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Manitowoc 1200Ref Service And Maintenance Manual

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Service and maintenance manual (724 pages)

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Manitowoc

SERVICE/MAINTENANCE MANUAL

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 10-02-13, Control # 210-03

This manual has been prepared for and is considered part of -

12000-1/12000E-1

This Manual is Divided into the following Sections:

SECTION 1

SECTION 2

SECTION 3

SECTION 4

SECTION 5

SECTION 6

SECTION 7

SECTION 8

SECTION 9

SECTION 10

SECTION 11

SECTION 12

SECTION 13

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.

Model Number

1200Ref

Serial Number

SAFETY SECTION

REFERENCE MATERIALS

TEST PROCEDURES

GENERAL

POWER TRAIN

HYDRAULIC SYSTEM

HOIST SYSTEM

BOOM HOIST SYSTEM

SWING SYSTEM

PROPEL SYSTEM

ELECTRICAL SYSTEM

AIR CONDITIONER

TRANSLIFTER SYSTEM

TROUBLESHOOTING

NOTICE

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Summary of Contents for Manitowoc 1200Ref

Page 1 SECTION 13 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
TABLE OF CONTENTS SAFETY 1. REFERENCE MATERIALS 1.1 12000-1 SPECIFICATION..................1-3 1.1.1 OUTER DIMENSION..................1-3 1.1.2 CRANE SPECIFICATION, PERFORMANCE............ 1-6 1.1.3 CRANE WORKING RANGES ................1-8 1.2 12000-1 DIMENSION, WEIGHT OF EACH COMPONENT ........1-11 1.2.1 MAIN MACHINERY ................... 1-11 1.2.2 COUNTERWEIGHT...................
Page 4 TABLE OF CONTENTS 3. GENERAL WORK STANDARD 3.1 TIGHTENING TORQUE OF CAP SCREWS AND NUTS ........3-3 3.1.1 STANDARD TIGHTENING TORQUE ............... 3-3 3.1.2 TIGHTENING TORQUE OF HYDRAULIC FITTINGS........3-6 3.2 STANDARD PARTS....................3-8 3.2.1 BOLT ......................... 3-8 3.2.2 O-RING......................3-9 3.2.3 BACK-UP RING....................
Page 5 TABLE OF CONTENTS 5.3.2 OUTLINE ......................5-27 5.3.3 OIL FLOW FROM No.1-1, No.1-2 ..............5-28 5.3.4 OIL FLOW FROM No.3-1, 3-2 PUMP..............5-30 5.3.5 OIL FLOW FROM No.4-1 PUMP............... 5-32 5.3.6 OIL FLOW FROM No.4-2 PUMP............... 5-36 5.3.7 OIL FLOW FROM No.5-1, 5-2 PUMP (CONTROL/AUX.ACTUATOR) ..... 5-38 5.4 VALVE ........................
Page 6 TABLE OF CONTENTS 7.5.4 LOWERING BOOM ................... 7-16 8. SWING SYSTEM 8.1 APPARATUS AND LOCATION OF COMPONENTS..........8-3 8.2 CONSTRUCTION AND FUNCTION ................ 8-4 8.2.1 HYDRAULIC SCHEMATIC................8-4 8.2.2 SWING ......................8-6 8.2.3 STOPPING ......................8-9 8.3 SWING REDUCTION UNIT ..................8-12 8.4 SWING BEARING ....................
Page 7 TABLE OF CONTENTS 10.1.15HOW TO CHECK THE FAILURE CONTENTS ..........10-183 10.1.16CHECKING OF DIAGNOSIS LAMP FUNCTION ..........10-189 10.1.17ENGINE ECU ....................10-190 10.2 LOAD SAFETY DEVICE ..................10-192 10.2.1 CONFIGURATION OF SCREENS ..............10-193 10.2.2 SYSTEM DAIGRAM ..................10-194 10.2.3 MONITOR INDICATION .................. 10-195 10.2.4 DETAIL OF MOMENT LIMITER CONNECTOR..........
Page 8 TABLE OF CONTENTS 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 11.3.8 REPLACING THE MOTOR ACTUATOR ............11-18 11.4 FAULT DETECTION FROM THE CONTROL PANEL INDICATION ..... 11-19 11.4.1 GENERAL .......................
Page 9: Safety
SAFETY 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 10 SAFETY 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 11: Safety Information
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 SAFETY EXPLANATION OF WARNING LABELS IN THE MACHINE Since the warning labels are installed in the machine and indicated with the three stages in the same way as the warning description, confirm the positions and contents of all warning labels first. Put them to the practical use to secure safety when operating, checking and performing maintenance.
Page 13: Label Layout
SAFETY LABEL LAYOUT * Numbers in the drawings correspond with those in the label explanation detail after P.0-15. 6 (12000E-1) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 14 SAFETY 32 (12000E-1) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 15 SAFETY 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 16 SAFETY 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 17 SAFETY 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 18 SAFETY 15 (12000E-1) 16 (12000-1 W/ 15 (12000-1 W/ J08-VM ENGINE) J08-UV ENGINE) 12000-1/12000E-1 0-10 Published 10-02-13, Control #210-03...
Page 19 SAFETY 0-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 20 SAFETY 30 (12000E-1) 30 (12000-1) 12000-1/12000E-1 0-12 Published 10-02-13, Control #210-03...
Page 21 SAFETY 0-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 22 SAFETY 12000-1/12000E-1 0-14 Published 10-02-13, Control #210-03...
Page 23 SAFETY 1. Ensure to read the operators manual before opera- tion / handling, assembly, / disassembly, transpor- tation, inspection / maintenance of the machine. 2. If the free fall speed select switch is in speed in- crease side and the brake is released and the drum may rotate automatically to lowering side even with- out lifting load and wire rope may be paid out to low- er the hook and rough spooling may be caused.
Page 24 SAFETY 5. If the brake pedal lock is not completely engaged, lifting load or hook may be lowered unexpectedly and is very dangerous. When locking the brake pedal, press the brake ped- al fully and confirm that the pedal is locked com- pletely.
Page 25 SAFETY 8. When the boom is assembled, disassembled, boom self erection / self lowering or crane work with the low gantry, the gantry or boom may be damaged and may fall off. Raise the gantry to the proper position for work. 9.
Page 26 SAFETY 12. Wrong handling of battery may cause burns, blind- ness or explosion by inflammation. 13. If accumulator is handled in wrong way, burns, loss of eyesight, explosion may be caused. Take extra care in handling accumulator. (Do not weld, flame cut, dispose or disassemble.) 14.
Page 27 SAFETY 15. Using the engine fuel other than the specified diesel fuel may cause engine failure, fire or explosion. Ensure to use the diesel fuel in the fuel tank. Use ultra low sulfur diesel fuel only. (S50 : sulfur content lower than 50 ppm) 16.
Page 28 SAFETY 19. When working on the upper surface of the guard, person may fall off the upper surface of the guard. During high place work on the upper surface of the guard, do not come close to the guard side face to prevent falling off.
Page 29 SAFETY 22. During engine running or straight after the engine is stopped, inside of the radiator becomes high pres- sure and hot. Person may get burns by hot water blow out when taking off the radiator cap. Take extra care of opening or closing of the radiator cap.
Page 30 SAFETY 25. When working on the engine area for inspection and maintenance, person may be entangled with the fan belt and may get injured if the engine is run- ning. Stop the engine when inspection or maintenance work is done. 26.
Page 31 SAFETY 29. Taking wrong method in using the spreader guide installed on the boom base may damage the spreader guide. Set the spreader guide to the stowing position ex- cept when the upper spreader is connected is con- nected to the boom base. 30.
Page 32 SAFETY 31. Free fall work of load may cause dropping the load by mishandling. Use power lowering of load in the crane work. (Even on neutral free side, power lowering is possi- ble by turning the lever to lowering side.) 32.
Page 33 SAFETY 35. If connection of the hyd. coupler is not tight enough, the strut backstop may be damaged. Ensure to connect the piping coupler firmly. 36. If the strut backstop pin is set in the wrong position, the strut backstop, the boom, the jib or the strut may be damaged and it may cause serious accident.
Page 34 SAFETY 38. Inserting the installation pins of the jib base forcibly or by hitting hard may damage the bushing of the pin hole. Ensure to align the installation pin holes of the jib base and then insert the pins by lightly hitting. 39.
Page 35: Caution Label
SAFETY 41. Inserting the connection pin of the guy cable from outside of the link to inside may cause interference between the connection pin and the hoist rope. This may result in premature wear of the connec- tion pin or falling off of the pin and is very danger- ous.
Page 36: General Safety Precautions
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 37 SAFETY 25. Illegal, unauthorized, or nonconforming modification is strictly prohibited. 26. Do not allow oil or dust to deposit around the engine. Otherwise, fire accident can result. Clean the oil or dust adhered to. 27. Place removed attachments and components safely so that they do not drop or fall down. 28.
Page 38 SAFETY 12000-1/12000E-1 0-30 Published 10-02-13, Control #210-03...
Page 39: Reference Materials
1. REFERENCE MATERIALS 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 40 1. REFERENCE MATERIALS 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 41: 12000-1 Specification
1. REFERENCE MATERIALS 12000-1 SPECIFICATION 1.1.1 OUTER DIMENSION 1. CRANE UNIT : mm (ft-in) 6,090 (20’ ) 1,100 (3’ 7” ) 3,360 (11’ ) 2,990 (9’ 10” ) 1,495 (4’ 11” ) 5,800 (19’ ) 6,770 (22’ 3” ) (3’ 1” ) 3,500 (11’...
Page 42 1. REFERENCE MATERIALS 2. LUFFING JIB UNIT : mm (ft-in) 18,195 (60’) 2,200 (7’ 3”) 1,100 (3’ 7”) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 43 1. REFERENCE MATERIALS 3. LUFFING UPPER BOOM UNIT : mm (ft-in) R4,860 (15’ 11” ) 1,100 (3’ 7” ) 18,195 (60’) 5,800 (19’ ) 6,770 (22’ 3” ) 2,990 (9’ 10” ) (2’ 11” ) 5,300 (17’ 5” ) (CRAWLER EXTENDED) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 44: Crane Specification, Performance
1. REFERENCE MATERIALS 1.1.2 CRANE SPECIFICATION, PERFORMANCE • CRANE Type Full swing, crawler type Max. rated load × work radius 108.9 t × 3.65 m (240,000 lbs × 12 ft) Basic boom 15.2 m (50 ft) Maximum boom 70.1 m (230 ft) Crane jib 9.1 m (30 ft) to 21.3 m (70 ft) Maximum boom and jib...
Page 45: Outside Dimensions
1. REFERENCE MATERIALS OUTSIDE DIMENSIONS Unit : mm (ft-in) Overall width of cab 2,990 (9’ 10”) 4,860 (15’ 11”) Radius of rear end (counterweight) 6,090 (20’) Center of rotation to rear end (Low gantry position) 1,100 (3’ 7”) Center of rotation to boom foot pin (from center of rotation) 2,200 (7’...
Page 46: Crane Working Ranges
1. REFERENCE MATERIALS 1.1.3 CRANE WORKING RANGES 1. CRANE WORKING RANGES Unit : m (ft) 75 (246) 75° 70° 65° 60° 55° 82° 70.1 (230) BOOM 67.1 (220) BOOM 70 (230) 64.0 (210) BOOM 50° 65 (213) 610 (200) BOOM 57.9 (190) BOOM 60 (197) 54.9 (180) BOOM...
Page 47 1. REFERENCE MATERIALS 2. JIB WORKING RANGE (1) Offset angle 10 degrees Unit : m (ft) 80° 10° 61.0 (200) Boom 85 (279) + 21.3 (70) Jib 61.0 (200) Boom + 18.3 (60) Jib 80 (263) 61.0 (200) Boom + 15.2 (50) Jib 61.0 (200) Boom 75 (246) + 12.2 (40) Jib...
Page 48 1. REFERENCE MATERIALS (2) Offset angle 30 degrees Unit : m (ft) 30° 80° 85 (279) 61.0 (200) Boom + 21.3 (70) Jib 61.0 (200) Boom 80 (263) + 18.3 (60) Jib 61.0 (200) Boom + 15.2 (50) Jib 61.0 (200) Boom 75 (246) + 12.2 (40) Jib 61.0 (200) Boom...
Page 49: 12000-1 Dimension, Weight Of Each Component
1. REFERENCE MATERIALS 12000-1 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 15,780 (51’ 9”) •...
Page 50 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) Translifter (705) /1piece 1,480 1,480 (4’ 10”) (4’ 10”) 12000-1/12000E-1 1-12 Published 10-02-13, Control #210-03...
Page 51: Counterweight
1. REFERENCE MATERIALS 1.2.2 COUNTERWEIGHT Weight Name Dimension mm (ft-in) kg (lbs) No.1 11,600 Counterweight (25,600) 4,430 (14’ 6”) 1,450 (2’ 11”) (4’ 9”) No.2, No.3 5,750 Counterweight (R) (12,680) 1,450 (4’ 9”) (2’ 11”) No.2, No.3 5,750 Counterweight (L) (12,680) 1-13 12000-1/12000E-1...
Page 52 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 3,320 Carbody weight (7,319) • With float /1piece 2,080 (6’ 10”) 3,250 Carbody weight (7,165) • Without float /1piece 2,080 (6’ 10”) 1,590 (5’ 3”) 980 (3’ 3”) Self removal unit (1,918) 12000-1/12000E-1 1-14...
Page 53: Crane Attachment
1. REFERENCE MATERIALS 1.2.3 CRANE ATTACHMENT Weight Name Dimension mm (ft-in) kg (lbs) 1,680 8,320 (27’ 4”) (5’ 6”) Boom tip 1,525 (3,360) 1,730 7,790 (25’ 7”) (5’ 8”) Boom base 2,235 (4,927) 1,680 3,160 (10’ 4”) (5’ 6”) 3.0 m Boom insert (840) 1,680...
Page 54 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 6,790 (22’ 3”) (970) Backstop (each) Jib tip (620) (2’ 8”) 5,000 (16’ 5”) Jib base (440) (2’ 8”) 4,810 (15’ 9”) 3,110 (10’ 2”) (2’ 8”) 3.0 m (220) Jib insert (2’...
Page 55 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 1,320 Gantry (2,910) 5,360 (17’ 7”) 1,780 (5’ 10”) (1’) Upper spreader (660) (9”) Lower spreader (440) 910 (2’ 12”) 1-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 56: Luffing Attachment
1. REFERENCE MATERIALS 1.2.4 LUFFING ATTACHMENT Weight Name Dimension mm (ft-in) kg (lbs) 2,615 (8’ 7”) 1,715 (5’ 8”) 1,280 Luffing boom tip (2,830) 1,680 (5’ 6”) 9,260 (30’ 5”) 9.1 m 1,160 Special boom insert (2,558) 6,390 (21’) Front strut (1,202) 5,315 (17’...
Page 57 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 1,170 Jib tip (2,580) 6,910 (22’ 8”) 1,510 (4’ 11”) 1,490 (4’ 11”) Jib base (1,903) 5,970 (19’ 7”) 3.0 m (684) Jib insert 3,165 (10’ 5”) 1,490 (4’ 11”) 6.1 m (1,147) Jib insert...
Page 58 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 1,070 (3’ 6”) 895 (2’ 11”) Auxiliary sheave (838) Section A-A 8,190 (26’ 10”) Luffing boom tip 3,580 assembly (7,895) (With point sheave) Width : 1,715 (5’ 8”) 8,145 (26’ 9”) Luffing boom tip 3,350 assembly...
Page 59: 12000-1 Swing And Propel Stability
1. REFERENCE MATERIALS 12000-1 SWING AND PROPEL STABILITY 1. Without carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler When jacked up Forward Backward extend retract without crawler (Without) 11.6 (25,573) (No abrupt (No.1) lever control) Without attachment (Base machine only) 23.1 (50,925)
Page 60 1. REFERENCE MATERIALS 2. With carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler When jacked up Forward Backward extend retract without crawler (Without) 11.6 (25,573) (No.1) Without attachment (Base machine only) 23.1 (50,925) (Slope:5 deg. (No.1 to No.2) or less) 34.6 (76,277)
Page 61: 12000-1 Propel Allowable Slope Angle
1. REFERENCE MATERIALS 12000-1 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. If the machine has to propel by some reason, observe the following points.
Page 62 1. REFERENCE MATERIALS 1. 12000-1 CRANE PROPEL ALLOWABLE SLOPE ANGLE (1) Without aux. sheave (Unit : Degree) Forward Backward Boom length m (ft) Boom angle Boom angle 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)
Page 63 1. REFERENCE MATERIALS 2. 12000-1 FIXED JIB PROPEL ALLOW SLOPE AN- (Unit : Degree) Jib length m (ft) 9.1 (30) Offset angle Configuration Forward Backward Boom angle Boom angle Boom length m (ft) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150)
Page 64 1. REFERENCE MATERIALS (Unit : Degree) 12.2 (40) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 65 1. REFERENCE MATERIALS (Unit : Degree) Jib length m (ft) 15.2 (50) Offset angle Configuration Forward Backward Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 66 1. REFERENCE MATERIALS (Unit : Degree) 18.3 (60) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 67 1. REFERENCE MATERIALS (Unit : Degree) 21.3 (70) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 68: Luffing Jib Attachment
1. REFERENCE MATERIALS 1.4.2 LUFFING JIB ATTACHMENT 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. If the machine has to propel by some reason, observe the following points.
Page 69 1. REFERENCE MATERIALS 1. 12000-1 LUFFING JIB PROPEL ALLOW SLOPE ANGLE 21.3 (70) Jib length m (ft) 18.3 (60) Jib length m (ft) 25° Jib offset angle 25° Jib offset angle Forward Backward Configuration Forward Backward Configuration Boom angle Boom angle Boom length Boom angle Boom angle...
Page 70 1. REFERENCE MATERIALS 30.5 (100) 33.5 (110) Jib length m (ft) Jib length m (ft) 25° 25° Jib offset angle Jib offset angle Forward Backward Forward Backward Configuration Configuration Boom angle Boom angle Boom angle Boom angle Boom length Boom length m (ft) m (ft) 75°...
Page 71 1. REFERENCE MATERIALS 42.7 (140) 45.7 (150) Jib length m (ft) Jib length m (ft) 25° 25° Jib offset angle Jib offset angle Forward Backward Forward Backward Configuration Configuration Boom angle Boom angle Boom angle Boom angle Boom length Boom length m (ft) m (ft) 75°...
Page 72: 12000E-1 Specification
1. REFERENCE MATERIALS 12000E-1 SPECIFICATION 1.5.1 CRANE OUTER DIMENSION UNIT : mm (ft-in) 6,090 (20’ ) 1,100 (3’ 7” ) 3,360 (11’ ) 2,990 (9’ 10” ) 1,495 (4’ 11” ) 5,800 (19’ ) 6,770 (22’ 3” ) (3’ 1” ) 3,500 (11’...
Page 73: Crane Specification, Performance
1. REFERENCE MATERIALS 1.5.2 CRANE SPECIFICATION, PERFORMANCE Type Full swing, crawler type Max. rated load × work radius 110 t × 3.6 m (242,500 lbs × 11.8 ft) Basic boom 15.2 m (50 ft) Maximum boom 70.1 m (230 ft) Crane jib 9.1 m (30 ft) to 21.3 m (70 ft) Maximum boom and jib...
Page 74: Crane Working Ranges
1. REFERENCE MATERIALS 1.5.3 CRANE WORKING RANGES 1. CRANE WORKING RANGES 12000-1/12000E-1 1-36 Published 10-02-13, Control #210-03...
Page 75 1. REFERENCE MATERIALS 2. JIB WORKING RANGE (1) Offset angle 10 degrees 1-37 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 76 1. REFERENCE MATERIALS (2) Offset angle 30 degrees 12000-1/12000E-1 1-38 Published 10-02-13, Control #210-03...
Page 77: 12000E-1 Dimension, Weight Of Each Component
1. REFERENCE MATERIALS 12000E-1 DIMENSION, WEIGHT OF EACH COMPONENT Dimension and weight of each component when disassembled is shown here. Use this as reference value. 1.6.1 MAIN MACHINERY Weight Name Dimension mm (ft-in) kg (lbs) Base Machine • Boom base 15,780 (51’...
Page 78 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) Translifter (705) /1piece 1,480 1,480 (4’ 10”) (4’ 10”) 12000-1/12000E-1 1-40 Published 10-02-13, Control #210-03...
Page 79: Counterweight
1. REFERENCE MATERIALS 1.6.2 COUNTERWEIGHT Weight Name Dimension mm (ft-in) kg (lbs) No.1 11,600 Counterweight (25,600) 4,430 (14’ 6”) 1,450 (2’ 11”) (4’ 9”) No.2, No.3 5,750 Counterweight (R) (12,680) 1,450 (4’ 9”) (2’ 11”) No.2, No.3 5,750 Counterweight (L) (12,680) 1-41 12000-1/12000E-1...
Page 80 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 3,320 Carbody weight (7,319) • With float /1piece 2,080 (6’ 10”) 3,250 Carbody weight (7,165) • Without float /1piece 2,080 (6’ 10”) 1,590 (5’ 3”) 980 (3’ 3”) Self removal unit (1,918) 12000-1/12000E-1 1-42...
Page 81: Attachment
1. REFERENCE MATERIALS 1.6.3 ATTACHMENT Weight Name Dimension mm (ft-in) kg (lbs) 1,680 (5’ 6”) 8,320 (27’ 4”) Boom tip 1,525 (3,360) 1,730 7,790 (25’ 7”) (5’ 8”) Boom base 2,235 (4,930) 1,680 3,160 (10’ 4”) (5’ 6”) 3.0 m Boom insert (840) 1,680...
Page 82 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 6,790 (22’ 3”) (970) Backstop (each) Jib tip (620) (2’ 8”) 5,000 (16’ 5”) Jib base (440) (2’ 8”) 4,810 (15’ 9”) 3,110 (10’ 2”) (2’ 8”) 3.0 m Jib insert (220) 6,160 (20’...
Page 83 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 1,320 Gantry (2,910) 5,360 (17’ 7”) 1,780 (5’ 10”) (1’) Upper spreader (660) (9”) Lower spreader (440) 910 (2’ 12”) 1-45 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 84 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) (1’ 3”) Ball hook (990) (1’ 4”) (2’ 4”) 35t Hook (1,545) (1’ 3”) (2’ 4”) 70t Hook (1,985) (2’ 4”) (2’ 4”) 1,700 110t Hook (3,750) 12000-1/12000E-1 1-46 Published 10-02-13, Control #210-03...
Page 85: 12000E-1 Swing And Propel Stability
