Page 1 584E-SM1110-01 1/2 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.
Page 2: Table Of Contents
CONTENTS ITEM Page GENERAL 1. SPECIFICATION DIMENSIONNAL DRAWING 2. PRINCIPLE SPECIFICATION LIST 3. EACH UNIT WEIGHT LIST 4. FUEL, COOLANT AND LUBRICATIONS TABLE 5. WORKING RADIUS LIFTING HEIGHT 6. TOTAL RATED LOAD CHART 7. FLY-JIB WORKING RADIUS AND LIFTING HEIGHT (OPTIONAL) 1-10 8.
Page 3: Item Page
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...
Page 4 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...
Page 5 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...
Page 6 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.
Page 7 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...
Page 8 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.
Page 10: General
GENERAL 1. SPECIFICATION DIMENSIONNAL DRAWING 2. PRINCIPLE SPECIFICATION LIST 3. EACH UNIT WEIGHT LIST 4. FUEL, COOLANT AND LUBRICATIONS TABLE 5. WORKING RADIUS LIFTING HEIGHT 6. RATED TOTAL LOAD CHART 7. FLY-JIB WORKING RADIUS AND LIFTING HEIGHT (OPTIONAL) 1-10 8. FLY-JIB RATED TOTAL LOAD CHART (OPTIONAL) 1-10...
Page 11 1. SPECIFICATION DIMENSIONAL DRAWING...
Page 12: Principle Specification List
. PRINCIPLE SPECIFICATION LIST System / Item LC1385M-8B Machine mass 15640kg 6545mm x 2490mm x 2965mm Overall length width height Distance between idler and sprocket 2880mm Mass and dimensions Track gauge 1990mm Track width 500mm 1600mm Swing radius at machine rear end Maximum rated total load 6.0t x 2.6m...
Page 13: Each Unit Weight List
. EACH UNIT WEIGHT LIST Unit: kg LC1385M-8B ITEM Engine Assembly (Dry) Engine (Dry) Engine Mount 18.1 Hydraulic Oil Pump Cooling Assembly (Dry) 82.2 Radiator (Dry) Oil Cooler (Dry) 10.2 After Cooler Fuel Cooler (Dry) Revolving Frame 1400 Operator s Cab...
Page 14: Fuel, Coolant And Lubrications Table
. FUEL, COOLANT AND LUBRICATIONS TABLE Use of fuel, coolant and lubricant should vary with changes in temperature. Ambient Temperature (degrees C) Reservoir Fluid type Recommended Fluids Min. Max. SAE 0W30 (Note.1) SAE 5W40 (Note.1) Engine oil pan Engine oil SAE 10W30DH SAE 15W40DH SAE 30DH...
Page 15: Working Radius Lifting Height
5. WORKING RADIUS AND LIFTING HEIGHT...
Page 16: Rated Total Load Chart
6. RATED TOTAL LOAD CHART [1] RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS Unit: kg 13.385m 16.265m 4.745m Boom 7.625m Boom 10.505m Boom Working Boom Boom radius (m) Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary 2.00...
Page 17 [2] RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS Unit: kg 13.385m 16.265m 4.745m Boom 7.625m Boom 10.505m Boom Working Boom Boom radius (m) Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary 2.00 3000 1000 3000...
Page 18 [3] RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL Unit: kg 13.385m 16.265m 4.745m Boom 7.625m Boom 10.505m Boom Working Boom Boom radius (m) Stationary Pick & Carry Stationary Pick & Carry Stationary Pick & Carry Stationary Stationary 2.00 1500 1500 1500...
Page 19: Fly-Jib Working Radius And Lifting Height (Optional)
7. FLY-JIB WORKING RADIUS AND LIFTING HEIGHT (OPTIONAL) 8. FLY-JIB RATED TOTAL LOAD CHART (OPTIONAL) Unit: kg Fly-jib Tilt Angle Loaded Boom Angle (degree) 0 and 20 degrees 40 and 60 degrees Prohibited Under 65 degrees 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.
Page 20: Structur, Function & Maintenance Standard
STRUCTUR, FUNCTION & MAINTENANCE STANDARD 1. ENGINE AND COLLING SYSTEM 2 POWER TRAIN 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.
Page 21: Engine Specifications
1. ENGINE AND COOLING SYSTEM 1.1 ENGINE SPECIFICATIONS System / Item LC1385M-8B Model Komatsu SAA4D95LE-5 Vertical in-line 4-cylinder, Water cooled, 4-cycle, Direct fuel injection type, Type With turbocharger and air cooled after-cooler No. of Cylinders Bore X Stroke 95mm X 115mm Displacement 3.26 liters (3260cc)
Page 22: Engine Mounting
1.2 ENGINE MOUNTING...
Page 23: Pto (Power Take Off)
1.3 PTO (Power Take Off)
Page 25: Cooling System
1.4 COOLING SYSTEM...
Page 27: Power Train
2. POWER TRAIN 2.1 POWER TRAIN DRAWING...
Page 28: Swing Circle
2.2 SWING CIRCLE...
Page 29: Swing Machinery
2.3 SWING MACHINERY 2-10...
Page 30 2-11...
Page 31: Undercarriage And Frame
3. UNDERCARRIAGE AND FRAME 3.1 TRACK FRAME 2-12...
Page 32: Idler Cushion
3.2 IDLER CUSHION 2-13...
Page 33: Idler
3.3 IDLER 2-14...
Page 34: Track Roller
3.4 TRACK ROLLER 2-15...
Page 35: Carrier Roller
3.5 CARRIER ROLLER 2-16...
Page 36: Sprocket
3.6 SPROCKET 2-17...
Page 37: Track Shoe
3.7 TRACK SHOE 2-18...
Page 38 2-19...
Page 39 2-20...
Page 40 3.7.1 TRIPLE GROUSER SHOE 2-21...
Page 41 3.7.2 SINGLE GROUSER SHOE 2-22...
Page 42: Hydraulic Cercuit Diagram
Note: A version of this hydraulic circuit diagram enlarged to A2 size is prepared as an appendix. Refer to the separate A2 size circuit diagram for details. 4. HYDRAULIC CERCUIT DIAGRAM 2-23...
Page 43 2-24...
Page 44 2-25...
Page 45: Hydraulic System
5. HYDRAULIC SYSTEM 5.1 HYDRAULIC EQUIPMENT LAYOUT DRAWING 2-26...
Page 46 1. Hydraulic Oil Tank 2. Hydraulic Oil Pump 3. Control Valve 4. Center Swivel Joint 5. Travelling PPC Valve 6. Left Travelling Motor 7. Right Travelling Motor 8. Left Crane PPC Valve 9. Right Crane PPC Valve 10. Swing Motor 11.
Page 47: Hydraulic Tank And Filter
5.2 HYDRAULIC TANK AND FILTER 2-28...
Page 48 2-29...
