Maeda LC1385M-8BF User manual

584E-OM0912-02
OPERATION MANUAL
CRAWLER CRANE
Serial No. 8009 and up
Unsafe use of this machine may cause serious injury or death. Operators
must read this manual before operating this machine. This manual should
be kept near the machine for reference and periodically reviewed by all
personnelwho willcomeinto contact withit.
NOTICE
MAEDAhas Operation Manual written in some other languages. If a foreign
language manualisnecessary,contact yourlocaldistributorfor availability.

0-1
CONTENTS
ITEM
Page
INTRODUCTION
1- 1
1. INTRODUCTION
1- 2
2.FOR SAFE USE OF MACHINE
1- 3
3. MACHINE OVERVIEW
1- 4
3.1 SPECIFIED OPERATIONS
1- 4
3.2 MACHINE CONFIGURATION
1- 4
3.3 MACHINE FUNCTIONS
1- 5
4. QUALIFICATION FOR OPERATION
1- 6
4.1 QUALIFICATION FOR CRANE OPERATION
1- 6
5. TERMINOLOGY
1- 7
5.1 DEFINITIONS OF TERMS
1- 7
5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT
1- 8
5.3 RATED TOTAL LOAD TABLE
1- 9
SAFETY
2- 1
1. BASIC PRECAUTIONS
2- 2
1.1 PRECAUTIONS FOR BEFORE STARTING OPERATION
2- 2
1.2 PREPARARATIONS OF SAFETY OPERATION
2- 3
1.3 PRECAUTIONS FOR FIRE PREVENTION
2- 5
1.4 PRECAUTIONS WHEN GETTING ON OR OFF
2- 6
1.5 OTHER PRECAUTIONS
2- 7
2. DRIVING RELATED PRECAUTIONS
2- 8
2.1 PRECAUTIONS FOR JOBSITE
2- 8
2.2 PRECAUTIONS WHEN ENGINE STARTING
2-11
2.3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE
2-13
2.4 PRECAUTIONS WHEN WORKING WITH CRANE
2-16
3. TRANSPORT PRECAUTIONS
2-25
4. TOWING PRECAUTIONS
2-26
5. MAINTENANCE PRECAUTIONS
2-27
5.1 PRECAUTIONS BEFORE MAINTENANCE
2-27
5.2 PRECAUTIONS DURING MAINTENANCE
2-30
6. SAFETY LABEL LOCATIONS
2-34
OPERATION
3- 1
1. MACHINE EACH SECTION
3- 2
1.1 MACHINE EACH UNIT
3- 2
1.2 OPERATOR’S COMPARTMENT EQUIPMENT
3- 3
1.2.1 MACHINE MONITOR
3- 4
1.2.2 MOMENTOLIMITER RELATED SWITCH BOX
3- 5
2. EXPLANATION OF DEVICES
3- 6
2.1 MACHINE MONITOR
3- 6
2.1.1 BASIC OPERATION OF MACHINE MONITOR
3- 7
2.1.2 EMERGENCY STOP ITEMS
3-11
2.1.3 CAUTION ITEMS
3-13