1. REFERENCE MATERIALS 12000E-1 SWING AND PROPEL STABILITY 1. Without carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler When jacked up Forward Backward extend retract without crawler (Without) 11.6 (25,573) (No abrupt (No.1) lever control) Without attachment (Base machine only) 23.1 (50,925)
Page 86 1. REFERENCE MATERIALS 2. With carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler When jacked up Forward Backward extend retract without crawler (Without) 11.6 (25,573) (No.1) Without attachment (Base machine only) 23.1 (50,925) (Slope:5 deg. (No.1 to No.2) or less) 34.6 (76,277)
Page 87: 12000E-1 Propel Allowable Slope Angle
1. REFERENCE MATERIALS 12000E-1 PROPEL ALLOWABLE SLOPE ANGLE 1.8.1 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. If the machine has to propel by some reason, observe the following points.
Page 88 1. REFERENCE MATERIALS 1. 12000E-1 CRANE PROPEL ALLOWABLE SLOPE ANGLE (1) Without aux. sheave (Unit : Degree) Forward Backward Boom length m (ft) Boom angle Boom angle 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)
Page 89 1. REFERENCE MATERIALS 2. 12000E-1 FIXED JIB PROPEL ALLOWABLE SLOPE ANGLE (Unit : Degree) Jib length m (ft) 9.1 (30) Offset angle Configuration Forward Backward Boom angle Boom angle Boom length m (ft) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150)
Page 90 1. REFERENCE MATERIALS (Unit : Degree) 12.2 (40) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 91 1. REFERENCE MATERIALS (Unit : Degree) 15.2 (50) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 92 1. REFERENCE MATERIALS (Unit : Degree) 18.3 (60) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 93 1. REFERENCE MATERIALS (Unit : Degree) 21.3 (70) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 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) 57.9 (190)
Page 94: Engine Main Specification
1. REFERENCE MATERIALS ENGINE MAIN SPECIFICATION 12000-1 : Hino Model J08E-UV diesel engine Engine (complying with the Interim Tier4 & Stage IIIB Emission Regulations) 12000E-1 : Hino Model J08E-UV diesel engine (complying with the Interim Tier4 & Stage IIIB Emission Regulations) 12000-1 : Hino Model J08E-VM diesel engine Configuration of engine...
Page 95: Engine Performance Curve
1. REFERENCE MATERIALS 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 ) 1-57 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 96 1. REFERENCE MATERIALS 12000-1/12000E-1 1-58 Published 10-02-13, Control #210-03...
Page 97: Maintenance Standards Test Procedures
2. MAINTENANCE STANDARDS TEST PROCEDURES 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 98 2. MAINTENANCE STANDARDS TEST PROCEDURES 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 99: Maintenance Standard
2. MAINTENANCE STANDARDS TEST PROCEDURES MAINTENANCE STANDARD 2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE 1. Pin, Bushing d’ D’ Bushing Unit : mm (inch) Std. Usable Name Location Item dimension limit Remedy figure D’ Front/rear 44.0 43.82 Fig.2-1 drum (1.732) (1.725) (P.2-6) Pawl...
Page 100 2. MAINTENANCE STANDARDS TEST PROCEDURES 2. Spring Free length Free length Unit : mm (inch) Std. free Usable limit of 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)
Page 101 2. MAINTENANCE STANDARDS TEST PROCEDURES 3. Sheave Standard root diameter Groove 40 to 45 degrees Radius Unit : mm (inch) Std. root Groove Location Item Remedy diameter limit radius figure 15.5 Boom point (19.449) (19.331) (0.610) 15.5 Idler sheave (21.614) (21.496) (0.610) Fig.2-6...
Page 102 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 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 103 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-3 Boom drum lock assy 109 mm (4.291 inch) Wear Limit : 3 mm (0.118 inch) Fig.2-4 Pawl 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 104 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-5 Brake pedal Fig.2-6 Crane assy 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 105 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-7 Jib assy Fig.2-8 Gantry assy 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 106: Propel Device
2. MAINTENANCE STANDARDS TEST PROCEDURES 2.1.2 PROPEL DEVICE 1. Crawler shoe (1.752) (1.752) (0.906) (5.512) (0.394) (0.630) (0.394) (11.417) Wear limit : 2 mm (0.079 inch) Remedy : Build-up or replace Unit : mm (inch) Unit : mm(inch) Std. dimension Usable limit Remedy 46.6...
Page 107 2. MAINTENANCE STANDARDS TEST PROCEDURES 2. Drive tumbler (0.394) (0.394) 36.5 (1.437) (0.394) (0.630) (0.394) Wear limit : 2 mm (0.079 inch) Remedy : Build-up or replace (5.984) (1.417) (1.575) (0.472) (0.394) (1.5748) (1.181) Hardened area (0.394) (0.394) Wear limit : 2 (0.079) SECTION A - A SECTION C - C...
Page 108 2. MAINTENANCE STANDARDS TEST PROCEDURES 3. Idler Wear limit : 4 mm (0.158 inch) (2.913) Remedy : Build-up or replace (5.906) Unit : mm (inch) Wear limit : 2 mm (0.079 inch) Remedy : Build-up or replace Build-up or Outer diameter 785 (30.906) (30.591) replace...
Page 109 2. MAINTENANCE STANDARDS TEST PROCEDURES 4. Track roller (Lower roller) (17.638) (10.551) (8.345) 76.4 (3.008) (0.394) (0.197) Unit : mm (inch) Unit : mm (inch) Build-up or Outer deameter 288 to 292 (11.339 to 11.496) (11.102) replace Std. Tolerance standard Allowable dimension -0.036...
Page 110 2. MAINTENANCE STANDARDS TEST PROCEDURES 5. Guide roller (Upper roller) (0.197) (0.394) (2.362) (2.362) (3.150) (7.874) Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Outer diameter replace (9.056) (8.740) 12000-1/12000E-1 2-14 Published 10-02-13, Control #210-03...
Page 111 2. MAINTENANCE STANDARDS TEST PROCEDURES 6. Guide bar LEFT SIDE RIGHT SIDE (23.622) (23.622) (23.622) t = 32 mm (1.260 inch) (23.622) (1.496) DETAIL A Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Height of guide bar (2.165)
Page 112 2. MAINTENANCE STANDARDS TEST PROCEDURES 7. Propel brake plate SEPARATOR PLATE FRICTION PLATE Std. dimension Wear limit Name of plate Number Std. brake torque (Total) (Total) Friction plate 21.2 mm 22.7 mm (0.835 inch) 528 to 712 N-m (0.894 inch) Amount of wear : (389 to 525 lbs-ft) Separator plate...
Page 113: Performance Standard And Test Procedure
2. MAINTENANCE STANDARDS TEST PROCEDURES PERFORMANCE STANDARD AND TEST PROCEDURE 1. TERMINOLOGY Standard value : Standard of assembling new ma- chine. When the value exceeds the standard, repair or re- place the part as required to maintain machine per- formance and or safety. Temperature of oil : It means temperature of hy- draulic oil.
Page 114: Operating Speed
2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.1 OPERATING SPEED t i d Mode : Power mode Measure the time taken to Boom Engine min : High idling rotate drum 10 times. hoist Temperature of oil : 45 to 55°C (Start measuring after rotation 17.9 to 21.1 sec rope (113 to 131°F)
Page 115: Point And Method Of Measuring Pressure
2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.2 POINT AND METHOD OF MEASURING PRESSURE Use a pressure gauge which has a surplus of more than 10 MPa for pressures to be measured and which has passed the inspection. Prior to pressure measurement, clean the port for pres- sure measurement so as to be free from oil and dust.
Page 116 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 2 Main • Engine speed : High idling 1. Lower the front drum hook onto the 31.9 MPa ground. (4,627 psi) • Propel left • Temperature of oil : 45 to 55°...
Page 117 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 4 Swing • Engine speed : High idling 1. Lock the upper not to turn with the 27.5 MPa swing lock pin and parking brake. (3,989 psi) • Temperature of oil : 45 to 55°...
Page 118 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 5 Control • Temperature of oil : Remove the cap of plug installed in Relief valve : Circuit 45 to 55° C (113 to 131° F) valve block, and instal the pressure 7.0 MPa (Primary gauge.
Page 119 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 7 Gantry • Engine speed : High idling 1. Raise the gantry high, and fix it with Port relief set raising/ the gantry fixing pin. Raise : 20.6 MPa •...
Page 120: Slewing Ring
2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.3 SLEWING RING UPPER FRAME WITHIN 100 mm (3.937 inch) Measuring point. Front center or rear center of the upper frame. DIAL GAUGE LOWER FRAME Measuring point. Front center or rear center of the lower frame. COUNTERWEIGHT : FULL Condition of measurement Amount of play...
Page 121: General Work Standard
3. GENERAL WORK STANDARD 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 122 3. GENERAL WORK STANDARD 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 123: Tightening Torque Of Cap Screws And Nuts
3. GENERAL WORK STANDARD TIGHTENING TORQUE OF CAP SCREWS AND NUTS 3.1.1 STANDARD TIGHTENING TORQUE Unless otherwise specified, torque all screws and nuts on this machine to the values shown in the following tables. METRIC COARSE THREADS (PLATED) Classification Nominal size Tightening torque N-m (ft-lbs) Tightening torque N-m (ft-lbs)
Page 124 3. GENERAL WORK STANDARD METRIC FINE THREADS (PLATED) Classification Nominal size Tightening torque N-m (ft-lbs) Tightening torque N-m (ft-lbs) Lubricated Lubricated 11.6 to 14.2 9.8 to 12 25.6 to 31.2 21.1 to 25.9 (8.6 to 10.4) (7.2 to 8.8) (18.8 to 23) (15.6 to 19) 22.9 to 28.1 19.4 to 23.8...
Page 125 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) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 126: Tightening Torque Of Hydraulic Fittings
3. GENERAL WORK STANDARD 3.1.2 TIGHTENING TORQUE OF HYDRAULIC FITTINGS Excessive or insufficient tightening of hose or tube fittings can cause oil leak and deformation or damage to the metal fittings. Therefore, to secure and obtain good fixing and performance of fittings it is necessary to tighten to the proper torque. The follows are the recommended torques.
Page 127 3. GENERAL WORK STANDARD (4) Jubilee Clip (Low Pressure and Suction) Nominal Diameter Recommended torque Working pressure range cord BS5315 inches ft-lbs kg/cm 3/8" - 1/2" 9.5 - 12 56.0 1/2" - 5/8" 11 - 16 56.0 1/2" - 3/4" 13 - 20 56.0 5/8"...
Page 128: Standard Parts
3. GENERAL WORK STANDARD STANDARD PARTS 3.2.1 BOLT Size and kind of bolt can be identified as shown below. This part indicates the nominal bolt length. (L) This part indicates the nominal size of bolt. (D) C indicates coarse thread. F indicates fine thread.
Page 129: O-Ring
3. GENERAL WORK STANDARD 3.2.2 O-RING Size and kind of O-Ring are identified as shown below. INNER DIAMETER It indicate inner dia. (mm) This part indicate the thickness of the O-ring. P is for dynamic purpose. G is for stationary purpose. It indicates the type of rubber.
Page 130: Back-Up Ring
3. GENERAL WORK STANDARD 3.2.3 BACK-UP RING Size and kind of back-up ring are identified as shown below. This part indicates the inner diameter (mm) of the back-up rings. This part indicates the width of the back-up rings. This part indicates the shape of the back-up rings.
Page 131: Bite Type Fitting
3. GENERAL WORK STANDARD 3.2.4 BITE TYPE FITTING PLUG for tube Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF83H10000 ZA82P10000 ZF83H15000 ZA82P15000 ZF83H18000 ZA82P18000 ZF83H22000 ZA82P22000 — ZA82P28000 — ZA82P35000 PLUG for connector Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC...
Page 132 3. GENERAL WORK STANDARD Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF93N10000 ZA93N10000 ZF93N15000 ZA93N15000 ZF93N18000 ZA93N18000 ZF93N22000 ZA93N22000 — ZA93N28000 ZF93N35000 ZA93N35000 SLEEVE Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA)
Page 133: Conversion Table
3. GENERAL WORK STANDARD CONVERSION TABLE 3.3.1 UNIT CONVERSION [Remarks] Figures in ( ) show number of zero down a decimal point Example : 0.(2)1 = 0.001 1. Length Unit mile 0.001 0.000001 0.03937 0.0032808 0.0010936 0.(6)6214 0.01 0.00001 0.3937 0.032808 0.010936 0.(5)6214...
Page 134: Millimeter : Inch Conversion Table
3. GENERAL WORK STANDARD 3.3.2 MILLIMETER : INCH CONVERSION TABLE 1. mm (Millimeter)  in (Inch) 1 mm to 99 mm 0.0000 0.0394 0.0787 0.1181 0.1575 0.1969 0.2362 0.2756 0.3150 0.3543 0.3937 0.4331 0.4724 0.5118 0.5512 0.5906 0.6299 0.6693 0.7087 0.7480 0.7874 0.8268...
Page 135 3. GENERAL WORK STANDARD 2. in (Inch)  mm (Millimeter) 0.000 25.400 50.800 76.200 101.600 127.000 152.400 177.800 203.200 228.600 1/64 0.397 25.797 51.197 76.597 101.997 127.397 152.797 178.197 203.597 228.997 1/32 0.794 26.194 51.594 76.994 102.394 127.794 153.194 178.594 203.994 229.394 1/16 1.588 26.988...
Page 136: Meter And Foot Conversion Table
3. GENERAL WORK STANDARD 3.3.3 METER AND FOOT CONVERSION TABLE Foot Meter Foot Meter Foot Meter 1.52 53.34 105.12 3.05 54.86 106.68 4.57 56.39 108.20 6.10 57.91 109.73 7.62 59.44 111.25 9.14 60.96 112.78 10.67 62.48 114.30 12.19 64.01 115.82 13.72 65.53 117.35...
Page 137: Grade Conversion Table
3. GENERAL WORK STANDARD 3.3.4 GRADE CONVERSION TABLE Degree (°) Degree (°) Degree (°) 28.7 60.1 30.6 62.5 32.5 64.9 34.4 67.5 36.4 70.0 10.5 38.4 72.7 12.3 40.4 75.4 14.1 42.5 78.1 15.8 44.5 81.0 17.6 46.6 83.9 19.4 48.8 86.9 21.3...
Page 138: System International (Si) Unit Conversion Table
3. GENERAL WORK STANDARD 3.3.6 SYSTEM INTERNATIONAL (SI) UNIT CONVERSION TABLE International System of Units (SI : System International Unit) Conversion Formula CGS unit system to SI unit system Unit Types Meaning symbols Mass Kilogram Mass (kg) = Weight (kgf) F = gravity Newton 1 (N) = 1 (kg) ×...
Page 139: Power Train
4. POWER TRAIN 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 140 4. POWER TRAIN 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 141: Introduction
4. POWER TRAIN INTRODUCTION This crane is a full hydraulic crawler crane. The engine drives one set of the 2 section plunger type main pump and one plunger type swing pump and 2 section gear pump connected to the power divider and 2 section gear pump connected to swing pump through the pow- er divider.
Page 142 4. POWER TRAIN FUEL TANK FRONT DRUM HYD. OIL TANK FRONT DRUM MOTOR AND REDUCTION UNIT REAR DRUM POWER DIVIDOR REAR DRUM MOTOR AND REDUCTION UNIT ENGINE DIESEL PARTICULATE FILTER RADIATOR & OIL COOLER SEPARATE OIL COOLER AIR CLEANER BOOM DRUM MOTOR BOOM DRUM BOOM DRUM REDUCTION UNIT...
Page 143 4. POWER TRAIN MAIN CONTROL VALVE MAIN CONTROL VALVE GEAR PUMP MAIN PUMP (CONTROL & AUX. UNIT) POWER DIVIDER (SWING & BOOM HOIST) GEAR PUMP MAIN PUMP (COOLING) (HOIST & PROPEL) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 144 4. POWER TRAIN DRIVE TUMBLER PROPEL MOTOR PROPEL REDUCTION UNIT SWING BEARING CRAWLER EXT/RET CYLINDER SWING RING GEAR SWIVEL JOINT 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 145: Engine
4. POWER TRAIN ENGINE 4.2.1 INTRODUCTION This chapter explains how to remove and re-install the engine. Refer to the manual provided by the engine manufac- turer for maintenance and repair details. 4.2.2 REMOVAL Proceed as follows when removing the engine from the machine.
Page 146 4. POWER TRAIN 1. Lower the boom on the ground and secure the up- per spreader to the boom base with pins. Set the gantry to the propel configuration. AIR INLET HOSE 2. Take out the ground cable first in the battery. COVER OF DIESEL 3.
Page 147: Lifting Hook
4. POWER TRAIN 13. Install the appropriate capacity of lifting gear to the engine. (The engine has three lifting hooks.) 14. Remove the bolts and washers from the rubber mounts on the engine and the power divider. 15. Lift up the engine and pump drive assy. as one unit slowly and take out from the machine.
Page 148: Repair And Maintenance
4. POWER TRAIN 4.2.3 REPAIR AND MAINTENANCE Regarding the repair and maintenance of the engine, refer to the manual provided by the manufacturer. The engine manufacturer : HINO MOTORS, LTD. The engine model : J08E-UV 4.2.4 INSTALLATION Proceed as follows when installing the engine. 1.
Page 149 4. POWER TRAIN 9. Install the air inter cooler hose that were removed when the engine was removed. Install the exhaust tube and the diesel particulate filter cover. 10. Install all the hydraulic hoses to the hydraulic pumps. 11. Refill the engine with coolant water and engine oil to the required levels.
Page 150 4. POWER TRAIN Tightening torque 109 to 133 N-m (81 to 98 lbs-ft) (Apply LOCTITE #271) Tightening torque 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)
Page 151: Pump Drive Assembly
4. POWER TRAIN PUMP DRIVE ASSEMBLY 4.3.1 INTRODUCTION This chapter explains how to remove, inspect, repair and re-install the pump drive assembly. The pump drive assembly is mounted directly onto the front of the engine. It consists of a coupling, a power di- vider, main pumps, and 2 section gear pumps for con- trol and gantry hoist (aux.
Page 152: Removal
4. POWER TRAIN 4.3.2 REMOVAL Proceed as follows when removing the pump drive as- sembly. (See next page) Pump drive assembly should be removed from the en- gine according to the following procedure only after the engine has been removed from the machine as de- scribed in Section 4.2.
Page 153 4. POWER TRAIN LIFTING SCREW HOLE (M16) AIR BREATHER CONTROL PUMP STAND GANTRY HOIST PUMP (POWER DIVIDER SIDE) BOOM PUMP (AUX. DEVICE) SWING PUMP STAND (ENGINE SIDE) ADAPTER PLATE (ENGINE SIDE) NAME PLATE OIL FILL PORT COUPLING OIL LEVEL GAUGE MAIN PUMP FRONT / REAR DRUM COOLING PUMP (FRANGE WHEN “FREE LESS”...
Page 154 4. POWER TRAIN POWER DIVIDER ASSY STAND (POWER DEVIDER SIDE) STAND (ENGINE SIDE) 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) 12000-1/12000E-1...
Page 155: Disassembling The Power Divider
4. POWER TRAIN 4.3.3 DISASSEMBLING THE POWER DIVIDER Proceed as follows when disassembling the power di- vider. (Refer to P.4-23 to 4-26 for corresponding num- bers in the explanation below.) 1. Place the power divider on the block facing the fly- wheel side up.
Page 156 4. POWER TRAIN 14. Remove the cap screws (33) and remove the sup- port (46) using two pull out screw holes (M10) of the support (46). If required, remove the screws (34) and the plate (48). 15. Remove the gear (44) and both side bearings (21), (24).
Page 157: Check And Repair Of The Power Divider
4. POWER TRAIN 4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER Check all parts prior to reassembling the power divider. All questionable parts should be replaced to maximize the re-assembled power divider’s service life and to avoid further break downs. Checking should proceed in the following order.
Page 158: Assembling The Power Divider
4. POWER TRAIN 4.3.5 ASSEMBLING THE POWER DIVIDER Assembling the power diver is in reverse order of disas- sembling. Take extra care on the following points in as- sembling. (Refer to P.4-23 to 4-26 for corresponding numbers in the explanation below.) 1.
Page 159: Re-Installation
4. POWER TRAIN 4.3.6 RE-INSTALLATION Assemble the pump drive assy. as follows. (Refer to P.4-27 for corresponding numbers in the ex- planation below.) 1. Apply grease on the spline area of the input shaft (1) and insert the clamping hub (2) to 65 mm point from the shaft end as shown in P.4-27 (the clamping hub touches lightly on spline step area).
Page 160 4. POWER TRAIN 6. Attach the appropriate capacity lifting gear to the power divider and insert the coupling side element of the power divider to the wheel side insert. Install the power divider to the stand (engine side) which is installed on the flange wheel housing. 7.
Page 161 4. POWER TRAIN Note on “S” clearance control 39 Tighten lightly. Tightening torque (See P.4-26) and phase angle. Do not use seal tape etc. 88.2 to 107.8 N-m (65.1 to 79.5 lbs-ft) Apply LOCTITE #515 evenly Apply LOCTITE #577 on mating surface with “HOUSING” item 1. Install with two face cut area on Do not use seal tape upper and random direction.
