Download Print this page

Manitowoc 10000B-1 Service And Maintenance Manual

Table Of Contents

Advertisement

Quick Links

Download this manual

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 10-09-13, Control # 215-03

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

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.

10000B-1

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

Table of Contents

Advertisement

Troubleshooting

Need help?

Need help?

Do you have a question about the 10000B-1 and is the answer not in the manual?

Questions and answers

Summary of Contents for Manitowoc 10000B-1

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 INTENTIONALLY LEFT BLANK...
Page 3: Table Of Contents
1.1 10000B-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 10000B-1 DIMENSION, WEIGHT OF EACH COMPONENT........1-11 1.2.1 MAIN MACHINERY ................... 1-11 1.2.2 COUNTERWEIGHT................... 1-13 1.2.3 CRANE ATTACHMENT..................1-15 1.2.4...
Page 4 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........................5-40 6. HOIST SYSTEM 6.1 APPARATUS AND LOCATION OF COMPONENTS..........6-3 6.2 ADJUSTMENT OF DRUM LOCK................6-5 10000B-1 Published 10-09-13, Control # 215-03...
Page 5 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 ....................8-15 8.5 SWING LOCK......................8-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 6 10.2.2 SYSTEM DAIGRAM ..................10-194 10.2.3 MONITOR INDICATION.................. 10-195 10.2.4 DETAIL OF MOMENT LIMITER CONNECTOR..........10-201 10.2.5 SHIFTING TO MAINTENANCE SCREEN............10-214 10.2.6 INPUT, OUTPUT SIGNAL................10-216 10.2.7 ML FUNCTION SETTING ................10-225 10.2.8 DATA COPY, FORMAT................... 10-229 10000B-1 Published 10-09-13, Control # 215-03...
Page 7 11.4.2 FAULT IN THE INPUT AND OUTPUT CIRCUIT OF THE MOTOR ACTUATOR ................11-19 11.4.3 FAULT IN THE THERMISTOR SENSOR CIRCUIT ........11-19 11.5 BASIC SYSTEM OF HVAC ..................11-20 11.6 RECHARGING OF THE COOLANT............... 11-25 11.6.1 CAUTION AT WORK..................11-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 8 12.2 REMOTE CONTROL ..................... 12-5 12.3 CONSTRUCTION AND FUNCTION ..............12-8 12.3.1 OUTLINE ......................12-8 12.4 FUNCTION......................12-10 12.4.1 RAISING THE TRANSLIFTER ................ 12-10 12.4.2 LOWERING THE TRANSLIFTER ..............12-12 13. TROUBLESHOOTING 13.1 TROUBLESHOOTING ................... 13-3 10000B-1 Published 10-09-13, Control # 215-03...
Page 9: Safety
SAFETY 10000B-1 Published 10-09-13, Control # 215-03...
Page 10 SAFETY 10000B-1 Published 10-09-13, Control # 215-03...
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 1. When the warning label is damaged or stained, order it to the designated service shop. 2. Do not remove the warning labels. 3. When the surface of the warning label is soiled and difficult to be seen, wipe it cleanly. 10000B-1 Published 10-09-13, Control # 215-03...
Page 13: Label Layout
SAFETY LABEL LAYOUT * Numbers in the drawings correspond with those in the label explanation detail after P.0-15. 10000B-1 Published 10-09-13, Control # 215-03...
Page 14 SAFETY 32 (12000E-1) 10000B-1 Published 10-09-13, Control # 215-03...
Page 15 SAFETY 10000B-1 Published 10-09-13, Control # 215-03...
Page 16 SAFETY 10000B-1 Published 10-09-13, Control # 215-03...
Page 17 SAFETY 10000B-1 Published 10-09-13, Control # 215-03...
Page 18 SAFETY 16 (10000B-1 W/ 15 (10000B-1 W/ J08-VM) J08-UV) 10000B-1 0-10 Published 10-09-13, Control # 215-03...
Page 19 SAFETY 0-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 20 SAFETY 30 (10000B-1) 10000B-1 0-12 Published 10-09-13, Control # 215-03...
Page 21 SAFETY 0-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 22 SAFETY 10000B-1 0-14 Published 10-09-13, Control # 215-03...
Page 23 4. If machine swings or is assembled / disassembled with crawler retracted, main machinery may turn over to rear side. Read the operator’s manual carefully and set the crane to the proper configuration. 0-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 24 7. When work is done on the upper surface of the guard or counterweight, person may fall off by mis- take. Ensure to engage the safety hook on the specified place. 10000B-1 0-16 Published 10-09-13, Control # 215-03...
Page 25 Do not weld or apply heat without checking with your authorized dealer. Unauthorized modifications may weaken the ma- chine. 11. Do not lift people with this crane. Failure to do so may cause serious injury. 0-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 26 Take extra care in handling accumulator. (Do not weld, flame cut, dispose or disassemble.) 14. The accumulator is charged with high pressure ni- trogen gas. Charge the nitrogen gas within the specified pres- sure. 10000B-1 0-18 Published 10-09-13, Control # 215-03...
Page 27 Otherwise the gantry may come off and the boom may drop off. 18. Handling the counterweight in wrong way is very dangerous. Never allow any person to enter under the lifting counterweight. 0-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 28 Never allow anybody to enter the swing range. 21. During engine running or straight after the engine is stopped, hydraulic oil tank, engine and muffler are hot. Touching them may cause burns. Do not touch the hot area. 10000B-1 0-20 Published 10-09-13, Control # 215-03...
Page 29 Stop the crane and then remove the drum cover. 24. When the machine is transported with the low gan- try, connect the tension bar to the revolving frame or counterweight. 0-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 30 28. Taking wrong procedure in boom assembly or dis- assembly may cause boom falling off and person may get injured. Do not allow any person to enter the inside or under the boom during assembly or disassembly. 10000B-1 0-22 Published 10-09-13, Control # 215-03...
Page 31 30. Taking the wrong installing direction when the rope sockets are installed to the boom tip and jib tip, may damage the boom or may break the wire rope. Install the rope socket in the proper direction. 0-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 32 34. If the cock of the oil tank is open, the cylinder may retract and the jib may be over hoisted causing very dangerous condition. Ensure to check that the oil tank cock is closed firm- 10000B-1 0-24 Published 10-09-13, Control # 215-03...
Page 33 37. If the boom top is not placed properly, the boom top may be damaged. When the boom top or jib base are transported or placed on the ground, ensure to place three (3) wooden blocks under the boom top assembly as shown. 0-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 34 Ensure to close the oil tank cock when the crane operation is to be done after the cylinder is installed to the taper boom. 10000B-1 0-26 Published 10-09-13, Control # 215-03...
Page 35: Caution Label
Keep the caution label in good condition to read. • Whenever they become dirty, wash them with water or detergent. • Whenever they are damaged or missed, replace them with the new and same ones. 0-27 10000B-1 Published 10-09-13, Control # 215-03...
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 30. Battery fluid and oils are harmful to human health. If touching any of these materials, immediately wash it away. 31. When lifting a load with a crane, first confirm that a load is lifted off the ground surely and then continue lifting work. 0-29 10000B-1 Published 10-09-13, Control # 215-03...
Page 38 SAFETY 10000B-1 0-30 Published 10-09-13, Control # 215-03...
Page 39: Reference Materials
1. REFERENCE MATERIALS 10000B-1 Published 10-09-13, Control # 215-03...
Page 40 1. REFERENCE MATERIALS 10000B-1 Published 10-09-13, Control # 215-03...
Page 41: 10000B-1 Specification
1. REFERENCE MATERIALS 10000B-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”) 10000B-1 Published 10-09-13, Control # 215-03...
Page 43 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) 10000B-1 Published 10-09-13, Control # 215-03...
Page 44: Crane Specification, Performance
Jib lowering speed * 60 m/min (197 ft/min) 1. Above speeds based on single part of line and at first layer of rope drum. 2. The speed marked with * varies depending on the load. 10000B-1 Published 10-09-13, Control # 215-03...
Page 45: Outside Dimensions
5,800 (19’) Distance between centers of tumblers 5,300 / 3,500 (17’ 5” / 11’ 6”) Overall width of crawlers (Extend/Retract) Width of crawler shoe 900 (2’ 11”) 450 (1’ 6”) Ground clearance of carbody 10000B-1 Published 10-09-13, Control # 215-03...
Page 46: Crane Working Ranges
25° 25 (82) 21.3 (70) BOOM 18.3 (60) BOOM 20 (66) 15.2 (50) BOOM (33) (49) (66) (82) (98) (115) (131) (148) (164) (180) Radius from center of rotation Center of 1.10 (3.6) rotation 10000B-1 Published 10-09-13, Control # 215-03...
Page 47 40 (131) + 9.1 (30) Jib 35 (115) 30 (98) 25 (82) 20 (66) (33) (49) (66) (82) (98) (115) (131) (148) (164) (180) Radius from center of rotation Center of 1.10 (3.6) rotation 10000B-1 Published 10-09-13, Control # 215-03...
Page 48 27.4 (90) Boom + 9.1 (30) Jib 35 (115) 30 (98) 25 (82) 20 (66) (33) (49) (66) (82) (98) (115) (131) (148) (164) (180) Radius from center of rotation Center of 1.10 (3.6) rotation 10000B-1 1-10 Published 10-09-13, Control # 215-03...
Page 49: 10000B-1 Dimension, Weight Of Each Component
1. REFERENCE MATERIALS 10000B-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”) 10000B-1 1-12 Published 10-09-13, Control # 215-03...
Page 51: Counterweight
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 10000B-1 Published 10-09-13, Control # 215-03...
Page 52 (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) 10000B-1 1-14 Published 10-09-13, Control # 215-03...
Page 53: Crane Attachment
(5’ 6”) 6.1 m Boom insert (1,445) 1,680 12,310 (40’ 4”) (5’ 6”) 12.2 m 1,195 Boom insert (2,635) 1,680 12,310 (40’ 4”) (5’ 6”) 12.2 m Boom insert 1,220 (2,690) (With lug) 1-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 54 4,810 (15’ 9”) 3,110 (10’ 2”) (2’ 8”) 3.0 m (220) Jib insert (2’ 8”) 6,160 (20’ 3”) 6.0 m Jib insert (400) Strut 3,620 (11’ 11”) (550) 2,010 (6’ 7”) Auxiliary sheave (660) 10000B-1 1-16 Published 10-09-13, Control # 215-03...
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 10000B-1 Published 10-09-13, Control # 215-03...
Page 56: Luffing Attachment
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’ 5”) Rear strut (1,323) 10000B-1 1-18 Published 10-09-13, Control # 215-03...
Page 57 3.0 m (684) Jib insert 3,165 (10’ 5”) 1,490 (4’ 11”) 6.1 m (1,147) Jib insert 6,210 (20’ 5”) 1,490 (4’ 11”) 12.2 m (2,117) Jib insert 12,305 (40’ 4”) 1,490 (4’ 11”) 1-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 58 Luffing boom tip 3,350 assembly (7,390) (Without point sheave) Width : 1,715 (5’ 8”) Note : Luffing jib winch (also used as 3rd winch) weight is 2,300 kg (5,080 lbs) (including wire rope). 10000B-1 1-20 Published 10-09-13, Control # 215-03...
Page 59: 10000B-1 Swing And Propel Stability
1. REFERENCE MATERIALS 10000B-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)
Page 60 (ground, crane configuration). (4) Travelling forward means the case where the coun- terweight is at the lower slope and the traveling backward where it is at the upper slope. Propel motor Traveling backward 10000B-1 1-22 Published 10-09-13, Control # 215-03...
Page 61: 10000B-1 Propel Allowable Slope Angle
1. REFERENCE MATERIALS 10000B-1 PROPEL ALLOWABLE SLOPE ANGLE 1.4.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION In the area showing [-] mark, do not propel. Machine may overturn. Failure to observe this precaution may result in serous injuries or loss of life.
Page 62 1. REFERENCE MATERIALS 1. 10000B-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)
Page 63 1. REFERENCE MATERIALS 2. 10000B-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)
Page 64 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) 61.0 (200) 10000B-1 1-26 Published 10-09-13, Control # 215-03...
Page 65 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) 61.0 (200) 1-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 66 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) 61.0 (200) 10000B-1 1-28 Published 10-09-13, Control # 215-03...
Page 67 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) 61.0 (200) 1-29 10000B-1 Published 10-09-13, Control # 215-03...
Page 68: Luffing Jib Attachment
Provide the gentle slope at the beginning and end positions of slope. Propel upward downward on slope : allowable angle) FORWARD BACKWARD JIB OFFSET ANGLE JIB OFFSET ANGLE LUFFING BOOM ANGLE LUFFING BOOM ANGLE 10000B-1 1-30 Published 10-09-13, Control # 215-03...
Page 69 1. REFERENCE MATERIALS 1. 10000B-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...
Page 70 30.4 (100) 2° 4° 1° 30.4 (100) 2° 4° 33.4 (110) 2° 3° 33.4 (110) 2° 4° 36.5 (120) 2° 3° 36.5 (120) 2° 3° 39.5 (130) 2° 3° 39.5 (130) 2° 3° 10000B-1 1-32 Published 10-09-13, Control # 215-03...
Page 71 5° 27.3 (90) 3° 4° 27.3 (90) 3° 4° 30.4 (100) 3° 4° 30.4 (100) 3° 4° 33.4 (110) 3° 4° 33.4 (110) 3° 4° 36.5 (120) 2° 4° 36.5 (120) 3° 4° 1-33 10000B-1 Published 10-09-13, Control # 215-03...
Page 72: Engine Main Specification
1. REFERENCE MATERIALS ENGINE MAIN SPECIFICATION 10000B-1 : Hino Model J08E-UV diesel engine Engine (complying with the Interim Tier4 & Stage IIIB Emission Regulations) 10000B-1 : Hino Model J08E-VM diesel engine Configuration of engine 4 cycle, water cooled, vertical in-line 6, direct injection, turbo-charged,...
Page 73: 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 ) 1-35 10000B-1 Published 10-09-13, Control # 215-03...
Page 74 1. REFERENCE MATERIALS 10000B-1 1-36 Published 10-09-13, Control # 215-03...
Page 75: Maintenance Standards Test Procedures
2. MAINTENANCE STANDARDS TEST PROCEDURES 10000B-1 Published 10-09-13, Control # 215-03...
Page 76 2. MAINTENANCE STANDARDS TEST PROCEDURES 10000B-1 Published 10-09-13, Control # 215-03...
Page 77: Maintenance Standard
Item dimension limit Remedy figure d’ 44.0 44.26 Fig.2-1 Pawl (Front/rear) Replace (1.732) (1.743) (P.2-6) 45.0 45.27 Fig.2-3 Bushing Pawl (Boom) Replace (1.772) (1.782) (P.2-7) 115.0 115.35 Fig.2-6 Boom foot Replace (4.528) (4.541) (P.2-8) 10000B-1 Published 10-09-13, Control # 215-03...
Page 78 Item Remedy length free length figure 68.4 Fig.2-1 Front/rear drum pawl (2.835) (2.693) (P.2-6) (Compression) 68.4 Fig.2-3 Boom drum pawl (2.835) Replace (2.693) (P.2-7) (Compression) 61.5 63.9 Fig.2-5 Brake pedal (2.421) (2.516) (P.2-8) (Tension) 10000B-1 Published 10-09-13, Control # 215-03...
Page 79 Upper spreader (15.000) (14.941) (0.433) build-up 379.5 11.0 Fig.2-8 Lower spreader (15.000) (14.941) (0.433) (P.2-9) Jib point 14.0 Fig.2-7 (21.614) (21.496) (0.551) (P.2-9) Jib strut 379.5 11.5 Fig.2-8 Gantry peak (15.000) (14.941) (0.453) (P.2-9) 10000B-1 Published 10-09-13, Control # 215-03...
Page 80 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 81 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 82 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-5 Brake pedal Fig.2-6 Crane assy 10000B-1 Published 10-09-13, Control # 215-03...
Page 83 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-7 Jib assy Fig.2-8 Gantry assy 10000B-1 Published 10-09-13, Control # 215-03...
Page 84: Propel Device
Build-up 44.45 44.25 (1.750) (1.742) replace 234.6 Pitch (P) (8.976) (9.236) Distance between pins when 6 pcs of shoes are connected and tension applied : 1368 to 1378 mm (53.858 to 54.252 inch) 10000B-1 2-10 Published 10-09-13, Control # 215-03...
Page 85 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 Unit : mm (inch) 2-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 86 0.232 (0.009) (+0.006) Bore Replacement +0.139 (+0.006) of bushing +0.117 (+0.005) Shaft Interference Interference of +0.092 0.057 (0.002) Interference (+0.004) sprocket and 125 (4.921) 0 (0) bushing 0.117 (0.005) +0.047 Bore (+0.002) +0 (+0) 10000B-1 2-12 Published 10-09-13, Control # 215-03...
Page 87 0.266 (0.011) (3.543) +0.28 (0.032) 0.37 (0.014) (+0.011) Bore +0.23 (+0.009) +0.12 (+0.005) Shaft +0.11 Interference Interference (+0.004) Interference of roller 0.075 (0.003) Replace and bushing (4.134) +0.035 0.12 (0.005) (+0.001) Bore 2-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 88 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) 10000B-1 2-14 Published 10-09-13, Control # 215-03...
Page 89 = 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) (1.181) replace 2-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 90 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 1.5 mm (0.059 inch) 10000B-1 2-16 Published 10-09-13, Control # 215-03...