Page 49: Hydraulic Oil Pump
5.3 HYDRAULIC OIL PUMP 2-30...
Page 50 2-31...
Page 51 2-32...
Page 52 2-33...
Page 53 2-34...
Page 54 2-35...
Page 55: Ls Valve
5.3.1 LS VALVE 2-36...
Page 56 2-37...
Page 57 2-38...
Page 58 2-39...
Page 59 2-40...
Page 60: Pc Valve
5.3.2 PC VALVE 2-41...
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: Pc-Epc Valve
5.3.3 PC-EPC VALVE 2-51...
Page 71 2-52...
Page 72 2-53...
Page 73: Check Valve
5.3.4 CHECK VALVE 2-54...
Page 74: Shuttle Valve
5.3.5 SHUTTLE VALVE 2-55...
Page 75: Control Valve
5.4 CONTROL VALVE 2-56...
Page 76 A1 : To swingr motor PA1 : From swing counter clockwise PPC valve A2 : To blade cylinder bottom PA2 : From blade lowering PPC valve A3 : To left travelling motor PA3 : From left travelling forward PPC valve A4 : To right travelling motor PA4 : From right travelling forward PPC valve A5 : To winch motor port A...
Page 77 2-58...
Page 78 1. Suction valve (Derricking) 13. Suction valve (Telescoping) 2. Suction valve (Telescoping) 14. Suction valve (Derricking) 3. Suction valve (Winch) 15. Suction safety valve 4. Lift check valve 16. Spool (Derricking) 5. Suction valve (Right travelling) 17. Spool (Telescoping) 6. Suction valve (Left travelling) 18.
Page 79 2-60...
Page 80 1. Cooler bypass valve 9. Pressure compensation valve F (Swing) 2. Pressure compensation valve R (Derricking) 10. Pressure compensation valve F (Blade) 3. Pressure compensation valve R (Telescoping) 11. Pressure compensation valve F (Left travelling) 4. Pressure compensation valve R (Winch) 12.
Page 81 2-62...
Page 82 1. Pressure compensation valve F (Swing) 10. Pressure compensation valve R (Left travelling) 2. Spool (Swing) 11. Suction valve (Left travelling) 3. Pressure compensation valve R (Swing) 12. Suction valve (Left travelling) 4. Swing bleeding Valve 13. Spool (Left travelling) 5.
Page 83 2-64...
Page 84 1. Pressure compensation valve F (Right travelling) 11. Cooler Bypass valve 2. Suction valve (Right travelling) 12. Lift check valve 3. Suction valve (Right travelling) 13. Pressure compensation valve F (Winch) 4. Spool (Right travelling) 14. Suction valve (Winch) 5. Pressure compensation valve R (Right travelling) 15.
Page 85 2-66...
Page 86 1. Pressure compensation valve F (Telescoping) 9. Spool (Derricking) 2. Suction valve (Telescoping) 10. Pressure compensation valve R (Derricking) 3. Suction valve (Telescoping) 11. Suction safety valve 4. Spool (Telescoping) 12. Pressure release plug 5. Pressure compensation valve R (Telescoping) 6.
Page 87: Clss
5.5 CLSS 5.5.1 OUTLINE OF CLSS 2-68...
Page 88 2-69...
Page 89 2-70...
Page 90 2-71...
Page 91: Functions And Operation By Valve
5.6 FUNCTIONS AND OPERATION BY VALVE 5.6.1 HYDRAULIC CIRCUIT DIAGRAM AND THE NAME OF VALVES 2-72...
Page 92 1. Swing valve 2. Blade valve 3. Left travelling valve 4. Right travelling valve 5. Winch valve 6. Boom telescoping valve 7. Boom derricking valve 8. Swing spool 9. Blade spool 10. Left travelling spool 11. Right travelling spool 12. Winch spool 13.
Page 93: Unload Valve
5.6.2 UNLOAD VALVE 2-74...
Page 94 2-75...
Page 95 2-76...
Page 96 2-77...
Page 97 2-78...
Page 98 2-79...
Page 99: Merge-Divider Valve
5.6.3 MERGE-DIVIDER VALVE 2-80...
Page 100 2-81...
Page 101: Introduction Of Ls Pressure
5.6.4 INTRODUCTION OF LS PRESSURE 2-82...
Page 102 2-83...
Page 103: Ls Bypass Valve
5.6.5 LS BYPASS VALVE 2-84...
Page 104 2-85...
Page 105: Pressure Compensation Valve
5.6.6 PRESSURE COMPENSATION VALVE 2-86...
Page 106 2-87...
Page 107: Area Ratio Of Pressure Compensation Valve
5.6.7 AREA RATIO OF PRESSURE COMPENSATION VALVE 2-88...
Page 108: Swing Bleeding Valve
5.6.8 SWING BLEEDING VALVE 2-89...
Page 109 5.6.9 TRAVELLING JUNCTION VALVE 2-90...
Page 110: Self Pressure Reducing Valve
5.6.10 SELF PRESSURE REDUCING VALVE 2-91...
Page 111: Ppcvalve
5.7 PPCVALVE 5.7.1 WORK EQUIPMENT AND SWING PPC VALVE P : From self pressure reducing valve P1: Left PPC valve (Boom extending port/Right PPC valve Winch lowering port P2: Left PPC valve (Boom retracting port/Right PPC valve Winch raising port P3: Left PPC valve (Swing left port/Right PPC valve Boom raising port P4: Left PPC valve (Swing right port/Right PPC valve Boom lowering port T : To tank...
Page 112 2-93...
Page 113 2-94...
Page 114 2-95...
Page 115 2-96...
Page 116 5.7.2 TRAVELLING PPC VALVE 2-97...
Page 117 2-98...
Page 118 2-99...
Page 119 2-100...
Page 120 2-101...
Page 121: Blade Ppc Valve
5.7.3 BLADE PPC VALVE 2-102...
Page 122 2-103...
Page 123 5.8 SOLENOID VALVE ASS Y 2-104...
Page 124 2-105...
Page 125 2-106...
Page 126: 5-Section Solenoid Valve
5.9 5-SECTION SOLENOID VALVE A1: From right crane PPC valve port P2 B1: To control valve port PB5 A2: From right crane PPC valve port P1 B2: To control valve port PA5 A3: From right crane PPC valve port P4 B3: To control valve port PA7 A4: From left crane PPC valve port P1 B4: To control valve port PA6...
Page 127: Winch Brake Release Valve
5.10 WINCH 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 : To winch motor 2-108...
Page 128 1. Flange plug 2. O-ring 3. Body 4. Spool 5. Retainer 6. Compression spring 7. O-ring 8. Plug 9. Spool 10. Steel ball Function This is a pilot type selector valve. When no pressure is applied to the ports A and B, the 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 interconnect to the port C and a pressure will occur from port P to port C.
