Linkbelt Service Manual Serial n6j8 0875 PDF

MODEL 218 HSL
BOOK No. 1059

LBCE SERIAL No.
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.
Link-Belt Construction Equipment Company

This Page Left Blank
Intentionally
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.
BOOK1059 N6072508 Page 1 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 2 of 4
Conversion Tables
Length Conversion Table
millimeter, mm centimeter, cm meter, m inch, in., " foot, ft., '

1 0.1 0.001 0.03937 0.00328
10 1 0.01 0.3937 0.03281
1000 100 1 39.37 3.281
25.40 2.540 0.0254 1 0.08333
304.8 30.48 0.3048 12 1
mile, mi kilometer, km
1 1.6093
0.6214 1
Area Conversion Table
square millimeter, square centimeter, square meter, m2 square inch, in2 square foot, ft2
mm2 cm2
1 0.01 0.000001 0.00155
100 1 0.0001 0.155 0.001076
1 000 000 1 0000 1 1550 10.764
645.2 6.452 0.000645 1 0.006944
92903.0 929.03 0.09290 144 1
Volume Conversion Table
cubic centimeter, cubic meter, m3 cubic inch, in3 cubic foot, ft3
cm3, cc
1 0.000001 0.0610 0.0000353
1 000 000 1 61024 35.31
16.39 0.0000164 1 0.000579
28320 0.02832 1728 1
gallon, gal. cubic inch, in3 liter, lit., l

1 231 3.785
0.004329 1 0.01639
0.2642 61.02 1
Page 3 of 4
Conversion Tables – (continued)
Weight Conversion Table
gram, g kilogram, kg ounce, oz pound, lb. metric ton, t short ton, s.t.
1 0.001 0.03527 0.0022
1000 1 35.27 2.205 0.001 0.001102
28.349 0.02835 1 0.0625 0.00002835 0.00003125
453.592 0.4536 16 1 0.0004536 0.0005
1 000 000 1 000 35274 2205 1 1.102
907185 907.2 32 000 2000 0.9072 1
Pressure Conversion Table
bar kg/cm3 lb./in2, PSI

1 1.0197 14.50
0.9807 1 14.22
0.06895 0.07031 1
Work, Energy Conversion Table
kg.cm kg.m foot-pound, ft.-lb. inch-pound,.in-lb.

1 0.01 0.0723 0.8681
100 1 7.233 86.81
13.83 0.1383 1 12
1.1525 0.01153 0.08333 1
Centigrade-Fahrenheit Conversion Table
°F °C °F °C °F °C °F °C
-450 -267.78 -200 -128.89 5 -15.00 30 -1.11
-400 -240.00 -150 -101.11 10 -12.22 35 1.67
-350 -212.22 -100 -73.33 15 -9.44 40 4.44
-300 -184.44 -50 -45.56 20 -6.67 45 7.22
-250 -156.67 0 -17.78 25 -3.89 50 10.00
°F °C °F °C °F °C °F °C
55 12.78 80 26.67 150 65.56 400 204.44
60 15.56 85 29.44 200 93.33 450 232.22
65 18.33 90 32.22 250 121.11 500 260.00
70 21.11 95 35.00 300 148.89 550 287.78
75 23.89 100 37.78 350 176.67 600 315.56
Page 4 of 4
INTRODUCTION
TO THE READER
x This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
ADDITIONAL REFERENCES
x Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• The Operator’s Manual

• The Parts Catalog
PAGE NUMBER
x 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
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and x CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. x IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
x NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED
x SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature qC qF qCu1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgfm 1.0197 mL/rev cc/rev 1.0
Nm lbfft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
x 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.
SA-001
001-E01A-0001-2
UNDERSTAND SIGNAL WORDS

x 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.
x CAUTION also calls attention to safety messages in this
manual.
x To avoid confusing machine protection with personal SA-1223
safety messages, a signal word IMPORTANT indicates

a situation which, if not avoided, could result in damage
to the machine.
x NOTE indicates an additional explanation for an ele-

ment of information.
002-E01A-0461-6
S-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
x Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
x 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). SA-003
x Learn how to operate the machine and its controls cor-

rectly and safely.
x Allow only trained, qualified, authorized personnel to

operate the machine.
x Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.
x 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
PREPARE FOR EMERGENCIES
x 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 SA-437
your telephone.
004-E01A-0437-3
S-2
SAFETY
WEAR PROTECTIVE CLOTHING
x 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 SA-438
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.
x 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
PROTECT AGAINST NOISE

x 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.
SA-434
006-E01A-0434-2
INSPECT MACHINE
x 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.
SA-435
007-E01A-0435-2
S-3
SAFETY
USE HANDHOLDS AND STEPS
x 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, SA-439
and handrails when leaving the machine.
008-E01A-0439-3
ADJUST THE OPERATOR’S SEAT

x 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 SA-464
again.
009-E01A-0464-3
S-4
SAFETY
FASTEN YOUR SEAT BELT (IF EQUIPPED)
x 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 SA-237
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
OPERATE ONLY FROM OPERATOR’S SEAT

x 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.
SA-444
• Before starting the engine, confirm that all control lev-
ers are in neutral.
012-E01B-0444-3
S-5
SAFETY
JUMP STARTING
x 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.
SA-032
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway ma-
chine.
013-E01A-0032-3
S-6
SAFETY
PROTECT AGAINST FLYING DEBRIS
x 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.
SA-432
031-E01A-0432-2
S-7
SAFETY
PARK MACHINE SAFELY •Engage all brake and drum locks. Shutdown the
engine.
To avoid accidents:
•Remove the key from the key switch. Lock the
cab and all access doors.
• Park machine on a firm, level ground.
• Lower the boom to the ground.
033-E04A-0470-3
• 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.
HANDLE FLUIDS SAFELY᧩AVOID FIRES

x 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.
SA-018
x 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.
SA-019
034-E01A-0496-4
S-8
SAFETY
SAFE TRANSPORTATION
x 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.
Less than 15q SA-475A

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-᧲
TOWING MACHINE
x 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.
Pulling Rope
SA-605
061-E01A-0605-2
S-9
SAFETY
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.
SA-028
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 SA-527
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
S-10
SAFETY
WARN OTHERS OF SERVICE WORK
x 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.
SA-287
501-E01A-0287-2
SUPPORT MACHINE PROPERLY

x 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 SA-527
props that may crumble under continuous load. Do
not work under a machine that is supported solely by
a jack.
519-E01A-0527-3
STAY CLEAR OF MOVING PARTS

x 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.
SA-026
502-E01A-0026-2
S-11
SAFETY
PREVENT BURNS
Hot spraying fluids:
x 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. SA-039
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:
x Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well. SA-225
• Wait for the oil and components to cool before starting

any maintenance or inspection work.
505-E01B-0498-5
REPLACE RUBBER HOSES PERIODICALLY
x 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.

SA-019
x 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
S-12
SAFETY
AVOID HIGH-PRESSURE FLUIDS
x 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 SA-031
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.
SA-292
SA-044
507-E01A-0499-5
NEVER ATTEMPT TO MODIFY SAFETY

MECHANISM, HYDRAULIC COMPONENTS,
OR ELECTRICAL WIRING
x 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.
SA-019
x 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
S-13
SAFETY
PREVENT FIRES
Check for Oil Leaks: Check Heat Shields:
x Fuel, hydraulic oil and lubricant leaks can lead to fires. x Damaged or missing heat shields may load to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each • Damaged or missing heat shields must be re-
other, damage to the oil-cooler, and loose oil-cooler paired or replaced before operating the ma-
flange bolts. chine.
• Tighten, repair or replace any missing, loose or dam- 508-E02B-0019-9
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:
x Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
SA-019
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:
x 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:
x 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
S-14
SAFETY
EVACUATING IN CASE OF FIRE
x 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.
SA-393
518-E02A-0393-2
BEWARE OF EXHAUST FUMES

x 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 SA-016

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
S-15
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
x 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- SA-030
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
REMOVE PAINT BEFORE WELDING OR

HEATING
x 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. SA-029
• 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
S-16
SAFETY
PREVENT BATTERY EXPLOSIONS
x 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 qC (60 qF) first.
• Do not continue to use or charge the battery when SA-032
electrolyte level is lower than specified. Explosion of
the battery may result
• Loose terminals may produce sparks. Securely
tighten all terminals.
x 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
S-17
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
x 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 SA-309
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
DISPOSE OF WASTE PROPERLY
x 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
S-18
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Group 2 Tightening Torque

Tightening Torque Specification ............... W1-2-1
Torque Chart............................................ W1-2-2
Piping Joint.............................................. W1-2-5
Periodic Replacement of Parts ................ W1-2-9
2BDW-1-1
(Blank)
2BDW-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING

Precautions for Disassembling and Assembling • Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
x Clean the Machine manner that will prevent loss.
Thoroughly wash the machine before bringing it into • Inspect the contact or sliding surfaces of
the shop. Bringing a dirty machine into the shop disassembled parts for abnormal wear, sticking,
may cause machine components to be or other damage.
contaminated during disassembling/assembling, • Measure and record the degree of wear and
resulting in damage to machine components, as clearances.
well as decreased efficiency in service work.
x Precautions for Assembling
x Inspect the Machine • Be sure to clean all parts and inspect them for
Be sure to thoroughly read and understand all any damage. If any damage is found, repair or
disassembling/assembling procedures before replace it.
starting any repair work. Understanding these • Dirt or debris on the contact or sliding surfaces
procedures will help avoid incorrect disassembling may shorten the service life of the machine. Take
of components as well as the purchasing of care not to contaminate any contact or sliding
unnecessary service parts. surfaces.
• Before assembling, coat all inner parts with clean
• The machine model, machine serial number, and hydraulic oil or gear oil. Especially coat the
hour meter reading. sliding surfaces with clean hydraulic oil or gear
oil.
• Reason for disassembly (symptoms, failed parts,
• Be sure to replace O-rings, backup rings, and oil
and causes).
seals with new ones once they are disassembled.
• Clogging of filters and oil, water or air leaks, if
Apply a film of grease before installing.
any. • Be sure that liquid-gasket-applied surfaces are
• Capacities and condition of lubricants. clean and dry.
• Loose or damaged parts. • If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
x Prepare and Clean Tools and Disassembly Area remove the agent.
Prepare the necessary tools to be used and the • Utilize matching marks when assembling.
area for disassembling work. • Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
x Precautions for Disassembling • Keep a record of the number of tools used for
• To prevent dirt from entering, cap or plug the disassembly/assembly. After assembling is
removed pipes. complete, count the number of tools, so as to
• Before disassembling, clean the exterior of the make sure that no tools are missing.
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.

W1-1-1
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.

x 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.

x 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.

x Bleeding Air from Hydraulic Circuit
W24Y-01-01-001
• 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.
W1-1-2
Floating Seal Precautions
A
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.
B
W105-03-05-019
(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. Correct
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 Incorrect
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.
D
W105-03-05-020
(4) After installing the floating seal, check that

seal surface (C) is parallel with the seal
Correct C Incorrect
a a
mounting bore end face (D) and O-ring (B) as
illustrated. B

b b
a=b
a㻛b
W110-03-05-004
W1-1-3
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings Correct Eyehole
safely. Lifting Method
• 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 qC (212 qF). If unavoidably lifting a load
with a temperature of 100 qC (212 qF) 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. W24Y-01-01-002
• When lifting a load using an eyehole, be sure to Incorrect Eyehole

eliminate any gaps between the sling and load. Lifting Method
(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. W24Y-01-01-003
• 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.

Bent Sling W162-01-01-009
W1-1-4

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may
result. Be sure to visually check the nylon
sling for any damage before using.

W162-01-01-002
Scuffing

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 W162-01-01-003
7-years. Fuzz
Broken Sewing
Thread

W162-01-01-004
Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Scoring Separation of W162-01-01-006
Belt

W162-01-01-007
Fuzz Scuffing

Broken Warp

W162-01-01-008
W1-1-5
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.”

W1-1-6
GENERAL INFORMATION / Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
Bolts and Nuts of Machine: Standard Tightening
Torque Chart
Wrench Torque
No. Descriptions Bolt Dia. Q’ty Size
mm mm Nm kgfm lbfft
1. Swing Bearing Mounting Bolt 36 87 55 2940 300 2170
Front 16 4 24 175 18 130
2. Engine Mounting Bolt 22 2 32 740 75 540
Rear
16 4 24 265 27 195
3. Counterweight Mounting Bolt 39 6 60 1130 115 830
4. Cab Bed Mounting Bolt 16 15 24 205 21 152
5. Cab Mounting Bolt 16 4 24 205 21 152
6. Valve Bed Mounting Bolt 16 15 24 205 21 152
7. Upper Roller Mounting Bolt 16 24 24 205 21 152
8. Lower Roller Mounting Bolt 27 104 41 1370 140 1010
9. Travel Device Mounting Bolt (Right/Left) 33 52 50 2350 240 1740
10. Travel Motor Mounting Bolt (Right/Left) 18 4 27 295 30 215
11. Hoist Device Mounting Bolt (Main/Aux.) 36 4 55 1570 160 1160
12. Hoist Motor Mounting Bolt (Main/Aux.) 20 8 30 539 55 398
13. Boom Hoist Device Mounting Bolt 36 4 55 1570 160 1160
14. Boom Hoist Motor Mounting Bolt 20 20 30 490 50 360
15. Swing Device Mounting Bolt (Front/Rear) 20 36 30 539 55 400
16. Swing Motor Mounting Bolt (Front/Rear) 16 4 24 235 24 170
41 to 4.2 to
17. Pump Assembly Mounting Bolt 10 12 17 17.
45 4.6
20 4 17 400 41 18.
18. Main Pump Mounting Bolt 179 to 18.3 to 132 to
16 2 24
194 19.8 143
19. Swing Pump Mounting Bolt 16 4 14 240 24.5 19.
20. Hydraulic Oil Tank Mounting Bolt 16 4 24 205 21 152
21. Fuel Tank Mounting Bolt 10 4 17 20 2 14.5
22. Radiator Mounting Bolt 16 4 24 205 21 152
23. Radiator Stay Mounting Bolt 16 4 24 205 21 152

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.
W1-2-1
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, SA-040
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.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W157-01-01-001
Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt, Socket Bolt H Bolt M Bolt
Dia. Size Wrench
Size Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft
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
W1-2-2
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 r10 %.
(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.
Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally
1,4 1 12 9 4 1 6 7 14
6 3
4 5
2 13 8 5 2 3 10 11
2,3
W105-01-01-003
W1-2-3
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 W105-01-01-015
O-rings. Inspect O-rings for any WRONG

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. W105-01-01-016
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 W105-01-01-008
before tighten the others, RIGHT WRONG

resulting in damage to O-rings or
uneven tightening of bolts.
Bend along edge sharply Do not bend it round

Nut and Bolt Locking
x Lock Plate RIGHT RIGHT WRONG

IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Bend along edge sharply

W105-01-01-009

RIGHT RIGHT WRONG
x Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening.
RIGHT Loosen WRONG

x Lock Wire
Tighten
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

W105-01-01-010
W1-2-4
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening

Torque Specifications 1 4 3 5 2
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.
Joint Body
IMPORTANT: (1) Do not over-tighten union nut (3). M202-07-051
Excessive force will be applied

to metal sealing surfaces (4) and
(5), possibly cracking adaptor (1). 37q
Be sure to tighten union nut (3) 30q
to specifications.
(2) Scratches or other damage to

sealing surfaces (4) or (5) will Male Union Joint Female Union Joint

cause oil leakage at the joint. W105-01-01-017
Take care not to damage them

when connecting /disconnecting.
Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm kgfm Ibfft
30q Male Union 17 17 24.5 2.5 18
Joint 19 19 29.5 3.0 22
22 22 39 4.0 29
27 27 93 9.5 69
32 32 137 14.0 101
36 36 175 18.0 129
41 41 205 21.0 151
37q Female Union 17 14 24.5 2.5 18
Joint 19 17 29.5 3.0 22
22 19 39 4.0 29
27 22 93 9.5 69
32 27 137 14.0 101
36 32 175 18.0 129
41 36 205 21.0 151
W1-2-5
O-Ring Seal Joint
7 6 9
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), Joint Body

confirm that O-ring (6) is seated 8 10
correctly in O-ring groove (8). M104-07-033
Tightening union nut (9) with
O-ring (6) displaced will damage
O-ring (6), resulting in oil Wrench Size Tightening Torque
leakage. Union Nut Joint Body Nm kgfm Ibfft
19 17 29.5 3.0 22
(3) Take care not to damage O-ring 22 19 69 7.0 51
groove (8) or sealing face (10). 27 22 93 9.5 69
Damage to O-ring (6) will cause
32 27 137 14.0 101
oil leakage.
36 30, 32 175 18.0 129
(4) If union nut (9) is found to be 41 36 205 21.0 151
loose, causing oil leakage, do 46 41 205 21.0 151
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.
W1-2-6
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in

30q
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.
Male Tapered Thread Male Straight Thread
W105-01-01-018

Male Tapered Thread
Wrench Tightening Torque
Joint Body Nm kgfm Ibfft
17, 19 59 6 43
19, 22 98 10 72
27, 22 118 12 87
36, 32 235 24 134
41 295 30 215
50 490 50 360
60 670 68 490
70 980 100 720
Seal Tape Application
Internal Thread
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 External Thread Clearance
thread clearances. Do not over wrap.
W105-01-01-019
Leave one to two pitch threads uncovered

x 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.

M114-07-041
Low-Pressure-Hose Clamp Tightening Torque

T-Bolt Type Worm Gear Type
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 Nm (0.45 kgfm, 3.25 lbfft )
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgfm, 4.3 to 5.1 lbfft )
M114-07-042 M114-07-043
W1-2-7
Connecting Hose
WRONG RIGHT
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 W105-01-01-011
leakage, hose rupture or separation of
fitting. Utilize print marks on hoses when
installing hoses to prevent hose from
being installed kinked. WRONG RIGHT
(3) If hoses rub against each other, wear to Rubbing Against
the hoses will result, leading to hose Each Other
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.
W105-01-01-012

WRONG RIGHT
Clamp Clamp
Rubbing

W105-01-01-013

WRONG RIGHT

Rubbing

Clamp

W105-01-01-014
W1-2-8
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine Therefore, these parts should be replaced at regular
ages and are worn out or fatigued by repeated loads, intervals even if no abnormalities are noticed. In
resulting in possible severe personal injury and/or case any abnormalities are found on a part at any
machine trouble. The service life of these parts can time regardless of its specified replacement interval,
not be detected through machine operation or visual immediately replace the part.
inspection.
Part Location Part to be Replaced Q’ty Interval (Hours or Period)

Pendant rope Crane: 400 hrs /2 years
Bucket, Lifting Magnet
Front -
(Heavy Duty Work)
Attachment
: 2000 hrs / 2 years
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 - 2000 hrs / 2 years
pump)
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.
W1-2-9
(Blank)
W1-2-10
SECTION 2
CRANE UPPER
— CONTENTS —
Group1 Cab Remove and Install Gear Pump
Remove and Install Cab..............................W2-1-1 for HYD. Tagline .................................W2-4-79
Dimensions of the Cab Glass .....................W2-1-9 Disassemble Gear Pump
for HYD. Tagline .................................W2-4-82
Group 2 Couterweight Assemble Gear Pump
Remove and Install Counterweight .............W2-2-1 for HYD. Tagline .................................W2-4-84
Group 3 Upper Revolving Frame Group 5 Control Valve

Remove and Install Upper Revolving Remove and Install Front / Rear 4-Unit
Frame ........................................................W2-3-1 Control Valve.............................................W2-5-1
Disassemble Front / Rear 4-Unit Control
Valve .........................................................W2-5-4
Group 4 Pump Assembly
Assemble Front / Rear 4-Unit Control
Remove and Install Main Pump ............... W2-4-1 Valve .......................................................W2-5-10
Disassemble Main Pump ......................... W2-4-4 Remove and Install 4-Unit Control
Assemble Main Pump............................ W2-4-10 Valve .......................................................W2-5-17
Maintenance Standard........................... W2-4-16 Disassemble 4-Unit Control Valve ............W2-5-20
Disassemble Front Regulator ................ W2-4-18 Assemble 4-Unit Control Valve ...............W2-5-26
Assemble Front Regulator ..................... W2-4-24 Remove and Install 1-Unit Control
Valve .......................................................W2-5-33
Disassemble Rear Regulator................. W2-4-28
Disassemble 1-Unit Control Valve ............W2-5-36
Assemble Rear Regulator ..................... W2-4-34
Assemble 1-Unit Control Valve .................W2-5-38
Disassemble Reduction Gear ................ W2-4-40
Remove and Install Hoisting Drum
Assemble Reduction Gear ................... W2-4-42 Control Valve (Optional) ........................W2-5-41
Maintenance Standard ......................... W2-4-44 Disassemble Winch Drum Control
Remove and Install Swing Pump ........... W2-4-45 Valve ......................................................W2-5-42
Disassemble Swing Pump ..................... W2-4-48 Assemble Winch Drum Control Valve .......W2-5-46
Assemble Swing Pump.......................... W2-4-52
Maintenance Standard ......................... W2-4-54 Group 6 Swing Mechanism
Disassemble Regulator ......................... W2-4-56 Remove and Install Swing Reduction
Assemble Regulator .............................. W2-4-62 Unit............................................................W2-6-1
Remove and Install 2-Unit Gear Pump .. W2-4-69 Disassemble Swing Reduction Unit............W2-6-4
Disassemble 2-Unit Gear Pump ............ W2-4-72 Assemble Swing Reduction Unit.................W2-6-8
Assemble 2-Unit Gear Pump ................. W2-4-74 Disassemble Swing Motor ........................W2-6-14
Assemble Swing Motor .............................W2-6-18
Maintenance Standard ............................W2-6-20
2BDW-2-1
Group 7 Winch Assembly Group 9 Remote Control Valve
Remove and Install Front And Rear Remove and Install Remote Control
Valves for Hoisting, Raising/Lowering
Winch Assenbly ................................... W2-7-1 Drum and Travel .......................................W2-9-1
Disassemble Winch Assenbly.................. W2-7-8 Remove and Install Swing Remote
Assemble Winch Assenbly..................... W2-7-12 Control Valve.............................................W2-9-5
Disassemble Winch Motor ..................... W2-7-18 Disassemble Remote Control Valve ...........W2-9-8
Assemble Winch Motor.......................... W2-7-22 Assemble Remote Control Valve ..............W2-9-14
Maintenance Standard ......................... W2-7-27
Disassemble Regulator ......................... W2-7-30 Group 10 Solenoid Valve
Assemble Regulator .............................. W2-7-32 Remove and Install Solenoid Valve
Disassemble Counterbalance Valve ...... W2-7-34 Unit..........................................................W2-10-1
Assemble Counterbalance Valve ......... W2-7-36 Disassemble and Assemble Solenoid
Valve Unit ................................................W2-10-2
Disassemble Brake Unit ........................ W2-7-38
Assemble Brake Unit ............................. W2-7-40
Remove and Install Fourth Winch
Group 11 Cylinder
Assenbly ............................................ W2-7-43 Remove and Install Counterweight
Installation / Removal Cylinder ............... W2-11-1
Disassemble Fourth Winch Assenbly..... W2-7-52
Disassemble Cylinder ............................... W2-11-4
Assemble Fourth Winch Assenbly ......... W2-7-56
Assemble Cylinder .................................... W2-11-8
Disassemble Fourth Winch Motor.......... W2-7-62
Assemble Fourth Winch Motor .............. W2-7-68
Maintenance Standard ......................... W2-7-64
Disassemble Counterbalance Valve ...... W2-7-76
Assemble Counterbalance Valve ........... W2-7-78
Disassemble Regulator ......................... W2-7-80
Assemble Regulator ............................ W2-7-82
Disassemble Brake Unit ........................ W2-7-84
Assemble Brake Unit ............................. W2-7-86
Group 8 Raising/Lowering Mechanism

Remove and Install Raising/Lowering
Mechanism................................................W2-8-1
Disassemble Raising/Lowering
Mechanism................................................W2-8-8
Assemble Raising/Lowering Mechanism ..W2-8-14
Disassemble Raising/Lowering Motor ......W2-8-20
Assemble Raising/Lowering Motor .........W2-8-22
Disassemble Brake Valve .........................W2-8-24
Assemble Brake Valve ..............................W2-8-26
2BDW-2-2
CRANE UPPER / Cab
REMOVE AND INSTALL CAB

Removal 2
1
1. Remove bolts (1) (4 used) and remove seat (2).
: 13 mm

W24X-02-01-001
2. Loosen screws (8) (19 used) and bolts (9) (4
8
used). Remove covers (3 to 7) behind the seat. 8
: 17 mm 5
3 8
8
7
6
4
8 9

W2BD-02-01-001

3. Remove screws (18) (4 used) and bolts (19) (4 16
used). Remove covers (16, 17) on the bottom of 14
front display.
: 17 mm 12 18 14
4. Remove screws (14) (14 used) and socket bolts

(15) (2 used). Remove covers (11 to 13) from left 13
stand (10).
14
: 4 mm
19
5. Loosen bolts (20) (4 used) of left stand (10). (in
order to move the left stand)
: 13 mm
20
6. Move left stand (10) about 20 mm to the inside. 11 14
10 17
15

W24X-02-01-003
W2-1-1
CRANE UPPER / Cab
7. Remove screws (25) (14 used) and socket bolts
(26) (2 used). Remove covers (22 to 24) from right 25
stand (21). 23
: 4 mm 27 24
26 25
8. Loosen bolts (27) (4 used) of right stand (21). (in

order to move the right stand) 26
25
: 13 mm
9. Move right stand (21) about 20 mm to the inside.

25
21
27 22

W24X-02-01-004
10. Loosen bolts (31) (13 used). Remove under

covers (28 to 30) in front of the right platform.
: 17 mm
28
31
30 29 31
31
W2BD-02-01-002

11. Remove all connectors (32) of electric wiring for
each equipment installed to the cab. 33 32 32
12. Loosen hose clamp (34). Remove air conditioner

hoses (33) (2 used).

34
32
32
32

W2BD-02-01-003
W2-1-2
CRANE UPPER / Cab
13. Remove bolt (35) (5 used). Remove cover (36). 36
: 10 mm
35

W2BC-02-01-002
14. Loosen hose clamps (37) (2 used). Remove

hoses (38) (2 used). Disconnect connectors (39)
(2 used).

W2BC-02-01-003
39 38 37
W2-1-3
CRANE UPPER / Cab
15. Remove bolt (40) and nuts (41) (7 used).
41
40

W2BD-02-01-002

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)

42
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-02-01-004
W2-1-4
CRANE UPPER / Cab
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. 42
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.

W2BD-02-01-004
3. Install bolt (40) and nuts (41) (7 used).

: 24 mm
: 68.1 to 79.4 Nm (6.9 to 8.1 kgfm)
(50 to 59 lbfft)
41
40

W2BD-02-01-002
4. Tighten and install air conditioner hoses (33) (2 33 32 32

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.
34
32
32
32

W2BD-02-01-003
W2-1-5
CRANE UPPER / Cab
6. Install cover (36) with bolts (35) (5 used). 36
: 10 mm
35

W2BC-02-01-002
7. Tighten and install hoses (38) (2 used) with hose

clamp (37). Connect connectors (39) (2 used).

W2BC-02-01-003
39 38 37

W2-1-6
CRANE UPPER / Cab
8. Install under covers (28 to 30) in front of the right
platform with bolts (31) (13 used).
: 17 mm
: 41 to 45 Nm (4.2 to 4.6 kgfm)
(30 to 33 lbfft)
28
31
30 29 31
31
W2BD-02-01-002

9. Push right stand (21) onto the wall in cab.
25
23
10. Tighten bolts (27) (4 used) in right stand (21).
26 27 24 25
: 13 mm
11. Install covers (22 to 24) to the right stand (21) with 26
screws (25) (14 used) and socket bolts (26) (2 25
used).
: 4 mm
25
12. Push left stand (10) onto the wall in cab.
21
13. Tighten bolts (20) (4 used) in left stand (10).
: 13 mm 27 22

14. Install covers (11 to 13) to left stand (10) with W24X-02-01-004

screws (14) (14 used) and socket bolts (15) (2
used). 16
: 4 mm 14
12 18 14
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 13
: 41 to 45 Nm (4.2 to 4.6 kgfm) 14
(30 to 33 lbfft)
19
20
11 14
10 17
15

W24X-02-01-003
W2-1-7
CRANE UPPER / Cab
16. Install covers (3 to 7) behind the seat with screws
(8) (19 used) and bolts (9) (4 used). 8
: 17 mm 5
3 8
: 41 to 45 Nm (4.2 to 4.6 kgfm)
(30 to 33 lbfft) 8
7
6
4
8 9

W2BD-02-01-001
17. Install seat (2) with bolts (1) (4 used).

: 13 mm
2
1

8

W24X-02-01-001

W2-1-8
CRANE UPPER / Cab
DIMENSIONS OF THE CAB GLASS
NOTE: JIS R3211, 3212 or equivalent Unit: mm
565.2
25
25
R30
R55
810
Thickness :
776
517.7 6.8 mm
26 26
22.5 22 22 22.5
25 25
857.5
166 R53
276.5
466 R5 469.8 (134.7) 53
57.5 I11
64
R75.9 R75.9 42.5
32 88
Thickness : Thickness : 897.5
4 mm 4 mm 122.5
I12.2 Thickness:
763 763 5 mm
40 40
39.5 39.5
312.4 312.4 R5
R5
604.5 768
R5
376.6
Thickness:
5 mm 558.5
R61 R40
758
Thickness :
4 mm 497.7
65.8
498
186.4
R61
R2519
Thickness : 372.6
4 mm
650.8 371.2
802.9
R61
123.2 406.8 735.9 148.3
Thickness :
233.5
4 mm
264.3 R61 R61
648
Thickness : 623 667.7 Thickness : 4 mm
251.6 4 mm 840
530
172.3

W2BC-02-01-001
W2-1-9
CRANE UPPER / Cab
(Blank)
W2-1-10
CRANE UPPER / Counterweight
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 Counterweight Weight: kg (lbs)

Counterweight A with cylinders 11,501 (25,360)
The counterweight sling wire ropes are provided as
follows : Counterweight R (2 pieces) 4,280 (9,440)
Counterweight L (2 pieces) 4,270 (9,420)
Wire ropes: I. 25 mm u 2.8 m 2 ropes
Total 28,601 (63,065)
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.
W2-2-1
4. Turn the CTWT Removal / Jacks Select Switch
(1) to the "CTWT" position. 2 Acceleration
Deceleration
5. Turn accelerator dial (2) to the LOW IDLE
position.
1

W2BC-02-02-001
6. Check that the Lock Lever (3) is in the UNLOCK LOCK

position.
3
UNLOCK

W2BC-02-02-002
7. Place the ladder (4) onto the platform (5) of the

6
upper frame rear side.
5
8. Go up to the platform (5) by the ladder (4).
4
9. Set the chain (6) to prevent personnel falling
accident.

W2BC-02-02-003
W2-2-2
10. Extend the counterweight installation/removal
cylinders until able to turn the cylinder rods (7) for
90 degrees. 7
8
11. Position the pins (8) onto the rear of the upper
frame.

W2BC-02-02-004
12. Fully retract the cylinders (9). And then

10 11
disconnect the ring pins (10) and remove the pins
(11) from each side of platform.

W2BC-02-02-005
13. Lower the counterweights to ground by extending 9

the cylinders (9).

W2BC-02-02-006
W2-2-3
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.

W2BC-02-02-007
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).

13
12

W2BC-02-02-008
W2-2-4
Installation
The counterweights can be installed by using the 9 9

Observe the following working conditions for

installing and removing counterweights.
14
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 W2BC-02-02-009
counterweights into position for lifting with

the counterweight installation/removal 16
cylinders. Refer to "Quick Draw" Self
Assembly System of the Operator's
Manual.
18
19
3. Place the counterweight "A" (14) and the
cylinders (9) on the ground.
11
4. Position the counterweights "R" (15) and “L” (16)
onto the counterweight "A" (14) and connect with 15
the link plates (17) and ring pins (18).
17 14
5. Remove the pins (11) and hung them from the 18 W2BC-02-02-010
brackets (19).
6. Position the crane and/or counterweights so that

counterweights can be lifted with the
Position the upper parallel to the side frames.

W2BC-02-02-006
W2-2-5
7. Engage the swing lock and all lever locks.
2 Acceleration
8. Turn the CTWT Removal / Jacks Select Switch
Deceleration
(1) to the "CTWT" position.
9. Turn accelerator dial (2) to the LOW IDLE 1

position.

W2BC-02-02-001
10. Check that the Lock Lever (3) is in the UNLOCK LOCK
position.
3
UNLOCK

W2BC-02-02-002
11. Connect the hoses (12) of counterweight

installation/removal cylinders to the ports (13) on
the rear of the upper frame.
13
12

W2BC-02-02-008
W2-2-6
12. Place the ladder (4) onto the platform (5) of the
upper frame rear side. 6
13. Go up to the platform (5) by the ladder (4). 5
14. Set the chain (6) to prevent personnel falling 4

accident.

W2BC-02-02-006
15. Fully extend the counterweight

installation/removal cylinders by the control
switches (20).
20 20

W2BC-02-02-011
W2-2-7
16. Position the pins (21) onto the rear of the upper
frame.
21
17. Retract simultaneously both of the cylinders to lift

up the counterweights.

W2BD-02-02-001
18. Install the pins (11) into the holes and connect the
ring pins (10) to fix the counterweights.
10 11

W2BC-02-02-005
19. Extend the cylinders for approx. 3' and turn the
cylinder rods (7) for 90 degrees.

W2BC-02-02-012
W2-2-8
20. Fully retract the cylinders as storage position.

W2BC-02-02-004
W2-2-9
(Blank)
W2-2-10
CRANE UPPER / Upper Revolving Frame
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

1
counterweight, refer to W2-2 in this section.
3. Disconnect connector (1).

W2BC-02-03-001
4. Disconnect plugs on the terminal box (2).
5. Remove the live-mast, boom stop and boom.

W2BC-02-03-002
2
W2-3-1
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.)
3
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.

W2BC-02-03-003
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). W324-02-03-005
12. Remove bolts (4) in the outer race of turntable Center㩷

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. 4 4
W324-02-03-006
W2-3-2
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. W324-02-03-005
NOTE: As the length of bolt is different (two types), 5

check each position.
Center㩷
6. Tighten the nuts diagonally and alternately. Install

the stopper. 6
: 46 mm
: 1200 to 1300 Nm
(123 to 133 kgfm, 885 to 959 lbfft)
7. Install all hoses to the rotating joint. Refer to W3-3

4 4
in the following section.)
W324-02-03-006
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.)
W2-3-3
10. Install the live-mast, boom stop and boom.
10
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
W2-3-4
CRANE UPPER / Pump Assembly
REMOVE AND INSTALL MAIN PUMP

Before draining hydraulic oil,
lower the boom onto the ground.
Apply each brake and the drum
lock. 1

Preparation W24X-02-04-001
1. Shutdown the engine.䎃 Operate the lever several

times and release the remaining pressure in the
circuit. 2
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. 3
W2CM-02-04-001
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
W2-4-1
CAUTION: Swing pump weight:

4. Remove bolt (4). Lift swing pump with the crane 2

and remove them.
: 14 mm
Installation 4

1. Install swing pump and tighten with bolt (4).

: 14 mm
: 240 Nm (24.5 kgfm, 177 lbfft)
CAUTION: Main pump weight:

3
2. Lift the main pump with the crane and install it on
the coupling and bracket. W2CM-02-04-001
3. Apply LOCTITE onto bolts (2, 3). Install bolts (2, 3).
: 24 mm
: 179 to 194 Nm (18.3 to 19.8 kgfm)
(132 to 143 lbfft)
: 17 mm
: 400 Nm (41.0 kgfm, 295 lbfft)
4. Install all hoses, pipes and wire harness to the

main pump.
: 22 mm
: 39 Nm (4.0 kgfm, 29 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 36 mm
: 175 Nm (18.0 kgfm, 129 lbfft)
: 8 mm
: 48 to 50 Nm (4.9 to 5.1 kgfm)
(35 to 37 lbfft)
: 10 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
5. Remove the filler port cover of the hydraulic tank.

Fill hydraulic oil to specified level.
W2-4-2
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 Nm (17.0 kgfm, 125 lbfft)
5
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.
: 36 mm
: 170 Nm (17 kgfm, 125 lbfft)

W2CM-02-04-001
W2-4-3
DISASSEMBLE MAIN PUMP
17 18
19
16
14, 15
20
13 21
22
12
11
9 10
8 23
63 24
25 44
7
5 26 27
6 45
27 43
5
4 28
2 3
29 42 10
26 51
1 52
41
40 53
39
38 49
37
36 10
35 46
33, 34 47 50
32
31 54
48
30
17
62
61
18 60
59
58
56
26
55
40
46 57
W2BD-02-04-001
W2-4-4
1- Socket Bolt (4 Used) 17 - Socket Bolt (4 Used) 33 - Piston (18 Used) 49 - O-Ring (2 Used)
2- Plate 18 - Socket Bolt (4 Used) 34 - Shoe (18 Used) 50 - Valve (2 Used)
3- O-Ring 19 - Stopper (2 Used) 35 - Plate (2 Used) 51 - O-Ring (2 Used)
4- Retaining Ring (2 Used) 20 - Backup Ring (2 Used) 36 - Bushing (2 Used) 52 - Pin (2 Used)
5- Spacer (3 Used) 21 - O-Ring (2 Used) 37 - Spring (18 Used) 53 - Flange Socket (4 Used)
6- Bearing (2 Used) 22 - Servo Piston (2 Used) 38 - Cylinder Block (2 Used) 54 - Reduction Gear
7- Shaft 23 - O-Ring (4 Used) 39 - Valve Plate 55 - Valve Plate
8- Lock Nut (2 Used) 24 - Plug (4 Used) 40 - Bearing (2 Used) 56 - O-Ring (16 Used)
9- Setscrew (2 Used) 25 - Pump Casing (2 Used) 41 - Gear 57 - Shaft
10 - Spring Pin (4 Used) 26 - O-Ring (4 Used) 42 - Block 58 - Regulator
11 - Stopper (2 Used) 27 - Plug (31 Used) 43 - Setscrew (2 Used) 59 - O-Ring
12 - Backup Ring (2 Used) 28 - Support (2 Used) 44 - Nut (2 Used) 60 - Oil Seal
13 - O-Ring (2 Used) 29 - Socket Bolt (8 Used) 45 - Eyebolt (2 Used) 61 - Cover
14 - Feedback Pin (2 Used) 30 - Plate (2 Used) 46 - Pin (2 Used) 62 - Socket Bolt (4 Used)
15 - Tilt Pin (2 Used) 31 - Bushing (2 Used) 47 - O-Ring (4 Used) 63 - Block (4 Used)
16 - Regulator 32 - Plate (2 Used) 48 - Plug (2 Used)
W2-4-5
17 18
16
24
25
28
2
29 42
1
41
53
38
36
35
33, 34
54
30
17
62
61
18 60
58

W2BD-02-04-001
W2-4-6
Disassemble Main Pump
• Thoroughly read “PRECAUTIONS FOR

DISASSEMBLING AND ASSEMBLING” (W1-1-1)
before disassembling.
IMPORTANT: Place the rubber plate or cloth on IMPORTANT: Place the rubber plate on the
the workbench in order not to workbench in order not to damage
damage the parts. the regulator mounting surface.
1. Select the place to disassemble. 7. Place the pump onto the workbench horizontally
NOTE: Select the clean place. with the regulator mounting surface facing
downward. Separate pump casing (25) from block
2. Remove any dust and rust from the pump surface (42).
with using the washing oil. NOTE: When separating block (42) from pump
casing (25), remove gear (41) at the same
3. Remove plug (24). Drain oil from pump casing time.
(25).
: 36 mm IMPORTANT: Do not damage the sliding surfaces
NOTE: Drain off the oil from each plug in cylinder block (38), bushing (36),
corresponded to the front and rear pump. shoe (34) and plate (30).
8. Remove cylinder block (38) from pump casing
4. Remove socket bolts (17, 18) and flange socket (25) straightly. Remove piston (33), plate (35),
(53). Remove regulators (16, 58) and reduction bushing (36) and spring (37).
gear (54).
: 6 mm, 12 mm IMPORTANT: Do not damage oil seal (60) when
removing cover (61).
NOTE: As for disassembly of regulators (16, 58)
9. Remove socket bolt (62). Remove cover (61).
and reduction gear (54), refer to the
: 6 mm
corresponding section.
NOTE: In case inserting the bolt into the hole (M6
tap) on cover (61), cover (61) can be
5. Remove the socket bolt (1) and remove the plate removed easily.
(2).
: 12 mm

6. Loosen the socket bolt (29) that tightens the
support (28), pump casing (25) and block (42).
17 mm
W2-4-7
19
15
20
21
22
11
8
25 44
7
28
42
40
39
32
30
55
40
57
W2BD-02-04-001
W2-4-8
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).
W2-4-9
ASSEMBLE MAIN PUMP
58 16
18 18
17 17
12 13 22 31 14 15 56 21 20 19 44 45 43 26 33 34 32
11
9
8 7
10 3
26 2
62
61
60
57
5
59
46
4 29
37 40 41 51
6 27 28 30 35 36 23, 24 55 42 49, 50 47, 48 39 38 25
54
53
67
66
65 52
64
63
68 1

W2BD-02-04-002
W2-4-10
1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Plate (2 Used) 52 - Pin (2 Used)
2- Plate 19 - Stopper (2 Used) 36 - Bushing (2 Used) 53 - Flange Socket (4 Used)
3- O-Ring 20 - Backup Ring (2 Used) 37 - Spring (18 Used) 54 - Reduction Gear
4- Retaining Ring (2 Used) 21 - O-Ring (2 Used) 38 - Cylinder Block (2 Used) 55 - Valve Plate
5- Spacer (3 Used) 22 - Servo Piston (2 Used) 39 - Valve Plate 56 - O-Ring (16 Used)
6- Bearing (2 Used) 23 - O-Ring (4 Used) 40 - Bearing (2 Used) 57 - Shaft
7- Shaft 24 - Plug (4 Used) 41 - Gear 58 - Regulator
8- Lock Nut (2 Used) 25 - Pump Casing (2 Used) 42 - Block 59 - O-Ring
9- Setscrew (2 Used) 26 - O-Ring (4 Used) 43 - Setscrew (2 Used) 60 - Oil Seal
10 - Spring Pin (4 Used) 27 - Plug (31 Used) 44 - Nut (2 Used) 61 - Cover
11 - Stopper (2 Used) 28 - Support (2 Used) 45 - Eyebolt (2 Used) 62 - Socket Bolt (4 Used)
12 - Backup Ring (2 Used) 29 - Socket Bolt (8 Used) 46 - Pin (2 Used) 63 - Block (4 Used)
13 - O-Ring (2 Used) 30 - Plate (2 Used) 47 - O-Ring (4 Used) 64 - Seat (4 Used)
14 - Feedback Pin (2 Used) 31 - Bushing (2 Used 48 - Plug (2 Used) 65 - Steel Ball (4 Used)
15 - Tilt Pin (2 Used) 32 - Plate (2 Used) 49 - O-Ring (2 Used) 66 - Stopper (2 Used)
16 - Regulator 33 - Piston (18 Used) 50 - Valve (2 Used) 67 - Stopper (2 Used)
17 - Socket Bolt (4 Used) 34 - Shoe (18 Used) 51 - O-Ring (2 Used) 68 - Reducing Valve
W2-4-11
22 31 14 15 19 33 34
11
62
61
60
57
5
59
46
4 37
6 28 30 35 36 55 42 38 25

W2BD-02-04-002
W2-4-12
Assemble Main Pump
IMPORTANT: When tightening servo piston (22) IMPORTANT: Do not damage oil seal (60).
and tilt pin (15), use special tool in 4. Secure cover (61) to pump casing (25) with
order not to damage the head of tilt socket bolt (62).
pin (15) and feedback pin (14). : 6 mm
Apply Three Bond #1305N (medium : 29 Nm (3.0 kgfm, 21 lbfft)
intensity) onto the thread part. NOTE: Apply a film of grease to oil seal (60) in
1. Lightly tap and install support (28) to pump casing cover (61).
(25) with using a hammer.
NOTE: When removing servo piston (22), tilt pin 5. Assemble the piston cylinder sub assembly
(15) and stoppers (19, 11), install them to (cylinder block (38), piston (33), shoe (34), plate
pump casing (25) first. (35), bushing (36) and spring (37)).䎃 Align the
splines of bushing (36) and cylinder block (38).䎃
2. Place pump casing (25) with the regulator Insert the piston cylinder sub assembly into pump
mounting surface facing downward.䎃 Install casing (25).
bushing (31) in plate (30) to tilt pin (15).䎃 Install
plate (30) to support (28). IMPORTANT: Check the direction of suction and
NOTE: Check if plate (30) can move smoothly by delivery in valve plate (55).
fingers. 6. Align with pin (46) and install valve plate (55) to
In case grease is applied onto plate (30) block (42).
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).䎃 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.
W2-4-13
58 16
18 18
17 17
14 15
57
29
41
24 42 25
54
53
63
1

W2BD-02-04-002
W2-4-14
IMPORTANT: Check the direction of block (42).
(Install block (42) with regulator (58)
facing upward and the suction flange
facing to left.)
7. Install block (42) to pump casing (25).䎃 Tighten
socket bolt (29).
: 17 mm
: 430 Nm (44 kgfm, 317 lbfft)
NOTE: Assemble the rear pump first.
Insert gear (41) into block (42).䎃 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 Nm (10.0 kgfm, 72 lbfft)
9. Insert feedback pin (14) in tilt pin (15) into the

feedback lever in regulators (16, 58).䎃 Install
regulators (16, 58) and reduction gear (54).䎃
Tighten socket bolts (17, 18) and flange socket
(53).
: 6 mm
: 29 Nm (3.0 kgfm, 21 lbfft)
: 12 mm
: 33 Nm (3.4 kgfm, 24 lbfft)
10. Install plug (24).

: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)
W2-4-15
MAINTENANCE STANDARD
1. Clearance between piston outer diameter and
cylinder inner bore.
Unit: mm (in)
Standard Allowable Limit d D
D-d 0.035 (0.001) 0.062 (0.002)

W25N-02-04-005
2. Clearance between piston and shoe
Unit: mm (in)
Standard Allowable Limit
㱐
Ǭ 0 to 0.1 (0 to 0.004) 0.3 (0.012)
t
W25N-02-04-006
3. Shoe thickness

Unit: mm (in)
t 4.9 (0.19) 4.7 (0.19)
4. Free length of cylinder spring
Unit: mm (in)
L
L 39.5 (1.56) 38.7 (1.52) W25N-02-04-007
5. Height of plate and spherical bushing

H
h
Unit: mm (in)
Standard Allowable Limit W25N-02-04-008㩷
H-h 23.0 (0.91) 22.0 (0.89)
W2-4-16
(Blank)㩷
W2-4-17
DISASSEMBLE FRONT REGULATOR
3
11
10
9
8
21
7
6 20 12
16 19
5 17 13
4
3 14
2 22
1 15
23
24 16
25
26 18
29
30 44
27
28 43 41
42 45
41
40
36 37 39
38
31
30 32
46
47
33 47
35 48
34
30 49
50
56
54
55 54 53 52 51
58 57 49 50

W2CH-02-04-001
W2-4-18
1- Pin㩷 16 - Pin (2 Used)㩷 31 - Cover㩷 45 - Setscrew㩷

2- Sleeve㩷 17 - Lever㩷 32 - O-Ring㩷 46 - Casing㩷
3- O-Ring (2 Used)㩷 18 - Pin㩷 33 - O-Ring (3 Used)㩷 47 - Pin (2 Used)㩷
4- O-Ring㩷 19 - Pin㩷 34 - O-Ring㩷 48 - Plug㩷
5- Casing㩷 20 - Feedback Lever㩷 35 - Plug (5 Used)㩷 49 - O-Ring (2 Used)㩷
6- Piston㩷 21 - Lever㩷 36 - Socket Bolt (2 Used)㩷 50 - Retaining Ring (2 Used)㩷
7- Rod㩷 22 - Spool㩷 37 - Socket Bolt (2 Used)㩷 51 - Plug㩷
8- Spring Seat㩷 23 - Sleeve㩷 38 - O-Ring㩷 52 - Pin㩷
9- Spring㩷 24 - Retaining Ring㩷 39 - Adjusting Screw㩷 53 - O-Ring㩷
10 - Spring㩷 25 - Set Spring㩷 40 - Adjusting Screw㩷 54 - O-Ring (9 Used)㩷
11 - Adjusting Rod㩷 26 - Return Springs㩷 41 - Nut (2 Used)㩷 55 - O-Ring㩷
12 - O-Ring㩷 27 - Spring Seat㩷 42 - O-Ring㩷 56 - O-Ring㩷
13 - Adjusting Rod㩷 28 - Retaining Ring㩷 43 - Cover㩷 57 - Cover㩷
14 - Spring㩷 29 - Piston㩷 44 - Lock Nut㩷 58 - Socket Bolt (2 Used)㩷
15 - Spring Seat㩷 30 - Socket Bolt (10 Used)㩷㩷㩷
W2-4-19
11
10
9
8
13
14
15
23
24
25
26
30 44
27
28 43 41
45
40
36 37 39
48
30
50
54 51
58 57 50

W2CH-02-04-001㩷
W2-4-20
Disassemble Front Regulator

IMPORTANT: Put the rubber plate or cloth on the IMPORTANT: When removing retaining ring (28),
workbench in order not to damage return spring (26) flies out.䎃 Do not
the parts. lose return spring (26).
As the parts are small, do not lose 7. Remove retaining ring (28).䎃 Remove spring seat
the parts. (27), return spring (26) and sleeve (23).
1. Select the place to disassemble. NOTE: Retaining ring (24) is installed to sleeve
NOTE: Select the clean place. (23).
2. Remove any dust and rust from the regulator 8. Remove retaining ring (50) and remove plugs (48,
surface with using the washing oil. 51).
IMPORTANT: Do not lose O-ring (54). NOTE: Plugs (48, 51) can be easily removed with
3. Remove socket bolts (36, 37).䎃 Remove the using the bolt (M6).
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).䎃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.䎃 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).䎃Remove cover (57).

Remove set spring (25) from the pilot part after
removing cover (57).
: 5 mm
W2-4-21
21
7
6 20
16 19
5 17
22
16
29
30
31
30
30

W2CH-02-04-001㩷
W2-4-22
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).

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).
: 5 mm
W2-4-23
ASSEMBLE FRONT REGULATOR
30 32 36 30 14 30
31
45
41
33 35 54 55 58 56 29 53 15 13 12
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50
57 39
28 41
48
40
51 3
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52
W25N-02-04-010
1- Pin㩷 16 - Pin (2 Used)㩷 31 - Cover㩷 45 - Setscrew

2- Sleeve㩷 17 - Lever㩷 32 - O-Ring㩷 46 - Casing㩷
3- O-Ring (2 Used)㩷 18 - Pin㩷 33 - O-Ring (3 Used)㩷 47 - Pin (2 Used)㩷
4- O-Ring㩷 19 - Pin㩷 34 - O-Ring㩷 48 - Plug㩷
5- Casing㩷 20 - Feedback Lever㩷 35 - Plug (5 Used)㩷 49 - O-Ring (2 Used)㩷
6- Piston㩷 21 - Lever㩷 36 - Socket Bolt (2 Used)㩷 50 - Retaining Ring (2 Used)㩷
10 - Spring㩷 25 - Set Spring㩷 40 - Adjusting Screw㩷 54 - O-Ring (9 Used)㩷
11 - Adjusting Rod㩷 26 - Return Springs㩷 41 - Nut (2 Used)㩷 55 - O-Ring㩷
12 - O-Ring㩷 27 - Spring Seat㩷 42 - O-Ring㩷 56 - O-Ring㩷
13 - Adjusting Rod㩷 28 - Retaining Ring㩷 43 - Cover㩷 57 - Cover㩷
14 - Spring㩷 29 - Piston㩷 44 - Lock Nut㩷 58 - Socket Bolt (2 Used)㩷
15 - Spring Seat㩷 30 - Socket Bolt (10 Used)㩷㩷㩷
W2-4-24
Assemble Front Regulator
1. Install rod (7) into the compensating hole on 5. Install piston (29) into the hole for negative control
casing (46). on casing (46).
NOTE: Check if piston (29) moves smoothly.
2. Install pin (16) to lever (21).䎃Insert pin (16) into the
groove of rod (7).䎃 Install pin (47) to casing (46).䎃 6. Install pin (16) to lever (17).䎃Insert pin (16) into the
Install lever (21) into pin (47). groove of piston (29).䎃Install lever (17).
IMPORTANT: Check if spool (22) and sleeve (23) IMPORTANT: Check the holes for plugs (48, 51).
can move in casing (46) smoothly. 7. Install pin (47) to plug (48).䎃Align pin (47) with the
Check the direction of spool (22). pin hole on lever (17) and install plug (48). Install
retaining ring (50).
8. Insert plug (51).䎃Install retaining ring (50).

NOTE: Check if feedback lever (20) has too big
play or moves smoothly.
22㩷 20㩷
9. Install return spring (26) and spring seat (27) to
W25N-02-04-011
the spool hole.䎃Install retaining ring (28).
3. Install spool (22) and sleeve (23) into the spool

hole on casing (46).
IMPORTANT: Check the direction of feedback

lever (20).
Lever (21) Side

Lever (17) Side
(Plugs (48, 51) Side)㩷
W25N-02-04-012
4. Install feedback lever (20).䎃 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.
W2-4-25
30 14 30
45
41
58 15 13
25 8 43 44
57 39
41
40
11
5 6 9 10
W25N-02-04-010
W2-4-26
10. Install set spring (25) to the spool hole and install
piston (6) and casing (5) to the compensating hole.䎃
Tighten cover (57) with socket bolts (58, 30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
IMPORTANT: Check the direction of spring seat

(15).
11. Install spring seat (15), spring (14) and adjusting
rod (13) to the pilot hole.䎃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).䎃 Install cover (43) and tighten socket
bolt (30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
13. Install the cover (31) and tighten the socket bolt
(30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-4-27
DISASSEMBLE REAR REGULATOR
3
11
10
9
8
21
7
6 20 12
16 19
5 17 13
4
3 14
2 22
1 15
23
24 16
25
26 18
29
27
28
44 45
43 41
42 46
35 41
40
39
38
36 37
31
30
32
33
47
48
33
34 48
60 49
61
50
51
44
57
55
56 55 54 53 52

59 58 50 51
W2CH-02-04-002
W2-4-28
1- Pin㩷 17 - Lever㩷 32 - O-Ring㩷 47 - Casing㩷

2- Sleeve㩷 18 - Pin㩷 33 - O-Ring㩷 48 - Pin (2 Used)㩷
3- O-Ring (2 Used)㩷 19 - Pin㩷 34 - O-Ring (2 Used)㩷 49 - Plug㩷
4- O-Ring㩷 20 - Feedback Lever㩷 35 - Solenoid Valve㩷 50 - O-Ring (2 Used)㩷
5- Casing㩷 21 - Lever㩷 36 - Socket Bolt (2 Used)㩷 51 - Retaining Ring (2 Used)㩷
6- Piston㩷 22 - Spool㩷 37 - Socket Bolt (2 Used)㩷 52 - Plug㩷
7- Rod㩷 23 - Sleeve㩷 38 - O-Ring㩷 53 - Pin㩷
8- Spring Seat㩷 24 - Retaining Ring㩷 39 - Adjusting Screw㩷 54 - O-Ring㩷
9- Spring㩷 25 - Set Spring㩷 40 - Adjusting Screw㩷 55 - O-Ring (9 Used)㩷
10 - Spring㩷 26 - Return Springs㩷 41 - Nut (2 Used)㩷 56 - O-Ring㩷
11 - Adjusting Rod㩷 27 - Spring Seat㩷 42 - O-Ring㩷 57 - O-Ring㩷
12 - O-Ring㩷 28 - Retaining Ring㩷 43 - Cover㩷 58 - Cover㩷
13 - Adjusting Rod㩷 29 - Piston㩷 44 - Socket Bolt (6 Used)㩷 59 - Socket Bolt (2 Used)㩷
14 - Spring㩷 30 - Socket Bolt (4 Used)㩷 45 - Lock Nut㩷 60 - Plug (7 Used)
15 - Spring Seat㩷 31 - Valve Casing㩷 46 - Setscrew 61 - O-Ring㩷
16 - Pin (2 Used) 㩷㩷
W2-4-29
11
10
9
8
13
14
15
23
24
25
26
27
28
44 45
43 41
46
41
40
39
36 37
49
51
44
55
55 52

59 58 51
W2CH-02-04-002
W2-4-30
Disassemble Rear Regulator

5. After removing cover (43) subassembly, remove

IMPORTANT: Put the rubber plate or cloth on the springs (9, 10) and spring seat (8) from the
workbench in order not to damage compensating part.䎃 Remove adjusting rod (13),
the parts. spring (14) and spring seat (15) from the pilot
As the parts are small, do not lose part.
the parts. NOTE: Adjusting rod (13) can be easily removed
1. Select the place to disassemble. with using the bolt (M4).
NOTE: Select the clean place.
6. Remove socket bolts (44,59).䎃Remove cover (58).
2. Remove any dust and rust from the regulator Remove set spring (25) from the pilot part.
surface with using the washing oil. : 5 mm
IMPORTANT: Do not lose O-ring (55). IMPORTANT: When removing retaining ring (28),
3. Remove socket bolts (36, 37).䎃 Remove the return spring (26) flies out.䎃 Do not
regulator from the pump. lose return spring (26).
: 6 mm 7. Remove retaining ring (28).䎃 Remove spring seat
(27), return spring (26) and sleeve (23).
IMPORTANT: Adjusting screws (39, 40), adjusting NOTE: Retaining ring (24) is installed to sleeve
rod (11), lock nut (45), nut (41) and (23).
setscrew (46) are installed to cover
(43).䎃As the setting flow rate changes,
do not loosen the screw and nut. 8. Remove retaining ring (51) and remove plugs (49,
4. Remove socket bolt (44) and remove cover (43). 52).
: 5 mm
NOTE: Plugs (49, 52) can be easily removed with
using the bolt (M6).
W2-4-31
21
7
6 20
16 19
5 17
22
16
29
35
31
30

W2CH-02-04-002㩷
W2-4-32
9. Remove the lever (17).
pair of tweezers.

with lever (21).



valve casing (31).
: 5 mm
15. Remove the solenoid valve (35) from the valve

casing (31).
: 32 mm
W2-4-33
ASSEMBLE REAR REGULATOR
35 32 33
34 34 60 60
14 44
30 36 44
46
31 60 55 55 56 59
57 29 54 15 13 12 41
25 61 27 26 24 23 22 47 8 43 45
37 18 48 19 50 51
58
21 39
49 28
41
52 3 40
17
16 1 11
3
20 2
38
4
42
5 6 7 9 10 53

W2CM-02-04-005
W2-4-34
1- Pin㩷 17 - Lever㩷 32 - O-Ring㩷 47 - Casing㩷

2- Sleeve㩷 18 - Pin㩷 33 - O-Ring㩷 48 - Pin (2 Used)㩷
4- O-Ring㩷 20 - Feedback Lever㩷 35 - Solenoid Valve㩷 50 - O-Ring (2 Used)㩷
5- Casing㩷 21 - Lever㩷 36 - Socket Bolt (2 Used)㩷 51 - Retaining Ring (2 Used)㩷
6- Piston㩷 22 - Spool㩷 37 - Socket Bolt (2 Used)㩷 52 - Plug㩷
7- Rod㩷 23 - Sleeve㩷 38 - O-Ring㩷 53 - Pin㩷
9- Spring㩷 25 - Set Spring㩷 40 - Adjusting Screw㩷 55 - O-Ring (9 Used)㩷
10 - Spring㩷 26 - Return Springs㩷 41 - Nut (2 Used)㩷 56 - O-Ring㩷
11 - Adjusting Rod㩷 27 - Spring Seat㩷 42 - O-Ring㩷 57 - O-Ring㩷
12 - O-Ring㩷 28 - Retaining Ring㩷 43 - Cover㩷 58 - Cover㩷
13 - Adjusting Rod㩷 29 - Piston㩷 44 - Socket Bolt (6 Used) 59 - Socket Bolt (2 Used)㩷
14 - Spring㩷 30 - Socket Bolt (4 Used)㩷 45 - Lock Nut㩷 60 - Plug (7 Used)
15 - Spring Seat㩷 31 - Valve Casing 46 - Setscrew㩷 61 - O-Ring
16 - Pin (2 Used) 㩷㩷
W2-4-35
29
27 26 23 22 47
48 19 51
21
49 28
52
17
16
20

W2CM-02-04-005
W2-4-36
Assemble Rear Regulator
2. Install pin (16) to lever (21).䎃Insert pin (16) into the
groove of rod (7).䎃 Install pin (48) to casing (47).䎃 6. Install pin (16) to lever (17).䎃Insert pin (16) into the
Install lever (21) into pin (48). groove of piston (29).䎃Install lever (17).
IMPORTANT: Check if spool (22) and sleeve (23) IMPORTANT: Check the holes for plugs (49, 52).
can move in casing (47) smoothly. 7. Install pin (48) to plug (49).䎃Align pin (48) with the
Check the direction of spool (22). pin hole on lever (17) and install plug (49). Install
8. Insert plug (52).䎃Install retaining ring (51).

22㩷 20㩷
9. Install return spring (26) and spring seat (27) to
W25N-02-04-011

hole on casing (47).

lever (20).
Lever (21) Side

Lever (17) Side
(Plugs (49, 52) Side)㩷
W25N-02-04-012

lever (20) a little first, the feedback lever
can be easily inserted.
W2-4-37
35
14 44
30 44
46
31 59
15 13 41
25 8 43 45
58
39
41
40
11
5 6 9 10

W2CM-02-04-005
W2-4-38
Tighten cover (58) with socket bolts (59, 44).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
IMPORTANT: Check the direction of spring seat

(15).

bolt (44).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
13. Install the solenoid valve (35) on the valve casing

(31).
: 32 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
(29 to 36 lbfft)
14. Install the valve casing (31) and tighten the socket
bolt (30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-4-39
DISASSEMBLE REDUCTION GEAR
21
1
4 18
3
7 16 17
2
18 10
1
6
5
19
16 20
14
15
14
13
18
18
12
11
10

W2CM-02-04-006
1- Spacer (2 Used) 7- O-Ring 12 - O-Ring 17 - Casing

2- Retaining Ring 8- Socket Bolt (2 Used) 13 - Retaining Ring 18 - Flange Socket (4 Used)
3- Bearing 9- Cover 14 - Ball Bearing (2 Used) 19 - O-Ring
4- Gear 10 - O-Ring (2 Used) 15 - Gear 20 - Plug
5- Retaining Ring 11 - Plate 16 - Pin (2 Used) 21 - Socket Bolt (2 Used)
6- Shaft
W2-4-40
Disassemble Reduction Gear

IMPORTANT: Place the rubber plate or cloth on 8. Remove retaining ring (13). Remove gear (15)
the workbench in order not to and ball bearing (14).
damage the parts. NOTE: Ball bearing (14) cannot be removed from
1. Select the place to disassemble. gear (15).
NOTE: Select the clean place.
2. Remove any dust and rust from the reduction

gear surface with using the washing oil.
3. Remove plug (20). Drain oil from the pump

casing.
: 36 mm
NOTE: Drain oil from the plug in front and rear
pump respectively.

2-unit gear pump.
: 8 mm
5. Remove the socket bolt (8). Remove the cover (9)

and plate (12).
: 8 mm
6. Remove flange socket (18) and remove the

reduction gear.
: 12 mm
7. Remove retaining ring (5) and remove shaft (6).

Remove gear (4), bearing (3) and spacer (1).
NOTE: Bearing (3) cannot be removed from gear
(4).
W2-4-41
ASSEMBLE REDUCTION GEAR

12 13 14 10
11 17 20
15 19
8
21
4
3
6 18 16
9 5
2

W2CM-02-04-007
1- Spacer (2 Used)㩷 7- O-Ring㩷 12 - O-Ring㩷 17 - Casing㩷

2- Retaining Ring㩷 8- Socket Bolt (2 Used)㩷 13 - Retaining Ring㩷 18 - Flange Socket (4 Used)㩷
3- Bearing㩷 9- Cover㩷 14 - Ball Bearing (2 Used)㩷 19 - O-Ring㩷
4- Gear㩷 10 - O-Ring (2 Used)㩷 15 - Gear㩷 20 - Plug㩷
5- Retaining Ring㩷 11 - Plate㩷 16 - Pin (2 Used)㩷 21 - Socket Bolt (2 Used)㩷
6- Shaft
W2-4-42
Assemble Reduction Gear
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 Nm (3.4 kgfm, 24 lbfft)
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 Nm (3.4 kgfm, 24 lbfft)
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 Nm (2.2 to 2.9 kgfm)
(16 to 21 lbfft)
7. Install plug (20) and O-ring (19) to casing (17).

: 36 mm
: 74 Nm (7.5 kgfm, 55 lbfft)
W2-4-43
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.
W2-4-44
REMOVE AND INSTALL SWING PUMP

Apply each brake and the drum
lock. 1

Preparation W24X-02-04-001
1. Shutdown the engine.䎃 Operate the lever several

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). 2
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.
3
CAUTION: Swing pump weight: W2CM-02-04-008
3. Remove bolts (2, 3). Lift swing pump with the

crane and remove them.
: 24 mm
: 14 mm
W2-4-45
Installation

Approx. 45 kg (100 lb) 4
1. Lift the swing pump and install it on the main 2

pump and bracket.
2. Install the swing pump mounting bolt (2) bolt (3)

with LOCTITE applied.
: 24 mm
: 179 to 194 Nm (18.3 to 19.8 kgfm)
(132 to 143 lbfft)
: 14 mm
: 240 Nm (24.5 kgfm, 177 lbfft)
3. Install all hoses, pipes and wire harness to the

swing pump.
: 22 mm
: 39 Nm (4.0 kgfm, 29 lbfft)
: 27 mm 3
: 93 Nm (9.5 kgfm, 69 lbfft) W2CM-02-04-008
: 10 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
4. Remove the filler port cover of the hydraulic tank.

Fill hydraulic oil to specified level.

: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)

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.
: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)
W2-4-46
(Blank)
W2-4-47
DISASSEMBLE SWING PUMP
19 20
18
16, 17
25 21
26
28 22
29 23
24
30
12 25
32 26
11
10
27
9 15
7 14
8 13 10
7
6 49
5
4 31
3
2
1 33 47
51
44 50
43
5
42
48
37, 38
36 12
39 46
35 45
34
41
40

W2CH-02-04-003
1- O-Ring 14 - Backup Ring 27 - Pump Casing 40 - Bushing

2- Socket Bolt (4 Used) 15 - O-Ring 28 - Nut 41 - Spring (9 Used)
3- Plate 16 - Feedback Pin 29 - Aye Bolt 42 - Cylinder Block
4- Oil Seal 17 - Tilt Pin 30 - O-Ring 43 - Valve Plate
5- O-Ring (2 Used) 18 - Regulator 31 - Plug (7 Used) 44 - Bearing
6- Retaining Ring 19 - Socket Bolt (2 Used) 32 - Support 45 - O-Ring
7- Spacer (2 Used) 20 - Socket Bolt (2 Used) 33 - Socket Bolt (4 Used) 46 - Pin
8- Bearing 21 - Stopper 34 - Plate 47 - O-Ring (9 Used)
9- Shaft 22 - Backup Ring 35 - Bushing 48 - Cover
10 - Lock Nut (2 Used) 23 - O-Ring 36 - Plate 49 - Setscrew
11 - Setscrew 24 - Servo Piston 37 - Piston (9 Used) 50 - Cover
12 - Spring Pin (2 Used) 25 - O-Ring (2 Used) 38 - Shoe (9 Used) 51 - Socket Bolt (2 Used)
13 - Stopper 26 - Plug (2 Used) 39 - Plate
W2-4-48
Disassemble Swing Pump

IMPORTANT: Place the rubber plate or cloth on the IMPORTANT: Do not damage the sliding surfaces
workbench in order not to damage of cylinder block (42), bushing (40),
the parts. shoe (38) and plate (34).
1. Select the place to disassemble. 7. Remove cylinder block (42) from pump casing
NOTE: Select the clean place. (27) straightly.䎃 Remove piston (37), plate (39),
bushing (40) and spring (41).
2. Remove any dust and rust from the pump surface
with using the washing oil. IMPORTANT: When removing cover (3), do not
damage oil seal (4).
3. Remove plug (26). Drain oil from pump casing 8. Remove socket bolt (2) and remove cover (3).
(27). : 5 mm
: 27 mm
9. Lightly tap the mounting flange part for support
4. Remove socket bolts (19, 20).䎃 Remove regulator (32) from the pump casing (27) side.䎃 Separate
(18). pump casing (27) from support (32).
: 6 mm
10. Remove plates (34, 36) from pump casing (27).
NOTE: Refer to the corresponding section as for
disassembly of regulator (18).
11. Tap the shaft end part of shaft (9) with using a
plastic hammer lightly.䎃 Remove shaft (9) from
5. Loosen socket bolt (33) that connects support (32),
support (32).
pump casing (27) and cover (48).
: 14 mm
12. Remove valve plate (43) from cover (48).
IMPORTANT: Place the rubber plate or cloth on the NOTE: Valve plate (43) may be removed at the
workbench in order not to damage step 6.
the mounting surface for regulator.
6. Place the pump onto the workbench horizontally
with the mounting surface for regulator facing
downward.䎃Separate pump casing (27) from cover
(48).
W2-4-49

17
21
24
32
10
27
13 10
44
48

W2CH-02-04-003

W2-4-50
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).䎃
Remove bearing (44) from cover (48).
W2-4-51
ASSEMBLE SWING PUMP
18
19 20
13 14 15 42 24 38 35 16,17 37 23 22 21 47 45 49
11
10
43
12 48
30
䋱
2
4 51
7
9
8
6
3
50
5
5
34
32 31 36 39 40 33 27 25, 26, 28,29 41 46 44

W2CH-02-04-004

1- O-Ring 14 - Backup Ring 27 - Pump Casing 40 - Bushing
2- Socket Bolt (4 Used) 15 - O-Ring 28 - Nut 41 - Spring (9 Used)
3- Plate 16 - Feedback Pin 29 - Aye Bolt 42 - Cylinder Block
4- Oil Seal 17 - Tilt Pin 30 - O-Ring 43 - Valve Plate
5- O-Ring (2 Used) 18 - Regulator 31 - Plug (7 Used) 44 - Bearing
6- Retaining Ring 19 - Socket Bolt (2 Used) 32 - Support 45 - O-Ring
7- Spacer (2 Used) 20 - Socket Bolt (2 Used) 33 - Socket Bolt (4 Used) 46 - Pin
8- Bearing 21 - Stopper 34 - Plate 47 - O-Ring (9 Used)
9- Shaft 22 - Backup Ring 35 - Bushing 48 - Cover
10 - Lock Nut (2 Used) 23 - O-Ring 36 - Plate 49 - Screw
11 - Screw 24 - Servo Piston 37 - Piston (9 Used) 50 - Cover
12 - Spring Pin (2 Used) 25 - O-Ring (2 Used) 38 - Shoe (9 Used) 51 - Socket Bolt (2 Used)
13 - Stopper 26 - Plug (2 Used) 39 - Plate
W2-4-52
Assemble Swing Pump
IMPORTANT: When tightening servo piston (24) IMPORTANT: Do not damage oil seal (4).
and tilt pin (17), use special tool in 4. Secure cover (3) to pump casing (27) with socket
order not to damage the head of tilt bolt (2).
pin (17) and feedback pin (16).䎃Apply : 5 mm
Three Bond #1305N onto the thread : 12 Nm (1.2 kgfm, 8.9 lbfft)
part. NOTE: Apply a film of grease onto oil seal (4) in
1. Lightly tap and install support (32) to pump casing cover (3).
(27) with using a hammer.
NOTE: When removing servo piston (24), tilt pin 5. Assemble the piston cylinder sub assembly
(17) and stoppers (13, 21), install them to (cylinder block (42), piston (37), shoe (38), plate
pump casing (27) first. (39), bushing (40) and spring (41)).䎃 Align the
splines of bushing (40) and cylinder block (42) and
2. Place pump casing (27) with the mounting surface insert the piston cylinder sub assembly into pump
for regulator facing downward.䎃Install bushing (35) casing (27).
in plate (34) into tilt pin (17).䎃 Install plate (34) to
support (32). IMPORTANT: Check the direction of suction and
NOTE: Check if plate (34) can move smoothly by delivery in valve plate (43).
fingers. 6. Align with pin (46) and install valve plate (43) on
In case grease is applied onto plate (34) cover (48).
and support (32), shaft (9) can be installed
easily. 7. Install cover (48) on pump casing (27).䎃 Tighten
socket bolt (33).
IMPORTANT: Do not tap shaft (9) with using a : 14 mm
hammer. : 240 Nm (24.0 kgfm, 177 lbfft)
3. Install bearing (8), spacer (7) and retaining ring
(6) onto shaft (9). Install shaft (9) to support (32). 8. Insert feedback pin (16) in tilt pin (17) into the
feedback lever in regulator (18).䎃 Install regulator
NOTE: Lightly tap the outer ring in bearing (8) with
(18).䎃Tighten socket bolts (19, 20).
using a plastic hammer and install bearing
: 6 mm
(8) with using a steel bar completely.
: 29 Nm (3.0 kgfm, 21 lbfft)
9. Install plug (26).

: 27 mm
: 110 Nm (11.0 kgfm, 81 lbfft)
W2-4-53
Unit: mm (in)
Standard Allowable Limit d D
D-d 0.028 (0.001) 0.056 (0.002)
W25N-02-04-005
Unit: mm (in)
Ǭ 0 to 0.1 (0 to 0.004) 0.3 (0.12)
㱐
3. Shoe thickness
W25N-02-04-006
Unit: mm (in)
t 3.9 (0.15) 3.7 (0.15)
4. Free length of cylinder spring
Unit: mm (in)
L
L 31.3 (1.23) 30.5 (1.20)
W25N-02-04-007
5. Height of plate and spherical bushing
H
Unit: mm (in) h
H-h 19.0 (0.75) 18.3 (0.72)
W25N-02-04-008㩷
W2-4-54
(Blank)
W2-4-55
DISASSEMBLE REGULATOR
3
11
10
9
8
21
7
6 20 12
16 19
5 17 13
4
3 14
2 22
1 15
23
24 16
25
26 18
29
30 44
27
28 43 41
42 45
41
40
36 37 39
38
31
30 49
46
33 47
35
57 48
34
49
50
47
35 56
55
4 54 53 49 52 51
32 59 58 49 50

W2CH-02-04-005
W2-4-56
1- Pin㩷 16 - Pin (2 Used)㩷 31 - Cover㩷 46 - Casing㩷

2- Sleeve㩷 17 - Lever㩷 32 - Socket Bolt (5 Used)㩷 47 - Pin (2 Used)㩷
4- O-Ring (2 Used)㩷 19 - Pin㩷 34 - O-Ring㩷 49 - O-Ring (5 Used)㩷
5- Casing㩷 20 - Feedback Lever㩷 35 - Plug (8 Used)㩷 50 - Retaining Ring (2 Used)㩷
6- Piston㩷 21 - Lever㩷 36 - Socket Bolt (2 Used)㩷 51 - Plug㩷
10 - Spring㩷 25 - Set Spring㩷 40 - Adjusting Screw㩷 55 - O-Ring㩷
11 - Adjusting Rod㩷 26 - Return Spring㩷 41 - Nut (2 Used)㩷 56 - O-Ring㩷
12 - O-Ring㩷 27 - Spring Seat㩷 42 - O-Ring㩷 57 - O-Ring (12 Used)㩷
13 - Adjusting Rod㩷 28 - Retaining Ring㩷 43 - Cover㩷 58 - Solenoid Valve㩷
14 - Spring㩷 29 - Piston㩷 44 - Lock Nut㩷 59 - Cover㩷
15 - Spring Seat㩷 30 - Socket Bolt (8 Used)㩷 45 - Setscrew㩷㩷
W2-4-57
11
10
9
8
13
4
14
15
23
24
25
26
30 44
27
28 43 41
45
41
40
36 37 39
30 49
48
49
50
4 49 52 51
32 59 58 49 50

W2CH-02-04-005㩷
W2-4-58
Disassemble Regulator

IMPORTANT: Place the rubber plate or cloth on 6. Remove socket bolt (32) and remove cover (59).
the workbench in order not to Remove set spring (25) from the pilot part after
damage the parts. As the parts are removing the cover (59).
small, do not lose the parts. : 5 mm
1. Select the place to disassemble.
NOTE: Select the clean place. 7. Remove the solenoid valve (58) from the cover
(59).
2. Remove any dust and rust from the regulator : 32 mm
surface with using the washing oil.
IMPORTANT: When removing retaining ring (28),
IMPORTANT: Do not lose O-ring (4). return spring (26) flies out. Do not
3. Remove socket bolts (36, 37) and remove the lose return spring (26).
regulator from the pump. 8. Remove retaining ring (28). Remove spring seat
: 6 mm (27), return spring (26) and sleeve (23).
NOTE: Retaining ring (24) is installed to sleeve
IMPORTANT: Adjusting screws (39, 40), adjusting (23).
rod (11), lock nut (44), nut (41) and
setscrew (45) are installed to cover 9. Remove retaining ring (50) and remove plugs (48,
(43). As the setting flow rate 51).
changes, do not loosen the screw NOTE: Plugs (48, 51) can be removed with using
and nut. the bolt (M6) easily.
4. Remove socket bolt (30) and remove cover (43).
: 5 mm 10. Remove the plug (52) and remove the O-ring
(49).
5. Remove springs (9, 10) and spring seat (8) from : 19 mm
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.
W2-4-59
21
7
6 20
16 19
5 17
22
16
29

W2CH-02-04-005㩷
W2-4-60
11. Remove lever (17) by using a pair of tweezers.
pair of tweezers.

with lever (21).


W2-4-61
ASSEMBLE REGULATOR
58 62 49
60
61
30 31 36 32 35 14 30
59
49
33
45
56 29 54 15 13 12 41
4 57 55 49, 52
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50
39
28 41
48 40
3
51
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 53

W2CG-02-04-008
W2-4-62
1- Pin㩷 17 - Lever㩷 33 - O-Ring (2 Used)㩷 48 - Plug㩷

2- Sleeve㩷 18 - Pin㩷 34 - O-Ring㩷 49 - O-Ring (5 Used)㩷
3- O-Ring (2 Used)㩷 19 - Pin㩷 35 - Plug (8 Used)㩷 50 - Retaining Ring (2 Used)㩷
4- O-Ring (2 Used)㩷 20 - Feedback Lever㩷 36 - Socket Bolt (2 Used)㩷 51 - Plug㩷
5- Casing㩷 21 - Lever㩷 37 - Socket Bolt (2 Used)㩷 52 - Plug㩷
6- Piston㩷 22 - Spool㩷 38 - O-Ring㩷 53 - Pin㩷
7- Rod㩷 23 - Sleeve㩷 39 - Adjusting Screw㩷 54 - O-Ring㩷
9- Spring㩷 25 - Set Spring㩷 41 - Nut (2 Used)㩷 56 - O-Ring㩷
10 - Spring㩷 26 - Return Spring㩷 42 - O-Ring㩷 57 - O-Ring (12 Used)㩷
11 - Adjusting Rod㩷 27 - Spring Seat㩷 43 - Cover㩷 58 - Solenoid Valve㩷
12 - O-Ring㩷 28 - Retaining Ring㩷 44 - Lock Nut㩷 59 - Cover㩷
13 - Adjusting Rod㩷 29 - Piston㩷 45 - Setscrew㩷 60 - Seat (2 Used)㩷
14 - Spring㩷 30 - Socket Bolt (8 Used)㩷 46 - Casing㩷 61 - Stopper (2 Used)㩷
15 - Spring Seat㩷 31 - Cover㩷 47 - Pin (2 Used)㩷 62 - Ball (2 Used)㩷
16 - Pin (2 Used)㩷 32 - Socket Bolt (5 Used)㩷㩷㩷
W2-4-63
49
49, 52 29
27 26 23 22 46
21 47 19 49 50
48
51
17
16
20

W2CG-02-04-008

W2-4-64
Assemble Regulator
2. Install pin (16) to lever (21). Insert pin (16) into the
groove of rod (7). Install pin (47) to casing (46). 6. Install pin (16) to lever (17). Insert pin (16) into the
Install lever (21) into pin (47). groove of piston (29). Install lever (17).
IMPORTANT: Check if spool (22) and sleeve (23) IMPORTANT: Check the inserting hole of the plugs
can move in casing (46) smoothly. (48) and (51).
Check the direction of spool (22). 7. Install pin (47) to plug (51). Align pin (47) with the
pin hole on lever (17) and install plug (51). Install
8. Insert plug (48). Install retaining ring (50).

22㩷 20㩷 9. Install the O-ring (49) and plug (52) on the casing
(46).
W25N-02-04-011
: 19 mm
: 36 Nm (3.7 kgfm, 27 lbfft)
hole on casing (46). 10. Install return spring (26) and spring seat (27) to
lever (20).
Lever (21) Side Lever (17) Side

(Plugs (48, 51) Side)
W25N-02-04-012

lever (20) a little first, the pin can be
inserted easily.
W2-4-65
58
30 32 14 30
59
45
15 13 41
25 8 43 44
39
41
40
11
5 6 9 10

W2CG-02-04-008
W2-4-66
11. Install the solenoid valve (58) on the cover (59).
: 32 mm
: 39 to 49 Nm (4.5 to 5.0 kgfm)
(29 to 36 lbfft)
Tighten cover (59) with socket bolt (32).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
IMPORTANT: Check the direction of spring seat (15).


bolt (30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-4-67
(Blank)㩷
W2-4-68
REMOVE AND INSTALL 2-UNIT GEAR
PUMP


Apply each brake and the drum 1
lock.
W24X-02-04-001
Preparation
1. Stop the engine.䎃Operate the lever several times

and release the remaining pressure in the circuit.
2. Remove drain plug (1) and drain off hydraulic oil 2

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) W2CM-02-04-013
3. Remove the 2-unit gear pump mounting bolt (2)

and remove the 2-unit gear pump.
: 8 mm
W2-4-69
Installation
CAUTION: 2-unit gear pump weight: 4

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 Nm (2.2 to 2.9 kgfm)
(16 to 21 lbfft)
3. Install all hoses, pipes, and wire harness to the 2

2-unit gear pump.
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 8 mm
: 48 to 50 Nm (4.9 to 5.1 kgfm)
(35 to 37 lbfft)
W2CM-02-04-013
4. Remove hydraulic oil tank cover. Fill hydraulic oil

to specified level.

: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)

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.
: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)
W2-4-70
(Blank)
W2-4-71
DISASSEMBLE 2-UNIT GEAR PUMP
10
7
6
5 14
4
3
2 13
1 8 7
6
5
4 4
11
4 10
5
6
7 4
17
4
16
4
5
6
15

W2CM-02-04-014
1- Retaining Ring㩷 6- Gasket (4 Used)㩷 10 - Body㩷 14 - Body㩷

2- Oil Seal㩷 7- Side Plate (4 Used)㩷 11 - Adapter Plate㩷 15 - Rear Cover㩷
3- Front Cover㩷 8- Driven Gear㩷 12 - Driven Gear㩷 16 - Washer (4 Used)㩷
4- Bushing (8 Used) 9- Drive Gear㩷 13 - Drive Gear㩷 17 - Socket Bolt (4 Used)㩷
5- Gasket (4 Used)
W2-4-72
Disassemble 2-Unit Gear Pump

NOTE: Although gaskets (5, 6) and side plate (7) 9. Remove bushing (4), gaskets (5, 6) and side plate
are the same type, the directions to install (7).
are different. Attach an identification tag for
assembling. 10. Remove adapter plate (11).
The orders of driven gears (8, 12) are
symmetrical. Attach an identification tag 11. Remove bushing (4), gaskets (5, 6) and side plate
onto the shaft part when disassembling. (7).
1. Remove any dust and rust from the pump surface 12. Remove body (10).
with using the washing oil.
13. Remove bushing (4), gaskets (5, 6) and side plate
2. Face the rear cover (15) side upward.䎃Clamp the (7).
mounting part of front cover (3) in a vise.
14. Remove drive gear (9) and driven gear (8).
3. Put the matching marks on the matching part in 15. Remove front cover (3) from the vise.
the drive side of front cover (3), body (10),
adapter plate (11), body (14) and rear cover (15). 16. Remove retaining ring (1).
4. Remove socket bolt (17).
: 10 mm 17. Remove oil seal (2).
5. Remove rear cover (15).
6. Remove bushing (4), gaskets (5, 6) and side plate

2
(7).
8. Remove body (14).
W25N-02-04-018
W2-4-73
ASSEMBLE 2-UNIT GEAR PUMP
9 1 2 10 7 5 11 14 13 16 17
3 8 6 4 12 15 18 19

W2CM-02-04-015
1- Retaining Ring㩷 6- Gasket (4 Used)㩷 11 - Adapter Plate㩷 16 - Washer (4 Used)㩷

2- Oil Seal㩷 7- Side Plate (4 Used)㩷 12 - Driven Gear㩷 17 - Socket Bolt (4 Used)㩷
3- Front Cover㩷 8- Driven Gear㩷 13 - Drive Gear㩷 18 - Plug㩷
4- Bushing (8 Used)㩷 9- Drive Gear㩷 14 - Body㩷 19 - O-Ring㩷
5- Gasket (4 Used)㩷 10 - Body㩷 15 - Rear Cover㩷㩷
W2-4-74
Assemble 2-Unit Gear Pump
• 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.䎃
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. Delivery Side Suction Side㩷
Gears (8, 9, 12, 13) are asymmetrical.䎃䎃
Mesh the gears with small notch
each other and assemble them. Long
Short Pulling-Out
Pulling-Out
Hole㩷
Hole㩷
NOTE: Secure gaskets (5, 6) and side plate (7)
with applying grease in order not to twist
and bind.䎃
W25N-02-04-022
Align the matching marks and assemble
front cover (3), body (10), adapter plate Rotating Direction of
Drive Gear㩷
(11), body (14) and rear cover (15).䎃
Check the direction of mark and install Large Notch㩷
Small Notch
driven gears (8, 12). (No Bound Side)
(Bound Side)
1. Secure front cover (3) with the mounting surface

for body (10) facing upward in a vise. Delivery Suction
Side㩷 Side
2. Install bushing (4), gaskets (5, 6) and side plate
(7) on front cover (3).
3. Install body (10) to front cover (3). Rotating Direction of

Driven Gear㩷
W25N-02-04-023
W2-4-75
9 1 2 10 7 5 11 14 13 16 17
3 8 6 4 12 15 18 19

W2CM-02-04-015
W2-4-76
4. Install drive gear (9) and driven gear (8) onto body
(10).

(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).

(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 Nm (9.0 to 9.5 kgfm)
(65 to 69 lbfft)
2
12. Turn over the pump with the side where oil seal
(2) is installed facing upward. Clamp the pump in
Dust Lip
a vise.
Fill grease.
13. Fill grease main lip and dust lip in oil seal (2).
Main Lip
W25N-02-04-021
W2-4-77
IMPORTANT: Do not damage oil seal (2).
14. Install oil seal (2) to front cover (3) with using a
guide and pipe.
Pipe
Guide

W2CM-02-04-016

15. Install retaining ring (1).

W2CM-02-04-017
W2-4-78
REMOVE AND INSTALL GEAR PUMP FOR
HYD. TAGLINE


Apply each brake and the drum 1
lock.
W24X-02-04-001
Preparation
1. Stop the engine.䎃Operate the lever several times 2

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.
W2CM-02-04-018
: 8 mm
W2-4-79
Installation
2
CAUTION: Gear pump weight:
Approx. 2.3 kg (5.1 lb)
3
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.

: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)
W2CM-02-04-018

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.
: 36 mm
: 170 Nm (17.0 kgfm, 125 lbfft)
W2-4-80
(Blank)
W2-4-81
DISASSEMBLE GEAR PUMP FOR HYD. TAGLINE
9
3 8
1
14
13
12
11
10
6
7

W23F-02-04-012
1- Retaining Ring㩷 5- Gasket㩷 9- Drive Gear㩷 12 - Rear Cover㩷

2- Oil Seal㩷 6- Gasket (2 Used)㩷 10 - Bushing (2 Used)㩷 13 - Washer (4 Used)㩷
3- Front Cover㩷 7- Side Plate (2 Used)㩷 11 - 㪙㪸㫃㫃㩷(2 Used)㩷 14 - Socket Bolt (4 Used)㩷
4- Bushing (2 Used) 8- Driven Gear㩷㩷㩷
W2-4-82
Disassemble Gear Pump

NOTE: Although gaskets (6) and side plate (7) are 8. Remove gaskets (5, 6) and side plate (7).
the same type, the directions to install are
different. Attach an identification tag for 9. Remove ball (11) and bushing (4).
assembling.
The orders of driven gears (8) are
10. Remove front cover (3) from the vise.
symmetrical. Attach an identification tag
onto the shaft part when disassembling.
11. Remove retaining ring (1).
1. Remove any dust and rust from the pump surface
with using the washing oil. 12. Remove oil seal (2).
2. Face the rear cover (12) side upward.䎃Clamp the

mounting part of front cover (3) in a vise.
2
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
3
5. Remove rear cover (12).
6. Remove bushing (10), gaskets (6) and side plate

(7). W25N-02-04-018
W2-4-83
ASSEMBLE GEAR PUMP FOR HYD. TAGLINE

9 3 4 11 7 10
10
6
2
6 7 5 12 8 13 14

W23F-02-04-014
1- Retaining Ring㩷 5- Gasket㩷 9- Drive Gear㩷 12 - Rear Cover㩷

2- Oil Seal㩷 6- Gasket (2 Used)㩷 10 - Bushing (2 Used)㩷 13 - Washer (4 Used)㩷
3- Front Cover㩷 7- Side Plate (2 Used)㩷 11 - 㪙㪸㫃㫃㩷(2 Used)㩷 14 - Socket Bolt (4 Used)㩷
4- Bushing (2 Used) 8- Driven Gear㩷㩷㩷
W2-4-84
Assemble Gear Pump
• 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.䎃
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 Delivery Side Suction Side㩷
side.
Gears (8, 9) are asymmetrical.䎃䎃 Mesh
the gears with small notch each Pulling-Out Hole
other and assemble them.
NOTE: Secure gaskets (5, 6) and side plate (7)

with applying grease in order not to twist
W25N-02-04-022
and bind.䎃
Align the matching marks and assemble Rotating Direction of
Drive Gear㩷
front cover (3) and rear cover (12).䎃
Check the direction of mark and install Large Notch㩷
Small Notch
driven gears (8). (No Bound Side)
(Bound Side)
1. Secure front cover (3) with the mounting surface

for body (12) facing upward in a vise. Delivery Suction
Side㩷 Side
2. Install bushing (4) on front cover (3).
3. Install gaskets (5, 6) and side plate on front cover

(3). Rotating Direction of
Driven Gear㩷
W25N-02-04-023
W2-4-85
9 3 11 7 10
10
6
2
6 7 12 8 13 14

W23F-02-04-014
W2-4-86
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 Nm (9.0 to 9.5 kgfm)
(65 to 69 lbfft)
2
10. Turn over the pump with the side where oil seal
(2) is installed facing upward. Clamp the pump in Dust Lip
a vise.
Fill grease.
11. Fill grease main lip and dust lip in oil seal (2).
Main Lip
W25N-02-04-021
Pipe
IMPORTANT: Do not damage oil seal (2).
12. Install oil seal (2) to front cover (3) with using a
guide and pipe.
Guide

W2CM-02-04-016
W2-4-87
13. Install retaining ring (1).

W2CM-02-04-017
W2-4-88
CRANE UPPER / Control Valve
REMOVE AND INSTALL FRONT / REAR
4-UNIT CONTROL VALVE

Removal
1. Stop the engine. Operate the lever several times

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).

1
: 19 mm
3
CAUTION: Control valve (1) weight: 2
Approx. 80 kg (176 lb) 3
Control valve (2) weight:
W25N-02-05-001
4. Hoist and remove control valves (1, 2).
W2-5-1
Installation
CAUTION: Control valve (1) weight:

Control valve (2) weight:
1. Install control valves (1, 2) to the frame. Secure to

the frame with bolt (3).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
2. Install all hoses and pipes to control valves (1, 2).

: 22 mm 1
: 39 Nm (4.0 kgfm, 28.8 lbfft)
: 36 mm 3
: 175 Nm (18 kgfm, 129 lbfft) 2
: 8 mm
3
: 54 to 66 Nm
(5.5 to 6.7 kgfm, 40 to 49 lbfft) W25N-02-05-001
: 10 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
IMPORTANT: After completing the work, check the

oil level. Check for any oil leaks.
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE FRONT / REAR 4-UNIT
CONTROL VALVE
14 13 15 B 20 13 12
50 35 51 52
13 12
16
12 11 53
17
11 11
18 49
9 10 15 54
19
48
8 C 21
47 55
7
22 46 56
6 45
23 57
5 44 58
4 24 43 42
Section C㩷 59
3 25
2 E
1
7
26
60
27
41 30 35 28
40 28
36 30 29
14 27
18 31
11 61
17 32 Section E
12
39 37 16 11
13
38 12 13 19
13 12
11 34
F A D
33
76
62
62
85 34 9
63
37 75 63 63
74
39 63
73
64
84 77 64
64 72
83 78 64
71
82 65
36 70
67 38 41
32
81 62
69
80
66
Section B Section F
67
79
68 W2BC-02-05-002
Section A Section D
W2-5-4

1- Spring Washer (8 Used)㩷 23 - O-Ring (2 Used)㩷 44 - Plug (2 Used)㩷 65 - Plate㩷
2- Nut (8 Used)㩷 24 - O-Ring㩷 45 - Plug㩷 66 - Plug (4 Used)㩷
3- Bolt (4 Used)㩷 25 - Plug㩷 46 - O-Ring㩷 67 - O-Ring (10 Used)㩷
4- O-Ring (6 Used)㩷 26 - O-Ring (16 Used)㩷 47 - Spring㩷 68 - Plug (16 Used)㩷
5- O-Ring (6 Used)㩷 27 - O-Ring (2 Used)㩷 48 - Spring㩷 69 - Solenoid Valve (2 Used)㩷
6- O-Ring (12 Used)㩷 28 - Plug (2 Used)㩷 49 - Cover㩷 70 - Plug㩷
7- Valve Section㩷 29 - Plug (7 Used)㩷 50 - Socket Bolt (4 Used)㩷 71 - O-Ring㩷
8- Relief Valve㩷 30 - O-Ring (9 Used)㩷 51 - Spool㩷 72 - O-Ring㩷
9- Valve Section㩷 31 - Socket Bolt (4 Used)㩷 52 - Plug㩷 73 - Cover㩷
10 - Socket Bolt (16 Used)㩷 32 - Spool㩷 53 - Orifice㩷 74 - Socket Bolt (4 Used)㩷
11 - Spring (6 Used)㩷 33 - End Cover㩷 54 - Cover㩷 75 - O-Ring㩷
12 - Spring (6 Used)㩷 34 - Valve Section㩷 55 - Spring㩷 76 - Relief Valve㩷
13 - Spring Seat (6 Used)㩷 35 - Casing㩷 56 - Socket Bolt (4 Used)㩷 77 - Spring㩷
14 - End Cover (2 Used)㩷 36 - Spool㩷 57 - O-Ring (2 Used)㩷 78 - Check Valve㩷
15 - End Cover (3 Used)㩷 37 - Valve Section㩷 58 - Steel Ball㩷 79 - Solenoid Valve (2 Used)㩷
16 - End Cover (2 Used)㩷 38 - Spool㩷 59 - Filter㩷 80 - Air Bleeding Valve㩷
17 - Spring (2 Used)㩷 39 - Valve Section㩷 60 - O-Ring㩷 81 - Adapter㩷
18 - Spring (2 Used)㩷 40 - Plug (3 Used)㩷 61 - Plug㩷 82 - Plug㩷
19 - Spring Seat (2 Used)㩷 41 - Spool㩷 62 - O-Ring (14 Used)㩷 83 - O-Ring㩷
20 - Plug㩷 42 - Plug (2 Used)㩷 63 - O-Ring (4 Used)㩷 84 - O-Ring㩷
21 - Socket Bolt (12 Used)㩷 43 - O-Ring (2 Used)㩷 64 - Plug (4 Used)㩷 85 - Valve㩷
22 - Valve Section㩷㩷㩷㩷
W2-5-5
14 13 15 B 20 13 12
50 35 51
13 12
16
12 11
17
11 11
18 49
10 15
19
48
8 C 21
47
7
57
Section C㩷
E
41 30 35
40 36 30
14 18
11 17 32 Section E
12
11
13
38 12 13 19
13 12
11
F A D
33
36 41
38
69
Section B Section F
79
W2BC-02-05-002
Section A Section D

W2-5-6
Disassemble Front / Rear 4-Unit Control Valve
• 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: CAUTION: Do not damage the holes on

Approx. 80 kg (176 lb) spool and valve section.
1. Place the control valve assembly on a workbench. 8. Turn and remove spools (32, 36, 38 and 41) from
each valve section.
IMPORTANT: Do not loosen the adjusting screw in NOTE: Do not remove plugs (20) and (40) (3 used)
solenoid valves (69, 79). from spools (32, 38, 41) unless necessary.
2. Remove solenoid valves (69, 79) (2 used for
each) from end covers (15) (3 used) and (33). 9. Remove socket bolts (50) (4 used). Remove
: 32 mm cover (49), springs (47, 48) and O-ring (57) from
casing (35).
3. Remove socket bolts (10) (16 used) and (21) (14 : 8 mm
used). Remove end covers (14) (2 used), (15) (3
used), (16) and (33) from each valve section.
: 5 mm CAUTION: Do not damage the holes on
spool (51) and casing (35).
4. Remove spring seat (13) (2 used), springs (11,
12) (2 used for each) and O-rings (30) (2 used) 10. Turn and remove the spool (51) assembly from
from end covers (14) (2 used). casing (35).
5. Remove spring seat (19) (2 used), springs (17, IMPORTANT: Do not disassemble relief valve (8).
18) (2 used for each) and O-rings (30) (2 used) 11. Remove relief valve (8) from valve section (7).
from end covers (16) (2 used). : 30 mm
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,

from end covers (15, 33).
W2-5-7
B
35
9 54
C
7
22 56
6
23 57
5
4
Section C㩷
3
2 E
1 7
26
35
Section E
39 37
34
F A D
76
85 34 9
63
37 63 63
39 63
64
84 77 64
64 72 64
83 78
71
82
70
Section B Section F
W2BC-02-05-002
Section A Section D

W2-5-8
IMPORTANT: Do not disassemble relief valve (76). 20. Turn over the control valve.
12. Remove relief valve (76) from valve section (34).
: 30 mm 21. Remove nuts (2) (4 used) and spring washers (1)
(4 used).䎃 Remove bolts (3) (4 used) from each
13. Remove valve (85) from valve section (39). valve section.
: 24 mm
14. Remove plugs (82, 70) from valve sections (39,
34). 22. Divide into each valve section (7, 9, 22, 34, 37,
: 30 mm 39) and casing (3).
15. Remove O-rings (84, 72, 83, 71) from plugs (82, 23. Remove O-rings (4) (6 used), (5) (6 used), (6) (12
70). used), (23) (2 used) and (26) (16 used) from each
valve section (7, 9, 22, 34, 37, 39) and casing
16. Turn over the control valve. Remove plugs (64) (4 (35).
used).
41 mm
17. Remove check valve (78) and spring (77) from

valve section (37).
18. Remove O-rings (63) (4 used) from plugs (64) (4

used).
19. Remove socket bolts (56) (4 used). Remove

cover (54) and O-ring (57) from casing (35).
: 8 mm
W2-5-9
ASSEMBLE FRONT / REAR 4-UNIT
CONTROL VALVE
14 13 15 B 20 13 12
50 35 51 52
13 12
16
12 11 53
17
11 11
18 49
9 10 15 54
19
48
8 C 21
47 55
7
22 46 56
6 45
23 57
5 44 58
4 24 43 42
Section C㩷 59
3 25
2 E
1
7
26
60
27
41 30 35 28
40 28
36 30 29
14 27
18 31
11 61
17 32 Section E
12
39 37 16 11
13
38 12 13 19
13 12
11 34
F A D
33
76
62
62
85 34 9
63
37 75 63 63
74
39 63
73
64
84 77 64
64 72
83 78 64
71
82 65
36 70
67 38 41
32
81 62
69
80
66
Section B Section F
67
79
68 W2BC-02-05-002
Section A Section D

W2-5-10

1- Spring Washer (8 Used)㩷 23 - O-Ring (2 Used)㩷 44 - Plug (2 Used)㩷 65 - Plate㩷
2- Nut (8 Used)㩷 24 - O-Ring㩷 45 - Plug㩷 66 - Plug (4 Used)㩷
3- Bolt (4 Used)㩷 25 - Plug㩷 46 - O-Ring㩷 67 - O-Ring (10 Used)㩷
4- O-Ring (6 Used)㩷 26 - O-Ring (16 Used)㩷 47 - Spring㩷 68 - Plug (16 Used)㩷
5- O-Ring (6 Used)㩷 27 - O-Ring (2 Used)㩷 48 - Spring㩷 69 - Solenoid Valve (2 Used)㩷
6- O-Ring (12 Used)㩷 28 - Plug (2 Used)㩷 49 - Cover㩷 70 - Plug㩷
7- Valve Section㩷 29 - Plug (7 Used)㩷 50 - Socket Bolt (4 Used)㩷 71 - O-Ring㩷
8- Relief Valve㩷 30 - O-Ring (9 Used)㩷 51 - Spool㩷 72 - O-Ring㩷
9- Valve Section㩷 31 - Socket Bolt (4 Used)㩷 52 - Plug㩷 73 - Cover㩷
10 - Socket Bolt (16 Used)㩷 32 - Spool㩷 53 - Orifice㩷 74 - Socket Bolt (4 Used)㩷
11 - Spring (6 Used)㩷 33 - End Cover㩷 54 - Cover㩷 75 - O-Ring㩷
12 - Spring (6 Used)㩷 34 - Valve Section㩷 55 - Spring㩷 76 - Relief Valve㩷
13 - Spring Seat (6 Used)㩷 35 - Casing㩷 56 - Socket Bolt (4 Used)㩷 77 - Spring㩷
14 - End Cover (2 Used)㩷 36 - Spool㩷 57 - O-Ring (2 Used)㩷 78 - Check Valve㩷
15 - End Cover (3 Used)㩷 37 - Valve Section㩷 58 - Steel Ball㩷 79 - Solenoid Valve (2 Used)㩷
16 - End Cover (2 Used)㩷 38 - Spool㩷 59 - Filter㩷 80 - Air Bleeding Valve㩷
17 - Spring (2 Used)㩷 39 - Valve Section㩷 60 - O-Ring㩷 81 - Adapter㩷
18 - Spring (2 Used)㩷 40 - Plug (3 Used)㩷 61 - Plug㩷 82 - Plug㩷
19 - Spring Seat (2 Used)㩷 41 - Spool㩷 62 - O-Ring (14 Used)㩷 83 - O-Ring㩷
20 - Plug㩷 42 - Plug (2 Used)㩷 63 - O-Ring (4 Used)㩷 84 - O-Ring㩷
21 - Socket Bolt (12 Used)㩷 43 - O-Ring (2 Used)㩷 64 - Plug (4 Used)㩷 85 - Valve㩷
22 - Valve Section㩷㩷㩷㩷
W2-5-11
14 13 B 13 12
50 35 51
13 12
12 11
11 11
49
9 54
48
C
47
7
22 56
6
5 57
4
Section C㩷
3
2 E
1 7
26
27
41 30 35
36 30
14 27
11
32 Section E
12
39 37 11
13
38 12 13
13 12
11 34
F A D
34 9
63
37 63 63
39 63
64
84 77 64
64 72 64
83 78
71
82
36 70
38 41
32
Section B Section F
W2BC-02-05-002
Section A Section D

W2-5-12
Assemble Front / Rear 4-Unit Control Valve
1. Install O-rings (4, 5) (6 used for each), (6) (12 9. Install plug (70) to valve section (34).
used), (27) (2 used) and (26) (16 used) to each : 30 mm
valve section (7, 9, 22, 34, 37, 39) and casing : 75r50 Nm (8.0r5.1 kgfm, 55r37 lbfft)
(35).
10. Install plug (82) to valve section (39).
2. Arrange each valve section (7, 9, 39, 37), casing : 30 mm
(35) and valve sections (34, 22) in this order. : 110r10 Nm (11.2r1.0 kgfm, 81r7.4 lbfft)
3. Install bolts (3) (4 used) to each valve section (7,

CAUTION: Do not damage the holes on
9, 39, 37), casing (35) and valve sections (34, 22).䎃
Tighten spring washers (1) (4 used) with nuts (2) spool and valve section.
(4 used).
: 24 mm IMPORTANT: Check the inserting positions for
: 110r10 Nm (11.2r1.0 kgfm, 81r7.4 lbfft) spool (32, 36, 38, 41).
11. Insert spools (32, 36, 38, 41) into valve sections
4. Turn over the control valve. Install check valve (34, 37, 39, 9).
(78) and spring (77) to valve section (37).
5. Install O-rings (63) (4 used) to plugs (64) (4 used). spool (51) and casing (35).
Install to valve sections (9, 39, 37, 34).
: 41 mm 12. Insert the spool (51) assembly into casing (35).
: 200r10 Nm (20r1.0 kgfm, 148r7.4 lbfft) Install springs (47, 48) to spool (51).
6. Install O-ring (57) and cover (54) onto casing (35). 13. Install O-ring (57) to casing (35). Install cover (49)
Install cover (54) onto casing (35) with socket onto casing (35). Install cover (49) to casing (35)
bolts (56) (4 used). with socket bolts (50) (4 used).
: 8 mm
7. Turn over the control valve. : 57r6.0 Nm (5.8r0.6 kgfm, 42r4.4 lbfft)
8. Install O-rings (71, 83, 72, 84) to plugs (70, 82). 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).

