Maeda LC1385M-8B User manual

584E-SM1004-00
SERVICE MANUAL
CRAWLER CRANE
Serial No. 80002 and up
The parts numbers and lists written in this service manual are the
references for the services such as disassembling and assembling
Be sure to ALWAYS refer to the latest parts catalog (the latest
information) before ordering any part, since the parts and the model
numbers are subject to change during the endless improvements and
changes of our Machine
584E-SM1110-01 1/2

0-1
CONTENTS
ITEM
Page
ENERAL
1-1
1 SPECIFICATION DIMENSIONNAL DRAWING 1-2
2 PRINCIPLE SPECIFICATION LIST 1-3
3 EACH UNIT WEIGHT LIST 1-4
4 FUEL, COOLANT AND LUBRICATIONS TABLE 1-5
5 WORKING RADIUS LIFTING HEIGHT 1-6
6 TOTAL RATED LOAD CHART 1-7
7 FLY-JIB WORKING RADIUS AND LIFTING HEIGHT (OPTIONAL) 1-10
8 FLY-JIB TOTAL RATED LOAD CHART (OPTIONAL) 1-10
STRUCTUR, FUNCTION & MAINTENANCE STANDARD
2-1
1 ENGINE AND COLLING SYSTEM 2-2
1 1 ENGINE SPECIFICATIONS 2-2
1 2 ENGINE MOUNTING 2-3
1 3 PTO (POWER TAKE OFF) 2-4
1 4 COOLING SYSTEM 2-6
2 POWER TRAIN 2-8
2 1 POWER TRAIN DRAWING 2-8
2 2 SWING CIRCLE 2-9
2 3 SWING MACHINERY 2-10
3 UNDERCARRIAGE AND FRAME 2-12
3 1 TRACK FRAME 2-12
3 2 IDLER CUSHION 2-13
3 3 IDLER 2-14
3 4 TRACK ROLLER 2-15
3 5 CARRIER ROLLER 2-16
3 6 SPROCKET 2-17
3 7 TRACK SHOE 2-18
4 HYDRAULIC CERCUIT DIAGRAM 2-23
5 HYDRAULIC SYSTEM 2-26
5 1 HYDRAULIC EQUIPMENT LAYOUT DRAWING 2-26
5 2 HYDRAULIC TANK AND FILTER 2-28
5 3 HYDRAULIC OIL PUMP 2-30
5 3 1 LS VALVE 2-36
5 3 2 PC VALVE 2-41
5 3 3 PC-EPC VALVE 2-51
5 3 4 CHECK VALVE 2-54
5 3 5 SHUTTLE VALVE 2-55
5 4 CONTROL VALVE 2-56
5 5 CLSS 2-68
5 5 1 OUTLINE OF CLSS 2-68

