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Maeda LC1385M-8B, Service Manual, Page: 1 / 431

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Maeda LC1385M-8B Service Manual Download Page 1

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

Summary of Contents for LC1385M-8B

Page 1: ...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...

Page 2: ...UNTING 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...

Page 3: ...VE 2 107 5 10WINCH 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 1...

Page 4: ...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...

Page 5: ...ALIBRATION 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 B...

Page 6: ...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 ADJUST...

Page 7: ...5 13 REMOVAL AND INSTALLATION OF ENGINE ANDWORK 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...

Page 8: ...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...

Page 9: ...0 8...

Page 10: ...E SPECIFICATION LIST 1 3 3 EACH UNITWEIGHT 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 JIBWORKING RADIUS AND LIFTING HEIGH...

Page 11: ...1 2 1 SPECIFICATION DIMENSIONAL DRAWING...

Page 12: ...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 displacem...

Page 13: ...bly 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 Trip...

Page 14: ...or 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...

Page 15: ...1 6 5 WORKING RADIUS AND LIFTING HEIGHT...

Page 16: ...640 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 156...

Page 17: ...0 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...

Page 18: ...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 14...

Page 19: ...oaded Boom Angle degree Fly jib Tilt Angle 0and 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 deg...

Page 20: ...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...

Page 21: ...ke 95mm X 115mm Displacement 3 26 liters 3260cc Rated Horsepower t ISO 9249 SAE J1349 68 4kW 2200min 1 91 7HP 2200rpm 72 1kW 2200min 1 96 6HP 2200rpm Max Torque 1 1 High Idling Speed 2 300 min 1 Low I...

Page 22: ...2 3 1 2 ENGINE MOUNTING...

Page 23: ...2 4 1 3 PTO Power Take Off...

Page 24: ...2 5...

Page 25: ...2 6 1 4 COOLING SYSTEM...

Page 26: ...2 7...

Page 27: ...2 8 2 POWER TRAIN 2 1 POWER TRAIN DRAWING...

Page 28: ...2 9 2 2 SWING CIRCLE...

Page 29: ...2 10 2 3 SWING MACHINERY...

Page 30: ...2 11...

Page 31: ...2 12 3 UNDERCARRIAGE AND FRAME 3 1 TRACK FRAME...

Page 32: ...2 13 3 2 IDLER CUSHION...

Page 33: ...2 14 3 3 IDLER...

Page 34: ...2 15 3 4 TRACK ROLLER...

Page 35: ...2 16 3 5 CARRIER ROLLER...

Page 36: ...2 17 3 6 SPROCKET...

Page 37: ...2 18 3 7 TRACK SHOE...

Page 38: ...2 19...

Page 39: ...2 20...

Page 40: ...2 21 3 7 1 TRIPLE GROUSER SHOE...

Page 41: ...2 22 3 7 2 SINGLE GROUSER SHOE...

Page 42: ...2 23 4 HYDRAULIC CERCUIT DIAGRAM Note A version of this hydraulic circuit diagram enlarged toA2 sizeispreparedasanappendix Refer to theseparateA2sizecircuit diagram for details...

Page 43: ...2 24...

Page 44: ...2 25...

Page 45: ...2 26 5 HYDRAULIC SYSTEM 5 1 HYDRAULIC EQUIPMENT LAYOUT DRAWING...

Page 46: ...tor 7 Right Travelling Motor 8 Left Crane PPC Valve 9 Right Crane PPC Valve 10 Swing Motor 11 Winch Motor 12 Winch Brake Release Valve 13 6 section Solenoid Valve 14 Solenoid Valve Assy 15 Accumulator...

Page 47: ...2 28 5 2 HYDRAULIC TANK AND FILTER...

Page 48: ...2 29...

Page 49: ...2 30 5 3 HYDRAULIC OIL PUMP...

Page 50: ...2 31...

Page 51: ...2 32...

Page 52: ...2 33...

Page 53: ...2 34...

Page 54: ...2 35...

Page 55: ...2 36 5 3 1 LS VALVE...

Page 56: ...2 37...

Page 57: ...2 38...

Page 58: ...2 39...

Page 59: ...2 40...

Page 60: ...2 41 5 3 2 PC VALVE...

Page 61: ...2 42...

Page 62: ...2 43...

Page 63: ...2 44...

Page 64: ...2 45...

Page 65: ...2 46...

Page 66: ...2 47...

Page 67: ...2 48...

Page 68: ...2 49...

Page 69: ...2 50...

Page 70: ...2 51 5 3 3 PC EPC VALVE...

Page 71: ...2 52...

Page 72: ...2 53...

Page 73: ...2 54 5 3 4 CHECK VALVE...

Page 74: ...2 55 5 3 5 SHUTTLE VALVE...

Page 75: ...2 56 5 4 CONTROL VALVE...

Page 76: ...C valve PA4 From right travelling forward PPC valve PA5 from hook raising PPC valve PA6 from boom extending PPC valve PA7 from boom raising PPC valve PA8 from service PPC valve PB1 From swing clockwis...