Page 129: Ppc Accumulator
5.11 PPC ACCUMULATOR 2-110...
Page 130: Low Pressure Selector Valve (For Over Hoisting Release)
5.12 LOW PRESSURE SELECTOR VALVE (For Hook Stowing) Principle of low pressure circuit function (with low pressure selector valve) When the over-hoisting cancel switch is turned on, low pressure selector valve opens, and LS circuit is interconnected to tank, and then LS pressure becomes just about 0MPa .
Page 131: Telescoping Cylinder
5.13 TELESCOPING CYLINDER 5.13.1 TELESCOPING ASSEMBLY 2-112...
Page 132 1. Cylinder Assembly 2. Wire Rope (For extending) 3. Support Assembly 4. Nut 5. Wire Rope (For Retracting) 6. Sheave Assembly 7. Hex. Socket Head Bolt 8. Spring Washer 9. Support 10. Spring Washer 11. Bolt 12. Counter Balance Valve 13.
Page 133: Telescoping Cylinder
5.13.2 TELESCOPING CYLINDER 2-114...
Page 134 1. Nut 28. Plane Bearing 2. Spring Washer 29. O-ring 3. Piston 30. Piston 4. O-ring 31. Set Screw 5. Plane Bearing 32. No.1 Piston Rod 6. Plane Bearing 33. No.1 Cylinder 7. Plane Bearing 34. O-ring 8. Piston 35. Packing 9.
Page 135 FUNCTION 1. After extending No.1 cylinder fully, extend No.2 cylinder. 2. After extending No.2 cylinder fully, extend No.3 cylinder. 2-116...
Page 136 3. After retracting No.3 cylinder fully, Retract No.2 cylinder. 4. After retracting No.2 cylinder fully, retract No.1 cylinder. 2-117...
Page 137 [1] MECHANICAL CHECK VALVE FOR EXTENDING This check valve is No.17 of the telescoping cylinder. 1. O-ring 2. Back-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.
Page 138 [3] COUNTER BALANCE VALVE FOR TELESCOPING CYLINDER 1. Body 6. O-ring 11. Spring 2. Spool 7. Plug 12. O-ring 3. Plug 8. Plug 13. O-ring 4. Back-up Ring 9. Plug 5. Spring 10. Poppet 2-119...
Page 139: Derricking Cylinder
5.14 DERRICKING CYLINDER 2-120...
Page 140 1. Cylinder Tube Assembly 2. Piston Rod Assembly 3. Cylinder Head 4. Bushing 5. 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.
Page 141 5.14.1 COUNTER BALANCE VALVE FOR DERRICKING CYLINDER Specifications Max. Common Use Pressure 20.6 MPa (210 kgf / cm Resiting Pressure 30.9 MPa (315 kgf / cm Max. Flow Capacity 50 L / min Rated Flow Capacity 40 L / min Allowable Leakage Capacity Less than 0.05 L / min (Apply 20.6 MPa [210 kgf / cm ] From Port B)
Page 142: Winch Motor
5.15 WINCH MOTOR Specifications Rated Output Torque (At started) 4,100 N m (420 kgf m) Max. Output Revolution 170 min Reduction Ratio 24.2 Specifications of Hydraulic Oil Motor Capacity per Stroke 54.3 cm / rev Max. Common Use Pressure 24.5 MPa (250 kgf / cm Max.
Page 143: Inner Structure Drawing
5.15.1 INNER STRUCTURE DRAWING 1. Counter Balance Valve Portion 2. Hydraulic Oil Motor Portion (With Hi-Lo 2-speed changing system and Mechanical brake) 3. Reduction Gear Portion Function CH04VB motor is a hydraulic actuator for operating winch and is composed of three sections of counterbalance valve section, hydraulic motor section, and reduction gear section.
Page 144: Counter Balance Valve
5.15.2 COUNTER BALANCE VALVE [1] OUTLINE This valve section generates braking pressure, which is necessary when lowering load with the winch, to the hydraulic motor to prevent load from own weight fall and adjusts the lowering speed in proportion to oil amount supplied to the hydraulic motor. This valve is directly connected with rear flange of hydraulic motor.
Page 145 2. When Lowering and Stop of Lowering Contrary to lifting, a pressurized oil, when supplied to port (B) of counterbalance valve, enters the cylinder of the hydraulic motor from the port (C2) through chamber in the body (301) and tries to rotate the hydraulic motor. However, the return port (C1) side of the hydraulic motor cannot rotate the hydraulic motor because the valve (313) and main spool (302) block the passage to the port (A) and holding pressure and port (C2) hydraulic pressure are generated in the port (C1).
Page 146: Hydraulic Oil Motor
5.15.3 HYDRAULIC OIL MOTOR [1] MOTOR FUNCTION A pressurized oil from the hydraulic motor enters the rear flange (401) of the CH motor and flows in the cylinder block (204) from the timing plate (209) through the brake valve mechanism. The hydraulic motor is structured so that the pressurized oil flows to the one side only of (Y1-Y2) connecting the upper and the lower fulcrums of the piston (261) stroke.
Page 147 [2] FUNCTION OF HIGH-LOW 2-SPEED SELECTOR VALVE SYSTEM 1. When Low Speed When no pilot pressure is supplied, the valve (472) is returned to the upper side by the spring (466) tension force. As for the high pressure oil (A) or (B) in the circuit, the valve (472) blocks the passage hole to the 2-speed changeover piston (261). To the contrary, the oil in the 2-speed piston room (X) is released in the motor case via the valve (472).
Page 148 [3] FUNCTION OF MECHANICAL BREKE 1. When Release (pilot pressure is more than 1.37MPa) When a pressured oil is supplied to the brake release port (P) from outside of the CH04VB motor, the pressurized oil enters the cylinder chamber (Z) composed of the spindle (102) and the piston (212).
Page 149: Reduction Gear
5.15.4 REDUCTION GEAR FUNCTION The rotational motion of the hydraulic motor shaft is transmitted to the first sun gear (104). At the time, the first planetary gear (105) is engaged with the sun gear (104), and the planetary gear (105) rotates and be engaged with the hub (101), and makes orbital motion.
Page 150: Swing Motor
5.16 SWING MOTOR Type: KMF45ABE-5 2-131...
Page 151 2-132...
Page 152 2-133...
Page 153: Swing Holding Brake
5.16.1 SWING HOLDING BRAKE 2-134...
Page 154: Relief Valve Portion
5.16.2 RELIEF VALVE PORTION 2-135...
Page 155: Reverse Prevention Valve
5.16.3 REVERSE PREVENTION VALVE 2-136...
Page 156 2-137...
Page 157 2-138...
Page 158 2-139...