Page 91: Performance Standard And Test Procedure
Draw the ropes around the area where the machine operates to keep out everyone. Check that the overhoist prevention (for hook/ boom) correctly operates. Lock all functions that are not used. Do not attempt sudden startup/sudden stop. 2-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 92: Operating Speed
Within 600 mm deflection Boom Length : Basic boom more than 2 m (6.6 ft) before (23.622 inch) Place : Firm and starting the measuring. level ground Take average of 3 times measuring. 10000B-1 2-18 Published 10-09-13, Control # 215-03...
Page 93: Point And Method Of Measuring Pressure
2. Lock the rear winch drum with the • Rear drum drum lock. • Mode : Power mode 3. Make the valve relieve by rear drum winch lowering operation. RELIEF VALVE PRESSURE GAUGE PORT (PF1/4) 2-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 94 2. Lock the boom drum. 45 to 55° C (113 to 131° F) 3. Make the valve relieved by boom • Mode : Power mode lowering operation. PRESSURE GAUGE RELIEF VALVE PORT (PF1/4) 10000B-1 2-20 Published 10-09-13, Control # 215-03...
Page 95 45 to 55° C (113 to 131° F) 2. Make the valve relieved by swing operation. • Swing mode : Free high • Mode : Power mode PRESSURE GAUGE PORT (PF 1/4) VIEW FROM A RELIEF VALVE 2-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 96 1.42 to 1.62 MPa (206 to 235 psi) Swing 1.62 to 1.92 MPa (235 to 278 psi) Third drum 2.65 to 2.94 MPa (384 to 426 psi) Boom 2.50 to 2.79 MPa (363 to 405 psi) 10000B-1 2-22 Published 10-09-13, Control # 215-03...
Page 97 Lower Circuit : 20.6 MPa (2,988 psi) RELIEF VALVE (RAISING) 20.6 MPa (2,988 psi) RELIEF VALVE PRESSURE GAUGE RELIEF VALVE (LOWERING) (GANTRY RAISE/LOWER) PORT (PF 1/4) 4.9 MPa (711 psi) 20.6 MPa (2,988 psi) 2-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 98: Slewing Ring
COUNTERWEIGHT : FULL Condition of measurement Amount of play Boom length : 15.2 m (50 ft) Less than 3 mm Radius : 9.14 m (30 ft) (0.118 inch) Load : 36.8 t (82,500 lbs) 10000B-1 2-24 Published 10-09-13, Control # 215-03...
Page 99: General Work Standard
3. GENERAL WORK STANDARD 10000B-1 Published 10-09-13, Control # 215-03...
Page 100 3. GENERAL WORK STANDARD 10000B-1 Published 10-09-13, Control # 215-03...
Page 101: Tightening Torque Of Cap Screws And Nuts
(585 to 715) (488 to 596) (1267 to 1549) (1066 to 1302) 1023 to 1251 856 to 1046 2205 to 2659 1843 to 2253 (754 to 922) (630 to 770) (1625 to 1985) (1358 to 1660) 10000B-1 Published 10-09-13, Control # 215-03...
Page 102 1304.3 (962) 2520.3 (1859) 2118.0 (1562) 1 3/8 912.0 (673) 764.9 (564) 2049.6 (1512) 1716.2 (1266) 3314.6 (2445) 2785.1 (2054) 1 1/2 1216.0 (897) 1019.9 (752) 2716.4 (2004) 2275.1 (1678) 4403.2 (3248) 3687.3 (2720) 10000B-1 Published 10-09-13, Control # 215-03...
Page 103 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) 10000B-1 Published 10-09-13, Control # 215-03...
Page 104: Tightening Torque Of Hydraulic Fittings
118 to 157 (87 to 116) 1" 147 to 186 (108 to 137) 1 1/4" 167 to 226 (123 to 166) 1 1/2" 216 to 275 (159 to 202) 2" 255 to 333 (188 to 246) 10000B-1 Published 10-09-13, Control # 215-03...
Page 105 185 - 215 8 1/4" - 9 1/2" 205 - 240 9 1/4" - 10 1/2" 235 - 270 10 1/4" - 11 1/2" 255 - 290 11 1/4" - 12 1/2" 285 - 320 10000B-1 Published 10-09-13, Control # 215-03...
Page 106: Standard Parts
In case of 13 or 18, it indicates 10T class. In case of 23, it indicates Hexagon socket set screw. 4.8 (4T) 10.9 (10T) ZS11F ZS12F ZS13F ZS16F ZS17F ZS18F ZS11C ZS12C ZS13C ZS16C ZS17C ZS18C 10000B-1 Published 10-09-13, Control # 215-03...
Page 107: O-Ring
Green is of fluorine rubber and is ranged from -15°C to 200°C. One blue dot ZD11 Nitrile rubber Hs70 Two blue dots ZD12 Nitrile rubber Hs90 One red dot Nitrile rubber Hs70 One yellow dot Styrol rubber Hs70 One green dot Fluorine rubber Hs70 10000B-1 Published 10-09-13, Control # 215-03...
Page 108: Back-Up Ring
The numeric 85 indicates "BIAS CUT". The numeric 95 indicates "SPIRAL". WIDTH INNER DIAMETER BIAS CUT BACK-UP RING O-RING PRESSURE PRESSURE 1pce. of the back-up ring is used. 2pce. of the back-up rings are used. 10000B-1 3-10 Published 10-09-13, Control # 215-03...
Page 109: Bite Type Fitting
— ZA82P28000 — ZA82P35000 PLUG for connector Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF83P10000 ZA83P10000 ZF83P15000 ZA83P15000 ZF83P18000 ZA83P18000 ZF83P22000 ZA83P22000 ZF83P28000 ZA83P28000 — ZA83P35000 3-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 110 108 to 128 128 to 166 197 to 235 246 to 304 385 to 443 N-m (ft-lbs) (28 to 36) (80 to 94) (94 to 122) (146 to 174) (180 to 220) (291 to 319) 10000B-1 3-12 Published 10-09-13, Control # 215-03...
Page 111: Conversion Table
0.00050 0.(3)4460 0.(3)4536 907.185 32000 2000 0.89286 0.90719 1016.05 35840 2240 1.12 1.01605 1000 35274 2204.6 1.10231 0.98421 [ Remakes ] mt : ton (Metric) nt : ton (U.s.unit) gt : (British Unit) 3-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 112: Millimeter : Inch Conversion Table
2.8346 2.8740 2.9134 2.9528 2.9921 3.0315 3.0709 3.1102 3.1496 3.1890 3.2283 3.2677 3.3071 3.3465 3.3858 3.4252 3.4646 3.5039 3.5433 3.5827 3.6220 3.6614 3.7008 3.7402 3.7795 3.8189 3.8583 3.8976 25.4 mm = 1 inch 10000B-1 3-14 Published 10-09-13, Control # 215-03...
Page 113 29/32 23.019 48.419 73.819 99.219 124.619 150.019 175.419 200.819 226.219 251.619 15/16 23.813 49.213 74.613 100.013 125.413 150.813 176.213 201.613 227.013 252.413 31/32 24.606 50.006 75.406 100.806 126.206 151.606 177.006 202.406 227.806 253.206 3-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 114: Meter And Foot Conversion Table
38.10 89.92 141.73 39.62 91.44 143.26 41.15 92.96 144.78 42.67 94.49 146.30 44.20 96.01 147.83 45.72 97.54 149.35 47.24 99.06 150.88 48.77 100.58 152.40 50.29 102.11 51.82 103.63 1 foot = 0.3048 meter 10000B-1 3-16 Published 10-09-13, Control # 215-03...
Page 115: Grade Conversion Table
Steel Coal powder Cast iron Coke Aluminum Concrete Cedar Soil Cypress Gravel Paulownia Weight of wood is that of the dried. Value shown in the table may well be taken for specific gravity. 3-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 116: System International (Si) Unit Conversion Table
9.807 0.1013 kcal 4186 lbf/in 0.0069 kgf s/cm 98067 Pa s kgf/cm 98.1 0.001 Pa s 101.3 Pa s lbt/in 1 X 10 mm Hg 133.3 0.0001 atm cc/s 0.1013 Pa m 10000B-1 3-18 Published 10-09-13, Control # 215-03...
Page 117: Power Train
4. POWER TRAIN 10000B-1 Published 10-09-13, Control # 215-03...
Page 118 4. POWER TRAIN 10000B-1 Published 10-09-13, Control # 215-03...
Page 119: Introduction
(option). The 2 section gear pump (option) connected to the power divider provides the pressured oil to free fall brake cooling line of the front and rear drum. 10000B-1 Published 10-09-13, Control # 215-03...
Page 120 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 121 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) 10000B-1 Published 10-09-13, Control # 215-03...
Page 122 4. POWER TRAIN DRIVE TUMBLER PROPEL MOTOR PROPEL REDUCTION UNIT SWING BEARING CRAWLER EXT/RET CYLINDER SWING RING GEAR SWIVEL JOINT 10000B-1 Published 10-09-13, Control # 215-03...
Page 123: Engine
Wait until temperature comes down. On the other hand, warm up oil to appropriate temperature (approx. 20 to 40° C) for oil drain if oil is cooled down. 10000B-1 Published 10-09-13, Control # 215-03...
Page 124 12. Check that all the electric wiring, mechanical con- nection and fuel piping are disconnected and there would be no interference for removing the engine. 10000B-1 Published 10-09-13, Control # 215-03...
Page 125: Lifting Hook
Weight is approx. 1,250 kg (2,756 lbs). Take necessary action to prevent overturning of the en- gine. LIFTING HOOK LIFTING HOOK 16. Inspect the rubber mount and replace them if re- quired. 10000B-1 Published 10-09-13, Control # 215-03...
Page 126: Repair And Maintenance
Do not place any metal objects such as tools on or around of the battery to prevent causing spark. Ensure to properly use booster cables to prevent explosion sue to miss-use. 10000B-1 4-10 Published 10-09-13, Control # 215-03...
Page 127 109 to 133 N-m 504 to 616 N-m 261 to 319 N-m (Apply LOCTITE #271) (81 to 98 lbs-ft) (372 to 454 lbs-ft) (193 to 235 lbs-ft) (Apply LOCTITE #271) (Apply LOCTITE #271) (Apply LOCTITE #271) 4-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 128 SECTION A-A (Apply LOCTITE #271) Tightening torque 261 to 319 N-m (193 to 235 lbs-ft) (Apply LOCTITE #271) Tightening torque 504 to 616 N-m (372 to 454 lbs-ft) SECTION B-B (Apply LOCTITE #271) 10000B-1 4-12 Published 10-09-13, Control # 215-03...
Page 129: Pump Drive Assembly
The power then is divided by 4 sets of helical gears to the main pump shaft, swing pump shaft, control and gantry hoist pump shaft, cooling pump shaft. (Closed with the flange when free less is selected.) (See 4.3.2) 4-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 130: Removal
Weight of the power divider : Approx. 260 kg (573 lbs) 4. The main part of this coupling will be removed with the power divider connected to its shaft. Remove the remaining coupling bushing (engine side) or element. 10000B-1 4-14 Published 10-09-13, Control # 215-03...
Page 131 ADAPTER PLATE (ENGINE SIDE) NAME PLATE OIL FILL PORT COUPLING OIL LEVEL GAUGE MAIN PUMP FRONT / REAR DRUM COOLING PUMP (FRANGE WHEN “FREE LESS” IS SELECTED) OIL DRAIN COCK Fig.4-1 PUMP DRIVE (1/2) 4-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 132 (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) 10000B-1 4-16 Published 10-09-13, Control # 215-03...
Page 133: Disassembling The Power Divider
If required, remove the cap screws (32) and the plate (15). 12. Remove the gear (5) and both side bearings (21), (22) if required. 13. Remove the cap screw (32) and the plate (12). 4-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 134 18. Remove the gear (7) and if required, remove both side bearing (25), (26). 19. If required, remove the screws (34) and the plate (19). 20. If required, remove the cap screws (32) and plates (14). 10000B-1 4-18 Published 10-09-13, Control # 215-03...
Page 135: Check And Repair Of The Power Divider
11. Check cap screw threadings and screw hole threadings and replace or repair any that show signs of cross-threading and or strippage. 12. Take out the breather cap and clean in the pipe and check the orifice hole for clogging. 4-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 136: Assembling The Power Divider
(46) to the housing (1) to make oil groove comes to the position as shown in P.4-23. (UP cast mark up- ward) 4. After assembly, check that the input shaft turns lightly by hand. 10000B-1 4-20 Published 10-09-13, Control # 215-03...
Page 137: Re-Installation
440 to 490 N-m (324.6 to 361.5 lbs- ft) torque. (LOCTITE not necessary with micro capsule coat- ing) In case of micro capsule coating, if tightened once, remove completely first and then apply LOCTITE #242. 4-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 138 (Approx. 10.0 ltr.) 10. Install the power divider with engine attached to the machine referring to [4.2 ENGINE] 11. Start the engine and check for unusual noise or oil leak during low idling speed. 10000B-1 4-22 Published 10-09-13, Control # 215-03...
Page 139 Install with cast “UP” mark facing upward. (Note 1) ARROW “H” Tightening torque 4.9 to 9.8 N-m (3.7 to 7.2 lbs-ft) Apply LOCTITE #515 between screw and packing seal. ARROW “A” Fig.4-3 POWER DIVIDER (1/3) 4-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 140 31.5 to 38.5 N-m (23.3 to 28.3 lbs-ft) Apply LOCTITE #242 Note on direction (Note 1) Apply LOCTITE #515 evenly on SECTION F-F mating surface of item 1 “HOUSING” Fig.4-4 POWER DIVIDER (2/3) 10000B-1 4-24 Published 10-09-13, Control # 215-03...
Page 141 (4) Install stand into housing 0 to 0.15 mm with shim. (5) Check for shim to be in right place before oil seal installation. DETAIL OF “F” (6) Install oil seal. Fig.4-5 POWER DIVIDER (3/3) 4-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 142 2 STAND and item, 9, 11, 45, 46 SUPPORT. (See figure) • (NOTE 2) Install item 24, 25 BEARING so that position of one side shield becomes on pump mounting side. (See figure) 10000B-1 4-26 Published 10-09-13, Control # 215-03...
Page 143: Spring Pin
(324.6 to 361.5 lbs-ft) (See item 3 in P.4-22) DETAIL OF “B” SECTION A-A Fig.4-6 COUPLING 1. ELEMENT 4. HUB 7. SPRING PIN 2. INSERT 5. CAPSCREW 8. NUT 3. INSERT 6. SETSCREW 4-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 144 4. POWER TRAIN 10000B-1 4-28 Published 10-09-13, Control # 215-03...
Page 145: Hydraulic System
5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 146 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 147: Location Of Main Hydraulic Components
REDUCTION UNIT ENGINE THIRD DRUM MOTOR THIRD DRUM REDUCTION UNIT RADIATOR AND OIL COOLER SEPARATE OIL CONTROL VALVE COOLER BOOM DRUM MOTOR PROPEL REDUCTION UNIT MOTOR TRANSLIFTER CYLINDER BOOM DRUM LOWER MACHINERY UPPER MACHINERY 10000B-1 Published 10-09-13, Control # 215-03...
Page 148 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 149 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 150 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 151 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 152 5. HYDRAULIC SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 153: Hydraulic Circuits And Components
5. HYDRAULIC SYSTEM HYDRAULIC CIRCUITS AND COMPONENTS 5.2.1 COMPONENT SPECIFICATIONS 10000B-1 Published 10-09-13, Control # 215-03...
Page 154 5. HYDRAULIC SYSTEM 10000B-1 5-10 Published 10-09-13, Control # 215-03...
Page 155 5. HYDRAULIC SYSTEM 5-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 156 5. HYDRAULIC SYSTEM 10000B-1 5-12 Published 10-09-13, Control # 215-03...
Page 157 5. HYDRAULIC SYSTEM 5-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 158: Layout Of Hydraulic Components
3. PUMP (SWING/ REDUCTION UNIT BOOM HOIST) 24. CONTROL VALVE (COUNTER SELF REMOVAL) ENGINE REDUCTION UNIT THIRD DRUM SEPARATE OIL RADIATOR & COOLER OIL COOLER 10. MOTOR (BOOM) 22. CONTROL VALVE (GANTRY) BOOM DRUM 10000B-1 5-14 Published 10-09-13, Control # 215-03...
Page 159 12. MOTOR (SWING) 47. REMOTE CONTROL VALVE (PROPEL) SWING CONTROL LEVER 83. PRESSURE SWITCH (PROPEL REMO-CON PRESS. DETECT) THIRD DRUM CONTROL LEVER 50. REMOTE CONTROL VALVE (THIRD) 46. REMOTE CONTROL VALVE (SWING) 76. ACCUMULATOR 5-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 160 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) 10000B-1 5-16 Published 10-09-13, Control # 215-03...
Page 161 5. HYDRAULIC SYSTEM 43. INDEPENDENT, CONFLUENCE SELECT 40. PILOT PRESSURE CHANGE-OVER VALVE 39. PILOT CHANGE-OVER VALVE 5-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 162: 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 10000B-1 5-18 Published 10-09-13, Control # 215-03...
Page 163 5. HYDRAULIC SYSTEM 32. VALVE BLOCK 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) POWER DIVIDER REAR 5-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 164 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) 10000B-1 5-20 Published 10-09-13, Control # 215-03...
Page 165 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 166: Hydraulic Oil Tank
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. HYD. OIL TEMPERATURE SENSOR (FOR HYD. OIL TANK) 10000B-1 5-22 Published 10-09-13, Control # 215-03...
Page 167 5. HYDRAULIC SYSTEM 4. GANTRY 9. CYLINDER (GANTRY HOIST) 9. CYLINDER (GANTRY HOIST) 57. SWIVEL JOINT 22. CONTROL VALVE (GANTRY) 5-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 168: Winch Motor
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) 10000B-1 5-24 Published 10-09-13, Control # 215-03...
Page 169 5. HYDRAULIC SYSTEM 7. HYDRAULIC OIL PUMP 3. BOOM, SWING PUMP 4. GEAR PUMP 5. GEAR PUMP 1. MAIN PUMP 5-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 170 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) 10000B-1 5-26 Published 10-09-13, Control # 215-03...
Page 171: Hydraulic System
2 gear pumps directly connected with power divider are for front and rear drum brake cooling. 3. BOOM, SWING PUMP 4. GEAR PUMP (CONTROL PURPOSE, AUX.) 5. GEAR PUMP (COOLING) 1. MAIN PUMP 5-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 172: Oil Flow From No.1-1, No.1-2
When the inching speed switch is handled, inching speed solenoid becomes energized to actuate the pump regulator and minimize oil delivery from the main pump. 10000B-1 5-28 Published 10-09-13, Control # 215-03...
