MODEL BOOK No. LBCE SERIAL No. 1059 CRANE SERIAL NUMBER The crane serial number is on the Crane Rating Manual located inside the operator’s cab. The serial number should always be furnished when ordering parts for the crane or when corresponding with the distributor or factory concerning the crane. Providing the serial number is the only way of ensuring the correct parts and/or information can be furnished. In the event the serial number is not readable, a number is stamped on the upper revolving frame which can be used to identify the crane. This number is located on the front face of the upper frame, between the boom foot mounting lugs. 218 HSL Link-Belt Construction Equipment Company
Transcript
MODEL
BOOK No.
LBCE SERIAL No.
1059
CRANE SERIAL NUMBERThe crane serial number is on the Crane Rating Manual located inside the operator’s cab. Theserial number should always be furnished when ordering parts for the crane or whencorresponding with the distributor or factory concerning the crane. Providing the serialnumber is the only way of ensuring the correct parts and/or information can be furnished.
In the event the serial number is not readable, a number is stamped on the upper revolvingframe which can be used to identify the crane. This number is located on the front face of theupper frame, between the boom foot mounting lugs.
218 HSL
Link-Belt Construction Equipment Company
This Page Left Blank Intentionally
BOOK1059 N6072508 Page 1 of 4
General Information and Manual Layout
This manual is divided into 3 Sections separated by Tabs.
The front Section is the Workshop Instruction portion of the manual. It contains the removal/installation (R&I) and the assembly/disassembly (Recondition) instructions for major crane components. These pages are coded with a “W” in front of the Section/Group/Page numbers. Example, the pages coded/numbered W2-4-1 through W2-4-64, contain the instructions for R&I and Recondition of the main pump. (Code W2-4-1 identifies a page in the Workshop Instruction Manual, Section 2, Group 4, and Page 1.)There are “Contents” pages at the beginning of each sub-section, in front of pages W1-1-1, W2-1-1, and W3-1-1.
The 2nd and 3rd Sections are the Principles of Operation/Specifications and Troubleshooting portions of the manual. These pages are coded with a “T” in front of the Section/Group/Page numbers. Example, the pages coded/numbered T1-3-1 through T1-3-4, contain the specifications for the engine and engine accessories. The Section behind Tab 1 contains the specifications and how main components operate to perform their intended functions. (Code T1-3-1 identifies a page in the Principles of Operation/Specifications/Troubleshooting Manual, Section 1, Group 3, and Page 1.) There are “Contents” pages at the beginning of each sub-section, in front of pages T1-2-1, T2-1-1, and T3-1-1. The Section behind Tab 2 contains Performance Tests/Standards and Troubleshooting for major components. There are “Contents” pages at the beginning of each sub-section, in front of pages T4-1-1 and T5-1-1.
Page 2 of 4
Terms/Terminology, Nomenclature, and Abbreviations
The following terms/terminology, nomenclature, and abbreviations are given to help identify common terms/terminology, nomenclature, and abbreviations used in this manual that, due to language translations, may not be easily understood.
Auxiliary Hoisting Mechanism = Auxiliary Winch Assembly / Winch Drum Boom Pendant Rope = Boom Pendants Center Joint = Rotating Joint Crawler Shoe = Track Shoe Derricking = Boom Hoist Derricking Drum = Boom Hoist Drum Derricking Mechanism = Boom Hoist System Derricking Motor = Boom Hoist Motor Drive Tumbler = Travel Drive Sprocket Hoisting Drum = Winch Drum Hoisting Drum Control Valve = Winch Drum Control Valve Hoisting Mechanism = Winch Assembly / Winch Drum Hoisting Motor = Winch Motor Pump Mechanism = Pump Assembly Screwed-In Connection = Threaded Connection Slewing = Swing Slewing Frame = Upper Revolving Frame Slewing Mechanism = Swing Reduction Unit Slewing Motor = Swing Motor Slewing Pump = Swing Pump Slewing Ring = Turntable Bearing Stopper = Plug Take-Up Tumbler = Track Take-Up Idler Travel Mechanism = Travel Motor and Reduction Gears Upperstructure = Crane Upper
Page 3 of 4
Conversion Tables
Length Conversion Table
millimeter, mm centimeter, cm meter, m inch, in., " foot, ft., ' 1
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for cor-rect product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this man-ual. (Note: Do not tear off the form. Copy it for us-age.):
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual • The Parts Catalog
• Operation Manual of the Engine • Parts Catalog of the Engine
PAGE NUMBER
Each page has a number, located on the center lower part of the page, and each number contains the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual
INTRODUCTION
IN-02
SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.
This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri-ate lifting techniques and equipment when lifting heavy parts.
CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.
IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.
NOTE: Indicates supplementary technical information or know-how.
UNITS USED
SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposees.
Quantity To Convert From Into Multiply By
MPa kgf/cm2 10.197 Pressure MPa psi 145.0 kW PS 1.360 Power kW HP 1.341
Temperature C F C 1.8+32 km/h mph 0.6214 Velocity min-1 rpm 1.0
Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0
Quantity To Convert From Into Multiply By
mm in 0.03937 Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057
Volume
m3 yd3 1.308 Weight kg lb 2.205
N kgf 0.10197 ForceN lbf 0.2248
N m kgf m 1.0197 Torque N m lbf ft 0.7375
SAFETY
S-1
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
•When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
•Follow recommended precautions and safe operating practices.
001-E01A-0001-2SA-001
UNDERSTAND SIGNAL WORDS
On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.
•DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
•WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
•CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
•DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this manual.
To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.
NOTE indicates an additional explanation for an ele-ment of information.
002-E01A-0461-6
SA-1223
SAFETY
S-2
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine and all safety messages in this manual.
Safety signs should be installed, maintained and re-placed when necessary.
•If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).
Learn how to operate the machine and its controls cor-rectly and safely.
Allow only trained, qualified, authorized personnel to operate the machine.
Keep your machine in proper working condition.
•Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.
The safety messages in this SAFETY chapter are in-tended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operat-ing or performing maintenance work on the machine.
003-E01B-0003-5
SA-003
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or if an accident occurs.
•Keep a first aid kit and fire extinguisher on hand.
•Thoroughly read and understand the label attached on the fire extinguisher to use it properly.
•Establish emergency procedure guidelines to cope with fires and accidents.
•Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.
004-E01A-0437-3
SA-437
SAFETY
S-3
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appro-priate to the job.
You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the job. Do not take any chances.
•Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.
005-E01A-0438-4
SA-438
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss of hearing.
•Wear a suitable hearing protective mechanism such as earmuffs or earplugs to protect against objection-able or uncomfortably loud noises.
006-E01A-0434-2
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
•In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter.
007-E01A-0435-2
SA-435
SAFETY
S-4
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
•When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.
•Do not use any controls as handholds.
•Never jump on or off the machine. Never mount or dismount a moving machine.
•Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
008-E01A-0439-3
SA-439
ADJUST THE OPERATOR’S SEAT
A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.
•The seat should be adjusted whenever changing the operator for the machine.
•The operator should be able to fully depress the ped-als and to correctly operate the control levers with his back against the seat back.
•If not, move the seat forward or backward, and check again.
009-E01A-0464-3
SA-464
SAFETY
S-5
FASTEN YOUR SEAT BELT (IF EQUIPPED)
If the machine should overturn, the operator may be-come injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning ma-chine, resulting in serious injury or death.
•Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or compo-nent before operating the machine.
•Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.
•We recommend that the seat belt be replaced every three years regardless of its apparent condition.
010-E02B-0237-3
SA-237
OPERATE ONLY FROM OPERATOR’S SEAT
Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.
•Start the engine only from the operator’s seat.
•NEVER start the engine while standing on the crawler shoe or on ground.
•Do not start engine by shorting across starter termi-nals.
•Before starting the engine, confirm that all control lev-ers are in neutral.
012-E01B-0444-3
SA-444
SAFETY
S-6
JUMP STARTING
Battery gas can explode, resulting in serious injury.
•If the engine must be jump-started, be sure to follow the instructions shown in the “OPERATING THE EN-GINE” chapter.
•The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump-starting is a two-person operation.
•Never use a frozen battery.
•Failure to follow correct jump starting procedures could result in a battery explosion or a runaway ma-chine.
013-E01A-0032-3
SA-032
SAFETY
S-7
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body, se-rious injury may result.
•Guard against injury from flying pieces of metal or de-bris; wear goggles or safety glasses.
•Keep bystanders away from the working area before striking any object.
031-E01A-0432-2
SA-432
SAFETY
S-8
PARK MACHINE SAFELY
To avoid accidents:
•Park machine on a firm, level ground.
•Lower the boom to the ground.
•In a work site where the boom cannot be lowered to the ground, secure the boom using guy ropes so as to minimize the wind effect on the boom,
•Run the engine at slow idle for five (5) minutes to cool the engine down.
•Engage all brake and drum locks. Shutdown the engine.
•Remove the key from the key switch. Lock the cab and all access doors.
033-E04A-0470-3
HANDLE FLUIDS SAFELY AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel ig-nites, an explosion and/or a fire may occur, possibly re-sulting in serious injury or death.
•Do not refuel the machine while smoking or when near open flame or sparks.
•Always shutdown the engine before refueling the ma-chine.
•Fill the fuel tank outdoors.
All fuels, most lubricants, and some coolants are flam-mable.
•Store flammable fluids well away from fire hazards.
•Do not incinerate or puncture pressurized containers.
•Do not store oily rags; they can ignite and burn spon-taneously.
034-E01A-0496-4
SA-018
SA-019
SAFETY
S-9
SAFE TRANSPORTATION
The danger of tipping is present when loading/unloading machine onto/from a truck or trailer bed.
•Be sure to observe local regulations when transporting the machine on public roads.
•Be sure to have a signal person when loading/unload-ing the machine.
•Provide an appropriate trailer for transporting the ma-chine.
Take the following precautions when loading/unloading the machine:
1) Select firm, level ground.
2) Be sure to use a loading dock or ramp.
3) When using a loading ramp, use one which has antislip bands on the surface.
4) Drive the machine at very slow speed.
5) Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is un-avoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.
6) Do not operate any levers besides the travel lev-ers when driving up or down the ramp.
7) The top of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.
8) Securely fasten chains or cables to the machine frame.
035-E03A-0475-
SA-475A
TOWING MACHINE
When towing the machine, be sure to attach tow wire ropes around the lower frames as illustrated. To prevent the wire ropes from being damaged, place protective material between the lower frames and the wire ropes.
061-E01A-0605-2 SA-605
Less than 15
Pulling Rope
SAFETY
S-10
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is mov-ing.
• Keep hands, feet and clothing away from power-driven parts.
• Before servicing the machine:
1) Park machine on a solid, level surface.
2) Lower the boom to the ground. If the boom cannot be fully lowered, secure the boom with guy ropes to prevent the boom from being blown by wind.
3) Run the engine at slow idle speed without load for 5 minutes.
4) Apply all brakes and locks.
5) Turn the key switch to OFF to shutdown engine.
6) Remove the key from the switch.
7) Move the pilot shut-off lever to the LOCK position.
8) Attach a “Do Not Operate” tag on the cab door.
• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.
• Securely support any machine elements that must be raised for service work. If the machine must be raised, place supporting blocks under the frame.
• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris.
• Disconnect battery ground cable (–) before making adjustments to electrical systems or before perform-ing welding on the machine.
500-E07A-0497-8
SA-028
SA-527
SAFETY
S-11
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious in-jury.
• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.
501-E01A-0287-2 SA-287
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without securing the machine first.
• Always lower the attachment to the ground before you work on the machine.
• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.
519-E01A-0527-3
SA-527
STAY CLEAR OF MOVING PARTS
Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not be-come entangled when working around rotating parts.
502-E01A-0026-2
SA-026
SAFETY
S-12
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under pres-sure. Hot water or steam is contained in the engine, ra-diator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.
• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be release before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.
Hot fluids and surfaces:
Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting any maintenance or inspection work.
505-E01B-0498-5
SA-039
SA-225
REPLACE RUBBER HOSES PERIODICALLY
Rubber hoses that contain flammable fluids under pres-sure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspec-tion alone.
• Periodically replace the rubber hoses.
Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.
506-E01A-0019-3
SA-019
SAFETY
S-13
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.
• Avoid this hazard by relieving pressure before dis-connecting hydraulic or other lines.
• Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.
507-E01A-0499-5
SA-031
SA-292
SA-044
NEVER ATTEMPT TO MODIFY SAFETY MECHANISM, HYDRAULIC COMPONENTS, OR ELECTRICAL WIRING
Incorrect modification or adjustment may cause acci-dent.
• Do not modify or adjust the preadjusted parts of hy-draulic components or safety mechanism. If read-justment or modification is required, consult your au-thorized dealer.
Alternation on electrical wiring may cause fire.
• If modification or alternation of electrical wiring is re-quired, consult your authorized dealer.
520-E01A-0019-3
SA-019
SAFETY
S-14
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or dam-aged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
Check for Shorts:
Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.
• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, accumu-lated coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flam-mables immediately.
Check Key Switch:
If a fire breaks out, failure to shutdown the engine will escalate the fire, hampering fire fighting.
• Always check key switch function before operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that the engine stops.
• If any abnormalities are found, be sure to repair them before operating the machine.
508-E02B-0019-9
Check Heat Shields:
Damaged or missing heat shields may load to fires.
• Damaged or missing heat shields must be re-paired or replaced before operating the ma-chine.
508-E02B-0019-9
SA-019
SAFETY
S-15
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the follow-ing way:
• Shutdown the engine with turning the key switch to the OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
518-E02A-0393-2
SA-393
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
• If you must operate in a building, be sure there is ade-quate ventilation. Either use an exhaust pipe exten-sion to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
•Be aware of California Proposition 65 Warning which reads “Diesel engine exhaust and some of its con-stituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm”.
509-E01A-0016-2
SA-016
SAFETY
S-16
AVOID HEATING NEAR PRESSURIZED FLUID LINES
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to you and bystanders.
• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable mate-rials.
• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install tem-porary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.
AVOID APPLYING HEAT TO LINES CON-TAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flammable fluids.
• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.
510-E01B-0030-4
SA-030
REMOVE PAINT BEFORE WELDING OR HEATING
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
511-E01A-0029-4
SA-029
SAFETY
S-17
PREVENT BATTERY EXPLOSIONS
Battery gas can explode, resulting in serious injury.
• Keep sparks, lighted matches, and flame away from the top of battery.
• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the battery to 16 C (60 F) first.
• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result
• Loose terminals may produce sparks. Securely tighten all terminals.
Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If splashed in eyes, flush with water for 15 minutes. Get medical attention immediately.
• Be sure to wear eye protection when checking electrolyte specific gravity.
512-E01B-0032-4
SA-032
SAFETY
S-18
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s on chemical products used with your machine.
515-E01A-0309-4
SA-309
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or into any water source.
• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.
516-E01A-0226-4
2BDW-1-1
SECTION 1GENERAL
CONTENTSGroup 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and Assembling ............................................ W1-1-1
Group 2 Tightening Torque Tightening Torque Specification ............... W1-2-1Torque Chart............................................ W1-2-2Piping Joint.............................................. W1-2-5Periodic Replacement of Parts ................ W1-2-9
2BDW-1-2
(Blank)
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-1
PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.
Inspect the Machine Be sure to thoroughly read and understand all disassembling/assembling procedures before starting any repair work. Understanding these procedures will help avoid incorrect disassembling of components as well as the purchasing of unnecessary service parts.
• The machine model, machine serial number, and hour meter reading.
• Reason for disassembly (symptoms, failed parts, and causes).
• Clogging of filters and oil, water or air leaks, if any.
• Capacities and condition of lubricants. • Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.
Precautions for Disassembling • To prevent dirt from entering, cap or plug the
removed pipes. • Before disassembling, clean the exterior of the
components and place it on a work bench. • Before disassembling, drain gear oil from the
reduction gear. • Be sure to provide appropriate containers for
draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when
instructed.• If a part or component cannot be removed after
removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and tag them as necessary.
• Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.
• Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.
• Measure and record the degree of wear and clearances.
Precautions for Assembling • Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or replace it.
• Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.
• Before assembling, coat all inner parts with clean hydraulic oil or gear oil. Especially coat the sliding surfaces with clean hydraulic oil or gear oil.
• Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are clean and dry.
• If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.
• Utilize matching marks when assembling. • Be sure to use the designated tools to assemble
bearings, bushings and oil seals. • Keep a record of the number of tools used for
disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and install of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:
IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result.If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.
Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.
Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes.
• Reposition the front attachment to check hydraulic oil level.
• Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.
W24Y-01-01-001
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-3
Floating Seal Precautions
1. In general, replace the floating seal with a new one.If the floating is to be reused, follow these procedures:
(1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces.
(2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation or hardening.
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.
(1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.
(2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it.
(3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal surface (C) is parallel with the seal mounting bore end face (D) and O-ring (B) as illustrated.
W105-03-05-019
W105-03-05-020
W110-03-05-004
A
B
B
D
b
aa
b
C
Incorrect
Correct
a ba=b
Correct Incorrect
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings safely.
• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slipping.
• Lower the temperature of the lifted load to lower than 100 C (212 F). If unavoidably lifting a load with a temperature of 100 C (212 F) or more, reduce the load weight.
• Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet.
The load may slip. • When required to use more than one sling, use
slings with the same width and length to keep the lifted load balanced.
• When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.
• Avoid using twisted, bound, connected, or hitched slings.
• Do not place any object on twisted or bent slings. (Refer to the right illustration.)
• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.
• Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece.
• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.
• Store the nylon slings indoors so they won't deteriorate with heat, sunlight, or chemicals.
W24Y-01-01-002
W24Y-01-01-003
W162-01-01-009
Correct Eyehole Lifting Method
Incorrect Eyehole Lifting Method
Bent Sling
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-5
CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.
Damaged Appearance
W162-01-01-002
W162-01-01-003
W162-01-01-004
W162-01-01-005
W162-01-01-006
W162-01-01-007
W162-01-01-008
Broken Sewing Thread
Scuffing
Broken Sewing Thread
Fuzz
Broken SewingThread
Separation of Belt
Broken Sewing Thread
Scuffing
Scoring
Broken Warp Fuzz
GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-6
Maintenance Standard Terminology
“Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies
adjusted to specification. Tolerances are indicated as necessary.
“Allowable Limit” 1. Machine cannot operate normally with the parts
exceeding this dimension installed. 2. Repair or adjustment is impossible if this
dimension is exceeded. 3. To maintain high machine availability and to save
the repair expense, the machine parts should be repaired or replaced before reaching the “Allowable Limit.”
GENERAL INFORMATION / Tightening Torque
W1-2-1
TIGHTENING TORQUE SPECIFICATIONSBolts and Nuts of Machine: Standard Tightening Torque Chart
NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients. (2) Remove rust, dirt, and dust before installing fasteners. (3) Apply LOCTITE onto the boom hoist system mounting bolt, boom hoist motor mounting bolt, pump assembly mounting bolt, main pump mounting bolt and gear pump mounting bolt.
GENERAL INFORMATION / Tightening Torque
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolts, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.
SA-040
W157-01-01-001
Specified Tightening Torque Chart T Bolt, Socket Bolt H Bolt M Bolt Bolt
Dia.Wrench
Size HexagonWrench
Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M 8 13 6 30 3.1 22 20 2.0 15 10 1.0 7.4 M 10 17 8 65 6.6 48 50 5.1 37 20 2.0 15 M 12 19 10 110 11.0 81 90 9.2 66 35 3.6 26 M 14 22 12 180 18.5 133 140 14.0 103 55 5.6 41 M 16 24 14 270 27.5 199 210 21.5 155 80 8.2 59 M 18 27 14 400 41.0 295 300 30.5 221 120 12.0 89 M 20 30 17 550 56.0 406 400 41.0 295 170 17.0 125 M 22 32 750 76.5 553 550 56.0 406 220 22.5 162 M 24 36 950 97.0 701 700 71.5 516 280 28.5 207 M 27 41 1400 143 1033 1050 107 774 400 41.0 295 M 30 46 1950 200 1438 1450 148 1069 550 56.0 406 M 33 50 2600 265 1918 1950 200 1438 750 76.5 553 M 36 55 3200 325 2360 2450 250 1807 950 97.0 701
Socket Bolt Hexagon M Bolt Hexagon H BoltHexagon T Bolt
GENERAL INFORMATION / Tightening Torque
W1-2-3
IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients.
(2) Torque tolerance is 10 %. (3) Be sure to use bolts of correct
length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.
(4) The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.
(5) Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
W105-01-01-003
Tighten from center and diagonally
Tighten diagonally Equally tighten upper and lower alternately
1476149126
42
5
31
2,3
1,4
1110325813
GENERAL INFORMATION / Tightening Torque
W1-2-4
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be removed, replace the component.
(2) Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place.
(3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring.
(4) Tighten bolts alternately and diagonally, as shown, to ensure even tightening.
(5) Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.
Nut and Bolt Locking
Lock Plate IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while loosening.
Lock Wire IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the bolt-loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
WRONG
WRONG
WRONGRIGHTRIGHT
Bend along edge sharply
Do not bend it round Bend along edge sharply
RIGHT
Tighten
Loosen WRONG
WRONGRIGHT
RIGHT
RIGHT
GENERAL INFORMATION / Tightening Torque
W1-2-5
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening Torque Specifications
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.
IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.
(2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting.
M202-07-051
W105-01-01-017
Wrench Size Tightening Torque Type Union Nut Joint Body N m kgf m Ibf ft
30 Male Union Joint
17192227323641
17192227323641
24.529.53993
137175205
2.53.04.09.514.018.021.0
18222969101129151
37 Female Union Joint
17192227323641
14171922273236
24.529.53993
137175205
2.53.04.09.514.018.021.0
18222969101129151
Female Union JointMale Union Joint
37
30
Joint Body
1 4 3 5 2
GENERAL INFORMATION / Tightening Torque
W1-2-6
O-Ring Seal Joint
O-ring (6) seats against the end face of adaptor (7) to seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting.
(2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.
(3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage.
(4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.
M104-07-033
Wrench Size Tightening Torque Union Nut Joint Body N m kgf m Ibf ft
19222732364146
17192227
30, 32 3641
29.56993
137175205205
3.07.09.5
14.018.021.021.0
225169
101129151151
7 6 9
8 10Joint Body
GENERAL INFORMATION / Tightening Torque
W1-2-7
Screwed-In Connection
IMPORTANT: Many types of screwed-in connec-tions are used for hose connections.Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.
Seal Tape Application
Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not over wrap.
Application Procedure
Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.
T-Bolt Type Band Clamp: 4.4 N m (0.45 kgf m, 3.25 lbf ft )
Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft )
W105-01-01-018
Male Tapered Thread Wrench Tightening Torque
Joint Body N m kgf m Ibf ft 17, 19 19, 22 27, 22 36, 32
41506070
5998118 235295490670980
6101224305068100
437287134215360490720
W105-01-01-019
M114-07-041
M114-07-042 M114-07-043
Male Straight Thread Male Tapered Thread
ClearanceExternal Thread
Internal Thread
Leave one to two pitch threads uncovered
PT
30
PF
T-Bolt Type Worm Gear Type
GENERAL INFORMATION / Tightening Torque
W1-2-8
Connecting Hose
CAUTION: (1) When replacing hoses, be sure to use
genuine manufacture parts. Using hoses other than genuine manufacture parts may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine.
(2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked.
(3) If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014
RIGHTWRONG
Rubbing Against Each Other
RIGHTWRONG
RIGHTWRONG
Rubbing
Clamp Clamp
WRONG
Rubbing
Clamp
RIGHT
GENERAL INFORMATION / Tightening Torque
W1-2-9
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected through machine operation or visual inspection.
Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.
Part Location Part to be Replaced Q’ty Interval (Hours or Period) Pendant rope
-
Crane: 400 hrs /2 years Bucket, Lifting Magnet (Heavy Duty Work) : 2000 hrs / 2 years
FrontAttachment
Ball bearing (oil less bearing in the hook sleeve) - 2000 hrs / 2 years Winch Ball bearing (boom hoist winch pedestal) 1 2000 hrs / 2 years
Fuel hose (between the fuel tank and filter) - 2000 hrs / 2 years Engine Fuel hose (between the fuel tank and injection
pump)- 2000 hrs / 2 years
IMPORTANT: Each hose has an individual service life. If any abnormalities are found during the regular interval check and/or maintenance service, be sure to replace with a new one.
GENERAL INFORMATION / Tightening Torque
W1-2-10
(Blank)
2BDW-2-1
SECTION 2CRANE UPPER
— CONTENTS — Group1 Cab
Remove and Install Cab..............................W2-1-1Dimensions of the Cab Glass .....................W2-1-9
Group 2 Couterweight Remove and Install Counterweight .............W2-2-1
Group 3 Upper Revolving Frame Remove and Install Upper Revolving Frame........................................................W2-3-1
Group 4 Pump Assembly
Remove and Install Main Pump............... W2-4-1 Disassemble Main Pump ......................... W2-4-4 Assemble Main Pump............................ W2-4-10Maintenance Standard........................... W2-4-16Disassemble Front Regulator ................ W2-4-18Assemble Front Regulator ..................... W2-4-24Disassemble Rear Regulator................. W2-4-28Assemble Rear Regulator ..................... W2-4-34Disassemble Reduction Gear ................ W2-4-40Assemble Reduction Gear ................... W2-4-42Maintenance Standard ......................... W2-4-44Remove and Install Swing Pump ........... W2-4-45 Disassemble Swing Pump ..................... W2-4-48Assemble Swing Pump.......................... W2-4-52Maintenance Standard ......................... W2-4-54Disassemble Regulator ......................... W2-4-56Assemble Regulator .............................. W2-4-62Remove and Install 2-Unit Gear Pump .. W2-4-69 Disassemble 2-Unit Gear Pump ............ W2-4-72Assemble 2-Unit Gear Pump ................. W2-4-74
Remove and Install Gear Pump for HYD. Tagline .................................W2-4-79
Disassemble Gear Pump for HYD. Tagline .................................W2-4-82
Assemble Gear Pump for HYD. Tagline .................................W2-4-84
Group 5 Control Valve Remove and Install Front / Rear 4-Unit
Control Valve.............................................W2-5-1 Disassemble Front / Rear 4-Unit Control
Valve .........................................................W2-5-4Assemble Front / Rear 4-Unit Control
Valve .......................................................W2-5-10Remove and Install 4-Unit Control
Valve .......................................................W2-5-17Disassemble 4-Unit Control Valve ............W2-5-20 Assemble 4-Unit Control Valve ...............W2-5-26
Remove and Install 1-Unit Control Valve .......................................................W2-5-33
Disassemble 1-Unit Control Valve ............W2-5-36 Assemble 1-Unit Control Valve .................W2-5-38Remove and Install Hoisting Drum
Control Valve (Optional) ........................W2-5-41Disassemble Winch Drum Control
Valve ......................................................W2-5-42Assemble Winch Drum Control Valve.......W2-5-46
Group 6 Swing Mechanism Remove and Install Swing Reduction
Unit............................................................W2-6-1Disassemble Swing Reduction Unit............W2-6-4 Assemble Swing Reduction Unit.................W2-6-8 Disassemble Swing Motor ........................W2-6-14Assemble Swing Motor .............................W2-6-18Maintenance Standard ............................W2-6-20
2BDW-2-2
Group 7 Winch Assembly
Remove and Install Front And Rear Winch Assenbly ................................... W2-7-1
Disassemble Winch Assenbly.................. W2-7-8Assemble Winch Assenbly..................... W2-7-12Disassemble Winch Motor ..................... W2-7-18Assemble Winch Motor.......................... W2-7-22Maintenance Standard ......................... W2-7-27Disassemble Regulator ......................... W2-7-30Assemble Regulator .............................. W2-7-32Disassemble Counterbalance Valve ...... W2-7-34 Assemble Counterbalance Valve ......... W2-7-36 Disassemble Brake Unit ........................ W2-7-38Assemble Brake Unit ............................. W2-7-40Remove and Install Fourth Winch
16. Attach a wire rope on the lifting position (M12) (4 places) of the cab (42) head and support it with the crane.
CAUTION: Cab weight: Approx. 230 kg(507lb)
17. Carefully lift the cab (42) not to hit against the rear stand, left stand, right stand and each equipment on the floor plate.
W2BD-02-01-002
W2BD-02-01-004
41
40
42
CRANE UPPER / Cab
W2-1-5
Installation
CAUTION: Cab weight: Approx. 230 kg(507lb)
1. Attach a wire rope onto the lifting position (4 places) on the top of cab (42) and lift it with the crane.
2. Carefully lower cab (42) in order not to touch the rear stand, the left stand, the right stand and other equipments on floor plate.
3. Install bolt (40) and nuts (41) (7 used). : 24 mm : 68.1 to 79.4 N m (6.9 to 8.1 kgf m)
(50 to 59 lbf ft)
4. Tighten and install air conditioner hoses (33) (2 used) to the air conditioner with hose clamps (34) (2 used).
5. Install all connectors (32) of electric wiring for each equipment installed to the cab.
W2BD-02-01-004
W2BD-02-01-002
W2BD-02-01-003
42
41
40
32
32
32
32
34
33 32
CRANE UPPER / Cab
W2-1-6
6. Install cover (36) with bolts (35) (5 used). : 10 mm
7. Tighten and install hoses (38) (2 used) with hose clamp (37). Connect connectors (39) (2 used).
W2BC-02-01-002
W2BC-02-01-003
36
35
3839 37
CRANE UPPER / Cab
W2-1-7
8. Install under covers (28 to 30) in front of the right platform with bolts (31) (13 used).
: 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m)
(30 to 33 lbf ft)
9. Push right stand (21) onto the wall in cab.
10. Tighten bolts (27) (4 used) in right stand (21). : 13 mm
11. Install covers (22 to 24) to the right stand (21) with screws (25) (14 used) and socket bolts (26) (2 used).
: 4 mm
12. Push left stand (10) onto the wall in cab.
13. Tighten bolts (20) (4 used) in left stand (10). : 13 mm
14. Install covers (11 to 13) to left stand (10) with screws (14) (14 used) and socket bolts (15) (2 used).
: 4 mm
15. Install covers (16 to 17) onto the bottom of front display with screws (18) (4 used) and socket bolts (19) (4 used).
: 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m)
(30 to 33 lbf ft)
W2BD-02-01-002
W24X-02-01-004
W24X-02-01-003
21
22
24
23
25
25
25
26
26
27
27
25
10
14
11
14
12
14
13
14
15
16
17
18
19
20
313131
28
2930
CRANE UPPER / Cab
W2-1-8
16. Install covers (3 to 7) behind the seat with screws (8) (19 used) and bolts (9) (4 used).
: 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m)
(30 to 33 lbf ft)
17. Install seat (2) with bolts (1) (4 used). : 13 mm
W2BD-02-01-001
W24X-02-01-001
1 2
8
3
4
5
67
9
8
8
9
8
8
CRANE UPPER / Cab
W2-1-9
DIMENSIONS OF THE CAB GLASS
NOTE: JIS R3211, 3212 or equivalent Unit: mm
W2BC-02-01-001
565.2
857.5
Thickness :6.8 mm
R30
Thickness :4 mm
R5
12.2
466
Thickness : 4 mm
40
312.439.5
R75.9
R5
376.6
498
406.8
Thickness : 4 mm 251.6
R61
Thickness : 4 mm
R61
Thickness : 4 mm
R61
371.2
65.8
648
R61
R53
11
776
Thickness:5 mm
Thickness : 4 mm
R2519
25
25
517.7
810
25 25
469.8
76376340
R75.9
39.5312.4
(134.7)
Thickness : 4 mm
758R61
497.7
897.5
22 22.52626
64
8832
53
R5
122.5
42.5
276.5166
57.5
2222.5
768
558.5
R40
R5
735.9 148.3
840667.7
172.3
186.4
372.6
650.8802.9
264.3
123.2
530
623
R55
604.5
233.5
Thickness: 5 mm
CRANE UPPER / Cab
W2-1-10
(Blank)
CRANE UPPER / Counterweight
W2-2-1
REMOVE AND INSTALL COUNTERWEIGHT
CAUTION: • Never allow the workers enter the space
under the upper frame and the counterweights.
• If the upper frame with the counterweights is rotated without extending the width of the side frames, the machine may tip over.
• Do not hoist a set of counterweights A, R, and L. The slings and lugs may be broken, possibly resulting in falling of the counterweights.
Removal
The counterweight sling wire ropes are provided as follows :
Wire ropes: . 25 mm 2.8 m 2 ropes
The counterweights can be removed by using the counterweight installation/removal cylinders.
Observe the following working conditions for installing and removing counterweights.
1. Place the crane on firm, level ground and position the upper parallel to the side frames.
2. The side frames must be locked in the fully extended position.
NOTE: The "Quick Draw" Self Assembly System can be used to lift and position the counterweights into position for lifting with the counterweight installation/removal cylinders. Refer to "Quick Draw" Self Assembly System of the Operator's Manual.
3. Engage the slewing lock and all lever locks.
Counterweight Weight: kg (lbs)
Counterweight A with cylinders 11,501 (25,360)
Counterweight R (2 pieces) 4,280 (9,440)
Counterweight L (2 pieces) 4,270 (9,420)
Total 28,601 (63,065)
CRANE UPPER / Counterweight
W2-2-2
4. Turn the CTWT Removal / Jacks Select Switch (1) to the "CTWT" position.
5. Turn accelerator dial (2) to the LOW IDLE position.
6. Check that the Lock Lever (3) is in the UNLOCK position.
7. Place the ladder (4) onto the platform (5) of the upper frame rear side.
8. Go up to the platform (5) by the ladder (4).
9. Set the chain (6) to prevent personnel falling accident.
W2BC-02-02-001
W2BC-02-02-002
W2BC-02-02-003
4
5
6
UNLOCK
LOCK
3
Deceleration
Acceleration
1
2
CRANE UPPER / Counterweight
W2-2-3
10. Extend the counterweight installation/removal cylinders until able to turn the cylinder rods (7) for 90 degrees.
11. Position the pins (8) onto the rear of the upper frame.
12. Fully retract the cylinders (9). And then disconnect the ring pins (10) and remove the pins (11) from each side of platform.
13. Lower the counterweights to ground by extending the cylinders (9).
W2BC-02-02-004
W2BC-02-02-005
W2BC-02-02-006
7
8
9
9
4
10 11
CRANE UPPER / Counterweight
W2-2-4
14. Continue to extend the cylinders (9) after counterweight contacts the ground. Tilt cylinders (9) away from machine for clearance.
15. Fully retract the cylinders (9) as storage position.
16. Disconnect the hoses (12) of counterweight installation/removal cylinders from the ports (13) on the rear of the upper frame.
17. Take off the ladder (4).
W2BC-02-02-007
W2BC-02-02-008
12
13
9
CRANE UPPER / Counterweight
W2-2-5
Installation
The counterweights can be installed by using the counterweight installation/removal cylinders.
Observe the following working conditions for installing and removing counterweights.
1. Place the crane on firm, level ground.
2. The side frames must be locked in the fully extended position.
NOTE: The "Quick Draw" Self Assembly System can be used to lift and position the counterweights into position for lifting with the counterweight installation/removal cylinders. Refer to "Quick Draw" Self Assembly System of the Operator's Manual.
3. Place the counterweight "A" (14) and the cylinders (9) on the ground.
4. Position the counterweights "R" (15) and “L” (16) onto the counterweight "A" (14) and connect with the link plates (17) and ring pins (18).
5. Remove the pins (11) and hung them from the brackets (19).
6. Position the crane and/or counterweights so that counterweights can be lifted with the counterweight installation/removal cylinders. Position the upper parallel to the side frames.
W2BC-02-02-009
W2BC-02-02-010
W2BC-02-02-006
9 9
14
17
18
18
16
19
11
15
14
CRANE UPPER / Counterweight
W2-2-6
7. Engage the swing lock and all lever locks.
8. Turn the CTWT Removal / Jacks Select Switch (1) to the "CTWT" position.
9. Turn accelerator dial (2) to the LOW IDLE position.
10. Check that the Lock Lever (3) is in the UNLOCK position.
11. Connect the hoses (12) of counterweight installation/removal cylinders to the ports (13) on the rear of the upper frame.
W2BC-02-02-001
W2BC-02-02-002
W2BC-02-02-008
UNLOCK
LOCK
3
Deceleration
Acceleration
1
2
12
13
CRANE UPPER / Counterweight
W2-2-7
12. Place the ladder (4) onto the platform (5) of the upper frame rear side.
13. Go up to the platform (5) by the ladder (4).
14. Set the chain (6) to prevent personnel falling accident.
15. Fully extend the counterweight installation/removal cylinders by the control switches (20).
W2BC-02-02-006
W2BC-02-02-011
6
5
4
2020
6
CRANE UPPER / Counterweight
W2-2-8
16. Position the pins (21) onto the rear of the upper frame.
17. Retract simultaneously both of the cylinders to lift up the counterweights.
18. Install the pins (11) into the holes and connect the ring pins (10) to fix the counterweights.
19. Extend the cylinders for approx. 3' and turn the cylinder rods (7) for 90 degrees.
W2BD-02-02-001
W2BC-02-02-005
W2BC-02-02-012
7
10 11
21
CRANE UPPER / Counterweight
W2-2-9
20. Fully retract the cylinders as storage position.
W2BC-02-02-004
CRANE UPPER / Counterweight
W2-2-10
(Blank)
CRANE UPPER / Upper Revolving Frame
W2-3-1
REMOVE AND INSTALL UPPER REVOLVING FRAME
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Lower the boom. Remove the (boom) pendants, extension and top section. (As for removal of the (boom) pendants, extension and top section, refer to the Operator's Manual.)
2. Remove the counterweight. As for removal of the counterweight, refer to W2-2 in this section.
3. Disconnect connector (1).
4. Disconnect plugs on the terminal box (2).
5. Remove the live-mast, boom stop and boom.
W2BC-02-03-001
W2BC-02-03-002
1
2
CRANE UPPER / Upper Revolving Frame
W2-3-2
6. Remove the hose in crane upper side only from the rotating joint. (Refer to “REMOVE AND INSTALL ROTATING JOINT” on W3-3 in the following section.)
7. Attach a wire rope onto shackle (3). Install shackle (3) to the boom foot part of upper revolving frame and the mounting position for lower stay in the a-frame.
CAUTION: Crane Upper weight: Approx. 18 t (40000 lb)
8. Level and hold the crane upper by using a wire rope and chain block.
9. Put the matching marks on the outer race of turntable bearing and upper revolving frame.
10. Loosen bolts (4) 10 mm (0.39 in) in the outer race of turntable bearing in both crawler frames, to the direction of center. Do the same procedures in case of rear side. (The illustration is seen from the front.)
: 46 mm
11. Hoist and level the crane upper 10 mm (0.39 in).
12. Remove bolts (4) in the outer race of turntable bearing in both side frames, to the direction of center.
: 46 mm NOTE: As the length of bolt is different (two types),
check each position.
13. Hoist and remove the crane upper.
W2BC-02-03-003
W324-02-03-005
W324-02-03-006
Center
3
4 4
CRANE UPPER / Upper Revolving Frame
W2-3-3
Installation
CAUTION: Crane Upper weight: Approx. 18 t (40000 lb)
1. Level and hoist the crane upper.
2. Clean the mounting surface between upper revolving frame (5) and turntable bearing (6) and apply THREEBOND #1102.
3. Align the matching marks on the outer race of turntable bearing and upper revolving frame. Lower and hold the crane upper.
4. Insert bolt (4) into the outer race of turntable bearing. Install the washer and nut to bolt (4).
5. Tighten all the nuts temporarily. Lower the crane upper completely.
NOTE: As the length of bolt is different (two types), check each position.
6. Tighten the nuts diagonally and alternately. Install the stopper.
: 46 mm : 1200 to 1300 N m
(123 to 133 kgf m, 885 to 959 lbf ft)
7. Install all hoses to the rotating joint. Refer to W3-3 in the following section.)
8. Install the base section. (As for installation of the base section, refer to the Operator's Manual.)
9. Install the backstop. (As for installation of the backstop, refer to the Operator's Manual.)
W324-02-03-005
W324-02-03-006
Center
4 4
6
5
CRANE UPPER / Upper Revolving Frame
W2-3-4
10. Install the live-mast, boom stop and boom.
11. Connect plugs on the terminal box (11).
12. Connect connector (10).
13. Install the counterweight. (Refer to W2-2 in this section.)
14. Install the extension boom, upper boom, and (boom) pendants. (As for installation of the extension boom, upper boom and (boom) pendants, refer to the Operator's Manual.)
W2BC-02-03-001
W2BC-02-03-002
11
10
CRANE UPPER / Pump Assembly
W2-4-1
REMOVE AND INSTALL MAIN PUMP
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
Preparation
1. Shutdown the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Place a container (capacity: approx. 500 L (132 US gal)) under the drain plug (1) and drain off the hydraulic oil with removing the drain plug (1). Install the drain plug (1).
: 19 mm
Removal
1. Remove all hoses, pipes and wire harness from the pump device. Cap the removed hoses.
: 22 mm, 27 mm, 36 mm : 8 mm, 10 mm
2. Attach a wire rope onto the main pump. Hold the main pump.
CAUTION: Main pump weight: Approx. 190 kg (419 lb)
3. Remove bolts (2, 3). Lift main pump with the crane and remove them.
: 24 mm : 17 mm
W24X-02-04-001
W2CM-02-04-001
1
2
3
CRANE UPPER / Pump Assembly
W2-4-2
CAUTION: Swing pump weight: Approx. 45 kg (99 lb)
4. Remove bolt (4). Lift swing pump with the crane and remove them.
: 14 mm
Installation
CAUTION: Swing pump weight: Approx. 45 kg (99 lb)
1. Install swing pump and tighten with bolt (4). : 14 mm : 240 N m (24.5 kgf m, 177 lbf ft)
CAUTION: Main pump weight: Approx. 190 kg (419 lb)
2. Lift the main pump with the crane and install it on the coupling and bracket.
3. Apply LOCTITE onto bolts (2, 3). Install bolts (2, 3). : 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m)
(132 to 143 lbf ft) : 17 mm : 400 N m (41.0 kgf m, 295 lbf ft)
4. Install all hoses, pipes and wire harness to the main pump.
: 22 mm : 39 N m (4.0 kgf m, 29 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18.0 kgf m, 129 lbf ft) : 8 mm : 48 to 50 N m (4.9 to 5.1 kgf m)
(35 to 37 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft)
5. Remove the filler port cover of the hydraulic tank. Fill hydraulic oil to specified level.
W2CM-02-04-001
2
3
4
CRANE UPPER / Pump Assembly
W2-4-3
6. Remove air bleed plug (5) from the top of main pump. Fill hydraulic oil. Install air bleed plug (5). Start the engine and run at low idling speed.
: 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
7. Loosen air bleed plug (5). Release the pressure in the pump.
: 36 mm
8. After releasing the air, tighten the air bleed plug (5) and check each operation at a low idling speed. Check the hydraulic oil level and any oil leakage.
NOTE: In case inserting the bolt into the hole (M6 tap) on cover (61), cover (61) can be removed easily.
CRANE UPPER / Pump Assembly
W2-4-8
W2BD-02-04-001
7
8
11
15
19
2021
22
25
28
30
32
3940
42
44
55
57
40
CRANE UPPER / Pump Assembly
W2-4-9
10. Tap the mounting flange part for support (28) from the pump casing (25) side. Separate support (28) from pump casing (25).
11. Remove plates (30, 32) from pump casing (25).
12. Tap the ends of shafts (7, 57) with using a plastic hammer. Remove shafts (7, 57) from support (28).
13. Remove valve plates (39, 55) from block (42). NOTE: Valve plate (39, 55) may be removed at
step 7.
IMPORTANT: When removing tilt pin (15), use special tool in order not to damage the head of tilt pin (15).As LOCTITE has been applied onto the contacting part between tilt pin (15) and servo piston (22), do not damage servo piston (22).Do not remove bearing (40) unless necessary.As the setting of flow rate changes, do not loosen lock nut (8) and nut (44) in block (42) and support (28).
14. If necessary, remove stoppers (19, 11), servo piston (22) and tilt pin (15) from pump casing (25). Remove bearing (40) from block (42).
IMPORTANT: When tightening servo piston (22) and tilt pin (15), use special tool in order not to damage the head of tilt pin (15) and feedback pin (14). Apply Three Bond #1305N (medium intensity) onto the thread part.
1. Lightly tap and install support (28) to pump casing (25) with using a hammer.
NOTE: When removing servo piston (22), tilt pin (15) and stoppers (19, 11), install them to pump casing (25) first.
2. Place pump casing (25) with the regulator mounting surface facing downward. Install bushing (31) in plate (30) to tilt pin (15). Install plate (30) to support (28).
NOTE: Check if plate (30) can move smoothly by fingers.In case grease is applied onto plate (30) and support (28), shafts (7, 57) can be installed easily.
IMPORTANT: Do not tap shaft (57) with using a hammer.
3. Install bearing (6), spacer (5) and retaining ring (4) onto shaft (57). Install shaft (57) to support (28).
NOTE: Lightly tap the outer ring in bearing (6) with using a plastic hammer and install bearing (6) with using a steel bar completely.
IMPORTANT: Do not damage oil seal (60).4. Secure cover (61) to pump casing (25) with
socket bolt (62). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft)
NOTE: Apply a film of grease to oil seal (60) in cover (61).
5. Assemble the piston cylinder sub assembly (cylinder block (38), piston (33), shoe (34), plate (35), bushing (36) and spring (37)). Align the splines of bushing (36) and cylinder block (38).Insert the piston cylinder sub assembly into pump casing (25).
IMPORTANT: Check the direction of suction and delivery in valve plate (55).
6. Align with pin (46) and install valve plate (55) to block (42).
CRANE UPPER / Pump Assembly
W2-4-14
W2BD-02-04-002
1
2
7
14 15
17
24 25
2941
42
57
16
53
63
1817
18
58
54
CRANE UPPER / Pump Assembly
W2-4-15
IMPORTANT: Check the direction of block (42). (Install block (42) with regulator (58) facing upward and the suction flange facing to left.)
NOTE: Assemble the rear pump first.Insert gear (41) into block (42). Connect gear (41) to the contact spline in drive shaft of shafts (7, 57).
IMPORTANT: Check regulators (16, 58) for the front and rear.
8. Install the swing pump (2) on the support of the rear side and tighten it with the socket bolt (1) and block (63).
: 12 mm : 98 N m (10.0 kgf m, 72 lbf ft)
9. Insert feedback pin (14) in tilt pin (15) into the feedback lever in regulators (16, 58). Install regulators (16, 58) and reduction gear (54).Tighten socket bolts (17, 18) and flange socket (53).
: 6 mm : 29 N m (3.0 kgf m, 21 lbf ft) : 12 mm : 33 N m (3.4 kgf m, 24 lbf ft)
10. Install plug (24). : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
CRANE UPPER / Pump Assembly
W2-4-16
MAINTENANCE STANDARD
1. Clearance between piston outer diameter and cylinder inner bore.
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Put the rubber plate or cloth on the workbench in order not to damage the parts.As the parts are small, do not lose the parts.
1. Select the place to disassemble. NOTE: Select the clean place.
2. Remove any dust and rust from the regulator surface with using the washing oil.
IMPORTANT: Do not lose O-ring (54).3. Remove socket bolts (36, 37). Remove the
regulator from the pump. : 6 mm
IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) are installed to cover (43). As the setting flow rate changes, do not loosen the screw and nut.
4. Remove socket bolt (30) and remove cover (43). : 5 mm
5. After removing cover (43) subassembly, remove springs (9, 10) and spring seat (8) from the compensating part. Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part.
NOTE: Adjusting rod (13) can be removed with using the bolt (M4) easily.
6. Remove socket bolts (30, 58). Remove cover (57).Remove set spring (25) from the pilot part after removing cover (57).
: 5 mm
IMPORTANT: When removing retaining ring (28), return spring (26) flies out. Do not lose return spring (26).
7. Remove retaining ring (28). Remove spring seat (27), return spring (26) and sleeve (23).
NOTE: Retaining ring (24) is installed to sleeve (23).
8. Remove retaining ring (50) and remove plugs (48, 51).
NOTE: Plugs (48, 51) can be easily removed with using the bolt (M6).
CRANE UPPER / Pump Assembly
W2-4-22
W2CH-02-04-001
56
7
16
1719
2021
22
29
16
3031
30
30
CRANE UPPER / Pump Assembly
W2-4-23
IMPORTANT: Do not remove pin (16).9. Remove the lever (17). NOTE: The lever can be easily removed by using a
pair of tweezers.
10. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with
using a thin steel bar in order not to touch with lever (21).
IMPORTANT: Do not remove pin (16).11. Remove lever (21).
12. Remove piston (29) and spool (22).
13. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of
casing (5) and remove casing (5).
14. Remove the socket bolt (30) and remove the cover (31).
1. Install rod (7) into the compensating hole on casing (46).
2. Install pin (16) to lever (21). Insert pin (16) into the groove of rod (7). Install pin (47) to casing (46).Install lever (21) into pin (47).
IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (46) smoothly.Check the direction of spool (22).
W25N-02-04-011
3. Install spool (22) and sleeve (23) into the spool hole on casing (46).
IMPORTANT: Check the direction of feedback lever (20).
W25N-02-04-012
4. Install feedback lever (20). Align the pin hole on feedback lever (20) and insert pin (19).
NOTE: In case inserting pin (19) into feedback lever (20) a little first, install easily.
5. Install piston (29) into the hole for negative control on casing (46).
NOTE: Check if piston (29) moves smoothly.
6. Install pin (16) to lever (17). Insert pin (16) into the groove of piston (29). Install lever (17).
IMPORTANT: Check the holes for plugs (48, 51).7. Install pin (47) to plug (48). Align pin (47) with the
pin hole on lever (17) and install plug (48). Install retaining ring (50).
8. Insert plug (51). Install retaining ring (50). NOTE: Check if feedback lever (20) has too big
play or moves smoothly.
9. Install return spring (26) and spring seat (27) to the spool hole. Install retaining ring (28).
2022
Lever (21) Side Lever (17) Side (Plugs (48, 51) Side)
CRANE UPPER / Pump Assembly
W2-4-26
W25N-02-04-010
5 6
8
9 10
11
13
14
15
25
30
39
4041
43 44
45
57
58
30
41
CRANE UPPER / Pump Assembly
W2-4-27
10. Install set spring (25) to the spool hole and install piston (6) and casing (5) to the compensating hole.Tighten cover (57) with socket bolts (58, 30).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
IMPORTANT: Check the direction of spring seat (15).
11. Install spring seat (15), spring (14) and adjusting rod (13) to the pilot hole. Install spring seat (8) and springs (10, 9) to the compensating hole.
12. Install adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) to cover (43). Install cover (43) and tighten socket bolt (30).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
13. Install the cover (31) and tighten the socket bolt (30).
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Put the rubber plate or cloth on the workbench in order not to damage the parts.As the parts are small, do not lose the parts.
1. Select the place to disassemble. NOTE: Select the clean place.
2. Remove any dust and rust from the regulator surface with using the washing oil.
IMPORTANT: Do not lose O-ring (55).3. Remove socket bolts (36, 37). Remove the
regulator from the pump. : 6 mm
IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (45), nut (41) and setscrew (46) are installed to cover (43). As the setting flow rate changes, do not loosen the screw and nut.
4. Remove socket bolt (44) and remove cover (43). : 5 mm
5. After removing cover (43) subassembly, remove springs (9, 10) and spring seat (8) from the compensating part. Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part.
NOTE: Adjusting rod (13) can be easily removed with using the bolt (M4).
6. Remove socket bolts (44,59). Remove cover (58).Remove set spring (25) from the pilot part.
: 5 mm
IMPORTANT: When removing retaining ring (28), return spring (26) flies out. Do not lose return spring (26).
7. Remove retaining ring (28). Remove spring seat (27), return spring (26) and sleeve (23).
NOTE: Retaining ring (24) is installed to sleeve (23).
8. Remove retaining ring (51) and remove plugs (49, 52).
NOTE: Plugs (49, 52) can be easily removed with using the bolt (M6).
CRANE UPPER / Pump Assembly
W2-4-32
W2CH-02-04-002
56
7
16
1719
2021
22
29
3031
16
35
CRANE UPPER / Pump Assembly
W2-4-33
IMPORTANT: Do not remove pin (16).9. Remove the lever (17). NOTE: The lever can be easily removed by using a
pair of tweezers.
10. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with
using a thin steel bar in order not to touch with lever (21).
IMPORTANT: Do not remove pin (16).11. Remove lever (21).
12. Remove piston (29) and spool (22).
13. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of
casing (5) and remove casing (5).
14. Remove the socket bolt (30) and remove the valve casing (31).
: 5 mm
15. Remove the solenoid valve (35) from the valve casing (31).
1. Install rod (7) into the compensating hole on casing (47).
2. Install pin (16) to lever (21). Insert pin (16) into the groove of rod (7). Install pin (48) to casing (47).Install lever (21) into pin (48).
IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (47) smoothly.Check the direction of spool (22).
W25N-02-04-011
3. Install spool (22) and sleeve (23) into the spool hole on casing (47).
IMPORTANT: Check the direction of feedback lever (20).
W25N-02-04-012
4. Install feedback lever (20). Align the pin hole on feedback lever (20) and insert pin (19).
NOTE: In case inserting pin (19) into feedback lever (20) a little first, the feedback lever can be easily inserted.
5. Install piston (29) into the hole for negative control on casing (47).
NOTE: Check if piston (29) moves smoothly.
6. Install pin (16) to lever (17). Insert pin (16) into the groove of piston (29). Install lever (17).
IMPORTANT: Check the holes for plugs (49, 52).7. Install pin (48) to plug (49). Align pin (48) with the
pin hole on lever (17) and install plug (49). Install retaining ring (51).
8. Insert plug (52). Install retaining ring (51). NOTE: Check if feedback lever (20) has too big
play or moves smoothly.
9. Install return spring (26) and spring seat (27) to the spool hole. Install retaining ring (28).
2022
Lever (21) Side Lever (17) Side (Plugs (49, 52) Side)
CRANE UPPER / Pump Assembly
W2-4-38
W2CM-02-04-005
14
4631
444430
59411315
25
58
5 6 9 10
11
404139
45438
35
CRANE UPPER / Pump Assembly
W2-4-39
10. Install set spring (25) to the spool hole and install piston (6) and casing (5) to the compensating hole.Tighten cover (58) with socket bolts (59, 44).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
IMPORTANT: Check the direction of spring seat (15).
11. Install spring seat (15), spring (14) and adjusting rod (13) to the pilot hole. Install spring seat (8) and springs (10, 9) to the compensating hole.
12. Install adjusting screws (39, 40), adjusting rod (11), lock nut (45), nut (41) and setscrew (46) to cover (43). Install cover (43) and tighten socket bolt (44).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
13. Install the solenoid valve (35) on the valve casing (31).
: 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m)
(29 to 36 lbf ft)
14. Install the valve casing (31) and tighten the socket bolt (30).
1. Install gear (15) and ball bearing (14) to casing (17). Install retaining ring (13).
2. Install gear (4), bearing (3) and spacer (1) to casing (17). Insert shaft (6). Install retaining ring (5).
3. Install the O-ring (7) and reduction gear to the valve block in main pump. Tighten flange socket (18).
: 12 mm : 33 N m (3.4 kgf m, 24 lbf ft)
4. Install the plate (11) and O-ring (12) on the reduction gear.
5. Install the cover (9) and O-ring (10) on the reduction gear and tighten the socket bolt (8).
: 8 mm : 33 N m (3.4 kgf m, 24 lbf ft)
6. Install the 2-unit gear pump and O-ring (10) on the reduction gear and tighten the socket bolt (21) with LOCTITE applied.
: 8 mm : 22 to 28 N m (2.2 to 2.9 kgf m)
(16 to 21 lbf ft)
7. Install plug (20) and O-ring (19) to casing (17). : 36 mm : 74 N m (7.5 kgf m, 55 lbf ft)
CRANE UPPER / Pump Assembly
W2-4-44
MAINTENANCE STANDARD
Replacement Standard for Wear Parts
Replace the parts when the pitting (beyond 1 mm (0.039 in) a pit, beyond 5 % on the rate of area) occurs in tooth of gears (4, 15). In case the pitting does not occur and the damage on general view is found, replace the parts.
CRANE UPPER / Pump Assembly
W2-4-45
REMOVE AND INSTALL SWING PUMP
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
Preparation
1. Shutdown the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Place a container (capacity: approx. 500 L (132 US gal)) under the drain plug (1) and drain off the hydraulic oil with removing the drain plug (1). Install the drain plug (1).
: 19 mm
Removal
1. Remove all hoses, pipes and wire harness from the pump device. Cap the removed hoses.
: 22 mm, 27 mm : 10 mm
2. Attach a wire rope onto the swing pump. Hold the swing pump.
CAUTION: Swing pump weight: Approx. 45 kg (100 lb)
3. Remove bolts (2, 3). Lift swing pump with the crane and remove them.
: 24 mm : 14 mm
W24X-02-04-001
W2CM-02-04-008
1
2
3
CRANE UPPER / Pump Assembly
W2-4-46
Installation
CAUTION: Swing pump weight: Approx. 45 kg (100 lb)
1. Lift the swing pump and install it on the main pump and bracket.
2. Install the swing pump mounting bolt (2) bolt (3) with LOCTITE applied.
: 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m)
(132 to 143 lbf ft) : 14 mm : 240 N m (24.5 kgf m, 177 lbf ft)
3. Install all hoses, pipes and wire harness to the swing pump.
: 22 mm : 39 N m (4.0 kgf m, 29 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft)
4. Remove the filler port cover of the hydraulic tank. Fill hydraulic oil to specified level.
5. Remove air bleed plug (4) from the top of main pump. Fill hydraulic oil. Install air bleed plug (4). Start the engine and run at low idling speed.
: 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
6. Loosen air bleed plug (4). Release the pressure in the pump.
: 36 mm
7. After releasing the air, tighten the air bleed plug (4) and check each operation at a low idling speed. Check the hydraulic oil level and any oil leakage.
: 6 mm NOTE: Refer to the corresponding section as for
disassembly of regulator (18).
5. Loosen socket bolt (33) that connects support (32), pump casing (27) and cover (48).
: 14 mm
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the mounting surface for regulator.
6. Place the pump onto the workbench horizontally with the mounting surface for regulator facing downward. Separate pump casing (27) from cover (48).
IMPORTANT: Do not damage the sliding surfaces of cylinder block (42), bushing (40), shoe (38) and plate (34).
7. Remove cylinder block (42) from pump casing (27) straightly. Remove piston (37), plate (39), bushing (40) and spring (41).
IMPORTANT: When removing cover (3), do not damage oil seal (4).
8. Remove socket bolt (2) and remove cover (3). : 5 mm
9. Lightly tap the mounting flange part for support (32) from the pump casing (27) side. Separate pump casing (27) from support (32).
10. Remove plates (34, 36) from pump casing (27).
11. Tap the shaft end part of shaft (9) with using a plastic hammer lightly. Remove shaft (9) from support (32).
12. Remove valve plate (43) from cover (48). NOTE: Valve plate (43) may be removed at the
step 6.
CRANE UPPER / Pump Assembly
W2-4-50
W2CH-02-04-003
10
32
17
21
24
27
13
44
48
10
CRANE UPPER / Pump Assembly
W2-4-51
IMPORTANT: When removing tilt pin (17), use special tool in order not to damage the head of tilt pin (17).As LOCTITE has been applied onto the contacting part between tilt pin (17) and servo piston (24), do not damage servo piton (24).Do not remove bearings (44) unless necessary.As the setting of flow rate changes, do not loosen lock nut (10) in cover (48) and support (32).
13. If necessary, remove stoppers (13, 21), servo piston (24) and tilt pin (17) from pump casing (27).Remove bearing (44) from cover (48).
IMPORTANT: When tightening servo piston (24) and tilt pin (17), use special tool in order not to damage the head of tilt pin (17) and feedback pin (16). Apply Three Bond #1305N onto the thread part.
1. Lightly tap and install support (32) to pump casing (27) with using a hammer.
NOTE: When removing servo piston (24), tilt pin (17) and stoppers (13, 21), install them to pump casing (27) first.
2. Place pump casing (27) with the mounting surface for regulator facing downward. Install bushing (35) in plate (34) into tilt pin (17). Install plate (34) to support (32).
NOTE: Check if plate (34) can move smoothly by fingers.In case grease is applied onto plate (34) and support (32), shaft (9) can be installed easily.
IMPORTANT: Do not tap shaft (9) with using a hammer.
3. Install bearing (8), spacer (7) and retaining ring (6) onto shaft (9). Install shaft (9) to support (32).
NOTE: Lightly tap the outer ring in bearing (8) with using a plastic hammer and install bearing (8) with using a steel bar completely.
IMPORTANT: Do not damage oil seal (4).4. Secure cover (3) to pump casing (27) with socket
bolt (2). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
NOTE: Apply a film of grease onto oil seal (4) in cover (3).
5. Assemble the piston cylinder sub assembly (cylinder block (42), piston (37), shoe (38), plate (39), bushing (40) and spring (41)). Align the splines of bushing (40) and cylinder block (42) and insert the piston cylinder sub assembly into pump casing (27).
IMPORTANT: Check the direction of suction and delivery in valve plate (43).
6. Align with pin (46) and install valve plate (43) on cover (48).
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the parts. As the parts are small, do not lose the parts.
1. Select the place to disassemble. NOTE: Select the clean place.
2. Remove any dust and rust from the regulator surface with using the washing oil.
IMPORTANT: Do not lose O-ring (4).3. Remove socket bolts (36, 37) and remove the
regulator from the pump. : 6 mm
IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) are installed to cover (43). As the setting flow rate changes, do not loosen the screw and nut.
4. Remove socket bolt (30) and remove cover (43). : 5 mm
5. Remove springs (9, 10) and spring seat (8) from the compensating part. Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part.
NOTE: Adjusting rod (13) can be removed with using the bolt (M4) easily.
6. Remove socket bolt (32) and remove cover (59).Remove set spring (25) from the pilot part after removing the cover (59).
: 5 mm
7. Remove the solenoid valve (58) from the cover (59).
: 32 mm
IMPORTANT: When removing retaining ring (28), return spring (26) flies out. Do not lose return spring (26).
8. Remove retaining ring (28). Remove spring seat (27), return spring (26) and sleeve (23).
NOTE: Retaining ring (24) is installed to sleeve (23).
9. Remove retaining ring (50) and remove plugs (48, 51).
NOTE: Plugs (48, 51) can be removed with using the bolt (M6) easily.
10. Remove the plug (52) and remove the O-ring (49).
: 19 mm
CRANE UPPER / Pump Assembly
W2-4-60
W2CH-02-04-005
56
7
16
1719
2021
22
29
16
CRANE UPPER / Pump Assembly
W2-4-61
IMPORTANT: Do not remove pin (16).11. Remove lever (17) by using a pair of tweezers.
NOTE: The lever can be easily removed by using a pair of tweezers.
12. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with
using a thin steel bar in order not to touch with lever (21).
IMPORTANT: Do not remove pin (16).13. Remove lever (21).
14. Remove piston (29) and spool (22).
15. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of
1. Install rod (7) into the compensating hole on casing (46).
2. Install pin (16) to lever (21). Insert pin (16) into the groove of rod (7). Install pin (47) to casing (46). Install lever (21) into pin (47).
IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (46) smoothly. Check the direction of spool (22).
W25N-02-04-011
3. Install spool (22) and sleeve (23) into the spool hole on casing (46).
IMPORTANT: Check the direction of feedback lever (20).
W25N-02-04-012
4. Install feedback lever (20). Align the pin hole on feedback lever (20) and insert pin (19).
NOTE: In case inserting pin (19) into feedback lever (20) a little first, the pin can be inserted easily.
5. Install piston (29) into the hole for negative control on casing (46).
NOTE: Check if piston (29) moves smoothly.
6. Install pin (16) to lever (17). Insert pin (16) into the groove of piston (29). Install lever (17).
IMPORTANT: Check the inserting hole of the plugs (48) and (51).
7. Install pin (47) to plug (51). Align pin (47) with the pin hole on lever (17) and install plug (51). Install retaining ring (50).
8. Insert plug (48). Install retaining ring (50). NOTE: Check if feedback lever (20) has too big
play or moves smoothly.
9. Install the O-ring (49) and plug (52) on the casing (46).
: 19 mm : 36 N m (3.7 kgf m, 27 lbf ft)
10. Install return spring (26) and spring seat (27) to the spool hole. Install retaining ring (28).
2022
Lever (21) Side Lever (17) Side (Plugs (48, 51) Side)
CRANE UPPER / Pump Assembly
W2-4-66
W2CG-02-04-008
5 6
8
9 10
11
13
14
15
25
30 32
39
4041
43 44
45
58
30
41
59
CRANE UPPER / Pump Assembly
W2-4-67
11. Install the solenoid valve (58) on the cover (59). : 32 mm : 39 to 49 N m (4.5 to 5.0 kgf m)
(29 to 36 lbf ft)
12. Install set spring (25) to the spool hole and install piston (6) and casing (5) to the compensating hole.Tighten cover (59) with socket bolt (32).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
IMPORTANT: Check the direction of spring seat (15).13. Install spring seat (15), spring (14) and adjusting
rod (13) to the pilot hole. Install spring seat (8) and springs (9, 10) to the compensating hole.
14. Install adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) to cover (43). Install cover (43) and tighten socket bolt (30).
: 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
CRANE UPPER / Pump Assembly
W2-4-68
(Blank)
CRANE UPPER / Pump Assembly
W2-4-69
REMOVE AND INSTALL 2-UNIT GEAR PUMP
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
Preparation
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove drain plug (1) and drain off hydraulic oil by using a container (500 L (132 US gal)).
: 19 mm
Removal
1. Remove all hoses, pipes, and wire harness from the 2-unit gear pump. Cap the removed hoses.
: 27 mm : 8 mm
2. Support the 2-unit gear pump.
CAUTION: 2-unit gear pump weight: Approx. 7.6 kg (17 lb)
3. Remove the 2-unit gear pump mounting bolt (2) and remove the 2-unit gear pump.
: 8 mm
W24X-02-04-001
W2CM-02-04-013
1
2
CRANE UPPER / Pump Assembly
W2-4-70
Installation
CAUTION: 2-unit gear pump weight: Approx. 7.6 kg (17 lb)
1. Install the 2-unit gear pump on the reduction gear of the main pump.
2. Install the 2-unit gear pump mounting bolt (2). : 8 mm : 22 to 28 N m (2.2 to 2.9 kgf m)
(16 to 21 lbf ft)
3. Install all hoses, pipes, and wire harness to the 2-unit gear pump.
: 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 8 mm : 48 to 50 N m (4.9 to 5.1 kgf m)
(35 to 37 lbf ft)
4. Remove hydraulic oil tank cover. Fill hydraulic oil to specified level.
5. Remove air bleed plug (3) from the top of main pump. Fill hydraulic oil. Install air bleed plug (3). Start the engine and run at low idling speed.
: 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
6. Loosen air bleed plug (3). Release the pressure in the pump.
: 36 mm
7. Tighten air bleed plug (3). Do the work at low idling speed. Check the hydraulic oil level and any oil leakage.
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
NOTE: Although gaskets (5, 6) and side plate (7) are the same type, the directions to install are different. Attach an identification tag for assembling.The orders of driven gears (8, 12) are symmetrical. Attach an identification tag onto the shaft part when disassembling.
1. Remove any dust and rust from the pump surface with using the washing oil.
2. Face the rear cover (15) side upward. Clamp the mounting part of front cover (3) in a vise.
3. Put the matching marks on the matching part in the drive side of front cover (3), body (10), adapter plate (11), body (14) and rear cover (15).
4. Remove socket bolt (17). : 10 mm
5. Remove rear cover (15).
6. Remove bushing (4), gaskets (5, 6) and side plate (7).
7. Remove drive gear (13) and driven gear (12).
8. Remove body (14).
9. Remove bushing (4), gaskets (5, 6) and side plate (7).
10. Remove adapter plate (11).
11. Remove bushing (4), gaskets (5, 6) and side plate (7).
12. Remove body (10).
13. Remove bushing (4), gaskets (5, 6) and side plate (7).
• Replace all oil seals and gaskets with the new ones.Before assembling, clean each parts with using clean washing oil and dry.Apply clean hydraulic oil onto the inner parts.Specially apply hydraulic oil onto the sliding part in order not to seize.
IMPORTANT: Install gasket (6) so that the flat surface is located in the bottom of groove. Assemble side plate (7) so that the yellow surface faces to the gear side and the long pulling-out hole faces to the suction side.Gears (8, 9, 12, 13) are asymmetrical.Mesh the gears with small notch each other and assemble them.
NOTE: Secure gaskets (5, 6) and side plate (7) with applying grease in order not to twist and bind.Align the matching marks and assemble front cover (3), body (10), adapter plate (11), body (14) and rear cover (15).Check the direction of mark and install driven gears (8, 12).
1. Secure front cover (3) with the mounting surface for body (10) facing upward in a vise.
2. Install bushing (4), gaskets (5, 6) and side plate (7) on front cover (3).
3. Install body (10) to front cover (3).
W25N-02-04-022
W25N-02-04-023
Rotating Direction of Drive Gear
Small Notch(Bound Side)
SuctionSide
Rotating Direction of Driven Gear
Delivery Side
Large Notch(No Bound Side)
Suction Side
LongPulling-OutHole
Short Pulling-Out Hole
Delivery Side
CRANE UPPER / Pump Assembly
W2-4-76
W2CM-02-04-015
1 2
3
5
6
7
8
9 10 11
12
1314
15
16 17
4 18 19
CRANE UPPER / Pump Assembly
W2-4-77
4. Install drive gear (9) and driven gear (8) onto body (10).
5. Install bushing (4), gaskets (5, 6) and side plate (7) to the front and rear of the adapter plate (11).
6. Install adapter plate (11) to body (10).
7. Install body (14) to adapter plate (11).
8. Install drive gear (13) and driven gear (12) to body (14).
9. Install bushing (4), gaskets (5, 6) and side plate (7) on the rear cover (15).
10. Install rear cover (15) to body (14).
11. Install socket bolt (17). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m)
(65 to 69 lbf ft)
12. Turn over the pump with the side where oil seal (2) is installed facing upward. Clamp the pump in a vise.
13. Fill grease main lip and dust lip in oil seal (2).
W25N-02-04-021
Dust Lip
Fill grease.
Main Lip
2
CRANE UPPER / Pump Assembly
W2-4-78
IMPORTANT: Do not damage oil seal (2).14. Install oil seal (2) to front cover (3) with using a
guide and pipe.
15. Install retaining ring (1).
W2CM-02-04-016
W2CM-02-04-017
2
Pipe
Guide
3
1
CRANE UPPER / Pump Assembly
W2-4-79
REMOVE AND INSTALL GEAR PUMP FOR HYD. TAGLINE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
Preparation
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove drain plug (1) and drain off hydraulic oil by using a container (500 L (132 US gal)).
: 19 mm
Removal
1. Remove all hoses, pipes, and wire harness from the gear pump. Cap the removed hoses.
2. Support the gear pump.
CAUTION: Gear pump weight: Approx. 2.3 kg (5.1 lb)
3. Remove the gear pump mounting bolt (2) and remove the gear pump.
: 8 mm
W24X-02-04-001
W2CM-02-04-018
1
2
CRANE UPPER / Pump Assembly
W2-4-80
Installation
CAUTION: Gear pump weight: Approx. 2.3 kg (5.1 lb)
1. Install the gear pump on the reduction gear of the main pump.
2. Install the gear pump mounting bolt (2).
3. Install all hoses, pipes, and wire harness to the gear pump.
4. Remove hydraulic oil tank cover. Fill hydraulic oil to specified level.
5. Remove air bleed plug (3) from the top of main pump. Fill hydraulic oil. Install air bleed plug (3). Start the engine and run at low idling speed.
: 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
6. Loosen air bleed plug (3). Release the pressure in the pump.
: 36 mm
7. Tighten air bleed plug (3). Do the work at low idling speed. Check the hydraulic oil level and any oil leakage.
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
NOTE: Although gaskets (6) and side plate (7) are the same type, the directions to install are different. Attach an identification tag for assembling.The orders of driven gears (8) are symmetrical. Attach an identification tag onto the shaft part when disassembling.
1. Remove any dust and rust from the pump surface with using the washing oil.
2. Face the rear cover (12) side upward. Clamp the mounting part of front cover (3) in a vise.
3. Put the matching marks on the matching part in the drive side of front cover (3) and rear cover (12).
4. Remove socket bolt (14). : 10 mm
5. Remove rear cover (12).
6. Remove bushing (10), gaskets (6) and side plate (7).
• Replace all oil seals and gaskets with the new ones.Before assembling, clean each parts with using clean washing oil and dry.Apply clean hydraulic oil onto the inner parts.Specially apply hydraulic oil onto the sliding part in order not to seize.
IMPORTANT: Install gasket (6) so that the flat surface is located at front cover (3) and rear cover (12). Assemble side plate (7) so that the opposite side to gasket (6) mounting surface faces the gear side and the pulling-out hole faces the delivery side.Gears (8, 9) are asymmetrical. Meshthe gears with small notch each other and assemble them.
NOTE: Secure gaskets (5, 6) and side plate (7) with applying grease in order not to twist and bind.Align the matching marks and assemble front cover (3) and rear cover (12).Check the direction of mark and install driven gears (8).
1. Secure front cover (3) with the mounting surface for body (12) facing upward in a vise.
2. Install bushing (4) on front cover (3).
3. Install gaskets (5, 6) and side plate on front cover (3).
W25N-02-04-022
W25N-02-04-023
Rotating Direction of Drive Gear
Small Notch(Bound Side)
SuctionSide
Rotating Direction of Driven Gear
Delivery Side
Large Notch(No Bound Side)
Suction Side
Pulling-Out Hole
Delivery Side
CRANE UPPER / Pump Assembly
W2-4-86
W23F-02-04-014
9 3 11 7 10
10
6
141381276
2
CRANE UPPER / Pump Assembly
W2-4-87
4. Install drive gear (9) and driven gear (8) on front cover (3).
5. Install ball (11) on front cover (3).
6. Install bushing (10) on rear cover (12).
7. Install gaskets (6) and side plate (7) on the rear cover (12).
8. Install rear cover (12) to front cover (3).
9. Install socket bolt (14) with washer (13). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m)
(65 to 69 lbf ft)
10. Turn over the pump with the side where oil seal (2) is installed facing upward. Clamp the pump in a vise.
11. Fill grease main lip and dust lip in oil seal (2).
IMPORTANT: Do not damage oil seal (2). 12. Install oil seal (2) to front cover (3) with using a
guide and pipe.
W25N-02-04-021
W2CM-02-04-016
Dust Lip
Fill grease.
Main Lip
2
2
Pipe
Guide
3
CRANE UPPER / Pump Assembly
W2-4-88
13. Install retaining ring (1).
W2CM-02-04-017
1
CRANE UPPER / Control Valve
W2-5-1
REMOVE AND INSTALL FRONT / REAR 4-UNIT CONTROL VALVE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove all hoses and pipes from control valves (1, 2)
: 22 mm : 36 mm : 8 mm : 10 mm
NOTE: Cap all the removed hoses and pipes. Attach an identification tag for assembling.
3. Remove bolt (3). : 19 mm
CAUTION: Control valve (1) weight: Approx. 80 kg (176 lb) Control valve (2) weight: Approx. 85 kg (187 lb)
4. Hoist and remove control valves (1, 2).
W25N-02-05-001
1
2
3
3
CRANE UPPER / Control Valve
W2-5-2
Installation
CAUTION: Control valve (1) weight: Approx. 80 kg (176 lb) Control valve (2) weight: Approx. 85 kg (187 lb)
1. Install control valves (1, 2) to the frame. Secure to the frame with bolt (3).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
2. Install all hoses and pipes to control valves (1, 2). : 22 mm : 39 N m (4.0 kgf m, 28.8 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 8 mm : 54 to 66 N m
(5.5 to 6.7 kgf m, 40 to 49 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft)
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
• The disassembling and assembling procedures of 4-spool spool control valves for travel (left), third, rear and front are explained here. As the construction is similar, refer to this section when disassembling and assembling other 4-unit control valve.
CAUTION: Control valve weight: Approx. 80 kg (176 lb)
1. Place the control valve assembly on a workbench.
IMPORTANT: Do not loosen the adjusting screw in solenoid valves (69, 79).
2. Remove solenoid valves (69, 79) (2 used for each) from end covers (15) (3 used) and (33).
: 32 mm
3. Remove socket bolts (10) (16 used) and (21) (14 used). Remove end covers (14) (2 used), (15) (3 used), (16) and (33) from each valve section.
: 5 mm
4. Remove spring seat (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (2 used) from end covers (14) (2 used).
5. Remove spring seat (19) (2 used), springs (17, 18) (2 used for each) and O-rings (30) (2 used) from end covers (16) (2 used).
6. Remove spring seat (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (2 used) from end covers (15) (2 used).
7. Remove spring seats (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (3 used) from end covers (15, 33).
CAUTION: Do not damage the holes on spool and valve section.
8. Turn and remove spools (32, 36, 38 and 41) from each valve section.
NOTE: Do not remove plugs (20) and (40) (3 used) from spools (32, 38, 41) unless necessary.
9. Remove socket bolts (50) (4 used). Remove cover (49), springs (47, 48) and O-ring (57) from casing (35).
: 8 mm
CAUTION: Do not damage the holes on spool (51) and casing (35).
10. Turn and remove the spool (51) assembly from casing (35).
IMPORTANT: Do not disassemble relief valve (8).11. Remove relief valve (8) from valve section (7).
: 30 mm
CRANE UPPER / Control Valve
W2-5-8
W2BC-02-05-002
35
54
56
57
Section C
63
Section E
7
64
Section F
Section D
Section B
Section A
9
7
654
E321
F
39
B
D
37
35
A 34
26
23
22
C
85
39
848382
64
63
37
7877
64
6334
76
63
727170
64
9
CRANE UPPER / Control Valve
W2-5-9
IMPORTANT: Do not disassemble relief valve (76). 12. Remove relief valve (76) from valve section (34).
: 30 mm
13. Remove valve (85) from valve section (39).
14. Remove plugs (82, 70) from valve sections (39, 34).
CAUTION: Do not damage the holes on spool (51) and casing (35).
12. Insert the spool (51) assembly into casing (35). Install springs (47, 48) to spool (51).
13. Install O-ring (57) to casing (35). Install cover (49) onto casing (35). Install cover (49) to casing (35) with socket bolts (50) (4 used).
: 8 mm : 57 6.0 N m (5.8 0.6 kgf m, 42 4.4 lbf ft)
14. Install O-rings (30) (2 used), springs (11, 12) (2 used for each) and spring seats (13) (2 used) to end covers (14) (2 used).
CRANE UPPER / Control Valve
W2-5-14
W2BC-02-05-002
12
Section C
Section E
7
Section F
Section D
Section B
Section A
1413
11
1312
11 109
8
7
E
30
1411 12
F
3913
B
D11 12 13
37 16
1718
A 3433
13 12
11
3130
21
15
11
13
C
18
1716
15 12
6285
39
79
37
34
76 62
69 62
65
9
CRANE UPPER / Control Valve
W2-5-15
15. Install the end cover (14) assemblies (2 used) to valve section (9). Install end cover (14) to valve section (9) with socket bolts (10) (4 used).
: 5 mm : 21 1 N m (2.1 0.1 kgf m, 15 0.7 lbf ft)
16. Install O-rings (30) (3 used), (62) (6 used), springs (11, 12) (3 used for each) and spring seats (13) (3 used) to end covers (15) (3 used).
17. Install the end cover (15) assemblies (3 used) to valve sections (34, 39). Install end covers (15) (3 used) to valve sections (34, 39) with socket bolts (21) (6 used).
: 5 mm : 16 1.0 N m (1.6 0.1 kgf m, 11.8 0.7 lbf ft)
18. Install O-rings (30) (2 used), springs (17, 18) (2 used for each) and spring seats (19) (2 used) to end covers (16) (2 used).
19. Install end covers (16) (2 used) assembly to valve section (37) with socket bolts (10) (4 used).
: 5 mm : 12 1.0 N m (1.2 0.1 kgf m, 8.9 0.7 lbf ft)
20. Install O-ring (30) to plate (65).
21. Install O-rings (62) (4 used), springs (11, 12) and spring seat (13) to end cover (33).
22. Install the end cover (33) assembly and plate (65) to valve section (34). Install end cover (33) to valve section (34) with socket bolts (31) (2 used).
: 5 mm : 12 1.0 N m (1.2 0.1 kgf m, 8.9 0.7 lbf ft)
23. Install relief valve (8) to valve section (7). : 30 mm : 74 5.0 N m
(7.5 0.5 kgf m, 54.6 3.7 lbf ft)
24. Install relief valve (76) to valve section (34). : 30 mm : 74 5.0 N m
(7.5 0.5 kgf m, 54.6 3.7 lbf ft)
25. Install valve (85) to valve section (39). : 30 mm : 110 10 N m
(11.2 1.0 kgf m, 81.1 7.4 lbf ft)
26. Install solenoid valves (69, 79) (2 used for each) to end covers (15) (3 used) and (33).
: 32 mm : 44 5.0 N m
(4.5 0.5 kgf m, 32.5 3.7 lbf ft)
CRANE UPPER / Control Valve
W2-5-16
(Blank)
CRANE UPPER / Control Valve
W2-5-17
REMOVE AND INSTALL 4-UNIT CONTROL VALVE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove all hoses and harness connectors from control valve (1).
: 17 mm, 27 mm NOTE: Cap the removed hoses. Attach an
identification tag for assembling.
3. Remove bolts (2) (3 used). : 17 mm
CAUTION: Control valve (1) weight: Approx. 22 kg (49 lb)
4. Hoist and remove control valve (1).
W2BC-02-05-001
12
CRANE UPPER / Control Valve
W2-5-18
Installation
CAUTION: Control valve (1) weight: Approx. 22 kg (49 lb)
1. Install control valve (1) to the frame with bolts (2) (3 used).
: 17 mm : 50 N m (5.1 kgf m, 37 lbf ft)
2. Install all hoses and harness connectors to control valve (1).
: 17 mm : 50 N m (5.1 kgf m, 37 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft)
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
The disassembling and assembling procedures of 4-spool control valves for counterweight, left travel motor and quick draw are explained here.
CAUTION: Control valve weight: Approx. 22 kg (49 lb)
1. Place the control valve assembly on a workbench.
IMPORTANT: Do not loosen the adjusting screw in solenoid (35).
2. Remove solenoids (35) (8 used) from end covers (10) (8 used). Remove O-rings (37) (8 used) from solenoids (35) (8 used).
: 32 mm
IMPORTANT: Do not disassemble relief valve (34). 3. Remove relief valves (34) (2 used) from casings
(8) (2 used). : 30 mm
4. Remove plugs (40) (8 used) from end cover (10). Remove O-rings (39) (8 used) from plugs (40) (8 used).
: 5 mm
CAUTION: Do not damage the hole on end cover (10).
5. Remove spools (38) (8 used) and springs (36) (8 used) from end covers (10) (8 used).
6. Remove plugs (14) (16 used) from end covers (10) (8 used).
: 5 mm
7. Remove socket bolt (42). Remove end covers (10) (8 used) from casings (8, 9) (2 used for each).
: 4 mm
8. Remove spring seat (12) (8 used), springs (11) (8 used) and O-rings (13) (8 used) from end covers (10) (8 used).
CAUTION: Do not damage the holes on casings (8, 9).
9. Turn and remove spools (19) (4 used) from casings (8, 9).
10. Remove plugs (32) (4 used) from casings (8, 9). Remove O-rings (33) (4 used) from plugs (32) (4 used).
: 41 mm
11. Remove springs (31) (4 used) and check valves (30) (4 used) from casings (8, 9).
12. Remove plugs (27) (2 used) from casings (8) (2 used). Remove O-rings (28, 29) (2 used for each) from plugs (27) (2 used).
: 30 mm
13. Remove plugs (25) (2 used) from the upper surface of end section 1 (2). Remove O-rings (24) (2 used) from plugs (25) (2 used).
: 8 mm
14. Remove springs (3, 33) from end section 1 (2).
15. Remove plugs (25) (2 used) from the lower surface of end section 1 (2). Remove O-rings (24) (2 used) from plugs (25) (2 used).
: 8 mm
CRANE UPPER / Control Valve
W2-5-24
W2BC-02-05-004
W2BC-02-05-003
W2BC-02-05-005
W2BC-02-05-006
24
1
Section A
5
67
8
16
1514
17
18
9
C
B
A
C
26
Section B
Section C
22
21
20
4
CRANE UPPER / Control Valve
W2-5-25
CAUTION: Do not damage the holes on end section 1 (2).
16. Remove spools (1, 22) from end section 1 (2).
IMPORTANT: Do not disassemble relief valve (7). Do not loosen the adjusting screw in relief valve (7).
17. Remove relief valve (7) from end section 1 (2). : 22 mm
18. Remove plug (6) from end section 1 (2). Remove O-ring (5) from plug (6).
: 6 mm
19. Remove plugs (4) (6 used) from end section 1 (2). : 4 mm
20. Remove plugs (4) (4 used) from end section 2 (17).
: 4 mm
21. Remove nuts (15) (4 used) and spring washers (14) (4 used). Remove end section 2 (17), plate (18) and casings (8, 9) (2 used for each) from bolt (16) in this order.
: 13 mm
22. Remove O-rings (20) (22 used), (21) (6 used) and (26) (18 used) from end section 1 (2), casings (8, 9) (2 used for each) and plate (18).
1. Install O-rings (20) (2 used), (21) (6 used) and (26) (18 used) to end section 1 (2), casings (8, 9) (2 used for each) and plate (18).
2. Install casings (8, 9) (2 used for each), plate (18) and end section 2 (17) to bolts (16) (4 used) with end section 1 (2) attached in this order. Install spring washers (14) (4 used) to bolts (16) (4 used) and tighten with nuts (15) (4 used).
: 13 mm : 20 to 25 N m
(2.0 to 2.6 kgf m, 14.8 to 18.4 lbf ft)
3. Wind the seal tape onto plugs (4) (4 used). Install plugs (4) (4 used) to end section 2 (17).
: 4 mm : 7.8 to 9.8 N m
(0.8 to 1.0 kgf m, 5.8 to 7.2 lbf ft)
4. Wind the seal tape onto plug (4). Install plugs (4) (6 used) to end section 1 (2).
: 4 mm : 7.8 to 9.8 N m
(0.8 to 1.0 kgf m, 5.8 to 7.2 lbf ft)
5. Install O-ring (5) to plug (6). Install plug (6) to end section 1 (2).
: 6 mm : 34 to 38 N m
(3.5 to 3.9 kgf m, 25 to 28 lbf ft)
IMPORTANT: Do not loosen the adjusting screw in relief valve (7).
6. Install relief valve (7) to end section 1 (2). : 22 mm : 41 to 47 N m
(4.2 to 4.8 kgf m, 30 to 35 lbf ft)
7. Install O-rings (24) (2 used) onto plugs (25) (2 used). Install plugs (25) (2 used) to the lower surface of end section 1 (2).
: 8 mm : 69 to 78 N m
(7.0 to 8.0 kgf m, 51 to 58 lbf ft)
IMPORTANT: Check the position and direction to insert spools (1, 22).
8. Install spools (1, 22) and springs (3, 23) from the upper side of end section 1 (2).
10. Install O-rings (28, 29) (2 used for each) to plugs (27) (2 used).
11. Install plugs (27) (2 used) to casings (8) (2 used). : 30 mm : 39 to 49 N m
(4.0 to 5.0 kgf m, 29 to 36 lbf ft)
CRANE UPPER / Control Valve
W2-5-30
W2BC-02-05-004
W2BC-02-05-003
W2BC-02-05-005
W2BC-02-05-006
23 4
1
Section A
5
67
8
16
1514
17
18
19
9 10
11
12
13
C
B
A
C
26
Section B
Section C
43
24
23
22
21
25
20 4241
40
3938373635
34
33
32
31
30
29
28
27
8
CRANE UPPER / Control Valve
W2-5-31
12. Install check valves (30) (4 used) and springs (31) (4 used) to casings (8, 9) (2 used for each).
13. Install O-rings (33) (4 used) onto plugs (32) (4 used). Install plugs (32) (4 used) to casings (8, 9) (2 used for each).
: 41 mm : 49 to 59 N m
(5.0 to 6.0 kgf m, 36 to 44 lbf ft)
IMPORTANT: Check the direction to insert spools (19) (4 used).
14. Install spools (19) (4 used) to casings (8, 9) (2 used for each).
15. Install springs (11) (8 used), spring seat (12) (8 used), O-rings (13) (8 used) and (43) (16 used) to end covers (10) (8 used).
16. Install the end covers (10) (8 used) assembly to casings (8, 9) (2 used for each). Install end covers (10) (8 used) to casings (8, 9) (2 used for each) with socket bolts (42) (32 used).
: 4 mm : 5.9 to 7.8 N m
(0.6 to 0.8 kgf m, 4.4 to 5.8 lbf ft)
17. Wind the seal tape onto plug (41). Install plugs (41) (16 used) to end covers (10) (4 used).
: 5 mm : 8.3 to 11 N m
(0.8 to 1.1 kgf m, 6.1 to 8.1 lbf ft)
18. Install O-rings (39) (8 used) to plugs (40) (8 used). Install plugs (40) (8 used) to end covers (10) (8 used).
: 5 mm : 13 to 17 N m
(1.3 to 1.7 kgf m, 9.6 to 12.6 lbf ft)
19. Install springs (36) (8 used) and spools (38) (8 used) to end covers (10) (8 used).
IMPORTANT: Do not loosen the adjusting screw in solenoid (35). Check the position to install solenoid (35).
21. Install O-rings (37) (8 used) to solenoids (35) (8 used). Install solenoids (35) (8 used) to end covers (10) (8 used).
: 32 mm : 39 to 49 N m
(4.0 to 5.0 kgf m, 29 to 36 lbf ft)
CRANE UPPER / Control Valve
W2-5-32
(Blank)
CRANE UPPER / Control Valve
W2-5-33
REMOVE AND INSTALL 1-UNIT CONTROL VALVE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove all hoses and pipes from control valve (1).
: 8 mm, 10 mm : 22 mm, 36 mm, 41 mm
NOTE: Cap all the removed hoses and pipes. Attach an identification tag for assembling.
Remove bolts (2) (3 used). : 19 mm
CAUTION: Control valve (1) weight: Approx. 38 kg (84 lb)
4. Hoist and remove control valve (1).
W25N-02-05-003
1
2
CRANE UPPER / Control Valve
W2-5-34
Installation
CAUTION: Control valve (1) weight: Approx. 38 kg (84 lb)
1. Install control valve (1) to the frame with bolts (2) (3 used).
: 19 mm : 90 N m (9.2 kgf m)
2. Install all hoses and pipes to control valve (1). : 8 mm : 50 N m (5.1 kgf m, 36.9 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft) : 22 mm : 69 N m (7.0 kgf m, 51 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151.2 lbf ft)
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
1. Install O-rings (8) (2 used), (9) (4 used) and (10) (2 used) to valve section (3) and outlet section (2).
2. As for each section, arrange inlet section (1), valve section (3) and outlet section (2) in this order.
3. Install bolts (23) (4 used) to each section. Tighten to bolts (23) (4 used) with spring washers (25) (4 used) and nuts (24) (4 used).
: 24 mm : 100 to 120 N m
(10 to 12 kgf m, 74 to 89 lbf ft)
4. Turn over the control valve. Install O-ring (21) to cap (20). Install cap (20) to valve section (3).
: 41 mm : 190 to 210 N m
(19 to 21.5 kgf m, 140 to 155 lbf ft)
5. Turn over the control valve.
6. Install O-ring (7) to plug (5). Install plug (5) to inlet section (1).
: 21 mm : 370 to 410 N m
(38 to 42 kgf m, 273 to 302 lbf ft)
7. Install O-ring (6) to plug (4). Install plug (4) to plug (5).
: 6 mm : 34 to 38 N m
(3.5 to 3.9 kgf m, 25 to 28 lbf ft)
CAUTION: Do not damage the holes on spool (16) and valve section (3).
8. Insert spool (16) into valve section (3).
9. Install O-ring (14), springs (17, 18) (2 used for each) and spring seats (19) (2 used) to end covers (11) (2 used).
10. Install the end cover (11) assemblies (2 used) to valve section (3). Tighten the end cover (11) assemblies (2 used) with socket bolt (15).
: 5 mm : 11 to 13 N m
(1.1 to 1.3 kgf m, 8.1 to 9.6 lbf ft)
11. Install O-rings (2 used) to relief valve (22). Install to inlet section (1).
: 30 mm : 120 to 140 N m
(12 to 14 kgf m, 89 to 103 lbf ft)
CRANE UPPER / Control Valve
W2-5-40
(Blank)
CRANE UPPER / Control Valve
W2-5-41
REMOVE AND INSTALL WINCH DRUM CONTROL VALVE (OPTIONAL)
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove bolt (1). Remove all hoses and pipes from winch drum control valve (3).
: 19 mm NOTE: Attach an identification tag onto the
removed houses and pipes for assembling. Cap the open ends.
CAUTION: Winch drum control valve weight: 40 kg (88 lb)
3. Remove bolts (2) (4 used). Hoist and remove winch drum control valve (3).
: 19 mm
Installation
CAUTION: Winch drum control valve weight: 40 kg (88 lb)
1. Hoist and install winch drum control valve (3) with bolts (2) (4 used)
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
2. Install pipes (4 used) with bolts (4) : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
3. Install elbows (5) (2 used) to winch drum control valve (3).
: 19 mm : 27 to 33 N m
(2.8 to 3.4 kgf m, 20 to 24.5 lbf ft)
4. Install bracket (6) with bolt (1) : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
7. Install plug (5) on valve section (2). : 30 mm : 70 to 80 N m
(7.1 to 8.2 kgf m, 52 to 59 lbf ft)
8. Install plug (6) on valve section (3). : 30 mm : 100 to 120 N m
(10 to 12 kgf m, 74 to 89 lbf ft)
CAUTION: Do not damage the holes on spool and valve section.
9. Insert spool (25) into valve sections (3).
CRANE UPPER / Control Valve
W2-5-48
W2BC-02-05-009
12
11 4133534333637
9
10
6201618
24
19
20
17
22
30
31
2
7212315282726321 38
29
3 25 26 27 28 14 5 8
39
CRANE UPPER / Control Valve
W2-5-49
10. Install O-rings (36, 37) (2 used), springs (49, 48) and spring seat (53) to end cover (28).
11. Install the end cover (28) assembly to valve section (4) and tighten with socket bolt (38).
: 5 mm : 15 to 17 N m
(1.5 to 1.7 kgf m, 11 to 12.5 lbf ft)
12. Install relief valve (32) to inlet section (1). : 30 mm : 69 to 79 N m
(7.0 to 8.1 kgf m, 51 to 58 lbf ft)
13. Install valve (29) to valve section (3). : 30 mm : 100 to 120 N m
(10 to 12 kgf m, 74 to 89 lbf ft)
14. Install solenoid valve (24) to end covers (15) (2 used).
: 32 mm : 39 to 49 N m
(4.0 to 5.0 kgf m, 28.5 to 36 lbf ft)
CRANE UPPER / Control Valve
W2-5-50
(Blank)
CRANE UPPER / Swing Reduction Unit
W2-6-1
REMOVE AND INSTALL SWING REDUCTION UNIT
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Preparation
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
Removal
1. Remove hoses (1 to 10) from the swing reduction unit. Cap the removed hoses.
: 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft)
2. Remove bolt (11). : 30 mm : 550 N m (56 kgf m, 410 lbf ft)
CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb)
3. Hoist and remove the swing reduction unit.
W25N-02-06-001
1
2
3
4
56
7
8
9
10
115
CRANE UPPER / Swing Reduction Unit
W2-6-2
Installation
NOTE: Refer to the Removal section for the wrench size and tightening torque.
CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb)
1. Apply liquid packing onto the reduction gear side and the mounting side for upper revolving frame. Hoist and install the swing reduction unit to the upper revolving frame.
2. Install bolt (11).
3. Install hoses (1 to 10) to the swing reduction unit.
CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb)
1. Remove plug (23) and drain off gear oil.Gear oil: Approx. 3.4 L (3.6 US qt)
NOTE: Put gear oil in the clean container and check the powder because of wearing.
