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Manitowoc
SERVICE/MAINTENANCE MANUAL
This manual has been prepared for and is considered part of -
The serial number of the crane is the only method Manitowoc has of providing you with
correct parts and service information.
Always furnish serial number of crane and its attachments when ordering parts
or discussing service problems with your Manitowoc distributor or the factory.
©2013 Manitowoc
Published 08-16-13, Control # 208-03
8500-1/8500E-1
Model Number
8500Ref
Serial Number
This Manual is Divided into the following Sections:
SAFETY SECTION
SECTION 1
REFERENCE MATERIALS
SECTION 2
TEST PROCEDURES
SECTION 3
GENERAL
SECTION 4
POWER TRAIN
SECTION 5
HYDRAULIC SYSTEM
SECTION 6
HOIST SYSTEM
SECTION 7
BOOM HOIST SYSTEM
SECTION 8
SWING SYSTEM
SECTION 9
PROPEL SYSTEM
SECTION 10
ELECTRICAL SYSTEM
SECTION 11
AIR CONDITIONER
SECTION 12
TROUBLESHOOTING
NOTICE
To prevent death or serious injury:
Avoid unsafe operation and maintenance.
Crane and attachments must be operated and maintained by trained
and experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
Do not operate or work on crane or attachments without first reading
and understanding instructions contained in Operator Information
Manual and Service Manual supplied with crane and applicable
attachments.
Store Operator Information Manual and Service Manual in operator's
cab.
If Operator Information Manual or Service Manual is missing from cab,
contact your Manitowoc distributor for a new one.

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Summary of Contents for Manitowoc 8500-1

  • Page 1 SECTION 12 TROUBLESHOOTING NOTICE The serial number of the crane is the only method Manitowoc has of providing you with correct parts and service information. Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc distributor or the factory.
  • Page 2 This Page Blank...
  • Page 3: Table Of Contents

    1.1 8500-1 SPECIFICATION..................1-3 1.1.1 CRANE OUTER DIMENSION ................1-3 1.1.2 CRANE SPECIFICATION, PERFORMANCE............ 1-4 1.1.3 CRANE WORKING RANGES ................1-5 1.2 8500-1 DIMENSION, WEIGHT OF EACH COMPONENT ........1-8 1.2.1 MAIN MACHINERY ................... 1-8 1.2.2 COUNTERWEIGHT................... 1-9 1.2.3 ATTACHMENT ....................1-11 1.3 8500-1 SWING AND PROPEL STABILITY ..............
  • Page 4 5.2 HYDRAULIC CIRCUITS AND COMPONENTS ............5-9 5.2.1 COMPONENT SPECIFICATIONS ..............5-9 5.2.2 LAYOUT OF HYDRAULIC COMPONENTS............5-13 5.3 HYDRAULIC SYSTEM..................... 5-27 5.3.1 PREFACE......................5-27 5.3.2 OUTLINE ......................5-27 5.3.3 OIL FLOW FROM No.1 AND No.2 PUMPS ............5-28 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 5 ADJUSTING THE BOOM DRUM LOCK............7-7 7.4 REDUCTION UNIT....................7-8 7.5 CONSTRUCTION AND FUNCTION ................ 7-11 7.5.1 HYDRAULIC SCHEMATIC................7-11 7.5.2 RAISING THE BOOM..................7-12 7.5.3 NEUTRAL (HOLDING BOOM) ................7-14 7.5.4 LOWERING BOOM ................... 7-16 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 6 10.1.12LOAD CELL (CRANE)..................10-186 10.1.13ANGLE SENSOR .................... 10-187 10.1.14TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE. 10-188 10.1.15 HOW TO CHECK THE FAILURE CONTENTS ..........10-189 10.1.16CHECKING OF DIAGNOSIS LAMP FUNCTION ..........10-195 10.1.17ENGINE ECU ....................10-196 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 7 11.3.3 REPLACING THE BLOWER CONTROLLER..........11-15 11.3.4 REMOVAL OF THE HEATER CORE .............. 11-15 11.3.5 REMOVAL OF THE AIR-CON UNIT CASE-FRONT AND- REAR ....11-16 11.3.6 REPLACING THE EVAPORATOR AND EXPANSION VALVE....... 11-17 11.3.7 INSTALLATION OF EVAPORATOR SENSOR ..........11-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 8 11.5 BASIC SYSTEM OF HVAC..................11-20 11.6 RECHARGING OF THE COOLANT ..............11-25 11.6.1 CAUTION AT WORK..................11-25 11.6.2 WORK PROCEDURE ..................11-27 11.6.3 RECHARGING PROCEDURE ................ 11-29 11.7 ELECTRIC WIRING DIAGRAM ................11-35 12. TROUBLESHOOTING 12.1 TROUBLESHOOTING ................... 12-3 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 9: Safety

    SAFETY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 10 SAFETY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 11 It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured by operating this machine according to methods recommended by Manitowoc. While operating machine, be sure to perform work with great care, so as to not damage the machine, or let accidents occur.
  • Page 12 1. When the warning label is damaged or stained, order it to the designated service shop. 2. Do not remove the warning labels. 3. When the surface of the warning label is soiled and difficult to be seen, wipe it cleanly. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 13 SAFETY LABEL LAYOUT * Numbers in the drawings correspond with those in the label explanation detail after P.0-14. 6 (8500E-1) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 14 SAFETY 32 (8500E-1) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 15 SAFETY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 16 SAFETY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 17 SAFETY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 18 SAFETY 15 (8500E-1) 15 (8500-1 w/ J08E-UV) 16 (8500-1 w/ J08E-VM) 8500-1/8500E-1 0-10 Published 08-16-13, Control #208-03...
  • Page 19 SAFETY 0-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 20 SAFETY 8500-1/8500E-1 0-12 Published 08-16-13, Control #208-03...
  • Page 21 SAFETY 0-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 22 4. If machine swings or is assembled / disassembled with crawler retracted, main machinery may turn over to rear side. Read the operator’s manual carefully and set the crane to the proper configuration. 8500-1/8500E-1 0-14 Published 08-16-13, Control #208-03...
  • Page 23 Keep the boom away from the tower or power lines for safety. 7. When work is done on the upper surface of the guard or counterweight, person may fall off by mis- take. Ensure to engage the safety hook on the specified place. 0-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 24 Do not weld or apply heat without checking with your authorized dealer. Unauthorized modifications may weaken the ma- chine. 11. Do not lift people with this crane. Failure to do so may cause serious injury. 8500-1/8500E-1 0-16 Published 08-16-13, Control #208-03...
  • Page 25 Take extra care in handling accumulator. (Do not weld, flame cut, dispose or disassemble.) 14. The accumulator is charged with high pressure ni- trogen gas. Charge the nitrogen gas within the specified pres- sure. 0-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 26 Otherwise the gantry may come off and the boom may drop off. 18. Handling the counterweight in wrong way is very dangerous. Never allow any person to enter under the lifting counterweight. 8500-1/8500E-1 0-18 Published 08-16-13, Control #208-03...
  • Page 27 Never allow anybody to enter the swing range. 21. During engine running or straight after the engine is stopped, hydraulic oil tank, engine and muffler are hot. Touching them may cause burns. Do not touch the hot area. 0-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 28 Stop the crane and then remove the drum cover. 24. When the machine is transported with the low gan- try, connect the tension bar to the revolving frame or counterweight. 8500-1/8500E-1 0-20 Published 08-16-13, Control #208-03...
  • Page 29 28. Taking wrong procedure in boom assembly or dis- assembly may cause boom falling off and person may get injured. Do not allow any person to enter the inside or under the boom during assembly or disassembly. 0-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 30 30. Taking the wrong installing direction when the rope sockets are installed to the boom tip and jib tip, may damage the boom or may break the wire rope. Install the rope socket in the proper direction. 8500-1/8500E-1 0-22 Published 08-16-13, Control #208-03...
  • Page 31 Keep the caution label in good condition to read. • Whenever they become dirty, wash them with water or detergent. • Whenever they are damaged or missed, replace them with the new and same ones. 0-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 32 12. Before starting a cleaning or lubrication work on the machine, always shut down the engine. 13. Use genuine Manitowoc replacement parts and oils only. 14. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also, fill clean, fresh oils only.
  • Page 33 30. Battery fluid and oils are harmful to human health. If touching any of these materials, immediately wash it away. 31. When lifting a load with a crane, first confirm that a load is lifted off the ground surely and then continue lifting work. 0-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 34 SAFETY 8500-1/8500E-1 0-26 Published 08-16-13, Control #208-03...
  • Page 35: Reference Materials

    1. REFERENCE MATERIALS 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 36 1. REFERENCE MATERIALS 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 37: 8500-1 Specification

    1. REFERENCE MATERIALS 8500-1 SPECIFICATION 1.1.1 CRANE OUTER DIMENSION UNIT : mm (ft - in) 5,140 (16’ 10” ) 1,100 (3’ 7” ) 3,160 (10’ 4” ) 2,990 (9’ 10” ) 5,440 (17’ 10” ) 1,495 6,280 (20’ 7” ) (4’...
  • Page 38: Crane Specification, Performance

    Overall length of crawlers 5,440 (17’ 10”) Distance between centers of tumblers 5,244 / 3,614 (17’ 2” / 11’ 10”) Overall width of crawlers (Extend/Retract) Width of crawler shoe 914 (3’) 390 (1’ 3”) Ground clearance of carbody 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 39: Crane Working Ranges

    25 (82) 21.3 (70) BOOM 20° 18.3 (60) BOOM 20 (66) 15.2 (50) BOOM 12.2 (40) BOOM (33) (49) (66) (82) (98) (115) (131) (148) (164) Radius from center of rotation Center of rotation 1.10 (3.6) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 40 + 12.2 (40) Jib 24.4 (80) Boom 35 (115) + 9.1 (30) Jib 30 (98) 25 (82) 20 (66) (33) (49) (66) (82) (98) (115) (131) (148) (164) Radius from center of rotation Center of rotation 1.10 (3.6) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 41 + 12.2 (40) Jib 24.4 (80) Boom 35 (115) + 9.1 (30) Jib 30 (98) 25 (82) 20 (66) (33) (49) (66) (82) (98) (115) (131) (148) (164) Radius from center of rotation Center of rotation 1.10 (3.6) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 42: 8500-1 Dimension, Weight Of Each Component

    1. REFERENCE MATERIALS 8500-1 DIMENSION, WEIGHT OF EACH COMPONENT Dimension and weight of each component when disassembled is shown here. Use this as reference value. 1.2.1 MAIN MACHINERY Weight Name Dimension mm (ft-in) kg (lbs) Base Machine 12,090 (39’ 8”) •...
  • Page 43: Counterweight

    Name Dimension mm (ft-in) kg (lbs) No.1 9,320 Counterweight (20,550) 4,430 (14’ 6”) 1,450 (4’ 9”) (2’ 11”) No.2, No.3 4,200 Counterweight (R) (9,260) 1,450 (4’ 9”) (2’ 11”) No.2, No.3 4,200 Counterweight (L) (9,260) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 44 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 3,270 Carbody weight (7,209) /1piece 1,640 (5’ 5”) 1,590 (5’ 3”) 880 (2’ 11”) Self removal unit (1,896) 8500-1/8500E-1 1-10 Published 08-16-13, Control #208-03...
  • Page 45 6.1m (20ft) (1,025) Boom insert 1,360 6,210 (20’ 5”) (4’ 6”) 12.2m (40ft) (1,896) Boom insert 1,360 12,310 (40’ 5”) (4’ 6”) 12.2m (40ft) Boom insert with lug (1,929) 1,360 (4’ 6”) 12,310 (40’ 5”) 1-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 46 Jib base (440) 4,810 (15’ 9”) (2’ 8”) 3.0m (10ft) (210) Jib insert 3,110 (10’ 2”) (2’ 8”) 6.1m (20ft) (390) Jib insert 6,160 (20’ 3”) (2’ 8”) Jib strut (456) 3,620 (11’ 11”) 8500-1/8500E-1 1-12 Published 08-16-13, Control #208-03...
  • Page 47 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) Auxiliary sheave (320) (1’ 2”) 830 (2’ 9”) Upper spreader (514) (11’) 1,460 (4’ 9”) 1-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 48: Attachment

    1. REFERENCE MATERIALS 8500-1 SWING AND PROPEL STABILITY 1. Without carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler Forward Backward extend retract (Without) 9.32 (20,550) (Slope:14 deg. Without attachment (No.1) or less) (Base machine only) 17.72 (39,070)
  • Page 49 Propel motor Traveling forward (4) Travelling forward means the case where the coun- terweight is at the lower slope and the traveling backward where it is at the upper slope. Propel motor Traveling backward 1-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 50: 8500-1 Propel Allowable Slope Angle

    1. REFERENCE MATERIALS 8500-1 PROPEL ALLOWABLE SLOPE ANGLE 1.4.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION In the area showing [-] mark, do not propel. Machine may overturn. Failure to observe this precaution may result in serous injuries or loss of life.
  • Page 51 1. REFERENCE MATERIALS 1. 8500-1 CRANE PROPEL ALLOWABLE SLOPE AN- (1) Without aux. sheave (Unit : Degree) Forward Backward Boom length m (ft) Boom angle Boom angle 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110)
  • Page 52 1. REFERENCE MATERIALS 2. 8500-1 FIXED JIB PROPEL ALLOWABLE SLOPE ANGLE (Unit : Degree) 9.1 (30) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120)
  • Page 53 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 1-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 54 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 8500-1/8500E-1 1-20 Published 08-16-13, Control #208-03...
  • Page 55 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 1-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 56: 8500E-1 Specification

    3,160 (10’ 4” ) 2,990 (9’ 10” ) 1,495 5,440 (17’ 10” ) (4’ 11” ) 6,280 (20’ 7” ) (3’ 1” ) 3,500 (11’ 6” ) (CRAWLER RETRACTED) 5,130 (16’ 10” ) (CRAWLER EXTENDED) 8500-1/8500E-1 1-22 Published 08-16-13, Control #208-03...
  • Page 57 3,160 (10’ 4” ) 2,990 (9’ 10” ) 5,440 (17’ 10” ) 1,495 6,280 (20’ 7” ) (4’ 11” ) (3’ 1” ) 3,500 (11’ 6” ) (CRAWLER RETRACTED) 5,130 (16’ 10” ) (CRAWLER EXTENDED) 1-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 58: Crane Specification, Performance

    5,440 (17’ 10”) Distance between centers of tumblers 5,130 / 3,500 (16’ 10” / 11’ 6”) Overall width of crawlers (Extend/Retract) 800 (2’ 8’) Width of crawler shoe Ground clearance of carbody 390 (1’ 3”) 8500-1/8500E-1 1-24 Published 08-16-13, Control #208-03...
  • Page 59: Crane Working Ranges

    1. REFERENCE MATERIALS 1.5.3 CRANE WORKING RANGES 1. CRANE WORKING RANGES 1-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 60 1. REFERENCE MATERIALS 2. JIB WORKING RANGE (1) Offset angle 10 degrees 8500-1/8500E-1 1-26 Published 08-16-13, Control #208-03...
  • Page 61 1. REFERENCE MATERIALS (2) Offset angle 30 degrees 1-27 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 62: 8500E-1 Dimension, Weight Of Each Component

    800 (2’ 8”) 6,280 (20’ 7”) 7,180 (15,829) 1,040 (3’ 5”) *1 With the side step on cabin side : 3,170 (10’ 5”) With the side steps on the both side : 3,340 (11’) 8500-1/8500E-1 1-28 Published 08-16-13, Control #208-03...
  • Page 63: Counterweight

    3,500 (11’ 6”) 6,410 Counterweight (3) (14,131) 3,500 (11’ 6”) 1,000 (3’ 3”) (2’ 1”) 1,660 Counterweight (L) (3,660) (2’ 1”) 1,370 (4’ 6”) 2,740 Counterweight (R) (6,041) 3,270 Carbody weight (7,209) /1piece 1,640 (5’ 5”) 1-29 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 64: Counterweight With Self-Removable Device (Option)

    (2’ 11”) (4’ 9”) Counterweight (R) 4,200 (3) (5) (9,260) (Option) 1,450 (4’ 9”) (2’ 11”) Counterweight (L) 4,200 (2) (4) (9,260) (Option) 880 (2’ 11”) 1,590 (5’ 3”) Self removal unit (1,896) (Option) 8500-1/8500E-1 1-30 Published 08-16-13, Control #208-03...
  • Page 65: Attachment

    Boom insert with lug (1,201) 1,490 6,210 (20’ 5”) (4’ 11”) 9.1m (30ft) Boom insert (1,636) 1,490 (4’ 11”) 9,260 (30’ 5”) 9.1m (30ft) Boom insert with lug (1,687) 1,490 9,260 (30’ 5”) (4’ 11”) 1-31 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 66 Jib tip (320) (2’ 2”) 3,400 (11’ 2”) Jib base (275) 3,180 (10’ 5”) (2’ 2”) 6.1m (20ft) Jib insert (310) 6,160 (20’ 3”) (2’ 2”) Jib strut (420) 3,620 (11’ 11”) 840 (2’ 9”) 8500-1/8500E-1 1-32 Published 08-16-13, Control #208-03...
  • Page 67 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 470 (1’ 7”) Auxiliary sheave (309) 1,120 (3’ 8”) Upper spreader (620) 1,580 (5’ 2”) (1’) Lower spreader (474) 870 (2’ 10”) (0’ 11”) 1-33 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 68 (lbs) Φ300 (1’) Ball hook (353) (1’ 11”) (1’ 3”) 19t Hook (882) (1’ 1”) (1’ 11”) 32t Hook (1,102) (1’ 5”) (1’ 11”) 50t Hook (1,433) (1’ 9”) (2’) 80t Hook (1,764) 8500-1/8500E-1 1-34 Published 08-16-13, Control #208-03...
  • Page 69 (ground, crane configuration). Traveling forward (4) Travelling forward means the case where the coun- terweight is at the lower slope and the traveling backward where it is at the upper slope. propel motor Traveling backward 1-35 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 70 (ground, crane configuration). Traveling forward (4) Travelling forward means the case where the coun- terweight is at the lower slope and the traveling backward where it is at the upper slope. propel motor Traveling backward 8500-1/8500E-1 1-36 Published 08-16-13, Control #208-03...
  • Page 71: 8500E-1 Propel Allowable Slope Angle

    • Propel straight against slope. • Provide the gentle slope at the beginning and end positions of slope. Propel upward downward on slope : allowable angle) FORWARD BACKWARD BOOM ANGLE BOOM ANGLE 1-37 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 72 Boom angle Boom angle 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 8500-1/8500E-1 1-38 Published 08-16-13, Control #208-03...
  • Page 73 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 1-39 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 74 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 8500-1/8500E-1 1-40 Published 08-16-13, Control #208-03...
  • Page 75 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 1-41 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 76 Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180) 8500-1/8500E-1 1-42 Published 08-16-13, Control #208-03...
  • Page 77: Engine Main Specification

    1. REFERENCE MATERIALS ENGINE MAIN SPECIFICATION 8500-1 : Hino Model J08E-UV diesel engine Engine (complying with the Interim Tier4 & Stage IIIB Emission Regulations) 8500E-1 : Hino Model J08E-UV diesel engine (complying with the Interim Tier4 & Stage IIIB Emission Regulations)
  • Page 78 ENGINE PERFORMANCE CURVE This indicates performance curve of single unit of engine. This does not include performance lowering based on work load. (N m) 1000 (kW) 1000 1400 1800 2200 2600 3000 Engine speed (min ) 8500-1/8500E-1 1-44 Published 08-16-13, Control #208-03...
  • Page 79: Maintenance Standards Test Procedures

    2. MAINTENANCE STANDARDS TEST PROCEDURES 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 80 2. MAINTENANCE STANDARDS TEST PROCEDURES 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 81: Maintenance Standard