Page 162 4. POWER TRAIN Tightening torque 1.17 to 1.43 N-m (0.9 to 1.0 lbs-ft) Apply LOCTITE #242 Tightening torque 1.17 to 1.43 N-m 18, 34 (0.9 to 1.0 lbs-ft) (Note 1) Apply LOCTITE #242 Apply LOCTITE #515 evenly on mating surface of item 1 “HOUSING”...
Page 163 4. POWER TRAIN (Note 1) Note on installation phase angle. Bearing fill in port of item 2 “STAND” should be on upper side. Bearing fill in port Bearing fill in port Tightening torque Tightening torque 31.5 to 38.5 N-m 31.5 to 38.5 N-m (23.3 to 28.3 lbs) (23.3 to 28.3 lbs) Apply LOCTITE #242...
Page 164 4. POWER TRAIN 1. HOUSING 21. BEARING 36. 90 DEGREES ELBOW 2. STAND 22. ROLLER BEARING 37. TUBE 3. SHAFT 23. BALL BEARING 38. CAP 4. GEAR 24. BALL BEARING 39. PLUG 5. GEAR 25. BALL BEARING 40. SHIM 7. GEAR 26.
Page 165: Spring Pin
4. POWER TRAIN M10 X 1.25 (Fine) Tightening torque 36.4 to 44.6 N-m (26.9 to 32.8 lbs-ft) Apply LOCTITE #242 (See item 7 in P.4-23) Tightening torque 440 to 490 N-m (324.6 to 361.5 lbs-ft) (See item 5 in P.4-23) Tightening torque 200 to 220 N-m (147.6 to 162.2 lbs-ft)
Page 166 4. POWER TRAIN 12000-1/12000E-1 4-28 Published 10-02-13, Control #210-03...
Page 167: Hydraulic System
5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 168 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 169: Location Of Main Hydraulic Components
5. HYDRAULIC SYSTEM 5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS SWING BEARING SWING MOTOR SWING REDUCTION UNIT SWING CONTROL VALVE CONTROL VALVE SWING GEAR REDUCTION UNIT HYDRAULIC OIL TANK CRAWLER EXT./RET. FRONT DRUM MOTOR CYLINDER GEAR PUMP CONTROL VALVE MAIN PUMP CONTROL VALVE GEAR PUMP REAR DRUM MOTOR...
Page 170 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 171 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 172 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 173 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 174 5. HYDRAULIC SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 175: Hydraulic Circuits And Components
5. HYDRAULIC SYSTEM HYDRAULIC CIRCUITS AND COMPONENTS 5.2.1 COMPONENT SPECIFICATIONS 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 176 5. HYDRAULIC SYSTEM 12000-1/12000E-1 5-10 Published 10-02-13, Control #210-03...
Page 177 5. HYDRAULIC SYSTEM 5-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 178 5. HYDRAULIC SYSTEM 12000-1/12000E-1 5-12 Published 10-02-13, Control #210-03...
Page 179 5. HYDRAULIC SYSTEM 5-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 180: Layout Of Hydraulic Components
5. HYDRAULIC SYSTEM 5.2.2 LAYOUT OF HYDRAULIC COMPONENTS 1. UPPER MACHINERY 80. PRESSURE SENSOR (SWING) 46. REMOTE CONTROL VALVE (SWING) 50. REMOTE CONTROL VALVE (THIRD) 12. MOTOR (SWING) 20. SWING CONTROL VALVE 87. PROP. VALVE 59. SWIVEL JOINT 30. VALVE BLOCK (PROPEL SPEED, SWING PRESSURE) REDUCTION UNIT...
Page 181 5. HYDRAULIC SYSTEM 32. VALVE BLOCK 49. REMOTE CONTROL VALVE (2-SECTION) (BOOM HOIST PEDAL) 30. VALVE BLOCK (2-SECTION) (REMO-CON PRESS.SOURCE CUT ETC) 76. ACCUMULATOR 82. PRESSURE SWITCH 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) 79. PRESSURE SENSOR (REMO-CON PRESS. DETECT) FLOOR PLATE (VIEW FROM CAB LOWER FACE) PROPEL CONTROL LEVER...
Page 182 5. HYDRAULIC SYSTEM 27.VALVE BLOCK (8-SECTION) (AUTOMATIC STOP & SPEED CONTROL) 79. PRESSURE SENSOR (PIPING UNDER SOLENOID) 41. SOLENOID VALVE (OPTION) 42. SOLENOID VALVE (OPTION) 44. CHECK VALVE 28. VALVE BLOCK (5-SECTION, LIMIT STOP) 29.VALVE BLOCK (4-SECTION) LEFT DECK FUEL TANK FRONT (MOTOR BRAKE) 12000-1/12000E-1 5-16...
Page 183 5. HYDRAULIC SYSTEM 43. INDEPENDENT, CONFLUENCE SELECT 40. PILOT PRESSURE CHANGE-OVER VALVE 39. PILOT CHANGE-OVER VALVE 5-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 184: Valve Block
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 12000-1/12000E-1 5-18 Published 10-02-13, Control #210-03...
Page 185 5. HYDRAULIC SYSTEM 32. VALVE BLOCK 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) POWER DIVIDER REAR 5-19 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 186 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) 12000-1/12000E-1 5-20 Published 10-02-13, Control #210-03...
Page 187 5. HYDRAULIC SYSTEM HYD. OIL TANK FRONT WINCH REAR WINCH 86. HYD. OIL TEMPERATURE SWITCH (FOR HYD. OIL HEAT) 36. VALVE BLOCK (FOR HYD. OIL HEAT) 5-21 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 188: Hydraulic Oil Tank
5. HYDRAULIC SYSTEM 3. HYDRAULIC OIL TANK 73. BYPASS CHECK VALVE 67. RETURN FILTER 66. SUCTION STRAINER SECTION B-B SECTION A-A 69. DRAIN FILTER 68. RETURN FILTER (WET TYPE CLUTCH) 60. RELIEF VALVE /REDUCING VALVE (CONTROL) 35. VALVE BLOCK 70. LINE FILTER (CONTROL) 84.
Page 189 5. HYDRAULIC SYSTEM 4. GANTRY 9. CYLINDER (GANTRY HOIST) 9. CYLINDER (GANTRY HOIST) 57. SWIVEL JOINT 22. CONTROL VALVE (GANTRY) 5-23 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 190: Winch Motor
5. HYDRAULIC SYSTEM 5. WINCH MOTOR 8. MOTOR (FRONT & REAR DRUM) 8. MOTOR (THIRD DRUM) 10. MOTOR (BOOM) 65. SLOW RETURN CHECK VALVE (FOR MOTOR BRAKE) 6. LEFT DECK 17. CONTROL VALVE (PROPEL L. H. , MAIN1, AUX.2) 16. CONTROL VALVE (PROPEL R. H., MAIN2, AUX.1) CONTROL VALVE (THIRD DRUM) 12000-1/12000E-1 5-24...
Page 191 5. HYDRAULIC SYSTEM 7. HYDRAULIC OIL PUMP 3. BOOM, SWING PUMP 4. GEAR PUMP 5. GEAR PUMP 1. MAIN PUMP 5-25 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 192 5. HYDRAULIC SYSTEM 8. LOWER MACHINERY SWING BEARING 23. CONTROL VALVE (TRANSLIFTER /CRAWLER EXT.) 52. CYLINDER (CRAWLER EXT. /RET.) 59. SWIVEL JOINT SWING GEAR PROPEL REDUCTION UNIT 51. CYLINDER (TRANSLIFTER) 13. MOTOR (PROPEL) 12000-1/12000E-1 5-26 Published 10-02-13, Control #210-03...
Page 193: Hydraulic System
5. HYDRAULIC SYSTEM HYDRAULIC SYSTEM 5.3.1 PREFACE This chapter provides a general outline of the overall hydraulic system. 5.3.2 OUTLINE The pressurized oil in this circuit is supplied by the 4 variable displacement pumps driven with the power di- vider directly connected to the engine and 2 section gear pumps connected to power divider.
Page 194: Oil Flow From No.1-1, No.1-2
5. HYDRAULIC SYSTEM 5.3.3 OIL FLOW FROM No.1-1, No.1-2 No.1-1 and No.1-2 pumps are main pumps and are tan- dem connected variable displacement double pumps. At neutral, pressurized oil from No.1-1 pump flows into 3 section side control valve circuit (front / rear drum / right propel) At the same time, pressurized oil from No.1-2 pump flows into 3 section side control valve cir- cuit (front / rear drum / left propel) and passes through...
Page 195 5. HYDRAULIC SYSTEM OIL FLOW FROM No.1-1, No.1-2 REAR DRUM FRONT DRUM PROPEL (R.H.) PROPEL (L.H.) SWIVEL JOINT No.1-1 No.1-2 BOOM HOIST SWING No.3-1 No.3-2 CONTROL / AUX. OIL COOLER No.4-1 No.4-2 DRUM BRAKE COOLING No.5-1 No.5-2 RETURN FILTER SUCTION STRAINER 5-29 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 196 5. HYDRAULIC SYSTEM 5.3.4 OIL FLOW FROM No.3-1, 3-2 PUMP No.3-1 pump are main pumps and are tandem connect- ed variable displacement double pumps. At neutral, pressurized oil from No.3-1 pump flows into boom control valve and passes through control valve and return to the oil tank without load.
Page 197: Oil Flow From No.3-1, 3-2 Pump
5. HYDRAULIC SYSTEM OIL FLOW FROM No.3-1, 3-2 PUMP SWING BOOM HOIST MAIN CONTROL VALVE CONTROL VALVE No.1-1 No.1-2 No.3-1 No.3-2 CONTROL / AUX. OIL COOLER No.4-1 No.4-2 DRUM BRAKE COOLING No.5-1 No.5-2 RETURN FILTER SUCTION STRAINER 5-31 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 198 5. HYDRAULIC SYSTEM 5.3.5 OIL FLOW FROM No.4-1 PUMP No.4-1 pump is gear pump and is used for control. Pressurized oil from the pump passes through the line filter and is pressure-reduced to 5.4 MPa and flows into the accumulator and then flows into 2 4-section valve and 2 2-section valve and the foot brake valve.
Page 199 5. HYDRAULIC SYSTEM OIL FLOW FROM No.4-1 PUMP (WHEN FUNCTION LOCK LEVER IS IN "LOCK" POSITION) REAR DRUM FRONT DRUM No.1-1 No.1-2 BOOM HOIST SWING ACCUMULATOR No.3-1 No.3-2 OIL COOLER PRESS. REDUSE VALVE LINE FILTER RELIEF VALVE GANTRY/ COUNTERWEIGHT No.4-1 No.4-2 DRUM BRAKE COOLING No.5-1...
Page 200 5. HYDRAULIC SYSTEM 2. WHEN FUNCTION LOCK LEVER IS IN "WORK" POSITION When the function lock lever is in "WORK" position, pressurized oil sent to 2-section valve passes through the function lock (Remo-con cut) solenoid valve (SOL-3) and flows into the remote control valve.
Page 201: Oil Flow From No.4-1 Pump
5. HYDRAULIC SYSTEM OIL FLOW FROM No.4-1 PUMP (WHEN FUNCTION LOCK LEVER IS IN "WORK" POSITION REAR DRUM FRONT DRUM No.1-1 No.1-2 BOOM HOIST SWING ACCUMULATOR No.3-1 No.3-2 OIL COOLER PRESS. REDUSE VALVE LINE FILTER RELIEF VALVE GANTRY/ COUNTERWEIGHT No.4-1 No.4-2 DRUM BRAKE COOLING No.5-1...
Page 202: Oil Flow From No.4-2 Pump
5. HYDRAULIC SYSTEM 5.3.6 OIL FLOW FROM No.4-2 PUMP 1. CRAWLER EXTENDING CYLINDER No.4-2 pump (Aux. device pump) is fixed displace- ment gear pump and is used for crawler extending cylinder. When the lower pressure source valve located in the downstream side of the gantry hoist control valve is operated, the pressurized oil from the pump passes through the swivel joint and flows into the crawler extending valve.
Page 203 5. HYDRAULIC SYSTEM OIL FLOW FROM No.4-2 PUMP • GANTRY HOIST CYLINDER • TRANSLIFTER • CRAWLER EXT./RET. • COUNTERWEIGHT SELF REMOVAL CYLINDER TRANSLIFTER (RIGHT SIDE) TRANSLIFTER (LEFT SIDE) CRAWLER CYLINDER COUNTERWEIGHT SELF REMOVAL CYLINDER GANTRY CYLINDER SWIVEL JOINT MAIN CONTROL VALVE No.1-1 No.1-2 BOOM HOIST...
Page 204 5. HYDRAULIC SYSTEM 5.3.7 OIL FLOW FROM No.5-1, 5-2 PUMP (CONTROL/AUX.ACTUATOR) No.5-1 and No.5-2 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.
Page 205: Oil Flow From No.5-1, 5-2 Pump (Control/Aux.actuator)
5. HYDRAULIC SYSTEM OIL FLOW FROM No.5-1, 5-2 PUMP (CONTROL/AUX.ACTUATOR) REAR DRUM FRONT DRUM No.1-1 No.1-2 BOOM HOIST SWING No.3-1 No.3-2 CONTROL / AUX. OIL COOLER No.4-1 No.4-2 No.5-1 No.5-2 RETURN FILTER SUCTION STRAINER 5-39 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 206: 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 12000-1/12000E-1 5-40 Published 10-02-13, Control #210-03...
Page 207 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 5-41 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 208 5. HYDRAULIC SYSTEM 4-SECTION VALVE REAR DRUM FREE FALL SPEED FROM FRONT DRUM FOOT BRAKE ACCELERATION FRONT DRUM FREE FALL SPEED ACCELERATION FROM REAR DRUM FOOT BRAKE FRONT DRUM FREE FALL SPEED REAR DRUM FREE FALL SPEED ACCELERATION ACCELERATION FROM FRONT DRUM FOOT BRAKE FROM REAR DRUM FOOT BRAKE 12000-1/12000E-1 5-42...
Page 209 5. HYDRAULIC SYSTEM 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 5-43 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 210 5. HYDRAULIC SYSTEM 5-SECTION VALVE TO TANK FRONT DRUM RAISE REAR DRUM RAISE BOOM DRUM RAISE BOOM DRUM LOWER 12000-1/12000E-1 5-44 Published 10-02-13, Control #210-03...
Page 211 5. HYDRAULIC SYSTEM 2-SECTION VALVE 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) 5-45 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 212 5. HYDRAULIC SYSTEM 1-SECTION VALVE TO SWING REMO-CON VALVE (SWING COUNTERFORCE) TO SWING REMO-CON VALVE (SWING COUNTERFORCE) 12000-1/12000E-1 5-46 Published 10-02-13, Control #210-03...
Page 213 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (3-SECTION) REAR 1ST SP. RAISE FRONT 2ND SP. RAISE RAIGHT PROPEL (FORWARD) RAIGHT PROPEL REAR 1ST SP. LOWER FRONT 2ND SP. LOWER (FORWARD) RIGHT PROPEL REAR 1ST SP. RAISE FRONT 2ND SP. RAISE (BACKWARD) RIGHT PROPEL FRONT 2ND DP.
Page 214 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (3-SECTION) REAR 2ND SP. RAISE FRONT 1ST SP. RAISE LEFT PROPEL (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.
Page 215 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (THIRD 1-SECTION) THIRD RAISE THIRD LOWER 5-49 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 216 5. HYDRAULIC SYSTEM PILOT CHANGE-OVER VALVE TO CONTROL VALVE TO CONTROL VALVE (PDM2) (PDA2) TO DR FROM 4-SECTION VALVE FROM 4-SECTION VALVE (PDM) (PDA) FROM 4-SECTION VALVE FROM 4-SECTION VALVE (PUM) (PUA) TO CONTROL VALVE TO CONTROL VALVE (PUA2) (PUM2) FROM 3-SECTION VALVE FROM 3-SECTION VALVE (REAR)
Page 217 5. HYDRAULIC SYSTEM PILOT PRESSURE CHANGE-OVER VALVE FROM 8-SECTION VALVE (PDA) FROM 5-SECTION VALVE (PUA) FROM 3-SECTION VALVE (REAR) TO CONTROL VALVE (PDA1) TO CONTROL VALVE (PUA1) TO CONTROL VALVE (PDM1) FROM 3-SECTION TO CONTROL VALVE VALVE (FRONT) (PUM1) FROM 5-SECTION VALVE FROM 8-SECTION VALVE (PUM) (PDM)
Page 218 5. HYDRAULIC SYSTEM 3-SECTION VALVE TO PILOT CHANGE-OVER VALVE (FRONT) TO PILOT CHANGE-OVER VALVE (REAR) FROM PRESSURE SOURCE BLOCK TO DR TO PILOT PRESSURE CHANGE-OVER VALVE (FRONT) TO PILOT PRESSURE CHANGE-OVER VALVE (REAR) TO WINCH MOTOR (FRONT, REAR) 12000-1/12000E-1 5-52 Published 10-02-13, Control #210-03...
Page 219: Hoist System
6. HOIST SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 220 6. HOIST SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 221: Apparatus And Location Of Components
6. HOIST SYSTEM APPARATUS AND LOCATION OF COMPONENTS The hoist system consists of the front drum and rear drum assembly. Each drum assy. consists of hoist motor (brake built in), reduction unit, drum clutch (common to free fall brake) and drum lock. The pressured oil delivered from 2 main pumps (No.1, No.2) is controlled by the control valve and flaws into each motor.
Page 222: Hydraulic Pump
6. HOIST SYSTEM HYDRAULIC PUMP WINCH FRONT DRUM MOTOR FRONT DRUM GEAR PUMP SWING PUMP (CONTROL, AUX.) REDUCTION UNIT POWER DIVIDER GEAR PUMP MAIN PUMP (COOLING) (HOIST / PROPEL) REAR DRUM REAR DRUM MOTOR DRUM LOCK FRONT DRUM LOCK KNOB REAR DRUM LOCK KNOB Refer to P.6-17 to 6-49 for circuit diagram and function.
Page 223: Adjustment Of Drum Lock
6. HOIST SYSTEM ADJUSTMENT OF DRUM LOCK Do not adjust the drums locks until the boom, hook block, and load have been lowered to the ground. Failure to observe this precaution may result in se- rious injury or loss of life. 1.
Page 224: Winch
6. HOIST SYSTEM WINCH 6.3.1 WINCH INSTALLATION Tightening torque 333 to 407 N-m 53 mm (246 to 300 lbs-ft) Stick out the rope end. (2.1 inch) But not exceeding flange O.D. DRUM FLANGE O.D. CLAMP CLAMPING PROCEDURE OF ROPE END MACHINE FRONT Install pin after Install pin after...
Page 225 6. HOIST SYSTEM Install pin after Install pin after applying grease. applying grease. Tightening torque Tightening torque 35.1 to 42.9 N-m 35.1 to 42.9 N-m (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...
Page 226: Winch Assembly
6. HOIST SYSTEM 6.3.2 WINCH ASSEMBLY CLUTCH REDUCTION UNIT (FREE FALL BRAKE) PLUG BREATHERS (Install before motor installation.) Tightening torque Tightening torque 39 to 49 N-m 88.2 to 107.8 N-m (28.8 to 36.1 lbs-ft) (65.1 to 79.5 lbs-ft) Apply LOCTITE #577 Apply LOCTITE #577 TUBE FOR WINCH...
Page 227 6. HOIST SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 228: Reduction Unit Assembly
6. HOIST SYSTEM 6.3.3 REDUCTION UNIT ASSEMBLY Apply three bond #1215 evenly on outer periphery area and apply grease lightly on lip area and assemble. Oil seal is to be hit with hammer etc. Clearance adjustment with shim item 32 (shim) to 0.3 to 1.0 mm (0.0118 to 0.0394 inch).
Page 229 6. HOIST SYSTEM 1. Carrier 12. Oil seal 23. Snap ring 2. Gear ring 13. Sleeve 24. Snap ring 3. Retainer 14. Sleeve 25. Bearing 4. Sun gear 15. Bearing 26. Spring pin 5. Support housing 16. Spacer 27. Thrust washer 6.
Page 230: 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 12000-1/12000E-1 6-12 Published 10-02-13, Control #210-03...
Page 231: Machine Front
6. HOIST SYSTEM MACHINE FRONT SECTION F-F SECTION G-G 1. Bracket 20. Spacer 39. Pedal 2. Lever assembly 21. Bolt 40. Brake valve 3. Link 22. Spacer 41. Sems bolt 4. Pedal 23. Shim (0.4) 42. Capscrew 5. Pawl 24. Shim (0.6) 43.
Page 232: Adjusting The Brake Pedal
6. HOIST SYSTEM 6.4.2 ADJUSTING THE BRAKE PEDAL EYE BOLT ADJUSTING STROKE : 15 mm (0.6 inch) 112 mm (4.41 inch) Adjustment 1. Adjust the eye bolt until the dimension S is 53 mm (2.09 inch). 2. Depress the brake pedal until the valve spool reaches the stroke end.
Page 233: Bleeding Air From Brake Circuit
6. HOIST SYSTEM BLEEDING AIR FROM BRAKE CIRCUIT BYPASS HOSE (9999407879) If air remains in the piping from the brake valve to the cylinder built in the winch, the brake response becomes poor. If the brake valve and piping are removed, bleed air by the following sequences shown below.
Page 234 6. HOIST SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 6-16 Published 10-02-13, Control #210-03...
Page 235: Construction And Function
6. HOIST SYSTEM 6.6 CONSTRUCTION AND FUNCTION 6.6.1 HYDRAULIC SCHEMATIC 6-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 236 6. HOIST SYSTEM 12000-1/12000E-1 6-18 Published 10-02-13, Control #210-03...
Page 237 6. HOIST SYSTEM 6-19 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 238: Lifting A Load
6. HOIST SYSTEM 6.6.2 LIFTING A LOAD Function of the front drum and the rear drum are exactly same. The front drum is explained here as an example. While the function lock lever is in the "Work" po- sition (SOL-3 : On position), oil pressure from the control pump flows through the accumulator and into the foot brake valve block, the clutch valve block, brake valve block (4-section pilot operat-...
Page 239 6. HOIST SYSTEM Lifting (1/3) 6-21 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 240 6. HOIST SYSTEM Lifting (2/3) 12000-1/12000E-1 6-22 Published 10-02-13, Control #210-03...
Page 241 6. HOIST SYSTEM Lifting (3/3) 6-23 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 242: Holding A Raised Load
6. HOIST SYSTEM 6.6.3 HOLDING A RAISED LOAD With the main control lever turned back to its neutral position, the control pressure coming from the remote control valve is cut and the spool in the main control valve returns to its neu- tral position.
Page 243 6. HOIST SYSTEM Holding (1/2) 6-25 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 244 6. HOIST SYSTEM Holding (2/2) 12000-1/12000E-1 6-26 Published 10-02-13, Control #210-03...
Page 245 6. HOIST SYSTEM This page is blank for editing convenience. 6-27 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 246: Lowering A Load (Power Lowering)
6. HOIST SYSTEM 6.6.4 LOWERING A LOAD (POWER LOWERING) Function of the front drum and the rear drum are exactly same. The front drum is explained here as an example. When the function lock lever is in the "Work" po- sition (SOL-3 : ON position), oil pressure from the control pump flows past the accumulator and into the foot brake valve block, the clutch valve...
Page 247 6. HOIST SYSTEM Lowering (Power lowering) (1/3) 6-29 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 248 6. HOIST SYSTEM Lowering (Power lowering) (2/3) 12000-1/12000E-1 6-30 Published 10-02-13, Control #210-03...
Page 249 6. HOIST SYSTEM Lowering (Power lowering) (3/3) 6-31 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 250: Free Fall Operation
6. HOIST SYSTEM 6.6.5 FREE FALL OPERATION When the brake select switch is set to the "FREE FALL" side, the solenoid valve (SOL-22) in the clutch valve block (4-section solenoid valves) is switched over. When the solenoid valve is switched over and the front drum foot brake is released, the pres- surized oil in the "CLM"...
Page 251 6. HOIST SYSTEM Free Fall (1/2) 6-33 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 252 6. HOIST SYSTEM Free Fall (2/2) 12000-1/12000E-1 6-34 Published 10-02-13, Control #210-03...
Page 253 6. HOIST SYSTEM Free Fall Control (1/2) 6-35 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 254 6. HOIST SYSTEM Free Fall Control (2/2) 12000-1/12000E-1 6-36 Published 10-02-13, Control #210-03...
