Tadano GT-550E-2 Maintenance Manual
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Safety
T002423E
Most accidents that occur during crane operation
and maintenance are caused by failure to observe
basic safety rules and precautions. Before operating
your machine or performing maintenance, read and
become familiar with all the safety precautions and
recommendations given in this section. Remember
that failure to observe even a single precaution
could involve you and the people around the ma-
chine in a serious accident.
Foreseeing potential dangers is vital for preventing
accidents. All personnel working with the machine,
including the supervisor, crane operator and oiler,
should be sensitive to potentially dangerous situa-
tions and take the necessary measures to prevent
accidents.
Safety precautions and recommendations are
outlined in this section and are also included in the
operation and maintenance instructions given in
subsequent sections. Warning labels are also
provided on the machine.
The cautionary instructions in this manual are
identified as “DANGER”, “WARNING”, “CAUTION”
or “NOTICE”. These terms are defined as follows:
It is virtually impossible to anticipate every situation
that might present a hazard. The safety precautions
given in this manual and on the machine labels are
not exhaustive.
It is important, therefore, to strictly follow the in-
structions in this manual and be sensitive to
potential dangers in order to prevent bodily injury
and damage to the machine.
Remember that your most important duty is to en-
sure the safety of you, your co-workers and any
other people in the area.
DANGER
DANGER indicates an imminently hazardous
situation, which, if not avoided, would result in
death or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous sit-
uation, which, if not avoided, may result in a minor
or moderate injury.
[NOTICE]
◆NOTICE indicates an important operational or
maintenance procedure or condition, which, if not
strictly observed, can result in damage to machine
components or deteriorated machine performance.
Safety Safety
A-1
Safety Rules
T20001
Operationand
Maintenance
Manual
取り扱い説明書
T019605E
WARNING
Use of improper or unauthorized method dur-
ing operation or maintenance of this machine can
be dangerous and could lead to serious injury or
death. Read this manual thoroughly and be famil-
iar with the proper operating and maintenance
procedures before using the machine. Do not op-
erate the machine or perform maintenance on it
until you understand the instructions in this man-
ual.
CAUTION
“Safety Rules” section describes the general
instructions about operation with a hydraulic
truck crane. For more detailed instructions about
your machine, see corresponding pages (white
pages) of this manual.
The figures in this manual are for reference show-
ing the important points. They may be different
from an actual machine.
Before Operation
Qualifications of the Operator
The operator must be fully trained and qualified.
The operator must be fully familiar with on-site safe-
ty rules, and national and local crane operation
regulations.
Study the Operation and Maintenance
Manual
Improper operation, inspection or maintenance can
damage the machine or cause injury or death.
Study the manual carefully. Become familiar with the
proper procedures for operation, inspection and
maintenance.
Keep the Operation and Maintenance Manual in the
crane operator’s cab so that it is always readily ac-
cessible.
Before Operation・・・・・・・・・・・・・・・・・・・・・・・・・・A-2
Rules for Operation (Setting Outriggers) ・・・・・・・・・A-7
Rules for Operation (General) ・・・・・・・・・・・・・・・・・A-8
Rules for Operation (Weather) ・・・・・・・・・・・・・・・A-17
Rules for Operation (Power Lines, Radio Waves) ・・A-18
Rules for Operation (Special Operation) ・・・・・・・・A-20
After Operation ・・・・・・・・・・・
・・・・・・・・・・・・・・・A-20
Rules for Road Travel・・・・・・・・・・・・・・・・・・・・・・A-21
Rules for Inspection and Maintenance ・・・・・・・・・・A-22
Follow All Instructions and Warnings
The Operation and Maintenance Manual and the
warning labels on the machine contain instructions
and must be followed to ensure safe operation.
Read and understand all DANGER, WARNING and
CAUTION labels. Neglecting these instructions and
warnings can result in injury or death.
If the manual is lost or any labels (decals) become il-
legible, order replacements from the nearest
authorized TADANO distributor or dealer.
Safety Rules Safety Rules
A-2
T019605E
T20002
Always Maintain Labels
The warning labels on various parts of the machine
provide important instructions for safe operation.
Always keep the labels (decals) clean and visible.
Should labels become lost or damaged, order re-
placements from the nearest authorized TADANO
distributor or dealer.
Wear Proper Clothing
Sloppy clothing may result in sleeves or cuffs being
caught and then cause an accident.
Avoid Overwork. Never Operate under
the Influence of Alcohol or Drugs
If the operator is tired, lacking in sleep, or under the
influence of medication or alcohol, the probability of
an accident event is greatly increased since atten-
tiveness and judgment are impaired. Maintain
proper physical fitness for crane operation.
Keep All Footings and Shoes Clean
Oil, water or mud on soles of shoes, steps or decks
can cause slip off and fall mishaps or cause acci-
dental release of a control pedal. Always remove oil,
mud, water or snow before operation and keep
shoes and floor of the operator’s cab clean.
Do not leave any parts or tools on the operator’s
cab floor or passageway.
Safely Climbing onto and Descending
Wear Approved Protective Gear
To ensure safety, always wear a hard hat and safety
shoes. Also protective goggles, dust mask,
earplugs, work gloves, safety belt, etc. must be
worn as the situation requires. Check that all protec-
tive gear is in good condition before wearing it.
T00041
from the Machine
Do not jump onto or off the machine.
Do not climb onto or descend from the machine with
objects in hand.
Only climb onto or descend from the machine while
it is completely at standstill. Use the handrails and
steps, always support your hands and feet firmly
(three point support); that is, one hand-two feet or
two hands-one foot.
Never use the steering wheel or control levers as
handrails.
