7055 Manual Crane

OPERATION &
MAINTENANCE
MANUAL
7055-3
(Model 7055-3F)
APPLICABLE : from GB04-03093

BOOK CODE : S2GB22001ZE11 (C) Printed in Japan 2014.07
TABLE OF CONTENTS
IMPORTANT INFORMATION
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART.......................................................... 2-1
2.1.1 CRANE ATTACHMENT..................................................................................... 2-1
2.1.2 TOWER CRANE................................................................................................ 2-2
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ..................................... 2-3
2.2.1 OPERATING SWITCHES.................................................................................. 2-7
2.2.2 GAUGE CLUSTER CONFIGURATION............................................................. 2-17
2.2.3 OPERATING THE AIR CONDITIONER ............................................................ 2-30
2.2.4 AM/FM RADIO (OPTION).................................................................................. 2-32
2.2.5 1WAY CALL (TRANSMITTER) (OPTION) ........................................................ 2-34
2.3 CRANE OPERATION............................................................................................... 2-35
2.3.1 ADJUSTING THE OPERATOR'S SEAT........................................................... 2-35
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION ......................................... 2-35
2.3.3 STARTING AND STOPPING THE ENGINE ..................................................... 2-36
2.3.4 FUNCTION LOCK LEVER................................................................................. 2-39
2.3.5 PROPELLING OPERATION.............................................................................. 2-40
2.3.6 SWINGING OPERATION .................................................................................. 2-42
2.3.7 BOOM RAISING/LOWERING OPERATION ..................................................... 2-45
2.3.8 HOOK RAISING/LOWERING OPERATION...................................................... 2-47
2.4 TOWER CRANE OPERATION ................................................................................ 2-50
2.4.1 HOISTING TOWER CRANE ATTACHMENT.................................................... 2-51
2.4.2 HOISTING TOWER JIB CRANE ATTACHMENT.............................................. 2-53
2.4.3 HOOK HOIST DRUM CONTROL...................................................................... 2-54
2.5 FREE FALL OPERATION (OPTION) ....................................................................... 2-56
2.6 CLAMSHELL OPERATION ...................................................................................... 2-60
2.7 HANDLING OF HYDRAULIC TAGLINE (OPTION).................................................. 2-62
2.8 HANDLING OF VIBROHAMMER............................................................................. 2-64
3. LOAD SAFETY DEVICE

3.1 ARRANGEMENT OF EQUIPMENTS....................................................................... 3-1
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS........................................................... 3-5
3.3 CONNECTING PROCEDURE OF WIRING ............................................................. 3-13
3.3.1 CRANE ATTACHMENT..................................................................................... 3-13
3.3.2 TOWER ATTACHMENT.................................................................................... 3-18
3.4 FUNCTION OF CONTROLLER/MONITOR ............................................................. 3-24
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TABLE OF CONTENTS
3.5 OPERATING PROCEDURE OF CONTROLLER..................................................... 3-28

3.5.1 SETTING SCREEN ........................................................................................... 3-29
3.5.2 SETTING OF THE CRANE CONFIGURATION ................................................ 3-35
3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING........................................................ 3-42
3.5.4 SETTING OF WORKING AREA LIMIT VALUE................................................. 3-43
3.5.5 SETTING OF THE TIME ................................................................................... 3-47
3.6 LOAD HISTORY....................................................................................................... 3-49
3.7 WARNING ALARM AND AUTOMATIC STOP ......................................................... 3-50
3.7.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP ................................ 3-50
3.7.2 CONTENTS OF AUTOMATIC STOP................................................................ 3-52
3.7.3 RELEASE OF AUTOMATIC STOP ................................................................... 3-55
3.8 INSPECTION ........................................................................................................... 3-62
3.8.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF
ATTACHMENT IS COMPLETED ...................................................................... 3-62
3.8.2 INSPECTION AFTER ERECTING THE ATTACHMENT .................................. 3-68
3.9 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE..................................... 3-70
3.10 INDICATION OF ERRORS AND REMEDY ............................................................. 3-71
3.11 INDICATION OF MESSAGE AND ALARM.............................................................. 3-72
3.12 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE ........................... 3-74
4. UNLOADING/LOADING THE BASIC MACHINE

4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER .................................. 4-2
4.2 LOADING THE MACHINE ON A TRAILER ............................................................. 4-2
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE

5.1 EXTENDING/RETRACTING THE CRAWLERS ...................................................... 5-2
5.1.1 EXTENDING THE CRAWLERS ........................................................................ 5-2
5.1.2 RETRACTING THE CRAWLER ........................................................................ 5-5
5.2 ERECTING/LOWERING THE GANTRY .................................................................. 5-7
5.2.1 ERECTING THE GANTRY................................................................................ 5-7
5.2.2 LOWERING THE GANTRY............................................................................... 5-9
5.3 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT
(WHEN USING THE AUXILIARY CRANE) .............................................................. 5-10
5.3.1 INSTALLATION OF THE COUNTERWEIGHT................................................. 5-10
5.3.2 REMOVAL OF THE COUNTERWEIGHT......................................................... 5-12
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT

6.1 ASSEMBLING THE ATTACHMENT ........................................................................ 6-3
6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE..................................................... 6-4
6.1.2 INSTALLING THE BACKSTOP......................................................................... 6-16
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6.1.3 INSTALLING THE BOOM BASE ....................................................................... 6-17

6.1.4 INSTALLING THE BACKSTOP TO THE REVOLVING FRAME ....................... 6-19
6.1.5 INSTALLING THE UPPER SPREADER ........................................................... 6-20
6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER .. 6-21
6.1.7 INSTALLING THE BOOM TIP ........................................................................... 6-23
6.1.8 INSTALLATION OF THE BASIC GUY LINE ..................................................... 6-25
6.1.9 MAIN HOIST WIRE ROPE REEVING ............................................................... 6-26
6.1.10 CONNECTING THE INSERT BOOMS.............................................................. 6-30
6.1.11 INSTALLING THE CABLE ROLLERS ............................................................... 6-38
6.1.12 CONNECTING THE BOOM GUY LINES .......................................................... 6-39
6.1.13 CAUTION FOR CANTILEVER .......................................................................... 6-41
6.1.14 ASSEMBLING THE JIB ..................................................................................... 6-43
6.1.15 REEVING OF REAR DRUM WIRE ROPE ....................................................... 6-47
6.1.16 INSTALLING THE AUXILIARY SHEAVE .......................................................... 6-50
6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE .... 6-51
6.2 ERECTING THE ATTACHMENT ............................................................................. 6-52
6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT .......................... 6-52
6.2.2 ERECTING THE ATTACHMENT ...................................................................... 6-53
6.3 LOWERING THE ATTACHMENT ............................................................................ 6-55
6.3.1 LOWERING THE ATTACHMENT ..................................................................... 6-56
6.4 DISASSEMBLING THE ATTACHMENT .................................................................. 6-57
6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING ................................. 6-57
6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES..................... 6-57
6.4.3 DISASSEMBLING THE JIB ............................................................................... 6-58
6.4.4 REMOVING THE BOOM GUY LINE ................................................................. 6-60
6.4.5 DISASSEMBLING THE BOOM ......................................................................... 6-62
6.4.6 REMOVING THE BOOM BASE ........................................................................ 6-63
6.4.7 REMOVAL OF THE COUNTERWEIGHT.......................................................... 6-64
6.4.8 LOWERING THE GANTRY ............................................................................... 6-64
6.5 CAUTION WHEN TRANSPORTING BOOM............................................................ 6-65
7. ASSEMBLY/DISASSEMBLY OF TOWER CRANE

ATTACHMENT
7.1 ASSEMBLING TOWER ATTACHMENT .................................................................. 7-3
7.1.1 PREPARATION OF TOWER BOOM/JIB/GUY LINE......................................... 7-4
7.1.2 CHANGE OF BASIC MACHINE TO TOWER CRANE ATTACHMENT ............ 7-9
7.1.3 ASSEMBLY OF TOWER ATTACHMENT ......................................................... 7-11
7.1.4 ASSEMBLY OF TOWER JIB............................................................................ 7-31
7.1.5 FUNCTION CHECK OF EACH LIMIT SWITCH ................................................ 7-45
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TABLE OF CONTENTS
7.2 ERECTING THE TOWER ATTACHMENT............................................................... 7-46

7.2.1 ERECTING THE TOWER BOOM ..................................................................... 7-46
7.2.2 ERECTING THE JIB.......................................................................................... 7-53
7.2.3 INSPECTION BEFORE USE ............................................................................ 7-56
7.3 LOWERING THE TOWER ....................................................................................... 7-59
7.3.1 LOWERING THE JIB......................................................................................... 7-59
7.3.2 LOWERING THE TOWER ................................................................................ 7-62
7.4 DISASSEMBLY OF THE TOWER ........................................................................... 7-65
7.4.1 DISCONNECT OF THE JIB .............................................................................. 7-67
7.4.2 DISASSEMBLY OF THE JIB............................................................................. 7-71
7.4.3 DISASSEMBLY OF TOWER GUY LINE AND TOWER .................................... 7-73
8. WIRE ROPE
8.1 HANDLING OF WIRE ROPE ................................................................................... 8-2
8.1.1 UNREELING METHOD OF WIRE ROPE ......................................................... 8-2
8.1.2 WINDING WIRE ROPE ONTO THE DRUM...................................................... 8-3
8.1.3 INSTALLING THE ROPE SOCKET .................................................................. 8-5
8.1.4 SPECIFICATION OF WIRE ROPE ................................................................... 8-6
8.1.5 WIRE ROPE LENGTH ...................................................................................... 8-7
9. MAINTENANCE
9.1 CHECKS .................................................................................................................. 9-6
9.1.1 CHECKS OF THE UPPER ................................................................................ 9-6
9.1.1.1 CHECK OF UPPER, DAILY OR EVERY 8 HOURS................................... 9-8
9.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS......................... 9-13
9.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS ............. 9-17
9.1.1.4 CHECK OF UPPER, WEEKLY OR EVERY 50 HOURS ............................ 9-18
9.1.1.5 CHECK OF UPPER, EVERY 5000 HOURS............................................... 9-18
9.1.2 CHECK OF LOWER.......................................................................................... 9-20
9.1.2.1CHECK OF LOWER DAILY OR EVERY 8 HOURS ................................... 9-21
9.1.2.2CHECK OF LOWER MONTHLY OR EVERY 100 HOURS........................ 9-22
9.1.2.3CHECK OF LOWER QUARTERLY EVERY 3 MONTHS OR EVERY 250
HOURS....................................................................................................... 9-24
9.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS ............ 9-25
9.1.3 CHECK OF ATTACHMENT .............................................................................. 9-26
9.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 5 HOURS........................ 9-28
9.2 OIL/GREASE SUPPLY AND WATER SERVICE ..................................................... 9-36
9.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY) ........................................... 9-40
9.2.2 LOWER LUBRICATION .................................................................................... 9-42
9.2.3 ATTACHMENT LUBRICATION......................................................................... 9-44
9.2.4 GREASE............................................................................................................ 9-46
9.2.5 ENGINE OIL ...................................................................................................... 9-50
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TABLE OF CONTENTS
9.2.6 FUEL.................................................................................................................. 9-51

9.2.7 COOLANT ......................................................................................................... 9-52
9.2.8 HYDRAULIC OIL ............................................................................................... 9-54
9.2.9 GEAR OIL.......................................................................................................... 9-56
9.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER ............. 9-62
9.4 BATTERY INSPECTION .......................................................................................... 9-73
9.5 LOCATION AND USE OF FUSE.............................................................................. 9-76
9.6 OPERATION UNDER UNUSUAL CONDITIONS..................................................... 9-78
9.7 MACHINE STORAGE .............................................................................................. 9-80
9.8 TIGHTENING TORQUE VALUES............................................................................ 9-81
9.9 SECURITY PARTS TO BE REPLACED PERIODICALLY ....................................... 9-83
9.10 ADJUSTMENT ......................................................................................................... 9-84
9.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS................................... 9-84
9.10.2 ADJUSTMENT OF BOOM DRUM LOCK .......................................................... 9-85
9.10.3 CRAWLER SHOES ADJUSTMENT .................................................................. 9-86
9.11 CONSUMABLE PARTS LIST................................................................................... 9-87
10.REFERENCE MATERIALS
10.1 SPECIFICATION .................................................................................................... 10-1
10.1.1 PERFORMANCE............................................................................................. 10-1
10.1.2 TOWER CRANE PERFORMANCE................................................................. 10-1
10.1.3 OUTSIDE DIMENSIONS ................................................................................. 10-2
10.1.4 WORKING RANGES ....................................................................................... 10-4
10.1.5 RATED CRANE LOADS.................................................................................. 10-9
10.1.6 RATED TOWER CRANE LOADS ................................................................... 10-24
10.2 DIMENSIONS AND WEIGHT OF EACH PARTS................................................... 10-40
10.2.1 BASE MACHINE............................................................................................. 10-40
10.2.2 COUNTERWEIGHT......................................................................................... 10-41
10.2.3 ATTACHMENT ................................................................................................ 10-42
10.3 STABILITY IN SWINGING AND TRAVELING ....................................................... 10-48
10.4 ALLOWABLE ANGLE OF MACHINE INCLINATION
WHEN PROPELLING............................................................................................. 10-49
10.5 SYSTEM SCHEMATIC........................................................................................... 10-51
10.5.1 HYDRAULIC SCHEMATIC.............................................................................. 10-51
10.5.2 ELECTRIC SYSTEM SCHEMATIC ................................................................. 10-52
10.6 SAFETY DEVICE LIST (OPTION) ......................................................................... 10-66
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TABLE OF CONTENTS
6
Thank you for your purchasing KOBELCO crawler crane. Our 7000 series full-hydraulically operated crawler crane
is manufactured based on our long years of experience and expertise. This manual describes the important infor-
mation about Model 7055-3.
Before operating the machine, be sure to thoroughly read this manual to use the machine safely and efficiently.
Do not operate or maintain this machine until you read this manual and understand the instructions. Improp-
er operation or maintenance of this machine may cause accidents and could result in serious injury or
death.
Always keep this manual in the operators cab.
If it is missing or damaged, place an order to a KOBELCO authorize distributor for a replacement.
If you have any questions, please consult your KOBELCO authorize distributor.
SAFETY INFORMATION
Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Suf-
ficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of per-
sonnel.
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 marks. The safety information contained in this manual is intended only
general safety information.
Messages of safety appear in this manual and on the machine. 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 result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against possible damage to the machine and its components.
Supplementary explanation.
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 KOBELCO. While operating machine, be sure to
perform work with great care, so as to not damage the machine, or let accidents occur.
Please continue studying this manual until proper operation is completely understood.
0-1 7055-3
MACHINE SERIAL NUMBER

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 name plate and the total number of hours indicated on the hourmeter which is located
in the gauge.
HOURMETER
MACHINE SERIAL NUMBER
N o. G B 0 4 - 0 3 0 1 9
ENGINE NUMBER
MODEL CODE MACHINE SERIAL NUMBER
J08E --------------
ENTER MACHINE SERIAL NUMBER OF THIS MACHINE
MACHINE MACHINE
7055-3F GB04- ENGINE No. J08E-
MODEL SERIAL No.
WARRANTY
The terms under which this machine is guaranteed are clearly defined in the 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.
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 every specified period of time.
7055-3 0-2
EXPLANATION OF WARNING LABELS

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.
HANDLING OF WARNING LABELS

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.
0-3 7055-3
7055-3 0-4
0-5 7055-3
7055-3 0-6
0-7 7055-3
7055-3 0-8
36.6m and shorter
12.2m and shorter
0-9 7055-3
7055-3 0-10
0-11 7055-3
7055-3 0-12

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 inju-
ry, death, or property damage.
General safe practices for working on machinery must

be followed as well as the safe operating practices rec-
ommended here.
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 op-
erating.
He must understand how to read the rating plate and

know that his machine can safely lift each load before
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 or
boom angle.
Never attempt to operate the crane at conditions ex-

ceeding those shown on the rating chart. Such opera-
tion can cause tipping or structural failure of the crane
that can result in damage, injury, or death.
He must be alert, physically fit, and free from the influ-

ences of alcohol, drugs, or medications that might af-
fect 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 barricaded.
When an operator's vision is restricted or when operat-

ing in hazardous places such as near electrical power
lines or around people, a signalman must be used. Be-
cause the operator is not always in the best position to
judge distances and can not see all parts of the jobsite,
a signalman may also be necessary at other times. Op-
erators must understand standard crane signals and
take signals only from designated signalmen.
1-1 7055-3
SIGNALMAN'S RESPONSIBILITY
The primary duty of a signalman is to assist the opera-
tor 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 clearly seen
and where they can safely observe the entire operation.
Standard crane signals must be used unless other
methods of signaling, such as two way radios or flags
have been agreed upon.
CREW MEMBER'S RESPONSIBILITY

Any unsafe condition or practice must be corrected
or reported to the job supervisor.
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 erec-
tion and 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
equipment or unstable ground conditions.
MANAGEMENT'S RESPONSIBILITY
See that operators are trained, competent, physical-
ly fit and, if required, licensed. Good vision is re-
quired, 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 judg-

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

distances and to select proper lifting tackle. Rigging
is a complex subject far beyond the scope of this
manual. It is management's responsibility to employ
qualified riggers.
Crew members must be given specific safety re-

sponsibilities and instructed to report any unsafe
conditions to their supervisors.
7055-3 1-2
PLANNING THE JOB

Most accidents can be avoided by careful job plan-
ning. The person in charge must have a clear un-
derstanding of the work to be done and equipment
capabilities. He must consider all dangers at the
jobsite, 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 re-
sponsibilities will they be given?
• What is the weight of the load to be lifted, the lift
radius, boom angle, and the rated capacity of
the crane?
• How will the signalmen communicate with the
operator?
• What equipment is required to do the job safely?
Is a crane the best equipment for the job?
• How can the equipment be safely transported to
the jobsite?
• Are there gas lines, electrical power lines or
structures that must be moved or avoided?
• Is the surface strong enough to support the ma-
chine and load?
• How will loads be rigged?
• What special safety precautions must be taken
if a crane must travel with a suspended load or
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
work area?
• How can the crane be positioned to use the
shortest boom and radius possible?
1-3 7055-3
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
safety devices.
• Carefully inspect load bearing parts such as wire
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.
• 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.
• After starting the engine, check all gauges for prop-
er readings.
• Test all controls for proper operation.
• Check brakes and clutches. Test load brakes by
lifting a load a few inches off the ground and holding
it.
7055-3 1-4
OPERATING PRECAUTIONS
The following recommendations represent our experi-
ence in regard to the most likely causes of personal in-
jury 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:

(1) Load radius (the distance between the center of 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.
(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 rat-
ing chart. It is dangerous to guess the capacity for
boom length or radii between those listed on the
rating plate.
Trying to left a load without knowing whether it is

within the rated capacity while expecting the crane
to start to tip to warn of an overload is very danger-
ous and should never be done. Cranes may sud-
denly tip over or collapse is too heavy.
Always operate within the rated capacity. The oper-

ator must reduce the load under adverse field con-
ditions until, in his judgment, the machine can
safety handle the left. (See Operating Precautions
#3, 10, 16, 19, 27, and 28.)
2. Cranes may tip over or collapse if the operating sur-

face 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 ex-
ceeded.
Determine the load bearing capacity of the ground
or other surface on which machines will be operat-
ing. Be sure cranes are adequately supported.
Avoid soft or unstable ground, sand, areas with
high water tables, and partially frozen ground.
When machines are working near trenches, the
trenches should be shored or sloped to prevent
cave-ins or slides.
1-5 7055-3
3. The rated capacity of a crane is determined with the

crane leveled within ± 0.5 deg. of grade (1 foot drop
or rise in 100 foot distance). Out of level more than
± 0.5 deg. will drastically reduce the lifting capacity.
Be sure cranes are level.
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 clear before swinging.
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 ob-
structions.
6. Many people have been injured when riding crane

hooks or loads or while being lifted in manbaskets.
They have no control over how they are handled
and no protection from impacts or falls. Small mis-
takes can be fatal.
Never permit anyone to ride loads, slings, hooks,

etc., for any reason.
7055-3 1-6
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. OSHA regulations
require at least 3.05 meter (10 feet) of clearance
from lines carrying 50,000 volts or less.
Greater clearances are required for lines with high-
er voltages. Some states require greater clearanc-
es than OSHA. Safety requires that you stay as far
as possible from power lines and never violate min-
imum clearances.
Operation Near High Voltage Power Lines
Always take these precautions if power lines are Normal Voltage, kV Minimum Required
present. (Phase to Phase) Clearance, m(ft)
to 50 3.05 (10)
(1) Notify the electrical power Company before begin- Over 50 to 200 4.60 (15)
ning work. Over 200 to 350 6.10 (20)
Over 350 to 500 7.62 (25)
(2) You and the Power Company must take specific Over 500 to 750 10.67 (35)
Over 750 to 1000 13.72 (45)
precautions. These may include locating cranes
and materials away from electrical power lines, de- Operation in Transit With No Load and
Boom or Mast Lowered.
energizing and grounding lines, rerouting lines, re-
Normal Voltage, kV Minimum Required
moving barricading lines, and insulating lines with (Phase to Phase) Clearance, m(ft)
rubber sleeves. to 0.75 1.22 (4)
Over 0.75 to 50 1.83 (6)
(3) Use a signalman to maintain a safe distance be- Over 50 to 345 3.05 (10)
tween any part of the machine or load and electrical Over 345 to 750 4.87 (16)
Over 750 to 1000 6.10 (20)
power lines. The operator is not in the best position
(extracted from ASME/ANSI Standard B30.5-2004)
to judge distances. SAFE MAINTENANCE PRACTICES
(4) Warn people to stay away from the machine and Required Clearances for Operation
load at all times. Near High Voltage Power Lines
If the load must be guided into place, ask the Power
Company about special precautions such as insu-
lated poles or hot sticks.
(5) Slow down. Give yourself time to react to problems
and to double check the distance between electrical
power lines and any part of the machine or load.
1-7 7055-3
Careful planning and supervision offer better pro-

tection 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 con-
taminated with dust and water.
Operation of proximity warning devices can be af-
fected by different arrangements of power lines, the
movement of trucks, materials, and the crane itself,
and other influences. Relying on any of these de-
vices could be dangerous because users may think
they are 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 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.
8. The load line can break if the hook block contacts

the end of the boom. This is called "two blocking".
Two blocking, for example, can be caused by hoist-
ing the hook into the end of the boom or lowering
the boom without paying out load line. Two block-
ing can pull jibs and lattice booms over backwards
or cause structural damage at boom or jib points.
Always keep space between the hook block and
boom point. Lower the hook when lowering the
boom.
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.
10. Rapid swings or sudden starts and stops can cause

the hook and attached load to swing out of control.
Always start and stop movements smoothly and
swing at speeds that will keep the load under con-
trol.
7055-3 1-8
11. Dirty windows, darkness, bright sunlight, fog, rain

and other conditions can make it difficult for the op-
erator 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 ma-

chine. Their exact location and description of the
hazard are reviewed in this section. Please take
the time to familiarize yourself with these safety
signs.
Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
the pictures. When cleaning the labels use a cloth,
water and soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing

or cannot be read. If a label is on a part that is re-
placed, make sure a new label is installed on the re-
placed part.
12. Even light winds can blow loads out of control, col-
lapse booms, or tip cranes. Winds aloft can be
much stronger than at ground level.
Do not lift loads if winds create a hazard. Lower the

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

booms or loads with large surface areas.
13. Carelessness in getting on and off equipment can

result in 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

loose items can cause falls.
Keep the machine clean and dry.
1-9 7055-3
15. Damaged crane booms may collapse. Lattice type

booms will be weakened by damaged chords, bent
or missing lacings, or cracked welds. Inspect the
crane boom daily for damage. Do not use dam-
aged booms.
Due to the high strength steels used in booms and jibs,

special repair procedures are required. Consult your lo-
cal authorized KOBELCO authorize distributor for in-
structions.
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, winds, or lifting when the crane is not lev-
el.
Take care to avoid side loading.
17. If the load strikes the boom or the boom hits a build-
ing 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.
When releasing loads be sure the boom never tight-
ens against the backstops. Release loads slowly
booming out if necessary while releasing.
19. The load will swing out of control if it is not 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

load when lifting. Make certain all personnel stand
clear of the load as it is lifted.
7055-3 1-10
20. Trying to lift a load which is stuck, frozen or at-

tached to something else may result in tipping,
boom collapse or other damage.
Be sure that loads are free before lifting.
21. If there is not enough wire rope on the drum the

rope can snap loose.
Keep at least two full wraps of wire rope on drums

when operating.
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.
23. Trying to repair or adjust equipment with a sus-

pended hook or load or with the boom raised could
release machinery and let it move unexpectedly.
Always lower the load to the ground and the boom
onto proper cribbing before doing maintenance or
repair work.
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 hydrau-
lic 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.
25. Pin-connected booms and jibs may fall if not prop-

erly supported when removing pins.
Make sure both ends of each boom and jib section
are supported and the boom suspension lines com-
pletely slacked off before removing pins.
Never stand on, inside, or under booms or jibs dur-
ing assembly or disassembly.
1-11 7055-3
26. As with all heavy equipment, care must be taken

when cranes are driven (traveled), whether on or off
the jobsite. Watch for people, electrical power lines,
low or narrow clearances, bridge or road load limits,
and steep hills or uneven terrain. Use a signalman
in close quarters. Know the height, width and
weight of your machine. Set swing brake or lock
before traveling.
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 in-
cluding the increased possibility of side loading or
tipping.
Because of the many variables involved in pick and car-
ry operations, the user must evaluate conditions and
take appropriate precautions such as these:
• Follow the travel precautions listed in rule 26.
• Check the rating plate for limitations.
• Position the boom in line with the direction of travel.
• Reduce the maximum load while traveling to reflect
operating conditions. The safe load will vary de-
pending on speed, crane, and other conditions.
• Travel slowly and avoid sudden stops and starts.
• Avoid backing away from the load. This could in-
crease 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.
7055-3 1-12
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 en-
gineering 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.
• Review the lifting plan with operators, signalmen
and other crew members before beginning the lift.
• Carefully coordinate crane movements through ev-
ery stage of the lift.
• Avoid boom side loading (see #16).
29. Leaving a machine unattended can be very danger-

ous. Before leaving his seat, the operator must
take the following steps to prevent his machine
from moving:
• Lower the load or bucket to the ground. Lower the
boom when necessary.
• Set the swing brake or lock.
• Set all drum locks.
• Set parking brakes.
• Set propel brakes or locks on crawler machines.
• Disengage the engine clutch or shut off the engine.
• Place the function lock lever in the shut down posi-
tion.
1-13 7055-3
30. All wire rope must be inspected daily to determine

whether it should be replaced. Wire rope should be
replaced when any of the following conditions exist:
• In running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
in one lay [for special conditions relating to rotation
resistant rope]
• Wear of one-third the original diameter of outside
individual wires;
• Kinking, crushing, bird caging, or other damage re-
sulting in distortion of the rope structure;
• Evidence of damage from rust or corrosion.
• Evidence of any heat damage from any cause;
• Reductions from nominal diameter of more than;

(1) 0.4 mm (1/64 in.) for diameters up to and
including 8.0 mm (5/16 in.);
(2) 0.8 mm (1/32 in.) for diameters 9.5 mm
(3/8 in.), to and including 13.0 mm (1/2 in.);
(9/16 in.), to and including 19.0 mm (3/4 in.);
(7/8 in.), to and including 29.0 mm (1-1.8 in.);
(5) 2.4 mm (3/32 in.) for diameter 32.0 mm
(1-1/4 in.), to and including 38.0 mm (1-1/2 in.)
• In standing ropes, more than two broken wires in

one lay in sections beyond end connections or
more than one broken wire at an end connection.
Never handle wire rope with bare hands.
31. Improper wire rope connections may fail under

load. Wire rope and connections must be installed
properly and inspected daily.
• Wedge sockets should be installed so that the load-
ed side of the rope is in a straight line with the edge
of the socket and not bent by the wedge.
• U-bolt clamps (clips) must not be installed on the
loaded side of the load line.
7055-3 1-14
32. 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 func-
tioning retainer latch.
• Crane loads, grapples, or buckets do not pass over
the heads of workmen nor in any way endanger
their safety. All loose objects must be removed
from the load. Non-operating personnel should be
warned, or told to leave the immediate area, when
making crane lifts.
33. Always replace protective guards and panels be-

fore operating the machine.
34. Never wear loose clothing rings or other objects

which may become entangled in the moving ma-
chinery.
35. The operator should test the winch brakes when a

load is first lifted, and when the load is only a few
inches above its starting position, to assure the abil-
ity of the brakes to hold the load while it is aloft.
1-15 7055-3
36. When refueling, be careful not to smoke. 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.
Make sure to use light oil. (However, replenish the

fuel which matches the regional conditions in cold
climates.)
If the fuel other than the specified type is used or
gasoline, kerosene and alcohol group fuels are
supplied or used after mixing them, it may cause
malfunction due to the sliding defect on the fuel
sliding section in the injection pump and/or in the
injector, or it may adversely affect the engine and
result in damages.
Check that the fuel is the specified product when
fueling to your vehicle. If a wrong product was sup-
plied, thoroughly drain it.
If the engine is started with the wrong fuel filled, it
is very dangerous because it may cause fire disas-
ter or damage to the engine.
37. If an overheated condition necessitates an engine

shutdown, use extreme care when checking the ra-
diator, 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.
38. 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 may wash
out the footing.
39. When leaving the crane unattended, always re-

move keys and lock all cab doors to prevent unau-
thorized person from tampering with the machine
and possibly injuring themselves or others.
7055-3 1-16
MEASURES FOR RADIO TRANSMITTERS

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. High volt-
age 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. Ground personnel should be warned to stay
away from the machine.
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. Turn off the power source of
the load safety device and main switch.
(3) Advise all personnel to stay away from the sur-
rounding area of the machine.
2. If a lightning strike occurs check the machine be-

fore operating it.
(1) Check for burns and damage.
(2) Check the electrical devices and load safety device
for performance.
(3) Check each function for abnormality.
MEASURES FOR EARTHQUAKE

1. When earthquakes occur, immediately take the fol-
lowing step:
(1) Stop the work, and lower the load and hook 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),
stop the engine, and turn off the electrical power of
the main switch and load safety device.
(3) Advise all personnel to stay away from the sur-
rounding area of the machine.
2. After the earthquake is over, check the machine be-

fore operating.
(1) Check each function for performance.
(2) Check the electrical devices and load safety device
for performance.
1-17 7055-3
INFLUENCE OF WIND
Influence of the wind on the machine becomes larger in
proportion to the size of a lifted load, lifting height, and
boom length. The following conditions are very danger-
ous, so utmost care is necessary for operation.
1. When lifting a load of wide area, against which the
wind blows hard, the wind could cause the overturn
of the machine and damage to the boom. The wind
could also blow the load against the boom, and
could cause damage.
2. When the boom is fully raised without a load, the

wind could blow the boom backward resulting in an
overturn of the machine.
7055-3 1-18
CAUTIONS FOR WIND

When performing crane or tower operation in strong wind, utmost cautions are required according to the wind ve-
locity, machine condition and working environment. The wind velocity is different on the ground than in the high air.
It is also different on flat ground and in city air. Always consider these conditions and take proper measures to meet
the situation. The wind velocity mentioned here means the instantaneous wind speed. When the wind velocity ex-
ceeds 10 m/sec. (33 ft/sec.) stop the work.
METHOD OF WIND VELOCITY MEASUREMENT

1. If an instantaneous anemometer is provided in the
machine, measure the wind velocity with the ane-
mometer provided on the boom tip section or the
tower cap.
2. If an instantaneous anemometer is not provided in
the machine, the wind velocity given by a weather
report can be converted to the instantaneous wind
speed.
3. The instantaneous wind speed can be approximat-
ed by the Beaufort chart (see next page).
The position where the wind works against the ma-
chine is the height above the ground which corre-
sponds to 60% of the boom length at that time.
1-19 7055-3
Beaufort Wind Scale Chart
Approximate wind velocity

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

Wind velocity 3 5 8 10
of weather
report
Flat area City area Flat area City area Flat area City area Flat area City area
Height
above
ground Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst. Av. Inst.
m (ft)
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
5 (17)
(8.9) (32.2) (8.2) (32.8) (14.8) (38.4) (13.8) (37.4) (23.3) (47.6) (22.0) (45.9) (29.2) (53.5) (27.6) (51.8)
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)
(9.8) (33.5) (9.8) (33.5) (16.4) (40.4) (16.4) (40.4) (26.2) (50.5) (26.2) (50.5) (32.8) (57.4) (32.8) (57.4)
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)
(10.5) (34.1) (10.8) (34.5) (17.7) (41.7) (18.4) (42.3) (28.2) (52.5) (29.2) (53.5) (35.1) (59.7) (36.4) (61.4)
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)
(11.2) (34.5) (11.8) (35.4) (18.4) (42.3) (19.7) (43.6) (29.5) (54.1) (31.2) (55.8) (36.7) (61.7) (39.0) (64.0)
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)
(11.5) (35.1) (12.5) (36.1) (19.4) (43.3) (20.7) (44.6) (30.8) (55.4) (33.1) (57.7) (38.4) (63.3) (41.3) (66.3)
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)
(11.8) (35.4) (13.1) (36.7) (19.7) (43.6) (21.7) (45.6) (31.5) (56.1) (34.8) (59.4) (39.4) (64.3) (43.3) (68.6)
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
40 (132)
(12.5) (36.1) (13.8) (37.7) (20.7) (44.6) (23.3) (47.6) (33.1) (57.7) (37.1) (62.0) (41.3) (66.3) (46.3) (71.5)
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
50 (164)
(12.8) (36.4) (14.8) (38.4) (21.7) (45.6) (24.6) (48.9) (34.5) (59.1) (39.4) (64.3) (43.0) (68.2) (49.2) (74.8)
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
75 (260)
(13.8) (37.4) (16.4) (40.0) (23.0) (47.2) (27.2) (51.5) (36.7) (61.7) (43.3) (68.6) (45.9) (71.2) (54.1) (81.4)
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
100 (328)
(14.4) (38.1) (17.4) (41.3) (24.3) (48.6) (29.2) (53.5) (38.7) (63.7) (46.6) (71.9) (48.2) (73.5) (58.4) (87.6)
7055-3 1-20
2. OPERATION
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART
2.1.1 CRANE ATTACHMENT
AUXILIARY
IDLER SHEAVE SHEAVE
GUY LINE (BOOM)
UPPER SPREADER
BOOM HOIST WIRE ROPE
LOWER SPREADER
BOOM BACKSTOP
GANTRY
BOOM TIP
AUXILIARY
HOOK
COUNTER WEIGHT MAIN HOOK
BOOM BASE
UPPER ROLLER
IDLER
PROPEL MOTOR AND SWING BEARING LOWER ROLLER

REDUCTION UNIT
POWER DIVIDER BATTERY
HYDRAULIC OIL TANK ENGINE RADIATOR
PUMP AIR CLEANER
REAR DRUM
BOOM DRUM
SWING MOTOR
AND REDUCTION UNIT
SWIVEL JOINT
FRONT DRUM
ACCUMULATOR
BOOM DRUM MOTER
AND REDUCTION UNIT CONTROL VALVE
FUEL TANK REAR DRUM MOTOR FRONT DRUM MOTOR
AND REDUCTION UNIT AND REDUCTION UNIT
2-1 7055-3
2. OPERATION
2.1.2 TOWER CRANE
GUY LINE (JIB SIDE)
JIB POINT SHEAVE

FRONT STRUT
REAR STRUT
JIB BACKSTOP
REAR GUIDE
ROLLER JIB TIP
INSERT JIB
JIB BASE
TOWER GUY LINE TOWER CAP
MAIN HOIST WIRE ROPE
JIB GUY LINE
(TOWER SIDE)
INSERT TOWER
UPPER SPREADER
(FOR JIB)
JIB HOIST
WIRE ROPE
LOWER SPREADER
(FOR JIB) 9.1m SPECIAL INSERT TOWER
GUIDE SHEAVE
(FOR MAIN HOIST
WIRE ROPE)
UPPER SPREADER (FOR TOWER)
TOWER BASE
TOWER HOIST WIRE ROPE
LOWER SPREADER (FOR TOWER)
BACKSTOP
7055-3 2-2
2. OPERATION
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS
Do not use the devices and equipment provided in this machine for any purpose other than the purposes
specified in this manual.
Failure to observe this precaution may result in serious injury or death.
Optional items are also included in this figure.
THIRD DRUM CONTROL LEVER (OPTION) THIRD DRUM BRAKE SELECTOR SWITCH (OPTION)
SWING CONTROL LEVER

LOAD SAFETY DEVICE CONTROLLER
HORN SWITCH AND SWING BRAKE SWITCH
ACCELERATER GRIP FRONT DRUM CONTROL LEVER

FRONT DRUM BRAKE SELECTOR
LEFT SIDE STAND PANEL
SWITCH (OPTION)
ENGINE EMERGENCY REAR DRUM CONTROL LEVER
STOP SWITCH
LEFT SIDE PANEL REAR DRUM BRAKE SELECTOR
SWITCH (OPTION)
AIR CONDITIONER
CONTROL PANEL BOOM DRUM CONTROL LEVER
SPOT
GAUGE CLUSTER
LIGHT
DRUM SPEED
CONTROL
TRIMMER BOX
RADIO FUNCTION
LOCK LEVER
SWING LOCK BOOM DRUM CONTROL
CONTROL LEVER PEDAL (OPTION)
CRAWLER REAR DRUM BRAKE PEDAL (OPTION)

EXTEND / RETRACT LEVER
FRONT DRUM BRAKE PEDAL (OPTION)
AUXILIARY ACCELERATOR RIGHT PROPEL CONTROL LEVER
LEFT PROPEL CONTROL LEVER
PROPEL CONTROL LEVER LOCK
THIRD DRUM BRAKE PEDAL (OPTION)
2-3 7055-3
2. OPERATION
LEFT SIDE STAND PANEL
1. SWING BRAKE MODE SELECTOR SWITCH
2. SWING FREE INDICATOR LAMP 15. CIGALETTE LIGHTER
ENGAGE RELEASE
16. THIRD DRUM SPEED ADJUSTING KNOB

(OPTION)
51. SWING BRAKE

START
ON
ACC
17. KEY SWITCH

OFF
18. ENGINE TROUBLE DETECT LAMP

(RED)
19. ENGINE EMERGENCY STOP SWITCH
5. THIRD DRUM LOCK KNOB (OPTION) 3. FRONT DRUM LOCK KNOB
6. BOOM DRUM LOCK KNOB 4. REAR DRUM LOCK KNOB
7. HOOK OVERHOIST RELEASE SWITCH 20. FRONT DRUM FREE FALL SPEED
(ANTI TWO BLOCK) ACCELERATION SELECTOR SWITCH
21. REAR DRUM FREE FALL SPEED
8. BOOM OVERHOIST RELEASE SWITCH ACCELERATION SELECTOR SWITCH
22. THIRD DRUM FREE FALL SPEED
9. OVERLOAD RELEASE SWITCH ACCELERATION SELECTOR SWITCH (OPTION)
10. RELEASE SWITCH MASTER KEY 23. FREE FALL LOCK SWITCH (OPTION)
11. AUTOMATIC STOP CHECK SWITCH 24. GANTRY CONTROL SWITCH

12. BOOM ANGLE FIXING SWITCH
(ONLY FOR TOWER CRANE)
25. HYDRAULIC SELECTOR SWITCH
(NOT USED)
13. MODE SELECTOR SWITCH (B)
14. HYDRAULIC OIL HEATING SWITCH 26. MODE SELECTOR SWITCH (A)
(OPTION)
7055-3 2-4
2. OPERATION
BRAKE SELECTOR SWITCH FREE FALL INDICATOR LAMP
30.REAR DRUM FREE FALL

INDICATOR LAMP
29.THIRD DRUM BRAKE 31.FRONT DRUM FREE FALL
SELECTOR SWITCH (OPTION) INDICATOR LAMP
32.THIRD DRUM FREE FALL
INDICATOR LAMP (OPTION)
27.REAR DRUM BRAKE SELECTOR

SWITCH
28.FRONT DRUM BRAKE SELECTOR

SWITCH
DRUM SPEED CONTROL TRIMMER BOX PROPEL CONTROL LEVER STAND PANEL
33. FRONT DRUM SPEED

ADJUSTING KNOB
34. REAR DRUM SPEED

ADJUSTING KNOB
35. BOOM DRUM SPEED

ADJUSTING KNOB
36. PROPEL SPEED
SELECTOR SWITCH
2-5 7055-3
2. OPERATION
LEFT SIDE PANEL
40. HEAD LIGHT SWITCH

39. WIPER SWITCH (SKYLIGHT)
41. REAR WORK LIGHT SWITCH 38. WIPER SWITCH (OPTION)

(Lower side of front window)
42. SWING ALARM SELECTOR SWITCH

37. WIPER SWITCH
46. SPARE (Upper side of front window)
45. DRUM TURN GRIP

SELECTOR SWITCH
(OPTION)
44. DRUM WORK LIGHT SWITCH AIRCONDITIONER CONTROL PANEL

(OPTION) 47.TAGLINE TENSION
ADJUSTING KNOB (OPTION)
43. PROPEL ALARM SWITCH

(OPTION)
BOOM DRUM CONTROL LEVER LOAD SAFETY DEVICE

BYPASS SWITCH
48. INCHING SPEED SWITCH

BOOM DRUM
CONTROL LEVER
50. LOAD SAFETY

DEVICE BYPASS
CONFIGURATION
SELECT SWITCH
49. LOAD SAFETY

DEVICE BYPASS
SWITCH MAIN KEY
7055-3 2-6
2. OPERATION
2.2.1 OPERATING SWITCHES
Standard and optional controls for this machine are

identified and described in the following list.
Therefore the following list contains controls which are
not furnished on every machine.
The functions of each switch are explained on the fol-

lowing pages. For operating instructions for each lever,
see 2.3 CRANE OPERATION.
1. SWING BRAKE MODE SELECTOR SWITCH

High swing speed is selected, but
the swing brake will not function au-
FREE HIGH tomatically when the swing control
lever is returned to the neutral posi-
tion.
Low swing speed is selected, but
the swing brake will not function au-
FREE LOW tomatically when the swing control
lever is returned to the neutral posi-
tion.
Swing brake functions automatical-
ly when the swing control lever is
BRAKE
returned to the neutral position and
low swing speed is selected.
Swing brake mode be selected according to the

job application.
• The swing parking brake cannot be applied even if

the machine enters the brake mode.
To apply the swing parking brake, use the swing
brake switch located at the top of the swing lever.
• When selecting your intended swing mode, engage
the swing brake and run the engine at a low speed
to prevent damage to the hydraulic components.
2-7 7055-3
2. OPERATION
2. SWING FREE INDICATOR LAMP

This lamp lights up when the swing brake mode se-
lector switch (item 1) is set to the FREE position.
3. FRONT DRUM LOCK KNOB

LOCK
4. REAR DRUM LOCK KNOB
5. THIRD DRUM LOCK KNOB (OPTION) RELEASE
6. BOOM DRUM LOCK KNOB
Engage the drum lock by pulling up the drum lock
knob when the drum is not used for long time.
To release, push the knob while pushing the button
on the knob top.
The drum lock is engaged.

(LOCK)
The drum lock is released.

(RELEASE)
When the engine is stopped while the boom drum
lock is released, the warning buzzer will sound for
approximately four seconds.
7. HOOK OVERHOIST RELEASE SWITCH

(ANTI TWO BLOCK) Automatic return
An automatic stop due to hook
overhoist can only be released
RELEASE RELEASE
when this switch is controlled to the
RELEASE position.
The switch is automatically returned when re-
leased.
This switch is effective only when the "10. RE-
LEASE SWITCH MASTER KEY" is set to the RE-
LEASE position.
8. BOOM OVERHOIST RELEASE SWITCH

An automatic stop due to boom Automatic return
overhoist can only be released
RELEASE
when this switch is controlled to the
RELEASE
RELEASE position.
leased.
LEASE position.
7055-3 2-8
2. OPERATION
9. OVERLOAD RELEASE SWITCH

An automatic stop due to overload Automatic return
can only be released when this
RELEASE
switch is controlled to the RE-
LEASE position. RELEASE

leased.
LEASE position.
10. RELEASE SWITCH MASTER KEY

Functions of the overload release,
boom overhoist release, and the
LOCK
anti-two block release switches are
disabled.
Functions of the overload release,
boom overhoist release, and the
RELEASE
anti-two block release switches can
be actuated and released.
The key can be taken off in the LOCK position.
11. AUTOMATIC STOP CHECK SWITCH

Automatic stop function can be checked by this Automatic return
switch.
Automatic stop function is actuated,
CHECK and boom raising and lowering and CHECK
hook raising become unavailable.
The switch automatically returns when released.
12. BOOM ANGLE FIXING SWITCH

(TOWER CRANE)
FIX Boom angle is fixed.
Boom raising and lowering is possi-
RELEASE
ble.
Use for tower operation only.
13. MODE SELECTOR SWITCH (B)

HIGH Normal work
LOW Special work
Use this switch when it is hard to tune the front

drum and the rear drum for heavy work and clam-
shell operation.
2-9 7055-3
2. OPERATION
14. HYDRAULIC OIL HEATING SWITCH (OPTION)

The hydraulic oil heater is activat-
ed. When hydraulic oil is heated to
approximately 50 deg., the switch is
automatically turned off even if the
ON switch is set to the "ON" position.
When oil is cooled down to approx-
imately 40 deg., the switch is auto-
matically turned on. Use this switch
in the morning or winter.
The hydraulic oil heater will not be
OFF
actived.
15. CIGARETTE LIGHTER

To operate lighter, push in. The lighter will pop out
when ready to use.
If the lighter knob does not pop up within 30 sec-

onds after it is depressed, the lighter is not operat-
ing properly.
Pull out the cigarette lighter and take it to the ser-
vice shop. Do not install 12 V accessory into the
lighter receptacle.
16. THIRD DRUM SPEED ADJUSTING KNOB

(OPTION)
The rotating speeds of the third
RIGHT TURN
drum are accelerated.
The rotating speeds of the third
LEFT TURN
drum are decelerated.
17. KEY SWITCH

OFF
Position to stop the engine. (Posi- ACC
OFF tion to insert the key and to take it
ON
out.)
Position to connect the accessory
ACC
electrical circuit. START
Position to connect the electrical
ON
circuit for the engine.
START Position to start the engine.
7055-3 2-10
2. OPERATION
18. ENGINE TROUBLE DETECT LAMP

The lamp lights up when the engine control unit
(ECU) detects any fault related to the engine. De-
(RED)
tails of the fault can be checked by turning on the
diagnosis switch. (It changes to blinking.)
At normal condition (without any error), the lamp
lights up when key switch is on position and lights
off when the engine started.
19. ENGINE EMERGENCY STOP SWITCH RIGHT TURN

PUSH
Press the switch to stop the engine emergency.
When the switch is pressed once, it will be held be-
ing pushed in. To reset the switch, turn it to the
right.
ENGINE STOP RELEASE
20. FRONT DRUM FREE FALL SPEED ACCELERA-

TION SELECTOR SWITCH
21. REAR DRUM FREE FALL SPEED ACCELERA-
22. THIRD DRUM FREE FALL SPEED ACCELERA-
(OPTION)
Free fall speed is increased.
When the brake is released with
this switch set to the "HIGH" side,
the drum is automatically rotated
HIGH without load. This side is for crane
operation, and for acceleration of
the free fall of light-weight loads
such as a ball hook block without a
load.
Free fall speed is adjusted to nor-
NORMAL mal.
This side is for bucket operation.
These switches are effective only in the free fall
mode condition.
DO NOT set this switch to the "HIGH" side for the

free fall of heavy loads, or works other than crane
operation, such as wire reeving.
2-11 7055-3
2. OPERATION
23. FREE FALL LOCK SWITCH

(OPTION)
Free falling of the front drum and
LOCK
rear drum become impossible.
Only while this switch is turned to
the right, free falling of the front
RELEASE
drum and rear drum can be operat-
ed.
When this switch is set in the LOCK side, even if
the brake selector switches are set in the FREE
FALL side, free falling cannot be operated.
The key can be taken off in the LOCK side.
24. GANTRY CONTROL SWITCH

UP The gantry is raised up.
DOWN The gantry is lowered down.
NEUTRAL The gantry is held.

leased.
26. MODE SELECTOR SWITCH (A)

(1) For simultaneous operation of
"front" and "rear" drums.
Fluctuation in hook raising
speed decreases.
TOWER (2) For simultaneous operation of
"boom or jib" and "front" drum.
Fluctuation in "boom hoisting
or jib raising" and "hook rais-
ing" speeds decreases.
For simultaneous operation of
"boom" and "front or rear" drums.
CRANE
Fluctuation in "boom hoisting" and
"hook raising" speeds decreases.
7055-3 2-12
2. OPERATION
27. REAR DRUM BRAKE SELECTOR SWITCH

28. FRONT DRUM BRAKE SELECTOR SWITCH
DRUM BRAKE
29. THIRD DRUM BRAKE SELECTOR SWITCH SELECTOR SWITCH
(OPTION)
For details of free fall operation, refer to the
"2.5 FREE FALL OPERATION (OPTION)".
(1)FREE FALL MODE

To select the free fall mode, set the free fall lock
switch to the "RELEASE" position, fully depress
the drum brake pedal, and push the switch.
Then, the free fall indicator lamp lights up to
show that the free fall mode is selected (braking
can be actuated with the brake pedal).
(2)NEUTRAL BRAKE MODE
To select the neutral brake mode, fully depress THIRD DRUM FREE FALL
INDICATOR LAMP
the drum brake pedal, and push the switch (OPTION)
again.
Fr.DRUM FREE FALL
Then, the free fall indicator lamp goes out (brak- INDICATOR LAMP
ing is automatically actuated).
Re.DRUM FREE FALL
INDICATOR LAMP
30. REAR DRUM FREE FALL INDICATOR LAMP

This lamp lights up when the rear drum is in free
fall mode.
31. FRONT DRUM FREE FALL INDICATOR LAMP
This lamp lights up when the front drum is in free
fall mode.
32. THIRD DRUM FREE FALL INDICATOR LAMP
(RED LAMP)
(OPTION)
This lamp lights up when the third drum is in free
fall mode.
33. FRONT DRUM SPEED ADJUSTING KNOB

34. REAR DRUM SPEED ADJUSTING KNOB
35. BOOM DRUM SPEED ADJUSTING KNOB
The rotating speeds of the front
RIGHT TURN drum, rear drum and boom hoist
drum are accelerated.
The rotating speeds of the front
LEFT TURN drum, rear drum and boom hoist
drum are decelerated.
2-13 7055-3
2. OPERATION
36. PROPEL SPEED SELECTOR SWITCH

HIGH SPEED High speed is selected
LOW SPEED Low speed is selected
37. WIPER SWITCH

(UPPER SIDE OF FRONT WINDOW) 1
38. WIPER SWITCH
(LOWER SIDE OF FRONT WINDOW) 2
(OPTION)
39. WIPER SWITCH (SKYLIGHT) 3
ON The wiper operates continuously.
INT The wiper operates intermittently.
By pushing this switch while in the ON or INT posi-
tion, washer liquid is squirted out.
Press the center of the switch in to operate the
washer system.
40. HEADLIGHT SWITCH 4

41. REAR WORKLIGHT SWITCH (OPTION) 5
ON The lights are illuminated.
OFF The lights are turned off.
42. SWING ALARM SELECTOR SWITCH

This is used to select the alarm when swinging.
The buzzer sounds and the swing

(WARNING
LAMP
flasher goes on and off.
BUZZER)
(WARNING The swing flasher goes on and off.

