LIMIT values.
en
ME080 None-standard transmission error

ME084 Inclination range X error
ME085 Inclination range Y error
ME086 MC1 redundancy switch is operating.
er
ME087 MC2 redundancy switch is operating.

ME089 Time out error of synchronizing check during the MC1 start-up process.
ME090 Time out error of synchronizing check during the MC2 start-up process.
ME092 Error No.1 of ML internal setting values abnormality. (Optional item setting)
ef
ME093 Error No.2 of ML internal setting values abnormality. (Crane data)

ME094 Error No.3 of ML internal setting values abnormality. (Manufacturer adjustment data)
ME095 Error No.4 of ML internal setting values abnormality. (Temporary adjustment data)
R
ME096 Error No.5 of ML internal setting values abnormality. (Crane operation data)
ME097 Error No.6 of ML internal setting values abnormality. (Data for each case)
ME099 Error No.8 of ML internal setting values abnormality. (Failure history data)
ME100 Writing error of optional item setting.
ME101 Writing error of crane data.
ME102 Writing error of manufacturer adjustment data.
ME103 Writing error of temporary adjustment data.
ME104 Writing error of crane operation data.
ME105 Writing error of the data of each case.
10000A-1

Code Message
ME106 Load history data writing error
ME107 Writing error of failure history data.
ME108 Error of the MC crane model number unmatched.
ME109 Error of the MC optional item setting unmatched.
ME110 Communication error between touch panel monitor.
ME111 Time out error of MC1 & MC2 adjustment response.
ME112 CAN communication error with MC1.
ME113 CAN communication error with MC2.
y
ME114 CAN communication sending error with MC1 & MC2.
ME115 Error No.9 of ML internal setting values abnormality. (Failure history data of MC1)
nl
ME116 Error No.10 of ML internal setting values abnormality. (Failure history data of MC2)
ME117 Writing error of failure history data for MC1.
ME118 Writing error of failure history data for MC2.
O
ME119 Error No.11 of ML internal setting values abnormality. (Operator identification ID and/or password)
ME120 Error No.12 of ML internal setting values abnormality. (Working area limit values)
ME121 Access error to NOR flash memory in ML. Setting values can not be written.
ME122 MC1 & MC2 reset is detected.
ce
ME123 Writing error of system information for MC1 or MC2.
ME124 Writing error of optional item setting for MC1 or MC2.
ME125 Writing error of adjustment data for MC1 or MC2.
ME126 Writing error of crane operation data for MC1 or MC2.
en
ME127 Writing error of No.2. manufacturer adjustment data.

ME128 Error No.13 of ML internal setting values abnormality. (No.2 manufacturer adjustment data)
MC1-A01 Not use
MC1-A02 Not use
er
MC1-A03 Fr. drum motor speed adjusting trimmer

MC1-A04 Re. drum motor speed adjusting trimmer
MC1-A05 Jib (third) motor speed adjusting trimmer
MC1-A06 Boom motor speed adjusting trimmer
ef
MC1-A07 Not use

MC1-A08 Hand throttle potentiometer
MC1-A09 Foot throttle potentiometer
R
MC1-A10 Hydraulic oil temperature sensor

MC1-A11 Tagline trimmer
MC1-A12 Control primary pressure sensor
MC1-A13 Swing pump pressure sensor
MC1-A14 Swing operation pressure sensor (R)
MC1-A15 Swing operation pressure sensor (L)
MC1-A16 Qmax cut pressure sensor
MC1-A17 Power shift pressure sensor
MC1-A18 Boom power shift pressure sensor

11000-1

Code Message
MC1-A19 Inclination sensor (X)
MC1-A20 Inclination sensor (Y)
MC1-A21 Fr. drum clutch pressure sensor
MC1-A22 3rd. drum clutch pressure sensor
MC1-A23 Re. drum clutch pressure sensor
MC1-D01 Main pump power control proportional valve
MC1-D02 Boom pump power control proportional valve
MC1-D03 Swing speed control
y
MC1-D04 Swing reaction proportional valve
MC1-D05 Boom pump control proportional valve
nl
MC1-D06 Fr. electromagnetic detent
MC1-D07 Re. electromagnetic detent
MC1-D08 Main pump control proportional valve 1
O
MC1-D09 Main pump control proportional valve 2
MC1-D10 Tagline proportional valve
MC1-D11 Left swing proportional valve
MC1-D12 Right swing proportional valve
ce
MC1-C01 Fr. drum clutch CLM
MC1-C02 Fr. drum clutch ESM
MC1-C03 Re. drum clutch CLA
MC1-C04 Re. drum clutch ESA
en
MC1-C05 3rd. drum clutch CLT

MC1-C06 3rd. drum clutch EST
MC1-C07 Sub battery relay energizing
MC1-C08 Swing parking brake
er
MC1-C09 Adjustment mode

MC1-C10 Hyd. oil heat
MC1-C11 Qmax cut
MC1-C12 Swing flasher
ef
MC1-C13 Battery relay energizing

MC1-C14 Not use
MC1-C15 Battery relay energizing
R
MC1-C16 Load safety device bypass switch reset

MC1-C17 Solenoid valve cut relay
MC1-C18 E/G warning
MC1-C19 AIS Air conditioner ON
MC1-C20 Swing brake mode select
MC1-C21 Boom drum turn detecting grip
MC1-C22 Key return
MC1-C23 Tower latch cylinder relay
MC1-C24 Camera power
10000A-1

Code Message
MC1-C25 GITC reset relay
MC1-C26 Manual regeneration
MC1-C27 E/G restart
MC1-C28 Control primary pressure cut
MC1-C29 Fr. drum turn detecting grip
MC1-C30 Re. drum turn detection grip
MC1-C31 Safety relay
MC1-C32 E/G stop relay
y
MC1-C33 Swing voice alarm (not used)
MC1-C34 Re. / 3rd. drum change
nl
MC1-C35 Not use
MC1-C36 3rd. drum turn detection grip
MC1-H01 Not use
O
MC1-H02 Overload auto stop is being released
MC1-H03 Flash memory data failure
MC1-H04 MC adjustment is irrelevant
MC1-H05 Receiving error from ML
ce
MC1-H06 Receiving error from MC2
MC1-H07 Not use
MC1-H08 System information abnormal (E10-4)
MC1-H09 Optional item setting abnormal 1 (E10-1)
en

MC1-H12 Adjustment data abnormal (E10-5)
MC1-H13 Crane operation data abnormal (E10-6)
er
MC1-H14 Error of the distinguishing signal between MC1 and MC2. (E10-7)
MC1-H15 Error of previous MC1 or MC2 start-up mode discrepancy. (E10-8)
MC2-A01 Not use
MC2-A02 Not use
ef
MC2-A03 Fr. motor tilt pressure sensor

MC2-A04 Re. motor tilt pressure sensor
MC2-A05 3rd. motor tilt pressure sensor
R
MC2-A06 Not use

MC2-A07 Fuel level sensor
MC2-A08 Fr. independence/confluence pressure sensor
MC2-A09 Re. independence/confluence pressure sensor
MC2-A10 Not use
MC2-A11 Constant horse power cracking pressure sensor
MC2-A12 Not use
MC2-A13 Not use
MC2-A14 Not use

11000-1

Code Message
MC2-A15 Not use
MC2-A16 Boom raise pressure sensor
MC2-A17 Boom lower pressure sensor
MC2-A18 Fr. drum hoisting pressure sensor
MC2-A19 Fr. drum lowering pressure sensor
MC2-A20 Re. drum hoisting pressure sensor
MC2-A21 Re. drum lowering pressure sensor
MC2-A22 3rd. drum hoisting pressure sensor
y
MC2-A23 3rd. drum lowering pressure sensor
MC2-D01 Boom raising speed control P. SOL
nl
MC2-D02 Boom lowering speed control P. SOL
MC2-D03 Fr. drum hoisting speed control P. SOL
MC2-D04 Fr. drum lowering speed control P. SOL
O
MC2-D05 Re. drum hoisting speed control P. SOL
MC2-D06 Re. drum lowering speed control P. SOL
MC2-D07 3rd. drum hoisting speed control P. SOL
MC2-D08 3rd. drum lowering speed control P. SOL
ce
MC2-D09 Constant horse power (Motor CHP pressure P. SOL)
MC2-D10 Fr. drum motor tilt control pressure P. SOL
MC2-D11 Re. drum motor tilt control pressure P. SOL
MC2-D12 3rd drum motor tilt control pressure P. SOL
en
MC2-C01 Not use

MC2-C02 Not use
MC2-C03 Not use
MC2-C04 Not use
er
MC2-C05 Not use

MC2-C06 Not use
MC2-C07 Not use
MC2-C08 Not use
ef
MC2-C09 Not use

MC2-C10 Not use
MC2-C11 Not use
R
MC2-C12 Not use

MC2-C13 Not use
MC2-C14 Not use
MC2-C15 Fr. drum motor boost SOL
MC2-C16 Oil cooler motor
MC2-C17 Fr. independence/confluence
MC2-C18 Re. independence/confluence
MC2-C19 DPF load SOL valve
MC2-C20 Not use
10000A-1

Code Message
MC2-C21 Re. drum motor boost
MC2-C22 3rd. drum motor boost
MC2-C23 Not use
MC2-C24 Not use
MC2-C25 Not use
MC2-C26 Fr. drum operation signal
MC2-C27 Re. drum operation signal
MC2-C28 3rd. drum operation signal
y
MC2-C29 Fr. drum C/V
MC2-C30 Re. drum C/V
nl
MC2-C31 Not use
MC2-C32 Not use
MC2-C33 Not use
O
MC2-C34 Not use
MC2-C35 Not use
MC2-C36 3rd. drum C/V
MC2-H01 Not use
ce
MC2-H02 Overload auto stop is being released
MC2-H03 Flash memory data failure
MC2-H04 MC1 adjustment is irrelevant
MC2-H05 Receiving error from ML
en
MC2-H06 Receiving error from MC1

MC2-H07 Not use
MC2-H08 System information abnormal (E10-4)
er

MC2-H12 Adjustment data abnormal (E10-5)
MC2-H13 Crane operation data abnormal (E10-6)
ef
MC2-H14 Error of the distinguishing signal between MC1 and MC2. (E10-7)
MC2-H15 Error of previous MC1 or MC2 start-up mode discrepancy. (E10-8)
R

11000-1
3.13 WARNING CODE LIST AND CONDITION, ACTION

Various messages are indicated based on crane
condition.
These are not errors.
The display indicates the code as listed below.

Follows the instruction is shown.
y
nl
Following code list shown all of codes and some
of codes would not be indicated depending on the
O
model.
WARNING CODE LIST

ce
Code Message Condition, Action
ME001 Out of working angle. Out of capacity set range.
Hook overhoist release switch is
ME002 The hook overhoist automatic stop release switch is actuated.
operating.
en
Boom/Jib overhoist release switch is

ME003 The boom overhoist automatic stop release switch is actuated.
operating.
ME004 Overload release switch is operating. Overload status is canceled.
The loading ratio exceeds the specified level.
ME005 Over load condition.
Lower the load to the ground or raise the boom, jib.
er
ME006 Head wind is strong. The guy line support force becomes lower than the specified level.
The boom is out of the maximum working radius area.
ME007 Boom is lowered too much.
Raise the boom.
The boom is out of the minimum working radius area.
ef
ME008 Boom is raised too much.

Lower the boom.
The boom is out of maximum working radius area.
ME011 Boom is lowered too much.
Raise the boom.
R
The boom is out of minimum working radius area.

ME012 Boom is raised too much.
Lower the boom.
The jib is out of maximum working radius area.
ME013 Jib is lowered too much.
Raise the jib
The jib is out of minimum working radius area.
ME014 Jib is raised too much.
Lower the jib
The mast is out of minimum working radius area.
ME015 Mast is raised too much.
Lower the mast
The mast is out of maximum working radius area.
ME016 Mast is lowered too much.
Raise the mast.
10000A-1
WARNING CODE LIST

The hook exceed the overhoist limit position.
ME017 Hook overhoist.
Lower the hook.
The hook exceed the overhoist limit position.
ME018 Hook overhoist.
Lower the hook.
Mast cylinder limit switch has not The support is not out of stowed position for mast.
ME019
been turned on. Extend the mast support.
Detecting limit switch for high gantry The gantry is not raised for mast raising.
ME020
position has not been turned on. Raise the gantry.
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The boom overhoist limit switch is actuated.
ME021 Boom overhoist.
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Lower the boom.
The jib overhoist limit switch is actuated.
ME022 Jib overhoist.
Lower the jib
ME024 Overload precautions. Loading ratio is 90 % or more.
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Reached the load limitation value of Lifting load exceeds the lifting load limit value set by operator.
ME025
working area limit function. Lower the load or raise the jib or boom.
Reached 90% of the load limitation
ME026 Lifting load exceeds 90% of the lifting load limit value set by operator.
value of working area limit function.
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The boom reaches the boom angle upper limit point (stop point) set by
Boom angle reached upper limitation
ME027 operator.
Lower the boom.
The boom reaches the boom angle lower limit point (stop point) set by
Boom angle reached lower limitation
ME028 operator.
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Raise the boom.
Jib angle reached upper limitation The jib reaches the jib angle upper limit point (stop point) set by operator.
ME029
value of working area limit function. Lower the jib.
Jib angle reached lower limitation The jib reaches the jib angle lower limit point (stop point) set by operator.
ME030
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value of working area limit function. Raise the jib.

The boom reaches the working radius limit point (stop point) set by
Working radius reached limitation
ME031 operator.
Raise the boom or jib.
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The boom reaches the boom height limit point (stop point) set by
Boom point elevation reached limitation
ME032 operator.
Lower the boom.
Jib point elevation reached limitation Operator set height limit is reached.
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ME033
value of working area limit function. Lower the jib.
The attachment set data is abnormal.
ME034 Crane configuration setting is wrong.
Re-set the attachment.
Data unmatched of civil engineering Setting posture is not civil engineering mode.
ME052
mode. Perform re setting.
ME056 Inspection mode for overload condition. Load safety device check mode
ME058 Set the swing brake mode. Apply the swing parking brake and set to the swing brake mode.
The boom overhoist No.2 limit switch is actuated.
ME060 Boom overhoist.
Lower the boom.

11000-1
WARNING CODE LIST

The tension of the hoist wire rope exceeds the forecast alarm value,
Jib winch wire rope is tightened a little
ME061 during erecting the tower.
more than normal.
Loosen the jib hoist wire rope.
The tension of the hoist wire rope exceeds the alarm value, during
Jib winch wire rope is abnormally
ME062 erecting the tower.
tightened.
Loosen the jib hoist wire rope.
ML crane configuration does not The input signal from the counterweight detector does not match the data.
ME063 correspond to the counter weight Check the counterweight detector or check for proper counterweight
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detecting signal. selecting in the attachment setting.
ML crane configuration does not The input signal from the carbody-weight detector does not match the data.
ME064 correspond to the carbody-weight Check the counterweight detector or check for proper counterweight
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detecting signal. selecting in the attachment setting.
Danger!! The jib connecting pin is not pulled out at lowering of maximum tower length.
ME066
The jib tip touches at the ground. Pull out the pin. (Only 7200G)
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Boom winch wire rope is abnormally
ME067 Loose the boom hoist rope before operate the mast.
tightened.
The front drum over pay out preventive device is actuated.
ME081 Front winch over pay out
Operate the front drum toward wind up direction.
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The rear drum over pay out preventive device is actuated.
ME082 Rear winch over pay out
Operate the rear drum toward wind up direction.
The third drum over pay out preventive device is actuated.
ME083 Third winch over pay out
Operate the third drum toward wind up direction.
Counterweights detection is not completed.
en
ME088 Connect the weight

Confirm wiring connection.
The message is displayed when the engine coolant temperature is
MC1-W01 Engine preheat
0 degrees or less with the key switch turned ON.
MC1-W02 Preheat completed The message is displayed for 5 seconds after the preheat is complete.
er
The charging circuit is malfunctioned.

Consult with your nearest Manitowoc authorize distributor.
MC1-W03 Charging problem
* It is not fault even this item is momentarily displayed immediately after
the engine is started.
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The control primary pressure is abnormal.

Stop the operation, and consult with your nearest Manitowoc authorize
MC1-W04 Pilot pressure (primary) abnormal distributor.
* It is not fault even this item is momentarily displayed immediately after
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the engine is started.

The engine oil pressure is abnormal. Stop the engine at once, and
MC1-W05 Engine oil pressure
consult with your nearest Manitowoc authorize distributor.
The cooling water level in the radiator is insufficient. Refill the radiator
MC1-W06 Engine water level
with cooling water.
The coolant temperature is excessively high. Idle the engine to lower
MC1-W08 Engine coolant temperature temperature, and consult with your nearest Manitowoc authorize
distributor.
The engine oil filter is clogged.
MC1-W09 Engine oil filter
Replace the filter.
10000A-1
WARNING CODE LIST

MC1-W10 Engine air filter The engine air cleaner is clogged. Clean or replace the element.
MC2-W11 Empty fuel The fuel level is insufficient. Refuel.
The hydraulic oil temperature is excessively high.
MC1-W12 Hydraulic oil temperature Adjust the engine speed to the medium level to lower the oil temperature,
and consult with your nearest Manitowoc authorize distributor.
The temperature of clutch cooling oil of the front drum is excessively high.
Idle the engine at a high speed to lower the oil temperature.
Front winch cooling circuit oil If this code frequently appears during normal operations, consult with
MC1-W13
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temperature your nearest Manitowoc authorize distributor.
At the same time, inform the Manitowoc service of the details of the
operation (lifting load, free fall distance, speed, and duration).
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The temperature of clutch cooling oil of the front drum is excessively high.
Idle the engine at a high speed to lower the oil temperature.
Rear winch cooling circuit oil If this code frequently appears during normal operations, consult with
MC1-W14
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temperature your nearest Manitowoc authorize distributor.
At the same time, inform the Manitowoc service of the details of the
operation (lifting load, free fall distance, speed, and duration).
The winch cooling line filter is clogged.
Replace the filter cartridge.
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This code may appear during cold weather even when the filter is not
MC1-W15 Winch filter clogged
clogged.
If the code disappear during warm-up, the cartridge does not need to be
replaced.
The front drum clutch emergency system is actuated.
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The free fall of the front drum cannot be normally performed.

Place a load and the hook onto the ground, and turn the key switch to the
Front safety ESM solenoid valve is
MC1-W16 OFF position.
energized
Then, consult your nearest Manitowoc authorize distributor.
DO NOT operate the key switch with a load or the hook hung in the air,
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since it may cause drop of the load or the hook.

The rear drum clutch emergency system is actuated.
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Rear safety ESA solenoid valve is

energized
Do not operate the key switch with a load or the hook hung in the air,
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The 3rd drum clutch emergency system is actuated.

3rd safety EST solenoid valve is
energized
Do not operate the key switch with a load or the hook hung in the air,
Hook overhoist release switch is
MC1-W19 The hook overhoist automatic stop release switch is actuated.
operating

11000-1
WARNING CODE LIST

Boom overhoist release switch is
MC1-W20 The boom overhoist automatic stop release switch is actuated.
operating
The moment limiter redundancy switch is actuated.
The moment limiter is malfunctioned, and automatic stop operation due
MC2-W21 ML bypass switch is operating to overload and the overhoisted hook block is impossible.
Immediately stop the operation, or return extremely carefully, and consult
with your nearest Manitowoc authorize distributor.
Option setting dose not match with engine spec.
MC1-W22 DPF option setting abnormal
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Contact Manitowoc service shop.
Front drum rotation sensor is not functioning properly.
MC1-W23 Front drum rotation sensor adjustment Adjust sensor position.
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If not corrected even after adjustment, contact Manitowoc service shop.
Rear drum rotation sensor is not functioning properly.
MC1-W24 Rear drum rotation sensor adjustment Adjust sensor position.
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If not corrected even after adjustment, contact Manitowoc service shop.
Front drum negative brake function may be abnormal.
MC2-W31 Front drum negative brake abnormal
Rear drum negative brake function may be abnormal.
MC2-W32 Rear drum negative brake abnormal
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3rd. drum negative brake function may be abnormal.
MC2-W33 3rd. drum negative brake abnormal
Battery relay contact may be adhered.
MC1-W35 Battery relay abnormal Inspect battery relay.
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Replace if the deposited at the contact point of the relay.

Propel (travel) lever is kept ON. Pilot pressure is cut.
MC1-W36 Propel lever interlocked
Return propel (travel) lever back to neutral.
Front drum is stopped since front drum lever is kept ON.
MC2-W37 Front drum lever interlocked
Return front drum lever back to neutral.
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Rear drum is stopped since rear drum lever is kept ON.

MC2-W38 Rear drum lever interlocked
Return rear drum lever back to neutral.
3rd. drum is stopped since 3rd. drum lever is kept ON.
MC2-W39 3rd. drum lever interlocked
Return 3rd. drum lever back to neutral.
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Boom drum is stopped since boom drum lever is kept ON.

MC2-W40 Boom drum lever interlocked
Return boom drum lever back to neutral.
Remote control is connected.
MC1-W41 Remote controller connected
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Disconnect remote control for crane work.

MC1-W42 Charge signal differs on each MC.
MC1, 2 charge signal abnormal
MC2-W42 Contact Manitowoc service shop.
MC1-W44 Function lock signal differs on each MC.
MC1, 2 function lock signal abnormal
MC2-W44 Contact Manitowoc service shop.
MC1-W45 Mc1, 2 inching speed select signal Inching speed select signal differs on each MC.
MC2-W45 abnormal Contact Manitowoc service shop.
10000A-1
WARNING CODE LIST

Qmax cut solenoid relay contact is adhered at energize side.
The engine revolution will be restricted not to raising the maximum
MC1-W46 Qmax cut sol output off abnormal
revolution.
Qmax cut solenoid relay is not functioned.
The engine revolution will be restricted not to raising the maximum
MC1-W47 Qmax cut sol output on abnormal
revolution.
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Actual rotation is higher than no load Either front or rear winch motor is running over speed or engine speed is over.
MC1-W48
rotation Contact Manitowoc service shop.
The engine reached to the maximum torque situation, be sure, there is a
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possibility of stopping the engine by further engine load due to the abrupt
operation is taken.
MC1-W49 High load torque Avoid abrupt lever operation and work with the care.
Although the warning will be released by decline the engine load, if
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frequently happen it, there is a possibility of clogging the fuel filter,
recommend replace the filter earlier.
Joy stick accel switch exceeds neutral range.
MC1-W50 Joy stick abnormal Return it to neutral position.
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If error continues even at neutral position, contact Manitowoc service shop.
Back up fuse (F-4) of each controller is blown off.
MC1-W51 Back up fuse blown out
Replace with new one.
MC2 detects hook overhoist.
MC2-W52 Hook overhoist LS Check ML or hook overhoist signal and then contact Manitowoc service
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shop.
MC2 detects boom overhoist.
MC2-W53 Boom overhoist LS Check ML or boom overhoist signal and then contact Manitowoc service
shop.
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MC2 detects jib overhoist.

MC2-W54 Jib overhoist LS Check ML or jib overhoist signal and then contact Manitowoc service
shop.
MC2 detects boom backstop No.1 overhoist.
ef
MC2-W55 Boom backstop No.1 LS Check ML or boom backstop No.1 overhoist signal and then contact
Manitowoc service shop.
MC2 detects boom backstop No.2 overhoist.
MC2-W56 Boom backstop No.2 LS Check ML or boom backstop No.2 overhoist signal and then contact
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Manitowoc service shop.

11000-1
3.14 CHECKING PROCEDURE OF LOAD SAFETY DEVICE

Check the following point of the load safety device
once a year.
1. Check of work radius indication
(1) Indicate the work radius in the certain point

within the work area in lowering motion of boom.
(2) Measure the actual work radius with measuring
tape and check if it matches with the work
radius indication value.
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2. Check of actual load indication
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(1) Lift a load weight which is exactly known in
advance.
(2) Check if the load (lifting load + hook weight +
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sling wire weight) matches exactly with the load
indication value.
If indication value and actually measured value

differ significantly, contact Manitowoc service
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shop.
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10000A-1
[ 4. ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY ]

4.1 SWING AND TRAVEL STABILITY ..................................................................................... 4-1
4.2 HANDLING THE REMOTE CONTROL SWITCH BOX................................................ 4-4
4.3 ASSEMBLING OF BASE MACHINE ................................................................................. 4-8
4.3.1 CAB STEP EXTENSION.................................................................................................. 4-10
4.3.2 UNLOADING BASE MACHINE FROM TRAILER .................................................... 4-12
4.3.3 EXTENDING THE CRAWLER ....................................................................................... 4-13
4.3.4 INSTALLING OF LADDER FOR MACHINERY GUARD ........................................ 4-20
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4.3.5 RAISING GANTRY ............................................................................................................ 4-21
4.3.6 INSTALLING THE BOOM TIP ........................................................................................ 4-26
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4.3.7 INSTALLATION OF THE BASE GUY LINE ................................................................ 4-28
4.3.9 CARBODY WEIGHT INSTALLATION (USING SELF REMOVAL DEVICE) ..... 4-35
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DEVICE)................................................................................................................................ 4-50
4.3.11 MOUNTING THE ASSEMBLED COUNTERWEIGHT TO BASE MACHINE
(USING SELF REMOVAL DEVICE) ............................................................................. 4-58
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4.4 DISASSEMBLY OF BASE MACHINE ............................................................................... 4-67
SELF REMOVAL DEVICE) .............................................................................................. 4-69
4.4.2 DISASSEMBLY OF THE COUNTERWEIGHT .......................................................... 4-78
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4.4.3 CARBODY WEIGHT REMOVAL (USING SELF REMOVAL DEVICE)............... 4-83

4.4.4 WINDING UP THE FRONT DRUM WIRE ROPE ..................................................... 4-97
4.4.5 REMOVING THE BOOM GUY LINE ............................................................................ 4-99
4.4.6 DISASSEMBLING THE BOOM TIP .............................................................................. 4-101
4.4.7 LOWERING THE GANTRY............................................................................................. 4-103
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4.4.8 REMOVAL OF LADDER FOR MACHINERY GUARD ............................................ 4-108

4.4.9 RETRACTING THE CRAWLERS .................................................................................. 4-109
4.4.10 BASE MACHINERY LOADING ONTO TRAILER ..................................................... 4-115
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4.4.11 STORE AND REMOVAL OF CAB STEP..................................................................... 4-118

4.5 TRANSPORTATION ............................................................................................................... 4-120
4.6 INSTALLATION/REMOVAL OF BOOM BASE ................................................................ 4-121
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4.6.1 BOOM BASE INSTALLATION ........................................................................................ 4-121

4.6.2 BACKSTOP INSTALLATION .......................................................................................... 4-123
4.6.3 UPPER SPREADER INSTALLATION .......................................................................... 4-124
4.6.4 REEVING BOOM HOIST WIRE ROPE ....................................................................... 4-125
4.6.5 INSTALLATION OF BOOM HOIST WIRE ROPE TO THE DRUM ...................... 4-127
4.6.6 WINDING UP OF BOOM HOIST WIRE ROPE TO THE DRUM .......................... 4-128
4.6.7 UPPER SPREADER REMOVAL ................................................................................... 4-130
4.6.8 BACKSTOP REMOVAL.................................................................................................... 4-131
4.6.9 REMOVAL OF BOOM BASE .......................................................................................... 4-132

11000-1
4.7 CARBODY WEIGHT INSTALLATION (WHEN USING ASSIST CRANE)............... 4-134

4.8 SELF REMOVAL CYLINDER (OPTION) INSTALLATION/REMOVAL..................... 4-141
4.9 SELF REMOVAL CYLINDER (OPTION) TAKEOUT/STORAGE............................... 4-145
4.9.1 TAKEOUT OF CYLINDER................................................................................................ 4-145
4.9.2 STORAGE OF CYLINDER............................................................................................... 4-149
4.10 CRAWLER INSTALLATION/REMOVAL (USING SELF REMOVAL CYLINDER
[OPTION])................................................................................................................................... 4-152
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4.10.1 INSTALLATION OF CRAWLER...................................................................................... 4-152
4.10.2 REMOVAL OF CRAWLER................................................................................................ 4-169
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4.11 CARBODY WEIGHT INSTALLATION/REMOVAL (USING SELF REMOVAL
CYLINDER [OPTION])............................................................................................................ 4-182
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10000A-1

In this article, indication of some ladders, steps etc
may be neglected to make figure easier to view.
4.1 SWING AND TRAVEL STABILITY

The stability while swinging and traveling of the
machine is to be varied depending on the mass of
counterweight, condition of the attachment, extension
or retraction of the crawler and traveling on the slope.
The operation must be started after confirm the
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machine stability while swinging and traveling by
referring with following table.
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1. The table above shows the values for operation
on firm ground.
On a weak ground, operate with care after
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improving the ground. TRAVEL MOTOR
2. Swinging on a trailer is prohibited. Traveling forward
3. Maximum slope angle is 21.8 degrees (40%).

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This may become lower depending on condition
(ground, crane configuration).
TRAVEL MOTOR
4. Traveling “forward” means that the counterweight
is at the lower side of the slope, and “backward” Traveling backward
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is the counterweight is at the higher side of the

slope.
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11000-1
TABLE FOR STABILITY (WITHOUT CARBODY WEIGHT)

All-round swing Travel on slope
Attachment Counterweight
Crawler extend Crawler retract Forward Backward
Without : 0 t
No.1 :
(No abrupt (Slope 16 degrees
8.31 t (18,320 lbs)
Without attachment lever control) or less)
(Base machine only)
No.1 to No.2 :
(No abrupt (No abrupt
19.81 t (43,674 lbs)
lever control) lever control)
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No.1 to No.3 :
31.31 t (69,028 lbs)
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Without : 0 t
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No.1 :
With boom base 8.31 t (18,320 lbs)
(Boom angle :
10 degrees or less) No.1 to No.2 :
19.81 t (43,674 lbs)
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No.1 to No.3 :
31.31 t (69,028 lbs)
Without : 0 t
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No.1 :
With basic boom 8.31 t (18,320 lbs)
(Boom angle :
(Slope 7 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
: Allowed : With restriction : Not allowed
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10000A-1
TABLE FOR STABILITY (WITH CARBODY WEIGHT)

Without : 0 t
No.1 :
8.31 t (18,320 lbs)
Without attachment
(Base machine only)
No.1 to No.2 :
(Slope 8 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
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Without : 0 t
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No.1 :
(Boom angle :
(Slope 12 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
Without : 0 t
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No.1 :
(Boom angle :
19.81 t (43,674 lbs)
lever control) or less)
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No.1 to No.3 :
(Slope 3 degrees
31.31 t (69,028 lbs)
or less)
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11000-1
4.2 HANDLING THE REMOTE CONTROL SWITCH BOX

This machine provides the remote control switch box
(here after called “remo-con”) for operate the machine
from outside at the assembling/disassembling.
When a power switch of remote control switch

box (remo-con) is ON position, the engine can’t be
started with the engine key in the operator’s cab.
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Remo-con
When starting the engine from key switch in the connecting portion
㸦Carbody side㸧
operator’s cab, ensure to turn the power switch of
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remote control box OFF position.
1. Connection with the carbody side
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(3) ENGINE EMERGENCY STOP
SWITCH
(2) HORN SWITCH
(5) ABNORMAL INDICATING LAMP
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(1) POWER SWITCH (4) ENGINE SPEED CONTROL SWITCH
(6) VERTICAL CYLINDER (6) VERTICAL CYLINDER

CONTROL SWITCH CONTROL SWITCH
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(7) CRAWLER EXT./RET. SWITCH
(7) CRAWLER EXT./RET. SWITCH

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(6) VERTICAL CYLINDER (6) VERTICAL CYLINDER

REMOTE CONTROL SWITCH BOX

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Remo-con
connecting portion
Machine front
10000A-1
(1) POWER SWITCH
Power off. / Engine stop.

Turning to this position stops the engine.
Power is supplied to crane portion.
Engine starts.
When released, the switch automatically
return to ON position.
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The engine can’t start from the operator’s cab if in
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case this power switch is on position.
(2) HORN SWITCH
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Press this switch to sound the horn.
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(3) ENGINE EMERGENCY STOP SWITCH
Press this switch to stop the engine in emergency.
The switch stays at depressed position.
To reset, turn the switch to right or pull.
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* Use only to stop the engine at emergency case.
(4) ENGINE SPEED CONTROL SWITCH

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Increase the engine speed.
Decrease the engine speed.

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This lamp turns ON when the engine abnormality
occurs.
When this lamp is ON, check the detail of
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abnormality by the cab monitor and take

appropriate action.

11000-1
(6) VERTICAL CYLINDER CONTROL SWITCH

This switch is used to control the translifter.
Vertical cylinder extends.
Vertical cylinder retracts.
(7) CRAWLER EXTEND/RETRACT SWITCH

This switch is used to control the crawler
extend/retract cylinder.
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Crawler extend/retract cylinder extends.
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Crawler extend/retract cylinder retracts.
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10000A-1
2. Connection with the self removal device side
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Remo-con connecting portion
㸦Self removal device side㸧
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(3) ENGINE EMERGENCY STOP
SWITCH
(2) HORN SWITCH
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(1) POWER SWITCH (4) ENGINE SPEED CONTROL SWITCH
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(6) SELF REMOVAL DEVICE (6) SELF REMOVAL DEVICE

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REMOTE CONTROL SWITCH BOX
Switches (1) to (5) are same functions when connect

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the switch box with carbody.
(6) SELF REMOVAL DEVICE CONTROL SWITCH

This switch is used to control self-removal
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cylinders.
Self-removal cylinder extends.
Self-removal cylinder retracts.

11000-1
4.3 ASSEMBLING OF BASE MACHINE

This article explains assembly of the main machinery
for unloading, changing to work configuration.
Any work on the base machine would be dangerous

if proper procedure is not taken.
Hold a pre-work meeting to go over the procedure to
prevent accident and proceed with the work safely.
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Do not insert finger or hand into a pin hole when
aligning, inserting or removing pin.
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• The ground where base machine is placed

during assembly/disassembly may receive
large load.
• Ensure the ground for operation is firm and
level and place the steel plate or improve the
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ground condition as required.

• Use proper rated assist crane, slings,
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shackles and other equipment.

Failure to observe these precautions may
result in a serious accident.
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10000A-1
1. Check points prior to work
• A qualified supervisor who is competent in the

procedures.
• Hold a pre-work meeting for safety.
Review potential hazards and hazardous
locations in the course of work.
• Make every worker aware of work contents,
procedure and signal.
• Inspect assist crane and other equipment for
their condition.
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2. Securing place
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• Select a firm and level space enough for the
task.
Place the planking such as steel plates or crane
mats on the ground as required.
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• Assign areas for the assist crane, parts storage
and trailer access.
3. Preparation before assembling/disassembling

work
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• Secure the setting place of assist crane and
prepare the required lifting gears, protective
materials and tools.
• Secure required number of workers for the work.
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(Crane operators, assistant operators, slinging

workers and signal persons)
• Take appropriate action to keep unrelated
person off the work area other than workers
during work.
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4. Cautions during assembly/disassembly work
• During work, install the waterproof cap on the

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cable end of the hook overhoist preventing device.

During crane work, remove the waterproof cap
and wire the overhoist cable properly.
• Refer to the article “8.2 DIMENSION, WEIGHT
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OF EACH COMPONENT” for weight, dimension

during work.
• The operator has to be informed if any person
moved to out of sight from the operator or at
hazardous location when equipment or machine
part moves.

11000-1
4.3.1 CAB STEP EXTENSION

Steps provided at the cab door are for the safe access
to the operator cab.
Extend the steps during work, and stow or remove for
transportation.
Stowed position
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Extended position
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CAB STEP
SECURING PIN
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ADJUSTING BOLT
1. Extension of the step from stowed position

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(1) Remove the securing pin and lift up the outer
end of the step full and then rotate it toward
outer side to extend to horizontal position.
(2) If the step is not horizontal after extended, adjust
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two bolts to make the step in horizontal position.

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Stowed position
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Extended position
10000A-1
2. Installation of the step
(1) Put the step to the place where the step installing
and securing on the guard and rotate the step as
shown.
When installing the step, ensure not to bite the

finger by bracket and the like.
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(2) Lower the step and align the groove on the step
with the notch on the guard.
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(3) Install the bracket to prevent unhinged the step.

(2 pieces for one step) BRACKET TO PREVENT UNHINGED
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(4) Insert the securing pin for bracket.

Confirm the steps are firmly secured. SECURING PIN
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11000-1
4.3.2 UNLOADING BASE MACHINE FROM TRAILER

1. After checking the ground condition where the
base machine is placed, stop the trailer.
2. Start the engine and set the speed to low.

(800 min-1 [800 rpm])
3. Engage the swing brake and turn the function

lock lever to “WORK” position while the swing
lock pin is inserted.
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4. Travel the machine slowly using the loading
plates.
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Do not raise the boom to higher than 10 degrees
angle when loading into trailer.
The machine may overturn backward.
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Do not swing the upper machinery on the trailer to
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avoid the machine overturning.

serious accident.
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The gravity center may shift suddenly at the

border between the loading ramp and the trailer.
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Set the travel speed select switch to LOW and

travel with slow and constant speed.
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LOADING RAMP TRAILER

Set angle as small as possible. (Less than 15 degrees)
10000A-1
4.3.3 EXTENDING THE CRAWLER

This article explains that the sequence of extension of
crawlers starting from the basic machine with crawlers
fully retracted.
Approx.
Although the crawler extending/retracting can be 10 degrees
done without the boom base, this article explains the Axle insert area
procedure with boom base attached.
Perform the crawler extending/retracting work under

the following conditions.
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• Counterweight : None
nl
• Boom : Boom base only
• Boom angle : Approx. 10 degrees
O
Ensure the ground for operation is firm and level
and place the steel plate or improve the ground
condition as required.
ce
serious accident.
Prior to extending/retracting, clean the axle extension

en
thoroughly and apply grease (Molybdenum disulphide

grease) to the slide area.
If mud is left on, extension or retraction work could be
difficult.
er
Coat the grease on the sliding surface of axle.
Apply the molybdenum disulphide grease to the

ef
axle.
R

11000-1
1. Pull out the securing pin (a) connecting the

carbody and both right hand and left hand links.
y
nl
SECURING PIN (a)
SECURING PIN (a)
O
ce
2. Pull out the axle extension securing pin which
secure the axle extension and the crawler frame. AXLE EXTENSION
SECURING PIN
(4 pieces on right and left)
en
er
AXLE EXTENSION
SPRING PIN
ef
R
10000A-1
3. Turn all four axle extensions for 90 degrees AXLE EXTENSION SECURING PIN
toward outside to make them parallel to the
axles.
Axle extension securing pin is to be installed on
the crawler frame side.
Pay attention to the installation direction of axle
extension securing pin for safety as shown.
SPRING PIN
y
nl
O
SPRING PIN
ce
4. Insert the rotation preventive bracket to the pivot ROTATION PREVENTIVE BRACKET
(Installation place)
area of the axle extension from the direction as
shown.
(The rotation preventive bracket has been
stored on the crawler frame.)
en
er
ef
ROTATION PREVENTIVE BRACKET

(Stowed place)
R

11000-1
5. Take out the clearance adjusting shims between SHIM

the crawler and the axle.
CRAWLER FLAME
AXLE
Do not insert the finger or hand into the gap

between the crawler and axle when installing or
removing the shim.
Failure to observe this precaution may result of a
serious injury.
y
nl
O
ce
6. Face the upper machinery to the front.
en
To prevent overturn of the base machine ensure to

engage the swing brake and lock.
Failure to observe this precaution may result in a Extending Extending
side side
serious accident.
er
7. Check to see that there are no obstacles in the

area of crawler extension.
Turn the crawler extend switch to extending Far side :
Extending side
ef
side.
If the crawler can’t be extended smoothly,
repeats manipulate the switch both sides for
extending and retracting or travel forward and Near side :
R
Retracting side
backward.
(Both right and left crawler will be extend
simultaneously) CRAWLER EXTEND SWITCH
10000A-1
8. If the crawler still can’t be extended with the

step 7 above performed due to bad ground
condition, swing the upper machinery slowly to
right angle with the crawler.
In this case, ensure to make the crawler to be
extended comes to the front side (operator cab
side). Extending side
9. Extend the crawler until the block on link to the

bracket on the carbody is to be contacted.
Extended the crawler, align the pin hole (at
extending) between the carbody side bracket
y
and crawler connecting link and insert the
securing pin (a).
nl
O
A
ce
CRAWLER CONNECTING LINK
SECURING PIN (a)
CARBODY SIDE
en
BLOCK BRACKET
PIN HOLE
(At retracting)
er
PIN HOLE
(At extending)
BLOCK
View from A
ef
10. In case of extending the crawler by one side,

swing the upper machinery 180 degrees and
extend the remaining crawler as same order as
other side.
R

11000-1
11. Confirm both of crawlers are extended fully and

all of securing pin (a) are inserted to the pin holes
for extending position.
Ensure to insert the securing pin (a) at extend

position when the crawler extended.
When it is inserted to retract position, the extended
width of crawler is not enough resulted the machine
may overturn at erection or lifting work.
y
Failure to observe this precautions may result in a
serious injuries or loss of life.
nl
12. Swing the upper machinery to widen a clearance
SHIM
between the crawler frame and the axle and
O
inserting the adjusting shim at four places. CRAWLER FRAME
Each shim has a unique number stamped and AXLE
install it accordingly.
ce
removing the shim.
en

serious injury.
er
Insert the adjusting shim to all axles.

Otherwise the crawler frame would become
ef
misaligned and result in premature shoes or roller

wear.
damage the parts.
R
10000A-1
13. Remove the securing pin connecting the crawler

ext./ret. cylinder with the crawler frame and SECURING PIN
retract cylinder fully.
The removed securing pin is to be inserted to
the crawler side pin hole and secure with the
spring lock pin.
CRAWLER EXT./RET.
CYLINDER

y
nl
SPRING LOCK PIN
O
The crawler Ext./Ret. cylinder should be kept in
full retract position unless the crawler is to be
extend or retract.
Otherwise may result in premature damage of
ce
cylinder due to sticking of dust/dirt on the sliding
part of cylinder.
damage the parts.
en
er
ef
R

11000-1
4.3.4 INSTALLING OF LADDER FOR MACHINERY GUARD

1. Insert the ladder on the right hand guide.
y
nl
O
2. Turn the ladder and align the pin hole for the
left hand side bracket of ladder and insert the
ce
securing pin.
3. Confirm the ladder installed securely.

en

er

ef
SECURING PIN
R
10000A-1
4.3.5 RAISING GANTRY
Do not stand on, or enter under/inside of the

attachment being assembling/disassembling.
y
nl
Do not enter under or inside of the gantry (or mast).
• When handling the wire rope, use leather
O
ce
gloves to prevent injury on the fingers or
hands.
• Take extra care to work on the moving wire
en
rope not to touch the sheave and wire rope

to prevent accident of being crushed or
being entangled.
er
ef
Ensure to perform the gantry raising/lowering

work with the boom placed on the wood blocking
of approx. 100 mm (3-15/16 in.) in height.
R
Take extra care on slack or tension of the boom.

damage the parts.

11000-1
1. Place the boom base on the block.
Do not lower the boom base tip below ground level,

otherwise interfere the boom and/or backstop with
surrounding components and lead to damage parts.
Approx. 100 mm (3-15/16″)
2. Pull out the travel kit securing pin, and remove it

from swing frame.
y
Travel kit securing pin secured with spring lock
pin.
nl
O
ce
3. Start the engine and set the speed to approx.
SPRING LOCK PIN
1,000 min-1 (1,000 rpm).
en
Sound the signal horn to warn the surrounding

personnel before starting the engine.
er
TRAVEL KIT
serious injury or loss of life. TRAVEL KIT SECURING PIN
ef
R
10000A-1
4. By turning the gantry control switch to raising

side (outward), raise the gantry with the
cylinders. Far side :
Raising side
Near side :
Lowering side
• When the gantry is raised or lowered, make
sure that there is no persons around the
gantry area and observe the raising or GANTRY CONTROL SWITCH
lowering condition of the gantry.
y
• Before operating the gantry control switch,
nl
sound the horn to warn the person around.
• During crane work or raising the boom, do
O
not operate the gantry control switch.
Failure to observe this precautions may
ce
Never raise the gantry using the boom hoist wire
rope or using the assist crane.
en
The gantry may suddenly drop immediately when

the gantry securing pin is pulled out during gantry
lowering.
er
ef
R

11000-1
5. When the gantry reaches to the “WORK”

position, insert the gantry securing pin into the
gantry on both sides and secure the them with
the spring pins.
6. Secure the travel kit to the stopper on gantry

with travel kit securing pin.
y
nl
SPRING
O
ce
LOCK PIN
TRAVEL KIT
SECURING PIN
TRAVEL KIT
STOPPER
en
SPRING
LOCK PIN
er
GANTRY
SECURING PIN
ef
R
GANTRY SECURING
PIN HOLDER
(Stored position)
SPRING LOCK PIN
10000A-1
7. Confirm the upper spreader is secured to the

bracket on the boom base tip with securing
pins, wind up the boom wire rope slowly until
the slack is taken up.
In this case, wind up the wire rope to the drum
neatly by applying tension on the rope to avoid
rough spooling.
Place a signalman to prevent accident from rotating
y
drum.
nl
serious injury.
O
Latch (2 places) fasten it to the position
of the chain marked with a piece of tape.
ce
In case of the machine works certain period, retract
the gantry cylinder and secure it while working.
For fixing, use the chain, of which is the attached
tool of the machine.
en
er
When cylinder is retracted at work

ef
R

11000-1
4.3.6 INSTALLING THE BOOM TIP

1. Align the top connecting parts of boom base SPRING LOCK PIN
and boom tip and insert the connecting pins (with
flange) by tapping it.
The pin shall be inserted with the connecting
pin hole is to be vertical direction and insert the
spring lock pins.
CONNECTING PIN
y
(With flange)
nl
O
Be sure to tap the connecting pins (with flange)
from the outside to the inside.
ce
en
er
ef
R
10000A-1
2. Raise the boom base until the lower pin holes

are aligned and insert the connecting pins
(double tapered) by tapping it.
The pin shall be inserted with the connecting
pin hole is to be vertical direction and insert the
spring lock pins.
SPRING LOCK PIN
Do not stand on, or enter under/inside of the SPRING

LOCK PIN
y
nl
CONNECTING PIN
(Double tapered)
O
Do not stand in line with the connecting pins
(double tapered) being inserted/removed.
The pin may fly out from the pinhole.
ce
en

er
ef
R

11000-1
4.3.7 INSTALLATION OF THE BASE GUY LINE

1. Install the base guy lines between the boom tip
UPPER SPREADER
and upper spreader.
SPLIT PIN GUY LINE
Open the split pin of the guy line connecting
pins to approx. 60 degrees.
2. Remove the spreader securing pins.

