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Linkbelt Service Manual Serial n6j8 0875 PDF
Linkbelt Service Manual Serial n6j8 0875 PDF
The front Section is the Workshop Instruction portion of the manual. It contains the
removal/installation (R&I) and the assembly/disassembly (Recondition) instructions for
major crane components. These pages are coded with a “W” in front of the
Section/Group/Page numbers. Example, the pages coded/numbered W2-4-1 through W2-
4-64, contain the instructions for R&I and Recondition of the main pump. (Code W2-4-1
identifies a page in the Workshop Instruction Manual, Section 2, Group 4, and Page 1.)
There are “Contents” pages at the beginning of each sub-section, in front of pages W1-1-
1, W2-1-1, and W3-1-1.
The 2nd and 3rd Sections are the Principles of Operation/Specifications and
Troubleshooting portions of the manual. These pages are coded with a “T” in front of the
Section/Group/Page numbers. Example, the pages coded/numbered T1-3-1 through T1-
3-4, contain the specifications for the engine and engine accessories. The Section behind
Tab 1 contains the specifications and how main components operate to perform their
intended functions. (Code T1-3-1 identifies a page in the Principles of
Operation/Specifications/Troubleshooting Manual, Section 1, Group 3, and Page 1.)
There are “Contents” pages at the beginning of each sub-section, in front of pages T1-2-
1, T2-1-1, and T3-1-1. The Section behind Tab 2 contains Performance Tests/Standards
and Troubleshooting for major components. There are “Contents” pages at the
beginning of each sub-section, in front of pages T4-1-1 and T5-1-1.
Page 2 of 4
Conversion Tables
mile, mi kilometer, km
1 1.6093
0.6214 1
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
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
Page 3 of 4
Conversion Tables – (continued)
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
°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
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
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.
SA-001
001-E01A-0001-2
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.
003-E01B-0003-5
004-E01A-0437-3
S-2
SAFETY
WEAR PROTECTIVE CLOTHING
x Wear close fitting clothing and safety equipment appro-
priate to the job.
005-E01A-0438-4
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
• 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
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.
010-E02B-0237-3
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.
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.
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.
035-E03A-0475-᧲
TOWING MACHINE
SA-605
061-E01A-0605-2
S-9
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
500-E07A-0497-8
S-10
SAFETY
WARN OTHERS OF SERVICE WORK
x Unexpected machine movement can cause serious in-
jury.
SA-287
501-E01A-0287-2
519-E01A-0527-3
SA-026
502-E01A-0026-2
S-11
SAFETY
PREVENT BURNS
Hot spraying fluids:
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
505-E01B-0498-5
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.
SA-292
SA-044
507-E01A-0499-5
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.
Clean up Flammables:
S-14
SAFETY
EVACUATING IN CASE OF FIRE
x If a fire breaks out, evacuate the machine in the follow-
ing way:
SA-393
518-E02A-0393-2
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.
510-E01B-0030-4
511-E01A-0029-4
S-16
SAFETY
PREVENT BATTERY EXPLOSIONS
x Battery gas can explode, resulting in serious injury.
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.
515-E01A-0309-4
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
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
GENERAL INFORMATION / Precautions for Disassembling and Assembling
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
GENERAL INFORMATION / Precautions for Disassembling and Assembling
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:
b b
a=b
a㻛b
W110-03-05-004
W1-1-3
GENERAL INFORMATION / Precautions for Disassembling and Assembling
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
Bent Sling W162-01-01-009
W1-1-4
GENERAL INFORMATION / Precautions for Disassembling and Assembling
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
GENERAL INFORMATION / Precautions for Disassembling and Assembling
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
GENERAL INFORMATION / Tightening Torque
TORQUE CHART
Bolt Types
W157-01-01-001
W1-2-2
GENERAL INFORMATION / Tightening Torque
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.
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
GENERAL INFORMATION / Tightening Torque
Service Recommendations for Split Flange
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.
W1-2-4
GENERAL INFORMATION / Tightening Torque
PIPING JOINT
Union Joint
W1-2-5
GENERAL INFORMATION / Tightening Torque
O-Ring Seal Joint
7 6 9
O-ring (6) seats against the end face of adaptor (7)
to seal pressure oil.
W1-2-6
GENERAL INFORMATION / Tightening Torque
Screwed-In Connection
PT PF
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
M114-07-041
W1-2-7
GENERAL INFORMATION / Tightening Torque
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
GENERAL INFORMATION / Tightening Torque
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.
W1-2-9
GENERAL INFORMATION / Tightening Torque
(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
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
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
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
21
27 22
W24X-02-01-004
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
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
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.
W2BD-02-01-004
W2-1-4
CRANE UPPER / Cab
Installation
W2BD-02-01-004
40
W2BD-02-01-002
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
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
W24X-02-01-001
W2-1-8
CRANE UPPER / Cab
DIMENSIONS OF THE CAB GLASS
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.
W2-2-1
CRANE UPPER / Counterweight
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
UNLOCK
W2BC-02-02-002
W2BC-02-02-003
W2-2-2
CRANE UPPER / Counterweight
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
W2BC-02-02-005
W2BC-02-02-006
W2-2-3
CRANE UPPER / Counterweight
14. Continue to extend the cylinders (9) after
counterweight contacts the ground. Tilt cylinders
(9) away from machine for clearance.
W2BC-02-02-007
12
W2BC-02-02-008
W2-2-4
CRANE UPPER / Counterweight
Installation
brackets (19).
W2BC-02-02-006
W2-2-5
CRANE UPPER / Counterweight
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.
W2BC-02-02-001
10. Check that the Lock Lever (3) is in the UNLOCK LOCK
position.
3
UNLOCK
W2BC-02-02-002
13
12
W2BC-02-02-008
W2-2-6
CRANE UPPER / Counterweight
12. Place the ladder (4) onto the platform (5) of the
upper frame rear side. 6
W2BC-02-02-006
20 20
W2BC-02-02-011
W2-2-7
CRANE UPPER / Counterweight
16. Position the pins (21) onto the rear of the upper
frame.
21
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
CRANE UPPER / Counterweight
20. Fully retract the cylinders as storage position.
W2BC-02-02-004
W2-2-9
CRANE UPPER / Counterweight
(Blank)
W2-2-10
CRANE UPPER / Upper Revolving Frame
REMOVE AND INSTALL UPPER
REVOLVING FRAME
Removal
W2BC-02-03-001
W2BC-02-03-002
2
W2-3-1
CRANE UPPER / Upper Revolving Frame
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
11. Hoist and level the crane upper 10 mm (0.39 in). W324-02-03-005
W324-02-03-006
W2-3-2
CRANE UPPER / Upper Revolving Frame
Installation
W2-3-3
CRANE UPPER / Upper Revolving Frame
10. Install the live-mast, boom stop and boom.
10
11. Connect plugs on the terminal box (11).
W2BC-02-03-002
11
W2-3-4
CRANE UPPER / Pump Assembly
REMOVE AND INSTALL MAIN PUMP
CAUTION: Escaping fluid under pressure
may penetrate the skin and eyes,
and cause serious injury. Release
the pressure before removing the
hydraulic or other lines.
Hot hydraulic oil just after
operation may spout and cause
severe burns. Wait for oil in order
to cool before starting any work.
Before draining hydraulic oil,
lower the boom onto the ground.
Apply each brake and the drum
lock. 1
Preparation W24X-02-04-001
Removal
3. Remove bolts (2, 3). Lift main pump with the crane
and remove them.
: 24 mm
: 17 mm
W2-4-1
CRANE UPPER / Pump Assembly
Installation 4
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)
W2-4-2
CRANE UPPER / Pump Assembly
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
W2CM-02-04-001
W2-4-3
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
Disassemble Main Pump
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
10. Tap the mounting flange part for support (28) from
the pump casing (25) side. Separate support (28)
from pump casing (25).
12. Tap the ends of shafts (7, 57) with using a plastic
hammer. Remove shafts (7, 57) from support (28).
W2-4-9
CRANE UPPER / Pump Assembly
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
54
53
67
66
65 52
64
63
68 1
W2BD-02-04-002
W2-4-10
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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.
W2-4-13
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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).
W2-4-15
CRANE UPPER / Pump Assembly
MAINTENANCE STANDARD
1. Clearance between piston outer diameter and
cylinder inner bore.
Unit: mm (in)
Standard Allowable Limit d D
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)
Standard Allowable Limit
t 4.9 (0.19) 4.7 (0.19)
Unit: mm (in)
L
Standard Allowable Limit
L 39.5 (1.56) 38.7 (1.52) W25N-02-04-007
Unit: mm (in)
Standard Allowable Limit W25N-02-04-008㩷
W2-4-16
CRANE UPPER / Pump Assembly
(Blank)㩷
W2-4-17
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
W2-4-19
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
W2-4-21
CRANE UPPER / Pump Assembly
21
7
6 20
16 19
5 17
22
16
29
30
31
30
30
W2CH-02-04-001㩷
W2-4-22
CRANE UPPER / Pump Assembly
IMPORTANT: Do not remove pin (16).
9. Remove the lever (17).
NOTE: The lever can be easily removed by using a
pair of tweezers.
W2-4-23
CRANE UPPER / Pump Assembly
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
W2-4-24
CRANE UPPER / Pump Assembly
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).
W25N-02-04-012
W2-4-25
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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)
13. Install the cover (31) and tighten the socket bolt
(30).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-4-27
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
W2-4-29
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
Disassemble Rear Regulator
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
CRANE UPPER / Pump Assembly
21
7
6 20
16 19
5 17
22
16
29
35
31
30
W2CH-02-04-002㩷
W2-4-32
CRANE UPPER / Pump Assembly
IMPORTANT: Do not remove pin (16).
9. Remove the lever (17).
NOTE: The lever can be easily removed by using a
pair of tweezers.
W2-4-33
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
W2-4-35
CRANE UPPER / Pump Assembly
29
27 26 23 22 47
48 19 51
21
49 28
52
17
16
20
W2CM-02-04-005
W2-4-36
CRANE UPPER / Pump Assembly
Assemble Rear Regulator
1. Install rod (7) into the compensating hole on 5. Install piston (29) into the hole for negative control
casing (47). on casing (47).
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 (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
retaining ring (51).
W25N-02-04-012
W2-4-37
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
10. Install set spring (25) to the spool hole and install
piston (6) and casing (5) to the compensating hole.䎃
Tighten cover (58) with socket bolts (59, 44).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 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
CRANE UPPER / Pump Assembly
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
W2-4-40
CRANE UPPER / Pump Assembly
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.
W2-4-41
CRANE UPPER / Pump Assembly
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
W2-4-42
CRANE UPPER / Pump Assembly
Assemble Reduction Gear
W2-4-43
CRANE UPPER / Pump Assembly
MAINTENANCE STANDARD
Replacement Standard for Wear Parts
W2-4-44
CRANE UPPER / Pump Assembly
REMOVE AND INSTALL SWING PUMP
CAUTION: Escaping fluid under pressure
may penetrate the skin and eyes,
and cause serious injury. Release
the pressure before removing the
hydraulic or other lines.
Hot hydraulic oil just after
operation may spout and cause
severe burns. Wait for oil in order
to cool before starting any work.
Before draining hydraulic oil,
lower the boom onto the ground.
Apply each brake and the drum
lock. 1
Preparation W24X-02-04-001
Removal
W2-4-45
CRANE UPPER / Pump Assembly
Installation
CAUTION: Swing pump weight:
Approx. 45 kg (100 lb) 4
W2-4-46
CRANE UPPER / Pump Assembly
(Blank)
W2-4-47
CRANE UPPER / Pump Assembly
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
W2-4-48
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
17
21
24
32
10
27
13 10
44
48
W2CH-02-04-003
W2-4-50
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
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
CRANE UPPER / Pump Assembly
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)
W2-4-53
CRANE UPPER / Pump Assembly
MAINTENANCE STANDARD
1. Clearance between piston outer diameter and
cylinder inner bore.
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)
Standard Allowable Limit
Ǭ 0 to 0.1 (0 to 0.004) 0.3 (0.12)
㱐
3. Shoe thickness
W25N-02-04-006
Unit: mm (in)
Standard Allowable Limit
t 3.9 (0.15) 3.7 (0.15)
Unit: mm (in)
Standard Allowable Limit
L
L 31.3 (1.23) 30.5 (1.20)
W25N-02-04-007
H
Unit: mm (in) h
Standard Allowable Limit
H-h 19.0 (0.75) 18.3 (0.72)
W25N-02-04-008㩷
W2-4-54
CRANE UPPER / Pump Assembly
(Blank)
W2-4-55
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
W2-4-57
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
21
7
6 20
16 19
5 17
22
16
29
W2CH-02-04-005㩷
W2-4-60
CRANE UPPER / Pump Assembly
IMPORTANT: Do not remove pin (16).
11. Remove lever (17) by using a pair of tweezers.
NOTE: The lever can be easily removed by using a
pair of tweezers.
W2-4-61
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
W2-4-63
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
Assemble 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). 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
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)
3. Install spool (22) and sleeve (23) into the spool
hole on casing (46). 10. Install return spring (26) and spring seat (27) to
the spool hole.䎃Install retaining ring (28).
IMPORTANT: Check the direction of feedback
lever (20).
W25N-02-04-012
W2-4-65
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
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)
12. Install set spring (25) to the spool hole and install
piston (6) and casing (5) to the compensating hole.䎃
Tighten cover (59) with socket bolt (32).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
W2-4-67
CRANE UPPER / Pump Assembly
(Blank)㩷
W2-4-68
CRANE UPPER / Pump Assembly
REMOVE AND INSTALL 2-UNIT GEAR
PUMP
Removal
W2-4-69
CRANE UPPER / Pump Assembly
Installation
W2-4-70
CRANE UPPER / Pump Assembly
(Blank)
W2-4-71
CRANE UPPER / Pump Assembly
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
W2-4-72
CRANE UPPER / Pump Assembly
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).
W25N-02-04-018
W2-4-73
CRANE UPPER / Pump Assembly
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
W2-4-74
CRANE UPPER / Pump Assembly
Assemble 2-Unit Gear Pump
W2-4-75
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
4. Install drive gear (9) and driven gear (8) onto body
(10).
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
CRANE UPPER / Pump Assembly
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
CRANE UPPER / Pump Assembly
REMOVE AND INSTALL GEAR PUMP FOR
HYD. TAGLINE
Removal
W2-4-79
CRANE UPPER / Pump Assembly
Installation
2
CAUTION: Gear pump weight:
Approx. 2.3 kg (5.1 lb)
3
W2-4-80
CRANE UPPER / Pump Assembly
(Blank)
W2-4-81
CRANE UPPER / Pump Assembly
DISASSEMBLE GEAR PUMP FOR HYD. TAGLINE
9
3 8
1
14
13
12
11
10
6
7
W23F-02-04-012
W2-4-82
CRANE UPPER / Pump Assembly
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).
W2-4-83
CRANE UPPER / Pump Assembly
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
W2-4-84
CRANE UPPER / Pump Assembly
Assemble Gear Pump
W2-4-85
CRANE UPPER / Pump Assembly
9 3 11 7 10
10
6
2
6 7 12 8 13 14
W23F-02-04-014
W2-4-86
CRANE UPPER / Pump Assembly
4. Install drive gear (9) and driven gear (8) on front
cover (3).
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
CRANE UPPER / Pump Assembly
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
W2-5-1
CRANE UPPER / Control Valve
Installation
: 10 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
W2-5-2
CRANE UPPER / Control Valve
(Blank)
W2-5-3
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
Disassemble Front / Rear 4-Unit Control Valve
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
W2-5-7
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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
W2-5-9
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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)
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
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
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)
end covers (16) (2 used).
19. Install end covers (16) (2 used) assembly to valve
section (37) with socket bolts (10) (4 used).
: 5 mm
: 12r1.0 Nm (1.2r0.1 kgfm, 8.9r0.7 lbfft)
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
CRANE UPPER / Control Valve
(Blank)
W2-5-16
CRANE UPPER / Control Valve
REMOVE AND INSTALL 4-UNIT CONTROL
VALVE
Removal
W2-5-17
CRANE UPPER / Control Valve
Installation
W2-5-18
CRANE UPPER / Control Valve
(Blank)
W2-5-19
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
W2-5-21
CRANE UPPER / 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
W2-5-22
CRANE UPPER / Control Valve
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).
1. Place the control valve assembly on a workbench. 9. Turn and remove spools (19) (4 used) from
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
W2-5-23
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
W2-5-25
CRANE UPPER / Control Valve
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
CRANE UPPER / Control Valve
W2-5-27
CRANE UPPER / 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
W2-5-28
CRANE UPPER / Control Valve
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
CRANE UPPER / 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
W2-5-30
CRANE UPPER / Control Valve
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
end covers (10) (8 used).
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)
W2-5-31
CRANE UPPER / Control Valve
(Blank)
W2-5-32
CRANE UPPER / Control Valve
REMOVE AND INSTALL 1-UNIT CONTROL
VALVE
Removal
W2-5-33
CRANE UPPER / Control Valve
Installation
W2-5-34
CRANE UPPER / Control Valve
(Blank)
W2-5-35
CRANE UPPER / Control Valve
DISASSEMBLE 1-UNIT CONTROL VALVE
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
W2-5-36
CRANE UPPER / Control Valve
Disassemble 1-Unit Control Valve
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
18) (2 used for each) and O-rings (14) (2 used)
from end covers (11) (2 used). 12. Divide each section into inlet section (1), valve
section (3) and outlet section (2).
CAUTION: Do not damage the holes on
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).
W2-5-37
CRANE UPPER / Control Valve
ASSEMBLE 1-UNIT CONTROL VALVE
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
W2-5-38
CRANE UPPER / Control Valve
Assemble 1-Unit Control Valve
W2-5-39
CRANE UPPER / Control Valve
(Blank)
W2-5-40
CRANE UPPER / Control Valve
REMOVE AND INSTALL WINCH DRUM
CONTROL VALVE (OPTIONAL)
Removal
W2-5-41
CRANE UPPER / Control Valve
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
W2-5-42
CRANE UPPER / Control Valve
Disassemble Winch Drum Control Valve
W2-5-43
CRANE UPPER / 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
W2-5-44
CRANE UPPER / Control Valve
7. Remove valve (29) from valve section (3).䎃
W2-5-45
CRANE UPPER / Control Valve
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
W2-5-46
CRANE UPPER / Control Valve
Assemble Winch Drum Control Valve
W2-5-47
CRANE UPPER / 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
W2-5-48
CRANE UPPER / Control Valve
10. Install O-rings (36, 37) (2 used), springs (49, 48)
and spring seat (53) to end cover (28).
W2-5-49
CRANE UPPER / Control Valve
(Blank)
W2-5-50
CRANE UPPER / Swing Reduction Unit
REMOVE AND INSTALL SWING
REDUCTION UNIT
Preparation
Removal
W2-6-1
CRANE UPPER / Swing Reduction Unit
Installation
W2-6-2
CRANE UPPER / Swing Reduction Unit
(Blank)
W2-6-3
CRANE UPPER / Swing Reduction Unit
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
W2-6-4
CRANE UPPER / Swing Reduction Unit
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.
10. Remove side plate (12) of the lower side from pins
(11) (3 used).
W2-6-5
CRANE UPPER / Swing Reduction Unit
18
22
17
28
2㩷
W25N-02-06-002
W2-6-6
CRANE UPPER / Swing Reduction Unit
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).
Press㩷
W25N-02-06-004
W2-6-7
CRANE UPPER / Swing Reduction Unit
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
W2-6-8
CRANE UPPER / Swing Reduction Unit
Assemble Swing Reduction Unit
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.
㱢156㩷
㱢125㩷
W2-6-9
CRANE UPPER / Swing Reduction Unit
21 20 31
3
10
8
4
18
13
24
30
27
2㩷
W25N-02-06-002
W2-6-10
CRANE UPPER / Swing Reduction Unit
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.
㱢160㩷
㱢93㩷
11. Align with the pin (10) hole on carrier (8) and
place side plates (13) (4 used).
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
W2-6-11
CRANE UPPER / Swing Reduction Unit
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
CRANE UPPER / Swing Reduction Unit
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).
W2-6-13
CRANE UPPER / Swing Reduction Unit
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
W2-6-14
CRANE UPPER / Swing Reduction Unit
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).
W2-6-15
CRANE UPPER / Swing Reduction Unit
8 6 29 24
2 1 28
9 3
7
11
15
23
5
16
W25N-02-06-008
W2-6-16
CRANE UPPER / Swing Reduction Unit
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.
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).
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
M16
㱢8
W2-6-17
CRANE UPPER / Swing Reduction Unit
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
W2-6-18
CRANE UPPER / Swing Reduction Unit
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).
W2-6-19
CRANE UPPER / Swing Reduction Unit
27 12
20 3 14
13
11
22
19
10 36
35
W25N-02-06-008
W2-6-20
CRANE UPPER / Swing Reduction Unit
17. Apply grease onto the valve casing (3) mounting
surfaces of valve plate (10).䎃Install valve plate (10)
to valve casing (3).
W2-6-21
CRANE UPPER / Swing Reduction Unit
MAINTENANCE STANDARD
Swing Reduction Unit
Swing Motor
Unit: mm (in)
Standard Allowable Limit
D-d 0.028 (0.001) 0.058 (0.002)
d D
2. Clearance between piston and shoe
W25N-02-04-005
Unit: mm (in)
Standard Allowable Limit
Ǭ 0 (0) 0.3 (0.012)
3. Shoe thickness
Unit: mm (in)
Standard Allowable Limit 㱐
W2-6-22
CRANE UPPER / Winch Assembly
REMOVE AND INSTALL FRONT AND
REAR WINCH ASSEMBLY
Removal 3
W2-7-1
CRANE UPPER / Winch Assembly
9. Remove bolts (9) (16 used) and remove drum 9 5 9 6
covers (5), (6), (7), (8).
: 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
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
Installation
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
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
7. Install the backstop. (As for installation of the
backstop, refer to the Operator's Manual.)
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
CRANE UPPER / Winch Assembly
(Blank)
W2-7-7
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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
Approx. 2000 kg (4410 lb)
10. Remove oil seal (48) from retainer (50).
1. Remove plug (25) and drain off gear oil.
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.
Approx. 220 kg (485 lb)
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
used) from carrier (35).
W2-7-9
CRANE UPPER / Winch Assembly
1 2 12
12
42
12
35 26
41 39 38 37 36
43 44
45
W2BD-02-07-003
W2-7-10
CRANE UPPER / Winch Assembly
24. Remove spacer (2) from carrier (35).
26. Remove bolts (39) (18 used). Lift drum (1) with
the crane and remove it.
: 19 mm
32. Remove bolts (12) (30 used). Lift brake unit (42)
with the crane and remove it from bracket (41).
: 30 mm
W2-7-11
CRANE UPPER / Winch Assembly
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
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
W2-7-12
CRANE UPPER / Winch Assembly
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).
