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Manitowoc 1100Ref Operating/Service/Maintenance Manual
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Manitowoc
SERVICE/MAINTENANCE MANUAL
The serial number of the crane is the only method Manitowoc has of providing you with
correct parts and service information.
Always furnish serial number of crane and its attachments when ordering parts
or discussing service problems with your Manitowoc distributor or the factory.
©2013 Manitowoc
Published 10-09-13, Control # 218-02
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
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.
10000A-1
Model Number
1100Ref
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
TROUBLESHOOTING
NOTICE

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Summary of Contents for Manitowoc 1100Ref

  • Page 1 SECTION 12 TROUBLESHOOTING NOTICE The serial number of the crane is the only method Manitowoc has of providing you with correct parts and service information. Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc distributor or the factory.
  • Page 2 This Page Blank...
  • Page 3 TABLE OF CONTENTS SAFETY 1. REFERENCE MATERIALS 1.1 10000A-1 SPECIFICATION ..................1-3 1.1.1 CRANE OUTER DIMENSION ................1-3 1.1.2 CRANE SPECIFICATION, PERFORMANCE............ 1-4 1.1.3 CRANE WORKING RANGES ................1-5 1.2 10000A-1 DIMENSION, WEIGHT OF EACH COMPONENT........1-8 1.2.1 MAIN MACHINERY ................... 1-8 1.2.2 COUNTERWEIGHT...................
  • Page 4 TABLE OF CONTENTS 3.3.5 UNIT WEIGHT TABLE ..................3-17 3.3.6 SYSTEM INTERNATIONAL (SI) UNIT CONVERSION TABLE ......3-18 4. POWER TRAIN 4.1 INTRODUCTION...................... 4-3 4.2 ENGINE........................4-6 4.2.1 INTRODUCTION ....................4-6 4.2.2 REMOVAL ......................4-6 4.2.3 REPAIR AND MAINTENANCE ................. 4-10 4.2.4 INSTALLATION ....................
  • Page 5 TABLE OF CONTENTS 6.3.3 REDUCTION UNIT ASSEMBLY................ 6-10 6.4 BRAKE PEDAL......................6-12 6.4.1 ASSEMBLY DRAWING ..................6-12 6.4.2 ADJUSTING THE BRAKE PEDAL ..............6-14 6.5 BLEEDING AIR FROM BRAKE CIRCUIT ..............6-15 6.6 CONSTRUCTION AND FUNCTION ................ 6-17 6.6.1 HYDRAULIC SCHEMATIC................6-17 6.6.2 LIFTING A LOAD....................
  • Page 6 TABLE OF CONTENTS 9.2 PROPEL REDUCTION UNIT ................... 9-4 9.2.1 MOTOR AND REDUCTION UNIT..............9-6 9.3 ADJUSTMENT ......................9-10 9.4 CONSTRUCTION AND FUNCTION ................ 9-11 9.4.1 HYDRAULIC SCHEMATIC................9-11 9.4.2 PROPELLING (RIGHT SIDE FORWARD) ............9-12 9.4.3 STOPPING ......................9-14 10.
  • Page 7 TABLE OF CONTENTS 10.2.12OPERATION PROGRESS ................10-271 10.2.13VERSION INFORMATION ................10-273 10.2.14FAILURE HISTORY..................10-274 10.2.15ADJUSTMENT DATA ..................10-278 10.2.16DOWNLOAD ML PROGRAM ................10-286 10.2.17DOWNLOAD OF MONITOR PROGRAM ............10-288 10.3 MAIN CONTROLLER ..................... 10-294 10.3.1 ARRANGEMENT OF MAIN CONTROLLER ........... 10-294 10.3.2 COMPOSITION OF SYSTEM .................
  • Page 8 TABLE OF CONTENTS 12. TROUBLESHOOTING 12.1 TROUBLESHOOTING ................... 12-3 10000A-1 Published 10-09-13, Control #218-02...
  • Page 9 SAFETY 10000A-1 Published 10-09-13, Control #218-02...
  • Page 10 SAFETY 10000A-1 Published 10-09-13, Control #218-02...
  • Page 11 It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured by operating this machine according to methods recommended by Manitowoc. While operating machine, be sure to perform work with great care, so as to not damage the machine, or let accidents occur.
  • Page 12 SAFETY EXPLANATION OF WARNING LABELS IN THE MACHINE Since the warning labels are installed in the machine and indicated with the three stages in the same way as the warning description, confirm the positions and contents of all warning labels first. Put them to the practical use to secure safety when operating, checking and performing maintenance.
  • Page 13 SAFETY LABEL LAYOUT * Numbers in the drawings correspond with those in the label explanation detail after P.0-14. 6 (10000E-1) 10000A-1 Published 10-09-13, Control #218-02...
  • Page 14 SAFETY 32 (10000E-1) 10000A-1 Published 10-09-13, Control #218-02...
  • Page 15 SAFETY 10000A-1 Published 10-09-13, Control #218-02...
  • Page 16 SAFETY 10000A-1 Published 10-09-13, Control #218-02...
  • Page 17 SAFETY 10000A-1 Published 10-09-13, Control #218-02...
  • Page 18 SAFETY 15 (10000E-1) 16 (10000A-1 15 (10000A-1 w/ J08E-VM) w/ J08E-UV) 10000A-1 0-10 Published 10-09-13, Control #218-02...
  • Page 19 SAFETY 0-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 20 SAFETY 20 (10000E-1) 20 (10000E-1) 10000A-1 0-12 Published 10-09-13, Control #218-02...
  • Page 21 SAFETY 30 (10000A-1) 30 (10000E-1) 0-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 22 SAFETY 1. Ensure to read the operators manual before operation / handling, assembly, / disassembly, transportation, inspection / maintenance of the machine. 2. If the free fall speed select switch is in speed increase side and the brake is released and the drum may ratate automatically to lowering side even without lifting load and wire rope may be paid out to lower the hook and rough spooling may be...
  • Page 23 SAFETY 5. If the brake pedal lock is not completely engaged, lifting load or hook may be lowered unexpectedly and is very dangerous. When locking the brake pedal, press the brake pedal fully and confirm that the pedal is locked completely.
  • Page 24 SAFETY 8. When the boom is assembled, disassembled, boom self erection / self lowering or crane work with the low gantry, the gantry or boom may be damaged and may fall off. Raise the gantry to the proper position for work. 9.
  • Page 25 SAFETY 12. Wrong handling of battery may cause burns, blindness or explosion by inflammation. 13. If accumulator is handled in wrong way, burns, loss of eyesight, explosion may be caused. Take extra care in handling accumulator. (Do not weld, flame cut, dispose or disassemble.) 14.
  • Page 26 SAFETY 15. Using the engine fuel other than the specified diesel fuel may cause engine failure, fire or explosion. Ensure to use the diesel fuel in the fuel tank. Use ultra low sulfur diesel fuel only. (S50 : sulfur content lower than 50 ppm) 16.
  • Page 27 SAFETY 19. When working on the upper surface of the guard, person may fall off the upper surface of the guard. During high place work on the upper surface of the guard, do not come close to the guard side face to prevent falling off.
  • Page 28 SAFETY 22. During engine running or straight after the engine is stopped, inside of the radiator becomes high pressure and hot. Person may get burns by hot water blow out when taking off the radiator cap. Take extra care of opening or closing of the radiator cap.
  • Page 29 SAFETY 25. When working on the engine area for inspection and maintenance, person may be entangled with the fan belt and may get injured if the engine is running. Stop the engine when inspection or maintenance work is done. 26. There are some moving parts near. 27.
  • Page 30 SAFETY 29. Taking wrong method in using the spreader guide installed on the boom base may damage the spreader guide. Set the spreader guide to the stowing position except when the upper spreader is connected is connected to the boom base. 30.
  • Page 31 SAFETY 31. Free fall work of load may cause dropping the load by mishandling. Use power lowering of load in the crane work. (Even on neutral free side, power lowering is possible by turning the lever to lowering side.) 32. Simultaneous control of the front and the rear drum may results in serious accident.
  • Page 32 12. Before starting a cleaning or lubrication work on the machine, always shut down the engine. 13. Use genuine Manitowoc replacement parts and oils only. 14. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also, fill clean, fresh oils only.
  • Page 33 SAFETY 25. Illegal, unauthorized, or nonconforming modification is strictly prohibited. 26. Do not allow oil or dust to deposit around the engine. Otherwise, fire accident can result. Clean the oil or dust adhered to. 27. Place removed attachments and components safely so that they do not drop or fall down. 28.
  • Page 34 SAFETY 10000A-1 0-26 Published 10-09-13, Control #218-02...
  • Page 35 1. REFERENCE MATERIALS 10000A-1 Published 10-09-13, Control #218-02...
  • Page 36 1. REFERENCE MATERIALS 10000A-1 Published 10-09-13, Control #218-02...
  • Page 37 1. REFERENCE MATERIALS 10000A-1 SPECIFICATION 1.1.1 CRANE OUTER DIMENSION UNIT : mm (ft - in) 1,100 (3’ 7” ) 5,140 (16’ 10” ) 2,990 (9’ 10” ) 1,495 (4’ 11” ) 5,440 (17’ 10” ) (3’ 1” ) 6,280 (20’ 7” ) 3,614 (11’...
  • Page 38 1. REFERENCE MATERIALS 1.1.2 CRANE SPECIFICATION, PERFORMANCE Type Full swing, crawler type 99.8 t × 3.35 m (220,000 lbs × 11 ft) Max. rated load × work radius 12.2 m (40 ft) Basic boom 61.0 m (200 ft) Maximum boom 9.1 m (30 ft) to 18.3 m (60 ft) Crane jib 57.9 m (190 ft) Boom + 18.3 m (60 ft) Jib...
  • Page 39 1. REFERENCE MATERIALS 1.1.3 CRANE WORKING RANGES 1. CRANE WORKING RANGES Unit : m (ft) 82° 75° 70° 65° 60° 55° 65 (213) 61.0 (200) BOOM 50° 57.9 (190) BOOM 60 (197) 54.9 (180) BOOM 55 (180) 51.8 (170) BOOM 45°...
  • Page 40 1. REFERENCE MATERIALS 2. JIB WORKING RANGE (1) Offset angle 10 degrees Unit : m (ft) 80 (263) 10° 57.9 (190) Boom + 18.3 (60) Jib 80° 57.9 (190) Boom 75 (246) + 15.2 (50) Jib 57.9 (190) Boom + 12.2 (40) Jib 70 (230) 57.9 (190) Boom + 9.1 (30) Jib...
  • Page 41 1. REFERENCE MATERIALS (2) Offset angle 30 degrees Unit : m (ft) 80 (263) 80° 30° 57.9 (190) Boom + 18.3 (60) Jib 75 (246) 57.9 (190) Boom + 15.2 (50) Jib 57.9 (190) Boom 70 (230) + 12.2 (40) Jib 57.9 (190) Boom + 9.1 (30) Jib 65 (213)
  • Page 42 1. REFERENCE MATERIALS 10000A-1 DIMENSION, WEIGHT OF EACH COMPONENT Dimension and weight of each component when disassembled is shown here. Use this as reference value. 1.2.1 MAIN MACHINERY Weight Name Dimension mm (ft-in) kg (lbs) Base Machine 12,090 (39’ 8”) •...
  • Page 43 1. REFERENCE MATERIALS 1.2.2 COUNTERWEIGHT Weight Name Dimension mm (ft-in) kg (lbs) No.1 8,310 Counterweight (18,300) 4,430 (14’ 6”) 1,450 (2’ 11”) (4’ 9”) 5,750 / No.2, No.3 1 piece Counterweight (R) (12,680) 1,450 (4’ 9”) (2’ 11”) 5,750 / No.2, No.3 1 piece Counterweight (L)
  • Page 44 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) 1,590 (5’ 3”) 980 (3’ 3”) Self removal unit (1,918) 10000A-1 1-10 Published 10-09-13, Control #218-02...
  • Page 45 1. REFERENCE MATERIALS 1.2.3 ATTACHMENT Weight Name Dimension mm (ft-in) kg (lbs) 1,170 Boom tip (2,580) 1,510 (4’ 11”) 6,910 (22’ 8”) 1,475 Boom base (3,252) 5,970 (19’ 7”) 1,490 (4’ 11”) 3.0m (10ft) (685) Boom insert 1,490 3,160 (10’ 4”) (4’...
  • Page 46 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) Backstop (595) 5,130 (16’ 10”) (617) Jib tip (2’ 7”) 5,000 (16’ 5”) Jib base (440) (2’ 8”) 4,810 (15’ 9”) 3.0m (10ft) (220) Jib insert 3,110 (10’ 2”) (2’ 8”) 6.1m (20ft) (395) Jib insert...
  • Page 47 1. REFERENCE MATERIALS Weight Name Dimension mm (ft-in) kg (lbs) Auxiliary sheave (430) 870 (2’ 10”) (1’ 7”) Upper spreader (518) (1’) 1,580 (5’ 2”) 1-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 48 1. REFERENCE MATERIALS 10000A-1 SWING AND PROPEL STABILITY 1. Without carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler Forward Backward extend retract (Without) 8.31 (18,320) (No abrupt (No.1) lever control) Without attachment (Base machine only) 19.81 (43,674) (No abrupt (No.1 to No.2)
  • Page 49 1. REFERENCE MATERIALS 2. With carbody weight All-round swing Propelling on slope Counterweight Attachment ton (lbs) Crawler Crawler Forward Backward extend retract (Without) 8.31 (18,320) (No.1) Without attachment (Base machine only) 19.81 (43,674) (Slope:8 deg. (No.1 to No.2) or less) 31.31 (69,028) (No abrupt (No.1 to No.3)
  • Page 50 1. REFERENCE MATERIALS 10000A-1 PROPEL ALLOWABLE SLOPE ANGLE 1.4.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION In the area showing [-] mark, do not propel. Machine may overturn. Failure to observe this precaution may result in serous injuries or loss of life. If the machine has to propel by some reason, observe the following points.
  • Page 51 1. REFERENCE MATERIALS 1. 10000A-1 CRANE PROPEL ALLOWABLE SLOPE ANGLE (1) Without aux. sheave (Unit : Degree) Forward Backward Boom length m (ft) Boom angle Boom angle 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130)
  • Page 52 1. REFERENCE MATERIALS 2. 10000A-1 FIXED JIB PROPEL ALLOWABLE SLOPE ANGLE (Unit : Degree) Jib length m (ft) 9.1 (30) Offset angle Configuration Forward Backward Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140)
  • Page 53 1. REFERENCE MATERIALS (Unit : Degree) Jib length m (ft) 12.2 (40) Offset angle Configuration Forward Backward Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180)
  • Page 54 1. REFERENCE MATERIALS (Unit : Degree) 15.2 (50) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180)
  • Page 55 1. REFERENCE MATERIALS (Unit : Degree) 18.3 (60) Jib length m (ft) Offset angle Forward Backward Configuration Boom angle Boom angle Boom length m (ft) 24.4 (80) 27.4 (90) 30.5 (100) 33.5 (110) 36.6 (120) 39.6 (130) 42.7 (140) 45.7 (150) 48.8 (160) 51.8 (170) 54.9 (180)
  • Page 56 1. REFERENCE MATERIALS ENGINE MAIN SPECIFICATION 10000A-1 : Hino Model J08E-UV diesel engine Engine (complying with the Interim Tier 4 & Stage IIIB Emission Regulations) Configuration of engine 4 cycle, water cooled, vertical in-line 6, direct injection, turbo-charged, intercooled Total poston displacement 7.684 Litter Roted output 213 kW / 2,100 min-1...
  • Page 57 1. REFERENCE MATERIALS ENGINE PERFORMANCE CURVE This indicates performance curve of single unit of engine. This does not include performance lowering based on work load. (N m) 1000 (kW) 1000 1400 1800 2200 2600 3000 Engine speed (min ) 1-23 10000A-1 Published 10-09-13, Control #218-02...
  • Page 58 1. REFERENCE MATERIALS 10000A-1 1-24 Published 10-09-13, Control #218-02...
  • Page 59 2. MAINTENANCE STANDARDS TEST PROCEDURES 10000A-1 Published 10-09-13, Control #218-02...
  • Page 60 2. MAINTENANCE STANDARDS TEST PROCEDURES 10000A-1 Published 10-09-13, Control #218-02...
  • Page 61 2. MAINTENANCE STANDARDS TEST PROCEDURES MAINTENANCE STANDARD 2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE 1. Pin, Bushing d’ D’ Bushing Unit : mm (inch) Std. Usable Name Location Item dimension limit Remedy figure D’ Front/rear 44.0 43.84 Fig.2-1 drum (1.732) (1.726) (P.2-6) Pawl...
  • Page 62 2. MAINTENANCE STANDARDS TEST PROCEDURES 2. Spring Free length Free length Unit : mm (inch) Std. free Usable limit of Location Item Remedy length free length figure 68.4 Fig.2-1 Front/rear drum pawl (2.835) (2.693) (P.2-6) (Compression) 68.4 Fig.2-3 Boom drum pawl (2.835) Replace (2.693)
  • Page 63 2. MAINTENANCE STANDARDS TEST PROCEDURES 3. Sheave Standard root diameter Groove 40 degrees Radius Unit : mm (inch) Std. root Groove Location Item Remedy diameter limit radius figure 569.5 14.0 Boom point (22.638) (22.413) (0.551) 569.5 14.0 Idler sheave (22.638) (22.413) (0.551) Fig.2-6...
  • Page 64 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 10000A-1 Published 10-09-13, Control #218-02...
  • Page 65 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-3 Boom drum lock assy 110 mm (4.331 inch) Wear Limit : 3 mm (0.118 inch) Fig.2-4 Pawl 10000A-1 Published 10-09-13, Control #218-02...
  • Page 66 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-5 Brake pedal Fig.2-6 Crane assy 10000A-1 Published 10-09-13, Control #218-02...
  • Page 67 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2-7 Jib assy Fig.2-8 Gantry assy 10000A-1 Published 10-09-13, Control #218-02...
  • Page 68 2. MAINTENANCE STANDARDS TEST PROCEDURES 2.1.2 PROPEL DEVICE 1. Crawler shoe • 914 mm (6.299) (1.575) (0.394) (0.787) (0.394) (0.118) (1.969) (4.173) (3.150) (0.472) (1.575) (0.472) (1.378) Wear limit : 2 mm (0.079 inch) Remedy : Build-up or replace (7.992) Unit : mm (inch) Unit : mm(inch) Std.
  • Page 69 2. MAINTENANCE STANDARDS TEST PROCEDURES • 800 mm (6.693) (1.575) (0.787) (0.394) (1.181) (0.394) (0.394) (0.472) (0.197) (0.315) (1.969) 10 (0.394) (4.173) (3.150) (1.575) (0.472) (0.472) (0.197) (0.472) Wear limit : 2 mm (0.079 inch) Remedy : Build-up or replace (7.992) Unit : mm (inch) Unit : mm(inch)
  • Page 70 2. MAINTENANCE STANDARDS TEST PROCEDURES 2. Drive tumbler (0.394) (0.394) (0.394) (0.394) (1.339) (1.181) (0.630) (0.394) (0.394) (1.969) 30 deg. 15 deg. Wear limit : 2 mm (0.079 inch) 10 deg. +0 deg. Remedy : Build-up or replace - 3 deg. (5.118) (1.181) (1.378)
  • Page 71 2. MAINTENANCE STANDARDS TEST PROCEDURES 3. Idler (0.236) (0.118) Wear limit : 4 mm (0.158 inch) Remedy : Build-up or replace (2.362) (4.331) Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Outer diameter 700 (27.559) 692 (27.244)
  • Page 72 2. MAINTENANCE STANDARDS TEST PROCEDURES 4. Track roller (Lower roller) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Outer deameter 260 (10.236) 252 (9.921) replace Std. Tolerance standard Allowable dimension -0.05 (-0.002) Shaft Gap between of shaft -0.08 Replacement of and bushing...
  • Page 73 2. MAINTENANCE STANDARDS TEST PROCEDURES 5. Guide roller (Upper roller) (0.197) (0.197) (1.575) (1.575) (2.362) (5.512) Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Outer diameter replace (7.874) (7.559) 2-15 10000A-1 Published 10-09-13, Control #218-02...
  • Page 74 2. MAINTENANCE STANDARDS TEST PROCEDURES 6. Guide bar LEFT SIDE RIGHT SIDE (23.622) (23.622) (23.622) t = 32 mm (1.260 inch) (23.622) (1.260) DETAIL A Unit : mm (inch) Unit : mm (inch) Symbol Item Std. dimension Usable limit Remedy Build-up or Height of guide bar (2.165)
  • Page 75 2. MAINTENANCE STANDARDS TEST PROCEDURES 7. Propel brake plate SEPARATOR PLATE FRICTION PLATE Unit : mm (inch) Std. dimension Wear limit Name of plate Number Std. brake torque (Total) (Total) Friction plate 16.92 to 18.32 mm -0.7 mm More than 426 N-m (0666 to 0.721 inch) (-0.028 inch) (More than 314 lbs-ft)
  • Page 76 2. MAINTENANCE STANDARDS TEST PROCEDURES PERFORMANCE STANDARD AND TEST PROCEDURE 1. TERMINOLOGY Standard value : Standard of assembling new machine. When the value exceeds the standard, repair or replace the part as required to maintain machine performance and or safety. Temperature of oil : It means temperature of hydraulic oil.
  • Page 77 2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.1 OPERATING SPEED Item Test condition Test procedure Standard value Mode : Power mode Measure the time taken to Boom Engine min : High idling rotate drum 10 times. hoist Temperature of oil : 45 to 55°C (Start measuring after rotation 8.8 to 10.6 sec rope...
  • Page 78 2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.2 POINT AND METHOD OF MEASURING PRESSURE Use a pressure gauge which has a surplus of more than 10 MPa for pressures to be measured and which has passed the inspection. Prior to pressure measurement, clean the port for pressure measurement so as to be free from oil and dust.
  • Page 79 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 2 Main • Engine speed : High idling 1. Lower the front drum hook onto the 31.9 MPa ground. (4,627 psi) • Propel left • Temperature of oil : 45 to 55°...
  • Page 80 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 4 Control • Temperature of oil : Remove the cap of plug installed in Relief valve : Circuit 45 to 55° C (113 to 131° F) valve block, and instal the pressure 7.0 MPa (Primary gauge.