Adjust tension of the boom hoist wire rope
Insert the
during the process. guy line connecting pin
from inside.
y
nl
• When working at a high elevation, be sure to
use a safety belt to prevent falling. SPLIT PIN GUY LINE
Failure to observe this precaution may result *Open the split pin to approx. 60 degrees
O
• Use a scaffolding board for working on the
attachment.
ce
en

er
ef
R
10000A-1
3. Turn the boom drum control lever to the raise

side and wind the boom hoist wire rope slowly.
During this operation, apply tension on the BASE GUY LINE
lower layer rope to prevent rope upsetting and

tap the rope lightly with a hammer to make rope
wind evenly.
Stop winding the boom hoist wire rope just
before the boom tip leaves the ground.
y
use a safety belt to prevent falling.
nl
attachment.
O
ce
en
er
ef
R

11000-1
4.3.8 FRONT DRUM WIRE ROPE REEVING

hands.
y
being entangled.
nl
• Place a signal person to prevent accident
from rotating drum.
O
ce
The hook is to be installed correct direction.
When passing the hoist wire rope to the hook, face
the striker (hook side weight catch) contacting the
en
hook overhoist limit switch weight to the boom

foot side.
er
ef
R
10000A-1
1. Place the hook, overhoist limit switch, weight

and socket, near the boom tip.
IDLER SHEAVE
2. Turn the front drum control lever to lower side to
pay out the wire rope to the boom tip.
WIRE ROPE
3. Pass the wire rope through the idler sheave
and boom point sheave by referring to the right
figure. BOOM POINT
SHEAVE
* However, in case of the number of reeving is 7

parts of line or more, pass the wire rope through
y
the middle idler sheave and pass it to the
View from A
auxiliary sheave.
nl
(Refer to the article “HOIST ROPE REEVING
IN BOOM POINT AREA”.)
O
ce A
4. Install the overhoist limit switch and weight to

the left side bracket on the tip end of the boom.
en
Insert the split pin into the shackle pin to secure it.
5. Pass the front drum wire rope through the hook

sheave(s) and boom point sheave(s) in order.
Terminate the wire rope end with the rope socket
er
at the boom point for even number part reeving

and at the hook for odd number part reeving.
Be sure to pass the wire rope through the hook
overhoist limit switch weight.
ef
LIMIT SWITCH
R
SHACKLE
WEIGHT LIFTING
WIRE ROPE
WEIGHT

11000-1
HOIST ROPE REEVING IN BOOM POINT AREA
IDLER SHEAVE
BOOM POINT SHEAVE
AUX. SHEAVE
y
8 Parts HOOK SHEAVE 7 Parts 6 Parts
nl
O
ce
5 Parts 4 Parts 2 Parts
(This figure is view from the boom tip side.)

en
When use of 7 and 8 parts of line, require to install

the auxiliary sheave block to the boom tip.
er
As to the installation of auxiliary sheave, refer

to the article “5.1.7 INSTALLING THE AUXILIARY
SHEAVE” for the detail.
ef
R
10000A-1
HOOK INSTALLING DIRECTION STRIKER STRIKER
When passing the hoist wire rope to the hook, face the
striker (hook side weight catch) contacting the hook
overhoist limit switch weight to the boom foot side.
Boom foot side Boom foot side
When installing the rope socket to the boom point, pay

attention to the direction of rope socket.
y
Be sure to pass the wire rope through the hook overhoist
limit switch weight.
nl
O
ce
Boom inside Boom outside
Install the bolt from

inside to outside
en
of the boom.
Secure the bolt with a
nut and split pin, and
open the split pin to
approx. 60 degrees.
er
ROPE SOCKET
ef
R

11000-1
6. Load safety device connection
(1) Secure the junction cables or limit switch wiring

to the boom with the hanger.
(2) Connect the attachment wiring to the base
machine junction panel. LOAD
DETECTOR
(3) Check the connection of load detector connector.
(Boom hoist winch plate area)
(4) Connect the cable reel wiring to the boom tip
junction panel.
(5) Connect the hook overhoist cable reel connector.
(6) Check the connection of hook overhoist limit
y
switch wiring to the boom tip junction panel.
nl
If jib or aux. sheave is not used, connect the hook
overhoist limit switch wiring at this time.
For detail of wiring connection, refer to the article “3.3
CONNECTING PROCEDURE OF WIRING”.
O
CONTROLLER
(5)
ce
(4), (6)
en
(3) (2)
(1)
7. Set the crane configuration into the controller

(Overload safety device) by referring the article
“3.5.1 SETTING OF CRANE CONFIGURATION”.
er
ef

serious accident.
R
Type Type of overhoist Type of stop Auto-stop angle

Controller (against ground angle) Approx. 82 degrees to 82.5 degrees
Limit switch (against machine angle) 84.5 degrees to 85.5 degrees
10000A-1
4.3.9 CARBODY WEIGHT INSTALLATION (USING SELF REMOVAL DEVICE)
Do not enter under the weight or stand between

the weight and surrounding object.
y
nl
Be extremely careful of the ratchet lever hoist
handling.
O
1. Preparation of carbody weight installation
(1) This machine’s carbody weight is composed of

ce
two pieces.
Never use the carbody weight other than
specified one.
WEIGHT (1)
en
EACH WEIGHT MASS

Carbody weight Weight
Weight (1) 7.2 t (15,873 lbs)
Weight (2) 7.2 t (15,873 lbs)
er
(2) Before installing the carbody weight, check that

the machine is in the following conditions.
• Boom : Basic boom with 35 t hook, 2 part of line.

ef
• Gantry : Work position

• Ground : Firm and level
• Crawlers : Extended
R
As to the stability in swing and traveling to avoid WEIGHT (2)


11000-1
(3) When installing/removing the carbody weight,

prepare the tools as listed below.
TOOL
• Attached tool set
• Sling wire rope
28 mm dia. (1-3/32″ dia.) × 5 m (17′) × 2
• Shackle 5 t (11,025 lbs) × 4 Max.
approx.
• Ratchet lever hoist 6.3 t (13,890 lbs) × 2 84 degrees
SHACKLE
y
SLING
WIRE ROPE
nl
A
O
RATCHET
LEVER HOIST
ce
SHACKLE
en
CARBODY
View from A WEIGHT
er
ef
R
10000A-1
2. Setting of LMI
When removing or installing the carbody weight,

set up the LMI as the following.
Unless the setting of load safety device, the auto-

stop function will be works and the machine would
not be operated.
y
(1) Press icon on the main screen to display the
nl
menu.
(2) On the selected screen, press icon.
O
ce
en
(3) Crane attachment select screen is displayed.

er
Select “10 (Self removal mode)”.

ef
R

11000-1
(4) The operation select screen is displayed.

Select “3 (C/W removal mode)”.
y
nl
(5) Finally the parts of line input screen is displayed.
Press “0” potion of hook 1.
O
ce
en
(6) The numeral portion turns highlighting and Turn highlighting

displayed numerical keypad.
Press “2”.
er
ef
R
10000A-1
(7) Press .
y
nl
(8) Data is being loaded.
O
ce
en
(9) After data is loaded, the result of selection is

displayed.
er
• If correct, press .
The screen returns to the main screen.
ef
• If not correct, press to restart the input.

R

the result.

11000-1
3. Place the carbody weight on the ground.
70 degrees
y
nl
Approx. 5 to 6 m
(16′ 5″ to 19′ 8″)
O
4. Move the machine closer to the carbody weight
to approx. 3.9 m (12 ft. 10 in.) point.
ce
en
70 degrees
er
Approx. 3.9 m
(12′ 10″)
ef
R
10000A-1
5. Place the boom tip on the ground.

y
nl
second.
O
becomes possible.

ce
en

er
WEIGHT

ef

R


11000-1
6. Set the slings, shackles and ratchet lever hoist

for the carbody weight lift.
y
nl
Approx. 3.9 m
(12′ 10″)
O
7. Setting of LMI

ce
menu.
en

er
ef
R
10000A-1

y
nl
Select “2 (CB/W removal mode)”.
O
ce
en

er
ef
R

11000-1

Press “2”.
y
nl
(7) Press .
O
ce
en

er
ef
R
10000A-1

displayed.
y
the result.
nl
8. Lift up the carbody weight slightly.
O
9. Swing the upper machinery for approx. 4.5
degrees.
4.5 degrees
ce
en
er
ef
R

11000-1
10. Raise the boom to bring the carbody weight

closer.
11. Bring the carbody weight (a) portion to right above

the carbody side hanging bracket and align with it.
Do not enter under the weight or stand between 84 degrees
5,996 mm (19′ 8″)

y
nl
O
BRACKET
handling. (Carbody side) CARBODY
Failure to observe this precaution may result in a (a)
WEIGHT
ce
Detail of carbody weight installation part
en
er
ef
R
10000A-1
12. Lower the ratchet lever hoist and rest the

carbody weight (a) portion to the carbody side
hanging bracket.

handling.
Failure to observe this precaution may result in a 84 degrees
y
nl
RATCHET
LEVER HOIST
Approx. 1.3 m (4′ 3-3/16″)
O
BRACKET
(Carbody side)
(a)
ce
en
er
ef
R

11000-1
13. Insert the carbody weight installation pin and

CARBODY WEIGHT
secure the pin with spring pin. SECURING PIN
(2 places both left and right side)
SPRING PIN

y
nl
O
ce
14. Install the carbody weight (2) as same manner
en
as carbody weight (1).

er
ef
R
10000A-1
15. In case of the carbody weight detecting unit is

equipped (option)
• Connect the detect harness installed on the

front side weight (1) and base machine harness
(CN-914F) and both water proof caps.
• Detect harness installed on the rear side weight
(2) is not required to connect. (No harness is
provided on the base machine rear side)
• If the carbody is not equipped as use of reduced
weight specification, leave the base machine
harness and water proof cap as is.
y
CN-914F
nl
O
ce
en
• When setting the LMI, ensure to select the item STD Reduced
matched with the actual weight configuration.
If wrong item is selected, an error [ML-ME064]
will appear on the monitor and buzzer will sound.
er
In case the carbody weight is not equipped as

ef
reduced weight specification, leave the base

machine harness with cap as is.
R

11000-1

DEVICE)
Do not enter under the revolving frame or

counterweight.
Swing while the crawlers retracted with the
counterweight installed may result in machine
overturning.
y
a serious injury or loss of life.
nl
Counterweight of this machine is composed of 5
pieces.
Do not transport the machine with counterweight on.
O
Firmly tighten the counterweight installation bolts to
prevent them from becoming loose during work.
Never use the counterweight other than specified one.
ce
EACH WEIGHT MASS
Counterweight Weight WEIGHT (4) WEIGHT (5)
WEIGHT (1) 8.31 t (18,300 lbs)
WEIGHT (2), (4) 5.75 t (12,680 lbs)
WEIGHT (2) WEIGHT (3)
WEIGHT (3), (5) 5.75 t (12,680 lbs)
en
WEIGHT (1)
er
ef
R
10000A-1
1. Setting of LMI
When removing or installing the counterweight,


not be operated.
y
nl
menu.
O
ce
en

er

ef
R

11000-1

y
nl
O
ce
en

Press “2”.
er
ef
R
10000A-1
(7) Press .
y
nl
O
ce
en

displayed.
er
ef

R

the result.

11000-1
2. Preparation of counterweight installation
Prior to install the counterweight, confirm the WEIGHT (1)

following conditions are satisfied.
• The ground for assembling is firm and level.

• The base machine is in work condition.
• Secure the place for counterweight assembling.
• Place blocking on the ground where the counter Label
weight (1) to be placed.
WOODEN BLOCK
y
nl
Check the labels to confirm that the counterweights
are of the specified ones for this machine before 18,300 lbs
8,310 kg
assembling.
O
Detail of label
(1) Attach the slings to lifting brackets and lift the

weight (1) and place it on the blocking.
ce
en
WEIGHT (1)
er
WOODEN BLOCK
ef
R
10000A-1
(2) As to the front side links, the link (a) to be

leaned on to the lifting bracket and the link (b)
turns backward.
(3) As to the rear side the links, link (a) to be made
vertical and secure with securing pin and the
link (b) turns backward. LINK (a)
LINK (b)
Do not insert finger or hand into a pin hole when LIFTING
Detail of front side link BRACKET
y
nl
Machine front
O
ce
LINK (b)
en
SPRING PIN
er
LINK (a)
SECURING
ef
PIN
Detail of rear side link

R

11000-1
(4) Place the weights (2) and (3) in order onto the
weight (1).
Do not lift more than one weights at a time.

Lifting brackets may break.
serious injury or loss of life. WEIGHT (2)
WEIGHT (3)
y
nl
O
WEIGHT (1)
ce
(5) Place the weights (4) and (5) in order.
en

WEIGHT (4)
er
serious injury or loss of life. WEIGHT (5)

ef

R

10000A-1
(6) Secure right and left counterweights with

the securing pins accordingly and retain the
securing pins with the spring pins. (8 locations)

y
nl
O SECURING PIN
ce
SPRING PIN
en
er
ef
R

11000-1
4.3.11 MOUNTING THE ASSEMBLED COUNTERWEIGHT TO BASE

MACHINE (USING SELF REMOVAL DEVICE)

y
nl
Place a signalman to prevent an incident from
caught.
O
ce
serious accident.
en
Place the planking as steel plates if the inclination

is 1% or more to the base machine horizontal.
er
If in the case of 1 % or more inclination, the self

removal cylinder and/or its rods may damage due
to uneven loads would be received.
ef

R
Perform the work with engine speed 1,000 min-1

(1,000 rpm) or less.
If exceeded, the cylinder speed becomes faster
and excessive force could be applied on the
cylinder at start or stop of motion.
This may damage the cylinder rod.
damage parts.
10000A-1
1. Travel the machine to the position that the

counterweight lifting links can be connected to
the counterweight lifting point.

y
nl
Assign the signalman at visible place from the
operator.
O
ce
Slowly travel the machine while paying attention
to prevent any interference of the base machine
with the counterweights.
damage parts.
en
er
ef
R

11000-1
2. Set the machine horizontally.
When the translifter is to be used, remove the

counter weights and carbody weights.
If the translifter is used with these weights, the
machine turnover or damage the translifter may be
caused.
serious accident.
y
nl
O
ce
In case of
right hand side is lower
en
er
BLOCK
In case of
front side is lower
ef
R
BLOCK
In case of
rear side is lower
BLOCK
10000A-1
3. As to the rear side links, the link (b) to be raised SPRING

LOCK PIN LINK (c)
and connect with the link (c).
4. As to the front side links, raise the links (a) and

CONNECTING
(b) so that not to interfere with self-removal PIN
cylinder. LINK (b)
Connect the link (b) with the link (c) and secure
the link (a) with the securing pin.
SPRING PIN
y
nl
LINK (a)
SECURING
O
PIN
Detail of front side link

ce
en
er
ef
SPRING
R
LOCK PIN LINK (c)
CONNECTING
PIN
LINK (b)

11000-1
5. Disengage the counterweight securing pin with

using the extension bar.
COUNTERWEIGHT SECURING PIN
Rotate
LOCK PIN
y
EXTENSION BAR SPRING PIN
Engage position
nl
O
Extension bar storage place
ce
Disengage position
6. Connect the remo-con cable to the connecting

en
portion on the self-removal device.

er
ef

R
10000A-1
7. Start the engine with the remote control and the

speed to approx. 1,000 min-1 (1,000 rpm).
ENGINE SPEED
POWER SWITCH CONTROL SWITCH
8. Operate the remote control to lift the counter
weight.

y
nl
When raising or lowering the counterweight,
O
keep the both counterweight cylinders even by SELF REMOVAL DEVICE
CONTROL SWITCH
operating the both at the same time.
If the counterweight becomes uneven, ALWAYS
correct the situation by RISING the “LOWER” side.
If the higher side’s cylinder is lowered, the load
ce
will be concentrated on that cylinder and may be
damaged.
damage parts.
en
Slowly control lifting/lowering the counterweight.

er
serious accident.
ef
While installing and removing the counterweight,

ensure the remote control cable not to get caught.
R
When use of self-removal device for assembling/

disassembling of the counterweight, ensure that
the remote control cable should not get caught
between the frame of self-removal device and the
counterweight.

11000-1
9. Set the counterweight securing pins on both

sides with using the extension bar.
After inserting the securing pin, the extension
bar to be kept to the storage place on the
counterweight (1).
10. Retract the cylinder by approx. 50 mm (2 in.).

The counterweight unit is now supported by
counterweight securing pins.
11. Go up onto weight (1) with using a ladder.

Set the lock pin and spring pin on both sides.
y
nl
When working at a high elevation, be sure to use a
safety belt to prevent falling.
O
ce
Rotate
en
EXTENSION BAR Disengage position

er
ef
LOCK PIN
R
SPRING PIN
Engage position
10000A-1
12. Fully retract the cylinders by controlling the

remote control switch.
y
nl
O
13. Stop the engine with the remote control switch
and disconnect the remote control cable
connector on self-removal device.
ce
en
er
ef
R

11000-1
14. In case of counterweight quantity detect device

is equipped (option).
• Connect all harnesses among the base machine

and each counterweights.
• All the water proof caps also connect together
respectively.
• After connection is completed, secure the
harness with the cramps provided.
• If the number of weight is less as use as
reduced weight, connect the base machine
harness from the lower side in order.
y
nl
O
HARNESS CLAMP
ce
CN-002 or CN-003
HARNESS CLAMP HARNESS CLAMP
CN-001M CN-001M
en
CN-001F CN-001F
CN-843 CN-843
er
Standard counterweight configuration Reduced counterweight configuration
ef

will appear on the monitor and buzzer will
sound.
R
10000A-1
4.4 DISASSEMBLY OF BASE MACHINE

This article explains disassembly of base machine and
loading to trailer for transportation.
Any work on the base machine would be dangerous

if proper procedure is not taken.
Hold a pre-work meeting to go over the procedure to
prevent accident and proceed with the work safely.
y
nl
O
ce
en
• The ground where base machine is placed

during assembly/disassembly may receive
large load.
• Ensure the ground for operation is firm and
level and place the steel plate or improve the
er
ground condition as required.

• Use proper rated assist crane, slings,
ef
shackles and other equipment.

Failure to observe these precautions may
R

11000-1
1. Check points prior to work

procedures.
their condition.
y
2. Securing place
nl
• Select a firm and level space enough for the
task.
Place the planking such as steel plates or crane
mats on the ground as required.
O
and trailer access.
3. Preparation before assembling/disassembling

work
ce
• Secure required number of workers for the
en
work.
• Take appropriate action to keep unrelated
person off the work area other than workers
er
during work.
4. Cautions during assembly/disassembly work

ef
• During work, install the waterproof cap on the

cable end of the hook overhoist preventing
device.
During crane work, remove the waterproof cap
R
and wire the overhoist cable properly.

during work.
part moves.
10000A-1

SELF REMOVAL DEVICE)

y
nl
Place a signalman to prevent an incident from
caught.
O
ce
serious accident.
en

er

ef

R

damage parts.

11000-1
1. If the counterweight quantity detect device is

equipped.
• Disconnect the detect harnesses installed on all

of the counterweights from the base machine
harness.
• After disconnection, put the water proof caps on
both detect and the base machinery harnesses.
y
nl
HARNESS CLAMP
O
CN-002 or CN-003

ce
CN-001M CN-001M
CN-001F CN-001F
en
CN-843 CN-843
Standard counterweight configuration Reduced counterweight configuration

er
ef
R
10000A-1
2. Connect the remo-con cable to the connecting

portion on the self-removal device.
y
nl
O
ce
en
er
ef
R

11000-1
3. Start the engine with the remote control and the

speed to approx. 1,000 min-1 (1,000 rpm).
ENGINE SPEED
4. Control the remote control switch, and fully
extend the both right and left cylinders.

y
nl
O
SELF REMOVAL DEVICE
ce CONTROL SWITCH
en
er
ef
R
10000A-1
5. Go up onto weight (1) with using the ladder.

Pull out the lock pin and spring pin on both
sides.
6. Pull out the weight support pin on both sides

with using an extension bar.

y
nl
O
Rotate
LOCK PIN
ce
EXTENSION BAR SPRING PIN
Engage position
en
er
Extension bar storage place

ef
Disengage position
R

11000-1
7. Lower the weight on firm and level ground. If

needed, place wooded block.
ENGINE SPEED

y
nl
When raising or lowering the counterweight,
keep the both counterweight cylinders even by
operating the both at the same time.
If the counterweight becomes uneven, ALWAYS
O
correct the situation by RISING the “LOWER” side. SELF REMOVAL DEVICE
CONTROL SWITCH
If the higher side’s cylinder is lowered, the load
will be concentrated on that cylinder and may be
damaged.
ce
damage parts.
en
Slowly control lifting/lowering the counterweight.

serious accident.
er
ef
R
10000A-1


y
nl
damage parts.
O
ce
When use of self-removal device for assembling/
disassembling of the counterweight, ensure that
the remote control cable should not get caught
between the frame of self-removal device and the
counterweight.
en
er
ef
R

11000-1
8. As to the front side links, remove securing pin SPRING

LOCK PIN LINK (c)
and draw out the connecting pin.
The link (a) to be turned inside so that not to
interfere with the self-removal cylinder and turn
CONNECTING
the link (b) backward. PIN
LINK (b)
9. As to the rear side link, draw out the connecting

pin and turn the link (b) backward.
SPRING PIN
y
nl
LINK (a)
SECURING
O
PIN
Detail of front side link

ce
en
er
ef
SPRING
R
LOCK PIN LINK (c)
CONNECTING
PIN
LINK (b)
10000A-1
10. Travel straight to keep the base machine away

from the counterweights.

y
nl
Assign the signalman at visible place from the
operator.
O
Slowly travel the machine while paying attention
to prevent any interference of the base machine
with the counterweights.
ce
damage parts.
en
er
ef
R
11. Stop the engine with the remote control switch

and disconnect the remote control cable
connector on self-removal device.

11000-1
4.4.2 DISASSEMBLY OF THE COUNTERWEIGHT

1. Setting of LMI
When removing or installing the counterweight,


y
not be operated.
nl
menu.
O
ce
en
er

ef
R
10000A-1

y
nl
O
ce
en

Press “2”.
er
ef
R

11000-1
(7) Press .
y
nl
O
ce
en

displayed.
er
ef

R

the result.
10000A-1
2. Remove the spring pins and securing pins

accordingly (8 locations).

y
nl
O SECURING PIN
ce
SPRING PIN
en
er
ef
R

11000-1
3. Remove the weights (4), (5), (2) and (3) one by

one in order.

WEIGHT (4)
Failure to observe this precaution may result in a WEIGHT (5)
y
nl
O
WEIGHT (2)
WEIGHT (1)
ce
WEIGHT (3)
4. Lay down the counterweight side links outside

en
as shown onto the counterweight (1)

er
ef
R
10000A-1
4.4.3 CARBODY WEIGHT REMOVAL (USING SELF REMOVAL DEVICE)

y
nl
handling.
O
1. Preparation of carbody weight removal

ce
two pieces.
EACH WEIGHT MASS

Carbody weight Weight WEIGHT (1)
en
Weight (1) 7.2 t (15,873 lbs)

Weight (2) 7.2 t (15,873 lbs)
(2) Before removing the carbody weight, check that

er
• Boom : Basic boom with 35 t hook, 2 part of line.

ef
R

SWING AND TRAVEL STABILITY”. WEIGHT (2)

11000-1
(3) When installing/removing the carbody weight,

TOOL
• Sling wire rope
28 mm dia. (1-3/32″ dia.) × 5 m (17′) × 2
• Shackle 5 t (11,025 lbs) × 4 Max.
approx.
• Ratchet lever hoist 6.3 t (13,890 lbs) × 2 84 degrees
SHACKLE
y
SLING
WIRE ROPE
nl
A
O
RATCHET
LEVER HOIST
ce
SHACKLE
en
CARBODY
View from A WEIGHT
er
ef
R
10000A-1
2. Setting of LMI
When removing or installing the carbody weight,


not be operated.
y
nl
menu.
O
ce
en

er

ef
R

11000-1

y
nl
(5) Finally the parts of line input screen is
displayed.
O
ce
en

Press “2”.
er
ef
R
10000A-1
(7) Press .
y
nl
O
ce
en

displayed.
er
ef

R

the result.

11000-1

degrees.
4.5 degrees
4. Install the shackles to the carbody weight and

connect the sling from ratchet lever hoist.
y
nl
RATCHET
LEVER HOIST
O
Max.
approx.
84 degrees
SHACKLE
SHACKLE
ce
SLING
WIRE ROPE
CARBODY
WEIGHT A
View from A
en
er
ef
R
10000A-1
5. For the model equipped with weight detect

harness (CN-914F) at the front side of the main
machinery, disconnect the harness and apply
the waterproof caps on both weight and the
main machinery sides.

y
CN-914F
nl
O
ce
en
er
ef
R

11000-1
6. Remove the carbody weight securing pins.

CARBODY WEIGHT
SECURING PIN
SPRING PIN

y
nl
O
ce
en
er
ef
R
10000A-1
7. Lift up the ratchet lever hoist to leave the (a)

portion of the carbody weight from the carbody
hanging bracket.

Failure to observe this precaution may result in a 84 degrees
y
nl
RATCHET
Be extremely careful of the ratchet lever hoist LEVER HOIST
handling.
O
BRACKET
serious injury or loss of life. (Carbody side)
(a)
ce
en
8. Lower the boom slightly and move the carbody

weight away from the base machine.
9. Lower the boom further and place the weight to

er
the ground and disconnect the slings.

ef
R
10. Remove the carbody weight (2) as same

manner as carbody weight (1).

11000-1
11. Place the boom tip on the ground.

y
nl
second.
O
becomes possible.

ce
en

er
WEIGHT

ef

R

10000A-1
12. Remove the slings and ratchet lever hoist from

the boom base.
y
Remove Remove
nl
13. Setting of LMI

menu.
O
ce
en
er

ef
R

11000-1

y
nl
O
ce
en

Press “2”.
er
ef
R
10000A-1
(7) Press .
y
nl
O
ce
en

displayed.
er
ef

R

the result.

11000-1
14. Place the carbody weights on the track.
y
nl
O
ce
en
er
ef
R
10000A-1
4.4.4 WINDING UP THE FRONT DRUM WIRE ROPE
Confirm that the hook is placed in the stable

condition.
1. Remove the rope socket and clamp from the

wire rope end.
y
nl
SPLIT PIN CLAMP
O
ce
ROPE SOCKET
2. Remove the hook overhoist limit switch and

weight from the left side bracket on the tip end
of the boom..
en
LIMIT SWITCH
SHACKLE
er
WEIGHT LIFTING
WIRE ROPE
WEIGHT
ef
R

11000-1
3. Slowly operate the front drum control lever

to wild up the hoist wire rope onto the
corresponding drum and be careful not to tangle
the hoist wore rope with sheave (s).

hands.
y
nl
being entangled.
O
• Keep away from rope end when removing
the wire rope if may suddenly jump and
cause injury.
ce
4. Fix the wire rope end to the drum outer layer

with a steel wire after winding up.
en
er
ef
R
10000A-1
4.4.5 REMOVING THE BOOM GUY LINE

1. Set the spreader guide to the work position, and GUIDE SECURING PIN
slowly loosen the boom hoist wire rope. SPREADER GUIDE
2. Refer to the article “5.1.3 HANDLING OF

SPREADER GUIDE” for how to use spreader
guide.
Stowed position
y
Place a signalman to prevent accident from rotating
drum.
nl
serious injury.
GUIDE
SECURING PIN
O
ce
Work position
3. Use the spreader guide, and install the upper

spreader on the boom base with the spreader
securing pin.
en
Be sure to support the spreader guide with hands,

er
when removing the pin and handling the guide.

ef
SPREADER
SECURING PIN
R
If in case of difficulty to stow the spreader due

to incline of it, wind boom hoist wire rope a bit to
leave the spreader from the guide and attempt to
stow it again.
Move the spreader up and down by mean of
shaking the boom hoist wire rope to obtain
alignment easier between spreader and lower
boom securing holes.

11000-1
4. Disconnect the guy lines from the upper spreader.

UPPER SPREADER
Put the connecting pins back to the upper
SPLIT PIN GUY LINE
spreader.
Remove the
guy line connecting pins.
y
SPLIT PIN GUY LINE
nl
O
ce
en
er
ef
R
10000A-1
4.4.6 DISASSEMBLING THE BOOM TIP

1. Operate the boom hoist control lever to tighten
the boom hoist wire rope to remove load from
the bottom connector section.
2. Draw out the connecting pin (double tapered)

from outside of the bottom connecting part.
SPRING LOCK PIN
y
attachment being assembling/disassembling. CONNECTING PIN
nl
(Double tapered)
SPRING
LOCK PIN
O
ce
en

er

ef
R

11000-1
3. Hold the boom tip with the assist crane. SPRING LOCK PIN
Place a wooden block under the boom base tip
section and lower the boom base.
Then draw out the top connecting pins (with
flange).
CONNECTING PIN
Do not stand on, or enter under/inside of the (With flange)
y
nl
O
ce
en

er
ef
R
10000A-1
4.4.7 LOWERING THE GANTRY

y
nl
O
ce
hands.
en

being entangled.
er
ef
Ensure to perform the gantry raising/lowering

work with the boom placed on the wood blocking
of approx. 100 mm (3-15/16 in.) in height.
R
Take extra care on slack or tension of the boom.

damage the parts.

11000-1
1. Start the engine and set the speed to LOW

(800 min-1 [800 rpm]).
2. Turn the boom drum control lever to lowering

side and pay out the boom hoist wire rope
slowly until the ropes are placed on the boom
base and the gantry.
At this time take extra care not to cause
entangling of wire rope or derailing from the
sheave.
y
nl
O
ce
en
er
ef
R
10000A-1
3. Pull out the travel kit securing pin from the travel
kit and remove the travel kit from the stopper.
4. Take out the spring lock pin and pull out the
gantry securing pin from the gantry both right
and left sides and store them to the holders.

y
nl
O
SPRING
LOCK PIN
ce
TRAVEL KIT
SECURING PIN
TRAVEL KIT
STOPPER
en
SPRING
LOCK PIN
GANTRY
er
SECURING PIN
ef
R
GANTRY SECURING
PIN HOLDER
(Stored position)
SPRING LOCK PIN

11000-1
5. Start the engine and set the speed to approx.

1,000 min-1 (1,000 rpm).
Far side :
Raising side
6. Turning the gantry control switch to lowering
side (inward) to lower the gantry.
At this time, pay out the boom hoist rope to
prevent the boom from becoming lifted. Near side :
Lowering side
GANTRY CONTROL SWITCH
y
nl
O
• When the gantry is raised or lowered, make
sure that there is no persons around the
gantry area and observe the raising or
lowering condition of the gantry.
ce
• Before operating the gantry control switch,
sound the horn to warn the person around.
en

• During crane work or raising the boom, do
not operate the gantry control switch.
Failure to observe this precautions may
er
ef
Never raise the gantry using the boom hoist wire

rope or using the assist crane.
The gantry may suddenly drop immediately when
R
the gantry securing pin is pulled out during gantry

lowering.
10000A-1
7. Secure the travel kit links on both right and left

side with travel kit securing pin and retain with
the spring lock pin.
Ensure to connect the travel kit as shown,

otherwise the boom may fall down when the
gantry is in low position.
y
nl
SPRING LOCK PIN
O
ce
TRAVEL KIT
TRAVEL KIT SECURING PIN
en
8. Winding up of the boom hoist wire rope to BOOM HOIST WIRE ROPE
suspend the boom base.
er

ef

attachment.
R

• Do not stand on component being connected
or disconnected.
Failure to observe these precaution may
result in a serious injury or loss of life.

11000-1
4.4.8 REMOVAL OF LADDER FOR MACHINERY GUARD

1. Remove the securing pin from left hand side
bracket and turn the ladder.
y
nl
O
SECURING PIN
ce
en
2. Lift up the ladder and remove from the right

hand guide.
er

ef

R
10000A-1
4.4.9 RETRACTING THE CRAWLERS

The crawler retracting procedure is explained in this
section.
Perform the crawler extending/retracting work under Approx.

the following conditions. 10 degrees
Axle insert area

• Place
Check a firm and level space enough for the task.
Also, confirm steel plates or crane mats is
placed if necessary.
y
• Base machine configuration
nl
Counterweight : None
Boom : Boom base only
Boom angle : Approx. 10 degrees
O
* Although the crawler extending/retracting
can be done without the boom base, this
article explains the procedure with boom base
attached.
ce
en
serious accident.
er
Prior to extending/retracting, clean the axle extension

thoroughly and apply grease (Molybdenum disulphide
grease) to the slide area.
If mud is left on, extension or retraction work could be
ef
difficult.
R

axle.

11000-1
1. Remove the securing lock pin for crawler ext./

ret. cylinder on the crawler frame side. SECURING PIN
2. Extend the crawler extension cylinder and align

with the crawler frame side hole and the insert
securing pin.
CRAWLER EXT./RET.
CYLINDER
Keep out of the spaces under the lifted crawler frame

or between the machine and the crawler frame avoid
y
being trapped.
nl
serious injury or loss of life. SPRING LOCK PIN
O
ce
3. Swing the main machinery to widen the

SHIM
clearance between the crawler and axle and
en
remove the adjusting shims at four places.

Each shim has a unique number stamped and
CRAWLER FLAME
stow it accordingly.
AXLE
er

ef
removing the shim.

serious injury.
R
10000A-1
4. Take out the securing pin (a) connecting the

carbody and link.

PIN HOLE
(At retracting)
y
nl
SECURING PIN (a)
O
CARBODY SIDE
BRACKET
ce
PIN HOLE
(At extending)
en
5. Face the upper machinery to the front.

er
To prevent overturn of the base machine ensure to

engage the swing brake and lock.
Failure to observe this precaution may result in a Retracting Retracting
ef
side side
serious accident.
R

11000-1
6. Check to see that there are obstacles in the

area of crawler retraction.
Turn the crawler retract switch to retracting Far side :
Extending side
side. If the crawler can’t be retracted smoothly,
repeats manipulate the switch both sides for
extending and retracting or travel forward and
backward. Near side :
Retracting side
CRAWLER EXTEND SWITCH
y
nl
O
7. If the crawler still can’t be retracted with the step
6 above performed due to bad ground condition,
swing the upper machinery slowly to toward the
side of the crawler desire to be retracted until
the upper machine comes to right angle with the
ce
crawler.
In this case, ensure to make the crawler to be Retracting side
retracted comes to the front side (operator cab
side).
en
8. Insert the securing pin (a) when the crawler

connecting link come fully retracted position.
er
ef
R
SECURING PIN (a)
SECURING PIN (a)
10000A-1
9. Remove the rotation preventive brackets from ROTATION PREVENTIVE BRACKET

(Installation place)
the pivot area of the axle extension and place
them to storage places at all 4 locations.
y
nl
ROTATION PREVENTIVE BRACKET
(Stowed place)
10. Remove the axle extension securing pins on the
O
crawler frame. AXLE EXTENSION
SECURING PIN
ce
en
SPRING PIN
er
ef
R

11000-1
11. Rotate all 4 axle extensions for 90 degrees AXLE EXTENSION SECURING PIN
toward the frame to make them right angle with
axles.
12. Secure the axle extension to the crawler frame

with the axle extension securing pin and insert
the spring pin on all 4 locations.
Pay attention to the installation direction of axle
SPRING PIN
extension securing pin for safety as shown.
y
nl
AXLE EXTENSION
O
ce
ext./ret. cylinder with the crawler frame and SECURING PIN
The removed securing pin is to be inserted to
the crawler side pin hole and secure with the
spring lock pin.
en
CRAWLER EXT./RET.
CYLINDER

er

SPRING LOCK PIN
ef
R

extend or retract.
part of cylinder.
damage the parts.
10000A-1
4.4.10 BASE MACHINERY LOADING ONTO TRAILER

Check the following points before starting the work.
• Place
Ground must be firm and level.
The ground has been improved and steel plates
have been placed.
• Meeting for work procedure and safety

Prior to work, a meeting must be held to review
the work procedure and safety with all personnel
y
and confirm of each personnel’s roles and
responsibilities.
nl
• Pre-work inspection
Conduct the pre-work inspection.
O
• Transportation dimensions, mass
Transporting the base machinery on a trailer
may require permit(s) issued by the related
authority(ies).
Refer to the article “8.2 DIMENSION, WEIGHT
ce
OF EACH COMPONENT”.
Prepare proper trailer for the machinery weight
and size.
• Transportation figure
en
Set the boom angle between 5 degrees to 10

degrees range.
Adjust the angle so that the boom will not hit the
trailer during loading to the trailer.
Boom angle also must be adjusted to fit within
er
the allowable transport height.

ef
Do not raise the boom to higher than 10 degrees

angle when loading into trailer.
The machine may overturn backward.
R


11000-1
1. Start the engine and set the speed to low.

(800 mim-1 [800 rpm])
Swing the upper machinery to parallel with the
crawler and engage the swing lock and brake.
2. Loading the machine onto trailer using the

loading ramp with the drive tumbler at rear side.
Do not swing the upper machinery on the trailer to
y
avoid the machine overturning.
nl
serious accident.
O
Ensure to connect the travel kit as shown,
otherwise the boom may fall down when the
gantry is in low position.
ce
en
The gravity center may shift suddenly at the

border between the loading ramp and the trailer.
Set the travel speed select switch to LOW and
er
travel with slow and constant speed.

ef
R
LOADING RAMP TRAILER

Set angle as small as possible. (Less than 15 degrees)
10000A-1
3. Secure the lower machinery to the trailer with

proper gears (tie downs and binder chains) to
prevent it from shifting during transportation.
y
PROTECTIVE TIE DOWNS, BINDER CHAINS
CLOTH
nl
4. Close and lock the cab door, window and guard
doors.
O
ce
en
er
ef
R

11000-1
4.4.11 STORE AND REMOVAL OF CAB STEP

Stow or remove the cab step by the following procedure
for transportation.
To make transportation width to 2,990 mm (9 ft. 10

in.), remove all side steps completely.
y
Stowed position
nl
Extended position
O
CAB STEP
SECURING PIN
ce
ADJUSTING BOLT
1. Store the cab step

en
(1) Rotate the cab step to upward.

(2) Slide the step to lower side for storage position
and secure the steps with the securing pins
respectively.
er
ef
Stowed position
R
Extended position
10000A-1
2. Removal of cab step

BRACKET TO PREVENT UNHINGED
(1) Remove securing pin from the bracket for
prevent unhinge the step and remove the SECURING PIN
bracket.
(2) Rotate the step to approx. 85 degrees.

At this time care the step not to interfere with
y
the guard and cab.
nl
O
ce
(3) Lift the step and remove the securing part of
installation bracket from the guard.
en
INSTALLATION BRACKET
er
Pull out
ef
(4) W h e n d i s e n g a g e t h e s e c u r i n g p a r t , t h e
installation bracket will rotate by its self-weight
and remove the step toward to pull closer from
the guard.
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INSTALLATION BRACKET

11000-1
4.5 TRANSPORTATION
In case of transport the machine or an attachment
with trailer/track, there will be various combinations in
deferent weight, size or type of trailer/track and the fleet
configurations.
Carefully review the dimensions and weight of

components for a safe transportation.
There will be limitations on the size and weight due to

regulations.
y
Submit the necessary document to obtain the permit(s)
from the respective authority(ies).
nl
For the details, refer to the applicable traffic regulations.
Refer to the article “9.2 DIMENSION, WEIGHT OF

EACH COMPONENT”.
Do not make excessive loading limit or dimension
O
ce
limit.
Do not perform unreasonable transportation since it
may lead to accident involving person or property.
en
Check if the base machine has been made following

conditions before transportation.
• Make sure that the swing lock, each drum lock

er
are engaged.
• Make sure that each control lever, switch are in
neutral or at stop position.
• Make sure that the room lights or outside lights
ef
are off and the engine is stopped.

• Make sure that the steps, mirrors, hand rails or
any protruding object are stowed or removed.
• Place the wood blocking between the carbody
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or axle extension and the trailer bed to prevent

the machinery from slipping.
• Securely tie-down the load onto the trailer/track
firmly with proper gears (tie downs and binder
chains) to prevent them from shifting during
transportation.
• In case of transportation with the crawler
removed, do not secure by the axle extension.
Secure at the axle.
10000A-1
4.6 INSTALLATION/REMOVAL OF BOOM BASE

4.6.1 BOOM BASE INSTALLATION
The boom base installation is explained here.
Prior to work, check the machine condition again.
• Machine must be placed on the firm and level

ground.
• The crawlers are extended.
• Securing pins are installed to the crawlers and
the shims are inserted on the axles.
y
nl
O
1. Apply grease on the boom foot pins and pin holes.

ce
Confirm no foreign particle on the pin and pin
hole.
2. With use of proper rigging equipment and

method, lift up the boom base with an assist
en
crane and install it to the base machine.

When lifting the boom, should be lifted
horizontally.
Secure the backstop to prevent it from coming off.
er
ef
TIE-ROPE BACKSTOP
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BOOM BASE

11000-1
3. Align the boom foot pin hole on both sides and BOOM BASE
insert the right side pin from inside then the left. SHIM
Insert the lock pins from top to bottom and fix
BOOM BASE
them with the split pins.
BOOM FOOT PIN
4. To reduce the gap between the boom base and

the swing frame, insert shims while inserting the
foot pins.
Do not use hammer to force the shim into the
SPLIT PIN
gap.
LOCK PIN
SWING FLAME
y
(Inside)
Boom foot area
nl
O
5. Place the boom base connector portion on the
wood blocking and remove the sling wire rope.
ce
en
6. Apply grease to the left and right boom foot pins

at the grease fittings.
er
GREASE FITTING
ef
Boom foot area

R
7. Connect the cable reel and angle detector

wiring refer to the article “3. LOAD SAFETY
DEVICE”.
10000A-1
4.6.2 BACKSTOP INSTALLATION

1. Lift and support the back stop outer pipe by
an assist crane and sliding out the inner pipe SPRING LOCK PIN
SWING FLAME
toward to base machine.
2. Align the pin holes between the swing frame

and the backstop and insert the securing pin
from inside. (Both sides) SWING FLAME
SECURING PIN
3. Insert the spring lock pin to the securing pin.
y
SECURING BACKSTOP
PIN
nl
aligning, inserting or removing pin. BACKSTOP
Failure to observe this precaution may result in a SPRING LOCK PIN
O
serious injury or loss of life. *Insert the securing pin from inside of swing frame
ce
Do not stand under, or on inline or projection of
the backstop to prevent accident.
en
er
Insert pin from inside.

ef
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11000-1
4.6.3 UPPER SPREADER INSTALLATION

1. Lift the upper spreader by an assist crane and
align the holes of upper spreader and boom SHACKLE
UPPER
base tip bracket. SPREADER SPREADER
SECURING PIN
2. Inserting the spreader securing pins and be

secure the upper spreader.
(This pin will be removed after the boom hoist BOOM BASE
wire rope has been reeved between lower and TIP BRACKET
upper spreader.)
y
nl
O
ce
en

attachment.
er
ef
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10000A-1
4.6.4 REEVING BOOM HOIST WIRE ROPE

This is to explain reeving method when the boom hoist LOWER SPREADER
wire rope has been wound on the boom hoist drum. UPPER SPREADER

hands.
y
nl
being entangled.
O
1. Turn the boom drum control lever to lowering UPPER SPREADER

side to pay out the wire rope from the boom
ce
drum. 12
10
2
2. Reeve the wire rope through the upper spreader 8
6
and the lower spreader preventing with the 4
wire rope from twisting, kink or coming out of
en
sheaves.
11
3
9
er
7 5
Be sure to follow the instruction of reeving order
of wire rope.
Otherwise wire rope interference may occur and
result in a strand cut or damaged rope. 13
ef
Failure to observe this precaution may lead to 1 LOWER SPREADER

damage the parts.
GANTRY PEAK SHEAVE
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engine. LOAD CELL
CONNECTING PLATE
position, the engine can start. BOOM DRUM

11000-1
3. Secure the wire rope end to the winch link using

the rope socket, wedge and clamp.
CLAMP
WEDGE
SOCKET
attachment.
y
LINK
LOAD
in a serious injury or loss of life. DETECTOR BOOM DRUM
nl
O
ce
en
er
ef
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10000A-1
4.6.5 INSTALLATION OF BOOM HOIST WIRE ROPE TO THE DRUM

engine.
y
nl
O
hands.
ce
being entangled.
en
1. Secure the wire rope end to the boom hoist Do not allow wire rope
drum with the wedge. to come out of wedge end.
er
2. Wind up the wire rope to the boom drum.

ef
R
Correct Protrusion Inverse insertion

11000-1
4.6.6 WINDING UP OF BOOM HOIST WIRE ROPE TO THE DRUM

This is to explain boom hoist wire winding method to
the drum.

y
attachment.
nl
O
1. Confirm if the upper spreader is securing with LOWER SPREADER
the pin to the boom base tip bracket. UPPER SPREADER
ce
2. Disconnect wire rope end from the link on the
winch.
en
CLAMP
WEDGE
er

SOCKET
hands.
ef
• Take extra care to work on the moving wire LINK

LOAD
to prevent accident of being crushed or DETECTOR BOOM DRUM
being entangled.
R

10000A-1
3. Wind the wire rope to the boom drum.