Page 173 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 174 When the swing control valve is actuated with the pres- surized oil from the remote control valve, pressurized oil from the swing pump flows into the swing motor to swing the upper machinery. 10000B-1 5-30 Published 10-09-13, Control # 215-03...
Page 175: Oil Flow From No.3-1, 3-2 Pump
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 10000B-1 Published 10-09-13, Control # 215-03...
Page 176 (SOL-3) and is not sent to the remote control valve. Therefore under this condition, even when the con- trol valve is operated, control pressure would not be generated and the machine would not move. 10000B-1 5-32 Published 10-09-13, Control # 215-03...
Page 177 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 No.5-2 RETURN FILTER SUCTION STRAINER 5-33 10000B-1 Published 10-09-13, Control # 215-03...
Page 178 (SOL-3) and flows into the remote control valve. Under this condition, when the control valve is op- erated, remote control pressure is sent to the main control valve and make each actuator functioned. 10000B-1 5-34 Published 10-09-13, Control # 215-03...
Page 179: Oil Flow From No.4-1 Pump
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 No.5-2 RETURN FILTER SUCTION STRAINER 5-35 10000B-1 Published 10-09-13, Control # 215-03...
Page 180: Oil Flow From No.4-2 Pump
The pressurized oil from the pump flows into the counterweight self removal control valve. When the counterweight self removal control valve is in neu- tral, the pressurized oil passes through the valve and returns to the tank without load. 10000B-1 5-36 Published 10-09-13, Control # 215-03...
Page 181 CRAWLER CYLINDER COUNTERWEIGHT SELF REMOVAL CYLINDER GANTRY CYLINDER SWIVEL JOINT MAIN CONTROL VALVE No.1-1 No.1-2 BOOM HOIST SWING No.3-1 No.3-2 CONTROL No.4-1 No.4-2 DRUM BRAKE COOLING OIL COOLER No.5-1 No.5-2 RETURN FILTER SUCTION STRAINER 5-37 10000B-1 Published 10-09-13, Control # 215-03...
Page 182 (clutch). The pressurized oil from both pumps passes through the front and rear drum brake (clutch) and returns to the tank through the filter. 10000B-1 5-38 Published 10-09-13, Control # 215-03...
Page 183: 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 184: 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 10000B-1 5-40 Published 10-09-13, Control # 215-03...
Page 185 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 186 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 10000B-1 5-42 Published 10-09-13, Control # 215-03...
Page 187 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 188 5. HYDRAULIC SYSTEM 5-SECTION VALVE TO TANK FRONT DRUM RAISE REAR DRUM RAISE BOOM DRUM RAISE BOOM DRUM LOWER 10000B-1 5-44 Published 10-09-13, Control # 215-03...
Page 189 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 190 5. HYDRAULIC SYSTEM 1-SECTION VALVE TO SWING REMO-CON VALVE (SWING COUNTERFORCE) TO SWING REMO-CON VALVE (SWING COUNTERFORCE) 10000B-1 5-46 Published 10-09-13, Control # 215-03...
Page 191 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. LOWER (BACKWARD) REAR 1ST SP. LOWER 5-47 10000B-1 Published 10-09-13, Control # 215-03...
Page 192 LEFT PROPEL REAR 2ND SP. LOWER FRONT 1ST SP. LOWER (FORWARD) LEFT PROPEL (BACKWARD) REAR 2ND SP. RAISE FRONT 1ST SP. RAISE FRONT 1ST SP. LOWER LEFT PROPEL (FORWARD) REAR 2ND SP. LOWER 10000B-1 5-48 Published 10-09-13, Control # 215-03...
Page 193 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (THIRD 1-SECTION) THIRD RAISE THIRD LOWER 5-49 10000B-1 Published 10-09-13, Control # 215-03...
Page 194 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) (FRONT) 10000B-1 5-50 Published 10-09-13, Control # 215-03...
Page 195 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) TO DR 5-51 10000B-1 Published 10-09-13, Control # 215-03...
Page 196 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) 10000B-1 5-52 Published 10-09-13, Control # 215-03...
Page 197: Hoist System
6. HOIST SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 198 6. HOIST SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 199: Apparatus And Location Of Components
REAR DRUM MOTOR AND (Refer to next page.) REDUCTION UNIT ENGINE THIRD DRUM MOTOR AND THIRD DRUM REDUCTION UNIT (OPTION) (OPTION) RADIATOR AND BATTERY OIL COOLER SEPARATE OIL COOLER BOOM DRUM MOTOR AND BOOM DRUM REDUCTION UNIT 10000B-1 Published 10-09-13, Control # 215-03...
Page 200: Hydraulic Pump
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. 10000B-1 Published 10-09-13, Control # 215-03...
Page 201: Adjustment Of Drum Lock
20 mm (13/16 inch). Operate the knob to the LOCK position and to the RELEASE position and confirm that the pawl moves smoothly. 58 mm 58 mm (2-5/16”) (2-5/16”) 126 mm (4-15/16”) FRONT AND REAR DRUM LOCK 10000B-1 Published 10-09-13, Control # 215-03...
Page 202: Winch
(114 to 139 lbs-ft) to make it engaged completely with pin groove. Nut tightening torque 154 to 188 N-m (114 to 139 lbs-ft) Install keeper plate to make it engaged completely with pin groove. SECTION A-A 10000B-1 Published 10-09-13, Control # 215-03...
Page 203 (25.9 to 31.6 lbs-ft) Apply LOCTITE #271 Apply LOCTITE #271 Install keeper plate Install keeper plate to make it engaged to make it engaged completely with pin completely with pin groove. groove. SECTION B-B 10000B-1 Published 10-09-13, Control # 215-03...
Page 204: Winch Assembly
NOTE : After assembly, fill oil to the specified level. (approx. 23 ltr.) Higher than level gauge red point and within the oil : Extreme pressure gear oil SAE #80W-90 (APOLOIL GEAR HE MULTI-SPECIAL). 10000B-1 Published 10-09-13, Control # 215-03...
Page 205 6. HOIST SYSTEM This page is blank for editing convenience. 10000B-1 Published 10-09-13, Control # 215-03...
Page 206: Reduction Unit Assembly
As for paint and film thickness, follow KS52M6050. D0003. After assembling is completed, press the 1st sun gear into the reduction unit by tapping it lightly and confirm that it turns easily. PUNCHING POINT DETAIL OF A DETAIL OF B 10000B-1 6-10 Published 10-09-13, Control # 215-03...
Page 207 7. Support 18. Thrust washer 29. Pinion 8. Ring gear 19. Bearing 30. Pin 9. Spacer 20. Pinion 31. Snap ring 10. Collar 21. Spring pin 32. Shim 11. Bearing 22. Bolt 33. Pin 6-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 208: 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 10000B-1 6-12 Published 10-09-13, Control # 215-03...
Page 209: Machine Front
(27.5 to 33.2 lbs-ft) 30.4 to 38.2 N-m Capscrew M10 X 70 (22.4 to 28.2 lbs-ft) • When installing item 16 bearing, fill in enough amount of grease. • Apply MOLYKOTE on each rotating area. 6-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 210: Adjusting The Brake Pedal
(2.76 inch) in the status described in the 4 above. 6. Ensure that the effective stroke of the valve (No.40) from the time when the pedal is depressed to the time it is released is 15 mm (0.6 inch). 10000B-1 6-14 Published 10-09-13, Control # 215-03...
Page 211: Bleeding Air From Brake Circuit
At this time, air bleed. 5. Return to the "Neutral brake mode", and stop the engine. After the engine is stopped, wait until the control pressure is released (approx. 1 minute), and then, remove the bypass hose. 6-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 212 6. HOIST SYSTEM This page is blank for editing convenience. 10000B-1 6-16 Published 10-09-13, Control # 215-03...
Page 213: Construction And Function
6. HOIST SYSTEM 6.6 CONSTRUCTION AND FUNCTION 6.6.1 HYDRAULIC SCHEMATIC 6-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 214 6. HOIST SYSTEM 10000B-1 6-18 Published 10-09-13, Control # 215-03...
Page 215 6. HOIST SYSTEM 6-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 216: Lifting A Load
As directed by the position of the spool, the main pump (No.2) oil flowing into the control valve is sent to the raising side of the hoist motor to drive the front drum and thereby raise the load. 10000B-1 6-20 Published 10-09-13, Control # 215-03...
Page 217 6. HOIST SYSTEM Lifting (1/3) 6-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 218 6. HOIST SYSTEM Lifting (2/3) 10000B-1 6-22 Published 10-09-13, Control # 215-03...
Page 219 6. HOIST SYSTEM Lifting (3/3) 6-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 220: Holding A Raised Load
Therefore, the clutch remains engaged with the spring. The load is now held in suspension by the com- bined effects of the motor counterbalance valve, the motor brake and the clutch. 10000B-1 6-24 Published 10-09-13, Control # 215-03...
Page 221 6. HOIST SYSTEM Holding (1/2) 6-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 222 6. HOIST SYSTEM Holding (2/2) 10000B-1 6-26 Published 10-09-13, Control # 215-03...
Page 223 6. HOIST SYSTEM This page is blank for editing convenience. 6-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 224: Lowering A Load (Power Lowering)
The counterbalance valve is opened by pilot pressure from the "running in" side to allow the main motor to rotate and lower the load. 10000B-1 6-28 Published 10-09-13, Control # 215-03...
Page 225 6. HOIST SYSTEM Lowering (Power lowering) (1/3) 6-29 10000B-1 Published 10-09-13, Control # 215-03...
Page 226 6. HOIST SYSTEM Lowering (Power lowering) (2/3) 10000B-1 6-30 Published 10-09-13, Control # 215-03...
Page 227 6. HOIST SYSTEM Lowering (Power lowering) (3/3) 6-31 10000B-1 Published 10-09-13, Control # 215-03...
Page 228: Free Fall Operation
"CLM" side oil chamber of the clutch cylinder through the front drum foot brake valve, and the cylinder thrust force is decreased to actuate the brake (braking with the clutch). 10000B-1 6-32 Published 10-09-13, Control # 215-03...
Page 229 6. HOIST SYSTEM Free Fall (1/2) 6-33 10000B-1 Published 10-09-13, Control # 215-03...
Page 230 6. HOIST SYSTEM Free Fall (2/2) 10000B-1 6-34 Published 10-09-13, Control # 215-03...
Page 231 6. HOIST SYSTEM Free Fall Control (1/2) 6-35 10000B-1 Published 10-09-13, Control # 215-03...
Page 232 6. HOIST SYSTEM Free Fall Control (2/2) 10000B-1 6-36 Published 10-09-13, Control # 215-03...
Page 233 6. HOIST SYSTEM This page is blank for editing convenience. 6-37 10000B-1 Published 10-09-13, Control # 215-03...
Page 234 (SOL-10) to return the main control valve spool to the neutral position. When the spool is returned to the neutral posi- tion, pressurized oil to the motor is shut off, and the main motor stops rotating. 10000B-1 6-38 Published 10-09-13, Control # 215-03...
Page 235 6. HOIST SYSTEM Free Fall Speed Acceleration (1/2) 6-39 10000B-1 Published 10-09-13, Control # 215-03...
Page 236 6. HOIST SYSTEM Free Fall Speed Acceleration (2/2) 10000B-1 6-40 Published 10-09-13, Control # 215-03...
Page 237 6. HOIST SYSTEM This page is blank for editing convenience. 6-41 10000B-1 Published 10-09-13, Control # 215-03...
Page 238: G Winch Mode Lifting
As directed by the position of the spool, the main pump (No.1, No.2) oil flowing into the control valve is sent to the raising side of the hoist motor to drive the front drum and thereby raise the load. 10000B-1 6-42 Published 10-09-13, Control # 215-03...
Page 239 6. HOIST SYSTEM Lifting (1/3) 6-43 10000B-1 Published 10-09-13, Control # 215-03...
Page 240 6. HOIST SYSTEM Lifting (2/3) 10000B-1 6-44 Published 10-09-13, Control # 215-03...
Page 241 6. HOIST SYSTEM Lifting (3/3) 6-45 10000B-1 Published 10-09-13, Control # 215-03...
Page 242: G Winch Mode Lowering
The counterbalance valve is opened by pilot pressure from the "running in" side to allow the main motor to rotate and lower the load. 10000B-1 6-46 Published 10-09-13, Control # 215-03...
Page 243 6. HOIST SYSTEM Lowering (1/3) 6-47 10000B-1 Published 10-09-13, Control # 215-03...
Page 244 6. HOIST SYSTEM Lowering (2/3) 10000B-1 6-48 Published 10-09-13, Control # 215-03...
Page 245 6. HOIST SYSTEM Lowering (3/3) 6-49 10000B-1 Published 10-09-13, Control # 215-03...
Page 246 6. HOIST SYSTEM This page is blank for editing convenience. 10000B-1 6-50 Published 10-09-13, Control # 215-03...
Page 247: Boom Hoist System
7. BOOM HOIST SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 248 7. BOOM HOIST SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 249: Apparatus And Location Of Components
From this pump, the oil flows through the 4 section side control valve to drive the motor of the boom drum. HYD. OIL TANK GEAR PUMP MAIN PUMP CONTROL VALVE BOOM DRUM MOTOR AND REDUCTION UNIT 10000B-1 Published 10-09-13, Control # 215-03...
Page 250 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. 10000B-1 Published 10-09-13, Control # 215-03...
Page 251: Boom Hoist Winch Installation
Then tighten the nuts to the specified torque. Before installing the winch, place the blocks into the swing frame bracket as shown. DETAIL OF A 10000B-1 Published 10-09-13, Control # 215-03...
Page 252: Boom Drum Lock
CONNECTOR Tightening torque : 21.5 to 24.5 N-m Apply LOCTITE #577 SEMS BOLT BRACKET Tightening torque : 19.4 to 23.6 N-m GREASE FITTING Tightening torque : 21.5 to 24.5 N-m Apply LOCTITE #577 10000B-1 Published 10-09-13, Control # 215-03...
Page 253: Adjusting The Boom Drum Lock
3. Push and pull the knob for a several times to check for the smooth movement of the pawl. Keep hands and clothing clear of the rotating drum. Failure to observe this precaution may result in se- rious injury or loss of life. 10000B-1 Published 10-09-13, Control # 215-03...
Page 254: Reduction Unit
Apply LOCTITE #515 on oil seal O.D. surface. Apply LOCTITE #515 on oil seal O.D. surface. 0.2 to 1.0 0.2 to 1.0 (GAP) (GAP) DETAIL “A” DETAIL “B” 10000B-1 Published 10-09-13, Control # 215-03...
Page 255: Tightening Torque Table
63 to 77 Capscrew M12 X 30 109 to 133 Plug PF3/4 113.1 to 122.9 Capscrew M12 X 40 109 to 133 Capscrew M10 X 85 35.1 to 42.9 Capscrew M8 X 20 31.5 to 38.5 10000B-1 Published 10-09-13, Control # 215-03...
Page 256 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 10000B-1 7-10 Published 10-09-13, Control # 215-03...
Page 257: Construction And Function
7. BOOM HOIST SYSTEM 7.5 CONSTRUCTION AND FUNCTION 7.5.1 HYDRAULIC SCHEMATIC BOOM HOIST HYD. CIRCUIT 7-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 258: Raising The Boom
Main pressured oil flown into the control valve enters into the raising side of the boom drum motor by the boom section spool and the boom is raised. 10000B-1 7-12 Published 10-09-13, Control # 215-03...
Page 259 7. BOOM HOIST SYSTEM BOOM RAISING 7-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 260: Neutral (Holding Boom)
(4 section hyd. se- lecting valve) and the motor brake becomes ac- tuated. (Negative brake) Therefore the boom is held by the counterbal- ance motor brake. 10000B-1 7-14 Published 10-09-13, Control # 215-03...
Page 261 7. BOOM HOIST SYSTEM BOOM HOLDING 7-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 262: Lowering Boom
Main pressured oil flown into the control valve enters into the lowering side of the boom drum motor by the control valve and open the return counterbalance valve and the boom is lowered. 10000B-1 7-16 Published 10-09-13, Control # 215-03...
Page 263 7. BOOM HOIST SYSTEM BOOM LOWERING 7-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 264 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 10000B-1 7-18 Published 10-09-13, Control # 215-03...
Page 265: Swing System
8. SWING SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 266 8. SWING SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 267: Apparatus And Location Of Components
SWING MOTOR AND SWING CONTROL VALVE REDUCTION UNIT SWING BEARING SWING GEAR SWING PUMP 10000B-1 Published 10-09-13, Control # 215-03...
Page 268: Construction And Function
8. SWING SYSTEM CONSTRUCTION AND FUNCTION 8.2.1 HYDRAULIC SCHEMATIC Swing hydraulic schematic 10000B-1 Published 10-09-13, Control # 215-03...
Page 269 8. SWING SYSTEM This page is blank for editing convenience. 10000B-1 Published 10-09-13, Control # 215-03...
Page 270: Swing
(PSb) port of the control valve to move the spools (A) and (B) at the same time. The main pressurized oil controlled by the control valve is fed to the swing motor to run the motor. 10000B-1 Published 10-09-13, Control # 215-03...
Page 271 8. SWING SYSTEM SWING (Neutral Free Mode) 10000B-1 Published 10-09-13, Control # 215-03...
Page 272 8. SWING SYSTEM SWING (Neutral Brake Mode) 10000B-1 Published 10-09-13, Control # 215-03...
Page 273: Stopping
Low side.) However, remember that the motor will not be stopped com- pletely when external forces are always applied, in- cluding the operation on a slope or on windy days. 10000B-1 Published 10-09-13, Control # 215-03...
Page 274 8. SWING SYSTEM STOP (Neutral Free Mode) 10000B-1 8-10 Published 10-09-13, Control # 215-03...
Page 275 8. SWING SYSTEM STOP (Neutral Brake Mode) 8-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 276: Swing Reduction Unit