    Location Item dimension limit Remedy figure d’ 44.0 44.26 Fig.2-1 Pawl (Front/rear) Replace (1.732) (1.743) (P.2-6) 45.0 45.27 Fig.2-4 Bushing Pawl (Boom) Replace (1.772) (1.782) (P.2-7) 100.0 100.67 Fig.2-6 Boom foot Replace (3.937) (3.963) (P.2-9) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 82 Location Item Remedy length free length figure 68.4 Fig.2-1 Front/rear drum pawl (2.835) (2.693) (P.2-6) (Compression) 68.4 Fig.2-3 Boom drum pawl (2.835) Replace (2.693) (P.2-7) (Compression) 61.5 63.9 Fig.2-5 Brake pedal (2.421) (2.516) (P.2-8) (Tension) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 83 12.5 Upper spreader (13.858) (13.669) (0.492) build-up 347.2 10.0 Fig.2-8 Lower spreader (13.858) (13.669) (0.394) (P.2-10) Jib point 12.5 Fig.2-7 (16.850) (16.732) (0.492) (P.2-9) Jib strut 347.2 10.0 Fig.2-8 Gantry peak (13.858) (13.669) (0.394) (P.2-10) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 84 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-1 Front/rear drum lock assy 117 mm (4.606 inch) Wear Limit : 3 mm (0.118 inch) Fig.2-2 Pawl 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 85 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-3 Boom drum lock assy 110 mm (4.331 inch) Wear Limit : 3 mm (0.118 inch) Fig.2-4 Pawl 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 86 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-5 Brake pedal 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 87 2. MAINTENANCE STANDARDS TEST PROCEDURES 8500E-1 8500-1 Fig.2-6 Crane assy Fig.2-7 Jib assy 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 88 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-8 Gantry assy 8500-1/8500E-1 2-10 Published 08-16-13, Control #208-03...
  • Page 89: Propel Device

    (1.535) Build-up 34.0 (1.339) (1.417) replace 205.0 203.2 Pitch (P) (8.071) (8.000) Distance between pins when 6 pcs of shoes are connected and tension applied : 1213.2 to 1225.2 mm (47.764 to 48.236 inch) 2-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 90 (1.535) Build-up 34.0 (1.339) (1.417) replace 205.0 203.2 Pitch (P) (8.071) (8.000) Distance between pins when 6 pcs of shoes are connected and tension applied : 1213.2 to 1225.2 mm (47.764 to 48.236 inch) 8500-1/8500E-1 2-12 Published 08-16-13, Control #208-03...
  • Page 91 - 3 deg. (5.118) (1.181) (1.378) (0.236) (1.378) 7 deg. Wear limit : 2 (0.079) Hardened area Wear limit : 2 (0.079) SECTION A - A SECTION C - C Unit : mm (inch) 2-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 92 Interference of 0.052 (0.002) Interference (+0.004) sprocket and 125 (4.921) 0 (0) bushing +0.040 0.117 (0.005) Bore (+0.002) +0 (+0) Side clearance of 0.02 to 0.74 (0.001 to 0.029) 1.2 (0.047) idler (One side) 8500-1/8500E-1 2-14 Published 08-16-13, Control #208-03...
  • Page 93 Interference Interference (+0.003) Interference of roller 0.045 (0.002) Replace and bushing (3.543) +0.035 0.11 (0.004) (+0.001) Bore Side clearance of Replacement of roller 0.02 to 0.053 (0.001 to 0.047) 1.2 (0.047) bushing (One side) 2-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 94 2. MAINTENANCE STANDARDS TEST PROCEDURES 5. Guide roller (Upper roller) (0.197) (0.197) (1.575) (1.575) (2.362) (5.512) Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Outer diameter replace (7.874) (7.559) 8500-1/8500E-1 2-16 Published 08-16-13, Control #208-03...
  • Page 95 = 32 mm (1.260 inch) (23.622) (1.260) DETAIL A Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Height of guide bar (2.165) (1.181) replace 2-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 96 Wear limit Name of plate Number Std. brake torque (Total) (Total) Friction plate 16.92 to 18.32 mm -0.7 mm More than 426 N-m (0666 to 0.721 inch) (-0.028 inch) (More than 314 lbs-ft) Separator plate 8500-1/8500E-1 2-18 Published 08-16-13, Control #208-03...
  • Page 97: Performance Standard And Test Procedure

    Draw the ropes around the area where the machine operates to keep out everyone. Check that the overhoist prevention (for hook/ boom) correctly operates. Lock all functions that are not used. Do not attempt sudden startup/sudden stop. 2-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 98: Operating Speed

    Boom Length : Basic boom more than 2 m (6.6 ft) before (23.622 inch) Place : Firm and starting the measuring. level ground Take average of 3 times measuring. 20 m (66 ft) 8500-1/8500E-1 2-20 Published 08-16-13, Control #208-03...
  • Page 99: Point And Method Of Measuring Pressure

    • Boom • Mode : Power mode 3. Make the valve relieved by boom • Rear drum drum winch lowering operation. 1st speed • Front drum 2nd speed RELIEF VALVE PRESSURE GAUGE PORT (PF1/4) 2-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 100 45 to 55° C (113 to 131° F) 2. Make the valve relieved by swing operation. • Swing mode : Free high • Mode : Power mode PRESSURE GAUGE PORT (PF 1/4) RELIEF VALVE VIEW FROM A 8500-1/8500E-1 2-22 Published 08-16-13, Control #208-03...
  • Page 101 1.42 to 1.62 MPa (206 to 235 psi) Swing 1.62 to 1.92 MPa (235 to 278 psi) Third drum 2.65 to 2.94 MPa (384 to 426 psi) Boom 2.50 to 2.79 MPa (363 to 405 psi) 2-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 102 2. Make the valve relieved by operat- ing crawler retraction or extension. Retraction 20.6 MPa (2,988 psi) MACHINE FRONT PRESSURE GAUGE PORT (PF 1/4) EXT. PORT RELIEF VALVE (R.H., L.H.) RET. PORT RELIEF VALVE (R.H., L.H.) 8500-1/8500E-1 2-24 Published 08-16-13, Control #208-03...
  • Page 103 Lower : 4.9 MPa (711 psi) RELIEF VALVE (RAISING) 20.6 MPa (2,988 psi) RELIEF VALVE PRESSURE GAUGE RELIEF VALVE (LOWERING) (GANTRY RAISE/LOWER) PORT (PF 1/4) 4.9 MPa (711 psi) 20.6 MPa (2,988 psi) 2-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 104: Slewing Ring

    COUNTERWEIGHT : FULL Condition of measurement Amount of play Boom length : 12.2 m (40 ft) Less than 3 mm Radius : 5.5 m (18 ft) (0.118 inch) Load : 51.4 t (113,318 lbs) 8500-1/8500E-1 2-26 Published 08-16-13, Control #208-03...
  • Page 105: General Work Standard

    3. GENERAL WORK STANDARD 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 106 3. GENERAL WORK STANDARD 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 107: Tightening Torque Of Cap Screws And Nuts

    (585 to 715) (488 to 596) (1267 to 1549) (1066 to 1302) 1023 to 1251 856 to 1046 2205 to 2659 1843 to 2253 (754 to 922) (630 to 770) (1625 to 1985) (1358 to 1660) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 108 1559.3 (1150) 1304.3 (962) 2520.3 (1859) 2118.0 (1562) 1 3/8 912.0 (673) 764.9 (564) 2049.6 (1512) 1716.2 (1266) 3314.6 (2445) 2785.1 (2054) 1 1/2 1216.0 (897) 1019.9 (752) 2716.4 (2004) 2275.1 (1678) 4403.2 (3248) 3687.3 (2720) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 109 4020.7 (2966) Use thread lock to prevent bolt and nut from loosening. (LOCTITE #242) Before using thread lock, wash rust, dirt and oil on thread area and dry completely. MANITOWOC GENUINE THREAD LOCK (LOCTITE #242) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 110: Tightening Torque Of Hydraulic Fittings

    118 to 157 (87 to 116) 1" 147 to 186 (108 to 137) 1 1/4" 167 to 226 (123 to 166) 1 1/2" 216 to 275 (159 to 202) 2" 255 to 333 (188 to 246) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 111 185 - 215 8 1/4" - 9 1/2" 205 - 240 9 1/4" - 10 1/2" 235 - 270 10 1/4" - 11 1/2" 255 - 290 11 1/4" - 12 1/2" 285 - 320 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 112: Standard Parts

    In case of 13 or 18, it indicates 10T class. In case of 23, it indicates Hexagon socket set screw. 4.8 (4T) 10.9 (10T) ZS11F ZS12F ZS13F ZS16F ZS17F ZS18F ZS11C ZS12C ZS13C ZS16C ZS17C ZS18C 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 113: O-Ring

    Green is of fluorine rubber and is ranged from -15°C to 200°C. One blue dot ZD11 Nitrile rubber Hs70 Two blue dots ZD12 Nitrile rubber Hs90 One red dot Nitrile rubber Hs70 One yellow dot Styrol rubber Hs70 One green dot Fluorine rubber Hs70 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 114: Back-Up Ring

    The numeric 85 indicates "BIAS CUT". The numeric 95 indicates "SPIRAL". WIDTH INNER DIAMETER BIAS CUT BACK-UP RING O-RING PRESSURE PRESSURE 1pce. of the back-up ring is used. 2pce. of the back-up rings are used. 8500-1/8500E-1 3-10 Published 08-16-13, Control #208-03...
  • Page 115: Bite Type Fitting

    ZA82P22000 — ZA82P28000 — ZA82P35000 PLUG for connector Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF83P10000 ZA83P10000 ZF83P15000 ZA83P15000 ZF83P18000 ZA83P18000 ZF83P22000 ZA83P22000 ZF83P28000 ZA83P28000 — ZA83P35000 3-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 116 108 to 128 128 to 166 197 to 235 246 to 304 385 to 443 N-m (ft-lbs) (28 to 36) (80 to 94) (94 to 122) (146 to 174) (180 to 220) (291 to 319) 8500-1/8500E-1 3-12 Published 08-16-13, Control #208-03...
  • Page 117: Conversion Table

    0.45359 0.00050 0.(3)4460 0.(3)4536 907.185 32000 2000 0.89286 0.90719 1016.05 35840 2240 1.12 1.01605 1000 35274 2204.6 1.10231 0.98421 [ Remakes ] mt : ton (Metric) nt : ton (U.s.unit) gt : (British Unit) 3-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 118: Millimeter : Inch Conversion Table

    2.7953 2.8346 2.8740 2.9134 2.9528 2.9921 3.0315 3.0709 3.1102 3.1496 3.1890 3.2283 3.2677 3.3071 3.3465 3.3858 3.4252 3.4646 3.5039 3.5433 3.5827 3.6220 3.6614 3.7008 3.7402 3.7795 3.8189 3.8583 3.8976 25.4 mm = 1 inch 8500-1/8500E-1 3-14 Published 08-16-13, Control #208-03...
  • Page 119 123.825 149.225 174.625 200.025 225.425 250.825 29/32 23.019 48.419 73.819 99.219 124.619 150.019 175.419 200.819 226.219 251.619 15/16 23.813 49.213 74.613 100.013 125.413 150.813 176.213 201.613 227.013 252.413 31/32 24.606 50.006 75.406 100.806 126.206 151.606 177.006 202.406 227.806 253.206 3-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 120: Meter And Foot Conversion Table

    140.21 38.10 89.92 141.73 39.62 91.44 143.26 41.15 92.96 144.78 42.67 94.49 146.30 44.20 96.01 147.83 45.72 97.54 149.35 47.24 99.06 150.88 48.77 100.58 152.40 50.29 102.11 51.82 103.63 1 foot = 0.3048 meter 8500-1/8500E-1 3-16 Published 08-16-13, Control #208-03...
  • Page 121: Grade Conversion Table

    Coal cold Steel Coal powder Cast iron Coke Aluminum Concrete Cedar Soil Cypress Gravel Paulownia Weight of wood is that of the dried. Value shown in the table may well be taken for specific gravity. 3-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 122: System International (Si) Unit Conversion Table

    9.807 0.1013 kcal 4186 lbf/in 0.0069 kgf s/cm 98067 Pa s kgf/cm 98.1 0.001 Pa s 101.3 Pa s lbt/in 1 X 10 mm Hg 133.3 0.0001 atm cc/s 0.1013 Pa m 8500-1/8500E-1 3-18 Published 08-16-13, Control #208-03...
  • Page 123: Power Train

    4. POWER TRAIN 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 124 4. POWER TRAIN 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 125: Introduction

    (option). The 2 section gear pump (option) connected to the power divider provides the pressured oil to free fall brake cooling line of the front and rear drum. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 126 HYD. OIL TANK REAR DRUM REAR DRUM REDUCTION UNIT POWER DIVIDOR REAR DRUM MOTOR ENGINE DIESEL PARTICULATE FILTER RADIATOR & OIL COOLER SEPARATE OIL COOLER AIR CLEANER BOOM DRUM BOOM DRUM BOOM DRUM MOTOR REDUCTION UNIT 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 127 GEAR PUMP MAIN (CONTROL & CONTROL VALVE AUX. UNIT) MAIN PUMP MAIN CONTROL VALVE GEAR PUMP (COOLING) SWING PUMP DRIVE TUMBLER PROPEL MOTOR PROPEL REDUCTION UNIT SWING BEARING CRAWLER EXT/RET CYLINDER SWING RING GEAR SWIVEL JOINT 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 128: Engine

    12. Check that all the electric wiring, mechanical con- nection and fuel piping are disconnected and there would be no interference for removing the engine. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 129 Weight is approx. 1,250 kg (2,756 lbs). Take necessary action to prevent overturning of the en- gine. LIFTING HOOK LIFTING HOOK 16. Inspect the rubber mount and replace them if re- quired. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 130 4. POWER TRAIN This page is blank for editing convenience. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 131: Repair And Maintenance

    Never bring a flame close to the battery to prevent inflammation or explosion. Do not place any metal objects such as tools on or around of the battery to prevent causing spark. Ensure to properly use booster cables to prevent explosion sue to miss-use. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 132 109 to 133 N-m 504 to 616 N-m 261 to 319 N-m (Apply LOCTITE #271) (81 to 98 lbs-ft) (372 to 454 lbs-ft) (193 to 235 lbs-ft) (Apply LOCTITE #271) (Apply LOCTITE #271) (Apply LOCTITE #271) 8500-1/8500E-1 4-10 Published 08-16-13, Control #208-03...
  • Page 133 360 to 440 N-m (266 to 324 lbs-ft) SECTION A-A (Apply LOCTITE #271) Tightening torque 261 to 319 N-m (193 to 235 lbs-ft) (Apply LOCTITE #271) Tightening torque 504 to 616 N-m (372 to 454 lbs-ft) SECTION B-B (Apply LOCTITE #271) 4-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 134: Pump Drive Assembly

    The power then is divided by 3 sets of helical gears (4 sets when option is selected) to the main pump shaft, swing pump shaft, cooling pump shaft. (Closed with the flange when free less is selected.) (See 4.3.2) 8500-1/8500E-1 4-12 Published 08-16-13, Control #208-03...
  • Page 135: Removal

    4. The main part of this coupling will be removed with the power divider connected to its shaft. Remove the remaining coupling bushing (engine side) or element. 4-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 136 FRONT / REAR DRUM COOLING PUMP (Flange When “Free Less” Is Selected) OIL FILL PORT COUPLING OIL LEVEL GAUGE MAIN PUMP FLANGE (OPT : When Not Selected) OIL DRAIN COCK Fig.4-1 PUMP DRIVE (1/2) 8500-1/8500E-1 4-14 Published 08-16-13, Control #208-03...
  • Page 137 ADAPTER PLATE (ENGINE SIDE) ELEMENT BUSHING (ENGINE SIDE) FLYWHEEL COUPLING CLAMPING SCREW (POWER DIVIDER SIDE) CLAMPING HUB (POWER DIVIDER SIDE) OUTER HUB (POWER DIVIDER SIDE) INSERT (POWER DIVIDER SIDE) FLYWHEEL HOUSING Fig.4-2 PUMP DRIVE (2/2) 4-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 138: Disassembling The Power Divider

    (10) using two pull out screw holes (M10) of the support (10). If required, remove the screws (36) and the plate (18). 13. Remove the gear (6) and both side bearings (24), (25). 8500-1/8500E-1 4-16 Published 08-16-13, Control #208-03...
  • Page 139 16. Remove the gear (7) and if required, remove both side bearing (26), (27). 17. If required, remove the screws (36) and the plate (20). 18. If required, remove the cap screws (34) and plate (15). 4-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 140: Check And Repair Of The Power Divider

    11. Check cap screw threadings and screw hole threadings and replace or repair any that show signs of cross-threading and or strippage. 12. Take out the breather cap and clean in the pipe and check the orifice hole for clogging. 8500-1/8500E-1 4-18 Published 08-16-13, Control #208-03...
  • Page 141: Assembling The Power Divider

    (11) to the housing (1) to make oil groove comes to the position as shown in P.4-22. (UP cast mark up- ward) 4. After assembly, check that the input shaft turns lightly by hand. 4-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 142: Re-Installation

    440 to 490 N-m (324.6 to 361.5 lbs- ft) torque. (LOCTITE not necessary with micro capsule coat- ing) In case of micro capsule coating, if tightened once, remove completely first and then apply LOCTITE #242. 8500-1/8500E-1 4-20 Published 08-16-13, Control #208-03...
  • Page 143 (Approx. 10.7 ltr., When option is selected, approx. 10.0 ltr.) 10. Install the power divider with engine attached to the machine referring to [4.2 ENGINE] 11. Start the engine and check for unusual noise or oil leak during low idling speed. 4-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 144 Install with cast “UP” mark facing upward. (Note 1) ARROW “D” Tightening torque 4.9 to 9.8 N-m (3.7 to 7.2 lbs-ft) Apply LOCTITE #515 between ARROW “E” screw and packing seal. Fig.4-3 POWER DIVIDER (1/3) 8500-1/8500E-1 4-22 Published 08-16-13, Control #208-03...
  • Page 145 Tightening torque 31.5 to 38.5 N-m (23.3 to 28.3 lbs-ft) Apply LOCTITE #242 Note on direction (Note 1) Apply LOCTITE #515 evenly on mating surface of item 1 “HOUSING” SECTION B-B Fig.4-4 POWER DIVIDER (2/3) 4-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 146 (3) Insert shim into stand and install bearing outerlace only. DETAIL OF “F” (4) Install stand into housing (5) Check for shim to be in right place before oil seal installation. (6) Install oil seal. Fig.4-5 POWER DIVIDER (3/3) 8500-1/8500E-1 4-24 Published 08-16-13, Control #208-03...
  • Page 147 2 Stand and item 8, 9, 10, 11 Support. (See figure) • (NOTE 2) Install item 25, 26 Bearing so that position of one side shield becomes on pump mounting side. (See figure) 4-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 148 13. Spring pin 2. Clamping hub 8. Flywheel 14. Capscrew 3. Clamping screw 9. Outer hub 15. Adapter plate 4. Spring pin 10. Bushing 16. Capscrew 5. Element 11. Capscrew 6. Insert 12. Nut (M10 fine) 8500-1/8500E-1 4-26 Published 08-16-13, Control #208-03...
  • Page 149: Hydraulic System

    5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 150 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 151: Location Of Main Hydraulic Components

    CONTROL VALVE ENGINE (COUNTERWEIGHT SELF REMOVAL) THIRD DRUM MOTOR REDUCTION UNIT THIRD DRUM SEPARATE OIL COOLER RADIATOR AND OIL COOLER CONTROL VALVE BOOM DRUM MOTOR REDUCTION UNIT PROPEL MOTOR BOOM DRUM LOWER MACHINERY UPPER MACHINERY 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 152 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 153 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 154 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 155 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 156 5. HYDRAULIC SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 157: Hydraulic Circuits And Components