W2-5-13
14 13 15 B 13 12
13 12
16
12 11
17
11 11
18
9 10 15
8 C 21
7
Section C㩷
E
30
30
14 18 31
11 17 Section E
12
39 37 16 11
13
12 13
13 12
11 34
F A D
33
76
62
62
85 34 9
37
39
65
62
69
Section B Section F
79
W2BC-02-05-002
Section A Section D

W2-5-14
15. Install the end cover (14) assemblies (2 used) to 23. Install relief valve (8) to valve section (7).
valve section (9). Install end cover (14) to valve : 30 mm
section (9) with socket bolts (10) (4 used). : 74r5.0 Nm
: 5 mm (7.5r0.5 kgfm, 54.6r3.7 lbfft)
: 21r1 Nm (2.1r0.1 kgfm, 15r0.7 lbfft)
24. Install relief valve (76) to valve section (34).
16. Install O-rings (30) (3 used), (62) (6 used), springs : 30 mm
(11, 12) (3 used for each) and spring seats (13) (3 : 74r5.0 Nm
used) to end covers (15) (3 used). (7.5r0.5 kgfm, 54.6r3.7 lbfft)
17. Install the end cover (15) assemblies (3 used) to 25. Install valve (85) to valve section (39).
valve sections (34, 39). Install end covers (15) (3 : 30 mm
used) to valve sections (34, 39) with socket bolts : 110r10 Nm
(21) (6 used). (11.2r1.0 kgfm, 81.1r7.4 lbfft)
: 5 mm
: 16r1.0 Nm (1.6r0.1 kgfm, 11.8r0.7 lbfft) 26. Install solenoid valves (69, 79) (2 used for each)
to end covers (15) (3 used) and (33).
: 32 mm
18. Install O-rings (30) (2 used), springs (17, 18) (2 : 44r5.0 Nm
used for each) and spring seats (19) (2 used) to (4.5r0.5 kgfm, 32.5r3.7 lbfft)

19. Install end covers (16) (2 used) assembly to valve
section (37) with socket bolts (10) (4 used).
: 5 mm
: 12r1.0 Nm (1.2r0.1 kgfm, 8.9r0.7 lbfft)
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
: 12r1.0 Nm (1.2r0.1 kgfm, 8.9r0.7 lbfft)
W2-5-15
(Blank)
W2-5-16
REMOVE AND INSTALL 4-UNIT CONTROL
VALVE

Removal

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 1
2
W2BC-02-05-001
4. Hoist and remove control valve (1).
W2-5-17
Installation

1. Install control valve (1) to the frame with bolts (2)

(3 used).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
2. Install all hoses and harness connectors to control

valve (1).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft) 1
: 27 mm
2
: 93 Nm (9.5 kgfm, 69 lbfft)
W2BC-02-05-001
W2-5-18
(Blank)
W2-5-19
DISASSEMBLE 4-UNIT CONTROL VALVE
8 9 10
11
1 2 12
3 4 14
13
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
19
W2BC-02-05-003
27
25 26 28
8
24 29
30
23
31
22
32
21
33
34 43
W2BC-02-05-005
20
Section B 42
41
40
35 36 37 38 39
W2BC-02-05-006
Section C
W2-5-20
1- Spool㩷 12 - Spring Seat (8 Used)㩷 23 - Spring㩷 34 - Relief Valve (2 Used)㩷

2- End Section 1㩷 13 - O-Ring (8 Used)㩷 24 - O-Ring (4 Used)㩷 35 - Solenoid (8 Used)㩷
3- Spring㩷 14 - Spring Washer (4 Used)㩷 25 - Plug (4 Used)㩷 36 - Spring (8 Used)㩷
4- Plug (10 Used)㩷 15 - Nut (4 Used)㩷 26 - O-Ring (18 Used)㩷 37 - O-Ring (8 Used)㩷
5- O-Ring㩷 16 - Bolt (4 Used)㩷 27 - Plug (2 Used)㩷 38 - Spool (8 Used)㩷
6- Plug㩷 17 - End Section 2㩷 28 - O-Ring (2 Used)㩷 39 - O-Ring (8 Used)㩷
7- Relief Valve㩷 18 - Plate㩷 29 - O-Ring (2 Used)㩷 40 - Plug (8 Used)㩷
8- Casing (2 Used)㩷 19 - Spool (4 Used)㩷 30 - Check Valve (4 Used)㩷 41 - Plug (24 Used)㩷
9- Casing (2 Used)㩷 20 - O-Ring (22 Used)㩷 31 - Spring (4 Used)㩷 42 - Socket Bolt (32 Used)㩷
10 - End Cover (8 Used)㩷 21 - O-Ring (6 Used)㩷 32 - Plug (4 Used)㩷 43 - O-Ring (16 Used)㩷
11 - Spring (8 Used)㩷 22 - Spool㩷 33 - O-Ring (4 Used)㩷㩷
W2-5-21
8 9 10
11
1 2 12
3 4 14
13
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
19
W2BC-02-05-003
C C
27
25 26 28
8
24 29
30
23
31
22
32
21
33
34 43
W2BC-02-05-005
20
Section B 42
41
40
35 36 37 38 39
W2BC-02-05-006
Section C
W2-5-22
Disassemble 4-Unit Control Valve
The disassembling and assembling procedures of 8. Remove spring seat (12) (8 used), springs (11) (8
4-spool control valves for counterweight, left travel used) and O-rings (13) (8 used) from end covers
motor and quick draw are explained here. (10) (8 used).
CAUTION: Control valve weight: CAUTION: Do not damage the holes on

Approx. 22 kg (49 lb) casings (8, 9).
1. Place the control valve assembly on a workbench. 9. Turn and remove spools (19) (4 used) from
IMPORTANT: Do not loosen the adjusting screw in casings (8, 9).

solenoid (35).
2. Remove solenoids (35) (8 used) from end covers 10. Remove plugs (32) (4 used) from casings (8, 9).
(10) (8 used). Remove O-rings (37) (8 used) from Remove O-rings (33) (4 used) from plugs (32) (4
solenoids (35) (8 used). used).
: 32 mm : 41 mm
IMPORTANT: Do not disassemble relief valve (34). 11. Remove springs (31) (4 used) and check valves
3. Remove relief valves (34) (2 used) from casings (30) (4 used) from casings (8, 9).
(8) (2 used).
: 30 mm 12. Remove plugs (27) (2 used) from casings (8) (2
used).䎃 Remove O-rings (28, 29) (2 used for
4. Remove plugs (40) (8 used) from end cover (10). each) from plugs (27) (2 used).
Remove O-rings (39) (8 used) from plugs (40) (8 : 30 mm
used).
: 5 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).
CAUTION: Do not damage the hole on end
: 8 mm
cover (10).
14. Remove springs (3, 33) from end section 1 (2).
5. Remove spools (38) (8 used) and springs (36) (8
used) from end covers (10) (8 used). 15. Remove plugs (25) (2 used) from the lower
surface of end section 1 (2). Remove O-rings (24)
6. Remove plugs (14) (16 used) from end covers (2 used) from plugs (25) (2 used).
(10) (8 used). : 8 mm
: 5 mm
7. Remove socket bolt (42). Remove end covers

(10) (8 used) from casings (8, 9) (2 used for
each).
: 4 mm
W2-5-23
8 9
4
1 2
4 14
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
W2BC-02-05-003
C C
26
22
21
W2BC-02-05-005
20
Section B
W2BC-02-05-006
Section C
W2-5-24
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).
W2-5-25
ASSEMBLE 4-UNIT CONTROL VALVE
8 9 10
11
1 2 12
3 4 14
13
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
19
W2BC-02-05-003
C C
27
25 26 28
8
24 29
30
23
31
22
32
21
33
34 43
W2BC-02-05-005
20
Section B 42
41
40
35 36 37 38 39
W2BC-02-05-006
Section C
W2-5-26
1- Spool㩷 12 - Spring Seat (8 Used)㩷 23 - Spring㩷 34 - Relief Valve (2 Used)㩷

2- End Section 1㩷 13 - O-Ring (8 Used)㩷 24 - O-Ring (4 Used)㩷 35 - Solenoid (8 Used)㩷
3- Spring㩷 14 - Spring Washer (4 Used)㩷 25 - Plug (4 Used)㩷 36 - Spring (8 Used)㩷
4- Plug (10 Used)㩷 15 - Nut (4 Used)㩷 26 - O-Ring (18 Used)㩷 37 - O-Ring (8 Used)㩷
5- O-Ring㩷 16 - Bolt (4 Used)㩷 27 - Plug (2 Used)㩷 38 - Spool (8 Used)㩷
6- Plug㩷 17 - End Section 2㩷 28 - O-Ring (2 Used)㩷 39 - O-Ring (8 Used)㩷
7- Relief Valve㩷 18 - Plate㩷 29 - O-Ring (2 Used)㩷 40 - Plug (8 Used)㩷
8- Casing (2 Used)㩷 19 - Spool (4 Used)㩷 30 - Check Valve (4 Used)㩷 41 - Plug (24 Used)㩷
9- Casing (2 Used)㩷 20 - O-Ring (22 Used)㩷 31 - Spring (4 Used)㩷 42 - Socket Bolt (32 Used)㩷
10 - End Cover (8 Used)㩷 21 - O-Ring (6 Used)㩷 32 - Plug (4 Used)㩷 43 - O-Ring (16 Used)㩷
11 - Spring (8 Used)㩷 22 - Spool㩷 33 - O-Ring (4 Used)㩷㩷
W2-5-27
8 9 10
11
1 2 12
3 4 14
13
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
19
W2BC-02-05-003
C C
27
25 26 28
8
24 29
30
23
31
22
32
21
33
34 43
W2BC-02-05-005
20
Section B 42
41
40
35 36 37 38 39
W2BC-02-05-006
Section C
W2-5-28
Assemble 4-Unit Control Valve
1. Install O-rings (20) (2 used), (21) (6 used) and IMPORTANT: Do not loosen the adjusting screw in
(26) (18 used) to end section 1 (2), casings (8, 9) relief valve (7).
(2 used for each) and plate (18). 6. Install relief valve (7) to end section 1 (2).
: 22 mm
2. Install casings (8, 9) (2 used for each), plate (18) : 41 to 47 Nm
and end section 2 (17) to bolts (16) (4 used) with (4.2 to 4.8 kgfm, 30 to 35 lbfft)
end section 1 (2) attached in this order.䎃 Install
spring washers (14) (4 used) to bolts (16) (4 used) 7. Install O-rings (24) (2 used) onto plugs (25) (2
and tighten with nuts (15) (4 used). used). Install plugs (25) (2 used) to the lower
: 13 mm surface of end section 1 (2).
: 20 to 25 Nm : 8 mm
(2.0 to 2.6 kgfm, 14.8 to 18.4 lbfft) : 69 to 78 Nm
(7.0 to 8.0 kgfm, 51 to 58 lbfft)
3. Wind the seal tape onto plugs (4) (4 used). Install
plugs (4) (4 used) to end section 2 (17). IMPORTANT: Check the position and direction to
: 4 mm insert spools (1, 22).
: 7.8 to 9.8 Nm 8. Install spools (1, 22) and springs (3, 23) from the
(0.8 to 1.0 kgfm, 5.8 to 7.2 lbfft) upper side of end section 1 (2).
4. Wind the seal tape onto plug (4). Install plugs (4) 9. Install O-rings (24) (2 used) onto plugs (25) (2
(6 used) to end section 1 (2). used). Install plugs (25) (2 used) to end section 1
: 4 mm (2).
: 7.8 to 9.8 Nm : 8 mm
(0.8 to 1.0 kgfm, 5.8 to 7.2 lbfft) : 69 to 78 Nm
(7.0 to 8.0 kgfm, 51 to 58 lbfft)
5. Install O-ring (5) to plug (6). Install plug (6) to end
section 1 (2). 10. Install O-rings (28, 29) (2 used for each) to plugs
: 6 mm (27) (2 used).
: 34 to 38 Nm
(3.5 to 3.9 kgfm, 25 to 28 lbfft) 11. Install plugs (27) (2 used) to casings (8) (2 used).
: 30 mm
: 39 to 49 Nm
(4.0 to 5.0 kgfm, 29 to 36 lbfft)
W2-5-29
8 9 10
11
1 2 12
3 4 14
13
15
16
5
17
6 18
7
W2BC-02-05-004 A
Section A
19
W2BC-02-05-003
C C
27
25 26 28
8
24 29
30
23
31
22
32
21
33
34 43
W2BC-02-05-005
20
Section B 42
41
40
35 36 37 38 39
W2BC-02-05-006
Section C
W2-5-30
12. Install check valves (30) (4 used) and springs (31) 20. Install relief valves (34) (2 used) to casings (8) (2
(4 used) to casings (8, 9) (2 used for each). used).
: 30 mm
13. Install O-rings (33) (4 used) onto plugs (32) (4 : 69 to 79 Nm
used). Install plugs (32) (4 used) to casings (8, 9) (7.0 to 8.0 kgfm, 51 to 58 lbfft)
(2 used for each).
: 41 mm IMPORTANT: Do not loosen the adjusting screw in
: 49 to 59 Nm solenoid (35).
(5.0 to 6.0 kgfm, 36 to 44 lbfft) Check the position to install
solenoid (35).
IMPORTANT: Check the direction to insert spools 21. Install O-rings (37) (8 used) to solenoids (35) (8
(19) (4 used). used). Install solenoids (35) (8 used) to end
14. Install spools (19) (4 used) to casings (8, 9) (2 covers (10) (8 used).
used for each). : 32 mm
: 39 to 49 Nm
15. Install springs (11) (8 used), spring seat (12) (8 (4.0 to 5.0 kgfm, 29 to 36 lbfft)
used), O-rings (13) (8 used) and (43) (16 used) to
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 Nm
(0.6 to 0.8 kgfm, 4.4 to 5.8 lbfft)
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 Nm
(0.8 to 1.1 kgfm, 6.1 to 8.1 lbfft)
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 Nm
(1.3 to 1.7 kgfm, 9.6 to 12.6 lbfft)
19. Install springs (36) (8 used) and spools (38) (8

used) to end covers (10) (8 used).
W2-5-31
(Blank)
W2-5-32
VALVE

Removal

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.
1
Remove bolts (2) (3 used).
: 19 mm
2
W25N-02-05-003
4. Hoist and remove control valve (1).
W2-5-33
Installation

1. Install control valve (1) to the frame with bolts (2)

(3 used).
: 19 mm
: 90 Nm (9.2 kgfm)
2. Install all hoses and pipes to control valve (1).

: 8 mm
: 50 Nm (5.1 kgfm, 36.9 lbfft)
: 10 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
: 22 mm 1
: 69 Nm (7.0 kgfm, 51 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft) 2
: 41 mm W25N-02-05-003
: 205 Nm (21 kgfm, 151.2 lbfft)

W2-5-34
(Blank)
W2-5-35
1 22 9 15 18 11 17 14 2
8 21
20
10
24
23
25
13
12
3 16 18 17 19
Section C
W25N-02-05-004
1- Inlet Section㩷 8 - O-Ring (2 Used)㩷 14 - O-Ring (2 Used)㩷 20 - Cap㩷

2- Outlet Section㩷 9 - O-Ring (4 Used)㩷 15 - Socket Bolt (4 Used)㩷 21 - O-Ring㩷
3- Valve Section㩷 10 - O-Ring (2 Used)㩷 16 - Spool㩷 22 - Relief Valve㩷
4- Plug㩷 11 - End Cover (2 Used)㩷 17 - Spring (2 Used)㩷 23 - Bolt (4 Used)㩷
5- Plug㩷 12 - Plug (2 Used)㩷 18 - Spring (2 Used)㩷 24 - Nut (8 Used)㩷
6- O-Ring㩷 13 - O-Ring (2 Used)㩷 19 - Spring Seat (2 Used)㩷 25 - Spring Washer (8 Used)㩷
7- O-Ring㩷㩷㩷㩷
W2-5-36
CAUTION: Control valve weight: 8. Turn over the control valve. Remove cap (20).
Approx. 38 kg (84 lb) : 41 mm
1. Place the control valve assembly on a workbench. 9. Remove O-ring (21) from cap (20).
2. Remove socket bolts (15) (4 used). Remove end 10. Turn over the control valve.
covers (11) (2 used) from valve section (3).
: 5 mm 11. Remove nuts (24) (4 used). Remove bolts (23) (4
used) from inlet section (1) and outlet section (2).
3. Remove spring seats (19) (2 used), springs (17, : 24 mm
from end covers (11) (2 used). 12. Divide each section into inlet section (1), valve
section (3) and outlet section (2).
13. Remove O-rings (8) (2 used), (9)(4 used) and (10)
spool (16) and valve section (3). (2 used) from valve section (3) and outlet section
(2).
4. Turn and remove spool (16) from valve section
(3).
IMPORTANT: Do not disassemble relief valve (22).

5. Remove relief valve (22) from inlet section (1).
: 30 mm
6. Remove plug (4) from plug (5). Remove O-ring (6)

from plug (4).
: 6 mm
7. Remove plug (5) from inlet section (1). Remove

: 21 mm
W2-5-37
1 22 9 15 18 11 17 14 2
8 21
20
10
24
23
25
13
12
3 16 18 17 19
Section C
W25N-02-05-004
1- Inlet Section㩷 8 - O-Ring (2 Used)㩷 14 - O-Ring (2 Used)㩷 20 - Cap㩷

2- Outlet Section㩷 9 - O-Ring (4 Used)㩷 15 - Socket Bolt (4 Used)㩷 21 - O-Ring㩷
3- Valve Section㩷 10 - O-Ring (2 Used)㩷 16 - Spool㩷 22 - Relief Valve㩷
4- Plug㩷 11 - End Cover (2 Used)㩷 17 - Spring (2 Used)㩷 23 - Bolt (4 Used)㩷
5- Plug㩷 12 - Plug (2 Used)㩷 18 - Spring (2 Used)㩷 24 - Nut (8 Used)㩷
6- O-Ring㩷 13 - O-Ring (2 Used)㩷 19 - Spring Seat (2 Used)㩷 25 - Spring Washer (8 Used)㩷
7- O-Ring㩷㩷㩷㩷
W2-5-38
1. Install O-rings (8) (2 used), (9) (4 used) and (10)

(2 used) to valve section (3) and outlet section (2). 9. Install O-ring (14), springs (17, 18) (2 used for
each) and spring seats (19) (2 used) to end
2. As for each section, arrange inlet section (1), covers (11) (2 used).
valve section (3) and outlet section (2) in this
order. 10. Install the end cover (11) assemblies (2 used) to
valve section (3). Tighten the end cover (11)
3. Install bolts (23) (4 used) to each section. Tighten assemblies (2 used) with socket bolt (15).
to bolts (23) (4 used) with spring washers (25) (4 : 5 mm
used) and nuts (24) (4 used). : 11 to 13 Nm
: 24 mm (1.1 to 1.3 kgfm, 8.1 to 9.6 lbfft)
: 100 to 120 Nm
(10 to 12 kgfm, 74 to 89 lbfft) 11. Install O-rings (2 used) to relief valve (22). Install
to inlet section (1).
4. Turn over the control valve. Install O-ring (21) to : 30 mm
cap (20). Install cap (20) to valve section (3). : 120 to 140 Nm
: 41 mm (12 to 14 kgfm, 89 to 103 lbfft)
: 190 to 210 Nm
(19 to 21.5 kgfm, 140 to 155 lbfft)
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 Nm
(38 to 42 kgfm, 273 to 302 lbfft)
7. Install O-ring (6) to plug (4). Install plug (4) to plug

(5).
: 6 mm
: 34 to 38 Nm
(3.5 to 3.9 kgfm, 25 to 28 lbfft)

spool (16) and valve section (3).
8. Insert spool (16) into valve section (3).
W2-5-39
(Blank)
W2-5-40
REMOVE AND INSTALL WINCH DRUM
CONTROL VALVE (OPTIONAL)

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

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.
W2BC-02-05-007
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
2
1
2
Installation
4
CAUTION: Winch drum control valve weight: 4

6
40 kg (88 lb)
1. Hoist and install winch drum control valve (3) with

bolts (2) (4 used)
5 2 4 3 4 2 5
: 19 mm W2BC-02-05-008
: 90 Nm (9.2 kgfm, 66 lbfft)
2. Install pipes (4 used) with bolts (4)

: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
3. Install elbows (5) (2 used) to winch drum control

valve (3).
: 19 mm
: 27 to 33 Nm
(2.8 to 3.4 kgfm, 20 to 24.5 lbfft)
4. Install bracket (6) with bolt (1)

: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
W2-5-41
DISASSEMBLE WINCH DRUM CONTROL VALVE
1 32 26 27 28 15 23 21 7 38
29
12
31
11
4
30
13
35
34
33
36 9
37 10
6
20 22
16
18
24
17
20

19
3 25 26 27 28 14 5 8
39
W2BC-02-05-009
1- Inlet Section 11 - O-Ring 21 - O-Ring 31 - O-Ring

2- Outlet Section 12 - O-Ring 22 - O-Ring 32 - Relief Valve
3- Valve Section 13 - O-Ring 23 - Socket Bolt 33 - Bolt
4- Plug 14 - O-Ring 24 - Solenoid Valve 34 - Nut
5- Plug 15 - Cover 25 - Spool 35 - Spring Washer
6- Plug 16 - Valve Seat 26 - Spring 36 - Plate
7- Plug 17 - Plug 27 - Spring 37 - Pin
8- O-Ring 18 - Plug 28 - Spring Seat 38 - Band
9- O-Ring 19 - Plug 29 - Valve 39 - Band
10 - O-Ring 20 - O-Ring 30 - Cap
W2-5-42
Disassemble Winch Drum Control Valve
• These procedures are explained for disassembly

and assembly of winch drum control valve for
optional winch drum.
CAUTION: Control valve weight: 40 kg (88 lb)
1. Place the control valve assembly on a clean

workbench.
IMPORTANT: Do not loosen the adjusting screw in

solenoid valve (24).
2. Remove solenoid valve (24) from covers (15) (2
used)
: 32 mm
3. Remove socket bolts (23). (8 used) Remove end

covers (15) (2 used), from each valve section.
: 5 mm
4. Remove spring seat (28), spring (26, 27) and

O-ring (21) (2 used) and O-ring (22) (4 used) from

spool and valve section.
5. Remove spool (25) from valve section (3).
6. Remove relief valve (32) from inlet section (1).

: 30 mm
NOTE: Do not disassemble relief valve (32).
W2-5-43
1 32 26 27 28 15 23 21 7 38
29
12
31
11
4
30
13
35
34
33
36 9
37 10
6
20 22
16
18
24
17
20
19
3 25 26 27 28 14 5 8
39
W2BC-02-05-009
W2-5-44
7. Remove valve (29) from valve section (3).䎃
8. Remove plugs (5, 6) from valve sections (2, 3).

: 30 mm
9. Remove O-rings (8, 9, 10) from plugs (5, 6).
10. Turn over the control valve. Remove caps (30)

from valve section (3).
: 41 mm
11. Remove O-ring (31) from caps (30).
13. Remove nut (34) and remove bolts (33) (4 used)

from valve section
: 24 mm
14. Divide each section into inlet section (1), valve

sections (3) and outlet section (2).
15. Remove O-rings (11) (2 used), (12) (4 used), (13)

(2 used), (14) (8 used) from each section.
W2-5-45
ASSEMBLE WINCH DRUM CONTROL VALVE
1 32 26 27 28 15 23 21 7 38
29
12
31
11
4
30
13
35
34
33
36 9
37 10
6
20 22
16
18
24
17
20
19
3 25 26 27 28 14 5 8
39
W2BC-02-05-009
1- Inlet Section 11 - O-Ring 21 - O-Ring 31 - O-Ring

2- Outlet Section 12 - O-Ring 22 - O-Ring 32 - Relief Valve
3- Valve Section 13 - O-Ring 23 - Socket Bolt 33 - Bolt
4- Plug 14 - O-Ring 24 - Solenoid Valve 34 - Nut
5- Plug 15 - Cover 25 - Spool 35 - Spring Washer
6- Plug 16 - Valve Seat 26 - Spring 36 - Plate
7- Plug 17 - Plug 27 - Spring 37 - Pin
8- O-Ring 18 - Plug 28 - Spring Seat 38 - Band
9- O-Ring 19 - Plug 29 - Valve 39 - Band
10 - O-Ring 20 - O-Ring 30 - Cap
W2-5-46
Assemble Winch Drum Control Valve
1. Install O-rings (11) (2 used), (12) (4 used), (13) (2

used), (14) (8 used) to each section.
2. As for each section, arrange inlet section (1),

valve section (2) and outlet section (2) in this
order.
3. Install bolts (33) (4 used) to each section. Install

spring washer (35) (4 used) and tighten with nut
(34) (4 used).
: 24 mm
: 100 to 120 Nm
(10 to 12 kgfm, 74 to 89 lbfft)
4. Install O-ring (31) onto caps (30) 䎃 Install cap (30)

onto valve sections (3).
: 41 mm
: 190 to 210 Nm
(19 to 21.5 kgfm, 140 to 155 lbfft)
6. Install O-rings (8, 9, 10) onto plugs (5, 6).
7. Install plug (5) on valve section (2).

: 30 mm
: 70 to 80 Nm
(7.1 to 8.2 kgfm, 52 to 59 lbfft)
8. Install plug (6) on valve section (3).

: 30 mm
: 100 to 120 Nm

spool and valve section.
9. Insert spool (25) into valve sections (3).䎃
W2-5-47
1 32 26 27 28 15 23 21 7 38
29
12
31
11
4
30
13
35
34
33
36 9
37 10
6
20 22
16
18
24
17
20
19
3 25 26 27 28 14 5 8
39
W2BC-02-05-009
W2-5-48
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 Nm
(1.5 to 1.7 kgfm, 11 to 12.5 lbfft)
12. Install relief valve (32) to inlet section (1).

: 30 mm
: 69 to 79 Nm
(7.0 to 8.1 kgfm, 51 to 58 lbfft)
13. Install valve (29) to valve section (3).

: 30 mm
: 100 to 120 Nm
14. Install solenoid valve (24) to end covers (15)

(2 used).
: 32 mm
: 39 to 49 Nm
(4.0 to 5.0 kgfm, 28.5 to 36 lbfft)
W2-5-49
(Blank)
W2-5-50
CRANE UPPER / Swing Reduction Unit
REMOVE AND INSTALL SWING
REDUCTION UNIT

Preparation

Removal
1. Remove hoses (1 to 10) from the swing reduction

unit. Cap the removed hoses. 10 8
: 22 mm 7 4 1
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm 2
: 93 Nm (9.5 kgfm, 69 lbfft) 3
9
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)
2. Remove bolt (11).

: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)
5
11 6
CAUTION: Swing reduction unit assembly W25N-02-06-001
weight: 219 kg (490 lb)
3. Hoist and remove the swing reduction unit.
W2-6-1
Installation
NOTE: Refer to the Removal section for the

wrench size and tightening torque.
10 8
7 4 1
CAUTION: Swing reduction unit assembly
weight: 219 kg (490 lb) 2
1. Apply liquid packing onto the reduction gear side 9 3

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.

5
11 6
W25N-02-06-001
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING REDUCTION UNIT
21 20 9 31 5 7 26 14 11 25 12 19
6
15
16
12
3
10
8
4
18
13
22
24
30
27
23
29
17
28
2㩷
W25N-02-06-002
1- Casing㩷 9- Carrier㩷 17 - Bearing㩷 25 - Retaining Ring (3 Used)㩷

2- Shaft㩷 10 - Pin (4 Used)㩷 18 - Bearing㩷 26 - Retaining Ring㩷
3- Ring Gear㩷 11 - Pin (3 Used)㩷 19 - Needle Bearing (3 Used)㩷 27 - Retaining Ring㩷
4- Planetary Gear (4 Used)㩷 12 - Side Plate (6 Used)㩷 20 - Socket Bolt (14 Used)㩷 28 - Bearing Seal㩷
5- Sun Gear㩷 13 - Side Plate (4 Used)㩷 21 - Washer (14 Used)㩷 29 - Relief Fitting㩷
6- Planetary Gear (3 Used)㩷 14 - Side Plate㩷 22 - Oil Seal㩷 30 - Grease Nipple㩷
7- Sun Gear㩷 15 - Level Gauge㩷 23 - Plug㩷 31 - Motor㩷
8- Carrier㩷 16 - Pipe㩷 24 - Spring Pin (4 Used)㩷㩷
W2-6-4
Disassemble Swing Reduction Unit
CAUTION: Swing reduction unit assembly IMPORTANT: Do not remove pins (11) (3 used)
weight: 219 kg (490 lb) from carrier (9) unless necessary.
12. Remove sun gear (5).
1. Remove plug (23) and drain off gear oil.
13. Remove the carrier (8) assembly.
Gear oil: Approx. 3.4 L (3.6 US qt)
NOTE: Put gear oil in the clean container and IMPORTANT: Do not disassemble the carrier (8)
check the powder because of wearing. assembly further.䎃 Inspect the parts
in carrier (8) assembly in this
2. Put the matching marks on casing (1), ring gear condition.
(3) and motor (31). Although the carrier (8) assembly is
replaced as an assembly, do the
3. Remove socket bolt (20). following procedures when
: 12 mm replacing a part of assembly.
Do not use pin (10) again.
14. Insert spring pin (24) further.䎃Remove pins (10) (4
CAUTION: Motor weight: 70 kg (155 lb) used).
4. Remove motor (31). 15. Remove planetary gears (4) (4 used) and side
plates (13) (4 used) from the carrier (8) assembly
5. Remove sun gear (7). horizontally.
6. Remove the carrier (9) assembly with planetary IMPORTANT: Do not damage the mating surfaces
gear (6) and so on attached from ring gear (3). between casing (1) and ring gear (3).
16. Insert a screwdriver into the pulling-out notch (2
7. Put the marks on each planetary gear (6) and pin places) on the mating surfaces in casing (1) and
(11). ring gear (3).䎃 Remove ring gear (3) from casing
(1).
8. Remove retaining ring (25) from pins (11) (3 used)
in the carrier (9) assembly.䎃 Remove side plate 17. Remove retaining ring (27) from shaft (2).
(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.
W2-6-5
18
22
17
28
2㩷
W25N-02-06-002
W2-6-6
IMPORTANT: Shaft (2) falls off.䎃 Do not damage
shaft (2).
18. Turn over casing (1).䎃 Support the flange part of
casing (1) and place casing (1) on the workbench.䎃
Tap and remove shaft (2) by using a plastic
hammer downward.
176
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 146
condition.
166
Although the shaft (2) assembly is
replaced as an assembly, do the 㱢10㩷
following procedures when
replacing a part of assembly. 㱢156㩷
Oil seal (22) and bearing seal (28)
cannot be used again.
19. Support the shaft (2) assembly.䎃Remove bearing
seal (28) and bearing (17) by using a press.
NOTE: Use special tool.
Special Tool for Bearing (17)
W25N-02-06-003
20. Remove oil seal (22) from casing (1).
Press㩷
W25N-02-06-004
W2-6-7
ASSEMBLE SWING REDUCTION UNIT
21 20 9 31 5 7 26 14 11 25 12 19 6
15
16
12
3
10
8
4
18
13
22
24
30
27
23
29
17
28
2㩷
W25N-02-06-002
1- Casing㩷 9- Carrier㩷 17 - Bearing㩷 25 - Retaining Ring (3 Used)㩷

2- Shaft㩷 10 - Pin (4 Used)㩷 18 - Bearing㩷 26 - Retaining Ring㩷
3- Ring Gear㩷 11 - Pin (3 Used)㩷 19 - Needle Bearing (3 Used)㩷 27 - Retaining Ring㩷
4- Planetary Gear (4 Used)㩷 12 - Side Plate (6 Used)㩷 20 - Socket Bolt (14 Used)㩷 28 - Bearing Seal㩷
5- Sun Gear㩷 13 - Side Plate (4 Used)㩷 21 - Washer (14 Used)㩷 29 - Relief Fitting㩷
6- Planetary Gear (3 Used)㩷 14 - Side Plate㩷 22 - Oil Seal㩷 30 - Grease Nipple㩷
7- Sun Gear㩷 15 - Level Gauge㩷 23 - Plug㩷 31 - Motor㩷
8- Carrier㩷 16 - Pipe㩷 24 - Spring Pin (4 Used)㩷㩷
W2-6-8
Assemble Swing Reduction Unit
1. Insert bearing seal (28) into shaft (2).

2
2. Apply much grease into the inside of bearing (17).䎃 Grease
Install bearing (17) to shaft (2) by using a press
completely. 17
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.䎃
Install the shaft (2) assembly to casing (1).
NOTE: Level the outer ring of bearing (17).䎃 Tap
W25N-02-06-005
bearing (17) lightly and install the shaft (2)
assembly.䎃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) 176
assembly facing downward. 䎃 Support the flange
part of casing (1) and place casing (1) on the
workbench.
IMPORTANT: Do not damage the lip of oil seal (22). 146

7. Insert oil seal (22) into casing (1). 166
㱢10㩷
㱢156㩷

W25N-02-06-003
㱢125㩷
Special Tool for Oil Seal (22)

W25N-02-06-006
W2-6-9
21 20 31
3
10
8
4
18
13
24
30
27
2㩷
W25N-02-06-002
W2-6-10
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).
㱢160㩷
㱢93㩷
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.䎃 Align the
directions of holes in carrier (8) and pin (10)
where spring pin (24) will be inserted.䎃 45

W25N-02-06-007
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).䎃Install washer (21) onto socket bolt
(20).䎃 Tighten socket bolts (20) (4 used)
temporarily.
: 12 mm
: 78.5 Nm (8.0 kgfm, 58 lbfft)
W2-6-11
21 20 9 31 5 7 26 14 11 25 12 19
6
15
16
12
3
23
W25N-02-06-002
W2-6-12
16. Install the carrier (8) assembly into ring gear (3).
26. Install retaining ring (26) to the shaft of motor (31).
17. Install sun gear (5) to the carrier (8) assembly.
27. Hoist motor (31) vertically.䎃 Align the splines and
18. Place the carrier (9) assembly onto the stand install motor (31) to sun gear (7) and ring gear (3).
horizontally. Tighten socket bolt (20) and washer (21).
: 12 mm
19. Insert side plate (14) into the center of carrier (9) : 196 Nm (20 kgfm, 145 lbfft)
assembly.
28. Install plug (23) to casing (1).
20. Install side plate (12) to pins (11) (3 used). : 10 mm
: 65 Nm (6.6 kgfm, 48 lbfft)
21. Install needle bearing (19) and planetary gear (6)
to pins (11) (3 used). NOTE: Wind the seal tape onto plug (23).
29. Add gear oil.

22. Install side plate (12) into pins (11)(3 used).䎃Install
Gear oil: Approx. 3.4 L (3.6 US qt)
NOTE: Install pipe (16) and level gauge (15)
temporarily.䎃Check the amount of gear oil.䎃
23. Install the carrier (9) assembly to sun gear (5).
After installing the swing reduction unit to
NOTE: Check if side plate (14) is installed in the the machine frame, remove the seal tape
convex part in sun gear (5). from the thread part and wipe off grease.
Attach the seal tape and install pipe (16)
24. Install sun gear (7) to the carrier (9) assembly. and level gauge (15).
25. Remove socket bolt (20) with washer (21), which

was tightened temporarily at step 15.䎃Apply liquid
packing onto the motor (31) mounting surface on
ring gear (3).
: 12 mm
W2-6-13
DISASSEMBLE SWING MOTOR
17 8 6 29 25 32 24 27 12
2 1 28
9 26 20 3 14
7 21 13
11
18 22
15
23
5 31
30
16 19 33
10 36
34 4 35
W25N-02-06-008
1- Piston (9 Used)㩷 10 - Valve Plate㩷 19 - Plug (2 Used)㩷 28 - Friction Plate (3 Used)㩷

2- Shoe㩷 11 - Casing㩷 20 - O-Ring㩷 29 - Separator Plate (4 Used)㩷
3- Valve Casing㩷 12 - Plunger (2 Used)㩷 21 - O-Ring (2 Used)㩷 30 - Plug㩷
4- Pin (2 Used)㩷 13 - Spring (2 Used)㩷 22 - O-Ring (2 Used)㩷 31 - Plug㩷
5- Shaft㩷 14 - Socket Bolt (4 Used)㩷 23 - Oil Seal㩷 32 - Plug㩷
6- Cylinder㩷 15 - Bearing㩷 24 - Brake Piston㩷 33 - Plug㩷
7- Spring㩷 16 - Bearing㩷 25 - O-Ring㩷 34 - Plug㩷
8- Retainer㩷 17 - Pin㩷 26 - O-Ring㩷 35 - Relief Valve (2 Used)㩷
9- Shoe Plate㩷 18 - Plug (2 Used)㩷 27 - Spring (20 Used)㩷 36 - O-Ring (2 Used)㩷
W2-6-14
Disassemble Swing Motor
CAUTION: Motor weight: 70 kg (155 lb) IMPORTANT: Do not fall off valve plate (10) from
valve casing (3). (Valve plate (10)
1. Put the matching marks on valve casing (3) and may be attached on the cylinder (6)
casing (11). side.) Do not damage the mating
surfaces between valve casing (3)
2. Remove plug (30) from valve casing (3).䎃Drain off and casing (11) by using a
hydraulic oil. screwdriver.
: 8 mm 6. Remove socket bolt (14).䎃 Remove valve casing
(3) from casing (11).
3. Secure shaft (5) on the workbench with the shaft : 17 mm
end facing downward. NOTE: When loosening socket bolt (14), valve
NOTE: Place the rubber plate or cloth on the casing (3) is floated by spring (27).
workbench in order not to damage the
parts. 7. Remove valve plate (10) from valve casing (3).
4. Remove relief valve (35) from valve casing (3).䎃 8. Remove spring (27) from brake piston (24).
Remove O-ring (36).
: 41 mm
NOTE: When loosening relief valve (35), O-ring
(36) is damaged.䎃Replace O-ring (36).
IMPORTANT: Do not damage the seat part of

plunger (12).
5. Remove plug (19) from valve casing (3).䎃Remove
O-ring (22), spring (13) and plunger (12).
: 17 mm
W2-6-15
8 6 29 24
2 1 28
9 3
7
11
15
23
5
16
W25N-02-06-008
W2-6-16
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.
Special
Tool㩷
10. Place the motor horizontally.
IMPORTANT: Do not damage the sliding surfaces 24

of cylinder (6) and shoe (2).
11. Remove cylinder (6), piston (1), retainer (8) and
11
spring (7) from shaft (5).
12. Remove friction plate (28) and separator plate

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). W25N-02-06-009
• Do the following procedures if necessary.䎃Do not

use bearings (15, 16) again. 14
85㩷
15. Remove the inner ring of bearing (15) from shaft 75㩷
(5). 30㩷
15㩷
NOTE: Evenly tap and remove the inner ring of
bearing (15) by using a steel bar.
35㩷
R12.5㩷
16. Remove the outer ring of bearing (15) from casing
(11). M16 Penetration㩷
NOTE: Evenly tap and remove the outer ring of
100㩷
bearing (15) by using a steel bar.

30㩷
14㩷
44㩷
17. Remove bearing (16) from valve casing (3).

4㩷 8㩷
M16
㱢8
Special Tool for Brake Piston (24)

W25N-02-06-010
W2-6-17
ASSEMBLE SWING MOTOR
17 8 6 29 25 32 24 27 12
2 1 28
9 26 20 3 14
7 21 13
11
18 22
15
23
5 31
30
16 19 33
10 36
34 4 35
W25N-02-06-008
1- Piston (9 Used)㩷 10 - Valve Plate㩷 19 - Plug (2 Used)㩷 28 - Friction Plate (3 Used)㩷

2- Shoe㩷 11 - Casing㩷 20 - O-Ring㩷 29 - Separator Plate (4 Used)㩷
3- Valve Casing㩷 12 - Plunger (2 Used)㩷 21 - O-Ring (2 Used)㩷 30 - Plug㩷
4- Pin (2 Used)㩷 13 - Spring (2 Used)㩷 22 - O-Ring (2 Used)㩷 31 - Plug㩷
5- Shaft㩷 14 - Socket Bolt (4 Used)㩷 23 - Oil Seal㩷 32 - Plug㩷
6- Cylinder㩷 15 - Bearing㩷 24 - Brake Piston㩷 33 - Plug㩷
7- Spring㩷 16 - Bearing㩷 25 - O-Ring㩷 34 - Plug㩷
8- Retainer㩷 17 - Pin㩷 26 - O-Ring㩷 35 - Relief Valve (2 Used)㩷
9- Shoe Plate㩷 18 - Plug (2 Used)㩷 27 - Spring (20 Used)㩷 36 - O-Ring (2 Used)㩷
W2-6-18
Assemble Swing Motor
1. Place casing (11) onto the workbench with the 8. Install piston (1) to retainer (8).䎃 Install piston (1)
valve casing (3) side facing upward. into cylinder (6).
IMPORTANT: Check the direction of the flange in 9. Align the splines of cylinder (6) and shaft (5) and
bearing (15). install the cylinder (6) assembly to shaft (5).
2. Install bearing (15) onto shaft (5).
NOTE: Shrink the inner ring. 10. Place casing (11) with the oil seal (23) side facing
downward.
IMPORTANT: Check the direction to install oil seal
(23).䎃 Do not damage the outer 11. Install separator plates (29) (4 used) and friction
surface of oil seal (23). plates (28) (3 used) to casing (11) alternately.
3. Insert oil seal (23) to casing (11). Install separator plate (29) first.
NOTE: Apply grease to the lip part in oil seal (23).
Use special tool. 12. Install O-rings (25, 26) onto casing (11).
4. Wind a vinyl tape onto the spline part of shaft (5) 13. Apply a film of grease to O-rings (25, 26).
assembly in order not to damage the lip of oil seal
(23). Install the shaft (5) assembly to casing (11). 14. Install brake piston (24) to casing (11).
15. Install spring (27) to brake piston (24).

5. Place casing (11) horizontally.
16. Lightly tap and insert the outer ring of bearing (16)
6. Insert shoe plate (9) into casing (11).
into valve casing (3) by using a steel bar.
NOTE: Face the larger chamfered side of shoe
NOTE: Evenly tap and insert the outer ring of
plate (9) to the inner side of casing (11).
bearing (16) until the outer ring stops at the
Apply grease onto the mating surface in
step part in valve casing (3).
order not to fall off.
7. Install retainer (8) and spring (7). Install piston (1)

with shoe (2) attached.
W2-6-19
27 12
20 3 14
13
11
22
19
10 36
35
W25N-02-06-008
W2-6-20
17. Apply grease onto the valve casing (3) mounting
surfaces of valve plate (10).䎃Install valve plate (10)
to valve casing (3).
IMPORTANT: Check the direction to install valve

casing (3).
Do not fall off valve plate (10).
Do not fall off spring (27).
18. Install O-ring (20) to valve casing (3).䎃 Install
valve casing (3) to casing (11).䎃 Tighten socket
bolt (14).
: 17 mm
: 430 Nm (44 kgfm, 320 lbfft)
19. Insert plunger (12) and spring (3) into valve

casing (3).
NOTE: Check if spool (12) moves smoothly.
20. Install O-ring (22) to plug (19).䎃Tighten plug (19) to

valve casing (3).
: 17 mm
: 539 Nm (55 kgfm, 400 lbfft)
21. Install O-ring (36) onto relief valve (35).䎃 Install

relief valve (35) to valve casing (3).
: 41 mm
: 177 Nm (18 kgfm, 131 lbfft)
W2-6-21
Swing Reduction Unit
• Replacement Standard for Gear
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

Unit: mm (in)
D-d 0.028 (0.001) 0.058 (0.002)
d D
W25N-02-04-005
Unit: mm (in)
Ǭ 0 (0) 0.3 (0.012)
3. Shoe thickness
Unit: mm (in)
Standard Allowable Limit 㱐
t 5.5 (0.22) 5.3 (0.20)

t
4. Friction plate thickness

W25N-02-04-006
Unit: mm (in)
2.0 (0.079) 1.6 (0.063)
W2-6-22
CRANE UPPER / Winch Assembly
REMOVE AND INSTALL FRONT AND
REAR WINCH ASSEMBLY

Removal 3
1. Lower the boom and live-mast.䎃

2 4
2. Remove the wire rope from front and rear drums.
1
3. Remove the counterweight. (As for removal of the
counterweight, refer to W2-2 in this section.)
3
4. Remove bolts (3), (4) from the front and rear
hoisting motors. Remove the washer tank, hose
3
clamps (2 used) and cables in the right house (1).
Hoist and remove right houses (1), (2).
: 17 mm 3
5. Lower the live-mast.䎃Remove the boom hoist wire 3

rope. (As for removal of the boom hoist wire rope,
refer to the Operator's Manual.) W2BD-02-07-001
6. Remove the backstop. (As for removal of the

W2-7-1
9. Remove bolts (9) (16 used) and remove drum 9 5 9 6
covers (5), (6), (7), (8).
: 19 mm
10. Turn the front and rear drum lock switches in

operator's cab into the UNLOCK position.䎃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. 9 9 9 9 9 9
: 19 mm
: 22 mm 7 8
: 27 mm
: 32 mm 9
9
: 36 mm
12. Remove bolt (11).䎃 Remove brackets (12), (13)

from the drum speed sensors.
: 19 mm
9 9 9 9 9 9
9 9
W2BC-02-07-001

13 11
11
12

W2BD-02-07-002
W2-7-2
CAUTION: Main winch assembly weight:

Auxiliary winch assembly weight:
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.䎃Hold the winch assembly.
14. Remove nuts (17) and remove bolts (18).

: 24 mm
15. Remove retaining rings (15) (8 used).䎃 Remove

pins (16) (8 used).䎃 Hoist and remove the hoist
10
mechanism. 17, 18
16
15
10
17, 18
16
15
W2BC-02-07-002
16 15 16 15 16
16 16 16
15
18 15
17 15
17
18 10 18 18 10 17 W2BC-02-07-003
W2-7-3
Installation


motor.

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).䎃 Install retaining 10
17,18
rings (15) (8 used). 16
15
3. Adjust the position of bolts (18) (8 used) so that 10
the flange of drum can mesh with the claw of 17, 18
drum lock.䎃Tighten nut (17) (8 used). 16
: 24 mm
: 179 to 194 Nm (18.3 to 19.8 kgfm) 15
W2BC-02-07-002
(132 to 143 lbfft)
16 15 16 15 16
16 16 16
15
18 15
17 15
17
18 10 18 18 10 17 W2BC-02-07-003
W2-7-4
4. Install brackets (12), (13) of the drum speed
sensors to the winch assembly with bolts (11) (4
used). 13 11
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
11
5. Install the wire harness and all hoses to winch
motor (10).
: 19 mm 12
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 32 mm
: 137 Nm (14 kgfm, 101 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft) W2BD-02-07-002
6. Install drum covers (5), (6), (7), (8) onto the upper 9 5 9 6
revolving frame with bolts (9) (16 used).
: 19 mm
: 72 to 78 Nm (7.4 to 8.0 kgfm)
(54 to 57 lbfft)
9 9 9 9 9 9
7 8
9
9
9 9 9 9 9 9
9 9
W2BC-02-07-001
W2BC-02-07-014
18 17 17 18
W2-7-5
8. Wind the boom hoist wire rope. Extend the

live-mast. (As for winding the boom hoist wire 3
rope, refer to the Operator's Manual.)
9. Hoist and install right houses (1), (2).䎃Tighten bolts 2 4

(3), (4).
: 17 mm 1
: 41 to 45 Nm (4.2 to 4.6 kgfm)
(31 to 33 lbfft) 3
10. Install the washer tank, hose clamps (2 used) and

cables in the right house (1). 3
11. Install the counterweight. (Refer to W2-2 in this 3

section.)
12. Wind the wire rope into the front and rear drums. 3

W2BD-02-07-001
13. Check the brake condition of front and rear drum

and any oil leakage for winch motor.
W2-7-6
(Blank)
W2-7-7
DISASSEMBLE WINCH ASSEMBLY
1 2 3 4 5 6 7 8 9 11 13 14 13 12 15
10 12
16
42 17
20
18
12
35 26 21
13 27 24
34 32 30 22
41 39 40 38 37 36 33 31 29 28 25 23 19
43 44
47 46
48
45 49
50

W2BD-02-07-003

1- Drum㩷 14 - Air Breather㩷 27 - Needle Bearing (6 Used)㩷 39 - Bolt (18 Used)㩷
2- Spacer㩷 15 - Level Gauge㩷 28 - Thrust Plate (6 used)㩷 40 - Washer (18 Used)㩷
3- Sun Gear㩷 16 - Motor㩷 29 - Pin (3 Used)㩷 41 - Bracket㩷
4- Carrier㩷 17 - Bolt (2 Used)㩷 30 - Spring Pin (4 Used)㩷 42 - Brake Unit㩷
5- Spacer㩷 18 - Lock Plate㩷 31 - Needle Bearing (8 Used)㩷 43 - Sleeve㩷
6- Planetary Gear (3 Used)㩷 19 - Plug㩷 32 - Planetary Gear (4 Used)㩷 44 - O-Ring㩷
7- Spring Pin (3 Used)㩷 20 - Nut㩷 33 - Thrust Plate (8 used)㩷 45 - Oil Seal㩷
8- Shaft㩷 21 - Bearing (2 Used)㩷 34 - Pin (4 Used)㩷 46 - O-Ring㩷
9- Cork (2 Used)㩷 22 - Pedestal㩷 35 - Carrier㩷 47 - Sleeve㩷
10 - Bolt (28 Used)㩷 23 - Bracket㩷 36 - Retaining Ring㩷 48 - Oil Seal㩷
11 - Washer (28 Used)㩷 24 - Cover㩷 37 - Bearing㩷 49 - Socket Bolt (8 Used)㩷
12 - Bolt (46 Used)㩷 25 - Plug (2 Used)㩷 38 - Retainer㩷 50 - Retainer
13 - Washer (46 Used)㩷 26 - Ring Gear㩷
W2-7-8
Disassemble Winch Assembly

CAUTION: Front winch assembly weight: 9. Remove socket bolts (49) (8 used). Remove
Approx. 2000 kg (4410 lb) retainer (50) from pedestal (22).
Rear winch assembly weight: : 10 mm
10. Remove oil seal (48) from retainer (50).
Gear oil : 22.5 L (5.9 US gal) 11. Remove bearing (21) from pedestal (22).
: 14 mm
12. Remove sleeve (47) from cover (24).
NOTE: Drain off gear oil in the clean container and
check the metal powder due wear. 13. Remove O-ring (46) from sleeve (47).
2. Lift the winch assembly with the crane and place it 14. Remove bolts (10) (28 used) and remove cover
on a workbench with placing the brake unit (42) (24).
downward. At this time, place the wooden block : 30 mm
(200 mm square) under the bracket (41) to stable
the winch assembly. 15. Remove shaft (8).
CAUTION: Winch motor (16) weight: 16. Remove the carrier (4) assembly.
17. Remove spring pin (7). Remove pistons (29) (3
3. Remove bolts (12) (4 used). Lift the motor (16) used) from carrier (4).
assembly with the crane and remove it.
: 30 mm 18. Remove planetary gears (6) (3 used), thrust
plates (28) (6 used) and needle bearings (27) (6
4. Remove bolts (12) (12 used). Lift bracket (23) with used) from carrier (4).
the crane and remove it.
: 30 mm 19. Remove spacer (5) from carrier (4).
5. Remove bolts (17) (2 used) and remove lock plate 20. Remove sun gear (3).
(18).
: 19 mm 21. Remove the carrier (35) assembly.
6. Remove nut (20). 22. Remove spring pin (30). Remove pins (34) (4
used) from carrier (35).
7. Remove the pedestal (22) assembly.
23. Remove planetary gears (32) (4 used), thrust
8. Remove bearing (21) from pedestal (22). plates (33) (8 used) and needle bearings (31) (8
W2-7-9
1 2 12
12
42
12
35 26
41 39 38 37 36
43 44
45

W2BD-02-07-003
W2-7-10
24. Remove spacer (2) from carrier (35).
25. Remove ring gear (26) from drum (1).
26. Remove bolts (39) (18 used). Lift drum (1) with
: 19 mm
27. Remove retaining ring (36) from brake unit (42).

Remove bearing (37).
28. Remove retainer (38).
30. Remove sleeve (43) from brake unit (42).
31. Remove O-ring (44) from sleeve (43).
CAUTION: Brake unit (42) weight:

32. Remove bolts (12) (30 used). Lift brake unit (42)
with the crane and remove it from bracket (41).
: 30 mm
W2-7-11
ASSEMBLE WINCH ASSEMBLY
1 2 3 4 5 6 7 8 9 11 13 14 13 12 15
10 12
16
42 17
20
18
12
35 26 21
13 27 24
34 32 30 22
41 39 40 38 37 36 33 31 29 28 25 23 19
43 44
47 46
48
45 49
50

W2BD-02-07-003

W2-7-12
Assemble Winch Assembly
1. Lift bracket (41) with the crane and place it onto 11. Install ring gear (26) to drum (1).
the workbench. Place the wooden block (200 mm
square) under bracket (41). 12. Place spacer (2) onto carrier (35).
13. Install planetary gears (32) (4 used), thrust plates

(33) (8 used) and needle bearings (31) (8 used) to
Approx. 680 kg (1500 lb) carrier (35).
2. Lift brake unit (42) with the crane and install it to 14. Install pins (34) (4 used) to carrier (35). Insert
bracket (41). Install washer (13) to bolts (12) (30 spring pin (30). Face the slit part of spring pin (30)
used). Tighten bolts (12) (30 used). to the shaft of winch assembly.
: 30 mm
: 539 Nm (55 kgfm, 398 lbfft) 15. Install the carrier (35) assembly to ring gear (26)
and brake unit (42).
3. Install O-ring (44) onto sleeve (43).
4. Install sleeve (43) to brake unit (42).
17. Place spacer (5) onto carrier (4).
5. Install oil seal (45) to retainer (38).
6. Install retainer (38) into brake unit (42). (28) (6 used) and needle bearings (27) (6 used) to
carrier (4).
7. Install bearing (37) onto brake unit (42). Install
retaining ring (36). 19. Install pins (29) (3 used) to carrier (4). Insert
spring pin (7).䎃Face the slit part of spring pin (7) to
8. Apply liquid packing (ThreeBond #1389) on the the shaft of winch assembly.
mating surface of the drum (1) and the retainer
(38). 20. Install the carrier (4) assembly to ring gear (26)
and sun gear (3).
9. Install the drum (1) on the brake unit (42) and
tighten it with the bolts (39) (18 used) with the 21. Install shaft (8) to the carrier (4) assembly.
washer (40) applied LOCTITE #262.
: 19 mm 22. Apply liquid packing (ThreeBond #1389) on the
: 88 Nm (9.0 kgfm, 64 lbfft) mating surface of the cover (24) and the ring gear
(26).
10. Apply liquid packing (ThreeBond #1389) on the
mating surface of the ring gear (26) and the drum
(1).
W2-7-13
8 11 13 13 12
10 12
17
20
18
12
26 21
13 24 22
23
47 46
48
49
50

W2BD-02-07-003
W2-7-14
23. Install cover (24) to ring gear (26). Install washer 32. Tighten nut (20) to cover (24) with placing the
(11) to bolts (10) (28 used). Tighten bolts (10) (28 step part to the bearing (21) side.
used). : 226 Nm (23 kgfm, 167 lbfft)
: 30 mm
: 539 Nm (55 kgfm, 398 lbfft) 33. Rotate pedestal (22) clockwise and
counterclockwise 4 to 5 times.
34. Tap the end of pedestal (22) with using a plastic
25. Install sleeve (47) on cover (24). hammer. Tighten nut (20) to cover (24) again.
(Repeat it twice.) Adjust dimension C to 14 to 16
26. Install bearing (21) to the retainer (50) side of mm.
pedestal (22). : 226 Nm (23 kgfm, 167 lbfft)
27. Install oil seal (48) to retainer (50). 35. Apply LOCTITE #262 onto bolts (17) (2 used).
Install lock plate (18) onto nut (20) with bolts (17)
28. Apply liquid packing (ThreeBond #1389) on the (2 used).
mating surface of the pedestal (22) and the : 19 mm
retainer (50). : 88 Nm (9.0 kgfm, 65 lbfft)
29. Install retainer (50) to pedestal (22). Apply 36. Lift the bracket (23) with the crane and tighten it
LOCTITE #262 onto socket bolts (49) (8 used). with the bolts (12) (12 used) with the washer (13)
Tighten socket bolts (49) (8 used). attached.
: 10 mm : 30 mm
: 88 Nm (9.0 kgfm, 651 lbfft) : 539 Nm (55 kgfm, 398 lbfft)
30. Install bearing (21) to pedestal (22). 37. Tap the end of shaft (8) with using a plastic
hammer several times.䎃 Check if dimension L
31. Install the pedestal (22) assembly to cover (24). between the end of pedestal (22) and that of shaft
(8) is 22 to 23 mm.
W2-7-15
13 13 12 15
12
16
12
13 24 22
25

W2BD-02-07-003
W2-7-16
mating surface of the motor (16) and the pedestal
(22).
CAUTION: Winch motor (16) weight:

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 Nm (55 kgfm, 398 lbfft)
CAUTION: Front winch assembly weight:

Rear winch assembly weight:
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
NOTE: Wind the seal tape onto plug (25).
W2-7-17
DISASSEMBLE WINCH MOTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20
21
46
22
45
44 23
43
42
41
24
25
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26
27
19 28
A W2CM-02-07-006
1- Spacer 13 - Pin 25 - Cover 36 - Spring (9 Used)

2- Retaining Ring 14 - Valve Cover 26 - Socket Bolt (12 Used) 37 - Piston (9 Used)
3- Holder 15 - Socket Bolt 27 - O-Ring (3 Used) 38 - Plate
4- Pin 16 - O-Ring 28 - Plug (3 Used) 39 - Shoe (9 Used)
5- Casing 17 - O-Ring 29 - Friction Plate (7 Used) 40 - Shoe Plate
6- O-Ring (5 Used) 18 - O-Ring 30 - Plate (8 Used) 41 - Bolt (4 Used)
7- Plug (5 Used) 19 - Casing 31 - Shim (1 Set) 42 - Bearing
8- Rotor 20 - O-Ring 32 - Coupling 43 - Shaft
9- Valve Plate 21 - Brake Piston 33 - O-Ring 44 - Oil Seal
10 - O-Ring (4 Used) 22 - Retaining Ring 34 - Socket Bolt (9 Used) 45 - Front Cover
11 - Socket Bolt (6 Used) 23 - Plug 35 - Needle Bearing 46 - O-Ring
12 - Sub Plate 24 - Spring (16 Used)
W2-7-18
Disassemble Winch Motor

CAUTION: Winch motor weight: IMPORTANT: Do not drop valve plate (9) when
Approx. 175 kg (390 lb) removing valve cover (14).
10. Loosen socket bolts (15) and (34) (9 used).
1. Place the winch motor on a workbench. Remove Remove valve cover (14) and O-rings (10)
plug (7) from casing (5). Drain off hydraulic oil. (4 used) from casing (5).
: 36 mm : 14 mm
2. Remove socket bolts (11) (6 used) and remove 11. Remove valve plate (9) and O-ring (33) from valve
sub plate (12) from valve cover (14). cover (14).
: 10 mm NOTE: Do not remove needle bearing (35) unless
necessary.
3. Put the matching marks onto casing (5), valve
cover (14), casing (19) and cover (25). IMPORTANT: Do not damage the sliding surfaces
on rotor (8), holder (3) and shoe (39).
4. Loosen socket bolts (26) (12 used). Remove 12. Remove rotor (8), piston (37) (9 used), shoes (39)
cover (25) from casing (19). (9 used), holder (3) and plate (38) from casing (5).
: 10 mm NOTE: Use the lifting tool for rotor.
5. Remove O-ring (20) from cover (25). 13. Remove springs (36) (9 used) from rotor (8).
6. Remove springs (24) (16 used) and brake piston 14. Remove shoe plate (40) from casing (5).
15. Loosen bolts (41) (4 used). Remove front cover
7. Remove casing (19) from valve cover (14). : 17 mm
Remove O-rings (17, 18) from casing (19).
16. Remove oil seal (44) and O-ring (46) from front
8. Remove retaining ring (22) and coupling (32) from cover (45).
shaft (43).
17. Remove shaft (43) from casing (5).
9. Remove plates (30) (8 used), friction plates (29)
(7 used), shim (31) and O-ring (16) from valve
cover (14).
W2-7-19

1 2 14
43
42
35

A W2CM-02-07-006
W2-7-20
18. Remove retaining ring (2) and spacer (1) from
shaft (43). Pull out bearing (42) with using a
press.
19. Remove needle bearing (35) from valve cover

(14) if necessary.
W2-7-21
ASSEMBLE WINCH MOTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20
21
46
22
45
44 23
43
42
41
24
25
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26
27
19 28
A W2CM-02-07-006
1- Spacer 13 - Pin 25 - Cover 36 - Spring (9 Used)

2- Retaining Ring 14 - Valve Cover 26 - Socket Bolt (12 Used) 37 - Piston (9 Used)
3- Holder 15 - Socket Bolt 27 - O-Ring (3 Used) 38 - Plate
4- Pin 16 - O-Ring 28 - Plug (3 Used) 39 - Shoe (9 Used)
5- Casing 17 - O-Ring 29 - Friction Plate (7 Used) 40 - Shoe Plate
6- O-Ring (5 Used) 18 - O-Ring 30 - Plate (8 Used) 41 - Bolt (4 Used)
7- Plug (5 Used) 19 - Casing 31 - Shim (1 Set) 42 - Bearing
8- Rotor 20 - O-Ring 32 - Coupling 43 - Shaft
9- Valve Plate 21 - Brake Piston 33 - O-Ring 44 - Oil Seal
10 - O-Ring (4 Used) 22 - Retaining Ring 34 - Socket Bolt (9 Used) 45 - Front Cover
11 - Socket Bolt (6 Used) 23 - Plug 35 - Needle Bearing 46 - O-Ring
12 - Sub Plate 24 - Spring (16 Used)
W2-7-22
Assemble Winch Motor
1. Install pin (4) to casing (5). 11. Insert needle bearing (35) into valve cover (14).
NOTE: Insert the needle bearing (35) until it stops
2. Fit bearing (42) on shaft (43) with shrinking. Install at the step part of the valve cover (14) as
spacer (1) and retaining ring (2). tapping the outer ring evenly with a
hammer through the needle bearing outer
3. Fit the inner ring of needle bearing (35) to shaft ring inserting tool.
(43) with shrinking.
4. Tap the outer race of bearing (42) with using a 12. Install pin (13) to valve cover (14).
copper bar lightly and install shaft (43) to casing
(5). 13. Apply grease to valve plate (9). Align the pin (13)
positions and install valve plate (9) on valve cover
5. Insert oil seal (44) into front cover (45). Install (14).
O-ring (46).
14. Install O-ring (33) to valve cover (14).
NOTE: Use the oil seal inserting tool.
15. Install valve cover (14) onto casing (5) with socket
6. Install front cover (45) onto casing (5) and install bolts (15) and (34) (9 used).
bolts (41) (4 used). : 14 mm
: 17 mm : 333 Nm (34.0 kgfm, 246 lbfft)
: 57 Nm (5.8 kgfm, 42 lbfft)
16. Install coupling (32) to shaft (43). Install retaining
NOTE: Align the pin hole on shoe plate (40) with ring (22).
pin (4).
7. Install shoe plate (40) to casing (5). IMPORTANT: Align the notches on plate (30) and
friction plate (29). Adjust with shim
8. Install springs (36) (9 used) to rotor (8). Install (31) so that the dimension between
holder (3). the ends of valve cover (14) and
plate (30) becomes 3.1 mm (0.12 in).
9. Install piston (37) (9 used) and shoes (39) (9 used) 17. Install shim (31) to valve cover (14) and coupling
to plate (38). Insert piston (37) (9 used) and shoe (32). Install plates (30) (8 used) and friction plates
(39) into rotor (8). (29) (7 used) in this order alternately.
10. Align the rotor (8) assembly with shaft (43) spline
and the spline of rotor (8) and holder (3) and 18. Install O-ring (16) to valve cover (14).
install it to shaft (43).
NOTE: Use the lifting tool for rotor. 19. Install O-rings (17, 18) to casing (19). Install brake
piston (21).
W2-7-23

5 6 7 10 11 12 14 19
20
21
23
24
25
28 27 26
27
28

A W2CM-02-07-006
W2-7-24
20. Install springs (24) (16 used) to brake piston (21).
21. Install O-rings (10) (4 used) to casing (5).
22. Install O-ring (20) onto cover (25). Install cover

(25) onto casing (19). Install casing (19) and
cover (25) onto casing (5) with socket bolts (26)
(12 used).
: 10 mm
: 98 Nm (10.0 kgfm, 72 lbfft)
23. Install plug (23) to cover (25).

: 8 mm
: 44 Nm (4.5 kgfm, 32 lbfft)
24. Install O-ring (27) to plugs (28) (3 used). Install

plugs (28) (3 used) to casing (19).
: 19 mm
: 36 Nm (3.7 kgfm, 27 lbfft)
25. Install O-ring (6) to plug (7). Install plug (7) to

casing (5).
: 36 mm
: 167 Nm (17.0 kgfm, 123 lbfft)
26. Install sub plate (12) to valve cover (14) with

socket bolts (11) (6 used).
: 10 mm
: 98 Nm (10.0 kgfm, 72 lbfft)
W2-7-25
Special Tool
45 160
25
20
M16
For lifting
bolt
250
20
3 130
ĭ110㩷 ĭ60
70
Special Tool
For Rotor㩷
W24X-02-07-007
25
25 10
10
ĭ57㩷 ĭ75
ĭ76 ĭ100
Special Tool When Inserting Special Tool When

Outer Ring Of Needle Bearing㩷 Inserting Oil Seal㩷
W24X-02-07-008
W2-7-26
MAINTENANCE STANDARD Dial Gauge㩷
1. Secure the plunger with the shoe attached in a

vise. Clearance㩷
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 Guide
beyond allowable limit, replace the plunger and
shoe assembly.
Unit: mm (in)
0 to 0.1 (0 to 0.004) 0.3 (0.012) Vise㩷 Soft Liner㩷
W309-04-05-002
Remedy: Replace the shoe and plunger as an

assembly.
2. Measure the plunger diameter at upper, middle, 㩷

lower positions (2 places for each) with using a 㩷
micrometer. Measure the diameter at the second W309-04-05-003
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)
0.039 (0.002) 0.078 (0.003)
Remedy: Replace the plunger or rotor.

W309-04-05-004
3. Measure shoe thickness C with using a micro

meter.
C
Unit: mm (in) W309-04-05-005

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.
W2-7-27
4. Measure heights of H and h.
Plate㩷 Holder
Unit: mm (in)
H-h 32.2 (1.27) 31.6 (1.24)
H
h
Remedy: Replace the holder and plate as an
assembly.
W309-04-05-006
5. Measure dimension (A).

Unit: mm (in)
Standard Allowable Limit A
A 3.1 (0.12) 3.6 (0.14)
Remedy: Adjust with the shims.
6. Measure the brake spring length. W309-04-05-007
Unit: mm (in)
54 (2.13) 53.2 (2.09)
Remedy: Replace the spring.
7. Measure the thickness of plate and friction plate.

(15 used)
Unit: mm (in)
32.4 (1.28) 31.7 (1.25)
Remedy: Replace the plate and friction plate.
8. Measure the rotor spring length.

Unit: mm (in)
52.9 (2.08) 51.3 (2.02)
W2-7-28
(Blank)
W2-7-29
29 2 1 3 4 6 17 16
15
17
7
40
8
41
43
9
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5
W25N-02-07-009
1- Plug (2 Used)㩷 12 - Nut (2 Used)㩷 23 - Spool㩷 34 - Piston㩷

2- O-Ring (2 Used)㩷 13 - Adjusting Screw (2 Used)㩷 24 - Spring Seat㩷 35 - Pin㩷
3- Plug㩷 14 - Pin㩷 25 - Spring Seat㩷 36 - O-Ring㩷
4- Casing㩷 15 - Spring Seat㩷 26 - O-Ring㩷 37 - Socket Bolt (6 Used)㩷
5- Socket Bolt (4 Used)㩷 16 - Spool㩷 27 - Spring㩷 38 - Cover㩷
6- Solenoid Valve㩷 17 - Sleeve㩷 28 - O-Ring㩷 39 - O-Ring㩷
7- Spring㩷 18 - Lock Pin㩷 29 - O-Ring㩷 40 - Sleeve㩷
8- O-Ring㩷 19 - Spring㩷 30 - O-Ring㩷 41 - Piston㩷
9- Spring Seat㩷 20 - O-Ring㩷 31 - Orifice㩷 42 - Lever㩷
10 - Cover (2 Used)㩷 21 - Plug㩷 32 - Plug㩷 43 - Pin㩷
11 - Socket Bolt (4 Used)㩷 22 - Sleeve㩷 33 - O-Ring㩷
W2-7-30
1. Remove solenoid valve (6) from casing (4).

: 32 mm
2. Remove socket bolts (5) (4 used). Remove casing

(4) from the winch motor.
: 6 mm
3. Remove O-rings (28, 30) from casing (4).
4. Remove orifice (31) from casing (4).

: 4 mm
5. Remove socket bolts (37) (6 used).䎃 Remove

cover (38) from casing (4).
: 5 mm
6. Remove O-rings (29, 36, 39) from casing (4).
7. Remove pin (35) and piston (34) from cover (38).
8. Remove piston (41) and sleeve (40) from cover

(38).
IMPORTANT: Do not disassemble adjusting screw

(13) and nut (12).
9. Remove socket bolt (11).䎃Remove covers (10) (2
used) from casing (4).
: 5 mm
10. Remove plug (32) from casing (4).
11. Remove O-ring (33) from plug (32).
12. Remove lever (42) from sleeve (17).
13. Remove spring seat (9), spring (7), spring seat

(15), spool (16) and sleeve (17) from casing (4).
14. Remove O-ring (8) from spring seat (9).
15. Remove plug (21) from casing (4). Remove spring

(19) and lock pin (18).
: 13 mm

W2-7-31
ASSEMBLE REGULATOR
29 2 1 3 4 6 17 16
15
17
7
40
8
41
43
9
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5
W25N-02-07-009
1- Plug (2 Used)㩷 12 - Nut (2 Used)㩷 23 - Spool㩷 34 - Piston㩷

2- O-Ring (2 Used)㩷 13 - Adjusting Screw (2 Used)㩷 24 - Spring Seat㩷 35 - Pin㩷
3- Plug㩷 14 - Pin㩷 25 - Spring Seat㩷 36 - O-Ring㩷
4- Casing㩷 15 - Spring Seat㩷 26 - O-Ring㩷 37 - Socket Bolt (6 Used)㩷
5- Socket Bolt (4 Used)㩷 16 - Spool㩷 27 - Spring㩷 38 - Cover㩷
6- Solenoid Valve㩷 17 - Sleeve㩷 28 - O-Ring㩷 39 - O-Ring㩷
7- Spring㩷 18 - Lock Pin㩷 29 - O-Ring㩷 40 - Sleeve㩷
8- O-Ring㩷 19 - Spring㩷 30 - O-Ring㩷 41 - Piston㩷
9- Spring Seat㩷 20 - O-Ring㩷 31 - Orifice㩷 42 - Lever㩷
10 - Cover (2 Used)㩷 21 - Plug㩷 32 - Plug㩷 43 - Pin㩷
11 - Socket Bolt (4 Used)㩷 22 - Sleeve㩷 33 - O-Ring㩷
W2-7-32
Assemble Regulator
1. Install sleeve (22), spool (23), spring seat (24) and 12. Install piston (34) to casing (4).
spring (27) to casing (4).
13. Install O-rings (29, 36, 39) on casing (4).
2. Install O-ring (26) to spring seat (25). Install spring
seat (25) to casing (4). 14. Install pin (35) to cover (38).
3. Install cover (10) to casing (4) with socket bolt 15. Install sleeve (40) and piston (41) to cover (38).
(11).
: 5 mm 16. Install cover (38) onto casing (4) with socket bolts
: 12 Nm (1.2 kgfm, 8.9 lbfft) (37) (6 used).
: 5 mm
4. Install lock pin (18) and spring (19) to casing (4). : 12 Nm (1.2 kgfm, 8.9 lbfft)
5. Install O-ring (20) to plug (21).䎃Install plug (21) to 17. Install orifice (31) to casing (4).䎃Install O-rings (28,
casing (4). 30).
: 13 mm : 4 mm
: 29 Nm (3.0 kgfm, 21 lbfft) : 9 Nm (0.9 kgfm, 6.6 lbfft)
6. Install sleeve (17) and spool (16) to casing (4). 18. Install casing (4) to the winch motor with socket
bolts (5) (4 used).
7. Install lever (42) to sleeve (17). : 6 mm
: 29 Nm (3.0 kgfm, 21 lbfft)
8. Install O-ring (33) to plug (32).䎃 Install plug (32) to
casing (4). 19. Install solenoid valve (6) to casing (4).
: 32 mm
9. Install spring seat (15) and spring (7) to casing (4). : 44 Nm (4.5 kgfm, 32.5 lbfft)
10. Install O-ring (8) to spring seat (9).䎃 Install spring

seat (9) to casing (4).
11. Install cover (10) to casing (4) with socket bolt

(11).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-7-33
DISASSEMBLE COUNTERBALANCE VALVE
9
8
7
19
21 15 6
20
35
5 3
16 4 2
17
18 12 1
13
22 14
23
24
25
26
12
27 13 10
28 11
29
30
31
32
33
33 34

W25N-02-07-010
1- Socket Bolt (4 Used)㩷 10 - Plug㩷 19 - Air Bleed Valve㩷 28 - Plunger㩷

2- Spring Washer (4 Used)㩷 11 - O-Ring㩷 20 - O-Ring㩷 29 - Spring㩷
3- Cover㩷 12 - Plug (2 Used)㩷 21 - Plug㩷 30 - O-Ring㩷
4- O-Ring㩷 13 - O-Ring (2 Used)㩷 22 - Socket Bolt (4 Used)㩷 31 - Backup Ring㩷
5- Plug㩷 14 - Casing㩷 23 - Spring Washer (4 Used)㩷 32 - Plug㩷
6- Spool㩷 15 - Socket Bolt (6 Used)㩷 24 - Cover㩷 33 - O-Ring (2 Used)㩷
7- Steel Ball㩷 16 - Spring Washer (6 Used)㩷 25 - O-Ring㩷 34 - Relief Valve㩷
8- Spring㩷 17 - Plug㩷 26 - Spring㩷 35 - Filter㩷
9- Orifice㩷 18 - O-Ring㩷 27 - Seat㩷
W2-7-34
Disassemble Counterbalance Valve
1. Remove O-rings (33) (2 used) from casing (14).
2. Remove socket bolts (1, 22) (4 used for each).

Remove covers (3, 24) from casing (14).
: 10 mm
3. Remove plug (21) from cover (24). Remove

: 6 mm
4. Remove plug (10) from cover (3). Remove O-ring

(10) from plug (11).
: 6 mm
5. Remove springs (26) and O-rings (4, 25) from

casing (14).
6. Remove the spool (6) assembly from casing (14).
7. Remove plug (5) from spool (6). Remove filter

(35) from plug (5).
8. Remove orifice (9), spring (8) and steel ball (7)

from spool (6).

: 50 mm
10. Remove O-ring (30) and backup ring (31) from

plug (32).
11. Remove spring (29) and plunger (28) from casing

(14).
NOTE: Do not remove seat (27) unless necessary.
12. Remove relief valve (34) from casing (14).

Remove O-ring and backup ring from relief valve
(34).
: 50 mm
W2-7-35
ASSEMBLE COUNTERBALANCE VALVE
22 23 24 25 26 9 8 7 14 6 13 12 35 5 4 3
11
20
10
21
1
27 28 29 32 31 30 34
19 17 18 15
16
33
W25N-02-07-011

W2-7-36
Assemble Counterbalance Valve
1. Install O-ring and backup ring to relief valve (34). 12. Install cover (24) on casing (14). Tighten socket
bolts (22) and spring washers (23) (4 used for
2. Install relief valve (34) to casing (14). each).
: 50 mm : 10 mm
: 166 to 186 Nm (17 to 19 kgfm) : 88 to 108 Nm (9 to 11 kgfm)
(122 to 137 lbfft) (65 to 80 lbfft)
3. Install O-ring (30) and backup ring (31) to plug 13. Install O-ring (11) to plug (10). Install plug (10) on
(32). cover (3).
: 6 mm
4. Install spring (29) into plunger (28). Install plunger : 34 to 38 Nm (3.5 to 3.9 kgfm)
(28) to plug (32). (25 to 28 lbfft)
5. Install plug (32) to casing (14). 14. Install O-ring (20) to plug (21). Install plug (21) on
: 50 mm cover (24).
: 181 to 211 Nm (18.5 to 21.5 kgfm) : 6 mm
(134 to 156 lbfft) : 34 to 38 Nm (3.5 to 3.9 kgfm)
(25 to 28 lbfft)
6. Install filter (35) into plug (5). Install plug (5) to
spool (6). 15. Install O-rings (33) (2 used) onto casing (14).
7. Install steel ball (7), spring (8) and orifice (9) to

spool (6).
IMPORTANT: Check if spool (6) moves smoothly.

8. Insert spool (6) into casing (14).
9. Install spring (26) to casing (14).
10. Install O-rings (4, 25) onto casing (14).
11. Install cover (3) to casing (14). Tighten socket

bolts (1) and spring washers (2) (4 used for each).
: 10 mm
: 88 to 108 Nm (9.0 to 11 kgfm)
(65 to 80 lbfft)
W2-7-37
DISASSEMBLE BRAKE UNIT
25
28
29
33
26
30 34
31 32
27
35
1 2 3 4 5 6 7
8
24
9
23
22
10
11
21
12
20 19 18 17 16 15 14 13
W25N-02-07-012
1- Plug (3 Used)㩷 10 - Bolt (8 Used)㩷 19 - O-Ring㩷 28 - O-Ring㩷

2- Spacer㩷 11 - Washer (8 Used)㩷 20 - Washer (24 Used)㩷 29 - Adapter㩷
3- Casing㩷 12 - Retainer㩷 21 - Bolt (24 Used)㩷 30 - Rod㩷
4- O-Ring㩷 13 - Bearing㩷 22 - Spring (18 Used)㩷 31 - O-Ring㩷
5- Socket Bolt (30 Used)㩷 14 - Brake Plate (26 Used)㩷 23 - Piston㩷 32 - Spring㩷
6- Pedestal㩷 15 - Friction Disc (25 Used)㩷 24 - Cover㩷 33 - Oil Seal㩷
7- Bearing (2 Used)㩷 16 - Spacer㩷 25 - Cork (2 Used)㩷 34 - Sleeve㩷
8- Retaining Ring㩷 17 - Packing㩷 26 - Plug (4 Used)㩷 35 - O-Ring㩷
9- Shaft㩷 18 - Packing㩷 27 - O-Ring (4 Used)㩷
W2-7-38
Disassemble Brake Unit

CAUTION: Brake unit weight: 13. Remove adapter (29) from cover (24).
14. Remove O-rings (28, 31) from adapter (29).
1. Hoist and place the brake unit on a workbench
with shaft (9) facing upward. 15. Remove rod (30) and spring (32) from cover (24).
2. Remove bolts (10) (8 used) and remove retainer 16. Remove bolts (21) (24 used). Remove cover (24)
(12). from casing (3).
: 19 mm : 24 mm
3. Remove bearing (13) from pedestal (6). 17. Remove O-ring (19) from cover (24).
4. Remove retaining ring (8) from shaft (9). 18. Remove springs (22) (18 used) from casing (3).
5. Remove socket bolts (5) (30 used). Remove the 19. Remove spacer (2) from casing (3).
pedestal (6) assembly from casing (3).
: 12 mm 20. Remove piston (23) from casing (3).
6. Remove bearings (7) (2 used), oil seal (33) and 21. Remove packings (17, 18) from piston (23).
O-ring (4) from pedestal (6).
7. Remove sleeve (34) from shaft (9).
10. Remove brake plates (14) (26 used) and friction

discs (15) (25 used) from casing (3).
11. Remove spacer (16) from casing (3).
12. Turn over and place the casing (3) assembly on a

workbench.
W2-7-39
ASSEMBLE BRAKE UNIT
25
28
29
33
26
30 34
31 32
27
35
1 2 3 4 5 6 7
8
24
9
23
22
10
11
21
12
20 19 18 17 16 15 14 13
W25N-02-07-012

6- Pedestal㩷 15 - Friction Plate (25 Used)㩷 24 - Cover㩷 33 - Oil Seal㩷
W2-7-40
Assemble Brake Unit
1. Place casing (3) on the workbench with the flange 15. Install O-ring (35) onto sleeve (34).
part facing upward.
16. Install sleeve (34) to shaft (9) with the larger
2. Install packings (17, 18) to piston (23). chamfered outer surface facing upward.
3. Install piston (23) to casing (3). 17. Install oil seal (30) and O-ring (4) to pedestal (6).
4. Install spacer (2) to casing (3). 18. Install pedestal (6) to casing (3). Apply LOCTITE
#262 to socket bolts (5) (30 used). Tighten socket
5. Install springs (22) (18 used) to casing (3). bolts (5) (30 used).
: 12 mm
6. Install O-ring (19) on cover (24). : 140 Nm (14 kgfm, 103 lbfft)
7. Install cover (24) onto casing (3). Install washer 19. Install bearings (7)(2 used) to shaft (9).
(20) to bolts (21) (24 used). Apply LOCTITE #262
on bolts (21) (24 used). Tighten bolts (21) (24 20. Install retaining ring (8) to shaft (9).
used).
: 24 mm 21. Install bearing (13) to pedestal (6).
: 270 Nm (27.5 kgfm, 199 lbfft)
22. Install retainer (12) to pedestal (6). Install washer
8. Insert rod (30) and spring (32) into cover (24). (11) to bolts (10) (8 used). Apply LOCTITE #262
on bolts (10) (8 used). Tighten bolts (10) (8 used).
9. Install O-rings (28, 31) to adapter (29). : 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
10. Install adapter (29) to cover (24).

workbench.
12. Install spacer (16) to casing (3).
13. Install brake plates (14) (26 used) and friction

discs (15) (25 used) to casing (3).
14. Install shaft (9) to casing (3).
W2-7-41
(Blank)
W2-7-42
REMOVE AND INSTALL FOURTH WINCH
ASSEMBLY (OPTIONAL)

and cause serious injury. Release 1
2
Removal
1. Lower the boom and live-mast.䎃 3
2. Remove the wire rope from front and rear drums.

4. Remove bolts (3, 4) (8 used) from the tool box (1).

Disconnect connector (4) in the right house (7). 䎃
Hoist and remove tool box (1). W2BC-02-07-004
: 17 mm

4 W2BC-02-07-005
W2-7-43
5. Remove bolts (5, 6) (8 used) from the right house
(7). Hoist and remove the right house (7).
6. Lower the live-mast.䎃Remove the boom hoist wire

rope. (As for removal of the boom hoist wire rope,
refer to the Operator's Manual.)
7
7. Remove the backstop. (As for removal of the
6
5

W2BC-02-07-006
W2-7-44
8. Remove bolts (8) (3 used) and remove drum
9 8
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.䎃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.

winch motor. Attach a plug onto the removed
hoses.
8 W2BC-02-07-007
: 19 mm
: 22 mm
: 27 mm
: 32 mm 10 11
: 36 mm

W2BC-02-07-008
W2-7-45

1980 kg (4365 lb)
1980 kg (4365 lb)

motor.
assembly.䎃Hold the winch assembly.
12. Remove nut (14) (4 used) and remove bolt (15) (4

used). 13 12
: 24 mm 13 12 W2BC-02-07-009
13. Remove retaining rings (12) (4 used).䎃 Remove

pins (13) (4 used).䎃 Hoist and remove the hoist
mechanism.

13 12 14 12 13 W2BC-02-07-010
12 13 12
13 14 15 12 13
14

W2BC-02-07-011
W2-7-46
Installation

1980 kg (4365 lb)
1980 kg (4365 lb)

motor.
assembly. Hoist and align the winch assembly
with the upper revolving frame. 13 12
13 12 W2BC-02-07-009
2. Install the winch assembly to the upper revolving
frame with pins (13) (4 used).䎃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.䎃Tighten nut (14) (4 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

13 12 14 12 13 W2BC-02-07-010
12 13 12
15

W2BC-02-07-015
14
13 14 15 12 13
14

W2BC-02-07-011
W2-7-47
4. Install the wire harness and all hoses to winch
9 8
motor.
: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 32 mm
: 137 Nm (14 kgfm, 101 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
5. Install drum cover R (9) onto the upper revolving

frame with bolts (8) (3 used). Install drum cover L 8 W2BC-02-07-007
(11) onto the upper revolving frame with bolts (10)

(3 used).
: 19 mm 10 11
: 90 Nm (9.2 kgfm, 66 lbfft)

W2BC-02-07-008
W2-7-48
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.
7
8. Hoist and install right house (7).䎃Tighten bolts (5, 6).
6
: 17 mm
: 65 Nm (6.6 kgfm, 48 lbfft)
5

W2BC-02-07-006
W2-7-49
9. Connect connector (4) in the right house (7).
10. Hoist and install tool box (1).

Tighten bolts (2, 3)
: 17 mm
: 65 Nm (6.6 kgfm, 48 lbfft)
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. 4 W2BC-02-07-005

W2BC-02-07-004
W2-7-50
(Blank)
W2-7-51
DISASSEMBLE FOURTH WINCH ASSENBLY
1 2 3 4 5 6 7 8 9 11 13 14 13 12 15
10 12
16
42 17
20
18
12
35 26 21
13 27 24
34 32 30 22
41 39 40 38 37 36 33 31 29 28 25 23 19
43 44
47 46
48
45 49
50

W2BD-02-07-004

W2-7-52
Disassemble Fourth Winch Assenbly

CAUTION: Fourth winch assenbly weight: 10. Remove oil seal (48) from retainer (50).
11. Remove bearing (21) from pedestal (22).
Gear oil : 22.5 L (5.9 US gal) 12. Remove sleeve (47) from cover (24).
: 14 mm
check the metal powder due wear. 14. Remove bolts (10) (28 used) and remove cover
(24).
2. Lift the fourth winch assenbly with the crane and
place it on a workbench with placing the brake 30 mm
unit (42) downward. At this time, place the
wooden block (200 mm square) under the bracket 15. Remove shaft (8).
(41) to stable the fourth drum.
CAUTION: Fourth Winch motor (16) weight: 17. Remove spring pin (7). Remove pistons (29) (3
Approx. 220 kg (485 lb) used) from carrier (4).
3. Remove bolts (12) (4 used). Lift the motor (16) 18. Remove planetary gears (6) (3 used), thrust
assembly with the crane and remove it. plates (28) (6 used) and needle bearings (27) (6
: 30 mm used) from carrier (4).
4. Remove bolts (12) (12 used). Lift bracket (23) with 19. Remove spacer (5) from carrier (4).
: 30 mm 20. Remove sun gear (3).
5. Remove bolts (17) (2 used) and remove lock plate 21. Remove the carrier (35) assembly.
(18).
: 19 mm 22. Remove spring pin (30). Remove pins (34) (4
6. Remove nut (20).
7. Remove the pedestal (22) assembly. plates (33) (8 used) and needle bearings (31) (8
8. Remove bearing (21) from pedestal (22).

retainer (50) from pedestal (22).
: 10 mm
W2-7-53
1 2
42
12
35 26
41 39 38 37 36
43 44
45

W2BD-02-07-004
W2-7-54
25. Remove ring gear (26) from drum (1).
26. Remove bolts (39) (18 used). Lift drum (1) with
: 19 mm
27. Remove retaining ring (36) from brake unit (42).

Remove bearing (37).
28. Remove retainer (38).
30. Remove sleeve (43) from brake unit (42).

32. Remove bolts (12) (30 used). Lift brake unit (42)
with the crane and remove it from bracket (41).
: 30 mm
W2-7-55
ASSEMBLE FOURTH WINCH ASSENBLY
1 2 3 4 5 6 7 8 9 11 13 14 13 12 15
10 12
16
42 17
20
18
12
35 26 21
13 27 24
34 32 30 22
41 39 40 38 37 36 33 31 29 28 25 23 19
43 44
47 46
48
45 49
50

W2BD-02-07-004

W2-7-56
Assemble Fourth Winch Assenbly
1. Lift bracket (41) with the crane and place it onto 11. Install ring gear (26) to drum (1).
the workbench. Place the wooden block (200 mm
square) under bracket (41). 12. Place spacer (2) onto carrier (35).

(33) (8 used) and needle bearings (31) (8 used) to
Approx. 680 kg (1500 lb) carrier (35).
2. Lift brake unit (42) with the crane and install it to 14. Install pins (34) (4 used) to carrier (35). Insert
bracket (41). Install washer (13) to bolts (12) (30 spring pin (30). Face the slit part of spring pin (30)
used). Tighten bolts (12) (30 used). to the shaft of winch assembly.
: 30 mm
: 539 Nm (55 kgfm, 398 lbfft) 15. Install the carrier (35) assembly to ring gear (26)
and brake unit (42).
4. Install sleeve (43) to brake unit (42).
17. Place spacer (5) onto carrier (4).
5. Install oil seal (45) to retainer (38).
6. Install retainer (38) into brake unit (42). (28) (6 used) and needle bearings (27) (6 used) to
carrier (4).
7. Install bearing (37) onto brake unit (42). Install
retaining ring (36). 19. Install pins (29) (3 used) to carrier (4). Insert
spring pin (7).䎃Face the slit part of spring pin (7) to
8. Apply liquid packing (ThreeBond #1389) on the the shaft of winch assembly.
mating surface of the drum (1) and the retainer
(38). 20. Install the carrier (4) assembly to ring gear (26)
and sun gear (3).
9. Install the drum (1) on the brake unit (42) and
tighten it with the bolts (39) (18 used) with the 21. Install shaft (8) to the carrier (4) assembly.
washer (40) applied LOCTITE #262.
: 19 mm 22. Apply liquid packing (ThreeBond #1389) on the
: 88 Nm (9.0 kgfm, 65 lbfft) mating surface of the cover (24) and the ring gear
(26).
mating surface of the ring gear (26) and the drum
(1).
W2-7-57
8 11 13
10 12
17
20
18
26 21
24 22
23
47 46
48
49
50

W2BD-02-07-004
W2-7-58
23. Install cover (24) to ring gear (26). Install washer 32. Tighten nut (20) to cover (24) with placing the
(11) to bolts (10) (28 used). Tighten bolts (10) (28 step part to the bearing (21) side.
used). : 226 Nm (23 kgfm, 167 lbfft)
: 30 mm
: 539 Nm (55 kgfm, 398 lbfft) 33. Rotate pedestal (22) clockwise and
counterclockwise 4 to 5 times.
34. Tap the end of pedestal (22) with using a plastic
25. Install sleeve (47) on cover (24). hammer. Tighten nut (20) to cover (24) again.
(Repeat it twice.) Adjust dimension C to 14 to 16
26. Install bearing (21) to the retainer (50) side of mm.
pedestal (22). : 226 Nm (23 kgfm, 167 lbfft)
27. Install oil seal (48) to retainer (50). 35. Apply LOCTITE #262 onto bolts (17) (2 used).
Install lock plate (18) onto nut (20) with bolts (17)
28. Apply liquid packing (ThreeBond #1389) on the (2 used).
mating surface of the pedestal (22) and the : 19 mm
retainer (50). : 88 Nm (9.0 kgfm, 65 lbfft)
29. Install retainer (50) to pedestal (22). Apply 36. Lift the bracket (23) with the crane and tighten it
LOCTITE #262 onto socket bolts (49) (8 used). with the bolts (12) (12 used) with the washer (13)
Tighten socket bolts (49) (8 used). attached.
: 10 mm : 30 mm
: 88 Nm (9.0 kgfm, 65 lbfft) : 539 Nm (55 kgfm, 398 lbfft)
30. Install bearing (21) to pedestal (22). 37. Tap the end of shaft (8) with using a plastic
hammer several times.䎃 Check if dimension L
31. Install the pedestal (22) assembly to cover (24). between the end of pedestal (22) and that of shaft
(8) is 22 to 23 mm.
W2-7-59
13 12 15
16
24 22
25

W2BD-02-07-004
W2-7-60
mating surface of the motor (16) and the pedestal
(22).
CAUTION: Fourth winch motor (16) weight:

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 Nm (55 kgfm, 398 lbfft)
CAUTION: Fourth winch assenbly weight:

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
NOTE: Wind the seal tape onto plug (25).
W2-7-61
DISASSEMBLE FOURTH WINCH MOTOR
5
32
4 31
3 7 30
2 19 29
6 18
17 28
16 27
15 26
13
14 25
12
1 11 24
10
9
8
23
20 21
36 38
22
37
53
34
52 51
35
50
49 51
43 49
44
33 49
49
52
48
42 51
45 55
52
55
41 55 62
40 61 63
47
39 34
60
46
59
58
35
57
56
54 34
35

W2CM-02-07-009
W2-7-62
1- Bolt (4 Used)㩷 17 - Stopper㩷 33 - Socket Bolt (14 Used)㩷 49 - Plate (8 Used)㩷

2- Front Cover㩷 18 - Cover㩷 34 - O-Ring (5 Used)㩷 50 - Retaining Ring㩷
3- Oil Seal㩷 19 - Socket Bolt (4 Used)㩷 35 - Plug (5 Used)㩷 51 - O-Ring (3 Used)㩷
4- O-Ring㩷 20 - Front Casing㩷 36 - Select Plate㩷 52 - Plug (3 Used)㩷
5- Output Shaft㩷 21 - O-Ring㩷 37 - Socket Bolt (4 Used)㩷 53 - Casing㩷
6- Bearing㩷 22 - O-Ring (4 Used)㩷 38 - Plunger (9 Used)㩷 54 - Socket Bolt (9 Used)㩷
7- Retaining Ring㩷 23 - Casing㩷 39 - O-Ring㩷 55 - Friction Plate (7 Used)㩷
8- Socket Bolt (4 Used)㩷 24 - Pin㩷 40 - Pin㩷 56 - O-Ring㩷
9- Cover㩷 25 - Swash Plate㩷 41 - Valve Cover㩷 57 - O-Ring㩷
10 - Stopper㩷 26 - Shoe Plate㩷 42 - Spring Washer (6 Used)㩷 58 - Piston㩷
11 - O-Ring㩷 27 - Plate㩷 43 - Socket Bolt (6 Used)㩷 59 - Spring (16 Used)㩷
12 - Piston㩷 28 - Holder㩷 44 - Counterbalance Valve㩷 60 - O-Ring㩷
13 - Socket Bolt (4 Used)㩷 29 - Spring (9 Used)㩷 45 - Socket bolt㩷 61 - Cover㩷
14 - Regulator㩷 30 - Rotor㩷 46 - O-Ring㩷 62 - Socket Bolt (12 Used)㩷
15 - Piston 31 - Valve Plate 47 - Shim (1 Set) 63 - Plug
16 - O-Ring 32 - Needle Bearing 48 - Coupling
W2-7-63
5
32
4 31
3 30
2 19
18
17 28
16 27
15
13
14
12
1 11
10
9
8
23
20
36 38
37
53
35
50
49
43 49
44
33 49
49
48
42
45 55
55
41 55 62
61
47
39
60
46
59
58
35
57
56
54
35

W2CM-02-07-009
W2-7-64
Disassemble Fourth Winch Motor

CAUTION: Fourth winch motor weight: 10. Remove retaining ring (50) and coupling (48) from
Approx. 220 kg (485 lb) output shaft (5).
1. Place the fourth winch motor on a workbench.䎃 11. Remove plates (49) (8 used), friction plates (55)
Remove plug (35) from casing (23). Drain off (7 used), shim (47) and O-ring (46) from valve
hydraulic oil. cover (41).
: 36 mm
IMPORTANT: Valve plate (31) may be removed
with valve cover (41) together.䎃 Do
CAUTION: Regulator weight:
not fall off valve plate (31).
Approx. 8.0 kg (18 lb) 12. Remove socket bolts (45) and (54) (9 used).䎃
Remove valve cover (41) from casing (23).
2. Remove socket bolts (13) (4 used). Remove the : 14 mm
regulator (14) from fourth winch motor.
: 6 mm
13. Remove valve plate (31) and O-ring (39) from
valve cover (41).
CAUTION: Counterbalance valve weight:
NOTE: Do not remove needle bearing (32) unless
necessary.
3. Remove socket bolts (43) (6 used) and spring
14. Remove rotor (30), plungers (38) (9 used), holder
washer (42) (6 used). Remove the
(28) and plate (27) from casing (23).
counterbalance valve (44) from fourth winch
motor.
15. Remove socket bolts (8) (4 used) and (19) (4
: 10 mm
used). 䎃 Remove covers (9, 18) from casing (23).
: 10 mm, 12 mm
CAUTION: Select plate weight:
Approx. 7.0 kg (15 lb) 16. Remove stoppers (10, 17) and pistons (12, 15)
from casing (23).
4. Remove socket bolts (37) (4 used). Remove the NOTE: Remove stoppers (10, 17) with using a
select plate (36) from fourth winch motor. screw (M6).
: 5 mm
17. Remove O-rings (11, 16) from stoppers (10, 17).
5. Put the matching marks onto front casing (20),
casing (23), valve cover (41), casing (53) and 18. Remove bolts (1) (4 used). Remove front cover
cover (61). (2) from front casing (20).
: 17 mm
cover (61) from casing (53). 19. Remove oil seal (3) and O-ring (4) from front
: 10 mm cover (2).
7. Remove O-ring (60) from cover (61). 20. Remove socket bolts (33) (14 used). Remove
front casing (20) from casing (23).
8. Remove springs (59) (16 used) and piston (58) : 10 mm
from casing (53).
9. Remove casing (53) from valve cover (41).䎃

Remove O-rings (56, 57) from casing (53).
W2-7-65
7
6
26
25
23
20 21
22

W2CM-02-07-009
W2-7-66
21. Remove O-rings (22) (4 used) from casing (23)
and O-ring (21) from front casing (20)
respectively.
22. Remove output shaft (5) from front casing (20).
23. Remove retaining ring (7) from output shaft (5).

Remove bearing (6) with using a press.
24. Remove swash plate (25) from casing (23).

Remove shoe plate (26) from swash plate (25).
W2-7-67
ASSEMBLE FOURTH WINCH MOTOR
13 14
43
44
36
23 42
37
41
10 8 11 12 24 23 15 17 16 18 19 40 41 45 47 49 55 46 56
9
57
22
60
21
3 58
5 59
7 61
63
35
6 34
2 50
62
20
48
33 25 26 27 34 35 28 38 29 30 39 31 54 32 52 51 53

W2CM-02-07-010
W2-7-68
1- Bolt (4 Used)㩷 17 - Stopper㩷 33 - Socket Bolt (14 Used)㩷 49 - Plate (8 Used)㩷

2- Front Cover㩷 18 - Cover㩷 34 - O-Ring (5 Used)㩷 50 - Retaining Ring㩷
3- Oil Seal㩷 19 - Socket Bolt (4 Used)㩷 35 - Plug (5 Used)㩷 51 - O-Ring (3 Used)㩷
4- O-Ring㩷 20 - Front Casing㩷 36 - Select Plate㩷 52 - Plug (3 Used)㩷
5- Output Shaft㩷 21 - O-Ring㩷 37 - Socket Bolt (4 Used)㩷 53 - Casing㩷
6- Bearing㩷 22 - O-Ring (4 Used)㩷 38 - Plunger (9 Used)㩷 54 - Socket Bolt (9 Used)㩷
7- Retaining Ring㩷 23 - Casing㩷 39 - O-Ring㩷 55 - Friction Plate (7 Used)㩷
8- Socket Bolt (4 Used)㩷 24 - Pin㩷 40 - Pin㩷 56 - O-Ring㩷
9- Cover㩷 25 - Swash Plate㩷 41 - Valve Cover㩷 57 - O-Ring㩷
10 - Stopper㩷 26 - Shoe Plate㩷 42 - Spring Washer (6 Used)㩷 58 - Piston㩷
11 - O-Ring㩷 27 - Plate㩷 43 - Socket Bolt (6 Used)㩷 59 - Spring (16 Used)㩷
12 - Piston㩷 28 - Holder㩷 44 - Counterbalance Valve㩷 60 - O-Ring㩷
13 - Socket Bolt (4 Used)㩷 29 - Spring (9 Used)㩷 45 - Socket bolt㩷 61 - Cover㩷
14 - Regulator㩷 30 - Rotor㩷 46 - O-Ring㩷 62 - Socket Bolt (12 Used)㩷
15 - Piston 31 - Valve Plate 47 - Shim (1 Set) 63 - Plug
16 - O-Ring 32 - Needle Bearing 48 - Coupling
W2-7-69
23
10 8 11 12 23 15 17 16 18 19 40 41 45
22
21
20
33 25 26 27 28 38 29 30 39 31 54

W2CM-02-07-010
W2-7-70
Assemble Fourth Winch Motor
1. Install shoe plate (26) to swash plate (25). Install 12. Install cover (9) onto casing (23) with socket bolts
swash plate (25) to casing (23). (8) (4 used).
NOTE: Face the larger chamfered side of shoe : 10 mm
plate (26) to the swash plate (25) side. : 98 Nm (10 kgfm, 72 lbfft)
13. Install springs (29) (9 used) to rotor (30). Install

2. Install bearing (6) onto output shaft (5) with using holder (28).
a press. Install retaining ring (7).
14. Install plungers (38) (9 used) to plate (27). Install
3. Lightly tap the outer race of bearing (6) and install plunger (38) to rotor (30).
output shaft (5) to front casing (20) with using a
copper bar.
15. Align the spline of output shaft (5) with that of rotor
4. Install O-ring (21) to front casing (20) and O-rings (30) and holder (28). Install the rotor (30)
(22) (4 used) to casing (23) respectively. assembly to output shaft (5).
5. Install front casing (20) and output shaft (5) onto 16. Apply grease onto valve plate (31).䎃Align it with pin
casing (23). (40) and install valve plate (31) on valve cover
(41). Install O-ring (39) onto valve cover (41).
IMPORTANT: Check if swash plate (25) moves 17. Place casing (23) on the workbench vertically.
smoothly.
6. Install socket bolts (33) (14 used). 18. Install valve cover (41) onto casing (23) with
: 10 mm socket bolts (45) and (54) (9 used).
: 98 Nm (10 kgfm, 72 lbfft) : 14 mm
: 333 Nm (34 kgfm, 246 lbfft)
7. Install oil seal (3) onto front cover (2). Install
O-ring (4).
8. Install front cover (2) to front casing (20) with

: 17 mm
: 57 Nm (5.8 kgfm, 42 lbfft)
9. Install piston (12) to the front casing (20) side of

casing (23) and piston (15) to the valve cover (41)
side.
10. Install O-ring (11) to stopper (10) and o-ring (16)

to stopper (17) respectively. Install stoppers (10,
17) to casing (23).
NOTE: Install stoppers (10, 17) until stoppers (10,
17) touch with the end of casing (23).
11. Install cover (18) onto casing (23) with socket

bolts (19) (4 used).
: 12 mm
: 160 Nm (16.5 kgfm, 118 lbfft)
W2-7-71
13 14
43
44
36
23 42
37
41
41 47 49 55 46 56
57
60
58
5 59
61
35
34
50
62
48
34 35 53

W2CM-02-07-010
W2-7-72
19. Install coupling (48) to output shaft (5). Install CAUTION: Regulator weight:
retaining ring (50). Approx. 8.0 kg (18 lb)
IMPORTANT: Align the notches on plate (49) and 28. Install regulator (14) to casing (23) with socket
friction plate (55). Adjust shims (47) bolts (13) (4 used).
so that the dimension between end : 6 mm
of valve cover (41) and plate (49) : 29 Nm (3.0 kgfm, 21 lbfft)
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.
21. Install O-ring (46) onto valve cover (41).
22. Install O-rings (56, 57) onto casing (53). Install

piston (58).
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 Nm (10 kgfm, 72 lbfft)
25. Install O-ring (34) to plug (35). Install plug (35) to

casing (23).
: 36 mm
: 167 Nm (17 kgfm, 123 lbfft)
CAUTION: Select plate weight:

26. Install select plate (36) to the casing (23) with

: 5 mm
: 12 Nm (1.2 kgfm)

27. Install counterbalance valve (44) to valve cover

(41) with socket bolts (43) (6 used) and spring
washer (42) (6 used).
: 10 mm
: 69 Nm (7.0 kgfm, 8.9 lbfft)
W2-7-73
Dial Gauge㩷
1. Secure the plunger with the shoe attached in a

vise. Clearance㩷
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
Guide
beyond allowable limit, replace the plunger and
shoe assembly.
Unit: mm (in)
0 to 0.1 (0 to 0.004) 0.3 (0.012) Vise㩷 Soft Liner㩷
W309-04-05-002
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. W309-04-05-003
Unit: mm (in)
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)
8.8 (0.35) 8.6 (0.34) W309-04-05-004
B
W309-04-05-005㩷
W2-7-74
4. Measure heights of H and h.
C=H-h Plate㩷 Holder
Unit: mm (in)
32.2 (1.27) 31.6 (1.24) H
h
Remedy: Replace the holder and plate as an

assembly.
W309-04-05-006
5. Measure dimension (A).

Unit: mm (in)
3.1 (0.12) 3.6 (0.14)
A
Remedy: Adjust the shims.
6. Measure the brake spring length.

Unit: mm (in)
Standard Allowable Limit W309-04-05-007
54 (2.13) 53.2 (2.09)
7. Measure the thickness of plate and friction plate.

(15 used)
Unit: mm (in)
32.4 (1.28) 31.7 (1.25)
Remedy: Replace the plate.
W2-7-75
DISASSEMBLE COUNTERBALANCE VALVE

9
8
7
19
21 15 6
20
35
5 3
16 4 2
17
18 12 1
13
22 14
23
24
25
26
12
27 13 10
28 11
29
30
31
32
33
33 34

W25N-02-07-010

W2-7-76
Disassemble Counterbalance Valve

CAUTION: Counterbalance valve weight: 14. Remove spring (29) and plunger (28) from casing
Approx. 20 kg (45 lb) (14).
NOTE: Do not remove seat (27) unless necessary.
1. Remove socket bolts (15) (6 used) and spring
washers (16) (6 used). Remove counterbalance 15. Remove relief valve (34) from casing (14).
valve from the motor. : 36 mm
: 10 mm
16. Remove O-ring and backup ring from relief valve
2. Remove O-rings (33) (2 used) from casing (14). (34).
3. Remove socket bolts (1, 22) (4 used for each).
Remove covers (3, 24) from casing (14).
: 10 mm
4. Remove plug (21) from cover (24).

: 6 mm
5. Remove plug (10) from cover (3). Remove O-ring

(10) from plug (11).
: 6 mm
7. Remove springs (26) and O-rings (4, 25) from

casing (14).
8. Remove the spool (6) assembly from casing (14).
9. Remove plug (5) from spool (6). Remove filter

(35) from plug (5).
10. Remove filter (35) from plug (5).
11. Remove orifice (9), spring (8) and steel ball (7)
from spool (6).