Far side :
Taking care while winding the wire rope, give BOOM DRUM CONTROL LEVER
Lowering side
adequate tension on the rope and so that not to
rough spooling by tapping the hummer.
Near side :
Raising side
y
4. After the wire rope winding is completed, secure
nl
the wire rope end to the outer layer on the drum
with the thin wire.
O
ce
en
er
ef
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11000-1
4.6.7 UPPER SPREADER REMOVAL

The upper spreader removal after the boom hoist wire
rope is wound up to the drum is explained here. SHACKLE
UPPER
SPREADER SPREADER
SECURING PIN
1. Remove the spreader securing pins at the boom
base tip bracket.
2. Lift the upper spreader by assist crane and BOOM BASE

lower it to the ground. TIP BRACKET
y
nl
O
ce
en

attachment.
er
ef
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10000A-1
4.6.8 BACKSTOP REMOVAL

1. Support the backstop outer pipe with an assist
SPRING LOCK PIN
crane.
SWING FLAME
2. Remove the spring lock pin and securing pin

from swing frame and slid in the back stop inner
pipe toward to the boom base tip side.
SWING FLAME
Removed securing pins and spring pins are to
SECURING PIN
be installed on the backstop side.
y
SECURING BACKSTOP
PIN
nl
Failure to observe this precaution may result in a BACKSTOP
SPRING LOCK PIN
O
ce
Do not stand under, or on inline or projection of
the backstop to prevent accident.
en
3. Secure the backstop to the boom base with

TIE-ROPE BACKSTOP
tie-rope while supporting the backstop with an
er
assist crane. (Both sides)

ef
BOOM BASE
R

11000-1
4.6.9 REMOVAL OF BOOM BASE

Although this machine is designed to transport with the
boom base attached, this article explains the removal
procedure of the boom base if it becomes necessary
to transport with the boom base removed.
Prior to work, check the machine condition again.
• Machine must be placed on the firm and level

ground.
• The crawlers are extended.
y
• Securing pins are installed to the crawlers and
the shims are inserted on the axles.
nl
O
ce
Do not stand or work under, inside or on the boom
en
structure to prevent accident due to sudden fall of

the attachment.
er
1. Remove the wiring of the cable reel and the

angle detector refer to the article “3. LOAD
SAFETY DEVICE”.
ef
2. Place the boom base connector portion on to

the wooden block and support the boom base
with an assist crane.
R
10000A-1
3. Pull out the cab side (right side) boom foot pin BOOM BASE
first and then left side foot pin. SHIM
Remove the shims too while removing the foot
BOOM BASE
pins.
BOOM FOOT PIN

SPLIT PIN
LOCK PIN
serious injury or loss of life. SWING FLAME
y
(Inside)
Boom foot area
nl
4. Travel the machine backward slightly and lower
the boom base on the ground with the assist
crane.
O
ce
en
er
ef
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11000-1
4.7 CARBODY WEIGHT INSTALLATION (WHEN USING ASSIST

CRANE)
4.7.1 CARBODY WEIGHT INSTALLATION

y
nl
O
two pieces.
specified one.
WEIGHT (1)
ce
EACH WEIGHT MASS
Weight (1) 7.2 t (15,873 lbs)
Weight (2) 7.2 t (15,873 lbs)
en
er
ef
WEIGHT (2)
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10000A-1



y
nl
(3) When installing or removing the carbody weight,
O
TOOL

ce
• Assist crane 25 t (55,120 lbs) capacity
• Sling wire rope
25 mm dia. (2-15/16″ dia.) × 8 m (26′) × 2
• Shackle 10 t (22,050 lbs) × 2
en
2. Carbody weight installation
(1) Attach the shackles to the lifting brackets of the

weight(1) and lift up with the assist crane.
er

ef

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(2) Bring the carbody weight (a) portion to right

BRACKET CARBODY
above the carbody side hanging bracket and (Carbody side) WEIGHT
(a)
rest it on the bracket.

11000-1
(3) Insert the carbody weight installation pin and

CARBODY WEIGHT
(2 places both left and right side)
SPRING PIN

y
nl
O
ce
(4) Install the carbody weight (2) as same manner
en

er
ef
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10000A-1

equipped (option)

front side weight and base machinery harness
(CN-914F) and both water proof caps too.
• Detect harness installed on the weight (2) is not
to be connected.
• If the carbody weight is not equipped as use
as reduced weight, leave the base machinery
harness with cap as is.
y
CN-914F
nl
O
ce
en
er

ef

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11000-1
4.7.2 CARBODY WEIGHT REMOVAL

y
nl
two pieces.
EACH WEIGHT MASS

O
Weight (1) 7.2 t (15,873 lbs)
Weight (2) 7.2 t (15,873 lbs)

ce

en

er

ef

R
TOOL

• Assist crane 25 t (55,120 lbs) capacity
• Sling wire rope
25 mm dia. (2-15/16″ dia.) × 8 m (26′) × 2
• Shackle 10 t (22,050 lbs) × 2
10000A-1
2. Carbody weight removal
(1) For the model equipped with weight detect

y
reduced weight specification, leave the base CN-914F
nl
O
ce
en
er
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11000-1
(2) Remove the carbody weight securing pin and

CARBODY WEIGHT
SPRING PIN

y
nl
O
ce
(3) Lift the carbody weight with an assist crane and
en
BRACKET
detach from the carbody side hanging bracket. CARBODY
(Carbody side)
WEIGHT
er

ef
(4) Remove the carbody weight (2) as same

R
10000A-1
4.8 SELF REMOVAL CYLINDER (OPTION) INSTALLATION/

REMOVAL
This article is to explain the installation method of
self removal cylinder to the boom base, although the
transportation can be made with cylinder equipped.
1. Place the cylinder on the stable wooden block.

CYLINDER CYLINDER HANGING BRACKET
2. Connect the cylinder head to cylinder hanging

bracket with the securing pin and secure with
y
washer and split pin.
nl
WASHER
SPLIT PIN
SECURING PIN
O
WOOD BLOCKING
ce
3. The securing pin and spring pin for cylinder SPRING PIN
storage to be leave as is. SECURING PIN
en
er
4. Travel the base machine to meet the self removal

cylinder hanging bracket and its installation part
on the boom base tip.
ef
Installation
part
R

11000-1
5. Lower the boom base and connect the self

removal cylinder hanging bracket and its
installation part with the securing pin, washer
and split pin (2 locations on the left and right)
y
nl
WASHER
O
SECURING PIN SPLIT PIN
ce
6. Attach a link on the bracket for cylinder storage.
7. Install the assembled cylinder storage bracket CYLINDER STORAGE BRACKET

with the U-bolts, washers and nuts to the boom
base near the cable reel. NUT, WASHER
en
SECURING PIN
LINK
er
SPLIT PIN
U-BOLT
ef
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811 mm Storage bracket

(2′ 8″) installation position
10000A-1
8. Connect two hydraulic hoses between the valve

on the boom foot area and cylinder.
9. Clamp the hoses to the cylinder securing bracket

and boom base.
Secure with Clamp the hose length in

the clamp this range is to be adjusted
605 mm (2′).
Secure with Clamp the hose length in
y
the clamp this range is to be adjusted
433 mm (1′ 5″).
nl
Connect
To self removal
cylinder rod side
O
Connect
View from A (Clamping for cylinder storage bracket portion)

ce
en
A
er
500 ′ 8″)
(1
ef
mm
960 mm
(3′ 2″) 980 mm
(3′ 2″) 1,060 mm
(3′ 6″)
R
Secure with the clamp Secure with the

clamp
Secure with the clamp
Clamping for cylinder storage bracket portion Boom clamp portion Boom clamp portion

11000-1
10. Connect 2 hydraulic hoses from the base

machine to the valve on the boom foot portion.
Connect
y
nl
O
11. Raise the boom base slowly.
ce
en
er
ef
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12. The removal of the cylinder is to be performed

as reverse order as installation.
10000A-1
4.9 SELF REMOVAL CYLINDER (OPTION) TAKEOUT/STORAGE

4.9.1 TAKEOUT OF CYLINDER
1. Connect two hydraulic hoses from the base
machine to the valve on the side of boom foot.
Connect
y
nl
O
ce
en
er
ef
R

11000-1
2. Remove the link and securing pin and spring pin

for secure the cylinder.
The securing pin and spring pin are to be
reinstalled to cylinder side pin hole.
CYLINDER STORAGE BRACKET
LINK
y
SECURING PIN
SELF REMOVAL
CYLINDER
nl
SPRING PIN
O
ce
en
er
ef
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10000A-1
3. Raise the boom base up to 84 degrees.
4. Manipulate the self removal cylinder control

switch in the operator’s cab and extend the
cylinder. 84 degrees
y
Left : Retract cylinder
nl
Right : Extend cylinder
O
ce
SELF REMOVAL CYLINDER CONTROL SWITCH
en
er
ef
R

11000-1
5. Hold the end of cylinder rod and take off from

the storage hook.
While removing the cylinder, extra care for

unexpected movement.
serious injury.
y
nl
STORAGE HOOK
O
6. Lower the boom base to approximate 50
degrees and manipulate the control switch in the
operator’s cab to retract the cylinder.
ce
50 degrees
en

er

ef

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10000A-1
4.9.2 STORAGE OF CYLINDER

1. Raise the boom base up to 84 degrees.
84 degrees
y
nl
O
ce
en
er
ef
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11000-1
2. Extend the self removal cylinder and hold the

end of cylinder and hang to the storage hook.
y
nl
STORAGE HOOK
O
3. Manipulate the self removal cylinder control
switch in the operator’s cab and retract the Left : Retract cylinder
cylinder.
ce
en

er
ef
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10000A-1
4. Lower the boom base.
Do not lower the boom with the extended cylinder.

The cylinder may interfere with the carbody.
damaging the cylinder.
5. Insert the securing pin when align the hole for
y
CYLINDER STORAGE BRACKET
the link and self removal cylinder side.
Insert the spring pin to the securing pin.
nl
LINK
SECURING PIN
SELF REMOVAL
CYLINDER
O
SPRING PIN
ce
en
er
6. Store the hoses as shown.

ef
R

11000-1
4.10 CRAWLER INSTALLATION/REMOVAL (USING SELF

REMOVAL CYLINDER [OPTION])
4.10.1 INSTALLATION OF CRAWLER

Installation method of crawler has 2 ways, one is use
of self removal cylinder and other is use of assist
crane.
As occasion, carry out the assembly with the safer way.
1. Preparation of crawler installation
y
TOOL
nl
• Translifter
• Corner protectors
• Shackle 10 t (20,050 lbs)
O
• Shackle 5 t (11,025 lbs) × 4 SELF REMOVAL
CYLINDER
• Sling wire rope
16 mm dia. (20/32″ dia.) × 1.5 m (7′) × 4
ce
When the translifter is to be used, set the machine
on the level and firm ground. When the translifter
en
is used on inclined or soft ground, a serious

accident such as overturning of the machine or
damaging the translifter may be caused.
serious accident.
er
ef
When the translifter is to be used, remove the

counter weights and carbody weights.
If the translifter is used with these weights, the
R
machine turnover or damage the translifter may be

caused.
serious accident.
10000A-1
Ensure the translifter must be secured at work Storage position

position for working.
If secured it for transportation position lead to
turn-over while swinging.
serious accident or loss of life. Work position
Transport position
y
nl
Check if there is any abnormality on the ground
condition of the float contacting area to prevent
overturning of the machine.
O
serious accident.
ce
• After contacting the float to the ground, the
vertical cylinder can be able to control one
by one.
en
• To avoid the turnover of the machine, keep

the machine horizontally with monitoring a
leveler while translifter is in operation.
er
• Ensure all four floats should be contacting

with the ground evenly.
ef
To prevent overturn of the base machinery, ensure

R
to engage the swing brake and lock when handling

the translifter.
serious accident.

11000-1
(1) Swing the upper machinery to right angle

against traveling direction to install the crawler
and secure the swing lock and brake.
(2) Rotate the axle extension toward to extended

direction. (All 4 locations)
AXLE
y
nl
O
AXLE EXTENSION
(3) Install the rotation preventive bracket after the

axle extension is extended position.
ce
en
ROTATION PREVENTIVE
BRACKET
er
ef
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10000A-1
(4) Adjust the road clearance to approx. 600 mm (2

ft.).
Confirm and adjust the level with the leveler
whether the lower machinery is horizontal.
Do not swing when connecting or disconnecting

hydraulic hose of crawler to avoid accident of
being caught. Approx. 600 mm (2′)
y
nl
O
by one.
ce
en
er
ef
R

11000-1
(5) In case of the crawler connecting link is not

installed on the carbody, insert the link to the
carbody and set to the fully retracted position.
Insert the guide pin then secure with the spring
pin.
y
nl
GUIDE PIN
O
ce GUIDE PIN
CRAWLER
CONNECTING LINK
en
(6) In order to sliding smoothly, apply grease on the

axle sliding surface. (4 locations)
er

axle.
ef
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10000A-1
2. Setting of LMI
When removing or installing the crawler, set up

the LMI as the following.

not be operated.
y
nl
menu.
O
ce
en

er
Select “9 (Self removal cylinder)”.

ef
R

11000-1

Select “2 (Crawler removal mode)”.
y
nl
(5) Press .
O
ce
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er
ef
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10000A-1

displayed.
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the result.
nl
O
ce
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er
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11000-1
3. One side of crawler installation

SELF REMOVAL CYLINDER
(1) Bring the trailer loading of the crawler to the

base machine as much as closer.
(2) Confirm the installation direction of crawler and
lift it by the self removal cylinder.
One side crawler mass : 7,600 kg (16,760 lbs) SHACKLE
10 t (22,050 lbs) SLING WIRE ROPE
16 mm dia. (20/32″ dia.)
• Upon lifting the crawler, use protectors to avoid × 1.5 m (7′)
entering the sling into the gap of shoes. A
y
A
TRAVEL MOTOR
nl
CORNER
PROTECTORS
O
SHACKLE
5 t (11,025 lbs )
ce
Section A-A
• When the crawler is not installed to the base CRAWLER

machine, the upper machinery allowed to rotate
en
360 degrees with the lifting of crawler by self

Maximum work radius
removal cylinder.
4.1 m (13′ )
er
Keep the working radius within 4.1 m (13 ft.) while

swinging with lifting the crawler by self removal
cylinder to prevent overturning of the machine.
ef

serious accident.
R
Translifter work position
10000A-1
(3) Adjust the crawler installation position with the

swing motion slowly.
Do not swing abruptly to prevent machine over

turning.
serious accident.
y
(4) Confirm not to attach the adjusting shim for axle
clearance.
nl
(5) Insert the crawler into both front and rear axle
extension by controlling the boom base and self
removal cylinder.
O
ce
being trapped.
en
(6) Remove the securing pin for crawler extension/

retract cylinder on the crawler frame side. SECURING PIN
(7) Extend the crawler extension cylinder and align
with the crawler frame side hole and the insert
securing pin.
er
CRAWLER EXT./RET.
CYLINDER
ef

being trapped.
R

SPRING LOCK PIN


11000-1
(8) Control the crawler extension/retract cylinder

to pulling in the crawler inside from present
position.
When bring in the crawler frame by Ext./Ret. cylinder,

should be the base machine is kept horizontally with
the translifter and make a parallel between the side
of crawler and side of base machine.
If the crawler is inclined, adjust the vertical
y
cylinder to make a parallel between them.
If leave the incline of crawler and bring in with undue
nl
force may cause of damage the crawler frame.
(9) Remove the securing pin (a) from the retract
O
position of the crawler connecting link.
ce
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SECURING PIN (a)

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SECURING PIN (a)

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CRAWLER
CONNECTING LINK
10000A-1
(10) Extend the crawler connecting link and align

with the crawler frame side hole and then insert
the securing pin (b) with the spring pin.

y
SECURING PIN (b)
nl
BRACKET
(crawler frame side)
O
SPRING PIN
ce
(11) Control the crawler extension/retract cylinder to
extend the crawler connecting link fully out.
en
(12) Insert the securing pin (a) on the carbody side

bracket.
er

ef
SECURING PIN (a)

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Ensure to insert the securing pin (a) at extend

position when the crawler extended.
When it is inserted to retract position, the extended
width of crawler is not enough resulted the machine CRAWLER CONNECTING LINK
may overturn at erection or lifting work.
serious injuries or loss of life. BRACKET
(Carbody side)

11000-1
4. Other side of crawler installation

(1) Bring the trailer loading of the crawler to the

base machine as much as closer.
(2) Confirm the installation direction of crawler and
lift it by the self removal cylinder.
One side crawler mass : 7,600 kg (16,760 lbs) SHACKLE
16 mm dia. (20/32″ dia.)
• Upon lifting the crawler, use protectors to avoid × 1.5 m (7′)
entering the sling into the gap of shoes. A
y
A
TRAVEL MOTOR
nl
CORNER
PROTECTORS
O
SHACKLE
5 t (11,025 lbs )
ce
Section A-A
CRAWLER
en
CRAWLER
Keep the working radius within 4.1 m (13 ft.)
and also keep the center to center distance (90
degrees) of lifting side translifter cylinders as
well while swinging when one side crawler is
er
installed with lifting the other side of crawler by

self removal cylinder to prevent overturning of the 90 degrees
machine.
ef
serious accident.
R
Maximum work radius Translifter work position

4.1 m (13′)
10000A-1
(3) Adjust the crawler installation position with the

swing motion slowly.
(4) Install the crawler with the same manner as the
previous side of crawler.
Do not swing abruptly to prevent machine over

turning.
serious accident.
y
5. Installation of shim
nl
(1) After completion of both crawlers installation,
retract the four vertical cylinders with keep the
base machine horizontal by monitoring the
O
leveler until the both crawlers are to be placed
on the ground.
(2) Swing the upper machinery to widen clearance
between the crawler and the axle and install the
adjusting shims at four places.
ce
Each shim has a unique number stamped and
install it accordingly.
SHIM
en
CRAWLER FRAME
Insert the adjusting shim to all axles.
AXLE
Otherwise the crawler frame would become
misaligned and result in premature shoes or roller
wear.
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damage the parts.
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removing the shim.
serious injury.

11000-1

ext./ret. cylinder and the crawler frame and SECURING PIN
The removed securing pin to be insert the
crawler side pin hole and secure with the spring
lock pin.
CRAWLER EXT./RET.
CYLINDER

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removing the shim.
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serious injury. SPRING LOCK PIN
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extend or retract.
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part of cylinder.
damage the parts.
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10000A-1
7. Storage of translifter
(1) If not equipped the carbody weight, the float is

VERTICAL CYLINDER
to be stored to the place on the translifter
(2) Remove the securing pin for vertical cylinder
and tilt the vertical cylinder.
(3) Insert the securing pin when align the securing
pin hole for storage.
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TRANSLIFTER
FLOAT STORE PLACE
VERTICAL CYLINDER SECURING PIN
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Failure to observe this precaution may result in a (Pin hole at extended)
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(Pin hole at store)
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(4) Stop the engine after completion of all crawler

frame installation works.
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11000-1
8. Connection of crawler piping
Open the cover by removing the fixing bolts. COVER

Connect both right and left hydraulic hoses for
travel at quick coupler portion.
(4 hoses/one side)
Confirm if certainly connected by pulling all
hoses after connection.
COVER SECURING BOLT
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hydraulic hose of crawler to avoid accident of
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being caught.
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Connect
• Perform the connection/disconnection of
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quick coupler when the circuit pressure is
lowered after the engine stop.
If the pressure is remained, connection/
disconnection would be difficult or oil would
spray flies.
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• When connect the quick coupler, remove dirt

and dust from both coupling parts.
The incomplete connection of coupling may
result of oil leak and damage on the travel
motor, reduction unit etc.
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Failure to observe this precaution may lead

to damage the parts.
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10000A-1
4.10.2 REMOVAL OF CRAWLER

There is a case of deleting the translifter, crawler etc.
from the illustration to easily visible.
This article is explained of the removal method of both

side crawlers using the self removal cylinder from the
condition of without counterweight, gantry is in work
position and all the piping of translifter are connected.
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by one.
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the translifter.
serious accident.
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11000-1
1. One side of crawler removal
(1) Swing the upper machinery to widen clearance

between the crawler and the axle and remove
the adjusting shims at four places on both sides.

removing the shim.
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serious injury.
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SHIM
CRAWLER FLAME
AXLE
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10000A-1
(2) Remove the securing pin for crawler ext./ret.

cylinder on the crawler frame side.
(3) Extend the crawler ext./ret. cylinder and align
with the crawler frame side hole and the insert SECURING PIN
securing pin.
CRAWLER EXT./RET.
CYLINDER
being trapped.
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SPRING LOCK PIN
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(4) Remove the securing pin (a).
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SECURING PIN (a)

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BRACKET
(Carbody side)

11000-1
(5) Retract the crawler and align the pin holes of

crawler connecting link and bracket then secure
with the securing pin.
The securing pin is to be fixed with spring pin.

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SECURING PIN (b)
BRACKET
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BRACKET
(Carbody side)
BRACKET
SPRING PIN
(Carbody side)
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SECURING PIN (b)

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SECURING PIN (b)

BRACKET
SECURING PIN (a)

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SPRING PIN
SECURING PIN (a)

SPRING PIN
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CRAWLER CONNECTING LINK SECURING PIN (b)

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SPRING PIN
(6) Swing the upper machinery to parallel against

traveling direction and secure the swing lock
and brake.
10000A-1
(7) Stop the engine.

(8) Open the cover by removing the fixing bolts.
Disconnect both right and left hydraulic hoses COVER
for travel at quick coupler portion.
(4 hoses/one side)

hydraulic hose of crawler to avoid accident of COVER SECURING BOLT
being caught.
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• Perform the connection/disconnection of
quick coupler when the circuit pressure is
lowered after the engine stop. Disconnect
If the pressure is remained, connection/
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disconnection would be difficult or oil would
spray flies.
• When connect the quick coupler, remove dirt
and dust from both coupling parts.
The incomplete connection of coupling may
en
result of oil leak and damage on the travel

motor, reduction unit etc.
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11000-1
(9) Connect the remo-con cable to the receptacle

on the carbody.
Remo-con
connecting portion
㸦Carbody side㸧
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(10) Extend the translifter to the work position and TRANSLIFTER SECURING PIN
secure with the translifter securing pin. (Work position)
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Ensure the translifter must be secured at work
position for working.
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If secured it for transportation position lead to

turn-over while swinging.
serious accident or loss of life.
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Do not insert finger or hand into a pin hole when Storage position
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Work position
Transport position
10000A-1
(11) Remove the vertical cylinder securing pin.

(12) Stand the vertical cylinder to extended position VERTICAL
CYLINDER
and insert the vertical cylinder securing pin to
secure the work position.

Failure to observe this precaution may result in a (Pin hole at store)
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(Pin hole at extended)
(13) Attach the float to the vertical cylinder and

secure with the securing pin.
(14) Place the steel plate under the float for safety.
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serious injury or loss of life. SECURING PIN
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FLOAT
STEEL PLATES
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The float weight is approx. 25 kg (55 lbs.).

Handle the float with two people to prevent injuries.

11000-1
(15) Confirm if the hydraulic hoses have been HYDRAULIC HOSE

connected to the vertical cylinder. FOR TRANSLIFTER
(4 places total 8 hoses)

Connect
Check to see that the coupler does not come apart

when pulled.
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(16) Start the engine and set the speed to low.
(approx. 800 min-1 [800 rpm])
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(17) Engage the swing lock pin and apply swing
brake.
Turn the function lock lever to “LOCK” position.
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10000A-1
(18) Extend the vertical cylinder until obtain the

slightly clearance between the crawler shoe and
the rollers.
(19) Reconfirm if all four floats are firmly contacting
with the ground and lift up the base machine
further and adjust 600 mm (2 ft.) of the load
clearance.
Check if there is any abnormality on the ground
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condition of the float contacting area to prevent
overturning of the machine.
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serious accident.
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VERTICAL CYLINDER VERTICAL CYLINDER

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by one.
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• Ensure all four floats should be contacting Approx. 600 mm (2′)
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the translifter.
serious accident.
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11000-1
(20) Attach the slings to the left hand crawler frame

and hold it with the self removal cylinder.
One side crawler mass : 7,600 kg (16,760 lbs)
• Upon lifting the crawler, use protectors to avoid

entering the sling into the gap of shoes.
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SHACKLE
16 mm dia. (20/32″ dia.)
× 1.5 m (7′)
A
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A
TRAVEL MOTOR
CORNER
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PROTECTORS
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SHACKLE
5 t (11,025 lbs )
Section A-A
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10000A-1

ext./ret. cylinder and the crawler frame and SECURING PIN
The removed securing pin to be insert the
crawler side pin hole and secure with the spring
lock pin.
CRAWLER EXT./RET.
CYLINDER

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SPRING LOCK PIN
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extend or retract.
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part of cylinder.
damage the parts.
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11000-1
(1) Remove the left hand crawler from axle extension

by controlling the boom base and self removal
cylinder.
When draw out the crawler frame from the axle,

keep the crawler securely and slowly removed so
that the sudden load is not applied.
serious accident.
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CRAWLER
CRAWLER
Keep the working radius within 4.1 m (13 ft.)
O
and also keep the center to center distance (90
degrees) of lifting side translifter cylinders as
well while swinging when one side crawler is
installed with lifting the other side of crawler by
self removal cylinder to prevent overturning of the 90 degrees
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machine.
serious accident.
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Maximum work radius Translifter work position

4.1 m (13′)
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10000A-1
3. Other side of crawler removal CRAWLER
(1) Remove the crawler with the same manner as
Maximum work radius

the previous side of crawler.
4.1 m (13′ )
• When the crawler is not installed to the base
machine, the upper machinery allowed to rotate
360 degrees with the lifting of crawler by self
removal cylinder.
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Keep the working radius within 4.1 m (13 ft.) while
nl
swinging with lifting the crawler by self removal
cylinder to prevent overturning of the machine. Translifter work position
serious accident.
O
(2) Place the removed crawler on the trailer.
(3) Remove the retaining bracket being located at
the root of axle extension.
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(4) Rotate the all four axle extensions toward to right
angle to the axle and secure with securing pins.
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11000-1
4.11 CARBODY WEIGHT INSTALLATION/REMOVAL (USING

SELF REMOVAL CYLINDER [OPTION])
4.11.1 CARBODY WEIGHT INSTALLATION

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two pieces.
specified one.
WEIGHT (1)
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EACH WEIGHT MASS
Weight (1) 7.2 t (15,873 lbs)
Weight (2) 7.2 t (15,873 lbs)
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WEIGHT (2)
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10000A-1



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TOOL
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• Sling wire rope
22 mm dia. (7/8″ dia.) × 0.8 m (3′) × 2
• Shackle 10 t (22,050 lbs) × 2
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11000-1
2. Setting of LMI
When removing or installing the crawler, set up

the LMI as the following.

not be operated.
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menu.
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Select “9 (Self removal cylinder)”.

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10000A-1

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(5) Press .
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11000-1

displayed.
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the result.
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10000A-1
3. Display main screen and ready to crane operation. AREA FOR MESSAGE DISPLAY
DATA CODE (for product support)
0.0
10 . 0 f t 800
10021000000600120420
SELF REMOVAL MODE 2015/05/10 10:00
0. 0
70 . 0 deg
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40 . 3 f t
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L+S 0.3
RESET S
SET D 0.2
BOOM ANGLE DISPLAY

WORK RADIUS DISPLAY
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AUTOSTOP AT SELF REMOVAL MODE
When the machine stops due to reach to the

danger condition, the machine can’t be moved
to the direction toward to the side with marked
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“×”, other than the direction marked “×” can be
moved the machine without using release switch.
OVERLOAD BOOM RAISING (Controlled by ML controller)

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11000-1
4. Carbody weight (1) installation
(1) Attach the sling to the carbody weight on the

trailer and lift it by self removal cylinder.

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SHACKLE 10 t
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SLING WIRE ROPE
Φ22 × 0.8 m
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SHACKLE 10 t
CARBODY WEIGHT
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(2) Swing the upper machinery for approx. 4.5
degrees.
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4.5 degrees
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10000A-1
(3) Raise the boom to bring the carbody weight

closer.
(4) Bring the carbody weight (a) portion to right
above the carbody side hanging bracket and
6,213 mm (20′ 5″)

align with it. 84 degrees

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BRACKET
(Carbody side)
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(a)
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CARBODY WEIGHT
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(5) Extend the self removal cylinder and rest the
carbody weight (a) portion to the carbody side
hanging bracket.
84 degrees
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BRACKET
(Carbody side)
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(a)
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CARBODY WEIGHT

11000-1
(6) Insert the carbody weight securing pin and

CARBODY WEIGHT
(2 places both left and right side.)
SPRING PIN

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(7) Install the carbody weight (2) as same manner
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10000A-1

equipped (option)

front side weight and base machinery harness
(CN-914F) and both water proof caps too.
• Detect harness installed on the weight (2) is not
to be connected.
• If the carbody weight is not equipped as use
as reduced weight, leave the base machinery
harness with cap as is.
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CN-914F
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11000-1
4.11.2 CARBODY WEIGHT REMOVAL

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two pieces.
EACH WEIGHT MASS

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Weight (1) 7.2 t (15,873 lbs)
Weight (2) 7.2 t (15,873 lbs)

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TOOL
• Sling wire rope
22 mm dia. (7/8″ dia.) × 0.8 m (3′) × 2
• Shackle 10 t (22,050 lbs) × 2
10000A-1

degrees.
4.5 degrees
3. For the model equipped with weight detect

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After removing of the carbody weight, surely
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connect the waterproof cap to the main machinery
harness.
CN-914F
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11000-1
4. Remove the carbody weight installation pin and

CARBODY WEIGHT
secure the pin with retaining pin. SECURING PIN
(Right and left 2 locations)
SPRING PIN
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O
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5. Attach the sling to the carbody weight.
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Lift the carbody weight by the boom base and

self removal cylinder and leave the carbody
weight (a) portion from the carbody side
hanging bracket. 84 degrees
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BRACKET
(Carbody side)
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(a)
CARBODY WEIGHTT
10000A-1
6. Lower the boom slightly and move the carbody

weight away from the main machinery.
7. Lower the boom further and place the weight to

the ground or on the trailer and disconnect the
slings.
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8. Remove the carbody weight (2) as same
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11000-1
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10000A-1
[ 5. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT ]

5.1 ASSEMBLING THE ATTACHMENT .................................................................................. 5-5
5.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE ............................................................. 5-6
5.1.2 BOOM AND GUY LINE ARRANGEMENT .................................................................. 5-8
5.1.3 HANDLING OF SPREADER GUIDE ............................................................................ 5-15
5.1.4 INSTALLING THE BOOM ................................................................................................ 5-18
5.1.5 CAUTION FOR CANTILEVER ....................................................................................... 5-28
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5.1.7 INSTALLING THE AUXILIARY SHEAVE..................................................................... 5-34
5.1.8 REAR DRUM WIRE ROPE REEVING TO AUXILIARY SHEAVE........................ 5-35
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5.1.9 ASSEMBLING THE FIXED JIB ...................................................................................... 5-38
5.1.10 REAR DRUM WIRE ROPE REEVING TO THE FIXED JIB .................................. 5-41
5.1.11 FUNCTION CHECK OF EACH LIMIT SWITCH........................................................ 5-44
5.2 ERECTING THE ATTACHMENT ........................................................................................ 5-45
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5.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT .............................. 5-45
5.2.2 ERECTING THE ATTACHMENT ................................................................................... 5-46
5.2.3 CONFIRMATION BEFORE LOWERING THE ATTACHMENT ............................. 5-49
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5.2.4 LOWERING THE ATTACHMENT .................................................................................. 5-50
5.3 DISASSEMBLING THE ATTACHMENT ........................................................................... 5-51
5.3.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING...................................... 5-52
5.3.2 WINDING UP THE FRONT/REAR DRUM WIRE ROPES ..................................... 5-54
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5.3.3 DISASSEMBLING THE JIB............................................................................................. 5-56

5.3.4 REMOVING THE AUXILIARY SHEAVE ...................................................................... 5-59
5.3.5 DISASSEMBLING THE BOOM...................................................................................... 5-60
5.4 CAUTION WHEN TRANSPORTING BOOM................................................................... 5-65
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11000-1
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5. ASSEMBLY/DISASSEMBLY OF CRANE
ATTACHMENT
This section covers assembling, erecting, lowering and
disassembling of the crane attachment and transport
of the boom.
This assembly procedure starts when the machine is
under the following conditions.
• The crawler is extended position.

• Counterweights and carbody weights are
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installed for the desired configuration.
• The boom hoist rope has been roved through
nl
the upper and lower spreader and the gantry is
in work position (high gantry).
• The boom base is attached to the base
machine.
O
• The crane backstops have been installed.
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Before starting the work, confirm the following items.
1. Place
(1) Check point prior to work

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procedures.
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their condition.
(2) Securing place

• Select a firm and level space enough for the task.
Place steel plates or crane mats.
and trailer access.
• The ground shall be drained unless the place is
in marshes or wetland.

11000-1
2. Work procedure and prearrangement for safety.
Have a qualified supervisor who is competent in

assembly and disassembly procedures.
Before assembling work, gather the all concerned
to make previous arrangement for the working
procedure and safety, and make precise role and
responsibility of each person.
3. Preparation before work
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• Secure required number of workers for the
work.
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• Take appropriate action to keep personnel off
the work area other than workers during work.
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4. Cautions during assembly or disassembly work
• During assembly or disassembly work, install

the waterproof cap on the cable end of the hook
overhoist preventing device.
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During crane work, wire the overhoist cable

properly and remove the waterproof cap.
during assembly.
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part moves.
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10000A-1
Do not apply slings directly to a sharp edge part to

prevent the slings from cutting.
Apply the sling to the guy cable pin hole or
bracket for lifting through a shackle.
a serious accident.
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attachment.
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To avoid an accident resulting in injury or death

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by dropping the guy line which being on the lattice

pipe, secure the both ends of guy line to the lattice
pipe by wire or lower the guy line to the ground
with assist crane.
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11000-1
When lifting the boom, jib use the protector or the

synthetic fiber sling.
Do not lift at lattice pipe. In case of lifting semi-
assembled boom, jib lift at connecting part.
damage parts.
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Hanger bracket which is shown right figure can be
used only when the boom is at a single part.
Do not use it when the plural booms are connected.
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HANGAR BRACKET
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10000A-1
5.1 ASSEMBLING THE ATTACHMENT

TOOL
• Assist Crane (25 t capacity)
• Wire Rope Slings (Synthetic Fiber Sling)
• Wood block
• Corner Protectors
When assembling the crane attachment, press 0.0

(assy/disassy icon).
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10 . 0 f t 800
Then, the load safety device enters the assy/disassy 10021000000600120420
mode, and the automatic stop is canceled.

2015/05/10 10:00
nl
4 1
100 . 3 f t
Use.
Use.
100 f t
30 . 0 POUNDS
× 1000
30 . 8 POUNDS
× 1000
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0. 0
Press (assy/disassy icon), (boom, jib 70 . 0 deg

40 . 3 f t 40 . 3 f t
L+S 0.3
RESET S
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SET D 0.2
ASSY/DISASSY ICON

cannot be set.
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Refer to the article “8.2 DIMENSION, WEIGHT OF

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EACH COMPONENT” for individual dimension, weight

of the crane attachment.
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11000-1
5.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE

1. Boom and jib
Prepare the boom and jib following the arrangement

chart.
Do not assemble the boom which is not shown
in the arrangement chart.
Check the each boom and jib component for
damage.
If damage is found, repair the damage at the
designated service shop.
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The boom length in which the jib The boom length in which the
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Specification Counterweight Boom length
can be installed aux. sheave can be installed
12.2 m to 61.0 m 24.4 m to 57.9 m 12.2 m to 57.9 m
STD
(40′ to 200′) (80′ to 190′) (40′ to 190′)
STD crane
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12.2 m to 57.9 m 12.2 m to 54.9 m
Reduced
(40′ to 190′) (40′ to 180′)
ce
Do not use damaged boom, jib which may cause
of collapse and lead to personnel injuries or loss
of life.
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serious accident.
2. Guy line
(Front)
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Prepare the guy lines following the arrangement Part No. : Ex or

chart.
(Back)
The diameter of the boom guy line is 30 mm (1-
3/16 in.), and the diameter of the jib guy line is Manufacturing date : Ex 02-5
ef
20 mm (13/16 in.).
To identify each guy line, see the part number
stamped on the connector. (last 5 digits)
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10000A-1
3. Steel plate
As for crane specification, when erecting or

lowering of the combination of main boom 57.9
m (190 ft.) length and the jib of any length, place
steel plates between the ends of the crawlers
and the ground as shown.
Center of idler and Center of shoe and
steel plate steel plate
600 mm
(1′ 11-5/8″)
Travel the crane until the idler center comes to the
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center of the steel plate. 50 mm
(1-15/12″)
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450 mm
(1′ 5-11/16″)
STEEL PLATE
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11000-1
5.1.2 BOOM AND GUY LINE ARRANGEMENT

1. Boom and guy line configuration
B B C
10 10 10 10
Depending on the purchased configuration of B B C D

boom, boom may not be able to arrange as shown
10 10 20 10 10 20
on the chart.
The boom arrangement with the “ ” is the preferred
C C D
configuration.
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Using the “ ” arrangement will allow any shorter 20 20 20 20
boom length to be assembled.
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Shown below the “ ” configurations are acceptable
arrangement if required due to boom that was
purchased.
The number of guy lines to supply is minimum
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number of which can be arranged with purchased
boom configuration and depending the boom
arrangement, guy line may not be able to arrange
as shown the chart.
In that case, guy line configuration substitutes as
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shown right figure.
Cable roller installation position

Mark shows the boom insert with lug.
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Mark shows the boom insert with lugs attached and

the guy line installing position when the jib is used.
Mark shows the installing of the cable roller for the
insert boom.
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Mark shows the installing of the cable roller for the

boom tip. Cable roller installation position
Max. parts Boom

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Boom With With of line self

length : Boom and guy line configuration aux. fixed erecting
m (ft.) sheave jib Front Rear at side
drum drum direction
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12.2 A
8 1
(40)
B
15.2 A
10
8 1
(50)
B B
A
10 10
18.3
8 1
(60) C
A
20
: Allowed : Not allowed
10000A-1
Max. parts Boom

drum drum direction
B C
21.3 A
10 20
6 1
(70)
B B C
A
10 10 20
24.4 D
A
6 1
(80) 40A
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C C
A
20 20
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B C C
A
10 20 20
27.4
5 1
(90) B D
A
10 40A
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B B C C
A
10 10 20 20
30.5 B B D
A
5 1
(100) 10 10 40A
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C D
A
20 40A
B C D
33.5 A
10 20 40A
4 1
(110)
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B B C D
A
10 10 20 40A
36.6 D D
A
4 1
(120) 40 40A
C C D
A
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20 20 40A
B C C D
A
10 20 20 40A
39.6
4 1
(130) B D D
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A
10 40 40A
B B C C D
A
10 10 20 20 40A
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42.7 B B D D
A
4 1
(140) 10 10 40 40A
C D D
A
20 40 40A
B C D D
45.7 A
10 20 40 40A
4 1
(150)

11000-1
Max. parts Boom

drum drum direction
B B C D D
A
10 10 20 40 40A
48.8 C C D D
A
2 1
(160) 20 20 40 40A
D D D
A
40 40 40A
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B C C D D
A
10 20 20 40 40A
51.8
2 1
(170)
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B D D D
A
10 40 40 40A
B B C C D D
A
10 10 20 20 40 40A
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54.9 B B D D D
A
2 1
(180) 10 10 40 40 40A
C D D D
A
20 40 40 40A
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57.9 B C D D D
A
* 2 1
(190) 10 20 40 40 40A
61.0 B B C D D D
A
2
(200) 10 10 20 40 40 40A
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* When raising / lowering the boom with jib, require steel plate.
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10000A-1
KIND OF BOOM INSERT

Symbol Boom length Specification
10 3.0 m (10′) Without lug
40A 12.2 m (40′) With lug
In case of with jib configuration, 12.2 m (40 ft.) boom
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insert with lug is required.
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KIND OF BOOM GUY LINE
Guy line dimension
Symbol Part number Remarks : m (ft.) Connector type
Diameter : mm (in.) Length : m (ft. in.)
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A 30 (1-3/16″) 6.17 (20′ 2-15/16″) Boom tip
B 30 (1-3/16″) 3.05 (10′) 3.0 (10′) Boom insert
C 30 (1-3/16″) 6.10 (20′) 6.1 (20′) Boom insert

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D 30 (1-3/16″) 12.20 (40′) 12.2 (40′) Boom insert
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11000-1
ARRANGEMENT OF JIB AND GUY LINE

Offset Angle
The length of the boom in which the jib can be

attached is 24.4 m (80 ft.) to 57.9 m (190 ft.).
STRUT
BACKSTOP
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10 degrees
10 degrees (or 30 degrees)
E (or 30 degrees) Jib tip
E F
Jib tip
10′
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Jib base Jib base
Boom tip Boom tip
H H
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40′ (With lug) 40′ (With lug)
(J) (J)
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9.1 m (30′) jib 12.2 m (40′) jib
F
Jib tip
Jib tip
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E 10′
G E G
10 degrees 10 degrees
(or 30 degrees) (or 30 degrees)
20′ 20′
Jib base Jib base

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Boom tip Boom tip
H H
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40′ (With lug) 40′ (With lug)
(J) (J)
15.2 m (50′) jib 18.3 m (60′) jib
10000A-1
KIND OF JIB INSERT

Symbol Jib length Specification
10 3.0 m (10′) Jib
20 6.1 m (20′) Jib
ARRANGEMENT OF GUY LINE IN BOOM SIDE
Boom arrangement
Offset angle
(Boom tip + 12.2 m [40′]) Arrangement
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10 degrees H
30 degrees H+J
nl
J : Additional guy line when the offset angle is 30 degrees
ARRANGEMENT OF GUY LINE IN JIB SIDE
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9.1 m (30′) Jib 12.2 m (40′) Jib 15.2 m (50′) Jib 18.3 m (60′) Jib
E E+F E+G E+F+G
KIND OF GUY LINE

ce
Symbol Diameter : mm (in.) Length : m (ft. in.) Part No. Connector type
E 22 (7/8″) 19.34 (63′ 1/2″)
F 22 (7/8″) 5.88 (19′ 3-1/2″)
G 22 (7/8″) 11.75 (38′ 6-5/8″)

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H 22 (7/8″) 37.54 (123′ 1-15/16″)
J 22 (7/8″) 2.44 (8′ 1-16″)

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11000-1
COMBINATION OF CRANE BOOM AND JIB
Boom length Jib length : m (ft.) Boom with jib self

Steel plate
m (ft.) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) erecting at side direction
24.4 (80)
27.4 (90)
30.5 (100)
33.5 (110)
36.6 (120)
39.6 (130)
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42.7 (140)
45.7 (150)
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48.8 (160)
51.8 (170)
54.9 (180)
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57.9 (190) Need
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10000A-1
5.1.3 HANDLING OF SPREADER GUIDE

1. Draw out guide securing pin and change the GUIDE SECURING PIN
spreader guide from the stowed position to work SPREADER GUIDE
position.
Then put back the guide securing pin to the
original position.
Do not insert finger or hand into a pin hole when Stowed position
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nl
GUIDE
SECURING PIN
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Work position
2. After the boom tip has been grounded, slowly

loosen the boom hoist wire rope more.
The spreader is lowered along the spreader guide.
en
When the hole of the spreader is aligned with

the pin hole of the bracket on the boom base
section, insert spreader securing pin to connect
the spreader to the boom base bracket.
er

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aligning, inserting or removing pin. SPREADER

Failure to observe this precaution may result in a SECURING PIN

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If in case of difficulty to stow the spreader due to

incline of it, wind boom hoist wire rope a bit to leave
the spreader from the guide and attempt to stow it
again.
Move the spreader up and down by mean of shaking
the boom hoist wire rope to obtain alignment easier
between spreader and lower boom securing holes.