    Max. delivery :255ltr./min Control valve (Third drum) [Option] Max. working pressure :31.9MPa (325kgf/cm Control valve Max. working pressure :27.5MPa (280kgf/cm (Swing) Crawler extending Control valve (Translifter / crawler ext.) Press Push: 17.0MPa Pull : 21.0Mpa 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 158 (2-section feathering Qmax cut) Third drum clutch Valve block (2-section) (Third wet type free fall) [Option] Third drum emergency clutch engage Solenoid valve [Option] Third drum automatic stop Solenoid valve [Option] Third drum limit stop 8500-1/8500E-1 5-10 Published 08-16-13, Control #208-03...
  • Page 159 Flow control valve (Tagline) [Option] Shuttle valve [Option] Slow return check valve (Tagline) [Option] Slow return check valve (For motor brake) Suction strainer 80 Mesh 5,300cm Return filter 22,500cm Return filter (Wet type clutch) 7,230cm Drain filter 2,000cm 5-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 160 Pressure switch (Propel remo-con press. detect) Hyd. oil temperature sensor (For hyd. oil tank) Hyd. oil temperature switch (266°F) (Front, rear drum brake cooling) Hyd. oil temperature switch (140°F) (For hyd. oil heat) Valve block DPF re-generation 8500-1/8500E-1 5-12 Published 08-16-13, Control #208-03...
  • Page 161: Layout Of Hydraulic Components

    (WET TYPE FREE (COUNTERWEIGHT FALL SPEED SELF REMOVAL) ACCELERATION) 8. 9. MOTOR (THIRD DRUM) ENGINE REDUCTION UNIT THIRD DRUM SEPARATE OIL RADIATOR & COOLER OIL COOLER 10. MOTOR (BOOM) 22. CONTROL VALVE (GANTRY) BOOM DRUM 5-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 162 12. MOTOR (SWING) 47. REMOTE CONTROL VALVE (PROPEL) SWING CONTROL LEVER 83. PRESSURE SWITCH (PROPEL REMO-CON PRESS. DETECT) THIRD DRUM CONTROL LEVER 46. REMOTE CONTROL VALVE (SWING) 50. REMOTE CONTROL VALVE (THIRD) 76. ACCUMULATOR 8500-1/8500E-1 5-14 Published 08-16-13, Control #208-03...
  • Page 163 (AUTOMATIC STOP & SPEED CONTROL) 79. PRESSURE SENSOR (PIPING UNDER SOLENOID) 41. SOLENOID VALVE (OPTION) 42. SOLENOID VALVE (OPTION) 54. CHECK VALVE 28. VALVE BLOCK (5-SECTION, LIMIT STOP) 29.VALVE BLOCK (4-SECTION) LEFT DECK FUEL TANK FRONT (MOTOR BRAKE) 5-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 164 5. HYDRAULIC SYSTEM HYDRAULIC OIL TANK 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) 33. VALVE BLOCK (4-SECTION, WET TYPE FREE FALL) RIGHT DECK HYD. TANK REAR 8500-1/8500E-1 5-16 Published 08-16-13, Control #208-03...
  • Page 165 5. HYDRAULIC SYSTEM 39. VALVE BLOCK (2-SECTION) (THIRD WET TYPE FREE FALL) 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) POWER DIVIDER REAR 5-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 166 5. HYDRAULIC SYSTEM 2. DRUM COOLING LINE FRONT WINCH HYD. OIL TANK REAR WINCH 85. HYD. OIL TEMPERATURE SWITCH 74. BYPASS CHECK VALVE (FRONT, REAR DRUM BRAKE COOLING) (FRONT, REAR DRUM BRAKE COOLING) 8500-1/8500E-1 5-18 Published 08-16-13, Control #208-03...
  • Page 167 5. HYDRAULIC SYSTEM FRONT WINCH HYD. OIL TANK REAR WINCH 86. HYD. OIL TEMPERATURE SWITCH (FOR HYD. OIL HEAT) 36. VALVE BLOCK (FOR HYD. OIL HEAT) 5-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 168 68. RETURN FILTER 69. DRAIN FILTER (WET TYPE CLUTCH) 60. RELIEF VALVE /REDUCING VALVE (CONTROL) 37. VALVE BLOCK (2-SECTION FEATHERING QMAX CUT) 70. LINE FILTER (CONTROL) 84. HYD. OIL TEMPERATURE SENSOR (FOR HYD. OIL TANK) 8500-1/8500E-1 5-20 Published 08-16-13, Control #208-03...
  • Page 169 5. HYDRAULIC SYSTEM 4. GANTRY 51. CYLINDER (GANTRY HOIST) 51. CYLINDER (GANTRY HOIST) 58. SWIVEL JOINT 22. CONTROL VALVE (GANTRY) 5-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 170 5. HYDRAULIC SYSTEM 5. WINCH MOTOR 8. 9. MOTOR (FRONT & REAR DRUM) 8. 9. MOTOR (THIRD DRUM) 10. MOTOR (BOOM) 65. SLOW RETURN CHECK VALVE (FOR MOTOR BRAKE) 8500-1/8500E-1 5-22 Published 08-16-13, Control #208-03...
  • Page 171 5. HYDRAULIC SYSTEM 6. LEFT DECK 18. CONTROL VALVE (PROPEL L. H., MAIN1, AUX.2) 17. CONTROL VALVE (PROPEL R. H. , BOOM, MAIN2, AUX.1) 19. CONTROL VALVE (THIRD DRUM) 5-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 172 5. HYDRAULIC SYSTEM 7. HYDRAULIC OIL PUMP 5. GEAR PUMP (FRONT & REAR DRUM BRAKE COOLING) 4. NO.6 GEAR PUMP (CONTROL/GANTRY) 3. NO.3 PUMP (SWING) 2. NO.2 MAIN PUMP 1. NO.1 MAIN PUMP 8500-1/8500E-1 5-24 Published 08-16-13, Control #208-03...
  • Page 173 5. HYDRAULIC SYSTEM 8. LOWER MACHINERY SWING BEARING 21. CONTROL VALVE (TRANSLIFTER /CRAWLER EXT.) 52. CYLINDER (CRAWLER EXT. /RET.) 59. SWIVEL JOINT SWING GEAR PROPEL REDUCTION UNIT 13. MOTOR (PROPEL) 5-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 174 5. HYDRAULIC SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 5-26 Published 08-16-13, Control #208-03...
  • Page 175: Hydraulic System

    POWER DIVIDER SWING PUMP (No.3) CONTROL PUMP (No.6) AUX. PUMP (GANTRY) (No.7) GEAR PUMP (DRUM BRAKE COOLING) (No.5) GEAR PUMP (DRUM BRAKE COOLING) (No.4) MAIN PUMP (No.1) MAIN PUMP (No.2) 5-27 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 176: Oil Flow From No.1 And No.2 Pumps

    When the inching speed switch is handled, inching speed solenoid becomes energized to actuate the pump regulator and minimize oil delivery from the main pump. 8500-1/8500E-1 5-28 Published 08-16-13, Control #208-03...
  • Page 177 5. HYDRAULIC SYSTEM OIL FLOW FROM No.1 AND No.2 PUMPS 5-29 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 178: Oil Flow From No.3 Pump

    When the swing control valve is actuated with the pres- surized oil from the remote control valve, pressurized oil from the swing pump flows into the swing motor to swing the upper machinery. 8500-1/8500E-1 5-30 Published 08-16-13, Control #208-03...
  • Page 179 5. HYDRAULIC SYSTEM OIL FLOW FROM No.3 PUMP 5-31 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 180: Oil Flow From No.4 And No.5 Pumps (Front, Rear Drum Brake Cooling)

    No.4 and No.5 pumps are gear pumps and are used for cooling of front and rear drum brake (clutch). The pressurized oil from both pumps passes through the front and rear drum brake (clutch) and returns to the tank through the filter. 8500-1/8500E-1 5-32 Published 08-16-13, Control #208-03...
  • Page 181 5. HYDRAULIC SYSTEM OIL FLOW FROM No.4 AND No.5 PUMPS (FRONT, REAR DRUM BRAKE COOLING) 5-33 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 182: Oil Flow From No.6 Pump

    (SOL-3) and is not sent to the remote control valve. Therefore under this condition, even when the con- trol valve is operated, control pressure would not be generated and the machine would not move. 8500-1/8500E-1 5-34 Published 08-16-13, Control #208-03...
  • Page 183 5. HYDRAULIC SYSTEM OIL FLOW FROM No.6 PUMP (WHEN FUNCTION LOCK LEVER IS IN "LOCK" POSITION) 5-35 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 184 (SOL-3) and flows into the remote control valve. Under this condition, when the control valve is op- erated, remote control pressure is sent to the main control valve and make each actuator functioned. 8500-1/8500E-1 5-36 Published 08-16-13, Control #208-03...
  • Page 185 5. HYDRAULIC SYSTEM OIL FLOW FROM No.6 PUMP (WHEN FUNCTION LOCK LEVER IS IN "WORK" POSITION) 5-37 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 186: Oil Flow From No.7 Pump

    When the crawler extending cylinder is being oper- ated, return oil from the cylinder passes through the swivel joint and returns to the tank. 8500-1/8500E-1 5-38 Published 08-16-13, Control #208-03...
  • Page 187 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (CRAWLER EXTENDING CYLINDER) 5-39 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 188 When the translifter cylinder is being operated, re- turn oil from the cylinder passes through the swivel joint and returns to the tank. 8500-1/8500E-1 5-40 Published 08-16-13, Control #208-03...
  • Page 189 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (TRANSLIFTER) 5-41 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 190 When the gantry hoist control valve is in neutral, the pressurized oil passes through the valve and re- turns to the tank without load. 8500-1/8500E-1 5-42 Published 08-16-13, Control #208-03...
  • Page 191 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (GANTRY HOIST CYLINDER) 5-43 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 192 The pressurized oil from the pump flows into the counterweight self removal control valve. When the counterweight self removal control valve is in neu- tral, the pressurized oil passes through the valve and returns to the tank without load. 8500-1/8500E-1 5-44 Published 08-16-13, Control #208-03...
  • Page 193 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (COUNTERWEIGHT SELF REMOVAL CYLINDER) 5-45 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 194: Valve

    5. HYDRAULIC SYSTEM VALVE 4-SECTION VALVE BOOM RAISE BOOM LOWER REAR DRUM RAISE REAR DRUM LOWER FRONT DRUM RAISE FRONT DRUM LOWER THIRD DRUM RAISE THIRD DRUM LOWER 8500-1/8500E-1 5-46 Published 08-16-13, Control #208-03...
  • Page 195 5. HYDRAULIC SYSTEM 8-SECTION VALVE (WITH SHUTTLE VALVE) TO RETURN BLOCK THIRD DRUM LOWER BOOM DRUM RAISE THIRD DRUM RAISE BOOM DRUM LOWER FRONT DRUM LOWER REAR DRUM RAISE FRONT DRUM RAISE REAR DRUM LOWER 5-47 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 196 ACCELERATION FRONT DRUM FREE FALL SPEED ACCELERATION FROM REAR DRUM FOOT BRAKE REAR DRUM FREE FALL SPEED FRONT DRUM FREE FALL SPEED ACCELERATION ACCELERATION FROM FRONT DRUM FOOT BRAKE FROM REAR DRUM FOOT BRAKE 8500-1/8500E-1 5-48 Published 08-16-13, Control #208-03...
  • Page 197 3-SECTION VALVE REAR DRUM FREE FALL SPEED ACCELERATION FRONT DRUM FREE FALL SPEED ACCELERATION TO TANK FROM 4-SECTION VALVE REAR DRUM FREE FALL SPEED ACCELERATION FROM 4-SECTION VALVE FRONT DRUM FREE FALL SPEED ACCELERATION 5-49 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 198 5. HYDRAULIC SYSTEM 5-SECTION VALVE TO TANK FRONT DRUM RAISE REAR DRUM RAISE BOOM DRUM RAISE BOOM DRUM LOWER 8500-1/8500E-1 5-50 Published 08-16-13, Control #208-03...
  • Page 199 TO SWING RELIEF SELECT TO PROPEL MOTOR HI/LOW SELECT TO SWING RELIEF SELECT TO PROPEL MOTOR HI/LOW SELECT TO SWING PARKING BRAKE TO SWING REMO-CON CUT PARKING BRAKE REMO-CON CUT (TO FLOOR UNDER MANIFOLD) 5-51 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 200 5. HYDRAULIC SYSTEM 1-SECTION VALVE TO SWING REMO-CON VALVE (SWING COUNTERFORCE) TO SWING REMO-CON VALVE (SWING COUNTERFORCE) 8500-1/8500E-1 5-52 Published 08-16-13, Control #208-03...
  • Page 201 REAR 1ST SP. LOWER FRONT 2ND SP. LOWER (FORWARD) RIGHT PROPEL BOOM RAISE REAR 1ST SP. RAISE FRONT 2ND SP. RAISE (BACKWARD) RIGHT PROPEL FRONT 2ND DP. LOWER (BACKWARD) BOOM LOWER REAR 1ST SP. LOWER 5-53 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 202 (BACKWARD) LEFT PROPEL REAR 2ND SP. LOWER FRONT 1ST SP. LOWER (FORWARD) LEFT PROPEL (BACKWARD) REAR 2ND SP. RAISE FRONT 1ST SP. RAISE FRONT 1ST SP. LOWER LEFT PROPEL (FORWARD) REAR 2ND SP. LOWER 8500-1/8500E-1 5-54 Published 08-16-13, Control #208-03...
  • Page 203 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (THIRD 1-SECTION) THIRD RAISE THIRD LOWER 5-55 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 204 5. HYDRAULIC SYSTEM 8500-1/8500E-1 5-56 Published 08-16-13, Control #208-03...
  • Page 205: Hoist System

    6. HOIST SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 206 6. HOIST SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 207: Apparatus And Location Of Components

    (Refer to next page.) REDUCTION UNIT ENGINE THIRD DRUM MOTOR AND THIRD DRUM REDUCTION UNIT (OPTION) (OPTION) RADIATOR AND BATTERY OIL COOLER AIR CLEANER SEPARATE OIL COOLER BOOM DRUM MOTOR AND BOOM DRUM REDUCTION UNIT 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 208 (MAIN AND AUX. COOLANT) REDUCTION UNIT SWING PUMP POWER DIVIDER REAR DRUM MOTOR REAR DRUM DRUM LOCK FRONT DRUM LOCK KNOB REAR DRUM LOCK KNOB Refer to P.6-17 to 6-40 for circuit diagram and function. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 209: Adjustment Of Drum Lock

    20 mm (13/16 inch). Operate the knob to the LOCK position and to the RELEASE position and confirm that the pawl moves smoothly. 58 mm 58 mm (2-5/16”) (2-5/16”) 126 mm (4-15/16”) FRONT AND REAR DRUM LOCK 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 210: Winch

    (114 to 139 lbs-ft) to make it engaged completely with pin groove. Nut tightening torque 154 to 188 N-m Install keeper plate (114 to 139 lbs-ft) to make it engaged completely with pin groove. SECTION A-A 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 211 (25.9 to 31.6 lbs-ft) (25.9 to 31.6 lbs-ft) Apply LOCTITE #271 Apply LOCTITE #271 Install keeper plate Install keeper plate to make it engaged to make it engaged completely with pin completely with pin groove. groove. SECTION B-B 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 212: Winch Assembly

    VIEW FROM B NOTE : After assembly, fill oil to the specified level. (approx.15 ltr.) Higher than level gauge red point and within the oil : Extreme pressure gear oil SAE #80W-90 (APOLOIL GEAR HE MULTI-SPECIAL). 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 213 6. HOIST SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 214: Reduction Unit Assembly

    Apply 1 coat painting before winch drum is installed. But except machining face. As for paint and film thickness, follow KS52M6050. D0003. PUNCHING POINT DETAIL OF A DETAIL OF B 8500-1/8500E-1 6-10 Published 08-16-13, Control #208-03...
  • Page 215 7. Support 18. Thrust washer 29. Pinion 8. Ring gear 19. Bearing 30. Pin 9. Spacer 20. Pinion 31. Snap ring 10. Collar 21. Spring pin 32. Shim 11. Bearing 22. Bolt 33. Pin 6-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 216: Brake Pedal

    6. HOIST SYSTEM BRAKE PEDAL 6.4.1 ASSEMBLY DRAWING SECTION A-A VIEW FROM B SECTION C-C SECTION D-D SECTION E-E 8500-1/8500E-1 6-12 Published 08-16-13, Control #208-03...
  • Page 217 (27.5 to 33.2 lbs-ft) 30.4 to 38.2 N-m Capscrew M10 X 70 (22.4 to 28.2 lbs-ft) • When installing item 16 bearing, fill in enough amount of grease. • Apply MOLYKOTE on each rotating area. 6-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 218: Adjusting The Brake Pedal

    (2.76 inch) in the status described in the 4 above. 6. Ensure that the effective stroke of the valve (No.40) from the time when the pedal is depressed to the time it is released is 15 mm (0.6 inch). 8500-1/8500E-1 6-14 Published 08-16-13, Control #208-03...
  • Page 219: Bleeding Air From Brake Circuit

    At this time, air bleed. 5. Return to the "Neutral brake mode", and stop the engine. After the engine is stopped, wait until the control pressure is released (approx. 1 minute), and then, remove the bypass hose. 6-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 220 6. HOIST SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 6-16 Published 08-16-13, Control #208-03...
  • Page 221: Construction And Function

    6. HOIST SYSTEM 6.6 CONSTRUCTION AND FUNCTION 6.6.1 HYDRAULIC SCHEMATIC 6-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 222 6. HOIST SYSTEM 8500-1/8500E-1 6-18 Published 08-16-13, Control #208-03...
  • Page 223 6. HOIST SYSTEM This page is blank for editing convenience. 6-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 224: Lifting A Load

    As directed by the position of the spool, the main pump (No.1, No.2) oil flowing into the control valve is sent to the raising side of the hoist motor to drive the front drum and thereby raise the load. 8500-1/8500E-1 6-20 Published 08-16-13, Control #208-03...
  • Page 225 6. HOIST SYSTEM Lifting (1/2) 6-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 226 6. HOIST SYSTEM Lifting (2/2) 8500-1/8500E-1 6-22 Published 08-16-13, Control #208-03...
  • Page 227 6. HOIST SYSTEM This page is blank for editing convenience. 6-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 228: Holding A Raised Load

    Therefore, the clutch remains engaged with the spring. The load is now held in suspension by the com- bined effects of the motor counterbalance valve, the motor brake and the clutch. 8500-1/8500E-1 6-24 Published 08-16-13, Control #208-03...
  • Page 229 6. HOIST SYSTEM Lifting (1/2) 6-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 230 6. HOIST SYSTEM Lifting (2/2) 8500-1/8500E-1 6-26 Published 08-16-13, Control #208-03...
  • Page 231 6. HOIST SYSTEM This page is blank for editing convenience. 6-27 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 232: Lowering A Load (Power Lowering)

    The counterbalance valve is opened by pilot pressure from the "running in" side to allow the main motor to rotate and lower the load. 8500-1/8500E-1 6-28 Published 08-16-13, Control #208-03...
  • Page 233 6. HOIST SYSTEM Holding (1/2) 6-29 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 234 6. HOIST SYSTEM Holding (2/2) 8500-1/8500E-1 6-30 Published 08-16-13, Control #208-03...
  • Page 235 6. HOIST SYSTEM This page is blank for editing convenience. 6-31 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 236: Free Fall Operation

    "CLM" side oil chamber of the clutch cylinder through the front drum foot brake valve, and the cylinder thrust force is decreased to actuate the brake (braking with the clutch). 8500-1/8500E-1 6-32 Published 08-16-13, Control #208-03...
  • Page 237 6. HOIST SYSTEM Free Fall (1/2) 6-33 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 238 6. HOIST SYSTEM Free Fall (2/2) 8500-1/8500E-1 6-34 Published 08-16-13, Control #208-03...
  • Page 239 6. HOIST SYSTEM Free Fall Control (1/2) 6-35 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 240 6. HOIST SYSTEM Free Fall Control (2/2) 8500-1/8500E-1 6-36 Published 08-16-13, Control #208-03...
  • Page 241 6. HOIST SYSTEM This page is blank for editing convenience. 6-37 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 242 (SOL-10) to return the main control valve spool to the neutral position. When the spool is returned to the neutral posi- tion, pressurized oil to the motor is shut off, and the main motor stops rotating. 8500-1/8500E-1 6-38 Published 08-16-13, Control #208-03...
  • Page 243 6. HOIST SYSTEM Free Fall Speed Acceleration (1/2) 6-39 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 244 6. HOIST SYSTEM Free Fall Speed Acceleration (2/2) 8500-1/8500E-1 6-40 Published 08-16-13, Control #208-03...
  • Page 245: Boom Hoist System