: 41 mm
13. Remove O-ring (30) and backup ring (31) from

plug (32).
W2-7-77
ASSEMBLE COUNTERBALANCE VALVE
22 23 24 25 26 9 8 7 14 6 13 12 35 5 4 3
11
20
10
21
1
27 28 29 32 31 30 34
19 17 18 15
16
33
W25N-02-07-011

W2-7-78
Assemble Counterbalance Valve
1. Install O-ring and backup ring to relief valve (34). 12. Install cover (24) to casing (14) with socket bolts
(22) (4 used) and spring washers (23) (4 used).
2. Install relief valve (34) to casing (14). : 10 mm
: 36 mm : 88 to 108 Nm (9.0 to 11.0 kgfm)
: 166 to 186 Nm (17.0 to 19.0 kgfm) (65 to 80 lbfft)
(122 to 137 lbfft)
13. Install O-ring (11) to plug (10).
3. Install O-ring (30) and backup ring (31) to plug
(32). 14. Install plug (10) on cover (3).
: 6 mm
4. Install spring (29) to plunger (28). Install plunger : 34 to 38 Nm (3.5 to 3.9 kgfm)
(28) to plug (32). (25 to 28 lbfft)
5. Install plug (32) to casing (14). 15. Install O-ring (20) to plug (21).
: 41 mm
: 181 to 211 Nm (18.5 to 21.5 kgfm) 16. Install plug (21) on cover (24).
(134 to 156 lbfft) : 6 mm
: 34 to 38 Nm (3.5 to 3.9 kgfm)
6. Install filter (35) to plug (5). Install plug (5) to spool (25 to 28 lbfft)
(6).
17. Install O-rings (33) (2 used) onto casing (14).
7. Install steel ball (7), spring (8) and orifice (9) to
spool (6).
IMPORTANT: Check if spool (6) moves smoothly. Approx. 20 kg (45 lb)
8. Install spool (6) to casing (14).
18. Install counterbalance valve to motor with socket
9. Install spring (26) to casing (14). bolts (15) (6 used) and spring washers (16) (6 used).
: 10 mm
: 69 Nm (7.0 kgfm, 51 lbfft)
10. Install O-rings (4, 25) onto casing (14).
11. Install cover (3) to casing (14) with socket bolts (1)
(4 used) and spring washers (2) (4 used).
: 10 mm
: 88 to 108 Nm (9.0 to 11.0 kgfm)
(65 to 80 lbfft)
W2-7-79
1 2 3 4 5 6 7 8
7
10
33
11
32
34
12
35
31 13
14
30
15
29 16
17
28
36
4 27 26 25 24 23 22 21 20 9 19 18
37
38 39 1 40 41

W25N-02-07-009
1- O-Ring (3 Used)㩷 12 - Spring Seat㩷 22 - Plug㩷 32 - Piston㩷

2- O-Ring (2 Used)㩷 13 - Cover (2 Used)㩷 23 - Spring㩷 33 - Sleeve㩷
3- Plug (2 Used)㩷 14 - Adjusting Screw (2 Used)㩷 24 - Spool㩷 34 - Pin㩷
4- Plug (12 Used)㩷 15 - Nut (2 Used)㩷 25 - Sleeve㩷 35 - Lever㩷
5- Casing㩷 16 - Socket Bolt (4 Used)㩷 26 - O-Ring㩷 36 - O-Ring㩷
6- Solenoid Valve㩷 17 - Spring Seat㩷 27 - Piston㩷 37 - Plug㩷
7- Sleeve㩷 18 - O-Ring㩷 28 - Pin㩷 38 - Pin㩷
8- Spool㩷 19 - Spring㩷 29 - Cover㩷 39 - Orifice㩷
9- Spring Seat (2 Used)㩷 20 - Lock Pin㩷 30 - O-Ring㩷 40 - O-Ring㩷
10 - Spring㩷 21 - O-Ring㩷 31 - Socket Bolt (6 Used)㩷 41 - Socket Bolt (4 Used)㩷
11 - O-Ring
W2-7-80

CAUTION: Regulator weight: 16. Remove lever (21) from sleeve (22).
1. Remove socket bolts (41) (4 used). Remove (9), spool (24) and sleeve (25) from casing (5).
regulator from the motor.
: 6 mm 18. Remove O-ring (18) from spring seat (17).
2. Remove solenoid valve (6) from casing (5).

: 32 mm
3. Remove O-rings (1, 40) from casing (5).
4. Remove orifice (39) from casing (5).

: 4 mm
5. Remove socket bolts (31) (6 used).䎃Remove cover

: 5 mm
6. Remove O-rings (1, 26, 30) from casing (5).
7. Remove pin (28) and piston (27) from cover (29).
8. Remove piston (32) and sleeve (33) from cover

(29).
IMPORTANT: Do not disassemble adjusting screw

(14) and nut (15).
9. Remove socket bolt (16).䎃Remove covers (13) (2
used) from casing (5).
: 5 mm

: 8 mm
12. Remove lever (35) from sleeve (7).

15. Remove plug (22) from casing (5). Remove spring

(23) and lock pin (20).
: 13 mm
W2-7-81
ASSEMBLE REGULATOR
1 2 3 4 5 6 7 8
7
10
33
11
32
34
12
35
31 13
14
30
15
29 16
17
28
36
4 27 26 25 24 23 22 21 20 9 19 18
37
38 39 1 40 41

W25N-02-07-009
1- O-Ring (3 Used)㩷 12 - Spring Seat㩷 22 - Plug㩷 32 - Piston㩷

2- O-Ring (2 Used)㩷 13 - Cover (2 Used)㩷 23 - Spring㩷 33 - Sleeve㩷
3- Plug (2 Used)㩷 14 - Adjusting Screw (2 Used)㩷 24 - Spool㩷 34 - Pin㩷
4- Plug (12 Used)㩷 15 - Nut (2 Used)㩷 25 - Sleeve㩷 35 - Lever㩷
5- Casing㩷 16 - Socket Bolt (4 Used)㩷 26 - O-Ring㩷 36 - O-Ring㩷
6- Solenoid Valve㩷 17 - Spring Seat㩷 27 - Piston㩷 37 - Plug㩷
7- Sleeve㩷 18 - O-Ring㩷 28 - Pin㩷 38 - Pin㩷
8- Spool㩷 19 - Spring㩷 29 - Cover㩷 39 - Orifice㩷
9- Spring Seat (2 Used)㩷 20 - Lock Pin㩷 30 - O-Ring㩷 40 - O-Ring㩷
10 - Spring㩷 21 - O-Ring㩷 31 - Socket Bolt (6 Used)㩷 41 - Socket Bolt (4 Used)㩷
11 - O-Ring
W2-7-82
Assemble Regulator
1. Install sleeve (25), spool (24), spring seat (9) and 17. Install orifice (39) to casing (5).䎃Install O-rings (1, 40).
spring (19) to casing (5). : 4 mm
: 9 Nm (0.9 kgfm, 6.7 lbfft)
2. Install O-ring (18) to spring seat (17). Install spring
seat (17) to casing (5). 18. Install solenoid valve (6) to casing (5).
: 32 mm
3. Install cover (13) to casing (5) with socket bolt : 44 Nm (4.5 kgfm, 32 lbfft)
(16).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft) CAUTION: Regulator weight:
4. Install lock pin (20) and spring (23) to casing (5).
19. Install regulator to the motor with socket bolts (41)
5. Install O-ring (21) to plug (22).䎃Install plug (22) to (4 used).
casing (5). : 6 mm
: 13 mm : 29 Nm (3.0 kgfm, 21 lbfft)
: 29 Nm (3.0 kgfm, 21 lbfft)
6. Install sleeve (7) and spool (8) to casing (5).
7. Install lever (35) to sleeve (7).
8. Install O-ring (36) to plug (37).䎃 Install plug (32) to

casing (5).
: 8 mm
: 44 Nm (4.5 kgfm, 32 lbfft)
9. Install spring seat (9) and spring (10) to casing

(5).
10. Install O-ring (11) to spring seat (12).䎃Install spring

seat (12) to casing (5).
11. Install cover (13) to casing (5) with socket bolt

(16).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
12. Install piston (27) to casing (5).
13. Install O-rings (1, 26, 30) on casing (5).
14. Install pin (28) to cover (29).
15. Install sleeve (33) and piston (32) to cover (29).
16. Install cover (29) onto casing (5) with socket bolts
(31) (6 used).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-7-83
SWING MACHINERY / Winch Assembly
DISASSEMBLE BRAKE UNIT
25
28
29
33
26
30 34
31 32
27
35
1 2 3 4 5 6 7
8
24
9
23
22
10
11
21
12
20 19 18 17 16 15 14 13
W25N-02-07-012

6- Pedestal㩷 15 - Friction Disc (25 Used)㩷 24 - Cover㩷 33 - Oil Seal㩷
W2-7-84
Disassemble Brake Unit

CAUTION: Brake unit weight: 13. Remove adapter (29) from cover (24).
14. Remove O-rings (28, 31) from adapter (29).
1. Hoist and place the brake unit on a workbench
with shaft (9) facing upward. 15. Remove rod (30) and spring (32) from cover (24).
2. Remove bolts (10) (8 used) and remove retainer 16. Remove bolts (21) (24 used). Remove cover (24)
(12). from casing (3).
: 19 mm : 24 mm
3. Remove bearing (13) from pedestal (6). 17. Remove O-ring (19) from cover (24).
4. Remove retaining ring (8) from shaft (9). 18. Remove springs (22) (18 used) from casing (3).
5. Remove socket bolts (5) (30 used). Remove the 19. Remove spacer (2) from casing (3).
pedestal (6) assembly from casing (3).
: 12 mm 20. Remove piston (23) from casing (3).
6. Remove bearings (7) (2 used), oil seal (33) and 21. Remove packings (17, 18) from piston (23).
O-ring (4) from pedestal (6).
7. Remove sleeve (34) from shaft (9).
10. Remove brake plates (14) (26 used) and friction

discs (15) (25 used) from casing (3).
11. Remove spacer (16) from casing (3).

workbench.
W2-7-85
ASSEMBLE BRAKE UNIT
25
28
29
33
26
30 34
31 32
27
35
1 2 3 4 5 6 7
8
24
9
23
22
10
11
21
12
20 19 18 17 16 15 14 13
W25N-02-07-012

6- Pedestal㩷 15 - Friction Plate (25 Used)㩷 24 - Cover㩷 33 - Oil Seal㩷
W2-7-86
Assemble Brake Unit
1. Place casing (3) on the workbench with the flange 15. Install O-ring (35) onto sleeve (34).
part facing upward.
16. Install sleeve (34) to shaft (9) with the larger
2. Install packings (17, 18) to piston (23). chamfered outer surface facing upward.
3. Install piston (23) to casing (3). 17. Install oil seal (30) and O-ring (4) to pedestal (6).
4. Install spacer (2) to casing (3). 18. Install pedestal (6) to casing (3). Apply LOCTITE
#262 to socket bolts (5) (30 used). Tighten socket
5. Install springs (22) (18 used) to casing (3). bolts (5) (30 used).
: 12 mm
6. Install O-ring (19) on cover (24). : 140 Nm (14 kgfm, 103 lbfft)
7. Install cover (24) onto casing (3). Install washer 19. Install bearings (7)(2 used) to shaft (9).
(20) to bolts (21) (24 used). Apply LOCTITE #262
on bolts (21) (24 used). Tighten bolts (21) (24 20. Install retaining ring (8) to shaft (9).
used).
: 24 mm 21. Install bearing (13) to pedestal (6).
: 270 Nm (27.5 kgfm, 199 lbfft)
22. Install retainer (12) to pedestal (6). Install washer
8. Insert rod (30) and spring (32) into cover (24). (11) to bolts (10) (8 used). Apply LOCTITE #262
on bolts (10) (8 used). Tighten bolts (10) (8 used).
9. Install O-rings (28, 31) to adapter (29). : 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
10. Install adapter (29) to cover (24).

workbench.
12. Install spacer (16) to casing (3).
13. Install brake plates (14) (26 used) and friction

discs (15) (25 used) to casing (3).
14. Install shaft (9) to casing (3).
W2-7-87
(Blank)
W2-7-88
CRANE UPPER / Raising/Lowering Mechanism
REMOVE AND INSTALL RAISING/LOWERING
MECHANISM 1

Removal

W2BC-02-08-005
1. Lower the boom and live-mast.

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.
W2-8-1
5. Disconnect connector (2).
2

W2BC-02-03-001
CAUTION: Boom stop lower frame weight :

4
6. Attach a wire rope onto the boom stop 5
lower-frame (3). Hold the boom stop lower frame
(3).
7. Remove lock pins (4) (4 used).

3
Remove pins (5) (4 used).
4
8. Hoist and remove the boom stop lower frame (3).
4
5

W2BC-02-08-001
4 5
W2-8-2
9. Remove bolts (6) (3 used), (7) (1 used) and
remove drum cover L (8). 8 6
: 19 mm
10. Remove bolts (6) (3 used), (7) (3 used) and 7

remove drum cover R (9).
: 19 mm
6 9
7
W2BD-02-08-001
W2-8-3
11. Remove bolts (11). Remove bracket (10) in the
drum speed sensor.
10
: 19 mm
11
boom hoist system.
: 27 mm
: 41 mm
W25N-02-08-002
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. 15
14. Remove nuts (13) (4 used) and remove bolts (12). 13

: 24 mm
15. Remove retaining rings (14) (4 used). Remove

pins (15) (4 used). Hoist and remove the boom
hoist system.
14 12

W2BC-02-08-003
12
12
13
13
12 12
15
15

W2BC-02-08-004
14
W2-8-4
Installation
12
CAUTION: Raising/Lowering mechanism 12
weight: Approx. 870 kg (1920 lb) 13
13
1. Attach a wire rope onto the boom hoist system.
Hoist and align the boom hoist system with the 12 12
upper revolving frame.
2. Install the boom hoist system to the upper

revolving frame with pins (15) (4 used). Install 15
15
retaining rings (14) (4 used).

W2BC-02-08-004
3. Adjust the boom hoist system by using bolts (12) 14
(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 Nm (18.3 to 19.8 kgfm)
(132 to 143 lbfft) 15
13
14 12

W2BC-02-08-003
10
4. Install bracket (10) in the drum speed sensor to
the boom hoist system with bolts (11). 11
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
W25N-02-08-002
W2-8-5
5. Install all hoses to boom hoist motor.
: 27 mm 8 6
: 93 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft) 7
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).
: 19 mm 6
: 72 to 78 Nm (7.4 to 8.0 kgfm)
(54 to 57 lbfft)
6 9
7
W2BD-02-08-001
W2-8-6
7. Connect Connector (2)
2

W2BC-02-03-001
CAUTION: Boom stop lower frame weight :

8. Attach a wire rope onto the boom stop 4

lower-frame (3). Hoist and install boom stop lower 5
frame (3).
9. Install pins (5) (4 used).

Install lock pins (4) (4 used)
3
5

W2BC-02-08-001
4 5
10. Set and install hanger (1). 1
11. Wind the boom hoist wire rope.
12. Install the counterweight. (As for install of the


W2BC-02-08-005
W2-8-7
DISASSEMBLE RAISING/LOWERING MECHANISM
8 9 10 11 12 7 13 14 7
6
15
16
1 2㩷 3 4 5㩷 3 6 7 17
18
19
20
21
22
23
24
25
26
27
33
34 28
46 45 44 43 42 41 40 39 38 37 36 35 32 31 30 29
1
47 23 48
43 49
41 50
42 51
52
53
20
21
22
W25N-02-08-004
W2-8-8
1- Motor㩷 15 - Cover㩷 28 - Thrust Plate (6 used)㩷 41 - Bolt (2 Used)㩷

2- Bolt (20 Used)㩷 16 - Shaft㩷 29 - Bolt (16 Used)㩷 42 - Lock Plate㩷
3- Washer (20 Used)㩷 17 - Retaining Ring㩷 30 - Spring Pin (3 Used)㩷 43 - Nut㩷
4- Bracket㩷 18 - Bearing㩷 31 - Thrust Plate (6 used)㩷 44 - Drum㩷
5- Bolt (20 Used)㩷 19 - Pin㩷 32 - Pin (3 Used)㩷 45 - Bearing (2 Used)㩷
6- Plug (6 Used)㩷 20 - Bolt (2 Used)㩷 33 - Needle Bearing (3 Used)㩷 46 - Floating Seal㩷
7- Spacer (3 Used)㩷 21 - Washer (2 Used)㩷 34 - Planetary Gear (3 Used)㩷 47 - Bearing㩷
8- Drum㩷 22 - Retainer㩷 35 - Spring Pin (3 Used)㩷 48 - Retainer㩷
9- Carrier㩷 23 - Bracket㩷 36 - Thrust Plate (6 used)㩷 49 - Washer (6 Used)㩷
10 - Sun Gear㩷 24 - Planetary Gear (3 Used)㩷 37 - Pin (3 Used)㩷 50 - Bolt (6 Used)㩷
11 - Ring Gear㩷 25 - Spring Pin (3 Used)㩷 38 - Planetary Gear (3 Used)㩷 51 - Grease Nipple㩷
12 - Carrier㩷 26 - Needle Bearing (3 Used)㩷 39 - Bolt (28 Used)㩷 52 - Oil Seal㩷
13 - Sun Gear㩷 27 - Pin (3 Used)㩷 40 - Needle Bearing (6 Used)㩷 53 - Sleeve㩷
14 - Carrier
W2-8-9
8 9 10 11 12 7 13 14 7
15
16
1 4 5㩷 6 17
18
19
20
22
23
24
25
26
27
33
34 28
39 32 31 30 29
1
47 23 48
50
52
53
20
22
W25N-02-08-004
W2-8-10
Disassemble Raising/Lowering Mechanism

CAUTION: Raising/Lowering mechanism 11. Remove pin (19) from cover (15).
weight: Approx. 870 kg (1920 lb)
12. Remove retaining ring (17) from cover (15).
1. Hoist and place the boom hoist system on a Remove bearing (18).
workbench. Remove plug (6) and drain off gear
oil. 13. Remove shaft (16).
Gear oil: 9.2 L (9.7 US qt)
: 10 mm 14. Remove the carrier (14) assembly.
NOTE: Put gear oil in the clean container and
check the metal powder because of 15. Remove spring pin (25). Remove pins (27) (3
wearing. used) from carrier (14).
2. Remove bolts (20) (2 used) and remove retainer 16. Remove planetary gears (24) (3 used), thrust
(22). plates (28) (6 used) and needle bearings (26) (3
: 19 mm used) from carrier (14).
3. Remove bolts (50) (6 used) and remove retainer 17. Remove spacer (7) from carrier (14).
(48).
: 19 mm 18. Remove sun gear (13).

20. Remove spring pin (30). Remove pins (32) (3
5. Remove sleeve (53) from drum (8). used) from carrier (12).
6. Hoist and remove bracket (23) from drum (8). 21. Remove planetary gears (34) (3 used), thrust
7. Remove bearing (47) from bracket (23). used) from carrier (12).
8. Hoist and place the boom hoist system on a 22. Remove spacer (7) from carrier (12).
workbench with motor (1) facing downward. Place
the wooden block (200 mm square) under bracket 23. Remove sun gear (10).
(4).
9. Remove bolts (5) (20 used). Hoist and remove ring gear (11).
drum (8). : 24 mm
: 30 mm
10. Remove bolts (29) (16 used) and remove cover
(15).
: 19 mm
W2-8-11
1 2㩷 4 7
46 45 44 43 42 41 40 38 37 36 35
43
41
42
W25N-02-08-004
W2-8-12
26. Remove spring pin (35). Remove pins (37) (3

29. Remove bolts (41) (2 used) and remove lock plate

(42).
: 19 mm
30. Remove nut (43).
31. Remove drum (44) from motor (1).
32. Remove bearing (45) from drum (44).
33. Remove bearing (45) and floating seal (46) from

motor (1).
CAUTION: Motor (1) weight:


motor (1) from bracket (4).
: 30 mm
W2-8-13
ASSEMBLE BOOM RAISING/LOWERING MECHANISM
8 9 10 11 12 7 13 14 7
6
15
16
1 2㩷 3 4 5㩷 3 6 7 17
18
19
20
21
22
23
24
25
26
27
33
34 28
46 45 44 43 42 41 40 39 38 37 36 35 32 31 30 29
1
47 23 48
43 49
41 50
42 51
52
53
20
21
22
W25N-02-08-004
W2-8-14
1- Motor㩷 15 - Cover㩷 28 - Thrust Plate (6 used)㩷 41 - Bolt (2 Used)㩷

2- Bolt (20 Used)㩷 16 - Shaft㩷 29 - Bolt (16 Used)㩷 42 - Lock Plate㩷
3- Washer (20 Used)㩷 17 - Retaining Ring㩷 30 - Spring Pin (3 Used)㩷 43 - Nut㩷
4- Bracket㩷 18 - Bearing㩷 31 - Thrust Plate (6 used)㩷 44 - Drum㩷
5- Bolt (20 Used)㩷 19 - Pin㩷 32 - Pin (3 Used)㩷 45 - Bearing (2 Used)㩷
6- Plug (6 Used)㩷 20 - Bolt (2 Used)㩷 33 - Needle Bearing (3 Used)㩷 46 - Floating Seal㩷
7- Spacer (3 Used)㩷 21 - Washer (2 Used)㩷 34 - Planetary Gear (3 Used)㩷 47 - Bearing㩷
8- Drum㩷 22 - Retainer㩷 35 - Spring Pin (3 Used)㩷 48 - Retainer㩷
9- Carrier㩷 23 - Bracket㩷 36 - Thrust Plate (6 used)㩷 49 - Washer (6 Used)㩷
10 - Sun Gear㩷 24 - Planetary Gear (3 Used)㩷 37 - Pin (3 Used)㩷 50 - Bolt (6 Used)㩷
11 - Ring Gear㩷 25 - Spring Pin (3 Used)㩷 38 - Planetary Gear (3 Used)㩷 51 - Grease Nipple㩷
12 - Carrier㩷 26 - Needle Bearing (3 Used)㩷 39 - Bolt (28 Used)㩷 52 - Oil Seal㩷
13 - Sun Gear㩷 27 - Pin (3 Used)㩷 40 - Needle Bearing (6 Used)㩷 53 - Sleeve㩷
14 - Carrier
W2-8-15
9 10 11 12 7 13
15
1 2㩷 3 4 7
33
34
46 45 44 43 42 41 40 39 38 37 36 35 32 31 30
43
41
42
W25N-02-08-004
W2-8-16
Assemble Raising/Lowering Mechanism 10. Install spacer (7) to carrier (9). Install planetary
gears (38) (3 used), thrust plates (36) (6 used)
1. Hoist and install bracket (4) on a workbench. and needle bearings (40) (6 used). Face the
grove side of planetary gear (38) to cover (15).
Place the wooden block (200 mm square) under
bracket (4). 11. Install pins (37) (3 used) to carrier (9). Insert
spring pin (35). Face the slit of spring pin (35) to
cover (15).
CAUTION: Motor (1) weight:
Approx. 140 kg (309 lb) 12. Install the carrier (9) assembly to motor (1).
2. Hoist and install motor (1) to bracket (4). Install 13. Apply liquid packing (THREEBOND #1389B) onto
washer (3) to bolts (2) (20 used). Apply LOCTITE the mating surface on drum (44) for ring gear (11).
#262 on bolts (2) (20 used). Tighten bolts (2) (20
used).
: 30 mm 14. Install ring gear (11) to drum (44). Apply LOCTITE
: 490 Nm (50 kgfm, 361 lbfft) #262 on bolts (39) (28 used). Tighten bolts (39)
(28 used).
3. Apply grease to floating seal (46). Install bearing : 24 mm
(45) and floating seal (46) to motor (1). : 265 Nm (27 kgfm, 195 Ibfft)

4. Install drum (44) to motor (1).
5. Install bearing (45) to drum (44). 16. Place spacer (7) onto carrier (12). Install planetary
gears (34) (3 used), thrust plates (31) (6 used)
6. Tighten nut (43) to motor (1) with the step part and needle bearings (33) (3 used).
facing to bearing (45).
: 490 Nm (50 kgfm, 361 lbfft) 17. Install pins (32) (3 used) to carrier (12). Insert
spring pin (30). Face the slit of spring pin (30) to
7. Rotate drum (44) clockwise and counterclockwise cover (15).
and 4 to 5 times.
18. Install the carrier (12) assembly to ring gear (11)
and sun gear (10).
8. Tap the end of drum (44) by using a plastic
hammer.䎃 Tighten nut (43) to motor (1) again.
(Repeat it twice.)
: 490 Nm (50 kgfm, 361 lbfft)
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 Nm (9.0 kgfm, 65 lbfft)
W2-8-17
8 11 13 14 7
15
16
1 5㩷 3 6 17
18
19
20
21
22
23
24
25
26
27
28
29
1
47 23 48
49
50
51
52
53
20
21
22
W25N-02-08-004
W2-8-18
20. Install spacer (7) to carrier (14). Install planetary 29. Hoist and place the boom hoist system onto the
gears (24) (3 used), thrust plates (28) (6 used) workbench horizontally.
and needle bearings (26) (3 used). Face the step
part of planetary gear (24) to motor (1). 30. Install bearing (47) to bracket (23) with the seal
surface facing inside.
21. Install pins (27) (3 used) to carrier (14). Insert
spring pin (25). Face the slit of spring pin (25) to 31. Hoist and install bracket (23) to drum (8).
cover (15).
32. Install sleeve (53) to drum (8).
22. Install the carrier (14) assembly to ring gear (11)
and sun gear (13). 33. Install oil seal (52) to retainer (48).
23. Install shaft (16) to the carrier (14) assembly. 34. Apply liquid packing onto the mating surface on
Check if shaft (16) can rotate by hands. bracket (23) for retainer (48).
24. Install bearing (18) to cover (15). Install retaining 35. Install retainer (48) to bracket (23). Install washer
ring (17). (49) to bolts (50) (6 used). Tighten bolts (50) (6
used).
25. Install pin (19) to cover (15). : 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
26. Apply liquid packing (THREEBOND #1389B) onto
the mating surface on ring gear (11) on cover 36. Apply liquid packing onto the mating surface on
(15). sleeve (53) for retainer (22).
27. Install cover (15) onto ring gear (11). Install the 37. Install washer (21) to bolts (20) (2 used). Tighten
washer to bolts (29) (16 used). Apply LOCTITE retainer (22) to the end of sleeve (53) with bolts
#262 on bolts (29) (16 used). Tighten bolts (29) (20) (2 used).
(16 used). : 19 mm
: 19 mm : 90 Nm (9.2 kgfm, 66 lbfft)
: 108 Nm (11 kgfm, 80 lbfft)
38. Add gear oil through the oil filler. Install plug (6).
28. Hoist and install drum (8) to the boom hoist Gear oil: 9.2 L (9.7 US qt)
system. Install washer (3) to bolts (5) (20 used). : 10 mm
Apply LOCTITE #262 on bolts (5) (20 used). : 49.5 Nm (5.0 kgfm, 37 lbfft)
Tighten bolts (5) (20 used). Align the hole (3
places) on drum (8) with plug (6) in the oil filler of 39. Apply grease through grease nipple (51) until
boom hoist system. grease comes out from the clearance of oil seal
: 30 mm (52).
: 490 Nm (50 kgfm, 361 lbfft)
W2-8-19
DISASSEMBLE Raising/Lowering MOTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
19
20
30 29 28 27 26 25 24 23 22 21

W2CM-02-08-004

1- Bearing 9- Spring (6 Used) 17 - Housing 24 - Plug
2- Pin 10 - Rotor 18 - Oil Seal 25 - O-Ring
3- Plate 11 - Retainer 19 - Retaining Ring 26 - O-Ring
4- Pin 12 - Swash Plate 20 - Shaft 27 - Disk Spring (2 Used)
5- Brake Valve 13 - Bushing 21 - Friction Plate (6 Used) 28 - Valve Plate
6- O-Ring 14 - Bearing 22 - Plate (6 Used) 29 - Socket Bolt (8 Used)
7- O-Ring 15 - Pin 23 - Brake Piston 30 - Plug (2 Used)
8- Piston (9 Used) 16 - Retaining Ring (2 Used)
W2-8-20
Disassemble Raising/Lowering Motor

CAUTION: Raising/Lowering motor weight: 13. Remove pistons (8) (9 used) from retainer (11).
14. Remove friction plates (21) (6 used) and plates
1. Lift the raising/lowering motor with the crane and (22) (6 used) from housing (17).
place it on a workbench. Remove plug (30). Drain
off gear oil. 15. Remove bushing (13) from shaft (20).
: 10 mm
16. Remove retainer (11) from housing (17).
check the metal powder due to wear.
17. Remove swash plate (12) from housing (17).
CAUTION: Brake valve weight: 18. Remove the shaft (20) assembly from housing
Approx. 23 kg (51 lb) (17).
2. Remove socket bolts (29) (8 used). Remove 19. Remove retaining rings (16) (2 used) from shaft
brake valve (5) from housing (17). (20). Remove bearing (14).
: 17 mm
20. Remove retaining ring (19) from housing (17).
Remove oil seal (18).
3. Remove O-ring (7) from brake valve (5).
4. Remove O-ring (6) from housing (17).
5. Remove disk springs (27) (2 used) from brake

piston (23).
6. Remove plate (3) from valve plate (28).
7. Remove bearing (1) from shaft (20).
8. Remove valve plate (28).
9. Remove brake piston (23) from housing (17).
10. Remove O-rings (25, 26) from brake piston (23).
11. Remove rotor (10) from shaft (20) and piston (8).
12. Remove springs (9) (6 used) from rotor (10).
W2-8-21
ASSEMBLE Raising/Lowering MOTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
19
20
30 29 28 27 26 25 24 23 22 21

W2CM-02-08-004
1- Bearing 9- Spring (6 Used) 17 - Housing 24 - Plug

2- Pin 10 - Rotor 18 - Oil Seal 25 - O-Ring
3- Plate 11 - Retainer 19 - Retaining Ring 26 - O-Ring
4- Pin 12 - Swash Plate 20 - Shaft 27 - Disk Spring (2 Used)
5- Brake Valve 13 - Bushing 21 - Friction Plate (6 Used) 28 - Valve Plate
6- O-Ring 14 - Bearing 22 - Plate (6 Used) 29 - Socket Bolt (8 Used)
7- O-Ring 15 - Pin 23 - Brake Piston 30 - Plug (2 Used)
8- Piston (9 Used) 16 - Retaining Ring (2 Used)
W2-8-22
Assemble Raising/Lowering Motor
1. Apply grease (Ocean #7) onto the inner surface of 13. Install valve plate (28) to plate (3). Install plate (3)
oil seal (18). Install oil seal (18) to housing (17). to rotor (10).
Install retaining ring (19).
14. Install bearing (1) to shaft (20) and plate (3).
IMPORTANT: Do not damage the sliding surface
on oil seal (18) in shaft (20). 15. Apply grease to O-ring (6). Install O-ring (6) to
2. Install bearing (14) and retaining rings (16) (2 housing (17).
used) to shaft (20). At this time, install the bearing
(14) so that the flange ring is positioned at the 16. Apply grease to O-ring (7). Install O-ring (7) to
small diameter of the shaft (20). brake valve (5).
3. Install the shaft (20) assembly to housing (17).

CAUTION: Brake valve weight:
4. Install swash plate (12) to housing (17). Approx. 23 kg (51 lb)
5. Install retainer (11) to housing (17). 17. Install brake valve (5) to housing (17) and install
with socket bolts (29) (8 used).
6. Install bushing (13) to shaft (20). : 17 mm
: 400 Nm (41.0 kgfm, 295 lbfft)
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.
W2-8-23
DISASSEMBLE BRAKE VALVE
1 2㩷 3 4 5 6 7 8
9
20
10
19
11
12
18
13, 14
17㩷
16 15

W25N-02-08-006

1- Retaining Ring㩷 6- Casing㩷 11 - Plug (2 Used)㩷 16 - Relief Valve㩷
2- Spring Guide㩷 7- Stopper㩷 12 - O-Ring (2 Used)㩷 17 - Spring㩷
3- Spring㩷 8- Spring (2 Used)㩷 13 - Plug (2 Used)㩷 18 - Poppet㩷
4- Ball㩷 9- O-Ring (2 Used)㩷 14 - O-Ring (2 Used)㩷 19 - Spring㩷
5- Spool㩷 10 - Plug (2 Used)㩷 15 - Plug㩷 20 - Stopper㩷
W2-8-24
Disassemble Brake Valve
• Thoroughly read “PRECAUTIONS FOR 13. Remove O-rings (2 used) and backup rings (2
DISASSEMBLING AND ASSEMBLING” (W1-1-1) used) from relief valve (16).
1. Remove plug (10) from casing (6). : 41 mm
: 41 mm
15. Remove O-rings (2 used) and backup rings (2
2. Remove spring (8), O-ring (9) and plug (11) from used) from plug (15).
plug (10).
: 5 mm 16. Remove plugs (13) (2 used) from casing (6).
: 6 mm
4. Remove stopper (7) from casing (6).

: 41 mm
6. Remove springs (8, 19), O-ring (9) and plug (11)

from plug (10).
: 5 mm
8. Remove stopper (20) from casing (6).
9. Remove spool (5) from casing (6).
10. Remove retaining ring (1) from spool (5). Remove

spring guide (2) and ball (4).
11. Remove spring (3) from spring guide (2).
12. Remove relief valve (16) from casing (6). Remove

spring (17) and poppet (18).
: 41 mm
W2-8-25
ASSEMBLE BRAKE VALVE
1 2㩷 3 4 5 6 7 8
9
20
10
19
11
12
18
13, 14
17
16 15
W25N-02-08-006
㪈㩷㪄㩷 Retaining Ring㩷 6- Casing㩷 11 - Plug (2 Used)㩷 16 - Relief Valve㩷

㪉㩷㪄㩷 Spring Guide㩷 7- Stopper㩷 12 - O-Ring (2 Used)㩷 17 - Spring㩷
㪊㩷㪄㩷 Spring㩷 8- Spring (2 Used)㩷 13 - Plug (2 Used)㩷 18 - Poppet㩷
㪋㩷㪄㩷 Ball㩷 9- O-Ring (2 Used)㩷 14 - O-Ring (2 Used)㩷 19 - Spring㩷
㪌㩷㪄㩷 Spool㩷 10 - Plug (2 Used)㩷 15 - Plug㩷 20 - Stopper㩷
W2-8-26
Assemble Brake Valve
1. Apply grease to O-ring (14). Install O-ring (14) to 9. Install ball (4) and spring guide (2) to spool (5).
plugs (13) (2 used). Install retaining ring (1).
2. Install plugs (13) (2 used) to casing (6). 10. Install spool (5) to casing (6).
: 6 mm
: 35 Nm (3.6 kgfm, 26 lbfft) 11. Apply grease to O-ring (12). Install O-ring (12)
plugs (11) (2 used).
3. Install O-rings (2 used) and backup rings (2 used)
to plug (15). Apply grease to O-ring and the 12. Install plug (11) to plugs (10) (2 used).
O-ring mounting part of plug (15). : 5 mm
: 15 Nm (1.5 kgfm, 11 lbfft)
4. Install plug (15) to casing (6).
: 41 mm 13. Apply grease to O-ring (9). Install O-ring (9) to
: 450 Nm (46.0 kgfm, 332 lbfft) plugs (10) (2 used).
5. Install O-rings (2 used) and backup rings (2 used) 14. Install stopper (20) to casing (6).
to relief valve (16). Apply grease to O-ring and the
O-ring mounting part of relief valve (16). 15. Install springs (8, 19) to plug (10). Install plug (10)
to casing (6).
6. Install spring (17) to poppet (18). Install poppet : 41 mm
(18) to casing (6). : 350 Nm (36.0 kgfm, 258 lbfft)
7. Install relief valve (16) to casing (6). 16. Install stopper (7) to casing (6).
: 41 mm
: 450 Nm (46.0 kgfm, 332 lbfft) 17. Insert spring (8) into plug (10). Install plug (10) to
casing (6).
8. Install spring (3) to spring guide (2). : 41 mm
: 350 Nm (36.0 kgfm, 258 lbfft)
W2-8-27
(Blank)㩷
㩷
W2-8-28
CRANE UPPER / Remote Control Valve
REMOVE AND INSTALL REMOTE
CONTROL VALVES FOR HOISTING,
RAISING/LOWERING DRUM AND TRAVEL 2
1

Removal

W24X-02-01-001
8
2. Remove bolts (1) (4 used) and remove seat (2). 9
10
: 13 mm
3. Remove covers (3 to 6) from the right stand. 16
11
4. Remove the lever (8 to 10) assemblies and the
harness connector for pressure sensors (23) (2 15
used).
5. Remove nuts (11) (2 used for each).䎃Remove the

lever (8 to 10) assemblies from remote control
valve (13).䎃Remove the lever (15, 16) assemblies 11
from remote control valve (14).
: 19 mm
W2BC-02-09-001
23
5
13
14
W2BC-02-09-002
W2-9-1
6. Remove hoses (19) (10 used) from elbows (20,
21) with remote control valve (13) attached. 12 13 12 14
: 22 mm
7. Remove elbows (20) (8 used) and (21) (2 used)

: 19 mm 21
8. Remove hoses (25) (9 used) from elbow (21) and

adapter (22) with remote control valve (14)
attached. 20
: 22 mm
9. Remove elbows (21) (3 used), adapters (22) (6

used) and pressure sensors (23) (2 used) from 19
13
remote control valve (14). 14
: 19 mm

remote control valves (13, 14) from the right 21
stand.
: 6 mm
19
25 19
14
21
21
22
25
19
23 25 19 20 W2BC-02-09-003
W2-9-2
Installation
12 13 12 14
1. Install remote control valves (13, 14) to the right
stand with socket bolts (12) (12 used).
: 6 mm
: 20 Nm (2.0 kgfm, 14.5 lbfft)
21
2. Install elbows (21) (3 used), adapters (22) (6
used) and pressure sensors (23) (2 used) to
remote control valve (14).
: 19 mm 20
: 27 to 33 Nm (2.8 to 3.4 kgfm)
(20 to 24.5 lbfft)
3. Install hoses (25) (9 used) to elbow (21) and 19

13
adapter (22) with remote control valve (14) 14
attached.
: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
21
4. Install elbows (20) (8 used) and (21) (2 used) to
remote control valve (13). 19
: 19 mm
: 27 to 33 Nm (2.8 to 3.4 kgfm)
(20 to 24.5 lbfft)
5. Install hoses (19) (10 used) to elbows (20, 21) 25 19

with remote control valve (13) attached.
: 22 mm 14
: 39 Nm (4.0 kgfm, 28.5 lbfft)
21
21
22
25
19
23 25 19 20 W2BC-02-09-003
W2-9-3
6. Install the lever (8 to 10) assemblies to remote
control valve (13). Install the lever (15, 16) 8
9
assemblies to remote control valve (14). Tighten 10
nuts (11) (2 used for each).
: 19 mm
16
: 90 Nm (9.2 kgfm, 66 lbfft)
11
7. Install the lever (8 to 10) assemblies and the 15
harness connector for pressure sensors (23) (2
used).
8. Install covers (3 to 6) to the right stand.

11
9. Install seat (2) with bolt (1).
: 13 mm
: 10 Nm (1.0 kgfm, 7.4 lbfft) 23
W2BC-02-09-001
13
14
W2BC-02-09-002
2
1

W24X-02-01-001
W2-9-4
REMOVE AND INSTALL SWING REMOTE
CONTROL VALVE
2
1
Removal


W24X-02-01-001
2. Remove bolts (1) (4 used) and remove seat (2).
: 13 mm
11 12 14 7
3. Remove covers (3, 5) and panel (12) from the left 4
console.
3 8 6
4. Remove the harness connector from the lever
(14) assembly.
5
5. Remove nut (13).䎃Remove the lever (14) assembly
6
: 19 mm 10
6. Remove hoses (18) (4 used) from elbow (17) and

attached.
: 22 mm 3
9
4
7. Remove elbows (17) (2 used) and adapters (19)
W24X-02-01-003
(2 used) from remote control valve (16).
: 6 mm
14
: 19 mm 13
15
8. Remove bolts (15) (2 used).䎃 Remove remote
control valve (16) from the left console. 15
: 13 mm
17
19
18
16
18 W2BC-02-09-004
W2-9-5
Installation
14
1. Install remote control valve (16) to the left console 13
with bolts (15) (2 used). 15
: 13 mm 15
: 10 Nm (1.0 kgfm, 7.4 lbfft)
2. Install elbows (17) (2 used) and adapters (19) (2 17

19
used) to remote control valve (16). 18
: 6 mm
16
: 34 Nm (3.5 kgfm, 25 lbfft)
: 19 mm
: 27 to 33 Nm (2.8 to 3.4 kgfm)
(20 to 24.5 lbfft) 18 W2BC-02-09-004
3. Install hoses (18) (4 used) to elbow (17) and

11 12 14 7
4
attached.
: 22 mm 3 8 6
: 39 Nm (4.0 kgfm, 28.5 lbfft)
4. Pass the lever part of lever (14) assembly through 5

panel (12). Install the lever (14) assembly to
remote control valve (16). Tighten nut (13). 6
: 19 mm
10
: 90 Nm (9.2 kgfm, 66 lbfft)
5. Pass and install the harness connector to the

lever (14) assembly through panel (12).
3
6. Install covers (3, 5) and panel (12) to the left 9
console. 4
W24X-02-01-003
7. Install seat (2) with bolt (1).

: 13 mm 2
1
: 10 Nm (1.0 kgfm, 7.4 lbfft)

W24X-02-01-001
W2-9-6
(Blank)㩷
W2-9-7
DISASSEMBLE REMOTE CONTROL VALVE
38
36
37
35
8
33,49
7
6
5
31
1 31
3 1
4 2
2 4
44 3
5
6
30, 48 7
44 8
34 9 29
11
14
12
17 32
16 13 18
4 25
19
39
26
10
22
45
15
21
18
20
24
41
27 40
28 43
42
15 46 47 23
W25N-02-09-004
W2-9-8
1- Steel Ball㩷 14 - Spring Seat㩷 26 - Casing㩷 38 - Boot㩷

2- Holder㩷 15 - Bolt㩷 27 - Socket bolt㩷 39 - Casing㩷
3- O-Ring㩷 16 - Spring㩷 28 - Bushing㩷 40 - Seat㩷
4- Washer㩷 17 - Spring㩷 29 - Seal㩷 41 - Steel Ball㩷
5- Detent Plug㩷 18 - Nut㩷 30 - Cover㩷 42 - Plug㩷
6- Spring㩷 19 - Spool㩷 31 - Socket bolt㩷 43 - O-Ring㩷
7- Lock Nut㩷 20 - Plug㩷 32 - Push Rods㩷 44 - Set Screw㩷
8- Adjusting Nut㩷 21 - O-Ring㩷 33 - Disc㩷 45 - Plug㩷
9- Bushing㩷 22 - Casing㩷 34 - Camshaft㩷 46 - Plate㩷
10 - Spring Pin㩷 23 - O-Ring㩷 35 - Set Screw㩷 47 - Socket bolt㩷
11 - Plug㩷 24 - Plate㩷 36 - Socket bolt㩷 48 - Cover㩷
12 - O-Ring㩷 25 - O-Ring㩷 37 - Lever㩷 49 - Disc㩷
13 - Washer㩷
W2-9-9
Disassemble Remote Control Valve
• 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.䎃 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. 38
2. Remove nut (18) and remove bolt (15).䎃Separate

the remote control valve into one unit.
: 13 mm 48
26, 25
3. Remove O-ring (25) from casings (26, 39). 15, 18
30
39, 25
W25N-02-09-005
4. Remove socket bolt (31).䎃Separate the cover (30)

assembly from the casing (39) assembly. 31
: 5 mm
30
39
W25N-02-09-006
W2-9-10
CAUTION: Plug (11) may fly out by spring

(17).
5. Remove plug (11) from casing (39).䎃Remove push 32

rod (32) from plug (11).
11
39
W25N-02-09-007㩷
6. Align the matching marks on the spool (19) 19

assembly, spring (17) and casing (39).䎃 Remove
the spool (19) assembly and spring (17) from 17
casing (39).
39
W25N-02-09-008
7. Remove socket bolt (27) and remove plate (24).

39
: 6 mm
8. Remove O-ring (23) and bushing (28) from casing 23

(39).
24
28
27
W25N-02-09-009㩷
W2-9-11
9. Place the spool (19) assembly on the workbench
vertically.䎃 Push spring seat (14) downward.䎃 Push 13
out washers (13) (2 used) by using a screwdriver. 14
19
W324-02-09-011
IMPORTANT: Handle the parts as an assembly by 14

each port.
Washer (4) is used when adjusting 16
spring (16) for the setting of 4
secondary pressure and the
thickness is different according to 19
the spool (19) assembly.
10. Remove spring seat (14), spring (16) and washer
(4) from spool (19).
W333-02-09-001㩷
IMPORTANT: Do not damage the inner surface of

plug (11). 29
11. Remove O-ring (12) and seal (29) from plug (11).
11
12
W324-02-09-013
12. Remove the detent plug (5) assembly from cover 30

(30) slowly in order not to fly out steel ball (1),
1
holder (2) and spring (6). 2
: 24 mm 4
3
5
6
7
8
W324-02-09-014
W2-9-12
13. Remove socket bolt (36). Remove lever (37) from
36
disc (33).
: 6 mm
37
33
W324-02-09-015
14. Remove set screw (35) from disc (33).

: 4 mm
35
15. Attach a round bar onto the end of camshaft (34). 33
Lightly tap and remove camshaft (34) by using a
hammer. Remove disc (33).
34
W324-02-09-016
16. Remove plug (42) from plate (24).䎃Remove steel 24

ball (41) and seat (40).
: 10 mm 41
40
43
17. Remove O-ring (43) from plug (42). 42
W25N-02-09-010
W2-9-13
ASSEMBLE REMOTE CONTROL VALVE
49
48
47
46
38 1 2 4 3 5 7 8
37
36
35
34 6
31
9
33
44 11 10
32 12
13
30
14
29 45
4 16 15
17 18
19
20
21
23
28 42
43
27 41 40 24
22 25 39 26
W25N-02-09-011
W2-9-14
1- Steel Ball㩷 14 - Spring Seat㩷 26 - Casing㩷 38 - Boot㩷

2- Holder㩷 15 - Bolt㩷 27 - Socket bolt㩷 39 - Casing㩷
3- O-Ring㩷 16 - Spring㩷 28 - Bushing㩷 40 - Seat㩷
4- Washer㩷 17 - Spring㩷 29 - Seal㩷 41 - Steel Ball㩷
5- Detent Plug㩷 18 - Nut㩷 30 - Cover㩷 42 - Plug㩷
6- Spring㩷 19 - Spool㩷 31 - Socket bolt㩷 43 - O-Ring㩷
7- Lock Nut㩷 20 - Plug㩷 32 - Push Rods㩷 44 - Set Screw㩷
8- Adjusting Nut㩷 21 - O-Ring㩷 33 - Disc㩷 45 - Plug㩷
9- Bushing㩷 22 - Casing㩷 34 - Camshaft㩷 46 - Plate㩷
10 - Spring Pin㩷 23 - O-Ring㩷 35 - Set Screw㩷 47 - Socket bolt㩷
11 - Plug㩷 24 - Plate㩷 36 - Socket bolt㩷 48 - Cover㩷
12 - O-Ring㩷 25 - O-Ring㩷 37 - Lever㩷 49 - Disc㩷
13 - Washer㩷
W2-9-15
Assemble Remote Control Valve
1. Install steel ball (41) and seat (40) to plate (24). 24
41
2. Install O-ring (43) to plug (42).䎃Install plug (42) to
40
plate (24). 43
: 10 mm 42
: 24.5 to 29.4 Nm (2.5 to 3.0 kgfm)
(18 to 21.5 lbfft)
W25N-02-09-010
3. Install bushing (28) and O-ring (23) to casing (39).䎃 39

Tighten plate (24) with socket bolt (27).
: 6 mm 23
: 27.4 to 31.4 Nm (2.8 to 3.2 kgfm)
(20 to 23 lbfft)
24
28
27
W25N-02-09-009㩷
14
16
4. Install washer (4), spring (16) and spring seat (14)
4
to spool (19) in this order.
19
W333-02-09-001
13
14
5. Place spool (19) on the workbench vertically.䎃
Push spring seat (14) upward.䎃Install washers (13)
(2 used) onto spring seat (14).
19
W324-02-09-011㩷
W2-9-16
6. Install washer (13) with the sharp edge side 13 19
facing upward so that washer (13) can mesh with
the head of spool (19).
Sharp Edge Side
W324-02-09-018
IMPORTANT: When inserting the spool (19)

assembly, do not attach the lower 19
end of spool onto the corner of
17
casing (39) strongly.
7. Insert spring (17) and the spool (19) assembly
39
into casing (39).
W25N-02-09-008
8. Apply a film of grease to seal (29).䎃Install seal (29)

and O-ring (12) to plug (11). 29
11
12
W324-02-09-013
9. Apply hydraulic oil onto the surface of push rod

(32).䎃Insert push rod (32) into plug (11). 11
32
W324-02-09-019㩷
W2-9-17
10. Install the push rod (32) assembly to casing (39).
32
39
W25N-02-09-007㩷
11. Install disc (33) to cover (30). Insert camshaft 33

(34).
30
34
W324-02-09-020
35
12. Apply LOCTITE #241 onto set screw (35). Tighten
33
set screw (35) to disc (33).
: 4 mm
: 15.7 to 17.7 Nm (1.6 to 1.8 kgfm)
(11.5 to 13 lbfft)
NOTE: Check if the end of set screw (35) is
inserted into the groove in camshaft (34).
W324-02-09-021
36
13. Install lever (37) to disc (33) and tighten with
socket bolt (36). 37
: 6 mm
: 27.4 to 31.4 Nm (2.8 to 3.2 kgfm) 33
(20 to 23 lbfft)
W324-02-09-015㩷
W2-9-18
14. Apply much grease to holder (2).䎃 Secure and
insert steel ball (1) into detent plug (5). 30
1
15. Install O-ring (3) to detent plug (5). Tighten detent 2
4
plug (5) to cover (30). 3
: 24 mm 5
6
: 38.3 to 44.1 Nm (3.9 to 4.5 kgfm) 7
(28 to 32.5 lbfft) 8
16. Insert washer (4) and spring (6) into detent plug
(5).䎃Install lock nut (7) and adjusting nut (8).
: 24 mm
: 38.3 to 44.1 Nm (3.9 to 4.5 kgfm) W324-02-09-014
(28 to 32.5 lbfft)
17. Install the end cover (39) assembly to casings (3,

4) and tighten with socket bolt (31).
: 5 mm 31
: 10.8 to 12.8 Nm (1.1 to 1.3 kgfm)
(8.0 to 9.4 lbfft)
30
39
W25N-02-09-012
18. Install boot (38) to covers (30, 48).
19. Install O-ring (25) to casing (39) in remote control 38

valve for rear drum and casing (26) in remote
control valve for front drum.䎃 Place the remote
control valve assembly (3-unit) on the flat 30
workbench.䎃Align spring pin (10) with the pin hole 48
26, 25
and install bolts (15) (2 used). Tighten nut (18).
: 13 mm 15, 18
: 15.7 to 17.7 Nm (1.6 to 1.8 kgfm)
22
(11.5 to 13 lbfft)
39, 25
W25N-02-09-005
W2-9-19
(Blank)
W2-9-20
CRANE UPPER / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT

Removal

2. Remove each harness of the solenoid valve from

the connector.
2 1
3. Remove all hoses from solenoid valve unit (2).
Remove the adapter, elbow and tee.
: 19 mm
: 22 mm
: 27 mm

solenoid valve unit (2).
: 13 mm

Installation W24X-02-10-001
1. Install solenoid valve unit (2) with bolts (1) (2

used).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 lbfft)
2. Install the adapter, elbow and tee to solenoid

valve unit (2).
: 19 mm
: 34 to 38 Nm (3.5 to 3.9 kgfm)
(26 to 28 lbfft)
: 22 mm
: 69 to 79 Nm (7 to 8 kgfm, 51 to 58 lbfft)
3. Install all hoses.

: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
4. Install each harness of the solenoid valve to the

connector.
W2-10-1
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE BLOCK
1 1 1 1 2
12㩷
11㩷
10㩷
9㩷
8㩷 3
7㩷 6㩷 5 4
W24X-02-10-002
1 - Solenoid (4 Used) 4- Plug (2 Used) 7- O-Ring (4 Used) 10 - O-Ring (4 Used)

2 - Reducing Valve 5- Casing 8- Spool (4 Used) 11 - O-Ring (4 Used)
3 - O-Ring (2 Used) 6- Sleeve (4 Used) 9- O-Ring (4 Used) 12 - Spring (4 Used)
W2-10-2
Disassemble Solenoid Valve Block Assemble Solenoid Valve Block
IMPORTANT: Do not loosen the adjusting screw in 1. Install spool (8) and spring (12) to sleeve (6).
solenoid (1).
1. Remove solenoids (1) (4 used) from casing (5). IMPORTANT: Do not loosen the adjusting screw in
: 32 mm solenoid (1).
NOTE: Solenoid (1) is removed as an assembly. 2. Secure sleeve (6) and install solenoid (1).
: 32 mm
2. Remove O-rings (7, 9, 10 and 11) from solenoid : 27 to 33 Nm (2.8 to 3.4 kgfm)
(1) and sleeve (6). (20 to 24 lbfft)
3. Apply grease to O-rings (7, 9, 10 and 11). Install

IMPORTANT: Do not loosen the adjusting screw in
O-rings (7, 9, 10 and 11) to solenoid (1) and
solenoid (1).
sleeve (6).
3. Secure sleeve (6). Loosen solenoid (1). Remove
sleeve (6) from solenoid (1).
: 32 mm IMPORTANT: Do not loosen the adjusting screw in
solenoid (1).
4. Install solenoid (1) and sleeve (6) (4 units) to
4. Remove spring (12) and spool (8) from sleeve (6). casing (5).
NOTE: Remove spool (8) slowly. : 32 mm
: 39 to 49 Nm (4 to 5 kgfm)
IMPORTANT: Do not loosen the adjusting screw in (29 to 36 lbfft)
reducing valve (2).
5. Remove reducing valve (2) from casing (5). IMPORTANT: Do not loosen the adjusting screw in
: 22 mm reducing valve (2).
5. Install reducing valve (2) to casing (5).
6. Remove plugs (4) (2 used) from casing (5). : 22 mm
: 6 mm : 39 to 49 Nm (4 to 5 kgfm)
(29 to 36 lbfft)
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 Nm (3.5 to 3.9 kgfm)
(26 to 28 lbfft)
W2-10-3
(Blank)
W2-10-4
CRANE UPPER / Cylinder
REMOVE AND INSTALL
COUNTERWEIGHT INSTALLATION /
REMOVAL CYLINDER
CAUTION: Remove and install the cylinder 5 A

on the level, solid ground. 5
Escaping fluid under pressure
may penetrate the skin and eyes, 1 1
the pressure before removing the 4
Hot hydraulic oil just after 3
2
Removal 3
1. Remove the counterweight. As for removal of the

2. Remove hoses (1) (2 used/cylinder) 4

W2BC-02-11-001
CAUTION: Cylinder (1) weight: 200 kg (441 lb)
3. Attach a wire rope onto the cylinder rod (A). Hold

cylinder (5).
4. Remove sprit pins (2) (2 used/cylinder). Remove

pins (3) (2 used/cylinder). 5
5. Remove bracket (4) (2 used/cylinder).

3
6. Hoist cylinder (5) and remove it.
4
W2BC-02-11-002
W2-11-1
Installation
1. Install the counterweight. As for removal of the

5 A
2. Install hoses (1) (2 used/cylinder)
5
CAUTION: Cylinder (1) weight: 200 kg (441 lb) 1 1
3. Attach a wire rope onto the cylinder rod (A). 4

Hoist cylinder (5) and install it.
3
4. Install bracket (4) (2 used/cylinder).
2
5. Install pins (3) (2 used/cylinder). Install sprit pins
(2) (2 used/cylinder).
3
4
W2BC-02-11-001
4
W2BC-02-11-002
W2-11-2
(Blank)
W2-11-3
DISASSEMBLE CYLINDER
19
18
23, 24
25
22
21, 20
12
3
16
6
11
10
15
14
5
4
13
8
9 1
7
17 2
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
W2-11-4
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).
W2-11-5
19
18
23, 24
25
22
21, 20
12
3
16
6
11
10
15
14
5
4
13
8
9 1
7
17 2
W2BC-02-11-003
W2-11-6
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).
W2-11-7
ASSEMBLE CYLINDER
19
18
23, 24
25
22
21, 20
12
3
16
6
11
10
15
14
5
4
13
8
9 1
7
17 2
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
W2-11-8
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 Nm (63 to 77 kgfm)
(460 to 560 lbfft)
7. Install set screw (17) to piston (4).

: 4 mm Special Tool㩷
: 20 Nm (2.0 kgfm, 14.5 lbfft)
8. Clamp cylinder tube (1) in a vise. Secure cylinder

tube (1) horizontally.
47mm
W25N-03-07-008
W2-11-9
19
18
23, 24
25
22
21, 20
12
3
16
6
11
10
15
14
5
4
13
8
9 1
7
17 2
W2BC-02-11-003
W2-11-10
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 Nm (77 to 94 kgfm)
(550 to 680 lbfft)
W2-11-11
(Blank)
W2-11-12

SECTION 3
BASE CARRIER
— CONTENTS —
Group 1 Turntable Bearing Group 5 Upper and Lower Rollers
Remove and Install Turntable Bearing........W3-1-1 Remove and Install Upper Roller ............... W3-5-1
Disassemble Turntable Bearing ..................W3-1-4 Disassemble Upper Roller.......................... W3-5-4
Assemble Turntable Bearing.......................W3-1-6 Assemble Upper Roller............................... W3-5-6
Maintenance Standard................................ W3-5-8
Group 2 Travel Mechanism Remove and Install Lower Roller ............... W3-5-9
Remove and Install Travel Mechanism .......W3-2-1 Disassemble Lower Roller........................ W3-5-12
Disassemble Travel Mechanism Assemble Lower Roller............................. W3-5-14
(Reduction Gear) ......................................W3-2-4 Maintenance Standard.............................. W3-5-16
Assemble Travel Mechanism
(Reduction Gear) ......................................W3-2-8
Group 6 Track Shoe
Disassemble Travel Motor ........................W3-2-14
Remove and Install Track Shoe ................. W3-6-1
Assemble Travel Motor .............................W3-2-20
Maintenance Standard................................ W3-6-5
Maintenance Standard ..............................W3-2-30
Group 7 Cylinder
Group 3 Rotating Joint
Remove and Install Retract Cylinder.......... W3-7-1
Remove and Install Rotating Joint ..............W3-3-1
Disassemble Cylinder................................. W3-7-8
Disassemble Rotating Joint ........................W3-3-4
Assemble Cylinder.................................... W3-7-12
Assemble Rotating Joint .............................W3-3-6
Remove and Install Track Adjustment
Maintenance Standard ................................W3-3-8 Cylinder (Optional).................................. W3-7-17
Disassemble Track Adjustment Cylinder .. W3-7-22
Group 4 Take-Up Tumbler Assemble Track Adjustment Cylinder....... W3-7-24
Remove and Install Take-Up Tumbler.........W3-4-1 Remove and Install Jack-up Cylinder
Disassemble Take-Up Tumbler ...................W3-4-2 (Optional)................................................ W3-7-27
Assemble Take-Up Tumbler........................W3-4-4 Disassemble Jack-up Cylinder ................. W3-7-30
Maintenance Standard ................................W3-4-6 Assemble Jack-up Cylinder...................... W3-7-32
Group 8 Control Valve

Remove 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-3-1

(Blank)
2BDW-3-2
BASE CARRIER / Turntable Bearing
REMOVE AND INSTALL TURNTABLE 6
BEARING 11
Before removing the turntable bearing, the upper

7
revolving frame must be removed first. For removal
and installation of the upper revolving frame, refer to
“Remove and Install Upper Revolving Frame” section. 2
3 1
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).
5 4
2. Remove bolts (6) (4 used) from outer race (1). W2BC-03-01-001
Remove covers (7, 11) (2 used).
: 24 mm 8 Matching Mark
9
3. Put the matching marks on inner race (8) and

lower frame (9).
W25N-03-01-002
10
4. Remove bolts (10) (48 used).

46 mm
W25N-03-01-003
W3-1-1
CAUTION: Turntable bearing weight:

870 kg (1920 lb)
5. Attach a lifting tool onto outer race (1).䎃 Hoist and 1

remove the turntable bearing.
W25N-03-01-004
W3-1-2
Installation
Clean the mounting surfaces of lower frame and

turntable bearing. Apply THREEBOND #1102.
CAUTION: Turntable bearing weight: Matching

870 kg (1920 lb) Mark㩷
1. Hoist the turntable bearing and align the matching 8 10

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 Nm (195 kgfm, 1410 lbfft) 9
W25N-03-01-005
3. Install covers (7, 11) (2 used) to outer race (1) 6

with bolts (6) (4 used). 11
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
7
4. Install elbows (2) (2 used), hoses (3) (2 used) and

2
block (4) to outer race (1). 3 1
: 17 mm
: Bolt(5):50 Nm (5.1 kgfm, 37 lbfft)
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).
5 4
W2BC-03-01-001
W3-1-3
DISASSEMBLE TURNTABLE BEARING
1 2 3 2 4 5
8 6 7 6
W25N-03-01-006
1- Pin㩷 3- Inner Race㩷 5- Outer Race㩷 7- Support (96 Used)㩷

2- Seal㩷 4- Ball 㩿96 Used)㩷 6- Seal㩷 8- Plug㩷
W3-1-4
BASE CARRIER / Slewing Ring
Disassemble Turntable Bearing
1. Grind off the caulked part of pin (1). Tap and

remove pin (1) from the bottom side of plug (8).
1
W25N-03-01-007
2. Remove plug (8).

NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5) of plug (8).䎃Tap or pull out the bolt
from the inner side.
W25N-03-01-008

870 kg (1920 lb)
3. Horizontally hoist outer race (5) of turntable 5

2
bearing a little. Remove seals (2, 6). 4
4. Rotate inner race (3) and remove ball (4) and

support (7) from the plug (8) part. 3
Remove ball (4) by using magnet (A). Use wire
(B) and remove support (7).
A 6
W25N-03-01-009
7
W105-03-01-010㩷
W3-1-5
ASSEMBLE TURNTABLE BEARING
1 2 3 2 4 5
8 6 7 6
W25N-03-01-006
1- Pin㩷 3- Inner Race㩷 5- Outer Race㩷 7- Support (96 Used)㩷

2- Seal㩷 4- Ball㩷㩿96 Used)㩷 6- Seal㩷 8- Plug㩷
W3-1-6
Assemble Turntable Bearing

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).䎃Apply THREEBOND #1735.
Install seals (2, 6).
2. Apply grease to balls (4) and supports (7). Install 2

balls (4) (96 used) and supports (7) (96 used)
through the plug (8) part.䎃Install ball (4) first. 4
3. Install plug (8) into outer race (5). Install pin (1).
Crimp the head of pin (1) by using a punch. 6
Apply much grease (Alvania EP2 grease or W25N-03-01-011
equivalent) onto the turntable bearing.
W25N-03-01-012㩷
W25N-03-01-007
W3-1-7
(Blank)㩷
㩷
W3-1-8
BASE CARRIER / Travel Mechanism
REMOVE AND INSTALL TRAVEL
MECHANISM

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.
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
W3-2-1
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 1
Installation

890 kg (1970 lb)
2
1. Hoist and install travel mechanism (1) onto side 3
frame (3) with bolt (2). W25N-03-02-002
: 19 mm
: 1400 Nm (143 kgfm, 1030 lbfft)
2. Install all the pipes.

: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 50 mm
: 306 to 374 Nm (31 to 38 kgfm)
(225 to 275 lbfft)
3. Install the cover.

: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
Cover
W25N-03-02-001
W3-2-2
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.
W3-2-3
DISASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR)
46 47 7 11 12 24 30 31
19 23 32 38
45
44
39
40
41
37
36
34
35
33
42
14 18 28
15 16 26 29 43
49 48 50 1 2㩷 4 3 6 5 8 9 10 21 20 22 13 17 25 27
W25N-03-02-003
1- Housing㩷 14 - Needle Bearing (8 Used)㩷 27 - Thrust Plate (8 used)㩷 39 - Cover㩷

2- Floating Seal㩷 15 - Spacer (4 Used)㩷 28 - Pin (4 Used)㩷 40 - Bearing㩷
3- Bearing (2 Used)㩷 16 - Thrust Plate (8 used)㩷 29 - Spring Pin (4 Used)㩷 41 - Pin㩷
4- Drum㩷 17 - Spacer (4 Used)㩷 30 - Sun Gear㩷 42 - Bolt (18 Used)㩷
5- Travel Drive Sprocket㩷 18 - Spring Pin (4 Used)㩷 31 - Carrier㩷 43 - Spring Washer (18 Used)㩷
6- Socket Bolt (34 Used)㩷 19 - Sun Gear㩷 32 - Spacer㩷 44 - Plug (3 Used)㩷
7- Cork (2 Used)㩷 20 - Ring Gear㩷 33 - Planetary Gear (3 Used)㩷 45 - Cork (2 Used)㩷
8- Nut㩷 21 - O-Ring㩷 34 - Needle Bearing (3 Used)㩷 46 - Coupling㩷
9- Lock Plate㩷 22 - Socket Bolt (30 Used)㩷 35 - Thrust Plate (6 used)㩷 47 - Retaining Ring㩷
10 - Bolt (2 Used)㩷 23 - Carrier㩷 36 - Pin (3 Used)㩷 48 - Motor㩷
11 - Carrier㩷 24 - Spacer㩷 37 - Spring Pin (3 Used)㩷 49 - Socket Bolt (3 Used)㩷
12 - Spacer㩷 25 - Planetary Gear (4 Used)㩷 38 - Shaft㩷 50 - O-Ring㩷
13 - Planetary Gear (4 Used)㩷 26 - Needle Bearing (4 Used)㩷
W3-2-4
Disassemble Travel Mechanism (Reduction Gear)

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.䎃
䎃 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 44-B (Oil Filler Plug)
bolt.
: 12 mm
44-A
CAUTION: Travel motor weight:
100 kg (220 lb)
Level
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 44

gear) weight: W25N-03-02-004
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.
W3-2-5
11 24 30 31
19 23 32
37
36
34
35
33
14 18 28
15 16 26 29
1 2㩷 4 3 6 5 9 10 21 20 22 13 17 25 27
W25N-03-02-003
W3-2-6
9. Remove second stage sun gear (30) from second 22. Remove pins (17) (4 used) from third carrier (11).䎃
stage carrier (23). Remove third stage planetary gears (13) (4 used)
and thrust plates (16) (8 used).
10. Remove the second stage carrier (23) assembly.
23. Remove spacer (15) from third stage carrier (11).
11. Remove socket bolt (22). Remove ring gear (20)
from drum (4). 24. Remove needle bearings (14) (8 used) from third
: 17 mm stage planetary gears (13) (4 used).
12. Remove O-ring (21) from drum (4). 25. Remove spring pins (29) (4 used) from the
second stage carrier (23) assembly.
13. Remove third stage sun gear (19) from third stage
carrier (11). 26. Remove pins (28) (4 used) from second stage
carrier (23). Remove second stage planetary
14. Remove the third stage carrier (11) assembly. gears (25) (4 used) and thrust plates (27) (8
used).
15. Remove socket bolt (10). Remove lock plate (9)
from housing (1). 27. Remove spacer (24) from second stage carrier
: 19 mm (23).
16. Hoist and remove drum (4) with bearing (3) in the 28. Remove needle bearings (26) (4 used) from
reduction side and travel drive sprocket (5) second stage planetary gears (25) (4 used).
attached from housing (1).
29. Remove spring pins (37) (3 used) from the first
17. Remove bearing (3) from the motor side. stage carrier (31) assembly.
18. Remove floating seal (2). 30. Remove pins (36) (3 used) from first stage carrier
(31). Remove first stage planetary gears (33) (3
19. Turn over drum (4). Remove socket bolt (6). used) and thrust plates (35) (6 used).
Remove travel drive sprocket (5) from drum (4).
: 19 mm
31. Remove spacer (32) from first stage carrier (31).
20. Remove bearing (3) from the travel motor side.
32. Remove needle bearing (34) from first stage
21. Remove spring pins (18) (4 used) from the third planetary gears (33) (3 used).
stage carrier (11) assembly.
W3-2-7
ASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR)
46 47 7 11 12 24 30 31
19 23 32 38
45
44
39
40
41
37
36
34
35
33
42
14 18 28
15 16 26 29 43
49 48 50 1 2㩷 4 3 6 5 8 9 10 21 20 22 13 17 25 27
W25N-03-02-003
1- Housing㩷 14 - Needle Bearing (8 Used)㩷 27 - Thrust Plate (8 used)㩷 39 - Cover㩷

2- Floating Seal㩷 15 - Spacer (4 Used)㩷 28 - Pin (4 Used)㩷 40 - Bearing㩷
3- Bearing (2 Used)㩷 16 - Thrust Plate (8 used)㩷 29 - Spring Pin (4 Used)㩷 41 - Pin㩷
4- Drum㩷 17 - Spacer (4 Used)㩷 30 - Sun Gear㩷 42 - Bolt (18 Used)㩷
5- Travel Drive Sprocket㩷 18 - Spring Pin (4 Used)㩷 31 - Carrier㩷 43 - Spring Washer (18 Used)㩷
6- Socket Bolt (34 Used)㩷 19 - Sun Gear㩷 32 - Spacer㩷 44 - Plug (3 Used)㩷
7- Cork (2 Used)㩷 20 - Ring Gear㩷 33 - Planetary Gear (3 Used)㩷 45 - Cork (2 Used)㩷
8- Nut㩷 21 - O-Ring㩷 34 - Needle Bearing (3 Used)㩷 46 - Coupling㩷
9- Lock Plate㩷 22 - Socket Bolt (30 Used)㩷 35 - Thrust Plate (6 used)㩷 47 - Retaining Ring㩷
10 - Bolt (2 Used)㩷 23 - Carrier㩷 36 - Pin (3 Used)㩷 48 - Motor㩷
11 - Carrier㩷 24 - Spacer㩷 37 - Spring Pin (3 Used)㩷 49 - Socket Bolt (3 Used)㩷
12 - Spacer㩷 25 - Planetary Gear (4 Used)㩷 38 - Shaft㩷 50 - O-Ring㩷
13 - Planetary Gear (4 Used)㩷 26 - Needle Bearing (4 Used)㩷
W3-2-8
Assemble Travel Mechanism (Reduction Gear)
1. Install needle bearing (34) to first stage planetary 10. Install spacer (15) to third stage carrier (11).
gears (33) (3 used).
11. Install third stage planetary gears (13) (4 used)
2. Install spacer (32) to first stage carrier (31). and thrust plates (16) (8 used) to third stage
carrier (11).
3. Install first stage planetary gears (33) (3 used)
and thrust plates (35) (6 used) to first stage carrier NOTE: Face the groove in end of third stage
(31). planetary gear (13) to cover (39).
4. Align with the spring pin hole on first stage carrier 12. Align with the spring pin hole on third stage carrier
(31) and install pins (36) (3 used). (11) and install pins (17) (3 used).
13. Install spring pins (18) (3 used) into third stage

5. Install spring pins (37) (3 used) into first stage
carrier (11) and pin (17). Face the slit of spring pin
(18) to the end of third stage carrier (11) (cover
(37) to the end of first stage carrier (31) (cover
(39) side).
(39) side).
IMPORTANT: For handling floating seal (2), refer
6. Install spacer (24), second stage planetary gears to the section “Precautions for
(25) (4 used), needle bearings (26) (4 used) and Handling Floating Seal” on page
thrust plates (27) (8 used) to second stage carrier W1-1-3.
(23) in the same procedures steps 1 to 3. 14. Apply grease to floating seal (2). Install a pair of
floating seal (2) to housing (1) by using bamboo
7. Align with the spring pin hole on second stage spatula.
carrier (23) and install pins (28) (4 used).
15. Install bearing (3) at travel motor side to housing
(1).
8. Install spring pins (29) (4 used) into second stage
(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).
W3-2-9
11 30 31
19 23 38
33
1 2㩷 4 3 6 5 8 9 21 20 22 13
W25N-03-02-003
W3-2-10
IMPORTANT: For handling floating seal (2), refer 26. Apply grease into the spline in third stage carrier
to the section “Precautions for (11). Hoist and install the third stage carrier (11)
Handling Floating Seal” on page assembly onto housing (1).
W1-1-3.
16. Apply grease to floating seal (2). Install other pair 27. Install third stage sun gear (19) to third stage
of floating seal (2) to drum (4) by using bamboo carrier (11).
spatula.
28. Hoist ring gear (20). Mesh ring gear (20) with third
17. Hoist and install travel drive sprocket (5) to drum stage planetary gear (13) and install ring gear (20)
(4). Apply LOCTITE #262 to socket bolts (6) (34 to drum (4).
used). Tighten socket bolt (6).
: 19 mm 29. Apply LOCTITE #262 to socket bolts (22) (30
: 950 Nm (97 kgfm, 700 lbfft) used). Tighten socket bolt (22).
: 17 mm
18. Apply grease to O-ring (21). Install O-ring (21) to : 750 Nm (77 kgfm, 550 lbfft)
drum (4). Hoist and install drum (4) to housing (1).
30. Hoist and install the second stage carrier (23)
19. Install bearing (3) to housing (1). assembly onto third stage sun gear (19).
20. Tighten nut (8) to housing (1). 31. Install second stage sun gear (30) to second
: 800 Nm (82 kgfm, 590 lbfft) stage carrier (23).
21. Rotate travel drive sprocket (5) clockwise and 32. Hoist and install the first stage carrier (31)
counterclockwise and 4 to 5 times. assembly onto second stage sun gear (30).
22. Tap the end of travel drive sprocket (5) by using a 33. Install shaft (38) into the center of first stage
hammer. carrier (31) and mesh with first stage planetary
gear (33).
23. Tighten nut (8) again.
: 800 Nm (82 kgfm, 590 lbfft)
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 Nm (97 kgfm, 700 lbfft)
W3-2-11
46
38
44
39
40
41
42
43
49 50 20
W25N-03-02-003
W3-2-12
34. Install bearing (40) and pin (41) to cover (39).
NOTE: After installing bearing (40), caulk the arrow
part (2 places) on cover (39) by using a
punch.
35. Apply THREEBOND #1215 onto the cover (39)

mounting surface on ring gear (20). Install cover
(39).
36. Install spring washers (43) (18 used) to socket

bolts (42) (18 used). Tighten socket bolt (42).
: 22 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
37. Wind the seal tape onto plugs (44) (3 used).

Install plug (44) to cover (39).
: 17 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
CAUTION: Travel mechanism (reduction

gear) weight:
790 kg (1750 lb)
38. Turn over the travel mechanism (reduction gear)

and add gear oil.
Gear oil: 20 L (5.3 US gal)
39. Apply grease to O-ring (50). Install O-ring (50) to

travel motor.
40. Apply grease to the spline of coupling (46). Install

coupling (46) to shaft (38).
CAUTION: Travel motor weight:

100 kg (220 lb)
41. Align the spline of travel motor with the hole on

coupling (46). Install the travel motor to the travel
mechanism (reduction gear).
42. Tighten socket bolts (49) (3 used).

: 12 mm
: 180 Nm (18.5 kgfm, 133 lbfft)
W3-2-13
DISASSEMBLE TRAVEL MOTOR

85 70 69
69
86 70
69
84 70
69
87
82
71
83 72
88 73
89 74
90
75
76 63
77
64
87 78 65
79
91 80 66
81 67
68
6
7
8
9
10
11
12
13
1
2
3 50
16 5 54
49
32 53
15 50
17 52
51 2
18 14
19
20 33
22 34
21 33
23 37
35
24 36 41
38 42
25 43
39 44
26 26 40
39
27 55 45 15
28 31
56 30 46
29 29 47 17
30 28 48
59 27 16
57 60 25
61 24
58 23
50
22
18
19
20
21
W25N-03-02-005
W3-2-14
1- Plug㩷 25 - Spring Seat (2 Used) 49 - Socket Bolt (10 Used) 72 - Spring Seat㩷
2- O-Ring (2 Used) 26 - Plunger Assembly㩷 50 - Plug (12 Used) 73 - Spring㩷
3- Spring Guide㩷 27 - Plug (2 Used) 51 - Plug (3 Used) 74 - Spring Seat㩷
4- Washer (2 Used) 28 - O-Ring (2 Used) 52 - Base Plate㩷 75 - Cylinder Block㩷
5- Spring㩷 29 - Spring (2 Used) 53 - Orifice (2 Used) 76 - Pin (3 Used)
6- Spool Assembly 30 - Check Valve (2 Used) 54 - Orifice (2 Used) 77 - Holder㩷
7- Spool㩷 31 - Plunger㩷 55 - Pin (4 Used) 78 - Retainer Plate㩷
8- Backup Ring㩷 32 - Relief Valve (2 Used) 56 - Pin㩷 79 - Piston (9 Used)
9- O-Ring㩷 33 - Backup Ring (4 Used) 57 - Spring (4 Used) 80 - Swash Plate㩷
10 - O-Ring㩷 34 - O-Ring (2 Used) 58 - Spring (8 Used) 81 - Steel Ball (2 Used)
11 - Backup Ring㩷 35 - Poppet Seat (2 Used) 59 - O-Ring (2 Used) 82 - Shaft㩷
12 - Filter㩷 36 - Poppet (2 Used) 60 - Plug (2 Used) 83 - Bearing㩷
13 - Retaining Ring㩷 37 - Housing (2 Used) 61 - Plug㩷 84 - Oil Seal㩷
14 - Plug㩷 38 - Piston (2 Used) 62 - Plug㩷 85 - Piston (2 Used)
15 - Cap Assembly (2 Used)㩷 39 - Backup Ring (2 Used) 63 - O-Ring㩷 86 - Spring (2 Used)㩷
16 - Socket Bolt (2 Used)㩷 40 - O-Ring (2 Used) 64 - Bearing㩷 87 - Plug (4 Used)㩷
17 - Cap (2 Used)㩷 41 - Spring Seat (2 Used) 65 - Valve Plate㩷 88 - Orifice㩷
18 - Plug (2 Used)㩷 42 - Spring (2 Used) 66 - Brake Piston㩷 89 - O-Ring㩷
19 - O-Ring (2 Used)㩷 43 - Spring Guide (2 Used) 67 - D-Ring㩷 90 - Casing㩷
20 - Spring (2 Used)㩷 44 - O-Ring (2 Used) 68 - D-Ring㩷 91 - O-Ring㩷
21 - Steel Ball (2 Used)㩷 45 - O-Ring (2 Used) 69 - Friction Plate (3 Used)㩷 92 - Adjusting Screw㩷
22 - O-Ring (2 Used)㩷 46 - Plug (2 Used) 70 - Disc (4 Used)㩷 93 - Plug (2 Used)㩷
23 - Spring Seat (2 Used)㩷 47 - Nut (2 Used) 71 - Retaining Ring㩷 94 - Socket Bolt (3 Used)㩷
24 - Spring (2 Used) 48 - Adjusting Screw (2 Used)
W3-2-15
90
63
64
65
1
2
3
16 5 54
49
32 53
17 52
2
18 14
19
20 33
22 34
21 33
23 35
24
25
26 26
55
56 46
47 17
48
25 16
57 24
58 23
22
18
19
20
21
W25N-03-02-005
W3-2-16
Disassemble Travel Motor
IMPORTANT: As the relief set pressure changes,

CAUTION: Slowly turn and remove spool
do not loosen nut (47) and adjusting
scarew (48) in relief valve assembly assembly (6) in order not to
(32). damage the hole on base plate
Do not remove relief valve assembly (52).
(32) unless necessary.
1. Remove plug (46). Remove relief valve 7. Remove plugs (1, 14). Remove O-rings (2) (2
assemblies (32) (2 used) from base plate (52). used), spring guide (3), spring (5) and spool
: 27mm assembly (6).
: 10mm
2. Remove poppet seats (35) (2 used), backup

CAUTION: Pin (55) may be stuck by the
rings (33) (4 used) and O-rings (34) (2 used)
screwdriver.
from base plate (52).
IMPORTANT: As base plate (52) is pushed upward
IMPORTANT: Push cap (17) by hands in order not by springs (57, 58), loosen socket
to fly out cap (17) because of spring bolt (49) evenly.
(24) and remove socket bolt (16). 8. Remove socket bolts (49) (10 used). Remove
3. Remove socket bolts (16) (8 used). Remove caps base plate (52).
(17) (2 used) and O-rings (22) (2 used) from base : 12mm
plate (52).
: 14mm
CAUTION: When removing pins (55, 56), do
4. Remove spring seat (23), spring (24) and spring not damage the outer surface by
seat (25) from base plate (52). using a pair of pliers.
Do not damage the sliding
surface on valve plate (65).
CAUTION: Do not damage the hole on base
plate (52). 9. Remove valve plate (65), bearing (64), pins (55)
(4 used), (56), O-ring (63), springs (57, 58),
5. Slowly turn and remove plunger assembly (26) orifices (53) (2 used) and (54) (2 used) from base
from base plate (52). plate (52).
NOTE: Springs (57, 58) and valve plate (65) may
6. Remove plugs (18) (2 used), O-rings (19) (2 be left in casing (90).
used), springs (20) (2 used) and steel balls (21) (2
used) from base plate (52).
: 14mm
W3-2-17
85 70 69
69
86 70
69
84 70
69
82
71
83 72
88 73
74
90
75
76
77
78
79
80 66
81 67
68
26 26
27
28 31
30
29 29
30 28
27
W25N-03-02-005
W3-2-18
CAUTION: When removing brake piston (66) CAUTION: Do not damage the sliding
by using the compressed air, surface on plunger (31).
cover brake piston (66) by using a
cloth in order to prevent brake IMPORTANT: Do not remove plunger assembly
piston (66) from flying out. (26) unless necessary.
Do not damage the sliding 15. Insert a roud bar (dia. Ǿ10) through the hole in
surface on valve cover. arrow part of plunger assembly (26). Clamp
plunger assembly (26) in a vise. Remove plugs
10. Add the compressed air (294 to 490 kPa (3 to 5 (27) (2 used).
kgf/ cm2, 42.7 to 71 psi) into the orifice (88)
mounting part in casing (90). Remove brake 16. Remove plugs (29) (2 used), check valves (30) (2
piston (66) from casing (90). Remove D-rings (67, used) and O-rings (28) (2 used) from plunger
68), friction plate (69) and disc (70). (31).
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).
W3-2-19
ASSEMBLE TRAVEL MOTOR
6
13 11 10 12 9 8 7 32
33 35 39 45 44 43 46 47
48
50 50 50 50 50 34 33 36 37 41 38 40 39 42
5 4 3
55 66 63 89 55 87 92 67 68 91
6 56
70
52 62
1 69
79
14
83
2 50
32 84
15 51
17
51
22
21
82
16
64 90
77
23 65
19 80
24
30 27 28 20 57 76
60 25 59 93 61 94 31 29 18
58 49 50 89 88 87 71 72 75 73 74 78
26
50 53 54 89
85 87
87
86
81
W25N-03-02-006
W3-2-20

1- Plug㩷 25 - Spring Seat (2 Used)㩷 49 - Socket Bolt (10 Used)㩷 72 - Spring Seat㩷
2- O-Ring (2 Used)㩷 26 - Plunger Assembly㩷 50 - Plug (12 Used)㩷 73 - Spring㩷
3- Spring Guide㩷 27 - Plug (2 Used)㩷 51 - Plug (3 Used)㩷 74 - Spring Seat㩷
4- Washer (2 Used)㩷 28 - O-Ring (2 Used)㩷 52 - 㪙㪸㫊㪼㩷㪧㫃㪸㫋㪼㩷 75 - Cylinder Block㩷
5- Spring㩷 29 - Spring (2 Used)㩷 53 - Orifice (2 Used)㩷 76 - Pin (3 Used)㩷
6- Spool Assembly㩷 30 - Check Valve (2 Used)㩷 54 - Orifice (2 Used)㩷 77 - Holder㩷
7- Spool㩷 31 - Plunger㩷 55 - Pin (4 Used)㩷 78 - Retainer Plate㩷
8- Backup Ring㩷 32 - Relief Valve (2 Used)㩷 56 - Pin㩷 79 - Piston (9 Used)㩷
9- O-Ring㩷 33 - Backup Ring (4 Used)㩷 57 - Spring (4 Used)㩷 80 - Swash Plate㩷
10 - O-Ring㩷 34 - O-Ring (2 Used)㩷 58 - Spring (8 Used)㩷 81 - Steel Ball (2 Used)㩷
11 - Backup Ring㩷 35 - Poppet Seat (2 Used)㩷 59 - O-Ring (2 Used)㩷 82 - Shaft㩷
12 - Filter㩷 36 - Poppet (2 Used)㩷 60 - Plug (2 Used)㩷 83 - Bearing㩷
13 - Retaining Ring㩷 37 - Housing (2 Used)㩷 61 - Plug㩷 84 - Oil Seal㩷
14 - Plug㩷 38 - Piston (2 Used)㩷 62 - Plug㩷 85 - Piston (2 Used)㩷
15 - Cap Assembly (2 Used)㩷 39 - Backup Ring (2 Used)㩷 63 - O-Ring㩷 86 - Spring (2 Used)㩷
16 - Socket Bolt (2 Used)㩷 40 - O-Ring (2 Used)㩷 64 - Bearing㩷 87 - Plug (4 Used)㩷
17 - Cap (2 Used)㩷 41 - Spring Seat (2 Used)㩷 65 - Valve Plate㩷 88 - Orifice㩷
18 - Plug (2 Used)㩷 42 - Spring (2 Used)㩷 66 - Brake Piston㩷 89 - O-Ring㩷
19 - O-Ring (2 Used)㩷 43 - Spring Guide (2 Used)㩷 67 - D-Ring㩷 90 - Casing㩷
20 - Spring (2 Used)㩷 44 - O-Ring (2 Used)㩷 68 - D-Ring㩷 91 - O-Ring㩷
21 - Steel Ball (2 Used)㩷 45 - O-Ring (2 Used)㩷 69 - Friction Plate (3 Used)㩷 92 - Adjusting Screw㩷
22 - O-Ring (2 Used)㩷 46 - Plug (2 Used)㩷 70 - Disc (4 Used)㩷 93 - Plug (2 Used)㩷
23 - Spring Seat (2 Used)㩷 47 - Nut (2 Used)㩷 71 - Retaining Ring㩷 94 - Socket Bolt (3 Used)㩷
24 - Spring (2 Used)㩷 48 - Adjusting Screw (2 Used)㩷
W3-2-21
66 67 68
70
69
79
83
84
82
90
77
80
57 76
58 71 72 75 73 74 78
85
86
81
W25N-03-02-006
W3-2-22
Assemble Travel Motor
1. Install spring seat (74), spring (73) and spring IMPORTANT: Check if the cylinder block (75)
seat (72) to cylinder block (75) in this order. Install assembly rotates smoothly and the
retaining ring (71). piston (79) assembly reciprocates.
11. Place casing (90) on a workbench horizontally.
2. Apply grease onto pins (76) (3 used). Install pin Apply hydraulic oil onto swash plate (80). Insert
(76) into the hole (3 places) on cylinder block (75). the cylinder block (75) assembly into casing (90).
Install holder (77) to cylinder block (75).
12. Install discs (70) (4 used) and friction plates (69)
IMPORTANT: Install piston (79) so that the small (3 used) to caing (90). Install disc (70) first.
diameter side of inner taper part in
retainer plate (78) comes in contact 13. Apply grease to brake piston (66). Install D-rings
with the shoe flange part of piston (67, 68).
(79) assembly.
3. Install pistons (79) (9 used) to retainer plate (78). IMPORTANT: The pin hole (2 places) on brake
piston (66) and the pin hole (2
4. Apply hydraulic oil onto the piston hole on cylinder places) on casing (90) should be in
block (75). Insert the piston (79) assembly. line.
14. Install brake piston (66) to casing (90).
5. Secure casing (90) on a workbench.
15. Place special tool (A). Tap the head of special tool
6. Install oil seal (84) to casing (90). (A) by using a plastic hammer and insert into
NOTE: As for datails on special tools (C,B), refer to brake piston (66).
W3-2-29. NOTE: As for datails on special tools (A), refer to
W3-2-28.
7. Install bearing (83) to casing (90).
NOTE: As for datails on special tools (D,B), refer to 16. Install springs (57, 58) to brake piston (66).
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).
W3-2-23
32
33 35
34 33
55 63 55
56
52
32
15
17
22
21
16
64 90
23 65
19
24
30 27 28 20
25 31 29 18
49 75
26
53 54
W25N-03-02-006
W3-2-24
17. Install O-ring (63) to casing (90). IMPORTANT: Check if plunger assembly (26)
moves smoothly.
22. Apply hydraulic oil onto the sliding surface of
CAUTION: Do not damage the sliding
plunger assembly (26). Slowly rotate and install
surface on valve plate (65). plunger assembly (26) to base plate (52).
IMPORTANT: Apply grease onto non-sliding 23. Install O-ring (22) on cap (17).
surface on valve plate (65) and base
plate (52). 24. Install spring seat (25), spring (24) and spring
18. Secure base plate (52) horizontally on a seat (23) to base plate (52) in this order.
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). IMPORTANT: Push cap (17) by hands in order not
to fly out cap (17) because of spring
(24) and tighten socket bolt (16).
CAUTION: Do not fall off valve plate (65). Do 25. Install cap assembly (15) to base plate (52) with
not damage the cage of bearing socket bolts (16) (4 used).
(64). : 14 mm
: 98 to 118 Nm (10 to 12 kgfm)
IMPORTANT: Apply hydraulic oil onto the sliding (72 to 87 lbfft)
surface on the cylinder block (75)
assembly and valve plate (65).
26. Install steel balls (21) (2 used), springs (20) (2
Align pin (55) with the pin hole on
used), O-rings (19) (2 used) and plugs (18) (2
casing (90).
used) to base plate (52).
19. Clamp casing (90) in a vise. Install base plate (52)
to casing (90) with socket bolts (49) (10 used).
27. Install O-rings (34) (2 used) and backup rings
: 12 mm
(33)(4 used) onto poppet seats (35) (2 used).
: 176 to 206 Nm (18 to 21 kgfm)
Install poppet seat (35) to base plate (52).
(130 to 152 lbfft)
28. Install the relief valve (32) assembly to base plate
20. Insert a round bar (dia. Ǿ10) through the hole in
(52).
arrow part of plunger (31). Clamp plunger (31) in
: 27 mm
a vise and install check valve (30) and spring (29)
: 353 to 393 Nm (36 to 40 kgfm)
in this order.
(260 to 290 lbfft)
21. Install plug (27) with O-ring (28) attached to

plunger (31).
: 22 mm
: 127 to 147 Nm (13 to 15 kgfm)
(94 to 108 lbfft)
W3-2-25
5 4 3
6
52 1
14
2
W25N-03-02-006
W3-2-26
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 Nm (11.5 to 12.5 kgfm)
(83 to 91 lbfft)
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 Nm (11.5 to 12.5 kgfm)
(83 to 91 lbfft)
W3-2-27
Special Tool
x Special Tool (A): For position of the brake piston
274
200
28 30 28
37
20
150
370
18
175
4 3 2 1
㱢8
㱢5
18
13
㱢12
8
W25N-03-02-007㩷
1 M4㬍0.7 Screw Length 12 2 M4㬍0.7 Screw Length 12

Bottom Hole Length: Bottom Hole Length:
30㫦㩷
30㫦㩷
17 or less㩷 17 or less㩷
㱢12㩷
㱢11㩷
㱢12㩷
㱢11㩷
9.5
10
2 2
3 7 3 7
3 22 4 22
M4㬍0.7 Screw Length 12 M4㬍0.7 Screw Length 12
30㫦㩷
30㫦㩷
Bottom Hole Length: Bottom Hole Length:

17 or less㩷 17 or less㩷
㱢12㩷
㱢12㩷
㱢11㩷
㱢11㩷
10.2
9.8
2 2
3 7 3 7
22 22
W25N-03-02-008
NOTE: Unit: mm, 1 mm = 0.03937 in
W3-2-28
x Special Tool (B): For installation of the casing
㱢23㩷
㱢24㩷
㱢23㩷
30㫦
30㫦
2 2
27 27
180
W25N-03-02-009
x Special Tool (C): For installation of the oil seal
21
0.5
C3
㱢23 Hole Depth㩷 25 4 C3

2
30㫦
(㱢18)㩷
㱢49.6㩷
㱢71.6㩷
㱢46㩷
㱢78㩷
㱢36㩷
㱢23㩷
30㫦
25
54
W25N-03-02-010
x Special Tool (D): For installation of the bearing
C3
25
C3 2
C2
(㱢18)㩷
㱢46㩷
㱢23㩷
㱢36㩷
㱢94㩷
30㫦
5 25
45
W25N-03-02-011
NOTE: Unit: mm, 1 mm = 0.03937 in

W3-2-29
MAINTENANCE STANDARD Rotor㩷
Plunger㩷
1. Measure the clearance between plunger outer
diameter (d) of travel motor and rotor bore inner
diameter (D).
d D
Unit: mm (in)
D-d Maximum 0.03 0.06

(0.001) (0.002) W117-02-02-009
2. Move the plunger of travel motor upward and Plunger㩷

downward. Measure clearance Ǭ between
plunger and shoe.
Shoe㩷
㱐
Unit: mm (in)
Maximum 0.15 (0.006) 0.4 (0.016)

W107-02-06-140
W3-2-30
BASE CARRIER / Rotating Joint
REMOVE AND INSTALL ROTATING JOINT

4 3 2 1
and cause serious injury. Release 9
11
to cool before starting any work. 12
13
Removal
5

14
2. Remove pipes (1 to 17), hoses. 10 15
: 19 mm, 22 mm, 27 mm, 36 mm, 41 mm,
50 mm 16 6
NOTE: Cap the pipes and hoses.
17 7
8
W2BC-03-03-001
26
28
3. Remove bolt (24) and remove plate (25). 27
24
: 24 mm 25
4. Remove bolt (26) and remove plate (27).

: 24 mm
CAUTION: Rotating joint weight: W2BC-03-03-002

64 kg (140 lb)
5. Hoist and hold the rotating joint.
6. Remove bolt (28). Remove the rotating joint.

: 19 mm
W3-3-1
Installation
26
CAUTION: Rotating joint weight:
64 kg (140 lb)
28
27
1. Hoist and install the rotating joint with bolt (28). 24
25
: 19 mm
: 110 Nm (11 kgfm, 81 lbfft)
2. Install plate (27) to the rotating joint with bolt (26).

: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft) W2BC-03-03-002
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 Nm (27.5 kgfm, 200 lbfft)
4. Install bracket (23) with bolt (22).

: 17 mm
: 65 Nm (6.6 kgfm, 48 lbfft) 11
12
5. Install pipes (1 to 17), hoses.
: 19 mm 13
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm
14
: 93 Nm (9.5 kgfm, 69 lbfft)
: 36 mm 15
: 175 Nm (18 kgfm, 129 lbfft)
: 41 mm 16
: 205 Nm (21 kgfm, 151 lbfft)
: 50 mm 17 7
: 306 to 374 Nm (31 to 38 kgfm)
(225 to 275 lbfft) W2BC-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE ROTATING JOINT
1 9
3
2㩷
10
11
5
12
7
13
14
15
W25N-03-03-003㩷
1- Scraper㩷 5- O-Ring㩷 9- Seal㩷 13 - Flange㩷

2- O-Ring㩷 6- Socket bolt㩷 10 - O-Ring㩷 14 - Plug㩷
3- Socket bolt㩷 7- Thrust Plate㩷 11 - V-Ring㩷 15 - Plug㩷
4- Cover㩷 8- Body㩷 12 - Shaft㩷
W3-3-4
Disassemble Rotating Joint
CAUTION: Rotating joint weight:

64 kg (140 lb)
1. Remove socket bolts (3) (2 used) from cover

(4) diagonally. Hoist and install the rotating joint
by using eyebolt.
: 8 mm
2. Remove other socket bolts (3) (4 used). Remove

cover (4).
: 8 mm
3. Remove O-ring (5) from body (8).

2-㱢12Hole㩷
M20㬍350㩷
4. Remove socket bolts (6) (4 used) and remove M20Tap
thrust plate (7). (180)
2-M10㬍100
: 8 mm 151 40
IMPORTANT: Do not damage the seal sliding
30
surface of shaft (12).
5. Remove shaft (12) from body (8) by using special
tool (A) completely.
57
㱢25
6. Remove seals (9) (8 used), O-ring (10) and V-ring
(11) from body (8).
12
NOTE: Seal (5) can be removed easily by using Spacer
two pins.
Protection
Plate㩷
7. Remove scraper (1) and O-ring (2) from cover (4).
Special Tool (A)

W25N-03-03-004
W3-3-5
ASSEMBLE ROTATING JOINT
2㩷 1 3
7
5
6
10
11
13
12
14
15
W25N-03-03-005
1- Scraper㩷 5- O-Ring㩷 9- Seal㩷 13 - Flange㩷

2- O-Ring㩷 6- Socket bolt㩷 10 - O-Ring㩷 14 - Plug㩷
3- Socket bolt㩷 7- Thrust Plate㩷 11 - V-Ring㩷 15 - Plug㩷
4- Cover㩷 8- Body㩷 12 - Shaft㩷
W3-3-6
Assemble Rotating Joint
IMPORTANT: When installing the seals, apply

grease or hydraulic oil.
1. Install V-ring (11), O-ring (10) and seals (9)(8
used) to body (8). Apply grease onto the lip part of
O-ring (11), dust seal (10) and seal (9).
2. Install shaft (12) to body (8).
3. Install body (8) to shaft (12) by using a press.
4. Install thrust plate (7) with socket bolts (6) (4

used).
: 8 mm
: 52 to 56.8 Nm (5.3 to 5.8 kgfm)
(38 to 42 lbfft)
5. Install O-ring (5) to body (8).
6. Install O-ring (2) and scraper (1) on cover (4). 㱢70 or more㩷
NOTE: Evenly tap and install scraper (1) by using 㱢56㩷

special tool (B).
Press㩷
7. Install cover (4) and tighten with socket bolt (6).

: 8 mm
: 52 to 56.8 Nm (5.3 to 5.8 kgfm)
20
(38 to 42 lbfft)
7
1
Special Tool (B)
W25N-03-03-006
W3-3-7
Item Allowable limit (basis for judgment) Remedy

Body / Shaft Sliding surface and Scored or serious damage Replace
sealed part
Sliding surface of 1) Scored or abnormal wear of more Replace
body and shaft, than 0.1 mm (0.004 in)
except sealed part 2) Scored less than 0.1 mm (0.004 in) Repair and finish
deep with oil stone
Sliding surface and 1) Wear more than 0.5 mm (0.02 in) deep Replace
thrust plate and abnormal wear
2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
3) Scored or abnormal wear less than 0.5 Repair and finish
mm (0.02 in) and repairable
Cover Sliding surface and 1) Wear more than 0.5 mm (0.02 in) Replace
thrust plate 2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
3) Scored or abnormal wear less than 0.5 Repair and finish
mm (0.02 in) and repairable
W3-3-8
BASE CARRIER / Track Take-Up Tumbler
REMOVE AND INSTALL TRACK TAKE-UP
TUMBLER
• In this section, the procedure starts on the
premise that the track shoe has already been
removed.䎃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)
W324-03-05-001
1. Pry the track take-up tumbler by using a pry bar.䎃

Remove the track take-up idler and bearing from
the side frame.
Track Take-Up Idler
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.
Bearing㩷
Installation W324-03-05-002
CAUTION: Track take-up tumbler weight:

226 kg (500 lb)
IMPORTANT: Check the direction of bearing.䎃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.
W324-03-05-003
㩷
㩷
W3-4-1
DISASSEMBLE TRACK TAKE-UP TUMBLER
1 2㩷 3 4 5 6 7 8
W25N-03-04-001
1- Idler㩷 3- Shaft㩷 5- O-Ring (2 Used)㩷 7- Bearing (2 Used)㩷

2- Bushing (2 Used)㩷 4- Floating Seal (2 Used)㩷 6- Pin (2 Used)㩷 8- Plug (4 Used)㩷
W3-4-2
Disassemble Track Take-Up Tumbler
1. Remove plug (8) and drain off engine oil.

: 6 mm
2. Remove pin (6) from bearing (7) and shaft (3) by

using a bar.
3. Remove shaft (3) from bearing (7) by using a

press.䎃Shaft (3) and bearing (7) are removed from
track take-up idler (1).

to the section “Precautions for
Handling Floating Seal” on page
W1-1-3.
4. Remove floating seal (4) from track take-up idler
(1) and bearing (7).
5. Remove shaft (3) from bearing (7) by using a

press.
6. Remove O-ring (5) from shaft (3).
7. Remove bushing (2) from track take-up idler (1).
W3-4-3
ASSEMBLE TRACK TAKE-UP TUMBLER
1 2㩷 3 4 5 6 7 8
W25N-03-04-001
1- Idler㩷 3- Shaft㩷 5- O-Ring (2 Used)㩷 7- Bearing (2 Used)㩷

2- Bushing (2 Used)㩷 4- Floating Seal (2 Used)㩷 6- Pin (2 Used)㩷 8- Plug (4 Used)㩷
W3-4-4
Assemble Track Take-Up Tumbler
1. Install bushing (2) to track take-up idler (1).

10. Apply LOCTITE #503 to plug (8). Install plug (8) to
2. Install O-ring (5) to shaft (3). Align the pin (6) bearing (7).
holes and install shaft (3) to bearing (7). : 6 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
3. Install pin (6) into bearing (7) and shaft (3).

to the section “Precautions for
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 30
Engine oil amount: 1.4 L (1.5 US qt)
W3-4-5
Track Take-Up Tumbler
B A B
W25N-03-04-002
Unit : mm (in)
Standard Allowable Limit Remedy
A 56 (2.21) -
B 27 (1.06) -
Build up and
C 20 (0.79) -
finishing
D 730 (28.7) 709 (27.9)
E 262 (10.3) -
(Shaft / Bushing)
Unit : mm (in)
Shaft Outer Dia. 120 (4.72) 118 (4.65)
Inner Dia. 120 (4.72) 121 (4.76)
Replace
Bushing Flange
6 (0.24) -
Thickness
W3-4-6
Travel Drive Sprocket
A B
W25N-03-04-003
Unit : mm (in)
A 21.5 (0.85) -
B 57 (2.24) - Build up and
C 100 (3.94) - finishing
D 705.4 (27.8) 689 (27.1)
W3-4-7
(Blank)㩷
㩷
W3-4-8
BASE CARRIER / Upper and Lower Rollers
REMOVE AND INSTALL UPPER ROLLER
• Remove the upper roller on the level, solid

1 2
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 1
W25N-03-05-001
2. Install jack (4) to bracket (3) in the side frame.

Make the track shoe in tension. 4 3
When
extending jack
When W25N-03-05-012㩷
releasing jack
3. Remove bolt (5) from the side frame. Remove 5 6 7

plate (6). Remove all shims (7).
: 24 mm
W25N-03-05-002
W3-5-1
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
Crawler Shoe 8
CAUTION: Upper roller (8) weight:

22.6 kg (50 lb)
6. Remove upper roller (8) from the side frame.
Installation
W25N-03-05-003㩷
1. Install upper roller (8) to the side frame with bolt
(9).
8 9
: 19 mm
: 110 Nm (11 kgfm, 81 lbfft)
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.
W324-03-06-004
W3-5-2
(Blank)
W3-5-3
DISASSEMBLE UPPER ROLLER
1
2㩷
3
6 7
3
2
5 1
W25N-03-05-007
1- Wire (2 Used)㩷 3- Collar (2 Used)㩷 5- O-Ring (2 Used)㩷 7- Roller㩷

2- Plug (2 Used)㩷 4- Pivot Seal (2 Used)㩷 6- Bushing (2 Used)㩷 8- Shaft
W3-5-4
Disassemble Upper Roller
1. Remove plug (2) and drain engine oil out from the
upper roller.
: 5 mm
2. Remove wire (1) from collar (3) and shaft (8) by

using a bar.
3. Remove shaft (8) from collar (3) by using a press.

Shaft (8) and collar (3) are removed from roller
(7).
4. Remove two pairs of pivot seal (4) from roller (7)

and collar (3).
6. Remove O-rings (5) (2 used) from shaft (8).
7. Remove bushings (6) (2 used) from roller (7).
W3-5-5
ASSEMBLE UPPER ROLLER
5 3 2㩷
7 8 6 4
W25N-03-05-008
1- Wire (2 Used)㩷 3- Collar (2 Used)㩷 5- O-Ring (2 Used)㩷 7- Roller㩷

2- Plug (2 Used)㩷 4- Pivot Seal (2 Used)㩷 6- Bushing (2 Used)㩷 8- Shaft
W3-5-6
Assemble Upper Roller
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 amount: 40 to 45 cm3
9. Apply LOCTITE #503 to plug (2). Install plug (2) to

roller (7).
: 5 mm
: 14.7 Nm (1.5 kgfm, 10 lbfft)
W3-5-7
Upper Roller
B A B
C
W25N-03-05-010
Unit : mm (in)
A 70 (2.76)
Cladding by welding
B 30 (1.18)
and finish or replace
C 220 (8.66) 200 (7.87)
(Shaft / Bushing)
Unit : mm (in)
Shaft Outer Dia. 35 (1.38) 34.3 (1.35)
Inner Dia. 35 (1.38)

Replace
Bushing Flange
3.8 (0.15)
Thickness
W3-5-8
REMOVE AND INSTALL LOWER ROLLER
• Remove the lower roller on the level, solid ground.

Remove the lower roller with the upper revolving
1 2
frame parallel to the track shoe.
• Before removal of the lower roller, travel the
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. 2 1

Make the track shoe in tension. W25N-03-05-001
4 3
When
extending jack
3. Remove bolt (5) from the side frame. Remove

: 24 mm
When
W25N-03-05-012㩷
releasing jack
4. Remove jack (4). Operate the travel and loosen
the track shoe.
5 6 7
W25N-03-05-002
W3-5-9
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.
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
(10).
8
Crawler Shoe 9
Installation W24X-03-05-006
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 10
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 Nm (97 kgfm, 700 lbfft)
W25N-03-05-006
W3-5-10
IMPORTANT: Make the track shoe in the specified
tension. Group B
5. Install jack (4) to bracket (3) in the side frame. 4 3 6 5
Make the track shoe in tension. 7
IMPORTANT: Make the shaft of track take-up idler

parallel. When
extending jack
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).
When
: 24 mm releasing jack
W25N-03-05-012㩷
: 270 Nm (27.5 kgfm, 200 lbfft)
8. Remove jack (4).
9. Install cover (2) to the side frame with bolt (1).

: 19 mm 1 2
: 90 Nm (9.2 kgfm, 66 lbfft)

2 1
W25N-03-05-001
W3-5-11
DISASSEMBLE LOWER ROLLER
1 2 3 4
6 7 8
W25N-03-05-009
1- Bushing (2 Used)㩷 3- Floating Seal (2 Used)㩷 5- Shaft㩷 7- Stopper (2 Used)㩷

2- Roller㩷 4- O-Ring (2 Used)㩷 6- Collar (2 Used)㩷 8- Plug (2 Used)㩷
W3-5-12
Disassemble Lower Roller
1. Remove plug (8) and drain engine oil out from the
lower roller.
: 6 mm
2. Remove stopper (7) from collar (6) and shaft (5)

by using a bar.

Shaft (5) and collar (6) are removed from roller
(2).
IMPORTANT: For handling floating seal (3), refer to

the section “Precautions for
W1-1-3.
4. Remove two pairs of floating seal (3) from roller
(2) and collar (6).
6. Remove O-rings (4) (2 used) from shaft (5).
7. Remove bushings (1) (2 used) from roller (2).
W3-5-13
ASSEMBLE LOWER ROLLER
1 2 3 4
6 7 8
W25N-03-05-009
1- Bushing (2 Used)㩷 3- Floating Seal (2 Used)㩷 5- Shaft㩷 7- Stopper (2 Used)㩷

2- Roller㩷 4- O-Ring (2 Used)㩷 6- Collar (2 Used)㩷 8- Plug (2 Used)㩷
W3-5-14
Assemble Lower Roller
1. Install bushings (1) (2 used) to roller (2).
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
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 amount: 250 cm3
8. Apply LOCTITE #503 to plug (8). Install plug (8)

on collar (6).
: 6 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
W3-5-15
Lower Roller
B A B
D
W25N-03-05-011
Unit : mm (in)
A 60 (2.36)
B 75 (2.94) Cladding by welding

C 20 (0.79) 12 (0.47) and finish or replace
D 270 (10.6) 255 (10.0)
(Shaft / Bushing)
Unit : mm (in)
Shaft Outer Dia. 70 (2.76) 69.3 (2.73)
Inner Dia. 70 (2.76)

Replace
Bushing Flange
4.5 (0.18)
Thickness
W3-5-16
BASE CARRIER / Track Shoe
REMOVE AND INSTALL TRACK SHOE
1 2
• 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
• 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
2 1
1. Remove bolt (1). Remove cover (2) from the side W25N-03-05-001
frame.
: 19 mm 4 3
2. Install jack (4) to bracket (3) in the side frame.

Make track shoe (8) in tension. When
extending jack
3. Remove bolt (5) from the side frame. Remove
4. Remove jack (4).