LAMP)
OFF Nothing operates.
43. PROPEL ALARM SWITCH (OPTION)

This switch is used for selection of alarm condition
during travel.
ON Sound alarm is issued.
7055-3 2-14
2. OPERATION
44. DRUM WORK LIGHT SWITCH

(OPTION)
ON The light is illuminated.
OFF The light is turned off.
45. DRUM TURN GRIP SELECTOR SWITCH CENTER SECTION

(OPTION)
The center section of the grip
ON moves according to the drum rota-
tion speed.
* Available front and rear drums.
46. SPARE
47. TAGLINE TENSION ADJUSTING KNOB

(OPTION)
Tension of the tag line rope be-
RIGHT TURN
comes stronger.
Tension of the tag line rope be-
LEFT TURN
comes weaker.
Turn left fully when not in use.
The speed of the tagline drum cannot be adjusted
by using this knob.
48. INCHING SPEED SWITCH

INCHING NORMAL
The front drum, rear drum, boom SPEED
INCHING drum and propel speeds are re-

SPEED duced to about 1/4 of the normal
speeds.
NORMAL Normal speed.
The front drum, rear drum, propel speeds are not
reduced when in the free fall mode condition (the
front drum or rear drum). INCHING SPEED SWITCH
(Installed to the boom control lever only)
The boom drum, third drum speeds are not re-
duced when in the free fall mode condition (the
third drum).
2-15 7055-3
2. OPERATION
49. LOAD SAFETY DEVICE BYPASS SWITCH MAIN

OFF ON
KEY
Bypass function of load safety de-
ON
vice becomes effective.
OFF Normal condition.
50. LOAD SAFETY DEVICE BYPASS

CONFIGURATION SELECT SWITCH
Turn on the bypass switch based on crane config-
uration.
TW
Tower Turn the bypass switch to Upper
configuration side.
Crane Turn the bypass switch to Neutral CR
configuration side.
Luffing Turn the bypass switch to Lower
configuration side. (Not used)
LF
51. SWING BRAKE SWITCH

ENGAGE Swing brake is engaged.
RELEASE Swing brake is released.
ENGAGE RELEASE
7055-3 2-16
2. OPERATION
2.2.2 GAUGE CLUSTER CONFIGURATION

1. TERMINOLOGIES AND FUNCTIONS
ENGINE COOLING WATER

TEMPERATURE GAUGE
This gauge indicates the engine cooling FUEL GAUGE
water temperature. The fuel level is indicated
While the pointer is in the white area, the with the pointer.
temperature is normal.
If the pointer is in the red area, reduce the F = Full
engine speed to lower the cooling water E = Empty
temperature, and wait until the pointer
returns to the white area.
MULTI-DISPLAY
(LIQUID CRYSTAL DISPLY)
The current status of the
ZERO SWITCH machine is displayed.
(1) To reset the engine oil
change interval, push this
switch.
(2) To reset the lifting height
indicator (option), push
this switch.
SETTING SWITCH
(3) When this switch is pushed
(1) To set the engine oil change
for 2 seconds while faulty
interval and the number of
statuses are displayed, the
the wire rope wraps on the
display screen returns to
drum, push this switch.
the normal status (flashing
(2) When this switch is pushed
display).
while the normal display
screen is flashing (the zero
switch is pushed while
faulty statuses are displayed),
the screen returns to the fault
indicator display screen.
CHECK SWITCH
After this switch is pushed for
5 seconds while the engine oil
change interval is displayed, ADJUSTER (+, -) SWITCHES
the displayed values can be The engine oil change interval
adjusted. and the number of the wire rope
layers on the drum can be
adjusted with these switches.
BUZZER SWITCH DISPLAY SCREEN SELECTOR

The buzzer can be stopped ( , ) SWITCHS
when this switch is pushed The multi-display screens can
while the buzzer sounds (other be selected by pushing these
than the buzzer sounds emitted switches.
when the engine oil pressure is
decreased).
2-17 7055-3
2. OPERATION
2. CONFIGURATION OF MULTI-DISPLAY
(LIQUID CRYSTAL DISPLAY)
The display screen can be switched by pushing the
display screen selector switches, check switch, set-
ting switch, and the zero switch.
NORMAL DISPLAY
DISPLAY
SCREEN
SELECTOR
SWITCH
ENGINE SPEED
The number of the title LIFTING HEIGHT
of descriptions
3 (1)
DISPLAY
SCREEN
SELECTOR
SWITCH
Push the
check switch
for 5 seconds.
ENGINE OIL
ALTERATION OF
CHANGE INTERVAL
ENGINE OIL
3 (2)
CHANGE INTERVAL Setting
switch
5 DISPLAY
DISPLAY SCREEN Displayed only when the machine
SCREEN SELECTOR
SWITCH is equipped with the wind sensor
SELECTOR
SWITCH in the optional setup.
Push the
check switch
for 5 seconds.
WIND ALARM SET WIND SENSOR
7 3 (5)
Setting
switch
DISPLAY
DISPLAY SCREEN Displayed only when the machine
SCREEN SELECTOR is equipped with the lifting height
SELECTOR SWITCH
SWITCH indicator in the optional setup.
Push the
check switch
ADJUSTMENT for 5 seconds. NUMBER OF
NUMBER OF WIRE FAULT INDICATOR
WIRE ROPE LAYERS
ROPE LAYERS ON FAULTY
FRONT DRUM ON FRONT DRUM
6 (2) Setting 3 (3)
switch WARNING
DISPLAY NORMAL 4 (1)
SCREEN Automatic
DISPLAY SELECTOR
SCREEN SWITCH indicate
SELECTOR
Push the SWITCH
check switch
for 5 seconds. Setting switch
ADJUSTMENT NUMBER OF
NUMBER OF WIRE WIRE ROPE LAYERS SELF CHECK
ROPE LAYERS ON
ON REAR DRUM 4 (2)
REAR DRUM
6 (2) Setting 3 (4)
switch Push the zero
switch for
2 seconds.
7055-3 2-18
2. OPERATION
3. NORMAL DISPLAY
(1) ENGINE SPEED AND LIFTING HEIGHT DISPLAY
SCREEN
When the engine key is set to the "ON" position
while there is no fault, this screen appears. If any
faulty status is displayed, refer to the page .
The engine speed is displayed (20 rpm as a unit)

ENG. 1240 rpm
LIFT 0 m
The lifting height of the main or the aux. winch is

displayed (option)
INCHING OFF F6 R1 The current lifting height of the load is displayed after
resetting the counter with the zero switch.
The display screen of the lifting height of the main or
the aux. winch is automatically switched according to
the statuses of the "Mode switch" of the moment limiter.
When the switch is set to the "Main" position, the main
winch lifting height is displayed, and when it is set to
the "Aux." position, the aux. winch lifting height is displayed.
The number of the reeving aux. winch wire rope is

displayed, which is set with the KOBELCO LMI.
The inching switch status is displayed The number of the reeving main winch wire rope is
The status of the "inching switch" installed to displayed, which is set with the KOBELCO LMI.
the boom hoist lever grip is displayed.
. Normal..... The inching operation is OFF.
. Inching..... The inching operation is ON.
The lifting height gauge is not provided, the lifting height

is not displayed.
2-19 7055-3
2. OPERATION
(2) ENGINE OIL CHANGE INTERVAL DISPLAY SCREEN

When the " " display screen selector switch is pushed, the display screen below appears.
The elapsed time from the last engine

29Hr AFTER oil change is displayed
The engine running duration from the last engine oil
ENGINE OIL CHANGE
change is displayed as the elapsed time.
INCHING OFF F6 R1
(3) NUMBER OF WIRE ROPE LAYERS ON FRONT DRUM DISPLAY SCREEN

FRONT DRUM LAYER
The number of the current wire rope layers

3 on the front drum is displayed
The number of the current wire rope layers on the front
drum is displayed. When it changes in accordance with
INCHING OFF F6 R1 the winching-up/down, the displayed value also changes.
The lifting height gauge is optional, and if the lifting

height gauge is not provided, the display above does
not appear.
(4) NUMBER OF WIRE ROPE LAYERS ON REAR DRUM DISPLAY SCREEN

REAR DRUM LAYER
The number of the current wire rope layers

3 on the rear drum is displayed
The number of the current wire rope layers on the rear
drum is displayed. When it changes in accordance with
INCHING OFF F6 R1 the winching-up/down, the displayed value also changes.
The lifting height gauge is optional, and if the lifting

height gauge is not provided, the display above does
not appear.
7055-3 2-20
2. OPERATION
(5) WIND VELOCITY DISPLAY SCREEN (OPTION)

The screen appears after the "Engine oil change time display screen" described in 3 (2), if the machine is
equipped with the anemometer.
(It will not appear if the anemometer is not provided for the machine.)
The present wind velocity is displayed.

The present instantaneous wind velocity is displayed.
WIND 13.2m/s
SET 20m/s
The preset alarm wind velocity is displayed.
If the present wind velocity exceeds this set value,
alarm sounds (intermittent beep sounds) are emitted
INCHING OFF F6 R1 from the gauge cluster.
4. FAULT INDICATOR DISPLAY

When a fault occurs, the corresponding fault indica-
tor display appears.
(1) WARNING DISPLAY
* Buzzer alarms
: the buzzer repeatedly sounds for 0.2 seconds, with 0.3 seconds of intermittence (the buzzer sounds cannot
be stopped with the buzzer switch).
Blank: the buzzer does not sound.
O : the buzzer repeatedly sounds for 0.5 seconds, with 0.5 seconds of intermittence (the buzzer can be stopped
with the buzzer switch).
: the buzzer repeatedly sounds for 0.2 seconds, with 0.3 seconds of intermittence, and stop after 5 seconds.
Displayed items Descriptions and remedies Buzzer
The message is displayed when the engine cooling water temperature is

0°C or less with the key switch turned ON.
The message is displayed for 5 seconds after the operation is complete.
The charging circuit is malfunctioned.

Consult with your nearest KOBELCO authorize distributor.
* Note : That it is not fault even this item is momentarily displayed imme-
diately after the engine is started.
The control primary pressure is abnormal.
Stop the operation at once, and consult with your nearest KOBELCO au-
thorize distributor.
* Note : That it is not fault even this item is momentarily displayed imme-
diately after the engine is started.
2-21 7055-3
2. OPERATION

The engine oil pressure is abnormal.
Stop the engine at once, and consult with your nearest KOBELCO autho-
rize distributor.
The cooling water level in the radiator is insufficient.

Refill the radiator with cooling water.
The cooling water temperature is excessively high.

Idle the engine to lower temperature, and consult with your nearest O
KOBELCO authorize distributor.
The engine oil filter is clogged. Replace the filter.
The engine air cleaner is clogged.

Clean or replace the element.
The fuel level is insufficient.

Refuel.
The hydraulic oil temperature is excessively high.

Adjust the engine speed to the medium level to lower the oil temperature,
and consult with your nearest KOBELCO 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. If this item fre-
quently appears during normal operations, consult with your nearest
O
At the same time, inform the KOBELCO service of the details of the oper-
ation (lifting load, free fall distance, speed, and duration).
The temperature of clutch cooling oil of the rear drum is excessively high.
Idle the engine at a high speed to lower the oil temperature. If this item fre-
quently appears during normal operations, consult with your nearest
O
At the same time, inform the KOBELCO service of the details of the oper-
ation (lifting load, free fall distance, speed, and duration).
The winch cooling line filter is clogged.
Replace the filter cartridge.
This item may appear during cold weather even when the filter is not O
clogged. If the item disappear during warm-up, the cartridge does not need
to be replaced.
The front drum clutch emergency system is actuated. 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 OFF position. Then, consult your
O
nearest KOBELCO authorize distributor. DO NOT operate the key switch
with a load or the hook hung in the air, since it may cause drop of the load
or the hook.
7055-3 2-22
2. OPERATION

The rear drum clutch emergency system is actuated. The free fall of the
rear drum cannot be normally performed. Place a load and the hook onto
O
or the hook.
The third drum clutch emergency system is actuated. The free fall of the
third drum cannot be normally performed. Place a load and the hook onto
O
or the hook.
The hook block Anti-two-block (overhoist) stop status is released.

Stop the release, and operate in the normal status.
The boom overhoist stop status is released.

The moment limiter redundancy switch is actuated.

The moment limiter is malfunctioned, and automatic stop operation due to
overload and the overhoisted hook block is impossible.
Immediately stop the operation, or return extremely carefully, and consult
with your nearest KOBELCO authorize distributor.
The CPU is malfunctioned.

O
Consult with your nearest KOBELCO authorize distributor.
The overload automatic stop status is released.

This item is displayed whenever the engine is stopped. It does not mean
occurrence of a malfunction, but is intended for prevention of failure in en-
O
gagement of the drum lock.
* Note : This item is displayed even when the drum lock is engaged.
Drain water from the fuel filter when water pooled in the fuel filter.
The display can be erased by "ZERO" switch of the gauge cluster depress
more than 2 seconds.
* If water is left being pooled for a long time, it may cause the sensor mal-
function.
2-23 7055-3
2. OPERATION
(2) WARNING DISPLAY (SELF CHECK)

If the solenoid valve or the sensor has malfunctioned, the display screens below appear.
When there are multiple malfunctions, they will be displayed consecutively.
When these display screens appear, inform your nearest KOBELCO authorize distributor of the display screen
number (the number on the upper left corner of the display screen).
Number Error Number Error

D-1 BOOM RAISE PROPO-V C-21 Re.-C/V SOL-V
D-2 BOOM LOWER PROPO-V C-22 3RD-C/V SOL-V
D-3 Fr.-RAISE PROPO-V C-23 D/O SPARE
D-4 Fr.-LOWER PROPO-V C-24 D/O SPARE
D-5 Re.-RAISE PROPO-V C-25 D/O SPARE
D-6 Re.-LOWER PROPO-V C-26 Fr.-WINCH FREE FALL LAMP
D-7 3RD-RAISE PROPO-V C-27 Re.-WINCH FREE FALL LAMP
D-8 3RD-LOWER PROPO-V C-28 3RD-WINCH FREE FALL LAMP
D-9 Fr.-MOTOR PROPO-V
D-10 Re.-MOTOR PROPO-V A-1 Fr.-MOTOR POTENTIO
D-11 SWING SPEED PROPO-V A-2 Re.-MOTOR POTENTIO
D-12 MAIN PUMP PROPO-V A-3 THIRD MOTOR POTENTIO
D-13 3RD MOTOR PROPO-V A-4 A/D SPARE
D-14 SWING REACTION PROPO-V A-5 A/D SPARE
D-15 TAGLINE PROPO-V A-6 TAGLINE TENSION (NOT USED)
A-7 GRIP ACCELERATOR POTENTIO
C-1 BATTERY RELAY A-8 FOOT ACCELERATOR POTENTIO
C-2 D/O SPARE A-9 A/D SPARE
C-3 HYD. OIL HEAT RELAY A-10 A/D SPARE
C-4 D/O SPARE A-11 SWING PUMP PRESS. SENSOR
C-5 MAIN PUMP SPEED SOL-V A-12 3RD MOTOR POTENTIO
C-6 SPARE A-13 Fr.-RAISE PRESS. SENSOR
C-7 Fr.-WINCH CLM SOL-V A-14 Fr.-LOWER PRESS. SENSOR
C-8 Fr.-WINCH ESM SOL-V A-15 Re.-RAISE PRESS. SENSOR
C-9 SPARE A-16 Re.-LOWER PRESS. SENSOR
C-10 Re.-WINCH CLA SOL-V A-17 3RD-RAISE PRESS. SENSOR
C-11 Re.-WINCH ESA SOL-V A-18 3RD-LOWER PRESS. SENSOR
C-12 SPARE A-19 Fr.-CLUTCH PRESS. SENSOR
C-13 3RD-WINCH CLT SOL-V A-20 Re.-CLUTCH PRESS. SENSOR
C-14 3RD-WINCH EST SOL-V A-21 3RD-CLUTCH PRESS. SENSOR
C-15 Fr.-MOTOR BOOST SOL-V A-22 WIND VELOCITY SENSOR
C-16 Re.-MOTOR BOOST SOL-V A-23 A/D SPARE
C-17 3RD-MOTOR BOOST SOL-V A-24 BOOM RAISE PRESS. SENSOR
C-18 Fr.-WINCH REV. GRIP SOL-V A-25 BOOM LOWER PRESS. SENSOR
C-19 Re.-WINCH REV. GRIP SOL-V A-26 JIB TENSION
C-20 Fr.-C/V SOL-V
7055-3 2-24
2. OPERATION
(3) RETURN TO NORMAL DISPLAY SCREEN WHILE

While the fault indicator display screen appears,
FAULT INDICATOR DISPLAY SCREEN APPEARS push the zero switch for more than 2 seconds.
When a fault occurs, a fault indicator display screen
appears.
To return to the normal display when in this status,
The normal display screen flashes.
perform the steps described to the right.
When the setting switch is pushed while the

If the fault occurred is corrected while the normal dis- normal display screen is flashing, the fault
indicator display screen returns.
play screen is flashing, the screen enters the lit status
automatically.
5. ALTERATION OF ENGINE OIL CHANGE INTER-

VAL
Reset to "0" the engine oil change interval when the
oil change is complete.
(1) Display the "Engine oil change interval display
screen".
29Hr AFTER
(2) Press the check switch for more than 5 seconds.
The displayed oil change interval flashes. ENGINE OIL CHANGE
(3) When the zero switch is pressed for more than a
second, the oil change interval is reset to "0".
To set to an interval other than "0", press the adjust- INCHING OFF F6 R1
er "+" switch. The displayed oil change interval in-
creases by 1. The interval can be continuously
increased by pressing this switch.
By pressing the adjuster "-" switch, the displayed oil
change interval decreases by 1. The interval can
be continuously decreased by pressing this switch.
(4) Press the setting switch after adjusting the value.
The alteration is complete, and the screen returns
to the normal status.
(5) If no alteration is required, select another display
screen with the display screen selector switches
without pressing the setting switch.
The alteration will be canceled.
2-25 7055-3
2. OPERATION
6. LIFTING HEIGHT GAUGE (OPTION)

To obtain the correct lifting height, the setting of the
number of the reeving wire rope of the load safety
device controller (refer to the page 3-40) and the
initial adjustment of the lifting height gauge (refer to
the next page) are absolutely necessary.
(1) USE OF LIFTING HEIGHT GAUGE

(A) Display the "Engine speed and lifting height ENG. 1240 rpm
screen".
(B) Select the main lifting mode or the auxiliary lifting LIFT +34.5 m
mode with the "Mode selector" switch of the load
safety device controller.
The display screen will be switched according to
INCHING OFF F6 R1
the statuses of the switch.
Main………main lifting
Aux…………auxiliary lifting
(C) Make sure that the displayed number of the reeving
wire rope is correct by checking the actual number
of the reeving wire rope.
(D) Move the load to any position and press the zero
switch. The displayed lifting height is reset to "0 m".
The zero switch can be used only in the "Engine
Speed and Lifting Height Gauge" screen.
Resetting is impossible in other screens.
(E) The lifting height changes according to the winch-
ing-up/down and the raising/lowering of the boom
and jib.
When the lifting height exceeds the reset value, it is
indicated with the "+" mark, and when it is lower
than the reset value, it is indicated with the "-" mark.
7055-3 2-26
2. OPERATION
(2) INITIAL ADJUSTMENT OF LIFTING HEIGHT

GAUGE
If the drum is rotated without a wire rope wrap dur-
ing the wire rope replacement, or the drum is rotat-
ed with the wire rope caught in during the
disassembly and the assembly of the boom, the
wire rope layers on the drum must be adjusted.
If the adjustment is not performed correctly, the lift-
ing height may not be changed, or the displayed
value may be incorrect. Be sure to adjust it correct-
ly.
The initial adjustment of the lifting height gauge
must be performed for both of the main winch and
the auxiliary winch.
The adjustment steps are identical to the front drum
and the rear drum .
The adjustment steps for the front drum are de-
scribed below.
(A) Winch the main hook block (up or down), and stop
it at the position where the wire rope layers on the
drum changes.
(B) Display the "Front Drum Layers" display screen.
(C) Press the check switch for more than 5 seconds. FRONT DRUM LAYER
Then, the displayed value of the wire rope wraps on
the drum flashes.
(D) Press the adjuster "+" switch and the wire rope 2
wraps on the drum increases by 1. It can be con-
tinuously increased by pressing the switch. Press INCHING OFF F6 R1
the adjuster "-" switch and the value decreases by
1.
Adjust the displayed value of the wire rope wraps
on the drum to the current correct value. It can be
judged by the distance between the drum flange
end and the wire rope. Refer to the diagram below.
SETTING EXAMPLE
WIRE ROPE WRAPS
22
1st. Layer 2nd. Layer

41
59
7TH
78
97
6TH
115
2nd. Layer 3rd. Layer

134
5TH
4TH
3RD
2ND 3rd. Layer 4th. Layer
1ST
4th. Layer 5th. Layer
2-27 7055-3
2. OPERATION
(E) Press the setting switch after adjusting the value.

The adjustment is complete and the screen returns
to the normal status.
(F) If no alteration is required, select another display
screen with the display screen selector switch with-
out pressing the setting switch.
The alteration is canceled and the value returns to
the original one.
(G) Follow the steps described in the "(1) USE OF LIFT-

ING HEIGHT GAUGE" of the section 7, and ensure
that the lifting height value changes in accordance
with the setting.
(H) When the indicated lifting height is incorrect, the
sensor gap adjustment may be improper. Adjust
the gap of the proximity sensor. DRUM
The center of the proximity sensor must be
If the indicated lifting height is still incorrect, consult nearly aligened with the drum fin end
with your nearest KOBELCO authorize distributor.
GAP ADJUSTMENT : 3mm
ALLOWANCE 3 to 4mm
SECTION A-A
7. Altering preset alarm wind velocity (only when the

machine is equipped with the anemometer)
The preset alarm wind velocity can be altered arbi-
trarily. Set up it depending on the working condi-
tions.
(The factory set value is 10 m/s.)
ZERO RESET SWITCH
CHECK SWITCH
7055-3 2-28
2. OPERATION
(1) Access to the screen displaying wind velocity.

WIND 13.2m/s
SET 20m/s
INCHING OFF F6 R1
(2) Press the check switch for five seconds or longer.

The set value blinks.
(3) Press the increase (+) switch and the set value is in-
creased by one. It can be altered continuously by
pressing and holding the switch.
Press the decrease (-) switch and the set value is
decreased by one. It can be altered continuously
by pressing and holding the switch.
(4) After the alteration is completed, press the setting

switch. The alteration is ended, and the screen re-
mains lit up.
(5) To stop the alteration, change to another screen
with the screen selector switch without pressing the
setting switch. The alteration is cancelled.
If the wind velocity is 2 m or less, "0 m/s" is displayed.
SET SWITCH (+), (-) SWITCH
2-29 7055-3
2. OPERATION
2.2.3 OPERATING THE AIR CONDITIONER

1. CONTROL PANEL
(2) AIR VENT SELECTION SWITCH
(3) AIR INLET SELECTION SWITCH
(4) TEMPERATURE CONTROL SWITCH
AIR CONDITIONER INDICATOR SWITCH
(5) AIR CONDITIONER SWITCH
(1) FAN SWITCH
(1) FAN SWITCH

The switches control the air conditioner ON/OFF function and the blower speed.
position Low
position Medium
position High
(2) AIR VENT SELECTION SWITCH

These switches control the open/close position of each air vent.
Select the desired air flow mode from the three mode position.
The selected position is always shown by a lamp.
Select if the front glass is misted.
(3) AIR INLET SELECTION SWITCH Selector switch for selection

This switch selects the open or close position of air inlet. between internal air circulation and
open intake.
When this position is selected, the
air inlet is closed which causes the
air to recirculate inside the cab.
When this position is selected, the
air inlet is opened which allows fresh
air to be introduced into the cab.
(4) TEMPERATURE CONTROL SWITCH

These switches control the temperature of air coming
out of the air vents to any of five levels during heating Green indicator Red indicator
(red label) and cooling (green label).
1. Push the left switch ( ), and the range of the GREEN
lights decrease and the air temperature goes down.
2. Push the right switch ( ), and the range of the LED lights increase and the air temperature goes up.
(5) AIR CONDITIONER SWITCH

AIR CONDITIONER
This is used to turn ON and OFF the cooling function during cooling or INDICATOR LAMP
dehumidification heating.
AIR CONDITIONER
Push once to change over from ON/OFF to OFF/ON. SWITCH
When the switch is turned ON, the lamp on the upper part of the switch lights up.
7055-3 2-30
2. OPERATION
2. CAUTIONS
(1) Fresh air should be introduced into the cab, when
the air conditioner is used for long time.
(2) Do not lower the temperature more than necessary.
3. CHECK AND SERVICE

When the filter is clogged, wind volume is de-
creased, and capacity of the air conditioner is low-
ered.
Check the filter; clean or replace if it is dirty (Every
3 months).
(1) INSIDE AIR FILTER
Removal …
Lightly raise up the filter hook, then remove the filter
for cleaning or replacing.
(2) OUTSIDE AIR FILTER
Removal …
Unhook the latches located at the top and bottom,
then remove the outside air filter for cleaning or re-
placing.
2-31 7055-3
2. OPERATION
2.2.4 AM/FM RADIO (OPTION)

1. To Hear the Radio Broadcasting
(a) VOLUME CONTROL / POWER SWITCH
(1) Place the key switch in the ON or ACC position.
(b) TONE CONTROL
(2) Push power switch (a) to power on. (i) AM/FM SELECT BUTTON
Push the switch again to turn power off.
INDICATOR SELECT
(3) Turn volume control (a) to the right to turn volume (TIME/FREQUENCY)
high. (e) PRESET BUTTON
(4) Choose your desired radio station by operating the

manual tuning button (c), (d) or the preset button
(e).
(Refer to the method of tuning.)
When pushing preset button (e), push the button
within 1 seconds.
(5) After adjusting the volume properly, adjust tone INDICATOR
control (b) as desired. (g), (f) TIME SETTING BUTTON
Turn to the right to make the tone high, and turn to MANUAL TUNING BUTTON
the left to make the tone low. (c) : DOWN button
(d) : UP button
2. Method of Each Tuning

(1) Method of Auto Tuning
By pushing the manual tuning button (c) or (d) for
0.5 seconds or longer, the radio station of higher
frequency is selected, and the tuning is automati-
cally stopped when receiving the radio wave.
At this time, the received frequency is indicated on
the indicator.
(2) Method of Manual Tuning
When selecting a high frequency broadcasting,
push the "UP" button (d) of manual tuning button,
and when selecting a low frequency broadcasting,
push the "DOWN" button (c).
At this time, indicator indicates the received fre-
quency.
Method of Manual Tuning
(3) Method of Preset (Setting the Selecting Button)
(a) Choose AM or FM by pushing the AM/FM se-
lector button (i).
(b) Adjust the frequency to that of the radio station,
which you desire to memorize, by pushing the
"UP" button (d) and "DOWN" button (c).
(The received frequency is indicated on the in-
dicator.)
(c) By pushing the preset button (e) for 1 second or
longer, the selected frequency is memorized.
(In the AM/FM radio, six broadcasting frequen-
cies can be set respectively in AM and FM.)
7055-3 2-32
2. OPERATION
3. Setting Method of Time (h) INDICATOR SELECT

(1) Place the key switch in the ON or ACC Position.
(2) By pushing button (RST) (f) for 1 second or longer,
the o'clock indicator blinks and the time setting will
become possible.
(3) Adjust o'clock with button (h) of time setting button
(g), and adjust minute with button (m) of (g). INDICATOR
(g), (f) TIME SETTING BUTTON
By continuing pushing makes movement quick.
(4) By pushing button (RST) (f) once more for 1 second
or longer after setting is finished, the time setting
will be completed.
(5) Indicator shows the time regardless of ON and OFF
of the radio. When the broadcasting frequency is
desired to be checked, push "DISP" button (h).
2-33 7055-3
2. OPERATION
2.2.5 1WAY CALL (TRANSMITTER) (OPTION)

1. CONFIGURATION OF 1WAY CALL
The 1way call comprises the amplifier, microphone,
and external speaker.
2. OPERATION INSTRUCTION
(1) Set the power switch to the "ON" status.
(2) The operator's voice can be transmitted through the
outside speaker by talking to the microphone.
(3) The volume of the speaker can be adjusted with the
volume adjuster.
7055-3 2-34
2. OPERATION
2.3 CRANE OPERATION

2.3.1 ADJUSTING THE OPERATOR'S SEAT
1. ADJUSTING BACK AND FORWARD
Pull the lever (item No.1) to adjust the seat back-
ward and forward within 160 mm (6.3 inch) range. 㧡
After adjusting, release lever to set the position.
2. ADJUSTING HEIGHT 㧟
Pull up the lever (item No. 3) to lift the back of the
seat, push the lever down to lift the front of the seat.
To lower the seat, reverse the lifting procedure. 㧢
㧝
3. ADJUSTING RECLINING CONDITION

Pull the lever (item No. 2) to set the back of the seat
to the most suitable angle. After adjusting, release
the lever to set the seat.
4. ADJUSTING TILTING ANGLE
Pull the lever (item No. 3) to set the seat tilting an-
gle to the most suitable angle. After adjusting, re-
lease the lever to set the seat.
5. HEADREST
The headrest can be adjusted up or down.
6. ARMREST
The armrest can be turned 180 deg. backward.
(2) (1) (3)
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION

By loosening the nut, the control lever can be adjusted
for direction.
Adjust it to the most suitable position. After adjusting,
secure the lever with the nut.
Nut must be retightened before using crane.
NUT
2-35 7055-3
2. OPERATION
2.3.3 STARTING AND STOPPING THE ENGINE

1. STARTING THE ENGINE
Before starting the engine, set the control levers
and switches as follows:
(1) Boom hoist, front drum, rear drum, third drum (option), swing and propel control lever…… Neutral
(2) Function lock lever………………………………………………………………………………… Lock position
(3) Swing brake switch……………………………………………………………………………… Engaging side
(4) Front drum, rear drum, boom drum and third drum (option) lock knob……………………… Lock side
(5) Front drum, rear drum and third drum brake pedals (option)………………………………… Lock position
Be sure to set all the levers to the neutral positions

before the engine starts up in order to prevent the
machine from moving.
ENGAGE RELEASE
LOCK (3) SWING BRAKE

About 25 mm
(1) NEUTRAL
(4) DRUM LOCK KNOB
(5) LOCK POSITION
(2) LOCK POSITION

(1) NEUTRAL
7055-3 2-36
2. OPERATION
HORN SWITCH
Sound the signal horn to warn the surrounding per-

sonnel before starting the engine.
Failure to observe this precaution may result in se-
rious injury or death.
(1) Turn the key switch 2 steps to the right

(ON position).
Though the engine control warning lamp is lit up, it
is not fault (they are lit up to check burn-out of the
bulbs).
OFF
ACC
ON
START
(2) By turning the key switch one step more to the right
(START position), the engine starts. After the en- OFF
gine starts, immediately release the key. The key ACC
returns to the ON position automatically. ON

Do not allow the starter to run more than 15 sec-
onds continuously. If the engine does not start with-
START
in 15 seconds, release the key and wait for more
than 20 seconds, then start the engine again.
OFF
ACC
ON
START
(3) After the engine starts, immediately check the mon-

itor for abnormality. If the readings are improper,
stop the engine immediately and determine the
cause.
2-37 7055-3
2. OPERATION
(4) To adjust the engine speed, use the accelerator

grip. Desired control is available
In the range of 120 deg.
If it is impossible to adjust the engine speed with the
use of the accelerator grip, adjust by using the aux-
ACCELERATION
iliary accelerator (located under the operator's
DEACCELERATION
seat). If the accelerator fails, turn on the by-pass
switch (a) than operate the by-pass switch then op-
erate the auxiliary accelerator switch (b).
Do not operate auxiliary accelerator when the system

works properly.
Failure to observe this precaution may result in damage
to the system.
(a) by-pass switch
(b) AUXILIARY
ACCELERATOR
SWITCH
2. ENGINE WARMING OPERATION

Allow the engine to run at less than middle engine
speed for 5 to 10 minutes with no load. Extend the
warm-up time twice in a cold area.
If the crane is operated immediately without warming

up the engine, the engine and the hydraulic compo-
nents will be worn out earlier than usual or will become
damaged.
7055-3 2-38
2. OPERATION
3. STOPPING THE ENGINE

Before stopping the engine, set the control levers
and switches as follows:
(1) Boom hoist, front drum, rear drum, third drum (option), swing and propel control lever…… Neutral
(2) Function lock lever………………………………………………………………………………… Lock position
(3) Swing brake switch……………………………………………………………………………… Engaging side
(4) Front drum, rear drum, boom drum and third drum (option) lock knob……………………… Lock side
(5) Front drum, rear drum and third drum brake pedals (option)………………………………… Lock position
(A) Allow the engine to run at a low speed for approxi-

mately 5 minutes with no load before stopping the OFF
engine. ACC
(B) Turn the key switch to the OFF position (2 steps to ON
the left).
START
2.3.4 FUNCTION LOCK LEVER

When leaving the operator's seat, be sure to place this
lever in the LOCK position. Lock position
When this lever is placed in the LOCK position, the ma-
chine does not operate even if any control lever is op-
erated accidentally. Work position
Do not set the function lock lever to the "LOCK" po-

sition during operation.
Otherwise, all the operation functions are suddenly
stopped, causing extreme danger.
When operating the machine, place the function lock le-

ver in the WORK position.
Interlocking the control levers for main and aux. winch-

es, and boom
If the function lock lever is set to the "Lock" position

while any of the control levers is operated, rotation of
the drum is stopped. The drum will not be rotated even
if the function lock lever is set to the "Work" position
again, in this status.
After the control lever is returned to the neutral position,
the drum becomes operable again.
2-39 7055-3
2. OPERATION
2.3.5 PROPELLING OPERATION
Propelling forward
Before propelling the machine, strictly observe the Propelling backward

following procedures.
• Confirm that people and obstacles are kept out PROPEL LEVER LOCK
of the propelling area.
• Sound the horn to warn the surrounding peo-
ple. RIGHT PROPEL
CONTROL LEVER
• Be especially careful, when the boom is long,
boom angle is large, ground is uneven, or when LEFT PROPEL
CONTROL LEVER
a load is lifted.
• For stability of swinging and traveling, see page
10.3 STABILITY IN SWINGING AND TRAVELING.
• Use a signal person to direct operation.
Propel speed is regulated by turning the accelerator

grip, and by proportionally pushing and pulling the pro- HIGH
pel control levers. High and low propel speed is regu-
lated by operating the propel speed selector switch.
High speed …Use this speed on good ground con- LOW
ditions.
Low speed……Use this speed when a tractive
force is required on bad ground
PROPEL SPEED
conditions. SELECTOR SWITCH
7055-3 2-40
2. OPERATION
1. When the propel speed selector switch is placed in

the HIGH SPEED position, pivot turn and counter-
rotation cannot be operated depending on the
ground conditions and the engine speed.
2. Since the machine may propel partially on a rough
terrain, adjust propelling by the stroke of the propel
control levers.
Propelling forward is propelling toward the idler side,

FORWARD
and propelling backward is propelling toward the propel
motor side. When the cab positions to the propel motor
side, use caution with propelling operation in reverse PROPEL MOTOR IDLER
only.
Forward direction
Provide the gentle slope so that the machine does not

suddenly tilt and fall down at the beginning and end po-
sitions of slope. (Propel control levers)
(1) Release the propel control lever lock.

(2) It is possible for the machine to perform propelling
start/backward and pivot turn/spin turn/wide curve
Pivot turn
turn by operating the right and left propel control le-
vers.
(3) Engage the control lever lock when you do not want
to propel the machine.
• Do not perform sudden starts/stops/operation Counter rotate

of the machine. Failure to observe this warning
may result in serious accidents due to collision
or boom windage.
• If the main or auxiliary drum is operated while
propelling the machine, it may cause danger
because the propel speed changes or the direc-
tion slants. To operate these actions simulta- Turn with large radius
neously, lower the machine speed and slowly
operate the drum.
2-41 7055-3
2. OPERATION
2.3.6 SWINGING OPERATION
• Before initiating any swing operations, ensure

the area in the swing path of the hook and/or
load, and the tail swing area, is clear of all ob-
structions and personnel.
• Sound signal horn to warn personnel.
• For stability of swinging, see page 10.3 STABIL-
ITY IN SWINGING AND TRAVELING.
As for details of the swing brake modes, see the
section 2. on page 2-7.
LAMP AND BUZZER
LAMP
Swing speed is regulated by turning the accelerator

grip, and by proportionally pushing and pulling the
swing control lever.
1. According to working conditions, select the alarm

with the swing alarm selector switch.
2. The swing brake modes which consist of FREE
HIGH, FREE LOW and BRAKE should be selected
according to the job application. When FREE LOW
or BRAKE is selected, the swing speed becomes
slower.
When the BRAKE mode is selected, do not return the

swing control lever to the neutral position too quickly in
order to avoid shocks to the machine and booms.
7055-3 2-42
2. OPERATION
3. Release the swing lock pin and swing brake.
Lock
Release
SWING LOCK ENGAGE RELEASE
CONTROL SWITCH
SWING BRAKE
HORN SWITCH
Since the machine may swing naturally due to the wind

or ground inclination, pay attention to release the swing
brake. When the operator shut off lever is moved from
the lock position to the work position, care should be
taken because the machine also may swing naturally.
(Regardless of positions of the swing brake switch, if
the operator shut off lever is set at the lock position, it
means that the swing brake has been engaged.)
DO NOT set the swing brake switch to the "Engaging"

side during swinging (while the lever is operated).
2-43 7055-3
2. OPERATION
4. Push the swing control lever forward to swing the

upper to the left and pull the lever backward to
Swing left
swing the upper to the right.
To stop the swing motion
(1) FREE MODE
Slowly move the lever in the opposite direction. Swing right
(2) BRAKE MODE

Slowly return the lever to the neutral position.
• Avoid rapid swings or sudden starts and stops.

• After the swing motion has been completely
stopped, engage the swing parking brake.
• Do not use the swing parking brake for the pur-

Swing to the right
pose of stopping the swing motion.
• Always check to ensure that the load is hanging Swing to the left
free and directly under the boom tip before
swinging.
5. When pausing operations, orient the machine

straight ahead, and then, actuate the swing lock.
Activating the swing lock and swinging operation with

the machine in any position other than the swing lock
position (Machine oriented straight ahead) may lead to
the damage of the machine.
7055-3 2-44
2. OPERATION
2.3.7 BOOM RAISING/LOWERING OPERATION
LOCK RELEASE
PUSH
Before operating the boom, ensure that the area
above and beneath the boom is clear of all obstruc-
25 mm
tions and personnel. Failure to observe this pre-
caution may result in serious injury or death.
Speed of boom hoist can be adjusted by turning the ac-

celerator grip and pressing or pulling up the boom op-
erating lever and the maximum speed of boom up and
down motion can be also adjusted by operating the
drum speed adjusting knob.
BOOM HOIST DRUM LOCK KNOB
1. Release the drum lock by pushing the boom hoist BOOM DRUM
drum lock knob. CONTROL LEVER
2. Push the boom drum control lever forward to lower Lowering

the boom, and pull the lever backword to raise the
boom.
Raising
The load line can break if the hook block contacts

the end of the boom. This is called "two blocking". Lowering
Two blocking can be caused by lowering the boom
without paying out load line. Two blocking can pull Raising
jibs and lattice crane booms over backwards or
cause damage to the tip.
Always keep adequate space between the hook
block and boom point. Lower the hook when low-
BOOM DRUM
ering the boom. CONTROL PEDAL (OPTION)
When the boom is not lowered by operating the boom

Raising
hoist control lever to the boom lowering side, it is pos-
sible that the drum lock is engaged in the ratchet of the
drum. In this case, move the boom drum control lever
to the boom raising side slightly, then move the lever to Lowering
the lowering side again.
Do not activate the drum lock while the boom is

lowered. Otherwise, the drum or drum lock may be
damaged.
2-45 7055-3
2. OPERATION
(OPTION)
Boom operation can be done by the boom foot pedal.
When the far (fore) side of the boom foot pedal is
pressed down, the boom is lowered. When the near
(hind) side of the boom foot pedal is pressed down, the
boom is raised. Do not operate the boom drum control
lever and the boom foot pedal at the same time. If the
boom drum control lever and the boom foot pedal are
operated at the same time, precedence is taken by the
bigger side of the signal (valve stroke).
3. According to the working conditions, adjust the BOOM DRUM SPEED

ADJUSTING KNOB
speed of the drum with the drum speed adjusting
knob.
4. When the boom approaches the upper limit angle,
the hoisting speed is reduced.
The angle to start the speed reduction differs de-
pending on the engine revolution; accordingly
make sure to reduce the speed approximately 10
degrees before the upper limit angle in the case of
HIGH IDLE and approximately 3 degrees before
the upper limit angle in the case of LOW IDLE.
5. Be sure to stop the engine, and engage the drum
lock before leaving the operator's seat.
To engage the drum lock, push and hold the button,
and then fully pull the knob up.
Fully pull it up, although the resistance against pull-
ing may be altered halfway.
7055-3 2-46
2. OPERATION
2.3.8 HOOK RAISING/LOWERING OPERATION
When making lifts, strictly follow the capacity

charts for determining the loads that can be han-
dled as supplied by the manufacturer.
Follow good operating practice and procedures as
outlined in this manual.
The load line can break if the hook block contacts

the end of the boom. This is called "two blocking".
Two blocking can be caused by lowering the boom
without paying out load line. Two blocking can pull
jibs and lattice crane booms over backwards or
cause damage to the tip.
Always keep adequate space between the hook
block and boom point. Lower the hook when low-
ering the boom.
Raising and lowering speed is regulated by turning the

accelerator grip and by proportionally pushing and pull-
ing the drum control lever. The maximum raising and
lowering speed of the drum is regulated by operating
the drum speed adjusting knob.
2-47 7055-3
2. OPERATION
1. Ensure that the "FREE FALL INDICATOR LAMP"

stays out. REAR DRUM FREE FALL
INDICATOR LAMP (OPTION)
2. Release the drum lock by pushing the front, rear FRONT DRUM FREE FALL
and third hoist drum lock knob. INDICATOR LAMP (OPTION)
THIRD DRUM FREE FALL
When the hook is not lowered by operating the INDICATOR LAMP (OPTION)
drum control lever to the lowering side, it is possible
that the lock is engaged in the ratchet of the drum.
In this case, slightly move the control lever to the
raising side, then move to the lowering side again.
DRUM LOCK KNOB
FRONT
THIRD
REAR
Before releasing the drum lock confirm that the
drum brake mode is in the NEUTRAL BRAKE
MODE. If not, move the switch to the NEUTRAL
BRAKE MODE.
Do not actuate the drum lock while the hook is low-

ered. Otherwise, the drum or drum lock may be LOCK RELEASE
damaged. PUSH
25 mm
3. According to working condition, adjust the maxi-

mum speed of the drum with the drum speed ad-
justing knob.
FRONT DRUM SPEED

ADJUSTING KNOB
THIRD DRUM SPEED

ADJUSTING KNOB
(OPTION) REAR DRUM SPEED
ADJUSTING KNOB
7055-3 2-48
2. OPERATION
Raising / Lowering Operation FRONT DRUM BRAKE

1. RAISING FRONT DRUM SELECTOR SWITCH
CONTROL LEVER (OPTION)
Pull the drum control lever toward the raising side
to hoist a load. THIRD DRUM BRAKE
REAR DRUM
SELECTOR SWITCH
CONTROL LEVER
2. LOWERING (OPTION)
Push the drum control lever forward to lower the REAR DRUM
THIRD DRUM CONTROL BRAKE SELECTOR
load. LEVER (OPTION) SWITCH
(OPTION)
When the hook is not lowered by operating the
drum control lever to the lowering side, it is possible
that the lock is engaged in the ratchet of the drum.
In this case, slightly move the control lever to the
raising side, then move to the lowering side again.
3. STOPPING
When the drum control lever is returned to the neu-
tral position, the automatic brake operates to stop
the load.
When the load is held in the air for a long time, en-
REAR DRUM BRAKE
gage the drum lock. THIRD DRUM PEDAL (OPTION)
BRAKE PEDAL
To engage the drum lock, push and hold the button, (OPTION)
and then fully pull the knob up. Lowering
FRONT DRUM
BRAKE PEDAL
(OPTION)
Raising
Do not actuate the drum lock while the hook is low-
ered. Otherwise, the drum or drum lock may be
damaged.
Always keep your foot on the brake pedal or set the

Raising
brake pedal to the look position, even when the
neutral brake is used so that the foot pedal can be
operated at any time.
Lowering
The inching of the raising/lowering using the brake ped-

al together with the drum control lever is impossible be-
cause of the brake system.
Operate the "Mode selector switch (B)" depending on

the type of work. (Refer to page 2-9.)
2-49 7055-3
2. OPERATION
2.4 TOWER CRANE OPERATION

Controls peculiar to tower crane operation are de-
scribed here.
For tower crane operation, control levers, switches and
pedals are called as shown below.
HOOK HOISTING/LOWERING JIB RAISING/LOWERING

BRAKE SELECTOR SWITCH CONTROL LEVER
(OPTION)
HOOK HOISTING/LOWERING JIB RAISING/LOWERING DRUM
CONTROL LEVER BRAKE SELECTOR SWITCH (Not Used)
TOWER RAISING/LOWERING
CONTROL LEVER
HOOK HOISTING/LOWERING
DRUM LOCK KNOB
JIB RAISING/LOWERING HOOK HOISTING/LOWERING