T03833
Safety Rules Safety Rules
A-3
T019605E
T01938E
WARNING
DO NOT OPERATE
Correctly Position the Seat
Incorrect positioning of the operator’s seat can re-
sult in mistakes or fatigue, possibly leading to an
accident.
Before operating the machine, correctly position the
seat so that the pedals and levers can be manipulat-
ed correctly.
Maintain Good Visibility
Fouled window panels, lights or rearview mirrors
can limit the operator’s visibility, impairing safe op-
eration. Always keep the window panels and light
lenses clean.
Position mirrors correctly as required by job condi-
tions.
Perform Pre-Operation Inspection
Neglecting routine inspections and maintenance
can shorten service life of the machine or even re-
sult in an accident.
Before starting operation (and before taking over a
shift), perform the pre-operation inspection on the
carrier and the upper structure to ensure that the
machine is in proper condition and free from any
problems.
Should any problem be found, report it to the re-
sponsible person, remedy it, and only then start
operation.
Do Not Operate a Machine Being
Inspected or Serviced
Operating the machine while it is undergoing in-
spection or maintenance work can cause damage or
an accident.
Post a “DO NOT OPERATE” sign on the operator’s
cab door or any control lever. Do not attempt to op-
erate the machine until the sign is removed by
maintenance personnel.
Check the Position of Controls before
Starting the Engine
If any control lever is in a position other than “neu-
tral”, the machine may initiate some mechanical or
hydraulic function as soon as the engine is turned
over. This situation is very dangerous. Start the en-
gine only when completely sure that all controls are
in the proper neutral or inactive position.
Make Sure Work Area Is Safe before
Starting the Engine
Starting the engine without performing a thorough
safety check of the work area may cause damage to
the machine or injury or death.
Make sure there are no personnel or obstacles un-
derneath or around the machine.
Before starting the engine, sound the horn to warn
any nearby personnel.
Safety Rules Safety Rules
A-4
T019605E
T00020
Start the Engine from the Operator’s
Cab Only
If the engine is started from any location other than
the crane operator’s cab, it can become impossible
to avoid a dangerous hazard if some machine action
is initiated when the engine turns over.
Start the engine only from the operator’s seat.
Inspection after Starting the Engine
Failure to perform a basic inspection after starting
the engine can result in not detecting fault or abnor-
mality with the machine.
Inspect the machine in a safe location that is free
from obstacles and people other than maintenance
personnel.
Allow the engine to warm up after it is started while
the instrument readings and checking the machine
components. Once the engine is properly warmed
up, make a safety check of the work area, and run
the machine without a load to check out condition of
the controls, machine elements and safety devices.
Night Operation
Operation in the dark makes it difficult to ensure
good footing, and to locate nearby persons or ob-
stacles, increasing the probability of an accident.
When operating at night, turn on all working lamps.
Provide ancillary portable lighting equipment to illu-
minate the work area.
Keep the Engine Clean
Dead leaves, paper dust and oil stains on and
around the engine can catch fire. Remove all such
debris before commencing operation.
Warm Up the Machine
Failure to properly warm-up the engine and various
other machine components can result in decrease in
service life of the machine or malfunctions. In win-
ter, run the engine for at least five minutes for
proper warm-up.
Then, run the engine at low speed without a load to
warm up the hydraulic oil and other machine com-
ponents.
Keep Unauthorized Personnel Away
from the Work Area
Unauthorized personnel or vehicles in the work area
can result in collision accidents, injury or death.
Before operation, make sure there are no unautho-
rized personnel or obstacles within the work area.
If the work area is situated near heavy traffic, post a
control person to prevent vehicular accidents.
Barricade the work area with appropriate means ei-
ther colored tape or rope.
DANGER
STAY CLEAR
T01937E
Safety Rules Safety Rules
A-5
T019605E
T20004
Anticipate Accident Situations
To deal with possible accidents or fires, equip the
crane with a first-aid kit and fire extinguisher. Be
aware of the locations of these safety items, and
learn how to use them properly.
An emergency contact person and emergency liai-
son plan should be carefully prepared, and all
personnel concerned must be made aware of the de-
tails.
Observe Work-site Rules
Neglecting work-site rules can result in accidents.
To ensure safe operation, observe all work-site rules
covering prohibited practices, precautions and cor-
rect procedures.
Post a Signal Person
Assign a signal person for all crane operations as
necessary and always follow instructions especially
when:
• Working near power lines.
• The load is hidden from the crane operator’s view.
• Moving the carrier along narrow roads or when
the operator’s vision is obscured.
The signal person and the operator should commu-
nicate with each other using mobile transceiver
phones.
Hold Work Site Meetings with
Concerned All Personnel
Lack of sufficient communications with concerned
personnel can result in accidents.
Before starting the job, set up a liaison meeting with
the site supervisor, rigging personnel, signal per-
son, etc., to agree on the following details:
• Mass of load, lifting height (per rated lifting capac-
ity table), locations of loading and unloading,
work area of the machine, craning procedures,
rigging methods, etc.
• Conditions of ground where crane is set as well
as whether city-water and gas pipings are buried.
• Overturning prevention by use of block plates and
outriggers.
• Mutually agreed upon and OSHA approved signal
conventions between rigging personnel and sig-
nal person.
• Designation of off-limit areas, provision of barri-
cade.
• Work stations of all relevant workers.
• Emergency liaison plan and emergency contact
person, as well as the safety/health organization.
Safety Rules Safety Rules
A-6
T019605E
T20617
Always Study Work-site Conditions
Carefully
Pay due attention to surrounding conditions.
Before starting the job, inspect the work area, check
routes to the work area, and monitor the presence of
any obstacles and locations of other machinery.
Note changes in the surroundings or site conditions
as crane operations are carried out.