When
W25N-03-05-012
releasing jack
5. Remove bolt (9) and nut (10) from track shoe (8).
: 30 mm
5 6 7
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-03-05-002
8
9
10
11
W333-03-07-001
W3-6-1
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

850 mm Wooden Block
W2BC-03-06-004
W324-03-05-001
W3-6-2
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 W2BC-03-06-003
be installed in the forward direction. Turn the
travel drive sprocket and roll up track shoe (8).

850 mm Wooden Block
W2BC-03-06-004
W2BC-03-06-005
8
Take-Up
Drive Tumbler
Tumbler Side
Side㩷
W324-03-07-002
W3-6-3
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).
8
CAUTION: When aligning the joint pin (11) 9
hole, do not insert the fingers into
the hole. 10
6. Align the joint pin (11) hole on track shoe (8) and 11
install joint pin (11).
7. Install bolt (9) and nut (10) to joint pin (11).

: 30 mm
: 550 Nm (56 kgfm, 410 lbfft) W333-03-07-001
8. Weld bolt (9) and nut (10).
IMPORTANT: Make track shoe (8) in the specified Group B㩷

tension. 4 3 6 5
9. Install jack (4) to bracket (3) in side frame. Make 7
track shoe (8) in tension.
IMPORTANT: Make the shaft of track take-up idler When

extending jack
parallel.
10. Install shim (7) to the side frame. Insert the shim
selected from group B into the clearance.
11. Remove jack (4).

When
W25N-03-05-012
releasing jack
12. Install cover (2) onto the side frame with bolt (1).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft) 1 2
2 1
W25N-03-05-001
W3-6-4
Shoe
W2BC-03-06-001
W2BC-03-06-002
Unit: mm (in)
A 80 (3.15)
B 26 (1.02)
C 50 (1.97)
D 15 (0.59) Cladding by welding
E 60 (2.36) 47 (1.85) and hand finishing,
or replace
F 142 (5.59)
G 73 (2.87)
H 39 (1.54)
I 18.5 (0.73)
Joint Pin
B W324-03-07-004
Unit: mm (in)
A 38 (1.50) 34 (1.34)
Replace
B 311 (12.2)
W3-6-5
(Blank)
W3-6-6
BASE CARRIER / Cylinder
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.
1
Removal
1. Remove sidewalk (1) (6 used) in the upper

structure.
1

CAUTION: Upper Revolving Frame weight : W2BC-03-06-003
Approx. 18 t (39683 lb)
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)

Wooden Block 850 mm
W2BC-03-07-001
W3-7-1
3. Remove retainers (3) (4 used) and remove pins
(4) (4 used).
4. Operate SIDE FRAME switch (7) to extend side

frame (10, 11).
5. Remove bolts (5) (8 used) and remove bracket (6)

(4 used).
6. Remove all pipes from the travel motor. 7

: 19 mm, 27 mm, 50 mm
NOTE: Cap the removed pipe.

7. Place the lower frame (8) onto the wooden blocks. W2BC-03-07-005
8. Remove retainer (8) (2 used) and remove pins (9)

(2 used).
10
11

W2BC-03-07-002

W2BC-03-07-003
5 6 5
W2BC-03-07-004
3 4
W3-7-2
CAUTION: Side-frame weight :

3040 kg (6742 lb)
9. Hoist and remove side-frame (10, 11)
11 10

W2BC-03-07-013

and release the remaining pressure in the circuit. 13
11. Hold the rod side of cylinder (12) by using a sub 8

crane.
12. Remove nut (13). Remove U-bolt (15) from

bracket (14) in lower frame (8).
: 30 mm
Wooden Block
13. Insert the wooden block between bottoms of
cylinder (12) and lower frame (8). W2BC-03-07-010
12 15 14
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).
16. Pull out cylinder (12) from lower frame (8). Hoist
12
and remove cylinder (12). W2BC-03-07-011
17. Remove the other cylinder in the same

procedures.
W3-7-3
Installation

with parallel to the track shoe.

W2BC-03-06-003
CAUTION: Upper Revolving Frame weight :

Approx. 18 t (39683 lb)
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) 850 mm
Wooden Block
W2BC-03-07-001
W3-7-4
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). 17
8
16
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

Front
(8) with pin (16). 12
Wooden Block㩷
W2BC-03-07-012
5. Install all hoses to cylinder (12).
22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft) 8
12
6. Make cylinder (12) parallel by using a sub crane. W2BC-03-07-011
Install U-bolt (15) to bracket (14) in lower frame

(8) and support cylinder (12).
: 30 mm 13
: 170 Nm (17 kgfm, 125 lbfft)
8
7. Install the other cylinder in the same procedures.
Wooden Block
W2BC-03-07-010
12 15 14
CAUTION: Side-frame weight :

3040 kg (6742 lb)
8. Hoist and install side-frame (10, 11)
11 10

W2BC-03-07-013
W3-7-5
9. Install pins (9) (2 used) with retainers (8) (2 used).
10. Operate SIDE FRAME switch (7) to retract

side-frame (10, 11).
11. Install all pipes to the travel motor.
12. Install bracket (6) (4 used) with bolts (5) (8 used).

: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft) 7
13. Install pins (4) (4 used) with retainers (3) (4 used).

W2BC-03-07-005
10
11

W2BC-03-07-002

W2BC-03-07-003
5 6 5
W2BC-03-07-004
3 4
W3-7-6
(Blank)
W3-7-7
DISASSEMBLE CYLINDER
1
1
22
20
21
18
19
15 18
16
15 17
14
13
12
11
10
8
4
7
3
6
5
2
W25N-03-07-007
1- Grease Fitting (3 Used)㩷 7- Dust Wiper㩷 13 - Backup Ring㩷 18 - Wear Ring (2 Used)㩷
2- Piston Rod㩷 8- Cylinder Head㩷 14 - O-Ring㩷 19 - Piston Seal㩷
3- Boot Band㩷 9- Bushing㩷 15 - Backup Ring (2 Used)㩷 20 - Set Screw㩷
4- Boot㩷 10 - Backup Ring㩷 16 - O-Ring㩷 21 - Piston Nut㩷
5- Boot Band㩷 11 - Rod Seal㩷 17 - Piston㩷 22 - Cylinder Tube㩷
6- Retaining Ring㩷 12 - O-Ring㩷
W3-7-8
Disassemble Cylinder
1. Hoist and secure the cylinder horizontally. Drain

hydraulic oil out from the cylinder.
2. Loosen boot bands (3, 5).
3. Pull out piston rod (2) approximately 200 to 300

mm (7.87 to 11.8 in). Remove the cylinder head
(8) assembly from cylinder tube (22).

surface.

screw (20) from piston (17).
: 5 mm
NOTE: Grind off the caulked part by using a
grinder and remove set screw (20). Special Tools (A, B)㩷
6. Remove piston nut (21) from piston rod (2) by

using special tool (A).

(2) by using special tool (B). a
Dimension a㧦
Special Tool (A)=62mm (2.44 in)
Special Tool (B)=90mm (3.54 in)
W25N-03-07-008
W3-7-9
18
19
15 18
16
15 17
14
13
12
11
10
8
4
7
3
6
5
2
W25N-03-07-007
W3-7-10
8. Remove backup rings (15) (2 used) and O-rings
(16) (2 used) from the inner side of piston (17).
9. Remove wear rings (18) (2 used) and piston seal

(19) from the outer side of piston (17).
10. Remove the cylinder head (8) assembly from

piston rod (2).
11. Remove retaining ring (6), dust wiper (7), backup

ring (10), rod seal (11) and bushing (9) from the
inner side of cylinder head (8).
12. Remove O-rings (14, 12) and backup ring (13)

from the outer side of cylinder head (8).
13. Remove boot bands (3, 5) and boot (4) from

piston rod (2).
W3-7-11
ASSEMBLE CYLINDER
1 2 3 4 6 7 12 5 9 8 13 14 22 15 16 17 19 18 20 21
10
11
W25N-03-07-009
1- Grease Fitting (3 Used)㩷 7- Dust Wiper㩷 13 - Backup Ring㩷 18 - Wear Ring (2 Used)㩷
2- Piston Rod㩷 8- Cylinder Head㩷 14 - O-Ring㩷 19 - Piston Seal㩷
3- Boot Band㩷 9- Bushing㩷 15 - Backup Ring (2 Used)㩷 20 - Set Screw㩷
4- Boot㩷 10 - Backup Ring㩷 16 - O-Ring㩷 21 - Piston Nut㩷
5- Boot Band㩷 11 - Rod Seal㩷 17 - Piston㩷 22 - Cylinder Tube㩷
6- Retaining Ring㩷 12 - O-Ring㩷
W3-7-12
Assemble Cylinder
1. Install dust wiper (7), retaining ring (6), bushing

(9), rod seal (11) and backup ring (10) to the inner
side of cylinder head (8) in this order.

outer side of cylinder head (8).
3. Install piston seal (19) and wear rings (18) (2

used) to the piter side of piston (17).
4. Install O-ring (16) and backup rings (15) (2 used)

to the inner side of piston (17).
5. Install boot bands (3, 5) and boot (4) to piston rod

(2).
6. Install the cylinder head (8) assembly to piston

rod (2).
7. Secure the piston rod (2) assembly horizontally.

Install the piston (17) assembly to piston rod (2) Special Tools (A, B)㩷
by using special tool (B).
: 1163 to 1187 Nm (119 to 121 kgfm)
(860 to 880 lbfft)
8. Install piston nut (21) to piston rod (2) by using

special tool (A). a
: 2812 to 2868 Nm (285 to 295 kgfm)
(2070 to 2120 lbfft)
9. Tighten set screw (20) to piston (17). Caulk set

screw (20) (3 places) by using a caulking in order Dimension a㧦
Special Tool (A)=62mm (2.44 in)
not to pull out.
Special Tool (B)=90mm (3.54 in)
: 5 mm
: 22 to 27 Nm (2.2 to 2.8 kgfm) W25N-03-07-008
(16 to 20 lbfft)
10. Clamp cylinder tube (22) in a vise. Secure

cylinder tube (22) horizontally.
W3-7-13
2 3 4 5 8 22
W25N-03-07-009
W3-7-14
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 Nm (85 to 105 kgfm)
(620 to 760 lbfft)
13. Install boot (4) to piston rod (2) and cylinder tube
(22) with boot bands (3, 5).
W3-7-15
(Blank)
W3-7-16
REMOVE AND INSTALL TRACK
ADJUSTMENT CYLINDER (OPTIONAL)
procedures safely.
W2BC-03-07-007
sprocket, the track shoe can be removed easily. 4
Removal
1
1. Remove bolts (1) (3 used). Remove cover (2) 1
from the side frame. 3
: 19 mm
2. Remove drain plug (3) from check valve (4) to 1

drain hydraulic oil.
2 15 W2BC-03-07-008
3. Remove bolt (6) and nut (7) from track shoe (5).
: 30 mm
5
4. Place the wooden block under track shoe (5). 6
Secure track shoe (5). Remove joint pin (8) from
track shoe (5) by using a bar. 7
W333-03-07-001
W3-7-17
CAUTION: Track take-up idler weight:

226 kg (500 lb) Take-Up Tumbler
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.
9
10
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.
Bearing
7. When storing the track take-up idler for a while,
W324-03-05-002
place the track take-up idler horizontally on the
wooden blocks as illustrated. 10
9
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
Wooden Block W324-03-05-003
11. Remove bolts (14) (4 used) from plate (13) (2

used) and remove plate (13) (2 used). 9 11 12 13 15 14
: 24 mm
CAUTION: Take-up cylinder weight :

71 kg (157 lb)
16
12. Remove track adjustment cylinder (7).

17 12 13 14
W2BC-03-07-007
11 12

13 14 W2BC-03-07-009
W3-7-18
procedures safely. 9 11 12 13 15 14
machine slightly forward. In case the slack of 16
sprocket, the track shoe can be removed easily.
Installation
17 12 13 14
W2BC-03-07-007
CAUTION: Take-up cylinder weight :

71 kg (157 lb) 11 12
1. Install track adjustment cylinder (17) to the side

frame.
2. Install plate (13) (2 used) with bolts (14) (4 used).

: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
3. Install adapter (16) to track adjustment cylinder

(17).
: 24 mm

4. Install hose (15) to adapter (16). 13 14 W2BC-03-07-009
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
Take-Up Tumbler
CAUTION: Yoke weight : 83 kg (183 lb)
5. Install yoke (11) to the side frame.

9
10
CAUTION: Track take-up idler weight :
226 kg (150 lb)
6. Hoist and install track take-up idler (9) to the side Bearing
frame.
W324-03-05-002
W3-7-19
CAUTION: When aligning the joint pin (8)

hole, do not insert the fingers into
the hole.
5
7. Install bolt (6) to the track shoe and tighten nut (7).
: 30 mm 6
: 550 Nm (56 kgfm, 410 lbfft)
7
8. Install drain plug (3) to check valve (4). 8
9. Install cover (2) to the side frame with bolts (1) (3

used).
: 19 mm Wooden Block
: 90 Nm (9.2 kgfm, 66 lbfft) W333-03-07-001
10. State the engine. Operate the travel lever to the A 12 18 19

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 W2BC-03-07-007
plug (3) and drain hydraulic oil a little.

4
13. Apply grease onto the thread part of bolt (19).
14. Cover the thread part of bolt (19) with the heat 1
shrinkable tube. 1
3
2 15 W2BC-03-07-008
W3-7-20
(Blank)
W3-7-21
DISASSEMBLE TRACK ADJUSTMENT CYLINDER
2
8
3

W2BD-03-07-001
1 - Bolt (4 Used)㩷 4 - Dust Seal㩷 6 - O-Ring㩷 8 - Cylinder Head㩷

2 - Spring Washer (4 Used)㩷 5 - Backup Ring㩷 7 - Cylinder Tube㩷 9 - Piston㩷
3 - Retaining Ring㩷㩷㩷㩷
W3-7-22
Disassemble Track Adjustment Cylinder

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).
W3-7-23
ASSEMBLE TRACK ADJUSTMENT CYLINDER
1 2 3 4 5 6 7

9 8
W2BC-03-07-014
1 - Bolt (4 Used)㩷 4 - Dust Seal㩷 6 - O-Ring㩷 8 - Cylinder Head㩷

2 - Spring Washer (4 Used)㩷 5 - Backup Ring㩷 7 - Cylinder Tube㩷 9 - Piston㩷
3 - Retaining Ring㩷㩷㩷㩷
W3-7-24
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
W3-7-25
(Blank)
W3-7-26
REMOVE AND INSTALL JACK-UP
CYLINDER (OPTIONAL)

vertical to the track shoe.
Removal
2 3
1. Stop the engine. Operate the control lever several
circuit.
2. Remove all hoses from cylinder (4). Cap the

assembling.
: 22 mm
4

CAUTION: Jack-up cylinder (1) weight:
W2BC-03-07-006
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 5
CAUTION: Cylinder (4) weight: 103 kg (227 lb) 4

6
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).

W25N-03-07-012
W3-7-27
6. Remove the other jack-up cylinder (3 places) in
the same procedures.
Installation

5
1. Insert the valve side of cylinder (4) into the bottom
of jack beam (6) and install with bolts (5) (6 used). 4
: 19 mm
: 110 Nm (11 kgfm, 81 lbfft) 6
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
W25N-03-07-012
crane. Secure with stopper pin (2).
: 17 mm
: 65 Nm (6.6 kgfm, 48 lbfft)
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
2 3
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 4

Hose W2BC-03-07-006
: 39 Nm (4.0 kgfm, 28.5 lbfft)
Piping Joint
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
4. Install the other jack-up cylinder (3 places) in the

same procedures.
W3-7-28
(Blank)
W3-7-29
DISASSEMBLE JACK-UP CYLINDER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24
25
W25N-03-07-013
㩷
1- Retaining Ring㩷 8- O-Ring㩷 14 - Cylinder Tube㩷 20 - Set Screw㩷
2- Dust Seal㩷 9- Rod Packing㩷 15 - Piston㩷 21 - Steel Ball㩷
3- Plate㩷 10 - Plate㩷 16 - Backup Ring (2 Used)㩷 22 - Plug㩷
4- O-Ring㩷 11 - Clip㩷 17 - Piston Seal (2 Used)㩷 23 - Check Valve㩷
5- Bushing㩷 12 - Cylinder Head㩷 18 - O-Ring㩷 24 - Bolt㩷
6- Backup Ring㩷 13 - Piston Rod㩷 19 - Wear Ring㩷 25 - Spring Washer㩷
7- Backup Ring㩷
W3-7-30
Disassemble Jack-Up Cylinder
1. Remove bolt (24) from cylinder tube (14).

Remove check valve (22).
: 13 mm
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).

surface.

screw (20) and steel ball (21) from piston (15).
: 5 mm

(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).
W3-7-31
ASSEMBLE JACK-UP CYLINDER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24
25
W25N-03-07-013
㩷
1- Retaining Ring㩷 8- O-Ring㩷 14 - Cylinder Tube㩷 20 - Set Screw㩷
2- Dust Seal㩷 9- Rod Packing㩷 15 - Piston㩷 21 - Steel Ball㩷
3- Plate㩷 10 - Plate㩷 16 - Backup Ring (2 Used)㩷 22 - Plug㩷
4- O-Ring㩷 11 - Clip㩷 17 - Piston Seal (2 Used)㩷 23 - Check Valve㩷
5- Bushing㩷 12 - Cylinder Head㩷 18 - O-Ring㩷 24 - Bolt㩷
6- Backup Ring㩷 13 - Piston Rod㩷 19 - Wear Ring㩷 25 - Spring Washer㩷
7- Backup Ring㩷
W3-7-32
Assemble Jack-Up Cylinder
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 Nm (60 to 65 kgfm)
(430 to 470 lbfft)
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 Nm (1.8 to 2.2 kgfm)
(13 to 16 lbfft)
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).

outer side of cylinder head (12).
8. Install the cylinder head (12) assembly to cylinder

tube (14).
: 539 to 588 Nm (55 to 60 kgfm)
(400 to 430 lbfft)
9. Install check valve (22) to cylinder tube (14) with

bolt (24).
: 13 mm
: 19 to 21 Nm (1.9 to 2.1 kgfm)
(14 to 15.5 lbfft)
W3-7-33
(Blank)
W3-7-34
BASE CARRIER / Control Valve
VALVE FOR RETRACT AND JACK-UP
(OPTIONAL)
Removal
1. Remove bolts (2) (6 used) from cover (1).

: 17 mm
5
2. Remove all hoses from control valve (5). Cap the
assembling.
: 22 mm, 27 mm
W2BC-03-08-001
3. Remove bolts (3) (3 used) from control valve (5).

Remove control valve (5). 2
: 13 mm
W2BC-03-08-002
Installation
5
1. Install control valve (5) and tighten with bolts (3) (3

used). 3
: 13 mm
: 20 Nm (2.0 kgfm, 15 lbfft)
2. Install all hoses and harness connectors to control

valve (5).
: 22 mm
: 39 Nm (4.0 kgfm, 28.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
W2BC-03-08-003

3. Install cover (1) and tighten with bolts (2) (bused).

: 17 mm
: 50 Nm (5.1 kgfm, 3.7 lbfft)
W3-8-1
23 22 22 22 22 23 22
18 17 23 24
19
20
16
3
2 21
1 4
15 6
14
13
12 11 10 9 8 7

W2BD-03-08-001
1- Plug 8- Spool (6 Used) 15 - Screw (12 Used) 21 - Link Joint (6 Used)

2- O-Ring 9- Spool End (6 Used) 16 - Lever Bracket (6 Used) 22 - Lever (4 Used)
3- Housing 10 - Spring Cover (6 Used) 17 - Retaining Ring (12 Used) 23 - Lever (2 Used)
4- Plug (2 Used) 11 - Spring (6 Used) 18 - Pin (6 Used) 24 - Knob (6 Used)
5- O-Ring 12 - Spring Holder (12 Used) 19 - Socket Bolt (12 Used) 25 - Plug (4 Used)
6- Relief Valve 13 - Backup Ring (12 Used) 20 - Spring Washer (12 Used) 26 - O-Ring (4 Used)
7- Seal Holder (12 Used) 14 - O-Ring (12 Used)
W3-8-2


CAUTION: Control valve weight: 14. Remove the socket bolts (19) (12 used) and
Approx. 9 kg (20 lb) spring washers (20) (12 used) from the housing
(3).
1. Place the control valve assembly on a clean : 4 mm
workbench.
IMPORTANT: Check the length of the levers (22)
2. Remove the plug (1) from the housing (3) and and (23) removed from the spool (8).
drain off the hydraulic oil. 15. Remove the lever brackets (16) (6 used), link
joints (21) (6 used), levers (22) (4 used), levers
3. Remove the O-ring (2) from the plug (1). (23) (2 used) and knobs (24) (6 used) from the
housing.
4. Remove the plugs (4) (2 used) from the housing
(3). 16. Remove the knobs (24) (6 used) from the levers
: 6 mm (22) (4 used) and levers (23) (2 used).
5. Remove the plugs (25) (4 used) from the housing 17. Remove the seal holders (7) (6 used) from the
(3). housing (3).
6. Remove the O-rings (26) (4 used) from the plugs 18. Remove the spools (8) (6 used) from the housing
(25) (4 used). (3).

7. Remove the relief valve (6) from the housing (3). 19. Remove the backup rings (13) (12 used) and
O-rings (14) (12 used) from the housing.
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).
W3-8-3
23 22 22 22 22 23 22
18 17 23 24
19
20
16
3
2 21
1 4
15 6
14
13
12 11 10 9 8 7

W2BD-03-08-001
1- Plug 8- Spool (6 Used) 15 - Screw (12 Used) 21 - Link Joint (6 Used)

2- O-Ring 9- Spool End (6 Used) 16 - Lever Bracket (6 Used) 22 - Lever (4 Used)
3- Housing 10 - Spring Cover (6 Used) 17 - Retaining Ring (12 Used) 23 - Lever (2 Used)
4- Plug (2 Used) 11 - Spring (6 Used) 18 - Pin (6 Used) 24 - Knob (6 Used)
5- O-Ring 12 - Spring Holder (12 Used) 19 - Socket Bolt (12 Used) 25 - Plug (4 Used)
6- Relief Valve 13 - Backup Ring (12 Used) 20 - Spring Washer (12 Used) 26 - O-Ring (4 Used)
7- Seal Holder (12 Used) 14 - O-Ring (12 Used)
W3-8-4
1. Install the O-rings (14) (12 used) and backup rings 11. Install the O-ring (5) on the relief valve (6).
(13) (12 used) on the housing.
12. Install the relief valve (6) on the housing (3).
2. Install the spools (8) (6 used) on the housing (3).
13. Install the O-rings (26) (4 used) on the plugs (25)
3. Install the seal holders (7) (6 used) on the lever (4 used).
side of the housing (3).
14. Install the plugs (25) (4 used) on the housing (3).
4. Install the knobs (24) (6 used) on the levers (22)
(4 used) and lever (23) (2 used). 15. Install the plugs (4) (2 used) on the housing (3).
: 6 mm
IMPORTANT: Check the length of the levers (22)
and (23) removed from the spool (8). 16. Install the O-ring (2) on the plug (1).
5. Install the lever brackets (16) (6 used), link joints
(21) (6 used), levers (22) (4 used), levers (23) (2 17. Install the plug (1) on the housing (3).
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).
W3-8-5
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
Group 3 Component Specifications

Engine .......................................................... T1-3-1
Engine Accessories ...................................... T1-3-4
Hydraulic Equipment .................................... T1-3-5
Filters ............................................................ T1-3-9
Electrical Parts.............................................. T1-3-9
Lighting ....................................................... T1-3-10
2BCT-1-1
(Blank)
2BCT-1-2
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
Upper Structure 1 2 3 4 5 6
7
8
33 10
(Under Fuel Tank)
1
11* 㩷
1
32*
12
(Broken Line Part)㩷
31
13
30
29 14
28*1㩷 15
16
27
17
18
26
(Under Cab Back)㩷 19
25
20
T2BC-01-02-010
24 23 22 21
1- Fuel Tank㩷 10 - Pump Mechanism㩷 18 - Oil Cooler㩷 26 - Shuttle Valve㩷
1
2- Boom Derricking Drum㩷 11 - Third Drum Control Valve* 㩷 19 - Intercooler㩷 27 - Front Control Valve㩷
1
3- Slewing Control Valve㩷 12 - Engine㩷 20 - Battery㩷 28 - Rear Control Valve* 㩷
4- Derricking Drum Lock 13 - Pressure Compensator㩷 21 - Slewing Mechanism㩷 29 - Rear Drum㩷
Valve㩷
5 - 4-Spool Control Valve㩷 14 - Fourth Drum Brake Release 22 - Front Drum Brake Pedal 30 - Slewing Remote Control
Solenoid Valve (Optional)㩷 Unit㩷 Pressure Detection Valve㩷
6- Hydraulic 15 - Rear Drum Brake Release 23 - Fourth Drum Brake Pedal 31 - 4-Spool Solenoid Valve
Oil Tank㩷 Solenoid Valve㩷 Unit (Optional)㩷 Unit㩷
7 - Drain Filter㩷 16 - Front Drum Brake Release 24 - Rear Drum Brake Pedal 32 - Fourth Drum (Optional)㩷
Solenoid Valve㩷 Unit㩷
8- Pilot Filter㩷 17 - Radiator㩷 25 - Front Drum㩷 33 - Accumulator㩷
9- Gate Lock Valve㩷㩷㩷㩷
*1: As for the machine without fourth drum (32)
(optional), third drum control valve (11) is installed in
rear control valve (28).
T1-2-1
Base Carrier
8 3
4
5
6
13
8
12
9
11
Rear㩷 Left㩷
3 T2BC-01-02-001
7 Right㩷 Front㩷
10
1- Slewing Bearing㩷 5- Lower Frame㩷 8- Jack-Up Cylinder (4 Used) 11 - Lower Roller (20 Used)㩷
(Optional)㩷
1
2- Center Joint㩷 6- Take-Up Cylinder* (2 9 - Lower Control Valve 12 - Side Frame㩷
Used) (Optional)㩷 (Optional)㩷
3- Retract Cylinder㩷 7 - Front Idler (2 Used)㩷 10 - Upper Roller (4 Used)㩷 13 - Travel Mechanism (2
Used)㩷
4- Crawler Shoe㩷㩷㩷㩷
̪1㧦Installed in the side frame.
T1-2-2
Cab Inside
1 2 3 4 5 6
7
9 10 11
13
12
T2BC-01-02-003
T2BC-01-02-002
1- Front Drum Brake Pedal㩷 5- Front Drum Lever㩷 8- Lock Lever㩷 11 - Right Travel Lever㩷
2- Fourth Drum Brake Pedal 6- Rear Drum Lever㩷 9- Third/Fourth Drum Lever 12 - Slewing Lock Pedal㩷
(Optional)㩷 (Optional)㩷
3 - Rear Drum Brake Pedal㩷 7- Boom Derricking Drum 10 - Left Travel Lever㩷 13 - Slewing Lever㩷
Lever㩷
4- Accelerator pedal㩷㩷㩷㩷
T1-2-3
ELECTRICAL COMPONENT LAYOUT Solenoid Valve for Counterweight/Quick
Draw / Retract
(Refer to Counterweight/Quick Draw㩷 /㩷
Upperstructure Retract Control Valves.)㩷
8
1
Primary Pilot Pressure Sensor
(Refer to Accumulator.)㩷
(Under Fuel Tank)
Around Pump㩷
(Refer to Pump
Mechanism.)㩷
7
2
4-Spool Solenoid Valve
(Refer to 4-Spool
Solenoid Valve Unit.)㩷 3
Slewing Remote
Control Pressure
Sensor㩷 (Under Bed) Around Drum㩷
(Refer to Slewing (Refer to Drum.)
Remote Control
Pressure Sensor
Block.)㩷
Around Engine
(Refer to Engine.)㩷
4
Around Control Valve
(Refer to Front / Rear 5
Control Valves.)㩷
6
Around Battery㩷
(Refer to Batteries.)㩷
Inside Cab
(Refer to Cab Inside
Overall.)㩷
(Under Cab)
Around Brake Pedal
T2BC-01-02-013
(Refer to Brake Pedal Unit.)㩷
1- Oil Temperature Sensor㩷 4- Fourth Drum Brake Release Solenoid 7 - Fuel Sensor㩷
Valve (Optional)㩷
2- EC Motor㩷 5 - Rear Drum Brake Release Solenoid Valve 8 - Derricking Rotation Detection
Switch㩷
3- Air Filter Restriction Switch㩷 6- Front Drum Brake Release Solenoid Valve 㩷
T1-2-4
1 2 1
T2BC-01-02-004㩷
1- Operation Stop Switch㩷 2- Working Light (Right)㩷 3- Working Light (Left)㩷 4- Slewing Alarm Lamp㩷
T1-2-5
Cab Inside Overall
Monitor Panel
(Refer to Monitor Panel.)㩷
13
2
1
12 3
4 Travel Lever
8
Brake Mode Display Panel㩷 5
(Refer to Brake Mode Panel.)㩷
6
11 (Inside Cover)
10 7
T2BC-01-02-003
Left Control panel㩷
(Refer to Control Panel.)
Right Control Panel㩷

(Refer to Control Panel.)㩷
T2BC-01-02-006
Side Overhead Panel

14 (Refer to Overhead Panel.)㩷
Controller Box㩷
(Refer to Controller Box.)㩷 Rear Overhead Panel
(Refer to Overhead Panel.)㩷
15
Relay Panel㩷
(Refer to Relay Panel.)㩷
T2BC-01-02-005
1- Accelerator pedal㩷 5- Front Drum Brake Mode 9- Horn Switch㩷 13 - Moment Limiter㩷
Selection Switch㩷
2- Front Drum Rotation 6 - Lock Valve Limit Switch㩷 10 - Slewing Brake Switch㩷 14 - Antenna㩷
Sensing㩷
3 - Rear Drum Rotation 7- Rear Drum Brake Mode 11 - Accelerator grip㩷 15 - Air Conditioner Control
Sensing㩷 Selection Switch㩷 Panel㩷
4 - Boom Derricking Drum 8 - Fourth Drum Brake Mode 12 - Moment Limiter Control 㩷
Rotation Sensing㩷 Selection Switch㩷 Panel㩷
T1-2-6
Monitor Panel
1
15
14
13
2
12
11
10
9
3
6
4
T2BC-01-02-007
1- Coolant Temperature 5- Cigarette Lighter㩷 9- Glow Signal㩷 13 - Brake Unapplied Indicator㩷

Gauge㩷
2 - Fuel Gauge㩷 6- Overheat Indicator㩷 10 - Engine Oil Filter 14 - Engine Oil Pressure
Restriction Indicator㩷 Indicator㩷
3- Hour Meter㩷 7- Controller Failure 11 - Alternator Indicator㩷 15 - Pilot Pressure Indicator㩷
Indicator㩷
4- Key Switch㩷 8 - Air Filter Restriction 12 - Coolant Level Indicator㩷㩷
Indicator㩷
T1-2-7
Control Panel
• Left Control Panel
1 2 3 4 5 6 7 8 9
T2BC-01-02-008
12 11 10
• Right Control Panel
T2BC-01-02-009
13 14 15 16
1- Auto Stop Override 5- Auto Stop Release Front 9- Reeving Winch Switch㩷 13 - Accelerator Lock Switch㩷
Key Switch㩷 Drum Switch㩷
2 - Auto Stop Release 6 - Brake Mode Select Key 10 - Quick Draw Extend/Retract 14 - Front Drum Lock Switch㩷
Derricking Switch㩷 Switch㩷 Switch㩷
3 - Auto Stop Release 7 - Remote Control Pressure 11 - Third/Fourth Drum 15 - Rear Drum Lock Switch㩷
Third/Fourth Drum Switch㩷 Restoration Switch㩷 Selection Switch㩷
4 - Auto Stop Release Rear 8 - Side Frame Extend/Retract 12 - Counterweight/Jack-Up 16 - Fourth Drum Lock
Drum Switch㩷 Switch㩷 Switch (Optional)㩷 (Optional)㩷
T1-2-8
Overhead Panel
• Rear Overhead Panel

1 2 3 4 5 6 7
T2BC-01-02-011
• Side Overhead Panel

8 9 10 11 12
T2BC-01-02-012
1- FM/AM Radio㩷 4- (Auxiliary)㩷 7- Overhead Wiper / Washer 10 - Hydraulic Tagline Switch

Switch㩷 (Optional)㩷
2- Working Light Switch㩷 5- Electric Power socket㩷 8 - Emergency Engine Stop 11 - Drum rotation sensing SW
Switch㩷
3- Drum Light Switch 6- Front Wiper / Washer 9 - Slow Speed Lock Switch㩷 12 - Travel Mode Switch㩷
(Optional)㩷 Switch㩷
Brake Mode Display Panel

1 2 3
T2BC-01-02-014
6 5 4
1- Front Drum Free Mode 3 - Rear Drum Free Mode 5- Third / Fourth Drum Auto 6- Rear Drum Auto Brake Mode
Lamp (Red)㩷 Lamp (Red)㩷 Brake Mode Lamp (Green)㩷 Lamp (Green)㩷
2 - Third / Fourth Drum 4 - Front Drum Auto Brake 㩷㩷
Free Mode Lamp (Red)㩷 Mode Lamp (Green)㩷
T1-2-9
Relay Panel
1
2
3
1- Third Drum Lowering Stop Relay (R10)㩷

2- Moment Limiter Buzzer Relay (R9)㩷
3- Third/Fourth Drum Selection Relay Lower (R8)㩷
4- Slewing Alarm Relay (R1)㩷
5- Engine Oil Pressure Relay (R2)㩷
6- Engine Start Relay (R3)㩷
10 7- Horn Relay (R4)㩷
9 8- Jack Relay (R5)㩷
8
9- Motor Cutoff Relay (R6)㩷
7 10 - Third/Fourth Drum Selection Relay Upper (R7)㩷
6
T2BC-01-02-015
5
4
Controller Box
12
1
11
10
T2BC-01-02-016
8 7 6 5 4 3 2
1- Preheat Controller㩷 4- Memory Deletion Switch㩷 7- MC2/A 10 - Emergency Engine Stop
Switch㩷
2- ECU Lamp (Red)㩷 5- Troubleshooting Switch㩷 8- MC2/B 11 - Fuse Box㩷
3- ECU Lamp (Yellow)㩷 6- IDU 9- Maintenance Key Switch㩷 12 - IDU
T1-2-10
Brake Pedal Unit
Cab Floor㩷
T2BC-01-02-017
TBC-01-02-030 * Other Brakes are

4
1 2 3 installed to the same
positions.
1- Front Brake Depressing 2- Fourth Brake (Optional) 3- Rear Brake Depressing 4- Rear Brake Applied
Pressure Sensor㩷 Depressing Pressure Pressure Sensor㩷 Sensing Switch㩷
Sensor㩷
T1-2-11
Engine
1 2 3 4 5 6
10 9
11 12
Machine Front㩷 Machine Rear㩷㩷
䌔2䌂䌃-01-02-023
T25N-01-02-001 Machine Rear㩷 Machine Front㩷
13 14
T25N-01-02-003
1- Overheat Switch㩷 5 - TCV RTD Solenoid Valve㩷 9 - Engine Oil Filter Restriction 12 - Alternator㩷
Switch㩷
2- Coolant Temperature 6 - Engine Stop Solenoid Valve㩷 10 - Engine Oil Pressure Switch 13 - Timing Sensor㩷
Sensor㩷
3 - Air Heater㩷 7 - TDC Sensor㩷 11 - Starter㩷 14 - Rack Sensor㩷
4 - TCV ADV Solenoid Valve㩷 8 - Engine Rotation Detection 㩷㩷
Sensor㩷
T1-2-12
Batteries
7 10
3
6 4 9
㩷 T25N-01-02-005
Machine Right㩷㩷 Machine Upper㩷

T2BC-01-02-020
Machine Front㩷 Machine Rear㩷 Machine Front㩷 Machine Rear㩷
Machine Left㩷 Machine Lower
1- Engine Stop Relay㩷 4 - Battery Relay㩷 7- Load Dump Relay㩷 9- Receiver Drier Condenser
Fan Control Pressure
Switch㩷
2- Alternator Relay㩷 5 - Heater Relay㩷 8- Flasher㩷 10 - Coolant Level Switch㩷
3- Fusible Link㩷 6 - Starter Relay 2㩷㩷㩷
T1-2-13
Pump Mechanism
Fourth Drum Brake Cooling /
Hydraulic Tagline Drive /
Reeving Winch Drive Pump㩷
(Optional)㩷
Pump for Counterweight/Quick

Draw / Jack-Up / Retract㩷
Pilot Pump㩷
Slewing Pump
Machine Front㩷
䌔2䌂䌃-01-02-028
Machine Rear㩷
1- Power Increase Solenoid 2- Displacement Angle 3- Displacement Angle

Valve㩷 Proportional Solenoid Valve Proportional Solenoid Valve
(Main Pump)㩷 (Slewing Pump)㩷
T1-2-14
Front / Rear Control Valve
Upper Side of Control Valve
1 1
2* 㩷 3 4*1 5 6 7 8
Machine Left
Machine
Rear㩷
Machine
Machine Right㩷 Front㩷
Rear Control Valve

T2BC-01-02-018
Front Control Valve㩷
Bottom Side of Control Valve
Rear Control Valve㩷 Front Control Valve㩷
Machine Right
Machine
Rear㩷
Machine
Front㩷
Machine Left㩷
T2BC-01-02-019
1
9*1㩷 10 11 12* 13 14 15 16
1- Front Drum Hoisting 5 - Rear Drum Hoisting 9 - Third Hoisting Remote 13 - Boom Derricking Hoisting
Proportional Proportional Solenoid Valve㩷 Control Remote Control Pressure
Solenoid Valve㩷 Pressure Sensor*1㩷 Sensor㩷
2 - Third Drum Hoisting 6 - Boom Derricking Drum 10 - Front Drum Hoisting 14 - Rear Hoisting Remote
Proportional Solenoid Hoisting Proportional Remote Control Pressure Control Pressure Sensor㩷
1
Valve* 㩷 Solenoid Valve㩷 Sensor㩷
3 - Front Drum Lowering 7 - Rear Drum Lowering 11 - Front Drum Lowering 15 - Boom Derricking Lowering
Proportional Proportional Solenoid Valve㩷 Remote Control Pressure Remote Control Pressure
Solenoid Valve㩷 Sensor㩷 Sensor㩷
4 - Third Drum Lowering 8 - Boom Derricking Drum 12 - Third Drum Lowering 16 - Rear Lowering Remote
Proportional Solenoid Lowering Proportional Remote Control Pressure Control Pressure Sensor㩷
1 1
Valve* 㩷 Solenoid Valve㩷 Sensor* 㩷
*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.
T1-2-15
4-Spool Control Valve
Machine Front㩷
1 2*1㩷 3 4
Machine
Left㩷
Machine
Right㩷
Machine Rear
T2BC-01-02-021
8 7 6 5
1- Quick Draw Solenoid 5- Counterweight Solenoid

Valve (Extend)㩷 Valve (Right/Retract)㩷
2 - Retract Solenoid Valve 6 - Counterweight Solenoid
1
(Extend)* 㩷 Valve (Left/Retract)㩷
3 - Counterweight Solenoid 7 - Retract Solenoid Valve
Valve (Left/Extend)㩷 (Retract)㩷
4 - Counterweight Solenoid 8 - Quick Draw Solenoid
Valve (Right/Extend)㩷 Valve (Retract)㩷
*1: If the jack (optional) is installed, the lower power
solenoid valve is installed here.
T1-2-16
2
Detailed Position C
Around Drum
3
1
Detailed Position A㩷 Detailed Position B
Drum Lock㩷
Motor㩷
Motor㩷
Machine
Front㩷
T2BC-01-02-026 T2BC-01-02-027
Rotation Detection Sensor

(One sensor is installed to Machine Rear
the derricking drum.)㩷 T2BC-01-02-025
4 5 6 7 8
A A
Machine Front㩷
A
C C C
Fourth Drum㩷 Rear Drum㩷 Front Drum㩷

Boom Derricking
Drum㩷 (Optional)㩷
B B B
T2BC-01-02-024
9 10 11
1- Motor Cutoff High Pressure 4 - Derricking Drum Rotation 7- Front Drum Rotation 10 - Rear Drum Lock Motor㩷
Solenoid Valve (Only Front Detection Switch㩷 Detection Switch (A)㩷
/ Rear Drums)㩷
2 - Brake Release 5 - Rear Drum Rotation 8- Front Drum Rotation 11 - Front Drum Lock Motor㩷
Solenoid Valve㩷 Detection Switch (A)㩷 Detection Switch (B)㩷
3 - Motor Displacement Angle 6 - Rear Drum Rotation 9 - Fourth Drum (Optional) 㩷
Proportional Solenoid Valve㩷 Detection Switch (B)㩷 Lock Motor㩷
T1-2-17
4-Spool Solenoid Valve Unit
㩷
4-Spool Solenoid
Valve Unit㩷 1 2 3 4
Machine Left㩷
Machine
Rear㩷
Machine Front㩷
Machine Right㩷 T25N-03-08-001
1- Derricking Drum 3 - High / Low Speed

Unlocking Solenoid Selection Solenoid Valve㩷
Valve㩷
2 - Slewing Brake Solenoid 4 - Second Overhoist
Valve:㩷 Solenoid Valve㩷
Accumulator Slewing Remote Control Pressure Sensor Block
Accumulator㩷
Slewing Remote
M25N-07-030 Control Pressure
1 Sensor Block㩷
T25N-01-02-019
1- Primary Pilot Pressure 2- Right Slewing Remote 3- Left Slewing Remote

Sensor㩷 Control Pressure Sensor㩷 Control Pressure
Sensor㩷
T1-2-18
GENERAL / Component Specifications
ENGINE
Engine body
Manufacturer ................................................................MITSUBISHI Motor
Model ...........................................................................6D24-TLE2A
Type..............................................................................4-cycle water-cooled in-line direct injection,
turbocharged
No. 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...................................................................1-5-3-6-2-4
Rotational 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) ...........................................0.825
Thermostat ...................................................................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)
Charger
Method .........................................................................Alternating current type (with built-in regulator)
Voltage, current ............................................................24 V ⋅ 50 A
Drive .............................................................................V belt
Acceleration ratio ......................................................... 2.24
T1-3-1
Supercharger
Type.....................................................................Exhaust gas turbo type TD08H
Fuel system
Manufacturer .......................................................Bosch automotive system
Type.....................................................................Bosch type
Governor .............................................................Centrifugal full-speed control (mechanical)
Timer ...................................................................Electronic control
Performance
Lubricant 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
T1-3-2
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.
Torque
(kgf⋅m) (lbf⋅ft)
(122) (885)
(112) (811)
(102) (738)
(92) (664)
(HP)
(82) (590)
(255)
(241)
(215)
Output
Power
(188)
(161)
(134)
Specific
Fuel
Consumption
g/kW⋅h (g/PS⋅h)
(107)
(191)
(177)
(80)
(162)
(147)

-1
Engine Speed min (rpm) T25N-01-03-002
T1-3-3
ENGINE ACCESSORIES
Radiator assembly
Manufacturer .................................. Tokyo Radiator
Type................................................ 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)
T1-3-4
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 ...........................................................................K5V140DTP
Theoretical 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 ...........................................................................K5V80S
Theoretical 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 ...........................................................................SD1A3020
Theoretical 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-L
Theoretical displacement .............................................15.9 cm3(1.0 in3)/rev
Front control valve

Type..............................................................................4-spool
Model ...........................................................................MWP425S2CT758C
Main relief setting .........................................................31.4 MPa (320 kgf/cm2, 4570 psi)@275 L/min
(72.6 GPM)
Weight ..........................................................................107 kg (235 lb)
Rear control valve

Type..............................................................................4-spool
Model ...........................................................................MWP4253SC760B
(72.6 GPM)
Weight ..........................................................................85 kg (190 lb)
T1-3-5
4-Spool control valve for counterweight / quick draw / lower control valve
Type..............................................................................4-spool solenoid selection
Model ...........................................................................KMC10-4060
Main 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 ...........................................................................MW125T7196
Main 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 ...........................................................................MW125P5187A
(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-V1
Theoretical 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)

Hydraulic-released multi-plate .....................................9.8 MPa (100 kgf/cm2, 1025 psi)
Boom derricking mechanism

Reduction ratio .............................................................70.84
Main Composition ........................................................Derricking drum, reduction gear and derricking motor
Weight ..........................................................................872 Kg (1925 lb)
T1-3-6
Boom derricking motor
Type..............................................................................Swash plate type variable displacement axial plunger motor
Model ...........................................................................HMG125AF-5MA
Theoretical 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

Hydraulic-released multi plate......................................1.18 MPa (12 kgf/cm2, 172 psi)
Slewing mechanism
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 ...........................................................................M5X180CHB
Theoretical displacement .............................................158.9 cm3 (9.7 in3)/rev
Slewing parking brake

Travel mechanism
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-15
Theoretical 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)
Travel brake valve

Relief valve setting .......................................................31.4 MPa (320 kgf/cm2, 4550 psi)@270 L/min
(71.2 GPM)
Travel parking brake

Reeving winch (hydraulic tagline using combinedly) (optional)

Type..............................................................................NWA03F
Relief valve setting .......................................................11.8 MPa (120 kgf/cm2, 1715 psi)
T1-3-7
Counterweight cylinder
Type..............................................................................HC130-3500000
Dia. .............................................................................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..............................................................................Z007-60000
Stroke ...........................................................................1000 mm (39.4 in)
Weight ..........................................................................125 kg (276 lb)
Jack-up cylinder (optional)

Stroke ...........................................................................690 mm (27.2 in)
Weight ..........................................................................103 kg (227 lb)
Remote control valve hoisting and derricking

Type..............................................................................3-spool PPC valve
Model ...........................................................................TH40PC3068A
Plunger stroke ..............................................................6.5 mm (0.3 in)
Weight ..........................................................................13.5 kg (30 lb)
Remote control valve for travel and third / fourth drum

Model ...........................................................................TH40PC3077
Plunger 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

Model ...........................................................................TH40PC1042
Weight ..........................................................................4.5 kg (10 lb)
Remote control valve for brake

Type..............................................................................Foot-depression PPC valve
Model ...........................................................................15049-0001A
Center joint
Type..............................................................................YV7224
4-spool solenoid valve for derricking drum lock, slewing brake, travel (high) and second overhoist
Type..............................................................................4KWE5G-20/G24WS-420A
Reducing pressure setting ...........................................4.9 Mpa (50 kgf/cm2, 712 psi)
Weight ..........................................................................5.6 kg (12.3 lb)
Gate lock solenoid valve

Type..............................................................................CVB178-1
Relief pressure setting .................................................9.8 Mpa (100 kgf/cm2, 1425 psi)
T1-3-8
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 .............................................................................DMTG1
General 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)
Accumulator
Type .............................................................................Bladder type
Model ...........................................................................Mu150-700
Capacity .......................................................................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)
ELECTRICAL PARTS
Engine oil pressure switch

Manufacturer ................................................................Mitsubishi Motors (ME049261)
Operating pressure ......................................................OFF at 80±20 kPa (0.8±0.2 kgf/cm2, 11.4±2.84 psi)
or less
Overheat switch
Manufacturer ................................................................Mitsubishi Motors (ME049264)
Operating temperature.................................................101±2 °C (214±36 °F)
T1-3-9
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
Air cleaner restriction switch

Manufacturer ................................................................NIPPON DONALDSON (KAX801244)
Operating pressure ......................................................6.23 kPa (635 mmAq)
Fuel sensor
Resistance ...................................................................Idle : 90 Ω Upper limit : 10 Ω
Front/rear boom derricking rotation sensor

Model ...........................................................................YAMATAKE-Honeywell RL7M-8J6ND
Battery relay
Manufacturer 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 MITSUBISHI Motors (30890-03201)
Voltage and current 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 24 V ⋅100 A
Horn
Manufacturer ................................................................DENSO
Voltage and current ......................................................24 V ⋅1.5±0.5 A
Sound pressure............................................................113±5 dB (A)/2 m
Flasher
Manufacturer ................................................................Niles
Model ...........................................................................VF324L
Voltage .........................................................................24 V
LIGHTING
Side lamp
Manufacturer ................................................................EVER WING (7031)
Working lights
Manufacturer ................................................................Night Beam (ML-B133H)
Output ..........................................................................24 V ⋅ 70 W
T1-3-10
SECTION 2
SYSTEM
—CONTENTS—
Group 1 Control System
Outline .......................................................... T2-1-1
Engine Control ............................................. T2-1-2
Pump Control ............................................. T2-1-16
Other Control.............................................. T2-1-24
Group 2 Hydraulic System

Outline .......................................................... T2-2-1
Pilot Circuit ................................................... T2-2-2
Gate Lock Circuit.......................................... T2-2-3
Main Circuit .................................................. T2-2-4
Neutral Circuit .............................................. T2-2-6
Hoisting Circuit ............................................. T2-2-7
Hoisting Brake Circuit................................. T2-2-20
Boom Derricking Circuit ............................. T2-2-29
Travel Circuit .............................................. T2-2-31
Slewing Circuit ........................................... T2-2-35
Counterweight / Quick Draw Circuit ........... T2-2-37
Jack-up (Optional) / Retract Circuit............ T2-2-39
Hydraulic Tagline Circuit............................. T2-2-41
Reeving Winch Circuit (Optional)............... T2-2-42
Take-up Circuit (Optional) .......................... T2-2-43
Group 3 Electric System

Outline .......................................................... T2-3-1
Power Circuit................................................ T2-3-2
Preheating Circuit......................................... T2-3-4
Engine Starting Circuit ................................ T2-3-8
Charging Circuit ......................................... T2-3-10
Accessories Circuit..................................... T2-3-12
Engine Stop Circuit..................................... T2-3-13
Surge Voltage Prevention Circuit ............... T2-3-15
Drum Lock Circuit....................................... T2-3-17
Slewing Brake Release Circuit................... T2-3-19
2BCT-2-1
(Blank)
2BCT-2-2
SYSTEM / Control System
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
T2-1-1
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.
T2-1-2
Accelerator Grip Accelerator Pedal

Accelerator Lock
Switch
Key Switch
MC2/A

T25N-02-01-038
Governor Motor Engine Governor

Lever
T2-1-3
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.
T2-1-4
Key Switch
Accelerator Pedal
Accelerator Grip
Accelerator
Lock Switch
Drum Rotation Sensing MC2/A

Switch
Governor Motor
Potentio Sensor
MC2/B
Governor Motor Engine Governor Lever

Auto Stop Cancellation
Front Drum Switch

Rear Drum Switch

Fourth Drum Switch

T25N-02-01-039
T2-1-5
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.
T2-1-6
Accelerator Grip
Accelerator Pedal
Accelerator ON
Lock Switch
SET
MC2/A

T25N-02-01-014
Governor Motor Engine Governor Lever

T2-1-7
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.
Accelerator Grip
ON Accelerator
Pedal
Accelerator
Lock Switch
MC2/A
Engine Speed
Detection Sensor

T25N-02-01-041
Governor Motor Engine Governor

Lever
T2-1-8
(Blank)
T2-1-9
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.
ECU
To
MC2/A
Coolant Temperature
Sensor
Timing Sensor
TCV RTD So-

lenoid Valve
TCV ADV So-

lenoid Valve
To Engine From Engine

TDC Sensor T25N-02-01-001
Rack Sensor Electronic Timer
T2-1-10
Operation of TCV Solenoid Valve
To Advance Fuel Injection Timing: TCV ADV Solenoid

• TCV ADV solenoid valve: ON Valve
• TCV RTD solenoid valve: Stop TCV RTD Solenoid
When port P and port A are connected, oil pressure is Valve
transmitted to an electronic timer to advance fuel in-
jection timing.
Port P

Port A T25N-02-01-004
To Retain Fuel Injection Timing: TCV RTD Solenoid

• TCV ADV solenoid valve: Stop Valve
• TCV RTD solenoid valve: Stop TCV ADV Solenoid
Each port is blocked to retain the oil pressure in the Valve
electronic timer at a certain level, keeping the state of
the electronic timer.

Port A T25N-02-01-003
TCV RTD Solenoid

Valve
To Retard Fuel Injection Timing: Port R
• TCV ADV solenoid valve: Stop
• TCV RTD solenoid valve: ON TCV ADV Solenoid
Valve
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.

Port A
T25N-02-01-002
T2-1-11
ECU Failure Diagnosis Control TDC Timing Rack Coolant Tem-
Sensor Sensor Sensor perature
Purpose: Failure of the engine is detected through Sensor
various sensors connected to ECU, and its Failure Diagnosis
Switch
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).
ECU
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. Failure Diagnosis
Unit
MC2/A
Orange Red
ECU Lamps
IDU
Display

T25N-02-01-005
T2-1-12
Failure Diagnosis and Backup Mode
Fault indica-
tion (blinking Fault location Countermeasure by ECU (backup mode) Operation
frequency)
* 0-1 Normal − {
Feedback error (Actual advance angle of fuel Both timer control valves: OFF
* 1-2 injection timing does not follow the target advance Timer control (fuel injection timing control): Stop
angle.)
Timing sensor Both timer control valves: OFF
* 1-4
Timer control (fuel injection timing control): Stop
TDC sensor Determining engine speed from the number of tim-
* 1-5 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
c : 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.
Display
Display
MC2/A Input/Output monitor

MC2A_ECU1
RECEIVE NORMAL
TMR F. B. ERROR
RACK P. S. NORMAL
TIMING S. ERROR
OVER H. S. ERROR
TMR C. V. NORMAL
↑↓ Page selection × Return
Item
Item Signal Name Display Information

RECEIVE ECU NORMAL Normal
TMR F. B. Timer feedback ERROR Error
RACK P. S. Rack sensor ****** Communication error
TIMINGS. Timing sensor
TDC S. TDC sensor
OVER H. S. Coolant temperature sensor
TMR C. V. Timer control valve
T2-1-13
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.
T2-1-14
Drum Rotation Sensing MC2/A

Switch
ECU
Rack Sensor
MC2/B
Engine Governor Lever

Governor Motor
Front Drum Switch

Rear Drum Switch

Third / Fourth Drum Switch

T25N-02-01-035
T2-1-15
PUMP CONTROL
Main Pump Displacement Angle Control 9. Even if returning the accelerator grip rapidly,
MC2/A needs the primary time-lag for the rotating
Purpose: Controls the delivery flow of the main pump of the accelerator grip, thus preventing cavitation
according to the rotation of the accelerator in the derricking motor. (Response time to rapid
grip, and the control direction and slowdown returning: About two seconds)
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.
T2-1-16
Accelerator Grip
Accelerator Lock Switch

Unit
CAN
Displacement Angle
Proportional Solenoid
Valve
Engine Pilot
Pump
Main Main
Pump 1 Pump 2
T2BC-02-01-001
T2-1-17
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.
T2-1-18
Power
Increase
Solenoid
Valve
Pilot
Engine Pump
Main Main
Pump 1 Pump 2
T2BC-02-01-002
Rack Sensor Engine Speed

Sensor
T2-1-19
Power Increase Pressure Calibration
Purpose: Makes MC2/A store the power increase

output calibration data.
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)
T2-1-20
Accelerator Lock Auto Stop Cancellation

Switch Front Drum Switch
Pilot Pressure
Drop Indicator Auto Stop Cancellation
Rear Drum Switch
4-Spool Solenoid
Valve Unit
Power
Increase
Solenoid
Valve
Main Main Pilot

Pump 1 Pump 2 Pump
T2BC-02-01-003

Sensor
T2-1-21
Full Rack Calibration
Purpose: Makes MC2/A store the power increase

output and the engine speed at full rack.
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).)
T2-1-22
Accelerator Lock
Switch
Auto Stop Cancellation Derricking
Drum Switch
Pilot Pressure Drop

Indicator
4-Spool Solenoid
Valve Unit
Power
Increase
Solenoid
Valve
Governor
Potentio
Sensor
Main Main Pilot Pump

Pump 1 Pump 2
T2BC-02-01-004

sensor
Governor motor
T2-1-23
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.
T2-1-24
MC2/A
From Battery
Slewing Mechanism
Battery Relay
Slewing Alarm
Lamp Relay
Slewing Control
Valve
Slewing Alarm Lamp (Left)

Slewing
Lever
Slewing Pump
Flasher Relay
Slewing Alarm Lamp (Right)

Pilot Pump
T2BC-02-01-005
T2-1-25
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.
T2-1-26
NOTE: The illustration below shows the front drum rotation sensing system in operation.
Control Lever
Rod Rod Rod

Front㩷 Rear㩷 Derricking
Front Drum Rotation Vibration

Detection Sensor A㩷
Front Drum㩷
Front Drum Rotation
Detection Sensor B
Front Drum Rear Drum Derricking

Rear Drum Rotation Rotaion Rotaion
Rotaion
Detection Sensor A㩷 Sensing Sensing
Sensing
Solenoid Solenoid Solenoid
Rear Drum㩷
Rear Drum Rotation

Detection Sensor B
Boom Derricking
Drum Rotation
Detection Sensor A
Derricking MC2/A
Drum㩷
Drum Rotation Sensing

Switch㩷
T25N-02-01-020
T2-1-27
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.
4-Spool Solenoid
Valve Unit
Accumulator
Primary
Pilot
Pressure
Sensor
Pilot Pump
Pilot Pressure Drop

Alarm Lamp
From Battery
T2BC-02-01-006
T2-1-28
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.
T2-1-29
Brake Release
Solenoid Valve
Brake
Brake Mode Selection Front Drum

Key Switch
Brake Release
Solenoid Valve
MC2/A
Brake
Rear Drum
Brake Release
Solenoid Valve
Brake
Fourth Drum
(Optional)
Fourth
Remote Control (Optional)
Front Rear Pressure Sensor
4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-01-007
T2-1-30
• 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.
T2-1-31
Third / Fourth Selection

switch Front Hoisting Remote
Control Pressure Sensor
Front Lowering Remote

Second Control Pressure Sensor
Brake Mode Selection
Key Switch Overhoist
Rear Hoisting Remote
Limit
Switch
Rear Lowering Remote
Front Drum Brake Mode Control Pressure Sensor
Selection Switch Third / Fourth
Hoisting Remote
Control Pressure
Sensor
Rear Drum Brake (Optional)
Mode Selection Switch
Third / Fourth
Lowering Re-
MC2/A mote Control
Third / Fourth Drum Pressure Sensor
Brake Mode Selection (Optional)
Switch (Optional)
Brake Pedal
(Fourth)
(Optional)
Third Drum Rear Drum Front Drum

(Optional) Brake Pedal
(Rear)
Brake Release
Solenoid Valve
(Third) (Optional)
Fourth Brake Depressing Brake Release

Sensor (Optional) Solenoid Valve
(Rear) Brake Pedal
(Front)
Rear Brake
Depressing
Sensor
Brake Release
Solenoid Valve Front Brake De-
(Front) pressing Sensor
Pilot Pump
T2BC-02-01-008
T2-1-32
• Third Drum Free Mode Control third/fourth brake mode selection switch is turned
ON, MC2/A receives a switch-ON signal.
IMPORTANT: The free mode is applicable only 2. When operating the third drum lever to lowering,
when the brake mode selection key MC2/A activates the solenoid valve in third drum
switch is at the free brake position. motor and bypasses the holding pressure to the
lowering side.
1. When third drum is selected by using the third/ 3. The third drum motor becomes free and the load
fourth drum selection switch with the brake mode falls freely.
selection key switch at the free brake position and
Third / Fourth Drum

Selection Switch
Brake Mode
Selection Key Switch
Third / Fourth Hoisting
Remote Control Pressure
MC2/A Sensor
Third / Fourth Lowering
Third / Fourth Brake Mode Sensor
Selection Switch
4-Spool Solenoid
Valve Unit
Third Drum Motor
(Lowering) (Hoisting)

Pilot Pump T2BC-02-01-015
T2-1-33
• 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.
T2-1-34
Derricking Drum
Derricking
Motor Brake
Derricking
Drum Lock
Derricking
Motor
Derricking Drum Spool
Front Control Valve

Derricking Drum
Lowering
Proportional
Solenoid Valve
Remote Control
Pressure Sensor
Derricking Drum Hoisting

Proportional Solenoid Valve
Pump 1
4-Spool Solenoid
Valve Unit
Pilot Pump
Derricking Drum T2BC-02-01-009
Unlocking Solenoid
Valve
T2-1-35
Engine Start Interlock Control
Purpose: Locks the engine when engine starting will

result in dangerous state. Front Drum Brake Mode
Selection Switch
Operation:
1. When MC2/A receives a signal that indicates the
slewing brake switch at the brake position, and Rear Drum Brake Mode
MC2/A
Selection Switch
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. Third / Fourth Drum Brake
2. When the key switch is set to the start position, (Optional)
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. Slewing Brake
Switch
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. Key Switch
Interlock Indication
Lamp
Engine Starting
Relay
Starter Relay 1

Starter Motor

T25N-02-01-033
T2-1-36
Motor Cutoff Pressure Control Front Lowering
Remote Control
Pressure Sensor Motor Cutoff
Purpose: Lowers the cutoff pressures of the front and Relay
rear motors to regulate the lowering speed.
Operation: Rear Lowering

Remote Control MC2/A
1. MC2/A receives a voltage signal that indicates Pressure Sensor
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.
From Battery
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.
Front
Drum
Motor Cutoff High

Pressure Solenoid
Valve (Front)
Rear
Drum
Motor Cutoff High

Pressure Solenoid
Valve (Rear)
T2BC-02-01-016
T2-1-37
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.
Terminal E4: Derricking drum unlocking solenoid
valve
Terminal E18: Front motor brake release solenoid
valve
Terminal E5 l: Rear motor brake release solenoid
valve
Terminal E19: Fourth motor brake release sole-
noid valve (optional)
Terminal E17: Slewing brake release solenoid
valve
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.
T2-1-38
Front Motor Brake Release

Solenoid Valve
Front
Motor
Rear Motor Brake
Release Solenoid
Valve
Emergency
Operation Switch Rear
Motor
Fourth Motor Brake

Solenoid Valve
(Optional)
Fourth
Motor
(Optional)
Boom
Slewing Motor
Derricking
Motor
Pilot Pump

T2BC-02-01-022
T2-1-39
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.
T2-1-40
Derricking Drum
Hoisting Proportional
Solenoid Valve
Derricking Drum
Lowering Proportional
Solenoid Valve
Auto Stop Release

Derricking Switch Livemast
Lower Limit
Auto Stop Release Prevention
Key Switch
Boom Overhoist Prevention
Tower Upper Limit

Overhoist Prevention
Boom Second Overhoist

Prevention
Crane Relay Box
Main Hook
Overhoist
Prevention Derricking Drum
Hoisting Stop
Sub Hook
Overhoist Derricking Drum
Prevention Lowering Stop
Shouldering
Tower Relay Box Prevention
Tower Breakage
Prevention
Tower Jib
Overhoist
Prevention
Tower Jib
Backstop
Alignment
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention

T2BC-02-01-012
T2-1-41
Front Drum Auto Stop Control

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.
T2-1-42
Front Drum Hoisting

Valve
Front Drum Lowering

Valve
Auto Stop Release
Front Drum Switch
Auto Stop Release
Key Switch
Boom Second
Crane Relay Box
Main Hook
Overhoist
Prevention
Front Drum
Hoisting Stop
Sub Hook
Overhoist
Prevention Front Drum
Lowering Stop
Tower Relay Box

Shouldering
Prevention
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention

T2BC-02-01-013
T2-1-43
Rear Drum Auto Stop Control

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-
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.
T2-1-44
Rear Drum Hoisting

Valve
Rear Drum Lowering

Valve
Auto Stop Release

Rear Drum Switch
Auto Stop Release
Key Switch
Tower Upper Limit

Boom Second
Crane Relay Box
Main Hook
Overhoist
Prevention
Rear Drum
Hoisting Stop
Sub Hook
Overhoist Rear Drum
Shouldering
Prevention
Tower Relay Box
Tower Breakage
Prevention
Tower Jib
Overhoist
Prevention
Tower Jib
Backstop
Alignment
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-014
T2-1-45
Fourth Drum Auto Stop Control (Optional)

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:
2. MC2/B sends a voltage signal to the fourth drum
hoisting proportional solenoid valve or the fourth
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.
T2-1-46
Fourth Drum Hoisting

Valve
Fourth Drum Lowering

Auto Stop Release Proportional Solenoid
Fourth Drum Switch Valve
Auto Stop Release
Key Switch
Boom Second
Crane Relay Box
Main Hook
Overhoist
Prevention Fourth Drum
Hoisting Stop
Sub Hook
Overhoist Fourth Drum
Shouldering
Tower Relay Box Prevention
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-017
T2-1-47
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:
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.
T2-1-48
Second Overhoist
Solenoid Valve

Restoration Switch
Boom Second Overhoist

Prevention
Tower Relay Box
Tower Jib
Second
Overhoist
Prevention

T2BC-02-01-018
T2-1-49
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
2. At auto stop of the front drum, the front drum
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.
Front Drum Hoisting

Valve
Front Drum Lowering

Proportional solenoid
Valve
Shouldering
Prevention

T2BC-02-01-019
T2-1-50
2-Speed Tower Jib Derricking Flow Combining 2. The rear drum hoisting proportional solenoid
Control valve or the rear drum lowering proportional so-
lenoid valve delivers pressure oil from the rear
Purpose: When the attachment is a tower, prevents remote control valve to the hydraulic oil tank ac-
2-speed flow combining through the rear cording to this voltage signal. Thus, the 2-speed
spool by using the rear drum hoisting pro- flow combining from the rear spool is prevented.
portional solenoid valve or the rear drum
lowering proportional solenoid valve. Also,
slowly reduces the remote control pressure • Surge pressure reduction
applied to the rear spool (low) in the front 1. MC2/B sends a voltage signal to the rear drum
control valve by controlling the rear drum hoisting proportional solenoid valve or the rear
hoisting proportional solenoid valve or the drum lowering proportional solenoid valve.
rear drum lowering proportional solenoid 2. At auto stop of the rear drum, the rear drum
valve, thus reducing a surge pressure hoisting proportional solenoid valve or the rear
caused at auto stop of the rear drum. drum lowering proportional solenoid valve deliv-
ers pressure oil from the rear remote control valve
Operation: to the hydraulic oil tank according to this voltage
• 2-Speed Flow Combining Prevention signal. As a result, the surge pressure is reduced.
1. MC2/B sends a voltage signal to the rear drum
hoisting proportional solenoid valve and the rear
T2-1-51
Rear Drum Hoisting

Valve
Rear Drum Lowering

Valve

T2BC-02-01-020

T2-1-52
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.
Buzzer
Unit㩷
T2BC-02-01-021
Input Wiring Usage Sound

No.
Boom switch overhoist/
YB+Y9+Y22 Emergency bell sound (Plll㨯㨯㨯)
overloading
Y8 Hook overhoist/ work range
Sound (Pipipi Pipipi㨯㨯㨯)
limit
Y22 Others Sound (Pirara Pirara Pirara)

T2-1-53
Intentionally
SYSTEM / Hydraulic System
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
Hoisting Circuit (Rear, Front)
Hydraulic Boom Derricking Circuit
System
Jack-Up / Retract Circuit
Slewing Circuit
Main Circuit Counterweight / Quick Draw Circuit
Reeving Winch Circuit (Hydraulic Tagline using cimbinedly) (Optional)
Third Drum Circuit (Optional)
Fourth Drum Circuit (Optional)
Travel Circuit
Take-Up Circuit
Pilot Circuit: • Counterweight / Quick Draw Circuit:

Carries out spool selection in the control valve, pump Drives the counterweight cylinder or quick draw
control, valve control, motor control, and parking brake cylinder by using pressure oil from the jack-up /
releasing control by using pressure oil from the pilot retract pump in order to remove / install the
pump. counterweight or raise / lower the load for the
work assistance.
Main Circuit:
Drives each actuator by using pressure oil from pumps • Reeving Winch Circuit:
(1, 2), slewing pump, reeving pump and jack-up / re- Drives the reeving winch by using pressure oil
tract pump. from the reeving winch pump. In addition, the
• Hoisting circuit: reeving winch is optional and used with the hy-
Drives the front and rear drums by using pressure draulic tagline combinedly.
oil from pumps (1, 2) in order to raise and lower
the load. • Third Drum Circuit:
• Boom Derricking Circuit: Drives the third drum by using pressure oil from
Drives the boom derricking drum by using pres- pumps (1, 2). In addition, the third drum is op-
sure oil from pumps (1, 2) in order to operate the tional.
boom derricking.
• Jack-Up / Retract Circuit: • Fourth Drum Circuit:
Drives the jack-up cylinder or retract cylinder by Drives the fourth drum by using pressure oil from
using pressure oil from the jack-up / retract pump pumps (1, 2). In addition, the fourth drum is op-
in order to jack up the machine or extend / retract tional.
the side frame.
• Slewing Circuit: • Travel Circuit:
Drives the slewing mechanism by using pressure Drives the travel mechanism by using pressure oil
oil from the slewing pump in order to slew the from pumps (1, 2) in order to travel the machine.
upper structure.
• 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.
T2-2-1
PILOT CIRCUIT
The pilot circuit which pressure oil flows from the pilot Carries out delivery flow control of pump (1, 2) and
pump to consists of the followings below. slewing pump, spool selection in control valves, dis-
placement angle control in motors and brake control of
hoisting drum.
Pilot pump NOTE: *Optional devices

Pilot filter Accumulator Front motor brake
release solenoid valve
Front motor
Gate Pressure-
Rear motor brake
lock reducing valve Rear motor
valve
*Fourth motor brake
*Fourth motor
Regulator slewing
pump
Regulator Regulator
Slewing pump displace- pump 1 pump 2
ment angle proportional
Relief solenoid valve
valve
Pump displace-ment
angle proportional
solenoid valve
Power increase
solenoid valve
Slewing remote control

valve
Slewing control valve
Right travel remote

control valve
Left travel remote
control valve
Hydraulic tagline
and reeving winch
selection valve Front control valve Rear control valve
Second
overhoist Front remote Front drum hoisting and Rear control Front control
solenoid lowering proportional
control valve solenoid valve valve valve
valve
Rear remote Rear drum hoisting and Front control Rear control
lowering proportional
control valve solenoid valve valve valve
Derricking remote Boom derricking drum Front control

hoisting and lowering
control valve proportional solenoid valve valve
*Fourth remote *Fourth drum hoisting Rear control

and lowering proportional
control valve solenoid valve valve
High travel Travel speed

speed selection Brake release
solenoid valve selection valve Brake valve Front drum
solenoid valve
(front drum) (front drum) brake
Slewing brake Slewing brake
solenoid valve valve
Brake release
Derricking drum Brake valve solenoid valve Rear drum
Derricking (rear drum) brake
unlocking (rear drum)
solenoid valve drum lock
*Brake release
*Brake valve solenoid valve *Fourth drum
(Fourth drum) (Fourth drum) brake
T2-2-2
GATE LOCK CIRCUIT
If the gate lock lever keeps upward (ON position), the If the gate lock lever keeps downward (OFF position),
signal to the gate lock solenoid valve is not input. the signal to the gate lock solenoid valve is input.
Pressure oil from the pilot pump flows to the hydraulic As the circuit from pilot pump to hydraulic oil tank is
oil tank through the gate lock solenoid valve. blocked, the pilot circuit pressure keeps the pilot relief
Consequently pressure oil does not flow to the pilot valve setting.
circuit and each actuator cannot be operated. Consequently each actuator can be operated.
Gate lock lever: Upward (ON position) Gate lock lever: Downward (OFF position)
Gate Lock Solenoid Gate Lock Solenoid

Valve Valve
To Pilot Circuit To Pilot Circuit
Pilot Pump Pilot Pump
Pilot Filter Pilot Filter

Pilot Relief Pilot Relief T2BC-02-02-012
Valve Valve
T2-2-3
MAIN CIRCUIT
Pressure oil from main pump 1 flows to right travel Pressure oil from the slewing pump flows to the slew-
motor, boom derricking motor, rear motor and front ing motor. Return oil from pumps (1, 2) flows back to
motor through the front control valve. the hydraulic oil tank through the oil cooler. If oil tem-
Pressure oil from pump 2 flows to left travel motor, perature is low (with high viscosity), and flow resis-
fourth drum motor (optional), rear motor and front mo- tance is large in the oil cooler, the cooler relief valve
tor through the rear control valve. Pressure oil from opens in order to feed the return oil directly to the hy-
both pumps (1, 2) flows to the rear motor and front draulic oil tank.
motor. 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.
Rear Control Valve
Left Travel Travel Motor (Left)
Fourth Drum Fourth drum motor (Optional)

Pump 2 (Optional)
Suction Pump 1
Rear (High) Rear Motor
Filter
Slewing Pump Front (Low) Front Motor
Counterweight / Quick
Draw / Retract Pump㩷
Hydraulic Travel
Right Travel Motor (Right)
Front Control Valve
Tagline / Reeving
Oil Tank Winch Circuit (Op- Boom
tional)㩷 Boom Derricking Motor
derricking㩷
Rear (Low)
Cooler
Relief Valve Front (High)

Return Quick Draw
Filter Oil Cooler Cylinder
Quick Draw㩷
Lower Control Lower Control

(Optional)㩷 Circuit
Drain
Counterweight
Filter (Optional)㩷
Tagline / Reeving Counterweight Counterweight
Pump Circuit (Optional)㩷 Circuit
Slewing Control
Slewing Motor
Valve
T2-2-4
Slewing Remote
Control Valve Front / Rear / Boom
Derricking Remote
Control Valves
Fourth Drum / Travel
Remote Control Valve
Quick Draw Cylinder
Second Overhoist
Solenoid Valve
4-Spool Control Valve Accumulator

Slewing Slewing Gate Lock Valve
Oil Cooler
Front Control Valve
Right Travel
Boom Derricking
Rear (Low)
Pump 1 Front
Front (High)
Counterweight / Rear
Quick Draw / Engine
Retract Pump Fourth Drum (Optional)
Pilot Pump Rear Control Valve
Pump 2 Left Travel
Fourth Drum
Slewing Pump (Optional)
Rear (High)
Hydraulic
Oil Tank Front (Low)
Boom Derricking
Pilot Filter Counterweight Cylinder

Center Joint
Retract Jack-up
Lower Control
Valve
Retract Cylinder
Jack-up Cylinder (Optional)
Return Oil (Low Pressure)
Suction Oil
High Pressure Oil
Circuit Oil
Pilot Oil
Drain Oil
T2BC-02-02-035
T2-2-5
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.
Front Control Valve
Rear Control Valve
Slewing Control
Valve Oil Cooler
Pump 1 Pump 2 Slewing Pump

Hydraulic Oil Tank T2BC-02-02-013
T2-2-6
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
T2-2-7
Low-Speed Front Operation
Rear Motor Front Motor
Rear Control Valve

Front Control Valve
Rear (Low Speed)

Front
(High Speed)
Pump 2 Pump 1
Front Remote Control Valve

(First Detent Position of Lever)
4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-02-014
Second Overhoist
Solenoid Valve
T2-2-8
• 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.
T2-2-9
High-Speed Operation
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
T2BC-02-02-015
Second Overhoist Solenoid Valve
T2-2-10
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).
• Front Low Speed (1st Gear) + Rear Low Speed (1st

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.
T2-2-11
Front Low-Speed Operation + Rear Low-Speed Operation
Rear Drum Front Drum
Front (Low Speed)
Rear
(Low Speed)
Rear Control Valve
Front Control Valve

Rear (High Speed) Front (High Speed)
Pump 2 Pump 1
Rear Remote Control

Valve (First Detent
Position of Lever)
Front Remote Control

Valve (First Detent
Position of Lever)
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Solenoid Valve Pilot Pump
T2BC-02-02-022
T2-2-12
• 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.
T2-2-13
Front High-Speed Operation + Rear High-Speed Operation
Rear (High Speed) Rear

(Low Speed)
Rear Control Valve
Front Control Valve

Front (High Speed)
Front (Low Speed)
Pump 2 Pump 1
Rear Remote Control

Valve (First Detent
Position of Lever)

Valve (First Detent
Position of Lever)
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-023
T2-2-14
• 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.
T2-2-15
Front Low-Speed Operation + Rear High-Speed Operation
Front (Low Speed)

(Low Speed)
Rear Control Valve
Front Control Valve Front (High Speed)
Pump 2 Pump 1
Rear Remote Control

Valve (Second Detent
Position of Lever)

Position of Lever)
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-024
T2-2-16
• 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.
T2-2-17
Front High-Speed Operation + Rear Low-Speed Operation
Front (Low Speed)

(Low Speed)
Rear Control Valve
Front Control Valve Front (High Speed)
Pump 2 Pump 1
Rear Remote Control

Position of Lever)

Position of Lever)
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-033
T2-2-18
Fourth Motor Operation (Optional)
When operating the fourth remote control valve, the The return oil from fourth drum motor passes through
secondary pressure of remote control valve moves the fourth drum spool and returns to the hydraulic oil
the fourth drum spool in rear control valve. Pressure tank through the third drum control valve (optional).
oil from pump 2 passes through the fourth drum
spool and drives the fourth drum motor.
Fourth Drum
Fourth Drum Spool
Rear Control Valve
Third Drum Control

Valve (Optional)
Pump 2
Third / Fourth Remote

Control Valve
Second Overhoist
Solenoid Valve 4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-02-020
T2-2-19
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.
T2-2-20
Brake Mode Selection Key Switch
Front Drum Brake Mode Switch
Rear Drum Brake Mode Switch

MC2/A
Third / Forth Drum Brake Mode

Selection Switch (Optional)
Fourth Drum
Brake (Optional) Rear Drum Brake
Brake Valve
Front Drum Brake
(Third Drum)
(Optional)
Fourth Drum Rear Drum Front Drum Brake Release

(Optional) Solenoid Valve
(Fourth Drum)
(Optional) Brake Valve
(Rear Drum)
Brake Release
Solenoid Valve
(Rear Drum)
Brake Valve
(Front Drum)
Brake Release
Solenoid Valve
(Front Drum)
4-Spool Solenoid
Valve Unit
Pilot Pump

T2BC-02-02-016
T2-2-21
Free Mode
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.
T2-2-22
Brake Mode Key Switch
Front Drum Free Mode Switch
Rear Drum Free Mode Switch

MC2/A
Third / Fourth Drum Free Mode

Switch (Optional)
Fourth Drum Brake

(Optional) Rear Drum Brake
Brake Valve
Front Drum Brake (Third Drum)
(Optional)
Third Drum Rear Drum Front Drum

Brake Release
(Optional) Solenoid Valve
(Fourth Drum) Brake Valve
(Optional) (Rear Drum)
Brake Release
Solenoid Valve
(Rear Drum) Brake Valve
(Front Drum)
Brake Release
Solenoid Valve
(Front Drum)
4-Spool Solenoid
Valve Unit
Pilot Pump

T2BC-02-02-017
T2-2-23
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.
T2-2-24
Brake Mode Key Switch
Front Drum Free Mode Switch
Rear Drum Free Mode Switch

MC2/A
Third / Fourth Drum Free

Mode Switch (Optional)
Fourth Drum Brake

(Optional) Rear Drum Brake Brake Valve
Front Drum Brake (Fourth Drum)
(Optional)
Fourth Drum Rear Drum Front Drum

(Optional) Brake Release
Solenoid Valve
(Fourth Drum) Brake Valve
(Optional) (Rear Drum)
Brake Release
Solenoid Valve
(Rear Drum) Brake Valve
(Front Drum)
Brake Release
4-Spool Solenoid Solenoid Valve
Valve Unit (Front Drum)
Pilot Pump

T2BC-02-02-018
T2-2-25
Auto Stop Control
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.
T2-2-26
Normal Operation
Front (Low Speed)
Rear Control Valve
Front Control Valve

Front
MC2/B
(High Speed)
From Front Remote

Pump 2 Front Drum Hoisting Control Valve Pump 1
Auto Stop Valve
Front (Low Speed)
Remote Control Valve
Front Control Valve

MC2/B
Front
Front Drum Hoisting From Front Remote (High Speed)
Proportional Solenoid Control Valve

Pump 2 Pump 1 T2BC-02-02-021
Valve
T2-2-27
Derricking (Lowering)
In derricking (lowering) operation, the motor is likely When the oil feed pressure rises, the counterbalance
to be rotated forcibly by the inertial force and self valve spool moves to open the return oil passage
weight of the lifting load. The counterbalance valve from the motor. Thus, the motor turns and the return
controls derricking (lowering) speed by the oil feed oil comes to the tank via the control valve. (Figure 2)
quantity to prevent coasting. When the load begins to lower earlier than oil amount
Pressure oil from the control valve passes through supplied from the control valve, pressure at port B
Port B of the counterbalance valve, and goes to the side decreases, the counterbalance valve is closed
motor. and the load stops lowering. (Figure 3)
The return oil from the motor is blocked by the check When pressure at port B increases, the counterbal-
valve and the counterbalance valve. (Figure 1) 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
Figure 1 Figure 2
Figure 3

T2BC-02-02-019
T2-2-28
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 Derricking
Boom Derricking Motor Drum Lock
oil from pump 1 drives the boom derricking motor.
Boom Derricking
Motor Brake Boom Derricking Motor
Counterbalance
Valve
Boom Derricking
Front Control Valve
Boom Derricking Remote

Control Valve
Pump 1
Second Overhoist
Solenoid Valve
Derricking Drum Unlocking
Solenoid Valve
4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-02-025
T2-2-29
Auto Stop Control Circuit
When the boom derricking drum is overhoisted or NOTE: While operating the with the derricking
overloaded, MC2/B receives a signal from the over- stopped, the boom derricking drum
hoist switch or IDU. MC2/B stops the operation of unlocking valve does not turn OFF due to
proportional solenoid valve that is provided in the pressure in the boom derricking remote
circuit between boom derricking remote control valve control circuit (between spools of boom
spool and front control valve spool. The proportional derricking remote control valve and front
solenoid valve blocks the remote control pressure to control valve.)
the control valve spool, returns the control valve
spool to neutral position and stops hoisting.

Boom Derricking Drum Lock
Boom Derricking
Front Control Valve
Boom Derricking Drum

Solenoid Valve
Pump 1
MC2/B Boom Derricking Remote
Control Valve
Second Overhoist
Solenoid Valve Derricking Drum
Unlocking Solenoid Valve
Pilot Pump
Unit Valve T2BC-02-02-026
T2-2-30
TRAVEL CIRCUIT
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.
T2-2-31
Low Travel Speed
Pilot Valve
Tilt Piston Pilot Valve
Tilt Piston
Parking Brake Travel Motor (Left) Travel Motor (Right)

Travel (Left) Parking Brake
Travel (Right)
Left Travel Remote

Right Travel Remote
Control Valve
Control Valve
Pump 2 Pump 1
Pilot Pump
T2BC-02-02-027
High Travel Speed Selection
Solenoid Valve
T2-2-32
• 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.
T2-2-33
High Travel Speed
Tilt Piston Pilot Valve
Pilot Valve Tilt Piston
Travel Motor (Left) Travel Motor (Right)

Parking Brake Parking Brake
Left Travel Remote Right Travel Remote

Control Valve Control Valve
Pump 2 Pump 1
Pilot Pump

High Travel Speed Selection T2BC-02-02-028
Solenoid Valve
T2-2-34
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.
T2-2-35
Slewing Brake Make-Up Valve Make-Up Valve
Slewing Brake
Slewing Motor
Slewing Control
Valve
Slewing Pump
Slewing
Remote
Control
Valve
4-Spool Solenoid
Valve Unit
Pilot Pump

Slewing Brake Solenoid Valve
T2BC-02-02-029
T2-2-36
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 NOTE: The sequence valve is provided in order to
neutral, pressure oil from the pump flows into the front keep the operating pressure for each spool
and rear drums in order to cool through the neutral in 4-spool control valve.
circuit in each spool.
4-Spool Control Valve: Neutral
Quick Draw Front Drum

Cylinder
To Lower Control
Valve (Optional)
Quick Draw
Spool
Rear Drum
Counterweight Lower control

Cylinder (Left) Spool
Counterweight
Cylinder (Left)
Spool
Counterweight
Cylinder (Right)
Spool
Counterweight
Cylinder (Right) 4-Spool Control Valve
Sequence Valve

Counterweight / Quick T2BC-02-02-031
Draw / Retract Pump
T2-2-37
4-Spool Control Valve: Operating
The operation retracting the quick draw cylinder is This pressure oil retracts the quick draw cylinder.
explained here. The return oil from cylinder returns to the hydraulic oil
When turning the quick draw extend / retract switch in tank through quick draw spool.
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 NOTE: The Downsafety valve closes the check
quick draw spool so that the spool moves. valve part and prevents the load from
Consequently pressure oil from the counterweight / suddenly lowering when the flow rate in-
quick draw / retract pump opens the sequence valve creases abnormally due to the hose dam-
through the quick draw spool and flows into the quick age and so on. The downsafety valve is
draw cylinder rod side. also installed to the counterweight cylinder.
Quick Draw Front Drum

Cylinder
Counterbalance
Valve
To Lower Control Quick Draw

Valve (Optional) Spool
Rear Drum
Downsafety
Valve
Lower Control
Spool
Counterweight
Cylinder (Left)
Port Relief Valve
Counterweight
Cylinder (Left)
Spool
Port Relief Valve
Counterweight
Cylinder (Right)
Spool
Main Relief Valve

Counterweight
Cylinder (Right) 4-Spool Control Valve
Pressure Reducing
Valve
Sequence Valve
Counterweight / Quick Draw

Retract Pump
T2BC-02-02-032
T2-2-38
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 NOTE: The lower control valve, which is a manual
lower control valve through 4-spool control valve. control valve, is installed to the front part of
When moving the control lever for jack-up (right front) track frame with the jack-up mechanism
and retract (right) to extend, pressure oil from the pilot (optional) attached.
pump flows to each cylinder and extends the cylinder. The retract operation is performed cy using
The maximum pressure in lower control valve circuit is the side frame control switch in cab without
regulated cy the relief valve. the jack-up mechanism.
T2-2-39
When Extending the Left Retract Cylinder, with Jack (Right Front) Extended
Retract Cylinder Circuit Without

Jack-Up
Retract Retract
Cylinder Cylinder
(Left) (Right)
Lower Control Valve
T2BC-02-02-034
4-Spool Control
Valve
Retract Quick Draw
(Left)
Jack-Up Cylinder (Left Front)

Jack-Up
(Left Front)
Lower Control
Jack-Up Cylinder (Left Rear)
Jack-Up
(Left Rear)
Center Joint
Jack-Up Cylinder (Right Rear)

Jack-Up
(Right Rear)
Counterweight
Jack-Up Cylinder (Right Front)

Jack-Up
(Right Front)
Retract Pump for

(Right) Counterweight /
Quick Draw /
Jack-Up / Retract

T2BC-02-02-010
Relief valve
T2-2-40
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
Fourth
to the hydraulic oil tank after flowing through the fourth Drum
drum for cooling.
Hydraulic Oil Tank
Hydraulic
Tagline Motor
Hydraulic Tagline
Reeving Winch
Hydraulic
Tagline / Reeving
Winch Control
Valve

Hydraulic T25N-02-02-020
Tagline / Reeving
Winch Drive
Pump
T2-2-41
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. Fourth
Pressure oil from the hydraulic tagline / reeving winch Drum
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
Hydraulic Oil Tank
Hydraulic Tagline
Reeving Winch
Reeving
Winch
Brake
Reeving
Winch
Motor
Spool Reeving Winch Lowering

Solenoid Valve
Spool
From Reeving
Winch Hoisting
Switch
Hydraulic Tagline
/ Reeving Winch
Control Valve
From Pilot Pump
Reeving Winch
Hoisting Solenoid
Valve

Hydraulic T25N-02-02-021
Tagline / Reeving
Winch Drive
Pump
T2-2-42
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.
Return Check Return Check

Take-Up Cylinder Take-Up Cylinder
Valve Valve
(Left) Shuttle Valve (Right)
Front Idler (Left) Front Idler (Right)
Travel Motor (Left) Travel Motor (Right)
Shuttle Valve

T2BC-02-02-030
T2-2-43
(Blank)
T2-2-44
SYSTEM / Electric System
OUTLINE
The electric system can be divided roughly into the Main circuit
main circuit, the control circuit, the monitor circuit, the • Electric circuit that is an electric power source for
brake control circuit, the moment limiter, and the auto the electric system on the machine.
stop circuit. • Preheating circuit that assists the engine in starting
in cold weather.
• Main circuit • Starting circuit that starts the engine.
Engine-related circuit and accessories-related circuit • Charging circuit that charges batteries, and supplies
• Control circuit electricity to compensate power consumption.
Engine and pump control circuit consisting of ac- • Engine stop circuit that stops the engine through the
tuators such as solenoid valves, controllers (MC and engine stop solenoid.
ECU), switch boxes, sensors and switches • Accessories-related circuit that is actuated when the
• Monitor circuit key switch is at ON position.
Circuit that displays operating status of the machine • Surge voltage prevention circuit that prevents the
(consisting of monitor display, sensors, switches, occurrence of serge voltage when the engine is
etc.) stopped.
• Moment limiter and auto stop circuit • Drum lock circuit that locks and releases the front,
The circuit that warns of overloading and overhoist- rear and fourth drum lock.
ing, and makes auto stop of hoisting and boom der- • Slewing brake release circuit that releases the
ricking (consisting of the moment limiter that dis- slewing motor brake by delivering the pilot pressure
plays loading condition during crane operation and oil to the brake, with the slewing brake release so-
detects overloading; micro switch that detects boom lenoid valve ON.
and hook overhoisting; controller (MC) that performs
auto stop; and solenoid valve).
Here, major functions and construction of the main
circuit will be described.
T2-3-1
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.
Battery
Fuel Feed Pump Switch
Room Light Switch
Horn Relay Horn Switch
Horn
MC2/A
MC2/B
Battery Relay
IDU
Radio
Air Conditioner
Key Switch
T25N-02-03-001
T2-3-2
(Blank)
T2-3-3
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 excited‫ޔ‬electric 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.
T2-3-4
Preheating Operation
Battery
Engine Start-
ing Relay
MC2/A
Key Switch
Battery Relay
Starter
Relay 2 Coolant
Alternator Temperature
Sensor
Preheat
Controller
Air Heater
Heater Relay
Glow Lamp

T25N-02-03-002
T2-3-5
• 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.
T2-3-6
After-Heating Operation
Battery
Engine Start
Relay
MC2/A
Key Switch
Battery Relay
Starter Coolant
Relay 2 Temperature
Alternator
Sensor
Preheat
Controller
Air Heater
Heater Relay
Glow Lamp

T25N-02-03-003
T2-3-7
ENGINE STARTING CIRCUIT
1. When setting the key switch to ON position, elec- 8. At this time, when electric current is supplied from
tric current from terminal ACC of the key switch terminal S of starter relay 2 to terminal L of starter
excites the battery relay. relay 1, electric current from terminal S of starter
relay 1 flows to terminal S of the starter motor to
2. When the battery relay is excited, electric current
turn the starter.
from the battery flows through the battery relay,
and goes to B terminal of the starter motor. 9. When the engine starts, the alternator generates
power and electric current flows from terminals B,
3. In addition, electric current from the terminal ACC
L and P of the alternator.
excites the engine stop relay.
10. Electric current from terminal P of the alternator
4. Therefore, the engine stop relay is turned ON,
goes to terminal P of starter relay 2 in order to
and the engine stop solenoid is turned OFF.
block electric current flowing from terminal S of
The rack of the fuel injection pump, which is
starter relay 2.
linked to the engine stop solenoid, is released
from the engine stop position. 11. During the engine running (generating power by
As a result, the fuel is supplied to the engine, and the alternator), electric current does not flow to
the engine can start. terminal L of starter relay 1, so that the starter
does not turn even when setting the key switch to
5. In addition, electric current from the key switch
START position.
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.
T2-3-8
Battery
Engine Start
Relay
Front Drum Brake MC2/A
Rear Drum Brake
Third / Fourth Drum
Brake Mode Selection Slewing
Switch (Optional) Brake Switch
Key Switch
Battery Relay
Engine Stop Relay Engine

Stop
Solenoid
Starter
Relay 1
Starter
Motor
Starter
Relay 2
Alternator

T25N-02-03-006
T2-3-9
CHARGING CIRCUIT
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.
T2-3-10
Battery
Key Switch
Battery Relay
OFF Delay Relay
Alternator
Charge Relay
Charge Lamp

T25N-02-03-004
T2-3-11
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.
Radio㩷
Battery
Horn Switch
Clearance Light
Horn Relay㩷 Horn㩷
(Optional)
Dome Light㩷 Key Switch㩷
Battery
Work Light㩷 Relay
Drum Light
(Optional)
Cigarette
Lighter㩷

T2BC-02-03-003
T2-3-12
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.
T2-3-13
Battery
Key Switch
Battery Relay
OFF Delay Relay

Stop
Solenoid

T25N-02-03-007
T2-3-14
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.
T2-3-15
Battery
Key Switch
Battery Relay
Off Delay Relay
Starter Relay2
Alternator
Charge Relay

T25N-02-03-008
T2-3-16
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.
T2-3-17
NOTE: The following figure shows when each lock switch opens.
Battery
Key Switch
Battery Relay
Front Drum
Lock Switch Front Drum Lock
Rear Drum Lock

Rear Drum
Lock Switch
Fourth Drum Fourth Drum Lock

Lock Switch (Optional)
(Optional)

T25N-02-03-010
T2-3-18
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

Slewing Brake Indi-
cator Lamp
Monitor Lamp Unit
Slewing Brake
Switch: ON
MC/2A
To Slewing Brake
Pilot Pump

Slewing Brake Release T2BC-02-03-002
Solenoid Valve
T2-3-19
Intentionally

SECTION 3
COMPONENT OPERATION

—CONTENTS—
Group 1 Pump Mechanism Group 7 Slewing Mechanism
Outline ..........................................................T3-1-1 Outline ......................................................... T3-7-1
Main Pump ...................................................T3-1-2 Slewing Reduction Gear.............................. T3-7-2
Slewing Pump ..............................................T3-1-4 Slewing Motor .............................................. T3-7-3
Regulator......................................................T3-1-5 Slewing Parking Brake ................................ T3-7-4
Solenoid Valve............................................T3-1-21 Valve Unit..................................................... T3-7-6
Pilot Pump, Pump for Counterweight /
Quick Draw / Retract and Pump for Group 8 Hoisting Mechanism
Hydraulic Tagline and Reeving Winch ....T3-1-23 Outline ......................................................... T3-8-1
Motor............................................................ T3-8-2
Group 2 Front / Rear Control Valve Regulator ..................................................... T3-8-4
Outline ..........................................................T3-2-1 Counterbalance Valve.................................. T3-8-7
Composition .................................................T3-2-2 Brake ......................................................... T3-8-12
Internal Circuit ..............................................T3-2-6 Hoisting Drum ............................................ T3-8-13
Spool ............................................................T3-2-9 Reduction Gear.......................................... T3-8-14
Main Relief Valve........................................T3-2-11 Brake Unit .................................................. T3-8-15
Pump Relief Valve ....................................T3-2-13
Make-up Valve............................................T3-2-15 Group 9 Boom Derricking Device
Holding Valve .............................................T3-2-16 Outline ......................................................... T3-9-1
Pressure Compensation Valve...................T3-2-17 Reduction Gear............................................ T3-9-2
Boom Derricking Motor................................ T3-9-3
Group 3 Slewing Control Valve Boom Derricking Brake................................ T3-9-4
Slewing Control Valve ..................................T3-3-1 Brake Valve.................................................. T3-9-6
Counterbalance Valve.................................. T3-9-7
Group 4 Lower Control Valve Overload Relief Valve .................................. T3-9-9
Outline ..........................................................T3-4-1
Internal Composition ....................................T3-4-2 Group 10 Remote Control Valve
Relief Valve ..................................................T3-4-3 Outline ....................................................... T3-10-1
Travel Motor............................................... T3-10-2
Group 5 4-Unit Control Valve Parking Brake ............................................ T3-10-4
Outline ..........................................................T3-5-1 Travel Reduction Gear............................... T3-10-6
Composition .................................................T3-5-2 Travel Brake Valve..................................... T3-10-7
Pressure-Reducing Valve.............................T3-5-4 Travel Speed Selection............................ T3-10-10
Sequence Valve ...........................................T3-5-5
Solenoid Valve..............................................T3-5-6
Group 6 Remote Control Valve

Outline ..........................................................T3-6-1
Construction .................................................T3-6-4
Detent Function............................................T3-6-8
Operation....................................................T3-6-10
2BCT-3-1

Group 11 Others (Upper Structure)
4-Spool Solenoid Valve Unit.......................T3-11-1
Solenoid Valve............................................T3-11-3
Drum Unlocking Solenoid Valve.................T3-11-5
Gate Lock Valve .........................................T3-11-6
Brake Pedal Unit ........................................T3-11-9
Pressure-Reduction Valve........................T3-11-10
Counterweight Cylinder............................T3-11-16
Accumulator .............................................T3-11-17
Group 12 Others (Base Carrier)

Outline ........................................................T3-12-1
Slewing Ring ..............................................T3-12-2
Center Joint ................................................T3-12-3
Retract Cylinder .........................................T3-12-4
Jack-Up Cylinder (Optional).......................T3-12-5
Take-Up Cylinder (Optional).......................T3-12-8
2BCT-3-2
COMPONENT OPERATION / Pump Mechanism
OUTLINE
The pump device consists of main pump (pump 1 (10) The pilot pump (4), pump (3) for counterweight / quick
and pump 2 (8)), slewing pump (6), pilot pump (4), draw / jack-up retract and pump (1) for hydraulic tag-
pump (3) for counterweight / quick draw / jack-up / line / reeving winch are gear pumps.
retract tagline / reeving winch / fourth drum for cooling In addition, the PTO gearbox (2) is provided between
and PTO gearbox (2) pump 1(10) and pump 2 (8).
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.
1
2

3
10
6
T2BC-01-02-028
5

1 - Hydraulic Tagline / Reeving 4- Pilot Pump 7- Displacement Angle Solenoid 9- Power Increase
Winch Drive Valve (Op- Valve (For Main Pump) Solenoid Valve
tional)
2 - PTO Gearbox 5- Displacement Angle Solenoid 8- Pump 2 10 - Pump 1
Valve (For Slew Pump)
3 - Pump For Counterweight / 6 - Slewing Pump
Quick Draw / Jack-Up / Re-
tract
T3-1-1
MAIN PUMP
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.

Pump 1 Pump 2

2 3 4 4
5 6 5 4 3 2 T1F3-03-01-003
T3-1-2
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.
Servo Piston
Valve Plate
5
4
2 T117-02-01-003
T3-1-3
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.
Splined to
Pump 2

T25N-03-01-005
1 2 3 4 5
T3-1-4
REGULATOR
Outline
According to various pressure signals, the regulator The displacement angle proportional solenoid valve is
controls the displacement angle of maim pump attached to the pump 2 regulator and the displace-
(pumps (1, 2)) and changes the flow rate in order not ment angle solenoid valve is attached to the slewing
to exceed the engine horsepower. One regulator is pump regulator.
provided to each of pump 1, pump 2, and slewing In addition, the power increase solenoid valve is at-
pump. tached to the PTO gearbox.
The regulator in slewing pump fixes the maximum
displacement angle for slewing pump and does not
control the displacement angle.
PTO Gearbox Displacement Angle Proportional

Solenoid Valve
Displacement Angle
Solenoid Valve

Pump 1 Pump 2 Slewing Pump T25N-03-01-003
Power Increase
Regulator Regulator Regulator
Solenoid Valve
Layout
Power Increase So- Displacement Angle Proportional
lenoid Valve Solenoid Valve
Pump 2
Pump 1 Regulator
Regulator
Displacement Angle
Solenoid Valve
Slewing Pump
Regulator

T25N-03-01-010
PTO Gearbox
T3-1-5
Sectional View (Main Pump Regulator)
Pump 1 B Pump 2 B
A A

B A B A

T25N-03-01-006 T25N-03-01-007

Section A-A
1 2 3 4 5 6
8

T25N-03-01-011
T3-1-6
Section B-B
9 10 11 12 13 14 15 16

21 20 19 18 17 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
T3-1-7
Sectional View (Slewing Pump Regulator)

B
A
B A

T25N-03-01-014

Section A-A

1 2 3 4 5 6
7
8

T25N-03-01-012
T3-1-8
Section B-B

9 10 11 12 13 14 15 16

21 20 19 18 17 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

T3-1-9
Linkage Mechanism (Main Pump)
The movement of pilot piston (1) is transmitted Therefore, when lever 1 (13) or lever 2 (3) turns, pin
through pin (2) to lever 2 (3). Lever 2 (3) is turned (4) contacts the hole of the turned lever. Feedback
about pin (5) which is fixed to the axial plug. lever (7) turns about pin (8) attached to servo piston
The movement of compensating rod (19) is trans- (17). In addition, when servo piston (17) moves,
mitted through pin (18) to the lever 1 (13). The lever feedback lever (7) is moved through pin (8). At this
1(13) is turned about pin (12) which is fixed to the time, because neither lever 1 (13) nor lever 2 (3)
casing. move, feedback lever (7) turns about pin (4), and
Pin (4) is attached to feedback lever (7). Both ends spool (11) moves.
of pin (4) are inserted into holes of lever 1 (13) and
lever 2 (3).

NOTE: Displacement angle decrease
Displacement angle increase
12
18
13
Casing Hole
7
19
14
4
3
Hole
5
2
11 Axial Plug
17 T142-02-01-005

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
T3-1-10
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. Flow Rate
(Q) Pressure Increase

• Control by self pump pressure or companion pump Flow Decrease
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- 0 Pressure (P)
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- Flow Rate
tion control) (Q)
• 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, 0 Pilot Pressure (Pi)
to the hydraulic oil tank. As a result, the delivery
flow is increased. (Power increase control)
(Refer to "Control System".)
T3-1-11
• Control by pilot pressure from displacement angle
proportional solenoid valve Flow Rate
(Q)
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)
0
(Refer to "Control System".)

Pr1 Main Pump Regulator Psv
Pz
P2
P1

Increase Decrease
Displacement Angle T25N-03-01-008

P1 - Pump 1 Delivery Pz - Power Increase Control Pressure Pr1 - Displacement Angle
Pressure (From Power Increase Solenoid Proportional Pressure
Valve) (From Displacement Angle
Proportional Solenoid Valve.)
P2 - Pump 2 Delivery Psv - Pilot Pressure
Pressure
T3-1-12
Operation of Regulator
• Control by Self Pump Pressure and Companion

Pump Pressure 6. When servo piston (17) moves, feedback lever (7)
is moved through pin (8). As neither compensat-
NOTE: Reference: Control by self pump pressure ing rod (19) nor lever 1 (13) move, feedback lever
and companion pump pressure is divided (7) turns counterclockwise about pin (4) and
into the following two functions. moves spool (11) to the left. The notches of spool
(11) and sleeve (10) are closed completely, so self
x Flow reduction (overload prevention)
pump delivery pressure does not act to the large
When the load (pressure) increases,
diameter chamber side of servo piston (17) and
controls so that the load does not exceed
the movement of servo piston (17) stops.
the engine horsepower by reducing the
pump delivery flow rate. 7. The pump delivery flow rate is decreased by
x Flow rate increase (flow rate restoration) these operations and the load to the pump is re-
When the load (pressure) decreases, in- duced.
creases the pump delivery flow rate for
efficient use of engine horsepower.
Flow Rate
• Flow reduction (overload prevention) (Q)

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-
0 Pressure (P)
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-
P2
though self pump delivery pressure P acts to the
P1
small diameter chamber side, servo piston (17) 20
moves to the right due to the difference in area.
11
5. The pump displacement angle reduces according 13 7
to the movement of servo piston (17) and the
17
pump delivery flow rate decreases.

Increase Decrease
T25N-03-01-023
Displacement Angle

T3-1-13
10 11 12 13 4 15 16
P1
P2
20 19 18 8 7 17

T25N-03-01-016
10 11 12 13 4 15 16
20 19 18 8 7 17

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
T3-1-14
• 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 Flow Rate
compensating rod (19) to the left, to the position (Q)
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.

inserted into the hole of lever 1(13). Therefore,
feedback lever (7) rotates counterclockwise about
0 Pressure (P)
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 15, 16 10
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- P2
ing to the movement of servo piston (17) and the P1
pump delivery flow rate increases. 20
6. When servo piston (17) moves, feedback lever (7) 11
is moved through pin (8). As neither compensat- 13 7
ing rod (19) nor lever 1 (13) moves, feedback 17
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 Increase Decrease
(17) is not connected to the hydraulic oil tank and Displacement Angle
T25N-03-01-025
the movement of servo piston (17) stops.
7. By these movements, the pump delivery flow rate
increases.

T3-1-15
To Hydraulic
10 11 Oil Tank 12 13 4 15 16
P1
20 19 18 8 7 17

T25N-03-01-016

10 11 12 13 4 15 16
20 19 18 8 7 17

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
T3-1-16
Control by Pilot Pressure of Power Increase So-
lenoid Valve
Power increase control pressure Pz from the power 7. When servo piston (17) moves, feedback lever (7)
increase control solenoid valve acts and increases is moved through pin (8). As neither compensat-
the pump delivery flow. ing rod (19) nor lever 1 (13) moves, feedback
lever (7) turns clockwise about pin (4) and moves
1. When the power increase solenoid valve is ex- spool (11) to the right. The notches of spool (11)
cited by a signal from MC2/A, the pilot pressure and sleeve (10) are closed completely, so the
acting on pin (21) is transmitted to the hydraulic large diameter chamber side of servo piston (17)
oil tank. is not connected to the hydraulic oil tank and the
movement of servo piston (17) stops.
2. Compensating piston (20) is returned together
with compensating rod (19) to the left, to the posi- 8. By these movements, the pump delivery flow rate
tion that outer spring (15) and inner spring (16) increases.
are balanced.

3. Compensating rod (19) moves lever 1 (13)
through pin (18). Lever 1 (13) turns clockwise Flow Rate
about pin (12) fixed to the casing. (Q)

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 0 Pump Control Pressure (Pi)
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
15, 16 10
the left.
6. The pump displacement angle increases accord-
ing to the movement of servo piston (17) and the Pz
pump delivery flow rate increases.
P1
20
11
13 7
17
Increase Decrease

Displacement Angle
T25N-03-01-027
T3-1-17
To Hydraulic To Hydraulic
Oil Tank 10 11 Oil Tank 12 13 4 15 16
Pz
21
20 19 18 8 7 17

T25N-03-01-016

10 11 12 13 4 15 16
21
20 19 18 8 7 17

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
T3-1-18
Control by Pilot Pressure from Displacement An-
gle Proportional Solenoid Valve
1. When the displacement angle proportional sole- 7. When servo piston (17) moves, feedback lever (7)
noid valve is excited by a signal from MC2/A, pilot is moved through pin (8). As neither compensa-
pressure acts to pilot piston (1). tion rod (19) nor lever 1 (13) moves, feedback
lever (7) turns counterclockwise about the pin (4)
2. When pilot pressure increases, pilot piston (1)
and moves spool (11) to the left. The notches of
moves to the right, to the position where pilot
spool (11) and sleeve (10) are closed completely,
pressure is balanced with the pilot spring (6)
so self pump delivery pressure does not act to the
force.
large diameter chamber side of servo piston (17)
3. Pilot piston (1) moves lever 2 (3) through pin (2). and the movement of servo piston (17) stops.
Lever 2 (3) turns counterclockwise about pin (5)
8. The pump delivery flow rate is decreased by
fixed to the axial plug.
these movements and the load to the pump is
4. Pin (4), which is attached to feedback lever (7), is reduced.
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. Flow Rate
(Q)
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 0 Pump Control Pressure (Pi)
pump delivery flow rate decreases.
Pilot Pressure
13 10
P1
11
7
17

Increase Decrease
1 3 6 Displacement Angle
T25N-03-01-028
T3-1-19

1 2 3 4 5 6

Pilot Pressure
8

T25N-03-01-015

10 11 13 4
19 8 7 17

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
T3-1-20
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 In Neutral State
1. In neutral state, port T and the output port are
connected through the notch of spool (4) and
1 2 3 4
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 T Output P
5 Port T25N-03-01-019
side (B) diameter, spool (4) returns to the left.