11000-1
3. When stowing the spreader guide, slowly

tighten the boom hoist wire rope. Clearance
When there is a clearance between the spreader

and the guide, draw out guide securing pin, and
return the guide to the stowed position.
GUIDE
SECURING PIN
Be sure to support the spreader guide with hands,

when removing the pin and handling the guide.
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O
• When the gantry is in the lowered condition,
be sure to set the spreader guide in the
stowed position.
If left in the work position, the guide could Stowed position
be damaged when raising the boom.

ce
• When the gantry is lowered and the upper
spreader is connected to the boom base, set
the spreader guide in the stowed position.
en
At this time, do not raise the boom higher

than 20 degrees.
If the boom is raised beyond 20 degrees, the
boom hoist rope may be damaged.
er

ef
Since the clearance would not be made with boom

base section only, perform this before the boom
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disassembly.
10000A-1
4. When boom assembling is completed, remove

SPREADER
the spreader securing pin and wind up a boom SECURING PIN
hoist rope as to the spreader to be sliding on
the guide.
Sudden winding may cause the bending
damage of guide due to the spreader may
caught with the guide. In case of caught, loosen
the rope once and wind the boom control lever
manipulates intermittently to rising side so that
release from the caught.
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5. Return the spreader guide to stowed position
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ce
GUIDE SECURING PIN
for crane operation. SPREADER GUIDE
en
Stowed position
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11000-1
5.1.4 INSTALLING THE BOOM

1. Steel plate

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600 mm
(1′ 11-5/8″)
nl
(1-15/12″)
450 mm
(1′ 5-11/16″)
O
STEEL PLATE
2. Connecting the boom insert

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(1) Referring to the boom and guy line configuration LUG
chart, prepare the required boom components, (Assemble so that this
part is position on the top.)
careful on top/bottom sides, and place near the Top
boom base section.
en
Correct
Bottom
er
Top
Wrong
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Bottom
LUG
When assembling/disassembling the attachment,

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do not place the attachment direct to the ground.

Place a wooden block and place the attachment
stably on it.
10000A-1
(2) Align the top connecting holes of boom base

SPRING LOCK PIN
and boom insert and insert the connecting pin
(with flange).
Insert the connecting pin (with flange) should be
oriented vertical its pin hole and secure with the
spring lock pin.
CONNECTING PIN
(With flange)
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nl
O
As to the boom length able to connect with
cantilever condition, refer to the article “5.1.5
CAUTION FOR CANTILEVER”.
ce
en

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11000-1
(3) Align the connecting pin holes of the boom

SPRING LOCK PIN
inserts and insert the connecting pin (with
flange).
spring lock pin.
CONNECTING PIN
(With flange)
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SPRING LOCK PIN
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CONNECTING PIN
(With flange)
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stably on it.
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10000A-1
(4) Referring to boom and guy line arrangement

SPRING LOCK PIN
chart, connect the boom inserts in order in the
same way.

CONNECTING PIN
Failure to observe this precaution may result in a (With flange)
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do not place the attachment direct to the ground. SPRING LOCK PIN
O
stably on it.
ce
Be sure to tap the connecting pins (with flange) CONNECTING PIN
from the outside to the inside. (With flange)
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er
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11000-1
3. Connecting the boom tip

SPRING LOCK PIN
Align the connecting holes of boom insert and

boom tip and insert the connecting pin (with
flange).
spring lock pin.
CONNECTING PIN
(With flange)
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SPRING LOCK PIN
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CONNECTING PIN
(With flange)
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10000A-1
4. Connecting the boom base and boom insert
Lift at the connection part between the boom

base and boom insert and insert the connecting
pins (double tapered) after align the bottom part
of connection holes.
Insert the connecting pin (double tapered)
should be oriented vertical its pin hole and secure
with the spring lock pins on both sides.
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nl
SPRING LOCK PIN
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SPRING
LOCK PIN

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CONNECTING PIN
serious injury or loss of life. (Double tapered)
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er

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11000-1
5. Installing the cable rollers
Install the cable rollers to the location as shown

in the boom configuration chart.
For boom insert For boom tip
SPACER SPACER CABLE ROLLER
CABLE ROLLER
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BOOM INSERT BOOM INSERT BOOM TIP BOOM TIP
nl
O
6. Connecting the boom guy lines
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(1) Prepare guy line according to the guy line
configuration chart.
Insert the guy line connecting pin from the
inside.
en
Boom base side Boom tip side
GUY LINE
CONNECTING PIN
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10000A-1
(2) Connect the prepared guy lines starting at

the boom tip side to the basic machine side in
order.
Do not leave slack on the guy line.
If the guy line is loose the end may not reach
the upper spreader.

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attachment.
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GUY LINE GUY LINE CONNECTING PIN GUY LINE

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Open the split pin to

approx. 60 degrees
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11000-1
(3) Connect the guy line to the upper spreader.

UPPER SPREADER
(4) Loosen the boom hoist wire rope to relieve
SPLIT PIN GUY LINE
tension.
Inset the
guy line connecting pin
from inside.
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SPLIT PIN GUY LINE
nl
*Open the split pin to approx. 60 degrees
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(5) Use the spreader guide to remove the spreader SPREADER GUIDE
securing pin. SPREADER
SECURING PIN
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GUY LINE
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10000A-1
(6) Wind up the boom hoist rope.

Pay attention not making rough spooling on the
drum.
Place a signal person to prevent accident from

rotating drum.
serious injury.
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nl
After the assembly has been completed, be sure
to confirm that all connecting pins and split pins
O
are correctly installed.
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11000-1
5.1.5 CAUTION FOR CANTILEVER
Ensure to work with the gantry is set at “WORK”

position and the inching switch should be set in
inching position.
The allowable cantilever condition while supporting by

the boom base are as follows;
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nl
With base boom
O
Boom tip only.
12.2 m (40′) boom insert

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or less
12.2 m (40′) or less

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Do not perform the hoisting work or travel while

the boom is supported with the cantilever.
er

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10000A-1
5.1.6 FRONT DRUM WIRE ROPE REEVING

hands.
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being entangled.
nl
• Place a signal person to prevent accident
from rotating drum.
O
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The hook is to be installed correct direction.
When passing the hoist wire rope to the hook, face
the striker (hook side weight catch) contacting the
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hook overhoist limit switch weight to the boom

foot side.
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11000-1
1. Place the hook, overhoist limit switch, weight

and socket, near the boom tip.
IDLER SHEAVE
2. Turn the front drum control lever to lower side to
pay out the wire rope to the boom tip.
WIRE ROPE
3. Pass the wire rope through the idler sheave
and boom point sheave by referring to the right
figure. BOOM POINT
SHEAVE
* However, in case of the number of reeving is 7

parts of line or more, pass the wire rope through
y
the middle idler sheave and pass it to the
View from A
auxiliary sheave.
nl
(Refer to the article “HOIST ROPE REEVING
IN BOOM POINT AREA”.)
O
ce A

the left side bracket on the tip end of the boom.
en
5. Pass the front drum wire rope through the hook

sheave(s) and boom point sheave(s) in order.
Terminate the wire rope end with the rope socket
er
at the boom point for even number part reeving

and at the hook for odd number part reeving.
Be sure to pass the wire rope through the hook
overhoist limit switch weight.
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LIMIT SWITCH
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SHACKLE
WEIGHT LIFTING
WIRE ROPE
WEIGHT
10000A-1
HOIST ROPE REEVING IN BOOM POINT AREA
IDLER SHEAVE
BOOM POINT SHEAVE
AUX. SHEAVE
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8 Parts HOOK SHEAVE 7 Parts 6 Parts
nl
O
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5 Parts 4 Parts 2 Parts
(This figure is view from the boom tip side.)

en
When use of 7 and 8 parts of line, require to install

the auxiliary sheave block to the boom tip.
er
As to the installation of auxiliary sheave, refer

to the article “5.1.7 INSTALLING THE AUXILIARY
SHEAVE” for the detail.
ef
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11000-1
HOOK INSTALLING DIRECTION STRIKER STRIKER
When passing the hoist wire rope to the hook, face the
striker (hook side weight catch) contacting the hook
overhoist limit switch weight to the boom foot side.
Boom foot side Boom foot side
When installing the rope socket to the boom point, pay

attention on the side of rope socket.
y
Be sure to pass the wire rope through the hook overhoist
limit switch weight.
nl
O
ce
Boom inside Boom outside
Install the bolt from

inside to outside
en
of the boom.
Secure the bolt with a
nut and split pin, and
open the split pin to
approx. 60 degrees.
er
ROPE SOCKET
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10000A-1
6. Load safety device connection
(1) Secure the junction cables or limit switch wiring

to the boom with the hanger.
(2) Connect the attachment wiring to the main
machinery junction panel. LOAD
DETECTOR
(3) Check the connection of load detector connector.
(Boom hoist winch plate area)
(4) Connect the cable reel wiring to the boom tip
junction panel.
(5) Connect the hook overhoist cable reel connector.
(6) Check the connection of hook overhoist limit
y
switch wiring to the boom tip junction panel.
(7) If needed,place steel plate at the front end the
nl
crawlers.
If jib or aux. sheave is not used, connect the hook

overhoist limit switch wiring at this time.
O
For detail of wiring connection, refer to the article “3.3
CONNECTING PROCEDURE OF WIRING”.
CONTROLLER
ce
(5)
(4)
(6)
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(3) (2) (7)
(1)
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serious accident.
Type Type of overhoist Type of stop Auto-stop angle

Controller (against ground angle) Approx. 82 degrees to 82.5 degrees
Limit switch (against machine angle) 84.5 degrees to 85.5 degrees

11000-1
5.1.7 INSTALLING THE AUXILIARY SHEAVE
The length of boom in which the auxiliary sheave can be AUXILIARY SHEAVE
equipped.
STD 12.2 m to 57.9 m
counterweight (40′ to 190′)
STD crane
Reduced 12.2 m to 54.9 m
counterweight (40′ to 180′)
Auxiliary sheave weight : 195 kg (430 lbs)
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nl
1. Align the holes of boom tip and auxiliary sheave
O
ce
frame.
en
er
2. Insert the securing pin to secure the auxiliary

SPRING LOCK PIN
sheave.
ef
Insert the spring lock pin in to the securing pin

hole.
SECURING PIN
R

10000A-1
5.1.8 REAR DRUM WIRE ROPE REEVING TO AUXILIARY SHEAVE

hands.
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being entangled.
nl
O
1. Place the ball hook near the tip of the auxiliary
sheave.
IDLER SHEAVE
2. Turn the rear drum control lever to lower side
to pay out the wire rope to put through the
ce
idler sheave at the boom tip and pass it to the WIRE ROPE
auxiliary sheave.
en
AUXILIARY
SHEAVE
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View from A
A
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11000-1

the auxiliary sheave.
LIMIT SWITCH
4. Pass the wire rope through the weight for the
hook overhoist limit switch, and secure the rope SHACKLE
end to the ball hook with a rope socket.
WEIGHT LIFTING
WIRE ROPE
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WEIGHT
Detail of hook overhoist limit switch
O
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BALL HOOK
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CLAMP
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ROPE SOCKET
approx. 60 degrees
ef
5. Connecting the load safety device
Connect the auxiliary sheave frame wiring to

the boom tip wiring for overhoist limit switch.
R
For detail of wiring connection, referring the

article “3.3 CONNECTING PROCEDURE OF
WIRING”.
10000A-1


serious accident.
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nl
Ensure to confirm the functioning of the overload
prevention device, as for the details of how
O
to confirm, refer to “3.10.1 CHECK BEFORE
ERECT THE BOOM AFTER ASSEMBLY OF THE
ATTACHMENT”.
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en
er
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11000-1
5.1.9 ASSEMBLING THE FIXED JIB

As to the jib and jib guy line arrangement, refer to the
article “5.1.2 BOOM AND GUY LINE ARRANGEMENT”. JIB GUY LINE
The boom length in which the jib can be installed is (JIB SIDE)
24.4 m (80 ft.) to 57.9 m (190 ft.).
JIB
STRUT
Do not stand on, or enter under/inside of the JIB GUY LINE

attachment being assembling/disassembling. (BOOM SIDE)
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nl
12.2 m (40′)
BOOM INSERT
WITH LUG
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1. Assemble jib and strut on the extension line of
SPRING LOCK PIN
the boom tip.
ce
Align the top and bottom connection parts and
insert the connecting pins (with flange).
en
spring lock pin.
CONNECTING PIN
(With flange)
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SPRING LOCK PIN
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CONNECTING PIN
(With flange)
10000A-1
2. Lift up the pre-assembled jib with an assist

crane and connect it to the boom point.
3. Prepare the jib guy lines.

OFFSET ANGLE
(The jib side and boom side) (10 or 30 degrees)
Insert the guy line connecting pins from outside.
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• The length of the jib guy line of the jib side
varies according to the jib length.
nl
• The length of the jib guy line of the boom side
varies according to the jib offset angle (10
degrees or 30 degrees).
O
ce
4. Temporarily remove the equalizer sheave of
the jib strut, and put the jib guy line through the
sheave. BOOM SIDE JIB SIDE
Reinstall the sheave back to the original
en
position.
(Keep the strut down.)
EQUALIZER SHEAVE
er
Do this work by two persons.

JIB GUY LINE JIB GUY LINE
(BOOM SIDE) (JIB SIDE)
ef
5. Connect both ends of the jib guy line to the top Insert the securing pin
end of the jib. from outside.
R

approx. 60 degrees
View from boom inside

11000-1
6. Raise the strut with the assist crane and install

STRUT
the strut backstop.
STRUT BACKSTOP
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nl
O
7. By holding the jib strut, connect the both ends
of the boom side jib guy line to the lug on the
boom insert.
The guy line connection pins must be inserted
ce
from outside to inside and be secured with the GUY LINE CONNECTION PINS
split pins.
Open the split pins to approx. 60 degrees.
8. Remove the sling wire rope from the jib strut.

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JIB GUY LINE (BOOM SIDE)

Connect
BOOM INSERT WITH LUG

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10000A-1
5.1.10 REAR DRUM WIRE ROPE REEVING TO THE FIXED JIB

hands.
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being entangled.
nl
O
1. Place the hook near the jib tip.
2. Turn the rear drum control lever to lowering side

to pay out the wire rope to put through the idler
sheave at the strut and pass it to the jib point
ce
sheave.
REAR DRUM WIRE ROPE
3. Install the hook overhoist limit switch and weight

to the jib point section.
en
Insert the split pin into the shackle pin to secure it. JIB POINT
JIB POINT
LIMIT SWITCH
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SHACKLE
WEIGHT LIFTING
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WIRE ROPE
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WEIGHT

11000-1
4. Pass the wire rope end though the weight for

the limit switch, and secure the end to the hook
by the rope socket with the bolt, nut and pin.
CLAMP
ROPE SOCKET
y
approx. 60 degrees
nl
5. R e f e r t o t h e a r t i c l e “ 3 . 3 C O N N E C T I N G
PROCEDURE OF WIRING”, connect the wiring
for jib hoist hook overhoist limit switch.
O
ce
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6. Connecting the load safety device
• Connect a junction cable to the jib cable reel

from boom tip junction panel and wiring of
jib cable reel wiring connect to the jib hook
er
overhoist limit switch.

• Connect the jib angle meter wiring to the boom
tip junction panel.
For detail of wiring connection, refer to the
ef
article “3.3 CONNECTING PROCEDURE OF

WIRING”.
LOAD DETECTOR
R
CONTROLLER
CABLE REEL
10000A-1


serious accident.
y
nl
Ensure to confirm the functioning of the overload
prevention device, as for the details of how
O
to confirm, refer to “3.10.1 CHECK BEFORE
ERECT THE BOOM AFTER ASSEMBLY OF THE
ATTACHMENT”.
ce
en
er
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11000-1
5.1.11 FUNCTION CHECK OF EACH LIMIT SWITCH

engine.
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nl
1. Start the engine.
2. Check the function of the limit switch for the

front, rear drum hook and boom overhoist.
O
For the detail of checking method, refer to the
article “3. LOAD SAFETY DEVICE”.
If any of overhoist limit switch or striker shows
damage, deformation, looseness, or deviated
ce
from angle indication or parts replaced,
readjustment is necessary.
Contact authorized Manitowoc service provider.
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er
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10000A-1
5.2 ERECTING THE ATTACHMENT

5.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT
Check the following items, and confirm that there is no
abnormality, then erect the boom.
(1) Preoperational check completed.

(2) Lubrication to the required part of the attachment
performed.
(3) Crawlers are in fully extended position.
(4) Wire ropes have reeved correctly.
y
(5) No tools or articles left on the attachment.
(6) Off limit signs posted at surrounding area of the
nl
attachment.
(7) Wiring for the front and rear drum hook and boom
overhoist limit switches connected properly.
(8) Limit switch (es) functions.
O
(9) Load safety device correctly wired.
(10) Proper crane configuration data set.
Proper hook mode selected.
(11) Travel motor set to rear side.
(12) For the configuration of main boom of 57.9 m (190
ce
ft.) length and the jib of any length, place the
steel plates at front end of the crawlers.
(2), (4), (5), (7)

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(1),(8),(9),(10)
(11) (3) (12)

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(6) (6) (6) (6) (6) (6)
Crane boom - longest - approx. 61 m (200′)
Crane boom with jib - longest - approx. 76 m (250′)

ef
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11000-1
5.2.2 ERECTING THE ATTACHMENT

the attachment.
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nl
To prevent from being dragged or struck by
sudden moving hook, stay off from the hook when
the attachment is erected.
O
1. Cautions when erecting

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(1) Erecting of the attachment must be performed
in the front direction of the crawler.
(2) Keep the hook block on the ground until the
machine get into working range.
en
(3) Operation must be performed at a low speed.

Sudden movement must be avoided.
(4) Prevent the wire rope from catching and kink in
the tip of the boom and jib.
er
2. Release the drum lock(s) on which the hook is

attached.
3. Operate the boom hoist control lever toward the

ef
RAISING side to raise the boom slowly.
4. Paying close attention to catching and kink of

the hoist wire rope, raise the hook.
R
5. Remove the steel plates when enter to the

working range.
10000A-1
6. Before starting actual work, confirm the

following items.
(1) When the hook is hoisted to strike against the

WEIGHT
weight of the hook overhoist limit switch, the
hoisting motion must be auto-stopped.
HOOK
hoisting/
loweing
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nl
O
(2) When the boom is raised to approx. 82 degrees
of boom angle, the boom raising must be auto-
stopped.
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en
Approx. 82 degrees
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(3) If it is difficult to test auto-stop function due to

overload by lifting the actual load, check can be
ef
done in the display.

Perform this test in “WORK” position.
The test will not work in assembly/disassembly
mode.
R
Press icon to indicate menu and then

press.

11000-1
(4) Press icon.
(5) The crane turns to the simulated overload

condition and auto-stop occurs.
y
(Overload check mode)
Check to see that the hook hoisting or boom
nl
lowering can’t be done.
During check mode, message [ME056] appears
in the message area.
(6) After the check, press icon to cancel the
O
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check mode and is completed.
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er
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10000A-1
5.2.3 CONFIRMATION BEFORE LOWERING THE ATTACHMENT

When lowering the attachment, observe following
items;
1. Lowering of the attachment must be performed

in the front direction of the crawler.
2. Steel plate

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nl
O
600 mm
(1′ 11-5/8″)
(1-15/12″)
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450 mm
(1′ 5-11/16″)
STEEL PLATE
3. Lower the hook block on to the ground when

en
the machine get into out of working range.
4. Operation must be performed at a low speed.

Sudden movement must be avoided.
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5. Prevent the wire rope from catching and kink in

the tip end of the boom and jib.
ef

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the attachment.

11000-1
5.2.4 LOWERING THE ATTACHMENT

1. Lower the boom at a low speed.
2. When the boom angle exceeds the working

area, boom lowering is automatically stopped,
and the warning alarm sounds.
BOOM (JIB) LOWEING ICON
3. Lower the hook onto the ground.
4. Return the control lever to neutral then press

(boom/jib lowering icon) on the screen for 1
y
second.
The automatic stop will be released.
nl
Lower the boom further.
5. The crane enters to the boom lowering mode

and the auto-stop due to low boom angle is
O
released to continue lowering the boom.
However, when the weight of hook overhoist
switch contacts the ground, the auto-stop occurs
again due to hook overhoist preventive device. ASSY/DISASSY ICON
ce
To lower the boom further, return the control
lever to neutral then press (assy/disassy
icon) for 1 second.
Now the crane enters to the assy/disassy mode

en
and the auto-stop due to hook overhoist is

released to continue lowering the boom.
Operate with care because the hook overhoist
automatic stop does not function in the assy/
disassy mode.
er

ef

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10000A-1
5.3 DISASSEMBLING THE ATTACHMENT

When disassembling the crane attachment, press
(assy/disassy icon) for 1 second.
Then, the load safety device enters the assy/disassy
mode, and the automatic stop functions are disable.
ASSY/DISASSY ICON

y
nl
O
cannot be set.
ce
TOOL

• Assist crane (25 t capacity)
en
• Wire rope slings (Synthetic fiber sling)

• Wood block
• Corner protectors
• Steel bar
20 mm dia. (25/32″ dia.) × 300 mm (11-13/16″)
er
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11000-1
5.3.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING

1. Disconnecting the jib wiring
If the jib is installed, disconnect the wiring at jib

tip and wind up to the cable reel.
Put the waterproof caps to the disconnected
connectors.
y
nl
O
Disconnect the connector
from hook overhoist limit switch.
ce
CABLE REEL
Remove the
thimble from the hook.
en
To jib foot
Disconnect the connector.

HOOK OVERHOIST LIMIT SWICH
er
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attachment.
10000A-1
2. Disconnecting the load safety device wiring on

the boom tip
Disconnect the hook overhoist limit switch

wiring at the boom tip.
Also disconnect the wiring for the auxiliary
sheave if used.
Put the waterproof caps on the disconnected
connectors.
WATERPROOF CAP (3P)

FRONT DRUM HOOK
y
OVERHOIST LIMIT SWITCH
WATERPROOF CAP (3P)
nl
Remove the
O
WATERPROOF CAP (3P) Boom tip area CONNECT WATERPROOF CAP (3P)
ce
WATERPROOF CAP (3P)
FRONT DRUM HOOK
OVERHOIST LIMIT SWITCH
WATERPROOF CAP (3P)
en
Remove the
er
WATERPROOF CAP (3P) WATERPROOF CAP (3P)

REAR DRUM HOOK
Boom tip area with aux. sheave OVERHOIST LIMIT SWITCH
ef
(AUX. SHEAVE)
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attachment.

11000-1
5.3.2 WINDING UP THE FRONT/REAR DRUM WIRE ROPES
Confirm that the hook is placed in the stable

condition.
1. Remove the rope socket and clamp from the

wire rope end.
y
nl
SPLIT PIN CLAMP
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ROPE SOCKET
2. Remove the hook overhoist limit switch and

ce
weight from the jib point area.
JIB POINT JIB POINT

en
LIMIT SWITCH
SHACKLE
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WEIGHT LIFTING
WIRE ROPE
ef
WEIGHT
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10000A-1
3. Slowly operate the front or rear drum control

lever to wild up the hoist wire rope onto the
corresponding drum and be careful not to tangle
the hoist wore rope with sheave (s).

hands.
y
nl
being entangled.
O
• Keep away from rope end when removing
the wire rope if may suddenly jump and
cause injury.
ce
4. Fix the wire rope end to the drum outer layer

with a steel wire after winding up.
en
er
ef
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11000-1
5.3.3 DISASSEMBLING THE JIB

1. After lowering the jib on the ground, hold the
strut with an assist crane.
Disconnect the boom side jib guy lines from the
lugs on the boom insert.
GUY LINE CONNECTION PINS
y
JIB GUY LINE (BOOM SIDE)
Disconnect
nl
O
ce
2. Remove the strut backstop from the strut, and
STRUT
lay it down toward the jib side while holding the
en
strut.
STRUT BACKSTOP
er
ef
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10000A-1
3. Take off the jib guy line from the jib tip. JIB GUY LINE
SPLIT PIN
View from boom inside
y
4. Remove the strut equalizer sheaves to take off
nl
the jib guy lines.
Reinstall the removed equalizer sheaves back BOOM SIDE JIB SIDE
to the original positions.
O
EQUALIZER SHEAVE
ce
JIB GUY LINE JIB GUY LINE
(BOOM SIDE) (JIB SIDE)
5. With the jib being held with an assist crane,

en
detach the jib from the boom.

Place the jib on wood blockings.
er
ef
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11000-1
6. First remove the jib tip then jib base, followed

by jib insert (s) by disconnecting the pins.
While supporting the component with an assist
crane, remove the top pins first and then
remove the bottom pins.
When disconnecting the jib connection points,
support the jib with the wood blockings to
provide stability.
y
nl
Remove the top connecting pin.
O
ce
en
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10000A-1
5.3.4 REMOVING THE AUXILIARY SHEAVE

When the auxiliary sheave is equipped, remove the
auxiliary sheave with the following procedure.
Auxiliary sheave weight : 195 kg (430 lbs)
1. Remove the bolt, nut and split pin first and then
remove the rope socket from the ball hook.
2. Remove the overhoist limit switch and weight

from the auxiliary sheave.
y
3. Wind up the rear drum rope slowly.
nl
BALL HOOK WEIGHT
O
ce SPLIT PIN CLAMP
ROPE SOCKET
4. Remove the upper then lower securing pins on

SPRING LOCK PIN
the boom tip while holding the auxiliary sheave
en
with an assist crane.
SECURING PIN
er

ef
5. Remove the auxiliary sheave assembly from the

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boom tip.

11000-1
5.3.5 DISASSEMBLING THE BOOM

1. Removing the boom guy line
(1) Set the both spreader guides to the work

position, and slowly loosen the boom hoist wire
rope.
(2) Use the spreader guide, to install the upper
spreader on the boom base with the spreader
securing pin.
(Refer to 5.1.3 HANDLING OF SPREADER
GUIDE).
y
nl
Place a signalman to prevent an incident from SPREADER
caught. SECURING PIN
O
ce
en
stably on it.
(3) Disconnect the guy lines from the upper

spreader. UPPER SPREADER
er
Put back the guy line connecting pins to the SPLIT PIN GUY LINE
upper spreader.
ef
Remove the
guy line connecting pins.
R
SPLIT PIN GUY LINE
10000A-1
(4) Disconnect guy lines step by step in order.

(5) Using an assist crane, lower the guy lines to the
ground.
Be careful not to damage the boom.
y
nl
GUY LINE GUY LINE CONNECTING PIN GUY LINE
O SPLIT PIN
ce
2. Removing the cable roller
Remove the cable roller which is installed on

the boom insert.
en
Remove the cable roller installed on the boom

tip if required.
For boom insert For boom tip

er
SPACER SPACER CABLE ROLLER
CABLE ROLLER
ef
BOOM INSERT BOOM INSERT BOOM TIP BOOM TIP

R

11000-1
3. Disconnecting the boom base and boom insert
(1) Lift up the connecting point of the boom base

and the boom insert to relief the force on the
lower connecting point.
(2) Draw out the lower connecting pin (double
tapered) from outside.
(3) Insert a steel bar in to the hole after removing
the connecting pin (double tapered) to avoiding
out of alignment.
(4) Remove other side of connecting pin (double
tapered) in the same way.
y
nl
SPRING LOCK PIN
O
CONNECTING PIN
(Double tapered)
ce
aligning, inserting or removing pin. STEEL BAR
en

er

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10000A-1
(5) Remove the bar and slowly lower the boom

SPRING LOCK PIN
base which is supported by an assist crane and
place it on the wood blockings.
(6) After confirming that the boom base is stable
on the wood blockings, remove the upper
connecting pins (with flange) and disconnect it
from the boom insert.
CONNECTING PIN
(With flange)
y
nl
4. Disconnecting the boom tip
O
SPRING LOCK PIN
While holding the boom tip with an assist crane,

draw out the bottom side connecting pins.
Then, draw out the top side connecting pins, to
disconnect the boom tip.
ce
Remove the boom tip with using the assist
crane.
CONNECTING PIN
(With flange)
en

er
SPRING LOCK PIN

ef
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CONNECTING PIN
(With flange)

11000-1
5. Disassembling the boom insert

SPRING LOCK PIN
Disconnect the boom insert from boom tip

side in order by removing the top and bottom
connecting pins (with flange).
CONNECTING PIN
Do not insert finger or hand into a pin hole when (With flange)
y
nl
O
SPRING LOCK PIN
ce
CONNECTING PIN
en
(With flange)
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10000A-1
5.4 CAUTION WHEN TRANSPORTING BOOM

1. In order to prevent damaging the boom, do not PROTECTION OF BOOM
apply the slings directly to the main chords.
Do not apply slings to the lacings. MAIN CHORD
Use only synthetic fiber slings.
Do not apply slings to lattice pipes for transport.

The lattice pipes may be damaged.
y
nl
LATTICE PIPE
O
2. Place wood blockings under the both ends of
the boom.
ce
3. When placing a boom on top of another boom,
place wood blockings in similar manner to the
bottom one.
en
If one of them has lugs, place it at the bottom to

keep the transport height low.
er

ef
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11000-1
y
nl
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ce
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10000A-1
[ 6. WIRE ROPE ]
6. WIRE ROPE
6.1 HANDLING OF WIRE ROPE ............................................................................................... 6-1
6.1.1 SPECIFICATION OF WIRE ROPE ............................................................................... 6-2
6.1.2 WIRE ROPE LENGTH...................................................................................................... 6-5
6.1.3 CAUTIONS IN HANDLING WIRE ROPE .................................................................... 6-7
6.1.4 WINDING WIRE ROPE TO THE DRUM ..................................................................... 6-8
6.1.5 CORRECTING METHOD OF ENTANGLED WIRE ROPE .................................... 6-12
6.1.6 ROPE SOCKET INSTALLATION................................................................................... 6-14
y
6.1.7 REPLACEMENT STANDARDS FOR WIRE ROPE ................................................. 6-15
nl
O
ce
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11000-1
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nl
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[ 6. WIRE ROPE ]
6. WIRE ROPE
6.1 HANDLING OF WIRE ROPE
When the crane is shipped from factory, maximum

length of wire rope required for boom and jib
configuration and a number of part lines which is
possible has been wound on the drum.
If boom length is short and a number of parts lines
y
are less, rough spooling such as looseness of
wire rope, cross winding or biting may occur.
nl
Use of proper rope length based on crane
operating conditions (length of boom or jib,
number of part lines of rope, lifting height) is
recommended.
O
(Refer to the table in "6.1.2 WIRE ROPE LENGTH".)
The hook has been removed at the factory
shipment. Winding of rope may be loose and rope
biting may occur.
If wire rope is loose, rewind the wire rope applying
ce
some tension.
en
If rope diameter is out of specified range, biting or

rough spooling may occur.
Recommend use genuine wire rope.
er
ef
Set the hook and number of parts line of rope

properly based on lifting load and length of boom
and jib.
R
serious accident.

and may create the rough spooling of wire rope on
the drum or load swinging.

11000-1
[ 6. WIRE ROPE ]
6.1.1 SPECIFICATION OF WIRE ROPE
WIRE ROPE FOR CRANE

Breaking strength : Rope dia. : Rope length :
Use Rope spec. Part No.
kN (lbs) mm m (ft)
U3 × SeS (48)
601 (135,110)
Right-hand Regular lay
Front drum 26 235 (771)
IWRC 6 × Fi (29)
534 (120,048)
U3 × SeS (48)
601 (135,110)
y
Rear drum 26 160 (525)
IWRC 6 × Fi (29)
534 (120,048)
nl
Boom hoist IWRC 6 × P·WS (31)
210 (47,210) 16 150 (492)
drum Right-hand Regular lay
Third drum IWRC 6 × Fi (29)
363 (81,606) 22 145 (476)
O
(Option) Right-hand Regular lay
ce
• To properly wind the wire rope to the drum,
it is recommended to use wire rope with its
diameter of 3.5 ± 1% larger than nominal
value.
• If rope diameter is out of specified range,
en
biting or rough spooling may occur.

Recommend use genuine wire rope.
WIRE ROPE FOR HYDRAULIC TAGLINE (OPTION)

er
Breaking strength : Rope dia. : Rope length :

Use Rope spec. Part No.
kN (lbs) mm m (ft)
Hydraulic FC 6 × W (19)
58 (13,039) 10 45 (148)
ef
tagline Right-hand Regular lay
• Ensure to use the specified type of wire rope on

each drum as factory shipment by Manitowoc.
R
• If the diameter of the rope used is out of

dimension tolerance range on each drum
groove, rope upsetting may be caused.
10000A-1
[ 6. WIRE ROPE ]
WINDING CAPACITY OF WIRE ROPE ON EACH DRUM
Front drum, Rear drum

Drum winding capacity on min. Pcd with 26 mm dia. rope.
Min Pcd : Winding L on each Total winding Min Pcd means theoretical value
Layer Row calculated from the figure below
m (ft) layer : m (ft) length : m (ft)
on 2nd or higher layer.
1 22 0.614 (2.014) 42.4 (139) 42.4 (139) 26
2 22 0.658 (2.159) 45.5 (149) 87.9 (288)
3 22 0.702 (2.303) 48.6 (159) 136.5 (448)
4 22 0.747 (2.451) 51.6 (169) 188.1 (617)
Min Pcd
y (0.9)
22.1
5 22 0.791 (2.595) 54.6 (179) 242.7 (796)
27.4
6 22 0.835 (2.740) 57.7 (189) 300.4 (986) (1.1)
nl
Unit : mm (in.)
7 22 0.879 (2.884) 60.8 (199) 361.2 (1,185)
Third drum (option)

O
Min Pcd : Winding L on each Total winding Min Pcd means theoretical value
Layer Row calculated from the figure below
on 2nd or higher layer.
1 23 0.550 (1.805) 39.7 (130) 39.7 (130) 22
2 23 0.587 (1.926) 42.5 (139) 82.2 (270)
ce
3 23 0.624 (2.047) 45.1 (148) 127.3 (418)
4 23 0.662 (2.172) 47.9 (157) 175.2 (575) Min Pcd
(0.7)
18.7
5 23 0.700 (2.297) 50.5 (166) 225.7 (740)
23.2
6 23 0.737 (2.418) 53.3 (175) 279.0 (915) (0.9)
en
Unit : mm (in.)
7 23 0.774 (2.539) 55.9 (183) 334.9 (1,098)
Boom drum
er
Min Pcd : Winding L on each Total winding

Layer Row
1 12 0.376 (1.234) 14.2 (47) 14.2 (47) Min Pcd means theoretical value
calculated from the figure below
2 12 0.403 (1.322) 15.2 (50) 29.4 (96) on 2nd or higher layer.
ef
16
3 12 0.430 (1.411) 16.2 (53) 45.6 (150)
4 12 0.458 (1.503) 17.3 (57) 62.9 (206)
5 12 0.485 (1.591) 18.2 (60) 81.1 (266)
Min Pcd
R
6 12 0.512 (1.680) 19.3 (63) 100.4 (329)

(0.5)
13.6
7 12 0.539 (1.768) 20.3 (67) 120.7 (396) 16.9

(0.6)
8 12 0.566 (1.857) 21.4 (70) 142.1 (466) Unit : mm (in.)
9 12 0.594 (1.949) 22.4 (73) 164.5 (540)
10 12 0.621 (2.037) 23.4 (77) 187.9 (616)

11000-1
[ 6. WIRE ROPE ]
TYPE OF WIRE ROPE
The factory shipped wire ropes do not satisfy all

working condition.
Selection of proper wire rope to the working condition
is required.
The wire rope has its own characteristics.
Select the proper wire rope to the working condition
referring to the table below.
PRINCIPAL WORK CONTENTS AND ITS RECOMMENDED HOIST WIRE ROPE TYPE
y
Work contents Type of wire rope Remarks
High lifting work
nl
• Crane, Tower Even non rotating type, it has rotating
U3 × SeS (48)
• Jib, Aux. sheave property.
• Rope number of parts line 1 to 2
General crane work
O
• Work with boom shorter than half of
maximum boom.
Work cycle is comparatively low. IWRC 6 × Fi (29)
• Assisting crane work to foundation
work
ce
• Clamshell work
Heavy load, High cycle work
• Block lifting / transposition work
IWRC 6 × Fi (29)
• Port loading / unloading work
(Grab bucket work)
en

IWRC 6 × Fi (29) * Even non rotating type, it has rotating
• Under ground excavating work
U3 × SeS (48)* property.
(Hammer grab work)
IWRC 6 × Fi (29) * Even non rotating type, it has rotating
er
• Underground diaphragm wall work

U3 × SeS (48)* property.
(Diaphragm wall bucket work)
Light load, High cycle work
IWRC 6 × Fi (29)
• Lifting magnet work
ef
TYPE OF WIRE ROPE FOR BOOM AND JIB HOIST
Work contents Type of wire rope Remarks

R
All construction and foundation work

• Crane boom hoist
IWRC 6 × P·WS (31)
• Tower hoist
• Tower jib hoist
10000A-1
[ 6. WIRE ROPE ]
6.1.2 WIRE ROPE LENGTH
WIRE ROPE LENGTH OF FRONT DRUM FOR CRANE Unit : m (ft.)
Boom length : Parts of line

m (ft.) 1 part 2 part 4 part 5 part 6 part 7 part 8 part
12.2 (40) 28 (92) 40 (131) 65 (213) 78 (256) 90 (295) 103 (338) 115 (377)
15.2 (50) 34 (112) 49 (161) 80 (262) 96 (315) 111 (364) 127 (417) 142 (466)
18.3 (60) 40 (131) 58 (190) 95 (312) 114 (374) 132 (433) 151 (495) 169 (554)
21.3 (70) 46 (151) 67 (220) 110 (361) 132 (433) 153 (502)
24.4 (80) 52 (171) 76 (249) 125 (410) 150 (492) 174 (571)
y
27.4 (90) 58 (190) 85 (279) 140 (459) 168 (551)
30.5 (100) 64 (210) 95 (312) 156 (512) 186 (610)
nl
33.5 (110) 70 (230) 104 (341) 171 (561)
36.6 (120) 76 (249) 113 (371) 186 (610)
39.6 (130) 82 (269) 122 (400) 201 (659)
O
42.7 (140) 88 (289) 131 (430) 216 (709)
45.7 (150) 94 (308) 140 (459) 231 (759)
48.8 (160) 100 (328) 149 (489)
51.8 (170) 106 (348) 158 (518)
ce
54.9 (180) 112 (367) 167 (548)
57.9 (190) 118 (387) 176 (577)
61.0 (200) 124 (407) 185 (607)
en
If the longer rope is used, rope rough spooling on

the drum may likely occur.
er
ef
This table indicates the required rope length in

case the hook height is about boom foot.
If in case the below ground work is required, the
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wire length shall be determined accordingly.

11000-1
[ 6. WIRE ROPE ]
WIRE ROPE LENGTH OF REAR DRUM FOR FIXED JIB Unit : m (ft.)
Boom length : Jib length : m (ft.)

m (ft.) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60)
24.4 (80) 72 (236) 78 (256) 83 (272) 89 (292)
27.4 (90) 78 (256) 84 (276) 90 (295) 95 (312)
30.5 (100) 84 (276) 90 (295) 96 (315) 101 (331)
33.5 (110) 90 (295) 96 (315) 102 (335) 108 (354)
36.6 (120) 96 (315) 102 (335) 108 (354) 114 (374)
39.6 (130) 102 (335) 108 (354) 114 (374) 120 (394)
y
42.7 (140) 108 (354) 114 (374) 120 (394) 126 (413)
45.7 (150) 114 (374) 120 (394) 126 (413) 132 (433)
nl
48.8 (160) 120 (394) 126 (413) 132 (433) 138 (453)
51.8 (170) 126 (413) 132 (433) 138 (453) 144 (472)
54.9 (180) 132 (433) 138 (453) 144 (472) 150 (492)
O
57.9 (190) 138 (453) 144 (472) 150 (492) 156 (512)
ce
If the longer rope is used, rope rough spooling on
the drum may likely occur.
en
This table indicates the required rope length in

case the hook height is about boom foot.
If in case the below ground work is required, the
er
wire length shall be determined accordingly.

ef
R
10000A-1
[ 6. WIRE ROPE ]
6.1.3 CAUTIONS IN HANDLING WIRE ROPE

1. Cautions in unloading or during transportation
• Do not drop from the load deck.

• When rolling the wooden rope reel with lever
etc, do not touch the wire rope direct with the
lever but touch the outer flange area.
• In case of coiled wire rope, do not place or roll
over directly on the sandy ground or on the
steel pieces.
y
2. Cautions in storing
nl
• Store the wire rope in dry atmosphere.
In case of outdoor storage, ensure to put the
cover to protect from rain.
• Do not place the wire rope directly on the
O
ground but place them approx. 200 to 300
mm (8″ to 12″) above the ground with wooden
blocks.
3. Unreeving the wire rope

ce
When unreeving the wire rope, take extra care
not to allow kinking.
It would be convenient to use the jig as shown
right.
en
If such jig is not available, unreeve the wire rope

by rolling the reel on the ground taking care not
to allow sand or iron pieces adhered.
er
To drum
Kink : Deformation by twisting of wire rope

ef
(1) Loop by twisting wire rope
(2) Pulled up condition under tension

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(3) Kink occurred
Wire rope does not return to original

(4)
shape
Unreeving method of wire rope

11000-1
[ 6. WIRE ROPE ]
6.1.4 WINDING WIRE ROPE TO THE DRUM

1. In case of front and rear drum
When the crane is shipped from factory, maximum

length of wire rope required for boom and jib
configuration and a number of part lines which is
possible has been wound on the drum.
If boom length is short and a number of parts lines
y
are less, rough spooling such as looseness of
wire rope, cross winding or biting may occur.
nl
Use of proper rope length based on crane
operating conditions (length of boom or jib,
number of part lines of rope, lifting height) is
recommended.
O
(Refer to the table in "6.1.2 WIRE ROPE LENGTH".)
The hook has been removed at the factory
shipment. Winding of rope may be loose and rope
biting may occur.
If wire rope is loose, rewind the wire rope applying
ce
some tension.
en
er
ef
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10000A-1
[ 6. WIRE ROPE ]
(1) Pass the wire rope through the inside of the

drum flange and secure it to the drum flange by
clamping with two mounting plates.
Do not allow the rope end to protrude from the
drum flange.
Paint the wire rope

here in “WHITE”.
If the rope end is not firmly secured, rope may slip

out and the load may drop off.
Ensure to secure the rope end properly.
y
serious accident.
nl
(2 × 2 - M20 × 65)
Tightening torque : Rope end should come out of mounting
333 to 407 N·m plate end but not to protrude from drum
(246 to 300 ft·lbs) flange outer dia.
O
ce
en
(2) Pull the wire rope manually and wind up on the

drum groove while guiding the rope along the
drum end guide.
er
Make sure that minimum 3 turns remain on

FLANGE
the drum even wire rope is paid out to the
maximum.
ef
If more than 3 turns do not remain on the drum, Tap Lightly

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wire rope may slip out and lifting load may drop.
Ensure to have minimum 3 turns remained on the
drum.
serious accident.

11000-1
[ 6. WIRE ROPE ]
(3) Winding the wire rope to the drum with applying

the tension approximate 2 to 4% of its breaking
strength.
To apply the tension on the wire rope, lift the
required load with the necessary lifting height,
pull the load which is placed on the ground in
front or traveling to the load with applying the
tension by winding the hoist drum.
2. In case of boom drum Do not allow wire rope

to come out of wedge end.
(1) Do not allow the wire rope end to come out of
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drum wedge hole.
Tension side rope should come to the straight
nl
face side of socket.
Install the wedge firmly on the drum.
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WEDGE
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Correct Protrusion Inverse insertion
(2) Pull the boom hoist wire rope manually and tap Pull Pull Pull
en
lightly on the wire rope to align and wind the

wire rope slowly.
Apply tension on the wire rope by boom weight
and slowly wind on the drum.
er
Take extra care to work on the moving wire rope

ef
not to touch the sheave and wire rope to prevent

accident of being crushed or being entangled.
R
Lightly tap Lightly Twist Lightly tap
10000A-1
[ 6. WIRE ROPE ]
(3) Make sure that minimum 3 turns remain on

the drum even wire rope is paid out to the
maximum.
If more than 3 turns do not remain on the drum,

wire rope may slip out and lifting load may drop off.
Ensure to have minimum 3 turns remained on the
drum.
y
serious accident.
nl
(4) Winding the wire rope to the drum with applying
the tension approximate 2 to 4% of its breaking
strength.
O
To apply the tension on the wire rope, lift up
the whole of boom hoist wire rope between the
upper and lower spreader with an assist crane
or the apply the boom weight to the upper and
lower spreader.
ce
3. If the layer change occurs on the drum flange
protruding point (change from 1st layer to 2nd
layer), wire rope and drum end area is guided
by protruding portion and clearance of approx.
en
1/2 of wire rope dia. may be created.