  • Page 81 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 6 Crawler • Engine speed : High idling 1. Insert the crawler fixing pins to fix Extension extening the crawlers. 17.0 MPa • Temperature of Hydraulic oil : (2,466 psi) 45 to 55°...
  • Page 82 2. MAINTENANCE STANDARDS TEST PROCEDURES Item Test condition Test procedure Standard value 7 Gantry • Engine speed : High idling 1. Raise the gantry high, and fix it with Port relief set raising/ the gantry fixing pin. Raise : 20.6 MPa •...
  • Page 83 2. MAINTENANCE STANDARDS TEST PROCEDURES 2.2.3 SLEWING RING UPPER FRAME WITHIN 100 mm (3.937 inch) Measuring point. Front center or rear center of the upper frame. DIAL GAUGE LOWER FRAME Measuring point. Front center or rear center of the lower frame. COUNTERWEIGHT : FULL Condition of measurement Amount of play...
  • Page 84 2. MAINTENANCE STANDARDS TEST PROCEDURES 10000A-1 2-26 Published 10-09-13, Control #218-02...
  • Page 85 3. GENERAL WORK STANDARD 10000A-1 Published 10-09-13, Control #218-02...
  • Page 86 3. GENERAL WORK STANDARD 10000A-1 Published 10-09-13, Control #218-02...
  • Page 87 3. GENERAL WORK STANDARD TIGHTENING TORQUE OF CAP SCREWS AND NUTS 3.1.1 STANDARD TIGHTENING TORQUE Unless otherwise specified, torque all screws and nuts on this machine to the values shown in the following tables. METRIC COARSE THREADS (PLATED) Classification Nominal size Tightening torque N-m (ft-lbs) Tightening torque N-m (ft-lbs)
  • Page 88 3. GENERAL WORK STANDARD METRIC FINE THREADS (PLATED) Classification Nominal size Tightening torque N-m (ft-lbs) Tightening torque N-m (ft-lbs) Lubricated Lubricated 11.6 to 14.2 9.8 to 12 25.6 to 31.2 21.1 to 25.9 (8.6 to 10.4) (7.2 to 8.8) (18.8 to 23) (15.6 to 19) 22.9 to 28.1 19.4 to 23.8...
  • Page 89 Use thread lock to prevent bolt and nut from loosening. (LOCTITE #242, PART No. = KSP1) Before using thread lock wash rust, dirt and oil on thread area and dry completely. MANITOWOC GENUINE THREAD LOCK (LOCTITE #242) 10000A-1 Published 10-09-13, Control #218-02...
  • Page 90 3. GENERAL WORK STANDARD 3.1.2 TIGHTENING TORQUE OF HYDRAULIC FITTINGS Excessive or insufficient tightening of hose or tube fittings can cause oil leak and deformation or damage to the metal fittings. Therefore, to secure and obtain good fixing and performance of fittings it is necessary to tighten to the proper torque. The follows are the recommended torques.
  • Page 91 3. GENERAL WORK STANDARD (4) Jubilee Clip (Low Pressure and Suction) Nominal Diameter Recommended torque Working pressure range cord BS5315 inches ft-lbs kg/cm 3/8" - 1/2" 9.5 - 12 56.0 1/2" - 5/8" 11 - 16 56.0 1/2" - 3/4" 13 - 20 56.0 5/8"...
  • Page 92 3. GENERAL WORK STANDARD STANDARD PARTS 3.2.1 BOLT Size and kind of bolt can be identified as shown below. This part indicates the nominal bolt length. (L) This part indicates the nominal size of bolt. (D) C indicates coarse thread. F indicates fine thread.
  • Page 93 3. GENERAL WORK STANDARD 3.2.2 O-RING Size and kind of O-Ring are identified as shown below. INNER DIAMETER It indicate inner dia. (mm) This part indicate the thickness of the O-ring. P is for dynamic purpose. G is for stationary purpose. It indicates the type of rubber.
  • Page 94 3. GENERAL WORK STANDARD 3.2.3 BACK-UP RING Size and kind of back-up ring are identified as shown below. This part indicates the inner diameter (mm) of the back-up rings. This part indicates the width of the back-up rings. This part indicates the shape of the back-up rings.
  • Page 95 3. GENERAL WORK STANDARD 3.2.4 BITE TYPE FITTING PLUG for tube Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF83H10000 ZA82P10000 ZF83H15000 ZA82P15000 ZF83H18000 ZA82P18000 ZF83H22000 ZA82P22000 — ZA82P28000 — ZA82P35000 PLUG for connector Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC...
  • Page 96 3. GENERAL WORK STANDARD Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA) ZF93N10000 ZA93N10000 ZF93N15000 ZA93N15000 ZF93N18000 ZA93N18000 ZF93N22000 ZA93N22000 — ZA93N28000 ZF93N35000 ZA93N35000 SLEEVE Nominal diameter Made by IHARA KOHATSU Made by NIHON AMC Nominal Diameter (ZF) (ZA)
  • Page 97 3. GENERAL WORK STANDARD CONVERSION TABLE 3.3.1 UNIT CONVERSION [Remarks] Figures in ( ) show number of zero down a decimal point Example : 0.(2)1 = 0.001 1. Length Unit mile 0.001 0.000001 0.03937 0.0032808 0.0010936 0.(6)6214 0.01 0.00001 0.3937 0.032808 0.010936 0.(5)6214...
  • Page 98 3. GENERAL WORK STANDARD 3.3.2 MILLIMETER : INCH CONVERSION TABLE 1. mm (Millimeter)  in (Inch) 1 mm to 99 mm 0.0000 0.0394 0.0787 0.1181 0.1575 0.1969 0.2362 0.2756 0.3150 0.3543 0.3937 0.4331 0.4724 0.5118 0.5512 0.5906 0.6299 0.6693 0.7087 0.7480 0.7874 0.8268...
  • Page 99 3. GENERAL WORK STANDARD 2. in (Inch)  mm (Millimeter) 0.000 25.400 50.800 76.200 101.600 127.000 152.400 177.800 203.200 228.600 1/64 0.397 25.797 51.197 76.597 101.997 127.397 152.797 178.197 203.597 228.997 1/32 0.794 26.194 51.594 76.994 102.394 127.794 153.194 178.594 203.994 229.394 1/16 1.588 26.988...
  • Page 100 3. GENERAL WORK STANDARD 3.3.3 METER AND FOOT CONVERSION TABLE Foot Meter Foot Meter Foot Meter 1.52 53.34 105.12 3.05 54.86 106.68 4.57 56.39 108.20 6.10 57.91 109.73 7.62 59.44 111.25 9.14 60.96 112.78 10.67 62.48 114.30 12.19 64.01 115.82 13.72 65.53 117.35...
  • Page 101 3. GENERAL WORK STANDARD 3.3.4 GRADE CONVERSION TABLE Degree (°) Degree (°) Degree (°) 28.7 60.1 30.6 62.5 32.5 64.9 34.4 67.5 36.4 70.0 10.5 38.4 72.7 12.3 40.4 75.4 14.1 42.5 78.1 15.8 44.5 81.0 17.6 46.6 83.9 19.4 48.8 86.9 21.3...
  • Page 102 3. GENERAL WORK STANDARD 3.3.6 SYSTEM INTERNATIONAL (SI) UNIT CONVERSION TABLE International System of Units (SI : System International Unit) Conversion Formula CGS unit system to SI unit system Unit Types Meaning symbols Mass Kilogram Mass (kg) = Weight (kgf) F = gravity Newton 1 (N) = 1 (kg) ×...
  • Page 103 4. POWER TRAIN 10000A-1 Published 10-09-13, Control #218-02...
  • Page 104 4. POWER TRAIN 10000A-1 Published 10-09-13, Control #218-02...
  • Page 105 4. POWER TRAIN INTRODUCTION This crane is a full hydraulic crawler crane. The engine drives one set of the 2 section plunger type main pump and one plunger type swing pump and 2 section gear pump connected to the power divider and 2 section gear pump connected to swing pump through the power divider.
  • Page 106 4. POWER TRAIN FUEL TANK FRONT DRUM FRONT DRUM REDUCTION UNIT FRONT DRUM MOTOR HYD. OIL TANK REAR DRUM REAR DRUM REDUCTION UNIT POWER DIVIDOR REAR DRUM MOTOR ENGINE DIESEL PARTICULATE FILTER RADIATOR & OIL COOLER SEPARATE OIL COOLER AIR CLEANER BOOM DRUM BOOM DRUM BOOM DRUM MOTOR...
  • Page 107 4. POWER TRAIN GEAR PUMP MAIN (CONTROL & CONTROL VALVE AUX. UNIT) MAIN PUMP MAIN CONTROL VALVE GEAR PUMP (COOLING) SWING PUMP DRIVE TUMBLER PROPEL MOTOR PROPEL REDUCTION UNIT SWING BEARING CRAWLER EXT/RET CYLINDER SWING RING GEAR SWIVEL JOINT 10000A-1 Published 10-09-13, Control #218-02...
  • Page 108 4. POWER TRAIN ENGINE 4.2.1 INTRODUCTION This chapter explains how to remove and re-install the engine. Refer to the manual provided by the engine manufacturer for maintenance and repair details. 4.2.2 REMOVAL Proceed as follows when removing the engine from the machine.
  • Page 109 4. POWER TRAIN 1. Lower the boom on the ground and secure the upper spreader to the boom base with pins. Set the gantry to the propel configuration. AIR INLET HOSE 2. Take out the ground cable first in the battery. COVER OF DIESEL 3.
  • Page 110 4. POWER TRAIN 13. Install the appropriate capacity of lifting gear to the engine. (The engine has three lifting hooks.) 14. Remove the bolts and washers from the rubber mounts on the engine and the power divider. 15. Lift up the engine and pump drive assy. as one unit slowly and take out from the machine.
  • Page 111 4. POWER TRAIN This page is blank for editing convenience. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 112 4. POWER TRAIN 4.2.3 REPAIR AND MAINTENANCE Regarding the repair and maintenance of the engine, refer to the manual provided by the manufacturer. The engine manufacturer : HINO MOTORS, LTD. The engine model : J08E-UV 4.2.4 INSTALLATION Proceed as follows when installing the engine. 1.
  • Page 113 4. POWER TRAIN 9. Install the air inter cooler hose that were removed when the engine was removed. Install the exhaust tube and the diesel particulate filter cover. 10. Install all the hydraulic hoses to the hydraulic pumps. 11. Refill the engine with coolant water and engine oil to the required levels.
  • Page 114 4. POWER TRAIN Tightening torque 109 to 133 N-m (81 to 98 lbs-ft) (Apply LOCTITE #271) Tightening torque 360 to 440 N-m (266 to 324 lbs-ft) SECTION A-A (Apply LOCTITE #271) Tightening torque 261 to 319 N-m (193 to 235 lbs-ft) (Apply LOCTITE #271) Tightening torque 504 to 616 N-m (372 to 454 lbs-ft)
  • Page 115 4. POWER TRAIN PUMP DRIVE ASSEMBLY 4.3.1 INTRODUCTION This chapter explains how to remove, inspect, repair and re-install the pump drive assembly. The pump drive assembly is mounted directly onto the front of the engine. It consists of a coupling, a power divider, main pumps, and 2 section gear pumps, swing pump and 2 section gear pumps which are connecting to the swing pump.
  • Page 116 4. POWER TRAIN 4.3.2 REMOVAL Proceed as follows when removing the pump drive assembly. (See next page) Pump drive assembly should be removed from the engine according to the following procedure only after the engine has been removed from the machine as described in Section 4.2.
  • Page 117 4. POWER TRAIN LIFTING SCREW HOLE (M16) AIR BREATHER NAME PLATE STAND (POWER DIVIDER SIDE) SWING PUMP CONTROL PUMP STAND (ENGINE SIDE) GANTRY HOIST PUMP (AUX. DEVICE) ADAPTER PLATE (ENGINE SIDE) FRONT / REAR DRUM COOLING PUMP (Flange When “Free Less” Is Selected) OIL FILL PORT COUPLING OIL LEVEL GAUGE...
  • Page 118 4. POWER TRAIN POWER DIVIDER ASSY STAND (POWER DEVIDER SIDE) STAND (ENGINE SIDE) ADAPTER PLATE (ENGINE SIDE) ELEMENT BUSHING (ENGINE SIDE) FLYWHEEL COUPLING CLAMPING SCREW (POWER DIVIDER SIDE) CLAMPING HUB (POWER DIVIDER SIDE) OUTER HUB (POWER DIVIDER SIDE) INSERT (POWER DIVIDER SIDE) FLYWHEEL HOUSING Fig.4-2 PUMP DRIVE (2/2) 10000A-1...
  • Page 119 4. POWER TRAIN 4.3.3 DISASSEMBLING THE POWER DIVIDER Proceed as follows when disassembling the power divider. (Refer to P.4-23 to 4-26 for corresponding numbers in the explanation below.) 1. Place the power divider on the block facing the flywheel side up. 2.
  • Page 120 4. POWER TRAIN 14. If required, remove the screws (36) and the plate (17). 15. Remove the cap screws (35) and the support (11) using two pull out screw holes (M10) of the support (11). If required, remove the screws (36) and the plate (19).
  • Page 121 4. POWER TRAIN 4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER Check all parts prior to reassembling the power divider. All questionable parts should be replaced to maximize the re-assembled power divider’s service life and to avoid further break downs. Checking should proceed in the following order.
  • Page 122 4. POWER TRAIN 4.3.5 ASSEMBLING THE POWER DIVIDER Assembling the power diver is in reverse order of disassembling. Take extra care on the following points in assembling. (Refer to P.4-23 to 4-26 for corresponding numbers in the explanation below.) 1. Apply clean oil on each part and then assemble. But ensure to remove any oil on the mating face of the housing (1), the stand (2) and the support (8), (9), (10), (11) and apply LOCTITE #515 evenly on...
  • Page 123 4. POWER TRAIN 4.3.6 RE-INSTALLATION Assemble the pump drive assy. as follows. (Refer to P.4-27 for corresponding numbers in the explanation below.) 1. Apply grease on the spline area of the input shaft (1) and insert the clamping hub (2) to 65 mm point from the shaft end as shown in P.4-27 (the clamping hub touches lightly on spline step area).
  • Page 124 4. POWER TRAIN 6. Attach the appropriate capacity lifting gear to the power divider and insert the coupling side element of the power divider to the wheel side insert. Install the power divider to the stand (engine side) which is installed on the flange wheel housing. 7.
  • Page 125 4. POWER TRAIN 41 Use seal tape etc. Tightening torque 88.2 to 107.8 N-m (65.1 to 79.5 lbs-ft) Note on “S” clearance control Apply LOCTITE #577 (See P.4-24) and phase angle. Install with two face cut area on Do not use seal tape Apply LOCTITE #515 evenly upper and random direction.
  • Page 126 4. POWER TRAIN Tightening torque 1.17 to 1.43 N-m (0.9 to 1.0 lbs-ft) Apply LOCTITE #242 Tightening torque 1.17 to 1.43 N-m 19 , 36 (0.9 to 1.0 lbs-ft) (Note 1) Apply LOCTITE #242 Apply LOCTITE #515 evenly on mating surface of item 1 “HOUSING”...
  • Page 127 4. POWER TRAIN (Note 1) Note on installation phase angle. Bearing fill in port of item 2 “STAND” should be on upper side. Tightening torque Tightening torque 31.5 to 38.5 N-m 31.5 to 38.5 N-m (23.3 to 28.3 lbs) (23.3 to 28.3 lbs) Apply LOCTITE #242 Apply LOCTITE #242 Tightening torque...
  • Page 128 4. POWER TRAIN 1. Housing 16. Plate 31. Plate 2. Stand 17. Plate 32. Rivet 3. Shaft 18. Plate 33. Capscrew 4. Gear 19. Plate 34. Capscrew 5. Gear 20. Plate 35. Capscrew 6. Gear 21. Plate 36. Machine screw 7.
  • Page 129 4. POWER TRAIN M10 X 1.25 (Fine) Tightening torque 36.4 to 44.6 N-m (26.9 to 32.8 lbs-ft) Apply LOCTITE #242 (See item 7 in P.4-21) Tightening torque 440 to 490 N-m (324.6 to 361.5 lbs-ft) (See item 5 in P.4-21) Tightening torque 200 to 220 N-m (147.6 to 162.2 lbs-ft)
  • Page 130 4. POWER TRAIN 10000A-1 4-28 Published 10-09-13, Control #218-02...
  • Page 131 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 132 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 133 5. HYDRAULIC SYSTEM 5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS SWING BEARING SWING SWING MOTOR REDUCTION UNIT SWING CONTROL VALVE CONTROL VALVE SWING GEAR REDUCTION UNIT HYDRAULIC OIL TANK FRONT DRUM MOTOR GEAR PUMP CRAWLER EXT./RET. CYLINDER CONTROL VALVE MAIN PUMP CONTROL VALVE GEAR PUMP REAR DRUM MOTOR...
  • Page 134 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 135 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 136 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 137 5. HYDRAULIC SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 138 5. HYDRAULIC SYSTEM This page is blank for editing convenience. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 139 5. HYDRAULIC SYSTEM HYDRAULIC CIRCUITS AND COMPONENTS 5.2.1 COMPONENT SPECIFICATIONS Item Name of Component Specification Swash plate type, variable displacement Pump (Boom, front and rear drum, propel, Max. delivery :255ltr./min X 2 third) Max. working pressure :31.9MPa (325kgf/cm Swash plate type, variable displacement Pump Max.
  • Page 140 5. HYDRAULIC SYSTEM Item Name of Component Specification :20.6MPa / 4.9Mpa Control valve (Gantry) Set pressure :(210kgf/cm / 50kgf/cm (10000E-1 OPT.) Valve block Swing angle limit (3-Section sol prop valve) Front drum hoist remote control pressure Front drum lowering remote control pressure Rear drum hoist remote control pressure Rear drum lowering remote control pressure Valve block (8-section)
  • Page 141 5. HYDRAULIC SYSTEM Item Name of Component Specification Front and rear drum : 2.65 to 2.94 Mpa (27 to 30kgf/cm Remote control valve (Front and rear drum, boom drum) Boom drum : 2.50 to 2.79 Mpa (25.5 to 28.5kgf/cm Swing : 1.62 to 1.92 Mpa Remote control valve (Swing) (16.5 to 19.6kgf/cm Press : 1.42 to 1.62MPa...
  • Page 142 5. HYDRAULIC SYSTEM Item Name of Component Specification Line filter (Control) 100 Mesh (149 ) 370cm Line filter (Aux. actuator) 100 Mesh (149 ) 380cm Bypass check valve (Oil cooler) 0.294MPa Bypass check valve 0.294MPa (Front, rear drum brake cooling) Bypass check valve (For third) [Option] 0.490MPa Accumulator...
  • Page 143 5. HYDRAULIC SYSTEM 5.2.2 LAYOUT OF HYDRAULIC COMPONENTS 1. UPPER MACHINERY 80. PRESSURE SENSOR (SWING) 46. REMOTE CONTROL 61. SOL. PROP RELIEF VALVE VALVE (SWING) 14. MOTOR (TAGLINE) 50. REMOTE CONTROL VALVE (THIRD) 48. CONTROL VALVE (BRAKE) 45. REMOTE CONTROL VALVE 12.
  • Page 144 5. HYDRAULIC SYSTEM 31. VALVE BLOCK 49. REMOTE CONTROL VALVE (SWING COUNTERFORCE) (BOOM HOIST PEDAL) 30. VALVE BLOCK (2-SECTION) (REMO-CON PRESS.SOURCE CUT ETC) 76. ACCUMULATOR 82. PRESSURE SWITCH 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) 79. PRESSURE SENSOR (REMO-CON PRESS. DETECT) FLOOR PLATE (VIEW FROM CAB LOWER FACE) PROPEL CONTROL LEVER...
  • Page 145 5. HYDRAULIC SYSTEM 27.VALVE BLOCK (8-SECTION) (AUTOMATIC STOP & SPEED CONTROL) 79. PRESSURE SENSOR (PIPING UNDER SOLENOID) 41. SOLENOID VALVE (OPTION) 42. SOLENOID VALVE (OPTION) 54. CHECK VALVE 28. VALVE BLOCK (5-SECTION, LIMIT STOP) 29.VALVE BLOCK (4-SECTION) LEFT DECK FUEL TANK FRONT (MOTOR BRAKE) 5-15 10000A-1...
  • Page 146 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 10000A-1 5-16 Published 10-09-13, Control #218-02...
  • Page 147 5. HYDRAULIC SYSTEM 39. VALVE BLOCK (2-SECTION) (THIRD WET TYPE FREE FALL) 81. PRESSURE SENSOR (FOR CLUTCH) (CONTROL PRESS. DETECT) POWER DIVIDER REAR 5-17 10000A-1 Published 10-09-13, Control #218-02...
  • Page 148 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) 10000A-1 5-18 Published 10-09-13, Control #218-02...
  • Page 149 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) 5-19 10000A-1 Published 10-09-13, Control #218-02...
  • Page 150 5. HYDRAULIC SYSTEM 3. HYDRAULIC OIL TANK 73. BYPASS CHECK VALVE 66. SUCTION STRAINER 67. RETURN FILTER SECTION B-B SECTION A-A 68. RETURN FILTER 69. DRAIN FILTER (WET TYPE CLUTCH) 60. RELIEF VALVE /REDUCING VALVE (CONTROL) 37. VALVE BLOCK (2-SECTION FEATHERING QMAX CUT) 70.
  • Page 151 5. HYDRAULIC SYSTEM 4. GANTRY 51. CYLINDER (GANTRY HOIST) 51. CYLINDER (GANTRY HOIST) 58. SWIVEL JOINT 22. CONTROL VALVE (GANTRY) 5-21 10000A-1 Published 10-09-13, Control #218-02...
  • Page 152 5. HYDRAULIC SYSTEM 5. WINCH MOTOR 8. 9. MOTOR (FRONT & REAR DRUM) 8. 9. MOTOR (THIRD DRUM) 10. MOTOR (BOOM) 65. SLOW RETURN CHECK VALVE (FOR MOTOR BRAKE) 10000A-1 5-22 Published 10-09-13, Control #218-02...