In Operation
1 2 3 A B 4
T Output P
5 Port
T25N-03-01-020

T3-1-21
Operation of Power Increase Solenoid Valve
1. In neutral state, port P and the output port are 1 2 3 4

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. T Output P
5 Port T25N-03-01-021
1 2 3 4 A B
T Output P
5 Port
T25N-03-01-022
T3-1-22
PILOT PUMP, PUMP FOR COUNTER-
WEIGHT / QUICK DRAW / RETRACT AND 1
Suction Port
PUMP FOR HYDRAULIC TAGLINE AND
REEVING WINCH 2
Drive gear (1) is driven through the transmission and

driven gear (2) engaged therewith is also rotated.
Delivery Port

T137-02-03-005
1 - Drive Gear 2 - Driven Gear

T3-1-23
Intentionally
COMPONENT OPERATION / Front / Rear Control Valve
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.
T3-2-1
COMPOSITION
Front Control Valve
2 3 4 5 6 4 7 8
1
9
T2BC-03-02-002
17 16 15 14 13 12 11 10
1 2 5 17 7 13 8 12 16
T25N-03-05-030 T2BC-03-02-001
14 10 11 15
1- Main Relief Valve㩷 7- Port Relief Valve (with 10 - Rear Drum Hoisting 14 - Boom Derricking Drum
Make-Up Function)㩷 Proportional Solenoid Valve㩷 Hoisting Proportional
Solenoid Valve㩷
2- Right Travel Spool㩷 8- Rear Drum (Low Speed) 11 - Rear Hoisting Remote 15 - Derricking Hoisting
Spool㩷 Control Pressure Sensor㩷 Remote Control Pressure
Sensor㩷
3- Make-Up Valve㩷 9- Front Drum (High Speed) 12 - Rear Drum Lowering 16 - Derricking Drum Lowering
Spool㩷 Remote Control Pressure Remote Control Pressure
Sensor㩷 Sensor㩷
4- Pressure Compensation 10 - Holding Valve㩷 13 - Rear Lowering 17 - Derricking Lowering
Valve (2 Used)㩷 Proportional Solenoid Valve㩷 Proportional Solenoid Valve㩷
5 - Boom Derricking Spool㩷㩷㩷㩷
T3-2-2
17
1 3
14
13
4 2 8
7
10
T2BC-03-02-003
T3-2-3
Rear Control Valve
2 3 4 5 6 7
8
1
T2BC-03-02-006
17 16 15 14 13 12 11 10
1 2 4 17 5 7 12 11 16
T2BC-03-02-004 T2BC-03-02-005
14 9 10 15
1- Main Relief Valve㩷 6- Port Relief Valve (with 11 - Front Lowering Remote 15 - Fourth Lowering Remote
Make-Up Function)㩷 Control Pressure Sensor㩷 Control Pressure Sensor㩷
2- Left Travel Spool㩷 7- Front Drum (Low Speed) 12 - Front Drum Lowering 16 - Fourth Hoisting Remote
Spool㩷 Proportional Solenoid Valve㩷 Control Pressure Sensor㩷
3- Make-Up Valve㩷 8- Pressure Compensation 13 - Holding Valve㩷 17 - Third/Fourth Hoisting
Valve㩷 Solenoid Valve㩷
4- Third/Fourth Spool㩷 9- Front Drum Hoisting 14 - Third/Fourth Lowering 㩷
Proportional Solenoid Valve㩷
Solenoid Valve㩷
5- Rear Drum (High Speed) 10 - Front Hoisting Remote 㩷㩷
Spool㩷 Control Pressure Sensor㩷
T3-2-4
12
17
7 2
4 13
14 9
T2BC-03-02-007
T3-2-5
INTERNAL CIRCUIT
Pilot Pressure Control Circuit

Pilot pressure oil from the remote control valve acts to
the spool in control valve in order to move the spool.
Front Control Valve
12 11
T2BC-03-02-016
1 2 3 4 5 6
Rear Control Valve
5 6
T2BC-03-02-017
7 8 9 10 11 12 㩷
1- Travel (Right Reverse)㩷 4- Boom Derricking Hoisting㩷 7 - Travel (Left Forward)㩷 10 - Third Drum Lowering㩷
2- Travel (Right Forward)㩷 5- Rear Drum Hoisting㩷 8 - Travel (Left Reverse)㩷 11 - Front Drum (Low Speed)
Lowering㩷
3- Boom Derricking Lowering㩷 6- Rear Drum Lowering㩷 9 - Third Drum Hoisting㩷 12 - Front Drum (Low Speed)
Hoisting㩷
T3-2-6
Main Circuit
The internal circuits are arranged in the right travel and

series circuits.
1. Each section is connected through passage.

2. With the spool in neutral, oil from the pump
passes through passage and flows to the next
section.
3. When the spool moves, pressure oil from port P Passage㩷
passes through port B or port A and goes to the
actuator. A B
4. The return oil from actuator flows through port A
or port B and spool, and goes to the downstream
passage. P T
5. Therefore, the full oil flow, after passing through
upstream section and actuator, flows to the
downstream section. T324-02-06-029
Front Control Valve Rear Control Valve

Passage㩷 Port A㩷 Passage Port A㩷
T2BC-03-02-018
Port P㩷 Port B㩷
T2BC-03-02-019
Port P㩷 Port B㩷
T3-2-7
Carry-Over Circuit (Optional)
In case the fourth drum (optional) is provided, pressure

oil to the fourth drum motor is supplied from port CO in
end section of rear control valve.
Without Fourth Drum With Fourth Drum

To Fourth
Drum Motor
T2BC-03-02-020
Remove the plug and port CO cover from the end Therefore, the return circuit from spool to port T is
section in rear control valve. blocked and return oil flows to port CO.
Install the carry-over selection plug into the hole on
plug.
Without Fourth Drum With Fourth Drum
Port T㩷
Port T㩷
Port CO㩷
Port CO
Cover㩷
Plug㩷 Carry-Over
Selection
Plug㩷
T2BC-03-02-02
T3-2-8
SPOOL
The closed center type, open center type and P

semi-open center type are used for the spool. T
B A
• Closed Center Type Spool 2
When the spool is in neutral, oil in port A and B is

blocked by spool (2). Therefore, oil in port A and B
does not flow to port T.
• Front drum (high speed)
• Rear drum (high speed)
6
• Open Center Type Spool

T B A
T
When the spool is in neutral, oil in port A or port B
passes through passage (1) in the spool and port T, 1
1
and flows to the hydraulic oil tank.
• Travel (right)
• Travel (left)
6
• Semi-Open Center Type Spool B

T
A
The oil in port A flows to the hydraulic oil tank through 1

passage (1) and port T in the spool. Oil in port B is
blocked by spool (2).
• Boom derricking
• Rear drum (low speed)
• Third/fourth drum
• Front drum (low speed) 2
6
1- Passage㩷 2- Spool㩷
T3-2-9
Operation of Spool
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 Port T A B
through port A and passage (5).
NOTE: As two upstream spools constitute a series 1
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.
2
5 3 6
Port P㩷
T25N-03-05-002
1- Spring㩷 3- Passage㩷 4 - Spool (Boom Derricking)㩷 5 - Passage㩷

2- Spool 㩷㩷㩷
(Rear Drum (Low Speed))㩷
T3-2-10
MAIN RELIEF VALVE
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).
T3-2-11
Normal state

1 2 3 4 5
HP
LP
6
T2BC-03-02-008

Relief State
1 2 3 4 5
HP
6 LP
T2BC-03-02-009
1 2 3 4 5
HP
6 LP
T2BC-03-02-010
1- Main Poppet㩷 3 - Spring A㩷 5 - Spring B㩷 6- Orifice㩷

2- Spring Chamber㩷 4 - Pilot Poppet㩷㩷㩷
T3-2-12
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 Make-Up Operation

1. Pressure in port HP (actuator circuit) acts to pilot 1. When pressure in port HP (actuator circuit)
poppet (6) through orifice (10) in piston (1). decreases lower than pressure in port LP
(hydraulic oil tank), sleeve (3) moves to the right
2. When pressure in port HP reaches pressure set
due to pressure at port LP and the seat surface
by spring B (7), pilot poppet (6) opens pressure oil
on sleeve (3) is opened.
from passage (8) in spring chamber (5) flows
along the external circumference of sleeve (3) 2. Hydraulic oil in port LP flows into port HP in order
and goes to port LP (hydraulic oil tank). to prevent cavitation.
3. At this time, a pressure difference is caused 3. When pressure in port HP rises to the fixed level,
between port HP and spring chamber (5) due to the seat surface on sleeve (3) is closed by the
orifice (10). force of spring A (4).
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).
T3-2-13
Normal state
1 2 3 4 5 6 7
LP

T2BC-03-02-011
10 9 8
Relief State
1 2 3 4 5 6 7
T2BC-03-02-012
10 9 8
3 4
T2BC-03-02-013
1- Piston㩷 4 - Spring A㩷 7 - Spring B㩷 9 - Spring C㩷

2- Main Poppet㩷 5 - Spring Chamber㩷 8 - Passage㩷 10 - Orifice㩷
3- Sleeve㩷 6 - Pilot Poppet㩷㩷㩷
T3-2-14
MAKE-UP VALVE Port T
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. Port B
Operation
1. 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
Port B㩷 Port T㩷
㩷
Area Y
Poppet㩷 Area X㩷
T331-03-05-012
T3-2-15
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.

3
T2BC-03-02-022

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.
2

T2BC-03-02-023
3

1 - Spool 3 - Holding Valve
(Low Speed Side)
2 - Spool
(High Speed Side)

T3-2-16
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 Spring㩷 To Actuator㩷
through the internal passage in control valve.
Pressure oil flows into chamber E through the To
internal passage in compensating spool and acts Pressure Downstream
to the end of compensating spool. Compensation Section㩷
Valve
2. When moving the boom derricking lever, pressure
oil through the spool flows to passage A and acts
to spring chamber B. Spool
From Port P㩷 (Boom
3. With the lever operation small, pressure acting to Derricking)
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
T25N-03-05-041
(E) and B becomes large, the compensating spool Spring
compresses the spring in the spring chamber and Chamber
Spring㩷
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.
Compensating
Spool㩷
T2BC-03-02-024
T3-2-17
Operation (with large lever stroke)
1. Pressure oil from port P flows to chamber A
through the internal passage.䎃 Pressure oil flows Spring㩷 To Actuator㩷
into chamber B through the internal passage in
compensating spool and acts to the end of
compensating spool. Pressure
2. When moving the boom derricking lever, pressure Compensation
Valve
oil through the spool flows to passage A and acts
to spring chamber B. Spool
3. With the lever operation large, the reduced From Port P㩷 (Boom
pressure is smaller by the spool, a pressure Derricking)
difference between chamber C (E) and B
becomes small.
4. When a pressure difference between chambers C
(E) and B becomes small, the compensating T25N-03-05-040
spool is compressed by the spring force in spring
chamber B downward.
5. Consequently, as the passage between chambers Spring
Chamber Spring㩷
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.
Compensating
Spool㩷
T2BC-03-02-025
T3-2-18
COMPONENT OPERATION / Slewing Control Valve
SLEWING CONTROL VALVE
Composition
The slewing control valve is a hydraulic pilot spool type, NOTE: As for operation of the main relief valve and
and consists of the main relief valve and spool. the spool, refer to "Front / Rear Control
The spool in the slewing control valve is an open cen- Valves".
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. Spool

Main Relief
Valve
Main Relief
T2BC-03-03-003
Valve T2BC-03-03-002
Main Relief
Valve
Spool

T2BC-03-03-001

T3-3-1
Intentionally
COMPONENT OPERATION / Lower Control Valve
OUTLINE
The lower control valve is the direct-acting type control NOTE: The lower control valve is optional.
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.
Port P㩷
Retract
(Right) Relief
Valve㩷
Jack-Up (Right Front)
Jack-Up (Right Rear)
Jack-Up (Left Rear)
Jack-Up (Left Front)
Retract
(Left)
Port T㩷
T2BC-03-04-001
T3-4-1
INTERNAL COMPOSITION
The inside of lower control valve is a parallel circuit.䎃

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.䎃 The relief valve regulates the maximum
pressure in the lower control circuit.
T2BC-03-04-004
1- Retract (Left)㩷 3 - Jack-Up (Left Rear)㩷 5 - Jack-Up (Right Front)㩷 7 - Relief Valve㩷
2- Jack-Up (Left Front)㩷 4 - Jack-Up (Right Rear)㩷 6 - Retract (Right)㩷㩷
T3-4-2
RELIEF VALVE
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 Operation Normal State:

1. Pressure in port P (main circuit) acts to the end of
T
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 P
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.
T2BC-03-04-005
5. When pressure at port P decreases to the fixed
level, poppet (3) is closed by the force of spring
(2). 1 2 3 4 5
6. The relief setting pressure is adjusted by
adjusting screw (1).
Relief State:
T
T2BC-03-04-006
1 2 3 4 5
1- Adjusting Screw㩷 4- Seat㩷

2- Spring㩷 5- Plug㩷
3- Poppet㩷㩷

T3-4-3
Intentionally
COMPONENT OPERATION / 4-Unit Control Valve
OUTLINE
The 4-unit control valve is an When operating the counterweight switch, the spool in
electromagnetic-hydraulic pilot spool type and consists counterweight is switched and pressure oil from the
of main relief valve, sequence valve, pump for counterweight/quick draw/retract flows to the
pressure-reducing valve, holding valve, port relief counterweight cylinder in order to extend/retract the
valve, solenoid valve and spool. cylinder.
The spool in 4-unit control valve is a semi-open center When operating the quick draw switch and retract
type using parallel circuits. switch, pressure oil flows to the cylinder in order to
When the spool is in neutral, pressure oil from the operate the cylinder in the same procedures.
pump for counterweight/jack-up/retract flows to the When turning the lower power switch ON with the
front and rear drums in order to cool the brake unit in lower jack mechanism (optional) attached, the spool in
front and rear drums. 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".
1 2 3 4 3 5 3 6 3 7
T2BC-03-05-001
13 12 10 11 10 9 8
1- Pressure-Reducing valve:㩷 5- Counterweight Solenoid 8- Quick Draw Solenoid Valve 11 - Counterweight Solenoid
Valve (Left/Retract)㩷 (Extend)㩷 Valve (Left/Extend)㩷
2- Sequence Valve㩷 6 - Retract Solenoid Valve 9 - Retract Solenoid Valve 12 - Counterweight Solenoid
(Retract) *㩷 (Extend) *㩷 Valve (Right/Extend)㩷
3- Holding Valve㩷 7 - Quick Draw Solenoid Valve 10 - Port Relief Valve㩷 13 - Main Relief Valve㩷
(Retract)㩷
4- Counterweight Solenoid 㩷㩷㩷
Valve (Right/Retract)㩷
NOTE: *: If the jack-up (optional) is installed, the

lower power solenoid valve is installed
here.
T3-5-1
COMPOSITION
4 5 6 7
13
12 11 9 8 T2BC-03-05-002
1- Pressure reducing valve:㩷 5- Counterweight Solenoid 8- Quick Draw Solenoid Valve 11 - Counterweight Solenoid
Valve (Left/Retract)㩷 (Extend)㩷 Valve (Left/Extend)㩷
2- Sequence Valve㩷 6 - Retract Solenoid Valve 9 - Retract Solenoid Valve 12 - Counterweight Solenoid
(Retract) *㩷 (Extend)*㩷 Valve (Right/Extend)㩷
3- Holding Valve㩷 7 - Quick Draw Solenoid Valve 10 - Port Relief Valve㩷 13 - Main Relief Valve㩷
(Retract)㩷
4- Counterweight Solenoid 㩷㩷㩷
Valve (Right/Retract)㩷
NOTE: *: If the jack-up (optional) is installed, the lower power solenoid valve is installed here.
T3-5-2
2 3
13
3 3
10
T2BC-03-05-008
T3-5-3
PRESSURE-REDUCING VALVE
Pressure-Reducing
Pressur Sequence
SEQUENCE
Valve㩷 Valve㩷
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. Spool 1
Operation Spring 1
1. Pressure oil from port P flows to chamber E Spool 2㩷
through passage (C). Spring 2㩷
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).䎃 To Solenoid
Pressure oil flows to spring chamber (A) in the Valve
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
spool (1) and pressure in chamber G increases
again. Spring 1
8. Therefore, pressure from port P becomes lower Spool 2㩷
than pressure set by spring (1) and pressure
Spring 2㩷
through the solenoid valve keeps constant.
To Solenoid
Valve
Pressure-Reducing To Solenoid Valve㩷
Valve㩷
To Control Valve
Spool㩷
T2BC-03-05-005
Sequence To Solenoid Valve㩷
Valve㩷
T2BC-03-05-004
T3-5-4
SEQUENCE VALVE
Pressure-Reducing Sequence
The sequence valve blocks pressure oil from port P Valve㩷 Valve㩷
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. Spring 2㩷
Spool 2㩷
Operation
1. Pressure in the pressure-reducing valve circuit
always flows spring chamber (A) in the sequence
To
valve through passage (B). Control
2. Spool (2) in the sequence valve is pushed down To Solenoid Valve
by the pressure-reduced oil and the force of Valve Spool㩷
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.
Spring 2㩷
7. Thus, by setting a time lag in operation between
pressure-reducing valve and sequence valve, the Spool 2㩷
primary pressure (output pressure) of pressure
reducing valve is obtained.
To
Pressure-Reducing Control
To Solenoid
Valve㩷 To Solenoid Valve Valve
Valve
Spool㩷
To Control Valve
Spool㩷
Sequence
Valve㩷
T2BC-03-05-006
T2BC-03-05-004
To Solenoid
Valve㩷
T3-5-5
SOLENOID VALVE
Each solenoid valve in 4-unit control valve is an In Neutral State

ON/OFF solenoid valve. Control Valve
Solenoid㩷 Spool㩷
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
Spring
the spool.
Solenoid
Valve Spool
Operation
1. 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. Exciting state
Control Valve
Solenoid㩷 Spool㩷
Spring
Solenoid
Valve Spool
T2BC-03-05-007
T3-5-6
COMPONENT OPERATION / Remote Control Valve
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.
1 2 3 4 5 6 7
10
Shuttle Valve
Block
9 7

T2BC-03-06-001
Hoisting Travel Slewing
Remote Control Remote Control Remote Control
Valve Valve Valve
1 - Boom Derricking Remote 4 - Third Drum Remote Control 7 - Slewing Remote Control 9- Travel Remote Control
Control Valve Valve (Optional) Valve Pressure Sensor (L)
2 - Rear Drum Remote Control 5 - Left Travel Remote Control 8 - Travel Remote Control 10 - Detent Plug
Valve Valve Pressure Sensor (R)
3 - Front Drum Remote 6 - Right Travel Remote
Control Valve Control Valve
T3-6-1
• Hoisting Remote Control Valve
Parts Name Port No. Connected to Boom 㩷㩷

Derricking Rear㩷 Front㩷
Boom 1 Hoisting
derricking 2 Lowering
3 Hoisting
T
Rear 4 Lowering P
8 Motor
5 Hoisting
Front 6 Lowering
9 Motor
Boom
4㩷
Derricking㩷 Rear㩷 Front㩷
2 1 4 8 3 6 9 5 2 6㩷
9㩷
8 5㩷
1
T2BC-03-06-002
3㩷
P T
㩷
T2BC-03-06-004
• Travel Remote Control Valve

㩷㩷
Third/Fourth Travel Travel
Port (Optional)㩷 (left)㩷 (right)㩷
Parts Name Connected to
No.
1 Hoisting
2 Lowering
Third / fourth 7 Fourth drum displacement T
(optional) angle control signal
P
pressure
P
3 Forward
Travel (left) 4 Reverse
8 Remote control pressure
Forward 8 4
5
Travel (right) 6 Reverse
2㩷 6
9 Remote control pressure
9
7㩷
Third/Fourth 㩷㩷 5
(Optional)㩷 Travel (left) Travel (right)㩷 1㩷
2 7 1 4 8 3 6 9 5 T25N-03-06-006
3㩷
P P T T25N-03-06-003
T3-6-2
• Slewing Remote Control Valve
Parts Name Port No. Connected to

1 Right Slewing
Slewing
2 Left Slewing
T
P
1 2
P T 1
T25N-03-06-004
T2BC-03-06-003
T3-6-3
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.
T3-6-4
Hoisting Remote Control Valve
1
2
3
5
6
7
1
2
T2BC-03-06-005
1- Screw Joint㩷 4 - Pusher㩷 7 - Return Spring㩷 9 - Shuttle Valve Block㩷

2- Cam㩷 5 - Spring Guide㩷 8 - Spool㩷 10 - Spring Pin㩷
3- Detent Plug㩷 6 - Balance Spring㩷㩷㩷
T3-6-5
Travel Remote Control Valve
2
3
T2BC-03-06-006
1- Screw Joint㩷 4 - Pusher㩷 7 - Return Spring㩷 9 - Shuttle Valve Block㩷

2- Cam㩷 5 - Spring Guide㩷 8 - Spool㩷 10 - Spring Pin㩷
3- Detent Plug㩷 6 - Balance Spring㩷㩷㩷
T3-6-6
Slewing Remote Control Valve
D
Section D
T25N-03-06-011 T25N-03-06-012
1- Screw Joint㩷 4 - Pusher㩷 6- Balance Spring㩷 8- Spool㩷

2- Cam㩷 5 - Spring Guide㩷 7- Return Spring㩷 9- Shuttle Valve Block㩷
T3-6-7
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.
T3-6-8
Control Lever Operating Control Force
2
A (First Detent
Position)㩷
3
B (Second Detent
Position)㩷
3
4
5 4
T25N-03-06-015
1- Control Lever㩷 3 - Ball㩷 5 - Spring㩷 7 - Return Spring㩷

2- Cam㩷 4 - Holder㩷 6 - Pusher㩷㩷
T3-6-9
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.
3 4 5
Port T
(To hydraulic oil tank)
Port P
(From pilot pump)
From main To hydraulic

pump oil tank
Output Port

T324-02-07-010
1 - Control Lever 3 - Control Valve 4 - Spool 5 - Spring

2 - Remote Control Valve

T3-6-10
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).
Port T (Hydraulic Oil Tank)㩷
Port P (Primary Pilot Pressure)㩷
Output Port (Secondary Pilot 6
Pressure)㩷
㪈㩷㪄㩷 Return Spring㩷 2 - Spool㩷
T3-6-11
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).
Port T 2
Primary Pilot
Pressure
Port P
Output Port 6

Clearance
Secondary Pilot
Pressure
2 - Spool㩷 3 - Control Lever㩷 4 - Cam㩷 5 - Pusher㩷
T3-6-12
Maintaining Secondary Pressure
5. Pressure oil from port P (primary pilot pressure)

acts on diameters d1 and d2 in spool (2). 9. After repeating these procedures, the pressure
6. This pressure pushes spool (2) upward due to the according to the stroke of control lever (3) is
difference of area (d1>d2). routed to the output port.
7. Spool (2) is pushed upward and the output port is 10. Balance spring (6) is compressed to the same
connected to port T. amount as spool (2) was pushed downward. The
8. The pressure in output port decreases and spool pressure which the spring force and the force
(2) is pushed downward again by the reaction acting to spool (2) are balanced with is the output
force of balance spring (6). port pressure.
Port T
2
Clearance
Primary Pilot
Pressure
Port P
Output Port
6
Secondary Pilot
Pressure
㪉㩷㪄㩷 Spool㩷 3 - Control Lever㩷 6 - Balance Spring㩷
T3-6-13
Intentionally
COMPONENT OPERATION / Slewing Mechanism
OUTLINE
The slewing mechanism consists of the valve unit, the The slewing reduction gear turns the slewing motors
slewing motors and the slewing reduction gear. with large torque at a low speed and slews the super-
The valve unit prevents the cavitation in the slewing structure.
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.
Valve Unit
Slewing Motor
Slewing Reduction Gear

T25N-03-02-008

T3-7-1
SLEWING REDUCTION GEAR
The slewing reduction gear is a two-stage planetary Shaft (6) is engaged with the internal gear of slew
reduction gear. bearing fixed to the undercarriage in order to slew the
Ring gear (3) is monolithically built with housing (5) superstructure.
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). 1

10
2
9
3
8
4
7

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
T3-7-2
SLEWING MOTOR

The slewing motor consists of the swash plate (6), When pressure oil is supplied from the pump, plunger
rotor (11), plungers (10), valve plates (12), housing (8) (10) is pushed. Shoe (9) at the top of plunger (10)
and slewing parking brake (springs (1), brake piston slides over the swash plate (6), so that rotor (11) ro-
(2), plate (3) and friction plate (4)). tates.
Shaft (7) is splined to rotor (11) into which plungers The top of shaft (7) is splined to the first stage sun
(10) are inserted. gear of slewing reduction gear. Therefore, the rotation
of shaft (7) is transmitted to the slewing reduction gear.

12
1
11
10
9 6

T25N-03-02-002

1 - Spring 4 - Friction Plate 7 - Shaft 10 - Plunger
2 - Brake Piston 5 - Retainer 8 - Housing 11 - Rotor
3 - Plate 6 - Swash Plate 9 - Shoe 12 - Valve Plate
T3-7-3
SLEWING PARKING BRAKE
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
2. As a result, the force of spring (1) acts on friction
plate (4), which is engaged with the external cir- 1
cumference of rotor (11), and on plate (3), which
is engaged with the inside of housing (8), through Slewing
Brake Switch Slewing Brake
brake piston (2). Thus, the external circumference
Solenoid Valve
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
Hydraulic Oil Tank
Pb.

Pilot
When Brake Is Released Pump
T25N-03-02-009

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
2
piston chamber.
Brake Piston
3. Brake piston (2) moves by compressing spring Chamber
(1). Slewing
Brake Switch 1
4. As a result, plate (3) and friction plate (4) are Slewing Brake
freed and the brake is released. Solenoid Valve

Pilot T25N-03-02-010
Pump

T3-7-4
When Brake is Applied: When Brake is Released:

1 1
2 2
3 3
Pb Pb
To Hydraulic From Pilot
Oil Tank Pump
4 4
8 8
Brake Piston 11 Brake Piston 11

Chamber T25N-03-02-006 Chamber
T25N-03-02-006

1 - Spring 3 - Plate 8- Housing 11 - Rotor

2 - Brake Piston 4 - Friction Plate
T3-7-5
VALVE UNIT
The valve unit is provided with a make-up valve.

The make-up valve prevents the cavitation in the cir-
cuit.
Make-Up
Make-up valve 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
Port M
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 Control Valve
than that in the return circuit (port M), and sucks the
hydraulic oil in order to compensate the lack of oil T25N-03-02-007
feed.
Control Valve

Poppet
Make-Up Valve Make-Up

Valve
Port M

T25N-03-02-003
T3-7-6
COMPONENT OPERATION / Hoisting Mechanism
OUTLINE
The front drum and rear drum are driven separately. In Hoisting motor (2) consists of the motor, counterbal-
crane operation, hosting and lowering (power lowering ance valve (3), regulator (4), shuttle valve block, drum
and free fall) of, and stopping (holding) of the load is brake release solenoid valve and wet type multiplate
done with the front drum using boom hook and with the brake.
rear drum using the jib hook. The front drum and rear Regulator (4) is provided with the motor displacement
drum consist of the same parts respectively. The fol- angle proportional solenoid valve and motor cutoff high
lowing explanation is made in terms of the front drum. pressure solenoid valve.
Hoisting drum (1) consists of two-stage planetary re-
The front drum consists of the hoisting motor (2) and duction gear (5), which is built in the drum, and brake
hoisting drum (1). unit (6).
Front Drum
Rear Drum
Jib Hook
Boom Hook

T324-02-04-001
1 2

T25N-03-03-003
6 5

1 - Hoisting Drum 3 - Counterbalance Valve 5- Reduction Gear 6- Brake Unit
2 - Hoisting Motor 4 - Regulator (Two-Stage Planetary)
T3-8-1
MOTOR
The motor is a swash plate type variable displacement Plunger (1) slides over the slope of the shoe plate (4)
axial piston motor capable of selecting high/low in order to rotate rotor (2).
speeds. Rotor (2) is splined to output shaft (7) in order to turn
The high/low speed selection of motor is controlled by output shaft (7).
the regulator. Swash plate (5) is located between tilt pistons (8) (2
The wet type multiplate brake is built into the rear case used). The displacement angle is chanced by the op-
(9) side of motor. eration of regulator.
The motor has plungers (1) (9 used). In each plunger
(1), shoe (3) is crimped into rotor (2).

8
Wet Type Multiplate Brake
7
9
3
2
1
6
T324-02-04-003

1 - Plunger 4 - Shoe Plate 6 - Valve Plate 8 - Tilt Piston
2 - Rotor 5 - Swash Plate 7 - Output Shaft 9 - Rear Case
3 - Shoe
T3-8-2
Operation
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.

B A
7
5
6

T324-02-05-029
4 3 1 2

1 - Plunger 3 - Shoe 5 - Swashplate 7 - Output Shaft
2 - Rotor 4 - Shoe Plate 6 - Valve Plate

T3-8-3
REGULATOR
The regulator controls the larger motor displacement

angle in proportion to the increasing pressure in
hoisting motor circuit (Maximum Displacement Angle Motor Displace-
Lock Control). ment Angle
Maximum Displacement Angle Lock Control

When 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). 0 Pump Delivery
In addition, the motor cutoff high pressure solenoid Pressure㩷
valve (3) controls the instructions for the maximum
displacement angle in order to select the set pressure
Speed㩷
to the maximum displacement angles for hoisting and
lowering operations.
0 Pump Delivery
Pressure㩷

7 8 9 10 11 1
5 12
Pump 1㩷 Pump 2
Pilot 3
T2BC-03-08-001
Pump
1- Hoisting Motor㩷 4 - Piston 1㩷 7 - Motor Displacement Angle 10 - Orifice㩷

Proportional Solenoid Valve㩷
2- Tilt Piston㩷 5 - Spool 1㩷 8 - Piston 2㩷 11 - Spring 2㩷
3- Motor Cutoff High Pressure 6 - Spring 1㩷 9 - Spool 2㩷 12 - Shuttle Valve㩷
Solenoid Valve㩷
T3-8-4
• In Hoisting Operation
1. In hoisting operation, no signal comes to motor

cutoff high pressure solenoid valve (3), so that 6. When pump delivery pressure increases further,
motor cutoff high pressure solenoid valve (3) is spool 1 (5) is pushed by piston 1 (4) and pressure
not selected. oil on the large diameter chamber side of tilt pis-
ton (2) passes through spool 1 (5) to the hydraulic
2. Pilot pressure is applied through motor cutoff high
oil tank.
pressure solenoid valve (3) to piston 1 (4).
7. As a result, the tilt piston (2) is pushed to the left
3. Pump delivery pressure acts on piston 1 (4).
and motor (1) is set to the maximum displacement
4. When pump delivery pressure exceeds the pilot angle.
pressure acting on piston 1 (4) plus spring 1 (6)
8. Thus, by setting the pressure of spool 1 (5) at
force, piston 1 (4) moves to the left, to the position
higher level than that in lowering operation, an
when pump delivery pressure is balanced with
instruction for maximum displacement angle of
those pressures.
motor (1) is retarded to retain the horsepower for
5. As spool 1 (5) is pushed by piston 1 (4), the line to hoisting operation.
the large diameter chamber side of tilt piston (2) is In addition, during the pump delivery pressure in-
reduced. creasing, the maximum displacement angle of
motor (1) is retained.

1
Pump delivery pressure: Low Pump delivery pressure: High
1
6 6
2 2
5 5
Pump Delivery Pump Delivery

Pressure Pressure
4 4
3
3
T25N-03-03-014 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
T3-8-5
• Lowering Operation
1. For lowering operation, motor cutoff high pressure 6. When the pump delivery pressure increases fur-
solenoid valve (3) is selected by a signal from ther, spool 1 (5) is pushed by piston 1 (4) and
MC2/A. pressure oil in the large diameter chamber of tilt
piston (2) flows through spool 1 (5) to the hydrau-
2. Pressure oil acting on piston 1 (4) passes through
lic oil tank.
motor cutoff high pressure solenoid valve (3) to
the hydraulic oil tank. 7. As a result, spool 1 (5) moves by the pump deliv-
ery pressure lower than that in hoisting operation,
3. Therefore, the force against pump delivery pres-
thus setting motor (1) at the maximum displace-
sure acting on piston 1 (4) is only the force of
ment angle.
spring 1 (6).
8. Thus, by setting the pressure for hoisting or low-
4. When the pump delivery pressure becomes
ering operation, the horsepower is retained for
higher than the force of spring 1 (6), piston 1 (4)
hoisting operation, or the motor speed is con-
moves to the left to the position where pump de-
trolled for lowering operation.
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.
1
Pump delivery pressure: Low Pump delivery pressure: High
1
6 6
2 2
5 5
Pump Delivery Pump Delivery

4 Pressure 4 Pressure
3
3
T25N-03-03-016 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

T3-8-6
COUNTERBALANCE VALVE
The counterbalance valve consists of counterbalance 1

spool (4), spring (3), check valve (1) and relief valve 2
(2).

3 4 T2BC-03-08-002
Functions of Counterbalance
1. The counterbalance valve is provided in the low-
ering circuit.
Lowering
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 2
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. 1
6. In order to prevent this coasting, the counterbal-
ance valve is used.

T2BC-03-08-003

1 - Check Valve 2 - Relief Valve 3 - Spring 4 - Counterbalance Spool

T3-8-7
In Hosting Operation
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.
Hoisting㩷
Hoisting㩷
1 C
D C
A B A
4
A B
T2BC-03-08-004
㪈㩷㪄㩷 Check Valve㩷 4 - Counterbalance Spool㩷 T2BC-03-08-005
T3-8-8
Lowering Operation
1. In lowering operation, pressure oil from the pump 8. On the contrary, when the oil flow rate decreases,
passes through ports B and C, and flows to the passage resistance in counterbalance spool (4)
motor. decreases, lowering the feed pressure.
2. The pressure oil also flows into pilot passage (5) 9. Counterbalance spool (4) is returned, the pas-
of counterbalance spool (4). The return oil is sage is narrowed, lowering the motor speed.
blocked by check valve (1), so that the motor
10. When lowering the load, the motor is likely to be
does not turn, and the oil feed pressure in-
turned in excess of the oil feed quantity, so that
creases.
the feed pressure is lowered.
3. This pressure oil passes through pilot passage (5)
11. In order to avoid that the motor is turned in excess
and moves counterbalance spool (4) leftward
of the oil feed quantity, counterbalance spool (4)
(rightward in circuit diagram).
is returned, and the flow passage is narrowed.
4. The pressure oil opens ports D and A to return the
12. Thus, the lowering speed changes according to
return oil from the motor to the hydraulic oil tank
the oil feed quantity.
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.

Lowering Lowering

1 C
4 䌄 5
D C
D
A B A B
4

T2BC-03-08-006 T2BC-03-08-003

1 - Check Valve 4- Counterbalance Spool 5 - Pilot Passage
T3-8-9
In Neutral State
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.

B A

T2BC-03-08-007
1 - Check Valve 4 - Counterbalance Spool

T3-8-10
Relief Valve
Relief valve (2), provided in counterbalance valve (6), 6 2

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

T2BC-03-08-002
when reaching the set pressure, poppet (3) in re-
lief valve (2) moves and the pressure is released.

T2BC-03-08-008

3 5
Port D

T324-02-04-023

2 - Relief Valve 3 - Poppet 5 - Spring 6 - Counterbalance Valve Body
T3-8-11
BRAKE 1 PR
2
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) 3
(Refer to Control System.)
Operation
4
1. Spline joint (4) is splined to output shaft (5).
Spline joint (4) is splined to friction plates (7) (7 5
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 7 6
applied. T25N-03-03-012
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, 2 8
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.
7. As a result, the brake is released.
Pilot
Pump T25N-03-03-009

1 - Valve Cover 3- Spring 5- Output Shaft 7- Friction Plate
2 - Brake Piston 4- Spline Joint 6- Disc Plate 8- Brake Release Solenoid Valve
T3-8-12
HOISTING DRUM
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.

Hoisting Drum Motor

T25N-03-03-003

Brake Unit Reduction Gear

T3-8-13
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.

1 2

Motor

9 8 7 6 5 4 3 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

T3-8-14
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
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.
T3-8-15

Brake Drum Brake Sole-
Pedal noid Valve
1 2 3 4 5 6
Hydraulic
Oil Tank
Pilot
Pump
Reduction
Gear

T25N-03-03-011

8 A 7

1 - Casing 3- Brake Piston 5- Friction Plate 7- Spacer
2 - Passage 4- Disk Plate 6- Shaft 8- Spring

T3-8-16
COMPONENT OPERATION / Boom Derricking Device
OUTLINE
The boom derricking device consists of the boom der- The reduction gear is a three-stage planetary reduction
ricking motor, the reduction gear, the brake valve, the gear and converts the rotation, transmitted from the
boom derricking drum and the derricking drum lock. boom derricking motor, to a low-speed large torque in
The boom derricking motor is an axial plunger motor order to rotate the boom derricking drum.
and the parking brake (wet type spring-set / hydrau- The brake valve prevents overload to the boom der-
lic-released multiplate brake) is built in. The boom derricking circuit and cavitation.
ricking motor is driven by pressure oil from the pump
and transmits the rotation to the reduction gear.

Derricking Drum Lock Brake Reduction
Valve Gear

T25N-03-04-003

Boom T25N-03-04-001
Boom Der-
ricking Motor Derricking
Drum

T3-9-1
REDUCTION GEAR
The reduction gear is a three-stage planetary reduction Housing (13) for the boom derricking motor is fixed
gear. with bolts to the track frame and fixed with bearing nut
The boom derricking motor rotates propeller shaft (7). (11) to third stage carrier (2). Ring gear (1), drum (12)
This rotation is transmitted to ring gear (1) through first and the boom derricking drum are bolted respectively.
stage planetary gear (8), first stage carrier (6), second Therefore, when ring gear (1) rotates, drum (12) and
stage sun gear (5), second stage planetary gear (9), the boom derricking drum are also turned.
second stage carrier (4), third stage sun gear (3), third
stage planetary gear (10) and third stage carrier (2).
1 2 3 4 5 6

T25N-03-04-002
13 12 11 10 9 8

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

T3-9-2
BOOM DERRICKING MOTOR
The boom derricking motor is a swash plate type When pressure oil from the pump is supplied, plunger
variable displacement axial plunger motor and con- (6) is pushed. Shoe (5) at the top of plunger (6) slides
sists of valve plates (1), swash plate (4), rotor (2), over swash plate (4), so that rotor (2) rotates.
plunger (6) and shaft (3).
Shaft (3) is splined to rotor (2) into which plungers (6)
are inserted.

1 2 3

T25N-03-04-004
6 5 4

1 - Valve Plate 3 - Shaft 5 - Shoe 6- Plunger
2 - Rotor 4 - Swash plate
T3-9-3
BOOM DERRICKING BRAKE
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 Derricking Drum Unlock-

ing Solenoid Valve
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- Pilot
lic oil tank. Pump
2. As a result, the force of disk spring (1) acts on Hydraulic

plates (3) engaged with the inside of housing (6) Oil Tank
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. Derricking
Drum Lock
3. In the derricking drum lock, pawl (9) is moved by T25N-03-04-006
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. Derricking Drum Unlock-
ing Solenoid Valve
3. The pilot pressure fed to port C acts to the brake
piston chamber.
4. Brake piston (2) moves by compressing disc Pilot
Pump
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.
Derricking
7. As a result, the boom derricking drum is unlocked. Drum Lock
T25N-03-04-005
T3-9-4
When brake is applied
To Hydraulic
1 2 3 4 5 9

Oil Tank
Brake Piston 8
Chamber
C
T25N-03-04-008
To Hydraulic T25N-03-04-003
Oil Tank 6

When brake is released

1 2 3 4 5
From 9
Pilot Pump

Brake Piston
Chamber 8
C
T25N-03-04-008
From Pilot
Pump 6 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
T3-9-5
BRAKE VALVE
The brake valve, located at head of the boom derrick-

ing motor, consists of the following valves.
• Overload relief valve • Check valve

Prevents overloading to the motor circuit and surge Assists the counterbalance valve in operation and
pressure. prevents cavitation in the motor circuit.
• Counterbalance valve
Prevents overturning of the motor caused by the
load or self weight in lowering operation.

Counterbalance Valve

Check Valve

T25N-03-04-007
Overload Relief
Valve

T3-9-6
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 BM AM
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 Check
hoisting work. Valve
B A
T25N-03-04-010

• 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. BM
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 B Spool A
can be lowered while applying the brake. This is
T25N-03-04-009
called “Power Lowering”.

T3-9-7
Boom hoisting

A B
AM
BM
Check Valve

T25N-03-04-007

Boom lowering
Spool
Spring A B
Spring Chamber
AM
BM
Check Valve

T25N-03-04-007
T3-9-8
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.

Poppet Spring

T25N-03-04-012
Port AM To Hydraulic
Oil Tank

T3-9-9
Intentionally
COMPONENT OPERATION / Travel Mechanism
OUTLINE
The travel mechanism consists of the travel motor, The travel reduction gear is a threee-stage planetary
travel reduction gear and travel brake valve. reduction gear and converts the rotation, transmitted
The travel motor is an axial plunger motor and incor- from the travel motor, to a low-speed high torque in
porates the parking brake of wet spring-set / hydrau- order to rotate the drive tumblers and crawler shoes.
lic-released multiplate type. The travel brake valve prevents the overload to the
The travel motor operates by pressure oil from the travel circuit as well as cavitation.
pump and transmits the rotation to the travel reduction
gear.

Travel Brake
Valve Travel Reduction Gear

T25N-03-07-001

Travel Motor
T3-10-1
TRAVEL MOTOR
The travel motor is a swash plate type variable dis- Tilt pistons (4) (4 used) are provided in order to change
placement axial plunger motor and consists of valve the inclination of swash plate (7) by using balls (6).
plates (1), plungers (2), shoes (3), shaft (5), swash Rotor (8) is pressed to valve plate (1) by the force of
plate (7) and rotor (8). spring (9).
Shaft (5) is splined to rotor (8) into which plungers (2)
are inserted.

4
1 2 3 5

T25N-03-07-003

9 8 7 6

1 - Valve Plate 4 - Tilt Piston 6- Ball 8- Rotor
2 - Plunger 5 - Shaft 7- Swash Plate 9- Spring
3 - Shoe
T3-10-2
Operation

1. When pressure oil is delivered to port A of valve
plate (1), it goes into one side of rotor (8) and
pushes plunger (2).
2. Due to this force and the inclination of swash
plate (7), shoe (3) slides over swash plate (7) and
rotates rotor (8) and output shaft (5).
3. With the rotation of rotor (8), when plungers (2)
reach port B in sequence, oil is returned to the
hydraulic oil tank.
4. Advance and reverse are determined by whether
pressure oil goes into port A or B.
Port B Port A
Port B
Port A
1
8
3
5 7
Valve Plate

T183-03-05-009

1 - Valve Plate 3 - Shoe 7- Swash Plate 8- Rotor
2 - Plunger 5 - Shaft

T3-10-3
PARKING BRAKE
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.
1 2

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.

Hydraulic
Oil Tank
T25N-03-07-004

When Brake Is Released
1. When moving the travel lever, self pressure in the
main circuit acts to brake chamber M. 1 2
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.

T25N-03-07-005

T3-10-4
When brake is applied

1
2 M
3

T2BC-03-10-002

When brake is released

1
2 M

T2BC-03-10-003

1 - Spring 3 - Brake Piston 5 - Friction Plate 6- Casing
2 - Rotor 4 - Plate

T3-10-5
TRAVEL REDUCTION GEAR
The travel reduction gear is a three-stage planetary Third stage carrier (6) is fixed to housing (2) of travel
reduction gear. motor (1) and does not turn.
Travel motor (1) rotates shaft (11) and its turning Ring gear (5) and drive tumbler (3) are both bolted to
torque is transmitted to third stage carrier (6) and ring drum (4) and turn together.
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).

1 2 3 4 5 6 7 8 9

10
11
Third Second First

Stage Stage Stage

14 13 12
T111-03-04-011
T25N-03-07-001
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
T3-10-6
TRAVEL BRAKE VALVE
The travel brake valve is located at the head of travel

motor and consists of the following valves.
• Overload relief valve: • Check valve:

Prevents overloading to the motor circuit and surge Assists the counterbalance valve in operation and
pressure. prevents cavitation in the motor circuit.
• Counterbalance valve: • Travel motor displacement angle selection valve:
Makes starting and stopping of travel smoothly and The tilt piston is controlled by pilot pressure from the
prevents coasting when descending slope. high speed selection solenoid valve.

Travel Motor Displacement
Angle Selection Valve

Overload Relief
Overload Relief Valve
Valve
Counterbalance
Valve

T2BC-03-10-001
Check Valve

T3-10-7
When Traveling Circuit Protection
1. When pressure oil from the control valve goes 1. When internal pressure of the circuit exceeds the
into port P1 (4), check valve (2) opens and oil set pressure of overload relief valve (9), this valve
flows into motor port a1 (8). opens and release high pressure to the low pres-
sure side in order to prevent the travel motor from
2. On the other hand, return oil from the travel motor
overloading.
returns to motor port a2 (7), but is blocked by
check valve (2). 2. In addition, this releases shock pressure caused
by the inertial force at the stop of travel motor.
3. When pressure in port P1 (4) increases further,
pressure oil goes through orifice (1) acts on the 3. When the travel motor sucks oil by pumping ac-
end of spool (3) and moves to the right. tion, check valve (2) opens (by make-up action) in
order to prevent cavitation.
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). Shuttle Function
Now, pressure oil flows to turn the travel motor.
1. When spool (3) moves, port P1 (4) or port P2 (6)
5. When moving the travel lever to neutral, spool (3) is connected to port P3 (5) (for parking brake).
returns to original position by the spring force and Pressure oil goes into the parking brake chamber
blocks the circuit in order to stop the rotation of and the parking brake is released.
travel motor.
2. When the travel motor stops, spool (3) returns to
neutral, port P3 (5) is closed. Pressure oil in the
When Descending Slope parking brake chamber flows to the drain port the
parking brake is applied.
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.
T3-10-8

From Control To Control
Valve Valve
1 2 3 4 5 6
9 8 10 7

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
Angle Selection Valve
3 - Spool (Counterbalance Valve) 6 - Port P2

T3-10-9
TRAVEL SPEED SELECTION
Piston (1) is located next to swash plate (3) and 3. Pressure oil from motor port a2 (7) or a1 (8) on
changes the displacement angle of swash plate (3) high pressure side is blocked by spool (5) and oil
according to the movement of piston (1) in order to in piston (1) returns to the hydraulic oil tank
select the travel speed. through spool (5).
4. Swash plate (3) is pushed by plunger in the travel
• Low speed
motor until surface A of swash plate (3) contacts
1. When the high/low travel speed selection switch
the casing.
is set to low speed position, high travel speed
selection solenoid valve is not selected, so that 5. As a result, the displacement angle of swash
pilot pressure is not fed to port PS (4). plate (3) is maximized and plunger stroke in-
creases so that the travel motor runs at a low
2. As a result, spool (5) is pushed by spring (6) to
speed.
the left.

6 4 5 6

T165-03-05-005
SurfaceA
3
2 7 8
Swash Plate Surface Surface B Valve Plate
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
T3-10-10
• High Speed
3. Pressure oil in motor port a2 (7) or a1 (8) on high
1. When the high/low travel speed selection switch
pressure side acts on piston (1) through spool (5).
is set to high speed position, the high travel speed
selection solenoid valve is selected. 4. Piston (1) pushes swash plate (3) so that surface
B of swash plate (3) contacts with casing and re-
2. As a result, pilot pressure is fed from port PS (4)
duces the displacement angle of swash plate (3).
in order to move spool (5) to the right.
Plunger stroke in the travel motor is reduced in
order to run the travel motor at a high speed.
6 4 5 6

T165-03-05-007
Surface A
3
2 8
7
Valve Plate
Swash Plate Surface
Surface B

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
T3-10-11
Intentionally
COMPONENT OPERATION / Others (Upper Structure)
4-SOOL SOLENOID VALVE UNIT
Composition
The 4-spool solenoid valve unit consists of the follow-
ing valves.
• Pressure-reducing valve: Reduces pressure in the • Derricking drum unlocking solenoid valve: By signal
pilot circuit and supplies pressure oil. from MC2/A, delivers pressure oil to boom derricking
• Second overhoist solenoid valve: By signal from brake and boom derricking drum lock.
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.
To Front, Rear, Derricking and Third/Fourth Remote

Control Valves㩷
To Travel Displacement Angle Selection
Valve㩷
To Slewing Parking Brake㩷
To Derricking Drum Lock㩷
From Pilot
Pump㩷
1 2 3 4 5 T2BC-03-11-002
1- Second Overhoist Solenoid 3- Slewing Brake Solenoid 4- Derricking Drum Unlocking 5- Pressure-Reducing Valve㩷
Valve㩷 Valve㩷 Solenoid Valve㩷
2 - High-Speed Travel Sole- 㩷㩷㩷
noid Valve㩷
T3-11-1
Internal Construction
1 2 3 4 5
T2BC-03-11-001
1- Second Overhoist Solenoid 3 - Slewing Brake Solenoid 4 - Derricking Drum 5- Pressure-Reducing Valve㩷
Valve㩷 Valve㩷 Unlocking Solenoid
Valve㩷
2- High-Speed Travel Sole- 㩷㩷㩷
noid Valve㩷
T3-11-2
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.
T3-11-3
Neutral state
Output
T Port P

Spool Spring Solenoid T324-02-08-007

Exciting stage
Output
T Port P

Spool Spring Solenoid T324-02-08-007

T3-11-4
DRUM UNLOCKING SOLENOID VALVE

The drum unlocking solenoid valve is an ON/OFF so- NOTE: As for operation of drum unlocking solenoid
lenoid valve of normally closed type. valve, refer to the section for 4-spool unit.
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.
Port 3
(From Pilot Pump)
Port 2
(Output Port)

Port 1
T25N-03-08-008
(Hydraulic Oil Tank)
T3-11-5
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.
Gate Lock Solenoid

Valve
Gate Lock Valve㩷
T2BC-03-11-003
Pilot Relief Valve㩷
Pilot Relief Valve㩷

Gate Lock Solenoid
Valve㩷
T2BC-03-11-004
T3-11-6
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.䎃 Therefore,
pressure at port P’ (output port) does not rise and op-
erate the circuit. Gate Lock Sole-
When the gate lock lever is at the UNLOCK position, noid Valve㩷
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) Pilot
from the pilot pump. Consequently the circuit is oper- Pump㩷
ated.
To Pilot Pilot Relief T2BC-03-11-005

Circuit㩷 Valve㩷
Gate Lock: LOCK Gate Lock: UNLOCK
SoL. Spool㩷 SoL. Spool㩷
T2BC-03-11-006
T3-11-7
Pilot Relief Valve
The pilot relief valve is a relief valve which keeps

pressure in the pilot circuit.䎃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.
Gate Lock
Solenoid
Valve㩷
Pilot Pump
To Pilot To Pilot Relief

T2BC-03-11-007
Circuit㩷 Valve㩷
T3-11-8
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)

Fourth Brake Pedal Front Brake
Rear Brake (Optional) Pedal
Pedal

T2BC-03-11-008

1
2

T2BC-01-02-017
7 6 5 4 3

1 - Lock Pedal 3 - Brake Depressing Pressure 5- Link 7- Lever
Sensor
2 - Brake Pedal 4 - Pressure-Reducing Valve 6- Applied Sensing Switch
T3-11-9
PRESSURE-REDUCING VALVE
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.
Drum Brake
Release A B
2. Rod (1) compresses both balance spring (4) and Pressure
return spring (5) through retainer (2) and spring
guide (3). C

3. As a result, balance spring (4) pushes spool (6) to
the right through spring seat (7).

D
4. When spool (6) moves to the right and the notch
of spool (6) reaches port P, pressure oil from port E F
P flows to output port and pressure in output in- 0 Pedal Stroke
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.
T3-11-10

1 2 3 4 5 6 7 Output 8
Port

T25N-03-08-010
T Hole Piston P
Chamber

1 - Rod 3 - Spring Guide 5 - Return Spring 7 - Spring Seat
2 - Retainer 4 - Balance Spring 6 - Spool 8 - Piston
T3-11-11
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- Drum Brake

Release A B
lic oil tank), so that pressure in output port de- Pressure
creases.
C
5. When pressure in output port decreases, pres-
sure in piston chamber also decreases at the

same time.
D
smaller than the force of balance spring (4), spool E F
(6) moves to the right by balance spring (4) 0 Pedal Stroke
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.
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.

T3-11-12
When pressure decreases

1 2 3 4 5 6 7 Output 8
Port

T25N-03-08-010
T Hole Piston P
Chamber
When pressure increases

1 2 3 4 5 6 7 Output 8
Port

T25N-03-08-010
T Hole Piston P
Chamber

1 - Rod 3 - Spring Guide 5 - Return Spring 7 - Spring Seat
2 - Retainer 4 - Balance Spring 6 - Spool 8 - Piston
T3-11-13
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
Drum Brake
port T and the output port are connected. Release A B
4. Pressure oil in output port flows to port T (hydrau- Pressure
lic oil tank). C

In addition, pressure oil in piston chamber passes
through hole of spool (6) at the same time, and
goes to port T.
D
smaller than the force of balance spring (4), spool E F
(6) moves to the right by balance spring (4) 0 Pedal Stroke

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.

T3-11-14

1 2 4 5 6 7 Output 8
Port

T25N-03-08-010
T Hole Piston P
Chamber

1 - Rod 4- Balance Spring 6- Spool 8- Piston
2 - Retainer 5- Return Spring 7- Spring Seat

T3-11-15
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.
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17
T2BC-03-11-009
1- Set Screw㩷 6- O-Ring㩷 11 - Ring㩷 15 - Valve Block㩷

2- Wear Ring㩷 7- Backup Ring㩷 12 - Dust Seal㩷 16 - Piston Rod㩷
3- Packing㩷 8- Bushing㩷 13 - Piston㩷 17 - Cylinder Head㩷
4- Wear Ring㩷 9- Packing㩷 14 - Cylinder Tube㩷㩷
5- O-Ring㩷 10 - Backup Ring㩷㩷㩷
T3-11-16
ACCUMULATOR
The accumulator is provided in pilot circuit, and func- 6
1
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 Nitrogen Gas
(4), poppet (1) and bladder (2) that contains nitrogen 5 (N2) 2
gas (N2) hermetically.
4
• Pressure oil from pilot pump passes through port
A, and enters accumulator and compresses
Pilot Pressure
bladder (2) until pressure oil is balanced with ni- Oil
trogen gas in bladder (2). 3
• 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.
A

T105-02-10-003
1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug

GOVERNOR MOTOR Output
Output
Gear Shaft Worm Gear
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".)
Motor

Sensor Gear Governor Worm Wheel T157-02-05-018
Potentio Sensor

T3-11-17
Intentionally
COMPONENT OPERATION / Others (Base Carrier)
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).
3
4
2
1 5
12 6
11
10
9
8
T2BC-01-02-001
1- Jack-Up Cylinder (4 Used) 4- Crawler Shoe (2 Used)㩷 7- Take-Up Cylinder (2 Used)㩷 10 - Side Frame (2 Used)㩷
(Optional)㩷
2 - Center Joint㩷 5- Lower Frame㩷 8- Retract Cylinder (2 Used)㩷 11 - Upper Roller (2 Used)㩷
3 - Slewing Ring㩷 6- Front Idler (2 Used)㩷 9- Lower Roller (20 Used)㩷 12 - Travel Mechanism (2
Used)㩷
T3-12-1
SLEWING RING
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.
6
7
T135-03-02-001
1- Outer Race㩷 3 - Inner Race㩷 5 - Support㩷㪎㩷㪄㩷 Ball㩷

2- Seal㩷 4 - Seal㩷 6 - Support㩷㩷
T3-12-2
CENTER JOINT
The center joint is a full 360 qturn joint and delivers Pressure oil from each port of the body passes through
pressure oil to travel motors while preventing hoses spindle and flows to left and right travel motors and
from kinking when the upper structure slews. retract cylinders and jack-up cylinders (optional)
The spindle is fixed at the center of slew of the base through lower control valves. The seal provided
carrier. between spindle and body prevents oil leakage.
H
A
Body㩷
B
C
E
D
G
F
Spindle㩷
G E
D
B
T2BC-03-12-002
C H
Port A - Right Travel Forward㩷 Port D - Left Travel Forward㩷 Port G - High / Low Travel Speed
Selection Pilot Pressure㩷
Port B - Right Travel Reverse㩷 Port E - Retract Cylinder Extend (with Jack: Port H - Travel Mechanism Drain㩷
Lower Circuit Hydraulic Source)
Port C - Left Travel Reverse㩷 Port F - Retract Cylinder Retract (with Jack: 㩷
Lower Circuit Link Line)㩷
T3-12-3
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 Retract Cylinder㩷
M25N-07-035
valve (manual operation) with the jack-up (optional)

attached.䎃 When operating the lever for retract
operation, the spool is selected and pressure oil flows
to the retract cylinder.
1 2 3 4 5 6 7 8 9 10
T25N-03-09-002
1- Boot㩷 4 - U-Ring㩷 7 - Piston㩷 9 - Wear Ring㩷

2- Cylinder Head㩷 5 - Cylinder Tube㩷 8 - Piston Seal㩷 10 - Piston Nut㩷
3- Bushing㩷 6 - Piston Rod㩷㩷㩷
T3-12-4
JACK-UP CYLINDER (OPTIONAL)
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 Jack-Up Cylinder㩷
lower frame into upper and lower sections for transport
of the machine, and reassemble them for operation. Lower Frame㩷
While the lower frame is lifted by jack-up cylinders,
crawler frames are attached, or removed for loading
onto a trailer. Crawler Frame
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.
M25N-07-034
Double Check Valve
1
2
3
4
5
6
7
T2BC-03-12-003
1- Piston㩷 3 - Wear Ring㩷 5 - Cylinder Tube㩷 7 - Cylinder Head㩷

2- U-Ring㩷 4 - Piston Rod㩷 6 - Bushing㩷 8 - U-Ring㩷
T3-12-5
Double Check Valve
The double check valve maintains pressures on the
Jack-Up
rod side and the bottom side of jack-up cylinder.
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 Check Valve Check Valve
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
Check Valve
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
B
hydraulic oil tank.
A
4. As a result, the jack-up cylinder extends.
T25N-03-09-006
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 Jack-Up
to neutral, so that extend/retract of jack-up Cylinder
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.
Check Valve Check Valve

T25N-03-09-008
T3-12-6
Slow Return Check Valves
The slow return check valve is provided in the extend
Jack-Up
circuit of jack-up cylinder.
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
Orifice
the check valve in slow return check valve.
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 B A
machine.

T25N-03-09-007

Orifice Check Valve Slow Return
Check Valve
To Lower Control From Jack-Up

Valve Cylinder

T25N-03-09-003

T3-12-7
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.
1 2 3 4 5 6 From Travel Circuit㩷
T2BC-03-12-001
1- Head Cap㩷 3- Scraper㩷 5 - Housing㩷 6- Piston Rod㩷

2- Scraper㩷 4- O-Ring㩷㩷㩷
T3-12-8
SECTION 4
OPERATIONAL
PERFORMANCE TEST

—CONTENTS—
Group 1 Introduction Group 5 Component Test
Operational Performance Tests .............. T4-1-1 Pilot Circuit Primary Pilot Pressure ........ T4-5-1
Preparation For Performance Tests ........ T4-1-2 Brake Circuit Primary Pilot Pressure...... T4-5-3
Precautions For Starting Engine ............. T4-1-3 Remote Control Valve
Secondary Pilot Pressure ................... T4-5-5
Group 2 Standard High / Low Travel Speed
Performance Standards ......................... T4-2-1 Selection Pressure ............................. T4-5-7
Main Pump P-Q Diagram....................... T4-2-4 Slewing Brake Release Pressure........... T4-5-8
Slewing Pump P-Q Diagram .................. T4-2-6 Main Relief Valve Pressure .................... T4-5-9
Port Relief Valve Pressure ..................... T4-5-16
Group 3 Engine Test Main / Slewing Pump Flow Rate ............ T4-5-17
Engine Speed ........................................ T4-3-1 Regulator Adjustment (Main Pump) ....... T4-5-22
Engine Compression Pressure .............. T4-3-2 Regulator Adjustment (Slewing Pump) ...... T4-5-25
Valve Clearance Adjustment .................. T4-3-3 Slewing Motor Drainage......................... T4-5-26
Nozzle Check ........................................ T4-3-5 Travel Motor Drainage ........................... T4-5-28
Boom Dericking Motor Drainage ............ T4-5-30
Group 4 Crane Test
Travel Speed ......................................... T4-4-1
Mistrack ................................................. T4-4-2
Travel Parking Brake Drift...................... T4-4-3
Slewing Speed....................................... T4-4-4
Slewing ring Play ................................... T4-4-5
Hoist / Lower Speeds
(Front / Rear Drums) .......................... T4-4-6
Regulator Adjustment ............................ T4-4-7
Boom Derricking Speed ......................... T4-4-8
Counterweight Cylinder Speed .............. T4-4-9
Jack-Up (Optional) Speed ..................... T4-4-10
Retract Speed........................................ T4-4-11
Lifting Load Lowering
By Front / Rear Drums ....................... T4-4-12
Control Lever Operating Force .............. T4-4-13
Control Lever Stroke............................. . T4-4-14
2BCT-4-1
Group 6 Adjustment
MC2/A Adjustment ................................. T4-6-1
High Idle Calibration .............................. T4-6-2
Rack Zero Calibration............................ T4-6-4
Power Increase Pressure Calibration .... T4-6-6
Full Rack Calibration ............................. T4-6-8
Brake 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
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 T105-06-01-003
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 SA-331
values of the measurements.
T4-1-2
PRECAUTIONS FOR STARTING ENGINE
1. Check that lock lever (1) is placed in the LOCK Lock Position
position. 1
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” T2BC-04-04-001
mode.

4. Check that slewing brake switch (8) is ON (Brake 3 1
8 2
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).

T2BC-04-01-002
7 6 5
4

T2BC-01-02-003
T4-1-3
Intentionally
OPERATIONAL PERFORMANCE TEST / Standards
PERFORMANCE STANDARDS
The performance standards show the required per- Measuring conditions:

formance measurements. Engine speed : High idle
For details including measuring method, refer to T4-3 Hydraulic oil temperature : 50r5 qC (122r41qF)
onward.
Data in ( ) is given for reference.

Performance Reference
Performance Test Designation Remarks
Standard Page
-1
Engine Speed min T4-3-1
Maximum Speed (High Idle) 2070 to 2130
Minimum Speed (Low Idle) 760 to 820
Starting Speed 885 to 945
2
Engine Compression Pressure MPa (kgf/cm , psi) 2.7 (28, 390) After Warming Up T4-3-2
Valve Clearance mm Cold T4-3-3
IN 0.4
EX 0.6
2
Nozzle Injection Pressure MPa (kgf/cm , psi) 25.5r1 (260r10, T4-3-5
3710r145)
Travel Speeds sec/10 m T4-4-1
(Slow) 26.5 to 29.3
(Fast) 15.1 to 16.7
Mistrack mm/10 m 60 or less At High Speed Travel T4-4-2
Travel Motor Leakage T4-4-3
Slippage Until Brake is Applied turn (1/6 or less)
Motor Slippage When Parking mm/5 min (0)
Slewing Speed sec/3 turn 64.7 to 71.4 T4-4-4
Slewing Ring Play mm (5 to 6) Allowable Limit T4-4-5
Hoisting and Lowering Speeds sec/Drum 6 turns T4-4-6
Fixed Low Speed 16.1 to 17.8 Low Speed Lock Switch:
Lock
Fixed High Speed 8.1 to 8.9 Low Speed Lock Switch:
Front / Rear Lock
Normal Low Speed 11.2 to 12.4
Normal High Speed 5.6 to 6.2
Fourth (Optional) 11.2 to 12.4
Boom Derricking Speed sec/Drum 6 turns 10.7 to 11.8 T4-4-8
T4-2-1

Performance Reference
Performance Test Designation Remarks
Standard Page
Counterweight Cylinder Speed sec/Full Stroke T4-4-9
Extend 190 to 200 Engine Speed:
Low Idle
Retract 30 to 33 No Load
Jack-up (Optional) Speed mm/290 min T4-4-10
Retract 33 to 38 Low Idle
Retract Speed sec/Full Stroke T4-4-11

Retract 30 to 38 Low Idle
Load Lowering By Front / Rear Drums mm/2 min (0) T4-4-12

Control Lever Operating Control Force N (kgf, lbf) T4-4-18
Front / Rear Drum Lever First Detent 4.4 to 15.1
(0.4 to 1.5,
1.0 to 3.4)
Second Detent 15.1 to 22.0
(1.5 to 2.2,
3.4 to 5.0)
Third / Fourth Lever First Detent 4.2 to 12.4
(0.4 to 1.3,
0.9 to 2.8)
(1.3 to 1.9,
2.8 to 4.3)
Boom Derricking Lever 4.4 to 22.0
(0.4 to 2.2,
1.0 to 5.0)
Travel Lever 5.3 to 15.9
(0.5 to 1.6,
1.2 to 3.6)
Slewing Lever 7.5 to 16.1
(0.8 to 1.6,
1.7 to 3.6)
Control Lever Stroke mm T4-4-14
Front / Rear Drum Lever First Detent 49.5 to 51.6
Third / Fourth Lever First Detent 21.7 to 53.9
Boom Derricking Lever 84.9 to 87.1
Travel Lever 40.9 to 42.6
Slewing Lever 64.6 to 67.3
T4-2-2

Reference
Performance Test Designation Performance Standard Remarks
Page
Hydraulic System
2
Primary Pilot Pressure MPa (kgf/cm , psi)
Pilot Circuit Primary Pilot Pressure 4.90.50 (5050, 712730) T4-5-1

0.5 5 73
Brake Circuit Primary Pilot Pressure 9.8 0 (100 0, 1420 0) T4-5-3
Remote control Valve Secondary Pilot Pressure T4-5-5
2
MPa (kgf/cm , psi)
Front / Rear Lever First Detent (2.0r0.2) ((20r2, 290r29)

Second Detent (3.7r0.2) ((38r2, 529r29))
Boom Derricking (3.7r0.2) ((38r2, 542r29))
Travel (2.0r0.2) ((20r2, 290r29))
Slewing (2.90.50) ((305 0, 42273 0))
High / Low Travel Speed Selection PressureMPa (kgf/cm2, psi) (1.5 (15.3, 218) or more) T4-5-7
Slewing Brake Release Pressure (On) 2
MPa (kgf/cm , psi) (4.90.50 (5050, 712 73
0)) T4-5-8
2
Main Relief Valve Pressure MPa (kgf/cm , psi)
Front / Rear Control Valve 28.3 to 34.5 T4-5-9

(289 to 352, 4110 to 5020)
Slewing Control Valve 28.7 to 35.1
T4-5-11
(293 to 358, 4170 to 5100)
4-Spool Control Valve 20.6 (210, 2995) T4-5-13
Lower Control Valve 17.2 to 19.6
T4-5-15
(175 to 200, 2500 to 2850)
2
Port Relief Valve Pressure MPa (kgf/cm , psi) T4-5-16
Front / Rear / Fourth (Optional) (34.3r0.5)
((350r5, 4990r73))
Boom Derricking (34.820)
((355200, 50602900))
Travel (32.4) ((330, 4710))
Main / Slewing Pump Flow Rate 㧙 T4-5-17
Slewing Motor Drain L/min 㧙 T4-5-25
Travel Motor Drain L/min 㧙 T4-5-27
Derricking Motor Drain L/min 㧙 T4-5-29

T4-2-3
Main Pump P-Q Diagram
P-Q control (Torque Control)

(Reference: Measured at Test Stand)
• Rated pump speed: 2000 min-1 (rpm)
• Hydraulic oil temperature: 50r5 qC (122r41 qF)
• Power increase/displacement angle proportional
solenoid valve current: “I” mA
NOTE: Refer to T4-5-18.
Flow rate
L/min 400
300 A B C
I=800 mA
D
F
200 G
E
100 I=0 mA

0 5 10 15 20 25 30 35 T25N-04-05-004
2
Delivery pressure Mpa (kgf/cm )
P-Q point:I=800 mA P-Q point: I=0 mA

Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2) L/min MPa (kgf/cm2) L/min
A 7.0 (71) 276 F 3.9 (40) 239
B 11.8 (120) 273 G 5.0 (51) 224
C 21.1 (215) 267 H 31.4 (320) 56
D 25.3 (258) 211 Data in ( ) is given for reference.
E 31.4 (320) 172
T4-2-4
P-Q Control by Pump Control Pilot Pressure Signal
• Rated pump speed:2000 min-1 (rpm)
• Hydraulic oil temperature:50r5 qC (122r41 qF)
Flow rate
L/min
300
A
200
100
B

0 1 2 3 4 T25N-04-05-005
2
Pilot pressure MPa (kgf/cm )
P-Q point
Swash angle proportional solenoid
Pilot Control Pressure Flow Rate
valve current
MPa (kgf/cm2) L/min
mA
A 0.86 (8.8) 276r1.5 315+100
B 2.92 (29.8) 53r3 586
T4-2-5
Slewing Pump P-Q Diagram
P-Q control (Torque Control)

• Rated pump speed:2000 min-1 (rpm)
Flow rate 200

L/min
A
150
B
C
100
50

0 5 10 15 20 25 30 35 T25N-04-05-006
2
Delivery pressure MPa (kgf/cm )
P-Q point
Delivery Pressure Flow Rate
MPa (kgf/cm2) L/min
A 20.6 (210) 156
B 25.4 (259) 121
C 31.9 (325) 99
T4-2-6
P-Q Control by Pump Control Pilot Pressure Signal
• Specified pump speed:2000 min-1 (rpm)
B
Flow rate
L/min 150
A
100
50

0 1 2 3 T25N-04-05-007
2
Pilot pressure MPa (kgf/cm )
P-Q point
Swash angle proportional solenoid
Pilot Control Pressure Flow Rate
valve current
MPa (kgf/cm2) L/min
mA
A 1.11r0.2 (11.3r2) 94r3 340r30
B 1.96r0.2 (20r2) 158r3 457r30
T4-2-7
Intentionally
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 Slow Idle Speed Position Fast Idle Speed Position
performing any tests..
2.The engine speed after starting, is the 2
slow idle speed plus 125 min-1 (125 rpm).
1 1
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 T333-04-02-001
coolant temperature reaches 50 qC (122 qF) or

more, also, maintain the hydraulic oil temperature
at 50r5 qC (122r9 qF).
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.
T4-3-1
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. T333-04-02-002
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.
T4-3-2
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 T333-04-02-003
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 “u” in the table below.)
Measure all valve clearances.
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
u u u u u u
started from cylinder No.6
T4-3-3
Evaluation:
Standard Valve Clearance (Cold Engine):
• Intake valve: 0.40 mm (0.016 in) Adjusting Screw
Lock Nut
• Exhaust valve: 0.60 mm (0.024 in) Rocker Arm
Adjustment:
If the measured valve clearances do not conform to
the standard value, adjust the valve clearance in the Feeler Gauge
same order of the measurement.
1. After loosening the lock nut on the rocker arm, Valve Cap
completely loosen all adjust screws.
T333-04-02-004
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.
㧦59 Nm (6 kgfm, 43 lbfft)
3. Recheck the valve clearance after tightening the

lock nut.
T4-3-4
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.

Preparation
1. 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 T107-06-02-006
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.
T4-3-5
Evaluation:
1. Standard Injection Pressure:
Refer to Operational Performance Standard in
T4-2. Normal Abnormal
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.
T523-06-02-001

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.

T107-06-02-007
T4-3-6
OPERATIONAL PERFORMANCE TEST / Crane Test
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
2 m (6.5
motor) comprehensively. 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 60q
acceleration and deceleration.
3. The machine should be equipped with the basic
boom with the hook.
Set the boom angle to 60q, and hoist the hook T2BC-04-04-003
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.)
4. While maintaning hydraulic oil temperature at
50r5 qC (122r41 qF), 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 Deceleration
End
10 m Zone
upperstructure 180q. Then, measure the reverse 3 to 5 m
Accelera- (33 ft)
travel time. tionZone (9.8to 16 ft)
3 to 5 m Start
5. Repeat the measurements three times. Calculate (9.8 to 16 ft)
the average values.
T324-06-03-002

Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy:
Refer to TROUBLE SHOOTING in T5-4.
T4-4-1
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 2m
hydraulic pump to the travel motor) performance. (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.
60q
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 accel-
eration and deceleration.

3. The machine should be equipped with the basic T2BC-04-04-003
boom and hook. Hoist the hook to approx. 2m

below the height which the hoisting limiter buzzer
starts to operate.
4. While maintaining hydraulic oil temperature at
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 Distance
5. Repeat the measurement three times. Calculate
the average values.
10 m (33 ft)
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. Extra Length for Acceleration
3 to 5 m (9.8 to 16 ft)
T324-06-03-003
Remedy:
T4-4-2
TRAVEL PARKING BRAKE DRIFT
Summary:
Measure the travel parking brake drift on a specified
angle slope. 2m
(6.5 ft)
Preparation:
1. The test slope shall be smooth with a gradient of
20 % (11.31 q).
60q
2. Put a mark on the travel reduction gear cover.
3. Use the basic boom with the hook. Set the boom
angle to 60 q. (Or dismount the front attachment 20%
and counterweight.)
T2BC-04-04-004
4. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF).
Position where the machine

Measurement: stops.
Measure in both fast and slow travel speed modes. comes to a stop.
Position when the travel levers
• Track movement (sprocket rotation) until the are in neutral.
parking brake is applied. Movement
1. Climb the slope and place the travel levers in (Rotation Angle)
Mark
neutral.
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:

T324-06-03-005
2 3 1
T4-4-3
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
2. Place the machine on a level and solid ground ft)
with ample space for swinging. Do not test on a
slope.
angle to 60q. (Or dismount the front attachment
and counterweight.)
60q
oil to the measured hydraulic circuit for two
munutes or longer.
T2BC-04-04-003

Measurement: Accelerator Grip
1. Turn the slewing brake switch ON.
Slewing Brake
2. Run the engine at the maximum speed by using Switch
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:

T2BC-04-04-014
Remedy:
Refer to TROUBLESHOOTING in T5-4.
T4-4-4
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
60q
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. T2BC-04-04-006
4. Position the upperstructure in the same direction Position A

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
Needle Point
ground. Use the basic boom with the hook. Set
the boom angle to 60q. Apply a maximum lifting
load (100 %) to the hook.
7. Maintain the hydraulic oil temperature at 50r5 qC Detailed Position A
T324-06-03-013
(122r41 qF).
Measurement of (h1)
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 60q
Evaluation:
Refer to T4-2 STANDARD SPECIFICATIONS.
T2BC-04-04-006

Measurement of (h2)
60q

T2BC-04-04-007
T4-4-5
HOIST / LOWER SPEEDS (FRONT / REAR
DRUMS) (STD. LEVER)

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 60q. Lower the hook until it
comes close to the ground surface.
3. After raising the hydraulic oil temperature to the
range of 50r5 qC (122r41 qF) 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
60q
functions at the specified position.
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 T2BC-04-04-008
stroke.

Measurement:
Front Drum L Rear Drum
1. Turn the low speed lock switch LOCK. ever Lever x Fast Speed
2. Run the engine at the maximum speed by using Lowering

x Slow Speed
Neutral
x
3. Operate the hoist lever (front and rear drum Position
lever) corresponding to the drum to be x Slow Speed Hoisting
measured.
x Fast Speed
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. Slow Speed M25N-04-008
Lock Switch
6. Release the low speed lock switch. Repeat steps
2 to 5 in order to measure.
Evaluation:

T2BC-04-04-010
T4-4-6
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.
4

T25N-03-03-024
Adjustment Item Adjustment Procedure Remarks

1. Swash angle set pressure Loosen lock nut (1) and turn ad- 1) Other control characteristics are
justing screw (2). One turn of ad- not influenced.
Flow Rate
justing screw (2) changes the pres- 2) Securely retighten lock nut (1)
sure as follows. after adjustment.
Front/rear drums:
530 kPa (5.4 kgf/cm2, 77 psi)
3rd drum (optional):
250 kPa (2.5 kgf/cm2, 36 psi)
Pilot Pressure
: 13 mm
: 16 Nm (1.6 kgfm, 12 lbfft)
2. Power set pressure Loosen lock nut (4) and turn ad- 1) Other control characteristics are
justing screw (3). not influenced.
Pressure One turn of adjusting screw (3) 2) Securely retighten lock nut (4)
changes the pressure as follow. after adjustment.
21.5 MPa (219 kgf/cm2, 3130 psi)
: 13 mm
: 16 Nm (1.6 kgfm, 12 lbfft)
Torque
T4-4-7
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.
2m
(6.5 ft)
Preparation:
1. Use the basic boom with the hook. (Or dismount
the front attachment and counterweight.)
delivering hydraulic oil to the measured hydraulic 60q
3. Check that the boom derricking drum brake
functions properly.
4. Check that the derricking limiter functions T2BC-04-04-003
properly.

Measurement:
1. Run the engine at the maximum speed by using

Boom
2. Operate the boom derricking lever. Accelerator Derricking
Grip Lever
3. 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:
Remedy:

T2BC-04-04-015

T4-4-8
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 50r5 qC (122r41 qF)
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
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:
two minutes or longer while making the jack-up
cylinder operation at hydraulic oil temperature of
50r5 qC (122r41 qF).
2. Carry out measurement after extending jack-up
cylinder fully.
Measurement:
Make measurement at each measuring point.
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- T25N-04-04-004
Jack-up Cylinder
Evaluation:
T4-4-10
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:
angle to 60q. (The machine without front attach-
ment and counterweight is acceptable.)
two minutes or longer while making retract opera-
tion at hydraulic oil temperature of 50r5 qC
(122r41 qF).
3. Place the wooden blocks under the cylinder
tubes of retraction cylinders to be measured.
IMPORTANT: Place the wooden blocks under the

60q
cylinder tube in order not to wind
the retract cylinder.
4. Pull out the pin from the rod side of retraction cyl-
inder to be measured. (Do not remove the pin T2BC-04-04-005
from the not-measured side of retract cylinder.)

Measurement:
Measure one side for each.
using an accelerator grip.
2. Turn the retract switch to the EXTEND position. Pin Cylinder Tube
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-
Evaluation:

T2BC-04-04-017

T4-4-11
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 1
the motor circuit.
2
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.
50±5 qC (122±41 qF), make measurement after

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 60q.
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 60q
drum flange. Measure for two minutes.
6. Restore number of rope reeving as it was. 0.5 m
(20 in)
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. T2BC-04-04-012

Remedy:


T4-4-12
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:
(122r41 qF).
Measurement:
1. Measure on each control lever.
2. Stop the engine.
3. Operate each lever full stroke to measure the
maximum operating force.
the average values.
Evaluation:
Measurement Position for Slewing Lever Measurement Position for Hoisting / Travel Lever
Hoisting
Lever
Slewing
Lever

Travel Lever
Measurement
Position

Measurement T2BC-04-04-019
Position
T2BC-04-04-018

T4-4-13
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:
(122r41 qF).
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.
the average values.
Evaluation:
Measurement Position for Slewing Lever Measurement Position for Hoisting / Travel Levers
Slewing Lever Hoisting

Lever
Measurement
Position

Measurement
Position
Travel Lever
Measurement
Position
Measurement
Position

T2BC-04-04-018 T2BC-04-04-019

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 4-Spool Solenoid
3. Install a pressure gauge port P1. Valve Unit㩷
4. Start the engine. Check for oil leaks at the
pressure gauge unit connector.
(122r41 qF).
Adapter 1
Measurement:
1. Run the engine at the maximum speed.
2. Measure the pilot pressure under no load
condition by using a pressure gauge.
the average values.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. Port P1㩷
T2BC-04-05-002
T4-5-1
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 Nm (0.8 kgfm, 5.8 lbfft)
4. Check the set pressure after adjustment.
Adjusting
Screw㩷 Lock Nut㩷
T2BC-04-05-003
T4-5-2
BRAKE CIRCUIT PRIMARY PILOT
PRESSURE 㩷
㩷
Preparations:
㩷
1. Stop the engine.
㩷
2. Install a pressure gauge to the coupler for
㩷
measurement in manifold (under the cab bed).
㩷
㩷
㩷
㩷
(122r41 qF).
㩷
Measurement:
2. Measure the pilot pressure under no load
condition by using a pressure gauge.
the average values.
Evaluation:
Under Cab Bed
Manifold㩷
Coupler for
Measurement㩷
Brake Unit㩷
T2BC-04-05-004
T4-5-3
Adjustment of Brake Circuit Primary Pilot 㩷
Pressure
Adjustment:
Adjust the set pressure of pilot relief valve in gate lock
valve by using a pressure gauge if necessary.

: 17 mm
: 8 mm
: 17 mm
: 10.8 Nm (1.1 kgfm, 8 lbfft)
Adjusting
Screw Pilot Relief Gate Lock
Valve㩷 Valve㩷
Lock Nut
T2BC-03-11-004
T4-5-4
REMOTE CONTROL VALVE SECONDARY 㩷
PILOT PRESSURE
Preparations:
1. Stop the engine. 2-3. Sewing Circuit
2. Install a pressure gauge unit to the circuit to be • Remove the plug from port 3 (G1/4) in the
measured. slewing remote control valve. Install a pressure
2-1. Front / Rear / Boom Derricking Drums Circuit gauge.
• Remove the plug from port 9 (G1/4) in the front : 6 mm
remote control valve, port 8 (G1/4) in the rear 3. Start the engine. Check for oil leaks at the
remote control valve and port 3 (G1/4) in the pressure gauge unit connector.
boom derricking remote control valve respectively. 4. Maintain the hydraulic oil temperature at 50r5 qC
Install a pressure gauge. (122r41 qF).
: 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
: 16r1.6 Nm (1.6r0.2 kgfm, 12r1.2 lbfft)
• Remove the hose and adapter from port 7 (G1/4)
in the third / fourth remote control valve. Install a
pressure gauge.
: 19 mm
Travel
Boom Front Third / Fourth Travel
Derricking㩷 Rear Drum㩷 Drum㩷 Drum㩷 (Left) (Right) Slewing㩷
Port 9㩷 Port 9㩷 Port 3㩷

Port 3
Port 7
T2BC-04-05-005
Port 8
Port 8
T4-5-5
Measurement:
1. In case of measurement in the front / rear and
Slewing
boom derricking circuits, engage the respective Brake Switch㩷 Lock Lever
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 Slewing

Lock Pedal㩷
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:
Remedy: T2BC-01-02-006
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.
T4-5-6
HIGH / LOW TRAVEL SPEED SELECTION
PRESSURE
Travel Fast /
Preparations: Slow Speed
Control Hose
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
(122r41 qF).
Measurement:
Elbow
1. Measure the pressures by using a pressure
gauge while the machine is traveling at both slow
T2BC-04-05-007
and fast speeds.
2. Repeat the measurement three times. Calculate
the average value. NOTE: The illustration shows the left travel.
Evaluation:
Pressure Gauge㩷
Remedy:
check the primary pilot pressure. When the primary
pilot pressure is normal, the solenoid valve or
electrical system may be faulty.
Nipple 7/16-20UNF㩷
Adapter㩷
7/16-20 UNF
(Hose)
T324-06-04-025
T4-5-7
SLEWING BRAKE RELEASE PRESSURE
Preparations:
1. Stop the engine.
2. Remove the slewing brake release hose from Slewing Motor
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
pressure gauge unit connector. Tee㩷
(122r41 qF).
Measurement: Slewing Brake

1. With the slewing brake switch turned to both the Release Hose T25N-04-05-009
ON and OFF positions, measure the slewing

Pressure
brake release pilot pressure. Gauge㩷
the average values.
Evaluation:
Remedy:
Nipple 9/16-18UNF㩷
check the primary pilot pressure. When the primary
pilot pressure is normal, the solenoid valve or
electrical system may be faulty.
Adapter㩷
9/16-18 UNF
(Hose)
T324-06-04-025
T4-5-8
MAIN RELIEF VALVE PRESSURE
Preparations:
1. Stop the engine.
2. Install a pressure gauge to the pressure check Pump 2㩷 Pump 1㩷
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. T2BC-04-05-006
Port a2㩷 Port a1㩷
4. Start the engine. Check for oil leaks at the pipe
connection part.
(122r41 qF).
Pipe for Forward
Travel㩷
Measurement: Pipe for Reverse
Travel㩷
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.
the average values. Travel Motor
T2BC-04-05-007
NOTE: The illustration shows the right travel.
T4-5-9
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. Main Relief Valve㩷
Remedy:
Adjustment:
Check the pressure gauge and adjust the set
pressure of main relief valve if necessary.

: 22 mm
: 6 mm
3. Tighten lock nut (3)
: 22 mm
: 16.7 to 19.6 Nm
Front Control Valve㩷 T25N-03-05-030
(1.7 to 2.0 kgfm, 12 to 14 lbfft)
Main Relief
Valve㩷
Lock Nut㩷
Adjusting
Screw㩷
Pressure
Pressure
Decrease㩷
Increase㩷
W107-02-05-129
Rear Control Valve㩷 T2BC-03-02-004

Lock Nut㩷
Adjusting
Screw㩷

Main Relief Valve㩷 T326-06-04-002
T4-5-10
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. Port a4㩷
(122r41 qF).
Measurement:
1. Turn the slewing lock pedal in the LOCK position
and lock the slewing function. Port a4
3. Relieve the oil pressure by slowly pushing or
T2BC-04-05-006
pulling the slewing control lever. Read the
pressure at this time. Slewing Pump
4. Repeat the measurement three times in each
direction. Calculate the average values.
Evaluation:
Slewing Slewing Lock

Lever㩷 Pedal㩷
T2BC-01-02-006
T4-5-11
Adjustment:
pressure of main relief valve if necessary.

: 19 mm
: 6 mm
3. Tighten lock nut (3)
: 19 mm
: 31.4 Nm (3.2 kgfm, 23 lbfft)
Main Relief Valve

T25N-01-02-021
Adjusting Lock Nut㩷

Screw
T326-06-04-002
Lock Nut㩷
Adjusting
Screw㩷
Pressure Pressure
Increase Decrease㩷
W107-02-05-129
T4-5-12
Preparations:
1. Stop the engine.
2. Install a pressure gauge to pressure check port
P’ in the 4-spool control valve.
(122r41 qF).
Measurement:
2. Operate and relieve the retract cylinder. Read the
pressure at this time.
T2BC-04-05-008
Port P’㩷
㩷
T4-5-13
Evaluation:
Adjustment:
pressure of relief valve if necessary.

: 13 mm
: 6 mm
: 6.9 to 8.8 Nm
(0.7 to 0.9 kgfm, 5 to 6 lbfft)
T2BC-04-05-008
Relief Valve㩷㩷
Lock Nut㩷
Adjusting
Screw㩷
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-14
Lower Control Valve (Optional)
Preparations:
1. Stop the engine. Pressure
Check Port㩷 Relief Valve
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.
(122r41 qF). T2BC-04-05-009
Measurement:
2. Relieve the jack-up cylinder by operating the
control lever to RETRACT. Read the pressure at
this time.
Evaluation:
Adjustment:
pressure of relief valve if necessary.
1. Remove the cap from the relief valve.

3. Install the cap.
Adjusting
4. Check the set pressure after adjustment. Screw㩷 Cap㩷
Relief Valve㩷
Section A
T2BC-04-05-010
T4-5-15
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
MAIN/SLEWING PUMP FLOW RATE
x P-Q Control (Torque Control)

Summary:
Main (pump 1, pump 2) / slewing pump performance 7. Remove the vacuum pump. Loosen the air bleed
is checked by measuring the pump flow rate by using plug on the top of pump casing. Bleed air from
a hydraulic tester installed at the main (pump 1, pump the pump casing until oil only comes out.
2) / slewing pump delivery port to be measured. Use 8. Fully open the loading valve of portable hydraulic
the moment limiter and a pressure gauge at the same tester.
time. 9. Start the engine. Check for oil leaks at the
IMPORTANT: This measurement procedure is a
simple method. The measured data Measurement:
will be lower by approx. 5% than the 1. Maintain the hydraulic oil temperature at 50r5 qC
accurately measured value. In order (122r41 qF).
to measure accurately, disconnect 2. Measure the maximum and minimum flow rates
the return circuit from the control under no load.
valve and connect it to the hydraulic 3. Select each switch position as follows:
oil tank. Accelerator Grip Accelerator Lock Switch
Fast Idle Slow Idle ON
Preparations:
1. Stop the engine. Push the air bleed valve in 4. Slowly close the loading valve of hydraulic tester.
hydraulic oil tank and bleed air. Install a vacuum Measure the flow rates and engine speeds at
pump to the oil filler port. each pressure point at the I=800 mA side in the
NOTE: Operate the vacuum pump with the pump P-Q curve. (Refer to T4-2.)
flow rate test line connected. 5. Repeat the measurements three times. Calculate
2. Remove the delivery hose from the control valve the average values.
side of pump to be measured.
Air Bleed Plug
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.
T2BC-04-05-006
Outlet for Slewing Outlet for Pump 2 Outlet for Pump 1

Pump Pressure㩷 Pressure㩷 Pressure㩷
T4-5-17
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following Refer to STANDARD SPECIFICATIONS in T4-2.
formulas:
Qc = NsuQ/Ne
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Pump Speed: 2000 min-1
Ne : Measured Engine Speed: Moment Limiter
Pump㩷 Portable
Hydraulic Tester Control Valve㩷
T2BC-04-05-012
Delivery Hose㩷 Loading Valve Hydraulic

Hose for Test
㩷
Pump 1㩷 Pump 2
Slewing Pump㩷
Power Increase
Solenoid Valve㩷
Swash Angle Proportional
Solenoid Valve㩷
T2BC-04-05-011
Swash Angle
Solenoid Valve㩷
T4-5-18
x Pilot Characteristics (Swash Angle Proportional
Solenoid Valve)
Summary:
Main pump (pump 1, pump 2) performance is checked 6. Remove the connector from displacement angle
by measuring the pump flow rate by using a hydraulic proportional solenoid valve.
tester installed at the main (pump 1, pump 2) pump 7. Remove the hose for power increase solenoid
delivery port to be measured. Use the moment limiter valve.
and a pressure gauge at the same time. 8. Install a pressure gauge to the hose at secondary
As the maximum swash angle is fixed, the slewing pressure side in 4-spool solenoid valve.
pump need not be measured. 9. Remove the vacuum pump. Loosen the air bleed
plug on the top of pump casing. Bleed air from
IMPORTANT: This measurement procedure is a the pump casing until oil only comes out.
simple method. The measured data 10. Fully open the loading valve of hydraulic tester.
will be lower by approx. 5% than the 11. Start the engine. Check for oil leaks at the pipe
accurately measured value. In order connection part.
to measure accurately, disconnect
the return circuit from the control Measurement:
valve and connect it to the hydraulic 1. Maintain the hydraulic oil temperature at 50r5 qC
oil tank. (122r41 qF).
2. The pump flow rate in response to the external
Preparations: command pilot pressure is measured.
1. Check pilot circuit primary pilot pressure first. 3. Select each switch position as follows:
Adjust pilot circuit primary pilot pressure if Accelerator Grip Accelerator Lock Switch
necessary. Fast Idle ON
(Refer to “Pilot Circuit Primary Pilot Pressure2” in 4. Adjust the set pressure of 4-spool solenoid valve
this section.) to each pressure point specified along the main /
2. Referring to steps 1 to 4 on page T4-5-18, slewing pump P-Q curve. (Pilot Characteristics)
connect a hydraulic tester to the pump to be (Refer to T4-2-5, 7)
measured. Measure the flow rates and engine speeds at the
3. Remove the hose from port Pr1 in the swash pressure points specified in the P-Q curve.
angle proportional solenoid valve. 5. Repeat the measurements three times. Calculate
: 19 mm, 17 mm the average values.
4. Remove hose (7/16-20 UNF) from port Pi in the
pump to be measured.
Pump 2 Pump 1
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
Air Bleed Plug T2BC-04-05-013
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.
T4-5-19
Connection of Portable Hydraulic Tester
Pump㩷 Portable Hydraulic

Tester㩷 Control Valve㩷
T2BC-04-05-012
Delivery Hose㩷 Loading Hydraulic

Valve㩷 Hose for Test
Connection of Pressure Gauge 4-Spool Solenoid

Valve Unit㩷
Pressure Gauge㩷
Pilot Pump㩷
To Main Pump㩷
T2BC-04-05-017
Tee
Connecting Port
Swash Angle Proportional
Port Pi1㩷 Port Pr1 Solenoid Valve㩷
T2BC-04-05-014
Port Pi2㩷 Hose for Power
Increase㩷
T4-5-20
Evaluation:
1. Convert the measured flow rates to those at the
specified pump speed using the following
formulas:
Qc = NsuQ/Ne
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Pump Speed:2000 min-1
Ne : Measured Engine Speed: Moment Limiter
2. Standard Flow Rate

T4-5-21
REGULATOR ADJUSTMENT (MAIN PUMP)
x Minimum and Maximum Flow Rate Adjustment
This regulator can adjust minimum and maximum flow

rates by using adjusting screws (1) and (2) at each
main pump body.

3 4 2 4 3
1 1
Main Pump 1㩷 Main Pump 2㩷 T1F3-03-01-003
1- Adjusting Screw (For 2- Adjusting Screw (For 3- Lock Nut (For Minimum 4- Lock Nut (For Maximum
Minimum Flow)㩷 Maximum Flow)㩷 Flow)㩷 Flow)㩷

1. Minimum Flow Rate Loosen lock nut (3) and turn • Other control characteristics remain
Q adjusting screw (1). unchanged. Check that the required
Rotating adjusting screw (1) 1/4 power is increased at maximum
a turn clockwise increases the delivery pressure if tightened
minimum pump flow rate by 5.0 excessively.
L/min. (305 in3/min). • Securely retighten lock nut (3) after
: 24 mm adjustment.
: 130 Nm (13.3 kgfm, 96
lbfft)
I
2. Maximum Flow Rate Loosen lock nut (4) and turn • Other control characteristics remain
adjusting screw (2). unchanged, except that only
Q
Rotating adjusting screw (2) 1/4 maximum oil rate varies.
a turn clockwise decreases the • Securely retighten lock nut (4) after
maximum pump flow rate by 6.2 adjustment.
L/min. (378 in3/min).
㧦 30 mm
㧦 240 Nm (24.5 kgfm,
177 lbfft)
T4-5-22
x 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
5
10

T1F3-03-01-008

1. Outer Spring Adjustment Loosen lock nut (7) and turn • When adjusting screw (5) is
adjusting screw (5). turned, inner spring (8) set-force
Q
varies. Therefore, when adjusting
Rotating adjusting screw (5) 1/4 a screw (5) is turned clockwise, turn
turn clockwise: adjusting screw (6) 2.17 times
• Compensating: turns of adjusting screw (5)
+ 1.75 Mpa (17.8 kgf/cm2, 254 counterclockwise.
psi) • Securely retighten lock nut (7) and
• Torque: + 84.3 Nm (8.6 kgfm, 62 Lock nut (10) after the adjustment.
lbfft)
Pd : 46 mm : Lock Nut (7)
P1+P2
: 160 Nm (16.5 kgfm, 118
lbfft)
2. Inner Spring Adjustment Loosen lock nut (10) and turn • Securely retighten lock nut (10)
adjusting screw (6). after the adjustment.
Q Rotating adjusting screw (6) 1/4 a

turn clockwise:
• Pump flow rate: + 10.2 L/min.
(622 in3/min).
• Torque: + 56.9 Nm (5.8 kgfm, 42
lbfft)
: 13 mm : Lock Nut (10)
: 16 Nm (1.6 kgfm, 12 lbfft)
P1+P2 Pd
T4-5-23
x Pilot Pressure Characteristics
11
12

T25N-03-01-011

Pilot Pressure Characteristics Loosen lock nut (11) and turn • Securely retighten lock nut (11)
adjusting screw (12). after the adjustment.
Q
Rotating adjusting screw (12) 1/4 a
turn clockwise:
• Pump flow rate: 16.2 L/min.
(988 in3/min).
• Flow rate control starting
pressure: + 150 kPa (1.5 kgf/cm2,
21 psi)
Pi : 13 mm : Luck Nut (11)
: 16 Nm (1.6 kgfm, 12 lbfft)
T4-5-24
REGULATOR ADJUSTMENT
(SLEWING PUMP)
x Maximum Flow Rate Adjustment
This regulator can adjust maximum flow rate by
using adjusting screws (1) and (2) at slewing pump
body.
1

T25N-03-01-005
1 - Lock Nut 2- Adjusting Screw

(For Maximum Flow) (For Maximum Flow)

Maximum Flow Rate Loosen lock nut (1) and turn • Other control characteristics
adjusting screw (2). remain unchanged, except that
Q
Rotating adjusting screw (2) 1/4 a only maximum oil rate varies.
turn clockwise decreases the • Securely retighten lock nut (4)
maximum pump flow rate by 3.2 after the adjustment.
L/min. (195 in3/min).
: 24 mm
: 130 Nm (13.3 kgfm, 96
lbfft)
Pi
T4-5-25
SLEWING MOTOR DRAINAGE
Summary:
Drain Hose
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: T25N-04-05-009
1. Place the machine or a level and solid ground

with ample space for slewing. Do not measure on
a slope.
(122r41 qF). 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
T4-5-26
Measurement:
Amount of Oil Drained While Relieving Slewing.
1. Attach the basic boom with the boom angle set at

60q. (Or dismount the front attachment and
counterweight.)
2. Turn the slewing lock lever placed to the LOCK 2m
position and turn the slewing brake switch in ON. (6.5 ft)
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. 60q
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 T2BC-04-04-003
seconds.

Evaluation:
x 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:
60
'Q = uq
t
Where:
'Q: Drain Oil Amount (L/min)
t: Measuring Time (sec)
q: Measured Drain Oil Amount (L)
T107-06-05-008
T4-5-27
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 Drain Hose㩷 Travel Motor
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:
T2BC-04-05-007
(122r41 qF). Rotate the travel motor and warm
the inside of motor.
2. Stop the engine. Remove drain hose (1) from the NOTE: The illustration shows the left travel.
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
T4-5-28
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.

60q. (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. 2m
(6.5 ft)
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. 60q㩷
Evaluation:
* Conversion of the Measured Values
Receive the drain oil with a measuring vessel
such as a measuring cylinder or cup. Obtain the
T2BC-04-04-003
converted drain oil amount using the formula
㩷
below:

'Q = uq
V
'Q : Drain Oil Amount (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil Amount (L)
T4-5-29
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. Derricking Drum Boom Derricking
Lock cylinder㩷 Port A㩷 Drain Hose㩷 Motor㩷
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
T2BC-04-05-016
temperature at 50r5 qC (122r41 qF).
2. Stop the engine. Remove the drain hose from the
boom derricking motor at the return oil port to the T2BC-04-05-015
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).
T4-5-30
Measurement:
60q.
(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.
the average values.
5. Take the measurement for more than 45 2m
seconds. (6.5 ft)
Evaluation:
* Conversion of the Measured Values
Receive the drain oil with a measuring vessel
such as a measuring cylinder or cup. Obtain the
60q㩷
converted drain oil amount using the formula
below:

'Q = uq
V T2BC-04-04-003
'Q : Drain Oil Amount (L/min)

t : Measuring Time (sec)
q : Measured Drain Oil Amount (L)
T4-5-31
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 1, 2, 4
pump is replaced
When the engine control cable or 1
governor motor is replaced
When engine high idle speed de-
creases
When the pump or pump power 3
increase solenoid valve is replaced
MC2/A adjustment falls into four below.
Adjustment items
1. 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
HIGH IDLE CALIBRATION
Monitor Panel
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. 1
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).

T2BC-04-06-001

Right Control Panel

T2BC-04-06-003

Side Overhead Panel

T2BC-04-06-002
4

T4-6-2
Calibration Starting
1. Turn front drum auto stop cancellation switch (5) Monitor Panel
to ON position.
NOTE: Now, MC2/A turns the governor motor in
forward direction. (Refer to Section "Control
System".)
1
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: 2
Motor rotation control range setting
(145 to 356 counts (12.83q to 31.5q)
IMPORTANT: When turning the key switch to OFF

position, record the completed cali-
T2BC-04-06-001
bration to EEPROM (MC2/A) for five
seconds. Do not operate key switch
(2) during this time. Left Control Panel 5

3. Turn key switch (2) to OFF position and check if
five seconds or longer pass.

T2BC-04-06-004

T4-6-3
RACK ZERO CALIBRATION
Monitor Panel
Adjustment:

preset position (SET) and turn key switch (2) to 1
ON position under this condition.

sition (OFF).

T2BC-04-06-001

Right Contorl Panel

T2BC-04-06-003

Side Overhead Panel 4

T2BC-04-06-002

T4-6-4
1. Turn rear drum auto stop cancellation switch (6) to
ON position. Monitor Panel
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 1

blinks other than every 0.5 second, turn rear drum
auto stop cancellation switch (6) to OFF position.
Pilot pressure indicator (1): ON
Pilot pressure indicator (1): Blinking every
0.1 second

• Engine : Stop
• Rack sensory output : Available
• Rack sensor input : Rack sensory output
normal range (0.25 to 4.75 V) 2
• Rack sensor input voltage : Rack sensor zero
point setting range (1.5 to 4.5 V)
• Governor motor initial position setting:
Normal completion
T2BC-04-06-001
IMPORTANT: When turning key switch (2) to OFF

position, record the completed cali- Left Control Panel
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


T2BC-04-06-004
6 5
T4-6-5
POWER INCREASE PRESSURE CALI-
BRATION
Preparation:
1. Install a pressure gauge (5 Mpa) to the pressure
check port.
Adjustment:
rear / boom derricking drums to ON position. T25N-04-06-001
2. Turn accelerator lock switch (3) to accelerator Pressure Check Power Increase
Port Solenoid Valve
Monitor Panel

1
sition (OFF).
Side Overhead Panel

4 T2BC-04-06-001

Right Control Panel

T2BC-04-06-002

T2BC-04-06-003

T4-6-6
1. Start the engine. IMPORTANT: When turning the key switch (2) to
2. Turn front drum auto stop cancellation switch (5) OFF position, record the completed
and rear drum auto stop cancellation switch (6) to calibration to EEPROM (MC2/A) for
ON position. five seconds. Do not operate key
NOTE: Now, MC2/A blinks pilot pressure indicator switch (2) during this time.
(1) at monitor panel. (Refer to Section
"Control System".) 6. Turn the key switch (2) to OFF position and check
if five seconds or longer passes.
3. If pilot pressure indicator (1) blinks other than 7. Remove the pressure gauge.
every 0.5 second, turn front / rear drum auto stop
cancellation switches (5, 6) to OFF position. Monitor Panel
preset position (SET) and turn to accelerator
unlock position (OFF).
NOTE: Now, the power increase pressure de- 1
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).
0.1 second
2
• Power increase electric current offset d Offset
adjusting range (150 mA)
[Power increase electric current offset = Output
current - Adjustment point power increase electric T2BC-04-06-001
current (608 mA)] Right Control Panel
• Output current d Upper limit electric current (800
mA)
Left Control Panel 6 5 3
T2BC-04-06-003
T2BC-04-06-004
T4-6-7
FULL RACK CALIBRATION
Preparation:
1. Turn slewing lock pedal to LOCK position and Monitor Panel
apply the slewing brake.
2. Disconnect the connector from front motor brake
release solenoid valve (8).
1
Adjustment:

sition (OFF).
2

Left Control Panel
7

T2BC-04-06-001
Right Control Panel

3
T2BC-04-06-004

Front Motor
8

T2BC-04-06-003

Side Overhead Panel
4

T2BC-04-06-002

T2BC-04-06-005
T4-6-8
Calibration Stating
1. Start the engine. IMPORTANT: When turning key switch (2) to OFF
2. Turn boom derricking drum auto stop cancellation position, record the completed cali-
switch (7) to ON position. bration to EEPROM (MC2/A) for five
NOTE: Now, MC2/A blink pilot pressure indicator seconds. Do not operate key switch
(1) at monitor panel. (Refer to Control Sys- (2) during this time.
tem / SYSTEM) 8. Turn key switch (2) to OFF position and check if
3. If pilot pressure indicator (1) blinks other than 9. Connect the connector to front motor brake re-
every 0.5 second, turn boom derricking drum auto lease solenoid valve (8).
stop cancellation switch (7) to OFF position.
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.
0.1 second.
Normal Completion condition:

x Engine speed d Set speed (1950 min-1)
• Rack sensor input voltage t Rated rack point ad-
justment lower limit (2.803 V)
x Engine speed ! Set speed (1950 min-1)
• Rack sensor input voltage t Rated rack point
lower limit in full load (2.352 V)
• Maximum power increase
T4-6-9
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.
A
Adjustment:
Adjusting brake pedal position C
1. Tighten lock nut (1) so that dimension A becomes

specification.
Dimension A: 45r1 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-
B T25N-04-06-005
sure-reducing valve is pushed to its stroke end.
4. Confirm that floor plate (6) and height of pin (5)
Brake Pedal
(dimension C) are set to specification.
Dimension C: 80±2 mm (3.1±0.08 in) 5 6 1
5. If dimension C is different from specification, ad-
just as follows.
1-1. Loosen lock nut (7).
㧦17 mm
1-2. Set a spanner at width across flats (9) of rod (8)
and turn rod (8) in the adjusting direction.
㧦14 mm
1-3. When dimension C becomes specification,

loosen lock nut (7).
4 3 2
㧦17 mm
T25N-04-06-005
㧦19.5r2.0 Nm
(2.0r0.2 kgfm, 14.5±1.5 lbfft)
7 8
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.
9
8. Confirm that dimensions B and C meet specifica-
tion.
Dimension B: 27 to 28 mm (1.06 to 1.10 in)

Pressure-Reducing Valve
T25N-04-06-002
T4-6-10
9. Loosen lock nut (10) and tighten stopper bolt (11) Lock Pedal
sufficiently. 4 8
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) 14
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 13
lock with lock nut (10).
12 11 10 Pressure-reducing
valve
Adjusting pedal lock position T25N-04-06-006
13. 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

D T25N-04-06-006
T4-6-11
Intentionally

SECTION 5
TROUBLESHOOTING

—CONTENTS—
Group 1 Diagnosing Procedure Failure of Front Drum
Introduction ........................................... T5-1-1 Auto Stop Control System .................. T5-3-109
Diagnosing Procedure ........................... T5-1-2 Failure of Rear Drum
Power Supply Monitor ........................... T5-1-4 Auto Stop Control System .................. T5-3-114
Trobleshooting Monitor .......................... T5-1-6 Failure of Third Drum
Auto Stop Control System .................. T5-3-119
Group 2 Component Layout
Failure of FourthDrum Auto Stop
Main Components Layout ...................... T5-2-1
Control System (Optional) .................. T5-3-127
Electrical Components Layout ............... T5-2-4
Failure of Second Overhoist
Group 3 Troubleshooting A Auto Stop Control System .................. T5-3-134

Troubleshooting A Procedure ................ T5-3-1 Failure of Front and Rear Motor
Failure of MC2/A or MC2/B Battery and Speed Control System........................ T5-3-138
Sensor System Power Supply ............ T5-3-10 Failure of Front Drum Surge Pressure
Failure of Engine Controller System ...... T5-3-25 Reduction Control System.................. T5-3-143
Failure of Brake Control System ............ T5-3-32 Failure of Tower Jib Derricking 2-Speed Flow
Failure of Main Pump Delivery Flow Combining Limit Control System ........ T5-3-145
Rate Control System .......................... T5-3-62
Group 4 Troubleshooting B
Failure of Main Pump Power Increase
Troubleshooting B Procedure ................ T5-4-1
Control System .................................. T5-3-65
Troubleshooting List............................... T5-4-2
Failure of Slewing
Engine System Troubleshooting ............ T5-4-3
Alarm Control System ........................ T5-3-68
Power Supply System Failure ................ T5-4-6
Failure of Rotation
Actuator Troubleshooting ....................... T5-4-19
Sensing Control System..................... T5-3-72
Hoist Drum Troubleshooting .................. T5-4-20
Failure of Engine Start
Boom Derricking Drum Troubleshooting T5-4-28
Interlock Control System .................... T5-3-82
Slewing System Troubleshooting ........... T5-4-30
Failure of Pilot Pressure Drop Warning
Travel System Troubleshooting.............. T5-4-33
Lamp Control System......................... T5-3-88
Other Troubleshooting ........................... T5-4-36
Failure of Monitor Cutoff Pressure
Control System .................................. T5-3-90
Failure of Derricking Drum
Auto Stop Control System .................. T5-3-92
2BCT-5-1
Group 5 Troubleshooting C Fault Code W47 ..................................... T5-6-27
Trobleshooting C Procedure .................. T5-5-1 Fault Code W48 ..................................... T5-6-30
Malfunction of Fault Code W49 ..................................... T5-6-31
Coolant Temperature Gauge .............. T5-5-2 Fault Code W90 ..................................... T5-6-33
Malfunction of Fuel Gauge..................... T5-5-4 Fault Code W91 ..................................... T5-6-34
Malfunction of Fault Code WA1..................................... T5-6-35
Engine Oil Pressure Indicator ............ T5-5-6 Fault Code WB2 .................................... T5-6-36
Malfunction of Coolant Level Indicator... T5-5-7 Fault Code WB3 .................................... T5-6-37
Malfunction of Engine Oil Filter
Restriction Indicator ........................... T5-5-9
Group 7 Troubleshooting E
Trobleshooting E Procedure .................. T5-7-1
Malfunction of Air Filter
How to Read Fault Code in
Restriction Indicator ........................... T5-5-11
ECU Engine Troubleshooting ............. T5-7-2
Malfunction of Overheat Indicator .......... T5-5-13
Malfunction of Controller Group 8 Troubleshooting F
Failure Indicator ................................. T5-5-15 Information Display Unit (IDU)
Malfunction of Preheat Indicator ............ T5-5-17 Technical Manual ............................... T5-8-1
Malfunction of Alternator Indicator ......... T5-5-18
Group 9 Electrical System Inspection
Malfunction of Brake Unapplied Indicator T5-5-20
Precautions for Inspection
Malfunction of Pilot Pressure
and Maintenance................................ T5-9-1
Drop Indicator .................................... T5-5-21
Instruction for Disconnecting Connectors T5-9-3
Malfunction of Hour Meter ..................... T5-5-22
Battery Voltage Check ........................... T5-9-4
Fusible Link Inspection .......................... T5-9-5
Group 6 Troubleshooting D
Fuse Inspection ..................................... T5-9-6
Troubleshooting D Procedure ................ T5-6-1
How to Check Alternator ........................ T5-9-9
Fault Code Table ................................... T5-6-2
Voltage Check........................................ T5-9-10
Fault Code E20, E22 ............................. T5-6-4
Check by False Signal ........................... T5-9-19
Fault Code E21, E26 ............................. T5-6-5
Continuity Check.................................... T5-9-20
Fault Code E30 ..................................... T5-6-7
Fault Code E31 ..................................... T5-6-9
Fault Code E40 ..................................... T5-6-12
Fault Code E43 ..................................... T5-6-12
Fault Code E44 ..................................... T5-6-13
Fault Code E45 ..................................... T5-6-14
Fault Code E50 (Crane) ........................ T5-6-16
Fault Code E50 (Tower)......................... T-5-6-18
Fault Code E51 ..................................... T5-6-20
Fault Code E52 ..................................... T5-6-22
2BCT-5-2
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
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 operator

Before inspecting, get the full story of
malfunctions from your star witness --- the T107-07-01-001
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 machine

Before starting the troubleshooting procedure,
cheek the machine’s daily maintenance points, T107-07-01-002
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.
T107-07-01-003
Always check fuses using a tester.