DRUM LOCK KNOB DRUM SPEED ADJUSTING KNOB
DRUM LOCK KNOB
TOWER ANGLE
FIXING SWITCH
TOWER DRUM SPEED

ADJUSTING KNOB
JIB DRUM SPEED

ADJUSTING KNOB
DRUM BRAKE PEDAL (OPTION)
7055-3 2-50
2. OPERATION
2.4.1 HOISTING TOWER CRANE ATTACHMENT

This section describes the operating method during the
LOCK RELEASE
tower operation.
PUSH
For the tower raising operation from the ground and the
tower lowering operation to the ground, refer to "7. AS-
25 mm
SEMBLY/DISASSEMBLY OF TOWER CRANEAT-
TACHMENT" .
Make sure there is no person in the working area of the

tower crane attachment.
TOWER HOIST DRUM LOCK KNOB
1. Referring to Section 3. LOAD SAFETY DEVICE, in-

put the crane configuration in the load safety de- TOWER RAISING/LOWERING
CONTROL LEVER
vice.
Lowering
2. Release the drum lock by pushing the drum lock
knob of the tower hoist drum.
When tower crane attachment is not lowered even
if the tower hoist control lever is pushed forward, Raising
the drum lock pawl may be engaged with the rachet
of the drum. In this case, pull the tower hoist control
lever slightly backward and then pushed forward.
3. The tower hoist control lever is pushed forward, the

tower attachment is lowered and pulled backward
the tower attachment is raised. The tower hoist con-
trol lever is returned to the neutral, the drum brake
is automatically set and hold the tower attachment. Raising
Lowering
Lowering the tower attachment beyond the allow-

able limit angle will cause unbalanced condition
and the crane may turn over.
2-51 7055-3
2. OPERATION

justing knob.
Low High
speed speed
SPEED ADJUSTING KNOB
5. When the tower boom approaches the upper limit

angle, the hoisting speed is reduced. RELEASE
FIX
degrees before the upper limit angle in the case of
HIGH IDLE and approximately 3 degrees before
6. When the tower attachment needs to be fixed at a
certain angle, put the tower angle fixing switch into
TOWER ANGLE
fix. FIXING SWITCH
In this case the tower angle will not be moved even
with the tower hoist control lever motion.
With the tower hoist, when the tower over hoist
No.1 limit switch is actuated, alarm buzzer sounds.
To stop the alarm buzzer, put the tower angle fixing
switch into fix.
If the tower angle reaches the upper limit set value
set up with the LMI controller and alarm sound is
emitted, return the lever to the neutral position.
Then, alarm sound is stopped.
When the tower over hoist No.2 limit is actuated,
alarm sound can not be canceled. Lower the tower
immediately until proper angle.
7055-3 2-52
2. OPERATION
2.4.2 HOISTING TOWER JIB CRANE ATTACHMENT

Release the drum lock by pushing the tower jib hoist
LOCK RELEASE
drum lock knob. PUSH
1. HOIST
Pull the jib hoist control lever backward to hoist the
25 mm
jib.
2. LOWERING
Push the jib hoist control lever forward to lower the
jib.
3. STOP
Return the jib hoist control lever into the neutral po-
sition to set the brake automatically and stop the jib.
If the jib is set for long time, engage the drum lock.
TOWER JIB HOIST DRUM
LOCK KNOB
Raising
JIB RAISING/LOWERING
CONTROL LEVER
Lowering
Lowering
Raising

Low High
justing knob. speed speed
5. When the jib approaches the upper limit angle, the
hoisting speed is reduced.
degrees before the upper limit angle in the case of JIB RAISING/LOWERING
HIGH IDLE and approximately 3 degrees before SPEED ADJUSTING KNOB
2-53 7055-3
2. OPERATION
2.4.3 HOOK HOIST DRUM CONTROL

For the machine with the free fall function, refer to "2.5
FREE FALL OPERATION (OPTION)".
LOCK RELEASE
PUSH
When hoisting load, always observe the provided rated
load chart.
25 mm
Hoisting and lowering speed can be adjusted by the ac-
celerator grip and/or the drum control lever.
The maximum hoisting and lowering speed of the drum
is regulated by operating the drum speed adjusting
knob.
1. Release the drum lock by pushing the front drum
lock knob.
FRONT DRUM LOCK KNOB
Low High
2. According to working condition, adjust the maxi- speed speed
justing knob.
SPEED ADJUSTING KNOB
3. Recommend the mode selector switch "A" to select

"Tower" side.
7055-3 2-54
2. OPERATION
HOOK HOIST DRUM CONTROL DRUM BRAKE

HOOK HOIST/LOWERING CONTROL SWITCH (OPTION)
1. HOIST CONTROL LEVER (FOR FREE FALL)
Pull the hook hoist drum lever backward to hoist the
load.
2. LOWER Lowering
Push the hook hoist drum lever forward to lower the
load.
Raising
Even when the hook hoist drum lever is pushed for-
ward and load is not lowered, the drum lock pawl
may be engaged with the rachet of the drum. In this
case move the lever slightly for the raising side and
then for the lowering side.
3. STOP
Return the hook hoist drum control lever to the neu-
tral position to set the brake automatically and to
hold the load. Set the drum pawl lock when the load
will be suspended in the air for the long time.
HOOK HOIST/LOWERING
BRAKE PEDAL
(FOR FREE FALL)
Always keep your foot on the brake pedal even

when the neutral brake is used so that the foot ped- Hoisting
al can be operated at any time. Failure to observe
this precaution may result in serious injury or
death.
Lowering
2-55 7055-3
2. OPERATION
2.5 FREE FALL OPERATION (OPTION)
• Do not perform operations in the FREE FALL

mode until you have confirmed that the brake is
functioning properly and will hold the load that
will be lifted.
• Do not release your foot from the brake pedal
when operating in the FREE FALL mode.
FREE FALL INDICATOR LAMP
• Do not apply the foot brake suddenly, and avoid
abrupt stops when lowering the hoist line while
DRUM BRAKE
operating in the FREE FALL mode. SELECTOR SWITCH
• Do not use the drum lock to stop the lowering
of the hoist line while operating in the FREE
FALL mode.
• Do not operate the lever while the load is being
lowered during the free fall mode.
• Do not overheat the brake by operating in the
FREE FALL mode repeatedly at high heights.
Failure to observe these precautions may result in
serious injury or death.
The use of the free fall must be limited to excavating op-

erations with the bucket. When lifting or lowering the
bucket during the FREE FALL mode, be sure to follow
the procedures below. REAR DRUM
BRAKE PEDAL
FRONT DRUM
BRAKE PEDAL
Release
Engage
1. Set the "Free Fall Lock Switch" (with key in the left
side stand) to the "Release" position.
2. Set the control lever to the neutral position, and with
the brake pedal depressed fully, push the brake se-
lector switch at once. The free fall indicator lamp
lights up to indicate that the brake is in the free fall
condition.
7055-3 2-56
2. OPERATION
3. Raising
Pulling the drum control lever backward, raising is
possible even while the brake pedal remains de-
pressed.
4. Lowering (Power Lowering)
After pushing the drum control lever forward, lower-
ing is possible even while the brake pedal remains
depressed.
5. Stopping
Depress the brake pedal, and return the drum con-
trol lever to the NEUTRAL position. The bucket is
stopped.
When the load is held in the air for a long time, in
the NEUTRAL BRAKE mode, engage the drum
lock.
6. Free fall
(A) Depress the brake pedal fully.
(B) Return the drum control lever to the neutral posi-
tion.
(C) Slowly release the brake pedal to free fall the buck-
et.
(D) Lowering speed is adjusted by adjusting pressure
to the brake pedal.
• When the depressed brake reaches to the specified

position, the brake pedal slightly vibrates. If the
brake pedal is depressed further from this position,
the brake is activated.
Before operating the foot brake in the free fall po-

sition, be sure to confirm that the brake is function-
ing by depressing the brake pedal fully. Failure to
observe this precaution may result in serious injury
or death.
DO NOT release the brake pedal while the hook placed

on the ground FREE FALL ACCELERATION SELEC-
TOR SWITCH set to the "HIGH" side.
Otherwise, the drum is automatically rotated in the low-
ering direction, leading to rope upsetting.
2-57 7055-3
2. OPERATION
FREE BRAKE MODE SWITCHING

BRAKE→FREE FREE→BRAKE
FUNCTION LOCK
WORK POSITION WORK POSITION
LEVER
FREE FALL LOCK
RELEASE RELEASE
SWITCH
DRUM CONTROL
NEUTRAL NEUTRAL
LEVER
BRAKE PEDAL DEPRESS DEPRESS
BRAKE SELEC- PUSH PUSH
TOR SWITCH (ONCE) (ONCE)
FREE LAMP LIGHT UP GOES OUT
MODE FREE BRAKE
(7) Switching from "FREE FALL MODE" to "BRAKE

MODE"
While the "FREE FALL MODE" is selected, set the
drum control lever to the NEUTRAL position, and
fully depress the brake pedal. Push the brake se-
lector switch on the control lever again.
The free fall indicator lamp goes out to indicate that
the "BRAKE MODE" is selected.
• When a light bucket is lowered during the free fall

mode in cold weather, the lowering speed may be
slow. While engaging the drum lock, winch down to
warm-up the hydraulic oil (perform this step for ap-
proximately five minutes).
• If the feel of brake operation changes after the hy-
draulic oil is changed, contact your nearest
Do not use the FREE FALL ACCELERATION SELEC-

TOR SWITCH during the free fall of heavy-weight
loads. Otherwise, a great shock may occur when the
free fall speed is changed. FREE FALL ACCELERATION
SELECTOR SWITCH
When the brake is released with the FREE FALL AC-

CELERATION SELECTOR SWITCH in "HIGH" posi-
tion, the drum pays out without load.
Be sure to set the FREE FALL ACCELERATION SE-
LECTOR SWITCH to the "NORMAL" position when
spooling out the wire rope.
7055-3 2-58
2. OPERATION
The speed may be slow when the light bucket is low-

ered by free fall in the cold weather. In such cases, turn
ON the Åghydraulic oil heat circuit selector switchÅh.
Produce an increase in the hydraulic oil temperature to
a certain temperature.
When the hydraulic oil has been replaced, the feeling of

brake operation may change from the experience in the
past. In this case, consult our designated service shop.
When the messages as shown right are indicated on

the cluster gauge during the operation, the free fall
movement will be disabled.
Lower the sling load and hook to the ground and turn
OFF the key switch.
Power supply will be shut off about 90 seconds later.
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, stop the operation and contact our des-
ignated service shop.
When the error message is indicated, do not stop

the engine with the sling load and hook held in the
air. If failed to observe this caution, the sling load or
the hook may fall.
2-59 7055-3
2. OPERATION
2.6 CLAMSHELL OPERATION

In clamshell operation, the control levers and brake
pedals are called with the designations shown in the
following figure.
CLOSING ROPE DRUM CONTROL LEVER

(FRONT DRUM)
CLOSING ROPE DRUM BRAKE
SELECTOR SWITCH (FRONT DRUM)
HOLDING ROPE DRUM CONTROL LEVER

(REAR DRUM)
HOLDING ROPE DRUM BRAKE

SELECTOR SWITCH (REAR DRUM)
BOOM DRUM CONTROL LEVER
MODE SELECTOR SWITCH (B)
CLOSING ROPE DRUM BRAKE PEDAL

(FRONT DRUM)
HOLDING ROPE DRUM BRAKE PEDAL
(REAR DRUM)
CLOSING ROPE DRUM SPEED
ADJUSTING KNOB
(FRONT DRUM)
HOLDING ROPE DRUM SPEED

ADJUSTING KNOB
(REAR DRUM)
7055-3 2-60
2. OPERATION
1. Set the drum speed adjusting knob to the HIGH

SPEED side.
When the drum speed adjusting knob is set to the posi-

tions other than the "HIGH" position, closing operation
and holding operation do not synchronize. HIGH
SPEED
HIGH
SPEED
HOLDING ROPE
CLOSING ROPE
2. Set the MODE SELECTOR SWITCH (B) to the

HIGH SPEED
"LOW SPEED" position (fixed low speed).
LOW SPEED
If the "HIGH SPEED" position is selected during heavy MODE SELECTOR SWITCH(B)
digging, the closing rope and the holding rope cannot
be synchronized. Set the MODE SELECTOR SWITCH
(B) to the "LOW SPEED" side (fixed low speed).
2-61 7055-3
2. OPERATION
2.7 HANDLING OF HYDRAULIC TAGLINE (OPTION)

1. Stop the engine, and set the tagline tension adjust-
ing knob to the lowest setting (fully turn to the left).
LEFT RIGHT
TURN TURN
LOW HIGH
2. Loosen the lock bolt.

CLAMP
3. Reeve the wire rope end through the outside of the
drum flange, and fix it with a clamp.
MOTOR
4. Set the other end of the wire rope to the bucket via FLANGE
the guide sheave.
5. Confirm that the tagline tension adjusting knob is at
the lowest setting (fully turned to the left), and then
start and idle the engine.
LOCK BOLT
Take caution that the tagline rope may be suddenly ten-
sioned or slackened when starting or stopping the en-
gine.
GUIDE SHEAVE
7055-3 2-62
2. OPERATION
6. To wind up the rope on the drum, turn the tagline

adjusting knob somewhat to the higher setting,
while tensioning the wire rope.
When the tag line rope is slack, the winding motion sud-
denly starts by operating the tension adjusting switch.
Keep clear of the drum and tag line rope.
Make sure to turn the adjusting switch to the weakest
position (turning fully counterclockwise) when you
come close to the drum and tag line rope.
7. Adjust the wire rope tension with the tagline adjust-

ing knob. Be sure to turn it carefully.
Turn to the right Tension increases.
Turn to the left Tension decreases.
8. Turn the flow adjusting handle (B) in case of wind- FLOW ADJUSTING HANDLE (B) SWING MOTOR COVER
ing speed need to be changed.
Remove the swingmotor cover to access the ad-
justing handle.
Turn clockwise : Winding speed decrease.
Turn counterclockwise : Winding speed increase.
At the time of shipment, the flow adjusting handle
set up at fully counterclockwise position(high speed
side).
When not using the tagline:

1. Fully wind up the wire rope on the drum, and fix the
wire rope end.
2. Set the tension adjusting knob to the lowest setting
(fully turn to the left).
3. Fix the drum flange with the lock bolt.
2-63 7055-3
2. OPERATION
2.8 HANDLING OF VIBROHAMMER

1. CAUTIONS WHEN USING
(1) Be sure to use a vibrohammer within the rated load.
• When driving a pile in : Total load = (Hook weight + Pile weight + Vibrohammer weight)
• When extracting a pile : Total load = (Hook weight + Pile weight + Vibrohammer weight +
Vibration starting force of vibrohammer x 1/4)
(2) Use of Lifting Wire Rope

Place a lifting wire rope in a way that vibration start-
ing force of the vibrohammer is not transmitted di-
rectly to the hook.
Use the hook and lifting wire rope commensurate with

Lifting
vibration starting force. wire rope
Buffer spring
2. CAUTIONS WHEN WORKING

(1) When starting operation
Place the vibrohammer on the head of the pile, and
start with the winch wire rope loosened.
(2) While operating
Adjust the hook lowering so that the buffer springs
are not tight (closely compressed). If the buffer
springs are tight, it is feared that vibration of the vi-
brohammer is directly transmitted to the hook, wire
rope and boom to damage them.
(3) When stopping operation
In order to minimize resonance generated when
stopping as far as possible, place the vibrohammer
on the head of the pile, and stop operation.
Do not operate (idle) the vibrohammer only or with
a pile lifted up in the air.
Do not overload when extracting a pile. Failure to

observe this precaution may result in injury or
death.
7055-3 2-64
2. OPERATION
3. CHECK AND MAINTENANCE

Since larger loads and vibrations are repeated in a
short time in vibrohammer operation comparing
with crane operation, damage to the boom and
hook, etc. and looseness of screws are apt to gen-
erate.
Be sure to check carefully before and after opera-
tion. If any abnormality is found, immediately repair
or replace.
The warranty does not cover any damage to the equip-

ment caused by failure to follow operating instructions
and cautions described above.
2-65 7055-3
2. OPERATION
7055-3 2-66

The Load Safety Device (Prevention device from Overload and Overhoist condition) is a safety device which is pro-
vided in order to prevent damage to the machine and/or overturn accident due to an overload. Therefore, be sure to
use this device in order to perform crane operation more safely. Descriptions in this chapter are applicable to the
typical model, and illustrations and displayed values may differ from those of the model actually used. In such a case,
take them as references.
3.1 ARRANGEMENT OF EQUIPMENTS

The item numbers of part names in the figure of arrangement of equipments correspond to the numbers in the de-
scription up to topic 3.3 CONNECTING PROCEDURE OF WIRING.
BOOM
LOAD DETECTOR (2) BOOM OVERHOIST

LIMIT SWITCH (7)
VIEW A
Inside of left guard
JUNCTION PANEL (4)

(FOR LOAD DETECTOR)
HOOK OVERHOIST
LIMIT SWITCH (9) CONTROLLER (1)
CABLE (12)
(FOR HOOK OVERHOIST
LIMIT SWITCH)
CABLE REEL (13)
BOOM ANGLE DETECTOR (3)
CRANE BOOM
OVERHOIST
LIMIT SWITCH (7) RELEASE SWITCH (10)
LOAD SAFETY DEVICE

BYPASS SWITCH (20)
JUNCTION PANEL (5)

(FOR ATTACHMENT CABLE)
3-1 7055-3
FIXED JIB
HOOK OVERHOIST
LIMIT SWITCH (9)
CABLE REEL (13)
AUXILIARY SHEAVE
HOOK OVERHOIST
LIMIT SWITCH (9)
7055-3 3-2
TOWER
TOWER JUNCTION BOX TOWER JIB OVERHOIST

LIMIT SWITCH (8)
HOOK OVERHOIST
LIMIT SWITCH (9)
CABLE (12)
(For hook overhoist limit switch)
CABLE REEL (13)

(For hook overhoist)
TOWER JIB ANGLE DETECTOR (3)
LOAD
DETECTOR (2)
JUNCTION CABLE (11)
LATCH LIMIT SWITCH
CABLE REEL (13)

(For tower cable)
CABLE REEL (13)

(For latch limit switch)
TOWER ANGLE
DETECTOR (3)
CONTROLLER (1)
TOWER BOOM OVERHOIST JUNCTION PANEL (5)

LIMIT SWITCH (Right) (18) (For attachment cable)
TOWER BOOM OVERHOIST
LIMIT SWITCH (Left) (19)
(LIMIT STOP)
3-3 7055-3
DETAIL OF OPERATOR'S ROOM INSIDE
HOOK OVERHOIST RELEASE SWITCH

(ANTI-TWO BLOCK)
BOOM OVERHOIST RELEASE SWITCH
OVERLOAD RELEASE SWITCH
RELEASE SWITCH MASTER KEY
DETAIL OF BOOM OVERHOIST LIMIT SWITCH
STRIKER LIMIT SWITCH
CRANE
STRIKER STRIKER
TOWER
Machine Machine
LIMIT SWITCH front side
front side
(Inside of right frame) (Inside of left frame)
7055-3 3-4
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS
CONTROLLER/MONITOR (1)
This figure indicates the machine condition, and issues
the signals for the alarms and stop.
V RELAY OUTPUT
POWER INPUT
CONNECTOR
O CONNECTOR
COMMUNICATION
CONNECTOR
LIMIT SWITCH
INPUT CONNECTOR
ANALOGUE
OUTPUT
CONNECTOR NOT USED
LOAD CELL INPUT NOT USED

CONNECTOR
BOOM ANGLE DETECTOR
INPUT CONNECTOR
All numeral value in the (1) DISPLAY in the chapter 3.

LOAD SAFETY DEVICE give an example only.
3-5 7055-3
LOAD DETECTOR (2)

This pin detects load.
CRANE TOWER JIB
LOAD
LINK DETECTOR
LOAD
DETECTOR
ANGLE DETECTOR (3)

This device detects the angle of boom and tower jib.
SENSOR
CONNECTOR
WATER
PROOF CAP
CABLE
JUNCTION PANEL (FOR LOAD DETECTOR) (4)

This is the junction panel for the cable from the load de-
tector and the cable from the operator's room.
To controller in
From load detector operator’s room
7055-3 3-6
ATTACHMENT JUNCTION PANEL (5)

This is the junction of the cable from the attachment de-
tector and the cable in the operator's room.
FROM CRANE CABLE REEL FROM TOWER CABLE REEL
CRANE TOWER
TOWER JUNCTION BOX (6)

This is the junction box for detector and limit switch.
JUNCTION CABLE
CONNECTOR
JIB ANGLE DETECTOR
JIB OVERHOIST
WIND SENSOR
(OPTION)
CRANE BOOM OVERHOIST LIMIT SWITCH (7)

This prevents the boom from overhoisting.
STRIKER BOOM OVERHOIST
When the boom hoist operation is stopped by the boom LIMIT SWITCH
overhoist limit switch, the stop function cannot be re-
leased by the boom overhoist limit switch.
When the tower crane is operated, the automatic stop

function will not be started even if the boom overhoist
limit switch is actuated.
3-7 7055-3
TOWER JIB OVERHOIST LIMIT SWITCH (8)

This switch prevents the tower jib from overhoisting.
When the tower jib hoist operation is stopped by the LIMIT SWITCH TOWER JIB
tower jib overhoist limit switch, the stop function cannot
be released by the boom overhoist release switch.
HOOK OVERHOIST LIMIT SWITCH (9)

This switch prevents the hook overhoisting.
LIMIT SWITCH
SHACKLE
WIRE ROPE
(For weight)
WEIGHT
7055-3 3-8
RELEASE SWITCH (10)

This switch is used to release automatic stop by safety
device. (Refer to page 2-9)

(ANTI-TWO BLOCK)
TOWER JUNCTION CABLE (11)

This cable connects the tower junction box (6) and the
attachment junction panel (5).
CABLE
WATER PROOF CAP WATER PROOF CAP
3-9 7055-3
CABLE (FOR HOOK OVERHOIST LIMIT SWITCH) (12)

This cable connects the limit switch (9) and the junction
panel.
CONNECTOR CABLE CONNECTOR
To junction panel To cable reel
SHORT CIRCUIT CAP
WATER PROOF CAP
CABLE
WATER PROOF CAP SHORT CIRCUIT CAP
CABLE REEL (13)
CABLE REEL
STOPPER
7055-3 3-10
OVER LOAD ALARM LAMP (14) (OPTION)
Indicated status Red Yellow Green

Loading ratio is less than 90 % O
Loading ratio ranges from 90 % to 100 % O
Loadting ratio is 100 % or more O
Hook overhoist O
Boom overlowering O
Boom overhoist O
Tower jib overhoist O
Tower jib overlowering O
Assembly posture (at assembly and disassembly) O
While the overload release switch is actuated O
ROTATED TYPE
RED
YELLOW
GREEN
OVERLOAD ALARM LAMP (14)
TOWER BOOM OVERHOIST LIMIT SWITCH (18)(19)

This prevents the tower boom from overhoisting.
If the crane is shut down automatically due to the acti- BACKSTOP
vation of left side limit switch, automatic stop function BACKSTOP
can not be released.
Machine Machine
front side LIMIT SWITCH front side
Inside of right frame Inside of left frame
3-11 7055-3
LOAD SAFETY DEVICE BYPASS SWITCH (20)

This switch is used to release the auto-stop function
when the load safety device becomes failed. LOAD SAFETY DEVICE
LOAD SAFETY DEVICE BYPASS CONFIGURATION
BYPASS SWITCH MAIN KEY SELECT SWITCH
• When the controller is functioning properly, by-

pass function does not become functional even
when the bypass switch is handled.
• During the crane work with using the bypass
switch, indication, warning or auto-stop does
not work.
(Auto-stop function by over hoist preventive
device works.)
• Repair or replace the controller immediately.
• LOAD SAFETY DEVICE BYPASS SWITCH MAIN

KEY OFF ON
In case of load safety device failure, the following

configuration select switch becomes effective.
MAIN KEY
• LOAD SAFETY DEVICE BYPASS

CONFIGURATION SELECT SWITCH
While the main key is turned ON, selecting the con-
figuration can release each auto-stop function.
TW
TW : Select when the tower configuration is to be se-

lected. CR
CR : Select when the crane configuration is to be se-
lected.
LF : Select when the luffing configuration is to be se- LF CONFIGURATION
lected. (Not used) SELECT SWITCH
7055-3 3-12
3.3 CONNECTING PROCEDURE OF WIRING

3.3.1 CRANE ATTACHMENT
DIAGRAM OF SYSTEM
1. CRANE ONLY
LOAD DETECTOR (2)
JUNCTION PANEL
FOR LOAD DETECTOR (4)
CONTROLLER (1) BOOM ANGLE DETECTOR (3)
JUNCTION PANEL
FOR ATTACHMENT (5)
V
CABLE REEL (13)
V
MAIN HOOK
AUXILIARY HOOK
OR FIXD JIB HOOK
RELEASE SWITCH (10) BOOM OVERHOIST LIMIT SWITCH (7)
2. CRANE AND TOWER
LOAD DETECTOR (2)
CONTROLLER (1) JUNCTION PANEL

BOOM ANGLE DETECTOR (3)
JUNCTION PANEL
FOR ATTACHMENT (5)
CABLE REEL (13)
MAIN HOOK
AUXILIARY HOOK
RELEASE SWITCH (10)

JUNCTION CABLE
FOR TOWER (11)
BOOM OVERHOIST LIMIT SWITCH (7)
TOWER BOOM OVERHOIST LIMIT SWITCH (Right) (15)

* When the crane operation, cannot be actuate.
TOWER BOOM OVERHOIST LIMIT SWITCH (Left) (16)

(LIMIT STOP) * It functions when the crane working.
3-13 7055-3
3. CONNECTING PROCEDURE
The cable should be handled with care in order to avoid 㪜㫅㫊㫌㫉㪼㩷㫋㫆㩷㫄㪸㫋㪺㪿㩷㫋㪿㪼㩷㫂㪼㫐㩷㫇㫆㫊㫀㫋㫀㫆㫅㩷㫆㪽㩷㫋㪿㪼㩷㫇㫃㫌㪾㩷㪸㫅㪻

damage. 㫉㪼㪺㪼㫇㫋㪸㪺㫃㪼㩷㫎㪿㪼㫅㩷㪺㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫋㪿㪼㩷㫋㪿㪼㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉㩷㫋㫆㩷㪸㫍㫆㫀㪻
㪻㪸㫄㪸㪾㪼㩷㫋㫆㩷㫋㪿㪼㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉㪅
When assembling the basic machine and attachment, KEY

(5 pieces)
make the connections as follows. And, when disassem-
bling, disconnect the connectors in the reverse order.
Before connecting the connectors, make sure that no
water remains in the connecting section of the connec-
tor in order to avoid water damage.
PLUG RECEPTACLE
Overload preventive device may not work correctly if
water enters into connectors. KEY
Ensure to turn the key switch OFF to avoid any adverse

affect to the electric devices when the connectors are in
the process of connecting or disconnecting.
PLUG RECEPTACLE
When making the connections, in order to prevent wa-

ter from entering,
(1) Tighten with hands fully.
(2) Connect the removed caps together.
(3) After disconnecting, install the cap securely.
LOAD DETECTOR (2)

CONTROLLER (1) (E)
(D) (F)
(C)
(B)
(A) (G)
[A] Fix the junction cables and cables for the limit switches to the boom and jib with the hangers.
HANGER
7055-3 3-14
[B] CONNECTING ATTACHMENT HARNESS TO BODY HARNESS
A CAP CAP
JUNCTION PANEL
DETAIL OF JUNCTION PANEL
To cable reel &

angle detector
CABLE
View A
[C] CONNECTING JUNCTION PANEL FOR LOAD DETECTOR (4)
FROM LOAD DETECTOR(2) TO CONTROLLER(1)
WATER PROOF CAP

(When the crane working,the
cap is connected mutually.)
[D] CONNECTING CABLE REEL (13)
• FOR OPERATING CRANE
To Hook overhoist
Connect this connector limit switch (9)
To Junction panel (5)

WATER PROOF CAP
SHORT CIRCUIT CAP
Do not operate crane with short circuit cap, con-

nect. Failure to observe this precaution may lead to
automatic stop and alarm unable to work in event of
hook overhoist and may lead to serious injury or
death.
3-15 7055-3
• FOR TRANSPORTATION
Disconnect connector
and connect short
circuit
Connect water proof cap
To junction panel
for attachment
WATER PROOF CAP
[E] CONNECTION OF CABLES AT BOOM TIP SECTION
MAIN HOOK OVERHOIST LIMIT SWITCH
A thimble hook for supporting the cable is provided on

the boom tip section. If the cable is not hung to this
hook, unreasonable force is loaded to the connector for
THIMBLE
connecting the hook limit switch.
Be sure to hang the thimble to this hook. Connect short cap (3P)
Connect water proof cap (2P)
Connection when only boom is used
[F] CONNECTION OF THE HOOK OVERHOIST LIMIT SWITCH SECTION

(Crane operation, with aux. sheave)
MAIN HOOK OVERHOIST LIMIT SWITCH
AUXILIARY HOOK
SHORT CAP (3P) OVERHOIST LIMIT SWITCH
Connect water proof cap (2P) SHORT CAP (3P)
Connection when only boom is used
7055-3 3-16
[G] CONNECTION AT THE JIB SECTION
HOOK OVERHOIST
LIMIT SWITCH (9)
CABLE FOR HOOK OVERHOIST
LIMIT SWITCH
CABLE REEL (13)
Connect this connector.
Hang hook to thimble.
Connect this connector.
HOOK OBERHOIST LIMIT SWITCH (9)
To jib foot
3-17 7055-3
3.3.2 TOWER ATTACHMENT
1. DIAGRAM OF SYSTEM
LOAD DETECTOR (2)

(CRANE)
CONTROLLER (1) JUNCTION PANEL

BOOM ANGLE
DETECTOR (3)
JUNCTION PANEL
FOR ATTACHMENT (5)
CABLE REEL (13)
LATCH LIMIT SWITCH
LOAD DETECTOR (2)

(TOWER CRANE)
CABLE REEL (13)
RELEASE SWITCH (10)
TOWER JIB OVERHOIST

LIMIT SWITCH (8)
JUNCTION CABLE
FOR TOWER (11) CABLE REEL (13)
HOOK OVERHOIST
LIMIT SWITCH (9)
WIND SENSOR (OPTION)
TOWER CABLE
JUNCTION BOX (6)
CRANE BOOM OVERHOIST LIMIT SWITCH (7)

(Not function for tower crane)
TOWER BOOM OVERHOIST LIMIT SWITCH

(Right) (15)
TOWER BOOM OVERHOIST LIMIT SWITCH

(Left) (16)
7055-3 3-18
2. CONNECTING PROCEDURE
The cable should be handled with care in order to avoid 㪜㫅㫊㫌㫉㪼㩷㫋㫆㩷㫄㪸㫋㪺㪿㩷㫋㪿㪼㩷㫂㪼㫐㩷㫇㫆㫊㫀㫋㫀㫆㫅㩷㫆㪽㩷㫋㪿㪼㩷㫇㫃㫌㪾㩷㪸㫅㪻

damage. 㫉㪼㪺㪼㫇㫋㪸㪺㫃㪼㩷㫎㪿㪼㫅㩷㪺㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫋㪿㪼㩷㫋㪿㪼㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉㩷㫋㫆㩷㪸㫍㫆㫀㪻
㪻㪸㫄㪸㪾㪼㩷㫋㫆㩷㫋㪿㪼㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉㪅
When assembling the basic machine and attachment,
connect the connectors as follows. KEY
(5 pieces)
And, when disassembling, disconnect the connectors
in the reverse order.
Prior to the connection of the connector, first, make
sure that no water remains in the connecting section of
the connector to avoid any water intrusion.
Be sure to remove water completely before the connec-
tion.
(1) Tighten with hands fully securely.
(2) Connect the removed caps each other too. PLUG RECEPTACLE
(3) After disconnecting, install the cap securely. KEY
Overhoist preventive device may not work correctly if

water enters into connectors.
PLUG RECEPTACLE
Ensure to turn the key switch OFF to avoid any adverse

affect to the electric devices when the connectors are in
the process of connecting or disconnecting.
Fix the junction cables and cables for the limit switches
to the boom with the hangers.
HANGER
[1] CONNECTION OF JUNCTION PANEL (5) FOR ATTACHMENT
Connect cable for boom Connect cable for load cell for tower
angle detector for tower (3)
Connect junction cable Connect cable for latch limit switch for tower
for tower (11)
3-19 7055-3
[2] CONNECTION OF CABLE AT CABLE REEL
Connect this connector Connect this connector
For latch limit switch (Lower side) For tower junction cable (Upper side)
Connect this connector
CAP
CABLE FOR HOOK OVERHOIST LIMIT SWITCH (14)
7055-3 3-20
[3] CONNECTION OF CABLE AT TOWER CAP
WIND SENSOR (OPTION)

CABLE FOR HOOK OVERHOIST LIMIT SWITCH
JUNCTION BOX FOR TOWER (6)
THIMBLE HOOK
THIMBLE
JUNCTION CABLE FOR TOWER (11)
Thimble hook
If the cable is not hang to this hook,
excessive force is loaded to the connector
for the tower junction cable.
Be sure to hang the thimble to this hook.
TOWER JUNCTION BOX
Connect tower junction cable (13)
Connect cable for jib angle detector (3)

Connect cable for hook overhoist limit switch (14)
Connect cable for wind sensor (OPTION) (Always connected)
3-21 7055-3
[4] CONNECTION OF CABLE AT TOWER JIB POINT
WATER PROOF CAP SHORT CIRCUIT CAP
Connect this connector
HOOK
THIMBLE
If the cable is not hang to this hook,

excessive force is loaded to the
connector for the hook limit switch.
Be sure to hang the thimble to this
hook.
7055-3 3-22
[5] CONNECTION OF CABLE AT LATCH

Connect the connector to the limit switch of latch.(2
place)
LATCH DISENGAGE DETECTION LIMIT SWITCH
to cable reel (13)

HANGER
Unconnect (2P)
LATCH ENGAGE DETECTION LIMIT SWITCH (3P)
3-23 7055-3
3.4 FUNCTION OF CONTROLLER/MONITOR
(3) SPEAKER (peep)

(2) BUZZER (beep)
m (1) DISPLAY
(4) CONTROL SWITCH
(5) COVER
(6) MEMORY CARD SLOT

(8) SETTING AND
ADJUSTING SWITCH
(7) MEMORY CARD (7) MEMORY CARD

(SMART MEDIA TYPE) (SD CARD TYPE)
All numeral value in the (1) DISPLAY in the chapter 3.

LOAD SAFETY DEVICE give an example only.
Do not touch these switches (8) and memory card (7)

unless approved by KOBELCO authorize distributor.
7055-3 3-24
1. DISPLAY
Current status of the crane is displayed.
(For details, refer to 3.5 OPERATING PROCE-
DURE OF CONTROLLER.)
2. BUZZER (beep)
Warning buzzers mainly related to overload (includ-
ing load limit warning) are issued. When the mo-
ment ratio is 90% or more, intermittent buzzers
(beep) are issued, and continuous buzzers are is-
sued when it is 100%. Intervals of intermittent buzz-
ers become shorter according to increasing of the
moment ratio.
Buzzer types Buzzers

Intermittent beep, beep, beep, .....
Continuous beep
3. SPEAKER (peep)
Boom or hook blocks overhoist and/or boom work-
ing area limit warning buzzers (peep) are issued.
When the boom exceeds the working area limit
prenotice point, intermittent buzzers are issued.
When the boom reaches the working area limit stop
point or the hook blocks or boom is overhoisted,
continuous buzzers are issued. Intervals of inter-
mittent buzzers become shorter according to ac-
cessing to the boom stop point.
Buzzer types Buzzers

Intermittent peep, peep, peep, .....
Continuous peep
1. Buzzers warning overhoist

Buzzers warning boom overhoist are issued when the limit switch is actuated. Buzzers warning hook overhoist
are issued when the limit switch is actuated to stop the hook blocks, and the winch lever is set to the "WINCH"
position or the boom lever is set to the "LOWER" position.
(No warning buzzer is issued while the levers are set to the "NEUTRAL" positions.)
2. Buzzers warning working area limit
Unless the prenotice point is set, warning buzzers are issued when the boom reaches the position 5 degree be-
fore or 1 m before the stop point.
3-25 7055-3
4. CONTROL SWITCH
Use this switch to change the display colors or decrease figures.

COLOR
* To change the colors, depress and hold this switch for three seconds or longer.
Use this switch to switch the mode between the MAIN and AUX. modes or increase figures.
MODE
* To change the current mode, depress and hold this switch for three seconds or longer.
Use this switch to adjust the brightness of the display screen (to darken) or select any in-
CONTRAST tended item.
* To adjust the contrast, depress and hold this switch for three seconds or longer. Then,
the brightness of the screen is changed a little every three seconds. To change the
brightness extremely, depress and hold it for several tens of seconds.
Use this switch to adjust the brightness of the display screen (to brighten) or select any in-
CONTRAST tended item.
* To adjust the contrast, depress and hold this switch for three seconds or longer. Then,
the brightness of the screen is changed a little every three seconds. To change the
brightness extremely, depress and hold it for several tens of seconds.
Use this switch to display or cancel the list of selection items.
Use this switch to decide or execute the selected item.
Use this switch to switch the mode between the assembly/disassembly and operation
modes.
* To change the current mode, depress and hold this switch for three seconds or longer.
Use this switch when it is necessary to lower the boom onto the ground at out of angle (low-
er limit angle/no rated load) without any load only.
Refer to page 3-57 " 3.BOOM /JIB LOWERING METHOD AT OUT OF ANGLE".
* Depress and hold this switch for three seconds or longer for cancellation.
7055-3 3-26
Do not lift any load when lowering the boom with
this switch .
Failure to observe this precaution may result in
overturning and/or damage of the machine and
may lead to serious injury or death.
5. COVER
DO NOT open unless you need to load the memory
card or operate the setting and adjusting switches.
6. MEMORY CARD SLOT

Insert the data memory card here.
SMART MEDIA TYPE SD CARD TYPE
7. MEMORY CARD
This card contains the data related to the crane ca-
pacity.
Always keep this card in the memory card slot and do

not remove or touch it.
SMART MEDIA TYPE SD CARD TYPE
8. SETTING AND ADJUSTING SWITCHES

This switches are used for upgrading of programs
or adjustment only.
1 2 3 4 5 6 7 8
Do not touch these switches unless approved by

3-27 7055-3
3.5 OPERATING PROCEDURE OF CONTROLLER

Referring to the setting items (following table), perform necessary setting.
Classification of Operation
Setting Item Operation after Operation at Initial
Daily Operation
Changing Attachment Erection
(1) Setting of crane configuration X O O
(2) Section of main/aux. lifting O O
(3) Setting of working area limit value
NOTE : O = Necessary X = Unnecessary = If Necessary

Since the set value is memorized in the controller even by stopping the engine and turning the power off, resetting
is not required.
TURNING POWER ON
When the key switch is set to the ON position, power is automatically supplied to the controller. If power is not sup-
plied to the controller, check the fuse in the fuse box located in the left side stand.
Just after power is supplied, the alarm sounds, but the alarm goes off soon. Then, start operation.
When power is supplied to the controller, the following screen is displayed on the controller as follows.
The main screen is displayed and the crane is ready to operate.
CRANE
Ma in s c re e n without s ilhoue tte Ma in s c re e n with s ilhoue tte
B=Boom
A=Actual
R=Rated
TOWER
Ma in s c re e n without s ilhoue tte Ma in s c re e n with s ilhoue tte
J= Ji b
B=Boom
A=Actual
R=Rated
Either of two main screens, main screen with crane silhouette (figure) or without crane silhouette, can be selected
with SETTING SCREEN procedure.
7055-3 3-28
3.5.1 SETTING SCREEN

The controller display patterns can be altered.
1. Press the MENU switch while the main screen is displayed. Then, the item selection screen appears.
V
V
O
V
V
Press
O
Main screen I t e m se l e ct i o n sc re e n
2. On the item selection screen, select the "SETTING" with the and switches, and press the SET switch.
Press
Sel ect
3-29 7055-3
3. Next, select the [SETTING OF THE SCREEN] among the items displayed on the screen with the and switch-
es, and press the SET switch.
Pres s
Sel ect
I t e m se l e ct i o n sc re e n
4. Then, the screen to alter display patterns appears. Select any intended item with the or switch, and
choose any intended choice between "NO" and "YES", with the or switch.
Pres s
Choice area
E xa m p l e : Cra n e si l h o u e t t e
Whether the crane silhouette (figure) is displayed or not can be chosen

CRANE SILHOUETTE
(refer to the next page).
BOOM POINT ELEV. Whether the boom point elevation is displayed or not can be chosen.
JIB OFFSET ANGLE Tower jib only.
THE CHOICE OF THE LANGUAGE The language used can be switched. Choose "ENG (SI UNIT)" for 7070.
* For both of the "BOOM POINT ELEV." and the "JIB OFFSET ANGLE", "YES" cannot be chosen at the same time.
7055-3 3-30
Press the MENU switch on the main screen. Then, the item selection screen appears.
CRANE
B : Boom
When thi s i tem i s sel ected, a rated l oad tabl e i s B.P : Boom Point
di spl ayed on the l ower part of the screen.
When thi s i tem i s sel ected, rated l oad curves and

current posi ti on are di spl ayed on the l ower part of
the screen.
When thi s i tem i s sel ected, a graph i ndi cati ng

worki ng area i s di spl ayed on the l ower part of the
screen wi th the worki ng area l i m i t setti ngs refl ected.
When thi s i tem i s sel ected, the setti ng screen appears.
When thi s i tem i s sel ected, any of l oad statuses recorded

i n the control l er i s di spl ayed here.
TOWER
JIB OFFSET ANGLE

B : Boom
J : Jib
When thi s i tem i s sel ected, the setting screen appears.
When thi s i tem i s sel ected, any of load statuses recorded

in the controller is displayed hear.
3-31 7055-3
• Screen when the [RATED LOAD TABLE] is select-

ed.
(Crane operation only)
• Screen when the [RATED LOAD CURVE] is select-

ed.
The maximum lifting load is displayed.
LOAD 16.0 t
Yellow area
In this area, the moment ratio is 90% or more
and less than 100%
The current point is indicated.
RADIUS
12.0 m
The maximum working radius is displayed.

Green area
In this area, the moment ratio is less than 90%
7055-3 3-32
• Screen when the [WORKING AREA] is selected.

*Upper limit of boom angle by.

limit function ; 71.0 deg.
Upper limit angle of capacity

Elevation limit by limit
data 80.0 deg.
function (m) 115
*Lower limit of boom angle by

limit function ; 35.5 deg.
*Lower limit of angle of capacity

data 30.0 deg.
*Limit of working radius by

limit switch function (m) 100
• Screen when the [LOAD RECORD] is selected.

Past load statuses are displayed. In respect of items such as moment ratio, working radius, boom length, jib
length, operation mode (Main/Aux.), and date,
(1) Ten records in order of the height of moment ratio.
When the [LOAD RECORD] is selected with the cursor and the SET switch is pressed, ten records are dis-
played in order of the height of moment ratio.
3-33 7055-3
(2) Ten records in order of the recentness of date are recorded and displayed.
When the or switch is pressed, ten records are displayed in order of the recentness of date.
The main screen is displayed and the crane is ready to operate. ( Example of main screen )
7055-3 3-34
3.5.2 SETTING OF THE CRANE CONFIGURATION
Always check if the selected crane configuration is correct. Failure to observe this precaution may result in
overturning of crane or damage of crane and may lead to serious injury or death.
Setting of the crane configuration is necessary in order to use the load safety device correctly according to the
type of the attachment, boom length, jib length, installation of the auxiliary sheave and type of the hook to be
used.
1. Setting
(1) Press the MENU switch while the main screen is displayed. Then, the item selection screen appears.
Pr ess
Sel ect
Ma i n s c r e e n Me n u s c r e e n
* If the load ratio is less than 90%,
“SETTING” cannot done.
(2) On the item selection screen, select the "SETTING" with the and switches, and press the SET switch.
Pr ess
SETTING Select screen
3-35 7055-3
(3) Next, select the [SETTING OF THE CRANE POSTURE] among the items displayed on the screen with the
and switches, and press the SET switch.
Pr ess Choose the type of crane attachment.
Sel ect Crane

Tower crane
SETTING OF THE CRANE

POSTURE
7055-3 3-36
(4) For setting hereafter, follow the instructions displayed on the item selection screen. The items to be selected
comprise the boom length, type of attachment, jib type, jib offset angle, main hook, auxiliary hook, and number
of the parts of line of wire rope on hook blocks.
Example of setting
• Select of attachment : Crane, Standard type
• Boom length : 30.5 m
• Jib type : With auxiliary sheave
• Main hook, Auxiliary hook : Main hook = 32 t, Auxiliary hook = 7 t
• Number of the parts of line of wire rope : Main hook = 4, Auxiliary hook = 1
The followings are examples of panel screen and the

actual panel screen may slightly differ.
Select in order of number (A) to (G)

(A) Attachment type selection screen is displayed.
Select "Crane".
Choose the type of crane attachment.
Crane Pr ess
Select
Select Tower crane
Crane
First screen
3-37 7055-3
(B) Boom length selection screen is displayed.

Select "30.5 m".
Choose the length of boom.

9.1 m 39.6 m
12.2 m 42.7 m
Select 15.2 m 45.7 m
Pr ess
18.3 m 48.8 m
21.3 m 51.8 m
Selec t 24.4 m
27.4 m
30.5 m 30.5 m
33.5 m
36.6 m
(C) Jib type selection screen is displayed.

Select "Aux. sheave".
Choose the type of jib.
Sel ect Pr ess

6.1 m
Aux. sheave
12.2 m
Select 18.3 m
7055-3 3-38
(D) Jib offset angle selection screen is displayed.

Select "Un-use", since the machine is not equipped
with the jib.
Choose the jib offset angle.

Sel ect
Un-use
Press
Select
(E) Main hook selection screen is displayed.

Select "32 t".
Choose a main hook.
55 t
32 t Press
Sel ect 19 t
Select
32 t
3-39 7055-3
(F) Auxiliary hook selection.

Select "7 t".
Choose a main hook.
Sel ect 7t
Select Press
7 t
(G) Lastly, the number of part line input selection.

Enter "4" for the main hook, and "1" for the auxiliary
hook.
Only the parts of line of wire rope on the hook for
which "Use" is selected is displayed.
Select MAIN/MAIN
Select
Select #7:,+$
Pr ess
Select In p u t
4
1
The par ts of line input s c r een
Check the settings

After all the settings and input are complete, the
screen automatically returns to the main screen.
7055-3 3-40
In case of error occurred After all settings are complete,

the corresponding data is searched. If no correspond-
ing data is found, an error message is displayed and a
buzzer sounds.
All controller/monitor display messages may be subject

to grammatically incorrect phrasing due to computer-
ized language translations. If the message being dis-
played is unclear, contact your nearest KOBELCO
representative for clarification.
If an error occurs, press the or switch to reset the

screen status. Then recheck the installed attachment
and reenter the settings.
SETTLEMENT OF NUMBER
When date is normally read in :
OF PART LINE
There are no applicable crane data.
3 Push SET if you set it up again. Push MENU if it
1
is stopped.
There are no applicable crane data.
Push SET if you set it up again. Push MENU if it
is stopped.
The screen automatically returns to the main screen, and the settings are displayed on the lower part of the
screen.
3-41 7055-3
3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING
Always check if the selected crane configuration is

correct.
overturning of crane or damage of crane and may
lead to serious injury or death.
For crane
If the machine is equipped with the main hook (front
drum) and aux. hook (rear drum) together, be sure to
select either of the main (front drum) or the aux. (rear
drum) according to the hook to be used, and to select
the capacity.
Selecting procedure is as follows:
For tower crane

Changeover is not necessary because the machine is
equipped only with the main hook.
By pushing switch on the controller, select the lift-
ing. Press and hold the switch for three seconds or

longer.
Every pushing toggles the mode of the main lifting and
aux. lifting alternately.
MAIN/JIB/AUX.
indicator
Aux.
Main
In case of the pictorial

make of “crane” , marks
of main hoist and auxiliary
hoist light up alternately.
Without silhouette With silhouette

(Crane)
Main
With silhouette
(Tower crane)
7055-3 3-42
3.5.4 SETTING OF WORKING AREA LIMIT VALUE

When working inside a building or in a narrow
place, the sphere in which the machine can be op-
erated can be set as desired in addition to the rated
range specified by the Load Safety Device. (Func-
tion to limit the working area)
Working area limit value can be set for the boom
upper and lower limit angles, maximum load, maxi-
mum working radius, and maximum point height.
For the items other than the maximum load, warn-
ing point and stopping point can be set individually.
If only the stopping point is set, a warning is provid-
ed at the specified position (refer to the table shown
below).
When the boom reaches the warning point, inter-
mittent buzzer sounds are issued. When the boom
reaches the stopping point, continuous buzzer
sounds are issued, and the boom is automatically
stopped if it is operated in the dangerous direction.
Both of intermittent buzzer sounds and continuous
buzzer sounds are issued only when the control le-
ver is operated toward the dangerous direction.
They are not issued when the lever is set to the
neutral position (or the boom is operated in the safe
direction), even if the boom reaches the warning or
stopping point.
By this setting, contacting accidents of the boom
and etc. due to careless mistake during operation
can be prevented.
Working Area Limit Value possible to be set.