Page 159: Center Swivel Joint
5.17 CENTER SWIVEL JOINT A1: From control valve (Right travelling motor reverse) A2: To right travelling motor port A B1: From control valve (Left travelling motor forward) A2: To left travelling motor port A C1: From control valve (Right travelling motor forward) C2: To right travelling motor port B D1: From control valve (Left travelling motor reverse) D2: To left travelling motor port B...
Page 160 2-141...
Page 161 5.18 TRAVELLING MOTOR A: From center swivel joint, port B2 (Left travelling motor) From center swivel joint, port C2 (Right travelling motor) B: From center swivel joint, port D2 (Left travelling motor) From center swivel joint, port A2 (Right travelling motor) D: To center swivel joint, port DR2 E: From center swivel joint, port E2 1.
Page 162 2-143...
Page 163 2-144...
Page 164 2-145...
Page 165 2-146...
Page 166: Brake Valve
5.18.1 BRAKE VALVE 2-147...
Page 167 2-148...
Page 168: Relief Valve
5.18.2 RELIEF VALVE 2-149...
Page 169: Blade Cylinder
5.19 BLADE CYLINDER Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Clearance between size clearance limit piston rod and bushing Shaft Hole -0.030 +0.279 0.095 0.355 0.455 -0.076 +0.065 Replace bushing Clearance between -0.030 +0.190 piston rod support shaft 0.120 0.290 -0.100 +0.090...
Page 170 2-151...
Page 171: Boom Assembly
6. BOOM ASSEMBLY 2-152...
Page 172 2-153...
Page 173 1. Base Boom 22. Snap Ring 44. Slide Plate 2. No.2 Boom 23. Roller 45. Cap 3. No.3 Boom 24. Pin 46. Flange Bolt 4. No.4 Boom 25. Snap Ring 47. Shim 5. Top Boom 26. Nut 48. Bolt 6. Name plate 27.
Page 174 2-155...
Page 175: Boom Telescoping System
6.1 BOOM TELESCOPING SYSTEM 1. No.2 boom telescoping cylinder 2. No.3 boom telescoping cylinder 3. Counter balance valve 4. Mechanical check valve (For extending) 5. Mechanical check valve (For retracting) 6. Sheave (For No.5 boom retracting) 7. Wire rope (For No.5 boom retracting) 8.
Page 176 2-157...
Page 177: Fly-Jib (Optional)
7. FLY-JIB (OPTION) 2-158...
Page 178 2-159...
Page 179 1. Fly-jib Base 2. No.1 Fly-jib 3. No.2 Fly-jib 4. Outer Rod 5. Inner Rod 6. Position Pin (diameter 35 295L) 7. Fly-jib Foot Pin 8. Sems Bolt 9. Fly-jib Point Pin 10. Sems Bolt 11. Seave Assembly 12. Snap Seave (diameter 71 31W) 13.
Page 180: Electric Circuit Diagram (1/6 To 6/6)
Note: A version of this electrical circuit diagram enlarged to A2 size is prepared as an appendix. Refer to the separate A2 size circuit diagram for details. 8. ELECTRIC CIRCUIT DIAGRAM (1/6) 2-161...
Page 181 8. ELECTRIC CIRCUIT DIAGRAM (2/6) 2-162...
Page 182 8. ELECTRIC CIRCUIT DIAGRAM (3/6) 2-163...
Page 183 8. ELECTRIC CIRCUIT DIAGRAM (4/6) 2-164...
Page 184 8. ELECTRIC CIRCUIT DIAGRAM (5/6) 2-165...
Page 185 8. ELECTRIC CIRCUIT DIAGRAM (6/6) 2-166...
Page 186 2-167...
Page 187: Air Conditioner
9. AIR CONDITIONER 9.1 AIR CONDITIONER PIPING DIAGRAM 2-168...
Page 188 2-169...
Page 189 2-170...
Page 190 2-171...
Page 191: Air Conditioner Unit
9.2 AIR CONDITIONER UNIT 2-172...
Page 192 2-173...
Page 193 2-174...
Page 194: Air Conditioner Controller
9.3 AIR CONDITIONER CONTROLLER 2-175...
Page 195: Compressor
9.4 COMPRESSOR 2-176...
Page 196: Condennser
9.5 CONDENNSER 2-177...
Page 197: Sensor
9.6 SENSOR 2-178...
Page 198 2-179...
Page 199: Electrical System
10. ELECTRICAL SYSTEM 10.1 ELECTRICAL CONTROL SYSTEM 2-180...
Page 200 10. ELECTRICAL SYSTEM 10.1 ELECTRICAL CONTROL SYSTEM 2-181...
Page 201: Electrical Control Function
10.1 .1 ELECTRICAL CONTROL FUNCTION 2-182...
Page 202 2-183...
Page 203: Pump And Engine Mutual Control Function
10.1 .2 PUMP AND ENGINE MUTUAL CONTROL FUNCTION 2-184...
Page 204 2-185...
Page 205 2-186...
Page 206 2-187...
Page 207 2-188...
Page 208: Auto-Decelerator Function
10.1 .3 AUTO-DECELERATOR FUNCTION 2-189...
Page 209 2-190...
Page 210: Engine Automatic Warm-Up Function
10.1 .4 ENGINE AUTOMATIC WARM-UP FUNCTION 2-191...
Page 211 2-192...
Page 212: Overheat Prevention Function
10.1 .5 OVERHEAT PREVENTION FUNCTION See 10.1.4 Engine Automatic Warm-Up Function for circuit diagram. 2-193...
Page 213: Overheat Prevention Function
10.1 .6 OVERHEAT PREVENTION FUNCTION See 10.1.4 Engine Automatic Warm-Up Function for circuit diagram. 2-194...
Page 214: Swing Control Function
10.1 .7 SWING CONTROL FUNCTION 2-195...
Page 215 2-196...
Page 216 2-197...
Page 217: Travel Control Function
10.1 .8 TRAVEL CONTROL FUNCTION 2-198...
Page 218 2-199...
Page 219 2-200...
Page 220: Ppc Lock Function
10.1 .9 PPC LOCK FUNCTION 2-201...
Page 221: System Components
10.1 .10 SYSTEM COMPONENTS [1] ENGINE CONTROLLER 2-202...
Page 222 2-203...
Page 223 [2] ENGINE CONTROLLER 2-204...
Page 224 2-205...
Page 225 [3] FUEL CONTROL DIAL 2-206...
Page 226 [4] RESISTOR 2-207...
Page 227 [5] ENGINE OIL PRESSURE SWITCH 2-208...
Page 228 [6] PPC OIL PRESSURE SWITCH 2-209...
Page 229 2-210...
Page 230: Monitor System
10.2 MONITOR SYSTEM 2-211...
Page 231: Machine Monitor
10.2.1 MACHINE MONITOR 2-212...
Page 232 2-213...
Page 233: Display
10.2.2 DISPLAY 2-214...
Page 234 2-215...