W2-7-13
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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.
24. Install O-ring (46) onto sleeve (47).
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
CRANE UPPER / Winch Assembly
13 13 12 15
12
16
12
13 24 22
25
W2BD-02-07-003
W2-7-16
CRANE UPPER / Winch Assembly
38. Apply liquid packing (ThreeBond #1389) on the
mating surface of the motor (16) and the pedestal
(22).
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)
40. Lift the winch assembly with the crane and place it
onto the workbench horizontally.
W2-7-17
CRANE UPPER / Winch Assembly
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
W2-7-18
CRANE UPPER / Winch Assembly
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).
(21) from casing (19).
15. Loosen bolts (41) (4 used). Remove front cover
(45) from casing (5).
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
CRANE UPPER / Winch Assembly
1 2 14
43
42
35
A W2CM-02-07-006
W2-7-20
CRANE UPPER / Winch Assembly
18. Remove retaining ring (2) and spacer (1) from
shaft (43). Pull out bearing (42) with using a
press.
W2-7-21
CRANE UPPER / Winch Assembly
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
W2-7-22
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
20. Install springs (24) (16 used) to brake piston (21).
W2-7-25
CRANE UPPER / Winch Assembly
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
W2-7-26
CRANE UPPER / Winch Assembly
MAINTENANCE STANDARD Dial Gauge㩷
W2-7-27
CRANE UPPER / Winch Assembly
4. Measure heights of H and h.
Plate㩷 Holder
Unit: mm (in)
Standard Allowable Limit
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
Unit: mm (in)
Standard Allowable Limit
54 (2.13) 53.2 (2.09)
W2-7-28
CRANE UPPER / Winch Assembly
(Blank)
W2-7-29
CRANE UPPER / Winch Assembly
DISASSEMBLE 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
W2-7-30
CRANE UPPER / Winch Assembly
Disassemble Regulator
W2-7-31
CRANE UPPER / Winch Assembly
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
W2-7-32
CRANE UPPER / Winch Assembly
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)
W2-7-33
CRANE UPPER / Winch Assembly
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
W2-7-34
CRANE UPPER / Winch Assembly
Disassemble Counterbalance Valve
W2-7-35
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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).
W2-7-37
CRANE UPPER / 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
W2-7-38
CRANE UPPER / Winch Assembly
Disassemble Brake Unit
CAUTION: Brake unit weight: 13. Remove adapter (29) from cover (24).
Approx. 675 kg (1490 lb)
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).
W2-7-39
CRANE UPPER / Winch Assembly
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
W2-7-40
CRANE UPPER / Winch Assembly
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).
W2-7-41
CRANE UPPER / Winch Assembly
(Blank)
W2-7-42
CRANE UPPER / Winch Assembly
REMOVE AND INSTALL FOURTH WINCH
ASSEMBLY (OPTIONAL)
4 W2BC-02-07-005
W2-7-43
CRANE UPPER / Winch Assembly
5. Remove bolts (5, 6) (8 used) from the right house
(7). Hoist and remove the right house (7).
5
W2BC-02-07-006
W2-7-44
CRANE UPPER / Winch Assembly
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
W2BC-02-07-008
W2-7-45
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
Installation
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
CRANE UPPER / Winch Assembly
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)
W2BC-02-07-008
W2-7-48
CRANE UPPER / Winch Assembly
6. Install the backstop. (As for installation of the
backstop, refer to the Operator's Manual.)
5
W2BC-02-07-006
W2-7-49
CRANE UPPER / Winch Assembly
9. Connect connector (4) in the right house (7).
12. Wind the wire rope into the front and rear drums.
W2BC-02-07-004
W2-7-50
CRANE UPPER / Winch Assembly
(Blank)
W2-7-51
CRANE UPPER / Winch Assembly
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
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
W2-7-52
CRANE UPPER / Winch Assembly
Disassemble Fourth Winch Assenbly
CAUTION: Fourth winch assenbly weight: 10. Remove oil seal (48) from retainer (50).
Approx. 2000 kg (4410 lb)
11. Remove bearing (21) from pedestal (22).
1. Remove plug (25) and drain off gear oil.
Gear oil : 22.5 L (5.9 US gal) 12. Remove sleeve (47) from cover (24).
: 14 mm
13. Remove O-ring (46) from sleeve (47).
NOTE: Drain off gear oil in the clean container and
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.
16. Remove the carrier (4) assembly.
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).
the crane and remove it.
: 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
used) from carrier (35).
6. Remove nut (20).
23. Remove planetary gears (32) (4 used), thrust
7. Remove the pedestal (22) assembly. plates (33) (8 used) and needle bearings (31) (8
used) from carrier (35).
8. Remove bearing (21) from pedestal (22).
W2-7-53
CRANE UPPER / Winch Assembly
1 2
42
12
35 26
41 39 38 37 36
43 44
45
W2BD-02-07-004
W2-7-54
CRANE UPPER / Winch Assembly
24. Remove spacer (2) from carrier (35).
26. Remove bolts (39) (18 used). Lift drum (1) with
the crane and remove it.
: 19 mm
32. Remove bolts (12) (30 used). Lift brake unit (42)
with the crane and remove it from bracket (41).
: 30 mm
W2-7-55
CRANE UPPER / Winch Assembly
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
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
W2-7-56
CRANE UPPER / Winch Assembly
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).
W2-7-57
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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.
24. Install O-ring (46) onto sleeve (47).
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
CRANE UPPER / Winch Assembly
13 12 15
16
24 22
25
W2BD-02-07-004
W2-7-60
CRANE UPPER / Winch Assembly
38. Apply liquid packing (ThreeBond #1389) on the
mating surface of the motor (16) and the pedestal
(22).
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)
40. Lift the fourth winch assenbly with the crane and
place it onto the workbench horizontally.
W2-7-61
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
W2-7-63
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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
Approx. 20 kg (44 lb)
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
6. Remove socket bolts (62) (12 used).䎃 Remove
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).
W2-7-65
CRANE UPPER / Winch Assembly
7
6
26
25
23
20 21
22
W2CM-02-07-009
W2-7-66
CRANE UPPER / Winch Assembly
21. Remove O-rings (22) (4 used) from casing (23)
and O-ring (21) from front casing (20)
respectively.
W2-7-67
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
W2-7-69
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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)
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).
W2-7-71
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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.
W2-7-73
CRANE UPPER / Winch Assembly
MAINTENANCE STANDARD
Dial Gauge㩷
Unit: mm (in)
Standard Allowable Limit
0.039 (0.002) 0.078 (0.003)
B
W309-04-05-005㩷
W2-7-74
CRANE UPPER / Winch Assembly
4. Measure heights of H and h.
Unit: mm (in)
Standard Allowable Limit
32.2 (1.27) 31.6 (1.24) H
h
A
Remedy: Adjust the shims.
W2-7-75
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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
11. Remove orifice (9), spring (8) and steel ball (7)
from spool (6).
W2-7-77
CRANE UPPER / Winch Assembly
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
CRANE UPPER / Winch Assembly
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).
CAUTION: Counterbalance valve weight:
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
CRANE UPPER / Winch Assembly
DISASSEMBLE 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
W2-7-80
CRANE UPPER / Winch Assembly
Disassemble Regulator
CAUTION: Regulator weight: 16. Remove lever (21) from sleeve (22).
Approx. 8.0 kg (18 lb)
17. Remove spring seat (17), spring (19), spring seat
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).
W2-7-81
CRANE UPPER / Winch Assembly
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
W2-7-82
CRANE UPPER / Winch Assembly
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:
Approx. 8.0 kg (18 lb)
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)
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
W2-7-84
SWING MACHINERY / Winch Assembly
Disassemble Brake Unit
CAUTION: Brake unit weight: 13. Remove adapter (29) from cover (24).
Approx. 675 kg (1490 lb)
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).
W2-7-85
SWING MACHINERY / Winch Assembly
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
W2-7-86
SWING MACHINERY / Winch Assembly
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).
W2-7-87
SWING MACHINERY / Winch Assembly
(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.
W2-8-1
CRANE UPPER / Raising/Lowering Mechanism
5. Disconnect connector (2).
2
W2BC-02-03-001
5
W2BC-02-08-001
4 5
W2-8-2
CRANE UPPER / Raising/Lowering Mechanism
9. Remove bolts (6) (3 used), (7) (1 used) and
remove drum cover L (8). 8 6
: 19 mm
6 9
7
W2BD-02-08-001
W2-8-3
CRANE UPPER / Raising/Lowering Mechanism
11. Remove bolts (11). Remove bracket (10) in the
drum speed sensor.
10
: 19 mm
11
12. Remove the wire harness and all hoses from
boom hoist system.
: 27 mm
: 41 mm
W25N-02-08-002
12
12
13
13
12 12
15
15
W2BC-02-08-004
14
W2-8-4
CRANE UPPER / Raising/Lowering Mechanism
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.
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
CRANE UPPER / Raising/Lowering Mechanism
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
7
W2BD-02-08-001
W2-8-6
CRANE UPPER / Raising/Lowering Mechanism
7. Connect Connector (2)
2
W2BC-02-03-001
5
W2BC-02-08-001
4 5
W2BC-02-08-005
W2-8-7
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
W2-8-9
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
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).
W2-8-11
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
26. Remove spring pin (35). Remove pins (37) (3
used) from carrier (9).
W2-8-13
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
W2-8-15
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
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)
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.
19. Install sun gear (13) to the carrier (12) assembly.
(Repeat it twice.)
: 490 Nm (50 kgfm, 361 lbfft)
W2-8-17
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
Disassemble Raising/Lowering Motor
CAUTION: Raising/Lowering motor weight: 13. Remove pistons (8) (9 used) from retainer (11).
Approx. 140 kg (310 lb)
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).
NOTE: Drain off gear oil in the clean container and
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).
11. Remove rotor (10) from shaft (20) and piston (8).
W2-8-21
CRANE UPPER / Raising/Lowering Mechanism
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
W2-8-22
CRANE UPPER / Raising/Lowering Mechanism
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).
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).
W2-8-23
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
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).
before disassembling.
14. Remove plug (15) from casing (6).
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
3. Remove O-ring (12) from plug (11).
17. Remove O-ring (14) from plug (13).
4. Remove stopper (7) from casing (6).
W2-8-25
CRANE UPPER / Raising/Lowering Mechanism
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
W2-8-26
CRANE UPPER / Raising/Lowering Mechanism
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
CRANE UPPER / Raising/Lowering Mechanism
(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
11
4. Remove the lever (8 to 10) assemblies and the
harness connector for pressure sensors (23) (2 15
used).
13
14
W2BC-02-09-002
W2-9-1
CRANE UPPER / Remote Control Valve
6. Remove hoses (19) (10 used) from elbows (20,
21) with remote control valve (13) attached. 12 13 12 14
: 22 mm
25 19
14
21
21
22
25
19
23 25 19 20 W2BC-02-09-003
W2-9-2
CRANE UPPER / Remote Control Valve
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)
21
21
22
25
19
23 25 19 20 W2BC-02-09-003
W2-9-3
CRANE UPPER / Remote Control Valve
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).
13
14
W2BC-02-09-002
2
1
W24X-02-01-001
W2-9-4
CRANE UPPER / Remote Control Valve
REMOVE AND INSTALL SWING REMOTE
CONTROL VALVE
2
1
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
18 W2BC-02-09-004
W2-9-5
CRANE UPPER / Remote Control Valve
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)
W24X-02-01-001
W2-9-6
CRANE UPPER / Remote Control Valve
(Blank)㩷
W2-9-7
CRANE UPPER / Remote Control Valve
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
CRANE UPPER / Remote Control Valve
W2-9-9
CRANE UPPER / Remote Control Valve
Disassemble Remote Control Valve
39, 25
W25N-02-09-005
30
39
W25N-02-09-006
W2-9-10
CRANE UPPER / Remote Control Valve
39
W25N-02-09-007㩷
W25N-02-09-008
27
W25N-02-09-009㩷
W2-9-11
CRANE UPPER / Remote Control Valve
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
W333-02-09-001㩷
12
W324-02-09-013
W324-02-09-014
W2-9-12
CRANE UPPER / Remote Control Valve
13. Remove socket bolt (36). Remove lever (37) from
36
disc (33).
: 6 mm
37
33
W324-02-09-015
W324-02-09-016
W25N-02-09-010
W2-9-13
CRANE UPPER / Remote Control Valve
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
CRANE UPPER / Remote Control Valve
W2-9-15
CRANE UPPER / Remote Control Valve
Assemble Remote Control Valve
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
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
CRANE UPPER / Remote Control Valve
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).
W324-02-09-018
W25N-02-09-008
11
12
W324-02-09-013
32
W324-02-09-019㩷
W2-9-17
CRANE UPPER / Remote Control Valve
10. Install the push rod (32) assembly to casing (39).
32
39
W25N-02-09-007㩷
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
CRANE UPPER / Remote Control Valve
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)
39
W25N-02-09-012
39, 25
W25N-02-09-005
W2-9-19
CRANE UPPER / Remote Control Valve
(Blank)
W2-9-20
CRANE UPPER / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT
Removal
Installation W24X-02-10-001
W2-10-1
CRANE UPPER / Solenoid Valve
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
W2-10-2
CRANE UPPER / Solenoid Valve
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)
W2-10-3
CRANE UPPER / Solenoid Valve
(Blank)
W2-10-4
CRANE UPPER / Cylinder
REMOVE AND INSTALL
COUNTERWEIGHT INSTALLATION /
REMOVAL CYLINDER
Removal 3
4
W2BC-02-11-002
W2-11-1
CRANE UPPER / Cylinder
Installation
4
W2BC-02-11-001
4
W2BC-02-11-002
W2-11-2
CRANE UPPER / Cylinder
(Blank)
W2-11-3
CRANE UPPER / Cylinder
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
W2-11-4
CRANE UPPER / Cylinder
Disassemble Cylinder
W2-11-5
CRANE UPPER / 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
W2-11-6
CRANE UPPER / Cylinder
9. Remove dust seal (12), ring (6), backup ring (11),
packing (10) and bushing (5) from the inner side
of cover (3).
W2-11-7
CRANE UPPER / Cylinder
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
W2-11-8
CRANE UPPER / Cylinder
Assemble Cylinder
47mm
W25N-03-07-008
W2-11-9
CRANE UPPER / 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
W2-11-10
CRANE UPPER / Cylinder
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.
W2-11-11
CRANE UPPER / Cylinder
(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
2BDW-3-1
(Blank)
2BDW-3-2
BASE CARRIER / Turntable Bearing
REMOVE AND INSTALL TURNTABLE 6
BEARING 11
Removal
W25N-03-01-002
10
W25N-03-01-003
W3-1-1
BASE CARRIER / Turntable Bearing
W25N-03-01-004
W3-1-2
BASE CARRIER / Turntable Bearing
Installation
W25N-03-01-005
5 4
W2BC-03-01-001
W3-1-3
BASE CARRIER / Turntable Bearing
DISASSEMBLE TURNTABLE BEARING
1 2 3 2 4 5
8 6 7 6
W25N-03-01-006
W3-1-4
BASE CARRIER / Slewing Ring
Disassemble Turntable Bearing
W25N-03-01-007
W25N-03-01-008
7
W105-03-01-010㩷
W3-1-5
BASE CARRIER / Slewing Ring
ASSEMBLE TURNTABLE BEARING
1 2 3 2 4 5
8 6 7 6
W25N-03-01-006
W3-1-6
BASE CARRIER / Slewing Ring
Assemble Turntable Bearing
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
W25N-03-01-012㩷
W25N-03-01-007
W3-1-7
BASE CARRIER / Slewing Ring
(Blank)㩷
㩷
W3-1-8
BASE CARRIER / Travel Mechanism
REMOVE AND INSTALL TRAVEL
MECHANISM
Removal
W25N-03-02-001
W3-2-1
BASE CARRIER / Travel Mechanism
Installation
: 19 mm
: 1400 Nm (143 kgfm, 1030 lbfft)
Cover
W25N-03-02-001
W3-2-2
BASE CARRIER / Travel Mechanism
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).
W3-2-3
BASE CARRIER / Travel Mechanism
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
W3-2-4
BASE CARRIER / Travel Mechanism
Disassemble Travel Mechanism (Reduction Gear)
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).
W3-2-5
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
W3-2-8
BASE CARRIER / Travel Mechanism
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).
W3-2-9
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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)
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
BASE CARRIER / Travel Mechanism
46
38
44
39
40
41
42
43
49 50 20
W25N-03-02-003
W3-2-12
BASE CARRIER / Travel Mechanism
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.
W3-2-13
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
Disassemble Travel Motor
W3-2-17
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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).
W3-2-19
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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.
W3-2-23
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
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)
W3-2-25
BASE CARRIER / Travel Mechanism
5 4 3
6
52 1
14
2
W25N-03-02-006
W3-2-26
BASE CARRIER / Travel Mechanism
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
BASE CARRIER / Travel Mechanism
Special Tool
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
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
㱢11㩷
10.2
9.8
2 2
3 7 3 7
22 22
W25N-03-02-008
W3-2-28
BASE CARRIER / Travel Mechanism
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
21
0.5
C3
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
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
W3-2-29
BASE CARRIER / Travel Mechanism
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)
Standard Allowable Limit
W3-2-30
BASE CARRIER / Rotating Joint
REMOVE AND INSTALL ROTATING JOINT
8
W2BC-03-03-001
26
28
3. Remove bolt (24) and remove plate (25). 27
24
: 24 mm 25
W3-3-1
BASE CARRIER / Rotating Joint
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)
W3-3-2
BASE CARRIER / Rotating Joint
(Blank)
W3-3-3
BASE CARRIER / Rotating Joint
DISASSEMBLE ROTATING JOINT
1 9
3
2㩷
10
11
5
12
7
13
14
15
W25N-03-03-003㩷
W3-3-4
BASE CARRIER / Rotating Joint
Disassemble Rotating Joint
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).
W3-3-5
BASE CARRIER / Rotating Joint
ASSEMBLE ROTATING JOINT
2㩷 1 3
7
5
6
10
11
13
12
14
15
W25N-03-03-005
W3-3-6
BASE CARRIER / Rotating Joint
Assemble Rotating Joint
6. Install O-ring (2) and scraper (1) on cover (4). 㱢70 or more㩷
20
(38 to 42 lbfft)
7
1
Special Tool (B)
W25N-03-03-006
W3-3-7
BASE CARRIER / Rotating Joint
MAINTENANCE STANDARD
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
Installation W324-03-05-002
㩷
㩷
W3-4-1
BASE CARRIER / Track Take-Up Tumbler
DISASSEMBLE TRACK TAKE-UP TUMBLER
1 2㩷 3 4 5 6 7 8
W25N-03-04-001
W3-4-2
BASE CARRIER / Track Take-Up Tumbler
Disassemble Track Take-Up Tumbler
W3-4-3
BASE CARRIER / Track Take-Up Tumbler
ASSEMBLE TRACK TAKE-UP TUMBLER
1 2㩷 3 4 5 6 7 8
W25N-03-04-001
W3-4-4
BASE CARRIER / Track Take-Up Tumbler
Assemble Track Take-Up Tumbler
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).
W3-4-5
BASE CARRIER / Track Take-Up Tumbler
MAINTENANCE STANDARD
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)
Standard Allowable Limit Remedy
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
BASE CARRIER / Track Take-Up Tumbler
Travel Drive Sprocket
A B
W25N-03-04-003
Unit : mm (in)
Standard Allowable Limit Remedy
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
BASE CARRIER / Track Take-Up Tumbler
(Blank)㩷
㩷
W3-4-8
BASE CARRIER / Upper and Lower Rollers
REMOVE AND INSTALL UPPER ROLLER
Removal
2 1
W25N-03-05-001
When
extending jack
When W25N-03-05-012㩷
releasing jack
W25N-03-05-002
W3-5-1
BASE CARRIER / Upper and Lower Rollers
4. Remove jack (4). Hoist the track shoe so that
upper roller (8) may keep away from track shoe.
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)
W324-03-06-004
W3-5-2
BASE CARRIER / Upper and Lower Rollers
(Blank)
W3-5-3
BASE CARRIER / Upper and Lower Rollers
DISASSEMBLE UPPER ROLLER
1
2㩷
3
6 7
3
2
5 1
W25N-03-05-007
W3-5-4
BASE CARRIER / Upper and Lower Rollers
Disassemble Upper Roller
1. Remove plug (2) and drain engine oil out from the
upper roller.
: 5 mm
W3-5-5
BASE CARRIER / Upper and Lower Rollers
ASSEMBLE UPPER ROLLER
5 3 2㩷
7 8 6 4
W25N-03-05-008
W3-5-6
BASE CARRIER / Upper and Lower Rollers
Assemble Upper Roller
W3-5-7
BASE CARRIER / Upper and Lower Rollers
MAINTENANCE STANDARD
Upper Roller
B A B
C
W25N-03-05-010
Unit : mm (in)
Standard Allowable Limit Remedy
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)
Standard Allowable Limit Remedy
W3-5-8
BASE CARRIER / Upper and Lower Rollers
REMOVE AND INSTALL LOWER ROLLER
Removal
4 3
When
extending jack
5 6 7
W25N-03-05-002
W3-5-9
BASE CARRIER / Upper and Lower Rollers
5. Remove bolt (8).
: 36 mm
W3-5-10
BASE CARRIER / Upper and Lower Rollers
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
2 1
W25N-03-05-001
W3-5-11
BASE CARRIER / Upper and Lower Rollers
DISASSEMBLE LOWER ROLLER
1 2 3 4
6 7 8
W25N-03-05-009
W3-5-12
BASE CARRIER / Upper and Lower Rollers
Disassemble Lower Roller
1. Remove plug (8) and drain engine oil out from the
lower roller.
: 6 mm
W3-5-13
BASE CARRIER / Upper and Lower Rollers
ASSEMBLE LOWER ROLLER
1 2 3 4
6 7 8
W25N-03-05-009
W3-5-14
BASE CARRIER / Upper and Lower Rollers
Assemble Lower Roller
W3-5-15
BASE CARRIER / Upper and Lower Rollers
MAINTENANCE STANDARD
Lower Roller
B A B
D
W25N-03-05-011
Unit : mm (in)
Standard Allowable Limit Remedy
A 60 (2.36)
(Shaft / Bushing)
Unit : mm (in)
Standard Allowable Limit Remedy
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
frame parallel to the track shoe.
• Before removing the track shoe, travel the
machine slightly forward. In case the slack of track
shoe is located at the top of the travel drive
sprocket, the track shoe can be removed easily.
Removal
2 1
1. Remove bolt (1). Remove cover (2) from the side W25N-03-05-001
frame.
: 19 mm 4 3
W25N-03-05-002
8
9
10
11
W333-03-07-001
W3-6-1
BASE CARRIER / Track Shoe
7. Operate the travel lever into the reverse position
slowly. Extend track shoe (8).