2. Put the matching marks on casing (1), ring gear (3) and motor (31).
3. Remove socket bolt (20). : 12 mm
CAUTION: Motor weight: 70 kg (155 lb)
4. Remove motor (31).
5. Remove sun gear (7).
6. Remove the carrier (9) assembly with planetary gear (6) and so on attached from ring gear (3).
7. Put the marks on each planetary gear (6) and pin (11).
8. Remove retaining ring (25) from pins (11) (3 used) in the carrier (9) assembly. Remove side plate (12) of the upper side.
9. Remove planetary gear (6) and needle bearing (19) from pins (11) (3 used).
10. Remove side plate (12) of the lower side from pins (11) (3 used).
11. Remove side plate (14) from the carrier (9) assembly.
IMPORTANT: Do not remove pins (11) (3 used) from carrier (9) unless necessary.
12. Remove sun gear (5).
13. Remove the carrier (8) assembly.
IMPORTANT: Do not disassemble the carrier (8) assembly further. Inspect the parts in carrier (8) assembly in this condition.Although the carrier (8) assembly is replaced as an assembly, do the following procedures when replacing a part of assembly. Do not use pin (10) again.
15. Remove planetary gears (4) (4 used) and side plates (13) (4 used) from the carrier (8) assembly horizontally.
IMPORTANT: Do not damage the mating surfaces between casing (1) and ring gear (3).
16. Insert a screwdriver into the pulling-out notch (2 places) on the mating surfaces in casing (1) and ring gear (3). Remove ring gear (3) from casing (1).
17. Remove retaining ring (27) from shaft (2).
CRANE UPPER / Swing Reduction Unit
W2-6-6
W25N-02-06-002
1
2
17
18
22
28
CRANE UPPER / Swing Reduction Unit
W2-6-7
IMPORTANT: Shaft (2) falls off. Do not damage shaft (2).
18. Turn over casing (1). Support the flange part of casing (1) and place casing (1) on the workbench.Tap and remove shaft (2) by using a plastic hammer downward.
NOTE: Bearing (18) is left in casing (1).
IMPORTANT: Do not disassemble the shaft (2) assembly further. Inspect the parts in shaft (2) assembly in this condition.Although the shaft (2) assembly is replaced as an assembly, do the following procedures when replacing a part of assembly. Oil seal (22) and bearing seal (28) cannot be used again.
19. Support the shaft (2) assembly. Remove bearing seal (28) and bearing (17) by using a press.
NOTE: Use special tool.
20. Remove oil seal (22) from casing (1). W25N-02-06-003
2. Apply much grease into the inside of bearing (17).Install bearing (17) to shaft (2) by using a press completely.
NOTE: Use special tool.
3. Apply much grease to the upper surface on bearing (17).
4. Place casing (1) on the workbench horizontally.
5. Vertically hoist the shaft (2) assembly by using a thread in the shaft end of shaft (2) assembly.Install the shaft (2) assembly to casing (1).
NOTE: Level the outer ring of bearing (17). Tap bearing (17) lightly and install the shaft (2) assembly. If the shaft (2) assembly cannot be installed, remove the shaft (2) assembly, level the outer ring of bearing (17) and repeat the procedure.
6. Turn over casing (1) with the shaft end of shaft (2) assembly facing downward. Support the flange part of casing (1) and place casing (1) on the workbench.
IMPORTANT: Do not damage the lip of oil seal (22).7. Insert oil seal (22) into casing (1). NOTE: Use special tool.
W25N-02-06-005
W25N-02-06-003
W25N-02-06-006
2
17
Grease
Special Tool for Bearing (17)
176
156
146166
125
Special Tool for Oil Seal (22)
10
CRANE UPPER / Swing Reduction Unit
W2-6-10
W25N-02-06-002
1
2
3
48
10
13
18
2021
24
2730
31
CRANE UPPER / Swing Reduction Unit
W2-6-11
8. Insert bearing (18) by using special tool to push the inner and outer rings, and a press.
NOTE: Check the dimension between shaft end and end of inner ring by using special tool.
9. Install retaining ring (27) to shaft (2).
10. Fill grease through grease nipple (30).
11. Align with the pin (10) hole on carrier (8) and place side plates (13) (4 used).
12. Insert planetary gears (4) (4 used) into carrier (8).
13. Align the pin (10) holes and insert pins (10) (4 used) into carrier (8) while tapping. Align the directions of holes in carrier (8) and pin (10) where spring pin (24) will be inserted.
14. Apply liquid packing onto the mating surfaces between casing (1) and ring gear (3).
IMPORTANT: Do not damage the mating surface for motor (31).
15. Align the matching marks and install ring gear (3) on casing (1). Install washer (21) onto socket bolt (20). Tighten socket bolts (20) (4 used) temporarily.
: 12 mm : 78.5 N m (8.0 kgf m, 58 lbf ft)
W25N-02-06-007
Special Tool for Bearing (18)
45
93160
CRANE UPPER / Swing Reduction Unit
W2-6-12
W25N-02-06-002
1
3
5 67
8
9 11 1214
1516
192021
23
252631
12
CRANE UPPER / Swing Reduction Unit
W2-6-13
16. Install the carrier (8) assembly into ring gear (3).
17. Install sun gear (5) to the carrier (8) assembly.
18. Place the carrier (9) assembly onto the stand horizontally.
19. Insert side plate (14) into the center of carrier (9) assembly.
20. Install side plate (12) to pins (11) (3 used).
21. Install needle bearing (19) and planetary gear (6) to pins (11) (3 used).
22. Install side plate (12) into pins (11)(3 used). Install retaining ring (25).
23. Install the carrier (9) assembly to sun gear (5). NOTE: Check if side plate (14) is installed in the
convex part in sun gear (5).
24. Install sun gear (7) to the carrier (9) assembly.
25. Remove socket bolt (20) with washer (21), which was tightened temporarily at step 15. Apply liquid packing onto the motor (31) mounting surface on ring gear (3).
: 12 mm
26. Install retaining ring (26) to the shaft of motor (31).
27. Hoist motor (31) vertically. Align the splines and install motor (31) to sun gear (7) and ring gear (3). Tighten socket bolt (20) and washer (21).
: 12 mm : 196 N m (20 kgf m, 145 lbf ft)
28. Install plug (23) to casing (1). : 10 mm : 65 N m (6.6 kgf m, 48 lbf ft)
NOTE: Wind the seal tape onto plug (23).
29. Add gear oil.Gear oil: Approx. 3.4 L (3.6 US qt)
NOTE: Install pipe (16) and level gauge (15) temporarily. Check the amount of gear oil.After installing the swing reduction unit to the machine frame, remove the seal tape from the thread part and wipe off grease. Attach the seal tape and install pipe (16) and level gauge (15).
: 41 mm NOTE: When loosening relief valve (35), O-ring
(36) is damaged. Replace O-ring (36).
IMPORTANT: Do not damage the seat part of plunger (12).
5. Remove plug (19) from valve casing (3). Remove O-ring (22), spring (13) and plunger (12).
: 17 mm
IMPORTANT: Do not fall off valve plate (10) from valve casing (3). (Valve plate (10) may be attached on the cylinder (6) side.) Do not damage the mating surfaces between valve casing (3) and casing (11) by using a screwdriver.
: 17 mm NOTE: When loosening socket bolt (14), valve
casing (3) is floated by spring (27).
7. Remove valve plate (10) from valve casing (3).
8. Remove spring (27) from brake piston (24).
CRANE UPPER / Swing Reduction Unit
W2-6-16
W25N-02-06-008
123
5
6
7
8
9
11 15
16
23
2428
29
CRANE UPPER / Swing Reduction Unit
W2-6-17
9. Remove brake piston (24) from casing (11). : 14 mm
NOTE: Attach the claw of brake piston (24) and remove brake piston (24) upward straightly.
10. Place the motor horizontally.
IMPORTANT: Do not damage the sliding surfaces of cylinder (6) and shoe (2).
11. Remove cylinder (6), piston (1), retainer (8) and spring (7) from shaft (5).
12. Remove friction plate (28) and separator plate (29) from casing (11).
13. Wind a vinyl tape onto the spline part of shaft (5) assembly in order not to damage oil seal (23). Remove the shaft (5) assembly and shoe plate (9) from casing (11).
14. Remove oil seal (23) from casing (11).
• Do the following procedures if necessary. Do not use bearings (15, 16) again.
15. Remove the inner ring of bearing (15) from shaft (5).
NOTE: Evenly tap and remove the inner ring of bearing (15) by using a steel bar.
16. Remove the outer ring of bearing (15) from casing (11).
NOTE: Evenly tap and remove the outer ring of bearing (15) by using a steel bar.
IMPORTANT: Check the direction to install oil seal (23). Do not damage the outer surface of oil seal (23).
3. Insert oil seal (23) to casing (11). NOTE: Apply grease to the lip part in oil seal (23).
Use special tool.
4. Wind a vinyl tape onto the spline part of shaft (5) assembly in order not to damage the lip of oil seal (23). Install the shaft (5) assembly to casing (11).
5. Place casing (11) horizontally.
6. Insert shoe plate (9) into casing (11). NOTE: Face the larger chamfered side of shoe
plate (9) to the inner side of casing (11). Apply grease onto the mating surface in order not to fall off.
7. Install retainer (8) and spring (7). Install piston (1) with shoe (2) attached.
8. Install piston (1) to retainer (8). Install piston (1) into cylinder (6).
9. Align the splines of cylinder (6) and shaft (5) and install the cylinder (6) assembly to shaft (5).
10. Place casing (11) with the oil seal (23) side facing downward.
Replace the parts when the pitting (beyond 1 mm a pit, beyond 5% on the rate of area) occurs in tooth of sun gears (5,7), planetary gears (4,6) and ring gear (3).In case the pitting does not occur and the damage on general view is found, replace the parts.
Swing Motor
1. Clearance between piston outer diameter and cylinder inner bore.
Unit: mm (in)
Standard Allowable Limit
D-d 0.028 (0.001) 0.058 (0.002)
2. Clearance between piston and shoe
Unit: mm (in)
Standard Allowable Limit
0 (0) 0.3 (0.012)
3. Shoe thicknessUnit: mm (in)
Standard Allowable Limit
t 5.5 (0.22) 5.3 (0.20)
4. Friction plate thicknessUnit: mm (in)
Standard Allowable Limit
2.0 (0.079) 1.6 (0.063)
W25N-02-04-005
W25N-02-04-006
Dd
t
CRANE UPPER / Winch Assembly
W2-7-1
REMOVE AND INSTALL FRONT AND REAR WINCH ASSEMBLY
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Lower the boom and live-mast.
2. Remove the wire rope from front and rear drums.
3. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.)
4. Remove bolts (3), (4) from the front and rear hoisting motors. Remove the washer tank, hose clamps (2 used) and cables in the right house (1). Hoist and remove right houses (1), (2).
: 17 mm
5. Lower the live-mast. Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.)
6. Remove the backstop. (As for removal of the backstop, refer to the Operator's Manual.)
10. Turn the front and rear drum lock switches in operator's cab into the UNLOCK position. Release the drum lock.
NOTE: In case the claw is not removed, turn the hoisting lever into the HOISTING side a little with the drum lock switch in UNLOCK.
11. Remove the wire harness and all hoses from winch motor (10). Attach a plug onto the removed hoses.
: 19 mm : 22 mm : 27 mm : 32 mm : 36 mm
12. Remove bolt (11). Remove brackets (12), (13) from the drum speed sensors.
: 19 mm
W2BC-02-07-001
W2BD-02-07-002
9 5 9 6
9 99 9 9 9
87
99
9 9 9 99 9
9 9
13
11
11
12
CRANE UPPER / Winch Assembly
W2-7-3
CAUTION: Main winch assembly weight: Approx. 2000 kg (4410 lb)Auxiliary winch assembly weight: Approx. 2000 kg (4410 lb)
IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor.
13. Attach a wire rope onto the drum of winch assembly. Hold the winch assembly.
14. Remove nuts (17) and remove bolts (18). : 24 mm
15. Remove retaining rings (15) (8 used). Remove pins (16) (8 used). Hoist and remove the hoist mechanism.
W2BC-02-07-002
W2BC-02-07-003
1017, 18
1615
1017, 18
16
15
15
17
16
18 10 18
16
15
18 10 17
181615
15 16161516
17
CRANE UPPER / Winch Assembly
W2-7-4
Installation
CAUTION: Main winch assembly weight: Approx. 2000 kg (4410 lb) Auxiliary winch assembly weight: Approx. 2000 kg (4410 lb)
IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor.
1. Attach a wire rope onto the drum of winch assembly. Hoist and align the winch assembly with the upper revolving frame.
2. Install the winch assembly to the upper revolving frame with pins (16) (8 used). Install retaining rings (15) (8 used).
3. Adjust the position of bolts (18) (8 used) so that the flange of drum can mesh with the claw of drum lock. Tighten nut (17) (8 used).
: 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m)
(132 to 143 lbf ft) W2BC-02-07-002
W2BC-02-07-003
1017,18
1615
1017, 18
16
15
15
17
16
18 10 18
16
15
18 10 17
181615
15 16161516
17
CRANE UPPER / Winch Assembly
W2-7-5
4. Install brackets (12), (13) of the drum speed sensors to the winch assembly with bolts (11) (4 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
5. Install the wire harness and all hoses to winch motor (10).
: 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 32 mm : 137 N m (14 kgf m, 101 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft)
6. Install drum covers (5), (6), (7), (8) onto the upper revolving frame with bolts (9) (16 used).
: 19 mm : 72 to 78 N m (7.4 to 8.0 kgf m)
(54 to 57 lbf ft)
W2BC-02-07-014
W2BD-02-07-002
W2BC-02-07-001
9 5 9 6
9 99 9 9 9
87
99
9 9 9 99 9
9 9
18 17 1817
13
11
11
12
CRANE UPPER / Winch Assembly
W2-7-6
7. Install the backstop. (As for installation of the backstop, refer to the Operator's Manual.)
8. Wind the boom hoist wire rope. Extend the live-mast. (As for winding the boom hoist wire rope, refer to the Operator's Manual.)
9. Hoist and install right houses (1), (2). Tighten bolts (3), (4).
: 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m)
(31 to 33 lbf ft)
10. Install the washer tank, hose clamps (2 used) and cables in the right house (1).
11. Install the counterweight. (Refer to W2-2 in this section.)
12. Wind the wire rope into the front and rear drums.
13. Check the brake condition of front and rear drum and any oil leakage for winch motor.
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Front winch assembly weight: Approx. 2000 kg (4410 lb) Rear winch assembly weight: Approx. 2000 kg (4410 lb)
1. Remove plug (25) and drain off gear oil.Gear oil : 22.5 L (5.9 US gal)
: 14 mm NOTE: Drain off gear oil in the clean container and
check the metal powder due wear.
2. Lift the winch assembly with the crane and place it on a workbench with placing the brake unit (42) downward. At this time, place the wooden block (200 mm square) under the bracket (41) to stable the winch assembly.
CAUTION: Winch motor (16) weight: Approx. 220 kg (485 lb)
3. Remove bolts (12) (4 used). Lift the motor (16) assembly with the crane and remove it.
: 30 mm
4. Remove bolts (12) (12 used). Lift bracket (23) with the crane and remove it.
31. Install the pedestal (22) assembly to cover (24).
32. Tighten nut (20) to cover (24) with placing the step part to the bearing (21) side.
: 226 N m (23 kgf m, 167 lbf ft)
33. Rotate pedestal (22) clockwise and counterclockwise 4 to 5 times.
34. Tap the end of pedestal (22) with using a plastic hammer. Tighten nut (20) to cover (24) again. (Repeat it twice.) Adjust dimension C to 14 to 16 mm.
36. Lift the bracket (23) with the crane and tighten it with the bolts (12) (12 used) with the washer (13) attached.
: 30 mm : 539 N m (55 kgf m, 398 lbf ft)
37. Tap the end of shaft (8) with using a plastic hammer several times. Check if dimension L between the end of pedestal (22) and that of shaft (8) is 22 to 23 mm.
CRANE UPPER / Winch Assembly
W2-7-16
W2BD-02-07-003
12
13 15
16
2224
25
12
13
13 12
CRANE UPPER / Winch Assembly
W2-7-17
38. Apply liquid packing (ThreeBond #1389) on the mating surface of the motor (16) and the pedestal (22).
CAUTION: Winch motor (16) weight: Approx. 220 kg (485 lb)
39. Lift the motor (16) assembly with the crane and install it on the pedestal (22). Tighten it with the bolts (12) (4 used) with the washer (13) installed.
: 30 mm : 539 N m (55 kgf m, 398 lbf ft)
CAUTION: Front winch assembly weight: Approx. 2000 kg (4410 lb) Rear winch assembly weight: Approx. 2000 kg (4410 lb)
40. Lift the winch assembly with the crane and place it onto the workbench horizontally.
41. Add gear oil to the middle of level gauge (15) through the oil filler on cover (24).Gear oil: 22.5 L (5.9 US gal)
42. Install plug (25) on oil filler of cover (24). : 14 mm
9. Install piston (37) (9 used) and shoes (39) (9 used) to plate (38). Insert piston (37) (9 used) and shoe (39) into rotor (8).
10. Align the rotor (8) assembly with shaft (43) spline and the spline of rotor (8) and holder (3) and install it to shaft (43).
NOTE: Use the lifting tool for rotor.
11. Insert needle bearing (35) into valve cover (14). NOTE: Insert the needle bearing (35) until it stops
at the step part of the valve cover (14) as tapping the outer ring evenly with a hammer through the needle bearing outer ring inserting tool.
12. Install pin (13) to valve cover (14).
13. Apply grease to valve plate (9). Align the pin (13) positions and install valve plate (9) on valve cover (14).
14. Install O-ring (33) to valve cover (14).
15. Install valve cover (14) onto casing (5) with socket bolts (15) and (34) (9 used).
: 14 mm : 333 N m (34.0 kgf m, 246 lbf ft)
16. Install coupling (32) to shaft (43). Install retaining ring (22).
IMPORTANT: Align the notches on plate (30) and friction plate (29). Adjust with shim (31) so that the dimension between the ends of valve cover (14) and plate (30) becomes 3.1 mm (0.12 in).
17. Install shim (31) to valve cover (14) and coupling (32). Install plates (30) (8 used) and friction plates (29) (7 used) in this order alternately.
23. Install plug (23) to cover (25). : 8 mm : 44 N m (4.5 kgf m, 32 lbf ft)
24. Install O-ring (27) to plugs (28) (3 used). Install plugs (28) (3 used) to casing (19).
: 19 mm : 36 N m (3.7 kgf m, 27 lbf ft)
25. Install O-ring (6) to plug (7). Install plug (7) to casing (5).
: 36 mm : 167 N m (17.0 kgf m, 123 lbf ft)
26. Install sub plate (12) to valve cover (14) with socket bolts (11) (6 used).
: 10 mm : 98 N m (10.0 kgf m, 72 lbf ft)
CRANE UPPER / Winch Assembly
W2-7-26
Special Tool
W24X-02-07-007
W24X-02-07-008
16025
20
1303
250
70
60
45
M16For lifting bolt
20
110
25
57
76
10
25
75
100
10
Special Tool For Rotor
Special Tool When Inserting Outer Ring Of Needle Bearing
Special Tool When Inserting Oil Seal
CRANE UPPER / Winch Assembly
W2-7-27
MAINTENANCE STANDARD
1. Secure the plunger with the shoe attached in a vise. Install the dial gauge to the shoe. Move the shoe upward and downward and measure the clearance between shoe and spherical part of plunger. In case the measurement value is beyond allowable limit, replace the plunger and shoe assembly.
Unit: mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.3 (0.012)
Remedy: Replace the shoe and plunger as an assembly.
2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90° away from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.
Unit: mm (in)
Standard Allowable Limit
0.039 (0.002) 0.078 (0.003)
Remedy: Replace the plunger or rotor.
3. Measure shoe thickness C with using a micro meter.
Unit: mm (in)
Standard Allowable Limit
C 8.8 (0.35) 8.6 (0.34) Make sure that a scattering of shoes (9 used) is within 0.03 mm (0.001 in).
Remedy: Replace the shoe and piston as an assembly.
W309-04-05-002
W309-04-05-003
W309-04-05-004
W309-04-05-005
Soft LinerVise
Dial Gauge
Clearance
Guide
C
CRANE UPPER / Winch Assembly
W2-7-28
4. Measure heights of H and h. Unit: mm (in)
Standard Allowable Limit
H-h 32.2 (1.27) 31.6 (1.24)
Remedy: Replace the holder and plate as an assembly.
5. Measure dimension (A).Unit: mm (in)
Standard Allowable Limit
A 3.1 (0.12) 3.6 (0.14)
Remedy: Adjust with the shims.
6. Measure the brake spring length.Unit: mm (in)
Standard Allowable Limit
54 (2.13) 53.2 (2.09)
Remedy: Replace the spring.
7. Measure the thickness of plate and friction plate. (15 used)
22. Install retainer (12) to pedestal (6). Install washer (11) to bolts (10) (8 used). Apply LOCTITE #262 on bolts (10) (8 used). Tighten bolts (10) (8 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
CRANE UPPER / Winch Assembly
W2-7-42
(Blank)
CRANE UPPER / Winch Assembly
W2-7-43
REMOVE AND INSTALL FOURTH WINCH ASSEMBLY (OPTIONAL)
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Lower the boom and live-mast.
2. Remove the wire rope from front and rear drums.
3. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.)
4. Remove bolts (3, 4) (8 used) from the tool box (1). Disconnect connector (4) in the right house (7). Hoist and remove tool box (1).
: 17 mmW2BC-02-07-004
W2BC-02-07-005
1
2
3
4
CRANE UPPER / Winch Assembly
W2-7-44
5. Remove bolts (5, 6) (8 used) from the right house (7). Hoist and remove the right house (7).
6. Lower the live-mast. Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.)
7. Remove the backstop. (As for removal of the backstop, refer to the Operator's Manual.)
W2BC-02-07-006
5
6
7
CRANE UPPER / Winch Assembly
W2-7-45
8. Remove bolts (8) (3 used) and remove drum cover R (9). Remove bolts (10) (3 used) and remove drum cover L (11).
: 19 mm
9. Turn the drum lock switches in operator's cab into the UNLOCK position. Release the drum lock.
NOTE: In case the claw is not removed, turn the hoisting lever into the HOISTING side a little with the drum lock switch in UNLOCK.
10. Remove the wire harness and all hoses from winch motor. Attach a plug onto the removed hoses.
: 19 mm : 22 mm : 27 mm : 32 mm : 36 mm
W2BC-02-07-007
W2BC-02-07-008
89
8
11 10
CRANE UPPER / Winch Assembly
W2-7-46
CAUTION: Main winch assembly weight: 1980 kg (4365 lb)Auxiliary winch assembly weight: 1980 kg (4365 lb)
IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor.
11. Attach a wire rope onto the drum of winch assembly. Hold the winch assembly.
13. Remove retaining rings (12) (4 used). Remove pins (13) (4 used). Hoist and remove the hoist mechanism.
W2BC-02-07-009
W2BC-02-07-010
W2BC-02-07-011
13 1213 12
13 12 14 12 13
12 13
14
151413
1312 12
CRANE UPPER / Winch Assembly
W2-7-47
Installation
CAUTION: Main winch assembly weight: 1980 kg (4365 lb) Auxiliary winch assembly weight: 1980 kg (4365 lb)
IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor.
1. Attach a wire rope onto the drum of winch assembly. Hoist and align the winch assembly with the upper revolving frame.
2. Install the winch assembly to the upper revolving frame with pins (13) (4 used). Install retaining ring (12) (4 used).
3. Adjust the position of bolt (15) (4 used) so that the flange of drum can mesh with the claw of drum lock. Tighten nut (14) (4 used).
: 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
W2BC-02-07-015
W2BC-02-07-009
W2BC-02-07-010
W2BC-02-07-011
13 1213 12
13 12 14 12 13
12 13
14
151413
1312 12
14
15
CRANE UPPER / Winch Assembly
W2-7-48
4. Install the wire harness and all hoses to winch motor.
: 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 32 mm : 137 N m (14 kgf m, 101 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft)
5. Install drum cover R (9) onto the upper revolving frame with bolts (8) (3 used). Install drum cover L (11) onto the upper revolving frame with bolts (10) (3 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
W2BC-02-07-007
W2BC-02-07-008
89
8
11 10
CRANE UPPER / Winch Assembly
W2-7-49
6. Install the backstop. (As for installation of the backstop, refer to the Operator's Manual.)
7. Wind the boom hoist wire rope. Extend the live-mast. (As for winding the boom hoist wire rope, refer to the Operator's Manual.
8. Hoist and install right house (7). Tighten bolts (5, 6). : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft)
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Fourth winch assenbly weight: Approx. 2000 kg (4410 lb)
1. Remove plug (25) and drain off gear oil.Gear oil : 22.5 L (5.9 US gal)
: 14 mm NOTE: Drain off gear oil in the clean container and
check the metal powder due wear.
2. Lift the fourth winch assenbly with the crane and place it on a workbench with placing the brake unit (42) downward. At this time, place the wooden block (200 mm square) under the bracket (41) to stable the fourth drum.
CAUTION: Fourth Winch motor (16) weight: Approx. 220 kg (485 lb)
3. Remove bolts (12) (4 used). Lift the motor (16) assembly with the crane and remove it.
: 30 mm
4. Remove bolts (12) (12 used). Lift bracket (23) with the crane and remove it.
31. Install the pedestal (22) assembly to cover (24).
32. Tighten nut (20) to cover (24) with placing the step part to the bearing (21) side.
: 226 N m (23 kgf m, 167 lbf ft)
33. Rotate pedestal (22) clockwise and counterclockwise 4 to 5 times.
34. Tap the end of pedestal (22) with using a plastic hammer. Tighten nut (20) to cover (24) again. (Repeat it twice.) Adjust dimension C to 14 to 16 mm.
36. Lift the bracket (23) with the crane and tighten it with the bolts (12) (12 used) with the washer (13) attached.
: 30 mm : 539 N m (55 kgf m, 398 lbf ft)
37. Tap the end of shaft (8) with using a plastic hammer several times. Check if dimension L between the end of pedestal (22) and that of shaft (8) is 22 to 23 mm.
CRANE UPPER / Winch Assembly
W2-7-60
W2BD-02-07-004
15
16
2224
25
13 12
CRANE UPPER / Winch Assembly
W2-7-61
38. Apply liquid packing (ThreeBond #1389) on the mating surface of the motor (16) and the pedestal (22).
CAUTION: Fourth winch motor (16) weight: Approx. 220 kg (485 lb)
39. Lift the motor (16) assembly with the crane and install it on the pedestal (22). Tighten it with the bolts (12) (4 used) with the washer (13) installed.
: 30 mm : 539 N m (55 kgf m, 398 lbf ft)
CAUTION: Fourth winch assenbly weight: Approx. 2000 kg (4410 lb)
40. Lift the fourth winch assenbly with the crane and place it onto the workbench horizontally.
41. Add gear oil to the middle of level gauge (15) through the oil filler on cover (24).Gear oil: 22.5 L (5.9 US gal)
42. Install plug (25) on oil filler of cover (24). : 14 mm
14. Install plungers (38) (9 used) to plate (27). Install plunger (38) to rotor (30).
15. Align the spline of output shaft (5) with that of rotor (30) and holder (28). Install the rotor (30) assembly to output shaft (5).
16. Apply grease onto valve plate (31). Align it with pin (40) and install valve plate (31) on valve cover (41). Install O-ring (39) onto valve cover (41).
17. Place casing (23) on the workbench vertically.
18. Install valve cover (41) onto casing (23) with socket bolts (45) and (54) (9 used).
: 14 mm : 333 N m (34 kgf m, 246 lbf ft)
CRANE UPPER / Winch Assembly
W2-7-72
W2CM-02-07-010
4313 14
42
48
2336
37
44
41
50
34
35
61
59
58
53
62
3534
5
41 5547 49 46 56
57
60
CRANE UPPER / Winch Assembly
W2-7-73
19. Install coupling (48) to output shaft (5). Install retaining ring (50).
IMPORTANT: Align the notches on plate (49) and friction plate (55). Adjust shims (47) so that the dimension between end of valve cover (41) and plate (49) becomes 3.1 mm (0.12 in).
20. Install shims (47), plates (49) (8 used) and friction plates (55) (7 used) to valve cover (41) and coupling (48) in order.
23. Install springs (59) (16 used) on piston (58).
24. Install O-ring (60) to cover (61). Install cover (61) to casing (53) with socket bolts (62) (12 used).
: 10 mm : 98 N m (10 kgf m, 72 lbf ft)
25. Install O-ring (34) to plug (35). Install plug (35) to casing (23).
: 36 mm : 167 N m (17 kgf m, 123 lbf ft)
CAUTION: Select plate weight: Approx. 7.0 kg (15 lb)
26. Install select plate (36) to the casing (23) with socket bolts (37) (4 used).
: 5 mm : 12 N m (1.2 kgf m)
CAUTION: Counterbalance valve weight: Approx. 20 kg (44 lb)
27. Install counterbalance valve (44) to valve cover (41) with socket bolts (43) (6 used) and spring washer (42) (6 used).
: 10 mm : 69 N m (7.0 kgf m, 8.9 lbf ft)
CAUTION: Regulator weight: Approx. 8.0 kg (18 lb)
28. Install regulator (14) to casing (23) with socket bolts (13) (4 used).
: 6 mm : 29 N m (3.0 kgf m, 21 lbf ft)
CRANE UPPER / Winch Assembly
W2-7-74
MAINTENANCE STANDARD
1. Secure the plunger with the shoe attached in a vise. Install the dial gauge to the shoe. Move the shoe upward and downward and measure the clearance between shoe and spherical part of plunger. In case the measurement value is beyond allowable limit, replace the plunger and shoe assembly.
Unit: mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.3 (0.012)
Remedy: Replace the shoe and plunger as an assembly.
2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90° away from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.
Unit: mm (in)
Standard Allowable Limit
0.039 (0.002) 0.078 (0.003)
Remedy: Replace the plunger or rotor.
3. Measure shoe thickness B with using a micrometer.
Unit: mm (in)
Standard Allowable Limit
8.8 (0.35) 8.6 (0.34)
W309-04-05-002
W309-04-05-003
W309-04-05-004
W309-04-05-005
Soft LinerVise
Dial Gauge
Clearance
Guide
B
CRANE UPPER / Winch Assembly
W2-7-75
4. Measure heights of H and h.
C=H-hUnit: mm (in)
Standard Allowable Limit
32.2 (1.27) 31.6 (1.24)
Remedy: Replace the holder and plate as an assembly.
5. Measure dimension (A).Unit: mm (in)
Standard Allowable Limit
3.1 (0.12) 3.6 (0.14)
Remedy: Adjust the shims.
6. Measure the brake spring length.Unit: mm (in)
Standard Allowable Limit
54 (2.13) 53.2 (2.09)
Remedy: Replace the spring.
7. Measure the thickness of plate and friction plate. (15 used)
22. Install retainer (12) to pedestal (6). Install washer (11) to bolts (10) (8 used). Apply LOCTITE #262 on bolts (10) (8 used). Tighten bolts (10) (8 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
SWING MACHINERY / Winch Assembly
W2-7-88
(Blank)
CRANE UPPER / Raising/Lowering Mechanism
W2-8-1
REMOVE AND INSTALL RAISING/LOWERING MECHANISM
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Lower the boom and live-mast.
2. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.)
3. Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.)
4. Set and secure hanger (1) in order not to lie down inside.
8. Hoist and remove the boom stop lower frame (3).
W2BC-02-03-001
W2BC-02-08-001
2
3
4
54
5
4
45
CRANE UPPER / Raising/Lowering Mechanism
W2-8-3
9. Remove bolts (6) (3 used), (7) (1 used) and remove drum cover L (8).
: 19 mm
10. Remove bolts (6) (3 used), (7) (3 used) and remove drum cover R (9).
: 19 mm
W2BD-02-08-001
7
8 6
6
7
96
CRANE UPPER / Raising/Lowering Mechanism
W2-8-4
11. Remove bolts (11). Remove bracket (10) in the drum speed sensor.
: 19 mm
12. Remove the wire harness and all hoses from boom hoist system.
: 27 mm : 41 mm
CAUTION: Raising/Lowering mechanism weight: Approx. 870 kg (1920 lb)
13. Attach a wire rope onto the boom hoist system. Hold the boom hoist system.
14. Remove nuts (13) (4 used) and remove bolts (12). : 24 mm
15. Remove retaining rings (14) (4 used). Remove pins (15) (4 used). Hoist and remove the boom hoist system.
W25N-02-08-002
W2BC-02-08-003
W2BC-02-08-004
14
15
12
13
12
14
13
12
1515
12
13
12
10
11
CRANE UPPER / Raising/Lowering Mechanism
W2-8-5
Installation
CAUTION: Raising/Lowering mechanism weight: Approx. 870 kg (1920 lb)
1. Attach a wire rope onto the boom hoist system. Hoist and align the boom hoist system with the upper revolving frame.
2. Install the boom hoist system to the upper revolving frame with pins (15) (4 used). Install retaining rings (14) (4 used).
3. Adjust the boom hoist system by using bolts (12) (4 used) so that the flange of drum can be aligned with the claw of drum lock. Tighten nuts (13) (4 used).
: 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m)
(132 to 143 lbf ft)
4. Install bracket (10) in the drum speed sensor to the boom hoist system with bolts (11).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
W2BC-02-08-004
W2BC-02-08-003
W25N-02-08-002
12
14
13
12
1515
12
13
12
14
15
12
13
10
11
CRANE UPPER / Raising/Lowering Mechanism
W2-8-6
5. Install all hoses to boom hoist motor. : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft)
6. Install drum cover L (8) to the upper revolving frame with bolts (6) (3 used), (7) (1 used). Install drum cover R (9) to upper revolving frame with bolts (6) (3 used), (7) (3 used).
1. Hoist and install bracket (4) on a workbench. Place the wooden block (200 mm square) underbracket (4).
CAUTION: Motor (1) weight: Approx. 140 kg (309 lb)
2. Hoist and install motor (1) to bracket (4). Install washer (3) to bolts (2) (20 used). Apply LOCTITE #262 on bolts (2) (20 used). Tighten bolts (2) (20 used).
: 30 mm : 490 N m (50 kgf m, 361 lbf ft)
3. Apply grease to floating seal (46). Install bearing (45) and floating seal (46) to motor (1).
4. Install drum (44) to motor (1).
5. Install bearing (45) to drum (44).
6. Tighten nut (43) to motor (1) with the step part facing to bearing (45).
: 490 N m (50 kgf m, 361 lbf ft)
7. Rotate drum (44) clockwise and counterclockwise and 4 to 5 times.
8. Tap the end of drum (44) by using a plastic hammer. Tighten nut (43) to motor (1) again. (Repeat it twice.)
: 490 N m (50 kgf m, 361 lbf ft)
9. Apply LOCTITE #262 on bolts (41) (2 used). Install lock plate (42) to nut (43) with bolts (41) (2 used). Align lock plate (42) with one notch on motor (1) and install lock plate (42).
: 19 mm : 88.3 N m (9.0 kgf m, 65 lbf ft)
10. Install spacer (7) to carrier (9). Install planetary gears (38) (3 used), thrust plates (36) (6 used) and needle bearings (40) (6 used). Face the grove side of planetary gear (38) to cover (15).
11. Install pins (37) (3 used) to carrier (9). Insert spring pin (35). Face the slit of spring pin (35) to cover (15).
12. Install the carrier (9) assembly to motor (1).
13. Apply liquid packing (THREEBOND #1389B) onto the mating surface on drum (44) for ring gear (11).
14. Install ring gear (11) to drum (44). Apply LOCTITE #262 on bolts (39) (28 used). Tighten bolts (39) (28 used).
: 24 mm : 265 N m (27 kgf m, 195 Ibf ft)
15. Install sun gear (10) to the carrier (9) assembly.
17. Install pins (32) (3 used) to carrier (12). Insert spring pin (30). Face the slit of spring pin (30) to cover (15).
18. Install the carrier (12) assembly to ring gear (11) and sun gear (10).
19. Install sun gear (13) to the carrier (12) assembly.
CRANE UPPER / Raising/Lowering Mechanism
W2-8-18
W25N-02-08-004
1
8 13 14
16
15
171819
20
21
22
23
24
28
25
26
27
29
47 48
5049
515253
1
6
7
20
21
22
23
5 3
11
CRANE UPPER / Raising/Lowering Mechanism
W2-8-19
20. Install spacer (7) to carrier (14). Install planetary gears (24) (3 used), thrust plates (28) (6 used) and needle bearings (26) (3 used). Face the step part of planetary gear (24) to motor (1).
21. Install pins (27) (3 used) to carrier (14). Insert spring pin (25). Face the slit of spring pin (25) to cover (15).
22. Install the carrier (14) assembly to ring gear (11) and sun gear (13).
23. Install shaft (16) to the carrier (14) assembly. Check if shaft (16) can rotate by hands.
24. Install bearing (18) to cover (15). Install retaining ring (17).
25. Install pin (19) to cover (15).
26. Apply liquid packing (THREEBOND #1389B) onto the mating surface on ring gear (11) on cover (15).
27. Install cover (15) onto ring gear (11). Install the washer to bolts (29) (16 used). Apply LOCTITE #262 on bolts (29) (16 used). Tighten bolts (29) (16 used).
: 19 mm : 108 N m (11 kgf m, 80 lbf ft)
28. Hoist and install drum (8) to the boom hoist system. Install washer (3) to bolts (5) (20 used). Apply LOCTITE #262 on bolts (5) (20 used). Tighten bolts (5) (20 used). Align the hole (3 places) on drum (8) with plug (6) in the oil filler of boom hoist system.
: 30 mm : 490 N m (50 kgf m, 361 lbf ft)
29. Hoist and place the boom hoist system onto the workbench horizontally.
30. Install bearing (47) to bracket (23) with the seal surface facing inside.
31. Hoist and install bracket (23) to drum (8).
32. Install sleeve (53) to drum (8).
33. Install oil seal (52) to retainer (48).
34. Apply liquid packing onto the mating surface on bracket (23) for retainer (48).
35. Install retainer (48) to bracket (23). Install washer (49) to bolts (50) (6 used). Tighten bolts (50) (6 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
36. Apply liquid packing onto the mating surface on sleeve (53) for retainer (22).
37. Install washer (21) to bolts (20) (2 used). Tighten retainer (22) to the end of sleeve (53) with bolts (20) (2 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
38. Add gear oil through the oil filler. Install plug (6).Gear oil: 9.2 L (9.7 US qt)
: 10 mm : 49.5 N m (5.0 kgf m, 37 lbf ft)
39. Apply grease through grease nipple (51) until grease comes out from the clearance of oil seal (52).
1. Apply grease (Ocean #7) onto the inner surface of oil seal (18). Install oil seal (18) to housing (17). Install retaining ring (19).
IMPORTANT: Do not damage the sliding surface on oil seal (18) in shaft (20).
2. Install bearing (14) and retaining rings (16) (2 used) to shaft (20). At this time, install the bearing (14) so that the flange ring is positioned at the small diameter of the shaft (20).
3. Install the shaft (20) assembly to housing (17).
4. Install swash plate (12) to housing (17).
5. Install retainer (11) to housing (17).
6. Install bushing (13) to shaft (20).
7. Install springs (9) (6 used) and pistons (8) (9 used) to rotor (10).
8. Install the rotor (10) assembly to shaft (20).
9. Install friction plates (21) (6 used) and plates (22) (6 used) to housing (17) and rotor (10).
10. Apply grease to O-rings (25, 26). Install O-rings (25, 26) to brake piston (23).
11. Install brake piston (23) to housing (17).
12. Install disk springs (27) (2 used) to brake piston (23) with taking care about the direction.
13. Install valve plate (28) to plate (3). Install plate (3) to rotor (10).
14. Install bearing (1) to shaft (20) and plate (3).
15. Apply grease to O-ring (6). Install O-ring (6) to housing (17).
16. Apply grease to O-ring (7). Install O-ring (7) to brake valve (5).
CAUTION: Brake valve weight: Approx. 23 kg (51 lb)
17. Install brake valve (5) to housing (17) and install with socket bolts (29) (8 used).
12. Install plug (11) to plugs (10) (2 used). : 5 mm : 15 N m (1.5 kgf m, 11 lbf ft)
13. Apply grease to O-ring (9). Install O-ring (9) to plugs (10) (2 used).
14. Install stopper (20) to casing (6).
15. Install springs (8, 19) to plug (10). Install plug (10) to casing (6).
: 41 mm : 350 N m (36.0 kgf m, 258 lbf ft)
16. Install stopper (7) to casing (6).
17. Insert spring (8) into plug (10). Install plug (10) to casing (6).
: 41 mm : 350 N m (36.0 kgf m, 258 lbf ft)
CRANE UPPER / Raising/Lowering Mechanism
W2-8-28
(Blank)
CRANE UPPER / Remote Control Valve
W2-9-1
REMOVE AND INSTALL REMOTE CONTROL VALVES FOR HOISTING, RAISING/LOWERING DRUM AND TRAVEL
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove bolts (1) (4 used) and remove seat (2). : 13 mm
3. Remove covers (3 to 6) from the right stand.
4. Remove the lever (8 to 10) assemblies and the harness connector for pressure sensors (23) (2 used).
5. Remove nuts (11) (2 used for each). Remove the lever (8 to 10) assemblies from remote control valve (13). Remove the lever (15, 16) assemblies from remote control valve (14).
: 19 mm
W24X-02-01-001
W2BC-02-09-001
W2BC-02-09-002
3
5
14
6
4
1 2
8 9 10
11
23
11
15
16
13
CRANE UPPER / Remote Control Valve
W2-9-2
6. Remove hoses (19) (10 used) from elbows (20, 21) with remote control valve (13) attached.
: 22 mm
7. Remove elbows (20) (8 used) and (21) (2 used) from remote control valve (13).
: 19 mm
8. Remove hoses (25) (9 used) from elbow (21) and adapter (22) with remote control valve (14) attached.
: 22 mm
9. Remove elbows (21) (3 used), adapters (22) (6 used) and pressure sensors (23) (2 used) from remote control valve (14).
: 19 mm
10. Remove socket bolts (12) (12 used). Remove remote control valves (13, 14) from the right stand.
: 6 mm
W2BC-02-09-003
14
21
121312
20
1913
14
21
19
25 19
14
21
22
25
21
19
192523 20
CRANE UPPER / Remote Control Valve
W2-9-3
Installation
1. Install remote control valves (13, 14) to the right stand with socket bolts (12) (12 used).
: 6 mm : 20 N m (2.0 kgf m, 14.5 lbf ft)
2. Install elbows (21) (3 used), adapters (22) (6 used) and pressure sensors (23) (2 used) to remote control valve (14).
: 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m)
(20 to 24.5 lbf ft)
3. Install hoses (25) (9 used) to elbow (21) and adapter (22) with remote control valve (14) attached.
: 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
4. Install elbows (20) (8 used) and (21) (2 used) to remote control valve (13).
: 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m)
(20 to 24.5 lbf ft)
5. Install hoses (19) (10 used) to elbows (20, 21) with remote control valve (13) attached.
: 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
W2BC-02-09-003
14
21
121312
20
1913
14
21
19
25 19
14
21
22
25
21
19
192523 20
CRANE UPPER / Remote Control Valve
W2-9-4
6. Install the lever (8 to 10) assemblies to remote control valve (13). Install the lever (15, 16) assemblies to remote control valve (14). Tighten nuts (11) (2 used for each).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
7. Install the lever (8 to 10) assemblies and the harness connector for pressure sensors (23) (2 used).
8. Install covers (3 to 6) to the right stand.
9. Install seat (2) with bolt (1). : 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft) W2BC-02-09-001
W2BC-02-09-002
W24X-02-01-001
1 2
3
5
14
6
4
13
8 9 10
11
23
11
15
16
CRANE UPPER / Remote Control Valve
W2-9-5
REMOVE AND INSTALL SWING REMOTE CONTROL VALVE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove bolts (1) (4 used) and remove seat (2). : 13 mm
3. Remove covers (3, 5) and panel (12) from the left console.
4. Remove the harness connector from the lever (14) assembly.
5. Remove nut (13). Remove the lever (14) assembly from remote control valve (16).
: 19 mm
6. Remove hoses (18) (4 used) from elbow (17) and adapter (19) with remote control valve (16) attached.
: 22 mm
7. Remove elbows (17) (2 used) and adapters (19) (2 used) from remote control valve (16).
: 6 mm : 19 mm
8. Remove bolts (15) (2 used). Remove remote control valve (16) from the left console.
: 13 mm
W24X-02-01-001
W24X-02-01-003
W2BC-02-09-004
1 2
6
3
4
3
5
6
4
7
9
8
10
141211
1314
15
17
15
1816
18
19
CRANE UPPER / Remote Control Valve
W2-9-6
Installation
1. Install remote control valve (16) to the left console with bolts (15) (2 used).
: 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft)
2. Install elbows (17) (2 used) and adapters (19) (2 used) to remote control valve (16).
: 6 mm : 34 N m (3.5 kgf m, 25 lbf ft) : 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m)
(20 to 24.5 lbf ft)
3. Install hoses (18) (4 used) to elbow (17) and adapter (19) with remote control valve (16) attached.
: 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
4. Pass the lever part of lever (14) assembly through panel (12). Install the lever (14) assembly to remote control valve (16). Tighten nut (13).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
5. Pass and install the harness connector to the lever (14) assembly through panel (12).
6. Install covers (3, 5) and panel (12) to the left console.
7. Install seat (2) with bolt (1). : 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft)
• As the structure of remote control valve is same as for the front drum, rear drum, boom hoist drum, travel and swing, the remote control valve for rear drum is explained here. As spring seat (14), springs (16, 17), spool (19), cover (30) and disc (33) are different respectively, indicate by each remote control valve in order not to confuse the disassembled parts.
• As the parts are made precisely, handle them carefully.
• Clean the outer surface before disassembling.
1. Remove the lower end of boot (38) from covers (30, 48) upward.
2. Remove nut (18) and remove bolt (15). Separate the remote control valve into one unit.
: 13 mm
3. Remove O-ring (25) from casings (26, 39).
4. Remove socket bolt (31). Separate the cover (30) assembly from the casing (39) assembly.
: 5 mm
W25N-02-09-005
W25N-02-09-006
15, 18
38
30
31
30
39
48
39, 25
26, 25
CRANE UPPER / Remote Control Valve
W2-9-11
CAUTION: Plug (11) may fly out by spring (17).
5. Remove plug (11) from casing (39). Remove push rod (32) from plug (11).
6. Align the matching marks on the spool (19) assembly, spring (17) and casing (39). Remove the spool (19) assembly and spring (17) from casing (39).
7. Remove socket bolt (27) and remove plate (24). : 6 mm
8. Remove O-ring (23) and bushing (28) from casing (39).
W25N-02-09-007
W25N-02-09-008
W25N-02-09-009
19
17
39
28
39
23
24
27
32
11
39
CRANE UPPER / Remote Control Valve
W2-9-12
9. Place the spool (19) assembly on the workbench vertically. Push spring seat (14) downward. Push out washers (13) (2 used) by using a screwdriver.
IMPORTANT: Handle the parts as an assembly by each port.Washer (4) is used when adjusting spring (16) for the setting of secondary pressure and the thickness is different according to the spool (19) assembly.
10. Remove spring seat (14), spring (16) and washer (4) from spool (19).
IMPORTANT: Do not damage the inner surface of plug (11).
11. Remove O-ring (12) and seal (29) from plug (11).
12. Remove the detent plug (5) assembly from cover (30) slowly in order not to fly out steel ball (1), holder (2) and spring (6).
: 24 mm
W324-02-09-011
W333-02-09-001
W324-02-09-013
W324-02-09-014
19
1413
19
4
16
14
29
11
12
30
12
43
56
78
CRANE UPPER / Remote Control Valve
W2-9-13
13. Remove socket bolt (36). Remove lever (37) from disc (33).
: 6 mm
14. Remove set screw (35) from disc (33). : 4 mm
15. Attach a round bar onto the end of camshaft (34). Lightly tap and remove camshaft (34) by using a hammer. Remove disc (33).
16. Remove plug (42) from plate (24). Remove steel ball (41) and seat (40).
1. Install steel ball (41) and seat (40) to plate (24).
2. Install O-ring (43) to plug (42). Install plug (42) to plate (24).
: 10 mm : 24.5 to 29.4 N m (2.5 to 3.0 kgf m)
(18 to 21.5 lbf ft)
3. Install bushing (28) and O-ring (23) to casing (39).Tighten plate (24) with socket bolt (27).
: 6 mm : 27.4 to 31.4 N m (2.8 to 3.2 kgf m)
(20 to 23 lbf ft)
4. Install washer (4), spring (16) and spring seat (14) to spool (19) in this order.
5. Place spool (19) on the workbench vertically.Push spring seat (14) upward. Install washers (13) (2 used) onto spring seat (14).
W25N-02-09-010
W25N-02-09-009
W333-02-09-001
W324-02-09-011
19
4
16
14
19
14
13
24
4140
4342
28
39
23
24
27
CRANE UPPER / Remote Control Valve
W2-9-17
6. Install washer (13) with the sharp edge side facing upward so that washer (13) can mesh with the head of spool (19).
IMPORTANT: When inserting the spool (19) assembly, do not attach the lower end of spool onto the corner of casing (39) strongly.
7. Insert spring (17) and the spool (19) assembly into casing (39).
8. Apply a film of grease to seal (29). Install seal (29) and O-ring (12) to plug (11).
9. Apply hydraulic oil onto the surface of push rod (32). Insert push rod (32) into plug (11).
W324-02-09-018
W25N-02-09-008
W324-02-09-013
W324-02-09-019
1913
Sharp Edge Side
29
11
12
11
32
19
17
39
CRANE UPPER / Remote Control Valve
W2-9-18
10. Install the push rod (32) assembly to casing (39).
11. Install disc (33) to cover (30). Insert camshaft (34).
12. Apply LOCTITE #241 onto set screw (35). Tighten set screw (35) to disc (33).
: 4 mm : 15.7 to 17.7 N m (1.6 to 1.8 kgf m)
(11.5 to 13 lbf ft) NOTE: Check if the end of set screw (35) is
inserted into the groove in camshaft (34).
13. Install lever (37) to disc (33) and tighten with socket bolt (36).
: 6 mm : 27.4 to 31.4 N m (2.8 to 3.2 kgf m)
(20 to 23 lbf ft)
W25N-02-09-007
W324-02-09-020
W324-02-09-021
W324-02-09-015
33
30
34
35
33
36
37
33
32
39
CRANE UPPER / Remote Control Valve
W2-9-19
14. Apply much grease to holder (2). Secure and insert steel ball (1) into detent plug (5).
15. Install O-ring (3) to detent plug (5). Tighten detent plug (5) to cover (30).
: 24 mm : 38.3 to 44.1 N m (3.9 to 4.5 kgf m)
(28 to 32.5 lbf ft)
16. Insert washer (4) and spring (6) into detent plug (5). Install lock nut (7) and adjusting nut (8).
: 24 mm : 38.3 to 44.1 N m (3.9 to 4.5 kgf m)
(28 to 32.5 lbf ft)
17. Install the end cover (39) assembly to casings (3, 4) and tighten with socket bolt (31).
: 5 mm : 10.8 to 12.8 N m (1.1 to 1.3 kgf m)
(8.0 to 9.4 lbf ft)
18. Install boot (38) to covers (30, 48).
19. Install O-ring (25) to casing (39) in remote control valve for rear drum and casing (26) in remote control valve for front drum. Place the remote control valve assembly (3-unit) on the flat workbench. Align spring pin (10) with the pin hole and install bolts (15) (2 used). Tighten nut (18).
: 13 mm : 15.7 to 17.7 N m (1.6 to 1.8 kgf m)
(11.5 to 13 lbf ft)
W324-02-09-014
W25N-02-09-012
W25N-02-09-005
30
12
43
56
78
30
31
39
15, 18
38
22
48
39, 25
26, 25
30
CRANE UPPER / Remote Control Valve
W2-9-20
(Blank)
CRANE UPPER / Solenoid Valve
W2-10-1
REMOVE AND INSTALL SOLENOID VALVE UNIT
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove each harness of the solenoid valve from the connector.
3. Remove all hoses from solenoid valve unit (2). Remove the adapter, elbow and tee.
4. Remove spring (12) and spool (8) from sleeve (6). NOTE: Remove spool (8) slowly.
IMPORTANT: Do not loosen the adjusting screw in reducing valve (2).
5. Remove reducing valve (2) from casing (5). : 22 mm
6. Remove plugs (4) (2 used) from casing (5). : 6 mm
7. Remove O-ring (3) from plug (4).
Assemble Solenoid Valve Block
1. Install spool (8) and spring (12) to sleeve (6).
IMPORTANT: Do not loosen the adjusting screw in solenoid (1).
2. Secure sleeve (6) and install solenoid (1). : 32 mm : 27 to 33 N m (2.8 to 3.4 kgf m)
(20 to 24 lbf ft)
3. Apply grease to O-rings (7, 9, 10 and 11). Install O-rings (7, 9, 10 and 11) to solenoid (1) and sleeve (6).
IMPORTANT: Do not loosen the adjusting screw in solenoid (1).
4. Install solenoid (1) and sleeve (6) (4 units) to casing (5).
: 32 mm : 39 to 49 N m (4 to 5 kgf m)
(29 to 36 lbf ft)
IMPORTANT: Do not loosen the adjusting screw in reducing valve (2).
5. Install reducing valve (2) to casing (5). : 22 mm : 39 to 49 N m (4 to 5 kgf m)
(29 to 36 lbf ft)
6. Apply grease to O-ring (3). Install O-ring (3) to plug (4).
7. Install plugs (4) (2 used) to casing (5). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m)
(26 to 28 lbf ft)
CRANE UPPER / Solenoid Valve
W2-10-4
(Blank)
CRANE UPPER / Cylinder
W2-11-1
REMOVE AND INSTALL COUNTERWEIGHT INSTALLATION / REMOVAL CYLINDER
CAUTION: Remove and install the cylinder on the level, solid ground.
Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Remove the counterweight. As for removal of the counterweight, refer to W2-2 in this section.
2. Remove hoses (1) (2 used/cylinder)
CAUTION: Cylinder (1) weight: 200 kg (441 lb)
3. Attach a wire rope onto the cylinder rod (A). Hold cylinder (5).
1 - Cylinder Tube 8 - Wear Ring 14 - O-Ring 20 - Plug 2 - Cylinder Rod 9 - Packing 15 - Backup Ring 21 - O-Ring 3 - Cover 10 - Packing 16 - O-Ring 22 - Valve 4 - Piston 11 - Backup Ring 17 - Set Screw 23 - Manifold 5 - Bushing 12 - Dust Seal 18 - Bushing 24 - O-Ring 6 - Ring 13 - O-Ring 19 - Retaining Ring 25 - Socket Bolt 7 - Wear Ring
19
18
25
23, 24
22
21, 20
1
2
123166111015145413897
17
CRANE UPPER / Cylinder
W2-11-5
Disassemble Cylinder
CAUTION: Cylinder weight: 200 kg (441 lb)
1. Hoist and secure the cylinder horizontally. Drain off hydraulic oil from the cylinder.
2. Pull out piston rod (2) approximately 200 to 300 mm (7.87 to 11.8 in). Remove the cover (3) assembly from cylinder tube (1).
3. Remove piston rod (2) from cylinder tube (1) straightly in order not to damage the sliding surface.
4. Secure piston rod (2) horizontally. Remove set screw (17) from piston (4).
: 4 mm
5. Remove the piston (4) assembly from piston rod (2).
6. Remove O-ring (13) from the inner side of piston (4).
7. Remove wear rings (7, 8) from the outer side of piston (4).
8. Remove the cover (3) from piston rod (2).
CRANE UPPER / Cylinder
W2-11-6
W2BC-02-11-003
19
18
25
23, 24
22
21, 20
1
2
123166111015145413897
17
CRANE UPPER / Cylinder
W2-11-7
9. Remove dust seal (12), ring (6), backup ring (11), packing (10) and bushing (5) from the inner side of cover (3).
10. Remove O-rings (14, 16) and backup ring (15) from the outer side of cover (3).
11. Remove O-ring (13) from piston rod (2).
12. Remove bushing (18) and retaining ring (19) from piston rod (2).
CRANE UPPER / Cylinder
W2-11-8
ASSEMBLE CYLINDER
W2BC-02-11-003
1 - Cylinder Tube 8 - Wear Ring 14 - O-Ring 20 - Plug 2 - Cylinder Rod 9 - Packing 15 - Backup Ring 21 - O-Ring 3 - Cover 10 - Packing 16 - O-Ring 22 - Valve 4 - Piston 11 - Backup Ring 17 - Set Screw 23 - Manifold 5 - Bushing 12 - Dust Seal 18 - Bushing 24 - O-Ring 6 - Ring 13 - O-Ring 19 - Retaining Ring 25 - Socket Bolt 7 - Wear Ring
19
18
25
23, 24
22
21, 20
1
2
123166111015145413897
17
CRANE UPPER / Cylinder
W2-11-9
Assemble Cylinder
1. Install bushing (5), packing (10), backup ring (11), ring (6) and dust seal (12) to the inner side of cover (3) in this order.
2. Install backup ring (15) and O-rings (14, 16) to the outer side of cover (3) in this order.
3. Install wear rings (7, 8) to the outer side of piston (4) in this order.
4. Install O-ring (13) to the inner side of piston (4).
5. Install the cylinder head (3) assembly to piston rod (2).
6. Secure the piston rod (2) assembly horizontally. Install the piston (4) assembly to piston rod (2) by using special tool.
: 618 to 755 N m (63 to 77 kgf m)(460 to 560 lbf ft)
7. Install set screw (17) to piston (4). : 4 mm : 20 N m (2.0 kgf m, 14.5 lbf ft)
8. Clamp cylinder tube (1) in a vise. Secure cylinder tube (1) horizontally.
W25N-03-07-008
Special Tool
47mm
CRANE UPPER / Cylinder
W2-11-10
W2BC-02-11-003
19
18
25
23, 24
22
21, 20
1
2
123166111015145413897
17
CRANE UPPER / Cylinder
W2-11-11
9. Align piston rod (2) with the center of cylinder tube (1). Insert the piston rod (2) assembly into cylinder tube (1) straightly in order not to damage the rings.
10. Tighten cover (3) to cylinder tube (1). : 750 to 917 N m (77 to 94 kgf m)
(Reduction Gear) ......................................W3-2-8Disassemble Travel Motor ........................W3-2-14Assemble Travel Motor .............................W3-2-20Maintenance Standard ..............................W3-2-30
Group 3 Rotating JointRemove and Install Rotating Joint ..............W3-3-1 Disassemble Rotating Joint ........................W3-3-4 Assemble Rotating Joint .............................W3-3-6 Maintenance Standard ................................W3-3-8
Group 4 Take-Up TumblerRemove and Install Take-Up Tumbler.........W3-4-1 Disassemble Take-Up Tumbler ...................W3-4-2 Assemble Take-Up Tumbler........................W3-4-4 Maintenance Standard ................................W3-4-6
Group 5 Upper and Lower RollersRemove and Install Upper Roller ............... W3-5-1 Disassemble Upper Roller.......................... W3-5-4Assemble Upper Roller............................... W3-5-6Maintenance Standard................................ W3-5-8Remove and Install Lower Roller ............... W3-5-9 Disassemble Lower Roller........................ W3-5-12Assemble Lower Roller............................. W3-5-14Maintenance Standard.............................. W3-5-16
Group 6 Track ShoeRemove and Install Track Shoe ................. W3-6-1 Maintenance Standard................................ W3-6-5
Group 7 CylinderRemove and Install Retract Cylinder.......... W3-7-1 Disassemble Cylinder................................. W3-7-8 Assemble Cylinder.................................... W3-7-12Remove and Install Track Adjustment
Group 8 Control ValveRemove and Install 6-Unit Control Valve
for Retract and Jack-up (Optional) ........... W3-8-1 Disassemble 6-Unit Control Valve.............. W3-8-2 Assemble 6-Unit Control Valve................... W3-8-4
2BDW-3-2
(Blank)
BASE CARRIER / Turntable Bearing
W3-1-1
REMOVE AND INSTALL TURNTABLE BEARING
Before removing the turntable bearing, the upper revolving frame must be removed first. For removal and installation of the upper revolving frame, refer to “Remove and Install Upper Revolving Frame” section.In this section, the procedure starts on the premise that the upper revolving frame has already been removed.
Removal
1. Remove elbows (2) (2 used), hoses (3) (2 used) and block (4) from outer race (1).
: 17 mm NOTE: Remove bolt (5) and remove block (4).
3. Put the matching marks on inner race (8) and lower frame (9).
4. Remove bolts (10) (48 used).46 mm
W2BC-03-01-001
W25N-03-01-002
W25N-03-01-003
Matching Mark 98
10
45
32
1
11
7
6
BASE CARRIER / Turntable Bearing
W3-1-2
CAUTION: Turntable bearing weight: 870 kg (1920 lb)
5. Attach a lifting tool onto outer race (1). Hoist and remove the turntable bearing.
W25N-03-01-004
1
BASE CARRIER / Turntable Bearing
W3-1-3
Installation
Clean the mounting surfaces of lower frame and turntable bearing. Apply THREEBOND #1102.
CAUTION: Turntable bearing weight: 870 kg (1920 lb)
1. Hoist the turntable bearing and align the matching marks on lower frame (9) and inner race (8).
NOTE: If the matching marks do not align, the position of soft zone of inner race (8) will be dislocated.
2. Tighten bolts (10) (48 used). : 46 mm : 1910 N m (195 kgf m, 1410 lbf ft)
3. Install covers (7, 11) (2 used) to outer race (1) with bolts (6) (4 used).
: 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
4. Install elbows (2) (2 used), hoses (3) (2 used) and block (4) to outer race (1).
: 17 mm : Bolt(5):50 N m (5.1 kgf m, 37 lbf ft)
NOTE: Install block (4) with bolt (5).
5. Secure hoses (3) (2 used) onto hole (A) (4 places) on cover (7) with band clips (11) (4 used).
W25N-03-01-005
W2BC-03-01-001
MatchingMark
9
8 10
45
32
1
11
7
6
BASE CARRIER / Turntable Bearing
W3-1-4
DISASSEMBLE TURNTABLE BEARING
W25N-03-01-006
1 - Pin 3 - Inner Race 5 - Outer Race 7 - Support (96 Used)2 - Seal 4 - Ball 96 Used) 6 - Seal 8 - Plug
1 3 5
6
2
78
42
6
BASE CARRIER / Slewing Ring
W3-1-5
Disassemble Turntable Bearing
1. Grind off the caulked part of pin (1). Tap and remove pin (1) from the bottom side of plug (8).
2. Remove plug (8). NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5) of plug (8). Tap or pull out the bolt from the inner side.
CAUTION: Turntable bearing weight: 870 kg (1920 lb)
3. Horizontally hoist outer race (5) of turntable bearing a little. Remove seals (2, 6).
4. Rotate inner race (3) and remove ball (4) and support (7) from the plug (8) part.Remove ball (4) by using magnet (A). Use wire (B) and remove support (7).
W25N-03-01-007
W25N-03-01-008
W25N-03-01-009
W105-03-01-010
1
8
8
5
A
3
24
6
B
7
BASE CARRIER / Slewing Ring
W3-1-6
ASSEMBLE TURNTABLE BEARING
W25N-03-01-006
1 - Pin 3 - Inner Race 5 - Outer Race 7 - Support (96 Used)2 - Seal 4 - Ball 96 Used) 6 - Seal 8 - Plug
1 3 5
6
2
78
42
6
BASE CARRIER / Slewing Ring
W3-1-7
Assemble Turntable Bearing
CAUTION: Turntable bearing weight: 870 kg (1920 lb)
1. Before installing the inner race and outer race of turntable bearing, wipe off grease from the groove part for seals (2, 6). Apply THREEBOND #1735. Install seals (2, 6).
2. Apply grease to balls (4) and supports (7). Install balls (4) (96 used) and supports (7) (96 used) through the plug (8) part. Install ball (4) first.
3. Install plug (8) into outer race (5). Install pin (1).Crimp the head of pin (1) by using a punch.Apply much grease (Alvania EP2 grease or equivalent) onto the turntable bearing.
W25N-03-01-011
W25N-03-01-012
W25N-03-01-007
4
7
2
6
1
8
5
BASE CARRIER / Slewing Ring
W3-1-8
(Blank)
BASE CARRIER / Travel Mechanism
W3-2-1
REMOVE AND INSTALL TRAVEL MECHANISM
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
The procedure starts on the premise that the track shoe has already been removed. As for removal and installation of track shoe, refer to W3-6-1.
IMPORTANT: After stopping the engine, remove and install the quick coupling.If the engine does not stop, the quick coupling cannot be inserted or O-ring in the quick coupling may be damaged because of the remaining pressure in the circuit. Before installing, clean the quick coupling.The quick coupling may be damaged if the quick coupling hits.Handle the quick coupling carefully.
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. Remove the quick couplings (4 places in one side, 8 places in total) of travel hydraulic hose.
2. Remove all pipes and covers. : 19 mm, 27 mm, 50 mm
NOTE: Cap the removed pipes.
W25N-03-02-001
BASE CARRIER / Travel Mechanism
W3-2-2
CAUTION: Travel mechanism weight: 890 kg (1970 lb)
3. Hoist travel device (1). Remove bolt (2). Remove travel mechanism (1) from side frame (3).
: 19 mm
Installation
CAUTION: Travel mechanism weight: 890 kg (1970 lb)
1. Hoist and install travel mechanism (1) onto side frame (3) with bolt (2).
: 19 mm : 1400 N m (143 kgf m, 1030 lbf ft)
2. Install all the pipes. : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 50 mm : 306 to 374 N m (31 to 38 kgf m)
(225 to 275 lbf ft)
3. Install the cover. : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
W25N-03-02-002
W25N-03-02-001
1
2
3
Cover
BASE CARRIER / Travel Mechanism
W3-2-3
IMPORTANT: After stopping the engine, remove and install the quick coupling.If the engine does not stop, the quick coupling cannot be inserted or O-ring in the quick coupling may be damaged because of the remaining pressure in the circuit. Before installing, clean the quick coupling. The quick coupling may be damaged if the quick coupling hits.Handle the quick coupling carefully.
4. Install the travel hydraulic hose onto the pipes on travel motor side by using the quick couplings (4 places in one side, 8 places in total).
IMPORTANT: After installing the travel motor, fill hydraulic oil in the travel motor. After installing the travel motor or travel mechanism, in order to prevent the travel motor from seizing, perform the break-in operation. Check for any oil leaks.
CAUTION: Travel mechanism weight: 890 kg (1970 lb)
Loosen the plug slowly and release the remaining pressure in the travel mechanism completely.
As the plug or gear oil gush out, do not loosen the plug suddenly.
Keep away from the plug.
1. Hoist the travel mechanism with plug (44) facing downward. Loosen plug (44-A) 2 to 3 turns and release the remaining pressure in the reduction gear. Remove plug (44) and drain gear oil out from the reduction gear.
2. Place the travel motor on the workbench with the travel motor facing upward. Remove the socket bolt.
: 12 mm
CAUTION: Travel motor weight: 100 kg (220 lb)
3. Remove socket bolt (49). Remove the motor from the travel mechanism. Remove O-ring (50).
4. Remove coupling (46) from shaft (38) in the travel mechanism.
CAUTION: Travel mechanism (reduction gear) weight: 790 kg (1750 lb)
5. Turn over the travel mechanism (reduction gear). Remove socket bolt (49) and remove cover (39).
: 12 mm
6. Remove pin (41) from cover (39). Remove bearing (40).
7. Remove the first stage carrier (31) assembly with shaft (38).
8. Remove shaft (38) from the first stage carrier (31) assembly.
W25N-03-02-004
Level
44-A
44
44-B (Oil Filler Plug)
BASE CARRIER / Travel Mechanism
W3-2-6
W25N-03-02-003
1 2 34 56 9 10
11
13
1415 16
17
18
19
2021 22
23
24
2526
27
2829
30 31
32
33
34
35
36
37
BASE CARRIER / Travel Mechanism
W3-2-7
9. Remove second stage sun gear (30) from second stage carrier (23).
10. Remove the second stage carrier (23) assembly.
11. Remove socket bolt (22). Remove ring gear (20) from drum (4).
: 17 mm
12. Remove O-ring (21) from drum (4).
13. Remove third stage sun gear (19) from third stage carrier (11).
1. Install needle bearing (34) to first stage planetary gears (33) (3 used).
2. Install spacer (32) to first stage carrier (31).
3. Install first stage planetary gears (33) (3 used) and thrust plates (35) (6 used) to first stage carrier (31).
4. Align with the spring pin hole on first stage carrier (31) and install pins (36) (3 used).
5. Install spring pins (37) (3 used) into first stage carrier (31) and pin (36). Face the slit of spring pin (37) to the end of first stage carrier (31) (cover (39) side).
6. Install spacer (24), second stage planetary gears (25) (4 used), needle bearings (26) (4 used) and thrust plates (27) (8 used) to second stage carrier (23) in the same procedures steps 1 to 3.
7. Align with the spring pin hole on second stage carrier (23) and install pins (28) (4 used).
8. Install spring pins (29) (4 used) into second stage carrier (23) and pin (28). Face the slit of spring pin (29) to the end of second stage carrier (23) (cover (39) side).
9. Install needle bearings (14) (8 used) to third stage planetary gears (13) (4 used).
10. Install spacer (15) to third stage carrier (11).
11. Install third stage planetary gears (13) (4 used) and thrust plates (16) (8 used) to third stage carrier (11).
NOTE: Face the groove in end of third stage planetary gear (13) to cover (39).
12. Align with the spring pin hole on third stage carrier (11) and install pins (17) (3 used).
13. Install spring pins (18) (3 used) into third stage carrier (11) and pin (17). Face the slit of spring pin (18) to the end of third stage carrier (11) (cover (39) side).
IMPORTANT: For handling floating seal (2), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3.
14. Apply grease to floating seal (2). Install a pair of floating seal (2) to housing (1) by using bamboo spatula.
15. Install bearing (3) at travel motor side to housing (1).
BASE CARRIER / Travel Mechanism
W3-2-10
W25N-03-02-003
1 2 34 56 8 9
11
13
19
2021 22
23
30 31
33
38
BASE CARRIER / Travel Mechanism
W3-2-11
IMPORTANT: For handling floating seal (2), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3.
16. Apply grease to floating seal (2). Install other pair of floating seal (2) to drum (4) by using bamboo spatula.
17. Hoist and install travel drive sprocket (5) to drum (4). Apply LOCTITE #262 to socket bolts (6) (34 used). Tighten socket bolt (6).
: 19 mm : 950 N m (97 kgf m, 700 lbf ft)
18. Apply grease to O-ring (21). Install O-ring (21) to drum (4). Hoist and install drum (4) to housing (1).
19. Install bearing (3) to housing (1).
20. Tighten nut (8) to housing (1). : 800 N m (82 kgf m, 590 lbf ft)
21. Rotate travel drive sprocket (5) clockwise and counterclockwise and 4 to 5 times.
22. Tap the end of travel drive sprocket (5) by using a hammer.
23. Tighten nut (8) again. : 800 N m (82 kgf m, 590 lbf ft)
24. Repeat steps 21 to 23.
25. Align with the notch on housing (1) and install lock plate (9). Apply LOCTITE #262 onto the bolt (2 used). Tighten the bolt.
: 19 mm : 950 N m (97 kgf m, 700 lbf ft)
26. Apply grease into the spline in third stage carrier (11). Hoist and install the third stage carrier (11) assembly onto housing (1).
27. Install third stage sun gear (19) to third stage carrier (11).
28. Hoist ring gear (20). Mesh ring gear (20) with third stage planetary gear (13) and install ring gear (20) to drum (4).
IMPORTANT: As the relief set pressure changes, do not loosen nut (47) and adjusting scarew (48) in relief valve assembly (32).Do not remove relief valve assembly (32) unless necessary.
1. Remove plug (46). Remove relief valve assemblies (32) (2 used) from base plate (52).
: 27mm
2. Remove poppet seats (35) (2 used), backup rings (33) (4 used) and O-rings (34) (2 used) from base plate (52).
IMPORTANT: Push cap (17) by hands in order not to fly out cap (17) because of spring (24) and remove socket bolt (16).
3. Remove socket bolts (16) (8 used). Remove caps (17) (2 used) and O-rings (22) (2 used) from base plate (52).
: 14mm
4. Remove spring seat (23), spring (24) and spring seat (25) from base plate (52).
CAUTION: Do not damage the hole on base plate (52).
5. Slowly turn and remove plunger assembly (26) from base plate (52).
6. Remove plugs (18) (2 used), O-rings (19) (2 used), springs (20) (2 used) and steel balls (21) (2 used) from base plate (52).
: 14mm
CAUTION: Slowly turn and remove spool assembly (6) in order not to damage the hole on base plate (52).
7. Remove plugs (1, 14). Remove O-rings (2) (2 used), spring guide (3), spring (5) and spool assembly (6).
: 10mm
CAUTION: Pin (55) may be stuck by the screwdriver.
IMPORTANT: As base plate (52) is pushed upward by springs (57, 58), loosen socket bolt (49) evenly.
CAUTION: When removing pins (55, 56), do not damage the outer surface by using a pair of pliers. Do not damage the sliding surface on valve plate (65).
9. Remove valve plate (65), bearing (64), pins (55) (4 used), (56), O-ring (63), springs (57, 58), orifices (53) (2 used) and (54) (2 used) from base plate (52).
NOTE: Springs (57, 58) and valve plate (65) may be left in casing (90).
BASE CARRIER / Travel Mechanism
W3-2-18
W25N-03-02-005
2627282930
31
66
67
68
69
7172
7374
7576
77
7879
80
81
8283
84
8586
88
90
7069
7069 70 69
2728
2930
26
BASE CARRIER / Travel Mechanism
W3-2-19
CAUTION: When removing brake piston (66) by using the compressed air, cover brake piston (66) by using a cloth in order to prevent brake piston (66) from flying out.
Do not damage the sliding surface on valve cover.
10. Add the compressed air (294 to 490 kPa (3 to 5 kgf/ cm2, 42.7 to 71 psi) into the orifice (88) mounting part in casing (90). Remove brake piston (66) from casing (90). Remove D-rings (67, 68), friction plate (69) and disc (70).
CAUTION: Do not damage the sliding surfaces on cylinder block (75), the piston (75) assembly, swash plate (80).
11. Place casing (90) on the workbench horizontally. Remove retaining ring (71), spring seat (72), spring (73), spring seat (74), cylinder block (75), pins (76) (3 used), holder (77), retainer plate (78) and the piston (79) assembly from casing (90).
12. Remove pins (76) (3 used), holder (77), retainer plate (78) and the piston (79) assembly from cylinder block (75).
13. Remove retaining ring (71) from cylinder block (75). Remove spring (73) and spring seat (74).
14. Remove shaft (82) from casing (90). Remove swash plate (80), pistons (85) (2 used), springs (86) (2 used), steel balls (81) (2 used), bearing (83) and oil seal (84).
CAUTION: Do not damage the sliding surface on plunger (31).
IMPORTANT: Do not remove plunger assembly (26) unless necessary.
15. Insert a roud bar (dia. 10) through the hole in arrow part of plunger assembly (26). Clamp plunger assembly (26) in a vise. Remove plugs (27) (2 used).
16. Remove plugs (29) (2 used), check valves (30) (2 used) and O-rings (28) (2 used) from plunger (31).
1. Install spring seat (74), spring (73) and spring seat (72) to cylinder block (75) in this order. Install retaining ring (71).
2. Apply grease onto pins (76) (3 used). Install pin (76) into the hole (3 places) on cylinder block (75). Install holder (77) to cylinder block (75).
IMPORTANT: Install piston (79) so that the small diameter side of inner taper part in retainer plate (78) comes in contact with the shoe flange part of piston (79) assembly.
3. Install pistons (79) (9 used) to retainer plate (78).
4. Apply hydraulic oil onto the piston hole on cylinder block (75). Insert the piston (79) assembly.
5. Secure casing (90) on a workbench.
6. Install oil seal (84) to casing (90). NOTE: As for datails on special tools (C,B), refer to
W3-2-29.
7. Install bearing (83) to casing (90). NOTE: As for datails on special tools (D,B), refer to
W3-2-29.
8. Install steel balls (81) (2 used), springs (86) (2 used) and the piston (85) assemblies (2 used) to casing (90).
CAUTION: Do not damage the lip of oil seal (84).
9. Install the shaft (82) assembly on casing (90).
10. Install swash plate (80) to casing (90).
IMPORTANT: Check if the cylinder block (75) assembly rotates smoothly and the piston (79) assembly reciprocates.
11. Place casing (90) on a workbench horizontally. Apply hydraulic oil onto swash plate (80). Insert the cylinder block (75) assembly into casing (90).
12. Install discs (70) (4 used) and friction plates (69) (3 used) to caing (90). Install disc (70) first.
IMPORTANT: The pin hole (2 places) on brake piston (66) and the pin hole (2 places) on casing (90) should be in line.
14. Install brake piston (66) to casing (90).
15. Place special tool (A). Tap the head of special tool (A) by using a plastic hammer and insert into brake piston (66).
NOTE: As for datails on special tools (A), refer to W3-2-28.
16. Install springs (57, 58) to brake piston (66).
BASE CARRIER / Travel Mechanism
W3-2-24
W25N-03-02-006
63
64
65
90
15
16
17
18
19
20
2122
23
24
2526
27 2829
3031
3233
34
35
49
52
53 54
5556
33
32
55
75
BASE CARRIER / Travel Mechanism
W3-2-25
17. Install O-ring (63) to casing (90).
CAUTION: Do not damage the sliding surface on valve plate (65).
IMPORTANT: Apply grease onto non-sliding surface on valve plate (65) and base plate (52).
18. Secure base plate (52) horizontally on a workbench. Install the outer race assembly of bearing (64), pins (55) (4 used), (56), orifices (53) (2 used), (54) (2 used) and valve plate (65).
CAUTION: Do not fall off valve plate (65). Do not damage the cage of bearing (64).
IMPORTANT: Apply hydraulic oil onto the sliding surface on the cylinder block (75) assembly and valve plate (65). Align pin (55) with the pin hole on casing (90).
19. Clamp casing (90) in a vise. Install base plate (52) to casing (90) with socket bolts (49) (10 used).
: 12 mm : 176 to 206 N m (18 to 21 kgf m)
(130 to 152 lbf ft)
20. Insert a round bar (dia. 10) through the hole in arrow part of plunger (31). Clamp plunger (31) in a vise and install check valve (30) and spring (29) in this order.
21. Install plug (27) with O-ring (28) attached to plunger (31).
: 22 mm : 127 to 147 N m (13 to 15 kgf m)
(94 to 108 lbf ft)
IMPORTANT: Check if plunger assembly (26) moves smoothly.
22. Apply hydraulic oil onto the sliding surface of plunger assembly (26). Slowly rotate and install plunger assembly (26) to base plate (52).
23. Install O-ring (22) on cap (17).
24. Install spring seat (25), spring (24) and spring seat (23) to base plate (52) in this order.
IMPORTANT: Push cap (17) by hands in order not to fly out cap (17) because of spring (24) and tighten socket bolt (16).
25. Install cap assembly (15) to base plate (52) with socket bolts (16) (4 used).
: 14 mm : 98 to 118 N m (10 to 12 kgf m)
(72 to 87 lbf ft)
26. Install steel balls (21) (2 used), springs (20) (2 used), O-rings (19) (2 used) and plugs (18) (2 used) to base plate (52).
27. Install O-rings (34) (2 used) and backup rings (33)(4 used) onto poppet seats (35) (2 used). Install poppet seat (35) to base plate (52).
28. Install the relief valve (32) assembly to base plate (52).
: 27 mm : 353 to 393 N m (36 to 40 kgf m)
(260 to 290 lbf ft)
BASE CARRIER / Travel Mechanism
W3-2-26
W25N-03-02-006
1
35
6
14
52
4
6
2
BASE CARRIER / Travel Mechanism
W3-2-27
CAUTION: Check the direction to install spool assembly (6).
29. Install spool assembly (6) to base plate (52).
30. Install O-ring (2) to plug (14). Install washers (4) (2 used) and plug (14) to base plate (52).
: 10 mm : 112.1 to 123.9 N m (11.5 to 12.5 kgf m)
(83 to 91 lbf ft)
31. Install spring (5), spring guide (3) and O-ring (2) to plug (1). Install plug (1) on base plate (52).
: 10 mm : 112.1 to 123.9 N m (11.5 to 12.5 kgf m)
(83 to 91 lbf ft)
BASE CARRIER / Travel Mechanism
W3-2-28
Special Tool
Special Tool (A): For position of the brake piston
W25N-03-02-007
W25N-03-02-008
NOTE: Unit: mm, 1 mm = 0.03937 in
9.5
10.2
3030
3030
11 12 11 12
11 12 11 12
109.
8
2
73
22
2
73
22
2
73
22
2
73
22
M4 0.7 Screw Length 12Bottom Hole Length: 17 or less
1 2
3 4
M4 0.7 Screw Length 12 Bottom Hole Length: 17 or less
M4 0.7 Screw Length 12 Bottom Hole Length:
17 or less
M4 0.7 Screw Length 12Bottom Hole Length:
17 or less
274
200
3028 28
150
370
12
17518 13
88
5
1820
375
1234
BASE CARRIER / Travel Mechanism
W3-2-29
Special Tool (B): For installation of the casing
W25N-03-02-009
Special Tool (C): For installation of the oil seal
W25N-03-02-010
Special Tool (D): For installation of the bearing
W25N-03-02-011
NOTE: Unit: mm, 1 mm = 0.03937 in
(18
)
5
94 46 23
45
2
C3
C2
C3
36
25
30
25
30
46
225
54
21
36 23
(18
)
30
23 Hole Depth
49.6
7871.6
25
4
0.5C3
C3
30
24
227
23
180
2330
227
BASE CARRIER / Travel Mechanism
W3-2-30
MAINTENANCE STANDARD
1. Measure the clearance between plunger outer diameter (d) of travel motor and rotor bore inner diameter (D).
Unit: mm (in)
Standard Allowable Limit
D-d Maximum 0.03 (0.001)
0.06(0.002)
2. Move the plunger of travel motor upward and downward. Measure clearance between plunger and shoe.
Unit: mm (in)
Standard Allowable Limit
Maximum 0.15 (0.006) 0.4 (0.016)
W117-02-02-009
W107-02-06-140
Dd
Plunger
Rotor
Shoe
Plunger
BASE CARRIER / Rotating Joint
W3-3-1
REMOVE AND INSTALL ROTATING JOINT
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
2. Remove pipes (1 to 17), hoses. : 19 mm, 22 mm, 27 mm, 36 mm, 41 mm,
50 mm NOTE: Cap the pipes and hoses.
3. Remove bolt (24) and remove plate (25). : 24 mm
4. Remove bolt (26) and remove plate (27). : 24 mm
CAUTION: Rotating joint weight: 64 kg (140 lb)
5. Hoist and hold the rotating joint.
6. Remove bolt (28). Remove the rotating joint. : 19 mm
W2BC-03-03-001
W2BC-03-03-002
2425
26
2728
1234
5
6
8
9
10
17
14
15
16
11
12
13
7
BASE CARRIER / Rotating Joint
W3-3-2
Installation
CAUTION: Rotating joint weight: 64 kg (140 lb)
1. Hoist and install the rotating joint with bolt (28). : 19 mm : 110 N m (11 kgf m, 81 lbf ft)
2. Install plate (27) to the rotating joint with bolt (26). : 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
3. Install plate (25) to the upper revolving frame with bolt (24) so that the convex part of plate (27) can be inserted into the concave part of plate (25).
: 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
4. Install bracket (23) with bolt (22). : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft)
5. Install pipes (1 to 17), hoses. : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft) : 50 mm : 306 to 374 N m (31 to 38 kgf m)
6. Install O-ring (2) and scraper (1) on cover (4). NOTE: Evenly tap and install scraper (1) by using
special tool (B).
7. Install cover (4) and tighten with socket bolt (6). : 8 mm : 52 to 56.8 N m (5.3 to 5.8 kgf m)
(38 to 42 lbf ft)
W25N-03-03-006
56
70 or more
Press
20
7
1Special Tool (B)
BASE CARRIER / Rotating Joint
W3-3-8
MAINTENANCE STANDARD
Item Allowable limit (basis for judgment) Remedy
Sliding surface and sealed part
Scored or serious damage Replace
1) Scored or abnormal wear of more than 0.1 mm (0.004 in)
ReplaceSliding surface of body and shaft, except sealed part 2) Scored less than 0.1 mm (0.004 in)
deepRepair and finish with oil stone
1) Wear more than 0.5 mm (0.02 in) deep and abnormal wear
Replace
2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
Body / Shaft
Sliding surface and thrust plate
3) Scored or abnormal wear less than 0.5 mm (0.02 in) and repairable
Repair and finish
1) Wear more than 0.5 mm (0.02 in) Replace
2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
Cover Sliding surface and thrust plate
3) Scored or abnormal wear less than 0.5 mm (0.02 in) and repairable
Repair and finish
BASE CARRIER / Track Take-Up Tumbler
W3-4-1
REMOVE AND INSTALL TRACK TAKE-UP TUMBLER
• In this section, the procedure starts on the premise that the track shoe has already been removed. As for removal and installation of track shoe, refer to the “REMOVE AND INSTALL TRACK SHOE” section on W3-6.
Removal
CAUTION: Track take-up tumbler weight: 226 kg (500 lb)
1. Pry the track take-up tumbler by using a pry bar.Remove the track take-up idler and bearing from the side frame.
2. Attach a wire rope onto the track take-up tumbler. Hoist and remove the track take-up tumbler assembly from the side frame.
3. When storing the track take-up tumbler for a while, place the track take-up idler horizontally on the wooden blocks as illustrated.
Installation
CAUTION: Track take-up tumbler weight: 226 kg (500 lb)
IMPORTANT: Check the direction of bearing. Clean and apply grease onto the sliding part of side frame and bearing.
1. Hoist and install the track take-up tumbler to the side frame.
1. Install bushing (2) to track take-up idler (1).
2. Install O-ring (5) to shaft (3). Align the pin (6) holes and install shaft (3) to bearing (7).
3. Install pin (6) into bearing (7) and shaft (3).
IMPORTANT: For handling floating seal (4), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3.
4. Install a pair of floating seals (4) to track take-up idler (1) and bearing (7).
5. Insert shaft (3) into track take-up idler (1) from the side where floating seal (4) was installed. Install O-ring (5) to shaft (3).
6. Install the other floating seals (4) to track take-up idler (1) and bearing (7).
7. Align the pin (6) holes and install bearing (7) to shaft (3).
8. Tap pin (6) into bearing (7) and shaft (3).
9. Add engine oil through the plug (8) hole in bearing (7).Engine oil: Class CD, SAE 30Engine oil amount: 1.4 L (1.5 US qt)
10. Apply LOCTITE #503 to plug (8). Install plug (8) to bearing (7).
: 6 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
BASE CARRIER / Track Take-Up Tumbler
W3-4-6
MAINTENANCE STANDARD
Track Take-Up Tumbler
W25N-03-04-002
Unit : mm (in)
Standard Allowable Limit Remedy
A 56 (2.21) -
B 27 (1.06) -
C 20 (0.79) -
D 730 (28.7) 709 (27.9)
E 262 (10.3) -
Build up and finishing
(Shaft / Bushing) Unit : mm (in)
Standard Allowable Limit Remedy
Shaft Outer Dia. 120 (4.72) 118 (4.65)
Inner Dia. 120 (4.72) 121 (4.76) Bushing Flange
Thickness6 (0.24) -
Replace
A B
C
D
E
B
BASE CARRIER / Track Take-Up Tumbler
W3-4-7
Travel Drive Sprocket
W25N-03-04-003
Unit : mm (in)
Standard Allowable Limit Remedy
A 21.5 (0.85) -
B 57 (2.24) -
C 100 (3.94) -
D 705.4 (27.8) 689 (27.1)
Build up and finishing
A B
C
D
BASE CARRIER / Track Take-Up Tumbler
W3-4-8
(Blank)
BASE CARRIER / Upper and Lower Rollers
W3-5-1
REMOVE AND INSTALL UPPER ROLLER
• Remove the upper roller on the level, solid ground.
• Before removal of the upper roller, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, removal is easy.
Removal
1. Remove bolt (1). Remove cover (2) from the side frame.
: 19 mm
2. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension.
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7).
: 24 mm
W25N-03-05-001
W25N-03-05-012
W25N-03-05-002
1 2
12
34
Whenextending jack
Whenreleasing jack
5 6 7
BASE CARRIER / Upper and Lower Rollers
W3-5-2
4. Remove jack (4). Hoist the track shoe so that upper roller (8) may keep away from track shoe.
5. Remove bolt (9). : 19 mm
CAUTION: Upper roller (8) weight: 22.6 kg (50 lb)
6. Remove upper roller (8) from the side frame.
Installation
1. Install upper roller (8) to the side frame with bolt (9).
: 19 mm : 110 N m (11 kgf m, 81 lbf ft)
2. Lower the track shoe and adjust the tension of track shoe.
NOTE: As for tension adjustment of track shoe, refer to the “Install Lower Roller” section.
1. Install O-ring (5) to shaft (8). Install shaft (8) to collar (3).
2. Install bushings (6)(2 used) to roller (7).
3. Install a pair of pivot seal (4) to roller (7) and collar (3).
4. Install shaft (8) to roller (7) from the side where pivot seal (4) was installed. Install O-ring (5) to shaft (8).
5. Install other pair of pivot seal (4) to roller (7) and collar (3).
6. Install collar (3) to shaft (8).
7. Install wire (1) to collar (3) and shaft (8).
8. Add engine oil through the plug (2) hole in roller (7).Engine oil: Class CD, SAE 30 Engine oil amount: 40 to 45 cm3
9. Apply LOCTITE #503 to plug (2). Install plug (2) to roller (7).
: 5 mm : 14.7 N m (1.5 kgf m, 10 lbf ft)
BASE CARRIER / Upper and Lower Rollers
W3-5-8
MAINTENANCE STANDARD
Upper Roller
W25N-03-05-010
Unit : mm (in)
Standard Allowable Limit Remedy
A 70 (2.76)
B 30 (1.18)
C 220 (8.66) 200 (7.87)
Cladding by welding and finish or replace
(Shaft / Bushing)Unit : mm (in)
Standard Allowable Limit Remedy
Shaft Outer Dia. 35 (1.38) 34.3 (1.35)
Inner Dia. 35 (1.38) Bushing Flange
Thickness 3.8 (0.15)
Replace
BB A
C
BASE CARRIER / Upper and Lower Rollers
W3-5-9
REMOVE AND INSTALL LOWER ROLLER
• Remove the lower roller on the level, solid ground. Remove the lower roller with the upper revolving frame parallel to the track shoe.
• Before removal of the lower roller, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, removal is easy.
Removal
1. Remove bolt (1). Remove cover (2) from the side frame.
: 19 mm
2. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension.
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7).
: 24 mm
4. Remove jack (4). Operate the travel and loosen the track shoe.
W25N-03-05-001
W25N-03-05-012
W25N-03-05-002
1 2
12
34
Whenextending jack
Whenreleasing jack
5 6 7
BASE CARRIER / Upper and Lower Rollers
W3-5-10
5. Remove bolt (8). : 36 mm
6. Hoist the machine. Place the wooden blocks (500 mm (19.7 in) square (4 used) under lower frame.
CAUTION: Lower roller (10) weight: 82.7 kg (180 lb)
7. Remove lower roller (10) from the track shoe by using a pry bar. Hoist and remove lower roller (10).
Installation
CAUTION: Lower roller (10) weight: 82.7 kg (180 lb)
1. Hoist the machine. Place the wooden blocks (500 mm (19.7 in) square (4 used) under lower frame.
2. Hoist and install lower roller (10) to the bottom of side frame.
3. Align the bolt holes and tighten bolt (8). : 36 mm : 950 N m (97 kgf m, 700 lbf ft)
W24X-03-05-006
W25N-03-05-006
810
10
Crawler Shoe 9
Lower Frame
BASE CARRIER / Upper and Lower Rollers
W3-5-11
IMPORTANT: Make the track shoe in the specified tension.
5. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension.
IMPORTANT: Make the shaft of track take-up idler parallel.
6. Install shim (7) to the side frame. Insert the shim selected from group B into the clearance.
7. Install plate (6) to the side frame with bolt (5). Secure shim (7).
: 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
8. Remove jack (4).
9. Install cover (2) to the side frame with bolt (1). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
2. Install O-ring (4) to shaft (5). Install shaft (5) to collar (6).
IMPORTANT: For handling floating seal (3), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3.
3. Install a pair of floating seal (3) to roller (2) and collar (6).
4. Insert shaft (5) to roller (2) from the side where floating seal (3) was installed. Install O-ring (4) to shaft (5).
5. Install other pair of floating seal (3) to roller (2) and collar (6).
6. Install collar (6) to shaft (5).
7. Add engine oil through the plug (8) hole in collar (6).Engine oil: Class CD, SAE 30 Engine oil amount: 250 cm3
8. Apply LOCTITE #503 to plug (8). Install plug (8) on collar (6).
: 6 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
BASE CARRIER / Upper and Lower Rollers
W3-5-16
MAINTENANCE STANDARD
Lower Roller
W25N-03-05-011
Unit : mm (in)
Standard Allowable Limit Remedy
A 60 (2.36)
B 75 (2.94)
C 20 (0.79) 12 (0.47)
D 270 (10.6) 255 (10.0)
Cladding by welding and finish or replace
(Shaft / Bushing)Unit : mm (in)
Standard Allowable Limit Remedy
Shaft Outer Dia. 70 (2.76) 69.3 (2.73)
Inner Dia. 70 (2.76) Bushing Flange
Thickness 4.5 (0.18)
Replace
BB A
C
D
BASE CARRIER / Track Shoe
W3-6-1
REMOVE AND INSTALL TRACK SHOE
• Remove and install the track shoe in the right procedures safely.
• Remove the track shoe on the level, solid ground. Remove the track shoe with the upper revolving frame parallel to the track shoe.
• Before removing the track shoe, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, the track shoe can be removed easily.
Removal
1. Remove bolt (1). Remove cover (2) from the side frame.
: 19 mm
2. Install jack (4) to bracket (3) in the side frame. Make track shoe (8) in tension.
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7).
4. Remove jack (4).
5. Remove bolt (9) and nut (10) from track shoe (8). : 30 mm
6. Place the wooden block under track shoe (8). Secure track shoe (8). Remove joint pin (11) from track shoe (8) by using a bar.
W25N-03-05-001
W25N-03-05-012
W25N-03-05-002
W333-03-07-001
34
Whenextending jack
Whenreleasing jack
1 2
12
5 6 7
8
10
11
9
BASE CARRIER / Track Shoe
W3-6-2
7. Operate the travel lever into the reverse position slowly. Extend track shoe (8).
CAUTION: Track shoe weight: 3550 kg (7826 lb)
8. Hoist the machine and place wooden block (2 used) under the lower frame.
9. Remove track shoe (8).
W2BC-03-06-003
W2BC-03-06-004
W324-03-05-001
850 mm Wooden Block
8
BASE CARRIER / Track Shoe
W3-6-3
Installation
IMPORTANT: Check the direction of track shoe. 1. Hoist the machine and place wooden block (2
used) under the lower frame.
2. Install track shoe (8) under the machine so that the travel drive sprocket can mesh with the end of track shoe (8).
3. Hoist and mesh track shoe (8) with the travel drive sprocket.
4. Operate the travel lever for the track shoe (8) to be installed in the forward direction. Turn the travel drive sprocket and roll up track shoe (8).
W2BC-03-06-003
W2BC-03-06-004
W2BC-03-06-005
W324-03-07-002
Take-Up Tumbler SideDrive Tumbler
Side
8
8
850 mm Wooden Block
BASE CARRIER / Track Shoe
W3-6-4
5. When the connecting part of track shoe (8) reaches the track take-up idler side, lower the machine. Insert the wooden blocks under track shoe (8).
CAUTION: When aligning the joint pin (11) hole, do not insert the fingers into the hole.
6. Align the joint pin (11) hole on track shoe (8) and install joint pin (11).
7. Install bolt (9) and nut (10) to joint pin (11). : 30 mm : 550 N m (56 kgf m, 410 lbf ft)
8. Weld bolt (9) and nut (10).
IMPORTANT: Make track shoe (8) in the specified tension.
9. Install jack (4) to bracket (3) in side frame. Make track shoe (8) in tension.
IMPORTANT: Make the shaft of track take-up idler parallel.