Page 255 6. HOIST SYSTEM This page is blank for editing convenience. 6-37 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 256 6. HOIST SYSTEM FREE FALL ACCELERATION Free fall with the "FREE FALL SPEED SELECT SWITCH" on the left upper switch panel set to the "HIGH" position. When the front drum foot brake pedal is re- leased, the solenoid valve (SOL-10) is switched over, and pressurized oil from the clutch valve block (4-section SOL) flows into the "PDM1"...
Page 257 6. HOIST SYSTEM Free Fall Speed Acceleration (1/2) 6-39 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 258 6. HOIST SYSTEM Free Fall Speed Acceleration (2/2) 12000-1/12000E-1 6-40 Published 10-02-13, Control #210-03...
Page 259 6. HOIST SYSTEM This page is blank for editing convenience. 6-41 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 260: G Winch Mode Lifting
6. HOIST SYSTEM 6.6.6 G WINCH MODE LIFTING Refer to ELECTRIC CONTROL for condition of switching over to G winch mode. Function of the front drum and the rear drum are exactly same. The front drum is explained here as an example. While the function lock lever is in the "Work"...
Page 261 6. HOIST SYSTEM Lifting (1/3) 6-43 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 262 6. HOIST SYSTEM Lifting (2/3) 12000-1/12000E-1 6-44 Published 10-02-13, Control #210-03...
Page 263 6. HOIST SYSTEM Lifting (3/3) 6-45 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 264: G Winch Mode Lowering
6. HOIST SYSTEM 6.6.7 G WINCH MODE LOWERING Refer to ELECTRIC CONTROL for condition of switching over to G winch mode. Function of the front drum and the rear drum are exactly same. The motions are same for the front drum and the rear drum.
Page 265 6. HOIST SYSTEM Lowering (1/3) 6-47 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 266 6. HOIST SYSTEM Lowering (2/3) 12000-1/12000E-1 6-48 Published 10-02-13, Control #210-03...
Page 267 6. HOIST SYSTEM Lowering (3/3) 6-49 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 268 6. HOIST SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 6-50 Published 10-02-13, Control #210-03...
Page 269: Boom Hoist System
7. BOOM HOIST SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 270 7. BOOM HOIST SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 271: Apparatus And Location Of Components
7. BOOM HOIST SYSTEM APPARATUS AND LOCATION OF COMPONENTS The boom hoist system consists of the main pump, the main control valve, the boom drum motor, the reduction unit, the boom drum and the drum lock mechanism. The pressurized oil for the boom hoist system is sup- plied by the main pump (No.1) installed on the engine’s power divider.
Page 272 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. 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 273: Boom Hoist Winch Installation
7. BOOM HOIST SYSTEM BOOM HOIST WINCH INSTALLATION When boom hoist winch is to be installed or removed, perform work observing the following tightening torque and note. When replacing the gear oil, use the specified type of oil and fill in to the specified level. Specified type of oil : Extreme pressure gear oil SAE#90 (API-GL4) or SAE#80W-90 Specified volume :...
Page 274: Boom Drum Lock
7. BOOM HOIST SYSTEM BOOM DRUM LOCK 7.3.1 ASSEMBLY DRAWING When the assembly is complete, fill grease until it is squeezed out from the clearances of the pawl. Tightening torque : 24.1 to 33.9 N-m HOSE Adjust the hose bending to prevent the hose from interefering with the frame corner.
Page 275: Adjusting The Boom Drum Lock
7. BOOM HOIST SYSTEM 7.3.2 ADJUSTING THE BOOM DRUM LOCK Ensure to adjust the boom hoist drum lock while the boom has been lowered to the ground. Failure to observe this precaution may result in se- rious injury or loss of life. 1.
Page 276: Reduction Unit
7. BOOM HOIST SYSTEM REDUCTION UNIT Tightening torque : 109 to 133 N-m Apply LOCTITE #242 (To hole side) Tightening torque After insertion, : 31.5 to 38.5 N-m Tightening torque Apply LOCTITE #515 Apply LOCTITE #242 : 113.1 to 122.9 N-m punch to lock.
Page 277: Tightening Torque Table
7. BOOM HOIST SYSTEM 3. Capscrew 23. Plate 49. Bearing 4. Capscrew 24. O-ring 50. Retainer 5. Sleeve 26. Collar 51. Capscrew 6. Oil seal 27. Retaining ring 52. Grease fitting 7. Retainer 28. Retainer 53. Breather 8. Spacer 29. Pin 54.
Page 278 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 7-10 Published 10-02-13, Control #210-03...
Page 279: Construction And Function
7. BOOM HOIST SYSTEM 7.5 CONSTRUCTION AND FUNCTION 7.5.1 HYDRAULIC SCHEMATIC BOOM HOIST HYD. CIRCUIT 7-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 280: Raising The Boom
7. BOOM HOIST SYSTEM 7.5.2 RAISING THE BOOM Pressurized hydraulic oil from the main pump (No.1) flows into 1 section side of the main con- trol valve. The control pressurized oil from the control valve flows into the valve block and remote control valve through the accumulator.
Page 281 7. BOOM HOIST SYSTEM BOOM RAISING 7-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 282: Neutral (Holding Boom)
7. BOOM HOIST SYSTEM 7.5.3 NEUTRAL (HOLDING BOOM) When the control lever is returned to neutral, control pressure of the remote control valve is shut off and main control valve spool returns to neutral and pressured oil from the main pump (No.1) passes through the control valve and re- turns to the tank without load.
Page 283 7. BOOM HOIST SYSTEM BOOM HOLDING 7-15 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 284 7. BOOM HOIST SYSTEM 7.5.4 LOWERING BOOM The pressured oil from the No.1 main pump flows into the 1 section side main control valve. The control pressured oil from the control pump flows into the valve block and remote control valve through the accumulator.
Page 285 7. BOOM HOIST SYSTEM BOOM LOWERING 7-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 286 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 7-18 Published 10-02-13, Control #210-03...
Page 287: Swing System
8. SWING SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 288 8. SWING SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 289 8. SWING SYSTEM APPARATUS AND LOCATION OF COMPONENTS The swing system consists of the swing pump, the swing motor (built in swing brake), the swing control valve, the reduction unit, the swing bearing ring, the swivel joint, the swing gear and the swing lock. To swing the machine’s upper machinery, pressurized oil from the swing pump (No.3) mounted on the power divider is sent to the swing motor by way of the control...
Page 290: Construction And Function
8. SWING SYSTEM CONSTRUCTION AND FUNCTION 8.2.1 HYDRAULIC SCHEMATIC Swing hydraulic schematic 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 291 8. SWING SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 292: Swing
8. SWING SYSTEM 8.2.2 SWING The working principle of the rightward swing, identical to that of the leftward swing, is shown below. [The swing brake is released ("SPB" SOL-5 is actuated).] The pressurized oil from the swing pump is led to the swing control valve.
Page 293 8. SWING SYSTEM SWING (Neutral Free Mode) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 294 8. SWING SYSTEM SWING (Neutral Brake Mode) 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 295: Stopping
8. SWING SYSTEM 8.2.3 STOPPING When the swing control lever is returned from the swing mode to the neutral mode, the control pressure from the remote control valve is lost, and the control valve spool (A) returns to neutral. Thus, the main pressurized oil returns to the tank with no load.
Page 296 8. SWING SYSTEM STOP (Neutral Free Mode) 12000-1/12000E-1 8-10 Published 10-02-13, Control #210-03...
Page 297 8. SWING SYSTEM STOP (Neutral Brake Mode) 8-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 298: Swing Reduction Unit
8. SWING SYSTEM SWING REDUCTION UNIT Item Name Tightening Torque Weight Reduction unit 396 kg (873 lbs) Motor 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) 12000-1/12000E-1...
Page 299 8. SWING SYSTEM Apply LOCTITE #515 Apply LOCTITE #515 41, 40, 39, 38, 37, 36, 35, 34 32,33 Apply LOCTITE #515 Shim adjustment 0 to 0.2 mm (0 to 0.0079 inch) Bolt hole M20 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Wrap seal tape or Apply LOCTITE #577...
Page 300: Tightening Torque
8. SWING SYSTEM 1. Housing 17. Bearing 34. Shim (t=1.1) 2. Housing 18. Bearing 35. Shim (t=1.2) 3. Housing 19. Bearing 36. Shim (t=1.3) 4. Pinion 20. Bearing 37. Shim (t=1.4) 5. Shaft 21. Oil seal 38. Shim (t=1.5) 6. Ring gear 22.
Page 301: Swing Bearing
8. SWING SYSTEM SWING BEARING Tightening force : 423 to 517 kN (95,094 to 116,226 lbf) Apply LOCTITE #242 Tightening force : 423 to 517 kN (95,094 to 116,226 lbf) Apply LOCTITE #242 SECTION A-A Upper machinery front Outer ring soft zone Inner ring soft zone (Stop plug) (“S”...
Page 302 8. SWING SYSTEM BOLT TIGHTENING PROCEDURE Lower frame side 1. Tighten 2 bolts which are positioned 180 degrees apart each other on the lower frame side with 147 N-m (108 lbs-ft) torque. 2. Tighten 2 bolts which are positioned 90 degrees apart from the previously tightened bolts.
Page 303: 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 8-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 304 8. SWING SYSTEM 12000-1/12000E-1 8-18 Published 10-02-13, Control #210-03...
Page 305: Propel System
9. PROPEL SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 306 9. PROPEL SYSTEM 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 307: Apparatus And Location Of Components
9. PROPEL SYSTEM APPARATUS AND LOCATION OF COMPONENTS The Propel system consists of the main pump, the main control valves, the propel motors, the propel reduction units, the upper/lower rollers, the drive tumblers, idlers and shoes. Pressurized oil from the main pumps (No.1 and No.2 pumps installed on the power divider) is controlled through the 2 main control valves.
Page 308: Propel Reduction Unit
9. PROPEL SYSTEM PROPEL REDUCTION UNIT G (PF) 1/2 (D) 2-G (PF) 1 (VA, VB) 2-G (PF) 1/4 Tightening torque : 677 to 833 N-m Apply Loctite #242 Tightening torque : 1740 to 2140 N-m Apply Loctite #242 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 309 9. PROPEL SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 310: Reduction Unit
9. PROPEL SYSTEM 9.2.1 REDUCTION UNIT 31 38 34 18 21 19 20 “A” shim adjust 1.1 to 1.6mm DETAILE “A” 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 311 9. PROPEL SYSTEM 1. Cover 15. Gear 29. Spring pin 2. Spider 16. Spring pin 30. Floating seal 3. Pin 17. Sun gear 31. Cover 4. Bearing 18. Spider 32. Ring 5. Thrust washer 19. Pin 33. Shim 6. Gear 20.
Page 312: Motor
9. PROPEL SYSTEM 9.2.2 MOTOR 7 5 15 6 16 39 29 41 36 1 18 10 26 30 12 9 Tightening Torque : 17.5 to 21.5 N-m (12.9 to 15.9 ft-lbs) G (PF) 1/4 (P) Tightening Torque : Tightening Torque : 70.7 to 86.4 N-m 98.1 to 117.7 N-m (52.1 to 63.7 ft-lbs)
Page 313: Hydraulic Circuit
9. PROPEL SYSTEM 1. Case 16. Seal 31. Bearing 2. Cover 17. Check valve 32. Capscrew 3. Block 18. Retaining ring 33. Shim 4. Retainer 19. Retaining ring 34. Pin 5. Plate 20. Piston 35. O-ring 6. Piston 21. Piston seal 36.
Page 314: Adjustment
9. PROPEL SYSTEM ADJUSTMENT If the crawler shoes are too tight, the shoes wear quick- ly and a connection between two shoes could break. On the other hand, if the shoes are too loose, the shoes may ride off the drive sprocket and idler wheel during the travel operation.
Page 315: Construction And Function
9. PROPEL SYSTEM 9.4 CONSTRUCTION AND FUNCTION 9.4.1 HYDRAULIC SCHEMATIC 9-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 316: Propelling (Right Side Forward)
9. PROPEL SYSTEM 9.4.2 PROPELLING (RIGHT SIDE FORWARD) Propelling the right and/or left sides and to the forward and reverse are basically the same op- eration. We will use a right side forward operation as the example here. Pressurised oil from the No.1 pump is directed into the control valve.
Page 317 9. PROPEL SYSTEM PROPEL (R.H. FORWARD) 9-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 318: Stopping
9. PROPEL SYSTEM 9.4.3 STOPPING When the right propel control lever is shifted back to neutral from propel position, the flow from the remote control valve is cut and the spool of the control valve repositions itself. At the same time, the pilot pressure on the propel brake valve is discontinued, and the spool in the brake valve also repositions itself.
Page 319 9. PROPEL SYSTEM PROPEL STOPPING 9-15 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 320 9. PROPEL SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 9-16 Published 10-02-13, Control #210-03...
Page 321: Electric System
10. ELECTRIC SYSTEM 10-1 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 322 10. ELECTRIC SYSTEM Before unplugging or plugging in the connector, be sure to shut off the power supply (set the starter switch to the OFF position). When unplugging the connector, hold it with both hands and draw it straight, while pressing down the catch. DO NOT pull on the cable.
Page 323: Electrical
10. ELECTRIC SYSTEM 10.1 ELECTRICAL 10.1.1 ELECTRICAL WIRING SCHEMATIC (1/18) 10-3 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 324 10. ELECTRIC SYSTEM (2/18) 12000-1/12000E-1 10-4 Published 10-02-13, Control #210-03...
Page 325 10. ELECTRIC SYSTEM (3/18) 10-5 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 326 10. ELECTRIC SYSTEM (4/18) 12000-1/12000E-1 10-6 Published 10-02-13, Control #210-03...
Page 327 10. ELECTRIC SYSTEM (5/18) 10-7 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 328 10. ELECTRIC SYSTEM (6/18) 12000-1/12000E-1 10-8 Published 10-02-13, Control #210-03...
Page 329 10. ELECTRIC SYSTEM (7/18) 10-9 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 330 10. ELECTRIC SYSTEM (8/18) 12000-1/12000E-1 10-10 Published 10-02-13, Control #210-03...
Page 331 10. ELECTRIC SYSTEM (9/18) 10-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 332 10. ELECTRIC SYSTEM (10/18) 12000-1/12000E-1 10-12 Published 10-02-13, Control #210-03...
Page 333 10. ELECTRIC SYSTEM (11/18) 10-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 334 10. ELECTRIC SYSTEM (12/18) 12000-1/12000E-1 10-14 Published 10-02-13, Control #210-03...
Page 335 10. ELECTRIC SYSTEM (13/18) 10-15 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 336 10. ELECTRIC SYSTEM (14/18) 12000-1/12000E-1 10-16 Published 10-02-13, Control #210-03...
Page 337 10. ELECTRIC SYSTEM (15/18) 10-17 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 338 10. ELECTRIC SYSTEM (16/18) 12000-1/12000E-1 10-18 Published 10-02-13, Control #210-03...
Page 339 10. ELECTRIC SYSTEM (17/18) 10-19 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 340 10. ELECTRIC SYSTEM (18/18) 12000-1/12000E-1 10-20 Published 10-02-13, Control #210-03...
Page 341: Connector Layout
10. ELECTRIC SYSTEM 10.1.2 CONNECTOR LAYOUT Wire color list Basic single color HARNESS NAME Color Name Color Sign Basic single color Base Color FLOOR PLATE Ｂ Black White Ｗ FLOOR A Ｒ Green FLOOR B ＧＹ Yellow OUT INDICATING LIGHT RELAY JUNCTION HARNESS Ｂ...
Page 342 10. ELECTRIC SYSTEM HARNESS NAME HYDRAULIC OIL HEAT HYDRAULIC OIL HEAT BOOM BASE (INSERT INCLUDED) BOOM BASE (INSERT INCLUDED) BOOM TIP CRAWLER SELF REMOVAL FIXED JIB FIXED JIB CAMERA CONTROLLER CAMERA CONTROLLER CAMERA CONTROLLER IT CONTROLLER INSTALLATION 12000-1/12000E-1 10-22 Published 10-02-13, Control #210-03...
Page 343 10. ELECTRIC SYSTEM 1.ELECTRICAL PART OF FLOOR PLATE SOL : SOLENOID VALVE CN-401AF CN-452 SW : SWITCH INCHING SPEED SELECT SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT CN-453 C/W : COUNTER WEIGHT REAR DRUM G-WINCH SELECT CB/W : CARBODY WEIGHT CN-401M SWITCH CN-454 FRONT DRUM G-WINCH SELECT SWITCH CN-455 REAR DRUM FREE-FALL SELECT SWITCH...
Page 344 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-436 CN-218 OVERHOIST GANTRY CONTROL SWITCH RELEASE SWITCH CN-437 VIEW FROM “C” BOOM OVERHOIST RELEASE SWITCH CN-216 CN-438 CRAWLER EXT.
Page 345 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT REAR DRUM TURN DETECTION GRIP REAR DRUM FREE-FALL FRONT DRUM TURN SELECT SWITCH DRUM INCHING SPEED REAR DRUM DETECTION GRIP SELECT SWITCH...
Page 346 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CA-B10 CN-484 CN-483 SPOT LIGHT CA-B12 A/C CONTROL PANEL RELAY BOX CN-511M LA-B19 CN-477 LOAD SAFETY DEVICE HARNESS CN-511AF FUSE BOX...
Page 347 10. ELECTRIC SYSTEM OUT INDICATING LIGHT RELAY JUNCTION HARNESS (1/2) 10-27 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 348 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-28 Published 10-02-13, Control #210-03...
Page 349 10. ELECTRIC SYSTEM FLOOR HARNESS A (1/5) 10-29 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 350 10. ELECTRIC SYSTEM (2/5) 12000-1/12000E-1 10-30 Published 10-02-13, Control #210-03...
Page 351 10. ELECTRIC SYSTEM (3/5) 10-31 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 352 10. ELECTRIC SYSTEM (4/5) 12000-1/12000E-1 10-32 Published 10-02-13, Control #210-03...
Page 353 10. ELECTRIC SYSTEM (5/5) 10-33 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 354 10. ELECTRIC SYSTEM FLOOR HARNESS B (1/5) 12000-1/12000E-1 10-34 Published 10-02-13, Control #210-03...
Page 355 10. ELECTRIC SYSTEM (2/5) 10-35 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 356 10. ELECTRIC SYSTEM (3/5) 12000-1/12000E-1 10-36 Published 10-02-13, Control #210-03...
Page 357 10. ELECTRIC SYSTEM (4/5) 10-37 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 358 10. ELECTRIC SYSTEM (5/5) 12000-1/12000E-1 10-38 Published 10-02-13, Control #210-03...
Page 359 10. ELECTRIC SYSTEM 2.ELECTRICAL PART OF LOWER SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (1/2) 10-39 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 360 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/2) 12000-1/12000E-1 10-40 Published 10-02-13, Control #210-03...
Page 361 10. ELECTRIC SYSTEM LOWER HARNESS (1/4) 10-41 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 362 10. ELECTRIC SYSTEM (2/4) 12000-1/12000E-1 10-42 Published 10-02-13, Control #210-03...
Page 363 10. ELECTRIC SYSTEM (3/4) 10-43 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 364 10. ELECTRIC SYSTEM (4/4) 12000-1/12000E-1 10-44 Published 10-02-13, Control #210-03...
Page 365 10. ELECTRIC SYSTEM TRANS LIFTER REMOTE CONTROLLER CABLE HARNESS (OPTION) (1/3) 10-45 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 366 10. ELECTRIC SYSTEM (2/3) 12000-1/12000E-1 10-46 Published 10-02-13, Control #210-03...
Page 367 10. ELECTRIC SYSTEM (3/3) 10-47 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 368 10. ELECTRIC SYSTEM 3. ELECTRICAL PART OF LEFT DECK SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT FRONT DRUM INDEPENDENT. CONFLUENCE SELECT (SOL-101) CN-836F REAR DRUM INDEPENDENT.
Page 369 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH 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”...
Page 370 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT TO LEFT GUARD FUEL PUMP FRONT DRUM TILT SENSOR (PT-20) CN-802F FRONT DRUM TILT SENSOR (PT-20) CN-802F FRONT DRUM TILT PROP.
Page 371 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT OIL COOLER MOTOR 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...
Page 372 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-804F, 835, 841 REAR DRUM MOTOR BOOST (SOL-16) CN-840F REAR DRUM TILT SENSOR (SOL-14) CN-803F REAR DRUM TILT PROP.
Page 373 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-868F CN-854F CN-855F THIRD MOTOR TILT PROP. VALVE (SOL-67) CN-835F OIL COOLER MOTOR RELAY (RL-3) CN-818F THIRD TILT SENSOR (PT-15) CUT OUT RELAY (R-C)
Page 374 10. ELECTRIC SYSTEM LEFT DECK HARNESS (1/5) 12000-1/12000E-1 10-54 Published 10-02-13, Control #210-03...
Page 375 10. ELECTRIC SYSTEM (2/5) 10-55 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 376 10. ELECTRIC SYSTEM (3/5) 12000-1/12000E-1 10-56 Published 10-02-13, Control #210-03...