Symbol Working Area Limit Setting Unit Warning Point
Limit value of upper and lower limit boom Setting on 0.1 degrees of 5 degrees before limit value
A
or tower boom angle unit (When warning point is not set)
Limit value of lifting load
B Setting on 0.1 t of unit 90%
(Main / Aux.)
Limit value of operating radius 1 m before limit value
C Setting on 0.1 m of unit
(Main / Aux.) (When warning point is not set)
1 m before limit value
D Limit value of point height Setting on 0.1 m of unit
(When warning point is not set)
Limit value of upper and lower limit jib an- Setting on 0.1degrees of 5 degrees before limit value
E
gle unit (When offset point is not set)
Plural settings of above A through E are possible si-

multaneously. The value set once is memorized un-
til it is changed even by turning power off.
The intermittent alarm is issued before reaching the
limit value, and when operation exceeds the limit
value, continuous alarm sounds, and operation is
automatically stopped.
3-43 7055-3
1. Setting
(A) Press the MENU switch while the main screen is displayed. Then, the item selection screen appears.
Press
Ma i n s c r e e n
(B) On the item selection screen, select the "SETTING" with the and switches, and press the SET switch.
Press
Sel ect
7055-3 3-44
(C) Next, select the [SETTING OF THE WORKING TERRITORY LIMITATION] among the items displayed on the
screen with the and switches, and press the SET switch. The working area limit setting screen is dis-
played.
Sel ect
It e m s e l e c t i o n s c r e e n
Two types of input methods are available for entering

numerical characters; teaching method and increase/
decrease method. To enter numerical characters, move
Press
the boom to the point to be limited in advance. In this
status, move the cursor (light blue) onto the intended
limit item, and press the SET switch. The numerical

characters on the cursor indicate the current boom po-
sition. If the displayed numerical characters are accept-
able, press the SET switch (teaching method). If you

need to change the displayed value further, increase or
decrease it with the or switch until the desired
value is obtained, and press the SET switch (increase/

decrease method).
The functions of the limit items set as shown above will
be effective.
• The maximum point height cannot be set for the
main and auxiliary hoist modes individually. In the
main hoist mode, the limit function is activated Wo r ki n g a r e a l i mi t s e t t i n g s c r e e n
when the boom tip reaches the set point. In the aux-
iliary hoist mode, it is activated when the jib (or aux-
iliary sheave) tip reaches the set point.
• When inputting limit load values, only the increase/
decrease method is available.
3-45 7055-3
Warning point and stopping point

For the items that both of warning point and stopping
point can be set, the warning point must be set to the
side safer than the stopping point. Failure to observe
this rule during setting will lead to the display of warning
messages and rejection of set values. In such a case,
retry setting.
When canceling input halfway

Canceling is possible just after the cursor is moved onto
the item intended and the SET switch is pressed. Press
the MENU switch. Then, the screen returns to the previous

one, and you can retry input from the beginning.
When limit function is not used

If [0.0] is input for a limit item, the limit function for the
item will not work. Thus, input "0.0" for each limit item
when you do not need the limit function for it.
7055-3 3-46
3.5.5 SETTING OF THE TIME

The current time is displayed on the lower right part of the main screen.
If the displayed time is not correct, adjust it by using the following procedures.
1. Setting Time
(A) Press the MENU switch while the main screen is displayed. Then, the item selection screen appears.
Press
Ma i n s c r e e n
(B) On the item selection screen, select the "SETTING" with the and switches, and press the SET switch.
Press
Sel ect
3-47 7055-3
(C) Next, press the "SETTING OF THE TIME" among the items displayed on the screen with the and switch-
es, and press the SET switch.
Pres s
Sel ect
I t e m se l e ct i o n sc re e n
(D) The time setting screen appears. Select any intended item with the or switch, and adjust it with the
or switch.
After adjusting all the settings, press the SET switch to complete the setting.
SELECT
㪈㪋㪑㪇㪐
Mai n scr een

This input time is indicated
switch:movement of cursor ( MARK)
switch:increase
switch:decrease
switch:set completion
7055-3 3-48
3.6 LOAD HISTORY

This controller is equipped with the recording function
of the dangerous condition in order to investigate the
cause of accident. (Load history function)
• In case of load ratio exceeding 100%

• In case that the boom angle, tower jib angle exceed
the upper limit angle.
• In case that the Load safety device bypass main
key or load safety device release switch input is de-
tected.
In case of the above, recording will start.
The peak value and 5 seconds before this is recorded
on every 1 second interval.
The peak value and 4 seconds after this is recorded on
every 1 second interval.
So, total 10 second conditions are recorded.
3-49 7055-3
3.7 WARNING ALARM AND AUTOMATIC STOP

3.7.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP
When the machine enters respective hazardous
condition, the controller issues warning alarm and/
or stops the machine automatically as shown in the
following table. When the machine stops automati-
cally, immediately operate the machine to the safer
side.
CRANE
Indication and Stop

Color change in indicator Buzzer
Hazardous Code
Overload Overhoist Automat-
Conditions Boom Loading Actual Rated Operating display
Mode warning warning ic stop
angle ratio load load radious **
buzzer buzzer
Loading ratio Intermit-
- Yellow - - - - (24) - -
more than 90 % tent
Loading ratio Continu-
- Red - - - - (5) - Stop
more than 100% ous
Main hook block Continu-
- - - - - Red (17) - Stop
overhoist ous*
Auxiliary hook Continu-
- - - - - Red (18) - Stop
block overhoist ous*
Continu-
Boom overhoist Red - - - - - (8) - Stop
ous*
Boom overhoist Continu-
Red - - - Red - (21) - Stop
(limit) ous*
Boom over low- Continu-
Red --- --- 0.0 Red - (7) - Stop
ering ous
* Only when the lever is operated in the more dangerous direction.

** Refer to error code table in page 3-72.
7055-3 3-50
TOWER
Indication and Stop

Color change in indicator Buzzer
Hazardous Code
Operat- Overload Overhoist Automat-
Conditions Boom Loading Actual Rated Jib display
ing Mode warning warning ic stop
angle ratio load load angle **
radious buzzer buzzer
Loading ratio
Intermit-
more than - Yellow - - - - - (24) - -
tent
90%
Loading ratio
Continu-
more than - Red - - - - - (5) - Stop
ous
100%
Hook Continu-
- - - - - - Red (17) - Stop
overhoist ous*
Boom Continu-
Red - - - - - - (8) - Stop
overhoist ous*
Boom
overhoist Continu-
Red - - - Red - - (21) - Stop
(No.1 limit ous
switch)
Boom Continu-
Red - --- 0.0 Red - - (7) - Stop
overlowering ous
Boom
overhoist Continu-
Red - - - Red - - (60) - Stop
(No.2 limit ous
switch)
Jib Continu-
- - - - - Red - (14) - Stop
overhoist ous
Jib
Continu-
overhoist - - - - Red Red - (22) - Stop
ous
(Limit switch)
Jib over Continu-
- - --- 0.0 Red Red - (13) - Stop
lowering ous
* Only when the lever is operated in the more dangerous direction.

** Refer to error code table in page 3-72.
3-51 7055-3
3.7.2 CONTENTS OF AUTOMATIC STOP

When the machine stops automatically due to re-
spective hazardous condition, the machine cannot
be operated in the X mark direction in the following
figures. Since the direction without the X mark is
safer side, the machine can be operated in this di-
rection even without operating the release switch.
When the machine stops automatically, immediate-
ly operate the machine to the safer side.
CRANE OPERATION
(1) OVERLOAD (2) HOOK OVERHOIST (Anti-two Block)
(3) BOOM OVERHOIST (4) BOOM OVERHOIST

(Controlled by LMI) (Controlled by boom overhoist limit switch)
Generally, when the boom is overhoisted, the LMI con-

troller stops boom hoist automatically, according to the
rating conditions.
Even if the operator tries to raise the boom higher with
the boom overhoist release switch, the boom overhoist
limit switch (located near the boom foot) automatically
stops.
The automatic stop cannot be released at this time.
7055-3 3-52
TOWER CRANE OPERATION
(1) OVERLOAD (2) HOOK OVERHOIST
(4) TOWER BOOM OVERHOIST

(3) TOWER BOOM OVERHOIST (Controlled by No.1 limit switch)
Right side
(Automatic stop can be released)

*In case that the jib and the boom are connected
with the jib latch, both the hook hoist and the jib
hoist are shut down automatically .
(5) TOWER BOOM OVERHOIST
(Controlled by No.2 limit switch)
Left side
(Automatic stop cannot be released)
3-53 7055-3
(6) TOWER BOOM OVERLOWERING (7) TOWER JIB OVERHOIST
(8) TOWER JIB OVERHOIST

(Controlled by overhoist limit switch) (9) TOWER JIB OVERLOWERING
( Automatic stop cannot be released)
Generally, when the boom is overhoisted, the controller

of LMI functions to stop boom hoist automatically ac-
cording to the rating conditions.
Even if the operator tries to raise the tower boom or
tower jib higher with the overhoist release switch, the
tower boom or tower jib overhoist limit switch (No.2 limit
switch) automatically stops. The automatic stop cannot
be released at this time.
7055-3 3-54
3.7.3 RELEASE OF AUTOMATIC STOP

1. AUTOMATIC STOP RELEASE SWITCH
Use the release switch only under necessary cir-

cumstances such as disassembling and assem-
bling the machine.
Do not operate crane with keeping the release

switches fixed in the RELEASE position.
overturning and/or serious damage of the crane
and leads to serious injury or death.

(ANTI-TWO BLOCK)
2. OPERATION OF AUTOMATIC STOP RELEASE

SWITCH
Use this switch only when releasing the automatic

stop to operate the machine for emergency or
maintenance work is required.
• OVERLOAD RELEASE SWITCH (LMI)
This switch releases the automatic stop function Automatic return
due to overload and when the operating radius ex-
ceeds the limit. RELEASE
By placing the switch in the RELEASE position, the
automatic stop is released.
3-55 7055-3
• BOOM OVERHOIST RELEASE SWITCH

This releases the automatic stop function due to Automatic return
boom overhoist.
By placing the switch in the RELEASE position, the RELEASE
• HOOK OVERHOIST RELEASE SWITCH

(Anti-two Block) Automatic return
This switch releases the automatic stop when the

hook is overhoisted. RELEASE
By placing the switch in the RELEASE position, the
When releasing the automatic stop function due to

overhoist, push and hold the release switch as it is.
If released, the switch returns to the neutral position
to allow the automatic stop function to operate.
When releasing the automatic stop function, be
sure to operate the corresponding release switch.
Even by operating a release switch without relation,
the automatic stop function cannot be released.
Use the release switch only under necessary cir-

cumstances such as disassembling and assem-
bling the machine.
Do not operate crane with keeping the release

switches fixed in the RELEASE position.
overturning and/or serious damage of the crane
and leads to serious injury or death.
7055-3 3-56
• RELEASE SWITCH MASTER KEY

Release function of automatic stop with "OVER-
LOAD RELEASE SWITCH", "BOOM OVERHOIST
RELEASE SWITCH", and "HOOK OVERHOIST
RELEASE SWITCH" can be controlled with this
key.
This key can be removed when it is at the "LOCK"
position.
Release of automatic stop with the release switch-
es is cancelled by turning this key to the "LOCK"
position. It becomes possible when the key is
turned to the "RELEASE" position.
(See page 2-9No. 10.)
3. BOOM /JIB LOWERING METHOD AT OUT OF AN-

GLE
Set up
mode switch
(1) When lowering only main boom (boom length is Boom lowering
33.5 m or shorter) with aux. sheave. switch
If the boom is equipped with the hook block only,

the boom can be lowered onto the ground without
stopping. However, the automatic stop works be-
cause of the overhoisted hook when the limit switch
weight touches the ground and opens the point of
contact in the limit switch.
Cancel this mode when assembling
To lower the boom further, return the control lever to is completed and you causea
boom
the neutral position, and press the set up mode This mode is canceled when an
setup switch is pushed.
switch once for more than 3 (three) seconds.

Then, the SETUP mode is actuated, and boom low-
ering becomes possible.
Screen displayed when the switch is pressed.
3-57 7055-3
(2) When lowering only main boom (boom length is

36.6 m or longer) with aux. sheave or fixed jib.
Lower the boom until it is automatically stopped.

When it is stopped, press the boom lowering switch
once for more than 3 (three) seconds.

Then, the boom lowering mode is actuated, auto-
matic stop function is released, and boom lowering
becomes possible.
However, when the hook overhoist weight touches
the ground, the hook overhoist automatic stop func-
tion is actuated.
To lower the boom further, return the control lever to

(7) Boom is lowered too much
the neutral position, and press the set up switch
Screen displayed when the boom is lowered and
once.
stopped at the lower limit angle.
Then, the SETUP mode is actuated, and boom low-
ering becomes possible.
When pressing or switch, hold it for three sec-

onds or longer.
(1) Out of angle
(1) Out of angle

is completed and you causea
boom
This mode is canceled when an
(1) Out of angle
7055-3 3-58
(3) When lowering tower jib

Set the tower angle about 90 degrees, lower the jib
until it is automatically stopped. When it is stopped,
press the boom lowering switch once for more

than 3(three) seconds. The jib lowering mode is ac-
tuated, automatic stop function is released, and jib
lowering becomes possible.
(13) Jib is lowered too much
(13) Jib is lowered too much
Screen displayed when the jib is lowered and

stopped at the lower limit angle.
(1) Out of angle
(1) Out of angle
3-59 7055-3
4. RELEASE OF AUTOMATIC STOP WHEN

ASSEMBLING AND DISASSEMBLING THE
BOOM
(1) Release by Short-circuiting the Cable for the Hook

Overhoist Limit Switch
When the cable for the hook overhoist limit switch Connect this connector
is not completely connected, the automatic stop

function operates. When raising or lowering the
boom or when winding the winch wire rope onto the
drum in assembling and disassembling work, make
the following measures. To Base machine
Using the short circuit cap, short-circuit the cable WATER PROOF CAP
SHORT CIRCUIT CAP
for the hook overhoist limit switch in the place of the
cable reel for the boom base section.
Connect connector
Absolutely do not use the short circuit cap except and connect short
when disassembling and assembling the basic ma- circuit cap.
chine.
rious accident and leads to mode serious injury or To Base machine
death.
WATER PROOF CAP
7055-3 3-60
(2) Release by Set up Mode

When the attachment is not installed and when the
boom angle detector and hook overhoist limit
switch cable are not completely connected, the au-
tomatic stop function operates.
The load safety device can be entered the SETUP/
mode by pressing the mode set up switch once. is completed and you causea
boom
At this time, the automatic stop and alarm sounds This mode is canceled when an
are canceled. However, remember that the auto-
matic stop by the boom overhoist limit switch works.
When the load safety device enters the SETUP
mode, the boom angle and messages to inform of
the SETUP MODE are displayed on the screen.
When the boom is raised after the assembly/disas-
sembly is completed, the mode can be switched to
the operation mode by pressing the SETUP switch
once again. If the boom is raised during the
SETUP mode, the SETUP mode is automatically
switched to the operation mode when the boom an-
gle is 15 degrees. (Tower angle is about 40 de-
grees.)
Therefore, the SETUP mode cannot be actuated
while the boom is raised even when the SETUP
switch is pushed.
The SETUP mode is cancelled when the power to
the controller is shut down. Therefore, press the
switch again to enter the SETUP mode when

the power is supplied to the controller.
When pressing switch, hold it for three seconds or

longer.
The SET UP mode cannot be actuated while the boom

is raised or any load applied to the load cell even when
the SET UP switch is pushed.
3-61 7055-3
3.8 INSPECTION
3.8.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF
ATTACHMENT IS COMPLETED
After the assembly of attachment is completed, inspect
the safety device relation for performance, and confirm
that there is no abnormality, then raise the boom.
Besides, since sometimes the limit switch may already
operate, pull the limit switch once to set to the safe con-
dition, then inspect respectively as follows:
CRANE ATTACHMENT
BOOM OVERHOIST LIMIT SWITCH MAIN HOOK OVERHOIST LIMIT SWITCH

(BOOM FOOT) (MAIN HOOK) AUXILIARY HOOK OVERHOIST
LIMIT SWITCH (AUX.HOOK)
• Inspection of Boom Overhoist Limit Switch

Push the roller of the limit switch by hand, and con-
firm that the boom angle indicator on the controller
turns red and either of the following messages ap-
pears in the message display window.
If the right side of the backstop is pressed, a mes-
sage "(21) Boom over hoist" will appear.
64.6 95.8
67
Boom foot limit switch
17.8
( 21 ) Boom over hoist
26.4
47.1
(21) Boom over hoist

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
HOOK : Ma Use Aux. Use
L/No. : Ma Aux.
Main screen
7055-3 3-62
• Inspection of Main Hook Overhoist Limit Switch

Push up the weight lifting rope of the limit switch to
confirm that the message of "(17) Hook over hoist"
is displayed in the message display window, and
pull the rope with hand to confirm that this message
disappears.
64.6 95.8
67
17.8
26.4 ( 17 ) Hook over hoist
47.1
(17) Hook over hoist

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
• Inspection of Auxiliary Hook Overhoist Limit Switch

disappears.
64.6 95.8
67
17.8
26.4 ( 18 ) Hook over hoist
47.1

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
3-63 7055-3
TOWER CRANE ATTACHMENT
TOWER BOOM OVERHOIST

LIMIT SWITCH
HOOK OVERHOIST
LIMIT SWITCH
TOWER JIB OVERHOIST

LIMIT SWITCH
• Inspection of Tower Boom Overhoist Limit Switch

Push the roller of the limit switch with hand, and
confirm that the boom angle indicator turns into red,
and the message of "(21) Boom over hoist" or "(60)
Boom overhoist" is displayed in the message dis-
play window.
The message when pushing limit switch (No.1) is
"(21) Boom Overhoist".
The message when pushing limit switch (No.2) is
"(60) Boom Overhoist".
64.6 95.8
( 21 ) Boom over hoist

67
or
17.8
26.4 ( 60 ) Boom over hoist
47.1
(21) Boom over hoist

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
7055-3 3-64
• Inspection of Tower Jib Overhoist Limit Switch

(Right and Left)
Push the roller of the limit switch with hand, and
confirm that the boom angle indicator turns into red,
and the message of "(22) Jib over hoist" is dis-
played in the message display window.
64.6 95.8
67
17.8
26.4
( 22 ) Jib over hoist
47.1
(22) Jib over hoist

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
• Inspection of Main Hook Overhoist Limit Switch

disappears.
64.6 95.8
67
17.8
26.4
( 17 ) Hook over hoist
47.1

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
3-65 7055-3
• Inspection of Latch Limit Switch

LATCH
Pushing the rod of limit switch at the "ENGAGE"
(RED) ON OFF
side by hand, the controller's indicator "ON" will turn
red.
LATCH
Pushing the rod of limit switch at the "DISENGAGE"
ON OFF (GREEN)
side by hand, the controller's indicator "OFF" will
turn green.
64.6 95.8
67
17.8
26.4
LATCH
LATCH
47.1
ON OFF
ON OFF

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
Main screen
7055-3 3-66
• Check of the load safety device with controller

If it is difficult to check the automatic stop function
in case of overload by lifting a load actually, the
function can be checked with the LMI controller.
Access the main screen, and press and hold the

SET switch. Then, the device simulates the overload
status and the automatic stop function is actuated
(LMI check mode).
In this status, ensure that the hoisting of the hook

blocks and the lowering of the boom are impossi-
ble.
The LMI check mode is started when approx. three
seconds have passed after the SET switch is

pressed, and the mode continues until the switch is
released. The message of "(56) Check mode (Over
load condition)" is displayed on the screen during
the LMI check mode.
64.6 95.8
67
17.8
26.4
47.1
(56) Check mode (Over load condition)

Crane STD. Weight
BOOM : 100 m JIB : 30 m
Jib angle 10
L/No. : Ma Aux.
(56) Check mode (Over load condition)
3-67 7055-3
3.8.2 INSPECTION AFTER ERECTING THE ATTACHMENT

Operate the machine up to the respective hazardous
condition, and confirm the boom overhoist automatic
stop/warning alarm functions and indications of the
controller have no abnormality. The automatic stop an-
gle of the boom in the overhoist side is shown in the fol-
lowing table. Besides, the automatic stop angle in the
over-lowering side varies according to the boom length.
Classification Kind of Overhoist Classification of Stop Automatic Stop Angle

LMI Controller 80.0 to 80.5 degrees
Crane Boom overhoist
Limit switch 81.5 to 82.5 degrees
LMI Controller 90.0 degrees
Tower Boom overhoist Right side limit switch 90.2 degrees
Tower Left side Limit switch 90.7 degrees (Note.2)
LMI Controller 75.0 degrees (Note.1)
Jib overhoist
Limit switch 77.0 degrees (Note.2)
* Angle of automatic stop by LMI depends on the conditions such as boom length and jib length.
• Note 1
The automatic stop angle for the tower jib overhoist
is the value assuming the tower boom angle is at 90
g.
degrees. 13 de 13
deg
75
.
de
If the tower boom angle is changed, then the value
g.
65
77
will vary accordingly.
67
de
de
g.
g.
For example, when tower boom angle is at 80 de-
deg
.
grees, the stop angle for the jib will be set as shown
in the figure B on the right.
90
80
de
de
g.
g.
(A) (B)
7055-3 3-68
• Note 2
TOWER BOOM
The stop angles for the tower boom overhoist left
side limit switch and the tower jib overhoist limit
switch are reference angles.
The accurate size should be defined by the size of
the rod and the spring of the backstop.
605 ± 5 mm (90.7 )
TOWER JIB
377 to 390 mm (76.5 to 77 )
3-69 7055-3
3.9 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE

1. WELDING WORK
Avoid damage of the controller and other electrical
parts from a high electric current by welding work to
the machine. When welding work to the machine,
stop the engine, and turn the key switch to the OFF
position and also disconnect the battery cable to be
more complete.
2. OBSTRUCTION OF ELECTRIC WAVE (JAM-
MING)
When a broadcasting station is near and when the
machine is subjected to jamming, consult your local
3. OBSTRUCTION OF STATIC ELECTRICITY
If the surface of the controller is rubbed with a dry
nylon cloth, etc. strongly, static electricity is gener-
ated.
Static electricity has a bad effect on the controller.
Do not rub strongly.
Refer to page 1-7 "Required Clearances for Operation

Near High Voltage Power Lines".
7055-3 3-70
3.10 INDICATION OF ERRORS AND REMEDY

When an error is detected, the message is indicated on
the message display window.
When an error code is indicated, the machine stops au-
tomatically, and the buzzer sounds. However, releasing
by operating the overload release switch is possible.
Error Message Table

Malfunction Error Code and the Message Buzzer Remedy
Crane configuration (34) Code setup error beep Reset crane configuration.
(35) Adjustment data are unusual.
Adjustment data peep Readjustment.
Adjust again.
(36) The trouble of the load cell for the
Load detector (Crane) beep Replace load detector or cable.
boom (1).
(44) The trouble of the boom base angle Replace boom angle detector or ca-
Boom angle detector beep
sensor. ble.
Abnormality in communi- Check communication line.
(57) Communication unusual. -
cation with total controller Replace total controller or LMI.
Replace load detector or cable or
Load detector (Tower) (38) The trouble of the load cell for the jib beep
junction box.
(47) The trouble of the lower jib angle sen- Replace jib angle detector or cable
Jib angle detector beep
sor or junction box.
When boom angle detector is replaced, the controller

should be adjusted.
Ask your nearest KOBELCO authorize distributor for
the controller adjustment.
3-71 7055-3
3.11 INDICATION OF MESSAGE AND ALARM

Note that the machine is not malfunctioned when mes-
sages shown below are displayed depending on the
conditions of the crane. These messages disappear SPEAKER
(peep)
when the control lever is operated to the safer side. BUZZER
(beep)
CODE AND THE MASSAGE

DISPLAY WINDOW
Message Table
Code and the Message Buzzer Display conditions (machine status)
(1) Out of angle. - Out of capacity set range
The hook overhoist automatic stop release switch
(2) Stop by the hook overhoist is canceled. -
is actuated.
The boom overhoist automatic stop release switch
(3) Stop by the boom/jib overhoist is canceled. -
is actuated.
(4) Stop by the overload is canceled. - Overload status is canceled.
(5) Overload condition. beep The loading ratio exceeds the specified level.
(6) Head wind is strong. beep The head wind alarm is issued.
The boom is out of the maximum working radius
(7) Boom is lowered too much. beep
area.
The boom is out of the minimum working radius
(8) Boom is raised too much. peep
area.
(13) Jib is lowered too much. beep The jib offset angle is larger than the set value.
(14) Jib is raised too much. peep The jib offset angle is smaller than the set value.
(17) Hook overhoist. peep The main hook overhoist limit switch is actuated.
(18) Hook overhoist. peep The aux. hook overhoist limit switch is actuated.
(21) Boom overhoist. peep The boom overhoist limit switch is actuted.
(22) Jib overhoist. peep The jib overhoist limit switch is actuated.
beep,
Loading ratio is 90% or more, and lower than the
(24) Overload forecast. beep
specified level.
...
Lifting load exceeds the lifting load limit value set
(25) Reached the setup value of the load limitation. beep
by operator.
beep,
Lifting load exceeds 90% of the lifting load limit
(26) Reached 90% of the load limitation value. beep
value set by operator.
...
The boom reaches the boom angle upper limit
(27) Boom angle reached upper limitation value. peep
point (stop point) set by operator.
The boom reaches the boom angle lower limit
(28) Boom angle reached lower limitation value. peep
point (stop point) set by operator.
The jib reaches the jib angle upper limit point (stop
(29) Jib angle reached upper limitation value. peep
point) set by operator.
7055-3 3-72
Message Table
Code and the Message Buzzer Display conditions (machine status)
The jib reaches the jib angle lower limit point (stop
(30) Jib angle reached lower limitation value. peep
point) set by operator.
The boom reaches the working radius limit point
(31) Working radius reached limitation value. peep
(stop point) set by operator.
The boom reaches the boom height limit point
(32) Boom point elevation reached limitation value. peep
(stop point) set by operator.
The luffing boom overhoist limit switch (left) is ac-
(60) Boom overhoist peep tuated. CONFIRMING PROPER FUNCTIONING
OF LOAD SAFETY DEVICE
beep,
The tension of the hoist wire rope exceeds the
(61) Jib reeving rope tends to draw. beep
forecast alarm value, during erecting the tower.
...
The tension of the hoist wire rope exceeds the
(62) Jib reeving rope is drawn tight. beep
warning alarm value, during erecting the tower.
The input signal from the counterweight detector
(63) CWT detect error. beep
does not match the data.
In conditions with , the buzzer sounds only when the control lever is operated in the direction / function of danger-
ous side.
3-73 7055-3
3.12 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE

The load safety device should be checked with follow-
ing items at least once a year.
1. Indication of operating radius
(1) Lower the boom and stop it within allowable work-
ing range.
(2) Measure the actual operating radius, and be sure to
check correct indication of operating radius on the
controller.
2. Indication of actual load

(1) Lift a known weight (load).
(2) Be sure to check the reading of actual load on the
controller with total load for correct indication.
The total load should be weight of load being lifted,
weight of hook block and weight of lifting device.
The total safety device should be adjusted when the

discrepancy of indication exceeds the allowable range.
Ask your nearest KOBELCO authorize distributor for
the controller adjustment.
7055-3 3-74

This section covers the basic machine unloading from
and loading on a transport trailer, with the condition of
the basic machine of which the counterweight has been
removed and the gantry and crawlers have been set to
the transport positions (retracted positions).
Confirm the following items before entering the actual
work.
1. PLACE
The ground must be level and firm, and improve the
ground as required.
2. WORKING PROCEDURE AND PREARRANGE-
MENT FOR SAFETY
Before working, all concerned must gather, make
prearrangement for procedure and safety, and
make precise role and responsibility of each per-
son.
3. PREOPERATION CHECKS
Perform preoperation checks of the basic machine.
4. When transporting, install the short circuit cap of
the hook overhoist cable to release the hook over-
hoist. Be sure to remove the short circuit cap when
operating the machine.
• Disassembly and assembly work requires co-

operation among workers. It is therefore essen-
tial to nominate a supervisor and to make
thorough arrangements beforehand as to sig-
nals, so as to avoid any possible misunder-
standings.
• Do not stand under any part of the crane or jib.
Do not handle boom or jib sections with chains,
hooks or wire ropes attached directly to chords
or lacings. This can cause structural damage
which can result in collapse of the section un-
der load.
4-1 7055-3
4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER

1. After confirming the ground condition of a place
where the basic machine is unloaded, stop the trail-
er.
2. Using treading boards, unload the machine with the
drive sprocket setting down word.
Do not swing the machine on the trailer to avoid

overturning.
TRAILER
TREADING BOARD
Make angle as small as possible
4.2 LOADING THE MACHINE ON A TRAILER

1. Swing the upper so that the upper becomes parallel
with the crawlers, insert the swing lock pin, and en-
gage the swing brake.
2. Using treading boards, load the machine with the
sprockets to the rear on a trailer.
Do not swing the machine on the trailer to avoid

overturning.
3. Secure the basic machine to the trailer.
7055-3 4-2

This section covers extending and retracting the crawl-
ers, erecting and lowering the gantry, and installation
and removal of the counterweight. Before starting ac-
tual work, confirm the following items.
1. PLACE
(1) The ground must be level and firm. Improve
ground condition a required, and place sheet plates
of iron.
(2) There must be adequate room to set an assisting
crane and to allow free passage of vehicles.
2. WORKING PROCEDURE AND PREVIOUS AR-
RANGEMENT FOR SAFETY
Before assembling work, gather all concerned to
make previous arrangement for the working proce-
dure and safety, and make precise role and respon-
sibility of each person.
Perform the preoperation checks for the basic ma-
chine.
When assembly, coat the all pins with grease.
Since both safe and efficient operation are required of

the operator, this section and the sections on controls
and operation and Safe Operating Practices in the be-
ginning of this manual should be studied before operat-
ing this machine. Before actually rigging the machine,
certain preparations should be made. They include the
following:
1. Perform daily maintenance checks as specified in
the section on Preventive Maintenance of this man-
ual.
2. Determine the area to perform rigging operation
considering that the boom must be hoisted directly
in front of or behind the undercarriage.
3. Before dismantling or assembling the crane, re-
move any obstacles from the work area.
Surround the work area with barricades in order to
keep out unauthorized personnel, and allow space
for vehicles carrying materials necessary for as-
sembly to come and go freely.
4. When using an assisting crane, use a crane of suf-
ficient lifting capacity and use suitable slings.
5-1 7055-3
5.1 EXTENDING/RETRACTING THE CRAWLERS
Be sure to confirm that people and obstacles are

kept away from the area where the crawler is being
extended.
9.1m
When extending and retracting the crawlers, perform APPROX.
the operation in the following conditions: 60°
Without counterweight
Boom length……less than 9.1m
Boom angle…… approx. 60°
Before operating extending and retracting work, suffi-
ciently clean the axles and extension axles, and coat AXLE
the insert sections with grease. If they are covered with

mud, sometimes extending and retracting work cannot
be operated normally.
5.1.1 EXTENDING THE CRAWLERS

1. Draw pins "A", which connect the crawler and the
Insert pin “A” which is
axles, out from holes (1), and insert them into link PIN “A” DRAW OUT
drawn out from hole (1)㩷
㪸㫊㩷㫋㪿㫀㫊
holes (2).
(2)

2. Draw pins "B", which fix the extension axles to the

crawler frame, out (all four pins).
CRAWLER
FRAME
PIN “B”
EXTENTION AXLE
3. Turn the four extension axles by 90 degrees toward

AXLE
the outside so that they are parallel with the axles.
PIN “B”
EXTENSION AXLE
7055-3 5-2
4. Remove lock brackets "C" for the extension axles

from the crawler frame and insert them into the foot
side of extension axles.
CRAWLER FRAME
BRACKET “C”
5. Remove the shims for adjusting the clearance be-

tween the crawlers and axles.
SHIM
CRAWLER FRAME
AXLE
6. Turn the upper slowly so that the upper is at right

angle to the crawlers.
At this time, turn the upper so that the front of the
upper (operator's room) comes to the crawler side
which is desired to be extended.
Be sure to confirm the machine stability to avoid

machine from overturning. Failure to observe this
precaution may result in serious injury or death.
EXTENDING SIDE
5-3 7055-3
7. After confirming that there is no obstacle in the ENTERS

crawler extending side, operate the crawler ex-
tending/retracting control levers to the EXTEND-
FIXING PIN “A”
ING side to extend the crawler.
If the crawler is not smoothly extended, while mov-
ing the crawler a little forward and backward, ex-
tend the crawler.
When the crawler is extended to the extended po-
sition, fixing pins "A" enter automatically. Insert the
lock pins "D" into fixing pins "A".
8. Turn the upper by 180 deg. , and extend the other

crawler in the same way.
9. Turn the upper so that the clearance between the

crawler and the axles becomes large, and install
the clearance adjusting shims.
As the shims are stamped with numbers, install the
shims so that the numbers coincide with the num-
bers of the frame sides.
SHIM
CRAWLER FRAME
AXLE
7055-3 5-4
5.1.2 RETRACTING THE CRAWLER
Do not retract crawler without moving counter-

weight. Failure do observe this precaution may re-
sult in serious injury or death.
1. Remove the counterweight

Draw out pins "A" which connect the crawlers to the Insert pin “A” drawn
out from hole (2) as
axles from hole (2), and insert them into link holes this. DRAW OUT
(1).
PIN “A”
Remove pins "B" from the tip ends of the extension (1)
axles. (2)
2. Remove the shims for adjusting the clearance be-

tween the crawlers and axles.
SHIM
CRAWLER FRAME
AXLE
3. Slowly turn the upper so that the upper becomes

right angle to the crawlers.
At this time, turn the upper so that the front of the
upper (operator's room side) comes to the side of
the crawler which is desired to be retracted.
Be sure to confirm the machine stability to avoid

machine from overturning. Failure to observe this
RETRACTING SIDE
5-5 7055-3
4. After confirming that there is no obstacle in the

ENTERS FIXING PIN “A”
crawler retracting side, operate the crawler extend-
ing/retracting control lever to the RETRACT side to
retract the crawlers.
If the crawlers are not smoothly retracted, move the
crawler in the retracting side forward and backward
a little to retract it. LOCK PIN “D”
When the crawlers are retracted to the retracting
position, fixing pins "A" enter automatically.
Insert the lock pins "D" into fixing pins "A".
5. Turn the upper by 180 degrees , and retract the oth-
er side crawler in the same way, too.
6. Remove lock brackets "C" from the foot of the ex-

AXLE
tension axles, and move them to the crawler frame. CRAWLER FRAME
BRACKET “C”
PIN “B”
7. Turn all four extension axles by 90 degrees to the

inside so that the extension axles are at right angle
to the axles.
8. Fix the extension axles and crawler frames with

pins "B".
9. Turn the upper by 180 degrees, and retract the oth-
er side crawler in the same way, too. CRAWLER
FRAME
PIN “B”
EXTENTION AXLE
7055-3 5-6
5.2 ERECTING/LOWERING THE GANTRY
Boom should be placed on the ground and no load on

boom hoist line when raising or lowering the gantry.
5.2.1 ERECTING THE GANTRY

Erect the gantry to change the machine condition from Storage position of
the transport posture to the working posture. Transport posture the PIN “B”
1. Detach the pin "A", fixing the tension bar to the

frame, and remove the tension bar.
2. Then, turn the link of the tension bar by 180° , and
fix the link to the tension bar with the fixing pin "A" FIXING PIN “A”
(link storage position).
3. Place the gantry control switch in the UP position
(farside).
The gantry is pushed up with the cylinders.
TENSION BAR
LINK
Do not operate gantry control switch during crane oper-

Turn the link FIXING PIN “A”
ation or when boom hoist line is loaded. by 180°
4. When the gantry is raised to the working position,

insert fixing pins "B" and secure them with the
spring pins.
5. Turn the link stopper attached to the gantry, fit it to
the link-side pin.
GANTRY CONTROL SWITCH
GANTRY
TENSION BAR
LINK
STOPPER
5-7 7055-3
6. Detach the pin "C" and retract the gantry cylinder.
Do not raise the gantry by using the boom hoist

wire rope or the aux. crane.
The gantry may suddenly drop at the moment that
the fixing pin is removed to lower the gantry.
LINK STOPPER
1RGTCVKPIRQUVWTG
PIN “A”
Working position of
the gantry cylinder
PIN “C”
Storage position of
the gantry cylinder
PIN “B”
7055-3 5-8
5.2.2 LOWERING THE GANTRY

1. Connect the gantry cylinder to the "working posi-
tion", and securely support the gantry with the gan-
try cylinder.
Since the tension bar and link stopper may be dam-

aged, always remove the link stopper from the tension
bar and store it when the gantry is lowered.
2. Store the link stopper, and remove the gantry fixing

pin "B".
GANTRY CONTROL SWITCH

Do not stand under the gantry when raising or low-
Storage position of
ering the gantry. Failure to observe this precaution the pin “B”
may result in serious injury or death.
3. Place the gantry control switch in the DOWN posi-

tion (inside) to lower the gantry.
4. Insert gantry fixing pins "B" into the storage posi-
tion.
5. Turn the link, and connect the tension bar to the
FIXING PIN “A”
frame to fix the gantry.
TENSION BAR
To lower the gantry with the counterweight loaded,
operate the gantry with the link stored in order to
LINK
prevent interfering with the upper part of the coun-
terweight.
FIXING PIN “A”
Turn the link

by 180°
5-9 7055-3
5.3 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT

(WHEN USING THE AUXILIARY CRANE)
The counterweight of this machine is composed of four
section. Remove the counterweight at transportation.
Never use the weight which is not specified.
The mounting bolts of the counterweight must be tight-
ened securely enough and not to come loose. No.2 WEIGHT
No.1 WEIGHT
WEIGHT OF EACH SECTION

Section Weight (t)
No.1 Weight 7.5
No.2 Weight 7.7
5.3.1 INSTALLATION OF THE COUNTERWEIGHT

Prior to installation, check the following points of the ba-
sic machine.
(1) Gantry must be in the operating position.
(2) The basic machine is placed on the leveled and firm
ground.
(3) The crawlers are in the operating position.
Make sure machine is in stability range during

swing and propel P.9-8 to avoid machine turn-over.
rious accident.
(Tool)
• One set of attached tools.
• Assisting crane (25 ton class)
• Lifting wire rope
25 mm dia x 8m 2sets
7055-3 5-10
1. Installation of No.1 weight.

(1) Install the lifting shackle to the lifting bracket of No.1
weight and lift it with the assisting crane.
Do not stand under lifted counterweight or between No.1 “㧭” “B”

WEIGHT
counterweight and the basic machine to avoid acci-
dent of drop or being caught. Failure to observe
death.
(2) Place the portion "A" of No.1 weight to the portion

"B" of the basic machine and install the pin "C" and
the lock pin.
(3) Adjust No.1 weight to become leveled with the bolts
"D" and lock them with the nut "E". (At time of fac-
tory shipment, this point has been adjusted to be- PIN “C”
come leveled.)
NUT “E”
BOLT “D”
2. Installation of No.2 weight. BOLT “F”

(1) Lift No. 2 weight with the assisting crane.
(2) Place No. 2 weight on No. 1 weight in such way that
the dented area of No. 2 weight sits on the bracket
of No. 1 weight. No.2
(3) Insert the bolt "F" from top through the weights and
tighten them with the nut "G"
Tightening torque : 549 N-m ( 56 kg - m )
No.1
(4) Make sure to use the assisting crane for lifting and
insert the bolt "F" to avoid accident of drop from the
top of counter weight.
Weight of the bolt : 18.2 kg
PIN
SPACER “H”
NUT “G”
LOCK PIN
5-11 7055-3
5.3.2 REMOVAL OF THE COUNTERWEIGHT

1. Loosen the nut "G" and pull out the bolt "F". BOLT “F”
Do not stand under lifted counterweight or between

counterweight and the basic machine to avoid acci- No.2
dent of drop or being caught. Failure to observe

death. No.1
2. Make sure to use the assisting crane for lifting and

insert the bolt "F" to avoid accident of drop from the
top of counter weight.
Weight of the bolt : 15.6 kg
3. Remove the weight No.2, and No.1 in its order one
by one.
PIN
SPACER “H”
NUT “G”
LOCK PIN
PIN “C”
7055-3 5-12

This section covers assembling, erecting, lowering and
disassembling of the crane attachment and transport of
the boom.
Before starting the actual work, confirm the following
items.
1. PLACE
(1) Paying attention to that erecting and lowering of the
attachment must be operated in front or rear of the
crawlers.
(2) There must be adequate room for assembling and
the ground must be firm and level.
(3) Improve the ground as required and lay sheet
plates of iron.
(4) There must be also adequate room to set an assist-
ing crane and to allow free passage of vehicles de-
livering necessary parts and for unloading and
storing the parts until they are required.
2. WORKING PROCEDURE AND PREARRANGE-
MENT FOR SAFETY.
Before assembling work, gather the all concerned
to make previous arrangement for the working pro-
cedure and safety, and make precise role and re-
sponsibility of each person.
Perform the preoperation checks of the basic ma-
chine.
When the engine starts, the warning alarm of the safety

device always sounds for two to three seconds.
Do not stand or work under, inside, or on the boom

when installing or removing the connecting pins at
anytime. Failure to observe this precaution may re-
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.
6-1 7055-3
Never attempt to fabricate or modify a crane, a jib/

or a backstop.
Before climbing on machine, make certain that the

guard and walk ways are clean and dry, and use life
belt in order to prevent falls due to slippery surface.
Do not put your hand or finger into a pin hole.
To avoid serious injury, fix guy line to both ends of

each boom when placing guy lines on the booms
during boom connection.
Do not handle boom or jib sections with chains, hooks

or wire rope attached directly to main chords or lacings.
Either use soft material sling points or use fabric type
slings.
7055-3 6-2
6.1 ASSEMBLING THE ATTACHMENT

[TOOLS]
• One set of attached tools
• Assisting crane (25 t class)
• Lifting wire rope (fiber belt)
• Wooden blocking
• Sling cloths
• Steel bar
When assembling the crane attachment, push the
"SETUP" switch. Then, the load safety device en-
ters the "SETUP" mode, and the automatic stop is
canceled.
SET UP SWITCH
• Press a "SETUP" switch three seconds or more.

• The "SETUP" mode cannot be actuated while the
boom is raised.
When the boom is raised after the assembly is com-

pleted, and the "SETUP" mode is canceled.
6-3 7055-3
6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE

1. PREPARATION OF BOOM/JIB/GUY LINE AND
STEEL BLOCKING PLATE
Prepare necessary parts.
(1) Boom and Jib
Prepare the boom and jib following to the ar-
rangement chart.
Do not assemble the boom with boom arrange-
ment not specified in the arrangement chart.
And also, check the each boom and jib for dam-
age.
If damage is confirmed, repair the damage in the
designated service shop.
The boom length in which the

30.5 m to 42.7 m
jib can be installed
The boom length in which the
9.1 m to 48.8 m
Aux. sheave can be installed
Do not use damaged boom section. The damaged

booms may collapse and cause serious injury or
death.
(2) Guy Line

Prepare the guy lines following the arrangement (Face)
chart. The diameter of the boom guy line is 30 mm, Part No. : Ex. JJ71A6D1
and the diameter of the jib guy line is 20 mm.
To discriminate each guy line, see the part number (Back)
stamped on the connector. Manufacturing date : Ex. 9903
7055-3 6-4
2. BOOM AND GUY LINE ARRANGEMENT
1. Depending on the purchased configuration of

boom, boom arrangement will be limited and NOT
be able to made all arrangements of boom as
shown on the chart.
2. The boom arrangement with " " mark purchased,

which can be able to assemble one of the boom ar-
rangement shorter than you choose on respective
boom length in the chart.
Main Hoist Aux. Hoist

Boom
Boom And Guy Line Arrangement Chart With Aux. Reeving Reeving
Length With Jib
(3 m + 6 m) Sheave (No. of (No. of
m (ft)
Line) Line)
9.1
b t O X 8 1
(30)
12.2
b t O X 8 1
(40)
b t
15.2
O X 8 1
(50)
b t
18.3
b t O X 7 1
(60)
b t
21.3
O X 6 1
(70)
b t
24.4
b t O X 5 1
(80)
b t
27.4
O X 4 1
(90)
b t
6-5 7055-3

Boom
Length With Jib
m (ft)
Line) Line)
30.5 b t
O O 4 1
(100)
b t
b t
33.5
O O 4 1
(110)
b t
b t
36.6
O O 3 1
(120)
b t
b t
39.6
O O 3 1
(130)
b t
b t
42.7
O O 3 1
(140)
b t
b t
45.7
O X 2 1
(150)
b t
b t
48.8
O X 2 1
(160)
b t
7055-3 6-6

Boom
Length With Jib
m (ft)
Line) Line)
51.8
O X 2 1
(170) b t
6-7 7055-3

Boom
Length With Jib
(3 m + 6 m + 9 m) Sheave (No. of (No. of
m (ft)
Line) Line)
9.1
b t O X 8 1
(30)
12.2
b t O X 8 1
(40)
b t
15.2
O X 8 1
(50)
b t
b t
18.3
O X 7 1
(60)
b t
b t
21.3
O X 6 1
(70) b t
b t
b t
24.4
O X 5 1
(80) b t
b t
b t
27.4
O X 4 1
(90) b t
b t
7055-3 6-8

Boom
Length With Jib
m (ft)
Line) Line)
b t
30.5
O O 4 1
(100) b t
b t
b t
b t
33.5 b t
O O 4 1
(110)
b t
b t
b t
b t
36.6
O O 3 1
(120)
b t
b t
b t
6-9 7055-3

Boom
Length With Jib
m (ft)
Line) Line)
b t
b t
b t
39.6
O O 3 1
(130)
b t
b t
b t
b t
42.7 b t
O O 3 1
(140)
b t
b t
45.7 b t O X 2 1
(150)
b t
7055-3 6-10

Boom
Length With Jib
m (ft)
Line) Line)
b t
48.8
O X 2 1
(160)
b t
b t
51.8
X X 2 1
(170)
b t
O : Attachable X : Not attachable
ٌ mark shows the boom with lugs attached.

ٌ mark shows the insert boom with lugs attached and
the guy line installing position when the jib is used.
mark shows the installing position of the cable roller
for the boom tip section. (Standard)
for the insert boom section. (Option)
boom is used to assemble tower.

The boom arrangement with " " mark purchased.
In the following case, one of 6.1 m or 9.1 m boom insert

with lugs attached is required.
• In case that the jib is attached.
• When assembling the boom of more than 39.6 m
without the use of the assisting crane.
6-11 7055-3
Kind of insert boom and Long insert jib

Symbol Length Specification
3.0 3.0 m Without lug
6.1 6.1 m With lug
9.1 9.1 m With lug
9.1B 9.1 m Special boom
Although the special insert boom (with bracket) is basi-

cally used for the tower, it can be also used for the
crane by removing the guide sheave for the tower
crane.
Boom Guy Line Chart

Guy Line
Sym- Dimension Connector type
Part Number Remarks [m(ft)]
bol Diameter
Length (m)
(mm)
A 30 3.32 2430R209D31 Upper Boom
3.0 (10)
B 30 3.05 2430R209D1
Insert Boom
6.1 (20)
C 30 6.10 2430R209D2
Insert Boom
9.1 (30)
D 30 9.14 2430R209D3
Insert Boom
7055-3 6-12
When the crane is equipped with the lifting magnet and

the clamshell special machine is used;
Boom Guy Line Chart ( 36)

Guy Line
Sym- Dimension
Part Number Remarks
bol Diameter
Length (m)
(mm)
C 36 7.62 GG71A00001F4 Boom hoist rope
Extension between
upper & lower
D 36 10.67 GG71A00001F5
spreader type
(with Link)
C 36 8.75 GG71A00001F7 Boom hoist rope
Standard between
upper & lower
D 36 11.80 GG71A00001F8
spreader type
(with Link)
LINK E - GG71A01001P1 Contained in Assy
LINK F - GG71A01002P1 listed above
Either guy line of C, D will be prepared corresponding

BOOM AND GUY LINE ARRANGEMENNT CHART
to the longest length of the boom when an order is
made.
Please consult us if the guy line shorter than the lengths LINK 㧲
listed above is required. LINK E
㧰
b 3.0 6.1 t 18.3m (60)
for the boom tip section.