    7. BOOM HOIST SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 246 7. BOOM HOIST SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 247: Apparatus And Location Of Components

    From this pump, the oil flows through the 4 section side control valve to drive the motor of the boom drum. HYD. OIL TANK GEAR POMP MAIN POMP CONTROL VALVE BOOM DRUM MOTOR AND REDUCTION UNIT 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 248 7. BOOM HOIST SYSTEM DRUM LOCK KNOB As for raising, neutral and lowering circuit and func- tions, refer to P.7-11 to 7-17. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 249: Boom Hoist Winch Installation

    After installation of the winch, tighten the bolts to extent that the winch does not move. Before installing the winch, place the Then tighten the nuts to the specified torque. blocks into the swing frame bracket as shown. SECTION AA 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 250: Boom Drum Lock

    Tightening torque : 24.1 to 33.9 N-m CONNECTOR Tightening torque : 21.5 to 24.5 N-m Apply LOCTITE #577 SEMS BOLT BRACKET Tightening torque : 19.4 to 23.6 N-m GREASE FITTING Tightening torque : 21.5 to 24.5 N-m Apply LOCTITE #577 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 251: Adjusting The Boom Drum Lock

    3. Push and pull the knob for a several times to check for the smooth movement of the pawl. Keep hands and clothing clear of the rotating drum. Failure to observe this precaution may result in se- rious injury or loss of life. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 252: Reduction Unit

    Apply Loctite #242 then assemble. Fill the grease inside and inside cavity of this bearing. NOTE (Shell alvania EP-2 or equivalent) 1. Apply Loctite #515 on the mating surface as shown 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 253 222 to 272 Capscrew M16 X 35 222 to 272 Capscrew M20 X 70 436 to 534 Capscrew M12 X 85 92 to 112 Capscrew M12 X 25 92 to 112 Plug 70.6 to 86.4 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 254 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 7-10 Published 08-16-13, Control #208-03...
  • Page 255: Construction And Function

    7. BOOM HOIST SYSTEM 7.5 CONSTRUCTION AND FUNCTION 7.5.1 HYDRAULIC SCHEMATIC BOOM HOIST HYD. CIRCUIT 7-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 256: Raising The Boom

    (4 section hyd. selecting valve) and the motor brake is released. Main pressured oil flown into the control valve enters into the raising side of the boom drum motor by the boom section spool and the boom is raised. 8500-1/8500E-1 7-12 Published 08-16-13, Control #208-03...
  • Page 257 7. BOOM HOIST SYSTEM BOOM RAISING 7-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 258: Neutral (Holding Boom)

    (4 section hyd. se- lecting valve) and the motor brake becomes ac- tuated. (Negative brake) Therefore the boom is held by the counterbal- ance motor brake. 8500-1/8500E-1 7-14 Published 08-16-13, Control #208-03...
  • Page 259 7. BOOM HOIST SYSTEM BOOM HOLDING 7-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 260: Lowering Boom

    Main pressured oil flown into the control valve enters into the lowering side of the boom drum motor by the control valve and open the return counterbalance valve and the boom is lowered. 8500-1/8500E-1 7-16 Published 08-16-13, Control #208-03...
  • Page 261 7. BOOM HOIST SYSTEM BOOM LOWERING 7-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 262 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 7-18 Published 08-16-13, Control #208-03...
  • Page 263 8. SWING SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 264 8. SWING SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 265 SWING MOTOR AND SWING CONTROL VALVE REDUCTION UNIT SWING BEARING SWING GEAR SWING PUMP 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 266: Construction And Function

    8. SWING SYSTEM CONSTRUCTION AND FUNCTION 8.2.1 HYDRAULIC SCHEMATIC 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 267 8. SWING SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 268: Swing

    (PSb) port of the control valve and move the spool (A). The main pressured oil controlled by the control valve flows into the swing motor to run the swing motor. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 269 8. SWING SYSTEM SWING (Neutral Free Mode) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 270: Stopping

    (The swing brake is released.) To stop the swing motion, turn the swing control lever gently to the opposite direction to generate the brake pressure at the swing motor outlet port by the pump pressure. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 271 8. SWING SYSTEM STOP (Neutral Free Mode) 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 272 8. SWING SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 8-10 Published 08-16-13, Control #208-03...
  • Page 273: Swing Reduction Unit

    64 kg (141 lbs) O-Ring Bolt M16 X 45 mm / 145 to 177 N-m (107 to 131 lbs-ft) Tube Level gauge Bolt M20 X 140 mm / 504 to 616 N-m (372 to 454 lbs-ft) 8-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 274 Bolt hole M20 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Shim adjustment 0.05 to 0.15 mm (0.0020 to 0.0059 inch) A area 8500-1/8500E-1 8-12 Published 08-16-13, Control #208-03...
  • Page 275 M10 X 25 63 to 77 (46.5 to 56.8) Capscrew M8 X 20 31.5 to 38.5 (23.2 to 28.4) Apply LOCTITE #242 to capscrew. Assembly total weight : Approx. 396 kg (873 lbs) (Without motor) 8-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 276: Swing Bearing

    Tightening force : 255 to 311 kN (57,326 to 69,915 lbf) Apply LOCTITE #242 SECTION A-A Upper machinery front Outer ring soft zone Inner ring soft zone (Stop plug) (“S” mark) Upper machinery rear 8500-1/8500E-1 8-14 Published 08-16-13, Control #208-03...
  • Page 277 Ref : tightening torque 1.28 to 1.56 kN-m (944 to 1,150 lbs-ft) Bearing inner ring soft zone (S mark position) shall be positioned against the lower machinery as shown. Assembly total weight : Approx. 769 kg (1,695 lbs) 8-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 278: Swing Lock

    8. SWING SYSTEM SWING LOCK YOKE LOCK NUT SECTION A-A LEFT DECK Apply grease when installing. UPPER FRAME CARBODY Lock released position Locked position 8500-1/8500E-1 8-16 Published 08-16-13, Control #208-03...
  • Page 279: Propel System

    9. PROPEL SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 280 9. PROPEL SYSTEM 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 281: Apparatus And Location Of Components

    (built-in type). As for circuit diagram and function of propel (right for- ward), stop, refer to P.9-11 to 9-15. REDUCTION UNIT DRIVE TUMBLER PROPEL MOTOR SWIVEL JOINT SHOE UPPER ROLLER IDLER LOWER ROLLER 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 282: Propel Reduction Unit

    PF1/2 (D) 2-PF1 (VA, VB) PF1/4 (P) Tightening torque : 500 to 618 N-m Apply LOCTITE #242 Tightening torque : 1,010 to 1,250 N-m Apply LOCTITE #242 Crawler Frame Assembly Weight : Approx. 510 kg 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 283 9. PROPEL SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 284: Motor And Reduction Unit

    Seal tape Apply LOCTITE #515 0 to 0.17 mm clearance Adjust clearace with one Apply LOCTITE #515 Apply oil to contact surface. or two pieces of shim 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 285 9. PROPEL SYSTEM 88 77, 84 80 77, 81 Without removing rust-preventive agent. Assembling piston of carrier pin relating to valve port (VA, VB) to be as shown. Without removing rust-preventive agent. VIEW A-A 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 286 92. O-rings 29. Spring pin 61. M6 restrictor 93. O-ring 30. Floating seal 62. Oil seal 94. Socket head cap screw 31. Thrust ring 63. Spring of check valve 32. Shim 64. Spring of cylinder 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 287 Overload relief assy 98.1 to 118 Plug G3/8 49 to 58.8 Connector 49 to 58.8 Plug 24.5 to 29.4 Socket Head cap screw M12 X 35 88.29 to 107.91 Assembly weight : Approx. 508 kg 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 288: Adjustment

    Insert the remaining shims into pack (A). SLACKEN 5. Remove the hydraulic jack. Store spare shims in 10mm to 20mm (0.4 to 0.8inch) the shim pack (A). Equalize the tension in right and left crawler tracks. JACK 8500-1/8500E-1 9-10 Published 08-16-13, Control #208-03...
  • Page 289: Construction And Function

    9. PROPEL SYSTEM 9.4 CONSTRUCTION AND FUNCTION 9.4.1 HYDRAULIC SCHEMATIC 9-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 290: Propelling (Right Side Forward)

    The pressurized oil that activated in the propel motor is free to return to the reservoir. 8500-1/8500E-1 9-12 Published 08-16-13, Control #208-03...
  • Page 291 9. PROPEL SYSTEM PROPEL (R.H. FORWARD) 9-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 292: Stopping

    At the same time, the pressurized oil in the brake cylinder is returned to the reservoir, and the parking brake engages slowly. 8500-1/8500E-1 9-14 Published 08-16-13, Control #208-03...
  • Page 293 9. PROPEL SYSTEM PROPEL STOPPING 9-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 294 9. PROPEL SYSTEM This page is blank for editing convenience. 8500-1/8500E-1 9-16 Published 08-16-13, Control #208-03...
  • Page 295: Electric System

    10. ELECTRIC SYSTEM 10-1 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 296 Therefore, place the measurement probes onto the ter- minals on the female side connector. NEVER forcibly insert the measurement probe. Otherwise, disconnection can occur later. Short-circuiting across terminals inside a connector can damage electronic components. Be absolutely careful to prevent short-circuit. 8500-1/8500E-1 10-2 Published 08-16-13, Control #208-03...
  • Page 297: Electrical

    10. ELECTRIC SYSTEM 10.1 ELECTRICAL 10.1.1 ELECTRICAL WIRING SCHEMATIC (1/18) 10-3 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 298 10. ELECTRIC SYSTEM (2/18) 8500-1/8500E-1 10-4 Published 08-16-13, Control #208-03...
  • Page 299 10. ELECTRIC SYSTEM (3/18) 10-5 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 300 10. ELECTRIC SYSTEM (4/18) 8500-1/8500E-1 10-6 Published 08-16-13, Control #208-03...
  • Page 301 10. ELECTRIC SYSTEM (5/18) 10-7 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 302 10. ELECTRIC SYSTEM (6/18) 8500-1/8500E-1 10-8 Published 08-16-13, Control #208-03...
  • Page 303 10. ELECTRIC SYSTEM (7/18) 10-9 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 304 10. ELECTRIC SYSTEM (8/18) 8500-1/8500E-1 10-10 Published 08-16-13, Control #208-03...
  • Page 305 10. ELECTRIC SYSTEM (9/18) 10-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 306 10. ELECTRIC SYSTEM (10/18) 8500-1/8500E-1 10-12 Published 08-16-13, Control #208-03...
  • Page 307 10. ELECTRIC SYSTEM (11/18) 10-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 308 10. ELECTRIC SYSTEM (12/18) 8500-1/8500E-1 10-14 Published 08-16-13, Control #208-03...
  • Page 309 10. ELECTRIC SYSTEM (13/18) 10-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 310 10. ELECTRIC SYSTEM (14/18) 8500-1/8500E-1 10-16 Published 08-16-13, Control #208-03...
  • Page 311 10. ELECTRIC SYSTEM (15/18) 10-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 312 10. ELECTRIC SYSTEM (16/18) 8500-1/8500E-1 10-18 Published 08-16-13, Control #208-03...
  • Page 313 10. ELECTRIC SYSTEM (17/18) 10-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 314 10. ELECTRIC SYSTEM (18/18) 8500-1/8500E-1 10-20 Published 08-16-13, Control #208-03...
  • Page 315: Connector Layout