0-2
ITEM
Page
5 6 FUNCTIONS AND OPERATION BY VALVE 2-72
5 6 1 HYDRAULIC CIRCUIT DIAGRAM AND THE NAME OF VALVES 2-72
5 6 2 UNLOAD VALVE 2-74
5 6 3 MERGE-DIVIDER VALVE 2-80
5 6 4 INTRODUCTION OF LS PRESSURE 2-82
5 6 5 LS BYPASS VALVE 2-84
5 6 6 PRESSURE COMPENSATION VALVE 2-86
5 6 7 AREA RATIO OF PRESSURE COMPENSATION VALVE 2-88
5 6 8 SWING BLEEDING VALVE 2-89
5 6 9 TRAVEL JUNCTION VALVE 2-90
5 6 10 SELF PRESSURE REDUCING VALVE 2-91
5 7 PPCVALVE 2-92
5 7 1 WORK EQUIPMENT AND SWING PPC VALVE 2-92
5 7 2 TRAVEL PPC VALVE 2-97
5 7 3 BLADE PPC VALVE 2-102
5 8 6-SECTION SOLENOID VALVE 2-104
5 9 5-SECTION SOLENOID VALVE 2-107
5 10 WINCH BRAKE RELEASE VALVE 2-108
5 11 PPC ACCUMULATOR 2-110
5 12 LOW PRESSURE SELECTOR VALVE (For Over Hoisting Release) 2-111
5 13 TELESCOPING CYLINDER 2-112
5 13 1 TELESCOPING ASSEMBLY 2-112
5 13 2 TELESCOPING CYLINDER 2-114
5 14 DERRICKING CYLINDER 2-120
5 14 1 COUNTER BALANCE VALVE FOR TELESCOPING 2-122
5 15 WINCH MOTOR 2-123
5 15 1 INNER STRUCTURE DRAWING 2-124
5 15 2 COUNTER BALANCE VALVE 2-125
5 15 3 HYDRAULIC OIL MOTOR 2-127
5 15 4 REDUCTION GEAR 2-130
5 16 SWING MOTOR 2-131
5 16 1 SWING HOLDING BRAKE 2-134
5 16 2 RELIEF VALVE PORTION 2-135
5 16 3 REVERSE PREVENTION VALVE 2-136
5 17 CENTER SWIVEL JOINT 2-140
5 18 TRAVEL MOTOR 2-142
5 18 1 BRAKE VALVE 2-147
5 18 2 RELIEF VALVE 2-149
5 19 BLADE CYLINDER 2-150
6 BOOM ASSEMBLY 2-152
6 1 BOOM TELESCOPING SYSTEM 2-156
7 FLY-JIB (OPTIONAL) 2-158

0-3
ITEM
Page
8 ELECTRIC CIRCUIT DIAGRAM (1/6 to 6/6) 2-161
9 AIR CONDITIONER 2-168
9 1 AIR CONDITIONER PIPING DIAGRAM 2-168
9 2 AIR CONDITIONER UNIT 2-172
9 3 AIR CONDITIONER CONTROLLER 2-175
9 4 COMPRESSOR 2-176
9 5 CONDENNSER 2-177
9 6 SENSOR 2-178
10 ELECTRICAL SYSTEM 2-180
10 1 ELECTRICAL CONTROL SYSTEM 2-180
10 1 1 ELECTRICAL CONTROL FUNCTION 2-182
10 1 2 PUMP AND ENGINE MUTUAL CONTROL FUNCTION 2-184
10 1 3 AUTO-DECELERATOR FUNCTION 2-189
10 1 4 ENGINE AUTOMATIC WARM-UP FUNCTION 2-191
10 1 5 OVERHEAT PREVENTION FUNCTION 2-193
10 1 6 OVERHEAT PREVENTION FUNCTION 2-194
10 1 7 SWING CONTROL FUNCTION 2-195
10 1 8 TRAVEL CONTROL FUNCTION 2-198
10 1 9 PPC LOCK FUNCTION 2-201
10 1 10 SYSTEM COMPONENTS 2-202
10 2 MONITOR SYSTEM 2-211
10 2 1 MACHINE MONITOR 2-212
10 2 2 DISPLAY 2-214
10 2 3 SWITCHES 2-218
10 2 4 OPERATION MODE FUNCTION 2-222
10 2 5 OPERATION MODE FUNCTION 2-224
10 3 KOMTRAX SYSTEM 2-225
10 3 1 KOMTRAX TERMINAL 2-226
10 4 SENSOR 2-227
11 CRANE OPERATING DATA LOGGER 2-233
11 1CRANE OPERATING DATA LOGGER EXTERIOR VIEW 2-234
12 MOMENT LIMITER 2-238
12 1 MOMENT LIMITER RELATED 2-238
12 1 1 DISPLAY UNIT 2-238
12 1 2 TRANSDUCER 2-240
12 1 3 LENGTH, ANGLE AND PRESSURE SENSOR 2-241
12 1 4 BOOM DERRICKING POSITION DETECTOR 2-246
12 1 5 BLADE GROUNDING DETECTOR 2-248
12 1 6 FLY-JIB POSITION DETECTOR 2-250
12 1 7 OVER HOIST STOP SYSTEM 2-253
12 1 8 OVER HOIST STOP SYSTEM (FOR SINGLE HOOK) 2-255
12 1 9 OVER HOIST STOP SYSTEM (FOR FLY-JIB) 2-256
12 1 10 OVER UN-WINDING DETECTOR 2-257