10. Install shim (7) to the side frame. Insert the shim selected from group B into the clearance.
11. Remove jack (4).
12. Install cover (2) onto the side frame with bolt (1). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
W333-03-07-001
W25N-03-05-012
W25N-03-05-001
8
10
11
9
1 2
12
34
Whenextending jack
Whenreleasing jack
67
5Group B
BASE CARRIER / Track Shoe
W3-6-5
MAINTENANCE STANDARD
Shoe
W2BC-03-06-001 W2BC-03-06-002
Unit: mm (in) Standard Allowable Limit Remedy
A 80 (3.15)
B 26 (1.02)
C 50 (1.97)
D 15 (0.59)
E 60 (2.36) 47 (1.85)
F 142 (5.59)
G 73 (2.87)
H 39 (1.54)
I 18.5 (0.73)
Cladding by welding and hand finishing,
or replace
Joint Pin
W324-03-07-004
Unit: mm (in) Standard Allowable Limit Remedy
A 38 (1.50) 34 (1.34)
B 311 (12.2) Replace
B
A
BASE CARRIER / Track Shoe
W3-6-6
(Blank)
BASE CARRIER / Cylinder
W3-7-1
REMOVE AND INSTALL RETRACT CYLINDER
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame with parallel to the track shoe.
Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Remove sidewalk (1) (6 used) in the upper structure.
2. Hoist the machine horizontally. Place the wooden blocks (500 mm (19.7 in) square) (4 used) under lower frame (8) as illustrated. (4 places on both front and rear, right and left)
10. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
11. Hold the rod side of cylinder (12) by using a sub crane.
12. Remove nut (13). Remove U-bolt (15) from bracket (14) in lower frame (8).
: 30 mm
13. Insert the wooden block between bottoms of cylinder (12) and lower frame (8).
14. Remove all hoses from cylinder (12). Cap the removed hoses. Attach an identification tag for assembling.
: 22 mm
15. Remove pin (16) from cylinder (12).
CAUTION: Cylinder (4) weight: 125 kg (275 lb)
16. Pull out cylinder (12) from lower frame (8). Hoist and remove cylinder (12).
17. Remove the other cylinder in the same procedures.
W2BC-03-07-013
W2BC-03-07-010
W2BC-03-07-011
1011
Wooden Block
8
13
141512
12
BASE CARRIER / Cylinder
W3-7-4
Installation
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame with parallel to the track shoe.
Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines.
Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
1. Hoist the machine horizontally. Place the wooden blocks (500 mm (19.7 in) square) (4 used) under lower frame (8) as illustrated. (4 places on both front and rear, right and left)
W2BC-03-06-003
W2BC-03-07-001
850 mmWooden Block
BASE CARRIER / Cylinder
W3-7-5
2. Insert the wooden blocks under the bottom of lower frame (8) around bracket (17) and the part to insert cylinder in order to support cylinder (12).
CAUTION: Cylinder (4) weight: 125 kg (275 lb)
3. Hoist cylinder (12) by using a sub crane and insert the tube side of cylinder (12) into lower frame (8) with the port part of cylinder (12) facing forward.
4. Install cylinder (12) to bracket (17) in lower frame (8) with pin (16).
5. Install all hoses to cylinder (12).22 mm
: 39 N m (4.0 kgf m, 28.5 lbf ft)
6. Make cylinder (12) parallel by using a sub crane. Install U-bolt (15) to bracket (14) in lower frame (8) and support cylinder (12).
: 30 mm : 170 N m (17 kgf m, 125 lbf ft)
7. Install the other cylinder in the same procedures.
11. Align piston rod (2) with the center of cylinder tube (22). Insert the piston rod (2) assembly into cylinder tube (22) straightly in order not to damage the rings.
12. Tighten cylinder head (8) to cylinder tube (22). : 837 to 1023 N m (85 to 105 kgf m)
(620 to 760 lbf ft)
13. Install boot (4) to piston rod (2) and cylinder tube (22) with boot bands (3, 5).
BASE CARRIER / Cylinder
W3-7-16
(Blank)
BASE CARRIER / Cylinder
W3-7-17
REMOVE AND INSTALL TRACK ADJUSTMENT CYLINDER (OPTIONAL)
• Remove and install the track shoe in the right procedures safely.
• Remove the track shoe on the level, solid ground. Remove the track shoe with the upper revolving frame parallel to the track shoe.
• Before removing the track shoe, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, the track shoe can be removed easily.
Removal
1. Remove bolts (1) (3 used). Remove cover (2) from the side frame.
: 19 mm
2. Remove drain plug (3) from check valve (4) to drain hydraulic oil.
3. Remove bolt (6) and nut (7) from track shoe (5). : 30 mm
4. Place the wooden block under track shoe (5). Secure track shoe (5). Remove joint pin (8) from track shoe (5) by using a bar.
W2BC-03-07-007
W2BC-03-07-008
W333-03-07-001
5
7
8
6
4
15
1
3
2
1
1
BASE CARRIER / Cylinder
W3-7-18
CAUTION: Track take-up idler weight: 226 kg (500 lb)
5. Pry the track take-up idler (9) by using a pry bar. Remove the track take-up idler (9) and bearing (10) from the side frame.
6. Attach a wire rope onto the track take-up idler (9). Hoist and remove the track take-up idler (9) assembly from the side frame.
7. When storing the track take-up idler for a while, place the track take-up idler horizontally on the wooden blocks as illustrated.
8. Remove nuts (12) (4 used) and remove yoke (11). : 65 mm
9. Remove hose (15) from adapter (16). : 19 mm
10. Remove adapter (16) from track adjustment cylinder (17).
: 24 mm
11. Remove bolts (14) (4 used) from plate (13) (2 used) and remove plate (13) (2 used).
: 24 mm
CAUTION: Take-up cylinder weight : 71 kg (157 lb)
12. Remove track adjustment cylinder (7).
W324-03-05-002
W324-03-05-003
W2BC-03-07-007
W2BC-03-07-009
Take-Up Tumbler
910
Bearing
10
Wooden Block
9
1415131211 9
14
16
131217
11 12
13 14
BASE CARRIER / Cylinder
W3-7-19
• Remove and install the track shoe in the right procedures safely.
• Remove the track shoe on the level, solid ground. Remove the track shoe with the upper revolving frame parallel to the track shoe.
• Before removing the track shoe, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, the track shoe can be removed easily.
Installation
CAUTION: Take-up cylinder weight : 71 kg (157 lb)
1. Install track adjustment cylinder (17) to the side frame.
2. Install plate (13) (2 used) with bolts (14) (4 used). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
3. Install adapter (16) to track adjustment cylinder (17).
: 24 mm
4. Install hose (15) to adapter (16). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
CAUTION: Yoke weight : 83 kg (183 lb)
5. Install yoke (11) to the side frame.
CAUTION: Track take-up idler weight : 226 kg (150 lb)
6. Hoist and install track take-up idler (9) to the side frame.
W2BC-03-07-007
W2BC-03-07-009
W324-03-05-002
1415131211 9
14
16
131217
11 12
13 14
Take-Up Tumbler
910
Bearing
BASE CARRIER / Cylinder
W3-7-20
CAUTION: When aligning the joint pin (8) hole, do not insert the fingers into the hole.
7. Install bolt (6) to the track shoe and tighten nut (7). : 30 mm : 550 N m (56 kgf m, 410 lbf ft)
8. Install drain plug (3) to check valve (4).
9. Install cover (2) to the side frame with bolts (1) (3 used).
: 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
10. State the engine. Operate the travel lever to the front or revere direction to supply hydraulic oil to the track adjustment cylinder.
11. Turn nut (12) until nut (12) comes in contact with frame (A).
12. Stop the engine. Turn nut (12) by one turn clockwise. Tighten and lock nut (18) to not (12).
NOTE: If nut (18) cannot be turned, loosen drain plug (3) and drain hydraulic oil a little.
13. Apply grease onto the thread part of bolt (19).
14. Cover the thread part of bolt (19) with the heat shrinkable tube.
W333-03-07-001
W2BC-03-07-007
W2BC-03-07-008
5
7
8
6
Wooden Block
4
15
1
3
2
1
1
191812A
BASE CARRIER / Cylinder
W3-7-21
(Blank)
BASE CARRIER / Cylinder
W3-7-22
DISASSEMBLE TRACK ADJUSTMENT CYLINDER
W2BD-03-07-001
1 - Bolt (4 Used) 4 - Dust Seal 6 - O-Ring 8 - Cylinder Head2 - Spring Washer (4 Used) 5 - Backup Ring 7 - Cylinder Tube 9 - Piston3 - Retaining Ring
9
4
7
6
3
1
2
5
8
BASE CARRIER / Cylinder
W3-7-23
Disassemble Track Adjustment Cylinder
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Cylinder weight: Approx. 71 kg (157 lb)
1. Lift the cylinder with the crane and secure it horizontally. Drain off the hydraulic oil in the cylinder.
2. Remove the bolts (1) (4 used) and washers (2) (4 used) and remove the cylinder head (8) assembly from the cylinder tube (7).
: 13 mm
3. Remove the retaining ring (3) from the inside of the cylinder head (8).
CAUTION: Pull out the piston rod (9) straightly not to damage the sliding surface.
4. Pull out the piston rod (9) from the cylinder tube (7).
5. Remove the dust seal (4), O-ring (6) and backup ring (5) from the inside of the cylinder tube (7).
BASE CARRIER / Cylinder
W3-7-24
ASSEMBLE TRACK ADJUSTMENT CYLINDER
W2BC-03-07-014
1 - Bolt (4 Used) 4 - Dust Seal 6 - O-Ring 8 - Cylinder Head2 - Spring Washer (4 Used) 5 - Backup Ring 7 - Cylinder Tube 9 - Piston3 - Retaining Ring
7
8
654321
9
BASE CARRIER / Cylinder
W3-7-25
Assemble Track Adjustment Cylinder
1. Apply Vaseline on the O-ring (6) and dust seal (4) and install the O-ring (6), backup ring (5) and dust seal (4) on the cylinder tube (7).
IMPORTANT: Insert the piston rod (9) straightly with aligning with the center of the cylinder tube (7) not to damage the rings.
2. Apply Vaseline on the outer surface of the piston rod (9) and insert the piston rod (9) into the cylinder tube (7).
3. Install the retaining ring (3) on the inside of the cylinder head (8).
4. Install the cylinder head (8) assembly on the cylinder tube (7).
5. Install the washers (2) (4 used) and bolts (1) (4 used) on the cylinder head (8) assembly.
: 13 mm
BASE CARRIER / Cylinder
W3-7-26
(Blank)
BASE CARRIER / Cylinder
W3-7-27
REMOVE AND INSTALL JACK-UP CYLINDER (OPTIONAL)
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame vertical to the track shoe. Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
1. Stop the engine. Operate the control lever several times and release the remaining pressure in the circuit.
2. Remove all hoses from cylinder (4). Cap the removed hoses. Attach an identification tag for assembling.
: 22 mm
CAUTION: Jack-up cylinder (1) weight: 312 kg (688 lb)
3. Hold jack-up cylinder (1) by using a sub crane. Remove stopper pin (2) and supporting pin (3) and remove jack-up cylinder (1).
: 17 mm
CAUTION: Cylinder (4) weight: 103 kg (227 lb)
4. Place jack-up cylinder (1) horizontally. Remove bolts (5) (6 used). Remove cylinder (4) from jack beam (6).
: 19 mm
5. Drain hydraulic oil out from cylinder (4).
W2BC-03-07-006
W25N-03-07-012
4
5
6
4
32
BASE CARRIER / Cylinder
W3-7-28
6. Remove the other jack-up cylinder (3 places) in the same procedures.
Installation
CAUTION: Cylinder (4) weight: 103 kg (227 lb)
1. Insert the valve side of cylinder (4) into the bottom of jack beam (6) and install with bolts (5) (6 used).
: 19 mm : 110 N m (11 kgf m, 81 lbf ft)
CAUTION: Jack-up cylinder (1) weight: 312 kg (688 lb)
2. Hoist and install jack-up cylinder (1) to lower frame (7) with supporting pin (3) by using a sub crane. Secure with stopper pin (2).
: 17 mm : 65 N m (6.6 kgf m, 48 lbf ft)
NOTE: The numbers (1 to 4) are indicated on jack-up cylinder (1) and lower frame (7). Install jack-up cylinder (1) to the position where the number is matched. The position to secure jack-up cylinder (1) is the follows (3 places). • When retracting the side frame • When disassembling / assembling the
side frame while working • When transporting
3. Install all hoses to cylinder (4). : 22 mm
Hose : 39 N m (4.0 kgf m, 28.5 lbf ft)
Piping Joint : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
4. Install the other jack-up cylinder (3 places) in the same procedures.
W25N-03-07-012
W2BC-03-07-006
4
5
6
4
32
BASE CARRIER / Cylinder
W3-7-29
(Blank)
BASE CARRIER / Cylinder
W3-7-30
DISASSEMBLE JACK-UP CYLINDER
W25N-03-07-013
1 - Retaining Ring 8 - O-Ring 14 - Cylinder Tube 20 - Set Screw2 - Dust Seal 9 - Rod Packing 15 - Piston 21 - Steel Ball3 - Plate 10 - Plate 16 - Backup Ring (2 Used) 22 - Plug4 - O-Ring 11 - Clip 17 - Piston Seal (2 Used) 23 - Check Valve5 - Bushing 12 - Cylinder Head 18 - O-Ring 24 - Bolt6 - Backup Ring 13 - Piston Rod 19 - Wear Ring 25 - Spring Washer7 - Backup Ring
2. Remove the cylinder head (12) assembly from cylinder tube (14).
3. Remove O-rings (4, 8) and backup ring (7) from the outer side of cylinder head (12).
4. Remove retaining ring (6), dust seal (2), clip (11), plate (10), backup ring (6), rod packing (9) and bushing (5) from the inner side of cylinder head (12).
5. Remove piston rod (13) from cylinder tube (14) straightly in order not to damage the sliding surface.
6. Secure piston rod (13) horizontally. Remove set screw (20) and steel ball (21) from piston (15).
: 5 mm
7. Remove the piston (15) assembly from piston rod (13).
8. Remove O-ring (18) from piston rod (13).
9. Remove piston seals (17) (2 used), backup rings (16) (2 used) and wear ring (19) from the outer side of piston (15).
BASE CARRIER / Cylinder
W3-7-32
ASSEMBLE JACK-UP CYLINDER
W25N-03-07-013
1 - Retaining Ring 8 - O-Ring 14 - Cylinder Tube 20 - Set Screw2 - Dust Seal 9 - Rod Packing 15 - Piston 21 - Steel Ball3 - Plate 10 - Plate 16 - Backup Ring (2 Used) 22 - Plug4 - O-Ring 11 - Clip 17 - Piston Seal (2 Used) 23 - Check Valve5 - Bushing 12 - Cylinder Head 18 - O-Ring 24 - Bolt6 - Backup Ring 13 - Piston Rod 19 - Wear Ring 25 - Spring Washer7 - Backup Ring
1. Install wear ring (19), piston seals (17)(2 used) and backup rings (16) (2 used) to the outer side of piston (15).
2. Install O-ring (18) to piston rod (13).
3. Install the piston (15) assembly to piston rod (13). : 588 to 637 N m (60 to 65 kgf m)
(430 to 470 lbf ft)
4. Install steel ball (21) and set screw (20) to piston (15). Caulk set screw (20) (2 places) by using a punch.
: 5 mm : 17.6 to 21.6 N m (1.8 to 2.2 kgf m)
(13 to 16 lbf ft)
5. Secure cylinder tube (14) horizontally. Align piston rod (13) with the center of cylinder tube (14). Insert the piston rod (13) assembly into cylinder tube (14) straightly in order not to damage the rings.
6. Install bushing (5), rod packing (9), backup ring (6), plate (10), clip (11), dust seal (2) and retaining ring (1) to the inner side of cylinder head (12).
7. Install backup ring (7) and O-rings (4, 8) to the outer side of cylinder head (12).
8. Install the cylinder head (12) assembly to cylinder tube (14).
: 539 to 588 N m (55 to 60 kgf m)(400 to 430 lbf ft)
9. Install check valve (22) to cylinder tube (14) with bolt (24).
: 13 mm : 19 to 21 N m (1.9 to 2.1 kgf m)
(14 to 15.5 lbf ft)
BASE CARRIER / Cylinder
W3-7-34
(Blank)
BASE CARRIER / Control Valve
W3-8-1
REMOVE AND INSTALL 6-UNIT CONTROL VALVE FOR RETRACT AND JACK-UP (OPTIONAL)
Removal
1. Remove bolts (2) (6 used) from cover (1). : 17 mm
2. Remove all hoses from control valve (5). Cap the removed hoses. Attach an identification tag for assembling.
: 22 mm, 27 mm
3. Remove bolts (3) (3 used) from control valve (5). Remove control valve (5).
: 13 mm
Installation
1. Install control valve (5) and tighten with bolts (3) (3 used).
: 13 mm : 20 N m (2.0 kgf m, 15 lbf ft)
2. Install all hoses and harness connectors to control valve (5).
: 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft)
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
3. Install cover (1) and tighten with bolts (2) (bused). : 17 mm : 50 N m (5.1 kgf m, 3.7 lbf ft)
• Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Control valve weight: Approx. 9 kg (20 lb)
1. Place the control valve assembly on a clean workbench.
2. Remove the plug (1) from the housing (3) and drain off the hydraulic oil.
3. Remove the O-ring (2) from the plug (1).
4. Remove the plugs (4) (2 used) from the housing (3).
: 6 mm
5. Remove the plugs (25) (4 used) from the housing (3).
6. Remove the O-rings (26) (4 used) from the plugs (25) (4 used).
7. Remove the relief valve (6) from the housing (3).
8. Remove the O-ring (5) from the relief valve (6).
9. Remove the screws (15) (12 used) from the housing (3) and remove the spring covers (10) (6 used).
10. Remove the spool ends (9) (6 used) from the spools (8) (6 used).
11. Remove the spring holders (12) (12 used) and springs (11) (6 used) from the spools (8) (6 used).
12. Remove the seal holders (7) (6 used) from the housing (3).
13. Remove the retaining rings (17) (12 used) and pins (18) (6 used) from the spools (8) (6 used).
14. Remove the socket bolts (19) (12 used) and spring washers (20) (12 used) from the housing (3).
: 4 mm
IMPORTANT: Check the length of the levers (22) and (23) removed from the spool (8).
15. Remove the lever brackets (16) (6 used), link joints (21) (6 used), levers (22) (4 used), levers (23) (2 used) and knobs (24) (6 used) from the housing.
16. Remove the knobs (24) (6 used) from the levers (22) (4 used) and levers (23) (2 used).
17. Remove the seal holders (7) (6 used) from the housing (3).
18. Remove the spools (8) (6 used) from the housing (3).
19. Remove the backup rings (13) (12 used) and O-rings (14) (12 used) from the housing.
1. Install the O-rings (14) (12 used) and backup rings (13) (12 used) on the housing.
2. Install the spools (8) (6 used) on the housing (3).
3. Install the seal holders (7) (6 used) on the lever side of the housing (3).
4. Install the knobs (24) (6 used) on the levers (22) (4 used) and lever (23) (2 used).
IMPORTANT: Check the length of the levers (22) and (23) removed from the spool (8).
5. Install the lever brackets (16) (6 used), link joints (21) (6 used), levers (22) (4 used), levers (23) (2 used) and knobs (24) (6 used) on the housing (3). Tighten them with the socket bolts (19) (12 used) with the spring washers (20) (12 used).
: 4 mm
6. Install the levers (22) (4 used) and levers (23) (2 used) on the spools (8) (6 used) with the pins (18) (6 used) and retaining rings (17) (12 used).
7. Install the seal holders (7) (6 used) on the spring side of the housing (3).
8. Install the spring holders (12) (12 used) and springs (11) (6 used) on the spools (8) (6 used).
9. Install the spool ends (9) (6 used) on the spools (8) (6 used).
10. Install the spring covers (10) (6 used) on the housing with the screws (15) (12 used).
11. Install the O-ring (5) on the relief valve (6).
12. Install the relief valve (6) on the housing (3).
13. Install the O-rings (26) (4 used) on the plugs (25) (4 used).
14. Install the plugs (25) (4 used) on the housing (3).
15. Install the plugs (4) (2 used) on the housing (3). : 6 mm
16. Install the O-ring (2) on the plug (1).
17. Install the plug (1) on the housing (3).
BASE CARRIER / Control Valve
W3-8-6
SECTION 1 GENERAL
—CONTENTS—Group 1 Specifications
Specifications........................................................... (Refer to Link-Belt Technical Data Manual.)
Group 2 Component Layout Main Components ........................................ T1-2-1 Electric Component Layout .......................... T1-2-4
12 - Third Drum Lowering Remote Control Pressure Sensor*1
16 - Rear Lowering Remote Control Pressure Sensor
*1: If fourth drum (optional) is installed, these valves are used for the fourth drum.The valve for third drum should be newly installed under the fourth drum.
Front Control Valve
Rear Control Valve
Front Control ValveRear Control Valve
14 16
1 2*1 3 4*1 65 7 8
13 15109*1 12*111
Machine Front
Machine Rear
Machine Right
Machine Left
Machine Front
Machine Rear
Machine Left
Machine Right
GENERAL / Component Layout
T1-2-16
4-Spool Control Valve
T2BC-01-02-021
1 - Quick Draw Solenoid Valve (Extend)
5 - Counterweight Solenoid Valve (Right/Retract)
2 - Retract Solenoid Valve (Extend)*1
6 - Counterweight Solenoid Valve (Left/Retract)
3 - Counterweight Solenoid Valve (Left/Extend)
7 - Retract Solenoid Valve (Retract)
4 - Counterweight Solenoid Valve (Right/Extend)
8 - Quick Draw Solenoid Valve (Retract)
*1: If the jack (optional) is installed, the lower power solenoid valve is installed here.
2*11
5
Machine Front
Machine Rear
43
678
Machine Right
Machine Left
GENERAL / Component Layout
T1-2-17
Around Drum
T2BC-01-02-026
T2BC-01-02-025
T2BC-01-02-024
1 - Motor Cutoff High Pressure Solenoid Valve (Only Front / Rear Drums)
4 - Derricking Drum Rotation Detection Switch
7 - Front Drum Rotation Detection Switch (A)
10 - Rear Drum Lock Motor
2 - Brake Release Solenoid Valve
5 - Rear Drum Rotation Detection Switch (A)
8 - Front Drum Rotation Detection Switch (B)
11 - Front Drum Lock Motor
3 - Motor Displacement Angle Proportional Solenoid Valve
6 - Rear Drum Rotation Detection Switch (B)
9 - Fourth Drum (Optional) Lock Motor
Detailed Position C
Machine Front
B BB
9 10 11
A A
C CC
A
4 6 85 7
Front DrumBoom DerrickingDrum
Fourth Drum(Optional)
Rear Drum
Machine Front
Detailed Position A
T2BC-01-02-027
Detailed Position B
Rotation Detection Sensor (One sensor is installed to the derricking drum.)
Drum LockMotor
1
2
3
Machine Rear
Motor
GENERAL / Component Layout
T1-2-18
4-Spool Solenoid Valve Unit
T25N-03-08-001
1 - Derricking Drum Unlocking Solenoid Valve
3 - High / Low Speed Selection Solenoid Valve
2 - Slewing Brake Solenoid Valve:
4 - Second Overhoist Solenoid Valve
Accumulator
M25N-07-030
Slewing Remote Control Pressure Sensor Block
T25N-01-02-019
1 - Primary Pilot Pressure Sensor
2 - Right Slewing Remote Control Pressure Sensor
3 - Left Slewing Remote Control Pressure Sensor
1
Machine Front
Machine Rear
Machine Right
Machine Left
1 2 3 44-Spool Solenoid Valve Unit
Accumulator
2
3
Slewing Remote Control PressureSensor Block
GENERAL / Component Specifications
T1-3-1
ENGINE
Engine body Manufacturer ................................................................MITSUBISHI Motor Model ...........................................................................6D24-TLE2AType..............................................................................4-cycle water-cooled in-line direct injection,turbochargedNo. of cylinders-bore × stroke ......................................6-130 mm × 150 mm (6-5.12 in × 5.91 in) Displacement ...............................................................11.945 L (728.9 in3)Rated output.................................................................184 kW/2000 min-1(250 PS/2000 rpm) Compression ratio........................................................17.5 Dry weight ....................................................................1080 kg (2380 lb) Firing order...................................................................1-5-3-6-2-4Rotational direction ......................................................Clockwise, viewed from fan Length × width × height................................................1473 × 869 × 1246 mm (58×34×39 in) Allowable angle of inclination.......................................Front and back, left and right: 30°
Cooling system Cooling fan ...................................................................φ850 6-blade PPG suction type Fan/pulley ratio (flank/fan) ...........................................0.825Thermostat ...................................................................Humidity at start of opening at Temperature.:
76.5°C (169.7 °F) Full-open temperature: 90°C (194 °F)Water pump..................................................................Centrifugal swirl pump, V belt drive
Lubricating system Lubrication pump type..................................................Gear pump Filter .............................................................................Full-flow/bypass Cooler...........................................................................Built-in water-cooled flat tube type
Starter Manufacturer ................................................................MITSUBISHI Electric Electric motor ...............................................................Solenoid depressing type speed reduction Voltage, output .............................................................24 V ⋅ 7.0 kW
Shut-down system Method .........................................................................Fuel shut-off method (stop solenoid method)
ChargerMethod .........................................................................Alternating current type (with built-in regulator)Voltage, current ............................................................24 V ⋅ 50 A Drive.............................................................................V belt Acceleration ratio ......................................................... 2.24
GENERAL / Component Specifications
T1-3-2
SuperchargerType.....................................................................Exhaust gas turbo type TD08H
Fuel system Manufacturer .......................................................Bosch automotive system Type.....................................................................Bosch type Governor .............................................................Centrifugal full-speed control (mechanical) Timer ...................................................................Electronic control
PerformanceLubricant consumption........................................100 mL or less (at rating using new lubricant) Fuel consumption ratio........................................244±7 g/kW·h(180±7 g/PS·h) or less (at rating using new lubricant) Injection timing ....................................................At 2°before compression TDC Maximum output torque ......................................1150 N·m(117 kgf·m, 850 lbf⋅ft) or more/1400 min-1.Injection starting pressure...................................21.6 MPa(220 kgf/cm2, 3140 psi) Compression pressure........................................2.7 MPa(28 kgf/cm2, 393 psi) Valve clearance (intake/exhaust) ........................Suction valve 0.4mm(0.016 in)/exhaust valve 0.6 mm(0.024 in) Unloaded speed..................................................Min.: 800±20 min-1 Max.: 2200±15 min-1
GENERAL / Component Specifications
T1-3-3
Engine Performance Curve (6D24-TL)
Test conditions
1. JIS D 0006 (Specifications for Diesel Engine for Construction Machinery and Performance Test Method) under standard atmospheric conditions
2. Fan, air cleaner and generator are provided.
T25N-01-03-002
Specific Fuel Consumption
Torque
Engine Speed min-1 (rpm)
OutputPower
(HP)
(255)
(241)
(215)
(188)
(161)
(134)
(107)
(80)
(191)
(177)
(162)
(147)
g/kW⋅h (g/PS⋅h)
(122)
(112)
(102)
(92)
(kgf⋅m)
(885)
(811)
(738)
(664)
(lbf⋅ft)
(82) (590)
GENERAL / Component Specifications
T1-3-4
ENGINE ACCESSORIES
Radiator assembly Manufacturer .................................. Tokyo RadiatorType................................................ Radiator / oil cooler / intercooler in-line type Dry weight ...................................... 150 Kg (330 lb)
Radiator Oil cooler Intercooler No. of core lines 5 1 1 Fin pitch 4.0 3.0 5.0 Fin shape Corrugated fin Corrugated fin Corrugated fin Capacity 8.1 L (2.14 US gal) 4.1 L (1.1 US gal) 12 L (3.17 US gal) Heat dissipation area 64.3 m2 (692.1 ft2) 29.91 m2 (322 ft2) 19.64 m2 (211.4 ft2)Heat exchange capacity 452.1 × 106 J/h 343.3 × 106 J/h 150 × 106 J/h (108000 kcal/h) (82000 kcal/h) (35729 kcal/h) Resisting pressure 100 kPa 1500 kPa 250 kPa (1.0 kgf/cm2, psi) (15.3 kgf/cm2, psi) (2.6 kgf/cm2, psi) Cap opening pressure 49 kPa (0.5 kgf/cm2, 7.1 psi) −
Battery Type................................................ 195G51-MF (Hybrid type) Capacity ......................................... 170 Ah (20- hour rating) Voltage ........................................... 12 V Discharge current........................... 500 A (-15 °C)Duration.......................................... 4.8 minutes or longer 30-second voltage.......................... 9.4 V or more High × wide × long.......................... 257 × 222 × 508 mm (10.1 × 8.7 × 20 in) Weight ............................................ 41 kg (90 lb)
GENERAL / Component Specifications
T1-3-5
HYDRAULIC EQUIPMENT
Pump Mechanism Speed ratio ...................................................................Main pump (1, 2) 1.0 Slewing pump 1.0 Pilot pump 1.0
Main pumps (1, 2) Type..............................................................................Swash plate type variable displacement plunger pump Model ...........................................................................K5V140DTPTheoretical displacement .............................................28 to 140 cm3(1.7 to 8.5 in3)/rev Maximum oil flow rate (theoretical) ..............................280 L/min (73.9 GPM)
Slewing pump Type..............................................................................Swash plate type variable displacement plunger pump Model ...........................................................................K5V80STheoretical displacement .............................................48/80 cm3 (2.9/4.9 in3)/rev (two steps) Maximum oil flow rate (theoretical) ..............................160 L/min (42.2 GPM) Main pumps (1, 2) and slewing pump..........................185 kg (408 lb) total
Pilot pump Type..............................................................................Constant capacity type gear pump (2-spool) Model ...........................................................................SD1A3020Theoretical displacement .............................................28.9/20.4 cm3(1.8/1.2 in3)/rev (front side / rear side) Maximum oil flow rate (theoretical) ..............................59.8/40.8 L/min (15.8/10.8 GPM) (front side/rear side)
Reeving pump (hydraulic tagline / forth drum brake for cooling using combinedly) (optional) Type..............................................................................Constant gear pump Model ...........................................................................YP15A16A2H5-LTheoretical displacement .............................................15.9 cm3(1.0 in3)/rev
Front control valve Type..............................................................................4-spoolModel ...........................................................................MWP425S2CT758CMain relief setting.........................................................31.4 MPa (320 kgf/cm2, 4570 psi)@275 L/min
(72.6 GPM) Weight ..........................................................................107 kg (235 lb)
(72.6 GPM) Weight ..........................................................................85 kg (190 lb)
GENERAL / Component Specifications
T1-3-6
4-Spool control valve for counterweight / quick draw / lower control valve Type..............................................................................4-spool solenoid selection Model ...........................................................................KMC10-4060Main relief setting .........................................................20.6 MPa (210 kgf/cm2, 2990 psi)@70 L/min (18.5 GPM) Weight ..........................................................................22 kg (49 lb)
Lower control valve for jack-up and retract cylinder (optional) Type..............................................................................6-spool manual operation Main relief setting .........................................................19.6 MPa (200 kgf/cm2, 2850 psi)@54 L/min (14.2 GPM) Weight ..........................................................................9 kg (20 lb)
Control valve for third drum (with fourth drum attached) Type..............................................................................Oil pressure pilot type Model ...........................................................................MW125T7196Main relief setting .........................................................27.4 MPa (280 kgf/cm2, 3985 psi)@275 L/min (72.6
GPM)Weight ..........................................................................40 kg (88 lb)
Slewing control valve Type..............................................................................1-spool oil pressure pilot type Model ...........................................................................MW125P5187AMain relief setting.........................................................31.9 MPa (325 kgf/cm2, 4620 psi)@155 L/min
(40.9 GPM) Weight ..........................................................................38 kg (84 lb)
Hoisting mechanism (front / rear) Type..............................................................................2-stage planetary gear reduction Reduction ratio .............................................................24.94 Main composition .........................................................Hoisting drum, reduction gear, hoisting motor and brake unit Weight.............................................................................. 1980 Kg (4365 lb) (front , rear)
Hoisting motors (front / rear) Type..............................................................................Swash plate type variable displacement axial piston motor Model ...........................................................................M3B530BP-533/370-038B-V1Theoretical displacement (at high / low speed) ...........370/533 cm3 (22.6/33 in3)/rev Overload relief setting ..................................................34.3MPa (350 kgf/cm2, 4990 psi)@30 L/min
(7.9 GPM) Weight ..........................................................................214 kg (472 lb)
Hoisting motor brakes (front / rear) Type..............................................................................Wet type spring-set Hydraulic-released multi-plate .....................................3.1 MPa (31.6 kgf/cm2, 450 psi)
Hoisting brake units (front / rear) Type..............................................................................Wet type spring-set Hydraulic-released multi-plate .....................................9.8 MPa (100 kgf/cm2, 1025 psi)
Boom derricking mechanism Type..............................................................................3-stage planetary gear reduction Reduction ratio .............................................................70.84 Main Composition ........................................................Derricking drum, reduction gear and derricking motor Weight ..........................................................................872 Kg (1925 lb)
GENERAL / Component Specifications
T1-3-7
Boom derricking motor Type..............................................................................Swash plate type variable displacement axial plunger motor Model ...........................................................................HMG125AF-5MATheoretical displacement .............................................124.8 cm3 (7.6 in3)/rev Overload relief setting ..................................................34.8 MPa (355 kgf/cm2, 5060 psi)@56 L/min (14.8 GPM) Weight ..........................................................................389 kg (355 lb) including reduction gear
Boom derricking motor brake Type..............................................................................Wet type spring-set Hydraulic-released multi plate......................................1.18 MPa (12 kgf/cm2, 172 psi)
Slewing mechanism Type..............................................................................2-stage planetary gear reduction Reduction ratio .............................................................20.04 Main composition .........................................................Reduction gear and slewing motor Weight ..........................................................................219×2 kg (483×2 lb)
Slewing motor Type..............................................................................Swash plate type constant displacement axial plunger motor Model ...........................................................................M5X180CHBTheoretical displacement .............................................158.9 cm3 (9.7 in3)/rev
Slewing parking brake Type..............................................................................Wet type spring-set Hydraulic-released multi plate......................................3.4 MPa (35 kgf/cm2, 498 psi)
Travel mechanism Type..............................................................................3-stage planetary gear reduction Reduction ratio .............................................................143.314 Main composition .........................................................Reduction gear and travel motor Weight ..........................................................................884 kg (1860 lb)
Travel motors Type..............................................................................Swash plate type variable displacement axial plunger motor Model ...........................................................................MSF-230VP-15Theoretical displacement (at high/low speed) .............130.7/228.9 cm3 (8.0/14.0 in3)/rev Overload relief seting ...................................................32.4 Mpa (330 kgf/cm2, 4710 psi) ) @40 L/min (10.6 GPM) Weight ..........................................................................100 kg (220 lb)
Counterweight cylinder Type..............................................................................HC130-3500000Dia. .............................................................................Bore dia. : 130 mm (5.1 in) Rod dia. : 80 mm (3.2 in) Fully retracted length ...................................................1852 mm (72.9 in) Stroke ...........................................................................1495 mm (58.9 in) Weight ..........................................................................181 kg (400 lb)
Retract cylinder Type..............................................................................Z007-60000Dia. .............................................................................Bore dia. : 140 mm (5.5 in) Rod dia. : 65 mm (2.6 in) Fully retracted length ...................................................1530 mm (60.2 in) Stroke ...........................................................................1000 mm (39.4 in) Weight ..........................................................................125 kg (276 lb)
Jack-up cylinder (optional) Dia. .............................................................................Bore dia. : 125 mm (4.9 in) Rod dia. : 80 mm (3.1 in) Fully retracted length ...................................................1035 mm (40.7 in) Stroke ...........................................................................690 mm (27.2 in) Weight ..........................................................................103 kg (227 lb)
Remote control valve hoisting and derricking Type..............................................................................3-spool PPC valve Model ...........................................................................TH40PC3068APlunger stroke ..............................................................6.5 mm (0.3 in) Weight ..........................................................................13.5 kg (30 lb)
Remote control valve for travel and third / fourth drum Type..............................................................................3-spool PPC valve Model ...........................................................................TH40PC3077Plunger stroke ..............................................................3.5 mm (0.14 in) (travel) 6.5 mm (0.3 in) (third / fourth drum) Weight ..........................................................................9 kg (20 lb)
Remote control valve for slewing Type..............................................................................1-spool PPC valve Model ...........................................................................TH40PC1042Plunger stroke ..............................................................7.0 mm (0.3 in) Weight ..........................................................................4.5 kg (10 lb)
Remote control valve for brake Type..............................................................................Foot-depression PPC valve Model ...........................................................................15049-0001APlunger stroke ..............................................................13.0 mm (0.5 in)
Center joint Type..............................................................................YV7224
4-spool solenoid valve for derricking drum lock, slewing brake, travel (high) and second overhoist Type..............................................................................4KWE5G-20/G24WS-420AReducing pressure setting ...........................................4.9 Mpa (50 kgf/cm2, 712 psi) Weight ..........................................................................5.6 kg (12.3 lb)
Reeving solenoid valve 1 (Hydraulic tagline using combinedly) (optional) Type .............................................................................DE6P10-208-WD24-C54
Reeving solenoid valve 2 (Hydraulic tagline using combinedly) (optional) Type .............................................................................DE6P10-208-WD24-C55
Reeving pressure gauge Type .............................................................................DMTG1General pressure .........................................................5.9 to 11.3 Mpa (60 to 115 kgf/cm2, 860 to 1643 psi)
Reeving relief valve (optional) Type .............................................................................DBDA10P-K12/200-115/25 Rated pressure ............................................................5.9 to 11.3 Mpa (60 to 115 kgf/cm2, 860 to 1643 psi)
AccumulatorType .............................................................................Bladder type Model ...........................................................................Mu150-700Capacity .......................................................................700 cm3 (42.7 in3)Weight ..........................................................................3.9 Mpa (40 kgf/cm2, 570 psi)
FILTERS Filtration grain size Remarks
Return filter .............................................................. 10 μm (Yamashin Industry Y-467500) Line filter .................................................................. 10 μm (Yamashin Industry GT04L-30-15) Suction filter ............................................................. 177 μm (80 meshes) (Yamashin Industry) Drain filter ................................................................ 10 μm (Yamashin Industry SP10-10-10)
Coolant temperature gauge sensor (water temp. unit) Manufacturer ................................................................MITSUBISHI Motors (MC844972) Operating temperature.................................................93 to 97 °C (199 to 207 °F)
Coolant level switch Method .........................................................................Float reed switch type
Front/rear boom derricking rotation sensor Model ...........................................................................YAMATAKE-Honeywell RL7M-8J6ND
Battery relay Manufacturer MITSUBISHI Motors (30890-03201) Voltage and current 24 V ⋅100 A
HornManufacturer ................................................................DENSO Voltage and current ......................................................24 V ⋅1.5±0.5 A Sound pressure............................................................113±5 dB (A)/2 m
FlasherManufacturer ................................................................Niles Model ...........................................................................VF324LVoltage .........................................................................24 V
LIGHTING
Side lamp Manufacturer ................................................................EVER WING (7031)
Working lights Manufacturer ................................................................Night Beam (ML-B133H) Output ..........................................................................24 V ⋅ 70 W
2BCT-2-1
SECTION 2 SYSTEM
—CONTENTS—Group 1 Control System
Outline ..........................................................T2-1-1Engine Control ............................................. T2-1-2 Pump Control .............................................T2-1-16Other Control..............................................T2-1-24
Group 3 Electric System Outline ..........................................................T2-3-1Power Circuit ................................................ T2-3-2 Preheating Circuit......................................... T2-3-4 Engine Starting Circuit ................................T2-3-8Charging Circuit .........................................T2-3-10Accessories Circuit.....................................T2-3-12Engine Stop Circuit.....................................T2-3-13Surge Voltage Prevention Circuit ...............T2-3-15 Drum Lock Circuit.......................................T2-3-17Slewing Brake Release Circuit...................T2-3-19
2BCT-2-2
(Blank)
SYSTEM / Control System
T2-1-1
OUTLINE
Two MCs (Main Controllers) (2/A and 2/B each incor-porating a microcomputer), IDU (Information Display Unit), and ECU (Engine Control Unit) are used to con-trol the machine. Signals from the engine control accelerator, engine speed sensor and various switches go to MC2/A, MC2/B or ECU in which arithmetic operation is made, to drive the solenoid valve and control the engine and the pumps.
Engine Control • Engine starting speed control • Low/high idle calibration • Engine rotational speed control • High idle cutting control • Fuel injection timing control • ECU failure diagnosis control • Rack zero calibration
Pump Control • Main pump displacement angle control • Main pump power increase control • Power increase pressure calibration • Full rack calibration
Other Control • Slewing alarm control • Drum rotation sensing control • Pilot pressure drop warning lamp control • Winch brake mode control • Engine start interlock control • Motor cutoff pressure control • Emergency operation control • Boom derricking drum auto stop control • Front drum auto stop control • Rear drum auto stop control • Fourth drum auto stop control • Second overhoist auto stop control • Front drum surge pressure reduction control • 2-speed tower jib raise/lower flow-combining con-
trol• Warning sound output control
SYSTEM / Control System
T2-1-2
ENGINE CONTROL
Engine Starting Speed Control
Purpose: At engine starting, the governor motor is controlled so that the engine governor lever is set to the engine starting speed (1000 min-1) position.
Operation:
1. When the key switch is turned ON, low idle is calibrated, and MC2/A controls the governor mo-tor so that the governor lever is set to the starting speed (1000 min-1) position. However, engine starting speed control will be stopped if the speed, which is set with the accelerator grip (JOY-STICK LEVER : accelerator dial), accelerator pedal (op-tional) or accelerator lock switch, exceeds the en-gine starting speed in the period from key switch ON to engine starting. Engine starting speed is set to the highest speed by the accelerator operated.
2. After engine starting, engine starting speed con-trol is completed when the engine speed reaches the engine start speed position set by the accel-erator grip, accelerator lock switch or accelerator pedal of accelerator control switches. After that, the engine speed reaches the highest speed set by one of three accelerator systems in-cluding the accelerator pedal.
SYSTEM / Control System
T2-1-3
T25N-02-01-038
Accelerator Lock Switch
Accelerator Grip Accelerator Pedal
MC2/A
Governor Motor Engine Governor Lever
Key Switch
SYSTEM / Control System
T2-1-4
Low/High Idle Calibration
Purpose: The low idle position and high idle position of the engine governor lever are stored in MC2/A.
Low idle calibration
Operation:
1. When the key switch is turned ON, the power supply of MC2/A is turned ON. Then, MC2/A re-verses the governor motor until the output of the governor motor potentio sensor becomes 2.4V or less.
2. 2. After that, MC2/A turns the governor motor in normal direction, and stores the position where the output of the governor potentio sensor be-comes 2.5 V as a low idle position. Whenever the key switch is turned ON, the low idle calibration is automatically done.
High idle calibration
Operation:
1. When the auto stop cancellation front drum switch is turned ON after completion of basic calibration operation (refer to T4), MC2/A calibrates the above-mentioned low idle.
2. In addition, MC2/A turns the governor motor in normal direction, and stores the position where the output of the governor motor potentio sensor for upper limit of governor becomes constant (i.e., the position where the engine governor lever contacts the high idle stopper).
High idle calibration is carried out at the shipment from factory, and stored in EEPROM. Therefore, the subsequent calibration is not required. However, it is needed to carry out the high idle calibration in the following cases.
• When not reaching the specified high idle speed due to the expansion of a control cable or wear of the fork end.
• When replacing controller MC2/A.
SYSTEM / Control System
T2-1-5
T25N-02-01-039
Key Switch
Accelerator Lock Switch
Accelerator Grip Accelerator Pedal
MC2/A Drum Rotation Sensing Switch
Auto Stop Cancellation Front Drum Switch
Governor Motor Engine Governor Lever
Auto Stop Cancellation Rear Drum Switch
Auto Stop Cancellation Fourth Drum Switch
Governor Motor Potentio Sensor
MC2/B
SYSTEM / Control System
T2-1-6
Engine Speed Control
Purpose: Engine speed is controlled by turning the accelerator grip, depressing the accelerator pedal (optional) and handling the accelerator lock switch.
Operation:
1. When turning the accelerator grip, depressing the accelerator pedal, or setting the accelerator lock switch to the accelerator lock position, voltage signals are sent to MC2/A from the accelerator grip, accelerator pedal or accelerator lock switch.
2. When the accelerator lock switch is OFF, voltage signal from the accelerator control switch be-comes ineffective, and voltage signals from the accelerator grip and accelerator pedal becomes effective.
3. When accelerator lock switch is ON, voltage sig-nals from the accelerator pedal and accelerator lock switch becomes effective and voltage signal from the accelerator grip becomes ineffective.
4. MC2/A converts the maximum effective voltage signal to a command speed signal, and computes the number of pulses with steps according to the converted speed in order to drive the governor motor.
5. The governor motor keeps the excitation of stator coil in the governor motor by the last driven pulse, and generates the holding torque to lock the en-gine governor lever in an appropriate position.
6. When voltage signals from the accelerator grip, the accelerator pedal, and the accelerator lock switch become ineffective, MC2/A sets the engine speed to 800 min-1.
7. The engine speed, set by the accelerator grip or accelerator pedal, becomes the engine speed when the accelerator lock switch is turned ON.
SYSTEM / Control System
T2-1-7
T25N-02-01-014
Accelerator Lock Switch
Accelerator Grip
Accelerator Pedal
MC2/A
Governor Motor Engine Governor Lever
SET
ON
SYSTEM / Control System
T2-1-8
High Idle Cut Control
Purpose: At engine high idle, engine speed is con-trolled to prevent engine overspeed.
Operation: When the command speed of the accel-erator is 1920 min-1 or more, MC2/A turns the governor motor to maintain the engine speed, sensed by the engine speed sen-sor, at 2100 ± 20 min-1.
T25N-02-01-041
Accelerator Lock Switch
Accelerator Grip Accelerator Pedal
MC2/A
Governor Motor
Engine Speed Detection Sensor
Engine Governor Lever
ON
SYSTEM / Control System
T2-1-9
(Blank)
SYSTEM / Control System
T2-1-10
Fuel Injection Timing Control
Purpose: ECU detects engine speed, load, coolant temperature and injection timing through various sensors to set optimum fuel injection timing.
Operation: ECU receives signals from the TDC sen-sor, timing sensor, the rack sensor, and coolant temperature sensor. According to these signals, ECU operates the TCV ADV solenoid valve or TCV RTD solenoid valve in order to regulate engine oil pressure which is transmitted to an electronic timer for control of fuel injection timing.
T25N-02-01-001
ECU
Coolant Temperature Sensor
Timing Sensor
TDC Sensor
To MC2/A
From Engine To Engine
TCV RTD So-lenoid Valve
Electronic TimerRack Sensor
TCV ADV So-lenoid Valve
SYSTEM / Control System
T2-1-11
Operation of TCV Solenoid Valve
To Advance Fuel Injection Timing: • TCV ADV solenoid valve: ON • TCV RTD solenoid valve: Stop
When port P and port A are connected, oil pressure is transmitted to an electronic timer to advance fuel in-jection timing.
Each port is blocked to retain the oil pressure in the electronic timer at a certain level, keeping the state of the electronic timer.
To Retard Fuel Injection Timing: • TCV ADV solenoid valve: Stop • TCV RTD solenoid valve: ON
When port A and R port are connected, oil pressure in the electronic timer is returned to the oil pan in order to retard fuel injection timing.
T25N-02-01-004
T25N-02-01-003
T25N-02-01-002
TCV RTD Solenoid Valve
TCV ADV Solenoid Valve
Port P
Port A
TCV RTD Solenoid Valve
TCV ADV Solenoid Valve
Port A
TCV RTD Solenoid Valve
TCV ADV Solenoid Valve
Port R
Port A
SYSTEM / Control System
T2-1-12
ECU Failure Diagnosis Control
Purpose: Failure of the engine is detected through various sensors connected to ECU, and its information is displayed by blinking warning lamps.
Operation:
1. The ECU receives signals from various sensors. ECU judges receiving erratic data signal outside the specified range as failure.
2. In this case, ECU lights the ECU lamp (orange).
3. At this time, when the failure diagnosis switch is set to ON position, ECU inputs a signal, which corresponds to failure location, to MC2/A, making ECU lamp (red) blink.
4. MC2/A transmits error information to IDU corre-sponding to the signal.
5. IDU displays error information on the connected display.
T25N-02-01-005
Failure Diagnosis Switch
TDC Sensor
Timing Sensor
RackSensor
Coolant Tem-perature Sensor
ECU
Failure Diagnosis Unit
MC2/A
Red Orange
IDU
ECU Lamps
Display
SYSTEM / Control System
T2-1-13
Failure Diagnosis and Backup Mode Fault indica-tion (blinking frequency)
Fault location Countermeasure by ECU (backup mode) Operation
* 0-1 Normal −
* 1-2 Feedback error (Actual advance angle of fuel injection timing does not follow the target advance angle.)
Both timer control valves: OFF Timer control (fuel injection timing control): Stop
* 1-4 Timing sensor Both timer control valves: OFF
Timer control (fuel injection timing control): Stop
* 1-5 TDC sensor Determining engine speed from the number of tim-
ing pulses. Timer control (fuel injection timing control): Stop
* 2-1 Coolant temperature sensor Keeping coolant temperature at 80 °C* 2-2 Rack position sensor Locking rack is at full load position * 2-3 TCV ADV and TCV RTD solenoid valves Timer control (fuel injection timing control): Stop
: Operable : Operable in the backup mode* : (1-5) implies that one-time blinking, one-time interruption, and five-time blinking of ECU lamp. Important: Avoid long hours operation or heavy load operation in the backup mode.
Item Signal Name RECEIVE ECU TMR F. B. Timer feedback RACK P. S. Rack sensor TIMINGS. Timing sensor TDC S. TDC sensor OVER H. S. Coolant temperature sensor TMR C. V. Timer control valve
Display Information NORMAL Normal ERROR Error ****** Communication error
MC2/A Input/Output monitor
↑↓ Page selection × Return
MC2A_ECU1
RECEIVE NORMAL
TMR F. B. ERROR
RACK P. S. NORMAL
TIMING S. ERROR
OVER H. S. ERROR
TMR C. V. NORMAL
Display Display
Item
SYSTEM / Control System
T2-1-14
Rack Zero Calibration
Purpose: Makes MC2/A store zero point of the rack sensor.
Operation:1. After completion of basic calibration operation
(refer to T4), when the auto stop cancellation rear drum switch is turned ON, signal from MC2/B is input to MC2/A.
2. MC2/A drives the governor motor, and sets the engine governor lever to the low idle position.
3. Three seconds later, signal from the rack sensor is input to MC2/A via ECU. MC2/A stores the zero point of the rack sensor.
SYSTEM / Control System
T2-1-15
T25N-02-01-035
MC2/A Drum Rotation SensingSwitch
Auto Stop Cancellation Front Drum Switch
Governor Motor Engine Governor Lever
MC2/B
Auto Stop Cancellation Rear Drum Switch
Auto Stop Cancellation Third / Fourth Drum Switch
ECU
Rack Sensor
SYSTEM / Control System
T2-1-16
PUMP CONTROL
Main Pump Displacement Angle Control
Purpose: Controls the delivery flow of the main pump according to the rotation of the accelerator grip, and the control direction and slowdown in control direction of the hoisting motor through M/L (Moment Limiter).
Operation:1. Voltage signal is input from the accelerator grip to
MC2/A. 2. MC2/A sends signals to the displacement angle
proportional solenoid valve. Such signals regulate the delivery flow from minimum to maximum ac-cording to the rotation (0 to 35%) of the accelerator grip, with the accelerator lock switch OFF, and to the rotation (0 to 100%) of the accelerator grip with the accelerator lock switch ON.
3. The displacement angle proportional solenoid valve supplies pilot pressure oil to the regulator of the main pump according to these signals to change the pump displacement angle.
4. As a result, the delivery flow of the main pump becomes proportional to the rotation of the ac-celerator grip.
5. At this time, MC2/A sends a signal to the dis-placement angle proportional solenoid valve ac-cording to the data on the turning direction and slowdown in each turning direction of the hoisting motor received from M/L through CAN.
6. According to this signal, the displacement angle proportional solenoid valve controls the quantity of pilot pressure oil to the regulator so that the main pump delivery flow is reduced to 20% of the accelerator grip delivery flow.
7. When operation of the hoisting motor is completed or when slowdown is returned to 100% through M/L, MC2/A sends a signal to the displacement angle proportional solenoid valve for five seconds (maxi-mum) so that the main pump delivery flow is returned to the accelerator grip delivery flow.
8. According to this signal, the displacement angle proportional solenoid valve adjusts the pilot pressure oil supplied to the regulator so that the main pump delivery flow is returned to the accel-erator grip delivery flow for five seconds (maxi-mum). As a result, a rapid speed increase is pre-vented.
9. Even if returning the accelerator grip rapidly, MC2/A needs the primary time-lag for the rotating of the accelerator grip, thus preventing cavitation in the derricking motor. (Response time to rapid returning: About two seconds)
SYSTEM / Control System
T2-1-17
T2BC-02-01-001
Accelerator Grip
Engine
Main Pump 1
Main Pump 2
PilotPump
Displacement Angle Proportional Solenoid Valve
Accelerator Lock Switch
CAN
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-18
Main Pump Power Increase Control
Purpose: Regulates the delivery flow of the pump ac-cording to engine speed and load for effec-tive use of engine horsepower.
Operation:
1. The engine speed sensor sends the engine speed signal to MC2/A.
2. The rack sensor sends a voltage signal of rack position to MC2/A via ECU.
3. MC2/A sends a signal according to engine speed and load to the power increase solenoid valve.
4. The power increase solenoid valve supplies the pilot pressure oil according to this signal to the regulator for the main pump, thus increasing the pump absorption horsepower.
5. As a result, the pump delivery flow increases, and working speed of the actuator increases.
6. When the output from the rack sensor reaches engine stall prevention voltage (2.515 to 3.1 V), MC2/A sends a signal to the power increase so-lenoid valve to minimize the pump absorption horsepower.
SYSTEM / Control System
T2-1-19
T2BC-02-01-002
Engine Speed Sensor
Main Pump 1
Main Pump 2
PilotPump
Rack Sensor
Power Increase Solenoid Valve
Engine
SYSTEM / Control System
T2-1-20
Power Increase Pressure Calibration
Purpose: Makes MC2/A store the power increase output calibration data.
Operation:
1. After completion of basic calibration operation (refer to T4), start the engine.
2. When turning ON the auto stop cancellation front drum switch and auto stop cancellation rear drum switch, MC2/B sends a signal to MC2/A.
3. MC2/A makes the pilot pressure drop warning lamp blink.
4. If the pilot pressure drop indicator blinks at a cycle other that the specified cycle of 0.5-second ON and 0.5-second OFF, the auto stop cancellation front drum switch and the auto stop cancellation rear drum switch are turned OFF.
5. When turning the accelerator lock switch ON and OFF, calibration can be made.
6. When selecting the power increase pressure calibration mode, MC2/A changes the power in-crease solenoid valve current at the rate of + 7 mA/3 sec.
7. When the power increase pressure reaches 0.3 MPa, MC2/A stores the power increase output current as a calibrated value by the accelerator lock switch. (Accelerator lock switch ON→OFF)
SYSTEM / Control System
T2-1-21
T2BC-02-01-003
Engine Speed Sensor
Main Pump 1
Main Pump 2
PilotPump
Rack Sensor
Power Increase Solenoid Valve
Accelerator Lock Switch
Pilot PressureDrop Indicator
Auto Stop Cancellation Front Drum Switch
Auto Stop Cancellation Rear Drum Switch
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-22
Full Rack Calibration
Purpose: Makes MC2/A store the power increase output and the engine speed at full rack.
Operation:
1. After completion of basic calibration operation (refer to T4), start the engine.
2. When the auto stop cancellation derricking drum switch is turned ON, the signal is input from MC2/B to MC2/A.
3. MC2/A turns ON and OFF the pilot pressure drop warning lamp.
4. If the pilot pressure drop indicator blinks at a cycle other than the specified cycle of 0.5-second ON and 0.5-second OFF, the auto stop cancellation derricking drum switch is turned OFF.
5. When turning the accelerator lock switch is turned ON and OFF, calibration can be made.
6. At this time, MC2/A sends signals to the governor motor and the power increase solenoid valve to reduce the power so that the engine speed is set to high idle, and main pump delivery flow to maximum.
7. When the engine speed is 2000 min-1 or higher, and the pilot pressure drop indicator blinks at a cycle of 0.1 second ON and 0.4 second OFF, MC2/A sends a signal to the power increase so-lenoid valve when the slewing lever and front drum lever are moved for quick hoisting.
8. The power increase pressure varies at the rate of -0.01MPa/sec through the power increase sole-noid valve, increasing the horsepower.
9. When the engine speed reaches the preset level (1950 min-1) or less under this condition, MC2/A receives a signal from the governor potentio sensor, and stores it as a full rack.
10. In addition, when the engine speed reaches the preset speed (1950 min-1) or less, MC2/A auto-matically reads the rack data. (Upon completion of reading, the engine speed is set to low idle, pump delivery flow to minimum, and power increase solenoid valve current to the preset level (0 mA).)
SYSTEM / Control System
T2-1-23
T2BC-02-01-004
Engine Speed sensor
Main Pump 1
Main Pump 2
Pilot Pump
Rack Sensor
Power Increase Solenoid Valve
Pilot Pressure DropIndicator
Auto Stop Cancellation Derricking Drum Switch
Governor Potentio Sensor
Governor motor
Accelerator Lock Switch
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-24
OTHER CONTROL
Slewing Alarm Control
Purpose: Lights the slewing warning lamp when the slewing lever is moved.
Operation:
1. When the slewing control lever is moved, MC2/A receives voltage signal from the slewing remote control pressure sensor on the side where slewing is made.
2. MC2/A excites the slewing warning lamp relay.
3. As a result, current from the battery passes through the battery relay, slewing alarm lamp relay, and flasher relay, lighting the slewing warning lamp.
SYSTEM / Control System
T2-1-25
T2BC-02-01-005
MC2/A
Battery Relay
From Battery
Slewing Alarm Lamp Relay
Slewing Alarm Lamp (Left)
Slewing Alarm Lamp (Right)
Flasher Relay
Slewing Lever
Slewing Pump
Pilot Pump
Slewing Control Valve
Slewing Mechanism
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-26
Drum Rotation Sensing System
Purpose: During superfine speed mode hoist/lower operation, the operator can accurately con-trol the hook position without directly check-ing the drum movement.
Operation:1. When the drum is rotated with the drum rotation
sensing switch OFF, the drum rotation detection sensor sends pulse voltage signals to MC2/A.
2. During a fixed time (30 m sec) only, MC2/A deliv-ers pulse current to the rotation sensing solenoid installed to the front, rear and derricking levers.
3. The rotation sensing solenoid causes the rods in-stalled in the control levers to vibrate so that the operator can feel the rotation of the drum.
4. When the frequency of signals sent to MC2/A is slower than 4Hz, MC2/A delivers the electric pulse current (100 %) to the rotation sensing so-lenoid.
5. When the frequency of signals sent to MC2/A becomes faster than 4Hz, MC2/A delivers the reduced electric pulse to the rotation sensing so-lenoid in reverse proportion to the frequency of signals that flows the rotation sensing solenoid.
SYSTEM / Control System
T2-1-27
NOTE: The illustration below shows the front drum rotation sensing system in operation.
T25N-02-01-020
Front Drum
Rear Drum
Derricking Drum
Boom Derricking Drum Rotation Detection Sensor A
Drum Rotation Sensing Switch
MC2/A
Front Drum Rotation Detection Sensor A
Control Lever
Front Rear DerrickingRod
Vibration
Front Drum Rotaion Sensing Solenoid
Front Drum Rotation Detection Sensor B
Rear Drum Rotation Detection Sensor A
Rear Drum Rotation Detection Sensor B
Rod Rod
Rear Drum Rotaion Sensing Solenoid
Derricking Rotaion Sensing Solenoid
SYSTEM / Control System
T2-1-28
Pilot Pressure Drop Alarm Lamp Control
Purpose: Tells the operator of the pilot pressure drop by lighting the pilot pressure drop alarm lamp.
Operation:
1. MC2/A receives a voltage signal from the primary pilot pressure sensor.
2. When the pilot pressure reaches the set pressure of 3MPa or lower, MC2/A lights the pilot pressure drop alarm lamp.
T2BC-02-01-006
Accumulator
Primary PilotPressure Sensor
Pilot Pressure Drop Alarm Lamp
Pilot Pump
From Battery
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-29
Winch Brake Control
Purpose: Controls the brake for the front drum, rear drum and fourth drum optional motors. Controls the brake mode for the front and fourth drum (optional). Locks the derricking drum.
Operation:
• Motor Brake Control
1. When hoisting or lowering by the front, rear or fourth (optional), MC2/A receives a voltage signal from the remote control pressure sensor in the concerned pilot circuit.
2. MC2/A actuates the brake release solenoid valve for the concerned motor.
3. As a result, pressure oil from the pilot pump flows through the pressure-reducing valve and the brake release solenoid valve to the motor brake in order to release the motor brake.
SYSTEM / Control System
T2-1-30
T2BC-02-01-007
Brake Mode Selection Key Switch
MC2/A
Brake Release Solenoid Valve
Brake
Front Drum
Brake Release Solenoid Valve
Brake
Rear Drum
Brake Release Solenoid Valve
Brake
Fourth Drum (Optional)
Rear Front
Pilot Pump
Fourth (Optional) Remote Control
Pressure Sensor
4-Spool Solenoid Valve Unit
SYSTEM / Control System
T2-1-31
• Drum Brake Mode Control (Free Mode Control)
IMPORTANT: The free mode is applicable only when the brake mode selection key switch is at the free brake position.
1. With the brake mode selection key switch set to the free brake position and the tower not hoisted or lowered, when fourth is selected by using the front, rear or third / fourth drum selection switch with the brake pedal for fourth (optional) de-pressed and the brake mode selection key switch for the concerned drum is turned ON, MC2/A re-ceives a switch-ON signal from the brake mode selection key switch.
2. MC2/A actuates the drum brake release solenoid valve corresponding to the brake mode selection key switch for front, rear or fourth (optional) turned ON.
3. When releasing the brake pedal, pressure oil from the pilot pump flows through the brake valve and the drum brake release solenoid valve to the drum brake, thus releasing the drum brake.
4. As a result, the drum becomes free.
5. In addition, MC2/A stops the operation of the drum brake release solenoid valve and allow hoisting and lowering.
NOTE: The free mode is switched to the auto brake mode under the following conditions.
• The brake mode selection key switch is set to the auto brake position.
• The free mode selection switch is OFF. • The primary pilot pressure is other than
high pressure 3 MPa (31 kgf/cm2) (436 psi)).
• The second overhoist stop is actuated. • The hoisting remote control pressure
sensor fails.
SYSTEM / Control System
T2-1-32
T2BC-02-01-008
Third / Fourth Selection switch
Brake Mode Selection Key Switch
Front Drum Brake Mode Selection Switch
Rear Drum Brake Mode Selection Switch
Third Drum (Optional)
Rear Drum Front Drum
Brake Pedal (Fourth) (Optional)
Brake Pedal (Rear)
Brake Pedal (Front)
MC2/A
Brake Release Solenoid Valve (Third) (Optional)
Brake Release Solenoid Valve (Rear)
Brake Release Solenoid Valve (Front)
Pilot Pump
Front Brake De-pressing Sensor
Rear Brake Depressing Sensor
Fourth Brake Depressing Sensor (Optional)
Second Overhoist Limit Switch
Front Hoisting Remote Control Pressure Sensor
Front Lowering Remote Control Pressure Sensor
Rear Hoisting Remote Control Pressure Sensor
Rear Lowering Remote Control Pressure Sensor
Third / Fourth Lowering Re-mote Control Pressure Sensor (Optional)
Third / Fourth Drum Brake Mode Selection Switch (Optional)
Third / Fourth Hoisting Remote Control Pressure Sensor (Optional)
SYSTEM / Control System
T2-1-33
• Third Drum Free Mode Control
IMPORTANT: The free mode is applicable only when the brake mode selection key switch is at the free brake position.
1. When third drum is selected by using the third/ fourth drum selection switch with the brake mode selection key switch at the free brake position and
third/fourth brake mode selection switch is turned ON, MC2/A receives a switch-ON signal.
2. When operating the third drum lever to lowering, MC2/A activates the solenoid valve in third drum motor and bypasses the holding pressure to the lowering side.
3. The third drum motor becomes free and the load falls freely.
T2BC-02-01-015
Third / Fourth Drum Selection Switch
Brake Mode Selection Key Switch
Third / Fourth Brake Mode Selection Switch
4-Spool Solenoid Valve Unit
Third / Fourth Hoisting Remote Control Pressure Sensor
Third / Fourth Lowering Remote Control Pressure Sensor
Third Drum Motor
(Hoisting) (Lowering)
Pilot Pump
MC2/A
SYSTEM / Control System
T2-1-34
• Derricking Lock Control 1. When derricking hoisting or lowering, MC2/A re-
ceives a voltage signal from the concerned re-mote control pressure sensor.
2. MC2/A actuates the derricking drum unlocking solenoid valve in 4-spool solenoid valve.
3. As a result, pressure oil from the pilot pump flows through the pressure-reducing valve and derrick-ing drum unlocking solenoid valve to the derrick-ing drum lock and derricking motor bake in order to release the lock and brake.
Purpose: Locks the engine when engine starting will result in dangerous state.
Operation:
1. When MC2/A receives a signal that indicates the slewing brake switch at the brake position, and brake mode selection switch for the front, rear and third / fourth (optional) at the auto brake posi-tion, MC2/A actuates the engine starting relay.
2. When the key switch is set to the start position, voltage signal passes through the engine starting relay, thus actuating the starter relay 1 to turn the starter motor. As a result, the engine starts.
3. With the engine starting relay OFF, when the key switch is set to the start position, MC2/A lights the interlock indication lamp for five seconds.
T25N-02-01-033
Front Drum Brake Mode Selection Switch
Rear Drum Brake Mode Selection Switch
Third / Fourth Drum Brake Mode Selection Switch (Optional)
Slewing Brake Switch
MC2/A
Interlock Indication Lamp
Key Switch
Engine Starting Relay
Starter Relay 1
Starter Motor
SYSTEM / Control System
T2-1-37
Motor Cutoff Pressure Control
Purpose: Lowers the cutoff pressures of the front and rear motors to regulate the lowering speed.
Operation:
1. MC2/A receives a voltage signal that indicates operating pressure of either of front or rear low-ering remote control pressure sensor is 0.3 MPa or more, MC2/A stops the exciting current through the motor cutoff relay.
2. As a result, the motor cutoff relay is turned OFF, so that current does not flow, and the motor cutoff high pressure solenoid valve stops.
3. When the motor cutoff high pressure solenoid valve stops, the motor cutoff pressure is reduced to regulate the lowering speed.
T2BC-02-01-016
Front Lowering Remote Control Pressure Sensor
MC2/A
Motor Cutoff High Pressure Solenoid Valve (Front)
Rear Lowering Remote Control Pressure Sensor
Rear Drum
Motor Cutoff High Pressure Solenoid Valve (Rear)
Front Drum
From Battery
Motor CutoffRelay
SYSTEM / Control System
T2-1-38
Emergency Operation Control
Purpose: In the failure of MC2/A, changes over the brake release solenoid valve and releases the drum motor brake by setting the emergency operation switch to ON posi-tion.
Operation:
1. If signal from MC2/A is blocked against brake re-lease solenoid valve in the failure of MC2/A in-ternal logic circuit, the brake release solenoid valve is changed over so that pilot pressure oil acting on drum motor brake is returned to hy-draulic oil tank.
2. As a result, the drum motor brake is applied suddenly during hoisting, boom hoisting or slew-ing.
3. At this time, when the emergency operation switch is set to ON position, current flows from terminal D4 to terminal A23 of MC2/A.
4. Then, current flows from terminal A23 through logic circuit in MC2/A, and goes to slewing brake release solenoid valve, derricking drum unlocking solenoid valve and front / rear / fourth (optional) motor brake release solenoid valves from termi-nals E4, E18, E5, E19 and E17.
5. As a result, each motor brake release solenoid valve and derricking drum unlocking solenoid valve for front / rear / fourth (optional) drums are changed over so that pressure oil from the pilot pump is applied to the drum motor brake.
6. As a result, the drum motor brake is released so that hoisting, boom hoisting and slewing can be done in the failure of the logic circuit in MC2/A.
SYSTEM / Control System
T2-1-39
T2BC-02-01-022
Front Motor Brake Release Solenoid Valve
Emergency Operation Switch
Rear Motor Brake Release Solenoid Valve
Fourth Motor Brake Solenoid Valve (Optional)
Fourth Motor (Optional)
Boom Derricking Motor
4-Spool Solenoid Valve Unit Pilot Pump
Rear Motor
Front Motor
Slewing Motor
SYSTEM / Control System
T2-1-40
Boom Derricking Drum Auto Stop Control
Purpose: Controls the pilot pressure by actuating the derricking drum hoisting proportional sole-noid valve or the derricking drum lowering proportional solenoid valve according to overhoist prevention switch signal, IDU data and release switch signal.
Operation:
1. MC2/B receives voltage signals from the overhoist prevention switch, IDU and release switch.
2. MC2/B sends a voltage signal to the derricking drum hoisting proportional solenoid valve or the derricking drum lowering proportional solenoid valve.
3. As a result, the derricking drum hoisting propor-tional solenoid valve or the derricking drum low-ering proportional solenoid valve operates to block the pilot pressure oil flowing through the derricking spool in the front control valve.
4. Then, the derricking spool returns to neutral posi-tion, so that pressure oil from the main pump 1 does not flow, and the boom derricking motor stops.
Purpose: Controls the pilot pressure by actuating the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve according to overhoist pre-vention switch signal, IDU data and release switch signal.
Operation:
1. MC2/B receives a voltage signal from the over-hoist prevention switch, IDU and release switch.
2. MC2/B sends voltage signals to the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve.
3. As a result, the front drum hoisting proportional solenoid valve or the front drum lowering propor-tional solenoid valve operates to block the pilot pressure oil flowing through the front spool (low) in the rear control valve.
4. The front spool (low) returns to neutral position, so that pressure oil from pump 2 does not flow, and the front motor stops.
SYSTEM / Control System
T2-1-43
T2BC-02-01-013
Auto Stop Release Key Switch
Boom Second Overhoist Prevention
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lowering Proportional Solenoid Valve
Shouldering Prevention
Front Drum Lowering Stop
Front Drum Hoisting Stop
Auto Stop Release Front Drum Switch
Crane Relay Box
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Tower Jib SecondOverhoist Prevention
Tower Relay Box
SYSTEM / Control System
T2-1-44
Rear Drum Auto Stop Control
Purpose: Controls the pilot pressure by actuating the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve according to overhoist pre-vention switch signal, IDU data and release switch signal.
Operation:
1. MC2/B receives voltage signals from the over-hoist prevention switch, IDU and release switch.
2. MC2/B sends a voltage signal to the derricking drum hoisting proportional solenoid valve or the derricking drum lowering proportional solenoid valve.
3. As a result, the rear drum hoisting proportional solenoid valve or the rear drum lowering propor-tional solenoid valve operates to block the pilot pressure oil flowing through the rear spool (low) in the front control valve.
4. The rear spool (low) returns to neutral position, so that pressure oil from pump 1 does not flow, and the rear motor stops.
SYSTEM / Control System
T2-1-45
T2BC-02-01-014
Auto Stop Release Key Switch
Rear Drum Lowering Proportional Solenoid Valve
Rear Drum Hoisting Stop
Rear Drum Lowering Stop
Shouldering Prevention
Tower Breakage Prevention
Rear Drum Hoisting Proportional Solenoid Valve
Crane Relay Box
Auto Stop Release Rear Drum Switch
Tower Relay Box
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Tower Jib Overhoist Prevention
Tower Jib BackstopAlignment
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Tower Jib SecondOverhoist Prevention
Boom Second Overhoist Prevention
Tower Upper Limit Overhoist Prevention
SYSTEM / Control System
T2-1-46
Fourth Drum Auto Stop Control (Optional)
Purpose: Controls the pilot pressure by actuating the fourth drum hoisting proportional solenoid valve or the fourth drum lowering propor-tional solenoid valve according to overhoist prevention switch signal, IDU data and re-lease switch signal.
Operation:
1. MC2/B receives voltage signals from the over-hoist prevention switch, IDU and release switch.
2. MC2/B sends a voltage signal to the fourth drum hoisting proportional solenoid valve or the fourth drum lowering proportional solenoid valve.
3. As a result, the fourth drum hoisting proportional solenoid valve or the fourth drum lowering pro-portional solenoid valve operates to block the pilot pressure oil flowing through the fourth spool in the rear control valve.
4. Then, the fourth spool returns to neutral position, so that pressure oil from pump 2 does not flow, and the third motor stops.
SYSTEM / Control System
T2-1-47
T2BC-02-01-017
Auto Stop Release Key Switch
Fourth Drum Lowering Proportional Solenoid Valve
Fourth Drum Hoisting Stop
Fourth Drum Lowering Stop
Shouldering Prevention
Fourth Drum Hoisting Proportional Solenoid Valve
Crane Relay Box
Auto Stop Release Fourth Drum Switch
Tower Relay Box
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Tower Jib SecondOverhoist Prevention
Boom Second Overhoist Prevention
SYSTEM / Control System
T2-1-48
Second Overhoist Auto Stop Control
Purpose: Controls the primary pilot pressure for the front, rear, third and boom raise/lower by turning ON and OFF the second overhoist-ing solenoid valve according to overhoist prevention switch signal and remote control pressure restoration switch signal.
Operation:
1. MC2/B receives voltage signals from the over-hoist prevention switch in the case of overhoisting, rope breaking or short-circuiting.
2. MC2/B turns OFF the second overhoisting sole-noid valve in order to block the remote control pressure oil flowing through the front, rear, fourth and boom derricking pilot valve.
3. The spool corresponding to the front or rear con-trol valve returns to neutral position, so that the front, rear, fourth and boom derricking motors stop.
4. MC2/B receives a signal from the remote control pressure restoration switch when it is set to ON position.
5. MC2/B turns ON the second overhoisting sole-noid valve to deliver pressure oil from the pilot pump to the front, rear, fourth and boom derrick-ing remote control valve.
SYSTEM / Control System
T2-1-49
T2BC-02-01-018
Remote Control Pressure Restoration Switch
Boom Second Overhoist Prevention
Tower Relay Box
Tower Jib Second Overhoist Prevention
Second Overhoist Solenoid Valve
SYSTEM / Control System
T2-1-50
Front Drum Surge Pressure Reduction Control
Purpose: Controls the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve in order to re-duce the surge pressure caused at auto stop of the front drum, thus slowly reducing the remote control pressure applied to the front spool (low) in rear control valve.
Operation:
1. MC2/B sends a voltage signal to the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve.
2. At auto stop of the front drum, the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve deliv-ers pressure oil from the front remote control valve to the hydraulic oil tank according to this voltage signal. As a result, the surge pressure is reduced.
T2BC-02-01-019
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lowering Proportional solenoidValve
Shouldering Prevention
SYSTEM / Control System
T2-1-51
2-Speed Tower Jib Derricking Flow Combining Control
Purpose: When the attachment is a tower, prevents 2-speed flow combining through the rear spool by using the rear drum hoisting pro-portional solenoid valve or the rear drum lowering proportional solenoid valve. Also, slowly reduces the remote control pressure applied to the rear spool (low) in the front control valve by controlling the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve, thus reducing a surge pressure caused at auto stop of the rear drum.
Operation:
• 2-Speed Flow Combining Prevention 1. MC2/B sends a voltage signal to the rear drum
hoisting proportional solenoid valve and the rear drum lowering proportional solenoid valve.
2. The rear drum hoisting proportional solenoid valve or the rear drum lowering proportional so-lenoid valve delivers pressure oil from the rear remote control valve to the hydraulic oil tank ac-cording to this voltage signal. Thus, the 2-speed flow combining from the rear spool is prevented.
• Surge pressure reduction 1. MC2/B sends a voltage signal to the rear drum
hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve.
2. At auto stop of the rear drum, the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve deliv-ers pressure oil from the rear remote control valve to the hydraulic oil tank according to this voltage signal. As a result, the surge pressure is reduced.
SYSTEM / Control System
T2-1-52
T2BC-02-01-020
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lowering Proportional Solenoid Valve
SYSTEM / Control System
T2-1-53
Warning Sound Output Control
Purpose: Outputs the warning sound from buzzer unit according to IDU information and operating condition.
Operation:1. The voltage signal according to IDU information
and operating condition is input to MC2/B.2. MC2/B sends the output according to the voltage
signal to the buzzer unit.3. The buzzer unit selects the sound according to
the output signal from MC2/B.
T2BC-02-01-021
Input Wiring No.
Usage Sound
YB+Y9+Y22 Boom switch overhoist/ overloading
Emergency bell sound (Plll )
Y8 Hook overhoist/ work range limit
Sound (Pipipi Pipipi )
Y22 Others Sound (Pirara Pirara Pirara)
Buzzer Unit
This Page Left Blank Intentionally
SYSTEM / Hydraulic System
T2-2-1
OUTLINE
The hydraulic system consists of the pilot circuit, main circuit, A-frame raise/lower, jack-up and retract circuits, and hydraulic tag-line and reeving winch drive circuits.
Pilot Circuit: Carries out spool selection in the control valve, pump control, valve control, motor control, and parking brake releasing control by using pressure oil from the pilot pump.
Main Circuit: Drives each actuator by using pressure oil from pumps (1, 2), slewing pump, reeving pump and jack-up / re-tract pump.
• Hoisting circuit: Drives the front and rear drums by using pressure oil from pumps (1, 2) in order to raise and lower the load.
• Boom Derricking Circuit: Drives the boom derricking drum by using pres-sure oil from pumps (1, 2) in order to operate the boom derricking.
• Jack-Up / Retract Circuit: Drives the jack-up cylinder or retract cylinder by using pressure oil from the jack-up / retract pump in order to jack up the machine or extend / retract the side frame.
• Slewing Circuit: Drives the slewing mechanism by using pressure oil from the slewing pump in order to slew the upper structure.
• Counterweight / Quick Draw Circuit: Drives the counterweight cylinder or quick draw cylinder by using pressure oil from the jack-up / retract pump in order to remove / install the counterweight or raise / lower the load for the work assistance.
• Reeving Winch Circuit: Drives the reeving winch by using pressure oil from the reeving winch pump. In addition, the reeving winch is optional and used with the hy-draulic tagline combinedly.
• Third Drum Circuit: Drives the third drum by using pressure oil from pumps (1, 2). In addition, the third drum is op-tional.
• Fourth Drum Circuit: Drives the fourth drum by using pressure oil from pumps (1, 2). In addition, the fourth drum is op-tional.
• Travel Circuit: Drives the travel mechanism by using pressure oil from pumps (1, 2) in order to travel the machine.
• Take-Up Circuit (optional): Pushes out the front idler by using the travel cir-cuit pressure in order to give the shoe a constant tension.
HydraulicSystem
Main Circuit
SYSTEM / Hydraulic System
T2-2-2
PILOT CIRCUIT
The pilot circuit which pressure oil flows from the pilot pump to consists of the followings below.
Carries out delivery flow control of pump (1, 2) and slewing pump, spool selection in control valves, dis-placement angle control in motors and brake control of hoisting drum.
Front drum hoisting and lowering proportional solenoid valve
*Fourth drum hoisting and lowering proportional solenoid valve
Rear remote control valve
Front control valve
Rear control valve
Rear drum hoisting and lowering proportional solenoid valve
Derricking remotecontrol valve
Front control valve
Boom derricking drum hoisting and lowering proportional solenoid valve
SYSTEM / Hydraulic System
T2-2-3
GATE LOCK CIRCUIT
If the gate lock lever keeps upward (ON position), the signal to the gate lock solenoid valve is not input.Pressure oil from the pilot pump flows to the hydraulic oil tank through the gate lock solenoid valve.Consequently pressure oil does not flow to the pilot circuit and each actuator cannot be operated.
If the gate lock lever keeps downward (OFF position), the signal to the gate lock solenoid valve is input.As the circuit from pilot pump to hydraulic oil tank is blocked, the pilot circuit pressure keeps the pilot relief valve setting.Consequently each actuator can be operated.
Pressure oil from main pump 1 flows to right travel motor, boom derricking motor, rear motor and front motor through the front control valve. Pressure oil from pump 2 flows to left travel motor, fourth drum motor (optional), rear motor and front mo-tor through the rear control valve. Pressure oil from both pumps (1, 2) flows to the rear motor and front motor.
Pressure oil from the slewing pump flows to the slew-ing motor. Return oil from pumps (1, 2) flows back to the hydraulic oil tank through the oil cooler. If oil tem-perature is low (with high viscosity), and flow resis-tance is large in the oil cooler, the cooler relief valve opens in order to feed the return oil directly to the hy-draulic oil tank. The return oil from the slewing motor goes directly to the hydraulic oil tank. The fourth drum, tagline / reeeving pump circuit, lower control circuit and counterweight circuit are optional.
Suction
Filter Pump 1
Pump 2
Slewing Pump
Boom Derricking Motor
Travel Motor (Right)
Travel Motor (Left)
Rear Motor
Front Motor
Return
Filter
Drain
Filter
Oil Cooler
Hydraulic
Oil Tank
Rear C
ontrol Valve Fourth Drum(Optional)
Front (Low)
Rear (High)
Left Travel
Front Control Valve
Boom derricking
Front (High)
Rear (Low)
Right Travel Tagline / ReevingWinch Circuit (Op-tional)
Counterweight / Quick Draw / Retract Pump
Cooler
Relief Valve
Tagline / Reeving
Pump Circuit
Quick Draw
Cylinder
Counterweight
Circuit
Lower Control
Circuit
4-Spool Control Valve Counterweight
(Optional)
Counterweight (Optional)
Quick Draw
Lower Control (Optional)
Slewing Control
ValveSlewing Motor
Fourth drum motor (Optional)
SYSTEM / Hydraulic System
T2-2-5
T2BC-02-02-035
Front / Rear / Boom Derricking Remote Control Valves
Right Travel
Hydraulic Oil Tank
Counterweight Cylinder Center Joint
Slewing Pump
4-Spool Control Valve
Oil Cooler
Pilot Pump
Pump 2
Pump 1
Pilot Filter
Engine
Jack-up
Rear
Front
Slewing
Retract Cylinder
Lower Control Valve
Jack-up Cylinder (Optional)
Drain Oil Pilot Oil
Circuit Oil
High Pressure Oil
Suction Oil
Return Oil (Low Pressure)
Boom Derricking
Rear Control Valve
Front Control Valve
Fourth Drum / Travel Remote Control Valve
Slewing Remote Control Valve
Second Overhoist Solenoid Valve
Boom Derricking
Rear (Low)
Front (High)
Retract
Left Travel
Fourth Drum (Optional) Rear (High)
Front (Low)
Accumulator
Gate Lock Valve
Fourth Drum (Optional)
Slewing
Quick Draw Cylinder
Counterweight / Quick Draw / Retract Pump
SYSTEM / Hydraulic System
T2-2-6
NEUTRAL CIRCUIT
When all control levers are at neutral positions, signal pressure from remote control valve does not act on each spool in the control valve. Then, pressure oil from pump 1 through the front control valve and pressure oil from pump 2 through the rear control valve return to the hydraulic oil tank through the oil cooler. Pressure oil from the slewing pump through the slew control valve returns to the hydraulic oil tank.
T2BC-02-02-013
Front Control Valve
Rear Control Valve
Slewing Control Valve
Hydraulic Oil Tank
Oil Cooler
Slewing PumpPump 1 Pump 2
SYSTEM / Hydraulic System
T2-2-7
HOISTING CIRCUIT
Single Operation
• Low speed (1st gear) operation The front (low speed) is explained here, which is similar to the rear (low speed). When the front and rear remote control valves are set to the low speed position (first detent), the second pressure of remote control valve acts on the spools in the front (low speed) and the front (high speed). As the output pressure is small, only the spools in the front (low speed) moves. Consequently only pressure oil from pump 2 flows to the front motor. Pressure oil from pump 1 does not flow to the front motor and returns to the hydraulic oil tank through neutral circuit in the front (high speed) spool. The return oil from the front motor returns to the hy-draulic tank through the front (low speed) spool.
NOTE: The remote control valve is PPC valve. Although the primary pressure is constant, the secondary pressure rises according to the operating stroke of control lever PPC: Pressure Proportional Control
SYSTEM / Hydraulic System
T2-2-8
Low-Speed Front Operation
T2BC-02-02-014
Rear Motor Front Motor
Rear Control Valve Front Control Valve
Rear (Low Speed) Front (High Speed)
Pump 1 Pump 2
Front Remote Control Valve (First Detent Position of Lever)
4-Spool SolenoidValve Unit
Second Overhoist Solenoid Valve
Pilot Pump
SYSTEM / Hydraulic System
T2-2-9
• High Speed (2nd Speed) Operation When setting the front remote control valve to the second detent position, the second pressure in the remote control valve increases and move the front spool (high speed). Pressure oils from pumps (1, 2) pass through the front (high speed) and front (low speed) spools and are then combined. Pressure oil flows into the front motor. Consequently the front motor turns at high speed. The rear motor is also in the same proce-dures.
SYSTEM / Hydraulic System
T2-2-10
High-Speed Operation
T2BC-02-02-015
Rear Motor Front Motor
Rear Control Valve Front Control Valve
Front (Low Speed) Front (High Speed)
Pump 2 Pump 1
Front Remote Control Valve (Second Detent Position of Lever)
Pilot Pump
4-Spool Solenoid Valve Unit
Second Overhoist Solenoid Valve
SYSTEM / Hydraulic System
T2-2-11
Combined Operation Circuit
The combined operation of front rear is explained here.
NOTE: As pressure oil does not flow to the front motor during the combined operation of front low speed (1st gear) + rear high speed (2nd gear), the front motor does not turn. (Refer to the combined operation of front low speed (1st gear) + rear high speed (2nd
Gear)The front and rear remote control valves are at the first detent position. As the secondary pressure in each remote control valve is low, only low speed for front or rear in the control calve moves. (Refer to the hoisting signal operation.) Pressure oil from pump 2 flows to the front motor through the front low speed spool in rear control valve and the front drum turns. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve and the rear durum turns. The front drum and rear drum turn by using pressure oil from pump 2 and pump 1 respectively.
SYSTEM / Hydraulic System
T2-2-12
Front Low-Speed Operation + Rear Low-Speed Operation
T2BC-02-02-022
Rear Drum Front Drum
Front (Low Speed)
Rear Control Valve
Pump 2 Pump 1
Rear (High Speed) Front Control Valve
Front (High Speed)
Rear (Low Speed)
Rear Remote Control Valve (First Detent Position of Lever)
Front Remote Control Valve (First Detent Position of Lever)
4-Spool Solenoid Valve Unit
Pilot Pump Solenoid Overhoist Solenoid Valve
SYSTEM / Hydraulic System
T2-2-13
• Front High Speed (2nd Gear) + Rear High Speed (2nd
Gear)
The front and rear remote control valves are at the second detent position. As the secondary pressure in each remote control valve is high, both low and high speed for front and rear in the control valve move. (Refer to the hoisting single operation.) Pressure oil from pump 2 flows to the rear motor through the rear high speed spool in rear control valve. The return oil from rear motor flows to the front speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve. The return oil from rear motor flows to the front motor through the rear high speed or rear low speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Pressure oil from pumps (1, 2) are combined and pressure oil turns the front and rear drum at the high speed.
SYSTEM / Hydraulic System
T2-2-14
Front High-Speed Operation + Rear High-Speed Operation
T2BC-02-02-023
Rear Drum Front Drum
Front (Low Speed)
Rear Control Valve
Pump 2 Pump 1
Rear (High Speed)
Front Control ValveFront (High Speed)
Rear (Low Speed)
Rear Remote Control Valve (First Detent Position of Lever)
Front Remote Control Valve (First Detent Position of Lever)
4-Spool Solenoid Valve Unit
Pilot Pump Solenoid Overhoist Solenoid Valve
SYSTEM / Hydraulic System
T2-2-15
• Front Low Speed (1st Gear) + Rear High Speed (2nd
Gear)
In this case, the rear drum turns at high speed, but the front drum does not turn. The front remote control valve is at the first detent po-sition only low speed spool for front spool in the control valve moves. The rear remote control valve is at the second detent position. Both low and high speeds for rear spool in the control valve move. Pressure oils in pumps (1, 2) are combined and flow into the rear motor after passing through the front control valve. The rear drum turns at high speed. As the front high speed spool is at neutral position, the return circuit from rear motor is released to the hy-draulic oil tank through rear low speed and front high speed spools. The return oil flows the hydraulic oil tank and the front drum cannot turn due to the load.
SYSTEM / Hydraulic System
T2-2-16
Front Low-Speed Operation + Rear High-Speed Operation
T2BC-02-02-024
Rear Drum Front Drum
Front (Low Speed)
Rear Control Valve
Pump 2 Pump 1
Rear (High Speed)
Front Control Valve Front (High Speed)
Rear (Low Speed)
Rear Remote Control Valve (Second Detent Position of Lever)
Front Remote Control Valve (Second Detent Position of Lever)
4-Spool Solenoid Valve Unit
Pilot Pump Solenoid Overhoist Solenoid Valve
SYSTEM / Hydraulic System
T2-2-17
• Front High Speed (2nd Gear) + Rear Low Speed (1st
Gear)
The front remote control valve is at the second detent position and the rear remote control valve is at the first detent position. As the secondary pressure in front remote control valve is high, both low and high speed spools for front in control valve move. (Refer to the hoisting single operation.)
Pressure oil from pump 2 flows to the front motor in the front low speed spool in rear control valve. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve. The return oil flows to the front motor through the front high speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Consequently the front drum turns at high speed and the rear drum turns at low speed.
SYSTEM / Hydraulic System
T2-2-18
Front High-Speed Operation + Rear Low-Speed Operation
T2BC-02-02-033
Rear Drum Front Drum
Front (Low Speed)
Rear Control Valve
Pump 2 Pump 1
Rear (High Speed)
Front Control Valve Front (High Speed)
Rear (Low Speed)
Rear Remote Control Valve (Second Detent Position of Lever)
Front Remote Control Valve (Second Detent Position of Lever)
4-Spool Solenoid Valve Unit
Pilot Pump Solenoid Overhoist Solenoid Valve
SYSTEM / Hydraulic System
T2-2-19
Fourth Motor Operation (Optional)
When operating the fourth remote control valve, the secondary pressure of remote control valve moves the fourth drum spool in rear control valve. Pressure oil from pump 2 passes through the fourth drum spool and drives the fourth drum motor.
The return oil from fourth drum motor passes through the fourth drum spool and returns to the hydraulic oil tank through the third drum control valve (optional).
T2BC-02-02-020
Fourth Drum
Rear Control Valve
Pump 2
Third / Fourth Remote Control Valve
Pilot Pump
4-Spool Solenoid Valve Unit
Second Overhoist Solenoid Valve
Fourth Drum Spool
Third Drum Control Valve (Optional)
SYSTEM / Hydraulic System
T2-2-20
HOISTING BRAKE CIRCUIT
Auto Brake Mode
When the brake mode Selection key switch is at the auto brake mode position, pressure oil from the pilot pump is blocked by the brake release solenoid valve, avoiding flowing to the drum brake. Therefore, under this state, hydraulic oil from the drum brake is re-turned to the hydraulic oil tank through the brake re-lease solenoid valve, applying the drum brake. The hoisting winch utilizes the planetary gear mechanism so that the drum rotates only when the hoisting motor is driven with the drum brake being engaged. As mentioned above, hoisting and lowering opera-tions are done.
SYSTEM / Hydraulic System
T2-2-21
T2BC-02-02-016
Brake Mode Selection Key Switch
Front Drum Brake Mode Switch
Rear Drum Brake Mode Switch
Third / Forth Drum Brake Mode Selection Switch (Optional)
With brake mode selection key switch at ON position, when the front, rear or fourth (optional) drum brake mode selection switch is turned ON, a signal comes to MC2/A. MC2/A actuates the brake release sole-noid valve of the turned-ON brake mode selection switch. Pressure oil from the pilot pump passes through the brake valve and the brake release sole-noid valve and flows to the front, rear or fourth (op-tional) drum brake in order to release the brake. Therefore, the free-fall becomes possible.
In the free mode, when operating the brake pedal, pressure oil from the pilot pump is blocked by the brake valve and does not flow to the drum brake. Therefore, under this state, hydraulic oil from the drum brake is returned to the hydraulic oil tank through the brake release solenoid valve and solenoid valve and the drum brake is applied. The hoisting winch utilizes the planetary gear mecha-nism so that the drum rotates only when the hoisting motor is driven with the drum brake being engaged. As a result, hoisting and lowering operation can be done.
When the front and rear are overhoisted and over-loaded, the hoisting / lowering operations automati-cally stop. The hoisting operation of front motor is explained here. The lowering operation and that of rear motor are same.
When the front hoisting operation is overhoisted or overloaded, MC2/B receives a signal from the over-hoist switch or IDU. MC2/B stops the operation of the hoisting proportional solenoid valve that is provided in the circuit between remote control valve spool and control valve spool. The hoisting proportional solenoid valve blocks the secondary pressure from remote control pressure and returns the control valve spool to neutral position in order to stop the hoisting.
SYSTEM / Hydraulic System
T2-2-27
Normal Operation
T2BC-02-02-021
Pump 2
Remote Control Valve
MC2/B
Front Drum Hoisting Proportional Solenoid Valve
Rear Drum Front Drum
Front (Low Speed)
Rear Control Valve
Front Control Valve Front (High Speed)
Front Drum Rear Drum
Pump 2
MC2/B
Pump 1
Pump 1From Front Remote Control Valve
Front (Low Speed)
Front (High Speed)
Front Control Valve
From Front Remote Control Valve
Front Drum Hoisting Proportional Solenoid Valve
Auto Stop
SYSTEM / Hydraulic System
T2-2-28
Derricking (Lowering)
In derricking (lowering) operation, the motor is likely to be rotated forcibly by the inertial force and self weight of the lifting load. The counterbalance valve controls derricking (lowering) speed by the oil feed quantity to prevent coasting. Pressure oil from the control valve passes through Port B of the counterbalance valve, and goes to the motor. The return oil from the motor is blocked by the check valve and the counterbalance valve. (Figure 1)
When the oil feed pressure rises, the counterbalance valve spool moves to open the return oil passage from the motor. Thus, the motor turns and the return oil comes to the tank via the control valve. (Figure 2) When the load begins to lower earlier than oil amount supplied from the control valve, pressure at port B side decreases, the counterbalance valve is closed and the load stops lowering. (Figure 3) When pressure at port B increases, the counterbal-ance valve is open and the load begins to lower again. In this way, the load lowers at the speed in proportion to oil amount from the control valve. As pressure oil from port A through the check valve flows to the motor during the hoisting, the speed is not controlled due to the counterbalance valve.
Counterbalance valve function
T2BC-02-02-019
Figure 1 Figure 2
Figure 3
SYSTEM / Hydraulic System
T2-2-29
BOOM DERRICKING CIRCUIT
Boom Derricking When operating the boom derricking remote control valve, the secondary pressure of remote control valve moves the boom derricking spool in front control valve. The pressure oil from the pilot pump releases the der-ricking drum lock and the boom derricking motor brake through the derricking drum unlocking solenoid valve. Pressure oil from pump 1 passes through the boom derricking spool and selects the counterbalance valve in boom derricking motor. When the counterbalance valve is selected, pressure oil from pump 1 drives the boom derricking motor.
T2BC-02-02-025
Boom Derricking Motor Derricking Drum Lock
Boom Derricking Motor Brake Boom Derricking Motor
Boom Derricking
Front Control Valve
Pump 1
Boom Derricking Remote Control Valve
Pilot Pump
Second Overhoist Solenoid Valve
Derricking Drum Unlocking Solenoid Valve
4-Spool Solenoid Valve Unit
Counterbalance Valve
SYSTEM / Hydraulic System
T2-2-30
Auto Stop Control Circuit
When the boom derricking drum is overhoisted or overloaded, MC2/B receives a signal from the over-hoist switch or IDU. MC2/B stops the operation of proportional solenoid valve that is provided in the circuit between boom derricking remote control valve spool and front control valve spool. The proportional solenoid valve blocks the remote control pressure to the control valve spool, returns the control valve spool to neutral position and stops hoisting.