W2BC-03-06-003
850 mm Wooden Block
W2BC-03-06-004
W324-03-05-001
W3-6-2
BASE CARRIER / Track Shoe
Installation
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
BASE CARRIER / Track Shoe
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).
2 1
W25N-03-05-001
W3-6-4
BASE CARRIER / Track Shoe
MAINTENANCE STANDARD
Shoe
W2BC-03-06-001
W2BC-03-06-002
Unit: mm (in)
Standard Allowable Limit Remedy
A 80 (3.15)
B 26 (1.02)
C 50 (1.97)
D 15 (0.59) 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)
Standard Allowable Limit Remedy
A 38 (1.50) 34 (1.34)
Replace
B 311 (12.2)
W3-6-5
BASE CARRIER / Track Shoe
(Blank)
W3-6-6
BASE CARRIER / Cylinder
REMOVE AND INSTALL RETRACT
CYLINDER
Removal
Wooden Block 850 mm
W2BC-03-07-001
W3-7-1
BASE CARRIER / Cylinder
3. Remove retainers (3) (4 used) and remove pins
(4) (4 used).
11
W2BC-03-07-002
W2BC-03-07-003
5 6 5
W2BC-03-07-004
3 4
W3-7-2
BASE CARRIER / Cylinder
11 10
W2BC-03-07-013
16. Pull out cylinder (12) from lower frame (8). Hoist
12
and remove cylinder (12). W2BC-03-07-011
W3-7-3
BASE CARRIER / Cylinder
Installation
W3-7-4
BASE CARRIER / Cylinder
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
CAUTION: Cylinder (4) weight: 125 kg (275 lb)
12
6. Make cylinder (12) parallel by using a sub crane. W2BC-03-07-011
Wooden Block
W2BC-03-07-010
12 15 14
11 10
W2BC-03-07-013
W3-7-5
BASE CARRIER / Cylinder
9. Install pins (9) (2 used) with retainers (8) (2 used).
10
11
W2BC-03-07-002
W2BC-03-07-003
5 6 5
W2BC-03-07-004
3 4
W3-7-6
BASE CARRIER / Cylinder
(Blank)
W3-7-7
BASE CARRIER / Cylinder
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
BASE CARRIER / Cylinder
Disassemble Cylinder
Dimension a㧦
Special Tool (A)=62mm (2.44 in)
Special Tool (B)=90mm (3.54 in)
W25N-03-07-008
W3-7-9
BASE CARRIER / Cylinder
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
BASE CARRIER / Cylinder
8. Remove backup rings (15) (2 used) and O-rings
(16) (2 used) from the inner side of piston (17).
W3-7-11
BASE CARRIER / Cylinder
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
BASE CARRIER / Cylinder
Assemble Cylinder
(16 to 20 lbfft)
W3-7-13
BASE CARRIER / Cylinder
2 3 4 5 8 22
W25N-03-07-009
W3-7-14
BASE CARRIER / Cylinder
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.
13. Install boot (4) to piston rod (2) and cylinder tube
(22) with boot bands (3, 5).
W3-7-15
BASE CARRIER / Cylinder
(Blank)
W3-7-16
BASE CARRIER / Cylinder
REMOVE AND INSTALL TRACK
ADJUSTMENT CYLINDER (OPTIONAL)
• Remove and install the track shoe in the right
procedures safely.
• Remove the track shoe on the level, solid ground.
Remove the track shoe with the upper revolving
frame parallel to the track shoe.
• Before removing the track shoe, travel the
machine slightly forward. In case the slack of
W2BC-03-07-007
track shoe is located at the top of the travel drive
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 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
BASE CARRIER / Cylinder
9
8. Remove nuts (12) (4 used) and remove yoke (11).
: 65 mm
17 12 13 14
W2BC-03-07-007
11 12
13 14 W2BC-03-07-009
W3-7-18
BASE CARRIER / Cylinder
• Remove and install the track shoe in the right
procedures safely. 9 11 12 13 15 14
• Remove the track shoe on the level, solid ground.
Remove the track shoe with the upper revolving
frame parallel to the track shoe.
• Before removing the track shoe, travel the
machine slightly forward. In case the slack of 16
track shoe is located at the top of the travel drive
sprocket, the track shoe can be removed easily.
Installation
17 12 13 14
W2BC-03-07-007
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
Take-Up Tumbler
6. Hoist and install track take-up idler (9) to the side Bearing
frame.
W324-03-05-002
W3-7-19
BASE CARRIER / Cylinder
11. Turn nut (12) until nut (12) comes in contact with
frame (A).
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
BASE CARRIER / Cylinder
(Blank)
W3-7-21
BASE CARRIER / Cylinder
DISASSEMBLE TRACK ADJUSTMENT CYLINDER
2
8
3
W2BD-03-07-001
W3-7-22
BASE CARRIER / Cylinder
Disassemble Track Adjustment Cylinder
4. Pull out the piston rod (9) from the cylinder tube (7).
W3-7-23
BASE CARRIER / Cylinder
ASSEMBLE TRACK ADJUSTMENT CYLINDER
1 2 3 4 5 6 7
9 8
W2BC-03-07-014
W3-7-24
BASE CARRIER / Cylinder
Assemble Track Adjustment Cylinder
W3-7-25
BASE CARRIER / Cylinder
(Blank)
W3-7-26
BASE CARRIER / Cylinder
REMOVE AND INSTALL JACK-UP
CYLINDER (OPTIONAL)
Removal
2 3
1. Stop the engine. Operate the control lever several
times and release the remaining pressure in the
circuit.
W3-7-27
BASE CARRIER / Cylinder
6. Remove the other jack-up cylinder (3 places) in
the same procedures.
Installation
W3-7-28
BASE CARRIER / Cylinder
(Blank)
W3-7-29
BASE CARRIER / Cylinder
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
BASE CARRIER / Cylinder
Disassemble Jack-Up Cylinder
W3-7-31
BASE CARRIER / Cylinder
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
BASE CARRIER / Cylinder
Assemble Jack-Up Cylinder
W3-7-33
BASE CARRIER / Cylinder
(Blank)
W3-7-34
BASE CARRIER / Control Valve
REMOVE AND INSTALL 6-UNIT CONTROL
VALVE FOR RETRACT AND JACK-UP
(OPTIONAL)
Removal
W2BC-03-08-002
Installation
5
W3-8-1
BASE CARRIER / Control Valve
DISASSEMBLE 6-UNIT CONTROL VALVE
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
W3-8-2
BASE CARRIER / Control Valve
Disassemble 6-Unit Control Valve
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).
W3-8-3
BASE CARRIER / Control Valve
ASSEMBLE 6-UNIT CONTROL VALVE
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
W3-8-4
BASE CARRIER / Control Valve
Assemble 6-Unit Control Valve
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
W3-8-5
BASE CARRIER / Control Valve
W3-8-6
SECTION 1
GENERAL
—CONTENTS—
Group 1 Specifications
Specifications...........................................................
(Refer to Link-Belt Technical Data Manual.)
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
GENERAL / Component Layout
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
GENERAL / Component Layout
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
GENERAL / Component Layout
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
GENERAL / Component Layout
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
GENERAL / Component Layout
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.)
T2BC-01-02-006
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
GENERAL / Component Layout
Monitor Panel
1
15
14
13
2
12
11
10
9
3
6
4
T2BC-01-02-007
T1-2-7
GENERAL / Component Layout
Control Panel
1 2 3 4 5 6 7 8 9
T2BC-01-02-008
12 11 10
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
GENERAL / Component Layout
Overhead Panel
T2BC-01-02-011
T2BC-01-02-012
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
GENERAL / Component Layout
Relay Panel
1
2
3
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
GENERAL / Component Layout
Brake Pedal Unit
Cab Floor㩷
T2BC-01-02-017
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
GENERAL / Component Layout
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
GENERAL / Component Layout
Batteries
7 10
3
6 4 9
㩷 T25N-01-02-005
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
GENERAL / Component Layout
Pump Mechanism
Fourth Drum Brake Cooling /
Hydraulic Tagline Drive /
Reeving Winch Drive Pump㩷
(Optional)㩷
Pilot Pump㩷
Slewing Pump
Machine Front㩷
䌔2䌂䌃-01-02-028
Machine Rear㩷
T1-2-14
GENERAL / Component Layout
Front / Rear Control Valve
1 1
2* 㩷 3 4*1 5 6 7 8
Machine Left
Machine
Rear㩷
Machine
Machine Right㩷 Front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
GENERAL / Component Layout
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
T1-2-16
GENERAL / Component Layout
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
4 5 6 7 8
A A
Machine Front㩷
A
C C C
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
GENERAL / Component Layout
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
Accumulator㩷
Slewing Remote
M25N-07-030 Control Pressure
1 Sensor Block㩷
T25N-01-02-019
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
GENERAL / Component Specifications
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
GENERAL / Component Specifications
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
GENERAL / Component Specifications
ENGINE ACCESSORIES
Radiator assembly
Manufacturer .................................. Tokyo Radiator
Type................................................ Radiator / oil cooler / intercooler in-line type
Dry weight ...................................... 150 Kg (330 lb)
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
GENERAL / Component Specifications
HYDRAULIC EQUIPMENT
Pump Mechanism
Speed ratio ...................................................................Main pump (1, 2) 1.0
Slewing pump 1.0
Pilot pump 1.0
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
T1-3-5
GENERAL / Component Specifications
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)
T1-3-6
GENERAL / Component Specifications
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
Slewing mechanism
Type..............................................................................2-stage planetary gear reduction
Reduction ratio .............................................................20.04
Main composition .........................................................Reduction gear and slewing motor
Weight ..........................................................................219×2 kg (483×2 lb)
Slewing motor
Type..............................................................................Swash plate type constant displacement axial plunger motor
Model ...........................................................................M5X180CHB
Theoretical displacement .............................................158.9 cm3 (9.7 in3)/rev
Travel mechanism
Type..............................................................................3-stage planetary gear reduction
Reduction ratio .............................................................143.314
Main composition .........................................................Reduction gear and travel motor
Weight ..........................................................................884 kg (1860 lb)
Travel motors
Type..............................................................................Swash plate type variable displacement axial plunger motor
Model ...........................................................................MSF-230VP-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)
T1-3-7
GENERAL / Component Specifications
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
Dia. .............................................................................Bore dia. : 140 mm (5.5 in) Rod dia. : 65 mm (2.6 in)
Fully retracted length ...................................................1530 mm (60.2 in)
Stroke ...........................................................................1000 mm (39.4 in)
Weight ..........................................................................125 kg (276 lb)
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)
T1-3-8
GENERAL / Component Specifications
Reeving solenoid valve 1 (Hydraulic tagline using combinedly) (optional)
Type .............................................................................DE6P10-208-WD24-C54
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
Overheat switch
Manufacturer ................................................................Mitsubishi Motors (ME049264)
Operating temperature.................................................101±2 °C (214±36 °F)
T1-3-9
GENERAL / Component Specifications
Coolant temperature gauge sensor (water temp. unit)
Manufacturer ................................................................MITSUBISHI Motors (MC844972)
Operating temperature.................................................93 to 97 °C (199 to 207 °F)
Fuel sensor
Resistance ...................................................................Idle : 90 Ω Upper limit : 10 Ω
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
2BCT-2-1
(Blank)
2BCT-2-2
SYSTEM / Control System
OUTLINE
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
SYSTEM / Control System
ENGINE CONTROL
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
SYSTEM / Control System
Key Switch
MC2/A
T25N-02-01-038
T2-1-3
SYSTEM / Control System
Low/High Idle Calibration
Purpose: The low idle position and high idle position of
the engine governor lever are stored in
MC2/A.
T2-1-4
SYSTEM / Control System
Key Switch
Accelerator Pedal
Accelerator Grip
Accelerator
Lock Switch
Governor Motor
Potentio Sensor
MC2/B
T25N-02-01-039
T2-1-5
SYSTEM / Control System
Engine Speed Control
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
SYSTEM / Control System
Accelerator Grip
Accelerator Pedal
Accelerator ON
Lock Switch
SET
MC2/A
T25N-02-01-014
T2-1-7
SYSTEM / Control System
High Idle Cut Control
Accelerator Grip
ON Accelerator
Pedal
Accelerator
Lock Switch
MC2/A
Engine Speed
Detection Sensor
T25N-02-01-041
T2-1-8
SYSTEM / Control System
(Blank)
T2-1-9
SYSTEM / Control System
Fuel Injection Timing Control
ECU
To
MC2/A
Coolant Temperature
Sensor
Timing Sensor
T2-1-10
SYSTEM / Control System
Operation of TCV Solenoid Valve
Port A T25N-02-01-004
Port A T25N-02-01-003
Port A
T25N-02-01-002
T2-1-11
SYSTEM / Control System
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
SYSTEM / Control System
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
Item
T2-1-13
SYSTEM / Control System
Rack Zero Calibration
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
SYSTEM / Control System
ECU
Rack Sensor
MC2/B
T25N-02-01-035
T2-1-15
SYSTEM / Control System
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
SYSTEM / Control System
Accelerator Grip
CAN
Displacement Angle
Proportional Solenoid
Valve
Engine Pilot
Pump
Main Main
Pump 1 Pump 2
T2BC-02-01-001
T2-1-17
SYSTEM / Control System
Main Pump Power Increase Control
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
SYSTEM / Control System
Power
Increase
Solenoid
Valve
Pilot
Engine Pump
Main Main
Pump 1 Pump 2
T2BC-02-01-002
T2-1-19
SYSTEM / Control System
Power Increase Pressure Calibration
Operation:
1. After completion of basic calibration operation
(refer to T4), start the engine.
2. When turning ON the auto stop cancellation front
drum switch and auto stop cancellation rear drum
switch, MC2/B sends a signal to MC2/A.
3. MC2/A makes the pilot pressure drop warning
lamp blink.
4. If the pilot pressure drop indicator blinks at a cycle
other that the specified cycle of 0.5-second ON
and 0.5-second OFF, the auto stop cancellation
front drum switch and the auto stop cancellation
rear drum switch are turned OFF.
5. When turning the accelerator lock switch ON and
OFF, calibration can be made.
6. When selecting the power increase pressure
calibration mode, MC2/A changes the power in-
crease solenoid valve current at the rate of + 7
mA/3 sec.
7. When the power increase pressure reaches 0.3
MPa, MC2/A stores the power increase output
current as a calibrated value by the accelerator
lock switch.
(Accelerator lock switch ON→OFF)
T2-1-20
SYSTEM / Control System
Pilot Pressure
Drop Indicator Auto Stop Cancellation
Rear Drum Switch
4-Spool Solenoid
Valve Unit
Power
Increase
Solenoid
Valve
T2-1-21
SYSTEM / Control System
Full Rack Calibration
Operation:
1. After completion of basic calibration operation
(refer to T4), start the engine.
2. When the auto stop cancellation derricking drum
switch is turned ON, the signal is input from
MC2/B to MC2/A.
3. MC2/A turns ON and OFF the pilot pressure drop
warning lamp.
4. If the pilot pressure drop indicator blinks at a cycle
other than the specified cycle of 0.5-second ON
and 0.5-second OFF, the auto stop cancellation
derricking drum switch is turned OFF.
5. When turning the accelerator lock switch is turned
ON and OFF, calibration can be made.
6. At this time, MC2/A sends signals to the governor
motor and the power increase solenoid valve to
reduce the power so that the engine speed is set
to high idle, and main pump delivery flow to
maximum.
7. When the engine speed is 2000 min-1 or higher,
and the pilot pressure drop indicator blinks at a
cycle of 0.1 second ON and 0.4 second OFF,
MC2/A sends a signal to the power increase so-
lenoid valve when the slewing lever and front
drum lever are moved for quick hoisting.
8. The power increase pressure varies at the rate of
-0.01MPa/sec through the power increase sole-
noid valve, increasing the horsepower.
9. When the engine speed reaches the preset level
(1950 min-1) or less under this condition, MC2/A
receives a signal from the governor potentio
sensor, and stores it as a full rack.
10. In addition, when the engine speed reaches the
preset speed (1950 min-1) or less, MC2/A auto-
matically reads the rack data. (Upon completion of
reading, the engine speed is set to low idle, pump
delivery flow to minimum, and power increase
solenoid valve current to the preset level (0 mA).)
T2-1-22
SYSTEM / Control System
Accelerator Lock
Switch
Auto Stop Cancellation Derricking
Drum Switch
4-Spool Solenoid
Valve Unit
Power
Increase
Solenoid
Valve
Governor
Potentio
Sensor
T2-1-23
SYSTEM / Control System
OTHER CONTROL
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
SYSTEM / Control System
MC2/A
From Battery
Slewing Mechanism
Battery Relay
Slewing Alarm
Lamp Relay
Slewing Control
Valve
Slewing Pump
Flasher Relay
Pilot Pump
4-Spool Solenoid Valve Unit
T2BC-02-01-005
T2-1-25
SYSTEM / Control System
Drum Rotation Sensing System
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
SYSTEM / Control System
NOTE: The illustration below shows the front drum rotation sensing system in operation.
Control Lever
Front Drum㩷
Front Drum Rotation
Detection Sensor B
Rear Drum㩷
Boom Derricking
Drum Rotation
Detection Sensor A
Derricking MC2/A
Drum㩷
T25N-02-01-020
T2-1-27
SYSTEM / Control System
Pilot Pressure Drop Alarm Lamp Control
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
From Battery
T2BC-02-01-006
T2-1-28
SYSTEM / Control System
Winch Brake Control
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
SYSTEM / Control System
Brake Release
Solenoid Valve
Brake
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
SYSTEM / Control System
• Drum Brake Mode Control (Free Mode Control)
T2-1-31
SYSTEM / Control System
Brake Pedal
(Fourth)
(Optional)
Brake Release
Solenoid Valve
(Third) (Optional)
Rear Brake
Depressing
Sensor
Brake Release
Solenoid Valve Front Brake De-
(Front) pressing Sensor
Pilot Pump
T2BC-02-01-008
T2-1-32
SYSTEM / Control System
• 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
Brake Mode
Selection Key Switch
Third / Fourth Hoisting
Remote Control Pressure
MC2/A Sensor
Third / Fourth Lowering
Remote Control Pressure
Third / Fourth Brake Mode Sensor
Selection Switch
4-Spool Solenoid
Valve Unit
(Lowering) (Hoisting)
Pilot Pump T2BC-02-01-015
T2-1-33
SYSTEM / Control System
• 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
SYSTEM / Control System
Derricking Drum
Derricking
Motor Brake
Derricking
Drum Lock
Derricking
Motor
Remote Control
Pressure Sensor
4-Spool Solenoid
Valve Unit
Pilot Pump
Derricking Drum T2BC-02-01-009
Unlocking Solenoid
Valve
T2-1-35
SYSTEM / Control System
Engine Start Interlock Control
Interlock Indication
Lamp
Engine Starting
Relay
Starter Relay 1
Starter Motor
T25N-02-01-033
T2-1-36
SYSTEM / Control System
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.
Front
Drum
Rear
Drum
T2-1-37
SYSTEM / Control System
Emergency Operation Control
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
T2-1-38
SYSTEM / Control System
Front
Motor
Rear Motor Brake
Release Solenoid
Valve
Emergency
Operation Switch Rear
Motor
Fourth
Motor
(Optional)
Boom
Slewing Motor
Derricking
Motor
Pilot Pump
4-Spool Solenoid Valve Unit
T2BC-02-01-022
T2-1-39
SYSTEM / Control System
Boom Derricking Drum Auto Stop Control
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
SYSTEM / Control System
Derricking Drum
Hoisting Proportional
Solenoid Valve
Derricking Drum
Lowering Proportional
Solenoid Valve
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
SYSTEM / Control System
Front Drum Auto Stop Control
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
SYSTEM / Control System
Boom Second
Overhoist Prevention
Main Hook
Overhoist
Prevention
Front Drum
Hoisting Stop
Sub Hook
Overhoist
Prevention Front Drum
Lowering Stop
Main Hook
Overhoist
Prevention
Sub Hook
Overhoist
Prevention
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-013
T2-1-43
SYSTEM / Control System
Rear Drum Auto Stop Control
Operation:
1. MC2/B receives voltage signals from the over-
hoist prevention switch, IDU and release switch.
2. MC2/B sends a voltage signal to the derricking
drum hoisting proportional solenoid valve or the
derricking drum lowering proportional solenoid
valve.
3. As a result, the rear drum hoisting proportional
solenoid valve or the rear drum lowering propor-
tional solenoid valve operates to block the pilot
pressure oil flowing through the rear spool (low) in
the front control valve.
4. The rear spool (low) returns to neutral position, so
that pressure oil from pump 1 does not flow, and
the rear motor stops.
T2-1-44
SYSTEM / Control System
Main Hook
Overhoist
Prevention
Rear Drum
Hoisting Stop
Sub Hook
Overhoist Rear Drum
Prevention Lowering Stop
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
SYSTEM / Control System
Fourth Drum Auto Stop Control (Optional)
Operation:
1. MC2/B receives voltage signals from the over-
hoist prevention switch, IDU and release switch.
2. MC2/B sends a voltage signal to the fourth drum
hoisting proportional solenoid valve or the fourth
drum lowering proportional solenoid valve.
3. As a result, the fourth drum hoisting proportional
solenoid valve or the fourth drum lowering pro-
portional solenoid valve operates to block the pilot
pressure oil flowing through the fourth spool in the
rear control valve.
4. Then, the fourth spool returns to neutral position,
so that pressure oil from pump 2 does not flow,
and the third motor stops.
T2-1-46
SYSTEM / Control System
Boom Second
Overhoist Prevention
Main Hook
Overhoist
Prevention Fourth Drum
Hoisting Stop
Sub Hook
Overhoist Fourth Drum
Prevention Lowering Stop
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
SYSTEM / Control System
Second Overhoist Auto Stop Control
Operation:
1. MC2/B receives voltage signals from the over-
hoist prevention switch in the case of overhoisting,
rope breaking or short-circuiting.
2. MC2/B turns OFF the second overhoisting sole-
noid valve in order to block the remote control
pressure oil flowing through the front, rear, fourth
and boom derricking pilot valve.
3. The spool corresponding to the front or rear con-
trol valve returns to neutral position, so that the
front, rear, fourth and boom derricking motors
stop.
4. MC2/B receives a signal from the remote control
pressure restoration switch when it is set to ON
position.
5. MC2/B turns ON the second overhoisting sole-
noid valve to deliver pressure oil from the pilot
pump to the front, rear, fourth and boom derrick-
ing remote control valve.
T2-1-48
SYSTEM / Control System
Second Overhoist
Solenoid Valve
Tower Jib
Second
Overhoist
Prevention
T2BC-02-01-018
T2-1-49
SYSTEM / Control System
Front Drum Surge Pressure Reduction Control
Operation:
1. MC2/B sends a voltage signal to the front drum
hoisting proportional solenoid valve or the front
drum lowering proportional solenoid valve.
