Maeda LC785M-8B User manual

557E-OM1202-00
OPERATION MANUAL
CRAWLER CRANE
Serial No. 32024 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
personnel who will come into contact with it.
NOTICE
MAEDA has Operation Manuals written in some other languages. If a
foreign language manual is necessary, contact your local distributor for
availability.

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 CHART 1 – 9
6. NECESSARY INFORMATION FOR SERVICE 1 – 12
SAFETY 2 – 1
1. BASIC PRECAUTIONS 2 – 2
1.1 PRECAUTIONS BEFORE STARTING OPERATION 2 – 2
1.2 PREPARATIONS 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 JOB SITE 2 – 8
2.2 PRECAUTIONS WHEN STARTING ENGINE 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 – 24
4. TOWING PRECAUTIONS 2 – 25
5. MAINTENANCE PRECAUTIONS 2 – 26
5.1 PRECAUTIONS BEFORE MAINTENANCE 2 – 26
5.2 PRECAUTIONS DURING MAINTENANCE 2 – 29
6. SAFETY LABEL LOCATIONS 2 – 33
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 MOMENT LIMITER RELATED SWITCH BOX 3 – 5

ITEM Page
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 – 10
2.1.3 CAUTION ITEMS 3 – 12
2.1.4 BASIC CHECK ITEMS 3 – 14
2.1.5 METER DISPLAY PORTION 3 – 15
2.1.6 MONITOR SWITCHES PORTION 3 – 21
2.1.7 HANDLING FUNCTION SWITCHES 3 – 27
2.2 SWITCHES 3 – 40
2.3 CONTROL LEVERS AND PEDALS 3 – 49
2.4 MOMENT LIMITER(OVERLOAD DETECTOR) 3 – 53
2.4 1 MOMENT LIMITER CONFIGURATION 3 – 53
2.4.2 FUNCTION MOMENT LIMITER 3 – 54
2.4.3 MOMENT LIMITER OPERATIONS 3 – 56
2.4.4 NAMES OF MOMENT LIMITER DISPLAY UNIT 3 – 58
2.4.5 MOMENT LIMITER FUNCTIONS 3 – 67
2.4.6 MOMENT LIMITER STARTING STATUS 3 – 71
2.4.7 MOMENT LIMITER WORKING ENVELOPE SETTING 3 – 71
2.4.8 PICK & CARRY / STAITIONARY MODE SELECT 3 – 72
2.4.9 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO TAKEN 3 – 73
2.5 OVER HOIST DETECTOR 3 – 74
2.6 AIR CONDITIONER CONTROLS 3 – 75
2.6.1 AIR CONDITIONER CONTROL PANEL 3 – 75
2.6.2 AIR CONDITIONER OPERATION METHOD 3 – 79
2.6.3 USE AIR CONDITIONER WITH CARE 3 – 85
2.6.4 INSPECTION AND MAINTENANCE OF AIR CONDITIONER 3 – 85
2.7 RADIO 3 – 86
2.7.1 CONTROL PANEL 3 – 86
2.7.2 CONTROL OF RADIO 3 – 88
2.7.3 USE RADIO WITH CARE 3 – 90
2.8 FUSE 3 – 91
2.9 FUSIBLE LINK 3 – 92
2.10 POWER OUTLET 3 – 93
2.11 CONTROLLERS 3 – 94
2.12 WINDSHIELD 3 – 95
2.13 SLIDING DOOR 3 – 100
2.14 EMERGENCY ESCAPE HAMMER 3 – 100
2.15 CAP WITH LOCK 3 – 101
2.16 ENGINE HOOD 3 – 103
2.17 MAINTENANCE DOOR ON REAR RIGHT 3 – 104
2.18 MAINTENANCE DOOR ON REAR LEFT 3 – 104
2.19 BATTERY INSPECTION COVER 3 – 105