NOTE: While operating the with the derricking stopped, the boom derricking drum unlocking valve does not turn OFF due to pressure in the boom derricking remote control circuit (between spools of boom derricking remote control valve and front control valve.)
The delivery flow from pump 1 drives the travel motor (right), and the delivery flow from pump 2 drives the travel motor (left), releasing the parking brake. The travel motor is a variable displacement type. High speed and low speed are selected by the travel mode switch.
• Low Travel Speed When the travel mode switch is at the low speed position, electric current does not flow to the high travel speed selection solenoid valve. The pilot valve of the travel motor is not selected because the high-speed travel solenoid valve is not selected, so that pressure oil from the travel circuit of the control valve is not supplied to the tilt piston. As a result, the displacement angle of the travel motor becomes a large angle, so that the travel motor rotates at a low speed.
SYSTEM / Hydraulic System
T2-2-32
Low Travel Speed
T2BC-02-02-027
Tilt Piston Pilot Valve Pilot Valve
Tilt Piston
Parking Brake Parking Brake Travel Motor (Left) Travel Motor (Right)
Travel (Left)
Rear Control Valve Front Control Valve
Travel (Right)
Pump 2 Pump 1
Left Travel Remote Control Valve Right Travel Remote
Control Valve
Pilot Pump
High Travel Speed Selection Solenoid Valve
SYSTEM / Hydraulic System
T2-2-33
• High Travel Speed When the travel mode switch is at the high speed position, electric current flows to the high travel speed selection solenoid valve. Then, high speed travel selection solenoid valve is changed over, the pilot valve of the travel motor is changed over by the pilot pressure oil from the high travel speed selection solenoid valve, and the pressure oil from the travel circuit of the control valve is supplied to the tilt piston in order to set the displacement angle to a small angle, thus turning the travel motor at a high speed.
SYSTEM / Hydraulic System
T2-2-34
High Travel Speed
T2BC-02-02-028
Tilt Piston Pilot Valve
Pilot Valve Tilt Piston
Parking Brake Parking Brake Travel Motor (Left) Travel Motor (Right)
Rear Control Valve Front Control Valve
Pump 2 Pump 1
Left Travel Remote Control Valve
Right Travel Remote Control Valve
Pilot Pump
4-Spool Solenoid Valve Unit
High Travel Speed Selection Solenoid Valve
SYSTEM / Hydraulic System
T2-2-35
SLEWING CIRCUIT
When operating the slewing remote control valve, the spool in the slewing control valve moves, the delivery flow from the slewing pump passes through the slew-ing control valve, and goes to the slewing motor. The return oil from slewing motor returns to the hy-draulic oil tank. In slewing operation, when the slewing motor is driven by the inertial force of the slewing frame, cavitation is caused in the motor because motor rotation is too fast, compared to the oil feed form the pump. In order to avoid this, a make-up valve is provided, sucks the oil from the return circuit and compensates the lack of oil feed. The slewing brake solenoid valve is driven by the slewing brake switch in order to release the slewing brake.
SYSTEM / Hydraulic System
T2-2-36
T2BC-02-02-029
Slewing Motor
Slewing Brake
Slewing Brake
Slewing Control Valve
Slewing Pump
Slewing Remote Control Valve
Pilot Pump
4-Spool Solenoid Valve Unit
Slewing Brake Solenoid Valve
Make-Up Valve Make-Up Valve
SYSTEM / Hydraulic System
T2-2-37
COUNTERWEIGHT / QUICK DRAW CIR-CUIT
4- Spool Control Valve: Neutral When all the spools in 4-Spool control valve are in neutral, pressure oil from the counterweight / quick draw / retract pump is used to cool the front and rear drums. Pressure oil from the counterweight / quick draw / re-tract pump flows into the 4-spool control valve. Pres-sure oil opens the sequence valve and flows to the neutral circuit. When all the spools in 4-spool control valve are in neutral, pressure oil from the pump flows into the front and rear drums in order to cool through the neutral circuit in each spool.
NOTE: The sequence valve is provided in order to keep the operating pressure for each spool in 4-spool control valve.
4-Spool Control Valve: Neutral
T2BC-02-02-031
Front Drum
Quick Draw Spool
Sequence Valve
Counterweight / Quick Draw / Retract Pump
4-Spool Control Valve
Rear Drum
Lower control Spool
Counterweight Cylinder (Left) Spool
Counterweight Cylinder (Left)
To Lower Control Valve (Optional)
Quick Draw Cylinder
Counterweight Cylinder (Right)
Counterweight Cylinder (Right) Spool
SYSTEM / Hydraulic System
T2-2-38
4-Spool Control Valve: Operating
The operation retracting the quick draw cylinder is explained here. When turning the quick draw extend / retract switch in operator’s seat to retract, the solenoid valve (retract) in quick draw spool is operated. Pressure oil from the counterweight / quick draw / retract pump is reduced at the pressure-reducing valve and acts on the end of quick draw spool so that the spool moves. Consequently pressure oil from the counterweight / quick draw / retract pump opens the sequence valve through the quick draw spool and flows into the quick draw cylinder rod side.
This pressure oil retracts the quick draw cylinder. The return oil from cylinder returns to the hydraulic oil tank through quick draw spool.
NOTE: The Downsafety valve closes the check valve part and prevents the load from suddenly lowering when the flow rate in-creases abnormally due to the hose dam-age and so on. The downsafety valve is also installed to the counterweight cylinder.
T2BC-02-02-032
Front Drum
Counterbalance Valve
Counterweight Cylinder (Right) Pressure Reducing
Valve
Main Relief Valve
Counterweight / Quick Draw Retract Pump
Rear Drum
Counterweight Cylinder (Left)
Quick Draw Cylinder
Sequence Valve
4-Spool Control Valve
Quick Draw Spool
Lower Control Spool
Counterweight Cylinder (Left) Spool
Port Relief Valve
Port Relief Valve
Counterweight Cylinder (Right) Spool
To Lower ControlValve (Optional)
Downsafety Valve
SYSTEM / Hydraulic System
T2-2-39
JACK-UP (OPTIONAL) / RETRACT CIR-CUIT
The operation extend the jack-up cylinder (right front) and retract cylinder (left) is explained here. The jack-up is optional. When turning the lower control switch in cab ON, the lower control valve spool in 4-spool control valve moves. Pressure oil from the pilot pump flows to the lower control valve through 4-spool control valve. When moving the control lever for jack-up (right front) and retract (right) to extend, pressure oil from the pilot pump flows to each cylinder and extends the cylinder. The maximum pressure in lower control valve circuit is regulated cy the relief valve.
NOTE: The lower control valve, which is a manual control valve, is installed to the front part of track frame with the jack-up mechanism (optional) attached. The retract operation is performed cy using the side frame control switch in cab without the jack-up mechanism.
SYSTEM / Hydraulic System
T2-2-40
When Extending the Left Retract Cylinder, with Jack (Right Front) Extended
T2BC-02-02-010
Jack-Up Cylinder (Left Rear)
Jack-Up Cylinder (Right Rear)
Jack-Up Cylinder (Left Front)
Jack-Up Cylinder (Right Front)
Relief valve
Retract (Left)
Retract Cylinder (Left)
Lower Control Valve
Retract Cylinder Circuit WithoutJack-Up
T2BC-02-02-034
Retract Cylinder (Right)
4-Spool Control Valve
Quick Draw
Lower Control
Center Joint
Counterweight
Pump for Counterweight / Quick Draw / Jack-Up / Retract
Retract (Right)
Jack-Up (Right Front)
Jack-Up (Right Rear)
Jack-Up (Left Rear)
Jack-Up (Left Front)
SYSTEM / Hydraulic System
T2-2-41
HYDRAULIC TAGLINE CIRCUIT (OPTIONAL)
Pressure oil from the hydraulic tagline / reeving winch drive pump passes through the hydraulic tagline / reeving winch control valve, and goes to the hydraulic tagline motor to drive the hydraulic tagline motor. The return oil from the hydraulic tagline motor returns to the hydraulic oil tank after flowing through the fourth drum for cooling.
T25N-02-02-020
Fourth Drum
Hydraulic Oil Tank
Hydraulic Tagline
Hydraulic Tagline Motor
Reeving Winch
Hydraulic Tagline / Reeving Winch Control Valve
Hydraulic Tagline / Reeving Winch Drive Pump
SYSTEM / Hydraulic System
T2-2-42
REEVING WINCH CIRCUIT (OPTIONAL)
When the reeving winch hoisting switch is turned ON, the reeving winch hoisting solenoid valve is selected by electric current from the reeving winch hoisting switch. As a result, pressure oil from the pilot pump passes through the reeving winch hoisting solenoid valve to move the spool in the hydraulic tagline / reeving winch control valve for switching. Pressure oil from the hydraulic tagline / reeving winch drive pump passes through the hydraulic tagline / reeving winch control valve, and goes to the reeving winch to move the spool in the reeving winch for switching, thus releasing the reeving winch brake and driving the reeving winch motor. The return oil from reeving winch passes through the hydraulic tagline / reeving winch control valve, flows through the fourth drum for cooling and then returns to the hydraulic oil tank.
T25N-02-02-021
Fourth Drum
Hydraulic Oil Tank
Hydraulic Tagline Reeving Winch
Hydraulic Tagline / Reeving Winch Control Valve
Hydraulic Tagline / Reeving Winch Drive Pump
Reeving WinchBrake
Reeving WinchMotor
From Pilot Pump
Reeving Winch Lowering Solenoid Valve
Spool
From Reeving Winch Hoisting Switch
Reeving Winch Hoisting Solenoid Valve
Spool
SYSTEM / Hydraulic System
T2-2-43
TAKE-UP CIRCUIT (OPTIONAL)
The take-up mechanism pushes the left and right front idlers forward by using the travel circuit pressure and gives a constant tension the track shoe.
Travel circuit pressure is supplied to the bottom sides of left and right take-up cylinders through the shuttle valve. Consequently the front idler is pushed and the left and right track shoes are given a constant tension. When the excessive power acts on the front idler, the return check valve is open and release pressure oil from the bottom side of take-up cylinder in order to absorb the shock.
T2BC-02-02-030
Take-Up Cylinder (Left)
Return Check Valve
Shuttle ValveTake-Up Cylinder (Right)
Return Check Valve
Shuttle Valve
Travel Motor (Left) Travel Motor (Right)
Front Idler (Right) Front Idler (Left)
SYSTEM / Hydraulic System
T2-2-44
(Blank)
SYSTEM / Electric System
T2-3-1
OUTLINE
The electric system can be divided roughly into the main circuit, the control circuit, the monitor circuit, the brake control circuit, the moment limiter, and the auto stop circuit.
• Main circuit Engine-related circuit and accessories-related circuit
• Control circuit Engine and pump control circuit consisting of ac-tuators such as solenoid valves, controllers (MC and ECU), switch boxes, sensors and switches
• Monitor circuit Circuit that displays operating status of the machine (consisting of monitor display, sensors, switches, etc.)
• Moment limiter and auto stop circuit The circuit that warns of overloading and overhoist-ing, and makes auto stop of hoisting and boom der-ricking (consisting of the moment limiter that dis-plays loading condition during crane operation and detects overloading; micro switch that detects boom and hook overhoisting; controller (MC) that performs auto stop; and solenoid valve). Here, major functions and construction of the main circuit will be described.
Main circuit • Electric circuit that is an electric power source for
the electric system on the machine. • Preheating circuit that assists the engine in starting
in cold weather. • Starting circuit that starts the engine. • Charging circuit that charges batteries, and supplies
electricity to compensate power consumption. • Engine stop circuit that stops the engine through the
engine stop solenoid. • Accessories-related circuit that is actuated when the
key switch is at ON position. • Surge voltage prevention circuit that prevents the
occurrence of serge voltage when the engine is stopped.
• Drum lock circuit that locks and releases the front, rear and fourth drum lock.
• Slewing brake release circuit that releases the slewing motor brake by delivering the pilot pressure oil to the brake, with the slewing brake release so-lenoid valve ON.
SYSTEM / Electric System
T2-3-2
POWER CIRCUIT
With the minus terminal of the battery connected to the machine, the battery serves as a backup power supply for the radio and air conditioner when the key switch is at OFF position. Also, the battery serves as a main power supply for MC2/A, MC2/B, IDU, key switch, fuel feed pump switch, room light switch and horn relay.
T25N-02-03-001
Key Switch
Battery
Room Light Switch
Fuel Feed Pump Switch
Horn Relay Horn Switch
Horn
Battery Relay
MC2/A
MC2/B
IDU
Radio
Air Conditioner
SYSTEM / Electric System
T2-3-3
(Blank)
SYSTEM / Electric System
T2-3-4
PREHEATING CIRCUIT
When setting the preheat key switch to ON position, terminal B is connected to terminal ACC in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excited electric current from the battery flows to terminals #7 and #8 of the preheat controller. When coolant temperature (resistance of the coolant temperature sensor) is 0 °C or lower, the preheat con-troller sets the preheating time (5 to 20 seconds) ac-cording to coolant temperature. In the preheating time, in order to excite the heater relay, the preheat con-troller lets battery current flow through the heater relay, lights a glow lamp, and turns on the air heater for preheating the engine.
SYSTEM / Electric System
T2-3-5
Preheating Operation
T25N-02-03-002
Battery
Key Switch
MC2/A
Engine Start-ing Relay
Battery Relay
Alternator
Starter Relay 2 Coolant
Temperature Sensor
Preheat Controller
Heater Relay Air Heater Glow Lamp
SYSTEM / Electric System
T2-3-6
• After-Heating Operation After-preheating is carried out when starting the preheated engine. Immediately after completion of preheating, the engine cylinders are not warmed sufficiently, leading to incomplete combustion. In order to avoid this, after-heating is carried out as fol-lows.When the engine starts, electric current from termi-nal C of the key switch flows to MC2/A. As a result, MC2/A excites the engine start relay. When the en-gine starting relay is excited, electric current from terminal C of the key switch passes through the en-gine start relay and #6 terminal of the preheat con-troller. Also, when the engine is cranked, the alter-nator starts power generation, and electric current from terminal L flows to terminal #4 of the preheat controller. For 30 seconds after electric current from terminal C of this key switch and terminal L of the alternator flows into the preheat controller, the heater relay is excited to actuate the air heater.
SYSTEM / Electric System
T2-3-7
After-Heating Operation
T25N-02-03-003
Battery
Key Switch
MC2/A
Engine Start Relay
Battery Relay
Alternator
Starter Relay 2 Coolant
Temperature Sensor
Preheat Controller
Heater Relay Air Heater Glow Lamp
SYSTEM / Electric System
T2-3-8
ENGINE STARTING CIRCUIT
1. When setting the key switch to ON position, elec-tric current from terminal ACC of the key switch excites the battery relay.
2. When the battery relay is excited, electric current from the battery flows through the battery relay, and goes to B terminal of the starter motor.
3. In addition, electric current from the terminal ACC excites the engine stop relay.
4. Therefore, the engine stop relay is turned ON, and the engine stop solenoid is turned OFF. The rack of the fuel injection pump, which is linked to the engine stop solenoid, is released from the engine stop position. As a result, the fuel is supplied to the engine, and the engine can start.
5. In addition, electric current from the key switch ACC flows to terminal R of starter relay 2.
6. When the slew brake switch is at the brake posi-tion, and the front, rear or third / fourth drum brake mode selection switch is at the auto brake posi-tion, MC2/A excites the engine start relay.
7. When the key switch is set to the start position while engine starter relay 1 is being excited, elec-tric current from terminal C of the key switch flows to terminal SW of starter relay 1.
8. At this time, when electric current is supplied from terminal S of starter relay 2 to terminal L of starter relay 1, electric current from terminal S of starter relay 1 flows to terminal S of the starter motor to turn the starter.
9. When the engine starts, the alternator generates power and electric current flows from terminals B, L and P of the alternator.
10. Electric current from terminal P of the alternator goes to terminal P of starter relay 2 in order to block electric current flowing from terminal S of starter relay 2.
11. During the engine running (generating power by the alternator), electric current does not flow to terminal L of starter relay 1, so that the starter does not turn even when setting the key switch to START position.
After starting the engine, when leaving the hand from the key switch, the key switch returns to ON position. With the key switch at ON position, terminal B is con-nected to terminal ACC in the key switch. Electric current from terminal B of the alternator charges the battery through battery relay. In addition, electric current flows to each circuit via a fuse. With the engine running, the alternator rotates to gen-erate electrical current. Electric current from terminal L flows to terminal #2 of the charge relay. As a result, charge relay is turned OFF. The charge relay turned OFF, the charge lamp ground circuit goes OFF, and the charge lamp is turned OFF too.
SYSTEM / Electric System
T2-3-11
T25N-02-03-004
Battery
Key Switch
Battery Relay
Alternator
Charge Relay
Charge Lamp
OFF Delay Relay
SYSTEM / Electric System
T2-3-12
ACCESSORIES CIRCUIT
When setting the key switch to ON position, terminal B and ACC are connected in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excited, electric current from the battery passes through the battery relay, and flows to the radio, clearance light (optional), dome light, work light and drum light. The power for horn and cigarette lighter is supplied from the battery circuit di-rectly without the key switch. The cigarette lighter is a 12V specification.
T2BC-02-03-003
Battery
Horn Switch
Radio
Clearance Light (Optional)
Dome Light
Drum Light (Optional)
Cigarette Lighter
Work Light
Key Switch
HornHorn Relay
Battery Relay
SYSTEM / Electric System
T2-3-13
ENGINE STOP CIRCUIT
Engine Stop Circuit Using Engine Stop Solenoid
When setting the key switch to OFF position, exciting current does not flow from terminal ACC of the key switch to the engine stop relay. Because the exciting current disappears, the engine stop relay is turned OFF, electric current flows from the battery relay to the engine stop solenoid. The engine stop solenoid stops the fuel feed, and the en-gine stops. After that, the off delay relay goes OFF, and the bat-tery relay also goes OFF, thus stopping the current to the engine stop solenoid.
SYSTEM / Electric System
T2-3-14
T25N-02-03-007
Battery
Key Switch
Battery Relay
Engine Stop Relay Engine Stop Solenoid
OFF Delay Relay
SYSTEM / Electric System
T2-3-15
SURGE VOLTAGE PREVENTION CIRCUIT
When stopping the engine (by turning the key switch OFF), electric current from terminal ACC of the key switch stops, and the battery relay turns OFF. Even if turning OFF the key switch, the engine does not stop at once, and rotates by the inertia, so that the alterna-tor keeps generating power. Because the generated power current does not flow through the battery, the surge voltage (voltage rise) is generated in the circuit, causing failure of electronic equipment such as con-troller, and components. Therefore, the surge voltage prevention circuit is provided. The battery relay is excited by the off delay relay until the engine stops. As a result, the generated power current from terminal B of the alternator passes through the battery relay and goes to the battery, thus preventing the occurrence of serge voltage.
SYSTEM / Electric System
T2-3-16
T25N-02-03-008
Battery
Key Switch
Battery Relay
Off Delay Relay
Starter Relay2Alternator
Charge Relay
SYSTEM / Electric System
T2-3-17
DRUM LOCK CIRCUIT
When setting the key switch to ON position, terminal B and ACC terminal are connected in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excited, electric current from the battery passes through the battery relay, and flows through terminal B of the front, rear and the fourth drum locks. Under this condition, when setting the front, rear or fourth drum lock switch (optional) to OFF position, electric current flows from terminal B of the drum lock connected to the switch to be set. This electric current passes through terminal P2 and lock switch, and goes to terminal A in order to unlock the drum. Similarly, when setting the front, rear or fourth drum lock switch (optional) to ON position, electric current from terminal B of the drum lock connected to the switch to be set passes through terminal P1, and goes terminal A in order to lock the drum.
SYSTEM / Electric System
T2-3-18
NOTE: The following figure shows when each lock switch opens.
T25N-02-03-010
Battery
Key Switch
Battery Relay
Front Drum Lock
Rear Drum Lock
Fourth Drum Lock (Optional)
Front Drum Lock Switch
Rear Drum Lock Switch
Fourth Drum Lock Switch (Optional)
SYSTEM / Electric System
T2-3-19
SLEWING BRAKE RELEASE CIRCUIT
1. When the slewing brake switch is at OFF position, the slewing brake indication lamp is turned on and the slewing brake is applied.
2. When the slewing brake switch is at ON position, electric current flows from the battery to MC2/A.
3. MC2/A turns off the slewing brake indication lamp.
4. At the same time, MC2/A passes electric current the slewing brake release solenoid valve and se-lects the slewing brake release solenoid valve. As a result, pressure oil from the pilot pump flows through the slewing brake release valve and goes to the slewing brake in order to release the brake.
Slewing Brake Switch: ON
T2BC-02-03-002
Slewing Brake Indi-cator Lamp
Monitor Lamp Unit
Slewing Brake Switch: ON
MC/2A
To Slewing Brake
Pilot Pump
Slewing Brake Release Solenoid Valve
This Page Left Blank Intentionally
2BCT-3-1
SECTION 3 COMPONENT OPERATION
—CONTENTS—Group 1 Pump Mechanism
Outline ..........................................................T3-1-1Main Pump ...................................................T3-1-2Slewing Pump ..............................................T3-1-4 Regulator......................................................T3-1-5Solenoid Valve............................................T3-1-21Pilot Pump, Pump for Counterweight / Quick Draw / Retract and Pump for Hydraulic Tagline and Reeving Winch ....T3-1-23
Group 2 Front / Rear Control Valve Outline ..........................................................T3-2-1Composition .................................................T3-2-2 Internal Circuit ..............................................T3-2-6Spool ............................................................T3-2-9Main Relief Valve........................................T3-2-11 Pump Relief Valve ....................................T3-2-13Make-up Valve............................................T3-2-15Holding Valve .............................................T3-2-16Pressure Compensation Valve...................T3-2-17
Group 3 Slewing Control Valve Slewing Control Valve ..................................T3-3-1
Group 4 Lower Control Valve Outline ..........................................................T3-4-1Internal Composition ....................................T3-4-2Relief Valve ..................................................T3-4-3
Group 5 4-Unit Control Valve Outline ..........................................................T3-5-1Composition .................................................T3-5-2 Pressure-Reducing Valve.............................T3-5-4 Sequence Valve ...........................................T3-5-5 Solenoid Valve..............................................T3-5-6
Group 6 Remote Control Valve Outline ..........................................................T3-6-1Construction .................................................T3-6-4 Detent Function............................................T3-6-8Operation....................................................T3-6-10
Group 7 Slewing Mechanism Outline ......................................................... T3-7-1Slewing Reduction Gear.............................. T3-7-2Slewing Motor .............................................. T3-7-3 Slewing Parking Brake ................................ T3-7-4Valve Unit..................................................... T3-7-6
Group 12 Others (Base Carrier) Outline ........................................................T3-12-1Slewing Ring ..............................................T3-12-2Center Joint ................................................T3-12-3Retract Cylinder .........................................T3-12-4Jack-Up Cylinder (Optional).......................T3-12-5Take-Up Cylinder (Optional).......................T3-12-8
COMPONENT OPERATION / Pump Mechanism
T3-1-1
OUTLINE
The pump device consists of main pump (pump 1 (10) and pump 2 (8)), slewing pump (6), pilot pump (4), pump (3) for counterweight / quick draw / jack-up / retract tagline / reeving winch / fourth drum for cooling and PTO gearbox (2) The main pump is a dual swash plate type variable displacement plunger pump, and the slew pump is a single swash plate type variable displacement plunger pump. These pumps deliver high pressure oil to the main circuit for operation.
The pilot pump (4), pump (3) for counterweight / quick draw / jack-up retract and pump (1) for hydraulic tag-line / reeving winch are gear pumps. In addition, the PTO gearbox (2) is provided between pump 1(10) and pump 2 (8).
The main pump is a dual swash plate type axial plunger pump and consists of pumps (1 and 2). Two shafts (1) are connected with gear (6), each pro-vided with a pump of the same type. Cylinder block (5) is splined on shaft (1). Plunger (4) is inserted into cylinder block (5). The rotation of engine is transmitted through the cou-pling to shaft (1). When shaft (1) rotates, plunger (4) rotates with cylin-der block (5). Plunger (4) slide over shoe plate (3) and reciprocates in the bore of cylinder block (5) according to the incli-nation of swash plate (2). By this reciprocation, suction and delivery of hydraulic oil are carried out.
T1F3-03-01-003
Pump 2 Pump 1
1
2 44 53 6 5 4 3 2
COMPONENT OPERATION / Pump Mechanism
T3-1-3
Delivery Flow Adjustment
The pump delivery flow is adjusted by changing the inclination angle of swash plate (2) in order to change the stroke of plunger (4). The servo piston is moved by the pressure oil from the regulator. Swash plate (2) is connected to the servo piston, so that the inclination angle of swash plate (2) is changed according to the movement of the servo piston in order to adjust the delivery flow.
T117-02-01-003
Servo Piston
Valve Plate
1
54
2
COMPONENT OPERATION / Pump Mechanism
T3-1-4
SLEWING PUMP
The Slewing pump is a one-spool swash plate type axial plunger pump. Shaft (1) is splined to shaft (1) of pump 2. The shaft (1) is provided with a pump whose type is the same as the main pump. Shaft (1) is splined to cylinder block (5) into which plungers are inserted. The rotation of engine is transmitted through pump 2 to shaft (1). When shaft (1) rotates, plunger (4) rotates with cylinder block (5). Plunger (4) slides over shoe plate (3) and reciprocates in the bore of cylinder block (5) according to the inclination of swash plate (2). By this reciprocation, suction and delivery of hydraulic oil are carried out. The slewing pump is used with the maximum displacement angle fixed.
T25N-03-01-005
54321
Splined to Pump 2
COMPONENT OPERATION / Pump Mechanism
T3-1-5
REGULATOR
OutlineAccording to various pressure signals, the regulator controls the displacement angle of maim pump (pumps (1, 2)) and changes the flow rate in order not to exceed the engine horsepower. One regulator is provided to each of pump 1, pump 2, and slewing pump.The regulator in slewing pump fixes the maximum displacement angle for slewing pump and does not control the displacement angle.
The displacement angle proportional solenoid valve is attached to the pump 2 regulator and the displace-ment angle solenoid valve is attached to the slewing pump regulator. In addition, the power increase solenoid valve is at-tached to the PTO gearbox.
T25N-03-01-003
Layout
T25N-03-01-010
PTO Gearbox
Pump 2 Regulator
Displacement Angle Proportional Solenoid Valve
Slewing Pump Regulator
Pump 1 Regulator
Power Increase Solenoid Valve
Pump 2 Regulator
Displacement Angle Solenoid Valve
Slewing Pump Regulator
PTO Gearbox
Pump 1 Regulator
Displacement Angle Proportional Solenoid Valve
Power Increase So-lenoid Valve
Displacement Angle Solenoid Valve
COMPONENT OPERATION / Pump Mechanism
T3-1-6
Sectional View (Main Pump Regulator)
Pump 1
T25N-03-01-006
Pump 2
T25N-03-01-007
Section A-A
T25N-03-01-011
1 2 4 5 6
7
8
BA
B A
BA
B A
3
COMPONENT OPERATION / Pump Mechanism
T3-1-7
Section B-B
T1F3-03-01-008
1 - Pilot Piston 7 - Feedback Lever 12 - Pin 17 - Servo Piston 2 - Pin 8 - Pin 13 - Lever 1 18 - Pin 3 - Lever 2 9 - Return Spring 14 - Pin 19 - Compensating Rod 4 - Pin 10 - Sleeve 15 - Outer Spring 20 - Compensating Piston 5 - Pin 11 - Spool 16 - Inner Spring 21 - Piston 6 - Pilot Spring
9 10 11 12 13 14 15 16
21 20 19 18 17
COMPONENT OPERATION / Pump Mechanism
T3-1-8
Sectional View (Slewing Pump Regulator)
T25N-03-01-014
Section A-A
T25N-03-01-012
AB
1 2 3 4 5 6
7
8
B A
COMPONENT OPERATION / Pump Mechanism
T3-1-9
Section B-B
T25N-03-01-013
1 - Pilot Piston 7 - Feedback Lever 12 - Pin 17 - Servo Piston 2 - Pin 8 - Pin 13 - Lever 1 18 - Pin 3 - Lever 2 9 - Return Spring 14 - Pin 19 - Compensating Rod 4 - Pin 10 - Sleeve 15 - Outer Spring 20 - Compensating Piston 5 - Pin 11 - Spool 16 - Inner Spring 21 - Piston 6 - Pilot Spring
9 10 11 12 13 14 15 16
1718192021
COMPONENT OPERATION / Pump Mechanism
T3-1-10
Linkage Mechanism (Main Pump)
The movement of pilot piston (1) is transmitted through pin (2) to lever 2 (3). Lever 2 (3) is turned about pin (5) which is fixed to the axial plug. The movement of compensating rod (19) is trans-mitted through pin (18) to the lever 1 (13). The lever 1(13) is turned about pin (12) which is fixed to the casing. Pin (4) is attached to feedback lever (7). Both ends of pin (4) are inserted into holes of lever 1 (13) and lever 2 (3).
Therefore, when lever 1 (13) or lever 2 (3) turns, pin (4) contacts the hole of the turned lever. Feedback lever (7) turns about pin (8) attached to servo piston (17). In addition, when servo piston (17) moves, feedback lever (7) is moved through pin (8). At this time, because neither lever 1 (13) nor lever 2 (3) move, feedback lever (7) turns about pin (4), and spool (11) moves.
1 - Pilot Piston 5 - Pin 12 - Pin 17 - Servo Piston 2 - Pin 7 - Feedback Lever 13 - Lever 1 18 - Pin 3 - Lever 2 8 - Pin 14 - Pin 19 - Compensating Rod 4 - Pin 11 - Spool
Axial Plug
Casing
1218
13Hole
144
Hole
2
1
8
11
197
17
3
5
COMPONENT OPERATION / Pump Mechanism
T3-1-11
Regulator Control Functions
The regulator of main pump is explained here. That of slewing pump is omitted.
The regulator has the following three control func-tions.
• Control by self pump pressure or companion pump pressure Self pump pressure P1 and companion pump pres-sure P2 are applied to the regulator. (The slewing pump uses only self pump pressure P3.) When the mean pressure of these two pump pres-sures exceed the preset P-Q curve, both pump de-livery flow rates of both pumps are reduced to fol-low the P-Q curve. As a result, overloading to the engine is prevented. In addition, because the P-Q curve is preset by the mean pressure of both pumps, both pump delivery flow rates become almost equal. Therefore, higher pressure pump is subjected to larger load, while lower pressure pump to smaller load. Thus, the total becomes equal to the engine horsepower. (Summa-tion control)
• Control by pilot pressure from power increase so-lenoid valve (only main pump) MC2/A sends a signal according to engine speed and load to the power increase solenoid valve. The power increase solenoid valve operates ac-cording to this signal, and returns pressure oil, which acts on the compensating piston of regulator, to the hydraulic oil tank. As a result, the delivery flow is increased. (Power increase control) (Refer to "Control System".)
Flow Rate (Q) Pressure Increase
Flow Decrease
Pressure (P)0
Flow Rate (Q)
Pilot Pressure (Pi)0
COMPONENT OPERATION / Pump Mechanism
T3-1-12
• Control by pilot pressure from displacement angle proportional solenoid valve
MC2/A sends a signal, which is proportional to the rotation of the acceleration grip (JOY-STICK LEVER : accelerator dial), to the displacement an-gle proportional solenoid valve. The displacement angle proportional solenoid valve sends pilot pressure, which depends on this signal, to the regulator to increase or decrease the pump delivery flow rate. (Displacement angle control) (Refer to "Control System".)
T25N-03-01-008
P1 - Pump 1 Delivery Pressure
Pz - Power Increase Control Pressure(From Power Increase Solenoid Valve)
• Control by Self Pump Pressure and Companion Pump Pressure
NOTE: Reference: Control by self pump pressure and companion pump pressure is divided into the following two functions. Flow reduction (overload prevention) When the load (pressure) increases, controls so that the load does not exceed the engine horsepower by reducing the pump delivery flow rate.
Flow rate increase (flow rate restoration) When the load (pressure) decreases, in-creases the pump delivery flow rate for efficient use of engine horsepower.
• Flow reduction (overload prevention)
1. When self pump delivery pressure P1 and com-panion pump delivery pressure P2 increase, compensating piston (20) moves compensating rod (19) to the position where outer spring (15) force and inner spring (16) forces are balanced.
2. Compensating rod (19) moves lever 1 (13) through pin (18). Lever 1 (13) turns counter-clockwise about pin (12) fixed to the casing.
3. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 1 (13). Therefore, feedback lever (7) rotates clockwise about pin (8) by the turning of lever 1 (13) and moves spool (11) to the right.
4. When spool (11) moves, self pump delivery pressure P acts through spool (11) to the large diameter chamber side of servo piston (17). Al-though self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the right due to the difference in area.
5. The pump displacement angle reduces according to the movement of servo piston (17) and the pump delivery flow rate decreases.
6. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensat-ing rod (19) nor lever 1 (13) move, feedback lever (7) turns counterclockwise about pin (4) and moves spool (11) to the left. The notches of spool (11) and sleeve (10) are closed completely, so self pump delivery pressure does not act to the large diameter chamber side of servo piston (17) and the movement of servo piston (17) stops.
7. The pump delivery flow rate is decreased by these operations and the load to the pump is re-duced.
T25N-03-01-023
Flow Rate(Q)
Pressure (P)0
P2P1
20
1311 717
Increase Decrease Displacement Angle
COMPONENT OPERATION / Pump Mechanism
T3-1-14
T25N-03-01-016
T25N-03-01-016
4 - Pin 11 - Spool 15 - Outer Spring 18 - Pin 7 - Feedback Lever 12 - Pin 16 - Inner Spring 19 - Compensating Rod 8 - Pin 13 - Lever 1 17 - Servo Piston 20 - Compensating Piston 10 - Sleeve
10 11 12 13 4 15 16
78181920
10 11 12 13 4 15 16
78181920
P1P2
17
17
COMPONENT OPERATION / Pump Mechanism
T3-1-15
• Flow rate increase (flow rate restoration)
1. When self pump delivery pressure P1 and com-panion pump delivery pressure P2 decrease, compensating piston (20) moves together with compensating rod (19) to the left, to the position where outer spring (15) force and inner spring (16) forces are balanced.
2. Compensation rod (19) moves lever 1(13) through pin (18). Lever 1 (13) turns clockwise about pin (12) fixed to the casing.
3. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 1(13). Therefore, feedback lever (7) rotates counterclockwise about pin (8) by the turning of lever 1 (13) and move spool (11) to the left.
4. When spool (11) moves, the large diameter chamber side of servo piston (17) is connected to the hydraulic oil tank through spool (11). As self pump delivery pressure P acts to the small di-ameter chamber side, servo piston (17) moves to the left.
5. The pump displacement angle increases accord-ing to the movement of servo piston (17) and the pump delivery flow rate increases.
6. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensat-ing rod (19) nor lever 1 (13) moves, feedback lever (7) turns clockwise about pin (4) and moves the spool (11) to the right. The notches of spool (11) and sleeve (10) are closed completely, so the large diameter chamber side of the servo piston (17) is not connected to the hydraulic oil tank and the movement of servo piston (17) stops.
7. By these movements, the pump delivery flow rate increases.
T25N-03-01-025
Flow Rate(Q)
Pressure (P) 0
P2P1
20
1311 717
Increase Decrease Displacement Angle
15, 16 10
COMPONENT OPERATION / Pump Mechanism
T3-1-16
T25N-03-01-016
T25N-03-01-016
4 - Pin 11 - Spool 15 - Outer Spring 18 - Pin 7 - Feedback Lever 12 - Pin 16 - Inner Spring 19 - Compensating Rod 8 - Pin 13 - Lever 1 17 - Servo Piston 20 - Compensating Piston 10 - Sleeve
10 11 12 13 4 15 16
78181920
10 11 12 13 4 15 16
78181920
P1
To Hydraulic Oil Tank
17
17
COMPONENT OPERATION / Pump Mechanism
T3-1-17
Control by Pilot Pressure of Power Increase So-lenoid Valve
Power increase control pressure Pz from the power increase control solenoid valve acts and increases the pump delivery flow.
1. When the power increase solenoid valve is ex-cited by a signal from MC2/A, the pilot pressure acting on pin (21) is transmitted to the hydraulic oil tank.
2. Compensating piston (20) is returned together with compensating rod (19) to the left, to the posi-tion that outer spring (15) and inner spring (16) are balanced.
3. Compensating rod (19) moves lever 1 (13) through pin (18). Lever 1 (13) turns clockwise about pin (12) fixed to the casing.
4. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 1(13). Therefore, feedback lever (7) rotates counterclockwise about pin (8) by the turning of lever 1 (13) and move the spool (11) to the left.
5. When spool (11) moves, the large diameter chamber side of servo piston (17) is connected to the hydraulic oil tank through spool (11). As self pump delivery pressure P acts to the small di-ameter chamber side, servo piston (17) moves to the left.
6. The pump displacement angle increases accord-ing to the movement of servo piston (17) and the pump delivery flow rate increases.
7. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensat-ing rod (19) nor lever 1 (13) moves, feedback lever (7) turns clockwise about pin (4) and moves spool (11) to the right. The notches of spool (11) and sleeve (10) are closed completely, so the large diameter chamber side of servo piston (17) is not connected to the hydraulic oil tank and the movement of servo piston (17) stops.
8. By these movements, the pump delivery flow rate increases.
T25N-03-01-027
Flow Rate(Q)
Pump Control Pressure (Pi)0
Pz
P120
1311 717
Increase Decrease Displacement Angle
15, 16 10
COMPONENT OPERATION / Pump Mechanism
T3-1-18
T25N-03-01-016
T25N-03-01-016
4 - Pin 11 - Spool 16 - Inner Spring 19 - Compensating Rod 7 - Feedback Lever 12 - Pin 17 - Servo Piston 20 - Compensating Piston 8 - Pin 13 - Lever 1 18 - Pin 21 - Pin 10 - Sleeve 15 - Outer Spring
10 11 12 13 4 15 16
78181920
10 11 12 13 4 15 16
78181920
P
Pz
To Hydraulic Oil Tank
17
17
21
21
To Hydraulic Oil Tank
COMPONENT OPERATION / Pump Mechanism
T3-1-19
Control by Pilot Pressure from Displacement An-gle Proportional Solenoid Valve
1. When the displacement angle proportional sole-noid valve is excited by a signal from MC2/A, pilot pressure acts to pilot piston (1).
2. When pilot pressure increases, pilot piston (1) moves to the right, to the position where pilot pressure is balanced with the pilot spring (6) force.
3. Pilot piston (1) moves lever 2 (3) through pin (2). Lever 2 (3) turns counterclockwise about pin (5) fixed to the axial plug.
4. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 2 (3). Therefore, feedback lever (7) rotates clockwise about pin (8) by the turning of lever 2 (3) and moves spool (11) to the right.
5. When spool (11) moves, self pump delivery pressure P acts through spool (11) to the large diameter chamber side of servo piston (17). Though self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the right due to the difference in area.
6. The pump displacement angle reduces according to the movement of servo piston (17) and the pump delivery flow rate decreases.
7. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensa-tion rod (19) nor lever 1 (13) moves, feedback lever (7) turns counterclockwise about the pin (4) and moves spool (11) to the left. The notches of spool (11) and sleeve (10) are closed completely, so self pump delivery pressure does not act to the large diameter chamber side of servo piston (17) and the movement of servo piston (17) stops.
8. The pump delivery flow rate is decreased by these movements and the load to the pump is reduced.
T25N-03-01-028
Flow Rate(Q)
Pump Control Pressure (Pi)0
Pilot Pressure
P1
11 717
1 3Increase Decrease
Displacement Angle 6
13 10
COMPONENT OPERATION / Pump Mechanism
T3-1-20
T25N-03-01-015
T25N-03-01-016
1 - Pilot Piston 5 - Pin 8 - Pin 13- Lever 1 2 - Pin 6 - Pilot Spring 10 - Sleeve 17- Servo Piston 3 - Lever 2 7 - Feedback Lever 11 - Spool 19- Compensating Rod 4 - Pin
1 2 3 4 5 6
7
8
Pilot Pressure
10 11 13 4
7819
P
17
COMPONENT OPERATION / Pump Mechanism
T3-1-21
SOLENOID VALVE
The displacement angle proportional solenoid valve is attached to the pump 2 regulator. The power increase solenoid valve is provided to the PTO gearbox between pump 1 and pump 2. (Refer to Section "Control Functions of Regulator".)
Operation of Displacement Angle Proportional Solenoid Valve
1. In neutral state, port T and the output port are connected through the notch of spool (4) and pressure oil from port P is blocked completely by spool (4).
2. When electric current from MC2/A goes to sole-noid (1), solenoid (1) is excited and pushes spool (4) to the right.
3. The output port is connected to port P through the notch of spool (4) and pressure oil from port P flows to the output port.
4. Spring chamber (5) is connected to port T through hole (3) of spool (4). As the left side (A) diameter of the notch of spool (4) is larger than the right side (B) diameter, spool (4) returns to the left.
In Neutral State
T25N-03-01-019
In Operation
T25N-03-01-020
3 421
5T Output
PortP
3 B21
5T Output
PortP
A 4
COMPONENT OPERATION / Pump Mechanism
T3-1-22
Operation of Power Increase Solenoid Valve
1. In neutral state, port P and the output port are connected through the notch of spool (4).
2. When electric current from MC2/A goes to sole-noid (1), solenoid (1) is excited and pushes spool (4) to the right.
3. The output port is connected to port T through the notch of spool (4) and the pressure in the output port decreases.
4. Spring chamber (5) is connected to port T through hole (3) of spool (4). As the left side (A) diameter of the notch of spool (4) is larger than the right side (B) diameter, spool (4) returns to the left.
T25N-03-01-021
T25N-03-01-022
3 421
5T Output
PortP
3 B21
5T Output
PortP
A4
COMPONENT OPERATION / Pump Mechanism
T3-1-23
PILOT PUMP, PUMP FOR COUNTER-WEIGHT / QUICK DRAW / RETRACT AND PUMP FOR HYDRAULIC TAGLINE AND REEVING WINCH
Drive gear (1) is driven through the transmission and driven gear (2) engaged therewith is also rotated.
T137-02-03-005
1 - Drive Gear 2 - Driven Gear
2
1Suction Port
Delivery Port
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COMPONENT OPERATION / Front / Rear Control Valve
T3-2-1
OUTLINE
The control valve controls the pressure, flow rate and flow direction in the hydraulic circuit.
The front/rear control valve is a 4-spool type and consists of main relief valve, port relief valve, make-up valve, holding valve, pressure compensation valve, proportional solenoid valve, remote control pressure sensor and spool.The spool in front control valve is provided for travel (right), boom derricking, rear drum (low speed) and front drum (high speed).The spool in rear control valve is provided for travel (left), rear drum (high speed) and front drum (low speed).The spool is selected by pressure oil from the remote control valve and proportional solenoid valve in order to deliver pressure oil from the main pump (pumps 1, 2) to the travel mechanism, boom derricking mechanism and front/rear drums.
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-2
COMPOSITIONFront Control Valve
T2BC-03-02-002
T25N-03-05-030 T2BC-03-02-001
1 - Main Relief Valve 7 - Port Relief Valve (with Make-Up Function)
NOTE: The rear drum spool in the front control valve (low speed) is exemplified.
1. When spool (2) moves to the right by compressing spring (1), pressure oil from port P flows to the actuator through passage (3) and port B.
2. The return oil from actuator flows to port T through port A and passage (5).
NOTE: As two upstream spools constitute a series circuit, when moving spools (2) and (4) simultaneously, for instance, and if the actuator for upstream spool (4) stops due to overloading, the actuator for downstream spool (2) also stops simultaneously.
The main relief valve serves so that the pressure in the main circuit does not exceed the set pressure when the actuator such as motor or cylinder is in operation. Thus, oil leak from hose and pipe joints as well as breakage of the actuator are prevented.
Relief operation
1. Pressure in port HP (main circuit) acts to pilot poppet (4) through orifice (6) in the main poppet (1).
2. When pressure in port HP reaches pressure set by spring B (5), pilot poppet (4) moves to open a passage, so pressure oil flows into port LP (hydraulic oil tank).
3. At this time, pressure is generated between port HP and spring chamber (2) through orifice (6).
4. When this pressure difference reaches pressure set by spring A (3), main poppet (1) moves to open a passage, so pressure oil from port HP flows to port LP.
5. As a result, pressure in the main circuit decreases.
6. When pressure in the main circuit decreases to the fixed level, main poppet (1) moves to close a passage by the force of spring A (3).
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-12
Normal state
T2BC-03-02-008
Relief State
T2BC-03-02-009
T2BC-03-02-010
1 - Main Poppet 3 - Spring A 5 - Spring B 6 - Orifice2 - Spring Chamber 4 - Pilot Poppet
HP
LP
HP
1 2 3 4 5
6
1 2 3 4 5
6
LP
HP
LP
1 2 3 4 5
6
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-13
PORT RELIEF VALVE (With Make-Up Function)
The port relief valve with make-up relief function is provided in the lowering circuit for front drum (low speed) and rear drum (low speed). When each actuator is actuated by external force, the port relief functions so that pressure in each actuator circuit is not increased abnormally. In addition, make-up function is provided to supplement oil from the hydraulic oil tank in order, thus preventing cavitation when pressure in the actuator circuit decreases.
Relief Operation
1. Pressure in port HP (actuator circuit) acts to pilot poppet (6) through orifice (10) in piston (1).
2. When pressure in port HP reaches pressure set by spring B (7), pilot poppet (6) opens pressure oil from passage (8) in spring chamber (5) flows along the external circumference of sleeve (3) and goes to port LP (hydraulic oil tank).
3. At this time, a pressure difference is caused between port HP and spring chamber (5) due to orifice (10).
4. When this pressure difference reaches pressure set by spring A (4), main poppet (2) opens and pressure oil from port HP flows to port LP.
5. As a result, pressure in the actuator circuit decreases.
6. When pressure in the actuator circuit decreases to the fixed level, pilot poppet (6) is closed by the force of spring B (7) and pressure in spring chamber (5) increases. Main poppet (2) is closed by the force of spring A (4).
Make-Up Operation
1. When pressure in port HP (actuator circuit) decreases lower than pressure in port LP (hydraulic oil tank), sleeve (3) moves to the right due to pressure at port LP and the seat surface on sleeve (3) is opened.
2. Hydraulic oil in port LP flows into port HP in order to prevent cavitation.
3. When pressure in port HP rises to the fixed level, the seat surface on sleeve (3) is closed by the force of spring A (4).
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-14
Normal state
T2BC-03-02-011
Relief State
T2BC-03-02-012
T2BC-03-02-013
1 - Piston 4 - Spring A 7 - Spring B 9 - Spring C2 - Main Poppet 5 - Spring Chamber 8 - Passage 10 - Orifice3 - Sleeve 6 - Pilot Poppet
3 4
1 2 3 4 6
10
5 7
9 8
LP
1 2 3 4 6
10
5 7
9 8
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-15
MAKE-UP VALVE
The make-up valve is provided in the lowering circuit for boom derricking and third/fourth drum (optional).The make-up valve, when pressure in port B becomes minus, feeds the oil from port T in order to prevent cavitation.
Operation1. When pressure in port B becomes minus, the
poppet, which is pressed rightward, moves leftward by pressure in port T due to a difference in pressure-receiving areas (X>Y).
2. As a result, oil is fed from port T to port B in order to prevent cavitation.
T2BC-03-02-014
T331-03-05-012
Area X
Area Y
Poppet
Port B Port T
Port T
Port B
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-16
HOLDING VALVE
Holding valve (3) allows the oil flow in the only one direction. Holding valve (3) is provided in the front and rear high speed circuits.
Low Speed Hoisting
In low speed hoisting, only lower speed spool (1) works. High speed pool (2) is kept closed.
High Speed Hoisting
When shifting the hoisting lever from low speed to high speed position, pressure oil tends to flow backward from the motor side to the pump side, as pump side pressure is lower than motor side pressure at the start of opening of higher speed spool (2). In order to avoid this, holding valve (3) is utilized.
T2BC-03-02-022
T2BC-03-02-023
1 - Spool (Low Speed Side)
3 - Holding Valve
2 - Spool (High Speed Side)
1
2
3
2
3
1
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-17
PRESSURE COMPENSATION VALVE
The pressure compensation valve is a pressure compensation type flow rate adjusting valve and provided in the boom derricking, rear drum (low speed) and front drum (low speed) circuits. The pressure compensation valve compensates the required flow rate to the actuator regardless of the load.
NOTE: Boom derricking operation is exemplified.
Operation (with small lever stroke) 1. Pressure oil from port P flows to chamber C
through the internal passage in control valve. Pressure oil flows into chamber E through the internal passage in compensating spool and acts to the end of compensating spool.
2. When moving the boom derricking lever, pressure oil through the spool flows to passage A and acts to spring chamber B.
3. With the lever operation small, pressure acting to spring chamber B is greatly reduced by the spool and a pressure difference between chambers C (E) and B is kept large.
4. When a pressure difference between chambers A (E) and B becomes large, the compensating spool compresses the spring in the spring chamber and moves up.
5. As a result, pressure oil from port P flows to Chamber D through chamber C and goes to the downstream section.
6. Thus, by releasing excess pressure, an optimum flow rate to the actuator is obtained.
T25N-03-05-041
T2BC-03-02-024
Spring To Actuator
To Downstream Section
Spool (Boom Derricking)
From Port P
PressureCompensation
Valve
Spring Chamber Spring
Compensating Spool
COMPONENT OPERATION / Front / Rear Control Valve
T3-2-18
Operation (with large lever stroke) 1. Pressure oil from port P flows to chamber A
through the internal passage. Pressure oil flows into chamber B through the internal passage in compensating spool and acts to the end of compensating spool.
2. When moving the boom derricking lever, pressure oil through the spool flows to passage A and acts to spring chamber B.
3. With the lever operation large, the reduced pressure is smaller by the spool, a pressure difference between chamber C (E) and B becomes small.
4. When a pressure difference between chambers C (E) and B becomes small, the compensating spool is compressed by the spring force in spring chamber B downward.
5. Consequently, as the passage between chambers C and D is blocked, a large quantity of oil flows to the actuator.
6. Thus, the oil flow rate is delivered to the actuator according to lever stroke.
T25N-03-05-040
T2BC-03-02-025
Spring To Actuator
Spool (Boom Derricking)
From Port P
PressureCompensation
Valve
Spring Chamber Spring
Compensating Spool
COMPONENT OPERATION / Slewing Control Valve
T3-3-1
SLEWING CONTROL VALVE
Composition The slewing control valve is a hydraulic pilot spool type, and consists of the main relief valve and spool. The spool in the slewing control valve is an open cen-ter type using tandem circuits. The spool is selected by pressure oil from the slewing remote control valve in order to deliver pressure oil from the slewing pump to the slewing motor.
T2BC-03-03-002
NOTE: As for operation of the main relief valve and the spool, refer to "Front / Rear Control Valves".
T2BC-03-03-003
T2BC-03-03-001
Main Relief Valve
Spool
Main Relief Valve
Main Relief Valve
Spool
This Page Left Blank Intentionally
COMPONENT OPERATION / Lower Control Valve
T3-4-1
OUTLINE
The lower control valve is the direct-acting type control valve and the spools (6 used) and the relief valve are built in. The spool is selected by the lever operation and delivers pressure oil from port P to the jack-up cylinder and retract cylinder.
NOTE: The lower control valve is optional.
T2BC-03-04-001
Port P
Retract(Right)
Jack-Up (Right Front)
Jack-Up (Right Rear)
Jack-Up (Left Rear)
Jack-Up (Left Front)
Retract(Left)
Port T
ReliefValve
COMPONENT OPERATION / Lower Control Valve
T3-4-2
INTERNAL COMPOSITION
The inside of lower control valve is a parallel circuit.Pressure oil from port P can be supplied to all the spools at the same time. The direct-acting type relief valve is installed behind port P. The relief valve regulates the maximum pressure in the lower control circuit.
The relief valve is a direct-acting type and prevents the pressure in circuit from increasing beyond the setting during operation of the lower control valve. Thus, oil leak from hose and pipe joints and breakage of the actuator are prevented.
Relief Operation1. Pressure in port P (main circuit) acts to the end of
poppet (3) through the orifice in plug (5).2. When pressure at port P reaches the setting
pressure for spring (2), poppet (3) moves to the left and the passage between poppet (3) and seat (4) is connected.
3. Pressure oil from port P flows to port T through this passage.
4. As a result, pressure at port P decreases.5. When pressure at port P decreases to the fixed
level, poppet (3) is closed by the force of spring (2).
6. The relief setting pressure is adjusted by adjusting screw (1).
The 4-unit control valve is an electromagnetic-hydraulic pilot spool type and consists of main relief valve, sequence valve, pressure-reducing valve, holding valve, port relief valve, solenoid valve and spool. The spool in 4-unit control valve is a semi-open center type using parallel circuits. When the spool is in neutral, pressure oil from the pump for counterweight/jack-up/retract flows to the front and rear drums in order to cool the brake unit in front and rear drums.
When operating the counterweight switch, the spool in counterweight is switched and pressure oil from the pump for counterweight/quick draw/retract flows to the counterweight cylinder in order to extend/retract the cylinder. When operating the quick draw switch and retract switch, pressure oil flows to the cylinder in order to operate the cylinder in the same procedures. When turning the lower power switch ON with the lower jack mechanism (optional) attached, the spool in lower power selection is switched and pressure oil from the pump for counterweight/quick draw/retract flows to the lower control valve (optional).
NOTE: As for operation of main relief valve, port relief valve, holding valve and spool, refer to Section "Front / Rear Control Valves".
NOTE: *: If the jack-up (optional) is installed, the lower power solenoid valve is installed here.
4 5 6 7
2
1
13
12 11 9 8
COMPONENT OPERATION / 4-Unit Control Valve
T3-5-3
T2BC-03-05-008
1
2
13
3
2 3
3
10
COMPONENT OPERATION / 4-Unit Control Valve
T3-5-4
PRESSURE-REDUCING VALVE
The pressure-reducing valve reduces pressure oil from port P (pressure oil from the pump for counterweight/quick draw/ retract) to the fixed pressure and supplies to the solenoid valve.
Operation1. Pressure oil from port P flows to chamber E
through passage (C).2. Pressure oil flows to chamber G through notch (E)
of spool (1) and acts to the solenoid valve.3. Pressure oil in chamber G passes through spool
(1) and acts to chamber D at the end of spool (1).Pressure oil flows to spring chamber (A) in the sequence valve through passage (B) and pushes spool (2) downward with the spring (2) force together.
4. When pressure acting to the lower surface of spool (1) exceeds the force of spring (1), spool (1) moves up to the position where pressure is balanced with the force of spring (1).
5. Spring chamber (J) is connected to the hydraulic oil tank. Pressure oil from chamber G flows to the hydraulic oil tank through notch (H) of spool (1) and pressure in chamber G decreases.
6. When pressure in chamber G decreases, the chamber D pressure acting to the surface of spool (1) decreases, too.
7. Spool (1) moves down by the force of spring (1) to the position where the force of spring (1) is balanced with pressure acting to the surface of spool (1) and pressure in chamber G increases again.
8. Therefore, pressure from port P becomes lower than pressure set by spring (1) and pressure through the solenoid valve keeps constant.
T2BC-03-05-004
T2BC-03-05-005
To Solenoid Valve
To Control Valve Spool
Pressure-Reducing Valve
Sequence Valve
Pressur SEQUENCE
To SolenoidValve
Spool 2
Spring 2
Spool 1
Spring 1
Spool 1
Spring 1
To SolenoidValve
Spool 2
Spring 2
Sequence Valve
Pressure-Reducing Valve
To Solenoid Valve
COMPONENT OPERATION / 4-Unit Control Valve
T3-5-5
SEQUENCE VALVE
The sequence valve blocks pressure oil from port P and the pressure-reducing valve is operated prior to the sequence valve. When pressure in the main circuit decreases rapidly, the sequence valve keeps the primary pressure in sequence valve (the primary pressure in pressure-reducing valve) and compensates operation of the solenoid valve.
Operation1. Pressure in the pressure-reducing valve circuit
always flows spring chamber (A) in the sequence valve through passage (B).
2. Spool (2) in the sequence valve is pushed down by the pressure-reduced oil and the force of spring (2). Therefore, pressure at port P (the primary pressure in sequence valve and pressure-reducing valve) keeps pressure which the secondary pressure in pressure-reducing valve acts to spring (2). Consequently the operating pressure of solenoid valve is always obtained.
3. Pressure oil from port P flows to chamber D in the sequence valve.
4. Pressure oil in chamber D passes through spool (2) and acts to chamber E at the end of spool (2).
5. When pressure in chamber D exceeds pressure in spring chamber (A) and the force of spring (2), spool (2) compresses spring (2) and moves up.
6. Pressure oil flows from chamber D to chamber K and goes to the spool in control valve.
7. Thus, by setting a time lag in operation between pressure-reducing valve and sequence valve, the primary pressure (output pressure) of pressure reducing valve is obtained.
T2BC-03-05-004 T2BC-03-05-006
To Solenoid Valve
To Control Valve Spool
To Solenoid Valve
Pressure-Reducing Valve
Sequence Valve
Pressure-Reducing Valve
Sequence Valve
To SolenoidValve
Spring 2
Spool 2
To SolenoidValve
Spring 2
Spool 2
To Control Valve Spool
To Control Valve Spool
COMPONENT OPERATION / 4-Unit Control Valve
T3-5-6
SOLENOID VALVE
Each solenoid valve in 4-unit control valve is an ON/OFF solenoid valve. When each selection switch is set to ON position, the solenoid valve is excited and switches the spool in solenoid valve. As a result, pressure oil from the pressure-reducing valve acts to the spool in control valve and switches the spool.
Operation1. When the operating switch is set to OFF position,
pressure oil from port P (pressure- reducing valve) is blocked by the spool in solenoid valve.Chamber A or C is connected to the hydraulic oil tank.
2. When the operating switch is set to ON position, the solenoid is excited.
3. The spool in solenoid valve moves downward by compressing the spring.
4. As chamber B is connected to chamber C, pressure oil from port P flows to spring chamber (D) in the control valve.
5. As a result, the spool in control valve is switched.
T2BC-03-05-007
In Neutral State
Exciting state
Spring
SolenoidValve Spool
SolenoidControl ValveSpool
Spring
SolenoidValve Spool
SolenoidControl ValveSpool
COMPONENT OPERATION / Remote Control Valve
T3-6-1
OUTLINE
The remote control valve controls the pilot pressure oil in order to move the spool in the control valve. There are three remote control valves: 3-section derricking valve, 3-section travel valve and 1-section slewing valve (7). The hoisting remote control valve consists of boom derricking (1), rear drum (2) and front drum (3). The travel remote control valve consists of third / fourth drum (4) (optional), left travel (5) and right travel (6). The hoisting and travel remote control valves are each made of three sections combined through spring pins. The hoisting and travel remote control valves are each provided with detent plugs (10). The travel remote control valve is provided with remote control pressure sensors (8) and (9).
NOTE: These remote control valves have the same structure except for detent plug (10) and the shuttle valve block.
T2BC-03-06-001
1 - Boom Derricking Remote Control Valve
4 - Third Drum Remote Control Valve (Optional)
7 - Slewing Remote Control Valve
9 - Travel Remote Control Pressure Sensor (L)
2 - Rear Drum Remote Control Valve
5 - Left Travel Remote Control Valve
8 - Travel Remote Control Pressure Sensor (R)
10 - Detent Plug
3 - Front Drum Remote Control Valve
6 - Right Travel Remote Control Valve
7654321
10
Shuttle Valve Block
79
Hoisting Remote Control Valve
Travel Remote Control Valve
Slewing Remote Control Valve
COMPONENT OPERATION / Remote Control Valve
T3-6-2
• Hoisting Remote Control Valve
Parts Name Port No. Connected to1 HoistingBoom
derricking 2 Lowering
3 Hoisting4 LoweringRear8 Motor5 Hoisting6 LoweringFront9 Motor
T2BC-03-06-004
• Travel Remote Control Valve
Parts NamePortNo.
Connected to
1 Hoisting2 Lowering
Third / fourth(optional)
7 Fourth drum displacement angle control signal pressure
3 Forward4 ReverseTravel (left)8 Remote control pressure 5 Forward6 ReverseTravel (right)9 Remote control pressure
T25N-03-06-003
T2BC-03-06-002
T25N-03-06-006
Travel (right)Third/Fourth
(Optional)
P
2 7 1 4 8 3 6 9 5
P T
Travel (left)
FrontBoom
Derricking2 1 4 8 3 6 9 5
P T
Rear
Third/Fourth (Optional)
Travel (left)
Travel (right)
TP
P
6
9
5
8 4
2
7
1
3
Boom Derricking Rear Front
4
PT
2958
1
6
3
COMPONENT OPERATION / Remote Control Valve
T3-6-3
• Slewing Remote Control Valve
Parts Name Port No. Connected to1 Right Slewing
Slewing2 Left Slewing
T25N-03-06-004
T2BC-03-06-003
P
T
2
1
1
P T
2
COMPONENT OPERATION / Remote Control Valve
T3-6-4
CONSTRUCTION
The remote control valve consists of screw joint (1), cam (2), detent plug (3), pusher (4), balance spring (6), return spring (7) and spool (8). Remote control valves for hoisting and travel are each made of three sections combined though spring pins (10). The control lever is attached to screw joint (1) that is bolted to cam (2) so that they move together.
The bottom surface of head of spool (8) is supported by the top surface of spring guide (5). The two surfaces are mated through balance spring (6). Pusher (4) is lifted by return spring (7) through spring guide (5). Detent plug (3) maintains the control lever in the fixed position even when releasing the control lever and lets the actuator operate at a constant speed. Shuttle block (9) selects the secondary pilot pressure on control side and lets guide pressure oil flow to another output port.
COMPONENT OPERATION / Remote Control Valve
T3-6-5
Hoisting Remote Control Valve
T2BC-03-06-005
1 - Screw Joint 4 - Pusher 7 - Return Spring 9 - Shuttle Valve Block2 - Cam 5 - Spring Guide 8 - Spool 10 - Spring Pin3 - Detent Plug 6 - Balance Spring
123
4
5
67
8
9
1
2
3
4
6
7
8
5
9
COMPONENT OPERATION / Remote Control Valve
T3-6-6
Travel Remote Control Valve
T2BC-03-06-006
1 - Screw Joint 4 - Pusher 7 - Return Spring 9 - Shuttle Valve Block2 - Cam 5 - Spring Guide 8 - Spool 10 - Spring Pin3 - Detent Plug 6 - Balance Spring
4
1
2
3
5
6
8
9
7
1
2
3
4
5
COMPONENT OPERATION / Remote Control Valve
T3-6-7
Slewing Remote Control Valve
T25N-03-06-011 T25N-03-06-012
1 - Screw Joint 4 - Pusher 6 - Balance Spring 8 - Spool2 - Cam 5 - Spring Guide 7 - Return Spring 9 - Shuttle Valve Block
D Section D
1
2
4
5
6
7
8
9
COMPONENT OPERATION / Remote Control Valve
T3-6-8
DETENT FUNCTION
The front, rear and third / forth remote control valves for hoisting are each provided with two detent plugs. The boom derricking and travel remote control valves for hoisting are each provided with one detent plug. The detent plug maintains the control lever in the fixed position even when releasing the control lever and lets the actuator operate at a constant speed.
Operation
1. With control lever (1) in neutral, ball (3) and holder (4) are pressed to cam (2) through spring (5).
2. When tilting control lever (1), notch A of cam (2) reaches ball (3) and ball (3) and holder (4) are shifted at a distance of notch A by the force of spring (5).
3. With control lever (1) tilted, pusher (6) always acts to push cam (2) upward through return spring (7).
4. However, notch A of cam (2) is engaged with ball (3) so that cam (2) does not move.
5. As a result, control lever is held in the first detent position even when releasing control lever (1).
6. When tilting control lever (1) further from the first detent position, notch B of cam (2) reaches ball (3) and ball (3) and holder (4) are shifted at a distance of notch B by the force of spring (5).
7. As a result, cam (2) is engaged with ball (3) again control lever (1) is held in the second detent position even when releasing control lever (1) in a manner similar to the first detent position.
8. Thus, control lever (1) is held in the fixed position so that the actuator operates at a constant speed, and facilitates combined operations.
NOTE: The first detent of front and rear remote control valves is used for low-speed operation and its second detent is for high-speed operation. (Refer to Derricking Circuit, HYDRAULIC SYSTEM). The detent plugs provided at boom derricking, left travel and right travel can be made the combined operations.
COMPONENT OPERATION / Remote Control Valve
T3-6-9
Control Lever Operating Control Force
T25N-03-06-015
1 - Control Lever 3 - Ball 5 - Spring 7 - Return Spring2 - Cam 4 - Holder 6 - Pusher
A (First Detent Position)
3
4
5 4
3
1
B (Second Detent Position)
5
6
7
2
COMPONENT OPERATION / Remote Control Valve
T3-6-10
OPERATION
When control lever (1) in the operator’s cab is operated, the secondary pilot oil pressure is delivered in response to the control lever operation stroke. This delivered secondary pilot pressure is routed to spool (4) end of control valve (3) so that spool (4) is moved until the pilot pressure force balances with spring (5) force.
T324-02-07-010
1 - Control Lever 3 - Control Valve 4 - Spool 5 - Spring 2 - Remote Control Valve
1
2
3 4 5
Port P (From pilot pump)
To hydraulic oil tank
From main pump
Port T (To hydraulic oil tank)
Output Port
COMPONENT OPERATION / Remote Control Valve
T3-6-11
Neutral Position
1. When in neutral, spool (2) is raised upward by return spring (1) force, the primary pilot pressure from port P is blocked.
2. The output port (secondary pilot pressure) is connected to port T (hydraulic oil tank).
Return Spring 2 - Spool
1
Output Port (Secondary Pilot Pressure)
Port P (Primary Pilot Pressure)
Port T (Hydraulic Oil Tank)
2
COMPONENT OPERATION / Remote Control Valve
T3-6-12
Beginning to Deliver Output (Increasing Secondary Pressure)
3. When control lever (3) is operated, cam (4) is slanted so that pusher (5) is pushed downward in proportion to cam (4) slant amount, closing the oil passage to port T by spool (2).
4. The pressure oil from port P (primary pilot pressure side) is routed to the output port (secondary pilot pressure side) through the clearance around spool (2).
2 - Spool 3 - Control Lever 4 - Cam 5 - Pusher
3
4
5
2
ClearanceOutput Port
Primary Pilot Pressure
Secondary Pilot Pressure
Port P
Port T
COMPONENT OPERATION / Remote Control Valve
T3-6-13
Maintaining Secondary Pressure
5. Pressure oil from port P (primary pilot pressure) acts on diameters d1 and d2 in spool (2).
6. This pressure pushes spool (2) upward due to the difference of area (d1>d2).
7. Spool (2) is pushed upward and the output port is connected to port T.
8. The pressure in output port decreases and spool (2) is pushed downward again by the reaction force of balance spring (6).
9. After repeating these procedures, the pressure according to the stroke of control lever (3) is routed to the output port.
10. Balance spring (6) is compressed to the same amount as spool (2) was pushed downward. The pressure which the spring force and the force acting to spool (2) are balanced with is the output port pressure.
Spool 3 - Control Lever 6 - Balance Spring
3
6
2
Secondary Pilot Pressure
Primary Pilot Pressure
Clearance
Output Port
Port P
Port T
This Page Left Blank Intentionally
COMPONENT OPERATION / Slewing Mechanism
T3-7-1
OUTLINE
The slewing mechanism consists of the valve unit, the slewing motors and the slewing reduction gear. The valve unit prevents the cavitation in the slewing circuit. The slewing motor is a swash plate type axial plunger motor (with built-in slewing parking brake), which is driven by pressure oil from the pump, and is provided with the slewing reduction gear.
The slewing reduction gear turns the slewing motors with large torque at a low speed and slews the super-structure.
T25N-03-02-008
Valve Unit
Slewing Motor
Slewing Reduction Gear
COMPONENT OPERATION / Slewing Mechanism
T3-7-2
SLEWING REDUCTION GEAR
The slewing reduction gear is a two-stage planetary reduction gear. Ring gear (3) is monolithically built with housing (5) bolted to the superstructure, not allowing rotation. Shaft (1) of the slewing motor turns first stage sun gear (10) whose turning torque is transmitted to second stage sun gear (8) through first stage planetary gear (2) and first stage carrier (9). Second stage sun gear (8) turns shaft (6) through second stage planetary gear (4) and second stage carrier (7).
Shaft (6) is engaged with the internal gear of slew bearing fixed to the undercarriage in order to slew the superstructure.
T25N-03-02-001
1 - Shaft (Slewing Motor) 4 - Second Stage Planetary Gear 7 - Second Stage Carrier 9 - First Stage Carrier 2 - First Stage Planetary Gear 5 - Housing 8 - Second Stage Sun Gear 10 - First Stage Sun Gear 3 - Ring Gear 6 - Shaft
1
2
3
4
5
10
9
8
7
6
COMPONENT OPERATION / Slewing Mechanism
T3-7-3
SLEWING MOTOR
The slewing motor consists of the swash plate (6), rotor (11), plungers (10), valve plates (12), housing (8) and slewing parking brake (springs (1), brake piston (2), plate (3) and friction plate (4)). Shaft (7) is splined to rotor (11) into which plungers (10) are inserted.
When pressure oil is supplied from the pump, plunger (10) is pushed. Shoe (9) at the top of plunger (10) slides over the swash plate (6), so that rotor (11) ro-tates. The top of shaft (7) is splined to the first stage sun gear of slewing reduction gear. Therefore, the rotation of shaft (7) is transmitted to the slewing reduction gear.
The slewing parking brake is a wet type multiplate disc brake and a negative mechanism that releases the brake when brake release pressure acts in the brake piston chamber. The brake release pressure is supplied from the pilot pump only when the slewing brake switch is operated. In other cases (including engine stopping), the brake release pressure returns to the hydraulic oil tank, so that the brake is applied automatically by spring (1).
When Brake Is Applied
1. When the brake switch is set to OFF position, the slewing brake solenoid valve returns to neutral position, so that the pilot pressure, which is ap-plied to port Pb, is returned to the hydraulic oil tank.
2. As a result, the force of spring (1) acts on friction plate (4), which is engaged with the external cir-cumference of rotor (11), and on plate (3), which is engaged with the inside of housing (8), through brake piston (2). Thus, the external circumference of rotor (11) is secured with friction force.
3. When the engine stops, the brake is applied automatically as pressure is not applied to port Pb.
When Brake Is Released
1. When setting the slewing brake switch to ON po-sition, the slewing brake solenoid valve is se-lected. Then, pilot pressure from the pilot pump is applied to port Pb.
2. Pilot pressure applied to port Pb acts to the brake piston chamber.
3. Brake piston (2) moves by compressing spring (1).
4. As a result, plate (3) and friction plate (4) are freed and the brake is released.
The valve unit is provided with a make-up valve. The make-up valve prevents the cavitation in the cir-cuit.
Make-up valve
In slewing stopping operation, the slewing motor is driven by the inertial force of slewing frame. The slewing motor is turned forcibly in excess of oil pressure from the pump, so that the cavitation may be generated in the motor. In order to avoid this cavitation, the poppet opens when pressure in the slewing circuit becomes lower than that in the return circuit (port M), and sucks the hydraulic oil in order to compensate the lack of oil feed.
T25N-03-02-007
T25N-03-02-003
Make-UpValve
Port M
Control Valve
Port M
Make-Up Valve
Make-Up Valve
Poppet
Control Valve
COMPONENT OPERATION / Hoisting Mechanism
T3-8-1
OUTLINE
The front drum and rear drum are driven separately. In crane operation, hosting and lowering (power lowering and free fall) of, and stopping (holding) of the load is done with the front drum using boom hook and with the rear drum using the jib hook. The front drum and rear drum consist of the same parts respectively. The fol-lowing explanation is made in terms of the front drum.
The front drum consists of the hoisting motor (2) and hoisting drum (1).
Hoisting motor (2) consists of the motor, counterbal-ance valve (3), regulator (4), shuttle valve block, drum brake release solenoid valve and wet type multiplate brake. Regulator (4) is provided with the motor displacement angle proportional solenoid valve and motor cutoff high pressure solenoid valve. Hoisting drum (1) consists of two-stage planetary re-duction gear (5), which is built in the drum, and brake unit (6).
The motor is a swash plate type variable displacement axial piston motor capable of selecting high/low speeds. The high/low speed selection of motor is controlled by the regulator. The wet type multiplate brake is built into the rear case (9) side of motor. The motor has plungers (1) (9 used). In each plunger (1), shoe (3) is crimped into rotor (2).
Plunger (1) slides over the slope of the shoe plate (4) in order to rotate rotor (2). Rotor (2) is splined to output shaft (7) in order to turn output shaft (7). Swash plate (5) is located between tilt pistons (8) (2 used). The displacement angle is chanced by the op-eration of regulator.
1. Rotational speeds of the front and rear drums are changed according to the oil flow rate from pump.
2. When pressure oil from port A of valve plate (6) flows into the rotor (2) in order to push plunger (1).
3. Then, shoe (3) slides over shoe plate (4) on swash plate (5) in order to rotate rotor (2).
4. The turning torque of rotor (2) is transmitted to the reduction gear through output shaft (7). The re-turn oil flows through delivery port B and returns to the hydraulic oil tank.
5. When high pressure oil comes in port B, the rota-tion is reversed.
The regulator controls the larger motor displacement angle in proportion to the increasing pressure in hoisting motor circuit (Maximum Displacement Angle Lock Control).
Maximum Displacement Angle Lock ControlWhen delivery pressure from main pump (delivery pressure from pumps 1 and 2) increases, pressure oil to the large diameter chamber in tilt piston (2) is re-duced. When delivery pressure increases further, pressure oil to the large diameter chamber returns to the hydraulic oil tank. As a result, the displacement angle is fixed to the maximum (minimum speed).In addition, the motor cutoff high pressure solenoid valve (3) controls the instructions for the maximum displacement angle in order to select the set pressure to the maximum displacement angles for hoisting and lowering operations.
T2BC-03-08-001
1 - Hoisting Motor 4 - Piston 1 7 - Motor Displacement Angle Proportional Solenoid Valve
10 - Orifice
2 - Tilt Piston 5 - Spool 1 8 - Piston 2 11 - Spring 23 - Motor Cutoff High Pressure
1. In hoisting operation, no signal comes to motor cutoff high pressure solenoid valve (3), so that motor cutoff high pressure solenoid valve (3) is not selected.
2. Pilot pressure is applied through motor cutoff high pressure solenoid valve (3) to piston 1 (4).
3. Pump delivery pressure acts on piston 1 (4).
4. When pump delivery pressure exceeds the pilot pressure acting on piston 1 (4) plus spring 1 (6) force, piston 1 (4) moves to the left, to the position when pump delivery pressure is balanced with those pressures.
5. As spool 1 (5) is pushed by piston 1 (4), the line to the large diameter chamber side of tilt piston (2) is reduced.
6. When pump delivery pressure increases further, spool 1 (5) is pushed by piston 1 (4) and pressure oil on the large diameter chamber side of tilt pis-ton (2) passes through spool 1 (5) to the hydraulic oil tank.
7. As a result, the tilt piston (2) is pushed to the left and motor (1) is set to the maximum displacement angle.
8. Thus, by setting the pressure of spool 1 (5) at higher level than that in lowering operation, an instruction for maximum displacement angle of motor (1) is retarded to retain the horsepower for hoisting operation. In addition, during the pump delivery pressure in-creasing, the maximum displacement angle of motor (1) is retained.
Pump delivery pressure: Low
T25N-03-03-014
Pump delivery pressure: High
T25N-03-03-015
1 - Motor 3 - Motor Cutoff High Pressure Solenoid Valve 5 - Spool 1 6 - Spring 1 2 - Tilt Piston 4 - Piston 1
1
2
34
5
6
1
2
34
5
6
Pump Delivery Pressure
Pump DeliveryPressure
COMPONENT OPERATION / Hoisting Mechanism
T3-8-6
• Lowering Operation
1. For lowering operation, motor cutoff high pressure solenoid valve (3) is selected by a signal from MC2/A.
2. Pressure oil acting on piston 1 (4) passes through motor cutoff high pressure solenoid valve (3) to the hydraulic oil tank.
3. Therefore, the force against pump delivery pres-sure acting on piston 1 (4) is only the force of spring 1 (6).
4. When the pump delivery pressure becomes higher than the force of spring 1 (6), piston 1 (4) moves to the left to the position where pump de-livery pressure is balanced with the force of spring 1 (6).
5. As spool 1 (5) is pushed by piston 1 (4), the line to large diameter chamber side of tilt piston (2) is reduced.
6. When the pump delivery pressure increases fur-ther, spool 1 (5) is pushed by piston 1 (4) and pressure oil in the large diameter chamber of tilt piston (2) flows through spool 1 (5) to the hydrau-lic oil tank.
7. As a result, spool 1 (5) moves by the pump deliv-ery pressure lower than that in hoisting operation, thus setting motor (1) at the maximum displace-ment angle.
8. Thus, by setting the pressure for hoisting or low-ering operation, the horsepower is retained for hoisting operation, or the motor speed is con-trolled for lowering operation.
Pump delivery pressure: Low
T25N-03-03-016
Pump delivery pressure: High
T25N-03-03-017
1 - Motor 3 - Motor Cutoff High Pressure Solenoid Valve 5 - Spool 1 6 - Spring 1 2 - Tilt Piston 4 - Piston 1
1
2
34
5
6
Pump Delivery Pressure
2
34
5
6
1
Pump Delivery Pressure
COMPONENT OPERATION / Hoisting Mechanism
T3-8-7
COUNTERBALANCE VALVE
The counterbalance valve consists of counterbalance spool (4), spring (3), check valve (1) and relief valve (2).
Functions of Counterbalance
1. The counterbalance valve is provided in the low-ering circuit.
2. When lifting the load, its weight always works downward as an external force, so that the motor is subjected to turning torque in the lowering di-rection.
3. At this time, in the hoisting circuit, an internal pressure corresponding to this external force is generated.
4. When switching the control valve for lowering operation, the internal pressure in the hoisting circuit containing the motor is released.
5. The motor is turned by the external force working in lowering direction regardless of the oil flow rate from the pump, thus causing coasting.
6. In order to prevent this coasting, the counterbal-ance valve is used.
1. In hoisting operation, pressure oil from the pump passes through port A, pushes up the poppet of check valve (1), and flows through port D to the motor.
2. The return oil passes through ports C and B and return to the hydraulic oil tank.
3. In hoisting operation, only check valve (1) works.
1. In lowering operation, pressure oil from the pump passes through ports B and C, and flows to the motor.
2. The pressure oil also flows into pilot passage (5) of counterbalance spool (4). The return oil is blocked by check valve (1), so that the motor does not turn, and the oil feed pressure in-creases.
3. This pressure oil passes through pilot passage (5) and moves counterbalance spool (4) leftward (rightward in circuit diagram).
4. The pressure oil opens ports D and A to return the return oil from the motor to the hydraulic oil tank through the control valve.
5. As a result, the motor turns for lowering operation.
6. When increasing the oil feed quantity to the motor, passage resistance in counterbalance spool (4) increases.
7. The feed pressure increases to move counter-balance spool (4) further, widening the passage for higher motor speed.
T2BC-03-08-006
8. On the contrary, when the oil flow rate decreases, passage resistance in counterbalance spool (4) decreases, lowering the feed pressure.
9. Counterbalance spool (4) is returned, the pas-sage is narrowed, lowering the motor speed.
10. When lowering the load, the motor is likely to be turned in excess of the oil feed quantity, so that the feed pressure is lowered.
11. In order to avoid that the motor is turned in excess of the oil feed quantity, counterbalance spool (4) is returned, and the flow passage is narrowed.
12. Thus, the lowering speed changes according to the oil feed quantity.
1. When the spool in control valve is returned to neutral position, the hydraulic oil tank pressure is applied in port B and counterbalance spool (4) is returned to close the flow passage.
2. With check valve (1) closed, the internal pressure is generated corresponding to the lifting load to suspend the load in the air.
T2BC-03-08-007
1 - Check Valve 4 - Counterbalance Spool
4
B
1
A
COMPONENT OPERATION / Hoisting Mechanism
T3-8-11
Relief Valve
Relief valve (2), provided in counterbalance valve (6), absorbs shock pressure caused by the inertial force when the motor stops.
1. Relief valve (2) is built into the lowering circuit. Poppet (3) in relief valve (2) closes flow passage with the force of spring (5).
2. When the control lever is returned to neutral posi-tion, the motor is likely to be turned in lowering direction by the inertial force of load.
3. The pressure in port D increases instantly, and when reaching the set pressure, poppet (3) in re-lief valve (2) moves and the pressure is released.
T2BC-03-08-002
T2BC-03-08-008
T324-02-04-023
2 - Relief Valve 3 - Poppet 5 - Spring 6 - Counterbalance Valve Body
3 5
Port D
6 2
2
5
COMPONENT OPERATION / Hoisting Mechanism
T3-8-12
BRAKE
The brake is a wet type multiplate disk brake, applied and released by the brake release solenoid valve. For releasing the brake, there are two ways: hydraulic and electric. (Winch brake mode control) (Refer to Control System.)
Operation
1. Spline joint (4) is splined to output shaft (5). Spline joint (4) is splined to friction plates (7) (7 used). Disc plates (6) are splined to valve cover (1). Disc plates (6) and friction plates (7) are alternately in-stalled.
2. With the hoisting lever in neutral position, pres-sure oil in port PR can flow to the hydraulic oil tank.
3. When spring (3) pushes brake piston (2), and frictions plate (7) and disc plates (6) closely con-tact to each other under pressure, the brake is applied.
4. When hoisting or lowering with the front (rear) lever, a signal from MC2/A is sent to brake re-lease solenoid valve (8).
5. Then, brake release solenoid valve (8) is selected, so that pressure oil from pilot pump acts on brake piston (2) through port PR.
6. Brake piston (2) presses spring (3), so that disc plates (6) and friction plates (7) are freed.
The hoisting drum consists of reduction gear and brake unit. The reduction gear is a two-stage planetary reduction gear and converts the rotation, transmitted from the motor, to a low-speed large torque to rotate the drum. The brake unit is a wet type multiplate disc brake and applied with the brake pedal.
T25N-03-03-003
Hoisting Drum Motor
Brake Unit Reduction Gear
COMPONENT OPERATION / Hoisting Mechanism
T3-8-14
REDUCTION GEAR
1. The reduction gear is a two-stage planetary re-duction gear. The motor rotates propeller shaft (3).
2. This rotation is transmitted to ring gear (4) through first stage planetary gear (5), first stage carrier (6), sun gear (7), second stage planetary gear (8) and second stage carrier (9).
3. Ring gear (4) is fixed to drum (1) with bolts (2).
4. Therefore, when ring gear (4) turns, drum (1) also turns.
T25N-03-03-003
1 - Drum 4 - Ring Gear 6 - First Stage Carrier 8 - Second Stage Planetary Gear 2 - Bolt 5 - First Stage Planetary Gear 7 - Sun Gear 9 - Second Stage Carrier 3 - Propeller Shaft
1 2
3456789
Motor
COMPONENT OPERATION / Hoisting Mechanism
T3-8-15
BRAKE UNIT
With the brake mode selection key switch in the auto brake position, depress the brake pedal and turn ON the free mode switch for the drum. A signal is input to MC2/A in order to select the drum brake solenoid valve. (Free mode control) (Refer to Control System.)
Brake Releasing
1. The top of shaft (6) is splined to the second stage carrier of reduction gear. Friction plates (5) are splined to shaft (6). Disc plate (4) is splined to casing (1).
2. When the brake pedal is depressed or when the drum brake solenoid valve is not selected, oil from brake chamber (A) passes through passage (2) to the hydraulic oil tank.
3. Brake piston (3) is pressed by the force of spring (8) to the right.
4. When brake piston (3) pushes spacer (7), and disc plate (4) and friction plates (5) contact closely to each other under pressure, the brake is ap-plied.
5. When the drum brake solenoid valve is selected by a signal from MC2/A, pressure oil from the pilot pump passes through the brake pedal and the drum brake solenoid valve and flows to the port of casing (1).
6. Pressure oil flows through passage (2) to brake chamber (A).
7. The brake piston (2) moves to the left by com-pressing spring (8).
8. As a result, disc plate (4) and friction plates (4) are freed and the brake is released.
The boom derricking device consists of the boom der-ricking motor, the reduction gear, the brake valve, the boom derricking drum and the derricking drum lock. The boom derricking motor is an axial plunger motor and the parking brake (wet type spring-set / hydrau-lic-released multiplate brake) is built in. The boom der-ricking motor is driven by pressure oil from the pump and transmits the rotation to the reduction gear.
The reduction gear is a three-stage planetary reduction gear and converts the rotation, transmitted from the boom derricking motor, to a low-speed large torque in order to rotate the boom derricking drum. The brake valve prevents overload to the boom der-ricking circuit and cavitation.
T25N-03-04-003
T25N-03-04-001
Derricking Drum Lock Brake Valve
Reduction Gear
Boom Der-ricking Motor
Boom Derricking
Drum
COMPONENT OPERATION / Boom Derricking Device
T3-9-2
REDUCTION GEAR
The reduction gear is a three-stage planetary reduction gear. The boom derricking motor rotates propeller shaft (7). This rotation is transmitted to ring gear (1) through first stage planetary gear (8), first stage carrier (6), second stage sun gear (5), second stage planetary gear (9), second stage carrier (4), third stage sun gear (3), third stage planetary gear (10) and third stage carrier (2).
Housing (13) for the boom derricking motor is fixed with bolts to the track frame and fixed with bearing nut (11) to third stage carrier (2). Ring gear (1), drum (12) and the boom derricking drum are bolted respectively. Therefore, when ring gear (1) rotates, drum (12) and the boom derricking drum are also turned.
T25N-03-04-002
1 - Ring Gear 5 - Second Stage Sun Gear 8 - First Stage Planetary Gear 11 - Bearing Nut 2 - Third Stage Carrier 6 - First Stage Carrier 9 - Second Stage Planetary Gear 12 - Drum 3 - Third Stage Sun Gear 7 - Propeller Shaft 10 - Third Stage Planetary Gear 13 - Housing 4 - Second Stage Carrier
1 2 3 4 5 6
7
13 12 11 10 9 8
COMPONENT OPERATION / Boom Derricking Device
T3-9-3
BOOM DERRICKING MOTOR
The boom derricking motor is a swash plate type variable displacement axial plunger motor and con-sists of valve plates (1), swash plate (4), rotor (2), plunger (6) and shaft (3). Shaft (3) is splined to rotor (2) into which plungers (6) are inserted.
When pressure oil from the pump is supplied, plunger (6) is pushed. Shoe (5) at the top of plunger (6) slides over swash plate (4), so that rotor (2) rotates.
The boom derricking brake is a wet type multiplate disc brake and a negative mechanism that releases the brake when brake release pressure acts in the brake piston chamber. The wet type multiplate disc brake and the derricking drum lock are provided in the same circuit and work at the same time.
When Brake is Applied
1. When the boom derricking lever is in neutral posi-tion, the derricking drum unlocking solenoid valve is not selected, so that pilot pressure fed to port C and the derricking drum lock return to the hydrau-lic oil tank.
2. As a result, the force of disk spring (1) acts on plates (3) engaged with the inside of housing (6) and on friction plates (4) engaged with the exter-nal circumference of rotor (5) through brake pis-ton (2). Thus, the external circumference of rotor (5) is retained with friction force.
3. In the derricking drum lock, pawl (9) is moved by torsion spring (8) and locks the boom derricking drum.
When Brake is Released
1. When moving the boom derricking lever, the der-ricking drum lock solenoid valve is selected by a signal from MC2/A.
2. As a result, pilot pressure oil from the pilot pump is fed to port C and the derricking drum lock.
3. The pilot pressure fed to port C acts to the brake piston chamber.
4. Brake piston (2) moves by compressing disc spring (1).
5. As a result, plate (3) and friction plate (4) are freed and the brake is released.
6. In the derricking drum lock, ball joint (7) is pushed by pilot pressure oil and pawl (9) moves.
7. As a result, the boom derricking drum is unlocked.
T25N-03-04-006
T25N-03-04-005
Derricking Drum Unlock-ing Solenoid Valve
PilotPump
Hydraulic Oil Tank
Derricking Drum Lock
Derricking Drum Unlock-ing Solenoid Valve
PilotPump
Derricking Drum Lock
COMPONENT OPERATION / Boom Derricking Device
T3-9-5
When brake is applied
T25N-03-04-008
When brake is released
T25N-03-04-008
T25N-03-04-003
T25N-03-04-003
1 - Disk Spring 4 - Friction Plate 6 - Housing 8 - Torsion Spring 2 - Brake Piston 5 - Rotor 7 - Ball Joint 9 - Pawl 3 - Plate
1
Brake Piston Chamber
To Hydraulic Oil Tank
C
2 3 4 5
6
1
Brake Piston Chamber
From Pilot Pump
C
2 3 4 5
6
9To Hydraulic Oil Tank
7
8
From Pilot Pump
7
8
9
COMPONENT OPERATION / Boom Derricking Device
T3-9-6
BRAKE VALVE
The brake valve, located at head of the boom derrick-ing motor, consists of the following valves.
• Overload relief valve Prevents overloading to the motor circuit and surge pressure.
• Counterbalance valve Prevents overturning of the motor caused by the load or self weight in lowering operation.
• Check valve Assists the counterbalance valve in operation and prevents cavitation in the motor circuit.
T25N-03-04-007
Counterbalance Valve
Check Valve
Overload ReliefValve
COMPONENT OPERATION / Boom Derricking Device
T3-9-7
COUNTERBALANCE VALVE
Provides back pressure for the sake of control when the boom derricking lever is operated and stops the motor when the control valve is in neutral. In boom lowering, the motor might be driven by the inertial force of load, but the counterbalance valve provides back pressure in order to prevent overturning of the motor.
Operation
• Boom hoisting
1. In boom hoisting operation, pressure oil from the pump passes through ports A and AM and flows to the motor.
2. Pressure oil goes into port A, opens the check valve and goes to port AM.
3. The return oil passes through ports BM and B and returns to the hydraulic oil tank.
4. As a result, the oil flow is not reduced in boom hoisting work.
• Boom lowering (power lowering)
1. In boom lowering operation, pressure oil from the pump passes through ports B and BM and flows to the motor.
2. Pressure oil passes through the spool and goes to the spring chamber.
3. However, as the return oil from motor is blocked by the check valve, the motor does not turn.
4. As a result, back pressure is given to the circuit.
5. When the oil feed pressure rises, the spool moves by compressing the spring.
6. The return oil from motor returns to the hydraulic oil tank via the control valve.
7. As a result, the motor can turn so that the load can be lowered while applying the brake. This is called “Power Lowering”.
T25N-03-04-010
T25N-03-04-009
B A
BM AM
CheckValve
B A
BM
Spool
COMPONENT OPERATION / Boom Derricking Device
T3-9-8
Boom hoisting
T25N-03-04-007
Boom lowering
T25N-03-04-007
AM
A B
Check Valve
BM
AM
A B
Check Valve
BM
Spool
Spring
Spring Chamber
COMPONENT OPERATION / Boom Derricking Device
T3-9-9
OVERLOAD RELIEF VALVE
The overload relief valve is provided in the hoisting circuit. The overload relief valve serves as a cushion to ab-sorb shock caused by the inertial force when stopping the motor and prevents the overload to the motor.
Relief Operation
1. Normally, the poppet is closed by spring force.
2. When the control lever is returned to neutral, the motor is turned by the inertial force of load in lowering direction.
3. The pressure in port AM rises momentarily and when reaching the set pressure, the poppet moves to open and releases the pressure.
T25N-03-04-012
Poppet Spring
Port AM To Hydraulic Oil Tank
This Page Left Blank Intentionally
COMPONENT OPERATION / Travel Mechanism
T3-10-1
OUTLINE
The travel mechanism consists of the travel motor, travel reduction gear and travel brake valve. The travel motor is an axial plunger motor and incor-porates the parking brake of wet spring-set / hydrau-lic-released multiplate type. The travel motor operates by pressure oil from the pump and transmits the rotation to the travel reduction gear.
The travel reduction gear is a threee-stage planetary reduction gear and converts the rotation, transmitted from the travel motor, to a low-speed high torque in order to rotate the drive tumblers and crawler shoes. The travel brake valve prevents the overload to the travel circuit as well as cavitation.
T25N-03-07-001
Travel Motor
Travel Reduction Gear Travel Brake
Valve
COMPONENT OPERATION / Travel Mechanism
T3-10-2
TRAVEL MOTOR
The travel motor is a swash plate type variable dis-placement axial plunger motor and consists of valve plates (1), plungers (2), shoes (3), shaft (5), swash plate (7) and rotor (8). Shaft (5) is splined to rotor (8) into which plungers (2) are inserted.
Tilt pistons (4) (4 used) are provided in order to change the inclination of swash plate (7) by using balls (6). Rotor (8) is pressed to valve plate (1) by the force of spring (9).
The parking brake is a spring-set/hydraulic-released type that releases the brake when self pressure is ap-plied to brake chamber M. The parking brake is always applied, except for travel mode.Friction plate (5) is splined to rotor (2) and plate (4) is splined to casing (6), respectively.
When Brake Is Applied
1. When the travel lever in neutral, brake chamber M is connected to the hydraulic oil tank.
2. Brake piston (3) is pushed down by the force of spring (1).
3. As a result, plate (4) is pressed to friction plate (5), rotor (5) does not turn.
4. Thus, the parking brake is applied.
When Brake Is Released
1. When moving the travel lever, self pressure in the main circuit acts to brake chamber M.
2. Brake piston (3) moves upward by compressing spring (1).
3. As a result, plate (4) and friction plate (5) are freed and the parking brake is released.
The travel reduction gear is a three-stage planetary reduction gear. Travel motor (1) rotates shaft (11) and its turning torque is transmitted to third stage carrier (6) and ring gear (5) through first stage planetary gear (12), first stage carrier (10), second stage sun gear (9), second stage planetary gear (13), second stage carrier (8), third stage sun gear (7) and third stage planetary gear (14).
Third stage carrier (6) is fixed to housing (2) of travel motor (1) and does not turn. Ring gear (5) and drive tumbler (3) are both bolted to drum (4) and turn together.
T25N-03-07-001
T111-03-04-011
1 - Travel Motor 5 - Ring Gear 9 - Second Stage Sun Gear 12 - First Stage Planetary Gear 2 - Housing (Travel Motor) 6 - Third Stage Carrier 10 - First Stage Carrier 13 - Second Stage Planetary Gear 3 - Drive Tumbler 7 - Third Stage Sun Gear 11 - Shaft 14 - Third Stage Planetary Gear 4 - Drum 8 - Second Stage Carrier
First Stage
Second Stage
Third Stage
1 2 3 4 5 6 7 8 9
10
11
121314
COMPONENT OPERATION / Travel Mechanism
T3-10-7
TRAVEL BRAKE VALVE
The travel brake valve is located at the head of travel motor and consists of the following valves.
• Overload relief valve: Prevents overloading to the motor circuit and surge pressure.
• Counterbalance valve: Makes starting and stopping of travel smoothly and prevents coasting when descending slope.
• Check valve: Assists the counterbalance valve in operation and prevents cavitation in the motor circuit.
• Travel motor displacement angle selection valve: The tilt piston is controlled by pilot pressure from the high speed selection solenoid valve.
T2BC-03-10-001
Travel Motor Displacement Angle Selection Valve
Overload ReliefValve
Counterbalance Valve
Check Valve
Overload ReliefValve
COMPONENT OPERATION / Travel Mechanism
T3-10-8
When Traveling
1. When pressure oil from the control valve goes into port P1 (4), check valve (2) opens and oil flows into motor port a1 (8).
2. On the other hand, return oil from the travel motor returns to motor port a2 (7), but is blocked by check valve (2).
3. When pressure in port P1 (4) increases further, pressure oil goes through orifice (1) acts on the end of spool (3) and moves to the right.
4. As a result, return oil from the travel motor flows through the notch on external circumference of spool (3) and goes to port P2 (6). Now, pressure oil flows to turn the travel motor.
5. When moving the travel lever to neutral, spool (3) returns to original position by the spring force and blocks the circuit in order to stop the rotation of travel motor.