0-4
ITEM
Page
12 2 MOMENT LIMITER OVERVIEW AND FEATURES 2-258
12 2 1 OVERVIEW 2-258
12 2 2 SPECIFICATIONS 2-258
12 3 EXTERNAL VIEW OF MOMENT LIMITER 2-259
12 3 1 DISPLAY UNIT 2-259
12 3 2 REDUCER 2-260
12 4 CONNECTOR PIN ASSIGNMENT 2-262
12 4 1 REDUCER CONNECTORS 2-262
12 5 DISPLAYS 2-264
12 6 SWITCHES 2-266
12 7 DISPLAY UNIT; DETAIL OF EACH SEGMENT 2-268
12 8 START UP SEQUENCE 2-269
12 9 MOMENT LIMITER FUNCTIONS 2-269
12 10 DISPLAY OF SPECIFIC INDICATORS 2-270
12 11 CALIBRATION PROCEDURE 2-271
12 11 1 LIST OF ITEMS 2-271
12 11 2 PROCEDURE 2-272
12 11 3 CALL OUT OF CALIBRATION MODE 2-273
12 11 4 CALIBRATION OF BOOM LENGTH 2-275
12 11 5 CALIBRATION OF BOOM ANGLE 2-277
12 11 6 CALIBRATION OF WEIGHTING 2-279
12 11 7 DISPLAY DETAILS AT CALIBRATION MODE 2-282
12 12 FUNCTION MODE 2-283
12 12 1 LIST OF ITEMS 2-283
12 12 2 SELECTION OF FUNCTION 2-284
12 12 3 CONFIRMATION OF ROM VERSION 2-287
12 12 4 PROPORTIONAL CONTROL OUTPUT TEST FOR BOOM LOWERING SOLENOID VALVE 2-288
12 12 5 CONFIRMATION OF CONTACT STATE 2-289
12 12 6 CONFIRMATION OF CONTROL OUTPUT 2-290
12 12 7 CONFIRMATION OF VOICE OUTPUT 2-291
12 12 8 CALIBRATION AND INITIALIZATION OF EACH WORKING RANGE LIMITATION VALUE 2-292
12 13 ERROR MESSAGES 2-294
STANDARD VALUE TABLE
3-1
1 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 3-2
2 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 3-3
3 STANDARD VALUE TABLE FOR MOMENT LIMITER RELATED PARTS 3-7
TESTIN AND ADJUSTIN
4-1
1 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 4-2
2 TESTING ENGINE SPEED 4-5
3 TESTING EXHAUST TEMPERATURE 4-6
4 CHECKING EXHAUST GAS COLOR 4-7
5 ADJUSTING VALVE CLEARANCE 4-8
6 TESTING COMPRESSION PRESSURE 4-10
7 TESTING BLOW-BY PRESSURE 4-12