  • Page 153 5. HYDRAULIC SYSTEM 6. LEFT DECK 18. CONTROL VALVE (PROPEL L. H., MAIN1, AUX.2) 17. CONTROL VALVE (PROPEL R. H. , BOOM, MAIN2, AUX.1) 19. CONTROL VALVE (THIRD DRUM) 5-23 10000A-1 Published 10-09-13, Control #218-02...
  • Page 154 5. HYDRAULIC SYSTEM 7. HYDRAULIC OIL PUMP 5. GEAR PUMP (FRONT & REAR DRUM BRAKE COOLING) 4. NO.6 GEAR PUMP (CONTROL/GANTRY) 3. NO.3 PUMP (SWING) 2. NO.2 MAIN PUMP 1. NO.1 MAIN PUMP 10000A-1 5-24 Published 10-09-13, Control #218-02...
  • Page 155 5. HYDRAULIC SYSTEM 8. LOWER MACHINERY SWING BEARING 21. CONTROL VALVE (TRANSLIFTER /CRAWLER EXT.) 52. CYLINDER (CRAWLER EXT. /RET.) 59. SWIVEL JOINT SWING GEAR PROPEL REDUCTION UNIT 13. MOTOR (PROPEL) 5-25 10000A-1 Published 10-09-13, Control #218-02...
  • Page 156 5. HYDRAULIC SYSTEM This page is blank for editing convenience. 10000A-1 5-26 Published 10-09-13, Control #218-02...
  • Page 157 5. HYDRAULIC SYSTEM HYDRAULIC SYSTEM 5.3.1 PREFACE This chapter provides a general outline of the overall hydraulic system. 5.3.2 OUTLINE The pressurized oil in this circuit is supplied by the 3 variable displacement pumps driven with the power divider directly connected to the engine and 2 section gear pumps connected to them.
  • Page 158 5. HYDRAULIC SYSTEM 5.3.3 OIL FLOW FROM No.1 AND No.2 PUMPS No.1 and No.2 pumps are main pumps and are tandem connected variable displacement double pumps. At neutral, pressurized oil from No.1 pump flows into 4 section side control valve circuit (front / rear drum / right propel / boom).
  • Page 159 5. HYDRAULIC SYSTEM OIL FLOW FROM No.1 AND No.2 PUMPS 5-29 10000A-1 Published 10-09-13, Control #218-02...
  • Page 160 5. HYDRAULIC SYSTEM 5.3.4 OIL FLOW FROM No.3 PUMP No.3 pump is swing pump and is variable displacement pump. When the swing remote control valve is in neutral, pressurized oil from No.3 pump flows into the swing control valve and returns to oil tank without load. When the swing control valve is actuated with the pressurized oil from the remote control valve, pressurized oil from the swing pump flows into the...
  • Page 161 5. HYDRAULIC SYSTEM OIL FLOW FROM No.3 PUMP 5-31 10000A-1 Published 10-09-13, Control #218-02...
  • Page 162 5. HYDRAULIC SYSTEM 5.3.5 OIL FLOW FROM No.4 AND No.5 PUMPS (FRONT, REAR DRUM BRAKE COOLING) No.4 and No.5 pumps are gear pumps and are used for cooling of front and rear drum brake (clutch). The pressurized oil from both pumps passes through the front and rear drum brake (clutch) and returns to the tank through the filter.
  • Page 163 5. HYDRAULIC SYSTEM OIL FLOW FROM No.4 AND No.5 PUMPS (FRONT, REAR DRUM BRAKE COOLING) 5-33 10000A-1 Published 10-09-13, Control #218-02...
  • Page 164 5. HYDRAULIC SYSTEM 5.3.6 OIL FLOW FROM No.6 PUMP No.6 pump is gear pump and is used for control. Pressurized oil from the pump passes through the line filter and is pressure-reduced to 5.4 MPa and flows into the accumulator and then flows into 2 4-section valve and 2 2-section valve and the foot brake valve.
  • Page 165 5. HYDRAULIC SYSTEM OIL FLOW FROM No.6 PUMP (WHEN FUNCTION LOCK LEVER IS IN "LOCK" POSITION) 5-35 10000A-1 Published 10-09-13, Control #218-02...
  • Page 166 5. HYDRAULIC SYSTEM 2. WHEN FUNCTION LOCK LEVER IS IN "WORK" POSITION When the function lock lever is in "WORK" position, pressurized oil sent to 2-section valve passes through the function lock (Remo-con cut) solenoid valve (SOL-3) and flows into the remote control valve.
  • Page 167 5. HYDRAULIC SYSTEM OIL FLOW FROM No.6 PUMP (WHEN FUNCTION LOCK LEVER IS IN "WORK" POSITION) 5-37 10000A-1 Published 10-09-13, Control #218-02...
  • Page 168 5. HYDRAULIC SYSTEM 5.3.7 OIL FLOW FROM No.7 PUMP 1. CRAWLER EXTENDING CYLINDER No.7 pump (Aux. device pump) is fixed displacement gear pump and is used for crawler extending cylinder. When the lower pressure source valve located in the downstream side of the gantry hoist control valve is operated, the pressurized oil from the pump passes through the swivel joint and flows into the crawler extending valve.
  • Page 169 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (CRAWLER EXTENDING CYLINDER) 5-39 10000A-1 Published 10-09-13, Control #218-02...
  • Page 170 5. HYDRAULIC SYSTEM 2. TRANSLIFTER No.7 pump (Aux. device pump) is fixed displacement gear pump and is used for the translifter cylinder. When the lower pressure source valve located in the downstream side of the gantry hoist control valve is operated, the pressurized oil from the pump passes through the swivel joint and flows into the translifter valve.
  • Page 171 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (TRANSLIFTER) 5-41 10000A-1 Published 10-09-13, Control #218-02...
  • Page 172 5. HYDRAULIC SYSTEM 3. GANTRY HOIST CYLINDER No.7 pump (Aux. device pump) is fixed displacement gear pump and is used for gantry hoist.The pressurized oil from the pump flows into the gantry hoist control valve. When the gantry hoist control valve is in neutral, the pressurized oil passes through the valve and returns to the tank without load.
  • Page 173 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (GANTRY HOIST CYLINDER) 5-43 10000A-1 Published 10-09-13, Control #218-02...
  • Page 174 5. HYDRAULIC SYSTEM 4. COUNTERWEIGHT SELF REMOVAL CYLINDER No.7 pump (Aux. device pump) is fixed displacement gear pump and is used for counterweight self removal. The pressurized oil from the pump flows into the counterweight self removal control valve. When the counterweight self removal control valve is in neutral, the pressurized oil passes through the valve and returns to the tank without load.
  • Page 175 5. HYDRAULIC SYSTEM OIL FLOW FROM No.7 PUMP (COUNTERWEIGHT SELF REMOVAL CYLINDER) 5-45 10000A-1 Published 10-09-13, Control #218-02...
  • Page 176 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 10000A-1 5-46 Published 10-09-13, Control #218-02...
  • Page 177 5. HYDRAULIC SYSTEM 8-SECTION VALVE (WITH SHUTTLE VALVE) TO RETURN BLOCK THIRD DRUM LOWER BOOM DRUM RAISE THIRD DRUM RAISE BOOM DRUM LOWER FRONT DRUM LOWER REAR DRUM RAISE FRONT DRUM RAISE REAR DRUM LOWER 5-47 10000A-1 Published 10-09-13, Control #218-02...
  • Page 178 5. HYDRAULIC SYSTEM 4-SECTION VALVE REAR DRUM FREE FALL SPEED FROM FRONT DRUM FOOT BRAKE ACCELERATION FRONT DRUM FREE FALL SPEED ACCELERATION FROM REAR DRUM FOOT BRAKE FRONT DRUM FREE FALL SPEED REAR DRUM FREE FALL SPEED ACCELERATION ACCELERATION FROM FRONT DRUM FOOT BRAKE FROM REAR DRUM FOOT BRAKE 10000A-1 5-48...
  • Page 179 5. HYDRAULIC SYSTEM 3-SECTION VALVE REAR DRUM FREE FALL SPEED ACCELERATION FRONT DRUM FREE FALL SPEED ACCELERATION TO TANK FROM 4-SECTION VALVE REAR DRUM FREE FALL SPEED ACCELERATION FROM 4-SECTION VALVE FRONT DRUM FREE FALL SPEED ACCELERATION 5-49 10000A-1 Published 10-09-13, Control #218-02...
  • Page 180 5. HYDRAULIC SYSTEM 5-SECTION VALVE TO TANK FRONT DRUM RAISE REAR DRUM RAISE BOOM DRUM RAISE BOOM DRUM LOWER 10000A-1 5-50 Published 10-09-13, Control #218-02...
  • Page 181 5. HYDRAULIC SYSTEM 2-SECTION VALVE TO SWING RELIEF SELECT TO PROPEL MOTOR HI/LOW SELECT TO SWING RELIEF SELECT TO PROPEL MOTOR HI/LOW SELECT TO SWING PARKING BRAKE TO SWING REMO-CON CUT PARKING BRAKE REMO-CON CUT (TO FLOOR UNDER MANIFOLD) 5-51 10000A-1 Published 10-09-13, Control #218-02...
  • Page 182 5. HYDRAULIC SYSTEM 1-SECTION VALVE TO SWING REMO-CON VALVE (SWING COUNTERFORCE) TO SWING REMO-CON VALVE (SWING COUNTERFORCE) 10000A-1 5-52 Published 10-09-13, Control #218-02...
  • Page 183 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (4-SECTION) REAR 1ST SP. RAISE BOOM RAISE FRONT 2ND SP. RAISE RAIGHT PROPEL (FORWARD) RAIGHT PROPEL BOOM LOWER REAR 1ST SP. LOWER FRONT 2ND SP. LOWER (FORWARD) RIGHT PROPEL BOOM RAISE REAR 1ST SP. RAISE FRONT 2ND SP.
  • Page 184 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (3-SECTION) REAR 2ND SP. RAISE FRONT 1ST SP. RAISE LEFT PROPEL (BACKWARD) LEFT PROPEL REAR 2ND SP. LOWER FRONT 1ST SP. LOWER (FORWARD) LEFT PROPEL (BACKWARD) REAR 2ND SP. RAISE FRONT 1ST SP. RAISE FRONT 1ST SP.
  • Page 185 5. HYDRAULIC SYSTEM MAIN CONTROL VALVE (THIRD 1-SECTION) THIRD RAISE THIRD LOWER 5-55 10000A-1 Published 10-09-13, Control #218-02...
  • Page 186 5. HYDRAULIC SYSTEM 10000A-1 5-56 Published 10-09-13, Control #218-02...
  • Page 187 6. HOIST SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 188 6. HOIST SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 189 6. HOIST SYSTEM APPARATUS AND LOCATION OF COMPONENTS The hoist system consists of the front drum and rear drum assembly. Each drum assy. consists of hoist motor (brake built in), reduction unit, drum clutch (common to free fall brake) and drum lock. The pressured oil delivered from 2 main pumps (No.1, No.2) is controlled by the control valve and flaws into each motor.
  • Page 190 6. HOIST SYSTEM HYDRAULIC PUMP WINCH FRONT DRUM MOTOR FRONT DRUM MAIN PUMP GEAR PUMP (HOIST / PROPEL) (CONTROL / AUX.) GEAR PUMP (MAIN AND AUX. COOLANT) REDUCTION UNIT POWER DIVIDER SWING PUMP REAR DRUM MOTOR REAR DRUM DRUM LOCK FRONT DRUM LOCK KNOB REAR DRUM LOCK KNOB Refer to P.6-17 to 6-40 for circuit diagram and function.
  • Page 191 6. HOIST SYSTEM ADJUSTMENT OF DRUM LOCK Do not adjust the drums locks until the boom, hook block, and load have been lowered to the ground. Failure to observe this precaution may result in serious injury or loss of life. 1.
  • Page 192 6. HOIST SYSTEM WINCH 6.3.1 WINCH INSTALLATION Tightening torque 333 to 407 N-m 53 mm (246 to 300 lbs-ft) Stick out the rope end. (2.1 inch) But not exceeding flange O.D. DRUM FLANGE O.D. CLAMP CLAMPING PROCEDURE OF ROPE END MACHINE FRONT Install pin after Install pin after...
  • Page 193 6. HOIST SYSTEM Install pin after Install pin after applying grease. applying grease. Tightening torque Tightening torque 35.1 to 42.9 N-m 35.1 to 42.9 N-m (25.9 to 31.6 lbs-ft) (25.9 to 31.6 lbs-ft) Apply LOCTITE #271 Apply LOCTITE #271 Install keeper plate Install keeper plate to make it engaged to make it engaged...
  • Page 194 6. HOIST SYSTEM 6.3.2 WINCH ASSEMBLY CLUTCH REDUCTION UNIT (FREE FALL BRAKE) PLUG BREATHERS (Install before motor installation.) Tightening torque Tightening torque 39 to 49 N-m 88.2 to 107.8 N-m (28.8 to 36.1 lbs-ft) (65.1 to 79.5 lbs-ft) Apply LOCTITE #577 Apply LOCTITE #577 TUBE FOR WINCH...
  • Page 195 6. HOIST SYSTEM This page is blank for editing convenience. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 196 6. HOIST SYSTEM 6.3.3 REDUCTION UNIT ASSEMBLY Apply three bond #1215 evenly on outer periphery area and apply grease lightly on lip area and assemble. Oil seal is to be hit with hammer etc. Clearance adjustment with shim item 32 (shim) to 0.3 to 1.0 mm (0.0118 to 0.0394 inch).
  • Page 197 6. HOIST SYSTEM 1. Carrier 12. Oil seal 23. Snap ring 2. Gear ring 13. Sleeve 24. Snap ring 3. Retainer 14. Sleeve 25. Bearing 4. Sun gear 15. Bearing 26. Spring pin 5. Support housing 16. Spacer 27. Thrust washer 6.
  • Page 198 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 10000A-1 6-12 Published 10-09-13, Control #218-02...
  • Page 199 6. HOIST SYSTEM MACHINE FRONT SECTION F-F SECTION G-G 1. Bracket 20. Spacer 39. Pedal 2. Lever assembly 21. Bolt 40. Brake valve 3. Link 22. Spacer 41. Sems bolt 4. Pedal 23. Shim (0.4) 42. Capscrew 5. Pawl 24. Shim (0.6) 43.
  • Page 200 6. HOIST SYSTEM 6.4.2 ADJUSTING THE BRAKE PEDAL EYE BOLT ADJUSTING STROKE : 15 mm (0.6 inch) 112 mm (4.41 inch) Adjustment 1. Adjust the eye bolt until the dimension S is 53 mm (2.09 inch). 2. Depress the brake pedal until the valve spool reaches the stroke end.
  • Page 201 6. HOIST SYSTEM BLEEDING AIR FROM BRAKE CIRCUIT BYPASS HOSE (9999407879) If air remains in the piping from the brake valve to the cylinder built in the winch, the brake response becomes poor. If the brake valve and piping are removed, bleed air by the following sequences shown below.
  • Page 202 6. HOIST SYSTEM This page is blank for editing convenience. 10000A-1 6-16 Published 10-09-13, Control #218-02...
  • Page 203 6. HOIST SYSTEM 6.6 CONSTRUCTION AND FUNCTION 6.6.1 HYDRAULIC SCHEMATIC 6-17 10000A-1 Published 10-09-13, Control #218-02...
  • Page 204 6. HOIST SYSTEM 10000A-1 6-18 Published 10-09-13, Control #218-02...
  • Page 205 6. HOIST SYSTEM This page is blank for editing convenience. 6-19 10000A-1 Published 10-09-13, Control #218-02...
  • Page 206 6. HOIST SYSTEM 6.6.2 LIFTING A LOAD Function of the front drum and the rear drum are exactly same. Tne front drum is explained here as an example. Pressurized oil from the main pump (No.1, No.2) flows through the control valve to power the hoist system.
  • Page 207 6. HOIST SYSTEM Lifting (1/2) 6-21 10000A-1 Published 10-09-13, Control #218-02...
  • Page 208 6. HOIST SYSTEM Lifting (2/2) 10000A-1 6-22 Published 10-09-13, Control #218-02...
  • Page 209 6. HOIST SYSTEM This page is blank for editing convenience. 6-23 10000A-1 Published 10-09-13, Control #218-02...
  • Page 210 6. HOIST SYSTEM 6.6.3 HOLDING A RAISED LOAD With the main control lever turned back to its neutral position, the control pressure coming from the remote control valve is cut and the spool in the main control valve returns to its neu- tral position.
  • Page 211 6. HOIST SYSTEM Holding (1/2) 6-25 10000A-1 Published 10-09-13, Control #218-02...
  • Page 212 6. HOIST SYSTEM Holding (2/2) 10000A-1 6-26 Published 10-09-13, Control #218-02...
  • Page 213 6. HOIST SYSTEM This page is blank for editing convenience. 6-27 10000A-1 Published 10-09-13, Control #218-02...
  • Page 214 6. HOIST SYSTEM 6.6.4 LOWERING A LOAD (POWER LOWERING) Pressurized oil from the main pump (No.1, No.2) flows through the main control valve to power the front drum hoist system. When the function lock lever is in the "Work" po- sition (SOL-3 : ON position), oil pressure from the control pump flows past the accumulator and into the foot brake valve block, the clutch valve...
  • Page 215 6. HOIST SYSTEM Lowering (Power lowering) (1/2) 6-29 10000A-1 Published 10-09-13, Control #218-02...
  • Page 216 6. HOIST SYSTEM Lowering (Power lowering) (2/2) 10000A-1 6-30 Published 10-09-13, Control #218-02...
  • Page 217 6. HOIST SYSTEM This page is blank for editing convenience. 6-31 10000A-1 Published 10-09-13, Control #218-02...
  • Page 218 6. HOIST SYSTEM 6.6.5 FREE FALL OPERATION When the brake select switch is set to the "FREE FALL" side, the solenoid valve (SOL-22) in the clutch valve block (4-section solenoid valves) is switched over. When the solenoid valve is switched over and the front drum foot brake is released, the pres- surized oil in the "CLM"...
  • Page 219 6. HOIST SYSTEM Free Fall (1/2) 6-33 10000A-1 Published 10-09-13, Control #218-02...
  • Page 220 6. HOIST SYSTEM Free Fall (2/2) 10000A-1 6-34 Published 10-09-13, Control #218-02...
  • Page 221 6. HOIST SYSTEM Free Fall Control (1/2) 6-35 10000A-1 Published 10-09-13, Control #218-02...
  • Page 222 6. HOIST SYSTEM Free Fall Control (2/2) 10000A-1 6-36 Published 10-09-13, Control #218-02...
  • Page 223 6. HOIST SYSTEM This page is blank for editing convenience. 6-37 10000A-1 Published 10-09-13, Control #218-02...
  • Page 224 6. HOIST SYSTEM FREE FALL ACCELERATION Free fall with the "FREE FALL SPEED SELECT SWITCH" on the left upper switch panel set to the "HIGH" position When the front drum foot brake pedal is re- leased, the solenoid valve (SOL-10) is switched over, and pressurized oil from the clutch valve block (4-section SOL) flows into the "PDM"...
  • Page 225 6. HOIST SYSTEM Free Fall Speed Acceleration (1/2) 6-39 10000A-1 Published 10-09-13, Control #218-02...
  • Page 226 6. HOIST SYSTEM Free Fall Speed Acceleration (2/2) 10000A-1 6-40 Published 10-09-13, Control #218-02...
  • Page 227 7. BOOM HOIST SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 228 7. BOOM HOIST SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 229 7. BOOM HOIST SYSTEM APPARATUS AND LOCATION OF COMPONENTS The boom hoist system consists of the main pump, the main control valve, the boom drum motor, the reduction unit, the boom drum and the drum lock mechanism. The pressurized oil for the boom hoist system is supplied by the main pump (No.1) installed on the engine’s power divider.
  • Page 230 7. BOOM HOIST SYSTEM DRUM LOCK KNOB As for raising, neutral and lowering circuit and functions, refer to P.7-11 to 7-17. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 231 7. BOOM HOIST SYSTEM BOOM HOIST WINCH INSTALLATION When boom hoist winch is to be installed or removed, perform work observing the following tightening torque and note. When replacing the gear oil, use the specified type of oil and fill in to the specified level. Specified type of oil : Extreme pressure gear oil SAE#90 (API-GL4) or SAE#80W-90 Specified volume :...
  • Page 232 7. BOOM HOIST SYSTEM BOOM DRUM LOCK 7.3.1 ASSEMBLY DRAWING When the assembly is complete, fill grease until it is squeezed out from the clearances of the pawl. HOSE Tightening torque : 24.1 to 33.9 N-m CONNECTOR Tightening torque : 21.5 to 24.5 N-m Apply LOCTITE #577 SEMS BOLT BRACKET...
  • Page 233 7. BOOM HOIST SYSTEM 7.3.2 ADJUSTING THE BOOM DRUM LOCK Ensure to adjust the boom hoist drum lock while the boom has been lowered to the ground. Failure to observe this precaution may result in serious injury or loss of life. 1.
  • Page 234 7. BOOM HOIST SYSTEM REDUCTION UNIT Apply three bond #1215 on O.D. area and Tightening torque : 247 N-m grease lightly on lip area and assemble. Apply Loctite #242 After insertion, Note on assembly direction. (As shown) (To hole side) punch to lock.
  • Page 235 7. BOOM HOIST SYSTEM 1. Cover 19. Thrust washer 37. Sun gear 2. Grease fitting 20. Needle bearing 38. Ring gear 3. Cap 21. Pinion 39. Carrier 4. Sleeve 22. Hex. set screw 40. Spacer 5. Plate 23. Pin 41. Plug 6.
  • Page 236 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 10000A-1 7-10 Published 10-09-13, Control #218-02...
  • Page 237 7. BOOM HOIST SYSTEM 7.5 CONSTRUCTION AND FUNCTION 7.5.1 HYDRAULIC SCHEMATIC BOOM HOIST HYD. CIRCUIT 7-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 238 7. BOOM HOIST SYSTEM 7.5.2 RAISING THE BOOM Pressurized hydraulic oil from the main pump (No.1) flows into 4 section side of the main con- trol valve. The control pressurized oil from the control valve flows into the valve block and remote control valve through the accumulator.