When Descending Slope
1. When descending slope, the travel motor is turned forcibly by its self weight, acting as pump-ing.
2. When oil is sucked by the travel motor, pressure in port P1 (4) and pressure acting on the left end of spool (3) decrease, so that pool (3) moves to the left and reduces the return line from the travel motor.
3. Therefore, pressure on motor port a2 (7) side in-creases and the brake of the travel motor is func-tioned.
4. When the return line is reduced, pressure in port P1 (4) increases again and spool (3) moves to the right.By repeating these steps (hydraulic braking), coasting is prevented.
Circuit Protection
1. When internal pressure of the circuit exceeds the set pressure of overload relief valve (9), this valve opens and release high pressure to the low pres-sure side in order to prevent the travel motor from overloading.
2. In addition, this releases shock pressure caused by the inertial force at the stop of travel motor.
3. When the travel motor sucks oil by pumping ac-tion, check valve (2) opens (by make-up action) in order to prevent cavitation.
Shuttle Function
1. When spool (3) moves, port P1 (4) or port P2 (6) is connected to port P3 (5) (for parking brake). Pressure oil goes into the parking brake chamber and the parking brake is released.
2. When the travel motor stops, spool (3) returns to neutral, port P3 (5) is closed. Pressure oil in the parking brake chamber flows to the drain port the parking brake is applied.
COMPONENT OPERATION / Travel Mechanism
T3-10-9
T165-03-05-004
1 - Orifice 4 - Port P1 7 - Port a2 9 - Overload Relief Valve 2 - Check Valve 5 - Port P3 8 - Port a1 10 - Travel Motor Displacement
Piston (1) is located next to swash plate (3) and changes the displacement angle of swash plate (3) according to the movement of piston (1) in order to select the travel speed.
• Low speed 1. When the high/low travel speed selection switch
is set to low speed position, high travel speed selection solenoid valve is not selected, so that pilot pressure is not fed to port PS (4).
2. As a result, spool (5) is pushed by spring (6) to the left.
3. Pressure oil from motor port a2 (7) or a1 (8) on high pressure side is blocked by spool (5) and oil in piston (1) returns to the hydraulic oil tank through spool (5).
4. Swash plate (3) is pushed by plunger in the travel motor until surface A of swash plate (3) contacts the casing.
5. As a result, the displacement angle of swash plate (3) is maximized and plunger stroke in-creases so that the travel motor runs at a low speed.
T165-03-05-005
T165-03-05-010
1 - Piston 3 - Swash Plate 5 - Spool 7 - Port a2 2 - Steel Ball 4 - Port PS 6 - Spring 8 - Port a1
6546
1
23
7 8
Valve Plate Swash Plate Surface Surface B
SurfaceA
COMPONENT OPERATION / Travel Mechanism
T3-10-11
• High Speed1. When the high/low travel speed selection switch
is set to high speed position, the high travel speed selection solenoid valve is selected.
2. As a result, pilot pressure is fed from port PS (4) in order to move spool (5) to the right.
3. Pressure oil in motor port a2 (7) or a1 (8) on high pressure side acts on piston (1) through spool (5).
4. Piston (1) pushes swash plate (3) so that surface B of swash plate (3) contacts with casing and re-duces the displacement angle of swash plate (3). Plunger stroke in the travel motor is reduced in order to run the travel motor at a high speed.
T165-03-05-007
T165-03-05-011
1 - Piston 3 - Swash Plate 5 - Spool 7 - Port a2 2 - Steel Ball 4 - Port PS 6 - Spring 8 - Port a1
6546
Valve Plate Swash Plate Surface
1
23
7 8
Surface B
Surface A
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COMPONENT OPERATION / Others (Upper Structure)
T3-11-1
4-SOOL SOLENOID VALVE UNIT
CompositionThe 4-spool solenoid valve unit consists of the follow-ing valves.
• Pressure-reducing valve: Reduces pressure in the pilot circuit and supplies pressure oil.
• Second overhoist solenoid valve: By signal from MC2/B, blocks pressure oil to front, rear, boom der-ricking and third / fourth (optional) remote control valves.
• High travel speed selection solenoid valve: By high/low travel speed selection switch, delivers pressure oil to travel motor displacement angle se-lection valve.
• Slewing brake solenoid valve: By slewing brake switch, delivers pressure oil to the parking brake for slewing motor.
• Derricking drum unlocking solenoid valve: By signal from MC2/A, delivers pressure oil to boom derricking brake and boom derricking drum lock.
T2BC-03-11-002
1 - Second Overhoist Solenoid Valve
3 - Slewing Brake Solenoid Valve
4 - Derricking Drum Unlocking Solenoid Valve
5 - Pressure-Reducing Valve
2 - High-Speed Travel Sole-noid Valve
To Front, Rear, Derricking and Third/Fourth Remote Control Valves
To Travel Displacement Angle Selection Valve
To Slewing Parking Brake
To Derricking Drum Lock
From Pilot Pump
1 2 3 4 5
COMPONENT OPERATION / Others (Upper Structure)
T3-11-2
Internal Construction
T2BC-03-11-001
1 - Second Overhoist Solenoid Valve
3 - Slewing Brake Solenoid Valve
4 - Derricking Drum Unlocking Solenoid Valve
5 - Pressure-Reducing Valve
2 - High-Speed Travel Sole-noid Valve
1 2 3 4 5
COMPONENT OPERATION / Others (Upper Structure)
T3-11-3
SOLENOID VALVE
The solenoid valve is an ON/OFF solenoid valves of normally closed type.
Operation
1. In neutral state, port T and the output port are connected through the notch of spool and pres-sure oil from port P is blocked by the spool.
2. When electric current flows through the solenoid, the solenoid is excited and pushes spool.
3. Port T is blocked by spool and output port and port P are connected through the notch of spool.
4. As a result, pressure oil from port P flows to out-put port.
5. When stopping electric current to solenoid, the spool returns by spring force to the original posi-tion.
COMPONENT OPERATION / Others (Upper Structure)
T3-11-4
Neutral state
T324-02-08-007
Exciting stage
T324-02-08-007
TOutputPort P
Spool Spring Solenoid
TOutputPort P
Spool Spring Solenoid
COMPONENT OPERATION / Others (Upper Structure)
T3-11-5
DRUM UNLOCKING SOLENOID VALVE
The drum unlocking solenoid valve is an ON/OFF so-lenoid valve of normally closed type. Three drum unlocking solenoid valves are provided for front, rear and fourth (optional) drums.
When setting the brake mode key switch to auto brake position, depress the brake pedal and turn ON free mode switch for drum. Signal from MC2/A is input to the solenoid for drum unlocking solenoid valve. As a result, the solenoid is excited to operate the drum unlocking solenoid valve.
NOTE: As for operation of drum unlocking solenoid valve, refer to the section for 4-spool unit.
T25N-03-08-008
Port 3(From Pilot Pump)
Port 2 (Output Port)
Port 1 (Hydraulic Oil Tank)
COMPONENT OPERATION / Others (Upper Structure)
T3-11-6
GATE LOCK VALVE
The gate lock valve consists of gate lock solenoid valve and pilot relief valve.The gate lock valve turns ON/OFF in the pilot circuit. The pilot relief valve keeps the pressure in pilot circuit.
T2BC-03-11-003
T2BC-03-11-004
Gate Lock Valve
Pilot Relief Valve
Pilot Relief ValveGate Lock SolenoidValve
Gate Lock SolenoidValve
COMPONENT OPERATION / Others (Upper Structure)
T3-11-7
Gate Lock Solenoid Valve
The gate lock solenoid valve is operated by the gate lock lever operation and controls pressure oil which is supplied from the pilot pump to the pilot circuit. When the gale lock lever is at the LOCK position, the spool in solenoid valve is in neutral. As port P’ is connected to port A, pressure oil in the pilot pump flows to the tank from port T. Therefore, pressure at port P’ (output port) does not rise and op-erate the circuit. When the gate lock lever is at the UNLOCK position, the solenoid valve is operated and port P’ is connected to port B. Therefore, port P is blocked to the tank cir-cuit and pressure oil is supplied to port P1 (outlet port) from the pilot pump. Consequently the circuit is oper-ated.
T2BC-03-11-005
T2BC-03-11-006
Gate Lock Sole-noid Valve
PilotPump
Pilot Relief Valve
To Pilot Circuit
SpoolSoL.SoL. Spool
Gate Lock: LOCK Gate Lock: UNLOCK
COMPONENT OPERATION / Others (Upper Structure)
T3-11-8
Pilot Relief Valve
The pilot relief valve is a relief valve which keeps pressure in the pilot circuit. When pressure in the pilot circuit becomes higher than the set pressure in pilot relief valve, pressure oil from the pilot pump flows to port T in order to decrease pressure in the pilot circuit. When pressure in the pilot circuit becomes lower than the set pressure in pilot relief valve, the pilot relief valve is closed and pressure oil from the pilot pump flows to the pilot circuit side.
T2BC-03-11-007
Gate Lock Solenoid Valve
Pilot Pump
To Pilot Circuit
To Pilot ReliefValve
COMPONENT OPERATION / Others (Upper Structure)
T3-11-9
BRAKE PEDAL UNIT
The brake pedal unit consists of brake pedal (2), lock pedal (1) and pressure-reducing valve (5). With the drum brake release solenoid valve switched, when depressing brake pedal (2), pilot pressure acting to drum brake returns to the hydraulic oil tank, and drum brake is applied. (Spring-set/hydraulic-released control)
The pressure-reducing valve delivers pressure ac-cording to the depressing amount of the brake pedal to apply and release the drum brake.
Output Curve: A-B Range
1. When brake pedal is not depressed, rod (1) is pushed rightward to stroke end.
2. Rod (1) compresses both balance spring (4) and return spring (5) through retainer (2) and spring guide (3).
3. As a result, balance spring (4) pushes spool (6) to the right through spring seat (7).
4. When spool (6) moves to the right and the notch of spool (6) reaches port P, pressure oil from port P flows to output port and pressure in output in-creases.
5. At the same time, pressure oil in port P flows to piston chamber through hole in spool (6) and moves piston (8) to the right.
6. When pressure in piston chamber is smaller than the force of balance spring (4), spool (6) moves to the right and pressure in output port increases continuously.
7. When pressure in piston chamber becomes greater than the force of balance spring (4), spool (6) compresses balance spring (4) through spring seat (7), and moves leftward.
8. However, rod (1) stops the leftward movement of spool (6)
9. Therefore, port P and the output port are kept connected.
10. As a result, pilot pressure acts to the drum brake and the brake is released.
11. This state continues until the notch of spool (6) is connected to port T.
Drum BrakeRelease
Pressure
Pedal Stroke0
A B
C
D
E F
COMPONENT OPERATION / Others (Upper Structure)
T3-11-11
T25N-03-08-010
1 - Rod 3 - Spring Guide 5 - Return Spring 7 - Spring Seat 2 - Retainer 4 - Balance Spring 6 - Spool 8 - Piston
1 2 3 4 5 6 7 8OutputPort
T Hole Piston Chamber
P
COMPONENT OPERATION / Others (Upper Structure)
T3-11-12
Output Curve: C-D Range
1. When depressing the brake pedal, rod (1) moves to the left.
2. As spool (6) is pushed leftward by pressure in piston chamber, spool (6) moves together with rod (1) to the left.
3. When the notch of spool (6) reaches port T, port P and the output port are disconnected.
4. Pressure oil in output port flows to port T (hydrau-lic oil tank), so that pressure in output port de-creases.
5. When pressure in output port decreases, pres-sure in piston chamber also decreases at the same time.
6. When pressure in piston chamber becomes smaller than the force of balance spring (4), spool (6) moves to the right by balance spring (4) through spring seat (7).
7. When the notch of spool (6) reaches port P, port T and the output port are disconnected, while port P and the output port are connected.
8. Pressure oil from port P comes in, and pressures in output port and the piston chamber increase.
9. When pressure in piston chamber is smaller than the force of balance spring (4), spool (6) moves to the right and pressure in output port increases continuously.
10. When pressure in piston chamber becomes greater than the force of balance spring (4), spool (6) compresses balance spring (4) through spring seat (7), and moves to the left.
11. By repeating these steps, spool (6) is positioned depending on the movement of rod (1).
12. Thus, pressure is generated depending on the depressing amount of brake pedal.
Drum BrakeRelease
Pressure
Pedal Stroke0
A B
C
D
E F
COMPONENT OPERATION / Others (Upper Structure)
T3-11-13
When pressure decreases
T25N-03-08-010
When pressure increases
T25N-03-08-010
1 - Rod 3 - Spring Guide 5 - Return Spring 7 - Spring Seat 2 - Retainer 4 - Balance Spring 6 - Spool 8 - Piston
1 2 3 4 5 6 7 8OutputPort
T Hole Piston Chamber
P
1 2 3 4 5 6 7 8OutputPort
T Hole Piston Chamber
P
COMPONENT OPERATION / Others (Upper Structure)
T3-11-14
Output Curve: E-F Range
1. When depressing brake pedal down to stroke end, rod (1) also moves leftward to stroke end.
2. As a result, spool (6) also moves to the left until retainer (2) gets in contact with rod (1) by return spring (5).
3. Port P and output port are disconnected while port T and the output port are connected.
4. Pressure oil in output port flows to port T (hydrau-lic oil tank). In addition, pressure oil in piston chamber passes through hole of spool (6) at the same time, and goes to port T.
5. When pressure in piston chamber becomes smaller than the force of balance spring (4), spool (6) moves to the right by balance spring (4) through spring seat (7).
6. However, when brake pedal is depressed fully to stroke end, port P and output port are kept dis-connected.
7. Therefore, port T and output port are kept con-nected, so pressure in output port is equalized with pressure in port T (hydraulic oil tank).
8. As a result, pressure oil acting to drum brake flows to the hydraulic oil tank, so that brake is applied.
Drum BrakeRelease
Pressure
Pedal Stroke0
A B
C
D
E F
COMPONENT OPERATION / Others (Upper Structure)
T3-11-15
T25N-03-08-010
1 - Rod 4 - Balance Spring 6 - Spool 8 - Piston 2 - Retainer 5 - Return Spring 7 - Spring Seat
1 2 4 5 6 7 8OutputPort
T Hole Piston Chamber
P
COMPONENT OPERATION / Others (Upper Structure)
T3-11-16
COUNTERWEIGHT CYLINDER
The counterweight cylinder extends and retracts due to pressure oil from the 4-unit control valve, and re-moves and install the counterweight. The pipes at cylinder head is equipped with valve block (15) and incorporates the down safety valve and slow return valve. The down safety valve blocks the circuit and prevents the counterweight from falling when the hose is dam-aged. The slow return valve reduces the lower side circuit and prevents the counterweight from lowering rapidly due to the counterweight own weight.
T2BC-03-11-009
1 - Set Screw 6 - O-Ring 11 - Ring 15 - Valve Block2 - Wear Ring 7 - Backup Ring 12 - Dust Seal 16 - Piston Rod3 - Packing 8 - Bushing 13 - Piston 17 - Cylinder Head4 - Wear Ring 9 - Packing 14 - Cylinder Tube5 - O-Ring 10 - Backup Ring
1 2 3 4 5 6 8 9 10 11 127
13 14 15 16 17
COMPONENT OPERATION / Others (Upper Structure)
T3-11-17
ACCUMULATOR
The accumulator is provided in pilot circuit, and func-tions to absorb hydraulic surge and retain pilot pres-sure (for a short time) immediately after the engine stops. The accumulator consists mainly of body (5), holder (4), poppet (1) and bladder (2) that contains nitrogen gas (N2) hermetically.
• Pressure oil from pilot pump passes through port A, and enters accumulator and compresses bladder (2) until pressure oil is balanced with ni-trogen gas in bladder (2).
• If pressure oil is not obtained in circuit due to en-gine stalling or the like, compressed bladder (2) expands and delivers the accumulated oil through port A into pilot circuit.
T105-02-10-003
1 - Poppet 4 - Holder 2 - Bladder 5 - Body 3 - Oil Port 6 - Gas Plug
GOVERNOR MOTOR
The governor motor is used for engine control. The governor motor incorporates worm gear that pre-vents operation of the governor motor outside its con-trol range. The governor motor is also equipped with governor potentio sensor that detects the position of governor lever from the rotation of governor motor. (Refer to Section "Control System".)
T157-02-05-018
Nitrogen Gas (N2)
Pilot Pressure Oil
6
5
4
1
2
3
A
OutputGear
Sensor Gear Governor Potentio Sensor
OutputShaft
Motor
Worm Wheel
Worm Gear
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COMPONENT OPERATION / Others (Base Carrier)
T3-12-1
OUTLINE
The base carrier performs travel and sustains self weight of the upper structure. The base carrier consists of lower frame (5), side frame (10), center joint (2), slewing bearing (3), front idler (6), upper roller (11), lower roller (9), crawler shoe (4), travel mechanism (12), retract cylinder (8), jack-up cylinder (1) (optional) and take-up cylinder (7) (optional).
The slewing ring sustains self weight of the upper structure and makes smooth slewing. This ring is a single row type ball ring and consists of outer race (1), inner race (3), ball (7), supports (5, 6) and seals (2, 4). Outer race (1) is bolted to the upper structure and inner race (3) is bolted to the base carrier. The internal teeth of inner race (3) are enmeshed with output shaft of slewing reduction gear.
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support Ball2 - Seal 4 - Seal 6 - Support
1
2
4
3
5
76
COMPONENT OPERATION / Others (Base Carrier)
T3-12-3
CENTER JOINT
The center joint is a full 360 turn joint and delivers pressure oil to travel motors while preventing hoses from kinking when the upper structure slews. The spindle is fixed at the center of slew of the base carrier.
Pressure oil from each port of the body passes through spindle and flows to left and right travel motors and retract cylinders and jack-up cylinders (optional) through lower control valves. The seal provided between spindle and body prevents oil leakage.
T2BC-03-12-002
Port A - Right Travel Forward Port D - Left Travel Forward Port G - High / Low Travel Speed Selection Pilot Pressure
Port B - Right Travel Reverse Port E - Retract Cylinder Extend (with Jack: Lower Circuit Hydraulic Source)
Port H - Travel Mechanism Drain
Port C - Left Travel Reverse Port F - Retract Cylinder Retract (with Jack: Lower Circuit Link Line)
A
A
H
C
D
F
B
E
G
Body
Spindle
E
D
HC
B
E
G
COMPONENT OPERATION / Others (Base Carrier)
T3-12-4
RETRACT CYLINDER
The retract cylinders are used to extend and retract the crawler frames by hydraulic cylinders. The crawler frames are extended for higher operating stability. Retraced the retract cylinder for convenience of transport.
The retract cylinder is controlled by the retract cylinder extend / retract solenoid valve in 4-spool control valve as for the STD specification machine. When selecting the retract cylinder extend/retract solenoid valves, pressure oil is delivered to the retract cylinder through the spools in 4-spool control valve. The retract cylinder is controlled by the lower control valve (manual operation) with the jack-up (optional) attached. When operating the lever for retract operation, the spool is selected and pressure oil flows to the retract cylinder.
The jack-up cylinder consists of cylinder and pilot check. In addition, slow return check valve is provided in the return line on the jack-up cylinder retract side. The jack-up cylinders are used to disassemble the lower frame into upper and lower sections for transport of the machine, and reassemble them for operation. While the lower frame is lifted by jack-up cylinders, crawler frames are attached, or removed for loading onto a trailer.
The jack-up cylinder is controlled by the lower control valve (manual operation). When operating the lever for jack-up, pressure oil flows to the jack-up cylinder through the spool in lower control valve.
The double check valve maintains pressures on the rod side and the bottom side of jack-up cylinder. Thus, even if jack-up cylinders are subjected to external forces, extension and retraction of jack-up cylinders are prevented.
Operation
1. Pressure oil from port A (jack-up cylinder extend side) opens the check valve at slow return check valve and acts to the pilot check valve.
2. Pressure oil opens the check valve on jack-up cylinder extend side, flows to the bottom side of jack-up cylinder and acts to the check valve on jack-up cylinder retract side.
3. Pressure oil also opens the check valve on rod side (return side), so that pressure oil on the rod side passes through check valve and flows to the hydraulic oil tank.
4. As a result, the jack-up cylinder extends.
5. When setting key switch to OFF position, jack extend/retract solenoid valve returns to neutral.
6. The main spool in lower control valve also returns to neutral, so that extend/retract of jack-up cylinder stops.
7. At this time, even if the jack-up cylinders are subjected to external forces, the jack-up cylinders are kept in position as the return line is blocked by the check valve.
T25N-03-09-006
T25N-03-09-008
Jack-Up Cylinder
Check ValveCheck Valve
Jack-Up Cylinder
Check Valve
A
B
Check Valve
Check Valve
COMPONENT OPERATION / Others (Base Carrier)
T3-12-7
Slow Return Check Valves
The slow return check valve is provided in the extend circuit of jack-up cylinder. By reducing the return line on the jack-up cylinder retract side in order to deliver pressure oil slowly, rapid lowering of the machine by self weight is prevented.
Operation
1. Pressure oil from port B flows to the rod side of jack-up cylinder.
2. On the other hand, pressure oil in return line passes through double check valve and acts to the check valve in slow return check valve.
3. Return oil is blocked by the check valve, so that return oil flows through the orifice to port A.
4. As a result, the jack-up cylinder retract speed is reduced and prevents rapid lowering of the machine.
T25N-03-09-007
T25N-03-09-003
Jack-UpCylinder
Check Valve
AB
Orifice
Check ValveOrifice Slow Return Check Valve
From Jack-Up Cylinder
To Lower Control Valve
COMPONENT OPERATION / Others (Base Carrier)
T3-12-8
TAKE-UP CYLINDER (OPTIONAL)
The take-up cylinder pushes the left and right front idlers forward by using the travel circuit pressure and gives a constant tension the track shoe.
The travel circuit pressure is supplied to the bottom side of take-up cylinder. Consequently, the front idler is pushed and the left and right track shoes are given a constant tension. When the excessive power acts on the front idler, the return check valve is open and release pressure oil from the bottom side of take-up cylinder in order to absorb the shock.
T2BC-03-12-001
1 - Head Cap 3 - Scraper 5 - Housing 6 - Piston Rod2 - Scraper 4 - O-Ring
1 2 3 4 5 6 From Travel Circuit
SECTION 4OPERATIONAL PERFORMANCE TEST
—CONTENTS—Group 1 Introduction
Operational Performance Tests .............. T4-1-1 Preparation For Performance Tests ........ T4-1-2 Precautions For Starting Engine ............. T4-1-3
Group 2 Standard Performance Standards ......................... T4-2-1 Main Pump P-Q Diagram....................... T4-2-4 Slewing Pump P-Q Diagram .................. T4-2-6
Group 3 Engine Test Engine Speed ........................................ T4-3-1Engine Compression Pressure .............. T4-3-2Valve Clearance Adjustment .................. T4-3-3 Nozzle Check ........................................ T4-3-5
Group 4 Crane Test Travel Speed ......................................... T4-4-1 Mistrack................................................. T4-4-2 Travel Parking Brake Drift...................... T4-4-3Slewing Speed....................................... T4-4-4 Slewing ring Play................................... T4-4-5Hoist / Lower Speeds
By Front / Rear Drums ....................... T4-4-12Control Lever Operating Force .............. T4-4-13 Control Lever Stroke............................. . T4-4-14
Group 5 Component Test Pilot Circuit Primary Pilot Pressure ........ T4-5-1 Brake Circuit Primary Pilot Pressure...... T4-5-3 Remote Control Valve
Secondary Pilot Pressure ................... T4-5-5High / Low Travel Speed
Group 6 Adjustment MC2/A Adjustment ................................. T4-6-1High Idle Calibration .............................. T4-6-2Rack Zero Calibration............................ T4-6-4Power Increase Pressure Calibration .... T4-6-6 Full Rack Calibration ............................. T4-6-8Brake Pedal Unit Adjustment ................. T4-6-10
2BCT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to quantitatively check all systems and functions on the machine.
Kinds of Operational Performance Tests 1. System Performance and Function Test
Each system such as engine, travel, swing, and hydraulic cylinder is individually tested.
2. Component Performance and Function Test Each component such as hydraulic pump, motor, and various valves is individually tested.
Purpose of Operational Performance Tests 1. To evaluate the performance and function of a
system or component by comparing the test re-sults to the standard specifications.
2. According to the evaluation above, repair, adjust, or replace the system or component as neces-sary to restore the systems and functions to the required performance level.
3. To ensure safety and high efficiency operation.
Standard Specifications New machine applied specifications are described in this manual for test evaluation purposes. Tolerances are indicated as necessary.
Precautions for the Test Result Evaluation 1. Besides determining whether the test results
meet the standard specifications or not, check which level of standards the test results corre-spond to.
2. In compliance with how long and under what type of work or conditions the machine has operated, or the machine maintenance condition, the extent of deterioration of the machine’s performance may differ. Decide the degree of repair, adjust-ment, and/or replacement corresponding to the machine operation hours.
NOTE: With the passage of time, the machine's operational performance deteriorates, so that the machine needs to be serviced pe-riodically. Before servicing the machine, conduct performance tests to check the extent of deterioration and to decide what kind of service needs to be done referring to the standard specifications.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE TESTS
Observe the following rules in order to carry out per-formance tests accurately and safely.
1. The Machine Before starting performance tests, perform a sight-inspection of the machine. Then, if any ab-normalities such as oil or coolant leaks, loose bolts, or cracks are found, repair them.
2. Test Area and Measuring Instrument (1) Select a hard and level surface. (2) Secure enough space to allow the machine to
run straight for more than 10 m (33 ft). (3) Secure enough space to allow the machine to
make a full swing with the front attachment ex-tended.
(4) Provide equipment and measuring instruments suitable to the test to be performed.
(5) If required, rope off the test area and provide signboards to keep unauthorized personnel away.
(6) Provide measuring weights or equivalent ones. (7) Coordinate work signals and procedures with
co-workers.
3. Precautions
(1) While testing, always monitor the work site con-ditions to avoid accidents due to landslides or contact with high-voltage power lines.
(2) Always give first priority to safety. Be sure to adhere to work signals and operate the machine carefully.
(3) Avoid contaminating the machine and the ground with leaking oil. When removing hydrau-lic pipings, use oil pans to catch escaping oil.
(4) After completing the tests, properly dispose of the waste oil or the used shop towels to protect the work site from pollution.
4. Precise Measurement (1) Accurately calibrate test instruments in advance
to obtain correct data. (2) Carry out tests under the exact test conditions
prescribed for each test item. (3) Repeat the same test and confirm that the test
data obtained can be repeated. Use the average values of the measurements.
T105-06-01-003
SA-331
T4-1-2
OPERATIONAL PERFORMANCE TEST / Introduction
PRECAUTIONS FOR STARTING ENGINE
1. Check that lock lever (1) is placed in the LOCK position.
2. Check that all control levers are placed in the NEUTRAL position.
3. Check that front, rear and fourth (optional) brake pedals (5, 7 and 6) are applied, and front, rear and fourth (optional) drum brake mode selection switches (2, 3 and 4) are set to the “Auto Brake” mode.
4. Check that slewing brake switch (8) is ON (Brake position).
NOTE: Engine starts when front, rear and fourth (optional) drum mode selection switches (2, 3 and 4) are set to the “Auto Brake” mode, and slewing brake switch (8) is turned ON (Brake position).
Lock Position 1
T2BC-04-04-001
T2BC-04-01-002
T2BC-01-02-003
2 3 18
67 5
4
T4-1-3
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OPERATIONAL PERFORMANCE TEST / Standards
PERFORMANCE STANDARDS
The performance standards show the required per-formance measurements. For details including measuring method, refer to T4-3 onward.Data in ( ) is given for reference.
Measuring conditions: Engine speed : High idle Hydraulic oil temperature : 50 5 C (122 41 F)
Performance Test Designation PerformanceStandard Remarks Reference
Page
Engine Speed min-1 T4-3-1Maximum Speed (High Idle) 2070 to 2130 Minimum Speed (Low Idle) 760 to 820 Starting Speed 885 to 945
Engine Compression Pressure MPa (kgf/cm2, psi) 2.7 (28, 390) After Warming Up T4-3-2
B 1.96 0.2 (20 2) 158 3 457 30Data in ( ) is given for reference.
T4-2-7
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OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Measure the engine speed by using the moment lim-iter speed indicator.
NOTE: 1. If the engine speed is out of specification, all other measured performance data will also be out of specification. Accordingly, always measure the engine speed before performing any tests..
2. The engine speed after starting, is the slow idle speed plus 125 min-1 (125 rpm). In order to reduce the engine speed to the slow idle speed, increase the engine speed faster than the starting speed by operating the accelerator dial. Then, re-turn the accelerator dial to the slow idle speed position.
Preparation: 1. Sufficiently warm up the machine until the engine
coolant temperature reaches 50 C (122 F) or more, also, maintain the hydraulic oil temperature at 50 5 C (122 9 F).
2. Check that fuel injection pump governor lever (2) comes in contact with both slow and fast-idle stopper (1) when the accelerator lever in the left console is fully stroked to both sides.
NOTE: Do not adjust stopper (1).
Measurement:Measure the slow and fast idle speeds.
Evaluation: Refer to Operational Performance Standard in T4-2.
Remedy: Refer to the engine shop manual.
Fast Idle Speed PositionSlow Idle Speed Position
T333-04-02-001
2
1 1
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary: 1. Measure compression pressure in each cylinder
to check for a decline in engine power.
2. Check exhaust color and the amount of blow-by gas from the crankcase. Keep track of engine oil consumption.
3. Check the intake system, including the air filter, for any abnormalities.
Preparations: 1. Check that the valve clearances are correct.
2. Charge the batteries are sufficiently charged.
3. Warm up (run) the engine until the coolant temperature reaches the operating range.
4. Remove the nozzle holders and injection lines from each cylinder.
5. Install adapter (MITSUBISHI MH061461) and a pressure gauge on the nozzle holder mounting opening. (Securely tighten them in order to pre-vent an air leak.)
Measurement:1. Turn the starter. Record compression pressure
for each cylinder.
2. Repeat the measurement three times for each cylinder and calculate the mean values.
Evaluation: Refer to Operational Performance Standard in T4-2.
Remedy: Refer to the engine shop manual.
T333-04-02-002
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary: 1. Measure when the engine is cool.
2. Clean the head cover mounting area in order to prevent any foreign material from entering the engine.
Preparation: 1. Remove the head cover.
2. Locate top dead center (TDC) in compression stroke. Remove the lower left side flywheel housing cover. Align the pointer installed on the flywheel housing inspection hole edge with marked scale 1.6 on the flywheel. The piston in either cylinder No.1 or No.6 is at TDC in its compression stroke. Measure from either cylinder No. 1 or No. 6 that is TDC in its compression stroke.
Measurement:1. Insert a feeler gauge between the rocker arm and
valve stem in order to measure the valve clear-ance.
NOTE: The cylinders are arranged from No. 1 to No. 6 in this order as viewed from the fan side.
3. When measuring cylinder No.1, perform the same measurement for the valves marked with “ ” in the table below. (When measuring from cylinder No.6, perform the same measurement for the valves marked with “ ” in the table below.) Measure all valve clearances.
T333-04-02-003
Cylinder No. No.1 No.2 No.3 No.4 No.5 No.6
Valve Layout In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
When the measurement is started from cylinder No.1
When the measurement is started from cylinder No.6
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation: Standard Valve Clearance (Cold Engine): • Intake valve: 0.40 mm (0.016 in) • Exhaust valve: 0.60 mm (0.024 in)
Adjustment: If the measured valve clearances do not conform to the standard value, adjust the valve clearance in the same order of the measurement.
1. After loosening the lock nut on the rocker arm, completely loosen all adjust screws.
2. Insert the specified feeler gauge into the gap between the rocker arm and the valve. Tighten the rocker arm adjusting screw until the feeler gauge becomes slightly tight to move.
3. After adjustment, tighten the lock nut and secure the adjusting screw.
59 N m (6 kgf m, 43 lbf ft)
3. Recheck the valve clearance after tightening the lock nut.
T333-04-02-004
Adjusting Screw Lock Nut
Rocker Arm
Feeler Gauge
Valve Cap
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:1. Check the injection pressure and the spray pat-
tern with a nozzle tester. 2. Before starting work, clean the nozzle holder
mounting area in order to avoid contamination in the engine.
Preparation1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-ings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Do not touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel pene-trates into the blood stream, it may cause blood toxication.
IMPORTANT: Use clean diesel oil.
1. Injection pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure. If adjustment is required, loosen the lock nuts and adjust the adjusting screws. Turn clockwise to increase the pressure and counterclockwise to decrease the pressure.
2. Spray pattern For this test, turn the pressure tester knob to by-pass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pat-tern.
3. Oil tight condition Keep the pressure slightly below the injection pressure from nozzle tip. Check for fuel leak from around the nozzle tip.
T107-06-02-006
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation: 1. Standard Injection Pressure:
Refer to Operational Performance Standard in T4-2.
2. Spray Pattern • Large-size spray should not be visible to the na-
ked eye. • No stray sideways sprays should be seen. • During initial injection stage, spray size should be
fine and injected intermittently. • There should be no drips found. • Injection spray angle must be normal.
3. Oil Tight Condition No fuel leaks.
Adjustment: 1. In order to adjust the injection pressure, loosen
the lock nuts. Adjust the adjusting screw. Turn clockwise to increase the pressure and counterclockwise to decrease the pressure.
2. After adjusting, retighten the lock nuts.
T523-06-02-001
T107-06-02-007
Normal Abnormal
T4-3-6
OPERATIONAL PERFORMANCE TEST / Crane Test
T4-4-1
TRAVEL SPEED
Summary: 1. Measure the time to travel 10 m (33 ft) and check
the operational performance of the travel power system (from the hydraulic pump to the travel motor) comprehensively. 2 m (6.5
ft)
Preparation: 1. Adjust both the right and left sags equally.
2. Prepare a level and solid test track 10 m (33 ft) long, with an extra length of 3 to 5 m (9.8 to 16 ft) on both ends of the test track for machine acceleration and deceleration.
60
3. The machine should be equipped with the basic boom with the hook. Set the boom angle to 60 , and hoist the hook until it reaches 2 m (6.5 ft) below the height at which the hoisting limiter buzzer starts to operate. (Or dismount the front attachment and counterweight.)
T2BC-04-04-003
4. While maintaning hydraulic oil temperature at 50 5 C (122 41 F), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer.
Measurement:Measure in both fast and slow travel modes.
1. Increase the engine speed to the maximum.
2. Start driving the machine from the acceleration zone with both the right and left travel levers at full stroke.
3. Measure the time required to travel the 10 m (33 ft) test track.
4. After measuring forward travel time, turn the upperstructure 180 . Then, measure the reverse travel time.
5. Repeat the measurements three times. Calculate the average values.
End
Start
10 m (33 ft) Accelera-
tionZone3 to 5 m (9.8 to 16 ft)
DecelerationZone3 to 5 m (9.8 to 16 ft)
T324-06-03-002
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: Refer to TROUBLE SHOOTING in T5-4.
OPERATIONAL PERFORMANCE TEST / Crane Test
MISTRACK
Summary: 1. Measure the maximum distance between the 10
m (33 ft) straight line and check the variation be-tween the right and left travel power line (from the hydraulic pump to the travel motor) performance.
2 m (6.5 ft)
2. Mistrack is generally reduced when measured on a concrete surface.
Preparation: 1. Adjust both the right and left track sags equally.
602. Prepare a level and solid test track 10 m (33 ft) long, with an extra length of 3 to 5 m (9.8 to 16 ft) on both ends of the test track for machine accel-eration and deceleration.
3. The machine should be equipped with the basic boom and hook. Hoist the hook to approx. 2m below the height which the hoisting limiter buzzer starts to operate.
T2BC-04-04-003
4. While maintaining hydraulic oil temperature at 50 5 C (122 41 F), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer.
Measurement:Measure in both fast and slow travel modes.
1. Increase the engine speed to the maximum.
2. Start driving the machine from the acceleration zone with both the right and left travel levers at full stroke.
3. Measure the maximum distance from a straight 10 m (33 ft) line to the machine rut.
4. After measuring in forward travel, measure in re-verse travel. 2 m (6.5 ft)
Maximum Distance5. Repeat the measurement three times. Calculate
the average values.
10 m (33 ft)Evaluation:
Extra Length for Acceleration3 to 5 m (9.8 to 16 ft) Refer to STANDARD SPECIFICATIONS in T4-2.
T324-06-03-003
Remedy: Refer to TROUBLE SHOOTING in T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Crane Test
TRAVEL PARKING BRAKE DRIFT
Summary: Measure the travel parking brake drift on a specified angle slope. 2 m
(6.5 ft)
Preparation: 1. The test slope shall be smooth with a gradient of
20 % (11.31 ).60
2. Put a mark on the travel reduction gear cover.
3. Use the basic boom with the hook. Set the boom angle to 60 . (Or dismount the front attachment and counterweight.)
20%
T2BC-04-04-004
4. Maintain the hydraulic oil temperature at 50 5 C(122 41 F).
Movement(Rotation Angle)
Position when the travel levers are in neutral.
Position where the machine stops. comes to a stop.
Measurement:Measure in both fast and slow travel speed modes.
• Track movement (sprocket rotation) until the parking brake is applied.
1. Climb the slope and place the travel levers in neutral. Mark
2. Measure the travel reduction gear cover mark movement from the position when the lever is placed in neutral to the position when the ma-chine stops (when the brake is applied).
• Travel motor slip while parking T107-06-03-002
3. Climb the slope and place the travel levers in neutral.
4. Stop the engine. 5. After parking the machine, put the matching
marks on the shoe and side frame. 6. After 5 minutes have passed, measure the dif-
ference (3) between mark (1) on the side frame and mark (2) on the shoe.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
3 12
T324-06-03-005
T4-4-3
OPERATIONAL PERFORMANCE TEST / Crane Test
SLEWING SPEED
Summary: 1. Measure the time to slewing three complete turns
and check the operational performance of the slewing power system (from the hydraulic pump to the slewing motor) comprehensively.
Preparation: 1. Check the lubrication of the slewing gear and
slewing ring. 2 m (6.5 ft) 2. Place the machine on a level and solid ground
with ample space for swinging. Do not test on a slope.
3. Use the basic boom with the hook. Set the boom angle to 60 . (Or dismount the front attachment and counterweight.)
604. While maintaining hydraulic oil temperature at 50 5 C (122 41 F), make measurement after delivering hydraulic oil to the measured hydraulic oil to the measured hydraulic circuit for two munutes or longer.
T2BC-04-04-003
Measurement:1. Turn the slewing brake switch ON. 2. Run the engine at the maximum speed by using
an accelerator grip.
IMPORTANT: Do not operate the control lever rapidly. Otherwise, a large swing of the hook may result, potentially causing the hook to come in contact with the boom.
3. Operate the slewing control lever fully. 4. After the slewing speed becomes constant,
measure the time required for the upperstructure to rotate three turns in one direction.
5. Measure on the right and left slewing. 6. Repeat the measurements three times. Calculate
the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: Refer to TROUBLESHOOTING in T5-4.
Slewing Brake Switch
Accelerator Grip
T2BC-04-04-014
T4-4-4
OPERATIONAL PERFORMANCE TEST / Crane Test
SLEWING RING PLAY
Summary: 1. Measure the slewing ring play between inner
race and auter race and check the wear or slewing ring races and balls..
Preparation: 1. Check slewing ring mounting bolts for looseness. 2. Check lubrication of the slewing ring. Check that
ring the slewing ring rotation is smooth and without noise.
3. Install a dial gauge on the upper surface on lower frame by using amagnetic base.
4. Position the upperstructure in the same direction as traveling the lower frame.
5. Position the dial gauge so that its needle point comes into contact with the bottom surface of slewing ring outer race.
6. Perform the measurement on level and solid ground. Use the basic boom with the hook. Set the boom angle to 60 . Apply a maximum lifting load (100 %) to the hook.
7. Maintain the hydraulic oil temperature at 50 5 C(122 41 F).
Measurement:1. Before lifting a load, read the dial gauge
indication (h1).2. Lift up a weight (100 % load) until the bottom of
the weight leaves the ground. Then, read the dial gauge indication (h2).
3. Obtain the slewing bearing play (H) by calculating the difference between (h1) and (h2).That is, H = h2-h1
Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.
Summary: 1. Measure the time required for the front and rear
drum to rotate six complete turns to comprehensively check the operational performance of the hydraulic pump and the front and rear drum motors in the front and rear drum drive system.
Preparation: 1. Use the basic boom with the hook. (Or dismount
the front attachment and counterweight.)
2. Set the boom angle to 60 . Lower the hook until it comes close to the ground surface.
3. After raising the hydraulic oil temperature to the range of 50 5 C (122 41 F) by operating the drum motors, let the hydraulic oil flow into the circuits to be measured for more than two min-utes before starting the test.
4. Check that the weight of the hoisting limiter functions at the specified position. 60
NOTE: Depending on the number of the wire rope falls, the hook travel for six turns of the hoist drum varies. Start the measurement from the position having enough margin in stroke.
T2BC-04-04-008
Measurement:1. Turn the low speed lock switch LOCK.
2. Run the engine at the maximum speed by using an accelerator grip.
3. Operate the hoist lever (front and rear drum lever) corresponding to the drum to be measured.
4. After the drum rotation speed becomes constant, measure the time required to rotate six turns.
5. Repeat the measurements three times in each direction. Calculate the average values.
6. Release the low speed lock switch. Repeat steps 2 to 5 in order to measure.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Rear Drum Lever
Front Drum Lever Fast Speed
LoweringSlow Speed
NeutralPosition
Slow Speed Hoisting
Fast Speed
M25N-04-008 Slow SpeedLock Switch
T2BC-04-04-010
T4-4-6
OPERATIONAL PERFORMANCE TEST / Crane Test
REGULATOR ADJUSTMENT
Swash Angle Set Pressure and Power Set Pres-sure Adjustment Motor speed can be adjusted with adjusting screws (1) and (2) at regulator.
2
1
3
4
T25N-03-03-024
Adjustment Item Adjustment Procedure Remarks1. Swash angle set pressure Loosen lock nut (1) and turn ad-
justing screw (2). One turn of ad-justing screw (2) changes the pres-sure as follows. Front/rear drums: 530 kPa (5.4 kgf/cm2, 77 psi) 3rd drum (optional): 250 kPa (2.5 kgf/cm2, 36 psi)
: 13 mm : 16 N m (1.6 kgf m, 12 lbf ft)
1) Other control characteristics are not influenced.
2) Securely retighten lock nut (1) after adjustment.
2. Power set pressure Loosen lock nut (4) and turn ad-justing screw (3). One turn of adjusting screw (3) changes the pressure as follow. 21.5 MPa (219 kgf/cm2, 3130 psi)
: 13 mm : 16 N m (1.6 kgf m, 12 lbf ft)
1) Other control characteristics are not influenced.
2) Securely retighten lock nut (4) after adjustment.
Flow Rate
Pilot Pressure
Pressure
Torque
T4-4-7
OPERATIONAL PERFORMANCE TEST / Crane Test
BOOM DERRICKING SPEED
Summary: 1. Measure the time required for the boom
derricking drum to rotate six complete turns and comprehensively check the operational performance of main pump and boom derricking drum motor in the boom derricking drive system.
2 m (6.5 ft)Preparation:
1. Use the basic boom with the hook. (Or dismount the front attachment and counterweight.)
2. While maintaining hydraulic oil temperature at 50 5 C (122 41 F), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer.
60
3. Check that the boom derricking drum brake functions properly.
4. Check that the derricking limiter functions properly.
T2BC-04-04-003
Measurement:1. Run the engine at the maximum speed by using
an accelerator grip.
2. Operate the boom derricking lever. Accelerator Grip
BoomDerricking Lever3. After the boom derricking drum rotation speed
becomes constant, measure the time required to rotate six turns.
4. Repeat the measurements three times in both hoisting and lowering directions. Calculate the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: Refer to TROUBLE SHOOTING in T5-4.
T2BC-04-04-015
T4-4-8
OPERATIONAL PERFORMANCE TEST / Crane Test
COUNTERWEIGHT CYLINDER SPEED
Summary: 1. Measure the extension time of counterweight
cylinder from minimum retraction length to maxi-mum extension length time without load and check the operational performance of drive power system (from the pump for counterweight / jack-up retract the counterweight cylinder) com-prehensively.
Preparation: 1. Lower the front attachment onto ground and re-
move the counterweight from the machine. 2. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making the counter-weight cylinder operation at hydraulic oil tem-perature of 50 5 C (122 41 F)
3. After retraction the counterweight cylinder fully, measure the time.
T2BC-04-04-016
Measurement:Measure for each cylinder of right and left respec-tively.
1. Set the engine speed to the minimum speed by using an accelerator grip.
2. Turn the counterweight switch to the EXTEND position.
3. Measure the required time length for extending the counterweight cylinder fully.
4. Turn the counterweight switch to the RETRACT position.
5. Measure the required time length for retracting the counterweight cylinder fully.
6. Carry out measurement three times, and deter-mine the average of measurements.
Evaluation: Refer to STANDERD SPECIFICATIONS in T4-2.
T4-4-9
OPERATIONAL PERFORMANCE TEST / Crane Test
JACK-UP (OPTIONAL) SPEED
Summary: 1. Measure the extension time of jack-up cylinder
from minimum retraction length to maximum ex-tension length and check the operational per-formance of jack-up cylinder drive power system (from the pump for counterweight / jack-up / re-tract to the jack-up cylinder).
Preparation: 1. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making the jack-up cylinder operation at hydraulic oil temperature of 50 5 C (122 41 F).
2. Carry out measurement after extending jack-up cylinder fully.
Measurement:Make measurement at each measuring point.
1. Set the engine speed to the minimum speed by using an a accelerator grip.
2. Turn the jack-up lever the EXTEND position. 3. Measure the extension time of jack-up cylinder
from fully retracted position. 4. With the jack-up lever at the RETRACT position
and the jack-up cylinder resting on the ground, measure the retraction time of jack-up cylinder to the minimum retraction length.
5. Carry out measurement three times, and deter-mine the average of measurements.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
T25N-04-04-004
Jack-up Cylinder
T4-4-10
OPERATIONAL PERFORMANCE TEST / Crane Test
RETRACT SPEED
Summary: 1. Measure the extension time of retract cylinder
from minimum retraction length to maximum ex-tension length and check the operational per-formance of retract cylinder drive power system (from the pump for counterweight / jack-up retract to the retract cylinder).
Preparation: 1. Use the basic boom with the hook. Set the boom
angle to 60 . (The machine without front attach-ment and counterweight is acceptable.)
2. Deliver oil into the measured hydraulic circuit for two minutes or longer while making retract opera-tion at hydraulic oil temperature of 50 5 C(122 41 F).
3. Place the wooden blocks under the cylinder tubes of retraction cylinders to be measured.
IMPORTANT: Place the wooden blocks under the cylinder tube in order not to wind the retract cylinder.
60
4. Pull out the pin from the rod side of retraction cyl-inder to be measured. (Do not remove the pin from the not-measured side of retract cylinder.)
T2BC-04-04-005
Measurement:Measure one side for each.
1. Set the engine speed to the minimum speed by using an accelerator grip.
2. Turn the retract switch to the EXTEND position. 3. Measure the required time length for extending
retraction cylinder fully. 4. With the retract switches at the RETRACT posi-
tion, measure the required time for retracting the retract cylinder fully.
5. Carry out measurement three times, and deter-mine the average of measurements.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Pin Cylinder Tube
T2BC-04-04-017
T4-4-11
OPERATIONAL PERFORMANCE TEST / Crane Test
LIFTING LOAD LOWERING BY FRONT / REAR DRUMS
Summary: 1. Measure slippage at the drum flange for two min-
utes with the engine idling and check the load lowering by front (rear) motor. Check leakage in the motor circuit.
Preparation: 1. Use the basis boom with the hook. 2. Number of rope reeving at the boom hook is four
or less. 3. Set the front / rear drum brake mode selection
switches (1 and 2) to the “Auto Brake” position. 4. While maintaining hydraulic oil temperature at
50±5 C (122±41 F), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer.
T2BC-04-04-011 5. Hoist the weight, stop it, and make measurement.
Measurement:1. Set boom angle to 60 .2. Set the load to about 11 tons when converted to
line pull at the bare drum (at boom hook, about 44 tons at 4 rope reeving, and about 33 tons at 3 rope reeving).
3. Lift and suspend the weight 0.5 m (20 in) above the ground.
4. Set engine speed to Low Idle. 5. Measure slippage length at outer surface of the
drum flange. Measure for two minutes. 6. Restore number of rope reeving as it was.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: Refer to TROUBLE SHOOTING in T5-4.
0.5 m (20 in)
21
60
T2BC-04-04-012
T4-4-12
OPERATIONAL PERFORMANCE TEST / Crane Test
CONTROL LEVER OPERATING FORCE
Summary: 1. Check the operating function of each control
lever and measure the operating force. 2. Measure the maximum operating force of the
front attachment control lever. 3. Measure the operating stroke at the lever bottom
of each control lever.
Preparation: 1. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Measure on each control lever. 2. Stop the engine. 3. Operate each lever full stroke to measure the
maximum operating force. 4. Repeat the measurements three times. Calculate
the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Measurement Position for Hoisting / Travel Lever Measurement Position for Slewing Lever
T2BC-04-04-018
T2BC-04-04-019
HoistingLever
MeasurementPosition
Slewing Lever
Travel Lever
MeasurementPosition
T4-4-13
OPERATIONAL PERFORMANCE TEST / Crane Test
CONTTROL LEVER STROKE
Summary: 1. Check a play and operating function of each
control lever and measure the stroke. 2. Measure the lever stroke at the grip center of
each control lever. 3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both side lever strokes.
Preparation: 1. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Stop the engine. 2. Measure the lever stroke from the neutral
position to stroke end at the grip top. 3. Measure the linear strokes. 4. Repeat the measurements three times. Calculate
the average values.
Evaluation: Refer to T4-5 STANDARD SPECIFICATIONS.
Measurement Position for Hoisting / Travel Levers Measurement Position for Slewing Lever
Slewing Lever HoistingLever
Travel Lever
MeasurementPosition
MeasurementPosition
MeasurementPosition
MeasurementPosition
T2BC-04-04-019 T2BC-04-04-018
T4-4-14
OPERATIONAL PERFORMANCE TEST / Component Test
PILOT CIRCUIT PRIMARY PILOT PRESSURE
Preparations: 1. Stop the engine. 2. Remove adapter 1 from port P1 (G 3/8) on the
4-spool solenoid valve unit. : 22 mm
3. Install a pressure gauge port P1. 4. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Run the engine at the maximum speed. 2. Measure the pilot pressure under no load
condition by using a pressure gauge. 3. Repeat the measurements three times. Calculate
the average values.
Evaluation:Refer to STANDARD SPECIFICATIONS in T4-2.
4-Spool Solenoid Valve Unit
Adapter 1
Port P1
T2BC-04-05-002
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Pilot Circuit Primary Pilot Pressure
Adjustment: Adjust the set pressure of pressure reducing valve provided on the 4-spool solenoid valve unit if necessary.
1. Loosen the lock nut. : 14 mm
2. Turn the adjusting screw. : 6 mm
3. Tighten the lock nut. : 14 mm : 7.8 N m (0.8 kgf m, 5.8 lbf ft)
4. Check the set pressure after adjustment.
AdjustingScrew Lock Nut
T2BC-04-05-003
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE CIRCUIT PRIMARY PILOT PRESSURE
Preparations: 1. Stop the engine. 2. Install a pressure gauge to the coupler for
measurement in manifold (under the cab bed). 3. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Run the engine at the maximum speed. 2. Measure the pilot pressure under no load
condition by using a pressure gauge. 3. Repeat the measurements three times. Calculate
the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Under Cab Bed
Manifold
Coupler for Measurement
Brake Unit
T2BC-04-05-004
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Brake Circuit Primary Pilot Pressure
Adjustment: Adjust the set pressure of pilot relief valve in gate lock valve by using a pressure gauge if necessary.
1. Loosen the lock nut. : 17 mm
2. Turn the adjusting screw. : 8 mm
3. Tighten the lock nut. : 17 mm : 10.8 N m (1.1 kgf m, 8 lbf ft)
4. Check the set pressure after adjustment.
T2BC-03-11-004
Gate Lock Valve
Pilot Relief Valve
AdjustingScrew
Lock Nut
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
REMOTE CONTROL VALVE SECONDARY PILOT PRESSURE
Preparations: 1. Stop the engine. 2. Install a pressure gauge unit to the circuit to be
measured.2-1. Front / Rear / Boom Derricking Drums Circuit • Remove the plug from port 9 (G1/4) in the front
remote control valve, port 8 (G1/4) in the rear remote control valve and port 3 (G1/4) in the boom derricking remote control valve respectively. Install a pressure gauge.
: 19 mm 2-2. Travel and Third Drum Circuits • Remove the travel remote control pressure
sensor from ports 8, 9 (G1/4) in the right and left travel remote control valves. Install a pressure gauge.
: 24 mm : 16 1.6 N m (1.6 0.2 kgf m, 12 1.2 lbf ft)
• Remove the hose and adapter from port 7 (G1/4) in the third / fourth remote control valve. Install a pressure gauge.
: 19 mm
2-3. Sewing Circuit • Remove the plug from port 3 (G1/4) in the
slewing remote control valve. Install a pressure gauge.
: 6 mm 3. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
T2BC-04-05-005
BoomDerricking Rear Drum
FrontDrum
Third / Fourth Drum
Travel (Left)
Travel (Right) Slewing
Port 9 Port 3Port 9Port 3
Port 7
Port 8Port 8
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:1. In case of measurement in the front / rear and
boom derricking circuits, engage the respective drum locks. In case of measurement in the slewing circuit, turn the slewing lock pedal in the LOCK position and turn the slewing brake switch in ON.
CAUTION: When measuring in the travel circuit near the rotating parts, take care not to allow your hand, foot, and/or clothes to become entangled in the rotating parts.
2. Lower the lock lever to the UNLOCK position. Operate the control lever corresponding to the circuit in which the secondary pilot pressure is to be measured at each detent position. Then, measure the pilot pressure at each detent position by using a pressure gauge.
3. Repeat the measurement three times at each detent position. Calculate the average value.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: In case the measured results are out of specifications, check the pilot circuit primary pilot pressure. When the primary pilot pressure is normal, the remote control valve may be faulty.
NOTE: If it is difficult to measure at the port on bottom of remote control valve, measure at the spool end of control valve corresponding to each port.
Slewing Brake Switch Lock Lever
Slewing Lock Pedal
T2BC-01-02-006
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
HIGH / LOW TRAVEL SPEED SELECTION PRESSURE
Preparations: 1. Stop the engine. 2. Remove the travel speed control hose. 3. Install the adapter to the elbow.
Install the hose and nipple to the adapter. Install the pressure gauge unit to the nipple.
: 19 mm 4. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Measure the pressures by using a pressure
gauge while the machine is traveling at both slow and fast speeds.
2. Repeat the measurement three times. Calculate the average value.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: In case the measured results are out of specifications, check the primary pilot pressure. When the primary pilot pressure is normal, the solenoid valve or electrical system may be faulty.
T2BC-04-05-007
NOTE: The illustration shows the left travel.
T324-06-04-025
Pressure Gauge
Nipple 7/16-20UNF
Adapter7/16-20 UNF
(Hose)
Travel Fast / Slow Speed Control Hose
Elbow
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
SLEWING BRAKE RELEASE PRESSURE
Preparations: 1. Stop the engine. 2. Remove the slewing brake release hose from
port Pb (G 1/4) on the slewing motor. : 22 mm
3. Install the adapter to the tee. Install the hose and nipple to the adapter. Install the pressure gauge unit to the nipple.
: 22 mm, 19 mm 4. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. With the slewing brake switch turned to both the
ON and OFF positions, measure the slewing brake release pilot pressure.
2. Repeat the measurements three times. Calculate the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: In case the measured results are out of specifications, check the primary pilot pressure. When the primary pilot pressure is normal, the solenoid valve or electrical system may be faulty.
Slewing Motor
Tee
T25N-04-05-009
Slewing Brake Release Hose
Pressure Gauge
Nipple 9/16-18UNF
T324-06-04-025
Adapter9/16-18 UNF
(Hose)
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE PRESSURE Front / Rear Control Valve
Preparations: 1. Stop the engine. 2. Install a pressure gauge to the pressure check
ports (a1, a2)(G1/4) at the delivery port side of main pump (pump 1, pump 2).
: 6 mm 3. Measurement of the main relief valve set
pressure on the front control valve (connected to pump 1): Remove pipe (3) for the forward of right travel motor and install the plug. Measurement of the main relief valve set pressure on the rear control valve (connected to pump 2): Remove pipe (1) for the forward of left travel motor and install the plug.
4. Start the engine. Check for oil leaks at the pipe connection part.
5. Maintain the hydraulic oil temperature at 50 5 C(122 41 F).
Measurement:1. Run the engine at the maximum speed. 2. Measure main relief valve set pressure on the
front control valve (connected to pump 1) with the right travel lever stroked in the FORWARD position.Measure main relief valve set pressure on the rear control valve (connected to pump 2) with the left travel lever stroked in the FORWARD position. Read the pressure when the relief valve relieves.
3. Repeat the measurements three times. Calculate the average values.
T2BC-04-05-006
T2BC-04-05-007
NOTE: The illustration shows the right travel.
Port a2 Port a1
Pump 2 Pump 1
Pipe for Forward Travel
Pipe for ReverseTravel
Travel Motor
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: Refer to TROUBLE SHOOTING in T5-4.
Adjustment: Check the pressure gauge and adjust the set pressure of main relief valve if necessary.
1. Loosen the lock nut. : 22 mm
2. Turn the adjusting screw. : 6 mm
3. Tighten lock nut (3) : 22 mm : 16.7 to 19.6 N m
(1.7 to 2.0 kgf m, 12 to 14 lbf ft) 4. Check the set pressure after adjustment.
W107-02-05-129
Main Relief Valve
Front Control Valve T25N-03-05-030
Main Relief Valve
Lock Nut
AdjustingScrew
Pressure DecreasePressure
Increase
Rear Control Valve T2BC-03-02-004
Lock NutAdjustingScrew
Main Relief ValveT326-06-04-002
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Slewing Control Valve
Preparations: 1. Stop the engine. 2. Install a pressure gauge to pressure check port
(a4) (G 1/4) at the slewing pump delivery port. 3. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Turn the slewing lock pedal in the LOCK position
and lock the slewing function. 2. Run the engine at the maximum speed. 3. Relieve the oil pressure by slowly pushing or
pulling the slewing control lever. Read the pressure at this time.
4. Repeat the measurement three times in each direction. Calculate the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Port a4
T2BC-04-05-006
Port a4
Slewing Pump
Slewing Lever
Slewing Lock Pedal
T2BC-01-02-006
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment: Check the pressure gauge and adjust the set pressure of main relief valve if necessary.
1. Loosen the lock nut. : 19 mm
2. Turn the adjusting screw. : 6 mm
3. Tighten lock nut (3) : 19 mm : 31.4 N m (3.2 kgf m, 23 lbf ft)
4. Check the set pressure after adjustment.
Main Relief ValveT25N-01-02-021
T326-06-04-002
W107-02-05-129
Pressure Increase
Pressure Decrease
Lock Nut
AdjustingScrew
Lock NutAdjustingScrew
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
4-Spool Control Valve
Preparations: 1. Stop the engine. 2. Install a pressure gauge to pressure check port
P’ in the 4-spool control valve. 3. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Run the engine at the maximum speed. 2. Operate and relieve the retract cylinder. Read the
pressure at this time. 3. Repeat the measurement three times in each
direction. Calculate the average values.
T2BC-04-05-008
Port P’
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Adjustment: Check the pressure gauge and adjust the set pressure of relief valve if necessary.
1. Loosen the lock nut. : 13 mm
2. Turn the adjusting screw. : 6 mm
3. Tighten the lock nut. : 6.9 to 8.8 N m
(0.7 to 0.9 kgf m, 5 to 6 lbf ft) 4. Check the set pressure after adjustment.
T2BC-04-05-008
Relief Valve
Lock Nut
AdjustingScrew
Pressure Decrease
Pressure Increase
W107-02-05-129
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
Lower Control Valve (Optional)
Preparations: 1. Stop the engine. 2. Remove the plug from pressure check port (PT
1/4) in the lower control valve. : 6 mm
3. Install a pressure gauge to the open part. 4. Start the engine. Check for oil leaks at the
pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).
Measurement:1. Run the engine at the maximum speed. 2. Relieve the jack-up cylinder by operating the
control lever to RETRACT. Read the pressure at this time.
3. Repeat the measurement three times in each direction. Calculate the average values.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Adjustment: Check the pressure gauge and adjust the set pressure of relief valve if necessary.
1. Remove the cap from the relief valve. 2. Turn the adjusting screw. 3. Install the cap. 4. Check the set pressure after adjustment.
Pressure Check Port Relief Valve
T2BC-04-05-009
Section A
AdjustingScrew CapRelief Valve
T2BC-04-05-010
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
PORT RELIEF VALVE PRESSURE
Summary: 1. No safe and reliable method to measure the
overload relief valve set pressure is available, because the circuit oil pressure must be raised by blocking the return circuit of the control valve and applying an external load to a hydraulic actuator. Doing so would create a high potential to easily damage the machine.
2. Comparing the oil flow rate delivered from the main pump, the quantity of relieving oil flow from the overload relief valve is very small. Therefore, checking the overload relief pressure by letting the main pump deliver oil to the overload relief valve does not meet the test conditions. Accordingly, if the check is required, remove the port relief valve assembly from the machine, and perform the unit test of the port relief valve on a specified test bench using the correct oil flow rate.
3. As explained above, checking the port relief valve pressure setting on the machine is not recommended. Therefore, when the main circuit relief pressure is normal, the port relief pressure setting is also considered to be normal.
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN/SLEWING PUMP FLOW RATE
P-Q Control (Torque Control) Summary:
Main (pump 1, pump 2) / slewing pump performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main (pump 1, pump 2) / slewing pump delivery port to be measured. Use the moment limiter and a pressure gauge at the same time.
IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5% than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.
Preparations: 1. Stop the engine. Push the air bleed valve in
hydraulic oil tank and bleed air. Install a vacuum pump to the oil filler port.
NOTE: Operate the vacuum pump with the pump flow rate test line connected.
2. Remove the delivery hose from the control valve side of pump to be measured.
3. Install a portable hydraulic tester to the delivery hose to be removed.
4. Connect the portable hydraulic pressure tester to the control valve by using a hydraulic hose for a test.
5. Install a pressure gauge to the pump to be measured.
7. Remove the vacuum pump. Loosen the air bleed plug on the top of pump casing. Bleed air from the pump casing until oil only comes out.
8. Fully open the loading valve of portable hydraulic tester.
9. Start the engine. Check for oil leaks at the pressure gauge unit connector.
Measurement:1. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).2. Measure the maximum and minimum flow rates
under no load. 3. Select each switch position as follows:
Accelerator Grip Accelerator Lock SwitchFast Idle Slow Idle ON
4. Slowly close the loading valve of hydraulic tester. Measure the flow rates and engine speeds at each pressure point at the I=800 mA side in the P-Q curve. (Refer to T4-2.)
5. Repeat the measurements three times. Calculate the average values.
Air Bleed Plug
T2BC-04-05-006
Outlet for Pump 1 Pressure
Outlet for Slewing Pump Pressure
Outlet for Pump 2 Pressure
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation: 1. Convert the measured flow rates to those at the
specified pump speed using the following formulas:
2. Standard Flow Rate Refer to STANDARD SPECIFICATIONS in T4-2.
Pilot Characteristics (Swash Angle Proportional Solenoid Valve)
Summary: Main pump (pump 1, pump 2) performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main (pump 1, pump 2) pump delivery port to be measured. Use the moment limiter and a pressure gauge at the same time. As the maximum swash angle is fixed, the slewing pump need not be measured.
IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5% than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.
Preparations: 1. Check pilot circuit primary pilot pressure first.
Adjust pilot circuit primary pilot pressure if necessary. (Refer to “Pilot Circuit Primary Pilot Pressure2” in this section.)
2. Referring to steps 1 to 4 on page T4-5-18, connect a hydraulic tester to the pump to be measured.
3. Remove the hose from port Pr1 in the swash angle proportional solenoid valve.
: 19 mm, 17 mm 4. Remove hose (7/16-20 UNF) from port Pi in the
pump to be measured. Pump 1: Port Pi1 Pump 2: Port Pi2
: 17 mm, 19 mm 5. Install the hose removed from port Pr1 to port Pi
in the pump to be measured. At this time, use a conversion adapter because of difference of screw.
: 17 mm, 19 mm NOTE: The screws for port Pr1 in the swash angle
proportional solenoid valve and for port Pi in the pump are G1/4. Therefore, if removing the elbow from port Pr1 and replacing it with the elbow of port Pr1, the conversion adapter need not be used.
6. Remove the connector from displacement angle proportional solenoid valve.
7. Remove the hose for power increase solenoid valve.
8. Install a pressure gauge to the hose at secondary pressure side in 4-spool solenoid valve.
9. Remove the vacuum pump. Loosen the air bleed plug on the top of pump casing. Bleed air from the pump casing until oil only comes out.
10. Fully open the loading valve of hydraulic tester. 11. Start the engine. Check for oil leaks at the pipe
connection part.
Measurement:1. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F).2. The pump flow rate in response to the external
command pilot pressure is measured. 3. Select each switch position as follows: Accelerator Grip Accelerator Lock Switch
Fast Idle ON 4. Adjust the set pressure of 4-spool solenoid valve
to each pressure point specified along the main / slewing pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-5, 7) Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve.
5. Repeat the measurements three times. Calculate the average values.
T2BC-04-05-013
Pump 2 Pump 1
Air Bleed Plug
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Connection of Portable Hydraulic Tester
T2BC-04-05-012
Connection of Pressure Gauge
T2BC-04-05-017
Connecting Port
T2BC-04-05-014
Control ValvePortable Hydraulic Tester
Pump
Delivery Hose LoadingValve
Hydraulic Hose for Test
Port Pi1 Port Pr1
Port Pi2
Swash Angle Proportional Solenoid Valve
Hose for Power Increase
Pilot Pump
4-Spool Solenoid Valve Unit Pressure Gauge
To Main Pump
Tee
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation: 1. Convert the measured flow rates to those at the
specified pump speed using the following formulas:
adjusting screw (1). Rotating adjusting screw (1) 1/4 a turn clockwise increases the minimum pump flow rate by 5.0 L/min. (305 in3/min).
: 24 mm : 130 N m (13.3 kgf m, 96
lbf ft)
• Other control characteristics remain unchanged. Check that the required power is increased at maximum delivery pressure if tightened excessively.
• Securely retighten lock nut (3) after adjustment.
2. Maximum Flow Rate Loosen lock nut (4) and turn adjusting screw (2). Rotating adjusting screw (2) 1/4 a turn clockwise decreases the maximum pump flow rate by 6.2 L/min. (378 in3/min).
30 mm 240 N m (24.5 kgf m,
177 lbf ft)
• Other control characteristics remain unchanged, except that only maximum oil rate varies.
• Securely retighten lock nut (4) after adjustment.
Main Pump 1 Main Pump 2
2
11
3 344
Q
I
I
Q
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
Torque Adjustment (P-Q Control) For torque adjustment, similarly adjust both the adjusting screws (5) and (6) at main pumps 1 and 2. Pressure change due to adjustment is that when both the pumps are pressurized at the same time.
9 8
T1F3-03-01-008
Adjustment Item Adjustment Procedure Remarks1. Outer Spring Adjustment Loosen lock nut (7) and turn
adjusting screw (5).
Rotating adjusting screw (5) 1/4 a turn clockwise: •Compensating:
+ 1.75 Mpa (17.8 kgf/cm2, 254 psi)
•Torque: + 84.3 N m (8.6 kgf m, 62 lbf ft)
: 46 mm : Lock Nut (7) : 160 N m (16.5 kgf m, 118
lbf ft)
•When adjusting screw (5) is turned, inner spring (8) set-force varies. Therefore, when adjusting screw (5) is turned clockwise, turn adjusting screw (6) 2.17 times turns of adjusting screw (5) counterclockwise.
•Securely retighten lock nut (7) and Lock nut (10) after the adjustment.
2. Inner Spring Adjustment Loosen lock nut (10) and turn adjusting screw (6).
adjusting screw (2). Rotating adjusting screw (2) 1/4 a turn clockwise decreases the maximum pump flow rate by 3.2 L/min. (195 in3/min).
: 24 mm : 130 N m (13.3 kgf m, 96
lbf ft)
•Other control characteristics remain unchanged, except that only maximum oil rate varies.
•Securely retighten lock nut (4) after the adjustment.
Q
Pi
1
2
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
SLEWING MOTOR DRAINAGE
Summary: Turn the slewing lock lever to the LOCK position and turn the slewing brake switch in ON. Operate the slewing lever and relieve the slewing relief valve. Under this condition, measure the drain oil amount from the slewing motor and check the slewing motor performance.
1. Secure the inspectors’ safety during measurement. Take care not to damage any surrounding buildings or vegetation.
2. The amount of drain oil from the slewing motor will be greatly affected by the oil temperature. Maintain the oil temperature in the proper range.
Preparation: 1. Place the machine or a level and solid ground
with ample space for slewing. Do not measure on a slope.
2. Maintain the hydraulic oil temperature at 50 5 C(122 41 F). Rotate the slewing motor and warm the inside of motor.
3. Stop the engine. Disconnect drain hoses from the slewing motor at the return oil port to the hydraulic oil tank. Put plugs (1-7/16-12UN) to the removed return oil ports to the hydraulic oil tank.
: 41 mm
Drain Hose
T25N-04-05-009
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:Amount of Oil Drained While Relieving Slewing.
1. Attach the basic boom with the boom angle set at 60 . (Or dismount the front attachment and counterweight.)
2. Turn the slewing lock lever placed to the LOCK position and turn the slewing brake switch in ON.
3. Start the engine and run it at the fast idle speed. While operating the slewing lever full stroke, receive the hydraulic oil coming out of the drain hose and measure the time and the volume at the same time.
4. Repeat the measurement three times each in both clockwise and counterclockwise directions and calculate the average value.
5. Take the measurement for more than 45 seconds.
Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.
Conversion of the Measured Values Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below:
Q = q
Where:Q: Drain Oil Amount (L/min)
t: Measuring Time (sec) q: Measured Drain Oil Amount (L)
60
2 m (6.5 ft)
T2BC-04-04-003
60t
T107-06-05-008
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary: 1. The travel motor performance is checked by
measuring the drain oil amount from the travel motor while driving the machine straight on a level solid surface to rotate the travel motor.
2. Secure the inspectors’ safety during the measurement. Take care not to damage any surrounding buildings or vegetation. Use a guide to check the safety in the front of and the rear of the machine.
3. The travel motor performance should be judged comprehensively while referring to the check results of travel speeds, mistrack amount together with the drain oil amount.
4. Drain oil amount from the travel motor will be greatly affected by the oil temperature. Maintain the oil temperature in the proper range.
Preparations: 1. Maintain the hydraulic oil temperature at 50 5 C
(122 41 F). Rotate the travel motor and warm the inside of motor.
2. Stop the engine. Remove drain hose (1) from the travel motor. Install plug (3/4-16UNF) to the removed hose end. Install drain measuring hose (3/4-16UNF) to the travel motor.
: 27 mm
Drain Hose Travel Motor
T2BC-04-05-007
NOTE: The illustration shows the left travel.
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
CAUTION: When doing any work near the rotating parts, take care not to allow your hand, foot, and/or clothes to become entangled in the rotating parts.
1. Attach the basic boom with the boom angle set at 60 . (Or dismount the front attachment and counterweight.)
2. Insert a round bar (Dia. 100mm, Length 200mm) between drive tumbler and track link.
3. Start the engine. Run the engine at maximum speed. Operate the travel lever to FORWARD according to the guide and relieve the travel.
4. Receive the hydraulic oil coming out of the drain hose and measure the time at the same time.
5. Repeat the measurement three times each side and calculate the average value.
6. Take the measurement for more than 45 seconds.
Evaluation: * Conversion of the Measured Values
Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below:
Q = q
Q : Drain Oil Amount (L/min) t : Measuring Time (sec) q : Measured Drain Oil Amount (L)
60
2 m (6.5 ft)
T2BC-04-04-003
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
BOOM DERRICKING MOTOR DRAINAGE
Summary: 1. Engage the boom derricking drum lock. Operate
the boom derricking lever to LOWER slowly in order to relieve. Under this condition, measure the drain oil amount from the boom derricking motor and check the boom derricking motor performance.
2. Secure the inspectors’ safety during measurement. Take care not to damage any surrounding buildings or vegetation.
3. Drain oil amount from the boom derricking motor will be greatly affected by the oil temperature. Maintain the oil temperature in the proper range.
Preparations:
CAUTION: Check around the drum, the condition of boom and hook, and the safety around machine.
1. Rotate the boom derricking motor and warm the inside of motor. Maintain the hydraulic oil temperature at 50 5 C (122 41 F).
2. Stop the engine. Remove the drain hose from the boom derricking motor at the return oil port to the hydraulic oil tank. Install plug (13/16-16UN) to the removed return oil ports to the hydraulic oil tank.
: 27 mm 3. Disconnect the derricking drum lock cylinder
hose at port A. Install plug (9/16-18 UNF).
T2BC-04-05-016
T2BC-04-05-015
Derricking Drum Lock cylinder Port A Drain Hose
Boom Derricking Motor
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:1. Attach the basic boom with the boom angle set at
60 .(Or dismount the front attachment and counterweight.)
2. Start the engine and engage the derricking drum lock. Operate the boom derricking lever to LOWER slowly in order to relieve and run the engine at the maximum speed.
3. Receive the hydraulic oil coming out of the drain hose and measure the time at the same time.
4. Repeat the measurements three times. Calculate the average values.
5. Take the measurement for more than 45 seconds.
Evaluation: * Conversion of the Measured Values
Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below:
Q = q
Q : Drain Oil Amount (L/min) t : Measuring Time (sec) q : Measured Drain Oil Amount (L)
2 m (6.5 ft)
60
T2BC-04-04-003
T4-5-31
This Page Left Blank Intentionally
OPERATIONAL PERFORMANCE TEST / Adjustment
MC2/A ADJUSTMENT
When the following repair or check is carried out, or when the engine speed is deviated, adjust MC2/A.
Description Adjusting items
When MC2/A is replaced 1, 2, 3, 4
When the engine or fuel injection pump is replaced
1, 2, 4
When the engine control cable or governor motor is replaced When engine high idle speed de-creases
1
When the pump or pump power increase solenoid valve is replaced
3
MC2/A adjustment falls into four below.
Adjustment items1. High idle calibration
Makes MC2/A store the position where the output of governor potentio sensor becomes constant (or the engine governor lever gets in contact with high idle stopper) at upper limit of the governor. (Refer to Section "Engine Control, Control System".)
2. Rack zero calibration Makes MC2/A store zero calibration of the rack sensor at engine stopping. (Refer to Section "Engine Control, Control Sys-tem".)
3. Power increase pressure calibration Makes MC2/A store power increase output cali-bration data. (Refer to Section "Engine Control, Control Sys-tem".)
4. Full rack calibration Makes MC2/A store high idle governor position and rack sensor calibration under full load. (Refer to Section "Pump Control, Control Sys-tem".)
IMPORTANT: Full rack calibration must be made when item 1 (high idle calibration), and item 3 (power increase pressure calibration) are carried out correctly. If the above-mentioned items are done incorrectly, wrong rack calibra-tion is stored, reducing pump horsepower.
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
HIGH IDLE CALIBRATION
Adjustment:1. Turn drum rotation sensing switch (4) for front /
rear / boom derricking drums to ON position. 2. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn key switch (2) to ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
3. After pilot pressure indicator (1) blinks, turn ac-celerator lock switch (3) to accelerator unlock po-sition (OFF).
Monitor Panel
1
2
T2BC-04-06-001
Right Control Panel
3
T2BC-04-06-003
Side Overhead Panel
T2BC-04-06-002
4
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
1. Turn front drum auto stop cancellation switch (5) to ON position.
NOTE: Now, MC2/A turns the governor motor in forward direction. (Refer to Section "Control System".)
2. If pilot pressure Indicator (1) at monitor panel blinks other than every 0.5 second, turn front drum auto stop cancellation switch (5) to OFF position.
NOTE: Normal completion: Pilot pressure Indicator (1): ON Abnormal completion: Pilot pressure Indicator (1): Blinking every 0.1 second
Normal completion condition:• Engine : Stop • Governor motor output : Available • Governor motor setting count:
Motor rotation control range setting (145 to 356 counts (12.83 to 31.5 )
IMPORTANT: When turning the key switch to OFF position, record the completed cali-bration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time.
3. Turn key switch (2) to OFF position and check if five seconds or longer pass.
Monitor Panel
1
2
T2BC-04-06-001
Left Control Panel 5
T2BC-04-06-004
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
RACK ZERO CALIBRATION
Adjustment:
1. Turn drum rotation sensing switch (4) for front / rear / boom derricking drums to ON position.
2. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn key switch (2) to ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
3. After pilot pressure indicator (1) blinks, turn ac-celerator lock switch (3) to accelerator unlock po-sition (OFF).
Monitor Panel
1
2
T2BC-04-06-001
Right Contorl Panel
3
T2BC-04-06-003
Side Overhead Panel 4
T2BC-04-06-002
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
1. Turn rear drum auto stop cancellation switch (6) to ON position.
NOTE: Now, MC2/A sets the governor lever to the low idle position. (Refer to Section "Control System".)
2. If pilot pressure indicator (1) at monitor panel blinks other than every 0.5 second, turn rear drum auto stop cancellation switch (6) to OFF position.
NOTE: Normal completion: Pilot pressure indicator (1): ON Abnormal completion: Pilot pressure indicator (1): Blinking every 0.1 second
normal range (0.25 to 4.75 V) • Rack sensor input voltage : Rack sensor zero
point setting range (1.5 to 4.5 V) • Governor motor initial position setting:
Normal completion
IMPORTANT: When turning key switch (2) to OFF position, record the completed cali-bration to EEPROM (MC2/A) for five seconds. Do not operate the key switch (2) during this time.
3. Turn key switch (2) to OFF position and check if five seconds or longer pass.
Monitor Panel
1
2
T2BC-04-06-001
Left Control Panel
T2BC-04-06-004
6 5
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
POWER INCREASE PRESSURE CALI-BRATION
Preparation:1. Install a pressure gauge (5 Mpa) to the pressure
check port.
Adjustment:1. Turn drum rotation sensing switch (4) for front /
rear / boom derricking drums to ON position.2. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn key switch (2) to ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
3. After pilot pressure indicator (1) blinks, turn ac-celerator lock switch (3) to accelerator unlock po-sition (OFF).
Side Overhead Panel
T2BC-04-06-002
T25N-04-06-001 Pressure Check Port
Power Increase Solenoid Valve
Monitor Panel
1
2
4 T2BC-04-06-001
Right Control Panel
3
T2BC-04-06-003
T4-6-6
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
1. Start the engine.2. Turn front drum auto stop cancellation switch (5)
and rear drum auto stop cancellation switch (6) to ON position.
NOTE: Now, MC2/A blinks pilot pressure indicator (1) at monitor panel. (Refer to Section "Control System".)
3. If pilot pressure indicator (1) blinks other than every 0.5 second, turn front / rear drum auto stop cancellation switches (5, 6) to OFF position.
4. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF).
NOTE: Now, the power increase pressure de-creases gradually. Pilot pressure indicator (1) blinks a cycle of 0.4 second ON and 0.1 second OFF during this time.
5. When the power increase pressure reaches the set pressure (0.3 MPa), turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF).
NOTE: Normal completion:Pilot pressure indicator (1): ON Abnormal completion:Pilot pressure indicator (1): Blinking every 0.1 second
Normal completion condition:• Power increase electric current offset Offset
adjusting range (150 mA) [Power increase electric current offset = Output current - Adjustment point power increase electric current (608 mA)]
• Output current Upper limit electric current (800 mA)
Left Control Panel
T2BC-04-06-004
IMPORTANT: When turning the key switch (2) to OFF position, record the completed calibration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time.
6. Turn the key switch (2) to OFF position and check if five seconds or longer passes.
7. Remove the pressure gauge.
Monitor Panel
1
2
T2BC-04-06-001
Right Control Panel
3
T2BC-04-06-003
6 5
T4-6-7
OPERATIONAL PERFORMANCE TEST / Adjustment
FULL RACK CALIBRATION
Preparation:1. Turn slewing lock pedal to LOCK position and
apply the slewing brake. 2. Disconnect the connector from front motor brake
release solenoid valve (8).
Adjustment:1. Turn drum rotation sensing switch (4) for front /
rear / boom derricking drums to ON position. 2. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn key switch (2) to ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
3. After pilot pressure indicator (1) blinks, turn ac-celerator lock switch (3) to accelerator unlock po-sition (OFF).
Left Control Panel
T2BC-04-06-004
Front Motor
T2BC-04-06-005
Monitor Panel
1
2
7
T2BC-04-06-001
Right Control Panel
3
8
T2BC-04-06-003
Side Overhead Panel 4
T2BC-04-06-002
T4-6-8
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Stating
1. Start the engine. 2. Turn boom derricking drum auto stop cancellation
switch (7) to ON position. NOTE: Now, MC2/A blink pilot pressure indicator
(1) at monitor panel. (Refer to Control Sys-tem / SYSTEM)
3. If pilot pressure indicator (1) blinks other than every 0.5 second, turn boom derricking drum auto stop cancellation switch (7) to OFF position.
4. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF).
NOTE: As result, the engine speed becomes high idle and the main pump delivery flow is maximized.
5. When the engine speed reaches 2000 min-1 or more, pilot pressure indicator (1) at monitor panel blinks at cycle of 0.1 second ON and 0.4 second OFF.
6. After the blinking of pilot pressure indicator (1) changes, carry out hoisting by using the front drum lever while operating the slewing lever.
NOTE: Pilot pressure indicator (1) blinks a cycle of 0.4 second ON and 0.1 second OFF. After this, when the engine speed reaches the set speed (1950 min-1) or less, MC2/A stores it as a full rack.
7. When the engine speed reaches the set speed (1950 min-1) or less, MC2/A automatically reads the rack date. After reading it, the engine speed becomes low idle.
NOTE: Normal completion: Pilot pressure indicator (1): ON Abnormal completion: Pilot pressure indicator (1): Blinking every 0.1 second.
Normal Completion condition: Engine speed Set speed (1950 min-1)• Rack sensor input voltage Rated rack point ad-
justment lower limit (2.803 V) Engine speed Set speed (1950 min-1) • Rack sensor input voltage Rated rack point
lower limit in full load (2.352 V) • Maximum power increase
IMPORTANT: When turning key switch (2) to OFF position, record the completed cali-bration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time.
8. Turn key switch (2) to OFF position and check if five seconds or longer pass.
9. Connect the connector to front motor brake re-lease solenoid valve (8).
T4-6-9
OPERATIONAL PERFORMANCE TEST / Adjustment
BRAKE PEDAL UNIT ADJUSTMENT
IMPORTANT: After repairing or inspecting the brake pedal unit, adjust the brake pedal unit. If failing to make this adjustment, the brake is unlikely to work.
Adjustment:Adjusting brake pedal position
1. Tighten lock nut (1) so that dimension A becomes specification. Dimension A: 45 1 mm
2. Loosen lock nut (2). Tighten stopper bolt (3) until lever (4) is clear of stopper bolt (3).
3. At this time, confirm that rod (8) of pres-sure-reducing valve is pushed to its stroke end.
4. Confirm that floor plate (6) and height of pin (5) (dimension C) are set to specification. Dimension C: 80±2 mm (3.1±0.08 in)
5. If dimension C is different from specification, ad-just as follows.
1-1. Loosen lock nut (7). 17 mm
1-2. Set a spanner at width across flats (9) of rod (8) and turn rod (8) in the adjusting direction.
14 mm
1-3. When dimension C becomes specification, loosen lock nut (7).
17 mm 19.5 2.0 N m(2.0 0.2 kgf m, 14.5±1.5 lbf ft)
6. Loosen stopper bolt (3) until stopper bolt (3) gets in contact with lever (4).
7. When stopper bolt (3) contacts lever (4), loosen stopper bolt (3) a half turn from that position and lock with lock nut (2).
IMPORTANT: When if dimensions B and C are dif-ferent from specification, return to Step 2 above for readjustment.
8. Confirm that dimensions B and C meet specifica-tion.Dimension B: 27 to 28 mm (1.06 to 1.10 in)
10. Lower lever (4) until rod (8) of pressure-reducing valve reaches its stroke end and hold lever (4) in position.
11. Loosen stopper bolt (11) until stopper bolt (11) gets in contact with lever (4).
12. When stopper bolt (11) contacts lever (4), loosen stopper bolt (11) a half turn from that position and lock with lock nut (10).
Adjusting pedal lock position13. Loosen two bolts (13).
IMPORTANT: If lock position is too low, unlocking is unlikely to be made. Adjust it with care.
14. By changing the thickness of shim (14) and by repositioning the latch (12), make adjustment so that stroke required for unlocking the pedal is ob-tained and locking at stroke end is achieved.Thicknesses of shims (14): 4.5 mm (0.18 in)
6.0 mm (0.24 in) 9.0 mm (0.35 in) 12.0 mm (0.47 in)
15. In pedal lock position, confirm that dimension D meets specification. Dimension D: 40 mm or more
Group 3 Troubleshooting ATroubleshooting A Procedure ................ T5-3-1Failure of MC2/A or MC2/B Battery and
Sensor System Power Supply............ T5-3-10 Failure of Engine Controller System ...... T5-3-25 Failure of Brake Control System............ T5-3-32 Failure of Main Pump Delivery Flow
Rate Control System.......................... T5-3-62Failure of Main Pump Power Increase
Control System .................................. T5-3-65Failure of Slewing
Alarm Control System ........................ T5-3-68Failure of Rotation
Sensing Control System..................... T5-3-72Failure of Engine Start
Interlock Control System.................... T5-3-82 Failure of Pilot Pressure Drop Warning
Lamp Control System......................... T5-3-88Failure of Monitor Cutoff Pressure
Control System .................................. T5-3-90Failure of Derricking Drum
Auto Stop Control System .................. T5-3-92
Failure of Front Drum Auto Stop Control System .................. T5-3-109
Failure of Rear Drum Auto Stop Control System .................. T5-3-114
Failure of Third Drum Auto Stop Control System .................. T5-3-119
Failure of FourthDrum Auto Stop Control System (Optional) .................. T5-3-127
Failure of Second Overhoist Auto Stop Control System .................. T5-3-134
Failure of Front and Rear Motor Speed Control System........................ T5-3-138
Failure of Front Drum Surge Pressure Reduction Control System.................. T5-3-143
Failure of Tower Jib Derricking 2-Speed Flow Combining Limit Control System ........ T5-3-145
Group 4 Troubleshooting B Troubleshooting B Procedure ................ T5-4-1Troubleshooting List............................... T5-4-2Engine System Troubleshooting ............ T5-4-3 Power Supply System Failure ................ T5-4-6Actuator Troubleshooting ....................... T5-4-19Hoist Drum Troubleshooting .................. T5-4-20 Boom Derricking Drum Troubleshooting T5-4-28 Slewing System Troubleshooting ........... T5-4-30 Travel System Troubleshooting.............. T5-4-33 Other Troubleshooting ........................... T5-4-36
2BCT-5-2
Group 5 Troubleshooting C Trobleshooting C Procedure .................. T5-5-1Malfunction of
Coolant Temperature Gauge .............. T5-5-2Malfunction of Fuel Gauge..................... T5-5-4Malfunction of
Engine Oil Pressure Indicator ............ T5-5-6 Malfunction of Coolant Level Indicator... T5-5-7 Malfunction of Engine Oil Filter
Restriction Indicator ........................... T5-5-9 Malfunction of Air Filter
Restriction Indicator ........................... T5-5-11 Malfunction of Overheat Indicator .......... T5-5-13 Malfunction of Controller
Failure Indicator ................................. T5-5-15Malfunction of Preheat Indicator ............ T5-5-17 Malfunction of Alternator Indicator ......... T5-5-18 Malfunction of Brake Unapplied Indicator T5-5-20 Malfunction of Pilot Pressure
Drop Indicator .................................... T5-5-21Malfunction of Hour Meter ..................... T5-5-22
Group 9 Electrical System Inspection Precautions for Inspection
and Maintenance................................ T5-9-1Instruction for Disconnecting Connectors T5-9-3Battery Voltage Check ........................... T5-9-4Fusible Link Inspection .......................... T5-9-5Fuse Inspection ..................................... T5-9-6How to Check Alternator ........................ T5-9-9Voltage Check........................................ T5-9-10Check by False Signal ........................... T5-9-19Continuity Check.................................... T5-9-20
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Inspection procedures for troubleshooting are presented in an orderly fashion in this section in order to enable you locate the source of any problems that may arise.
The troubleshooting section consists of 9 groups: the diagnosing procedure, component layout, troubleshooting A (control system), troubleshooting B (base machine operation system), troubleshooting C (monitor system), troubleshooting D (IDU system), troubleshooting E (engine control system), troubleshooting F (crane monitor system) and electrical system inspection.
• Troubleshooting A (Control System) Use this group when a controller failure indicator on the monitor panel is blinking.Example: Abnormal accelerator control.
• Troubleshooting B (Base Machine Operation System) Use this group when any trouble exists in the base machine operation system except the main controller and/or auto-stop controller system.Example: Hoist and/or lower function is inoperable.
• Troubleshooting C (Monitor System) Use this group when any trouble regarding monitors such as gauges and/or indicators occur.Example: Fuel gauge is inoperable.
• Troubleshooting D (IDU System) Use this group when auto-stop is performed although auto-stop is not required.
• Troubleshooting E (Engine Control System) Use this group when blinking the ECU lamp and displaying the fault code.(ECU records the trouble condition of electrical signal system as a fault code by using a self-diagnosis function.)
• Electrical System Inspection Refer to this group when precautions and/or inspection data for the electrical system check is required.
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient troubleshooting:
1. Study the system Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.
2. Ask the operatorBefore inspecting, get the full story of malfunctions from your star witness --- the operator.
(a) How is the machine being used? (Find out if the machine is being operated correctly)
(b) When was the trouble noticed, and what types of work the machine doing at that time?
(c) What are details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time?
(d) Did the machine have any other troubles previously? If so, which parts were repaired before?
3. Inspect the machineBefore starting the troubleshooting procedure, cheek the machine’s daily maintenance points, as shown in the operator’s manual.
Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.
If troubleshooting is started without noticing a blown fuse, incorrect diagnosis may result along with a large amount of lost time. Be sure to check if any fuse has blown before starting troubleshooting.Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Always check fuses using a tester.
T107-07-01-001
T107-07-01-002
T107-07-01-003
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses.
5. Perform troubleshooting
CAUTION: Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines.
First identify in which group the trouble is present. Then, perform the troubleshooting, system by system, in accordance with the classification of Troubleshooting A, B, C, D and E as described in this group.
6. Trace possible causesBefore reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.
T324-07-01-002
T324-07-01-003
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
POWER SUPPLY MONITOR
Outputs monitoring results and conversion values of A/D voltage at IDU in terms of main power voltage of MC2/A and MC2/M, 5 V sensor power voltage and 24 V sensor power supply voltage. Monitoring results and A/D voltage conversions are indicated on the display connected to IDU.
Indication1. Turn ON the maintenance key switch, press
key on the ML window and indicate the maintenance menu.
2. Select "Monitor" by pressing or key and press key in order to indicate the monitor menu.
3. Select "Power Supply Monitor" in the monitor menu by using or key and press key.
Maintenance Key Switch T25N-05-01-001
Boom suspend
Jibsuspend
1-rope reeving
4-rope reeving
Overheat
Hyd. oil temp.
Brake oil temp.
Suspend selection Menu
Maintenance Menu Load FactorLoad Factor
1. Inspection Menu
2. Adjustment Menu
5. Record Menu
3. Monitor
4. Version Indication Menu
6. Spec Setting Menu
7. Service Manual
Selection Cancellation Determination
Monitor Menu Load Factor
Selection Cancellation Determination
1. Power Supply Monitor
2. Key Check
3. IDU Monitor
4. MC2/A Monitor
5. MC2/B Monitor
T5-1-4
TROUBLESHOOTING / Diagnosing Procedure
Power Supply Monitor
MC2/A Input / Output Monitor
Page Selection Return
MC2/AMAIN_B NORMAL
5V LOW ER
24V_1 HI ER
24V_2 SHORT
24V_3 SHORT
1/1
Description
Item
MC2/BMAIN_B NORMAL
5V LOW ER
24V_1 HI ER
24V_2 SHORT
24V_3 SHORT
IDUMAIN_B xx. xxV
5V x. xxV
10V xx. xxV
24V xx. xxV
Item Signal NameMAIN_B Main power supply5V Analog sensor power supply24V_1 For each switch input24V_2 For throttle control switch
MC2/A
24V_3 For emergency operation switchMAIN_B Main power supply5V Analog sensor power supply
24V_1 For three-winding layer detector (No connection)
24V_2 For overhoist switch on machine
MC2/B
24V_3 For overhoist switch on attachmentMAIN_B Main power supply5V Angle detector power supply10V Load detector power supply
IDU
24V Power supply for shift switch (No connection)
Description ExplanationNORMAL NormalLOW ER Lower limit error HI ER Upper limit error SHORT Short circuit xx. xxV A/D voltage
conversionCommunication error
T5-1-5
TROUBLESHOOTING / Diagnosing Procedure
TROUBLESHOOTING MONITOR
Outputs diagnostic results of analog inputs, digital inputs and digital outputs of MC2/A, MC2/B and IDU. Diagnostic results are indicated on the display connected to IDU.
Indication1. Turn ON the maintenance key switch, push the
key on the ML screen and indicate the maintenance menu.
2. Select "Monitor" by using or switch and press key in order to indicate the monitor menu.
3. Select the wanted item in the monitor Menu by using or key and press key.
T25N-05-01-001
Maintenance Key Switch
Boom suspend
Jibsuspend
1-rope reeving
4-rope reeving
Overheat
Hyd. oil temp.
Brake oil temp.