ITEM Page
2.20 OPERATION MANUAL STORAGE 3 – 106
2.21 CUP HOLDER 3 – 106
2.22 GREASE PUMP HOLDER 3 – 106
2.23 ASHTRAY 3 – 106
2.24 WIND-IN TYPE SEAT BELT 3 – 107
3. MACHINE OPERATIONS AND CONTROLS 3 – 108
3.1 CHECKING BEFORE OPERATION 3 – 108
3.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) 3 – 108
3.1.2 CHECKING BEFORE STARTING ENGINE 3 – 111
3.1.3 OPERATIONS BEFORE STARTING ENGINE 3 – 123
3.1.4 CHECKING AFTER STARTING ENGINE 3 – 125
3.2 STARTING ENGINE 3 – 128
3.2.1 NORMAL STARTING ENGINE 3 – 128
3.2.2 STARTING ENGINE IN COLD WEATHER 3 – 130
3.3 OPERATIONS AFTER STARTING ENGINE 3 – 133
3.3.1 ENGINE WARM-UP 3 – 134
3.3.2 HYDRAULIC EQUIPMENT WARM-UP 3 – 135
3.3.3 OPERATION AFTER COMPLETION OF WARM-UP OPERATION 3 – 141
3.4 STOPPING ENGINE 3 – 142
3.5 BREAKING-IN MACHINE 3 – 143
3.6 MACHINE TRAVELLING POSTURE 3 – 144
3.7 STARTING / MOVING / STOPPING MACHINE 3 – 145
3.8 STEERING MACHINE 3 – 149
3.9 SLEWING 3 – 151
3.10 WORKING MODE OPERATION 3 – 152
3.11 CAUTIONS BEFORE CRANE OPERATION 3 – 153
3.12 OPERATIONS BEFORE OPERATING THE CRANE 3 – 155
3.13 CRANE OPERATION POSTURE 3 – 157
3.14 HOOK RAISING / LOWERING OPERATION 3 – 158
3.14.1 NORMAL HOOK RAISING / LOWERING OPERATION 3 – 158
3.14.2 HIGH SPEED HOOK RAISING / LOWERING OPERATION 3 – 159
3.14.3 HOOK RAISING OPERATION BY HOOK STOWAGE SWITCH 3 – 160
3.15 BOOM DERRICKING OPERATION 3 – 161
3.16 BOOM TELESCOPING OPERATION 3 – 162
3.17 SLEWING OPERATION 3 – 163
3.18 ACCELERATION OPERATION 3 – 164
3.19 STOWAGE OPERATION OF CRANE 3 – 165
3.19.1 CRANE OPERATION FOR TEMPORARY HOOK BLOCK STOWAGE 3 – 165
3.19.2 CRANE OPERATION FOR REGULAR HOOK BLOCK STOWAGE 3 – 168
3.20 DO’S AND DON’TS DURING OPERATION 3 – 171
3.21 PICK & CARRY OPERATION 3 – 174
3.21.1 SAFETY PRECAUTIONS FOR PICK & CARRY OPERATION 3 – 174
3.21.2 POSTURE FOR PICK & CARRY OPERATION 3 – 175

ITEM Page
3.21.3 OPERATIONS DURING PICK & CARRY OPERATION 3 – 176
3.21.4 RELEASING PICK & CARRY OPERATION POSTURE 3 – 176
3.22 OPERATION OF BLADE 3 – 177
3.22.1 PRECAUTION OF BLADE OPERATION 3 – 177
3.22.2 OPERATION OF BLADE 3 – 178
3.22.3 WORKING WITH A BLADE GROUND LEVELLING 3 – 178
3.23 PARKING MACHINE 3 – 179
3.24 MACHINE INSPECTION AFTER DAILY WORK 3 – 180
3.24.1 BEFORE STOPPING ENGINE 3 – 180
3.24.2 AFTER STOPPING ENGINE 3 – 180
3.24.3 LOCKING 3 – 180
3.25 CAUTIONS IN TRAVELLING 3 – 181
4. HANDLING WIRE CABLES 3 – 184
4.1 BENCHMARK FOR REPLACING WIRE CABLES 3 – 184
4.2 WINCH WIRE ROPE FALL MODE AND RATED TOTAL LOAD 3 – 186
4.3 WHAT TO DO WITH TWISTED WINCH WIRE ROPE 3 – 187
5. TRANSPORTATION 3 – 190
5.1 LOADING / UNLOADING 3 – 191
5.1.1 LOADING 3 – 192
5.1.2 SECURING MACHINE 3 – 194
5.1.3 UNLOADING 3 – 195
5.2 LIFTING MACHINE 3 – 196
5.2.1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE 3 – 196
5.2.2 LIFTING UP THE MACHINE IN THE BOOM RAISED POSTURE 3 – 198
5.3 TRANSPORTATION PROCEDURE 3 – 199
6. HANDLING IN COLD WEATHER 3 – 200
6.1 PREPARING FOR LOW TEMPERATURE 3 – 200
7. LONG TERM STORAGE 3 – 202
7.1 BEFORE STORAGE MACHINE 3 – 202
7.2 DURING STORAGE 3 – 202
7.3 AFTER STORAGE 3 – 202
8. TROUBLES AND ACTIONS 3 – 203
8.1 RUNNING OUT FUEL 3 – 203
8.2 PHENOMENA THAT ARE NOT FAILURES 3 – 203
8.3 METHOD FOR TOWING 3 – 204
8.4 DISCHARGED BATTERY 3 – 205
8.4.1 CAUTIONS IN BATTERY HANDLING 3 – 205
8.4.2 BATTERY REMOVAL AND INSTALLATION 3 – 206
8.4.3 CAUTIONS IN BATTERY CHARGING 3 – 207
8.4.4 STARTING ENGINE WITH BOOSTER CABLE 3 – 208
8.5 OTHER TROUBLE 3 – 210
8.5.1 ELECTRICAL SYSTEM 3 – 210
8.5.2 CHASSIS 3 – 211
8.5.3 ENGINE 3 – 212