Multi-Crane Operation
In lift situations involving the coordination of two or
more cranes, establish an agreed system for com-
munications and assign a signal person. The crane
operators must proceed cautiously, strictly observ-
ing all instructions of the signal person.
Rules for Operation
(Setting Outriggers)
Set the Crane on Firm Level Ground
The machine should not be located on soft ground,
which can lead to sinking, sliding or overturning,
nor on the edge of a pit, bank or slope.
If the ground conditions are doubtful, use blocks or
steel plates of sufficient strength and size below the
outrigger floats to disperse the load.
Set the Crane Level
If the crane is tilted, and the load is swung over the
side, the load radius will increase, and the machine
can overturn.
When setting the outriggers, level the machine care-
fully using a level.
T00008
Safety Rules Safety Rules
A-7
T019605E
T01939E
Fully extended
Fully Extend the Outriggers
If the outriggers are not extended correctly, the
crane may become unstable, causing the crane to
overturn.
As a general rule, always extend the outriggers fully,
even if the crane is rated for operation with the out-
riggers at middle or minimum extension. If it is
absolutely necessary to use the outriggers at middle
or minimum extension, make sure the machine is
within the rated limits.
Rules for Operation (General)
Observe Working Conditions
Operating the crane under conditions (outrigger
beam length, boom length, load radius, etc.) other
than specified in the rated lifting capacity table can
cause overturn even when not lifting a load.
Follow all instructions in the rated lifting capacity
table.
Do not Exceed Rated Lifting Capacity
Exceeding the rated lifting capacity will overload the
machine. Damage or overturning can result from
this practice.
Check the rated lifting capacity table before operat-
ing to ensure that the lift is safe. Load lifting
capacity of the crane varies depending on boom
length and load radius. Never exceed the lifting ca-
pacity in the table.
Check the Outrigger Setting
Incorrect setting of the outriggers can decrease the
load lifting capacity of the machine and result in
overturning. To avoid crane instability, make sure:
• The machine is absolutely level.
• All outrigger floats are stable and set firmly on the
ground or blocks.
• All tires are clear of the ground.
• The outriggers are secured with lock pins (if lock
pins are available).
Mass of hook block
Rated lifting capacity
Lifting capacity
T21566E
Use Safety Devices Correctly
Improper use of safety devices including the over-
load cutout can lead to damage or overturn the
crane.
Use all safety devices according to instructions in
the manual.
Safety Rules Safety Rules
A-8
T019605E
T03802E
Boom deflects
Load radius
Do Not Rely Exclusively on Safety
Devices
A safety device is not a substitute for human skill
and judgment.
The overload cutout, for example, does not warn the
operator about conditions on the ground, effects of
wind, improperly adjusted devices, load being
pulled sideways, or other possibly hazardous situa-
tions.
All safety devices are merely auxiliary means to help
the operator perform the task at hand. Safe crane
work requires the qualities of a good operator, such
as skill, experience, judgment, and safety aware-
ness.
Do Not Deactivate Any Safety Devices
Avoid any action that impairs normal operation of
the safety devices.
Intentionally deactivating any safety device may re-
sult in the inability to detect overloading or
overwinding during operation, and lead to a serious
accident.
Ensure that all safety devices are functioning cor-
rectly before starting any operation.
Rig the Load Securely
Improper rigging procedure can result in the lifted
load being dropped. Rig the load securely, paying
special attention to the following points:
• Know the mass, shape and center of gravity of the
load, and use suitable load handling devices and
rigging hardware.
• The load handling devices including wire ropes,
chains and rigging hardware must have enough
strength and be free from damage or excessive
wear.
• Rig the load so that it is suspended at a point
above its center of gravity. Otherwise, the load
can overturn or come loose of the handling device
when it is raised. Also, wire ropes and chains
must not be crossed or twisted around each oth-
er.
• Do not rig the load with a single wire rope. Such
rigging practice is very dangerous as the load can
rotate, and untwist the wire rope, reducing its
strength.
• When rigging a load with sharp corners, fit protec-
tive softeners at the load corners to protect the
wire ropes and the load itself against damage.
Before Lifting a Load
Make sure of the following before attempting to pick
up a load:
• The mass does not exceed the rated lifting capaci-
ty.
• The number of rope parts conforms to the stan-
dard in the rated lifting capacity table.
• A proper load handling device is used and the
load is securely rigged.
• The hook block is located directly above the cen-
ter of gravity of the load.
• The wire ropes runs are plumb so that the load
can be lifted vertically.
• The safety latch on the hook is working properly.
• The wire rope has no entanglement or disorderly
winding on the drum.
Consider Boom Deflection before Lifting
the Load
When a load is lifted, the boom will deflect down-
ward, increasing the load radius. Swaying of the
load also poses a hazard to the people around the
crane, and may lead to overloading.
If the load starts to sway when lifted clear of the
ground, lower the load back on the ground.
When lifting a heavy load or using the extended
boom, anticipate the possible increase in the boom
load radius.
Safety Rules Safety Rules
A-9
T019605E
T00011
Lift Single Loads Only
Do not lift two or more loads simultaneously even if
their total mass is within the specified rated lifting
capacity; otherwise, the loads may lose balance. It
is usually not possible to maintain complete atten-
tion to multiple loads.
Operate According to Signals
If signals are not obeyed or if signals are improperly
made, accidents can occur.
Follow instructions of the signal person. An emer-
gency shut down signal must be acknowledged
whoever gives it.
Operate the Crane from the Operator’s
Conduct a Safety Check within the Load
Radius of the Crane before Starting
Operation
Any person located close to the crane may become
caught between machine components or between
the counterweight and a fixed obstacle. Before
starting any swing motion, make sure that there is
no one nearby. Sound the horn to warn all immedi-
ate personnel of crane startup.