2. At auto stop of the front drum, the front drum
hoisting proportional solenoid valve or the front
drum lowering proportional solenoid valve deliv-
ers pressure oil from the front remote control
valve to the hydraulic oil tank according to this
voltage signal. As a result, the surge pressure is
reduced.
Shouldering
Prevention
T2BC-02-01-019
T2-1-50
SYSTEM / Control System
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
drum lowering proportional solenoid valve.
T2-1-51
SYSTEM / Control System
T2BC-02-01-020
T2-1-52
SYSTEM / Control System
Warning Sound Output Control
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
T2-1-53
This Page Left Blank
Intentionally
SYSTEM / Hydraulic System
OUTLINE
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
T2-2-1
SYSTEM / Hydraulic System
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.
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
*Brake release
*Brake valve solenoid valve *Fourth drum
(Fourth drum) (Fourth drum) brake
T2-2-2
SYSTEM / Hydraulic System
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)
Pilot Relief Pilot Relief T2BC-02-02-012
Valve Valve
T2-2-3
SYSTEM / Hydraulic System
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.
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
Slewing Control
Slewing Motor
Valve
T2-2-4
SYSTEM / Hydraulic System
Slewing Remote
Control Valve Front / Rear / Boom
Derricking Remote
Control Valves
Fourth Drum / Travel
Remote Control Valve
Quick Draw Cylinder
Second Overhoist
Solenoid 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)
Fourth Drum
Slewing Pump (Optional)
Rear (High)
Hydraulic
Oil Tank Front (Low)
Boom Derricking
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
SYSTEM / Hydraulic System
NEUTRAL CIRCUIT
Slewing Control
Valve Oil Cooler
Hydraulic Oil Tank T2BC-02-02-013
T2-2-6
SYSTEM / Hydraulic System
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.
T2-2-7
SYSTEM / Hydraulic System
Low-Speed Front Operation
Pump 2 Pump 1
4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-02-014
Second Overhoist
Solenoid Valve
T2-2-8
SYSTEM / Hydraulic System
• 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
SYSTEM / Hydraulic System
High-Speed Operation
Pump 2 Pump 1
Pilot Pump
T2BC-02-02-015
Second Overhoist Solenoid Valve
T2-2-10
SYSTEM / Hydraulic System
Combined Operation Circuit
T2-2-11
SYSTEM / Hydraulic System
Front Low-Speed Operation + Rear Low-Speed Operation
Rear
(Low Speed)
Pump 2 Pump 1
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Solenoid Valve Pilot Pump
T2BC-02-02-022
T2-2-12
SYSTEM / Hydraulic System
• Front High Speed (2nd Gear) + Rear High Speed (2nd
Gear)
T2-2-13
SYSTEM / Hydraulic System
Front High-Speed Operation + Rear High-Speed Operation
Pump 2 Pump 1
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-023
T2-2-14
SYSTEM / Hydraulic System
• 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
SYSTEM / Hydraulic System
Front Low-Speed Operation + Rear High-Speed Operation
Pump 2 Pump 1
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-024
T2-2-16
SYSTEM / Hydraulic System
• Front High Speed (2nd Gear) + Rear Low Speed (1st
Gear)
T2-2-17
SYSTEM / Hydraulic System
Front High-Speed Operation + Rear Low-Speed Operation
Pump 2 Pump 1
4-Spool Solenoid
Valve Unit
Solenoid Overhoist
Pilot Pump
Solenoid Valve
T2BC-02-02-033
T2-2-18
SYSTEM / Hydraulic System
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
Pump 2
Second Overhoist
Solenoid Valve 4-Spool Solenoid
Valve Unit
Pilot Pump
T2BC-02-02-020
T2-2-19
SYSTEM / Hydraulic System
HOISTING BRAKE CIRCUIT
T2-2-20
SYSTEM / Hydraulic System
Fourth Drum
Brake (Optional) Rear Drum Brake
Brake Valve
Front Drum Brake
(Third Drum)
(Optional)
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
SYSTEM / Hydraulic System
Free Mode
T2-2-22
SYSTEM / Hydraulic System
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
SYSTEM / Hydraulic System
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
SYSTEM / Hydraulic System
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
SYSTEM / Hydraulic System
Auto Stop Control
T2-2-26
SYSTEM / Hydraulic System
Normal Operation
Rear Drum Front Drum
T2-2-27
SYSTEM / Hydraulic System
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.
Figure 1 Figure 2
Figure 3
T2BC-02-02-019
T2-2-28
SYSTEM / Hydraulic System
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
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
SYSTEM / Hydraulic System
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
Pump 1
MC2/B Boom Derricking Remote
Control Valve
Second Overhoist
Solenoid Valve Derricking Drum
Unlocking Solenoid Valve
Pilot Pump
4-Spool Solenoid Valve
Unit Valve T2BC-02-02-026
T2-2-30
SYSTEM / Hydraulic System
TRAVEL CIRCUIT
T2-2-31
SYSTEM / Hydraulic System
Low Travel Speed
Pilot Valve
Tilt Piston Pilot Valve
Tilt Piston
Pump 2 Pump 1
Pilot Pump
T2BC-02-02-027
High Travel Speed Selection
Solenoid Valve
T2-2-32
SYSTEM / Hydraulic System
• 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
SYSTEM / Hydraulic System
High Travel Speed
Pump 2 Pump 1
Pilot Pump
High Travel Speed Selection T2BC-02-02-028
Solenoid Valve
T2-2-34
SYSTEM / Hydraulic System
SLEWING CIRCUIT
T2-2-35
SYSTEM / Hydraulic System
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
SYSTEM / Hydraulic System
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.
To Lower Control
Valve (Optional)
Quick Draw
Spool
Rear Drum
Counterweight
Cylinder (Left)
Spool
Counterweight
Cylinder (Right)
Spool
Counterweight
Cylinder (Right) 4-Spool Control Valve
Sequence Valve
Counterweight / Quick T2BC-02-02-031
T2-2-37
SYSTEM / Hydraulic System
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.
Counterbalance
Valve
Counterweight
Cylinder (Left)
Spool
Port Relief Valve
Counterweight
Cylinder (Right)
Spool
T2-2-38
SYSTEM / Hydraulic System
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
SYSTEM / Hydraulic System
When Extending the Left Retract Cylinder, with Jack (Right Front) Extended
Retract Retract
Cylinder Cylinder
(Left) (Right)
Lower Control Valve
T2BC-02-02-034
4-Spool Control
Valve
Retract Quick Draw
(Left)
Lower Control
Jack-Up Cylinder (Left Rear)
Jack-Up
(Left Rear)
Center Joint
Counterweight
T2BC-02-02-010
Relief valve
T2-2-40
SYSTEM / Hydraulic System
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
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
SYSTEM / Hydraulic System
REEVING WINCH CIRCUIT (OPTIONAL)
Hydraulic Tagline
Reeving Winch
Reeving
Winch
Brake
Reeving
Winch
Motor
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
SYSTEM / Hydraulic System
TAKE-UP CIRCUIT (OPTIONAL)
Shuttle Valve
T2BC-02-02-030
T2-2-43
SYSTEM / Hydraulic System
(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
SYSTEM / Electric System
POWER CIRCUIT
Battery
Horn
MC2/A
MC2/B
Battery Relay
IDU
Radio
Air Conditioner
Key Switch
T25N-02-03-001
T2-3-2
SYSTEM / Electric System
(Blank)
T2-3-3
SYSTEM / Electric System
PREHEATING CIRCUIT
T2-3-4
SYSTEM / Electric System
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
SYSTEM / Electric System
• 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
SYSTEM / Electric System
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
SYSTEM / Electric System
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
SYSTEM / Electric System
Battery
Engine Start
Relay
Front Drum Brake MC2/A
Mode Selection Switch
Rear Drum Brake
Mode Selection Switch
Third / Fourth Drum
Brake Mode Selection Slewing
Switch (Optional) Brake Switch
Key Switch
Battery Relay
Starter
Relay 1
Starter
Motor
Starter
Relay 2
Alternator
T25N-02-03-006
T2-3-9
SYSTEM / Electric System
CHARGING CIRCUIT
T2-3-10
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
Alternator
Charge Relay
Charge Lamp
T25N-02-03-004
T2-3-11
SYSTEM / Electric System
ACCESSORIES CIRCUIT
Radio㩷
Battery
Horn Switch
Clearance Light
Horn Relay㩷 Horn㩷
(Optional)
Battery
Work Light㩷 Relay
Drum Light
(Optional)
Cigarette
Lighter㩷
T2BC-02-03-003
T2-3-12
SYSTEM / Electric System
ENGINE STOP CIRCUIT
T2-3-13
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
T25N-02-03-007
T2-3-14
SYSTEM / Electric System
SURGE VOLTAGE PREVENTION CIRCUIT
T2-3-15
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
Starter Relay2
Alternator
Charge Relay
T25N-02-03-008
T2-3-16
SYSTEM / Electric System
DRUM LOCK CIRCUIT
T2-3-17
SYSTEM / Electric System
NOTE: The following figure shows when each lock switch opens.
Battery
Key Switch
Battery Relay
Front Drum
Lock Switch Front Drum Lock
T25N-02-03-010
T2-3-18
SYSTEM / Electric System
SLEWING BRAKE RELEASE CIRCUIT
Slewing Brake
Switch: ON
MC/2A
To Slewing Brake
Pilot Pump
Slewing Brake Release T2BC-02-03-002
Solenoid Valve
T2-3-19
This Page Left Blank
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
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
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
COMPONENT OPERATION / Pump Mechanism
MAIN PUMP
2 3 4 4
5 6 5 4 3 2 T1F3-03-01-003
T3-1-2
COMPONENT OPERATION / Pump Mechanism
Delivery Flow Adjustment
Servo Piston
Valve Plate
5
4
2 T117-02-01-003
T3-1-3
COMPONENT OPERATION / Pump Mechanism
SLEWING PUMP
Splined to
Pump 2
T25N-03-01-005
1 2 3 4 5
T3-1-4
COMPONENT OPERATION / Pump Mechanism
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.
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
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
Section B-B
9 10 11 12 13 14 15 16
21 20 19 18 17 T1F3-03-01-008
T3-1-7
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
Section B-B
9 10 11 12 13 14 15 16
21 20 19 18 17 T25N-03-01-013
T3-1-9
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
Regulator Control Functions
T3-1-11
COMPONENT OPERATION / Pump Mechanism
• 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".)
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
COMPONENT OPERATION / Pump Mechanism
Operation of Regulator
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
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
• Flow rate increase (flow rate restoration)
T3-1-15
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
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)
P1
20
11
13 7
17
Increase Decrease
Displacement Angle
T25N-03-01-027
T3-1-17
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
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
COMPONENT OPERATION / Pump Mechanism
SOLENOID VALVE
1 2 3 A B 4
T Output P
5 Port
T25N-03-01-020
T3-1-21
COMPONENT OPERATION / Pump Mechanism
1 2 3 4 A B
T Output P
5 Port
T25N-03-01-022
T3-1-22
COMPONENT OPERATION / Pump Mechanism
PILOT PUMP, PUMP FOR COUNTER-
WEIGHT / QUICK DRAW / RETRACT AND 1
Suction Port
PUMP FOR HYDRAULIC TAGLINE AND
REEVING WINCH 2
Delivery Port
T137-02-03-005
T3-1-23
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Intentionally
COMPONENT OPERATION / Front / Rear Control Valve
OUTLINE
T3-2-1
COMPONENT OPERATION / Front / Rear Control Valve
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
COMPONENT OPERATION / Front / Rear Control Valve
17
1 3
14
13
4 2 8
7
10
T2BC-03-02-003
T3-2-3
COMPONENT OPERATION / Front / Rear Control Valve
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
COMPONENT OPERATION / Front / Rear Control Valve
12
17
7 2
4 13
14 9
T2BC-03-02-007
T3-2-5
COMPONENT OPERATION / Front / Rear Control Valve
INTERNAL CIRCUIT
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
COMPONENT OPERATION / Front / Rear Control Valve
Main Circuit
T2BC-03-02-018
Port P㩷 Port B㩷
T2BC-03-02-019
Port P㩷 Port B㩷
T3-2-7
COMPONENT OPERATION / Front / Rear Control Valve
Carry-Over Circuit (Optional)
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.
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
COMPONENT OPERATION / Front / Rear Control Valve
SPOOL
6
1- Passage㩷 2- Spool㩷
T3-2-9
COMPONENT OPERATION / Front / Rear Control Valve
Operation of Spool
Port P㩷
T25N-03-05-002
T3-2-10
COMPONENT OPERATION / Front / Rear Control Valve
MAIN RELIEF VALVE
Relief operation
T3-2-11
COMPONENT OPERATION / Front / Rear Control Valve
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
T3-2-12
COMPONENT OPERATION / Front / Rear Control Valve
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.
T3-2-13
COMPONENT OPERATION / Front / Rear Control Valve
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
T3-2-14
COMPONENT OPERATION / Front / Rear Control Valve
MAKE-UP VALVE Port T
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
COMPONENT OPERATION / Front / Rear Control Valve
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.
3
T2BC-03-02-022
T2BC-03-02-023
3
1 - Spool 3 - Holding Valve
(Low Speed Side)
2 - Spool
(High Speed Side)
T3-2-16
COMPONENT OPERATION / Front / Rear Control Valve
PRESSURE COMPENSATION VALVE
Compensating
Spool㩷
T2BC-03-02-024
T3-2-17
COMPONENT OPERATION / Front / Rear Control Valve
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
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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)
Retract
(Left)
Port T㩷
T2BC-03-04-001
T3-4-1
COMPONENT OPERATION / Lower Control Valve
INTERNAL COMPOSITION
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
COMPONENT OPERATION / Lower Control Valve
RELIEF VALVE
T2BC-03-04-006
1 2 3 4 5
T3-4-3
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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
T3-5-1
COMPONENT OPERATION / 4-Unit Control Valve
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
COMPONENT OPERATION / 4-Unit Control Valve
2 3
13
3 3
10
T2BC-03-05-008
T3-5-3
COMPONENT OPERATION / 4-Unit Control Valve
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
COMPONENT OPERATION / 4-Unit Control Valve
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
COMPONENT OPERATION / 4-Unit Control Valve
SOLENOID VALVE
Control Valve
Solenoid㩷 Spool㩷
Spring
Solenoid
Valve Spool
T2BC-03-05-007
T3-5-6
COMPONENT OPERATION / Remote Control Valve
OUTLINE
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
COMPONENT OPERATION / Remote Control Valve
• Hoisting Remote Control Valve
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
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
COMPONENT OPERATION / Remote Control Valve
• Slewing Remote Control Valve
T
P
1 2
P T 1
T25N-03-06-004
T2BC-03-06-003
T3-6-3
COMPONENT OPERATION / Remote Control Valve
CONSTRUCTION
T3-6-4
COMPONENT OPERATION / Remote Control Valve
Hoisting Remote Control Valve
1
2
3
5
6
7
1
2
T2BC-03-06-005
T3-6-5
COMPONENT OPERATION / Remote Control Valve
Travel Remote Control Valve
2
3
T2BC-03-06-006
T3-6-6
COMPONENT OPERATION / Remote Control Valve
D
Section D
T25N-03-06-011 T25N-03-06-012
T3-6-7
COMPONENT OPERATION / Remote Control Valve
DETENT FUNCTION
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.
T3-6-8
COMPONENT OPERATION / Remote Control Valve
2
A (First Detent
Position)㩷
3
B (Second Detent
Position)㩷
3
4
5 4
T25N-03-06-015
T3-6-9
COMPONENT OPERATION / Remote Control Valve
OPERATION
3 4 5
Port T
(To hydraulic oil tank)
Port P
(From pilot pump)
Output Port
T324-02-07-010
T3-6-10
COMPONENT OPERATION / Remote Control Valve
Neutral Position
Pressure)㩷
㪈㩷㪄㩷 Return Spring㩷 2 - Spool㩷
T3-6-11
COMPONENT OPERATION / Remote Control Valve
Beginning to Deliver Output (Increasing
Secondary Pressure)
Port T 2
Primary Pilot
Pressure
Port P
T3-6-12
COMPONENT OPERATION / Remote Control Valve
Maintaining Secondary Pressure
Port T
2
Clearance
Primary Pilot
Pressure
Port P
Output Port
6
Secondary Pilot
Pressure
T3-6-13
This Page Left Blank
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
T25N-03-02-008
T3-7-1
COMPONENT OPERATION / Slewing Mechanism
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
COMPONENT OPERATION / Slewing Mechanism
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
COMPONENT OPERATION / Slewing Mechanism
SLEWING PARKING BRAKE
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
COMPONENT OPERATION / Slewing Mechanism
1 1
2 2
3 3
Pb Pb
To Hydraulic From Pilot
Oil Tank Pump
4 4
8 8
T3-7-5
COMPONENT OPERATION / Slewing Mechanism
VALVE UNIT
feed.
Control Valve
Poppet
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
COMPONENT OPERATION / Hoisting Mechanism
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
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
COMPONENT OPERATION / Hoisting Mechanism
Operation
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
COMPONENT OPERATION / Hoisting Mechanism
REGULATOR
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
T3-8-4
COMPONENT OPERATION / Hoisting Mechanism
• In Hoisting Operation
1
Pump delivery pressure: Low Pump delivery pressure: High
1
6 6
2 2
5 5
1 - Motor 3- Motor Cutoff High Pressure Solenoid Valve 5- Spool 1 6- Spring 1
2 - Tilt Piston 4- Piston 1
T3-8-5
COMPONENT OPERATION / Hoisting Mechanism
• 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
1 - Motor 3- Motor Cutoff High Pressure Solenoid Valve 5- Spool 1 6- Spring 1
2 - Tilt Piston 4- Piston 1
T3-8-6
COMPONENT OPERATION / Hoisting Mechanism
COUNTERBALANCE VALVE
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
COMPONENT OPERATION / Hoisting Mechanism
In Hosting Operation
Hoisting㩷
Hoisting㩷
1 C
D C
A B A
4
A B
T2BC-03-08-004
T3-8-8
COMPONENT OPERATION / Hoisting Mechanism
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
COMPONENT OPERATION / Hoisting Mechanism
In Neutral State
B A
T2BC-03-08-007
T3-8-10
COMPONENT OPERATION / Hoisting Mechanism
Relief Valve
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
COMPONENT OPERATION / Hoisting Mechanism
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
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
COMPONENT OPERATION / Hoisting Mechanism
HOISTING DRUM
Hoisting Drum Motor
T25N-03-03-003
Brake Unit Reduction Gear
T3-8-13
COMPONENT OPERATION / Hoisting Mechanism
REDUCTION GEAR
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
COMPONENT OPERATION / Hoisting Mechanism
BRAKE UNIT
Brake Releasing
1. The top of shaft (6) is splined to the second stage
carrier of reduction gear.
Friction plates (5) are splined to shaft (6).
Disc plate (4) is splined to casing (1).
2. When the brake pedal is depressed or when the
drum brake solenoid valve is not selected, oil from
brake chamber (A) passes through passage (2) to
the hydraulic oil tank.
3. Brake piston (3) is pressed by the force of spring
(8) to the right.
4. When brake piston (3) pushes spacer (7), and
disc plate (4) and friction plates (5) contact closely
to each other under pressure, the brake is ap-
plied.
5. When the drum brake solenoid valve is selected
by a signal from MC2/A, pressure oil from the pilot
pump passes through the brake pedal and the
drum brake solenoid valve and flows to the port of
casing (1).
6. Pressure oil flows through passage (2) to brake
chamber (A).
7. The brake piston (2) moves to the left by com-
pressing spring (8).
8. As a result, disc plate (4) and friction plates (4)
are freed and the brake is released.
T3-8-15
COMPONENT OPERATION / Hoisting Mechanism
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 der- ricking 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
COMPONENT OPERATION / Boom Derricking Device
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
COMPONENT OPERATION / Boom Derricking Device
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
COMPONENT OPERATION / Boom Derricking Device
BOOM DERRICKING BRAKE
T25N-03-04-005
T3-9-4
COMPONENT OPERATION / Boom Derricking Device
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
COMPONENT OPERATION / Boom Derricking Device
BRAKE VALVE
Counterbalance Valve
Check Valve
T25N-03-04-007
Overload Relief
Valve
T3-9-6
COMPONENT OPERATION / Boom Derricking Device
COUNTERBALANCE VALVE
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
T3-9-7
COMPONENT OPERATION / Boom Derricking Device
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
COMPONENT OPERATION / Boom Derricking Device
OVERLOAD RELIEF VALVE
Relief Operation
Poppet Spring
T25N-03-04-012
Port AM To Hydraulic
Oil Tank
T3-9-9
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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
COMPONENT OPERATION / Travel Mechanism
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
COMPONENT OPERATION / Travel Mechanism
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
COMPONENT OPERATION / Travel Mechanism
PARKING BRAKE
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
COMPONENT OPERATION / Travel Mechanism
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
COMPONENT OPERATION / Travel Mechanism
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
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
COMPONENT OPERATION / Travel Mechanism
TRAVEL BRAKE VALVE
Travel Motor Displacement
Angle Selection Valve
Overload Relief
Overload Relief Valve
Valve
Counterbalance
Valve
T2BC-03-10-001
Check Valve
T3-10-7
COMPONENT OPERATION / Travel Mechanism
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
COMPONENT OPERATION / Travel Mechanism
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
COMPONENT OPERATION / Travel Mechanism
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
T3-10-10
COMPONENT OPERATION / Travel Mechanism
• 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
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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.
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
COMPONENT OPERATION / Others (Upper Structure)
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
COMPONENT OPERATION / Others (Upper Structure)
SOLENOID VALVE
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
COMPONENT OPERATION / Others (Upper Structure)
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
COMPONENT OPERATION / Others (Upper Structure)
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
COMPONENT OPERATION / Others (Upper Structure)
GATE LOCK VALVE
T2BC-03-11-003
Pilot Relief Valve㩷
T2BC-03-11-004
T3-11-6
COMPONENT OPERATION / Others (Upper Structure)
Gate Lock Solenoid Valve
T2BC-03-11-006
T3-11-7
COMPONENT OPERATION / Others (Upper Structure)
Pilot Relief Valve
Pilot Pump
T3-11-8
COMPONENT OPERATION / Others (Upper Structure)
BRAKE PEDAL UNIT
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
COMPONENT OPERATION / Others (Upper Structure)
PRESSURE-REDUCING VALVE
T3-11-10
COMPONENT OPERATION / Others (Upper Structure)
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
COMPONENT OPERATION / Others (Upper Structure)
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.