Page 377 10. ELECTRIC SYSTEM (4/5) 10-57 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 378 10. ELECTRIC SYSTEM (5/5) 12000-1/12000E-1 10-58 Published 10-02-13, Control #210-03...
Page 379 10. ELECTRIC SYSTEM RELAY HARNESS (1/3) 10-59 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 380 10. ELECTRIC SYSTEM (2/3) 12000-1/12000E-1 10-60 Published 10-02-13, Control #210-03...
Page 381 10. ELECTRIC SYSTEM (3/3) 10-61 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 382 10. ELECTRIC SYSTEM 4. ELECTRICAL PART OF RIGHT DECK SOL : SOLENOID VALVE CN-404 SWING FRAME CN-473 SW : SWITCH HARNESS CN-403 PSW : PRESSURE SWITCH CN-471 CN-401 LEFT DACK ATT. : ATTACHMENT CN-472 CN-402 HARNESS C/W : COUNTER WEIGHT ATT.
Page 383 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CN-626 HYD. OIL CB/W : CARBODY WEIGHT THIRD DRUM CLUTCH PRESS. SENSOR HEAT SYSTEM (OPTION) CN-604 CN-603 THIRD CLUTCH SOL Re DRUM CLUTCH PRESS.
Page 384 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-626 CN-626 3rd. CLUTCH SOL 3rd. CLUTCH SOL CONNECT TO HYD. HEAT SYSTEM HARNESS (OPTION) SECTION “G-G”...
Page 385 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE CN-611 SW : SWITCH SWING CONSTANT PSW : PRESSURE SWITCH LOW SPEED SOL ATT. : ATTACHMENT CN-623 CN-611 C/W : COUNTER WEIGHT BOOM PUMP SWING CONSTANT CB/W : CARBODY WEIGHT INCHING SPEED SOL LOW SPEED SOL CN-612 BOOM PUMP...
Page 386 10. ELECTRIC SYSTEM RIGHT DECK HARNESS (1/4) 12000-1/12000E-1 10-66 Published 10-02-13, Control #210-03...
Page 387 10. ELECTRIC SYSTEM (2/4) 10-67 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 388 10. ELECTRIC SYSTEM (3/4) 12000-1/12000E-1 10-68 Published 10-02-13, Control #210-03...
Page 389 10. ELECTRIC SYSTEM (4/4) 10-69 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 390 10. ELECTRIC SYSTEM POWER SUPPLY HARNESS (1/3) 12000-1/12000E-1 10-70 Published 10-02-13, Control #210-03...
Page 391 10. ELECTRIC SYSTEM (2/3) 10-71 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 392 10. ELECTRIC SYSTEM (3/3) 12000-1/12000E-1 10-72 Published 10-02-13, Control #210-03...
Page 393 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL B) TO BATTERY RELAY HARNESS 10-73 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 394 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL C) TO SAFETY RELAY HARNESS 12000-1/12000E-1 10-74 Published 10-02-13, Control #210-03...
Page 395 10. ELECTRIC SYSTEM GLOW RELAY HARNESS TO ENGINE SUB HARNESS 10-75 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 396 10. ELECTRIC SYSTEM 5. ELECTRICAL PART OF RIGHT DECK (GUARD) SOL : SOLENOID VALVE SW : SWITCH CN-632F PSW : PRESSURE SWITCH AIR FLOW METER ATT. : ATTACHMENT INTAKE AIR TEMP. SENSOR C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-632M CN-630F CN-630F...
Page 397 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH CN-641M CN-640M PSW : PRESSURE SWITCH FOR DPR INLET TEMP. SENSOR FOR DPR EXIT TEMP. SENSOR ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-642F FOR DPR PRESS. DIFF SENSOR CN-842 CONNECT TO...
Page 398 10. ELECTRIC SYSTEM GUARD HARNESS A (1/3) 12000-1/12000E-1 10-78 Published 10-02-13, Control #210-03...
Page 399 10. ELECTRIC SYSTEM (2/3) 10-79 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 400 10. ELECTRIC SYSTEM (3/3) 12000-1/12000E-1 10-80 Published 10-02-13, Control #210-03...
Page 401 10. ELECTRIC SYSTEM GUARD HARNESS B (1/3) 10-81 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 402 10. ELECTRIC SYSTEM (2/3) 12000-1/12000E-1 10-82 Published 10-02-13, Control #210-03...
Page 403 10. ELECTRIC SYSTEM (3/3) 10-83 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 404 10. ELECTRIC SYSTEM GUARD HARNESS C (1/2) 12000-1/12000E-1 10-84 Published 10-02-13, Control #210-03...
Page 405 10. ELECTRIC SYSTEM (2/2) 10-85 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 406 10. ELECTRIC SYSTEM 6. ELECTRICAL PART OF SWING FRAME SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (1/3) 12000-1/12000E-1 10-86 Published 10-02-13, Control #210-03...
Page 407 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/3) 10-87 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 408 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 12000-1/12000E-1 10-88 Published 10-02-13, Control #210-03...
Page 409 10. ELECTRIC SYSTEM SWING FRAME HARNESS (1/4) 10-89 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 410 10. ELECTRIC SYSTEM (2/4) 12000-1/12000E-1 10-90 Published 10-02-13, Control #210-03...
Page 411 10. ELECTRIC SYSTEM (3/4) 10-91 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 412 10. ELECTRIC SYSTEM (4/4) 12000-1/12000E-1 10-92 Published 10-02-13, Control #210-03...
Page 413 10. ELECTRIC SYSTEM ATT. JUNCTION HARNESS (1/3) 10-93 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 414 10. ELECTRIC SYSTEM (2/3) 12000-1/12000E-1 10-94 Published 10-02-13, Control #210-03...
Page 415 10. ELECTRIC SYSTEM (3/3) 10-95 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 416 10. ELECTRIC SYSTEM 7. ELECTRICAL PART OF CAB SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT SKYLIGHT WIPER CB/W : CARBODY WEIGHT INTERMITTENT UNIT CN-233 FRONT WINDOW FRONT WINDOW WIPER INTERMITTENT WIPER INTERMITTENT UNIT UNIT...
Page 417 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-240 OVER HOIST OVER LOAD BUZZER CN-226 RADIO (OPTION) CN-234 MULTI VOICE ALARM (OPTION) CN-240 OVER HOIST OVER LOAD BUZZER CN-227 SPEAKER (LEFT)
Page 418 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CN-435 CB/W : CARBODY WEIGHT CN205 THIRD DRUM FREE FALL ACCELERATION SW (OPTION) REAR WORK LIGHT SW CN201 CN203 (OPTION) WASHER SW WIPER SW...
Page 419 10. ELECTRIC SYSTEM CAB HARNESS (1/6) 10-99 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 420 10. ELECTRIC SYSTEM (2/6) 12000-1/12000E-1 10-100 Published 10-02-13, Control #210-03...
Page 421 10. ELECTRIC SYSTEM (3/6) 10-101 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 422 10. ELECTRIC SYSTEM (4/6) 12000-1/12000E-1 10-102 Published 10-02-13, Control #210-03...
Page 423 10. ELECTRIC SYSTEM (5/6) 10-103 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 424 10. ELECTRIC SYSTEM (6/6) 12000-1/12000E-1 10-104 Published 10-02-13, Control #210-03...
Page 425 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 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 426 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TO ENGINE GROUND HARNESS 12000-1/12000E-1 10-106 Published 10-02-13, Control #210-03...
Page 427 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TARMINAL B ALTERNATOR HARNESS TARMINAL B 10-107 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 428 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 12000-1/12000E-1 10-108 Published 10-02-13, Control #210-03...
Page 429 10. ELECTRIC SYSTEM MONITOR HARNESS (1/2) 10-109 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 430 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-110 Published 10-02-13, Control #210-03...
Page 431 10. ELECTRIC SYSTEM 10. ELECTRICAL PART OF COUNTER WEIGHT SELF REMOVAL (OPTION) 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...
Page 432 10. ELECTRIC SYSTEM COUNTER WEIGHT SELF REMOVAL HARNESS (1/3) 12000-1/12000E-1 10-112 Published 10-02-13, Control #210-03...
Page 433 10. ELECTRIC SYSTEM (2/3) 10-113 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 434 10. ELECTRIC SYSTEM (3/3) 12000-1/12000E-1 10-114 Published 10-02-13, Control #210-03...
Page 435 10. ELECTRIC SYSTEM 11. OVER LOAD PREVENT (M. MACHINERY) (1/2) 10-115 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 436 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-116 Published 10-02-13, Control #210-03...
Page 437 10. ELECTRIC SYSTEM 14. ELECTRICAL PART OF HYDRAULIC OIL HEAT SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT 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...
Page 438 10. ELECTRIC SYSTEM HYDRAULIC OIL HEAT HARNESS (1/2) 12000-1/12000E-1 10-118 Published 10-02-13, Control #210-03...
Page 439 10. ELECTRIC SYSTEM (2/2) 10-119 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 440 10. ELECTRIC SYSTEM 15. ELECTRICAL PART OF BOOM BASE (INSERT INCLUDED) SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (1/3) 12000-1/12000E-1 10-120 Published 10-02-13, Control #210-03...
Page 441 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/3) 10-121 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 442 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 12000-1/12000E-1 10-122 Published 10-02-13, Control #210-03...
Page 443 10. ELECTRIC SYSTEM BOOM BASE HARNESS (INSERT INCLUDED) (1/2) 10-123 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 444 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-124 Published 10-02-13, Control #210-03...
Page 445 10. ELECTRIC SYSTEM CABLE (1/2) 10-125 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 446 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-126 Published 10-02-13, Control #210-03...
Page 447 10. ELECTRIC SYSTEM 16. BOOM TIP HARNESS (1/2) 10-127 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 448 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-128 Published 10-02-13, Control #210-03...
Page 449 10. ELECTRIC SYSTEM CABLE (1/2) 10-129 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 450 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-130 Published 10-02-13, Control #210-03...
Page 451 10. ELECTRIC SYSTEM CABLE (1/2) 10-131 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 452 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-132 Published 10-02-13, Control #210-03...
Page 453 10. ELECTRIC SYSTEM 17. ELECTRICAL PART OF CRAWLER SELF REMOVAL 10-133 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 454 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 12000-1/12000E-1 10-134 Published 10-02-13, Control #210-03...
Page 455 10. ELECTRIC SYSTEM FIXED JIB HARNESS 10-135 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 456 10. ELECTRIC SYSTEM CABLE (1/2) 12000-1/12000E-1 10-136 Published 10-02-13, Control #210-03...
Page 457 10. ELECTRIC SYSTEM (2/2) 10-137 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 458 10. ELECTRIC SYSTEM CABLE (1/2) 12000-1/12000E-1 10-138 Published 10-02-13, Control #210-03...
Page 459 10. ELECTRIC SYSTEM (2/2) 10-139 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 460 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) 12000-1/12000E-1 10-140 Published 10-02-13, Control #210-03...
Page 461 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/3) 10-141 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 462 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 12000-1/12000E-1 10-142 Published 10-02-13, Control #210-03...
Page 463 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10-143 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 464 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-144 Published 10-02-13, Control #210-03...
Page 465 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10-145 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 466 10. ELECTRIC SYSTEM (2/2) 12000-1/12000E-1 10-146 Published 10-02-13, Control #210-03...
Page 467 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 10-147 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 468 10. ELECTRIC SYSTEM This page is blank for editing convenience. 12000-1/12000E-1 10-148 Published 10-02-13, Control #210-03...
Page 469: 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 10-149 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 470 10. ELECTRIC SYSTEM Classification of Fuse Use Fuse No. Location Capacity Type Line No. – Main power – AIS air-con battery voltage – – ML, MC1.MC2 radio backup – Bypass switch – Release switch – For ML control Automotive Fuse box –...
Page 471 10. ELECTRIC SYSTEM Classification of Fuse Use Fuse No. Capacity Type Line No. Location – Generating detect – PCV1 – PCV2 – ECU (+BF) – ECU (J08E : + B) – ECU (P11C : + B) – Dc motor for oil cooler ① Automotive Fuse box –...
Page 472 10. ELECTRIC SYSTEM 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. 12000-1/12000E-1 10-152 Published 10-02-13, Control #210-03...
Page 473 10. ELECTRIC SYSTEM 10-153 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 474 10. ELECTRIC SYSTEM 12000-1/12000E-1 10-154 Published 10-02-13, Control #210-03...
Page 475: Wiper Control Relay (2479R1366)
10. ELECTRIC SYSTEM 10.1.4 WIPER CONTROL RELAY Wiper intermediate relay Wiper intermediate relay Wiper switch Stop Intermited Continuous Wiper switch 10-155 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 476: Pressure Switch (For Propel Motion Detect)
10. ELECTRIC SYSTEM 10.1.5 PRESSURE SWITCH (FOR PROPEL MOTION DETECT) 1 : POWER (+) 2 : EARTH (-) Load N.O. Pressure 24 V Pressure source 19 × 26 HEX. 539 ± 49 KPa : ON Tightening torque 14.7 ± 2.9 N-m 343 ±...
Page 477: Pressure Switch (Foot Brake)
10. ELECTRIC SYSTEM 10.1.6 PRESSURE SWITCH (FOOT BRAKE) COMMON 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 10-157 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 478: Pressure Sensor
10. ELECTRIC SYSTEM 10.1.7 PRESSURE SENSOR (9999430139 • 9999430134) 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 12000-1/12000E-1 10-158 Published 10-02-13, Control #210-03...
Page 479 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 10-159 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 480 10. ELECTRIC SYSTEM Pressure raqnge Part number Power (V) Out-put (V) MPa (Psi) Main pump power control shift control pressure Swing motion detect pressure (R L) 0 to 3 CHP start pressure 9999430134 0.5 to 4.5 (0 to 435) Remote control pressure (Front Rear 3rd Swing Boom) Motor control pressure (Front Rear 3rd)
Page 481 10. ELECTRIC SYSTEM 9999426022 Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 0.5 to 4.5 V 22×23 HEX. O-RING P14 PF3/8A Pressure range Part number Power (V) Out-put (V) MPa (psi) Clutch pressure (Front • Rear • 3rd) 0 to 19.6 9999426022 0.5 to 4.5...
Page 482: Inclination Sensor
10. ELECTRIC SYSTEM 10.1.8 INCLINATION SENSOR Type N4AA20010 Resolution 0.04° Specification Linear error 1%typ. of angle range Recurrence Angle range ±5° ±0.2°typ. accuracy Power source 10 to 30VDC Temperature drift 1.3% typ. Power typ.22mA Protection class IP 67 consumption Output X-axis 0.5 to 4.5V Temperature -40 to 70...
Page 483: Buzzer Unit
10. ELECTRIC SYSTEM 10.1.9 BUZZER UNIT 10-163 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 484 10. ELECTRIC SYSTEM Buzzer to be used High-pitched tone FDK corp. EB2210A-38C-12V Bass Star precession Low-pitched tone TMX-12F corp. 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...
Page 485 10. ELECTRIC SYSTEM 10.1.10 RELAY BOX 1. ARRANGEMENT OF CONNECTOR 10-165 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 486 10. ELECTRIC SYSTEM 12000-1/12000E-1 10-166 Published 10-02-13, Control #210-03...
Page 487 10. ELECTRIC SYSTEM Name Name Generation detect RL-1 DPR Regeneration RL-37 Safety RL-2 RL-38 Swing flasher (L) Separate oil cooler motor RL-3 RL-39 Swing flasher (R ) RL-4 Pump Qmax cut RL-40 Starter lock RL-5 RL-41 Certify release RL-6 RL-42 Engine stop RL-7 RL-43...
Page 488 10. ELECTRIC SYSTEM 2. RELAY BOX SCHEMATIC F-12 F-21 ALTERNATOR F-12 (L TERMINAL) BATTERY RELAY IGNITION SW AIR-CON CUT RELAY (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)
Page 489 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 10-169 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 490 10. ELECTRIC SYSTEM SWING HI/LO F-36 SPEED SELECT SOL-42 SWING NEUTRAL SELECT SOL-48, 49 MC1(D/O) PROPEL ALARM PROPEL VOICE 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.
Page 491 10. ELECTRIC SYSTEM RIGHT SWING F-05 STOP PSOL-109 MC1(PSOL) MC1 (PSOL) PSOL-109 LEFT SWING STOP MC1(PSOL) PSOL-110 MC1 (PSOL) PSOL-110 MAIN PUMP 1 MC1(PSOL) PSOL-1 PSOL-1 MAIN PUMP 2 MC1(PSOL) PSOL-2 PSOL-6 MC1(PSOL) BOOM PUMP PSOL-2 MC1(PSOL) PSOL-2 MC1(PSOL) MC1(D/O) ML BYPASS SW SW-37 ML BYPASS SW...
Page 492 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 12000-1/12000E-1 10-172 Published 10-02-13, Control #210-03...
Page 493 10. ELECTRIC SYSTEM F-29 MC1 (D/O) OVERLOAD ALARM LAMP (GREEN) M/L (D/O) OVERLOAD ALARM LAMP (YELLOW) M/L (D/O) OVERLOAD ALARM LAMP (YELLOW) M/L (D/O) Fr.DRUM FREE-FALL F-38 SELECT SW-53 Fr.DRUM FOOT BRAKE PRESS. PSW-1 Re.DRUM FREE-FALL SELECT SW-54 Re.DRUM FOOT BRAKE PRESS.
Page 494 10. ELECTRIC SYSTEM F-36 MC1(D/O) SWING FLASHER (L) MC1(D/O) SWING FLASHER (L) MC1(D/O) Q-max CUT 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)
Page 495 10. ELECTRIC SYSTEM AUTO STOP SW BOOM LOWER STOP SW-35 SOL-36 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...
Page 496: Relay Box
10. ELECTRIC SYSTEM 10.1.11 RELAY BOX 12000-1/12000E-1 10-176 Published 10-02-13, Control #210-03...
Page 497 10. ELECTRIC SYSTEM Name Boom hoist raise stop relay RL-60 Boom hoist lower stop relay RL-61 Front raise stop relay RL-62 Front lower stop relay RL-63 Rear raise stop relay RL-64 Rear lower stop relay RL-65 Third raise stop relay RL-66 Third lower stop relay RL-67...
Page 498 10. ELECTRIC SYSTEM BYPASS SW SW-39 F-05 M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) BOOM HOIST BOOM HOIST REMO-CON MC-2 (P/O) (PSOL-52) Fr.DRUM LOWER BOOM HOIST REMO-CON MC-2 (P/O) (PSOL-52) BOOM LOWER BOOM LOWER REMO-CON (PSOL-53)
Page 499 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) 10-179 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 500: 12Load Cell (Crane)
10. ELECTRIC SYSTEM 10.1.12 LOAD CELL (CRANE) Model name : LTP-S-100-KNSA7 Detective capacity: Guy-cable support power Rated capacity : 10 ton (98.07KN) Load capacity : 150% Output voltage : with no load 1V ± 0.01V (at shipping) with rated load 5V ± 0.040V Power source : DC9V ±...
Page 501: Angle Sensor
10. ELECTRIC SYSTEM 10.1.13 ANGLE SENSOR Model name : MLA-901A-**C Detection capacity : Boom angle against ground Valid operating range : 0 to ± 90 degree Operation range : 360° endless Rated output sensitivity : 0.255V/V±0.5% Input voltage : Input resistance : ±...
Page 502: 14Troubleshooting Of Exhaust Gas Third Regulation Engine
10. ELECTRIC SYSTEM 10.1.14 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE 1. FAILURE DIAGNOSIS FUNCTION ECU always diagnoses whether or not the sensors malfunction while the key switch (M) is turned ON, and it lights on the diagnosis lamp when the sensor is judged as being malfunctioned and restores the place of failure at the same time to inform the oper- ator of abnormality and ECU restricts the injection...
Page 503: 15How To Check The Failure Contents
10. ELECTRIC SYSTEM 10.1.15 HOW TO CHECK THE FAILURE CONTENTS 1. Failure diagnosis code table (J08E Engine) When the failure is detected by diagnosis lamp, di- ag. code can be checked by connecting diag. con- nector CN-878F, CN-879M Component location related to diagnosis. •...
Page 504 10. ELECTRIC SYSTEM Diag. lamp (Red) 12000-1/12000E-1 10-184 Published 10-02-13, Control #210-03...
Page 505 10. ELECTRIC SYSTEM 2. Table of Diagnosis codes (J08E-TI) 10-185 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 506 10. ELECTRIC SYSTEM 12000-1/12000E-1 10-186 Published 10-02-13, Control #210-03...
Page 507 10. ELECTRIC SYSTEM 10-187 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 508 10. ELECTRIC SYSTEM 3. Indication of diagnosis codes (1) For example, the following chart shows the case when the diagnosis codes 32 and 21 are displayed. The display method is based on the blinking inter- vals of the lamp. First, the first code makes the lamp light on the figure "3"...
Page 509: 16Checking Of Diagnosis Lamp Function