T5-1-2
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 T324-07-01-002
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 causes
Before 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.

T324-07-01-003

T5-1-3
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.

Maintenance Key Switch
T25N-05-01-001
Boom suspend
Indication
1. Turn ON the maintenance key switch, press
1-rope
key on the ML window and indicate the Jib
suspend reeving
maintenance menu.
4-rope
reeving

Overheat

Hyd. oil temp.

Brake oil temp.

Suspend selection Menu

2. Select "Monitor" by pressing or key and
press key in order to indicate the monitor Maintenance Menu Load Factor
menu. 1. Inspection Menu
2. Adjustment Menu
3. Monitor
4. Version Indication Menu
5. Record Menu
6. Spec Setting Menu
7. Service Manual
Selection Cancellation Determination

3. Select "Power Supply Monitor" in the monitor
Monitor Menu Load Factor
menu by using or key and press
key. 1. Power Supply Monitor
2. Key Check
3. IDU Monitor
4. MC2/A Monitor
5. MC2/B Monitor

T5-1-4
Power Supply Monitor
Description
MC2/A Input / OutputMonitor
MC2/A MC2/B IDU 1/1

MAIN_B NORMAL MAIN_B NORMAL MAIN_B xx. xxV
5V LOW ER 5V LOW ER 5V x. xxV
24V_1 HI ER 24V_1 HI ER 10V xx. xxV
24V_2 SHORT 24V_2 SHORT 24V xx. xxV
24V_3 SHORT 24V_3 SHORT

χχ ω Page Selection Return
Item

Item Signal Name Description Explanation
MC2/A MAIN_B Main power supply NORMAL Normal
5V Analog sensor power supply LOW ER Lower limit error
24V_1 For each switch input HI ER Upper limit error
24V_2 For throttle control switch SHORT Short circuit
24V_3 For emergency operation switch xx. xxV A/D voltage
MC2/B MAIN_B Main power supply conversion
5V Analog sensor power supply Communication error
For three-winding layer detector
24V_1
(No connection)
24V_2 For overhoist switch on machine
24V_3 For overhoist switch on attachment
IDU MAIN_B Main power supply
5V Angle detector power supply
10V Load detector power supply
Power supply for shift switch
24V
(No connection)
T5-1-5
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.
Indication Maintenance Key Switch

1. Turn ON the maintenance key switch, push the T25N-05-01-001
key on the ML screen and indicate the
Boom suspend
maintenance menu.
Jib 1-rope
suspend reeving
4-rope
reeving
Overheat

2. Select "Monitor" by using or switch and Hyd. oil temp.
press key in order to indicate the monitor Brake oil temp.
menu. Suspend selection Menu

Maintenance Menu Load Factor
1. Inspection Menu
2. Adjustment Menu
3. Monitor
4. Version Indication Menu
5. Record Menu
6. Spec Setting Menu
7. Service Manual

3. Select the wanted item in the monitor Menu by Monitor Menu Load Factor
using or key and press key.
1. Power Supply Monitor

2. Key Check
3. IDU Monitor
4. MC2/A Monitor
5. MC2/B Monitor

T5-1-6
MC2/A Analog Inputs

Description

MC2/A Input / Output Monitor

MC2/A AI1 MC2/A AI2 MC2/A AI3 1/4
THROT. GRIP NORMAL DD HST PRS xMPa
x. SL RGT PRS x. xMPa
THROT. FOOT NORMAL DD LWR PRS LOW
ER SL LFT PRS LOW ER
RACK. P. HI ER FD HST PRS HI ER PILOT PRS NORMAL

THROL. M. P. NORMAL FD LWR PRS RSV ER FD BRK PRS LOW ER
xMPa
SL CTRL SP 2.50 V RD HST PRS x. RD BRK PRS HI ER
THRT. 3RD LOW ER RD LWR PRS LOW
ER 3D BRK PRS RSV ER
TRPGT. PRS HI ER 3D HST PRS
HI ER (AN_IN22) NORMAL
TRLFT. PRS RSV ER 3D LWR PRS RSV ER (AN_IN23) LOW ER

χ ω Page Selection Return

Item

Item Signal name Description Explanation
MC2/A THROT. GRIP Accelerator grip signal NORMAL Normal
AI1 THROT. FOOT Accelerator pedal signal LOW ER Lower limit error
RACK. P. Rack position signal HI ER Upper limit error
THROL. M. P. Governor motor potentio sensor signal RSV ER Spare
SL CTRL SP Slewing speed dial signal
(No connection) x. xV Normal (voltage)
THRT. 3RD Third drum acceleration LOW ER Lower limit error
TRRGT.PRS Right travel remote control pressure HI ER Upper limit error
TRLFT. PRS Left travel remote control pressure RSV ER Spare
MC2/A DD HST PRS Derricking drum hoisting remote
AI2 control pressure x. xMPa Operating pressure
DD LWR PRS Derricking drum lowering remote LOW ER Lower limit error
control pressure HI ER Upper limit error
FD HST PRS Front drum hoisting remote control DBL ER Double errors
pressure
FD LWR PRS Front drum lowering remote control ****** Communication error
pressure
RD HST PRS Rear drum hoisting remote control
pressure
RD LWR PRS Rear drum lowering remote control NORMAL Normal operation OFF
pressure LOW ER Lower limit error
3D HST PRS Forrth drum hoisting remote control HI er Upper limit error
pressure
RSV ER Normal operation ON
3D LWR PRS Third / fourth lowering remote control
pressure
MC2/A SL RGT PRS Slewing (right) remote control pressure
AI3 SL 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
T5-1-7
MC2/A Digital Inputs

Description


MC2/A SWITCH MC2/A CAN1 MC2/A CAN2 2/4
FD FREE SW ON FD FREE MD BRAKE FD PLS CNT -xxxxx
RD FREE SW OFF RD FREE MD BRAKE RD PLS CNT -xxxxx
3D FREE SW ON 3D FREE MD FREE DD PLS STOP
ENG. START OFF RACK P. S.
x. xx V
x. xx V
THROT. FIX ON RACK P. STP OVERH2 SIG NORMAL
THROT. PRE OFF RACK P. FUL x. xx V ATTACHMENT SHORT
GATE LOCK ON INC. TQ. CUR -xxxmA SD. CAN. SW OFF

SL BRK SW OFF OFFSET CUR xxxxmA PMP. FIX. SW OFF


Item

MC2/A FD FREE SW Front drum free mode switch ON Open contact
SWITCH RD FREE SW Rear drum free mode switch OFF Closed contact
3D FREE SW Third / fourth drum free mode switch BRAKE Auto brake mode
ENG. START Engine start signal FREE Free mode
THROT. FIX Throttle lock switch x. xx V A/D voltage conversion
THROT. PRE Throttle preset switch -xxxmA Electric current offset
GATE LOCK Gate Lock Switch -xxxxx Drum pulse counter
SL BRK SW Slewing brake switch ROTATE Rotation
MC2/A CAN1 FD FREE MD Front drum free mode control STOP Stop
RD FREE MD Rear drum free mode control CANCEL Cancellation
3D FREE MD Third / fourth drum free mode NORMAL Normal
control SHORT Short circuit
RACK P. S. Rack position signal CRANE Crane
RACK P. STP Engine stop rack position TOWER Tower
RACK P. FUL Full rack position OPEN Open circuit
INC. TQ. CUR Power increase proportional ****** Communication error
solenoid valve
OFFSET CUR Power increase electric current
offset
MC2/A CAN2 FD PLS CNT Front drum pulse counter
RD PLS CNT Rear drum pulse counter
DD PLS Derricking drum rotation detection
BRK MD SW Brake mode switch
OVERH2 SIG Second overhoist solenoid valve
ATTACHMENT Wiring detection
SD. CAN. SW Slowdown cancellation switch (No
connection)
PMP. FIS. SW Maximum pump delivery lock switch
(No connection)
T5-1-8
MC2/A Digital Output

Description


MC2/A D01 MC2/A D02 MC2/A D03 3/4
M PMP CUR xxxxmA FD PLS SOL
NORMAL DD LCK REL NORMAL
INC. TQ CUR LOW ER RD PLS SOL
ERROR FM BRK REL ERROR
SL RGT CUR HI ER DD PLS SOL NORMAL RM BRK REL NORMAL
ERROR
SL LFT CUR RES ER SL PRS SOL 3M BRK REL ERROR
SL PMP CUR CANCEL CAL IB. CUR
NORMAL MT CUT OFF NORMAL
FD BRK REL xxxxmA ENG. INTLCK ERROR
RD BRK REL LOW ER 3D BRK LP NORMAL

3D BRK REL HI ER SL ALAM LP ERROR


Item

MC2/A M PMP CUR Main pump displacement angle xxxxmA Control current
D01 proportional solenoid valve LOW ER Lower limit error
INC. TQ CUR Power increase solenoid valve HI ER Upper limit error
SL RGT CUR Slewing multi (right) proportional solenoid RES ER Reset error
valve (No connection) CANCEL Feedback cancellation
SL LFT CUR Slewing multi (left) proportional solenoid
valve (No connection) NORMAL Normal
SL PMP Slewing pump swash angle proportional LOW ER Lower limit error
CUR solenoid valve (No connection) HI ER Upper limit error
FD BRK REL Front drum brake release solenoid valve RES ER Reset error
RD BRK REL Rear drum brake release solenoid valve RSV Feedback cancellation
3D BRK REL Fourth drum brake release solenoid valve
MC2/A FD PLS SOL Front drum rotation sensing solenoid NORMAL Calibration electric current
D02 RD PLS SOL Rear drum rotation sensing solenoid LOW ER Lower limit error
DD PLS SOL Derricking drum rotation sensing solenoid HI ER Upper limit error
SL PKS SOL Slewing remote control pressure RES ER Reset error
hydraulic source Solenoid (No
RSV Auxiliary
connection)
CAL IB. CUR Calibration electric current
NORMAL Normal
MC2/A DD LCK REL Derricking drum unlocking solenoid valve
ERROR Short circuit
D03 FM BRK REL Front motor brake release solenoid valve
****** Communication error
RM BRK
Rear motor brake release solenoid valve
REL
3M BRK REL Fourth motor brake release solenoid
valve
MT CUT OFF Motor cutoff relay
ENG.
Engine start interlock
INTLCK
3D BRK LP Third / fourth auto brake indicator
SL ALAM LP Slewing warning lamp relay
T5-1-9
ECU Status

Description


MC2/A_ECU1
4/4
RECEIVE NORMAL
TMR F. B. ERROR

RACK P. S. NORMAL

TIMING S. ERROR
TDC S. INVLD
OVER H. S. ERROR
TMR. C. V. NORMAL

Ĺ ĻPage Selection Return

Item

MC2/A_ECU1 RECEIVE ECU NORMAL Normal
TIMING S. Timing sensor

TDC S. TDC sensor
T5-1-10
MC2/B Analog Inputs

Description

MC2/B Input / Output Monitor

MC2/B AI1 MC2/B AI2 MC2/B DI 1/3

FD CTRL SP NORMAL TR RGT PRS x. xMPa FD ROPE ED R. END
RD CTRL SP LOW ER TR LET PRS x. xMPa RD ROPE ED ALLOFF
DD CTRL SP HI ER (AN_IN10) NORMAL 3D ROPE ED ALLON
(AN_IN3) RSV (AN_IN11) LOW ER (DAN_IN20) NORMAL

(AN_IN4) NORMAL (AN_IN12) HI ER (DAN_IN21) ERROR

(AN_IN5) LOW ER (AN_IN13) RSV (DAN_IN22) NORMAL
(AN_IN6) HI ER (DAN_IN23) ERROR

(AN_IN7) RSV


Item

MC2/B AI1 FD CTRL SP Front drum speed setting dial signal NORMAL Normal
(No connection) LOW ER Lower limit error
RD CTRL SP Rear drum speed setting dial signal HI ER Upper limit error
(No connection) RSV Spare
DD CTRL SP Derricking drum speed setting dial x. xMPa Normal (pressure)
signal (No connection) DBL ER Double errors
(AN_IN3) No connection R. END Extra hoisting
(AN_IN4) No connection ALLOFF Open circuit
(AN_IN5) No connection ALLON Shorted harnesses
(AN_IN6) No connection ****** Communication error
MC2/B AI2 TR RGT PRS Travel (right) remote control
pressure
TR LET PRS Travel (left) remote control pressure
MC2/B DI FD ROPE ED Front drum three-winding layer
detection (No connection))
RD ROPE ED Front drum three-winding layer
3D ROPE ED Front drum three-winding layer
(DAN_IN20) No connection
T5-1-11
MC2/B Digital Inputs

Description


MC2/B SWITCH1 MC2/B SWITCH2 MC2/B DI 2/3
DD REL SW NORMAL BM OVERH
NORMAL DD HST STP NORMAL
FD REL SW REL BT OVERH2 OVERH DD LWR STP STOP
RD REL SW NORMAL TW OVERH ALLOFF FD HST STP NORMAL

3D REL SW REL BT LOWER L ALLON FD LWR STP STOP

REL KEY SW NORMAL JB OVERH NORMAL RD HST STP NORMAL
OH2 REL SW REL JB OVERH2 OVERH RD LWR STP STOP
JB FOLD FOLD HK OVERH ALLOFF
3D HST STP NORMAL
ATTACHMENT CRANE SWL OVERH ALLON 3D LWR STP STOP


Item

MC2/B DD REL SW Derricking drum auto stop release NORMAL Auto stop
SWICH1 FD REL SW Front drum auto stop release REL Release operation
RD REL SW Rear drum auto stop release INHBIT Release prohibition
3D REL SW Third drum auto stop release
HM FIX SW Hoisting motor low speed lock ON Closed contact
OH2 REL SW Second overhoist restoration switch OFF Open contact
JB FOLD Jib folding
ATTACHMENT Wiring detection NORMAL Auto stop
MC2/B BM OVERH Boom overhoist REL Release operation
SWITCH2 BT OVERH2 Boom / tower second overhoist (No
connection) FOLD Jib folding
TW OVERH Tower overhoist UNFOLD Jib unfolding
BT LOWER L Boom / tower lower limit (No ALLOFF Open circuit
connection) ALLON Shorted harnesses
JB OVERH Jib overhoist
JB OVERH2 Jib second overhoist SHORT Short circuit
HK OVERH Hook overhoist CRANE Crane
SWL OVERH Tower jib backstop alignment TOWER Tower
MC2/B DI DD HST STP Derricking drum hoisting stop OPEN Open circuit
DD LWR STP Derricking drum lowering stop
FD HST STP Front drum hoisting stop NORMAL Normal
FD LWR STP Front drum lowering stop OVERH Overhoist
RD HST STP Rear drum hoisting stop ALLOFF Open circuit
RD LWR STP Rear drum lowering stop ALLON Shorted harnesses
3D HST STP Fourth drum hoisting stop solenoid LOWER Lower limit
valve
3D LWR STP Fourth drum lowering stop solenoid NORMAL Operation
valve STOP Stop

T5-1-12
MC2/B Digital Outputs

Description


MC2/B D01 MC2/B D02
3/3
DD HST CUR xxxxmA GREEM LMP
NORMAL
DD LWR CUR LOW ER YELLOW LMP
ERROR
FD HST CUR HI ER RED LMP NORMAL
ERROR
FD LWR CUR RES ER OVERH2 SOL
RD HST CUR CANCEL 3D HST SOL
NORMAL
RD LWR CUR xxxxmA 3D LWR SOL ERROR
FM CAP CUR LOW ER CALIB. CUR LOW ER

RM CAP CUR HI ER


Item

MC2/B DD HST CUR Derricking drum hoisting xxxxmA Control current
DD LWR CUR Derricking drum lowering HI ER Upper limit error
proportional solenoid valve RES ER Reset error
FD HST CUR Front drum hoisting proportional CANCEL Feedback cancellation
solenoid valve NORMAL Normal
FD LWR CUR Front drum lowering proportional ERROR Short circuit
solenoid valve
RD HST CUR Rear drum hoisting proportional NORMAL Calibration electric current
solenoid valve
LOW ER Lower limit error
RD LWR CUR Rear drum lowering proportional
HI ER Upper limit error
solenoid valve
RES ER Reset error
FM CAP CUR Front motor swash angle
RSV Auxiliary
proportional solenoid valve
RM CAP CUR Rear motor swash angle
proportional solenoid valve ****** Communication error
MC2/B GREEM LMP External indicator green (No
D02 connection)
YELLOW LMP External indicator yellow (No
connection)
RED LMP External indicator red (No
connection)
OVERH2 SOL Second overhoist solenoid valve
3D HST SOL Fourth drum hoisting solenoid
valve
3D LWR SOL Fourth drum lowering solenoid
valve
CALIB. CUR Calibration electric current

T5-1-13
IDU Analog Inputs

Description

IDU Input / Output Monitor

IDU AI1 IDU AI2 IDU AI3
1/3
JB ANGLE X.XXV (AN_IN0) X.XXV (AN_IN8) X.XXV
JB ANGLE2 X.XXV (AN_IN1) X.XXV (AN_IN9) X.XXV

BM ANGLE X.XXV (AN_IN2) X.XXV (AN_IN10) X.XXV
(AN_IN11)
BM LOAD X.XXV (AN_IN3) X.XXV X.XXV
JB LOAD X.XXV HYD THM X.XXV
JB ANGLE X.XXV FD BRK THM X.XXV
JB ANGLE2 X.XXV RD BRK THM X.XXV

BM ANGLE X.XXV 3D BRK THM X.XXV


Item

IDU AI1 JB ANGLE Jib angle sensor (S) (No connection) X.XX V A/D voltage conversion
JB ANGLE2 Jib angle (-) sensor (S) (No connection) ****** Communication error
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)
BM ANGLE Boom angle sensor (D)
IDU AI2 (AN_IN0) No connection
HYD THM Hydraulic oil temperature sensor
FD BRK THM Front brake temperature sensor
RD BRK THM Rear brake temperature sensor
3D BRK THM Third brake temperature sensor
IDU AI3 (AN_IN8) No connection
T5-1-14
IDU Digital Inputs

Description

IDU Input / OutputMonitor

IDU DI1 IDU DI2 IDU DI/PI
2/3
CLAMSHELL ON REAR ON OVERHEART ON
DRAGLINE OFF ADD CW1 OFF (PLS_IN1) OFF
JB CATCH CATCH ADD CW2 ON (PLS_IN2) OFF

BM OH LINE OFF DEC CW1 OFF (PLS_IN3) OFF
JB OH LINE ON DEC CW2 ON (PLS_IN4) OFF
(DG_IN13) OFF DEC CW3 OFF (PLS_IN5) OFF
DEC CW4 ON (PLS_IN6) OFF
(PLS_IN7) OFF


Item

IDU DI1 CLAMSHELL Clamshell mode (No connection) ON Closed contact
DRAGLINE Dragline mode(No connection) OFF Open contact
JB CATCH Jib catch detection(No connection) CATCH Jib catch
BM OH LINE Overhoist wiring detection (boom) REL. Jib release
JB OH LINE Overhoist wiring detection (jib) ALLOFF Open circuit
(DG_IN13) No connection ALLON Shorted harnesses
IDU DI2 REAR Shift 1 (rear suspend) (No connection) ****** Communication error
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)
(No connection)
(No connection)
(No connection)
IDU DI/PI OVERHEART Thermo switch
(PLS_IN1) No connection
T5-1-15
IDU Digital Outputs

Description

IDU Input / Output Monitor

IDU D01 IDU D02 CAN
IDU
3/3
DD HST STP NORMAL B/J LOW T. NORMAL DD HST SD% XXX. %
DD LWR STP STOP JB OVER T. STOP DD LWR SD% XXX. %

FD HST STP NORMAL (OC_OUT10) ON FD HST SD% XXX. %
FD LWR SD%
FD LWR STP STOP (OC_OUT11) OFF XXX. %
RD HST STP NORMAL (OC_OUT12) ON RD HST SD% XXX. %
RD LWR STP STOP (OC_OUT13) OFF RD LWR SD% XXX. %
3D HST STP NORMAL LAMP CHK ON 3D HST SD% XXX. %

3D LWR STP STOP BUZZER OFF 3D LWR SD% XXX. %


Item

IDU D01 DD HST STP M/L derricking drum hoisting stop NORMAL Normal
DD LWR STP M/L derricking drum lowering stop STOP Stop
FD HST STP M/L front drum hoisting stop ON Drive
FD LWR STP M/L front drum lowering stop OFF Non-drive
RD HST STP M/L rear drum hoisting stop ****** Communication error
RD LWR STP M/L rear drum lowering stop
3D HST STP M/L fourth drum hoisting stop
3D LWR STP M/L fourth drum lowering stop
IDU D02 B/J LOW T. M/L shouldering prevention

JB OVER T. M/L tower breakage prevention
(OC_OUT10) No connection
LAMP CHK Lamp check relay
BUZZER Buzzer
IDU CAN DD 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 %
3D LWR SD% Third drum lowering slow down %
T5-1-16
TROUBLESHOOTONG / Component Layout
MAIN COMPONENT LAYOUT
Upper Structure 1 2 3 4 5 6
7
8
33 10
(Under Fuel
Tank)㩷
11*1
1
32*
(Broken Line Part)㩷 12
31
13
30
29 14
28*1 15
16
27
17
18
26
(Under Cab Back)㩷 19
25
20
T2BC-01-02-010
24 23 22 21
1- Fuel Tank㩷 10 - Pump Mechanism㩷 18 - Oil Cooler㩷 26 - Shuttle Valve㩷
2- Boom Derricking Drum㩷 11 - Third Drum Control Valve*1㩷 19 - Intercooler㩷 27 - Front Control Valve㩷
3- Slewing Control Valve㩷 12 - Engine㩷 20 - Battery㩷 28 - Rear Control Valve*1㩷
4- Derricking Drum Lock 13 - Pressure Compensator㩷 21 - Slewing Mechanism㩷 29 - Rear Drum㩷
Valve㩷
5 - 4-Spool Control Valve㩷 14 - Fourth Drum Brake Release 22 - Front Drum Brake Pedal 30 - Slewing Remote Control
Solenoid Valve (Optional)㩷 Unit㩷 Pressure Detection Valve㩷
6- Hydraulic 15 - Rear Drum Brake Release 23 - Fourth Drum Brake Pedal 31 - 4-Spool Solenoid Valve
Oil Tank㩷 Solenoid Valve㩷 Unit (Optional)㩷 Unit㩷
7 - Drain Filter㩷 16 - Front Drum Brake Release 24 - Rear Drum Brake Pedal 32 - Fourth Drum (Optional)㩷
Solenoid Valve㩷 Unit㩷
8- Pilot Filter㩷 17 - Radiator㩷 25 - Front Drum㩷 33 - Accumulator㩷
9- Gate Lock Valve㩷㩷㩷㩷
*1: As for the machine without fourth drum (32)
(optional), third drum control valve (11) is installed in
rear control valve (28).
T5-2-1
Base Carrier
8 3
4
5
6
13
8
12
9
11
Rear㩷
Left
3 T2BC-01-02-001
7 Right㩷
Front㩷
10
1- Slewing Ring㩷 5 - Lower Frame㩷 8- Jack-Up Cylinder (4 Used) 11 - Lower Roller (20 Used)㩷
(Optional)㩷
2- Center Joint㩷 6 - Take-Up Cylinder*1 (2 9 - Lower Control Valve 12 - Side Frame㩷
Used) (Optional)㩷 (Optional)㩷
3- Retract Cylinder㩷 7 - Front Idler (2 Used)㩷 10 - Upper Roller (4 Used)㩷 13 - Travel Mechanism (2
Used)㩷
4- Crawler Shoe㩷㩷㩷㩷
̪1: Installed in the side frame.
T5-2-2
Cab Interior
1 2 3 4 5 6
7
9 10 11
13
12
T2BC-01-02-003
T2BC-01-02-002
1- Front Drum Brake Pedal㩷 5- Front Drum Lever㩷 8- Lock Lever㩷 11 - Right Travel Lever㩷
2- Fourth Drum Brake Pedal 6- Rear Drum Lever㩷 9- Third/Fourth Drum Lever 12 - Slewing Lock Pedal㩷
(Optional)㩷 (Optional)㩷
3 - Rear Drum Brake Pedal㩷 7- Boom Derricking Drum 10 - Left Travel Lever㩷 13 - Slewing Lever㩷
Lever㩷
4- Accelerator pedal㩷㩷㩷㩷
T5-2-3
ELECTRICAL COMPONENT LAYOUT Solenoid Valve for Counterweight /
Quick Draw / Retract
(Refer to Counterweight / Quick
Upper Structure Draw / Retract Control Valves.)㩷
8
1
Primary Pilot Pressure
Sensor㩷(Refer to
Accumulator.)㩷
(Under Fuel Tank) Around Pump㩷(Refer

to Pump Mechanism.)
7
4-Spool Solenoid Valve 2
(Refer to 4-Spool
Solenoid Valve Unit.)㩷
3
Slewing Remote Control

Pressure Sensor㩷㩷
(Refer to Slewing Around Drum㩷
Remote Control (Refer to Drum.)㩷
Pressure Sensor Block.)㩷
(Under Bed)
Around Engine
(Refer to Engine.)㩷
4
Around Control Valve
(Refer to Front / Rear 5
Control Valves.)㩷
6
Around Battery㩷
(Refer to
Inside Cab Batteries.)㩷
(Refer to Cab
Inside Overall.)㩷
Around Brake Pedal

(Refer to Brake Pedal Unit.)㩷 (Under Cab Back) T2BC-01-02-013
1- Oil Temperature Sensor㩷 4 - Fourth Drum Brake Release Solenoid 7 - Fuel Sensor㩷
Valve (Optional)㩷
2- EC Motor㩷 5 - Rear Drum Brake Release Solenoid Valve 8 - Derricking Rotation Detection
Switch㩷
3- Air Filter Restriction Switch㩷 6 - Front Drum Brake Release Solenoid Valve 㩷
T5-2-4
1 2 1
T2BC-01-02-004㩷
1- Operation Stop Switch㩷 2- Working Light (Right)㩷 3- Working Light (Left)㩷 4- Slewing Alarm Lamp㩷
T5-2-5
Cab Inside Overall
Monitor Panel
(Refer to Monitor Panel.)
13
2
1
12 3
4 Travel Lever㩷
8
Brake Mode Display Panel㩷 5
(Refer to Brake Mode Panel.)㩷
6
11 (Inside Cover)
10 7
T2BC-01-02-003
Left Control Panel㩷

(Refer to Control Panel.)
Right Control Panel㩷
(Refer to Control Panel.)㩷
T2BC-01-02-006
14 Side Overhead Panel

(Refer to Overhead Panel.)
Controller Box㩷㩷
(Refer to Controller Box.)㩷 Rear Overhead Panel
(Refer to Overhead Panel.)
15
Relay Panel㩷㩷
(Refer to Relay Panel.)㩷
T2BC-01-02-005
1- Accelerator Pedal㩷 5- Front Drum Brake Mode 9- Horn Switch㩷 13 - Moment Limiter㩷
Switch㩷
2- Front Drum Rotation 6 - Lock Valve Limit Switch㩷 10 - Slewing Brake Switch㩷 14 - Antenna㩷
Sensing㩷
3 - Rear Drum Rotation 7- Rear Drum Brake Mode 11 - Accelerator grip㩷 15 - Air Conditioner Control
Sensing㩷 Switch㩷 Panel㩷
4 - Boom Derricking Drum 8 - Fourth Drum Brake Mode 12 - Moment Limiter Control 㩷
Rotation Sensing㩷 Switch㩷 Panel㩷
T5-2-6
Monitor Panel
1
15
14
13
2
12
11
10
9
3
6
4
T2BC-01-02-007
1- Coolant Temperature 5 - Cigarette Lighter㩷 9 - Glow Signal㩷 13 - Brake Unapplied Indicator㩷

Gauge㩷
2 - Fuel Gauge㩷 6 - Overheat Indicator㩷 10 - Engine Oil Filter 14 - Engine Oil Pressure
Restriction Indicator㩷 Indicator㩷
3- Hour Meter㩷 7 - Controller Failure 11 - Alternator Indicator㩷 15 - Pilot Pressure Indicator㩷
Indicator㩷
4- Key Switch㩷 8 - Air Filter Restriction 12 - Coolant Level Indicator㩷㩷
Indicator㩷
T5-2-7
Control Panel
• Left Control Panel
1 2 3 4 5 6 7 8 9
T2BC-01-02-008
12 11 10
• Right Control Panel
T2BC-01-02-009
13 14 15 16
1- Auto Stop Release 5 - Auto Stop Release Front 9 - Reeving Winch Switch㩷 13 - Accelerator Lock Switch㩷
Key Switch㩷 Drum Switch㩷
2 - Auto Stop Release 6 - Brake Mode Select Key 10 - Quick Draw Extend/Retract 14 - Front Drum Lock Switch㩷
Derricking Switch㩷 Switch㩷 Switch㩷
3 - Auto Stop Release 7 - Remote Control Pressure 11 - Third/Fourth Drum 15 - Rear Drum Lock Switch㩷
Third/Fourth Drum Switch㩷 Restoration Switch㩷 Selection Switch㩷
4 - Auto Stop Release Rear 8 - Side Frame Extend/Retract 12 - Counterweight/Jack-Up 16 - Fourth Drum Lock
Drum Switch㩷 Switch㩷 Switch (Optional)㩷 (Optional)㩷
T5-2-8
Overhead Panel
• Rear Overhead Panel
1 2 3 4 5 6 7
T2BC-01-02-011
• Side Overhead Panel

8 9 10 11 12
T2BC-01-02-012
1- FM/AM Radio㩷 4- Auxiliary㩷 7 - Overhead Wiper / Washer 10 - Hydraulic Tagline Switch

Switch㩷 (Optional)㩷
2- Working Light Switch㩷 5- Electric Power Socket㩷 8 - Emergency Engine Stop 11 - Drum Rotation Sensing
Switch㩷 Switch㩷
3- Drum Light Switch 6- Front Wiper / Washer 9 - Slow Speed Lock Switch㩷 12 - Travel Mode Switch㩷
(Optional)㩷 Switch㩷
Brake Mode Display Panel

1 2 3
T2BC-01-02-014
6 5 4
1- Front Drum Free Mode 3 - Rear Drum Free Mode 5 - Third / Fourth Drum Auto 6- Rear Drum Auto Brake Mode
Lamp (Red)㩷 Lamp (Red)㩷 Brake Mode Lamp (Green)㩷 Lamp (Green)㩷
2 - Third / Fourth Drum 4 - Front Drum Auto Brake 㩷㩷
Free Mode Lamp (Red)㩷 Mode Lamp (Green)㩷
T5-2-9
Relay Panel
1
2
3
㪈㩷㪄㩷 Third Drum Lowering Stop Relay (R10)㩷

㪉㩷㪄㩷 Moment Limiter Buzzer Relay (R9)㩷
㪊㩷㪄㩷 Third/Fourth Drum Selection Relay Lower (R8)㩷
㪋㩷㪄㩷 Slewing Alarm Relay (R1)㩷
㪌㩷㪄㩷 Engine Oil Pressure Relay (R2)㩷
㪍㩷㪄㩷 Engine Start Relay (R3)㩷
10 㪎㩷㪄㩷 Horn Relay (R4)㩷
9 㪏㩷㪄㩷 Jack Relay (R5)㩷
8
㪐㩷㪄㩷 Motor Cutoff Relay (R6)㩷
7 㪈㪇㩷㪄㩷Third/Fourth Drum Selection Relay Upper (R7)㩷
6
T2BC-01-02-015
5
4
Controller Box
12
1
11
10
T2BC-01-02-016
8 7 6 5 4 3 2
1- Preheat Controller㩷 4 - Memory Deletion Switch㩷 7 - MC2/A 10 - Emergency Engine Stop

Switch㩷
2- ECU Lamp (Red)㩷 5 - Troubleshooting Switch㩷 8 - MC2/B 11 - Fuse Boxes㩷
3- ECU Lamp (Yellow)㩷 6 - IDU 9 - Maintenance Key Switch㩷 12 - IDU
T5-2-10
Brake Pedal Unit
Cab Floor㩷
T2BC-01-02-017
TBC-01-02-030
4 * Other Brakes are
1 2 3 installed to the same
positions.
1- Front Brake Depressing 2- Fourth Brake (Optional) 3- Rear Brake Depressing 4- Rear Brake Applied
Pressure Sensor㩷 Depressing Pressure Pressure Sensor㩷 Sensing Switch㩷
Sensor㩷
T5-2-11
Engine
1 2 3 4 5 6
10 9
11 12
Machine Front㩷 Machine Rear 㩷
Machine Rear Machine Front 䌔2䌂䌃-01-02-023
T25N-01-02-001
13 14
T25N-01-02-003
1- Overheat Switch㩷 5 - TCV RTD Solenoid Valve㩷 9 - Engine Oil Filter Restriction 12 - Alternator㩷
Switch㩷
2- Coolant Temperature 6 - Engine Stop Solenoid Valve 10 - Engine Oil Pressure Switch 13 - Timing Sensor㩷
Sensor㩷
3 - Air Heater㩷 7 - TDC Sensor㩷 11 - Starter㩷 14 - Rack Sensor㩷
4 - TCV ADV Solenoid Valve㩷 8 - Engine Rotation Detection 㩷㩷
Sensor㩷
T5-2-12
Around Battery
7 10
3
6 4 9
㩷
Machine Right㩷㩷
T2BC-01-02-020 T25N-01-02-005
Machine Front㩷 Machine Rear Machine Upper㩷
Machine Left㩷 Machine Front Machine Rear
Machine Lower㩷
1- Engine Stop Relay㩷 4 - Battery Relay㩷 7 - Load Dump Relay㩷 9- Receiver Drier Condenser
Fan Control Pressure
Switch㩷
2- Alternator Relay㩷 5 - Heater Relay㩷 8 - Flasher㩷 10 - Coolant Level Switch㩷
3- Fusible Link㩷 6 - Starter Relay 2㩷㩷㩷
T5-2-13
Pump Mechanism
Fourth Drum Brake Cooling /

Hydraulic Tagline Drive /
Reeving Winch Drive Pump
(Optional)㩷
Pump for Counterweight/Quick

Draw/Jack-Up/Retract㩷
Pilot Pump㩷 Slewing

Pump㩷
Machine Front㩷䌔2䌂䌃-01-02-028
Machine Rear
1- Power Increase Solenoid 2- Displacement Angle 3- Displacement Angle

Valve Proportional Solenoid Valve Proportional Solenoid Valve
㩷 (Main Pump)㩷 (Slewing Pump)㩷
T5-2-14
Upper Side of Control Valve
1 2*1 3 4*1 5 6 7 8
Machine Left
Machine
Rear㩷
Machine
Machine Right Front㩷
Rear Control Valve

T2BC-01-02-018
Front Control Valve㩷
Bottom Side of Control Valve
Rear Control Valve㩷 Front Control Valve㩷
Machine Right
Machine
Rear㩷
Machine
Front㩷
Machine Left
T2BC-01-02-019
1 1
9* 10 11 12* 13 14 15 16
1- Front Drum Hoisting 5 - Rear Drum Hoisting 9 - Third Drum Hoisting 13 - Boom Derricking Hoisting
Proportional Proportional Solenoid Valve Remote Control Pressure Remote Control Pressure
Solenoid Valve㩷 Sensor*1㩷 Sensor㩷
2 - Third Drum Hoisting 6 - Boom Derricking Drum 10 - Front Drum Hoisting 14 - Rear Hoisting Remote
Solenoid Valve *1㩷 Hoisting Proportional Remote Control Pressure Control Pressure Sensor㩷
Solenoid Valve㩷 Sensor㩷
3- Front Drum Lowering 7 - Rear Drum Lowering 11 - Front Drum Lowering 15 - Boom Derricking Lowering
Proportional Proportional Solenoid Valve Remote Control Pressure Remote Control Pressure
Solenoid Valve㩷 Sensor㩷 Sensor㩷
4 - Third Drum Lowering 8 - Boom Derricking Drum 12 - Third Drum Lowering 16 - Rear Lowering Remote
Solenoid Valve *1㩷 Lowering Proportional Remote Control Pressure Control Pressure Sensor㩷
Solenoid Valve㩷 Sensor*1㩷
*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.
T5-2-15
1 2*1 3 4
Machine Front㩷
Machine
Left㩷 Machine
Right㩷
Machine Rear㩷
T2BC-01-02-021
8 7 6 5
1- Quick Draw Solenoid 5- Counterweight Solenoid

Valve (Extend)㩷 Valve (Right/Retract)㩷
2 - Retract Solenoid Valve 6 - Counterweight Solenoid
1
(Extend)* 㩷 Valve (Left/Retract)㩷
3 - Counterweight Solenoid 7 - Retract Solenoid Valve
Valve (Left/Extend)㩷 (Retract)㩷
4 - Counterweight Solenoid 8 - Quick Draw Solenoid
Valve (Right/Extend)㩷 Valve (Retract)㩷
*1: If the jack (optional) is installed, the lower power
solenoid valve is installed here.
T5-2-16
Detailed 2
Position C
Around Drum 㩷
3
Detailed Position B 1
Detailed Position A㩷
Drum Lock
Motor㩷
Motor
Machine
Front㩷
T2BC-01-02-026
T2BC-01-02-027
Rotation Detection
Sensor㩷
(One sensor is installed Machine
to the derricking drum.) Rear㩷 T2BC-01-02-025
4 5 6 7 8
Machine
Front㩷
A A
C C C
Boom Derricking Drum Fourth Drum Rear Drum㩷 Front Drum㩷

(Optional)㩷
B B B
T2BC-01-02-024
9 10 11
1- Motor Cutoff High Pressure 4 - Derricking Drum Rotation 7- Front Rotation Detection 10 - Rear Drum Lock Motor㩷
Solenoid Valve (Only Detection Switch㩷 Switch (A)㩷
Front/Rear Drums)㩷
2 - Brake Release Solenoid 5 - Rear Drum Rotation 8- Front Drum Rotation 11 - Front Drum Lock Motor㩷
Valve㩷 Detection Switch (A)㩷 Detection Switch (B)㩷
3 - Motor Displacement Angle 6 - Rear Drum Rotation 9 - Fourth Drum (Optional) 㩷
Proportional Solenoid Valve㩷 Detection Switch (B)㩷 Lock Motor㩷
T5-2-17
㩷
4-Spool Solenoid
Valve Unit㩷 1 2 3 4
Machine Left㩷
Machine
Rear㩷
Machine
Front㩷
Machine Right㩷 T25N-03-08-001
1- Derricking Drum 3 - High / Low Speed

Unlocking Solenoid Selection Solenoid Valve
Valve㩷
2 - Slewing Brake Solenoid 4 - Second Overhoist
Valve:㩷 Solenoid Valve㩷
Accumulator Slewing Remote Control Pressure Sensor Block
Accumulator㩷
Slewing Remote
M25N-07-030 Control Pressure
1 Sensor Block㩷
T25N-01-02-019
1- Primary Pilot Pressure 2- Right Slewing Remote 3- Left Slewing Remote

Sensor㩷 Control Pressure Sensor㩷 Control Pressure
Sensor㩷
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.
x How to read troubleshooting flowchart

YES(OK)
(2)
Perform inspection or measurement in box (1), and select YES (OK)
࡮ (1) or NO (NOT OK) according to (1), and go to the next box (2) or (3).

(3)
NO(NOT OK)

࡮ Under the box is inspection or measuring method or references.
Be careful that if inspection or measuring method is incorrect, finding the cause of failure
· Key switch: ON becomes 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.

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
T5-3-1
Power Supply Monitor
Description
MC2/A Input / OutputMonitor
MC2/A MC2/B IDU 1/1

MAIN_B NORMAL MAIN_B NORMAL MAIN_B xx. xxV
5V LOW ER 5V LOW ER 5V x. xxV
24V_1 HI ER 24V_1 HI ER 10V xx. xxV
24V_2 SHORT 24V_2 SHORT 24V xx. xxV
24V_3 SHORT 24V_3 SHORT

χχ ω Page Selection Return
Item

MC2/A MAIN_B Main power supply NORMAL Normal
5V Analog sensor power supply LOW ER Lower limit error
24V_1 For each switch input HI ER Upper limit error
24V_2 For throttle control switch SHORT Short circuit
For emergency operation xx. xxV A/D voltage
24V_3
switch conversion
MC2/B MAIN_B Main power supply Communication error
5V Analog sensor power supply
For three-winding layer
24V_1
detector (no connection)
For overhoist switch on
24V_2
machine
For overhoist switch on
24V_3
attachment
IDU MAIN_B Main power supply
5V Angle detector power supply
10V Load detector power supply
Power supply for shift switch
24V
(no connection)

T5-3-2
MC2/A Analog Inputs

Description


MC2/A AI3
MC2/A AI1 MC2/A AI2 1/4
THROT. GRIP NORMAL DD HST PRS x. xMPa SL RGT PRS x. xMPa
THROT. FOOT NORMAL DD LWR PRS LOW ER SL LFT PRS LOW ER
RACK. P. S HI ER FD HST PRS HI ER PILOT PRS NORMAL

THROL. M. P. NORMAL FD LWR PRS RSV ER FD BRK PRS LOW ER
RD BRK PRS
SL CTRL SP 2.50 V RD HST PRS x. xMPa HI ER
THRT. 3RD LOW ER RD LWR PRS LOW ER 3D BRK PRS RSV ER
TRRGT. PRS HI ER 3D HST PRS HI ER
(AN_IN22) NORMAL
TRLFT. PRS RSV ER 3D LWR PRS RSV ER (AN_IN23) LOW ER


Item

MC2/A THROT. GRIP Accelerator grip signal NORMAL Normal
AI1 THROT. FOOT Accelerator pedal signal LOW ER Lower limit error
RACK. P. S. Rack position signal HI ER Upper limit error
THROL. M. P. Governor motor potentio sensor signal RSV ER Performance errors
SL CTRL SP Slew speed dial signal (no connection)
THRT. 3RD Third Accelerator x. xV Normal (voltage)
TRRGT. PRS Travel (right) remote control pressure LOW ER Lower limit error
TRLFT. PRS Travel (left) remote control pressure HI ER Upper limit error
MC2/A DD HST PRS Derricking drum hoisting remote control RSV ER Spare
AI2 pressure
DD LWR PRS Derricking drum lowering remote x. xMPa Operating pressure
control pressure LOW ER Lower limit error
FD HST PRS Front drum hoisting remote control HI ER Upper limit error
pressure DBL ER Double errors
FD LWR PRS Front drum lowering remote control
pressure ****** Communication error
pressure
RD LWR PRS Rear drum lowering remote control
pressure NORMAL Normal operation: OFF
3D HST PRS Third / fourth drum hoisting remote LOW ER Lower limit error
control pressure HI ER Upper limit error
3D LWR PRS Third / fourth drum lowering remote
RSV ER Normal operation: ON
control pressure
MC2/A SL RGT PRS Slew (right) remote control pressure
AI3 SL LFT PRS Slew (left) remote control pressure
PILOT PRS Primary pilot circuit pressure
FD BRK PRS Front brake depressing pressure
RD BRK PRS Rear brake depressing pressure
3D BRK PRS Fourth brake depressing pressure
T5-3-3
MC2/A Digital Inputs

Description


MC2/A CAN2
MC2/A SWITCH MC2/A CAN1 2/4
FD FREE SW ON FD FREE MD BRAKE FD PLS CNT -xxxxx
RD FREE SW OFF RD FREE MD BRAKE RD PLS CNT -xxxxx
3D FREE SW ON 3D FREE MD FREE DD PLS STOP

ENG. START OFF RACK P. S. x. xx V BRK MD SW OFF
OVERH2 SIG
THROT. FIX ON RACK P. STP x. xx V NORMAL
THROT. PRE OFF RACK P. FUL x. xx V ATTACHMENT SHORT
GATE LOCK ON INC. TQ. CUR -xxxmA SD. CAN SW OFF

SL BRK SW OFF OFFSET CUR xxxxmA PMP. FIX. SW OFF


Item

MC2/A FD FREE SW Front brake mode selection switch ON Closed contact
SWITCH RD FREE SW Rear brake mode selection switch OFF Open contact
3D FREE SW Third / fourth brake mode selection BRAKE Auto brake mode
switch FREE Free mode
ENG. START Engine start signal x. xx V A/D voltage conversion
THROT. FIX Throttle lock switch -xxxmA Electric current offset
THROT. PRE Throttle preset switch -xxxxx Drum pulse counter
GATE LOCK Gate lock switch ROTATE Rotation
SL BRK SW Slewing brake switch STOP Stop
MC2/A CAN1 FD FREE MD Front brake mode selection control CANCEL Cancellation
RD FREE MD Rear brake mode selection control NORMAL Normal
3D FREE MD Third / fourth brake mode selection SHORT Short circuit
control CRANE Crane
RACK P. S. Rack position signal TOWER Tower
RACK P. STP Engine stop rack position OPEN Open circuit
RACK P. FUL Full rack position ****** Communication error
INC. TQ. CUR Power increase proportional
solenoid valve
OFFSET CUR Power increase electric current
offset
MC2/A CAN2 FD PLS CNT Front drum pulse counter
RD PLS CNT Rear drum pulse counter
DD PLS Derricking drum rotation detection
BRK MD SW Brake mode key switch
OVERH2 SIG Second overhoist solenoid valve
ATTACHMENT Wiring detection
SD CAN. SW Slowdown cancellation switch (no
connection)
PMP FIX. SW Max. pump delivery flow rate lock
switch (no connection)
T5-3-4
MC2/A Digital Output

Description


MC2/A D01 MC2/A D02 MC2/A D03 3/4
M PMP CUR xxxxmA FD PLS SOL NORMAL DD LCK REL NORMAL
INC. TQ CUR LOW ER RD PLS SOL
ERROR FM BRK REL ERROR
SL RGT CUR HI ER DD PLS SOL NORMAL RM BRK REL NORMAL

SL LFT CUR RES ER SL PRS SOL
ERROR 3M BRK REL ERROR
NORMAL
SL PMP CUR CANCEL CAL IB. CUR MT CUT OFF NORMAL
FD BRK REL XxxxmA ENG. INTLCK ERROR
RD BRK REL LOW ER 3D BRK LP NORMAL

3D BRK REL HI ER SL ALAM LP ERROR


Item

MC2/A M PMP CUR Main pump displacement angle xxxxmA Control current
INC. TQ CUR Power increase solenoid valve HI ER Upper limit error
SL RGT CUR Slewing multi (right) proportional solenoid RES ER Reset error
valve (no connection) CANCEL Feedback cancellation
SL LFT CUR Slewing multi (left) proportional solenoid
valve (no connection) NORMAL Normal
SL PMP CUR Slewing pump displacement angle LOW ER Lower limit error
proportional solenoid valve (no
connection)
RES ER Reset error
FD BRK REL Front drum brake release solenoid valve
RSV Feedback cancellation
RD BRK REL Rear drum brake release solenoid valve
3D BRK REL Fourth drum brake release solenoid valve
NORMAL Calibration current
MC2/A FD PLS SOL Front drum rotation sensing solenoid
D02 RD PLS SOL Rear drum rotation sensing solenoid
DD PLS SOL Derricking drum rotation sensing solenoid
RES ER Reset error
SL PKS SOL Slewing remote control pressure
RSV Spare
hydraulic source solenoid (no connection)
CAL IB. CUR Calibration electric current
NORMAL Normal
MC2/A DD LCK REL Derricking drum unlocking solenoid valve
D03 ERROR Short circuit
FM BRK REL Front motor brake release solenoid valve
RM BRK REL Rear motor brake release solenoid valve
3M BRK REL Fourht motor brake release solenoid
valve
MT CUT OFF Motor cutoff relay
ENG. INTLCK Engine start interlock
3D BRK LP Third/fourth auto brake indicator
SL ALAM LP Slewing alarm lamp relay
T5-3-5
ECU Status

Description

MC2/A Input/Output Monitor

MC2/A_ECU1
4/4
RECEIVE NORMAL
TMR F. B. ERROR

RACK P. S. NORMAL

TIMING S. ERROR
TDC S. INVLD
OVER H. S. ERROR
TMR. C. V. NORMAL


Item

MC2/A_ECU1 RECEIVE ECU NORMAL Normal
TIMING S. Timing sensor

TDC S. TDC sensor
T5-3-6
MC2/B Analog Inputs

Description

MC2/B Input/Output Monitor

MC2/B DI
MC2/B AI1 MC2/B AI2
1/3
FD CTRL SP NORMAL TR RGT PRS x. xMPa FD ROPE ED R. END
RD CTRL SP LOW ER TR LET PRS x. xMPa
RD ROPE ED ALLOFF
DD CTRL SP HI ER (AN_IN10) NORMAL 3D ROPE ED ALLON

(AN_IN3) RSV (AN_IN11) LOW ER
(DAN_IN20) NORMAL
(DAN_IN21)
(AN_IN4) NORMAL (AN_IN12) HI ER ERROR
(AN_IN5) LOW ER (AN_IN13) RSY (DAN_IN22) NORMAL
(AN_IN6) HI ER (DAN_IN23) ERROR

(AN_IN7) RSV


Item

MC2/B AI1 FD CTRL SP Front drum speed set dial signal (no NORMAL Normal
connection) LOW ER Lower limit error
RD CTRL SP Rear drum speed set dial signal (no HI ER Upper limit error
connection)
RSV Spare
DD CTRL SP Derricking drum speed set dial signal (no
x. xMPa Normal (pressure)
connection)
DBL ER Double errors
R. END Extra hoisting
ALLOFF Open circuit
ALLON Shorted harnesses
MC2/B AI2 TR RGT PRS Travel (right) remote control pressure
TR LET PRS Travel (left) remote control pressure
MC2/B DI FD 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)
T5-3-7
MC2/B Digital Inputs

Description


MC2/B DI
MC2/B SWITCH1 MC2/B SWITCH2 2/3
DD REL SW NORMAL BM OVERH NORMAL DD HST STP NORMAL
FD REL SW REL BT OVERH2 OVERH DD LWR STP STOP
RD REL SW NORMAL TW OVERH ALLOFF FD HST STP NORMAL

3D REL SW REL BT LOWER L ALLON FD LWR STP STOP
RD HST STP
REL KEY SW NORMAL JB OVERH NORMAL NORMAL
OH2 REL SW REL JB OVERH2 OVERH RD LWR STP STOP
JB FOLD FOLD HK OVERH ALLOFF
3D HST STP NORMAL
ATTACHMENT CRANE SWL OVERH ALLON 3D LWR STP STOP


Item

MC2/B DD REL SW Derricking drum auto stop release
NORMAL Auto stop
SWICH1 FD REL SW Front drum auto stop release
REL Release operation
RD REL SW Rear drum auto stop release INHBIT Release inhibition
3D REL SW Third drum auto stop release
HM FIX SW Hoisting motor low speed lock
ON Closed contact
OH2 REL SW Second overhoist restoration switch OFF Open contact
JB FOLD Jib folding
ATTACHMENT Wiring detection NORMAL Auto stop
MC2/B BM OVERH Boom overhoist REL Release operation
SWITCH2 BT OVERH2 Boom/tower second overhoist
TW OVERH Tower overhoist FOLD Jib folding
BT LOWER L Boom/tower lower limit (no connection) UNFOLD Jib unfolding
JB OVERH Jib overhoist ALLOFF Open circuit
JB OVERH2 Jib second overhoist ALLON Shorted harnesses
HK OVERH Hook overhoist
SWL OVERH Tpwer jib backstop alignment SHORT Short circuit
MC2/B DI DD HST STP Derricking drum hoisting stop CRANE Crane
DD LWR STP Derricking drum lowering stop TOWER Tower
FD HST STP Front drum hoisting stop OPEN Open circuit
FD LWR STP Front drum lowering stop
RD HST STP Rear drum hoisting stop NORMAL Normal
RD LWR STP Rear drum lowering stop OVERH Overhoist
3D HST STP Fourth drum hoisting stop solenoid ALLOFF Open circuit
valve ALLON Shorted harnesses
3D LWR STP Fourth drum lowering stop solenoid LOWER Lower limit
valve
NORMAL Operation
STOP Stop
T5-3-8
MC2/B Digital Outputs

Description


MC2/B D01 MC2/B D02
3/3
DD HST CUR xxxxmA GREEM LMP NORMAL
DD LWR CUR LOW ER YELLOW LMP ERROR

FD HST CUR HI ER RED LMP NORMAL

FD LWR CUR RES ER OVERH2 SOL ERROR
RD HST CUR CANCEL 3D HST SOL NORMAL
RD LWR CUR xxxxmA 3D LWR SOL ERROR
FM CAP CUR LOW ER CALIB. CUR LOW ER

RM CAP CUR HI ER


Item

MC2/B D01 DD HST CUR Derricking drum hoisting proportional xxxxmA Control current
solenoid valve
DD LWR CUR Derricking drum lowering proportional RES ER Reset error
solenoid valve CANCEL Feedback cancellation
FD HST CUR Front drum hoisting proportional NORMAL Normal
solenoid valve ERROR Short circuit
FD LWR CUR Front drum lowering proportional
NORMAL Calibration current
solenoid valve
RD HST CUR Rear drum hoisting proportional solenoid HI ER Upper limit error
valve RES ER Reset error
RD LWR CUR Rear drum lowering proportional RSV Spare
solenoid valve
FM CAP CUR Front motor displacement angle control
RM CAP CUR Rear motor displacement angle control
MC2/B D02 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 valve
3D HST SOL Fourth drum hoisting solenoid valve
3D LWR SOL Fourth drum lowering solenoid valve
CALIB. CUR Calibration current
T5-3-9
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 Harness check
communication
failure
24V_3 Sensor 24V_3 NORMAL Normal 㧙
T5-3-10
Battery
Battery Relay
Key Switch
MC2/A MC2/B
P1 MAIN_B P1 MAIN_B
P17 P17
KEY_SW KEY_SW
E12 SOL_VB E12 SOL_VB
E13 PWM_VB E13 PWM_VB

D12 D12
MAIN_G
D5 D5
SENSOR_5V SENSOR_5V
D16 D16 IDU

SENSOR_5V SENSOR_5V
D2 D2
SENSOR_24V_1 SENSOR_24V_1
D3 SENSOR_24V_2 D3 SENSOR_24V_2
D4
SENSOR_24V_3 SENSOR_24V_3
CAN
D20 D9 D20 D9 D15 D14

T25N-05-03-001
T5-3-11
Check of Battery System
x Check the wiring connections first.

MC2/A side
YES Faulty battery.
Disconnect harness
from terminal minus
YES (-) of battery. Check
Disconnect harness for continuity between
from terminal plus (+) Harness open circuit
terminals minus (-) between battery and
of battery. Check for and machine.
NO continuity between NO ground, or faulty
terminal D1 of har- ground.
Disconnect connec-
tor MCA-1 from ness end connector of
connector MCA-1 and Faulty harness be-
MC2/A.
Check if tween MC2/A and
voltage between machine.
battery, or open circuit

terminal D1 of har- NO
at fuse #7.
ness end connector
machine is 24 V.
and
Faulty MC2/A.

YES

YES Faulty battery.
MC2/B side Disconnect harness
from terminal minus (-)
YES of battery.
Disconnect harness Check for continuity
Harness open circuit
from terminal minus between terminal mi-
between battery and
(-) of battery. nus (-) and machine.
NO NO ground, or faulty
Check for continuity ground.
Disconnect connec- between terminal X1
tor MCB-1 from of harness end con-
MC2/B. nector of connector Faulty harness be-
Check if voltage be- MCB-1 and machine. tween MC2/B and
tween terminal X1 of NO battery, open circuit at
harness end confuse #6.
nector and machine
is 24 V. Faulty MC2/B.
YES
Connector
MC2/B MC2/A
Connector MCA-1 Connector MCA-1
(harness end) (harness end)

T2BC-05-03-001 T2BC-05-03-002
T5-3-12
Check of Key Switch

MC2/A side
YES Faulty MC2/A.
Disconnect
connec-
tor MCA-1 from

MC2/A. YES Faulty key switch.
Check
if voltage
between terminal Check if voltage be-
Connect terminal YES
D17 of harness end tween terminal B in key
ACC in key switch to switch and machine is
connector and ma- Harness open circuit
is 24 V. machine. 24 V.
chine between key switch
Check for continuity
· Key switch: ON between terminal D17
NO and battery.
NO
of harness end con-
nector of connector
MCA-1 and machine. Harness open circuit
NO between MC2/A and
key switch, or open
circuit at fuse #18.
MC2/B side
YES Faulty MC2/B.
Disconnect connec-
tor MCB-1from
MC2/A. YES Faulty key switch.
Check if voltage
between terminal YES Check if voltage be-
Connect terminal tween terminal B in key
X17 of harness end ACC in key switch to
connector and ma- switch and machine is Harness open circuit
machine. 24 V.
chine is 24 V. Check for continuity between key switch
NO and battery.
· Key switch: ON NO between terminal X17
of harness end con-
nector of connector
MCB-1 and machine. Harness open circuit
NO between MC2/B and
key switch, or open
circuit at fuse #18.
Connector
MC2/A MC2/B
Connector MCA-1 Connector MCB-1 Monitor panel CN06F-W
(harness end) (harness end) (harness end)

T2BC-05-03-001
T2BC-05-03-002

T2BC-05-04-002
Terminal C
Terminal B Terminal ACC
T5-3-13
Check of Solenoid and PWM Power Supply

YES Faulty MC2/A.
MC2/A side
Disconnect har- YES

(A)
Disconnect connector ness 208 of battery
MCA-6 from MC2/A. relay and connect
Check if voltage be- YES
to machine.
tween terminal E12 or Check for continu-
E13 of harness end Connect ground ity between termi-
connector and ma- terminal of battery nal ACC in key
chine is 24 V. relay to machine. switch and ma-
YES Check if voltage between key switch
chine. NO and battery relay.
· Key switch: ON between terminal
E12 or E13 and
machine is 24 V.
Disconnect har- Harness open circuit
ness AV8 of bat- · Key switch: ON between battery relay
tery relay connect NO and ground, or faulty
to machine. ground.
NO Check for continu-
ity between termi-
nal E12 or E13 of In case of no continuity
harness end con- at terminal E12, har-
nector and ma- ness open circuit be-
chine. tween terminal E12 of
connector MCA-6 of
MC2/A and battery
relay, or open circuit at
fuse #28.
NO
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
fuse #30.
Disconnect har- YES Faulty battery relay.

ness from terminal
plus (+) of battery.
(A) Check for continu-
ity between termi-
nal of harness 60B
of battery relay
between battery relay
and machine. NO and battery
Connector
MC2/A
Connector MCA-6

T2BC-05-03-004
T5-3-14
MC2/B Side
YES Faulty MC2/B.
Disconnect har- YES

(A)
Disconnect connector ness 208 of battery
MCB-6 from MC2/B. relay and connect
Check if voltage be- YES to machine.
tween terminal Y12 or Check for continu-
Y13 of harness end Connect ground ity between termi-
connector and ma- terminal of battery nal ACC of key Harness open circuit
chine is 24 V. relay to machine. switch and ma- between key switch
YES chine.
Check if voltage NO and battery relay.
· Key switch: ON between terminal
Y12 or Y13 and
Disconnect har- machine is 24 V. Harness open circuit
ness AV8 of bat- between battery relay
· Key switch: ON and ground, faulty
tery relay. Check NO
for continuity be- ground.
NO tween terminal In case of no continuity
YE12 or Y13 of at terminal Y12, har-
harness end con- ness open circuit be-
nector and ma- tween terminal Y12 of
chine. connector MCB-6 of
MC2/B and battery
NO relay, or open circuit at
fuse #27.
at terminal Y13, har-
tween terminal Y13 of
connector MCB-6 of
MC2/B and battery
fuse #30.
Disconnect har-
Faulty battery relay
ness from terminal YES
plus (+) of battery.
Check for continu-
(A) ity between termi-
nal of harness 60B Harness open circuit
of battery relay between battery relay
and machine. NO and battery
Connector
MC2/B
Connector MCB-6

T2BC-05-03-003
T5-3-15
Check of 5 V Sensor on MC2/A

YES㩷 Faulty sensor.
Disconnect sensor
from connector.
Check if voltage be-
tween terminal R of
harness end connector
and machine is 5 V. Faulty MC2/A.
NO
· Key switch: ON

Harness D5 Harness D16
Sensor Harness end connector Sensor Harness end connector
Accelerator grip Derricking drum hoisting
remote control pressure R W B
Derricking drum lowering
B W R
Front drum hoisting
Slew lever Front drum lowering
T25N-05-03-023 remote control pressure R W B
Accelerator pedal Rear drum hoisting
W R Rear drum lowering
B
Third / fourth drum
T25N-05-03-024
hoisting remote control R W B
pressure
Throttle motor
Third / fourth drum
position B W R lowering remote control R W B
pressure
Slewing (right) remote
T25N-05-03-025 R W B
control pressure

Slewing (left) remote
R W B
control pressure
Primary pilot circuit
R B
pressure
W
T25N-05-03-002
Front brake depressing

R B
pressure
W
T25N-05-03-002
Rear brake depressing

R B
pressure
W
T25N-05-03-002
Third brake depressing

R B
pressure
W
T25N-05-03-002
T5-3-16
Check of 5V Sensor of MC2/B

Disconnect sensor YES㩷 Faulty sensor.
from connector.
tween terminal R of
and machine is 5 V. Faulty MC2/B.
NO
· 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
Check of 24 V_1 Sensor on MC2/A

Front / rear drum brake mode selection switch
Disconnect connector YES㩷 Faulty brake mode
of brake mode selec- selection switch.
tion switch.
tween machine and
terminal #4 of harness Faulty MC2/A.
end connector is 24 V. NO

· Key switch: ON

Harness D2

Front drum brake
mode selection
switch
Rear drum brake
mode selection T2BC-05-03-005
switch

Third drum brake mode selection switch
YES㩷 Faulty brake mode
Disconnect connector
selection switch.
of brake mode selec-
tion switch.
tween machine and

· Key switch: ON
Harness D2

Third / fourth drum
brake mode
selection switch
T2BC-05-03-005
T5-3-18
Front, rear and fourth drum brake pedal

YES㩷 Faulty brake mode
of limit switch. selection switch.

tween machine and
terminal #1 of harness
Faulty MC2/A.
end connector is 24 V.
NO
· Key switch: ON
Harness D2

Fron, rear and fourth
drum pedal limit
switch
T2BC-05-04-008
T5-3-19

Disconnect connector YES㩷 Faulty accelerator
62C-12FW of right con- control switch.
trol panel.
tween machine and
NO
· Key switch: ON

Harness D3

Accelerator control
switch

T2BC-05-03-006
Right control panel

62C-12F-W


Disconnect connector YES㩷 Faulty emergency
of emergency opera- operation switch.
tion switch.
tween machine and

· Key switch: ON

Harness D4

Emergency
operation switch

T2BC-05-03-007

T5-3-20
Check of 24 V_2 Sensor on MC2/B

YES㩷 Faulty limit switch.
of limit switch.
tween machine and
terminal #c of harness
Faulty MC2/B.
NO
· Key switch: ON

Harness X3

Boom overhoist
switch a b c

T25N-05-03-005

Tower overhoist
switch b c
a

T25N-05-03-003
Boom / tower
b c
second overhoist
switch
a

T25N-05-03-029
T5-3-21
Check of Sensor 24 V_3 on MC2/B
Jib overhoist, jib second overhoist, tower jib backstop

alignment switches
Disconnect limit switch
from connector.
tween machine and
terminal #1 of harness
end connector is 24 V. Faulty MC2/B.
NO
· Key switch: ON

Harness X4

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
Disconnect limit switch
from connector. Check if
voltage between ma-
chine and terminal #1 of
is 24 V. Faulty MC2/B.
NO
· Key switch: ON

Harness X4

Hook overhoist
switch

T2BC-05-03-010
T5-3-22
Check of CAN between MC2/A and IDU
x 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.
x 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
Check of CAN between MC2/B and IDU
x 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.
x 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-

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
FAILURE OF ENGINE CONTROL SYSTEM
Abnormality
x 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 Countermeasure

THROT. GRIP Accelerator grip LOW ER Lower limit error Controls as low Harness check
THROT. FOOT Accelerator pedal HI ER Upper limit error idle input. Sensor check
THROT. M. P Governor motor LOW ER Lower limit error Governor motor Harness check
Potentio HI ER Upper limit error control stop Sensor check
RSV ER Operation error
0/3.3 to 8.5V Pulses
24V Governor
motor
1.0 to 2.4 V
5V
Accelerator
grip
0.7 to 4.3 V
Accelerator
pedal
2.4䌾4.6V
Governor
motor
potentio
24 V
Accelerator 24 V (ON)
Control Switch 0 V (OFF)
Accelerator Lock
Accelerator Preset
0 to 6 V AC, 0 to 5.3 䌫Hz
Engine Speed
Detection

T2BC-05-03-058
T5-3-25
Check of Accelerator Grip Sensor

x 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. Reconnect the dis-
x If input voltage from the accelerator grip sensor is connected connec-
tor.
0.1 V or less, the cause of trouble may be harness
Measure voltage ;'5㩷 Faulty MC2/A.
open circuit between accelerator grip sensor and between terminal B5
MC2/A, or short circuit between sensor_ 5 V line and ;'5 of connector of
ground line. MC2/A and machine.

Turn key switch Turn key switch ON.
x Check the wiring connections first. OFF.
Faulty accelerator
Check if voltage grip sensor.
Connect terminal W reaches specification 01㩷
of harness end when moving accel-
connector of accel-
erator grip.
;'5 erator to machine by
using a clip. ·Insert a test bar into
Disconnect connec- the rear of connector.
tor MCA-3 of MC2/A. ·Specification: 1.0 to

Check for continuity 24 V

between terminal B5
of connector MCA-3
and machine.
Turn key switch ON.
Check if voltage be- Faulty harness up
tween terminals R to terminal W of
;'5㩷 and B of harness end accelerator grip
connector of accel- sensor.
01
erator grip sensor is
5r0.5 V. Turn key switch
OFF. ;'5㩷 Faulty MC2/A.

Turn key switch Check for continuity

OFF. ;'5 between terminal B
Turn key switch
ON.
Disconnect connec- of harness end Faulty harness up
Check if voltage
connector of accel-
tor of accelerator to terminal B of

between machine
erator grip sensor
sensor.
grip and terminal R of 01㩷 accelerator grip
Check and machine. sensor.
for continuity 01 harness end con-
between terminals R nector of accelerator

and B of accelerator grip sensor is 5r0.5 Faulty harness up
grip sensor. V. to terminal R of
01 accelerator grip
sensor.

Faulty accelerator
01㩷 grip sensor.
Connector
MC2/A
Accelerator grip sensor Connector MCA-3
(accelerator grip sensor end)
(harness end)

T2BC-05-03-013
T2BC-05-03-014
Accelerator grip sensor MC2/A
(harness end)
Connector MCA-1
(harness end)

T2BC-05-03-015

T2BC-05-03-001
T5-3-26
Check of Accelerator Pedal Sensor

x 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

accelerator pedal sensor end connector.
x If input voltage from the accelerator grip sensor is Reconnect the dis-
connected connector.
0.7 V or less, the cause of trouble may be harness
Measures voltage ;'5㩷 Faulty MC2/A.
open circuit between accelerator pedal sensor and between terminal B13
MC2/A, or short circuit between sensor_ 5 V line and of connector of
;'5
ground line. MC2/A and machine.
x Check the wiring connections first. Turn key switch ON.
Faulty accelerator
Check if voltage
Turn key switch OFF. pedal.
reaches specification 01㩷
Connect terminalW
when moving accel-
of harness end con-
erator pedal.
nector of accelerator
pedal sensor to ma- ·Insert a test bar into
;'5 chine by using a clip. the rear of connector.

Disconnect connector ·Specification: 0.7 to
MCA-3 of MC2/A. 4.3 V

between terminal B13
of connector MCA-3

and machine.

Turn key switch ON. Faulty harness up

Check if voltage be- to W terminal of
;'5㩷 tween terminals R accelerator pedal
01 sensor.
and B of harness end
connector of accel-
erator pedal sensor is Turn key switch ;'5㩷 Faulty MC2/A.
5r0.5 V. OFF.
;'5 between terminal B
Turn key switch
of harness end Faulty harness up
PFF. Turn key switch ON.
Disconnect
con- Check if voltage be- connector of accel- to terminal B of
nector of accelerator
tween machine and erator pedal sensor accelerator pedal
and machine. 01㩷
pedal sensor. terminal R of harness
sensor.
Check
for continuity 01 end connector of ac-
between terminals
celerator pedal sen- Faulty harness up
R and B of accel- sor is 5r0.5 V. to terminal R of
erator pedal sensor. accelerator pedal
01
sensor.

Faulty accelerator
pedal sensor.
01㩷
Connector
MC2/A
Accelerator pedal sensor
(accelerator pedal sensor end) Connector MCA-3
(harness end)

Accelerator pedal sensor T2BC-05-03-017 MC2/A T2BC-05-03-013
(harness end) Connector MCA-1

(harness end)

T2BC-05-03-016

T2BC-05-03-001
T5-3-27
Check of Governor Motor Potentio Sensor

x 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

sensor end connector.
x 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
Connect a test har-
circuit between sensor 5 V_ line and ground line. ness between gov-
x Check the wiring connections first. ernor motor potentio YES Faulty MC2/A.
sensor and harness
Turn key switch OFF.
Connect terminal W YES end connector of
machine.
of harness end con-
Turn key switch ON. Faulty governor
nector of governor
Check if voltage
motor potentio sensor motor potentio
reaches specifica- NO
sensor.
YES to machine by using a tion at low idle and
clip. high idle.
between machine ·Specification
and terminal B12 of Low idle: 2.4r0.5 V
Turn key switch ON.
harness end conector High idle: 4.6r0.3 V
Check if voltage be- of connector MCA-3

YES tween terminals R of MC2/A.
and B of harness end
Faulty harness up
connector of governor to terminal W of
Turn key switch motor potentio sensor
OFF. NO governor motor
is 5r0.5 V.
Disconnect gover- potentio sensor.
motor potentio
nor
sensor.
Turn key switch ON. Faulty harness up
Check if resistance Check if voltage be- YES to terminal B of

between terminals tween machine and governor motor
R and B of con- terminal R of harness potentio sensor.

nector of governor
NO
end connector of
motor
potentio
governor motor po- Faulty harness up
sensor is 2r0.6 :. tentio sensor is 5r0.5 to terminal R of
governor motor
V. NO
potentio sensor.

Faulty governor
motor potentio
NO sensor.
Connector
Governor motor potentio sensor MC2/A
Connector MCA-3
(governor motor potentio sensor end)
(harness end)

Red

T2BC-05-03-013
T2BC-05-03-019
Governor motor potentio sensor MC2/A

Connector MCA-1 Black

V
Test Harness

T107-07-03-009
T2BC-05-03-018
T2BC-05-03-001

..
T5-3-28
Check of Accelerator Control Switches


NO Faulty MC2/A.

Check if voltage
between machine Harness open
and terminal D3 of Reconnect the dis- NO circuit between
machine end con- connected connector. accelerator control
nector is 24 V㧚 Disconnect connector switch and MC2/A.
62C-12FW of right
· Key switch: ON control panel. Disconnect connector

YES Check if voltage be- MCA-4 of MC2/A. YES Faulty accelerator
tween machine and
Connect terminal A6 of
lock switch.
terminal #2 of har- Accelerator harness end connector to
ness end connector is
lock switch machine.

24 V. Check
for continuity be- Harness open
tween machine and termi- circuit between
· Key switch: ON nal #3 of harness end con-
NO accelerator lock
nector of connector switch and MC2/A.
62C-12FW.

YES
Disconnect connector YES Faulty accelerator
MCA-4 of MC2/A. preset switch.
Connect terminal A19 of
harness end connector to
machine. Harness open
Accelerator circuit between
Check for continuity be-
preset switch accelerator preset
tween machine and termi- NO
nal #1 of harness end con- switch and MC2/A.
nector of connector

62C-12FW.

Connector
MC2/A MC2/A Right control panel
Connector MCA-1 Connector MCA-4 Connector 62C-12FW
(Machine end)

T2BC-05-03-021 T2BC-05-03-020

T2BC-05-03-006
T5-3-29
Check of Engine Rotation Detection Sensors

MCA-5 of MC2/A. YES Faulty MC2/A.

Connect terminals F4
and F16 of harness
In case of no conti-
end connector of
nuity at terminal #1,
YES connector MCA-5 to
harness open circuit
machine.
between terminal #1
Disconnect con- of engine rotation
between machine and
nector of engine detection sensor and
rotation detection terminals # 1 and #2
MC2/A.
of harness end con-
sensor. NO In case of no conti-
nector of engine rota-
Check if resistance nuity at terminal #2,
between terminals tion detection sensor.
between terminal #2
#1 and #2 of ma- of engine rotation
chine end connec-
tor is 2.3r0.2:. detection sensor and
MC2/A.

Faulty engine rota-
tion detection sen-
NO sor.

Connector
MC2/A
Engine rotation Engine rotation
detection sensor detection sensor Connector MCA-5
(harness end) (sensor end) (harness end)

F4

F11 F1
F22 F12
#1 #2 #2 #1

T25N-05-03-008 T25N-05-03-004

F16

T5-3-30
Check of Governor Motor System

YES Faulty MC2/A.
Connect terminals
#2 to #4 of harness
end connector of
governor motor by Faulty harness up
YES using a clip. YES㩷 to terminal E24 of
Check for continu- connector MCA-6
ity between termi- Connect terminal of MC2/A.
E25 of harness
nals E24 and E25
of harness end end connector of
connector of MCA-6 to machine
Disconnect connector MCA-6. by using a clip.
MCA-6 of MC2/A. Check for continu-
Connect terminals NO
ity between ma-
E11 to E10 of har- chine and terminal
ness end connector of #2 of harness end
YES governor motor by connector of gov- Faulty harness up
using a clip. ernor motor. to terminal E25 of
Check for continuity connector MCA-6
between terminals NO㩷
of MC2/A.
E10 and E11 of har-
ness end connector of
Disconnect con-
nector of governor MCA-6.
Faulty harness up
Connect terminal
motor. E11 of harness
YES to terminal E10 of
Check if resis- connector MCA-6
tances between end connector of
of MC2/A.
terminals #1 and # MCA-6 to machine
3, and between by using a clip.
terminals #2 and Check for continu-
#4 are 5.7r0.57 :. NO ity between ma-
chine and terminal
ሩKey switch: OFF #1 of harness end Faulty harness up
connector of gov- to terminal E11 of
ernor motor.
NO connector MCA-6
of MC2/A.

Faulty governor
motor.
NO

Connector
governor motor MC2/A
Governor motor Connector Connector MCA-6
(governor motor end) (harness end) (harness end)

E10 E11

2 1 1 2
E1 E13
4 3 3 4 E14 E26
E24 E25
T5-3-31
FAILURE OF BRAKE CONTROL SYSTEM
Abnormality

normal.
MC2/B Batteries and Sensor Power Supply".
By using the MC2/A input/output monitor, confirm the

solenoid valve signal.

DD HST PRS Derricking drum hoisting remote LOW ER Lower limit error Brake mode: Harness check
control pressure HI ER Upper limit error Set to auto brake Sensor check
DD LWR PRS Derricking drum lowering remote mode
control pressure DBL ER Double errors
FD HST PRS Front drum hoisting remote control Motor brake:
pressure Input control with
FD LWR PRS Front drum lowering remote control lever in neutral
pressure
pressure
RD LWR PRS Rear drum lowering remote control
pressure
3D HST PRS Third drum hoisting remote control
pressure
3D LWR PRS Third drum lowering remote control
pressure
PILOT PRS Primary pilot pressure LOW ER Lower limit error Pressure drop Harness check
HI ER Upper limit error Input control Sensor check
FD BRK PRS Front brake depressing pressure LOW ER Lower limit error Brake return Harness check
RD BRK PRS Rear brake depressing pressure HI ER Upper limit error Input control Sensor check
DD LCK REL Derricking drum unlocking solenoid ERROR Short circuit ̆ Harness check
valve Solenoid valve
FM BRK REL Front motor brake release solenoid check
valve
RM BRK REL Rear motor brake release solenoid
valve
3M BRK REL Fourth motor brake release solenoid
valve
3D BRK LP Third/fourth auto brake indicator ERROR Short circuit ̆ Harness check
Solenoid valve
check

x 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".
x 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

Free Indicator
Front Drum Brake

Release Solenoid
Valve
Rear Drum Brake

Release Solenoid Valve
Derricking Drum Hoisting Fourth Drum Brake

Remote Control Pressure Release Solenoid Valve
Sensor
Derricking Drum Lowering
Sensor
Front Drum Hoisting Remote

Front Drum Lowering Derricking Drum

Remote Control Pressure Unlocking Solenoid
Sensor Valve
Rear Drum Hoisting Remote
Front Motor Brake
Release Solenoid
Rear Drum Lowering Valve
Sensor
Rear Motor Brake
Third / Fourth Drum Hoisting Release Solenoid
Remote Control Pressure Valve
Sensor
Third / Fourth Drum Lowering Fourth Motor Brake
Remote Control Pressure Release Solenoid
Sensor Valve
Primary Pilot Pressure Third / Fourth Free Indicator

Sensor
Front Brake Depress
Detection
Rear Brake Depress
Front Free Indicator
Detection
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

Check of Derricking Drum Hoisting Remote Con-
trol Pressure Sensor System

x 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.
x If input voltage from the derricking drum hoisting
remote control pressure sensor is less than 0.5V, Reconnect the
the cause of trouble may be harness open circuit disconnected ;'5㩷 Faulty MC2/A
connector. Check if
between derricking drum hoisting remote control voltage between
pressure sensor and MC2/A, or short circuit be- ;'5 machine and ter- Faulty derricking
tween SENSOR_5V line and ground line.
Turn key switch minal B1 of con- drum hoisting re-
x Check the wiring connections first. OFF. Connect nector of MC2/A 01㩷 mote control pres-
terminal W of har- meets specifica- sure sensor

ness end connection.
tor of derricking
·Insert a test bar into the
drum hoisting re-
rear of connector.
;'5 mote control pres- ·Specification: 0.5 to 4.5 V
sure sensor to
machine.
Disconnect con-
nector MCA-3 of Faulty harness up
to terminal W of
MC2/A. Check for
continuity between derricking drum
Turn key switch ON. terminal B1 of hoisting remote
Check if voltage be- control pressure
connector MCA-3
tween terminals R 01 sensor
and machine.
;'5㩷 and B of harness end
connector of derrick- ;'5㩷 Faulty MC2/A
Turn key switch
key switch ing drum hoisting
Turn OFF. Check for
remote control pres-
OFF. continuity between Faulty harness up
sure sensor is 5r0.5 machine and ter-
Disconnect con- to terminal B of
V.
nector
of derricking Turn key switch minal B of harness derricking drum
ON. Check if volt- ;'5 end connector of
drum hoisting re- hoisting remote
control pres-
mote age between ma- derricking drum 01㩷 control pressure
sure
sensor. chine and terminal hoisting remote sensor
Check for continu- R of harness end control pressure
itybetween termi- 01 connector of der-
sensor. Faulty harness up
nals R and B of ricking drum hoist- to terminal R of

derricking drum
ing remote control derricking drum
hoisting
remote pressure sensoris hoisting remote
control pressure 5r0.5 V. control pressure
01
sensor

Faulty derricking
Connector 01㩷 drum hoisting re-
Derricking drum hoisting remote control MC2/A
Connector MCA-3 mote control pres-
pressure sensor (harness end) (harness end) sure sensor

T2BC-05-03-013
T2BC-05-03-023
D erricking drum hoisting remote control MC2/A

pressure sensor (sensor end) Connector MCA-1
(harness end)

T2BC-05-03-024 T2BC-05-03-001
T5-3-34
Check of Derricking Drum Lowering Remote
Control Pressure Sensor System

x 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-
(ground) of derricking drum lowering remote control Reconnect the
disconnected
x If input voltage from the derricking drum lowering connector. ;'5㩷 Faulty MC2/A.
remote control pressure sensor is less than 0.5V, Check if voltage
the cause of trouble may be harness open circuit ;'5 between machine Faulty derricking
between derricking drum lowering remote control and terminal B9 of drum lowering
pressure sensor and MC2/A, or short circuit be- connector of
MC2/A meets 01㩷 remote control
tween SENSOR_5V line and ground line. Turn key switch pressure sensor.
x Check the wiring connections first. specification.
OFF.
Connect terminal ·Insert a test bar into the
rear of connector.
W of harness end

;'5 connector of der- ·Specification: 0.5 to 4.5 V
ricking drum low-

ering remote con-
trol pressure sen-
Faulty harness up
sor to machine.
Disconnect con- to terminal W of
derricking drum
Turn key switch ON. nector MCA-3 of
lowering remote
Check if voltage be- MC2/A.
01 control pressure
tween terminals R Check for continu-
sensor.
and B of harness end ity between ma-
;'5㩷 connector of derrick-
chine and terminal ;'5㩷 Faulty MC2/A.
ing drum lowering B9 of connector Turn key switch
Turn remote control pres- MCA-3. OFF.
key switch sure sensor is 5r0.5
OFF. Check for continu- Faulty harness up

Disconnect con- V. ity between ma- to terminal B of
nector of derricking Turn key switch chine and terminal derricking drum
;'5
drum lowering ON. B of harness end 01㩷 lowering remote

remote control Check if voltage connector of der- control pressure
pressure sensor. between machine ricking drum low- sensor.

Check for continu- and terminal Rof ering remote con-
ity between termi- 01 harness end control pressure sen- Faulty harness up
sor.
nals R and B of nector of derricking to terminal R of

derricking drum drum lowering derricking drum
lowering
remote remote control lowering remote
control pressure pressure sensor is control pressure
01

sensor. 5r0.5 V. sensor.
Faulty derricking
Connector 01㩷 drum lowering
remote control
MC2/A
Derricking drum lowering remote control Connector MCA-3 pressure sensor.
pressure sensor (sensor end)
(harness end)

T2BC-05-03-013
T2BC-05-03-023
Derricking drum lowering remote control MC2/A
pressure sensor (harness end) Connector MCA-1
(harness end)

T2BC-05-03-024 T2BC-05-03-001
T5-3-35
Check of Front Drum Hoisting Remote Control
Pressure Sensor System

x 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.
x 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 Reconnect the
drum hoisting remote control pressure sensor and
disconnected
MC2/A, or short circuit between SENSOR_5V line connector. ;'5㩷 Faulty MC2/A.
and ground line. Turn key switch Check if voltage
x Check the wiring connections first. ;'5 between machine
OFF.

Connect terminal and terminal C6 of Faulty front drum

W of harness end connector of hoisting remote

connector of front MC2/A meets 01㩷 control pressure
drum hoisting specification. sensor.
re-
;'5 mote control pres- ·Insert a test bar into the
sure sensor to rear of connector.
machine. ·Specification: 0.5 to 4.5 V
Disconnect con-
Turn key switch ON. nector MCA-2 of Faulty harness up
Check if voltage be- MC2/A. to terminal W of

Check for continu- front drum hoisting
tween terminals R
and B of harness end ity between ma-
remote control
;'5㩷 connector of front chine and terminal 01 pressure sensor.
drum hoisting remote
C6 of connector
control pressure MCA-2. Turn key switch
;'5㩷 Faulty MC2/A.
Turn key switch sensor is 5r0.5 V. OFF.

OFF.
Check for continu-
Turn key switch
Disconnect con- ON. ;'5 ity between ma- Faulty harness up
chine and terminal to terminal B of
nector of front Check if voltage
hoisting re-
drum
between machine B of harness end front drum hoisting
mote control pres- and terminalR of connector of front remote control
drum hoisting re- 01㩷 pressure sensor.
sure sensor. harness end con-
Check
for continu- mote control pres-
01 nector of front sure sensor. Faulty harness up
ity between termi- drum hoisting re- to terminal R of
R and B of
nals

mote control pres- front drum hoisting
front
drum hoisting sure sensor is remote control
remote control 5r0.5 V. pressure sensor.
01
pressure sensor.

Faulty front drum

hoisting remote
Connector 01㩷
control pressure
MC2/A sensor.
Front drum hoisting remote control Connector MCA-2
(harness end)

T2BC-05-03-025
T2BC-05-03-023
MC2/A
Front drum hoisting remote control Connector MCA-1
pressure sensor (harness end) (harness end)

T2BC-05-03-024 T2BC-05-03-001
T5-3-36
Check of Front Drum Lowering Remote Control

x If input voltage from the front drum lowering remote
of trouble may be failure of front lowering remote
of MC2/A and terminal B (ground) of front drum
lowering remote control pressure sensor end con-

nector.
x 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
Reconnect the
drum lowering remote control pressure sensor and disconnected
MC2/A, or short circuit between SENSOR_5V line connector. ;'5㩷 Faulty MC2/A.
and ground line. Turn key switch Check if voltage
x Check the wiring connections first. ;'5
OFF. between machine
W
Connect terminal and terminal C12 Faulty front drum
of harness end of connector of lowering remote

connector of front MC2/A meets 01㩷 control pressure
drum lowering re- specification. sensor.

;'5 mote control pres-
sure sensor to ma-
rear of connector.
chine.
·Specification: 0.5 to 4.5
Disconnect con-
V
nector MCA-2of Faulty harness up
Turn key switch ON. MC2/A. to terminal W of
Check for continuity front drum lower-
tween terminals R between machine
01 ing remote control
;'5㩷 and B of harness end and terminal C12 of pressure sensor.
connector of front
connector MCA-2.
drum lowering remote Turn key switch
OFF.
control pressure ;'5㩷 Faulty MC2/A.
Turn Check for continu-
key switch sensor is 5r0.5 V.
OFF. ity between ma-

Disconnect con-
Turn key switch ;'5 chine and terminal
nector of front ON. B of harness end Faulty harness up

Check if voltage connector of front
drum lowering to terminal B of

remote control between machine
drum lowering front drum lower-
and terminal R of remote control 01㩷
pressure sensor. ing remote control

Check for continu-
01 harness end con- pressure sensor. pressure sensor.
itybetween termi- nector of front

nals R and B of drum lowering Faulty harness up
drum lowering
front
remote control to terminal R of
remote control pressure sensor is 01 front drum lower-
5r0.5 V. ing remote control
pressure sensor.
pressure sensor.
Connector Faulty front drum
01㩷 lowering remote
Front drum lowering remote control MC2/A control pressure
Connector MCA-2
pressure sensor (sensor end) (harness end) sensor.

T2BC-05-03-025
T2BC-05-03-023
MC2/A
Front drum lowering remote control Connector MCA-1
pressure sensor (harness end)
(harness end)

T2BC-05-03-001
T2BC-05-03-024
T5-3-37
Check of Rear Drum Hoisting Remote Control

x If input voltage from the rear drum hoisting remote

of trouble may be failure of rear hoisting remote
of MC2/A and terminal B (ground) of rear drum
hoisting remote control pressure sensor end con- Reconnect the
nector. disconnected
x If input voltage from the rear drum hoisting remote connector. ;'5㩷 Faulty MC2/A.
control pressure sensor is less than 0.5V, the cause Check if voltage
of trouble may be harness open circuit between rear between machine
;'5 and terminal C5 of
drum hoisting remote control pressure sensor and connector of Faulty rear drum
MC2/A, or short circuit between SENSOR_5V line
and ground line. MC2/A meets 01㩷 hoisting remote
Turn key switch specification. control pressure
x Check the wiring connections first. OFF. sensor.
Connect terminal ·Insert a test bar into the
rear of connector.
W of harness end
connector of rear ·Specification: 0.5 to 4.5 V

;'5 drum hoisting re-

mote control pres-
sure sensor to
machine.
Disconnect con-
nector MCA-2 of
MC2/A. Faulty harness up
Turn key switch ON. Check for continu-
to terminal W of
Check if voltage be- ity between ma- rear drum hoisting
tween terminals R
chine and terminal remote control
;'5㩷 and B of harness end 01 pressure sensor.
C5 of connector
connector of rear MCA-2.
drum hoisting remote Turn key switch
OFF.
Turn key switch control pressure ;'5㩷 Faulty MC2/A.

OFF. sensor is 5r0.5 V. Check for continu-
Disconnect
con- Turn key switch ity between ma-
;'5 chine and terminal Faulty harness up
nector of rear drum ON. to terminal B of

hoisting remote Check if voltage
B of harness end
rear drum hoisting
control pressure between machine connector of rear
remote control
sensor. and terminal Rof drum hoisting re- 01㩷 pressure sensor.

Check for continu- 01 harness end con- mote control pres-
sure sensor.
ity between termi- nector of rear drum Faulty harness up

nals R and B of hoisting remote to terminal R of
rear
drum hoisting control pressure rear drum hoisting
remote control sensor is 5r0.5 V. 01 remote control

pressure sensor. pressure sensor.

Faulty rear drum
hoisting remote
Connector 01㩷 control pressure
Rear drum hoisting remote control MC2/A sensor.

ector MCA-2
Conn
(harness end)

T2BC-05-03-025
T2BC-05-03-023
Rear drum hoisting remote control MC2/A
(harness end)

T2BC-05-03-024 T2BC-05-03-001
T5-3-38
Check of Rear Drum Lowering Remote Control

x If input voltage from the rear drum lowering remote
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
Reconnect the
connector. disconnected
x If input voltage from the rear drum lowering remote connector. ;'5㩷 Faulty MC2/A.
control pressure sensor is less than 0.5V, the cause Check if voltage
of trouble may be harness open circuit between rear ;'5 between machine
drum lowering remote control pressure sensor and and terminal C11
Faulty rear drum
MC2/A, or short circuit between SENSOR_5V line of connector of
lowering remote
and ground line. MC2/A meets 01㩷
Turn key switch control pressure
x Check the wiring connections first. specification.
OFF. sensor.
Connect terminal W ·Insert a test bar into the
of harness end rear of connector
·Specification: 0.5 to 4.5 V
;'5 connector of rear
drum lowering re-
mote control pres-
sure sensor to ma-
chine.
Disconnect con-
Turn key switch ON. nector MCA-2 of
Check if voltage be- to terminal W of
tween terminals R Check for continuity
between machine rear drum lowering
and B of harness end remote control
;'5㩷 connector of rear and terminal C11 of 01
connector MCA-2. pressure sensor.
drum lowering remote Turn key switch
control pressure OFF.
Turn key switch sensor is 5r0.5 V. Check for continu- ;'5㩷 Faulty MC2/A.

OFF.
Turn key switch ity between ma-
Disconnect
con-
nector of rear drum
ON. ;'5 chine and terminal Faulty harness up
Check if voltage B of harness end

lowering remote
between machine connector of rear to terminal B of
control pressure rear drum lowering
and terminal R of drum lowering remote control
sensor. remote control 01㩷 pressure sensor.
harness end con-
Check
for continu- 01 nector of rear drum pressure sensor.
ity between termi- Faulty harness up
R and B of lowering remote
nals to terminal R of
control pressure
rear
drum lowering rear drum lowering
sensor is 5r0.5 V.
remote control remote control

pressure sensor. 01 pressure sensor.

Faulty rear drum
Connector 01㩷 lowering remote
MC2/A
Re ar drum lowering remote control Connector MCA-2 control pressure
pressu re sensor (sensor end) (harness end) sensor.

T2BC-05-03-023 T2BC-05-03-025
Rear drum lowering remote control MC2/A

(harness end)

T2BC-05-03-001
T2BC-05-03-024
T5-3-39
Check of Third / Fourth Drum Hoisting Remote
Control Pressure Sensor System (Optional)

x If input voltage from the third / fourth drum hoisting

cause of trouble may be failure of third / fourth drum
hoisting remote control sensor, or open circuit be-
(ground) of third/fourth drum hoisting remote control
x 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 Reconnect the
between third/fourth drum hoisting remote control disconnected ;'5㩷
connector. Faulty MC2/A.
pressure sensor and MC2/A, or short circuit be-
tween SENSOR_5V line and ground line. ;'5 Check if voltage
Turn key switch between machine
x Check the wiring connections first. OFF. and terminal C4 of Faulty third / fourth
Connect terminal connector of drum hoisting remote

W of harness end MC2/A meets 01㩷 control pressure
connector ofthird / specification. sensor.
;'5 fourth drum hoist- ·Insert a test bar into the

ing remote control
rear of connector.
pressure sensor
to ·Specification: 0.5 to 4.5 V
machine.

Disconnect con-
nector MCA-2 of
MC2/A. Faulty harness up to
Turn key switch ON. Check for continu- terminal W of third /
ity between ma- fourth drum hoisting
tween terminals R remote control
chine and terminal 01
and B of harness end pressure sensor.
;'5㩷
connector of third /
C4 of connector

MCA-2.
fourth drum hoisting
Turn key switch remote control pres- Turn key switch

OFF. sure sensor is 5r0.5 OFF. ;'5㩷
Check for continu- Faulty MC2/A.
Disconnect
con- V. Turn key switch
nector of third /
ity between ma-
ON. ;'5 Faulty harness up to
drum hoist-
fourth chine and terminal
Check if voltage terminal B of third /
ing B of harness end
remote control between terminals
pressure sensor. R and B of harness remote control pres-

Check for continu- fourth drum hoist- 01㩷 sure sensor.
end connector of
ity between termi- 01 third / fourth drum ing remote control
R and B of
nals pressure sensor. Faulty harness up to
hoisting remote
third
/ fourth drum control pressure terminal R of third /
hoisting remote
sensor is 5r0.5 V.

control pressure remote control pres-
01 sure sensor.
sensor.

Faulty third drum
01㩷 hoisting remote con-
Connector MC2/A trol pressure sensor.
Third / fourth drum hoisting remote Connector MCA-2
control pressure sensor (sensor end) (harness end)

T2BC-05-03-025
T2BC-05-03-023
Third / fourth drum hoisting remote MC2/A
Connector MCA-1
cont rol pressure sensor (harness end)
(harness end)

T2BC-05-03-001
T2BC-05-03-024
T5-3-40
Check of Third / Fourth Drum Lowering Remote
Control Pressure Sensor System (Optional)

• If input voltage from the third / fourth drum lowering

cause of trouble may be failure of third/fourth drum
lowering remote control sensor, or open circuit be-
(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- Reconnect the
tween third / fourth drum lowering remote control disconnected ;'5㩷 Faulty MC2/A.
connector.
pressure sensor and MC2/A, or short circuit between
SENSOR_5V line and ground line. ;'5 Check if voltage
between machine Faulty third / fourth
• Check the wiring connections first. Turn key switch
and terminal C10 drum lowering re-
OFF.
Connect terminal
of connector of 01㩷 mote control pres-
W of harness end MC2/A meets sure sensor.
/ specification.
connector of third
fourth drum lower-
;'5㩷 ing remote control rear of connector
pressure sensor to ·Specification: 0.5 to 4.5 V
machine.
Disconnect con-
nector MCA-2 of

Check for continu- to terminal W of
Turn key switch ON. ity between ma- third / fourth drum
Check if voltage be- chine and terminal lowering remote
tween terminals R
C10 of connector 01㩷 control pressure
;'5㩷 and B of harness end MCA-2. sensor.
fourth drum lowering Turn key switch
remote control pres-

Turn key switch OFF. ;'5㩷 Faulty MC2/A.

OFF. sure sensor is 5±0.5 Check for continu-
Disconnect
third / V. ity between ma-
fourth drum lower- Turn key switch ;'5㩷
chine and terminal Faulty harness up to
ing remote control ON. terminal B of third /
pressure sensor. Check if voltage B of harness end
fourth drum lower-
between machine connector of third /
Check for continu- fourth drum lowering remote control
and terminal R of 01㩷 pressure sensor.
itybetween termi- 01 harness end con- ing remote control
nals R and B of pressure sensor.
/ fourth drum
third nector of third / Faulty harness up to
fourth drum lower- terminal R of third /
lowering
remote fourth drum lower-
control pressure
ing remote control
pressure sensor is 01㩷 ing remote control

sensor. pressure sensor.
5±0.5 V.
Faulty third / fourth
01㩷 drum lowering re-

mote control pres-
Connector sure sensor.
Third / fourth drum lowering
MC2/A
MC2/A
Third / fourth drum lowering

remote control pressure remote control pressure sensor
sensor (sensor end) (harness end)

T2BC-05-03-025 T2BC-05-03-001
T2BC-05-03-023 T2BC-05-03-024

T5-3-41
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 Reconnect the
disconnected ;'5㩷 Faulty MC2/A.
harness open circuit primary pilot circuit pressure
connector.
sensor and MC2/A, or short circuit between SEN- Check if voltage
SOR_5V line and ground line. ;'5㩷
between machine
• Check the wiring connections first. Turn key switch
and terminal C2 of Faulty primary pilot
OFF.
Connect terminal connector of 01㩷 circuit pressure
end MC2/A meets sensor.
W of harness
connector ofpri- specification.
mary pilot circuit ·Insert a test bar into the
pressure sensor to rear of connector
;'5 machine.
Disconnect con-
nector MCA-2 of
MC2/A.

Check for continu-

ity between ma-
chine and terminal
Turn key switch ON. C2 of connector
Check if voltage be- MCA-2. Faulty harness up
to terminal W of
tween terminals R
;'5㩷 and B of harness end 01㩷 primary pilot circuit
pressure sensor.
connector of primary
pilot circuit pressure
Turn key switch
sensor is 5±0.5 V. OFF. ;'5 Faulty MC2/A.
key switch
Turn Check for continu-
OFF.
Turn key switch ;'5 ity between ma-
Disconnect con- chine and terminal
nector
of primary ON. Faulty harness up
Check if voltage B of harness end
pilot circuit pres- to terminal B of
sensor. between machine connector of pri-
sure mary pilot circuit 01㩷 primary pilot circuit

Check
for continu- 01㩷 and terminal R of pressure sensor.
pressure sensor.
ity between termi- harness end con-

nector of primary
R and B of
nals Faulty harness up

primary pilot circuit pilot circuit pres-
to terminal R of
pressure sensor. sure sensor is primary pilot circuit
5±0.5 V. 01
pressure sensor.

Faulty primary pilot
01㩷 circuit pressure
sensor.
Primary pilot circuit pressure Primary pilot circuit pressure

MC2/A MC2/A

sensor (sensor end) sensor (harness end) Connector MCA-2 Connector MCA-1

T2BC-05-03-025
T2BC-05-03-041 T2BC-05-03-001
T2BC-05-03-040

T5-3-42
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. Reconnect the
• If input voltage from the front brake depressing disconnected con-
pressure sensor is less than 0.5V, the cause of nector. ;'5 Faulty MC2/A.

trouble may be harness open circuit between front Check if voltage
;'5 between machine
brake depressing pressure sensor and MC2/A, or
short circuit between SENSOR_5V line and ground and terminal C8 of Faulty front brake
connector of depressing pres-
line. Turn key switch 01 sure sensor.
MC2/A meets
• Check the wiring connections first. OFF.

specification.

Connect terminal
W of harness end ·Insert a test bar into the
connector of front rear of connector.
brake depressing
;'5㩷 pressure sensor to
machine.
Disconnect con-
nector MCA-2 of
MC2/A.
Check for continu- Faulty harness up to
ma-
ity between
Turn key switch ON. terminal W of front
chine and terminal brake depressing
Check if voltage be- C8 of connector 01
tween terminals R pressure sensor.
MCA-2.
;'5㩷 and B of harness end
connector of front
brake depressing Turn key switch
pressure sensor is
Turn key switch OFF. ;'5㩷 Faulty MC2/A.
OFF. 5±0.5 V. Check for continu-
ity between ma-
Disconnect con- Turn key switch
;'5㩷
chine and terminal
nector of front
brake depressing ON. B of harness end Faulty harness up to
pressure sensor. Check if voltage connector of front terminal B of front
Check for continu-
between machine brake depressing brake depressing
01 pressure sensor.
ity between termi- 01 and terminal R of pressure sensor.
nals R and B of harness end con-
front brake de-
nector of front Faulty harness up to
brake depressing terminal R of front
pressing pressure
pressure sensor is brake depressing
sensor. 01 pressure sensor.
5±0.5 V.
Faulty front brake
01㩷 depressing pressure

sensor.
Connector
Front brake depressing MC2/A
Front brake depressing MC2/A
pressure sensor pressure sensor
(sensor end) (harness end) (harness end) (harness end)

T2BC-05-03-001
T2BC-05-03-025
T2BC-05-03-041
T2BC-05-03-040

T5-3-43
Check of Rear Brake Depressing Pressure Sensor
System

• If input voltage from the rear brake depressing

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. Reconnect the
• Check the wiring connections first. Turn key switch disconnected
;'5 Faulty MC2/A.
OFF. connector.
Check if voltage
Connect terminal
;'5㩷
W of harness end between machine

connector of rear and terminal C1 of Faulty rear brake
brake depressing connector of depressing pres-
MC2/A meets 01㩷 sure sensor.
pressure sensor to
;'5 machine. specification.
Disconnect con- ·Insert a test bar into the
nector MCA-2of rear of connector. Faulty harness up
MC2/A. ·Specification: 0.5 to 4.5 V to terminal W of
Check for continu- rear brake de-
ity between ma- pressing pressure
Turn key switch ON. chine and terminal 01
sensor.
Check if voltage be- C1 of connector
tween terminals R MCA-2. Turn key switch
;'5㩷 and B of harness end OFF. ;'5㩷 Faulty MC2/A.
connector of rear Check for continu-
key switch
Turn brake depressing Turn key switch ;'5㩷 ity between ma-
OFF.
pressure sensor is chine and terminal Faulty harness up
ON.
Disconnect con- 5±0.5 V. B of harness end to terminal B of
Check if voltage
nector of rear connector of rear rear brake de-
between machine 01 pressing pressure
brake brake depressing
depressing and terminal R of
sensor.
pressure sensor. pressure sensor.
01 harness end con-

Check for continu- nector of rear
R and B of brake depressing to terminal R of
nals pressure sensor
rear
is rear brake de-
brake de- 5±0.5 V. 01
pressing pressure pressing pressure

sensor. sensor.

Faulty rear brake

depressing pres-
01㩷
sure sensor.
Connector
brake depressing
Rear Rear
brake depressing MC2/A MC2/A
pressure sensor pressure sensor Connector MCA-1
Connector MCA-2
(harness end)

(sensor end) (harness end)
(harness end)

T2BC-05-03-001
T2BC-05-03-025

T2BC-05-03-041
T2BC-05-03-040

T5-3-44
Check of Fourth Brake Depressing Pressure
Sensor System

• If input voltage from the fourth brake depressing
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 Reconnect the
line.
disconnected
• Check the wiring connections first.
Turn key switch connector.
OFF.
;'5㩷 Check if voltage
Connect terminal between machine
and terminal C7 of Faulty fourth brake
W of harnessend
connector of fourth connector of depressing pres-
01㩷 sure sensor.
brake depressing MC2/A meets
pressure sensor to specification.
;'5 machine.