64 kg (141 lbs) O-Ring Bolt M16 X 45 mm / 145 to 177 N-m (107 to 131 lbs-ft) Tube Level gauge Bolt M20 X 140 mm / 504 to 616 N-m (372 to 454 lbs-ft) 10000B-1 8-12 Published 10-09-13, Control # 215-03...
Page 277 Bolt hole M20 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Shim adjustment 0.05 to 0.15 mm (0.0020 to 0.0059 inch) A area 8-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 278: Tightening Torque
M10 X 25 63 to 77 (46.5 to 56.8) Capscrew M8 X 20 31.5 to 38.5 (23.2 to 28.4) Apply LOCTITE #242 to capscrew. Assembly total weight : Approx. 396 kg (873 lbs) (Without motor) 10000B-1 8-14 Published 10-09-13, Control # 215-03...
Page 279: Swing Bearing
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” mark) Upper machinery rear 8-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 280 Ref: tightening torque 2.5 to 3.06 kN-m (1,844 to 2,257 lbs-ft) Bearing inner ring soft zone (S mark position) shall be positioned against the lower machinery as shown. Assembly total weight : Approx. 1,013 kg (2,233 lbs) 10000B-1 8-16 Published 10-09-13, Control # 215-03...
Page 281: 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 282 8. SWING SYSTEM 10000B-1 8-18 Published 10-09-13, Control # 215-03...
Page 283: Propel System
9. PROPEL SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 284 9. PROPEL SYSTEM 10000B-1 Published 10-09-13, Control # 215-03...
Page 285 (built-in type). As for circuit diagram and function of propel (right for- ward), stop, refer to P.9-11 to 9-15. SWIVEL JOINT PROPEL MOTOR SWIVEL JOINT DRIVE TUMBLER REDUCTION UNIT SHOE UPPER ROLLER IDLER LOWER ROLLER 10000B-1 Published 10-09-13, Control # 215-03...
Page 286: Propel Reduction Unit
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 10000B-1 Published 10-09-13, Control # 215-03...
Page 287 9. PROPEL SYSTEM This page is blank for editing convenience. 10000B-1 Published 10-09-13, Control # 215-03...
Page 288: 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” 10000B-1 Published 10-09-13, Control # 215-03...
Page 289 (45.5 to 55.6) 88.3 to 107.9 Plug R (PT) 3/4 (65.1 to 79.6) 26.5 to 32.3 Plug G (PF) 1/4 (19.5 to 23.8) Apply loctite #242 on capscrew. Assembly weight : Approx. 765 kg (1,687lbs) 10000B-1 Published 10-09-13, Control # 215-03...
Page 290: Motor
Tightening Torque : 70.7 to 86.4 N-m 98.1 to 117.7 N-m (52.1 to 63.7 ft-lbs) (72.4 to 86.8 ft-lbs) RED MEC NPT 1/6 (4 places) Tightening Torque : 9.81 to 11.8 N-m (7.24 to 8.70 ft-lbs) 10000B-1 Published 10-09-13, Control # 215-03...
Page 291: Hydraulic Circuit
11. Plate 26. Oil seal 41. Pilot valve 12. Ball 27. Spring 42. Brake valve 13. Holder 28. Spring 43. Plug 14. Piston assy 29. Spring 44. Plug 15. Seal 30. Bearing HYDRAULIC CIRCUIT 10000B-1 Published 10-09-13, Control # 215-03...
Page 292: Adjustment
Insert the remaining shims into pack (A). 5. Remove the hydraulic jack. Store spare shims in the shim pack (A). Equalize the tension in right and left crawler tracks. JACK Φ60 PORT POWER ADAPTER 10000B-1 9-10 Published 10-09-13, Control # 215-03...
Page 293: Construction And Function
9. PROPEL SYSTEM 9.4 CONSTRUCTION AND FUNCTION 9.4.1 HYDRAULIC SCHEMATIC 9-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 294: Propelling (Right Side Forward)
The pressurized oil that activated in the propel motor is free to return to the reservoir. 10000B-1 9-12 Published 10-09-13, Control # 215-03...
Page 295 9. PROPEL SYSTEM PROPEL (R.H. FORWARD) 9-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 296: Stopping
At the same time, the pressurized oil in the brake cylinder is returned to the reservoir, and the parking brake engages slowly. 10000B-1 9-14 Published 10-09-13, Control # 215-03...
Page 297 9. PROPEL SYSTEM PROPEL STOPPING 9-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 298 9. PROPEL SYSTEM This page is blank for editing convenience. 10000B-1 9-16 Published 10-09-13, Control # 215-03...
Page 299: Electric System
10. ELECTRIC SYSTEM 10-1 10000B-1 Published 10-09-13, Control # 215-03...
Page 300 NEVER forcibly insert the measurement probe. Otherwise, disconnection can occur later. Short-circuiting across terminals inside a connector can damage electronic components. Be absolutely careful to prevent short-circuit. 10000B-1 10-2 Published 10-09-13, Control # 215-03...
Page 301: Electrical
10. ELECTRIC SYSTEM 10.1 ELECTRICAL 10.1.1 ELECTRICAL WIRING SCHEMATIC (1/18) 10-3 10000B-1 Published 10-09-13, Control # 215-03...
Page 302 10. ELECTRIC SYSTEM (2/18) 10000B-1 10-4 Published 10-09-13, Control # 215-03...
Page 303 10. ELECTRIC SYSTEM (3/18) 10-5 10000B-1 Published 10-09-13, Control # 215-03...
Page 304 10. ELECTRIC SYSTEM (4/18) 10000B-1 10-6 Published 10-09-13, Control # 215-03...
Page 305 10. ELECTRIC SYSTEM (5/18) 10-7 10000B-1 Published 10-09-13, Control # 215-03...
Page 306 10. ELECTRIC SYSTEM (6/18) 10000B-1 10-8 Published 10-09-13, Control # 215-03...
Page 307 10. ELECTRIC SYSTEM (7/18) 10-9 10000B-1 Published 10-09-13, Control # 215-03...
Page 308 10. ELECTRIC SYSTEM (8/18) 10000B-1 10-10 Published 10-09-13, Control # 215-03...
Page 309 10. ELECTRIC SYSTEM (9/18) 10-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 310 10. ELECTRIC SYSTEM (10/18) 10000B-1 10-12 Published 10-09-13, Control # 215-03...
Page 311 10. ELECTRIC SYSTEM (11/18) 10-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 312 10. ELECTRIC SYSTEM (12/18) 10000B-1 10-14 Published 10-09-13, Control # 215-03...
Page 313 10. ELECTRIC SYSTEM (13/18) 10-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 314 10. ELECTRIC SYSTEM (14/18) 10000B-1 10-16 Published 10-09-13, Control # 215-03...
Page 315 10. ELECTRIC SYSTEM (15/18) 10-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 316 10. ELECTRIC SYSTEM (16/18) 10000B-1 10-18 Published 10-09-13, Control # 215-03...
Page 317 10. ELECTRIC SYSTEM (17/18) 10-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 318 10. ELECTRIC SYSTEM (18/18) 10000B-1 10-20 Published 10-09-13, Control # 215-03...
Page 319: Connector Layout
Brown Black Pink Green ＰＧ COUNTER WEIGHT SELF REMOVAL (OPTION) Ｂ rW Brown White Pink bLue ＰＬ COUNTER WEIGHT SELF REMOVAL Brown Violet Ｂ rR ＶＲ OVER LOAD PREVENT (M. MACHINERY) BLANK BLANK 10-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 320 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 10000B-1 10-22 Published 10-09-13, Control # 215-03...
Page 321 1 DRUM / 2 DRUM FOOT BRAKE PRESSURE FOOT BRAKE PRESSURE AIS AIR-CONDITIONER (REAR DRUM) SELECT SWITCH (OPTION) (FRONT DRUM) (THIRD DRUM PRESS. SWITCH PRESS. SWITCH PRESS. SWITCH (THIRD SPEC.) VIEW FROM THE FLOOR PLATE UNDER (1/4) 10-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 322 CAMERA ASSY CN-427 ML MONITOR CN-419 THIRD FREE-FALL SELECT SWITCH (THIRD SPEC.) CN-417 THROTTLE GRIP CN-418 SWING PARKING/ HPRN SWITCH CN-424 BYPASS SWITCH VIEW FROM “A” VIEW FROM “B” DETAIL OF LEFT STAND (2/4) 10000B-1 10-24 Published 10-09-13, Control # 215-03...
Page 323 REAR DRUM TURN DETECTION GRIP (OPTION) CN-489 CN-460 42C(W/B) RIGHT PROPEL CONTROL DETECTION PRESS.SWITCH CN-459 RIGHT PROPEL CONTROL DETECTION PRESS.SWITCH CN-458 FUNCTION LOCK LIMIT SWITCH SECTION “D-D” DETAIL OF RIGHT SIDE STAND (3/4) 10-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 324 DC-DC CONVERTER (FROM ECU HARNESS) CN-950F HARNESS CN-481 CN-482 TW. RACHCYLINDER CUT (OPT) AIS AIR COMPRESSOR ON (OPT) DETAIL OF RELAY BOX SECTION “E-E” DETAIL OF ECU CONNECTOR DETAIL OF SWITCH BOARD CONNECTOR (4/4) 10000B-1 10-26 Published 10-09-13, Control # 215-03...
Page 325 10. ELECTRIC SYSTEM OUT INDICATING LIGHT RELAY JUNCTION HARNESS (1/2) 10-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 326 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-28 Published 10-09-13, Control # 215-03...
Page 327 10. ELECTRIC SYSTEM FLOOR HARNESS A (1/5) 10-29 10000B-1 Published 10-09-13, Control # 215-03...
Page 328 10. ELECTRIC SYSTEM (2/5) 10000B-1 10-30 Published 10-09-13, Control # 215-03...
Page 329 10. ELECTRIC SYSTEM (3/5) 10-31 10000B-1 Published 10-09-13, Control # 215-03...
Page 330 10. ELECTRIC SYSTEM (4/5) 10000B-1 10-32 Published 10-09-13, Control # 215-03...
Page 331 10. ELECTRIC SYSTEM (5/5) 10-33 10000B-1 Published 10-09-13, Control # 215-03...
Page 332 10. ELECTRIC SYSTEM FLOOR HARNESS B (1/5) 10000B-1 10-34 Published 10-09-13, Control # 215-03...
Page 333 10. ELECTRIC SYSTEM (2/5) 10-35 10000B-1 Published 10-09-13, Control # 215-03...
Page 334 10. ELECTRIC SYSTEM (3/5) 10000B-1 10-36 Published 10-09-13, Control # 215-03...
Page 335 10. ELECTRIC SYSTEM (4/5) 10-37 10000B-1 Published 10-09-13, Control # 215-03...
Page 336 10. ELECTRIC SYSTEM (5/5) 10000B-1 10-38 Published 10-09-13, Control # 215-03...
Page 337 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 338 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/2) 10000B-1 10-40 Published 10-09-13, Control # 215-03...
Page 339 10. ELECTRIC SYSTEM LOWER HARNESS (1/4) 10-41 10000B-1 Published 10-09-13, Control # 215-03...
Page 340 10. ELECTRIC SYSTEM (2/4) 10000B-1 10-42 Published 10-09-13, Control # 215-03...
Page 341 10. ELECTRIC SYSTEM (3/4) 10-43 10000B-1 Published 10-09-13, Control # 215-03...
Page 342 10. ELECTRIC SYSTEM (4/4) 10000B-1 10-44 Published 10-09-13, Control # 215-03...
Page 343 10. ELECTRIC SYSTEM TRANS LIFTER REMOTE CONTROLLER CABLE HARNESS (OPTION) (1/3) 10-45 10000B-1 Published 10-09-13, Control # 215-03...
Page 344 10. ELECTRIC SYSTEM (2/3) 10000B-1 10-46 Published 10-09-13, Control # 215-03...
Page 345 10. ELECTRIC SYSTEM (3/3) 10-47 10000B-1 Published 10-09-13, Control # 215-03...
Page 346 MOTOR CHP CONTROL PROP.VALVE (SOL-103) CN-832F FRONT/REAR CHP PRESS. SENSOR (PT-19) CN-807F DETAIL OF “L” FOR 10000B-1 BOOM RAISE STOP (SOL-35) REAR DRUM RAISE REMO-CON. PROP.VALVE (SOL-56) CN-822F CN-828F BOOM LOWERING STOP (SOL-36) REAR DRUM LOWER REMO-CON. PROP.VALVE (SOL-57) CN-823F...
Page 347 PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-816F CN-39F CN-40F CN-41F CN-119F CN-111F CN-118F CN-112F CN-115F CN-113F CN-117F CN-116F CN-114F LEFT DECK INSIDE VIEW FROM “C” (2/6) 10-49 10000B-1 Published 10-09-13, Control # 215-03...
Page 348 CN-802F FRONT DRUM TILT PROP. VALVE (SOL-65) FUEL LEVEL CN-833F SENSOR FRONT DRUM MOTOR BOOST (SOL-15) CN-838F FRONT LEFT REAR VIEW OF LEFT DECK CENTER FUEL TANK AND FRONT DRUM MOTOR AREA (3/6) 10000B-1 10-50 Published 10-09-13, Control # 215-03...
Page 349 CN-871 CN-848 CONNECT TO RELAY UNIT HARNESS CN-851 CN-852 CONNECT TO REAR WORK LIGHT HARNESS CN-844F CONNECT TO DRUM LIGHT HARNESS CN-845F CONNECT TO C/W DETECTOR VIEW FROM “B” SECTION “F-F” CN-843 (4/6) 10-51 10000B-1 Published 10-09-13, Control # 215-03...
Page 350 REAR DRUM TILT SENSOR (SOL-14) CN-803F REAR DRUM TILT PROP. VALVE (SOL-66) CN-834F CN-849M TO SWING FRAME VIEW FROM “G” CONDENSOR FUN MOTOR AIR CON PRESSURE SW CN-847F CN-846F FRONT VIEW FROM “Q” (5/6) 10000B-1 10-52 Published 10-09-13, Control # 215-03...
Page 351 CN-818F THIRD TILT SENSOR (PT-15) CUT OUT RELAY (R-C) CN-804F CN-850F AIR HEATER RELAY (R-AH) CN-856F START BLOCK RELAY THIRD MOTOR BOOST (SOL-17) SAFETY RELAY CN-841F WHEN THIRD WINCH (OPTION) IS INSTALLED. (6/6) 10-53 10000B-1 Published 10-09-13, Control # 215-03...
Page 352 10. ELECTRIC SYSTEM LEFT DECK HARNESS (1/5) 10000B-1 10-54 Published 10-09-13, Control # 215-03...
Page 353 10. ELECTRIC SYSTEM (2/5) 10-55 10000B-1 Published 10-09-13, Control # 215-03...
Page 354 10. ELECTRIC SYSTEM (3/5) 10000B-1 10-56 Published 10-09-13, Control # 215-03...
Page 355 10. ELECTRIC SYSTEM (4/5) 10-57 10000B-1 Published 10-09-13, Control # 215-03...
Page 356 10. ELECTRIC SYSTEM (5/5) 10000B-1 10-58 Published 10-09-13, Control # 215-03...
Page 357 10. ELECTRIC SYSTEM RELAY HARNESS (1/3) 10-59 10000B-1 Published 10-09-13, Control # 215-03...
Page 358 10. ELECTRIC SYSTEM (2/3) 10000B-1 10-60 Published 10-09-13, Control # 215-03...
Page 359 10. ELECTRIC SYSTEM (3/3) 10-61 10000B-1 Published 10-09-13, Control # 215-03...
Page 360 E0 (B) LA-B03, B07 DETAIL OF CAB LOWER DECK SECTION “A-A” SECTION “B-B” FLOOR HARNESS “A” CAB MAIN HARNESS FLOOR HARNESS “B” CN-675 CN-674 CN-676 CN-671 CN-677 CN-670 CN-884 CN-678 CN-672 CN-679 CN-883 CN-673 (1/4) 10000B-1 10-62 Published 10-09-13, Control # 215-03...
Page 361 MAIN PUMP INCHING P1 SOL STARTER MOTOR “B” STARTER MOTOR “C” TERMINAL TERMINAL DETAIL OF “L” CN-413 CN-412 GUARD HARNESS CN-603 CN-618 CONNECT TO C/W SELF Re. CLUTCH PRESS. SENSOR REMOVAL HARNESS CN-619 VIEW FROM “C” (2/4) 10-63 10000B-1 Published 10-09-13, Control # 215-03...
Page 362 COOLING OIL TEMP. SWITCH COOLING OIL TEMP. SWITCH (REAR WET CLUTCH) (FRONT WET CLUTCH) CN-607 COOLING OIL TEMP. SWITCH CN-608 COOLING OIL TEMP. SWITCH (REAR WET CLUTCH) (FRONT WET CLUTCH) VIEW FROM “H” (3/4) 10000B-1 10-64 Published 10-09-13, Control # 215-03...
Page 363 INCHING SPEED SOL LOW SPEED SOL CN-612 BOOM PUMP POWER REDUCE SOL CN-637 Pf SENSOR CN-613 SWING PUMP MAIN PUMP POWER REDUCE SOL MAIN PUMP DETAIL OF “M” (AT INDEPENDENT, CONFLUENCE SELECTED) (4/4) 10-65 10000B-1 Published 10-09-13, Control # 215-03...
Page 364 10. ELECTRIC SYSTEM RIGHT DECK HARNESS (1/4) 10000B-1 10-66 Published 10-09-13, Control # 215-03...
Page 365 10. ELECTRIC SYSTEM (2/4) 10-67 10000B-1 Published 10-09-13, Control # 215-03...
Page 366 10. ELECTRIC SYSTEM (3/4) 10000B-1 10-68 Published 10-09-13, Control # 215-03...
Page 367 10. ELECTRIC SYSTEM (4/4) 10-69 10000B-1 Published 10-09-13, Control # 215-03...
Page 368 10. ELECTRIC SYSTEM POWER SUPPLY HARNESS (1/3) 10000B-1 10-70 Published 10-09-13, Control # 215-03...
Page 369 10. ELECTRIC SYSTEM (2/3) 10-71 10000B-1 Published 10-09-13, Control # 215-03...
Page 370 10. ELECTRIC SYSTEM (3/3) 10000B-1 10-72 Published 10-09-13, Control # 215-03...
Page 371 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL B) TO BATTERY RELAY HARNESS 10-73 10000B-1 Published 10-09-13, Control # 215-03...
Page 372 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL C) TO SAFETY RELAY HARNESS 10000B-1 10-74 Published 10-09-13, Control # 215-03...
Page 373 10. ELECTRIC SYSTEM GLOW RELAY HARNESS TO ENGINE SUB HARNESS 10-75 10000B-1 Published 10-09-13, Control # 215-03...
Page 374 INTAKE AIR TEMP. SENSOR C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-632M CN-630F CN-630F VIEW FROM “B” CN-609F RADIATOR WATER LEVEL ARALM SENSOR RIGHT DECK HARNESS CN-618M CN-629M VIEW FROM “A” (1/2) 10000B-1 10-76 Published 10-09-13, Control # 215-03...
Page 375 C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-642F FOR DPR PRESS. DIFF SENSOR CN-842 CONNECT TO OVERLOAD ALARM LAMP (OPTION) CN-632F VIEW FROM “C” VIEW FROM “D” MACHINE FRONT MACHINE FRONT (2/2) 10-77 10000B-1 Published 10-09-13, Control # 215-03...
Page 376 10. ELECTRIC SYSTEM GUARD HARNESS A (1/3) 10000B-1 10-78 Published 10-09-13, Control # 215-03...
Page 377 10. ELECTRIC SYSTEM (2/3) 10-79 10000B-1 Published 10-09-13, Control # 215-03...
Page 378 10. ELECTRIC SYSTEM (3/3) 10000B-1 10-80 Published 10-09-13, Control # 215-03...
Page 379 10. ELECTRIC SYSTEM GUARD HARNESS B (1/3) 10-81 10000B-1 Published 10-09-13, Control # 215-03...
Page 380 10. ELECTRIC SYSTEM (2/3) 10000B-1 10-82 Published 10-09-13, Control # 215-03...
Page 381 10. ELECTRIC SYSTEM (3/3) 10-83 10000B-1 Published 10-09-13, Control # 215-03...
Page 382 10. ELECTRIC SYSTEM GUARD HARNESS C (1/2) 10000B-1 10-84 Published 10-09-13, Control # 215-03...
Page 383 10. ELECTRIC SYSTEM (2/2) 10-85 10000B-1 Published 10-09-13, Control # 215-03...
Page 384 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) 10000B-1 10-86 Published 10-09-13, Control # 215-03...
Page 385 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 386 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10000B-1 10-88 Published 10-09-13, Control # 215-03...
Page 387 10. ELECTRIC SYSTEM SWING FRAME HARNESS (1/4) 10-89 10000B-1 Published 10-09-13, Control # 215-03...
Page 388 10. ELECTRIC SYSTEM (2/4) 10000B-1 10-90 Published 10-09-13, Control # 215-03...
Page 389 10. ELECTRIC SYSTEM (3/4) 10-91 10000B-1 Published 10-09-13, Control # 215-03...
Page 390 10. ELECTRIC SYSTEM (4/4) 10000B-1 10-92 Published 10-09-13, Control # 215-03...
Page 391 10. ELECTRIC SYSTEM ATT. JUNCTION HARNESS (1/3) 10-93 10000B-1 Published 10-09-13, Control # 215-03...
Page 392 10. ELECTRIC SYSTEM (2/3) 10000B-1 10-94 Published 10-09-13, Control # 215-03...
Page 393 10. ELECTRIC SYSTEM (3/3) 10-95 10000B-1 Published 10-09-13, Control # 215-03...
Page 394 LOAD DETECTOR HARNESS CN-302A CAB HARNESS CN-302B CB-A01 HEAD LIGHT (RIGHT) CN-302 CA-A01 CN-293 FLOOR A HARNESS CN-887M CN-291 CN-300 CN-887F CN-307A CN-307 CN-307B FLOOR B HARNESS VIEW FROM “J-J” DETAIL OF “B” (1/3) 10000B-1 10-96 Published 10-09-13, Control # 215-03...