0-5
ITEM
Page
8 TESTING ENGINE OIL PRESSURE 4-13
9 HANDLING FUEL SYSTEM PARTS 4-14
10 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 4-14
12 TESTING FUEL PRESSURE 4-15
13 TESTING FUEL RETURN RATE AND FUEL LEAKAGE 4-16
14 BLEEDING AIR FROM FUEL CIRCUIT 4-18
15 CHECKING FUEL CIRCUIT FOR LEAKAGE 4-20
16 TESTING AND ADJUSTING ALTERNATOR BELT TENSION 4-21
17 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 4-22
18 CHECKING AND ADJUSTING TRACK SHOE TENSION 4-23
19 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT 4-25
20 TESTING CONTROL CIRCUIT BASIC PRESSURE 4-28
21 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 4-29
22 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 4-32
23 TESTING SOLENOID VALVE OUTPUT PRESSURE 4-36
24 TESTING PPC VALVE OUTPUT PRESSURE 4-37
25 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 4-39
26 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 4-40
27 TESTING OIL LEAKAGE 4-41
28 BLEEDING AIR FROM EACH PART 4-43
29 CHECKING CAB TIPPING STOPPER 4-45
30 ADJUSTING MIRRORS 4-45
31 ADJUSTING CLEARANCE OF BOOM 4-46
32 ADJUSTING BOOM TELESCOPING WIREROPE 4-47
33 CRITERIA FOR WINCH WIRE ROPE REPLACEMENT 4-49
34 CHECKING HOOK BLOCK 4-50
35 SPECIAL FUNCTION OF MACHINE MONITOR 4-52
36 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER 4-102
37 PRECAUTION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 4-103
38 PROCEDURE FOR TESTING DIODES 4-108
TROUBLESHOOTIN
5-1
1 GENERAL INFORMATION ON TROUBLESHOOTING 5-2
1 1 POINTS TO REMENBER WHEN TROUBLESHOOTING 5-2
1 2 SEQUENCE OF EVENTS IN TROUBLESHOOTING 5-3
1 3 CHECKS BEFORE TROUBLESHOOTING 5-4
1 4 CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING 5-5
1 5 INFORMATION IN TROUBLESHOOTING TABLE 5-6
1 6 PHENOMENA LOOKING LIKE TROUBLES AND TROUBLESHOOTING NOS 5-8
1 7 WIRING TABLE FOR CONNECTOR PIN NUMBERS 5-11
1 8 T-ADAPTER BOX AND T-ADAPTER TABLE 5-44
1 9 FUSE LOCATIONS 5-48
2 TROUBLESHOOTING BY FAILURE CODE 5-101
2 1 FAILURE CODE TABLE 5-101

0-6
ITEM
Page
3 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 5-301
3 1 E-MODE TROUBLESHOOTING TABLE 5-301
3 2 INFORMATION IN TROUBLESHOOTING TABLE 5-302
4 TROUBLESHOOTING OF HYDRAULIC SYSTEM (H-MODE) 5-401
4 1 H-MODE TROUBLESHOOTING TABLE 5-401
4 2 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 5-402
5 TROUBLESHOOTING OF ENGINE (S-MODE) 5-501
5 1 H-MODE TROUBLESHOOTING TABLE 5-501
5 2 METHOD OF USING TROUBLESHOOTING CHART 5-502
DISASSEMBLY AND ASSEMBLY
6-1
1 HOW TO READ THIS MANUAL 6-4
2 LIST OF ADHESIVES 6-6
3 SPECIAL TOOL LIST 6-9
4 SKETCHE OF SPECIAL TOOL 6-13
5 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY 6-14
6 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY 6-16
7 REMOVAL AND INSTALLATION OF FRONT OIL SEAL 6-19
8 REMOVAL AND INSTALLATION OF REAR OIL SEAL 6-21
9 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 6-24
10 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 6-31
11 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY 6-33
12 REMOVAL AND INSTALLATION OF WORK EQUIPMENT OIL COOLER ASSEMBLY 6-35
13 REMOVAL AND INSTALLATION OF ENGINE AND WORK EQUIPMENT PUMP ASSEMBLY 6-38
14 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 6-43
15 REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 6-45
16 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 6-47
17 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY 6-49
18 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY 6-55
19 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 6-56
20 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 6-59
21 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY 6-62
22 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 6-65
23 REMOVAL AND INSTALLATION OF SPROCKET 6-67
24 REMOVAL AND INSTALLATION OF COUNTER WEIGHT ASSEMBLY (MACHINE WITHOUT ADD-ON
WEIGHT) 6-68
25 REMOVAL AND INSTALLATION OF COUNTER WEIGHT ASSEMBLY (MACHINE WITH ADD-ON
WEIGHT) 6-70
26 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 6-72
27 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 6-74
28 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 6-75
29 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 6-78
30 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 6-82
31 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 6-92