Page 77: ...2 58...

Page 78: ...ng Free length x Outside diameter Installed length Installed load Free length Installed load 46 8 x 7 5 40 6 5 49 N 0 56 kg 4 41 N 0 45 kg 26 Piston return spring 72 7 x 20 6 42 5 135 N 13 8 kg 108 N...

Page 79: ...2 60...

Page 80: ...ing 10 Pressure compensation valve F Blade 11 Pressure compensation valve F Left travelling 12 Pressure compensation valve F Right travelling 13 Merge divider valve spool 14 Pressure compensation valv...

Page 81: ...2 62...

Page 82: ...on valve Left travelling 12 Suction valve Left travelling 13 Spool Left travelling 14 Pressure compensation valve F Left travelling 15 LS check valve F Flow control valve R Reducing valve Unit mm No C...

Page 83: ...2 64...

Page 84: ...ressure compensation valve R Winch F Flow control valve R Reducing valve Unit mm No Check item Criteria Remedy 18 Spool return spring Standard size Repair limit If damaged or deformed replace spring F...

Page 85: ...2 66...

Page 86: ...pool Telescoping 5 Pressure compensation valve R Telescoping 6 Pressure compensation valve F Derricking 7 Suction valve Derricking 8 Suction valve Derricking 9 Spool Derricking 10 Pressure compensatio...

Page 87: ...2 68 5 5 CLSS 5 5 1 OUTLINE OF CLSS...

Page 88: ...2 69...

Page 89: ...2 70...

Page 90: ...2 71...

Page 91: ...2 72 5 6 FUNCTIONS AND OPERATION BY VALVE 5 6 1 HYDRAULIC CIRCUIT DIAGRAM AND THE NAME OF VALVES...

Page 92: ...icking spool 15 Pressure compensation valve 16 Suction valve 17 Pump merge divider valve 18 Self pressure reducing valve 19 Travelling junction solenoid valve 20 Lift check valve 21 Cooler bypass valv...

Page 93: ...2 74 5 6 2 UNLOAD VALVE...

Page 94: ...2 75...

Page 95: ...2 76...

Page 96: ...2 77...

Page 97: ...2 78...

Page 98: ...2 79...

Page 99: ...2 80 5 6 3 MERGE DIVIDER VALVE...

Page 100: ...2 81...

Page 101: ...2 82 5 6 4 INTRODUCTION OF LS PRESSURE...

Page 102: ...2 83...

Page 103: ...2 84 5 6 5 LS BYPASS VALVE...

Page 104: ...2 85...

Page 105: ...2 86 5 6 6 PRESSURE COMPENSATION VALVE...

Page 106: ...2 87...

Page 107: ...2 88 5 6 7 AREA RATIO OF PRESSURE COMPENSATION VALVE...

Page 108: ...2 89 5 6 8 SWING BLEEDING VALVE...

Page 109: ...2 90 5 6 9 TRAVELLING JUNCTION VALVE...

Page 110: ...2 91 5 6 10 SELF PRESSURE REDUCING VALVE...

Page 111: ...P1 Left PPC valve Boom extending port Right PPC valveWinch lowering port P2 Left PPC valve Boom retracting port Right PPC valveWinch raising port P3 Left PPC valve Swing left port Right PPC valve Boo...

Page 112: ...2 93...

Page 113: ...2 94...

Page 114: ...2 95...

Page 115: ...2 96...

Page 116: ...2 97 5 7 2 TRAVELLING PPC VALVE...

Page 117: ...2 98...

Page 118: ...2 99...

Page 119: ...2 100...

Page 120: ...2 101...

Page 121: ...2 102 5 7 3 BLADE PPC VALVE...

Page 122: ...2 103...

Page 123: ...2 104 5 8 SOLENOID VALVE ASS Y...

Page 124: ...2 105...

Page 125: ...2 106...

Page 126: ...1 A5 From right crane PPC valve port P3 B1 To control valve port PB5 B2 To control valve port PA5 B3 To control valve port PA7 B4 To control valve port PA6 B5 To control valve port PB7 1 Solenoid valv...

Page 127: ...CH BRAKE RELEASE VALVE P From solenoid valve assembly A1 T To tank A To control valve port PA5 and 5 section solenoid valve port B2 B To control valve port PB5 and 5 section solenoid valve port B1 C T...

Page 128: ...port C is interconnected to the port T The port P is blocked off With this condition when a pressure pilot pressure occurs to the port A or B and the spool 4 is pressed down the blocked port P will in...

Page 129: ...2 110 5 11 PPC ACCUMULATOR...

Page 130: ...s interconnected to tank and then LS pressure becomes just about 0MPa This makes pump swash plate angle inclines to minimum direction and discharge flow amount decreases Refer to the hydraulic pump se...

Page 131: ...2 112 5 13 TELESCOPING CYLINDER 5 13 1 TELESCOPING ASSEMBLY...