ITEM Page
8.5.4 ELECTRONIC CONTROL SYSTEM 3 – 214
8.5.5 MOMENT LIMITER 3 – 215
8.5.6 OVER HOIST DETECTOR 3 – 216
INSPECTION AND MAINTENANCE 4 – 1
1. PRECAUTIONS REGARDING MAINTENANCE 4 – 2
2. BASIC MAINTENANCE 4 – 4
3. LEGAL INSPECTION 4 – 7
4. SAFETY CRITICAL PARTS 4 – 8
5. CONSUMABLES 4 – 9
6. OTHER COMPONENTS 4 – 10
7. USE OF 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 – 17
10.1 INITIAL 500-HOUR MAINTENANCE
(ONLY FOR FIRST TIME MAINTENANCE OF A NEW MACHINE) 4 – 17
10.2 CHECKING BEFORE OPERATION 4 – 17
10.3 IRREGULAR MAINTENANCE 4 – 18
10.4 MAINTENANCE EVERY 50 HOURS 4 – 42
10.5 MAINTENANCE EVERY 100 HOURS 4 – 44
10.6 MAINTENANCE EVERY 250 HOURS 4 – 46
10.7 MAINTENANCE EVERY 500 HOURS 4 – 51
10.8 MAINTENANCE EVERY 1000 HOURS 4 – 60
10.9 MAINTENANCE EVERY 2000 HOURS 4 – 71
10.10 MAINTENANCE EVERY 4000 HOURS 4 – 72
10.11 MAINTENANCE EVERY 5000 HOURS 4 – 73
11. BLEEDING AIR FROM HYDRAULIC SYSTEM 4 – 76
12. METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT 4 – 80
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
2.1 SAFETY LABEL LOCATION AT FLY-JIB 6 – 4
3. WORKING RANGE CHART 6 – 5
4. TOTAL RATED LOAD CHART 6 – 6
5. FLY-JIB EACH SECTION 6 – 7

ITEM Page
6. FLY-JIB INSTALLATION AND STOWAGE 6 – 8
6.1 FLY-JIB INSTALLATION 6 – 9
6.2 EXTENDING NO.2 FLY-JIB 6 – 15
6.3 RETRACTIMG NO.2 FLY-JIB 6 – 15
6.4 FLY-JIB STOWAGE 6 – 16
7. HANDLING MOMENT LIMITER 6 – 20
7.1 MOMENT LIMITER DISPLAY 6 – 20
7.2 PRIOR TO USE MOMENT LIMITER, SAFETY PRECAUTIONS 6 – 22
7.3 MOMENT LIMITER FUNCTIONS 6 – 23
7.3.1 FLY-JIB MODE SWITCH DISPLAY 6 – 23
7.4 SETTING OF OPERATING CONDITIONS 6 – 24
7.4.1 FLY-JIB MODE SWITCH (FLY-JIB OPERATION) 6 – 24
8. OPERATIONS 6 – 25
9. TRANSPORTATIONS 6 – 25
10. INSPECTION AND MAINTENANCE 6 – 26
10.1 MAINTENANCE EVERY 50 HOURS 6 – 26
11. SPECIFICATIONS 6 – 27
11.1 SPECIFICATIONS 6 – 27
11.2 DIMENSIONS 6 – 27

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
6. NECESSARY INFORMATION FOR SERVICE 1 – 12
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1. INTRODUCTION
Thank you for purchasing our Crawler Crane “LC785M-8”.
This manual is a guidebook for safe and effective use of this machine.
This manual describes the procedures for proper operation and maintenance of the machine. Warnings
and precautions defined in this manual shall be observed for safety.
Many of the accidents are caused by failure to observe the basic precautions for operation, inspection
and maintenance.
Be sure to read this manual and understand the procedures for machine operation, inspection, and
maintenance thoroughly before performing any 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.
Keep this manual at a designated place for reference when necessary. All personnel who work
with this machine are to carry out periodic reference to the manual.
•Only those who have a thorough understanding of the fundamental procedures provided in
this manual are allowed to operate this machine.
•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
without notice.
Machine maintenance may be subject 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]
In magazine box on the left side in cab.
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