During crane operations, fence off or barricade the
work area to prevent unauthorized persons from ap-
proaching the machine.
Be Extremely Careful When Raising the
Load Clear of the Ground
Stop lifting the load once the rigging is fully taut,
check that the load is suspended at a point just
above its center of gravity, and that the load is not
stuck to the ground or interfering with a nearby
body or structure.
Lift the load vertically. When the load clears the
ground, stop lifting and suppress any swaying; then
check that the rigging is secure, the load is in a sta-
ble position, and the crane is not overloaded.
Then, recommence the lift again.
Cab Only
Controlling the machine from outside the cab,
through the cab window, is strictly forbidden and
extremely dangerous.
T00019
Do Not Lift the Load Clear of the Ground
by Raising or Extending the Boom
Raise a load clear of the ground by vertical hoisting
only.
Raising or extending the boom to lift a load clear of
the ground will cause the load to sway, posing a
hazard.
If the boom is elevated to raise a load clear of the
ground, the crane will not be automatically stopped
even in case of an overload. An overloaded machine
can overturn or be damaged.
Safety Rules Safety Rules
A-10
T019605E
T01941
Move a Lifted Load Carefully
When the crane state comes near the full rating, the
AML gives an intermittent alarm. Operate the crane
more carefully and slow the load-moving speed.
Take best care for over-loading in boom-lowering
operation which enlarges the load radius.
Do Not Lift an Unknown Load
Attempting to uproot a garden tree or raise an object
buried or driven into the ground can severely over-
load various components of the machine, possibly
causing the machine to overturn or be damaged. Do
not attempt to pull up poles or piles driven into the
ground, trees or any objects buried or frozen in mud
or sand.
Only lift objects free from all restraining forces.
Operate the Crane Carefully
Operating the controls too abruptly can result in an
accident: a swaying load can hit an object or dam-
age the machine.
Operate all control levers and pedals smoothly and
in a steady manner.
Do Not Make Inadvertent Swing
When the front jack is not employed, lifting capaci-
ties in the over-front area are inferior to those in the
over-rear and over-side areas. The crane may be
overturned if inadvertently swung to the over-front
area with a load lifted in the rear or side area.
Depending on boom length, boom angle, and outrig-
ger extension, even the unloaded crane may
overturn because of inadvertent swing.
Before operation, confirm the living capacity by the
rated lifting capacity table. If there is an inferior ca-
pacity area, place signal corns or ropes for swing
restriction to avoid swing into such a perilous area.
Avoid Overloading
A load below the rated lifting capacity can still
cause overloading of the crane if swaying occurs.
Do not trigger overloading while telescoping out or
lowering the boom. These actions increase the load
radius and are destabilizing.
When Overloading Occurs
When overloading occurs, never attempt to raise or
lower the boom rapidly. This situation is very dan-
gerous as the machine can readily overturn.
Immediately set the load on the ground by carefully
unwinding the wire rope off the winch drum.
Swing the Crane Carefully
If the swing speed is too high, substantial centrifu-
gal force is applied to a load, resulting in an
increased load radius. As a result, the machine may
become overloaded and overturn.
Stopping a swing operation abruptly can cause a
load to sway posing a hazard to nearby personnel
and possibly leading to boom failure.
Swing all loads slowly. Carefully stop any swinging.
Be extremely cautious when working with an ex-
tended boom.
T00029
Safety Rules Safety Rules
A-11
T019605E
T02212
Be Careful during Complex Operations
Actions of the crane will be slower during complex
operations. When switching from a complex opera-
tion to a simple operation, action of the machine will
become faster. When executing a complex opera-
tion, do not change speed immediately.
Do not attempt any complex operation until fully fa-
miliar with the crane operation.
Avoid Contact with Obstacles
While moving a load, be absolutely sure that the
load or any part of the crane does not come into
contact with nearby structures or other objects.
When working on a site where potential obstacles
are present, post a signal person, and only move the
load while following instructions.
Be Careful When the Boom Is at
Maximum Permissible Angle
When the boom is raised to its maximum permissi-
ble angle, there exists minimum horizontal
clearance between the boom and the load. A sway-
ing load may hit the boom or jib, and cause damage.
Handle the load carefully so that it does not strike
the boom or jib.
Be Careful in Demolition Work
It is very dangerous to lift parts or components of a
structure undergoing demolition, if the mass and
center of gravity are unknown. Before starting oper-
ation, ascertain the mass and center of gravity of the
loads, and establish the lift procedure to be taken.
Operate the Crane with Correct Boom
Position
When the boom configuration is irregular for pur-
pose of inspection or maintenance, never attempt to
lift a load.
During crane operation, check that all the boom sec-
tions are telescoping in the correct sequence. The
rated lifting capacity table has been developed
based on assumption that the boom sections are
telescoped in the correct sequence.
Do Not Extend the Boom Excessively
An excessively extended boom decreases the rated
lifting capacity and also can cause overswing of the
load or lower working efficiency.
Keep the length of the boom as short as possible
during operation.
T01944
Carefully Lift a Load in Water
When handling a load submerged in water, it is im-
portant not to lift the load out “all at once” when it
appears above the water’s surface. The load may be
impregnated with water and heavier than expected.
Allow the load to drain while raising it slowly.
A load lifted out of water, even when fully drained,
weighs more than it did when submerged because
of buoyancy effects. Lift the load carefully so as not
to cause overloading.
Safety Rules Safety Rules
A-12
T019605E
T00028
Handle Wide Loads Carefully
Be careful when lifting a wide load. The load can
swing and hit a rigging person, the crane itself or a
nearby structure.
Use tethers tied to either or both ends of the load to
control the position and/or movement of the load.
Do Not Overwind the Hook Block
When the boom is lowered or extended, the hook
block is wound up.