    COUNTER WEIGHT SELF REMOVAL (OPTION) B rB Brown Black Pink Green PG B rW Brown White Pink bLue PL COUNTER WEIGHT SELF REMOVAL Brown Violet B rR VR OVER LOAD PREVENT (M. MACHINERY) TRANS LIFTER (OPTION) BLANK 10-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 316 10. ELECTRIC SYSTEM HARNESS NAME HYDRAULIC OIL HEAT HYDRAULIC OIL HEAT BOOM BASE (INSERT INCLUDED) BOOM BASE (INSERT INCLUDED) BOOM TIP BLANK FIXED JIB FIXED JIB CAMERA CONTROLLER CAMERA CONTROLLER CAMERA CONTROLLER IT CONTROLLER INSTALLATION 8500-1/8500E-1 10-22 Published 08-16-13, Control #208-03...
  • Page 317 1 DRUM / 2 DRUM FOOT BRAKE PRESSURE FOOT BRAKE PRESSURE AIS AIR-CONDITIONER (REAR DRUM) SELECT SWITCH (OPTION) (FRONT DRUM) (THIRD DRUM PRESS. SWITCH PRESS. SWITCH PRESS. SWITCH (THIRD SPEC.) VIEW FROM THE FLOOR PLATE UNDER  (1/4) 10-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 318 CAMERA ASSY CN-427 ML MONITOR CN-419 THIRD FREE-FALL SELECT SWITCH (THIRD SPEC.) CN-417 THROTTLE GRIP CN-418 SWING PARKING/ HPRN SWITCH CN-424 BYPASS SWITCH VIEW FROM “A” VIEW FROM “B” DETAIL OF LEFT STAND (2/4) 8500-1/8500E-1 10-24 Published 08-16-13, Control #208-03...
  • Page 319 CN-464 REAR DRUM TURN DETECTION GRIP (OPTION) CN-489 CN-460 42C(W/B) RIGHT PROPEL CONTROL DETECTION PRESS.SWITCH CN-459 RIGHT PROPEL CONTROL DETECTION PRESS.SWITCH CN-458 FUNCTION LOCK LIMIT SWITCH SECTION “D-D” DETAIL OF RIGHT SIDE STAND  (3/4) 10-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 320 DC-DC CONVERTER (FROM ECU HARNESS) CN-950F HARNESS CN-481 CN-482 TW. RACHCYLINDER CUT (OPT) AIS AIR COMPRESSOR ON (OPT) DETAIL OF RELAY BOX SECTION “E-E” DETAIL OF ECU CONNECTOR DETAIL OF SWITCH BOARD CONNECTOR  (4/4) 8500-1/8500E-1 10-26 Published 08-16-13, Control #208-03...
  • Page 321 10. ELECTRIC SYSTEM OUT INDICATING LIGHT RELAY JUNCTION HARNESS (1/2) 10-27 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 322 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-28 Published 08-16-13, Control #208-03...
  • Page 323 10. ELECTRIC SYSTEM FLOOR HARNESS A  (1/5) 10-29 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 324 10. ELECTRIC SYSTEM (2/5) 8500-1/8500E-1 10-30 Published 08-16-13, Control #208-03...
  • Page 325 10. ELECTRIC SYSTEM (3/5) 10-31 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 326 10. ELECTRIC SYSTEM  (4/5) 8500-1/8500E-1 10-32 Published 08-16-13, Control #208-03...
  • Page 327 10. ELECTRIC SYSTEM (5/5) 10-33 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 328 10. ELECTRIC SYSTEM FLOOR HARNESS B (1/5) 8500-1/8500E-1 10-34 Published 08-16-13, Control #208-03...
  • Page 329 10. ELECTRIC SYSTEM (2/5) 10-35 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 330 10. ELECTRIC SYSTEM (3/5) 8500-1/8500E-1 10-36 Published 08-16-13, Control #208-03...
  • Page 331 10. ELECTRIC SYSTEM (4/5) 10-37 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 332 10. ELECTRIC SYSTEM (5/5) 8500-1/8500E-1 10-38 Published 08-16-13, Control #208-03...
  • Page 333 CARBODYWEIGHT CN-904F DETECT HARNESS (OPTION) VIEW FROM “A” CN-926F CONNECT TO CRAWLER EXT./RET. SOL. CN-924F CN-923F SOL-106 CN-922F TO 925F CRAWLER RET. CONNECT TO TRANSLIFTER SOL-105 CN925F CRAWLER EXT. CN922F VIEW FROM “B” (1/2) 10-39 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 334 SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT SECTION “D-D” SECTION “E-E” CN-910F INCLINATION SENSOR DETAIL OF SENSOR INSTALL (2/2) 8500-1/8500E-1 10-40 Published 08-16-13, Control #208-03...
  • Page 335 10. ELECTRIC SYSTEM LOWER HARNESS (1/4) 10-41 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 336 10. ELECTRIC SYSTEM (2/4) 8500-1/8500E-1 10-42 Published 08-16-13, Control #208-03...
  • Page 337 10. ELECTRIC SYSTEM (3/4) 10-43 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 338 10. ELECTRIC SYSTEM (4/4) 8500-1/8500E-1 10-44 Published 08-16-13, Control #208-03...
  • Page 339 10. ELECTRIC SYSTEM TRANS LIFTER REMOTE CONTROLLER CABLE HARNESS (OPTION) (1/3) 10-45 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 340 10. ELECTRIC SYSTEM (2/3) 8500-1/8500E-1 10-46 Published 08-16-13, Control #208-03...
  • Page 341 10. ELECTRIC SYSTEM (3/3) 10-47 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 342 FRONT DRUM LOWER PRESS. SENSOR (PT-4) CN-811F BOOM LOWER PRESS. SENSOR (PT-13) DETAIL OF “A” FRONT DRUM RAISE PRESS. SENSOR (PT-3) CN-809F CN-810F REAR DRUM LOWER PRESS. SENSOR (PT-6) CN-813F REAR DRUM RAISE PRESS. SENSOR (PT-5) CN-812F (1/6) 8500-1/8500E-1 10-48 Published 08-16-13, Control #208-03...
  • Page 343 PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-816F CN-39F CN-40F CN-41F CN-119F CN-111F CN-118F CN-112F CN-115F CN-113F CN-117F CN-116F CN-114F LEFT DECK INSIDE VIEW FROM “C” (2/6) 10-49 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 344 SENSOR (PT-20) CN-802F FRONT DRUM TILT PROP. VALVE (SOL-65) FUEL LEVEL CN-833F SENSOR FRONT DRUM MOTOR BOOST (SOL-15) CN-838F FRONT LEFT REAR VIEW OF LEFT DECK CENTER FUEL TANK AND FRONT DRUM MOTOR AREA (3/6) 8500-1/8500E-1 10-50 Published 08-16-13, Control #208-03...
  • Page 345 OIL COOLER MOTOR CN-871 CN-848 CONNECT TO RELAY UNIT HARNESS CN-851 CN-852 CONNECT TO REAR WORK LIGHT HARNESS CN-844F CONNECT TO DRUM LIGHT HARNESS CN-845F CONNECT TO C/W DETECTOR VIEW FROM “B” SECTION “F-F” CN-843 (4/6) 10-51 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 346 REAR DRUM TILT SENSOR (SOL-14) CN-803F REAR DRUM TILT PROP. VALVE (SOL-66) CN-834F CN-849M TO SWING FRAME VIEW FROM “G” CONDENSOR FUN MOTOR AIR CON PRESSURE SW CN-847F CN-846F FRONT VIEW FROM “Q” (5/6) 8500-1/8500E-1 10-52 Published 08-16-13, Control #208-03...
  • Page 347 MOTOR RELAY (RL-3) CN-818F THIRD TILT SENSOR (PT-15) CUT OUT RELAY (R-C) CN-804F CN-850F AIR HEATER RELAY (R-AH) CN-856F START BLOCK RELAY THIRD MOTOR BOOST (SOL-17) SAFETY RELAY CN-841F WHEN THIRD WINCH (OPTION) IS INSTALLED. (6/6) 10-53 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 348 10. ELECTRIC SYSTEM LEFT DECK HARNESS (1/5) 8500-1/8500E-1 10-54 Published 08-16-13, Control #208-03...
  • Page 349 10. ELECTRIC SYSTEM (2/5) 10-55 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 350 10. ELECTRIC SYSTEM (3/5) 8500-1/8500E-1 10-56 Published 08-16-13, Control #208-03...
  • Page 351 10. ELECTRIC SYSTEM (4/5) 10-57 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 352 10. ELECTRIC SYSTEM (5/5) 8500-1/8500E-1 10-58 Published 08-16-13, Control #208-03...
  • Page 353 10. ELECTRIC SYSTEM RELAY HARNESS (1/3) 10-59 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 354 10. ELECTRIC SYSTEM (2/3) 8500-1/8500E-1 10-60 Published 08-16-13, Control #208-03...
  • Page 355 10. ELECTRIC SYSTEM (3/3) 10-61 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 356 E0 (B) LA-B03, B07 DETAIL OF CAB LOWER DECK SECTION “A-A” SECTION “B-B” FLOOR HARNESS “A” CAB MAIN HARNESS FLOOR HARNESS “B” CN-675 CN-674 CN-676 CN-671 CN-677 CN-670 CN-884 CN-678 CN-672 CN-679 CN-883 CN-673 (1/4) 8500-1/8500E-1 10-62 Published 08-16-13, Control #208-03...
  • Page 357 MAIN PUMP INCHING P1 SOL STARTER MOTOR “B” STARTER MOTOR “C” TERMINAL TERMINAL DETAIL OF “L” CN-413 CN-412 GUARD HARNESS CN-603 CN-618 CONNECT TO C/W SELF Re. CLUTCH PRESS. SENSOR REMOVAL HARNESS CN-619 VIEW FROM “C” (2/4) 10-63 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 358 COOLING OIL TEMP. SWITCH COOLING OIL TEMP. SWITCH (REAR WET CLUTCH) (FRONT WET CLUTCH) CN-607 COOLING OIL TEMP. SWITCH CN-608 COOLING OIL TEMP. SWITCH (REAR WET CLUTCH) (FRONT WET CLUTCH) VIEW FROM “H” (3/4) 8500-1/8500E-1 10-64 Published 08-16-13, Control #208-03...
  • Page 359 SWING CONSTANT INCHING SPEED SOL LOW SPEED SOL CN-612 BOOM PUMP POWER REDUCE SOL CN-637 Pf SENSOR CN-613 SWING PUMP MAIN PUMP POWER REDUCE SOL MAIN PUMP DETAIL OF “M” (AT INDEPENDENT, CONFLUENCE SELECTED) (4/4) 10-65 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 360 10. ELECTRIC SYSTEM RIGHT DECK HARNESS (1/4) 8500-1/8500E-1 10-66 Published 08-16-13, Control #208-03...
  • Page 361 10. ELECTRIC SYSTEM (2/4) 10-67 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 362 10. ELECTRIC SYSTEM (3/4) 8500-1/8500E-1 10-68 Published 08-16-13, Control #208-03...
  • Page 363 10. ELECTRIC SYSTEM (4/4) 10-69 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 364 10. ELECTRIC SYSTEM POWER SUPPLY HARNESS (1/3) 8500-1/8500E-1 10-70 Published 08-16-13, Control #208-03...
  • Page 365 10. ELECTRIC SYSTEM (2/3) 10-71 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 366 10. ELECTRIC SYSTEM (3/3) 8500-1/8500E-1 10-72 Published 08-16-13, Control #208-03...
  • Page 367 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL B) TO BATTERY RELAY HARNESS 10-73 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 368 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL C) TO SAFETY RELAY HARNESS 8500-1/8500E-1 10-74 Published 08-16-13, Control #208-03...
  • Page 369 10. ELECTRIC SYSTEM GLOW RELAY HARNESS TO ENGINE SUB HARNESS 10-75 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 370 ATT. : ATTACHMENT INTAKE AIR TEMP. SENSOR C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-632M CN-630F CN-630F VIEW FROM “B” CN-609F RADIATOR WATER LEVEL ARALM SENSOR RIGHT DECK HARNESS CN-618M CN-629M VIEW FROM “A” (1/2) 8500-1/8500E-1 10-76 Published 08-16-13, Control #208-03...
  • Page 371 ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-642F FOR DPR PRESS. DIFF SENSOR CN-842 CONNECT TO OVERLOAD ALARM LAMP (OPTION) CN-632F VIEW FROM “C” VIEW FROM “D” MACHINE FRONT MACHINE FRONT (2/2) 10-77 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 372 10. ELECTRIC SYSTEM GUARD HARNESS A (1/3) 8500-1/8500E-1 10-78 Published 08-16-13, Control #208-03...
  • Page 373 10. ELECTRIC SYSTEM (2/3) 10-79 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 374 10. ELECTRIC SYSTEM (3/3) 8500-1/8500E-1 10-80 Published 08-16-13, Control #208-03...
  • Page 375 10. ELECTRIC SYSTEM GUARD HARNESS B (1/3) 10-81 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 376 10. ELECTRIC SYSTEM (2/3) 8500-1/8500E-1 10-82 Published 08-16-13, Control #208-03...
  • Page 377 10. ELECTRIC SYSTEM (3/3) 10-83 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 378 10. ELECTRIC SYSTEM GUARD HARNESS C (1/2) 8500-1/8500E-1 10-84 Published 08-16-13, Control #208-03...
  • Page 379 10. ELECTRIC SYSTEM (2/2) 10-85 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 380 BOOM OVERHOIST LS CN-763 CN-713 CN-764 RIGHT DECK HARNESS NOT USED CN-J73 CN-744 CONNECT TO SPARE SECTION “C-C” OVER PAYOUT LIMIT SWITCH CN-J72 CN-712 CN-680 THIRD DRUM ROTATION SENSOR CN-722 CN-772 SECTION “A-A” (1/3) 8500-1/8500E-1 10-86 Published 08-16-13, Control #208-03...
  • Page 381 HARNESS AND RELAY HARNESS. CN-702 CN-703 CN-704 CN-705 CONNECTION OF RIGHT DECK HARNESS AND RELAY HARNESS. CN-706 CN-J74 VIEW FROM “E-E” DETAIL OF “M” CN-1061 CN-1001 LEFT DECK HARNESS DETAIL OF “F” SECTION “D-D” (2/3) 10-87 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 382 CN-708 SWING FRAME HARNESS SECTION “G-G” SECTION “H-H” CN-709 CN-707 CN-701 RIGHT DECK HARNESS DETAIL OF “L” SWING BUZZER CN-732 VOICE ALARM CN-730 PROPEL BUZZER CN-731 HYD. SELECT GANTRY SOL CN-750 SECTION “J-J” (3/3) 8500-1/8500E-1 10-88 Published 08-16-13, Control #208-03...
  • Page 383 10. ELECTRIC SYSTEM SWING FRAME HARNESS (1/4) 10-89 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 384 10. ELECTRIC SYSTEM (2/4) 8500-1/8500E-1 10-90 Published 08-16-13, Control #208-03...
  • Page 385 10. ELECTRIC SYSTEM (3/4) 10-91 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 386 10. ELECTRIC SYSTEM (4/4) 8500-1/8500E-1 10-92 Published 08-16-13, Control #208-03...
  • Page 387 10. ELECTRIC SYSTEM ATT. JUNCTION HARNESS (1/3) 10-93 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 388 10. ELECTRIC SYSTEM (2/3) 8500-1/8500E-1 10-94 Published 08-16-13, Control #208-03...
  • Page 389 10. ELECTRIC SYSTEM (3/3) 10-95 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 390 LOAD DETECTOR HARNESS CN-302A CAB HARNESS CN-302B CB-A01 HEAD LIGHT (RIGHT) CN-302 CA-A01 CN-293 FLOOR A HARNESS CN-887M CN-291 CN-300 CN-887F CN-307A CN-307 CN-307B FLOOR B HARNESS VIEW FROM “J-J” DETAIL OF “B” (1/3) 8500-1/8500E-1 10-96 Published 08-16-13, Control #208-03...
  • Page 391 PROPEL VOICE ALARM SW (OPTION) VIEW FROM “J” CN-211 CN-213 MULTI VOICE SW G WINCH MAIN SW (OPTION) CN-226 CN-214 RADIO CN-210 AIS MAIN SW DRUM TURN SW (OPTION) CN-215 G MODE SW VIEW FROM “F” (2/3) 10-97 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 392 HYD. SOURCR SELECTOR SW (REEVING/ FOOT PIN) CN-11-4 CN-11-6B CN-221 PROPEL SPEED SELECTOR SW CN-11-6A CN-220 UNDULATION PEDAL SELECTOR SW (OPTION) CN-219 WINCH SELECTOR SW (OPTION) CB-11-2 CB-11-1B CB-11-1D CB-11-1A CB-11-1C M/L CONNECTOR VIEW FROM “H” (3/3) 8500-1/8500E-1 10-98 Published 08-16-13, Control #208-03...
  • Page 393 10. ELECTRIC SYSTEM CAB HARNESS (1/6) 10-99 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 394 10. ELECTRIC SYSTEM (2/6) 8500-1/8500E-1 10-100 Published 08-16-13, Control #208-03...
  • Page 395 10. ELECTRIC SYSTEM (3/6) 10-101 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 396 10. ELECTRIC SYSTEM (4/6) 8500-1/8500E-1 10-102 Published 08-16-13, Control #208-03...
  • Page 397 10. ELECTRIC SYSTEM (5/6) 10-103 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 398 10. ELECTRIC SYSTEM (6/6) 8500-1/8500E-1 10-104 Published 08-16-13, Control #208-03...
  • Page 399 10. ELECTRIC SYSTEM 8. ELECTRICAL PART OF ENGINE SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 10-105 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 400 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TO ENGINE GROUND HARNESS   8500-1/8500E-1 10-106 Published 08-16-13, Control #208-03...
  • Page 401 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TARMINAL B ALTERNATOR HARNESS TARMINAL B 10-107 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 402 10. ELECTRIC SYSTEM 9. ELECTRICAL PART OF MONITOR SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 8500-1/8500E-1 10-108 Published 08-16-13, Control #208-03...
  • Page 403 10. ELECTRIC SYSTEM MONITOR HARNESS (1/2) 10-109 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 404 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-110 Published 08-16-13, Control #208-03...
  • Page 405 SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT REMOTE CONTROL CONNECT (UPPER) CN-550F CN-413M CONNECT TO RIGHT DECK HARNESS CN-412M DETAIL OF “A” 10-111 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 406 10. ELECTRIC SYSTEM COUNTER WEIGHT SELF REMOVAL HARNESS (1/3) 8500-1/8500E-1 10-112 Published 08-16-13, Control #208-03...
  • Page 407 10. ELECTRIC SYSTEM (2/3) 10-113 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 408 10. ELECTRIC SYSTEM (3/3) 8500-1/8500E-1 10-114 Published 08-16-13, Control #208-03...
  • Page 409 10. ELECTRIC SYSTEM 11. OVER LOAD PREVENT (M. MACHINERY) (1/2) 10-115 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 410 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-116 Published 08-16-13, Control #208-03...
  • Page 411 10. ELECTRIC SYSTEM 12. ELECTRICAL PART OF TRANS LIFTER (OPTION) SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 10-117 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 412 CB/W : CARBODY WEIGHT CN-625 HYD. OIL HEAT (SOL-47) CN-634 HYD. OIL HEAT (SOL-47) RIGHT DECK HARNESS CN-634 CN-627 CN-625 HYD. OIL HEAT (SOL-47) OIL TEMP. SWITCH (LS-30) CN-627 OIL TEMP. SWITCH (LS-30) DETAIL OF “A”   8500-1/8500E-1 10-118 Published 08-16-13, Control #208-03...
  • Page 413 10. ELECTRIC SYSTEM HYDRAULIC OIL HEAT HARNESS (1/2) 10-119 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 414 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-120 Published 08-16-13, Control #208-03...
  • Page 415 SOL : SOLENOID VALVE SW : SWITCH 15. ELECTRICAL PART PSW : PRESSURE SWITCH OF BOOM BASE (IN- ATT. : ATTACHMENT C/W : COUNTER WEIGHT SERT INCLUDED) CB/W : CARBODY WEIGHT 8500-1, 11000-1 (1/9) 10-121 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 416 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT 8500-1, 11000-1 C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/9) 8500-1/8500E-1 10-122 Published 08-16-13, Control #208-03...
  • Page 417 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 8500E-1 (3/9) 10-123 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 418 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH 8500E-1 PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (4/9) 8500-1/8500E-1 10-124 Published 08-16-13, Control #208-03...
  • Page 419 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (5/9) 10-125 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 420 10. ELECTRIC SYSTEM (6/9) 8500-1/8500E-1 10-126 Published 08-16-13, Control #208-03...
  • Page 421 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (7/9) 10-127 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 422 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT 8500-1, 11000-1 8500E-1 CB/W : CARBODY WEIGHT (8/9) 8500-1/8500E-1 10-128 Published 08-16-13, Control #208-03...
  • Page 423 10. ELECTRIC SYSTEM (9/9) 10-129 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 424 10. ELECTRIC SYSTEM BOOM BASE HARNESS (INSERT INCLUDED) (1/2) 8500-1/8500E-1 10-130 Published 08-16-13, Control #208-03...
  • Page 425 10. ELECTRIC SYSTEM (2/2) 10-131 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 426 10. ELECTRIC SYSTEM CABLE (1/2) 8500-1/8500E-1 10-132 Published 08-16-13, Control #208-03...
  • Page 427 10. ELECTRIC SYSTEM (2/2) 10-133 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 428 10. ELECTRIC SYSTEM 16. BOOM TIP HARNESS (1/2) 8500-1/8500E-1 10-134 Published 08-16-13, Control #208-03...
  • Page 429 10. ELECTRIC SYSTEM (2/2) 10-135 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 430 10. ELECTRIC SYSTEM CABLE (1/2) 8500-1/8500E-1 10-136 Published 08-16-13, Control #208-03...
  • Page 431 10. ELECTRIC SYSTEM (2/2) 10-137 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 432 10. ELECTRIC SYSTEM CABLE (1/2) 8500-1/8500E-1 10-138 Published 08-16-13, Control #208-03...
  • Page 433 10. ELECTRIC SYSTEM (2/2) 10-139 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 434 10. ELECTRIC SYSTEM 18. ELECTRICAL PART OF FIXED JIB SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 8500-1/8500E-1 10-140 Published 08-16-13, Control #208-03...
  • Page 435 10. ELECTRIC SYSTEM FIXED JIB HARNESS (1/2) 10-141 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 436 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-142 Published 08-16-13, Control #208-03...
  • Page 437 10. ELECTRIC SYSTEM CABLE (1/2) 10-143 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 438 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-144 Published 08-16-13, Control #208-03...
  • Page 439 10. ELECTRIC SYSTEM CABLE (1/2) 10-145 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 440 10. ELECTRIC SYSTEM (2/2) 8500-1/8500E-1 10-146 Published 08-16-13, Control #208-03...
  • Page 441 10. ELECTRIC SYSTEM 19. ELECTRICAL PART OF CAMERA CONTROLLER SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (1/3) 10-147 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 442 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/3) 8500-1/8500E-1 10-148 Published 08-16-13, Control #208-03...
  • Page 443 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10-149 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 444 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 8500-1/8500E-1 10-150 Published 08-16-13, Control #208-03...
  • Page 445 10. ELECTRIC SYSTEM (2/2) 10-151 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 446 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 8500-1/8500E-1 10-152 Published 08-16-13, Control #208-03...
  • Page 447 10. ELECTRIC SYSTEM (2/2) 10-153 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 448 10. ELECTRIC SYSTEM 20. ELECTRICAL PART OF IT CONTROLLER INSTALLATION SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 8500-1/8500E-1 10-154 Published 08-16-13, Control #208-03...
  • Page 449: Location And Use Of Fuse

    10. ELECTRIC SYSTEM 10.1.3 LOCATION AND USE OF FUSE Fuse box and use Fuse box Replace plate fuse with the attached part of fuse box. Distribution panel Label Fuse box Part no. label position 10-155 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 450 For MC1 control – For MC1 output – Auto stop – Engine condition – One way radio – Wiper – Function lock – Remote control – Monitor – Air-con – Air-con 2 – Fan motor 8500-1/8500E-1 10-156 Published 08-16-13, Control #208-03...
  • Page 451 For MC2 ground output – Over hoist LS – Fuel pump / lighter – 46 For MC1 ground output 1 – For MC1 ground output 2 – 48 Neutral free – 49 Light – 50 Spare 10-157 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 452 Ensure to turn starter switch OFF when replacing fuse. Replace the fuse with the same capacity. If fuse blows off right after replaced, there is some abnormality in the electric circuit. Find out a cause and take necessary action. 8500-1/8500E-1 10-158 Published 08-16-13, Control #208-03...
  • Page 453 10. ELECTRIC SYSTEM 10-159 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 454 10. ELECTRIC SYSTEM 8500-1/8500E-1 10-160 Published 08-16-13, Control #208-03...
  • Page 455: Wiper Control Relay (2479R1366)

    10. ELECTRIC SYSTEM 10.1.4 WIPER CONTROL RELAY (2479R1366) Wiper intermediate relay Wiper intermediate relay Wiper switch Stop Intermited Continuous Wiper switch 10-161 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 456: Pressure Switch (For Propel Motion Detect)

    539 ± 49 KPa : ON Tightening torque 14.7 ± 2.9 N-m 343 ± 49 KPa : OFF [ON] Pressure (KPa) [OFF] Pressure (KPa) Propel motion detect pressure 539 ± 49 343 ± 49 8500-1/8500E-1 10-162 Published 08-16-13, Control #208-03...
  • Page 457: Pressure Switch (Foot Brake)

    POWER(+) OPEN COLLECTOR(+) 4.5 MPa (653 psi) : ON 3.7 MPa (537 psi) : OFF O-ring P14 (ZD11P01400) PF3/8 (Tightening torque : 29.4 N-m) [ON] Pressure (MPa) [OFF] Pressure (MPa) Propel motion detect pressure 10-163 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 458: Pressure Sensor

    10. ELECTRIC SYSTEM 10.1.7 PRESSURE SENSOR Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 9999430139 27 × 27.8 HEX 9999430139 PF 3/8 0.5 to 4.5 V CIRCUIT 8500-1/8500E-1 10-164 Published 08-16-13, Control #208-03...
  • Page 459 10. ELECTRIC SYSTEM Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 9999430134 19 × 20 HEX 9999430134 PF 1/4 0.5 to 4.5 V 10-165 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 460 Out-put : 1/10 Vcc =0.5 V to 4.5 V Out-put : 1/10 Vcc =0.5 V to 4.5 V Tightning torque : 73.5 N-m max (54.2 ft-lbs) Tightning torque : 32 N-m max (26.7 ft-lbs) 8500-1/8500E-1 10-166 Published 08-16-13, Control #208-03...
  • Page 461 Power (V) Out-put (V) MPa (psi) Clutch pressure (Front • Rear • 3rd) 0 to 19.6 9999426022 0.5 to 4.5 (0 to 2842) Control pressure (Primary side) NOTE 9999426022 Tightening torque : 73.5 N-m 10-167 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 462: Inclination Sensor

    Y-axis 0.5 to 4.5V Vibration Endurance 10 to 500HZ Amplitude resistance 3 mm width X.Y.Z, direction 96h (about 20G) Impact resistance Endurance 500/s (about 50G) Load resistance min 10k width X.Y.Z, direction about 10th Zero ±5° adjustment 8500-1/8500E-1 10-168 Published 08-16-13, Control #208-03...
  • Page 463: Buzzer Unit

    10. ELECTRIC SYSTEM 10.1.9 BUZZER UNIT 10-169 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 464 Rated Volt Work range (Volt) 19 to 32V Working temperature range -10 to 60 Storage temperature range -20 to 70 Humidity 0 to 90% Sound volume 75db/30cm MIN Consumption elec. current Max 50 mA 8500-1/8500E-1 10-170 Published 08-16-13, Control #208-03...
  • Page 465: Relay Box