T3-11-12
COMPONENT OPERATION / Others (Upper Structure)
T25N-03-08-010
T Hole Piston P
Chamber
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
COMPONENT OPERATION / Others (Upper Structure)
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
T3-11-14
COMPONENT OPERATION / Others (Upper Structure)
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
COMPONENT OPERATION / Others (Upper Structure)
COUNTERWEIGHT CYLINDER
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17
T2BC-03-11-009
T3-11-16
COMPONENT OPERATION / Others (Upper Structure)
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
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
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COMPONENT OPERATION / Others (Base Carrier)
OUTLINE
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
COMPONENT OPERATION / Others (Base Carrier)
SLEWING RING
6
7
T135-03-02-001
T3-12-2
COMPONENT OPERATION / Others (Base Carrier)
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
COMPONENT OPERATION / Others (Base Carrier)
RETRACT CYLINDER
1 2 3 4 5 6 7 8 9 10
T25N-03-09-002
T3-12-4
COMPONENT OPERATION / Others (Base Carrier)
JACK-UP CYLINDER (OPTIONAL)
M25N-07-034
1
2
3
4
5
6
7
T2BC-03-12-003
T3-12-5
COMPONENT OPERATION / Others (Base Carrier)
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.
T25N-03-09-008
T3-12-6
COMPONENT OPERATION / Others (Base Carrier)
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
T25N-03-09-003
T3-12-7
COMPONENT OPERATION / Others (Base Carrier)
TAKE-UP CYLINDER (OPTIONAL)
T2BC-03-12-001
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
Standard Specifications
New machine applied specifications are described in
this manual for test evaluation purposes. Tolerances
are indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
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.
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
T4-1-2
OPERATIONAL PERFORMANCE TEST / Introduction
PRECAUTIONS FOR STARTING ENGINE
1. Check that lock lever (1) is placed in the LOCK Lock Position
position. 1
mode.
4. Check that slewing brake switch (8) is ON (Brake 3 1
8 2
position).
T2BC-04-01-002
7 6 5
4
T2BC-01-02-003
T4-1-3
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OPERATIONAL PERFORMANCE TEST / Standards
PERFORMANCE STANDARDS
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standards
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
Extend 10 to 8 Engine Speed:
Retract 33 to 38 Low Idle
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standards
Reference
Performance Test Designation Performance Standard Remarks
Page
Hydraulic System
2
Primary Pilot Pressure MPa (kgf/cm , psi)
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standards
Main Pump P-Q Diagram
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 )
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standards
P-Q Control by Pump Control Pilot Pressure Signal
(Reference: Measured at Test Stand)
• 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
Data in ( ) is given for reference.
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standards
Slewing Pump P-Q Diagram
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
Data in ( ) is given for reference.
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standards
P-Q Control by Pump Control Pilot Pressure Signal
(Reference: Measured at Test Stand)
• Specified pump speed:2000 min-1 (rpm)
• Hydraulic oil temperature:50r5 qC (122r41 qF)
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
Data in ( ) is given for reference.
T4-2-7
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OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Preparation:
1. Sufficiently warm up the machine until the engine T333-04-02-001
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
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in each cylinder
to check for a decline in engine power.
2. Check exhaust color and the amount of blow-by
gas from the crankcase. Keep track of engine oil
consumption.
3. Check the intake system, including the air filter,
for any abnormalities.
Preparations:
1. Check that the valve clearances are correct.
2. Charge the batteries are sufficiently charged.
3. Warm up (run) the engine until the coolant
temperature reaches the operating range. T333-04-02-002
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
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Measure when the engine is cool.
2. Clean the head cover mounting area in order to
prevent any foreign material from entering the
engine.
Preparation:
1. Remove the head cover.
2. Locate top dead center (TDC) in compression
stroke.
Remove the lower left side flywheel housing T333-04-02-003
Measurement:
1. Insert a feeler gauge between the rocker arm and
valve stem in order to measure the valve clear-
ance.
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
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)
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area in order to avoid contamination in
the engine.
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.
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
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.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy:
Refer to TROUBLE SHOOTING in T5-4.
T4-4-1
OPERATIONAL PERFORMANCE TEST / Crane Test
MISTRACK
Summary:
1. Measure the maximum distance between the 10
m (33 ft) straight line and check the variation be-
tween the right and left travel power line (from the 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
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.
Remedy:
Refer to TROUBLE SHOOTING in T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Crane Test
TRAVEL PARKING BRAKE DRIFT
Summary:
Measure the travel parking brake drift on a specified
angle slope. 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).
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
T324-06-03-005
2 3 1
T4-4-3
OPERATIONAL PERFORMANCE TEST / Crane Test
SLEWING SPEED
Summary:
1. Measure the time to slewing three complete turns
and check the operational performance of the
slewing power system (from the hydraulic pump
to the slewing motor) comprehensively.
Preparation:
1. Check the lubrication of the slewing gear and
slewing ring.
2 m (6.5
2. Place the machine on a level and solid ground ft)
with ample space for swinging. Do not test on a
slope.
3. Use the basic boom with the hook. Set the boom
angle to 60q. (Or dismount the front attachment
and counterweight.)
60q
4. While maintaining hydraulic oil temperature at
50r5 qC (122r41 qF), make measurement after
delivering hydraulic oil to the measured hydraulic
oil to the measured hydraulic circuit for two
munutes or longer.
T2BC-04-04-003
Measurement: 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.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
T2BC-04-04-014
Remedy:
Refer to TROUBLESHOOTING in T5-4.
T4-4-4
OPERATIONAL PERFORMANCE TEST / Crane Test
SLEWING RING PLAY
Summary:
1. Measure the slewing ring play between inner
race and auter race and check the wear or
slewing ring races and balls..
Preparation:
1. Check slewing ring mounting bolts for looseness.
2. Check lubrication of the slewing ring. Check that
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
Evaluation:
Refer to T4-2 STANDARD SPECIFICATIONS.
T2BC-04-04-006
Measurement of (h2)
60q
T2BC-04-04-007
T4-4-5
OPERATIONAL PERFORMANCE TEST / Crane Test
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.
stroke.
Measurement:
Front Drum L Rear Drum
1. Turn the low speed lock switch LOCK. ever Lever x Fast Speed
Lock Switch
6. Release the low speed lock switch. Repeat steps
2 to 5 in order to measure.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
T2BC-04-04-010
T4-4-6
OPERATIONAL PERFORMANCE TEST / Crane Test
REGULATOR ADJUSTMENT
4
T25N-03-03-024
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
OPERATIONAL PERFORMANCE TEST / Crane Test
BOOM DERRICKING SPEED
Summary:
1. Measure the time required for the boom
derricking drum to rotate six complete turns and
comprehensively check the operational
performance of main pump and boom derricking
drum motor in the boom derricking drive system.
2m
(6.5 ft)
Preparation:
1. Use the basic boom with the hook. (Or dismount
the front attachment and counterweight.)
2. While maintaining hydraulic oil temperature at
50r5 qC (122r41 qF), make measurement after
delivering hydraulic oil to the measured hydraulic 60q
circuit for two minutes or longer.
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
an accelerator grip.
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:
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy:
Refer to TROUBLE SHOOTING in T5-4.
T2BC-04-04-015
T4-4-8
OPERATIONAL PERFORMANCE TEST / Crane Test
COUNTERWEIGHT CYLINDER SPEED
Summary:
1. Measure the extension time of counterweight
cylinder from minimum retraction length to maxi-
mum extension length time without load and
check the operational performance of drive
power system (from the pump for counterweight /
jack-up retract the counterweight cylinder) com-
prehensively.
Preparation:
1. Lower the front attachment onto ground and re-
move the counterweight from the machine.
2. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making the counter-
weight cylinder operation at hydraulic oil tem-
perature of 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
OPERATIONAL PERFORMANCE TEST / Crane Test
JACK-UP (OPTIONAL) SPEED
Summary:
1. Measure the extension time of jack-up cylinder
from minimum retraction length to maximum ex-
tension length and check the operational per-
formance of jack-up cylinder drive power system
(from the pump for counterweight / jack-up / re-
tract to the jack-up cylinder).
Preparation:
1. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making the jack-up
cylinder operation at hydraulic oil temperature of
50r5 qC (122r41 qF).
2. Carry out measurement after extending jack-up
cylinder fully.
Measurement:
Make measurement at each measuring point.
1. Set the engine speed to the minimum speed by
using an a accelerator grip.
2. Turn the jack-up lever the EXTEND position.
3. Measure the extension time of jack-up cylinder
from fully retracted position.
4. With the jack-up lever at the RETRACT position
and the jack-up cylinder resting on the ground,
measure the retraction time of jack-up cylinder to
the minimum retraction length.
5. Carry out measurement three times, and deter- T25N-04-04-004
mine the average of measurements.
Jack-up Cylinder
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
T4-4-10
OPERATIONAL PERFORMANCE TEST / Crane Test
RETRACT SPEED
Summary:
1. Measure the extension time of retract cylinder
from minimum retraction length to maximum ex-
tension length and check the operational per-
formance of retract cylinder drive power system
(from the pump for counterweight / jack-up retract
to the retract cylinder).
Preparation:
1. Use the basic boom with the hook. Set the boom
angle to 60q. (The machine without front attach-
ment and counterweight is acceptable.)
2. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making retract opera-
tion at hydraulic oil temperature of 50r5 qC
(122r41 qF).
3. Place the wooden blocks under the cylinder
tubes of retraction cylinders to be measured.
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
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
T2BC-04-04-017
T4-4-11
OPERATIONAL PERFORMANCE TEST / Crane Test
LIFTING LOAD LOWERING BY FRONT /
REAR DRUMS
Summary:
1. Measure slippage at the drum flange for two min-
utes with the engine idling and check the load
lowering by front (rear) motor. Check leakage in 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.
4. While maintaining hydraulic oil temperature at
50±5 qC (122±41 qF), make measurement after
delivering hydraulic oil to the measured hydraulic
circuit for two minutes or longer. T2BC-04-04-011
5. Hoist the weight, stop it, and make measurement.
Measurement:
1. Set boom angle to 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:
Refer to TROUBLE SHOOTING in T5-4.
T4-4-12
OPERATIONAL PERFORMANCE TEST / Crane Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Check the operating function of each control
lever and measure the operating force.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating stroke at the lever bottom
of each control lever.
Preparation:
1. Maintain the hydraulic oil temperature at 50r5 qC
(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.
4. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
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
OPERATIONAL PERFORMANCE TEST / Crane Test
CONTTROL LEVER STROKE
Summary:
1. Check a play and operating function of each
control lever and measure the stroke.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
1. Maintain the hydraulic oil temperature at 50r5 qC
(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.
4. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Refer to T4-5 STANDARD SPECIFICATIONS.
Measurement Position for Slewing Lever Measurement Position for Hoisting / Travel Levers
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.
5. Maintain the hydraulic oil temperature at 50r5 qC
(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.
3. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. Port P1㩷
T2BC-04-05-002
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Pilot Circuit Primary Pilot
Pressure
Adjustment:
Adjust the set pressure of pressure reducing valve
provided on the 4-spool solenoid valve unit if
necessary.
Adjusting
Screw㩷 Lock Nut㩷
T2BC-04-05-003
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
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
3. Start the engine. Check for oil leaks at the
㩷
pressure gauge unit connector.
㩷
4. Maintain the hydraulic oil temperature at 50r5 qC
㩷
(122r41 qF).
㩷
Measurement:
1. Run the engine at the maximum speed.
2. Measure the pilot pressure under no load
condition by using a pressure gauge.
3. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Manifold㩷
Coupler for
Measurement㩷
Brake Unit㩷
T2BC-04-05-004
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
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.
Adjusting
Screw Pilot Relief Gate Lock
Valve㩷 Valve㩷
Lock Nut
T2BC-03-11-004
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
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
T2BC-04-05-005
Port 8
Port 8
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
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.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy: T2BC-01-02-006
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
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
4. Start the engine. Check for oil leaks at the
pressure gauge unit connector.
5. Maintain the hydraulic oil temperature at 50r5 qC
(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
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy:
In case the measured results are out of specifications,
check the primary pilot pressure. When the primary
pilot pressure is normal, the solenoid valve or
electrical system may be faulty.
Nipple 7/16-20UNF㩷
Adapter㩷
7/16-20 UNF
(Hose)
T324-06-04-025
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
SLEWING BRAKE RELEASE PRESSURE
Preparations:
1. Stop the engine.
2. Remove the slewing brake release hose from 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
4. Start the engine. Check for oil leaks at the
pressure gauge unit connector. Tee㩷
5. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF).
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Remedy:
In case the measured results are out of specifications,
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
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE PRESSURE
Front / Rear Control Valve
Preparations:
1. Stop the engine.
2. Install a pressure gauge to the pressure check 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.
5. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF).
Pipe for Forward
Travel㩷
Measurement: Pipe for Reverse
Travel㩷
1. Run the engine at the maximum speed.
2. Measure main relief valve set pressure on the
front control valve (connected to pump 1) with the
right travel lever stroked in the FORWARD
position.
Measure main relief valve set pressure on the
rear control valve (connected to pump 2) with the
left travel lever stroked in the FORWARD position.
Read the pressure when the relief valve relieves.
3. Repeat the measurements three times. Calculate
the average values. Travel Motor
T2BC-04-05-007
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2. Main Relief Valve㩷
Remedy:
Refer to TROUBLE SHOOTING in T5-4.
Adjustment:
Check the pressure gauge and adjust the set
pressure of main relief valve if necessary.
Lock Nut㩷
Adjusting
Screw㩷
Pressure
Pressure
Decrease㩷
Increase㩷
W107-02-05-129
Lock Nut㩷
Adjusting
Screw㩷
Main Relief Valve㩷 T326-06-04-002
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Slewing Control Valve
Preparations:
1. Stop the engine.
2. Install a pressure gauge to pressure check port
(a4) (G 1/4) at the slewing pump delivery port. Port a4㩷
3. Start the engine. Check for oil leaks at the
pressure gauge unit connector.
4. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF).
Measurement:
1. Turn the slewing lock pedal in the LOCK position
and lock the slewing function. Port a4
2. Run the engine at the maximum speed.
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:
Refer to STANDARD SPECIFICATIONS in T4-2.
T2BC-01-02-006
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
Check the pressure gauge and adjust the set
pressure of main relief valve if necessary.
T326-06-04-002
Lock Nut㩷
Adjusting
Screw㩷
Pressure Pressure
Increase Decrease㩷
W107-02-05-129
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
4-Spool Control Valve
Preparations:
1. Stop the engine.
2. Install a pressure gauge to pressure check port
P’ in the 4-spool control valve.
3. Start the engine. Check for oil leaks at the
pressure gauge unit connector.
4. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF).
Measurement:
1. Run the engine at the maximum speed.
2. Operate and relieve the retract cylinder. Read the
pressure at this time.
3. Repeat the measurement three times in each
direction. Calculate the average values.
T2BC-04-05-008
Port P’㩷
㩷
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Adjustment:
Check the pressure gauge and adjust the set
pressure of relief valve if necessary.
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
OPERATIONAL PERFORMANCE TEST / Component Test
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.
4. Start the engine. Check for oil leaks at the
pressure gauge unit connector.
5. Maintain the hydraulic oil temperature at 50r5 qC
(122r41 qF). T2BC-04-05-009
Measurement:
1. Run the engine at the maximum speed.
2. Relieve the jack-up cylinder by operating the
control lever to RETRACT. Read the pressure at
this time.
3. Repeat the measurement three times in each
direction. Calculate the average values.
Evaluation:
Refer to STANDARD SPECIFICATIONS in T4-2.
Adjustment:
Check the pressure gauge and adjust the set
pressure of relief valve if necessary.
T2BC-04-05-010
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
PORT RELIEF VALVE PRESSURE
Summary:
1. No safe and reliable method to measure the
overload relief valve set pressure is available,
because the circuit oil pressure must be raised
by blocking the return circuit of the control valve
and applying an external load to a hydraulic
actuator. Doing so would create a high potential
to easily damage the machine.
2. Comparing the oil flow rate delivered from the
main pump, the quantity of relieving oil flow from
the overload relief valve is very small. Therefore,
checking the overload relief pressure by letting
the main pump deliver oil to the overload relief
valve does not meet the test conditions.
Accordingly, if the check is required, remove the
port relief valve assembly from the machine, and
perform the unit test of the port relief valve on a
specified test bench using the correct oil flow
rate.
3. As explained above, checking the port relief valve
pressure setting on the machine is not
recommended. Therefore, when the main circuit
relief pressure is normal, the port relief pressure
setting is also considered to be normal.
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN/SLEWING PUMP FLOW RATE
T2BC-04-05-006
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
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
Pump㩷 Portable
Hydraulic Tester Control Valve㩷
T2BC-04-05-012
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
OPERATIONAL PERFORMANCE TEST / Component Test
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
OPERATIONAL PERFORMANCE TEST / Component Test
T2BC-04-05-012
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
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the
specified pump speed using the following
formulas:
Qc = NsuQ/Ne
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
REGULATOR ADJUSTMENT (MAIN PUMP)
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
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
OPERATIONAL PERFORMANCE TEST / Component Test
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
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
x Pilot Pressure Characteristics
11
12
T25N-03-01-011
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
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
Pi
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
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.
Preparation: T25N-04-05-009
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Amount of Oil Drained While Relieving Slewing.
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
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. The travel motor performance is checked by
measuring the drain oil amount from the travel
motor while driving the machine straight on a
level solid surface to rotate the travel motor.
2. Secure the inspectors’ safety during the
measurement. Take care not to damage any 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:
1. Maintain the hydraulic oil temperature at 50r5 qC
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
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
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
OPERATIONAL PERFORMANCE TEST / Component Test
BOOM DERRICKING MOTOR DRAINAGE
Summary:
1. Engage the boom derricking drum lock. Operate
the boom derricking lever to LOWER slowly in
order to relieve. Under this condition, measure
the drain oil amount from the boom derricking
motor and check the boom derricking motor
performance. 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.
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Attach the basic boom with the boom angle set at
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.
4. Repeat the measurements three times. Calculate
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
T4-5-31
This Page Left Blank
Intentionally
OPERATIONAL PERFORMANCE TEST / Adjustment
MC2/A ADJUSTMENT
When the following repair or check is carried out, or
when the engine speed is deviated, adjust MC2/A.
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".)
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
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.
T2BC-04-06-001
Right Control Panel
T2BC-04-06-003
Side Overhead Panel
T2BC-04-06-002
4
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
1. Turn front drum auto stop cancellation switch (5) 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
T2BC-04-06-004
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
RACK ZERO 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 1
ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at
monitor panel blinks every 0.5 second.
T2BC-04-06-001
Right Contorl Panel
T2BC-04-06-003
Side Overhead Panel 4
T2BC-04-06-002
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
1. Turn rear drum auto stop cancellation switch (6) to
ON position. Monitor Panel
NOTE: Now, MC2/A sets the governor lever to the
low idle position. (Refer to Section "Control
System".)
T2BC-04-06-004
6 5
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
POWER INCREASE PRESSURE CALI-
BRATION
Preparation:
1. Install a pressure gauge (5 Mpa) to the pressure
check port.
Adjustment:
1. Turn drum rotation sensing switch (4) for front /
rear / boom derricking drums to ON position. T25N-04-06-001
2. Turn accelerator lock switch (3) to accelerator Pressure Check Power Increase
Port Solenoid Valve
preset position (SET) and turn key switch (2) to
ON position under this condition.
Monitor Panel
NOTE: After this, pilot pressure indicator (1) at
monitor panel blinks every 0.5 second.
Right Control Panel
T2BC-04-06-002
T2BC-04-06-003
T4-6-6
OPERATIONAL PERFORMANCE TEST / Adjustment
Calibration Starting
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
4. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn to accelerator
unlock position (OFF).
NOTE: Now, the power increase pressure de- 1
creases gradually. Pilot pressure indicator
(1) blinks a cycle of 0.4 second ON and 0.1
second OFF during this time.
T2BC-04-06-003
T2BC-04-06-004
T4-6-7
OPERATIONAL PERFORMANCE TEST / Adjustment
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:
1. Turn drum rotation sensing switch (4) for front /
rear / boom derricking drums to ON position.
2. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn key switch (2) to
ON position under this condition.
NOTE: After this, pilot pressure indicator (1) at
monitor panel blinks every 0.5 second.
T2BC-04-06-001
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
OPERATIONAL PERFORMANCE TEST / Adjustment
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
five seconds or longer pass.
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.
4. Turn accelerator lock switch (3) to accelerator
preset position (SET) and turn to accelerator
unlock position (OFF).
NOTE: As result, the engine speed becomes high
idle and the main pump delivery flow is
maximized.
T4-6-9
OPERATIONAL PERFORMANCE TEST / Adjustment
BRAKE PEDAL UNIT ADJUSTMENT
IMPORTANT: After repairing or inspecting the
brake pedal unit, adjust the brake
pedal unit.
If failing to make this adjustment, the
brake is unlikely to work.
A
Adjustment:
Adjusting brake pedal position C
T4-6-10
OPERATIONAL PERFORMANCE TEST / Adjustment
9. Loosen lock nut (10) and tighten stopper bolt (11) Lock Pedal
sufficiently. 4 8
T4-6-11
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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
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
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of
the wire harnesses.
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the
engine is running. The machine may
malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure T324-07-01-002
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
POWER SUPPLY MONITOR
Outputs monitoring results and conversion values of
A/D voltage at IDU in terms of main power voltage of
MC2/A and MC2/M, 5 V sensor power voltage and 24
V sensor power supply voltage.
Monitoring results and A/D voltage conversions are
indicated on the display connected to IDU.
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
5. Record Menu
7. Service Manual
3. IDU Monitor
4. MC2/A Monitor
5. MC2/B Monitor
T5-1-4
TROUBLESHOOTING / Diagnosing Procedure
Power Supply Monitor
Description
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 / Diagnosing Procedure
TROUBLESHOOTING MONITOR
Outputs diagnostic results of analog inputs, digital
inputs and digital outputs of MC2/A, MC2/B and IDU.
Diagnostic results are indicated on the display
connected to IDU.