Usually, overwinding the hook block will cause the
overwind cutout device to trip and the winch auto-
matically stops. However, if the device is damaged
or the automatic stop function has been deactivated
for some reason, the hook block can impact the
boom head.
Always be aware of the position of the hook block. If
the hook block approaches the boom head, wind off
the wire rope to lower the hook block and avoid con-
tact.
Know of the Number of Wire Rope Parts
If the number of the part lines is greater than speci-
fied for the boom length, the hoist line may become
too short. As a result, the line can unwind off the
winch drum causing the wire rope to be damaged or
broken.
When lowering a very light load, or a bare hook
block, the rope will unwind off the winch drum at a
faster rate. The rope may then become improperly
wound.
Use a number of part lines appropriate to the boom
length.
Wire Rope Must Be Properly Wound on
the Drum
Lifting a load with the wire rope improperly wound
on the winch drum can lead to damage of the wire
rope, not only decreasing service life of the rope but
possibly breaking wires and strands which can lead
to ultimate failure.
After reeving or replacement of the wire rope, make
sure that the line is properly seated in the sheaves
and on the winch drum.
Do Not Unwind the Wire Rope
If the entire rope is unwound from the winch drum,
the frictional anchoring force will be insufficient to
support a load. The rope will break or become dam-
aged.
At least three winds of rope must always be left on
the winch drum. This condition applies particularly
when a load must be lowered below ground level
such as a trench or excavation.
T00026
T00024
Safety Rules Safety Rules
A-13
T019605E
T00015
Do Not Leave a Load Suspended
Do not leave a load in a hoisted position. Actuate
the winch brake to hold the load safely. Use working
procedures that minimize the duration a load is left
suspended.
Use the Crane Only for Approved
Applications
The crane is designed to lift a freely suspended ver-
tical load. Never attempt to lift persons, or push/pull
a load with the boom.
Do Not Add Counterweights
Installing a counterweight(s) other than those speci-
fied can damage the machine, or cause the machine
to overturn to the rear owing to decreased rearward
stability.
Never install or place a counterweight(s) or equiva-
lent other than those specified.
T03804
Do Not Position Any Part of Your Body
Do Not Anchor the Machine
Do not attempt to hold down the crane frame or out-
rigger or contrary side to the lifted load, using wire
rope.
This practice might lead to crane damage or an acci-
dents.
T00002
Out of the Window on the Boom Side
Sticking any part of your body out from the window
on the boom side can result in being caught be-
tween the moving boom and the window frame.
Serious injury or death can result from this danger-
ous practice.
If the window is equipped with a confining guard, do
not remove it.
Do Not Look Away from the Load While
Operating the Crane
Looking away from the load, eating or performing
any other action that can detract from awareness
while operating the crane is very dangerous.
During operation, concentrate all attention on the
load and the signal person.
T00018
Safety Rules Safety Rules
A-14
T019605E
T00027
Do Not Pass a Load over Any Person
Passing a load over a person(s) is very dangerous
and must be avoided.
Do not allow anyone to enter the area below the
boom or the load.
Do Not Pull a Load Sideways, Do Not Lift
a Load Obliquely, Do not Drag a Load
Pulling a load sideways, lifting a load obliquely or
attempting to drag a load is very dangerous. Such
actions can damage the boom, jib or swing mecha-
nism, and lead to overturning of the crane.
Do not attempt to draw in a load that is located out-
side the load radius. To handle such a load, move
the crane to the vicinity of the load, and lift it verti-
cally.
Do Not Leave the Operator’s Cab While a
Load Is Suspended
Before leaving the operator’s cab for any reason, be
sure to:
• Lower the load to the ground.
• Fully retract the boom and stow it.
• Actuate all brakes.
• Place all control levers in their neutral positions.
• Shut off the engine, and remove the starter key.
• Lock the crane operator’s cab door.
Never Allow Anyone to Ride on the
Machine, Except the Operator
If any persons other than the operator (in the opera-
tor’s seat) are on the machine, they must be
stationed inside the operator’s cab.
Do Not Allow Anyone to Ride on the
Machine
Persons on the machine other than the operator (in
the operator’s seat) may fall or be caught by a ma-
chine component or other objects. Other persons
cause distraction and can disturb the attention and
work of the operator.
T00017
Do Not Push or Pull an Object with the
Boom
Never use the boom to push or pull an object. Do
not use the boom to thrust up an object or force the
boom into an object.
To move an object, use a machine designed for that
purpose, such as a fork lift truck or carryall.
Do not use the crane in applications other than
those specified.
T00016
Safety Rules Safety Rules
A-15
T019605E
T20527
Caution while Using the Jib (1)
Never attempt to lift separate loads on both the
boom and jib at the same time, or a single load us-
ing both the main and auxiliary winches.
Such practices can damage the boom or jib, or over-
turn the machine.
Caution while Using the Jib (2)
Lifting a load on the boom with the jib mounted
should be avoided, if possible.
If conditions require such a lift, observe the instruc-
tions given in the “AML” section of the manual and
perform the operation with the utmost care and at-
tention.
Mount and Stow the Jib Correctly
Failure to observe the specified procedures for
mounting and stowing the jib can damage the jib, or
may cause the jib to drop.
Be sure to mount and stow the jib in the correct
manner by referring to the “Jib” section in the man-
ual.
T00649
T00013
Safety Rules Safety Rules
A-16
Rules for Operation (Weather)
Stop Operation When Visibility Becomes
Poor
During bad weather such as rain, snow or fog, stop
operation and stow the machine. Wait until visibility
improves before resuming operation.
T019605E
Stop Operation When Strong Winds are
Present
Under strong winds, a lifted load will start swaying,
posing a danger to working personnel and nearby
structures and also possibly damaging the boom or
overturning the machine.