Page 132: ...Sheave Assembly 7 Hex Socket Head Bolt 8 SpringWasher 9 Support 10 SpringWasher 11 Bolt 12 Counter Balance Valve 13 Hex Socket Head Bolt 14 SpringWasher 15 Plate 16 Bolt 17 Support 18 Sheave Assembly...

Page 133: ...2 114 5 13 2 TELESCOPING CYLINDER...

Page 134: ...22 Rod Cover 23 Mechanical Check Valve Assembly For Retracting 24 Stopper 25 Pipe 26 No 2 Cylinder 27 No 2 Piston Rod 28 Plane Bearing 29 O ring 30 Piston 31 Set Screw 32 No 1 Piston Rod 33 No 1 Cylin...

Page 135: ...2 116 FUNCTION 1 After extending No 1 cylinder fully extend No 2 cylinder 2 After extending No 2 cylinder fully extend No 3 cylinder...

Page 136: ...2 117 3 After retracting No 3 cylinder fully Retract No 2 cylinder 4 After retracting No 2 cylinder fully retract No 1 cylinder...

Page 137: ...up Ring 3 Check Valve 4 O ring 5 Valve Seat 6 O ring 7 Spring 8 Plug 9 O ring 10 Plug 2 MECHANICAL CHECK VALVE FOR RETRACTING This check valve is No 23 of the telescoping cylinder 1 O ring 2 Spring 3...

Page 138: ...2 119 3 COUNTER BALANCE VALVE FOR TELESCOPING CYLINDER 1 Body 2 Spool 3 Plug 4 Back up Ring 5 Spring 6 O ring 7 Plug 8 Plug 9 Plug 10 Poppet 11 Spring 12 O ring 13 O ring...

Page 139: ...2 120 5 14 DERRICKING CYLINDER...

Page 140: ...Rod Packing 6 Back up Ring 7 Dust seal 8 O ring 9 Back up Ring 10 O ring 11 Piston 12 Piston Packing 13 Back up Ring 14 Wear Ring 15 O ring 16 Set Screw 17 Bushing 18 Bushing 19 Grease Nipple 20 Coun...

Page 141: ...D At Spool Stroked Check Valve Cracking Pressure 0 098 MPa 1 kgf cm 2 Operating Temperature Range 10 80 C TROUBLE SHOOTING Disorders Cause Counter action Derricking cylinder retract while boom raisin...

Page 142: ...ressure 24 5 MPa 250 kgf cm 2 Max Revolution 3 700 min 1 Max Flow Capacity 155 L min Changing Pressure of 2 speed range 1 96 to 6 86 MPa 20 to 70 kgf cm 2 Specifications of Conter Balance Valve Cracki...

Page 143: ...raulic pump flows through the counterbalance valve and rotates the hydraulic motor at high speed The reduction gear reduces the high speed rotation converts it to a low speed large torque and rotates...

Page 144: ...and reaches the valve 313 When pressure rises above 0 69MPa cracking pressure of the valve 313 the pressurized oil opens the valve 313 and enters the cylinder of the hydraulic motor through the port C...

Page 145: ...in the chamber b and the tension force of the springs 310 and 315 are balanced At the time the notch area is further increased and the oil comes to flow more and the lowering speed become faster The o...

Page 146: ...ized oil entered in one side of the cylinder block 204 pushes each piston to generate a force F MPa P MPa x A cm 2 This force is divided into component forces F2 and F3 because the cylinder block is f...

Page 147: ...he hydraulic motor comes to themaximum and the motor rotates at low speed 2 When High Speed pilot pressure is more than 1 96MPa When a pilot pressure more than 1 96MPa is supplied from the port P it e...

Page 148: ...5 nested in the cylinder block 204 of the hydraulic motor comes to move freely and the braking force to the cylinder block 204 of the hydraulic motor section is released and the hydraulic motor comes...

Page 149: ...h the hub 101 and makes orbital motion This orbital motion rotates the carrier 103 which supports rotation of the planetary gear 105 and the second sun gear 106 connected to the carrier This rotation...

Page 150: ...2 131 5 16 SWING MOTOR Type KMF45ABE 5...

Page 151: ...2 132...

Page 152: ...2 133...

Page 153: ...2 134 5 16 1 SWING HOLDING BRAKE...

Page 154: ...2 135 5 16 2 RELIEF VALVE PORTION...

Page 155: ...2 136 5 16 3 REVERSE PREVENTION VALVE...

Page 156: ...2 137...

Page 157: ...2 138...

Page 158: ...2 139...

Page 159: ...enoid valve F1 From control valve Blade lowering G1 From control valve Blade raising DR1 To hydraulic tank A2 To right travelling motor port A A2 To left travelling motor port A C2 To right travelling...

Page 160: ...2 141...

Page 161: ...rom center swivel joint port C2 Right travelling motor B From center swivel joint port D2 Left travelling motor B From center swivel joint port A2 Right travelling motor D To center swivel joint port...

Page 162: ...2 143...

Page 163: ...2 144...

Page 164: ...2 145...

Page 165: ...2 146...

Page 166: ...2 147 5 18 1 BRAKE VALVE...

Page 167: ...2 148...