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If wire rope wound without clearance having forced

to along with the protruding part may cause rope Clearance of approx.
No clearance 1/2 of wire rope dia.
upsetting.
Ensure to provide clearance as shown on right
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figure at the protruding part.

damage parts.
PARALLEL
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Even if the winding layer becomes multiple layer, wire CROSS - OVER
rope behavior in layer changing area is basically the
same as that of between 1st and 2nd layer.
However due to wire rope and drum manufacturing PARALLEL
unevenness, layer change area varies as layer
becomes larger. FLANGE PROTRUSION FLANGE PROTRUSION

11000-1
[ 6. WIRE ROPE ]
6.1.5 CORRECTING METHOD OF ENTANGLED WIRE ROPE

The wire rope has a tendency to rotate to the direction
for returning its lay when the load is applied due to its
construction.
This is called “wire rope rotating property”.
In case of high lifting crane or lifting with 2 to 3 parts
of line on hook, wire rope may be entangled or lifting
load may rotate due to rope rotating property and work
safety or efficiency may be suffered.
When the rope becomes entangled due to this
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wire rope rotating property, correct them as per the
following procedure.
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1. Type of wire rope lay
There are two types of wire rope lay, Right hand
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lay and Left hand lay.
Be careful about the type of lay.
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Right hand lay Left hand lay
2. Correcting method of entangled wire rope

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To correct the entangled wire rope,make

wire rope end free and loosen the wire rope
completely.
Turn the rope socket side end forcibly then
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repeating hook hoisting or lowering in such way

that the applied lay portion will move toward
drum side sequentially.
Perform running in of rope by repeating these.
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• Method to provide rotating of rope socket area.

Rotate the rope socket in the opposite direction
as that of the entangled rope hook.
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In case of right hand twisting : In case of left hand twisting :

Left rotation (remove laying) Right rotation (remove laying)
10000A-1
[ 6. WIRE ROPE ]
3. Cautions in correcting entangled wire rope
(1) Number of rotation of rope required for correcting

entangled rope.
Number of entanglement x rope number of parts
of line = correcting rotation number
Number of entanglement : number of rotation of
hook
(2) Too many rotation in one trial may cause rope

shape deformation.
Since it would be difficult to correct evenly
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throughout the entire length by one trial, limit
the rope rotations to 4 to 5 on one trial.
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Repeat the correcting for several times based
on the conditions.
(3) The cause of entanglement may vary based on
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the timing of entanglement occurrence.
Be careful on this point.
If the entanglement occurs just after the rope

installation or crane operation, correct them as
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per the previously mentioned procedure.
If the entanglement occurs sometime after crane

work, the following causes can be assumed.
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• Wire rope is drawn with the sheave and rope

lay move irregularly
• The sheave dia. is too small.
• Wear on sheave groove.
• Fleet angle is too large.
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Contact the nearest Manitowoc for the correction.

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Be careful on rope socket rotation due to rope lay

when removing the rope socket.
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serious injury.
(4) Removing method of rope lay of boom hoist

drum wire rope.
In the boom hoist drum wire rope, wire rope
may cause waving due to wire rope unlay.
In such case, remove the rope socket and take
out the rope lay.
At the same time, inspect the sheave rotation.

11000-1
[ 6. WIRE ROPE ]
6.1.6 ROPE SOCKET INSTALLATION

1. Pass the wire rope through the socket and ROPE SOCKET
make loop on the rope end.
Load line of the rope must be in the straight side WIRE ROPE
of the socket. WEDGE
2. Insert the wedge and pull the wire rope loop

with the wedge strongly to secure.
3. Secure the wire rope with the rope clamp.

Set the rope clamp to the proper direction.
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4. Install the socket to the boom or hook and apply
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the load to the wire rope to pull in the wedge to CLAMP
the final position.
When installing the rope socket to the boom
point, make sure to install in the proper direction.
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CLAMP
LOAD LINE DEAD END
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PULL
5. When installing the rope socket to the boom, Inner side of boom Outer side of boom
insert the mounting bolt from the boom inner
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side and secure it with the nut and split pin from
outer side. Direct the bolt from inner
side of the boom tip to
outer side. Secure the bolt with
nut and the split pin,
split the pin to
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approx. 60 degrees.
Insert the rope socket mounting bolt from boom

inner side and secure it with the nut and split pin
at the outer side.
ROPE SOCKET
If secured with nut at the inner side, the wire rope
and the split pin would interfere and the nut would
become loose and fall off.
serious accident.
10000A-1
[ 6. WIRE ROPE ]
6.1.7 REPLACEMENT STANDARDS FOR WIRE ROPE

1. Check and replacement standards of wire rope
If the wire rope is broken during operation, it

might cause a serious accident.
Therefore, check the rope periodically.
Never use those wire ropes that wire-cut,
abrasion, corrosion and other defects are
observed.
Such wire rope as given in Items (1) to (5) below
must be immediately replaced with a new rope.
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And wire rope subject to damage mentioned in
Items (6) onwards should be replaced with new
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one immediately according to the degree of
damage.
TYPE OF WIRE ROPE
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• HOOK HOIST WIRE ROPE
• BOOM HOIST WIRE ROPE
• THIRD DRUM WIRE ROPE (OPTION)
• GUY LINE
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• TAGLINE WIRE ROPE (OPTION)
• REEVING WINCH WIRE ROPE (OPTION)
(1) 10% or more steel wires are broken excepting Lay length of wire rope
filler wires in one lay of wires.
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Length of one lay. (one pitch)

Inspection of internal breakage of wires is
difficult. 1 2 3 4 5 6
To check breakage of wires in the valley section

of wire ropes, bend the rope sharply.
1 to 6 - Strand number
Broken element wires, if any, will be exposed.
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If breakage of wires in the valley section is Breakage in the valley Broken wire may expose
when bend the wire rope.
found, it is considered that internal breakage of
wires may also have been developed, and that
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in other words, fatigue of the whole rope may

have been developed.
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11000-1
[ 6. WIRE ROPE ]
(2) Wire rope of more than 7% (or 5%, under Method of measuring rope diameter.
OSHA 1926.1413) reduction in diameter from
the nominal diameter, caused by abrasion.
Correct Wrong
Core of the rope ROPE
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STRAND
ELEMENT WIRE
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(A) Breaking load and diameter
• Breaking load
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Strength of wire rope is indicated by breaking load.
Breaking load is decided on the strength of wire
and tensile strength of each class is specified.
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Even on the same diameter rope, different class
rope has different breaking load.
Be careful on this point.
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serious accident.
• Diameter
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Diameter of wire rope will be reduced by wear.

Diameter also is reduced by applying overload.
Therefore, it is necessary to keep measuring its
diameter for safety.
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Do not use the wire rope of which diameter is

reduced by 7% from its normal value.
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For example, nominal 22 mm diameter rope

22 - (22 × 0.07) = 20.46
To properly wind the wire rope to the drum, it is

recommended to use wire rope with its diameter
of 3.5 ±1% larger than nominal value.
10000A-1
[ 6. WIRE ROPE ]
(B) Measuring method of wire rope diameter

The table below shows how to measure rope
diameter.
Outer strand number Diameter measurement

In the same cross section, take measurement at
3 directions and take average value.
a
6 strands
a+b+c
d= c b
3
Even number
strand
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In the same cross sections, measure on almost
90 degrees angle and take average of two.
a
a
Others
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a+b
d= b b
2
In the same cross section, place the plate with 1/2
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to 1 layer length and its known thickness t at 3 positions
and take measurement as shown and deduct t from
a
3 strands its average value.
t
c b
a+b+c
d= -t
3
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Odd number
strand In the same cross section, place the plate with 1/2
to 1 layer length and its known thickness t at 3 positions
and take measurement as shown and deduct t from
a
Others its average value.
t
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b
a+b
d= -t
2
(C) Handling wire rope

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Wire rope supports large load and its role is

important.
If broken, it will cause a serious accident.
Therefore take extra care in handling wire rope.
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Degree of wire rope wear or damage varies

remarkably depending on handling method.
Take utmost care in safety matters.
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Do not bend sharply with directly rigged on the

sharp corner.
This will affect dramatically the strength of the
wire rope.
Put the protective materials on the sharp corner.
serious accident.

11000-1
[ 6. WIRE ROPE ]
(3) Kink is observed in the wire rope.
Kink due to lay jamming
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(4) Due to upper layer wire rope with load penetrated
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into lower layer wire rope and lower wire rope is
excessively deformed.
(5) Excessive deformation or corrosion is observed
on the wire rope.
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(6) Excessive elongation is observed due to
overloading or derailment from sheaves.
(7) A short circuit has been formed electrically.
(8) Those wire ropes that are subject to fire or
spark by electric current or by gas welding as
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well as subject to high temperature.
2. Replacement standard for guy line
Since corrosion and damage are caused by

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Recommended
fatigue are from the inside of the boom guy line, Contents of work
interval
replacement time cannot be judged from the
Normal crane work 6 years
appearance.
If the guy line is broken by progressing of Both crane and clamshell work, or
internal damage and/or corrosion, there is frequent crane work such as loading/ 4 years
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possibility to cause a serious accident. unloading work
Be sure to replace the guy line periodically. Lifting magnet or clamshell work only 2 years
Replacement time according to the content of
work is shown in the table.
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10000A-1
[ 6. WIRE ROPE ]
3. Overhoist limit switch weight rope
Replace the wire rope as soon as possible if its

vinyl insulation is broken or it is subject to the LIMIT SWITCH
above mentioned replacement standard.
WEIGHT ROPE
(VINYL INSULATION)
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WEIGHT
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11000-1
[ 6. WIRE ROPE ]
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10000A-1
[ 7. MAINTENANCE ]
7. MAINTENANCE
7.1 INSPECTION INTERVAL ...................................................................................................... 7-9
7.1.1 TABLE OF INSPECTION POINTS................................................................................ 7-9
7.1.2 TABLE OF OIL, GREASE AND WATER SUPPLY POINTS .................................. 7-11
7.2 INSPECTION ............................................................................................................................ 7-13
7.2.1 INSPECTION OF UPPER MACHINERY .................................................................... 7-13
7.2.2 INSPECTION OF LOWER MACHINERY ................................................................... 7-20
7.2.3 INSPECTION OF ATTACHMENT.................................................................................. 7-22
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7.2.4 INSPECTION METHOD OF EACH POINT ................................................................ 7-24
7.3 INSPECTION AND OIL/GREASE AND WATER SUPPLY .......................................... 7-54
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7.3.1 INSPECTION, OIL/GREASE AND WATER SUPPLY POINTS OF UPPER
MACHINERY ....................................................................................................................... 7-56
7.3.2 LOWER LUBRICATION ................................................................................................... 7-60
7.3.3 ATTACHMENT LUBRICATION ...................................................................................... 7-62
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7.3.4 INSPECTION, GREASING (WATER SUPPLY) ON EACH POINT ..................... 7-64
7.4 REPLACEMENT AND CLEANING/WASHING FILTER ELEMENT AND
STRAINER ................................................................................................................................ 7-86
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7.4.1 REPLACEMENT, CLEANING, WASHING POINTS OF FILTER ELEMENT
AND STRAINER ................................................................................................................. 7-86
ELEMENT AND STRAINER............................................................................................ 7-88
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7.5 BATTERY INSPECTION ....................................................................................................... 7-108

7.6 LOCATION AND USE OF FUSE ........................................................................................ 7-114
7.7 OPERATION UNDER SEVERE CONDITIONS ............................................................. 7-116
7.8 HANDLING OF DIESEL PARTICULATE FILTER .......................................................... 7-120
7.9 MACHINE STORAGE ............................................................................................................ 7-123
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7.10 TIGHTENING TORQUE VALUES ...................................................................................... 7-124

7.11 PERIODICAL REPLACING SECURITY PARTS ............................................................ 7-129
7.12 ADJUSTMENT ......................................................................................................................... 7-131
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7.12.1 ADJUSTMENT OF FRONT, REAR, THIRD (OPTION) DRUM LOCKS ............. 7-131
7.12.2 ADJUSTMENT OF BOOM DRUM LOCK ................................................................... 7-132
7.12.3 CRAWLER SHOES ADJUSTMENT ............................................................................. 7-133
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7.13 CONSUMABLE PARTS LIST .............................................................................................. 7-134

7.14 MEASURES REQUIRED FOR FRONT, REAR WINCH MONITORING................. 7-142
7.14.1 THEORETICAL SERVICE LIFE..................................................................................... 7-142
7.14.2 USED PROPORTION OF THEORETICAL SERVICE LIFE .................................. 7-143
7.14.3 DETERMINING OF THE RESIDUAL THEORETICAL SERVICE LIFE.............. 7-147

11000-1
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[ 7. MAINTENANCE ]
7. MAINTENANCE
In order to use this machine always safely in the best
condition, preventive maintenance is required.
When checking the machine, lower the boom

down to the ground, stop the engine and engage
all locks.
Also remove the keys or battery cables to prevent
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other personnel from starting the crane while
maintenance personnel are at work.
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1. Precautions when perform an inspection and
maintenance
• Carry out the inspection and maintenance with

a suitable working closes on.
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• Be sure to set the machine on a firm and level
ground, and post a notice board showing “Under
Check and Inspection”.
• The inspection and maintenance in an elevated
place be sure use a working scaffold and safety
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harness.
• When working to perform the inspection and
maintenance, determine the fixed signals, and
move the machine following the signals.
• When perform the inspection and maintenance
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of hydraulic components, be careful to prevent

dust and dirt from entering.
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11000-1
[ 7. MAINTENANCE ]
2. Inspection table
• The following the inspection table is based on

the average operation condition.
Consider the inspection schedule according to
the working condition and weather condition.
• The inspection table covers all items, but if an
operator and maintenance personnel judges
that additional items are necessary, adds them
to the inspection items.
• Whenever a question arises regarding the
inspection and maintenance, consult the
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When necessary repairs or adjustments are noted
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during an inspection, be sure to complete the
repairs or adjustments immediately.
3. Maintenance
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• Maintenance
When replacement of parts and readjustment
are required by check, immediately replace or
adjust.
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If repair is necessary, consult the authorized

• Parts
Use se the Manitowoc genuine parts for
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replacement parts and Manitowoc recommended

lubricant to be used in order to keep performance
of the machine.
The consumable items such as elements, etc.
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must be replaced somewhat early in order to

prevent deterioration.
Any questions, regarding the check and
maintenance, consult the authorized Manitowoc
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distributor.
10000A-1
[ 7. MAINTENANCE ]
4. Precautions when perform the inspections and

maintenance
• Be sure to use Manitowoc genuine parts for

replacement parts and Manitowoc specified
lubricant to be used.
The warranty does not cover malfunctions caused

by the use of parts other than Manitowoc specified.
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(Genuine oil, grease and filter).
nl
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fuel in the area.)
before refilling.
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white smoke.
or emission control device and white smoke
or failure may be resulted.
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11000-1
[ 7. MAINTENANCE ]
• Use clean oil and grease.

Keep the containers for oil and grease to
prevent dust and water from entering.
Be sure to use clean oil and grease.
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• Clean machine.
Wash the machine to make finding of oil leak,
crack, loosening and other wrong condition
easy.
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Especially, clean grease fittings, breathers and
oil level gauge parts (window for check of oil),
and avoid entering of dust.
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• Disposal of spilled oil.
Leaving oil spilled when refilling or replacing
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fuel, hydraulic oil, various lubricants, or

replacing the filter, may lead to a fire accident.
Thoroughly wipe it.
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• Caution when washing the machines.

Do not aim pressure wash or steam directly to
electric parts and connectors.
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10000A-1
[ 7. MAINTENANCE ]
• Place a warning plate before inspection.

When perform the inspection and maintenance,
be sure to indicate warning plate “Do not start
the engine, under inspection” to the control
lever.
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• Keep fire away.
Wastes with oil and combustibles should be
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stored in a safe place without fire.
Confirm the storage position and using method
of fire extinguisher for emergency.
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• Pay attention to moving parts!

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When checking fan belt tension or water pump,

it may become entangled in moving machinery.
Stop the engine, then work.
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11000-1
[ 7. MAINTENANCE ]
• Pay attention to temperature of water and oil.

Since draining oil, cooling water and replacing
filters just after the engine stops is dangerous,
wait until the temperature lowers, then perform
these works.
However, oil is cold case, rise the oil temperature
to approximate 20 °C to 50 °C (68°F to 122°F).
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• Check the drained oil and filter.
When replacing oil or filter, check the drained oil
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and oil filter to see if the significant amount of
metal powder or foreign material are included.
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• Pay attention to dust.

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Install the clean plug or cap to the oil holes

of the disconnected hyd. hoses to prevent
contamination of foreign material.
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10000A-1
[ 7. MAINTENANCE ]
• Clean mounting surfaces.

When sealing sections of O-rings and gaskets
were removed, clean the mounting surfaces,
then replace with new ones.
When assembling, apply a thin coat of oil to the
seals.
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• Pay attention to internal pressure.
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When removing hydraulic system, air system,
fuel system or pipings and connectors of
cooling system and other related parts which
have internal pressure, bleed internal pressure
beforehand.
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• Precaution when welding.

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1. Turn off power supply (turn the key switch off).

2. Disconnect the cable of side of the battery.
3. Do not apply voltage more than 200 volts
continuously.
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4. Provide earth (ground) within 1 meter from the

welding section.
5. There should be no seal and bearing to enter
between the welding section and earth point.
6. When welding near the load safety device and
controller, remove them to prevent damage.

11000-1
[ 7. MAINTENANCE ]
• Treatment of drained oil.

Be sure to drain discarded oil into a container,
and treat it as industrial discharges.
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• Caution for adjustment, disassembly.
Never adjust or disassembly the engine,
hydraulic component and the electronic
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components (controller etc.).
Failures due to unauthorized modification,
unauthorized parts installation or wrong
handling of components would not be covered
by WARRANTY.
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10000A-1
[ 7. MAINTENANCE ]
7.1 INSPECTION INTERVAL

7.1.1 TABLE OF INSPECTION POINTS
The number in the list below is corresponding to the
figure and table on “7.2 INSPECTION”.
Check interval (hourmeter : Hr)

Item Inspection point
8 50 100 250 500 1,000
1. FUEL AND HYDRAULIC LINES
2. ENGINE
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3. HOSE, PIPING AND CONNECTOR *
4. SWING BRAKE
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5. SWING LOCK
6. CONTROL LEVER, BRAKE PEDAL
7. GANTRY
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8. HORN, WORK LIGHT AND WIPER
9. AIR CLEANER
10. PIN, LINK AND COTTER PIN *
11. BOLT AND NUT *
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12. HOOK OVERHOIST PREVENTIVE DEVICE
13. BOOM OVERHOIST PREVENTIVE DEVICE
14. LOAD SAFETY DEVICE, MONITOR
15. DRUM LOCK
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Upper 16. WINDOW GLASS, STEP, HANDLE AND GUARD

machinery 17. DRUM BRAKE DISK (FRONT, REAR, THIRD [OPTION])
18. FUEL FILTER
19. FAN BELT
20. RADIATOR AND OIL COOLER
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21. ENGINE MOUNTING BOLT AND RUBBER MOUNT

22. POWER DIVIDER
23. HYDRAULIC MOTOR AND REDUCTION UNIT
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24. VALVE, ETC.

25. HYDRAULIC PUMP
26. GANTRY CYLINDERS
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27. DRUM LOCK PAWL, DRUM RATCHET

28. FUEL SUPPLY PUMP AND HOSE (OPTION)
29. SWING ALARM
30. ACCUMULATOR
31. SWING FRAME, COUNTERWEIGHT (1)
32. SCR *
* Not shown on the figure of “7.2 INSPECTION”.

11000-1
[ 7. MAINTENANCE ]

8 50 100 250 500
33. HOSE, PIPING AND CONNECTOR
35. BOLT AND NUT *
37. VALVE, ETC.
38. CRAWLER EXTEND/RETRACT CYLINDER

Lower
39. VERTICAL CYLINDER (OPTION)
machinery
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40. SWIVEL JOINT
41. SWING BEARING
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42. CRAWLER SHOE
43. DRIVE TUMBLER, IDLER WHEEL AND UPPER/LOWER ROLLER
44. SWING BEARING MOUNTING BOLT
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45. CARBODY, CRAWLER FRAME
46. UPPER SPREADER AND LOWER SPREADER
47. HOOK AND LATCH

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48. CABLE ROLLER AND GUIDE ROLLER
49. SHEAVE
50. BOOM AND JIB

Attachment
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52. BOLT AND NUT *
53. BACKSTOP
54. JIB STRUT
55. WIRE ROPE AND GUY LINE

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56. LOAD DETECTOR ROPE SOCKET PIN, BOLT, NUT
57. HOIST WIRE ROPE CLAMP BOLT

* Not shown on the figure of “7.2 INSPECTION”.
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OSHA : 1926.1412 Inspections

Item Content Every shift Every month Every year
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Ground conditions Soil, water inclusion
Equipment leveling Horizontalness shall satisfy maker's recommendation
Warning labels and decals Missing, unreadable condition
Operator seat Not appropriate for use
10000A-1
[ 7. MAINTENANCE ]
7.1.2 TABLE OF OIL, GREASE AND WATER SUPPLY POINTS

The number in the list below is corresponding to
the figure and table on “7.3 INSPECTION AND OIL/
GREASE AND WATER SUPPLY”.

8 50 100 250 500 1,000 2,000
1. REFUELING *1
2. ENGINE OIL LEVEL CHECK
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3. CHECKING OF COOLANT LEVEL
4. CHECK OF HYDRAULIC OIL LEVEL
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5. GREASING OF DRUM LOCK
6. DRAIN OF HYDRAULIC OIL TANK
7. OIL LEVEL CHECK OF SWING REDUCTION UNIT
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8. OIL LEVEL CHECK OF POWER DIVIDER
9. GREASING OF DRUM SHAFT BEARING
(FRONT, REAR, THIRD DRUM [OPTION])
10. OIL LEVEL CHECK OF REDUCTION UNIT
Upper
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machinery
11. OIL LEVEL CHECK OF REDUCTION UNIT (BOOM DRUM)
12. ENGINE OIL CHANGE *2
13. DRAIN OF FUEL TANK

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14. CHANGE OF COOLANT
15. OIL CHANGE OF SWING REDUCTION UNIT

16. OIL CHANGE OF REDUCTION UNIT
17. OIL CHANGE OF REDUCTION UNIT (BOOM DRUM)
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18. OIL CHANGE OF POWER DIVIDER
19. CHANGE OF HYDRAULIC OIL
20. INSPECT WATER LEVEL OF WASHER TANK

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*1 Perform as required.
*2 Perform when at first 30 hours from new and after overhauling too.
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11000-1
[ 7. MAINTENANCE ]

8 50 100 250 500 1,000 2,000
21. GREASING OF SWING BEARING
22. OIL LEVEL CHECK OF TRAVEL REDUCTION UNIT
23. GREASING OF SWING BEARING RING GEAR *3
24. GREASING OF AXLE EXTENSION

Lower
25. GREASING OF TRANSLIFTER PIN
machinery
26. OIL CHANGE OF TRAVEL REDUCTION UNIT
27. OIL CHANGE OF LOWER ROLLER *4
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28. OIL CHANGE OF UPPER ROLLER *4
29. OIL CHANGE OF IDLER WHEEL *4
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*3 Perform weekly or every 50 hours whichever comes first in case of the swing boom method operation such as the
clamshell and/or lifting magnet operation.
*4 Since no abnormal is found, perform replacement of oil at overhauling at authorized Manitowoc distributor.
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8 50 100 250 500 1,000 2,000
30. GREASING OF BOOM FOOT PIN
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31. GREASING OF GANTRY LINK
32. GREASING OF HOOK SHEAVE
33. GREASING OF HOOK BEARING
34. GREASING OF BALL HOOK BEARING

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35. GREASING OF BOOM POINT SHEAVE *5 *6
36. GREASING OF IDLER SHEAVE *5 *6
37. GREASING OF AUXILIARY SHEAVE *5 *6
38. GREASING OF UPPER SPREADER SHEAVE *5 *6

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Attachment 39. GREASING OF LOWER SPREADER SHEAVE *5 *6
40. GREASING OF GANTRY PEAK SHEAVE *5 *6
41. GREASING OF STRUT SHEAVE *5

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42. GREASING OF STRUT EQUALIZER SHEAVE *5
43. GREASING OF JIB POINT SHEAVE *5

44. LUBRICATION OF FRONT, REAR DRUM HOIST WIRE
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ROPE *7
45. LUBRICATION OF BOOM DRUM HOIST WIRE ROPE *7
46. LUBRICATION OF BOOM GUY LINE *7
47. LUBRICATION OF JIB GUY LINE *7
*5 Apply grease to the sheave by replacing a plug with a grease nipple.
In case of general crane work, grease on every 1,000 hours.
*6 Perform half yearly or every 500 hours whichever comes first in case of the swing boom method operation such as the
*7 Apply lubricant to the wire rope based on work condition.
Use brush or spray when applying lubricant to wire rope.
10000A-1
[ 7. MAINTENANCE ]
7.2 INSPECTION
7.2.1 INSPECTION OF UPPER MACHINERY
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32. SCR
9. AIR CLEANER
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2. ENGINE
1. FUEL AND HYDRAULIC LINES 19. FAN BELT
18. FUEL FILTER

22. POWER DIVIDER 20. RADIATOR AND OIL COOLER
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21. ENGINE MOUNTING BOLT AND

RUBBER MOUNT
24. VALVE, ETC.

25. HYDRAULIC PUMP
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24. VALVE, ETC.

28. FUEL SUPPLY PUMP
AND HOSE (OPTION) 24. VALVE, ETC.

11000-1
[ 7. MAINTENANCE ]
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23. HYDRAULIC MOTOR AND
REDUCTION UNIT
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17. DRUM BRAKE DISK
(FRONT, REAR, THIRD [OPTION])
17. DRUM BRAKE DISK

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17. DRUM BRAKE DISK
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REDUCTION UNIT
24. VALVE, ETC.

REDUCTION UNIT
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REDUCTION UNIT
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REDUCTION UNIT
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10000A-1
[ 7. MAINTENANCE ]
15. DRUM LOCK

27. DRUM LOCK PAWL,
DRUM RATCHET

31. SWING FRAME,
COUNTERWEIGHT (1)
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nl
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15. DRUM LOCK
27. DRUM LOCK PAWL,
DRUM RATCHET
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15. DRUM LOCK
27. DRUM LOCK PAWL,
DRUM RATCHET
15. DRUM LOCK
30. ACCUMULATOR
27. DRUM LOCK PAWL,
DRUM RATCHET
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11000-1
[ 7. MAINTENANCE ]
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14. LOAD SAFETY DEVICE,
MONITOR
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14. LOAD SAFETY DEVICE,
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MONITOR
4. SWING BRAKE

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6. CONTROL LEVER,
15. DRUM LOCK BRAKE PEDAL
5. SWING LOCK
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6. CONTROL LEVER,
BRAKE PEDAL
6. CONTROL LEVER,
BRAKE PEDAL
10000A-1
[ 7. MAINTENANCE ]
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nl
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7. GANTRY
16. WINDOW GLASS, STEP, HANDLE AND GUARD

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16. WINDOW GLASS, STEP, HANDLE AND GUARD
31. SWING FRAME,
COUNTERWEIGHT (1)
29. SWING ALARM 16. WINDOW GLASS, STEP, HANDLE AND GUARD
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11000-1
[ 7. MAINTENANCE ]

figure and table on “7.2.4 INSPECTION METHOD OF
EACH POINT”.
TABLE OF INSPECTION POINTS OF UPPER MACHINERY

Check Reference
Identification Check item Check method
interval page
1. FUEL AND HYDRAULIC LINES Damage Visual check P.7-24
Starting, leak, Starting,
2. ENGINE P.7-24
unusual noise check by hearing
y
3. HOSE, PIPING AND CONNECTOR * Oil leak Visual check P.7-24
4. SWING BRAKE Effectiveness Operation P.7-25
nl
5. SWING LOCK Performance Operation P.7-25
Operation,
6. CONTROL LEVER, BRAKE PEDAL Play, deformation P.7-26
visual check
7. GANTRY Deformation, crack Visual check P.7-26
O
Daily Operation,
or every 8. HORN, WORK LIGHT AND WIPER Performance P.7-26
visual check
8 hours
9. AIR CLEANER Missing (indicator) Visual check P.7-27
(Every shift)
10. PIN, LINK AND COTTER PIN * Damage, missing Visual check P.7-27
ce
11. BOLT AND NUT * Looseness, missing Visual check P.7-27
12. HOOK OVERHOIST PREVENTIVE DEVICE Performance Operation P.7-27
13. BOOM OVERHOIST PREVENTIVE DEVICE Performance Operation P.7-27
14. LOAD SAFETY DEVICE, MONITOR Performance Operation P.7-27
en
15. DRUM LOCK Performance Operation P.7-28

Damage, crack,
16. WINDOW GLASS, STEP, HANDLE AND GUARD Visual check P.7-28
missing
17. DRUM BRAKE DISK (FRONT, REAR, THIRD [OPTION]) Wear (indicator) Visual check P.7-29
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Weekly
or every 18. FUEL FILTER Water level Visual check P.7-30
50 hours
* Not shown on the figure of “7.2.1 INSPECTION OF UPPER MACHINERY”.
ef
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10000A-1
[ 7. MAINTENANCE ]
TABLE OF INSPECTION POINTS OF UPPER MACHINERY

Check Reference
interval page
Looseness, Push with finger,
19. FAN BELT P.7-32
damage visual check
20. RADIATOR AND OIL COOLER Oil leak, damage Visual check P.7-35
Looseness, Visual check,
21. ENGINE MOUNTING BOLT AND RUBBER MOUNT P.7-35
damage test hammer
Oil leak, Visual check,
22. POWER DIVIDER P.7-35
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Monthly 23. HYDRAULIC MOTOR AND REDUCTION UNIT P.7-36
or every
nl
24. VALVE, ETC. Oil leak Visual check P.7-36
100 hours
25. HYDRAULIC PUMP P.7-36
26. GANTRY CYLINDERS Oil leak, damage Visual check P.7-37
O
27. DRUM LOCK PAWL, DRUM RATCHET Wear, damage Visual check P.7-37
Performance, Operation,
28. FUEL SUPPLY PUMP AND HOSE (OPTION) P.7-38
damage visual check
Operation,
ce
29. SWING ALARM Alarm sound, lamp P.7-39
visual check
Half yearly 30. ACCUMULATOR Oil leak, damage Visual check P.7-40
or every Damage,
31. SWING FRAME, COUNTERWEIGHT (1) Visual check P.7-40
500 hours deformation crack
en
Yearly
Damage, crack,
or every 32. SCR * Visual check P.7-41
leak
1,000 hours
* Not shown on the figure of “7.2.1 INSPECTION OF UPPER MACHINERY”.
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11000-1
[ 7. MAINTENANCE ]
7.2.2 INSPECTION OF LOWER MACHINERY

42. CRAWLER SHOE 38. CRAWLER EXTEND/RETRACT CYLINDER

37. VALVE, ETC.
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39. VERTICAL CYLINDER 39. VERTICAL CYLINDER
(OPTION) (OPTION)
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39. VERTICAL CYLINDER
(OPTION)
O 39. VERTICAL CYLINDER

(OPTION)
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44. SWING BEARING

42. CRAWLER SHOE MOUNTING BOLT
45. CARBODY, CRAWLER FRAME 41. SWING BEARING
38. CRAWLER EXTEND/RETRACT
CYLINDER
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40. SWIVEL JOINT

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44. SWING BEARING

MOUNTING BOLT
36. HYDRAULIC MOTOR 43. DRIVE TUMBLER, IDLER WHEEL
AND REDUCTION UNIT AND UPPER/LOWER ROLLER
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45. CARBODY, CRAWLER FRAME

43. DRIVE TUMBLER, IDLER WHEEL 42. CRAWLER SHOE 43. DRIVE TUMBLER, IDLER WHEEL
AND UPPER/LOWER ROLLER AND UPPER/LOWER ROLLER
10000A-1
[ 7. MAINTENANCE ]

EACH POINT”.
TABLE OF INSPECTION POINTS OF LOWER MACHINERY

Check Reference
interval page
Daily 33. HOSE, PIPING AND CONNECTOR Oil leak, damage Visual check P.7-42
or every 34. PIN, LINK AND COTTER PIN * Damage, missing Visual check P.7-42
8 hours
(Every shift) 35. BOLT AND NUT * Looseness, missing Visual check P.7-42
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Oil leak,
36. HYDRAULIC MOTOR AND REDUCTION UNIT Visual check P.7-42
unusual noise
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37. VALVE, ETC. Oil leak Visual check P.7-42
Monthly 38. CRAWLER EXTEND/RETRACT CYLINDER Oil leak, damage Visual check P.7-42
or every 39. VERTICAL CYLINDER (OPTION) Oil leak, damage Visual check P.7-42
O
100 hours 40. SWIVEL JOINT Oil leak Visual check P.7-43
41. SWING BEARING Unusual noise Check by hearing P.7-43
Extension, damage,
42. CRAWLER SHOE Visual check P.7-43
wear
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Quarterly 43. DRIVE TUMBLER, IDLER WHEEL AND UPPER/
Oil leak, damage Visual check P.7-44
or every LOWER ROLLER
250 hours 44. SWING BEARING MOUNTING BOLT Looseness, missing Visual check P.7-44
Half yearly
Damage,
or every 45. CARBODY, CRAWLER FRAME Visual check P.7-45
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deformation crack
500 hours
* Not shown on the figure of “7.2.2 INSPECTION OF LOWER MACHINERY”.
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11000-1
[ 7. MAINTENANCE ]
7.2.3 INSPECTION OF ATTACHMENT
49. SHEAVE
49. SHEAVE
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46. UPPER SPREADER AND
LOWER SPREADER
49. SHEAVE 47. HOOK AND LATCH
nl
46. UPPER SPREADER AND 50. BOOM AND JIB

LOWER SPREADER
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49. SHEAVE
49. SHEAVE
53. BACKSTOP
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57. HOIST WIRE ROPE

CLAMP BOLT
56. LOAD DETECTOR

ROPE SOCKET PIN,
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BOLT, NUT 57. HOIST WIRE ROPE

CLAMP BOLT
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49. SHEAVE
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54. JIB STRUT 55. WIRE ROPE AND GUY LINE
49. SHEAVE
53. BACKSTOP
50. BOOM AND JIB
49. SHEAVE
49. SHEAVE
47. HOOK AND LATCH

10000A-1
[ 7. MAINTENANCE ]

EACH POINT”.
TABLE OF INSPECTION POINTS OF ATTACHMENT

Check Reference
interval page
46. UPPER SPREADER AND LOWER SPREADER Deformation, crack Visual check P.7-46
47. HOOK AND LATCH Damage, looseness Visual check P.7-46
Damage,
48. CABLE ROLLER AND GUIDE ROLLER Visual check P.7-46
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deformation, wear
Damage,
49. SHEAVE Visual check P.7-47
deformation, wear
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Damage,
50. BOOM AND JIB Visual check P.7-47
deformation
Daily
51. PIN, LINK AND COTTER PIN * Damage, missing Visual check P.7-47
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or every
52. BOLT AND NUT * Looseness, missing Visual check P.7-47
8 hours
(Every shift) Damage,
53. BACKSTOP Visual check P.7-48
deformation
Damage,
54. JIB STRUT Visual check P.7-48
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deformation
Damage,
55. WIRE ROPE AND GUY LINE Visual check P.7-49
deformation, wear
56. LOAD DETECTOR ROPE SOCKET PIN, BOLT,
Looseness, missing Visual check P.7-49
NUT
en
57. HOIST WIRE ROPE CLAMP BOLT Looseness, missing Visual check P.7-50
* Not shown on the figure of “7.2.3 INSPECTION OF ATTACHMENT”.
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11000-1
[ 7. MAINTENANCE ]
7.2.4 INSPECTION METHOD OF EACH POINT

[CHECK OF UPPER MACHINERY]
DAILY OR EVERY 8 HOURS (EVERY SHIFT)
1. FUEL AND HYDRAULIC LINES
Check the fuel and hydraulic lines for damage

and leak.
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nl
• Carefully wipe off any fuel splashed on to
the engine or its parts.
Otherwise it may cause of fire.
O
• If fuel or hydraulic oil leak is observed,
repair leak and remove adhered fuel/oil
immediately.
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2. ENGINE
en
Start the engine to confirm proper starting

condition and listen for unusual noise.

er
Check the hose, piping and connector, etc. for

oil leaks and damage.
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10000A-1
[ 7. MAINTENANCE ]
4. SWING BRAKE
Left : Right :
Confirm that the swing brake is functioning
properly.
SWING BRAKE SWITCH
With the swing brake switch in the ENGAGE
position, operate the swing control lever to
confirm the swing brake is functioning properly.
When the swing brake is engaged, swinging is
not possible.
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SWING CONTROL LEVER
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5. SWING LOCK SWING LOCK CONTROL LEVER
Confirm that the swing lock pin is inserted Near side : Far side :
smoothly and can be held being pulled out.
Check the lock pin and rod for deformation.
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11000-1
[ 7. MAINTENANCE ]
Check the control lever and brake pedal for

unusual play and for damage.
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CONTROL LEVER
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BRAKE PEDAL
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7. GANTRY
en
Check the gantry for damage.

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Special procedures are required for repair.

GANTRY
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Confirm that the horn, work light and wiper

operate normally by operating the switches.
10000A-1
[ 7. MAINTENANCE ]
9. AIR CLEANER
Use the sensor to determine if the air cleaner is

clogged.
When the air cleaner is clogged the error code
will be indicated on the monitor as below.
SENSOR
Clogging of air element is detected with air

cleaner sensor. AIR CLEANER
When clogging occurs, warning is
displayed on the monitor.
Clean or replace element.
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10. PIN, LINK AND COTTER PIN
Check the pin, link and cotter pin for damage

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and to determine if they are loose or missing.
11. BOLT AND NUT
Check the bolt and nut to determine if they are

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loose or missing.

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Confirm that the hook overhoist preventive

device operates normally.
(Refer to the article “3. LOAD SAFETY DEVICE”)
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Confirm that the boom overhoist limit switch

operates normally.
14. LOAD SAFETY DEVICE, MONITOR
Confirm that operation is automatically stopped.


11000-1
[ 7. MAINTENANCE ]
15. DRUM LOCK
Confirm that the drum lock functions normally.

Pull up the drum lock knob to Lock position and THIRD DRUM
confirm that the pawl is engaged. LOCK KNOB
(OPTION)
BOOM DRUM
LOCK KNOB
FRONT DRUM
LOCK KNOB
REAR DRUM
LOCK KNOB
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25 mm (31/32″)
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16. WINDOW GLASS, STEP, HANDLE AND
GUARD
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Always clean the window glass, step, handle

and guard, etc.
Immediately remove any grease and oil.
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10000A-1
[ 7. MAINTENANCE ]
17. DRUM BRAKE DISK

(FRONT, REAR, THIRD [OPTION]) Machine front
Check the wear of the brake disk with the

indicator. If the “FREE FALL” mode is selected,
the indicator is protruded by approx. 21 mm
(13/16 in.).
Stop the engine and press the indicator.
If the indicator protrudes from the end face
by approx. 8 mm (5/16 in.), the brake disk is
normal.
If the protrude length of the indicator is 5 mm
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(3/16 in.) or shorter (indicator recess disappears),
hoisting may become difficult.
nl
In such case, replace the brake disk by
contacting with authorized Manitowoc distributor. Protruded length during free fall mode :
Approx. 21 mm (13/16″)
O
Be sure to lower the hook block onto the ground
to prevent it from dropping abruptly. Normal protruded length :
Approx. 8 mm (5/16″)
Failure to observe this precaution may result in a (When pushed in after engine is stopped.)
serious accident.
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11000-1
[ 7. MAINTENANCE ]
WEEKLY OR EVERY 50 HOURS
18. FUEL FILTER
(1) Check accumulated water level

If the float ring in the fuel filter is located bottom
of the water cup.
Water dose not enter to the fuel system. Redline
When the float ring has risen to the red line,
FLOAT RING
drain the water as follows.
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WATER CUP
nl
(2) Drain water from fuel filter PRIMING PUMP
AIR BLEEDING BOLT
(A) Place a container under the drain pipe to

receive drained water.
O
(B) Loosen drain valve and air bleeding bolt.
(C) Discharge water from at the bottom of water cup
of fuel filter.
(D) Close the drain valve.
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The drained water contains the fuel.
Dispose them by following the rule specified by
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regional authority office.
DRAIN VALVE
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As air enters into the fuel system during the work,

air bleeding must be performed after completion
of the work.
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Take care that no brake fluid or parts containing

organic solvents (cleaner, paint, etc.) become
attached to the cup.
Since these substances can cause cracks.
10000A-1
[ 7. MAINTENANCE ]
(3) Air bleeding of the fuel system
SLIT for air venting

Take care that no dirt or water gets into the system
during the work.
Loosen Do not remove
(A) Operate the priming pump and bleed the air

from the system.
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nl
Make sure that the fuel filter air bleeding bolt has
been loosened.
The air bleeding bolt has a slit (groove) as shown
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ce
in the figure.
As air bleed out even when the bolt is not removed
completely, perform priming work with the bolt
loosened to an intermediate position in order to
prevent the entry of foreign matters to the fuel
en
system.
(B) Tighten the fuel filter air bleeding bolt.

Tightening torque : 1.69 to 2.26 N·m (1.25 to
er
1.67 ft·lbs)
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After work, wipe off the leaked fuel and start the
engine and make sure that there is no more fuel leak.
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a serious injury or loss of properties.

11000-1
[ 7. MAINTENANCE ]
MONTHLY OR EVERY 100 HOURS
19. FAN BELT
Check the fan belt for proper tension.
Turn the engine off before inspecting the fan belt.

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FAN BELT
(Alternator side)
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FAN BELT
(Compressor side)
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10000A-1
[ 7. MAINTENANCE ]
• COMPRESSOR SIDE FAN BELT 10 to 15 mm

Firmly press the middle of the fan belt with a (13/32 to 19/32″)
finger.
in.) Approx. 98 N (22 lbf)
Deflection of 10 to 15 mm (13/32 to 19/32 in.) is m( (Approx. 10 kg)
Lm
normal. (a)
• ALTERNATOR SIDE FAN BELT

The alternator side belt needs to be tension-
adjusted more precisely than the compressor
side belt.
Rough target of deflection is 3 to 5 mm (1/8 to
3/16 in.) but use of the ultrasonic tension meter
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is recommended for checking.
nl
Inadequate tension may cause not only belt to
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squeal but also may cause short life of accessories.
Adjust tension adequately.
damage parts.
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11000-1
[ 7. MAINTENANCE ]
• Checking method of tension
(1) Check “L” dimension.

(2) Turn the ultrasonic tension meter ON and input
the unit weight. (0.015 kg·m / 0.109 ft·lbs)
(3) Input the number of belt crest.
(4) Input the span length. (L mm / L inch)
(5) Put the microphone of the ultrasonic tension
meter near the measuring area (a).
With using a bar (extension bar) hit the (a) area
of the belt with a specified force.
The ultrasonic tension meter reads the belt
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frequency and indicates it.
(6) Repeat the above actions (5) for about five
nl
times and confirm that the average value is
within the specified value range.
Specified tension value :
1,324 to 1,422 N (298 to 320 lbf)
O
If not within the specified value, adjust the
alternator belt tension.
ce
Replace the belt with a new one if the belt squeals
even after the belt is adjusted properly and/or
crack or damage found on the belt.
If the belt is over-used, belt may break and may
en
cause damage to the other parts.

damage parts.
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10000A-1
[ 7. MAINTENANCE ]
Clean the radiator core.

Check the radiator and oil cooler for abnormalities
such as water leak, oil leak or deformation.
Radiator core clogging may cause engine over-
heat.
Take care not to damage the core while cleaning
the radiator core.
21. ENGINE MOUNTING BOLT AND RUBBER

MOUNT
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Check the engine mounting bolt for looseness,
nl
and the rubber mount for damage.
O RUBBER MOUNT
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RUBBER MOUNT
en
22. POWER DIVIDER
Check the power divider for oil leak and unusual

noise.
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POWER DIVIDER

11000-1
[ 7. MAINTENANCE ]
• Swing motor and reduction unit.

• Front, rear, third (option) drum motors and
reduction units.
• Boom hoist drum motor and reduction unit.
Check these for oil leak and unusual noise.
BOOM DRUM REDUCTION UNIT
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BOOM DRUM
MOTOR
THIRD DRUM
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MOTOR (OPTION)
THIRD DRUM
REDUCTION UNIT (OPTION)
SWING REDUCTION UNIT REAR DRUM MOTOR
SWING MOTOR REAR DRUM REDUCTION UNIT

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FRONT DRUM MOTOR
FRONT DRUM REDUCTION UNIT
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24. VALVE, ETC.
Check each valve for oil leak.

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25. HYDRAULIC PUMP HYDRAULIC PUMP

HYDRAULIC PUMP
Check the hydraulic pump for oil leak and for
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unusual noise.
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HYDRAULIC PUMP
10000A-1
[ 7. MAINTENANCE ]
Check the gantry cylinder for oil leak and GANTRY CYLINDER
damage.
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nl
27. DRUM LOCK PAWL, DRUM RATCHET
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Check the drum lock and drum ratchet for wear
and damage.
FRONT, REAR, THIRD (OPTION) DRUM LOCKS BOOM DRUM LOCK

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RATCHET
RATCHET
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PAWL
(lock position)
PAWL
PAWL (lock position)
(release position)
PAWL (release position)

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11000-1
[ 7. MAINTENANCE ]
28. FUEL SUPPLY PUMP AND HOSE (OPTION)
Check the fuel supply pump for normal

operation, and check the supply hose for
damage.
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PUMP SWITCH
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10000A-1
[ 7. MAINTENANCE ]
29. SWING ALARM
Make sure that the swing alarm and swing

flasher on left and right rear of main machinery
function properly when swinging for check.
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SWING FLASHER LAMP
Upper : Alarm light, buzzer side

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SWING ALARM
SELECT SWITCH
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Lower : Alarm light side

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11000-1
[ 7. MAINTENANCE ]
HALF YEARLY OR EVERY 500 HOURS
30. ACCUMULATOR
Check the accumulator for oil leak.
• Do not handle the accumulator roughly.