The influence of cross wind on machine stability is
directly proportional to length of the boom and size
of the load.
When the maximum instantaneous (i.e. gust) wind
speed exceeds 10 m/sec, stop crane operation and
stow the boom.
When the boom is substantially extended or a large-
sized load is lifted, stop crane operation even if the
wind speed is below 10 m/sec if there is any possi-
ble danger.
The table below lists wind speed ranges and the
ground conditions for each range. Note that the
wind speeds in the table are those at a point 10 m
above open level ground.
T00037
Stop All Operation If There is Any
Likelihood of Lightning
Lightning can not only damage the machine but also
injure the operator and working personnel. If light-
ning is forecast or expected, stop operation, stow
the boom, and leave the machine.
If the machine is struck by lightning:
• Stay in the cab. Do not try to move out.
• Warn people around not to approach the machine.
• Afterward, inspect the entire crane carefully and
have any damaged parts repaired.
Wind speed (m/sec) Ground conditions
5.5– 8.0
8.0–10.8
10.8–13.9
13.9–17.2
Safety Rules Safety Rules
Dust is raised, paper whirls up,
and small branches sway.
Shrubs with leaves start swaying.
Wave crests are apparent in
ponds or swamps.
Tree branches move. Power lines
whistle. It is difficult to open an
umbrella.
Whole trees sway. It is difficult to
walk against the wind.
T00038
A-17
T019605E
Cautions in Cold Weather
• Snow or ice on the crane should be removed be-
fore operation; it is especially important to
eliminate any accumulation on the boom, as it
could fall and injure someone when the boom is
moved.
• Do not let bare skin come in contact with the ma-
chine’s metallic parts when the temperature is
below freezing. Skin can freeze to the metallic sur-
face, if any moisture is present.
• Warm up the machine sufficiently. Then, check
that the machine is functioning correctly. Remove
ice and dry machine components as required.
• After starting operation, run the machine slowly
until oils fully circulates through all machine com-
ponents.
• Before lifting, make sure that the load is not
frozen to the ground or any other objects.
Attempting to lift a load which is frozen to the
ground can result in severe overloading and is
very dangerous.
• If possible, stow the machine indoors so that the
tires are not frozen to the ground. Remove mud
from the undercarriage.
• Maintain the battery. Use oils and fuel rated for
cold weather.
Rules for Operation
(Power Lines, Radio Waves)
Prevent Electric Shock Accidents
Approaching too close to power lines can result in
electric shock accidents. If conditions absolutely re-
quire operation near power lines or distribution
lines, implement the following preventive measures:
• Meet with the power company concerned to devel-
op a relevant safety plan.
• Require that working personnel wear approved
insulating shoes.
• Keep the crane and load beyond the required dis-
tance (stipulated by national or local laws and
regulations) and away from power lines.
• Post a full-time signal person to ensure the ma-
chine or load does not approach power lines or
unauthorized personnel do not enter the work
area.
• Personnel on the ground must not directly touch
the machine or load. When necessary to control
the lifted load, use dry fiber ropes as tethers to
prevent the load from rotating or swaying.
• Do not place a load below or near power lines.
• Operate the crane slowly with the utmost care and
attention.
(The data shown below describes the required dis-
tance recommended by Japanese power
companies.)
Voltage Required stand-off distance
Low voltage 100 V, 200 V
High voltage 6,600 V
22,000 V 3 meters
66,000 V 4 meters
Extra high 154,000 V 5 meters
voltage 187,000 V 6 meters
275,000 V 7 meters
500,000 V 11 meters
Should an electric shock accident occur, do not
panic. Follow the instructions below:
• Contact the power company to cut off the power
and obtain instructions for emergency action.
• Direct all personnel around the machine to evacu-
ate the site. Strictly control the site and keep
everyone away from the electrified crane and load.
Safety Rules Safety Rules
A-18
2 meters
Safety Rules Safety Rules
A-19
T019605E
T00650
Rules for Operation
(Special Operation)
Be Cautious in Multi-Crane Operation
Lifting a load with two or more cranes can be dan-
gerous. In these operations, loads are lifted at
points other than directly above the center of gravity
and there is possibility of the load falling, the ma-
chine being overturned, or the boom failing.
In multi-crane lifting operations, be absolutely care-
ful, and adhere to the following instructions:
• Meet with personnel to determine the proper
working procedure and lift strategy.
• Assign a work leader, and follow instructions.
• Equip every person concerned with an appropri-
ate communications device.
• Set each crane level on firm ground with the out-
riggers fully extended.
• The cranes used must have the same perfor-
mance, characteristics and sufficient capacity for
handling the load. Make sure that the cranes have
the same settings for the boom length, boom an-
gle, and number of rope parts.
• Lift the load so that the wire rope(s) of each crane
are only subjected to vertical line pulls.
• Attempt to rig the load so that all the cranes are
loaded equally.
• To move the load, use only the winches and
booms. Swinging operations should be avoided.
Do not perform hoisting, elevating (or telescop-
ing) of the boom or swinging at the same time.
• To prevent overloading, operate the separate
cranes simultaneously.
After Operation
After Operation, Stow the Machine
Leaving the machine unattended should be avoided.
Once operation is complete, stow the machine.
T21496
Cautions for Refilling the Fuel
Fuel and other oils are highly flammable and dan-
gerous.
Handle combustibles very carefully.
While refueling, observe the following instructions:
• Stop the engine.
• Refuel the machine outdoors in a well-ventilated
place.
• Keep sources of flames or sparks away from the
fuel.
• Wear a protective mask.
• Do not refuel in excess of fuel tank capacity.