Page 235 2-216...
Page 236 2-217...
Page 237: Switches
10.2.3 SWITCHES 2-218...
Page 238 2-219...
Page 239 2-220...
Page 240 2-221...
Page 241: Operation Mode Function
10.2.4 OPERATION MODE FUNCTION 2-222...
Page 242 2-223...
Page 243 10.2.5 SERVICE MODE FUNCTION 2-224...
Page 244: Komtrax System
10.3 KOMTRAX SYSTEM 2-225...
Page 245: Komtrax Terminal
10.3.1 KOMTRAX TERMINAL TH300 2-226...
Page 246: Sensor
10.4 SENSOR 2-227...
Page 247 2-228...
Page 248 2-229...
Page 249 2-230...
Page 250 2-231...
Page 251 2-232...
Page 252: Crane Operating Data Logger
11. CRANE OPERATING DATA LOGGER 1. Recorder Assembly 2. USB Memory 3. Bolt (With Washer) (M6X25L, Plating) 2-233...
Page 253: Crane Operating Data Logger Exterior View
11.1 CRANE OPERATING DATA LOGGER EXTERIOR VIEW 2-234...
Page 254 [1] WRITING DATA TO USB MEMORY 1. Remove watertight cap on the upper part of the data logger by rotating counter-clockwise with coin or such. Then USB connector can be found inside. After the work, make sure to close the cap by rotating clockwise.
Page 255 [2] VIEW USB MEMORY DATA / PRINT THE DATA The data in the USB memory is saved as CSV file. Insert the USB memory to by Microsoft Excel or similar software. Following is an example of data to be shown. To print the data, use function of Microsoft Excel or similar software.
Page 256 [4] SETTING CLOCK DATA 1. Push in two nails of lock parts on both side of data logger case to unlock, and hold connector panel and pull it out to front. Inside print board will appear. This print board is to be worked out. To prevent short circuit of the print board, place the print board on clean insulator such as a cardboard.
Page 257: Moment Limiter
12. MOMENT LIMITER 12.1 MOMENT LIMITER RELATED 12.1.1 DISPLAY UNIT 2-238...
Page 258 1. Display unit stay 2. Display unit stay support 3. Button bolt (M6X20L, plating) 4. Saddle 5. Screw (M5X14L, plating) 6. Plane washer (M5, plating) 7. Spring washer (M5, plating) 8. Nut (M5, plating) 9. Hinge (TH-145) 10. Button bolt (M5X10L, plating) 11.
Page 259 12.1.2 CONTROLLER 1. Controller mounting bracket 4. Hole plug (CP-30-HP-8) 2. Socket head bolt (M8X20L, plating) 5. Controller 3. Spring washer (M8) 6. Screw (With washer) (M5X12L, plating) 2-240...
Page 260: Length, Angle And Pressure Sensor
12.1.3 LENGTH, ANGLE AND PRESSURE SENSOR 1. ML sensor and light bracket 7. Bolt (With washer) (M6X16L, plating) 2. Bolt (With washer) (M10X20L, plating) 8. Pressure sensor 3. Boom length sensor 9. Pressure sensor cover 4. Bolt (With washer) (M8X15L, plating) 10.
Page 261 [1] ANGLE SENSOR Specifications Rated Voltage 12V DC Detection Angle Range -12 to +98 degrees At supply 12V DC between connector 1 (red) and 3 (black) Output Voltage 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 Between Connector 2 (white) and 3 (black) at boom angle 0°: 150.0±4.5 Resistance...
Page 262 1. Case 12. Terminal 2. Cap 13. Element 3. Weight 14. Print paper 4. Arm 15. Shaft 5. Terminal block 16. Bearing 6. O-ring 17. Plane washer 7. Dumper oil 18. Rotor mold 8. Wiring harness 19. Rotor arm 9. Tie band 20.
Page 263 [2] LENGTH SENSOR Specifications Outside Diameter of Code Wire Main Code 15.1 5m Code Length Sub Code 0.43 m Operating Temperature -30 to +80 degrees C Weight Above 5 kg Resistance value 5000±250 Potentiometer Electrical Rotating Angle 350±1.5 degrees Mechanical Rotating Angle 360 degrees Reduction Gear reduction ratio 1/50...
Page 264 1. Case 18. Clip 35. Nut 2. Base plate 19. Clamp 36. Spring washer 3. Super lock 20. Terminal 37. Screw (With washer) 4. Spring assembly 21. Terminal 38. Housing 5. Contact ring assembly 22. Cable assembly 39. Plane washer 6.
Page 265 [3] PRESSURE SENSOR Specifications Pressure Range 0 to 35 MPa Allowable Maximum Pressure 52.5 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 Temperature -20 to +70 degrees C Insulation Resistance...
Page 266: Boom Derricking Position Detector
12.1.4 BOOM DERRICKING POSITION DETECTOR 1. Boom upper limit switch 2. Boom lower limit switch Circuit Diagram 2-247...
Page 267: Blade Grounding Detector
12.1.5 BLADE GROUNDING DETECTOR 1. Pressure sensor 2. Adapter (Rc1/8 G3/8) 2-248...
Page 268 [1] PRESSURE SENSOR Specifications Pressure Range 0 to 35 MPa Allowable Maximum Pressure 52.5 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 Temperature -20 to +70 degrees C Insulation Resistance...
Page 269: Fly-Jib Position Detector
12.1.6 FLY-JIB POSITION DETECTOR 2-250...
Page 270 2-251...
Page 271 1. Limit switch 2. Screw (M4X30L, plating) 3. Plane washer (M4, plating) 4. Spring washer (M4, plating) 5. Nut (M4, plating) 6. Limit switch cover (A1) 7. Limit switch cover (A2) 8. Sems bolt (M6X10L, plating) 9. Limit switch cover (B) 10.
Page 272: Over Hoist Stop System
12.1.7 OVER HOIST STOP SYSTEM 1. Case 10. Socket head bolt (M6X20L, plating) 2. Over Hoist detector 11. Nut (M6, plating) 3. Grommet 12. Spring washer (M6, plating) 4. Extension cable 13. Plane washer (M12, plating) 5. Connector clip 14. Nut (M12, plating) 6.
Page 273 [1] OPERATION PRINCIPLE When the hook is raised too much, the weight hoisted through the wire rope is pushed up by the hook, and activates the over hoist detector switch. The contact 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.