Page 168: ...2 149 5 18 2 RELIEF VALVE...

Page 169: ...g Standard size Tolerance Standard clearance Clearance limit Shaft Hole 75 0 030 0 076 0 279 0 065 0 095 0 355 0 455 2 Clearance between piston rod support shaft and bushing 70 0 030 0 100 0 190 0 090...

Page 170: ...2 151...

Page 171: ...2 152 6 BOOM ASSEMBLY...

Page 172: ...2 153...

Page 173: ...Snap Ring 23 Roller 24 Pin 25 Snap Ring 26 Nut 27 Slide Plate 28 Shim 29 Shim 30 Tapping Screw 31 SpringWasher 32 Slide Plate 33 Slide Plate 34 Plate 35 Slide Plate 36 Flange Bolt 37 Support 38 Pin 4...

Page 174: ...2 155...

Page 175: ...linder 1 for telescoping the second boom and the telescoping cylinder 2 for telescoping the third boom and the mechanical check valves 4 and 5 for telescoping the third fourth and fifth booms subseque...

Page 176: ...2 157...

Page 177: ...2 158 7 FLY JIB OPTION...

Page 178: ...2 159...

Page 179: ...ameter 71 31W 13 Snap Seave Pin 77L 15 Sems Bolt 16 Slide Plate 17 Sems Bolt 18 Socket Head Set Screw 19 Nut 20 Stowing Support 21 Sems Bolt 22 Rubber Mount 23 Screw WithWasher 24 Linch Pin diameter 8...

Page 180: ...2 161 8 ELECTRIC CIRCUIT DIAGRAM 1 6 Note AversionofthiselectricalcircuitdiagramenlargedtoA2sizeispreparedasanappendix RefertotheseparateA2sizecircuitdiagramfordetails...

Page 181: ...2 162 8 ELECTRIC CIRCUIT DIAGRAM 2 6...

Page 182: ...2 163 8 ELECTRIC CIRCUIT DIAGRAM 3 6...

Page 183: ...2 164 8 ELECTRIC CIRCUIT DIAGRAM 4 6...

Page 184: ...2 165 8 ELECTRIC CIRCUIT DIAGRAM 5 6...

Page 185: ...2 166 8 ELECTRIC CIRCUIT DIAGRAM 6 6...

Page 186: ...2 167...

Page 187: ...2 168 9 AIR CONDITIONER 9 1 AIR CONDITIONER PIPING DIAGRAM...

Page 188: ...2 169...

Page 189: ...2 170...

Page 190: ...2 171...

Page 191: ...2 172 9 2 AIR CONDITIONER UNIT...

Page 192: ...2 173...

Page 193: ...2 174...

Page 194: ...2 175 9 3 AIR CONDITIONER CONTROLLER...

Page 195: ...2 176 9 4 COMPRESSOR...

Page 196: ...2 177 9 5 CONDENNSER...

Page 197: ...2 178 9 6 SENSOR...

Page 198: ...2 179...

Page 199: ...2 180 10 ELECTRICAL SYSTEM 10 1 ELECTRICAL CONTROL SYSTEM...

Page 200: ...2 181 10 ELECTRICAL SYSTEM 10 1 ELECTRICAL CONTROL SYSTEM...

Page 201: ...2 182 10 1 1 ELECTRICAL CONTROL FUNCTION...

Page 202: ...2 183...

Page 203: ...2 184 10 1 2 PUMP AND ENGINE MUTUAL CONTROL FUNCTION...

Page 204: ...2 185...

Page 205: ...2 186...

Page 206: ...2 187...

Page 207: ...2 188...

Page 208: ...2 189 10 1 3 AUTO DECELERATOR FUNCTION...

Page 209: ...2 190...

Page 210: ...2 191 10 1 4 ENGINE AUTOMATIC WARM UP FUNCTION...

Page 211: ...2 192...

Page 212: ...2 193 10 1 5 OVERHEAT PREVENTION FUNCTION See 10 1 4 Engine Automatic Warm Up Function for circuit diagram...

Page 213: ...2 194 10 1 6 OVERHEAT PREVENTION FUNCTION See 10 1 4 Engine Automatic Warm Up Function for circuit diagram...

Page 214: ...2 195 10 1 7 SWING CONTROL FUNCTION...

Page 215: ...2 196...

Page 216: ...2 197...

Page 217: ...2 198 10 1 8 TRAVEL CONTROL FUNCTION...

Page 218: ...2 199...

Page 219: ...2 200...

Page 220: ...2 201 10 1 9 PPC LOCK FUNCTION...

Page 221: ...2 202 10 1 10 SYSTEM COMPONENTS 1 ENGINE CONTROLLER...

Page 222: ...2 203...

Page 223: ...2 204 2 ENGINE CONTROLLER...

Page 224: ...2 205...

Page 225: ...2 206 3 FUEL CONTROL DIAL...

Page 226: ...2 207 4 RESISTOR...

Page 227: ...2 208 5 ENGINE OIL PRESSURE SWITCH...