㧯
When the lifting magnet or the clamshell is used, the
b 6.1 t 15.2m (50)
guy line fatigue is easy to occur in a short time because
the machine has high frequency of operation.
Use the guy line which diameter has been increased to
36 mm for these operations different from the standard
machine.
For the lifting magnet type or the clamshell special ma-

chine, make sure to replace with the new parts every
two years after the operation start in order to prevent
unexpected accidents of the guy line.
6-13 7055-3
1. ARRANGEMENT OF FIXING JIB AND GUY LINE

The length of the boom to which the jib is attached
is 30.5 m to 42.7 m.
When the 6.1 m boom insert is installed under the boom tip
T
10 degree (or 30 degree)
10 degree (or 30 degree) 10 degree (or 30 degree)
b b
b
T T
T
Insert boom with lug Insert boom with lug

Insert boom with lug
18.3 m (60ft) 12.2 m (40ft) 6.1 m (20ft)
When the 9.1 m boom insert is installed under the boom tip
T
10 degree (or 30 degree)
10 degree (or 30 degree) 10 degree (or 30 degree)
T
b b
b
T T
T
Insert boom with lug Insert boom with lug

18.3 m (60ft) 12.2 m (40ft) 6.1 m (20ft)
Arrangement of Guy Line in Boom Side

Boom Arrangement
Offset
(Boom Tip + 6.1 m) (Boom Tip + 9.1 m)
Angle
Arrangement Arrangement
10deg. G G+J
30deg. G+H G+J+H
Arrangement of Guy Line in Jib side

6.1 m Jib 12.2 m Jib 18.3 m Jib
E E+F E+F+F
7055-3 6-14
Kind of Guy Line

Connector type
Symbol Diameter (mm) Length (m) Part Number
E 20 13.87 2430R223D2
E 20 11.48 2430R175D4
G 20 21.12 2430R223D7
H 20 2.46 2430R175D5
J 20 5.96 2430R175D6
Offset Angle
To operate with the

6.1 m (20) jib at an offset
angle 10 degrees, SPLIT PIN
insert the pipe spacer
to the strut backstop
and adjust the length Strut backstop
with the two-split spacer
so that the guy line on
the boom side is stretched.
PIPE SPACER
6-15 7055-3
6.1.2 INSTALLING THE BACKSTOP

Connect the spring side of the backstop to the top of the
PIN
boom base, and also fix the outer pipe to the boom
base with a wire rope.
SPRIT PIN
To prevent damages caused by coming off of the SPRIT PIN
backstop inner pipe, firmly secure the inner pipe to
the boom base.
PIN
BACKSTOP
WIRE ROPE
7055-3 6-16
6.1.3 INSTALLING THE BOOM BASE

Before starting work, confirm the machine condition.
• The base machine must be placed on a firm and

level ground.
• The crawlers are extended, and the each lock pin
and shim are set.
• When assembling the crane attachment, push the

SET UP SWITCH
"SET UP" switch while 3 seconds. Then, the load
safety device enters the "SET UP" mode, and the
automatic stop is canceled.
Press a "SET UP" switch three seconds or more.
When the boom is raised after the assembly is complet-

ed, and the "SET UP" mode is canceled.
Do not stand or work under, inside the boom when

assembling the boom at anytime.
1. Using the assisting crane, lift up the boom base,

and install it to the basic machine. Lift up the boom
horizontally right and left. At this time, fix the back-
stop not to allow the backstop to come out.
2. Align the both boom foot pins with the holes surely.
Insert the right side pin from the inside, then insert BOOM BASE
the left side pin. (insert the lock pins from the top to
BOOM FOOT PIN
the bottom, and fix with fixing pins.)
LOCK PIN
Do not insert your hand or finger to pin hole to align
or check holes. Failure to observe this precaution FIXING PIN
may result in serious injury or death. Frame of

basic machine
6-17 7055-3
3. Place the connector section of the boom base on

BOOM FOOT
blocking, remove the lifting wire rope.
4. In order to reduce play in the boom foot section, in- SHIM
sert the shims.
Amount of the shims shall be adjusted to a degree
that the shim can be inserted lightly by hand. Do not
tap in forcibly.
5. Referring to chapter " 3. LOAD SAFETY DEVICE ",
connect the wiring for the boom angle detector.
7055-3 6-18
6.1.4 INSTALLING THE BACKSTOP TO THE REVOLVING FRAME

• Lifting up the outer pipe of the backstop, draw out it
to the basic machine side, and connect it to the re-
volving frame with the pin.
FRAME BACKSTOP
PIN
Never get close to the area where the backstop is re-
moved.
Failure to observe this precaution may result in serious
injury or death.
SPRING PIN
6-19 7055-3
6.1.5 INSTALLING THE UPPER SPREADER
Do not put your hand or finger to pin hole.

• Install the upper spreader to the boom base and

bracket with pins. After connecting the guy line, re-
move this pin.
Note that another installing method is available
when the boom hoist wire rope has been already
reeved.
CONNECTING
POSITION
SHACKLE
UPPER
SPREADER
CONNECTING
POSITION
To prevent any accidental drop, be sure to use a

safety belt during the operation at high places, and
use a scaffold board during the operation on the
boom. Failure to observe this precaution may re-
7055-3 6-20
6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER
• Do not touch a wire rope directly with bare

LOWER SPREADER
hands. If wire protrude, you could be injured.
UPPER SPREADER
• Keep hands and clothing clear of the rotating
drum running wire rope.
1. Before performing any work, place the upper

spreader on the ground. UPPER SPREADER
Operate the boom drum control lever, and unwind
the wire rope from the boom drum.
2. Correct any distorted, tangle on the rope and com-
ing off of the rope from the sheave, reeve the wire
rope through the upper spreader and lower spread-
er.
ROPE END
LOWER SPREADER
GANTRY SHEAVE
BOOM HOIST DRUM
3. Fix the wire rope end to the link at gantry with a

socket, wedge, and clamp. ROPE SOCKET
LINK
GANTRY
LINK
ROPE SOCKET
6-21 7055-3
4. Raise the gantry to the working posture.

(Refer to chapter 5.)
5. Install the counterweight.

(Refer to chapter 5.)
6. Slowly wind up the wire rope to take out the extra

slackening.
At this time, wind up the wire rope on the drum tidily
to prevent the wire rope from rough spooling.
To prevent any accidental drop, be sure to use a

safety belt during the operation at high places, and
use a scaffold board during the operation on the
boom. Failure to observe this precaution may re-
7055-3 6-22
6.1.7 INSTALLING THE BOOM TIP

1. Align the top connectors of the boom tip with that of
the boom base, tap the connecting pins (pin with
brim) in, and insert the spring pin into the side of the
connecting pins to fix them.
Be sure to tap the connecting pins (pin with brim) from

the outside to the inside.
SPRING PIN
CONNECTING PIN
(With brim)
6-23 7055-3
2. Hoist the lower boom until the lower pin holes are
aligned with each other. Only then, tap the connect-
ing pins (both ends of which are tapered) in, and in-
sert the spring pins into the both ends of the
connecting pin.
Do not stand under, inside, or on the boom struc-

ture when the connecting boom.
CONNECTING PIN
(Both taper)
7055-3 6-24
6.1.8 INSTALLATION OF THE BASIC GUY LINE

1. Install the basic guy line to the boom tip and upper
spreader.
BASIC GUY LINE
BASIC GUY LINE
2. Remove the upper spreader from top of boom

base.
Loosen the boom hoist wire rope enough not to ap-
ply tension to the upper spreader.
6-25 7055-3
6.1.9 MAIN HOIST WIRE ROPE REEVING
To prevent personnel from being caught by the

rope, be sure to post a signal person.
• Do not touch a wire rope directly with bare hands.

Protruding wires could cause serious injury.
Working gloves are recommended.
• Keep hands and clothing clear of the rotating drum
and running wire rope.
injury or death.
Install the hook block in the correct direction, so that the

striker is located to the machine side, and the striker
pins will hit to a weight for over hoist limit switch.
WEIGHT WEIGHT
STRIKER PINS STRIKER PINS
Machine side Machine side
WRONG CORRECT
7055-3 6-26
1. Prepare the hook, overhoist limit switch, weight and

socket, etc. to used near the tip end of the boom.
2. Operating the front drum control lever to the lower-
HOIST WIRE ROPE
ing side to pay out the wire rope to the tip end of the IDLER SHEAVE
boom, pass it through the idler sheave from the
right of the boom point.
BOOM POINT SHEAVE
3. Install the overhoist limit switch and weight to the

left side bracket on the tip end of the boom.
Insert the cotter pin into the shackle pin to fix it.
LIMIT SWITCH
SHACKLE
WIRE ROPE
WEIGHT
6-27 7055-3
4. Pass the front drum wire rope through the hook

sheave(s) and boom point sheave(s) in order. Fix
the wire rope end to the boom point for even num-
ber part reeving and to the hook for odd number
part reeving with the rope socket.
Confirm the direction and install the socket in the
boom point.
Do no forget to pass the wire rope through the
weight for the overhoist limit switch.
7055-3 6-28
Wire Rope Reeving
IDLER SHEAVE
BOOM POINT SHEAVE
HOOK SHEAVE 2 Parts 3 Parts 4 Parts
5 Parts 6 Parts 7 Parts
8 Parts (This figure looking from boom tip side)
5. Referring to chapter 3. LOAD SAFETY DEVICE,

not install the fixing jib and auxiliary sheave.
6. Referring to chapter 3. LOAD SAFETY DEVICE as
the same, input the crane configuration in the load
safety device.

correct. Failure to observe this precaution may re-
sult is overturning of crane and may lead to serious
injury or death.
6-29 7055-3
6.1.10 CONNECTING THE INSERT BOOMS

This topic covers procedure to connect the boom insert
(s) from the condition, that the basic-boom has been
once assembled, to assemble the long length boom.
1. KIND OF INSERT BOOMS
Six types of the insert boom.
Special Insert Boom for Tower

Standard Insert Boom Insert Boom with the lugs
(with bracket)
3.0 m — —
6.1 m 6.1 m —
9.1 m 9.1 m 9.1 m
Although the special insert boom (with bracket) is basi-

cally used for the tower, it can be also used for the
crane by removing the guide sheave for the tower
crane.
The case that the insert boom with the lugs attached is
LUG
as follows:
(1) For the specification with the fixing jib.
(2) Assembling more than 39.6 m boom without the
use of assisting crane.
2. WINDING UP THE MAIN HOIST WIRE ROPE

Remove the rope socket from the wire rope, and
wind up the wire rope onto the drum.
Take suitable step not to allow the wire rope wound
onto the drum to be loosened.

hands. If wire protrude, you could be injured.
• Keep away from rope end when removing the
wire rope. It may suddenly jump and cause inju-
ry.
drum and running wire rope. Failure to observe
death.
7055-3 6-30
3. REMOVING THE BOOM TIP SECTION

(1) Lowering the boom onto blocking, install the upper
spreader onto the top of the boom base with the
use of spreader guide.
How to use spreader guide is shown in the next
page. GUY LINE
GUY LINE
6-31 7055-3
HOW TO USE SPREADER GUIDE

(A) Draw out pin "A", change the spreader guide from
the storage position to the work position.
Place the pin "A" in the work position.
PIN “A”
PIN “A”
SPREADER GUIDE
Storage position Work position
(B) Lower the boom. After the tip end of the boom has
been grounded, slowly loosen the boom hoist wire
rope more. The spreader is lowered along the
spreader guide. When the hole of the spreader is
aligned with the pin hole of the bracket on the boom
base section, insert pin "B" to connect the spreader
to the bracket.
PIN “B”
7055-3 6-32
(C) When storing the spreader guide, slowly stretch the

boom hoist wire rope. When clearance is generated
between the spreader and the spreader guide,
draw out pin "A", and return the spreader guide to
the storage position.
Since the clearance is not be generated with boom
base section only, perform before disassembling
the boom.
• When the gantry is in the lowered condition, be sure

to set the guide in the storage position. If the guide
is left in the work position, the guide could be dam-
aged by boom hoisting.
• When the gantry is lowered and the upper spreader
is connected to the boom base section, set the
guide in the storage position. At this time, do not
raise the boom to more than 20 degrees. If the
boom is raised to more than 20 degrees, the winch
wire rope has possibility to be damaged.
Since the clearance is not be generated with boom

base section only, perform before disassembling the
boom.
Be sure to hold the guide end with hands. Only

then, remove the pin, and stow the spreader guide.
CLEARANCE
PIN “A”
Storage position
6-33 7055-3
(D) After change of the boom connection or assembly

has been finished, draw out pin "B", and wind up
the boom hoist wire rope so that the spreader slides
up on the guide.
Relating to the reeving way of the boom hoist wire
rope, the spreader slides up while rocking from side
to side. If the spreader is raised up at a stretch, the
spreader has possibility to be caught on the guide
and to bend the guide. If it is caught, loosen the wire
rope once, then move the boom drum control lever
to the RAISE side intermittently to remove hooking.
PIN “B”
(E) Return the spreader guide to the storage position.
PIN “A”
PIN “A” SPREADER GUIDE
Work position Storage position
(F) When setting the spreader guide to the work posi-

tion, after the boom connection is finished, stretch
the boom hoist wire rope, and set the spreader
guide to the work position.
(2) Remove the basic guy lines from the upper spread-
UPPER SPREADER
er.
GUY LINE
7055-3 6-34
(3) Operate the boom hoist control lever to stretch the

boom hoist wire rope to remove load from the bot- SPRING PIN
tom connector section, then draw out the bottom SPRING PIN
connecting pins (Both ends of which are tapered).
CONNECTING PIN
(Both taper)
Do not set stand or work under, inside or on the
boom structure when removing the connecting
pins.
(4) Place blocking under the boom tip section, lower the
SPRING PIN
boom base section, then draw out the top connect-
ing pins (With brim).
CONNECTING PIN
(With brim)

pins.
6-35 7055-3
4. CONNECTING THE INSERT BOOM

Assemble so that this part
For the notes on the cantilever support, refer to is positioned on the top.
page 6-41. t
(1) Referring to Boom and guy line arrangement chart,

lift the required insert boom(s), being careful not to (CORRECT)
mistake the top for the bottom, and bring it near the
boom base section. b
t
• Do not stand under the boom or inside the
(WRONG)
pins.
b
(2) Align the top connecting pin holes, insert the con-
SPRING PIN
necting pin with the lock pinholes facing up and
down. Insert the spring pins to fix the connecting
pins. CONNECTING PIN
Be sure to tap the connecting pins from the outside to

the inside.
Do not insert your hand or finger into pin hole. Fail-

ure to observe this precaution may result in serious
injury or death.
7055-3 6-36
(3) Lifting up the connecting section of the boom base

and the insert boom, align the bottom connecting
pin holes, and insert the connecting pins (both
ends of which are tapered) into these holes.
Insert the spring pins into the connecting pins to fix
them.
SPRING PIN
SPRIG PIN
CONNECTING PIN
(Both taper)
(4) Referring to Boom and guy line arrangement chart,

connect the insert booms in order in the same way.
6-37 7055-3
5. INSTALLING THE BOOM TIP

Lift up the boom tip, and install it to the insert boom
(Refer to 6.1.7 INSTALLING THE BOOM TIP. )
6.1.11 INSTALLING THE CABLE ROLLERS

Install the cable rollers. (Spanner : 17 mm)
For Insert Boom For Boom Tip
CABLE ROLLER
SPACER
CABLE ROLLER
UPPER BOOM UPPER BOOM
CABLE ROLLER
INSERT BOOM
7055-3 6-38
6.1.12 CONNECTING THE BOOM GUY LINES

1. Prepare guy line according to the guy line arrange-
ment chart.
BOOM BASE SIDE BOOM TIP SIDE
2. Connect the prepared guy lines from the boom tip

side to the basic machine side one by one. When
connecting from boom tip side one by one, do not
make the guy lines slacken.
If the guy lines slacken much, then guy lines may
not reach to the upper spreader.
Divide a split pin about 60 degrees.
6-39 7055-3
3. Connect the guy line to the upper spreader.

PIN “B”
UPPER SPREADER
GUY LINE
4. Loosen the boom hoist wire rope enough. SPREADER GUIDE

5. Use the spreader guide to remove the pin "B".
PIN “B”
6. Wind up the boom hoist rope to the boom hoist
drum paying attention not making rough winding.
Place an signal man to avoid accident of being

caught.
The assembly of the boom is completed by this.
7055-3 6-40
6.1.13 CAUTION FOR CANTILEVER

1. SUPPORT WITH BOOM BASE
• Be sure the confirm that gantry is set in high gantry

condition.
• Do not exceed the length of cantilever mentioned 36.6m and shorter
below.
• Operate crane at the slowest speed as possible.
Crane Boom only ..... Less than 36.6 m.

12.2m and shorter
36.6 m and shorter
33.5 m and shorter
With aux. sheave
Do not perform the hoisting work or propel while

the boom is supported with the cantilever.
6-41 7055-3
2. SUPPORT WITH INSERT BOOM WITH LUG

Set the guy line to the top of the insert boom with
lug, and remove the upper spreader from the boom
base.
The boom can be supported with the insert boom
with lug up to 12.2 m.
GUY LINE
12.2 m and shorter
For the details if connection of the insert boom, refer to

the topic of "6.1.10 CONNECTING THE INSERT
BOOMS".
Do not perform the hoisting work or propel while

the boom is supported with the cantilever.
7055-3 6-42
6.1.14 ASSEMBLING THE JIB

When the jib is not installed, go to "6.1.16 INSTALLING JIB GUY LINE
THE AUXILIARY SHEAVE". 㧔JIB SIDE㧕
For the jib and jib guy line configuration, refer to P.6-14.
JIB
Do not set stand or work under, inside or on the jib
structure when assembling jib.
STRUT
JIB GUY LINE
㧔BOOM SIDE㧕
The boom length to which the jib can be installed 30.5
m to 45.7 m.
However, the 18.3 m jib cannot be installed to the 45.7 6.1 m or 9.1 m
INSERT BOOM
m boom.
1. Assemble the jib and strut at the elongation of the

tip end of the tip boom.
Installation of strut back stop
The jib connecting pins are all pins with brim. so that bracket comes up ward.
2. Lifting up the preassembled jib, connect it to the

boom point section.
6-43 7055-3
3. Prepare the jib guy lines (the jib side and boom
side). OFFSET ANGLE
(10 degree or
• The length of the jib guy line of the jib side varies 30 degree)
according to the jib length.

• The length of the jib guy line of the boom side varies
according to the jib offset angle (10° or 30°).
4. Temporarily remove the equalizer sheave of the jib EQUALIZER SHEAVE

strut, and thread the jib guy line through the
sheave. Only then, reinstall the sheave. (Keep the
strut down.) BOOM SIDE JIB SIDE
JIB GUY LINE (BOOM SIDE) JIB GUY LINE (JIB SIDE)
5. Connect both end of the jib guy line to the top end
of the jib.
7055-3 6-44
6. Install the jib guy line link to the insert boom with
lug, referring to the "Boom and guy line arrange-
ment chart" (page 6-5).
LINK
LINK
PIN
SPLIT PIN
INSERT BOOM WITH LUG
7. Raise the strut with the assisting crane and install

the strut backstop. Insert the pipe spacer to the
strut back stop when operating with the 6.1 meter
jib at the offset angle of 10 deg.. (Refer to page 6-
15)
SPLIT PIN
STRUT
STRUT BACKSTOP
PIPE SPACER
8. With the jib strut held, connect the both ends of the
boom side jib guy line to the link on the insert boom.
6-45 7055-3
9. Remove the sling rope from the jib strut.

JIB GUY LINE
(BOOM SIDE)
7055-3 6-46
6.1.15 REEVING OF REAR DRUM WIRE ROPE
Do not touch a wire rope directly with bare hands.

If wire protrude, you could be injured. Working
gloves are recommended. Keep hands and clothing
clear of the rotating drum and running wire rope.
1. Place the ball hook near the tip end of the jib.
2. Push the rear drum control lever to the lowering
side to pay out the rear drum wire rope to the tip
end of the jib, and pass it through the jib point
sheave.
REAR DRUM WIRE ROPE
6-47 7055-3
3. Install the limit switch and weight to the jib point

section.
Insert the cotter pin into the shackle pin to secure it.
JIB POINT
JIB POINT
LIMIT SWITCH
SHACKLE
SHACKLE
4. Pass the wire rope end through the weight for the
limit switch, and secure the end to the hook with the
rope socket.
7055-3 6-48
5. Referring to Chapter 3. LOAD SAFETY DEVICE,

connect the wiring for the auxiliary hoist hook over-
hoist limit switch (see page 3-16).
6. Referring to chapter 3. LOAD SAFETY DEVICE as
the same, input the crane configuration in the load
safety device.
Input the "Crane Posture" correctly to prevent tip-

ping and damage of the machine.
6-49 7055-3
6.1.16 INSTALLING THE AUXILIARY SHEAVE

When the auxiliary sheave is not installed, go to "6.2 AUXILIARY SHEAVE
ERECTING THE ATTACHMENT". The boom length to
which the auxiliary sheave can be installed is 9.1 m to
51.8 m.
1. Install the lower frame of the auxiliary sheave to the

upper boom top.
2. Connect the upper boom.
3. Use the outer side hole position for the auxiliary

sheave frame to be connected to the upper boom. This pin is not used.
(For transport)
(Inner side hole is for the transportation.)
7055-3 6-50
6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE
• Do not touch a wire rope directly with bare hands. If

wire protrude, you could be injured. Working
gloves are recommended.
and running wire rope. Failure to observe this pre-
1. Place the hook block near the tip of the auxiliary

sheave.
2. Control the rear drum control lever to the lowering

position to pay out the wire rope up to the tip end of
the boom, and pass the wire rope through the idler
sheave and auxiliary sheave in this order.
3. Install the limit switch and weight to the auxiliary

sheave.
4. Pass the wire rope end through the weight for the
limit switch, and fix the end to the ball hook with the
use of the rope socket.
5. Connect the wiring of the auxiliary hook anti-two-

block (overhoist) limit switch, referring to chapter 3.
LOAD SAFETY DEVICE.
BOOL HOOK
6. Referring to chapter 3. LOAD SAFETY DEVICE the
same way, input the crane configuration in the load
safety device.
WEIGHT

correct. Failure to observe this precaution may re-
sult is overturning of crane and may lead to serious
injury or death.
6-51 7055-3
6.2 ERECTING THE ATTACHMENT

6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT
Check the following items, and confirm that there is no
abnormality, then erect the attachment.
1. Preoperation check,
2. Lubrication to the each part of the attachment,
3. The crawlers extended the working position,
4. The wire ropes correctly reeved,
5. Tools, etc. not left on the attachment,
6. The offlimiting step to the surrounding area of the
attachment was taken,
7. The wirings for the boom, main and auxiliary hook
overhoist limit switches correctly connected,
8. The wirings for the load detector and angle detector
correctly connected.
9. The load safety device is correctly set.
Appropriate mode (Main / Aux.) is chosen.
2. 4, 5, 7
1, 8, 9
3
6 6 6
7055-3 6-52
6.2.2 ERECTING THE ATTACHMENT

pins.
To prevent possible serious injury or death from

being dragged or struck by suddenly moving hook,
keep clear from the area near the hook when the at-
tachment is erected.
1. CAUTIONS WHEN ERECTING

(1) Erecting of the attachment must be performed in
the front and rear direction of the crawlers.
(2) When the boom angle is less than approximately 30
degrees, place the hook on the ground.
(3) Operation must be performed at a low speed.
Sudden start and stop must be avoided.
(4) Prevent the wire rope from catching and kink in the
tip of the boom and jib.
2. Release the drum lock in the side where the hook is

attached.
3. Operate the boom hoist control lever toward the
RAISING side to raise the boom slowly.
4. Paying close attention to catching and kink of the
hoist wire rope, raise the hook.
5. Before starting actual work, confirm the following
items.
(1) When the hook is raised to strike against the weight
for preventing overhoist, raising motion must be WEIGHT
stopped.
HOOK
hoisting /
lowering
6-53 7055-3
(2) When the boom is raised to approximately 80.0 de-

grees of boom angle, boom raising must be
stopped.
Approx. 80 deg.
(3) Check of the load safety device with controller if it

is difficult to check the automatic stop function in
case of overload by lifting a load actually, the func-
tion can be checked with the LMI controller.
Access the main screen, and press and hold the

SET switch. Then, the device simulates the over-
load status and the automatic stop function is actu-
ated (LMI check mode).
(56)Check mode
(Over load condition)
In this status, ensure that the hoisting of the hook
blocks and lowering of the boom are impossible.
(56)Check mode (Over load condition)
The LMI check mode is started when approx. three

seconds have pressed after the SET switch is
pressed, and passed after the SET switch is
pressed, and the mode continues until the switch is
released. The message of "(56) Check mode (over
load condition)" is displayed on the screen during
the LMI check mode.
7055-3 6-54
6.3 LOWERING THE ATTACHMENT

When lowering the attachment, observe the following
items.
1. Lowering of the attachment must be performed in
the front and rear direction of the crawlers.
2. When the boom angle is less than approximately 30
degrees, place the hook on the ground.
3. Operation must be performed at a low speed. Sud-
den start and stop must be avoided.
4. Prevent the wire rope from catching and kink in the
tip end of the boom and jib.
Before operating the boom ensure the area above

and beneath the boom is clear of all obstructions
and personnel.
6-55 7055-3
6.3.1 LOWERING THE ATTACHMENT

1. Lower the boom at a low speed.
2. When the boom angle exceeds the working area,

SET UP SWITCH
boom lowering is automatically stopped, and the
warning alarm sounds.
(The boom can be lowered onto the ground without
the automatic stop while the machine is in the spe-
cific posture. Refer to the page 3-57.)
3. Lower the hook onto the ground.
BOOM LOWERING SWITCH
4. Press and hold the "BOOM LOWERING SWITCH"
of the controller for about 3 seconds. The automatic
stop will be canceled. Lower the boom more.
5. By lowering the boom more, the hook overhoist limit
switch operates when the weight of the hook over-
hoist limit switch is placed on the ground, and the
boom lowering is automatically stopped again.
Press and hold the "SETUP" switch one time for
about 3 seconds and it becomes the "SETUP"
mode, and the boom can be lowered. Be careful be-
cause the hook overhoist automatic stop does not
operate in the "SETUP" mode.
7055-3 6-56
6.4 DISASSEMBLING THE ATTACHMENT

6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING
When disassembling the crane attachment, push the
"SETUP" switch. Then, the load safety device enters
the "SETUP" mode, and the automatic stop is can-
celed.
SET UP SWITCH
• Press a "SET UP" switch three seconds or more.

• The "SET UP" mode cannot be actuated while the
boom is raised.
When the boom is raised after the assembly is complet-

ed, the setup mode is canceled.
1. Disconnect the overhoist limit switch wiring in the

boom tip end, and wind it up onto the cable reel.
2. Disconnect the wiring between the cable reel and
the basic machine side, and install the short circuit
cap to the basic machine side wiring.
3. If the jib is attached, wind up the jib side wiring onto
the cable reel in the same way.
6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES

1. Confirm that the hook is set in the stabilized condi-
tion.
2. Remove the rope socket and clamp from the wire
rope end.
3. Slowly operate the front drum or rear hoist drum
control lever to wind up the hoist wire rope onto the
appropriate drum, being careful for being caught to
the sheave.

hands. Protruding wire could cause serious in-
jury. Working gloves are recommended.
• Keep away from rope end when removing the
wire rope. It may suddenly jump and cause inju-
ry.
drum and running wire rope.
6-57 7055-3
6.4.3 DISASSEMBLING THE JIB
Do not stand or work under, inside or on the jib

structure when assembling jib.
1. While holding the jib strut with the assisting crane,

disconnect the strut guy line from the insert boom.
Disconnect
JIB GUY LINE
STRUT
2. Remove the backstop from the strut, and lay down

the strut to the jib side.
3. Take off the jib guy line from the jib tip end.
4. Take off the jib side and boom side guy lines from
the strut.
5. With the jib held with the assisting crane, detach the
jib from the boom.
Place the jib on blocking.
7055-3 6-58
6. Disassemble the jib.

Draw out the top connecting pins first, then draw
out the bottom connecting pins.
To prevent the jib from jumping up when the jib con-
necting section is disconnected, support the jib with
blocking, etc.
Remove the top connecting pin.
6-59 7055-3
6.4.4 REMOVING THE BOOM GUY LINE

1. Set the spreader guide to the "working position",
and slowly slacken the boom hoist wire rope (Refer
to page HOW TO USE SPREADER GUIDE).
SPREADER GUIDE
Work position
2. Use the spreader guide, and install the upper

spreader on the lower boom with the pin.
UPPER SPREADER
Connecting with the pin
3. Disconnect the guy lines from the upper spreader.

UPPER SPREADER
GUY LINE
7055-3 6-60
4. Disconnect the connector sections of the guy lines

in order.
5. Using the assisting crane, lower the guy lines onto
the ground. At this time, be careful not to injure the
boom.
Disconnect
6-61 7055-3
6.4.5 DISASSEMBLING THE BOOM
Do not stand under, inside or on the boom struc-

ture when disassembling boom.
1. Disconnect the tip boom.

(1) While holding the tip boom with the assisting crane,
draw out the top side connecting pins.
Then, draw out the bottom side connecting pins,
and disconnect the tip boom.
2. Disconnect the insert boom.
(1) Hold the connecting section of the insert boom.
(2) Draw out the bottom side connecting pin in one side
only. After drawing out the pin, insert a bar to pre-
vent the pin hole from moving.
(3) Draw out the other bottom side connecting pin.
(4) Remove the moving preventive bar, and lower the
boom onto the ground with the use of the assisting
crane.
(5) Draw out the top side connecting pins, and discon-
nect the insert boom.
CONNECTING PIN
(PIN WITH BRIM)
7055-3 6-62
6.4.6 REMOVING THE BOOM BASE

1. Hold the upper spreader with the assisting crane.
Then, take off the upper spreader from the lower
boom, and place it on the ground to the left of the
basic machine.
2. While holding the backstop with the assisting

crane, take off the outer pipe from the revolving BACKSTOP
frame, retract it, and fix it to the bracket of boom
WIRE ROPE
base (both left and right).
3. While holding the foot side of the boom base with BASE BOOM
the assisting crane, draw out the boom foot pin in

the cab side (right side) first, then draw out the left
side boom foot pin.
Be careful that the lower boom can move suddenly,

once the boom foot pin is removed.
4. Move the basic machine backward a little, and low-

er the boom base onto the ground.
6-63 7055-3
6.4.7 REMOVAL OF THE COUNTERWEIGHT

Remove the counterweight as per section 5.3 INSTAL-
LATION, REMOVAL OF THE COUNTER-
WEIGHT(WHEN USING THE AUXILIARY CRANE).
Do not stand on or under the lifted counterweight or

between weight and the basic machine to avoid ac-
cident of being caught.
6.4.8 LOWERING THE GANTRY

Lower the gantry as per section 5.2 ERECTING/LOW-
ERING THE GANTRY.
Do not stand under the gantry to avoid accident of

being caught due to sudden drop of the gantry.
7055-3 6-64
6.5 CAUTION WHEN TRANSPORTING BOOM

1. In order to prevent the boom from damage, do not
Protection of
hook the fixing ropes directly to the main chord MAIN PIPE boom
members and lacing members. Be sure to use sling
cloth.
LATTICE
Do not transport the boom with the lattice pipe fixed.

Lattice pipe may be damaged.
2. Place wooden block under the both ends of the

boom.
3. When placing a boom upon another boom, place

blocking just above the under blocking.
Place the insert boom with lugs attached on the
bottom. If it is placed on the top, the transporting
height becomes high.
6-65 7055-3
7055-3 6-66
7. ASSEMBLY/DISASSEMBLY OF TOWER CRANE ATTACHMENT
7. ASSEMBLY/DISASSEMBLY OF TOWER CRANE

ATTACHMENT
This section covers : assembly, erecting, lowering and
disassembly the tower crane attachment.
Assembly procedure start when the crane is in the fol-
lowing condition.
• The crawler are extended.
• All of the counterweight are installed.
• Tower hoist rope is reeved through the upper and
lower spreader and the gantry is in working posi-
tion. (high gantry)
• The tower base section attached to the base ma-
chine.
• The spacer for crane is installed to the backstop.
• The guide sheave for main hoist wire rope is in-
stalled to the 9.1 m insert tower boom.
Confirm the following items before starting the work.

1. LOCATION
(1) The attachment must be erected in front or rear of
the crawlers.
(2) There must be adequate room for assembly, and
the ground must be firm and level.
(3) Cure the ground as required and lay sheet plates of
iron.
(4) There must also be adequate room for an assisting
crane, room for free passage of vehicles delivering
necessary parts, and room for unloading and stor-
ing the parts until they are needed.
2. WORKING PROCEDURE AND SAFETY PRE-
CAUTIONS
Before assembling work, ensure that all necessary
personnel understand the working procedures and
safety precautions, their precise role in the opera-
tion, and the reponsibilities of each person.
7-1 7055-3
3. PRE-OPERATION INSPECTIONS
Perform the pre-operation inspections of the basic
machine.
Do not stand or work under, inside the tower boom

or jib when assembling or disassembling the tower
boom or jib at anytime. Failure to observe this pre-
Do not apply slings directly to a sharp edge part to

prevent the slings from being cut. Apply the sling to
the guy cable pin hole or bracket for lifting through
a shackle.
Before climbing on machine, make certain that the

Use a scaffold board for work on the boom.
Do not put your hand or finger into a pin hole. Fail-

ure to observe this precaution may result in serious
injury or death.
Fix guy line ends with tower boom in order to prevent

accident due to fall of guy line from the tower boom
when the tower boom is transported. Failure to observe
this precaution may result in serious injury or death.
Do not handle tower boom or jib sections with chains,

hooks or wire rope attached directly to main chords. Ei-
ther use soft material sling points or use fabric type
slings. Do not put slings to the lacings of tower boom or
jib sections.
7055-3 7-2
7.1 ASSEMBLING TOWER ATTACHMENT

[ TOOLS ]
• Chain block (3t)
• Wooden block
• Steel bar
• Sling cloths
When assembling the tower attachment, push the "SET SET UP SWITCH
UP" switch. Then, the load safety device enters the
"SET UP" mode, and the automatic stop is canceled.

boom is raised.
When the tower is raised after the assembly is complet-
ed, and the "SET UP" mode is canceled.
7-3 7055-3
7.1.1 PREPARATION OF TOWER BOOM/JIB/GUY LINE

1. TOWER BOOM AND JIB
Prepare necessary sections according to the ar-
rangement chart.
Do not assemble the tower and jib which are not
specified in the arrangement chart.
Check for any damage on each tower and jib sec-
tion.
If any damage is confirmed, repair the damage in
the KOBELCO authorize distributor.
Do not use damaged tower boom or jib section. The

damaged section may collapse and cause serious
injury or death.
2. GUY LINE
Prepare necessary guy line according to the ar- (Face)
rangement chart as same manner as tower boom
Part No. : Ex. 209D1
and jib section.
The tower guy line and jib guy line are 30 mm in di-
ameter. Check the stamped part number (Five last (Back)
digits) on the connector section for identification.
Manufacturing date : Ex. 02-5
7055-3 7-4
3. Tower Boom and Guy Line Arrangement Chart
1. Depending on the purchased configuration of tower

boom, tower boom arrangement will be limited and
NOT be able to made all arrangements of tower
boom as shown on the chart.
2. The tower boom arrangement with " " mark pur-

chased, which can be able to assemble one of the
tower boom arrangement shorter than you choose
on respective tower boom length in the chart.
Tower Length m (ft) Tower and Guy line arrangement Chart
21.0 (69) Guard installing position

b T
17.8 m
3.5 m
b
24.1 (79)
b T
GUARD RAIL
b
27.1 (89) T
b T
b T
30.2 (99)
b T
b T
33.2 (109)
b T
7-5 7055-3
Tower Length m (ft) Tower and Guy line arrangement Chart
b T
36.3 (119)
b T
39.3 (129)
b T
42.4 (139)
b T
shown in the figure above should basically

used in the tower.

for the insert boom section. (option)
7055-3 7-6
Tower Length m (ft) Jib and Guy line arrangement Chart
16.8 (55)
b T
b T
19.8 (65)
b T
22.9 (75)
b T
b T
25.9 (85)
b T
29.0 (95)
b T

for the jib tip section. (standard)
for the insert jib section. (option)
7-7 7055-3
Tower Guy Line and Jib Guy Line

Diameter Length
Symbol Part Number Connector Type
(mm) (m)
A 30 1.70 2430R209D13
B 30 3.05 2430R209D1
C 30 6.10 2430R209D2
D 30 9.14 2430R209D3
E 28 7.70 2430R458D9
F 28 3.05 2430R458D2
G 28 6.10 2430R458D3
H 28 13.65 GB71A00002D1
J LINK 0.64 GB16A01034P1 —

K LINK 0.16 GB64A01041P1 —
L LINK 0.30 GB16A01035P1 —
COMBINATION OF TOWER AND TOWER JIB

Jib Length (m) Counter-
weight
Tower Length
for
(m) 16.8 19.8 22.9 25.9 29.0 Steel Plate
raising /
lowering
21.0 90° to 60° 90° to 60° — — — Needless Needless
24.1 90° to 60° 90° to 60° 90° to 60° — — Needless Needless
27.1 90° to 60° 90° to 60° 90° to 60° 90° to 60° - Needless Needless
30.2 90° to 60° 90° to 60° 90° to 60° 90° to 60° 90° to 70° Needless Needless
39.3 90° to 70° 90° to 70° 90° to 70° 90° to 70° 90° to 70° Need Needless
42.4 90° to 70° 90° to 70° 90° to 70° 90° to 70° 90° to 75° Need Need
19 t Installation Installation
Jib point Need Needless Needless
Hook prohibition prohibition
weight
Ball Installation Installation
(300 kg) X Need Needless
7055-3 7-8
7.1.2 CHANGE OF BASIC MACHINE TO TOWER CRANE ATTACHMENT

1. ALTERATION OF BACKSTOP
Remove the spacer for crane from the backstop.
CRANE SPACER
TOWER
7-9 7055-3
2. REMOVAL OF REAR DRUM WIRE ROPE
Before starting the engine, put each control lever to

neutral and make sure for safety around the ma-
chine.
• Do not touch a wire rope directly bare hands.

If wire protrude, you could be injured. Working
When the auxiliary wire rope has been wound on the

rear drum, pull out the entire wire rope.
(1) Start the engine.
(2) Put the rear drum control lever to lowering side.
(3) Remove the rope slowly.
(4) After the rope is removed, stop the engine.
(5) Store the pulled out wire rope carefully so that it is
not damaged.
7055-3 7-10
7.1.3 ASSEMBLY OF TOWER ATTACHMENT
Do not enter into the area under assembling, disas-

sembling of the tower and jib.
Wear safety belt for high place work to avoid acci-

dent. Use scaffold board for work on the tower.
Make sure that the working area is clear of persons

during hammering a pin to avoid accident of bro-
ken handle or broken piece.
Be sure to apply grease to all the connecting pins.
Prior to performing any further step, make sure that the

tower base is installed on the machine.
1. SETTING OF STEEL PLATES FOR ERECTING

AND LOWERING THE TOWER
To prevent turnover of the crawler crane during

erecting and lowering of the tower, place steel
plates between the end of the crawlers and the STEEL
PLATE
ground if the tower length is 39.3 m and 42.4 m.
(1) In case of tower length is 39.3 m and 42.4 m, when

the steel plate is required, place the steel plates in
front of the crawlers. Run the machine forward until
the front ends of the crawlers are aligned with those
of the steel plates.
7-11 7055-3
(2) Install the counterweight for raising/lowering with

the assisting crane when the tower length is 42.4 m
(the longest tower).
Counterweight for
raising/lowering
2. EXTENSION OF TOWER SPRING PIN

(1) Lift the 9.1 m special insert tower (with brackets)
with the assisting crane, and align the pin holes on
the upper side of the connection part with those on
the tower base. Insert the right and left connecting CONNECTING PIN
pins (with brims) so that the lock pin holes face up-
ward and downward. Then, lock the connecting
pins with the spring pins.
Do not put your hand or finger into pin holes.

rious injury.
(2) According to the tower arrangement charts connect

the insert towers one by one. All the pins used
have a brim.
Be sure to insert the pins with brims from outside into

inside.
Connect insert tower boom
Do not connect hear
7055-3 7-12
3. INSTALLATION OF TOWER CAP
(1) Install the guide roller to the tower cap with the pins.
GUIDE ROLLER
CONNECTING PIN CONNECTING

PIN
TOWER CAP
(2) Install the tower cap to the end section of the tower
insert boom.
(A) Lift the tower cap with assisting crane.
UPPER CONNECTING PIN
(B) Insert the upper connecting pins. Place the wooden

block under the tower cap and lower the tower cap
on it.
(C) Put a sling to the end of the insert tower section.
(D) Lift the insert tower boom slowly and insert the low-
er connecting pins.
(E) Lower the end of the tower cap on the wooden
block.
LOWER CONNECTING PIN
7-13 7055-3
4. INSTALLING THE UPPER SURFACE GUARD- 17.8 m : From center of tower foot pin
RAIL ON THE TOWER
Install the tower upper surface guardrail for the jib's
hoist upper part spreader.
For the installing position, refer to the tower con- TOWER TIP
struction drawing. SIDE
UPPER SURFACE
GUARDRAIL
UPPER
SURFACE GUARDRAIL
U-BOLT
BOOM
7055-3 7-14
5. REEVING OF MAIN HOIST WIRE ROPE

Pay out the main hoist wire rope from the front
drum, and reeve it through the guide sheave of the
tower cap. Pay out the top end of the wire rope
more approx. 10 m.
Wear safety belt for high place work to avoid acci-

dent. Use scaffold board for work on the tower.

Protruding wire could cause serious injury.
injury or death.
MAIN HOIST WIRE ROPE
Thread the wire rope

under the guide sheave
Extend about 10 m
7-15 7055-3
6. INSTALLATION OF STRUT
(1) Place the strut on the ground and install the guy line
( 28 mm x 7.7 m) to the strut link.
7.7 m GUY LINE
(2 pieces)
LINK (TOWER SIDE)

REAR STRUT
FRONT STRUT LINK (JIB SIDE)
(2) Separate the connected portion (A) holding the guy

line with the auxiliary crane and wind up the guy line
with the auxiliary crane until the angle that the rear
strut makes to the ground becomes around 80 de-
grees.
Approx. 80 deg.
(㧭)
(3) Remove the connection rod from the hook.
HOOK (A)
CONNECTING ROD
7055-3 7-16
(4) Gradually lower the guy line hoisted with the auxil-
iary crane while holding the (B) part of connection
rod so that it does not interfere with the front strut.
Connect the (B) part of connection rod to the con-
necting portion (A).
(B)
(5) Install the strut to the tower cap.
Make sure the surface and walkway are dry and use
life belt in order to prevent fall due to slippery sur-
face.
Use scaffold board on the tower.
Do not put your finger into pin hole.

rious injury.
SPRIT PIN
PIN
LOCK PIN
(6) Lower the strut slowly on the ground. Place guy line on the roller
LINK
7-17 7055-3
7. INSTALLATION OF STRUT GUY LINE

Connect the strut guy lines one by one from strut
side to the base machine side. GUY LINE
safety belt in order to prevent fall due to slippery
surface.
Guy line may move abruptly or flip off unexpectedly.

Pay attention for the movement of the guy line.
7055-3 7-18
8. INSTALLATION OF UPPER AND LOWER

SPREADER FOR JIB HOIST.
• The upper and the lower spreaders are shipped

with wire reeved from the factory.
• Once the wire is reeved, not necessary to reeve
again.

Protruding wire could case serious injury.
injury or death.
LOWER
SPREADER
UPPER
SPREADER
Bundle wit wire at a few place
Approx. 15 m Approx. 16 m
7-19 7055-3
To reeve a wire rope when replacing it, refer to the

drawings below, and reeve it through the upper and
lower spreaders.
Connect the rope end to the lower spreader with the
rope socket.
ROPE SOCKET
UPPER
SPREADER 6
UPPER
4 SPREADER
8
7
5
3
ROPE SOCKET
ROPE
SOCKET
LOWER
SPREADER
1
LOWER
SPREADER
GANTRY IDLER
SHEAVE
To jib drum
(Rear drum)
To jib drum
(Rear drum)
7055-3 7-20
(1) After reeving a wire rope through, install the upper

and lower spreader on the machine.
Do not put your finger into a pin hole.

rious injury.
(A) Lift the lower spreader with assisting crane and

connect it to the bracket of 9.1 m special insert tow-
er and fix with the pins.
PIN LOWER SPREADER
SPRIT PIN
(B) Connect the catwalk and the lower spreader with

LOWER SPREADER
the attached shackle and the wire rope.
SHACKLE
WIRE ROPE CATWALK
7-21 7055-3
(C) Lift the upper spreader with assisting crane, and

place it on the guard rail on the tower boom.
safety belt in order to prevent fall due to slippery
surface.
(D) Connect the strut guy line to the upper spreader.
UPPER SPREADER Connect the strut guy line
UPPER SURFACE GUARDRAIL
7055-3 7-22
9. INSTALLATION OF JIB HOIST WIRE ROPE TO

JIB HOIST DRUM (REAR DRUM)
Before starting engine, make sure each control le-

ver is in the neutral position and check for safety
around the crane.
GANTRY SHEAVE
COTTER
injury or death. Jib drum (Rear drum)
(1) Fix the end of the wire rope to the jib hoist drum
(rear drum) with wedge.
(2) Wind up the jib hoist rope for 3 to 4 rounds onto the
drum.
WIRE ROPE
DRUM FLANGE
COTTER
LOCK BRACKET
7-23 7055-3
10. INSTALLATION OF TOWER GUY LINE
Before climbing on machine make certain that the

guard and walkways are clean an dry and use safe-
ty belt in order to prevent falls due to slippery sur-
face.
Use step plate on the boom.
TOWER Connect
GUY LINE
Pay special attention to the movement of the guy line.
Guy line may abruptly flip off or unexpectedly move.
Connect the guy line first to the tower cap side.
(1) Lift the top guy line with assisting crane and con-
nect it to the tower cap link.
(2) Connect the tower guy lines according to following
the tower arrangement chart.
TOWER GUY LINE
(3) Slacken the tower hoist wire rope.