Suspend selection Menu
Maintenance Menu
1. Inspection Menu
2. Adjustment Menu
5. Record Menu
3. Monitor
6. Spec Setting Menu
7. Service Manual
Selection
Load FactorLoad Factor
Monitor Menu Load Factor
Cancellation Determination
Selection Cancellation Determination
1. Power Supply Monitor
2. Key Check
3. IDU Monitor
4. Version Indication Menu
5. MC2/B Monitor
4. MC2/A Monitor
T5-1-6
TROUBLESHOOTING / Diagnosing Procedure
MC2/A Analog Inputs
Item Signal name THROT. GRIP Accelerator grip signal THROT. FOOT Accelerator pedal signal RACK. P. Rack position signal THROL. M. P. Governor motor potentio sensor signalSL CTRL SP Slewing speed dial signal
(No connection) THRT. 3RD Third drum acceleration TRRGT.PRS Right travel remote control pressure
MC2/AAI1
TRLFT. PRS Left travel remote control pressure DD HST PRS Derricking drum hoisting remote
control pressure DD LWR PRS Derricking drum lowering remote
control pressure FD HST PRS Front drum hoisting remote control
pressureFD LWR PRS Front drum lowering remote control
pressureRD HST PRS Rear drum hoisting remote control
pressureRD LWR PRS Rear drum lowering remote control
pressure3D HST PRS Forrth drum hoisting remote control
pressure
MC2/AAI2
3D LWR PRS Third / fourth lowering remote control pressure
SL RGT PRS Slewing (right) remote control pressureSL LFT PRS Slewing (left) remote control pressure PILOT PRS Primary pilot pressure FD BRK PRS Front brake depressing pressure RD BRK PRS Rear brake depressing pressure 3D BRK PRS Fourth brake depressing pressure (AN_IN22) No connection
MC2/AAI3
(AN_IN23) No connection
MC2/A Input / Output Monitor
Page Selection Return
MC2/A AI1 THROT. GRIP NORMAL
THROT. FOOT NORMAL
RACK. P. HI ER
THROL. M. P. NORMAL
SL CTRL SP 2.50 V
THRT. 3RD LOW ER
TRPGT. PRS HI ER
TRLFT. PRS RSV ER
1/4
Description
Item
MC2/A AI2 DD HST PRS x. xMPa
DD LWR PRS LOW ER
FD HST PRS HI ER
FD LWR PRS RSV ER
RD HST PRS x. xMPa
RD LWR PRS LOW ER
3D HST PRS
MC2/A AI3 SL RGT PRS x. xMPa
SL LFT PRS LOW ER
PILOT PRS NORMAL
FD BRK PRS LOW ER
RD BRK PRS HI ER
3D BRK PRS RSV ER
Description ExplanationNORMAL NormalLOW ER Lower limit error HI ER Upper limit error RSV ER Spare
x. xV Normal (voltage) LOW ER Lower limit error HI ER Upper limit error RSV ER Spare
x. xMPa Operating pressure LOW ER Lower limit error HI ER Upper limit error DBL ER Double errors
****** Communication error
NORMAL Normal operation OFF LOW ER Lower limit error HI er Upper limit error RSV ER Normal operation ON
HI ER (AN_IN22) NORMAL
3D LWR PRS RSV ER (AN_IN23) LOW ER
T5-1-7
TROUBLESHOOTING / Diagnosing Procedure
MC2/A Digital Inputs
Item Signal nameFD FREE SW Front drum free mode switch RD FREE SW Rear drum free mode switch 3D FREE SW Third / fourth drum free mode switchENG. START Engine start signal THROT. FIX Throttle lock switch THROT. PRE Throttle preset switch GATE LOCK Gate Lock Switch
MC2/A SWITCH
SL BRK SW Slewing brake switch FD FREE MD Front drum free mode control RD FREE MD Rear drum free mode control 3D FREE MD Third / fourth drum free mode
controlRACK P. S. Rack position signal RACK P. STP Engine stop rack position RACK P. FUL Full rack position INC. TQ. CUR Power increase proportional
PMP. FIS. SW Maximum pump delivery lock switch (No connection)
MC2/A Input / Output Monitor
Page Selection Return
MC2/A SWITCH FD FREE SW ON
RD FREE SW OFF
3D FREE SW ON
ENG. START OFF
THROT. FIX ON
THROT. PRE OFF
GATE LOCK ON
SL BRK SW OFF
2/4
Description
Item
MC2/A CAN1 FD FREE MD
MC2/A CAN2 FD PLS CNT
Description ExplanationON Open contact OFF Closed contact BRAKE Auto brake mode FREE Free mode x. xx V A/D voltage conversion -xxxmA Electric current offset -xxxxx Drum pulse counter ROTATE Rotation STOP Stop CANCEL CancellationNORMAL NormalSHORT Short circuit CRANE CraneTOWER Tower OPEN Open circuit ****** Communication error
BRAKE -xxxxx
RD FREE MD BRAKE RD PLS CNT -xxxxx
3D FREE MD FREE DD PLS STOP
RACK P. S. x. xx V
RACK P. STP x. xx V OVERH2 SIG NORMAL
RACK P. FUL x. xx V ATTACHMENT SHORT
INC. TQ. CUR -xxxmA SD. CAN. SW OFF
OFFSET CUR xxxxmA PMP. FIX. SW OFF
T5-1-8
TROUBLESHOOTING / Diagnosing Procedure
MC2/A Digital Output
Item Signal nameM PMP CUR Main pump displacement angle
proportional solenoid valve INC. TQ CUR Power increase solenoid valve SL RGT CUR Slewing multi (right) proportional solenoid
valve (No connection) SL LFT CUR Slewing multi (left) proportional solenoid
valve (No connection) SL PMP CUR
Slewing pump swash angle proportional solenoid valve (No connection)
3D BRK REL Fourth drum brake release solenoid valveFD PLS SOL Front drum rotation sensing solenoid RD PLS SOL Rear drum rotation sensing solenoid DD PLS SOL Derricking drum rotation sensing solenoidSL PKS SOL Slewing remote control pressure
hydraulic source Solenoid (No connection)
MC2/A D02
CAL IB. CUR Calibration electric current DD LCK REL Derricking drum unlocking solenoid valveFM BRK REL Front motor brake release solenoid valveRM BRK REL Rear motor brake release solenoid valve
3M BRK REL Fourth motor brake release solenoid valve
MT CUT OFF Motor cutoff relay ENG. INTLCK Engine start interlock
3D BRK LP Third / fourth auto brake indicator
MC2/A D03
SL ALAM LP Slewing warning lamp relay
MC2/A Input / Output Monitor
Page Selection Return
MC2/A D01 M PMP CUR xxxxmA
INC. TQ CUR LOW ER
SL RGT CUR HI ER
SL LFT CUR RES ER
SL PMP CUR CANCEL
FD BRK REL xxxxmA
RD BRK REL LOW ER
3D BRK REL HI ER
3/4
Description
Item
MC2/A D02 FD PLS SOL NORMAL
RD PLS SOL
Description ExplanationxxxxmA Control current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error CANCEL Feedback cancellation
NORMAL NormalLOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Feedback cancellation
NORMAL Calibration electric current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Auxiliary
NORMAL NormalERROR Short circuit ****** Communication error
ERROR
DD PLS SOL NORMAL
SL PRS SOL ERROR
CAL IB. CUR NORMAL
MC2/A D03 DD LCK REL NORMAL
FM BRK REL ERROR
RM BRK REL NORMAL
3M BRK REL ERROR
MT CUT OFF NORMAL
ENG. INTLCK ERROR
3D BRK LP NORMAL
SL ALAM LP ERROR
T5-1-9
TROUBLESHOOTING / Diagnosing Procedure
ECU Status
Item Signal nameRECEIVE ECUTMR F. B. Timer feedback RACK P. S. Rack sensor TIMING S. Timing sensor TDC S. TDC sensor OVER H. S. Coolant temperature sensor
MC2/A_ECU1
TMR C. V. Timer control valve
MC2/A Input / Output Monitor
Page Selection Return
MC2/A_ECU1RECEIVE NORMAL
TMR F. B. ERROR
RACK P. S. NORMAL
TIMING S. ERROR
TDC S. INVLD
OVER H. S. ERROR
TMR. C. V. NORMAL
4/4
Description
Item
Description ExplanationNORMAL NormalERROR Error****** Communication error
T5-1-10
TROUBLESHOOTING / Diagnosing Procedure
MC2/B Analog Inputs
Item Signal nameFD CTRL SP Front drum speed setting dial signal
(No connection) RD CTRL SP Rear drum speed setting dial signal
(No connection) DD CTRL SP Derricking drum speed setting dial
signal (No connection) (AN_IN3) No connection (AN_IN4) No connection (AN_IN5) No connection (AN_IN6) No connection
MC2/B AI1
(AN_IN7) No connection TR RGT PRS Travel (right) remote control
pressureTR LET PRS Travel (left) remote control pressure(AN_IN10) No connection (AN_IN11) No connection (AN_IN12) No connection
MC2/B AI2
(AN_IN13) No connection FD ROPE ED Front drum three-winding layer
detection (No connection)) RD ROPE ED Front drum three-winding layer
detection (No connection)) 3D ROPE ED Front drum three-winding layer
detection (No connection)) (DAN_IN20) No connection (DAN_IN21) No connection (DAN_IN22) No connection
MC2/B DI
(DAN_IN23) No connection
MC2/B Input / Output Monitor
Page Selection Return
MC2/B AI1 FD CTRL SP NORMAL
RD CTRL SP LOW ER
DD CTRL SP HI ER
(AN_IN3) RSV
(AN_IN4) NORMAL
(AN_IN5) LOW ER
(AN_IN6) HI ER
(AN_IN7) RSV
1/3
Description
Item
MC2/B AI2 TR RGT PRS x. xMPa
TR LET PRS x. xMPa
(AN_IN10) NORMAL
(AN_IN11) LOW ER
(AN_IN12) HI ER
(AN_IN13) RSV
MC2/B DI FD ROPE ED R. END
RD ROPE ED ALLOFF
3D ROPE ED ALLON
(DAN_IN20) NORMAL
(DAN_IN21) ERROR
(DAN_IN22) NORMAL
(DAN_IN23) ERROR
Description ExplanationNORMAL NormalLOW ER Lower limit error HI ER Upper limit error RSV Spare x. xMPa Normal (pressure) DBL ER Double errors R. END Extra hoisting ALLOFF Open circuit ALLON Shorted harnesses ****** Communication error
T5-1-11
TROUBLESHOOTING / Diagnosing Procedure
MC2/B Digital Inputs
Item Signal nameDD REL SW Derricking drum auto stop release FD REL SW Front drum auto stop release RD REL SW Rear drum auto stop release 3D REL SW Third drum auto stop release HM FIX SW Hoisting motor low speed lock OH2 REL SW Second overhoist restoration switchJB FOLD Jib folding
MC2/BSWICH1
ATTACHMENT Wiring detection BM OVERH Boom overhoist BT OVERH2 Boom / tower second overhoist (No
connection)TW OVERH Tower overhoist BT LOWER L Boom / tower lower limit (No
connection)JB OVERH Jib overhoist JB OVERH2 Jib second overhoist HK OVERH Hook overhoist
SHORT Short circuit CRANE CraneTOWER Tower OPEN Open circuit
NORMAL NormalOVERH OverhoistALLOFF Open circuit ALLON Shorted harnesses LOWER Lower limit
NORMAL OperationSTOP Stop
****** Communication error
OVERH DD LWR STP STOP
TW OVERH ALLOFF FD HST STP NORMAL
BT LOWER L ALLON FD LWR STP STOP
JB OVERH NORMAL RD HST STP NORMAL
JB OVERH2 OVERH RD LWR STP STOP
HK OVERH ALLOFF 3D HST STP NORMAL
SWL OVERH ALLON 3D LWR STP STOP
T5-1-12
TROUBLESHOOTING / Diagnosing Procedure
MC2/B Digital Outputs
Item Signal nameDD HST CUR Derricking drum hoisting
proportional solenoid valve DD LWR CUR Derricking drum lowering
proportional solenoid valve FD HST CUR Front drum hoisting proportional
solenoid valve FD LWR CUR Front drum lowering proportional
solenoid valve RD HST CUR Rear drum hoisting proportional
solenoid valve RD LWR CUR Rear drum lowering proportional
solenoid valve FM CAP CUR Front motor swash angle
proportional solenoid valve
MC2/BD01
RM CAP CUR Rear motor swash angle proportional solenoid valve
GREEM LMP External indicator green (No connection)
YELLOW LMP External indicator yellow (No connection)
RED LMP External indicator red (No connection)
OVERH2 SOL Second overhoist solenoid valve3D HST SOL Fourth drum hoisting solenoid
valve3D LWR SOL Fourth drum lowering solenoid
valve
MC2/BD02
CALIB. CUR Calibration electric current
MC2/B Input / Output Monitor
Page Selection Return
MC2/B D01 DD HST CUR xxxxmA
DD LWR CUR LOW ER
FD HST CUR HI ER
FD LWR CUR RES ER
RD HST CUR CANCEL
RD LWR CUR xxxxmA
FM CAP CUR LOW ER
RM CAP CUR HI ER
3/3
Description
Item
MC2/B D02 GREEM LMP NORMAL
YELLOW LMP
Description ExplanationxxxxmA Control current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error CANCEL Feedback cancellationNORMAL NormalERROR Short circuit
NORMAL Calibration electric current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Auxiliary
****** Communication error
ERROR
RED LMP NORMAL
OVERH2 SOL ERROR
3D HST SOL NORMAL
3D LWR SOL ERROR
CALIB. CUR LOW ER
T5-1-13
TROUBLESHOOTING / Diagnosing Procedure
IDU Analog Inputs
Item Signal nameJB ANGLE Jib angle sensor (S) (No connection) JB ANGLE2 Jib angle (-) sensor (S) (No connection)BM ANGLE Boom angle sensor (S) (No connection)BM LOAD Boom derricking tension sensor JB LOAD Jib derricking tension sensor JB ANGLE Jib angle sensor (D) JB ANGLE2 Jib angle (-) sensor (D)
IDU AI1
BM ANGLE Boom angle sensor (D) (AN_IN0) No connection (AN_IN1) No connection (AN_IN2) No connection (AN_IN3) No connectionHYD THM Hydraulic oil temperature sensor FD BRK THM Front brake temperature sensor RD BRK THM Rear brake temperature sensor
IDU AI2
3D BRK THM Third brake temperature sensor (AN_IN8) No connection (AN_IN9) No connection (AN_IN10) No connection
IDU AI3
(AN_IN11) No connection
IDU Input / Output Monitor
Page Selection Return
IDU AI1 JB ANGLE X.XXV
JB ANGLE2 X.XXV
BM ANGLE X.XXV
BM LOAD X.XXV
JB LOAD X.XXV
JB ANGLE X.XXV
JB ANGLE2 X.XXV
BM ANGLE X.XXV
1/3
Description
Item
IDU AI3
Description ExplanationX.XX V A/D voltage conversion ****** Communication error
(AN_IN8) X.XXV
(AN_IN9) X.XXV
(AN_IN10) X.XXV
(AN_IN11) X.XXV
IDU AI2 (AN_IN0) X.XXV
(AN_IN1) X.XXV
(AN_IN2) X.XXV
(AN_IN3) X.XXV
HYD THM X.XXV
FD BRK THM X.XXV
RD BRK THM X.XXV
3D BRK THM X.XXV
T5-1-14
TROUBLESHOOTING / Diagnosing Procedure
IDU Digital Inputs
Item Signal nameCLAMSHELL Clamshell mode (No connection) DRAGLINE Dragline mode(No connection) JB CATCH Jib catch detection(No connection) BM OH LINE Overhoist wiring detection (boom) JB OH LINE Overhoist wiring detection (jib)
IDU DI1
(DG_IN13) No connection REAR Shift 1 (rear suspend) (No connection) ADD CW1 Shift 1 (load increase 1)
(No connection)ADD CW2 Shift 3 (load increase 2)
(No connection) DEC CW1 Shift 4 (load decrease 1)
(No connection) DEC CW2 Shift 5 (load decrease 2)
(No connection) DEC CW3 Shift 6 (load decrease 3)
(No connection)
IDU DI2
DEC CW4 Shift 7 (load decrease 4) (No connection)
OVERHEART Thermo switch (PLS_IN1) No connection(PLS_IN2) No connection (PLS_IN3) No connection(PLS_IN4) No connection (PLS_IN5) No connection(PLS_IN6) No connection
IDU DI/PI
(PLS_IN7) No connection
IDU Input / Output Monitor
Page Selection Return
IDU DI1 CLAMSHELL ON
DRAGLINE OFF
JB CATCH CATCH
BM OH LINE OFF
JB OH LINE ON
(DG_IN13) OFF
2/3
Description
Item
IDU DI2 REAR ON
ADD CW1 OFF
ADD CW2 ON
DEC CW1 OFF
DEC CW2 ON
DEC CW3 OFF
DEC CW4 ON
IDU DI/PI OVERHEART ON
(PLS_IN1) OFF
(PLS_IN2) OFF
(PLS_IN3) OFF
(PLS_IN4) OFF
(PLS_IN5) OFF
(PLS_IN6) OFF
(PLS_IN7) OFF
Description ExplanationON Closed contact OFF Open contact CATCH Jib catch REL. Jib release ALLOFF Open circuit ALLON Shorted harnesses ****** Communication error
3D LWR STP M/L fourth drum lowering stop B/J LOW T. M/L shouldering prevention JB OVER T. M/L tower breakage prevention(OC_OUT10) No connection(OC_OUT11) No connection (OC_OUT12) No connection(OC_OUT13) No connection LAMP CHK Lamp check relay
IDU D02
BUZZER BuzzerDD HST SD% Derricking drum hoisting slow down % DD LWR SD% Derricking drum lowering slow down %FD HST SD% Front hoisting slow down% FD LWR SD% Front lowering slow down%RD HST SD% Rear hoisting slow down % RD LWR SD% Rear drum lowering slow down %3D HST SD% Third drum hoisting slow down %
IDU CAN
3D LWR SD% Third drum lowering slow down %
IDU Input / Output Monitor
Page Selection Return
3/3
Description
Item
IDU CAN IDU D01 DD HST STP NORMAL
IDU D02 B/J LOW T. NORMAL
Description ExplanationNORMAL NormalSTOP Stop ON Drive OFF Non-drive****** Communication error
DD HST SD% XXX. %
DD LWR SD% XXX. %
FD HST SD% XXX. %
FD LWR SD% XXX. %
RD HST SD% XXX. %
RD LWR SD% XXX. %
3D HST SD% XXX. %
3D LWR SD% XXX. %
DD LWR STP STOP JB OVER T. STOP
FD HST STP NORMAL (OC_OUT10) ON
FD LWR STP STOP (OC_OUT11) OFF
RD HST STP NORMAL (OC_OUT12) ON
RD LWR STP STOP (OC_OUT13) OFF
3D HST STP NORMAL LAMP CHK ON
3D LWR STP STOP BUZZER OFF
T5-1-16
TROUBLESHOOTONG / Component Layout
MAIN COMPONENT LAYOUTUpper Structure
T2BC-01-02-010
1 - Fuel Tank 10 - Pump Mechanism 18 - Oil Cooler 26 - Shuttle Valve2 - Boom Derricking Drum 11 - Third Drum Control Valve*1 19 - Intercooler 27 - Front Control Valve3 - Slewing Control Valve 12 - Engine 20 - Battery 28 - Rear Control Valve*14 - Derricking Drum Lock
12 - Third Drum Lowering Remote Control Pressure Sensor*1
16 - Rear Lowering Remote Control Pressure Sensor
*1: If fourth drum (optional) is installed, these valves are used for the fourth drum.The valve for third drum should be newly installed under the fourth drum.
Front Control ValveRear Control Valve
Front Control ValveRear Control Valve
14 16
1 2*1 3 4*1 65 7 8
Machine LeftMachine Rear
Machine FrontMachine Right
Machine RightMachine Rear
Machine Front
13 15109*1 12*1
Machine Left
11
T5-2-15
TROUBLESHOOTONG / Component Layout
4-Spool Control Valve
T2BC-01-02-021
1 - Quick Draw Solenoid Valve (Extend)
5 - Counterweight Solenoid Valve (Right/Retract)
2 - Retract Solenoid Valve (Extend)*1
6 - Counterweight Solenoid Valve (Left/Retract)
3 - Counterweight Solenoid Valve (Left/Extend)
7 - Retract Solenoid Valve (Retract)
4 - Counterweight Solenoid Valve (Right/Extend)
8 - Quick Draw Solenoid Valve (Retract)
*1: If the jack (optional) is installed, the lower power solenoid valve is installed here.
2*11
5
Machine Front
Machine Rear
43
Machine Left Machine
Right
8 7 6
T5-2-16
TROUBLESHOOTONG / Component Layout
Around Drum
T2BC-01-02-026
T2BC-01-02-025
T2BC-01-02-024
1 - Motor Cutoff High Pressure Solenoid Valve (Only Front/Rear Drums)
4 - Derricking Drum Rotation Detection Switch
7 - Front Rotation Detection Switch (A)
10 - Rear Drum Lock Motor
2 - Brake Release Solenoid Valve
5 - Rear Drum Rotation Detection Switch (A)
8 - Front Drum Rotation Detection Switch (B)
11 - Front Drum Lock Motor
3 - Motor Displacement Angle Proportional Solenoid Valve
6 - Rear Drum Rotation Detection Switch (B)
9 - Fourth Drum (Optional) Lock Motor
Detailed Position C
Machine Front
B BB
9 10 11
A A
C CC
A
4 6 85 7
Front DrumBoom Derricking Drum Fourth Drum(Optional)
Rear Drum
Machine Front
Detailed Position A
T2BC-01-02-027
Detailed Position B
Rotation Detection Sensor
Drum Lock Motor
2
3
1
Motor
Machine Rear
(One sensor is installed to the derricking drum.)
T5-2-17
TROUBLESHOOTONG / Component Layout
4-Spool Solenoid Valve Unit
T25N-03-08-001
1 - Derricking Drum Unlocking Solenoid Valve
3 - High / Low Speed Selection Solenoid Valve
2 - Slewing Brake Solenoid Valve:
4 - Second Overhoist Solenoid Valve
4-Spool Solenoid Valve Unit
Accumulator
M25N-07-030
Slewing Remote Control Pressure Sensor Block
T25N-01-02-019
1 - Primary Pilot Pressure Sensor
2 - Right Slewing Remote Control Pressure Sensor
3 - Left Slewing Remote Control Pressure Sensor
1
Machine Front
Machine Rear
Machine Right
Machine Left
1 2 3 4
Accumulator
2
3
Slewing Remote Control Pressure Sensor Block
T5-2-18
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURES
Use troubleshooting A when error is indicated as a result that IDU diagnoses MC2/A and MC2/B.
How to read troubleshooting flowchart
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown.
T6L4-05-03-001
· Key switch: ON
NO(NOT OK)
(1)
(3)
(2)YES(OK)
Perform inspection or measurement in box (1), and select YES (OK)or NO (NOT OK) according to (1), and go to the next box (2) or (3).
Under the box is inspection or measuring method or references. Be careful that if inspection or measuring method is incorrect, finding the cause of failurebecomes difficult or the equipment may be damaged.
The bold line box shows a cause of failure. The bold line tells a location where possible cause of failure is present.
Harness Harness end connector
Mounting Surface
T5-3-1
TROUBLESHOOTING / Troubleshooting A
Power Supply Monitor
MC2/A Input / Output Monitor
Page Selection Return
MC2/A MAIN_B NORMAL
5V LOW ER
24V_1 HI ER
24V_2 SHORT
24V_3 SHORT
1/1
Description
Item
MC2/B MAIN_B NORMAL
5V LOW ER
24V_1 HI ER
24V_2 SHORT
24V_3 SHORT
IDU MAIN_B xx. xxV
5V x. xxV
10V xx. xxV
24V xx. xxV
Item Signal name MAIN_B Main power supply 5V Analog sensor power supply 24V_1 For each switch input 24V_2 For throttle control switch
MC2/A
24V_3 For emergency operation switch
MAIN_B Main power supply 5V Analog sensor power supply
24V_1 For three-winding layer detector (no connection)
24V_2 For overhoist switch on machine
MC2/B
24V_3 For overhoist switch on attachment
MAIN_B Main power supply 5V Angle detector power supply 10V Load detector power supply
IDU
24V Power supply for shift switch (no connection)
Description Explanation NORMAL NormalLOW ER Lower limit error HI ER Upper limit error SHORT Short circuit xx. xxV A/D voltage
conversionCommunication error
T5-3-2
TROUBLESHOOTING / Troubleshooting A
MC2/A Analog Inputs
Item Signal name THROT. GRIP Accelerator grip signal THROT. FOOT Accelerator pedal signal RACK. P. S. Rack position signal THROL. M. P. Governor motor potentio sensor signalSL CTRL SP Slew speed dial signal (no connection)THRT. 3RD Third Accelerator TRRGT. PRS Travel (right) remote control pressure
MC2/A AI1
TRLFT. PRS Travel (left) remote control pressure DD HST PRS Derricking drum hoisting remote control
Description Explanation ON Closed contact OFF Open contact BRAKE Auto brake mode FREE Free mode x. xx V A/D voltage conversion -xxxmA Electric current offset -xxxxx Drum pulse counter ROTATE Rotation STOP Stop CANCEL Cancellation NORMAL Normal SHORT Short circuit CRANE Crane TOWER Tower OPEN Open circuit ****** Communication error
MC2/A CAN2 S CNT -xxxxx FD PL
RD PLS CNT -xxxxx
DD PLS STOP
BRK MD SW OFF
OVERH2 SIG NORMAL
ATTACHMENT SHORT
SD. CAN SW OFF
PMP. FIX. SW OFF
T5-3-4
TROUBLESHOOTING / Troubleshooting A
MC2/A Digital Output
Item Signal name M PMP CUR Main pump displacement angle
proportional solenoid valve INC. TQ CUR Power increase solenoid valve SL RGT CUR Slewing multi (right) proportional solenoid
valve (no connection) SL LFT CUR Slewing multi (left) proportional solenoid
valve (no connection) SL PMP CUR Slewing pump displacement angle
3D BRK REL Fourth drum brake release solenoid valveFD PLS SOL Front drum rotation sensing solenoid RD PLS SOL Rear drum rotation sensing solenoid DD PLS SOL Derricking drum rotation sensing solenoidSL PKS SOL Slewing remote control pressure
hydraulic source solenoid (no connection)
MC2/A D02
CAL IB. CUR Calibration electric current DD LCK REL Derricking drum unlocking solenoid valveFM BRK REL Front motor brake release solenoid valveRM BRK REL Rear motor brake release solenoid valve3M BRK REL Fourht motor brake release solenoid
valveMT CUT OFF Motor cutoff relay ENG. INTLCK Engine start interlock 3D BRK LP Third/fourth auto brake indicator
MC2/A D03
SL ALAM LP Slewing alarm lamp relay
MC2/A Input / Output Monitor
Page Selection Return
MC2/A D01 M PMP CUR xxxxmA
INC. TQ CUR LOW ER
SL RGT CUR HI ER
SL LFT CUR RES ER
SL PMP CUR CANCEL
FD BRK REL XxxxmA
RD BRK REL LOW ER
3D BRK REL HI ER
3/4
Description
Item
MC2/A D02 FD PLS SOL
Description Explanation xxxxmA Control current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error CANCEL Feedback cancellation
NORMAL Normal LOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Feedback cancellation
NORMAL Calibration current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Spare
NORMAL Normal ERROR Short circuit ****** Communication error
NORMAL
RD PLS SOL ERROR
DD PLS SOL NORMAL
SL PRS SOL ERROR
CAL IB. CUR NORMAL
MC2/A D03 DD LCK REL NORMAL
FM BRK REL ERROR
RM BRK REL NORMAL
3M BRK REL ERROR
MT CUT OFF NORMAL
ENG. INTLCK ERROR
3D BRK LP NORMAL
SL ALAM LP ERROR
T5-3-5
TROUBLESHOOTING / Troubleshooting A
ECU Status
Item Signal name RECEIVE ECUTMR F. B. Timer feedbackRACK P. S. Rack sensorTIMING S. Timing sensorTDC S. TDC sensorOVER H. S. Coolant temperature sensor
MC2/A_ECU1
TMR C. V. Timer control valve
MC2/A Input/Output Monitor
Page Selection Return
MC2/A_ECU1
RECEIVE NORMAL
TMR F. B. ERROR
RACK P. S. NORMAL
TIMING S. ERROR
TDC S. INVLD
OVER H. S. ERROR
TMR. C. V. NORMAL
4/4
Description
Item
Description Explanation NORMAL Normal ERROR Error ****** Communication error
T5-3-6
TROUBLESHOOTING / Troubleshooting A
MC2/B Analog Inputs
Item Signal name FD CTRL SP Front drum speed set dial signal (no
connection) RD CTRL SP Rear drum speed set dial signal (no
connection)DD CTRL SP Derricking drum speed set dial signal (no
connection)(AN_IN3) No connection(AN_IN4) No connection(AN_IN5) No connection(AN_IN6) No connection
MC2/B AI1
(AN_IN7) No connectionTR RGT PRS Travel (right) remote control pressure TR LET PRS Travel (left) remote control pressure(AN_IN10) No connection(AN_IN11) No connection(AN_IN12) No connection
MC2/B AI2
(AN_IN13) No connectionFD ROPE ED Front drum three-winding layer detection
(no connection) RD ROPE ED Rear drum three-winding layer detection
(no connection) 3D ROPE ED Third drum three-winding layer detection
(no connection) (DAN_IN20) No connection(DAN_IN21) No connection(DAN_IN22) No connection
MC2/B DI
(DAN_IN23) No connection
MC2/B Input/Output Monitor
Page Selection Return
MC2/B AI1
FD CTRL SP NORMAL
RD CTRL SP LOW ER
DD CTRL SP HI ER
(AN_IN3) RSV
(AN_IN4) NORMAL
(AN_IN5) LOW ER
(AN_IN6) HI ER
(AN_IN7) RSV
1/3
Description
Item
MC2/B AI2
TR RGT PRS x. xMPa
TR LET PRS x. xMPa
(AN_IN10) NORMAL
(AN_IN11) LOW ER
(AN_IN12) HI ER
(AN_IN13) RSY
Description Explanation NORMAL Normal LOW ER Lower limit error HI ER Upper limit error RSV Spare x. xMPa Normal (pressure) DBL ER Double errors R. END Extra hoisting ALLOFF Open circuit ALLON Shorted harnesses ****** Communication error
MC2/B DI
FD ROPE ED R. END
RD ROPE ED ALLOFF
3D ROPE ED ALLON
(DAN_IN20) NORMAL
(DAN_IN21) ERROR
(DAN_IN22) NORMAL
(DAN_IN23) ERROR
T5-3-7
TROUBLESHOOTING / Troubleshooting A
MC2/B Digital Inputs
Item Signal name DD REL SW Derricking drum auto stop release FD REL SW Front drum auto stop releaseRD REL SW Rear drum auto stop release3D REL SW Third drum auto stop releaseHM FIX SW Hoisting motor low speed lockOH2 REL SW Second overhoist restoration switchJB FOLD Jib folding
MC2/B SWICH1
ATTACHMENT Wiring detectionBM OVERH Boom overhoist BT OVERH2 Boom/tower second overhoistTW OVERH Tower overhoistBT LOWER L Boom/tower lower limit (no connection)JB OVERH Jib overhoistJB OVERH2 Jib second overhoistHK OVERH Hook overhoist
SHORT Short circuit CRANE Crane TOWER Tower OPEN Open circuit
NORMAL Normal OVERH Overhoist ALLOFF Open circuit ALLON Shorted harnesses LOWER Lower limit
NORMAL Operation STOP Stop
****** Communication error
FD REL SW REL
RD REL SW NORMAL
3D REL SW REL
REL KEY SW NORMAL
OH2 REL SW REL
JB FOLD FOLD
ATTACHMENT CRANE
2/3MC2/B SWITCH2 BM OVERH NORMAL
MC2/B DI ST STP
Item
NORMAL DD H
BT OVERH2 OVERH DD LWR STP STOP
TW OVERH ALLOFF FD HST STP NORMAL
BT LOWER L ALLON FD LWR STP STOP
JB OVERH NORMAL RD HST STP NORMAL
JB OVERH2 OVERH RD LWR STP STOP
HK OVERH ALLOFF 3D HST STP NORMAL
SWL OVERH ALLON 3D LWR STP STOP
T5-3-8
TROUBLESHOOTING / Troubleshooting A
MC2/B Digital Outputs
MC2/B Input/Output Monitor
Page Selection Return
MC2/B D01
DD HST CUR xxxxmA
DD LWR CUR LOW ER
FD HST CUR HI ER
FD LWR CUR RES ER
RD HST CUR CANCEL
RD LWR CUR xxxxmA
FM CAP CUR LOW ER
RM CAP CUR HI ER
3/3
Description
Item
MC2/B D02
GREEM LMP NORMAL
YELLOW LMP ERROR
RED LMP NORMAL
OVERH2 SOL ERROR
3D HST SOL NORMAL
3D LWR SOL ERROR
CALIB. CUR LOW ER
Item Signal name DD HST CUR Derricking drum hoisting proportional
solenoid valve DD LWR CUR Derricking drum lowering proportional
solenoid valveFD HST CUR Front drum hoisting proportional
solenoid valveFD LWR CUR Front drum lowering proportional
solenoid valveRD HST CUR Rear drum hoisting proportional solenoid
valveRD LWR CUR Rear drum lowering proportional
solenoid valveFM CAP CUR Front motor displacement angle control
proportional solenoid valve
MC2/B D01
RM CAP CUR Rear motor displacement angle control proportional solenoid valve
GREEM LMP External indicator green (no connection)YELLOW LMP External indicator yellow (no connection)RED LMP External indicator red (no connection)OVERH2 SOL Second overhoist solenoid valve3D HST SOL Fourth drum hoisting solenoid valve3D LWR SOL Fourth drum lowering solenoid valve
MC2/B D02
CALIB. CUR Calibration current
Description Explanation xxxxmA Control current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error CANCEL Feedback cancellationNORMAL Normal ERROR Short circuit
NORMAL Calibration current LOW ER Lower limit error HI ER Upper limit error RES ER Reset error RSV Spare
****** Communication error
T5-3-9
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MC2/A OR MC2/B BATTERY AND SENSOR SYSTEM POWER SUPPLY
Abnormality Using the power supply monitor, check MC2/A and MC2/B battery and sensor system power supplies.
MC2/A, MC2/B Item Signal name Description Explanation Countermeasure
MAIN_B Battery LOW ER Lower limit error Harness check
5V Sensor 5V HI ER Upper limit error Harness check
24V_2 Sensor 24V_2 ***** CAN communication
failure
Harness check
24V_3 Sensor 24V_3 NORMAL Normal
T5-3-10
TROUBLESHOOTING / Troubleshooting A
Battery
Battery Relay
Key Switch
MC2/A MC2/B
P1
P17
P1 MAIN_B
KEY_SW
MAIN_B
P17
E12
E13
KEY_SW
E12 SOL_VB SOL_VB
E13D12
PWM_VB PWM_VB D12MAIN_G
D5 D5
D16
SENSOR_5V SENSOR_5V
IDU D16
D2
SENSOR_5V SENSOR_5V
SENSOR_24V_1
SENSOR_24V_2
D2
T25N-05-03-001
SENSOR_24V_3
D3 D3
D20
SENSOR_24V_1
SENSOR_24V_2
SENSOR_24V_3 D4
D20
CAN
D15 D14D9 D9
T5-3-11
TROUBLESHOOTING / Troubleshooting A
Check of Battery System
Check the wiring connections first.
MC2/A side
MC2/B side
YES
Disconnect harness from terminal plus (+) of battery. Check for continuity between terminal D1 of har-ness end connector ofconnector MCA-1 and machine.
NO
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminals minus (-) and machine.
YES
NO
NO
YES Faulty battery.
Faulty harness be-tween MC2/A and battery, or open circuitat fuse #7.
Harness open circuit between battery and ground, or faulty ground.
Faulty MC2/A.
Disconnect connec-tor MCA-1 from MC2/A. Check if voltage between terminal D1 of har-ness end connector and machine is 24 V.
YES
NO
YES
NO
NO
YES Faulty battery.
Faulty harness be-tween MC2/B and battery, open circuit atfuse #6.
Harness open circuit between battery and ground, or faulty ground.
Faulty MC2/B.
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminal X1 of harness end con-nector of connector MCB-1 and machine.
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminal mi-nus (-) and machine.
Connector
T2BC-05-03-001 T2BC-05-03-002
Disconnect contor
nec- MCB-1 from
. f voltage be-
ween terminal X1 of con-
machineV.
MC2/BCheck itharness endnector and is 24
MC2/B Connector MCA-1 (harness end)
MC2/A Connector MCA-1(harness end)
T5-3-12
TROUBLESHOOTING / Troubleshooting A
Check of Key Switch
Check the wiring connections first.
MC2/A side
MC2/B side
YES
Harness open circuit between MC2/A and key switch, or open circuit at fuse #18.
Faulty key switch.
Connect terminal ACC in key switch to machine.Check for continuity between terminal D17 of harness end con-nector of connector MCA-1 and machine.
Harness open circuit between key switch and battery.
NO
Faulty MC2/A.
YES
NO
NO
YES
Disconnect connec-tor MCA-1 from MC2/A. Check if voltage between terminal D17 of harness end connector and ma-chine is 24 V.
· Key switch: ON
Check if voltage be-tween terminal B in keyswitch and machine is 24 V.
YES Faulty MC2/B.
Connector
T2BC-05-03-001
T2BC-05-03-002
T2BC-05-04-002
Harness open circuit between MC2/B and key switch, or open circuit at fuse #18.
Faulty key switch.
Connect terminal ACC in key switch to machine.Check for continuity between terminal X17 of harness end con-nector of connector MCB-1 and machine.
Harness open circuit between key switch and battery.
NO
Disconnect connec- MCB-1from
. f voltage
ween terminal end
ma-V.
Key switch: ON
torMC2/A
YES
NO
NO
YESCheck i
Check if voltage be-tween terminal B in ke
bety
switch and machine is 24 V.
X17 of harness connector and chine is 24
·
MC2/A Connector MCA-1 (harness end)
MC2/B Connector MCB-1(harness end)
Monitor panel CN06F-W (harness end)
Terminal C
Terminal B Terminal ACC
T5-3-13
TROUBLESHOOTING / Troubleshooting A
Check of Solenoid and PWM Power Supply
Check the wiring connections first.
MC2/A side
Connector
T2BC-05-03-004
MC2/A Connector MCA-6
Disconnect har-ness from terminal plus (+) of battery. Check for continu-ity between termi-nal of harness 60B of battery relay and machine.
(A)
YES
NO
Faulty battery relay.
Harness open circuit between battery relay and battery
Disconnect connector from MC2/A. f voltage be-
ween terminal E12 or end
ma-V.
Key switch: ON
(A)
MCA-6Check itE13 of harness connector and chine is 24
·
Disconnect har-ness 208 of batteryrelay and connect to machine. Check for continu-ity between termi-nal ACC in key switch and ma-chine.
Connect ground terminal of battery relay to machine. Check if voltage between terminal E12 or E13 and machine is 24 V. Disconnect har-
ness AV8 of bat-tery relay connect to machine. Check for continu-ity between termi-nal E12 or E13 of harness end con-nector and ma-chine.
YES
NO
NO
YES
YES
YES
NO
NO
· Key switch: ON
Faulty MC2/A.
Harness open circuit between key switch and battery relay.
Harness open circuit between battery relay and ground, or faulty ground.
In case of no continuity at terminal E12, har-ness open circuit be-tween terminal E12 of connector MCA-6 of MC2/A and battery relay, or open circuit at fuse #28. In case of no continuity at terminal E13, har-ness open circuit be-tween terminal E13 of connector MCA-6 of MC2/A and battery relay, or open circuit at fuse #30.
T5-3-14
TROUBLESHOOTING / Troubleshooting A
MC2/B Side
Connector
T2BC-05-03-003
MC2/BConnector MCB-6
Disconnect connector from MC2/B. f voltage be-
ween terminal Y12 or end
ma-V.
· Key switch: ON
(A)
MCB-6Check itY13 of harness connector and chine is 24
Harness open circuit between battery relay and battery
Disconnect har-ness 208 of batteryrelay and connect to machine. Check for continu-ity between termi-nal ACC of key switch and ma-chine.
Connect ground terminal of battery relay to machine. Check if voltage between terminal Y12 or Y13 and machine is 24 V. Disconnect har-
ness AV8 of bat-tery relay. Check for continuity be-tween terminal YE12 or Y13 of harness end con-nector and ma-chine.
YES
NO
NO
YES
YES
YES
NO
NO
Faulty MC2/B.
Harness open circuit between key switch and battery relay.
Harness open circuit between battery relay and ground, faulty ground.
Disconnect har-ness from terminal plus (+) of battery. Check for continu-ity between termi-nal of harness 60B of battery relay and machine.
(A)
YES
NO
· Key switch: ON
In case of no continuity at terminal Y12, har-ness open circuit be-tween terminal Y12 of connector MCB-6 of MC2/B and battery relay, or open circuit at fuse #27. In case of no continuity at terminal Y13, har-ness open circuit be-tween terminal Y13 of connector MCB-6 of MC2/B and battery relay, or open circuit at fuse #30.
Faulty battery relay
T5-3-15
TROUBLESHOOTING / Troubleshooting A
Check of 5 V Sensor on MC2/A
Harness D5 Sensor Harness end connector
Accelerator grip
Slew lever T25N-05-03-023
Accelerator pedal
T25N-05-03-024
Throttle motor position
T25N-05-03-025
Faulty MC2/A.
Faulty sensor.
NO
YESDisconnect sensor from connector. Check if voltage be-tween terminal R of harness end connector and machine is 5 V.
· Key switch: ON
Harness D16 Sensor Harness end connector
Derricking drum hoisting remote control pressure R W B
Derricking drum lowering remote control pressure R W B
RFront drum hoisting remote control pressure R W B
Front drum lowering remote control pressure R W B
Rear drum hoisting remote control pressure R W B
Rear drum lowering remote control pressure R W B
Third / fourth drum hoisting remote control pressure
R W B
Third / fourth drum lowering remote control pressure
R W B
Slewing (right) remote control pressure R W B
Slewing (left) remote control pressure R W B
Primary pilot circuit pressure
T25N-05-03-002
Front brake depressing pressure
T25N-05-03-002
Rear brake depressing pressure
T25N-05-03-002
Third brake depressing pressure
T25N-05-03-002
WB
RW
B
B W R
R B
R B
W
R B
W
R B
W
W
T5-3-16
TROUBLESHOOTING / Troubleshooting A
Check of 5V Sensor of MC2/B
Faulty MC2/B.
Faulty sensor.
NO
YESDisconnect sensor from connector. Check if voltage be-tween terminal R of harness end connector and machine is 5 V.
· Key switch: ON
Harness X16 Sensor Harness end connector
Travel (right) remote control pressure R W B
Travel (left) remote control pressure R W B
T5-3-17
TROUBLESHOOTING / Troubleshooting A
Check of 24 V_1 Sensor on MC2/A
Front / rear drum brake mode selection switch
Harness D2
Faulty MC2/A.
Faulty brake mode selection switch.
NO
YESDisconnect connector of brake mode selec-tion switch. Check if voltage be-tween machine and terminal #4 of harness end connector is 24 V.· Key switch: ON
YESDisconnect connector of brake mode selec-tion switch. Check if voltage be-tween machine and terminal #4 of harness end connector is 24 V.
· Key switch: ON
Harness D2 Sensor Harness end connector
Third / fourth drum brake mode selection switch
T2BC-05-03-005
T5-3-18
TROUBLESHOOTING / Troubleshooting A
Front, rear and fourth drum brake pedal
Faulty MC2/A.
Faulty brake modeselection switch.
NO
YESDisconnect connector of limit switch. Check if voltage be-tween machine and terminal #1 of harness end connector is 24 V.
· Key switch: ON
Harness D2 Sensor Harness end connector
Fron, rear and fourth drum pedal limit switch
T2BC-05-04-008
T5-3-19
TROUBLESHOOTING / Troubleshooting A
Check of 24 V_2 Sensor on MC2/A
Harness D3
Faulty MC2/A.
Faulty accelerator control switch.
NO
YESDisconnect connector 62C-12FW of right con-trol panel. Check if voltage be-tween machine and terminal #2 of harness end connector is 24 V. · Key switch: ON
Sensor Harness end connector Accelerator control switch
T2BC-05-03-006
Right control panel 62C-12F-W
Check of 24 V_3 Sensor on MC2/A
Harness D4
Faulty MC2/A.
Faulty emergency operation switch.
NO
YESDisconnect connector of emergency opera-tion switch. Check if voltage be-tween machine and terminal #4 of harness end connector is 24 V.
· Key switch: ON
Sensor Harness end connectorEmergencyoperation switch
T2BC-05-03-007
T5-3-20
TROUBLESHOOTING / Troubleshooting A
Check of 24 V_2 Sensor on MC2/B
Faulty MC2/B.
Faulty limit switch.
NO
YESDisconnect connector of limit switch. Check if voltage be-tween machine and terminal #c of harness end connector is 24 V.
· Key switch: ON
Harness X3 Sensor Harness end connector
Boom overhoist switch
T25N-05-03-005
a b c
Tower overhoist switch
T25N-05-03-003
Boom / tower second overhoist switch
T25N-05-03-029
a
b c
a
cb
T5-3-21
TROUBLESHOOTING / Troubleshooting A
Check of Sensor 24 V_3 on MC2/B
Jib overhoist, jib second overhoist, tower jib backstop alignment switches
Faulty MC2/B.
Faulty limit switch.
NO
YESDisconnect limit switchfrom connector. Check if voltage be-tween machine and terminal #1 of harness end connector is 24 V.
· Key switch: ON
Harness X4 Sensor Harness end connector
Jib overhoist switch
T2BC-05-03-009
Jib second overhoist switch
T2BC-05-03-008
Tower jib backstop alignment switch
T2BC-05-03-009
Hook overhoist switch
Faulty MC2/B.
Faulty limit switch.
NO
YESDisconnect limit switch from connector. Check if voltage between ma-chine and terminal #1 of harness end connector is 24 V.
· Key switch: ON
Harness X4 Sensor Harness end connector
Hook overhoist switch
T2BC-05-03-010
T5-3-22
TROUBLESHOOTING / Troubleshooting A
Check of CAN between MC2/A and IDU
Check the wiring connections first.
Check for continuity between terminal D9 of harness end connector of connector MCA-1 of MC2/A and terminal J14 of harness end connector of connector IDU-4 of IDU.
Check for continuity between terminal D20 of har-ness end connector of connector MCA-1 of MC2/A and terminal J15 of harness end connector of con-nector IDU-4 of IDU.
Connector
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-001
IDU Connector IDU-4 (harness end)
T2BC-05-03-011
T5-3-23
TROUBLESHOOTING / Troubleshooting A
Check of CAN between MC2/B and IDU
Check the wiring connections first.
Check for continuity between terminal X9 of harness end connector of connector MCB-1 of MC2/B and terminal J14 of harness end connector of connector IDU-4 of IDU.
Check for continuity between terminal X20 of har-ness end connector of connector MCB-1 of MC2/B and terminal J15 of harness end connector of con-nector IDU-4 of IDU.
Connector MC2/B Connector MCB-1 (harness end)
T2BC-05-03-012
IDU Connector IDU-4 (harness end)
T2BC-05-03-011
T5-3-24
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ENGINE CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supply".
By using the MC2/A input/output monitor, check the sensor signal.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit errorTHROT. GRIP
THROT. FOOT Accelerator gripAccelerator pedal HI ER Upper limit error
Controls as low idle input.
Harness checkSensor check
LOW ER Lower limit errorHI ER Upper limit error
THROT. M. P Governor motorPotentio
RSV ER Operation error
Governor motor control stop
Harness checkSensor check
0/3.3 to 8.5V Pulses
24V Governor motor
1.0 to 2.4 V
Accelerator grip
5 V
0.7 to 4.3 V
Accelerator pedal
2.4 4.6V
Governor motor potentio
24 V24 V (ON)0 V (OFF)
Accelerator Preset Accelerator Lock
Accelerator Control Switch
Engine Speed Detection
0 to 6 V AC, 0 to 5.3 Hz
T2BC-05-03-058
T5-3-25
TROUBLESHOOTING / Troubleshooting A
Check of Accelerator Grip Sensor
When input voltage from the accelerator grip sensor is 4.9 V or more, the causes of trouble may be failure of accelerator grip sensor, or open circuit between terminal D14 of MC2/A and terminal B (ground) of accelerator grip sensor end connector. If input voltage from the accelerator grip sensor is 0.1 V or less, the cause of trouble may be harness open circuit between accelerator grip sensor and MC2/A, or short circuit between sensor_ 5 V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-014
T2BC-05-03-015
Faulty MC2/A.
Faulty accelerator grip sensor.
Faulty MC2/A.
Faulty harness up to terminal R of accelerator grip sensor.
Faulty harness up to terminal B of accelerator grip sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of accel-erator grip sensor is 5 0.5 V.
Faulty accelerator grip sensor.
Turn key switchOFF. Connect terminal W of harness end connector of accel-erator to machine by using a clip.
Disconnect connec-tor MCA-3 of MC2/A. Check for continuity between terminal B5of connector MCA-3 and machine.
Turn key switch ON. Check if voltage between machine and terminal R of harness end con-nector of accelerator grip sensor is 5 0.5V.
Turn key switch OFF. Disconnect connec-tor of accelerator grip sensor. Check for continuity between terminals R and B of accelerator grip sensor.
Faulty harness up to terminal W of accelerator grip sensor.
Turn key switch OFF. Check for continuity between terminal B of harness end connector of accel-erator grip sensor and machine.
·Insert a test bar into the rear of connector. ·Specification: 1.0 to
24 V
Reconnect the dis-connected connec-tor. Measure voltage between terminal B5 of connector of MC2/A and machine. Turn key switch ON. Check if voltage reaches specification when moving accel-erator grip.
T5-3-26
TROUBLESHOOTING / Troubleshooting A
Check of Accelerator Pedal Sensor
If input voltage from the accelerator pedal sensor is 4.9 V or more, the cause of trouble may be failure of accelerator pedal sensor, or open circuit between terminal D14 of MC2/A and terminal B (ground) of accelerator pedal sensor end connector. If input voltage from the accelerator grip sensor is 0.7 V or less, the cause of trouble may be harness open circuit between accelerator pedal sensor and MC2/A, or short circuit between sensor_ 5 V line and ground line. Check the wiring connections first.
Faulty harness up to terminal R of accelerator pedal sensor.
Faulty harness up to terminal B of accelerator pedal sensor.
Faulty accelerator pedal sensor.
Turn key switch PFF.Disconnect con-nector of acceleratorpedal sensor. Check for continuity between terminals R and B of accel-erator pedal sensor.
Faulty MC2/A.
Faulty accelerator pedal.
Faulty harness up to W terminal of accelerator pedal sensor.
·Insert a test bar into the rear of connector.
Reconnect the dis-connected connector. Measures voltage between terminal B13 of connector of MC2/A and machine. Turn key switch ON. Check if voltage reaches specification when moving accel-erator pedal.
·Specification: 0.7 to 4.3 V
Turn key switch OFF. Connect terminal W of harness end con-nector of accelerator pedal sensor to ma-chine by using a clip.Disconnect connector MCA-3 of MC2/A. Check for continuity between terminal B13of connector MCA-3 and machine.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of accel-erator pedal sensor is 5 0.5 V.
Turn key switch OFF. Check for continuity between terminal B of harness end connector of accel-erator pedal sensor and machine.
Turn key switch ON. Check if voltage be-tween machine and terminal R of harness end connector of ac-celerator pedal sen-sor is 5 0.5 V.
T5-3-27
TROUBLESHOOTING / Troubleshooting A
Check of Governor Motor Potentio Sensor
If input voltage from the governor potentio sensor is 4.9 V or more, the cause of trouble may be failure of governor potentio sensor, or open circuit between terminal D14 of MC2/A and terminal B (ground) of sensor end connector. If input voltage from the sensor is 0.1 V or less, the cause of trouble may be harness open circuit be-tween governor potentio sensor and MC2/A, or short circuit between sensor 5 V_ line and ground line. Check the wiring connections first.
Connector
YES
YES
YES
YES
Faulty MC2/A.
Faulty governor motor potentio sensor.
Faulty harness up to terminal B of governor motor potentio sensor.
Faulty harness up to terminal R of governor motor potentio sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of governor motor potentio sensor is 5 0.5 V.
Faulty governor motor potentio sensor.
Faulty harness up to terminal W of governor motor potentio sensor.
·SpecificationLow idle: 2.4 0.5 V High idle: 4.6 0.3 V
Turn key switch OFF. Disconnect gover-nor motor potentio sensor.Check if resistance between terminals R and B of con-nector of governor motor potentio sensor is 2 0.6 .
Turn key switch OFF. Connect terminal W of harness end con-nector of governor motor potentio sensor to machine by using aclip.Check for continuity between machine and terminal B12 of harness end conectorof connector MCA-3 of MC2/A.
Turn key switch
T2BC-05-03-019
T2BC-05-03-018
T2BC-05-03-013
T2BC-05-03-001
T107-07-03-009
..
Test Harness V
Black
Red
ON. Check if voltage be-tween machine and terminal R of harness end connector of governor motor po-tentio sensor is 5 0.5V.
Connect a test har-ness between gov-ernor motor potentio sensor and harness end connector of machine.Turn key switch ON. Check if voltage reaches specifica-tion at low idle and high idle.
NO
NO
NO
NO
NO
YES
MC2/A Connector MCA-3(harness end)
Governor motor potentio sensor (governor motor potentio sensor end)
MC2/A Connector MCA-1(harness end)
Governor motor potentio sensor (harness end)
T5-3-28
TROUBLESHOOTING / Troubleshooting A
Check of Accelerator Control Switches
Check the wiring connections first.
NO Faulty MC2/A.
Connector
T2BC-05-03-021 T2BC-05-03-020
T2BC-05-03-006
MC2/A Connector MCA-4 (harness end)
Right control panel Connector 62C-12FW (harness end)
MC2/A Connector MCA-1 (Machine end)
Harness open circuit between accelerator control switch and MC2/A.
Reconnect the dis-connected connector. Disconnect connector 62C-12FW of right control panel. Check if voltage be-tween machine and terminal #2 of har-ness end connector is 24 V.
Faulty accelerator lock switch.
Harness open circuit between accelerator lock switch and MC2/A.
Check if voltage between machine and terminal D3 of machine end con-nector is 24 V
NO
YES
YES
YES
NO
· Key switch: ON
· Key switch: ON
Faulty accelerator preset switch.
Harness open circuit between accelerator preset switch and MC2/A.
Accelerator lock switch
Disconnect connector MCA-4 of MC2/A. Connect terminal A6 of harness end connector to machine.Check for continuity be-tween machine and termi-nal #3 of harness end con-nector of connector 62C-12FW.
Disconnect connector MCA-4 of MC2/A. Connect terminal A19 of harness end connector to machine.Check for continuity be-tween machine and termi-nal #1 of harness end con-nector of connector 62C-12FW.
YES
Accelerator preset switch
NO
T5-3-29
TROUBLESHOOTING / Troubleshooting A
Check of Engine Rotation Detection Sensors
Check the wiring connections first.
Connector
Engine rotation detection sensor (harness end)
MC2/A Connector MCA-5 (harness end)
F1
F12
F11
F22
F4
F16
T25N-05-03-004
#1#2T25N-05-03-008
#2#1
NO
YES
NO
YESDisconnect connectorMCA-5 of MC2/A. Connect terminals F4 and F16 of harness end connector of connector MCA-5 to machine.Check for continuity between machine andterminals # 1 and #2 of harness end con-nector of engine rota-tion detection sensor.
Faulty MC2/A.
In case of no conti-nuity at terminal #1, harness open circuit between terminal #1 of engine rotation detection sensor and MC2/A. In case of no conti-nuity at terminal #2, harness open circuit between terminal #2 of engine rotation detection sensor and MC2/A.
Disconnect con-nector of engine rotation detection sensor.Check if resistance between terminals #1 and #2 of ma-chine end connec-tor is 2.3 0.2 .
Faulty engine rota-tion detection sen-sor.
Engine rotation detection sensor (sensor end)
T5-3-30
TROUBLESHOOTING / Troubleshooting A
Check of Governor Motor System
Check the wiring connections first. Faulty MC2/A.
Faulty harness up to terminal E24 of connector MCA-6 of MC2/A.
Faulty harness up to terminal E25 of connector MCA-6 of MC2/A.
Faulty harness up to terminal E10 of connector MCA-6 of MC2/A.
Faulty harness up to terminal E11 of connector MCA-6 of MC2/A.
Disconnect connector MCA-6 of MC2/A. Connect terminals E11 to E10 of har-ness end connector ofgovernor motor by using a clip. Check for continuity between terminals E10 and E11 of har-ness end connector ofMCA-6.
Faulty governormotor.
Connect terminals #2 to #4 of harness end connector of governor motor by using a clip. Check for continu-ity between termi-nals E24 and E25 of harness end connector of MCA-6.
Connect terminal E11 of harness end connector of MCA-6 to machine by using a clip. Check for continu-ity between ma-chine and terminal #1 of harness end connector of gov-ernor motor.
Disconnect con-nector of governor motor. Check if resis-tances between terminals #1 and # 3, and between terminals #2 and #4 are 5.7 0.57 .
Connect terminal E25 of harness end connector of MCA-6 to machine by using a clip. Check for continu-ity between ma-chine and terminal #2 of harness end connector of gov-ernor motor.
NO
YES
YES
NO
NO
NO
YES
YES
NO
YES
Key switch: OFF
Connector MC2/A Connector MCA-6
governor motorConnector Governor motor
(harness end) (governor motor end) (harness end)
4
2
3
1
E10
E1
E14
E13
E26
E24 E25
E11
3
1
4
2
T5-3-31
TROUBLESHOOTING / Troubleshooting A
FAILURE OF BRAKE CONTROL SYSTEM
Abnormality
By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supply".
By using the MC2/A input/output monitor, confirm the solenoid valve signal.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit error
HI ER Upper limit error
DD HST PRS
DD LWR PRS
FD HST PRS
FD LWR PRS
RD HST PRS
RD LWR PRS
3D HST PRS
3D LWR PRS
Derricking drum hoisting remote control pressure Derricking drum lowering remote control pressure Front drum hoisting remote control pressureFront drum lowering remote control pressureRear drum hoisting remote control pressureRear drum lowering remote control pressureThird drum hoisting remote control pressureThird drum lowering remote control pressure
DBL ER Double errors
Brake mode: Set to auto brake mode
Motor brake: Input control with lever in neutral
Harness check Sensor check
PILOT PRS Primary pilot pressure LOW ER Lower limit error Pressure drop Harness check HI ER Upper limit error Input control Sensor check
LOW ER Lower limit error FD BRK PRS RD BRK PRS
Front brake depressing pressure Rear brake depressing pressure HI ER Upper limit error
Brake return Input control
Harness check Sensor check
DD LCK REL
FM BRK REL
RM BRK REL
3M BRK REL
Derricking drum unlocking solenoid valveFront motor brake release solenoid valveRear motor brake release solenoid valveFourth motor brake release solenoid valve
ERROR Short circuit Harness check Solenoid valve check
3D BRK LP Third/fourth auto brake indicator ERROR Short circuit Harness check Solenoid valve check
For check of harness between MC2/A and IDU, refer to "Check of CAN between MC2/A and IDU" in Sec-tion "Failures of MC2/A or MC2/B Battery/Sensor System Power Supply". The monitor does not correspond to breakdown of front, rear and fourth drum brake pedal limit switch. (Breakdown is not displayed on the monitor.)
T5-3-32
TROUBLESHOOTING / Troubleshooting A
Free Indicator
Front Drum Brake Release Solenoid Valve
Rear Drum Brake Release Solenoid Valve
Derricking Drum Hoisting Remote Control Pressure Sensor
Fourth Drum Brake Release Solenoid Valve
Derricking Drum Lowering Remote Control Pressure Sensor
Front Drum Hoisting Remote Control Pressure Sensor
Front Drum Lowering Remote Control Pressure Sensor
Rear Drum Hoisting Remote Control Pressure Sensor
Derricking Drum Unlocking Solenoid Valve
Front Motor Brake Release Solenoid Valve Rear Drum Lowering
Remote Control Pressure Sensor
Rear Motor Brake Release Solenoid Valve
Third / Fourth Drum Hoisting Remote Control Pressure Sensor
Third / Fourth Drum Lowering Remote Control Pressure Sensor
Fourth Motor Brake Release Solenoid Valve
Primary Pilot Pressure Sensor
Third / Fourth Free Indicator
Front Brake Depress Detection
Rear Brake Depress Detection Front Free Indicator
Rear Free Indicator Third Brake Depress Detection
Brake Mode Switch
Front Brake Mode Selection Switch Second Overhoist Stop
Solenoid Release
Rear Brake Mode Selection Switch
Third Brake Mode Selection Switch
Front Pedal Limit Switch
Rear Pedal Limit Switch
Third Pedal Limit Switch
T2BC-05-03-022
T5-3-33
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Hoisting Remote Con-trol Pressure Sensor System
If input voltage from the derricking drum hoisting remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of derricking drum hoisting remote control sensor, or open circuit be-tween terminal D15 of MC2/A and terminal B (ground) of derricking drum hoisting remote control pressure sensor end connector. If input voltage from the derricking drum hoisting remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between derricking drum hoisting remote control pressure sensor and MC2/A, or short circuit be-tween SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-013
T2BC-05-03-001
Derricking drum hoisting remote control ressure sensor (harness end) p
MC2/A Connector MCA-3 (harness end)
Faulty MC2/A
Faulty derricking drum hoisting re-mote control pres-sure sensor
Faulty MC2/A
Faulty harness upto terminal R of derricking drum hoisting remote control pressure sensor
Faulty harness up to terminal B of derricking drum hoisting remote control pressure sensor
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of derrick-ing drum hoisting remote control pres-sure sensor is 5 0.5V.
Faulty derricking drum hoisting re-mote control pres-sure sensor
Turn key switchOFF. Connect terminal W of har-ness end connec-tor of derricking
Dp
erricking drum hoisting remote control ressure sensor (sensor end)
MC2/A Connector MCA-1(harness end)
drum hoisting re-mote control pres-sure sensor to machine.Disconnect con-nector MCA-3 of MC2/A. Check for continuity between terminal B1 of connector MCA-3 and machine.
Turn key switchON. Check if volt-age between ma-chine and terminal R of harness end connector of der-ricking drum hoist-ing remote control pressure sensor is 5 0.5 V.
Turn key switch OFF. Disconnect con-nector of derricking drum hoisting re-mote control pres-sure sensor. Check for continu-ity between termi-nals R and B of derricking drum hoisting remote control pressure
Turn key switch OFF. Check for continuity between machine and ter-minal B of harness end connector of derricking drum hoisting remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check ifvoltage between machine and ter-minal B1 of con-nector of MC2/A meets specifica-tion.
Faulty harness up to terminal W of derricking drum hoisting remote control pressure sensor
T5-3-34
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Lowering Remote Control Pressure Sensor System
If input voltage from derricking drum lowering re-mote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of derricking drum lowering remote control sensor, or open circuit be-tween terminal D15 of MC2/A and terminal B (ground) of derricking drum lowering remote control pressure sensor end connector. If input voltage from the derricking drum lowering remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between derricking drum lowering remote control pressure sensor and MC2/A, or short circuit be-tween SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-013
T2BC-05-03-001
Faulty MC2/A.
Faulty derricking drum lowering remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of derricking drum lowering remote control pressure sensor.
Faulty harness up to terminal B of derricking drum lowering remote control pressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of derrick-ing drum lowering remote control pres-sure sensor is 5 0.5V.
Faulty derricking drum lowering remote control pressure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of der-ricking drum low-ering remote con-trol pressure sen-sor to machine. Disconnect con-nector MCA-3 of MC2/A. Check for continu-ity between ma-chine and terminal B9 of connector MCA-3.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of derricking drum lowering remote controlpressure sensor is 5 0.5 V.
Turn key switch OFF. Disconnect con-nector of derricking drum lowering remote control pressure sensor. Check for continu-ity between termi-nals R and B of derricking drum lowering remote control pressure sensor.
Faulty harness up to terminal W of derricking drum lowering remote control pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of der-ricking drum low-ering remote con-trol pressure sen-sor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal B9 of connector of MC2/A meets specification.
MC2/A Connector MCA-3Derricking drum lowering remote control
pressure sensor (sensor end) (harness end)
MC2/A Connector MCA-1
Derricking drum lowering remote control pressure sensor (harness end)
(harness end)
T5-3-35
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Hoisting Remote Control Pressure Sensor System
If input voltage from the front drum hoisting remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of front hoisting remote control sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of front drum hoisting remote control pressure sensor end con-nector. If input voltage from the front drum hoisting remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between front drum hoisting remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
MC2/A Connector MCA-2
T2BC-05-03-025
T2BC-05-03-001
Front drum hoisting remote control essure sensor (sensor end) pr
Faulty MC2/A.
Faulty front drum hoisting remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of front drum hoisting remote control pressure sensor.
Faulty harness up to terminal B of front drum hoisting remote control pressure sensor.
Faulty front drum hoisting remote control pressure sensor.
Turn key switch OFF. Disconnect con-nector of front drum hoisting re-mote control pres-sure sensor. Check for continu-ity between termi-nals R and B of front drum hoisting remote control pressure sensor.
Faulty harness up to terminal W of front drum hoisting remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal C6 of connector of MC2/A meets specification.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of front drum hoisting re-mote control pres-sure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of front drum hoisting re-mote control pres-sure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C6 of connector MCA-2.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of front drum hoisting re-mote control pres-sure sensor is 5 0.5 V.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of front drum hoisting remote control pressure sensor is 5 0.5 V.
(harness end)
MC2/A Connector MCA-1Front drum hoisting remote control
pressure sensor (harness end) (harness end)
T5-3-36
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Lowering Remote Control Pressure Sensor System
If input voltage from the front drum lowering remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of front lowering remote control sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of front drum lowering remote control pressure sensor end con-nector. If input voltage from the front drum lowering remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between front drum lowering remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Check the wiring connections first.
Connector MC2/A Connector MCA-2
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
T2BC-05-03-001
Front drum lowering remote control ressure sensor (sensor end) p (harness end)
Faulty MC2/A.
Faulty front drum lowering remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of front drum lower-ing remote control pressure sensor.
Faulty harness up to terminal B of front drum lower-ing remote control pressure sensor.
Faulty front drum lowering remote control pressure sensor.
Turn key switch OFF. Disconnect con-nector of front drum lowering remote control pressure sensor. Check for continu-ity between termi-nals R and B of front drum lowering remote control pressure sensor.
Faulty harness up to terminal W of front drum lower-ing remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5
V
Reconnect the disconnected connector.Check if voltage between machine and terminal C12 of connector of MC2/A meets specification.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of front drum lowering remote control pressure sensor.
Turn key switchOFF. Connect terminal Wof harness end connector of front drum lowering re-mote control pres-sure sensor to ma-chine.Disconnect con-nector MCA-2 of MC2/A. Check for continuity between machine and terminal C12 ofconnector MCA-2.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of front drum lowering remote control pressure sensor is 5 0.5 V.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of front drum lowering remote control pressure sensor is 5 0.5 V.
MC2/A Connector MCA-1Front drum lowering remote control
pressure sensor (harness end) (harness end)
T5-3-37
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Hoisting Remote Control Pressure Sensor System
If input voltage from the rear drum hoisting remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of rear hoisting remote control sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of rear drum hoisting remote control pressure sensor end con-nector. If input voltage from the rear drum hoisting remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between rear drum hoisting remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
T2BC-05-03-001
Re r drum hoisting remote control pr sure sensor (sensor end)
aes
Rear drum hoisting remote control ressure sensor (harness end) p
MC2/A Connector MCA-1(harness end)
MC2/A C ector MCA-2onn
Faulty MC2/A.
Faulty rear drum hoisting remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of rear drum hoisting remote control pressure sensor.
Faulty harness up to terminal B of rear drum hoisting remote control pressure sensor.
Faulty rear drum hoisting remote control pressure sensor.
Turn key switch OFF. Disconnect con-nector of rear drum hoisting remote control pressure sensor.Check for continu-ity between termi-nals R and B of rear drum hoisting remote control pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of rear drum hoisting re-mote control pres-sure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal C5 of connector of MC2/A meets specification.
Faulty harness up to terminal W of rear drum hoisting remote control pressure sensor.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of rear drum hoisting remote control pressure sensor is 5 0.5 V.
Turn key switchOFF. Connect terminal W of harness end connector of rear drum hoisting re-mote control pres-sure sensor to
(h rness end) a
machine.Disconnect connector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C5 of connector MCA-2.
-
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of rear drum hoisting remote control pressure sensor is 5 0.5 V.
T5-3-38
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Lowering Remote Control Pressure Sensor System
If input voltage from the rear drum lowering remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of rear drum lowering re-mote control sensor, or open circuit between termi-nal D15 of MC2/A and terminal B (ground) of rear drum lowering remote control pressure sensor end connector. If input voltage from the rear drum lowering remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between rear drum lowering remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
T2BC-05-03-001
R ar drum lowering remote control pr re sensor (sensor end)
eessu
Rear drum lowering remote control pressure sensor (harness end)
MC2/A Connector MCA-1 (
MC2/A Connector MCA-2 (harness end)
Faulty MC2/A.
Faulty rear drum lowering remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of rear drum lowering remote control pressure sensor.
Faulty harness up to terminal B of rear drum lowering remote control pressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of rear drum lowering remote control pressure sensor is 5 0.5 V.
Faulty rear drum lowering remote control pressure sensor.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of rear drum lowering remote control pressure sensor is 5 0.5 V.
Turn key switch OFF. Disconnect con-nector of rear drum lowering remote control pressure sensor.Check for continu-ity between termi-nals R and B of rear drum lowering remote control pressure sensor.
Faulty harness up to terminal W of rear drum lowering remote control pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of rear drum lowering remote control pressure sensor.
·Insert a test bar into the rear of connector ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal C11 of connector of MC2/A meets specification. Turn key switch
OFF. Connect terminal W of harness end connector of rear drum lowering re-mote control pres-sure sensor to ma-chine.Disconnect con-nector MCA-2 of MC2/A. Check for continuity between machine and terminal C11 of connector MCA-2.
harness end)
T5-3-39
TROUBLESHOOTING / Troubleshooting A
Check of Third / Fourth Drum Hoisting Remote Control Pressure Sensor System (Optional)
If input voltage from the third / fourth drum hoisting remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of third / fourth drum hoisting remote control sensor, or open circuit be-tween terminal D15 of MC2/A and terminal B (ground) of third/fourth drum hoisting remote control pressure sensor end connector. If input voltage from the third / fourth drum hoisting remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between third/fourth drum hoisting remote control pressure sensor and MC2/A, or short circuit be-tween SENSOR_5V line and ground line. Check the wiring connections first.
Connector
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
T2BC-05-03-001
Third / fourth drum hoisting remote control pressure sensor (sensor end)
Third / fourth drum hoisting remote rol pressure sensor (harness end)cont
MC2/A nnector MCA-2Co
Turn key switch OFF. Disconnect con-nector of third / fourth drum hoist-ing remote control pressure sensor. Check for continu-ity between termi-nals R and B of third / fourth drum hoisting remote control pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of third / fourth drum hoist-ing remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal C4 of connector of MC2/A meets specification.
Turn key switchOFF. Connect terminal W of harness end connector of third / fourth drum hoist-ing remote control pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C4 of connector MCA-2.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of third / fourth drum hoisting remote control pres-sure sensor is 5 0.5V. Faulty MC2/A.
Faulty harness up to terminal B of third / fourth drum hoisting remote control pres-sure sensor.
Turn key switchON. Check if voltage between terminals R and B of harness end connector of third / fourth drum hoisting remote control pressure sensor is 5 0.5 V.
Faulty third drum hoisting remote con-trol pressure sensor.
Faulty harness up to terminal R of third / fourth drum hoisting remote control pres-sure sensor.
Faulty third / fourthdrum hoisting remote control pressure sensor.
Faulty harness up to terminal W of third / fourth drum hoisting remote control pressure sensor.
Faulty MC2/A.
(harness end)
MC2/A Connector MCA-1(harness end)
T5-3-40
TROUBLESHOOTING / Troubleshooting A
T5-3-41
Check of Third / Fourth Drum Lowering Remote Control Pressure Sensor System (Optional)
• If input voltage from the third / fourth drum lowering remote control pressure sensor is 4.6 V or more, the cause of trouble may be failure of third/fourth drum lowering remote control sensor, or open circuit be-tween terminal D15 of MC2/A and terminal B (ground) of third / fourth drum lowering remote con-trol pressure sensor end connector.
• If input voltage from the third / fourth drum lowering remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit be-tween third / fourth drum lowering remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line.
Faulty third / fourthdrum lowering re-mote control pres-sure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of third / fourth drum lower-ing remote control pressure sensor.
Faulty harness up to terminal B of third / fourth drum lower-ing remote control pressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of third / fourth drum lowering remote control pres-sure sensor is 5±0.5V.
Faulty third / fourth drum lowering re-mote control pres-sure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of third / fourth drum lower-ing remote control pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C10 of connector MCA-2.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of third / fourth drum lower-ing remote control pressure sensor is 5±0.5 V.
Turn key switch OFF. Disconnect third / fourth drum lower-ing remote control pressure sensor. Check for continu-ity between termi-nals R and B of third / fourth drum lowering remote control pressure sensor.
Faulty harness up to terminal W of third / fourth drum lowering remote control pressure sensor.
Turn key switchOFF. Check for continu-ity between ma-chine and terminal B of harness end connector of third / fourth drum lower-ing remote control pressure sensor.
·Insert a test bar into the rear of connector
·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check if voltage between machine and terminal C10 of connector of MC2/A meets specification.
Third / fourth drum lowering remote control pressure sensor (sensor end)
Third / fourth drum lowering remote control pressure sensor(harness end)
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-2 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-42
Check of Primary Pilot Circuit Pressure Sensor System
• If input voltage from the primary pilot circuit pressure sensor is 4.6 V or more, the cause of trouble may be failure of primary pilot circuit pressure sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of primary pilot circuit pressure sensor end connector.
• If input voltage from the primary pilot circuit pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit primary pilot circuit pressure sensor and MC2/A, or short circuit between SEN-SOR_5V line and ground line.
• Check the wiring connections first.
T2BC-05-03-041 T2BC-05-03-040
T2BC-05-03-025
T2BC-05-03-001
Primary pilot circuit pressure sensor (sensor end)
Primary pilot circuit pressure sensor (harness end)
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-2 (harness end)
Faulty MC2/A.
Faulty primary pilot circuit pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of primary pilot circuit pressure sensor.
Faulty harness up to terminal B of primary pilot circuitpressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of primary pilot circuit pressure sensor is 5±0.5 V.
Faulty primary pilot circuit pressure sensor.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of primary pilot circuit pres-sure sensor is 5±0.5 V.
Turn key switch OFF. Disconnect con-nector of primary pilot circuit pres-sure sensor. Check for continu-ity between termi-nals R and B of primary pilot circuit pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of pri-mary pilot circuit pressure sensor.
·Insert a test bar into the rear of connector
·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check if voltage between machine and terminal C2 of connector of MC2/A meets specification.
Faulty harness up to terminal W of primary pilot circuit pressure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of pri-mary pilot circuit pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C2 of connector MCA-2.
TROUBLESHOOTING / Troubleshooting A
T5-3-43
Check of Front Brake Depressing Pressure Sen-sor System
• If input voltage from the front brake depressing pressure sensor is 4.6 V or more, the cause of trou-ble may be failure of front brake depressing pressure sensor, or open circuit between terminal of MC2/A and terminal B (ground) of front brake depressing pressure sensor end connector.
• If input voltage from the front brake depressing pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between front brake depressing pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line.
• Check the wiring connections first.
Connector
T2BC-05-03-041
T2BC-05-03-040
T2BC-05-03-025 T2BC-05-03-001
Front brake depressing pressure sensor (sensor end)
Front brake depressing pressure sensor (harness end)
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-2(harness end)
Faulty MC2/A.
Faulty front brake depressing pres-sure sensor.
Turn key switch OFF. Disconnect con-nector of front brake depressing pressure sensor. Check for continu-ity between termi-nals R and B of front brake de-pressing pressure sensor.
Turn key switchOFF. Check for continu-ity between ma-chine and terminal B of harness end connector of front brake depressing pressure sensor.
·Insert a test bar into the rear of connector.
·Specification: 0.5 to 4.5 V
Reconnect the disconnected con-nector. Check if voltage between machine and terminal C8 of connector of MC2/A meets specification.
Faulty MC2/A.
Faulty harness up to terminal R of front brake depressing pressure sensor.
Faulty harness up to terminal B of front brake depressing pressure sensor.
Faulty front brake depressing pressure sensor.
Faulty harness up to terminal W of front brake depressing pressure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of front brake depressing pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C8 of connector MCA-2.
Turn key switchON. Check if voltage between machine and terminal R of harness end con-nector of front brake depressing pressure sensor is 5±0.5 V.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of front brake depressing pressure sensor is 5±0.5 V.
TROUBLESHOOTING / Troubleshooting A
T5-3-44
Check of Rear Brake Depressing Pressure Sensor System
• If input voltage from the rear brake depressing pressure sensor is 4.6 V or more, the cause of trou-ble may be failure of rear brake depressing pressure sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of rear brake de-pressing pressure sensor end connector.
• If input voltage from the rear brake depressing pres-sure sensor is less than 0.5V, the cause of trouble may be harness open circuit between rear brake depressing pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line.
Faulty harness up to terminal R of rear brake de-pressing pressure sensor.
Faulty harness up to terminal B of rear brake de-pressing pressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of rear brake depressing pressure sensor is 5±0.5 V.
Faulty rear brake depressing pres-sure sensor.
Turn key switchOFF. Connect terminal W of harness end connector of rear brake depressing pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C1 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of harness end con-nector of rear brake depressing pressure sensor is 5±0.5 V.
Faulty harness up to terminal W of rear brake de-pressing pressure sensor.
Turn key switch OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of rear brake depressing pressure sensor.
Faulty MC2/A.
Faulty rear brake depressing pres-sure sensor.
·Insert a test bar into the rear of connector.
·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check if voltage between machine and terminal C1 of connector of MC2/A meets specification.
Turn key switch OFF. Disconnect con-nector of rear brake depressing pressure sensor. Check for continu-ity between termi-nals R and B of rear brake de-pressing pressure sensor.
TROUBLESHOOTING / Troubleshooting A
T5-3-45
Check of Fourth Brake Depressing Pressure Sensor System
• If input voltage from the fourth brake depressing pressure sensor is 4.6 V or more, the cause of trou-ble may be failure of fourth brake depressing pres-sure sensor, or open circuit between terminal D15 of MC2/A and terminal B (ground) of fourth brake de-pressing pressure sensor end connector.
• If input voltage from the fourth brake depressing pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between fourth brake depressing pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line.
• Check the wiring connections first.
Connector
T2BC-05-03-041 T2BC-05-03-040
T2BC-05-03-025 T2BC-05-03-001
Faulty fourth brake depressing pres-sure sensor.
Faulty MC2/A.
Faulty fourth brakedepressing pres-sure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of fourth brake de-pressing pressure sensor.
Faulty harness up to terminal B of fourth brake de-pressing pressure sensor.
Turn key switch ON. Check if voltage be-tween terminals R and B of harness end connector of fourth brake depressing pressure sensor is 5±0.5 V.
Turn key switchOFF. Connect terminal W of harness end connector of fourth brake depressing pressure sensor to machine.Disconnect con-nector MCA-2 of MC2/A. Check for continu-ity between ma-chine and terminal C7 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of harness end con-nector of fourth brake depressing pressure sensor is 5±0.5 V.
Turn key switch OFF. Disconnect con-nector of fourth brake depressing pressure sensor. Check for continu-ity between termi-nals R and B of fourth brake de-pressing pressure sensor.
Faulty harness up to terminal W of fourth brake de-pressing pressure sensor.
·Insert a test bar into the rear of connector.
·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check if voltage between machine and terminal C7 of connector of MC2/A meets specification.
Turn key switch, OFF. Check for continu-ity between ma-chine and terminal B of harness end connector of fourth brake depressing pressure sensor.
• Check the wiring connections first. • The cause of trouble may be failure of derricking
drum hoisting remote control pressure sensor and derricking drum lowering remote control pressure sensor system. At first, check the derricking drum hoisting and der-ricking drum lowering remote control pressure sen-sors.
Disconnect connector MCA-6 of MC2/A. Check if continuity between terminal #2 of harness end con-nector of derricking drum unlocking sole-noid valve and termi-nal E4 of harness end connector of connec-tor MCA-6.
Disconnect con-nector of derricking drum unlocking solenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and derricking drum unlocking solenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and derricking drum unlocking solenoid valve.
Connect connector MCA-6. Connect terminal #2 of harness end con-nector of derricking drum unlocking sole-noid valve to ma-chine. Check if voltage be-tween terminal #2 andmachine is 24 V.
· Derricking drum hoisting or derrick-ing drum lowering operation · Derricking drum hoisting or
derricking drum lowering operation
TROUBLESHOOTING / Troubleshooting A
T5-3-47
Check of Front Motor Brake Release Solenoid Valve
• Check the wiring connections first. • The cause of trouble may be failure of derricking
drum hoisting remote control pressure sensor and derricking drum lowering remote control pressure sensor system. At first, check the front drum hoisting remote control pressure sensor and front drum lowering remote control pressure sensor.
Connector
T25N-05-03-011 T2BC-05-04-027
Front motor brake release solenoid valve (harness end)
MC2/A Connector MCA-6 (harness end)
Faulty front motor brake release so-lenoid valve.
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end con-nector of front motor brake release sole-noid valve and termi-nal E18 of harness end connector of connector MCA-6.
Disconnect con-nector of front mo-tor brake release solenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and front motor brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and front motor brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #1 of harness end con-nector of front motor brake release sole-noid valve to ma-chine. Check if voltage be-tween machine and terminal #1 is 24 V.
· Front drum hoisting or front drum lowering operation
· Front drum hoisting or front drum lowering operation
21
TROUBLESHOOTING / Troubleshooting A
T5-3-48
Check of Rear Motor Brake Release Solenoid Valve
• Check the wiring connections first. • The cause of trouble may be failure of rear drum
hoisting remote control pressure sensor and rear drum lowering remote control pressure sensor sys-tem. At first, check the rear hoisting derricking drum low-ering remote control pressure sensor and rear drum lowering remote control pressure sensor.
Connector
T25N-05-03-011 T2BC-05-04-027
Faulty rear motor brake release so-lenoid valve.
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end con-nector of rear motor brake release sole-noid valve and termi-nal E5 of harness end connector of connec-tor MCA-6.
Disconnect con-nector of rear mo-tor brake release solenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and rear motor brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and rear motor brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #1 of harness end con-nector of rear motor brake release sole-noid valve to ma-chine. Check if voltage be-tween terminal #1 and machine is 24 V.
Rear motor brake release solenoid valve (harness end)
MC2/A Connector MCA-6 (harness end)
21
TROUBLESHOOTING / Troubleshooting A
T5-3-49
Check of Fourth Motor Brake Release Solenoid Valve (Optional)
• Check the wiring connections first. • The cause of trouble may be failure of third / fourth
drum hoisting remote control pressure sensor and third / fourth drum lowering remote control pressure sensor system. At first, check the third / fourth drum hoisting remote control pressure sensor and third / fourth drum low-ering remote control pressure sensor.
Connector
T2BC-05-03-026
T2BC-05-04-027
Faulty fourth motor brake release so-lenoid valve.
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #2 of harness end con-nector of fourth winch connector and termi-nal E19 of harness end connector of connector MCA-6.
Disconnect fourth winch connector.Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and fourth motor brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and fourth motor brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #2 of harness end con-nector of fourth winch connector to machine.Check if voltage be-tween terminal #2 andmachine is 24 V.
· Fourth drum hoist-ing or fourth drum lowering operation
· Fourth drum hoist-ing or fourth drum lowering operation
Fourth winch (harness end)
MC2/A Connector MCA-6 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-50
Check of Third/Fourth Auto Brake Indicator (Op-tional)
• Check the wiring connections first.
Connector
T2BC-05-04-027
MC2/A Connector MCA-6 (harness end)
Disconnect con-nector MCA-6 of MC2/A. Check if third / fourth auto brake indicator goes OFF.
Faulty MC2/A.
Faulty harness be-tween MC2/A and third / fourth auto brake indicator.
TROUBLESHOOTING / Troubleshooting A
T5-3-51
Check of Brake Mode Key Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-04-022
MC2/A Connector MCA-4 (harness end)
Left control panel Connector 62C-16MW (harness end)
Faulty MC2/A.
Faulty brake mode key switch.
Disconnect connector MCA-1 of MC2/A and connector 62C-16MWof left control panel. Connect terminals D2 and A8 of harness end connector of connectors MCA-1 and MCA-4 to ma-chine. Check for continuity between machine andterminals #8 and #9 of harness end con-nector of left control panel.
In case of no con-tinuity at terminal #8, harness open circuit between terminal #8 of left control panel and MC2/A. In case of no con-tinuity at terminal #9, harness open circuit between terminal #9 of left control panel and MC2/A.
YES
NO
Disconnect con-nector MCA-4 from MC2/A. Check if voltage between terminal A8 of harness end connector and ma-chine is 24 V.
· Key switch: ON· Brake mode key
switch: ON
YES
NO
MC2/A Connector MCA-1 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-52
Check of Front Drum Brake Mode Selection Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
Faulty MC2/A.
Faulty front drum brake mode selec-tion switch.
Disconnect connector MCA-1 of MC2/A and connector of front lever. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of front lever, terminal A21 of connector MCA-4 and terminal #3 of con-nector of front lever.
In case of no con-tinuity at terminal #3, harness open circuit between front drum brake mode selection switch and MC2/A. In case of no con-tinuity at terminal #4, harness open circuit between front drum brake mode selection switch and MC2/A.
YES
NO
Disconnect con-nector MCA- of MC2/A. Check if voltage between terminal A21of harness end connector and ma-chine is 24 V. · Key switch: ON · Front drum brake
mode selection switch: ON
YES
NO
MC2/A Connector MCA-4 (harness end)
Connector of front drum brake mode selection switch (harness end)
MC2/A Connector MCA-1 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-53
Check of Rear Drum Brake Mode Selection Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
Faulty MC2/A.
Faulty rear drum brake mode selec-tion switch.
Disconnect connector MCA-1 of MC2/A and connector of rear lever. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of rear lever, terminal A9 of connector MCA-4 and terminal #3 of con-nector of rear lever.
In case of no con-tinuity at terminal #3, harness open circuit between rear drum brake mode selection switch and MC2/A. In case of no con-tinuity at terminal #4, harness open circuit between rear drum brake mode selection switch and MC2/A.
YES
NO
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A9 of harness end connector and ma-chine is 24 V. · Key switch: ON · Rear drum brake
mode selection switch: ON
YES
NO
MC2/A Connector MCA-4 (harness end)
Connector of rear drum brakemode selection switch (harness end)
MC2/A Connector MCA-1 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-54
Check of Third / Fourth Drum Brake Mode Selec-tion Switch System (Optional)
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
Faulty MC2/A.
Faulty third / fourth drum brake mode selection switch.
Disconnect connector MCA-1 of MC2/A. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of third / fourth lever, terminal A22 of connector MCA-4 and terminal #3 of connector of third / fourth lever.
In case of no con-tinuity at terminal #3, harness open circuit between third / fourth drum brake mode selec-tion switch and MC2/A. In case of no con-tinuity at terminal #4, harness open circuit between third / fourth drum brake mode selec-tion switch and MC2/A.
YES
NO
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A22 of harness end connector and ma-chine is 24 V.
· Key switch: ON · Third/fourth drum
brake mode se-lection switch: ON
YES
NO
MC2/A Connector MCA-4 (harness end)
Connector of third / fourth drum brake mode selection switch (harness end)
MC2/A Connector MCA-1 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-55
Check of Front Brake Pedal Limit Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
Connector of front brake pedal limit switch (harness end)
MC2/A Connector MCA-1 (harness end)
Faulty MC2/A.
Disconnect connector MCA-1 of MC2/A andconnector of front brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of connector of front brake pedal limit switch, terminal A11 of connector MCA-4 and terminal #2 of connector of front brake pedal limit switch.
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A11 of harness end connector and machine is 24 V.
Faulty front brakepedal limit switch.
In case of no con-tinuity at terminal #1, harness open circuit between front brake pedal limit switch and MC2/A. In case of no con-tinuity at terminal #2, harness open circuit between front brake pedal limit switch and MC2/A.
· Key switch: ON · Front brake pedal
limit switch: ON
MC2/A Connector MCA-4(harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-56
Check of Rear Brake Pedal Limit Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
Connector of rear brake pedal limit switch (harness end)
MC2/A Connector MCA-1 (harness end)
Faulty MC2/A.
Disconnect connector MCA-1 of MC2/A andconnector of rear brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of connector of rear brake pedal limit switch, terminal A24 of connector MCA-4 and terminal #2 of connector of rear brake pedal limit switch.
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A11 of harness end connector and machine is 24 V.
Faulty rear brakepedal limit switch.
In case of no con-tinuity at terminal #1, harness open circuit between rear brake pedal limit switch and MC2/A. In case of no con-tinuity at terminal #2, harness open circuit between rear brake pedal limit switch and MC2/A.
· Key switch: ON · Rear brake pedal
limit switch: ON
MC2/A Connector MCA-4(harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-57
Check of Fourth Brake Pedal (Optional) Limit Switch System
• Check the wiring connections first.
Connector
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
Connector of fourth brake pedal limit switch (harness end)
MC2/A Connector MCA-1 (harness end)
Faulty MC2/A.
Disconnect connector MCA-1 of MC2/A andconnector of fourth brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of connector of fourth brake pedal limit switch, terminal A12 of connector MCA-4 and terminal #2 of connector of fourth brake pedal limit switch.
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A9 of harness end connector and machine is 24 V.
Faulty fourth brake pedal limit switch.
In case of no con-tinuity at terminal #1, harness open circuit between fourth brake pedal limit switch and MC2/A. In case of no con-tinuity at terminal #2, harness open circuit between fourth brake pedal limit switch and MC2/A.
· Key switch: ON · Fourth brake pedal
limit switch: ON
MC2/A Connector MCA-4 (harness end)
TROUBLESHOOTING / Troubleshooting A
T5-3-58
Check of Front Drum Brake Release Solenoid Valve
• Check the wiring connections first.
Connector
T2BC-05-04-008
T2BC-05-03-004
Front drum brake release solenoid valve (harness end)
MC2/A Connector MCA-6 (harness end)
Faulty front drum brake release so-lenoid valve.
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end con-nector of front drum brake release sole-noid valve and termi-nal E14 of harness end connector of connector MCA-6.
Disconnect con-nector of front drum brake re-lease solenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and front drum brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and front drum brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #1 of harness end con-nector of front drum brake release sole-noid valve to ma-chine. Check if voltage be-tween terminal #1 andmachine is 24 V.
· Key switch: ON · Brake mode key
switch: ON · Front drum free
mode switch: ON · Key switch: ON · Brake mode key switch:
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end con-nector of rear drum brake release sole-noid valve and termi-nal E1 of harness end connector of connec-tor MCA-6.
Disconnect con-nector of rear drum brake release so-lenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and rear drum brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and rear drum brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #1 of harness end con-nector of rear drum brake release sole-noid valve to ma-chine. Check if voltage be-tween terminal #1 andmachine is 24 V.
· Key switch: ON · Brake mode key
switch: ON · Rear drum free
mode switch: ON · Key switch: ON · Brake mode key switch:
ON· Rear drum free mode
switch: ON
TROUBLESHOOTING / Troubleshooting A
T5-3-60
Check of Fourth Drum Brake Release Solenoid Valve (Optional)
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end con-nector of fourth drum brake release sole-noid valve and termi-nal E15 of harness end connector of connector MCA-6.
Disconnect con-nector of fourth drum brake re-lease solenoid valve. Check if voltage between terminals #1 and #2 of har-ness end connec-tor is 24 V.
Faulty harness between ground and fourth drum brake release so-lenoid valve, or faulty ground.
Faulty MC2/A.
Faulty harness between MC2/A and fourth drum brake release so-lenoid valve.
Connect connector MCA-6. Connect terminal #1 of harness end con-nector of fourth drum brake release sole-noid valve to ma-chine. Check if voltage be-tween terminal #1 andmachine is 24 V.
· Key switch: ON · Brake mode key
switch: ON · Fourth drum free
mode switch: ON · Key switch: ON · Brake mode key switch:
ON· Fourth drum free mode
switch: ON
TROUBLESHOOTING / Troubleshooting A
T5-3-61
Check of Harness between MC2/A and MC2/B
• Check the wiring connections first.
• Check for continuity between terminal Y17 of har-ness end connector of connector MCA-4 of MC2/A and terminal Y17 of harness end connector of con-nector MCB-6 of MC2/B.
• Check for continuity between terminal R8 of harness end connector of connector MCA-4 of MC2/A and terminal R8 of harness end connector of connector MCB-4 of MC2/B.
• Check for continuity between terminal R21 of har-ness end connector of connector MCA-4 of MC2/A and terminal R21 of harness end connector of con-nector MCB-4 of MC2/B.
Connector MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020
MC2/BConnector MCB-4 (harness end)
T2BC-05-03-027
MC2/BConnector MCB-6 (harness end)
T2BC-05-03-003
TROUBLESHOOTING / Troubleshooting A
T5-3-62
FAILURE OF MAIN PUMP DELIVERY FLOW RATE CONTROL SYSTEM
Abnormality • By using the power supply monitor, check if all of
battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the sensor and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit errorTHROT. GRIP Accelerator grip
HI ER Upper limit errorControls as a minimum input.
Harness checkSensor check
LOW ER Lower limit errorHI ER Upper limit error
M PMP GUR Main pump displacement angle proportional sole-noid valve RES ER Reset error
Controls current by controller in-ternal data.
Harness checkSolenoid valve check
DD HST PRS Derricking drum hoisting remote control pressure
LOW ER Lower limit error
DD LWR PRS Derricking drum lowering remote control pressure
FD HST PRS Front drum hoisting re-mote control pressure
FD LWR PRS Front drum lowering re-mote control pressure
RD HST PRS Rear drum hoisting re-mote control pressure
HI ER Upper limit error
RD LWR PRS Rear drum lowering re-mote control pressure
3D HST PRS Third/fourth drum hoist-ing remote control pres-sure
3D LWR PRS Third/fourth drum lower-ing remote control pres-sure
Controls with control lever in neutral.
Harness checkSensor check
• For checks of derricking drum hoisting, derricking drum lowering, front drum hoisting, front drum low-ering, rear drum hoisting, rear drum lowering, third / fourth drum hoisting and third/fourth drum lowering remote control pressure sensor systems, refer to Section "Failure of Brake Control System".
• For check of the accelerator grip, refer to Section "Failure of Engine Control System".
TROUBLESHOOTING / Troubleshooting A
700 to 0 mA, 12.3 to 0 V
Main Pump Displacement Angle Proportional SOL
24V
1.0 to 2.4V
Accelerator Grip
5V
IDU CAN_1L CAN_1H
Derricking Drum Hoisting Remote Control Pressure
1.0 to 2.4V 5V0V
Derricking Drum Lowering Remote Control Pressure
Front Drum Hoisting Remote Control Pressure
Front Drum Lowering Remote Control Pressure
Rear Drum Hoisting Remote Control Pressure
Rear Drum Lowering Remote Control Pressure
Third / Fourth Drum Hoisting Remote Control Pressure
Third / Fourth Drum Lowering Remote Control Pressure
24V24V(ON)0V(OFF)
Accelerator LockAccelerator Preset
T25N-05-03-013
T5-3-63
TROUBLESHOOTING / Troubleshooting A
Main Pump Displacement Angle Proportional Solenoid Valve
Check the wiring connections first.
Connector
Faulty main pump displacementangle proportional solenoid valve.
Faulty accelerator lock switch, or faulty harness between MC2/A and accelerator lock switch.
YES
NO
T2BC-05-04-015
T2BC-05-03-021
T2BC-05-03-028
T2BC-05-03-030
Disconnectconnector of main pump displacement
nal.
f electric tween
terminals #1 and #2 ss end
0 to 0 mA in accelerator
tation range to 100%.
· Accelerator lock switch: ON
angle proportiosolenoid valveCheck icurrent be
of harneconnector is 70
grip roof 0
Faulty MC2/A.
Faulty harness between MC2/A and main pump displacementangle proportional solenoid valve.
Refer to Section "Check of Accelerator Grip".
YES
NO
Check if voltage between terminal D3 of connector MCA-1 and terminalA6 of connector MCA-4 of MC2/A is 24 V. · Accelerator lock
switch: ON · Insert a test bar into
the rear of connector.
YES
NO
Disconnectconnector MCA-5 of MC2/A. Check if electric current between terminals F5 and F9 of machine end connector is 700 to 0 mA in accelerator grip rotation range of 0 to 100%. · Accelerator lock
switch: ON
Accelerator lock switch
Accelerator grip
Main pump displacement angle proportional solenoid valve (harness end)
MC2/A Connector MCA-1 (machine end)
MC2/A Connector MCA-5 (machine end)
MC2/AConnector MCA-4(machine end)
T5-3-64
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MAIN PUMP POWER INCREASE CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the solenoid valve signal.
Item Signal name Description Explanation State CountermeasureRACK P. S. Rack sensor ERROR Error Controls pump torque
according to engine speed. Harness check Sensor check
LOW ER Lower limit error HI ER Upper limit error
INC. TQ CUR Power increase solenoid valve
RES ER Reset error
Controls current by controller internal data.
Harness check Solenoid valve check
0 to 700 mA, 0 to 12.3 V
Power Increase Solenoid Valve24 V
1.9 to 3.1 V
RackSensor
0 to 6 VAC, 0 to 5.3 kHz
Engine Speed Detection
T25N-05-03-014
For check of engine rotation detection sensor, refer to "Check of Engine Rotation Detection Sensor" in Section "Failure of Engine Control System".
T5-3-65
TROUBLESHOOTING / Troubleshooting A
Check of Rack Sensor System
Check the wiring connections first.
Connector
Follow the failure code.
Harness open circuit between ECU and MC2/A, or faulty ground.
YES
NO
Diagnose ECU. Check if failure code of rack sensor is output.
Disconnect ECU connector 2. Check if voltage at terminal #1 of harness end connector is 24 V.
· Refer to Troubleshooting E.
Faulty MC2/A.
Faulty ECU.
· Key switch: ON
Harness open circuit between ECU and MC2/A.
YES
NO
Disconnectconnector MCA-3 ofMC2/A. Check for continuity between terminal B4 of harness end connector of MC2/A and terminal #8 of harness end connector of ECU connector 2.