    10. ELECTRIC SYSTEM 10.1.10 RELAY BOX 1. ARRANGEMENT OF CONNECTOR 10-171 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 466 10. ELECTRIC SYSTEM 8500-1/8500E-1 10-172 Published 08-16-13, Control #208-03...
  • Page 467 RL-27 Speed limit release RL-28 Speed limit RL-29 Outside indication lamp ( green ) RL-30 Outside indication lamp ( yellow ) RL-31 Outside indication lamp ( red ) RL-32 ML adjust mode select RL-36 10-173 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 468 (RL-81) F-21 MC1(D/O) SAFETY RELAY (RL-02) MC1(D/I) M/L (D/O) REMO-CON ENGINE EMERGENCY ST (SW-71) IGNITION SW AIS AIR-CON CUT RELAY (RL-04, 81) MC1(D/O) MC1(D/I) MC1(D/O) HORN RELAY REMO-CON SWING PARKING SW SWING PARKING SW-11 8500-1/8500E-1 10-174 Published 08-16-13, Control #208-03...
  • Page 469 10. ELECTRIC SYSTEM FANCTION LOCK MC1(D/O) LSW-1 FANCTION LOCK SOL-3 MC2(D/I) MC1(D/O) F-15 FRONT ROTAT GRIP MC1(D/O) PSOL-40 REAR ROTAT GRIP MC1(D/O) PSOL-41 F-02 MC1(A/I) MC1(A/I) CAMERA 10-175 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 470 BUZZER SW-26 PROPEL CONTROL PSW-7,10 PROPEL SWING VOICE ALARM HYD. SOURCE HYD. SOURCE SELECT SELECT SW-65 SOL-45 REMO-CON TRANSLIFTER SELECT SOL-44 REMO-CON HYD. OIL HEAT DOL-47 MC1(D/O) M/L (D/I) MC1(D/O) MC BYPASS SW SW-38 8500-1/8500E-1 10-176 Published 08-16-13, Control #208-03...
  • Page 471 MC1(PSOL) PSOL-110 MC1 (PSOL) PSOL-110 MAIN PUMP 1 MC1(PSOL) PSOL-1 PSOL-1 MAIN PUMP 2 PSOL-2 MC1(PSOL) PSOL-6 MC1(PSOL) BOOM PUMP MC1(PSOL) PSOL-2 PSOL-2 MC1(PSOL) MC1(D/O) ML BYPASS SW SW-37 ML BYPASS SW SW-37 F-05 10-177 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 472 10. ELECTRIC SYSTEM OVERLOAD,OVERHOIST RELEASE SW SW-15 ML BYPASS SW MC2(D/I) SW-37 RL-62 RL-63 RL-64 RL-65 RL-60 RL-61 RL-66 RL-67 SWING BUZZER 8500-1/8500E-1 10-178 Published 08-16-13, Control #208-03...
  • Page 473 Fr.DRUM FOOT BRAKE PRESS. PSW-1 Re.DRUM FREE-FALL SELECT SW-54 Re.DRUM FOOT BRAKE PRESS. PSW-2 3rd.DRUM FREE-FALL SELECT SW-55 3rd.DRUM FOOT BRAKE PRESS. PSW-3 RIGHT CYL. EXT. REMO-CON SOL-98 LEFT CYL. EXT. REMO-CON SOL-98 M/L (D/O) 10-179 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 474 SOL-104 MC1(D/O) Fr.DRUM CLUTCH CLM SOL-22 MC1(D/O) Fr.DRUM CLUTCH ESM SOL-19 MC1(D/O) Re.DRUM CLUTCH CLA F-37 SOL-23 MC1(D/O) Re.DRUM CLUTCH ESA SOL-20 MC1(D/O) 3rd.DRUM CLUTCH CLT F-37 SOL-24 MC1(D/O) 3rd.DRUM CLUTCH EST SOL-21 MC1(D/O) 8500-1/8500E-1 10-180 Published 08-16-13, Control #208-03...
  • Page 475 Fr. Re. 3rd. DRUM HOIST STOP SOL-37, 38, 18 BOOM HOIST STOP SOL-35 BOOM OVERHOIST LSW-7 F-34 BOOM B/S No.2 LSW-12 BOOM B/S No.1 LSW-9 M/L (D/O) M/L (D/O) M/L (D/O) CONFIGURATION SELECT SW-36 M/L (D/O) 10-181 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 476 10. ELECTRIC SYSTEM 10.1.11 RELAY BOX 8500-1/8500E-1 10-182 Published 08-16-13, Control #208-03...
  • Page 477 Rear raise stop relay RL-64 Rear lower stop relay RL-65 Third raise stop relay RL-66 Third lower stop relay RL-67 MC bypass relay 1 RL-68 Independence, confluence select (F) RL-69 Independence, confluence select (R) RL-70 10-183 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 478 MC-2 (P/O) Re.DRUM LOWER REMO-CON (PSOL-57) 3rd.DRUM HOIST 3rd.DRUM HOIST REMO-CON MC-2 (P/O) (PSOL-58) 3rd.DRUM HOIST REMO-CON MC-2 (P/O) (PSOL-58) 3rd.DRUM LOWER 3rd.DRUM LOWER REMO-CON MC-2 (P/O) (PSOL-59) MC-2 (P/O) 3rd.DRUM LOWER REMO-CON (PSOL-59) 8500-1/8500E-1 10-184 Published 08-16-13, Control #208-03...
  • Page 479 10. ELECTRIC SYSTEM Fr.DRUM IND./CONF. SELECT F-33 SOL-101 MC2 (D/O) Re.DRUM IND./CONF. SELECT SOL-102 MC2 (D/O) 10-185 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 480: 12Load Cell (Crane)

    245 m/s, 15mS X,Y, Z (3 times each) Water proof : Conforms to IP67 or equivalent (JIS C0920 non-seaping type) 5 × 10 Durability : times Noise proof : DC700V 100ns Total integrity : 2.9% RO Weight : About 6 kg 8500-1/8500E-1 10-186 Published 08-16-13, Control #208-03...
  • Page 481 Case material : Plastic (Toshiba premix AP-902S) Surface treatment : Non, stripe (Black) Temperature range : -20 to 70° C Store temp. : -40 to 80° C Weight : appr. 1.2kg (main body), appr. 65g/m (cable) 10-187 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 482: 14Troubleshooting Of Exhaust Gas Third Regulation Engine

    How to turn off the engine trouble detect lamp START STATER SWITCH LOCK STOP ENGINE START ENGINE TROUBLE DETECT LAMP TIME 8500-1/8500E-1 10-188 Published 08-16-13, Control #208-03...
  • Page 483: How To Check The Failure Contents

    CN-878F, CN-879M Component location related to diagnosis. • Diag. lamp location • Diag. connector CN-878F,CN-879M location • DST-1 diag. connector location Diag.SW CN-878F CN-879M DST-1 CN486F 10-189 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 484 10. ELECTRIC SYSTEM Diag. lamp (Red) 8500-1/8500E-1 10-190 Published 08-16-13, Control #208-03...
  • Page 485 10. ELECTRIC SYSTEM 2. Table of Diagnosis codes (J08E-TI) 10-191 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 486 10. ELECTRIC SYSTEM 8500-1/8500E-1 10-192 Published 08-16-13, Control #208-03...
  • Page 487 10. ELECTRIC SYSTEM 10-193 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 488 [Example] Display of diagnosis codes example 1) When codes 32 and 21 are displayed 0.5 sec 0.5 sec 1.5 sec CODE 32 CODE 21 CONTINUES example 2) Normality displayed 0.3 sec 8500-1/8500E-1 10-194 Published 08-16-13, Control #208-03...
  • Page 489: 16Checking Of Diagnosis Lamp Function

    Engine Key switch : ON position • No Engine RPM signal : 0 mim If the diagnosis lamp will not be lit up with the above conditions, inspect and repair the lamp or other relating parts. 10-195 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 490 ECU TERMINAL NUMBER Engine sub harness connector no. Connector A : Respond connector : CN-614 Connector B: Respond connector :CN-615 Connector C: Respond connector :CN-635 Connector D: Respond connector :CN-616 Connector E: Respond connector :CN-638 8500-1/8500E-1 10-196 Published 08-16-13, Control #208-03...
  • Page 491 10. ELECTRIC SYSTEM 10-197 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 492: Load Safety Device

    - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 All values in the figure are for reference only. 8500-1/8500E-1 10-198 Published 08-16-13, Control #208-03...
  • Page 493: Configuration Of Screens

    10. ELECTRIC SYSTEM 10.2.1 CONFIGURATION OF SCREENS 10-199 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 494: System Daigram

    Drum rotate sensor Eng. hyd. system alarm signal Relay Relay Winch system Pump. swing system Prop. valve Prop. valve Each solenoid valve Each solenoid valve Drum rotate grip Oil cooler Battery relay AIS circuit 8500-1/8500E-1 10-200 Published 08-16-13, Control #208-03...
  • Page 495: Monitor Indication

    Max transmission distance 5m * not used Extended unit interface 1 *1 For installation of extended unit (Transmission function) * not used VM unit interface 1 *1 This is to connect VM unit when camera is to be connected. 10-201 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 496 (No conductive dust) Contamination Contamination degree 2 *1 As for STN color LCD equipped model, long time use under ambient tenperature higher than 40 degrees C may cause indication quality lowering such as contrast. 8500-1/8500E-1 10-202 Published 08-16-13, Control #208-03...
  • Page 497 SD (TXD) Transmitted data ER (DSR) Data terminal ready Signal ground DR (DSR) Data set ready RS (RTS) Transmission request CS (CTS) Transmission permit CI (RI) / Indication (VCC) +5V ± 5% output 0.25A *1 10-203 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 498 Otherwise main body may be damaged. Ensure to connect FG terminal to earth. Otherwise electric shock may be caused in case of failure. Failure to observe these precautions may result in serious injuries or loss of life. 8500-1/8500E-1 10-204 Published 08-16-13, Control #208-03...
  • Page 499 These are all product of PHOENIX- CONTACT. Recommended screw SZF 1-0.6 X 3.5 (1204517) driver AI 0.75-8GY (3200519) AI 1-8RD (3200030) Recommended terminal AI 1.5-8BK (3200043) AI 2.5-8BU (3200522) Recommended crimping CRIMPFOX ZA 3 tool for terminal (1201882) 10-205 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 500 Do not solder on cable connection point. Otherwise extreme heat may cause failure of fire. 6. Install the power supply cable to GP and secure it to GP body with left and right power supply connector securing screws. 8500-1/8500E-1 10-206 Published 08-16-13, Control #208-03...
  • Page 501: Detail Of Moment Limiter Connector

    CONNECTOR CF CARD COVER • CF card contains the adjusted data as backup. When replacing the ML controller, ensure to re-in- sert the original CF card and copy the backup data to the controller. 10-207 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 502 10. ELECTRIC SYSTEM 2. ML controller connector pin layout (View from main machinery harness) 8500-1/8500E-1 10-208 Published 08-16-13, Control #208-03...
  • Page 503 12V load detector power -6 (+) 12V load detector power -7 (+) 12V load detecting signal -7 (0 to 6.2V) 12V load detector power (GND) 12V load detecting signal -7 (0 to 6.2V) 12V load detector power -8 (+) 10-209 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 504 Jib angle detector signal (OPT) 12V) Jib angle detector power (GND) 12V ML system sensor power 2 (GND) 12V ML system sensor signal 2-2 (0 to 12V) 12V ML system sensor power 2-2 (+) vacant vacant 8500-1/8500E-1 10-210 Published 08-16-13, Control #208-03...
  • Page 505 24V load detector signal -4 (0 to 12.5V) vacant vacant vacant vacant vacant vacant RS232C (+) Inter monitor transmission (TXD) RS232C (TXD) Inter monitor transmission (RXD) RS232C (RXD) Inter monitor transmission (GND) RS232C (GND) 10-211 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 506 Output power (-) Extended 24V power (GND) CN-11-4 Output power (-) Extended 25V power (GND) Extended 26V power (GND) Voice alarm output 4 Lg/Y Ground output (0.1A) Outside indication light (Red) Ground output (0.2A) 8500-1/8500E-1 10-212 Published 08-16-13, Control #208-03...
  • Page 507 Over payout prevent LS (front) 24V input Over payout prevent LS (rear) 24V input Over payout prevent LS (third) 24V input Main controller 1 bypass SW 24V input Main controller 2 bypass SW 24V input 10-213 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 508 Simultaneous control permit signal Ground input (330 ) Adjustment permit signal Ground input (4.7k ) Program rewrite permit signal Ground input (4.7k ) vacant vacant vacant vacant Wind speed sensor Pulse input (+) Pulse input (-) 8500-1/8500E-1 10-214 Published 08-16-13, Control #208-03...
  • Page 509 Voice alarm output 1 Ground output (0.1A) Voice alarm output 2 Ground output (0.1A) Outside indication light (yellow) Ground output (0.1A) Voice alarm output 3 Ground output (0.1A) Outside indication light (green) Ground output (0.1A) 10-215 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 510 16Mbyte (8M x 16 1pcs) EDO-Memory Outside memory 2Mbyte media CN7-1 Battery Backup SRAM Compact 2Mbyte (512K x 6 2pcs) Flash I/F MR-SHPC-01 * Battery is common to RTC XILINX CPLD 7Segment LED XC9572XL-7TQG100I 8500-1/8500E-1 10-216 Published 08-16-13, Control #208-03...
  • Page 511 Spare 0 to 12.5V CN11-63 Spare 0 to 12.5V CN11-64 Spare 0 to 12.5V CN11-73 Spare 0 to 12.5V CN11-74 (2) PULSE INPUT (BREAK IN) [E] Name Condition Signal level Remarks Anemometer GND/OPEN CN11-5-35 10-217 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 512 CEN spec. recognize signal CEN / Normal GND/OPEN CN11-5-29 Simultaneous operate permit Permit & CEN / Normal GND/OPEN CN11-5-30 For adjusting Adjusting / Normal GND/OPEN CN11-5-31 For program rewriting Rewrinting / Normal GND/OPEN CN11-5-32 8500-1/8500E-1 10-218 Published 08-16-13, Control #208-03...
  • Page 513 Voice alarm 5 Actuate / Normal GND/OPEN CN11-6-3 Outer indication light (green) On / Off GND/OPEN CN11-6-14 Outer indication light (yellow) On / Off GND/OPEN CN11-6-15 Outer indication light (red) On / Off GND/OPEN CN11-4-8 10-219 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 514: Shifting To Maintenance Screen

    3. Input the password (8 digits) with the keyboard. * In case of using capital letter, push CAPS switch. CLR : All clear DEL : One letter clear BS : One letter clear and back 8500-1/8500E-1 10-220 Published 08-16-13, Control #208-03...
  • Page 515 11000100000500010200 10:00 2010/12/01 2010/12/01 6. If password is not correct, password area blinks three times and then screen returns to 3. screen. Check the password and input again. 10-221 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 516: Input, Output Signal

    INPUT, OUTPUT SIGNAL This screen can check input signal condition of various sensors or switches or output signal condition of sole- noid valves, relays and proportional valves. 1. Push [I/O SIGNAL] in the maintenance menu. 8500-1/8500E-1 10-222 Published 08-16-13, Control #208-03...
  • Page 517 0 V is indicated on non connected point. 1.286 0.000 0.000 0.000 0.000 0.000 0.450 0.000 0.000 3.672 0.000 9.667 0.000 0.000 0.000 0.000 4.510 0.000 0.000 0.000 (B) By pushing [NEXT], digital input and digital output become indicated. 10-223 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 518 This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 8500-1/8500E-1 10-224 Published 08-16-13, Control #208-03...
  • Page 519 0.00 2.39 0.00 0.55 4.93 0.48 4.93 1.72 4.93 1.11 4.93 3.15 0.00 2.53 0.57 2.60 0.62 1.94 3.21 2.32 0.00 1.34 2.37 (B) By pushing [NEXT], digital input and digital output are indicated. 10-225 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 520 This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 8500-1/8500E-1 10-226 Published 08-16-13, Control #208-03...
  • Page 521 Unit of indicating figure is V (volt). This is used as accelerator signal to ECU. However this becomes effective only when G-28 accelerator control (MC option set) is "O". 1.00 0.00 Engine revolution (RPM) 00000000 ENGINE STATUS 10-227 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 522 0.00 0.00 0.00 0.00 0.68 0.00 1.45 0.59 1.25 0.54 0.00 2.46 1.93 0.58 0.65 0.13 0.36 0.17 0.00 0.07 0.98 0.32 0.00 (B) By pushing [NEXT], digital input and digital output are indicated. 8500-1/8500E-1 10-228 Published 08-16-13, Control #208-03...
  • Page 523 This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 10-229 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 524 Unit of indicating figure is mA (mille ampere). If instruct value is more than 100 mA and feedback value is about 0 mA, wire breakage is presumed. As for signal name and specification, refer to P.10- 343. 8500-1/8500E-1 10-230 Published 08-16-13, Control #208-03...
  • Page 525: Ml Function Setting

    2. Setting item becomes indicated. ME034 PSV MC1-D05 m i n ME093 PSV MC1-D08 19:19 2011/08/12 ME096 PSV MC1-D09 MC1-D02 PSV MC1-D11 MC1-D03 PSV MC1-D12 MC1-D04 D/O MC1-D04 10-231 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 526 (EX) In case of anemometer installed. (A) Push [ANEMOMETER] in the menu. (B) Option setting screen of anemometer becomes in- dicated. (C) Push [Enable]. * The selected side turns to blue indication. (D) Push [OK]. 8500-1/8500E-1 10-232 Published 08-16-13, Control #208-03...
  • Page 527 (EX) In case of making LVL function effective. (A) Push [USE OF LVL] in the menu. (B) LVL function screen becomes indicated. (C) Push [Enable]. * The selected side turns to blue indication. (D) Push [OK]. 10-233 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 528 (4) SETTING OF CRANE BODY COLOR This is to set crane body color. (EX) In case body color is selected to yellow. (A) Push [Color] in the menu. (B) Push [Enable] . (C) Push [Yellow] area. (D) Push [OK]. 8500-1/8500E-1 10-234 Published 08-16-13, Control #208-03...
  • Page 529: Data Copy, Format

    The backup data in the data card is not formatted. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 10-235 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 530 Be careful not to use in error. Select [CF Card → Controller] in the menu. The screen shown right becomes indicated. Push [SET] for 3 seconds to execute. 8500-1/8500E-1 10-236 Published 08-16-13, Control #208-03...
  • Page 531 In this case, check the function of ML adjusting mode select relay (R-36). Adjustment data reference error. 10-237 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 532 The screen shown right becomes indicated. Push [SET] for 3 seconds to execute. When completed properly, the screen shown right becomes indicated. By pushing [OK], the screen returns to the previous one. It was completed. Push OK. 8500-1/8500E-1 10-238 Published 08-16-13, Control #208-03...
  • Page 533 When using this function, the data in the controller be- ing used for calculation is overwritten. Be careful not to use in error. Select [FORMAT] in the menu. The screen shown below is indicated. Push [SET] for 3 seconds to execute. 10-239 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 534 In this case, check the function of ML adjusting mode select relay (R-36). Adjustment data reference error. 8500-1/8500E-1 10-240 Published 08-16-13, Control #208-03...
  • Page 535: Language, Unit Setting