(4) Lift and move forward the upper spreader for the
tower with the auxiliary crane, and connect it to the Temporarily connect
bracket on the 9.1 m special insert tower. the upper spreader
to this bracket
(5) Connect the tower guy line to the upper spreader.
7055-3 7-24
11. CONNECTION OF TOWER BASE AND 9.1 m

SPECIAL INSERT TOWER BOOM
Lift the connection part of tower base and 9.1 m
special insert tower, and align the lower pin holes.
Then, insert the tapered pins both in right side and
left side.
Do not put your finger into a pin hole.

rious injury.
CONNECTING PIN (Both taper)
12. WINDING UP OF TOWER HOIST ROPE

Wind up the tower hoist rope until the upper spread-
er detaches from the spreader guard.
GUY LINE
(1) Disconnect the upper spreader from the bracket on
UPPER SPREADER
the 9.1 m special insert tower.
(2) Wind up the tower hoist rope until the upper spread-
er for the tower detaches the spreader guard. Wind up
When lifting the guy line with the assisting crane, and
wind up the rope on the drum, be sure to apply a certain
load to it. Otherwise, rough spooling will occur.
7-25 7055-3
13. INSTALLATION OF TOWER JIB FOLDING LATCH

BRACKET
DETECTION LIMIT SWITCH

(Under the lever)
U-NUT
U-BOLT
LATCH BRACKET “A”
(TOWER SIDE)
U-NUT
LATCH BRACKET “B”

(JIB SIDE) U-BOLT
7055-3 7-26
(1) Install the tower side latch bracket "A" in the tower
according to the length of the jib to be installed.
Installation position of latch bracket
Jib Length
16.8 19.8 22.9 25.9 29.0
(m)
L
12.1 15.1 18.2 21.2 24.3
(m)
(2) Fix the bracket "A" with U-bolts to the specified

place shown. TOWER
LATCH BRACKET “A”
TOWER FOOT SIDE TOWER POINT SIDE U-BOLT

BRACKET “A”
7-27 7055-3
14. WIRING OF TOWER JUNCTION CABLE

Connect the tower junction cable wound on the ca-
ble reel which is located in the right side of the tow-
er base section. For detail refer to the Chapter 3.
LOAD SAFETY DEVICE.
Also connect the wiring of the anemometer (option)

and overhoist limit switch.
HANGER
HARNESS
Connect the tower junction cable
Position to connect the cable for the wind speed detector (Optional)
Operate the machine with this cable connected all the time.
7055-3 7-28
15. CONNECT THE ELECTRIC CABLE OF JIB

LATCH LIMIT SWITCH.
(1) Connect the electric cable to the limit switch of the

jib latch.
(A) Pull out the cable (for crane overhoist limit cable)
from the cable reel and fix it to the Bracket "A".
(B) Connect the cable and limit switch. (two places)
(C) Fix the cable to the hunger of the boom main pipe.
BRACKET “A”
THIMBLE
CABLE REEL FOR LATCH

(LOWER SIDE)
HANGER
LIMIT SWITCH
(2) Install the latch control rope.
CONTROL ROPE
7-29 7055-3
16. WIRING OF LOAD DETECTOR CABLE LOAD DETECTOR CABLE

(1) Connect the cables for tower jib load detector to the
load detector.
(A) Fix the cables for tower jib load detector to the
bracket with a thimble.
(B) Connect the cable for tower jib load detector with
the load detector cable. JUNCTION CABLE
(2) Connect the cables for the tower jib load detector to
the junction panel.
CLAMP
Do not pull or nip the cable to avoid damage of the load

detector cables.
THIMBLE
(3) Insert the junction panel to cable for crane load de-
tector.
CONNECTOR
FOR LOAD CELL
7055-3 7-30
7.1.4 ASSEMBLY OF TOWER JIB
Do not stand or work under, inside of boom and jib

structure when assembling and disassembling jib
and boom.

rious injury.
1. PREPARATION OF THE ASSEMBLING SPACE

FOR TOWER JIB.
Raise the tower and prepare the assembling space
for the tower jib.
(1) On the ground, mark the position of the tower cap

end and the center of the tower.
Mark on the ground
(2) Sling the strut with the auxiliary crane to erect the
tower at a low speed.
Stop the operation once when the strut made a little
dynamic lift off and remove the sling wire rope.
Wind up the jib hoist rope to the degree so that
slacks can be eliminated.
WIRE ROPE
7-31 7055-3
(3) Erect the tower to approximately 20 degrees at a

low speed.
Pay attention because the assembly/disassembly

mode is canceled and the automatic stop is activated if
the tower boom is erected to 40 degrees angle or more.
Fasten the main hoist

rope to the tower
guide roller.
Approx. 20 deg.
(4) Remove the swing lock pin and swing the machine
to make space for assembling tower jib.
Approx. Jib assembling yard

20 deg. MARK
MARK
2. ASSEMBLING THE TOWER JIB BASE

MACHINE
(1) Place the jib base upside down and the foot area on SIDE
the mark (tip of tower cap).
(2) Place the jib insert upside down and connect them
one by one according to the arrangement chart.
(3) Place the jib tip upside down and connect to the jib MARK
insert. POSITION
BASE MACHINE
SIDE
7055-3 7-32
3. PREPARATION OF THE HOOK

Place the 19 ton hook or 7 ton ball hook at the jib tip
area.
Do not use 7 ton ball hook with 16.8 m jib. In case, if ball
hook is used with 16.8 m jib, the jib can not be lowed
when the jib angle is more than 60°.
4. Installation of jib point weight

Install the jib point weight to the upper jib referring
to the following table.
To prevent the jib from erecting backward, always in-

stall the jib point weight when the jib length needs the
installation of jib point weight.
Do not install the jib point weight to the jibs longer

than 25.9 m. Installation may damage the jib.
Installation of jib point weight

7 ton
Jib length 19 ton Hook
Ball hook
16.8 m Need to install —
19.8 m Need not to install Need to install
22.9 m Need not to install Need not to install
25.9 m / 29.0 m Prohibited to install Prohibited to install
7-33 7055-3
(1) Place the rootstock under the front end of the jib.
Main unit side
(2) Install one jib point weight (150 kg x 2 pieces) each

at the right and left tip ends of upper jib.
(A) Put the weight on the section (a) of the upper jib us-
ing the auxiliary crane.
“a”
(B) Secure the weight with two pins (b). Bend the split
pin as shown in the right figure after attaching the
throttle nut. JIB TIP
WEIGHT
SPLIT PIN
“b”
7055-3 7-34
5. WIRING OF JIB SAFETY DEVICE

Connect the cable for the hook overhoist limit
switch.
(1) Pull the cable from the jib cable reel and fix it with
the thimble to the bracket.
(2) Install the hook overhoist limit switch.
(3) Connect the cable to the hook overhoist limit switch
to the cable of the cable reel.
(4) Connect the wiring of the tower jib backstop limit
switch.
Connect the cable
THIMBLE
Set the cable reel stopper

Thimble is fixed to bracket
after extending cable
HOOK OVERHOIST
LIMIT SWITCH
WEIGHT
7-35 7055-3
6. INSTALLATION OF JIB
(1) Swing the machine and make the center line of the
tower coincide with that of the jib.
Swing to right
on top of jib
(2) Lower the tower until the strut link lightly contacts
the ground.
LIFTING WIRE ROPE
(3) Hoist the wire rope which is installed to the strut us-
ing the auxiliary crane and lower the tower further
at a low speed while spacing the strut from the
ground.
Do not let the under side of the tower interfere with the
jib in order to prevent damage.
Afterward, leave the strut on the ground and re-

move the auxiliary crane.
7055-3 7-36
(4) Put the sling to the jib foot area through the inside of
the tower and lift the jib by the assist crane so that
the jib foot can be connected to the tower cap.
Make alignment of the pin holes on the jib foot and
the tower cap and connect them with pins.

rious injury.
PIN
TOWER CAP
TOWER JIB
Do not pinch the cable of the jib foot with the tower cap
and jib base.
7-37 7055-3
7. WIRING OF SAFETY DEVICE BETWEEN TOW-

ER AND JIB.
Connect the hook overhoist limit switch cable and
angle detector cable through the handle of jib foot
pin.
After it connect, the cable is clamped.
CLAMP
CABLE FOR HOOK

OVER HOIST LIMIT SWITCH
CABLE FOR JIB ANGLE
DETECTOR
8. INSTALLATION OF TOWER JIB FOLDING LATCH

BRACKET
(1) Install the jib side latch bracket "B" to the jib under
the tower side latch bracket (A). Fix the bracket "B"
temporary with U-bolt.
BRACKET “B”
BRACKET “A”
U-BOLT
7055-3 7-38
(2) Put the lifting sling to the tip of jib through the inside
of the tower, and lift the jib and make sure that the
brackets "A" and "B" meet each other correctly.
Put together
(3) Lower the jib slowly and put the jib weight on the jib 㨆
latch. In this case hoist the tower slightly if the tower
is lowered and the jib is touching on the ground.
Under this condition, adjust the position of the
bracket "B" so that distance "L" (from the end of the
bar "C" to the inner side of the bracket "A") in the
view shown right becomes 25 mm or less and se-
㨆
cure the bracket "B" with U-bolt.
If the distance "L" is 25 mm or longer, raise the as-
sisting crane and readjust the position of the brack-
et "B". BRACKET “A”
TOWER
BAR “C” “L” = 25 mm
40 mm JIB
JIB TIP SIDE BRACKET “B” JIB FOOT SIDE
SECTION Z-Z
7-39 7055-3
LEVER
SPRING “D”
• If the distance "L" is too large, the jib may be
Approx.196 mm
distorted and position of the bar "C" against the
tower varies and the bar "C" may push the
bracket "A" when hoisting and lowering the
tower. This may cause damage to the equip-
ment.
PLATE “F”
• The length of the spring "D" is set to 196 mm
BAR “C” PIN “E”
under the condition shown in the right figures
to prevent the pin "E" from coming off while the
jib is released.
Check that the parts are positioned as shown in
the right figure when the latch is installed.
(4) When the pin "E" is set correctly, it protrudes about

40 mm from the flange. Confirm it when the jib is
supported with the latch.
When the jib moves toward the tower, the bar "C"
pushes out the plate "F" and the pin "E" drops auto-
matically and fix the jib. PIN “E”
After wiring the latch limit switch, the movement of
the pin "E" can be monitored on the latch indicating
lamp (red) provided on the overload safety device
controller.
In order to release the latch, pull the latch control BAR “C”
40 mm
rope until the lever touches the stopper.
When the latch is engaged
STOPPER
LATCH CONTROL ROPE
When the latch is released
7055-3 7-40
9. SETTING JIB BACKSTOP
STORED POSITION WORK POSITION
(1) Hold the backstop with assisting crane and pull out
the Pin "A" and lower the left and right backstops.
PIN “A”
(2) Pull out the Pin "B" and lower the support.
SUPPORT
PIN “B”
(3) Connect both side backstops to the support with Pin

"B".
7-41 7055-3
10. INSTALLATION OF CABLE ROLLER FOR JIB

Install the cable roller to the place shown in the jib
arrangement chart in 7.1.1 PREPARATION OF
TOWER BOOM/JIB/GUY LINE.
(Refer to below figure for the dimension.)
FOR JIB TIP FOR INSERT JIB
11. CONNECTION OF JIB GUY LINE
Pay attention to the movement of the jib guy line.

Jib guy line may abruptly move or flip off unexpect-
edly.
(1) Connect the guy line from jib tip side to the jib foot
side.
JIB GUY LINE
(2) Erect the tower until the strut leaves about 500 mm
from the ground.
(3) Move the strut link as shown in the figure.

(Pull out the lock pin and move the link, and insert
the lock pin (A) again.)
ROD
LINK
LOCK PIN “A”
7055-3 7-42
(4) Lower the tower until the strut link touch to the
ground.
(5) Connect the jib guy line to the link of the strut.
Connect
7-43 7055-3
12. REEVING OF HOIST WIRE ROPE

injury or death.
(1) Pay out the hoist wire rope and reeve it as shown
below.
(2) Install the rope socket to the end of the wire rope.
(3) In case of two parts of line, connect the socket to
the pin.
In case of one part of line, connect the socket to the
hook.
TWO PARTS OF LINE ONE PART OF LINE
7055-3 7-44
13. WIRING OF OVERLOAD SAFETY DEVICE

Refer to Chapter 3. LOAD SAFETY DEVICE in de-
tail.
(1) Connect the angle detector cable to the junction
panel of the base machine.
(2) Connect the tower junction cable to the junction
panel of the base machine.
(3) Connect the tower latch limit switch cable to the
junction panel of the basic machine.
Connect cable for tower Connect cable for tower
(4) Input the attachment assembled to the controller. boom angle detector (3) load detector
Connect tower junction Connect cable for tower

cable (13) latch limit switch
7.1.5 FUNCTION CHECK OF EACH LIMIT SWITCH
Before starting the engine, all levers are in neutral

positions and make sure every one is clear of the
machine and work area.
1. Start the Engine.

2. Check functions of the tower overhoist limit switch,
the jib overhoist limit switch and hook over hoist lim-
it switch.
Refer to Chapter 3. LOAD SAFETY DEVICE to
check the functions.
When the parts of overhoist limit for tower and jib
are changed or moved, angle of limit must be adjust
again.
In such case, consult your KOBELCO authorize
distributor.
3. Check the controller display to make sure that the
jib latch limit switch works properly.
If the latch is engaged, the "ON (ENGAGE)" indica-
(RED) (GREEN)
tor will turn red. If it is disengaged, the "OFF (DIS-
ENGAGE)" indicator will turn green.
7-45 7055-3
7.2 ERECTING THE TOWER ATTACHMENT

7.2.1 ERECTING THE TOWER BOOM
Do not stand under the tower and jib attachment in

order to prevent accident due to rapid lowering of
the tower and the jib.
Placing a watchman is recommended.
Do not erect the tower or the jib under the strong

wind in order to prevent turnover accident due to
wind.
7055-3 7-46
1. Check each area referring to the next diagram for

safety before erecting the tower.
CHECK POINTS BEFORE ERECTING THE TOWER
(1) Check pins and split pins guy lines for surely installed.
(2) Check wire rope for correct reeving.
(3) Check wire rope for neither tangling nor hanging.
(4) Check all cables of safety device for proper connection.
(5) Check all limit switches for proper function.
(6) Check jib backstop for working position.
(7) Check tower backstop for working position.
(8) Check tower posture correctly input to the controller.
(9) Check propel motor for rear position of the machine.
(10) Check jib latch for securely engaged.
(11) Check swing lock pin for engaged.
(12) Check the rear drum is neutral.
(13) Check all tools, etc. not left on the attachment.
(14) Check to see if any provision of KEEP OFF under tower boom has been made.
(15) Check to see if guy lines are placed properly on the guide roller.
(16) Check to see if the lubrication has been done to all necessary points.
(17) Check wire rope on the tower hoist drum and jib hoist drum for tight and good spooling.
(18) Check that the steel plates for erecting and lowering tower are set .
• In the case of tower length are 39.3 m, 42.4 m tower.
(19) Check that the jib point weights (150 kg x 2 pieces) are installed when the 19 t hook is used with the 16.8 m
jib, and when the ball hook is used with the 19.8 m jib.
(20) Check that the main hoist rope is reeved under the guide roller.
(21) Check that the counterweight for raising/lowering is installed (when the tower length is 42.4 m).
(12)
(5) (11) (8) (7) (20) (1) (13) (15) (4)
(14)
(9) (18) (19) (5) (10) (1) (5) (6) (2)

(3)
(14) (14)
7-47 7055-3
2. Raise the tower. (from the ground to 75 degrees)

(1) Wind up the slack of jib hoist wire rope with operat-
ing jib drum (rear drum) to avoid rough spooling on
the drum, and stop operation of the jib drum (rear
drum) when the slack has been taken.
When taking a tower erecting configuration, jib
hoisting speed is slowed down.
(2) Raise the tower with slow speed.
(3) When the tower is raised, the jib hoist rope be-
comes slack. Control the jib hoist controller lever to
the hoisting position, and wind up the jib hoist rope
until the jib guy line is tensioned moderately.
Do not raise the tower nor raise the jib, if a forecast

buzzer (intermittent buzzer) sounds while raising
(lowering) the tower. Failure to observe this pre-
caution may lead the damaged attachment, and re-
To prevent the attachment from being damaged, when

the jib hoist rope is over tensioned while raising the tow-
er, a forecast buzzer (intermittent buzzer) sounds, and
the jib hoist speed is slowed down.
When a forecast buzzer (intermittent buzzer) sounds,
set the tower and jib hoist control lever to the neutral
position, and slowly set the jib hoist control lever to the
lowering position. Do not slacken the jib hoist rope too
much so that rough spooling does not occur on the jib
hoist drum.
• Tower hoist controller lever

In a fixed position
• Jib hoist controller lever
Control appropriately according to the slack on the
jib hoist rope.
7055-3 7-48
(4) When the tower is raised up to approx. 75 degrees,

stop raising the tower for a while. If the steel plates
for erecting and lowering tower are used, propel the
machine backward a little, and remove the steel
plates from under the crawlers.
The operation is also possible with the weight for
raising the longest tower (3.3 t) still installed, but the
backward stability can be improved when the
counter is removed.
Counterweight for
raising/lowering
STEEL
PLATE
7-49 7055-3
Check point for raising tower to 75 degrees
Jib guy line is properly seeting

on the guide roller
Raise up to about 75 degress
Adjust jib hoist rope

so that jib guy line is
moderately tensioned.
Off limit
Pay out the hook hoist wire rope

so that the hook block stays on
the ground
7055-3 7-50
3. Raise the tower to 80 degrees. As the tower angle

is closer to 90 degrees, the tower raising speed is
decreased.
(1) Shift the lever specially slow and carefully when Stop position
raising the tower angle from 85 to 90 degrees. Do
not quick operation of the lever.
When tower angle reaches 90 deg.

(2) Stop raising the tower when the indicator bar of the
backstop is aligned with the mark, as shown in the
right figure.
630 -10 mm
At this point, if the tower angle in the tower angle in-
+20
dicator of the load safety device controller is out of
range between 89.6 degree to 90.2 degree , contin-
ue housing the tower until the tower angle falls with-
in this range.
Unlike conventional constructions, the tower backstop

has a unique structure : the outer pipe reaches the bot-
tom before the spring comes into fall contact with the
tower backstop. When the outer pipe reaches the bot-
tom, the spring length is 590 mm, and the tower angle
is 91.1 degree.
To prevent any damage to the tower, DO NOT insert

the inner pipe of the tower backstop until it comes
into contact with the bottom of the outer pipe.
Failure to observe this precaution will lead to dam-
ages to the machine.
The overhoist No.1 limit switch (right) of the tower

boom is adjust so that the tower boom stop when
the tower angle reaches 90.2 degree. Confirm that
the spring length is 623 mm at that point.
In some case, the tower overhoist stop limit switch may

be actuated and an alarm sound may be emitted, owing
to the grade of ground.
7-51 7055-3
Check point when tower is raised upright
Jib guy line on the jib

side is loose
7055-3 7-52
7.2.2 ERECTING THE JIB
Do not stand on working area of the jib during

erecting the jib.
Do not raise or lower the jib while the tower boom

is inclined. (Angle is less than 89.4°)
1. Hoist the hook slightly from the ground.

2. Check to see if the rear drum speed adjusting knob
90 deg.
is LOW position.
Hoist the hook slightly

from the ground.
OFF LIMIT
7-53 7055-3
3. Disengage the jib latch.

(1) Pull the latch control rope.
(2) Check to see if the latch is disengaged.
(3) Fix the latch control rope under the pulled condition.
LATCH
(4) Check to see if the indicator lamps are as follows
from the controller of operator room.
ON LAMP: OFF
OFF LAMP: ON (GREEN)
LATCH CONTROL
ROPE
(GREEN)
7055-3 7-54
4. Raise the jib.
Do not raise the jib with jib latch is engaged.

(1) Control the jib control lever to hoist side after check-
ing that the jib latch is disengaged.
(2) Jib will start moving from the tower after hoisting jib
and the slack of jib guy line is taking up.
If it does not move apart from the tower, stop hoist
and check for cause.
(Engagement of the latch, tangled wire rope etc.)
5. Alarm buzzer starts sound when the jib angle about

8 to 13 degrees.
Keep raising the jib. When the jib angle comes with-
in the working range, the controller change its mode
from alarming mode to working mode.
7-55 7055-3
7.2.3 INSPECTION BEFORE USE

If indication error or wrong function is found, consult
your KOBELCO authorize distributor.
1. CONFIRMATION OF HOOK OVERHOIST PRE-

VENTIVE FUNCTION
(1) Confirm that the hoist function stops when the hook
touches the weight of the overhoist limit switch.
(2) Lower the hook to the safety range.
2. CONFIRMATION OF JIB OVERHOIST PREVEN-

TIVE FUNCTION
Do not operate the control lever quickly when the jib off-
set angle becomes smaller than 20 degrees in order to
prevent unstable movement of the jib.
(1) Confirm the stop function by controller. Raise the jib

by slow speed and confirm that the jib stops auto-
matically at the off-set angle of 14.5 degrees.
(2) Confirm the stop function of the jib overhoist limit
switch. Operate the boom overhoist release switch
and hoist the jib further and confirm that the jib
stops automatically again at the off-set angle of 13
degrees or more.
NEVER hoist the jib until the jib offset angle is below 13
degrees. If the jib hoisting is not stopped automatically
even when the jib offset angle reaches 13 degrees, low-
er the jib at once, and consult nearest KOBELCO au-
thorize distributor.
7055-3 7-56
(3) Lower the jib to the safety working range. Raise the jib at the off-set angle
of 14.5 degree.
3. CONFIRMATION OF TOWER OVERHOIST PRE-

VENTIVE FUNCTION
(1) Lower the tower to about 85 degrees. Push the tow-
er over hoist No.1 limit switch (right) by hand, con-
firm that the automatic stop function.
(2) Hoist the tower, and ensure that raising of the tower
is stopped automatically when the tower reaches
the upper limit of the working range (the tower an-
gle : 90.0 degrees), set the tower control lever to
the neutral position.
(3) Operate the boom overhoist release switch, and

hoist the tower. Then, ensure that raising of the tow-
er is stopped again automatically (the tower angle :
90.7 degrees) by tower overhoist No.2 limit switch
(left).
STRIKER
BACKSTOP
FRONT
LIMIT SWITCH
RIGHT INSIDE OF FRAME
7-57 7055-3
4. Confirm the jib low limit angle and tower low limit
angle.
Lowering stop
(1) Lower the jib and confirm that the jib stops at the
lowest limit of working range. At the same time con-
firm that either hoisting and lowering the tower can
not be done. Raise impossible
(2) Raise the jib to the safety range.

(3) Lower the tower and confirm that the tower stops at
the lowest limit of the working range. At the same
Lowering impossible
time confirm that either hoisting the hook and low-
ering the jib can not be done.
lowering
impossible
Lowering stop
Raising
impossible
7055-3 7-58
7.3 LOWERING THE TOWER

Lowering the tower must be done at firm and level
ground with enough space.
7.3.1 LOWERING THE JIB

1. PREPARATION OF LOWERING THE JIB
Do not stand in the working area of the jib during

erecting and lowering the jib. Placing a watchman
is recommended. Failure to observe this precau-
tion may result in serious injury or death.
Do not raise or lower the jib while the tower boom

is inclined. (Angle is less than 89.4 degrees) Failure
to observe this precaution may result in serious in-
july or death.
(1) Set the tower angle from 89.6 to 90.2 degrees.

“SET UP” SWITCH
(2) Keep the latch control wire rope loose.
BOOM LOWERING SWITCH
2. LOWERING THE JIB (B)

(A)
(1) Lower the jib to near horizontal level, proceed as (C)
follow.
(A) Lower the tower jib until it automatically stops.
(B) Set the rear drum speed control knob into LOW.
(C) Press and hold the boom (jib) operating switch
“LOWER” for 3 seconds or more. It will make the jib
lowering mode available and release the shutdown (D)
function.
(D) Further lower the tower jib.
The jib operation is possible without operating the
release switch.
7-59 7055-3
Confirm that the

jib guy line comes
Confirm that the guy lines are surely on the guide on the guide
sheave
roller during jib lowering. Failure to observe this
When the jib comes near the horizontal position, con- 㧭

firm that the jib guy line will come on the guide rollers
properly for both left and right side.
If the jib guy line does not come on the guide, stop low-
ering immediately and hoist the jib.
Then cconsult your KOBELCO authorize distributor.
Unleveled ground may cause it.
Do not make a sudden stop of lowering motion.
VIEW FROM A
(2) When the jib comes below horizontal level, the tow-
er may move slightly backward. Keep lowering the
jib.
The tower will move back to original position when
the jib is lowered.
(3) Adjust the hook height so that the hook comes to
near ground level.
7055-3 7-60
(4) When the jib comes down near the tower, the tower
lowering speed is decreased, but keep lowering
with the same lever position. When the jib touches
to tower the latch is engaged with slight shock.
Lower further until the jib guy line becomes loose.
(5) Confirm that the latch indicating red lamp is on.
Confirm visually the mechanical latch is engaged.
(RED)
Visual check of
latch engagement
Lower unit the guy

line become loose.
7-61 7055-3
7.3.2 LOWERING THE TOWER
Do not stand under the tower or jib during lowering

the tower in order to prevent accident due to quick
lowering of the tower and the jib.
Lower the tower at the front position of the crawlers.

Remove any obstacles in the yard of tower coming down.
1. Be careful of rough spooling, and slacken the jib
hoist wire rope.
2. Shift the tower hoist control lever to the lowering
side to lower the tower.
3. When the tower is lowered, the jib hoist wire rope
gets tensioned. Shift the jib hoist control lever to
the lowering side to pay out the rope until the jib guy
line is only moderately tensioned.
Do not lower the tower nor hoist the jib, if a warning

buzzer (intermittent buzzer) sounds while hoisting
(lowering) the tower. Failure to observe this pre-
caution may lead the damaged attachment, and re-
To prevent the attachment from being damaged, when

the jib hoisting rope is overtensioned while lowering the
tower, a warning buzzer (intermittent buzzer) sounds,
and the tower lowering speed is slowed down. When a
warning buzzer (intermittent buzzer) sounds, shift the
tower and jib hoist control lever to the original neutral
position, and carefully set the jib hoist control lever to
the lowering position. Only then, slacken the jib hoist-
ing rope so that rough spooling does not occur on the
jib hoisting drum.
4. When the tower is lowered to about 75 degrees,

stop lowering the tower, and insert the swing lock
pin.
7055-3 7-62
5. In the case of tower length are 39.3 m, 42.4 m get

the steel plates under the top ends of the crawlers.
STEEL
PLATE
6. Install the counterweight for lowering when the tow-

er length is 42.4 m.
7. Start lowering the tower again.
While the tower comes down, the jib guy line be-
comes tensioned. Pay out the jib hoist wire rope as
necessary.
Do not apply too much tension on the jib hoist wire

rope in order to prevent damage to the attachment.
Damaged attachment may result in serious acci-
dent.
Jib guy line

is loosen.
Off limit
7-63 7055-3
8. Lower the tower until the strut top slightly touch the
ground.
7055-3 7-64
7.4 DISASSEMBLY OF THE TOWER

Normally disassembly is done in the reverse order of
assembly.
Do not stand under the jib and tower boom during

the assembly and disassembly to prevent accident
due to fall of jib or tower boom.
Use the life belt for the job in high place in order to
avoid fall due to slippery surface.
Use scaffold boad during work on the tower boom.
Fix guy line ends with tower boom in order to pre-

vent accident due to fall of guy line from the tower
boom when tower boom is transported.
Observe the following precautions when pins are

drawn out in order to prevent accident due to fall or
abrupt move of tower boom.
• Do not put your finger into pin hole.
• Lift the boom properly with assisting crane.
• Do not stand on the place to where the load may
move.
Failure to observe these precaution may result in
[TOOLS]
• Chain block (3 t)
• Wooden blocking
• Sling cloths
• Steel bar
7-65 7055-3
When assembling the tower attachment, push the "SET

“SET UP” SWITCH
UP" switch. Then, the load safety device enters the
"SET UP" mode, and the automatic stop is canceled.

tower boom is raised.
When the tower boom is raised after the assembly is

completed, and the "SET UP" mode is canceled.
7055-3 7-66
7.4.1 DISCONNECT OF THE JIB

1. Disconnect the jib guy line from the strut link and jib
top.
Disconnect LINK
2. Sling the strut with the auxiliary crane, pull out the
pin (A) and point the strut link toward the stowing
side.
After the link is pointed toward the stowing side, in-
sert the lock pin (A) again so that the link does not
go down.
3. Sling the strut with the auxiliary crane and lower the
tower.
Stop lowering the tower before the jib or the back-
stop contacts the ground. LINK
LINK
LOCK PIN “A”
7-67 7055-3
4. Disconnect the jib latch.

Lift the jib tip with assisting crane and remove the
jib latch.
Lower and place the jib tip on the ground.
Disconnect
5. Disconnect the cable between the jib and the tower

cap.
(1) Disconnect the cable of the jib angle detector and
the hook overhoist limit switch cable.
Install the caps on disconnected cables.
CLAMP
CABLE FOR HOOK

OVER HOIST LIMIT SWITCH
CABLE FOR JIB ANGLE
DETECTOR
(2) Wind up the hook overhoist limit switch cable to the

cable reel.
7055-3 7-68
(3) Remove the hook overhoist limit switch and weight.
Connect the cable
THIMBLE
Set the cable reel stopper

Thimble is fixed to bracket
after extending cable
HOOK OVERHOIST
LIMIT SWITCH
WEIGHT
(4) Remove the hoist wire rope from the hook and jib
tip.

injury or death.
7-69 7055-3
(5) Store the jib backstop.
Connect
Store position
(6) Disconnect the jib foot from the tower cap and lower
the jib on the ground.
(7) Wind up the tower a little and swing it.
PIN
TOWER JIB
TOWER CAP
7055-3 7-70
7.4.2 DISASSEMBLY OF THE JIB

1. Disconnect the jib guy line.
Draw out the

upper side pin.
2. Disconnect the jib tip.
Support the jib tip and the jib base section with the
wooden blocks in order to prevent flip off of them.
At this time, if the jib point is installed to the front end of

the upper jib, remove the jib point weight from the upper
jib. Draw out the lower side pin.
3. Draw out the connecting pin and remove the jib

base.
Draw out the upper side pin.
Draw out the lower side pin.
7-71 7055-3
4. Draw out the connecting pin and remove the jib in-
sert.
Do not put your foot under the jib to prevent injury

due to fall of the jib.
Draw out the pins at 4 points.
rious injury.
5. More all jib sections away from the yard for disas-
sembly of the tower.
6. Wind up the hoist wire rope to the main drum.

• Keep away from rope end removing the wire rope.
It may suddenly jump and cause injury.
injury or death.
7055-3 7-72
7.4.3 DISASSEMBLY OF TOWER GUY LINE AND TOWER

1. Lower the tower to the wooden block.
2. Disconnect of wiring of safety device

(1) Disconnect the tower junction cable from the junc-
tion box.
(2) Take up the cable for latch limit switch and tower
junction cable on the cable reel.
3. Removal of tower side latch bracket.
TOWER
LATCH
BRACKET “A”
U-BOLT
7-73 7055-3
4. Disconnect the tower guy line

TOWER GUY LINE
Use the life belt on the high place work in order to

prevent fall due to slippery surface.
Scaffold board are recommended on the tower.

drawn out in order to prevent fall due to quick
movement of the boom.
• Hold the tower properly with assisting crane.
• Do not stand to where the load may move.
(1) Set the spreader guide provided on the special in-

sert tower to "Work position". Refer to "P.6-32 HOW
TO USE SPREADER GUIDE" in MAIN UNIT &
CRANE edition.
SPREADER GUIDE (Storage position) SPREADER GUIDE (Work position)
(2) When the tower hoist rope is loosened, the upper

spreader goes down along the guide.
(3) Secure the upper spreader to the bracket on the UPPER SPREADER
special insert tower with the pin. GUY LINE
(Disconnect)
Do not wind up the tower hoist rope with the upper

spreader secured to the special insert tower in or-
der to prevent the accident due to the damage on
the attachment.
7055-3 7-74
(4) Disconnect all guy lines for hoisting the tower.

(5) Sling the upper spreader with the auxiliary crane, re-
move it from the special insert tower and connect it
to the bracket on the lower tower.
5. Disconnecting the lower tower and insert tower

(1) Lift the connection between the lower tower and in-
sert tower with the auxiliary crane as shown in the
figure.
(2) Pull out the lower connecting pin from outside to in-
side.
Do not stand or work under, inside the tower boom

or jib when assembling or disassembling the tower
boom or jib at anytime. Failure to observe this pre-
caution may result in serious injury or death. CONNECTING PIN
(Both taper)
(3) Lower the tower to the wooden block.
6. Removal of jib hoist wire rope from rear drum

(1) Remove the wire rope from rear drum.
7-75 7055-3
7. Remove the upper and lower spreader for jib

(1) Separate the jib hoist wire rope in two directions,
and bundle with wire at a few place.
LOWER SPREADER
UPPER SPREADER
Bundle wit wire at a few place
(2) After disconnecting the strut guy line from the upper
spreader for jib hoisting, disconnect all the guy lines
except the guy line connected to the strut.
Be sure to fasten the guy lines on the boom with a

steel wire, or place them on the ground with the
aux. crane.
Failure to observe this precaution may lead falling
guy lines, and result in serious injury or death.
(3) Remove the upper and lower spreaders for jib hoist-
ing.
7055-3 7-76
8. Remove the strut
Use the life belt on the high place work in order to

prevent fall due to slippery surface.
Scaffold board are recommended on the tower.

drawn out in order to prevent fall due to quick
movement of the boom.
• Hold the tower properly with assisting crane.
serious injury or death. SPRIT PIN
PIN
LOCK PIN
(1) Lifting the guyline to hold the strut with assisting

crane.
(2) Remove one of the strut connecting pins under this
condition. Insert a bar into the pin hole in order to
prevent hole from out of alignment.
(3) Remove another pin.

(4) Make balance the strut with assisting crane and re-
move the bar from pin hole and lower the strut on
the ground. STRUT
To prevent hole from

out of alignment
7-77 7055-3
(5) Fold up the strut.

Follow the procedures in the inverse order of as-
sembly.
(Refer to P.7-16 "6. INSTALLATION OF STRUT")
LINK (TOWER SIDE)
REAR STRUT
PIN “A”
FRONT STRUT LINK (JIB SIDE)
9. Disassembly of the tower

(1) Wind up the hook hoist wire rope to the front drum.
Use the life belt for high place work in order to pre-
vent fall due to slippery surface.
Observe the following to prevent accident to quick

movement of boom during drawing out pins.
• Hold the load with assisting crane.
7055-3 7-78
(2) Remove the tower cap.

(A) Hold the tower cap with assisting crane and re-
move the underside pin.
(B) Remove the upper side pin.
(C) Remove the tower cap.
(3) Disassemble the tower inserts sections. SPRING PIN
Do not put your foot under the tower. CONNECTING PIN

(A) Remove four pins and disconnect the tower insert

section.
(B) Move the removed tower insert section.
Bundle the guy line with the wire when the guy line
is on the tower insert section.
THIS IS THE END DISASSEMBLY OF THE TOWER

CRANE ATTACHMENT.
7-79 7055-3
7055-3 7-80
8. WIRE ROPE
8. WIRE ROPE
1. At factory delivery, max. length of wire rope which

is matched with usable boom and jib combination
and their number of part line are wound on the
drum.
If the boom length is shorter or number of part line
is small, wire rope may cause rough spooling such
as loosening, lane-junmping or penetration.
It is recommended to use wire rope length matching
to the work condition (such as boom, jib length,
number of part line of rope, lifting height).
2. The hook is removed at factory delivery and it may
cause loose rope winding and penetration.
If the wire rope is loose, rewind the wire rope to the
drum with tension.
Incorrect dia. rope may cause penetration or rough

spooling. Use genuine wire rope.
Handle control lever slowly.

Returning the control lever abruptly to neutral may
cause sudden drum stop and may cause loosening of
wire rope, and rough spooling.
8-1 7055-3
8. WIRE ROPE
8.1 HANDLING OF WIRE ROPE

If wires protrude, you could be injured. Working
8.1.1 UNREELING METHOD OF WIRE ROPE

When unreeling the wire rope, take sufficient care to
prevent it from kinking. It is convenient to use a jig as
shown in the right figure.
If the method mentioned above is unavailable, being
careful not to soil the wire rope, roll over to extend it
straightly.
To drum
Unreeling method of wire rope
7055-3 8-2
8. WIRE ROPE
8.1.2 WINDING WIRE ROPE ONTO THE DRUM

1. In case of the front and rear drum
WIRE ROPE WEDGE
Pass the wire rope end through from the inside of
the drum flange and fix it to the socket on the drum
flange with a wedge.
Install the retaining bracket by contacting it against
the wire rope.
When the rope is installed into wedge area of drum,

DRUM FLANGE
rope end may spring out and may cause serious in-
jury.
LOCK BRACKET
Take extra care during this work.
rious injury.
If the wire rope end is not securely fixed, it may be

unfixed, causing the accidental drop of the lifted
load. Be sure to securely fix the wire rope end.
When unwinding the wire rope, remember that at

least three lines of the wire rope must be on the
drum.
If the number of the line of the wire rope on the

drum is smaller than three, the wire rope may be
unfixed, causing the accidental drop of the lifted
load.
DO NOT unwind the wire rope further if three lines
of the wire rope on the drum.
2. In case of the boom drum

Be careful not to allow the wire rope end to protrude
from the cotter hole.
Pass the tensile end of the wire rope through the
straight side of the rope socket. WEDGE
Surely install the wedge.
CORRECT WRONG
INSTALLING INSTALLING
INSTALLING WIRE ROPE
8-3 7055-3
8. WIRE ROPE
3. Lightly tap the rope to line up, and slowly wind it

PULL PULL PULL
onto the drum.
While pulling the rope, tightly wind the rope onto the
drum.

LIGHTLY TAP LIGHTLY TAP

LIGHTLY TWIST
WINDING WIRE ROPE
7055-3 8-4
8. WIRE ROPE
8.1.3 INSTALLING THE ROPE SOCKET

1. Thread the wire rope through the socket and bring
it around in an easy to handle loop. The live end of SOCKET
the rope must be in a straight line through the sock-
et.
2. Insert the wedge in the rope loop and pull the
wedge and rope loop tight enough to hold the
wedge in position while handling.
WEDGE
3. After the socket is pinned to the boom or hook
block, apply gradually increasing loads to the wire
rope until the wedge is in its final position.
PULL
4. Secure the wire rope with the rope clamp.
The rope clamp must be correctly installed not to
mistake the direction.
5. Install the rope socket in the correct direction.
8-5 7055-3
8. WIRE ROPE
8.1.4 SPECIFICATION OF WIRE ROPE

1. CRANE
Breaking
Diameter Length
Use Specification strength
(mm) (m)
(kN)
U4 X SeS (39) O/O
Front Drum 22 175 363
IWRC 6 X Fi (29) C/O
Rear Drum U4 X SeS (39) O/O 22 125 363
Boom Drum IWRC 6 X P • WS (31) O/O 16 150 210
2. TOWER
Breaking
Diameter Length
Use Specification strength
(mm) (m)
(kN)
Hook Hoist
U4 X SeS (39) O/O 22 220 363
(Front Drum)
Jib Hoist IWRC 6 X P • WS (31) O/O 22 120 397
Tower Hoist IWRC 6 X P • WS (31) O/O 16 170 210
7055-3 8-6
8. WIRE ROPE
8.1.5 WIRE ROPE LENGTH

1. CRANE
Unit : m
Boom Length 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part
9.1 21 31 41 50 60 70 79 89
12.2 27 40 53 65 78 91 103 116
15.2 33 49 65 80 96 112 127 143
18.3 39 58 77 95 114 133 151 -
21.3 45 67 89 110 132 154 - -
24.4 51 76 101 125 150 - - -
27.4 58 85 113 141 - - - -
30.5 64 94 125 156 - - - -
33.5 70 103 137 171 - - - -
36.6 76 112 149 - - - - -
39.6 82 121 161 - - - - -
42.7 88 130 173 - - - - -
45.7 94 139 - - - - - -
48.8 100 149 - - - - - -
51.8 106 158 - - - - - -
2. JIB
Unit : m
Jib Length
Boom Length
6.1 12.2 18.3
30.5 76.0 88.0 99.0
33.5 82.0 94.0 106.0
36.6 88.0 100.0 112.0
39.6 94.0 106.0 118.0
42.7 100.0 112.0 -
This table shows the necessary rope length when the

hook is lowered to the boom foot height.
If underground work is required, the corresponding
length is required.
Too long a rope may cause rough spooling on the drum.
8-7 7055-3
8. WIRE ROPE
7055-3 8-8
9. MAINTENANCE
9. 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

on to the ground, stop the engine and engage all
locks. Also remove the keys or battery cables to
prevent other personnel from starting the crane
while maintenance personnel are at work. Failure
to observe this precaution may result in serious in-
jury or death.
1. PRECAUTIONS WHEN PERFORMING CHECK

AND MAINTENANCE
• Carry out check and maintenance with a suitable
working clothes on.
• Be sure to set the machine on a firm and level
ground, and post a notice board showing "Under
Check and Inspection".
• Check and maintenance in a place of higher than
two meters are elevation work. Be sure to use a
working scaffold and safety band.
• When moving to perform check and maintenance,
determine the fixed signals, and move the machine
following the signals.
• When performing check and maintenance of hy-
draulic equipments, be careful to prevent dust and
dirt from entering.
2. INSPECTION TABLE
• The following check table is based on the average
operating condition.
Consider the check schedule according to the
working condition and weather condition.
• The check table covers all items, but if operators
and maintenance personnel judge that additional
items are necessary, add them to the check items.
• Whenever a question arises regarding check and
maintenance, consult the local presentative.
When necessary repairs or adjustments are noted

during an inspection, be sure to complete the re-
pairs or adjustments immediately.
9-1 7055-3
9. MAINTENANCE
3. MAINTENANCE
• Maintenance
When replacement of parts and readjustment are
required by check, immediately replace or adjust. If
repair is necessary, consult the service shop desig-
nated by our company.
• Parts
Use the KOBELCO genuine parts for replacement
parts and lubricant to be used in order to keep per-
formance of the machine.
The parts of consumption such as elements, etc.
must be replaced somewhat early in order to pre-
vent deterioration of performance due to delay of
replacement.
For doubtful point regarding check and mainte-
nance, consult the service shop designated by our
company.
4. PRECAUTIONS WHEN PERFORMING INSPECTIONS

AND MAINTENANCE
• Use genuine parts of our company.

Be sure to use KOBELCO genuine parts for re-
placement parts and lubricant to be used.
The warranty does not cover malfunctions caused by

the use of parts other than KOBELCO genuine parts
(genuine oil, grease and filter).
• Only use commercially available vehicle diesel fu-

els (EN590).
Grades such as marine diesel fuel, heating oils, etc.
are not permitted.
• Use clean oil and grease.

Keep the containers for oil and grease in a clean in-
side of a house to prevent dust and water from en-
tering.
Be sure to use clean oil and grease which do not
contain water.
7055-3 9-2
9. MAINTENANCE
• Clean carrier.
Cleanly wash the carrier to make finding of oil leak,
crack, loosening and other wrong condition easy.
Especially, clean grease fittings, breathers and oil
level gauge parts (window for check of oil), and
avoid entering of dust.
• Disposal of spilled oil

Leaving oil spilled when refilling or replacing fuel,
hydraulic oil, various lubricants, or replacing the fil-
ter, may lead to a fire accident. Thoroughly wipe it
away.
• Caution when washing the machines.

Do not pour steam directly to electric parts and con-
nectors.
• Place a warning plate under checking.

When performing check and maintenance, be sure
to indicate warning plate "Under checking. Do not
Start." to the key switch.
• The lighting of fires prohibited!

Wastes with oil adhered and combustibles should
be stored in a safe place without fire.
Confirm the storage position and using method of
fire extinguisher for emergency.
9-3 7055-3
9. MAINTENANCE
• Pay attention to rotating parts!

When checking fan belt tension or water pump, it
may become entangled in moving machinery. Stop
the engine, then work.
• Pay attention to temperature of water and oil.

Since draining oil, draining water and replacing fil-
ter just after the engine stops is dangerous, wait un-
til the temperature lowers, then perform these
works. However, when oil is cold, warm the oil prop-
erly (approximately 20°C to 50°C (68°F to 122°F)),
on the contrary, then drain the oil.
• Clean mounting Surfaces.

When sealing sections of O-rings and gaskets were
removed, clean the mounting surfaces, then re-
place with new ones.
When assembling, apply a thin coat of oil to the
seals.
• Pay attention to internal pressure.

When removing hydraulic system, air system, fuel
system or pipings and connectors of cooling sys-
tem and other related parts which have internal
pressure, bleed internal pressure beforehand.
• Precaution when welding.

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 con-
tinuously.
4. Provide earth (ground) within 1 meter from the
welding section.
5. Do not allow a seal and bearing to enter be-
tween the welding section and earth section.
6. When welding near the load safety device and
controller, remove them to prevent damage.
7055-3 9-4
9. MAINTENANCE
• Treatment of discarded oil.

Be sure to drain discarded oil into a container such
as oil can, and treat it as industrial discharges.
9-5 7055-3
9. MAINTENANCE
9.1 CHECKS
9.1.1 CHECKS OF THE UPPER
26
6
29 15 17
9 23 31 24
4
5
15,27
20 30
23
15,27
19
33
1 24
2
23
32
22
24
25
24 28
23
15,27
7055-3 9-6
9. MAINTENANCE
Item Reference
Check Interval Identification Check Item Check Method
No. page
1 Fuel and hydraulic system hose Damage Visual check 9-8
Starting, leak, unusual Starting, check by
2 Engine 9-8
noise hearing
3 Hose, piping, connector Oil leak Visual check 9-8
4 Swing brake Effectiveness Operation 9-8
5 Swing lock Performance Operation 9-9
Operation, visual
6 Control lever, Brake pedal Play, deformation 9-9
check
7 Gantry Deformation, crack Visual check 9-9
Operation, visual
8 Horn, head light, wiper Performance 9-9
Daily or every check
8 hours 9 Air cleaner Clogging(indicator) Visual check 9-10
10 Pin, link, cotter pin Damage, falling off Visual check 9-10
11 Bolt, nut Looseness, falling off Visual check 9-10
12 Hook overhoist preventive device Performance Operation 9-10
13 Boom overhoist preventive device Performance Operation 9-10
14 Load safety device Performance Operation 9-10
15 Drum lock knob Performance Operation 9-11
Damage, crack,
16 Window glass, step, handle, guard Visual check 9-11
falling off
17 Drum brake free fall indicator lamp Filament is gone Visual check 9-11
18 Drum brake disk Wear Visual check 9-12
Weekly or Fuel pre-filter
32 Water level Visual check 9-18
every 50 hours (Option)
Push with finger,
19 Fan belt Looseness, damage 9-13
visual check
20 Radiator, oil cooler Oil leak, damage Visual check 9-13
Engine mounting bolt, rubber Visual check, test
21 Looseness, damage 9-13
mount hammer
Visual check,
22 Power divider Oil leak, unusual noise 9-14
check by hearing
Visual check,
Monthly or 23 Hydraulic motor, Reduction unit Oil leak, unusual noise 9-14
check by hearing
every
24 Valve, etc. Oil leak Visual check 9-15
100 hours
Visual check,
25 Hydraulic pump Oil leak, unusual noise 9-15
check by hearing
26 Gantry cylinder Oil leak, damage Visual check 9-15
27 Drum lock Wear, damage Visual check 9-15
Fuel supply pump, hose Operation, visual
28 Performance, damage 9-16
(Option) check
Alarm sound, Filament Operation, visual
29 Swing alarm lamp 9-16
is gone check
Semi-annually 30 Accumulator Oil leak, damage Visual check 9-17
or very
31 Frame Damage, crack Visual check 9-17
600 hours
• The item numbers in the above table correspond to the numbers in the following description.
• The item numbers, 3, 8, 10, 11, 12, 13, 14, 16, 18 and 21 are not indicated in the drawing.
9-7 7055-3
9. MAINTENANCE
Check the following conditions when the machine is to be operated in the area where sulfur contents more than 5000
ppm in the fuel.
Check Item Reference

Identification Check Item Check Method
Interval No. page
Water leak,
5000 hours 33 EGR Cooler core Visual check 9-18
damage
9.1.1.1 CHECK OF UPPER, DAILY OR EVERY 8 HOURS

1. FUEL AND HYDRAULIC SYSTEM HOSE
Check the fuel and hydraulic system hose for dam-
age and for fuel leak.
If fuel leak is observed, repair leak and remove excess

fuel immediately.
2. ENGINE
Start the engine to confirm proper starting condition
and listen for unusual noise.
3. HOSE, PIPING AND CONNECTOR, ETC.

Check the hose, piping and connector, etc. for oil
leaks and for damage.
4. SWING BRAKE
Confirm that the swing brake is functioning proper-
ly.
With the swing brake switch placed in the ON po-
sition, operate the swing control lever to confirm
that the swing brake is functioning properly. When
the swing brake is engaged, swinging is impossi-
ble.
7055-3 9-8
9. MAINTENANCE
5. SWING LOCK
Confirm that the swing lock pin is inserted smoothly.
Check the lock pin and rod for deformities.
6. CONTROL LEVER, BRAKE PEDAL

Check the control lever and brake pedal for unusual
play and for damage.
7. GANTRY GANTRY
Check the gantry for damage.
Due to the high strength steels used in gantry and mast

manufacturing, special repair procedures are required.
Consult your local authorized KOBELCO authorize dis-
tributor for instructions.
8. HORN, HEAD LIGHT AND WIPER

Confirm that the horn, headlight and wiper operate
normally by switch operate.
9-9 7055-3
9. 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 gauge cluster as below.
AIR CLEANER
The engine air cleaner is clogged.

Clean or replace the element.
SENSOR
10. PIN, LINK AND COTTER PIN

Check the pin, link and cotter pin for damage and to
determine if they are loose or missing.
11. BOLT AND NUT

Check the bolt and nut to determine if they are
loose or missing.
12. HOOK OVER HOIST PREVENTIVE DEVICE

Confirm that the hook over hoist preventive device
operates normally. (Refer to chapter 3. LOAD
SAFETY DEVICE)
13. BOOM OVER HOIST PREVENTIVE DEVICE

Confirm that the boom overhoist limit switch oper-
ates normally. (Refer to chapter 3. LOAD SAFETY
DEVICE)

Confirm that operation is automatically stopped.
(Refer to chapter 3. LOAD SAFETY DEVICE)
7055-3 9-10
9. MAINTENANCE
15. DRUM LOCK KNOB

Confirm that the drum lock functions normally.
THIRD DRUM LOCK KNOB

(OPTION)
BOOM DRUM LOCK KNOB
DRUM LOCK
FRONT DRUM
LOCK KNOB
REAR DRUM
LOCK KNOB
16. WINDOW GLASS, STEP, HANDLE AND GUARD

Always clean the window glass, step, handle and
guard, etc.
Immediately remove any grease and oil.
17. DRUM BRAKE FREE FALL INDICATOR LAMP

Make sure that the free fall indicator lamp lights up
when a drum brake selector switch is shifted to free
fall position after the engine starts.
FREE FALL INDICATOR LAMP

BRAKE SELECTOR
SWITCH
Be sure to lower the hook block onto the ground to
prevent it from dropping abruptly.
9-11 7055-3
9. MAINTENANCE
18. DRUM BRAKE DISK

Check the wear of the brake disk with the indicator.
If the FREE FALL mode is selected, the indicator is
protruded by approximately 17 mm (5/8").
Stop the engine and press the indicator. If the indi-
cator protrudes from the end face by approximately
2.5 to 3.0 mm (3/32" to 1/8"), the brake disk is nor-
mal.
If the protruded length of the indicator is 0 mm (0
inch) or shorter, winching may be impossible. In
(LEFT SIDE VIEW)
such a case, replace the brake disk or contact your
nearest KOBELCO authorize distributor.
Protruded length during
free fall mode (Approx. 17 mm)
Normal protruded length

Be sure to lower the hook block onto the ground to (Approx. 2.5 to 3.0 mm)
prevent it from dropping abruptly.
7055-3 9-12
9. MAINTENANCE
9.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS

19. FAN BELT
Check the fan belt for proper tension.
Firmly push a middle of the fan belt with a finger.
Deflection of 10 to 15 mm (13/32" to 19/32") is nor-
mal.
Turn the engine off before inspecting the fan belt. FAN BELT
FAN BELT
10 to 15 mm
About 98 N
About 98 N
10 to 15 mm
20. RADIATOR AND OIL COOLER

Clean the radiator core. Check the radiator and oil
cooler for abnormalities.
21. ENGINE MOUNTING BOLT AND RUBBER

BOLT
MOUNT
Check the engine mounting bolt for looseness, and
the rubber mount for damage.
BOLT
RUBBER MOUNT RUBBER MOUNT
9-13 7055-3
9. MAINTENANCE
22. POWER DIVIDER

POWER DIVIDER
Check the power divider for oil leak and unusual
noise.
23. HYDRAULIC MOTOR AND REDUCTION UNIT

• Swing motor and reduction unit.
• Front and rear drum motors and reduction units.
• Boom hoist drum motor and reduction unit.
Check these for oil leak and unusual noise.
SWING MOTOR and REDUCTION UNIT
MOTOR
REDUCTION UNIT
FRONT AND REAR DRUM MOTORS
and REDUCTION UNITS
BOOM HOIST DRUM MOTOR

and REDUCTION UNIT
7055-3 9-14
9. MAINTENANCE
24. VALVE
Check each valve for oil leak.
25. HYDRAULIC PUMP

HYDRAULIC PUMP
Check the hydraulic pump for oil leak and for un-
usual noise.
HYDRAULIC PUMP
26. GANTRY CYLINDERS

Check the gantry cylinder for oil leak and damage.
GANTRY CYLINDER
27. DRUM LOCK

Check the drum lock and drum ratchet for wear and
damage. DRUM
RATCHET DRUM
RATCHET
FRONT & REAR DRUM LOCK BOOM DRUM LOCK
9-15 7055-3
9. MAINTENANCE
28. FUEL SUPPLY PUMP AND HOSE

SWITCH
Check the fuel supply pump for normal operation,
and check the supply hose for damage.
PUMP
29. SWING ALARM

Make sure that the swing alarm and swing flasher
function properly while operating machine swing.
LAMP AND BUZZER
LAMP
SWING FLASHER LAMP
7055-3 9-16
9. MAINTENANCE
9.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS

30. ACCUMULATOR
Check the accumulator for oil leak.
1. Do not handle the accumulator roughly.

2. Do not store or handle the accumulator near the
heat of fire.
3. Do not weld or machine the accumulator.
4. Do not remove valve cap except when charging
or discharging gas.
5. Do not step on or place heavy material on the
accumulator installed on the machine.
6. Check the accumulator for gas pressure every
two years.
7. Ask our authorized KOBELCO authorize distrib-
utor to charge the gas. ACCUMULATOR
8. Do not disassemble the accumulator.
The accumulator is charged with Nitrogen gas under

pressure of 3.4 to 3.7 MPa.
31. FRAME
Check the frame for crack and deformation.
9-17 7055-3
9. MAINTENANCE
9.1.1.4 CHECK OF UPPER, WEEKLY OR EVERY 50 HOURS

32. FUEL PRE-FILTER (OPTION)
DRAIN WATER FROM FUEL PRE-FILTER
If the red ring (A) of the pre-filter is on the bottom of
the case (B), water does not get in.
When the red ring (A) floats, the water reaches up
to the ring. Drain the water in accordance with the
following procedures.
1. Place a container to receive the drained water un-
der the drain hose. (B)
2. Loosen the water draining plug (C) of the fuel pre-

(A)
filter to drain water gathered at the bottom of the
fuel pre-filter case.
(C)
Drained water contains fuel, therefore, follow the pro-

cessing regulation specified in each region, when dis-
posing of it.
3. Tighten the water draining plug (C).