Disconnect con- rear of connector. Faulty harness up
nector MCA-2 of ·Specification: 0.5 to 4.5 V
to terminal W of
MC2/A.
fourth brake de-

Check for continu-
pressing pressure
ity between ma- 01㩷
Turn key switch ON. sensor.
chine and terminal
Check if voltage be- C7 of connector Turn key switch,

tween terminals R MCA-2. OFF.
;'5㩷 and B of harness end ;'5 Faulty MC2/A.
Check for continu-
connector of fourth ity between ma-
key switch Turn key switch

Turn brake depressing ;'5 chine and terminal
ON. Faulty harness up
OFF.
pressure sensor is B of harness end
Check if voltage to terminal B of
Disconnect con- 5±0.5 V. connector of fourth
of fourth between machine
fourth brake de-
nector and terminal R of brake depressing 01㩷 pressing pressure
brake
depressing harness endcon- pressure sensor.
pressure sensor. sensor.
01㩷 nector of fourth
for continu-
Check
brake depressing
R and B of pressure sensor
is to terminal R of
nals 5±0.5 V.
fourth
brake de- fourth brake de-
01
pressing pressure pressing pressure

sensor. sensor.

Faulty fourth brake
01㩷 depressing pres-
Connector sure sensor.

Fourth brake depressing Fourth brake depressing MC2/A MC2/A
pressure sensor
pressure sensor Connector MCA-2
Connector MCA-1
(sensor end) (harness end) (harness end) (harness end)

T2BC-05-03-001
T2BC-05-03-025

T2BC-05-03-041

T2BC-05-03-040

T5-3-45
Check of Derricking Drum Unlocking Solenoid
Valve


• The cause of trouble may be failure of derricking
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.

Faulty derricking
;'5㩷 drum unlocking
solenoid valve.

Disconnect con- Faulty harness
nector of derricking
Connect connector between ground
drum unlocking
MCA-6. ;'5 and derricking
solenoid valve. Connect terminal #2 drum unlocking
Check if voltage
of harness end con- solenoid valve, or
between terminals of derricking
nector faulty ground.
#1 and #2 of har- ;'5㩷 drum unlocking sole-
ness end connec- Disconnect connector
noid valve to ma-
tor is 24 V. MCA-6 of MC2/A.
chine.

Check if continuity
· Derricking drum Check if voltage be-
hoisting or derrick- between terminal #2 terminal #2 and
tween Faulty MC2/A.
of harness end con-
ing drum lowering machine
is 24 V. 01㩷
nector of derricking
operation 01㩷
drum unlocking sole- · Derricking drum hoisting or

noid valve and termi- derricking drum lowering Faulty harness
nal E4 of harness end
operation between MC2/A
connector of connec- and derricking
tor MCA-6.
01 drum unlocking
solenoid valve.

Connector
MC2/A
Connector MCA-6
Derricking drum unlocking
solenoid valve (harness end) (harness end)

T2BC-05-04-027
T2BC-05-04-010
T5-3-46
Check of Front Motor Brake Release Solenoid
Valve

• The cause of trouble may be failure of derricking
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.

;'5㩷
Faulty front motor
brake release so-
lenoid valve.

Disconnect con- Faulty harness
nector of front mo-
between ground
Connect connector ;'5
tor brake release MCA-6.
and front motor
solenoid valve. brake release so-
Check if voltage Connect terminal #1
lenoid valve, or
of harness end con-
between terminals nector of front motor
faulty ground.
#1 and #2 of har- Disconnect connector ;'5㩷
ness end connec- brake release sole-
MCA-6 of MC2/A. noid valve to ma-
tor is 24 V. Check for continuity
chine.
· Front drum hoisting or between terminal #1 Check if voltage be-
front drum lowering of harness end con- tween machine and Faulty MC2/A.
operation nector of front motor terminal #1 is 24 V. 01㩷
01㩷 brake release sole-
noid valve and termi- · Front drum hoisting or
nal E18 of harness front drum lowering Faulty harness
end connector of operation between MC2/A
connector MCA-6. and front motor
01 brake release so-
lenoid valve.

Connector
MC2/A
Front motor brake release Connector MCA-6
solenoid valve (harness end) (harness end)

1 2

T2BC-05-04-027
T25N-05-03-011

T5-3-47
Check of Rear Motor Brake Release Solenoid
Valve

• 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.

Faulty rear motor
;'5㩷
brake release so-
lenoid valve.

Disconnect con-
Faulty harness
nector of rear mo- Connect connector between ground
tor brake release MCA-6. ;'5㩷
solenoid valve. and rear motor
Connect terminal #1 brake release so-
Check if voltage of harness end con- lenoid valve, or
between terminals nector of rear motor
#1 and #2 of har- faulty ground.
;'5 brake release sole-
ness end connec- Disconnect connector noid valve to ma-
tor is 24 V. MCA-6 of MC2/A. chine.
· Rear drum hoisting Check for continuity Check if voltage be-
between terminal #1
or rear drum lower- of harness end con-
tween terminal #1 and Faulty MC2/A.
ing operation machine is 24 V.
nector of rear motor 01
01㩷 · Rear drum hoisting
brake release sole-
noid valve and termi- or rear drum lower-
ing operation Faulty harness
nal E5 of harness end between MC2/A
connector of connec- and rear motor
tor MCA-6. 01㩷 brake release so-
lenoid valve.

Connector
MC2/A
Rear motor brake release Connector MCA-6
(harness end)

solenoid valve (harness end)

1 2

T25N-05-03-011
T2BC-05-04-027

T5-3-48
Check of Fourth Motor Brake Release Solenoid
Valve (Optional)

• The cause of trouble may be failure of third / fourth
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.

;'5㩷
Faulty fourth motor
brake release so-
lenoid valve.

Faulty harness
Disconnect fourth
winch connector. between ground
Check if voltage Connect connector ;'5 and fourth motor
MCA-6.
brake release so-
between terminals Connect terminal #2 lenoid valve, or
#1 and #2 of har-
of harness end con- faulty ground.
ness end connec- nector
tor is 24 V. ;'5㩷 of fourth winch
Disconnect connector connector to machine.
MCA-6 of MC2/A. if voltage be-
Check
· Fourth drum hoist- Check for continuity tween terminal #2 and
ing or fourth drum
lowering operation between terminal #2 machine is 24 V.
of harness end con- Faulty MC2/A.
drum hoist-
· Fourth
nector of fourth winch 01㩷
01㩷 connector and termi- ingor fourth drum
nal E19 of harness lowering operation
Faulty harness
end connector of between MC2/A
connector MCA-6. and fourth motor
brake release so-
01
lenoid valve.

Connector
MC2/A
Fourth winch Connector MCA-6

T2BC-05-04-027

T2BC-05-03-026
T5-3-49
Check of Third/Fourth Auto Brake Indicator (Op-
tional)


Disconnect con-
nector
MCA-6 of
MC2/A.

Check if third /
fourth
auto brake Faulty harness be-
indicator goes tween MC2/A and

OFF. third / fourth auto
01㩷
brake indicator.

Connector
MC2/A
Connector MCA-6
(harness end)

T2BC-05-04-027

T5-3-50
Check of Brake Mode Key Switch System

YES Faulty MC2/A.

Disconnect con-
nector MCA-4 from
MC2/A. Disconnect connector
MCA-1 of MC2/A and YES Faulty brake mode
Check if voltage
between terminal connector 62C-16MW key switch.
of left control panel.
A8 of harness end Connect terminals D2
connector and ma-
chine is 24 V. and A8 of harness
end connector of
· Key switch: ON connectors MCA-1 In case of no con-
· Brake mode key and MCA-4 to ma- tinuity at terminal
switch: ON NO
chine. #8, harness open
Check for continuity circuit between
between machine and terminal #8 of left
terminals #8 and #9 control panel and
of harness end con- MC2/A.
nector of left control NO In case of no con-
panel. tinuity at terminal
#9, harness open
circuit between
terminal #9 of left
control panel and
MC2/A.

Connector

MC2/A MC2/A Left control panel
Connector MCA-1 Connector MCA-4 Connector 62C-16MW

T2BC-05-03-001 T2BC-05-03-020 T2BC-05-04-022

T5-3-51
Check of Front Drum Brake Mode Selection
Switch System


YES Faulty MC2/A.

Disconnect con-
nector MCA- of
MC2/A.
YES Faulty front drum
Check if voltage Disconnect connector
between terminal MCA-1 of MC2/A and brake mode selec-
A21of harness end connector of front tion switch.
lever.
connector and ma- Check for continuity
chine is 24 V.
between terminal D2 In case of no con-
· Key switch: ON tinuity at terminal
of connector MCA-1
· Front drum brake NO and terminal #4 of #3, harness open
mode selection circuit between
switch: ON connector of front
lever, terminal A21 of front drum brake
connector MCA-4 and mode selection
terminal #3 of con- switch and MC2/A.
nector of front lever. In case of no con-
NO tinuity at terminal
#4, harness open
circuit between
front drum brake
mode selection
switch and MC2/A.

Connector
MC2/A MC2/A Connector of front drum brake
Connector MCA-1 Connector MCA-4 mode selection switch


T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005

T5-3-52
Check of Rear Drum Brake Mode Selection Switch
System


YES Faulty MC2/A.

Disconnect con-
nector MCA-4 of
MC2/A.
Check if voltage Disconnect connector YES Faulty rear drum
between terminal MCA-1 of MC2/A and brake mode selec-
connector of rear tion switch.
A9 of harness end lever.
connector and ma-
chine is 24 V. Check for continuity
between terminal D2
· Key switch: ON of connector MCA-1 In case of no con-
· Rear drum brake and terminal #4 of tinuity at terminal
mode selection NO
connector of rear #3, harness open
switch: ON lever, terminal A9 of circuit between
connector MCA-4 and rear drum brake
terminal #3 of con- mode selection
nector of rear lever. switch and MC2/A.
NO In case of no con-
tinuity at terminal
#4, harness open
circuit between
rear drum brake
mode selection
switch and MC2/A.

Connector

MC2/A MC2/A Connector of rear drum brake
Connector MCA-1 Connector MCA-4 mode selection switch

T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005

T5-3-53
Check of Third / Fourth Drum Brake Mode Selec-
tion Switch System (Optional)

YES Faulty MC2/A.

Disconnect con-
nector MCA-4 of
MC2/A. YES Faulty third / fourth
Check if voltage Disconnect connector drum brake mode
between terminal MCA-1 of MC2/A.
A22 of harness end selection switch.
connector and ma- between terminal D2
chine is 24 V. of connector MCA-1 In case of no con-
and terminal #4 of
· Key switch: ON tinuity at terminal
· Third/fourth drum NO
connector of third / #3, harness open
fourth lever, terminal circuit between
brake mode se- A22 of connector
third / fourth drum
lection switch: ON
MCA-4 and terminal brake mode selec-
#3 of connector of
tion switch and
third / fourth lever. MC2/A.

NO In case of no con-
tinuity at terminal
#4, harness open
circuit between
third / fourth drum
brake mode selec-
tion switch and
MC2/A.

Connector

MC2/A MC2/A Connector of third / fourth drum

Connector MCA-1 Connector MCA-4 brake mode selection switch

T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005

T5-3-54
Check of Front Brake Pedal Limit Switch System



Disconnect con-
nector MCA-4 of

MC2/A.
Check if voltage
between terminal
A11 of harness
end connector and
machine is 24 V. MCA-1 of MC2/A and
connector of front ;'5㩷 Faulty front brake
· Key switch: ON pedal limit switch.
brake pedal limit
· Front brake pedal
limit switch: ON switch.
between terminal D2 In case of no con-
of connector MCA-1
tinuity at terminal

and terminal #1 of #1, harness open
01㩷 connector of front circuit between
brake pedal limit front brake pedal
limit switch and
switch, terminal A11
of connector MCA-4 MC2/A.
and terminal #2 of In case of no con-
connector of front tinuity at terminal
01
brake pedal limit #2, harness open
switch. circuit between
front brake pedal
limit switch and
MC2/A.

Connector

MC2/A MC2/A Connector of front brake pedal
Connector MCA-1 Connector MCA-4 limit switch

T2BC-05-03-001 T2BC-05-03-020

T2BC-05-04-008
T5-3-55
Check of Rear Brake Pedal Limit Switch System


Disconnect con-
nector MCA-4 of
MC2/A.
Check if voltage
between terminal
A11 of harness
MCA-1 of MC2/A and
end connector and connector of rear ;'5㩷 Faulty rear brake
machine is 24 V.
brake pedal limit pedal limit switch.
· Key switch: ON switch.
· Rear brake pedal Check for continuity
limit switch: ON between terminal D2
of connector MCA-1 In case of no con-
and terminal #1 of tinuity at terminal
01㩷 connector of rear #1, harness open
brake pedal limit circuit between
switch, terminal A24 rear brake pedal
of connector MCA-4 limit switch and
and terminal #2 of MC2/A.

connector of rear 01 In case of no con-
brake pedal limit tinuity at terminal
switch. #2, harness open
circuit between
rear brake pedal
limit switch and
Connector MC2/A.

Connector of rear brake pedal
MC2/A MC2/A
limit switch
(harness end)

T2BC-05-03-001 T2BC-05-03-020

T2BC-05-04-008

T5-3-56
Check of Fourth Brake Pedal (Optional) Limit
Switch System



Disconnect con-
nector MCA-4 of
MC2/A.
Check if voltage
between terminal
A9 of harness end MCA-1 of MC2/A and
connector and connector of fourth ;'5㩷 Faulty fourth brake
machine is 24 V. pedal limit switch.
brake pedal limit
· Key switch: ON switch.
· Fourth brake pedal between terminal D2 In case of no con-
limit switch: ON
of connector MCA-1 tinuity at terminal
and terminal #1 of #1, harness open
01㩷 connector of fourth circuit between
brake pedal limit fourth brake pedal
limit switch and
switch, terminal A12
of connector MCA-4 MC2/A.
and terminal #2 of In case of no con-
connector of fourth tinuity at terminal
01
brake pedal limit #2, harness open
switch. circuit between
fourth brake pedal
limit switch and
MC2/A.
Connector

Connector of fourth brake
MC2/A MC2/A pedal limit switch
Connector MCA-1 Connector MCA-4 (harness end)

T2BC-05-03-001 T2BC-05-03-020

T2BC-05-04-008

T5-3-57
Check of Front Drum Brake Release Solenoid
Valve

Faulty front drum
;'5㩷 brake release so-
lenoid valve.

Disconnect con-
nector of front
Faulty harness
drum brake re- between ground
lease solenoid Connect connector
;'5 and front drum
valve. MCA-6.
Connect brake release so-
Check if voltage
between terminals terminal #1 lenoid valve, or
of harness end con-
of front drum
nector faulty ground.
#1 and #2 of har-
ness end connec- ;'5㩷 brake release sole-
tor is 24 V.
noid valve to ma-
MCA-6 of MC2/A. chine.

· Key switch: ON Check for continuity Check if voltage be-
· Brake mode key terminal #1 and
tween Faulty MC2/A.
between terminal #1
machine
is 24 V.
switch: ON of harness end con- 01㩷
· Front drum free nector of front drum
01㩷 brake release sole- · Key
switch: ON
mode switch: ON
· Brake mode key switch:
noid valve and termi- ON
nal E14 of harness · Front Faulty harness
end connector of drum free mode
switch: ON between MC2/A
connector MCA-6. and front drum

lenoid valve.

Connector

Front drum brake release MC2/A
solenoid valve (harness end) Connector MCA-6
(harness end)

T2BC-05-03-004
T2BC-05-04-008

T5-3-58
Check of Rear Drum Brake Release Solenoid
Valve


Faulty rear drum
;'5㩷
brake release so-
lenoid valve.

Disconnect con-
nector of rear drum
Faulty harness
brake release so- between ground
lenoid valve. Connect connector
;'5 and rear drum
Check if voltage MCA-6.
brake release so-
between terminals Connect terminal #1
#1 and #2 of har- lenoid valve, or
ness end connec- nector of rear drum
tor is 24 V. ;'5㩷 brake release sole-
Disconnect connector noid valve to ma-
· Key switch: ON chine.
· Brake mode key MCA-6 of MC2/A.
Check for continuity Check if voltage be-
switch: ON between terminal #1 tween terminal #1 and Faulty MC2/A.
· Rear drum free machine is 24 V.
mode switch: ON of harness end con- 01㩷
nector of rear drum · Key switch: ON
01㩷 brake release sole-
nal E1 of harness end · Rear drum free mode Faulty harness
connector of connec- switch: ON between MC2/A
tor MCA-6. and rear drum

lenoid valve.

Connector
Rear drum brake release MC2/A
solenoid valve (harness end) Connector MCA-6
(harness end)

T2BC-05-03-004
T2BC-05-04-008
T5-3-59
Check of Fourth Drum Brake Release Solenoid
Valve (Optional)

Faulty fourth drum
;'5㩷 brake release so-
lenoid valve.

Disconnect con-
nector of fourth
Faulty harness
drum brake re- between ground
lease solenoid Connect connector
;'5 and fourth drum
valve. MCA-6.
brake release so-
Check if voltage Connect
terminal #1
between terminals lenoid valve, or
#1 and #2 of har- of fourth drum
nector
ness end connec- ;'5㩷 brake
release sole-
tor is 24 V. Disconnect connector noid valve to ma-
MCA-6 of MC2/A.
chine.
· Key switch: ON Check for continuity Check if voltage be-
· Brake mode key terminal #1 and
tween Faulty MC2/A.
between terminal #1
machine
is 24 V.
switch: ON of harness end con- 01㩷
· Fourth drum free nector of fourth drum
01㩷 brake release sole- · Key
switch: ON
mode switch: ON
nal E15 of harness · Fourth Faulty harness
end connector of drum free mode
switch: ON between MC2/A
connector MCA-6. and fourth drum

lenoid valve.

Connector
MC2/A
Fourth drum brake release
Connector MCA-6
solenoid valve (harness end)
(harness end)

T2BC-05-03-006
T2BC-05-04-010
T5-3-60
Check of Harness between MC2/A and MC2/B

• Check for continuity between terminal Y17 of har-
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-
and terminal R21 of harness end connector of con-

Connector
MC2/A
Connector MCA-4 (harness end)

T2BC-05-03-020
MC2/B
Connector MCB-4 (harness end)

T2BC-05-03-027
MC2/B

T2BC-05-03-003
T5-3-61
FAILURE OF MAIN PUMP DELIVERY
FLOW RATE CONTROL SYSTEM
Abnormality
• By using the power supply monitor, check if all of
normal.
MC2/B Batteries and Sensor Power Supplies".

sensor and solenoid valve signals.

THROT. GRIP Accelerator grip LOW ER Lower limit error Controls as a Harness check
HI ER Upper limit error minimum input. Sensor check
M PMP GUR Main pump displacement LOW ER Lower limit error Controls current Harness check
angle proportional sole- HI ER Upper limit error by controller in- Solenoid valve
noid valve RES ER Reset error ternal data. check
DD HST PRS Derricking drum hoisting LOW ER Lower limit error Controls with Harness check
remote control pressure control lever in Sensor check
DD LWR PRS Derricking drum lowering neutral.
remote control pressure
FD HST PRS Front drum hoisting re-
mote control pressure
FD LWR PRS Front drum lowering re-
RD HST PRS Rear drum hoisting re- HI ER Upper limit error
RD LWR PRS Rear drum lowering re-
3D HST PRS Third/fourth drum hoist-
ing remote control pres-
sure
3D LWR PRS Third/fourth drum lower-
ing remote control pres-
sure
• 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".
T5-3-62

700 to 0 mA, 12.3 to 0 V
Main Pump
24V Displacement Angle
Proportional SOL
1.0 to 2.4V
5V
Accelerator IDU
Grip CAN_1L
CAN_1H
1.0 to 2.4V 5V
0V
Derricking Drum
Hoisting Remote
Control Pressure
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
24V
24V(ON)
0V(OFF)
Accelerator Lock
Accelerator Preset

T25N-05-03-013
T5-3-63
Main Pump Displacement Angle Proportional
Solenoid Valve

Faulty main pump
Disconnect YES displacement
angle proportional
connector of main solenoid valve.
pump displacement
angle proportional
solenoid valve.
Check if electric Faulty harness
current between between MC2/A
terminals #1 and #2 YES and main pump
of harness end displacement
connector is 700 to Disconnect angle proportional
0 mA in accelerator connector MCA-5 solenoid valve.
grip rotation range of MC2/A.
of 0 to 100%. Check if electric
Faulty accelerator
· Accelerator lock current between
Check if voltage lock switch, or
switch: ON terminals F5 and
F9 of machine end
between terminal YES faulty harness
NO connector is 700 to D3 of connector between MC2/A
Accelerator MCA-1 and terminal and accelerator
0 mA in lock switch A6 of connector lock switch.
accelerator grip
MCA-4 of MC2/A is
rotation range of 0
24 V.
to 100%.
· Accelerator lock Faulty MC2/A.
· Accelerator lock NO
switch: ON
switch: ON
NO · Insert a test bar into
the rear of
connector.
Refer to Section
"Check of
Accelerator grip
Accelerator Grip".

Connector

Main pump displacement angle MC2/A MC2/A
proportional solenoid valve Connector MCA-1 Connector MCA-5
(harness end) (machine end) (machine end)

T2BC-05-03-021 T2BC-05-03-030
T2BC-05-04-015 MC2/A
Connector MCA-4
(machine end)

T2BC-05-03-028
T5-3-64
FAILURE OF MAIN PUMP POWER
INCREASE CONTROL SYSTEM

Abnormality
normal.

solenoid valve signal.

RACK P. S. Rack sensor ERROR Error Controls pump torque Harness check
according to engine speed. Sensor check
INC. TQ CUR Power increase LOW ER Lower limit error Controls current by Harness check
solenoid valve HI ER Upper limit error controller internal data. Solenoid valve
RES ER Reset error check

0 to 700 mA, 0 to 12.3 V
Power Increase
24 V Solenoid Valve
1.9 to 3.1 V
Rack
Sensor
0 to 6 VAC, 0 to 5.3 kHz
Engine Speed
Detection

T25N-05-03-014

x 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
Check of Rack Sensor System


YES Follow the failure

code.

Diagnose ECU.

Check if failure
YES Faulty ECU.

code
of rack sensor
is output.

· Refer to

Troubleshooting E. Disconnect ECU Harness open
Reconnect the YES circuit between
connector 2. disconnected
Check if voltage at ECU and MC2/A,
connector. or faulty ground.
terminal #1 of Disconnect
NO
harness end
YES
connector MCA-1 of
connector is 24 V. MC2/A.
Disconnect
· Key switch: ON of
connector MCA-3 Connect terminal
MC2/A. D14 of machine

Check for continuity end connector to
machine. Check if Faulty MC2/A.
between terminal

NORMAL is NO
NO B4 of harness end

connector of MC2/A indicated.
and terminal #8 of

harness end Harness open

connector of ECU circuit between
connector 2. NO ECU and MC2/A.

Connector
MC2/A MC2/A
ECU connector 2 Connector MCA-1 Connector MCA-3

T2BC-05-04-029 T2BC-05-03-001 T2BC-05-03-013

T5-3-66
Check of Power Increase Solenoid Valve

Harness short circuit
from
Disconnect clip YES between power
terminal F21 of
increase solenoid
harness end
valve and MC2/A.
connector of
MCA-5.

YES Check for continuity
Disconnect connector between machine

MCA-5 of MC2/A. and terminal #1 of
harness end
Connect terminals
F17 and F21 of connector of power Faulty MC2/A.

increase solenoid
harness end NO
connector of MCA-5 valve.
;'5㩷 to machine by using a
clip. In case of no
Check for continuity continuity at terminal
between machine and #1, harness open
circuit between
terminals #1 or #2 of
Disconnect harness end
terminal #1 of power
connector of power increase solenoid
increase solenoid connector of power
increase solenoid valve and MC2/A.
valve. valve.
In case of no
Check for continuity at terminal
continuity between 01 #2, harness open

terminals #1 and circuit between
#2 of machine end terminal #2 of power
connector.
increase solenoid
valve and MC2/A.
· Key switch: OFF
Faulty power
increase solenoid
01㩷 valve.

Connector

Power increase solenoid valve MC2/A
(machine end) Connector MCA-5
(harness end)

T2BC-05-03-031 T2BC-05-03-029
Power increase solenoid valve

(harness end)

T2BC-05-04-008

T5-3-67
FAILURE OF SLEWING ALARM CONTROL
SYSTEM

Abnormality
normal.

sensor and relay signal.

SL RGT PRS Slewing (right) LOW ER Lower limit error Controls as input with Harness check
SL LFT PRS remote control HI ER Upper limit error lever in neutral. Sensor check
pressure DBL ER Double errors Controls as input by
Slewing (left) remote lever control.
control pressure
SL ALAM LP Slewing alarm lamp ERROR Short circuit 㧙 Harness check
relay Relay check

24 V (ON)
0 V (OFF)
Slewing Alarm
24 V Lamp Relay
0V 5V
0.5 to 4.5 V
Slewing (Right)
Remote Control
Pressure
Slewing (Left)
Remote Control
Pressure

T25N-05-03-016

T5-3-68
Check of Slewing (Right) Remote Control


Connect terminal Reconnect the
W of harness end disconnected
connector. Check if ;'5㩷 Faulty MC2/A.
connector of

slewing (right) ;'5 voltage between
remote control machine and
terminal C3 of Faulty slewing
pressure sensor to (right) remote
machine byusing a connector of
MC2/A meets 01㩷 control pressure
clip. sensor.
;'5 Disconnect specification.
connector MCA-2
of MC2/A. rear of connector.
Check for ·Specification: 0.5 to 4.5 V
continuity between Faulty harness up
machine and to terminal W of
terminal C3of slewing (right)
01
Check if voltage harness end remote control
connector. pressure sensor.
between terminals R
and B of harness end ·Key switch:
OFF
;'5㩷 connector of slewing
(right) remote control
pressure sensor is Check for
5r0.5 V. continuity between ;'5㩷 Faulty MC2/A.

Disconnect machine and
·Key switch: ON terminal B of
connector
of ;'5 harness end
slewing (right) Check if voltage Faulty harness up

remote control
between machine connector of slew to terminal B of
pressure sensor. and terminal R of (right) remote slewing (right)
harness end control pressure
Check for 01㩷 remote control

continuity between connector of sensor. pressure sensor.
01 slewing (right)
terminals R and B ·Key switch: OFF
ofconnector of
remote control Faulty harness up
slewing
(right) pressure sensor
is to terminal R of
remote control 5r0.5 V. slewing (right)
01
pressure sensor. ·Key switch:ON remote control
pressure sensor.

Faulty slewing
(right) remote
01㩷 control pressure
sensor.
Connector
Slewing (right) remote control MC2/A
pressure sensor (machine end) Connector MCA-2

(harness end)

T2BC-05-03-023
Slewing (right) remote control T2BC-05-03-025


T2BC-05-03-024
T5-3-69
Check of Slewing (Left) Remote Control Pressure
Sensor System


Connect terminal Reconnect the
disconnected ;'5㩷 Faulty MC2/A.
W of harness end
connector.
connector of
slewing (left)
Check if voltage
;'5
remote control between machine

pressure sensor to and terminal C9 of Faulty slewing
machine byusing a connector of (left) remote
clip. MC2/A meets
sensor.
;'5 Disconnect specification.
connector MCA-2
of MC2/A.
rear of connector.
Check for
continuity between Faulty harness up
machine and to terminal W of
terminal C9of slewing (left)
harness end 01 remote control
Check if voltage
connector. pressure sensor.
between terminals R
and B of harness end ·Key switch: OFF
;'5㩷 connector of slewing
(left) remote control
pressure sensor is Check for ;'5㩷 Faulty MC2/A.
5r0.5 V. continuity between

Disconnect machine and
connector of ·Key switch: ON ;'5 terminal B of
Check if voltage
Faulty harness up
slewing (left) between terminal harness end to terminal B of
remote
control R of harness end connector of slew slewing (left)
pressure sensor. connector of (left) remote control
01㩷 remote control
Check for slewing (left) pressure sensor. pressure sensor.
continuity
between remote control
terminals R and B 01 pressure sensor ·Key switch: OFF
Faulty harness up
ofconnector of and machine is to terminal R of
slewing (left) 5r0.5 V. slewing (left)

remote control
·Key switch: ON remote control
pressure
sensor. 01 pressure sensor.

Faulty slewing
(left) remote
sensor.
Connector
MC2/A
Slewing (left) remote control Connector MCA-2
pressure sensor (machine end) (harness end)

T2BC-05-03-025
T2BC-05-03-023

Slewing (left) remote control

T2BC-05-03-024
T5-3-70
Check of Slewing Alarm Lamp Relay System


;'5㩷 Faulty slewing
alarm lamp relay.
Disconnect

connector of
slewing alarm lamp

relay.
Faulty harness
Check
if voltage
between machine ;'5 between MC2/A
terminal #1 of Disconnect connector and slewing alarm
and
MCA-6 of MC2/A. lamp relay.
harness end
Check if voltage
connector is 0 V.
between machine and
switch: ON
· Key 01㩷 terminal E21 of

machine end
connector is 0 V. Faulty MC2/A.
01
· Key switch: ON

Connector
MC2/A
Slewing alarm lamp relay Connector MCA-6

(harness end) (machine end)

2 4 1

5

3 T2BC-05-03-032

T5-3-71
FAILURE OF ROTATION SENSING
CONTROL SYSTEM
Abnormality
normal.

sensor and solenoid valve signals.

FD PLS SOL Front drum rotation sensing solenoid ERROR Short circuit 㧙 Harness check
RD PLS SOL Rear drum rotation sensing solenoid Solenoid check
DD PLS SOL Derricking drum rotation sensing
solenoid
Front Drum Rotation

Sensing Solenoid Valve
Rear Drum Rotation

Front Drum Rotation

Derricking Drum Rotation
Detection A Phase
Front Drum Rotation

Detection B Phase
Rear Drum Rotation

Detection A Phase
Rear Drum Rotation

Detection B Phase
Derricking Drum
Rotation Detection A
Phase
24 V: ON
0 V: OFF

Drum Rotation Sensing
T2BC-05-03-034
Cancellation Switch
T5-3-72
Check of Front Drum Rotation Sensing Solenoid
System


;'5㩷 Faulty front drum
rotation sensing
solenoid.
of front lever.
Check if voltage

between terminal #6 Faulty harness
of harness end between front
;'5
connector and Disconnect connector drum rotation

machine is 0 V. MCA-6 of MC2/A. sensing solenoid
and MC2/A.
Check if voltage
switch: ON
· Key between machine and
· Drum
rotation sensing 01㩷 terminal E2 of
cancellation switch: ON machine end

01
· Key switch: ON
· Drum rotation sensing
cancellation switch: ON

Connector
MC2/A
Front lever Connector MCA-6


T2BC-05-03-005 T2BC-05-03-032

T5-3-73
Check of Rear Drum Rotation Sensing Solenoid
System


;'5㩷 Faulty rear drum
Disconnect
rotation sensing
connector of rear solenoid.

lever.
Check
if voltage
between terminal Faulty harness
#6of harness end ;'5 between rear drum
Disconnect connector rotation sensing
connector and
MCA-6 of MC2/A. solenoid and
machine is 0 V. Check if voltage
MC2/A.
· Key switch: ON between machine and
01㩷 terminal E16 of
rotation
· Drum
sensing cancellation machine end
switch: ON
01
· Key switch: ON
· Drum rotation
sensing cancellation

switch: ON

Connector
MC2/A
Rear lever Connector MCA-6

T2BC-05-03-005 T2BC-05-03-032

T5-3-74
Check of Derricking Drum Rotation Sensing
Solenoid System


;'5㩷 Faulty derricking
drum rotation
sensing solenoid.
Disconnect
connector
of
derricking lever.
if voltage
Check Faulty harness
between
terminal #1 Disconnect connector ;'5 between derricking
of harness end MCA-6 of MC2/A. drum rotation

connector and
Check if voltage sensing solenoid
machine is 0 V. between machine and and MC2/A.

· Key switch: ON 01㩷 terminal E3 of
rotation
· Drum machine end
sensing cancellation connector is 0 V. Faulty MC2/A.

switch: ON · Key switch: ON 01

· Drum rotation
switch: ON

Connector
MC2/A
Derricking lever Connector MCA-6


T2BC-05-03-032
T2BC-05-04-008

T5-3-75
Check of Drum Rotation Sensing Cancellation
Switch System


Reconnect the
disconnected connector.
Disconnect connector Faulty drum rotation
YES sensing cancellation
MCA-5 of MC2/A and
connector 62C16F-W of switch.
left overhead panel.
Connect terminal F16 of In case of no
YES harness end connector continuity at terminal
of connector MCA-5 to A15, harness open
machine. circuit between input
Check for continuity end terminal of drum
Disconnect
connector MCA-4 of between machine and rotation sensing
MC2/A. terminals A15, F16 of cancellation switch
Check if voltage harness end connector NO and MC2/A.
of left overhead panel In case of no
between machine connector. continuity at terminal
and terminal A15 of
machine end F16, harness open
connector is 24 V. circuit between
ground end terminal
· Key Switch: ON of drum rotation
switch and MC2/A.

Faulty MC2/A.

NO

Connector
MC2/A MC2/A Left overhead panel
Connector 62C16F-W
(machine end) (harness end)
(harness end)

T2BC-05-03-028 T2BC-05-03-029 T2BC-05-03-033
MC2/A
Connector MCA-4
(harness end)

T2BC-05-03-020
T5-3-76
Check of Front Drum Rotation Detection Sensor A
System


Faulty front drum
;'5㩷
rotation detection
Replace front drum sensor A.
rotation detection
sensor A with rear
drum rotation of front drum rotation
detection sensor A
or derricking drum detection sensor A as
rotation detection well as connectors Faulty MC2/A.
sensor A. ;'5
MCA-4 and MCA-5 of
Check if error MC2/A.
indication on Connect terminal A13
In case of no
monitor of harness end
continuity at
connector of MCA-4
disappears. and terminal F16 of
terminal #1,
01㩷 harness open
harness end
circuit between
connector of MCA-5
terminal #1 of front
connector to machine.
drum rotation
detection sensor A
between machine and
01 and MC2/A.
terminals #1, #2 of
In case of no
harness end
continuity at
connector of front
terminal #2,
drum rotation
harness open
detection sensor A.
circuit between

drum rotation
detection sensor A

and MC2/A.

Connector
MC2/A MC2/A
Front drum rotation detection Connector MCA-4 Connector MCA-5
sensor A (harness end) (harness end) (harness end)

T2BC-05-03-020 T2BC-05-03-029
T2BC-05-04-008

T5-3-77
Check of Front Drum Rotation Detection Sensor B
System


;'5㩷 Faulty front drum
rotation detection
sensor B
Replace front drum
rotation detection Disconnect connector of
sensor B with rear front drum rotation
drum rotation detection sensor B as
detection sensor B. well as connectors
MCA-4 and MCA-5 of ;'5 Faulty MC2/A
Check if error
indication on monitor MC2/A.
disappears. Connect terminal A26 of
harness end connector In case of no
of connector MCA-4 continuity at terminal
and terminal F16 of #1, harness open

01㩷 harness end connector circuit between
of connector MCA-5 to terminal #1 of front
machine. drum rotation
detection sensor B
between machine and and MC2/A.
terminals #1 or #2 of 01 In case of no
harness end connector continuity at terminal
of front drum rotation #2, harness open

detection sensor B. circuit between
drum rotation
detection sensor B
and MC2/A.

Connector
Front drum rotation detection MC2/A MC2/A
sensor B (harness end) Connector MCA-4 Connector MCA-5

T2BC-05-03-020 T2BC-05-03-029
T2BC-05-04-008
T5-3-78
Check of Rear Drum Rotation Detection Sensor A
System


Faulty rear drum
;'5㩷
rotation detection
Replace rear drum sensor A.
rotation detection
sensor A with front
drum rotation detection Disconnect connector
sensor A or derricking of rear drum rotation
drum rotation detection detection sensor A as ;'5 Faulty MC2/A.
sensor A. well as connector
Check if error indication MCA-5 of MC2/A.
on monitor disappears. Connect terminals F12 In case of no
continuity at terminal
and F16 of harness end
connector of MCA-5 to #1, harness open
01㩷 machine. circuit between
Check for continuity terminal #1 of rear
between machine and drum rotation
terminals #1 or #2 of detection sensor A
harness end connector and MC2/A.
of rear drum rotation 01 In case of no
continuity at terminal
detection sensor A.
#2, harness open
circuit between
terminal #2 of rear
drum rotation
detection sensor A
and MC2/A.

Connector
MC2/A
Rear drum rotation detection Connector MCA-5
sensor A (harness end) (harness end)

T2BC-05-03-029
T2BC-05-04-008
T5-3-79
Check of Rear Drum Rotation Detection Sensor B
System

Faulty rear drum
;'5㩷
rotation detection
sensor B.
Replace rear drum
rotation detection
sensor B with front
drum rotation de- Disconnect connector
tection sensor B. of rear drum rotation
detection sensor B
Check if the error and connector MCA-5
;'5 Faulty MC2/A.
indication on moni-
tor disappears. of MC2/A.
Connect terminals F1 In case of no con-
and F16 of harness tinuity at terminal
end connector of #1, harness open
01㩷 MCA-5 to machine. circuit between
terminal #1 of rear
between machine and drum rotation de-
terminals # 1 or #2 of tection sensor B
harness end connec- and MC2/A.
tor of rear drum rota- 01 In case of no con-
tion detection sensor tinuity at terminal
B. #2, harness open
circuit between
terminal #2 of rear
drum rotation de-
tection sensor B
and MC2/A.

Connector
MC2/A

Rear drum rotation detection Connector MCA-5
sensor B (harness end) (harness end)

T2BC-05-03-029
T2BC-05-04-008

T5-3-80
Check of Derricking Drum Rotation Detection
Sensor A System

Faulty derricking
Replace derricking ;'5㩷 drum rotation de-
tection sensor A.
drum rotation detec-
tion sensor A with
front drum rotation
detection sensor A of derricking drum

or rear drum rota-
tion detection sen- rotation detection
;'5 Faulty MC2/A.
sor A. sensor A and con-
Check if the error
nector MCA-5 of
indication on moni- MC2/A.
tor disappears. Connect terminals In case of no con-
F13 and F16 of har- tinuity at terminal
ness end connector of #1, harness open
01㩷 MCA-5 to machine. circuit between
Check for continuity terminal #1 of der-
between machine and ricking drum rota-
tion detection
terminals # 1 or #2 of
harness end connec- sensor A and
01 MC2/A.
tor of derricking drum
rotation detection In case of no con-
sensor A. tinuity at terminal
#2, harness open
circuit between
terminal #2 of der-
ricking drum rota-
tion detection
sensor A and
MC2/A.

Connector
Derricking drum rotation detection
MC2/A
sensor A
(harness end)
Connector MCA-5

(harness end)

T2BC-05-04-008 T2BC-05-03-029

T5-3-81
FAILURE OF ENGINE START INTERLOCK
CONTROL SYSTEM
Abnormality
normal.

relay signal.

ENG. INTLCK Engine start relay ERROR Short circuit 㧙 Harness check
Relay check
Start Relay 1
Engine Start
Interlock
Front Drum Brake
Rear Drum Brake

24V
Third / Fourth Drum

Brake Mode Selection
Switch
Slewing Brake Switch
Starter Switch

T2BC-05-03-035
T5-3-82
Check of Engine Start Relay

;'5㩷 Faulty engine start
Disconnect con- relay.
nector of engine
start relay.
Check if voltage

between machine
and Faulty harness
terminal #1 of between MC2/A
harness end con- ;'5
Disconnect connector and engine start

nector is 24V.
MCA-6 of MC2/A. relay.
switch: ON
· Key
tween machine and
· Slewing
brake switch: 01㩷 terminal E20 of ma-
ON (brake applied)
chine end connector
· Front drum free mode Faulty MC2/A.
is 24 V.
switch:
OFF (auto 01
brake) · Connect terminals E12,

· Rear drum free mode E13 and E26 of both
switch: OFF (auto connectors by using a

brake) clip or the like.
· Third
drum free mode · Key switch: ON
switch: OFF (auto

brake)

Connector

MC2/A
Connector MCA-6

Engine start relay

1 4 2

5
T2BC-05-03-032
3

T5-3-83
Check of Slewing Brake Switch System



Disconnect con-

nector MCA-4 of
MC2/A.

Check if voltage Faulty harness

between terminal ;'5 between slewing
A18 of harness brake switch and
connector and
end Check if voltage be- MC2/A.

machine
is 0 V. tween machine and
· Key 01㩷 terminal #8 of slewing
switch: ON lever connector is 0 V.
· Slewing brake switch:

ON · Insert a test bar into the Faulty slewing
rear of connector. 01 brake switch.

· Key switch: ON
· Slewing brake switch:
ON

Connector
MC2/A
Slewing lever
Connector MCA-4
(harness end) (slewing lever end)

T2BC-05-03-020

T2BC-05-03-036

T5-3-84
Check of Front Drum Free Mode Switch System



Disconnect con-
nector MCA-4 of

MC2/A.
Check Disconnect connector
if voltage Faulty front drum
between terminal MCA-1 of MC2/A and
of harness
A21 front lever connector. ;'5 brake mode selec-
end Check for continuity tion switch.
connector and between terminal D2
machine is 0 V.
of connector MCA-1
· Key switch: ON
01㩷 and terminal #4 of In case of no conti-
· Front
drum free mode front lever connector, nuity at terminal #3,
switch: OFF terminal A21 of con- faulty harness be-

(auto brake) nector MCA-4 and tween terminal #3 of
01
terminal #3 of front front drum brake
lever connector. mode selection
switch and MC2/A.

faulty harness be-
tween terminal #4 of

front drum brake
mode selection
switch and MC2/A.

Connector
MC2/A Front lever
Connector MCA-4 (front lever end)
(harness end)

T2BC-05-03-020 T2BC-05-03-005
MC2/A
Connector MCA-1
(harness end)

T2BC-05-03-001
T5-3-85
Check of Rear Drum Free Mode Switch System


Disconnect con-
nector MCA-4 of

MC2/A.
Check
if voltage Disconnect connector
between terminal MCA-1 of MC2/A and
Faulty rear drum
of harness
A21 rear lever connector. ;'5 brake mode selec-
end Check for continuity
connector and between terminal D2
tion switch.
machine is 0 V.
switch: ON of connector MCA-1
· Key In case of no conti-
· Rear 01㩷 and terminal #4 of nuity at terminal #3,
drum free mode rear lever connector,
switch: OFF terminal A9 of con- faulty harness be-
brake)
(auto nector MCA-4 and tween terminal #3 of
01 rear drum brake
terminal #3 of rear
lever connector. mode selection
switch and MC2/A.
faulty harness be-

rear drum brake
mode selection
switch and MC2/A.

Connector
MC2/A
Connector MCA-4 Rear lever
(harness end) (rear lever end)

T2BC-05-03-020 T2BC-05-03-005
MC2/A
Connector MCA-1
(harness end)

T2BC-05-03-001

T5-3-86
Check of Fourth Drum Free Mode Switch System
(Optional)


Disconnect con-
nector
MCA-4 of Disconnect connector
MC2/A. MCA-1 of MC2/A and
third/fourth lever con-

Check if voltage
between terminal nector. Faulty third/fourth
;'5
drum brake mode
A22 of harness
connector and
end between terminal D2 selection switch.
machine is 0 V. of connector MCA-1
and terminal #3 of In case of no conti-
· Key switch: ON 01㩷 third / fourth lever nuity at terminal #3,

· Fourth drum free mode connector, terminal faulty harness be-
switch:
OFF A22 of connector
(auto brake) MCA-4 and terminal 01 third / fourth drum

#4 of third/fourth lever brake mode selec-
connector. tion switch and
MC2/A.
faulty harness be-
third/fourth drum
brake mode selec-
tion switch and
MC2/A.

Connector
Third / fourth lever
MC2/A (third / fourth lever end)
Connector MCA-4
(harness end)

T2BC-05-03-020 T2BC-05-03-005
MC2/A
Connector MCA-1
(harness end)

T2BC-05-03-001
T5-3-87
FAILURE OF PILOT PRESSURE DROP
WARNING LAMP CONTROL SYSTEM
Abnormality
normal.

sensor signal.

PILOT PRS Primary pilot pres- LOW ER Lower limit Controls as pressure Harness check
sure error drop input. Sensor check
HI ER Upper limit
error
24 V (ON)
0 V (OFF)
24 V
Pilot Pressure Drop

Indicator
0.5 to 4.5 V 0V 5V
Primary Pilot
Pressure
T25N-05-03-019
x For check of primary pilot pressure sensor, refer to

"Check of Primary Pilot Pressure" of "Failure of
Brake Control System".
T5-3-88
Check of Pilot Pressure Drop Indicator

Even when pilot pressure drops below the set pres-
sure, the indicator is not turned ON.
Burn-out of pilot
;'5㩷
Disconnect con- pressure drop

nector 62C-16FW indicator.
of monitor panel.

Check if voltage
between
terminals
E8 and #224 of ;'5 Faulty MC2/A.

harness end con- Disconnect connector
nector is 24 V.
MCA-6 of MC2/A.
switch: ON
· Key 01㩷 between terminal E8 Harness open
of harness end con-
nector and terminal circuit between
E8 of connector MC2/A and pilot
C62-16FW. 01 pressure drop
indicator.

Even when pilot pressure is at the set pressure, the
indicator is not turned OFF.
Disconnect con-

nector 62C-16FW
ofmonitor panel.
Check for continu-
itybetween termi-
nals
E8 and #224 Harness short
of harness end
circuit between

connector. MC2/A and pilot
· Key
switch: ON 01㩷 pressure drop
indicator.

Connector

Monitor panel MC2/A
Connector 62C-16FW Connector MCA-6

T2BC-05-03-037 T2BC-05-03-004

T5-3-89
FAILURE OF MOTOR CUTOFF PRESSURE
CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all bat-
tery and sensor power supply of MC2/A are normal.
MC2/B Batteries and Sensor Power Supplies"

sensor signal.

FD LWR PRS Front drum lowering re- LOW ER Lower limit Controls as input Harness check
RD LWR PRS mote control pressure error with lever in neu- Sensor check
Rear drum lowering re- HI ER Upper limit tral.
mote control pressure error
MT CUT OFF Motor cutoff high pressure ERROR Short circuit 㧙 Harness check
relay Solenoid valve
check
24 V (ON)
0 V (OFF)
24 V Motor Cutoff
Relay
0.5 to 4.5 V 0V 5V
Front Drum Lowering

Remote Control
Pressure
Rear Drum Lowering

Remote Control
Pressure
T25N-05-03-020
x 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
Check of Motor Cutoff Relay System

;'5㩷 Faulty motor cutoff
relay.
Disconnect con-
nector
of motor
cutoff relay.
if voltage
Check
Faulty harness
between machine
;'5 between MC2/A
and terminal #1 of Disconnect connector
and motor cutoff

harness end con- MCA-6 of MC2/A. relay.
nector is 0 V. Check if voltage be-
tween machine and
· Key switch: ON 01㩷 terminal E6 of ma-

chine end connector
is 0 V. Faulty MC2/A.
01
· Connect terminals E12,
E13 and E26 of both
connectors by using a
clip or the like.
· Key switch: ON

Connector
MC2/A
Connector MCA-6
Motor cutoff relay (machine end)
(harness end)

2 4 1

5
T2BC-05-03-032
3
T5-3-91
FAILURE OF DERRICKING DRUM AUTO
STOP CONTROL SYSTEM
Abnormality
battery and sensor power supply of MC2/B are nor-
mal.
By using the MC2/B input/output monitor, confirm the

limit switch and solenoid valve signals.

JB FOLD Jib folding ALL OFF Open circuit Controls as jib Harness check
(no connection) ALL ON Shorted harnesses unfolding
ATTACHMENT Wiring detection SHORT Short circuit on both Priority is given to Harness check
crane and tower the selection by
IDU during control
or error control.
OPEN Open circuit on both Priority is given to
IDU during control
or disassembly
position control.
BM OVERH Boom overhoist ALL OFF Open circuit Controls as over- Harness check
BM OVERH2 Boom/tower second hoist.
overhoist
TW OVERH Tower overhoist
BT LOWER L Boom/tower lowest
limit (no connection)
JB OVERH Jib overhoist ALL ON Shorted harnesses
JB OVERH2 Jib second overhoist
SWL OVERH Tower jib backstop
alignment
DD HST CUR Derricking drum LOW ER Lower limit error PWM output short Harness check
hoisting proportional circuit or open Solenoid valve
DD LWR CUR solenoid valve circuit check
Derricking drum low- OFF (stop) MC2/B hardware
ering proportional HI ER Upper limit error PWM output har- check
solenoid valve ness short circuit
OFF (stop)
RES ER Reset error Abnormal electric
current feedback
Electric current
control by open
loop
T5-3-92

Derricking Drum
Solenoid Valve
Derricking Drum
Lowering Proportional
Solenoid Valve
Auto Stop Release

Derricking Drum Live Mast
Switch Lower Limit
Prevention
Auto Stop Release
Key Switch
Boom Overhoist
Prevention
Tower Upper Limit
Boom Second
Overhoist
Prevention
Crane
Relay Box
Main Hook
Overhoist
Prevention Derricking Drum
Hoisting Stop
Sub Hook
Overhoist Derricking Drum
Shouldering
Tower Prevention
Relay Box
Tower Breakage
Prevention
Tower Jib
Overhoist
Prevention
Tower Jib
Backstop
Alignment
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-012
T5-3-93
Check of Wiring Detection Signal System

Crane Mode
NO between terminals #1
and #2 of relay box.
MCB-4 of MC2/B.
YES between terminal X4
of connector MCB-1 Disconnect connector
MCA-4 of MC2/A.
Disconnect connector and terminal R8 of
MCB-1 of MC2/B. connector MCB-4. Check for continuity
Check if voltage be- between terminal R8
tween machine and
of harness end con-
· Key switch: OFF
terminal X4 of connector of connector
nector of MC2/B is 24 MCA-4 and terminal
YES

V. R8 of harness end
connector of connec-
tor MCB-4.
· Connect terminals of
both disconnected Faulty MC2/B.
connectors by using a
clip or the like.
NO
· D1X1
· D17M18
· D12(B)
· Key switch: ON

Connector
MC2/B MC2/B
Connector MCB-1 Connector MCB-4

MC2/B T2BC-05-03-021 T2BC-05-03-027
Connector MCB-1
(harness end)

T2BC-05-03-038

T5-3-94
NO Faulty relay box.

Harness open cir-
cuit between
YES MC2/B and relay
box.
NO Harness open cir-

cuit between
MC2/A and MC2/B.
Faulty MC2/A.
YES
Connector
Relay Box
(machine end)

T2BC-05-03-039
MC2/A
Connector MCA-4
(harness end)

T2BC-05-03-020
T5-3-95
Tower Mode

YES
between terminals #1
and #3 of relay box.
MCB-4 of MC2/B.
YES between terminal X4 Disconnect connector
of connector MCB-1 MCA-4 of MC2/A.
and terminal R21 of Check for continuity
connector MCB-4. between terminal R8
MCB-1 of MC2/B.
of harness end con-
nector of connector
tween machine and · Key switch: OFF MCA-4 and terminal
terminal X4 of con- NO R21 of harness end
nector of MC2/B is 24
connector of connec-
V.
tor MCB-4.
· Connect terminals of
both disconnected
connectors by using a Faulty MC2/B.
clip or the like. NO
· D1X1
· D17M18
· D12(B)
· Key switch: ON
Connector
MC2/B MC2/B

T2BC-05-03-021
T2BC-05-03-027
MC2/B
Connector MCB-1
(harness end)

T2BC-05-03-038

T5-3-96
NO Faulty relay box.
Harness open cir-

cuit between
YES MC2/B and relay
box.
NO
Harness open cir-
cuit between
MC2/A and MC2/B.
Faulty MC2/A.
YES
Connector
Relay box
(machine end)

T2BC-05-03-039

MC2/A
Connector MCA-4
(harness end)

T2BC-05-03-020
T5-3-97
Check of Boom Overhoist Switch System


YES
Faulty MC2/B.
Connect boom overhoist
switch.
connector
Disconnect
MCB-4 of MC2/B.
continuity
Check for

between terminal X3 of
YES connector MCB-1 and
terminal R16 of connec-
tor MCB-4.

When operating boom
Disconnect connec- switch, check
overhoist
tor MCB-1 of MC2/B. for continuity between
Disconnect connec-
tor of boom overhoist YES Check if voltage at terminal X3of connector
terminal D3 of ma- MCB-1and terminal R3 Harness open circuit
switch. chine end connector of connector MCB-4. between boom
Check for continuity is 24 V. NO overhoist switch and
between terminals MC2/B.
· Connect terminals D1
#b and #c of ma- and X1, D17 and M18,
chine end connector.
When operating D12 and B of both Faulty MC2/B.
boom overhoist connectors by using a
switch, check for clip or the like. NO
· Key switch: ON
continuity between
terminals #a and #c Faulty boom over-
of machine end
NO hoist switch.
connector.

Connector
MC2/B
Boom overhoist switch
MC2/B Connector MCB-4
(machine end)
(machine end)

c b a

T2BC-05-03-021 T2BC-05-03-027
T25N-05-03-005

MC2/B
Connector MCB-1 (har-
ness end)

T2BC-05-03-038

T5-3-98
Check of Boom / Tower Second Overhoist Switch
System


Connect boom / tower
YES Faulty MC2/B.
second overhoist
switch.
MCB-4 of MC2/B.
between terminal X3 of
YES connector MCB-1 and
terminal R19 of con-
nector MCB-4.
When operating boom /
Disconnect connec- tower second overhoist
tor MCB-1 of MC2/B. switch, check for con-
Disconnect connector Check if voltage at tinuity between terminal Harness open circuit
of boom / tower sec- YES terminal D3 of ma- X3of connector MCB-1 between boom /
ond overhoist switch. chine end connector and terminal R5 of tower second over-
Check for continuity is 24 V. connector MCB-4. NO hoist switch and
between terminals #1 · Connect terminals MC2/B.
and #2 of machine D1 and X1, D17
end connector. and M18, D12 and
When operating B of both connec- Faulty MC2/B.
boom / tower second tors by using a
overhoist switch, NO
jumper line.
check for continuity · Key switch: ON
between terminals #1 Faulty boom / tower
and #3 of machine second overhoist
NO switch.
end connector.

Connector
MC2/B MC2/B
Boom / tower second overhoist Connector MCB-1 Connector MCB-4
switch (machine end) (machine end) (harness end)

T2BC-05-03-021 T2BC-05-03-027

MC2/B
T2BC-05-03-059
Connector MCB-1
(harness end)

T2BC-05-03-038

T5-3-99
Check of Tower Overhoist Switch System

Connect connector of YES
tower overhoist Faulty MC2/B.
switch.
Disconnect connec-
tor MCB-4 of MC2/B.

between terminal X3
YES of connector MCB-1
and R17 of connector
MCB-4.
When operating
Disconnect con- tower overhoist
nector MCB-1 of switch, check for
Disconnect connec- continuity between
tor of tower overhoist YES MC2/B. Harness open circuit
Check if voltage at terminal X3 of con- between tower
switch. terminal D3 of ma- nector MCB-1 and overhoist switch and
Check for continuity terminal R4 of con- NO
chine end connec- MC2/B.
between terminals #b tor is 24 V. nector MCB-4.
and #c of machine
end connector. · Connect D1 and
When operating X1, D17 and M18, Faulty MC2/B.
tower overhoist DR and B of both
switch, check for NO
connectors by us-
continuity between ing a jumper wire.
terminals #a and #c · Key switch: ON
of machine end Faulty tower over-
connector. NO hoist switch.

Connector
MC2/B
Tower overhoist switch Connector MCB-1 MC2/B
(machine end) (machine end) Connector MCB-4
(harness end)
c b

T2BC-05-03-021 T2BC-05-03-027
MC2/B
a Connector MCB-1
(harness end)

T25N-05-03-003

T2BC-05-03-038
T5-3-100
Check of Jib Overhoist Switch System


Connect connector

of jib overhoist YES
Faulty MC2/B.
switch.
Disconnect con-
nector MCB-4 of
MC2/B. Check for

continuity between

terminal X4 of con-
YES nector MCB-1 and Disconnect con-

R20 of connector Harness open circuit
nector CN1 of relay YES between jib overhoist
MCB-4. box.
When operating jib switch and MC2/B.
Disconnect con-
overhoist switch, between terminals
nector MCB-1 of check for continuity
#1 and #5 of relay
MC2/B. between terminal
Disconnect connec- YES box end.
tor of jib overhoist Check if voltage at X4 of connector
When operating jib
switch. terminal D4 of ma- MCB-1 and terminal overhoist switch,
chine end connec- NO Faulty relay box.
R6 of connector
Check for continuity tor is 24 V. MCB-4.
check for continuity
between terminals between terminals NO
#2 and #4 of ma- · Connect D1 and X1, #1 and #4.
chine end connector. D17 and M18, D12
When operating jib and B of both con- Faulty MC2/B.

overhoist switch, nectors by using a NO
check for continuity jumper wire.
between terminals · Key switch: ON

#1 and #3 of ma- Faulty jib overhoist
chine end connector. NO switch.

Connector
Jib overhoist switch MC2/B MC2/B

(machine end) Connector MCB-1 Connector MCB-4

T2BC-05-03-027
T2BC-05-03-038
T2BC-05-03-042
MC2/B
Relay box Connector MCB-1

T2BC-05-03-021

T2BC-05-03-039

T5-3-101
Check of Jib Second Overhoist Switch System


Connect connector
of jib secondover-
hoist switch.

Disconnect con- YES Faulty MC2/B.

nector MCB-4 of
MC2/B.

between terminal

YES
X4 of connector
MCB-1 and R22 of Disconnect con-
connector MCB-4. nector CN1 of relay Harness open circuit

When operating jib box. YES between jib second
overhoist switch and
second overhoist
Disconnect connec- MC2/B.
switch, check for between terminals
tor MCB-1 of MC2/B.
continuity between #1 and #9 of relay
Disconnect connector YES Check if voltage at terminal X4 of con-
of jib second overhoist
terminal D4 of ma- NO box end. When
switch. nector MCB-1 and operating jib second
chine end connector terminal R24 of overhoist switch,
Check for continuity Faulty relay box.
between terminals #1 is 24 V. connector MCB-4. check for continuity
between terminals NO
and #3 of machine · Connect D1 and
end connector. X1, D17 and M18, #1 and #8.
When operating jib D12 and B of both Faulty MC2/B.
second overhoist connectors by using
NO
switch, check for con- a jumper wire.
tinuity between ter- · Key switch: ON
minals #1 and #2 of Faulty jib second
machine end con-
NO overhoist switch.
nector.

Connector

Jib second overhoist switch MC2/B MC2/B
Connector MCB-1
(machine end) Connector MCB-4

1 2

3 4

T2BC-05-03-038 T2BC-05-03-027
Relay box
MC2/B
(machine end)
Connector MCB-1
(harness end)

T2BC-05-03-021
T2BC-05-03-039

T5-3-102
Check of Hook Overhoist Switch System


YES Faulty MC2/B.

Connect connector

of hook overhoist
switch.

Disconnect con-

nector MCB-4 of
YES MC2/B.

between terminal
Disconnect MCB-4
X4 of connector Harness open circuit
connector of YES between hook over-
Disconnect con- MCB-1 and R9 of MC2/B, connect A9
connector MCB-4. and A11 terminals
hoist switch and
YES MC2/B. When operating (harness end) of
Check if voltage at hook overhoist
connector to ma-
terminal D4 of ma- switch, check for chine, and check for

continuity between
Disconnect connec- chine end connec- NO continuity between
tor is 24 V. terminal X4 of con- machine and #1 or
tor of hook overhoist nector MCB-1 and #2 terminal (har-
switch. Check for · Connect D1, D12 and terminal R11 of ness end) of con-
continuity between D17 terminals of both connector MCB-4. nector of hook Faulty relay box.
terminals #2 and #4 connectors by using a
of machine end overhoist switch. NO
clip or the like.
connector. · Key switch: ON
between terminals
#1 and #3 of ma-

chine end connector.
Faulty MC2/B.
NO

Faulty hook overhoist
NO switch.
Connector
MC2/B MC2/B
Hook overhoist switch Connector MCB-1 Connector MCB-4
(harness end)

T2BC-05-03-027
T2BC-05-03-038

T2BC-05-03-043
MC2/B
Connector MCB-1

Relay box (machine end)

(machine end)

T2BC-05-03-021

T2BC-05-03-039
T5-3-103
Check of Backstop Alignment Overhoist Switch
System


Connect connector

of backstop align-

ment overhoist
YES Faulty MC2/B.
switch.
Disconnect connec-
tor MCB-4 of
MC2/B.

between terminal
X4
YES of connector MCB-1 Disconnect con-

and R20 of connec- nector CN1 of relay Harness open circuit
box. YES between backstop
tor MCB-4. When

Check for continuity alignment overhoist
operating backstop switch and MC2/B.

alignment overhoist between terminals
Disconnect connec- #1 and #5 of relay
tor MCB-1 of MC2/B. switch, check for
Disconnect connector box end.

of backstop alignment YES Check if voltage at continuity between
terminal X4 of con- NO When operating
overhoist
switch. terminal D4 of ma- backstop alignment
chine end connector nector MCB-1 and
Check for continuity overhoist switch,
is 24 V. terminal R6 of con- Faulty relay box.
between terminals #2 check for continuity
nector MCB-4.
NO
and
#4 of machine · Connect D1 and between terminals
end connector. X1, D17 and M18, #1 and #4.

When operating
Faulty MC2/B.
D12 and B of both
backstop alignment connectors by using NO

overhoist switch, a jumper wire.
check
for continuity · Key switch: ON
between terminals #1 Faulty backstop
#3 of machine alignment overhoist
and
NO switch
end
connector.

Connector
MC2/B
Backstop alignment Connector MCB-1 MC2/B
overhoist switch (machine end) Connector MCB-4
(harness end)

T2BC-05-03-042 T2BC-05-03-021 T2BC-05-03-027

MC2/B
Relay box
Connector MCB-1

T2BC-05-03-038

T2BC-05-03-039
T5-3-104
Check of Derricking Drum Hoisting Proportional
Solenoid Valve System

Connect terminal
D3 of connector YES between derricking
drum hoisting pro-
MCB-1 to terminal
A3 of connector portional solenoid
MCB-4 valve and MC2/B.
YES of MC2/B.
Check if voltage
between terminal
MCB-5 of MC2/B. Z9 of machine end
Connect terminals Z5
connector of con- Faulty MC2/B.
and Z9 of harness end nector
MCB-5 and
connector of connector NO
machine is 0 V.
YES
MCB-5 to machine.
Check for continuity · Key Switch: ON In case of no conti-
between machine and
· Derricking drum auto nuity at terminal #l,
terminals # 1, #2 of stop
release switch: harness open circuit
harness end connector OFF between terminal #1
of derricking drum
· Connect terminals D3 of derricking drum
Disconnect connec- hoisting proportional
hoisting proportional and A3 by using a
tor of derricking drum solenoid valve and
solenoid valve. jumper wire.
hoisting proportional MC2/B.
solenoid valve. In case of no conti-
NO nuity at terminal #2,
Check for continuity harness open circuit
between terminals between terminal #2
#1 and #2 of ma-
of derricking drum
chine end connector. hoisting proportional
solenoid valve and
MC2/B.

Faulty derricking
drum hoisting pro-
NO portional solenoid

valve.

Connector
Derricking drum hoisting MC2/B MC2/B
proportional solenoid valve Connector MCB-1 Connector MCB-4

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
Connector MCB-5
(harness end)

T2BC-05-03-044

T5-3-105
Check of Derricking Drum Lowering Proportional
Solenoid Valve System


Connect
terminal D3
of connector MCB-1 Harness short circuit

to terminal A3 of con- YES between derricking
nector MCB-4 of drum lowering propor-

MC2/B. tional solenoid valve
YES Check if voltage be- and MC2/B.

Disconnect connector tween terminal Z21 of
MCB-5 of MC2/B. end con-
machine
Connect terminals Z17 nector Faulty MC2/B.
of connector NO
and Z21 of harness MCB-5 and machine
end connector of con- is 0
V.
nector MCB-5 to ma- In case of no continuity
YES chine.
· Engine: Running at terminal #2, harness
Check for continuity · Derricking drum auto open circuit between

stop release switch:
between machine and terminal #2 of derrick-
terminals # 1, #2 of OFF ing drum lowering pro-
harness end connector · Connect terminals portional solenoid valve
Disconnect connec- D3and A3 from the and MC2/B, or faulty
of derricking drum
tor of derricking drum lowering proportional back
by using a live mast lower limit
lowering proportional solenoid valve. jumper wire. switch.
solenoid valve. In case of no continuity
NO
Check for continuity at terminal #1, harness
between terminals #1 open circuit between
and #2 of machine terminal #1 of derrick-
end connector. ing drum lowering pro-
portional solenoid valve
and MC2/B.

Faulty derricking drum
lowering proportional
NO solenoid valve.

Connector
MC2/B
Derricking drum lowering MC2/B Connector MCB-4
proportional solenoid valve Connector MCB-1

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
Connector MCB-5
(harness end)

T2BC-05-03-044

T5-3-106
Check of Auto Stop Release Selection Key Switch

Disconnect connectors
YES Faulty MC2/B.
MCB-4 and MCB-5 of
MC2/B.
Connect terminal R1 of

of connector MCB-4 In case of no continuity
YES
and terminal Z16 of at terminal R1, harness
open circuit between
of connector MCB-5 to terminal R1 of connec-
machine. tor 62C-16FW of left
Check for continuity control panel and
Disconnect connec- between machine and MC2/B.
tor 62C-16FW of left
terminals R1, Z16 of In case of no continuity
NO
control panel. harness end connector at terminal Z16, har-
Check for continuity of connector ness open circuit be-
between terminals 62C-16FW.
tween terminal Z16 of
R1 and Z16 of panel connector 62C-16FW
end connector.
of left control panel and
MC2/B.
· Auto stop release
selection key
switch: ON
Faulty auto stop re-
lease selection key
NO switch.

Connector
Left control panel MC2/B
Connector 62C-16FW Connector MCB-4
(panel end)
(harness end)

T2BC-05-03-047 T2BC-05-03-027


T2BC-05-03-046 T2BC-05-03-044

T5-3-107
Check of Derricking Drum Auto Stop Release
Switch


YES Faulty MC2/B.
MCB-3 and MCB-5 of
MC2/B.
Connect terminal S7 of
of connector MCB-3 In case of no continuity
YES
and terminal Z16 of at terminal S7, harness
harness end connector open circuit between
of connector MCB-5 to terminal S7 of connec-
machine.
tor 62C-16FW of left
Check for continuity control panel and
Disconnect connec- between machine and MC2/B.
tor 62C-16FW of left terminals S7, Z16 of In case of no continuity
harness end connector NO
control panel. at terminal Z16, har-
Check for continuity of connector ness open circuit be-
between terminals 62C-16FW. tween terminal Z16 of
S7 and Z16 of panel connector 62C-16FW
end connector.
· Derricking drum MC2/B.
auto stop release
switch: ON
Faulty derricking drum
NO auto stop release
switch.

Connector
(harness end)
(panel end)

T2BC-05-03-047 T2BC-05-03-048
Left control panel

MC2/B

T2BC-05-03-046 T2BC-05-03-044

T5-3-108
FAILURE OF FRONT DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
battery and sensor power supply of MC2/B are
normal.


IDU for control or
error control
IDU for control or
disassembly posi-
tion control
BT OVERH2 Boom/tower second ALLOFF Open circuit Controls as over- Harness check
overhoist hoist
HK OVERH Hook overhoist ALLON Shorted harnesses
FD HST CUR Front drum hoisting LOW ER Lower limit error PWM output short Harness check
proportional solenoid circuit or open Solenoid valve
FD LWR CUR valve circuit check
Front drum lowering OFF (stop) MC2/B hardware
proportional solenoid HI ER Upper limit error PWM output har- check
valve ness short circuit
OFF (stop)
current feedback
Current control by
open loop
x 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
Front Drum Hoisting

Valve
Front Drum Lowering

Auto Stop Release Valve
Front Switch
Auto Stop Release
Key Switch
Boom Second Overhost

Prevention
Crane Relay
Box
Main Hook
Overhost
Prevention
Front Drum
Sub Hook Hoising Stop
Overhost
Prevention
Front Drum
Lowering Stop
Tower Relay
Box Shouldering
Prevention
Main Hook
Overhost
Prevention
Sub Hook
Overhost
Prevention
Tower Jib
Second
Overhost
Prevention
T2BC-02-01-013
T5-3-110
Check of Front Drum Hoisting Proportional So-
lenoid Valve System


Connect terminal D3
YES between front drum
of connector
MCB-1
hoisting proportional
to terminal A5 of
solenoid valve and
connector MCB-4 of
YES MC2/B. Check if
MC2/B.

Disconnect connector voltage between
MCB-5 of MC2/B. F10 of ma-
terminal
Connect terminals Z6 chine end connector

of connector MCB-5 Faulty MC2/B.
and Z10 of harness
end connector of con- andmachine is 0 V. NO
nector MCB-5 to ma- · Engine: Running
YES
chine.
· Front drum auto stop
Check for continuity In case of no conti-
release switch: OFF
between machine and nuity at terminal #1,
· Connect
terminals D3
terminals #1, #2 of harness open circuit
and A5 by using a
harness end connector between terminal #1
Disconnect connec- wire.
jumper
of front drum hoisting
of front drum hoisting
tor of front drum proportional solenoid proportional solenoid
hoisting proportional valve. valve and MC2/B.
solenoid valve. In case of no conti-
NO
Check for continuity nuity at terminal #2,
between terminals
#1 and #2 of ma- between terminal #2
chine end connector. of front drum hoisting
proportional solenoid
valve and MC2/B.

Faulty front drum
hoisting proportional
NO
solenoid valve.
Connector
Front drum hoisting proportional MC2/B MC2/B
solenoid valve Connector MCB-1 Connector MCB-4

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
Connector MCB-5
(harness end)

T2BC-05-03-044

T5-3-111
Check of Front Drum Lowering Proportional So-
lenoid Valve System


Connect terminal D3 Harness short circuit

of connector MCB-1 between front drum
YES
to terminal
A5 of lowering proportional
connector MCB-4 of solenoid valve and

MC2/B. MC2/B.
YES
Disconnect connector tween terminal F22 of
MCB-5 of MC2/B.
machine end con- Faulty MC2/B.
Connect terminals Z18 nector of connector
and Z22 of harness

MCB-5 and machine
NO
end connector of con- is 0 V.

YES nector MCB-5 to ma-
· Engine:
Running
chine. In case of no continuity
· Front drum auto stop re-
Check for continuity switch: OFF at terminal #1, harness
lease
between machine and open circuit between
· Connect
terminals D3 and
terminals #1, #2 of terminal #1 of front
A5from the connector
harness end connector drum lowering propor-
Disconnect connec- of front drum lowering
by using a clip.
back
tor of front drum low- · Front drum lock switch: tional solenoid valve
ering proportional proportional solenoid and MC2/B. In case of
OFF
valve. no continuity at termi-
solenoid valve. NO nal #2, harness open
Check for continuity · Front drum lock
between terminals #1 switch: OFF circuit between terminal
and #2 of machine #2 of front drum lower-
end connector. ing proportional sole-
noid valve and MC2/B,
or faulty front drum lock
switch.
Faulty front drum low-
NO ering proportional so-
lenoid valve.

Connector
Front drum lowering MC2/B MC2/B
Connector MCB-4
(machine end)

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010
MC2/B
Connector MCB-5
(harness end)

T2BC-05-03-044
T5-3-112
Check of Front Drum Auto Stop Release Switch

MCB-3 and MCB-5 of
YES

MC2/B. Faulty MC2/B.
Connect terminal S15
of harness end con-
nector of connector
MCB-3 and terminal In case of no continuity
YES
Z16 of harness end at terminal S15, har-
connector of connector ness open circuit be-
MCB-5 to machine. tween terminal S15 of
Check for continuity connector 62C-16FW
between machine and
Disconnect con- terminals S15, Z16 of MC2/B.
nector 62C-16FW harness end connector
NO In case of no continuity
of left control panel. of connector at terminal Z16, har-
Check for continuity 62C-16FW. ness open circuit be-
between terminals tween terminal Z16 of
S15 and Z16 of connector 62C-16FW
panel connector. of left control panel and
· Front drum auto stop
MC2/B.
release switch: ON

Faulty front drum auto
stop release switch.
NO

Connector


T2BC-05-03-046 T2BC-05-03-048
Left control panel

MC2/B
(panel end) (harness end)

T2BC-05-03-047 T2BC-05-03-044

T5-3-113
FAILURE OF REAR DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
normal.


JB FOLD Jib folding ALL OFF Open circuit Controls as jib un- Harness check
ALL ON Harness short circuit folding
ATTACHMENT Wiring detection SHORT Short circuit on both Priority is given to the Harness check
crane and tower selection by IDU for
control or error con-
trol
OPEN Open circuit on both Priority is given to the
crane and tower selection by IDU for
control or disassem-
bly position control.
RD EOPE ED ALL OFF Open circuit Controls as overhoist Harness check
BT OVERH2 Boom/tower second

overhoist
TW OVERH Tower overhoist
JB OVERH Jib overhoist ALL ON Harness short circuit
SWL OVERH Tower jib backstop
alignment overhoist
RD HST CUR Rear drum hoisting pro- LOW ER Lower limit error PWM output short Harness check
portional solenoid valve circuit or open circuit Solenoid valve check
RD LWR CUR Rear drum lowering OFF (stop) MC2/B hardware
proportional solenoid HI ER Upper limit error PWM output harness check
valve short circuit
OFF (stop)
current feedback
Current control by
open loop
x 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
Rear Drum Hoisting

Valve
Rear Drum Lowering

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 Rear Drum
Shouldering
Prevention
Tower Relay Box
Tower Breakage
Prevention
Tower Jib
Overhoist
Prevention
Tower Jib
Backstop
Alignment
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-014
T5-3-115
Check of Rear Drum Hoisting Proportional Sole-
noid Valve System

Connect terminal Harness short circuit
D3 of connector YES between rear drum
MCB-1 to terminal hoisting proportional
A5 of connector solenoid valve and
MCB-4 of MC2/B. MC2/B.
YES
Check if voltage
between terminal
MCB-5 of MC2/B.
F11 of machine end
Connect terminals Z7
connector of con- Faulty MC2/B.
and Z11 of harness
nector MCB-5 and
end connector of con- NO
nector MCB-5 to ma-
machine is 0 V.
YES chine. · Engine: Running
Check for continuity · Rear drum auto stop In case of no continuity
between machine and release switch: OFF at terminal #1, harness
terminals #1, #2 of · Connect terminals D3 open circuit between
harness end connector and A5 by using a terminal #1 of rear
Disconnect connec- of rear drum hoisting jumper wire. drum hoisting propor-
tor of rear drum proportional solenoid tional solenoid valve
hoisting proportional valve. and MC2/B.
solenoid valve. NO In case of no continuity
Check for continuity at terminal #2, harness
between terminals open circuit between
#1 and #2 of ma- terminal #2 of rear
chine end connector. drum hoisting propor-
tional solenoid valve
and MC2/B.

Faulty rear drum hoist-
NO
ing proportional sole-
noid valve.

Connector
MC2/B
Rear drum hoisting proportional MC2/B
Connector MCB-4
solenoid valve Connector MCB-1
(machine end)

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
Connector MCB-5
(harness end)

T2BC-05-03-044
T5-3-116
Check of Rear Drum Lowering Proportional So-
lenoid Valve System


connector
D3 of YES between rear drum
MCB-1
and terminal lowering proportional
A5 of connector solenoid valve and

YES MCB-4 of MC2/B. MC2/B.
MCB-5 and MCB-6 of Check
if voltage
MC2/B. between machine
Connect terminal Z19 and terminal E14 of
of harness end con- machine end con- Faulty MC2/B.
of connector
nector
nector of connector NO
MCB-5 and terminal MCB-6
is 0 V.
YES Y14 of harness end · Engine: Running In case of no continuity

connector of connector · Rear drum auto stop release at terminal #2, harness
MCB-6 to machine. OFF
switch: open circuit between
Check for continuity · Connect terminals D3 and terminal #2 of rear
between machine and A5by using a clip or the like drum lowering propor-
Disconnect connec- terminals #1, #2 of at the
rear of connector. tional solenoid valve
tor of rear drum low- harness end connector · Rear drum lock switch: OFF and MC2/B.
ering proportional of rear drum lowering In case of no continuity
solenoid valve. proportional solenoid at terminal #1, harness
Check for continuity NO
valve. open circuit between
between terminals · Rear drum lock switch: OFF terminal #1 of rear
#1 and #2 of ma- drum lowering propor-
chine end connector. tional solenoid valve
and MC2/B, or faulty
read drum lock switch.

Faulty rear drum low-
NO ering proportional so-
lenoid valve.

Connector
Rear drum lowering proportional MC2/B MC2/B
solenoid valve Connector MCB-1 Connector MCB-4


T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
Connector MCB-5 MC2/B
(harness end) Connector MCB-6
(harness end)

T2BC-05-03-044 T2BC-05-03-003

T5-3-117
Check of Rear Drum Auto Stop Release Switch

Disconnect connectors YES Faulty MC2/B.
MCB-3 and MCB-5 of
MC2/B.
Connect terminal S8 of

YES of connector MCB-3 In case of no continuity
and terminal Z16 of at terminal S8, harness
harness end connector open circuit between
of connector MCB-5 to terminal S8 of connec-
machine. tor 62C-16FW of left
Disconnect con- Check for continuity control panel and
between machine and MC2/B.
nector 62C-16FW In case of no continuity
of left control panel. terminals S8, Z16 of NO
Check for continuity harness end connector at terminal Z16, har-
between terminals of connector ness open circuit be-
S8 and Z16 of 62C-16FW. tween terminal Z16 of
panel end connec- connector 62C-16FW
· Rear drum auto MC2/B.
stop release switch:
ON
Faulty rear drum auto
stop release switch.
NO

Connector

T2BC-05-03-046 T2BC-05-03-048


T2BC-05-03-044
T2BC-05-03-047

T5-3-118
FAILURE OF THIRD DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
normal.


IDU for control or
error control.
IDU for control or
disassembly posi-
tion control.
overhoist hoist
HK OVERH Hook overhoist ALLON Harness short cir-
cuit
3D HST SOL Third drum hoisting ERROR Short circuit OFF (stop) Harness check
solenoid valve Solenoid valve
3D LWR SOL Third drum lowering check
solenoid valve

x 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
Auto Stop Release Third /

Fourth Drum Switch
Auto Stop Release Key

Switch
Boom Second Overhost

Prevention
Crane Relay
Box Fourth Drum
Hoisting Stop
Third Drum
Main Hook Lowering Stop
Overhoist
Prevention
Shouldering
Prevention
Sub Hook
Overhoist
Prevention
Third Drum Hoisting

Solenoid Valve

Solenoid Valve
Third Drum Lowering

Solenoid Valve

Solenoid Valve

T2BC-05-03-049
T5-3-120
Check of Third Drum Hoisting Solenoid Valve
System


Check if voltage at ter-
YES minal 387 of relay har-
ness end connector is
Disconnect connector 24 V.
third/fourth drum selec-
tion (upper) relay. · Engine: Running
Connect terminal 377 · Third / fourth selection
of connector to ma- switch: Third
YES chine end.
between machine and
terminals #1, #2 of
harness end of con- In case of no continuity
nector of third drum at terminal #1, harness
Disconnect connec- open circuit between
tor of third drum hoisting solenoid valve.
hoisting solenoid relay and third drum
valve. hoisting solenoid valve.
Check for continuity NO In case of no continuity
at terminal #2, faulty
between terminals #1 ground of third drum
and #2 of machine
end connector. hoisting solenoid valve.

Faulty third drum
hoisting solenoid valve.
NO

Connector
Third / fourth drum selection MC2/B
Third drum hoisting solenoid valve
(harness end) (upper) relay Connector MCB-6

T2BC-05-03-003

T2BC-05-04-010
MC2/B
Connector MCB-6
T2BC-05-03-050
(machine end)

T2BC-05-03-032
T5-3-121
D3 of
Connect terminal
YES Harness short circuit
connector MCB-1 and ter- between third drum

minal A5 of connector hoisting solenoid
YES MCB-4 of MC2/B.
valve and MC2/B.
Check if voltage between
machine and terminal Y17
MCB-6 of MC2/B. of machine end connector Faulty MC2/B.
Connect terminal Y7 of
of connector MCB-6 is 0 V. NO

· Engine: Running
of connector MCB-6 to
YES machine. · Third drum auto
stop release
Check for continuity switch: OFF
between machine and
· Connect terminals D3 and
terminal #1 of harness A5 by using a clip or the like
end connector of third at the rear of connector.
drum hoisting solenoid · Third / fourthselection Faulty harness be-
valve. switch: Third tween MC2/B and

relay, or faulty relay.
· Connect relay harness. NO

· Third / fourth selection
switch: Third

selection switch.
NO

Connector
MC2/B MC2/B MC2/B
Connector MCB-1 Connector MCB-4 Connector MCB-6
(Machine end) (Machine end) (Machine end)

T2BC-05-03-021 T2BC-05-03-045 T2BC-05-03-003

T5-3-122
Check of Third Drum Lowering Solenoid Valve
System In case of no continuity

at terminal #2, faulty
• Check the wiring connections first. ground of third drum
lowering solenoid
valve.
Disconnect connector In case of no continuity
third drum lowering relay. NO at terminal #1, harness
Connect terminal 388 of open circuit between
connector to machine relay and third drum
YES end. lowering solenoid
Check for continuity be- valve.
tween machine and ter-
minals #1, #2 of harness

Check if voltage at
end of connector of third terminal 295 of con-
drum lowering solenoid
YES nector of third drum
Disconnect connec- valve. lowering stop relay is
tor of third drum low-
ering solenoid valve. 24 V.
between terminals #1 · Third / fourth brake
and #2 of machine mode selection switch:
end connector. AUTO

Faulty third drum low-
NO ering solenoid valve.

Connector
Third drum lowering solenoid valve
Third drum lowering stop relay Third / fourth drum selection
(harness end)
(harness end)

(lower) relay (harness end)

T2BC-05-04-010

T2BC-05-03-052
T2BC-05-03-051

T5-3-123

NO Faulty MC2/A.

Check if third /
NO fourth auto mode

lamp (green) is
turned on. Harness open cir-
cuit between free
YES mode switch and
third drum lowering
stop relay.

YES Faulty third drum
lowering stop relay.

Check if voltage at YES
A
terminal 378 of
Disconnect con-
connector of third Check if voltage at
YES drum lowering stop nector of third /
fourth drum selec- YES
terminal 378 be- Faulty third / fourth
relay is 24V. tween harness of drum selection
tion (lower) relay.
third / fourth drum (lower) relay or
· Third / fourth drum
between terminal selection (lower) faulty third / fourth
selection switch: Third
378 of harness end relay connector is NO drum selection
connector of third / 24V. switch.
NO
fourth drum selec-
tion (lower) relay
Harness open cir-
and terminal 378 of
cuit between third /
harness end con-
nector of third drum

NO
fourth drum selec-
tion (lower) relay
lowering stop relay. and third drum
lowering stop relay.

Connector
MC2/B
MC2/B MC2/B
Connector MCB-6
(machine end)

T2BC-05-03-003
T2BC-05-03-021 T2BC-05-03-045

Connector of third / fourth MC2/B
Connector of third drum low-
drum selection Connector MCB-6
ering relay
(harness end)

T2BC-05-03-032

T2BC-05-03-051
T2BC-05-03-060

T5-3-124

D3 of connector YES between third drum
MCB-1 to terminal
lowering solenoid
A5 of connector valve and MC2/B.
MCB-4 of MC2/B.
YES
Check if voltage at

terminal E21 of
Connect disconnected machine end of
relay harness. Dis- connector MCB-6 is Faulty MC2/B.
connect connector 0 V. NO
MCB-6 of MC2/B.

Connect terminal Y21 · Engine: Running
A of harness end con- · Third drum auto stop
nector of connector release switch: OFF
MCB-6 to machine.
· Connect terminals D3
Check for continuity and A5 by using a clip
between terminal #1 of or the like at the rear
harness end connector of connector.
of third drum lowering Harness open circuit
between MC2/B and
solenoid valve and
NO relay.
machine.

Connector MC2/B MC2/B
Third drum lowering solenoid (machine end)
(harness end)
valve (harness end)

T2BC-05-03-003 T2BC-05-03-045
MC2/B MC2/B
T2BC-05-04-010
(machine end)
(machine end)

T2BC-05-03-032 T2BC-05-03-021

T5-3-125
Check of Third Drum Auto Stop Release Switch


MCB-3 and MCB-5 of
MC2/B. YES Faulty MC2/B.
of harness end con-
nector of connector
MCB-3 and terminal
YES Z16 of harness end In case of no continuity
connector of connector at terminal S16, har-
MCB-5 to machine.
Check for continuity tween terminal S16 of
between machine and connector 62C-16FW
Disconnect connec- of left control panel
terminal S16, Z16 of
tor 62C-16FW of left harness end connector andMC2/B.
control panel. Check of connector NO In case of no continuity
for continuity be- 62C-16FW. at terminal Z16, har-
tween terminals S16 tween terminal Z16 of
and Z16 of panel end
connector. connector 62C-16FW
of left control panel
· Third / fourth drum andMC2/B.
auto stop release
switch: ON
drum auto stop release
NO switch.

Connector
Connector 62C-16FW Connector MCB-3 (har-
(harness end) ness end)

T2BC-05-03-046 T2BC-05-03-048

Connector 62C-16FW Connector MCB-5 (har-
(panel end) ness end)

T2BC-05-03-047 T2BC-05-03-044
T5-3-126
FAILURE OF FOURTH DRUM AUTO STOP
CONTROL SYSTEM (OPTIONAL)
Abnormality
normal.


IDU for control or
error control.
IDU for control or
disassembly posi-
tion control.
overhoist hoist
HK OVERH Hook overhoist ALLON Harness short cir-
cuit
3D HST SOL Fourth drum hoisting ERROR Short circuit OFF (stop) Harness check
3D LWR SOL Fourth drum lowering check
solenoid valve

x 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
Auto Stop Release Third /

Fourth Drum Switch
Auto Stop Release
Key Switch
Boom Overhoist
Prevention
Crane Relay
Fourth Drum
Box
Hoisting
Prevention
Third Drum
Main Hook Hoisting
Prevention
Shouldering
Prevention
Sub Hook
Overhoist
Prevention
Third Drum Hoisting

Solenoid Valve

Solenoid Valve
Third Drum Lowering

Solenoid Valve

Solenoid Valve

T2BC-05-03-049
T5-3-128
Check of Fourth Drum Hoisting Solenoid Valve
System


YES

Check if voltage at
Disconnect connector terminal 387 of
third / fourth drum se- relayharness end
lection (upper) relay. connector is 24 V.

Connect terminal 379 · Engine: Running
of connector to ma-
YES · Third / fourth selection
chine end. Fourth
switch:
between machine and
terminals #1, #2 of In case of no conti-
harness end of con- nuity at terminal #1,
Disconnect connec- nector of fourth drum between relay and
tor of fourth drum hoisting solenoid valve.
hoisting solenoid fourth drum hoisting
valve. solenoid valve.
Check for continuity NO In case of no conti-
between terminals
#1 and #2 of ma- faulty ground of
chine end connector. fourth drum hoisting
solenoid valve.

Faulty fourth drum
hoisting solenoid
NO valve.

Connector
Fourth drum hoisting solenoid valve Third / fourth drum selection MC2/B
(harness end) (upper) relay (harness end) Connector MCB-6
(harness end)

T2BC-05-03-003

T2BC-05-04-010

Fourth drum hoisting solenoid valve T2BC-05-03-050
(machine end)

T2BC-05-03-061
T5-3-129
Connect terminal
D3 of Harness short circuit
connector MCB-1 to ter- YES between fourth drum

minal A5 of connector hoisting solenoid valve
MCB-4 of MC2/B. and MC2/B.

YES Check if voltage between
machine and terminal E7
MCB-6 of MC2/B. Con- of machine end connector

of connector MCB-6 is 0 V.
nect terminal Y7 of har-
ness end connector of
· Engine: Running Faulty MC2/B.
connector MCB-6 to · Third drum auto
stop release NO
YES machine. switch: OFF
between machine and A5 by using a
terminal #1 of harness clip or the like
at the rear of connector.
end connector of fourth · Third / fourthselection
drum hoisting solenoid switch: Fourth Faulty harness be-
valve. tween MC2/B and re-
NO lay, or faulty relay.
· Connect relay har-
ness.
switch: Fourth
selection switch.
NO

Connector
MC2/B MC2/B MC2/B

(machine end) (machine end) (machine end)

T2BC-05-03-021 T2BC-05-03-045 T2BC-05-03-032
T5-3-130
Check of Fourth Drum Lowering Solenoid Valve
System


Check if voltage at
YES terminal 387 of relay
harness end con-
Disconnect connector of
third/fourth drum selection nector is 0 V.

(lower) relay. · Engine: Running
Connect terminal 380 of · Third/fourth selection
connector to machine switch: Fourth
end.

YES

tween machine and ter- In case of no continuity
minals #1, #2 of harness
at terminal #1, harness
end of connector of fourth open circuit between
Disconnect connec- drum lowering solenoid
tor of fourth drum relay and fourth drum
valve. lowering solenoid
lowering solenoid · Fourth drum lock switch:
valve, or faulty fourth
valve. drum lock switch.
OFF
Check for continuity NO In case of no continuity
between terminals at terminal #2, faulty
#1 and #2 of ma-
ground of fourth drum
chine end connector. lowering solenoid
valve.

Faulty fourth drum
lowering solenoid
NO valve.

Connector
Fourth drum lowering solenoid Third / fourth drum selection
valve (harness end) (lower) relay (harness end)

T2BC-05-04-010
T2BC-05-03-051

T5-3-131
D3 of YES
connector MCB-1 to ter- between fourth drum

minal A5 of connector lowering solenoid valve
YES MCB-4 of MC2/B. and MC2/B.

Check if voltage at termi-

nal E21 of machine end
connector of connector Faulty MC2/B.
Disconnect connector MCB-6 is 0 V. NO
MCB-6 of MC2/B.
Connect terminal Y21 of · Engine: Running
harness end connector of · Third / fourth
drum auto stop
connector MCB-6 to ma- release switch: OFF
chine.
YES A5 by using a clip or the like
tween terminal #1 of har- at the rear of connector.
ness end connector of · Third / fourth
selection
fourth drum lowering so- switch: Fourth
lenoid valve and machine.
Faulty harness between
MC2/B and relay, or
· Fourth drum lock switch:
YES faulty relay.
OFF
· Engine: Running
switch: Fourth
Faulty third/fourth selec-
NO tion switch.

Connector
MC2/B MC2/B MC2/B
(harness end)
(machine end) (machine end)

T2BC-05-03-021 T2BC-05-03-045 T2BC-05-03-003

Fourth drum lowering solenoid MC2/B
valve (harness end) Connector MCB-6
(machine end)

T2BC-05-03-032

T2BC-05-04-010
T5-3-132
Check of Fourth Drum Auto Stop Release Switch


MCB-3 and MCB-5 of
MC2/B.
YES Faulty MC2/B.
of harness end con-
nector of connector
YES
Z16 of harness end at terminal S16, harness
connector of connector open circuit between
MCB-5 to machine. terminal S16 of connec-
Check for continuity tor 62C-16FW of left
Disconnect connector between machine and control panel and
terminal S16, Z16 of MC2/B.
62C-16FW of left harness end connector
control panel. NO In case of no continuity
Check for continuity of connector at terminal Z16, harness
62C-16FW. open circuit between
between terminals terminal Z16 of connec-
S16 and Z16 of panel
end connector. tor 62C-16FW of left
control panel and
· Third / fourth drum MC2/B.
auto stop release
switch: ON
Faulty third / fourth drum
auto stop release switch.
NO

Connector

T2BC-05-03-046 T2BC-05-03-048


T2BC-05-03-047
T2BC-05-03-044

T5-3-133
FAILURE OF SECOND OVERHOIST AUTO
STOP CONTROL SYSTEM
Abnormality
normal.
By using the MC2/B input/output monitor, confirm

the limit switch and solenoid valve signals.

IDU for control or
error control.
IDU for control or
disassembly posi-
tion control
overhoist hoist.
ALLON Harness short cir-
cuit
OVERH2 SOL Second overhoist ERROR Short circuit OFF (stop) Harness check
check

x For check of limit switches and attachment wiring,
refer to Section "Failure of Derricking Drum Auto
Stop Control System".
T5-3-134
Second Overhoist
Solenoid Valve.

Restoration Switch
Boom Overhoist Prevention
Tower Relay
Box
Tower Jib Second


T2BC-02-01-018
T5-3-135
Check of Second Overhoist Solenoid Valve Sys-
tem


Connect terminal D3

of connector MCB-1 Harness short circuit
to terminal A5 of YES between second over-

connector MCB-4 of hoist solenoid valve and

MC2/B. MC2/B.
YES Check if voltage be-
tween terminal E17
Disconnect connector of machine
end
MCB-6 of MC2/B. Con- connector of con-
nect terminals Y17 and MCB-6 and
nector Faulty MC2/B.
Y26 of harness end machine is 0 V. NO

connector of connector · Engine: Running
YES MCB-6 to machine.
· Second overhoist restoration
Check for continuity be- switch: In case of no continuity
tween machine and ter-
OFF
· Connect terminals D3 and at terminal #1, harness
minals #1, #2 of harness A5 by using a clip or the like open circuit between
end connector of second at the terminal #1 of second
overhoist solenoid valve. rear of connector.
Disconnect connec- overhoist solenoid valve
tor of second over- andMC2/B.
hoist solenoid valve. In case of no continuity
Check for continuity NO at terminal #2, harness
between terminals open circuit between
#1 and #2 of ma- terminal #2 of second
chine end connector. overhoist solenoid valve
andMC2/B, or faulty
ground.

Faulty second overhoist
NO solenoid valve.

Connector
Second overhoist solenoid valve MC2/B MC2/B
(machine end)

T2BC-05-03-021 T2BC-05-03-045

T2BC-05-04-010 MC2/B
MC2/B

T2BC-05-03-003 T2BC-05-03-032

T5-3-136
Check of Second Overhoist Restoration Switch

MCB-4 and MCB-5 of
MC2/B.
YES Faulty MC2/B.
Connect terminal R14
of harness end con-
nector of connector
YES
Z16 of harness end at terminal R14, harness
connector of connector open circuit between
MCB-5 to machine. terminal R14 of connec-
Check for continuity tor 62C-16FW of left
between machine and control panel and
terminal R14, Z16 of
Disconnect connec- harness end connector
MC2/B.
tor 62C-16FW of left NO In case of no continuity
control panel. Check of connector at terminal Z16, harness
for continuity be- 62C-16FW. open circuit between
tween terminals R14 terminal Z16 of connec-
and Z16 of panel end tor 62C-16FW of left
connector. control panel and
MC2/B.
· Second overhoist
restoration switch:
Cancellation Faulty second overhoist
restoration switch.
NO

Connector
Left stand panel MC2/B

T2BC-05-03-046 T2BC-05-03-027
Left stand panel

MC2/B
Connector 62C-16FW
Connector MCB-5
(panel end)
(harness end)

T2BC-05-03-047
T2BC-05-03-044

T5-3-137
FAILURE OF FRONT AND REAR MOTOR
SPEED CONTROL SYSTEM
Abnormality
normal.

the sensor and solenoid valve signals.

FM CAP CUR Front motor dis- LOW ER Lower limit error PWM output short Harness check
placement angle con- circuit or open circuit
trol proportional so- Minimum motor ca-
lenoid valve pacity
HI ER Upper limit error PWM output harness Harness check
short circuit Solenoid valve
Minimum motor ca- check
pacity
RES ER Reset error Abnormal electric MC2/B hardware
current feedback check
Current control by
open loop
RM CAP CUR Rear motor dis- LOW ER Lower limit error PWM output short Harness check
placement angle con- circuit or open circuit
trol proportional so- Minimum motor ca-
lenoid valve pacity
Minimum motor ca- check
pacity
current feedback
check
Current control by
open loop
T5-3-138

Front Motor Displacement

Angle Proportinal Solenoid
Valve
Hoisting Displacement
Angle Lock Switch
Rear Motor Displacement

Angle Proportinal Solenoid
Valve

T2BC-05-03-053

T5-3-139
Check of Front Motor Displacement Angle Con-
trol Proportional Solenoid Valve System


YES between front motor
Check if voltage displacement angle con-
terminal
between trol proportional solenoid
Y1 of machine end valve and MC2/B.
YES
connector of con-
nector
MCB-6 and
machine is 0 V.
MCB-5 and MCB-6 of Faulty MC2/B.
· Connect
terminals E12
MC2/B. and Y12, E13 and Y13 NO
Connect terminal Z8 of
by using a clip.
YES harness end connector · Key switch: ON
of connector MCB-5 low speed
· Hoisting In case of no continuity
and terminal Y1 of switch: at terminal #1, harness
harness end of con- OFF open circuit between
nector MCB-6 to ma- terminal #1 of front motor
Disconnect connec- chine. displacement angle con-
tor of front motor Check for continuity trol proportional solenoid
displacement angle between terminals #1, valve and MC2/B.
control proportional
#2 of harness end NO
solenoid valve. connector of front mo- at terminal #2, harness
Check for continuity tor displacement angle open circuit between
between terminals #1 control proportional terminal #2 of front motor
and #2 of machine solenoid valve and displacement angle con-
end connector. machine. trol proportional solenoid
valve and MC2/B.

Faulty front motor dis-
placement angle control
NO proportional solenoid

valve.

Connector
MC2/B
Front motor displacement angle MC2/B
Connector MCB-6
control proportional solenoid
(harness end)
valve (harness end)

T2BC-05-03-003
T2BC-05-03-044
MC2/B
T2BC-05-04-010
Connector MCB-6
(machine end)

T2BC-05-03-032

T5-3-140
Check of Rear Motor Displacement Angle Control
Proportional Solenoid Valve System


YES between rear motor dis-
Check if voltage placement angle control
terminal
between proportional solenoid
Y15 of machine end valve and MC2/B.
YES
connector of con-
nector
MCB-6 and
machine is 0 V.
Disconnect connectors Faulty MC2/B.
MCB-5 and MCB-6 of · Connect terminals E12
MC2/B. NO
and Y12, E13 and Y13
Connect terminal Z20
by using a clip.
YES of harness end con- · Key switch: ON
nector of connector low speed
· Hoisting In case of no continuity
MCB-5 and terminal switch: at terminal #1, harness
Y15 of harness end of OFF
open circuit between
Disconnect connector connector MCB-6 to terminal #1 of rear motor
machine. displacement angle con-
of rear motor dis- Check for continuity trol proportional solenoid
placement angle
control proportional between terminals #1, valve and MC2/B.
solenoid valve. #2 of harness end NO In case of no continuity
Check for continuity connector of rear mo- at terminal #2, harness
tor displacement angle open circuit between
between terminals #1 control proportional
and #2 of machine terminal #2 of rear motor
end connector. solenoid valve and displacement angle con-
machine. trol proportional solenoid
valve and MC2/B.

Faulty rear motor dis-
placement angle control
NO proportional solenoid

valve.

Connector
Rear motor displacement angle control MC2/B
MC2/B
Connector MCB-5
(harness end)
(h arness end) (harness end)

T2BC-05-03-003
MC2/B
T2BC-05-03-044
Connector MCB-6
T2BC-05-04-010
Rear motor displacement angle control (machine end)

(machine end)

T2BC-05-03-032

T2BC-05-03-031
T5-3-141
Check of Hoisting Low Speed Lock Switch

MCB-4 and MCB-5 of
MC2/B. YES Faulty MC2/B.
Connect terminal R15

of harness end con-
nector of connector
MCB-4 and terminal
YES Z16 of harness end of
connector MCB-5 to In case of no continuity
at terminal R15, harness
machine.
Check for continuity open circuit between
between terminals terminal R15 of side
upper panel of connector
Disconnect connec- R15, Z16 of harness
end connector of con- 62C-16FW and MC2/B.
tor 62C-16FW of side In case of no continuity
nector 62C-16FW and NO
upper panel. machine. at terminal Z16, harness
Check for continuity open circuit between
between terminals terminal Z16 of side up-
R15 and Z16 of panel per panel of connector
end connector.
62C-16FW and MC2/B.
· Hoisting low speed
lock switch: ON
Faulty hoisting low
NO speed lock switch.

Connector
Side upper panel MC2/B

T2BC-05-03-054 T2BC-05-03-027

Side upper panel MC2/B

T2BC-05-03-055 T2BC-05-03-044

T5-3-142
FAILURE OF FRONT DRUM SURGE
PRESSURE REDUCTION CONTROL SYS-
TEM
Abnormality
normal.


FD HST CUR Front drum hoisting LOW ER Lower limit error PWM output short Harness check
proportional solenoid circuit or open circuit
valve OFF (stop)
OFF (stop) check
power feedback check
Controls electric cur-
rent by open loop.
FD LWR CUR Front drum lowering LOW ER Lower limit error PWM output short Harness check
valve OFF (stop)
OFF (stop) check
rent by open loop.
x 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
Front Drum Hoisting

Valve
Front Drum
Lock Switch Front Drum Lowering
Valve
Shouldering
Prevention

T2BC-05-03-056

T5-3-144
FAILURE OF TOWER JIB DERRICKING
2-SPEED FLOW COMBINING LIMIT CON-
TROL SYSTEM
Abnormality
normal.


RD HST CUR Rear drum hoisting LOW ER Lower limit error PWM output short Harness check
valve OFF (stop)
OFF (stop) check
rent by open loop
RD LWR CUR Rear drum lowering LOW ER Lower limit error PWM output short Harness check
valve OFF (stop)
OFF (stop) check
rent by open loop
x 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

Rear Drum Hoisting
Valve
Rear Drum
Lock Switch Front Drum Lowering
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.

x How to read troubleshooting flowchart

YES(OK)
(2)
(1) According to the result of inspection or measurement in (1), se-
࡮ (1) lect YES (OK) or NO (NO OK), and go to the next step (2) or (3).
(3)
NO(NOT OK)

࡮ 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
· Key switch: ON cause of failure, or may damage the equipment.

࡮ A bold line box shows a cause of failure.
The description in the bold-lined box helps you locate a possible cause of failure.

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


T5-4-1
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)
Engine system 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.
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
Hoisting drum
turned OFF.
system
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.
M-7 Even when setting to the auto brake mode, drum free indicator (red) is not
turned OFF.
Boom derricking B-1 Drum does not rotate.
drum system
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..
Miscellaneous O-3 Jack-up (optional) cannot be done.
O-4 Retraction cannot be done (with jack (optional) attached).
O-5 Retraction cannot be done (by using a switch in cab).
T5-4-2
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.
Broken harness be-
• A failure that starter does not run is not related to tween starter motor and
YES
electronic control systems such as MC2/A, ground, or faulty
MC2/B and IDU. ground.

Connect starter
Check if voltage
YES motor ground line
to machine. between C ter-
minal of key
Check if starter Check for continu- YES
runs. ity between termi- switch and (A)
nal B of starter machine is 24V
· Key switch: START or more.
motor and terminal
B of starter relay 1. · Key switch: START
NO Check for continu- · Insert a test bar into
ity between termi- the rear of connector.
nal S of starter
motor and terminal Broken harness be-
S of starter relay. tween terminal B of
starter motor and termi-
nal B of starter relay 1.
Check if voltage NO Broken harness be-
between machine tween terminal S of
and terminal B of
starter motor and termi-
starter motor is nal S of starter relay 1.
24V or more.

· Key switch: ON

To “Failure of power
NO supply system”

Connector
Key switch
Starter Relay 1 Starter Relay 1 Connector
(Harness end)

Terminal C
Terminal B
Terminal S

T333-05-04-012
T2BC-05-04-002
Starter Motor

T5-4-3

Connect terminal L
(harness end) of
connector of
starter relay to
machine. Discon-
YES nect connector of
(B)
Connect connector starter relay 2.
Check for continu-
of engine starting
relay. ity between ma-
chine and terminal
Disconnect con- YES Check if voltage S (harness end) of
nector of starter between machine
and terminal SW connector.
relay.
Connect terminal (harness end) of
connector is 24 V To “Failure of en-
SW (harness end) gine start interlock
YES of connector to or more.
control system” in
machine. · Key switch: START “Troubleshooting
Check for continu- N
Disconnect con- A”.
ity between termi-
nector of engine
nal #5 (harness
starting relay.
end) of connector
YES Check if voltage
of engine starting Broken harness
between machine
relay and machine. between engine
and terminal #3
starting relay and
(harness end) of N
connector is 24 V starter relay 1.
or more.

· Key switch: Broken harness
(A) START between key
NO switch and engine
start relay.

Faulty key switch.
NO

Connector
Engine Starting Relay Starter Relay 1

(Harness end) (Harness end)
Terminal L Terminal SW
Terminal #3
T5-4-4

Check if voltage
between machine
YES and terminal P
Check for continu- (harness end) of (C)
ity between ma- connector of
YES chine and terminal starter relay 2 is 0

E (harness end) of
connector of Broken harness
Disconnect con-
starter relay 2. between starter
nector of starter
relay 2 and
relay 2. N ground, or faulty
YES Check if voltage ground.
between machine

and terminal R
(harness end) of
Connect connector connector is 24 V
of starter relay 2. or more.
YES Check if electric Broken harness
· Key switch: ON
current at terminal between key
L (harness end) of switch and starter
N
connector of relay 2.
starter relay 1 is
0A.
(B)
· Key switch: START Faulty starter re-
NO lay.

Broken harness
between starter
N relay 2and starter
relay 1.

YES Faulty starter relay
2.

(C)
Faulty alternator,
or short-circuited
harness between
N alternator and
starter relay 2.
Connector
Starter Relay 2 Starter Relay 1

Terminal S Terminal R
Terminal L Terminal SW
Terminal E Terminal P
T5-4-5
POWER SUPPLY SYSTEM FAILURE

Broken harness be-
YES tween battery relay
and starter motor‫ޕ‬

Broken harness be-
Disconnect 206 tween battery relay
YES
harness of battery and ground, or faulty
Connect 206 har-
relay. ground.
ness.
Check if voltage at
YES Connect terminal ()
terminal (machine
of battery to machine.
end) is 24V or Disconnect harness
more. from terminal () of
tween machine and
· Key switch: ON terminal B of starter battery to machine.
motor is 24V or more. Disconnect connector
Check if battery of key switch.
voltage and spe- · Key switch: ON
NO Check for continuity
cific gravity of bat- between machine end
NO
tery electrolyte are terminal B (harness
normal. end) of connector.

Faulty battery.
NO

T5-4-6
Broken harness
YES between battery
relay and ground,
Connect ground
terminal of battery or faulty ground.
relay to machine.
between machine
and terminal B of
Connect the dis- starter motor is
connected har- Faulty battery re-
24V or more.
ness to connec- lay.
· Key switch: ON N
YES tor. Check if volt-
age between
machine and ter-
Disconnect 264
harness of battery minal ACC of key
relay. switch is 24V or
YES Connect 264 har- · Key switch: ON
ness to machine. · Insert a test bar
Check for continuity Faulty key switch.
into the rear of
between machine connector. N
and terminal ACC

(harness end) of Broken harness or
key switch connec- fuse #20 between
tor. key switch and
NO
battery relay.

Broken harness
between battery
NO and key switch.

Connector
Key Switch
(Harness end)
Terminal B

T2BC-05-04-002
Terminal ACC
T5-4-7
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.

YES
Faulty engine.

Check if engine gov-
ernor lever moves to
the start position.
YES
· Key switch: ON Faulty battery.
· Visual check Connect terminal
GD2 (harness end)
of engine stop sole-
noid to machine.
NO Check if engine gov-
ernor lever moves to
the start position.
Check if voltage be- YES Faulty engine stop
· Key switch: ON tween machine and solenoid.
· Visual check terminal 209 (har-
ness end) of engine Connect terminal #4
NO stop solenoid is 24V of engine stop relay
or more. to machine. Check if
· Key switch: ON NO engine governor
lever moves to the
start position.
· Key switch: ON
· Connect to machine
from the rear of
connector.
· Visual check
Connector
Engine Stop Relay
(Harness end)

T2BC-05-04-001
T5-4-8

Broken harness
between engine
YES stop relay and

ground, or faulty
ground.