Jib 1-rope
suspend reeving
4-rope
reeving
Overheat
2. Select "Monitor" by using or switch and Hyd. oil temp.
1. Inspection Menu
2. Adjustment Menu
3. Monitor
5. Record Menu
7. Service Manual
3. IDU Monitor
4. MC2/A Monitor
5. MC2/B Monitor
T5-1-6
TROUBLESHOOTING / Diagnosing Procedure
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
(AN_IN23) No connection
T5-1-7
TROUBLESHOOTING / Diagnosing Procedure
MC2/A Digital Inputs
Description
MC2/A Input / Output Monitor
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
TROUBLESHOOTING / Diagnosing Procedure
MC2/A Digital Output
Description
MC2/A Input / Output Monitor
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
TROUBLESHOOTING / Diagnosing Procedure
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
MC2/A_ECU1 RECEIVE ECU NORMAL Normal
TMR F. B. Timer feedback ERROR Error
RACK P. S. Rack sensor ****** Communication error
TIMING S. Timing sensor
TDC S. TDC sensor
OVER H. S. Coolant temperature sensor
TMR C. V. Timer control valve
T5-1-10
TROUBLESHOOTING / Diagnosing Procedure
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
(AN_IN7) No connection
MC2/B AI2 TR RGT PRS Travel (right) remote control
pressure
TR LET PRS Travel (left) remote control pressure
(AN_IN10) No connection
(AN_IN11) No connection
(AN_IN12) No connection
(AN_IN13) No connection
MC2/B DI FD ROPE ED Front drum three-winding layer
detection (No connection))
RD ROPE ED Front drum three-winding layer
detection (No connection))
3D ROPE ED Front drum three-winding layer
detection (No connection))
(DAN_IN20) No connection
(DAN_IN21) No connection
(DAN_IN22) No connection
(DAN_IN23) No connection
T5-1-11
TROUBLESHOOTING / Diagnosing Procedure
MC2/B Digital Inputs
Description
MC2/B Input / Output Monitor
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
****** Communication error
T5-1-12
TROUBLESHOOTING / Diagnosing Procedure
MC2/B Digital Outputs
Description
MC2/B Input / Output Monitor
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
MC2/B DD HST CUR Derricking drum hoisting xxxxmA Control current
D01 proportional solenoid valve LOW ER Lower limit error
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
TROUBLESHOOTING / Diagnosing Procedure
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
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
(AN_IN1) No connection
(AN_IN2) No connection
(AN_IN3) 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
(AN_IN9) No connection
(AN_IN10) No connection
(AN_IN11) No connection
T5-1-14
TROUBLESHOOTING / Diagnosing Procedure
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
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)
DEC CW2 Shift 5 (load decrease 2)
(No connection)
DEC CW3 Shift 6 (load decrease 3)
(No connection)
DEC CW4 Shift 7 (load decrease 4)
(No connection)
IDU DI/PI OVERHEART Thermo switch
(PLS_IN1) No connection
(PLS_IN2) No connection
(PLS_IN3) No connection
(PLS_IN4) No connection
(PLS_IN5) No connection
(PLS_IN6) No connection
(PLS_IN7) No connection
T5-1-15
TROUBLESHOOTING / Diagnosing Procedure
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. %
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
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
(OC_OUT11) No connection
(OC_OUT12) No connection
(OC_OUT13) 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
TROUBLESHOOTONG / Component Layout
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
TROUBLESHOOTONG / Component Layout
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
TROUBLESHOOTONG / Component Layout
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
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
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
TROUBLESHOOTONG / Component Layout
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
TROUBLESHOOTONG / Component Layout
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
T2BC-01-02-006
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
TROUBLESHOOTONG / Component Layout
Monitor Panel
1
15
14
13
2
12
11
10
9
3
6
4
T2BC-01-02-007
T5-2-7
TROUBLESHOOTONG / Component Layout
Control Panel
1 2 3 4 5 6 7 8 9
T2BC-01-02-008
12 11 10
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
TROUBLESHOOTONG / Component Layout
Overhead Panel
1 2 3 4 5 6 7
T2BC-01-02-011
T2BC-01-02-012
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
TROUBLESHOOTONG / Component Layout
Relay Panel
1
2
3
Controller Box
12
1
11
10
T2BC-01-02-016
8 7 6 5 4 3 2
T5-2-10
TROUBLESHOOTONG / Component Layout
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
TROUBLESHOOTONG / Component Layout
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
TROUBLESHOOTONG / Component Layout
Around Battery
7 10
3
6 4 9
㩷
Machine Right㩷 㩷
T2BC-01-02-020 T25N-01-02-005
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
TROUBLESHOOTONG / Component Layout
Pump Mechanism
Machine Rear
T5-2-14
TROUBLESHOOTONG / Component Layout
Front / Rear Control Valve
1 2*1 3 4*1 5 6 7 8
Machine Left
Machine
Rear㩷
Machine
Machine Right Front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
TROUBLESHOOTONG / Component Layout
4-Spool Control Valve
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
T5-2-16
TROUBLESHOOTONG / Component Layout
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
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
TROUBLESHOOTONG / Component Layout
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
Accumulator㩷
Slewing Remote
M25N-07-030 Control Pressure
1 Sensor Block㩷
T25N-01-02-019
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.
Harness
Harness end
connector
Mounting Surface T6L4-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A
Power Supply Monitor
Description
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
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
TROUBLESHOOTING / Troubleshooting A
MC2/A Analog Inputs
Description
MC2/A Input / Output Monitor
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
T5-3-3
TROUBLESHOOTING / Troubleshooting A
MC2/A Digital Inputs
Description
MC2/A Input / Output Monitor
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
TROUBLESHOOTING / Troubleshooting A
MC2/A Digital Output
Description
MC2/A Input / Output Monitor
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
T5-3-5
TROUBLESHOOTING / Troubleshooting A
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
MC2/A_ECU1 RECEIVE ECU NORMAL Normal
TMR F. B. Timer feedback ERROR Error
RACK P. S. Rack sensor ****** Communication error
TIMING S. Timing sensor
TDC S. TDC sensor
OVER H. S. Coolant temperature sensor
TMR C. V. Timer control valve
T5-3-6
TROUBLESHOOTING / Troubleshooting A
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
T5-3-7
TROUBLESHOOTING / Troubleshooting A
MC2/B Digital Inputs
Description
MC2/B Input/Output Monitor
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
χ ω Page Selection Return
Item
Item Signal name Description Explanation
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
TROUBLESHOOTING / Troubleshooting A
MC2/B Digital Outputs
Description
MC2/B Input/Output Monitor
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
Ĺ ĻPage Selection Return
Item
Item Signal name Description Explanation
MC2/B D01 DD HST CUR Derricking drum hoisting proportional xxxxmA Control current
LOW ER Lower limit error
solenoid valve
HI ER Upper limit error
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
LOW ER Lower limit error
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
****** Communication error
FM CAP CUR Front motor displacement angle control
proportional solenoid valve
RM CAP CUR Rear motor displacement angle control
proportional solenoid valve
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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MC2/A OR MC2/B BATTERY
AND SENSOR SYSTEM POWER SUPPLY
Abnormality
Using the power supply monitor, check MC2/A and
MC2/B battery and sensor system power supplies.
MC2/A, MC2/B
Item Signal name Description Explanation Countermeasure
MAIN_B Battery LOW ER Lower limit error Harness check
5V Sensor 5V HI ER Upper limit error Harness check
24V_2 Sensor 24V_2 ***** CAN Harness check
communication
failure
24V_3 Sensor 24V_3 NORMAL Normal 㧙
T5-3-10
TROUBLESHOOTING / Troubleshooting A
Battery
Battery Relay
Key Switch
MC2/A MC2/B
P1 MAIN_B P1 MAIN_B
P17 P17
KEY_SW KEY_SW
D5 D5
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
T25N-05-03-001
T5-3-11
TROUBLESHOOTING / Troubleshooting A
Check of Battery System
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
TROUBLESHOOTING / Troubleshooting A
Check of Key Switch
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
T5-3-13
TROUBLESHOOTING / Troubleshooting A
Check of Solenoid and PWM Power Supply
Connector
MC2/A
Connector MCA-6
T2BC-05-03-004
T5-3-14
TROUBLESHOOTING / Troubleshooting A
MC2/B Side
YES Faulty MC2/B.
Connector
MC2/B
Connector MCB-6
T2BC-05-03-003
T5-3-15
TROUBLESHOOTING / Troubleshooting A
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
remote control pressure R W B
B W R
Front drum hoisting
remote control pressure R W B
Slew lever Front drum lowering
T25N-05-03-023 remote control pressure R W B
Accelerator pedal Rear drum hoisting
remote control pressure R W B
W R Rear drum lowering
remote control pressure R W B
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
T25N-05-03-002
T25N-05-03-002
T25N-05-03-002
T5-3-16
TROUBLESHOOTING / Troubleshooting A
Check of 5V Sensor of MC2/B
Disconnect sensor YES㩷 Faulty sensor.
from connector.
Check if voltage be-
tween terminal R of
harness end connector
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
TROUBLESHOOTING / Troubleshooting A
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.
Check if voltage be-
tween machine and
terminal #4 of harness Faulty MC2/A.
end connector is 24 V. NO
· Key switch: ON
Harness D2
Sensor Harness end connector
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.
Check if voltage be-
tween machine and
terminal #4 of harness Faulty MC2/A.
end connector is 24 V. NO
· Key switch: ON
Harness D2
Sensor Harness end connector
Third / fourth drum
brake mode
selection switch
T2BC-05-03-005
T5-3-18
TROUBLESHOOTING / Troubleshooting A
Front, rear and fourth drum brake pedal
YES㩷 Faulty brake mode
Disconnect connector
of limit switch. selection switch.
Check if voltage be-
tween machine and
terminal #1 of harness
Faulty MC2/A.
end connector is 24 V.
NO
· Key switch: ON
Harness D2
Sensor Harness end connector
Fron, rear and fourth
drum pedal limit
switch
T2BC-05-04-008
T5-3-19
TROUBLESHOOTING / Troubleshooting A
Check of 24 V_2 Sensor on MC2/A
Disconnect connector YES㩷 Faulty accelerator
62C-12FW of right con- control switch.
trol panel.
Check if voltage be-
tween machine and
terminal #2 of harness Faulty MC2/A.
end connector is 24 V.
NO
· Key switch: ON
Harness D3
Sensor Harness end connector
Accelerator control
switch
T2BC-05-03-006
Check of 24 V_3 Sensor on MC2/A
Disconnect connector YES㩷 Faulty emergency
of emergency opera- operation switch.
tion switch.
Check if voltage be-
tween machine and
terminal #4 of harness Faulty MC2/A.
end connector is 24 V. NO
· Key switch: ON
Harness D4
Sensor Harness end connector
Emergency
operation switch
T2BC-05-03-007
T5-3-20
TROUBLESHOOTING / Troubleshooting A
Check of 24 V_2 Sensor on MC2/B
YES㩷 Faulty limit switch.
Disconnect connector
of limit switch.
Check if voltage be-
tween machine and
terminal #c of harness
Faulty MC2/B.
end connector is 24 V.
NO
· Key switch: ON
Harness X3
Sensor Harness end connector
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
TROUBLESHOOTING / Troubleshooting A
Check of Sensor 24 V_3 on MC2/B
T2BC-05-03-009
Jib second
overhoist switch
T2BC-05-03-008
Tower jib backstop
alignment switch
T2BC-05-03-009
Hook overhoist switch
YES㩷 Faulty limit switch.
Disconnect limit switch
from connector. Check if
voltage between ma-
chine and terminal #1 of
harness end connector
is 24 V. Faulty MC2/B.
NO
· Key switch: ON
Harness X4
Sensor Harness end connector
Hook overhoist
switch
T2BC-05-03-010
T5-3-22
TROUBLESHOOTING / Troubleshooting A
Check of CAN between MC2/A and IDU
T2BC-05-03-001
IDU
Connector IDU-4
(harness end)
T2BC-05-03-011
T5-3-23
TROUBLESHOOTING / Troubleshooting A
Check of CAN between MC2/B and IDU
T2BC-05-03-012
IDU
Connector IDU-4
(harness end)
T2BC-05-03-011
T5-3-24
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ENGINE CONTROL SYSTEM
Abnormality
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".
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
Engine Speed
Detection
T2BC-05-03-058
T5-3-25
TROUBLESHOOTING / Troubleshooting A
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
TROUBLESHOOTING / Troubleshooting A
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
terminal D14 of MC2/A and terminal B (ground) of
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
Check for continuity
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.
Check for continuity
;'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
T2BC-05-03-016
T2BC-05-03-001
T5-3-27
TROUBLESHOOTING / Troubleshooting A
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
terminal D14 of MC2/A and terminal B (ground) of
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.
Check for continuity
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
T107-07-03-009
T2BC-05-03-018
T2BC-05-03-001
..
T5-3-28
TROUBLESHOOTING / Troubleshooting A
Check of Accelerator Control Switches
x Check the wiring connections first.
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
(harness end) (harness end)
(Machine end)
T2BC-05-03-021 T2BC-05-03-020
T2BC-05-03-006
T5-3-29
TROUBLESHOOTING / Troubleshooting A
Check of Engine Rotation Detection Sensors
x Check the wiring connections first.
Disconnect connector
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
Check for continuity
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.
harness open circuit
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
TROUBLESHOOTING / Troubleshooting A
Check of Governor Motor System
E10 E11
2 1 1 2
E1 E13
4 3 3 4 E14 E26
E24 E25
T5-3-31
TROUBLESHOOTING / Troubleshooting A
FAILURE OF BRAKE CONTROL SYSTEM
Abnormality
T5-3-32
TROUBLESHOOTING / Troubleshooting A
Free Indicator
T2BC-05-03-022
T5-3-33
TROUBLESHOOTING / Troubleshooting A
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 connec- tion.
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
T2BC-05-03-024 T2BC-05-03-001
T5-3-34
TROUBLESHOOTING / Troubleshooting A
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-
tween terminal D15 of MC2/A and terminal B
(ground) of derricking drum lowering remote control Reconnect the
pressure sensor end connector.
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 con- trol 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
TROUBLESHOOTING / Troubleshooting A
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
pressure sensor (sensor end)
(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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Lowering Remote Control
Pressure Sensor System
x If input voltage from the front drum lowering remote
control pressure sensor is 4.6 V or more, the cause
of trouble may be failure of front lowering remote
control sensor, or open circuit between terminal D15
of MC2/A and terminal B (ground) of front drum
lowering remote control pressure sensor end con-
nector.
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-
·Insert a test bar into the
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 if voltage be-
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Hoisting Remote Control
Pressure Sensor System
x If input voltage from the rear drum hoisting remote
control pressure sensor is 4.6 V or more, the cause
of trouble may be failure of rear hoisting remote
control sensor, or open circuit between terminal D15
of MC2/A and terminal B (ground) of rear drum
hoisting remote control pressure sensor end con- 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.
pressure sensor (sensor end)
ector MCA-2
Conn
(harness end)
T2BC-05-03-025
T2BC-05-03-023
Rear drum hoisting remote control MC2/A
pressure sensor (harness end) Connector MCA-1
(harness end)
T2BC-05-03-024 T2BC-05-03-001
T5-3-38
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Lowering Remote Control
Pressure Sensor System
x If input voltage from the rear drum lowering remote
control pressure sensor is 4.6 V or more, the cause
of trouble may be failure of rear drum lowering re-
mote control sensor, or open circuit between termi-
nal D15 of MC2/A and terminal B (ground) of rear
drum lowering remote control pressure sensor end
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
MC2/A. Faulty harness up
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
T2BC-05-03-001
T2BC-05-03-024
T5-3-39
TROUBLESHOOTING / Troubleshooting A
Check of Third / Fourth Drum Hoisting Remote
Control Pressure Sensor System (Optional)
x If input voltage from the third / fourth drum hoisting
remote control pressure sensor is 4.6 V or more, the
cause of trouble may be failure of third / fourth drum
hoisting remote control sensor, or open circuit be-
tween terminal D15 of MC2/A and terminal B
(ground) of third/fourth drum hoisting remote control
pressure sensor end connector.
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 /
Check if voltage be-
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
connector of third /
fourth drum hoisting
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
fourth drum hoisting
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
TROUBLESHOOTING / Troubleshooting A
Check of Third / Fourth Drum Lowering Remote
Control Pressure Sensor System (Optional)
• If input voltage from the third / fourth drum lowering
remote control pressure sensor is 4.6 V or more, the
cause of trouble may be failure of third/fourth drum
lowering remote control sensor, or open circuit be-
tween terminal D15 of MC2/A and terminal B
(ground) of third / fourth drum lowering remote con-
trol pressure sensor end connector.
• If input voltage from the third / fourth drum lowering
remote control pressure sensor is less than 0.5V, the
cause of trouble may be harness open circuit be- 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-
·Insert a test bar into the
;'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
MC2/A. Faulty harness up
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.
connector of third /
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 lower- ing 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
Connector MCA-2 Connector MCA-1
remote control pressure remote control pressure sensor
(harness end) (harness end)
sensor (sensor end) (harness end)
T2BC-05-03-025 T2BC-05-03-001
T2BC-05-03-023 T2BC-05-03-024
T5-3-41
TROUBLESHOOTING / Troubleshooting A
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.
·Specification: 0.5 to 4.5 V
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.
T2BC-05-03-025
T2BC-05-03-041 T2BC-05-03-001
T2BC-05-03-040
T5-3-42
TROUBLESHOOTING / Troubleshooting A
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
·Specification: 0.5 to 4.5 V
;'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
Connector MCA-2 Connector MCA-1
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Brake Depressing Pressure Sensor
System
• If input voltage from the rear brake depressing
pressure sensor is 4.6 V or more, the cause of trou-
ble may be failure of rear brake depressing pressure
sensor, or open circuit between terminal D15 of
MC2/A and terminal B (ground) of rear brake de-
pressing pressure sensor end connector.
• If input voltage from the rear brake depressing pres-
sure sensor is less than 0.5V, the cause of trouble
may be harness open circuit between rear brake
depressing pressure sensor and MC2/A, or short
circuit between SENSOR_5V line and ground line. 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
ity between termi- Faulty harness up
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
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Brake Depressing Pressure
Sensor System
• If input voltage from the fourth brake depressing
pressure sensor is 4.6 V or more, the cause of trou-
ble may be failure of fourth brake depressing pres-
sure sensor, or open circuit between terminal D15 of
MC2/A and terminal B (ground) of fourth brake de-
pressing pressure sensor end connector.
• If input voltage from the fourth brake depressing
pressure sensor is less than 0.5V, the cause of
trouble may be harness open circuit between fourth
brake depressing pressure sensor and MC2/A, or
short circuit between SENSOR_5V line and ground Reconnect the
line.
disconnected
;'5㩷 Faulty MC2/A.
• 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.
·Insert a test bar into the
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
ity between termi- Faulty harness up
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
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Unlocking Solenoid
Valve
• Check the wiring connections first.
• The cause of trouble may be failure of derricking
drum hoisting remote control pressure sensor and
derricking drum lowering remote control pressure
sensor system.
At first, check the 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
TROUBLESHOOTING / Troubleshooting A
Check of Front Motor Brake Release Solenoid
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Motor Brake Release Solenoid
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
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Motor Brake Release Solenoid
Valve (Optional)
• Check the wiring connections first.
• The cause of trouble may be failure of third / fourth
drum hoisting remote control pressure sensor and
third / fourth drum lowering remote control pressure
sensor system.
At first, check the third / fourth drum hoisting remote
control pressure sensor and third / fourth drum low-
ering remote control pressure sensor.
;'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
(harness end) (harness end)
T2BC-05-04-027
T2BC-05-03-026
T5-3-49
TROUBLESHOOTING / Troubleshooting A
Check of Third/Fourth Auto Brake Indicator (Op-
tional)
Connector
MC2/A
Connector MCA-6
(harness end)
T2BC-05-04-027
T5-3-50
TROUBLESHOOTING / Troubleshooting A
Check of Brake Mode Key Switch System
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-04-022
T5-3-51
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Brake Mode Selection
Switch System
• Check the wiring connections first.
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
(harness end) (harness end) (harness end)
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
T5-3-52
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Brake Mode Selection Switch
System
• Check the wiring connections first.
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
(harness end) (harness end) (harness end)
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
T5-3-53
TROUBLESHOOTING / Troubleshooting A
Check of Third / Fourth Drum Brake Mode Selec-
tion Switch System (Optional)
T2BC-05-03-001 T2BC-05-03-020 T2BC-05-03-005
T5-3-54
TROUBLESHOOTING / Troubleshooting A
Check of Front Brake Pedal Limit Switch System
• Check the wiring connections first.
;'5㩷 Faulty MC2/A.
Disconnect con-
nector MCA-4 of
MC2/A.
Check if voltage
between terminal
A11 of harness
end connector and
Disconnect connector
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.
Check for continuity
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
(harness end) (harness end) (harness end)
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
T5-3-55
TROUBLESHOOTING / Troubleshooting A
Check of Rear Brake Pedal Limit Switch System
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
T5-3-56
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Brake Pedal (Optional) Limit
Switch System
• Check the wiring connections first.
;'5㩷 Faulty MC2/A.
Disconnect con-
nector MCA-4 of
MC2/A.
Check if voltage
between terminal
Disconnect connector
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.
Check for continuity
· 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)
(harness end) (harness end)
T2BC-05-03-001 T2BC-05-03-020
T2BC-05-04-008
T5-3-57
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Brake Release Solenoid
Valve
• Check the wiring connections first.
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-
Disconnect connector
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
01 brake release so-
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Brake Release Solenoid
Valve
• Check the wiring connections first.
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
of harness end con- faulty ground.
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-
· Brake mode key switch:
noid valve and termi- ON
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
01 brake release so-
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
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Brake Release Solenoid
Valve (Optional)
• Check the wiring connections first.
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
of harness end con- faulty ground.
#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
· Brake mode key switch:
noid valve and termi- 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
01 brake release so-
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
TROUBLESHOOTING / Troubleshooting A
Check of Harness between MC2/A and MC2/B
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
Connector MCB-6 (harness end)
T2BC-05-03-003
T5-3-61
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MAIN PUMP DELIVERY
FLOW RATE CONTROL SYSTEM
Abnormality
• By using the power supply monitor, check if all of
battery and sensor power supply of MC2/A are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-62
TROUBLESHOOTING / Troubleshooting A
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
T25N-05-03-013
T5-3-63
TROUBLESHOOTING / Troubleshooting A
Main Pump Displacement Angle Proportional
Solenoid Valve
x Check the wiring connections first.
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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF MAIN PUMP POWER
INCREASE 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 Supplies".
0 to 700 mA, 0 to 12.3 V
Power Increase
24 V Solenoid Valve
1.9 to 3.1 V
Rack
Sensor
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
TROUBLESHOOTING / Troubleshooting A
Check of Rack Sensor System
x Check the wiring connections first.
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
(harness end) (harness end) (harness end)
T2BC-05-04-029 T2BC-05-03-001 T2BC-05-03-013
T5-3-66
TROUBLESHOOTING / Troubleshooting A
Check of Power Increase Solenoid Valve
T2BC-05-03-031 T2BC-05-03-029
T2BC-05-04-008
T5-3-67
TROUBLESHOOTING / Troubleshooting A
FAILURE OF SLEWING ALARM 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 Supplies".
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
TROUBLESHOOTING / Troubleshooting A
Check of Slewing (Right) Remote Control
Pressure Sensor System
x Check the wiring connections first.
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
·Insert a test bar into the
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
pressure sensor (harness end)
T2BC-05-03-024
T5-3-69
TROUBLESHOOTING / Troubleshooting A
Check of Slewing (Left) Remote Control Pressure
Sensor System
x Check the wiring connections first.
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
01㩷 control pressure
clip. MC2/A meets
sensor.
;'5 Disconnect specification.
connector MCA-2
·Insert a test bar into the
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 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
01㩷 control pressure
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
pressure sensor (harness end)
T2BC-05-03-024
T5-3-70
TROUBLESHOOTING / Troubleshooting A
Check of Slewing Alarm Lamp Relay System
x Check the wiring connections first.