A00195
Safety Rules Safety Rules
A-20
T019605E
T21496
Rules for Road Travel
Observe All Vehicles Code
Requirements for Travel on Public Roads
Some national and local laws and rules exist regard-
ing the travel of crane vehicles on public roads.
Before traveling on roads, study the requirements
for road travel for the crane, and strictly obey all the
regulations.
Driving Crane (Carrier) in Road Travel
Configuration
A swaying hook block or boom, or extended outrig-
gers pose extreme hazards during crane road travel.
Before traveling, stow the hook block and boom in
position, and lock the outrigger beams, etc., in posi-
tion (if lock pins are available). Give a traveling
configuration to the machine by referring to the
manual.
Be Aware of Overhead Obstacles
Pay attention to overhead clearance when passing
under electric car wires, highway or railway bridges,
and passing through a tunnel.
If the planned route necessitates travel below over-
head railway lines or overhead bridges or through a
tunnel, check the clearances in advance.
T21495
Do Not Travel with Any Cargo on the
Crane
Carrying cargo on a traveling crane can result in a
spill or fall. Use a vehicle designed specifically for
cargo transport.
Safety Rules Safety Rules
A-21
Safety Rules Safety Rules
A-22
T019605E
T01951
Meet with Working Personnel
Working together with other persons on inspection
or maintenance tasks without observing mutually
agreed upon procedures can result in an accident.
Meet with all involved personnel to agree on the de-
tailed tasks. Also, assign a work leader, and always
follow his or her instructions.
Provide Effective Ventilation
Performing inspection or maintenance work in a
confined space without effective ventilation can lead
to toxic poisoning.
Be very careful when handling fuel, wash oil, and
paint.
When starting the engine in an enclosed space, pro-
vide a means of positive ventilation. Connect a hose
from the exhaust to vent the fumes outdoors. Open
doors and windows to allow fresh air circulation.
Install a ventilator as required.
Fire Prevention
To prevent the risk of fire during inspection and
maintenance work requiring handling of potentially
flammable substances, observe the following in-
structions.
• Use a non-flammable cleaning liquid to wash
parts and components.
• Store fuel and oils away from fire.
• Do not allow sources of flames or sparks near any
substance that is combustible.
• Do not smoke cigar or cigarette.
• Always carry a fire extinguisher in the operator’s
cab.
• When checking fuel, oils, and battery liquid, use
an explosion-proof lamp.
• When grinding or welding, keep flammable sub-
stances away from flying sparks or molten metal.
About Illumination
Inspection or maintenance work in a poorly illumi-
nated environment can lead to injury. Before
starting the work, provide proper illumination.
Never use the exposed flame of a match or lighter
for illumination, a fire accident may occur. The emit-
ted gas from open lead storage batteries can
explode.
Use explosion-preventive type illuminating devices
when checking fuel and battery liquid level.
Safety Rules Safety Rules
A-23
T019605E
Clean the Machine before Inspection
or Maintenance
Dirt and debris on the machine not only prevents
easy detection of faulty components or parts but
also can be trapped in components or parts. Also,
dust or mud can enter your eyes or cause you to
slip and be injured.
Before starting general inspection or maintenance
activities, wash the machine to ensure a safe work
area.
Cautions for Washing the Machine
Wet footing can cause to slip and fall injuries.
Always wear non-slip shoes.
When washing the machine with high-pressure
steam, the jet can penetrate skin or flying mud can
cause eye damage. Always wear suitable protective
gear during washing.
Do not direct water to electrical equipment, dis-
charge and/or shortcircuits can result and lead to
damage.
Labeling for Inspection or
Maintenance Work
If any unauthorized person starts the engine during
inspection or maintenance work, the machine may
be damaged or injury or even death may result.
When performing inspection or maintenance work,
remove the starter key, and post a “DO NOT OPER-
ATE” or “TAG OUT” sign on the door or control
levers of the operator’s cab as a warning.
Also, post relevant warning signs at entry to the
work area to prevent access of unauthorized per-
sonnel.
Start Inspection or Maintenance after
the Machine Has Cooled Down
When the crane is operated, various machine com-
ponents become very hot and can cause burns.
These components include the engine, muffler, en-
gine cooling water, radiator, hydraulic oil, reducer,
hydraulic equipment and hydraulic piping.
Allow these components and areas to cool down be-
fore starting inspection or maintenance work.
Inspect and Maintain the Machine on
Level Ground
It is difficult to inspect the machine properly if it is
parked on a slope or grade. Also, the machine is li-
able to start moving if not parked properly.
Park the crane on firm flat ground, activate the park-
ing brake, and chock the tires.
Keep the Work Area Clean and Tidy
Performing inspection or maintenance work in a dis-
orderly place can lead to personal injury or a falling
accident.
Remove obstacles.
Beware of High-Pressure Oils
High-pressure fuel or hydraulic oil that comes into
contact with skin or eyes can cause serious injury.
To avoid this danger:
• Release internal pressure, and only then, discon-
nect any piping.
• To check for leakage, wear protective goggles and
gloves and use a piece of cardboard or wood as a
monitor. Leaking high-pressure oil may be invisi-
ble.
Keep bare hands away from all leaking compo-
nents.
• Immediately obtain medical attention when high-
pressure oil accidentally cuts into skin or affects
the eyes.
Safety Rules Safety Rules
A-24
T019605E
T03835
Inspect or Maintain Equipment with
the Engine Shut Down
Performing inspection or maintenance work while
the engine is running is very dangerous, and should
be avoided. Unless otherwise necessary, be sure to
shut down the engine before starting inspection or
maintenance procedures.
Use Two Persons for Inspection or
Maintenance with the Engine Running
If for some reason it is necessary to perform an in-
spection or maintenance procedure with the engine
running, post at least two persons—one in the oper-
ator’s cab to shut down the engine immediately
when necessary, and the other(s) to perform mainte-
nance. During the maintenance, ensure safety of all
persons involved in the work.