4. Actuate the priming pump and bleed air from the
fuel system.
9.1.1.5 CHECK OF UPPER, EVERY 5000 HOURS

33. EGR COOLER (ENGINE)
Disassemble the EGR Cooler and check the inter-
nal core for water leakage or corrosion.
• For disassembly and check of EGR Cooler,

EGR COOLER
please ask your nearest KOBELCO authorized
distributor.
• If the operation is continued using the fuel with
much sulfur content (sulfur content: more than
5000 ppm), the EGR may be damaged due to the
affection of sulfur content in the fuel. In the
worst case, the engine unit may be damaged.
Always have the proper check and replace-
ment.
This Section is not applied in the area where the Emis-

sions Limit Law (Stage IIIA, Tier 3) is applied.
7055-3 9-18
9. MAINTENANCE
This page is blank for editing convenience.
9-19 7055-3
9. MAINTENANCE
9.1.2 CHECK OF LOWER
4 6
12
1
11
10 12 7 8 11 9 10
10
7055-3 9-20
9. MAINTENANCE
Item Reference
No. page
1 Hose, piping, connector Oil leak, damage Visual check 9-21
Daily or every
8 hours
Oil leak, unusual
4 Hydraulic motor, reduction unit Visual check 9-22
noise
5 Valve, etc. Oil leak Visual check 9-22
Translifter
Monthly 6 Oil leak, damage Visual check 9-22
Crawler extend/retract cylinder
or every
7 Swivel joint Oil leak Visual check 9-22
100 hours
Check by
8 Slewing ring bearing Unusual noise 9-22
hearing
Extension, damage,
9 Crawler shoe Visual check 9-23
wear
Quarterly or Drive sprocket, crawler idler, upper
10 Oil leak, damage Visual check 9-24
every and lower rollers
250 hours 11 Slewing ring bearing mounting bolt Looseness, falling off Visual check 9-24
Semi-annually
or every 12 Frame Damage, crack Visual check 9-25
600 hours
• The item number in the above table correspond to numbers in the following description.
• The item numbers, 2 and 3 are not indicated in the drawing.
9.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS
1. HOSE, PIPING AND CONNECTOR

Check the hose, piping and connector, etc. for oil
leak and damage.

Check the pin, link and cotter pin for damage, and
for falling off.
3. BOLT AND NUT

Check the bolt and nut for looseness and for falling
off.
9-21 7055-3
9. MAINTENANCE
9.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS
4. HYDRAULIC MOTOR AND REDUCTION UNIT

Check the propel motor and reduction unit for oil
leak and unusual noise.
MOTOR & REDUCTION UNIT
5. VALVE
Check the valve, etc. for oil leak.
6. CRAWLER EXTEND/RETRACT CYLINDER

CRAWLER EXTEND/RETRACT CYLINDER
Check the crawler extend/retract cylinder for oil
leak and damage.
7. SWIVEL JOINT
SWIVEL JOINT
Check the swivel joint for oil leak.
8. SLEWING RING BEARING

Check the slewing ring bearing for unusual noise.
SLEWING RING BEARING
7055-3 9-22
9. MAINTENANCE
9. CRAWLER SHOE SHOE

Check the crawler shoes for looseness and for
damage and wear.
If the crawler shoes are too tight, the shoes wear
quickly and a connection part of shoes could break.
On the other hand, if the shoes are too loose, the
shoes may ride off the drive sprocket and idler
wheel during propelling.
SLACK
10 to 20 mm
The slackening of 10 to 20 mm is normal condition
after propelling the machine forward about the
crawler length so that the slackening of the crawler
shoes appear on the upper side of the crawler.
9-23 7055-3
9. MAINTENANCE
9.1.2.3 CHECK OF LOWER QUARTERLY EVERY 3 MONTHS OR EVERY 250 HOURS
10. DRIVE SPROCKET, CRAWLER IDLER

UPPER ROLLER
AND UPPER/LOWER ROLLER
Check the drive sprocket, crawler idler and upper /
lower rollers for oil leak and damage.
DRIVE SPROCKET LOWER ROLLER CRAWLER IDLER
11. SLEWING RING BEARING MOUNTING BOLT

Check the slewing ring bearing mounting bolt for
looseness and falling off.
Remove and check the cover of the revolving frame
for the inner bolt.
If the bolt is loose, remove and check the bolt.
If the bolt is damaged, replace it with new one.
If the removed bolt is not damaged, clean and coat
it with Loctite #242 or equivalent, then securely
tighten it. BOLT (INNER)
Tightening torque :
• Outer Bolt = 1372 N-m (140 kgf-m)
• Inner Bolt = 1372 N-m (140 kgf-m)
BOLT (OUTER)
Remove this cover and

check the inner bolt.
7055-3 9-24
9. MAINTENANCE
9.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS

12. FRAME
Check the carbody and crawler frame for crack and
damage.
9-25 7055-3
9. MAINTENANCE
9.1.3 CHECK OF ATTACHMENT
4
1 10
4
10
1
4 10
3
8
5
2
11
10
3 8 3
3
9
4
10
10 5
2
4
10
1 10
10
2
1 5
4
1 10
4
10
9 10
1
4
10
8 8 2
4 5
7055-3 9-26
9. MAINTENANCE
Item Reference
No. page
1 Upper spreader, lower spreader Deformation, crack Visual check 9-28
2 Hook, latch Damage, looseness Visual check 9-28
Damage, deformation,
3 Cable roller, Guide roller Visual check 9-28
wear
4 Sheave Visual check 9-29
wear
5 Boom, Jib Damage, deformation Visual check 9-29
Daily or every
8 hours
8 Backstop Damage, deformation Visual check 9-30
9 Strut Damage, deformation Visual check 9-30
10 Wire rope, guy line Visual check 9-30
wear
Load detector connector pin,
11 Looseness, falling off Visual check 9-31
link and nut
* The item number in the above table correspond to numbers in the following description.
* The item numbers, 6 and 7 are not indicated in the drawing.
9-27 7055-3
9. MAINTENANCE
9.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 5 HOURS
1. UPPER SPREADER AND LOWER SPREADER

UPPER
Check the sheave and frame of the upper and lower SPREADER
spreaders (for boom, tower and tower jib) for dam- LOWER
SPREADER
age.

If wires protrude, you could be injured.

2. HOOK AND LATCHES

Check the sheave, bearing and latch of the hook SHEAVES
block for damage, and check the bolt and nut for
BEARING
falling off.
(See page 9-34 and 9-35)
BEARING
LATCH
3. CABLE ROLLER
• Cable roller for insert boom
• Cable roller for upper boom
• Guide roller
Check these parts for damage, deformation and wear.
7055-3 9-28
9. MAINTENANCE
4. SHEAVE
• Boom point sheave
• Idler sheave
• Auxiliary sheave
• Jib point sheave
• Strut sheave
• Gantry sheave
• Tower main hoist guide sheave
Check these sheaves for damage, deformation and
wear.
5. BOOM, TOWER BOOM, FIXED JIB AND TOWER

JIB
Check the boom for damage and deformation. Do
not use the damaged and/or deformed boom.
Be sure to replace the damaged boom and jib with
new ones, or repair.
BOOM
Due to the high strength steels used in boom and jibs,
special repair procedures are required. Consult your lo-
struction.
JIB
TOWER JIB
TOWER BOOM
9-29 7055-3
9. MAINTENANCE

Check the pin, link and cotter pin for damage and
falling off.
7. BOLT AND NUT

Check the bolt and nut for looseness and for falling
off.
8. BACKSTOP
GUY LINE
BOOM HOIST WIRE ROPE
• Boom backstop
• Tower backstop
BACK STOP
• Jib (tower jib) backstop
• Strut backstop
Check these backstops for damage and deformation.
Special procedures required for repair. Consult your lo- HOIST WIRE ROPE
struction.
9. STRUT JIB GUY LINE

Check the jib strut and tower strut for damage, de-
JIB STRUT
formities and usual play.
Special procedures required for repair. Consult your lo-

struction.
HOIST WIRE ROPE
STRUT BACK STOP
10. WIRE ROPE AND GUYLINE

GUY LINE
Check the wire rope and guy line for damage and (TOWER JIB)
deformation and wear. HOIST WIRE ROPE

TOWER STRUT
Do not use the wire rope and guy line of which wires
are broken or which are kinked.
See the following page "9-32 " .
GUY LINE
(TOWER JIB)
TOWER JIB BACKSTOP

The diametral tolerance of KOBELCO standard wire JIB HOIST
rope is +2.5% to +4.5% of the nominal diameter. If the WIRE ROPE
TOWER GUY LINE
wire rope other than the tolerance is used, it may cause
rope upsetting. TOWER HOIST
WIRE ROPE
TOWER BACKSTOP
7055-3 9-30
9. MAINTENANCE
11. LOAD DETECTOR CONNECT PIN AND NUT

PIN, BOLT
Check for the looseness and missing of the nuts.
9-31 7055-3
9. MAINTENANCE
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
are subject to wire-cut, abrasion, corrosion and oth-
er defects. Such wire rope as given in Items A to D
below must be immediately replaced with a new
rope. And wire rope subject to damage mentioned
in Items E onwards should be replaced with new
one as soon as possible according to the degree of
damage.
Kind of Wire rope

• HOIST WIRE ROPE
• GUY LINE
• BOOM HOIST WIRE ROPE
• TAGLINE WIRE ROPE (OPTION)
(A) 10% or more steel wires are broken excepting filler

wires in one lay of wires. Inspection of internal
breakage of wires is difficult. To check breakage of
wires in the valley section of wire ropes, bend the
rope sharply. Broken element wires, if any, will be
exposed.
If breakage of wires in the valley section is found, it

is considered that internal breakage of wires may
Band rope sharply to expose breakage
also have developed, and that in other words, fa-
tigue of the whole rope may have developed. Re-
place the rope at once.
(B) Wire rope of more than 7% reduction of diameter Method of measuring rope diameter
from the nominal diameter, caused by abrasion.
Correct Wrong
Core of the rope ROPE
STAND
ELEMENT WIRE
7055-3 9-32
9. MAINTENANCE
(C) Kink is observed in the wire rope.
(D) Excessive deformation or corrosion is observed on

the wire rope.
(E) Excessive elongation is observed due to overload-

ing or derailment from sheaves.
(F) A short circuit has been formed electrically.
(G) Those wire ropes that are subject to fire or spark by

electric current or by gas welding as well as subject
to high temperature.
(2) REPLACEMENT STANDARD FOR GUYLINE

Since damage and corrosion are caused by fatigue
from the inside in the boom guy line, replacement
time cannot be judged from the appearance.
If the guy line is broken by progressing of internal
damage and/or corrosion, there is possibility to
cause an serious accident. Be sure to replace the
guy line periodically.
Replacement time according to the content of work
is shown in the table.
Replacement
Contents of Work
Interval
Lifting magnet or clamshell work
2 years
only
Both crane and clamshell work, or
frequent crane work such as land- 4 years
ing work
Normal crane work 6 years
9-33 7055-3
9. MAINTENANCE
HOOK AND SHACKLE MAINTENANCE STANDARD

The operating condition of main and aux. hook can SHEAVES
change daily with use; therefore, they must be in-
TIE BOLT SHEAVE PIN
spected daily (at start of each shift) and observed
during operation for any defects which could affect
their safe operation. Correct all defects before us- GREASE
NIPPLE
ing the hook block or ball hook. HOOK PIN
Daily inspection and maintenance will include the fol- THRUST

lowing points. LATCH BEARING
(1) Clean the hook block or the ball hook.

SIDE PLATE
(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 " HOOK
4.HOOK SHEAVE" (Page 9-48). HOOK

(3) Tighten loose tie-bolts, capscrews, and setscrews.
Check that all cotter keys are installed and opened. HOOK GREASE
SWIVEL NIPPLE
(4) Check the sheaves for uneven wear in the grooves
and on the flanges. Check for loose or wobbly THRUST
BEARING
sheaves. These conditions indicate faulty bearings
or bushings. GREASE
NIPPLE
(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. The groove must be larger than
the wire rope, and the groove must be free of rough
edges and burrs. LATCH
The groove in a plastic sheave must be the same size HOOK

as the wire rope.
BALL HOOK
(6) Check that the hook, the trunnion, and the swivel ro-
tate freely without excessive play.
Faulty operation indicates faulty bushings or bear-
ings or inadequate lubrication.
(7) Check the swivel of the hook for the following con-
ditions:
Overloading: Spin the swivel by hand; if the motion
is rough or has a ratchet-like effect, the swivel bear-
ings are damaged.
(8) Check the main hook for signs of overloading:
spread side plates, elongated holes, bent or elon-
gated tie-bolts, and cracks.
7055-3 9-34
9. MAINTENANCE
(9) Check the wire rope for wear and broken wires at
the point the wire rope enters the dead-end socket. SOCKET
Check the socket for cracks. Tighten the wire-rope
clips at the dead end of the wire rope.
(10) Check that each hook is equipped with a hook
latch and that the latch operates properly. The latch
must not be wired open or removed.
WEDGE
The latch must retain slings or other rigging in hook un- PULL
der slack conditions. The latch is not intended as anti-
fouling device, and caution must be taken to prevent
hook latch from supporting any part of load. Slings or CHECK FOR WEAR
AND DEFORMATION
other rigging must be seated in hook when handling
load; they must never be in position to foul the latch.
CHECK FOR
CHECK THAT “OPENING UP”
HOOK IS NOT
TWISTED
(11) Inspect shackles for damage.
CHECK FOR
CRACKS AND
TWISTING
Check each hook and shackle at least yearly for cracks

using a dye penetrant test, MAG particle test, ultrasonic
CHECK FOR WEAR
test, or by X-raying. AND CRACKS
HOOK
Do not attempt to repair cracks in hooks and shackles

by welding. Furthermore, do not weld on any load bear- CHECK FOR WEAR
AND DEFORMATION
ing component unless proper welding methods are
used. (contact Service Department at factory for mate-
rial and welding specifications) CHECK FOR WEAR
AND STRAIGHTNESS
CHECK THAT PIN IS

ALWAYS SEATED
CHECK FOR
“OPENING UP”
SHACKLE
9-35 7055-3
9. MAINTENANCE
9.2 OIL/GREASE SUPPLY AND WATER SERVICE
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)
Points of Lubrication Kind Symbol Capacity ltr.
Engine Engine oil SAE #30 MO 28.5
Radiator Water (soft water) - 30
Fuel tank Light oil JIS #2 - 400
Hydraulic oil tank Hydraulic oil #46 HO 380
Upper
Power divider Gear oil #90 GO 2.8
Front/rear drum reduction unit Gear oil #80W-90 GO 18 /each
Boom hoist drum reduction unit Gear oil #90 GO 3.0
Swing reduction unit Gear oil #90 GO 16.5
Propel reduction unit Gear oil #90 GO 26
Idler wheel Gear oil #140 GO 0.25 /each
Lower
Lower roller Gear oil #140 GO 0.13 /each
Upper roller Gear oil #140 GO 0.06 /each
1. The radiator is supplied with coolant combined with

Long Life Coolant (antifreeze) of 30% to 50% con-
centration by volume. Note
2. When using the machine in extreme cold and ex-
treme heat places, refer to page 9-78.
7055-3 9-36
9. MAINTENANCE
KOBELCO Genuine Lubricant Chart

Kind Symbol Specification Part Number
KW46S 20 ltr. can →2421R157D5
(For general use) 200 ltr. can→2421R157D6
Hydraulic oil HO
KW32S (OPTION) 20 ltr. can →2421R157D3
(For cold region) 200 ltr. can→2421R157D4
Extreme pressure grease EPG - 2121Z183
High temperature grease HPG - 2421Z183D2
Molybdenum disulphide grease GL - 2421Z183D3
20 ltr. can →KSPSP90020
#90
200 ltr. can→KSPSP90200
Gear oil GO
#80W-90 18 ltr. can →GG01T01020D1
(For cold region) 200 ltr. can→GG01T01020D2
SAE #30 20 ltr. can →2421Z353D1
(Class CD in API) 200 ltr. can→2421Z353D2
SAE #10 20 ltr. can →2421Z354D1
Engine oil MO
(Class CD in API) 200 ltr.f can→2521Z354D2
SAE #10W-30 20 ltr. can →YN01T01053D1
(CF4/DH-1) 200 ltr.f can→YN01T01053D2
18 ltr. can→KSPLLC95-18
Long life coolant
20 ltr. can→KSPLLC95-20
Antifreeze -
18 ltr. can→KSPPT95-18
Permanent
20 ltr. can→KSPPT95-20
LUBRICATION CHART
Lubricant Symbol Recommended Lubricant (Initial Factory Fill)
Hydraulic oil with anti-wear, anti-oxidant an anti-harmful foaming
15 °C to -30 °C
55 °C to 5 °C 40 °C to 5 °C 30 °C to -25 °C
Hydraulic Oil HO
ISO ISO ISO ISO
VG68 VG46 VG32 VG22
Extreme pressure gear oil #90
Gear Oil GO
Grade GL-4 by API classification
Extreme pressure
EPG Multipurpose grease
Grease
NLGI No.2 Lithium base grease EP type
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
SAE40 SAE30 SAE10W-30
9-37 7055-3
9. MAINTENANCE
RECOMMENDED HYDRAULIC OIL

VG32 VG32 VG46 VG68
KW32S KW32 KW46 KW68
NUTO NUTO NUTO
ESSO -
H32 H46 H68
DTE DTE DTE
MOBIL DTE 13
24 25 26
RANDO RANDO RANDO
CALTEX -
HD32 HD46 HD68
TELLUS TELLUS TELLUS
SHELL -
32 46 68
GULF - HARMONY 32AW HARMONY 46AW HARMONY 68AW
• Do not mix different brands of oil. The same brand

of oil should be used.
• Do not mix the original factory supplied oil with rec-
ommended hydraulic oil.
7055-3 9-38
9. MAINTENANCE
This page is blank for editing convenience.
9-39 7055-3
9. MAINTENANCE
9.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)
9,15
3,14
11 19
12,16
2,8,13
11
10,17
1,6
4,7,18
5
12,16
7055-3 9-40
9. MAINTENANCE
Upper Lubrication Table

Check and Lubri- Kind of Reference
Item No. Check and Lubrication Place Required Service
cation Interval Lubricant Page
1 Fuel tank Supply fuel Light oil 9-51
2 Engine Check oil level MO 9-50
Daily or every
Check coolant
8 hours 3 Radiator Soft water 9-52
level
4 Hydraulic oil tank Check oil level HO 9-54
Drum lock pawl
Weekly or every 5 Grease EPG 9-47
(Front, rear, boom drums)
50 hours
7 Hydraulic oil tank Drain 9-54
First time only
8 Engine Replace oil MO 9-50
(50 hours)
Monthly or every 9 Swing reduction unit Check oil level GO 9-56
100 hours 10 Power divider Check oil level GO 9-59
11 Drumshaft bearing Grease EPG 9-48
Quarterly or every Winch reduction unit
12 Check oil level GO 9-57, 9-58
250 hours (Front, rear, boom)
13 Engine Replace oil MO 9-50
Half years or 500
6 Fuel tank Drain 9-51
hours
14 Radiator Replace coolant Soft water 9-52
15 Swing reduction unit Replace oil GO 9-59
Annually or every
Winch reduction unit
1000 hours 16 Replace oil GO 9-57, 9-58
(Front, rear, boom)
17 Power divider Replace oil GO 9-59
Every 2 years
18 Hydraulic oil tank Replace oil HO 9-54
or 2000 hours
Washer
19 Washer tank Supply liquid
liquid
9-41 7055-3
9. MAINTENANCE
9.2.2 LOWER LUBRICATION
2,4 1 5
1 8
3,6
7 5 9
5
7055-3 9-42
9. MAINTENANCE
Check and Item No. Required Service Kind of Reference

Lubrication Check and Lubrication Place Lubricant Page
Interval
1 Slewing ring bearing Grease EPG 9-49
Weekly or every
2 Slewing ring gear (When operating Grease GL 9-49
50 hours
clamshell or lifting magnet)
3 Propel reduction unit Check oil level GO 9-60
Quarterly or every
4 Slewing ring gear Grease GL 9-49
250 hours
5 Extension Axle Grease EPG 9-49
Annually or every
6 Propel reduction unit Change oil GO 9-60
1000 hours
7 Lower roller Change oil leak GO 9-61
Refer to note 8 Upper roller Check oil leak GO 9-61
9 Idler wheel Check oil leak GO 9-61
* As for items 7, 8 and 9 check for oil leaks. If any leak is found, overhaul is required.
9-43 7055-3
9. MAINTENANCE
9.2.3 ATTACHMENT LUBRICATION
10 21
8 7
19
11
18
3
2
4
23
8
15
14
18
23
3
9
4
8
21
12 18
20 5
13
22
7
6 8
18
19
22 5
19
7055-3 9-44
9. MAINTENANCE
Lubrication Kind of Reference

Item No. Lubrication Place Required Service
Interval Lubricant Page
Daily or every 8 1 Boom (Tower) foot pin Grease EPG 9-46
hours 2 Gantry link Grease EPG 9-47
3 Hook sheave Grease EPG 9-48
Weekly or
4 Hook bearing Grease EPG 9-48
every
5 Ball hook bearing Grease EPG 9-48
50 hours
6 Main hoist wire rope guide sheave Grease EPG 9-48
7 Boom point sheave, Jib point sheave Grease EPG
8 Idler sheave, Strut sheave Grease EPG
9 Auxiliary sheave Grease EPG
10 Upper spreader sheave (For Boom hoist) Grease EPG
11 Lower spreader sheave (For boom hoist) Grease EPG
See Note 1.
12 Upper spreader sheave (Tower jib hoist) Grease EPG
13 Lower spreader sheave (Tower jib hoist) Grease EPG
14 Rear guide roller Grease EPG
15 Rear guide sheave Grease EPG
16 Gantry sheave Grease EPG
18 Main and auxiliary hoist wire rope Lubricate WO
19 Boom hoist wire rope Lubricate WO
20 Tower jib hoist rope Lubricate WO
See Note 2.
21 Boom guy line Lubricate WO
22 Jib guy line Lubricate WO
23 Tower jib guy line Lubricate WO
1. Item No. 7 to 16 are grease sealing type bearing.

Lubricate or replace according to the operating
conditions.
2. Lubricate wire ropes, according to the operating
conditions.
To lubricate wire ropes, use a brush or spray.
9-45 7055-3
9. MAINTENANCE
9.2.4 GREASE
Greasing Place Kind of Greasing Time (Hourmeter: Hrs)

Lubricant 8 50 100 250 600
1 Boom (Tower) foot pin EPG O
2 Gantry link EPG O
Drum lock
3 EPG O
(Front, Rear and boom drums)
4 Hook sheave EPG O
5 Hook bearing EPG O
6 Ball hook bearing EPG O
7 Guide sheave for main hoist wire rope EPG O
8 Drum shaft bearing EPG O
9 Slewing ring bearing EPG O
10 Slewing ring gear GL O* O
11 Extension axle EPG O
* mark shows the time for clamshell and lifting magnet operation.
Before greasing, clean the grease fitting. Wipe off the
extra grease which is crowded out.
Shut off engine before lubrication.

1. BOOM FOOT PIN

Grease through the grease fitting on the foot pin
(left and right).
GREASE NIPPLE
7055-3 9-46
9. MAINTENANCE
2. GANTRY LINK
Grease through the grease fitting provided on the
front member.

guard and walk ways are clean and dry, and use life GREASE NIPPLE
belt in order to prevent falls due to slippery surface. GANTRY
3. DRUM LOCK
To grease the front and rear drum locks, grease
through the grease fittings provided in the front of
the revolving frame (two places).
GREASE NIPPLE
FRONT, REAR DRUM LOCK
To grease the boom hoist drum lock, grease the

grease fitting provided on the revolving frame.
GREASE NIPPLE
BOOM DRUM LOCK
9-47 7055-3
9. MAINTENANCE
4. HOOK SHEAVE
Grease from the grease fitting on the sheave pin.
5. HOOK BEARING
Grease from the grease fitting on the bearing cap.
GREASE
NIPPLE
GREASE
NIPPLE
6. BALL HOOK BEARING

Grease from the grease fitting provided on the GREASE NIPPLE
bearing cap.
7. MAIN HOIST WIRE ROPE GUIDE SHEAVE

GUIDE SHEAVE
Grease from the grease fitting inside of the lower
boom. GREASE NIPPLE
8. DRUM SHAFT BEARING

Grease through the grease fittings provided on the
side stand and drum shaft bearing retainer.
GREASE NIPPLE
7055-3 9-48
9. MAINTENANCE
9. SLEWING RING BEARING

Grease through the grease fitting provided on the
slewing ring bearing.
GREASE NIPPLE
10. SLEWING RING GEAR

Removing the swing motor cover, turn the upper lit-
tle by little, and grease so that grease goes around
COVER
the entire ring gear.
To avoid injury, do not apply grease to slewing ring

gear directly by hand.
11. EXTENSION AXLE

Retract the crawlers, and grease from the grease
nipple provided on the joint pin.
GREASE NIPPLE EXTENSION AXLE
9-49 7055-3
9. MAINTENANCE
9.2.5 ENGINE OIL
Check and Change Interval

Item No. Checking Item (hourmeter: Hr) Remarks
8 50 100 250 500 1000
Oil level check of engine oil O
1 Change of engine oil (First time only) O
Change of engine oil O 28.5 ltr.
1. CHECKING AND CHANGING OIL FOR ENGINE

PROPER
(1) CHECKING OIL LEVEL OIL LEVEL
Be sure to check the engine oil level before starting

operation.
After wiping the level gauge once, insert it again
and check the level.
If the oil level is between the meshes of the gauge,
it is normal.
Crane must be on level ground when oil level is

checked. Otherwise, reading may be inaccurate.
(2) CHANGING OIL

OIL FILL PORT
Do not open the drain cock while the engine oil

is hot. Oil will be extremely hot and may cause
burns.
(A) Prepare a container with a capacity of approximate-

ly 30 liters. OIL FILTER
(B) Loosen the drain plug and allow the oil to drain into
the prepared container.
(C) Tighten the drain plug.
(D) After inspecting drained oil ensure that metal parti-
cles do not exist, refill fresh oil through the fill port.
When changing the engine oil, change the oil filter to-
gether at the same time. DRAIN COCK
7055-3 9-50
9. MAINTENANCE
9.2.6 FUEL

Item No. Checking Item (hourmeter:Hr) Remarks
8 50 250 500 1000 2000
1 Drain of fuel tank O
Tank capacity:
2 Adding fuel *
400 ltr.
* As required
1. DRAIN OF FUEL TANK
Loosen the drain plug, and drain water and sedi-
ment from the tank.
DRAIN COCK
2. ADDING FUEL
FILL PORT SWITCH
After daily work is finished, fill the fuel tank as full as
possible in order to minimize condensation.
• Do not bring any spark or flame close to the fu-

el.
• Never smoke cigarettes while refueling. This
could ignite the fuel and cause property dam-
age, injury to personnel, or death.
Never run the fuel pump empty.
Only use commercially available vehicle diesel fuels

(EN590). Grades such as marine diesel fuel, heating
oils, etc. are not permitted.
The engine in this machine adopts the electronically
controlled, high-pressure fuel injection unit in order to
achieve the satisfactory fuel consumption and exhaust
gas characteristics.
The use of improper fuel may seriously affect the fuel
consumption and exhaust gas characteristics, resulting
in the premature damage and deterioration of the en-
gine body as well as the fuel injection unit.
9-51 7055-3
9. MAINTENANCE
9.2.7 COOLANT

Item No. Checking Item (hourmeter: Hr) Remarks
8 50 250 500 1000 2000
1 Check of coolant level O
2 Change of coolant O 30 ltr.
• Changing interval of coolant is for the Long Life coolant combined with soft water.
Otherwise, replace coolant semi-annually.
1. CHECKING OF COOLANT LEVEL

RADIATOR CAP
Do not remove the radiator cap while the engine is

hot. Use a heavy cloth or gloves to protect yourself
while slowly loosening the cap. Wait until any
sound or fluid flow stops before removing cap. En-
gine coolant is hot and under pressure when the
engine is at operating temperature.
SUB TANK
After removing the radiator cap, confirm coolant level,

and also confirm the coolant level of the sub-tank.
• When coolant is insufficient, fill the radiator up to
the foot of the water supply port. Fill the sub-tank
up to the FULL mark position with soft water (city
water).
7055-3 9-52
9. MAINTENANCE
2. CHANGE OF COOLANT
Do not drain the coolant when it is hot. The hot wa-

ter may spout out which could result in personal RADIATOR
injury. After the water has cooled, drain the wa-
ter.Failure to observe this precaution may result in
serious injury.
(1) Loosen the drain cock in the bottom of the radiator

and the plug of the water jacket, drain the coolant.
(2) Combine soft water (city water) and Long life cool-
ant, and fill the radiator up to the foot of the water
supply port. DRAIN COCK
In order to prevent air from entering, slowly pour
water. After water pouring, confirm that the water
level does not lower, then tighten the radiator cap.
(3) Start and run the engine for about 1 minute.
Stop the engine, and check water level. If insuffi-
cient, add water.
9-53 7055-3
9. MAINTENANCE
9.2.8 HYDRAULIC OIL

Item No. Check Item (hourmeter : Hr) Remarks
8 50 250 500 1000 2000
1 Check of hydraulic oil level O
2 Drain of hydraulic oil tank O
Tank capacity:
3 Change of hydraulic oil O
380 ltr.
1. CHECK OF HYDRAULIC OIL LEVEL

If the hydraulic oil level is in the center of the level
gauge with the following conditions and the engine
running, the oil level is normal.
[Oil temperature : 20 °C]
Gantry cylinder : Extended
Crawler ext /retr cylinder : Extended
LEVEL GAUGE
2. DRAIN OF HYDRAULIC OIL TANK

Before starting operation, loosen the drain plug to
drain water and sediment from the tank.
DRAIN PLUG
7055-3 9-54
9. MAINTENANCE
3. CHANGE OF HYDRAULIC OIL
Do not drain the oil when it is hot.

The hot oil may spout out which could result in per-
sonal injury. After the oil has cooled, drain the oil.
Extra care must be taken to insure that all the hydraulic

tank is completely filled with oil before the engine is re-
started.
Failure to properly prime the hydraulic pumps could re-
sult in a catastrophic failure of the pumps.
It is standard to replace hydraulic oil every 2000 hours

of the hourmeter, but if the oil is remarkably contaminat-
ed or deteriorated, replace the oil regardless of operat-
ing hours.
(1) Prepare a container of approx. 400 ltr..

(2) Remove the cap of the filler port and filter cover.
(3) Loosen the drain plug and drain the hydraulic oil
into the prepared container.
(4) Replace the drain plug, fill the tank with the speci-
fied hydraulic oil through the filler port up to the
specified level.
(5) Reinstall the filter cover and oil supply cap.
(6) Check the oil level again.
When changing hydraulic oil, change the filter also of
the same time.
9-55 7055-3
9. MAINTENANCE
9.2.9 GEAR OIL
Item Check Interval (hourmeter:Hr)

Check Item Remarks
No. 8 100 250 500 1000 2000
Oil level check of swing reduc-
O
tion unit
1
Oil change of swing reduction
O Oil quantity: 16.5 ltr.
unit
Oil level check of front and rear
O
drum reduction unit
2
Oil change of front and rear drum
O Oil quantity: 18 ltr./each
reduction unit
Oil level check of boom hoist
O
drum reduction unit
3
Oil change of boom hoist drum
reduction unit
Oil level check of power divider O
4
Oil change of power divider O Oil quantity: 2.8 ltr./each
Oil level check of propel
O
reduction unit
5
Oil change of propel reduction
unit
6 Oil change of lower roller Oil quantity: 0.13 ltr./each
7 Oil change of upper roller Oil quantity: 0.06 ltr./each
8 Oil change of idler wheel Oil quantity: 0.25 ltr./each
Replace the oil for the parts with item nos. 6, 7 or 8 at overhaul if there is no failure such as oil leak.
1. OIL LEVEL CHECK AND OIL CHANGE OF

SWING REDUCTION UNIT
(1) OIL LEVEL CHECK

Check the oil level more than 30 minutes after the
operation is stopped.
If the oil level is in the net meshes of the level
PROPER OIL LEVEL
gauge, it is normal.
LEVEL GAUGE
DRAIN COCK
7055-3 9-56
9. MAINTENANCE
(2) OIL CHANGE
Do not drain the oil when it is hot. The hot oil may
spout out which could result in personal injury. Af-
ter the oil has cooled, drain the oil. Failure to ob-
serve this precaution may result in serious injury.
(A) With the gauge stick drawn out, loosen the drain
cock, and drain the oil into a prepared container.
(B) Shut the drain cock and supply the specified oil
through the fill port until the oil level reaches the
specified level.

OIL FILL PORT
FRONT AND REAR REDUCTION UNITS
(1) OIL LEVEL CHECK

If the oil level in the reduction unit is up to the red
color mark of the level gauge, it is normal.
(2) OIL CHANGE
spout out which could result in personal injury. Af- DRAIN COCK LEVEL GAUGE
serve this precaution may result in serious injury.
(A) Prepare a container of approx. 20 ltr. capacity.

(B) With the oil fill plug removed, turn the lever of the
drain cock to drain the oil into the prepared contain-
er.
(C) Return the lever of the drain cock to the original po-
sition, and supply the specified oil through the oil fill
port until the oil level reaches the specified oil level.
9-57 7055-3
9. MAINTENANCE
3. OIL LEVEL CHECK AND OIL CHANGE OF BOOM OIL FILL PORT
HOIST DRUM REDUCTION UNIT
(1) OIL LEVEL CHECK

Check the oil level 30 minutes after machine running
is stopped.
If the oil level is to the level gauge, it is normal.
DRAIN PLUG LEVEL GAUGE
(2) OIL CHANGE
ter the oil has cooled, drain the oil.
rious injury.
(A) Prepare a container of approx. 5 ltr. of capacity.

(B) With the oil fill plug removed, removed the drain
plug to drain the oil into the container.
(C) 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 level.
7055-3 9-58
9. MAINTENANCE

BREATHER OIL FILL PORT
POWER DIVIDER
(1) OIL LEVEL CHECK

If the oil level is upto the red color mark of the level
gauge, it is normal.
(2) OIL CHANGE
Do not drain the oil when it is hot. The hot oil may DRAIN COCK
ter the oil has cooled, drain the oil.
Failure to observe this precaution may result in se- LEVEL GAUGE

(B) With the cap of the oil supply port removed, turn the
lever of the drain cock to drain the oil into the con-
tainer.
(C) Return the lever of the drain cock to the original po-
sition, pour the specified oil through the oil supply
port until the oil level reaches the specified level.
9-59 7055-3
9. MAINTENANCE

PROPEL REDUCTION UNIT
(1) OIL LEVEL CHECK

With the drain plug positioned at the right bottom, FILL / LEVEL PORT
remove the level plug. If the oil level is up to the bot-
tom of the level plug opening, it is normal.
(2) OIL CHANGE DRAIN PLUG

(B) With the level plug removed, remove the drain plug
to drain the oil into the container.
(C) Reinstall the drain plug, pour the specified oil
through the fill/level port until the oil reaches the
specified level.
serve this precaution may result in serious injury or
death.
7055-3 9-60
9. MAINTENANCE
6. OIL CHANGE OF LOWER ROLLER

Remove the both end plugs to drain the oil.
Supply the specified oil of specified amount.
To change oil, consult the local KOBELCO autho-
PLUG PLUG
rize distributor.
7. OIL CHANGE OF UPPER ROLLER

Remove the both end plugs to drain the oil.
PLUG
To change oil, consult the local KOBELCO autho- PLUG
rize distributor.
8. OIL CHANGE OF IDLER WHEEL

PLUG
Remove the plug of the sliding block to drain the oil.
To change oil, consult the local KOBELCO autho-
rize distributor.
9-61 7055-3
9. MAINTENANCE
9.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER
8-1 8-2
5
6
2 1 3 11 10
7 4-2 4-1
7055-3 9-62
9. MAINTENANCE
Cleaning/Washing/Changing Interval
Item (hourmeter: Hr)
Service Item for the Part No. Quantity
No.
first time 100 250 500 1000 2000
(50)
LS52V01002R110
1 Change of return filter O 1
(Repair kit)
Hydraulic oil tank
GB50V00004S001(element)
2 Change of suction filter O 1
ZD11G22000(O-ring)
3 Washing of oil fill port strainer O 1
2446R183S2 (filter)
4-1 O 1
45Z91D84 (O-ring)
R36P0019 (filter)
45Z91D84 (O-ring)
Washing of line filter
[to GB04-03030]
4-2 O 1
2446U346S5
(O-ring)
[GB04-03031 to]
5 Change of drain filter (cartridge) O O 2446U141S2 1
Change of cooling line filter
6 O O 2446U254S3 1
(cartridge)
7 Washing of fuel tank fill port strainer O 1
23390-E0010
8-1 Change of fuel filter O 1
(Hino Parts)
Change of fuel Pre-Filter YN21P01036R100
8-2 O 1
(Option) (element, O-ring)
15607-2190
9 Change of engine oil element O O 1
(Hino Parts)
Cleaning change
10 Cleaning and change of air element O O
GG11P00008S002 1
Check the following conditions when the machine is to be operated in the area where sulfur contents more than 5000
ppm in the fuel.
Cleaning/Washing/
Item
Service Item Changing Interval PART No. Quantity
No.
(hourmeter:Hr)
17309-1090
5000h
11 Inspect EGR cooler 17104-1990, 2000 1
O
(Hino Parts)
9-63 7055-3
9. MAINTENANCE
1. CHANGE OF HYDRAULIC OIL TANK RETURN

FILTERS
Do not change hydraulic oil filter when hydraulic oil

is hot.
After the oil has cooled and the pressure has been
released, change the filter.
Removing the filter cover, replace the element and O-

ring with new ones.
COVER
O-RING
SPRING
VALVE
O-RING
ELEMENT
PACKING
7055-3 9-64
9. MAINTENANCE
Procedure of replacing the return filter

(1) Remove the filter assembly and place it on the flat
surface.
(2) Hold the top mold plate and loosen the grip.
(3) Pull out the grip assembly.
(4) Turn over the filter.
9-65 7055-3
9. MAINTENANCE
(5) Hold the plate on which the end plate is attached.
(6) Loosen the end plate and replace the packing ma-
terial with new one.
Do not try to pull out the grip assembly by holding lower

portion.
This may make disassembly harder since the element
may be twisted and excessive force may be applied.
2. CHANGING HYDRAULIC OIL SUCTION FILTER

Remove the filter cover and replace the element
and O-ring.
Perform this change when changing the hydraulic
COVER
oil.
O-RING
FILTER
O-RING
(FILTER)
7055-3 9-66
9. MAINTENANCE
3. WASHING FILL PORT STRAINER

STRAINER
Remove the air breather cap, take out the fill port
strainer, and sufficiently wash it with washing liq- FILL PORT
uid.
4. WASHING OF LINE FILTER
After stopping engine, wait for five minutes to re-

lease pressure.
Remove the case, take out the filter and sufficiently

wash it.
Replace the O-ring with a new one.
LINE FILTER
(4-2)
CONTROL
LINE FILTER
(4-1)
O-RING
FILTER
9-67 7055-3
9. MAINTENANCE
5. CHANGING DRAIN FILTER (CARTRIDGE)

Loosen the plug of the filter cover to remove the re-
maining pressure in the tank.
Prepare an oil receptacle under the filter, and re-
place the cartridge with a new one.
LINE FILTER
for
BRAKE COOLING
DRAIN FILTER
6. CHANGE OF LINE FILTER FOR BRAKE

COOLING LINE (CARTRIDGE)
Loosen the plug of the filter cover to remove the re-
maining pressure in the tank.
Prepare a oil receptacle under the filter, and replace
the cartridge with a new one.
7. WASHING FUEL TANK FILL PORT STRAINER

Remove the cap, take out the strainer and suffi-
ciently wash it with washing liquid.
STRAINER
Keep fuel away from spark or flame.
7055-3 9-68
9. MAINTENANCE
8-1. CHANGE OF FUEL ELEMENT

(1) Removing the fuel filter element
a) Drain water from the fuel filter.
b) Remove the water cap of fuel filter.
c) Remove the fuel filter element.
Prepare a receptacle because the fuel remains in the

filter.
PRIMING PUMP AIR BLEEDER PLUG
ELEMENT
DRAIN VALVE
WATER CAP
(2) Installation of the fuel filter element PRIMING PUMP

a) Remove the contamination and foreign matter on
the installation surface.
b) Attach the fuel filter element to the fuel filter head.
ELEMENT
c) Attach the water cup of the fuel filter to the lower
part of fuel filter element. O-RING
d) Tighten the fuel filter water drain valve. O-RING
WATER CAP
Do not reuse an element.
e) Start the priming pump to bleed air in the system.
Check that the fuel filter air bleed bolt is loosened.
f) Tighten the fuel filter air bleed bolt.

Tightening torque: 1.7 to 2.6 N-m
Wipe off spilt fuel after works and check that the fuel is
not leaked once more after starting the engine.
9-69 7055-3
9. MAINTENANCE
DRAIN WATER FROM FUEL FILTER

If the condition with the water mixed in the fuel filter is
left for a long time, it may result in the premature dam-
age and deterioration of the engine body.
Thoroughly perform checking before starting daily
works and drain the water if mixed in.
The condition can be visually checked through the ball
section under the filter.
When the water reached a certain level, the warning
message in the figure is displayed in the gauge

cluster. Immediately drain the water.
<Water drainage instruction> PRIMING PUMP AIR BLEEDER PLUG

1. Place a container to receive the drained water un-
der the drain pipe.
2. Loosen the air bleeder plug and the water draining
valve of the fuel filter to drain water gathered at the
inside of the fuel filter case. ELEMENT
WATER CAP
Drained water contains fuel, therefore, follow the pro-
cessing regulation specified in each region, when dis- SENSOR DRAIN VALVE
posing of it.
3. Tighten the water draining valve and air bleeder

plug.
When the warning message is displayed in the

gauge cluster, immediately drain the water. The de-
tection sensor may be malfunctioned.
7055-3 9-70
9. MAINTENANCE
8-2. CHANGING OF FUEL PRE-FILTER (OPTION)

(1) Prepare container for drain oil. Fuel Pre-Filter
(2) Loosen air bleeder plug (A) and drain valve (B) and
drain fuel from fuel pre-filter.
(3) Fit the specified filter wrench to the lower side of
stiffening ribs and remove case (C).
Parts number : YT01T01008P1
(4) Remove drain valve (B).
(5) Remove dirt and foreign matter from attaching sur-
face.
(6) Apply light oil to new O-rings (D), (F) thinly, set it to
case (C) and replace it with new element (E).
(7) Fit case (C) to filter head by hand securely and
tighten it with filter wrench (Parts number :
YT01T01008P1). (A)
(8) Tighten air bleeder plug (A) and drain valve (B).
(9) Bleed air according to the air bleeding procedure
for fuel system.
(D)
(C)
• Do not reuse the element.
Replace old O-rings.
• Be careful not to damage the O-rings by twisting. (E)
• Check to see if the O-rings firmly contact to the
sealing surface.
(B) (F)
9-71 7055-3
9. MAINTENANCE
9. CHANGING OIL FILTER ELEMENT

(1) Removing the oil element
a) Prepare a suitable container to receive oil.
b) Remove the element using the filter wrench
which is the special tool.
(Turn counterclockwise.)
(2) Installation of the oil filter element
a) Remove the contamination such as dust and
mud on the sealing surface (the contacting sur-
face of element gasket) of the oil filter unit.
b) Apply engine oil to the gasket of new element O-RING
and install it turning slightly until it contacts the
sealing surface of the filter.
ELEMENT
• Make sure to use the new gasket provided in the el-

ement kit.
• Be careful that the gasket will not be damaged by
being twisted.
• Do not reuse an oil element.
c) After attaching it by turning slightly, use the filter

wrench to tighten it by 3/4 to 1 turn.
10. CLEANING AND CHANGING AIR ELEMENT

Remove the air element, and blow air from the in-
side to remove any dust.
If it is exceptionally dirty and the element is de-
formed, replace the element with a new one early.
7055-3 9-72
9. MAINTENANCE
9.4 BATTERY INSPECTION

Check Interval
Item No. Check Item (hourmeter: Hr) Remarks
8 100 250 500 1000 2000
1 Check of battery electrolyte level. O
2 Check of charge condition. As required
1. CHECKING BATTERY ELECTROLYTE LEVEL

If the battery electrolyte level is up to 10 mm (0.39
inch) above the plates, it is normal.
If insufficient, add distilled water.
(1) Checking the battery electrolyte level from the side
of the battery:
Clean around the level lines with a wet cloth, and
make sure that the electrolyte level is between the
upper level (U.L) and the lower level (L.L).
When the electrolyte level is lower than the level
halfway between the U.L and the L.L, add battery
electrolyte. After replenishment, securely tighten
the plug.
NEVER clean the battery with a dry cloth.

Otherwise, static electricity occurs, leading to com-
bustion and explosion.
(2) When you cannot check the battery electrolyte level

from the side of the battery, or no level lines are pro-
vided on the side of the battery:
Detach the plug at the top of the battery, and check
the battery electrolyte level from the filling port.
If the electrolyte level is lower than the sleeve, add
battery electrolyte to the bottom of the sleeve.
• Keep battery away from flame or spark.

• Never smoke cigarettes while checking electro-
lyte level. This could cause the battery electro-
lyte to ignite and cause property damage, injury
to personnel or death.
9-73 7055-3
9. MAINTENANCE
• Since the battery electrolyte is dilute sulfuric

acid, avoid battery acid contact with the skin,
eyes, or clothing. If accidentally contacted, im-
mediately flush the area with water and consult
a doctor immediately.
• Wear eye glasses to protect your eyes when
working with electrolyte.
• Do not short across the battery terminals.