Page 274: Over Hoist Stop System (For Single Hook)
12.1.8 OVER HOIST STOP SYSTEM (FOR SINGLE HOOK) Circuit Diagram 2-255...
Page 275: Over Hoist Stop System (For Fly-Jib)
12.1.9 OVER HOIST STOP SYSTEM (FOR FLY-JIB SINGLE HOOK) Circuit Diagram 2-256...
Page 276: Over Un-Winding Detector
12.1.10 OVER UN-WINDING DETECTOR Circuit Diagram 2-257...
Page 277: Moment Limiter Overview And Features
The device also calculates rated operating radii, operating radii and lifting heights from actual load, boom length and boom angle and displays them. 12.2.2 SPECIFICATIONS Items LC1385M-8B Type of Moment Limiter Automatic Cut Out Crane Rated Load 0 to 6.0 ton [Pressure Range: 0 to 20.6 MPa (0 to 210kg/cm...
Page 278: External View Of Moment Limiter
12.3 EXTERNAL VIEW OF MOMENT LIMITER CONTROLLER DISPLAY UNIT 2-259...
Page 279 12.4 CONTROLLER 2-260...
Page 280 Item Remarks When this switch is set to ON , input voltage of pressure transmitter 3 is read. When Blade / No blade Switch this switch is set to OFF , input voltage of pressure transmitter 3 is not read. (input voltage is ignored and error code is not displayed.) When This switch is set to ON, angle control is released.
Page 281: Connector Pin Assignment
12.4.1 CONNECTOR PIN ASSIGNMENT The Controller has five connectors. One Display Unit connector of five connectors is connected with a special cable. Pin assignment of each connector are as listed below: [1] POWER CONTROL CONNECTOR (CN1) Pin No. Signal Buzzer Output Buzzer GND Winch Motor Control Output Over Load Output...
Page 282 [3] SENSOR CONNECTOR (CN3) Pin No. Signal Pin No. Signal Fly-jib Stowing Input Voice Message Output 3 Fly-jib 1 Section Input Voice Message Output 4 Fly-jib Angle 1 Input Fly-jib Angle 2 Input Fly-jib Angle 3 Input Load Ratio Output TX+ Spare 3 Input Load Ratio Output TX- (GND) Voice Message Output 1...
Page 283: Displays
12.5 DISPLAYS 2-264...
Page 284 Item Type Remarks Actual Load Display 7 Segments (Red) Permanent Indication (Letter height 10mm) Rated Total Load Display 7 Segments (Red) Permanent Indication (Letter height 8mm) Working Radius Display 7 Segments (Red) Permanent Indication (Letter height 10mm) Rated Radius Display 7 Segments (Red) Permanent Indication (Letter height 8mm) Boom Angle Display...
Page 285: Switches
12.6 SWITCHES Function Remarks Push the Fall Mode Selector Switch to switch for another Wire Fall configuration. Keep pushing the switch for 2 seconds or more shall activate configuration change Fall Mode Selector Switch function. One push for more seconds shall not proceed continuously. Another push and keep shall switch to the further configuration.
Page 286 Function Remarks Push the Working Radius Upper Limit Switch to set or cancel the Working Radius Upper Limit. Push the Switch and hold for two seconds or more shall set the current radius as the upper Working Radius Upper Limit limit.
Page 287: Display Unit; Detail Of Each Segment
12.7 DISPLAY UNIT; DETAIL OF EACH SEGMENT [1] Over Hoist Detector input Controls as below shall be active when Over Hoist Over Hoist [2] Over Un-Winding Detector input Controls as below shall be active when Over Un- -Winding Over Un- [3] Boom Angle Upper Limit Detector input Controls as below shall be active when Boom Angle Upper Limit Boom Angle Upper Limit Detector output shall be...
Page 288: Start Up Sequence
12.8 START UP SEQUENCE 1. All LEDs shall light approximately for 2 seconds. Only Green of Green/Red combination LEDs shall light. 2. All the switches activation shall be checked. 3. Input from external devices shall be checked. 4. Status of output is as shown in the table below: Signals Output Buzzer output...
Page 289: Display Of Specific Indicators
12.10 DISPLAY OF SPECIFIC INDICATORS [1] ACTUAL LOAD INDICATOR al load. Actual Load shall be so converted and rounded off to one decimal place. (XX.X) Minus value is not available for display. Only in the calibration mode, Actual Load shall be rounded off to tow decimal places and displayed. (X.XX) [2] RATED LOAD INDICATOR Actual Load shall be so converted and rounded off to one decimal place.
Page 290: Calibration Procedure
12.11 CALIBRATION PROCEDURE 12.11.1 LIST OF ITEMS [Displays] Switches] (1) Pick & Carry / Stationary Mode Selector Switch (10) Actual Load Display (2) Fall Mode Selector Switch (11) Rated Total Load Display (3) Concealed Switch (12) Working Radius Display (4) Check Switch (13) Rated Radius Display (5) Cancel Switch (14) Boom Angle Display...
Page 291: Procedure
12.11.2 PROCEDURE Be sure to calibrate this system before first-time use. Starting operation without calibration may result in inaccurate measurements and malfunctions, leading to damage to the peripheral equipment and serious accidents. If the sensor is replaced even if the system has been calibrated, sensor output will disperse to cause errors in measurement results.
Page 292: Call Out Of Calibration Mode
12.11.3 CALL OUT OF CALIBRATION MODE This system can calibrate a Boom Length, Boom Angle and Actual load. How to select three subjects of calibration is explained below. Pick & Carry / Stationary Mode Selector At power-off condition, while pressing the Switch (1) and Check switch (4) at the same time, turn ON the power.
Page 293 3. Press the Pick & Carry / Stationary Mode Selector Switch (1). The Rated Load indicator shall turn to ANG . When carrying out boom angle calibration, refer to 11.5 Calibration of Boom Angle in this condition. 4. Press the Pick & Carry / Stationary Mode Selector Switch (1). The Rated Load indicator shall turn to WEG .
Page 294: Calibration Of Boom Length
12.11.4 CALIBRATION OF BOOM LENGTH When this calibration is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) 12.11.5 Calibration of Boom Angl Rated Load indicator NG . [1] Memory of fully retracted length (Offset length value) 1.
Page 295 [2] Memory of fully Extension length (Span length value) 1. Operate crane and extend the boom to the longest condition. 2. Adjust the figures in the Boom Length 16.3 by pressing Fall Mode Selector Switch (2) and/or Concealed Switch (3). Fall Mode Selector Switch (2): Decrements the indicated value.
Page 296: Calibration Of Boom Angle
12.11.5 CALIBRATION OF BOOM ANGLE When this calibration is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) 12.11.6 Calibration of Load when Rated Load indicator WEG . [1] Memory of fully lowered angle (Offset angle value) 1.
Page 297 2] Memory of fully raised angle (Span angle value) 1. Operate crane and raise the boom to the highest condition. 2. Ensure that Boom Angle Value of the level indicating angle. If the indicated value is misaligned, adjust the figures in the Boom Angle Indicator to Value of the level indicating angle by pressing Fall Mode Selector Switch (2) and/or Concealed Switch (3).