Page 395 (OPTION) VIEW FROM “J” CN-211 CN-213 MULTI VOICE SW G WINCH MAIN SW (OPTION) CN-226 CN-214 RADIO CN-210 AIS MAIN SW DRUM TURN SW (OPTION) CN-215 G MODE SW VIEW FROM “F” (2/3) 10-97 10000B-1 Published 10-09-13, Control # 215-03...
Page 396 (REEVING/ FOOT PIN) CN-11-4 CN-11-6B CN-221 PROPEL SPEED SELECTOR SW CN-11-6A CN-220 UNDULATION PEDAL SELECTOR SW (OPTION) CN-219 WINCH SELECTOR SW (OPTION) CB-11-2 CB-11-1B CB-11-1D CB-11-1A CB-11-1C M/L CONNECTOR VIEW FROM “H” (3/3) 10000B-1 10-98 Published 10-09-13, Control # 215-03...
Page 397 10. ELECTRIC SYSTEM CAB HARNESS (1/6) 10-99 10000B-1 Published 10-09-13, Control # 215-03...
Page 398 10. ELECTRIC SYSTEM (2/6) 10000B-1 10-100 Published 10-09-13, Control # 215-03...
Page 399 10. ELECTRIC SYSTEM (3/6) 10-101 10000B-1 Published 10-09-13, Control # 215-03...
Page 400 10. ELECTRIC SYSTEM (4/6) 10000B-1 10-102 Published 10-09-13, Control # 215-03...
Page 401 10. ELECTRIC SYSTEM (5/6) 10-103 10000B-1 Published 10-09-13, Control # 215-03...
Page 402 10. ELECTRIC SYSTEM (6/6) 10000B-1 10-104 Published 10-09-13, Control # 215-03...
Page 403 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 404 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TO ENGINE GROUND HARNESS 10000B-1 10-106 Published 10-09-13, Control # 215-03...
Page 405 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TARMINAL B ALTERNATOR HARNESS TARMINAL B 10-107 10000B-1 Published 10-09-13, Control # 215-03...
Page 406 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 10000B-1 10-108 Published 10-09-13, Control # 215-03...
Page 407 10. ELECTRIC SYSTEM MONITOR HARNESS (1/2) 10-109 10000B-1 Published 10-09-13, Control # 215-03...
Page 408 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-110 Published 10-09-13, Control # 215-03...
Page 409 SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT REMOTE CONTROL CONNECT (UPPER) CN-550F CN-413M CONNECT TO RIGHT DECK HARNESS CN-412M DETAIL OF “A” 10-111 10000B-1 Published 10-09-13, Control # 215-03...
Page 410 10. ELECTRIC SYSTEM COUNTER WEIGHT SELF REMOVAL HARNESS (1/3) 10000B-1 10-112 Published 10-09-13, Control # 215-03...
Page 411 10. ELECTRIC SYSTEM (2/3) 10-113 10000B-1 Published 10-09-13, Control # 215-03...
Page 412 10. ELECTRIC SYSTEM (3/3) 10000B-1 10-114 Published 10-09-13, Control # 215-03...
Page 413 10. ELECTRIC SYSTEM 11. OVER LOAD PREVENT (M. MACHINERY) (1/2) 10-115 10000B-1 Published 10-09-13, Control # 215-03...
Page 414 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-116 Published 10-09-13, Control # 215-03...
Page 415 CB/W : CARBODY WEIGHT CN-625 HYD. OIL HEAT (SOL-47) CN-634 HYD. OIL HEAT (SOL-47) RIGHT DECK HARNESS CN-634 CN-627 CN-625 HYD. OIL HEAT (SOL-47) OIL TEMP. SWITCH (LS-30) CN-627 OIL TEMP. SWITCH (LS-30) DETAIL OF “A” 10-117 10000B-1 Published 10-09-13, Control # 215-03...
Page 416 10. ELECTRIC SYSTEM HYDRAULIC OIL HEAT HARNESS (1/2) 10000B-1 10-118 Published 10-09-13, Control # 215-03...
Page 417 10. ELECTRIC SYSTEM (2/2) 10-119 10000B-1 Published 10-09-13, Control # 215-03...
Page 418 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) 10000B-1 10-120 Published 10-09-13, Control # 215-03...
Page 419 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 420 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10000B-1 10-122 Published 10-09-13, Control # 215-03...
Page 421 10. ELECTRIC SYSTEM BOOM BASE HARNESS (INSERT INCLUDED) (1/2) 10-123 10000B-1 Published 10-09-13, Control # 215-03...
Page 422 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-124 Published 10-09-13, Control # 215-03...
Page 423 10. ELECTRIC SYSTEM CABLE (1/2) 10-125 10000B-1 Published 10-09-13, Control # 215-03...
Page 424 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-126 Published 10-09-13, Control # 215-03...
Page 425 10. ELECTRIC SYSTEM 16. BOOM TIP HARNESS (1/2) 10-127 10000B-1 Published 10-09-13, Control # 215-03...
Page 426 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-128 Published 10-09-13, Control # 215-03...
Page 427 10. ELECTRIC SYSTEM CABLE (1/2) 10-129 10000B-1 Published 10-09-13, Control # 215-03...
Page 428 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-130 Published 10-09-13, Control # 215-03...
Page 429 10. ELECTRIC SYSTEM CABLE (1/2) 10-131 10000B-1 Published 10-09-13, Control # 215-03...
Page 430 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-132 Published 10-09-13, Control # 215-03...
Page 431 10. ELECTRIC SYSTEM 17. ELECTRICAL PART OF CRAWLER SELF REMOVAL 10-133 10000B-1 Published 10-09-13, Control # 215-03...
Page 432 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 10000B-1 10-134 Published 10-09-13, Control # 215-03...
Page 433 10. ELECTRIC SYSTEM FIXED JIB HARNESS 10-135 10000B-1 Published 10-09-13, Control # 215-03...
Page 434 10. ELECTRIC SYSTEM CABLE (1/2) 10000B-1 10-136 Published 10-09-13, Control # 215-03...
Page 435 10. ELECTRIC SYSTEM (2/2) 10-137 10000B-1 Published 10-09-13, Control # 215-03...
Page 436 10. ELECTRIC SYSTEM CABLE (1/2) 10000B-1 10-138 Published 10-09-13, Control # 215-03...
Page 437 10. ELECTRIC SYSTEM (2/2) 10-139 10000B-1 Published 10-09-13, Control # 215-03...
Page 438 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) 10000B-1 10-140 Published 10-09-13, Control # 215-03...
Page 439 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 440 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10000B-1 10-142 Published 10-09-13, Control # 215-03...
Page 441 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10-143 10000B-1 Published 10-09-13, Control # 215-03...
Page 442 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-144 Published 10-09-13, Control # 215-03...
Page 443 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10-145 10000B-1 Published 10-09-13, Control # 215-03...
Page 444 10. ELECTRIC SYSTEM (2/2) 10000B-1 10-146 Published 10-09-13, Control # 215-03...
Page 445 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 446 10. ELECTRIC SYSTEM This page is blank for editing convenience. 10000B-1 10-148 Published 10-09-13, Control # 215-03...
Page 447: 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 448 For MC1 control – For MC1 output – Auto stop – Engine condition – One way radio – Wiper – Function lock – Remote control – Monitor – Air-con – Air-con 2 – Fan motor 10000B-1 10-150 Published 10-09-13, Control # 215-03...
Page 449 For MC2 ground output – Over hoist LS – Fuel pump / lighter – 46 For MC1 ground output 1 – For MC1 ground output 2 – 48 Neutral free – 49 Light – 50 Spare 10-151 10000B-1 Published 10-09-13, Control # 215-03...
Page 450 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. 10000B-1 10-152 Published 10-09-13, Control # 215-03...
Page 451 10. ELECTRIC SYSTEM 10-153 10000B-1 Published 10-09-13, Control # 215-03...
Page 452 10. ELECTRIC SYSTEM 10000B-1 10-154 Published 10-09-13, Control # 215-03...
Page 453: 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 454: Pressure Switch (For Propel Motion Detect)
539 ± 49 KPa : ON Tightening torque 14.7 ± 2.9 N-m 343 ± 49 KPa : OFF [ON] Pressure (KPa) [OFF] Pressure (KPa) Propel motion detect pressure 539 ± 49 343 ± 49 10000B-1 10-156 Published 10-09-13, Control # 215-03...
Page 455: Pressure Switch (Foot Brake)
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 10000B-1 Published 10-09-13, Control # 215-03...
Page 456: 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 10000B-1 10-158 Published 10-09-13, Control # 215-03...
Page 457 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 458 Out-put : 1/10 Vcc =0.5 V to 4.5 V Out-put : 1/10 Vcc =0.5 V to 4.5 V Tightning torque : 32 N-m max (26.7 ft-lbs) Tightning torque : 73.5 N-m max (54.2 ft-lbs) 10000B-1 10-160 Published 10-09-13, Control # 215-03...
Page 459 Power (V) Out-put (V) MPa (psi) Clutch pressure (Front • Rear • 3rd) 0 to 19.6 9999426022 0.5 to 4.5 Control pressure (Primary side) (0 to 2842) NOTE 9999426022 Tightening torque : 73.5 N-m 10-161 10000B-1 Published 10-09-13, Control # 215-03...
Page 460: Inclination Sensor
Vibration Endurance 10 to 500HZ Amplitude resistance 3 mm width X.Y.Z, direction 96h (about 20G) Impact resistance Endurance 500/s (about 50G) Load resistance min 10k width X.Y.Z, direction about 10th Zero ±5° adjustment 10000B-1 10-162 Published 10-09-13, Control # 215-03...
Page 461: Buzzer Unit
10. ELECTRIC SYSTEM 10.1.9 BUZZER UNIT 10-163 10000B-1 Published 10-09-13, Control # 215-03...
Page 462 Rated Volt Work range (Volt) 19 to 32V Working temperature range -10 to 60 Storage temperature range -20 to 70 Humidity 0 to 90% Sound volume 75db/30cm MIN Consumption elec. current Max 50 mA 10000B-1 10-164 Published 10-09-13, Control # 215-03...
Page 463 10. ELECTRIC SYSTEM 10.1.10 RELAY BOX 1. ARRANGEMENT OF CONNECTOR 10-165 10000B-1 Published 10-09-13, Control # 215-03...
Page 464 10. ELECTRIC SYSTEM 10000B-1 10-166 Published 10-09-13, Control # 215-03...
Page 465 Speed limit release RL-28 Speed limit RL-29 Outside indication lamp ( green ) RL-30 Outside indication lamp ( yellow ) RL-31 Outside indication lamp ( red ) RL-32 ML adjust mode select RL-36 10-167 10000B-1 Published 10-09-13, Control # 215-03...
Page 466 F-21 MC1(D/O) SAFETY RELAY (RL-02) MC1(D/I) M/L (D/O) REMO-CON ENGINE EMERGENCY ST (SW-71) IGNITION SW AIS AIR-CON CUT RELAY (RL-04, 81) MC1(D/O) MC1(D/I) MC1(D/O) HORN RELAY REMO-CON SWING PARKING SW SWING PARKING SW-11 10000B-1 10-168 Published 10-09-13, Control # 215-03...
Page 467 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 468 SW-26 PROPEL CONTROL PSW-7,10 PROPEL SWING VOICE ALARM HYD. SOURCE HYD. SOURCE SELECT SELECT SW-65 SOL-45 REMO-CON TRANSLIFTER SELECT SOL-44 REMO-CON HYD. OIL HEAT DOL-47 MC1(D/O) M/L (D/I) MC1(D/O) MC BYPASS SW SW-38 10000B-1 10-170 Published 10-09-13, Control # 215-03...
Page 469 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 SW-37 F-05 10-171 10000B-1 Published 10-09-13, Control # 215-03...
Page 470 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 10000B-1 10-172 Published 10-09-13, Control # 215-03...
Page 471 BRAKE PRESS. PSW-1 Re.DRUM FREE-FALL SELECT SW-54 Re.DRUM FOOT BRAKE PRESS. PSW-2 3rd.DRUM FREE-FALL SELECT SW-55 3rd.DRUM FOOT BRAKE PRESS. PSW-3 RIGHT CYL. EXT. REMO-CON SOL-98 LEFT CYL. EXT. REMO-CON SOL-98 M/L (D/O) 10-173 10000B-1 Published 10-09-13, Control # 215-03...
Page 472 MC1(D/O) Fr.DRUM CLUTCH CLM SOL-22 MC1(D/O) Fr.DRUM CLUTCH ESM SOL-19 MC1(D/O) Re.DRUM CLUTCH CLA F-37 SOL-23 MC1(D/O) Re.DRUM CLUTCH ESA SOL-20 MC1(D/O) 3rd.DRUM CLUTCH CLT F-37 SOL-24 MC1(D/O) 3rd.DRUM CLUTCH EST SOL-21 MC1(D/O) 10000B-1 10-174 Published 10-09-13, Control # 215-03...
Page 473 Fr. Re. 3rd. DRUM HOIST STOP SOL-37, 38, 18 BOOM HOIST STOP SOL-35 BOOM OVERHOIST LSW-7 F-34 BOOM B/S No.2 LSW-12 BOOM B/S No.1 LSW-9 M/L (D/O) M/L (D/O) M/L (D/O) CONFIGURATION SELECT SW-36 M/L (D/O) 10-175 10000B-1 Published 10-09-13, Control # 215-03...
Page 474: Relay Box
10. ELECTRIC SYSTEM 10.1.11 RELAY BOX 10000B-1 10-176 Published 10-09-13, Control # 215-03...
Page 475 Rear raise stop relay RL-64 Rear lower stop relay RL-65 Third raise stop relay RL-66 Third lower stop relay RL-67 MC bypass relay 1 RL-68 Independence, confluence select (F) RL-69 Independence, confluence select (R) RL-70 10-177 10000B-1 Published 10-09-13, Control # 215-03...
Page 476 MC-2 (P/O) Re.DRUM LOWER REMO-CON (PSOL-57) 3rd.DRUM HOIST 3rd.DRUM HOIST REMO-CON MC-2 (P/O) (PSOL-58) 3rd.DRUM HOIST REMO-CON MC-2 (P/O) (PSOL-58) 3rd.DRUM LOWER 3rd.DRUM LOWER REMO-CON MC-2 (P/O) (PSOL-59) MC-2 (P/O) 3rd.DRUM LOWER REMO-CON (PSOL-59) 10000B-1 10-178 Published 10-09-13, Control # 215-03...
Page 477 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 478: 12Load Cell (Crane)
Water proof : Conforms to IP67 or equivalent (JIS C0920 non-seeping type) 5  10 Durability : times Noise proof : DC700V 100ns Total integrity : 2.9% RO Weight : About 6 kg 10000B-1 10-180 Published 10-09-13, Control # 215-03...
Page 479: Angle Sensor
Plastic (Toshiba premix AP-902S) Surface treatment : Non, stripe (Black) Temperature range : -20 to 70° C Store temp. : -40 to 80° C Weight : appr. 1.2kg (main body), appr. 65g/m (cable) 10-181 10000B-1 Published 10-09-13, Control # 215-03...
Page 480: 14Troubleshooting Of Exhaust Gas Third Regulation Engine
How to turn off the engine trouble detect lamp START STATER SWITCH LOCK STOP ENGINE START ENGINE TROUBLE DETECT LAMP TIME 10000B-1 10-182 Published 10-09-13, Control # 215-03...
Page 481: 15How To Check The Failure Contents
CN-878F, CN-879M Component location related to diagnosis. • Diag. lamp location • Diag. connector CN-878F,CN-879M location • DST-1 diag. connector location Diag.SW CN-878F CN-879M DST-1 CN486F 10-183 10000B-1 Published 10-09-13, Control # 215-03...
Page 482 10. ELECTRIC SYSTEM Diag. lamp (Red) 10000B-1 10-184 Published 10-09-13, Control # 215-03...
Page 483 10. ELECTRIC SYSTEM 2. Table of Diagnosis codes (J08E-TI) 10-185 10000B-1 Published 10-09-13, Control # 215-03...
Page 484 10. ELECTRIC SYSTEM 10000B-1 10-186 Published 10-09-13, Control # 215-03...
Page 485 10. ELECTRIC SYSTEM 10-187 10000B-1 Published 10-09-13, Control # 215-03...
Page 486 [Example] Display of diagnosis codes example 1) When codes 32 and 21 are displayed 0.5 sec 0.5 sec 1.5 sec CODE 32 CODE 21 CONTINUES example 2) Normality displayed 0.3 sec 10000B-1 10-188 Published 10-09-13, Control # 215-03...
Page 487: 16Checking Of Diagnosis Lamp Function
Engine Key switch : ON position • No Engine RPM signal : 0 mim If the diagnosis lamp will not be lit up with the above conditions, inspect and repair the lamp or other relating parts. 10-189 10000B-1 Published 10-09-13, Control # 215-03...
Page 488 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 10000B-1 10-190 Published 10-09-13, Control # 215-03...
Page 489 10. ELECTRIC SYSTEM 10-191 10000B-1 Published 10-09-13, Control # 215-03...
Page 490: Load Safety Device
- 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 All values in the figure are for reference only. 10000B-1 10-192 Published 10-09-13, Control # 215-03...
Page 491: Configuration Of Screens
10. ELECTRIC SYSTEM 10.2.1 CONFIGURATION OF SCREENS 10-193 10000B-1 Published 10-09-13, Control # 215-03...
Page 492: System Daigram
Drum rotate sensor Eng. hyd. system alarm signal Relay Relay Winch system Pump. swing system Prop. valve Prop. valve Each solenoid valve Each solenoid valve Drum rotate grip Oil cooler Battery relay AIS circuit 10000B-1 10-194 Published 10-09-13, Control # 215-03...
Page 493: Monitor Indication
Max transmission distance 5m * not used Extended unit interface 1 *1 For installation of extended unit (Transmission function) * not used VM unit interface 1 *1 This is to connect VM unit when camera is to be connected. 10-195 10000B-1 Published 10-09-13, Control # 215-03...
Page 494: General Specification
(No conductive dust) Contamination Contamination degree 2 *1 As for STN color LCD equipped model, long time use under ambient tenperature higher than 40 degrees C may cause indication quality lowering such as contrast. 10000B-1 10-196 Published 10-09-13, Control # 215-03...
Page 495 Transmitted data ER (DSR) Data terminal ready Signal ground DR (DSR) Data set ready RS (RTS) Transmission request CS (CTS) Transmission permit CI (RI) / Indication (VCC) +5V ± 5% output 0.25A *1 10-197 10000B-1 Published 10-09-13, Control # 215-03...
Page 496: Power Supply Wiring
Otherwise main body may be damaged. Ensure to connect FG terminal to earth. Otherwise electric shock may be caused in case of failure. Failure to observe these precautions may result in serious injuries or loss of life. 10000B-1 10-198 Published 10-09-13, Control # 215-03...
Page 497 These are all product of PHOENIX- CONTACT. Recommended screw SZF 1-0.6 X 3.5 (1204517) driver AI 0.75-8GY (3200519) AI 1-8RD (3200030) Recommended terminal AI 1.5-8BK (3200043) AI 2.5-8BU (3200522) Recommended crimping CRIMPFOX ZA 3 tool for terminal (1201882) 10-199 10000B-1 Published 10-09-13, Control # 215-03...
Page 498 Do not solder on cable connection point. Otherwise extreme heat may cause failure of fire. 6. Install the power supply cable to GP and secure it to GP body with left and right power supply connector securing screws. 10000B-1 10-200 Published 10-09-13, Control # 215-03...
Page 499: Detail Of Moment Limiter Connector
CF CARD COVER • CF card contains the adjusted data as backup. When replacing the ML controller, ensure to re-in- sert the original CF card and copy the backup data to the controller. 10-201 10000B-1 Published 10-09-13, Control # 215-03...
Page 500 10. ELECTRIC SYSTEM 2. ML controller connector pin layout (View from main machinery harness) 10000B-1 10-202 Published 10-09-13, Control # 215-03...