0-2
ITEM
Page
2.1.4 BASIC CHECK ITEMS
3-15
2.1.5 METER DISPLAY PORTION
3-16
2.1.6 MONITOR SWITCHES PORTION
3-22
2.1.7 HANDLING FUNCTION SWITCHES
3-28
2.2 SWITCHES
3-39
2.3 CONTROL LEVERS AND PEDALS
3-47
2.4 MOMENT LIMITER (OVERLOAD PROTECTOR)
3-51
2.4.1 MOMENT LIMITER CONFIGURATION
3-51
2.4.2 FUNCTION OF MOMENT LIMITER
3-52
2.4.3 MOMENT LIMITER OPERATIONS
3-54
2.4.4 NAMES OF MOMENT LIMITER DISPLAY UNIT
3-56
2.4.5 MOMENT LIMITER FUNCTIONS
3-64
2.4.6 MOMENT LIMITER STARTING STATUS
3-66
2.4.7 MOMENT LIMITER WORKING ENVELOPE SETTING
3-66
2.4.8 PICK & CARRY/STAITIONARY MODE SELECT
3-67
2.4.9 MOMENT LIMITER EMERGENCY STOP CANCEL SWITCH
3-68
2.4.10 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO BE TAKEN
3-69
2.5 OVER HOIST DETECTOR
3-70
2.6 AIR CONDITIONER CONTROLS
3-71
2.6.1 AIR CONDITIONER CONTROL PANEL
3-71
2.6.2 AIR CONDITIONER OPERATION METHOD
3-75
2.6.3 USE AIR CONDITIONER WITH CARE
3-79
2.6.4 INSPECTION AND MAINTENANCE OF AIR CONDITIONER
3-79
2.7 RADIO
3-80
2.7.1 CONTROL PANEL
3-80
2.7.2 CONTROL OF RADIO
3-82
2.7.3 USE RADIO WITH CARE
3-84
2.8 FUSE
3-85
2.9 FUSIBLE LINK
3-86
2.10 CONTROLLERS
3-87
2.11 WINDSHIELD
3-88
2.12 SLIDING DOOR
3-92
2.13 EMERGENCY ESCAPE HAMMER
3-92
2.14 CAP WITH LOCK
3-93
2.15 ENGINE HOOD
3-94
2.16 CAB REAR COVER
3-94
2.17 PUMP ROOM DOOR
3-95
2.18 BATTERY ROOM DOOR
3-95
2.19 DOOR AT FRONT OF TOOL BOX
3-96
2.20 OPERATION MANUAL STORAGE
3-96
2.21 TOOL BOX
3-96
2.22 GREASE PUMP HOLDER
3-97
2.23 CUP HOLDER
3-97
2.24 ASHTRAY
3-97
2.25 WIND-IN TYPE SEAT BELT
3-98

0-3
ITEM
Page
3. MACHINE OPERATIONS AND CONTROLS
3-99
3.1 CHECKING BEFORE OPERATION
3-99
3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS)
3-99
3.1.2 CHECKING BEFORE STARTING ENGINE
3-102
3.1.3 CHECKING AFTER STARTING ENGINE
3-115
3.2 OPERATIONS BEFORE ENGINE STARTING
3-118
3.3 STARTING ENGINE
3-120
3.3.1 NORMAL STARTING ENGINE
3-120
3.3.2 STARTING ENGINE IN COLD WEATHER
3-122
3.4 OPERATIONS AFTER STARTING ENGINE
3-124
3.4.1 ENGINE WARM-UP
3-124
3.4.2 HYDRAULIC EQUIPMENT WARM-UP
3-126
3.4.3 OPERATION AFTER COMPLETION OF WARM-UP OPERATION
3-131
3.5 STOPPING ENGINE
3-132
3.6 BREAKING-IN MACHINE
3-133
3.7 MACHINE TRAVELING POSTURE
3-134
3.8 STARTING/MOVING/STOPPING MACHINE
3-135
3.9 STEERING MACHINE
3-138
3.10 SWINGING
3-140
3.11 PARKING MACHINE
3-141
3.12 MACHINE INSPECTION AFTER DAILY WORK
3-142
3.12.1 BEFORE STOPPING ENGINE
3-142
3.12.2 AFTER STOPPING ENGINE
3-142
3.12.3 LOCKING
3-142
3.13 CAUTIONS IN TRAVELING
3-143
3.14 WORKING MODE OPERATION
3-145
3.15 CAUTIONS BEFORE CRANE OPERATION
3-146
3.16 OPERATIONS BEFORE CRANE OPERATION
3-147
3.17 CRANE OPERATION POSTURE
3-149
3.18 HOOK RAISING/LOWERING OPERATION
3-150
3.18.1 NORMAL HOOK RAISING/LOWERING OPERATION
3-150
3.18.2 HIGH SPEED HOOK RAISING/LOWERING OPERATION
3-151
3.18.3 HOOK RAISING/LOWERING OPERATION BY OVER-HOISTING CANCEL
SWITCH
3-152
3.19 BOOM DERRICKING OPERATION
3-153
3.20 BOOM TELESCOPING OPERATION
3-154
3.21 SLEWING OPERATION
3-155
3.22 ACCELERATION OPERATION
3-156
3.23 STOWAGE OPERATION OF CRANE
3-157
3.23.1 CRANE OPERATION FOR TEMPORARY HOOK BLOCK STOWAGE
3-157
3.23.2 CRANE OPERATION FOR REGULAR HOOK BLOCK STOWAGE
3-160
3.24 DOS AND DON’TS DURING OPERATION
3-162
3.25 PICK & CARRY OPERATION
3-164
3.25.1 SAFETY RRECAUTIONS FOR PICK & CARRY OPERATION
3-164
3.25.2 POSTURE FOR PICK & CARRY OPERATION
3-165
3.25.3 PICK & CARRY OPERATION
3-166