0-7
ITEM
Page
32 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 6-95
33 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 6-97
34 REMOVAL AND INSTALLATION OF OPERATOR S CAB ASSEMBLY 6-103
35 REMOVAL AND INSTALLATION OF OPERATOR S CAB GLASS 6-105
36 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY 6-114
37 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 6-115
38 REMOVAL AND INSTALLATION OF AIR COMPRESSOR ASSEMBLY 6-122
39 REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENNSOR 6-123
40 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 6-124
41 REMOVAL AND INSTALLATION OF MACHINE MONITOR ASSEMBLY 6-127
42 REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY 6-128
43 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY 6-129
44 REMOVAL AND INSTALLATION OF KOMTRAX COMMUNICATIONS MODULE 6-130
45 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY 6-132
46 DISASSEMBLY AND ASSEMBLY OF BOOM ASSEMBLY 6-134
47 DISASSEMBLY AND ASSEMBLY OF WINCH BRAKE RELEASE VALVE ASSEMBLY 6-139
48 REMOVAL AND INSTALLATION OF WINCH WIRE ROPE 6-140
49 DISASSEMBLY AND ASSEMBLY OF LENGTH GAUGE 6-144
50 REPLACEMENT OF MOMENT LIMITER FUSE 6-148

0-8

1-1
ENERAL
1 SPECIFICATION DIMENSIONNAL DRAWING 1-2
2 PRINCIPLE SPECIFICATION LIST 1-3
3 EACH UNIT WEIGHT LIST 1-4
4 FUEL, COOLANT AND LUBRICATIONS TABLE 1-5
5 WORKING RADIUS LIFTING HEIGHT 1-6
6 RATED TOTAL LOAD CHART 1-7
7 FLY-JIB WORKING RADIUS AND LIFTING HEIGHT (OPTIONAL) 1-10
8 FLY-JIB RATED TOTAL LOAD CHART (OPTIONAL) 1-10

1-2
1. SPECIFICATION DIMENSIONAL DRAWIN

1-3
2 . PRINCIPLE SPECIFICATION LIST
System / Item LC1385M-8B
Mass and
dimensions
Machine mass 15640kg
Overall length width height 6545mm x 2490mm x 2965mm
Distance between idler and sprocket 2880mm
Track gauge 1990mm
Track width 500mm
Swing radius at machine rear end
1600mm
Capacity
Maximum rated total load
working radius 6 0t x 2 6m
Maximum working radius 16 1m
Maximum lifting height 16 7m
Winch system
Method 2 speeds hydraulic motor with built-in automatic brake, Grooved drum
with a planetary differential type reduction gear
Number of falls 4-falls/2-falls (1-fall Optional)
Winding speed Low 28 0m/min (4th drum, 4 ropes)
High 41 0m/min (4th drum, 4 ropes)
Hoisting rope IWRC 6 x WS (29) 0/0 Type B mm x 115m
Boom
telescoping
system
Method 3 sequential telescoping double acting hydraulic cylinders + 1 wire
rope telescoping device
Boom type Hexagonal sectioned hydraulic automatic telescoping boom, 5
sections (sections 2 and 3: sequential,
sections 4 and 5: simultaneous)
Boom length 4 745m 7 625m 10 505m 13 385m - 16 265m
Boom telescoping stroke/time 11 52m/25sec
Boom derrick
system
Method Direct push-type hydraulic double-acting cylinder
Derrick angle/ time -5 to 80 deg /18sec
Swing system Method Fixed displacement piston type
Swing angle/ speed 360 degrees, continual, 3 4 rpm
Traveling
system
Method Variable displacement piston type
Travel speed Low Forward/backward: 0 2 9km/h
High Forward/backward: 0 5 1km/h
Gradeability 34 deg
Ground pressure [shoe width] 53 3kPa (0 54kgf/cm
2
) [500mm]
Hydraulic
system
Hydraulic pump Variable displacement piston type
Hydraulic oil tank capacity 120 liters
Engine
Model Komatsu SAA4D95LE-5
Type Vertical in-line 4-cylinder, Water cooled, 4-cycle, Direct fuel injection
type, With turbocharger
Displacement 3 26 liters (3260cc)
Rated output (continuous) 68 4kW/2200min
-
1
(93PS/2200rpm)
Fuel tank capacity Light oil/195 liters
Safety device
Over hoist detector, three-winding stop device, moment limiter (working envelope limited), slinging rope
detachment protector, hydraulic safety valve, telescoping cylinder hydraulic automatic locking device, derricking
cylinder hydraulic automatic locking device, alarm buzzer, machine body inclination alarm, working status lamp,
level, control lever lock lever