Use Proper Tools
Performing inspection or maintenance work without
the proper tools not only decreases work efficiency
but also can lead to damage to parts or even injury.
Do not use improper or damaged tools.
Beware of Overhead Obstacles and
Footing
Lack of awareness or loose footing can cause head
impact with the hook block, boom, or jib or slip and
falls off the machine.
Always be careful about overhead obstacles and
footing. Walk on the non-slip strips if provided on
the machine.
Cautions for Working at Heights
Working at heights involves the possibility of falling.
To reduce this risk, remove all obstacles, and any
spilled grease and oil. Keep all footing areas clean
and tidy.
To climb onto and descend from a position of high
elevation, face the machine directly. Use the
handrails and steps, always be supported by at least
three points of your hands and feet.
Be careful not to slip. When non-slip strips are pro-
vided on the machine, walk on them.
Use safety equipment such as safety belts ties, lan-
yards and platforms as the situation requires.
Cautions for Working Under the
Machine
When working under the crane with the jack cylin-
ders extended, place supports and wood blocks
beneath the outriggers to support the machine se-
curely. Do not work under the crane unless the
machine is securely and positively supported.
Do Not Stick Any Part of Your Body
Out from the Window on the Boom Side
Sticking any part of your body out from the window
on the boom side can result in being caught be-
tween the moving boom and the window frame.
Serious injury or death can result from this danger-
ous practice.
If the window is equipped with a confining guard, do
not remove it.
Safety Rules Safety Rules
A-25
T019605E
T00046
Keep Away from Moving Parts
Inadvertent motion of the machine, or contacting a
moving part can cause personal injury and even
death.
When necessary to inspect or maintain the machine
while running, do not approach moving parts such
as the boom, elevating cylinder, winch, fan, fan belt,
and propeller shaft, etc.
Keep hands and clothing away from moving parts.
Beware of an Overheated Cooling
Do Not Allow Tools and Parts to Drop
When working through an inspection hole while fac-
ing down, be careful not to drop objects into the
hole. Such mistakes can damage or lead to malfunc-
tion of the machine. Do not keep objects which are
not needed for inspection in open pockets.
Recover any object or tool that has dropped into the
machine.
Beware of Oil Smears
Oil smears on the clutch, lining and brake disks can
decrease braking effectiveness. Always keep these
assemblies free from oil accumulation.
Beware of Dust
Be careful not to inhale dust during inspection or
maintenance work. To inspect or maintain brakes
and linings, remove dust using a vacuum cleaner.
Do not use compressed air because this action will
scatter dust into the air.
System
Do not unfasten the radiator cap while the engine
cooling water is hot. Hot steam and water can spurt
out, causing burns.
First allow the radiator to cool down. Then, loosen
the cap very slowly while facing away to release the
internal pressure.
T00044
Lock the Inspection Hole Covers
An inspection hole cover that remains open can be
closed abruptly by a gust, etc., causing hands or a
leg to be caught and injured.
If an inspection hole cover or access door, or the
operator’s cab door must remain open, secure in po-
sition.
Safety Rules Safety Rules
A-26
T019605E
T21796E
1
4
2
3
Service vehicle battery
Booster cable
Booster cable
Disabled vehicle battery
Frame
About Starting the Engine with
Booster Cables
Using improper booster cables to start the engine
can cause the battery to explode or damage the ma-
chine.
When starting the engine using booster cables,
wear protective goggles. This procedure requires
two persons; one person must be seated in the op-
erator’s cab. The procedure consists of:
(1) Use an assist vehicle with a battery rated for 24
V. Do not use a 12 V or 48 V supply.
(2) Set the starter key to “OFF” position both for the
dead vehicle and assist vehicle.
(3) Connect the booster cables in the following or-
der:
[1] “+” terminal of the battery on the dead vehi-
cle.
[2] “+” terminal of the battery on the assist vehi-
cle.
[3] “-” terminal of the battery on the assist vehi-
cle.
[4] A portion of the frame or engine block of the
dead vehicle, apart from its battery.
(4) Start the engine of the assist vehicle.
(5) Start the engine of the dead vehicle.
(6) Once the engine of the dead vehicle has suc-
cessfully started, disconnect the booster cables
in the order of [4], [3], [2] and [1].
Disconnect the Battery Cable before
Inspecting or Maintaining the Electrical
System
Inspecting or maintaining the electrical system with-
out disconnecting the battery cable can cause the
wiring to be shortcircuited, possibly damaging the
electrical and electronic systems.
Before inspecting or maintaining the electrical sys-
tem, disconnect the battery cable from the minus
terminal (ground side) of the battery.
Be Cautious about Battery Fluid
The battery fluid contains dilute sulfuric acid.
Battery fluid entering the eyes could cause blind-
ness, and battery fluid on skin can cause burns.
When handling the battery, wear protective goggles,
protective gloves, and long-sleeved clothing.
If battery fluid touches your eyes or skin, wash with
a large amount of fresh water and seek medical at-
tention immediately.
Prevent Explosion of the Battery
The battery releases hydrogen gas. Do not light a
match or lighter near the battery.
To check the battery fluid level, use a flash light.
If battery fluid is frozen in extreme freezing weather,
do not charge the battery or start the engine with an
alternative power supply.
Warm up the battery to 15°C so to avoid trouble.
Safety Rules Safety Rules
H
L
Careful Handling of Wire Ropes
Careless handling of wire ropes can shorten their
service life, or cause them to break. Handle wire
ropes properly by observing all instructions in the
manual.
A-27
T00043
Safety Rules Safety Rules
A-28
Warning Labels Warning Labels
A-29
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