;'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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ROTATION SENSING
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 Supplies".
Derricking Drum
Rotation Detection A
Phase
24 V: ON
0 V: OFF
Drum Rotation Sensing
T2BC-05-03-034
Cancellation Switch
T5-3-72
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Rotation Sensing Solenoid
System
x Check the wiring connections first.
;'5㩷 Faulty front drum
rotation sensing
solenoid.
Disconnect connector
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
connector is 0 V. Faulty MC2/A.
01
· Key switch: ON
· Drum rotation sensing
cancellation switch: ON
Connector
MC2/A
Front lever Connector MCA-6
(harness end) (machine end)
T2BC-05-03-005 T2BC-05-03-032
T5-3-73
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Sensing Solenoid
System
x Check the wiring connections first.
;'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
connector is 0 V. Faulty MC2/A.
switch: ON
01
· Key switch: ON
· Drum rotation
sensing cancellation
switch: ON
Connector
MC2/A
Rear lever Connector MCA-6
(harness end) (machine end)
T2BC-05-03-005 T2BC-05-03-032
T5-3-74
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Rotation Sensing
Solenoid System
x Check the wiring connections first.
;'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
sensing cancellation
switch: ON
Connector
MC2/A
Derricking lever Connector MCA-6
(harness end) (machine end)
T2BC-05-03-032
T2BC-05-04-008
T5-3-75
TROUBLESHOOTING / Troubleshooting A
Check of Drum Rotation Sensing Cancellation
Switch System
x Check the wiring connections first.
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
sensing cancellation
switch and MC2/A.
Faulty MC2/A.
NO
Connector
MC2/A MC2/A Left overhead panel
Connector MCA-4 Connector MCA-5
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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Rotation Detection Sensor A
System
x Check the wiring connections first.
Faulty front drum
;'5㩷
rotation detection
Replace front drum sensor A.
rotation detection
sensor A with rear
Disconnect connector
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
Check for continuity
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
terminal #2 of front
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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Rotation Detection Sensor B
System
x Check the wiring connections first.
;'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
Check for continuity
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
terminal #2 of front
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
(harness end) (harness end)
T2BC-05-03-020 T2BC-05-03-029
T2BC-05-04-008
T5-3-78
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Detection Sensor A
System
x Check the wiring connections first.
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Rotation Detection Sensor B
System
x Check the wiring connections first.
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
Check for continuity
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
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Rotation Detection
Sensor A System
x Check the wiring connections first.
Faulty derricking
Replace derricking ;'5㩷 drum rotation de-
tection sensor A.
drum rotation detec-
tion sensor A with
front drum rotation
Disconnect connector
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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF ENGINE START INTERLOCK
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 Supplies".
Start Relay 1
Engine Start
Interlock
Front Drum Brake
Mode Selection Switch
24V
Starter Switch
T2BC-05-03-035
T5-3-82
TROUBLESHOOTING / Troubleshooting A
Check of Engine Start Relay
1 4 2
5
T2BC-05-03-032
3
T5-3-83
TROUBLESHOOTING / Troubleshooting A
Check of Slewing Brake Switch System
x Check the wiring connections first.
;'5㩷 Faulty MC2/A.
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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Free Mode Switch System
x Check the wiring connections first.
;'5㩷 Faulty MC2/A.
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.
In case of no conti-
nuity at terminal #4,
faulty harness be-
tween terminal #4 of
front drum brake
mode selection
switch and MC2/A.
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Free Mode Switch System
;'5㩷 Faulty MC2/A.
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.
In case of no conti-
nuity at terminal #4,
faulty harness be-
tween terminal #4 of
rear drum brake
mode selection
switch and MC2/A.
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
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Free Mode Switch System
(Optional)
;'5㩷 Faulty MC2/A.
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
Check for continuity
;'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
tween terminal #3 of
(auto brake) MCA-4 and terminal 01 third / fourth drum
#4 of third/fourth lever brake mode selec-
connector. tion switch and
MC2/A.
In case of no conti-
nuity at terminal #4,
faulty harness be-
tween terminal #4 of
third/fourth drum
brake mode selec-
tion switch and
MC2/A.
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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF PILOT PRESSURE DROP
WARNING LAMP 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 Supplies".
24 V (ON)
0 V (OFF)
24 V
0.5 to 4.5 V 0V 5V
Primary Pilot
Pressure
T25N-05-03-019
T5-3-88
TROUBLESHOOTING / Troubleshooting A
Check of Pilot Pressure Drop Indicator
T2BC-05-03-037 T2BC-05-03-004
T5-3-89
TROUBLESHOOTING / Troubleshooting A
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.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies"
24 V (ON)
0 V (OFF)
24 V Motor Cutoff
Relay
0.5 to 4.5 V 0V 5V
T25N-05-03-020
T5-3-90
TROUBLESHOOTING / Troubleshooting A
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
TROUBLESHOOTING / Troubleshooting A
FAILURE OF DERRICKING DRUM AUTO
STOP CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are nor-
mal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies"
T5-3-92
TROUBLESHOOTING / Troubleshooting A
Derricking Drum
Hoisting Proportional
Solenoid Valve
Derricking Drum
Lowering Proportional
Solenoid Valve
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 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
TROUBLESHOOTING / Troubleshooting A
Check of Wiring Detection Signal System
x Check the wiring connections first.
Crane Mode
Check for continuity
NO between terminals #1
and #2 of relay box.
Disconnect connector
MCB-4 of MC2/B.
Check for continuity
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 con- nector 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
(machine end) (harness end)
MC2/B T2BC-05-03-021 T2BC-05-03-027
Connector MCB-1
(harness end)
T2BC-05-03-038
T5-3-94
TROUBLESHOOTING / Troubleshooting A
Harness open cir-
cuit between
YES MC2/B and relay
box.
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
TROUBLESHOOTING / Troubleshooting A
Tower Mode
Connector
MC2/B MC2/B
Connector MCB-1 Connector MCB-4
(machine end) (harness end)
T2BC-05-03-021
T2BC-05-03-027
MC2/B
Connector MCB-1
(harness end)
T2BC-05-03-038
T5-3-96
TROUBLESHOOTING / Troubleshooting A
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
TROUBLESHOOTING / Troubleshooting A
Check of Boom Overhoist Switch System
x Check the wiring connections first.
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
Connector MCB-1 (harness end)
(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
TROUBLESHOOTING / Troubleshooting A
Check of Boom / Tower Second Overhoist Switch
System
x Check the wiring connections first.
Connect boom / tower
YES Faulty MC2/B.
second overhoist
switch.
Disconnect connector
MCB-4 of MC2/B.
Check for continuity
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
TROUBLESHOOTING / Troubleshooting A
Check of Tower Overhoist Switch System
x Check the wiring connections first.
Connect connector of YES
tower overhoist Faulty MC2/B.
switch.
Disconnect connec-
tor MCB-4 of MC2/B.
Check for continuity
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
TROUBLESHOOTING / Troubleshooting A
Check of Jib Overhoist Switch System
x Check the wiring connections first.
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.
Check for continuity
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
T2BC-05-03-027
T2BC-05-03-038
T2BC-05-03-042
MC2/B
Relay box Connector MCB-1
(machine end) (harness end)
T2BC-05-03-021
T2BC-05-03-039
T5-3-101
TROUBLESHOOTING / Troubleshooting A
Check of Jib Second Overhoist Switch System
x Check the wiring connections first.
Connect connector
of jib secondover-
hoist switch.
Disconnect con- YES Faulty MC2/B.
nector MCB-4 of
MC2/B.
Check for continuity
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
Check for continuity
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
(machine end) (harness end)
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
TROUBLESHOOTING / Troubleshooting A
Check of Hook Overhoist Switch System
x Check the wiring connections first.
YES Faulty MC2/B.
Connect connector
of hook overhoist
switch.
Disconnect con-
nector MCB-4 of
YES MC2/B.
Check for continuity
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
nector MCB-1 of MC2/B.
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
Check for continuity
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)
(machine end) (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
TROUBLESHOOTING / Troubleshooting A
Check of Backstop Alignment Overhoist Switch
System
x Check the wiring connections first.
Connect connector
of backstop align-
ment overhoist
YES Faulty MC2/B.
switch.
Disconnect connec-
tor MCB-4 of
MC2/B.
Check for continuity
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
(machine end) (harness end)
T2BC-05-03-038
T2BC-05-03-039
T5-3-104
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Hoisting Proportional
Solenoid Valve System
Harness short circuit
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
Disconnect connector
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
(harness end) (machine end) (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
T5-3-105
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Lowering Proportional
Solenoid Valve System
x Check the wiring connections first.
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
(harness end) (machine end) (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
T5-3-106
TROUBLESHOOTING / Troubleshooting A
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
harness end connector
of connector MCB-4 In case of no continuity
YES
and terminal Z16 of at terminal R1, harness
harness end connector
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
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Auto Stop Release
Switch
x Check the wiring connections first.
Disconnect connectors
YES Faulty MC2/B.
MCB-3 and MCB-5 of
MC2/B.
Connect terminal S7 of
harness end connector
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.
of left control panel and
· Derricking drum MC2/B.
auto stop release
switch: ON
Faulty derricking drum
NO auto stop release
switch.
Connector
Left control panel MC2/B
Connector 62C-16FW Connector MCB-3
(harness end)
(panel end)
T2BC-05-03-047 T2BC-05-03-048
T2BC-05-03-046 T2BC-05-03-044
T5-3-108
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies"
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)
RES ER Reset error Abnormal electric
current feedback
Current control by
open loop
T5-3-109
TROUBLESHOOTING / Troubleshooting A
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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Hoisting Proportional So-
lenoid Valve System
x Check the wiring connections first.
Connect terminal D3
Harness short circuit
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
harness open circuit
#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
(harness end) (machine end) (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
T5-3-111
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Lowering Proportional So-
lenoid Valve System
x Check the wiring connections first.
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
Check if voltage be-
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
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
TROUBLESHOOTING / Troubleshooting A
Check of Front Drum Auto Stop Release Switch
Disconnect connectors
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
of left control panel 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
Left control panel MC2/B
Connector 62C-16FW Connector MCB-3
(harness end) (harness end)
T2BC-05-03-046 T2BC-05-03-048
T2BC-05-03-047 T2BC-05-03-044
T5-3-113
TROUBLESHOOTING / Troubleshooting A
FAILURE OF REAR DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-114
TROUBLESHOOTING / Troubleshooting A
Main Hook
Overhoist
Prevention
Rear Drum
Hoisting Stop
Sub Hook
Overhoist Rear Drum
Prevention Lowering Stop
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Hoisting Proportional Sole-
noid Valve System
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Lowering Proportional So-
lenoid Valve System
x Check the wiring connections first.
Connect terminal Harness short circuit
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.
Disconnect connectors
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
(harness end) (machine end) (machine end)
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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Drum Auto Stop Release Switch
T2BC-05-03-046 T2BC-05-03-048
Left control panel MC2/B
Connector 62C-16FW Connector MCB-5
(panel end) (harness end)
T2BC-05-03-044
T2BC-05-03-047
T5-3-118
TROUBLESHOOTING / Troubleshooting A
FAILURE OF THIRD DRUM AUTO STOP
CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
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
TROUBLESHOOTING / Troubleshooting A
Crane Relay
Box Fourth Drum
Hoisting Stop
Third Drum
Main Hook Lowering Stop
Overhoist
Prevention
Shouldering
Prevention
Sub Hook
Overhoist
Prevention
T5-3-120
TROUBLESHOOTING / Troubleshooting A
Check of Third Drum Hoisting Solenoid Valve
System
x Check the wiring connections first.
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.
Check for continuity
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
(harness end) (harness end)
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
TROUBLESHOOTING / Troubleshooting A
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
Disconnect connector
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
harness end connector
· 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
Faulty third / fourth
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
TROUBLESHOOTING / Troubleshooting A
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.
Check for continuity
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
TROUBLESHOOTING / Troubleshooting A
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.
Check for continuity
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
Connector MCB-1 Connector MCB-4
(harness end) (machine end)
(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) (machine end)
(harness end)
T2BC-05-03-032
T2BC-05-03-051
T2BC-05-03-060
T5-3-124
TROUBLESHOOTING / Troubleshooting A
Connect terminal Harness short circuit
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
Connector MCB-6 Connector MCB-4
Third drum lowering solenoid (machine end)
(harness end)
valve (harness end)
T2BC-05-03-003 T2BC-05-03-045
MC2/B MC2/B
Connector MCB-6 Connector MCB-1
T2BC-05-04-010
(machine end)
(machine end)
T2BC-05-03-032 T2BC-05-03-021
T5-3-125
TROUBLESHOOTING / Troubleshooting A
Check of Third Drum Auto Stop Release Switch
x Check the wiring connections first.
Disconnect connectors
MCB-3 and MCB-5 of
MC2/B. YES Faulty MC2/B.
Connect terminal S16
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-
ness open circuit be-
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-
ness open circuit be-
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
Faulty third / fourth
drum auto stop release
NO switch.
Connector
Left control panel MC2/B
Connector 62C-16FW Connector MCB-3 (har-
(harness end) ness end)
T2BC-05-03-046 T2BC-05-03-048
T2BC-05-03-047 T2BC-05-03-044
T5-3-126
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FOURTH DRUM AUTO STOP
CONTROL SYSTEM (OPTIONAL)
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
3D HST SOL Fourth drum hoisting ERROR Short circuit OFF (stop) Harness check
solenoid valve Solenoid valve
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
TROUBLESHOOTING / Troubleshooting A
Boom Overhoist
Prevention
Crane Relay
Fourth Drum
Box
Hoisting
Prevention
Third Drum
Main Hook Hoisting
Overhoist Prevention
Prevention
Shouldering
Prevention
Sub Hook
Overhoist
Prevention
T5-3-128
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Hoisting Solenoid Valve
System
x Check the wiring connections first.
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:
Check for continuity
between machine and
terminals #1, #2 of In case of no conti-
harness end of con- nuity at terminal #1,
harness open circuit
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-
nuity at terminal #2,
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
TROUBLESHOOTING / Troubleshooting A
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
Disconnect connector
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
Check for continuity
· Connect terminals D3 and
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.
· Third / fourth selection
switch: Fourth
Faulty third / fourth
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-05-03-032
T5-3-130
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Lowering Solenoid Valve
System
• Check the wiring connections first.
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
Check for continuity be-
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
TROUBLESHOOTING / Troubleshooting A
Connect terminal Harness short circuit
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.
· Connect terminals D3 and
YES A5 by using a clip or the like
Check for continuity be-
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
· Third / fourth selection
switch: Fourth
Faulty third/fourth selec-
NO tion switch.
Connector
MC2/B MC2/B MC2/B
Connector MCB-1 Connector MCB-4 Connector MCB-6
(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
TROUBLESHOOTING / Troubleshooting A
Check of Fourth Drum Auto Stop Release Switch
x Check the wiring connections first.
Disconnect connectors
MCB-3 and MCB-5 of
MC2/B.
YES Faulty MC2/B.
Connect terminal S16
of harness end con-
nector of connector
MCB-3 and terminal In case of no continuity
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
Left control panel MC2/B
Connector 62C-16FW Connector MCB-3
(harness end) (harness end)
T2BC-05-03-046 T2BC-05-03-048
Left control panel MC2/B
Connector 62C-16FW Connector MCB-5
(panel end) (harness end)
T2BC-05-03-047
T2BC-05-03-044
T5-3-133
TROUBLESHOOTING / Troubleshooting A
FAILURE OF SECOND OVERHOIST AUTO
STOP CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-134
TROUBLESHOOTING / Troubleshooting A
Second Overhoist
Solenoid Valve.
Tower Relay
Box
T2BC-02-01-018
T5-3-135
TROUBLESHOOTING / Troubleshooting A
Check of Second Overhoist Solenoid Valve Sys-
tem
x Check the wiring connections first.
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
Connector MCB-1 Connector MCB-4
(harness end) (machine end)
(machine end)
T2BC-05-03-021 T2BC-05-03-045
T2BC-05-04-010 MC2/B
MC2/B
Connector MCB-6 Connector MCB-6
(harness end) (machine end)
T2BC-05-03-003 T2BC-05-03-032
T5-3-136
TROUBLESHOOTING / Troubleshooting A
Check of Second Overhoist Restoration Switch
T2BC-05-03-046 T2BC-05-03-027
T2BC-05-03-047
T2BC-05-03-044
T5-3-137
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT AND REAR MOTOR
SPEED CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-138
TROUBLESHOOTING / Troubleshooting A
Hoisting Displacement
Angle Lock Switch
T2BC-05-03-053
T5-3-139
TROUBLESHOOTING / Troubleshooting A
Check of Front Motor Displacement Angle Con-
trol Proportional Solenoid Valve System
x Check the wiring connections first.
Harness short circuit
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.
Disconnect connectors
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
In case of no continuity
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
Connector MCB-5 (harness end)
(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
TROUBLESHOOTING / Troubleshooting A
Check of Rear Motor Displacement Angle Control
Proportional Solenoid Valve System
x Check the wiring connections first.
Harness short circuit
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
proportional solenoid valve Connector MCB-6
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
T2BC-05-03-031
T5-3-141
TROUBLESHOOTING / Troubleshooting A
Check of Hoisting Low Speed Lock Switch
T2BC-05-03-054 T2BC-05-03-027
Side upper panel MC2/B
Connector 62C-16FW Connector MCB-5
(panel end) (harness end)
T2BC-05-03-055 T2BC-05-03-044
T5-3-142
TROUBLESHOOTING / Troubleshooting A
FAILURE OF FRONT DRUM SURGE
PRESSURE REDUCTION CONTROL SYS-
TEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-143
TROUBLESHOOTING / Troubleshooting A
Front Drum
Lock Switch Front Drum Lowering
Proportional Solenoid
Valve
Shouldering
Prevention
T2BC-05-03-056
T5-3-144
TROUBLESHOOTING / Troubleshooting A
FAILURE OF TOWER JIB DERRICKING
2-SPEED FLOW COMBINING LIMIT CON-
TROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of
battery and sensor power supply of MC2/B are
normal.
If error is indicated, refer to "Failure of MC2/A and
MC2/B Batteries and Sensor Power Supplies".
T5-3-145
TROUBLESHOOTING / Troubleshooting A
Rear Drum Hoisting
Proportional Solenoid
Valve
Rear Drum
Lock Switch Front Drum Lowering
Proportional Solenoid
Valve
Shouldering
Prevention
T2BC-05-03-057
T5-3-146
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
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
Mounting Surface T6L4-05-03-001
T5-4-1
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING LIST
T5-4-2
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
Terminal B
Terminal S
T333-05-04-012
T2BC-05-04-002
Starter Motor
T5-4-3
TROUBLESHOOTING / Troubleshooting B
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
Terminal L Terminal SW
Terminal #3
T5-4-4
TROUBLESHOOTING / Troubleshooting B
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
Terminal L Terminal SW
Terminal E Terminal P
T5-4-5
TROUBLESHOOTING / Troubleshooting B
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
Check if voltage be-
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
TROUBLESHOOTING / Troubleshooting B
Broken harness
YES between battery
relay and ground,
Connect ground
terminal of battery or faulty ground.
relay to machine.
YES Check if voltage
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
TROUBLESHOOTING / Troubleshooting B
E-2 Starter turns but engine does not start.
• Check the position of engine governor lever dur-
ing cranking.
If normal, the cause of failure may be malfunction
of engine itself.
• Check the wiring connections first.
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
TROUBLESHOOTING / Troubleshooting B
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
TROUBLESHOOTING / Troubleshooting B
E-3 Poor engine starting ability at low tempera-
ture (no preheating)
T5-4-10
TROUBLESHOOTING / Troubleshooting B
YES Faulty heater relay or
faulty ground.
Remove plug from
heater relay.
YES Check if voltage
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
· Insert a test bar
into the rear of
connector.
Connector
Preheat Controller
(Harness end)
T2BC-05-04-003
T5-4-11
TROUBLESHOOTING / Troubleshooting B
Connector
Preheat Controller Coolant Temperature Sensor
(Harness end) (Harness end)
T2BC-05-04-003
T5-4-12
TROUBLESHOOTING / Troubleshooting B
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
TROUBLESHOOTING / Troubleshooting B
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.
Check if voltage be-
· 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
TROUBLESHOOTING / Troubleshooting B
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
· Insert a test bar
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
TROUBLESHOOTING / Troubleshooting B
E-5 Idle speed is too fast or slow
• Incorrect engine speed may be resulted from
faulty adjustment of governor motor, link or lever,
or malfunction of fuel injection pump.
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
T5-4-16
TROUBLESHOOTING / Troubleshooting B
E-6 Maximum un-load speed is too slow
• Incorrect engine speed may be resulted from
faulty adjustment of governor motor, link or lever,
or malfunction of fuel injection pump.
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
TROUBLESHOOTING / Troubleshooting B
E-7 Engine does not stop.
• Engine is stopped by cutting off fuel by using an
engine stop solenoid.
• If engine does not stop, engine stop solenoid
may fail, or engine stop relay (which delivers a
stop signal to the engine stop solenoid), or key
switch (even in OFF state, 24V voltage is present
at its terminal ACC) may fail.
• Check the wiring connections first.
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
(Harness end) (Harness end)
Terminal C Terminal B
T2BC-05-04-001 T2BC-05-04-002
Terminal ACC
T5-4-18
TROUBLESHOOTING / Troubleshooting B
ACTUATOR TROUBLESHOOTING
T5-4-19
TROUBLESHOOTING / Troubleshooting B
HOISTING DRUM TROUBLESHOOTING
Counterbalance
Valve
PR Port (G1/4)
Port A4
T2BC-05-04-004
Hoisting
Motor
M25N-07-024
T5-4-20
TROUBLESHOOTING / Troubleshooting B
M-2 When moving hoisting lever to neutral,
the lifting load lowers.
(in the auto brake mode)
• In this case, hoisting drum brake may not be ap-
plied, or hoisting motor multi-plate brake may not
be applied.
• Refer to “Troubleshooting A”.
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
TROUBLESHOOTING / Troubleshooting B
M-3 Even when setting brake mode key switch
to auto brake position, auto brake indicator
(green) is not turned ON.
• Check if each brake mode selection switch is
OFF.
• If both pilot pressure drop indicator and slewing
brake indicator are not turned ON, 224 harness
may be open circuit.
• Check the wiring connections first.
• For check of brake mode selection switch and
front drum and rear drum brake mode selection
switches, refer to section "Failure of Brake Con-
trol System" in “Troubleshooting A”.
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
TROUBLESHOOTING / Troubleshooting B
M-4 Even when switching to the free mode,
auto brake indicator (green) is not turned
OFF.
• Check the wiring connections first.
• Refer to “Troubleshooting A”.
YES
Faulty MC2/A.
Disconnect connector
MCA-6 of MC2/A.
Check for continuity
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
TROUBLESHOOTING / Troubleshooting B
M-5 Even when setting free mode switch of
drum to ON position, free-fall cannot be
done.