10. ELECTRIC SYSTEM 10.1.16 CHECKING OF DIAGNOSIS LAMP FUNCTION The diagnosis lamp function is normal when the lamp is lit up with the following conditions. [Requirements for checking lit-up diagnosis lamps] • No any fault to be lit up the diagnosis lamp •...
Page 510 10. ELECTRIC SYSTEM 10.1.17 ENGINE ECU 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 12000-1/12000E-1 10-190 Published 10-02-13, Control #210-03...
Page 511 10. ELECTRIC SYSTEM 10-191 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 512: Load Safety Device
10. ELECTRIC SYSTEM 10.2 LOAD SAFETY DEVICE 100% - 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. 12000-1/12000E-1 10-192 Published 10-02-13, Control #210-03...
Page 513: Configuration Of Screens
10. ELECTRIC SYSTEM 10.2.1 CONFIGURATION OF SCREENS 10-193 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 514: System Daigram
10. ELECTRIC SYSTEM 10.2.2 SYSTEM DAIGRAM Each ML sensor Each limit switch Each switch Each camera Load detector Over hoist Hook over hoist release Front, rear drum Over payout etc. Angle detector Boom over hoist release Boom drum ML release etc. Rear area etc.
Page 515: Monitor Indication
10. ELECTRIC SYSTEM 10.2.3 MONITOR INDICATION FRONT VIEW LEFT VIEW BACK VIEW BOTTOM VIEW (CF cover open) Name Explanation Logic motion mode Color Indication Operation mode (pictorial) (when logic is effective) Off line Green Running Flashing Running STOP At power ON STATUS LED Flashing Runnning...
Page 516: General Specification
10. ELECTRIC SYSTEM Explanation Name G Aux. input/output / Voice output interface (AUX) Outside reset, alarm output, buzzer output, sound output. * not used H Extended memory interface * not used Green light is ON when CF card is inserted and cover is closed or CF card is being accessed.
Page 517 10. ELECTRIC SYSTEM • Installation specification Ground Functional grounding : D type ground (for both SG-FG) Protection : IP65f equivalent NEMA #250 TYPE 4X/13 Condition Construction *1 (Front surface at panel built in.) Shape : Built in type Installation method : Panel built in. Cooling type Natural cooling *1 Protective construction of the front area when this unit is installed in the panel.
Page 518: Power Supply Wiring
10. ELECTRIC SYSTEM • INSTALLATION PROCEDURE Upper face FITTING HOLE Bottom face (GP-3500 series) FITTING HOLE Hang fittings on the recess. PANEL INSTALL FITTING Tighten against the panel. HOOK Overtightening the screws may damage the GP. Proper tightening torque for drip proof effect is 0.5 N-m. POWER SUPPLY WIRING Electric shock may be caused.
Page 519 10. ELECTRIC SYSTEM • Power cable specification Use copper core wire. 0.75 to 2.5mm Size of power cable (18 - 12 AWG) Solid or strand wire *1 Core wire 7 mm Core wire length If strand wire is used, ensure that the core wire is properly stranded.
Page 520 10. ELECTRIC SYSTEM • Procedure of power cable connection 1. Ensure that the power is disconnected. 2. Take out the power supply connector (plug) from the main body. 3. Loosen the 3 screws in the center of power supply connector. 4.
Page 521: Detail Of Moment Limiter Connector
10. ELECTRIC SYSTEM 10.2.4 DETAIL OF MOMENT LIMITER CONNECTOR 1. Outside view and connector layout CONNECTOR LOCATION OF NAME 7-SEGMENT DISPLAY PLATE SEAL WATER PROOF WINDOW 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.
Page 522 10. ELECTRIC SYSTEM 2. ML controller connector pin layout (View from main machinery harness) 12000-1/12000E-1 10-202 Published 10-02-13, Control #210-03...
Page 523 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Control power (+) Main power (IG power +) Control power (+) Main power (IG power +) Control power (-) Main power (IG power GND) Control power (-) Main power (IG power GND) Backup power (+) Sub power (+B power +) Backup power (GND)
Page 524 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Inter main controller CAN0 H transmission 1 (H) Inter main controller CAN0 L transmission 1 (L) Inter main controller CAN0 H end transmission 1 (H end) Inter main controller CAN0 L end transmission 1 (L end) Shield earth Shield earth signal ground...
Page 525 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Swing angle detector power (+) 12V ML system sensor power 2-3 (+) 12V ML system sensor signal 2-3 (0 to Swing angle detector (A) signal 12V) Swing angle detector power (-) 12V ML system sensor power 2 (GND) 12V ML system sensor signal 2-4 (0 to Swing angle detector (B) signal...
Page 526 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Composite signal (+) vacant vacant CN-11-2 Camera power (+) 12V LCD monitor power (+) Composite signal (GND) Camera power (GND) 12V LCD monitor power (+GND) Connector Wire Wire Name Specification color Output power (+) Extended 24V power (+) Extended 25V power (+)
Page 527 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Hook over hoist LS1 24V input Hook over hoist LS2 24V input Gantry hoist detect LS 24V input (Not used) Boom backstop no.2 LS 24V input Crane boom over hoist LS 24V input Boom backstop no.1 LS 24V input...
Page 528 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Drum select SW (rear) 24V input Drum select SW (front) Br/R 24V input 24V input Download start signal 24V input Master key SW Gr/R 24V input Hook over hoist release SW 24V input Boom/Jib over hoist release SW 24V input...
Page 529 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color 24V Output Front drum raise stop 24V Output 24V Output Front drum lower stop 24V Output Rear drum raise stop 24V Output Mode select (luffing jib) Br/G 24V Output Rear drum lower stop 24V Output Mode select (mast) 24V Output...
Page 530 10. ELECTRIC SYSTEM 3. System block diagram Ignition power (IG) 24V load detector power Supply power (4 systems) CN11-1 CN11-1 +24VDC +24VDC Voltage Filter Filter monitor Return arrest 12V load detector power power (8 system) 5V power Ext power EXT CN11-1 supply 12V ML system sensor...
Page 531 10. ELECTRIC SYSTEM 4. ML INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Variation Input Voltage Remarks Crane boom load detector 0t to rated t 1 to 5V CN11-1-25 Spare CN11-1-26 Jib load detector CN11-1-20 Spare CN11-1-21 Spare CN11-1-30 Spare CN11-1-31 Spare CN11-1-4 Spare CN11-1-5...
Page 532 10. ELECTRIC SYSTEM (3) DIGITAL INTPUT [B] Name Condition Signal level Remarks Hook over hoist LS1 Normal / Over +24V/OPEN CN11-5-1 Hook over hoist LS2 Normal / Over +24V/OPEN CN11-5-2 Gantry raise detect LS Not detect / Detect +24V/OPEN CN11-5-3 Boom B/S No.2 LS Normal / Over +24V/OPEN...
Page 533 10. ELECTRIC SYSTEM (4) ANALOGUE OUTPUT [H] Name Condition Signal level Remarks (5) DIGITAL OUTPUT [C] Name Condition Signal level Remarks Front drum raise stop Actuate / Normal +24V/OPEN CN11-6-30 Front drum lower stop Actuate / Normal +24V/OPEN CN11-6-29 Rear drum raise stop Actuate / Normal +24V/OPEN CN11-6-11...
Page 534: Shifting To Maintenance Screen
10. ELECTRIC SYSTEM 10.2.5 SHIFTING TO MAINTENANCE SCREEN 1. Push the [MENU] icon in the main screen. 2. Push [A] switch. - 1 - 1 m i n m i n 11000100000500010200 10:00 2010/12/01 3. Input the password (8 digits) with the keyboard. * In case of using capital letter, push CAPS switch.
Page 535 10. ELECTRIC SYSTEM 4. Push [OK] switch. 5. If password is correct, the maintenance menu be- comes indicated. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 10:00 2010/12/01 2010/12/01 - 1 - 1...
Page 536: Input, Output Signal
10. ELECTRIC SYSTEM 10.2.6 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. 12000-1/12000E-1 10-216 Published 10-02-13, Control #210-03...
Page 537 10. ELECTRIC SYSTEM (1) INPUT, OUTPUT CHECK OF ML (MOMENT LIMITER) (A) Select [ML SCREEN] in the menu. The first screen indicates condition of analog signal of the load detector, angle detector. Unit of indicating figure is V (volt). Refer to P.10-211 for connection and signal level. 0 V is indicated on non connected point.
Page 538: Digital Input
10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
Page 539 10. ELECTRIC SYSTEM (2) INPUT, OUTPUT CHECK OF MC1 (MAIN CON- TROLLER 1) (A) Select "MC1" screen in the menu. The first screen indicates conditions of analog sig- nal of pressure sensors, potentiometers etc. Unit of indicating figure is V (volt). As for signal name and specification, refer to P.10- 333.
Page 540 10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
Page 541 10. ELECTRIC SYSTEM (C) By pushing [NEXT], output of proportional valve be- comes indicated. Instruct value is indicated on left hand and feed- back value on right hand. 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.
Page 542 10. ELECTRIC SYSTEM (3) INPUT, OUTPUT SIGNAL CHECK OF MC2 (MAIN CONTROLLER 2) (A) Select "MC2" screen in the menu. The first screen indicates conditions of analog sig- nal of pressure sensors, potentiometers etc. Unit of indicating figure is V (volt). As for signal name and specification, refer to P.10- 337.
Page 543 10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
Page 544 10. ELECTRIC SYSTEM (C) By pushing [NEXT], output of proportional valve be- comes indicated. Instruct value is indicated on left hand and feed- back value on right hand. 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.
Page 545: Ml Function Setting
10. ELECTRIC SYSTEM 10.2.7 ML FUNCTION SETTING 1. Push [ML FUNCTION SETTING] in the mainte- nance menu. - 1 - 1 m i n m i n 2. Setting item becomes indicated. ME034 PSV MC1-D05 m i n ME093 PSV MC1-D08 19:19 2011/08/12 ME096...
Page 546 10. ELECTRIC SYSTEM (1) OPTION SETTING OF ANEMOMETER This is to set with or without wind speed meter. (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.
Page 547 10. ELECTRIC SYSTEM (2) MAKING LVL FUNCTION EFFECTIVE This is to set LVL (auto stop load ratio) effective or not effective. Refer to P.10-254 to P.10-256. LVL setting for setting procedure of LVL value. (EX) In case of making LVL function effective. (A) Push [USE OF LVL] in the menu.
Page 548 10. ELECTRIC SYSTEM (3) SETTING OF CAMERA CONNECTION This is to set with or without camera. (EX) In case camera is added to channel 1. (A) Push [CAMERA CONNECTION] in the menu. (B) Camera connection setting screen becomes indi- cated. (C) Push [Enable] of channel 1.
Page 549: Data Copy, Format
10. ELECTRIC SYSTEM 10.2.8 DATA COPY, FORMAT 1. Push [DATA COPY, FORMAT] in the maintenance menu. 2. Items become indicated. (1) ADJUSTMENT DATA READING OUT This reads out backup data in the data card into memory in the controller. Memorized data in the controller are overwritten and is erased.
Page 550 10. ELECTRIC SYSTEM (A) ADJUSTMENT DATA READING OUT This is to read out the adjusted value (backup data) in the data card to the memory in the controller. When using this function, the data in the controller be- ing used for calculation is overwritten. Be careful not to use in error.
Page 551 10. ELECTRIC SYSTEM When completed properly, the screen shown below is indicated. By pushing [OK], the screen returns to the previous one. It was completed. Push OK. After execution, if error message as shown below is indicated, data card failure (including not enough insertion) is presumed.
Page 552 10. ELECTRIC SYSTEM (B) ADJUSTMENT DATA WRITING IN This is to copy the adjustment data in the memory of the controller to the data card. * Normally whenever adjustment is done, data is copied to the card, but this is used to copy forcibly. Select [Controller ...
Page 553 10. ELECTRIC SYSTEM After execution, if error message as shown right is indicated, data card failure (including not enough insertion) is presumed. Re-insert the card and try again. By pushing [BACK], screen returns to the previous one. Adjustment data reference error. (C) ADJUSTMENT DATA FORMATTING This is to format the adjustment data in the memory in the controller.
Page 554 10. ELECTRIC SYSTEM When completed properly, the screen shown below is indicated. By pushing [OK] the screen returns to the previous one. Unless both of ML B31 and MC1 C9 lamps indicat- ed on lower part of the screen light up, the card can not be accessed and reading out would not be com- pleted properly.
Page 555: Language, Unit Setting
10. ELECTRIC SYSTEM 10.2.9 LANGUAGE, UNIT SETTING 1. Push [LANGUAGE/UNIT] in the maintenance menu. 2. Item becomes indicated. Select the required lan- guage, unit. Indicated Indicated unit language Japanese m, t ENG (ft • lbs) English feet, lbs ENG (m • t) English m, t Selected item becomes indicated in blue letter.
Page 556 10. ELECTRIC SYSTEM 10.2.10 ML ADJUSTMENT (NORMAL) 1. Push [ML ADJUSTMENT (NORMAL)] in the mainte- nance menu. 2. Adjustment menu becomes indicated. 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...
Page 557 10. ELECTRIC SYSTEM (1) ANGLE DETECTOR ADJUSTMENT Select [ANGLE DETECTOR ADJUSTMENT] in the adjustment menu. Angle detector connected to presently set attach- ment becomes indicated. (Figure below shows example of crane with aux. sheave.) In case with jib, jib angle detector becomes indicat- ed and in case with mast, mast angle detector be- comes indicated.
Page 558 10. ELECTRIC SYSTEM Touch angle indicating area. 100% Angle indicating area becomes indicated in reverse and digit input becomes possible. 100% 12000-1/12000E-1 10-238 Published 10-02-13, Control #210-03...
Page 559 10. ELECTRIC SYSTEM Measure the actual boom angle with the level gauge and angle meter and input digit with numeric key. (EX) In case of input [79.5], input [7], [9], [.] [5]. After input, push [SET]. 100% Lower the boom for more than 25 degrees and stop.
Page 560 10. ELECTRIC SYSTEM Touch the second angle indicating area. 100% Angel indicating area becomes indicated in reverse and digit input becomes possible. 100% 12000-1/12000E-1 10-240 Published 10-02-13, Control #210-03...
Page 561 10. ELECTRIC SYSTEM Measure the actual boom angle with the level gauge and angle meter and input digit with numeric key. (EX) In case of input [35.7], input [3], [5], [.] [7]. After input, push [SET]. 100% When the adjustment is properly completed, the message shown below is indicated.
Page 562 10. ELECTRIC SYSTEM 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. 100% Adjustment is failure. Push SET, and adjust it again.
Page 563 10. ELECTRIC SYSTEM Release the tension on the boom hoist rope to "ze- ro" by releasing the boom hoist rope as much as possible or by removing the load detector. Push [SET] when prepared. THE ADJUSTMENT OF THE BOOM LOAD CELL 100% Make the tension applied to the load cell become a zero.
Page 564 10. ELECTRIC SYSTEM 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 after you reconfirm whether the tension applied to the load cell is a zero.
Page 565 10. ELECTRIC SYSTEM (3) LOAD LESS ADJUSTMENT Set the load to only the hook installed. Adjust each hook position based on the table be- low. (CKE Series) Weight of hook block Type of Weight of hook block to be when load is adjusted Mode attachments entered during adjustment...
Page 566 10. ELECTRIC SYSTEM Perform this adjustment by boom lowering motion control. Adjusting points shall be max. boom (jib) angle point and min. boom (jib) angle point and random selected 5 points between them. (Be sure to set up) Close to the maximum angle First point Can be omitted...
Page 567 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. 10-247 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 568 10. ELECTRIC SYSTEM Input hook weight with digit key. Refer to the table in the previous page for hook weight to be input. (EX) In case of input [2.0], input [2], [.], [0]. After input, push [SET]. After raising the boom to almost the upper limit an- gle and then lower by about 1 degree and then stop.
Page 569 10. ELECTRIC SYSTEM Lower the boom and stop. Then push [SET]. During boom lowering motion, control the hook raising motion to keep the hook in the same height. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. By pushing [SET], message memorizing the fist point is indicated.
Page 570 10. ELECTRIC SYSTEM By pushing [SET], message memorizing the sec- ond point is indicated. Second point is memorized. After lowering the boom further, push [SET]. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. The 2nd point was memorized.
Page 571 10. ELECTRIC SYSTEM If the adjustment is properly completed, the mes- sage shown below is indicated. At the same time K1, K2 values are indicated as ad- justment result. By pushing [SET], screen returns to the previous one. Adjustment went well. Push SET.
Page 572 10. ELECTRIC SYSTEM (4) SOME LOAD ADJUSTMENT Only the different point to without load adjustment is the load value input first. The rest are same. Different point to without load adjustment ONLY is explained here. Firstly lift the weight known load. Select [SOME LOAD ADJUSTMENT] in the adjust- ment menu.
Page 573 10. ELECTRIC SYSTEM If the adjustment is properly completed, the mes- sage shown below is indicated. At the same time K3, K4 values are indicated as ad- justment result. By pushing [SET], screen returns to the previous one. 100% If the adjustment is not properly completed, the message shown below is indicated.
Page 574 10. ELECTRIC SYSTEM (5) LVL ADJUSTMENT LVL means the load ratio to stop automatically. Normally auto stop load ratio is 105% but with this function this load ratio can be changed to 90 to 110%. LVL function is only effective when "EFFECTIVE" is set in "LVL SETTING"...
Page 575 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. 10-255 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 576 10. ELECTRIC SYSTEM LVL Function The following drawings are some examples of LVL function. (A) When the LVL function is OFF. 5% Hysteresis If the loading ratio is 105% or more while the LVL function is not actuated, operation toward the haz- Stop ardous side is automatically stopped.
Page 577 10. ELECTRIC SYSTEM (6) WORK RADIUS ADJUSTMENT This is used when difference between the indicated work radius and the actual work radius is large due to the boom deflection etc. Ensure to check if there is any error in angle indication. If error is larger than 0.3 degrees carry out angle adjust- ment first.
Page 578 10. ELECTRIC SYSTEM 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]. 12000-1/12000E-1 10-258 Published 10-02-13, Control #210-03...
Page 579 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]. 10-259 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 580 10. ELECTRIC SYSTEM If the adjustment is properly completed, the mes- sage shown below is indicated. By pushing [SET], screen returns to the previous one. Adjustment went well. Push SET. If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting.
Page 581 10. ELECTRIC SYSTEM (7) SWING ANGLE ADJUSTMENT Select [SWING ANGLE ADJUSTMENT] in the ad- justment menu. Face the crane toward front (idler side of crawler) and fix with the swing lock pin. Push [FR]. If the indication changes from [FR] to [OK], front side adjustment is properly completed.
Page 582 10. ELECTRIC SYSTEM Push [RE]. If indication changes from [RE] to [OK], rear side adjustment is properly completed. 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.
Page 583 10. ELECTRIC SYSTEM To rest adjusted value, push [A]. "OK" is indicated on both [FR] and [RE] and the val- ue is reset. 10-263 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 584: 11Ml Adjustment (Temporary)
10. ELECTRIC SYSTEM 10.2.11 ML ADJUSTMENT (TEMPORARY) This adjustment is used to match with the load tempo- rary when error exists in load indication due to load de- tector abnormality etc. There is no limit in adjustment value and adjustment would become possible even when error occurs in with- out load / with load adjustment in "10.2.10 ML ADJUST- MENT (NORMAL)".
Page 585: 12Operation Progress