  • Page 239 7. BOOM HOIST SYSTEM BOOM RAISING 7-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 240 7. BOOM HOIST SYSTEM 7.5.3 NEUTRAL (HOLDING BOOM) When the control lever is returned to neutral, control pressure of the remote control valve is shut off and main control valve spool returns to neutral and pressured oil from the main pump (No.1) passes through the control valve and re- turns to the tank without load.
  • Page 241 7. BOOM HOIST SYSTEM BOOM HOLDING 7-15 10000A-1 Published 10-09-13, Control #218-02...
  • Page 242 7. BOOM HOIST SYSTEM 7.5.4 LOWERING BOOM The pressured oil from the No.1 main pump flows into the 4 section side main control valve. The control pressured oil from the control pump flows into the valve block and remote control valve through the accumulator.
  • Page 243 7. BOOM HOIST SYSTEM BOOM LOWERING 7-17 10000A-1 Published 10-09-13, Control #218-02...
  • Page 244 7. BOOM HOIST SYSTEM This page is blank for editing convenience. 10000A-1 7-18 Published 10-09-13, Control #218-02...
  • Page 245 8. SWING SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 246 8. SWING SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 247 8. SWING SYSTEM APPARATUS AND LOCATION OF COMPONENTS The swing system consists of the swing pump, the swing motor (built in swing brake), the swing control valve, the reduction unit, the swing bearing ring, the swivel joint, the swing gear and the swing lock. To swing the machine’s upper machinery, pressurized oil from the swing pump (No.3) mounted on the power divider is sent to the swing motor by way of the control...
  • Page 248 8. SWING SYSTEM CONSTRUCTION AND FUNCTION 8.2.1 HYDRAULIC SCHEMATIC 10000A-1 Published 10-09-13, Control #218-02...
  • Page 249 8. SWING SYSTEM This page is blank for editing convenience. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 250 8. SWING SYSTEM 8.2.2 SWING The working principle of right swing, and left swing are identical. The right swing is explained here. [The swing brake is released ("SPB" SOL-5 is actuated).] The pressurized oil from the swing pump is led to the swing control valve.
  • Page 251 8. SWING SYSTEM SWING (Neutral Free Mode) 10000A-1 Published 10-09-13, Control #218-02...
  • Page 252 8. SWING SYSTEM 8.2.3 STOPPING When the swing control lever is returned from the swing position to the neutral position, the control pressure from the remote control valve is shut off, and the control valve spool (A) returns to neutral. As a result, the main pressurized oil from the swing pump returns to the tank with no load.
  • Page 253 8. SWING SYSTEM STOP (Neutral Free Mode) 10000A-1 Published 10-09-13, Control #218-02...
  • Page 254 8. SWING SYSTEM This page is blank for editing convenience. 10000A-1 8-10 Published 10-09-13, Control #218-02...
  • Page 255 8. SWING SYSTEM SWING REDUCTION UNIT Item Name Tightening Torque Weight Reduction unit 396 kg (873 lbs) Motor 64 kg (141 lbs) O-Ring Bolt M16 X 45 mm / 145 to 177 N-m (107 to 131 lbs-ft) Tube Level gauge Bolt M20 X 140 mm / 504 to 616 N-m (372 to 454 lbs-ft) 8-11...
  • Page 256 8. SWING SYSTEM Apply LOCTITE #515 Apply LOCTITE #515 41, 40, 39, 38, 37, 36, 35, 34 32,33 Apply LOCTITE #515 Shim adjustment 0 to 0.2 mm (0 to 0.0079 inch) Bolt hole M20 Wrap seal tape or Apply LOCTITE #577 Apply LOCTITE #515 Wrap seal tape or Apply LOCTITE #577...
  • Page 257 8. SWING SYSTEM 1. Housing 17. Bearing 34. Shim (t=1.1) 2. Housing 18. Bearing 35. Shim (t=1.2) 3. Housing 19. Bearing 36. Shim (t=1.3) 4. Pinion 20. Bearing 37. Shim (t=1.4) 5. Shaft 21. Oil seal 38. Shim (t=1.5) 6. Ring gear 22.
  • Page 258 8. SWING SYSTEM SWING BEARING Tightening force : 423 to 517 kN (95,094 to 116,226 lbf) Apply LOCTITE #242 Tightening force : 423 to 517 kN (95,094 to 116,226 lbf) Apply LOCTITE #242 SECTION A-A Upper machinery front Outer ring soft zone Inner ring soft zone (Stop plug) (“S”...
  • Page 259 8. SWING SYSTEM BOLT TIGHTENING PROCEDURE Lower frame side 1. Tighten 2 bolts which are positioned 180 degrees apart each other on the lower frame side with 147 N-m (108 lbs-ft) torque. 2. Tighten 2 bolts which are positioned 90 degrees apart from the previously tightened bolts.
  • Page 260 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 10000A-1 8-16 Published 10-09-13, Control #218-02...
  • Page 261 9. PROPEL SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 262 9. PROPEL SYSTEM 10000A-1 Published 10-09-13, Control #218-02...
  • Page 263 9. PROPEL SYSTEM APPARATUS AND LOCATION OF COMPONENTS The Propel system consists of the main pump, the main control valves, the propel motors, the propel reduction units, the upper/lower rollers, the drive tumblers, idlers and shoes. Pressurized oil from the main pumps (No.1 and No.2 pumps installed on the power divider) is controlled through the 2 main control valves.
  • Page 264 9. PROPEL SYSTEM PROPEL REDUCTION UNIT PF1/2 (D) 2-PF1 (VA, VB) PF1/4 (P) Tightening torque : 500 to 618 N-m Apply LOCTITE #242 Tightening torque : 1,010 to 1,250 N-m Apply LOCTITE #242 Crawler Frame Assembly Weight : Approx. 510 kg 10000A-1 Published 10-09-13, Control #218-02...
  • Page 265 9. PROPEL SYSTEM This page is blank for editing convenience. 10000A-1 Published 10-09-13, Control #218-02...
  • Page 266 9. PROPEL SYSTEM 9.2.1 MOTOR AND REDUCTION UNIT 2-M6 restrictor Apply LOCTITE #242 12 14 13 15 16 18 21 19 29 24 28 23 27 26 71 58 57 60 66 48 51 41 42 44 75 61 keep centerline parallel to ground surface in transportation...
  • Page 267 9. PROPEL SYSTEM 88 77, 84 80 77, 81 Without removing rust-preventive agent. Assembling piston of carrier pin relating to valve port (VA, VB) to be as shown. Without removing rust-preventive agent. VIEW A-A 10000A-1 Published 10-09-13, Control #218-02...
  • Page 268 9. PROPEL SYSTEM 1. Cover 33. Capscrew 65. Spring of brake 2. Carrier 34. Capscrew 66. Bearing 3. Carrier pin 35. Capscrew 67. Bearing 4. Bearing 36. Capscrew 68. Hex. socket head bolt 5. Thrust washer 37. Capscrew 69. Shim 6.
  • Page 269 9. PROPEL SYSTEM TIGHTENING TORQUE TABLE Tightening Item Name Size Remarks Torque (N-m) Capscrew M10 X 30 61.74 to 75.46 Apply LOCTITE #242 Capscrew M12 X 30 106.2 to 129.8 Apply LOCTITE #242 Capscrew M16 X 45 264.6 to 323.4 Apply LOCTITE #242 Capscrew R (PT) 3/4...
  • Page 270 9. PROPEL SYSTEM ADJUSTMENT If the crawler shoes are too tight, the shoes wear quickly and a connection between two shoes could break. On the other hand, if the shoes are too loose, the shoes may ride off the drive sprocket and idler wheel during the travel operation.
  • Page 271 9. PROPEL SYSTEM 9.4 CONSTRUCTION AND FUNCTION 9.4.1 HYDRAULIC SCHEMATIC 9-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 272 9. PROPEL SYSTEM 9.4.2 PROPELLING (RIGHT SIDE FORWARD) Propelling the right and/or left sides and to the forward and reverse are basically the same op- eration. We will use a right side forward operation as the example here. Pressurised oil from the No.1 pump is directed into the control valve.
  • Page 273 9. PROPEL SYSTEM PROPEL (R.H. FORWARD) 9-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 274 9. PROPEL SYSTEM 9.4.3 STOPPING When the right propel control lever is shifted back to neutral from propel position, the flow from the remote control valve is cut and the spool of the control valve repositions itself. At the same time, the pilot pressure on the propel brake valve is discontinued, and the spool in the brake valve also repositions itself.
  • Page 275 9. PROPEL SYSTEM PROPEL STOPPING 9-15 10000A-1 Published 10-09-13, Control #218-02...
  • Page 276 9. PROPEL SYSTEM This page is blank for editing convenience. 10000A-1 9-16 Published 10-09-13, Control #218-02...
  • Page 277 10. ELECTRIC SYSTEM 10-1 10000A-1 Published 10-09-13, Control #218-02...
  • Page 278 10. ELECTRIC SYSTEM Before unplugging or plugging in the connector, be sure to shut off the power supply (set the starter switch to the OFF position). When unplugging the connector, hold it with both hands and draw it straight, while pressing down the catch. DO NOT pull on the cable.
  • Page 279 10. ELECTRIC SYSTEM 10.1 ELECTRICAL 10.1.1 ELECTRICAL WIRING SCHEMATIC (1/18) 10-3 10000A-1 Published 10-09-13, Control #218-02...
  • Page 280 10. ELECTRIC SYSTEM (2/18) 10000A-1 10-4 Published 10-09-13, Control #218-02...
  • Page 281 10. ELECTRIC SYSTEM (3/18) 10-5 10000A-1 Published 10-09-13, Control #218-02...
  • Page 282 10. ELECTRIC SYSTEM (4/18) 10000A-1 10-6 Published 10-09-13, Control #218-02...
  • Page 283 10. ELECTRIC SYSTEM (5/18) 10-7 10000A-1 Published 10-09-13, Control #218-02...
  • Page 284 10. ELECTRIC SYSTEM (6/18) 10000A-1 10-8 Published 10-09-13, Control #218-02...
  • Page 285 10. ELECTRIC SYSTEM (7/18) 10-9 10000A-1 Published 10-09-13, Control #218-02...
  • Page 286 10. ELECTRIC SYSTEM (8/18) 10000A-1 10-10 Published 10-09-13, Control #218-02...
  • Page 287 10. ELECTRIC SYSTEM (9/18) 10-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 288 10. ELECTRIC SYSTEM (10/18) 10000A-1 10-12 Published 10-09-13, Control #218-02...
  • Page 289 10. ELECTRIC SYSTEM (11/18) 10-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 290 10. ELECTRIC SYSTEM (12/18) 10000A-1 10-14 Published 10-09-13, Control #218-02...
  • Page 291 10. ELECTRIC SYSTEM (13/18) 10-15 10000A-1 Published 10-09-13, Control #218-02...
  • Page 292 10. ELECTRIC SYSTEM (14/18) 10000A-1 10-16 Published 10-09-13, Control #218-02...
  • Page 293 10. ELECTRIC SYSTEM (15/18) 10-17 10000A-1 Published 10-09-13, Control #218-02...
  • Page 294 10. ELECTRIC SYSTEM (16/18) 10000A-1 10-18 Published 10-09-13, Control #218-02...
  • Page 295 10. ELECTRIC SYSTEM (17/18) 10-19 10000A-1 Published 10-09-13, Control #218-02...
  • Page 296 10. ELECTRIC SYSTEM (18/18) 10000A-1 10-20 Published 10-09-13, Control #218-02...
  • Page 297 10. ELECTRIC SYSTEM 10.1.2 CONNECTOR LAYOUT Wire color / Parts No. list Basic single color HARNESS NAME Color Name Color Sign Basic single color Base Color FLOOR PLATE B Black White W FLOOR A R FLOOR B Green G Y Yellow OUT INDICATING LIGHT RELAY JUNCTION HARNESS B...
  • Page 298 10. ELECTRIC SYSTEM HARNESS NAME HYDRAULIC OIL HEAT HYDRAULIC OIL HEAT BOOM BASE (INSERT INCLUDED) BOOM BASE (INSERT INCLUDED) BOOM TIP BLANK FIXED JIB FIXED JIB CAMERA CONTROLLER CAMERA CONTROLLER CAMERA CONTROLLER IT CONTROLLER INSTALLATION 10000A-1 10-22 Published 10-09-13, Control #218-02...
  • Page 299 10. ELECTRIC SYSTEM 1.ELECTRICAL PART OF FLOOR PLATE SOL : SOLENOID VALVE CN-401AF CN-452 SW : SWITCH INCHING SPEED SELECT SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT CN-453 C/W : COUNTER WEIGHT REAR DRUM G-WINCH SELECT CB/W : CARBODY WEIGHT CN-401M SWITCH CN-454 FRONT DRUM G-WINCH SELECT SWITCH CN-455 REAR DRUM FREE-FALL SELECT SWITCH...
  • Page 300 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-436 CN-218 OVERHOIST GANTRY CONTROL SWITCH RELEASE SWITCH CN-437 VIEW FROM “C” BOOM OVERHOIST RELEASE SWITCH CN-216 CN-438 CRAWLER EXT.
  • Page 301 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT REAR DRUM TURN DETECTION GRIP REAR DRUM FREE-FALL FRONT DRUM TURN SELECT SWITCH DRUM INCHING SPEED REAR DRUM DETECTION GRIP SELECT SWITCH...
  • Page 302 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CA-B10 CN-484 CN-483 SPOT LIGHT CA-B12 A/C CONTROL PANEL RELAY BOX CN-511M LA-B19 CN-477 LOAD SAFETY DEVICE HARNESS CN-511AF FUSE BOX...
  • Page 303 10. ELECTRIC SYSTEM OUT INDICATING LIGHT RELAY JUNCTION HARNESS (1/2) 10-27 10000A-1 Published 10-09-13, Control #218-02...
  • Page 304 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-28 Published 10-09-13, Control #218-02...
  • Page 305 10. ELECTRIC SYSTEM FLOOR HARNESS A  (1/5) 10-29 10000A-1 Published 10-09-13, Control #218-02...
  • Page 306 10. ELECTRIC SYSTEM (2/5) 10000A-1 10-30 Published 10-09-13, Control #218-02...
  • Page 307 10. ELECTRIC SYSTEM (3/5) 10-31 10000A-1 Published 10-09-13, Control #218-02...
  • Page 308 10. ELECTRIC SYSTEM  (4/5) 10000A-1 10-32 Published 10-09-13, Control #218-02...
  • Page 309 10. ELECTRIC SYSTEM (5/5) 10-33 10000A-1 Published 10-09-13, Control #218-02...
  • Page 310 10. ELECTRIC SYSTEM FLOOR HARNESS B (1/5) 10000A-1 10-34 Published 10-09-13, Control #218-02...
  • Page 311 10. ELECTRIC SYSTEM (2/5) 10-35 10000A-1 Published 10-09-13, Control #218-02...
  • Page 312 10. ELECTRIC SYSTEM (3/5) 10000A-1 10-36 Published 10-09-13, Control #218-02...
  • Page 313 10. ELECTRIC SYSTEM (4/5) 10-37 10000A-1 Published 10-09-13, Control #218-02...
  • Page 314 10. ELECTRIC SYSTEM (5/5) 10000A-1 10-38 Published 10-09-13, Control #218-02...
  • Page 315 10. ELECTRIC SYSTEM 2.ELECTRICAL PART OF LOWER CN-910F SOL : SOLENOID VALVE CONNECT TO SW : SWITCH INCLINATION SENSOR (OPTION) PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT MACHINE FRONT SLIP LING CABLE CN-905M CN-917 CN-906M...
  • Page 316 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT SECTION “D-D” SECTION “E-E” CN-910F INCLINATION SENSOR DETAIL OF SENSOR INSTALL (2/2) 10000A-1 10-40 Published 10-09-13, Control #218-02...
  • Page 317 10. ELECTRIC SYSTEM LOWER HARNESS (1/4) 10-41 10000A-1 Published 10-09-13, Control #218-02...
  • Page 318 10. ELECTRIC SYSTEM (2/4) 10000A-1 10-42 Published 10-09-13, Control #218-02...
  • Page 319 10. ELECTRIC SYSTEM (3/4) 10-43 10000A-1 Published 10-09-13, Control #218-02...
  • Page 320 10. ELECTRIC SYSTEM (4/4) 10000A-1 10-44 Published 10-09-13, Control #218-02...
  • Page 321 10. ELECTRIC SYSTEM TRANS LIFTER REMOTE CONTROLLER CABLE HARNESS (OPTION) (1/3) 10-45 10000A-1 Published 10-09-13, Control #218-02...
  • Page 322 10. ELECTRIC SYSTEM (2/3) 10000A-1 10-46 Published 10-09-13, Control #218-02...
  • Page 323 10. ELECTRIC SYSTEM (3/3) 10-47 10000A-1 Published 10-09-13, Control #218-02...
  • Page 324 10. ELECTRIC SYSTEM 3. ELECTRICAL PART OF LEFT DECK SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT FRONT DRUM INDEPENDENT. CONFLUENCE SELECT (SOL-101) CN-836F REAR DRUM INDEPENDENT.
  • Page 325 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-816F CN-39F CN-40F CN-41F CN-119F CN-111F CN-118F CN-112F CN-115F CN-113F CN-117F CN-116F CN-114F LEFT DECK INSIDE VIEW FROM “C”...
  • Page 326 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT TO LEFT GUARD FUEL PUMP FRONT DRUM TILT SENSOR (PT-20) CN-802F FRONT DRUM TILT SENSOR (PT-20) CN-802F FRONT DRUM TILT PROP.
  • Page 327 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT OIL COOLER MOTOR OIL COOLER MOTOR CN-871 CN-848 CONNECT TO RELAY UNIT HARNESS CN-851 CN-852 CONNECT TO REAR WORK LIGHT HARNESS CN-844F CONNECT TO DRUM LIGHT HARNESS...
  • Page 328 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-804F, 835, 841 REAR DRUM MOTOR BOOST (SOL-16) CN-840F REAR DRUM TILT SENSOR (SOL-14) CN-803F REAR DRUM TILT PROP.
  • Page 329 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-868F CN-854F CN-855F THIRD MOTOR TILT PROP. VALVE (SOL-67) CN-835F OIL COOLER MOTOR RELAY (RL-3) CN-818F THIRD TILT SENSOR (PT-15) CUT OUT RELAY (R-C)
  • Page 330 10. ELECTRIC SYSTEM LEFT DECK HARNESS (1/5) 10000A-1 10-54 Published 10-09-13, Control #218-02...
  • Page 331 10. ELECTRIC SYSTEM (2/5) 10-55 10000A-1 Published 10-09-13, Control #218-02...
  • Page 332 10. ELECTRIC SYSTEM (3/5) 10000A-1 10-56 Published 10-09-13, Control #218-02...
  • Page 333 10. ELECTRIC SYSTEM (4/5) 10-57 10000A-1 Published 10-09-13, Control #218-02...
  • Page 334 10. ELECTRIC SYSTEM (5/5) 10000A-1 10-58 Published 10-09-13, Control #218-02...
  • Page 335 10. ELECTRIC SYSTEM RELAY HARNESS (1/3) 10-59 10000A-1 Published 10-09-13, Control #218-02...
  • Page 336 10. ELECTRIC SYSTEM (2/3) 10000A-1 10-60 Published 10-09-13, Control #218-02...
  • Page 337 10. ELECTRIC SYSTEM (3/3) 10-61 10000A-1 Published 10-09-13, Control #218-02...
  • Page 338 10. ELECTRIC SYSTEM 4. ELECTRICAL PART OF RIGHT DECK SOL : SOLENOID VALVE CN-404 SWING FRAME CN-473 SW : SWITCH HARNESS CN-403 PSW : PRESSURE SWITCH CN-471 CN-401 LEFT DACK ATT. : ATTACHMENT CN-472 CN-402 HARNESS C/W : COUNTER WEIGHT ATT.
  • Page 339 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CN-626 HYD. OIL CB/W : CARBODY WEIGHT THIRD DRUM CLUTCH PRESS. SENSOR HEAT SYSTEM (OPTION) CN-604 CN-603 THIRD CLUTCH SOL Re DRUM CLUTCH PRESS.
  • Page 340 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-626 CN-626 3rd. CLUTCH SOL 3rd. CLUTCH SOL CONNECT TO HYD. HEAT SYSTEM HARNESS (OPTION) SECTION “G-G”...
  • Page 341 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE CN-611 SW : SWITCH SWING CONSTANT PSW : PRESSURE SWITCH LOW SPEED SOL ATT. : ATTACHMENT CN-623 CN-611 C/W : COUNTER WEIGHT BOOM PUMP SWING CONSTANT CB/W : CARBODY WEIGHT INCHING SPEED SOL LOW SPEED SOL CN-612 BOOM PUMP...
  • Page 342 10. ELECTRIC SYSTEM RIGHT DECK HARNESS (1/4) 10000A-1 10-66 Published 10-09-13, Control #218-02...
  • Page 343 10. ELECTRIC SYSTEM (2/4) 10-67 10000A-1 Published 10-09-13, Control #218-02...
  • Page 344 10. ELECTRIC SYSTEM (3/4) 10000A-1 10-68 Published 10-09-13, Control #218-02...
  • Page 345 10. ELECTRIC SYSTEM (4/4) 10-69 10000A-1 Published 10-09-13, Control #218-02...
  • Page 346 10. ELECTRIC SYSTEM POWER SUPPLY HARNESS (1/3) 10000A-1 10-70 Published 10-09-13, Control #218-02...
  • Page 347 10. ELECTRIC SYSTEM (2/3) 10-71 10000A-1 Published 10-09-13, Control #218-02...
  • Page 348 10. ELECTRIC SYSTEM (3/3) 10000A-1 10-72 Published 10-09-13, Control #218-02...
  • Page 349 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL B) TO BATTERY RELAY HARNESS 10-73 10000A-1 Published 10-09-13, Control #218-02...
  • Page 350 10. ELECTRIC SYSTEM STARTER HARNESS (TERMINAL C) TO SAFETY RELAY HARNESS 10000A-1 10-74 Published 10-09-13, Control #218-02...
  • Page 351 10. ELECTRIC SYSTEM GLOW RELAY HARNESS TO ENGINE SUB HARNESS 10-75 10000A-1 Published 10-09-13, Control #218-02...