Page 228: ...2 209 6 PPC OIL PRESSURE SWITCH...

Page 229: ...2 210...

Page 230: ...2 211 10 2 MONITOR SYSTEM...

Page 231: ...2 212 10 2 1 MACHINE MONITOR...

Page 232: ...2 213...

Page 233: ...2 214 10 2 2 DISPLAY...

Page 234: ...2 215...

Page 235: ...2 216...

Page 236: ...2 217...

Page 237: ...2 218 10 2 3 SWITCHES...

Page 238: ...2 219...

Page 239: ...2 220...

Page 240: ...2 221...

Page 241: ...2 222 10 2 4 OPERATION MODE FUNCTION...

Page 242: ...2 223...

Page 243: ...2 224 10 2 5 SERVICE MODE FUNCTION...

Page 244: ...2 225 10 3 KOMTRAX SYSTEM...

Page 245: ...2 226 10 3 1 KOMTRAX TERMINAL TH300...

Page 246: ...2 227 10 4 SENSOR...

Page 247: ...2 228...

Page 248: ...2 229...

Page 249: ...2 230...

Page 250: ...2 231...

Page 251: ...2 232...

Page 252: ...2 233 11 CRANE OPERATING DATA LOGGER 1 Recorder Assembly 2 USB Memory 3 Bolt WithWasher M6X25L Plating...

Page 253: ...2 234 11 1 CRANE OPERATING DATA LOGGER EXTERIOR VIEW...

Page 254: ...make sure to close the cap by rotating clockwise 2 Insert USB memory when emergency release When the access lamp turns off writing data is completed The written data will be saved as the file name Wit...

Page 255: ...value at the maximum load factor ON ON OFF Machine inclination angle 3 degrees or more to ON or OFF The receiving value at the maximum load factor ON ON OFF Blade contacting ground to ON or OFF The re...

Page 256: ...d push it in inside the case Then push the connector panel part until both sides of lock nails of the case will be locked completely 5 INITIALIZING THE RECORD DATA 1 Push in two nails of lock parts on...

Page 257: ...2 238 12 MOMENT LIMITER 12 1 MOMENT LIMITER RELATED 12 1 1 DISPLAY UNIT...

Page 258: ...ing 9 Hinge TH 145 10 Button bolt M5X10L plating 11 Display unit bracket 12 Moment limiter display unit 13 Screw With washer M4X8L plating 14 Connecting cable 15 Display unit cable bracket 1 16 Bolt w...

Page 259: ...2 240 12 1 2 CONTROLLER 1 Controller mounting bracket 2 Socket head bolt M8X20L plating 3 Spring washer M8 4 Hole plug CP 30 HP 8 5 Controller 6 Screw With washer M5X12L plating...

Page 260: ...2 Bolt With washer M10X20L plating 3 Boom length sensor 4 Bolt With washer M8X15L plating 5 Boom angle sensor 6 Boom angle sensor bracket 7 Bolt With washer M6X16L plating 8 Pressure sensor 9 Pressure...

Page 261: ...een connector 1 red and 3 black Between Connector 2 white and 3 black at boom angle 0 1 800 0 055V Between Connector 2 white and 3 black at boom angle 80 4 619 0 139V Resistance Between Connector 2 wh...

Page 262: ...Arm 5 Terminal block 6 O ring 7 Dumper oil 8 Wiring harness 9 Tie band 10 Potting 11 Element case 12 Terminal 13 Element 14 Print paper 15 Shaft 16 Bearing 17 Plane washer 18 Rotor mold 19 Rotor arm 2...

Page 263: ...mm Code Length Main Code 15 1 5m Sub Code 0 43 m Operating Temperature 30 to 80 degrees C Weight Above 5 kg Potentiometer Resistance value 5000 250 Electrical Rotating Angle 350 1 5 degrees Mechanica...

Page 264: ...rn spring 16 Cover 17 Clip 18 Clip 19 Clamp 20 Terminal 21 Terminal 22 Cable assembly 23 Cord guide 24 Packing 25 Packing 26 Packing 27 Terminal 28 Grommet 29 Socket head screw 30 Nut 31 Screw 32 Wash...

Page 265: ...5 MPa Power Supply Voltage DC 12V 10 Output Type DC 1 to 5 V 3 line Type Load Resistance 10 k or more Precision 1 0 Including linearity hysteresis and repeatability at 23 2 degrees Operating Temperat...

Page 266: ...2 247 12 1 4 BOOM DERRICKING POSITION DETECTOR 1 Boom upper limit switch 2 Boom lower limit switch Circuit Diagram...

Page 267: ...2 248 12 1 5 BLADE GROUNDING DETECTOR 1 Pressure sensor 2 Adapter Rc1 8 G3 8...

Page 268: ...5 MPa Power Supply Voltage DC 12V 10 Output Type DC 1 to 5 V 3 line Type Load Resistance 10 k or more Precision 1 0 Including linearity hysteresis and repeatability at 23 2 degrees Operating Temperat...

Page 269: ...2 250 12 1 6 FLY JIB POSITION DETECTOR...