• Do not store or handle the accumulator near
the heating or flammable area.
y
• Do not apply welding or machining to the
accumulator.
nl
• Do not remove the valve cap except when
charging or discharging the gas.
• Do not step on or place heavy material on
the accumulator installed on the machine.
O
• Check the accumulator for gas pressure
every two years.
Ask Manitowoc authorize distributor to ACCUMULATOR
charge the gas.

• Do not disassemble the accumulator and do
ce
not use it with other than the being purpose.
The accumulator is charged with Nitrogen gas

under pressure of 3.4 to 3.7 MPa (493 to 537
en
psi).
31. SWING FRAME, COUNTERWEIGHT (1)
Check the swing frame and counterweight (1)

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for crack and deformation.

COUNTERWEIGHT (1)
SWING FRAME
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10000A-1
[ 7. MAINTENANCE ]
YEARLY OR EVERY 1,000 HOURS
32. SCR
• Inspection of DEF/AdBlue® and cooling water

leakage.
Inspect if there is DEF/AdBlue ® and cooling
water leakage from DEF/AdBlue ® tank, DEF/
AdBlue® supply module, DEF/AdBlue® dosing
module and DEF/AdBlue® lines.
If in case a leakage is existed, contact
authorized Manitowoc distributor for repair.
y
• Inspection of DEF/AdBlue® lines.
nl
Inspect if the respective lines are properly
connected and existing looseness of securing
clips and or any defects such as cracks,
damages, brake and banding etc.
O
If you find such defects, contact authorized
Manitowoc distributor for repair.
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Right after stop the engine, the oils and cooling
water of the machine may be extremely hot and may
cause scald.
Inspection, replacement, draining and replenishment
en
are to be carry out after cool down.

serious injury.
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11000-1
[ 7. MAINTENANCE ]
[CHECK OF LOWER MACHINERY]
Check the hose, piping and connector, etc. for

oil leak and damage.
Check the pin, link and cotter pin for damage,
y
and for missing.
nl
35. BOLT AND NUT
Check the bolt and nut for looseness and for

missing.
O

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Check the hyd. motor and reduction unit for oil
leak and unusual noise.
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HYD. MOTOR AND REDUCTION UNIT
37. VALVE, ETC.
Check the valve, etc. for oil leak.

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38. CRAWLER EXTEND/RETRACT CYLINDER

39. VERTICAL CYLINDER (OPTION)
ef
Check the crawler extend/retract cylinder

and vertical cylinder (option) for oil leak and
damage.
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VERTICAL CYLINDER (OPTION)
CRAWLER EXTEND/RETRACT CYLINDER


CRAWLER EXTEND/RETRACT CYLINDER
10000A-1
[ 7. MAINTENANCE ]
40. SWIVEL JOINT SWIVEL JOINT
Check the swivel joint for oil leak.
41. SWING BEARING
Check the swing bearing for unusual noise.
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nl
SWING
BEARING
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42. CRAWLER SHOE
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SLACK SHOE
10 to 20 mm (13/32 to 13/16″)
Check the crawler shoes for looseness, damage
and wear.
If the crawler tension is too high, the shoes
wear quickly and a connection part of shoes
er
could break.
On the other hand, if the crawler tension is too
loose, the shoes may ride off the drive tumbler
or idler wheel during traveling.
ef
The slackening of 10 to 20 mm (13/32 to 13/16

in.) is normal condition after traveling the
machine forward about the crawler length when
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measuring at the upper side of the crawler.

11000-1
[ 7. MAINTENANCE ]
QUARTERLY OR EVERY 250 HOURS
43. DRIVE TUMBLER, IDLER WHEEL AND UPPER ROLLER UPPER ROLLER
UPPER/LOWER ROLLER
Check the drive tumbler, idler wheel and upper/

lower rollers for oil leak and damage.
DRIVE LOWER ROLLER IDLER
TUMBLER WHEEL
44. SWING BEARING MOUNTING BOLT
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Check the swing bearing mounting bolt for
looseness and missing.
nl
Remove the upper and lower covers of the
swing frame for the inner bolt checking.
If the bolt is loose, remove and check it.
And if it is damaged, replace it with new one.
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If the removed bolt is not damaged, clean and
coat it with LOCTITE #243 or equivalent, then
securely tighten it. UPPER COVER
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TIGHTENING TORQUE
Outer bolt 2,780 N·m (2,050 ft·lbs)
Inner bolt 2,780 N·m (2,050 ft·lbs)
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SWING FRAME
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LOWER COVER
BOLT (INNER)
BOLT (INNER)
BOLT (OUTER) Inspection bole of inner ring bolt.
10000A-1
[ 7. MAINTENANCE ]

CRAWLER FRAME (L.H.)
45. CARBODY, CRAWLER FRAME CARBODY
Check the carbody and crawler frame for crack

and damage.
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CRAWLER FRAME (R.H.)
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11000-1
[ 7. MAINTENANCE ]
[CHECK OF ATTACHMENT]
46. UPPER SPREADER AND LOWER SPREADER
Check the sheave and frame of the upper and

lower spreaders for damage.
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nl
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When handling the wire rope, use leather gloves
to prevent injury on the fingers or hands.
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serious injury.
47. HOOK AND LATCH

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Check the sheave, bearing and latch of the SHEAVE

hook block for damage, and check the bolt and
BEARING
nut for missing.
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BEARING
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LATCH
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• Cable roller for boom insert

• Cable roller for boom tip
• Guide roller
Check these parts for damage, deformation and

wear.
10000A-1
[ 7. MAINTENANCE ]
49. SHEAVE
• Boom point sheave

• Idler sheave
• Auxiliary sheave
• Jib point sheave
• Strut sheave
• Gantry peak sheave
• Upper / Lower spreader
Check these sheaves for damage, deformation

and wear.
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50. BOOM AND JIB
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Check the boom and jib for damage and
deformation.
Do not use the damaged and/or deformed boom
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and jib.
Be sure to replace the damaged boom and jib
with new ones, or repair.
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Due to the high strength steels used in boom and BOOM
jibs, special repair procedures are required.
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JIB
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Check the pin, link and cotter pin for damage

and missing.
52. BOLT AND NUT
Check the bolt and nut for looseness and

missing.

11000-1
[ 7. MAINTENANCE ]
53. BACKSTOP
• Boom backstop
• Strut backstop
Check these backstops for damage and BOOM BACKSTOP

deformation.
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JIB STRUT
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STRUT BACKSTOP
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54. JIB STRUT
Check the jib strut for damage, deformation and

unusual play.
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10000A-1
[ 7. MAINTENANCE ]
BOOM GUY LINE

Check the wire rope and guy line for damage
and deformation and wear. HOIST WIRE ROPE
Signs are ; Kink, Crushing, Unstranding,
Birdcage, Core Failure / Protrusion, Significant BOOM HOIST
WIRE ROPE
corrosion, Electric arc damage.
Also inspect socket and end conditions.
Do not use the wire rope and guy line sustaining
damages beyond regulations described.
Refer to the article “6. WIRE ROPE”.
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ce JIB GUY LINE
HOIST WIRE ROPE

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56. LOAD DETECTOR ROPE SOCKET PIN,

BOLT, NUT
Check for the looseness and missing of pin,

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bolt, nut.
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PIN
LINK
BOLT
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BOOM DRUM

11000-1
[ 7. MAINTENANCE ]
57. HOIST WIRE ROPE CLAMP BOLT
Ensure that the bolts securing the hoist wire

rope to the drum flange are securely tightened,
and the painted section of the wire rope is
correctly positioned.
Paint the wire rope
here in “WHITE”.
Tightening torque :
333 to 407 N·m (246 to 300 ft·lbs)
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(2 × 2 - M20 × 65)
Tightening torque : Rope end should come out of mounting
333 to 407 N·m plate end but not to protrude from drum
(246 to 300 ft·lbs) flange outer dia.
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10000A-1
[ 7. MAINTENANCE ]
[HOOK AND SHACKLE MAINTENANCE STANDARD]
The operating condition of main and aux. hook SHEAVES

can change daily with use; therefore, they must be
SHEAVE PIN
inspected daily (at start of each shift) and observed TIE BOLT
during operation for any defects which could affect GREASE
FITTING
their safe operation.
Correct all defects before using the hook block or ball THRUST
hook. HOOK PIN BEARING
SIDE PLATE
Daily inspection and maintenance will include the
LATCH
following points.
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HOOK
(1) Clean the hook block or the ball hook.
nl
(2) Lubricate the sheaves (if fittings provided), the
hook swivel, and any other part equipped with
a grease fitting at the intervals specified in the
“7.3.4 INSPECTION, GREASING (WATER HOOK SWIVEL
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GREASE FITTING
SUPPLY) ON EACH POINT”.
THRUST BEARING GREASE FITTING
(3) Tighten the loosen tie-bolts, capscrew and set
screws.
Check that all cotter pins are installed and
opened.
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(4) Check the sheaves for uneven wear in the
grooves and on the flanges.
Check for loose or wobbly sheaves.
These conditions indicate faulty bearings or
LATCH
bushings. HOOK
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(5) Check the fit of the wire rope in the groove of

each sheave.
An oversize wire rope can crack the lip of the
sheave flange causing rapid wear of the wire
rope and sheave.
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The groove must be larger than the wire rope,

and the groove must be free of rough edges
and burrs.
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Rope groove dia. shall be about 10% larger than

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rope nominal dia.

Take extra care since, larger or smaller dia. groove
may cause premature damage of the rope.
damage the parts.

11000-1
[ 7. MAINTENANCE ]
(6) Check that the hook, the trunnion, and the

SOCKET
swivel rotate freely without excessive play.
Faulty operation indicates faulty bushings or
bearings or inadequate lubrication.
(7) Check the swivel of the hook for the following
conditions :
Overloading : Spin the swivel by hand; if the
WEDGE
motion is rough or has a ratchet-like effect, the
swivel bearings are damaged.
(8) Check the main hook for signs of overloading:
spread side plates, elongated holes, bent or PULL
elongated tie-bolts, and cracks.
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(9) Check the wire rope for wear and broken wires
CHECK FOR WEAR
at the point the wire rope enters the dead-end AND DEFORMATION
nl
socket.
Check the socket for cracks. CHECK FOR
“OPENING UP”
Tighten the wire-rope clips at the dead end of
CHECK THAT
the wire rope. HOOK IS NOT
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TWISTED
(10) Check that each hook is equipped with a hook CHECK FOR
latch and that the latch operates properly. CRACKS AND
TWISTING
The latch must not be wired open or removed.
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CHECK FOR WEAR
HOOK AND CRACKS
The latch is not intended as an anti-falling device.
The latch must retain slings or other rigging in
hook under slack conditions as the lifting load
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locate on the ground, therefore it is not withstand

against the large loads.
Take extra caution that must be taken to prevent
hook latch from supporting any part of load.
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serious accident.
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10000A-1
[ 7. MAINTENANCE ]
(11) Inspect shackles for damage.
CHECK FOR WEAR

AND DEFORMATION
CHECK FOR WEAR
AND STRAIGHTNESS
Inspect each hook and shackle annually at least
for cracks using a dye penetrant test, MAG particle
test, or by X-raying.
CHECK THAT PIN IS
ALWAYS SEATED
CHECK FOR
“OPENING UP”
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SHACKLE
Do not attempt to repair cracks in hooks and
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shackles by welding.
Furthermore, do not weld on any load bearing
component unless proper welding methods are
used.
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(Contact authorized Manitowoc distributor for
required information.)
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11000-1
[ 7. MAINTENANCE ]
7.3 INSPECTION AND OIL/GREASE AND WATER SUPPLY

To ensure proper operation of this machine, all points
requiring lubrication must be serviced with the correct
lubricant (oil, grease and water) at the proper interval.
STANDARD OIL (WATER) SUPPLY CAPACITY TABLE (NOT INCLUDING GREASING POINT)
Part Points of lubrication Symbol Kind Capacity : L (gal)
SAE #10W-30
Engine MO Engine oil (JASO : DH-2, 28.5 (7.5)
API : CJ-4, ACEA E-6, E-9)
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Radiator LLC Long life coolant (LLC) 34 (9.0)
ULTRA LOW SULFUR FUEL.
Fuel tank 400 (105.6)
nl
Sulfur contained 50 ppm or less.
Upper #46
Hydraulic oil tank HO Hydraulic oil 380 (100.3)
#32 (OPTION)
Power divider GO Gear oil #90 10.7 (2.8)
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Front, rear drum reduction unit GO Gear oil #80W-90 22/each (5.8/each)
Boom hoist drum reduction unit GO Gear oil #90 5 (1.3)
Swing reduction unit GO Gear oil #90 16.5 (4.3)

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Travel reduction unit GO Gear oil #90 18 (4.8)
Idler wheel GO Gear oil #140 0.25/each (0.07/each)

Lower
Lower roller GO Gear oil #140 0.13/each (0.03/each)
Upper roller GO Gear oil #140 0.06/each (0.02/each)

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• Use ultra-low sulfur diesel fuel only (S50 : In order to keep good function of the emission
er
sulfur content lower than 50 ppm). control devices, it is recommended to use the
(For the cold region, use suitable low sulfur specified brand (recommended) engine oil.
fuel in the area.)
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before refilling.
white smoke. When ship the machine from factory, radiator is
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• If fuel other than specified one is used, supplied with coolant to prevent rust and freezing
adverse effect may be caused to the engine in the cooling circuit combined with Long life
or emission control device and white smoke coolant (antifreeze) of 30% or 55% (cold region)
or failure may be resulted. concentration by volume.
10000A-1
[ 7. MAINTENANCE ]
Manitowoc GENUINE LUBRICANT CHART

Kind Symbol Specification Part No.
20 L can
#46
200 L can
Hydraulic oil HO
20 L can
#32 (OPTION)
200 L can
Extreme pressure grease EPG
High temperature grease HPG
Molybdenum disulphide grease GL
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20 L can
#90
200 L can
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Gear oil GO 18 L can
#80W-90
200 L can
#140
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SAE #10W-30 20 L can
Engine oil MO
(DH-2, CJ-4, E-6) 200 L can
20 L can
Antifreeze Long life coolant
200 L can
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Red 18 L can
Wire rope grease WO*
Black 18 L can
* Select a same type of grease as applied on existing wire rope.
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LUBRICATION CHART
Lubricant Symbol Recommended lubricant (Initial factory fill)
Hydraulic oil with anti-wear, anti-oxidant an anti-harmful foaming
55°C to 5°C 40°C to 5°C 30°C to -25°C 15°C to -30°C
er
Hydraulic oil HO
(131°F to 41°F) (104°F to 41°F) (86°F to -13°F) (59°F to -22°F)
ISO VG68 ISO VG46 ISO VG32 ISO VG22
Extreme pressure gear oil #90

Gear oil GO
Grade GL-4 by API classification
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Extreme pressure
EPG Multipurpose grease
Grease
NLGI No.2 Lithium base grease EP type
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GL NLGI No.1 Lithium base with Mo52 grease

Above 40°C 40°C to - 0°C 40°C to -30°C
Engine oil MO (Above 104°F) (104°F to 32°F) (104°F to -22°F)
SAE40 SAE30 SAE10W-30

11000-1
[ 7. MAINTENANCE ]
7.3.1 INSPECTION, OIL/GREASE AND WATER SUPPLY POINTS OF

UPPER MACHINERY
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12. ENGINE OIL CHANGE
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4. CHECK OF HYDRAULIC OIL LEVEL 3. CHECKING OF COOLANT LEVEL
6. DRAIN OF HYDRAULIC OIL TANK 14. CHANGE OF COOLANT
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8. OIL LEVEL CHECK OF

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POWER DIVIDER
18. OIL CHANGE OF
POWER DIVIDER
20. INSPECT WATER LEVEL

OF WASHER TANK
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1. REFUELING
10000A-1
[ 7. MAINTENANCE ]
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11. OIL LEVEL CHECK OF REDUCTION
UNIT (BOOM DRUM)
17. OIL CHANGE OF REDUCTION
9. GREASING OF DRUM SHAFT BEARING UNIT (BOOM DRUM)
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16. OIL CHANGE OF REDUCTION UNIT
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7. OIL LEVEL CHECK OF SWING REDUCTION UNIT

15. OIL CHANGE OF SWING REDUCTION UNIT
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11000-1
[ 7. MAINTENANCE ]
5. GREASING OF
DRUM LOCK
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5. GREASING OF
DRUM LOCK
5. GREASING OF
DRUM LOCK
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5. GREASING OF
DRUM LOCK
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10000A-1
[ 7. MAINTENANCE ]

figure and table on “7.3.4 INSPECTION, GREASING
(WATER SUPPLY) ON EACH POINT”.
UPPER LUBRICATION TABLE (WATER SUPPLY)

Check Kind of Amount : Reference
Check and lubrication place
interval lubricant L (gal) page
1. REFUELING *1 Diesel fuel 400 (105.6) P.7-64

Daily
or every 2. ENGINE OIL LEVEL CHECK MO P.7-65
8 hours 3. CHECKING OF COOLANT LEVEL LLC P.7-66
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(Every shift)
4. CHECK OF HYDRAULIC OIL LEVEL HO P.7-67
Weekly 5. GREASING OF DRUM LOCK EPG P.7-68
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or every
6. DRAIN OF HYDRAULIC OIL TANK P.7-69
50 hours
Monthly 7. OIL LEVEL CHECK OF SWING REDUCTION UNIT GO P.7-70
or every
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8. OIL LEVEL CHECK OF POWER DIVIDER GO P.7-70
100 hours
EPG P.7-71
Quarterly
or every GO P.7-71
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250 hours
11. OIL LEVEL CHECK OF REDUCTION UNIT (BOOM DRUM) GO P.7-72
12. ENGINE OIL CHANGE *2 MO 28.5 (7.5) P.7-72
Half yearly
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or every 13. DRAIN OF FUEL TANK P.7-73

500 hours
14. CHANGE OF COOLANT Soft water 34 (9.0) P.7-74
15. OIL CHANGE OF SWING REDUCTION UNIT GO 16.5 (4.4) P.7-76
Yearly
16. OIL CHANGE OF REDUCTION UNIT 22/1 pc
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or every GO P.7-76
(FRONT, REAR, THIRD DRUM [OPTION]) (5.8/1 pc)
1,000 hours
17. OIL CHANGE OF REDUCTION UNIT (BOOM DRUM) GO 5 (1.3) P.7-77
18. OIL CHANGE OF POWER DIVIDER GO 10.7 (2.8) P.7-77
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2 yearly 19. CHANGE OF HYDRAULIC OIL HO 380 (100.3) P.7-78

or every Washer
20. INSPECT WATER LEVEL OF WASHER TANK P.7-78
2,000 hours liquid
*1 Perform as required.
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*2 Perform when at first 30 hours from new and after overhauling too.
Clean the grease fittings before greasing.

Wipe off the excess grease.
Stop the engine when supplying lubricants.

11000-1
[ 7. MAINTENANCE ]
7.3.2 LOWER LUBRICATION

25. GREASING OF 25. GREASING OF
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TRANSLIFTER PIN TRANSLIFTER PIN
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25. GREASING OF 25. GREASING OF
TRANSLIFTER PIN TRANSLIFTER PIN
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23. GREASING OF SWING

BEARING RING GEAR
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28. OIL CHANGE OF 28. OIL CHANGE OF

UPPER ROLLER UPPER ROLLER
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22. OIL LEVEL CHECK OF TRAVEL REDUCTION UNIT 27. OIL CHANGE OF 29. OIL CHANGE OF IDLER WHEEL
26. OIL CHANGE OF TRAVEL REDUCTION UNIT LOWER ROLLER
10000A-1
[ 7. MAINTENANCE ]

LOWER LUBRICATION TABLE (WATER SUPPLY)

Check Kind of Amount : Reference
Check and lubrication place
interval lubricant L (gal) page
Weekly
or every 21. GREASING OF SWING BEARING EPG P.7-79
50 hours
22. OIL LEVEL CHECK OF TRAVEL REDUCTION UNIT GO P.7-80
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Quarterly
23. GREASING OF SWING BEARING RING GEAR *3 GL P.7-80
or every
nl
24. GREASING OF AXLE EXTENSION EPG P.7-81
250 hours
25. GREASING OF TRANSLIFTER PIN EPG P.7-81
Yearly
18/pc
or every 26. OIL CHANGE OF TRAVEL REDUCTION UNIT GO P.7-81
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(4.8/pc)
1,000 hours
0.13/pc
27. OIL CHANGE OF LOWER ROLLER *4 GO P.7-82
(0.03/pc)
0.06/pc
As require 28. OIL CHANGE OF UPPER ROLLER *4 GO P.7-82
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(0.02/pc)
0.25/pc
29. OIL CHANGE OF IDLER WHEEL *4 GO P.7-82
(0.06/pc)
*3 Perform weekly or every 50 hours whichever comes first in case of the swing boom method operation such as the
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*4 Since no abnormal is found, perform replacement of oil at overhauling at authorized Manitowoc distributor.

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11000-1
[ 7. MAINTENANCE ]
7.3.3 ATTACHMENT LUBRICATION

37. GREASING OF AUXILIARY SHEAVE
36. GREASING OF IDLER SHEAVE
35. GREASING OF
BOOM POINT
46. LUBRICATION OF BOOM GUY LINE SHEAVE
34. GREASING OF
BALL HOOK
BEARING
44. LUBRICATION OF
FRONT, REAR DRUM HOIST WIRE ROPE
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38. GREASING OF
32. GREASING OF
UPPER SPREADER SHEAVE
HOOK SHEAVE
nl
33. GREASING OF
45. LUBRICATION OF HOOK BEARING
BOOM DRUM HOIST WIRE ROPE
39. GREASING OF
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LOWER SPREADER
SHEAVE
40. GREASING OF
GANTRY PEAK
SHEAVE
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31. GREASING OF
GANTRY LINK
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42. GREASING OF
STRUT EQUALIZER SHEAVE
44. LUBRICATION OF
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FRONT, REAR DRUM 43. GREASING OF

47. LUBRICATION OF JIB GUY LINE HOIST WIRE ROPE JIB POINT SHEAVE
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47. LUBRICATION OF
JIB GUY LINE
41. GREASING OF
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STRUT SHEAVE
34. GREASING OF
BALL HOOK BEARING
44. LUBRICATION OF
FRONT, REAR DRUM HOIST WIRE ROPE
10000A-1
[ 7. MAINTENANCE ]

ATTACHMENT LUBRICATION TABLE

Check and
Kind of Reference
lubrication Check and lubrication place
lubricant page
interval
Daily 30. GREASING OF BOOM FOOT PIN EPG P.7-83
or every
8 hours 31. GREASING OF GANTRY LINK EPG P.7-83
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(Every shift)
Weekly 32. GREASING OF HOOK SHEAVE EPG P.7-84
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or every 33. GREASING OF HOOK BEARING EPG P.7-84
50 hours 34. GREASING OF BALL HOOK BEARING EPG P.7-84
35. GREASING OF BOOM POINT SHEAVE *5 *6 EPG P.7-85
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36. GREASING OF IDLER SHEAVE *5 *6 EPG P.7-85
37. GREASING OF AUXILIARY SHEAVE *5 *6 EPG P.7-85
Yearly 38. GREASING OF UPPER SPREADER SHEAVE *5 *6 EPG P.7-85

or every 39. GREASING OF LOWER SPREADER SHEAVE *5 *6 EPG P.7-85
ce
1,000 hours 40. GREASING OF GANTRY PEAK SHEAVE *5 *6 EPG P.7-85
41. GREASING OF STRUT SHEAVE *5 EPG P.7-85
42. GREASING OF STRUT EQUALIZER SHEAVE *5 EPG P.7-85
43. GREASING OF JIB POINT SHEAVE *5 EPG P.7-85
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44. LUBRICATION OF FRONT, REAR DRUM HOIST WIRE ROPE *7 WO P.7-85

45. LUBRICATION OF BOOM DRUM HOIST WIRE ROPE *7 WO P.7-85
As require
46. LUBRICATION OF BOOM GUY LINE *7 WO P.7-85
47. LUBRICATION OF JIB GUY LINE *7 WO P.7-85
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*5 Apply grease to the sheave by replacing a plug with a grease nipple.

In case of general crane work, grease on every 1,000 hours.
*6 Perform half yearly or every 500 hours whichever comes first in case of the swing boom method operation such as the
ef
*7 Apply lubricant to the wire rope based on work condition.

Use brush or spray when applying lubricant to wire rope.

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11000-1
[ 7. MAINTENANCE ]
7.3.4 INSPECTION, GREASING (WATER SUPPLY) ON EACH POINT

[INSPECTION, GREASING (WATER SUPPLY) ON UPPER MACHINERY]
1. REFUELING FUEL PUMP

(OPTION)
After daily work is finished, fill the fuel tank as full

SWITCH
as possible in order to minimize condensation.
The fuel pump is optional item.
If the fuel pump is not equipped, supply fuel
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from the filler port. FUEL
FILLER
PORT
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Refer to P.7-73 for fuel tank drain.
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Never run the fuel pump with empty tank.
damage the parts.
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fuel in the area.)
before refilling.
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white smoke.
• When fuel is to be refilled, ensure to stop the
engine.
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• When fuel is to be refilled, do not overfill the fuel.
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• Keep away flammable from the fuel to
prevent an ignition and explosion.
serious injuries, property damage or loss of life.
10000A-1
[ 7. MAINTENANCE ]
Ensure to check the engine oil level prior to

work.
Wipe the level gauge clean once and then insert
the level gauge.
If the level is within the range of proper oil level,
it is normal.
Refer to P.7-72 for replacing engine oil.
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PROPER Full Level
OIL LEVEL
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LOW HIGH
LEVEL GAUGE
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11000-1
[ 7. MAINTENANCE ]
3. CHECKING OF COOLANT LEVEL

RADIATOR CAP

cause scald.
serious injury.
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SUB TANK
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• The long life coolant has an inflammability
property, keep away flammable at the
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inspection/replacement.
in serious injuries, property damage or loss
of life.
• The long life coolant is poisonous for human
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body, ensure not to enter/disperse to eyes
and skins.
If anything adhesive to the eyes or skin, wash
thoroughly with plenty of water and seeing a
doctor.
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After removing the radiator cap, confirm the

coolant level, and also confirm the coolant level
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of the sub-tank.
When cooling water is insufficient, fill the long

life coolant up to the throat of filling port of the
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radiator and fill up to “FULL” mark position of

sub-tank.
Refer to P.7-74 for replacing coolant. Capacity of coolant : 30 L (7.9 gal)

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Atmospheric Volume of
The concentration of the long life coolant is to Volume of
temperature Cooling water LLC ratio
be referred the table on the right. LLC : L (gal)
: °C (°F) : L (gal)
-17 (1.4) 21 (5.5) 9 (2.4) 30%
-21 (-5.8) 19 (5.0) 11 (2.9) 35%
-25 (-13) 18 (4.8) 12 (3.2) 40%
-31 (-23.8) 16 (4.2) 14 (3.7) 45%
-40 (-40) 15 (4.0) 15 (4.0) 50%
10000A-1
[ 7. MAINTENANCE ]
4. CHECK OF HYDRAULIC OIL LEVEL
If the hydraulic oil level is within the specified

range shown in the label of the level gauge with OIL LEVEL
the following conditions and the engine running, Label specified
range
the oil level is normal.
(Oil temperature : 20°C [68°F])
LEVEL GAUGE
Gantry cylinder Extended
Crawler ext/retr cylinder Extended
Translifter cylinder Retracted
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CWT self removal cylinder Retracted
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Refer to P.7-78 for replacing hydraulic oil.
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ce
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11000-1
[ 7. MAINTENANCE ]
5. GREASING OF DRUM LOCK
Supply grease to the drum lock of the front, rear

and third drum (option) from the grease fittings
provided on the front face of the swing frame.
(2 locations or 3 locations for 3rd drum is
equipped)
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GREASE FITTING
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Supply grease to the boom drum lock from the
grease fitting provided under the swing frame.
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BOOM DRUM LOCK

GREASE FITTING
10000A-1
[ 7. MAINTENANCE ]
6. DRAIN OF HYDRAULIC OIL TANK
Before starting operation, loosen the drain plug

to drain water and sediment from the tank.
(2 locations)
DRAIN PLUG
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HYDRAULIC OIL TANK
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11000-1
[ 7. MAINTENANCE ]
7. OIL LEVEL CHECK OF SWING REDUCTION LEVEL GAUGE

UNIT
Check the oil level more than 30 minutes after

the operation is stopped.
If the oil level is in the proper oil level, it is
normal.
Refer to P.7-76 for oil change of the swing

reduction unit.
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DRAIN COCK
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Meshed part
PROPER OIL LEVEL

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8. OIL LEVEL CHECK OF POWER DIVIDER

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If the oil level is up to the red color mark of the

level gauge, it is normal.
Refer to P.7-77 for oil change of the power

divider.
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BREATHER
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OIL FILL PORT

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LEVEL GAUGE DRAIN COCK
10000A-1
[ 7. MAINTENANCE ]

GREASE FITTING
Supply grease from the grease fitting provided

on the bearing sleeve on the rope clamp side.
There are 2 grease fittings but take one easiest
grease point. (It is not necessary to grease from
all 2 points.)
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10. OIL LEVEL CHECK OF REDUCTION UNIT OIL FILL PORT
More than 30 minutes of operation stop, check

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the oil level.

If the oil level is up to red mark on the oil level
meter, it is normal in case of front drum and rear
drum.
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Refer to P.7-76 for oil change of reduction unit

(front, rear and third drum [option]).
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LEVEL GAUGE LEVEL GAUGE

DRAIN COCK
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11000-1
[ 7. MAINTENANCE ]
11. OIL LEVEL CHECK OF REDUCTION UNIT OIL FILL PORT

(BOOM DRUM)
LEVEL GAUGE
More than 30 minutes of operation stop, check
the oil level.
If the level is up to the specified point, it is
normal.
Refer to P.7-77 for oil change of the winch

reduction unit (boom drum).
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DRAIN PLUG
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12. ENGINE OIL CHANGE
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cause scald. DRAIN COCK
Inspection, replacement, draining and replenishment View from A

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OIL FILL PORT
serious injury.
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er
OIL FILTER
(1) Prepare the container about 30 L (7.9 gal).

(2) Loosen the drain plug and drain the oil to the
ef
prepared container.
(3) Tighten the drain plug. A
(4) Check the drained oil for no metal powder
mixed and pour the new oil to the fill port.
R
When fill oil use the long nozzle oil jug which is
provided as an attached tool. PROPER Full Level
When changing oil, replace the oil filter. OIL LEVEL
(5) When the filter element and the total quantity of

the oil are changed, pour the oil using the full
level position of oil pouring. LOW HIGH
(Do not start the engine.)

Drive the engine for a few minutes. LEVEL GAUGE
Stop the engine for about 30 minutes.

Then confirm that the oil level is in the proper level.
10000A-1
[ 7. MAINTENANCE ]
Loosen the drain plug and drain the water or

sediment in the tank.
y
nl
O DRAIN COCK
ce
Bottom of tank
en
er
ef
R

11000-1
[ 7. MAINTENANCE ]
14. CHANGE OF COOLANT

RADIATOR CAP

cause scald.
y
serious injury.
nl
(1) Loosen the drain cock in the bottom of the
radiator and the plug of the water jacket, drain
O
the coolant.
(2) Combine soft water (tap water) and long life
coolant, and fill the radiator up to the foot of the
water supply port.
In order to prevent air from entering, slowly pour
ce
A
coolant.
After coolant pouring, confirm that the coolant
level does not lower, then tighten the radiator
cap.
(3) Start and run the engine for about 1 minute.
en
Stop the engine, and check coolant level.

If insufficient, add coolant.
er
WATER JACKET PLUG

ef
R
DRAIN COCK
View from A
10000A-1
[ 7. MAINTENANCE ]
• COOLANT BLENDING
Blend the coolant (long life coolant) based on

ambient temperature.
Refer to P.7-117 for blending.
• The long life coolant has an inflammability

property, keep away flammable at the
inspection/replacement.
y
nl
of life.
• The long life coolant is poisonous for human
body, ensure not to enter/disperse to eyes
and skins.
O
If anything adhesive to the eyes or skin, wash
thoroughly with plenty of water and seeing a
doctor.
ce
en
• When ship the machine from factory, radiator

is supplied with coolant to prevent rust and
freezing in the cooling circuit combined with
Long life coolant (antifreeze) of 30% or 55%
(cold region) concentration by volume.
er
• The cooling water shall be used clean soft

water (tap water) which has an anti-water
deposit combined with.
If the cooling water is getting dirty and./or
ef
bubble, replace as soon as possible.

• None-Amine anti-freezing is used for this
machine.
R

11000-1
[ 7. MAINTENANCE ]
15. OIL CHANGE OF SWING REDUCTION UNIT LEVEL GAUGE
With the gauge stick drawn out, loosen the drain

cock, and drain the oil into a prepared container.
Shut the drain cock and supply the specified oil
through the fill port until the oil level reaches the
specified level.
y
water of the machine may be extremely hot and may DRAIN COCK
cause scald.
nl
serious injury. Meshed part
O
PROPER OIL LEVEL
ce
16. OIL CHANGE OF REDUCTION UNIT OIL FILL PORT
Prepare a container of approx. 30 L (7.9 gal)

capacity.
en
With the oil fill plug removed, turn the lever of

the drain cock to drain the oil into the prepared
container.
Return the lever of the drain cock to the original
position, and supply the specified oil through the
er
oil fill port until the oil level reaches the specified
oil level.
ef
LEVEL GAUGE LEVEL GAUGE

DRAIN COCK
R
cause scald.
serious injury.
10000A-1
[ 7. MAINTENANCE ]
17. OIL CHANGE OF REDUCTION UNIT (BOOM OIL FILL PORT

DRUM)
LEVEL GAUGE
Prepare a container of approx. 5 L (1.3 gal) of
capacity.
Rotate the drum to make the level gauge in
horizontal position.
With the oil fill port plug removed, remove the
drain plug to drain the oil into the container.
Return the drain plug to the original position,
and supply the specified oil through the oil fill
port until the oil level reaches the specified
y
level. DRAIN PLUG
nl
18. OIL CHANGE OF POWER DIVIDER

capacity.
O
With the cap of the oil fill port plug removed,
turn the lever of the drain cock to drain the oil
into the container.
Return the lever of the drain cock to the original
position pour the specified oil through the oil
ce
fill port until the oil level reaches the specified
level.
LEVEL GAUGE
en
BREATHER
cause scald.
er

OIL FILL PORT
serious injury.
ef
DRAIN COCK
R

11000-1
[ 7. MAINTENANCE ]
EVERY TWO YEARS OR 2,000 HOURS
It is a guideline to replace hydraulic oil every

2 years or 2,000 hours counting by the hour
meter whichever comes first, but if the oil is
remarkably contaminated or deteriorated,
replace the oil regardless of such interval. DRAIN PLUG
(1) Prepare a container of approx. 400 L (105.6 gal).

(2) Remove the cap of the filler port and filter cover.
y
(3) Loosen the drain plug and drain the hydraulic oil
into the prepared container. HYDRAULIC OIL TANK
nl
(4) Reinstall the drain plug fill the tank with the
specified hydraulic oil through the fill port up to
the specified level.
(5) Reinstall the filter cover and oil supply cap.
O
(6) Check the oil level again.
When changing hydraulic oil, change the filter

also at the same time.
ce
en
cause scald.
serious injury.
er
ef
Take extra care not to stat the engine without

hydraulic oil in the tank to avoid catastrophic
failure of the pumps.
R
damage the parts.
20. INSPECT WATER LEVEL OF WASHER TANK FILLING PORT
Check the water level in the washer tank.

Add washer liquid to the tank if it is insufficient.
10000A-1
[ 7. MAINTENANCE ]
[INSPECTION, GREASING OF LOWER MACHINERY]
Grease through the grease fitting provided on

the swing bearing outer race.
y
nl
O
ce
en
GREASE FITTING
er
ef
R

11000-1
[ 7. MAINTENANCE ]
QUARTERLY OR EVERY 250 HOURS FILL / LEVEL PORT
22. OIL LEVEL CHECK OF TRAVEL REDUCTION

UNIT

With the drain plug positioned at the lower side,
remove the level plug.
If the oil level is up to the bottom of the level DRAIN PLUG
plug opening, it is normal.
y
Refer to P.7-82 for oil change of the travel
reduction unit.
nl
23. GREASING OF SWING BEARING RING GEAR
UPPER COVER
Removing the upper and lower cover in the
O
swing frame front, turn the upper little by little,
and grease so that grease goes around the
entire ring gear.
ce
Apply lubricant to the ring gear, use a brush or
pallet and not by hands to avoid being trapped.
en
serious injury.
er
ef
SWING FRAME
LOWER COVER
R
RING GEAR
Inspection hole of inner mounting bolt and greasing
10000A-1
[ 7. MAINTENANCE ]
Apply grease from the grease fitting provided in

the rotating area of the axle extension.
Greasing from the inside with the crawler
extended. (4 locations)
GREASE FITTING
y
nl
25. GREASING OF TRANSLIFTER PIN
O
ce
Supply grease from the grease fitting provided
on the rotating area of the translifter arm.
(4 locations on upper side, 4 locations on lower
side, total 8 locations)
en
er
GREASE FITTING
ef
R

11000-1
[ 7. MAINTENANCE ]
YEARLY OR EVERY 1,000 HOURS FILL / LEVEL PORT
26. OIL CHANGE OF TRAVEL REDUCTION UNIT

capacity.
With the level plug removed, remove the drain
plug to drain the oil into the container.
Reinstall the drain plug, pour the specified oil
through the fill/level port until the oil reaches the DRAIN PLUG
specified level.
y
nl
cause scald.
O
serious injury.
ce
AT OVERHAULING OR AS REQUIRED
27. OIL CHANGE OF LOWER ROLLER

PLUG PLUG
Remove the both end plugs to drain the oil.

en
Supply the specified oil of specified amount.

To replace oil, consult with authorized Manitowoc
distributor.
28. OIL CHANGE OF UPPER ROLLER

er
Remove the both end plugs to drain the oil.

ef
PLUG PLUG
distributor.
R
29. OIL CHANGE OF IDLER WHEEL PLUG
Remove the plug of the sliding block to drain

the oil.
distributor.
10000A-1
[ 7. MAINTENANCE ]
[INSPECTION, LUBRICATION OF ATTACHMENT]
Grease through the grease fitting on the foot

pin. (Left and right)
y
GREASE FITTING
nl
O
ce
31. GREASING OF GANTRY LINK
Grease through the grease fitting provided on

the front member.
en
GREASE FITTING
er

ef
R

11000-1
[ 7. MAINTENANCE ]
32. GREASING OF HOOK SHEAVE GREASE

FITTING
Grease from the grease fitting on the sheave

pin.
33. GREASING OF HOOK BEARING GREASE

FITTING
Grease from the grease fitting on the bearing
cap.
y
nl
34. GREASING OF BALL HOOK BEARING
GREASE FITTING
Grease from the grease fitting provided on the
O
bearing cap.
ce
en
er
ef
R
10000A-1
[ 7. MAINTENANCE ]
35. GREASING OF BOOM POINT SHEAVE

36. GREASING OF IDLER SHEAVE
37. GREASING OF AUXILIARY SHEAVE
38. GREASING OF UPPER SPREADER SHEAVE
39. GREASING OF LOWER SPREADER SHEAVE
40. GREASING OF GANTRY PEAK SHEAVE
41. GREASING OF STRUT SHEAVE
42. GREASING OF STRUT EQUALIZER SHEAVE
43. GREASING OF JIB POINT SHEAVE
y
Apply grease to the sheave pin or sheave by
replacing a plug with a grease nipple.
nl
O
ce
attachment.
en
AS REQUIRED
44. LUBRICATION OF FRONT, REAR DRUM

HOIST WIRE ROPE
45. LUBRICATION OF BOOM DRUM HOIST WIRE
er
ROPE
46. LUBRICATION OF BOOM GUY LINE
47. LUBRICATION OF JIB GUY LINE
ef
Apply lubricant to the wire rope based on work

condition.
Use brush or spray when applying lubricant to
wire rope.
R
When handling the wire rope, use leather gloves

to prevent injury on the fingers or hands.
serious injury.

11000-1
[ 7. MAINTENANCE ]
7.4 REPLACEMENT AND CLEANING/WASHING FILTER

ELEMENT AND STRAINER
7.4.1 REPLACEMENT, CLEANING, WASHING POINTS OF FILTER

13. REPLACING HYDRAULIC OIL 14. WASHING FILL PORT

SUCTION FILTER STRAINER
9. REPLACING OF
HYDRAULIC OIL TANK
4. REPLACING DRAIN FILTER RETURN FILTERS
y
(CARTRIDGE)
5. REPLACING OF LINE FILTER
nl
FOR BRAKE COOLING LINE
(CARTRIDGE)
11. WASHING OF
LINE FILTER (b)
O
ce
6. WASHING FUEL TANK
FILL PORT STRAINER
en
16. REPLACING DEF/AdBlue®

SUPPLY MODULE FILTER
er
10. WASHING OF LINE FILTER (a)

ef
1. CLEANING AIR ELEMENT,

12. REPLACING OF AIR ELEMENT 2. CLEANING AIR CONDITIONER FILTER
(INTERNAL AIR FILTER)
R
8. REPLACING FUEL FILTER
7. REPLACING OF
ENGINE OIL ELEMENT

(ON ENGINE)
17. CLEANING OR REPLACING 3. CLEANING AIR CONDITIONER FILTER

DIESEL PARTICULATE FILTER (OPEN AIR FILTER)
10000A-1
[ 7. MAINTENANCE ]
The number in the list below is corresponding to

the figure and table on “7.4.2 REPLACEMENT,
CLEANING, WASHING METHODS OF FILTER
ELEMENT AND STRAINER”.
Table of replacement, cleaning/washing points of filter element and strainer.

Check Reference
Check, lubrication, change point clean Part No. Quantity
interval page
1. CLEANING AIR ELEMENT 1 P.7-88

Monthly
2. CLEANING AIR CONDITIONER FILTER
or every 1 P.7-88
y
100 hours
1 P.7-88
(OPEN AIR FILTER)
nl
4. REPLACING DRAIN FILTER (CARTRIDGE) * 1 P.7-90
5. REPLACING OF LINE FILTER FOR BRAKE COOLING

Quarterly 1 P.7-90
LINE (CARTRIDGE) *
O
or every
250 hours 6. WASHING FUEL TANK FILL PORT STRAINER 1 P.7-90
7. REPLACING OF ENGINE OIL ELEMENT 1 P.7-91
Half yearly
ce
or every 8. REPLACING FUEL FILTER 1 P.7-93
500 hours
9. REPLACING OF HYDRAULIC OIL TANK RETURN
1 P.7-96
FILTERS
en
Yearly 10. WASHING OF LINE FILTER (a) 1 P.7-99

or every
1,000 hours 11. WASHING OF LINE FILTER (b) 1 P.7-99
12. REPLACING OF AIR ELEMENT 1 P.7-100

er
13. REPLACING HYDRAULIC OIL SUCTION FILTER 1 P.7-100

2 yearly
14. WASHING FILL PORT STRAINER 1 P.7-101
or every
15. REPLACING FUEL FILTER (ON ENGINE) 1 P.7-102
2,000 hours
16. REPLACING DEF/AdBlue® SUPPLY MODULE FILTER 1 P.7-104
ef
Every 17. CLEANING OR REPLACING DIESEL PARTICULATE

1 P.7-107
4,500 hours FILTER
* Perform when at first 50 hours from new and after overhauling too.
R
The part number described in the operator’s

manual is to be changed without prior notice.
When place an order, please confirm the part number
with the parts manual or the engine hand book.

11000-1
[ 7. MAINTENANCE ]

1. CLEANING AIR ELEMENT
Dismantle the air element and blow air from

inside to remove accumulated dust.
y
ELEMENT
nl
(OPEN AIR FILTER)
O
The clogged air conditioner filter causes air
volume to decrease and low air conditioner
performance.
Clean the filter according to the check and
ce
maintenance list.
A/C CONTROL PANEL

en
er
INTERNAL AIR FILTER

ef
R
OPEN AIR
FILTER
Air vent
AIR CONDITIONER UNIT
10000A-1
[ 7. MAINTENANCE ]
(1) Removal and installation
(A) Internal air filter

Remove the emergency cable cover.
Removal
Then, pick the tab of the filter, and remove the filter upward.
Installation Install the filter by reversing the removal steps.
(B) Open air filter

Removal Remove the cover on the rear of the seat and take out the filter upward.
Installation Take the reverse way of the installation.
y
(2) Cleaning
nl
(A) Internal air filter
• Remove the inspection window in rear of the operator’s seat.
• Draw out the filter upward.
• Remove any dirt including dusts from the filter with compressed air.
O
If the filter is excessively dirty or clogged,
immerse it in lukewarm water with a neutral
detergent dissolves, and wash it by moving it
up, down, right, left.
ce
Then rinse it with clean water, and let it dry
completely.
(B) Open air filter

en
• Remove the cover on the back of the operator’s seat.