    Indicated Indicated unit language Japanese m, t ENG (ft • lbs) English feet, klbs ENG (m • t) English m, t Selected item becomes indicated in blue letter. After select, push [OK]. 10-241 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 536 This is used when screen indication of swing direction and actual swing di- Swing sensor adjustment rection varies. This is also used whenever swing angle sensor (slip ring built- in) is replaced. 8500-1/8500E-1 10-242 Published 08-16-13, Control #208-03...
  • Page 537 [LOWER BOOM AN- GLE SENSOR]. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 10-243 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 538 10. ELECTRIC SYSTEM Touch angle indicating area. 100% Angle indicating area becomes indicated in reverse and digit input becomes possible. 100% 8500-1/8500E-1 10-244 Published 08-16-13, Control #208-03...
  • Page 539 Angle of 25 degrees is just a guideline for lowering the boom, and this guideline should not be necessarily ob- served. However, remember that the adjustment is ef- fective if the boom is lowered with an angle as large as possible. 100% 10-245 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 540 10. ELECTRIC SYSTEM Touch the second angle indicating area. 100% Angel indicating area becomes indicated in reverse and digit input becomes possible. 100% 8500-1/8500E-1 10-246 Published 08-16-13, Control #208-03...
  • Page 541 [SET]. 100% When the adjustment is properly completed, the message shown below is indicated. "Adjustment is properly completed. Push [SET]" By pushing [SET], the screen returns to the previ- ous one. 100% 10-247 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 542 Select the required load detec- tor to be adjusted. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 8500-1/8500E-1 10-248 Published 08-16-13, Control #208-03...
  • Page 543 0.8 to 1.2 V, the load cell is judged to be faulty and the adjustment is rejected. In such a case, replace the load cell. The message shown below becomes indicated when the adjustment is properly completed. By pushing [SET], screen returns to the previous one. 10-249 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 544 By pushing [SET], screen returns to the one during adjusting. Re-check the procedure and start adjust- ment again. Adjustment is failure. Push SET after you reconfirm whether the tension applied to the load cell is a zero. 8500-1/8500E-1 10-250 Published 08-16-13, Control #208-03...
  • Page 545 Boom foot Aux. sheave hook Luffing crane Jib hook + Jib lifting Boom foot (jib hook only) Aux. sheave hook *1 = 1/4 of distances from boom point sheave to ground. L / 4 10-251 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 546 Adjustment would become easier if the adjustment points (angle) are set in advance in the range be- tween the upper limit angle and lower limit angle di- vided into 6 in the adjustment required configuration. 8500-1/8500E-1 10-252 Published 08-16-13, Control #208-03...
  • Page 547 10. ELECTRIC SYSTEM Select [LOAD-LESS ADJUSTMENT] in the adjust- ment menu. Touch load indicating area. Load indicating area turns in reverse indication and digit input becomes possible. 10-253 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 548 After raising the boom to almost the upper limit an- gle and then lower by about 1 degree and then stop. There are some error in boom raising and boom lower- ing. So ensure to stop in boom lowering. Push [SET]. 8500-1/8500E-1 10-254 Published 08-16-13, Control #208-03...
  • Page 549 By pushing [SET], message memorizing the fist point is indicated. After lowering the boom, push [SET]. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. The 1st point was memorized. 10-255 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 550 [SET] is indicated. Lower the boom to almost minimum angle and push [SET]. The 5th point was memorized. Push SET after you make a boom or jib a minimum angle. 8500-1/8500E-1 10-256 Published 08-16-13, Control #208-03...
  • Page 551 In without load adjustment, if adjustment on more than two boom (jib) length is done, on boom (jib) length which is not adjusted yet, calibration by inter- polation by two closest length adjustment values is applied. 10-257 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 552 [SET]. * This includes weight of hook and lifting sling. The procedure afterward is as same as without load. Proceed as without load adjustment. 100% 8500-1/8500E-1 10-258 Published 08-16-13, Control #208-03...
  • Page 553 After pushing [SET], start adjustment again. With load adjustment is likely to be affected with lifting load swinging. Therefore when the actual load indication moves signif- icantly, wait until the lifting load swinging stops and push [SET]. 10-259 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 554 "LVL SETTING" in the "SETTING". If "NOT EFFEC- TIVE" is selected, normal 105% is applied even value is changed in this function. Select [LVL ADJUSTMENT] in the adjustment menu. Touch the load ratio indicating area. 8500-1/8500E-1 10-260 Published 08-16-13, Control #208-03...
  • Page 555 10. ELECTRIC SYSTEM The indicating area becomes reverse indication. In- put value with digit key. After value input is completed, push [SET]. Setting is completed and screen returns to previous one. 10-261 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 556 The load ratio is not affected by LVL function. • When the loading ratio is 90%, forecasting sounds (intermittent sounds) are emitted. Alarm sounds (continuous sounds) are emitted when the loading ratio is 100% (not affected by the LVL function). 8500-1/8500E-1 10-262 Published 08-16-13, Control #208-03...
  • Page 557 Raise the boom (jib) to almost upper limit angle and then lower by about 1 degree and then stop. Select [RADIUS ADJUSTMENT] in the adjustment menu. Touch the radius indication area. Radius indication area becomes reverse indication and digit input becomes possible. 10-263 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 558 Input actually measured work radius with digit key. (EX) In case of input [35.0], input [3], [5], [.] [0]. After input, push [SET]. Lower the boom (jib) to almost min. angle and stop. Then push [SET]. 8500-1/8500E-1 10-264 Published 08-16-13, Control #208-03...
  • Page 559 10. ELECTRIC SYSTEM Touch the radius indication area. Input actually measured work radius with digit key. (EX) In case of input [67.0], input [6], [7], [.] [0]. After input, push [SET]. 10-265 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 560 If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting. Re-check the procedure and start adjust- ment again. Adjustment is failure. Push SET, and adjust it again. 8500-1/8500E-1 10-266 Published 08-16-13, Control #208-03...
  • Page 561 If the indication changes from [FR] to [OK], front side adjustment is properly completed. Swing the crane by 180 degrees and face it toward rear (propel motor side) and fix with the swing lock pin. 10-267 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 562 When either [FR] or [RE] is pushed and "NG" is in- dicated, adjustment is in error. Check if the crane direction or sensor voltage is correct and start adjustment again. Below screen indicates NG in rear adjustment as an example. 8500-1/8500E-1 10-268 Published 08-16-13, Control #208-03...
  • Page 563 10. ELECTRIC SYSTEM To rest adjusted value, push [A]. "OK" is indicated on both [FR] and [RE] and the val- ue is reset. 10-269 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 564: 11Ml Adjustment (Temporary)

    The procedure of "WITHOUT LOAD ADJUSTMENT", "WITH LOAD ADJUSTMENT" are same as "WITHOUT LOAD ADJUSTMENT", "WITH LOAD ADJUSTMENT" of "10.2.10 ML ADJUSTMENT (NORMAL)". (Adjust in the same procedure as P.10-251 to 10-259.) 8500-1/8500E-1 10-270 Published 08-16-13, Control #208-03...
  • Page 565: 12Operation Progress

    Third winch rated load with current radius on the basis of data Calculated main winch operating radius before correction by radius adjustment Calculated aux. winch operating radius before correction by radius adjustment Calculated third winch operating radius before correction by radius adjustment 10-271 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 566 (5 - load cell zero adjustment value) x 0.08333 x (1.02 or 0.98) Load cell rated voltage Correction coefficient 1/reeving rope coefficient for raising (depending (depending on the machine models) on the machine models) Correction coefficient for lowering (depending on the machine models) 8500-1/8500E-1 10-272 Published 08-16-13, Control #208-03...
  • Page 567: 13Version Information

    Monitor Program Version Monitor Program Part No. MC1 Program Version MC2 Program Version MC1 Program No. MC2 Program No. M/L Data Model Name M/L Data Part No. M/L Setting Data Version M/L Capacity Data Version 10-273 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 568: 14Failure History

    Push [ML FAILURE HISTORY] in the menu. Past failures become indicated from latest one in order to max. 20 items. Failure content is indicated by code. Check the contents by the table in operator’s man- ual "3.13 MESSAGE TABLE". 8500-1/8500E-1 10-274 Published 08-16-13, Control #208-03...
  • Page 569 Touch GO for 1sec if it is good. Touch STOP if you stop it. In case of deletion, push [GO]. In case of stop, push [STOP]. Push [GO] for more than 1 second. By pushing [GO], data is deleted. 10-275 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 570 Touch GO for 1sec if it is good. Touch STOP if you stop it. In case of deletion, push [GO]. In case of stop, push [STOP]. If deleted, all pages are deleted at once. Push [GO] for more than 1 second. 8500-1/8500E-1 10-276 Published 08-16-13, Control #208-03...
  • Page 571 10. ELECTRIC SYSTEM By pushing [GO], data is deleted. (3) DELETING MC2 FAILURE HISTORY Push [DELETING MC2 FAILURE HISTORY] in the menu. Indication content and handling procedure are same as MC1. 10-277 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 572: 15Adjustment Data

    No.2 is for tower jib angle detector and No.3 is for tower jib angle detector. If adjustment is not done yet, shift = 0.000, span = 1.000 is indicated. ADJUSTMENT VALUE ANGLE SENSOR 100% 8500-1/8500E-1 10-278 Published 08-16-13, Control #208-03...
  • Page 573 In case of input [1.103], input [1], [.], [1], [0], [3]. If there is other changing area, change the digit in the same way. After all input is completed, push [A]. ADJUSTMENT VALUE ANGLE SENSOR 100% 10-279 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 574 ADJUSTMENT VALUE ANGLE SENSOR 100% Adjustment value was saved. (C) DELETING ADJUSTMENT DATA All of adjustment data are returned to initial values. Push [B] for 3 seconds to execute. ADJUSTMENT VALUE ANGLE SENSOR 100% 8500-1/8500E-1 10-280 Published 08-16-13, Control #208-03...
  • Page 575 10. ELECTRIC SYSTEM All adjustment data returns to the initial value. Initial value : Shift = 0.000, Span = 1.000 This is to complete deletion. Push [OK]. ADJUSTMENT VALUE ANGLE SENSOR 100% Adjustment value was erased. 10-281 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 576 Push [BACK] to return to the previous screen. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 8500-1/8500E-1 10-282 Published 08-16-13, Control #208-03...
  • Page 577 To return to previous screen, push [BACK]. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 10-283 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 578 (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. * In case of deletion, indicated group data ONLY are deleted. 8500-1/8500E-1 10-284 Published 08-16-13, Control #208-03...
  • Page 579 If adjustment is not done yet, shift = 0.000, span = 1.000 becomes indicated. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 10-285 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 580: 16Download Ml Program

    2. Connect write in permit connector CN- 420M on the right upper of the controller and CN-439F. 3. Turn on the key switch. 4. Download is started. 1. Insert card. 4. 7 SEGMENT 2. Connector connection. DISPLAY 8500-1/8500E-1 10-286 Published 08-16-13, Control #208-03...
  • Page 581 Approx. 10 seconds 5. When End is indicated, re-writing is completed. 6. Turn OFF the key switch. 7. Pull out write in permit connector. 8. Return the CF card back to the original position. 10-287 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 582: 17Download Of Monitor Program

    3. When the screen is started, tap on screen corners diagonally in succession. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 8500-1/8500E-1 10-288 Published 08-16-13, Control #208-03...
  • Page 583 10:00 10:00 2010/12/01 2010/12/01 5. Select [CF START]. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 10-289 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 584 CF card or cover to be closed. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 7. Select [DOWNLOAD (CF → Display)] 8500-1/8500E-1 10-290 Published 08-16-13, Control #208-03...
  • Page 585 10. ELECTRIC SYSTEM 8. Select [START]. 9. Select [YES]. 10-291 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 586 OS data write completed (4/4). System/Project data write completed (80/80). SRAM data write completed (2/2). Successfully completed. Please push the Back button. 11. Push [Back] to return to the screen before writing in starts. 8500-1/8500E-1 10-292 Published 08-16-13, Control #208-03...
  • Page 587 12. Push [Exit] to return to the screen 1 step before. 13. Push [Yes]. Monitor re-starts. This is to complete re-writing of program. Turn the key switch OFF and take out the CF card. 10-293 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 588: Main Controller

    ARRANGEMENT OF MAIN CONTROLLER 1. INSTALLATION POSITION (CAB) OF MAIN CONTROLLER 1 MAIN CONTROLLER 1 VIEW FROM “A” 2. INSTALLATION POSITION (LEFT CAB) OF MAIN CONTROLLER 2 MAIN CONTROLLER 2 FRONT LEFT DECK INSIDE VIEW FROM “C” 8500-1/8500E-1 10-294 Published 08-16-13, Control #208-03...
  • Page 589: Composition Of System

    PWM output 24 V Constant current circuit (Max 1 A) Proportional valve Output 100 to 700 mA Disconnection detection W/short-circuit protection Disconnection detection Solenoid valve Output 24 V 1 A W/short-circuit protection 10-295 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 590: Function Of Main Controller

    Adjustment 1 Model number setting Adjustment 2 Option setting Adjustment 3 Adjustment of grip throttle and foot throttle Adjustment 4 Engine speed adjustment Adjustment 5 Adjusting of inclination meter Adjustment 6 Supply pump adjustment 8500-1/8500E-1 10-296 Published 08-16-13, Control #208-03...
  • Page 591 If the wire of accelerator control or foot control is broken, output voltage to ECU becomes 0 V.) In this case, by turning the aux. accelerator switch to ON, low speed and middle speed becomes oper- ational. (High speed is not possible) 10-297 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 592 Battery is energized 1.5 seconds after the key switch is turned ON. Battery is de-energized 4 seconds *after the key switch is turned OFF. However in case of emergency solenoid being ac- tuated, 90 seconds after. 8500-1/8500E-1 10-298 Published 08-16-13, Control #208-03...
  • Page 593 Lower the actual speed is against target speed, larger the output current is. However in case of low idling, even the difference is small, output current is large. (to prevent engine stall) 10-299 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 594 10. ELECTRIC SYSTEM 3. WINCH MOTOR SPEED CONTROL 8500-1/8500E-1 10-300 Published 08-16-13, Control #208-03...
  • Page 595 > Trimmer control (during power low- ering) FRONT/REAR/THIRD (OPTION) MOTOR TILT CONTROL PROP. V. CURRENT FRONT/REAR/THIRD (OPTION) DRUM RAISE/LOWER REMO-CON PROP. V. CURRENT (mA) REMO-CON MOTOR CONTROL FRONT/REAR/THIRD (OPTION) DRUM SPEED ADJUST TRIMMER 10-301 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 596 If the trimmer is set to maximum value, the prop. valve becomes full open and the main valve open- ing becomes maximum. BOOM RAISE / LOWER PROP. VALVE CURRENT ENGINE HIGH (b) (mA) ENGINE LOW (a) BOOM SPEED ADJUST TRIMMER 0.47 8500-1/8500E-1 10-302 Published 08-16-13, Control #208-03...
  • Page 597 10. ELECTRIC SYSTEM 5. SWING COUNTERFORCE A reaction is applied to the lever depending on swing loads. SWING REACTION PROPORTIONAL VALVE CURRENT SWING NEUTRAL FREE (mA) SWING NEUTRAL BRAKE SWING PUMP PRESSURE 1.96 15.40 34.32 (MPa) 10-303 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 598 NEUTRAL FREE (LOW SPEED) or BRAKE NEUTRAL FREE (HIGH SPEED) GRIP THROTTLE • When the swing control signal is OFF for 10 sec- onds, or swing limit function is selected, the current becomes maximum value. (700 mA) 8500-1/8500E-1 10-304 Published 08-16-13, Control #208-03...
  • Page 599 Parking action is released when right control pres- sure is detected when stopped with left decelera- DECELERATION tion. SIGNAL Judging point of control pressure is more than 0.539 MPa. 10-305 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 600 10. ELECTRIC SYSTEM 8. WINCH CONTROL (1) Control lever neutral mode selection (2) Winch operation solenoid valve control 8500-1/8500E-1 10-306 Published 08-16-13, Control #208-03...
  • Page 601 When the lever is at the neutral position while the free fall mode is selected, output from the front 0.69 1.96 CLUTCH PRESSURE (MPa) drum (rear drum and third drum) down remote con- trol proportional valve should depend on the clutch pressure. 10-307 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 602 Even after the main power supply is shut down while the emergency solenoid valve is being actuated, power supply to the controller remains alive for ninety seconds after the engine is stopped. In this period, the residual clutch pressure is removed. 8500-1/8500E-1 10-308 Published 08-16-13, Control #208-03...
  • Page 603 10. ELECTRIC SYSTEM (3) Free fall acceleration 10-309 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 604 • Other conditions are restored to those of the normal control. The monitor control proportional valve is controlled according to the depression of the foot pedal (clutch PROPORTIONAL VALVE CURRENT (mA) pressure). 0.69 1.96 CLUTCH PRESSURE (MPa) 8500-1/8500E-1 10-310 Published 08-16-13, Control #208-03...
  • Page 605 Boost solenoid valve Front drum raise stop Front drum boost solenoid is immediately de-energized. Rear drum raise stop Rear drum boost solenoid is immediately de-energized. Third drum raise stop Third drum boost solenoid is immediately de-energized. 10-311 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 606 10 degrees), is minimized within 1.5 seconds, and the boom is the boom raise remote control proportional valve is slowly stopped. controlled and the boom raising speed is deceler- ated according to the boom angle. 8500-1/8500E-1 10-312 Published 08-16-13, Control #208-03...
  • Page 607 13. FRONT DRUM HOISTING STOP / REAR DRUM HOISTING STOP FRONT DRUM HOIST REAR DRUM HOIST PROPORTIONAL VALVE CURRENT PROPORTIONAL VALVE CURRENT (mA) (mA) STOP STOP FRONT DRUM HOIST STOP REAR DRUM HOIST STOP SIGNAL INPUT SIGNAL INPUT 10-313 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 608 10. ELECTRIC SYSTEM 14. MOTOR TILT ANGLE CONTROL 8500-1/8500E-1 10-314 Published 08-16-13, Control #208-03...
  • Page 609 0.98 (10) 0.98 (10) 1.77 (18) 1.96 (20) Third 1.96 (20) Third Lever remo-con 2nd press. MPa (kg/cm Max. speed is obtained Third tilt angle prop. valve control before turning to 2nd speed detent. 10-315 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 610 > clamshell mode (this section) > trimmer control (this section) > tower mode speed control (this section) Between trimmer lever control value or engine speed control value, smaller value is selected as maximum value. 8500-1/8500E-1 10-316 Published 08-16-13, Control #208-03...
  • Page 611 Boom hoist lower remo-con prop. valve Third raise remo-con prop. valve → But in case of luffing configuration. Third lower remo-con. prop. valve → But in case of luffing configuration only, stop action is executed. 10-317 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 612 Front, rear and third (jib) raise remo-con. prop. valve command current are set to inching speed level. (375 mA) If each lever is in operation, each tilt angle prop. valve output is fixed to Low. (310 mA) 8500-1/8500E-1 10-318 Published 08-16-13, Control #208-03...
  • Page 613 Grip solenoid output becomes OFF when the drum speed exceeds the specified level. Specified speed. = drum speed : about 61.5 min = more than 4 pulse at 50 m sec. Therefore there is no output from the total control- ler. 10-319 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 614 10. ELECTRIC SYSTEM 17. FRONT/BOOM PUMP CONTROL 8500-1/8500E-1 10-320 Published 08-16-13, Control #208-03...
  • Page 615 When ML bypass is effective and switch input is ON, same control as inching switch IN control (2) above is applied. When ML is released and switch input is ON, same control as inching switch IN control (2) above is ap- plied. 10-321 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 616 Difference between height of zero reset time and the present height is calculated and the boom or jib height is calculated. (7) Distance variation of hook and boom point (jib point) is calculated by angle variation of boom (jib). 8500-1/8500E-1 10-322 Published 08-16-13, Control #208-03...
  • Page 617 10. ELECTRIC SYSTEM (8) Actual height variation is calculated by adding (5) to (7) and is indicated on main monitor. • To make this control effective, option setting is re- quired. 10-323 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 618 10. ELECTRIC SYSTEM 19. LEVER INTERLOCK CONTROL 8500-1/8500E-1 10-324 Published 08-16-13, Control #208-03...
  • Page 619 → Either one of control is detected as MOTION, all prop. valve output stay minimum as is. Control stop condition by lever interlock function is advised to the monitor. 10-325 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 620 ECU. However load valve control and engine speed con- trol to raise exhaust temperature in order to prevent regeneration starting during crane control are done by crane side controller. 8500-1/8500E-1 10-326 Published 08-16-13, Control #208-03...
  • Page 621 This is the condition that exhaust temperature is reached to regeneration possible level and engine ECU started regeneration. The load valve remains ON but idling speed returns back. Long time idling can not be canceled. Others can cancel by only 1. 10-327 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 622 During Manual regeneration : This is the condition that exhaust temperature is reached to regeneration possible level and engine ECU started regeneration. Crane condition is as same as "Manual regenera- tion preparation". 8500-1/8500E-1 10-328 Published 08-16-13, Control #208-03...
  • Page 623 Crane operation is not possible. regeneration Control impossible Long time idling Load valve ON Auto regeneration is done. Load valve request Speed 800 to 1,000 min Crane operation is possible. During auto regeneration Control possible 10-329 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 624 10. ELECTRIC SYSTEM 22. G WINCH CONTROL GK, HF, GN, JD Gr. ONLY 8500-1/8500E-1 10-330 Published 08-16-13, Control #208-03...
  • Page 625 (neutral → operation → neutral) In case G winch function is required again, the indi- vidual switch is input. After switched to individual mode and individual switch is pushed again, function is cancelled. 10-331 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 626 Engine speed pressure SOL FB value control control 1,800 min At G engine 3 MPa or more or more OFF output 1,725 min * at speed abnormal At Normal Less than 3 MPa No judgement 8500-1/8500E-1 10-332 Published 08-16-13, Control #208-03...
  • Page 627 10. ELECTRIC SYSTEM 24. AIS CONTROL 10-333 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 628 (3) Key cut off fail preventing function AIS condition may be left for long time. If AIS condition is continued for longer than certain time, battery is turned OFF automatically. 8500-1/8500E-1 10-334 Published 08-16-13, Control #208-03...
  • Page 629 10. ELECTRIC SYSTEM 25. HYD. OIL HEAT (OPTION) Control Relay When all lever is in neutral Energized Either on lever is in operation De-energized 10-335 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 630: Main Controller 1, 2 (Hardware)