10. ELECTRIC SYSTEM 10.2.12 OPERATION PROGRESS 1. Push [OPERATION PROGRESS] in the mainte- nance menu. Information of internal operation indicated. Symbols Details Tare weight component during main winch lifting with current radius Tare weight component during aux. winch lifting with current radius Tare weight component during third winch lifting with current radius Load coefficient during main winch lifting with current radius Load coefficient during aux.
Page 586 10. ELECTRIC SYSTEM EXAMPLE OF USING OPERATION SCREEN The actual load W can be indicated by the formula shown below. Hoist guy line tension Dead weight component (M.A.R) Load-less adjustment value (Span) Load-less adjustment value (Shift) F - (FO X k1 + k2) Actual load W = (δ...
Page 587: 13Version Information
10. ELECTRIC SYSTEM 10.2.13 VERSION INFORMATION 1. Push [VERSION INFORMATION] in the mainte- nance menu. Each part number and version of ML program, monitor, MC1 program, MC2 program, ML data are indicated. M/L Program Version M/L Program Part No. Monitor Program Version Monitor Program Part No.
Page 588: 14Failure History
10. ELECTRIC SYSTEM 10.2.14 FAILURE HISTORY 1. Push [FAILURE HISTORY] in the maintenance menu. 2. Items are indicated. (1) ML FAILURE 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.
Page 589 10. ELECTRIC SYSTEM DELETING FAILURE HISTORY When the failure record is to be deleted, push [A]. The message below becomes indicated. Data is erased. 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].
Page 590 10. ELECTRIC SYSTEM (2) MC1 FAILURE HISTORY Push [MC1 FAILURE HISTORY] in the menu. Past failures become indicated from the latest one in order to max. 200 items (10 item X 20 page). By [A] page can be scrolled up and by [B] page can be scrolled down.
Page 591 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. 10-271 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 592: 15Adjustment Data
10. ELECTRIC SYSTEM 10.2.15 ADJUSTMENT DATA 1. Push [ADJUSTMENT DATA] in the maintenance menu. Adjustment data menu becomes indicated. 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 (1) ANGLE SENSOR...
Page 593 10. ELECTRIC SYSTEM (B) ADJUSTMENT DATA CHANGE In case of changing adjustment data, touch the digit area to be changed. Touched area becomes reverse indication and digit input becomes possible. ADJUSTMENT VALUE ANGLE SENSOR 100% Input digit with digit key. In case of input [1.103], input [1], [.], [1], [0], [3].
Page 594 10. ELECTRIC SYSTEM The message below becomes indicated. Push [OK]. 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% 12000-1/12000E-1 10-274...
Page 595 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. 10-275 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 596 10. ELECTRIC SYSTEM (2) LOAD DETECTOR ZERO ADJUSTMENT (A) ADJUSTMENT DATA INDICATION Push [Zero offset value of load cell] in the menu. LOAD DETECTOR ZERO POINT 100% Table of zero point adjustment data of load detector is indicated. They are indicated by load cell voltage value at time of zero adjustment.
Page 597 10. ELECTRIC SYSTEM (3) WITHOUT LOAD / WITH LOAD (TEMPORARY) (A) ADJUSTMENT DATA INDICATION Push [F0/d (temporary)] in the menu. 100% Table of adjustment data becomes indicated. M : Front lifting mode adjustment data A : Rear lifting mode adjustment data R : Third lifting mode adjustment data No.
Page 598 10. ELECTRIC SYSTEM (4) WITHOUT LOAD / WITH LOAD (NORMAL) (A) ADJUSTMENT DATA INDICATION Push [F0/d (normal)] in the menu. 100% Table of adjustment data becomes indicated. On this adjustment, 10 type of boom length adjust- ment are possible on each group of 1 to 30. At first, group 1 becomes indicated.
Page 599 10. ELECTRIC SYSTEM (5) SWING RADIUS (A) ADJUSTMENT DATA INDICATION Push [RADIUS] in the menu. 100% Table of adjustment data becomes indicated. This adjustment also consists of group 1 to 30 and the first screen indicates group 16 to 30. By pushing [] group 16 to 30 becomes indicated.
Page 600: 16Download Ml Program
10. ELECTRIC SYSTEM 10.2.16 DOWNLOAD ML PROGRAM 1. Take out data CF card from ML controller and insert CF card with new program filed in. * It is possible to write in by filing the program to data CF card. E Model will be need turn on to "H3"...
Page 601 10. ELECTRIC SYSTEM During download, 7 segment display of the control- ler changes as shown below. This may vary due to version of firmware (internal program). Blinking Approx. 10 seconds 5. When End is indicated, re-writing is completed. 6. Turn OFF the key switch. 7.
Page 602: 17Download Of Monitor Program
10. ELECTRIC SYSTEM 10.2.17 DOWNLOAD OF MONITOR PROGRAM 1. Insert the CF card with new program filed in to the CF card throttle on the back face of the monitor. * Ensure to close the cover. FRONT VIEW LEFT VIEW BACK VIEW CF CARD THROTTLE BOTTOM VIEW...
Page 603 10. ELECTRIC SYSTEM 4. Menu becomes indicated on the lower part of the screen. Select [CF/USB]. - 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 5.
Page 604 10. ELECTRIC SYSTEM 6. If the error as shown below is indicated, check for in- serted condition of 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...
Page 605 10. ELECTRIC SYSTEM 8. Select [START]. 9. Select [YES]. 10-285 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 606 10. ELECTRIC SYSTEM 10. Download starts. Write in [OS data], [System / Project data] in its or- der. If properly completed, message as shown bel- low becomes indicated. Push [Back]. OS data write completed (4/4). System/Project data write completed (80/80). SRAM data write completed (2/2).
Page 607 10. ELECTRIC SYSTEM 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. 10-287 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 608: Main Controller
10. ELECTRIC SYSTEM 10.3 MAIN CONTROLLER 10.3.1 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”...
Page 609: Composition Of System
10. ELECTRIC SYSTEM 10.3.2 COMPOSITION OF SYSTEM 1. SYSTEM COMPOSITION CHART (INPUT) (OUTPUT) SENSOR GRIP THROTTLE PROP. V. OUTPUT SENSOR SWITCH SOL. V. OUTPUT RELAY SWITCH / TRIMMER OTHER OUTPUT ENGINE CONTROL (INPUT) ENGINE SWING CONTROL MONITOR STOP SIGNAL PUMP CONTROL RS232C ENERGY SAVING RS232C...
Page 610: Function Of Main Controller
10. ELECTRIC SYSTEM 10.3.3 FUNCTION OF MAIN CONTROLLER CONTROL FUNCTION ACCELERATOR CONTROL HORSE POWER CONTROL WINCH MOTOR SPEED CONTROL SWING COUNTERFORCE SWING SPEED CONTROL SWING AUTO STOP WINCH CONTROL BOOST CONTROL 10 BOOM STOP CONTROL 11 - 12 - 13 FRONT/REAR HOIST STOP 14 MOTOR TILT ANGLE CONTROL 15 HOOK OVER HOIST CONTROL 16 DRUM ROTATION DETECT GRIP CONTROL...
Page 611: Accelerator Control
10. ELECTRIC SYSTEM 1. ACCELERATOR CONTROL (1) Accelerator control This provides command to ECU (engine control) based on input of grip throttle or foot throttle. In case of both throttles are equipped, throttle hav- ing larger amount of command has priority. To make foot throttle effective, option setting and adjustment is required.
Page 612 10. ELECTRIC SYSTEM (2) Power control 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. 12000-1/12000E-1 10-292 Published 10-02-13, Control #210-03...
Page 613 10. ELECTRIC SYSTEM 2. HORSE POWER CONTROL This is to control pump by calculating target speed from grip throttle and by matching with engine actu- al speed. 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.
Page 614 10. ELECTRIC SYSTEM 3. WINCH MOTOR SPEED CONTROL 12000-1/12000E-1 10-294 Published 10-02-13, Control #210-03...
Page 615: Motor Control
10. ELECTRIC SYSTEM (1) Front/Rear/Third (option) drum speed variable Max. current of remo-con prop. valve and motor control prop. valve is controlled as shown above. Priority order is as follows. Remo-con prop. valve Front, rear, third (option) stop, Lever interlock > Front, rear speed reducing >...
Page 616 10. ELECTRIC SYSTEM (2) Boom drum speed control In case of low engine speed, when engine speed is intended to raise by characteristic (a), it becomes closer to characteristic (b). If the trimmer is set to maximum value, the prop. valve becomes full open and the main valve open- ing becomes maximum.
Page 617 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) 10-297 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 618 10. ELECTRIC SYSTEM 6. SWING SPEED CONTROL CURRENT (mA) 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.
Page 619 10. ELECTRIC SYSTEM 7. SWING LIMIT CONTROL (1) Swing deceleration Swing stop prop. valve Based on swing deceleration signal (R and L) input (R and L) value (31  0), right swing / left swing stop prop. (mA) ENGINE HIGH valve output current is controlled.
Page 620 10. ELECTRIC SYSTEM 8. WINCH CONTROL (1) Control lever neutral mode selection (2) Winch operation solenoid valve control 12000-1/12000E-1 10-300 Published 10-02-13, Control #210-03...
Page 621 10. ELECTRIC SYSTEM (A) When power is supplied The machine always starts running in the neutral brake mode. (B) Switching from the brake mode to the free fall mode. Condition Output The free fall lock switch is set released. Select the free mode. Free release "ON"...
Page 622 10. ELECTRIC SYSTEM (E) Emergency solenoid valve control For the front drum, when either of the conditions be- low is satisfied, ESM (SOL-19) is energized to pre- vent a drop of a lifted load. 1) The clutch pressure is reduced although the brake mode is selected.
Page 623 10. ELECTRIC SYSTEM (3) Free fall acceleration 10-303 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 624 10. ELECTRIC SYSTEM The falling speed can be increased by idling the motor during the free fall. The speed is controlled as shown in the table be- low. Conditions Procedures 1. Free fall mode is selected. 2. The control lever is at the neutral position. •...
Page 625: Boost Control
10. ELECTRIC SYSTEM 9. BOOST CONTROL To prevent a momentary drop of a lifted load, apply a constant boost to the motor while the lever is in the neutral position. The boost solenoid valve is controlled as shown in the table below. Lever Boost solenoid valve Neutral...
Page 626 10. ELECTRIC SYSTEM 10. BOOM STOP CONTROL BOOM LOWER BOOM RAISE PROPORTIONAL VALVE PROPORTIONAL VALVE CURRENT CURRENT ENGINE HIGH SPEED (mA) (mA) ENGINE LOW SPEED STOP STOP 1.5 sec TIME BOOM LOWER STOP SIGNAL INPUT BOOM RAISE STOP BOOM RAISE SIGNAL INPUT DECELERATION SIGNAL INPUT...
Page 627 10. ELECTRIC SYSTEM 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 10-307 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 628 10. ELECTRIC SYSTEM 14. MOTOR TILT ANGLE CONTROL 12000-1/12000E-1 10-308 Published 10-02-13, Control #210-03...
Page 629 10. ELECTRIC SYSTEM (1) During raising or lowering at brake mode or free mode, current of each motor tilt angle prop. valve is controlled as follows. (Trimmer control) (A) Current of motor tilt angle prop. valve varies based on lever motion and speed variable trimmer posi- tion.
Page 630 10. ELECTRIC SYSTEM (B) Maximum current of motor tilt angle prop. valve is controlled by no load engine speed (Command vol- ume by grip). MAX CURRENT OF TILT ANGLE PROPORTIONAL VALVE (mA) NO LOAD ENGINE SPEED 1600 (2) When auto-stopped In case of drum auto-stop, output is to be 200 mA.
Page 631 10. ELECTRIC SYSTEM 15. HOOK OVER HOIST CONTROL (1) Action at hook over hoist Output of corresponding remo-con. valves shall be 150 mA when hook over hoist notice is received with CAN transmission from ML. At the same time, stop signal from ML is input and stop action is done.
Page 632 10. ELECTRIC SYSTEM (2) Action at hook over hoist When hook over hoist is released at hook over hoist occurs, the following action is done. Front, rear and third (jib) raise remo-con. prop. valve command current are set to inching speed level.
Page 633 10. ELECTRIC SYSTEM 16. DRUM ROTATION DETECT GRIP CONTROL (OPTION) This can control the grip solenoid based on drum rotation sensor input. 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.
Page 634 10. ELECTRIC SYSTEM 17. FRONT/BOOM PUMP CONTROL 12000-1/12000E-1 10-314 Published 10-02-13, Control #210-03...
Page 635 10. ELECTRIC SYSTEM (1) Feathering control : This is to control the tilt angle proportional (prop.) valve of each pump based on lever motion. Lever motion Pump Prop. valve Front Rear Boom Propel L Propel R Main F Main pump Release Release Release...
Page 636 10. ELECTRIC SYSTEM 18. HEIGHT METER (1) Drum rotation amount is detected by pulse counting with drum rotation sensor. (2) When raise pressure sensor input exists, variation is counted on raising side, and on the other case, vari- ation is counted as + or - on lowering side. (3) Layer no.
Page 637 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. 10-317 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 638 10. ELECTRIC SYSTEM 19. LEVER INTERLOCK CONTROL 12000-1/12000E-1 10-318 Published 10-02-13, Control #210-03...
Page 639 10. ELECTRIC SYSTEM This is to prevent drum unexpected rotation with engine start when the lever is in operating position and the function lock lever is in work position. (1) Before engine start Each prop. valve current is minimum. (150 mA) Pilot cut relay RL-13 is to be output.
Page 640 10. ELECTRIC SYSTEM 20. DPF REGENERATION CONTROL Regeneration starts when more than certain amount of soot is accumulated in DPF (Diesel Par- ticulate Filter). Counting of soot accumulated volume and regener- ation start timing etc are all done by engine 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...
Page 641 10. ELECTRIC SYSTEM (1) Auto regeneration Between 0 and 4 soot gauge bar, the following re- quests are issued from engine ECU. Long time idling : If low idling, low load work is continued, request is issued from ECU. Idling speed is raised (1,000 min ) and load valve becomes ON.
Page 642 10. ELECTRIC SYSTEM (2) Manual regeneration Between 5 and 9 soot gauge bar, the following re- quests are issued from engine ECU. Manual regeneration request : After engine ECU request, regeneration switch and cancel switch become indicated on the main moni- tor.
Page 643 10. ELECTRIC SYSTEM Manual regeneration is possible at soot gauge up to 7 bar. When soot gauge becomes 9 bar, forcible regener- ation starts by detecting no control condition. The content of action is as same as manual regen- eration and action starts without requesting permit to crane operator.
Page 644 10. ELECTRIC SYSTEM 21. INDEPENDENT/CONFLUENCE SELECT CONTROL (IND./CONF. SELECT FUNCTION EQUIPPED MODEL ONLY GK, HF, GN, JD) This is to make selection of independence and con- fluence circuit of front and rear possible by select switch. 12000-1/12000E-1 10-324 Published 10-02-13, Control #210-03...
Page 645 10. ELECTRIC SYSTEM (1) Front, rear mid detent When selecting confluence circuit, mid detent func- tion of front and rear drum to ON condition. The detent is of electro-magnetic type and detent force changing becomes possible by adjusting in the main monitor. At tower configuration, both of front and rear be- come independence mode.
Page 646 10. ELECTRIC SYSTEM 22. G WINCH CONTROL GK, HF, GN, JD Gr. ONLY 12000-1/12000E-1 10-326 Published 10-02-13, Control #210-03...
Page 647 10. ELECTRIC SYSTEM (1) G winch mode selecting This is to make individual select switch, which is set individually for front/rear based on input of G winch select switch effective. When individual switch is input, G winch condition is selected based on the conditions shown in the ta- ble.
Page 648 10. ELECTRIC SYSTEM 23. G ENGINE CONTROL (1) G engine function select switch After inputting into select switch, check is made on each lever control. If neutral Q max cut solenoid is energized. Input Output G engine Lever condition Q max cut SOL Engine speed control function select At G engine...
Page 649 10. ELECTRIC SYSTEM 24. AIS CONTROL 10-329 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 650 10. ELECTRIC SYSTEM The above circuit diagram is extract from the main diagram for only related portion of this control. (engine stop/re-start) When the condition bellows are met, engine stops automatically. Engine stop condition Meeting condition ML permit condition Configuration condition : ML permit ML permit condition Other than assembly/ disassembly, stowing...
Page 651 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 10-331 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 652: 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 12000-1/12000E-1 10-332 Published 10-02-13, Control #210-03...
Page 653: Specifications Of Main Controller Output
10. ELECTRIC SYSTEM 10.3.5 SPECIFICATIONS OF MAIN CONTROLLER OUTPUT 1. SPECIFICATIONS OF MAIN CONTROLLER 1 INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Range Input voltage A/D Spare A/D Spare Fr. drum motor speed adjusting trimmer 0 to FULL 0.43 to 5 V Re.
Page 654 10. ELECTRIC SYSTEM (2) DIGITAL INPUT [B] Name Status Signal level ECU status signal Power ON/OFF Ground (15 k Ω )/OPEN Engine hyd. pressure PSW Engine Stop/Work Ground (15 k Ω )/OPEN CB/W detect Detection/Non-detection Ground (15 k Ω )/OPEN Clogging of Engine air cleaner Clogging/Normal Ground (15 k Ω...
Page 655 10. ELECTRIC SYSTEM Name Status Signal level Hyd. oil heat LS (OPT) Energized/De-energized +24 V/OPEN Pump Qmax cut solenoid (FB) Energized/De-energized +24 V/OPEN Remote control connection signal Connected/Unconnected +24 V/OPEN Swing warning (flasher) Flasher ON/OFF +24 V/OPEN Swing warning (buzzer and flasher) Buzzer and flasher ON/OFF +24 V/OPEN DPF regeneration (FB)
Page 656 10. ELECTRIC SYSTEM (5) DIGITAL OUTPUT [C] Name Status Signal level Fr. drum motor CLM-SOL Energized/De-energized GND/OPEN Fr. drum motor ESM-SOL Energized/De-energized GND/OPEN Re. drum motor CLA-SOL Energized/De-energized GND/OPEN Re. drum motor ESA-SOL Energized/De-energized GND/OPEN Third drum motor CLT-SOL Energized/De-energized GND/OPEN Third drum motor EST-SOL Energized/De-energized...
Page 657 10. ELECTRIC SYSTEM 2. SPECIFICATIONS OF MAIN CONTROLLER 2 INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Range Input voltage Spare A/D Spare A/D Fr. drum motor tilt control press. sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Re. drum motor tilt control press. sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Third drum motor tilt control press.
Page 658 10. ELECTRIC SYSTEM (2) DIGITAL INPUT [B] Name Status Signal level C/W detect 3 GND (15 k Ω )/OPEN C/W detect 4 GND (15 k )/OPEN Ω C/W detect 5 (C4, C5) GND (15 k Ω )/OPEN C/W detect 6 (C5) GND (15 k )/OPEN Ω...
Page 659 10. ELECTRIC SYSTEM Name Status Signal level +24 V/OPEN +24 V/OPEN ML bypass (CR) ON/OFF +24 V/OPEN ML bypass (JIB) ON/OFF +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN (3) ANALOGUE OUTPUT [H] Name Status Signal level (4) PROPORTIONAL VALVE OUTPUT [D] Name Output current Dither...
Page 660 10. ELECTRIC SYSTEM (5) DIGITAL OUTPUT [C] Name Output current Dither GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN (300 mA) GND/OPEN (300 mA) GND/OPEN (300 mA) GND/OPEN GND/OPEN GND/OPEN GND/OPEN (PWM) GND/OPEN (PWM) Fr. drum motor boost SOL Boost/Normal +24 V/OPEN Oil cooler electric motor ON/OFF GND/OPEN...
Page 661: Arrangement Of Main Controller Connector Pin
10. ELECTRIC SYSTEM 10.3.6 ARRANGEMENT OF MAIN CONTROLLER CONNECTOR PIN 1. ARRANGEMENT OF MC1 CONNECTOR PIN Connector No. Pin No. Port name Function Specifications Ref. CN101 +5VA Spare Spare TXD2 Spare RXD2 Spare CANH1 CAN1_H CANL1 CAN1_L CAN1 termination Spare CAN1 termination Spare CANH2...
Page 662 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Ref. CN102 +5VA Fr. drum motor speed adjusting trimmer +5VA Re. drum motor speed adjusting trimmer +5VA Third drum motor speed adjusting trimmer +5VA Boom drum motor speed adjusting trimmer Resistance input Spare...