YES Faulty engine stop
Connect 209 har-
relay.
ness of engine
stop solenoid to
machine.
YES Check for continu-
ity between termi-
nal #6 (harness
Check if voltage
between machine end) of connector Broken harness
of engine start re- between engine
YES and terminal #1 lay and machine.
(harness end) of stop relay and en-
connector of en- NO gine stop solenoid.
Disconnect engine gine stop relay is
stop relay from 24 V or more.
connector. · Key switch: ON
Check if voltage Broken harness
between machine between key
NO and terminal #2 NO switch and engine
(harness end) of stop relay.
connector is 24 V.
Broken harness
· Key switch: ON between engine
NO stop relay and
battery relay.
T5-4-9
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
Broken harness
coolant temperature. YES between heater
For preheating, refer to Chapter “Electric system” Check if voltage relay and air
in “Operational Principle”. between machine heater.
• Check a fuse of heater relay first. YES and terminal 217
• Check the wiring connections first. (harness end) of
heater relay is Check if voltage
between machine
· Key switch: ON and terminal 206
· Check within 15 NO (harness end)of
Check if voltage seconds after turn- heater relay is
between machine ing key switch ON.
YES
and air heater · Key switch: ON
power terminal of
engine is 24V.
· Key switch: ON
Check if
coolant tem- Faulty air heater or
perature is 0 faulty ground.
NO
qC or lower.
Air heater does not

work. (Normal)
NO
T5-4-10

YES Faulty heater relay or
faulty ground.

Remove plug from
heater relay.
between machine Broken harness be-
YES tween preheat con-
and harness end
plug is 24 V. troller and heater re-
lay.
· Key switch: ON
Check if voltage
between machine
and terminal #1 of
NO preheat controller Broken harness be-
Connect terminal YES tween preheat con-
is 24V. #9 of preheat con-
troller and ground.
troller to machine.
· Key switch: ON
· Insert a test bar
Check if voltage
into the rear of NO between terminal
#1 and machine is
connector. Check if voltage be-
24V.
tween machine and
· Key switch: ON terminal #7 of preheat (A)
· Connect to ma- NO controller is 24V.
chine from the
rear of connector. · Key switch: ON
into the rear of
connector.
YES Broken harness be-

tween heater relay and
Check if voltage battery relay.
between machine
and terminal 206
NO (harness end) of
battery relay is
24V. To ”Check of key switch
· Key switch: ON NO and battery system”.
Connector
Preheat Controller
(Harness end)

T2BC-05-04-003
T5-4-11
YES Faulty preheat con-

Disconnect pre- Check if coolant troller.
YES temperature sen-
heat controller
from connector. sor is normal.
Faulty coolant tem-
Connect terminal NO perature sensor.
#5 (harness end)
of connector to
YES machine.
Disconnect coolant
temperature sen-
sor from connector Broken harness
Check if voltage Check for continu- between preheat
between machine ity between ma- controller and cool-
(A) and terminal #2 or chine and terminal ant temperature
#3 of preheat con- #2 (harness end) NO sensor.
troller is 24V. of connector.
· Key switch: ON
YES Broken harness
Check if voltage between preheat
between machine controller and bat-
and terminal 206 tery relay.
NO (harness end) of
battery relay is Go to "Check of key
24V. switch and battery
· Key switch: ON NO system".
Connector
Preheat Controller Coolant Temperature Sensor

T2BC-05-04-003
T5-4-12
Check of key switches and battery system

NO
Broken harness
between battery
Check if voltage and battery relay
YES between machine
and terminal 206 Connect ground
(harness end) of terminal of battery
Connect terminal () of battery relay is 24V. relay to machine.
battery to machine. Check if voltage
Check if voltage be- · Key switch: ON between machine
YES tween machine and YES and terminal 206
terminal 206 (harness (harness end) of
end) of battery relay is battery relay is
24V. 24V.
Check if volt- · Key switch: ON
age of battery · Key switch: ON
and specific
gravity of bat-
tery electrolyte Broken harness
are normal. between battery
and ground, or
NO
faulty ground.
Faulty battery.
NO
T5-4-13

Broken harness bat-
YES tery and ground, or
Faulty ground.

YES Faulty battery relay

Disconnect 264
harness of battery
relay.
Check if voltage
NO between machine YES Broken harness be-
and terminal (har- tween key switch

ness end) is 24V. and battery relay.

· Key switch: ON
Check if voltage
between machine
and terminal ACC
NO of key switch is
24V.
YES
· Key switch: ON Faulty key switch.
· Insert a test bar tween machine and
into the rear of terminal B of key
connector. NO
switch is 24V. Broken harness be-
· Key switch: ON NO tween key switch
· Insert a test bar into and battery.
the rear of connec-
tor.
Connector
Key Switch
(Harness end)
Terminal B

T2BC-05-04-002
Terminal ACC
T5-4-14
E-4 After-heating is not made after completion
of preheating.
Faulty alternator.
NO

YES

Broken harness
between preheat
Disconnect con- YES controller and al-
ternator.
nector of preheat
controller.
YES Check if voltage Check if voltage
between machine between machine
and terminal #7 and terminal L of
(harness end) of alternator is 0 V.
connector is 0 V.
· Key switch: START · Key switch: ON
· Insert a test bar into
the rear of connec- Faulty preheat con-
Check if voltage
NO tor. troller.
between machine
and terminal #4 of
preheat controller
is 24V.
· Key switch: ON
into the rear of
connector.
Broken harness
between engine
starting relay and
NO
preheat controller.
Connector
Preheat Controller
(Harness end)

T2BC-05-04-003
T5-4-15
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.
Go to "Failure of engine con-
Check if control YES trol system” in “Troubleshoot-
cable from gover- ing A".
NO nor motor, which is
Check if engine connected to gov- Faulty adjustment of control
Idle speed is too governor lever gets ernor lever, is set cable that connects governor
correctly.
fast or slow. in contact with low motor and governor lever.
idle stopper bolt. NO
· Key switch: ON Faulty adjustment of engine

· Set to low idle YES governor lever.
position by using
an accelerator
grip.
· Visual check.

T5-4-16
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.

NO
Carry out high idle calibration.
NO Check if high idle
calibration is done.
(A)
YES

Check if engine
Maximum un-load governor lever gets
speed is too low. in contact with high
idle stopper bolt.

· Key switch: ON YES Faulty governor lever or faulty
· Set to high idle po- rod.
sition by using an Check if engine
accelerator grip. governor lever, rod · Deformation of lever, rod or
the like
· Visual check. YES or the like is de-
formed.
Faulty engine or faulty fuel
NO system.

NO Faulty adjustment of control
Check if control ca- cable that connects governor
ble, which connects motor and governor lever.

(A) governor motor and
governor lever, is
set correctly. Go to "Failure of engine con-
trol system” in “Troubleshoot-
YES
ing A".

T5-4-17
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.

YES
Faulty engine stop solenoid.

Check if voltage
YES Faulty key switch.
between machine
Disconnect con-
and terminal 209 of key
(harness end) of YES nector
engine stop sole- switch.
if engine
Check Short-circuited harness be-
noid is 0 V. Disconnect engine stops.
tween key switch and battery
stop relay. NO relay, or faulty battery relay.
· Key switch: OFF
Check if voltage
between machine
NO and terminal #6
(harness end) of
connector is 0 V.
Short-circuited harness be-
· Key switch: OFF tween engine stop relay and
NO engine stop solenoid.

Connector
Engine Stop Relay Key Switch

Terminal C Terminal B

T2BC-05-04-001 T2BC-05-04-002
Terminal ACC

T5-4-18
ACTUATOR TROUBLESHOOTING
A-1 Two or more actuators do not work.
• Pilot system (pilot pump, gate lock valve, etc.)

and relief valves may malfunction. YES
Check if main relief Faulty main pump.
• If hoisting, lowering and derricking (lowering) pressure corre-
drums are not activated, refer to “Troubleshooting YES
sponding to failure is
A and D”. normal. Incorrect pressure
· Refer to Chapter setting of main relief
NO
"Performance valve.
Measurement".
Check if pilot circuit
YES primary pilot pres- Check if gate lock
sure is normal. valve, pres- NO Faulty pilot pump.
· Refer to Chapter sure-reducing valve
Check if gate lock "Performance and second overhoist
lever and emer- Measurement". NO solenoid valve in Faulty gate lock
valve, pres-
gency stop switch 4-spool solenoid
are in unlock posi- valve unit are ab- YES sure-reducing valve
tion. normal. or second overhoist
solenoid valve in
· Gate lock lever: · Disassembly 4spool solenoid

Pull valve.
· Emergency Stop
Switch: OFF Set lock lever and
emergency stop
NO
switch to unlock po-
sition.

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.

YES Faulty remote con-
trol valve.
· Even when control
Check if actuator lever is in neutral,
stops when setting pilot pressure is
lock lever to lock transmitted to con-
position. trol valve (spool).

Faulty control valve.
NO
· Pilot pressure is not
transmitted to con-
trol valve (spool),
but the oil passage
is open due to
sticking or the like.
T5-4-19
HOISTING DRUM TROUBLESHOOTING
M-1 Drum does not rotate

• 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. YES Faulty hoisting
• When safety device or drum lock motor functions, motor.
Check if pres-
drum stops. YES sure at port PR
• Refer to “Troubleshooting A and D” of hoisting motor Faulty motor brake
. Check if output is 4.9 MPa. release solenoid
NO
pressure from valve.
YES
control valveis
28.3 to 31.4 Stuck spool in con-
MPa.
trol valve or propor-

Check if sec- · Install pressure gauge to NO tional solenoid
port a or b of counter- valve.
YES ondary pilot
pressure is balance valve of hoisting
Disconnect piping normal. motor.
from A4 port of · Port a during hoisting.
4-spool solenoid · Refer to "Per-
· Port b during lowering. Faulty remote con-
valve unit. formance
Measurement". NO
trol valve.
Install pressure
gauge instead.
Check if output
pressure is 4.9

MPa.
Faulty second
overhoist solenoid
NO valve of 4-spool
solenoid valve unit.

4-Spool Solenoid Valve Unit Port 䌢(G3/8)

Port a (G3/8)
Counterbalance
Valve
PR Port (G1/4)

Port A4
T2BC-05-04-004
Hoisting
Motor
M25N-07-024
T5-4-20
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”.

YES Faulty drum brake.

Check if the lifting
load lowers when YES Faulty hoisting motor
depressing brake multi-plate brake.
NO Check if pressure at
pedal.
port PR of hoisting
motor is 0 MPa. Faulty hoisting motor

brake release sole-
NO noid valve.
Check if output
pressure at drum
brake release so-
NO lenoid valve is 0
MPa.

· Install pressure
gauge to port A of
drum brake release Faulty drum brake
release solenoid
solenoid valve to be YES
checked. valve.

Drum Brake Release Solenoid Valve

Port PR (G1/4)
Port
A (G3/8) Hoisting
T25N-05-04-002 Motor

M25N-07-024
T5-4-21
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.
• 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”.
YES
Faulty MC2/A.

Connect the disconnected con-
nector. If voltage between
Check if voltage between ma- terminal E9and ma-
YES E22 chine is not 24V, rear
chine and terminal E9 or
of connector MCA-6 of MC2/A auto brake indicator
is 24 V. bulb is burnt out.
Disconnect connector of brake If voltage between
· Key switch: ON terminal E22 and
indicator of left stand.
· Brake mode selectionswitch: machine is not 24V,

Connect terminals #7 and #8 NO
OFF (auto brake) front auto brake in-
(harness end) of connector to

machine.
· Front drum brake mode se- dicator bulb is burnt
lection switch: OFF out.
Disconnect
connector MCA-6
· Rear drum brake mode selec-
of MC2/A.
tion switch: OFF In case of no conti-
Check for continuity between
machine and terminal E9 or rear
· Insert a test bar into the nuity between ter-
of connector. minal E9 and ma-
E22 (harness end) of connec-

tor. chine, broken har-
ness between rear
auto brake indicator
and MC2/A.

NO In case of no conti-
nuity between ter-
minal E22 and ma-
chine, broken har-

ness between front
auto brake indicator
and MC2/A.

Connector

MC2/A Brake Indicator Lamp
Connector MCA-6 (Harness end)
(Harness end)

E9 Third / Fourth

Rear

T2BC-05-04-006

T2BC-05-04-005
Front
E9

T5-4-22
M-4 Even when switching to the free mode,
auto brake indicator (green) is not turned
OFF.


YES
Faulty MC2/A.

MCA-6 of MC2/A.

between machine and
terminal (machine
end) of connector.
Short-circuit harness
· Free mode between auto brake
· Connect terminals E12 NO indicator and MC2/A.
and E13 of both connec-
tors by using clips or the
like.
· Front auto brake indica-
tor: Make measurement
between terminal E22
and machine.
· Rear auto brake indica-
tor: Make measurement
between terminal E9 and
machine.

Connector

MC2/A
MCA-6 Connector
(Machine end)

E9

T2BC-05-04-007
E22

T5-4-23
M-5 Even when setting free mode switch of
drum to ON position, free-fall cannot be
done.

• While tower derricking or second overhoist sole-
noid valve stopping, the free mode cannot be
selected.

YES Follow correct free
mode switching pro-
cedure.

Check if brake mode
switching procedure is
correct. YES
· Engine: Running
· Brake mode key
switch: ON (free posi-
tion)
· Brake pedal: De- Check if primary pilot
pressing pressure (9.8 Mpa) in
· Brake mode selection brake circuit is normal.
NO
switch: ON
· Refer to "Perform-
ance Measurement".

Check pilot pump or
relief valve in gate lock
NO
valve.

T5-4-24

YES Faulty drum brake.

Check if pressure at
port A of brake release
solenoid valve is 9.8
MPa.

· Remove piping from Faulty drum brake re-
port A of drum brake lease solenoid valve.
release solenoid valve. NO
Install pressure gauge.

· Engine: Running
· Brake mode key
switch: ON (free posi-
tion)
· Brake Pedal: No op-
eration
· Drum free mode
switch: ON

Drum Brake Release Solenoid Valve
Port P (G3/8)

Port A (G3/8) T25N-05-04-002

T5-4-25
M-6 Even when setting to the free mode, drum
free indicator (red) is not turned ON.


YES Burn out of drum free
indicator bulb or faulty
ground.
YES tween machine and
terminal of brake indi-
cator connector of left
stand is 24 V.
Broken harness be-
· Insert a test bar into the rear of tween drum free indi-
connector. NO cator and MC2/A.
· Front drum free indicator: Make
measurement between terminal
Check if free fall is #2 and machine.
possible. · Rear drum free indicator: Make

#6 and machine.
· Third drum free indicator: Make
#5 and machine.
· Free mode.
Refer to M-5.
NO

Connector
Connector
Brake Indicator Lamp
(Harness end)
Front Drum Free Indicator

T2BC-05-04-006
Third / Fourth Rea Drum Free

Drum Free Indicator
Indicator
T5-4-26
M-7 Even when setting to the auto brake mode,
drum free indicator (red) is not turned OFF.


Disconnect connector MCA-6 YES
Faulty MC2/A.
of MC2/A.
Check if voltage between
machine and terminal (ma-
chine end) of connector is 24 Short-circuited har-
V. ness between drum
· Key switch: ON NO free indicator and
· Brake mode switch: OFF MC2/A.
(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:
tween terminal E9 and ma-
chine.
· Third drum free indicator:
tween terminal E7 and ma-
chine.

Connector
MC2A
Connector MCA-6
(Harness end)

E9 E7

T2BC-05-04-007
E22
T5-4-27
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”.

YES

Check if output
pressure from
YES control valve is
28.3 to 34.5
MPa.
Remove piping · Install pressure Stuck spool in front
at port A4 in gauge to port AM control valve, or
4-spool sole- or BM of boom faulty remote con-
noid valve unit. derricking motor. NO trol valve for boom
YES
Install pressure · Port AM during derricking.
Check if primary gauge. boom derricking
Check if output (housing).
pilot pressure in pressure is 4.9 · Port BM during
pilot circuit is MPa. boom derricking
normal. boom (lowering). Faulty second
derricking drum overhoist solenoid
lock. NO valve in 4-spool

· Refer to “Per-

formance Meas-
urement”.
Faulty pres-
sure-reducing valve
NO in 4-spool solenoid
valve unit.


Port A1

Port A4
T2BC-05-04-004
T5-4-28

YES Faulty boom derrick-
ing drum lock.

Check if there is abnormality
in boom derricking drum lock.

Faulty boom derrick-
NO ing motor.

Boom Derricking Drum Lock

From Pilot Pump
AM Port (G1/4)

BM Port (G1/4)

Pawl
Ball Joint
Boom Derricking Motor

Torsion Spring

T25N-03-04-003

T5-4-29
SLEWING SYSTEM TROUBLESHOOTING Port b (G 1/4)
S-1 Slewing speed is too slow, or slewing is dis-

abled

• If pilot pump, pressure-reducing valve of 4-spool
not only slew but travel and drum rotation are
deactivated.

M25N-07-023
Port a (G 1/4) Slewing Motor

Check if input NO Faulty slewing con-
pressure from trol valve.
slewing control
YES
valve is 28.7 to
Check if output
31.9 MPa.
pressure at port
A2 of 4-spool so-
· Install pressure A
Check if input gauge to port a or b YES lenoid valve unit is
pressure to of slewing motor. 4.9 MPa.
YES · Port b at slew (CW).
slewing control · Install pressure gauge to
valve is 28.7 to · Port a at slew port A2 of 4-spool sole-
31.9 MPa. noid valve unit.
Check if secon- · Slewing brake switch: ON
dary pilot pres- · Install pressure
sure to slewing gauge to pres-
control valve sure check port B
block is normal. NO
of slewing con-
· Refer to Group trol valve.
Faulty slewing re-
"Performance mote control valve.
Measurement". NO

Slewing Control Valve 4-Spool Solenoid Valve Unit

Slewing Brake So-
lenoid Valve

Port A2 T2BC-05-04-004

Pressure Check Port
T2BC-04-05-008
T5-4-30
Connector
Slewing Lever Slewing Brake Solenoid Valve

T2BC-05-04-010
T2BC-05-04-011

YES Faulty slewing
motor.
Faulty slewing
Check for conti- YES brake solenoid
nuity between valve of 4-spool
machine and solenoid valve
YES terminal #1 (har- unit.
Connect the dis- ness end) of
connected con- connector of Broken harness
nector. slewing brake between ground
A Disconnect con- solenoid valve. and slewing
nector from slew- NO brake solenoid
NO ing brake solenoid valve of 4-spool
valve of 4-spool solenoid valve
solenoid valve unit. unit, or faulty
Disconnect slewing
lever connector. Check if voltage ground.
Connect terminals between machine
#2 and #8 (har- and terminal #2
(harness end) of Broken harness
ness end) of con- between slewing
YES nector. connector is 24 V.
brake solenoid
Check if output · Key switch: ON valve of 4-spool
pressure at port A2 NO
· Slewing brake solenoid valve
of 4-spool solenoid switch: ON unit and slewing
Check if voltage valve unit is 4.9 brake.
between machine MPa.

and terminal #2 of · Key switch: ON
NO slewing lever con-
nector is 24 V. Faulty slewing

· Insert a test bar YES brake switch.
into the rear of
connector. Broken harness
· Key switch: ON between slewing

brake switch
NO
and battery.

T5-4-31
YES Faulty slewing

Disconnect con- pump.
nector of slewing
pump swash angle
solenoid valve.
B YES Faulty MC2/A.
Check if electric
current between Disconnect con-
terminal #1 and #2 nector MCA-5 of
is 700 mA. MC2/A.
Check for continu-
NO ity between termi- Faulty harness
nals #1 and F11, between MC2/A
#2 and F7. and slewing pump
NO swash angle pro-
portional solenoid
valve.
Slewing Pump Swash Angle Solenoid Valve

MC2/A
Connector MC
F7

T2BC-05-04-008
T2BC-05-04-009

T5-4-32
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
not only travel but slew and drum rotation are
deactivated.
YES
• If any one of tracks does not run, remote control
valve, control valve, travel motor, center joint or
pump may be faulty.

Check if travel re-
NO lief pressure at

slower track is
normal.
Check if failure
Check if failure phenomenon is
phenomenon is
reversed when
YES reversed when exchanging left
exchanging left NO and right travel re-
and right travel lief valves.
hoses at center
joint.
Check if secondary Stuck spool in
travel pilot pres- control valve.
sure is normal. YES

· Refer to "Per-
formance Meas-

urement".
Faulty remote con-
trol valve.
NO

Center Joint
Right Travel (Forward)
Left Travel (Reverse)
Right Travel (Reverse)
Left Travel (Forward)

T25N-05-04-006
T5-4-33

YES Faulty travel motor
Disassemble and or travel reduction
clean servo piston gear.
YES of travel motor.
Disassemble and Check if failure
clean counterbal- phenomenon
ance valve of arises again. Faulty servo piston
travel motor. NO of travel motor.
Check if failure
phenomenon Faulty counter-
arises again. balance valve.
NO

NO Faulty center joint.

Faulty travel relief
YES valve.

T5-4-34
T-2 Travel speed cannot be shifted.
Faulty sash angle
• Check the wiring connections first. YES selection mecha-
Check if input nism of travel mo-
YES pressure at port tor.
PS of travel motor
is 4.9 MPa.
Check if output · Install tee and pres- Stuck in shuttle

YES pressure at port sure gauge to port NO valve.
A3 of 4-spool so- PS of travel motor.
lenoid valve unit is
· High / low travel
4.9 MPa. speed selection Faulty high travel
Check for continu- speed selection
· Install pressure
gauge switch: High speed
YES ity between ma- to port A3 of 4-spool solenoid valve of
chine and terminal
NO 4-spool solenoid
Disconnect con- #1 (harness end) valve unit.
of connector. · Travel Mode Switch:
nector from high High speed
travel
speed se- Broken harness
lection solenoid between high travel
of 4-spool
valve NO speed selection
solenoid
valve solenoid valve and
unit. ground or fuse #23.

Check if voltage
at terminal #2 Broken harness

(harness end) of YES
Disconnect con- between travel
connector
is 24V. nector of travel
mode switch and
· High / low travel mode switch. battery or fuse #23.
speed selection Check for continu-
NO
switch: High ity between ter-
Faulty travel mode
speed minals #6 and #7.
NO switch.
· Travel Mode
Switch: High
speed
Connector
High Travel Speed Selection

Solenoid Valve
(Harness end)

T2BC-05-04-010
Travel Motor
PS Port
(G 1/4)

Port A3 T2BC-05-04-004
M25N-07-032
T5-4-35
OTHER TROUBLESHOOTING Connect the dis-
O-1 Drum lock does not work. connected con-
nector.
Disconnect con- YES Faulty drum lock
• Check the wiring connections first. nector of drum lock motor.
YES motor.
Disconnect con- Check for continu-
ity between termi- Broken harness
Drum lock is
nector SWP16F of between drum lock

right control panel. nals #1 and #3
not applied. (harness end) of NO switch and drum
Check for continu- lock motor.

ity between termi- connector.
nals (machine end)
· Drum lock
of connector. switch: ON

· Drum lock switch: ON Faulty drum lock
· Make measurement
NO switch.
between terminals #8
and #6 of front drum. Connect the dis-
· Make measurement connected con-
YES between terminals #12 nector. YES Faulty drum lock

and #10 of rear drum.
Disconnect con-
· Make measurement motor.
between terminals #16 YES nector of drum lock
and #14 of fourth motor.
drum. Check for continu- Broken harness
Disconnect con- ity between termi- between drum lock

nector SWP16F of nals #1 and #2 NO switch and drum

right control panel. (harness end) of lock motor.
Check for continu- connector.

ity between termi- · Drum lock
Check if ground of Drum lock
nals (machine end) switch: OFF
YES is not of connector.
drum lock motor is
normal.
released.
Faulty drum lock
· Drum lock switch: OFF NO switch.

· Make measurement between
terminals #8 and #7 of front
drum.
Check if voltage · Make measurement between

between terminal terminals #12 and #11 of rear
#6of drum lock drum.
motor and ma- · Make measurement between
is 24V. of fourth
terminals #16 and #15
chine
drum.
switch: ON
· Key
· Insert a test bar Faulty ground of
the rear of
into drum lock motor.
NO
connector.

Broken harness

between drum lock
NO motor and battery or
fuse (front: #22,
rear: #2, fourth:
#40).
Connector Right Control Panel
Drum Lock Motor Connector SWP16F

T2BC-05-04-012
T2BC-05-04-013
T5-4-36
O-2 Counterweight (optional) cannot be re-
moved and installed.



YES between terminals
#2 and #6 of
connector.
Disconnect
· Counterweight /
connector
jack-up switch:
(62C-16FB) of left
Counterweight
YES control panel.
id
Check if voltage at
terminal #2 (harness
end) of connector is
24V.
Broken harness
· Key switch: ON between jack relay
(R5) and terminal #2
NO (harness end) of
Check if quick draw
connector.
or retract cylinder
moves.

YES
Faulty jack relay
(R5).

Remove jack relay

(R5).
NO Check if voltage at
terminal #3 is 24V.
Broken harness
between fuse #39 or
· Key switch: ON
jack relay (R5) and
NO
battery relay.

Relay Panel
Left Control Panel

Connector (62C16FB)

(Harness end)

T2BC-05-04-017

Jack Relay (R5) T2BC-05-04-018

T5-4-37

YES Faulty counterweight /
jack-up switch.

Broken harness be-
NO tween relay connector
(1P) and connector in
left control panel.
Disconnect relay
Disconnect relay
connector (1P). connector (1P) or
Check if voltage at (4P). Faulty counterweight
NO NO
harness end terminal Check for continuity control box or har-
is 24V. betweeneach ter- ness.
minal (counterweight
end) of
control box
relay connector
(4P)
YES
and terminal (coun- Faulty counterweight
terweight control box solenoid valve, or
end) of relay con- broken harness be-

nector (1P). tween counterweight
YES
solenoid valve and
· Terminal #1: Right relay connector (4P).

cylinder extension
· Terminal #2; Right
cylinder retraction
· Terminal #3: Left
cylinderextension
· Terminal #4: Left
cylinderretraction

Counterweight
Control Box

Relay Connector
(Control box end)

4P 1P

T2BC-05-04-020
Relay Connector

T2BC-05-04-019
T5-4-38
O-3 Jack-up (optional) cannot be done.


YES
Faulty jack relay
(R5).

Replace jack relay
(R5) with horn relay

(R4). Check for continuity
Check if jack can be
YES between terminal #2
extended or re- of jack relay (R5)
tracted. connector and ma-

chine.

Remove jack relay
(R5).
Check if voltage at
NO terminal #3 (con-

nector end) is 24V.
· Key switch: ON

Broken harness
between jack relay

NO (R5) and battery re-

lay or fuse #39.

Relay Connector
(Harness end)

Jack Relay (R5)

Horn Relay (R4)

T2BC-05-04-014
T2BC-05-04-018
T5-4-39
Hydraulic Selection Solenoid
Valve Connector
(Harness end)

Hydraulic Selection T2BC-05-04-015
Solenoid Valve

Pressure Check Port T2BC-05-04-024

Broken harness
between counter-
weight / jack-up
NO switch and hydraulic
Disconnect connec-
tor from hydraulic selection solenoid
selection solenoid valve in 4-spool
valve of 4-spool con- control valve.

YES
trol valve.
Check for continuity Check if voltage at
between terminal #2 terminal #1 (harness
end) of connector is
YES (panel end) of con-
nector in left control 24V.
panel and terminal · Key switch: ON YES

#3 of 62C-16MW.
Disconnect connec-
tor from left control
panel. Faulty counterweight
Check if voltage at
NO / jack-up switch.
harness end terminal

#2 is 24V.
· Key switch: ON

Broken harness

between jack relay
(R5) and counter-
NO weight / jack-up
switch.

Control Panel Connector
Left
(Panel end)
Left Control Panel Connector
(Harness end)

62C-16MB 62C-16MW

T2BC-05-04-017 T2BC-05-04-023 T2BC-05-04-022

T5-4-40

YES Stuck spool.

Check if jack-up
YES
spool in lower control
valve moves.
Faulty jack-up cyl-

NO inder.
Check if relief pres-
YES sure in lower control
valve is 19.6 Mpa.
· Refer to T4-5.
Check for continuity Faulty relief valve in

between machine lower control valve.
and terminal #2 NO
(harness end) of
connector in hydrau-
lic selection solenoid
valve.
Broken harness
between hydraulic
NO selection solenoid
valve and machine,
or faulty ground.
T5-4-41
O-4 Retraction (with jack (optional) attached)
cannot be done.
YES Faulty jack relay

(R5).
Replace jack relay

(R5) with horn relay
(R4). Check for continuity
Check if jack can be between terminal #2
extended or re- YES
of jack relay (R5)
tracted. connector and ma-
chine.
Remove jack relay

(R5).
Check if voltage at
NO terminal #3 (con-
nector end) is 24V.
· Key switch: ON
Broken harness
between jack relay
NO (R5) and battery
relay or fuse #39.
Relay Connector
(Harness end)
Jack Relay (R5)

Horn Relay (R4)

T2BC-05-04-014

T2BC-05-04-018
T5-4-42

4-Spool Control Valve Hydraulic Selection Solenoid
Valve Connector
(Harness end)

T2BC-05-04-015
T2BC-05-04-024
Broken harness
between
counterweight /
NO jack-up switch and
Disconnect
connector from hydraulic selection
hydraulic selection solenoid valve in
solenoid valve of 4-spool control
YES
4-spool control
Check for continuity valve. Check if
between terminal #2 voltage at terminal
YES (panel end) of #1 (harness end) of
connector in left connector is 24V.
control panel and YES
terminal #3 of · Key switch: ON
62C-16MW.
Disconnect connec-
tor from left control
panel. Faulty counterweight
Check if voltage at NO / jack-up switch.
harness end terminal
#2 is 24V.
· Key switch: ON
Broken harness
between jack relay
(R5) and
NO counterweight /
jack-up switch.
Left Control Panel Connector

Left Control Panel Connector (Panel end)
(Harness end) 62C-16MB 62C-16MW

T2BC-05-04-017 T2BC-05-04-023 T2BC-05-04-022

T5-4-43
YES Stuck spool.
YES Check if retract

spool in lower control
valve moves.
Faulty retract cylin-

NO der.
Check if relief pres-
YES
sure of lower control
valve is 16.9 MPa.
· Refer to T4-5.
Faulty relief valve in

Check for continuity lower control valve.
between machine NO
and terminal #2
(harness end) of
connector of hydrau-
lic selection solenoid
valve.
Broken harness
between hydraulic
NO
selection solenoid
valve and machine,
or faulty ground.
T5-4-44
O-5 Retraction cannot be done (by using a
switch in cab).
YES
Faulty jack relay
(R5).
Broken harness
Replace jack relay YES between jack relay
(R5) with horn re- (R5) and battery
lay (R4). relay or fuse #39.
Check if retract
cylinder can be
extended or re-
tracted. Disconnect jack
relay (R5) from
· Engine: Running
connector.
· Side frame
Check if voltage
extend / retract
between terminal
switch: Extend or
#3 (harness end) of
retract NO connector and ma-
chine is 24V.
Connect the dis-
· Key switch: ON connected relay.
Disconnect con-
nector 62C-16FB of
YES left control panel.
Check if voltage
between terminal
Relay Panel #2 (harness end) of
Check for continuity connector and ma-
between machine chine is 24V.
NO and terminal #2 · Key switch: ON
(harness end) of
connector.
Broken harness
between jack relay
NO (R5) and ground, or
faulty ground.
Jack Relay (R5)

Horn Relay (R4) T2BC-05-04-018

Relay Connector Panel Connector
(Harness end) (62C-16FB)
(Harness end)

T2BC-05-04-025
T2BC-05-04-014
T5-4-45

Side Frame Retract
Solenoid Valve
Side Frame Extend Solenoid Broken harness

Valve (with optional attached) between side
NO frame extend so-
lenoid valve and
ground, or faulty
Check for continu- ground.
T2BC-05-04-024 ity between ma-
YES
chine and terminal
#2 (harness end)
Connect the dis- of connector.
connected con-
nector.
Disconnect con-
nector of side
frame extend so- Disconnect con-
YES
lenoid valve in nector of side
4-spool control frame retract so-
valve. lenoid valve.
Check if voltage at YES Check if voltage at
terminal #1 (har- terminal #1 (har-
ness end) of con- ness end) of con-
nector is 24V. nector is 24V.
Disconnect con-
nector 62C-16FW of · Key switch: ON · Key switch: ON
left control panel. · Side frame extend / · Side frame extend /
Check for continuity retract switch: retract switch:
between connectors Extend Retract
62C-16MB and
Broken harness
62C-16MW.
between side
· Side frame extend / frame extend /
retract switch: NO retract switch and
Extend side frame extend
between terminal #2 solenoid valve.
of connector 16MB
and terminal #3 of
connector 16MW
· Side frame extend / Faulty side frame
retract switch: extend / retract
Retract NO
switch.
between terminal #2
of connector 16MB
and terminal #4 of
connector 16MW
Panel Connector (62C-16MB) Panel Connector (62C-16MW) Solenoid Connector

(Panel end) (Panel end) (Harness end)

T2BC-05-04-023 T2BC-05-04-022 T2BC-05-04-015
T5-4-46
YES Faulty retract cyl-

inder.
Install a pressure
gauge to pressure
YES check port in
4-spool control
valve. Check if
pressure is 20.6 Faulty relief valve
MPa. in 4-spool control
valve, or faulty
NO pump for coun-
Check for continuity terweight / quick
YES between machine draw / retract.
and terminal #2
(harness end) of
connector.
Broken harness
between side frame
extend solenoid
NO valve and ground,
or faulty ground.
Broken harness
between side frame
NO extend / retract
switch and side
frame retract sole-
noid valve.

Side Frame Retract Solenoid
Valve Connector
(Harness end)

T2BC-05-04-015

T2BC-05-04-024
Pressure Check Port
T5-4-47
Intentionally
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
x How to Read Troubleshooting Flow Charts

YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK)
• (1) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(3)
NO(NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
• Incorrect measuring or checking methods will render troubleshooting impossible,
¨Key switch: ON and may damage components as well.
• • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.

are shown.

Harness
Harness end
connector

T5-5-1
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE

YES

Disconnect
coolant
temperature sensor. With coolant tempera-
YES Connect
harness end ture sensor discon-
terminal #1 to machine. nected, disconnect

Check if needle swings
connector C16F-W from
to
(H) side. monitor panel.
Check if coolant tem- ¨ Key switch: ON NO
Gauge needle does not perature sensor termi- between harness end
swing at all. nal is correctly con- connector terminal #12
nected. and coolant temperature
sensor terminal.

NO

YES

Check if needle returns
Gauge needle swings when coolant tempera-
ture sensor terminal is
YES
over scale. With coolant tempera-
disconnected. sensor discon-
ture
¨ Key switch: ON nected, disconnect

connector C16F-W
from
monitor panel.
NO

between harness end
connector
terminal #12
and machine. NO

YES

Disconnect coolant
temperature
sensor.
YES Connect harness end

terminal #1 to machine.
Check if needle swings

to (H) side and stays in
position.
that
Check if coolant tem-
perature sensor termi- ¨Key switch: ON NO
Gauge needle swings
unstably. nal is correctly con-
nected.

NO

T5-5-2

Faulty coolant temperature
sensor.

Connector (Harness end)

YES Faulty monitor panel.

Monitor Panel (C16F-W)

Broken harness between
monitor panel and coolant
NO temperature sensor.
T2BC-05-04-026

sensor terminal connection.
Coolant Temperature
Sensor

1
2
sensor.

Coolant Temperature and Electrical Resistance
Short-circuited harness be- Coolant Temperature Electrical Resistance
tween monitor panel and
qC (qF) :
coolant temperature sensor.
50r0.2 (122r0.4) (153.9)

80r0.2 (176r0.4) 51.9r4.0
100r0.2 (212r0.4) 27.4r1.9
120r0.2 (248r0.4) (16.1)
Faulty monitor panel.

NOTE: Values in ( ) are reference only.

sensor.


sensor terminal connection.

T5-5-3
MALFUNCTION OF FUEL GAUGE
YES
Disconnect fuel sensor.
Connect harness end
connector terminals #1
YES With fuel sensor dis-
and #2.
Check if gauge needle connected, disconnect
swings to (F) side. connector C16F-W
from monitor panel.
¨ Key switch: ON Check for continuity
¨Connect by using a NO between harness end
Gauge needle does not Check if fuel sensor is clip.
swing at all. correctly connected. connector terminal #4
and fuel sensor termi-
nal #2.
NO
YES

Gauge needle swings
Check if needle swings YES
over scale.
back to zero. With fuel sensor discon-
¨ Key switch: ON nected, disconnect con-
nector C16F-W from
monitor panel.
NO Check for continuity be-
tween harness end con-
nector terminal #2 and
machine. NO
YES
Connect harness end
connector terminals #1
YES
and #2.
Check if gauge needle
stably swings to (F)
side.
¨ Key switch: ON NO
Gauge needle swings Check if fuel sensor is ¨Connect by using a
unstably. correctly connected. clip.
NO
T5-5-4
Faulty fuel sensor.
YES Faulty monitor panel. Connector (Harness end)
Fuel Sensor

NO monitor panel and fuel sen- 2 1
Faulty fuel sensor connecter

connection.

T2BC-05-04-026

Faulty fuel sensor.
Float
FULL
Short-circuited harness be-
tween monitor panel and fuel
sensor. 3/4 Fuel Sensor
257 mm
138.5 mm 22q
R370 33q
70.5 mm
27q
1/2
228 mm 28q
Electrical Resistor
1/4
Faulty fuel sensor. 338 mm
EMPTY

T107-04-03-020
Faulty monitor panel. NOTE: 1 mm = 0.03937 in

Float Position and Electrical Resistance
Float Position Resistance ( : )
Full 10r1.00.5
Faulty fuel sensor terminal 3/4 (19.5)
connection.
1/2 32r3
1/4 (49.5)
Empty 80r2
T5-5-5
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR


YES Faulty engine oil pressure
switch.

Disconnect plug from
engine oil pressure
switch.
Indicator is not turned
ON although engine oil Connect terminals of
pressure is insufficient. harness 223 and GD2
harness.
¨Key switch: ON Check if indicator is terminal of 223
With YES Faulty monitor panel or
turned ON.
burnt indicator bulb.
Ëngine: Stop harness
connected to
¨ Key switch: ON machine.

C16F-W
of monitor
NO panel.

Check for continuity Broken harness between
between machine and monitor panel and engine

terminal #6 (harness NO oil pressure switch.
end)
of connector.

YES Faulty of engine oil pres-
sure switch or engine hy-
draulic system.
Indicator is not turned Check if indicator is

turned ON when plug
OFF although engine from engine oil pres-
runs.
sure switch is discon-
¨Check if oil filter is nected.
clogged or not.
¨ Key switch: ON Short-circuited harness
(If clogged, engine oil Ëngine: Stop
Disconnect plug from YES
between monitor panel and
restriction indicator is engine oil pressure
turned ON.) engine oil pressure switch.
switch and connector
C16F-W
from monitor
panel.
NO Check
for continuity
between
machine and
terminal #6 (harness Faulty monitor panel.
of connector.
end) NO

Engine oil pressure switch Connector (Harness end)
Pressure Operation Monitor Panel C16F-W
About 78.4 KPa
ON
(0.8 kgf/cm2, 11 psi) or less
About 78.4 KPa
OFF
(0.8 kgf/cm2, 11 psi) or more
T2BC-05-04-026
T5-5-6
MALFUNCTION OF COOLANT LEVEL
INDICATOR

• Other indicators blink normally.
• Check the wiring connections first. With terminals of cool-
ant level switch con-
nected.
NO㩷 C16F-W of monitor
Disconnect connector panel.
of coolant level switch. Check for continuity
between machine and
Connect terminals #2
YES and #3 (harness end) terminal #15 (harness
of connector. Check if end) of connector.

indicator is turned ON.

Faulty coolant level
Check if indicator is ¨ Key switch: ON
Indicator is not turned turned ON when reset- YES㩷 switch.
ON. ting key switch from
OFF to ON position.
¨Check if water level is
above Low level. YES㩷 Burnt indicator bulb.
¨ Key switch: OFF ļ ON

between machine and Disconnect connector
terminal #1 of connec- IDU-5 of IDU.
NO Connect terminal #3
tor C16F-W of monitor
panel. (harness end) of con-
nector to machine.
¨ Key switch: ON Disconnect connector
Ïnsert a test bar into NO㩷 C16F-W of monitor
the rear of connector. panel.
¨Check within 3 sec- Check for continuity
onds after turning key between machine and
switch ON. terminal #1 (harness

end) of connector.

Short-circuited harness
With connector of YES㩷 between coolant level
coolant level switch switch and monitor
disconnected. panel.
YES C16F-W of monitor
panel.
between machine and Check for continuity
Indicator is turned ON Check if indicator is terminal #15 (harness between machine and
although water level is turned ON when con- end) of connector. terminal #1 (harness
below the specified NO㩷
nector of coolant level end) of connector.
level. switch is disconnected.
¨ Key switch: ON
Faulty coolant level
NO switch.
T5-5-7

Reserve Tank
YES㩷
Faulty monitor panel. ON
FULL
LOW
Broken harness be- Radiator

tween coolant level OFF
NO switch and monitor
panel. Coolant Level Switch
T107-04-03-012


Monitor Panel C16F-W
YES㩷
Faulty IDU.

T2BC-05-04-026

Broken harness be-
tween monitor panel Coolant Level Indicator (Harness end)
NO and IDU.
1
3

YES㩷 Short-circuited har-
Connect the dis- ness between monitor
connected connec- panel and IDU. Connector IDU-5 Of IDU
tor.
YES㩷 Disconnect con-

Check if indicator is
turned ON.
· Key switch: ON Faulty IDU.
NO
T2BC-05-04-027

NO

T5-5-8
MALFUNCTION OF ENGINE OIL FILTER
RESTRICTION INDICATOR

• If engine oil filter is clogged, engine oil pressure
decreases and engine oil pressure indicator is
turned ON.

YES Faulty engine oil filter
restriction switch.
Disconnect terminal of
227 harness of engine
oil filter restriction
YES
switch.
Connect terminal (har- Connected the discon-
ness end) to machine. nected terminal.
Check if indicator is Connect terminal #5 of
Check if indicator is turned ON.
Indicator is not turned turned ON when reset-
connector C16F-W of
ON although engine oil · Key switch: ON monitor panel to ma-
ting key switch from
filter is clogged. OFF to ON position.
NO chine.
turned ON.
· Key switch: OFFņON
¨Key switch: ON
Ïnsert a test bar into the
rear of connector.
YES Indicator bulb is burned
out.
between machine and Disconnect connector
terminal #1 of connec- IDU-5 of IDU.
tor C16F-W of monitor Connect terminal #E3
panel. (harness end) of con-
¨ Key switch: ON nector to machine.

Ïnsert a test bar into NO Disconnect connector
the rear of connec- C16F-W of monitor
tor. panel.
¨Check within 3 sec-
onds after turning between machine and
key switch ON. terminal #1 (harness
end) of connector.
YES Faulty engine oil filter
restriction switch.
Indicator is turned ON turned OFF when ter-
minal of engine oil filter Disconnect terminal of
although engine oil filter restriction switch is engine oil filter restric- Short-circuited harness
is not clogged. tion switch and con-
disconnected. YES between monitor panel
nector C16F-W of and engine oil filter re-
· Key switch: ON monitor panel.
striction switch.
between machine and
end) of connector. Check for continuity
between machine and
NO terminal #1 (harness
end) of connector.
T5-5-9

YES monitor panel and engine

oil filter restriction switch.

T2BC-05-04-026

NO

Connector IDU-5 of IDU

YES
Faulty IDU.

T2BC-05-04-027

monitor panel and IDU.
NO

Connect the dis- YES between monitor panel
connected con- and IDU.
nector.
YES Disconnect con-
nector IDU-5 of
IDU.
Check if indicator Faulty IDU.
is turned ON. NO
· Key switch: ON

NO
T5-5-10
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR


YES Faulty air filter restriction
switch.
Disconnect plug of air

filter restriction switch.
Connect plug 228
YES (harness end) to ma-
With plug of air filter
chine.
Check if indicator is restriction switch con-
turned ON. nected to machine,
disconnect connector
¨ Key switch: ON C16F-W of monitor
NO panel.
Indicator is not turned turned ON when reset- Check for continuity
ON although air filter is ting key switch from between machine and
clogged. terminal #14 (harness
OFF to ON position.
end) of connector.
· Key switch: OFFlON

YES Burnt indicator bulb.

between machine and
terminal #1 of connec-
NO Disconnect connector
tor C16F-W of monitor
IDU-5 of IDU.
panel.
Connect terminal #E3
¨ Key switch: ON (harness end) of con-
Ïnsert a test bar into NO nector to machine.

the rear of connector. Disconnect connector
¨Check within 3 sec- C16F-W of monitor
onds after turning key panel.
switch ON. Check for continuity
between machine and
end) of connector.

YES Faulty air filter restriction
switch.

Indicator is turned ON Check if indicator is Short-circuited harness
although air filter is not turned OFF when plug YES between monitor panel
of air filter restriction Disconnect plug of air and air filter restriction
clogged. switch.
switch is disconnected. filter restriction switch
¨Disassembly and visual and connector C16F-W
check · Key switch: ON of monitor panel.
¨Confirm that air filter is Check for continuity
not dampened. NO
between machine and Check for continuity
terminal #14 (harness between machine and
end) of connector. terminal #1 (harness
NO
end) of connector.
T5-5-11

Air filter restriction switch
Pressure Operation
6.25r0.5 kPa or less
OFF
(635r58 mm H2O or less)
6.25r0.5 kPa or more
ON
(635r58 mm H2O or more)


YES
Faulty monitor panel. Monitor Panel C16F-W

monitor panel and air filter T2BC-05-04-026
NO restriction switch.


YES
Faulty IDU.

T2BC-05-04-027

NO

Connect the dis- YES between monitor panel
connected con- and IDU.
nector.
YES Disconnect con-
nector IDU-5 of
IDU.
is turned ON. NO
· Key switch: ON

NO
T5-5-12
MALFUNKTION OF OVERHEAT INDICA-
TOR

YES Faulty overheat switch.

overheat switch.
YES Connect terminal (har-
ness end) to machine. With terminal of over-
Check if indicator is heat switch connected
turned ON. to machine, disconnect
· Key switch: ON connector C16F-W of

Check if indicator is NO monitor panel.
turned ON when reset- Check for continuity
Indicator is not turned
ON when overheating. ting key switch from between machine and
OFF to ON position. terminal #10 (harness
end) of connector.
· Key switch: OFFlON


between machine and
terminal #1 of connec- Disconnect connector
NO tor C16F-W of monitor IDU-5 of IDU.
panel. Connect terminal #E3
¨ Key switch: ON (harness end) of con-
the rear of connector. Disconnect connector
¨Check within 3 sec- C16F-W of monitor
panel.
onds after turning key
switch ON. Check for continuity
between machine and
end) of connector.

YES Faulty overheat switch.

Indicator is turned ON turned OFF when ter- YES Short-circuited harness
although coolant tem- between monitor panel
minal of overheat and overheat switch.
perature is low. switch is disconnected.
overheat switch and
· Key switch: ON connector C16F-W of
NO monitor panel.
Check for continuity Check for continuity
between machine and between machine and
terminal #10 (harness NO terminal #1 (harness
end) of connector.
end) of connector.
T5-5-13

Overheat switch
Coolant temperature Operation
Lower than 101 qC (214 qF) OFF
101 qC (214 qF) or higher ON

YES Connector (Harness end)


monitor panel and over-
NO heat switch.
T2BC-05-04-026

YES
Faulty IDU.

Broken harness between T2BC-05-04-027
NO

Connect the dis- YES Short-circuited harness
connected con- between monitor panel
nector. and IDU.
YES Disconnect con-
nector IDU-5 of
IDU.
is turned ON. NO
· Key switch: ON

NO
T5-5-14
MALFUNCTION OF CONTROLLER FAIL-
URE INDICATOR


YES Faulty ECU.

Disconnect ECU con-
nector 2.

YES Connect terminal #15
or #16 (harness end) of Disconnect connector
connector to machine. C16F-W of monitor
Check if indicator is panel.
turned ON. Connect terminal #13
(harness end) of con-
Indicator is not turned nector to machine.
Check if indicator is NO Check for continuity
ON although abnormal- turned ON when reset- between machine and
ity is indicated by trou- ting key switch from
bleshooting monitor or terminal #15 or #16
OFF to ON position. (harness end) of ECU
ECU lamp.
· Key switch: OFFlON connector 2.


between machine and
terminal #1 of connec- Disconnect connector
NO tor C16F-W of monitor IDU-5 of IDU.
Connect terminal #E3
panel.
¨ Key switch: ON
the rear of connector. C16F-W of monitor
¨Check within 3 sec- panel.
onds after turning key Check for continuity
switch ON. between machine and
end) of connector.

YES
Faulty ECU.

Indicator is turned ON
although failure is not Check if indicator is
indicated by trouble- turned OFF when ECU YES Short-circuited harness
Disconnect ECU con- between monitor panel
shooting monitor or connector 2 is discon- and ECU.
nected. nector 2.
ECU lamp.
· Key switch: ON · Key switch: ON C16F-W of monitor
panel.
NO
Check for continuity Check for continuity
between machine and between machine and
terminal #13 (harness terminal #1 (harness
end) of connector. NO
end) of connector.
T5-5-15

ECU Connector 2

T2BC-05-04-029

YES Monitor Panel C16F-W

In case of no continuity at
terminal #15, broken
harness between monitor T2BC-05-04-026
panel and terminal #15 of
ECU connector 2.
NO In case of no continuity at

terminal #16, broken Connector IDU-5 of IDU
harness between monitor
panel and terminal #16 of
ECU connector 2.

YES
Faulty IDU.
T2BC-05-04-027

NO

Connect the dis- Short-circuited harness
YES
connected con- between monitor panel
nector. and IDU.
YES Disconnect con-
nector IDU-5 of
IDU.
is turned ON. NO
· Key switch: ON

NO
T5-5-16
MULFUNCTION OF PREHEAT INDICATOR

• If air heater does not work, refer to “Trouble-
shooting B”.

Faulty monitor panel or
YES
Disconnect connector burnt indicator bulb.
C16F-W of monitor

YES panel.
between machine and
terminal #8 (harness Broken harness between
end) of connector. monitor panel and
NO ground, or faulty ground.
Indicator is not turned tween machine and
ON while engine is terminal #11 of con-
being preheated. nector C16F-W of
monitor panel is 24 V.

¨ Insert a test bar into
the rear of connector.
¨Check within 15 sec-
heater relay and monitor
onds after turning key NO
panel.
switch ON.

YES Short-circuited harness
between heater relay and
monitor panel.
Indicator is turned ON tween machine and
even after engine is terminal #11 of con-
preheated. nector C16F-W of
monitor panel is 24 V.
· Insert a test bar into Faulty monitor panel.
the rear of connector. NO



T2BC-05-04-026
T5-5-17
MULFUNCTION OF ALTERNATOR INDI-
CATOR


YES Faulty alternator relay.

Replace alternator relay
Indicator is not turned with engine stop relay.
ON although charging Check if indicator is
Broken harness be-
is insufficient. turned ON. YES㩷
Disconnect
alternator tween alternator relay
relay. and ground, or faulty

Connect terminal #2 ground.
NO
nector to machine.
Connect terminal #7 of
Check
if indicator is
connector C16F-W of
turned ON.
monitor panel to ma-
· Key switch: ON chine.
NO㩷
turned ON.

¨Key switch: ON
Ïnsert a test bar into
the rear of connector.

YES Faulty alternator relay.

Replace alternator relay
Indicator is not turned with engine stop relay.
OFF even when engine Check if indicator is Check for continuity
runs. turned OFF.
Disconnect connector YES㩷 between machine and
· Engine: Running of
alternator relay and terminal #2 (harness
· Engine: Running connector C16F-W of end) of connector of

monitor panel. alternator relay.
NO Check
for continuity
between machine and

end)
of connector of Faulty monitor panel.
monitor panel.
NO㩷


Alternator Relay Monitor Panel (C16F-W)

T2BC-05-04-026
T2BC-05-04-030

T25N-05-03-027
T5-5-18

YES㩷 Broken harness be-

tween alternator relay
and monitor panel.

NO Faulty monitor panel, or
Check for continuity burnt indicator bulb.
between machine and
YES㩷
end) of connector of Short-circuited harness
alternator relay. between alternator and
tween machine and
YES alternator relay.
NO㩷
end) of connector of
alternator relay is 24 V.
Broken harness be-
· Key switch: ON tween alternator relay
NO㩷 and battery relay.

YES㩷
between alternator
relay and monitor
of alternator.
YES Faulty alternator.
Connect terminal #2
YES㩷 nector to machine.
Check if voltage be- Broken harness be-
between machine and tween alternator and
tween machine and terminal #4 (harness NO alternator relay.
terminal #1 (harness end) of connector of
NO㩷 end) of connector of
alternator relay.
alternator relay is 24 V.
Broken harness be-
· Key switch: ON tween alternator relay
NO㩷 and battery relay.

Alternator

T2BC-05-04-031
T5-5-19
MALFUNCTION OF BRAKE UNAPPLIED
INDICATOR


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 switcho‫ޟ‬OFF‫ޠ‬
• Front free brake mode selection switch NO Broken harness circuit
Disconnect connector between monitor panel
o"Free mode"
C16F-W of monitor and MC2/A.
• Rear free brake mode selection switch YES
panel.

o"Free mode" Connect terminal #9

Connect terminal #9 of nector to machine.

Indicator is not turned connector C16F-W of Disconnect connector
ON under indicator monitor panel to ma- MCA-6
of MC2/A. Faulty MC2/A.
lighting conditions. chine. Check for continuity
YES
Check if indicator is between machine and
x Key switch: Start terminal #23 (harness
turned ON.
NOTE: Turn ON slew- ¨ Key switch: ON end) of connector.
¨Connect to machine from
ing brake
switch, set the rear of connector. Faulty monitor panel or
burnt indicator bulb.
brake mode
NO
switch and

front/rear free
brake mode

selection switch
to "Auto brake

mode", and
confirm that

engine can YES Faulty MC2/A.
start.

Indicator is not turned turned OFF when con- YES Short-circuited harness
OFF even when engine nector MCA-6 of MC2/A

runs. Disconnect connector between monitor panel
is disconnected.
C16F-W of monitor and MC2/A.
Ëngine: Running panel.
· Key switch: ON
¨Key switch: ON Check for continuity

NO
between machine and
of connector. Faulty monitor panel.
end)
NO

Connector MCA-6 of MC2/A
(Harness end)

T2BC-05-04-026 T2BC-05-04-027
T5-5-20
MALFUNCTION OF PILOT PRESSURE
DROP INDICATOR

Faulty pilot pressure Refer to "Check of Pilot
Pressure Drop Indicator
drop indicator. " in "Troubleshooting
A".

T5-5-21
MALFUNCTION OF HOUR METER

YES Faulty monitor panel
Disconnect connector (hour meter).
C16F-W of monitor
panel.
Hour meter does not Check for continuity
work.
between machine and
¨Key switch: ON terminal #8 (harness Broken harness be-
end) of connector. tween monitor panel
NO and ground, or faulty
ground.



T2BC-05-04-026
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. Connector
• 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.
T331-05-07-001
Receptacle

T331-05-07-002
T5-6-1
FAULT CODE TABLE
Func- Failure Fault Failure explanation Judgment and conditions Reference
tion code page
Auto Boom angle E20 Boom angle upper limit failure Boom angle > Upper limit T5-6-4
stop E21 Boom angle lower limit failure Boom angle < Lower limit T5-6-6
Tower angle E22 Tower angle upper limit failure Tower angle > Upper limit T5-6-4
E26 Tower angle lower limit failure Tower angle < Lower limit T5-6-6
Jib angle E30 Jib angle upper limit failure Jib angle > Upper limit T5-6-8
E31 Jib angle lower limit failure Jib angle < Lower limit T5-6-10
Specification E40 No ML data available No data available corresponding to auto T5-6-13
selection specification selection
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 Boom/jib derricking force > Upper limit T5-6-18
failure
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 Boom/jib derricking force < Lower limit T5-6-22
failure
E53 Load cell power supply upper limit failure 10 V power supply monitoring voltage > Upper 㧙
limit
E54 Load cell power supply lower limit failure 10 V power supply monitoring voltage < Lower 㧙
limit 1
E55 Load cell power supply short circuit 10 V power supply monitoring voltage < Lower 㧙
failure limit 2
Monitor- Communica- W90 Control A communication failure MC2/A communication status T5-6-34
ing only tion
W91 Control B communication failure MC2/B communication status T5-6-35
Specification W47 Attachment wiring failure (open circuit) Wiring failure (open circuit) in non-disassembly T5-6-26
selection position
W49 Hook overhoist wiring failure No hook overhoist wiring available on selection T5-6-32
side
Power supply W10 Main power supply upper limit failure Monitoring voltage > Upper limit 㧙
W11 Main power supply lower limit failure Monitoring voltage < Lower limit 㧙
W14 Switch power supply short circuit failure 24V power supply monitoring voltage < Lower 㧙
limit 2
WA1 Switch power supply 1 short circuit (Control A) 24V1 power supply monitoring T5-6-36
(control A) voltage < Lower limit 2
WA2 Switch power supply 2 short circuit (control A) 24V2 power supply monitoring T5-6-36
WA3 Switch power supply 3 short circuit (Control A) 24V3 power supply monitoring T5-6-36
WA5 Sensor power supply short circuit (Control A) 5V power supply monitoring voltage 㧙
(control A) < Lower limit 2
WB1 Switch power supply 1 short circuit 㧙
(control B)
WB2 Switch power supply 2 short circuit (Control B) 24V2 power supply monitoring T5-6-37
(control B) voltage < Lower limit 2
WB3 Switch power supply supply 3 short (Control B) 24V3 power supply monitoring T5-6-38
circuit (control B) voltage < Lower limit 2
WB5 Sensor power supply short circuit (Control B) 5V power supply monitoring voltage 㧙
(control B) < Lower limit 2
Control W80 (Corresponding to new version) 㧙
system
W81 (Corresponding to new version) 㧙
T5-6-2
Failure Indication (Title Bar)

Func- Failure Fault Failure indication (title bar)
tion code Red: Auto stop Orange: Monitoring and warning
Auto Boom angle E20 E20: Boom angle is abnormal
stop E21 E21: Boom angle is abnormal
Angle E27 E27: Angle failure (open circuit)
Tower angle E22 E22: Tower angle is abnormal
E26 E26: Tower angle is abnormal
Jib angle E30 E30: Jib angle is abnormal
E31 E31: Jib angle is abnormal
E37 E37: Jib angle wiring failure (open circuit)
Specification E40 E40: No data available
selection E43 E43: Tower selection
E44 E44: Crane selection
E45 E45: Cable reel short circuit
Loads E50 E50: Load cell failure
E51 E51: Rope tension failure
E52 E52: Load cell failure
E53 E53: Load cell power supply failure
E54 E54: Load cell power drop
E55 E55: Load cell power supply short circuit
Monitor- Communi- W90 W90: Communication A failure
ing only cation W91 W91: Communication B failure
Angle wiring W38 W38: Jib angle wiring failure (open circuit)
Specification W47 W47: Cable reel failure (open circuit)
selection W48 W48: Counterweight detection failure
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)
WB5 WB5: Sensor power supply short circuit (5VB)
Control W80 W80: Engine control system failure
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
W89 W89: Speed control system failure
T5-6-3
FAULT CODE E20, E22

E22 E20

Check View B T25N-05-06-001
if attachment NO
of field machine
is crane.
Controller (IDU)
YES
On the operation set
window, select tower
Disconnect “1” connector (5P) of boom
angle detector from machine relay box. attachment.
“3” 22P (female)
Check if E20 YES (E21 or E26 indicated)

disappears.
Machine harness
NO “2”16P (female,
Boom angle detector failure 1.6 m
black)
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).
“1” 5P (male)

Boom angle Machine relay box
detector
YES T25N-05-06-002
0.2 V
(No voltage, or 4V or NO
more) Machine relay box failure View A
Disconnect “3” connector (22P) of T25N-05-06-003
controller (IDU), connect machine

harness to machine relay box, and
measure resistance between terminals
#4 and #7 of “2” connector (16P).

Connect terminal #6 of “3” connector
п (no resistance) (22P) of controller (IDU), machine relay
box and machine harness, and check
Resistance for continuity at terminal #6 of “2”
connector (16P).

0ǡ to 1Mǡ

Absent Present
Machine harness failure Continuity
Controller (IDU) failure
T5-6-4
FAULT CODE E21, E26

E21, E26
Controller (IDU)
Check if “1” connector (5P) of boom

angle detector is correctly connected.
Check if “2” 5P (female)

YES
connection is
correct. “1” 5 (male) 1.6 m
NO
Boom angle detector
Connect correctly connector of

boom angle detector.

Machine relay box
T25N-05-06-004

Disconnect “1” connector (5P) of “2” Connector (5P)
boom angle detector. Measure
Check if E21 NO
voltage between terminals #1 and #4
disappears. of “2” connector (5P) of machine
relay box.
YES
T25N-05-06-021
NO
Completion 4.4 V

YES A

Boom angle detector failure

T5-6-5

A E21, E26 (continued)

View B T25N-05-06-001

Connect machine harness to machine relay
box, and measure voltage between terminals
#4 and #7 of “3” connector (16P).

View C T25N-05-06-005

Controller (IDU)
YES
4.4 V
NO Machine relay box failure
Disconnect “4” connector (22P) and “5”

“5” 26P (female, white)
connector (26P) of controller (IDU), and
measure resistance at terminal #4 of “4”
connector and terminal #20 of “5” connector. “4” 22P (female, yellow)
“3” 16P (female, black)

1.6 m
0ǡ to Several 㧹ǡ Boom angle detector

Resistance
п (no resistance)

Machine relay box
T25N-05-06-006
Make short circuit between
terminals #4 and #7 of “3”
connector (16P) by using AV wire
or the like.

View A T25N-05-06-003

Check for continuity between terminal #4
of “4” connector (22P) and terminal #20
of “5” connectors (26P) of controller
(IDU).

No continuity
Continuity

Continued Machine harness failure
T5-6-6
FAULT CODE E30
“1”, “6” Connectors (5P)

E30

connector (5P) of jib angle detector from
boom-upper relay box, and measure voltage T2BC-05-06-004
between terminals #2 and #4 of opposite “2”
receptacle (5P) and “7” receptacle.
YES
0.2 V
(No voltage, or 4V or
more) NO Jib angle detector failure
Disconnect “3” connector (24P) of

cable reel wiring of boom-upper
relay box, and measure voltage “3” 24P (male)
between terminals #17 and #19
and terminals #17 and #20.
“5” 24P
(female)
“4” 24P (male)

“7” 5P (female)
“2” 5P (female)
Machine relay box
“6” 5P (male)
“1” 5P (male)
Boom-upper relay box T2BC-05-06-007

“2”, “7” Receptacles (5P)
YES
0.2 V

(No voltage, or 4 V or NO Boom-upper relay box failure
T2BC-05-06-003
more)
Disconnect “4” connector (24P) of cable
reel wiring of machine relay box, and
and #19 and terminals #17 and #20 of
opposite “5” receptacle.

T2BC-05-06-002
YES
0.2 V “5” Receptacle (24P)
(No voltage, or 4 V or NO Cable reel wiring failure

more)
B
T2BC-05-06-001
T5-6-7

B E30 (continued)

View C T25N-05-06-005

box, and measure voltage between
terminals #2 and #4 and terminals #1 and
#4 of “8” connector (12P). View B T25N-05-06-001
Controller (IDU)
YES
0.2 V
(No voltage, or 4 V or NO
more) Machine relay box failure
“9” 22P (female, yellow)
“8” 12P (female, black) 1.6 m
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 Machine relay box T2BC-05-06-006
(26P).
0: to Several M:
Resistance
View A T2BC-05-06-005

п (no resistance)

terminal #4 of “8” connector (12P)
and terminal #6 of “9” connector
(22P).

No continuity
Continuity
T5-6-8
FAULT CODE E31
E31
Check if “1” connector (5P) and “6”

connector (5P) of jib angle detector
are correctly connected.
“7” 5P (female)
“6” 5P (male)
Check if
connection is YES
correct.
“2” 5P (female)
NO “1” 5P (male)
Connect correctly “1”, “6”

connectors of jib angle detector.

Relay box T2BC-05-06-008


T2BC-05-06-004

“2”, “7” Receptacles (5P)

T2BC-05-06-003
Disconnect “1” connector (5P) and “6” connector (5P)
of jib angle detector.
Measure voltage between terminals #1 and #4 of “2”
Check if E31 NO receptacle (5P) and “7” receptacle (5P) opposite to “1”
disappears. connector (5P) and “6” connector (5P) of jib angle
detector respectively.
YES
Completion YES
4.8 V
NO Jib angle detector failure
T5-6-9
C E31 (continued)

Controller (IDU)
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.
YES
4.8 V
Machine harness
A
NO Boom-upper relay box failure
1.6 m
“3” 24P (male)
“5” 24P
(female)
“4” 24P (male)
Machine relay box

Disconnect “4” connector (24P) of cable
reel wiring of machine relay box, and
and #19, #16 and #20 of opposite “5”
receptacle (24P).

YES View A T2BC-05-06-005
4.8 V

“3” Connector (24P)
NO Cable reel wiring failure
Connect machine harness to machine

relay box, and measure voltage between
terminals #2 and #5, #1 and #5 of “8”
connector (12P).

T25N-05-06-023
“5” Receptacle (24P)

YES
4.8 V

T25N-05-03-028
T5-6-10

D E31 (continued)

With “8” connector (12P) disconnected, View B T25N-05-06-001

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” View C T25N-05-06-005
connector (26P).
Controller (IDU)
0 : to Several M :
Resistance
п (no resistance) Machine harness failure


Machine harness

1.6 m

Machine relay box T2BC-05-06-006

Disconnect “10” connector (26P) of controller
Check for continuity between terminals
(IDU).
#19 and #2 of “8” connector (12P). Check for
continuity between terminal #7 of “10” connector
and terminal #1 of “8” connector (12P).
(26P)

View A T2BC-05-06-005

No continuity
Continuity

Continued

Machine harness failure

T5-6-11
FAULT CODE E40

E40


FAULT CODE E43

E43

Check if

attachment of NO
field machine is a
tower.

YES
On the operation set window, check

the selection of attachment.
Check if tower NO
is selected.
YES
attachment.
T5-6-12
FAULT CODE E44

E44

Check if

attachment of field NO
machine is a
crane.
YES
On the operation set window, check

the selection of attachment.
Check if crane NO
is selected.
YES
attachment.
T5-6-13
FAULT CODE E45
E45

Disconnect “1” connector (24P) for
cable reel wiring of machine relay box, View A T25N-05-06-012
and measure resistance at terminals

#1, #2, and between terminals #1 and
#3 of plug.

View B T25N-05-06-003

In case of crane, Controller (MC2/B)
#1, #2 = 0:
#1 to #3 = no resistance NO
In case of tower,
#1, #2 = no resistance
#1 to #3 = 0:.
E
YES To T5-6-17
Cable reel wiring “2” 16P (male, white)

1.6 m
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 “1” 24P (male)
(16P).
Machine relay box

Boom-upper relay box
T25N-05-06-013
In case of crane,
#6, # 7 = 0:
#5 to #7 = no resistance. YES “1” Connector (24P)

In case of tower,
#6, #7 = no resistance.
#5 to #7 = 0: With “2” connector (16P) disconnected,
disconnect “3” connector (26P) of
controller (MC2/B), and measure
resistance between terminals #5 and #7,
NO and at terminals #6 and #7 of “4”
connector (16P). T25N-05-06-023
Machine relay box failure

#5 to #7, # 6, # 7: YES
no resistance

NO (500 k: or more) Controller (MC2/B) failure
T5-6-14

E E45 (continued)

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. T25N-05-03-028

Controller (MC2/B)
In case of crane,
#1, #2 = 0:
#1 to #3 = no resistance NO
In case of tower,
#1, #2 䋽 no resistance
#1 to #3 = 0:.
Boom-upper relay box failure

YES

Cable reel wiring failure
Cable reel wiring
“5” 24P (male) Machine relay box

T25N-05-06-013

T5-6-15
FAULT CODE E50 (CRANE)

E50
Controller (IDU)
Disconnect “1” connector (7P) from load cell.
Check if E50 YES (E52 indicated)

Machine harness Relay box
disappears. harness
“3” 16P
NO
Load cell failure Relay box
Reconnect “1” connector (7P) of Crane

load cell as it was. Load cell
“4” 4P (male)
Disconnect “2” connector (4P) that
connects load cell harness and
relay box.
Load cell harness

“1” 7P (female) T2BC-05-06-009

disappears.

NO
Load cell harness failure

A

T5-6-16

A

Controller (IDU)
Reconnect “2” connector of load

cell as it was.
Disconnect “3” connector of relay
box harness.

Machine harness Relay box
disappears. harness
“3” 16P
NO
Relay box failure Relay box
Reconnect “3” connector as it was. Crane

Disconnect “4” connector (26P) of Load cell
“4” 4P (male)
controller (IDU).
Load cell harness

“1” 7P (female) T2BC-05-06-009

disappears.
NO


T5-6-17
FAULT CODE E50 (TOWER)

E50
Controller (IDU)
Disconnect “1” connector (7P) from load cell.
Check if E50 YES (E52 indicated) “4” 26P (female, white)

disappears. Relay box
harness
“3” 16P
NO
Load cell failure Relay box
Reconnect “1” connector (7P) of Tower jib

load cell as it was. “2” 7P (male) load cell
Disconnect “2” connector that
connects load cell harness and
relay box.
Load cell harness

“1” 7P (female) T2BC-05-06-009

disappears.

NO

A

T5-6-18

A

Controller (IDU)
Reconnect “2” connector of load

cell as it was. Disconnect “3”
connector of relay box harness.

Relay box
harness
disappears. “3” 16P
Relay box
NO
Relay box failure
Tower jib
“2” 7P (male) load cell
Reconnect “3” connector as it was.
connector (IDU).
Load cell harness

“1” 7P (female) T2BC-05-06-009

disappears.

NO


T5-6-19
FAULT CODE E51

E51

Check the setting of boom (tower)
length, jib length, number of hoisting
rope reevings and hook capacity.

Check if the NO
setting is correct.

YES On the operation set window, make the
setting depending on field machine.

Check the difference between
actual load and indication load at
boom upper and boom lower.
Check if the YES

difference is large
(1 ton or more).
NO Grease boom foot pin, live

mast foot pin, hanger link pin,
Release load cell tension boom stop inner, etc.
completely.
Select the IDU monitor window.

Operation:
1. Turn ON maintenance key switch.
2. Press "‫ ޚ‬key" on the ML window. IDU monitor window
3. Select the monitor in the IDU Monitor Load factor 30%
maintenance menu window.
4. Select the IDU monitor in the IDU AI1 IDU AI2 IDU AI3 1/3
monitor menu window. JB ANGLE 0.00 V (AN_IN0) ****** (AN_IN8) ******
Load cell output JB ANGLE2 0.00 V (AN_IN1) ****** (AN_IN9) ******
(crane) BM ANGLE 0.00 V (AN_IN2) ****** (AN_IN10) ******
BM LOAD 0.50 V (AN_IN3) ****** (AN_IN11) ******
Check "BM LOAD" in the IDU monitor JB LOAD 0.50 V HYD THM 0.00 V
window (1/3 page). Load cell output JB ANGLE 0.50 V FD BRK THM 0.00 V
Check "JB LOAD" in case of tower. (tower) JB ANGLE2 0.00 V RD BRK THM 0.00 V
BM ANGLE 2.50 V 3D BRK THM 0.00 V
Move page Return
0.5 V r 0.04 V NO
YES F
T5-6-20

Load cell zero point correction window

F E51 (continued)
Load cell zero point correction Load factor 30%

Load cell output voltage 8
Corrected output voltage 8
Standard correction voltage 8
Correctable voltage range 8
Select the load cell zero point correction
Detach the load cell from the hoist rope to completely
window.
Operation: eliminate the load ratio from the load cell.
After detaching the load cell, press <START> key.
1. Turn ON maintenance key switch. Pay attention.
2. Press "‫ ޚ‬key" on the ML window.
3. Select the adjustment menu in the Don̉t disconnect the connector from the load cell.
maintenance menu window. Cancel Start

4. Select the load cell zero point correction in
the adjustment menu window.
In case of tower, select the jib load cell zero Load cell zero point correction completion window
point correction.
Load cell zero point correction Load factor 30%

Load cell output voltage 8

Corrected output voltage 8
Press ‫ ޚ‬keys once. Standard correction voltage 8
Load cell zero point correction is completed. Correctable voltage range 8

Detach the load cell from the hoist rope to completely
eliminate the load ratio from the load cell.
Select the IDU monitor window. After detaching the load cell, press <START> key.
Operation: Pay attention.
1. Turn ON maintenance key switch. Don̉t disconnect the connector from the load cell.
2. Press "‫ ޚ‬key" in the ML window. Cancel Start
3. Select the monitor in the maintenance menu
window.
4. Select the IDU monitor in the monitor menu IDU monitor window
window.
IDU Monitor Load factor 30%
IDU AI1 IDU AI2 IDU AI3 1/3
JB ANGLE 0.00 V (AN_IN0) ****** (AN_IN8) ******
Check "BM LOAD" in the IDU monitor window Load cell output JB ANGLE2 0.00 V (AN_IN1) ****** (AN_IN9) ******
(1/3 page). (crane) BM ANGLE 0.00 V (AN_IN2) ****** (AN_IN10) ******
In case of tower, check "JB LOAD". BM LOAD 0.50 V (AN_IN3) ****** (AN_IN11) ******
JB LOAD 0.50 V HYD THM 0.00 V
Load cell output JB ANGLE 0.50 V FD BRK THM 0.00 V
(tower) JB ANGLE2 0.00 V RD BRK THM 0.00 V
BM ANGLE 2.50 V 3D BRK THM 0.00 V
Move page Return

NO
0.5 V r 0.04 V
YES Load cell failure
Check if E51 NO
disappears.
YES Controller (IDU) failure
Completion
T5-6-21
FAULT CODE E52

In case of crane

E52 Controller (IDU)
Check if “1” connector (7P) of load

cell is correctly connected.
Check if YES
connection is
correct.
Relay box
NO
Load cell
Connect “1” connector (7P) of load
cell correctly.
Load cell harness

“1” 7P (female) T2BC-05-06-009

Check if E52 NO Measure voltage between terminals Connector (7P)
disappears. #A and #D of “1” connector (7P) of
load cell.
YES

T25N-05-06-022
YES
Completion 9.8 V

NO
Load cell failure
T5-6-22

G E52 (crane) (continued)
Controller (IDU)
Disconnect “2” connector (4P) of load cell

harness, and measure voltage between
terminals #1 and #3 of opposite “3”
connector (4P). “4” 22P (female,
yellow)
YES Machine harness

9.8 V “6” 16P
“5” Connector
NO Relay box
“3” Connector
Connect relay box and machine harness. Load cell
Disconnect “6” connector.
“2” Connector
Measure voltage at terminals #9, #11.
Load cell harness

“1” 7P (female) T2BC-05-06-009
YES
9.8 V
NO
Relay box failure
H
T25N-05-06-020
View A

T25N-05-06-001
View B

T25N-05-06-005
View C

T2BC-05-06-010
View D
T5-6-23

H
Controller (IDU)

connector (26P) of controller (IDU), and
connector and at terminal #18 of “5”
connector. “4” 22P (female,
yellow)
Machine harness
Resistance “6” 16P
“5” Connector
п (no resistance) Relay box
“3” Connector
Make short circuit between terminals Load cell
#9 and #11 of “6” connector (16P) by
“2” Connector
using jumper wire or the like.
Load cell harness

Check for continuity terminal #3 of “4”
connector (22P) of controller (IDU) and
terminal #18 of “5” connector (26P). “1” 7P (female) T2BC-05-06-009

No continuity
Continuity

T25N-05-06-020
View A
Continued



T25N-05-06-001
View B

T25N-05-06-005
View C

T2BC-05-06-010
View D
T5-6-24
In case of tower

E52
Controller (IDU)
Check if “1” connector (7P) of load cell

or “2” connector (7P) of machine relay
box is correctly connected.
Check if YES
connection is
correct. “1” 7P (female)
NO
Connect “1” connector or “2”

connector correctly.
Machine relay box
Load cell
“2” 7P (male)
T25N-05-06-018

Check if E52 NO Measure voltage betweenterminals
disappears. #A and #D of “1” connector (7P) of
load cell.

YES T25N-05-06-022

YES
Completion 9.8 V

NO
Load cell failure
I

T5-6-25
I E52 (tower) (continued)

Controller (IDU)
Measure voltage between terminals #A
and #D of “3” receptacle (7P) of machine
relay box.
YES “6” 26P

9.8 V (female, white)
Machine harness
“5” 22P
NO Load cell harness failure “4” 16P (female, yellow)
(female, black) 1.6 m
Connect machine harness and machine
relay box, and measure voltage between
terminals #11 and #16 of “4” connector
(16P).
“3” 7P (female)
Machine relay box

9.8 V YES Load cell

Load cell harness T25N-05-06-019


T25N-05-06-003
connector (26P) of controller (IDU), and View A
connector and terminal #6 of “6” connector.

T25N-05-06-001
View B
0: to Several M:
Resistance
п (no resistance)
T25N-05-06-005
View C
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).

T25N-05-06-022

No continuity
Continuity

T5-6-26
FAULT CODE W47
W47

Check for connection of “1”

connector (24P) and “2” connector
(24P) for cable reel wiring.

Check if NO
connection is
correct.

YES
A

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). Controller (MC2/B)
In case of crane,
#1, #2 = continuity
#1 to #3 = no continuity NO
In case of tower,
#1, #2 = no continuity Machine harness
#1-#3 = continuity
B
“3” 16P (male, white)
1.6 m
Cable reel wiring
YES
Reconnect “1” connector (24P) for cable reel

wiring as it was.
Connect machine harness to machine relay “1” 24P (male)
box, and measure resistance between terminals
#5 and #7, #6 and #7 of “3” connector (16P). “2” 24P (male)
Machine relay box

In case of crane,
#6, #7 = continuity T25N-05-06-012
#5 to #7 = no continuity YES View A
In case of tower,
#6, #7 = no continuity “1” Connector (24P)
#5 to #7 = continuity
C
NO
Machine relay box failure

T25N-05-06-023
T5-6-27

A W47 (continued)

Disassembly YES
position (for
transport)

NO

30 q or more
Boom angle

Less than 30 q
or no angle
Connect cable reel wiring gauge Set boom angle at less than
correctly. 30 q.
T5-6-28

B W47 (continued)

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.
T25N-05-03-028

Controller (MC2/B)
In case of crane,
#1 to #2 = continued
#1 to #3 = no continuity NO
In case of tower,
#1 to #2 = no continuity

YES
Cable reel wiring failure “6” 24P (female)
Cable reel wiring
“2” 24P (male) Machine relay box

(crane)
T25N-05-06-025
Cable reel wiring

“5” 24P (male)
Machine relay box

(tower)
T5-6-29

C W47 (continued)

Reconnect “3” connector (16P) as it

was. Disconnect “4” connector (22P) View B T25N-05-06-001
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).
T25N-05-06-005
View C

In case of crane,
#4 to #21 = no continuity YES
In case of tower,
#4 to #8 = no continuity

Controller (MC2/B) failure

NO Controller (MC2/B)

Machine harness

1.6 m
Cable reel wiring
Machine relay box

Boom-upper relay box T25N-05-06-033
T5-6-30
FAULT CODE W49

W49

Controller (IDU)

Check connection of “1” connector
(7P) for hook overhoist of
boom-upper relay box.
Check if NO
connection is
correct.
Connect connector correctly.

YES
Check for continuity between terminals

#5 and #6 of “1” connector (7P) for
hook overhoist.
“1” 7P (male)
Machine relay box

No continuity T25N-05-06-026
Continuity
Hook overhoist connector failure

Continued

Reconnect “1” connector (7P) for T2BC-05-03-010
hook overhoist as it was, and check

for continuity between terminals #1 Check for continuity between
and #14 (#1 and #15) of “2” “2” Receptacle (24P)
terminals in ( ) in case of sub
receptacle (24P) of boom-upper hook.
relay box.

T25N-05-03-028
No continuity
Continuity

Continued
D To T5-6-33
T5-6-31

D W49 (continued)

Reconnect “2” receptacle (24P) of
boom-upper relay box as it was.
Check for continuity between terminals Controller (MC2/B)
#1 and #14 (#1 and #15) of “3” Controller (IDU)
connector (24P) of machine relay box.
hook.
No continuity
Continuity “5” 16P
(female, yellow)
Continued “6” 22P (female, yellow)

Cable reel wiring failure Machine
harness
“3” 24P (male)
Reconnect “3” connector (24P) of machine “2” 24P (female)
“4” 16P
relay box as it was. (male, white)
box. Disconnect “4” connector (16P), and
check for continuity between terminals #7
and #10 (#7 and #9) of “4”connector (16P).
Cable reel wiring
between terminals in
( ) in case of sub Machine relay box
hook.

Boom-upper relay box T25N-05-06-027
No continuity
Continuity

Continued View A T25N-05-06-012
Machine relay box
failure
Reconnect “4” connector (16P) as it
was.

controller (IDU) and “6” connector
T25N-05-06-032
(22P) of controller (MC/2B). View B
Check for continuity between terminal
#10 (#3) of “5” connector (16P) of Check for continuity between
controller (IDU) and terminal #4 of “6”
connector (22P) of controller (MC2/B). hook.

T25N-05-06-001
View C

No continuity
Continuity

T25N-05-06-023
T5-6-32
FAULT CODE W90

W90 Controller (MC2/A) Controller (IDU)
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).
“1” 3P (male) Machine harness “3” 26P

(female,
No continuity “2” 3P (male) yellow)
Continuity

CAN cable
(Connected to all controllers)
Continued CAN cable failure
T25N-05-06-028

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).
T25N-05-06-029
View A

No continuity
Continuity
T25N-05-06-005
View B

Continued

#15 of “3” connector (26P) of controller View C T25N-05-06-001
(IDU) and terminal #20 of “4” connector

(22P) of controller (MC2/A).
No continuity
Continuity
Controller (IDU) failure or

controller (MC2/A) failure
T5-6-33
FAULT CODE W91

W91 Controller (MC2/B) Controller (IDU)
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/B).
“1” 3P (male) Machine harness “3” 6P

female,
No continuity “2” 3P (male) yellow)
Continuity

CAN cable
(Connected to all controllers)
Continued CAN cable failure
T25N-05-06-028

Reconnect connector for CAN
communication as it was.
#14 of “3” connector (26P) of controller
(22P) of controller (MC2/B).
T25N-05-06-029
View A

No continuity
Continuity
T25N-05-06-005
View B

Continued

#15 of “3” connector (26P) of controller View C T25N-05-06-001

(22P) of controller (MC2/B).
No continuity
Continuity
Controller (IDU) failure or

controller (MC2/B) failure
T5-6-34
FAULT CODE WA1
WA1

Disconnect connectors of free
mode switch.

Check if WA1 YES
disappears.

NO
Free mode switch wiring failure
Controller (MC2/A) failure

FAULT CODE WA2

WA2

Disconnect connectors of
emergency stop switch.

Check if WA2 YES
disappears.

NO
Emergency stop switch wiring failure

FAULT CODE WA3
WA3
T5-6-35
FAULT CODE WB2

WB2


T5-6-36
FAULT CODE WB3

WB3

Controller (MC2/B)
boom-upper relay box.
Check if WB3 YES

disappears.
Boom-upper relay box failure “2” 24P (male)

NO
“1” 24P (male)

machine relay box.
Cable reel wiring
Machine relay box

YES
Check if WB3
disappears. T25N-05-06-030

Cable reel wiring failure
NO

Connect machine harness to
machine relay box. Disconnect “3”
connector (16P).
Check if WB3 YES

disappears.

NO
T5-6-37
Intentionally
TROUBLESHOOTING/Troubleshooting E
TROUBLESHOOTING E PROCEDURE

Use Troubleshooting E when ECU lamp in cab lights
or blinks by ECU troubleshooting control (refer to
System/OPERATIONAL PRINCIPLE).


are shown.

Harness
Harness end
connector

T5-7-1
HOW TO READ FAULT CODE IN ECU EN-
GINE TROUBLESHOOTING

IMPORTANT: Record all indicated fault codes, and
ECU Lamp
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.
Troubleshooting Switch
When two or more fault codes are indicated, a T25N-01-02-010
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.

Example: Fault codes 2-1 and 2-3
The first The final The first The final
digit is "2". digit is "1". digit is "2". digit is "3".

Turn
ON
Period
between
Turn codes
OFF
Fault code 2-1 Fault code 2-3 T25N-05-07-007

T5-7-2
Failure and Number of Blinking of ECU Lamp

Failure
Countermeasure by ECU
(No. of Failure location㩷 Operation
(in backup mode)㩷
blinking)㩷
* 0-1 Normal㩷䋭㩷 |
Feedback error Both timer control valves: OFF㩷
(Actual advance angle of fuel injection Timer control (fuel injection timing control):
* 1-2 U
timing does not follow the target ad- Stop㩷
vance angle.)㩷
Timing sensor㩷 Both timer control valves: OFF㩷
* 1-4 Timer control (fuel injection timing control): U
Stop㩷
TDC sensor㩷 Determining engine speed from the number of
timing pulses.㩷
* 1-5 U
Timer control (fuel injection timing control):
Stop㩷
* 2-1 Coolant temperature sensor㩷 Keeping coolant temperature at 80C°.㩷 |
* 2-2 Rack sensor㩷 Locking rack to full load position.㩷 |
TCV ADV and TCV RTD solenoid Timer control (fuel injection timing control):
* 2-3 U
valves㩷 Stop㩷
| :Operable U: Operable in backup mode㩷

* :(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.㩷

T5-7-3
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.

Connectors of ECU and each sensor

TCV ADV Solenoid Valve, TCV RTD Solenoid Valves
TDC sensor (Harness end)
(Harness end)

Ground Sensor output TCV ADV
TCV RTD
solenoid valve solenoid valve
- Terminal - Terminal
TCV RTD TCV ADV

solenoid valve solenoid valve
T2BC-05-04-008
+ Terminal + Terminal
T2BC-05-07-002

Timing sensor (Harness end)
Troubleshooting Unit (Machine end)
Ground Power supply
Sensor output

1 2 3 4 5 6 7 8
T2BC-05-07-001
9 10 11 12 13 14 15 16

Rack sensor (Harness end)

K-Line Ground Ground DUT

MDL ECU Connector 1 (Harness end) T25N-05-07-006
Timing sensor㩷 Rack sensor
TCV ADV㩷
solenoid valve
Sensor output㩷 Ground㩷 MDL㩷 OSC Ground
Ground Terminal 䋫 Terminal 䋭
OSC T2BC-05-07-002

1 2 3 4 5 6 7 8 9 10 11 12 13
Coolant temperature sensor (Harness end)
14 15 16 17 18 19 20 21 22 23 24 25 26
Coolant tempera- Sensor output Ground Coolant Terminal 䋭 Terminal 䋫

ture output temperature
TCV RTD solenoid
TDC sensor sensor㩷
valve㩷

T2BC-05-07-003
ECU Connector 2 (Harness end)

Troubleshootingunit
K-Line
1 11
12 22
T5-7-4
TROUBLSHOOTING / Troubleshooting F
Information Display Unit (IDU) Technical Manual

1. Outline of IDU
IDU function consists of moment limiter(HSL-1) and monitor which shows various
inputs 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-1
Rewriting the controller CPU by personal computer.
SML-10
Change the ROM on the controller.
(2) Rated Capacity and Display Load

In case of Boom hook and Jib hook both available.
HSL-1
Subtract hook self weight which is not selected from rated capacity of selected hook.
SML-10
Add hook selff weight which is not selected to display load of selected hook load.
setting of jib boom hook jib hook

none boom hook weight +
boom hook lifting load
tip extension boom hook weight + jib hook weight +
boom hook lifting load jib hook lifting load +
jib boom hook weight
(3) Loadcell and Angle sensor
T5-8-1
2. Compornents
IDU consists of following parts.
(1) Controller IDU
(2) Display
(3) Switch Box
(4) Angle Senser
(5) Loadcell
(6) Conection Box
(7) Harness

%QPGEVKQP
$QZ

+&7

%CDNG4GGN
%QTF

%#0*CTPGUU

VQ/%#CPF/%$

&KURNC[
+PUKFGQH%CD
5YKVEJ$QZ

/CKP*CTPGUU

*CTPGUU

#PING
1WVUKFGQH 5GPUGT
% D

%QPGEVKQP$QZ
.QCFEGNN
Fig. 2.1 Compornents
T5-8-2
3. Structure and Function
3.1 Controller
The controller is attached in the rear stand of operater's seat back.
Four controllers are attached in the rear stand.

ECU, IDU, MC2A, and MC2B are attached from upper side.
Indicated as IDU on a label
Table 3.1 controller inputs outputs

item specification N0. note
analogue inpu A/D 12bit 8 Loadcell Angle sensor
A/D 10bit 12 temperature sensor
digital inputs +24V inputs 15
pull up 5V inputs 8 Switch Box
pull up 5V inputs 8 thermo switch
digital outputs open collector output 16 auto stop for MC2B
T5-8-3
3.2 Loadcell
The Loadcell is attached at the rope end of the boom hoist rope.
Fig 3.2 Loadcell
Tbl 3.2 Load-Output Voltage

Load(metlic ton) 0 3.0 6.0 9.0
Load(kips) 0 6.62 13.23 19.85
Output Voltage(V) 0.500 1.833 3.167 4.500
T5-8-4
3.3 Angle Sensor
An 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.
potentiometer
ࡐ࠹ࡦ࡚ࠪࡔ࡯࠲
㧻࡝ࡦࠣ
O ring
ᝄࠅሶ
pendulum
Fig 3.3 Angle Sensor
Tbl 3.3 Angle-Output Voltage

Angle(deg) -15 0 30 60 90
Output Voltage(V) 0.680 1.266 2.438 3.610 4.782
T5-8-5
3.4 Switch Box
The switch box is attached at forward left in a operator cab.
The power supply is driven by 24V outputted from IDU.
Fig 3.4.1 Switch Box
T5-8-6
connecter
ᛶ᛫ 㪣㪜㪛䋱䌾䌌䌅䌄䋸
㪈㪆㪋㪮䇭㪈㪢㱅
8 䋱
䌓䌗䋱
䋲
: 䌓䌗䋲
䋳
䌓䌗䋳
䋴
䌓䌗䋴
䋵
䋶
)0&
8
䋷
䌓䌗䋵
䋸
䌓䌗䋶
䋹
䌓䌗䋷
䋱䋰
! 䌓䌗䋸
䋱䋱
)0& 䋱䋲
Fig 3.4.2 Switch Box circuit
T5-8-7
3.5 Display
The display is the general-purpose article for car navigation.
(made from Panasonic).
Fig 3.5 Display
T5-8-8
4. Screens
HSL-1 has two kinds of Screen.
(1) Normal Screen which is displayed according to the machine state.
(2) Menu Screen which is displayed when push the menu botton.
4.1 Normal Screen

(1) Normal Screen Shift Order
Key switch ON
no
Is attachment available? Transport Configuration Screen

w/o attachment
yes
no
Is boom angle upper 10 deg? Transport Configuration Screen

w/ attachment
yes
(1) Machine Specifications Screen
(2) ML Screen
no
Out of radius and no load ?
yes
(3) 3sec push botton
(4) Erection/Fold Screen
no
Is boom angle upper 10 deg?
yes
yes
Out of radius?
no
T5-8-9
Fig. 4.1 Normal Screens (1) - (6)
(1) Machine Specifications Screen (4) Erection/Fold Screen
(2) ML Screen (5) Transport Configuration Screen

w/o attachment
(3) 3sec push botton (6) Transport Configuration Screen

w/ attachment
T5-8-10
4.2 Menu Screen
Menu Screen List
Push the Menu botton
QP for Service person

Maintenance Key Switch
off
for User
4.2.1 User Menu 4.2.2 Maintenance Menu

(1) Machine Specifications (1) Inspection Menu
(2) Inspection 1) Inspection of BM Overhoist(Sensor)
(3) Hook Height Reset 2) Inspection of BM Overhoist(L/S)
(4) Working Range Restriction (2) Adjustment Menu
(5) Gross Rated Load Table 1) Angle Correction
(6) Adjustment 2) Self-weight Correction
1) Clock Adjustment 3) Loadcell Zero Point Correction
2) Hook Height Adjustment (3) Monitor Menu
(7) Operation Instructions 1) Electric Source Monitor
2) Switch Panel Key Check
3) IDU I/O Monitor
4) MC2A I/O Monitor
5) MC2B I/O Monitor
6) Load Computing Monitor
(4) Specification Setting Men (can't use)
(5) Record Menu (can't use)
(6) Version Display
(7) Service Manual (can't use)
(8) Language Select (can't use)
T5-8-11
4.2.1 User Menu
(1) Machine Specifications
If you need change settings, use <SELECT> Move cursor to the item changed by the
key and <CHANGE> key. <CHANGE> key, and press the <SELECT>
key.
(2) Inspection (3) Hook Height Reset
Confirm each safety device stop as this table. The present hook height is set to 0.0ft.
Yes No
T5-8-12
(4) Working Range Restriction
Press <CHANGE> key to change the setting. When setting the numerical value,
press <DECIDE> key.
Press <DECIDE> key to end setting. ML/ Working Range Restriction Screen
In case of all restriction is set up.
(6)- 1) Clock Adjustment Skip

(5) Gross Rated Load Table (6)- 2) Hook Height Adjustment
Radius, Load, BM angle, Height After moving the cursor to the item to be
changed,
press <CHANGE> key to adjust the value.
(7) Operation Instructions Skip
T5-8-13
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 reaches
approximately 78 degrees approximately 80 degrees
(boom overhoist sensor activation angle) (boom overhoist limit switch activation angle)
(2) Adjustment Menu

1) Angle Correction
2) Self-weight Correction
3) Loadcell Zero Point Correction
T5-8-14
1) Angle Correction
After setting the boom angle to approximately Measure the actual working range for the
60 degrees press <START> key. selected hook.
Then, press <CHANGE> key to input the
actually measured value of the working range.
After completing input, press <NEXT> key.
Computing angle correction Hoist the boom until the boom overhoist
prevention 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 revised
selected hook, Then, press <CHANGE> key Press <END> key.
to input the actually measured value of the
working range.
After completing input, press <NEXT> key.
T5-8-15
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 is
completely 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 connector
from 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 Color

R Red W White
L Blue G Green
Or Orange Lg Light
green
Y 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
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 T107-07-06-002
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 Wind a Piece of Wire Tester Probe
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 Sharpen the end of the Wire
check the connector terminal numbers, T107-07-06-003
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.
T5-9-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
x Pull and Separate Type
x 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).

T107-04-05-004
x Remove Screw, Pull and Separate Type
NOTE: Use a spanner (10 mm).

Tighten the bolt until torque mark (pro-
truded) appears.

T107-04-05-002

x Raise Lock, Pull and Separate Type

Screw
Protruded Mark

T107-04-05-003

T107-04-05-005
T5-9-3
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.
T8HY-05-04-003
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.
T5-9-4
FUSIBLE LINK INSPECTION
Open the cap of fusible link and visually inspect the

fusible link.

T324-04-05-002
Parts Name Capacity Connected to Fusible Link 45A

Key Switch
Fusible Link 45A 45A Fuse Box1
(#9, #14 to 20) Fusible Link
Fuse Box1 65A
(#1 to 6, #12, #13)
Fusible Link 65A 65A
Fuse Box2
(#21 to 30, #32 to 40) Fusible Link
45A

T2BC-01-02-020
T5-9-5
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- Power Source ()
age in order to meet the circuit specification to be
measured.
(Measurement Range: 0 to 30 V)
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
Accessories ()
away from the center of the fuse box are
connected to loads (accessories).

T105-07-01-008
T5-9-6
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 5A Buzzer Relay Power Source
4 Radio 5A Radio Power Source
5 Pilot Shut-Off Lever / Operation Stop 5A Engine Oil Pressure Relay (R2), Alternator Relay Power Source
Power Source
6 Preheat Circuit Power Source 5A Preheat Controller Power Source
7 ECU 10 A ECU, Memory Clear Switch, ECU Lamp Power Source
8 Controller Key Switch 5A MC2/A, MC2/B, IDU Key Switch ON Signal
9 Monitor Panel Power Source 5A Monitor Panel Power Source
10 Battery Relay 10 A Battery Relay Power Source
11 Preheat Indicator 5A Monitor Panel Power Source
12 Rear Drum Lock SW Power Source 10 A Rear Drum Lock Power Source
13 Third / Fourth Drum Selection Power 3A Third / Fourth Drum Selection Switch Power Source
Source
14 Room Lamp 5A Room Lamp Switch Power Source
15 IDU 5A IDU Main Power Source
16 MC2/B 5A MC2/B Main Power Source
17 MC2/A 5A MC2/A Main Power Source
18 Horn 10 A Horn Relay Power Source
19 Back up Power Source 3A Radio, Air Conditioner Back up Source
20 Fuel Pump Power Source 10 A Fuel Pump Back up Source

T2BC-01-02-016

11 12 13 14 15 16 17 18 19 20

T18E-05-08-002
1 2 3 4 5 6 7 8 9 10
T5-9-7
Connection in Fuse Box 2
Fuse NO. Description Capacity Connected to Remarks
21 Air Conditioner Power Source 3A Air Conditioner Power Source
22 Option 10 A Optional Power Source
23 Amplifier for Microphone and 5 A Amplifier for Microphone, Anemometer Indicator Power Source
Speaker / Anemometer
24 Motor Output Limiter 5A Motor Cutoff Relay (R6) Power Source
25 Roof Wiper Power Source 5A Roof Wiper Switch, Timer, Roof Wiper Motor Power Source
26 Air Compressor Power Source 5A Air Compressor Power Source
27 Front Wiper Power Source 5A Front Wiper Switch, Timer, Front Wiper Motor Power Source
28 Lighter 20 A Lighter Power Source
29 Quick Draw / Counterweight Switch Power 10 A Quick Draw / Counterweight Relay (R5) Power Source
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
33 Travel Mode / Hyd. Tagline / Reeving 5A Travel Mode Switch, Hyd. Tagline Switch, Reeving Power Source
Winch Power Source Winch (Payout/Wind) Switch
34 Slewing Brake Power Source 3A 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
31 32 33 34 35 36 37 38 39 40

T18E-05-08-002
21 22 23 24 25 26 27 28 29 30
T5-9-8
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 Terminal E
of alternator circuit might be the cause of the
malfunction.
When voltage is 0 V, the wiring between fuse box Terminal B
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-
T2BC-05-09-003
ing normally.
If the rated voltage is not being generated
(around 24V), there is some trouble with the al-
ternator or the regulator.
T5-9-9
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:
Tester black terminal (minus): Vehicle frame (ground) When electric current does not flow
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 Measuring Point
reach the specified level (due to power consumption)
in some cases.
T141-05-06-002
When voltage does not reach the specified level,

power supply failure, short circuit or open circuit may Measurements
be caused. In this case, check circuit from the up- 24 V: Circuit from power supply to measuring
stream side (or downstream side) in sequence in or- point is normal.
der to find a defect. 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
When electric current flows
About 25.5 V
Engine running : Alternator voltage 2
About 28 V
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
Engine Key Switch Position to be Measured Specifiation

Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Battery 20 to 25 V
Stopped OFF Between (4) and (E): Battery Relay 20 to 25 V
Stopped OFF Between (5) and (E): Fusile Link 45A 20 to 25 V
Preheat Circuit
Stopped ON Between (6) and (E): Key Switch (ACC) 20 to 25 V
Stopped ON Between (7) and (E): Battery Relay (Coil) 20 to 25 V
Stopped ON Between (8) and (E): Battery Relay (Switch) 20 to 25 V
Stopped ON Between (9) and (E): Fusible Link 65A 20 to 25 V
Stopped ON Between (10) and (E): Preheat Controller 20 to 25 V
Stopped ON Between (11) and (E): Heater Relay 20 to 25 V
Stopped ON Between (12) and (E): Air Heater 20 to 25 V
Starting Circuit
Started START Between (6) and (E): Key Switch (ACC) 20 to 25 V
Started START Between (7) and (E): Battery Relay (Coil) 20 to 25 V
Started START Between (8) and (E): Battery Relay (Switch) 20 to 25 V
Started START Between (13) and (E): Engine Stop Relay (Terminal #2) 20 to 25 V
Started START Between (14) and (E): Engine Stop Solenoid 20 to 25 V
Started START Between (15) and (E): Engine Stop Relay (Terminal #1) 20 to 25 V
Started START Between (16) and (E): Starter Relay 2 (Terminal #3) 20 to 25 V
Started START Between (17) and (E): Starter (B) 20 to 25 V
Started START Between (18) and (E): Key Switch (C) 20 to 25 V
Started START Between (19) and (E): Engine Start Relay (Terminal #3) 20 to 25 V
Started START Between (20) and (E): Starter Relay 2 (Terminal #6) 13 to 30 V
Charging Circuit
Fast Speed ON Between (21) and (E): Alternator (B) 26 to 30 V
Fast Speed ON Between (8) and (E): Battery Relay (Switch) 26 to 30 V
Sarge Voltage
Prevention Circuit
Slow Idle ON㧙OFF Between (22) and (E): Battery Relay (Coil) 26 to 30 V
Slow Idle ON㧙OFF Between (23) and (E): Off-Delay Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (24) and (E): Radio 20 to 25 V
Stopped ON Between (25) and (E): Lighter 10 to 12.5 V
Stopped ON Between (26) and (E): Air Conditioner 20 to 25 V
NOTE: As for the points to be checked, refer to the illustrations in the following pages.
T5-9-11
Power Source Circuit
3 2 1
Fusible Link 45A
Fuel Feed Pump Switch
Room Lamp Switch
Horn Relay Horn Switch
Horn
MC2/A
MC2/B
Battery Relay
IDU
Key Switch

T2BC-05-09-001

T5-9-12
Preheat Circuit
Battery
Engine
Start Relay
MC2/A
8
7
Key Switch
Battery Relay
Fusible Link 65A 9
Starter Coolant
Relay 1 Temp.
Alternator
Sensor
Preheat
11
Controller
Heater Relay Air Heater
Preheat Lamp
10 12

T25N-02-03-002
T5-9-13
Engine Starting Circuit
Battery
Engine
Start Relay
19
MC2/A
Front Free Mode
SW
Rear Free Mode
SW
Third Free Mode Slewing
SW (optional) 8
Brake Switch
7
Key Switch
Battery Relay
6 18
15
13
14
Stop
Solenoid
16
17
Starter
Relay
20 Starter
Motor
Starter
Relay 2
Alternator

T25N-02-03-006
T5-9-14
Charging Circuit
Battery 8
Key Switch
Battery Relay
Off-Delay Relay
21
Alternator
Alternator
Relay
Alternator Indicator

T25N-02-03-004
T5-9-15
Surge Voltage Prevention Circuit
Battery
22
Key Switch
Battery Relay
23
Off-Delay Relay
Starter Relay 2
Alternator
Alternator
Relay
T25N-02-03-008
T5-9-16
Accessory Circuit
Battery
Key Switch
Battery Relay
24
Radio
Cigarette
Lighter
25
26
Air Conditioner

T2BC-05-09-002
T5-9-17
5-V Circuit
Power Signal or
x Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
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.
V
• Key switch: ON
• Tester black probe (minus):
Vehicle frame (ground)
• Tester red probe (plus):
T107-07-05-006
Terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5r0.5 volts, the
circuit up to terminal #1 is normal.
x Voltage between terminal #1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two Polarities
sensor connector. 1 2
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 V
conditions.

• Key switch: ON
• Tester black probe (minus):
Ground terminal
(terminal #2 or #3)
• Tester red probe (plus): T107-07-05-008
Terminal #1
Three Polarities
1 2 3
Evaluation:
If the measuring voltage is within 5r0.5 volts, the
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
V

T107-07-05-009
T5-9-18
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the
sensor connector, turn the key switch ON. Connect 1 2
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. Connect
IMPORTANT: Do not connect terminal #1 or #2 to

terminal #3 or to the vehicle frame
(ground) when checking a Three Polarities
T107-07-05-010
three-polarity connector.
1 2 3
Connect

T107-07-05-011
T5-9-19
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 : Continuity
f : Discontinuity
:
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
:
the vehicle
If the ohm-meter reading is: 0 : Continuity frame.
f: Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and u Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: : frame.
0 : Short circuit is present.
f : No short circuit is present.

T107-07-05-003
T5-9-20
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is f :, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
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 T107-07-05-004
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.
f : 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.
f : No short-circuit exists between the lines.
Short-circuit between harnesses.
A a
B u b
C c
T107-07-05-005
T5-9-21
Intentionally

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MODEL 218 HSL

BOOK No. 1059

CRANE SERIAL NUMBER

Link-Belt Construction Equipment Company

BOOK1059 N6072508 Page 1 of 4

Auxiliary Hoisting Mechanism = Auxiliary Winch Assembly / Winch Drum

Length Conversion Table

millimeter, mm centimeter, cm meter, m inch, in., " foot, ft., '

Area Conversion Table

Volume Conversion Table

gallon, gal. cubic inch, in3 liter, lit., l

Weight Conversion Table

Pressure Conversion Table

bar kg/cm3 lb./in2, PSI

Work, Energy Conversion Table

kg.cm kg.m foot-pound, ft.-lb. inch-pound,.in-lb.

Centigrade-Fahrenheit Conversion Table

• The Operator’s Manual

Consecutive Page Number for Each Group

• When you see this symbol on your machine or in this

UNDERSTAND SIGNAL WORDS

• DANGER indicates an imminently hazardous situation

x To avoid confusing machine protection with personal SA-1223

safety messages, a signal word IMPORTANT indicates

x NOTE indicates an additional explanation for an ele-

x Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or missing,

x Learn how to operate the machine and its controls cor-

x Allow only trained, qualified, authorized personnel to

x Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

x The safety messages in this SAFETY chapter are in-

PREPARE FOR EMERGENCIES

x Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other items

PROTECT AGAINST NOISE

• Wear a suitable hearing protective mechanism such

x Falling is one of the major causes of personal injury.

ADJUST THE OPERATOR’S SEAT

• The seat should be adjusted whenever changing the

• Prior to operating the machine, thoroughly examine

OPERATE ONLY FROM OPERATOR’S SEAT

• Start the engine only from the operator’s seat.

• Guard against injury from flying pieces of metal or de-

HANDLE FLUIDS SAFELY᧩AVOID FIRES

• Do not refuel the machine while smoking or when near

• Store flammable fluids well away from fire hazards.

• Be sure to observe local regulations when transporting

Less than 15q SA-475A

x When towing the machine, be sure to attach tow wire

• Understand service procedures before starting work.

• Before servicing the machine:

3) Run the engine at slow idle speed without load for

• If a maintenance procedure must be performed with

• Before performing any work on the machine, attach a

SUPPORT MACHINE PROPERLY

• Always lower the attachment to the ground before you

STAY CLEAR OF MOVING PARTS

• To prevent accidents, care should be taken to ensure

x After operation, engine coolant is hot and under pres-