Reconnect the disconnected connector.Disconnectconnector MCA-1 ofMC2/A. Connect terminal D14 of machine end connector to machine. Check if NORMAL is indicated.
YES
YES
NO
NO
MC2/A Connector MCA-3
MC2/A Connector MCA-1 (harness end)
ECU connector 2
T2BC-05-04-029 T2BC-05-03-001
(harness end) (harness end)
T2BC-05-03-013
T5-3-66
TROUBLESHOOTING / Troubleshooting A
Check of Power Increase Solenoid Valve
Check the wiring connections first.
Connector
T2BC-05-03-031
T2BC-05-04-008
T2BC-05-03-029
Disconnectconnector of power
Check for between
terminals #1 and end
increase solenoid valve.
continuity
#2 of machineconnector.
YES
YES
NO
Harness short circuit between power increase solenoid valve and MC2/A.
Disconnect clip from terminal F21 of harness endconnector of MCA-5. Check for continuity between machine and terminal #1 of harness end connector of power increase solenoid valve.
Disconnect connector MCA-5 of MC2/A. Connect terminals F17 and F21 of harness end connector of MCA-5 to machine by using a clip.Check for continuity between machine andterminals #1 or #2 of harness end connector of power increase solenoid valve.
Key switch: OFF
Faulty MC2/A.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of power increase solenoid valve and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of power increase solenoid valve and MC2/A. ·
Faulty power increase solenoid valve.
Power increase solenoid valve (machine end)
MC2/A Connector MCA-5 (harness end)
Power increase solenoid valve (harness end)
T5-3-67
TROUBLESHOOTING / Troubleshooting A
FAILURE OF SLEWING ALARM CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the sensor and relay signal.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit error
HI ER Upper limit error Controls as input with lever in neutral.
SL RGT PRS SL LFT PRS
Slewing (right) remote control pressure Slewing (left) remote control pressure
DBL ER Double errors Controls as input by lever control.
Harness check Sensor check
SL ALAM LP Slewing alarm lamp relay
ERROR Short circuit Harness check Relay check
24 V (ON)0 V (OFF)
Slewing Alarm Lamp Relay 24 V
5 V0 V0.5 to 4.5 V
Slewing (Right) Remote Control Pressure
Slewing (Left) Remote Control Pressure
T25N-05-03-016
T5-3-68
TROUBLESHOOTING / Troubleshooting A
Check of Slewing (Right) Remote Control Pressure Sensor System
Check the wiring connections first.
Connector
Faulty MC2/A.
Faulty slewing(right) remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of slewing (right) remote control pressure sensor.
Faulty harness up to terminal B of slewing (right) remote control pressure sensor.
Faulty slewing(right) remote control pressure sensor.
Disconnectconnector of slewing (right) remote control pressure sensor. Check for continuity between terminals R and B of connector of slewing (right) remote control pressure sensor.
Faulty harness up to terminal W of slewing (right) remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector. Check ifvoltage between machine and terminal C3 of connector of MC2/A meets specification.
Check for continuity between machine and terminal B of harness end connector of slew (right) remote control pressure sensor.
Connect terminalW of harness end connector of slewing (right) remote control pressure sensor to machine by using aclip.Disconnectconnector MCA-2 of MC2/A. Check for continuity between machine and terminal C3 of harness end connector.
Check if voltage between machine and terminal R of harness end connector of slewing (right) remote control pressure sensor is 5 0.5 V.
Check if voltage between terminals R and B of harness end connector of slewing (right) remote control pressure sensor is 5 0.5 V.
·Key switch: ON
·Key switch: OFF
·Key switch: OFF
·Key switch: ON
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
Slewing (right) remote control pressure sensor (machine end)
MC2/A Connector MCA-2 (harness end)
Slewing (right) remote control pressure sensor (harness end)
T5-3-69
TROUBLESHOOTING / Troubleshooting A
Check of Slewing (Left) Remote Control Pressure Sensor System
Check the wiring connections first.
Connector
Faulty MC2/A.
Faulty slewing(left) remote control pressure sensor.
Faulty MC2/A.
Faulty harness up to terminal R of slewing (left) remote control pressure sensor.
Faulty harness up to terminal B of slewing (left) remote control pressure sensor.
Faulty slewing(left) remote control pressure sensor.
Disconnectconnector of slewing (left) remote control pressure sensor. Check for continuity between terminals R and B of connector of slewing (left) remote control pressure sensor.
Faulty harness up to terminal W of slewing (left) remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Reconnect the disconnected connector.Check if voltage between machine and terminal C9 of connector of MC2/A meets specification.
Check for continuity between machine and terminal B of harness end connector of slew (left) remote control pressure sensor.
Connect terminalW of harness end connector of slewing (left) remote control pressure sensor to machine by using aclip.Disconnectconnector MCA-2 of MC2/A.
T2BC-05-03-023
T2BC-05-03-024
T2BC-05-03-025
Check for continuity between machine and terminal C9 of harness end connector.Check if voltage
between terminals R and B of harness end connector of slewing (left) remote control pressure sensor is 5 0.5 V.
Check if voltage between terminal R of harness end connector ofslewing (left) remote control pressure sensor and machine is 5 0.5 V.
·Key switch: ON
·Key switch: OFF
·Key switch: OFF
·Key switch: ON
MC2/A Connector MCA-2 Slewing (left) remote control
pressure sensor (machine end) (harness end)
Slewing (left) remote control pressure sensor (harness end)
T5-3-70
TROUBLESHOOTING / Troubleshooting A
Check of Slewing Alarm Lamp Relay System
Check the wiring connections first.
Connector
Faulty slewingalarm lamp relay.
Faulty harness between MC2/A and slewing alarm lamp relay.
Disconnectconnector of slewing alarm lamp relay. Check if voltage between machine and terminal #1 of harness end connector is 0 V.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine andterminal E21 of machine end connector is 0 V.
· Key switch: ON
· Key switch: ON
T2BC-05-03-032
MC2/A Connector MCA-6 Slewing alarm lamp relay
(harness end) (machine end)
2 4 1
5
3
T5-3-71
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ROTATION SENSING CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the sensor and solenoid valve signals.
Item Signal name Description Explanation State Countermeasure
Check of Front Drum Rotation Sensing Solenoid System
Check the wiring connections first.
Connector
Faulty front drum rotation sensing solenoid.
Faulty harness between front drum rotation sensing solenoid and MC2/A.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine andterminal E2 of machine end connector is 0 V.
· Key switch: ON · Drum rotation sensing
cancellation switch: ON
· Key switch: ON · Drum rotation sensing
cancellation switch: ON
Disconnect connector of front lever. Check if voltage between terminal #6 of harness end connector and machine is 0 V.
T2BC-05-03-005 T2BC-05-03-032
Front lever (harness end)
MC2/A Connector MCA-6 (machine end)
T5-3-73
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Sensing Solenoid System
Check the wiring connections first.
Connector
Faulty rear drum rotation sensing solenoid.
Faulty harness between rear drum rotation sensing solenoid and MC2/A.
Disconnectconnector of rear lever.Check if voltage between terminal #6 of harness end connector and machine is 0 V.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine andterminal E16 of machine end connector is 0 V.
· Key switch: ON · Drum rotation
sensing cancellation switch: ON
· Key switch: ON · Drum rotation
sensing cancellation switch: ON
MC2/A Connector MCA-6
T2BC-05-03-005
Rear lever (harness end) (machine end)
T2BC-05-03-032
T5-3-74
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Rotation Sensing Solenoid System
Check the wiring connections first.
Connector
Faulty derricking drum rotation sensing solenoid.
Faulty harness between derricking drum rotation sensing solenoid and MC2/A.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine andterminal E3 of machine end connector is 0 V.
· Key switch: ON · Drum rotation
sensing cancellation switch: ON · Key switch: ON
· Drum rotation sensing cancellation switch: ON
Disconnectconnector of derricking lever. Check if voltage between terminal #1 of harness end connector and machine is 0 V.
MC2/A Connector MCA-6
T2BC-05-04-008
T2BC-05-03-032
Derricking lever (machine end) (harness end)
T5-3-75
TROUBLESHOOTING / Troubleshooting A
Check of Drum Rotation Sensing Cancellation Switch System
Check the wiring connections first.
Connector
Faulty MC2/A.
Reconnect the disconnected connector. Disconnect connector MCA-5 of MC2/A and connector 62C16F-W of left overhead panel. Connect terminal F16 of harness end connector of connector MCA-5 to machine.Check for continuity between machine and terminals A15, F16 of harness end connector of left overhead panel connector.
YES
NO
Disconnect
Faulty drum rotation sensing cancellation switch.
In case of no continuity at terminal YES
NO
A15, harness open circuit between input end terminal of drum rotation sensing cancellation switch and MC2/A. In case of no continuity at terminal F16, harness open circuit between ground end terminal of drum rotation sensing cancellation switch and MC2/A.
T2BC-05-03-028
T2BC-05-03-020
T2BC-05-03-029 T2BC-05-03-033
connector MCA-4 of MC2/A.
f voltage ween machine
and terminal A15 of
V.
Key Switch: ON
Check ibet
machine end connector is 24
·
MC2/A Connector MCA-4
MC2/A Connector MCA-5
Left overhead panel Connector 62C16F-W
(machine end) (harness end) (harness end)
MC2/A Connector MCA-4 (harness end)
T5-3-76
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Rotation Detection Sensor A System
Check the wiring connections first.
Connector
Faulty front drum rotation detection sensor A.
Faulty MC2/A.
T2BC-05-04-008
T2BC-05-03-020 T2BC-05-03-029
Replace front drum rotation detection
with rear tion
detection sensor A drum
tion detection
f error indication on
sensor A drum rota
or derrickingrotasensor A. Check i
monitordisappears.
Disconnect connector of front drum rotation detection sensor A as well as connectors MCA-4 and MCA-5 of MC2/A. Connect terminal A13of harness end connector of MCA-4 and terminal F16 of harness end connector of MCA-5 connector to machine.Check for continuity between machine andterminals #1, #2 of harness end connector of front drum rotation detection sensor A.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum rotation detection sensor A and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum rotation detection sensor A and MC2/A.
MC2/A MC2/A Connector MCA-5 Connector MCA-4 Front drum rotation detection
sensor A (harness end) (harness end) (harness end)
T5-3-77
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Rotation Detection Sensor B System
Check the wiring connections first.
Connector
Disconnect connector of front drum rotation detection sensor B as well as connectors MCA-4 and MCA-5 of MC2/A. Connect terminal A26 of harness end connector of connector MCA-4 and terminal F16 of harness end connector of connector MCA-5 to machine.Check for continuity between machine and terminals #1 or #2 of harness end connector of front drum rotation detection sensor B.
Faulty front drum rotation detection sensor B
T2BC-05-04-008
T2BC-05-03-020 T2BC-05-03-029
Replace front drum rotation detection
with rear drum rotation
sensor B. f error
indication on monitor
sensor B
detection
MC2/A Connector MCA-4 (harness end)
Front drum rotation detection sensor B (harness end)
MC2/A Connector MCA-5 (harness end)
Check i
disappears.In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum rotation detection sensor B and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum rotation detection sensor B and MC2/A.
Faulty MC2/A
T5-3-78
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Detection Sensor A System
Check the wiring connections first.
Connector
Disconnect connector of rear drum rotation detection sensor A as well as connector MCA-5 of MC2/A. Connect terminals F12 and F16 of harness endconnector of MCA-5 to machine.Check for continuity between machine and terminals #1 or #2 of harness end connector of rear drum rotation detection sensor A.
Replace rear drum
Faulty rear drum rotation detection sensor A.
T2BC-05-04-008
T2BC-05-03-029
rotation detection with front
drum rotation detection A or derricking
tion detection sensor A.
f error indication on monitor disappears.
sensor A
sensordrum rota Faulty MC2/A.
Check iIn case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum rotation detection sensor A and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum rotation detection sensor A and MC2/A.
MC2/A Connector MCA-5 (harness end)
Rear drum rotation detection sensor A (harness end)
T5-3-79
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Detection Sensor B System
Check the wiring connections first.
Connector
Faulty rear drum rotation detection sensor B.
Faulty MC2/A.
Replace rear drum rotation detection sensor B with front drum rotation de-tection sensor B. Check if the error indication on moni-tor disappears.
In case of no con-tinuity at terminal #1, harness open circuit between terminal #1 of rear drum rotation de-tection sensor B and MC2/A. In case of no con-tinuity at terminal #2, harness open circuit between terminal #2 of rear drum rotation de-tection sensor B and MC2/A.
Disconnect connector of rear drum rotation detection sensor B and connector MCA-5 of MC2/A. Connect terminals F1 and F16 of harness end connector of MCA-5 to machine. Check for continuity between machine andterminals # 1 or #2 of harness end connec-tor of rear drum rota-tion detection sensor B.
T2BC-05-04-008 T2BC-05-03-029
MC2/A Connector MCA-5 (harness end)
Rear drum rotation detection sensor B (harness end)
T5-3-80
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Rotation Detection Sensor A System
Check the wiring connections first.
Connector
Faulty derrickingdrum rotation de-tection sensor A.
Faulty MC2/A.
T2BC-05-04-008 T2BC-05-03-029
Replace derricking tion detec-
tion sensor A with t drum rotation
sensor A or rear drum rota-
tection sen-sor A.
f the error moni-
tor disappears.
drum rota
frondetection
tion de
Check iindication on
Disconnect connector of derricking drum rotation detection sensor A and con-nector MCA-5 of MC2/A. Connect terminals F13 and F16 of har-ness end connector o
In case of no con-tinuity at terminal #1, harness open circuit between terminal #1 of der-ricking drum rota-tion detection sensor A and MC2/A. In case of no con-tinuity at terminal #2, harness open circuit between terminal #2 of der-ricking drum rota-tion detection sensor A and MC2/A.
fMCA-5 to machine. Check for continuity between machine andterminals # 1 or #2 of harness end connec-tor of derricking drum rotation detection sensor A.
Derricking drum rotation detection sensor A MC2/A
Connector MCA-5 (harness end) (harness end)
T5-3-81
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ENGINE START INTERLOCK CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the relay signal.
Item Signal name Description Explanation State CountermeasureENG. INTLCK Engine start relay ERROR Short circuit Harness check
Relay check
Start Relay 1
Engine Start Interlock
Front Drum Brake Mode Selection Switch
Rear Drum Brake Mode Selection Switch
24V
Third / Fourth Drum Brake Mode Selection Switch
Slewing Brake Switch
Starter Switch
T2BC-05-03-035
T5-3-82
TROUBLESHOOTING / Troubleshooting A
Check of Engine Start Relay
Check the wiring connections first.
Connector
Faulty engine start relay.
Faulty harness between MC2/A and engine start relay.
Disconnect con-nector of engine start relay. Check if voltage between machine and terminal #1 of harness end con-nector is 24V.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage be-tween machine and terminal E20 of ma-chine end connector is 24 V. · Connect terminals E12,
E13 and E26 of both connectors by using a clip or the like.
Faulty harness between slewing brake switch and MC2/A.
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A18 of harness end connector and machine is 0 V.
Faulty slewingbrake switch.
Check if voltage be-tween machine and terminal #8 of slewinglever connector is 0 V.
· Insert a test bar into the rear of connector.
· Key switch: ON · Slewing brake switch:
ON
· Key switch: ON · Slewing brake switch:
ON
T2BC-05-03-020 T2BC-05-03-036
MC2/A Slewing lever Connector MCA-4 (harness end) (slewing lever end)
T5-3-84
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Free Mode Switch System
Check the wiring connections first.
Connector
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A21 of harness end connector and machine is 0 V.
Disconnect connector MCA-1 of MC2/A and front lever connector. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of front lever connector, terminal A21 of con-nector MCA-4 and terminal #3 of front lever connector.
· Key switch: ON · Front drum free mode
switch: OFF (auto brake)
Faulty MC2/A.
Faulty front drum brake mode selec-tion switch.
In case of no conti-nuity at terminal #3, faulty harness be-tween terminal #3 of front drum brake mode selection switch and MC2/A. In case of no conti-nuity at terminal #4, faulty harness be-tween terminal #4 of front drum brake mode selection switch and MC2/A.
MC2/A Connector MCA-4
Front lever
T2BC-05-03-020
T2BC-05-03-001
T2BC-05-03-005
(front lever end) (harness end)
MC2/A Connector MCA-1 (harness end)
T5-3-85
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Free Mode Switch System
Check the wiring connections first.
Connector
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A21 of harness end connector and machine is 0 V.
Disconnect connector MCA-1 of MC2/A and rear lever connector. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of rear lever connector, terminal A9 of con-nector MCA-4 and terminal #3 of rear lever connector.
· Key switch: ON · Rear drum free mode
switch: OFF (auto brake)
Faulty MC2/A.
Faulty rear drum brake mode selec-tion switch.
In case of no conti-nuity at terminal #3, faulty harness be-tween terminal #3 of rear drum brake mode selection switch and MC2/A. In case of no conti-nuity at terminal #4, faulty harness be-tween terminal #4 of rear drum brake mode selection switch and MC2/A.
T2BC-05-03-020
T2BC-05-03-001
T2BC-05-03-005
Rear lever (rear lever end)
MC2/A Connector MCA-4 (harness end)
MC2/A Connector MCA-1 (harness end)
T5-3-86
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Free Mode Switch System (Optional)
Check the wiring connections first.
Connector
Disconnect con-nector MCA-4 of MC2/A. Check if voltage between terminal A22 of harness end connector and machine is 0 V.
Disconnect connector MCA-1 of MC2/A and third/fourth lever con-nector.Check for continuity between terminal D2 of connector MCA-1 and terminal #3 of third / fourth lever connector, terminal A22 of connector MCA-4 and terminal #4 of third/fourth lever connector.
In case of no conti-nuity at terminal #3, faulty harness be-tween terminal #3 of third / fourth drum brake mode selec-tion switch and MC2/A. In case of no conti-nuity at terminal #4, faulty harness be-tween terminal #4 of third/fourth drum brake mode selec-tion switch and MC2/A.
T2BC-05-03-020
T2BC-05-03-001
T2BC-05-03-005
Third / fourth lever MC2/A (third / fourth lever end) Connector MCA-4 (harness end)
MC2/A Connector MCA-1 (harness end)
T5-3-87
TROUBLESHOOTING / Troubleshooting A
FAILURE OF PILOT PRESSURE DROP WARNING LAMP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/A input/output monitor, confirm the sensor signal.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit
errorPILOT PRS Primary pilot pres-
sureHI ER Upper limit
error
Controls as pressure drop input.
Harness check Sensor check
24 V (ON)0 V (OFF)
24 V
Pilot Pressure Drop Indicator
5 V0 V0.5 to 4.5 V
Primary Pilot Pressure
T25N-05-03-019
For check of primary pilot pressure sensor, refer to "Check of Primary Pilot Pressure" of "Failure of Brake Control System".
T5-3-88
TROUBLESHOOTING / Troubleshooting A
Check of Pilot Pressure Drop Indicator
Check the wiring connections first.
Even when pilot pressure drops below the set pres-sure, the indicator is not turned ON.
Even when pilot pressure is at the set pressure, the indicator is not turned OFF.
Connector
Faulty MC2/A.
Burn-out of pilot pressure drop indicator.
Disconnect con-nector 62C-16FW of monitor panel. Check if voltage between terminals E8 and #224 of harness end con-nector is 24 V.
Harness open circuit between MC2/A and pilot pressure drop indicator.
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal E8 of harness end con-nector and terminal E8 of connector C62-16FW.
· Key switch: ON
Faulty MC2/A.Disconnect con-nector 62C-16FW of monitor panel. Check for continu-ity between termi-nals E8 and #224 of harness end connector.
Harness short circuit between MC2/A and pilot pressure drop indicator.
· Key switch: ON
T2BC-05-03-037 T2BC-05-03-004
Monitor panel Connector 62C-16FW (harness end)
MC2/A Connector MCA-6 (harness end)
T5-3-89
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MOTOR CUTOFF PRESSURE CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all bat-tery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies"
By using the MC2/A input/output monitor, confirm the sensor signal.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit
errorFD LWR PRS RD LWR PRS
Front drum lowering re-mote control pressure Rear drum lowering re-mote control pressure
HI ER Upper limit error
Controls as input with lever in neu-tral.
Harness check Sensor check
MT CUT OFF Motor cutoff high pressure relay
ERROR Short circuit Harness check Solenoid valve check
24 V (ON)0 V (OFF)
24 V
Front Drum Lowering Remote Control Pressure
Motor CutoffRelay
0.5 to 4.5 V 5 V0 V
Rear Drum Lowering Remote Control Pressure
T25N-05-03-020
For check of front drum and rear drum lowering re-mote control pressure sensors, refer to "Check of Front Drum Lowering Remote Control Pressure Sensor" and "Check of Rear Drum Lowering Remote Control Pressure Sensor” of "Failure of Brake Con-trol System".
T5-3-90
TROUBLESHOOTING / Troubleshooting A
Check of Motor Cutoff Relay System
Check the wiring connections first.
Connector
Faulty motor cutoff relay.
Faulty harness between MC2/A and motor cutoff relay.
Disconnect con-nector of motor cutoff relay. Check if voltage between machine and terminal #1 of harness end con-nector is 0 V.
Faulty MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage be-tween machine and terminal E6 of ma-chine end connector is 0 V.
· Connect terminals E12, E13 and E26 of both connectors by using a clip or the like.
· Key switch: ON
· Key switch: ON
T2BC-05-03-032
MC2/A Connector MCA-6
Motor cutoff relay (harness end)
(machine end)
2 4 1
5
3
T5-3-91
TROUBLESHOOTING / Troubleshooting A
FAILURE OF DERRICKING DRUM AUTO STOP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are nor-mal.If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies"
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureALL OFF Open circuit JB FOLD Jib folding
(no connection) ALL ON Shorted harnessesControls as jib unfolding
Harness check
SHORT Short circuit on both crane and tower
Priority is given to the selection by IDU during control or error control.
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU during control or disassembly position control.
Harness check
BM OVERH Boom overhoist BM OVERH2 Boom/tower second
overhoist TW OVERH Tower overhoist BT LOWER L Boom/tower lowest
limit (no connection)
ALL OFF Open circuit
JB OVERH Jib overhoist JB OVERH2 Jib second overhoist HK OVERH Hook overhoist SWL OVERH Tower jib backstop
alignment
ALL ON Shorted harnesses
Controls as over-hoist.
Harness check
LOW ER Lower limit error PWM output short circuit or open circuitOFF (stop)
HI ER Upper limit error PWM output har-ness short circuit OFF (stop)
Check of Wiring Detection Signal System Check the wiring connections first.
Crane Mode
Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and terminal R8 of connector MCB-4.
NO
YES
YES
Faulty MC2/B.NO
· Connect terminals of both disconnected connectors by using a clip or the like.
· D1 X1· D17 M18· D12 (B)· Key switch: ON
· Key switch: OFF
Disconnect connector MCB-1 of MC2/B. Check if voltage be-tween machine and terminal X4 of con-nector of MC2/B is 24 V.
Check for continuity between terminals #1 and #2 of relay box.
Disconnect connector MCA-4 of MC2/A. Check for continuity between terminal R8 of harness end con-nector of connector MCA-4 and terminal R8 of harness end connector of connec-tor MCB-4.
Connector
T2BC-05-03-021
T2BC-05-03-038
T2BC-05-03-027
MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (harness end)
MC2/B Connector MCB-1 (harness end)
T5-3-94
TROUBLESHOOTING / Troubleshooting A
Harness open cir-cuit between MC2/A and MC2/B.
Faulty MC2/A.
Faulty relay box.
Harness open cir-cuit between MC2/B and relay box.
NO
YES
YES
NO
Connector
Relay Box (machine end)
T2BC-05-03-039
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020
T5-3-95
TROUBLESHOOTING / Troubleshooting A
Tower Mode
Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and terminal R21 of connector MCB-4.
YES
NO
YES
Faulty MC2/B.NO
· Connect terminals of
Check for continuity between terminals #1 and #3 of relay box.
Disconnect connector MCA-4 of MC2/A. Check for continuity between terminal R8 of harness end con-nector of connector MCA-4 and terminal R21 of harness end connector of connec-tor MCB-4.
Connector
T2BC-05-03-021
T2BC-05-03-038
T2BC-05-03-027
both disconnected connectors by using a
the like. · D1 X1· D17 M18· D12 (B)· Key switch: ON
· Key switch: OFF
clip or
Disconnect connector of MC2/B. f voltage be-
ween machine and X4 of con-
nector of MC2/B is 24
MCB-1Check itterminal
V.
MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (harness end)
MC2/B Connector MCB-1 (harness end)
T5-3-96
TROUBLESHOOTING / Troubleshooting A
Faulty relay box.
Harness open cir-cuit between MC2/B and relay box.
NO
YES
Harness open cir-cuit between MC2/A and MC2/B.
Faulty MC2/A. YES
NO
Connector
Relay box (machine end)
T2BC-05-03-039
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020
T5-3-97
TROUBLESHOOTING / Troubleshooting A
Check of Boom Overhoist Switch System
Check the wiring connections first.
Connector
Faulty MC2/B.
Disconnect connec-tor MCB-1 of MC2/B. Check if voltage at terminal D3 of ma-chine end connector is 24 V.
Faulty MC2/B.Connect boom overhoistswitch. Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X3 of connector MCB-1 and terminal R16 of connec-tor MCB-4. When operating boom overhoist switch, check for continuity between terminal X3of connector MCB-1 and terminal R3 of connector MCB-4.
T25N-05-03-005 T2BC-05-03-021
T2BC-05-03-038
T2BC-05-03-027
Disconnect contor of boom ove
nec-rhoist
itch. Check for continuity
ween terminals
chine end connector. hen operating
witch, check for between
terminals #a and #c end
· Connect terminals D1 and X1, D17 and M18, D12 and B of both connectors by using a clip or the like.
· Key switch: ON
YES
NO
Harness open circuit between boom overhoist switch and MC2/B.
Check of Boom / Tower Second Overhoist Switch System
Check the wiring connections first.
Connector
Faulty MC2/B.
Disconnect connec-tor MCB-1 of MC2/B. Check if voltage at terminal D3 of ma-chine end connector is 24 V.
Disconnect connector of boom / tower sec-ond overhoist switch. Check for continuity between terminals #1 and #2 of machine end connector. When operating boom / tower second overhoist switch, check for continuity between terminals #1 and #3 of machine end connector.
· Connect terminals D1 and X1, D17 and M18, D12 and B of both connec-tors by using a jumper line.
· Key switch: ON
YES
NO
Connect boom / tower second overhoist switch. Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X3 of connector MCB-1 and terminal R19 of con-nector MCB-4. When operating boom /tower second overhoist switch, check for con-tinuity between terminalX3of connector MCB-1 and terminal R5 of connector MCB-4.
Faulty MC2/B.
Harness open circuit between boom / tower second over-hoist switch and MC2/B.
Faulty boom / tower second overhoist switch.
NO
YES
YES
NO
T2BC-05-03-059
MC2/B Connector MCB-1
T2BC-05-03-021
T2BC-05-03-038
MC2/B Connector MCB-4 Boom / tower second overhoist
switch (machine end) (machine end) (harness end)
T2BC-05-03-027
MC2/B Connector MCB-1 (harness end)
T5-3-99
TROUBLESHOOTING / Troubleshooting A
Check of Tower Overhoist Switch System Check the wiring connections first.
Connector
T25N-05-03-003
T2BC-05-03-021
T2BC-05-03-038
T2BC-05-03-027
MC2/B Connector MCB-1 (machine end)
Tower overhoist switch (machine end)
Faulty MC2/B.
Disconnect con-nector MCB-1 of MC2/B. Check if voltage at terminal D3 of ma-chine end connec-tor is 24 V.
Disconnect connec-
Connect connector oftower overhoist switch. Disconnect connec-tor MCB-4 of MC2/B. Check for continuity between terminal X3 of connector MCB-1 and R17 of connecto
tor of tower overhoist itch.
Check for continuity ween terminals #b
and #c of machine r.
hen operating tower overhoist witch, check for
between terminals #a and #c
end connector.
· Connect D1 and X1, D17 and M18, DR and B of both connectors by us-ing a jumper wire.
· Key switch: ON
YES
NO
sw
bet
end connectoW
scontinuity
of machine
rMCB-4. When operating tower overhoist switch, check for continuity between terminal X3 of con-nector MCB-1 and terminal R4 of con-nector MCB-4.
Faulty tower over-hoist switch.
NO
YES
YES
NO
Harness open circuit between tower overhoist switch and MC2/B.
Faulty MC2/B.
c b
a
MC2/B Connector MCB-4 (harness end)
MC2/B Connector MCB-1 (harness end)
T5-3-100
TROUBLESHOOTING / Troubleshooting A
Check of Jib Overhoist Switch System
Check the wiring connections first.
Connector
T2BC-05-03-042
T2BC-05-03-039
T2BC-05-03-038
T2BC-05-03-021
T2BC-05-03-027
MC2/B Connector MCB-1 (machine end)
Jib overhoist switch (machine end)
Relay box (machine end)
MC2/B Connector MCB-1 (harness end)
MC2/B Connector MCB-4 (harness end)
Faulty MC2/B.
Disconnect con-nector MCB-1 of MC2/B. Check if voltage at terminal D4 of ma-chine end connec-tor is 24 V.
Connect connector of jib overhoist switch. Disconnect con-nector MCB-4 of MC2/B. Check for continuity between terminal X4 of con-nector MCB-1 and R20 of connector MCB-4. When operating jib overhoist switch, check for continuity between terminal X4 of connector MCB-1 and terminalR6 of connector MCB-4.
Disconnect connec-tor of jib overhoist
itch. continuity
between terminals f ma-
ector.hen operating jib
witch, check for continuity
ween terminals f ma-
chine end connector.
· Connect D1 and X1, D17 and M18, D12 and B of both con-nectors by using a jumper wire.
· Key switch: ON
YES
NO
swCheck for
#2 and #4 ochine end connWoverhoist s
bet#1 and #3 o
Disconnect con-nector CN1 of relay box.Check for continuity between terminals #1 and #5 of relay box end. When operating jib overhoist switch, check for continuity between terminals #1 and #4.
Faulty jib overhoist switch.
NO
YES
YES
NO
NO
YES
Faulty MC2/B.
Harness open circuitbetween jib overhoist switch and MC2/B.
Faulty relay box.
T5-3-101
TROUBLESHOOTING / Troubleshooting A
Check of Jib Second Overhoist Switch System
Check the wiring connections first.
Connector
T2BC-05-03-039
T2BC-05-03-038
T2BC-05-03-021
T2BC-05-03-027
MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (harness end)
Jib second overhoist switch (machine end)
MC2/B Connector MCB-1 (harness end)
Relay box (machine end)
1 2
3 4
Faulty MC2/B.
Disconnect connec-tor MCB-1 of MC2/B. Check if voltage at terminal D4 of ma-chine end connector is 24 V.
Connect connector of jib second over-hoist switch. Disconnect con-nector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and R22 of connector MCB-4. When operating jib second overhoist switch, check for continuity between terminal X4 of con-nector MCB-1 and terminal R24 of connector MCB-4.
Disconnect connectorof jib second overhoistswitch. Check for continuity
ween terminals #1 chine
end connector. hen operating jib
rhoist switch, check for con-
between ter-minals #1 and #2 of
con-
· Connect D1 and X1, D17 and M18, D12 and B of both connectors by using a jumper wire.
· Key switch: ON
YES
NO
betand #3 of ma
Wsecond ove
tinuity
machine end nector.
Disconnect con-nector CN1 of relay box.Check for continuity between terminals #1 and #9 of relay box end. When operating jib secondoverhoist switch, check for continuity between terminals #1 and #8.
Faulty jib second overhoist switch.
NO
YES
YES
NO
NO
YES
Faulty MC2/B.
Harness open circuitbetween jib second overhoist switch and MC2/B.
Faulty relay box.
T5-3-102
TROUBLESHOOTING / Troubleshooting A
Check of Hook Overhoist Switch System
Check the wiring connections first.
Connector
T2BC-05-03-043
T2BC-05-03-039
T2BC-05-03-038
T2BC-05-03-021
T2BC-05-03-027
MC2/B Connector MCB-1 (harness end)
MC2/B Connector MCB-4 (harness end)
Hook overhoist switch (machine end)
Relay box (machine end)
MC2/B Connector MCB-1 (machine end)
Faulty MC2/B.
Disconnect connec-
switch. Check for between
s #2 and #4 end
Check for continuity ween terminals
#1 and #3 of ma-chine end connector.
YES
NO
tor of hook overhoist
continuityterminalof machine connector.
bet
Connect connector of hook overhoist switch. Disconnect con-nector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and R9 of connector MCB-4. When operating hook overhoist switch, check for continuity between terminal X4 of con-nector MCB-1 and terminal R11 of connector MCB-4.
Disconnect MCB-4 connector of MC2/B, connect A9 and A11 terminals (harness end) of connector to ma-chine, and check forcontinuity between machine and #1 or #2 terminal (har-ness end) of con-nector of hook overhoist switch.
NO
YES
YES
NO
NO
YES
Faulty MC2/B.
Harness open circuitbetween hook over-hoist switch and MC2/B.
Disconnect con-nector MCB-1 of MC2/B. Check if voltage at terminal D4 of ma-chine end connec-tor is 24 V.
· Connect D1, D12 and D17 terminals of both connectors by using a clip or the like.
· Key switch: ON
Faulty relay box.
Faulty hook overhoistswitch.
T5-3-103
TROUBLESHOOTING / Troubleshooting A
Check of Backstop Alignment Overhoist Switch System
Check the wiring connections first.
Connector
Faulty MC2/B.
Disconnect connec-tor MCB-1 of MC2/B. Check if voltage at terminal D4 of ma-chine end connector is 24 V.
Disconnect connector of backstop alignment overhoist switch. Check for continuity between terminals #2 and #4 of machine end connector. When operating backstop alignment overhoist switch, check for continuity between terminals #1 and #3 of machine end connector.
· Connect D1 and X1, D17 and M18, D12 and B of both connectors by using a jumper wire.
· Key switch: ON
YES
NO
Connect connector of backstop align-ment overhoist switch. Disconnect connec-tor MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and R20 of connec-tor MCB-4. When operating backstop alignment overhoist switch, check for continuity between terminal X4 of con-nector MCB-1 and terminal R6 of con-nector MCB-4.
Disconnect con-nector CN1 of relay box.Check for continuity between terminals #1 and #5 of relay box end. When operating backstop alignment overhoist switch, check for continuity between terminals #1 and #4.
Faulty backstop alignment overhoist switch
NO
YES
YES
NO
NO
YES
Faulty MC2/B.
Faulty relay box.
Harness open circuitbetween backstop alignment overhoist switch and MC2/B.
MC2/B Connector MCB-1
T2BC-05-03-042
T2BC-05-03-039
T2BC-05-03-021
T2BC-05-03-038
T2BC-05-03-027
MC2/B Connector MCB-4 (machine end)
Backstop alignment overhoist switch
MC2/B Connector MCB-1
(harness end)
Relay box (machine end) (harness end)
T5-3-104
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Hoisting Proportional Solenoid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-044
T2BC-05-03-045
Disconnect connector MCB-5 of MC2/B. Connect terminals Z5 and Z9 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals # 1, #2 of harness end connectorof derricking drum hoisting proportional solenoid valve.
Disconnect connec-cking drum
hoisting proportional .
continuity between terminals
f ma-chine end connector.
· Key Switch: ON· Derricking drum auto
stop release switch: OFF
· Connect terminals D3 and A3 by using a jumper wire.
YES
NO
tor of derri
solenoid valveCheck for
#1 and #2 o
Connect terminal D3 of connector MCB-1 to terminal
Harness short circuit between derricking drum hoisting pro-portional solenoid valve and MC2/B.
A3 of connector MCB-4 of MC2/B. Check if voltage between terminal Z9 of machine end connector of con-nector MCB-5 and machine is 0 V.
NO
YES
NO
YES
Faulty MC2/B.
In case of no conti-nuity at terminal #l, harness open circuit between terminal #1 of derricking drum hoisting proportional solenoid valve and MC2/B. In case of no conti-nuity at terminal #2, harness open circuit between terminal #2 of derricking drum hoisting proportional solenoid valve and MC2/B.
Check of Derricking Drum Lowering Proportional Solenoid Valve System
Check the wiring connections first.
Connector
Faulty MC2/B.
Disconnect connector MCB-5 of MC2/B. Connect terminals Z17and Z21 of harness end connector of con-nector MCB-5 to ma-chine.Check for continuity between machine and terminals # 1, #2 of harness end connectorof derricking drum lowering proportional solenoid valve.
Disconnect connec-tor of derricking drum lowering proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
· Engine: Running· Derricking drum auto
stop release switch: OFF
· Connect terminals D3 and A3 from the back by using a jumper wire.
YES
NO
Connect terminal D3 of connector MCB-1 to terminal A3 of con-nector MCB-4 of MC2/B. Check if voltage be-tween terminal Z21 of machine end con-nector of connector MCB-5 and machine is 0 V.
Harness short circuit between derricking drum lowering propor-tional solenoid valve and MC2/B.
In case of no continuity at terminal #2, harness open circuit between terminal #2 of derrick-ing drum lowering pro-portional solenoid valve and MC2/B, or faulty live mast lower limit switch. In case of no continuity at terminal #1, harness open circuit between terminal #1 of derrick-ing drum lowering pro-portional solenoid valve and MC2/B.
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R1 of harness end connectorof connector MCB-4 and terminal Z16 of harness end connectorof connector MCB-5 to machine.Check for continuity between machine and terminals R1, Z16 of harness end connectorof connector 62C-16FW.
Disconnect connec-NO
YES Faulty MC2/B.
In case of no continuity at terminal R1, harness open circuit between terminal R1 of connec-tor 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, har-ness open circuit be-tween terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
T2BC-05-03-047
T2BC-05-03-046
T2BC-05-03-027
T2BC-05-03-044
tor 62C-16FW of left panel.
Check for continuity ween terminals
Z16 of panel r.
YES
NO
stop release selection key switch: ON
control
betR1 and end connecto
· Auto
Faulty auto stop re-lease selection key switch.
MC2/B Connector MCB-4
Left control panel Connector 62C-16FW (panel end) (harness end)
MC2/B Connector MCB-5
Left control panel Connector 62C-16FW (harness end) (harness end)
T5-3-107
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Auto Stop Release Switch
Check the wiring connections first.
Connector
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S7 of harness end connectorof connector MCB-3 and terminal Z16 of harness end connectorof connector MCB-5 to machine.Check for continuity between machine and terminals S7, Z16 of harness end connectorof connector 62C-16FW.
Disconnect connec-NO
YES Faulty MC2/B.
In case of no continuity at terminal S7, harness open circuit between terminal S7 of connec-tor 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, har-ness open circuit be-tween terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
T2BC-05-03-047
T2BC-05-03-046
T2BC-05-03-048
T2BC-05-03-044
tor 62C-16FW of left panel.
Check for continuity ween terminals
Z16 of panel r.
YES
NO
d
control
betS7 and end connecto· Derricking rum
auto stop release switch: ON
Faulty derricking drumauto stop release switch.
MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (panel end)
Left control panel MC2/B Connector MCB-5 Connector 62C-16FW
(harness end) (harness end)
T5-3-108
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT DRUM AUTO STOP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies"
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureSHORT Short circuit on both
crane and tower Priority is given to the selection by IDU for control or error control
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU for control or disassembly posi-tion control
Harness check
ALLOFF Open circuit BT OVERH2
JB OVERH2 HK OVERH
Boom/tower second overhoist Jib second overhoist Hook overhoist ALLON Shorted harnesses
Controls as over-hoist
Harness check
LOW ER Lower limit error PWM output short circuit or open circuitOFF (stop)
HI ER Upper limit error PWM output har-ness short circuit OFF (stop)
For check of limit switch, attachment wiring and auto stop release selection key switch, refer to Section "Failure of Derricking Drum Auto Stop Control Sys-tem".
T5-3-109
TROUBLESHOOTING / Troubleshooting A
Front Drum HoistingProportional Solenoid Valve
Front Drum Lowering Proportional Solenoid Valve Auto Stop Release
Front Switch
Auto Stop Release Key Switch
Boom Second Overhost Prevention
Crane Relay Box
Main Hook Overhost Prevention
Front Drum Hoising Stop Sub Hook
Overhost Prevention
Tower Relay Box
Front Drum Lowering Stop
ShoulderingPrevention
Main Hook Overhost Prevention
Sub Hook Overhost Prevention
Tower Jib Second Overhost Prevention
T2BC-02-01-013
T5-3-110
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Hoisting Proportional So-lenoid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-044
T2BC-05-03-045
MC2/B Connector MCB-1 (machine end)
Front drum hoisting proportional solenoid valve (harness end)
MC2/B Connector MCB-5 (harness end)
Disconnect connector MCB-5 of MC2/B. Connect terminals Z6 and Z10 of harness end connector of con-nector MCB-5 to ma-chine.Check for continuity between machine and terminals #1, #2 of harness end connectorof front drum hoisting proportional solenoid valve.
Disconnect connec-tor of front drum hoisting proportional solenoid valve. Check for continuity between terminals #1 and #2 of ma-chine end connector.
· Engine: Running· Front drum auto stop
release switch: OFF· Connect terminals D3
and A5 by using a jumper wire.
YES
NO
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage between terminal F10 of ma-chine end connector of connector MCB-5 and machine is 0 V.
NO
YES
NO
YES
Faulty MC2/B.
Harness short circuit between front drum hoisting proportional solenoid valve and MC2/B.
In case of no conti-nuity at terminal #1, harness open circuit between terminal #1 of front drum hoisting proportional solenoid valve and MC2/B. In case of no conti-nuity at terminal #2, harness open circuit between terminal #2 of front drum hoisting proportional solenoid valve and MC2/B.
Faulty front drum hoisting proportional solenoid valve.
MC2/B Connector MCB-4 (machine end)
T5-3-111
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Lowering Proportional So-lenoid Valve System
Check the wiring connections first.
Connector
Disconnect connector MCB-5 of MC2/B. Connect terminals Z18 and Z22 of harness end connector of con-nector MCB-5 to ma-chine.Check for continuity between machine and terminals #1, #2 of harness end connectorof front drum lowering proportional solenoid valve.
Disconnect connec-tor of front drum low-ering proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
· Engine: Running· Front drum auto stop re-
lease switch: OFF · Connect terminals D3 and
A5from the connector back by using a clip.
· Front drum lock switch: OFF
YES
NO
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage be-tween terminal F22 of machine end con-nector of connector MCB-5 and machine is 0 V.
NO
YES
NO
YES
Faulty MC2/B.
Harness short circuit between front drum lowering proportional solenoid valve and MC2/B.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum lowering propor-tional solenoid valve and MC2/B. In case of no continuity at termi-nal #2, harness open circuit between terminal#2 of front drum lower-ing proportional sole-noid valve and MC2/B, or faulty front drum lock switch.
Faulty front drum low-ering proportional so-lenoid valve.
· Front drum lock switch: OFF
T2BC-05-04-010
MC2/B Connector MCB-1 (machine end)
Front drum lowering
T2BC-05-03-021
T2BC-05-03-044
MC2/B Connector MCB-4 (machine end)
proportional solenoid valve (harness end)
T2BC-05-03-045
MC2/B Connector MCB-5 (harness end)
T5-3-112
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Auto Stop Release Switch
Check the wiring connections first.
Connector
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S15 of harness end con-nector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals S15, Z16 of harness end connectorof connector 62C-16FW.
Disconnect con-nector 62C-16FW of left control panel. Check for continuity between terminals S15 and Z16 of panel connector.
YES
NOFaulty front drum auto stop release switch.
NO
YES Faulty MC2/B.
In case of no continuity at terminal S15, har-ness open circuit be-tween terminal S15 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, har-ness open circuit be-tween terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
T2BC-05-03-046
T2BC-05-03-047
T2BC-05-03-048
T2BC-05-03-044
· Front drum auto stop release switch: ON
MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
Left control panel MC2/B Connector MCB-5 Connector 62C-16FW
(panel end) (harness end)
T5-3-113
TROUBLESHOOTING / Troubleshooting A
FAILURE OF REAR DRUM AUTO STOP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureALL OFF Open circuit JB FOLD Jib folding ALL ON Harness short circuit
Controls as jib un-folding
Harness check
SHORT Short circuit on both crane and tower
Priority is given to the selection by IDU for control or error con-trol
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU for control or disassem-bly position control.
Harness check
ALL OFF Open circuit RD EOPE ED
BT OVERH2
TW OVERH JB OVERH JB OVERH2 HK OVERH SWL OVERH
Boom/tower second overhoistTower overhoist Jib overhoist Jib second overhoist Hook overhoist Tower jib backstop alignment overhoist
ALL ON Harness short circuit
Controls as overhoist Harness check
LOW ER Lower limit error PWM output short circuit or open circuit OFF (stop)
HI ER Upper limit error PWM output harness short circuit OFF (stop)
For check of limit switch, attachment wiring and auto stop release selection key switch, refer to Section "Failure of Derricking Drum Auto Stop Control Sys-tem".
T5-3-114
TROUBLESHOOTING / Troubleshooting A
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lowering Proportional Solenoid Valve
Auto Stop Release Rear Drum Switch Auto Stop Release Key Switch
Crane Relay Box
Main Hook Overhoist Prevention Rear Drum
Hoisting Stop
Sub Hook Overhoist Prevention
Rear Drum Lowering Stop
Shouldering Prevention
Tower Relay Box Tower Breakage Prevention
Tower Jib Overhoist Prevention
Tower Jib BackstopAlignment
Main Hook Overhoist Prevention
Sub Hook Overhoist Prevention
Tower Jib Second Overhoist Prevention
T2BC-02-01-014
T5-3-115
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Hoisting Proportional Sole-noid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-044
T2BC-05-03-045
Disconnect connector MCB-5 of MC2/B. Connect terminals Z7 and Z11 of harness end connector of con-nector MCB-5 to ma-chine.Check for continuity between machine and terminals #1, #2 of harness end connectorof rear drum hoisting proportional solenoid valve.
Disconnect connec-tor of rear drum
roportional .
Check for continuity ween terminals
f ma-ector.
· Engine: Running· Rear drum auto stop
release switch: OFF· Connect terminals D3
and A5 by using a jumper wire.
YES
NO
hoisting psolenoid valve
bet#1 and #2 ochine end conn
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage between terminal F11 of machine end connector of con-nector MCB-5 and machine is 0 V.
Harness short circuit between rear drum hoisting proportional solenoid valve and MC2/B.
NO
YES
NO
YES
Faulty MC2/B.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum hoisting propor-tional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum hoisting propor-tional solenoid valve and MC2/B.
Check of Rear Drum Lowering Proportional So-lenoid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-044
T2BC-05-03-045
T2BC-05-03-003
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z19 of harness end con-nector of connector MCB-5 and terminal Y14 of harness end connector of connector MCB-6 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of rear drum lowering proportional solenoid valve.
Disconnect connec-tor of rear drum low-
alsolenoid valve.
continuity ween terminals
#1 and #2 of ma- connector.
· Engine: Running· Rear drum auto stop release
switch: OFF · Connect terminals D3 and
A5 by using a clip or the like at the rear of connector.
· Rear drum lock switch: OFF
YES
NO
ering proportion
Check forbet
chine end
Connect terminal D3 of connector MCB-1 and terminal
Harness short circuit between rear drum lowering proportional solenoid valve and MC2/B.
A5 of connector MCB-4 of MC2/B. Check if voltage between machine and terminal E14 of machine end con-nector of connector MCB-6 is 0 V.
NO
YES
NO
YES
Faulty MC2/B.
In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum lowering propor-tional solenoid valve and MC2/B. In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum lowering propor-tional solenoid valve and MC2/B, or faulty read drum lock switch.
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S8 of harness end connectorof connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine.Check for continuity between machine and terminals S8, Z16 of harness end connector of connector 62C-16FW.
Disconnect con-nector 62C-16FW of left control panel. Check for continuity between terminals S8 and Z16 of panel end connec-
YES
NO
NO
YES Faulty MC2/B.
In case of no continuity at terminal S8, harness open circuit between terminal S8 of connec-tor 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, har-ness open circuit be-tween terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
T2BC-05-03-046
T2BC-05-03-047
T2BC-05-03-048
T2BC-05-03-044
· Rear drum auto stop release switch: ON
Faulty rear drum auto stop release switch.
MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-5 (harness end)
Left control panel Connector 62C-16FW (panel end)
T5-3-118
TROUBLESHOOTING / Troubleshooting A
FAILURE OF THIRD DRUM AUTO STOP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureSHORT Short circuit on both
crane and tower Priority is given to the selection by IDU for control or error control.
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU for control or disassembly posi-tion control.
Harness check
ALLOFF Open circuit BT OVERH2
JB OVERH2 HK OVERH
Boom/tower second overhoist Jib second overhoist Hook overhoist ALLON Harness short cir-
cuit
Controls as over-hoist
Harness check
3D HST SOL
3D LWR SOL
Third drum hoisting solenoid valve Third drum lowering solenoid valve
ERROR Short circuit OFF (stop) Harness check Solenoid valve check
For check of limit switches, attachment wiring and auto stop release selection key switches, refer to Section "Failure of Derricking Drum Auto Stop Con-trol System".
T5-3-119
TROUBLESHOOTING / Troubleshooting A
Auto Stop Release Third /Fourth Drum Switch
Fourth Drum Hoisting Stop
Boom Second Overhost Prevention
Auto Stop Release Key Switch
Crane Relay Box
Third Drum Lowering Stop Main Hook
Overhoist Prevention
ShoulderingPreventionSub Hook
Overhoist Prevention
Third Drum Hoisting Solenoid Valve
Fourth Drum Hoisting Solenoid Valve
Third Drum Lowering Solenoid Valve
Fourth Drum Lowering Solenoid Valve
T2BC-05-03-049
T5-3-120
TROUBLESHOOTING / Troubleshooting A
Check of Third Drum Hoisting Solenoid Valve System
Check the wiring connections first.
Connector
Disconnect connectorthird/fourth drum selec-tion (upper) relay. Connect terminal 377 of connector to ma-chine end. Check for continuity between machine and terminals #1, #2 of harness end of con-nector of third drum hoisting solenoid valve.
T2BC-05-04-010
T2BC-05-03-050
T2BC-05-03-003
T2BC-05-03-032
Disconnect connec-tor of third drum
valve. continuity
ween terminals #1 and #2 of machine nd connector.
· Engine: Running· Third / fourth selection
switch: Third YES
NO
Check if voltage at ter-minal 387 of relay har-ness end connector is 24 V.
NO
YES
In case of no continuity at terminal #1, harness open circuit between relay and third drum hoisting solenoid valve. In case of no continuity at terminal #2, faulty ground of third drum hoisting solenoid valve.
hoisting solenoid
Check forbet
e
Faulty third drum hoisting solenoid valve.
MC2/B Connector MCB-6
Third / fourth drum selection (upper) relay (harness end)
Third drum hoisting solenoid valve(harness end)
(harness end)
MC2/B Connector MCB-6 (machine end)
T5-3-121
TROUBLESHOOTING / Troubleshooting A
· Connect relay harness.· Third / fourth selection
switch: Third
Disconnect connector MCB-6 of MC2/B. Connect terminal Y7 of harness end connector of connector MCB-6 to machine.Check for continuity between machine and terminal #1 of harness end connector of third drum hoisting solenoid valve.
Faulty third / fourth selection switch.
YES
NO
· Engine: Running· Third drum auto stop release
switch: OFF · Connect terminals D3 and
A5 by using a clip or the like at the rear of connector.
· Third / fourth selection switch: Third
Connector
T2BC-05-03-021 T2BC-05-03-045 T2BC-05-03-003
Connect terminal D3 of connector MCB-1 and ter-minal A5 of connector MCB-4 of MC2/B. Check if voltage between machine and terminal Y17 of machine end connector of connector MCB-6 is 0 V.
Faulty MC2/B.
Harness short circuit between third drum hoisting solenoid valve and MC2/B.
YES
NO
YES
NO
Faulty harness be-tween MC2/B and relay, or faulty relay.
MC2/B Connector MCB-1 (Machine end)
MC2/B Connector MCB-4 (Machine end)
MC2/B Connector MCB-6 (Machine end)
T5-3-122
TROUBLESHOOTING / Troubleshooting A
Check of Third Drum Lowering Solenoid Valve System
• Check the wiring connections first.
Disconnect connectorthird drum lowering relay. Connect terminal 388 of connector to machine end.Check for continuity be-tween machine and ter-minals #1, #2 of harness end of connector of third drum lowering solenoid valve.Disconnect connec-
tor of third drum low-ering solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
YES
NO
In case of no continuity at terminal #2, faulty ground of third drum lowering solenoid valve.In case of no continuity at terminal #1, harness open circuit between relay and third drum lowering solenoid valve.
YES
NO
Faulty third drum low-ering solenoid valve.
Check if voltage at terminal 295 of con-nector of third drum lowering stop relay is 24 V.
· Third / fourth brake mode selection switch: AUTO
Connector
T2BC-05-04-010
T2BC-05-03-052
Third drum lowering solenoid valve(harness end)
Third drum lowering stop relay(harness end)
Third / fourth drum selection(lower) relay (harness end)
T2BC-05-03-051
T5-3-123
TROUBLESHOOTING / Troubleshooting A
Check if third / fourth auto mode lamp (green) is turned on.
Check if voltage at terminal 378 of connector of third drum lowering stop relay is 24V.
Faulty MC2/A.
Harness open cir-cuit between free mode switch and third drum lowering stop relay.
NO
YES
NO
YES
Faulty third drum lowering stop relay.
Disconnect con-nector of third / fourth drum selec-tion (lower) relay. Check for continuity between terminal 378 of harness end connector of third / fourth drum selec-tion (lower) relay and terminal 378 of harness end con-nector of third drum lowering stop relay.
Check if voltage at terminal 378 be-tween harness of third / fourth drum selection (lower) relay connector is 24V.
Harness open cir-cuit between third / fourth drum selec-tion (lower) relay and third drum lowering stop relay.
A
Faulty third / fourth drum selection (lower) relay or faulty third / fourth drum selection switch.
YES
NO
YES
NO
YES
NO
· Third / fourth drum selection switch: Third
Connector
T2BC-05-03-003
T2BC-05-03-051
T2BC-05-03-021
T2BC-05-03-060
MC2/B Connector MCB-6
MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (machine end) (harness end)
T2BC-05-03-045
Connector of third / fourthdrum selection (harness end)
MC2/B Connector of third drum low-ering relay (harness end)
Connector MCB-6 (machine end)
T2BC-05-03-032
T5-3-124
TROUBLESHOOTING / Troubleshooting A
Connector
T2BC-05-04-010
T2BC-05-03-003
T2BC-05-03-032
T2BC-05-03-045
T2BC-05-03-021
A
Connect disconnected relay harness. Dis-connect connector MCB-6 of MC2/B. Connect terminal Y21 of harness end con-nector of connector MCB-6 to machine. Check for continuity between terminal #1 of harness end connector of third drum lowering solenoid valve and machine.
· Engine: Running· Third drum auto stop
release switch: OFF· Connect terminals D3
and A5 by using a clip or the like at the rear of connector.
Connect terminal D3 of connector MCB-1 to terminal
Harness short circuit between third drum lowering solenoid valve and MC2/B.
NO
YES
A5 of connector MCB-4 of MC2/B. Check if voltage at terminal E21 of machine end of connector MCB-6 is 0 V.
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S16 of harness end con-nector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal S16, Z16 of harness end connectorof connector 62C-16FW.
NO
YES Faulty MC2/B.
In case of no continuity at terminal S16, har-ness open circuit be-tween terminal S16 of connector 62C-16FW of left control panel andMC2/B.In case of no continuity at terminal Z16, har-ness open circuit be-tween terminal Z16 of connector 62C-16FW of left control panel andMC2/B.
T2BC-05-03-046
T2BC-05-03-047
T2BC-05-03-048
T2BC-05-03-044
Disconnect connec-f left
control panel. Check ty be-
ween terminals S16 and Z16 of panel end
YES
NO
Third / fourth drum auto stop release switch: ON
tor 62C-16FW o
for continuit
connector.
·
Faulty third / fourthdrum auto stop releaseswitch.
MC2/B Connector MCB-3 (har-ness end)
Left control panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-5 (har-ness end)
Left control panel Connector 62C-16FW (panel end)
T5-3-126
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FOURTH DRUM AUTO STOP CONTROL SYSTEM (OPTIONAL)
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureSHORT Short circuit on both
crane and tower Priority is given to the selection by IDU for control or error control.
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU for control or disassembly posi-tion control.
Harness check
ALLOFF Open circuit BT OVERH2
JB OVERH2 HK OVERH
Boom/tower second overhoist Jib second overhoist Hook overhoist ALLON Harness short cir-
ERROR Short circuit OFF (stop) Harness check Solenoid valve check
For check of limit switches, attachment wiring and auto stop release selection key switches, refer to Section "Failure of Derricking Drum Auto Stop Con-trol System".
T5-3-127
TROUBLESHOOTING / Troubleshooting A
Auto Stop Release Third / Fourth Drum Switch
Auto Stop Release Key Switch
Boom Overhoist Prevention
Crane Relay Box
Main Hook Overhoist Prevention
Fourth Drum Hoisting Prevention
Third Drum Hoisting Prevention
Shouldering Prevention Sub Hook
Overhoist Prevention
Third Drum Hoisting Solenoid Valve
Fourth Drum Hoisting Solenoid Valve
Third Drum Lowering Solenoid Valve
Fourth Drum Lowering Solenoid Valve
T2BC-05-03-049
T5-3-128
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Hoisting Solenoid Valve System
Check the wiring connections first.
Connector
Disconnect connectorthird / fourth drum se-lection (upper) relay. Connect terminal 379 of connector to ma-chine end. Check for continuity between machine and terminals #1, #2 of harness end of con-nector of fourth drum hoisting solenoid valve.
T2BC-05-04-010
T2BC-05-03-061
T2BC-05-03-050
T2BC-05-03-003
Disconnect connec-tor of fourth drum
continuity ween terminals
#1 and #2 of ma-ector.
· Engine: Running· Third / fourth selection
switch: Fourth YES
NO
Check if voltage at terminal 387 of relay harness end connector is 24 V.
NO
YES
In case of no conti-nuity at terminal #1, harness open circuit between relay and fourth drum hoisting solenoid valve. In case of no conti-nuity at terminal #2, faulty ground of fourth drum hoisting solenoid valve.
hoisting solenoid valve.Check forbet
chine end conn
Faulty fourth drum hoisting solenoid valve.
MC2/B Connector MCB-6 (harness end)
Fourth drum hoisting solenoid valve (harness end)
Third / fourth drum selection (upper) relay (harness end)
Fourth drum hoisting solenoid valve (machine end)
T5-3-129
TROUBLESHOOTING / Troubleshooting A
Connector
· Connect relay har-ness.
· Third / fourth selection switch: Fourth
Disconnect connector MCB-6 of MC2/B. Con-nect terminal Y7 of har-ness end connector of connector MCB-6 to machine.Check for continuity between machine and terminal #1 of harness end connector of fourth drum hoisting solenoid valve.
Faulty third / fourth selection switch.
YES
NO
· Engine: Running· Third drum auto stop release
switch: OFF · Connect terminals D3 and
A5 by using a clip or the like at the rear of connector.
· Third / fourth selection switch: Fourth
Connect terminal D3 of connector MCB-1 to ter-minal A5 of connector MCB-4 of MC2/B. Check if voltage between machine and terminal E7 of machine end connector of connector MCB-6 is 0 V.
Faulty MC2/B.
Harness short circuit between fourth drum hoisting solenoid valve and MC2/B.
YES
NO
YES
NO
Faulty harness be-tween MC2/B and re-lay, or faulty relay.
T2BC-05-03-021 T2BC-05-03-045
MC2/B Connector MCB-4 (machine end)
MC2/B Connector MCB-6 (machine end)
MC2/B Connector MCB-1 (machine end)
T2BC-05-03-032
T5-3-130
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Lowering Solenoid Valve System
• Check the wiring connections first.
Disconnect connector ofthird/fourth drum selection(lower) relay. Connect terminal 380 of connector to machine end.Check for continuity be-tween machine and ter-minals #1, #2 of harness end of connector of fourthdrum lowering solenoid valve.
Disconnect connec-tor of fourth drum lowering solenoid valve.Check for continuity between terminals #1 and #2 of ma-chine end connector.
YES
NO
In case of no continuity at terminal #1, harness open circuit between relay and fourth drum lowering solenoid valve, or faulty fourth drum lock switch. In case of no continuity at terminal #2, faulty ground of fourth drum lowering solenoid valve.
YES
NO
Faulty fourth drum lowering solenoid valve.
Check if voltage at terminal 387 of relay harness end con-nector is 0 V.
· Engine: Running· Third/fourth selection
switch: Fourth
· Fourth drum lock switch:OFF
Connector
T2BC-05-04-010
Fourth drum lowering solenoidvalve (harness end)
Third / fourth drum selection(lower) relay (harness end)
T2BC-05-03-051
T5-3-131
TROUBLESHOOTING / Troubleshooting A
Connector
T2BC-05-03-021
T2BC-05-04-010
T2BC-05-03-045 T2BC-05-03-003
T2BC-05-03-032
Disconnect connector MCB-6 of MC2/B. Connect terminal Y21 of harness end connector of connector MCB-6 to ma-chine.Check for continuity be-tween terminal #1 of har-ness end connector of fourth drum lowering so-lenoid valve and machine.
Faulty third/fourth selec-tion switch.
YES
NO
· Engine: Running· Third / fourth drum auto stop
release switch: OFF · Connect terminals D3 and
A5 by using a clip or the like at the rear of connector.
· Third / fourth selection switch: Fourth
Connect terminal D3 of connector MCB-1 to ter-minal A5 of connector MCB-4 of MC2/B. Check if voltage at termi-nal E21 of machine end connector of connector MCB-6 is 0 V.
Harness short circuit between fourth drum lowering solenoid valve and MC2/B.
YES
YES
Faulty MC2/B.NO
Faulty harness between MC2/B and relay, or faulty relay.
· Fourth drum lock switch: OFF YES
· Engine: Running · Third / fourth selection
switch: Fourth
MC2/B Connector MCB-6
MC2/B Connector MCB-4
MC2/B Connector MCB-1
(harness end) (machine end) (machine end)
MC2/B Connector MCB-6
Fourth drum lowering solenoid valve (harness end)
(machine end)
T5-3-132
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Auto Stop Release Switch
Check the wiring connections first.
Connector
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S16 of harness end con-nector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal S16, Z16 of harness end connectorof connector 62C-16FW.
NO
YES Faulty MC2/B.
In case of no continuity at terminal S16, harness open circuit between terminal S16 of connec-tor 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connec-tor 62C-16FW of left control panel and MC2/B.
T2BC-05-03-046
T2BC-05-03-047
T2BC-05-03-048
T2BC-05-03-044
Disconnect connector of left
control panel. continuity
ween terminals S16 and Z16 of panel
r.
YES
NO
Third / fourth drum auto stop release switch: ON
62C-16FW
Check forbet
end connecto
·
Faulty third / fourth drum auto stop release switch.
MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-5 (harness end)
Left control panel Connector 62C-16FW (panel end)
T5-3-133
TROUBLESHOOTING / Troubleshooting A
FAILURE OF SECOND OVERHOIST AUTO STOP CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureSHORT Short circuit on both
crane and tower Priority is given to the selection by IDU for control or error control.
ATTACHMENT Wiring detection
OPEN Open circuit on both crane and tower
Priority is given to the selection by IDU for control or disassembly posi-tion control
Harness check
ALLOFF Open circuit BT OVERH2
JB OVERH2
Boom/tower second overhoist Jib second overhoist ALLON Harness short cir-
cuit
Controls as over-hoist.
Harness check
OVERH2 SOL Second overhoist solenoid valve
ERROR Short circuit OFF (stop) Harness check Solenoid valve check
For check of limit switches and attachment wiring, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-134
TROUBLESHOOTING / Troubleshooting A
Second Overhoist Solenoid Valve.
Remote Control Pressure Restoration Switch
Boom Overhoist Prevention
Tower Relay Box
Tower Jib Second Overhoist Prevention
T2BC-02-01-018
T5-3-135
TROUBLESHOOTING / Troubleshooting A
Check of Second Overhoist Solenoid Valve Sys-tem
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-003
T2BC-05-03-045
T2BC-05-03-032
Disconnect connector MCB-6 of MC2/B. Con-nect terminals Y17 and Y26 of harness end connector of connector MCB-6 to machine. Check for continuity be-tween machine and ter-minals #1, #2 of harness end connector of second overhoist solenoid valve.Disconnect connec-
over-hoist solenoid valve.
continuity ween terminals
#1 and #2 of ma-ector.
· Engine: Running· Second overhoist restoration
switch: OFF · Connect terminals D3 and
A5 by using a clip or the like at the rear of connector.
YES
NO
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage be-tween terminal E17 of machine end connector of con-nector MCB-6 and machine is 0 V.
Harness short circuit between second over-hoist solenoid valve and MC2/B.
NO
YES
NO
YES
Faulty MC2/B.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of second overhoist solenoid valve andMC2/B.In case of no continuity at terminal #2, harness open circuit between terminal #2 of second overhoist solenoid valve andMC2/B, or faulty ground.
tor of second
Check forbet
chine end conn
Faulty second overhoistsolenoid valve.
MC2/B Connector MCB-4
MC2/B Connector MCB-1
Second overhoist solenoid valve (harness end)
(machine end) (machine end)
MC2/B Connector MCB-6
MC2/B Connector MCB-6
(machine end) (harness end)
T5-3-136
TROUBLESHOOTING / Troubleshooting A
Check of Second Overhoist Restoration Switch
Check the wiring connections first.
Connector
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R14 of harness end con-nector of connector MCB-4 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal R14, Z16 of harness end connectorof connector 62C-16FW.
NO
YES Faulty MC2/B.
In case of no continuity at terminal R14, harness open circuit between terminal R14 of connec-tor 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connec-tor 62C-16FW of left control panel and MC2/B.
T2BC-05-03-046
T2BC-05-03-047
T2BC-05-03-027
T2BC-05-03-044
Disconnect connec-tor 62C-16FW of left
panel. Check for continuity be-ween terminals R14
16 of panel end connector.
YES
NO
· Second overhoist restoration switch: Cancellation
control
tand Z
Faulty second overhoistrestoration switch.
MC2/B Connector MCB-4
Left stand panel Connector 62C-16FW (harness end) (harness end)
Left stand panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (harness end)
T5-3-137
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT AND REAR MOTOR SPEED CONTROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit error PWM output short
circuit or open circuit Minimum motor ca-pacity
Harness check
HI ER Upper limit error PWM output harness short circuit Minimum motor ca-pacity
Harness check Solenoid valve check
FM CAP CUR Front motor dis-placement angle con-trol proportional so-lenoid valve
RES ER Reset error Abnormal electric current feedback Current control by open loop
MC2/B hardware check
LOW ER Lower limit error PWM output short circuit or open circuit Minimum motor ca-pacity
Harness check
HI ER Upper limit error PWM output harness short circuit Minimum motor ca-pacity
Harness check Solenoid valve check
RM CAP CUR Rear motor dis-placement angle con-trol proportional so-lenoid valve
RES ER Reset error Abnormal electric current feedback Current control by open loop
MC2/B hardware
check
T5-3-138
TROUBLESHOOTING / Troubleshooting A
Front Motor Displacement Angle Proportinal Solenoid Valve
Hoisting DisplacementAngle Lock Switch
Rear Motor Displacement Angle Proportinal Solenoid Valve
T2BC-05-03-053
T5-3-139
TROUBLESHOOTING / Troubleshooting A
Check of Front Motor Displacement Angle Con-trol Proportional Solenoid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-044 T2BC-05-03-003
T2BC-05-03-032
Front motor displacement angle control proportional solenoid
ness end) valve (har
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z8 of harness end connector of connector MCB-5 and terminal Y1 of harness end of con-nector MCB-6 to ma-chine.Check for continuity between terminals #1, #2 of harness end connector of front mo-tor displacement angle control proportional solenoid valve and machine.
Disconnect connec-tor of front motor displacement angle control proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
· Connect terminals E12 and Y12, E13 and Y13 by using a clip.
· Key switch: ON · Hoisting low speed
switch: OFF
YES
NO
Check if voltage between terminal Y1 of machine end connector of con-nector MCB-6 and machine is 0 V.
Harness short circuit between front motor displacement angle con-trol proportional solenoid valve and MC2/B.
YES
YES
Faulty MC2/B.NO
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front motordisplacement angle con-trol proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front motordisplacement angle con-trol proportional solenoid valve and MC2/B.
NO
Faulty front motor dis-placement angle control proportional solenoid valve.
MC2/B Connector MCB-6 MC2/B
Connector MCB-5 (harness end) (harness end)
MC2/B Connector MCB-6 (machine end)
T5-3-140
TROUBLESHOOTING / Troubleshooting A
Check of Rear Motor Displacement Angle Control Proportional Solenoid Valve System
Check the wiring connections first.
Connector
T2BC-05-04-010
T2BC-05-03-031
T2BC-05-03-044 T2BC-05-03-003
T2BC-05-03-032
Rear motor displacement angle control oportional solenoid valve
(h ness end) pr
ar
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z20 of harness end con-nector of connector MCB-5 and terminal Y15 of harness end of connector MCB-6 to machine.Check for continuity between terminals #1, #2 of harness end connector of rear mo-tor displacement angle control proportional solenoid valve and machine.
Disconnect connectorof rear motor dis-placement angle control proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
· Connect terminals E12 and Y12, E13 and Y13 by using a clip.
· Key switch: ON · Hoisting low speed
switch: OFF
YES
NO
Check if voltage between terminal Y15 of machine endconnector of con-nector MCB-6 and machine is 0 V.
Harness short circuit between rear motor dis-placement angle control proportional solenoid valve and MC2/B.
YES
YES
Faulty MC2/B.
NO
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear motor displacement angle con-trol proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear motor displacement angle con-trol proportional solenoid valve and MC2/B.
NO
Faulty rear motor dis-placement angle control proportional solenoid valve.
MC2/B Connector MCB-6
MC2/B Connector MCB-5
(harness end) (harness end)
MC2/B Connector MCB-6 (machine end)
Rear motor displacement angle control proportional solenoid valve (machine end)
T5-3-141
TROUBLESHOOTING / Troubleshooting A
Check of Hoisting Low Speed Lock Switch
Check the wiring connections first.
Connector
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R15 of harness end con-nector of connector MCB-4 and terminal Z16 of harness end of connector MCB-5 to machine.Check for continuity between terminals R15, Z16 of harness end connector of con-nector 62C-16FW and machine.
Disconnect connec-
NO
YES Faulty MC2/B.
T2BC-05-03-054
T2BC-05-03-055
T2BC-05-03-027
T2BC-05-03-044
MC2/B Connector MCB-4 (harness end)
Side upper panel Connector 62C-16FW (harness end)
Side upper panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (harness end)
tor 62C-16FW of side
Check for continuity ween terminals
R15 and Z16 of panelr.
YES
NO
Hoisting low speed lock switch: ON
In case of no continuity at terminal R15, harness open circuit between terminal R15 of side upper panel of connector62C-16FW and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of side up-per panel of connector 62C-16FW and MC2/B.
upper panel.
bet
end connecto
·
Faulty hoisting lowspeed lock switch.
T5-3-142
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT DRUM SURGE PRESSURE REDUCTION CONTROL SYS-TEM
Abnormality By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit error PWM output short
circuit or open circuit OFF (stop)
Harness check
HI ER Upper limit error PWM output harness short circuit OFF (stop)
Harness check Solenoid valve check
FD HST CUR Front drum hoisting proportional solenoid valve
RES ER Reset error Abnormal electric power feedback Controls electric cur-rent by open loop.
MC2/B hardware check
LOW ER Lower limit error PWM output short circuit or open circuit OFF (stop)
Harness check
HI ER Upper limit error PWM output harness short circuit OFF (stop)
Harness check Solenoid valve check
FD LWR CUR Front drum lowering proportional solenoid valve
RES ER Reset error Abnormal electric power feedback Controls electric cur-rent by open loop.
MC2/B hardware check
For check of front drum hoisting proportional so-lenoid valve and front drum lowering proportional solenoid valve, refer to Section "Failure of Front Drum Auto Stop Control System".
T5-3-143
TROUBLESHOOTING / Troubleshooting A
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lock Switch Front Drum Lowering
Proportional Solenoid Valve
Shouldering Prevention
T2BC-05-03-056
T5-3-144
TROUBLESHOOTING / Troubleshooting A
FAILURE OF TOWER JIB DERRICKING 2-SPEED FLOW COMBINING LIMIT CON-TROL SYSTEM
Abnormality By using the power supply monitor, check if all of battery and sensor power supply of MC2/B are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies".
By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals.
Item Signal name Description Explanation State CountermeasureLOW ER Lower limit error PWM output short
circuit or open circuit OFF (stop)
Harness check
HI ER Upper limit error PWM output harness short circuit OFF (stop)
Harness check Solenoid valve check
RD HST CUR Rear drum hoisting proportional solenoid valve
RES ER Reset error Abnormal electric power feedback Controls electric cur-rent by open loop
MC2/B hardware check
LOW ER Lower limit error PWM output short circuit or open circuit OFF (stop)
Harness check
HI ER Upper limit error PWM output harness short circuit OFF (stop)
Harness check Solenoid valve check
RD LWR CUR Rear drum lowering proportional solenoid valve
RES ER Reset error Abnormal electric power feedback Controls electric cur-rent by open loop
MC2/B hardware check
For check of rear drum hoisting proportional sole-noid valve and rear drum lowering proportional so-lenoid valve, refer to Section "Failure of Rear Drum Auto Stop Control System".
T5-3-145
TROUBLESHOOTING / Troubleshooting A
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lock Switch Front Drum Lowering
Proportional Solenoid Valve
Shouldering Prevention
T2BC-05-03-057
T5-3-146
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Troubleshooting procedures are used for failure di-agnosis based on trouble phenomena.
How to read troubleshooting flowchart
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown.
T6L4-05-03-001
NO(NOT OK)
YES(OK) (2)
(1) According to the result of inspection or measurement in (1), se-lect YES (OK) or NO (NO OK), and go to the next step (2) or (3). (1)
(3)
Under the box, inspection or measurement method, or reference may be added. Be careful that if incorrect inspection or measuring method will make it difficult to find the cause of failure, or may damage the equipment. · Key switch: ON
A bold line box shows a cause of failure. The description in the bold-lined box helps you locate a possible cause of failure.
Harness Harness end connector
Mounting Surface
T5-4-1
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING LIST
Failure sections Failure phenomena
E-1 Starter does not run.
E-2 Starter runs but the engine does not start.
E-3 Poor engine starting ability at low temperature (no preheating)
E-4 After completion of preheating, after-heating does not work.
E-5 Idle speed is too fast or slow.
E-6 Maximum un-load speed is too slow.
Engine system
E-7 Engine does not stop.
A-1 Two or more actuators do not work. Actuator system
A-2 Even when moving control lever to neutral, actuator does not stop.
M-1 Drum does not rotate.
M-2 When moving hoisting lever to neutral, the lifting load lowers (in the auto brake mode).
M-3 Even when setting brake mode key switch to auto brake position, auto brake indicator (green) is not turned ON.
M-4 Even when switching to the free mode, auto brake indicator (green) is not turned OFF.
M-5 Even when setting free mode switch of drum to ON position, free-fall cannot be done.
M-6 Even when setting to the free mode, drum free indicator (red) is not turned ON.
Hoisting drum system
M-7 Even when setting to the auto brake mode, drum free indicator (red) is not turned OFF.
Boom derricking drum system
B-1 Drum does not rotate.
Slewing system S-1 Slewing speed is too slow, or slewing is disabled.
T-1 One-side track does not run, travel speed is too slow, or mistrack is caused.Travel system
T-2 Travel speed cannot be shifted.
O-1 Drum lock does not work.
O-2 Counterweight (optional) cannot be removed and installed..
O-3 Jack-up (optional) cannot be done.
O-4 Retraction cannot be done (with jack (optional) attached).
Miscellaneous
O-5 Retraction cannot be done (by using a switch in cab).
T5-4-2
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not run. • Check if front, rear, and third / fourth brake mode
selection switches are set to the auto brake posi-tion, slewing brake switch is set to the brake po-sition, and the emergency stop switch in side overhead panel is released.
• Check the wiring connections first. Broken harness be-tween starter motor and ground, or faulty ground.
• A failure that starter does not run is not related to electronic control systems such as MC2/A, MC2/B and IDU.
YES
Connect starter motor ground line to machine. Check if starter runs.
Check if voltage between C ter-minal of key switch and machine is 24V or more.
YES
Connector
T2BC-05-04-002 T333-05-04-012
Starter Motor
Starter Relay 1 Connector
Terminal B
Terminal S
Starter Relay 1
(A)
Check if voltage between machine and terminal B of starter motor is 24V or more.
· Key switch: ON
· Key switch: START
NO
NO· Key switch: START· Insert a test bar into
the rear of connector.
Broken harness be-tween terminal B of starter motor and termi-nal B of starter relay 1. Broken harness be-tween terminal S of starter motor and termi-nal S of starter relay 1.
To “Failure of power supply system”
Check for continu-ity between termi-nal B of starter motor and terminal B of starter relay 1.Check for continu-ity between termi-nal S of starter motor and terminal S of starter relay.
YES
NO
Key switch (Harness end)
Terminal C
T5-4-3
TROUBLESHOOTING / Troubleshooting B
Connector
Starter Relay 1 (Harness end)
Terminal SW Terminal L
(B)
Faulty key switch.
Connect terminal L (harness end) of connector of starter relay to machine. Discon-nect connector of starter relay 2. Check for continu-ity between ma-chine and terminal S (harness end) of connector.
YES
Connect connector of engine starting relay. Check if voltage between machine and terminal SW (harness end) of connector is 24 V or more.
Disconnect con-nector of starter relay. Connect terminal SW (harness end) of connector to machine.Check for continu-ity between termi-nal #5 (harness end) of connector of engine starting relay and machine.
YES
To “Failure of en-gine start interlock control system” in “Troubleshooting A”.
YES· Key switch: START N
Disconnect con-nector of engine starting relay. Check if voltage between machine and terminal #3 (harness end) of connector is 24 V or more.
YESBroken harnessbetween engine starting relay and starter relay 1.
N
Broken harnessbetween key switch and engine start relay.
· Key switch: START (A)
NO
NO
Engine Starting Relay (Harness end)
Terminal #3
T5-4-4
TROUBLESHOOTING / Troubleshooting B
Connector
Terminal SWTerminal L
Terminal R Terminal S
Terminal P Terminal E
Starter Relay 1 (Harness end)
(C)
Faulty starter re-lay.
Connect connector of starter relay 2. Check if electric current at terminal L (harness end) of connector of starter relay 1 is 0A.
Broken harnessbetween starter relay 2 and ground, or faulty ground.
YES
N
Disconnect con-nector of starter relay 2. Check if voltage between machine and terminal R (harness end) of connector is 24 V or more.
Broken harnessbetween key switch and starter relay 2.
Broken harness between starter relay 2and starter relay 1.
NO
YES
YES
N
N
Check for continu-ity between ma-chine and terminal E (harness end) of connector of starter relay 2.
YES
Check if voltage between machine and terminal P (harness end) of connector of starter relay 2 is 0
· Key switch: ON
(B)· Key switch: START
YES Faulty starter relay 2.
(C)Faulty alternator, or short-circuited harness between alternator and starter relay 2.
N
Starter Relay 2 (Harness end)
T5-4-5
TROUBLESHOOTING / Troubleshooting B
POWER SUPPLY SYSTEM FAILURE
NO
Disconnect 206 harness of battery relay. Check if voltage at terminal (machine end) is 24V or more.
NO
YESBroken harness be-tween battery relay and starter motor
Check if battery voltage and spe-cific gravity of bat-tery electrolyte are normal.
Broken harness be-tween battery relay and ground, or faulty ground.
YES
· Key switch: ON
Faulty battery.
YES
NO
· Key switch: ON
Connect 206 har-ness.Connect terminal ( )of battery to machine. Check if voltage be-tween machine and terminal B of starter motor is 24V or more.
Disconnect harness from terminal ( ) of battery to machine. Disconnect connector of key switch. Check for continuity between machine end terminal B (harness end) of connector.
T5-4-6
TROUBLESHOOTING / Troubleshooting B
Connector
T2BC-05-04-002
NO
YES
Broken harness between battery and key switch.
Broken harness or fuse #20 between key switch and battery relay.
Disconnect 264 harness of battery relay. Connect 264 har-ness to machine. Check for continuity between machine and terminal ACC (harness end) of key switch connec-tor.
Faulty battery re-lay.
YES
Faulty key switch.
YES
N
N
Connect ground terminal of battery relay to machine. Check if voltage between machine and terminal B of starter motor is 24V or more.
YES
NO
· Key switch: ON· Insert a test bar
into the rear of connector.
Broken harness between battery relay and ground, or faulty ground.
· Key switch: ON
Connect the dis-connected har-ness to connec-tor. Check if volt-age between machine and ter-minal ACC of key switch is 24V or
Key Switch (Harness end)
Terminal B
Terminal ACC
T5-4-7
TROUBLESHOOTING / Troubleshooting B
E-2 Starter turns but engine does not start.
• Check the position of engine governor lever dur-ing cranking. If normal, the cause of failure may be malfunction of engine itself.
• Check the wiring connections first.
Check if engine gov-ernor lever moves to the start position.
NO
YES Faulty engine.
Connect terminal GD2 (harness end) of engine stop sole-noid to machine. Check if engine gov-ernor lever moves to the start position.
Check if voltage be-tween machine and terminal 209 (har-ness end) of engine stop solenoid is 24V or more.
Faulty engine stop solenoid.
NO
YES
· Key switch: ON · Visual check
Connect terminal #4 of engine stop relay to machine. Check if engine governor lever moves to the start position.
Faulty battery.YES
NO
· Key switch: ON
· Key switch: ON· Visual check
· Key switch: ON· Connect to machine
from the rear of connector.
· Visual check
ConnectorEngine Stop Relay (Harness end)
T2BC-05-04-001
T5-4-8
TROUBLESHOOTING / Troubleshooting B
NO
YES
Broken harnessbetween engine stop relay and ground, or faulty ground.
Faulty engine stop relay.
NO
YES
Broken harnessbetween key switch and engine stop relay.
YES
NO
· Key switch: ON
YES
NO
Broken harnessbetween engine stop relay and en-gine stop solenoid.
Broken harnessbetween engine stop relay and battery relay.
· Key switch: ON
Disconnect engine stop relay from connector.Check if voltage between machine and terminal #2 (harness end) of connector is 24 V.
Connect 209 har-ness of engine stop solenoid to machine.Check for continu-ity between termi-nal #6 (harness end) of connector of engine start re-lay and machine.
Check if voltage between machine and terminal #1 (harness end) of connector of en-gine stop relay is 24 V or more.
T5-4-9
TROUBLESHOOTING / Troubleshooting B
E-3 Poor engine starting ability at low tempera-ture (no preheating)
• The machine is equipped with an automatic pre-heating system. This automatic preheating system is automati-cally turned ON only when setting key switch to ON position at coolant temperature of 0°C or lower. Notice that preheating is not carried out at cool-ant temperature of 0°C or higher. Also, preheating time changes depending on coolant temperature. For preheating, refer to Chapter “Electric system” in “Operational Principle”.
• Check a fuse of heater relay first. • Check the wiring connections first.
NO
· Key switch: ON Check if coolant tem-perature is 0 C or lower.
· Key switch: ON· Check within 15
seconds after turn-ing key switch ON.
NO
NO
YES
YES
YES
Faulty air heater or faulty ground.
Broken harnessbetween heater relay and air heater.
Check if voltagebetween machine and terminal 217 (harness end) of heater relay is
Air heater does notwork. (Normal)
· Key switch: ON
Check if voltage between machine and air heater power terminal of engine is 24V.
Check if voltage between machine and terminal 206 (harness end)of heater relay is
T5-4-10
TROUBLESHOOTING / Troubleshooting B
Connector
T2BC-05-04-003
NO
NO
YES
YES
NO
· Key switch: ON· Insert a test bar
into the rear of connector.
YES
NO
Faulty heater relay or faulty ground.
YES
Remove plug from heater relay. Check if voltage between machine and harness end plug is 24 V. · Key switch: ON
· Key switch: ON
Broken harness be-tween preheat con-troller and ground.
NO
YES
Broken harness be-tween preheat con-troller and heater re-lay.
· Key switch: ON· Connect to ma-
chine from the rear of connector.
· Insert a test bar into the rear of connector.
· Key switch: ON
To ”Check of key switch and battery system”.
Broken harness be-tween heater relay and battery relay.
(A)
Check if voltage between machine and terminal #1 of preheat controller is 24V.
Connect terminal #9 of preheat con-troller to machine. Check if voltage between terminal #1 and machine is 24V. Check if voltage be-
tween machine and terminal #7 of preheat controller is 24V.
Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V.
Preheat Controller (Harness end)
T5-4-11
TROUBLESHOOTING / Troubleshooting B
Connector
T2BC-05-04-003
NO
YES
NO
YES Faulty preheat con-troller.
Broken harness between preheat controller and cool-ant temperature sensor.
Broken harness between preheat controller and bat-tery relay.
NO
YES
Faulty coolant tem-perature sensor.
Go to "Check of key switch and battery system". · Key switch: ON
Coolant Temperature Sensor (Harness end)
1
2
(A)
· Key switch: ON
NO
YES
Check if coolant temperature sen-sor is normal.
Disconnect pre-heat controller from connector. Connect terminal #5 (harness end) of connector to machine.Disconnect coolant temperature sen-sor from connector Check for continu-ity between ma-chine and terminal #2 (harness end) of connector.
Check if voltage between machine and terminal #2 or #3 of preheat con-troller is 24V.
Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V.
Preheat Controller (Harness end)
T5-4-12
TROUBLESHOOTING / Troubleshooting B
Check of key switches and battery system
NO
· Key switch: ON Check if volt-age of battery and specific gravity of bat-tery electrolyte are normal.
· Key switch: ON
NO
NO
YES
YES
YES
Broken harness between battery and ground, or faulty ground.
Broken harness between battery and battery relay
Faulty battery.
· Key switch: ON
Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V.Connect terminal ( ) of
battery to machine. Check if voltage be-tween machine and terminal 206 (harness end) of battery relay is 24V.
Connect ground terminal of battery relay to machine. Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V.
T5-4-13
TROUBLESHOOTING / Troubleshooting B
Connector
T2BC-05-04-002
Disconnect 264 harness of battery relay. Check if voltage between machine and terminal (har-ness end) is 24V.
NO
YES Faulty battery relay
Check if voltage between machine and terminal ACC of key switch is 24V.
Check if voltage be-tween machine and terminal B of key switch is 24V.
Faulty key switch.
NO
YES
· Key switch: ON
Broken harness be-tween key switch and battery relay.
YES
NO
· Key switch: ON· Insert a test bar into
the rear of connec-tor.
· Key switch: ON· Insert a test bar
into the rear of connector.
Broken harness bat-tery and ground, or Faulty ground.
YES
NO
Broken harness be-tween key switch and battery.
Key Switch (Harness end)
Terminal B
Terminal ACC
T5-4-14
TROUBLESHOOTING / Troubleshooting B
E-4 After-heating is not made after completion of preheating.
Connector
T2BC-05-04-003
NO
· Key switch: START
Check if voltage between machine and terminal #4 of preheat controller is 24V.
· Key switch: ON· Insert a test bar into
the rear of connec-tor.
NO
NO
YES
YES
YES
Faulty alternator.
Broken harness between preheat controller and al-ternator.
Faulty preheat con-troller.
Disconnect con-nector of preheat controller.Check if voltage between machine and terminal #7 (harness end) of connector is 0 V.
Check if voltage between machine and terminal L of alternator is 0 V.
· Key switch: ON · Insert a test bar
into the rear of connector.
Broken harness between engine starting relay and preheat controller.
Preheat Controller (Harness end)
T5-4-15
TROUBLESHOOTING / Troubleshooting B
E-5 Idle speed is too fast or slow
• Incorrect engine speed may be resulted from faulty adjustment of governor motor, link or lever, or malfunction of fuel injection pump.
· Key switch: ON · Set to low idle
position by using an accelerator grip.
Idle speed is too fast or slow.
NO
YES
NO
YESGo to "Failure of engine con-trol system” in “Troubleshoot-ing A".
Faulty adjustment of control cable that connects governor motor and governor lever.
Faulty adjustment of engine governor lever.
Check if control cable from gover-nor motor, which is connected to gov-ernor lever, is set correctly.
Check if engine governor lever gets in contact with low idle stopper bolt.
· Visual check.
T5-4-16
TROUBLESHOOTING / Troubleshooting B
E-6 Maximum un-load speed is too slow
• Incorrect engine speed may be resulted from faulty adjustment of governor motor, link or lever, or malfunction of fuel injection pump.
Maximum un-load speed is too low.
NO
YES
NO
YES
NO
YES· Key switch: ON · Set to high idle po-
sition by using an accelerator grip.
· Visual check.
Carry out high idle calibration.
Faulty governor lever or faulty rod.· Deformation of lever, rod or
the like
(A)
Faulty engine or faulty fuel system.
Check if engine governor lever gets in contact with high idle stopper bolt.
Check if high idle calibration is done.
Check if engine governor lever, rod or the like is de-formed.
Faulty adjustment of control cable that connects governor motor and governor lever.
Go to "Failure of engine con-trol system” in “Troubleshoot-ing A".
NO
YES
(A)
Check if control ca-ble, which connects governor motor and governor lever, is set correctly.
T5-4-17
TROUBLESHOOTING / Troubleshooting B
E-7 Engine does not stop.
• Engine is stopped by cutting off fuel by using an engine stop solenoid.
• If engine does not stop, engine stop solenoid may fail, or engine stop relay (which delivers a stop signal to the engine stop solenoid), or key switch (even in OFF state, 24V voltage is present at its terminal ACC) may fail.
• Check the wiring connections first.
Connector
T2BC-05-04-001 T2BC-05-04-002
· Key switch: OFF
Faulty engine stop solenoid.YES
Check if voltage YESbetween machine
(harness end) of and terminal 209
engine stop sole-noid is 0 V.
NO
NO
Faulty key switch.
Short-circuited harness be-tween key switch and battery relay, or faulty battery relay.
Short-circuited harness be-tween engine stop relay and engine stop solenoid. NO
YES
· Key switch: OFF
Disconnect con-nector of key switch. Check if engine stops.Disconnect engine
stop relay. Check if voltage between machine and terminal #6 (harness end) of connector is 0 V.
Engine Stop Relay (Harness end)
Key Switch (Harness end)
Terminal C Terminal B
Terminal ACC
T5-4-18
TROUBLESHOOTING / Troubleshooting B
ACTUATOR TROUBLESHOOTING
A-1 Two or more actuators do not work.
• Pilot system (pilot pump, gate lock valve, etc.) and relief valves may malfunction.
• If hoisting, lowering and derricking (lowering) drums are not activated, refer to “Troubleshooting A and D”.
Check if pilot circuit primary pilot pres-sure is normal.
Check if gate locklever and emer-gency stop switch are in unlock posi-tion.
NO
YES
NO
YES
NO
YES
· Refer to Chapter "PerformanceMeasurement".
· Refer to Chapter "PerformanceMeasurement".
Check if main relief pressure corre-sponding to failure is normal.
Check if gate lock valve, pres-sure-reducing valve and second overhoist solenoid valve in 4-spool solenoid valve unit are ab-normal.
NO
YESFaulty main pump.
Incorrect pressure setting of main relief valve.
Faulty pilot pump.
Faulty gate lock valve, pres-sure-reducing valve or second overhoist solenoid valve in 4spool solenoid valve.
Set lock lever and emergency stop switch to unlock po-sition.
· Disassembly· Gate lock lever: Pull
· Emergency Stop Switch: OFF
A-2 Even when moving control lever to neutral, actuator does not stop.
• Spool in remote control valve or spool in control valve may be stuck.
· Pilot pressure is not transmitted to con-trol valve (spool), but the oil passage is open due to sticking or the like.
Check if actuator stops when setting lock lever to lock position.
NO
YES Faulty remote con-trol valve.
Faulty control valve.
· Even when control lever is in neutral, pilot pressure is transmitted to con-trol valve (spool).
T5-4-19
TROUBLESHOOTING / Troubleshooting B
HOISTING DRUM TROUBLESHOOTING
M-1 Drum does not rotate
• Check the wiring connections first. • If pilot pump, pressure-reducing valve for 4-spool
solenoid valve unit, and gate lock valve are faulty, not only drum rotation but travel and slewing cannot be achieved.
• When safety device or drum lock motor functions, drum stops.
• Refer to “Troubleshooting A and D” .
4-Spool Solenoid Valve Unit
T2BC-05-04-004
Disconnect piping from A4 port of 4-spool solenoid valve unit. Install pressure gauge instead. Check if output pressure is 4.9 MPa.
NO
YES
NO
YES
NO
YES
Stuck spool in con-trol valve or propor-tional solenoid valve.
Faulty remote con-trol valve.
Faulty second overhoist solenoid valve of 4-spool solenoid valve unit.
NO
YES
Faulty motor brake release solenoid valve.
Check if output pressure from control valve is 28.3 to 31.4 MPa.
Check if pres-sure at port PR of hoisting motor is 4.9 MPa.
Check if sec-ondary pilot pressure is normal.· Refer to "Per-
formanceMeasurement".
· Install pressure gauge to port a or b of counter-balance valve of hoisting motor.
· Port a during hoisting. · Port b during lowering.
Faulty hoisting motor.
Port (G3/8)
Port a (G3/8)
CounterbalanceValve
M25N-07-024
Port A4 PR Port (G1/4)
HoistingMotor
T5-4-20
TROUBLESHOOTING / Troubleshooting B
M-2 When moving hoisting lever to neutral, the lifting load lowers. (in the auto brake mode)
• In this case, hoisting drum brake may not be ap-plied, or hoisting motor multi-plate brake may not be applied.
• Refer to “Troubleshooting A”.
Drum Brake Release Solenoid Valve
T25N-05-04-002
M25N-07-024
Check if the lifting load lowers when depressing brake pedal.
NO
YES Faulty drum brake.
Check if output pressure at drum brake release so-lenoid valve is 0 MPa.
Check if pressure at port PR of hoisting motor is 0 MPa.
NO
Faulty hoisting motor multi-plate brake.
YES
NO
Faulty hoisting motor brake release sole-noid valve.
· Install pressure gauge to port A of drum brake release solenoid valve to be checked.
Faulty drum brake release solenoid valve.YES
Port PR (G1/4)
HoistingMotor
Port A (G3/8)
T5-4-21
TROUBLESHOOTING / Troubleshooting B
M-3 Even when setting brake mode key switch to auto brake position, auto brake indicator (green) is not turned ON.
• Check if each brake mode selection switch is OFF.
• If both pilot pressure drop indicator and slewing brake indicator are not turned ON, 224 harness may be open circuit.
• Check the wiring connections first. • For check of brake mode selection switch and
front drum and rear drum brake mode selection switches, refer to section "Failure of Brake Con-trol System" in “Troubleshooting A”.
Connector
T2BC-05-04-005
Faulty MC2/A.
If voltage between terminal E9and ma-chine is not 24V, rear auto brake indicator bulb is burnt out. If voltage between terminal E22 and machine is not 24V, front auto brake in-dicator bulb is burnt out.
In case of no conti-nuity between ter-minal E9 and ma-chine, broken har-ness between rear auto brake indicator and MC2/A. In case of no conti-nuity between ter-minal E22 and ma-chine, broken har-ness between front auto brake indicator and MC2/A.
Disconnect connector of brake indicator of left stand. Connect terminals #7 and #8 (harness end) of connector to machine.Disconnect connector MCA-6 of MC2/A. Check for continuity between machine and terminal E9 or E22 (harness end) of connec-tor.
NO
YES
NO
YES
· Key switch: ON· Brake mode selection switch:
OFF (auto brake) · Front drum brake mode se-
lection switch: OFF · Rear drum brake mode selec-
tion switch: OFF · Insert a test bar into the rear
of connector.
Connect the disconnected con-nector.Check if voltage between ma-chine and terminal E9 or E22 of connector MCA-6 of MC2/A is 24 V.
M-7 Even when setting to the auto brake mode, drum free indicator (red) is not turned OFF.