• Draw out the filter.
• Remove any dirt including dusts from the filter with compressed air.
If the filter is excessively dirty or clogged,

immerse it in the lukewarm water with a neutral
er
detergent dissolved, and wash it by forcibly

moving it back and forth in the solution for
twenty to thirty seconds.
Then, rinse it with clean water until detergent
ef
bubbles are almost washed away, and shake

the filter two or three times to drain water off.
Then, blow compressed air (approx. 5 Pa)
right down to the whole surface of the filter for
R
approx. two minutes to dry it completely.
It is recommended that the filters be replaced

once a year in order to maintain the filter’s good
performance.
Carefully handle the filters not to make a hole, nor
break them.

11000-1
[ 7. MAINTENANCE ]
4. REPLACING DRAIN FILTER (CARTRIDGE)
Loosen the plug of the filter cover to remove the

remaining pressure in the tank.
Prepare an oil container under the filter, and
replace the cartridge with a new one. DRAIN FILTER
5. REPLACING OF LINE FILTER FOR BRAKE LINE FILTER FOR

BRAKE COOLING
COOLING LINE (CARTRIDGE)
y
Loosen the plug of the filter cover to remove the
remaining pressure in the tank.
nl
Prepare an oil container under the filter, and
replace the cartridge with a new one.
O
6. WASHING FUEL TANK FILL PORT STRAINER
Remove the cap, take out the strainer and

ce
sufficiently wash it with washing liquid.
en
Keep away flammable from the fuel to prevent an FILL PORT STRAINER
ignition and explosion.
serious injuries, property damage or loss of life.
er
ef
R
10000A-1
[ 7. MAINTENANCE ]
7. REPLACING OF ENGINE OIL ELEMENT
There potential to enter the dirt, ensure to carry out

the work with clean the surround of oil element.
(1) Place the container to receive the oil under the

filter.
(2) Turn the element to left and remove it using the
y
special oil filter wrench.
nl
O
cause scald.
ce
serious injury. O-RING
ELEMENT
en
er
ef
R

11000-1
[ 7. MAINTENANCE ]
(3) Remove the dirt or mud adhered to the seal

face of the oil filter body.
(4) Apply the engine oil on the gasket of the new
element and rotate it lightly to right until it
touches the body seal face.
• R e p l a c e O - r i n g s w i t h n e w o n e w h i c h
included in the element kit.
• Be careful not to damage the O-rings by
y
twisting.
Check to see if the O-rings firmly contact to
nl
the sealing surface.
O
(5) Under this condition, rotate the element for
about 3/4 to 1 turn with the oil filter wrench
supplied as special tool.
(6) After the element is replaced, start the engine
ce
and make the element filled with oil and then
check the engine oil level.
en
• After the element is replaced, start engine

and make sure that there is no oil leaks
around the filter.
er
immediately.
ef

R
10000A-1
[ 7. MAINTENANCE ]
• Removing fuel filter element
(1) Prepare the container to receive the drained

fuel under the drain valve.
A
(2) Loosen the drain valve and air bleed plug and
drain the fuel accumulated in the fuel filter
element.
(3) Remove the element from the filter body
together with a cup by the filter wrench.
(4) Remove the element from the cup by the filter
y
wrench or the pipe wrench.
The cup to be reused, therefore, it is not damaged
nl
FUEL FILTER
or throw it away.
Name Part number

Filter wrench
O
AIR BLEEDER
Pipe wrench PLUG
Accessory of machine tool :

“Refer to 7.13 CONSUMABLE PARTS LIST”
ce
The drained water contains the fuel. DRAIN VALVE
Dispose them by following the rule specified by View from A
en
regional authority office.
PRIMING PUMP
O-RING (a)
er
ELEMENT Replace
ef
O-RING (b)
CUP
R

11000-1
[ 7. MAINTENANCE ]
• Installing the fuel filter element

PRIMING PUMP
(1) Remove the dirt or foreign material adhered to
the installation surface.
O-RING (a)
(2) Slightly coat the fuel to the new O-ring and
install it to the sealing surface of cup.
ELEMENT
• Do not reuse the element. O-RING (b)
y
Failure to observe this precaution may lead CUP
nl
• R e p l a c e O - r i n g s w i t h n e w o n e w h i c h
included in the element kit.
• Be careful not to damage the O-rings by
twisting.
O
Check to see if the O-rings firmly contact to
the sealing surface.
ce
(3) Install by turning the cup approximate 1/2 to 3/4
of rotation after the O-ring (b) contacts with new
element.
Tightening torque
en
Cup 9 to 11.3 N·m (6.6 to 8.3 ft·lbs)

* Do not use tools. Hand-tighten.
(4) Install by turning the element approximate 1/2

of rotation after the O-ring (a) contacts with
er
priming pump housing.

Tightening torque
Element 9 to 11.3 N·m (6.6 to 8.3 ft·lbs)
ef
* Do not use tools. Hand-tighten.
(5) Tighten the drain valve.

Tightening torque
R
Drain valve 4 to 6 N·m (3 to 4.4 ft·lbs)
10000A-1
[ 7. MAINTENANCE ]
(6) Start the priming pump and bleed air in the

system.
As to air bleeding, refer to the 18. FUEL FILTER

P.7-30.
Make sure that the air bleed plug is loose.
y
nl
O
ce
en
er
ef
R

11000-1
[ 7. MAINTENANCE ]
9. REPLACING OF HYDRAULIC OIL TANK

COVER
RETURN FILTERS
O-RING
SPRING
Right after stop the engine, the oils and cooling VALVE
water of the machine may be extremely hot and may O-RING
cause scald.
y
ELEMENT
serious injury.
nl
• Procedure of replacing the return filter
PACKING
Remove the filter cover and replace the element
O
and O-ring with new ones.
ce
en
er
(1) Remove the filter assembly and place it on the

ef
flat surface.
R
10000A-1
[ 7. MAINTENANCE ]
(2) Hold the top mold plate and loosen the grip.
(3) Pull out the grip assembly.
y
nl
(4) Turn over the filter.
O
ce
en
(5) Hold the plate on which the end plate is

er
attached.
(6) Loosen the end plate and replace the packing
of the end plate with new one.
ef
R

11000-1
[ 7. MAINTENANCE ]
(7) This is to complete the disassembly.

To assemble, take the reverse way.
Do not rotate with holding the grip and element

lower portion at installation and dismantle.
This may result in excessive force by twisting and
may lead to damage the element and gasket.
parts damage.
y
nl
O
ce
en
er
ef
R
10000A-1
[ 7. MAINTENANCE ]
10. WASHING OF LINE FILTER (a)

11. WASHING OF LINE FILTER (b)
Remove the case, take out the filter and

O-RING
sufficiently wash it.
Replace the O-ring with a new one.
FILTER
After stopping engine, wait for five minutes to

release pressure. LINE FILTER
y
nl
LINE FILTER (a)
O
ce
en
er
ef
LINE FILTER (b)

R

11000-1
[ 7. MAINTENANCE ]
12. REPLACING OF AIR ELEMENT
If the element is exceptionally dirty and the

element is deformed, replace the element with a
new one early.
ELEMENT
13. REPLACING HYDRAULIC OIL SUCTION

FILTER
y
COVER
Remove the filter cover and replace the element
and O-ring.
nl
O-RING
Perform this replacement when replacing the
hydraulic oil.
O
ce
FILTER
O-RING
(Inside of filter)
en
er
ef
R
10000A-1
[ 7. MAINTENANCE ]
14. WASHING FILL PORT STRAINER
Remove the air breather cap, take out the

fill port strainer, and sufficiently wash it with
washing liquid.
FILL PORT STRAINER
y
nl
O
ce
en
er
ef
R

11000-1
[ 7. MAINTENANCE ]
15. REPLACING FUEL FILTER (ON ENGINE)
The fuel filter is an element type.

Its purpose is to remove moisture and fine dirt
particles from the fuel, the element is made
from resin and paper.
• Draining of fuel
(1) Clean the area around the fuel filter before the
start of work.
Otherwise dirt may enter.
y
(2) Provide a waste oil container under the fuel
filter.
nl
(3) After loosening the drain plug, loosen the air
bleeder plug and drain the fuel from the drain
pipe.
Use a drain hose (fuel) which is provided as an
O
CENTER BOLT
attached tool.
CAP AIR BLEEDER PLUG
* At this time, drain all fuel from the filter.

When the element is replaced without draining
all of the fuel, unfiltered fuel may remain inside
ce
the filter and later flow to the engine.
en

er
DRAIN PIPE DRAIN PLUG

• Keep away flammable from the fuel to
ef
of life.
• Place the container under the drain port and
collect all of drained oil for safety and not to
pollute the ground.
R
(4) Confirm that no more fuel flows from the drain

pipe and then tighten the drain plug.
Tightening torque
Drain plug 4.9 to 8.9 N·m (3.6 to 6.6 ft·lbs)
10000A-1
[ 7. MAINTENANCE ]
• Removing the fuel filter element
Loosen the center bolt, remove the cap, and

then remove the element. ELEMENT
• Installing the fuel filter element
(1) After replacing the element by a new one, install

the cap and tighten the center bolt and the air
bleeder plug.
Tightening torque
y
Center bolt 24.5 to 34.3 N·m (18.1 to 25.3 ft·lbs)
Air bleeder plug 4.9 to 8.9 N·m (3.6 to 6.6 ft·lbs)
nl
O
• Do not reuse the element.
• Replace with a new gasket provided in the
ce
element kit.
(2) After installation, bleed the air from the fuel

system.
en
• After the element is replaced, start engine

er
and make sure that there is no oil leaks

around the filter.
ef

immediately.
R
* Refer to P.7-30 for bleeding air from the fuel

system.

11000-1
[ 7. MAINTENANCE ]
16. REPLACING DEF/AdBlue® SUPPLY MODULE

FILTER
When DEF/AdBlue ® becomes dry, it will be

crystallized and change to white powder.
If you find any crystallized DEF/AdBlue ® on
the surface of DEF/AdBlue® tank, wipe it away
thoroughly with clean cloth.
When open the filter cap of DEF/AdBlue® tank,

don’t get close your face to the DEF/AdBlue ®
and/or smell it. DEF/AdBlue® may smell when
y
getting warm.
nl
Observe strictly followings to keep customer’s
safety and appropriate function of SCR system.
O
Dispose the DEF/AdBlue® as industrial wastes and
strictly follow the regulations/provisions specified
by regional authority.
ce
en
Use the DEF/AdBlue ® only for the purpose of

reduction NOx emission. DEF/AdBlue® SUPPLY
MODULE FILTER
Operate this machine without use of DEF/AdBlue®,
you may be punished.
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ef
The parts related with SCR system genuine parts

are mandatory, contact authorized Manitowoc
distributor for replace parts or repair.
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Don’t apply any modification, relocation to related

parts as DEF/AdBlue® tank, DEF/AdBlue® supply
module, DEF/AdBlue ® dosing module and DEF/
AdBlue® lines.
10000A-1
[ 7. MAINTENANCE ]
• Dismantle of DEF/AdBlue® supply module filter
(1) Turn filter cover counterclockwise and detach FILTER COVER

the DEF/AdBlue® supply module.
Spanner size : 27 mm (1-2/32 in.)
(2) Confirm if any defects as crack etc. are existed
on the filter cover. If the defects are existing,
replace filter cover is mandatory.
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In order to have any stain and damage, wipe
adhesive dust away thoroughly from the sealing
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surface of housing.
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When open the filter cover, DEF/AdBlue® will spill
over.
Prepare the container and waste cloths in advance
to receive spilled out DEF/AdBlue® and wipe them
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off.
(3) Take out an element from the DEF/AdBlue ®

supply module.
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When detach the element, squeezing with screw

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driver etc. may cause DEF/AdBlue® supply module

may be damaged and resulted DEF/AdBlue® may
be leaked. Handle with care gentry. ELEMENT
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(4) Check the color in the filter visually.

(Black or gray)
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(5) According with the color in the filter, select the When a filter is black. When a filter is gray.
direction of filter removal tool.

11000-1
[ 7. MAINTENANCE ]
(6) Detach the filter with the filter removal tool from
the DEF/AdBlue® supply module.
(7) Confirm if any defects as crack etc. are existed
on the housing.
If the defects are existing, replace DEF/AdBlue®
supply module is mandatory.
In order to have any stain and damage, wipe

adhesive dust away thoroughly from the sealing
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surface of housing.
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(8) Coat the oil slightly to O-ring and install new
filter and element.
Oil to be coated is Mobile berocite No. 6 or
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equivalent.
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O-ring
(9) Install the filter cover. FILTER COVER

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Spanner size : 27 mm (1-2/32 in.)

Tightening torque : 20 to 25 N·m (14.8 to 18.4 ft·lbs)
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10000A-1
[ 7. MAINTENANCE ]
17. CLEANING OR REPLACING DIESEL

PARTICULATE FILTER DPF
It is necessary to clean or replace the diesel

particulate filter under the specified inspection
interval.
Contact the nearest Manitowoc service shop to
carry out cleaning or replacement.
SCR
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11000-1
[ 7. MAINTENANCE ]
7.5 BATTERY INSPECTION
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BATTERY
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Check interval Check item
Monthly
or every 1. CHECKING BATTERY ELECTROLYTE LEVEL
100 hours
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2. CHECKING CHARGE CONDITION
As required 3. CHANGING BATTERY
4. USING BOOSTER CABLES
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10000A-1
[ 7. MAINTENANCE ]
1. CHECKING BATTERY ELECTROLYTE LEVEL
If the battery electrolyte level is up to 10 mm

(13/32 in.) above the plates, it is normal.
If insufficient, add distilled water.
(1) Checking the battery electrolyte level from the

side level line :
Clean around the level lines with a wet cloth,
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and make sure that the electrolyte level is
between the upper level and the lower level. Upper level
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When the electrolyte level is lower than the level
Lower level
halfway between the upper level and the lower
level, add battery electrolyte.
After replenishment, securely tighten the plug.
NEVER clean the battery with a dry cloth.
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ce
Otherwise, static electricity occurs, leading to
combustion and explosion.
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11000-1
[ 7. MAINTENANCE ]
(2) When you cannot check the battery electrolyte OIL FILL PORT
level from the side level line, or no level lines
are provided on the side of the battery :
Detach the plug at the top of the battery, and Upper level
(Bottom of sleeve)
check the battery electrolyte level from the filling
Lower level
port.
If the electrolyte level is lower than the sleeve,
add battery electrolyte to the bottom of the sleeve.
Sufficiently replenished Insufficiently replenished
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When the electrolyte level reaches the
When the electrolyte level does not
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bottom of the sleeve, the electrolyte
reach the bottom of the sleeve, the
surface is swelled by surface tension,
Liquid level is Liquid level is not pole plates seen to be straight.
and the pole plates seen to be warp.
reached to the reached to the
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sleeve bottom sleeve bottom
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• T h e b a t t e r y g e n e r a t e s t h e f l a m m a b l e
hydrogen gas, keep away flammable to
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of life.
• Do not put the tools or the likes on or near
the battery to avoid any sparks.
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of life.
• If the handling of booster cable is incorrect
may cause battery explosion.
Ensure to take correct handling and not to
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made mistake of terminal and terminal.

of life.
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10000A-1
[ 7. MAINTENANCE ]
2. CHECKING CHARGE CONDITION

BATTERY
HYDROMETER
The charge condition is judged by measuring
the specific gravity of the battery electrolyte.
The normal specific gravity is 1.25 to 1.27 at Read horizontally
20°C (68°F) of electrolyte temperature.

If the specific gravity is lower than 1.25, charge
the battery.
If the battery is not used for a long time, remove
the battery from the machine and store it in a
cold and dark place.
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Do not short across the battery terminals to check
charging condition.
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3. CHANGING BATTERY
(1) Place the machinery on the horizontal place and

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stop the engine.

(2) When changing to new battery, make sure to
change two batteries as one set.
(3) When removing the battery cable, make sure to
remove the earth side cable ( side terminal)
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first.
(4) After installed, put the red and black battery
terminal covers.
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11000-1
[ 7. MAINTENANCE ]
4. USING BOOSTER CABLES
When the battery is discharged and booster

machine battery is to be connected with the
booster cables to start the engine, observe the
following procedure.
• T h e b a t t e r y g e n e r a t e s t h e f l a m m a b l e
hydrogen gas, keep away flammable to
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of life.
• Do not put the tools or the likes on or near
the battery to avoid any sparks.
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of life.
• Place the machine and booster machine on
dry soil or concrete.
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Placing on the steel plate makes machine
grounded condition and may cause
unexpected spark.
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of life.
• If the handling of booster cable is incorrect
may cause battery explosion.
Ensure to take correct handling and not to
made mistake of terminal and terminal.
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of life.
• Do not use or charge the battery when the
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battery fluid level is lower than limit level.

This may cause battery explosion.
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of life.
This machine has a DC24 V system.

Ensure to use a DC24 V booster machine with
enough capacity to starting the engine.
10000A-1
[ 7. MAINTENANCE ]
• Connecting the booster cables
(1) Stop the booster machine engine. (a : Red)

(2) Connect one end of the booster cable (a : red)
to the battery terminal of this machine and Connect first.
the other end to the battery terminal of the
booster machine.
(3) Connect one end of the other booster cable (b
: black) to the battery terminal of the booster
machine and the other end to the swing frame Booster machine battery This machine battery
of this machine. (b : Black)
Since at the last connection, sparking will occur,
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To swing frame of this machine.
connect it separating from the battery as much
as possible. Booster cable connection
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(4) Make sure for connection and then start the
booster machine engine.
(5) Start this machine engine.
(6) After the engine is started, remove the booster
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cable (b : black) and (a : red) in this order in the
following procedure which is reverse way to the
connection.
• Removing the booster cable (a : Red)

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(1) Remove the booster cable (b : black) which is
connected to the swing frame of this machine.
(2) Remove the booster cable (b : black) which
is connected to the terminal of the booster
en
machine.
(3) Remove the booster cable (a : red) which is Booster machine battery This machine battery
connected to terminal of the booster machine. (b : Black)
(4) Remove the booster cable (a : red) which is To swing frame of this machine.
connected to terminal of this machine.
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(5) Put the red and black battery terminal covers as Booster cable removal Remove first.
the last step.
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11000-1
[ 7. MAINTENANCE ]
7.6 LOCATION AND USE OF FUSE

While lifting two locks on the side face of the fuse box,
open the cover.
Cover will not open unless the locks are completely
unlocked.
COVER
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FUSE BOX COVER FUSE BOX
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FUSE PULLING TOOL SOCKET
Row A : Fuse capacity (A)

Row F : Fuse No.
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F A F A F A F A
1 20 20A 11 10 21 5 10A 31 10
2 5 12 10 22 20 32 20
× ×
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3 5 13 5 23 5 33 5
4 5 2 14 20 24 15 5 34 5
5 10 15 10 25 20 35 10
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6 5 15A 16 10 26 15 5A 36 10
7 10 17 5 27 20 37 10
× ×
8 10 18 15 28 20 38 5
9 10 1 19 10 29 10 4 39 10
10 20 20 10 30 5 40 10
Spare fuse
10000A-1
[ 7. MAINTENANCE ]
CLASSIFICATION OF FUSE USE

Fuse No. Capacity Line No. Use
F1 20A 1A - 11 Main power supply, Work light
F2 5A 4-12 Sub battery voltage monitor
F3 5A 1B - 13 IT controller
F4 5A 1B - 14 Back-up (M/L, MC1, MC2, Radio)
F5 10A 2F - 15 Bypass circuit
F6 5A 2F - 16 Release circuit
F7 10A 2F - 17 Control power (M/L)
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F8 10A 2F - 18 Output power (M/L)
F9 10A 2F - 19 Control power (MC1)
F10 20A 2F - 20 Output power (MC1)
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F11 10A 2F - 21 Auto-stop
F12 10A 2F - 22 Engine condition
F13 5A 84 - 23 Radio, One-way call
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F14 20A 2G - 24 Wiper
F15 10A 2G - 25 Function lock
F16 10A 2G - 26 Remo-con
F17 5A 2G - 27 Monitor
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F18 15A 2E - 28 Air conditioner
F19 10A 2E - 29 Air conditioner 2
F20 10A 2E - 30 Fun motor
F21 5A 51 - 31 Generation detect
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F22 20A IC - 32 DCU

F23 5A IE - 33 ECU (BATT)
F24 15A 2J - 34 ECU (+BF)
F25 20A 2J - 35 ECU (+B)
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F26 15A 2J - 36 Spare

F27 20A 2I - 37 DC motor 1 for oil cooler
F28 20A 2I - 38 DC motor 2 for oil cooler
F29 10A 2I - 39 Swing flasher, Voice alarm
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F30 5A 54 - 40 Starter
F31 10A 2H - 41 Control power (MC2)
F32 20A 2H - 42 Output power (MC2)
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F33 5A 2H - 43 Solenoid valve (Confluence/independent)

F34 5A 2H - 44 Overhoist limit switch
F35 10A 2H - 45 Fuel pump, Cigarette lighter
F36 10A 2K - 46 Relay
F37 10A 2K - 47 Relay
F38 5A 2K - 48 Free fall
F39 10A 2K - 49 Light
F40 10A 2K - Spare

11000-1
[ 7. MAINTENANCE ]
7.7 OPERATION UNDER SEVERE CONDITIONS

OPERATION IN EXTREME COLD
• Engine oil
Atmospheric temperature 40°C to 0°C 10°C to -30°C 40°C to -30°C

when engine starting (104°F to 32°F) (50°F to -22°F) (104°F to -22°F)
Viscosity of oil SAE 30 SAE 10W SAE 10W-30
* Use engine oil suitable to the atmosphere temperature. (JASO DH-2, API CJ-4, ACEA E-6, E-9)
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• Do not mix with different brand of oil and
use of same brand of oil.
• In order to keep good function of the
O
emission control devices, it is recommended
to use the specified brand (recommended)
engine oil.
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• Fuel
Before starting work, drain water.
After the work is finished, fill the tank as full as
possible.
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Ambient temp. Type

-5°C (23°F) or more JIS 2 light oil
-5°C to -15°C (23°F to 5°F) JIS 3 light oil
-15°C (5°F) or less JIS 3 special light oil
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* Use engine oil suitable to the atmosphere temperature.

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fuel in the area.)

before refilling.
white smoke.
10000A-1
[ 7. MAINTENANCE ]
• Coolant
Capacity of coolant : 30 L (7.9 gal)

Atmospheric Volume of
Volume of
temperature Cooling water LLC ratio
LLC : L (gal)
: °C (°F) : L (gal)
-17 (1.4) 21 (5.5) 9 (2.4) 30%
-21 (-5.8) 19 (5.0) 11 (2.9) 35%
-25 (-13) 18 (4.8) 12 (3.2) 40%
-31 (-23.8) 16 (4.2) 14 (3.7) 45%
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-40 (-40) 15 (4.0) 15 (4.0) 50%
* Combine antifreeze (long life coolant) according to the
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atmospheric temperature.
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Sometimes, combination rate may be different
depending upon brands.
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• Battery
Sufficiently charge the battery.
(Maintain the specific gravity more 1.22.)
en
There is a possibility of freezing if the battery is

not enough charged.
After the distilled water has been filled, run the
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engine and mixed water and electrolyte.

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11000-1
[ 7. MAINTENANCE ]
OPERATION IN EXTREME HOT
• Engine oil
Atmospheric temperature 40°C (104°F) 40°C to 0°C

when engine starting or more (104°F to 32°F)
Viscosity of oil SAE 40 SAE 30
* Use engine oil suitable to the atmospheric temperature. (JASO DH-2, API CJ-4, ACEA E-6, E-9)
y
nl
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engine oil.
• Coolant
Use of long life coolant compounding ratio of
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30%.
• Battery
Always maintain the electrolyte level 10 mm
(13/32 in.) above the plates.
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OPERATION IN DUSTY PLACE
• Air cleaner
Perform washing and change of the element
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early.
• Radiator, oil cooler

Early clean the core not to allow dust to clog the
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core.
• Filter, element
Early replace with new ones.
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• Engine oil
Early change oil.
• Swing bearing ring gear

Early lubricate.
• Wire rope
Early clean and lubricate.
10000A-1
[ 7. MAINTENANCE ]
OPERATION IN SEASIDE
• Lubrication
Thoroughly and carefully lubricate each point.
Lubricate connector sections not equipped with
grease fittings.
• Basic machine
Sufficiently wash the basic machine, radiator
and oil cooler to wash salt off.
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11000-1
[ 7. MAINTENANCE ]
7.8 HANDLING OF DIESEL PARTICULATE FILTER

Diesel particulate filter system burns soot automatically
in the cleaning mode when the filter collected soot is
accumulated to certain level.
In order to prevent failure of diesel particulate filter,
observe the following points.
(* Soot accumulation time and burning time may vary
depending on work condition.)
What is the diesel particulate filter
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When the soot accumulated in the cleaner of the
diesel particulate filter reaches a certain level, the unit
nl
starts burning process (regeneration).
With this, the cleaning capacity of the diesel particulate
filter is kept to a satisfactory level.
In addition, with using the high performance catalyst
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and common-rail fuel injection system, it becomes
possible to burn (regenerate) soot during the crane
work.

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fuel in the area.)
before refilling.
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white smoke.
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10000A-1
[ 7. MAINTENANCE ]

engine oil.
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• Do not modify the tail pipe.
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If the tail pipe direction or length is changed,
performance of the exhaust gas recirculate
combustion devices would be adversely affected.
Do not modify the tail pipe. Should modification
become necessary for a certain reason, contact
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the authorized Manitowoc distributor.
• Diesel particulate filter burns (regenerates) soot

collected automatically.
en
Do not park the crane near the place where dry

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grass or inflammable objects are there.

After the work or during cleaning mode, exhaust
pipe area, muffler and exhaust gas become hot.
Inflammable object may cause fire.
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Hot exhaust gas may also cause burns to personnel.

a serious injury or loss of properties.
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11000-1
[ 7. MAINTENANCE ]
When the diesel particulate filter is working, take care

of the following points.
Due to some work conditions, burning (regeneration)

of the soot collected in the diesel particulate filter may
not be completed.
In such case, “soot burning (regenerate) icon” is
indicated on the main monitor.
This is to resume function of the diesel particulate filter
and is not a failure.
When “soot burning (regenerate) icon” is indicated on
the main monitor, push the soot burning (regenerate)
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icon to burn soot (regeneration).
If the crane is left idling for long time, idling speed may
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increase and load valve may actuate to prevent from
exhausting white smoke.
The diesel particulate filter may cause increase of
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engine idling speed and may actuate load valve and
lever operation may becomes impossible under the
following case.
This is to rise exhaust temperature and to clean the
exhaust gas but not a failure.
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• When the “soot burning (regenerate) icon” is
indicated on the main monitor and the icon is
pushed to burns (regenerate) the soot. (Lever
work becomes impossible.)
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• When it becomes auto-regeneration mode

during work. (Lever work becomes possible.)
• If the low exhaust system temperature continues
for long time (such as keep the idling longer
than 1 hour), and when as manipulate the lever
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to work, the function will be continued.

Refer to the article “2. OPERATION” for details.
The diesel particulate filter has the following features.

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• Since the exhaust gas is cleaned with the diesel

particulate filter, exhaust gas has different smell
compared with the conventional machines.
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• At machine start, white smoke comes out of the

tail pipe.
This is moisture and is normal.
• During soot burning (regenerating) white smoke
may come out from the muffler area.
This is exhaustion of moisture accumulated
around the muffler area and is normal.
10000A-1
[ 7. MAINTENANCE ]
7.9 MACHINE STORAGE

1. Short term storage (period of 30 days or less)
• Clean, sufficiently dry, and then carefully

lubricate the entire machine.
• Cover the machine to protect it from dust.
2. Long term storage (longer than one month and

less than 1 year)
• Clean, sufficiently dry, and then carefully
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lubricate the entire machine.
• Sufficiently grease the swing bearing ring gear.
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• Replace the reduction unit gear oil and hydraulic
oil with fresh oil.
• Replace all filters with new ones.
• Remove the battery and store it in a cool and,
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dark place.
• Apply thin coat of oil to places that are prone to
rust.
• Completely drain coolant and post a “No Water”
sign.
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• Cover the entire machine to protect it from dust.
As for the storage of the engine area, refer to the

engine manual (proper operating-long time storage).
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11000-1
[ 7. MAINTENANCE ]
7.10 TIGHTENING TORQUE VALUES

1. Unless otherwise specified, torque all metric
screws and bolts on this machine to the values
shown in the table below.
METRIC COARSE THREAD SCREW (PLATED)

Tightening torque : N·m (ft·lbs)
2 face width
Nominal 4T 7T
: mm (in.)
Dry Lubricated Dry Lubricated
y
4.6 to 5.6 3.9 to 4.7 10 to 12.2 8.4 to 10.2 10
M6
(3.4 to 4.1) (2.9 to 3.5) (7.4 to 9.0) (6.2 to 7.5) (13/32)
11.1 to 12.2 9.5 to 10.5 24.4 to 30.1 20.2 to 24.8 13
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M8
(8.2 to 9.0) (7.0 to 7.7) (18 to 22.2) (14.9 to 18.3) (1/2)
22 to 27 18.5 to 22.7 47.6 to 58.2 40.6 to 49.6 17
M10
(16.2 to 19.9) (13.6 to 16.7) (35.1 to 42.9) (29.9 to 36.6) (11/16)
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37.1 to 45.3 32.7 to 39.9 81.0 to 99.2 68.8 to 84.0 19
M12
(27.4 to 33.4) (24.1 to 29.4) (59.7 to 73.2) (50.7 to 62.0) (3/4)
59.1 to 72.3 50.2 to 61.5 129 to 157 109 to 133 22
M14
(43.6 to 53.3) (37.0 to 45.4) (95.1 to 115.8) (80.4 to 98.1) (7/8)
ce
90 to 110 75.9 to 92.7 194 to 238 163 to 199 24
M16
(66.4 to 81.1) (56.0 to 68.4) (143 to 176) (120 to 147) (15/16)
123 to 151 105 to 129 274 to 334 229 to 281 27
M18
(91 to 111) (77.4 to 95.1) (202 to 246) (169 to 207) (1-1/16)
174 to 212 146 to 178 379 to 463 318 to 388 30
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M20
(128 to 156) (108 to 131) (280 to 341) (235 to 286) (1-3/16)
229 to 281 194 to 238 503 to 615 423 to 517 32
M22
(169 to 207) (143 to 176) (371 to 454) (312 to 381) (1-1/4)
300 to 366 238 to 292 643 to 787 520 to 636 36
M24
(221 to 270) (176 to 215) (474 to 580) (384 to 469) (1-7/16)
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432 to 528 353 to 431 943 to 1153 768 to 938 41

M27
(319 to 389) (260 to 318) (696 to 850) (566 to 692) (1-5/8)
591 to 723 494 to 604 1279 to 1563 1075 to 1315 46
M30
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(436 to 533) (364 to 445) (943 to 1153) (793 to 970) (1-13/16)

794 to 970 661 to 809 1721 to 2101 1446 to 1768 50
M33
(586 to 715) (488 to 597) (1269 to 1550) (1067 to 1304) (1-15/16)
1023 to 1251 856 to 1046 2205 to 2659 1843 to 2253 55
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M36
(755 to 923) (631 to 771) (1626 to 1961) (1359 to 1662) (2-3/16)
10000A-1
[ 7. MAINTENANCE ]
METRIC FINE THREAD SCREW (PLATED)

Tightening torque : N·m (ft·lbs)
2 face width
Nominal 4T 7T
: mm (in.)
Dry Lubricated Dry Lubricated
11.6 to 14.2 9.8 to 12 25.6 to 31.2 21.1 to 25.9 13
M8
(8.6 to 10.5) (7.2 to 8.9) (18.9 to 23) (15.6 to 19.1) (1/2)
22.9 to 28.1 19.4 to 23.8 49.4 to 60.4 42.7 to 51.7 17
M10
(16.9 to 20.7) (14.3 to 17.6) (36.4 to 44.5) (31.5 to 38.1) (11/16)
40.6 to 49.6 34.4 to 42 87.3 to 106.7 73.2 to 89.4 19
M12
(29.9 to 36.6) (25.4 to 31) (64.4 to 78.7) (54 to 65.9) (3/4)
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94 to 116 79.4 to 97 202 to 248 172 to 210 24
M16
(69.3 to 85.6) (58.6 to 71.5) (149 to 183) (127 to 155) (15/16)
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185 to 227 157 to 191 406 to 496 335 to 409 30
M20
(136 to 167) (116 to 141) (299 to 366) (247 to 302) (1-3/16)
318 to 388 265 to 323 688 to 840 573 to 701 36
M24
(235 to 286) (195 to 238) (507 to 620) (423 to 517) (1-7/16)
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635 to 777 529 to 647 1393 to 1703 1156 to 1412 46
M30
(468 to 573) (390 to 477) (1027 to 1256) (853 to 1041) (1-13/16)
1058 to 1294 882 to 1078 2311 to 2825 1922 to 2350 55
M36
(780 to 954) (651 to 795) (1705 to 2084) (1418 to 1733) (2-3/16)
ce
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11000-1
[ 7. MAINTENANCE ]
2. Tightening torque of bolt, nut with special

specification are listed below.
• Tightening torque shall be within ±10% of the

value in the list.
• Apply LOCTITE #243 or equivalence to the
bolts and nuts.
• For maintenance, contact our Manitowoc
authorize distributor.
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(1) Swing bearing
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2,780 N·m (2,050 ft·lbs)
2,780 N·m (2,050 ft·lbs)

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161 N·m (119 ft·lbs) 559 N·m (412 ft·lbs)
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(2) Swing reduction unit

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10000A-1
[ 7. MAINTENANCE ]
121 N·m (89 ft·lbs)

(3) Engine
290 N·m (214 ft·lbs)

310 N·m (229 ft·lbs)
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400 N·m (295 ft·lbs)
560 N·m (413 ft·lbs)
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161 N·m (119 ft·lbs)
25 N·m (18 ft·lbs)

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(4) Pump assembly
25 N·m (18 ft·lbs)
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310 N·m (229 ft·lbs)
560 N·m (413 ft·lbs)

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(5) Travel reduction unit

assembly
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1,150 N·m (848 ft·lbs)

11000-1
[ 7. MAINTENANCE ]
39 N·m (29 ft·lbs)
39 N·m (29 ft·lbs)
(6) Front and rear drum

assembly
39 N·m (29 ft·lbs)
39 N·m (29 ft·lbs) 560 N·m (413 ft·lbs)
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39 N·m (29 ft·lbs)
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(7) Boom drum assembly ce
39 N·m (29 ft·lbs)
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10000A-1
[ 7. MAINTENANCE ]
7.11 PERIODICAL REPLACING SECURITY PARTS

In order to use the machine safely for long time,
it is requested to inspect and repair the machine
periodically.
Therefore replace the following parts periodically to
keep safety of the machine.
These parts may cause material deterioration by

aging, wear or fatigue and may lead to serious
accident.
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It would be difficult to judge these parts life by
operation or visual inspection.
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If there is any abnormality noticed on the periodic
inspection maintenance time, replace these parts with
new ones even before periodic replacement time as
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shown here.
Contact Manitowoc service shop for part replacement.
1. Hose damage related clutch brake and control

pressure may lead to the serious accident.
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Replacement
Hose related periodical replacing parts
Interval
Front drum CLM
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Front drum ESM

Rear drum CLA
(1) Front drum nega. posi-clutch main hose
Rear drum ESA
Third drum CLT
Third drum EST
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Front drum FBM

(2) Foot brake control hose Rear drum FBA
Third drum FBT
(3) Pressure control hose
Relief valve 2 years
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(Pump to line filter)

Manifold (P0)
(Line filter to accumulator)
Under floor block (PH0)
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Left deck front P block (P2)

2 section valve (Remocon. cut) (P1)
Remocon. valve (Brake pedal) (P3)
(Accumulator to valve block)
4 section valve (Free fall) (P4)
Remocon. valve (Third brake pedal)
2 section valve (Third free fall)
* Replace the following hoses as periodical replacing security parts on every 2 years or less.
As for all hydraulic hoses, inspect them periodically

and replace them if oil oozing or leaking are found.

11000-1
[ 7. MAINTENANCE ]
2. The guy lines are subject to damage caused

by internal fatigue or corrosion and can not be
judged for their replacement time by outer visual
inspections.
Water immersion
If the internal damage or corrosion is

progressed, guy line may be broken and may
cause serious accident.
Make sure to replace periodically based on
work condition.
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Guy line related periodically replacing parts Recommended replacement interval
General crane work. 6 years
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Crane work main with clamshell and bucket work as sub. 4 years
Only for lifting magnet, clamshell and hammer grab. 2 years
CRANE GUY LINE
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Guy line dimension Remarks :
Symbol Part number Connector type
Diameter : mm (in.) Length : m (ft. in.) m (ft.)
A 30 (1–3/16″) 6.17 (20′ 2-15/16″) Boom tip
B 30 (1–3/16″) 3.05 (10′) 3.0 (10′) Boom insert

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C 30 (1–3/16″) 6.10 (20′) 6.1 (20′) Boom insert
D 30 (1–3/16″) 12.20 (40′) 12.2 (40′) Boom insert
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CRANE JIB GUY LINE

Guy line dimension
Symbol Part number Connector type
Diameter : mm (in.) Length : m (ft. in.)
E 22 (7/8″) 19.34 (63′ 5-7/16″)
F 22 (7/8″) 5.88 (19′ 3-1/2″)
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G 22 (7/8″) 11.75 (38′ 6-5/8″)

H 22 (7/8″) 37.54 (123′ 1-15/16″)
J 22 (7/8″) 2.44 (8′ 1/16″)
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10000A-1
[ 7. MAINTENANCE ]
7.12 ADJUSTMENT
7.12.1 ADJUSTMENT OF FRONT, REAR, THIRD (OPTION) DRUM LOCKS
Do not adjust the drum locks until the boom and

hook block have been lowered to the ground.
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1. Pull the drum lock knob in the lock position and FRONT, REAR, THIRD (OPTION) DRUM LOCKS
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check to see that the pawl is engaged in the
bottom of the drum ratchet. RATCHET
If the pawl is not engaged in the bottom of the
ratchet, adjust the spring length to allow the
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20 mm (13/16″) or more
pawl to be engaged.
2. With the release position, adjust the respective

dimension as shown in the figure to the right.
PAWL (lock position)
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3. Push the drum lock knob in the release position PAWL (release position)
and check to see that the pawl is clear of the
ratchet by at least 20 mm (13/16 in.).
4. Operate the knob to the lock position, and to

en
the release position and confirm that the pawl

moves smoothly.
109 mm 126 mm
(4-5/16″) (5″)
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Release position Release position

Place a signal person to prevent accident from at control cable at spring
set length set length
rotating drum.
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serious injury.
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11000-1
[ 7. MAINTENANCE ]
7.12.2 ADJUSTMENT OF BOOM DRUM LOCK
Do not adjust the drum locks until the boom and

hook block have been lowered to the ground.
1. Pull the drum lock knob in the lock position and

check to see that the pawl is engaged in the
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bottom of the drum ratchet.
If the pawl is not engaged in the bottom of the
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ratchet, adjust the spring length to allow the
pawl to be engaged.
2. With the release position of drum lock, adjust
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the respective dimension as shown in the figure
to the below.
BOOM DRUM LOCK

Release
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po
spring s sition DW
RATCHET et length
126 mm
(5″)
58 mm
26 mm (1″) or more (2-5/16″) 58 mm
(2-5/16″)
PAWL
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Releas
(lock position) control e position at
cable se
PAWL t length
112 mm
(release position) (4-7/16″)
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3. Push the drum lock knob in the release position

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and check to see that the pawl is clear of the

ratchet by at least 26 mm (1 in.).
4. Operate the knob to the lock position, and to

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the release position and confirm that the pawl

moves smoothly.
Place a signal person to prevent accident from

rotating drum.
serious injury.
10000A-1
[ 7. MAINTENANCE ]
7.12.3 CRAWLER SHOES ADJUSTMENT

If the crawler tension is high, the shoes wear quickly
and connection between two shoes could break.
On the other hand, if the tension too loose, the shoes
may run off the drive tumbler or idler wheel during
travel.
To prevent these, it is necessary to adjust shoe
tension.
Travel forward about 7 m (23 ft.) with the drive tumbler

at rear and then adjust the shim to make upper shoe
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slackening to be 10 to 20 mm (13/32 to 13/16 in.).
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To adjust shoe tension, proceed as follows : FRAME COVER
(inside and outside)
1. Travel the machine forward about one crawler SHIM COVER IDLER WHEEL
length so that the slack in the crawler shoes
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appear on the top of the crawler.
2. Remove all the shims from shim pack (a).
3. Position the hydraulic jack between the bracket

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and block of the side frame.
Operate the jack to push the idler wheel and
remove the slack in the shoes.
4. Insert the shims removed from pack (a) in step

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(2) into the vacant room of pack (b). SHIM PACK (a) SHIM PACK (b)
Insert the remaining shims into pack (a).

JACK
5. After the shims are installed, install the mud INSTALL BRACKET
cover (c) on the shim installation area (a). JACK SLACK
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Install the cover (d) to the elongated hole area 10 to 20 mm

(13/32 to 13/16″)
of both crawler frames.
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Equalize the tension in right and left crawler tracks.

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ADAPTOR BLOCK

11000-1
[ 7. MAINTENANCE ]
7.13 CONSUMABLE PARTS LIST

1. OIL/GREASE
For the recommended oil and grease, refer to the

“Manitowoc GENUINE LUBRICANT CHART” on
P.7-55, and use genuine Manitowoc parts.
For the battery electrolyte and the window
washer liquid, use commercial items.
2. FILTER ELEMENT
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For the recommended filter element, refer to the
chart on P.7-87.
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3. FUSE
For the recommended fuse, refer to the chart on
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P.7-114.
4. WIRE ROPE
For the recommended wire rope, refer to the

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article “6. WIRE ROPE”.
5. LIGHT AND LAMP

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GANTRY LIGHT (L)

Assy :
Bulb :
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GANTRY LIGHT (R/L)

Assy :
Bulb :
ROOM LIGHT
Assy :
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Bulb :
WORK LIGHT (R/L)

Assy : SWING FLASHER LAMP
Bulb : Assy :
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Lens : Bulb :
Lens :
SPOTLIGHT
Assy :
OVERLOAD ALARM LAMP
Assy :
Bulb :
10000A-1
[ 7. MAINTENANCE ]
6. MIRROR
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DOOR MIRROR :
WORK MIRROR :
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REARVIEW MIRROR :
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REARVIEW MIRROR :
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7. BATTERY
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BATTERY㸸
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11000-1
[ 7. MAINTENANCE ]
8. WINDOW GLASS AND WIPER
WIPER BLADE :
RUBBER :
GLASS㸸
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GLASS㸸
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GLASS㸸
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GLASS㸸
SASH ASSY :
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GLASS㸸
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GLASS㸸
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WIPER BLADE :
RUBBER :
GLASS㸸
10000A-1
[ 7. MAINTENANCE ]
9. HOOK OVERHOIST LIMIT SWITCH
LIMIT SWITCH :
WIRE ROPE :
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WEIGHT :
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Main hook
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LIMIT SWITCH :
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WIRE ROPE : WIRE ROPE :
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Aux. hook
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SPLIT PIN :
PIN :
SHACKLE :
SHACKLE
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10. CABLE REEL
For crane hook overhoist

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For crane jib hook overhoist
11. KEY
For the cab door, the guard door and the engine
starting are used a common key.

11000-1
[ 7. MAINTENANCE ]
12. TOOL
Name Part No. Detail
TOOL BOX
PLIERS
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ADJUSTABLE WRENCH
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HAMMER
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DRIVER
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DRIVER
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ADAPTOR
(When adjustment of shoe)
JACK
(When adjustment of shoe)
10000A-1
[ 7. MAINTENANCE ]
RATCHET HANDLE
EXTENSION BAR
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SPANNER
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SOCKET
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TUBE
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GREASE NIPPLE
(a) (b) (c)

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TAPE
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GREASE PUMP
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HOSE
(For grease pump)

11000-1
[ 7. MAINTENANCE ]
DRAIN HOSE (FUEL)

(For engine maintenance)
CARTRIDGE
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CARTRIDGE
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GREASE
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GEAR OIL
(For swing gear)
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SHACKLE
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PIPE WRENCH
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SCREW KEY
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CHAIN
(For gantry cylinder)
10000A-1
[ 7. MAINTENANCE ]
FUEL FILTER (HINO

MADE) WRENCH
LONG NOZZLE OIL JUG

(Oil jug for J08E engine
maintenance)
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11000-1
[ 7. MAINTENANCE ]
7.14 MEASURES REQUIRED FOR FRONT, REAR WINCH

MONITORING
Refer to the information on the general inspection

of the front, rear winch too.
7.14.1 THEORETICAL SERVICE LIFE
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The theoretical service life is determined from certain
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operating conditions and a theoretical operating time
assumed by the design engineer when calculating and
dimensioning the winches of this crane.
The winches of this crane are classified as follows.
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(ISO 4301/1, FEM 1.001, DIN Calculating code for
power unit)
Power unit group M3

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Load spectrum Q 1 (L 1)
Load spectrum factor Km = 0.125
Theoretical service life D = 3,200 h
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The theoretical service life is not the same as the

real (actual) service life of a winch.
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The real service life of a winch is affected by a number

of additional external factors, such as :
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1. Overloading caused by improper use of the crane.