7055-3 9-74
9. MAINTENANCE
2. CHECKING CHARGE CONDITION

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 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.
NEVER use the battery when the battery electrolyte

level is lower than the lower level.
Doing so will cause deterioration of the battery in-
side, but could also cause the battery to explode.
Do not add battery electrolyte until the battery electro-

lyte level exceeds the upper level.
Otherwise, excess electrolyte leaks, causing corrosion
of the periphery of the battery.
If the battery will not be used for an extended period of

time, remove the battery, clean it thoroughly and store
it in a cool, dry location where the temperature will not
fall below 0°C (32°F).
If the battery cannot be removed and stored, then dis-
connect the terminals to avoid draining the battery.
If the level of battery electrolyte exceeds the upper level

or lower level of the sleeve, remove excess electrolyte
with a syringe until the level is at the upper level or low-
er level of the sleeve.
To treat the removed electrolyte, neutralize it with sodi-
um bicarbonate, and pour it out with a great deal of wa-
ter, or consult with the manufacturer of the battery.
9-75 7055-3
9. MAINTENANCE
9.5 LOCATION AND USE OF FUSE
OPERATOR’S ROOM Removal of fuse

LEFT SIDE STAND Fit the fuse to the comer of the
fuse box cover, and pull it out.
FUSE
FUSE BOX COVER
Classification of Fuse Use
Fuse No. Capacity Kind Line No. Use Location
F1 20A 1 – 11 Main power supply
F2 5A 1 – 12 Back-up
F3 5A 54 – 13 Engine start
F4 5A 3 – 14 Hour meter
F5 10A 2 – 15 Free fall
F6 10A 2 – 16 Solenoid valve
F7 5A 2 – 17 Load safety device control power supply
F8 5A Automotive 2 – 18 Load safety device output power supply Fuse box

Blade
F11 10A 52 – 21 Radio, One-way (Not used for this model)
F12 30A 2 – 22 Total controller
F13 10A 2 – 23 Gauge cluster
F14 10A 2 – 24 Swing flasher
F15 10A 2 – 25 Fuel pump, Fan
F16 10A 2 – 26 C/W Removal system control box
F17 10A 2 – 27 Redundancy circuit
F18 10A 2 – 28 Spare
F19 10A 2 – 29 Spare
F20 10A 2 – 30 Spare
F25 15A 2 – 35 Engine control unit
Fuse part No. : 1A=2479Z2812D1, 2A=2479Z2812D2, 5A=2479Z2812D5, 10A=2479Z2812D7,

‫ޓޓޓޓޓޓޓ‬15A=2479Z2812D8, 20A=2479Z2812D9, 30A=2479Z2812D11.
7055-3 9-76
9. MAINTENANCE
Classification of Fuse Use
Fuse No. Capacity Kind Line No. Use Location
F9 20A 2 – 19 Wiper
F10 20A 2 – 20 Air conditioner
18 – 103 Over hoist (#03001 to 03042)

F21 5A Automotive Fuse holder
Blade 2 – 103 Over hoist (from #03043)
F30 20A 2 – 40 Glow
(WUGpart No. : 1A=2479Z2812D1, 2A=2479Z2812D2, 5A=2479Z2812D5, 10A=2479Z2812D7,

‫ޓޓޓޓޓޓޓ‬15A=2479Z2812D8, 20A=2479Z2812D9, 30A=2479Z2812D11.
F29 2A
ENGINE CONTROL UNIT
F9 20A WIPER (CN-42AF)
FUSE BOX
F21 5A OVER HOIST

(#03001 to 03042.
from #03043 , refer to
right picture)
F10 20A AIR CONDITIONER (CN-42BF)

F21 5A OVER HOIST (CN42-CF)
(from #03043)
F30 20A GLOW
9-77 7055-3
9. MAINTENANCE
9.6 OPERATION UNDER UNUSUAL CONDITIONS

1. OPERATION IN EXTREME COLD
Item Treatment Caution
Engine Oil Use engine oil suitable to the atmospheric temperature. When adding oil, do not mix different
(See the engine manual.) brand and quality oil.
Class CD, CE, CF, CF-4, CH-4, CI-4 in API service classification.
Atmospheric temperature 40 C to 0 C 40 C to -30 C

when engine starting. (104 F to 32 F) (104 F to -22 F)
Viscosity of oil SAE 30 SAE10W-30
Fuel Use fuel, suitable to the atmospheric temperature.

Before starting work, drain water. After the work is finished,
fill the tank as full as possible.
NOTE
Only use commercially available vehicle diesel fuels (EN590).
Grades such as marine diesel fuel, heating oils, etc. are not permitted.
The engine in this machine adopts the electronically controlled, high-pressure fuel injection unit
in order to achieve the satisfactory fuel consumption and exhaust gas characteristics.
The use of improper fuel may seriously affect the fuel consumption and exhaust gas characteri-
stics, resulting in the premature damage and deterioration of the engine body as well as the fuel
injection unit.
Coolant Combine antifreeze (Long Life Coolant) according to the Sometimes, combination rate may be
atmospheric temperature. different depending upon brands.
[Capacity of coolant: 40 ltr. (10.6 gal.)]
Atmospheric Volume of Volume of

temperature cooling water antifreeze
36 ltr. 4 ltr. (1.1 gal.)
-4 C (9.5 gal.) (10%)
-7 C 34 ltr. 6 ltr. (1.6 gal.)
(9 gal.) (15%)
-13 C 30 ltr. 10 ltr. (2.6 gal.)
(7.9 gal.) (25%)
-17 C 28 ltr. 12 ltr. (3.2 gal.)
(7.4 gal.) (30%)
26 ltr. 14 ltr. (3.7 gal.)
-21 C (6.9 gal.) (35%)
-25 C 24 ltr. 16 ltr. (4.2 gal.)
(6.3 gal.) (40%)
22 ltr. 18 ltr. (4.8 gal.)
-31 C (5.8 gal.) (45%)
20 ltr. 20 ltr. (5.3 gal.)
-40 C (5.3 gal.) (50%)
Battery Sufficiently charge the battery. After distilled water has been added,
(Maintain the specific gravity more than 1.22.) start and run the engine to mix water
The electrolyte in a fully charged battery will resist freezing at and electrolyte.
lower temperatures better than a battery that is not fully charged.
7055-3 9-78
9. MAINTENANCE
2. OPERATION IN EXTREME HEAT
Engine Oil Use engine oil suitable to atmospheric temperature. Do not mix different brand and
(See the engine manual.) quality oil.
Class CD, CE, CF, CF-4, CH-4, CI-4 in API service classification.
Atmospheric temperature Higher than 40 C to 0 C

when starting engine 40 C (104 F) (104 F to 32 F)
Viscosity of oil SAE40 SAE30
Coolant Do not use antifreeze (Long Life Coolant), but mix anticorrosive
to fresh water and pour it.
Wash the inside of the radiator, too with washing liquid.
Battery Always maintain the electrolyte level 10mm (0.39 inch)

above the plates.
3. OPERATION IN DUSTY PLACE

Air cleaner Perform washing and change of the element early.
Radiator, oil cooler Early clean the core not to allow dust to clog the core.
Filter, element Early replace with new ones.
Engine oil Early change oil.
Slewing ring gear Early lubricate.
Wire rope Early clean and lubricate.
4. OPERATION IN SEASIDE

Thoroughly and carefully lubricate each point Lubricate connec-
Lubrication
tor sections not equipped with grease fittings.
Sufficiently wash the basic machine, radiator and oil cooler to
Basic machine
wash salt off.
9-79 7055-3
9. MAINTENANCE
9.7 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 lubricate the entire machine.
• Sufficiently grease the slewing ring gear.
• 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 cold, dark place.
• Apply thin coat of oil to places that are prone to rust.
• Completely drain coolant and post a "No Water" sign.
• Cover the entire machine to protect it from dust.
7055-3 9-80
9. MAINTENANCE
9.8 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 Course Screw Thread
4T 7T
Tightening Torque N•m (ft•lbs) Tightening Torque N•m (ft•lbs)
Nominal Dry Lubricated Dry Lubricated

M6 5.1±0.5 (3.8±0.4) 4.3±0.4(3.2±0.3) 11.1±1.1 (8.2±0.8) 9.3±0.9 (6.9±0.7)
M8 12.3±1.2 (9.0±0.9) 10.4±1.0 (7.7±0.8) 27.4±2.7 (20.2±2.0) 22.5±2.3 (16.6±1.7)
M10 24.5±2.5 (18.1±1.8) 20.6±2.1 (15.2±1.5) 52.9±5.3 (39.0±3.9) 45.1±4.5 (33.2±3.3)
M12 41.2±4.1 (30.3±3.0) 36.3±3.6 (26.7±2.7) 90.2±9.0 (66.4±6.6) 76.4±7.6 (56.3±5.6)
M14 65.7±6.6 (48.4±4.8) 55.9±5.6 (41.2±4.1) 143±14 (105±10.5) 121±12 (88.8±8.9)
M16 100±10 (73.6±7.4) 84.3±8.4 (62.1±6.2) 216±22 (159±16) 181±18 (134±13)
M18 137±14 (101±10) 117±12 (85.9±8.6) 304±30 (224±22) 255±26 (188±19)
M20 193±19 (142±14) 162±16(119±12) 421±42 (310±31) 353±35 (260±26)
M22 255±26 (188±19) 216±22 (159±16) 559±56 (412±41) 470±47 (347±35)
M24 333±33 (245±25) 265±27 (195±20) 715±72 (527±53) 578±58 (425±43)
M27 480±48(354±35) 392±39 (289±29) 1048±105 (773±77) 853±85 (643±64)
M30 657±66 (484±48) 549±55 (404±40) 1421±142 (1047±105) 1195±120 (881±88)
M33 882±88 (650±65) 735±74 (542±54) 1911±190 (1408±141) 1607±161 (1184±118)
M36 1137±114 (838±84) 951±95 (700±70) 2450±245 (1805±180) 2048±205 (1509±151)
Metric Fine Screw Thread
4T 7T
Tightening Torque N•m (ft•lbs) Tightening Torque N•m (ft•lbs)
Nominal Dry Lubricated Dry Lubricated

M8 12.9±1.3 (9.5±0.9) 10.9±1.1 (8.0±0.8) 28.4±2.8 (20.9±2.1) 23.5±2.4 (17.3±1.7)
M10 25.5±2.6 (18.8±1.9) 21.6±2.2 (15.9±1.6) 54.9±5.5 (40.4±4.0) 47.0±4.7 (34.7±3.5)
M12 45.1±4.5 (33.2±3.3) 38.2±3.8 (28.2±2.8) 97.0±9.7 (71.5±7.2) 81.3±8.1 (59.9±6.0)
M16 105±11 (77.3±7.7) 88.2±8.8 (65.0±6.5) 225±23 (166±17) 191±19 (141±14)
M20 206±21 (152±15) 174±17 (129±13) 451±45 (332±33) 372±37 (274±27)
M24 353±35 (260±26) 294±29 (217±22) 764±76 (563±56) 637±64 (469±47)
M30 706±71 (520±52) 588±59 (433±43) 1548±155 (1141±114) 1284±128 (946±95)
M36 1176±118 (866±87) 980±98 (722±72) 2568±257 (1892±189) 2136±214 (1574±157)
9-81 7055-3
9. MAINTENANCE
(2) The torque values required for the specified screws and bolts on this machine are shown in the table below.
The allowance of the torque values shown in the table is ±(plus and minus) 10%.
COUNTER
SWING BEARING SWING REDUCTION UNIT
WEIGHT
161 N-m(19.5 kgf-m)

1372 N-m(140 kgf-m)
559 N-m
(57 kgf-m)
1372 N-m(140 kgf-m) 549 N-m

(56 kgf-m)
ENGINE
121 N-m (12 kgf-m)
284 N-m (29 kgf-m)
402 N-m
(41 kgf-m) 559 N-m (57 kgf-m)
314 N-m
(32 kgf-m)
PUMP PROPEL REDUCTION UNIT

161 N-m 25 N-m
(16.4 kgf-m) (2.6 kgf-m) 559 N-m (57 kgf-m)
1130 N-m (92 kgf-m)
284 N-m (92 kgf-m)
314 N-m
(32 kgf-m)
FRONT & REAR DRUM ASSEMBLY BOOM DRUM ASSEMBLY
39 N-m
(3.0 kgf-m)
373 N-m (38 kgf-m)

559 N-m
(57 kgf-m)
Apply Loctite #242 or equivalence to the bolts and nuts.

For maintenance, contact our KOBELCO authorize distributor.
7055-3 9-82
9. MAINTENANCE
9.9 SECURITY PARTS TO BE REPLACED PERIODICALLY
Disrepair of parts related to brakes and clutches cause

serious accidents. Therefore, periodic replacement in-
tervals are set for these critical parts, as shown in the
following table. Replacement intervals are standard-
ized. Be sure to replace the security parts, shown in the
table below, (within) every 2 years.
Replacement In-
No. Security Parts to be Replaced Periodically Remarks
terval
1 Pressure line hose (accumulator to control line) 2 years
2 Pressure line hose (pump to line filter) 2 years
Since damage and corrosion of boom guy line are

caused by fatigue from the inside in the boom guy line,
replacement time cannot be judged from the appear-
ance only. If the guy line is broken by progressing in-
ternal damage and/or corrosion, there is possibility to
cause serious accidents. Be sure to replace the guy
line periodically.
Replacement time according to the content of work is
shown in the following table.
Replacement
Contents of Operation
Interval
Exclusive operation to lifting magnet
2 years
or clamshell
Both crane and clamshell operation,
or frequent crane operation such as 4 years
landing work
Normal crane operation 6 years
9-83 7055-3
9. MAINTENANCE
9.10 ADJUSTMENT
9.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS
22 mm or more
Do not adjust the drum locks until the boom, hook

block, and load 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 bottom
of the drum ratchet.
If the pawl is not engaged in the bottom of the ratch-
et, adjust the spring length to allow the pawl to be
engaged.
2. With the RELEASE position, adjust the respective
dimension as shown in the figure to the right.
3. Push the drum lock knob in the RELEASE position
and check to see that the pawl is clear of the ratchet 58 mm 58 mm
by at least 22 mm.
Operate the knob to the LOCK position, and to the 126 mm
RELEASE position and confirm that the pawl
moves smoothly. FRONT AND REAR DRUM LOCK
7055-3 9-84
9. MAINTENANCE
9.10.2 ADJUSTMENT OF BOOM DRUM LOCK
Do not adjust the boom hoist drum lock until the

boom has been lowered to the ground.
mm 53 mm
Failure to observe this precaution may result in se- 26 more
or 63 mm
1. Pull the drum lock knob in the LOCK position and

check to see that the pawl is engaged in the bottom
of the drum ratchet with the drum lock condition.
If the pawl is not engaged in the bottom of the ratch-
et, adjust the spring dimension to allow the pawl to
be engaged.
2. With the RELEASE position, adjust the respective
dimension as shown in the figure to the right.
3. Push the drum lock knob in the RELEASE position,
and check to see that the pawl is clear of the ratchet
by at least 26 mm.
Operate the knob to the LOCK position, and to the
RELEASE position, and confirm that the pawl
moves smoothly.
Keep hands and clothing clear of the rotating drum.

9-85 7055-3
9. MAINTENANCE
9.10.3 CRAWLER SHOES ADJUSTMENT

If the crawler shoes are too tight, the shoes wear quick-
SHIM PACK(A)
ly and a connection between two shoes could break.
On the other hand, if the shoes are too loose, the shoes SHIM PACK(B)
may ride off the drive sprocket and idler wheel during
travel operation. To prevent these from happening, it is
necessary to adjust shoe tension.
To adjust shoe tension, proceed as follows:
SPACER
1. Move the machine forward about one crawler
length so that the slackening in the crawler shoes
appear on the top of the crawler.
SLACKEN
2. Remove all the shims from shim pack (A). 10 to 20 mm
3. Position the hydraulic jack between the bracket and

block of the side frame.
Operate the jack to push the idler wheel and re-
move the slackening in the shoes.
4. Insert the shims removed from pack (A) in step (2)
into the vacant room of pack (B).
Insert the remaining shims into pack (A).
5. Remove the hydraulic jack and adapter. Store
spare shims in the shim pack (A). JACK
Equalize the tension in right and left crawler tracks.
7055-3 9-86
9. MAINTENANCE
9.11 CONSUMABLE PARTS LIST

1. OIL/GREASE
For the recommended oil and grease, refer to the
"KOBELCO Genuine Lubricant Chart" on page 9-
36, and be sure to use genuine KOBELCO parts.
For the battery electrolyte and the window washer
liquid, use commercial items.
2. FILTER ELEMENT
For the recommended filter element, refer to the
chart on page 9-62.
3. FUSE
For the recommended fuse, refer to the chart on
page 9-76.
4. WIRE ROPE
For the recommended wire rope, refer to the of
Chapter 8. WIRE ROPE.
5. LIGHT AND MIRROR
ROOM LIGHT
2456R315
HEAD LIGHT
YN80S00010F2
MIRROR
GB52C00003F1
PANEL LIGHT
SWING FLASHER, TAIL LIGHT GB80S00011P1
Assy FP80S00002F1
LOAD SAFETY DEVICE ALARM LAMP
Lamp 2456U145S15
Right
㪩㪼㪻
Lens GB80S00001S002 (Red)
㪰㪼㫃㫃㫆㫎
Lens GB80S00001S001 (Clear)
㪙㫃㫌㪼
Assy FP80S00001F1
Lamp 2456U145S15
Left
Lens GB80S00002S002 (Red) LAMP ASSY : EZ53E00013F1
Lens GB80S00002S001 (Clear) BULB : FOCUS24V10W
9-87 7055-3
9. MAINTENANCE
6. WIRE LOCK
LIGHT HOOK 7 t BALL HOOK
STOPPER : GB74A01001S016 STOPPER : 24100U255S10

SPRING : GB74A01001S018 SPRING : GB74A00002S019
BOLT : GB74A01001S017 BOLT : ZS16C12065
NUT : GB74A01001S020 NUT : ZN39C12011
SPLIT PIN : ZP16D03030
19 t HOOK 32 t HOOK 55 t HOOK
KIT : GB73A00007S018 KIT : GG73A01006F1 KIT : GG73A01006F1
7. WINDOW GLASS AND WIPER
WIPER BRAID
EW53C00005F1
GLASS
GLASS GB02C01254P1
EW02C01078P1
GLASS WIPER BRAID

GB02C01260P1 EW53C00005F1
GLASS GLASS
GB51C01027P2 GB02C01255P1
GLASS
GB02C01259P1
WIPER GRAID
GB53C00009P1
SASH ASSY
EW02C01236F1
GLASS
GB02C01261P1
GLASS
GB02C01262P1
GLASS
GB02C01263P1
7055-3 9-88
9. MAINTENANCE
8. HOOK OVER HOIST LIMIT SWITCH
LIMIT SWITCH
24100N6192F5
WIRE ROPE LIMIT SWITCH

2430Z223D2 24100N6192F5
WIRE ROPE
2430Z223D8
WIRE ROPE
2430Z223D5
WEIGHT
2422N1299 SPLIT PIN
ZD16D03020
PIN SHACKLE WEIGHT

GB51E01017P1 GB51E01019P1 2422P1171
9. CABLE REEL FOR LOAD SAFETY DEVICE
CRANE GG82S00005F1
JIB GG82S00006F1
10. KEY
ENGINE
DOOR
GUARD
YN50S01010P1
9-89 7055-3
9. MAINTENANCE
11. TOOL
TOOL BOX PLIERS ADJUST WRENCH HUMMER
4027R1 2421R393 ZT12D20000 (24 mm) 2421R397

ZT12D37500 (44 mm)
ADAPTOR
HUMMER (+) DRIVER (-) DRIBER
(When adjustment of shoe)
21Z72D4 GB01T01008D1 2421R395D2 (5.5 mm) GB54D01005P1

JACK
RATCHET HANDLE EXTENSION BAR SPANNER
(When adjustment of shoe)
2421Z228D16 2406R527 ( 12.7) 2406Z623D4 ( 12.7) ZT12A55000 (55 mm)

ZT31B19500 ( 19) ZT31D19400 ( 19)
PIPE
SOCKET GREASE NIPPLE FILTER WRENCH
(For wrench)
(A) (B) (C)
2408R587D1 (17 mm) 2420T3100 (A) ZG91S02000 (PT1/8) YT01T01008P1

2408R587D2 (19 mm) (B) ZG91S04000 (PT1/4)
2408R587D3 (22 mm) (C) ZG91U02000 (PT1/8)
2408R587D4 (24 mm)
ZT32A30000 (30 mm)
ZT32A55000 (55 mm)
7055-3 9-90
9. MAINTENANCE
HOSE (For grease pump) GREASE PUMP CLOTHES CARTRIDGE
44Z186 2421R107 EZ01T01018P1 2446U141S2

GEAR OIL
CARTRIDGE GREASE SHACKLE
(For swing gear)
2446U254S3 2421R114D11 21Z16D5 2420Z2134D1×2

(For 10.0 t)
2420Z604D6×4
(For 5.4 t)
9-91 7055-3
9. MAINTENANCE
7055-3 9-92
10. REFERENCE MATERIALS

10.1 SPECIFICATION
10.1.1 PERFORMANCE
Type Full hydraulic type

Max. lifting capacity 55 t x 3.7 m
Basic boom length 9.1 m
Max. boom length 51.8 m
42.7 m (Boom) + 12.2 m (Jib)
Max. boom length + Jib length
39.6 m (Boom) + 18.3 m (Jib)
Working weight (with basic boom, 55 t hook) Approx. 56.7 t
Average ground pressure (with basic boom, 55 t hook) 72.3 kPa (0.74 kgf/cm2)
Gradeability (tan ) 40%
Hino J08E-TM
Engine
159 kw/2000 min-1 (216 ps / 2000 rpm)
Main / Aux. lifting rope speed 120 to 3 m/min
Main / Aux. lowering rope speed 120 to 3 m/min
Boom raising rope speed 70 to 2 m/min
Boom lowering rope speed 70 to 2 m/min
Swing speed 4.0 min-1 (4.0 rpm)
Propel speed 2.4/1.5 km/h
• Above rope speeds are based on single part of line and at first layer of rope drum.
• Above speeds vary depending on the load.
10.1.2 TOWER CRANE PERFORMANCE
Max. lifting capacity 12.0 t X 10.0 m

Max. Tower length + Jib length 42.4 m (Tower) X 29.0 m (Jib)
Working weight 60.6 t
Average ground pressure 77.3 kPa (0.79 kgf / cm2)
• Above rope speeds are based on single part of line and at first layer of rope drum.
• Above speeds vary depending on the load.
10-1 7055-3
10.1.3 OUTSIDE DIMENSIONS
Overall width of cab 3,200 mm

Height above ground of cab 3,200 mm
Radius of rear end (counterweight) 3,800 mm
Center of rotation to rear end (Low gantry position) 5,235 mm
Center of rotation to boom foot pin (from center of rotation) 1,100 mm
Height from ground to boom foot pin 1,750 mm
Height to top of gantry (Working position) 6,180 mm
Height to top of gantry (Low gantry position) 3,300 mm
Counterweight ground clearance 1,100 mm
Overall length of crawlers 5,570 mm
Distance between centers of tumblers 4,720 mm
Overall width of crawlers (Extend/Retract) 4,530 mm / 3,200 mm
Width of crawler shoe 760 mm
Ground clearance of carbody 380 mm
7055-3 10-2
CRANE
3200
760
0
80
R3
1m
9.
5235
M
O
BO
3420 1100
3200
1600
940
6180
1775
3300
3200
1750
1100
380
4720 RET : 3,200
5570 EXT : 4,530
WPKVOO
10-3 7055-3
10.1.4 WORKING RANGES
CRANE
51.8m BOOM
48.8m BOOM
45.7m BOOM
42.7m BOOM
39.6m BOOM
36.6m BOOM
33.5m BOOM
30.5m BOOM
27.4m BOOM
24.4m BOOM
21.3m BOOM
18.3m BOOM
15.2m BOOM
Height above ground (m)
12.2m BOOM
9.1m BOOM
Radius from the center of rotation (m)

1.75m
1.1m
Center of
rotation
7055-3 10-4
JIB
(1) Offset Angle : 10 degree
39.6 m BOOM + 18.3 m JIB
42.7 m BOOM + 12.2 m JIB
42.7 m BOOM + 6.1 m JIB
30.5 m BOOM + 18.3 m JIB
30.5 m BOOM + 12.2 m JIB
30.5 m BOOM + 6.1 m JIB
ground (m)
Height above

1.75m
1.1m
Center of
rotation
10-5 7055-3
(2) Offset Angle : 30 degree
39.6 m BOOM + 18.3 m JIB
42.7 m BOOM + 12.2 m JIB
42.7 m BOOM + 6.1 m JIB
30.5 m BOOM + 18.3 m JIB
30.5 m BOOM + 12.2 m JIB
30.5 m BOOM + 6.1 m JIB
ground (m)
Height above

1.75m
1.1m
Center of
rotation
7055-3 10-6
TOWER CRANE
TOWER LENGTH(m)
TOWER ANGLE 90 deg.
29.0 m JIB
25.9 m JIB
22.9 m JIB
19.8 m JIB
Height above
16.8 m JIB
ground (m)
Radius from the
center of rotation (m)
CENTER OF
ROTATION
TOWER LENGTH(m)
TOWER ANGLE 80 deg.
29.0 m JIB
25.9 m JIB
22.9 m JIB
19.8 m JIB
Height above
16.8 m JIB
ground (m)
CENTER OF
ROTATION
Radius from the

10-7 7055-3
TOWER LENGTH(m)
TOWER ANGLE 70 deg.
29.0 m JIB
25.9 m JIB
22.9 m JIB
Height above
19.8 m JIB
ground (m)
16.8 m JIB
CENTER OF
ROTATION
Radius from the

TOWER LENGTH(m)
TOWER ANGLE 60 deg.
25.9 m JIB
22.9 m JIB
Height above
19.8 m JIB
ground (m)
16.8 m JIB
CENTER OF
ROTATION
Radius from the
7055-3 10-8
10.1.5 RATED CRANE LOADS

• Operating radius is the horizontal distance from
center line of rotation of a crane through the center
of gravity of the hoisting load.
• Ratings shown do not exceed 78% of tipping load
on the horizontal solid ground and this is the value
containing the weight of load handing accessories
such as the hook block and sling wire rope.
• To hoist the rated loads, the operator has the re-
sponsibility to judge the existing conditions and re-
duce lifted loads and operating speeds accordingly
when the condition such as wind effect on lifted
load, ground conditions and operating speed could
be harmful to the safe operation of this equipment.
• At radii and boom length where no ratings are
shown in the rated loads table, operation is not in-
tended or approved.
• Extend the right and left crawlers.
• Gantry must be in highest raised position during the
crane operation.
• For the configuration of the insert boom (jib) in the
entire boom (jib) length, make sure to observe the
instruction in the boom (jib) and guy line configura-
tion drawing.
• Standard boom rating loads
Actual hoisting load is the value by deducting the
weight of (load handling accessories such as main
hook plus sling wire rope) from the rated loads.
• Standard jib rating loads
Actual hoisting load is the value by deducting the
weight of (load handling accessories such as jib
• The rated load when the main hook is used with the
jib or the auxiliary sheave installed to the main
boom is the value by deducting the next value (in-
cluding the weight of the jib or the hook for auxiliary
sheave) from the rated loads of the main boom ac-
cording to the jib length and auxiliary sheave.
However, the minimum rated load is 1.1 tons.
Jib Length (m) 6.1 12.2 18.3 Auxiliary sheave

Deductions (t) 1.1 1.6 2.1 0.5
• Actual hoisting load is the value by deducting the

weight of (load handling accessories such as main
10-9 7055-3
• The rated load of the auxiliary sheave is the value

by deducting (0.3 tons + Main hook weight) from
the rated load of the main boom at the same work-
ing radius as the main boom, however it shall not
exceed the maximum rated load 7 tons when the
auxiliary sheave is used.
The maximum working radius when the auxiliary
sheave is used is the same as the maximum work-
ing radius of the main boom at the time.
The main boom length to which the jib can be in-
stalled is 30.5 m to 42.7 m.
However, the 18.3 m jib cannot be installed to the
main boom with the length of 42.7 m. To install the
jib, the boom insert with lug is required.
The main boom length to which the auxiliary
sheave can be installed is 9.1 m to 48.8 m.
• The table shows the maximum rated loads and

hook weight to the number of part line of hoisting
rope.
Maximum rated load for No. of part line

Maximum rated load (ton)
Hook Weight
1 Part 2 Parts 3 Parts 4 Parts 5 Parts 6 Parts 7 Parts 8 Parts
55 t — — — 28.0 35.0 42.0 49.0 55.0 0.65 t
32 t — — 21.0 28.0 32.0 — — — 0.50 t
19 t — 14.0 19.0 — — — — — 0.40 t
7t
7.0 — — — — — — — 0.16 t
(Ball hook)
7055-3 10-10
Combination of boom and jib

Counterweight Jib Length (m)
Boom Length (All) (Counterweight all attached)
(m) Main Boom Aux. Offset angle 10 degrees Offset angle 30 degrees
only Sheave 6.1 12.2 18.3 6.1 12.2 18.3
9.1 O O — — — — — —
12.2 O O — — — — — —
15.2 O O — — — — — —
18.3 O O — — — — — —
21.3 O O — — — — — —
24.4 O O — — — — — —
27.4 O O — — — — — —
30.5 O O O O O O O O
42.7 O O O O — O O —
45.7 O O — — — — — —
48.8 O O — — — — — —
51.8 O — — — — — — —
10-11 7055-3
7055-3 CRANE RATED LOADS
(Unit : Metric tons)

Boom
length
Load O O O O O O O O
radius ( m)
O O

O O
O O
O O

O
O

O
O
O

O
O
O
Boom
length O O O O O O O ‫ޓ‬
Load
radius ( m)
O O
O O
O O
O

O
O
O O
O O O
7055-3 10-12
7055-3 CRANE RATED LOADS WITH AUXILIARY SHEAVE

Boom
Load length O O O O O O O O
radius ( m)
O O

O O
O O
O O

O
O

O
O
O

O
O
O
Boom
Load length O O O O O O ‫ޓ‬
radius ( m)
O O
O O
O O

O
O O O O
O
10-13 7055-3
7055-3 AUXILIARY SHEAVE RATED LOADS (WITH 55 ton MAIN HOOK)

Boom
radius ( m)
O
O O
O O
O O
O

O
O

O
O
O

O
O
O
Boom
radius ( m)
O O
O O
O O

O O
O O O
O
7055-3 10-14

Boom
radius ( m)

O O
O O
O O
O

O
O

O
O
O

O
O
O
Boom
radius ( m)
O O

O O
O O

O O O O
O O
10-15 7055-3

Boom
radius ( m)
O

O O
O O
O O
O

O
O

O
O
O

O
O
O
Boom
radius ( m)
O O
O O
O O

O O O
O O O
7055-3 10-16
7055-3 AUXILIARY SHEAVE RATED LOADS (WITHOUT MAIN HOOK)

Boom
radius ( m)
O

O O
O O
O O
O

O
O

O
O
O

O
O
O
Boom
radius ( m)
O O

O O
O O

O
O O
O O O
10-17 7055-3
7055-3 CRANE RATED LOADS (WITH 6.1 m JIB)

Boom
Load length O O O O O
radius ( m)
O
O O
O O

O
O
O O O

Boom
Load length O O O O O
radius ( m)
O
O O
O O

O O O O O
7055-3 10-18

Boom
Load length O O O O
radius ( m)
O

O O
O

O
O O O
10-19 7055-3
7055-3 6.1 m JIB RATED LOADS (WITH 19 or 32 ton MAIN HOOK)

Boom
Load length O O O O O O O O O O
radius ( m)
Jib angle FGI FGI
O O
O O
O O O O O
O

Load radius (m)

O
O O O
O O O O
O O

Boom
radius ( m)
Jib angle FGI FGI
O O O O
O
O O O O
O

Load radius (m)

O O O O
O O O O O O
7055-3 10-20

Boom
radius ( m)
Jib angle FGI FGI
O O
O O

O O
O O
Load radius (m)

O O
O O O O O O
7055-3 6.1 m JIB RATED LOADS (WITHOUT MAIN HOOK)

Boom
radius ( m)
Jib angle FGI FGI
O O
O O
O O O O O
O

Load radius (m)

O
O O
O
O O O
O O O
10-21 7055-3

Boom
radius ( m)
Jib angle FGI FGI
O O O
O
O O O O
O

Load radius (m)

O
O O O
O O O O O O

Boom
radius ( m)
Jib angle FGI FGI
O O
O O

O O
O O
Load radius (m)

O O O O O O O O
7055-3 10-22
7055-3 THIRD DRUM RATED LOADS

Boom
length O O O O O O O O
Load
radius ( m)
O O

O O
O O
O O

O
O

O
O
O

O
O
O
Boom
length O O O O O O O ‫ޓ‬
Load
radius ( m)
O O

O O
O O
O

O
O
O O
O O O
10-23 7055-3
10.1.6 RATED TOWER CRANE LOADS

1. Basic precautions are the same as the rated load
for 7055-3 Model.
2. All rated loads are the values decided by the
strength and stability of the machine such as the
tower boom and jibs.
3. Install the weight (300 kg) for the jib tip to the upper
jib tip when the 19 tons hook is used for the jib
length of 16.8 m and when 7 tons hook is used for
the jib length of 19.8 m.
Do not install the weight for the jib tip when the jib
length is 25.9 m and 29.0 m.
The 7 tons ball hook cannot be used for the jib
length of 16.8 m.
4. When the tower is erected for self standing or low-
ered with the tower length of 39.3 m or more, al-
ways use the floor plate for self standing at the front
of the crawler frame.
5. When the tower is erected for self standing or low-
ered with the tower length of 42.4 m, always install
the weight for raising/lowering.
Maximum rated load for No. of part line

Max. Rated Loads (ton) Weight of
Hook
1 Part 2 Parts Hook
19 t 7 12 0.40 t
7 t ball hook 7 - 0.16 t
• The maximum value of the rated load is the value

when UNI-ROPE of 22 m diameter (by the factory
shipment) is used.
COMBINATION OF TOWER AND TOWER JIB

Jib Length (m) Counter-
weight
Tower Length
for
(m) 16.8 19.8 22.9 25.9 29.0 Steel Plate
raising /
lowering
21.0 90° to 60° 90° to 60° — — — Needless Needless
24.1 90° to 60° 90° to 60° 90° to 60° — — Needless Needless
27.1 90° to 60° 90° to 60° 90° to 60° 90° to 60° — Needless Needless
39.3 90° to 70° 90° to 70° 90° to 70° 90° to 70° 90° to 70° Need Needless
42.4 90° to 70° 90° to 70° 90° to 70° 90° to 70° 90° to 75° Need Need
19 t Installation Installation
Jib point Need Needless Needless
weight
Ball Installation Installation
(300 kg) X Need Needless
7055-3 10-24
TOWER RATED LOADS (TWO PARTS)

Tower length O
JIb length O O
Tower angle 㩩㩩㩩㩩㩩㩩
O
O

Load radius (m)
O

O

O
O
O O
O
O
O
O
10-25 7055-3

Tower length O
JIb length O O
O
O

Load radius (m)

O
O
O
O
O
O
O O

O
O
Tower length O

JIb length O
Tower angle 㩩㩩㩩
O

Load radius (m)
O

O

O
O

O
7055-3 10-26
(Unit : Metri ctons)

Tower length O
JIb length O O
O
O

O
Load radius (m)
O

O
O

O O
O
O
O

O
Tower length O

JIb length O O
O O

O
Load radius (m)
O

O
O
O
O O

O
O

O
10-27 7055-3

Tower length O
JIb length O O O
Tower angle 㩩㩩㩩㩩㩩㩩㩩㩩㩩
O
O
O

Load radius (m)
O O

O O
O

O
O O
O O
O O
O

O
O
Tower length O

JIb length O O
O
O

O

Load radius (m)
O

O O

O
O
O O

O
O
7055-3 10-28

Tower length O
JIb length O O O
O
O
O

O
Load radius (m)
O

O O
O

O O
O
O O O
O

O O
O
Tower length O

JIb length O O
O
O

O
O
Load radius (m)

O O
O
O
O
O

O
O
10-29 7055-3

Tower length O
JIb length O O O
O
O
O

O
Load radius (m)
O O

O
O
O
O O
O O

O O
O
O
O
Tower length O

JIb length O O
O
O

O
O
Load radius (m)

O O
O
O
O

O
O
O
7055-3 10-30

Tower length O
JIb length O O O
O
O
O

O O
Load radius (m)
O

O
O
O
O O O
O
O
O O

O
O
Tower length O

JIb length O O
O
O

O
O
Load radius (m)

O
O
O O
O

O O
O
10-31 7055-3

Tower length O
JIb length O O O
O
O
O

O O
Load radius (m)
O

O
O

O O O O
O
O
O
O
O
O
Tower length O

JIb length O O
O
O

O O
Load radius (m)

O
O
O
O

O O
O

O
7055-3 10-32
TOWER RATED LOADS (ONE PART)

Tower length O
JIb length O
O

Load radius (m)

O

O

O
O

O
Tower length O

JIb length O O
O
O

Load radius (m)

O
O
O

O
O O
O
O
O

O
10-33 7055-3

Tower length O
JIb length O O
O
O

Load radius (m)
O

O
O

O
O
O O
O

O
O
Tower length O

JIb length O
O

Load radius (m)
O

O

O
O

O
7055-3 10-34

Tower length O
JIb length O O
O
O

Load radius (m)

O O
O

O

O O
O O

O
O
Tower length O

JIb length O O
O O

O

Load radius (m)
O

O O

O
O
O O

O
O
10-35 7055-3

Tower length O
JIb length O O
O
O

Load radius (m)
O

O
O

O O

O O
O

O
O
Tower length O

JIb length O O
O O

O
O
Load radius (m)

O O
O
O
O
O

O
O
7055-3 10-36

Tower length O
JIb length O O
O
O

O
O
Load radius (m)

O

O O O
O

O
O

O
Tower length O

JIb length O O
O O

O
O

Load radius (m)

O O
O
O
O

O
O
O
10-37 7055-3

Tower length O
JIb length O O
O
O

O
O
Load radius (m)

O

O O
O
O
O

O
O
Tower length O

JIb length O O
O O

O O
Load radius (m)

O
O
O O
O

O O
O
7055-3 10-38

Tower length O
JIb length O O
O
O

Load radius (m)

O O

O

O
O O
O
O

O
O
Tower length O

JIb length O O
O O

Load radius (m)
O O

O
O
O
O

O O
O

O
10-39 7055-3
10.2 DIMENSIONS AND WEIGHT OF EACH PARTS

For your reference, the chart below shows the dimensions and weight of each parts.
Estimated weight may vary by ±1.0%.
10.2.1 BASE MACHINE
Name Dimension (mm) Weight (kg)
Base Machine 11,570
• Lower Boom
• Gantry
• Crawler 40,200
3,300
• Wire rope
(Fr. drum rope /
boom drum rope)
7,990
Base Machine 3,200
• Gantry
• Crawler
38,700
3,300
3,200
3,200
• Wire rope
(Fr. drum rope /
boom drum rope)
3,200
6,230
Base Machine
• Crawler
• Wire rope 37,200
3,200
(Fr. drum rope /

boom drum rope)
7,320
Base Machine
• Gantry
2,910
25,700
2,820
• Wire rope
(Fr. drum rope /
boom drum rope)
3,200
5,570 760
Crawler 6,500
985
7055-3 10-40
10.2.2 COUNTERWEIGHT
710
Counterweight (1) 7,510
1,045
3,200
710
Counterweight (2) 7,730
1,045
3,200
850
Counterweight for
3,300
raising / lowering
440
3,200
10-41 7055-3
10.2.3 ATTACHMENT
1,530
1,370
Boom Tip 1,010
1,360 4,540
1,700
Boom Base 980
5,340 1,350
1,370
3.0 m (10 ft)
255
Insert Boom
3,145 1,350
1,370
6.1 m (20 ft)

430
Insert Boom
6,190 1,350
1,500
6.1 m (20 ft)

445
Insert Boom with Lug
6,190 1,350
1,370
9.1 m (30 ft)

615
Insert Boom
9,240 1,350
7055-3 10-42
1,500
9.1 m (30 ft)
630
Insert Boom with Lug
9,240 1,350
625
Jib Tip 145
675 3,475
625
Jib Base 125
3,190 675
625
6.1 m (20 ft)
140
Insert Jib
6,160 675
500
Jib Strut 190
3,700 670
10-43 7055-3
9.1 m (30 ft)
1,990
1,370
Special Insert Boom 1,080
for tower
9,240 1,350
3,350
1,360
Tower Cap 600
1,320
1,010 3420
Tower Jib Tip 245

840
4,850 1,010
Tower Jib Base 400

840
3.120 1,020
3.0 m (10 ft)

115
Tower Insert Jib
840
6,170 1,020
6.1 m (20 ft)

195
Tower Insert Jib
840
1,460
890
Tower Jib Strut 760

4,520
840
7055-3 10-44
540
1,285
770
Auxiliary Sheave 140
1,010
1,325
630
Upper Spreader
280
(For Boom)
1,460 300
640 610
Upper Spreader
225
(For Tower Jib)
775
1,350 450
Lower Spreader
335
(For Tower Jib)
930
10-45 7055-3

Ǿ140
490
Lightness Hook 60
357
Ǿ300
7 t Ball Hook 160
815
385 590
940
19 t Hook 400
1,270
330 590
1,085
32 t Hook 500
1,530
435 590
1,020
50 t Hook 650
1,470
7055-3 10-46
10.3 STABILITY IN SWINGING AND TRAVELING

All-round swing Propelling on slope
Counterweight
Attachment Crawler Crawler
(ton) Forward Backward
Extend Retract
0 O O O O
Without Attachment 7.5 No.1 O X (Slope : O

(Base machine only) 10 deg. or less)
15.2 No.1 + No.2 X X O

(Swing slowly)
0 O O O O
With Boom Base
(Boom angle : 10 7.5 No.1 O (Slope : O
deg. or less) (Swing slowly)
15 deg. or less)
15.2 No.1 + No.2 O X X O
0 O O O O
With 9.1 m boom
7.5 No.1 O O O O
base
(Boom angle : 30
15.2 No.1 + No.2 O X (Slope : O
deg. or less)
7 deg. or less)
O : Able to be operated
: Able to be operated with conditions
X : Unable to be operated
1. The table above shows the values for operation on

a firm ground. On a weak ground, operate with
care after curing the ground.
2. As a principle, swinging on a trailer is prohibited.
3. Maximum slope angle is 21.8 deg. (40%).
4. Travelling forward means the case, where the
counterweight is at the lower slope and the travel-
Traveling forward
ing backward, where it is at the upper slope.
Traveling backward
10-47 7055-3
10.4 ALLOWABLE ANGLE OF MACHINE INCLINATION

WHEN PROPELLING
(Unit : Degree)
Jib Position
(3) β
75°
(2) β
(3)
Tower
Tower 75°
Length
Angle (1) (2)
m
(ß)
(ft) (1)
θ θ θ
(1) (2) (3) (1) (2) (3) (1) (2) (3)

0 2 4 - 12 12 12 12 12 12
5 4 7 3 12 12 12 12 12 12
10 7 9 6 12 12 12 12 12 12
21.0
15 9 12 9 12 12 12 12 12 12
(69)
20 11 12 11 12 12 12 12 12 12
25 12 12 12 12 12 12 12 12 12
30 12 12 12 12 12 12 12 12 12
0 1 3 - 12 12 12 12 12 12
5 3 5 2 12 12 12 12 12 12
10 6 8 5 12 12 12 12 12 12
24.1
15 8 11 8 12 12 12 12 12 12
(79)
20 11 12 11 12 12 12 12 12 12
25 12 12 12 12 12 12 12 12 12
30 12 12 12 12 12 12 12 12 12
0 - 1 - 12 12 12 12 12 10
5 2 4 1 12 12 12 12 12 10
10 5 7 5 12 12 12 12 12 11
27.1
15 8 10 8 12 12 12 12 12 11
(89)
20 11 12 11 12 12 12 12 12 12
25 12 12 12 12 12 10 12 12 12
30 12 12 12 12 10 8 12 12 12
0 - - - 12 12 12 12 10 8
5 1 3 1 12 12 12 12 11 8
10 4 6 4 12 12 12 12 11 8
30.2
15 7 9 7 12 9 9 12 12 8
(99)
20 10 12 10 12 7 7 12 12 9
25 12 12 12 12 5 4 12 12 9
30 12 12 12 12 3 1 12 12 10
7055-3 10-48
Jib Position
(3) β
75°
(2) β
(3)
Tower
Tower 75°
Length
Angle (1) (2)
m
(ß)
(ft) (1)
θ θ θ
(1) (2) (3) (1) (2) (3) (1) (2) (3)

0 - - - 12 12 12 11 8 6
5 1 3 - 12 10 11 11 9 6
10 4 6 3 12 8 8 11 9 6
33.2
15 7 9 7 12 5 5 12 10 6
(109)
20 10 12 10 12 3 3 12 11 7
25 12 12 12 12 - - 12 11 7
30 12 12 12 10 - - 12 12 8
0 - - - 12 11 12 9 7 4
5 - 2 - 12 8 9 9 7 5
10 3 5 3 12 5 6 10 7 5
36.3
15 6 8 6 12 3 3 10 8 5
(119)
20 10 12 10 10 - - 10 9 6
25 12 12 12 8 - - 11 10 6
30 12 12 12 6 - - 12 11 7
0 - - - 12 9 10 7 5 3
5 - 1 - 12 6 7 7 5 3
39.3
10 3 4 2 12 3 4 8 6 3
(129)
15 6 8 6 9 - 1 8 6 4
20 9 11 9 7 - - 8 7 4
0 - - - 12 7 9 6 4 2
5 - - - 12 4 6 6 4 2
42.4
10 2 4 2 10 1 2 6 4 2
(139)
15 6 7 6 7 - - 6 5 3
20 9 11 9 4 - - 7 6 3
10-49 7055-3
10.5 SYSTEM SCHEMATIC

10.5.1 HYDRAULIC SCHEMATIC
7055-3 10-50
10.5.2 ELECTRIC SYSTEM SCHEMATIC
Note : Tough the devices indicated

by dotted lines in the diagram
are not used in this model,
wirings related to them are
present.
10-51 7055-3
7055-3 10-52
10-53 7055-3
7055-3 10-54
10-55 7055-3
7055-3 10-56
10-57 7055-3
7055-3 10-58
10-59 7055-3
7055-3 10-60
10-61 7055-3
7055-3 10-62
10-63 7055-3
7055-3 10-64
10.6 SAFETY DEVICE LIST (OPTION)

Num-
Service name Description
ber
Counterweight rear watching Watches the condition of machine rear side and displays it on the monitor
1
camera display in the cabin.
2 Cab skylight guard Prevents the skylight glass from being broken by falling objects.
3 Boom backside overall foothold Foothold for workers to move at the boom backside during assembling.
4 Fire extinguisher ABC dry chemical extinguisher.
Main/auxiliary drum watching Watches the condition of drums and displays it on the monitor display in the
5
camera cabin.
Watches the condition of drums and displays it on the monitor display in the
6 Boom drum watching camera
cabin.
Upper boom ventral side pro-
7 Prevents the upper boom from being damaged by contacting with the hook.
tector
8 Auxiliary platform Right and left steps of the main body
External overload indicator Indicates the load condition to the external site by three color lamps (green/
9
lamp yellow/red).
10 Propel alarm unit Alarms during propelling in buzzer
10-65 7055-3
7055-3 10-66

7055 Manual Crane

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OPERATION &

APPLICABLE : from GB04-03093

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES

3. LOAD SAFETY DEVICE

3.5 OPERATING PROCEDURE OF CONTROLLER..................................................... 3-28

4. UNLOADING/LOADING THE BASIC MACHINE

5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE

6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT

6.1.3 INSTALLING THE BOOM BASE ....................................................................... 6-17

7. ASSEMBLY/DISASSEMBLY OF TOWER CRANE

7.2 ERECTING THE TOWER ATTACHMENT............................................................... 7-46

9.2.6 FUEL.................................................................................................................. 9-51

MACHINE SERIAL NUMBER

MACHINE SERIAL NUMBER

ENTER MACHINE SERIAL NUMBER OF THIS MACHINE

EXPLANATION OF WARNING LABELS

HANDLING OF WARNING LABELS

36.6m and shorter

12.2m and shorter

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES

General safe practices for working on machinery must

He must read and understand the Operator's Manual

He must understand how to read the rating plate and

He must never lift a load without knowing the length of

Never attempt to operate the crane at conditions ex-

He must be alert, physically fit, and free from the influ-

He must see that unnecessary people, equipment, and

When an operator's vision is restricted or when operat-

Signalmen must have a clear understanding of the

CREW MEMBER'S RESPONSIBILITY

Everyone who works around the crane, including

Watch for hazards during operations and alert the

Signalmen must have good vision and sound judg-

Riggers must be trained to determine weights and

Crew members must be given specific safety re-

PLANNING THE JOB

OPERATOR'S CHECK LIST

Several factors must be considered including:

Trying to left a load without knowing whether it is

Always operate within the rated capacity. The oper-

2. Cranes may tip over or collapse if the operating sur-

3. The rated capacity of a crane is determined with the

4. People can be crushed by the scissors-like action

5. People can be crushed by the rear (counterweight)

6. Many people have been injured when riding crane

Never permit anyone to ride loads, slings, hooks,

7. Power electrical lines have killed or serious injured

Always determine whether there are power lines in

Careful planning and supervision offer better pro-

8. The load line can break if the hook block contacts

9. People can be injured if the hook, boom, load or

10. Rapid swings or sudden starts and stops can cause

11. Dirty windows, darkness, bright sunlight, fog, rain

Keep windows clean. Do not operate if you cannot

There are several specific safety signs on your ma-

You must replace a label if it is damaged, missing

Do not lift loads if winds create a hazard. Lower the

Moderate winds may create a hazard for long

13. Carelessness in getting on and off equipment can

14. Slippery floors and steps, tools, trash, or other

15. Damaged crane booms may collapse. Lattice type

Due to the high strength steels used in booms and jibs,

16. Crane booms can collapse if side loaded (pulled

Take care to avoid side loading.