• Check the wiring connections first. • Refer to “Troubleshooting A”.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and terminal (ma-chine end) of connector is 24 V.
Short-circuited har-ness between drum free indicator and MC2/A.
YES
NO· Key switch: ON · Brake mode switch: OFF
(auto brake) · Connect terminals E12 and
E13 of both connectors by using clips or the like.
· Front drum free indicator: Make measurement be-tween terminal E32 and machine.
· Rear drum free indicator: Make measurement be-tween terminal E9 and ma-chine.
· Third drum free indicator: Make measurement be-tween terminal E7 and ma-chine.
Faulty MC2/A.
ConnectorMC2AConnector MCA-6 (Harness end)
E22
E9 E7
T2BC-05-04-007
T5-4-27
TROUBLESHOOTING / Troubleshooting B
BOOM DERRICKING DRUM TROUBLE- SHOOTING
B-1 Drum the does not rotate.
• Check wiring connections first. • If pilot pump, pressure-reducing valve for 4-spool
solenoid valve unit and gate lock valve are faulty, not only drum rotation but travel and slew cannot be achieved.
• If safety device works, drum stops. Refer to “Troubleshooting A and D”.
NO
YES
NO
YES
YES
· Install pressure gauge to port AM or BM of boom derricking motor.
· Port AM during boom derricking (housing).
· Port BM during boom derricking (lowering).
· Refer to “Per-formance Meas-urement”.
NO
Stuck spool in front control valve, or faulty remote con-trol valve for boom derricking.
Faulty pres-sure-reducing valve in 4-spool solenoid valve unit.
Check if output pressure from control valve is 28.3 to 34.5 MPa.
Remove piping at port A4 in 4-spool sole-noid valve unit. Install pressure gauge.Check if output pressure is 4.9 MPa.
4-Spool Solenoid Valve Unit
T2BC-05-04-004
Check if primary
pilot circuit is
lock.
pilot pressure in
Faulty second overhoist solenoid valve in 4-spool solenoid valve unit.
normal. boom derricking drum
Port A1
Port A4
T5-4-28
TROUBLESHOOTING / Troubleshooting B
Faulty boom derrick-ing drum lock.
YES
NOFaulty boom derrick-ing motor.
Check if there is abnormality in boom derricking drum lock.
Boom Derricking Drum Lock
From Pilot Pump AM Port (G1/4)
T25N-03-04-003
Boom Derricking Motor
BM Port (G1/4) Pawl
Torsion Spring
Ball Joint
T5-4-29
TROUBLESHOOTING / Troubleshooting B
SLEWING SYSTEM TROUBLESHOOTING
S-1 Slewing speed is too slow, or slewing is dis-abled
• Check the wiring connections first.• If pilot pump, pressure-reducing valve of 4-spool
solenoid valve unit and gate lock valve are faulty, not only slew but travel and drum rotation are deactivated.
Port b (G 1/4)
M25N-07-023 Port a (G 1/4) Slewing Motor
Slewing Control Valve
T2BC-04-05-008
4-Spool Solenoid Valve Unit
T2BC-05-04-004
NO
YES
NO
YES
· Install pressure gauge to pres-sure check port of slewing con-trol valve.
NO
YES
Faulty slewing re-mote control valve.
Faulty slewing con-trol valve.
· Install pressure gauge to port a or b of slewing motor.
· Port b at slew (CW).· Port a at slew
· Install pressure gauge to port A2 of 4-spool sole-noid valve unit.
· Refer to Group "PerformanceMeasurement".
· Slewing brake switch: ON
Check if input pressure from slewing control valve is 28.7 to 31.9 MPa. Check if output
pressure at port A2 of 4-spool so-lenoid valve unit is 4.9 MPa.
ACheck if input pressure to slewing control valve is 28.7 to 31.9 MPa. Check if secon-
dary pilot pres-ing
block is normal.
sure to slewBcontrol valve
Slewing Brake So-lenoid Valve
Port A2
Pressure Check Port
T5-4-30
TROUBLESHOOTING / Troubleshooting B
Connector
T2BC-05-04-011 T2BC-05-04-010
Slewing Lever (Harness end)
Slewing Brake Solenoid Valve (Harness end)
NO
NO
YES
YES
NO
YES
NO
YES
· Key switch: ON
· Key switch: ON · Slewing brake
switch: ON
· Insert a test bar into the rear of connector.
· Key switch: ON
Faulty slewingbrake switch.
Broken harness between slewingbrake switch and battery.
Faulty slewingmotor.
Broken harness between slewingbrake solenoid valve of 4-spool solenoid valve unit and slewing brake.
Faulty slewingbrake solenoid valve of 4-spool solenoid valve unit.
Broken harness between ground and slewing brake solenoid valve of 4-spool solenoid valve unit, or faulty ground.
YES
Disconnect slewinglever connector. Connect terminals #2 and #8 (har-ness end) of con-nector.Check if output pressure at port A2of 4-spool solenoid valve unit is 4.9 MPa.
Check for conti-nuity between machine and terminal #1 (har-ness end) of connector of slewing brake solenoid valve.
Connect the dis-connected con-nector.Disconnect con-nector from slew-ing brake solenoid valve of 4-spool solenoid valve unit. Check if voltage between machine and terminal #2 (harness end) of connector is 24 V.
A
Check if voltage between machine and terminal #2 of slewing lever con-nector is 24 V.
NO
T5-4-31
TROUBLESHOOTING / Troubleshooting B
Slewing Pump Swash Angle Solenoid Valve
T2BC-05-04-008
Faulty slewing pump.
Disconnect con-nector MCA-5 of MC2/A.Check for continu-ity between termi-nals #1 and F11, #2 and F7.
Faulty MC2/A.
Faulty harness between MC2/A and slewing pump swash angle pro-portional solenoid valve.
YES
NO
YES
NO
B
Disconnect con-nector of slewing pump swash angle solenoid valve. Check if electric current between terminal #1 and #2 is 700 mA.
MC2/AConnector MC
F7
T2BC-05-04-009
T5-4-32
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 One-side track does not run, travel speed is too slow, or mistrack is caused.
• If pilot pump, pressure-reducing valve of 4-spool solenoid valve unit and gate lock valve are faulty, not only travel but slew and drum rotation are deactivated.
• If any one of tracks does not run, remote control valve, control valve, travel motor, center joint or pump may be faulty.
Center Joint
T25N-05-04-006
Stuck spool in control valve.
Check if failure phenomenon is reversed when exchanging left and right travel hoses at center joint.
Check if secondary travel pilot pres-sure is normal.
Check if travel re-lief pressure at slower track is normal.
NO
YES
NO
YES
NO
YES
Check if failure phenomenon is reversed when exchanging left and right travel re-lief valves.
Faulty remote con-trol valve.
· Refer to "Per-formance Meas-urement".
Right Travel (Forward)
Left Travel (Reverse)
Right Travel (Reverse)
Left Travel (Forward)
T5-4-33
TROUBLESHOOTING / Troubleshooting B
Faulty travel motor or travel reduction gear.
Faulty servo pistonof travel motor.
Faulty counter-balance valve. NO
YES
NO
YES
Faulty center joint.
Faulty travel relief valve.
NO
YES
Disassemble and clean counterbal-ance valve of travel motor. Check if failure phenomenonarises again.
Disassemble and clean servo piston of travel motor. Check if failure phenomenonarises again.
T5-4-34
TROUBLESHOOTING / Troubleshooting B
T-2 Travel speed cannot be shifted.
• Check the wiring connections first.
Connector
T2BC-05-04-010
M25N-07-032
Disconnect con-nector from high travel speed se-lection solenoid valve of 4-spool solenoid valve unit.Check if voltage at terminal #2 (harness end) of connector is 24V.
NO
YES
NO
YES
NO
YES
Faulty sash angle selection mecha-nism of travel mo-tor.
Faulty high travel speed selection solenoid valve of 4-spool solenoid valve unit.
Broken harness between high travel speed selection solenoid valve and ground or fuse #23.
NO
YES
Stuck in shuttle valve.
NO
YES
· High / low travel speed selection
4-Spool Solenoid Valve Unit
T2BC-05-04-004
Travel Motor
PS Port(G 1/4)
Port A3
High Travel Speed Selection Solenoid Valve (Harness end)
switch: High
· Install pressure gauge to port A3 of 4-spool solenoid valve unit.
· Travel Mode Switch: High speed
· Install tee and pres-sure gauge to port PS of travel motor.
· High / low travel speed selection switch: High speed
Check if input pressure at port PS of travel motor is 4.9 MPa.
Check if output pressure at port A3 of 4-spool so-lenoid valve unit is 4.9 MPa.
Check for continu-ity between ma-chine and terminal #1 (harness end) of connector.
Broken harness between travel mode switch and battery or fuse #23.
Disconnect con-nector of travel mode switch. Check for continu-ity between ter-minals #6 and #7. Faulty travel mode
switch. speed· Travel Mode
Switch: High speed
T5-4-35
TROUBLESHOOTING / Troubleshooting B
OTHER TROUBLESHOOTING O-1 Drum lock does not work.
• Check the wiring connections first.
Connector
T2BC-05-04-012
Right Control Panel
NO
YES
Broken harness between drum lock switch and drum lock motor.
Faulty drum lock motor.
Check if voltage between terminal #6 of drum lock motor and ma-chine is 24V.
Faulty drum lock motor.
Faulty drum lockswitch.
Faulty drum lockswitch.
Broken harness between drum lock switch and drum lock motor.
· Drum lock switch: OFF
· Drum lock switch: ON
· Key switch: ON · Insert a test bar
into the rear of connector.
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
Drum lock is not released.
Drum lock is not applied.
Connect the dis-connected con-nector.Disconnect con-nector of drum lock motor.Check for continu-ity between termi-nals #1 and #2 (harness end) of connector.
Connect the dis-connected con-nector.Disconnect con-nector of drum lock motor.Check for continu-ity between termi-nals #1 and #3 (harness end) of connector.
Check if ground of drum lock motor is normal.
· Drum lock switch: ON· Make measurement
between terminals #8 and #6 of front drum.
· Make measurement between terminals #12 and #10 of rear drum.
· Make measurement between terminals #16and #14 of fourth drum.
· Drum lock switch: OFF· Make measurement between
terminals #8 and #7 of front drum.
· Make measurement between terminals #12 and #11 of rear drum.
· Make measurement between terminals #16 and #15 of fourth drum.
Disconnect con-nector SWP16F of right control panel. Check for continu-ity between termi-nals (machine end) of connector.
Disconnect con-nector SWP16F of right control panel. Check for continu-ity between termi-nals (machine end) of connector.
Broken harnessbetween drum lock motor and battery or fuse (front: #22, rear: #2, fourth: #40).
Faulty ground of drum lock motor.
Connector SWP16F (Harness end) Drum Lock Motor
(Harness end)
T2BC-05-04-013
T5-4-36
TROUBLESHOOTING / Troubleshooting B
O-2 Counterweight (optional) cannot be re-moved and installed.
• Check the wiring connections first.
T2BC-05-04-018
· Key switch: ON
YES
Disconnectconnector(62C-16FB) of left control panel. Check if voltage at terminal #2 (harness end) of connector is 24V.
Remove jack relay (R5).Check if voltage at terminal #3 is 24V.
Check for continuity between terminals #2 and #6 of connector.
· Counterweight /jack-up switch: Counterweight id
Broken harness between jack relay (R5) and terminal #2 (harness end) of connector.
NO
Faulty jack relay (R5).
Broken harness between fuse #39 or jack relay (R5) and battery relay.
YES
NO
YES
NO· Key switch: ON
Left Control Panel
T2BC-05-04-017
Check if quick drawor retract cylinder moves.
Relay Panel
Connector (62C16FB) (Harness end)
Jack Relay (R5)
T5-4-37
TROUBLESHOOTING / Troubleshooting B
T2BC-05-04-019
YES
Disconnect relay connector (1P). Check if voltage at harness end terminal is 24V.
NO
Disconnect relay connector (1P) or (4P).Check for continuity between each ter-minal (counterweight control box end) of relay connector (4P) and terminal (coun-terweight control box end) of relay con-nector (1P).
Faulty counterweight solenoid valve, or broken harness be-tween counterweight solenoid valve and relay connector (4P).
NO
YES
YES
NO
· Terminal #1: Right cylinder extension
· Terminal #2; Right cylinder retraction
· Terminal #3: Left cylinder extension
· Terminal #4: Left cylinder retraction
Faulty counterweight /jack-up switch.
Broken harness be-tween relay connector (1P) and connector in left control panel.
Faulty counterweight control box or har-ness.
Counterweight Control Box
Relay Connector (Control box end)
T2BC-05-04-020 Relay Connector
4P 1P
T5-4-38
TROUBLESHOOTING / Troubleshooting B
O-3 Jack-up (optional) cannot be done.
• Check the wiring connections first.
YES
Remove jack relay (R5).Check if voltage at terminal #3 (con-nector end) is 24V.
Faulty jack relay (R5).
NO
Check for continuity between terminal #2 of jack relay (R5) connector and ma-chine.
Broken harness between jack relay (R5) and battery re-lay or fuse #39.
· Key switch: ON
Replace jack relay (R5) with horn relay (R4).Check if jack can be extended or re-tracted.
Disconnect connec-tor from left control panel.Check if voltage at harness end terminal #2 is 24V.
Check for continuity between terminal #2 (panel end) of con-nector in left control panel and terminal #3 of 62C-16MW.
Broken harness between jack relay (R5) and counter-weight / jack-up switch.
· Key switch: ON
· Key switch: ON
Faulty counterweight/ jack-up switch.
Broken harness between counter-weight
Disconnect connec-tor from hydraulic selection solenoid valve of 4-spool con-trol valve. Check if voltage at terminal #1 (harness end) of connector is 24V.
/ jack-up switch and hydraulic selection solenoid valve in 4-spool control valve.
YES
YES
NO
YES
NO
NO
Left Control Panel Connector(Panel end) 62C-16MB
Left Control Panel Connector (Harness end) 62C-16MW
T5-4-40
TROUBLESHOOTING / Troubleshooting B
· Refer to T4-5.
Check for continuity between machine and terminal #2 (harness end) of connector in hydrau-lic selection solenoid valve.
Check if relief pres-sure in lower control valve is 19.6 Mpa.
Check if jack-upspool in lower control valve moves.
Faulty relief valve in lower control valve.
Broken harness between hydraulic selection solenoid valve and machine, or faulty ground.
Stuck spool.
Faulty jack-up cyl-inder.
YES
NO
YES
NO
YES
NO
T5-4-41
TROUBLESHOOTING / Troubleshooting B
O-4 Retraction (with jack (optional) attached) cannot be done.
• Check the wiring connections first.
YES
Remove jack relay (R5).Check if voltage at terminal #3 (con-nector end) is 24V.
Faulty jack relay (R5).
NO
Check for continuity between terminal #2 of jack relay (R5) connector and ma-chine.
Broken harness between jack relay (R5) and battery relay or fuse #39.
· Key switch: ON
T2BC-05-04-018
T2BC-05-04-014
Replace jack relayith horn relay
YES
NO
(R5) w(R4).Check if jack can be extended or re-tracted.
Disconnect connec-tor from left control panel.Check if voltage at harness end terminal #2 is 24V.
Check for continuity between terminal #2 (panel end) of connector in left control panel and terminal #3 of 62C-16MW.
Broken harness between jack relay (R5) and counterweight / jack-up switch.
· Key switch: ON
· Key switch: ON
Faulty counterweight/ jack-up switch.
Disconnectconnector from hydraulic selection solenoid valve of 4-spool control valve. Check if voltage at terminal #1 (harness end) of connector is 24V.
Broken harness between counterweight / jack-up switch and hydraulic selection solenoid valve in 4-spool control
YES
NO
YES
NO
NO
YES
T2BC-05-04-017 T2BC-05-04-023
Left Control Panel Connector (Panel end) 62C-16MB
Left Control Panel Connector (Harness end) 62C-16MW
T2BC-05-04-022
T5-4-43
TROUBLESHOOTING / Troubleshooting B
· Refer to T4-5.
Check for continuity between machine and terminal #2 (harness end) of connector of hydrau-lic selection solenoid valve.
Check if relief pres-sure of lower control valve is 16.9 MPa.
Check if retract spool in lower control valve moves.
Faulty relief valve in lower control valve.
Broken harness between hydraulic selection solenoid valve and machine, or faulty ground.
Stuck spool.
Faulty retract cylin-der.
YES
NO
YES
NO
YES
NO
T5-4-44
TROUBLESHOOTING / Troubleshooting B
O-5 Retraction cannot be done (by using a switch in cab).
• Check the wiring connections first.
T2BC-05-04-018
Faulty jack relay (R5).
· Engine: Running · Side frame
extend / retract switch: Extend or retract
· Key switch: ON
· Key switch: ON
YES
YES
NO
YES
NO
Broken harness between jack relay (R5) and ground, or faulty ground.
Connect the dis-connected relay. Disconnect con-nector 62C-16FB of left control panel. Check if voltage between terminal #2 (harness end) of connector and ma-chine is 24V.
Broken harness between jack relay (R5) and battery relay or fuse #39.
Replace jack relay (R5) with horn re-lay (R4). Check if retract cylinder can be extended or re-tracted. Disconnect jack
relay (R5) from connector.Check if voltage between terminal #3 (harness end) of connector and ma-chine is 24V.
Check for continuity between machine and terminal #2 (harness end) of connector.
NO
T2BC-05-04-014
T2BC-05-04-025
Relay Connector (Harness end)
Jack Relay (R5)
Relay Panel
Horn Relay (R4)
Panel Connector (62C-16FB)(Harness end)
T5-4-45
TROUBLESHOOTING / Troubleshooting B
4-Spool Control Valve
T2BC-05-04-024
Side Frame Retract Solenoid Valve
Side Frame Extend Solenoid Valve (with optional attached)
Disconnect con-nector 62C-16FW of left control panel. Check for continuity between connectors 62C-16MB and 62C-16MW.
Connect the dis-connected con-nector.Disconnect con-nector of side frame extend so-lenoid valve in 4-spool control valve.Check if voltage at terminal #1 (har-ness end) of con-nector is 24V.
Check for continu-ity between ma-chine and terminal #2 (harness end) of connector.
· Side frame extend / retract switch: Extendbetween terminal #2 of connector 16MB and terminal #3 of connector 16MW
· Side frame extend / retract switch: Retractbetween terminal #2 of connector 16MB and terminal #4 of connector 16MW
· Key switch: ON· Side frame extend /
retract switch: Extend
· Key switch: ON· Side frame extend /
retract switch: Retract
Broken harness between side frame extend / retract switch and side frame extend solenoid valve.
Faulty side frame extend / retract switch.
Broken harness between side frame extend so-lenoid valve and ground, or faulty ground.
Disconnect con-nector of side frame retract so-lenoid valve. Check if voltage at terminal #1 (har-ness end) of con-nector is 24V.
YES
NO
NO
NO
YES
YES
T2BC-05-04-023 T2BC-05-04-022 T2BC-05-04-015
Panel Connector (62C-16MB) (Panel end)
Panel Connector (62C-16MW)(Panel end)
Solenoid Connector (Harness end)
T5-4-46
TROUBLESHOOTING / Troubleshooting B
Broken harness between side frame extend solenoid valve and ground, or faulty ground.
Faulty retract cyl-inder.
Faulty relief valve in 4-spool control valve, or faulty pump for coun-terweight / quick draw / retract.
Broken harness between side frame extend / retract switch and side frame retract sole-noid valve.
Check for continuity between machine and terminal #2 (harness end) of connector.
YES
NO
YES
NO
YES
NO
Install a pressure gauge to pressure check port in 4-spool control valve. Check if pressure is 20.6 MPa.
4-Spool Control Valve
T2BC-05-04-024
T2BC-05-04-015
Side Frame Retract Solenoid Valve Connector (Harness end)
Pressure Check Port
T5-4-47
This Page Left Blank Intentionally
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as gauges or indicators malfunction.
How to Read Troubleshooting Flow Charts
•
•
•
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown.
T6L4-05-03-001
NO(NOT OK)
YES(OK) (2)• After checking or measuring item (1), select either YES (OK)
or NO (NOT OK) and proceed to item (2) or (3), as appropriate.(1)
(3)
• Special instructions or reference item are indicated in the spaces under the box.Incorrect measuring or checking methods will render troubleshooting impossible,and may damage components as well. Key switch: ON
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes can be seen without going through the flow chart.
Harness Harness end connector
Mounting Surface
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-PERATURE GAUGE
• Check the wiring connections first.
Check if coolant tem-perature sensor termi-nal is correctly con-nected.
Disconnect coolant temperature sensor. Connect harness end terminal #1 to machine.Check if needle swings to (H) side.
With coolant tempera-ture sensor discon-nected, disconnect connector C16F-W from monitor panel. Check for continuity between harness end connector terminal #12 and coolant temperature sensor terminal.
Gauge needle does not swing at all.
NO
NO
YES
YES
Check if coolant tem-perature sensor termi-nal is correctly con-nected.
Disconnect coolant temperature sensor. Connect harness end terminal #1 to machine.Check if needle swings to (H) side and stays in that position.
Gauge needle swings unstably.
Key
Key switch: ON
YES
YES
NO
NO
NO
YES
Check if needle returns when coolant tempera-ture sensor terminal is disconnected.
With coolant tempera-ture sensor discon-nected, disconnect connector C16F-W from monitor panel. Check for continuity between harness end connector terminal #12 and machine.
Gauge needle swings over scale.
Key switch: ON
YES
NO
switch: ON
T5-5-2
TROUBLESHOOTING / Troubleshooting C
T2BC-05-04-026
Coolant Temperature and Electrical Resistance Coolant Temperature
Broken harness between monitor panel and coolant temperature sensor.
Faulty coolant temperature sensor.
Connector (Harness end)
YES
Monitor Panel (C16F-W)
NO
Faulty coolant temperature sensor terminal connection.
Coolant Temperature Sensor
2
1
Faulty coolant temperature sensor.
Short-circuited harness be-tween monitor panel and coolant temperature sensor.
Faulty monitor panel.
Faulty coolant temperature sensor.
Faulty monitor panel.
Faulty coolant temperature sensor terminal connection.
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
• Check the wiring connections first.
NO
YES
NO
YES
Check if fuel sensor is correctly connected.
Disconnect fuel sensor. Connect harness end connector terminals #1 and #2. Check if gauge needle swings to (F) side.
With fuel sensor dis-connected, disconnect connector C16F-W from monitor panel. Check for continuity between harness end connector terminal #4 and fuel sensor termi-nal #2.
Gauge needle does not swing at all.
Key switch: ONConnect by using a clip.
NO
YES
Disconnect fuel sensor.Check if needle swings back to zero. With fuel sensor discon-
nected, disconnect con-nector C16F-W from monitor panel. Check for continuity be-tween harness end con-nector terminal #2 and machine.
Gauge needle swings
Key switch: ON
YESover scale.
NO
NO
YES
NO
YES
Check if fuel sensor iscorrectly connected.
Disconnect fuel sensor. Connect harness end connector terminals #1 and #2. Check if gauge needle stably swings to (F) side.
Gauge needle swings unstably.
Key switch: ONConnect by using a clip.
T5-5-4
TROUBLESHOOTING / Troubleshooting C
T2BC-05-04-026
T107-04-03-020
NOTE: 1 mm = 0.03937 in
Float Position and Electrical Resistance Float Position Resistance ( )
Full 10 1.00.5
3/4 (19.5)1/2 32 31/4 (49.5)
Empty 80 2
Faulty monitor panel.
Broken harness between monitor panel and fuel sen-
Faulty fuel sensor.
Connector (Harness end)
Faulty fuel sensor connecter connection.
Faulty fuel sensor.
Short-circuited harness be-tween monitor panel and fuel sensor.
Faulty monitor panel.
Faulty fuel sensor.
Faulty monitor panel.
Faulty fuel sensor terminal connection.
Fuel Sensor
12NO
YES
138.5 mm 22
Float
Electrical Resistor
Fuel Sensor
28
27
33
FULL
3/4
R370
1/2
1/4
EMPTY
338 mm
228 mm
70.5 mm
Monitor Panel (C16F-W)
257 mm
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-SURE INDICATOR
• Check the wiring connections first.
Engine oil pressure switch Pressure Operation
About 78.4 KPa (0.8 kgf/cm2, 11 psi) or less ON
About 78.4 KPa (0.8 kgf/cm2, 11 psi) or more OFF
Connector (Harness end)
T2BC-05-04-026
NO
YES Faulty engine oil pressure switch.
Disconnect plug from engine oil pressure switch. Connect terminals of harness 223 and GD2 harness.Check if indicator is turned ON.
Indicator is not turned ON although engine oil pressure is insufficient.
Faulty monitor panel or burnt indicator bulb.
Key switch: ON With terminal of 223 harness connected to machine.Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #6 (harness end) of connector.
Key switch: ON Engine: Stop
Engine: Stop Key switch: ON
NO
YES
Check if indicator is turned ON when plug from engine oil pres-sure switch is discon-nected.
Indicator is not turned OFF although engine runs.
Check if oil filter is clogged or not. (If clogged, engine oil restriction indicator is turned ON.)
Disconnect plug from engine oil pressure switch and connector C16F-W from monitor panel.Check for continuity between machine and terminal #6 (harness end) of connector.
YES
Broken harness between monitor panel and engine oil pressure switch. NO
Faulty of engine oil pres-sure switch or engine hy-draulic system.
Short-circuited harnessbetween monitor panel and engine oil pressure switch.
YES
Faulty monitor panel.NO
Monitor Panel C16F-W
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL INDICATOR
• Other indicators blink normally. • Check the wiring connections first.
Key switch: ONInsert a test bar into the rear of connector.
NO
YES
Check if indicator is turned ON when reset-ting key switch from OFF to ON position.
Indicator is not turned ON.
Check if water level is above Low level. Key switch: OFF ON
Disconnect connector of coolant level switch. Connect terminals #2 and #3 (harness end) of connector. Check if indicator is turned ON.
Key switch: ON
Check for continuity between machine and terminal #1 of connec-tor C16F-W of monitor panel.
Faulty coolant level switch.YES
NO
Burnt indicator bulb.
With terminals of cool-ant level switch con-nected.Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #15 (harness end) of connector.
YES
NO
Disconnect connector IDU-5 of IDU. Connect terminal #3 (harness end) of con-nector to machine. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #1 (harness end) of connector.
Check within 3 sec-onds after turning key switch ON.
YES
Check if indicator is turned ON when con-nector of coolant level switch is disconnected.
With connector of coolant level switch disconnected.Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #15 (harness end) of connector.
Indicator is turned ON although water level is below the specified level.
Key switch: ON Faulty coolant level switch.
Short-circuited harness between coolant level switch and monitor panel.
Check for continuity between machine and terminal #1 (harness end) of connector.
NO
YES
NO
T5-5-7
TROUBLESHOOTING / Troubleshooting C
Reserve Tank
T107-04-03-012
T2BC-05-04-026
T2BC-05-04-027
Connector (Harness end)
1
3
Radiator
YES
NO
Broken harness be-tween coolant level switch and monitor panel.
Faulty monitor panel. ON
FULL
LOW
OFF
Coolant Level Switch
Monitor Panel C16F-W
Broken harness be-tween monitor panel and IDU.
Faulty IDU. YES
NO Coolant Level Indicator (Harness end)
Short-circuited har-ness between monitorpanel and IDU.
Faulty IDU.
Faulty monitor panel.
Connect the dis-connected connec-tor.Disconnect con-nector IDU-5 of IDU. Check if indicator is turned ON.
YES
NO
YES
NO
· Key switch: ON
Connector IDU-5 Of IDU
T5-5-8
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL FILTER RESTRICTION INDICATOR
• Check the wiring connections first. • If engine oil filter is clogged, engine oil pressure
decreases and engine oil pressure indicator is turned ON.
NO
YES
NO
YES
Check if indicator is turned ON when reset-ting key switch from OFF to ON position.
Connected the discon-nected terminal. Connect terminal #5 of connector C16F-W of monitor panel to ma-chine.Check if indicator is turned ON.
Disconnect terminal of 227 harness of engine oil filter restriction switch. Connect terminal (har-ness end) to machine. Check if indicator is turned ON. Indicator is not turned
ON although engine oil filter is clogged.
Key switch: ONInsert a test bar into the rear of connector.
· Key switch: ON
· Key switch: OFF ON
Faulty engine oil filter restriction switch.
Check for continuity between machine and terminal #1 of connec-tor C16F-W of monitor panel.
Key switch: ONInsert a test bar into the rear of connec-tor.Check within 3 sec-onds after turning key switch ON.
Indicator bulb is burned out.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of con-nector to machine. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #1 (harness end) of connector.
YES
NO
· Key switch: ON NO
YES
Check if indicator is turned OFF when ter-minal of engine oil filter restriction switch is disconnected.
Disconnect terminal of engine oil filter restric-tion switch and con-nector C16F-W of monitor panel. Check for continuity between machine and terminal #5 (harness end) of connector.
Indicator is turned ON although engine oil filter is not clogged.
Faulty engine oil filter restriction switch.
YES
NO
Short-circuited harness between monitor panel and engine oil filter re-striction switch.
Check for continuity between machine and terminal #1 (harness end) of connector.
T5-5-9
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end)
Broken harness between monitor panel and engine oil filter restriction switch.
Faulty monitor panel. NO
YES Monitor Panel C16F-W
T2BC-05-04-026
Connector IDU-5 of IDU
Broken harness between monitor panel and IDU.
Faulty IDU.
NO
YES
T2BC-05-04-027
Faulty monitor panel.
Short-circuited harnessbetween monitor panel and IDU.
Faulty IDU.
Connect the dis-connected con-nector.Disconnect con-nector IDU-5 of IDU.Check if indicator is turned ON.
YES
NO
YES
NO
· Key switch: ON
T5-5-10
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-TION INDICATOR
• Check the wiring connections first.
NO
YES
NO
YES
Check if indicator is turned ON when reset-ting key switch from OFF to ON position.
Disconnect plug of air filter restriction switch. Connect plug 228 (harness end) to ma-chine.Check if indicator is turned ON.
Indicator is not turned ON although air filter is clogged.
Key switch: ON
· Key switch: OFF ON
Faulty air filter restriction switch.
Check for continuity between machine and terminal #1 of connec-tor C16F-W of monitor panel.
Key switch: ONInsert a test bar into the rear of connector.Check within 3 sec-onds after turning key switch ON.
Burnt indicator bulb.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of con-nector to machine. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #1 (harness end) of connector.
YES
NO
With plug of air filter restriction switch con-nected to machine, disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #14 (harness end) of connector.
NO
YES Faulty air filter restriction switch.
YES
NO
Short-circuited harness between monitor panel and air filter restriction switch.
Check for continuity between machine and terminal #1 (harness end) of connector.
Disassembly and visual checkConfirm that air filter is not dampened.
· Key switch: ON
Check if indicator is turned OFF when plug of air filter restriction switch is disconnected.
Indicator is turned ON although air filter is not clogged. Disconnect plug of air
filter restriction switch and connector C16F-W of monitor panel. Check for continuity between machine and terminal #14 (harness end) of connector.
T5-5-11
TROUBLESHOOTING / Troubleshooting C
Air filter restriction switch Pressure Operation
6.25 0.5 kPa or less (635 58 mm H2O or less) OFF
6.25 0.5 kPa or more (635 58 mm H2O or more) ON
Connector (Harness end)
Broken harness between monitor panel and air filter restriction switch.
Faulty monitor panel.
NO
YESMonitor Panel C16F-W
T2BC-05-04-026
Connector IDU-5 of IDU
Broken harness between monitor panel and IDU.
Faulty IDU.
NO
YES
T2BC-05-04-027
Faulty monitor panel.
Short-circuited harnessbetween monitor panel and IDU.
Faulty IDU.
Connect the dis-connected con-nector.Disconnect con-nector IDU-5 of IDU.Check if indicator is turned ON.
YES
NO
YES
NO
· Key switch: ON
T5-5-12
TROUBLESHOOTING / Troubleshooting C
MALFUNKTION OF OVERHEAT INDICA-TOR
• Check the wiring connections first.
NO
YES
NO
YES
Check if indicator is turned ON when reset-ting key switch from OFF to ON position.
· Key switch: ON
· Key switch: OFF ON
Faulty overheat switch.
Check for continuity between machine and terminal #1 of connec-tor C16F-W of monitor panel.
Key switch: ONInsert a test bar into the rear of connector.Check within 3 sec-onds after turning key switch ON.
Burnt indicator bulb.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of con-nector to machine. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #1 (harness end) of connector.
YES
NO
Indicator is not turned ON when overheating.
With terminal of over-heat switch connected to machine, disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #10 (harness end) of connector.
Disconnect terminal of overheat switch. Connect terminal (har-ness end) to machine. Check if indicator is turned ON.
NO
YES Faulty overheat switch.
YES
NO
Short-circuited harness between monitor panel and overheat switch.
Check for continuity between machine and terminal #1 (harness end) of connector.
· Key switch: ON
Check if indicator is turned OFF when ter-minal of overheat switch is disconnected.
Indicator is turned ON although coolant tem-perature is low. Disconnect terminal of
overheat switch and connector C16F-W of monitor panel. Check for continuity between machine and terminal #10 (harness end) of connector.
T5-5-13
TROUBLESHOOTING / Troubleshooting C
Overheat switch Coolant temperature Operation
Lower than 101 C (214 F) OFF
101 C (214 F) or higher ON
Broken harness between monitor panel and over-heat switch.
Faulty monitor panel.
NO
YES Connector (Harness end)
Monitor Panel C16F-W
T2BC-05-04-026
Connector IDU-5 of IDU
Broken harness between monitor panel and IDU.
Faulty IDU.
NO
YES
T2BC-05-04-027
Faulty monitor panel.
Short-circuited harnessbetween monitor panel and IDU.
Faulty IDU.
Connect the dis-connected con-nector.Disconnect con-nector IDU-5 of IDU.Check if indicator is turned ON.
YES
NO
YES
NO
· Key switch: ON
T5-5-14
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF CONTROLLER FAIL-URE INDICATOR
• Check the wiring connections first.
NO
YES
NO
YES
Check if indicator is turned ON when reset-ting key switch from OFF to ON position.
· Key switch: OFF ON
Faulty ECU.
Check for continuity between machine and terminal #1 of connec-tor C16F-W of monitor panel.
Key switch: ONInsert a test bar into the rear of connector.Check within 3 sec-onds after turning key switch ON.
Burnt indicator bulb.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of con-nector to machine. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #1 (harness end) of connector.
YES
NO
Disconnect connector C16F-W of monitor panel.Connect terminal #13 (harness end) of con-nector to machine. Check for continuity between machine and terminal #15 or #16 (harness end) of ECU connector 2.
Disconnect ECU con-nector 2. Connect terminal #15 or #16 (harness end) of connector to machine.Check if indicator is turned ON.
Indicator is not turned ON although abnormal-ity is indicated by trou-bleshooting monitor or ECU lamp.
NO
YESFaulty ECU.
YES
NO
Short-circuited harnessbetween monitor panel and ECU.
Check for continuity between machine and terminal #1 (harness end) of connector.
· Key switch: ON
Check if indicator is turned OFF when ECU connector 2 is discon-nected.
Disconnect ECU con-nector 2. Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #13 (harness end) of connector.
Indicator is turned ON although failure is not indicated by trouble-shooting monitor or ECU lamp.
· Key switch: ON
T5-5-15
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end) ECU Connector 2
Monitor Panel C16F-W
T2BC-05-04-029
In case of no continuity at terminal #15, broken harness between monitor panel and terminal #15 of ECU connector 2. In case of no continuity at terminal #16, broken harness between monitor panel and terminal #16 of ECU connector 2.
Faulty monitor panel.
NO
YES
T2BC-05-04-026
Connector IDU-5 of IDU
Broken harness between monitor panel and IDU.
Faulty IDU.
NO
YES
T2BC-05-04-027
Faulty monitor panel.
Short-circuited harness between monitor panel and IDU.
Faulty IDU.
Connect the dis-connected con-nector.Disconnect con-nector IDU-5 of IDU.Check if indicator is turned ON.
YES
NO
YES
NO
· Key switch: ON
T5-5-16
TROUBLESHOOTING / Troubleshooting C
MULFUNCTION OF PREHEAT INDICATOR
• Check the wiring connections first. • If air heater does not work, refer to “Trouble-
shooting B”.
T2BC-05-04-026
NO
YES
NO
YES
Check if voltage be-tween machine and terminal #11 of con-nector C16F-W of monitor panel is 24 V.
Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #8 (harness end) of connector.
Faulty monitor panel orburnt indicator bulb.
Broken harness between monitor panel and ground, or faulty ground.Indicator is not turned
ON while engine is being preheated.
Insert a test bar into the rear of connector. Broken harness between
heater relay and monitorpanel.
Check within 15 sec-onds after turning key switch ON.
Short-circuited harness between heater relay and monitor panel.
Indicator is turned ON even after engine is preheated.
Check if voltage be-tween machine and terminal #11 of con-nector C16F-W of monitor panel is 24 V.
· Insert a test bar into the rear of connector.
YES
Faulty monitor panel. NO
Connector (Harness end)
Monitor Panel (C16F-W)
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MULFUNCTION OF ALTERNATOR INDI-CATOR
• Check the wiring connections first.
Connector (Harness end)
T2BC-05-04-030
NO
YES
Indicator is not turned ON although charging is insufficient.
Disconnect alternatorrelay. Connect terminal #2 (harness end) of con-nector to machine. Check if indicator is turned ON.
Connect terminal #7 of connector C16F-W of monitor panel to ma-chine.Check if indicator is turned ON.
Broken harness be-tween alternator relay and ground, or faulty ground.
Faulty alternator relay.
Replace alternator relay with engine stop relay. Check if indicator is turned ON.
· Key switch: ON
YES
NO
Key switch: ONInsert a test bar into the rear of connector.
NO
YES
Disconnect connector of alternator relay and connector C16F-W of monitor panel. Check for continuity between machine and terminal #7 (harness end) of connector of monitor panel.
Check for continuity between machine and terminal #2 (harness end) of connector of alternator relay.
Faulty alternator relay.
YES
NO
· Engine: Running · Engine: Running
Faulty monitor panel.
Replace alternator relay with engine stop relay. Check if indicator is turned OFF.
Indicator is not turned OFF even when engine runs.
Monitor Panel (C16F-W) Alternator Relay
T2BC-05-04-026
T25N-05-03-027
T5-5-18
TROUBLESHOOTING / Troubleshooting C
Broken harness be-tween alternator relay and monitor panel.
Faulty monitor panel, or burnt indicator bulb.
Short-circuited harness between alternator and alternator relay.
Broken harness be-tween alternator relay and battery relay.
Check for continuity between machine and terminal #4 (harness end) of connector of alternator relay.Check if voltage be-
tween machine and terminal #1 (harness end) of connector of alternator relay is 24 V.
NO
YES
YES
YES
NO
NO
· Key switch: ON
Short-circuited harness between alternator relay and monitor
Faulty alternator.
Broken harness be-tween alternator and alternator relay.
Broken harness be-tween alternator relay and battery relay.
Disconnect connector of alternator. Connect terminal #2 (harness end) of con-nector to machine. Check for continuity between machine and terminal #4 (harness end) of connector of alternator relay.
Check if voltage be-tween machine and terminal #1 (harness end) of connector of alternator relay is 24 V.
NO
YES
YES
YES
NO· Key switch: ON
NO
Connector (Harness end)Alternator
T2BC-05-04-031
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE UNAPPLIED INDICATOR
• Check the wiring connections first.
Indicator lighting conditions: If key switch is set to "START" position under one or more conditions mentioned below, engine does not start and indicator is turned ON. • Slewing brake switch OFF• Front free brake mode selection switch
Connect terminal #9 of connector C16F-W of monitor panel to ma-chine.Check if indicator is turned ON.
Indicator is not turned ON under indicator lighting conditions.
NOTE: Turn ON slew-ing brake switch, set brake mode switch and front/rear free brake mode selection switchto "Auto brake mode", and confirm that engine can start.
Key switch: Start
Key switch: ON Connect to machine from the rear of connector.
Broken harness circuit between monitor panel and MC2/A.
Faulty MC2/A.
Faulty monitor panel or burnt indicator bulb.
Disconnect connector C16F-W of monitor panel.Connect terminal #9 (harness end) of con-nector to machine. Disconnect connector MCA-6 of MC2/A. Check for continuity between machine and terminal #23 (harness end) of connector.
NO
YES
Faulty monitor panel.
NO
Engine: Running Key switch: ON · Key switch: ON
YES
Check if indicator is turned OFF when con-nector MCA-6 of MC2/Ais disconnected.
Indicator is not turned OFF even when engine runs.
Faulty MC2/A.
Short-circuited harness between monitor panel and MC2/A.
YES
NO
Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #9 (harness end) of connector.
Monitor Panel (C16F-W) Connector MCA-6 of MC2/A (Harness end)
T2BC-05-04-027
T5-5-20
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PILOT PRESSURE DROP INDICATOR
Faulty pilot pressure drop indicator.
Refer to "Check of Pilot Pressure Drop Indicator" in "Troubleshooting A".
T5-5-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
• Check the wiring connections first.
Hour meter does not work.
Faulty monitor panel (hour meter).
Connector (Harness end)
T2BC-05-04-026
Key switch: ON
Disconnect connector C16F-W of monitor panel.Check for continuity between machine and terminal #8 (harness end) of connector.
YES
Broken harness be-tween monitor panel and ground, or faulty ground.
NO
Monitor Panel (C16F-W)
T5-5-22
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE If IDU itself or sensors connected to IDU fail, failure codes will be displayed on the monitor window of IDU. If error code is indicated, find a page showing troubleshooting procedures corresponding to an error code from table on the next page, and follow the flowchart for inspection.
Troubleshooting precautions: • Use a digital voltmeter for measurement of voltage
or resistance. • "Measure XX between A and B" described in the
flowchart implies that red tester stick of digital voltmeter is connected to A, and black tester stick to B.
• When measuring, be careful to make connection to connector side and receptacle side correctly.
• Before disconnecting connector, and turn OFF machine starter switch, and turn OFF IDU power.
Connector
Receptacle T331-05-07-001
T331-05-07-002
T5-6-1
TROUBLESHOOTING / Troubleshooting D
FAULT CODE TABLE Func- tion Failure Fault
code Failure explanation Judgment and conditions Reference page
E40 No ML data available No data available corresponding to auto specification selection T5-6-13
E43 Mode selection failure (tower) Crane is selected with tower attachment. T5-6-13 E44 Mode selection failure (crane) Tower is selected with crane attachment. T5-6-14 E45 Attachment wiring short circuit Wiring short circuit in non-disassembly position T5-6-16
Loads E50 Boom/jib derricking force upper limit failure
Boom/jib derricking force > Upper limit T5-6-18
E51 Boom/jib no-load derricking force failure Boom/jib derricking force < No-load criterion T5-6-20 E52 Boom/jib derricking force lower limit
failure Boom/jib derricking force < Lower limit T5-6-22
E53 Load cell power supply upper limit failure 10 V power supply monitoring voltage > Upper limit
E54 Load cell power supply lower limit failure 10 V power supply monitoring voltage < Lower limit 1
Auto stop
E55 Load cell power supply short circuit failure
10 V power supply monitoring voltage < Lower limit 2
Communica- tion
W90 Control A communication failure MC2/A communication status T5-6-34
W91 Control B communication failure MC2/B communication status T5-6-35 Specification selection
W47 Attachment wiring failure (open circuit) Wiring failure (open circuit) in non-disassembly position T5-6-26
W49 Hook overhoist wiring failure No hook overhoist wiring available on selection side T5-6-32
Power supply W10 Main power supply upper limit failure Monitoring voltage > Upper limit W11 Main power supply lower limit failure Monitoring voltage < Lower limit W14 Switch power supply short circuit failure 24V power supply monitoring voltage < Lower
limit 2 WA1 Switch power supply 1 short circuit
(control A) (Control A) 24V1 power supply monitoring voltage < Lower limit 2 T5-6-36
WA2 Switch power supply 2 short circuit (control A)
(control A) 24V2 power supply monitoring voltage < Lower limit 2 T5-6-36
WA3 Switch power supply 3 short circuit (control A)
(Control A) 24V3 power supply monitoring voltage < Lower limit 2 T5-6-36
WA5 Sensor power supply short circuit (control A)
(Control A) 5V power supply monitoring voltage < Lower limit 2
WB1 Switch power supply 1 short circuit (control B)
WB2 Switch power supply 2 short circuit (control B)
(Control B) 24V2 power supply monitoring voltage < Lower limit 2 T5-6-37
WB3 Switch power supply supply 3 short circuit (control B)
(Control B) 24V3 power supply monitoring voltage < Lower limit 2 T5-6-38
WB5 Sensor power supply short circuit (control B)
(Control B) 5V power supply monitoring voltage < Lower limit 2
Control system
W80 (Corresponding to new version)
W81 (Corresponding to new version) W82 (Corresponding to new version) W83 (Corresponding to new version) W84 (Corresponding to new version) W88 (Corresponding to new version)
Monitor- ing only
W89 (Corresponding to new version)
T5-6-2
TROUBLESHOOTING / Troubleshooting D
Failure Indication (Title Bar)
Func- tion Failure Fault
codeFailure indication (title bar)
Red: Auto stop Orange: Monitoring and warning Boom angle E20 E20: Boom angle is abnormal
W49 W49: Hook overhoist wiring failure Power supply W10 W10: Power supply voltage failure
W11 W11: Power supply voltage drop W14 W14: Sensor power supply short circuit(24V) WA1 WA1: Sensor power supply short circuit(24V1A) WA2 WA2: Sensor power supply short circuit (24V2A) WA3 WA3: Sensor power supply short circuit (24V3A) WA5 WA5: Sensor power supply short circuit (5VA) WB1 WB1: Sensor power supply short circuit (24V1B) WB2 WB2: Sensor power supply short circuit (24V2B) WB3 WB3: Sensor power supply short circuit (24V3B) WB5 WB5: Sensor power supply short circuit (5VB) W80 W80: Engine control system failure Control
system W81 W81: Horsepower control system failure W82 W82: Brake control system failure W83 W83: Slew control system failure W84 W84: Operating pressure detection failure W88 W88: Auto stop control system failure
Monitor- ing only
W89 W89: Speed control system failure
T5-6-3
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E20, E22
T25N-05-06-001
T25N-05-06-002
T25N-05-06-003
YES
NO
YES (E21 or E26 indicated)
With connector of boom angle detector disconnected, connect machine harness to machine relay box, and measure voltage between terminals #4 and #6 of “2” connector (16P).
0.2 V
Disconnect “3” connector (22P) of controller (IDU), connect machine harness to machine relay box, and measure resistance between terminals #4 and #7 of “2” connector (16P).
NO
Resistance (no resistance)
0 to 1M
Connect terminal #6 of “3” connector (22P) of controller (IDU), machine relay box and machine harness, and check for continuity at terminal #6 of “2” connector (16P).
Continuity Absent Present
Boom angle detector failure
Machine relay box failure
Machine harness failure
(No voltage, or 4V or more)
Check if E20 disappears.
View A
“2”16P (female, black)
“1” 5P (male)
Machine relay boxBoom angle detector
Machine harness
NO
Controller (IDU) failure
Disconnect “1” connector (5P) of boom angle detector from machine relay box.
E20
On the operation set window, select tower attachment.
YES
Check if attachment
of field machine is crane.
E22
View B
Controller (IDU)
“3” 22P (female)
1.6 m
T5-6-4
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E21, E26
T25N-05-06-004
T25N-05-06-021
Boom angle detector
Machine relay box
Check if connection is correct.
NO
YES
Connect correctly connector of boom angle detector.
Check if E21 disappears.
YES
NO
E21, E26
Check if “1” connector (5P) of boom angle detector is correctly connected.
Disconnect “1” connector (5P) of boom angle detector. Measure voltage between terminals #1 and #4 of “2” connector (5P) of machine relay box.
NO
YES A
4.4 V
“2” Connector (5P)
1.6 m“1” 5 (male)
“2” 5P (female)
Controller (IDU)
Boom angle detector failure
Completion
T5-6-5
TROUBLESHOOTING / Troubleshooting D
A E21, E26 (continued)
View B T25N-05-06-001
T25N-05-06-005
T25N-05-06-006
T25N-05-06-003
NO Machine relay box failure
4.4 V
Disconnect “4” connector (22P) and “5” connector (26P) of controller (IDU), and measure resistance at terminal #4 of “4” connector and terminal #20 of “5” connector.
Resistance
(no resistance)
0 to Several
Make short circuit between terminals #4 and #7 of “3” connector (16P) by using AV wire or the like.
Check for continuity between terminal #4 of “4” connector (22P) and terminal #20 of “5” connectors (26P) of controller (IDU).
No continuity
Machine harness failureContinued
Continuity
YES
Connect machine harness to machine relay box, and measure voltage between terminals #4 and #7 of “3” connector (16P).
View C
Controller (IDU)
Boom angle detector
Machine relay box
“5” 26P (female, white)
1.6 m
“4” 22P (female, yellow)
“3” 16P (female, black)
View A
Controller (IDU) failure
T5-6-6
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E30
T2BC-05-06-004
T2BC-05-06-007
T2BC-05-06-003
T2BC-05-06-002
Disconnect “1” connector (5P) and “6” connector (5P) of jib angle detector from boom-upper relay box, and measure voltage between terminals #2 and #4 of opposite “2” receptacle (5P) and “7” receptacle.
NO
YES
Disconnect “3” connector (24P) of cable reel wiring of boom-upper relay box, and measure voltage between terminals #17 and #19 and terminals #17 and #20.
YES
E30
Disconnect “4” connector (24P) of cable reel wiring of machine relay box, and measure voltage between terminals #17 and #19 and terminals #17 and #20 of opposite “5” receptacle.
NO
Jib angle detector failure
Cable reel wiring failure
B
0.2 V
0.2 V
YES
NO
0.2 V
Boom-upper relay box failure
(No voltage, or 4V or more)
(No voltage, or 4 V or
“1”, “6” Connectors (5P)
T2BC-05-06-001
more)
(No voltage, or 4 V or more)
Boom-upper relay box
“3” 24P (male)
“4” 24P (male)
“6” 5P (male)
“7” 5P (female)
“5” 24P (female)
Machine relay box“2” 5P (female)
“1” 5P (male)
“5” Receptacle (24P)
“3”, “4” Connectors (24P)
“2”, “7” Receptacles (5P)
T5-6-7
TROUBLESHOOTING / Troubleshooting D
T25N-05-06-005
T25N-05-06-001
T2BC-05-06-006
T2BC-05-06-005
Controller (IDU) failure
Check for continuity between terminal #4 of “8” connector (12P) and terminal #6 of “9” connector (22P).
Continuity No continuity
Continued
Connect machine harness to machine relaybox, and measure voltage between terminals #2 and #4 and terminals #1 and #4 of “8” connector (12P).
B E30 (continued)
NO
YES
Machine harness failure
Machine relay box failure
0.2 V
(No voltage, or 4 V ormore)
Disconnect “9” connector (22P) and “10” connector (26P) of controller (IDU), and measure resistance between terminal #4 of “9” connector (22P) and terminals #19, #7 of “10” connector (26P).
(no resistance)
0 to Several MResistance
View C
View B Controller (IDU)
“10” 24P (female, white)
1.6 m
“9” 22P (female, yellow)
“8” 12P (female, black)
View A
Machine relay box
T5-6-8
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E31
T2BC-05-06-008
T2BC-05-06-004
T2BC-05-06-003
“1”, “6” Connectors (5P)
Check if “1” connector (5P) and “6” connector (5P) of jib angle detector are correctly connected.
NO
YES
Connect correctly “1”, “6” connectors of jib angle detector.
NO
E31
YES
Check if connection is correct.
Check if E31 disappears.
Completion
Jib angle detector failure
Disconnect “1” connector (5P) and “6” connector (5P) of jib angle detector. Measure voltage between terminals #1 and #4 of “2” receptacle (5P) and “7” receptacle (5P) opposite to “1” connector (5P) and “6” connector (5P) of jib angle detector respectively.
C
NO
YES4.8 V
Relay box
“1” 5P (male)“2” 5P (female)
“6” 5P (male)“7” 5P (female)
“2”, “7” Receptacles (5P)
T5-6-9
TROUBLESHOOTING / Troubleshooting D
Disconnect “3” connector (24P) of cable reel wiring of boom-upper relay box, and measure voltage between terminals #16 and #19, #16 and #20 terminals.
C E31 (continued)
YES4.8 V
T2BC-05-06-007
T2BC-05-06-005
T25N-05-06-023
T25N-05-03-028
Connect machine harness to machine relay box, and measure voltage between terminals #2 and #5, #1 and #5 of “8” connector (12P).
Cable reel wiring failure
Boom-upper relay box failure
Disconnect “4” connector (24P) of cable wiring of machine relay box, and
voltage between terminals #16 and #20 of opposite “5”
reelmeasureand #19, #16receptacle (24P).
NO
YES4.8 V
NO
YES4.8 V
Machine relay box failure
D
NO
Machine harness
Machine relay box
“8” 12P (female, black)
A
1.6 m
“4” 24P (male)
“5” 24P (female)
“3” 24P (male)
Boom-upper relay box
“3” Connector (24P)
“5” Receptacle (24P)
View A
Controller (IDU)
T5-6-10
TROUBLESHOOTING / Troubleshooting D
T25N-05-06-001
T25N-05-06-005
T2BC-05-06-006
T2BC-05-06-005
With “8” connector (12P) disconnected, disconnect “10” connector (26P) and “9” connector (22P) of controller (IDU). Measure resistance between terminal #4 of “9” connector (22P) and terminal #7 of “10” connector (26P), terminal #4 of “9” connector (22P) and terminal #19 of “10”
D E31 (continued)
(no resistance)
0 to Several M
connector (26P).
Machine harness failure
Machine harness failure
Disconnect “10” connector (26P) of controller (IDU). Check for continuity between terminals #19 and #2 of “8” connector (12P). Check for continuity between terminal #7 of “10” connector (26P) and terminal #1 of “8” connector (12P).
Continued
No continuity
Controller (IDU) failure
Resistance
Continuity
View B
View C
Controller (IDU)
“10” 26P (female, white)
View A
1.6 m
“9” 22P (female, yellow)
Machine harness
“8” 12P (female, black)
Machine relay box
T5-6-11
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E40
E40
Controller (IDU) failure
FAULT CODE E43
E43
YES
NO
Controller (IDU) failure
On the operation set window, checkthe selection of attachment.
Check if tower is selected.
YES
NO
On the operation set window, select tower attachment.
Check if attachment of
field machine is a tower.
Controller (IDU) failure
T5-6-12
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E44
E44
YES
NO
Controller (IDU) failure
On the operation set window, checkthe selection of attachment.
Check if crane is selected.
YES
NO
On the operation set window, select tower attachment.
Check if attachment of field
machine is a crane.
Controller (IDU) failure
T5-6-13
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E45 E45
Disconnect “1” connector (24P) for cable reel wiring of machine relay box, and measure resistance at terminals #1, #2, and between terminals #1 and #3 of
T25N-05-06-012
T25N-05-06-003
T25N-05-06-013
T25N-05-06-023
View A
View B
Cable reel wiring
Machine relay box
Controller (MC2/B)
“3” 26P (female, yellow)
1.6 m
“4” 16P (female, white)
“2” 16P (male, white)
“1” 24P (male)
Boom-upper relay box
“1” Connector (24P)
plug.
E
To T5-6-17
Reconnect “1” connector (24P) for cable reel wiring as it was. Connect machine harness to machine relay box, and measure resistance between terminals #5 and #7, and at terminals #6 and #7 of “2” connector (16P).
Machine relay box failure
NO
YES
With “2” connector (16P) disconnected, disconnect “3” connector (26P) of controller (MC2/B), and measure resistance between terminals #5 and #7, and at terminals #6 and #7 of “4” connector (16P).
#5 to #7, # 6, # 7: no resistance
NO (500 k or more)
YES
Machine harness failure
Controller (MC2/B) failure
NO
YES
In case of crane, #1, #2 = 0
#1 to #3 = no resistance In case of tower,
#1, #2 = no resistance #1 to #3 = 0 .
In case of crane, #6, # 7 = 0
#5 to #7 = no resistance.In case of tower,
#6, #7 = no resistance. #5 to #7 = 0
T5-6-14
TROUBLESHOOTING / Troubleshooting D
E E45 (continued)
T25N-05-03-028
T25N-05-06-013
“6” Receptacle (24P)
Cable reel wiring
Machine relay box
Controller (MC2/B)
“6” 24P (female)
Boom-upper relay box
Disconnect “5” connector (24P) for cable reel wiring of boom-upper relay box, and measure resistance at terminals #1, #2, and between terminals #1 and #3 of “6” receptacle.
NO
YES
“5” 24P (male)
Boom-upper relay box failure
In case of crane, #1, #2 = 0
#1 to #3 = no resistance In case of tower,
#1, #2 no resistance #1 to #3 = 0 .
Cable reel wiring failure
T5-6-15
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E50 (CRANE)
T2BC-05-06-009
Disconnect “1” connector (7P) from load cell.
Check if E50 disappears.
NO
YES (E52 indicated)
Reconnect “1” connector (7P) of load cell as it was. Disconnect “2” connector (4P) that connects load cell harness and relay box.
Check if E50 disappears.
E50
NO
Load cell failure
Load cell harness failure
YES (E52 indicated)
A
CraneLoad cell
Load cell harness
Machine harness
Controller (IDU)
“3” 16P
“4” 26P (female, white)
“1” 7P (female)
“4” 4P (male)
Relay box harness
Relay box
T5-6-16
TROUBLESHOOTING / Troubleshooting D
T2BC-05-06-009
CraneLoad cell
Load cell harness
Machine harness
Controller (IDU)
“3” 16P
“4” 26P (female, white)
“1” 7P (female)
“4” 4P (male)
Relay box harness
Relay box
Reconnect “2” connector of load cell as it was. Disconnect “3” connector of relay box harness.
Check if E50 disappears.
NO
YES (E52 indicated)
Reconnect “3” connector as it was. Disconnect “4” connector (26P) of controller (IDU).
Check if E50 disappears.
NO
Relay box failure
Machine harness failure
YES (E52 indicated)
A
Controller (IDU) failure
T5-6-17
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E50 (TOWER)
T2BC-05-06-009
Tower jib load cell
Load cell harness
Controller (IDU)
“3” 16P
“4” 26P (female, white)
Relay box
Relay box harness
“1” 7P (female)
“2” 7P (male)
Disconnect “1” connector (7P) from load cell.
Check if E50 disappears.
NO
YES (E52 indicated)
Reconnect “1” connector (7P) of load cell as it was. Disconnect “2” connector that connects load cell harness and relay box.
Check if E50 disappears.
E50
NO
Load cell failure
Load cell harness failure
YES (E52 indicated)
A
T5-6-18
TROUBLESHOOTING / Troubleshooting D
T2BC-05-06-009
Tower jib load cell
Load cell harness
Controller (IDU)
“3” 16P
“4” 26P (female, white)
Relay box
Relay box harness
“1” 7P (female)
“2” 7P (male)
Check if E50 disappears.
Reconnect “2” connector of load cell as it was. Disconnect “3” connector of relay box harness.
NO
Check if E50 disappears.
NO
Relay box failure
Controller (IDU) failure
Machine harness failure
YES (E52 indicated)
YES (E52 indicated)
A
Reconnect “3” connector as it was. Disconnect “4” connector (26P) of connector (IDU).
T5-6-19
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E51
E51
Check the setting of boom (tower) length, jib length, number of hoisting rope reevings and hook capacity.
30%Load factorIDU Monitor
JB ANGLEIDU AI1
0.00 VIDU AI3IDU AI2
JB ANGLE2BM ANGLEBM LOADJB LOAD
(AN_IN8)
Return
0.00 V0.00 V0.50 V0.50 V
JB ANGLEJB ANGLE2BM ANGLE 2.50 V
0.00 V0.50 V
(AN_IN0) ******(AN_IN1)(AN_IN2)(AN_IN3)
0.00 VHYD THMFD BRK THM 0.00 V
0.00 VRD BRK THM3D BRK THM 0.00 V
(AN_IN9)(AN_IN10)(AN_IN11)
1/3
****************** ******
******************
Move page
Load cell output(crane)
Load cell output(tower)
NOCheck if the setting is correct.
YES
Check the difference between actual load and indication load at boom upper and boom lower.
On the operation set window, make the setting depending on field machine.
Check if the difference is large (1 ton or more).
NO
YES
Grease boom foot pin, live mast foot pin, hanger link pin, boom stop inner, etc.Release load cell tension
completely.
Select the IDU monitor window. Operation: 1. Turn ON maintenance key switch.2. Press " key" on the ML window.3. Select the monitor in the
maintenance menu window.4. Select the IDU monitor in the
monitor menu window.
Check "BM LOAD" in the IDU monitor window (1/3 page). Check "JB LOAD" in case of tower.
NO
YES
0.5 V 0.04 V
IDU monitor window
F
Controller (IDU) failure
T5-6-20
TROUBLESHOOTING / Troubleshooting D
30%Load factorIDU Monitor
JB ANGLEIDU AI1
0.00 VIDU AI3IDU AI2
JB ANGLE2BM ANGLEBM LOADJB LOAD
(AN_IN8)
Return
0.00 V0.00 V0.50 V0.50 V
JB ANGLEJB ANGLE2BM ANGLE 2.50 V
0.00 V0.50 V
(AN_IN0) ******(AN_IN1)(AN_IN2)(AN_IN3)
0.00 VHYD THMFD BRK THM 0.00 V
0.00 VRD BRK THM3D BRK THM 0.00 V
(AN_IN9)(AN_IN10)(AN_IN11)
1/3
****************** ******
******************
Move page
0.5 V 0.04 V
YES
NO
Controller (IDU) failure
Load cell failure
NO
YES
Check if E51 disappears.
F
Press keys once. Load cell zero point correction is completed.
Select the IDU monitor window. Operation: 1. Turn ON maintenance key switch. 2. Press " key" in the ML window. 3. Select the monitor in the maintenance menu
window. 4. Select the IDU monitor in the monitor menu
window.
Check "BM LOAD" in the IDU monitor window(1/3 page). In case of tower, check "JB LOAD".
Select the load cell zero point correction window. Operation: 1. Turn ON maintenance key switch. 2. Press " key" on the ML window. 3. Select the adjustment menu in the
maintenance menu window. 4. Select the load cell zero point correction in
the adjustment menu window. In case of tower, select the jib load cell zeropoint correction.
Load cell output(crane)
IDU monitor window
Load cell output(tower)
Load cell zero point correction completion window
Load cell zero point correction windowE51 (continued)
Detach the load cell from the hoist rope to completely
Pay attention.
30%
Cancel Start
eliminate the load ratio from the load cell.
Load cell zero point correction
After detaching the load cell, press <START> key.
Load cell output voltageCorrected output voltageStandard correction voltageCorrectable voltage range
Don t disconnect the connector from the load cell.
Load factor
Detach the load cell from the hoist rope to completely
Pay attention.
30%
Cancel Start
eliminate the load ratio from the load cell.
Load cell zero point correction
After detaching the load cell, press <START> key.
Load cell output voltageCorrected output voltageStandard correction voltageCorrectable voltage range
Don t disconnect the connector from the load cell.
Load factor
Completion
T5-6-21
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E52
T2BC-05-06-009
T25N-05-06-022
Check if connection is correct.
NO
YES
Connect “1” connector (7P) of load cell correctly.
Check if E52 disappears.
YES
NO
E52
Check if “1” connector (7P) of load cell is correctly connected.
Completion
Load cell failure
Measure voltage between terminals#A and #D of “1” connector (7P) of load cell.
YES
NO
G
9.8 V
In case of crane
Load cell
Load cell harness
Controller (IDU)
“1” 7P (female)
Connector (7P)
Relay box
T5-6-22
TROUBLESHOOTING / Troubleshooting D
T2BC-05-06-009
T25N-05-06-020
T25N-05-06-001
T25N-05-06-005
T2BC-05-06-010
View A
View B
View C
Load cell harness
Load cell
Machine harness
Controller (IDU)
“6” 16P
“5” 26P (female, white)
“1” 7P (female)
“3” Connector
“4” 22P (female,yellow)
“2” Connector
Relay box
“5” Connector
View D
Disconnect “2” connector (4P) of load cell harness, and measure voltage between terminals #1 and #3 of opposite “3” connector (4P).
G E52 (crane) (continued)
NO
YES9.8 V
Load cell harness failure
Connect relay box and machine harness. Disconnect “6” connector. Measure voltage at terminals #9, #11.
YES9.8 V
NORelay box failure
H
T5-6-23
TROUBLESHOOTING / Troubleshooting D
T2BC-05-06-009
T25N-05-06-020
T25N-05-06-001
T25N-05-06-005
T2BC-05-06-010
Disconnect “4” connector (22P) and “5” connector (26P) of controller (IDU), and measure resistance at terminal #14 of “4” connector and at terminal #18 of “5” connector.
Resistance
H
(no resistance)
Controller (IDU)
Make short circuit between terminals #9 and #11 of “6” connector (16P) by using jumper wire or the like.
Check for continuity terminal #3 of “4” connector (22P) of controller (IDU) and terminal #18 of “5” connector (26P).
Continuity
Continued
No continuity
Controller (IDU) failure
Controller (IDU) failure
View A
View B
View C
Load cell harness
Load cell
Machine harness“6” 16P
“5” 26P (female, white)
“1” 7P (female)
“4” 22P (female,yellow)
“3” Connector
“5” Connector
Relay box
“2” Connector
View D
T5-6-24
TROUBLESHOOTING / Troubleshooting D
In case of tower
E52Controller (IDU)
Check if “1” connector (7P) of load cell or “2” connector (7P) of machine relay box is correctly connected.
T25N-05-06-018
T25N-05-06-022
Check if connection is correct.
NO
Connect “1” connector or “2”connector correctly.
NO
Load cell failure
YES
NO
9.8 V
I
Measure voltage betweenterminals #A and #D of “1” connector (7P) of load cell.
YES
Completion
Check if E52 disappears.
YES
“1” 7P (female)
“2” 7P (male)
Machine relay boxLoad cell
“1” Connector (7P)
T5-6-25
TROUBLESHOOTING / Troubleshooting D
T25N-05-06-019
T25N-05-06-003
NO
YES
Disconnect “5” connector (22P) and “6” connector (26P) of controller (IDU), and measure resistance at terminal #14 of “5” connector and terminal #6 of “6” connector.
Connect machine harness and machine relay box, and measure voltage between terminals #11 and #16 of “4” connector (16P).
9.8 V
Machine relay box failure
Measure voltage between terminals #A and #D of “3” receptacle (7P) of machine relay box.
YES
NO Load cell harness failure
Load cell
1.6 m
Load cell harness
Machine harness
“6” 26P (female, white)
“3” 7P (female)
“5” 22P (female, yellow)
Machine relay box
“4” 16P (female, black)
View A
9.8 V
E52 (tower) (continued)I
Controller (IDU)
T25N-05-06-001
T25N-05-06-005
T25N-05-06-022
Resistance
(no resistance)
0 to Several M
Make short circuit between terminals #11 and #16 of “4” connector (16P) by using jumper wire or the like.
Check for continuity between terminal #3 of “5” connector (22P) of controller (IDU) and terminal #6 of “6” connector (26P).
Continuity
Continued
No continuity
Controller (IDU) failure
Machine harness failure
View B
View C
“3” Receptacle (7P)
T5-6-26
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W47
T2BC-05-06-013
T25N-05-06-012
T25N-05-06-023
View A
“1” Connector (24P)
W47
Machine relay box failure
In case of crane, #6, #7 = continuity #5 to #7 = no continuityIn case of tower, #6, #7 = no continuity#5 to #7 = continuity
YES
NO
Check if connection is correct.
NO
YES
Check for connection of “1” connector (24P) and “2” connector (24P) for cable reel wiring.
Disconnect “1” connector (24P) for cable reel wiring of machine relay box, and measure resistance at terminals #1, #2, and between terminals #1 and #3 of “1” connector (24P).
In case of crane, #1, #2 = continuity #1 to #3 = no continuityIn case of tower, #1, #2 = no continuity #1-#3 = continuity
NO
YES
Reconnect “1” connector (24P) for cable reel wiring as it was. Connect machine harness to machine relay box, and measure resistance between terminals#5 and #7, #6 and #7 of “3” connector (16P).
B
A
C
Cable reel wiring
Machine relay box
Controller (MC2/B)
1.6 m“3” 16P (male, white)
“1” 24P (male)
Boom-upper relay box
“2” 24P (male)
Machine harness
T5-6-27
TROUBLESHOOTING / Troubleshooting D
A W47 (continued)
Disassembly position (for transport)
YES
Set boom angle at less than 30 .
Boom angle30 or more
Less than 30 or no angle gaugeConnect cable reel wiring
correctly.
NO
Controller (IDU) failure
T5-6-28
TROUBLESHOOTING / Troubleshooting D
T25N-05-03-028
Disconnect “2” connector (24P) for cable reel wiring of boom-upper relay box, and check for continuity between terminals #1 and #2, terminals #1 and #3 of “6” receptacle.
In case of crane, #1 to #2 = continued #1 to #3 = no continuity In case of tower, #1 to #2 = no continuity #1 to #3 = continued
NO
YESBoom-upper relay box failure
Cable reel wiring failure
B W47 (continued)
Cable reel wiring
Machine relay box
Controller (MC2/B)
“6” 24P (female)
Boom-upper relay box(crane)
“2” 24P (male)
“6” Receptacle (24P)
T25N-05-06-025
T2BC-05-06-012
“6” 24P (female)
“5” 24P (male)
Cable reel wiring
Boom-upper relay box(tower)
Machine relay box
T5-6-29
TROUBLESHOOTING / Troubleshooting D
T25N-05-06-001
T25N-05-06-005
Reconnect “3” connector (16P) as it was. Disconnect “4” connector (22P) and “5” connector (26P) of controller (MC2/B), and check for continuity between terminal #4 of “4” connector (22P) and #8, #21 of “5” connector (26P).
Machine harness failure
Controller (MC2/B) failure
In case of crane, #4 to #8 = continued #4 to #21 = no continuity In case of tower, #4 to #8 = no continuity #4 to #21 = continued
YES
NO
C W47 (continued)
Cable reel wiring
“5” 26P (female, yellow)
1.6 m
“4” 22P (female, yellow)
Machine harness
“3” 16P (male, white)
Controller (MC2/B)
View C
View B
Machine relay box
Boom-upper relay box T25N-05-06-033
T5-6-30
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W49
T25N-05-06-026
T2BC-05-03-010
T25N-05-03-028
W49
Check if connection is correct.
NO
YES
Check connection of “1” connector (7P) for hook overhoist of boom-upper relay box.
Connect connector correctly.
Check for continuity between terminals#5 and #6 of “1” connector (7P) for hook overhoist.
Continuity
Continued Hook overhoist connector failure
Continuity No continuity
Continued
Reconnect “1” connector (7P) for hook overhoist as it was, and check for continuity between terminals #1 and #14 (#1 and #15) of “2” receptacle (24P) of boom-upper relay box.
Boom-upper relay box failure
Check for continuity between terminals in ( ) in case of sub hook.
D To T5-6-33
No continuity
“1” Connector (7P)
“2” Receptacle (24P)
Boom-upper relay box
“2” 24P (female)
Controller (IDU)
Machine relay box
“1” 7P (male)
T5-6-31
TROUBLESHOOTING / Troubleshooting D
D W49 (continued)
T25N-05-06-027
T25N-05-06-012
T25N-05-06-032
T25N-05-06-001
T25N-05-06-023
Machine relay box failure
Cable reel wiring
Machine relay box
Controller (IDU)
“6” 22P (female, yellow)
“3” 24P (male)
“5” 16P (female, yellow)
View A
View B
View C
“4” 16P (male, white)
Controller (MC2/B)
“2” 24P (female)
Check for continuity between terminals in ( ) in case of sub hook.
Reconnect “2” receptacle (24P) of boom-upper relay box as it was. Check for continuity between terminals #1 and #14 (#1 and #15) of “3” connector (24P) of machine relay box.
Continuity No continuity
Continued Cable reel wiring failure
Reconnect “3” connector (24P) of machine relay box as it was. Connect machine harness to machine relay box. Disconnect “4” connector (16P), and check for continuity between terminals #7 and #10 (#7 and #9) of “4”connector (16P).
Check for continuitybetween terminals in ( ) in case of sub hook.
Continuity
Continued
Continuity
Continued
Reconnect “4” connector (16P) as it was. Disconnect “5” connector (16P) of controller (IDU) and “6” connector (22P) of controller (MC/2B). Check for continuity between terminal #10 (#3) of “5” connector (16P) of controller (IDU) and terminal #4 of “6” connector (22P) of controller (MC2/B).
Machine harness failure
Check for continuity between terminals in ( ) in case of subhook.
Machine harness
No continuity
Controller (IDU) failure
No continuity
Boom-upper relay box
“3” Connector (24P)
T5-6-32
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W90
T25N-05-06-028
T25N-05-06-029
T25N-05-06-005
T25N-05-06-001
W90
Continuity No continuity
Continued
Check for continuity between terminals #A and #A, between terminals #B and #B of connector for CAN communication (“1” and “2”, 3P) provided between controller (IDU) and controller(MC2/A).
CAN cable failure
Continuity No continuity
Continued
Reconnect connector for CAN communication as it was. Check for continuity between terminal #14 of “3” connector (26P) of controller (IDU) and terminal #9 of “4” connector (22P) of controller (MC2/A).
Continuity No continuity
Continued
Check for continuity between terminal #15 of “3” connector (26P) of controller (IDU) and terminal #20 of “4” connector (22P) of controller (MC2/A).
Machine harness failure
Controller (IDU) failure or controller (MC2/A) failure
CAN cable (Connected to all controllers)
Machine harness
Controller (IDU) Controller (MC2/A)
“1” 3P (male)
“2” 3P (male)
View A
“3” 26P (female, yellow)
“4” 22P (female, yellow)
View B
View C
T5-6-33
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W91
T25N-05-06-028
T25N-05-06-029
T25N-05-06-005
“4” 22P (female, yellow)
Check for continuity between terminals #Aand #A, between terminals #B and #B of connector for CAN communication (“1” and “2”, 3P) provided between controller (IDU) and controller (MC2/B).
Continuity
Continued CAN cable failure
Continuity No continuity
Continued
Reconnect connector for CAN communication as it was. Check for continuity between terminal #14 of “3” connector (26P) of controller (IDU) and terminal #9 of “4” connector (22P) of controller (MC2/B).
Continuity No continuity
Continued
Check for continuity between terminal #15 of “3” connector (26P) of controller (IDU) and terminal #20 of “4” connector (22P) of controller (MC2/B).
Machine harness failure
Controller (IDU) failure or controller (MC2/B) failure
No continuity
W91 Controller (IDU) Controller (MC2/B)
CAN cable (Connected to all controllers)
Machine harness
“2” 3P (male)
View A
View B
“3” 6P female, yellow)
“1” 3P (male)
View C T25N-05-06-001
T5-6-34
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WA1 WA1
Check if WA1 disappears.
YES
NO
Disconnect connectors of free mode switch.
Free mode switch wiring failure
Controller (MC2/A) failure
FAULT CODE WA2
Disconnect connectors of emergency stop switch.
Check if WA2 disappears.
NO
Controller (MC2/A) failure
Emergency stop switch wiring failure
YES
WA2
FAULT CODE WA3
WA3
Controller (MC2/A) failure
T5-6-35
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WB2
WB2
Controller (MC2/B) failure
T5-6-36
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WB3
WB3
T25N-05-06-030
Check if WB3 disappears.
YES
NO
Disconnect “1” connector (24P) of boom-upper relay box.
Boom-upper relay box failure
Disconnect “2” connector (24P) of machine relay box.
Use Troubleshooting E when ECU lamp in cab lights or blinks by ECU troubleshooting control (refer to System/OPERATIONAL PRINCIPLE).
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown.
Harness Harness end connector
Mounting Surface T6L4-05-03-001
T5-7-1
TROUBLESHOOTING/Troubleshooting E
HOW TO READ FAULT CODE IN ECU EN-GINE TROUBLESHOOTING
IMPORTANT: Record all indicated fault codes, and verify that all recorded fault codes are correct by reference with the fa-ult code table in the following page.
1. With engine stopped, turn the key switch to the ON position.
2. Reset the troubleshooting switch to the ON posi-tion.ECU lamp starts indicating failure codes.
3. The fault code is indicated by a combination of numbers (1 to 5) in two digits. The code number is indicated by the number of blinking of ECU lamp. ECU lamp is turned OFF in a short period between digits. When two or more fault codes are indicated, a two-digit fault number (showing one fault code) is indicated first, the lamp is turned OFF in a long period, and then the next fault code is indicated.
4. After all fault codes are indicated, the first fault code is indicated again. This cycle is repeated.
5. When turning the key switch OFF, the indication of fault codes is finished.
ECU Lamp
Troubleshooting Switch T25N-01-02-010
Example: Fault codes 2-1 and 2-3 The first digit is "2".
The final digit is "3".
The first digit is "2".
Fault code 2-1
Periodbetween codes
Fault code 2-3
Turn ON
Turn OFF
The final digit is "1".
T25N-05-07-007
T5-7-2
TROUBLESHOOTING/Troubleshooting E
Failure and Number of Blinking of ECU Lamp Failure(No. of blinking)
Failure location Countermeasure by ECU (in backup mode) Operation
* 0-1 Normal
* 1-2
Feedback error (Actual advance angle of fuel injection timing does not follow the target ad-vance angle.)
Both timer control valves: OFFTimer control (fuel injection timing control): Stop
* 1-4 Timing sensor Both timer control valves: OFF
Timer control (fuel injection timing control): Stop
* 1-5
TDC sensor Determining engine speed from the number of timing pulses.Timer control (fuel injection timing control): Stop
* 2-1 Coolant temperature sensor Keeping coolant temperature at 80C°.* 2-2 Rack sensor Locking rack to full load position.
* 2-3 TCV ADV and TCV RTD solenoid valves
Timer control (fuel injection timing control): Stop
:Operable : Operable in backup mode* :(1-5) implies that one-time blinking, one-time interruption, and five-time blinking of ECU lamp.
IMPORTANT: Avoid long-hour operation or heavy load operation in the backup mode.
T5-7-3
TROUBLESHOOTING/Troubleshooting E
Checking:Check harness continuity and short circuit between ECU and each sensor according to the failure in Ta-ble.When harness is sound, the related sensor or ECU may be faulty.
1. Outline of IDUIDU function consists of moment limiter(HSL-1) and monitor which shows variousinputs and outputs.This manual explains the structure and the function of IDU.
1-1. Difference between HSL-1 and SML-10(1) Software install
HSL-1Rewriting the controller CPU by personal computer.
SML-10Change the ROM on the controller.
(2) Rated Capacity and Display LoadIn case of Boom hook and Jib hook both available.
HSL-1Subtract hook self weight which is not selected from rated capacity of selected hook.
SML-10Add hook selff weight which is not selected to display load of selected hook load.
3.3 Angle SensorAn angle sensor is attached in a lower boom part.The pendulum is dumped by silicone oil.Don't disassembly an angle sensor because an oil leak and easy to damage O ring.
Radius, Load, BM angle, Height After moving the cursor to the item to bechanged,press <CHANGE> key to adjust the value.
(7) Operation Instructions Skip
T5-8-13
TROUBLSHOOTING / Troubleshooting F
4.2.2 Maintenance Menu(1) Inspection Menu
1) Inspection of BM Overhoist(Sensor)2) Inspection of BM Overhoist(L/S)
1) Inspection of BM Overhoist(Sensor) 2) Inspection of BM Overhoist(L/S)
Hoist the boom until the boom angle reaches Hoist the boom until the boom angle reachesapproximately 78 degrees approximately 80 degrees(boom overhoist sensor activation angle) (boom overhoist limit switch activation angle)
(2) Adjustment Menu1) Angle Correction2) Self-weight Correction3) Loadcell Zero Point Correction
T5-8-14
TROUBLSHOOTING / Troubleshooting F
1) Angle Correction
After setting the boom angle to approximately Measure the actual working range for the60 degrees press <START> key. selected hook.
Then, press <CHANGE> key to input theactually measured value of the working range.After completing input, press <NEXT> key.
Computing angle correction Hoist the boom until the boom overhoistprevention system operates.After the boom hoist system is automatically stopped, press <NEXT> key.
Measure the actual working range for the The correction value has been revisedselected hook, Then, press <CHANGE> key Press <END> key.to input the actually measured value of theworking range.After completing input, press <NEXT> key.
T5-8-15
TROUBLSHOOTING / Troubleshooting F
2) Self-weight Correction
Hoist the boom until the insde of the start frame After moving the Boom hoist lever to flushes in green color. Then, after moving the neutral, press <START> key.boom hoist lever to neutral, press <START> key.
The Boom angle comes close to the correction Correction of the self-weight is complete.point, Change the Boom lower speed to the After returning the boom hoist lever to neutral,superfine speed mode. press <END> key.
3) Loadcell Zero Point Correction
Detach the loadcell from the hoist rope to Zero point adjustment of the load cell iscompletely eliminate the load ratio from the complete.load cell. Press <RETURN> key.After detaching the loadcell, press <START> key.Pay attention. Don't disconnect the connectorfrom the loadcell.
T5-8-16
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
1. Disconnect the power source. Remove the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. As for the color codes of wire harnesses in the electrical system, refer to the table below. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for base color, while the right initial stands for marking color.
Code Color Code ColorR Red W WhiteL Blue G GreenOr Orange Lg Light
greenY Yellow B Black Br Brown P Pink Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire with white fine-line marking.
2) Initials “O” and “Or” both stand for the color orange.
3) Wires with longitudinal stripes printed on them are not color coded. Do not confuse them with color coded wires.
T5-9-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to “Instructions for Disconnecting Connector” on page T5-4-3.)
2) The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting.
4) When connecting terminal connectors provided with a lock, insert them together until the lock “clicks.”
5) Pull the harness near the connector in order to check if it is correctly connected.
4. Precaution for using a circuit tester. 1) Before using a circuit tester, refer to the
instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity.
2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.
3) When checking the connector by using a tester, insert a tester probe from the harness end of connector in order not to damage the terminal inside connector.
T107-07-06-002
Wind a Piece of Wire Tester Probe
Sharpen the end of the Wire T107-07-06-003
T5-9-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
Push, Unlock and Separate Type
NOTE: Connectors will not be easily separated even if the lock is pushed while being pulled. Push the lock first before pulling the connectors.
The lock is located on female side con-nector (harness end side).
T107-04-05-002
Raise Lock, Pull and Separate Type
T107-04-05-003
Pull and Separate Type
T107-04-05-004
Remove Screw, Pull and Separate Type
NOTE: Use a spanner (10 mm). Tighten the bolt until torque mark (pro-truded) appears.
Screw
Protruded Mark
T107-04-05-005
T5-9-3
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between the battery positive terminal and the machine (ground).
Normal Voltage: 24 V or more
NOTE: If voltage is abnormal, recharge or replace the battery.
2. Start the engine. Check voltage between the battery positive terminal and the machine (fround).
Normal Voltage: 26 to 28.5 V
NOTE: If voltage is abnormal, check the charging system.
T8HY-05-04-003
T5-9-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION
Open the cap of fusible link and visually inspect the fusible link.
Parts Name Capacity Connected to
Fusible Link 45A 45AKey Switch Fuse Box1 (#9, #14 to 20)
Fusible Link 65A 65A
Fuse Box1 (#1 to 6, #12, #13) Fuse Box2 (#21 to 30, #32 to 40)
T324-04-05-002
Fusible Link 45A
Fusible Link 65A
Fusible Link 45A
T2BC-01-02-020
T5-9-5
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a tester in order to correctly inspect fuse continuity. Inspect the fuse by following the instructions described below.
1. Turn Key Switch ON When the key switch is turned ON, current from terminal M of key switch activates the battery re-lay so that electric power is supplied to all circuits. (Refer to the circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-age in order to meet the circuit specification to be measured.(Measurement Range: 0 to 30 V)
Power Source ( )
3. Ground the negative probe of the tester to the machine. Touch the terminals located away from the center of the fuse box with the positive probe of tester one at a time. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 V (battery voltage).
NOTE: All terminals located along the lengthwise centerline of the fuse box are connected to the power source, while terminals located away from the center of the fuse box are connected to loads (accessories).
Accessories ( )
T105-07-01-008
T5-9-6
TROUBLESHOOTING / Electrical System Inspection
Connection in Fuse Box 1 Fuse NO. Description Capacity Connected to Remarks
1 Air Conditioner Main Power Source 15 A Air Conditioner Main Power Source 2 Slewing Alarm Power Source 10 A Slewing Alarm Lamp Relay Power Source 3 Buzzer Power Source 5 A Buzzer Relay Power Source 4 Radio 5 A Radio Power Source
5 Pilot Shut-Off Lever / Operation Stop Power Source
5 A Engine Oil Pressure Relay (R2), Alternator Relay Power Source
6 Preheat Circuit Power Source 5 A Preheat Controller Power Source 7 ECU 10 A ECU, Memory Clear Switch, ECU Lamp Power Source 8 Controller Key Switch 5 A MC2/A, MC2/B, IDU Key Switch ON Signal9 Monitor Panel Power Source 5 A Monitor Panel Power Source
10 Battery Relay 10 A Battery Relay Power Source 11 Preheat Indicator 5 A Monitor Panel Power Source 12 Rear Drum Lock SW Power Source 10 A Rear Drum Lock Power Source
13 Third / Fourth Drum Selection Power Source
3 A Third / Fourth Drum Selection Switch Power Source
14 Room Lamp 5 A Room Lamp Switch Power Source 15 IDU 5 A IDU Main Power Source 16 MC2/B 5 A MC2/B Main Power Source 17 MC2/A 5 A MC2/A Main Power Source 18 Horn 10 A Horn Relay Power Source 19 Back up Power Source 3 A Radio, Air Conditioner Back up Source 20 Fuel Pump Power Source 10 A Fuel Pump Back up Source
T2BC-01-02-016
14131211 15 16 17 18 19 20
6321 4 75 8 9 10
T18E-05-08-002
T5-9-7
TROUBLESHOOTING / Electrical System Inspection
Connection in Fuse Box 2 Fuse NO. Description Capacity Connected to Remarks
21 Air Conditioner Power Source 3 A Air Conditioner Power Source 22 Option 10 A Optional Power Source
23 Amplifier for Microphone and Speaker / Anemometer
5 A Amplifier for Microphone, Anemometer Indicator Power Source
24 Motor Output Limiter 5 A Motor Cutoff Relay (R6) Power Source 25 Roof Wiper Power Source 5 A Roof Wiper Switch, Timer, Roof Wiper Motor Power Source 26 Air Compressor Power Source 5 A Air Compressor Power Source 27 Front Wiper Power Source 5 A Front Wiper Switch, Timer, Front Wiper Motor Power Source 28 Lighter 20 A Lighter Power Source
29 Quick Draw / Counterweight Switch Power Source
10 A Quick Draw / Counterweight Relay (R5) Power Source
30 Fourth Drum Lock Switch Power Source 10 A Front Drum Lock Power Source 31 Engine Start Signal 10 A Engine Start Relay Power Source 32 Front Drum Lock Switch Power Source 10 A Front Drum Lock Power Source
34 Slewing Brake Power Source 3 A Slewing Brake Switch Power Source 35 Work Light Power Source 20 A Work Light Switch Power Source 36 Clearance Light (Optional) 10 A Clearance Light Switch Power Source 37 Solenoid (MC2/B) 15 A MC2/B Power Source 38 Solenoid (MC2/A) 15 A MC2/A Power Source 39 PWM (MC2/B) 15 A MC2/B Power Source 40 PWM (MC2/A) 15 A MC2/A Power Source
T2BC-01-02-016
34333231 35 36 37 38 39 40
26 27 28 29 302524232221
T18E-05-08-002
T5-9-8
TROUBLESHOOTING / Electrical System Inspection
HOW TO CHECK ALTERNATOR
In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective.
How to Check Alternator
1. Turn the key switch to the ON position. Confirm that the alternator indicator comes on.
2. Measure voltage between terminals B and E of the alternator. If the measured voltage is around 24 V, the al-ternator circuit can be considered normal. If the measured voltage is low, a shortage in bat-tery capacity or looseness of the wire connectors of alternator circuit might be the cause of the malfunction.When voltage is 0 V, the wiring between fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if -the ground line is disconnected.
3. Next, start the engine and measure voltage gen-erated while as the alternator rotates. As described above, measure voltage between terminals B and E on the side of alternator. If voltage is around 28 V, the alternator is operat-ing normally. If the rated voltage is not being generated (around 24V), there is some trouble with the al-ternator or the regulator.
Terminal E
Terminal B
T2BC-05-09-003
T5-9-9
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE CHECK
Check voltage in order to judge whether voltage is normally supplied to the measuring point, and whether circuit from power supply to measuring point is nor-mal.
24-V Circuit Turn on each switch so that measuring voltage is sup-plied to a location to be measured, and then measure voltage.
Measurement Example 1: When electric current does not flow Tester black terminal (minus): Vehicle frame (ground)
Tester red terminal (plus): Position to be measured
When the specified voltage is supplied to measuring point, it can be judged that circuit from battery (alter-nator) to measuring point is normal. Notice that when electric current flows in this circuit, voltage may not reach the specified level (due to power consumption) in some cases.
Measuring Point
T141-05-06-002
When voltage does not reach the specified level, power supply failure, short circuit or open circuit may be caused. In this case, check circuit from the up-stream side (or downstream side) in sequence in or-der to find a defect.
Measurements 24 V: Circuit from power supply to measuring
point is normal. 0 V: Circuit from power supply to measuring
point is open circuit or short circuit.
Specified Voltage (When Power Supply Is Normal) Measurement Example 2: Engine stopping : Battery voltage
About 25.5 V When electric current flows
Engine running : Alternator voltage About 28 V
2
1 3
T141-05-06-003
Measuring points (1) ............ 24 V (2) ............ 20 V (3) .............. 0 V
Measurements do not reach the specified power volt-age due to voltage drop caused by resistance of elec-trical parts. However, it can be judged that circuit up to measuring point (where voltage is available) is normal.
T5-9-10
TROUBLESHOOTING / Electrical System Inspection
Engine Key Switch Position to be Measured SpecifiationPower Source Circuit Stopped Stopped Stopped Stopped Stopped
OFFOFFOFFOFFOFF
Between (2) and (1): One BatteryBetween (3) and (2): One BatteryBetween (3) and (1): Two BatteryBetween (4) and (E): Battery RelayBetween (5) and (E): Fusile Link 45A
10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V
Between (6) and (E): Key Switch (ACC) Between (7) and (E): Battery Relay (Coil) Between (8) and (E): Battery Relay (Switch) Between (9) and (E): Fusible Link 65A Between (10) and (E): Preheat Controller Between (11) and (E): Heater Relay Between (12) and (E): Air Heater
20 to 25 V20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V
Starting Circuit Started Started Started Started Started Started Started Started Started Started Started
Between (6) and (E): Key Switch (ACC) Between (7) and (E): Battery Relay (Coil) Between (8) and (E): Battery Relay (Switch)Between (13) and (E): Engine Stop Relay (Terminal #2) Between (14) and (E): Engine Stop Solenoid Between (15) and (E): Engine Stop Relay (Terminal #1) Between (16) and (E): Starter Relay 2 (Terminal #3) Between (17) and (E): Starter (B) Between (18) and (E): Key Switch (C) Between (19) and (E): Engine Start Relay (Terminal #3) Between (20) and (E): Starter Relay 2 (Terminal #6)
20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 13 to 30 V
Charging Circuit Fast Speed Fast Speed
ONON
Between (21) and (E): Alternator (B) Between (8) and (E): Battery Relay (Switch)
26 to 30 V 26 to 30 V
Sarge Voltage Prevention Circuit Slow Idle Slow Idle
ON OFFON OFF
Between (22) and (E): Battery Relay (Coil) Between (23) and (E): Off-Delay Relay
26 to 30 V 26 to 30 V
Accessory Circuit Stopped Stopped Stopped
ONONON
Between (24) and (E): Radio Between (25) and (E): Lighter Between (26) and (E): Air Conditioner
20 to 25 V 10 to 12.5 V 20 to 25 V
NOTE: As for the points to be checked, refer to the illustrations in the following pages.
T5-9-11
TROUBLESHOOTING / Electrical System Inspection
Power Source Circuit
3 2 1
Fusible Link 45A
Fuel Feed Pump Switch
Room Lamp Switch
Horn Switch Horn Relay
Horn
MC2/A
MC2/BBattery Relay
IDU
Key Switch
T2BC-05-09-001
T5-9-12
TROUBLESHOOTING / Electrical System Inspection
Preheat Circuit
Battery
EngineStart Relay
MC2/A
87
Key Switch
Battery Relay
6
Fusible Link 65A 9
Starter Relay 1 Coolant
Temp. Sensor
Alternator
Heater Relay Air Heater
12
11
10
PreheatController
Preheat Lamp
T25N-02-03-002
T5-9-13
TROUBLESHOOTING / Electrical System Inspection
Engine Starting Circuit
Battery
Key Switch
MC2/A
EngineStart Relay
Front Free Mode SW
Rear Free Mode SW
Third Free Mode SW (optional) Slewing
Brake Switch 8
19
7
Battery Relay
6 18
Engine Stop Relay 14
13
15
EngineStop Solenoid
1617
Starter Relay
20 Starter Motor
Starter Relay 2
Alternator
T25N-02-03-006
T5-9-14
TROUBLESHOOTING / Electrical System Inspection
Charging Circuit
8Battery
Key Switch
Battery Relay
Off-Delay Relay
21
Alternator
AlternatorRelay
Alternator Indicator
T25N-02-03-004
T5-9-15
TROUBLESHOOTING / Electrical System Inspection
Surge Voltage Prevention Circuit
Battery
22
Key Switch
Battery Relay
23
Off-Delay Relay
Starter Relay 2
Alternator
AlternatorRelay
T25N-02-03-008
T5-9-16
TROUBLESHOOTING / Electrical System Inspection
Accessory Circuit
Battery
Key Switch
Battery Relay
24
Radio
CigaretteLighter
25
26
Air Conditioner
T2BC-05-09-002
T5-9-17
TROUBLESHOOTING / Electrical System Inspection
5-V Circuit
Voltage between terminal #1 and the vehicle frame (ground)With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the vehicle (ground) under the following conditions.
• Key switch: ON • Tester black probe (minus):
Vehicle frame (ground) • Tester red probe (plus):
Terminal #1
Evaluation:If the measuring voltage is within 5 0.5 volts, the circuit up to terminal #1 is normal.
Voltage between terminal #1 and the ground terminalWith the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the ground terminal (terminal #2 for two polarities, or terminal #3 for three polarities) under the following conditions.
• Key switch: ON • Tester black probe (minus):
Ground terminal (terminal #2 or #3)
• Tester red probe (plus): Terminal #1
Evaluation:If the measuring voltage is within 5 0.5 volts, the circuit up to terminal #1 or the ground terminal (terminal #2 or #3) is normal.
T107-07-05-006
T107-07-05-007
T107-07-05-008
T107-07-05-009
V
V
1 2
1 2 3
V
V
1 2 3
1 2
Signal or Ground
Power SourceTwo Polarities
Power SourceThree Polarities GroundSignal
Two Polarities
Three Polarities
T5-9-18
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Three Polarities
Turn the key switch OFF. After disconnecting the sensor connector, turn the key switch ON. Connect machine harness end connector terminal #1 (power) to terminal #2 (signal). (Power voltage is used as a false signal.) At tins time, the maximum value signal is displayed. If the machine and gauge are operated according to the maximum value signal, the related harness is normal. When the pressure switch circuits are normal, “ON” is displayed.
IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the vehicle frame (ground) when checking a three-polarity connector.
Two Polarities
T107-07-05-010
1 2
Connect
1 2 3
Connect
T107-07-05-011
T5-9-19
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Continuity
Discontinuity
NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.
If the ohm-meter reading is: 0 Continuity Discontinuity
Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Short circuit is present.
No short circuit is present.
Harness
A a
Connect to the vehicle frame.
aA
Connect to the vehicle frame.
aA
Short-circuitbetween the harness and the vehicle frame.
T107-07-05-003
T5-9-20
TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is , either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).
NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).
If the ohm-meter reading is: 0 Line (B) - (b) has discontinuity.
Line (A) - (a) has discontinuity.
Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 Short-circuit exists between the lines.
![CD-0875[1] Copy](https://static.documents.pub/doc/80x56/55cf92fc550346f57b9ae726/cd-08751-copy.jpg)