2. Insufficient maintenance Oil is not changed at the specified intervals.
Extreme acceleration or deceleration of the load.
3. Operating errors
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Sudden load drops and stops while lifting load.

Wrong oil used. Incorrect filling quantity.
4. Improper maintenance
Contamination during oil change.
5. Improper assembly during maintenance and repair work.
6. Leaks which were ignored.
7. Improper adjustment of safety devices.
8. Concealed damage caused by accidents.
Extreme low or high temperatures.

9. Extreme environmental conditions
Severe climate condition. Dust and dirt.
10000A-1
[ 7. MAINTENANCE ]
7.14.2 USED PROPORTION OF THEORETICAL SERVICE LIFE

The crane operator must perform a crane inspection
at least once a year (ISO 9927-1).
This includes establishing the proportion of theoretical
service life that has been used.
If required, the crane operator is to appoint an expert
for this assessment.
The actual operating conditions (load spectrum) and
the operating hours of the hoists are to be determined
for each inspection interval when establishing the
proportion of theoretical service life that has been
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used.
The operator is responsible for proper documentation
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in the crane logbook.
Determining the operating conditions (Load spectrum)

The load spectrum of the crane is divided into groups :
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(also refer to ISO 430/1, JIS 8822-2)
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When establishing the load frequency distribution,
the existing wire rope condition is used as a
standard, i.e. under certain circumstances;
the crane is supporting a heavy load, whereby
the winch is actually supporting a light load
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depending on the number of lines on the hook.

Therefore, the following graphic representation
of the load distribution shall be considered to the
number of lines to winch.
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11000-1
[ 7. MAINTENANCE ]
1. Actual operating conditions (load spectrum)
One of the load spectrums listed below should

be selected on the basis of the actual operating
conditions and entered in the crane logbook for
the respective testing interval.
* The load spectrum L1 and the load spectrum

factor Km = 0.125 are generally applied to your
crane.
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Collective Collective
load Definition Proportion of operating time load factor Graphic representation
class Km =
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Load %
Power units or parts • 10% of the operating time with highest
100
thereof that are rarely load (dead load + 1/1 payload)
Light
subject to maximum • 40% of the operating time with dead 50 40%
Q1 0.125
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load , but are load + 1/3 payload 10%
L1
constantly subject to • 50% of the operating time with dead
0 50 100
minimal loads load only Operating time %
• 1/6 of the operating time with highest

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Load %
Power units or parts load (dead load + 1/1 payload)
100
thereof that are fairly • 1/6 of the operating time with dead 73%
Medium
often subject to load + 2/3 payload 50 47%
Q2 0.25 20%
maximum load, but • 1/6 of the operating time with dead
L2
continuously subject load + 1/3 payload
0 50 100
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minimal loads • 50% of the operating time with dead Operating time %
load only
Load %
Power units or parts
100
thereof that are often • 50% of the operating time with highest
Heavy
subject to maximum load (dead load + 1/1 payload)
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50 40%
Q3 0.5
load and continuously • 50% of the operating time with dead
L3
subject to medium load only
0 50 100
loads Operating time %
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Load %
Power units or parts 100
Very • 90% of the operating time with highest 80%
thereof that are
heavy load (dead load + 1/1 payload) 50
regularly subject 1
Q4 • 10% of the operating time with dead
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to loads close to
L4 load only
maximum load 0 50 100
Operating time %
2. Determination of the effective operating hours Ti
The effective operating hours, must be entered

into the crane log book for the corresponding
testing interval.
10000A-1
[ 7. MAINTENANCE ]
3. Determining the proportion of theoretical service

life used
For a testing interval “i” (max. 1 year according

to ISO 9927-1) the used proportion of theoretical
service life Si is calculated using the formula :
Kmi
Si = × Ti
Km
Load spectrum factor established during winch calculation.

Km
This factor is given in the operating instructions.
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Load spectrum factor in inspection interval “i” in accordance with the section
Kmi
“Determining the operating conditions (collective load)”
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Effective operating hours in the testing interval “i” according to section
Ti
“Determining the actual operating hours Ti”
This used proportion is subtracted from the
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remaining theoretical service life Di after every
testing interval (see example in the appendix to
this chapter).
If the remaining theoretical service life is not

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sufficient for the next operating period, then
a general overhaul of the winch must be
performed.
If theoretical service life D has been reached

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(7.14.1 THEORETICAL SERVICE LIFE), the

winch must not be operated until after a general
overhaul has been performed.
A general overhaul must be performed at least

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once every 10 years after commissioning of the

crane.
The general overhaul is to be arranged by the

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operator and performed by the manufacturer or

their representative.
The results are to be entered in the crane
logbook.
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The manufacturer or his representative will

specify a new theoretical service life D upon
completion of the general overhaul.
The next general overhaul must be performed

within 10 years.

11000-1
[ 7. MAINTENANCE ]
4. Alternative provision
If, after ten years, the theoretical service life has

not been used up, the winch can continue to be
operated without a general overhaul under the
following conditions.
The crane expert has confirmed that the used

portion of the service life is correct and proper
by signing his/her name in the crane test book
after every inspection.
In this case, the crane expert must closely
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inspect the winch.
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As a minimum, this includes :
• A visual inspection of the exterior

(for leaks, damage, malformation etc.)
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• An oil inspection (especially for metallic residue)
• A load inspection with minimum and maximum
rope pull and each with maximum possible
speed.
At least one position is to be wound.
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Pay attention to any unusual noises during the
load inspection.
This inspection must be confirmed in the crane

test book by the crane expert and there must
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be a declaration of continued operation for the

winch.
The next inspection takes place before the 12th
year of operation and must be repeated every
year thereafter.
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10000A-1
[ 7. MAINTENANCE ]
7.14.3 DETERMINING OF THE RESIDUAL THEORETICAL SERVICE LIFE
Power unit group M3

Load spectrum Light L1, Km = 0.125
Theoretical service life D = 3,200 h
The used proportion S of theoretical service life is

calculated over the individual inspection intervals as
follows :
1. Inspection (1st year)
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The crane was used for assembly work during
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the previous year : Load spectrum L1,
i.e. Km1 = 0.125.
The operating hour counter reads 800 h.
The winch was operated 20 % of the time,
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i.e. T1 = 160 h.
The used proportion S1 of theoretical service
life after the first inspection is therefore :
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0.125
Si = × 160 h = 160 h
0.125
Remaining theoretical service life :

D1 = 3,200 h - 160 h = 3,040 h
The aforementioned values are entered in the
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table (see table example P.7-149.)

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11000-1
[ 7. MAINTENANCE ]
2. Inspection (2nd year)
The crane was used for unloading work on

docks :
Load spectrum : L3, i.e. Km2 = 0.5.
The operating hour counter reads 2,000 h, i.e.
during this period :
2,000 h - 800 h = 1,200 h (800 h were used
during the first year).
The winch was operated 40 % of the time,
i.e. T2 = 480 h.
The used proportion S2 of theoretical service
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life after the second inspection is therefore :
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Si = 0.5 ×
480 h = 1,920 h
0.125
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D2 = 3,040 h - 1,920 h = 1,120 h
The values above are entered in the table
(see table example P.7-149.)
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3. Inspection (3rd year)
The crane was used for assembly work and

occasional unloading work on docks :
Load spectrum : L2, i.e. Km3 = 0.25.
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The operating hour counter reads 3,000 h, i.e.

during this period :
3,000 h - 2,000 h = 1,000 h (2,000 h were used
during the first two years).
The winch was operated 30% of the time,
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i.e. T3 = 300 h.
The used proportion S3 of theoretical service life
after the third inspection interval is therefore :
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0.25
Si = × 300 h = 600 h
0.125

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D3 = 1,220 h - 600 h = 520 h

The values are entered in the table
(see table example P.7-149.)
10000A-1
Sample table to determine the remaining theoretical service life on winch no. 1 (main hoisting winch)
Crane model :
R 1000
11000-10A-1
Work number : GH05-*****
Commissioned on : 01.01.2016
Serial number of the winch in accordance with the type plate :
Last general overhaul performed on : .......................
Winch design data (see operating instructions) :
Power unit group : M 3
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Load spectrum : Q 1 (L 1)
Factor of the load spectrum : Km = 0.125
Theoretical service life : D = 3,200 h
Published 01-28-16, Control #250-01

Inspection Date of Operational Load Operating Operating Operating Operating Operating Used Remaining Name of Signature Note Name of the Signature
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interval no. commission/ condition spectrum hours of the hours of the hours of the hours of the hours of the proportion of theoretical competent approved
(max.1 year) date of since the factor entire crane superstruc- superstruc- winch winch since theoretical service life person inspector
inspection last ture ture since the last service life D:
inspection the last inspection Di = Di-1 - Si
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
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7-149
0(*) 10. 6. 11 0 0 3,200
1 5. 6. 12 L1 0.125 800 800 160 160 3,040

(20% of 800)
480
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2 20. 5. 13 L2 0.5 2,000 1,200 1,920 1,120
(40% of 1,200)
3 18. 5. 14 L3 0.25 3,000 1,000 300 600 520

(30% of 1,000)
CAUTION : Si
O= Used proportion of theoretical service life since the last inspection
A general overhaul is to be performed every 10 years. Di = Remaining theoretical service life
Di-1 = Remaining theoretical service life after the previous inspection
Alternative provision, refer to [ALTERNATIVE PROVISION] in chapter “10.11.2 ” . Km = Load spectrum factor established during winch calculation.
This factor is given in the operating instructions.
Kmi = Load spectrum factor in the inspection interval “i” .
Ti = Effective working hours in the inspection interval “i” .
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Last general overhaul performed on .............................. (*) Copy last line of the previous page to the following pages.
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10000A-1
11000-1
[ 7. MAINTENANCE ]
[ 7. MAINTENANCE ]
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10000A-1
[ 8. REFERENCE MATERIALS ]
8.1 SPECIFICATION ..................................................................................................................... 8-1
8.1.1 CRANE OUTSIDE DIMENSION .................................................................................... 8-2
8.1.2 CRANE SPECIFICATION, PERFORMANCE ............................................................ 8-3
8.1.3 CRANE WORKING RANGES ........................................................................................ 8-5
8.2 DIMENSION, WEIGHT OF EACH COMPONENT ........................................................ 8-8
8.2.1 BASE MACHINE ................................................................................................................ 8-8
8.2.2 COUNTERWEIGHT .......................................................................................................... 8-10
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8.2.3 ATTACHMENT .................................................................................................................... 8-11
8.3 CLAMSHELL RATED LOADS (OPTION)......................................................................... 8-13
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8.4 SWING AND TRAVEL STABILITY ..................................................................................... 8-17
8.5 TRAVEL ALLOWABLE SLOPE ANGLE............................................................................ 8-20
8.5.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION ..... 8-20
8.6 LOW GANTRY POSITION ................................................................................................... 8-26
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8.7 SAFETY DEVICE LIST (OPTION) ..................................................................................... 8-27
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11000-1
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Actual lengths of boom section, wire rope are metric.

The values in ( ) are approximate conversion to feet.
8.1 SPECIFICATION
This crane is designed for normal work of lifting hook.
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Classification of this crane is as follows.
(ISO 4301/2, FEM 1.001)
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Class of utilization : U1
State of loading : Q2
Group Classification as crane : A1
In case of severer work condition such as bucket etc, components life may be lowered.
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In case of severer work condition, perform work referring to manufacture’s recommended condition.
As for Front or Rear winch, calculate service life of component referring to article “7.14. MEASURES REQUIRED
FOR WINCH MONITORING” and perform maintenance work under appropriate interval.
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11000-1
8.1.1 CRANE OUTSIDE DIMENSION

Unit : mm (ft. in.)
4,430 (14′ 6″)
′)
(40
914 (3′)
00
2,2
:1
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om
bo
sic
Ba
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″)
5 ′5 1,100
(1 5,140 (16′ 10″) (3′ 7″)
00
,7
R4
3,415 (11′ 2″)
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6,185 (20′ 3″)
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3,315 (10′ 10″)
(6′ 8″)
2,040
2,990 (9′ 10″)
1,495
(5′ 10″)
1,770
(4′ 11″)
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(3′ 8″)
1,115
940
(3′ 1″)
5,440 (17′ 10″)

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6,280 (20′ 7″)

390 (1′ 3″)
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3,614 (11′ 10″)

(Crawler retracted)
5,244 (17′ 2″)
(Crawler extended)
10000A-1
8.1.2 CRANE SPECIFICATION, PERFORMANCE
Type Full swing, crawler type

Max. rated load × work radius 99.8 t × 3.35 m (220,000 lbs × 11')
Boom length
• Basic boom 12.2 m (40')
• Maximum boom 61.0 m (200')
• Crane jib 9.1 m (30') to 18.3 m (60')
• Maximum boom and jib 57.9 m (190') Boom + 18.3 m (60') Jib
Work speed Wire rope dia.
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• Front / Rear hoisting rope speed 120 to 3 m/min (390 to 10 ft/min)
26 mm
• Front / Rear lowering rope speed 120 to 3 m/min (390 to 10 ft/min)
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• Boom raising rope speed 70 to 2 m/min (230 to 6.6 ft/min)
16 mm
• Boom lowering rope speed 70 to 2 m/min (230 to 6.6 ft/min)
• Third hoisting rope speed (option) 120 to 3 m/min (390 to 10 ft/min)
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22 mm
• Third lowering rope speed (option) 120 to 3 m/min (390 to 10 ft/min)
• Swing speed 4.0 min-1 (4.0 rpm)
• Travel speed 1.7/1.1 km/h (1.1/0.72 MPH)
Gradability 40%
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Working weight *1 90.05 t (198,500 lbs)
Average ground pressure *1 88.9 kPa (12.9 psi)
Engine
• Engine name Hino J08E-VV
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• Engine out put 213 kW/2,100 min-1 (286 HP/2,100 rpm)

*1 Crane (12.2 m [40'], Without rear drum rope, Without main hook)
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The wire rope speeds described above are the

value of the drum first layer.
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Each wire rope speed varies depend on the load.

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11000-1
OUTSIDE DIMENSIONS Unit : mm (ft. in.)

Overall width of cab 2,990 (9′ 10″)
Radius of rear end (counterweight) 4,700 (15′ 5″)
Center of rotation to rear end (low gantry position) 5,140 (16′ 10″)
Center of rotation to boom foot pin (from center of rotation) 1,100 (3′ 7″)
Height from ground to boom foot pin 1,770 (5′ 10″)
Height to top of gantry (working position) 6,185 (20′ 3″)
Height to top of gantry (low gantry position) 3,315 (10′ 10″)
Counterweight ground clearance 1,115 (3′ 8″)
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Overall length of crawlers 6,280 (20′ 7″)
Distance between centers of tumblers 5,440 (17′ 10″)
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Overall width of crawlers (extend/retract) 5,244 / 3,614 (17′ 2″ / 11′ 10″)
Width of crawler shoe 914 (3′)
Ground clearance of carbody 390 (1′ 3″)
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10000A-1
8.1.3 CRANE WORKING RANGES

1. Crane working ranges
Unit : m (ft.)
82° 75° 70° 65° 60° 55°

65 (213)
61.0 (200) BOOM
50°
57.9 (190) BOOM 60 (197)
54.9 (180) BOOM
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55 (180)
51.8 (170) BOOM
45°
48.8 (160) BOOM
50 (164)
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45.7 (150) BOOM
42.7 (140) BOOM 45 (148)

40°
39.6 (130) BOOM
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40 (131)
36.6 (120) BOOM
35°
33.5 (110) BOOM
35 (115)
30.5 (100) BOOM
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30°
27.4 (90) BOOM 30 (98)
24.4 (80) BOOM

25°
25 (82)
21.3 (70) BOOM
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18.3 (60) BOOM

20 (66)
20°
15.2 (50) BOOM
12.2 (40) BOOM

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Height above ground

1.77 (5.8)
10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
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Radius from center of rotation
Center of
rotation
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1.10 (3.6)

11000-1
2. Jib working range
(1) Offset angle 10 degrees
Unit : m (ft.)
80 (263)
57.9 (190) Boom 10°
+ 18.3 (60) Jib 80°
57.9 (190) Boom 75 (246)
+ 15.2 (50) Jib
57.9 (190) Boom
+ 12.2 (40) Jib
57.9 (190) Boom 70 (230)
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+ 9.1 (30) Jib
65 (213)
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60 (197)
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55 (180)
50 (164)
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24.4 (80) Boom 45 (148)
+ 18.3 (60) Jib
24.4 (80) Boom
+ 15.2 (50) Jib
40 (131)
24.4 (80) Boom
+ 12.2 (40) Jib
24.4 (80) Boom
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+ 9.1 (30) Jib 35 (115)
30 (98)
25 (82)
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20 (66)
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Height above ground

1.77 (5.8)
10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
Center of
rotation
1.10 (3.6)
10000A-1
(2) Offset angle 30 degrees
Unit : m (ft.)
80 (263)
80° 30°
57.9 (190) Boom
+ 18.3 (60) Jib 75 (246)
57.9 (190) Boom
+ 15.2 (50) Jib
57.9 (190) Boom
+ 12.2 (40) Jib 70 (230)
57.9 (190) Boom
+ 9.1 (30) Jib
65 (213)
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60 (197)
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55 (180)
50 (164)
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45 (148)
24.4 (80) Boom
+ 18.3 (60) Jib
24.4 (80) Boom
40 (131)
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+ 15.2 (50) Jib
24.4 (80) Boom
+ 12.2 (40) Jib
24.4 (80) Boom 35 (115)
+ 9.1 (30) Jib
30 (98)
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25 (82)
20 (66)
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Height above ground

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1.77 (5.8)
10 15 20 25 30 35 40 45 50
(33) (49) (66) (82) (98) (115) (131) (148) (164)
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Center of
rotation
1.10 (3.6)

11000-1
8.2 DIMENSION, WEIGHT OF EACH COMPONENT

Dimension and weight of each component when
disassembled is shown here.
Use this as reference value.
8.2.1 BASE MACHINE
Weight :
Name Dimension mm : (ft. in.)
kg (lbs)
Gantry
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Transportation configuration 1
Boom base
12,090 (39′ 8″)
Boom drum
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Wire rope
3,350 (11′)
(10′ 10″)
43,430
3,315
(Front, rear, boom drum)

(95,800)
Self removal device
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Side step 3,615
(11′ 10″)
Crawler
Translifter (option)
Gantry
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Boom base
8,210 (26′ 11″)
Boom drum
Wire rope 3,350 (11′)
(10′ 10″)
41,375
3,315

(91,200)
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Self removal device
Side step 3,615

(11′ 10″)
Crawler
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Gantry
Boom base
8,210 (26′ 11″)
Boom drum
Wire rope
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3,350 (11′)
(10′ 10″)
40,475
3,315

(89,300)
Self removal device
Side step 3,615

(11′ 10″)
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Crawler
: With : Without
10000A-1
Weight :
kg (lbs)
Gantry
Boom base 2,990

12,090 (39′ 8″) (9′ 10″)*1
Boom drum
Wire rope
29,450
(9′ 8″)
(9′ 9″)
2,930
2,960
(64,900)
Self removal device
Side step 4,175 2,990

(13′ 8″) (9′ 10″)
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Crawler
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Gantry
Boom base 2,990

7,700 (25′ 3″) (9′ 10″)*1
Boom drum
Wire rope
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27,395
(9′ 8″)
(9′ 9″)
2,930
2,960
(60,400)
Self removal device
Side step 4,175 2,990

(13′ 8″) (9′ 10″)
Crawler
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6,280 (20′ 7″) 914 (3′)
7,550
(3′ 3″)
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Crawler 980
(16,700)
1,080
(3′ 6″)
1,620 (5′ 4″)

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400 (1′ 4″)
290 (640)
/ 1 piece
710 (2′ 4″)
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: With : Without *1 With the side step on cabin side : 3,160 (10′ 4″)
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With the side steps on the both side : 3,340 (11′)

11000-1
8.2.2 COUNTERWEIGHT
Weight :
kg (lbs)
(3′ 12″)
1,210
8,310
Counterweight (1)
4,430 (14′ 6″) (18,300)
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(2′ 8″)
825
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910
(2′ 12″) 1,450 (4′ 9″)
Right side
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5,750 (12,700)
Counterweight (3),(5)
/ 1 piece
(3′ 10″)
1,180
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910
1,450 (4′ 9″) (2′ 12″)
Left side
5,750 (12,700)
Counterweight (2),(4)
/ 1 piece
(3′ 10″)
1,180
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7,200 (15,900)
Carbody weight (1), (2)
/ 1 piece
1,970 (6′ 6″)
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(2′ 1″)
625
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1,590 (5′ 3″) 980 (3′ 3″)
860
Self removal unit
1,900 (6′ 3″)
(1,900)
10000A-1
8.2.3 ATTACHMENT
Weight :
kg (lbs)
(4′ 10″)
1,480
(4′ 4″)
1,315
Boom tip 1,205 (2,700)
1,510
(4′ 11″) 6,910 (22′ 8″)
1,620 mm (5′ 4″)
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(5′ 7″)
1,700
Boom base 1,210 (2,700)
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1,490
5,970 (19′ 7″) (4′ 11″)
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(4′ 4″)
1,315
3.0 m (10')
310 (680)
Boom insert
1,510
3,165 (10′ 5″) (4′ 11″)
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(4′ 4″)
1,315
6.1 m (20')
525 (1,200)
Boom insert
1,510
6,210 (20′ 5″) (4′ 11″)
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(4′ 4″)
1,315
12.2 m (40')
965 (2,100)
Boom insert
1,510
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12,310 (40′ 5″) (4′ 11″)

1,430 (4′ 8″)
(4′ 4″)
1,315
12.2 m (40')
980 (2,200)
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Boom insert with lug

1,510
12,310 (40′ 5″) (4′ 11″)
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Backstop 270 (600)

5,130 (16′ 10″)

11000-1
Weight :
kg (lbs)
(2′ 8″)
800
Jib tip 280 (620)
800
(2′ 8″) 5,000 (16′ 5″)
(2′ 8″)
800
Jib base 200 (440)
800
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4,810 (15′ 9″) (2′ 8″)
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800
3.0 m (10')
100 (220)
Jib insert
800
3,110 (10′ 2″) (2′ 8″)
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800
6.1 m (20')
180 (400)
Jib insert
800
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6,160 (20′ 3″) (2′ 8″)
(2′ 9″)
840
340 (1′ 1″)

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Jib strut 250 (550)

620
(2′)
3,620 (11′ 11″)

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825 (2′ 8″)
Auxiliary sheave 195 (430)

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870 (2′ 10″) 480 (1′ 7″)

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680 (2′ 3″)
Upper spreader 280 (620)
1,580 (5′ 2″) 300 (1′)
10000A-1
8.3 CLAMSHELL RATED LOADS (OPTION)

CLAMSHELL SPECIFICATION
1. Rated loads included in the charts are the

maximum allowable freely suspended loads at a
given boom length, boom angle and load radius,
and have been determined for the machine
standing level on firm supporting surface under
ideal operating conditions.
The user must limit or de-rate rated loads to
allow for adverse conditions (such as soft or
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uneven ground, out-of-level conditions, wind,
side loads, pendulum action, jerking or sudden
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stopping of loads, inexperience of personnel,
multiple machine lifts, and traveling with a load).
2. Rated loads do not exceed 66% of minimum
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tipping loads.
Rated loads based on factors other than
machine stability such as structural competence
are shown by asterisk * in the charts.
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3. The machine must be reeved and set-up as
stated in the operation manual and all the
instruction manuals.
If these manuals are missing, obtain
replacements.
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• Boom backstops are required for all boom lengths.

• Gantry must be fully raised position for all
operations.
• Crawlers must be fully extended and be locked
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in position.
• The crane must be leveled to within 1% on a
firm supporting surface.
• 43,700 lbs Counterweight and without carbody
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weight.
4. Do not attempt to lift where no radius is shown

on the load chart as crane may tip or collapse.
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5. Attempting to lift more than rated loads may

cause machine to tip or collapse.
Do not tip machine to determine rated loads.
6. Weight of bucket, slings and other lifting devices

are a part of the total load.
Their total weight must be subtracted from the
rated load to obtain the weight that can be lifted.

11000-1
7. The boom should be erected over the front of

the crawlers, not laterally.
8. Least stable position is over the side.
MAXIMUM LOAD FOR MAIN BOOM

No. of Part of Line 1
Maximum Loads (lbs) 22,000
9. Rated loads listed later is to be applied only to

the machine as manufactured and designed by
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manufacture.
Do not apply any modification to this machine
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and do not use of this machine other than the
specified.
10. ASSEMBLING THE COUNTERWEIGHT
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• 43,700 lbs Counterweight
• Without carbody counterweight.
(2) (3)
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Operation of this equipment in excess of rated (1)
loads or disregard of instruction voids the warranty.
COUNTERWEIGHTS
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CARBODY WEIGHTS
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10000A-1
CLAMSHELL CAPACITIES IN POUNDS

THREE COUNTERWEIGHTS (43,700 lbs)
WITHOUT CARBODY WEIGHTS (0 lbs)
CRAWLERS : EXTENDED POSITION
40' Boom 50' Boom 60' Boom

Load Boom 360° Load Boom 360° Load Boom 360°
Radius Angle Rated Load Radius Angle Rated Load Radius Angle Rated Load
(ft.) (deg.) (lbs) (ft.) (deg.) (lbs) (ft.) (deg.) (lbs)
22.0 63.7 22,000 26.0 64.3 22,000 30.0 64.6 22,000
24.0 60.5 22,000 28.0 61.7 22,000 32.0 62.5 22,000
26.0 57.1 22,000 30.0 59.0 22,000 34.0 60.3 21,400
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28.0 53.5 22,000 32.0 56.3 22,000 36.0 58.1 20,200
30.0 49.8 22,000 34.0 53.5 21,400 38.0 55.8 19,200
32.0 45.9 22,000 36.0 50.5 20,200 40.0 53.4 18,200
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34.0 41.7 21,400 38.0 47.4 19,200 42.0 51.0 17,300
36.0 37.0 20,200 40.0 44.2 18,200 44.0 48.4 16,500
38.0 31.8 19,200 42.0 40.7 17,300 46.0 45.8 15,800
40.0 25.7 18,200 44.0 37.0 16,500 48.0 43.0 15,200
46.0 32.9 15,800 50.0 40.1 14,600
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48.0 28.3 15,200 52.0 37.0 14,000
54.0 33.6 13,500
56.0 29.9 13,000
58.0 25.7 12,500
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34.0 64.9 21,400 38.0 65.1 19,200 42.0 65.2 17,300
36.0 63.1 20,200 40.0 63.5 18,200 44.0 63.8 16,500
38.0 61.2 19,200 42.0 61.9 17,300 46.0 62.4 15,800
40.0 59.3 18,200 44.0 60.2 16,500 48.0 60.9 15,200
42.0 57.4 17,300 46.0 58.6 15,800 50.0 59.5 14,600
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44.0 55.4 16,500 48.0 56.9 15,200 52.0 58.0 14,000

46.0 53.4 15,800 50.0 55.1 14,600 54.0 56.4 13,500
48.0 51.3 15,200 52.0 53.3 14,000 56.0 54.9 13,000
50.0 49.1 14,600 54.0 51.5 13,500 58.0 53.3 12,500
52.0 46.9 14,000 56.0 49.6 13,000 60.0 51.7 12,100
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54.0 44.6 13,500 58.0 47.7 12,500 62.0 50.0 11,700

56.0 42.2 13,000 60.0 45.7 12,100 64.0 48.3 11,400
58.0 39.6 12,500 62.0 43.7 11,700 66.0 46.6 11,000
60.0 37.0 12,100 64.0 41.5 11,400 68.0 44.8 10,700
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62.0 34.1 11,700 66.0 39.3 11,000 70.0 43.0 10,400

64.0 31.0 11,400 68.0 37.0 10,700 72.0 41.0 10,100
66.0 27.6 11,000 70.0 34.5 10,400 74.0 39.0 9,700
72.0 31.8 10,100 76.0 36.9 9,200
74.0 28.9 9,800 78.0 34.7 9,000
76.0 25.7 9,400 80.0 32.4 8,500
82.0 29.9 8,300
84.0 27.2 7,900

11000-1
CLAMSHELL CAPACITIES IN POUNDS

THREE COUNTERWEIGHTS (43,700 lbs)
WITHOUT CARBODY WEIGHTS (0 lbs)
CRAWLERS : EXTENDED POSITION

46.0 65.4 15,800 56.0 62.0 11,900 56.0 64.5 11,400
48.0 64.1 15,200 58.0 60.8 11,700 58.0 63.4 11,300
50.0 62.8 14,600 60.0 59.6 11,600 60.0 62.3 11,200
52.0 61.5 14,000 62.0 58.3 11,300 62.0 61.3 11,000
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54.0 60.2 13,500 64.0 57.1 11,100 64.0 60.2 10,800
56.0 58.8 13,000 66.0 55.8 10,800 66.0 59.0 10,600
58.0 57.5 12,500 68.0 54.6 10,400 68.0 57.9 10,200
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60.0 56.1 12,100 70.0 53.3 10,100 70.0 56.8 9,900
62.0 54.7 11,700 72.0 52.0 9,700 72.0 55.6 9,500
64.0 53.3 11,400 74.0 50.6 9,300 74.0 54.5 9,100
66.0 51.8 11,000 76.0 49.2 8,900 76.0 53.3 8,800
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68.0 50.4 10,700 78.0 47.8 8,500 78.0 52.1 8,400
70.0 48.8 10,300 80.0 46.4 8,200 80.0 50.8 8,100
72.0 47.3 9,900 82.0 45.0 7,900 82.0 49.6 7,700
74.0 45.7 9,400 84.0 43.4 7,500 84.0 48.3 7,400
76.0 44.1 9,000 86.0 41.9 7,200 86.0 47.0 7,100
78.0 42.4 8,800 88.0 40.3 7,000 88.0 45.7 6,800
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80.0 40.6 8,300 90.0 38.6 6,800 90.0 44.3 6,600
82.0 38.8 8,100 92.0 36.9 6,600 92.0 42.9 6,400
84.0 36.9 7,700 94.0 35.1 6,400 94.0 41.5 6,200
86.0 35.0 7,400 96.0 33.3 6,200 96.0 40.0 6,000
88.0 32.9 7,200 98.0 31.3 5,900 98.0 38.5 5,700
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90.0 30.7 7,000 100.0 29.2 5,700 100.0 36.9 5,500

92.0 28.3 6,800 102.0 27.0 5,500 102.0 35.3 5,300
94.0 25.8 6,600 104.0 24.5 5,300 104.0 33.6 5,100
106.0 31.8 5,000
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10000A-1
8.4 SWING AND TRAVEL STABILITY

The stability while swinging and traveling of the
machine is to be varied depending on the mass of
counterweight, condition of the attachment, extension
or retraction of the crawler and traveling on the slope.
The operation must be started after confirm the
machine stability while swinging and traveling by
referring with following table.
1. The table above shows the values for operation

on firm ground.
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On a weak ground, operate with care after
improving the ground.
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2. Swinging on a trailer is prohibited.
TRAVEL Traveling forward
MOTOR
3. Maximum slope angle is 21.8 degrees (40%).
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This may become lower depending on condition
(ground, crane configuration).
4. Traveling “forward” means that the counterweight

is at the lower side of the slope, and “backward” TRAVEL
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MOTOR
is the counterweight is at the higher side of the
slope. Traveling backward
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11000-1
TABLE FOR STABILITY (WITHOUT CARBODY WEIGHT)

Without : 0 t
No.1 :
8.31 t (18,320 lbs)
Without attachment lever control) or less)
(Base machine only)
No.1 to No.2 :
19.81 t (43,674 lbs)
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No.1 to No.3 :
31.31 t (69,028 lbs)
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Without : 0 t
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No.1 :
(Boom angle :
19.81 t (43,674 lbs)
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No.1 to No.3 :
31.31 t (69,028 lbs)
Without : 0 t
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No.1 :
(Boom angle :
(Slope 7 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
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10000A-1
TABLE FOR STABILITY (WITH CARBODY WEIGHT)

Without : 0 t
No.1 :
8.31 t (18,320 lbs)
Without attachment
(Base machine only)
No.1 to No.2 :
(Slope 8 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
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Without : 0 t
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No.1 :
(Boom angle :
(Slope 12 degrees
19.81 t (43,674 lbs)
or less)
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No.1 to No.3 :
31.31 t (69,028 lbs)
Without : 0 t
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No.1 :
(Boom angle :
19.81 t (43,674 lbs)
lever control) or less)
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No.1 to No.3 :
(Slope 3 degrees
31.31 t (69,028 lbs)
or less)
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11000-1
8.5 TRAVEL ALLOWABLE SLOPE ANGLE

8.5.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION
Do not travel with the symbol of “ ” in the table.

The machine may possible turnover.
serious accident.
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If the machine has to travel by some reason, observe
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the following points.
• Do not travel with a load lifted.

• Travel with low speed and gently.
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• Travel on the flat and firm ground.
• Ensure to check the ground condition and travel
on the slope angle smaller than shown in the
chart.
• Travel straight against slope.
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• Provide the gentle slope at the beginning and
end positions of slope.
TRAVEL UPWARD DOWNWARD ON SLOPE (θ : ALLOWABLE ANGLE)

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Forward Backward
Boom angle
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Boom angle
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10000A-1
1. Crane travel allowable slope angle
(1) Without Aux. sheave
(Unit : Degrees)
Forward Backward
Boom length m (ft.) Boom angle Boom angle
35 40 50 40 50 60
12.2 (40) 5 5 4 8 8 8
15.2 (50) 7 6 5 8 8 8
18.3 (60) 8 8 6 8 8 8
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21.3 (70) 8 8 6 8 8 8
24.4 (80) 8 8 7 8 8 8
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27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 7 8 8
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51.8 (170) 8 8 8 5 6 8
54.9 (180) 8 8 8 3 4 6
57.9 (190) 8 8 8 1 2 5
61.0 (200) 8 8 8 - 1 3
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(2) With Aux. sheave

(Unit : Degrees)
Forward Backward
Boom length m (ft.) Boom angle Boom angle
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35 40 50 40 50 60
12.2 (40) 5 5 4 8 8 8
15.2 (50) 7 6 5 8 8 8
18.3 (60) 8 8 6 8 8 8
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21.3 (70) 8 8 6 8 8 8
24.4 (80) 8 8 7 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
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33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 7 8 8
51.8 (170) 8 8 8 5 6 8
54.9 (180) 8 8 8 3 4 6
57.9 (190) 8 8 8 1 2 5

11000-1
2. Fixed jib travel allow slope angle
(Unit : Degrees)
Jib length m (ft.) 9.1 (30)
Offset angle 10
Configuration Forward Backward
Boom angle Boom angle
Boom length m (ft.)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
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30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
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36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
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48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 6 8 8
57.9 (190) 8 8 8 2 6 8
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(Unit : Degrees)
Offset angle 30
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Boom length m (ft.)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
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30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
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39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
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51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 7 8 8
57.9 (190) 8 8 8 2 6 8
10000A-1
(Unit : Degrees)
Offset angle 10
Boom length m (ft.)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
y
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
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42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
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51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 4 8 8
57.9 (190) 8 8 8 - 4 8
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(Unit : Degrees)
Offset angle 30
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Boom length m (ft.)

35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
er
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
ef
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 8 8 8
54.9 (180) 8 8 8 4 8 8
R
57.9 (190) 8 8 8 - 4 8

11000-1
(Unit : Degrees)
Offset angle 10
Boom length m (ft.)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
y
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
nl
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
O
51.8 (170) 8 8 8 7 8 8
54.9 (180) 8 8 8 2 6 8
57.9 (190) 8 8 8 - 2 7
ce
(Unit : Degrees)
Offset angle 30
en
Boom length m (ft.)

35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
er
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
ef
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 7 8 8
R
54.9 (180) 8 8 8 2 6 8
57.9 (190) 8 8 8 - 2 7
10000A-1
(Unit : Degrees)
Offset angle 10
Boom length m (ft.)
35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
33.5 (110) 8 8 8 8 8 8
y
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
nl
42.7 (140) 8 8 8 8 8 8
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
O
51.8 (170) 8 8 8 5 8 8
54.9 (180) 8 8 8 - 4 8
57.9 (190) 8 8 8 - 1 6
ce
(Unit : Degrees)
Offset angle 30
en
Boom length m (ft.)

35 40 50 40 50 60
24.4 (80) 8 8 8 8 8 8
27.4 (90) 8 8 8 8 8 8
30.5 (100) 8 8 8 8 8 8
er
33.5 (110) 8 8 8 8 8 8
36.6 (120) 8 8 8 8 8 8
39.6 (130) 8 8 8 8 8 8
42.7 (140) 8 8 8 8 8 8
ef
45.7 (150) 8 8 8 8 8 8
48.8 (160) 8 8 8 8 8 8
51.8 (170) 8 8 8 5 8 8
R
54.9 (180) 8 8 8 - 4 8
57.9 (190) 8 8 8 - 1 5

11000-1
8.6 LOW GANTRY POSITION

During the work, if the machine must travel under low
overhead place such as under bridge, move with low
gantry position (Gantry is lowered).
Never lift a load with low gantry position.

Otherwise damage to the boom, gantry or travel
kit or coming up of counterweight may occur and
y
is very dangerous.
Ensure to see that there is enough clearance
nl
between the machine height / boom height and
the low overhead place. Make low gantry travel
distance as short as possible and slowly.
Failure to observe this precaution mat result in a
O
serious accident.
CONDITIONS
ce
• The crawlers are fully extended.
• All counterweight are equipped and secured
firmly with bolts.
• Install the travel kit to the counterweight firmly.
• Travel on level ground with low speed.
en
• The boom angle is horizontal or slightly up.

• Guy cable with proper length is connected on
the boom tip.
• Boom angle should be such that the guy cables
do not press down the boom tip guide roller. TRAVEL KIT
er
• The longest boom length is 15.2 m (50 ft.)

(The longest boom length with auxiliary sheave
is 15.2 m [50 ft.])
ef
R
15.2 m (50′)
15.2 m (50′)
* In case with aux. sheave
10000A-1
8.7 SAFETY DEVICE LIST (OPTION)

Item Assembly dwg No.
Front / rear drum monitor camera
1. MONITOR CAMERA
Boom drum monitor camera
Monitor camera installation for rope winding and
Machine rear monitor camera
machine rear condition.
Controller installation.
2. CAB CEILING WINDOW GUARD
Preventing damage of ceiling window by falling thing.
3. AUXILIARY PLATFORM
y
Stowing type step on the both side of machine deck. Width : 300 mm (1')
(width : 300 mm)
nl
4. LOAD SAFETY DEVICE EXTERNAL INDICATING LAMP
Indication of load condition by square type 3 color light
to outside (gr, ye. Re)
5. TRAVEL WARNING DEVICE
O
Warning at travel by buzzer intermittent sound.
6. EXTINGUISHER For EU
ABC powder type extinguisher
7. RIGHT AND LEFT GUARD UPPER FACE HANDRAIL (HIGH) For right guard
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Preventing falling off at guard upper face (folding type). For left guard
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11000-1
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10000A-1
[ 9. DIAGRAM ]
9. DIAGRAM
9.1 HYDRAULIC DIAGRAM ........................................................................................................ 9-1
9.2 ELECTRIC SCHEMATIC ...................................................................................................... 9-5
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11000-1
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[ 9. DIAGRAM ]
9. DIAGRAM
9.1 HYDRAULIC DIAGRAM
1. WITH FREE FALL
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(1/2)

11000-1
[ 9. DIAGRAM ]
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(2/2)
10000A-1
[ 9. DIAGRAM ]
2. WITHOUT FREE FALL
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(1/2)

11000-1
[ 9. DIAGRAM ]
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(2/2)
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[ 9. DIAGRAM ]
9.2 ELECTRIC SCHEMATIC
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(1/21)

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[ 9. DIAGRAM ]
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(2/21)
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[ 9. DIAGRAM ]
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(3/21)

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[ 9. DIAGRAM ]
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(4/21)
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[ 9. DIAGRAM ]
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(5/21)

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[ 9. DIAGRAM ]
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(7/21)

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[ 9. DIAGRAM ]
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[ 9. DIAGRAM ]
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(9/21)

11000-1
[ 9. DIAGRAM ]
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(10/21)
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[ 9. DIAGRAM ]
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(11/21)

11000-1
[ 9. DIAGRAM ]
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(12/21)
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[ 9. DIAGRAM ]
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(13/21)

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[ 9. DIAGRAM ]
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(14/21)
10000A-1
[ 9. DIAGRAM ]
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(15/21)

11000-1
[ 9. DIAGRAM ]
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(16/21)
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[ 9. DIAGRAM ]
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(17/21)

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[ 9. DIAGRAM ]
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[ 9. DIAGRAM ]
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(19/21)

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[ 9. DIAGRAM ]
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[ 9. DIAGRAM ]
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(21/21)

11000-1
[ 9. DIAGRAM ]
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10000A-1

10000a-1 T4F Com CTR250-01 01-28-16

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10000a-1 T4F Com CTR250-01 01-28-16

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OPERATOR MANUAL

This manual has been prepared for and is considered part of -

This Manual is divided into the following sections:

To prevent death or serious injury:

Crane and attachments must be operated and maintained by trained

and understanding instructions contained in Operator Information

3. LOAD SAFETY DEVICE

4. ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY

Published 01-28-16, Control #250-01 10000A-1

10000A-1 Published 01-28-16, Control #250-01

2.2.6 AIR CONDITIONER FOR AUTO-IDLE STOP (AIS AIR CONDITIONER)

2.2.9 MONITORING CAMERA (OPTION) ............................................................................. 2-73

2.3.2 GETTING ON AND OFF FROM / TO OPERATOR’S CAB .................................... 2-78

2.3.6 AUTO IDLE STOP FUNCTION ...................................................................................... 2-111

Published 01-28-16, Control #250-01 1 10000A-1

2.5.1 PREPARATION WORK..................................................................................................... 2-144

3. LOAD SAFETY DEVICE

3.7 LOAD HISTORY (DATA LOGGER)..................................................................................... 3-53

3.9.2 CONTENT OF AUTO-STOP............................................................................................ 3-57

ATTACHMENT ASSEMBLY WORK IS COMPLETED............................................. 3-64

3.12 ERROR CODE DISPLAY AND MESSAGE...................................................................... 3-69

4. ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY

4.3.1 CAB STEP EXTENSION.................................................................................................. 4-10

4.4.8 REMOVAL OF LADDER FOR MACHINERY GUARD ............................................ 4-108

4.6 INSTALLATION/REMOVAL OF BOOM BASE ................................................................ 4-121

4.6.3 UPPER SPREADER INSTALLATION .......................................................................... 4-124

Published 01-28-16, Control #250-01 3 10000A-1

4.9 SELF REMOVAL CYLINDER (OPTION) TAKEOUT/STORAGE............................... 4-145

5.1.9 ASSEMBLING THE FIXED JIB....................................................................................... 5-38

5.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT............................... 5-45

5.3 DISASSEMBLING THE ATTACHMENT............................................................................ 5-51

5.3.3 DISASSEMBLING THE JIB.............................................................................................. 5-56

6.1.2 WIRE ROPE LENGTH...................................................................................................... 6-5

7.4 REPLACEMENT AND CLEANING/WASHING FILTER ELEMENT AND

7.4.2 REPLACEMENT, CLEANING, WASHING METHODS OF FILTER

7.7 OPERATION UNDER SEVERE CONDITIONS ............................................................. 7-116

7.10 TIGHTENING TORQUE VALUES ...................................................................................... 7-124

Published 01-28-16, Control #250-01 5 10000A-1

7.14.1 THEORETICAL SERVICE LIFE...................................................................................... 7-142

9.2 ELECTRIC SCHEMATIC....................................................................................................... 9-5

This machine’s speciﬁcation is based on Mobile crane ASME B30.5.

Published 01-28-16, Control #250-01 1 10000A-1

MACHINE SERIAL NUMBER AND HOUR METER

Published 01-28-16, Control #250-01 3 10000A-1

Published 01-28-16, Control #250-01 1 10000A-1

10000A-1 Published 01-28-16, Control #250-01

Indicates an imminently hazardous situation which, if not avoided, will

Indicates a potentially hazardous situation which, if not avoided, could result

Published 01-28-16, Control #250-01 1-1 10000A-1

1.2 EXPLANATION OF WARNING LABELS IN THE MACHINE

1.2.1 HANDLING OF WARNING LABELS IN THE MACHINE

1.2.2 LABEL LAYOUT

INSIDE VIEW (R/H)

Published 01-28-16, Control #250-01 1-3 10000A-1

CAB INSIDE VIEW (REAR)

Published 01-28-16, Control #250-01 1-5 10000A-1

Section F-F (L/H) Section G-G (R/H) Section H-H

Published 01-28-16, Control #250-01 1-7 10000A-1

Published 01-28-16, Control #250-01 1-9 10000A-1

1.2.3 DETAIL OF LABEL

4. If machine swings or is assembled / disassembled

6. During crane work if the boom comes to close

7. When work is done on the upper surface of the