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ITEM
Page
3.26 OPERATION OF PLADE
3-167
3.26.1 PRECAUTION OF BLADE OPERATION
3-167
3.26.2 OPERATION OF BLADE
3-168
3.26.3 WORKS WITH A BLADE
3-168
4. HANDLING WIRE ROPES
3-169
4.1 BENCH MARK FOR REPLACING WIRE ROPES
3-169
4.2 WINCH WIRE ROPE FALL MODE AND RATED TOTAL LOAD
3-170
4.3 What TO DO WITH TWISTED WINCH WIRE ROPE
3-171
5. TRANSPORTATION
3-172
5.1 LOADING/UNLOADING
3-172
5.1.1 LOADING
3-173
5.1.2 SECURING MACHINE
3-175
5.1.3 UNLOADING
3-176
5.2 LIFTING MACHINE
3-177
5.2.1 LIFTING UP THE MACHINE IN THE BOOM LOWERED POSTURE
3-177
5.2.2 LIFTING UP THE MACHINE IN THE BOOM RAISED POSTURE
3-179
5.3 TRANSPORTATION PROCEDURE
3-180
6. HANDLING IN COLD WEATHER
3-181
6.1 PREPARING FOR LOW TEMPERATURE
3-181
7. LONG-TERM STORAGE
3-183
7.1 BEFORE STORAGE MACHINE
3-183
7.2 DURING STORAGE
3-183
7.3 AFTER STORAGE
3-183
8. TROUBLES AND ACTIONS
3-184
8.1 RUNNING OUT FUEL
3-184
8.2 PHENOMENA THAT ARE NOT FAILURES
3-184
8.3 LIGHTWEIGHT TOWING HOOK
3-184
8.4 DISCHARGED BATTERY
3-185
8.4.1 CAUTIONS IN BATTERY HANDLING
3-185
8.4.2 BATTERY REMOVAL AND INSTALLATION
3-186
8.4.3 CAUTIONS IN BATTERY CHARGING
3-187
8.4.4 STARTING ENGINE WITH BOOSTER CABLE
3-188
8.5 OTHER TROUBLE
3-190
8.5.1 ELECTRICAL SYSTEM
3-190
8.5.2 CHASSIS
3-191
8.5.3 ENGINE
3-192
8.5.4 ELECTRONIC CONTROL SYSTEM
3-194
8.5.5 MOMENT LIMITER
3-195
8.5.6 OVER HOIST DETECTOR
3-195
INSPECTION AND MAINTENANCE
4- 1
1. PRECAUTIONS FOR MAINTENANCE
4- 2
2. BASIC MAINTENANCE
4- 4
3. LEGAL INSPECTION
4- 7
4. SAFETY CRITICAL PARTS
4- 8
5. CONSUMABLES
4- 9