1-4
3 . EACH UNIT WEI HT LIST
Unit: kg
ITEM
LC1385M-8B
Engine Assembly (Dry)
Engine (Dry)
Engine Mount
PTO
Hydraulic Oil Pump
458
332
18 1
5 5
102
Cooling Assembly (Dry)
Radiator (Dry)
Oil Cooler (Dry)
After Cooler
Fuel Cooler (Dry)
82 2
7 9
10 2
8 1
0 7
Revolving Frame 1400
Operator s Cab 375
Operator s Seat 14
Fuel Tank (Dry) 90 6
Hydraulic Oil Tank (Dry) 79 5
Control Valve 99
Counter Weight 3240
Additional Counter Weight (1) 1000
Additional Counter Weight (2) 318
Swing Motor (Incl Brake Valve) 20
Swing Circle 152 6
Swing Machinery 71 6
Center Swivel Joint 43 6
Track Frame Assembly
Track Frame
Idler Assembly
Recoil Spring Assembly
Carrier Roller
Track Roller
Travel Motor
Sprocket
2410
1415
79 X 2
69 X 2
16 5 X 2
22 X 14
145 X 2
33 7 X 2
Track Shoe Assembly
Triple Grouser Shoe (Width 500mm)
Triple Grouser Shoe (Width 600mm)
Triple Grouser Shoe (Width 700mm)
Triple Grouser Shoe (Width 750mm)
Single Grouser Shoe (Width 510mm)
City Pad Shoe (Width 500mm)
Road Liner (Width 500mm)
755 X 2
840 X 2
930 X 2
975 X 2
860 X 2
750 X 2
810 X 2
Boom Assembly (Inc Telescoping Cylinder Assembly) 1383
Winch Assembly 207 6
Hook Block Assembly 91 6
Post Assembly 372 8
Derricking Cylinder Assembly 169 3 X 2
Telescoping Cylinder Assembly 203 7
Blade Assembly
Harded Blade (BOC Type, Inc BOC)
Blade (Edge Welded Type)
Harded Wide Plate
Wide Plate
688
688
702
682
Blade Cylinder Assembly 59 2 X 2
Fly-jib Assembly 218 4
Winch Wire Rope (IWRC6 X Fi (29) 0/0 10 X 115m) 50 6

1-5
4 . FUEL, COOLANT AND LUBRICATIONS TABLE
Use of fuel, coolant and lubricant should vary with changes in temperature
Reservoir Fluid type
Ambient Temperature
(degrees C) Recommended Fluids
Min Max
Engine oil pan Engine oil
-30 30 SAE 0W30 (Note 1)
-25 40 SAE 5W40 (Note 1)
-20 40 SAE 10W30DH
-15 40 SAE 15W40DH
0 40 SAE 30DH
Swing machinery case
Travel motor gear case
PTO gear case
Power train oil
(Note 2) -30 40 SAE 30
Hydraulic system Power train oil -20 40 SAE 10W
Hydraulic oil -20 40 ISO VG46
Winch motor gear case Gear oil -30 40 SAE 90G L4
Cooling system Supercoolant AF-NAC
(Note 3) -30 40 AF-NAC
Fuel tank Diesel fuel
-30 20 ASTM Grade No 1-D S16
ASTM Grade No 1-D S500
-10 40 ASTM Grade No 2-D S15
ASTM Grade No 2-D S500
*ASTM: American Society of Testing and Material
Unit: Litre (US gal) [UK gal]
Reservoir Specified Capacity Refill Capacity
Engine Oil Pan 11 5 (3 04) [2 53] 11 0 (2 91) [2 42]
Swing Machinery Case 2 5 (0 66) [0 55] 2 5 (0 66) [0 55]
Travel Motor Final Drive Case (each side) 2 1 (0 55) [0 46] 2 1 (0 55) [0 46]
PTO Case 0 75 (0 20) [0 17] 0 75 (0 20) [0 17]
Hydraulic System 120 (31 70) [26 40] 69 (18 23) [15 18]
Winch Reduction Gear Case 1 8 (0 48) [0 40] 1 8 (0 48) [0 40]
Fuel Tank 195 (51 52) [42 90] --
Cooling System 12 4 (3 28) [2 73] --