Page 501 12V load detector power -7 (+) 12V load detecting signal -7 (0 to 6.2V) 12V load detector power (GND) 12V load detecting signal -7 (0 to 6.2V) 12V load detector power -8 (+) 10-203 10000B-1 Published 10-09-13, Control # 215-03...
Page 502 Jib angle detector signal (OPT) 12V) Jib angle detector power (GND) 12V ML system sensor power 2 (GND) 12V ML system sensor signal 2-2 (0 to 12V) 12V ML system sensor power 2-2 (+) vacant vacant 10000B-1 10-204 Published 10-09-13, Control # 215-03...
Page 503 24V load detector signal -4 (0 to 12.5V) vacant vacant vacant vacant vacant vacant RS232C (+) Inter monitor transmission (TXD) RS232C (TXD) Inter monitor transmission (RXD) RS232C (RXD) Inter monitor transmission (GND) RS232C (GND) 10-205 10000B-1 Published 10-09-13, Control # 215-03...
Page 504 Output power (-) Extended 24V power (GND) CN-11-4 Output power (-) Extended 25V power (GND) Extended 26V power (GND) Voice alarm output 4 Lg/Y Ground output (0.1A) Outside indication light (Red) Ground output (0.2A) 10000B-1 10-206 Published 10-09-13, Control # 215-03...
Page 505 Over payout prevent LS (front) 24V input Over payout prevent LS (rear) 24V input Over payout prevent LS (third) 24V input Main controller 1 bypass SW 24V input Main controller 2 bypass SW 24V input 10-207 10000B-1 Published 10-09-13, Control # 215-03...
Page 506 Simultaneous control permit signal Ground input (330 ) Adjustment permit signal Ground input (4.7k ) Program rewrite permit signal Ground input (4.7k ) vacant vacant vacant vacant Wind speed sensor Pulse input (+) Pulse input (-) 10000B-1 10-208 Published 10-09-13, Control # 215-03...
Page 507 Voice alarm output 1 Ground output (0.1A) Voice alarm output 2 Ground output (0.1A) Outside indication light (yellow) Ground output (0.1A) Voice alarm output 3 Ground output (0.1A) Outside indication light (green) Ground output (0.1A) 10-209 10000B-1 Published 10-09-13, Control # 215-03...
Page 508 16Mbyte (8M x 16 1pcs) EDO-Memory Outside memory 2Mbyte media CN7-1 Battery Backup SRAM Compact 2Mbyte (512K x 6 2pcs) Flash I/F MR-SHPC-01 * Battery is common to RTC 7Segment LED XILINX CPLD XC9572XL-7TQG100I 10000B-1 10-210 Published 10-09-13, Control # 215-03...
Page 509 0 to 12.5V CN11-63 Spare 0 to 12.5V CN11-64 Spare 0 to 12.5V CN11-73 Spare 0 to 12.5V CN11-74 (2) PULSE INPUT (BREAK IN) [E] Name Condition Signal level Remarks Anemometer GND/OPEN CN11-5-35 10-211 10000B-1 Published 10-09-13, Control # 215-03...
Page 510 CEN spec. recognize signal CEN / Normal GND/OPEN CN11-5-29 Simultaneous operate permit Permit & CEN / Normal GND/OPEN CN11-5-30 For adjusting Adjusting / Normal GND/OPEN CN11-5-31 For program rewriting Rewrinting / Normal GND/OPEN CN11-5-32 10000B-1 10-212 Published 10-09-13, Control # 215-03...
Page 511 Voice alarm 5 Actuate / Normal GND/OPEN CN11-6-3 Outer indication light (green) On / Off GND/OPEN CN11-6-14 Outer indication light (yellow) On / Off GND/OPEN CN11-6-15 Outer indication light (red) On / Off GND/OPEN CN11-4-8 10-213 10000B-1 Published 10-09-13, Control # 215-03...
Page 512: Shifting To Maintenance Screen
3. Input the password (8 digits) with the keyboard. * In case of using capital letter, push CAPS switch. CLR : All clear DEL : One letter clear BS : One letter clear and back 10000B-1 10-214 Published 10-09-13, Control # 215-03...
Page 513 11000100000500010200 10:00 2010/12/01 2010/12/01 6. If password is not correct, password area blinks three times and then screen returns to 3. screen. Check the password and input again. 10-215 10000B-1 Published 10-09-13, Control # 215-03...
Page 514: Input, Output Signal
INPUT, OUTPUT SIGNAL This screen can check input signal condition of various sensors or switches or output signal condition of sole- noid valves, relays and proportional valves. 1. Push [I/O SIGNAL] in the maintenance menu. 10000B-1 10-216 Published 10-09-13, Control # 215-03...
Page 515 0 V is indicated on non connected point. 1.286 0.000 0.000 0.000 0.000 0.000 0.450 0.000 0.000 3.672 0.000 9.667 0.000 0.000 0.000 0.000 4.510 0.000 0.000 0.000 (B) By pushing [NEXT], digital input and digital output become indicated. 10-217 10000B-1 Published 10-09-13, Control # 215-03...
Page 516: Digital Input
This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 10000B-1 10-218 Published 10-09-13, Control # 215-03...
Page 517 2.39 0.00 0.55 4.93 0.48 4.93 1.72 4.93 1.11 4.93 3.15 0.00 2.53 0.57 2.60 0.62 1.94 3.21 2.32 0.00 1.34 2.37 (B) By pushing [NEXT], digital input and digital output are indicated. 10-219 10000B-1 Published 10-09-13, Control # 215-03...
Page 518 This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 10000B-1 10-220 Published 10-09-13, Control # 215-03...
Page 519 Unit of indicating figure is V (volt). This is used as accelerator signal to ECU. However this becomes effective only when G-28 accelerator control (MC option set) is "O". 1.00 0.00 (RPM) Engine revolution 00000000 ENGINE STATUS 10-221 10000B-1 Published 10-09-13, Control # 215-03...
Page 520 0.00 0.00 0.00 0.68 0.00 1.45 0.59 1.25 0.54 0.00 2.46 1.93 0.58 0.65 0.13 0.36 0.17 0.00 0.07 0.98 0.32 0.00 (B) By pushing [NEXT], digital input and digital output are indicated. 10000B-1 10-222 Published 10-09-13, Control # 215-03...
Page 521 This is indicated by "DOUT Fb". This is feedback signal of digital signal (DOUT) and corresponds to digital output condition. If it does not correspond to digital signal condition, wire breakage or ground fault is presumed. 10-223 10000B-1 Published 10-09-13, Control # 215-03...
Page 522 Unit of indicating figure is mA (mille ampere). If instruct value is more than 100 mA and feedback value is about 0 mA, wire breakage is presumed. As for signal name and specification, refer to P.10- 339. 10000B-1 10-224 Published 10-09-13, Control # 215-03...
Page 523: Ml Function Setting
2. Setting item becomes indicated. ME034 PSV MC1-D05 m i n ME093 PSV MC1-D08 19:19 2011/08/12 ME096 PSV MC1-D09 MC1-D02 PSV MC1-D11 MC1-D03 PSV MC1-D12 MC1-D04 D/O MC1-D04 10-225 10000B-1 Published 10-09-13, Control # 215-03...
Page 524 (EX) In case of anemometer installed. (A) Push [ANEMOMETER] in the menu. (B) Option setting screen of anemometer becomes in- dicated. (C) Push [Enable]. * The selected side turns to blue indication. (D) Push [OK]. 10000B-1 10-226 Published 10-09-13, Control # 215-03...
Page 525 (EX) In case of making LVL function effective. (A) Push [USE OF LVL] in the menu. (B) LVL function screen becomes indicated. (C) Push [Enable]. * The selected side turns to blue indication. (D) Push [OK]. 10-227 10000B-1 Published 10-09-13, Control # 215-03...
Page 526 This is to set crane body color. (EX) In case body color is selected to yellow. (A) Push [Color] in the menu. (B) Push [Enable] . (C) Push [Yellow] area. (D) Push [OK]. 10000B-1 10-228 Published 10-09-13, Control # 215-03...
Page 527: Data Copy, Format
The backup data in the data card is not formatted. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 10-229 10000B-1 Published 10-09-13, Control # 215-03...
Page 528 Be careful not to use in error. Select [CF Card  Controller] in the menu. The screen shown right becomes indicated. Push [SET] for 3 seconds to execute. 10000B-1 10-230 Published 10-09-13, Control # 215-03...
Page 529 In this case, check the function of ML adjusting mode select relay (R-36). Adjustment data reference error. 10-231 10000B-1 Published 10-09-13, Control # 215-03...
Page 530 The screen shown right becomes indicated. Push [SET] for 3 seconds to execute. When completed properly, the screen shown right becomes indicated. By pushing [OK], the screen returns to the previous one. It was completed. Push OK. 10000B-1 10-232 Published 10-09-13, Control # 215-03...
Page 531 When using this function, the data in the controller be- ing used for calculation is overwritten. Be careful not to use in error. Select [FORMAT] in the menu. The screen shown below is indicated. Push [SET] for 3 seconds to execute. 10-233 10000B-1 Published 10-09-13, Control # 215-03...
Page 532 In this case, check the function of ML adjusting mode select relay (R-36). Adjustment data reference error. 10000B-1 10-234 Published 10-09-13, Control # 215-03...
Page 533: Language, Unit Setting
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. After select, push [OK]. 10-235 10000B-1 Published 10-09-13, Control # 215-03...
Page 534 This is used when screen indication of swing direction and actual swing di- Swing sensor adjustment rection varies. This is also used whenever swing angle sensor (slip ring built- in) is replaced. 10000B-1 10-236 Published 10-09-13, Control # 215-03...
Page 535 [LOWER BOOM AN- GLE SENSOR]. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 10-237 10000B-1 Published 10-09-13, Control # 215-03...
Page 536 10. ELECTRIC SYSTEM Touch angle indicating area. 100% Angle indicating area becomes indicated in reverse and digit input becomes possible. 100% 10000B-1 10-238 Published 10-09-13, Control # 215-03...
Page 537 Angle of 25 degrees is just a guideline for lowering the boom, and this guideline should not be necessarily ob- served. However, remember that the adjustment is ef- fective if the boom is lowered with an angle as large as possible. 100% 10-239 10000B-1 Published 10-09-13, Control # 215-03...
Page 538 10. ELECTRIC SYSTEM Touch the second angle indicating area. 100% Angel indicating area becomes indicated in reverse and digit input becomes possible. 100% 10000B-1 10-240 Published 10-09-13, Control # 215-03...
Page 539 [SET]. 100% When the adjustment is properly completed, the message shown below is indicated. "Adjustment is properly completed. Push [SET]" By pushing [SET], the screen returns to the previ- ous one. 100% 10-241 10000B-1 Published 10-09-13, Control # 215-03...
Page 540 Select the required load detec- tor to be adjusted. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 10000B-1 10-242 Published 10-09-13, Control # 215-03...
Page 541 In such a case, replace the load cell. The message shown below becomes indicated when the adjustment is properly completed. By pushing [SET], screen returns to the previous one. 10-243 10000B-1 Published 10-09-13, Control # 215-03...
Page 542 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. 10000B-1 10-244 Published 10-09-13, Control # 215-03...
Page 543 Boom foot Aux. sheave hook Luffing crane Jib hook + Jib lifting Boom foot (jib hook only) Aux. sheave hook *1 = 1/4 of distances from boom point sheave to ground. L / 4 10-245 10000B-1 Published 10-09-13, Control # 215-03...
Page 544 Adjustment would become easier if the adjustment points (angle) are set in advance in the range be- tween the upper limit angle and lower limit angle di- vided into 6 in the adjustment required configuration. 10000B-1 10-246 Published 10-09-13, Control # 215-03...
Page 545 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 546 After raising the boom to almost the upper limit an- gle and then lower by about 1 degree and then stop. There are some error in boom raising and boom lower- ing. So ensure to stop in boom lowering. Push [SET]. 10000B-1 10-248 Published 10-09-13, Control # 215-03...
Page 547 By pushing [SET], message memorizing the fist point is indicated. After lowering the boom, push [SET]. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. The 1st point was memorized. 10-249 10000B-1 Published 10-09-13, Control # 215-03...
Page 548 [SET] is indicated. Lower the boom to almost minimum angle and push [SET]. The 5th point was memorized. Push SET after you make a boom or jib a minimum angle. 10000B-1 10-250 Published 10-09-13, Control # 215-03...
Page 549 In without load adjustment, if adjustment on more than two boom (jib) length is done, on boom (jib) length which is not adjusted yet, calibration by inter- polation by two closest length adjustment values is applied. 10-251 10000B-1 Published 10-09-13, Control # 215-03...
Page 550 [SET]. * This includes weight of hook and lifting sling. The procedure afterward is as same as without load. Proceed as without load adjustment. 100% 10000B-1 10-252 Published 10-09-13, Control # 215-03...
Page 551 After pushing [SET], start adjustment again. With load adjustment is likely to be affected with lifting load swinging. Therefore when the actual load indication moves signif- icantly, wait until the lifting load swinging stops and push [SET]. 10-253 10000B-1 Published 10-09-13, Control # 215-03...
Page 552 "LVL SETTING" in the "SETTING". If "NOT EFFEC- TIVE" is selected, normal 105% is applied even value is changed in this function. Select [LVL ADJUSTMENT] in the adjustment menu. Touch the load ratio indicating area. 10000B-1 10-254 Published 10-09-13, Control # 215-03...
Page 553 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 554 The load ratio is not affected by LVL function. • When the loading ratio is 90%, forecasting sounds (intermittent sounds) are emitted. Alarm sounds (continuous sounds) are emitted when the loading ratio is 100% (not affected by the LVL function). 10000B-1 10-256 Published 10-09-13, Control # 215-03...
Page 555 Raise the boom (jib) to almost upper limit angle and then lower by about 1 degree and then stop. Select [RADIUS ADJUSTMENT] in the adjustment menu. Touch the radius indication area. Radius indication area becomes reverse indication and digit input becomes possible. 10-257 10000B-1 Published 10-09-13, Control # 215-03...
Page 556 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]. 10000B-1 10-258 Published 10-09-13, Control # 215-03...
Page 557 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 558 If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting. Re-check the procedure and start adjust- ment again. Adjustment is failure. Push SET, and adjust it again. 10000B-1 10-260 Published 10-09-13, Control # 215-03...
Page 559 If the indication changes from [FR] to [OK], front side adjustment is properly completed. Swing the crane by 180 degrees and face it toward rear (propel motor side) and fix with the swing lock pin. 10-261 10000B-1 Published 10-09-13, Control # 215-03...
Page 560 When either [FR] or [RE] is pushed and "NG" is in- dicated, adjustment is in error. Check if the crane direction or sensor voltage is correct and start adjustment again. Below screen indicates NG in rear adjustment as an example. 10000B-1 10-262 Published 10-09-13, Control # 215-03...
Page 561 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 562: 11Ml Adjustment (Temporary)
The procedure of "WITHOUT LOAD ADJUSTMENT", "WITH LOAD ADJUSTMENT" are same as "WITHOUT LOAD ADJUSTMENT", "WITH LOAD ADJUSTMENT" of "10.2.10 ML ADJUSTMENT (NORMAL)". (Adjust in the same procedure as P.10-245 to 10-253.) 10000B-1 10-264 Published 10-09-13, Control # 215-03...
Page 563: 12Operation Progress
Third winch rated load with current radius on the basis of data Calculated main winch operating radius before correction by radius adjustment Calculated aux. winch operating radius before correction by radius adjustment Calculated third winch operating radius before correction by radius adjustment 10-265 10000B-1 Published 10-09-13, Control # 215-03...
Page 564 (5 - load cell zero adjustment value) x 0.08333 x (1.02 or 0.98) Load cell rated voltage Correction coefficient 1/reeving rope coefficient for raising (depending (depending on the machine models) on the machine models) Correction coefficient for lowering (depending on the machine models) 10000B-1 10-266 Published 10-09-13, Control # 215-03...
Page 565: 13Version Information
Monitor Program Version Monitor Program Part No. MC1 Program Version MC2 Program Version MC1 Program No. MC2 Program No. M/L Data Model Name M/L Data Part No. M/L Setting Data Version M/L Capacity Data Version 10-267 10000B-1 Published 10-09-13, Control # 215-03...
Page 566: 14Failure History
Push [ML FAILURE HISTORY] in the menu. Past failures become indicated from latest one in order to max. 20 items. Failure content is indicated by code. Check the contents by the table in operator’s man- ual "3.13 MESSAGE TABLE". 10000B-1 10-268 Published 10-09-13, Control # 215-03...
Page 567 Touch GO for 1sec if it is good. Touch STOP if you stop it. In case of deletion, push [GO]. In case of stop, push [STOP]. Push [GO] for more than 1 second. By pushing [GO], data is deleted. 10-269 10000B-1 Published 10-09-13, Control # 215-03...
Page 568 Touch STOP if you stop it. In case of deletion, push [GO]. In case of stop, push [STOP]. If deleted, all pages are deleted at once. Push [GO] for more than 1 second. 10000B-1 10-270 Published 10-09-13, Control # 215-03...
Page 569 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 570: Adjustment Data
No.2 is for tower jib angle detector and No.3 is for tower jib angle detector. If adjustment is not done yet, shift = 0.000, span = 1.000 is indicated. ADJUSTMENT VALUE ANGLE SENSOR 100% 10000B-1 10-272 Published 10-09-13, Control # 215-03...