0-5
ITEM
Page
6. OTHER COMPONENTS
4-10
7. RECOMMENDED FUEL, COOLANT AND LUBRICANT
4-11
7.1 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURES
4-11
8. TIGHTENING TORQUE SPECIFICATIONS
4-13
8.1 STANDARD TIGHTENING TORQUE LIST
4-13
9. INSPECTION AND MAINTENANCE LIST
4-14
10. MAINTENANCE PROCEDURES
4-16
10.1 CHECKING BEFORE OPERATION
4-16
10.2 IRREGULAR MAINTENANCE
4-17
10.3 MAINTENANCE EVERY 50 HOURS
4-35
10.4 MAINTENANCE EVERY 100 HOURS
4-37
10.5 MAINTENANCE EVERY 250 HOURS
4-38
10.6 MAINTENANCE EVERY 500 HOURS
4-44
10.7 MAINTENANCE EVERY 1000 HOURS
4-53
10.8 MAINTENANCE EVERY 2000 HOURS
4-60
10.9 MAINTENANCE EVERY 4000 HOURS
4-63
10.10 MAINTENANCE EVERY 5000 HOURS
4-65
10.11 MAINTENANCE EVERY 8000 HOURS
4-66
11. BLEEDING AIR FROM HYDRAULIC SYSTEM
4-67
12. METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT
4-71
SPECIFICATIONS
5- 1
1. SPECIFICATION LIST
5- 2
2. SPECIFICATION DIMENSIONAL DRAWING
5- 4
3. RATED TOTAL LOAD CHART
5- 5
4. WORKING RADIUS AND LIFTING HEIGHT
5- 8
FLY-JIB
6- 1
1. PRECAUTIONS OF FLY-JIB OPERATION
6- 2
2. SAFETY LABEL LOCATION
6- 4
3. WORKING RANGE CHART
6- 7
4. RATED TOTAL LOAD CHART
6- 8
5. FLY-JIB EACH SECTION
6- 9
6. FLY-JIB INSTALLATION AND STOWAGE
6-10
6.1 INSTALLATION OF FLY-JIB
6-11
6.2 CHANGING OF FLY-JIB TILT ANGLE
6-20
6.2.1 CHNAGING OF FLY-JIB TILT ANGLE
6-20
6.2.2 CHANGING OF FLY-JIB TILT ANGLE TO STOWAGE POSITION
6-22
6.3 EXTENDING AND RETRACTING NO.2 FLY-JIB
6-23
6.3.1 EXTENDING NO.2 FLY-JIB CONFIGURED 0 DEGRESS OR 20 DEGEREES
TILT ANGLE
6-23
6.3.2 EXTENDING NO.2 FLY-JIB CONFIGURED 40 DEGRESS OR 60 DEGEREES
TILT ANGLE
6-24
6.3.3 RETRACTING OF No.2 FLY-JIB
6-26
6.4 STOWAGE OF FLY-JIB
6-27
7. HANDLING MOMENT LIMITER
6-33
7.1 MOMENT LIMITER DISPLAY
6-33
7.2 MOMENT LIMITER FUNCTIONS
6-35

0-6
ITEM
Page
7.3 SETTING OF OPERATING CONDITIONS
6-37
8. OPERATIONS
6-38
8.1 CAUTIONS FOR FLY-JIB OPERATION
6-38
9. INSPECTION AND MAINTENANCE
6-39
9.1 CHECKING BEFORE OPERATION
6-39
9.2 MAITENANCE EVERY 50 HOURS
6-41
10. SPECIFICATIONS
6-42
11. DIMENSIONS
6-42

1-1
INTRODUCTION
1. INTRODUCTION
1- 2
2. FOR SAFE USE OF MACHINE
1- 3
3. MACHINE OVERVIEW
1- 4
4. QUALIFICATION FOR OPERATION
1- 6
5. TERMINOLOGY
1- 7

1-2
1. INTRODUCTION
Thank you for purchasing our Crawler Crane “LC1385M-8B”.
This manual is a guidebook for safe and effective use of this machine.
This manual describes the proceduresfor proper operation and maintenance of the machine.
Warnings and precautions defined in this manual shall be observed for safety.
Many of the accidentsare caused by the operation, inspection, or maintenance that does not
observe the basic precautions.
Be sure to read this manual and understand the procedures for machine operation,
inspection, and maintenance thoroughly before performing operation of this machine.
Failure to observe the basic precautions defined in this manual may lead to hazardous
accidents.
Failure to use this machine properly can lead to serious personal injury or death.
Operators and maintenance personnel must always read this manual prior to
operation or maintenance of this machine.
Save this manual at a designated place for reference when necessary. All personnel
who work on this machine are to carry out periodic reference.
•Only those who have thorough understanding of the fundamental procedures
provided in this manual are qualified to perform machine operation.
•Keep this manual handy for reference when necessary.
•Should you lose or damage this manual, contact Maeda or our sales service
agency immediately for ordering a new manual.
•This manual should always accompany this machine upon transfer of the machine
to the next owner. However, when the machine is sold to a third party without any
prior advice to us, we are not liable for any warranty.
•This manual has adopted data that was available at the time of the creation of the
manual.
The contents of this manual, including maintenance specifications, tightening
torque, pressure, measuring method, adjustment value, and illustrations, are
subject to change upon unremitting refinement of the machine, without notice.
Machine maintenance may be susceptible to revisions. Always obtain the latest
information from Maeda or our sales service agency before performing
maintenance of this machine.
For safety instructions, see “2. For Safe Use of Machine” on page 1-3 and “Safety”
on page 2-1.
[Storage location for the Operation and Maintenance Manual]
Magazine box at rear of cab