Page 270: ...2 251...

Page 271: ...ew M6X6L plating 14 Fly jib harness A 15 Fly jib harness B 16 Washer M10 plating 17 Nut M10 plating 18 Limit switch assembly 19 Socket head bolt M5X6L 20 Spring washer M5 plating 21 Limit switch cover...

Page 272: ...r clip 6 Bolt With washer M10X16L plating 7 Protect weight 8 Shackle 9 Protective wire rope 10 Socket head bolt M6X20L plating 11 Nut M6 plating 12 Spring washer M6 plating 13 Plane washer M12 plating...

Page 273: ...ct of the over hoist detector switch opens and the signal thereof enters the moment limiter controller and causes the hook raising and boom extending operations to stop At the same time the lamp at th...

Page 274: ...2 255 12 1 8 OVER HOIST STOP SYSTEM FOR SINGLE HOOK Circuit Diagram...

Page 275: ...2 256 12 1 9 OVER HOIST STOP SYSTEM FOR FLY JIB SINGLE HOOK Circuit Diagram...

Page 276: ...2 257 12 1 10 OVER UN WINDING DETECTOR Circuit Diagram...

Page 277: ...xpression stored in the internal memory and displays the operated results The device also calculates rated operating radii operating radii and lifting heights from actual load boom length and boom ang...

Page 278: ...2 259 12 3 EXTERNAL VIEW OF MOMENT LIMITER DISPLAY UNIT CONTROLLER...

Page 279: ...2 260 12 4 CONTROLLER...

Page 280: ...e 1 fall Setting Switch is set to ON simultaneously with this switch this switch works as priority 6 4 fall Setting Switch When this switch is set to ON the setting changes to 4 fall and fixed If the...

Page 281: ...put 14 0V Input 2 INPUT OUTPUT 1 CONNECTOR CN2 Pin No Signal Pin No Signal 1 Over Hoist detector Input 15 Hook Raising Output 2 Inclination Sensor Input 16 Hook Raising COM 3 Over Un winding detector...

Page 282: ...age Output 2 16 Communication Input RX GND 4 SENSOR CONNECTOR CN4 Pin No Signal Pin No Signal 1 Pressure Sensor 1 12V 11 Angle Sensor GND 2 Pressure Sensor 1 Input 12 Angle Sensor Shield 3 Pressure Se...

Page 283: ...2 264 12 5 DISPLAYS...

Page 284: ...1 LED 5mm LED Orange LED lights when Fly jib is installed 14 Fly jib Length 2 LED 5mm LED Orange LED lights when No 2 Fly jib is extended 15 Stationary Mode Selection LED 5mm LED Orange Keep pushing...

Page 285: ...uted When Travelling signal input is ON however this switch is invalid 3 Boom Angle Upper Limit Switch Push the Boom Angle Upper Limit Switch to set or cancel the Boom Angle Upper Limit Push the Switc...

Page 286: ...ll indicate values of specific setting Each one push shall indicate Boom Angle Indicator shows Boom Angle Upper Limit Boom Angle Upper Limit LED flashes Boom Angle Indicator shows Boom Angle Lower Lim...

Page 287: ...ontrols as below shall be active when Boom Angle Lower Limit Boom Angle Lower Limit 5 Load Factor 10 Segments Bar LED Load Factor shall be indicated per 10 by 10 Segments Bar in accordance with actual...

Page 288: ...put OFF Over Un winding output OFF Boom Raising output OFF Boom Extending output OFF Boom Lowering output OFF 12 9 MOMENT LIMITER FUNCTIONS 1 2 Controls as belowshall be active when the Load Factor is...

Page 289: ...NG RADIUS INDICATOR Working Radius shall be displ Meter so converted and rounded off to one decimal place XX X 4 RATED RADIUS INDICATOR Rated Radius shall be Meter so converted and rounded off to one...

Page 290: ...Switch 5 Cancel Switch 6 Boom Angle Upper Limit Switch 7 Boom Angle Lower Limit Switch 8 Working Radius Upper Limit Switch 9 Lifting Height Upper Limit Switch Displays 10 Actual Load Display 11 Rated...

Page 291: ...boom length boom angle etc When carrying out calibration park the crane on the flat and stable ground Ignorance of this instruction may result in inaccurate calibration consequently generating inaccu...

Page 292: ...tor Switch 1 and Check switch 4 at the same time turn ON the power All LEDs light and the Rated Radius indicator shall turn to display CAL and Rated Load indicator to SEL and other indicators to 0 0 o...

Page 293: ...1 6 Calibration of Load in this condition Press the Pick Carry Stationary Mode Selector Switch 1 The Rated Load indicator displays to BOM After this every pressing the Pick Carry Stationary Mode Selec...

Page 294: ...The Rated Radius indicator shall turn to display ZER and the Boom Length indicator displayto Current Boom Length with flash 3 4 7 If the indicated value is misaligned adjust the figures in the Boom L...

Page 295: ...sing the above switch increments or decrements the indicated value continuously 3 When the Boom Length Indicator display the value to 16 3 press the Check Switch 4 The Rated Radius indicator shall tur...