Page 571 In case of input [1.103], input [1], [.], [1], [0], [3]. If there is other changing area, change the digit in the same way. After all input is completed, push [A]. ADJUSTMENT VALUE ANGLE SENSOR 100% 10-273 10000B-1 Published 10-09-13, Control # 215-03...
Page 572 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% 10000B-1 10-274 Published 10-09-13, Control # 215-03...
Page 573 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 574 Push [BACK] to return to the previous screen. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 10000B-1 10-276 Published 10-09-13, Control # 215-03...
Page 575 To return to previous screen, push [BACK]. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 10-277 10000B-1 Published 10-09-13, Control # 215-03...
Page 576 (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. * In case of deletion, indicated group data ONLY are deleted. 10000B-1 10-278 Published 10-09-13, Control # 215-03...
Page 577 If adjustment is not done yet, shift = 0.000, span = 1.000 becomes indicated. (B) CHANGING OF ADJUSTMENT DATA (C) DELETION OF ADJUSTMENT DATA Adjustment data can be changed or deleted with the same way as that of adjustment data of angle detectors. 10-279 10000B-1 Published 10-09-13, Control # 215-03...
Page 578: 16Download Ml Program
2. Connect write in permit connector CN- 420M on the right upper of the controller and CN-439F. 3. Turn on the key switch. 4. Download is started. 1. Insert card. 4. 7 SEGMENT 2. Connector connection. DISPLAY 10000B-1 10-280 Published 10-09-13, Control # 215-03...
Page 579 Approx. 10 seconds 5. When End is indicated, re-writing is completed. 6. Turn OFF the key switch. 7. Pull out write in permit connector. 8. Return the CF card back to the original position. 10-281 10000B-1 Published 10-09-13, Control # 215-03...
Page 580: 17Download Of Monitor Program
3. When the screen is started, tap on screen corners diagonally in succession. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 10000B-1 10-282 Published 10-09-13, Control # 215-03...
Page 581 10:00 2010/12/01 2010/12/01 5. Select [CF START]. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 10-283 10000B-1 Published 10-09-13, Control # 215-03...
Page 582 CF card or cover to be closed. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 7. Select [DOWNLOAD (CF  Display)] 10000B-1 10-284 Published 10-09-13, Control # 215-03...
Page 583 10. ELECTRIC SYSTEM 8. Select [START]. 9. Select [YES]. 10-285 10000B-1 Published 10-09-13, Control # 215-03...
Page 584 OS data write completed (4/4). System/Project data write completed (80/80). SRAM data write completed (2/2). Successfully completed. Please push the Back button. 11. Push [Back] to return to the screen before writing in starts. 10000B-1 10-286 Published 10-09-13, Control # 215-03...
Page 585 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 586: 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” 10000B-1 10-288 Published 10-09-13, Control # 215-03...
Page 587: Composition Of System
PWM output 24 V Constant current circuit (Max 1 A) Proportional valve Output 100 to 700 mA Disconnection detection W/short-circuit protection Disconnection detection Solenoid valve Output 24 V 1 A W/short-circuit protection 10-289 10000B-1 Published 10-09-13, Control # 215-03...
Page 588: Function Of Main Controller
Adjustment 1 Model number setting Adjustment 2 Option setting Adjustment 3 Adjustment of grip throttle and foot throttle Adjustment 4 Engine speed adjustment Adjustment 5 Adjusting of inclination meter Adjustment 6 Supply pump adjustment 10000B-1 10-290 Published 10-09-13, Control # 215-03...
Page 589: Accelerator Control
If the wire of accelerator control or foot control is broken, output voltage to ECU becomes 0 V.) In this case, by turning the aux. accelerator switch to ON, low speed and middle speed becomes oper- ational. (High speed is not possible) 10-291 10000B-1 Published 10-09-13, Control # 215-03...
Page 590 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. 10000B-1 10-292 Published 10-09-13, Control # 215-03...
Page 591 Lower the actual speed is against target speed, larger the output current is. However in case of low idling, even the difference is small, output current is large. (to prevent engine stall) 10-293 10000B-1 Published 10-09-13, Control # 215-03...
Page 592 10. ELECTRIC SYSTEM 3. WINCH MOTOR SPEED CONTROL 10000B-1 10-294 Published 10-09-13, Control # 215-03...
Page 593: Motor Control
> Trimmer control (during power low- ering) FRONT/REAR/THIRD (OPTION) MOTOR TILT CONTROL PROP. V. CURRENT FRONT/REAR/THIRD (OPTION) DRUM RAISE/LOWER REMO-CON PROP. V. CURRENT (mA) REMO-CON MOTOR CONTROL FRONT/REAR/THIRD (OPTION) DRUM SPEED ADJUST TRIMMER 10-295 10000B-1 Published 10-09-13, Control # 215-03...
Page 594 If the trimmer is set to maximum value, the prop. valve becomes full open and the main valve open- ing becomes maximum. BOOM RAISE / LOWER PROP. VALVE CURRENT ENGINE HIGH (b) (mA) ENGINE LOW (a) BOOM SPEED ADJUST TRIMMER 0.47 10000B-1 10-296 Published 10-09-13, Control # 215-03...
Page 595 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 596 NEUTRAL FREE (LOW SPEED) or BRAKE NEUTRAL FREE (HIGH SPEED) GRIP THROTTLE • When the swing control signal is OFF for 10 sec- onds, or swing limit function is selected, the current becomes maximum value. (700 mA) 10000B-1 10-298 Published 10-09-13, Control # 215-03...
Page 597 Parking action is released when right control pres- sure is detected when stopped with left decelera- DECELERATION tion. SIGNAL Judging point of control pressure is more than 0.539 MPa. 10-299 10000B-1 Published 10-09-13, Control # 215-03...
Page 598 10. ELECTRIC SYSTEM 8. WINCH CONTROL (1) Control lever neutral mode selection (2) Winch operation solenoid valve control 10000B-1 10-300 Published 10-09-13, Control # 215-03...
Page 599 When the lever is at the neutral position while the free fall mode is selected, output from the front 0.69 1.96 CLUTCH PRESSURE (MPa) drum (rear drum and third drum) down remote con- trol proportional valve should depend on the clutch pressure. 10-301 10000B-1 Published 10-09-13, Control # 215-03...
Page 600 Even after the main power supply is shut down while the emergency solenoid valve is being actuated, power supply to the controller remains alive for ninety seconds after the engine is stopped. In this period, the residual clutch pressure is removed. 10000B-1 10-302 Published 10-09-13, Control # 215-03...
Page 601 10. ELECTRIC SYSTEM (3) Free fall acceleration 10-303 10000B-1 Published 10-09-13, Control # 215-03...
Page 602 • Other conditions are restored to those of the normal control. The monitor control proportional valve is controlled PROPORTIONAL VALVE CURRENT according to the depression of the foot pedal (clutch (mA) pressure). 0.69 1.96 CLUTCH PRESSURE (MPa) 10000B-1 10-304 Published 10-09-13, Control # 215-03...
Page 603: Boost Control
Front drum raise stop Front drum boost solenoid is immediately de-energized. Rear drum raise stop Rear drum boost solenoid is immediately de-energized. Third drum raise stop Third drum boost solenoid is immediately de-energized. 10-305 10000B-1 Published 10-09-13, Control # 215-03...
Page 604 1.5 seconds, and the boom is the boom raise remote control proportional valve is slowly stopped. controlled and the boom raising speed is deceler- ated according to the boom angle. 10000B-1 10-306 Published 10-09-13, Control # 215-03...
Page 605 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 606 10. ELECTRIC SYSTEM 14. MOTOR TILT ANGLE CONTROL 10000B-1 10-308 Published 10-09-13, Control # 215-03...
Page 607 Trimmer 750mA 750mA maximum maximum value value 1.77 (18) 0.98 (10) 0.98 (10) 1.77 (18) 1.96 (20) Third 1.96 (20) Third Lever remo-con 2nd press. MPa (kg/cm Third tilt angle prop. valve control 10-309 10000B-1 Published 10-09-13, Control # 215-03...
Page 608 > clamshell mode (this section) > trimmer control (this section) > tower mode speed control (this section) Between trimmer lever control value or engine speed control value, smaller value is selected as maximum value. 10000B-1 10-310 Published 10-09-13, Control # 215-03...
Page 609 Boom hoist lower remo-con prop. valve Third raise remo-con prop. valve  But in case of luffing configuration. Third lower remo-con. prop. valve  But in case of luffing configuration only, stop action is executed. 10-311 10000B-1 Published 10-09-13, Control # 215-03...
Page 610 Front, rear and third (jib) raise remo-con. prop. valve command current are set to inching speed level. (375 mA) If each lever is in operation, each tilt angle prop. valve output is fixed to Low. (310 mA) 10000B-1 10-312 Published 10-09-13, Control # 215-03...
Page 611 Specified speed. = drum speed : about 61.5 min = more than 4 pulse at 50 m sec. Therefore there is no output from the total control- ler. 10-313 10000B-1 Published 10-09-13, Control # 215-03...
Page 612 10. ELECTRIC SYSTEM 17. FRONT/BOOM PUMP CONTROL 10000B-1 10-314 Published 10-09-13, Control # 215-03...
Page 613 ON, same control as inching switch IN control (2) above is applied. When ML is released and switch input is ON, same control as inching switch IN control (2) above is ap- plied. 10-315 10000B-1 Published 10-09-13, Control # 215-03...
Page 614 Difference between height of zero reset time and the present height is calculated and the boom or jib height is calculated. (7) Distance variation of hook and boom point (jib point) is calculated by angle variation of boom (jib). 10000B-1 10-316 Published 10-09-13, Control # 215-03...
Page 615 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 10000B-1 Published 10-09-13, Control # 215-03...
Page 616 10. ELECTRIC SYSTEM 19. LEVER INTERLOCK CONTROL 10000B-1 10-318 Published 10-09-13, Control # 215-03...
Page 617  Either one of control is detected as MOTION, all prop. valve output stay minimum as is. Control stop condition by lever interlock function is advised to the monitor. 10-319 10000B-1 Published 10-09-13, Control # 215-03...
Page 618 ECU. However load valve control and engine speed con- trol to raise exhaust temperature in order to prevent regeneration starting during crane control are done by crane side controller. 10000B-1 10-320 Published 10-09-13, Control # 215-03...
Page 619 ECU started regeneration. The load valve remains ON but idling speed returns back. Long time idling can not be canceled. Others can cancel by only 1. 10-321 10000B-1 Published 10-09-13, Control # 215-03...
Page 620 During Manual regeneration : This is the condition that exhaust temperature is reached to regeneration possible level and engine ECU started regeneration. Crane condition is as same as "Manual regenera- tion preparation". 10000B-1 10-322 Published 10-09-13, Control # 215-03...
Page 621 Crane operation is not possible. regeneration Control impossible Long time idling Load valve ON Auto regeneration is done. Load valve request Speed 800 to 1,000 min Crane operation is possible. During auto regeneration Control possible 10-323 10000B-1 Published 10-09-13, Control # 215-03...
Page 622 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. 10000B-1 10-324 Published 10-09-13, Control # 215-03...
Page 623 Independence Neutral 150 mA independence independence Table for Table for GK, HF : 720 mA CR/LF confluence confluence GN, JD : 590 mA Confluence Neutral Table for Table for 150 mA independence independence 10-325 10000B-1 Published 10-09-13, Control # 215-03...
Page 624 10. ELECTRIC SYSTEM 22. G WINCH CONTROL GK, HF, GN, JD Gr. ONLY 10000B-1 10-326 Published 10-09-13, Control # 215-03...
Page 625 (neutral  operation  neutral) In case G winch function is required again, the indi- vidual switch is input. After switched to individual mode and individual switch is pushed again, function is cancelled. 10-327 10000B-1 Published 10-09-13, Control # 215-03...
Page 626 SOL FB value control control 1,800 min At G engine 3 MPa or more or more OFF output 1,725 min * at speed abnormal At Normal Less than 3 MPa No judgement 10000B-1 10-328 Published 10-09-13, Control # 215-03...
Page 627 10. ELECTRIC SYSTEM 24. AIS CONTROL 10-329 10000B-1 Published 10-09-13, Control # 215-03...
Page 628 (3) Key cut off fail preventing function AIS condition may be left for long time. If AIS condition is continued for longer than certain time, battery is turned OFF automatically. 10000B-1 10-330 Published 10-09-13, Control # 215-03...
Page 629 10. ELECTRIC SYSTEM 25. HYD. OIL HEAT (OPTION) Control Relay When all lever is in neutral Energized Either on lever is in operation De-energized 10-331 10000B-1 Published 10-09-13, Control # 215-03...
Page 630: Main Controller 1, 2 (Hardware)
10. ELECTRIC SYSTEM 10.3.4 MAIN CONTROLLER 1, 2 (HARDWARE) HARNESS SIDE CONNECTOR MC1 : CN-101F to CN-109F MC2 : CN-111F to CN-119F 10000B-1 10-332 Published 10-09-13, Control # 215-03...
Page 631: Specifications Of Main Controller Output
0 to 19.61 MPa 0.5 to 4.5 V Third drum clutch pressure sensor (option) 0 to 19.61 MPa 0.5 to 4.5 V Re. drum clutch pressure sensor 0 to 19.61 MPa 0.5 to 4.5 V 10-333 10000B-1 Published 10-09-13, Control # 215-03...
Page 632 +24 V/OPEN Re. drum motor CLA-SOL (FB) Energized/De-energized +24 V/OPEN Re. drum motor ESA-SOL (FB) Energized/De-energized +24 V/OPEN Third drum motor CLT-SOL (FB) Energized/De-energized +24 V/OPEN Third drum motor EST-SOL (FB) Energized/De-energized +24 V/OPEN 10000B-1 10-334 Published 10-09-13, Control # 215-03...
Page 633 100 to 700 mA 200 mAp-p 63 Hz Left swing stop prop. valve 100 to 700 mA 200 mAp-p 100 Hz Right swing stop prop. valve 100 to 700 mA 200 mAp-p 100 Hz 10-335 10000B-1 Published 10-09-13, Control # 215-03...
Page 634 Re. drum rotate detect grip (option) +24 V/OPEN Safety relay operation Operation/Normal GND/OPEN Engine stop relay operation Energized/De-energized GND/OPEN Swing voice alarm ON/OFF GND/OPEN Vacancy GND/OPEN Vacancy GND/OPEN (CPU error) Vacancy +24 V/OPEN 10000B-1 10-336 Published 10-09-13, Control # 215-03...
Page 635 0.5 to 4.5 V Third drum raise pressure sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Third drum lower pressure sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V 10-337 10000B-1 Published 10-09-13, Control # 215-03...
Page 636 +24 V/OPEN Boom drum raise stop Normal/Stop +24 V/OPEN Boom drum lower stop Normal/Stop +24 V/OPEN DPF load SOL Load ON/OFF +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN 10000B-1 10-338 Published 10-09-13, Control # 215-03...
Page 637 200 mAp-p 100 Hz Re. drum motor tilt control prop. valve 200 to 750 mA 200 mAp-p 100 Hz Third drum motor tilt control prop. valve 200 to 750 mA 200 mAp-p 100 Hz (option) 10-339 10000B-1 Published 10-09-13, Control # 215-03...
Page 638 Re. drum control signal GND/OPEN Third control signal GND/OPEN Fr. drum C/V-SOL Energized/De-energized +24 V/OPEN Re. drum C/V-SOL Energized/De-energized +24 V/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN (CPU error) Third C/V-SOL (option) Energized/De-energized +24 V/OPEN 10000B-1 10-340 Published 10-09-13, Control # 215-03...
Page 639: Arrangement Of Main Controller Connector Pin
Spare Spare SHG1 Spare TXD3 RXD3 Program DL serial Spare Engine turn sensor Spare Spare SHG3 Spare Accel. indicator voltage 1 Accel. indicator voltage 1 Accel. indicator voltage 2 Accel. indicator voltage 2 10-341 10000B-1 Published 10-09-13, Control # 215-03...
Page 640 Tagline trimmer (option) Control primary pressure Swing pump pressure sensor Swing control (right) pressure sensor GND for third clutch pressure sensor (option) Swing control (left) pressure sensor GND for swing control (right) pressure sensor 10000B-1 10-342 Published 10-09-13, Control # 215-03...
Page 641 Grounded input (15 K Ω ) Clogging of air cleaner Grounded input (3.3 K Ω ) Spare GND for Inclination sensor X '+5A Re. drum clutch pressure sensor Third drum clutch pressure sensor (option) 10-343 10000B-1 Published 10-09-13, Control # 215-03...
Page 642 Third drum free fall select. signal Grounded input (3.3 K Ω ) Fr. drum rotate sensor (and pulse input) Grounded input (3.3 K Ω ) Re. drum rotate sensor (and pulse input) For backup power supply +24 V 10000B-1 10-344 Published 10-09-13, Control # 215-03...
Page 643 +24 V input Engine emg. stop signal +24 V input Engine restart +24 V input Operator certificate wait signal +24 V input Swing parking switch +24 V input Drum rotate detecting grip selection 10-345 10000B-1 Published 10-09-13, Control # 215-03...
Page 644 +24 V input speed increase SW +24 V input Re. drum free fall speed increase SW Third drum free fall +24 V input speed increase SW (option) +24 V input Free fall permit signal 10000B-1 10-346 Published 10-09-13, Control # 215-03...