  • Page 352 10. ELECTRIC SYSTEM 5. ELECTRICAL PART OF RIGHT DECK (GUARD) SOL : SOLENOID VALVE SW : SWITCH CN-632F PSW : PRESSURE SWITCH AIR FLOW METER ATT. : ATTACHMENT INTAKE AIR TEMP. SENSOR C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-632M CN-630F CN-630F...
  • Page 353 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH CN-641M CN-640M PSW : PRESSURE SWITCH FOR DPR INLET TEMP. SENSOR FOR DPR EXIT TEMP. SENSOR ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-642F FOR DPR PRESS. DIFF SENSOR CN-842 CONNECT TO...
  • Page 354 10. ELECTRIC SYSTEM GUARD HARNESS A (1/3) 10000A-1 10-78 Published 10-09-13, Control #218-02...
  • Page 355 10. ELECTRIC SYSTEM (2/3) 10-79 10000A-1 Published 10-09-13, Control #218-02...
  • Page 356 10. ELECTRIC SYSTEM (3/3) 10000A-1 10-80 Published 10-09-13, Control #218-02...
  • Page 357 10. ELECTRIC SYSTEM GUARD HARNESS B (1/3) 10-81 10000A-1 Published 10-09-13, Control #218-02...
  • Page 358 10. ELECTRIC SYSTEM (2/3) 10000A-1 10-82 Published 10-09-13, Control #218-02...
  • Page 359 10. ELECTRIC SYSTEM (3/3) 10-83 10000A-1 Published 10-09-13, Control #218-02...
  • Page 360 10. ELECTRIC SYSTEM GUARD HARNESS C (1/2) 10000A-1 10-84 Published 10-09-13, Control #218-02...
  • Page 361 10. ELECTRIC SYSTEM (2/2) 10-85 10000A-1 Published 10-09-13, Control #218-02...
  • Page 362 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) 10000A-1 10-86 Published 10-09-13, Control #218-02...
  • Page 363 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 10000A-1 Published 10-09-13, Control #218-02...
  • Page 364 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10000A-1 10-88 Published 10-09-13, Control #218-02...
  • Page 365 10. ELECTRIC SYSTEM SWING FRAME HARNESS (1/4) 10-89 10000A-1 Published 10-09-13, Control #218-02...
  • Page 366 10. ELECTRIC SYSTEM (2/4) 10000A-1 10-90 Published 10-09-13, Control #218-02...
  • Page 367 10. ELECTRIC SYSTEM (3/4) 10-91 10000A-1 Published 10-09-13, Control #218-02...
  • Page 368 10. ELECTRIC SYSTEM (4/4) 10000A-1 10-92 Published 10-09-13, Control #218-02...
  • Page 369 10. ELECTRIC SYSTEM ATT. JUNCTION HARNESS (1/3) 10-93 10000A-1 Published 10-09-13, Control #218-02...
  • Page 370 10. ELECTRIC SYSTEM (2/3) 10000A-1 10-94 Published 10-09-13, Control #218-02...
  • Page 371 10. ELECTRIC SYSTEM (3/3) 10-95 10000A-1 Published 10-09-13, Control #218-02...
  • Page 372 10. ELECTRIC SYSTEM 7. ELECTRICAL PART OF CAB SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT SKYLIGHT WIPER CB/W : CARBODY WEIGHT INTERMITTENT UNIT CN-233 FRONT WINDOW FRONT WINDOW WIPER INTERMITTENT WIPER INTERMITTENT UNIT UNIT...
  • Page 373 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-240 OVER HOIST OVER LOAD BUZZER CN-226 RADIO (OPTION) CN-234 MULTI VOICE ALARM (OPTION) CN-240 OVER HOIST OVER LOAD BUZZER CN-227 SPEAKER (LEFT)
  • Page 374 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CN-435 CB/W : CARBODY WEIGHT CN205 THIRD DRUM FREE FALL ACCELERATION SW (OPTION) REAR WORK LIGHT SW CN201 CN203 (OPTION) WASHER SW WIPER SW...
  • Page 375 10. ELECTRIC SYSTEM CAB HARNESS (1/6) 10-99 10000A-1 Published 10-09-13, Control #218-02...
  • Page 376 10. ELECTRIC SYSTEM (2/6) 10000A-1 10-100 Published 10-09-13, Control #218-02...
  • Page 377 10. ELECTRIC SYSTEM (3/6) 10-101 10000A-1 Published 10-09-13, Control #218-02...
  • Page 378 10. ELECTRIC SYSTEM (4/6) 10000A-1 10-102 Published 10-09-13, Control #218-02...
  • Page 379 10. ELECTRIC SYSTEM (5/6) 10-103 10000A-1 Published 10-09-13, Control #218-02...
  • Page 380 10. ELECTRIC SYSTEM (6/6) 10000A-1 10-104 Published 10-09-13, Control #218-02...
  • Page 381 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 10000A-1 Published 10-09-13, Control #218-02...
  • Page 382 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TO ENGINE GROUND HARNESS   10000A-1 10-106 Published 10-09-13, Control #218-02...
  • Page 383 10. ELECTRIC SYSTEM STARTER MOTOR HARNESS TARMINAL B ALTERNATOR HARNESS TARMINAL B 10-107 10000A-1 Published 10-09-13, Control #218-02...
  • Page 384 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 10000A-1 10-108 Published 10-09-13, Control #218-02...
  • Page 385 10. ELECTRIC SYSTEM MONITOR HARNESS (1/2) 10-109 10000A-1 Published 10-09-13, Control #218-02...
  • Page 386 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-110 Published 10-09-13, Control #218-02...
  • Page 387 10. ELECTRIC SYSTEM 10. ELECTRICAL PART OF COUNTER WEIGHT SELF REMOVAL (OPTION) SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT REMOTE CONTROL CONNECT (UPPER) CN-550F CN-413M CONNECT TO RIGHT DECK HARNESS CN-412M...
  • Page 388 10. ELECTRIC SYSTEM COUNTER WEIGHT SELF REMOVAL HARNESS (1/3) 10000A-1 10-112 Published 10-09-13, Control #218-02...
  • Page 389 10. ELECTRIC SYSTEM (2/3) 10-113 10000A-1 Published 10-09-13, Control #218-02...
  • Page 390 10. ELECTRIC SYSTEM (3/3) 10000A-1 10-114 Published 10-09-13, Control #218-02...
  • Page 391 10. ELECTRIC SYSTEM 11. OVER LOAD PREVENT (M. MACHINERY) (1/2) 10-115 10000A-1 Published 10-09-13, Control #218-02...
  • Page 392 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-116 Published 10-09-13, Control #218-02...
  • Page 393 10. ELECTRIC SYSTEM 12. ELECTRICAL PART OF TRANS LIFTER (OPTION) SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 10-117 10000A-1 Published 10-09-13, Control #218-02...
  • Page 394 10. ELECTRIC SYSTEM 14. ELECTRICAL PART OF HYDRAULIC OIL HEAT SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT CN-625 HYD. OIL HEAT (SOL-47) CN-634 HYD. OIL HEAT (SOL-47) RIGHT DECK HARNESS CN-634 CN-627...
  • Page 395 10. ELECTRIC SYSTEM HYDRAULIC OIL HEAT HARNESS (1/2) 10-119 10000A-1 Published 10-09-13, Control #218-02...
  • Page 396 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-120 Published 10-09-13, Control #218-02...
  • Page 397 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 8500-1, 10000A-1 (1/9) 10-121 10000A-1 Published 10-09-13, Control #218-02...
  • Page 398 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT 8500-1, 10000A-1 C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/9) 10000A-1 10-122 Published 10-09-13, Control #218-02...
  • Page 399 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT 8500E-1, 10000E-1 (3/9) 10-123 10000A-1 Published 10-09-13, Control #218-02...
  • Page 400 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH 8500E-1, 10000E-1 PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (4/9) 10000A-1 10-124 Published 10-09-13, Control #218-02...
  • Page 401 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (5/9) 10-125 10000A-1 Published 10-09-13, Control #218-02...
  • Page 402 10. ELECTRIC SYSTEM (6/9) 10000A-1 10-126 Published 10-09-13, Control #218-02...
  • Page 403 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (7/9) 10-127 10000A-1 Published 10-09-13, Control #218-02...
  • Page 404 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT 8500E-1, 10000E-1 C/W : COUNTER WEIGHT 8500-1, 10000A-1 CB/W : CARBODY WEIGHT (8/9) 10000A-1 10-128 Published 10-09-13, Control #218-02...
  • Page 405 10. ELECTRIC SYSTEM (9/9) 10-129 10000A-1 Published 10-09-13, Control #218-02...
  • Page 406 10. ELECTRIC SYSTEM BOOM BASE HARNESS (INSERT INCLUDED) (1/2) 10000A-1 10-130 Published 10-09-13, Control #218-02...
  • Page 407 10. ELECTRIC SYSTEM (2/2) 10-131 10000A-1 Published 10-09-13, Control #218-02...
  • Page 408 10. ELECTRIC SYSTEM CABLE (1/2) 10000A-1 10-132 Published 10-09-13, Control #218-02...
  • Page 409 10. ELECTRIC SYSTEM (2/2) 10-133 10000A-1 Published 10-09-13, Control #218-02...
  • Page 410 10. ELECTRIC SYSTEM 16. BOOM TIP HARNESS (1/2) 10000A-1 10-134 Published 10-09-13, Control #218-02...
  • Page 411 10. ELECTRIC SYSTEM (2/2) 10-135 10000A-1 Published 10-09-13, Control #218-02...
  • Page 412 10. ELECTRIC SYSTEM CABLE (1/2) 10000A-1 10-136 Published 10-09-13, Control #218-02...
  • Page 413 10. ELECTRIC SYSTEM (2/2) 10-137 10000A-1 Published 10-09-13, Control #218-02...
  • Page 414 10. ELECTRIC SYSTEM CABLE (1/2) 10000A-1 10-138 Published 10-09-13, Control #218-02...
  • Page 415 10. ELECTRIC SYSTEM (2/2) 10-139 10000A-1 Published 10-09-13, Control #218-02...
  • Page 416 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 10000A-1 10-140 Published 10-09-13, Control #218-02...
  • Page 417 10. ELECTRIC SYSTEM FIXED JIB HARNESS (1/2) 10-141 10000A-1 Published 10-09-13, Control #218-02...
  • Page 418 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-142 Published 10-09-13, Control #218-02...
  • Page 419 10. ELECTRIC SYSTEM CABLE (1/2) 10-143 10000A-1 Published 10-09-13, Control #218-02...
  • Page 420 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-144 Published 10-09-13, Control #218-02...
  • Page 421 10. ELECTRIC SYSTEM CABLE (1/2) 10-145 10000A-1 Published 10-09-13, Control #218-02...
  • Page 422 10. ELECTRIC SYSTEM (2/2) 10000A-1 10-146 Published 10-09-13, Control #218-02...
  • Page 423 10. ELECTRIC SYSTEM 19. ELECTRICAL PART OF CAMERA CONTROLLER SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (1/3) 10-147 10000A-1 Published 10-09-13, Control #218-02...
  • Page 424 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (2/3) 10000A-1 10-148 Published 10-09-13, Control #218-02...
  • Page 425 10. ELECTRIC SYSTEM SOL : SOLENOID VALVE SW : SWITCH PSW : PRESSURE SWITCH ATT. : ATTACHMENT C/W : COUNTER WEIGHT CB/W : CARBODY WEIGHT (3/3) 10-149 10000A-1 Published 10-09-13, Control #218-02...
  • Page 426 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10000A-1 10-150 Published 10-09-13, Control #218-02...
  • Page 427 10. ELECTRIC SYSTEM (2/2) 10-151 10000A-1 Published 10-09-13, Control #218-02...
  • Page 428 10. ELECTRIC SYSTEM CAMERA CONTROLLER HARNESS (1/2) 10000A-1 10-152 Published 10-09-13, Control #218-02...
  • Page 429 10. ELECTRIC SYSTEM (2/2) 10-153 10000A-1 Published 10-09-13, Control #218-02...
  • Page 430 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 10000A-1 10-154 Published 10-09-13, Control #218-02...
  • Page 431 10. ELECTRIC SYSTEM 10.1.3 LOCATION AND USE OF FUSE Fuse box and use Fuse box Replace plate fuse with the attached part of fuse box Distribution panel Label Fuse box Part no. label position 10-155 10000A-1 Published 10-09-13, Control #218-02...
  • Page 432 10. ELECTRIC SYSTEM Classification of Fuse Use Fuse No. Capacity Type Line No. Location – Main power – AIS air-con battery voltage – – ML, MC1.MC2 radio backup – Bypass switch – Release switch – For ML control Automotive Fuse box –...
  • Page 433 10. ELECTRIC SYSTEM Classification of Fuse Use Fuse No. Capacity Type Line No. Location – Generating detect – PCV1 – PCV2 – ECU (+BF) – ECU (J08E : + B) – ECU (P11C : + B) – Dc motor for oil cooler ① Automotive Fuse box –...
  • Page 434 10. ELECTRIC SYSTEM Ensure to turn starter switch OFF when replacing fuse. Replace the fuse with the same capacity. If fuse blows off right after replaced, there is some abnormality in the electric circuit. Find out a cause and take necessary action. 10000A-1 10-158 Published 10-09-13, Control #218-02...
  • Page 435 10. ELECTRIC SYSTEM 10-159 10000A-1 Published 10-09-13, Control #218-02...
  • Page 436 10. ELECTRIC SYSTEM 10000A-1 10-160 Published 10-09-13, Control #218-02...
  • Page 437 10. ELECTRIC SYSTEM 10.1.4 WIPER CONTROL RELAY Wiper intermediate relay Wiper intermediate relay Wiper switch Stop Intermited Continuous Wiper switch 10-161 10000A-1 Published 10-09-13, Control #218-02...
  • Page 438 10. ELECTRIC SYSTEM 10.1.5 PRESSURE SWITCH (FOR PROPEL MOTION DETECT) 1 : POWER (+) 2 : EARTH (-) Load N.O. 24 V Pressure Pressure source 19 × 26 HEX. 539 ± 49 KPa : ON Tightening torque 14.7 ± 2.9 N-m 343 ±...
  • Page 439 10. ELECTRIC SYSTEM 10.1.6 PRESSURE SWITCH (FOOT BRAKE) COMMON POWER(+) OPEN COLLECTOR(+) 4.5 MPa (653 psi) : ON 3.7 MPa (537 psi) : OFF O-ring P14 PF3/8 (Tightening torque : 29.4 N-m) [ON] Pressure (MPa) [OFF] Pressure (MPa) Propel motion detect pressure 10-163 10000A-1 Published 10-09-13, Control #218-02...
  • Page 440 10. ELECTRIC SYSTEM 10.1.7 PRESSURE SENSOR (LS52S00015P1 • LC52S00019P1) Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 27 × 27.8 HEX PF 3/8 0.5 to 4.5 V CIRCUIT 10000A-1 10-164 Published 10-09-13, Control #218-02...
  • Page 441 10. ELECTRIC SYSTEM Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 19 × 20 HEX PF 1/4 0.5 to 4.5 V 10-165 10000A-1 Published 10-09-13, Control #218-02...
  • Page 442 10. ELECTRIC SYSTEM Pressure raqnge Part number Power (V) Out-put (V) MPa (Psi) Main pump power control shift control pressure Swing motion detect pressure (R L) 0 to 3 CHP start pressure 9999430134 0.5 to 4.5 (0 to 435) Remote control pressure (Front Rear 3rd Swing Boom) Motor control pressure (Front Rear 3rd)
  • Page 443 10. ELECTRIC SYSTEM GN52S00002P1 Location of connector terminal No. 1. COMMON 2. OUT - PUT (+) 3. POWER (+) 0.5 to 4.5 V 22×23 HEX. O-RING P14 PF3/8A Pressure raqnge Part number Power (V) Out-put (V) MPa (psi) Clutch pressure (Front • Rear • 3rd) 0 to 19.6 9999426022 0.5 to 4.5...
  • Page 444 10. ELECTRIC SYSTEM 10.1.8 INCLINATION SENSOR 9999431869 Type N4AA20010 Resolution 0.04° Specification Linear error 1%typ. of angle range Recurrence Angle range ±5° ±0.2°typ. accuracy Power source 10 to 30VDC Temperature drift 1.3% typ. Power typ.22mA Protection class IP 67 consumption Output X-axis 0.5 to 4.5V Temperature...
  • Page 445 10. ELECTRIC SYSTEM 10.1.9 BUZZER UNIT 9999431928 10-169 10000A-1 Published 10-09-13, Control #218-02...
  • Page 446 10. ELECTRIC SYSTEM Buzzer to be used High-pitched tone FDK corp. EB2210A-38C-12V Bass Star precession Low-pitched tone TMX-12F corp. Rated Volt Work range (Volt) 19 to 32V Working temperature range -10 to 60 Storage temperature range -20 to 70 Humidity 0 to 90% Sound volume 75db/30cm MIN...
  • Page 447 10. ELECTRIC SYSTEM 10.1.10 RELAY BOX 1. ARRANGEMENT OF CONNECTOR 10-171 10000A-1 Published 10-09-13, Control #218-02...
  • Page 448 10. ELECTRIC SYSTEM 10000A-1 10-172 Published 10-09-13, Control #218-02...
  • Page 449 10. ELECTRIC SYSTEM Name Name Generation detect RL-1 DPR Regeneration RL-37 Safety RL-2 RL-38 Swing flasher (L) Separate oil cooler motor Swing flasher (R ) RL-3 RL-39 RL-4 Pump Qmax cut RL-40 Starter lock RL-5 RL-41 Certify release RL-6 RL-42 Engine stop RL-7 RL-43...
  • Page 450 10. ELECTRIC SYSTEM 2. RELAY BOX SCHEMATIC F-12 F-21 ALTERNATOR F-12 (L TERMINAL) BATTERY RELAY IGNITION SW AIR-CON CUT RELAY (RL-81) F-21 MC1(D/O) SAFETY RELAY (RL-02) MC1(D/I) M/L (D/O) REMO-CON ENGINE EMERGENCY ST (SW-71) IGNITION SW AIS AIR-CON CUT RELAY (RL-04, 81) MC1(D/O) MC1(D/I)
  • Page 451 10. ELECTRIC SYSTEM FANCTION LOCK MC1(D/O) LSW-1 FANCTION LOCK SOL-3 MC2(D/I) MC1(D/O) F-15 FRONT ROTAT GRIP MC1(D/O) PSOL-40 REAR ROTAT GRIP MC1(D/O) PSOL-41 F-02 MC1(A/I) MC1(A/I) CAMERA 10-175 10000A-1 Published 10-09-13, Control #218-02...
  • Page 452 10. ELECTRIC SYSTEM SWING HI/LO F-36 SPEED SELECT SOL-42 SWING NEUTRAL SELECT SOL-48, 49 MC1(D/O) PROPEL ALARM PROPEL VOICE BUZZER SW-26 PROPEL CONTROL PSW-7,10 PROPEL SWING VOICE ALARM HYD. SOURCE HYD. SOURCE SELECT SELECT SW-65 SOL-45 REMO-CON TRANSLIFTER SELECT SOL-44 REMO-CON HYD.
  • Page 453 10. ELECTRIC SYSTEM RIGHT SWING F-05 STOP PSOL-109 MC1(PSOL) MC1 (PSOL) PSOL-109 LEFT SWING STOP MC1(PSOL) PSOL-110 MC1 (PSOL) PSOL-110 MAIN PUMP 1 MC1(PSOL) PSOL-1 PSOL-1 MAIN PUMP 2 PSOL-2 MC1(PSOL) PSOL-6 MC1(PSOL) BOOM PUMP PSOL-2 MC1(PSOL) PSOL-2 MC1(PSOL) MC1(D/O) ML BYPASS SW SW-37 ML BYPASS SW...
  • Page 454 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 10000A-1 10-178 Published 10-09-13, Control #218-02...
  • Page 455 10. ELECTRIC SYSTEM F-29 MC1 (D/O) OVERLOAD ALARM LAMP (GREEN) M/L (D/O) OVERLOAD ALARM LAMP (YELLOW) M/L (D/O) OVERLOAD ALARM LAMP (YELLOW) M/L (D/O) Fr.DRUM FREE-FALL F-38 SELECT SW-53 Fr.DRUM FOOT BRAKE PRESS. PSW-1 Re.DRUM FREE-FALL SELECT SW-54 Re.DRUM FOOT BRAKE PRESS.
  • Page 456 10. ELECTRIC SYSTEM F-36 MC1(D/O) SWING FLASHER (L) MC1(D/O) SWING FLASHER (L) MC1(D/O) Q-max CUT SOL-104 MC1(D/O) Fr.DRUM CLUTCH CLM SOL-22 MC1(D/O) Fr.DRUM CLUTCH ESM SOL-19 MC1(D/O) Re.DRUM CLUTCH CLA F-37 SOL-23 MC1(D/O) Re.DRUM CLUTCH ESA SOL-20 MC1(D/O) 3rd.DRUM CLUTCH CLT F-37 SOL-24 MC1(D/O)
  • Page 457 10. ELECTRIC SYSTEM AUTO STOP SW BOOM LOWER STOP SW-35 SOL-36 Fr. Re. 3rd. DRUM HOIST STOP SOL-37, 38, 18 BOOM HOIST STOP SOL-35 BOOM OVERHOIST LSW-7 F-34 BOOM B/S No.2 LSW-12 BOOM B/S No.1 LSW-9 M/L (D/O) M/L (D/O) M/L (D/O) CONFIGURATION SELECT...
  • Page 458 10. ELECTRIC SYSTEM 10.1.11 RELAY BOX 10000A-1 10-182 Published 10-09-13, Control #218-02...
  • Page 459 10. ELECTRIC SYSTEM Name Boom hoist raise stop relay RL-60 Boom hoist lower stop relay RL-61 Front raise stop relay RL-62 Front lower stop relay RL-63 Rear raise stop relay RL-64 Rear lower stop relay RL-65 Third raise stop relay RL-66 Third lower stop relay RL-67...
  • Page 460 10. ELECTRIC SYSTEM BYPASS SW SW-39 F-05 M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) M/L (D/O) BOOM HOIST BOOM HOIST REMO-CON MC-2 (P/O) (PSOL-52) Fr.DRUM LOWER BOOM HOIST REMO-CON MC-2 (P/O) (PSOL-52) BOOM LOWER BOOM LOWER REMO-CON MC-2 (P/O)
  • Page 461 10. ELECTRIC SYSTEM Fr.DRUM IND./CONF. SELECT F-33 SOL-101 MC2 (D/O) Re.DRUM IND./CONF. SELECT SOL-102 MC2 (D/O) 10-185 10000A-1 Published 10-09-13, Control #218-02...