Page 296: ...Switch 4 The Rated Radius indicator shall turn to display ZER and the Boom Angle indicator to Current Boom Angle with flash 3 Ensure that Boom Angle 0 0 If the indicated value ismisaligned adjust the...

Page 297: ...Concealed Switch 3 Increments the indicated value Keep pressing the above switch increments or decrements the indicated value continuously 3 When the Boom Angle Indicator display the value to Level in...

Page 298: ...t of Calibration Mode press the Check Switch 4 The Rated Radius indicator shall turn to display ZER and the Actual Load indicator to Current Actual Load with flash Actual Load Situations shall be cali...

Page 299: ...shows decimal place of 0 01 t Normally shown 0 1 t Fall Mode Selector Switch 2 Decrements the indicated value Concealed Switch 3 Increments the indicated value Keep pressing the above switch increment...

Page 300: ...witch 2 Decrements the indicated value Concealed Switch 3 Increments the indicated value Keep pressing the above switch increments or decrements the indicated value continuously 3 When the Actual Load...

Page 301: ...CALIBRATION MODE Indicator Calibration Items Rated Load Calibration Items Rated Radius Calibration Items Calibration Value Offset Length Span Length Offset Angle Span Angle Length and Angle at Load C...

Page 302: ...ch 5 Cancel Switch 6 Boom Angle Upper Limit Switch 7 Boom Angle Lower Limit Switch 8 Working Radius Upper Limit Switch 9 Lifting Height Upper Limit Switch Displays 10 Actual Load Display 11 Rated Tota...

Page 303: ...m lowering solenoid valve Confirmation of contact input state Confirmation of control output Confirmation of voice output Initialization of calibration and each working range limitation value 1 CALL O...

Page 304: ...id Valve in this condition 3 Press the Pick Carry Stationary Mode Selector Switch 1 The Rated Radius indicator shall turn to IN When carrying out confirmation of contact input state refer to 12 5 Conf...

Page 305: ...ibration and Initialization of each Working Range limitation value in this condition Press the Pick Carry Stationary Mode Selector Switch 1 The Rated Radius indicator shall turn to ROM After this ever...

Page 306: ...2 2 Call out of Function Mode press the Check Switch 4 The Working Radius indicator shall turn to display VER and the Rated Radius indicator displayto XXX XXX indicates a ROM version When exitingfrom...

Page 307: ...urrents are output from the Proportional Control Output for Boom Lowering Solenoid Valve Boomlowering Boom raising Boom extending Indication Output A Indication Output A Indication Output A D 0 0 0 U...

Page 308: ...4 5 6 7 8 9 A B C D E F Hook raising X O X O X O X O X O X O X O X O Hooklowering X X O O X X O O X X O O X X O O Slewingclockwise X X X X O O O O X X X X O O O O Slewingcounterclockwise X X X X X X X...

Page 309: ...inuously 3 Base on the indication each output operates as follows O Short circuit X Open Indication Low pressure Hook raising Hook lowering Prohibition operation Red lamp Green lamp Yellow lamp Spare...

Page 310: ...or to any of D 0 to D 7 and then press the Check Switch 4 Fall Mode Selector Switch 2 Decrements the indicated value Concealed Switch 3 Increments the indicated value Keep pressing the above switch in...

Page 311: ...by pressing Pick Carry StationaryMode Selector Switch 1 twice 2 3 Confirmation of ROM Version 1 After carrying out 12 2 Call out of Function Mode press the Check Switch 4 The Rated Radius indicator sh...

Page 312: ...es to continuous lighting and in several seconds it shall turn to display ROM When you see it the Initialization has been completed When canceling the Initialization press the Cancel Switch 5 The Rate...

Page 313: ...ngth detector is lower than the normal value Check the installation of the length detector E4H The input to length detector is higher than the normal value E5L The input to pressure sensor 5 is lower...

Page 314: ...3 1 STANDARD VALUE TABLE 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...

Page 315: ...320 to 360rpm MPa kg cm 2 Min 2 9 Max 30 2 0 20 Blow by pressure temperature Operating range Boom IN relief kPa mm H2O Max 0 59 Max 60 0 98 100 Engine oil pressure Oil temperature Min 80 C At rated ou...

Page 316: ...7 3 3 1 7 0 3 Max 25 6 Max 2 6 Telescopingcontrol lever operating force 16 7 3 3 1 7 0 3 Max 25 6 Max 2 6 Winch control lever operating force 13 7 2 7 1 4 0 3 Max 22 6 Max 2 3 Slewing control lever o...

Page 317: ...ength 4 7m Fully Lowering Raising 17 1 20 9 19 0 17 1 20 9 19 0 Fully Raising Lowering 31 5 38 5 35 0 31 5 38 5 35 0 Boom telescoping speed Hydraulic oil temperature 30 to 50 C Engine at high idle Boo...

Page 318: ...osture Travel posture boom retractingfullyand horizontal position hook stowing position Hydraulic oil temperature 45 to 55 C Engine at high idle Run up for at least 10 m and test deviation when travel...