Page 645 PWM output Spare PWM output Spare D/O FB Swing warning (flasher) D/O FB Swing warning (Buzzer and flasher) D/O FB DPF regeneration FB D/O FB Accel. signal (DOWN) D/O FB Accel. signal (UP) 10-347 10000B-1 Published 10-09-13, Control # 215-03...
Page 646 +24 V output Re. drum rotate detection grip (option) Grounded output Safety relay operation Grounded output Engine stop relay operation Grounded output Swing voice alarm Grounded output Spare Grounded output Spare +24 V output Spare 10000B-1 10-348 Published 10-09-13, Control # 215-03...
Page 647 CAN2 termination Vacancy CAN2 termination Vacancy Resistance input Vacancy Vacancy TXD1 Vacancy RXD1 Vacancy Vacancy SHG1 Vacancy TXD3 RXD3 Program DL serial Vacancy Engine rotate sensor Vacancy Vacancy SHG3 Vacancy Vacancy Vacancy Vacancy Vacancy 10-349 10000B-1 Published 10-09-13, Control # 215-03...
Page 648 Resistance input A/D spare Connector No. Pin No. Port name Function Specifications CN113 Fr./Re. drum CHP start pressure sensor A/D spare A/D spare A/D spare Third drum raise pressure sensor A/D spare A/D spare 10000B-1 10-350 Published 10-09-13, Control # 215-03...
Page 649 Grounded input (15 K Ω ) C/W detect 6 (C5) Grounded input (3.3 K Ω ) C/W detect 7 (C5) Fr. drum lower pressure sensor '+5A Third drum lower pressure sensor Third drum raise pressure sensor 10-351 10000B-1 Published 10-09-13, Control # 215-03...
Page 650 +24 V input Boom B/S No.2 signal Grounded input (3.3 K Ω ) Spare (and pulse input) Grounded input (3.3 K Ω ) Spare (and pulse input) For backup power supply +24 V Power supply 10000B-1 10-352 Published 10-09-13, Control # 215-03...
Page 651 Spare +24 V input Spare +24 V input Crane hook overhoist signal +24 V input Jib hook overhoist signal +24 V input Hook overhoist release signal +24 V input Boom overhoist release signal 10-353 10000B-1 Published 10-09-13, Control # 215-03...
Page 652 D/O FB Oil cooler motor relay +24 V input Third drum raise stop +24 V input Third drum lower stop +24 V input Boom drum raise stop +24 V input Boom drum lower stop 10000B-1 10-354 Published 10-09-13, Control # 215-03...
Page 653 D/O FB ML bypass (CR) Grounded output Spare Grounded output Spare PWM output Spare PWM output Spare D/O FB ML bypass (JIB) D/O FB Spare D/O FB Spare D/O FB Spare D/O FB Spare 10-355 10000B-1 Published 10-09-13, Control # 215-03...
Page 654 +24 V output Fr. drum C/V-SOL +24 V output Re. drum C/V-SOL Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare +24 V output Third C/V-SOL (option) 10000B-1 10-356 Published 10-09-13, Control # 215-03...
Page 655: Adjustment Of Main Controller
PSV MC1-D04 17.4deg Password 100% 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-C12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC1-C04 Password input MC adjustment 10-357 10000B-1 Published 10-09-13, Control # 215-03...
Page 656 (3) Select "O" (yes) or "X" (no) on each function setting. OPTION Use (c) icon for page change. 100% (4) After setting is completed, push "OK" and after page is changed, push "SET" to record. Unless "SET" is pushed, selection becomes inef- fective. 10000B-1 10-358 Published 10-09-13, Control # 215-03...
Page 657 NEXT If adjustment becomes NG, Engine revolution NG 1 : Accel open ratio Engine speed is abnormal. Check if engine error is output. NG 2 : Transmission is error. 10-359 10000B-1 Published 10-09-13, Control # 215-03...
Page 658 (3) Progress becomes indicated. 100% PSV MC1-D01 PSV MC1-D09 100% is reached after 5 minutes. PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC1-D04 10000B-1 10-360 Published 10-09-13, Control # 215-03...
Page 659: Controller Malfunction Emergency Measures
Malfunction of the proportional valves (D5, D8, D9, D11, D12 in MC1 and D1 to D8 in MC2) will be dis- played in the cluster gauge. (excluding the case when H-1 is displayed) MC2 BYPASS MC1 BYPASS SWITCH SWITCH FRONT 10-361 10000B-1 Published 10-09-13, Control # 215-03...
Page 660 10. ELECTRIC SYSTEM 10000B-1 10-362 Published 10-09-13, Control # 215-03...
Page 661: Air Conditioner
11. AIR CONDITIONER 11-1 10000B-1 Published 10-09-13, Control # 215-03...
Page 662 11. AIR CONDITIONER 10000B-1 11-2 Published 10-09-13, Control # 215-03...
Page 663 DEFROSTER SWITCH BLOW OUT OPENING, TEMP. SETTING AND AIR VOLUME INDICATING PANEL BLOW OUT OPENING IN-OUT AIR SELECTOR SWITCH SELECTOR SWITCH AIR CON. SWITCH POWER ON/OFF SWITCH TEMPERATURE AIR VOLUME CONTROL SWITCHES SELECTOR SWITCH 11-3 10000B-1 Published 10-09-13, Control # 215-03...
Page 664 (AIR CONDITIONER TEMP. SET) Pushing this switch changes temperature setting Pushing lowers temperature (blowing air temp.) when the air conditioner is running. Set temperature (d) is indicated on LCD display. (d) INDICATION CONTENT 10000B-1 11-4 Published 10-09-13, Control # 215-03...
Page 665: Defroster Switch
This is to defog on the inner side of the front glass or to defrost on the outer side of the front glass. * Air also blows from DEF. Blow volume is Foot < DEF. 11-5 10000B-1 Published 10-09-13, Control # 215-03...
Page 666: Air Conditioner Control
• While defrosting the windscreen do not set the tem- perature to max. cooling. • Cold air may make windscreen foggy from outside and it may disturb the operator's vision. 10000B-1 11-6 Published 10-09-13, Control # 215-03...
Page 667 SWITCH (3) or both. • If AIR CON. SWITCH (2) is pushed, air con. oper- ates on dry air warming • If blow out selector switch is on Foot position, air blow out from defroster too. 11-7 10000B-1 Published 10-09-13, Control # 215-03...
Page 668 By pushing BLOW OUT OPENING SELECTOR SWITCH (6), blow out opening returns to the set opening before DEFROSTER SWITCH (7) is pushed. • If blow out opening is set to DEF, air bows to foot too. 10000B-1 11-8 Published 10-09-13, Control # 215-03...
Page 669 If quick defogging is required, set the air volume to HIGH by AIR VOLUME SELECTOR SWITCH (3). • By pushing BLOW OUT OPENING SELECTOR SWITCH (6), blow out opening returns to the set opening before DEFROSTER SWITCH (7) is pushed. 11-9 10000B-1 Published 10-09-13, Control # 215-03...
Page 670 11. AIR CONDITIONER This page is blank for editing convenience. 10000B-1 11-10 Published 10-09-13, Control # 215-03...
Page 671: Parts Illustration
11. AIR CONDITIONER 11.2 PARTS ILLUSTRATION 11-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 672 11. AIR CONDITIONER 10000B-1 11-12 Published 10-09-13, Control # 215-03...
Page 673 57. DAMPER (IN) ASSY 17. LEVER (MAL1) 37. CLAMP 58. UNIT HARNESS ASSY 18. LEVER (AM) 38. ROD HOLDER 59. RELAY 19. LEVER (CM) 39. SENSOR HOLDER 20. LEVER (MO1) 40. CORD CLAMP A 11-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 674: Disassembly And Assembly Of The Unit
4. Remove three of the cross head screw (Phillips) For IN TAKE CASE MOUNTING (4 pcs) T5 X 14 (T1) and separate the blower case and the air-con. unit. IN TAKE CASE UNIT For BLOWER CASE MOUNTING (3 pcs) 10000B-1 11-14 Published 10-09-13, Control # 215-03...
Page 675: Replacing The Blower Motor
HEATER CORE Then pull out the heater core from the unit. 3. Installation is reverse way of the foregoing proce- dure. PIPE CLAMP UNIT PIPE CLAMP MOUNTING SCREW (1 pc) 11-15 10000B-1 Published 10-09-13, Control # 215-03...
Page 676: Removal Of The Air-Con Unit Case-Front And- Rear
In this case make sure that the heater core is re- moved from the unit case. EVAPORATOR ASSY EXPANSION VALVE EVAPORATOR SENSOR UNIT CASE LOWER UNIT CASE UPPER-LOWER MOUNTING SCREW (11 pcs) 10000B-1 11-16 Published 10-09-13, Control # 215-03...
Page 677: Replacing The Evaporator And Expansion Valve
INSTALLATION OF EVAPORATOR SENSOR Install the evaporator sensor precisely to the original place of the evaporator as shown. During the installation work, take care not to make the sensor cord jammed with the case. EVAPORATOR SENSOR 11-17 10000B-1 Published 10-09-13, Control # 215-03...
Page 678: Replacing The Motor Actuator
Remove the motor actuator from the unit while the lever MAL2 is attached. Remove the lever MAL2 from the motor actuator. Install the new motor actuator in the reverse way of the foregoing procedure. IN-OUT AIR MOTOR ACTUATOR 10000B-1 11-18 Published 10-09-13, Control # 215-03...
Page 679: Fault Detection From The Control Panel Indication
1. OPEN OR SHORT CIRCUIT Open circuit detect is indicated when there is an open or short circuit in the sensor line. OPEN CIRCUIT DETECT INDICATION FAULT LOCATION FAULT INDICATION EVAPORATOR SENSOR AIR CON. MARK BLINKING 11-19 10000B-1 Published 10-09-13, Control # 215-03...
Page 680: Basic System Of Hvac
(in-out blow port selector, air mix). The unit also has self diagnose function and can perform self diagnose easily. (For detail refer to the control specification) 10000B-1 11-20 Published 10-09-13, Control # 215-03...
Page 681 When the blower OFF relay turns ON, power is sup- plied to the blower motor and the blower motor VIEW FROM A starts. 6. COMPRESSOR RELAY This relay turns ON-OFF by the compressor control of the control amplifier. 11-21 10000B-1 Published 10-09-13, Control # 215-03...
Page 682 The contact moves together with motor and stops the motor by reaching to the target position. (Refer to inspection of the In-out motor actuator.) 10000B-1 11-22 Published 10-09-13, Control # 215-03...
Page 683: Evaporator Sensor
When the sensor detect temp. is 0° C : 7.2 k Resistance value between terminal to the sensor When the sensor detect temp. is 25° C : 2.2 k 11-23 10000B-1 Published 10-09-13, Control # 215-03...
Page 684 If the compressor stops at 3.14 MPa or around then the system if normal. (3) Check the continuity between the terminal to the switch and to the connector when the coolant is re- moved. If continuity is NO, the system is normal. 10000B-1 11-24 Published 10-09-13, Control # 215-03...
Page 685: Recharging Of The Coolant
Do not take the bottle into the closed operator’s room even at the winder time. Temperature in the storage box also rises to dan- gerous range at summer time. Be careful on this point. 11-25 10000B-1 Published 10-09-13, Control # 215-03...
Page 686 Assembling work of the air conditioner must be done quickly and take extra care to prevent water, dust entering into the system. Pay attention not to overcharge. Tighten all the pipe fittings with the specified torque. 10000B-1 11-26 Published 10-09-13, Control # 215-03...
Page 687: Work Procedure
COOLANT RECHARGING WORK VACUUMING WORK 30 minutes Leaving for or more 5 minutes -750 mmHg or less GAUGE IND. ABNORMAL CONNECTOR CHECK COOLANT GAS RECHARGING TO & REPAIR GAUGE PRESSURE 0.098 MPa (1 kg/cm 11-27 10000B-1 Published 10-09-13, Control # 215-03...
Page 688 11. AIR CONDITIONER 3. TOOL GAUGE MANIFOLD RED : HIGH PRESSURE SIDE CHARGING HOSE BLUE : LOW PRESSURE SIDE YELLOW : VACUUM PUMP SIDE QUICK JOINT Φ27.5 Φ23.5 10000B-1 11-28 Published 10-09-13, Control # 215-03...
Page 689: Recharging Procedure
(3) Connect the center valve of the gauge manifold and the vacuum pump with the charging hose. Some type of the gauge manifold does not have the open/close valve in their center. 11-29 10000B-1 Published 10-09-13, Control # 215-03...
Page 690 If the gauge moves back toward zero direction, there must be leaking point somewhere. Retighten all of pipe fittings and again repeat the vacuuming work and check for leak again. 10000B-1 11-30 Published 10-09-13, Control # 215-03...
Page 691: Air Purge
Check gas leak in the cooling cycle with the gas leak tester (electric type). If there is any leaking point, re-tighten. Make sure that the tester is for R134a coolant. (Tester for flon coolant is not usable due to low sensibil- ity) 11-31 10000B-1 Published 10-09-13, Control # 215-03...
Page 692 NEVER open the high pressure side valve of the gauge manifold. RECEIVER DRYER • NEVER place the service bottle upside down. (Liquid form of coolant may be injected into the cooling cycle and may damage the compressor valve.) 10000B-1 11-32 Published 10-09-13, Control # 215-03...
Page 693 (2) Keep the high pressure side until the high pressure gauge reading becomes lower than 0.98 MPa {10 kg/cm (3) Remove the high pressure side charging hose (red) in the same procedure as the low pressure side. 11-33 10000B-1 Published 10-09-13, Control # 215-03...
Page 694 11. AIR CONDITIONER This page is blank for editing convenience. 10000B-1 11-34 Published 10-09-13, Control # 215-03...
Page 695: Electric Wiring Diagram
YAZAKI 1. Wire meter is 0.5 mm unless otherwise spicified. 2. Dotted line ( ) is vehicle’s body wiring. 3. Connector pin layout color is a view on the mating face. YAZAKI : 11-35 10000B-1 Published 10-09-13, Control # 215-03...
Page 696 11. AIR CONDITIONER This page is blank for editing convenience. 10000B-1 11-36 Published 10-09-13, Control # 215-03...
Page 697: Translifter System
12. TRANSLIFTER SYSTEM 12-1 10000B-1 Published 10-09-13, Control # 215-03...
Page 698 12. TRANSLIFTER SYSTEM 10000B-1 12-2 Published 10-09-13, Control # 215-03...
Page 699: Apparatus And Location Of Components
LEFT CRAWLER RIGHT CRAWLER 2,900 CRAWLER EXT./RET. CYLINDER (HORIZONTAL CYLINDER) VERTICAL VERTICAL CYLINDER CYLINDER TRANSLIFTER CONTROL VALVE CRAWLER EXT./RET. CYLINDER VERTICAL VERTICAL (HORIZONTAL CYLINDER CYLINDER CYLINDER) LEVEL GAUGE Clearance when float is lifted. 12-3 10000B-1 Published 10-09-13, Control # 215-03...
Page 700 4. Engine rotation control switch 1. Power switch 5. Abnormal indicating lamp 7. Crawler extend control switch 6. Vertical cylinder 6. Vertical cylinder control switch control switch 7. Crawler extend control switch REMOTE CONTROL SWITCH BOX 10000B-1 12-4 Published 10-09-13, Control # 215-03...
Page 701: Remote Control
SW-T2 SW-T3 SW-T4 SW-T1 SW-T5 SW-T10 SW-T8 SW-T7 SW-T9 SW-T6 12-5 10000B-1 Published 10-09-13, Control # 215-03...
Page 702: Circuit Diagram
RET. SW-T8 0.7A L. CRAWLER About EXT. 0.7A L. CRAWLER About RET. SW-T9 0.7A L.R. VERTICAL About EXT. 0.7A L.R. VERTICAL About RET. SW-T10 0.7A L.F. VERTICAL About EXT. 0.7A L.F. VERTICAL RET. 10000B-1 12-6 Published 10-09-13, Control # 215-03...
Page 703 12. TRANSLIFTER SYSTEM This page is blank for editing convenience. 12-7 10000B-1 Published 10-09-13, Control # 215-03...
Page 704: Construction And Function
2-section control valve (gantry control valve), and is led to the translifter control valve through the swivel joint. The pressurized oil controlled by the remote con- troller is sent to the respective cylinders. POWER DIVIDER GEAR PUMP GEAR PUMP 10000B-1 12-8 Published 10-09-13, Control # 215-03...
Page 705 12. TRANSLIFTER SYSTEM 12-9 10000B-1 Published 10-09-13, Control # 215-03...
Page 706: Function
As a result, the oil in the rod side returns to the tank, and the right front vertical cylinder is extended. 10000B-1 12-10 Published 10-09-13, Control # 215-03...
Page 707: Raising The Translifter
12. TRANSLIFTER SYSTEM RAISING THE TRANSLIFTER 12-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 708 As a result, the oil in the head side returns to the tank, and the right front vertical cylinder is retracted. 10000B-1 12-12 Published 10-09-13, Control # 215-03...
Page 709: Lowering The Translifter
12. TRANSLIFTER SYSTEM LOWERING THE TRANSLIFTER 12-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 710 12. TRANSLIFTER SYSTEM 10000B-1 12-14 Published 10-09-13, Control # 215-03...
Page 711: Troubleshooting
13. TROUBLESHOOTING 13-1 10000B-1 Published 10-09-13, Control # 215-03...
Page 712 13. TROUBLESHOOTING 10000B-1 13-2 Published 10-09-13, Control # 215-03...
Page 713 13. TROUBLESHOOTING 13.1 TROUBLESHOOTING What actions should be taken upon occurrence of these problems ? 13-3 10000B-1 Published 10-09-13, Control # 215-03...
Page 714 13. TROUBLESHOOTING 10000B-1 13-4 Published 10-09-13, Control # 215-03...
Page 715 13. TROUBLESHOOTING 13-5 10000B-1 Published 10-09-13, Control # 215-03...
Page 716 13. TROUBLESHOOTING 10000B-1 13-6 Published 10-09-13, Control # 215-03...
Page 717 13. TROUBLESHOOTING 13-7 10000B-1 Published 10-09-13, Control # 215-03...
Page 718 13. TROUBLESHOOTING 10000B-1 13-8 Published 10-09-13, Control # 215-03...
Page 719 13. TROUBLESHOOTING 13-9 10000B-1 Published 10-09-13, Control # 215-03...
Page 720 13. TROUBLESHOOTING 10000B-1 13-10 Published 10-09-13, Control # 215-03...
Page 721 13. TROUBLESHOOTING 13-11 10000B-1 Published 10-09-13, Control # 215-03...
Page 722 13. TROUBLESHOOTING 10000B-1 13-12 Published 10-09-13, Control # 215-03...
Page 723 13. TROUBLESHOOTING 13-13 10000B-1 Published 10-09-13, Control # 215-03...
Page 724 13. TROUBLESHOOTING 10000B-1 13-14 Published 10-09-13, Control # 215-03...

This manual is also suitable for:

1200ref