  • Page 462 10. ELECTRIC SYSTEM 10.1.12 LOAD CELL (CRANE) Model name : LTP-S-50-KNSA10 Detective capacity: Guy-cable support power Rated capacity : 5 ton (49.03 KN) Load capacity : 150% Output voltage : with no load 1V ± 0.01V (at shipping) with rated load 5V ± 0.040V Power source : DC9V ±...
  • Page 463 10. ELECTRIC SYSTEM 10.1.13 ANGLE SENSOR Model name : MLA-901A-**C Detection capacity : Boom angle against ground Valid operating range : 0 to ± 90 degree Operation range : 360° endless Rated output sensitivity : 0.255V/V±0.5% Input voltage : Input resistance : ±...
  • Page 464 10. ELECTRIC SYSTEM 10.1.14 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE 1. FAILURE DIAGNOSIS FUNCTION ECU always diagnoses whether or not the sensors malfunction while the key switch (M) is turned ON, and it lights on the diagnosis lamp when the sensor is judged as being malfunctioned and restores the place of failure at the same time to inform the operator of abnormality and ECU restricts the...
  • Page 465 10. ELECTRIC SYSTEM 10.1.15 HOW TO CHECK THE FAILURE CONTENTS 1. Failure diagnosis code table (J08E Engine) When the failure is detected by diagnosis lamp, diag. code can be checked by connecting diag. connector CN-878F, CN-879M Component location related to diagnosis. •...
  • Page 466 10. ELECTRIC SYSTEM Diag. lamp (Red) 10000A-1 10-190 Published 10-09-13, Control #218-02...
  • Page 467 10. ELECTRIC SYSTEM 2. Table of Diagnosis codes (J08E-TI) 10-191 10000A-1 Published 10-09-13, Control #218-02...
  • Page 468 10. ELECTRIC SYSTEM 10000A-1 10-192 Published 10-09-13, Control #218-02...
  • Page 469 10. ELECTRIC SYSTEM 10-193 10000A-1 Published 10-09-13, Control #218-02...
  • Page 470 10. ELECTRIC SYSTEM 3. Indication of diagnosis codes (1) For example, the following chart shows the case when the diagnosis codes 32 and 21 are displayed. The display method is based on the blinking intervals of the lamp. First, the first code makes the lamp light on the figure "3"...
  • Page 471 10. ELECTRIC SYSTEM 10.1.16 CHECKING OF DIAGNOSIS LAMP FUNCTION The diagnosis lamp function is normal when the lamp is lit up with the following conditions. [Requirements for checking lit-up diagnosis lamps] • No any fault to be lit up the diagnosis lamp •...
  • Page 472 10. ELECTRIC SYSTEM 10.1.17 ENGINE ECU ECU TERMINAL NUMBER Engine sub harness connector no. Connector A : Respond connector : CN-614 Connector B: Respond connector :CN-615 Connector C: Respond connector :CN-635 Connector D: Respond connector :CN-616 Connector E: Respond connector :CN-638 10000A-1 10-196 Published 10-09-13, Control #218-02...
  • Page 473 10. ELECTRIC SYSTEM 10-197 10000A-1 Published 10-09-13, Control #218-02...
  • Page 474 10. ELECTRIC SYSTEM 10.2 LOAD SAFETY DEVICE 100% - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 All values in the figure are for reference only. 10000A-1 10-198 Published 10-09-13, Control #218-02...
  • Page 475 10. ELECTRIC SYSTEM 10.2.1 CONFIGURATION OF SCREENS 10-199 10000A-1 Published 10-09-13, Control #218-02...
  • Page 476 10. ELECTRIC SYSTEM 10.2.2 SYSTEM DAIGRAM Each ML sensor Each limit switch Each switch Each camera Load detector Over hoist Hook over hoist release Front, rear drum Over payout etc. Angle detector Boom over hoist release Boom drum ML release etc. Rear area etc.
  • Page 477 10. ELECTRIC SYSTEM 10.2.3 MONITOR INDICATION FRONT VIEW LEFT VIEW BACK VIEW BOTTOM VIEW (CF cover open) Explanation Name Logic motion mode Color Indication Operation mode (pictorial) (when logic is effective) Off line Green Running Flashing Running STOP At power ON STATUS LED Flashing Runnning...
  • Page 478 10. ELECTRIC SYSTEM Explanation Name G Aux. input/output / Voice output interface (AUX) Outside reset, alarm output, buzzer output, sound output. * not used H Extended memory interface * not used Green light is ON when CF card is inserted and cover is closed or CF card is being accessed.
  • Page 479 10. ELECTRIC SYSTEM • Installation specification Ground Functional grounding : D type ground (for both SG-FG) Protection : IP65f equivalent NEMA #250 TYPE 4X/13 Condition Construction *1 (Front surface at panel built in.) Shape : Built in type Installation method : Panel built in. Cooling type Natural cooling *1 Protective construction of the front area when this unit is installed in the panel.
  • Page 480 10. ELECTRIC SYSTEM • INSTALLATION PROCEDURE Upper face FITTING HOLE Bottom face (GP-3500 series) FITTING HOLE Hang fittings on the recess. PANEL INSTALL FITTING Tighten against the panel. HOOK Overtightening the screws may damage the GP. Proper tightening torque for drip proof effect is 0.5 N-m. POWER SUPPLY WIRING Electric shock may be caused.
  • Page 481 10. ELECTRIC SYSTEM • Power cable specification Use copper core wire. 0.75 to 2.5mm Size of power cable (18 - 12 AWG) Solid or strand wire *1 Core wire 7 mm Core wire length If strand wire is used, ensure that the core wire is properly stranded.
  • Page 482 10. ELECTRIC SYSTEM • Procedure of power cable connection 1. Ensure that the power is disconnected. 2. Take out the power supply connector (plug) from the main body. 3. Loosen the 3 screws in the center of power supply connector. 4.
  • Page 483 10. ELECTRIC SYSTEM 10.2.4 DETAIL OF MOMENT LIMITER CONNECTOR 1. Outside view and connector layout CONNECTOR LOCATION OF NAME 7-SEGMENT DISPLAY PLATE SEAL WATER PROOF WINDOW CONNECTOR CF CARD COVER • CF card contains the adjusted data as backup. When replacing the ML controller, ensure to re- insert the original CF card and copy the backup data to the controller.
  • Page 484 10. ELECTRIC SYSTEM 2. ML controller connector pin layout (View from main machinery harness) 10000A-1 10-208 Published 10-09-13, Control #218-02...
  • Page 485 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Control power (+) Main power (IG power +) Control power (+) Main power (IG power +) Control power (-) Main power (IG power GND) Control power (-) Main power (IG power GND) Backup power (+) Sub power (+B power +) Backup power (GND)
  • Page 486 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Inter main controller CAN0 H transmission 1 (H) Inter main controller CAN0 L transmission 1 (L) Inter main controller CAN0 H end transmission 1 (H end) Inter main controller CAN0 L end transmission 1 (L end) Shield earth Shield earth signal ground...
  • Page 487 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Swing angle detector power (+) 12V ML system sensor power 2-3 (+) 12V ML system sensor signal 2-3 (0 to Swing angle detector (A) signal 12V) Swing angle detector power (-) 12V ML system sensor power 2 (GND) 12V ML system sensor signal 2-4 (0 to Swing angle detector (B) signal...
  • Page 488 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Composite signal (+) vacant vacant CN-11-2 Camera power (+) 12V LCD monitor power (+) Composite signal (GND) Camera power (GND) 12V LCD monitor power (+GND) Connector Wire Wire Name Specification color Output power (+) Extended 24V power (+) Extended 25V power (+)
  • Page 489 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Hook over hoist LS1 24V input Hook over hoist LS2 24V input Gantry hoist detect LS 24V input (Not used) Boom backstop no.2 LS 24V input Crane boom over hoist LS 24V input Boom backstop no.1 LS 24V input...
  • Page 490 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color Drum select SW (rear) 24V input Drum select SW (front) Br/R 24V input 24V input Download start signal 24V input Master key SW Gr/R 24V input Hook over hoist release SW 24V input Boom/Jib over hoist release SW 24V input...
  • Page 491 10. ELECTRIC SYSTEM Connector Wire Wire Name Specification color 24V Output Front drum raise stop 24V Output 24V Output Front drum lower stop 24V Output Rear drum raise stop 24V Output Mode select (luffing jib) Br/G 24V Output Rear drum lower stop 24V Output Mode select (mast) 24V Output...
  • Page 492 10. ELECTRIC SYSTEM 3. System block diagram Ignition power (IG) Supply power 24V load detector power (4 systems) CN11-1 CN11-1 +24VDC +24VDC Voltage Filter Filter monitor Return arrest 12V load detector power power (8 system) 5V power Ext power EXT CN11-1 supply 12V ML system sensor...
  • Page 493 10. ELECTRIC SYSTEM 4. ML INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Variation Input Voltage Remarks Crane boom load detector 0t to rated t 1 to 5V CN11-1-25 Spare CN11-1-26 Jib load detector CN11-1-20 Spare CN11-1-21 Spare CN11-1-30 Spare CN11-1-31 Spare CN11-1-4 Spare CN11-1-5...
  • Page 494 10. ELECTRIC SYSTEM (3) DIGITAL INTPUT [B] Name Condition Signal level Remarks Hook over hoist LS1 Normal / Over +24V/OPEN CN11-5-1 Hook over hoist LS2 Normal / Over +24V/OPEN CN11-5-2 Gantry raise detect LS Not detect / Detect +24V/OPEN CN11-5-3 Boom B/S No.2 LS Normal / Over +24V/OPEN...
  • Page 495 10. ELECTRIC SYSTEM (4) ANALOGUE OUTPUT [H] Name Condition Signal level Remarks (5) DIGITAL OUTPUT [C] Name Condition Signal level Remarks Front drum raise stop Actuate / Normal +24V/OPEN CN11-6-30 Front drum lower stop Actuate / Normal +24V/OPEN CN11-6-29 Rear drum raise stop Actuate / Normal +24V/OPEN CN11-6-11...
  • Page 496 10. ELECTRIC SYSTEM 10.2.5 SHIFTING TO MAINTENANCE SCREEN 1. Push the [MENU] icon in the main screen. 2. Push [A] switch. - 1 - 1 m i n m i n 11000100000500010200 10:00 2010/12/01 3. Input the password (8 digits) with the keyboard. * In case of using capital letter, push CAPS switch.
  • Page 497 10. ELECTRIC SYSTEM 4. Push [OK] switch. 5. If password is correct, the maintenance menu becomes indicated. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 10:00 2010/12/01 2010/12/01 - 1 - 1 - 1 - 1...
  • Page 498 10. ELECTRIC SYSTEM 10.2.6 INPUT, OUTPUT SIGNAL This screen can check input signal condition of various sensors or switches or output signal condition of solenoid valves, relays and proportional valves. 1. Push [I/O SIGNAL] in the maintenance menu. 10000A-1 10-222 Published 10-09-13, Control #218-02...
  • Page 499 10. ELECTRIC SYSTEM (1) INPUT, OUTPUT CHECK OF ML (MOMENT LIMITER) (A) Select [ML SCREEN] in the menu. The first screen indicates condition of analog signal of the load detector, angle detector. Unit of indicating figure is V (volt). Refer to P.10-217 for connection and signal level. 0 V is indicated on non connected point.
  • Page 500 10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
  • Page 501 10. ELECTRIC SYSTEM (2) INPUT, OUTPUT CHECK OF MC1 (MAIN CONTROLLER 1) (A) Select "MC1" screen in the menu. The first screen indicates conditions of analog signal of pressure sensors, potentiometers etc. Unit of indicating figure is V (volt). As for signal name and specification, refer to P.10- 337.
  • Page 502 10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
  • Page 503 10. ELECTRIC SYSTEM (C) By pushing [NEXT], output of proportional valve becomes indicated. Instruct value is indicated on left hand and feedback value on right hand. Unit of indicating figure is mA (mille ampere). If instruct value is more than 100 mA and feedback value is about 0 mA, wire breakage is presumed.
  • Page 504 10. ELECTRIC SYSTEM (3) INPUT, OUTPUT SIGNAL CHECK OF MC2 (MAIN CONTROLLER 2) (A) Select "MC2" screen in the menu. The first screen indicates conditions of analog signal of pressure sensors, potentiometers etc. Unit of indicating figure is V (volt). As for signal name and specification, refer to P.10- 341.
  • Page 505 10. ELECTRIC SYSTEM 1) DIGITAL INPUT This is indicated by "IN". Digital input consists of 24 V input and ground (GND) input. In 24 V input, ON is indicated at 24 V and OFF at open (0 V). In ground input, ON is indicated at ground (GND) and OFF at open.
  • Page 506 10. ELECTRIC SYSTEM (C) By pushing [NEXT], output of proportional valve becomes indicated. Instruct value is indicated on left hand and feedback value on right hand. Unit of indicating figure is mA (mille ampere). If instruct value is more than 100 mA and feedback value is about 0 mA, wire breakage is presumed.
  • Page 507 10. ELECTRIC SYSTEM 10.2.7 ML FUNCTION SETTING 1. Push [ML FUNCTION SETTING] in the maintenance menu. - 1 - 1 m i n m i n 2. Setting item becomes indicated. ME034 PSV MC1-D05 m i n ME093 PSV MC1-D08 19:19 2011/08/12 ME096...
  • Page 508 10. ELECTRIC SYSTEM (1) OPTION SETTING OF ANEMOMETER This is to set with or without wind speed meter. (EX) In case of anemometer installed. (A) Push [ANEMOMETER] in the menu. (B) Option setting screen of anemometer becomes indicated. (C) Push [Enable]. * The selected side turns to blue indication.
  • Page 509 10. ELECTRIC SYSTEM (2) MAKING LVL FUNCTION EFFECTIVE This is to set LVL (auto stop load ratio) effective or not effective. Refer to P.10-260 to P.10-262. LVL setting for setting procedure of LVL value. (EX) In case of making LVL function effective. (A) Push [USE OF LVL] in the menu.
  • Page 510 10. ELECTRIC SYSTEM (3) SETTING OF CAMERA CONNECTION This is to set with or without camera. (EX) In case camera is added to channel 1. (A) Push [CAMERA CONNECTION] in the menu. (B) Camera connection setting screen becomes indicated. (C) Push [Enable] of channel 1. * The selected side turns to blue indication.
  • Page 511 10. ELECTRIC SYSTEM 10.2.8 DATA COPY, FORMAT 1. Push [DATA COPY, FORMAT] in the maintenance menu. 2. Items become indicated. (1) ADJUSTMENT DATA READING OUT This reads out backup data in the data card into memory in the controller. Memorized data in the controller are overwritten and is erased.
  • Page 512 10. ELECTRIC SYSTEM (A) ADJUSTMENT DATA READING OUT This is to read out the adjusted value (backup data) in the data card to the memory in the controller. When using this function, the data in the controller being used for calculation is overwritten. Be careful not to use in error.
  • Page 513 10. ELECTRIC SYSTEM When completed properly, the screen shown below is indicated. By pushing [OK], the screen returns to the previous one. It was completed. Push OK. After execution, if error message as shown below is indicated, data card failure (including not enough insertion) is presumed.
  • Page 514 10. ELECTRIC SYSTEM (B) ADJUSTMENT DATA WRITING IN This is to copy the adjustment data in the memory of the controller to the data card. * Normally whenever adjustment is done, data is copied to the card, but this is used to copy forcibly. Select [Controller ...
  • Page 515 10. ELECTRIC SYSTEM After execution, if error message as shown right is indicated, data card failure (including not enough insertion) is presumed. Re-insert the card and try again. By pushing [BACK], screen returns to the previous one. Adjustment data reference error. (C) ADJUSTMENT DATA FORMATTING This is to format the adjustment data in the memory in the controller.
  • Page 516 10. ELECTRIC SYSTEM When completed properly, the screen shown below is indicated. By pushing [OK] the screen returns to the previous one. Unless both of ML B31 and MC1 C9 lamps indicated on lower part of the screen light up, the card can not be accessed and reading out would not be completed properly.
  • Page 517 10. ELECTRIC SYSTEM 10.2.9 LANGUAGE, UNIT SETTING 1. Push [LANGUAGE/UNIT] in the maintenance menu. 2. Item becomes indicated. Select the required language, unit. Indicated Indicated unit language Japanese m, t ENG (ft • lbs) English feet, klbs ENG (m • t) English m, t Selected item becomes indicated in blue letter.
  • Page 518 10. ELECTRIC SYSTEM 10.2.10 ML ADJUSTMENT (NORMAL) 1. Push [ML ADJUSTMENT (NORMAL)] in the maintenance menu. 2. Adjustment menu becomes indicated. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01...
  • Page 519 10. ELECTRIC SYSTEM (1) ANGLE DETECTOR ADJUSTMENT Select [ANGLE DETECTOR ADJUSTMENT] in the adjustment menu. Angle detector connected to presently set attachment becomes indicated. (Figure below shows example of crane with aux. sheave.) In case with jib, jib angle detector becomes indicated and in case with mast, mast angle detector becomes indicated.
  • Page 520 10. ELECTRIC SYSTEM Touch angle indicating area. 100% Angle indicating area becomes indicated in reverse and digit input becomes possible. 100% 10000A-1 10-244 Published 10-09-13, Control #218-02...
  • Page 521 10. ELECTRIC SYSTEM Measure the actual boom angle with the level gauge and angle meter and input digit with numeric key. (EX) In case of input [79.5], input [7], [9], [.] [5]. After input, push [SET]. 100% Lower the boom for more than 25 degrees and stop.
  • Page 522 10. ELECTRIC SYSTEM Touch the second angle indicating area. 100% Angel indicating area becomes indicated in reverse and digit input becomes possible. 100% 10000A-1 10-246 Published 10-09-13, Control #218-02...
  • Page 523 10. ELECTRIC SYSTEM Measure the actual boom angle with the level gauge and angle meter and input digit with numeric key. (EX) In case of input [35.7], input [3], [5], [.] [7]. After input, push [SET]. 100% When the adjustment is properly completed, the message shown below is indicated.
  • Page 524 10. ELECTRIC SYSTEM If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting. Re-check the procedure and start adjustment again. 100% Adjustment is failure. Push SET, and adjust it again. Adjustment is failure.
  • Page 525 10. ELECTRIC SYSTEM Release the tension on the boom hoist rope to "zero" by releasing the boom hoist rope as much as possible or by removing the load detector. Push [SET] when prepared. THE ADJUSTMENT OF THE BOOM LOAD CELL 100% Make the tension applied to the load cell become a zero.
  • Page 526 10. ELECTRIC SYSTEM If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting. Re-check the procedure and start adjustment again. Adjustment is failure. Push SET after you reconfirm whether the tension applied to the load cell is a zero.
  • Page 527 10. ELECTRIC SYSTEM (3) LOAD LESS ADJUSTMENT Set the load to only the hook installed. Adjust each hook position based on the table below. (CKE Series) Weight of hook block Type of Weight of hook block to be when load is adjusted Mode attachments entered during adjustment...
  • Page 528 10. ELECTRIC SYSTEM Perform this adjustment by boom lowering motion control. Adjusting points shall be max. boom (jib) angle point and min. boom (jib) angle point and random selected 5 points between them. (Be sure to set up) Close to the maximum angle First point Can be omitted...
  • Page 529 10. ELECTRIC SYSTEM Select [LOAD-LESS ADJUSTMENT] in the adjustment menu. Touch load indicating area. Load indicating area turns in reverse indication and digit input becomes possible. 10-253 10000A-1 Published 10-09-13, Control #218-02...
  • Page 530 10. ELECTRIC SYSTEM Input hook weight with digit key. Refer to the table in the previous page for hook weight to be input. (EX) In case of input [2.0], input [2], [.], [0]. After input, push [SET]. After raising the boom to almost the upper limit angle and then lower by about 1 degree and then stop.
  • Page 531 10. ELECTRIC SYSTEM Lower the boom and stop. Then push [SET]. During boom lowering motion, control the hook raising motion to keep the hook in the same height. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. By pushing [SET], message memorizing the fist point is indicated.
  • Page 532 10. ELECTRIC SYSTEM By pushing [SET], message memorizing the second point is indicated. Second point is memorized. After lowering the boom further, push [SET]. If the points in between are to be skipped, push [SKIP]. They are skipped to the minimum angle. The 2nd point was memorized.
  • Page 533 10. ELECTRIC SYSTEM If the adjustment is properly completed, the message shown below is indicated. At the same time K1, K2 values are indicated as adjustment result. By pushing [SET], screen returns to the previous one. Adjustment went well. Push SET. If the adjustment is not properly completed, the message shown below is indicated.
  • Page 534 10. ELECTRIC SYSTEM (4) SOME LOAD ADJUSTMENT Only the different point to without load adjustment is the load value input first. The rest are same. Different point to without load adjustment ONLY is explained here. Firstly lift the weight known load. Select [SOME LOAD ADJUSTMENT] in the adjustment menu.
  • Page 535 10. ELECTRIC SYSTEM If the adjustment is properly completed, the message shown below is indicated. At the same time K3, K4 values are indicated as adjustment result. By pushing [SET], screen returns to the previous one. 100% If the adjustment is not properly completed, the message shown below is indicated.
  • Page 536 10. ELECTRIC SYSTEM (5) LVL ADJUSTMENT LVL means the load ratio to stop automatically. Normally auto stop load ratio is 105% but with this function this load ratio can be changed to 90 to 110%. LVL function is only effective when "EFFECTIVE" is set in "LVL SETTING"...
  • Page 537 10. ELECTRIC SYSTEM The indicating area becomes reverse indication. Input value with digit key. After value input is completed, push [SET]. Setting is completed and screen returns to previous one. 10-261 10000A-1 Published 10-09-13, Control #218-02...
  • Page 538 10. ELECTRIC SYSTEM LVL Function The following drawings are some examples of LVL function. (A) When the LVL function is OFF. 5% Hysteresis If the loading ratio is 105% or more while the LVL function is not actuated, operation toward the Stop hazardous side is automatically stopped.