Page 298 12.11.6 CALIBRATION OF LOAD When this calibration is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) 12.11.4 Calibration of Boom Length when Rated Load indicator BOM . [1] Memory of Load Calibration Situations 1.
Page 299 [2] Memory of zero load (Offset load value) 1. Adjust the figures in the Actual Load 0.10 by pressing Fall Mode Selector Switch (2) and/or Concealed Switch (3). When calibrating actulal load indication, the Actual Load Indicator shows decimal place of 0.01 t . (Normally shown 0.1 t ) Fall Mode Selector Switch (2): Decrements the indicated value.
Page 300 [3] Memory of specific load (Span Load value) Boom Length 10.0m and Boom Angle 60 degrees configuration as id [2] Memory [1] Memory of Load Calibration Situations When swing of the weight stops after lifting up. 2. Adjust the figures in the Actual Load 2.12 by pressing Fall Mode Selector Switch (2) and/or Concealed Switch (3).
Page 301: Display Details At Calibration Mode
12.11.7 DISPLAY DETAILS AT CALIBRATION MODE Indicator Rated Load Rated Radius Calibration Value (Calibration Items) (Calibration Items) Calibration Items Offset Length Span Length Offset Angle Span Angle Length and Angle at Load Calibration Offset Load Span Load 2-282...
Page 302: Function Mode
12.12 FUNCTION MODE 12.12.1 LIST OF ITEMS Switches] [Displays] (1) Pick & Carry / Stationary Mode Selector Switch (10) Actual Load Display (2) Fall Mode Selector Switch (11) Rated Total Load Display (3) Concealed Switch (12) Working Radius Display (4) Check Switch (13) Rated Radius Display (5) Cancel Switch (14) Boom Angle Display...
Page 303: Selection Of Function
12.12.2 SELECTION OF FUNCTION When function mode is active, various controls enter pause state; do not operate the crane when it is active. If the crane must be operated even in function mode, extreme caution must be taken not to allow various crane conditions to exceed the moment ratio of 100%.
Page 304 2. Press the Pick & Carry / Stationary Mode Selector Switch (1). The Rated Radius indicator shall turn to SOL . When carrying out proportional control output test for boom lowering solenoid valve, refer to 12.4 Proportional Control Output Test for Boom Lowering Solenoid Valve in this condition.
Page 305 5. Press the Pick & Carry / Stationary Mode Selector Switch (1). The Rated Radius indicator shall turn to VIC . When carrying out confirmation of voice output, refer to 12.6 Confirmation of Voice Output in this condition. 6. Press the Pick & Carry / Stationary Mode Selector Switch (1). The Rated Radius indicator shall turn to CLR .
Page 306: Confirmation Of Rom Version
12.12.3 CONFIRMATION OF ROM VERSION When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) twice. 2.4 Proportional Control Output for Boom Lowering Solenoid Valve . 1. After carrying out 12.2 Call out of Function Mode , press the Check Switch (4). The Working Radius indicator shall turn to display VER and the Rated Radius indicator display to XXX ( XXX indicates a ROM version).
Page 307: Proportional Control Output Test For Boom Lowering Solenoid Valve
12.12.4 PROPORTIONAL CONTROL OUTPUT TEST FOR BOOM LOWERING SOLENOID VALVE When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) twice. 2.5 Confirmation of Contact Input State . 1. After carrying out 12.2 Call out of Function Mode , press the Check Switch (4). The Working Radius indicator shall turn to display SOL and the Rated Radius indicator display to D-0 .
Page 308: Confirmation Of Contact State
12.12.5 CONFIRMATION OF CONTACT STATE When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) twice. 2.6 Confirmation of Control Output State . 1. After carrying out 12.2 Call out of Function Mode , press the Check Switch (4). The Working Radius indicator shall turn to display IN , and then the Rated Radius indicator display, Boom Angle Indicator and Rated Load indicator display to XXX.
Page 309: Confirmation Of Control Output
12.12.6 CONFIRMATION OF CONTROL OUTPUT When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) twice. 2.7 Confirmation of Voice Output . 1. After carrying out 12.2 Call out of Function Mode , press the Check Switch (4). The Working Radius indicator shall turn to display OUT and the Rated Radius indicator display to D-0 .
Page 310: Confirmation Of Voice Output
12.12.7 CONFIRMATION OF VOICE OUTPUT When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode Selector Switch (1) twice. 2.8 Calibration and Initialization of each Working Range Limitation Value . 1. After carrying out 12.2 Call out of Function Mode , press the Check Switch (4). The Working Radius indicator shall turn to display OUT and the Rated Radius indicator display to D-0 .
Page 311: Calibration And Initialization Of Each Working Range Limitation Value
12.12.8 CALIBRATION AND INITIALIZATION OF EACH WORKING RANGE LIMITATION VALUE When this function is not required, skip the operations below by pressing Pick & Carry / Stationary Mode 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 shall turn to display ZZZ .
Page 312 3. When carrying out the Initialization, press the Check Switch (4). The flashing CLR of the Rated Radius indicator changes 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).
Page 313 12.13 ERROR CODES Total rated load o display error codes. Error Code Error Details Actions to Be Taken The input to pressure sensor 1 is lower than the normal value. Check the installation of the pressure sensor 1. The input to pressure sensor 1 is higher than the normal value.
Page 314: Standard Value Table
STANDARD VALUE TABLE 1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 3. STANDARD VALUE TABLE FOR MOMENT LIMITER RELATED PARTS...
Page 315: Standard Value Table For Engine Related Parts
1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Applicable Model LC1385M-8 Engine SAA4D95LE-5 Standard Value Service Limit Item Test Condition Unit Value New Machine High idle 2300±60 temperature: Engine speed Low idle 1100±50 Operating range Rated speed 2200 At sudden Max.
Page 316: Standard Value Table For Chassis Related Parts
2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable Model LC1385M-8 Standard Value Service Limit Item Test Condition Unit Value New Machine Hydraulic oil temperature: 45 to 55°C Engine speed Engine oil pressure: Operating range 2200 (At 1-pump relief) Engine coolant temperature: Operating range Raising, Derricking control lever travel...
Page 317 Applicable Model LC1385M-8 Standard Value Service Limit Item Test Condition Unit Value New Machine Hydraulic oil Control lever at 3.4±1.0 3.4±1.0 temperature: 45 to HOLD {35±10} {35±10} Servo piston input pressure 55°C At pump relief 16.0±1.5 16.0±2.5 Engine at high idle (normal actuation) {163±15} {163±25}...
Page 318 Applicable Model LC1385M-8 Standard Value Service Limit Item Test Condition Unit Value New Machine Set the machine to travel posture Travel posture: boom retracting fully and horizontal position, hook stowing position Hydraulic oil temperature: 45 to 55°C Travel deviation Engine at high idle Max.
Page 319 Pump performance curve...