1-6
5. WORKIN RADIUS AND LIFTIN HEI HT

1-7
6. RATED TOTAL LOAD CHART
[1] RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS
Unit: kg
Working
radius (m)
4 745m Boom 7 625m Boom 10 505m Boom 13 385m
Boom
16 265m
Boom
Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary
2 00 6000 2000 6000 2000 3000 1500
2 50 6000 2000 6000 2000 3000 1500 3000
2 60 6000 2000 6000 2000 3000 1500 3000
3 00 5250 2000 5260 2000 3000 1500 3000 2600
3 20 4910 2000 4920 2000 3000 1500 3000 2600
3 50 4450 2000 4460 2000 3000 1500 3000 2600
3 85 4000 2000 4000 2000 3000 1500 3000 2600
4 00 3830 1915 3820 1910 3000 1500 3000 2600
4 50 3320 1660 3310 1655 3000 1500 3000 2600
4 58 3250 1625 3240 1620 3000 1500 2940 2600
4 60 3220 1610 3000 1500 2920 2600
5 00 2880 1440 2710 1355 2640 2600
5 50 2520 1260 2400 1200 2340 2320
6 00 2210 1105 2140 1070 2100 2080
6 50 1950 975 1920 960 1890 1880
7 00 1720 860 1720 860 1710 1710
7 46 1530 765 1570 785 1570 1580
7 50 1550 775 1560 1560
8 00 1400 700 1430 1430
8 50 1270 635 1310 1320
9 00 1150 575 1200 1210
10 00 940 470 1020 1040
10 34 880 440 970 980
11 00 880 890
12 00 750 770
13 00 650 670
13 22 630 650
14 00 580
15 00 500
16 00 440
16 10 430
Boom angle
range (deg)
0 64 3 0 74 4 0 78 8 0 80 0 0 80 0
Hook mass: 90kg
Boom length:
4 745m boom Boom retracted minimum
7 625m boom Boom length more than 4 745m less than 7 625m
10 505m boom Boom length more than 7 625m less than 10 505m
13 385m boom Boom length more than 10 505m less than 13 385m
16 265m boom Boom length 13 385m or more
The Rated Total Load Chart is based on the actual working radius including boom deflection
The weight of hook block must be included as part of the load shown in the Rated Total Load Chart

1-8
[2] RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS
Unit: kg
Working
radius (m)
4 745m Boom 7 625m Boom 10 505m Boom 13 385m
Boom
16 265m
Boom
Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary
2 00 3000 1000 3000 1000 3000 1000
2 50 3000 1000 3000 1000 3000 1000 3000
2 60 3000 1000 3000 1000 3000 1000 3000
3 00 3000 1000 3000 1000 3000 1000 3000 2600
3 20 3000 1000 3000 1000 3000 1000 3000 2600
3 50 3000 1000 3000 1000 3000 1000 3000 2600
3 85 3000 1000 3000 1000 3000 1000 3000 2600
4 00 3000 1000 3000 1000 3000 1000 3000 2600
4 50 3000 1000 3000 1000 3000 1000 3000 2600
4 58 3000 1000 3000 1000 3000 1000 2940 2600
4 60 3000 1000 3000 1000 2920 2600
5 00 2880 1000 2710 1000 2640 2600
5 50 2520 1000 2400 1000 2340 2320
6 00 2210 1000 2140 1000 2100 2080
6 50 1950 975 1920 960 1890 1880
7 00 1720 860 1720 860 1710 1710
7 46 1530 765 1570 785 1570 1580
7 50 1550 775 1560 1560
8 00 1400 700 1430 1430
8 50 1270 635 1310 1320
9 00 1150 575 1200 1210
10 00 940 470 1020 1040
10 34 880 440 970 980
11 00 880 890
12 00 750 770
13 00 650 670
13 22 630 650
14 00 580
15 00 500
16 00 440
16 10 430
Boom angle
range (deg)
0 64 3 0 74 4 0 78 8 0 80 0 0 80 0
Hook mass: 90kg
Boom length:
4 745m boom Boom retracted minimum
7 625m boom Boom length more than 4 745m less than 7 625m
10 505m boom Boom length more than 7 625m less than 10 505m
13 385m boom Boom length more than 10 505m less than 13 385m
16 265m boom Boom length 13 385m or more
The Rated Total Load Chart is based on the actual working radius including boom deflection
The weight of hook block must be included as part of the load shown in the Rated Total Load Chart