  • Page 539 10. ELECTRIC SYSTEM (6) WORK RADIUS ADJUSTMENT This is used when difference between the indicated work radius and the actual work radius is large due to the boom deflection etc. Ensure to check if there is any error in angle indication. If error is larger than 0.3 degrees carry out angle adjustment first.
  • Page 540 10. ELECTRIC SYSTEM Input actually measured work radius with digit key. (EX) In case of input [35.0], input [3], [5], [.] [0]. After input, push [SET]. Lower the boom (jib) to almost min. angle and stop. Then push [SET]. 10000A-1 10-264 Published 10-09-13, Control #218-02...
  • Page 541 10. ELECTRIC SYSTEM Touch the radius indication area. Input actually measured work radius with digit key. (EX) In case of input [67.0], input [6], [7], [.] [0]. After input, push [SET]. 10-265 10000A-1 Published 10-09-13, Control #218-02...
  • Page 542 10. ELECTRIC SYSTEM If the adjustment is properly completed, the message shown below is indicated. By pushing [SET], screen returns to the previous one. Adjustment went well. Push SET. If the adjustment is not properly completed, the message shown below is indicated. By pushing [SET], screen returns to the one during adjusting.
  • Page 543 10. ELECTRIC SYSTEM (7) SWING ANGLE ADJUSTMENT Select [SWING ANGLE ADJUSTMENT] in the adjustment menu. Face the crane toward front (idler side of crawler) and fix with the swing lock pin. Push [FR]. If the indication changes from [FR] to [OK], front side adjustment is properly completed.
  • Page 544 10. ELECTRIC SYSTEM Push [RE]. If indication changes from [RE] to [OK], rear side adjustment is properly completed. When either [FR] or [RE] is pushed and "NG" is indicated, adjustment is in error. Check if the crane direction or sensor voltage is correct and start adjustment again.
  • Page 545 10. ELECTRIC SYSTEM To rest adjusted value, push [A]. "OK" is indicated on both [FR] and [RE] and the value is reset. 10-269 10000A-1 Published 10-09-13, Control #218-02...
  • Page 546 10. ELECTRIC SYSTEM 10.2.11 ML ADJUSTMENT (TEMPORARY) This adjustment is used to match with the load temporary when error exists in load indication due to load detector abnormality etc. There is no limit in adjustment value and adjustment would become possible even when error occurs in without load / with load adjustment in "10.2.10 ML ADJUSTMENT (NORMAL)".
  • Page 547 10. ELECTRIC SYSTEM 10.2.12 OPERATION PROGRESS 1. Push [OPERATION PROGRESS] in the maintenance menu. Information of internal operation indicated. Symbols Details Tare weight component during main winch lifting with current radius Tare weight component during aux. winch lifting with current radius Tare weight component during third winch lifting with current radius Load coefficient during main winch lifting with current radius Load coefficient during aux.
  • Page 548 10. ELECTRIC SYSTEM EXAMPLE OF USING OPERATION SCREEN The actual load W can be indicated by the formula shown below. Hoist guy line tension Dead weight component (M.A.R) Load-less adjustment value (Span) Load-less adjustment value (Shift) F - (FO X k1 + k2) Actual load W = (δ...
  • Page 549 10. ELECTRIC SYSTEM 10.2.13 VERSION INFORMATION 1. Push [VERSION INFORMATION] in the maintenance menu. Each part number and version of ML program, monitor, MC1 program, MC2 program, ML data are indicated. M/L Program Version M/L Program Part No. Monitor Program Version Monitor Program Part No.
  • Page 550 10. ELECTRIC SYSTEM 10.2.14 FAILURE HISTORY 1. Push [FAILURE HISTORY] in the maintenance menu. 2. Items are indicated. (1) ML FAILURE HISTORY Push [ML FAILURE HISTORY] in the menu. Past failures become indicated from latest one in order to max. 20 items. Failure content is indicated by code.
  • Page 551 10. ELECTRIC SYSTEM DELETING FAILURE HISTORY When the failure record is to be deleted, push [A]. The message below becomes indicated. Data is erased. Touch GO for 1sec if it is good. Touch STOP if you stop it. In case of deletion, push [GO]. In case of stop, push [STOP].
  • Page 552 10. ELECTRIC SYSTEM (2) MC1 FAILURE HISTORY Push [MC1 FAILURE HISTORY] in the menu. Past failures become indicated from the latest one in order to max. 200 items (10 item X 20 page). By [A] page can be scrolled up and by [B] page can be scrolled down.
  • Page 553 10. ELECTRIC SYSTEM By pushing [GO], data is deleted. (3) DELETING MC2 FAILURE HISTORY Push [DELETING MC2 FAILURE HISTORY] in the menu. Indication content and handling procedure are same as MC1. 10-277 10000A-1 Published 10-09-13, Control #218-02...
  • Page 554 10. ELECTRIC SYSTEM 10.2.15 ADJUSTMENT DATA 1. Push [ADJUSTMENT DATA] in the maintenance menu. Adjustment data menu becomes indicated. 100% PSV MC1-D01 PSV MC1-D09 PSV MC1-D02 PSV MC1-D11 PSV MC1-D03 PSV MC1-D12 PSV MC1-D04 D/O MC1-C29 PSV MC1-D05 D/O MC1-C30 PSV MC1-D08 PSV MC2-D01 (1) ANGLE SENSOR...
  • Page 555 10. ELECTRIC SYSTEM (B) ADJUSTMENT DATA CHANGE In case of changing adjustment data, touch the digit area to be changed. Touched area becomes reverse indication and digit input becomes possible. ADJUSTMENT VALUE ANGLE SENSOR 100% Input digit with digit key. In case of input [1.103], input [1], [.], [1], [0], [3].
  • Page 556 10. ELECTRIC SYSTEM The message below becomes indicated. Push [OK]. ADJUSTMENT VALUE ANGLE SENSOR 100% Adjustment value was saved. (C) DELETING ADJUSTMENT DATA All of adjustment datas are returned to initial values. Push [B] for 3 seconds to execute. ADJUSTMENT VALUE ANGLE SENSOR 100% 10000A-1 10-280...
  • Page 557 10. ELECTRIC SYSTEM All adjustment data returns to the initial value. Initial value : Shift = 0.000, Span = 1.000 This is to complete deletion. Push [OK]. ADJUSTMENT VALUE ANGLE SENSOR 100% Adjustment value was erased. 10-281 10000A-1 Published 10-09-13, Control #218-02...
  • Page 558 10. ELECTRIC SYSTEM (2) LOAD DETECTOR ZERO ADJUSTMENT (A) ADJUSTMENT DATA INDICATION Push [Zero offset value of load cell] in the menu. LOAD DETECTOR ZERO POINT 100% Table of zero point adjustment data of load detector is indicated. They are indicated by load cell voltage value at time of zero adjustment.
  • Page 559 10. ELECTRIC SYSTEM (3) WITHOUT LOAD / WITH LOAD (TEMPORARY) (A) ADJUSTMENT DATA INDICATION Push [F0/d (temporary)] in the menu. 100% Table of adjustment datas becomes indicated. M : Front lifting mode adjustment data A : Rear lifting mode adjustment data R : Third lifting mode adjustment data No.
  • Page 560 10. ELECTRIC SYSTEM (4) WITHOUT LOAD / WITH LOAD (NORMAL) (A) ADJUSTMENT DATA INDICATION Push [F0/d (normal)] in the menu. 100% Table of adjustment data becomes indicated. On this adjustment, 10 type of boom length adjustment are possible on each group of 1 to 30. At first, group 1 becomes indicated.
  • Page 561 10. ELECTRIC SYSTEM (5) SWING RADIUS (A) ADJUSTMENT DATA INDICATION Push [RADIUS] in the menu. 100% Table of adjustment datas becomes indicated. This adjustment also consists of group 1 to 30 and the first screen indicates group 16 to 30. By pushing [] group 16 to 30 becomes indicated.
  • Page 562 10. ELECTRIC SYSTEM 10.2.16 DOWNLOAD ML PROGRAM 1. Take out data CF card from ML controller and insert CF card with new program filed in. * It is possible to write in by filing the program to data CF card. E Model will be need turn on to "H3"...
  • Page 563 10. ELECTRIC SYSTEM During download, 7 segment display of the controller changes as shown below. This may vary due to version of firmware (internal program). Blinking Approx. 10 seconds 5. When End is indicated, re-writing is completed. 6. Turn OFF the key switch. 7.
  • Page 564 10. ELECTRIC SYSTEM 10.2.17 DOWNLOAD OF MONITOR PROGRAM 1. Insert the CF card with new program filed in to the CF card throttle on the back face of the monitor. * Ensure to close the cover. FRONT VIEW LEFT VIEW BACK VIEW CF CARD THROTTLE BOTTOM VIEW...
  • Page 565 10. ELECTRIC SYSTEM 4. Menu becomes indicated on the lower part of the screen. Select [CF/USB]. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200 10:00 10:00 2010/12/01 2010/12/01 5.
  • Page 566 10. ELECTRIC SYSTEM 6. If the error as shown below is indicated, check for inserted condition of CF card or cover to be closed. - 1 - 1 - 1 - 1 m i n m i n m i n m i n 11000100000500010200 11000100000500010200...
  • Page 567 10. ELECTRIC SYSTEM 8. Select [START]. 9. Select [YES]. 10-291 10000A-1 Published 10-09-13, Control #218-02...
  • Page 568 10. ELECTRIC SYSTEM 10. Download starts. Write in [OS data], [System / Project data] in its order. If properly completed, message as shown bellow becomes indicated. Push [Back]. OS data write completed (4/4). System/Project data write completed (80/80). SRAM data write completed (2/2). Successfully completed.
  • Page 569 10. ELECTRIC SYSTEM 12. Push [Exit] to return to the screen 1 step before. 13. Push [Yes]. Monitor re-starts. This is to complete re-writing of program. Turn the key switch OFF and take out the CF card. 10-293 10000A-1 Published 10-09-13, Control #218-02...
  • Page 570 10. ELECTRIC SYSTEM 10.3 MAIN CONTROLLER 10.3.1 ARRANGEMENT OF MAIN CONTROLLER 1. INSTALLATION POSITION (CAB) OF MAIN CONTROLLER 1 MAIN CONTROLLER 1 VIEW FROM “A” 2. INSTALLATION POSITION (LEFT CAB) OF MAIN CONTROLLER 2 MAIN CONTROLLER 2 FRONT LEFT DECK INSIDE VIEW FROM “C”...
  • Page 571 10. ELECTRIC SYSTEM 10.3.2 COMPOSITION OF SYSTEM 1. SYSTEM COMPOSITION CHART (INPUT) (OUTPUT) SENSOR GRIP THROTTLE PROP. V. OUTPUT SWITCH SENSOR SOL. V. OUTPUT SWITCH / TRIMMER RELAY OTHER OUTPUT ENGINE CONTROL (INPUT) ENGINE SWING CONTROL MONITOR STOP SIGNAL PUMP CONTROL RS232C ENERGY SAVING RS232C...
  • Page 572 10. ELECTRIC SYSTEM 10.3.3 FUNCTION OF MAIN CONTROLLER CONTROL FUNCTION ACCELERATOR CONTROL HORSE POWER CONTROL WINCH MOTOR SPEED CONTROL SWING COUNTERFORCE SWING SPEED CONTROL SWING AUTO STOP WINCH CONTROL BOOST CONTROL 10 BOOM STOP CONTROL 11 - 12 - 13 FRONT/REAR HOIST STOP 14 MOTOR TILT ANGLE CONTROL 15 HOOK OVER HOIST CONTROL 16 DRUM ROTATION DETECT GRIP CONTROL...
  • Page 573 10. ELECTRIC SYSTEM 1. ACCELERATOR CONTROL (1) Accelerator control This provides command to ECU (engine control) based on input of grip throttle or foot throttle. In case of both throttles are equipped, throttle having larger amount of command has priority. To make foot throttle effective, option setting and adjustment is required.
  • Page 574 10. ELECTRIC SYSTEM (2) Power control Battery is energized 1.5 seconds after the key switch is turned ON. Battery is de-energized 4 seconds *after the key switch is turned OFF. However in case of emergency solenoid being actuated, 90 seconds after. 10000A-1 10-298 Published 10-09-13, Control #218-02...
  • Page 575 10. ELECTRIC SYSTEM 2. HORSE POWER CONTROL This is to control pump by calculating target speed from grip throttle and by matching with engine actual speed. Lower the actual speed is against target speed, larger the output current is. However in case of low idling, even the difference is small, output current is large.
  • Page 576 10. ELECTRIC SYSTEM 3. WINCH MOTOR SPEED CONTROL 10000A-1 10-300 Published 10-09-13, Control #218-02...
  • Page 577 10. ELECTRIC SYSTEM (1) Front/Rear/Third (option) drum speed variable Max. current of remo-con prop. valve and motor control prop. valve is controlled as shown above. Priority order is as follows. Remo-con prop. valve Front, rear, third (option) stop, Lever interlock > Front, rear speed reducing >...
  • Page 578 10. ELECTRIC SYSTEM (2) Boom drum speed control In case of low engine speed, when engine speed is intended to raise by characteristic (a), it becomes closer to characteristic (b). If the trimmer is set to maximum value, the prop. valve becomes full open and the main valve opening becomes maximum.
  • Page 579 10. ELECTRIC SYSTEM 5. SWING COUNTERFORCE A reaction is applied to the lever depending on swing loads. SWING REACTION PROPORTIONAL VALVE CURRENT SWING NEUTRAL FREE (mA) SWING NEUTRAL BRAKE SWING PUMP PRESSURE 1.96 15.40 34.32 (MPa) 10-303 10000A-1 Published 10-09-13, Control #218-02...
  • Page 580 10. ELECTRIC SYSTEM 6. SWING SPEED CONTROL CURRENT (mA) NEUTRAL FREE (LOW SPEED) or BRAKE NEUTRAL FREE (HIGH SPEED) GRIP THROTTLE • When the swing control signal is OFF for 10 seconds, or swing limit function is selected, the current becomes maximum value. (700 mA) 10000A-1 10-304 Published 10-09-13, Control #218-02...
  • Page 581 10. ELECTRIC SYSTEM 7. SWING LIMIT CONTROL (1) Swing deceleration Swing stop prop. valve Based on swing deceleration signal (R and L) input (R and L) value (31  0), right swing / left swing stop prop. (mA) ENGINE HIGH valve output current is controlled.
  • Page 582 10. ELECTRIC SYSTEM 8. WINCH CONTROL (1) Control lever neutral mode selection (2) Winch operation solenoid valve control 10000A-1 10-306 Published 10-09-13, Control #218-02...
  • Page 583 10. ELECTRIC SYSTEM (A) When power is supplied The machine always starts running in the neutral brake mode. (B) Switching from the brake mode to the free fall mode. Condition Output The free fall lock switch is set released. Select the free mode. Free release "ON"...
  • Page 584 10. ELECTRIC SYSTEM (E) Emergency solenoid valve control For the front drum, when either of the conditions below is satisfied, ESM (SOL-19) is energized to prevent a drop of a lifted load. 1) The clutch pressure is reduced although the brake mode is selected.
  • Page 585 10. ELECTRIC SYSTEM (3) Free fall acceleration 10-309 10000A-1 Published 10-09-13, Control #218-02...
  • Page 586 10. ELECTRIC SYSTEM The falling speed can be increased by idling the motor during the free fall. The speed is controlled as shown in the table below. Conditions Procedures 1. Free fall mode is selected. 2. The control lever is at the neutral position. •...
  • Page 587 10. ELECTRIC SYSTEM 9. BOOST CONTROL To prevent a momentary drop of a lifted load, apply a constant boost to the motor while the lever is in the neutral position. The boost solenoid valve is controlled as shown in the table below. Lever Boost solenoid valve Neutral...
  • Page 588 10. ELECTRIC SYSTEM 10. BOOM STOP CONTROL BOOM LOWER BOOM RAISE PROPORTIONAL VALVE PROPORTIONAL VALVE CURRENT CURRENT ENGINE HIGH SPEED (mA) (mA) ENGINE LOW SPEED STOP STOP 1.5 sec TIME BOOM LOWER STOP SIGNAL INPUT BOOM RAISE STOP BOOM RAISE SIGNAL INPUT DECELERATION SIGNAL INPUT...
  • Page 589 10. ELECTRIC SYSTEM 13. FRONT DRUM HOISTING STOP / REAR DRUM HOISTING STOP FRONT DRUM HOIST REAR DRUM HOIST PROPORTIONAL VALVE CURRENT PROPORTIONAL VALVE CURRENT (mA) (mA) STOP STOP FRONT DRUM HOIST STOP REAR DRUM HOIST STOP SIGNAL INPUT SIGNAL INPUT 10-313 10000A-1 Published 10-09-13, Control #218-02...
  • Page 590 10. ELECTRIC SYSTEM 14. MOTOR TILT ANGLE CONTROL 10000A-1 10-314 Published 10-09-13, Control #218-02...
  • Page 591 10. ELECTRIC SYSTEM (1) During raising or lowering at brake mode or free mode, current of each motor tilt angle prop. valve is controlled as follows. (Trimmer control) (A) Current of motor tilt angle prop. valve varies based on lever motion and speed variable trimmer position.
  • Page 592 10. ELECTRIC SYSTEM (B) Maximum current of motor tilt angle prop. valve is controlled by no load engine speed (Command volume by grip). MAX CURRENT OF TILT ANGLE PROPORTIONAL VALVE (mA) NO LOAD ENGINE SPEED 1600 (2) When auto-stopped In case of drum auto-stop, output is to be 200 mA. But if operated toward safe side (not auto-stop side), it shall return to the value by other control.
  • Page 593 10. ELECTRIC SYSTEM 15. HOOK OVER HOIST CONTROL (1) Action at hook over hoist Output of corresponding remo-con. valves shall be 150 mA when hook over hoist notice is received with CAN transmission from ML. At the same time, stop signal from ML is input and stop action is done.
  • Page 594 10. ELECTRIC SYSTEM (2) Action at hook over hoist When hook over hoist is released at hook over hoist occurs, the following action is done. Front, rear and third (jib) raise remo-con. prop. valve command current are set to inching speed level.
  • Page 595 10. ELECTRIC SYSTEM 16. DRUM ROTATION DETECT GRIP CONTROL (OPTION) This can control the grip solenoid based on drum rotation sensor input. Grip solenoid output becomes OFF when the drum speed exceeds the specified level. Specified speed. = drum speed : about 61.5 min = more than 4 pulse at 50 m sec.
  • Page 596 10. ELECTRIC SYSTEM 17. FRONT/BOOM PUMP CONTROL 10000A-1 10-320 Published 10-09-13, Control #218-02...
  • Page 597 10. ELECTRIC SYSTEM (1) Feathering control : This is to control the tilt angle proportional (prop.) valve of each pump based on lever motion. Lever motion Pump Prop. valve Front Rear Boom Propel L Propel R Main F Main pump Release Release Release...
  • Page 598 10. ELECTRIC SYSTEM 18. HEIGHT METER (1) Drum rotation amount is detected by pulse counting with drum rotation sensor. (2) When raise pressure sensor input exists, variation is counted on raising side, and on the other case, variation is counted as + or - on lowering side. (3) Layer no.
  • Page 599 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 required. 10-323 10000A-1 Published 10-09-13, Control #218-02...
  • Page 600 10. ELECTRIC SYSTEM 19. LEVER INTERLOCK CONTROL 10000A-1 10-324 Published 10-09-13, Control #218-02...
  • Page 601 10. ELECTRIC SYSTEM This is to prevent drum unexpected rotation with engine start when the lever is in operating position and the function lock lever is in work position. (1) Before engine start Each prop. valve current is minimum. (150 mA) Pilot cut relay RL-13 is to be output.
  • Page 602 10. ELECTRIC SYSTEM 20. DPF REGENERATION CONTROL Regeneration starts when more than certain amount of soot is accumulated in DPF (Diesel Particulate Filter). Counting of soot accumulated volume and regeneration start timing etc are all done by engine ECU. However load valve control and engine speed control to raise exhaust temperature in order to prevent regeneration starting during crane control are done by crane side controller.
  • Page 603 10. ELECTRIC SYSTEM (1) Auto regeneration Between 0 and 4 soot gauge bar, the following requests are issued from engine ECU. Long time idling : If low idling, low load work is continued, request is issued from ECU. Idling speed is raised (1,000 min ) and load valve becomes ON.
  • Page 604 10. ELECTRIC SYSTEM (2) Manual regeneration Between 5 and 9 soot gauge bar, the following requests are issued from engine ECU. Manual regeneration request : After engine ECU request, regeneration switch and cancel switch become indicated on the main monitor. Manual regeneration preparation : When regeneration switch is pushed, regeneration start signal from the main controller 1 to ECU is...
  • Page 605 10. ELECTRIC SYSTEM Manual regeneration is possible at soot gauge up to 7 bar. When soot gauge becomes 9 bar, forcible regeneration starts by detecting no control condition. The content of action is as same as manual regeneration and action starts without requesting permit to crane operator.
  • Page 606 10. ELECTRIC SYSTEM 22. G WINCH CONTROL GK, HF, GN, JD Gr. ONLY 10000A-1 10-330 Published 10-09-13, Control #218-02...
  • Page 607 10. ELECTRIC SYSTEM (1) G winch mode selecting This is to make individual select switch, which is set individually for front/rear based on input of G winch select switch effective. When individual switch is input, G winch condition is selected based on the conditions shown in the table.
  • Page 608 10. ELECTRIC SYSTEM 23. G ENGINE CONTROL (1) G engine function select switch After inputting into select switch, check is made on each lever control. If neutral Q max cut solenoid is energized. Input Output G engine Lever condition Q max cut SOL Engine speed control function select At G engine...
  • Page 609 10. ELECTRIC SYSTEM 24. AIS CONTROL 10-333 10000A-1 Published 10-09-13, Control #218-02...
  • Page 610 10. ELECTRIC SYSTEM The above circuit diagram is extract from the main diagram for only related portion of this control. (engine stop/re-start) When the condition bellows are met, engine stops automatically. Engine stop condition Meeting condition ML permit condition Configuration condition : ML permit ML permit condition Other than assembly/ disassembly, stowing...
  • Page 611 10. ELECTRIC SYSTEM 25. HYD. OIL HEAT (OPTION) Control Relay When all lever is in neutral Energized Either on lever is in operation De-energized 10-335 10000A-1 Published 10-09-13, Control #218-02...