Page 663 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN104 Grounded input (15 K Ω ) ECU signal Qmax cut solenoid detection pressure Power shift pressure sensor +5V for supply voltage monitoring Grounded input (15 K Ω ) Engine hyd.
Page 664 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN105 +24 V 1 Battery (+) Power supply +24 V Power supply +24 V Power supply Grounded input (3.3 K Ω ) Fr. drum brake cooling oil temperature Grounded input (3.3 K Ω...
Page 665 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN106 +24 V 1 Battery (+) Fr. drum middle detent Re. drum middle detent D11+ Left swing stop proportional valve D11- Main pump tilt control prop. valve 1 Main pump tilt control prop.
Page 666 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN107 D/O FB Controller ID 1 D/O FB Controller ID 2 +24 V input G mode/Normal selection +24 V input G winch (Fr.) +24 V input G winch (Re.) +24 V input G winch (main) D/O FB...
Page 667 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN108 Grounded output Fr. drum motor CLM-SOL Grounded output Fr. drum motor ESM-SOL Grounded output Re. drum motor CLA-SOL Grounded output Re. drum motor ESA-SOL Grounded output Third drum motor CLT-SOL D/O FB Fr.
Page 668 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN109 +24 V output Battery relay energizing Grounded output ML bypass reset Grounded output Solenoid cut relay energizing Grounded output Engine warning output Grounded output AIS air con. ON relay energizing Grounded output Swing neutral brake selection +24 V output...
Page 669 10. ELECTRIC SYSTEM 2. ARRANGEMENT OF MC2 CONNECTOR PIN Connector No. Pin No. Port name Function Specifications Ref. CN111 +5VA Vacancy Vacancy TXD2 Vacancy RXD2 Vacancy CANH1 CAN1_H CANL1 CAN1_L CAN1 termination Vacancy CAN1 termination Vacancy CANH2 CAN2_H CANL2 CAN2_L Vacancy Vacancy Vacancy...
Page 670 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN112 +5VA Fr. drum motor tilt control pressure sensor +5VA Re. drum motor tilt control pressure sensor +5VA Third drum motor tilt control pressure sensor +5VA A/D spare Resistance input Fuel level +5VA Confluence/Independence selection...
Page 671 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN114 Grounded input (15 K Ω ) C/W detect 3 Boom drum raise pressure sensor Boom drum lower pressure sensor Fr. drum raise pressure sensor Grounded input (15 K Ω ) C/W detect 4 Fr.
Page 672 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN115 +24 V 1 Battery (+) Power supply +24 V Power supply +24 V Power supply Grounded input (3.3 K Ω ) Fr. drum brake cooling oil temperature Grounded input (3.3 K Ω ) Re.
Page 673 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN116 +24 V 1 Battery (+) Power supply Re. drum lower proportional valve Third drum raise proportional valve (option) D11+ Re. drum motor tilt control prop. valve D11- Third drum lower prop.
Page 674 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN117 D/O FB Controller ID 1 D/O FB Controller ID 2 +24 V input Fr. drum raise stop +24 V input Fr. drum lower stop +24 V input Re.
Page 675 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN118 Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare D/O FB DPF load solenoid D/O FB Spare D/O FB Spare D/O FB Spare Grounded output Spare...
Page 676 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN119 +24 V output Fr. drum motor boost SOL Grounded output Oil cooler electric motor Confluence/Independence selection Grounded output solenoid (Fr. drum) Confluence/Independence selection Grounded output solenoid (Re. drum) Grounded output DPF load solenoid Grounded output...
Page 677: Adjustment Of Main Controller
10. ELECTRIC SYSTEM 10.3.7 ADJUSTMENT OF MAIN CONTROLLER 1. Model number setting Perform this setting only when controller is re- placed. If model setting is not properly done, machine does not work properly. Take extra care. (1) Turn the engine key ON. (2) Select the screen as follows.
Page 678 10. ELECTRIC SYSTEM (3) Select the indicated model group. (4) Push "OK" after model group is selected. 100% Unless "OK" is pushed, selection becomes ineffec- tive. 2. Option setting (1) Turn the engine key "ON". (2) Select the screen as follows. Main screen (a) ...
Page 679 10. ELECTRIC SYSTEM 3. Adjustment of grip throttle and foot throttle. (1) Turn the engine key "ON". (2) Select the screen as follows. Main screen (a)  (b)  Password input  MC adjustment  Grip adjustment (3) The screen changes to adjustment screen. Push adjustment start button (d).
Page 680 10. ELECTRIC SYSTEM 5. Adjusting of inclination meter Place the main machinery on the horizontal ground before adjustment using the level gauge etc. (1) Turn the engine key ON. (2) Select the screen as follows. Main screen (a)  (b)  Password input ...
Page 681: Controller Malfunction Emergency Measures
10. ELECTRIC SYSTEM 10.3.8 CONTROLLER MALFUNCTION EMERGENCY MEASURES When the controller is malfunctioned, as an emergency measure, set the BYPASS switch for the main controller in the left side stand to the "bypass" position. The crane operation becomes possible. Automatic stop is actuated by the load safety device even when the BYPASS switch is actuated.
Page 682 10. ELECTRIC SYSTEM 12000-1/12000E-1 10-362 Published 10-02-13, Control #210-03...
Page 683: Air Conditioner
11. AIR CONDITIONER 11-1 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 684 11. AIR CONDITIONER 12000-1/12000E-1 11-2 Published 10-02-13, Control #210-03...
Page 685 11. AIR CONDITIONER 11.1 AIR CONDITIONER 1. NAME OF THE AIR CONDITIONER PARTS AIR CON. CONTROL PANEL INTERNAL AIR FILTER BLOW OUT OPENING BLOW OUT OPENING BLOW OUT OPENING BLOW OUT OPENING OPEN AIR BLOW OUT FILTER OPENING AIR CONDITIONER UNIT 2.
Page 686 11. AIR CONDITIONER 3. FUNCTION OF EACH CONTROL DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) ON/OFF SWITCH (1) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (1) ON/OFF SWITCH (POWER SWITCH) It turns ON or OFF the air conditioner.
Page 687: Defroster Switch
11. AIR CONDITIONER (5) IN-OUT AIR SELECTOR SWITCH internal air circulation (R/F SWITCH) Every time when this switch is pushed, internal air / out air take in open air alternate and it is indicated (b) on LCD dis- (b) INDICATION CONTENT play.
Page 688: Air Conditioner Control
11. AIR CONDITIONER 4. AIR CONDITIONER CONTROL (1) To stop or to start air conditioner : Push ON/OFF SWITCH (1). IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) ON/OFF SWITCH (1) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (2) To cool :...
Page 689 11. AIR CONDITIONER (3) To warm : IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (A) Push the TEMPERATURE CONTROL SWITCH (4) to indicate on the LCD display. (d) TEMPERATURE CONTROL INDICATION (B) Push the AIR VOLUME SELECTOR SWITCH (3) for required air volume.
Page 690 11. AIR CONDITIONER (4) To defrost on the windscreen : DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (A) Push the TEMPERATURE CONTROL SWITCH (4) to indicate (d) on the LCD display.
Page 691 11. AIR CONDITIONER (5) To defog on the windscreen : DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) BLOW OUT OPENING AIR VOLUME SELECTOR SWITCH (6) SELECTOR SWITCH (3) (A) Push the AIR VOLUME SELECTOR SWITCH (3) for required air volume. (B) Push the DEFROSTER SWITCH (7) to change the blow out opening to DEF position (c).
Page 692 11. AIR CONDITIONER This page is blank for editing convenience. 12000-1/12000E-1 11-10 Published 10-02-13, Control #210-03...
Page 693: Parts Illustration
11. AIR CONDITIONER 11.2 PARTS ILLUSTRATION 11-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 694 11. AIR CONDITIONER 12000-1/12000E-1 11-12 Published 10-02-13, Control #210-03...
Page 695 11. AIR CONDITIONER 1. EVAPORATOR 21. LEVER (MO2) 41. FAN DRIVER 2. ACTUATOR 22. MODE CAM 42. UPPER BLOWER CASE 3. OUT AIR INTAKE PACKING 23. ROD AC 43. LOWER BLOWER CASE 4. FRONT UNIT CASE 24. AM ROD 44. BLOWER PACKING 5.
Page 696: Disassembly And Assembly Of The Unit
11. AIR CONDITIONER 11.3 DISASSEMBLY AND ASSEMBLY OF THE UNIT 11.3.1 REMOVAL OF THE BLOWER UNIT 1. Remove the various connectors attached to the in- out air motor actuator, blower motor and blower IN-OUT AIR MOTOR ACTUATOR CONNECTOR controller and harnesses attached to the blower case.
Page 697: Replacing The Blower Motor
11. AIR CONDITIONER 11.3.2 REPLACING THE BLOWER MOTOR 1. Remove the coolant hose coolant between the BLOWER CASE blower motor and the blower case. 2. Remove three of the cross head screw (Phillips) N5 X 16 (W) which are tightened from under the blower unit case and pull the blower unit out.
Page 698: Removal Of The Air-Con Unit Case-Front And- Rear
11. AIR CONDITIONER 11.3.5 REMOVAL OF THE AIR-CON UNIT CASE-FRONT AND- REAR 1. Remove the mode motor actuator and the evapora- tor sensor connector. UNIT CASE REAR 2. Remove the mode rod from the rod holder which is installed on the lever MAL1 of the mode motor ac- MODE ROD tuator.
Page 699: Replacing The Evaporator And Expansion Valve
11. AIR CONDITIONER 11.3.6 REPLACING THE EVAPORATOR AND EXPANSION VALVE 1. Pull out the evaporator assy from the case-lower with the case insulation material and the expansion EVAPORATOR valve attached. 2. After the evaporator assy is removed, then pull out O-RING the evaporator sensor and sensor holder as one EXPANSION...
Page 700: Replacing The Motor Actuator
11. AIR CONDITIONER 11.3.8 REPLACING THE MOTOR ACTUATOR 1. REPLACING THE MODE MOTOR ACTUATOR MODE ROD Remove the connector of the motor actuator. Re- UNIT CASE REAR move the mode rod which connects the motor actu- ator and the mode cam from the rod holder. Remove three of the cross head screw (Phillips) N4 X 30 (T1) which hold the motor actuator and re- move the motor actuator from the unit while the rod...
Page 701: Fault Detection From The Control Panel Indication
11. AIR CONDITIONER 11.4 FAULT DETECTION FROM THE CONTROL PANEL INDICATION 11.4.1 GENERAL When there is any fault in the input circuit of the control- ler of the motor actuator drive line or each sensor, fault detection is indicated. Once the fault is detected, fault detection is not reset even the fault returns to normal.
Page 702: Basic System Of Hvac
11. AIR CONDITIONER 11.5 BASIC SYSTEM OF HVAC This is the built in type air con. unit with evaporator, heater core and blower as one package and generate cool and warm air. 1. AIR CYCLE • HEATER The unit takes internal air of the cab or open air from the intake port and have them passed through the air filter and send them to the heater core of the air conditioner unit to exchange heat and send the...
Page 703 11. AIR CONDITIONER 3. FAN DRIVER The fan driver receives the control signal from the control unit and control the fan motor speed. NORMAL CONDITION TERMINAL NO. CONTINUITY – YES (4.7 k ± 5%) TESTER – – YES (DIODE PARALLEL FORWARD DIRECTION) (1) Remove the connector of the blower amplifier.
Page 704 11. AIR CONDITIONER 7. INSPECTION POINTS OF THE RELAY (1) RELAY (2) COIL RESISTANCE : 320 (3) VOLTAGE : DC20 V to 30 V (4) Note : This relay has coil polarity. (5) Inspection : Check the continuity between the ter- minal 3 to 4 under the following condition.
Page 705: Evaporator Sensor
11. AIR CONDITIONER 10. BLOW OUT MODE ACTUATOR The blow out mode actuator is installed in the back side of the air conditioner unit and opens or closes the blow out damper through the linkage. The bow out mode actuator has the potentiometer in its inside which is controlled by the shaft move- ment of the actuator.
Page 706 11. AIR CONDITIONER 12. DUAL PRESSURE SWITCH The dual pressure switch is installed in the receiver dryer and protect the cooling cycle by opening its contact and cutting the power supply to the com- pressor when the high pressure side of cooling be- comes malfunction (high pressure faulty, low pressure faulty).
Page 707: Recharging Of The Coolant
11. AIR CONDITIONER 11.6 RECHARGING OF THE COOLANT 11.6.1 CAUTION AT WORK 1. Make sure that the work is done by the specialist. Recharging work consist of high pressure gas han- dling. Make sure that the work is done with the spe- cialist who is familiar with the work.
Page 708 11. AIR CONDITIONER (5) Flaw, indent mark or deformation may decrease the strength of the bottle. Be careful on this point. (A) Do not drop or hit the bottle. (B) Take care in loading, transporting and unloading the bottles or packing case containing the bottles. Handle with care and do not drop or throw them.
Page 709: Work Procedure
11. AIR CONDITIONER 11.6.2 WORK PROCEDURE 1. Recharging work of the coolant into the air condition- er is divided into "Vacuuming work" and "Gas re- charging work". (1) "Vacuuming work" is to delete the water in the air conditioner piping completely. Even a slight amount of water is left in the piping, it will be frozen in the small holes in the expansion valve during the operation and may cause piping...
Page 710 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 12000-1/12000E-1 11-28 Published 10-02-13, Control #210-03...
Page 711: Recharging Procedure
11. AIR CONDITIONER 11.6.3 RECHARGING PROCEDURE VACUUMING WORK 1. CONNECTION OF GAUGE MANIFOLD HIGH PRESSURE LOW PRESSURE GAUGE GAUGE (1) Close the high pressure valve (HI) and low pres- GAUGE MANIFOLD sure valve (LO) of the gauge manifold. LOW PRESSURE HIGH PRESSURE (2) Connect the charging hose (Red and Blue) to the VALVE (CLOSE)
Page 712 11. AIR CONDITIONER 2. VACUUMING LOW PRESSURE (CLOSE) (1) Open the high pressure valve (HI) and low pressure VALVE (OPEN) valve (LO) of the gauge manifold. HIGH PRESSURE 30 minutes (CLOSE) VALVE (OPEN) or more (2) Turn ON the switch of the vacuum pump and con- tinue vacuuming work for more that 30 minutes.
Page 713: Air Purge
11. AIR CONDITIONER GAS RECHARGING WORK 1. RECHARGE FROM THE HIGH PRESSURE SIDE (1) Disconnect the charging hose (yellow) of the gauge manifold from the vacuum pump and reconnect it to AIR PURGE the service bottle after the vacuum pump is com- CLOSE pleted.
Page 714 11. AIR CONDITIONER 3. CHARGING FROM THE LOW PRESSURE SIDE (1) Make sure that the valves for high pressure side, low pressure side and service bottle are all closed. LOW PRESSURE HIGH PRESSURE VALVE (CLOSE) VALVE (CLOSE) (2) Start the engine and set the speed to 1400 to 1600 (CLOSE) (OPEN) (Close firmly)
Page 715 11. AIR CONDITIONER 4. GUIDEPOST OF RECHARGING COOLANT AMOUNT • JUDGEMENT FROM SIGHT GLASS VIEW OF THE RECEIVER DRYER JUDGEMENT FROM SIGHT GLASS VIEW OF THE RECEIVER DRYER IN CASE OF After A/C turned on, bubbles appear a little, hereafter PROPER CHARGE it becomes transparent, and shows milk-white.
Page 716 11. AIR CONDITIONER This page is blank for editing convenience. 12000-1/12000E-1 11-34 Published 10-02-13, Control #210-03...
Page 717: Electric Wiring Diagram
11. AIR CONDITIONER 11.7 ELECTRIC WIRING DIAGRAM YAZAKI YAZAKI FUSE YAZAKI YAZAKI FUSE FUSE FUSE FUSE YAZAKI PRESSURE SWITCH (RECEIVER DRYER) EVAPORATOR SENSOR YAZAKI BLOWER OFF RELAY COMPRESSOR MOTOR ACTUATOR (AIR MIX) BLOWER MOTOR MOTOR ACTUATOR CONDENSOR FAN MOTOR RELAY (MODE) RATED : 24V 10A BLOWER AMPLIFIER MOTOR ACTUATOR...
Page 718 11. AIR CONDITIONER This page is blank for editing convenience. 12000-1/12000E-1 11-36 Published 10-02-13, Control #210-03...
Page 719: Translifter System
12. TRANSLIFTER SYSTEM 12-1 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 720 12. TRANSLIFTER SYSTEM 12000-1/12000E-1 12-2 Published 10-02-13, Control #210-03...
Page 721: Apparatus And Location Of Components
12. TRANSLIFTER SYSTEM 12.1 APPARATUS AND LOCATION OF COMPONENTS The translifter system consists of the vertical cylinder, crawler EXT./RET. cylinder (horizontal cylinder), control valve, remote controller and junction box. LEFT CRAWLER RIGHT CRAWLER 2,900 CRAWLER EXT./RET. CYLINDER (HORIZONTAL CYLINDER) VERTICAL VERTICAL CYLINDER CYLINDER...
Page 722 12. TRANSLIFTER SYSTEM HANDLING OF REMOTE CONTROL SWITCH BOX Remove all counterweights and carbody-weight when the translifter is handled to prevent overturn- ing. Failure to observe this precaution may result in se- rious accident. REMOTE CONTROL SWITCH BOX CONNECTOR • REMOTE CONTROL SWITCH BOX 3.
Page 723: Remote Control
12. TRANSLIFTER SYSTEM 12.2 REMOTE CONTROL When the controller is failed or the cable breakage oc- curs but the machine still need to be operated, repair upon reviewing the controller circuit or apply voltage di- rectly on the solenoid valve. SW-T2 SW-T3 SW-T4...
Page 724: Circuit Diagram
12. TRANSLIFTER SYSTEM CIRCUIT DIAGRAM L.CONTACT SW-T1 BATTERY RELAY BATTERY (COIL) About R.CONTACT 0.5A BATTERY RELAY (CONTACT) MAX. STARTER RELAY About SW-T2 HORN RELAY SW-T3 ENGINE CONTROL UNIT SW-T4 MAIN CONTROLLER About SW-T5 0.7A R.F. VERTICAL About EXT. 0.7A R.F. VERTICAL About RET.
Page 725 12. TRANSLIFTER SYSTEM This page is blank for editing convenience. 12-7 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 726: Construction And Function
12. TRANSLIFTER SYSTEM 12.3 CONSTRUCTION AND FUNCTION 12.3.1 OUTLINE The pressurized oil discharged from the gear pump (the outside one of the two) directly connected to the main pump is controlled by the hydraulic selector section of the 2-section control valve (gantry control valve), and is led to the translifter control valve through the swivel joint.
Page 727 12. TRANSLIFTER SYSTEM 12-9 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 728: Function
12. TRANSLIFTER SYSTEM 12.4 FUNCTION The function is common to the four translifter vertical cylinders. The function of the crawler EXT./ RET. cylin- ders is almost identical to that of the vertical cylinders except double pilot check valve. The function of the translifter cylinders is described be- low taking the front right vertical cylinder as an exam- ple.
Page 729: Raising The Translifter
12. TRANSLIFTER SYSTEM RAISING THE TRANSLIFTER 12-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 730 12. TRANSLIFTER SYSTEM 12.4.2 LOWERING THE TRANSLIFTER The pressurized oil discharged from the auxiliary actu- ator gear pump is led into the gantry and hydraulic se- lector valve through the gantry section of the 2-section control valve. If the hydraulic selector switch in the op- erator's cab is in the "NEUTRAL (GANTRY)"...
Page 731: Lowering The Translifter
12. TRANSLIFTER SYSTEM LOWERING THE TRANSLIFTER 12-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 732 12. TRANSLIFTER SYSTEM 12000-1/12000E-1 12-14 Published 10-02-13, Control #210-03...
Page 733: Troubleshooting
13. TROUBLESHOOTING 13-1 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 734 13. TROUBLESHOOTING 12000-1/12000E-1 13-2 Published 10-02-13, Control #210-03...
Page 735 13. TROUBLESHOOTING 13.1 TROUBLESHOOTING What actions should be taken upon occurrence of these problems ? 13-3 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 736 13. TROUBLESHOOTING 12000-1/12000E-1 13-4 Published 10-02-13, Control #210-03...
Page 737 13. TROUBLESHOOTING 13-5 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 738 13. TROUBLESHOOTING 12000-1/12000E-1 13-6 Published 10-02-13, Control #210-03...
Page 739 13. TROUBLESHOOTING 13-7 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 740 13. TROUBLESHOOTING 12000-1/12000E-1 13-8 Published 10-02-13, Control #210-03...
Page 741 13. TROUBLESHOOTING 13-9 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 742 13. TROUBLESHOOTING 12000-1/12000E-1 13-10 Published 10-02-13, Control #210-03...
Page 743 13. TROUBLESHOOTING 13-11 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 744 13. TROUBLESHOOTING 12000-1/12000E-1 13-12 Published 10-02-13, Control #210-03...
Page 745 13. TROUBLESHOOTING 13-13 12000-1/12000E-1 Published 10-02-13, Control #210-03...
Page 746 13. TROUBLESHOOTING 12000-1/12000E-1 13-14 Published 10-02-13, Control #210-03...

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