1-9
[3] RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL
Unit: kg
Working
radius (m)
4 745m Boom 7 625m Boom 10 505m Boom 13 385m
Boom
16 265m
Boom
Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary
2 00 1500 500 1500 500 1500 500
2 50 1500 500 1500 500 1500 500 1500
2 60 1500 500 1500 500 1500 500 1500
3 00 1500 500 1500 500 1500 500 1500 1500
3 20 1500 500 1500 500 1500 500 1500 1500
3 50 1500 500 1500 500 1500 500 1500 1500
3 85 1500 500 1500 500 1500 500 1500 1500
4 00 1500 500 1500 500 1500 500 1500 1500
4 50 1500 500 1500 500 1500 500 1500 1500
4 60 1500 500 1500 500 1500 500 1500 1500
4 68 1500 500 1500 500 1500 500 1500 1500
5 00 1500 500 1500 500 1500 1500
5 50 1500 500 1500 500 1500 1500
6 00 1500 500 1500 500 1500 1500
6 50 1500 500 1500 500 1500 1500
7 00 1500 500 1500 500 1500 1500
7 50 1500 500 1500 500 1500 1500
7 56 1500 500 1500 500 1500 1500
8 00 1400 500 1430 1430
8 50 1270 500 1310 1320
9 00 1150 500 1200 1210
10 00 940 470 1020 1040
10 44 860 430 950 970
11 00 880 890
12 00 750 770
13 00 650 670
13 32 620 640
14 00 580
15 00 500
16 00 440
16 20 420
Boom angle
range (deg)
0 64 3 0 74 4 0 78 8 0 80 0 0 80 0
Hook mass: 20kg
Boom length:
4 745m boom Boom retracted minimum
7 625m boom Boom length more than 4 745m less than 7 625m
10 505m boom Boom length more than 7 625m less than 10 505m
13 385m boom Boom length more than 10 505m less than 13 385m
16 265m boom Boom length 13 385m or more
The Rated Total Load Chart is based on the actual working radius including boom deflection
The weight of hook block must be included as part of the load shown in the Rated Total Load Chart

1-10
7. FLY-JIB WORKIN RADIUS AND LIFTIN HEI HT (OPTIONAL)
8. FLY-JIB RATED TOTAL LOAD CHART (OPTIONAL)
Unit: kg
Loaded Boom Angle
(degree)
Fly-jib Tilt Angle
0 and 20 degrees 40 and 60 degrees
80 820 620
75 820 620
70 720 520
65 620 420
60 520
Prohibited Under 65 degrees
55 420
50 320
45 220
Prohibited Under 45 degrees
Hook mass: 20kg
The Rated Total Load Chart is same for both 1 section and 2 section of the Fly-jib length

2-1
STRUCTUR, FUNCTION &
MAINTENANCE STANDARD
1 ENGINE AND COLLING SYSTEM 2-2
2 POWER TRAIN 2-8
3 UNDERCARRIAGE AND FRAME 2-12
4 HYDRAULIC CERCUIT DIAGRAM 2-23
5 HYDRAULIC SYSTEM 2-26
6 BOOM ASSEMBLY 2-152
7 FLY-JIB (OPTIONAL) 2-158
8 ELECTRIC CIRCUIT DIAGRAM (1/6 to 6/6) 2-161
9 AIR CONDITIONER 2-168
10 ELECTRICAL SYSTEM 2-180
11 CRANE OPERATING DATA LOGGER 2-233
12 MOMENT LIMITER 2-238