1-3
2. FOR SAFE USE OF MACHINE
This manual classifies the risks into the following three categories to present the details of the safety
labels in easy-to-understand manner.
This denotes that there is an imminent hazard which will cause serious
personal injury or death.
The method of hazard circumvention is stated.
This denotes that there is a hazard which can cause serious personal injury
or death.
The method of hazard circumvention is stated.
This denotes that there is a potential hazard which may cause minor or
moderate personal injury or serious damage to this machine.
The method of hazard circumvention is stated.
This manual also provides the following to indicate what must be observed for the sake of the machine
and what will be of help.
This denotes that failure to handle the machine properly may damage the
machine or shorten its life.
This denotes helpful information.
Not only procedures for operation, inspection, and maintenance of this machine described in this manual
but also safety precautions should pertain to the case where this machineis only used forspecified tasks.
Every circumstance incidental to use of this machine is unforeseeable, and therefore, cautions given in
this manual and on this machine do not necessarily cover every safety-related issue.
Necessary safety actions should be taken under your responsibility if operation, inspection, and
maintenance in a situation that is not described in this manual are performed.
Even in the above case, never attempt the works and operations this manual prohibits you to do.
CAUTION
NOTES

1-4
3. MACHINE OVERVIEW
3.1 SPECIFIED OPERATIONS
This machine is to be used for operation listed below.
•Crane operation
•Pick & Carry operation
This machine is a mobile crane which consists of a crawler type carrier and an upper structure of a boom
equipped crane.
This self-propelled crane is capable of moving (traveling) in the worksite and lifting an object weighing
within the rated total load.
3.2 MACHINE CONFIGURATION
(1) Undercarriage
(2) Upper structure
(3) Safety device
In this manual, the terms front, rear, left and right refer to the travel
direction as viewed from the operator’s seat when the operator’s seat
is facing the front and the sprocket (a) is at the rear of the machine.
Boom slewing motion is determined with the machine viewed from
immediately above; slew clockwise denotes right-handed motion and
slew counterclockwise denotes left-handed motion.
EXTERNAL VIEW

1-5
This machine is composed of the units listed below.
[1] UNDERCARRIAGE
This is composed of a traveling gear and blade.
[2] UPPER STRUCTURE (CRANE)
This is composed of an engine, traveling operation unit, crane operation unit, telescoping system, derrick
system, slewing system, hook block, and winch system.
[3] SAFETY DEVICE
This is composed of the following parts and devices: Over hoist detector/automatic stop device,
three-winding stop alarm/automatic 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 tip-over alarm device, level,
working status lamp, crane and traveling control lever lock.
3.3 MACHINE FUNCTIONS
[1] UNDERCARRIAGE
•The carrier equips crawlers which enables this machine to enter into rough or soft terrains.
•Two-traveling lever operation enables not only direction changes among forward, backward, and
right/left but pivot turn and spin turn.
[2] UPPER STRUCTURE (CRANE)
• The upper structure allows continual 360 degree rotation.
• Thanks to extending/retracting, derricking up or down and/or swing operations of the boom, as well as
wind/un-wind operation of the winch, you can move the hoisted load to the designated location, subject
to the staying within the rated total road and working radius.