Page 320 3. STANDARD VALUE TABLE FOR MOMENT LIMITER RELATED PARTS Applicable Model LC1385M-8 Standard Value Service Limit Item Test Condition Unit Value New Machine Boom fully retracting Adjustment of boom length display Boom fully extending 16.3 16.3 Boom horizontal position Adjustment of boom angle Degree display Boom fully raising...
Page 322: Testing And Adjusting
TESTING AND ADJUSTING 1. TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 2. TESTING ENGINE SPEED 3. TESTING EXHAUST TEMPERATURE 4. CHECKING EXHAUST GAS COLOR 5. ADJUSTING VALVE CLEARANCE 6. TESTING COMPRESSION PRESSURE 4-10 7. TESTING BLOW-BY PRESSURE 4-12 8. TESTING ENGINE OIL PRESSURE 4-13 9.
Page 323: Tools For Testing, Adjusting And Troubleshooting
1. TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...
Page 326: Testing Engine Speed
2. TESTING ENGINE SPEED...
Page 327: Testing Exhaust Temperature
3. TESTING EXHAUST TEMPERATURE...
Page 328: Checking Exhaust Gas Color
4. CHECKING EXHAUST GAS COLOR...
Page 329: Adjusting Valve Clearance
5. ADJUSTING VALVE CLEARANCE...
Page 331: Testing Compression Pressure
6. TESTING COMPRESSION PRESSURE 4-10...
Page 332 4-11...
Page 333: Testing Blow-By Pressure
7. TESTING BLOW-BY PRESSURE 4-12...
Page 334: Testing Engine Oil Pressure
8. TESTING ENGINE OIL PRESSURE 4-13...
Page 335: Handling Fuel System Parts
9. HANDLING FUEL SYSTEM PARTS 10. RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 4-14...
Page 336: Testing Fuel Pressure
11. TESTING FUEL PRESSURE 4-15...
Page 337: Testing Fuel Return Rate And Fuel Leakage
12. TESTING FUEL RETURN RATE AND FUEL LEAKAGE 4-16...
Page 338 4-17...
Page 339: Bleeding Air From Fuel Circuit
13. BLEEDING AIR FROM FUEL CIRCUIT 4-18...
Page 340 4-19...
Page 341: Checking Fuel Circuit For Leakage
14. CHECKING FUEL CIRCUIT FOR LEAKAGE 4-20...
Page 342: Testing And Adjusting Alternator Belt Tension
15. TESTING AND ADJUSTING ALTERNATOR BELT TENSION 4-21...
Page 343 16. TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 4-22...
Page 344: Checking And Adjusting Track Shoe Tension
17. CHECKING AND ADJUSTING TRACK SHOE TENSION 4-23...
Page 345 4-24...
Page 346: Circuit
18. TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SLEWING AND TRAVEL CIRCUIT 4-25...
Page 347 4-26...
Page 348 4-27...
Page 349: Testing Control Circuit Basic Pressure
19. TESTING CONTROL CIRCUIT BASIC PRESSURE 4-28...
Page 350: Testing And Adjusting Oil Pressure In Pump Pc Control Circuit
20. TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 4-29...
Page 351 4-30...
Page 352 4-31...
Page 353: Testing And Adjusting Oil Pressure In Pump Ls Control Circuit
21. TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL 4-32...
Page 354 4-33...
Page 355 4-34...
Page 356 4-35...
Page 357: Testing Solenoid Valve Output Pressure
22. TESTING SOLENOID VALVE OUTPUT PRESSURE 4-36...
Page 358: Testing Ppc Valve Output Pressure
23. TESTING PPC VALVE OUTPUT PRESSURE 4-37...
Page 359 4-38...
Page 360: Adjusting Play Of Work Equipment And Slewing Ppc Valves
24. ADJUSTING PLAY OF WORK EQUIPMENT AND SLEWING PPC VALVES 4-39...
Page 361: Releasing Residual Pressure From Hydraulic Circuit
25. RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 4-40...
Page 362: Testing Oil Leakage
26. TESTING OIL LEAKAGE Testing tools for oil leakage Symbol Parts No. Parts name Commercially Measuring cylinder available Test the oil leakage under the following condition. Hydraulic oil temperature: Within operating range 1. Testing oil leakage from derrick cylinder 1) Move the derrick cylinder to the RAISE stroke end and stop the engine.
Page 363 4-42...
Page 364: Bleeding Air From Each Part
27. BLEEDING AIR FROM EACH PART 4-43...
Page 365 4-44...
Page 366: Checking Cab Tipping Stopper
28. CHECKING CAB TIPPING 29. ADJUSTING MIRRORS STOPPER 4-45...
Page 367: Adjusting Clearance Of Boom
30. ADJUSTING CLEARANCE OF BOOM Apply grease to each slide plates and greasing points before carrying out this adjustment. [1] How to install upper part slide plate Tighten the slide plate (2) with the button bolt (1) with lock-tight FIG.1 (correspondent to Three-bond 1305) applied on.
Page 368: Adjusting Boom Telescoping Wirerope
31. ADJUSTING BOOM TELESCOPING WIREROPE [1] Adjusting wire for Telescopic Assembly 1. Fully retract cylinders, and retain the cylinder condition so that cylinder dimension D (156.1mm) will not change when adjusting wire. (Retain retract pressure, or keep to be fully retracted with tools.) 2.
Page 369 [2] Adjusting wire in boom assembly Retract booms for several times and check for dimension F (the gap between top boom (21) and No.4 boom (22)). If F 2, readjustment is not needed. 1. If 2 < F 4 (1) Remove boom tip cover (23). Be careful not to damage cord of cord reel.
Page 370: Criteria For Winch Wire Rope Replacement
32. CRITERIA FOR WINCH WIRE ROPE REPLACEMENT A wire rope undergoes wear and tear over time. Prompt replacement is required if any of the following events appears in the wire rope. 1. Percentage of the snipped wires in total wires (except filler wires) in outer strands exceeds the ratio below: (1) 10% or more of the wires in one twist of the wire rope, or 5% or more when such nipped wires are in one single strand..
Page 371: Checking Hook Block
33. CHECKING HOOK BLOCK Hook block is one of the safety-critical parts. Always keep it in a safe condition by testing as below. If any defection is found from the testing, repair or replace it immediately. When replacing, modification inspection is necessary. a sharp edge exists, repair with grinders, etc.
Page 372 4-51...
Page 373: Special Function Of Machine Monitor
34. SPECIAL FUNCTION OF MACHINE MONITOR 4-52...
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Page 423: Handling Voltage Circuit Of Engine Controller
35. HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER 4-102...
Page 424: Precaution Work For Troubleshooting Of Electrical System
36. PRECAUTION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 4-103...
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Page 429: Procedure For Testing Diodes
37. PROCEDURE FOR TESTING DIODES 4-108...

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