  • Page 612 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 10000A-1 10-336 Published 10-09-13, Control #218-02...
  • Page 613 10. ELECTRIC SYSTEM 10.3.5 SPECIFICATIONS OF MAIN CONTROLLER OUTPUT 1. SPECIFICATIONS OF MAIN CONTROLLER 1 INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Range Input voltage A/D Spare A/D Spare Fr. drum motor speed adjusting trimmer 0 to FULL 0.43 to 5 V Re.
  • Page 614 10. ELECTRIC SYSTEM (2) DIGITAL INPUT [B] Name Status Signal level ECU status signal Power ON/OFF Ground (15 k Ω )/OPEN Engine hyd. pressure PSW Engine Stop/Work Ground (15 k Ω )/OPEN CB/W detect Detection/Non-detection Ground (15 k Ω )/OPEN Clogging of Engine air cleaner Clogging/Normal Ground (15 k Ω...
  • Page 615 10. ELECTRIC SYSTEM Name Status Signal level Hyd. oil heat LS (OPT) Energized/De-energized +24 V/OPEN Pump Qmax cut solenoid (FB) Energized/De-energized +24 V/OPEN Remote control connection signal Connected/Unconnected +24 V/OPEN Swing warning (flasher) Flasher ON/OFF +24 V/OPEN Swing warning (buzzer and flasher) Buzzer and flasher ON/OFF +24 V/OPEN DPF regeneration (FB)
  • Page 616 10. ELECTRIC SYSTEM (5) DIGITAL OUTPUT [C] Name Status Signal level Fr. drum motor CLM-SOL Energized/De-energized GND/OPEN Fr. drum motor ESM-SOL Energized/De-energized GND/OPEN Re. drum motor CLA-SOL Energized/De-energized GND/OPEN Re. drum motor ESA-SOL Energized/De-energized GND/OPEN Third drum motor CLT-SOL Energized/De-energized GND/OPEN Third drum motor EST-SOL Energized/De-energized...
  • Page 617 10. ELECTRIC SYSTEM 2. SPECIFICATIONS OF MAIN CONTROLLER 2 INPUT/OUTPUT (1) ANALOGUE INPUT [A] Name Range Input voltage Spare A/D Spare A/D Fr. drum motor tilt control press. sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Re. drum motor tilt control press. sensor 0 to 2.94 MPa (30 kg/cm 0.5 to 4.5 V Third drum motor tilt control press.
  • Page 618 10. ELECTRIC SYSTEM (2) DIGITAL INPUT [B] Name Status Signal level C/W detect 3 GND (15 k )/OPEN Ω C/W detect 4 GND (15 k )/OPEN Ω C/W detect 5 (C4, C5) GND (15 k Ω )/OPEN C/W detect 6 (C5) GND (15 k )/OPEN Ω...
  • Page 619 10. ELECTRIC SYSTEM Name Status Signal level +24 V/OPEN +24 V/OPEN ML bypass (CR) ON/OFF +24 V/OPEN ML bypass (JIB) ON/OFF +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN +24 V/OPEN (3) ANALOGUE OUTPUT [H] Name Status Signal level (4) PROPORTIONAL VALVE OUTPUT [D] Name Output current Dither...
  • Page 620 10. ELECTRIC SYSTEM (5) DIGITAL OUTPUT [C] Name Output current Dither GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN GND/OPEN (300 mA) GND/OPEN (300 mA) GND/OPEN (300 mA) GND/OPEN GND/OPEN GND/OPEN GND/OPEN (PWM) GND/OPEN (PWM) Fr. drum motor boost SOL Boost/Normal +24 V/OPEN Oil cooler electric motor ON/OFF GND/OPEN...
  • Page 621 10. ELECTRIC SYSTEM 10.3.6 ARRANGEMENT OF MAIN CONTROLLER CONNECTOR PIN 1. ARRANGEMENT OF MC1 CONNECTOR PIN Connector No. Pin No. Port name Function Specifications Ref. CN101 +5VA Spare Spare TXD2 Spare RXD2 Spare CANH1 CAN1_H CANL1 CAN1_L CAN1 termination Spare CAN1 termination Spare CANH2...
  • Page 622 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Ref. CN102 +5VA Fr. drum motor speed adjusting trimmer +5VA Re. drum motor speed adjusting trimmer +5VA Third drum motor speed adjusting trimmer +5VA Boom drum motor speed adjusting trimmer Resistance input Spare...
  • Page 623 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN104 Grounded input (15 K Ω ) ECU signal Qmax cut solenoid detection pressure Power shift pressure sensor +5V for supply voltage monitoring Grounded input (15 K Ω ) Engine hyd.
  • Page 624 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN105 +24 V 1 Battery (+) Power supply +24 V Power supply +24 V Power supply Grounded input (3.3 K Ω ) Fr. drum brake cooling oil temperature Grounded input (3.3 K Ω...
  • Page 625 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN106 +24 V 1 Battery (+) Fr. drum middle detent Re. drum middle detent D11+ Left swing stop proportional valve D11- Main pump tilt control prop. valve 1 Main pump tilt control prop.
  • Page 626 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN107 D/O FB Controller ID 1 D/O FB Controller ID 2 +24 V input G mode/Normal selection +24 V input G winch (Fr.) +24 V input G winch (Re.) +24 V input G winch (main) D/O FB...
  • Page 627 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN108 Grounded output Fr. drum motor CLM-SOL Grounded output Fr. drum motor ESM-SOL Grounded output Re. drum motor CLA-SOL Grounded output Re. drum motor ESA-SOL Grounded output Third drum motor CLT-SOL D/O FB Fr.
  • Page 628 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN109 +24 V output Battery relay energizing Grounded output ML bypass reset Grounded output Solenoid cut relay energizing Grounded output Engine warning output Grounded output AIS air con. ON relay energizing Grounded output Swing neutral brake selection +24 V output...
  • Page 629 10. ELECTRIC SYSTEM 2. ARRANGEMENT OF MC2 CONNECTOR PIN Connector No. Pin No. Port name Function Specifications Ref. CN111 +5VA Vacancy Vacancy TXD2 Vacancy RXD2 Vacancy CANH1 CAN1_H CANL1 CAN1_L CAN1 termination Vacancy CAN1 termination Vacancy CANH2 CAN2_H CANL2 CAN2_L Vacancy Vacancy Vacancy...
  • Page 630 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN112 +5VA Fr. drum motor tilt control pressure sensor +5VA Re. drum motor tilt control pressure sensor +5VA Third drum motor tilt control pressure sensor +5VA A/D spare Resistance input Fuel level +5VA Confluence/Independence selection...
  • Page 631 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN114 Grounded input (15 K Ω ) C/W detect 3 Boom drum raise pressure sensor Boom drum lower pressure sensor Fr. drum raise pressure sensor Grounded input (15 K Ω ) C/W detect 4 Fr.
  • Page 632 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications CN115 +24 V 1 Battery (+) Power supply +24 V Power supply +24 V Power supply Grounded input (3.3 K Ω ) Fr. drum brake cooling oil temperature Grounded input (3.3 K Ω ) Re.
  • Page 633 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN116 +24 V 1 Battery (+) Power supply Re. drum lower proportional valve Third drum raise proportional valve (option) D11+ Re. drum motor tilt control prop. valve D11- Third drum lower prop.
  • Page 634 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN117 D/O FB Controller ID 1 D/O FB Controller ID 2 +24 V input Fr. drum raise stop +24 V input Fr. drum lower stop +24 V input Re.
  • Page 635 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN118 Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare Grounded output Spare D/O FB DPF load solenoid D/O FB Spare D/O FB Spare D/O FB Spare Grounded output Spare...
  • Page 636 10. ELECTRIC SYSTEM Connector No. Pin No. Port name Function Specifications Remarks CN119 +24 V output Fr. drum motor boost SOL Grounded output Oil cooler electric motor Confluence/Independence selection Grounded output solenoid (Fr. drum) Confluence/Independence selection Grounded output solenoid (Re. drum) Grounded output DPF load solenoid Grounded output...
  • Page 637 10. ELECTRIC SYSTEM 10.3.7 ADJUSTMENT OF MAIN CONTROLLER 1. Model number setting Perform this setting only when controller is replaced. If model setting is not properly done, machine does not work properly. Take extra care. (1) Turn the engine key ON. (2) Select the screen as follows.
  • Page 638 10. ELECTRIC SYSTEM (3) Select the indicated model group. (4) Push "OK" after model group is selected. 100% Unless "OK" is pushed, selection becomes ineffective. 2. Option setting (1) Turn the engine key "ON". (2) Select the screen as follows. Main screen (a) ...
  • Page 639 10. ELECTRIC SYSTEM 3. Adjustment of grip throttle and foot throttle. (1) Turn the engine key "ON". (2) Select the screen as follows. Main screen (a)  (b)  Password input  MC adjustment  Grip adjustment (3) The screen changes to adjustment screen. Push adjustment start button (d).
  • Page 640 10. ELECTRIC SYSTEM 5. Adjusting of inclination meter Place the main machinery on the horizontal ground before adjustment using the level gauge etc. (1) Turn the engine key ON. (2) Select the screen as follows. Main screen (a)  (b)  Password input ...
  • Page 641 10. ELECTRIC SYSTEM 10.3.8 CONTROLLER MALFUNCTION EMERGENCY MEASURES When the controller is malfunctioned, as an emergency measure, set the BYPASS switch for the main controller in the left side stand to the "bypass" position. The crane operation becomes possible. Automatic stop is actuated by the load safety device even when the BYPASS switch is actuated.
  • Page 642 10. ELECTRIC SYSTEM 10000A-1 10-366 Published 10-09-13, Control #218-02...
  • Page 643 11. AIR CONDITIONER 11-1 10000A-1 Published 10-09-13, Control #218-02...
  • Page 644 11. AIR CONDITIONER 10000A-1 11-2 Published 10-09-13, Control #218-02...
  • Page 645 11. AIR CONDITIONER 11.1 AIR CONDITIONER 1. NAME OF THE AIR CONDITIONER PARTS AIR CON. CONTROL PANEL INTERNAL AIR FILTER BLOW OUT OPENING BLOW OUT OPENING BLOW OUT OPENING BLOW OUT OPENING OPEN AIR BLOW OUT FILTER OPENING AIR CONDITIONER UNIT 2.
  • Page 646 11. AIR CONDITIONER 3. FUNCTION OF EACH CONTROL DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) ON/OFF SWITCH (1) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (1) ON/OFF SWITCH (POWER SWITCH) It turns ON or OFF the air conditioner.
  • Page 647 11. AIR CONDITIONER (5) IN-OUT AIR SELECTOR SWITCH internal air circulation (R/F SWITCH) Every time when this switch is pushed, internal air / out air take in open air alternate and it is indicated (b) on LCD (b) INDICATION CONTENT display.
  • Page 648 11. AIR CONDITIONER 4. AIR CONDITIONER CONTROL (1) To stop or to start air conditioner : Push ON/OFF SWITCH (1). IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) ON/OFF SWITCH (1) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (2) To cool :...
  • Page 649 11. AIR CONDITIONER (3) To warm : IN-OUT AIR SELECTOR SWITCH (5) AIR CON. SWITCH (2) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (A) Push the TEMPERATURE CONTROL SWITCH (4) to indicate on the LCD display. (d) TEMPERATURE CONTROL INDICATION (B) Push the AIR VOLUME SELECTOR SWITCH (3) for required air volume.
  • Page 650 11. AIR CONDITIONER (4) To defrost on the windscreen : DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) BLOW OUT OPENING TEMPERATURE AIR VOLUME SELECTOR SWITCH (6) CONTROL SWITCH (4) SELECTOR SWITCH (3) (A) Push the TEMPERATURE CONTROL SWITCH (4) to indicate (d) on the LCD display.
  • Page 651 11. AIR CONDITIONER (5) To defog on the windscreen : DEFROSTER SWITCH (7) IN-OUT AIR SELECTOR SWITCH (5) BLOW OUT OPENING AIR VOLUME SELECTOR SWITCH (6) SELECTOR SWITCH (3) (A) Push the AIR VOLUME SELECTOR SWITCH (3) for required air volume. (B) Push the DEFROSTER SWITCH (7) to change the blow out opening to DEF position (c).
  • Page 652 11. AIR CONDITIONER This page is blank for editing convenience. 10000A-1 11-10 Published 10-09-13, Control #218-02...
  • Page 653 11. AIR CONDITIONER 11.2 PARTS ILLUSTRATION 11-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 654 11. AIR CONDITIONER 10000A-1 11-12 Published 10-09-13, Control #218-02...
  • Page 655 11. AIR CONDITIONER 1. EVAPORATOR 21. LEVER (MO2) 41. FAN DRIVER 2. ACTUATOR 22. MODE CAM 42. UPPER BLOWER CASE 3. OUT AIR INTAKE PACKING 23. ROD AC 43. LOWER BLOWER CASE 4. FRONT UNIT CASE 24. AM ROD 44. BLOWER PACKING 5.
  • Page 656 11. AIR CONDITIONER 11.3 DISASSEMBLY AND ASSEMBLY OF THE UNIT 11.3.1 REMOVAL OF THE BLOWER UNIT 1. Remove the various connectors attached to the in- out air motor actuator, blower motor and blower IN-OUT AIR MOTOR ACTUATOR CONNECTOR controller and harnesses attached to the blower case.
  • Page 657 11. AIR CONDITIONER 11.3.2 REPLACING THE BLOWER MOTOR 1. Remove the coolant hose coolant between the BLOWER CASE blower motor and the blower case. 2. Remove three of the cross head screw (Phillips) N5 X 16 (W) which are tightened from under the blower unit case and pull the blower unit out.
  • Page 658 11. AIR CONDITIONER 11.3.5 REMOVAL OF THE AIR-CON UNIT CASE-FRONT AND- REAR 1. Remove the mode motor actuator and the evaporator sensor connector. UNIT CASE REAR 2. Remove the mode rod from the rod holder which is installed on the lever MAL1 of the mode motor MODE ROD actuator.
  • Page 659 11. AIR CONDITIONER 11.3.6 REPLACING THE EVAPORATOR AND EXPANSION VALVE 1. Pull out the evaporator assy from the case-lower with the case insulation material and the expansion EVAPORATOR valve attached. 2. After the evaporator assy is removed, then pull out O-RING the evaporator sensor and sensor holder as one EXPANSION...
  • Page 660 11. AIR CONDITIONER 11.3.8 REPLACING THE MOTOR ACTUATOR 1. REPLACING THE MODE MOTOR ACTUATOR MODE ROD Remove the connector of the motor actuator. UNIT CASE REAR Remove the mode rod which connects the motor actuator and the mode cam from the rod holder. Remove three of the cross head screw (Phillips) N4 X 30 (T1) which hold the motor actuator and remove the motor actuator from the unit while the...
  • Page 661 11. AIR CONDITIONER 11.4 FAULT DETECTION FROM THE CONTROL PANEL INDICATION 11.4.1 GENERAL When there is any fault in the input circuit of the controller of the motor actuator drive line or each sensor, fault detection is indicated. Once the fault is detected, fault detection is not reset even the fault returns to normal.
  • Page 662 11. AIR CONDITIONER 11.5 BASIC SYSTEM OF HVAC This is the built in type air con. unit with evaporator, heater core and blower as one package and generate cool and warm air. 1. AIR CYCLE • HEATER The unit takes internal air of the cab or open air from the intake port and have them passed through the air filter and send them to the heater core of the air conditioner unit to exchange heat and send the...
  • Page 663 11. AIR CONDITIONER 3. FAN DRIVER The fan driver receives the control signal from the control unit and control the fan motor speed. NORMAL CONDITION TERMINAL NO. CONTINUITY – YES (4.7 k ± 5%) TESTER – – YES (DIODE PARALLEL FORWARD DIRECTION) (1) Remove the connector of the blower amplifier.
  • Page 664 11. AIR CONDITIONER 7. INSPECTION POINTS OF THE RELAY (1) RELAY (2) COIL RESISTANCE : 320 (3) VOLTAGE : DC20 V to 30 V (4) Note : This relay has coil polarity. (5) Inspection : Check the continuity between the terminal 3 to 4 under the following condition.
  • Page 665 11. AIR CONDITIONER 10. BLOW OUT MODE ACTUATOR The blow out mode actuator is installed in the back side of the air conditioner unit and opens or closes the blow out damper through the linkage. The bow out mode actuator has the potentiometer in its inside which is controlled by the shaft movement of the actuator.
  • Page 666 11. AIR CONDITIONER 12. DUAL PRESSURE SWITCH The dual pressure switch is installed in the receiver dryer and protect the cooling cycle by opening its contact and cutting the power supply to the compressor when the high pressure side of cooling becomes malfunction (high pressure faulty, low pressure faulty).
  • Page 667 11. AIR CONDITIONER 11.6 RECHARGING OF THE COOLANT 11.6.1 CAUTION AT WORK 1. Make sure that the work is done by the specialist. Recharging work consist of high pressure gas handling. Make sure that the work is done with the specialist who is familiar with the work.
  • Page 668 11. AIR CONDITIONER (5) Flaw, indent mark or deformation may decrease the strength of the bottle. Be careful on this point. (A) Do not drop or hit the bottle. (B) Take care in loading, transporting and unloading the bottles or packing case containing the bottles. Handle with care and do not drop or throw them.
  • Page 669 11. AIR CONDITIONER 11.6.2 WORK PROCEDURE 1. Recharging work of the coolant into the air conditioner is divided into "Vacuuming work" and "Gas recharging work". (1) "Vacuuming work" is to delete the water in the air conditioner piping completely. Even a slight amount of water is left in the piping, it will be frozen in the small holes in the expansion valve during the operation and may cause piping clogged or rust inside the piping or other trouble.
  • Page 670 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 10000A-1 11-28 Published 10-09-13, Control #218-02...
  • Page 671 11. AIR CONDITIONER 11.6.3 RECHARGING PROCEDURE VACUUMING WORK 1. CONNECTION OF GAUGE MANIFOLD HIGH PRESSURE LOW PRESSURE GAUGE GAUGE (1) Close the high pressure valve (HI) and low GAUGE MANIFOLD pressure valve (LO) of the gauge manifold. LOW PRESSURE HIGH PRESSURE (2) Connect the charging hose (Red and Blue) to the VALVE (CLOSE) VALVE (CLOSE)
  • Page 672 11. AIR CONDITIONER 2. VACUUMING LOW PRESSURE (CLOSE) (1) Open the high pressure valve (HI) and low pressure VALVE (OPEN) valve (LO) of the gauge manifold. HIGH PRESSURE 30 minutes (CLOSE) VALVE (OPEN) or more (2) Turn ON the switch of the vacuum pump and continue vacuuming work for more that 30 minutes.
  • Page 673 11. AIR CONDITIONER GAS RECHARGING WORK 1. RECHARGE FROM THE HIGH PRESSURE SIDE (1) Disconnect the charging hose (yellow) of the gauge manifold from the vacuum pump and reconnect it to AIR PURGE the service bottle after the vacuum pump is CLOSE completed.
  • Page 674 11. AIR CONDITIONER 3. CHARGING FROM THE LOW PRESSURE SIDE (1) Make sure that the valves for high pressure side, low pressure side and service bottle are all closed. LOW PRESSURE HIGH PRESSURE VALVE (CLOSE) VALVE (CLOSE) (2) Start the engine and set the speed to 1400 to 1600 (CLOSE) (OPEN) (Close firmly)
  • Page 675 11. AIR CONDITIONER 4. GUIDEPOST OF RECHARGING COOLANT AMOUNT • JUDGEMENT FROM SIGHT GLASS VIEW OF THE RECEIVER DRYER JUDGEMENT FROM SIGHT GLASS VIEW OF THE RECEIVER DRYER IN CASE OF After A/C turned on, bubbles appear a little, hereafter PROPER CHARGE it becomes transparent, and shows milk-white.
  • Page 676 11. AIR CONDITIONER This page is blank for editing convenience. 10000A-1 11-34 Published 10-09-13, Control #218-02...
  • Page 677 11. AIR CONDITIONER 11.7 ELECTRIC WIRING DIAGRAM YAZAKI YAZAKI FUSE YAZAKI YAZAKI FUSE FUSE FUSE FUSE YAZAKI PRESSURE SWITCH (RECEIVER DRYER) EVAPORATOR SENSOR YAZAKI BLOWER OFF RELAY COMPRESSOR MOTOR ACTUATOR (AIR MIX) BLOWER MOTOR MOTOR ACTUATOR CONDENSOR FAN MOTOR RELAY (MODE) RATED : 24V 10A BLOWER AMPLIFIER MOTOR ACTUATOR...
  • Page 678 11. AIR CONDITIONER This page is blank for editing convenience. 10000A-1 11-36 Published 10-09-13, Control #218-02...
  • Page 679 12. TROUBLESHOOTING 12-1 10000A-1 Published 10-09-13, Control #218-02...
  • Page 680 12. TROUBLESHOOTING 10000A-1 12-2 Published 10-09-13, Control #218-02...
  • Page 681 12. TROUBLESHOOTING 12.1 TROUBLESHOOTING What actions should be taken upon occurrence of these problems ? 12-3 10000A-1 Published 10-09-13, Control #218-02...
  • Page 682 12. TROUBLESHOOTING 10000A-1 12-4 Published 10-09-13, Control #218-02...
  • Page 683 12. TROUBLESHOOTING 12-5 10000A-1 Published 10-09-13, Control #218-02...
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  • Page 685 12. TROUBLESHOOTING 12-7 10000A-1 Published 10-09-13, Control #218-02...
  • Page 686 12. TROUBLESHOOTING 10000A-1 12-8 Published 10-09-13, Control #218-02...
  • Page 687 12. TROUBLESHOOTING 12-9 10000A-1 Published 10-09-13, Control #218-02...
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  • Page 689 12. TROUBLESHOOTING 12-11 10000A-1 Published 10-09-13, Control #218-02...
  • Page 690 12. TROUBLESHOOTING 10000A-1 12-12 Published 10-09-13, Control #218-02...
  • Page 691 12. TROUBLESHOOTING 12-13 10000A-1 Published 10-09-13, Control #218-02...
  • Page 692 12. TROUBLESHOOTING 10000A-1 12-14 Published 10-09-13, Control #218-02...

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10000a-1