1-6
4. QUALIFICATION FOR OPERATION
•A high incidence of occupational accidents in crane operation has been reported.
Be aware that experienced engineers are also no exception.
•Warnings and precautions defined in this manual shall be observed for safety assurance
during operation of the machine.
4.1 QUALIFICATION FOR CRANE OPERATION
Only personnel that have obtained the required license or training stipulated by laws and regulations
applicable to the place of use are qualified to operate this machine.
Contact the relevant government office or our sales service agency for further information.

1-7
5. TERMINOLOGY
5.1 DEFINITIONS OF TERMS
[1] RATED TOTAL LOAD
This is the maximum load that can be applied according to a
boom length and angle. The load includes the mass (weight)
of hoisting accessories (hooks) and slinging ropes.
[2] RATED LOAD
This is a load derived by subtracting the mass (weight) of
hoisting accessories (hooks) and slinging ropes from the rated
total load, which is a withstand load for hoisting.
[3] WORKING RADIUS
This is a horizontal distance between the axis of slewing and
the hook center.
[4] BOOM LENGTH
This is a distance between the boom primary pin and the
sheave pin of the end boom.
[5] BOOM ANGLE
This is an angle which the boom forms with the horizon.
[6] LIFTING HEIGHT ABOVE GROUND
This is a vertical distance between the hook bottom and the
ground with the hook raised to the upper limit.

1-8
5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT
•The diagram of working radius and lifting height shows the relationships the working radius of
this machine, boom angle, and lifting height above the ground with no object hoisted. The
diagram has been made allowing for no deflection in the boom.
•The boom (4) in the diagram of working radius and lifting height represents a state that half of
the “
mark”passes boom (3).
1. Point A denotes a boom angle and point B denotes a lifting
height above ground in the figure at right.
The same working radius is applied to points A and B.
2. The “diagram of working radius and lifting height” shows the
relationships the working radius, boom angle, and lifting
height at no load, allowing for no deflection in the boom.
A deflection occurs in the boom when an object is hoisted,
which causes the working radius to increase slightly.
The rated total load decreases with an increase in the
working radius.Actual crane operation requires the planning
of work, allowing for sufficient tolerance of more than that
shown in the diagram.

1-9
5.3 RATED TOTAL LOAD CHART
•All the values provided in the rated total load chart are based on the assumption that the
machine is placed on a level and firm surface.
•The values in the rated total load chart are determined based on the working radius allowing
for deflection that is developed when load is applied to the boom.
•When extending boom (3) even if only slightly, crane operation should proceed to the extent of
performance of “Boom (3)”.
•When extending boom (4) even if only slightly, crane operation should proceed to the extent of
performance of “Boom (4)”.
•When half of the “
mark” passes boom (3), crane operation should proceed to the extent of
performance of “Boom (5)”.
•If the working radius exceeds that stated in the table even if only slightly, crane operation
should proceed with respect to the rated total load corresponding to the working radius in the
following table.
•The rated total load is a load including the mass of a hoisting accessory (hook: 90kg).

1-10
The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in
parallel with the length of the boom. The loads are specified by working radius.
[1] BOOM LENGTH
The following figures illustrate the condition of the booms, “(1) 4.745m Boom”, “(2) 7.625m Boom”, “(3)
10.505m Boom”, “(4) 13.385m Boom”, and “(5) 16.265m Boom”in the preceding boxes in the rated total
load chart.
1. “(1) 4.745m Boom”: All the booms are retracted.
2. “(2) 7.625m Boom”: With booms (3), (4), and (5) retracted, boom (2) is fully extended.
Boom (2) is to apply to crane operation with boom (2) extended even if only slightly.
3. “(3) 10.505m Boom”: With booms (4) and (5) retracted, booms (2) and (3) are fully extended.
Boom (3) is to apply to crane operation with boom (3) extended even if only slightly.

1-11
4. “(4) 13.385m Boom”: With booms (2) and (3) fully extended, booms (4) and (5) are extended midway
(half of the “
mark” passes boom (3)).
Boom (4) is to apply to crane operation with booms (4) and (5) extended even if only slightly.
5. “(5) 16.265m Boom”: All the booms are fully extended.
Boom (5) is to apply to crane operation with half of the “
mark” on boom (4) passes boom (3).

1-12