Page 319: ...3 6 Pump performance curve...

Page 320: ...hoisting load Without load Total hoisting load 0 90t t 0 0 0 2 0 0 0 2 Hoisting load at 2 0t Total hoisting load 2 9t 2 0 2 2 2 0 2 2 Confirmation of warning alarm signal function Boom fully extendin...

Page 321: ...3 8...

Page 322: ...STING OIL PRESSURE INWORK EQUIPMENT SLEWING AND TRAVEL CIRCUIT 4 25 19 TESTING CONTROL CIRCUIT BASIC PRESSURE 4 28 20 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 4 29 21 TESTING AND...

Page 323: ...4 2 1 TOOLS FOR TESTING ADJUSTING AND TROUBLESHOOTING...

Page 324: ...4 3...

Page 325: ...4 4...

Page 326: ...4 5 2 TESTING ENGINE SPEED...

Page 327: ...4 6 3 TESTING EXHAUST TEMPERATURE...

Page 328: ...4 7 4 CHECKING EXHAUST GAS COLOR...

Page 329: ...4 8 5 ADJUSTING VALVE CLEARANCE...

Page 330: ...4 9...

Page 331: ...4 10 6 TESTING COMPRESSION PRESSURE...

Page 332: ...4 11...

Page 333: ...4 12 7 TESTING BLOW BY PRESSURE...

Page 334: ...4 13 8 TESTING ENGINE OIL PRESSURE...

Page 335: ...4 14 9 HANDLING FUEL SYSTEM PARTS 10 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM...

Page 336: ...4 15 11 TESTING FUEL PRESSURE...

Page 337: ...4 16 12 TESTING FUEL RETURN RATE AND FUEL LEAKAGE...

Page 338: ...4 17...

Page 339: ...4 18 13 BLEEDING AIR FROM FUEL CIRCUIT...

Page 340: ...4 19...

Page 341: ...4 20 14 CHECKING FUEL CIRCUIT FOR LEAKAGE...

Page 342: ...4 21 15 TESTING AND ADJUSTING ALTERNATOR BELT TENSION...

Page 343: ...4 22 16 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...

Page 344: ...4 23 17 CHECKING AND ADJUSTING TRACK SHOE TENSION...

Page 345: ...4 24...

Page 346: ...4 25 18 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT SLEWING AND TRAVEL CIRCUIT...

Page 347: ...4 26...

Page 348: ...4 27...

Page 349: ...4 28 19 TESTING CONTROL CIRCUIT BASIC PRESSURE...

Page 350: ...4 29 20 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...

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Page 353: ...4 32 21 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL...

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Page 357: ...4 36 22 TESTING SOLENOID VALVE OUTPUT PRESSURE...

Page 358: ...4 37 23 TESTING PPC VALVE OUTPUT PRESSURE...

Page 359: ...4 38...

Page 360: ...4 39 24 ADJUSTING PLAY OF WORK EQUIPMENT AND SLEWING PPC VALVES...

Page 361: ...4 40 25 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...

Page 362: ...e from the piping on the derrick cylinder head side For details see Releasing residual pressure from hydraulic circuit Operate the lever in the boom raising direction only however 2 Disconnect hose on...

Page 363: ...4 42...

Page 364: ...4 43 27 BLEEDING AIR FROM EACH PART...

Page 365: ...4 44...

Page 366: ...4 45 28 CHECKING CAB TIPPING 29 ADJUSTING MIRRORS STOPPER...

Page 367: ...ck with nut 5 Refer to the FIG 2 2 Adjust the dimension b by inserting shim 8 thickness 1 0mm and shim 9 thickness 0 5mm so that the amount boom curves to the side c Refer to the FIG 3 will be less th...

Page 368: ...face 4 With adjusting bolt 7 attached firmly on surface G tighten the adjusting bolt 7 until plate 14 is taken off lightly from the cylinder support 5 Fit jig of dimension C 300mm and tighten nut 8 If...

Page 369: ...F 4 1 Remove boom tip cover 23 Be careful not to damage cord of cord reel 2 Remove lock plate 3 bolt 4 and spring washer 5 and loosen right and left of adjusting bolts 6 for one turn 3 Tighten adjust...

Page 370: ...eter Replace a 10 mm diameter wire rope if it is 9 4 mm in diameter Replace a 8 mm diameter wire rope if it is 7 5 mm in diameter 3 The wire rope corroded as below 1 Wire surface has pitching and pitt...

Page 371: ...is firmly installed 4 Check whether the hook nut is firmly installed and replace immediately if the hook nut is worn out or damaged repair or replace 6 Check the hook for cracks by conducting magnaflu...

Page 372: ...4 51...

Page 373: ...4 52 34 SPECIAL FUNCTION OF MACHINE MONITOR...

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Page 423: ...4 102 35 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...

Page 424: ...4 103 36 PRECAUTION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...

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Page 429: ...4 108 37 PROCEDURE FOR TESTING DIODES...

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