    10. ELECTRIC SYSTEM 10.3.4 MAIN CONTROLLER 1, 2 (HARDWARE) HARNESS SIDE CONNECTOR MC1 : CN-101F to CN-109F MC2 : CN-111F to CN-119F 8500-1/8500E-1 10-336 Published 08-16-13, Control #208-03...
  • Page 631: Specifications Of Main Controller Output

    0 to 19.61 MPa 0.5 to 4.5 V Third drum clutch pressure sensor (option) 0 to 19.61 MPa 0.5 to 4.5 V Re. drum clutch pressure sensor 0 to 19.61 MPa 0.5 to 4.5 V 10-337 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 632 +24 V/OPEN Re. drum motor CLA-SOL (FB) Energized/De-energized +24 V/OPEN Re. drum motor ESA-SOL (FB) Energized/De-energized +24 V/OPEN Third drum motor CLT-SOL (FB) Energized/De-energized +24 V/OPEN Third drum motor EST-SOL (FB) Energized/De-energized +24 V/OPEN 8500-1/8500E-1 10-338 Published 08-16-13, Control #208-03...
  • Page 633 100 to 700 mA 200 mAp-p 63 Hz Left swing stop prop. valve 100 to 700 mA 200 mAp-p 100 Hz Right swing stop prop. valve 100 to 700 mA 200 mAp-p 100 Hz 10-339 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 634 +24 V/OPEN Re. drum rotate detect grip (option) +24 V/OPEN Safety relay operation Operation/Normal GND/OPEN Engine stop relay operation Energized/De-energized GND/OPEN Swing voice alarm ON/OFF GND/OPEN Vacancy GND/OPEN Vacancy GND/OPEN (CPU error) Vacancy +24 V/OPEN 8500-1/8500E-1 10-340 Published 08-16-13, Control #208-03...
  • Page 635 0.5 to 4.5 V Third drum raise pressure sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Third drum lower pressure sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V 10-341 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 636 Normal/Stop +24 V/OPEN Boom drum raise stop Normal/Stop +24 V/OPEN Boom drum lower stop Normal/Stop +24 V/OPEN DPF load SOL Load ON/OFF +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN 8500-1/8500E-1 10-342 Published 08-16-13, Control #208-03...
  • Page 637 200 mAp-p 100 Hz Re. drum motor tilt control prop. valve 200 to 750 mA 200 mAp-p 100 Hz Third drum motor tilt control prop. valve 200 to 750 mA 200 mAp-p 100 Hz (option) 10-343 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 638 Re. drum control signal GND/OPEN Third control signal GND/OPEN Fr. drum C/V-SOL Energized/De-energized +24 V/OPEN Re. drum C/V-SOL Energized/De-energized +24 V/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN (CPU error) Third C/V-SOL (option) Energized/De-energized +24 V/OPEN 8500-1/8500E-1 10-344 Published 08-16-13, Control #208-03...
  • Page 639: Arrangement Of Main Controller Connector Pin

    RXD1 Spare Spare SHG1 Spare TXD3 RXD3 Program DL serial Spare Engine turn sensor Spare Spare SHG3 Spare Accel. indicator voltage 1 Accel. indicator voltage 1 Accel. indicator voltage 2 Accel. indicator voltage 2 10-345 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 640 Tagline trimmer (option) Control primary pressure Swing pump pressure sensor Swing control (right) pressure sensor GND for third clutch pressure sensor (option) Swing control (left) pressure sensor GND for swing control (right) pressure sensor 8500-1/8500E-1 10-346 Published 08-16-13, Control #208-03...
  • Page 641 Grounded input (15 K Ω ) Clogging of air cleaner Grounded input (3.3 K Ω ) Spare GND for Inclination sensor X '+5A Re. drum clutch pressure sensor Third drum clutch pressure sensor (option) 10-347 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 642 Third drum free fall select. signal Grounded input (3.3 K Ω ) Fr. drum rotate sensor (and pulse input) Grounded input (3.3 K Ω ) Re. drum rotate sensor (and pulse input) For backup power supply +24 V 8500-1/8500E-1 10-348 Published 08-16-13, Control #208-03...
  • Page 643 Aux. accel. signal +24 V input Engine emg. stop signal +24 V input Engine restart +24 V input Operator certificate wait signal +24 V input Swing parking switch +24 V input Drum rotate detecting grip selection 10-349 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 644 +24 V input speed increase SW +24 V input Re. drum free fall speed increase SW Third drum free fall +24 V input speed increase SW (option) +24 V input Free fall permit signal 8500-1/8500E-1 10-350 Published 08-16-13, Control #208-03...
  • Page 645 Swing flasher PWM output Spare PWM output Spare D/O FB Swing warning (flasher) D/O FB Swing warning (Buzzer and flasher) D/O FB DPF regeneration FB D/O FB Accel. signal (DOWN) D/O FB Accel. signal (UP) 10-351 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 646 +24 V output Re. drum rotate detection grip (option) Grounded output Safety relay operation Grounded output Engine stop relay operation Grounded output Swing voice alarm Grounded output Spare Grounded output Spare +24 V output Spare 8500-1/8500E-1 10-352 Published 08-16-13, Control #208-03...
  • Page 647 CAN2 termination Vacancy CAN2 termination Vacancy Resistance input Vacancy Vacancy TXD1 Vacancy RXD1 Vacancy Vacancy SHG1 Vacancy TXD3 RXD3 Program DL serial Vacancy Engine rotate sensor Vacancy Vacancy SHG3 Vacancy Vacancy Vacancy Vacancy Vacancy 10-353 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 648 Resistance input A/D spare Connector No. Pin No. Port name Function Specifications CN113 Fr./Re. drum CHP start pressure sensor A/D spare A/D spare A/D spare Third drum raise pressure sensor A/D spare A/D spare 8500-1/8500E-1 10-354 Published 08-16-13, Control #208-03...
  • Page 649 Grounded input (15 K Ω ) C/W detect 6 (C5) Grounded input (3.3 K Ω ) C/W detect 7 (C5) Fr. drum lower pressure sensor '+5A Third drum lower pressure sensor Third drum raise pressure sensor 10-355 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 650 +24 V input Boom B/S No.2 signal Grounded input (3.3 K Ω ) Spare (and pulse input) Grounded input (3.3 K Ω ) Spare (and pulse input) For backup power supply +24 V Power supply 8500-1/8500E-1 10-356 Published 08-16-13, Control #208-03...
  • Page 651 +24 V input Spare +24 V input Spare +24 V input Crane hook overhoist signal +24 V input Jib hook overhoist signal +24 V input Hook overhoist release signal +24 V input Boom overhoist release signal 10-357 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 652 D/O FB Oil cooler motor relay +24 V input Third drum raise stop +24 V input Third drum lower stop +24 V input Boom drum raise stop +24 V input Boom drum lower stop 8500-1/8500E-1 10-358 Published 08-16-13, Control #208-03...
  • Page 653 D/O FB ML bypass (CR) Grounded output Spare Grounded output Spare PWM output Spare PWM output Spare D/O FB ML bypass (JIB) D/O FB Spare D/O FB Spare D/O FB Spare D/O FB Spare 10-359 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 654 Third drum control signal +24 V output Fr. drum C/V-SOL +24 V output Re. drum C/V-SOL Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare +24 V output Third C/V-SOL (option) 8500-1/8500E-1 10-360 Published 08-16-13, Control #208-03...
  • Page 655: Adjustment Of Main Controller

    PSV MC1-D04 17.4deg Password 100% 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-C12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC1-C04 Password input MC adjustment 10-361 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 656 (3) Select "O" (yes) or "X" (no) on each function setting. OPTION Use (c) icon for page change. 100% (4) After setting is completed, push "OK" and after page is changed, push "SET" to record. Unless "SET" is pushed, selection becomes inef- fective. 8500-1/8500E-1 10-362 Published 08-16-13, Control #208-03...
  • Page 657 Unless "SET" is pushed, selection becomes inef- engine revolution adjustment fective. NEXT If adjustment becomes NG, Engine revolution NG 1 : Accel open ratio Engine speed is abnormal. Check if engine error is output. NG 2 : Transmission is error. 10-363 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 658 (3) Progress becomes indicated. 100% PSV MC1-D01 PSV MC1-D09 100% is reached after 5 minutes. PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC1-D04 8500-1/8500E-1 10-364 Published 08-16-13, Control #208-03...
  • Page 659: Controller Malfunction Emergency Measures

    Malfunction of the proportional valves (D5, D8, D9, D11, D12 in MC1 and D1 to D8 in MC2) will be dis- played in the cluster gauge. (excluding the case when H-1 is displayed) MC2 BYPASS MC1 BYPASS SWITCH SWITCH FRONT 10-365 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 660 10. ELECTRIC SYSTEM 8500-1/8500E-1 10-366 Published 08-16-13, Control #208-03...
  • Page 661: Air Conditioner

    11. AIR CONDITIONER 11-1 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 662 11. AIR CONDITIONER 8500-1/8500E-1 11-2 Published 08-16-13, Control #208-03...
  • Page 663 DEFROSTER SWITCH BLOW OUT OPENING, TEMP. SETTING AND AIR VOLUME INDICATING PANEL BLOW OUT OPENING IN-OUT AIR SELECTOR SWITCH SELECTOR SWITCH AIR CON. SWITCH POWER ON/OFF SWITCH TEMPERATURE AIR VOLUME CONTROL SWITCHES SELECTOR SWITCH 11-3 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 664 (blowing air temp.) Pushing this switch changes temperature setting Pushing lowers temperature (blowing air temp.) when the air conditioner is running. Set temperature (d) is indicated on LCD display. (d) INDICATION CONTENT 8500-1/8500E-1 11-4 Published 08-16-13, Control #208-03...
  • Page 665 This is to defog on the inner side of the front glass or to defrost on the outer side of the front glass. * Air also blows from DEF. Blow volume is Foot < DEF. 11-5 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 666 • While defrosting the windscreen do not set the tem- perature to max. cooling. • Cold air may make windscreen foggy from outside and it may disturb the operator's vision. 8500-1/8500E-1 11-6 Published 08-16-13, Control #208-03...
  • Page 667 SWITCH (3) or both. • If AIR CON. SWITCH (2) is pushed, air con. oper- ates on dry air warming • If blow out selector switch is on Foot position, air blow out from defroster too. 11-7 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 668 By pushing BLOW OUT OPENING SELECTOR SWITCH (6), blow out opening returns to the set opening before DEFROSTER SWITCH (7) is pushed. • If blow out opening is set to DEF, air bows to foot too. 8500-1/8500E-1 11-8 Published 08-16-13, Control #208-03...
  • Page 669 If quick defogging is required, set the air volume to HIGH by AIR VOLUME SELECTOR SWITCH (3). • By pushing BLOW OUT OPENING SELECTOR SWITCH (6), blow out opening returns to the set opening before DEFROSTER SWITCH (7) is pushed. 11-9 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 670 11. AIR CONDITIONER This page is blank for editing convenience. 8500-1/8500E-1 11-10 Published 08-16-13, Control #208-03...
  • Page 671: Parts Illustration

    11. AIR CONDITIONER 11.2 PARTS ILLUSTRATION 11-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 672 11. AIR CONDITIONER 8500-1/8500E-1 11-12 Published 08-16-13, Control #208-03...
  • Page 673 57. DAMPER (IN) ASSY 17. LEVER (MAL1) 37. CLAMP 58. UNIT HARNESS ASSY 18. LEVER (AM) 38. ROD HOLDER 59. RELAY 19. LEVER (CM) 39. SENSOR HOLDER 20. LEVER (MO1) 40. CORD CLAMP A 11-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 674: Disassembly And Assembly Of The Unit

    4. Remove three of the cross head screw (Phillips) For IN TAKE CASE MOUNTING (4 pcs) T5 X 14 (T1) and separate the blower case and the air-con. unit. IN TAKE CASE UNIT For BLOWER CASE MOUNTING (3 pcs) 8500-1/8500E-1 11-14 Published 08-16-13, Control #208-03...
  • Page 675: Replacing The Blower Motor

    HEATER CORE Then pull out the heater core from the unit. 3. Installation is reverse way of the foregoing proce- dure. PIPE CLAMP UNIT PIPE CLAMP MOUNTING SCREW (1 pc) 11-15 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 676: Removal Of The Air-Con Unit Case-Front And- Rear

    In this case make sure that the heater core is re- moved from the unit case. EVAPORATOR ASSY EXPANSION VALVE EVAPORATOR SENSOR UNIT CASE LOWER UNIT CASE UPPER-LOWER MOUNTING SCREW (11 pcs) 8500-1/8500E-1 11-16 Published 08-16-13, Control #208-03...
  • Page 677: Replacing The Evaporator And Expansion Valve

    INSTALLATION OF EVAPORATOR SENSOR Install the evaporator sensor precisely to the original place of the evaporator as shown. During the installation work, take care not to make the sensor cord jammed with the case. EVAPORATOR SENSOR 11-17 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 678: Replacing The Motor Actuator

    Remove the motor actuator from the unit while the lever MAL2 is attached. Remove the lever MAL2 from the motor actuator. Install the new motor actuator in the reverse way of the foregoing procedure. IN-OUT AIR MOTOR ACTUATOR 8500-1/8500E-1 11-18 Published 08-16-13, Control #208-03...
  • Page 679: Fault Detection From The Control Panel Indication

    1. OPEN OR SHORT CIRCUIT Open circuit detect is indicated when there is an open or short circuit in the sensor line. OPEN CIRCUIT DETECT INDICATION FAULT LOCATION FAULT INDICATION EVAPORATOR SENSOR AIR CON. MARK BLINKING 11-19 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 680: Basic System Of Hvac

    (in-out blow port selector, air mix). The unit also has self diagnose function and can perform self diagnose easily. (For detail refer to the control specification) 8500-1/8500E-1 11-20 Published 08-16-13, Control #208-03...
  • Page 681 When the blower OFF relay turns ON, power is sup- plied to the blower motor and the blower motor VIEW FROM A starts. 6. COMPRESSOR RELAY This relay turns ON-OFF by the compressor control of the control amplifier. 11-21 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 682 The contact moves together with motor and stops the motor by reaching to the target position. (Refer to inspection of the In-out motor actuator.) 8500-1/8500E-1 11-22 Published 08-16-13, Control #208-03...
  • Page 683 When the sensor detect temp. is 0° C : 7.2 k Resistance value between terminal to the sensor When the sensor detect temp. is 25° C : 2.2 k 11-23 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 684 If the compressor stops at 3.14 MPa or around then the system if normal. (3) Check the continuity between the terminal to the switch and to the connector when the coolant is re- moved. If continuity is NO, the system is normal. 8500-1/8500E-1 11-24 Published 08-16-13, Control #208-03...
  • Page 685: Recharging Of The Coolant

    Do not take the bottle into the closed operator’s room even at the winder time. Temperature in the storage box also rises to dan- gerous range at summer time. Be careful on this point. 11-25 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 686 Assembling work of the air conditioner must be done quickly and take extra care to prevent water, dust entering into the system. Pay attention not to overcharge. Tighten all the pipe fittings with the specified torque. 8500-1/8500E-1 11-26 Published 08-16-13, Control #208-03...
  • Page 687: Work Procedure

    COOLANT RECHARGING WORK VACUUMING WORK 30 minutes Leaving for or more 5 minutes -750 mmHg or less GAUGE IND. ABNORMAL CONNECTOR CHECK COOLANT GAS RECHARGING TO & REPAIR GAUGE PRESSURE 0.098 MPa (1 kg/cm 11-27 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 688 11. AIR CONDITIONER 3. TOOL GAUGE MANIFOLD RED : HIGH PRESSURE SIDE CHARGING HOSE BLUE : LOW PRESSURE SIDE YELLOW : VACUUM PUMP SIDE QUICK JOINT Φ27.5 Φ23.5 8500-1/8500E-1 11-28 Published 08-16-13, Control #208-03...
  • Page 689: Recharging Procedure

    (3) Connect the center valve of the gauge manifold and the vacuum pump with the charging hose. Some type of the gauge manifold does not have the open/close valve in their center. 11-29 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 690 If the gauge moves back toward zero direction, there must be leaking point somewhere. Retighten all of pipe fittings and again repeat the vacuuming work and check for leak again. 8500-1/8500E-1 11-30 Published 08-16-13, Control #208-03...
  • Page 691 Check gas leak in the cooling cycle with the gas leak tester (electric type). If there is any leaking point, re-tighten. Make sure that the tester is for R134a coolant. (Tester for flon coolant is not usable due to low sensibil- ity) 11-31 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 692 NEVER open the high pressure side valve of the gauge manifold. RECEIVER DRYER • NEVER place the service bottle upside down. (Liquid form of coolant may be injected into the cooling cycle and may damage the compressor valve.) 8500-1/8500E-1 11-32 Published 08-16-13, Control #208-03...
  • Page 693 (2) Keep the high pressure side until the high pressure gauge reading becomes lower than 0.98 MPa {10 kg/cm (3) Remove the high pressure side charging hose (red) in the same procedure as the low pressure side. 11-33 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 694 11. AIR CONDITIONER This page is blank for editing convenience. 8500-1/8500E-1 11-34 Published 08-16-13, Control #208-03...
  • Page 695: Electric Wiring Diagram

    YAZAKI : YAZAKI 1. Wire meter is 0.5 mm unless otherwise spicified. 2. Dotted line ( ) is vehicle’s body wiring. 3. Connector pin layout color is a view on the mating face. YAZAKI : 11-35 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 696 11. AIR CONDITIONER This page is blank for editing convenience. 8500-1/8500E-1 11-36 Published 08-16-13, Control #208-03...
  • Page 697: Troubleshooting

    12. TROUBLESHOOTING 12-1 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 698 12. TROUBLESHOOTING 8500-1/8500E-1 12-2 Published 08-16-13, Control #208-03...
  • Page 699 12. TROUBLESHOOTING 12.1 TROUBLESHOOTING What actions should be taken upon occurrence of these problems ? 12-3 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 700 12. TROUBLESHOOTING 8500-1/8500E-1 12-4 Published 08-16-13, Control #208-03...
  • Page 701 12. TROUBLESHOOTING 12-5 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 702 12. TROUBLESHOOTING 8500-1/8500E-1 12-6 Published 08-16-13, Control #208-03...
  • Page 703 12. TROUBLESHOOTING 12-7 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 704 12. TROUBLESHOOTING 8500-1/8500E-1 12-8 Published 08-16-13, Control #208-03...
  • Page 705 12. TROUBLESHOOTING 12-9 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 706 12. TROUBLESHOOTING 8500-1/8500E-1 12-10 Published 08-16-13, Control #208-03...
  • Page 707 12. TROUBLESHOOTING 12-11 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 708 12. TROUBLESHOOTING 8500-1/8500E-1 12-12 Published 08-16-13, Control #208-03...
  • Page 709 12. TROUBLESHOOTING 12-13 8500-1/8500E-1 Published 08-16-13, Control #208-03...
  • Page 710 12. TROUBLESHOOTING 8500-1/8500E-1 12-14 Published 08-16-13, Control #208-03...

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