• Check the wiring connections first.
• While tower derricking or second overhoist sole-
noid valve stopping, the free mode cannot be
selected.
• Refer to “Troubleshooting A”.
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
TROUBLESHOOTING / Troubleshooting B
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
TROUBLESHOOTING / Troubleshooting B
M-6 Even when setting to the free mode, drum
free indicator (red) is not turned ON.
• Check the wiring connections first.
• Refer to “Troubleshooting A”.
YES Burn out of drum free
indicator bulb or faulty
ground.
Check if voltage be-
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
measurement between terminal
#6 and machine.
· Third drum free indicator: Make
measurement between terminal
#5 and machine.
· Free mode.
Refer to M-5.
NO
Connector
Connector
Brake Indicator Lamp
(Harness end)
T2BC-05-04-006
T5-4-26
TROUBLESHOOTING / Troubleshooting B
M-7 Even when setting to the auto brake mode,
drum free indicator (red) is not turned OFF.
• Check the wiring connections first.
• Refer to “Troubleshooting A”.
Disconnect connector MCA-6 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:
Make measurement be-
tween terminal E9 and ma-
chine.
· Third drum free indicator:
Make measurement be-
tween terminal E7 and ma-
chine.
Connector
MC2A
Connector MCA-6
(Harness end)
E9 E7
T2BC-05-04-007
E22
T5-4-27
TROUBLESHOOTING / Troubleshooting B
BOOM DERRICKING DRUM TROUBLE-
SHOOTING
B-1 Drum the does not rotate.
• Check wiring connections first.
• If pilot pump, pressure-reducing valve for 4-spool
solenoid valve unit and gate lock valve are faulty,
not only drum rotation but travel and slew cannot
be achieved.
• If safety device works, drum stops.
Refer to “Troubleshooting A and D”.
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-
solenoid valve unit.
formance Meas-
urement”.
Faulty pres-
sure-reducing valve
NO in 4-spool solenoid
valve unit.
4-Spool Solenoid Valve Unit
Port A1
Port A4
T2BC-05-04-004
T5-4-28
TROUBLESHOOTING / Troubleshooting B
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
T5-4-29
TROUBLESHOOTING / Troubleshooting B
SLEWING SYSTEM TROUBLESHOOTING Port b (G 1/4)
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
Port A2 T2BC-05-04-004
Pressure Check Port
T2BC-04-05-008
T5-4-30
TROUBLESHOOTING / Troubleshooting B
Connector
Slewing Lever Slewing Brake Solenoid Valve
(Harness end) (Harness end)
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
TROUBLESHOOTING / Troubleshooting B
F7
T2BC-05-04-008
T2BC-05-04-009
T5-4-32
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 One-side track does not run, travel speed is
too slow, or mistrack is caused.
• If pilot pump, pressure-reducing valve of 4-spool
solenoid valve unit and gate lock valve are faulty,
not only travel but slew and drum rotation are
deactivated.
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
T25N-05-04-006
T5-4-33
TROUBLESHOOTING / Troubleshooting B
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
TROUBLESHOOTING / Troubleshooting B
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
solenoid valve unit.
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
T2BC-05-04-010
4-Spool Solenoid Valve Unit
Travel Motor
PS Port
(G 1/4)
Port A3 T2BC-05-04-004
M25N-07-032
T5-4-35
TROUBLESHOOTING / Troubleshooting B
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
(Harness end) (Harness end)
T2BC-05-04-012
T2BC-05-04-013
T5-4-36
TROUBLESHOOTING / Troubleshooting B
O-2 Counterweight (optional) cannot be re-
moved and installed.
• Check the wiring connections first.
Check for continuity
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
TROUBLESHOOTING / Troubleshooting B
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
TROUBLESHOOTING / Troubleshooting B
O-3 Jack-up (optional) cannot be done.
• Check the wiring connections first.
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
TROUBLESHOOTING / Troubleshooting B
4-Spool Control Valve
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.
T2BC-05-04-017 T2BC-05-04-023 T2BC-05-04-022
T5-4-40
TROUBLESHOOTING / Troubleshooting B
YES Stuck spool.
Check if jack-up
YES
spool in lower control
valve moves.
Broken harness
between hydraulic
NO selection solenoid
valve and machine,
or faulty ground.
T5-4-41
TROUBLESHOOTING / Troubleshooting B
O-4 Retraction (with jack (optional) attached)
cannot be done.
Broken harness
between jack relay
NO (R5) and battery
relay or fuse #39.
Relay Connector
(Harness end)
T2BC-05-04-014
T2BC-05-04-018
T5-4-42
TROUBLESHOOTING / Troubleshooting B
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.
T2BC-05-04-017 T2BC-05-04-023 T2BC-05-04-022
T5-4-43
TROUBLESHOOTING / Troubleshooting B
Broken harness
between hydraulic
NO
selection solenoid
valve and machine,
or faulty ground.
T5-4-44
TROUBLESHOOTING / Troubleshooting B
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.
Relay Connector Panel Connector
(Harness end) (62C-16FB)
(Harness end)
T2BC-05-04-025
T2BC-05-04-014
T5-4-45
TROUBLESHOOTING / Troubleshooting B
T2BC-05-04-023 T2BC-05-04-022 T2BC-05-04-015
T5-4-46
TROUBLESHOOTING / Troubleshooting B
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.
4-Spool Control Valve
Side Frame Retract Solenoid
Valve Connector
(Harness end)
T2BC-05-04-015
T2BC-05-04-024
T5-4-47
This Page Left Blank
Intentionally
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
• 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.
Harness
Harness end
connector
Mounting Surface T6L4-05-03-001
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
• Check the wiring connections first.
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
Check for continuity
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
Check for continuity
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
TROUBLESHOOTING / Troubleshooting C
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
Coolant Temperature
Sensor
1
2
Faulty coolant temperature
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.
Faulty coolant temperature
sensor.
Faulty monitor panel.
Faulty coolant temperature
sensor terminal connection.
T5-5-3
TROUBLESHOOTING / Troubleshooting C
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
YES
Disconnect fuel sensor.
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
TROUBLESHOOTING / Troubleshooting C
Fuel Sensor
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
Faulty monitor panel.
70.5 mm
27q
1/2
228 mm 28q
Electrical Resistor
1/4
Faulty fuel sensor. 338 mm
EMPTY
T107-04-03-020
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
• Check the wiring connections first.
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.
¨Engine: Stop harness
connected to
¨ Key switch: ON machine.
Disconnect connector
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.
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL
INDICATOR
• Other indicators blink normally.
• Check the wiring connections first. With terminals of cool-
ant level switch con-
nected.
Disconnect connector
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
¨ Key switch: ON
Faulty coolant level
NO switch.
T5-5-7
TROUBLESHOOTING / Troubleshooting C
Reserve Tank
YES㩷
Faulty monitor panel. ON
FULL
LOW
Connector (Harness end)
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-
nector IDU-5 of IDU.
Check if indicator is
turned ON.
· Key switch: ON Faulty IDU.
NO
T2BC-05-04-027
Faulty monitor panel.
NO
T5-5-8
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL FILTER
RESTRICTION INDICATOR
• Check the wiring connections first.
• If engine oil filter is clogged, engine oil pressure
decreases and engine oil pressure indicator is
turned ON.
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.
Check if indicator is
turned ON.
· Key switch: OFFņON
¨Key switch: ON
¨Insert a test bar into the
rear of connector.
YES Indicator bulb is burned
out.
NO Check for continuity
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.
¨Insert a test bar into NO Disconnect connector
the rear of connec- C16F-W of monitor
tor. panel.
Check for continuity
¨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.
Check if indicator is
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.
NO Check for continuity
between machine and
terminal #5 (harness
end) of connector. Check for continuity
between machine and
NO terminal #1 (harness
end) of connector.
T5-5-9
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end)
Broken harness between
Monitor Panel C16F-W
YES monitor panel and engine
oil filter restriction switch.
T2BC-05-04-026
YES
Faulty IDU.
T2BC-05-04-027
Broken harness between
monitor panel and IDU.
NO
Short-circuited harness
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
Faulty monitor panel.
NO
T5-5-10
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
• Check the wiring connections first.
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
TROUBLESHOOTING / Troubleshooting C
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)
Connector (Harness end)
YES
Faulty monitor panel. Monitor Panel C16F-W
Broken harness between
monitor panel and air filter T2BC-05-04-026
NO restriction switch.
Connector IDU-5 of IDU
YES
Faulty IDU.
T2BC-05-04-027
Broken harness between
monitor panel and IDU.
NO
Short-circuited harness
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
Faulty monitor panel.
NO
T5-5-12
TROUBLESHOOTING / Troubleshooting C
MALFUNKTION OF OVERHEAT INDICA-
TOR
Disconnect terminal of
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
YES Burnt indicator bulb.
Check for continuity
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-
¨Insert a test bar into NO nector to machine.
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
terminal #1 (harness
end) of connector.
YES Faulty overheat switch.
Check if indicator is
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.
Disconnect terminal of
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
TROUBLESHOOTING / Troubleshooting C
Overheat switch
Coolant temperature Operation
Lower than 101 qC (214 qF) OFF
101 qC (214 qF) or higher ON
YES Connector (Harness end)
Faulty monitor panel.
Monitor Panel C16F-W
Broken harness between
monitor panel and over-
NO heat switch.
T2BC-05-04-026
Connector IDU-5 of IDU
YES
Faulty IDU.
Broken harness between T2BC-05-04-027
monitor panel and IDU.
NO
Connect the dis- YES Short-circuited harness
connected con- between monitor panel
nector. and IDU.
YES Disconnect con-
nector IDU-5 of
IDU.
Check if indicator Faulty IDU.
is turned ON. NO
· Key switch: ON
Faulty monitor panel.
NO
T5-5-14
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF CONTROLLER FAIL-
URE INDICATOR
• Check the wiring connections first.
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.
YES Burnt indicator bulb.
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.
Disconnect connector
· 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
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end)
ECU Connector 2
T2BC-05-04-029
YES Monitor Panel C16F-W
Faulty monitor panel.
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
Broken harness between
monitor panel and IDU.
NO
Connect the dis- Short-circuited harness
YES
connected con- between monitor panel
nector. and IDU.
YES Disconnect con-
nector IDU-5 of
IDU.
Check if indicator Faulty IDU.
is turned ON. NO
· Key switch: ON
Faulty monitor panel.
NO
T5-5-16
TROUBLESHOOTING / Troubleshooting C
MULFUNCTION OF PREHEAT INDICATOR
T2BC-05-04-026
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MULFUNCTION OF ALTERNATOR INDI-
CATOR
• Check the wiring connections first.
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.
(harness end) of con-
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
Check if indicator is
turned ON.
¨Key switch: ON
¨Insert 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
terminal #7 (harness
end)
of connector of Faulty monitor panel.
monitor panel.
NO㩷
Connector (Harness end)
Alternator Relay Monitor Panel (C16F-W)
T2BC-05-04-026
T2BC-05-04-030
T25N-05-03-027
T5-5-18
TROUBLESHOOTING / Troubleshooting C
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
terminal #4 (harness
Check if voltage be-
end) of connector of Short-circuited harness
alternator relay. between alternator and
tween machine and
YES alternator relay.
terminal #1 (harness
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.
Short-circuited harness
YES㩷
between alternator
relay and monitor
Disconnect connector
of alternator.
YES Faulty alternator.
Connect terminal #2
(harness end) of con-
YES㩷 nector to machine.
Check for continuity
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.
Connector (Harness end)
Alternator
T2BC-05-04-031
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE UNAPPLIED
INDICATOR
• Check the wiring connections first.
Indicator lighting conditions:
If key switch is set to "START" position under one
or more conditions mentioned below, engine does
not start and indicator is turned ON.
• Slewing brake 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
(harness end) of con-
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.
Check if indicator is
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.
¨Engine: Running panel.
· Key switch: ON
¨Key switch: ON Check for continuity
NO
between machine and
terminal #9 (harness
of connector. Faulty monitor panel.
end)
NO
Connector (Harness end)
Monitor Panel (C16F-W)
Connector MCA-6 of MC2/A
(Harness end)
T2BC-05-04-026 T2BC-05-04-027
T5-5-20
TROUBLESHOOTING / Troubleshooting C
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
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
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
TROUBLESHOOTING / Troubleshooting D
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
(control A) voltage < Lower limit 2
WA3 Switch power supply 3 short circuit (Control A) 24V3 power supply monitoring T5-6-36
(control A) voltage < Lower limit 2
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
W82 (Corresponding to new version) 㧙
W83 (Corresponding to new version) 㧙
W84 (Corresponding to new version) 㧙
W88 (Corresponding to new version) 㧙
W89 (Corresponding to new version) 㧙
T5-6-2
TROUBLESHOOTING / Troubleshooting D
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)
WB2 WB2: Sensor power supply short circuit (24V2B)
WB3 WB3: Sensor power supply short circuit (24V3B)
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
TROUBLESHOOTING / Troubleshooting D
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.
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
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
T5-6-4
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E21, E26
E21, E26
Controller (IDU)
NO
Boom angle detector
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
TROUBLESHOOTING / Troubleshooting D
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
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
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E30
“1”, “6” Connectors (5P)
E30
YES
0.2 V
(No voltage, or 4V or
more) NO Jib angle detector failure
“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)
“3”, “4” Connectors (24P)
Disconnect “4” connector (24P) of cable
reel wiring of machine relay box, and
measure voltage between terminals #17
and #19 and terminals #17 and #20 of
opposite “5” receptacle.
T2BC-05-06-002
YES
0.2 V “5” Receptacle (24P)
B
T2BC-05-06-001
T5-6-7
TROUBLESHOOTING / Troubleshooting D
B E30 (continued)
View C T25N-05-06-005
Connect machine harness to machine relay
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
(26P).
0: to Several M:
Resistance
View A T2BC-05-06-005
п (no resistance)
Check for continuity between
terminal #4 of “8” connector (12P)
and terminal #6 of “9” connector
(22P).
No continuity
Continuity
T5-6-8
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E31
E31
“7” 5P (female)
“6” 5P (male)
Check if
connection is YES
correct.
“2” 5P (female)
NO “1” 5P (male)
Relay box T2BC-05-06-008
“1”, “6” Connectors (5P)
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
T5-6-9
TROUBLESHOOTING / Troubleshooting D
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
“8” 12P (female, black)
1.6 m
“3” 24P (male)
“5” 24P
(female)
“4” 24P (male)
Disconnect “4” connector (24P) of cable
Boom-upper relay box T2BC-05-06-007
reel wiring of machine relay box, and
measure voltage between terminals #16
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
T5-6-10
TROUBLESHOOTING / Troubleshooting D
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
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
Controller (IDU) failure
T5-6-11
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E40
E40
Controller (IDU) failure
FAULT CODE E43
E43
Check if
attachment of NO
field machine is a
tower.
YES
Controller (IDU) failure
Check if tower NO
is selected.
YES
On the operation set
window, select tower
attachment.
Controller (IDU) failure
T5-6-12
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E44
E44
Check if
attachment of field NO
machine is a
crane.
YES
Controller (IDU) failure
Check if crane NO
is selected.
YES
On the operation set
window, select tower
attachment.
Controller (IDU) failure
T5-6-13
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E45
E45
Disconnect “1” connector (24P) for
cable reel wiring of machine relay box, View A T25N-05-06-012
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
“3” 26P (female, yellow)
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
#5 to #7, # 6, # 7: YES
no resistance
NO (500 k: or more) Controller (MC2/B) failure
T5-6-14
TROUBLESHOOTING / Troubleshooting D
E E45 (continued)
“6” Receptacle (24P)
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:.
T5-6-15
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E50 (CRANE)
E50
Controller (IDU)
NO
Load cell failure Relay box
“1” 7P (female) T2BC-05-06-009
Check if E50 YES (E52 indicated)
disappears.
NO
Load cell harness failure
A
T5-6-16
TROUBLESHOOTING / Troubleshooting D
A
Controller (IDU)
NO
Relay box failure Relay box
“1” 7P (female) T2BC-05-06-009
NO
Machine harness failure
Controller (IDU) failure
T5-6-17
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E50 (TOWER)
E50
Controller (IDU)
Check if E50 YES (E52 indicated)
disappears.
NO
Load cell harness failure
A
T5-6-18
TROUBLESHOOTING / Troubleshooting D
A
Controller (IDU)
Relay box
NO
Relay box failure
Tower jib
“2” 7P (male) load cell
Reconnect “3” connector as it was.
Disconnect “4” connector (26P) of
connector (IDU).
Check if E50 YES (E52 indicated)
disappears.
NO
Machine harness failure
Controller (IDU) failure
T5-6-19
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E51
E51
Check the setting of boom (tower)
length, jib length, number of hoisting
rope reevings and hook capacity.
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.
0.5 V r 0.04 V NO
YES F
T5-6-20
TROUBLESHOOTING / Troubleshooting D
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
Check if E51 NO
disappears.
Completion
T5-6-21
TROUBLESHOOTING / Troubleshooting D
FAULT CODE E52
In case of crane
E52 Controller (IDU)
Check if YES
connection is
correct.
Relay box
NO
Load cell
Connect “1” connector (7P) of load
cell correctly.
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
TROUBLESHOOTING / Troubleshooting D
G E52 (crane) (continued)
Controller (IDU)
NO Relay box
Load cell harness failure
“3” Connector
Connect relay box and machine harness. Load cell
Disconnect “6” connector.
“2” Connector
Measure voltage at terminals #9, #11.
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
TROUBLESHOOTING / Troubleshooting D
H
Controller (IDU)
Machine harness
Resistance “6” 16P
“5” Connector
“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.
No continuity
Continuity
T25N-05-06-020
View A
Continued
Controller (IDU) failure
Controller (IDU) failure
T25N-05-06-001
View B
T25N-05-06-005
View C
T2BC-05-06-010
View D
T5-6-24
TROUBLESHOOTING / Troubleshooting D
In case of tower
E52
Controller (IDU)
Check if YES
connection is
correct. “1” 7P (female)
NO
“1” Connector (7P)
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
TROUBLESHOOTING / Troubleshooting D
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)
NO Machine relay box failure
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.
“3” Receptacle (7P)
No continuity
Continuity
Continued Machine harness failure
T5-6-26
TROUBLESHOOTING / Troubleshooting D
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
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
T5-6-27
TROUBLESHOOTING / Troubleshooting D
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
TROUBLESHOOTING / Troubleshooting D
B W47 (continued)
“6” Receptacle (24P)
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
#1 to #3 = continued
Boom-upper relay box T2BC-05-06-012
(tower)
T5-6-29
TROUBLESHOOTING / Troubleshooting D
C W47 (continued)
T5-6-30
TROUBLESHOOTING / Troubleshooting D
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.
Continuity
“1” Connector (7P)
Reconnect “1” connector (7P) for T2BC-05-03-010
T25N-05-03-028
No continuity
Continuity
D To T5-6-33
T5-6-31
TROUBLESHOOTING / Troubleshooting D
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.
Check for continuity between
terminals in ( ) in case of sub
hook.
No continuity
Continuity “5” 16P
(female, yellow)
Continued View A T25N-05-06-012
Machine relay box
failure
Reconnect “4” connector (16P) as it
was.
Disconnect “5” connector (16P) of
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”
terminals in ( ) in case of sub
connector (22P) of controller (MC2/B). hook.
T25N-05-06-001
View C
“3” Connector (24P)
No continuity
Continuity
T5-6-32
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W90
W90 Controller (MC2/A) Controller (IDU)
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
No continuity
Continuity
T5-6-33
TROUBLESHOOTING / Troubleshooting D
FAULT CODE W91
W91 Controller (MC2/B) Controller (IDU)
Reconnect connector for CAN
communication as it was.
Check for continuity between terminal
#14 of “3” connector (26P) of controller
(IDU) and terminal #9 of “4” connector
(22P) of controller (MC2/B).
T25N-05-06-029
View A
No continuity
Continuity
T25N-05-06-005
View B
Continued
No continuity
Continuity
T5-6-34
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WA1
WA1
Disconnect connectors of free
mode switch.
Check if WA1 YES
disappears.
NO
Free mode switch wiring failure
NO
Emergency stop switch wiring failure
Controller (MC2/A) failure
FAULT CODE WA3
WA3
T5-6-35
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WB2
WB2
Controller (MC2/B) failure
T5-6-36
TROUBLESHOOTING / Troubleshooting D
FAULT CODE WB3
WB3
Controller (MC2/B)
Disconnect “1” connector (24P) of
boom-upper relay box.
Cable reel wiring failure
NO
Connect machine harness to
machine relay box. Disconnect “3”
connector (16P).
T5-6-37
This Page Left Blank
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).
Harness
Harness end
connector
Mounting Surface T6L4-05-03-001
T5-7-1
TROUBLESHOOTING/Troubleshooting E
HOW TO READ FAULT CODE IN ECU EN-
GINE TROUBLESHOOTING
IMPORTANT: Record all indicated fault codes, and
ECU Lamp
verify that all recorded fault codes
are correct by reference with the fa-
ult code table in the following page.
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
TROUBLESHOOTING/Troubleshooting E
IMPORTANT: Avoid long-hour operation or heavy load operation in the backup mode.㩷
T5-7-3
TROUBLESHOOTING/Troubleshooting E
Checking:
Check harness continuity and short circuit between
ECU and each sensor according to the failure in Ta-
ble.
When harness is sound, the related sensor or ECU
may be faulty.
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
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
1 11
12 22
T5-7-4
TROUBLSHOOTING / Troubleshooting F
SML-10
Change the ROM on the controller.
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.
T5-8-1
TROUBLSHOOTING / Troubleshooting F
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
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$QZ
+&7
%CDNG4GGN
%QTF
%#0*CTPGUU
VQ/%#CPF/%$
&KURNC[
+PUKFGQH%CD
5YKVEJ$QZ
/CKP*CTPGUU
*CTPGUU
#PING
1WVUKFGQH 5GPUGT
% D
%QPGEVKQP$QZ
.QCFEGNN
T5-8-2
TROUBLSHOOTING / Troubleshooting F
3. Structure and Function
3.1 Controller
The controller is attached in the rear stand of operater's seat back.
T5-8-3
TROUBLSHOOTING / Troubleshooting F
3.2 Loadcell
The Loadcell is attached at the rope end of the boom hoist rope.
T5-8-4
TROUBLSHOOTING / Troubleshooting F
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
T5-8-5
TROUBLSHOOTING / Troubleshooting F
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.
T5-8-6
TROUBLSHOOTING / Troubleshooting F
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
T5-8-7
TROUBLSHOOTING / Troubleshooting F
3.5 Display
The display is the general-purpose article for car navigation.
(made from Panasonic).
T5-8-8
TROUBLSHOOTING / Troubleshooting F
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.
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
(2) ML Screen
no
Out of radius and no load ?
yes
no
Is boom angle upper 10 deg?
yes
yes
Out of radius?
no
T5-8-9
TROUBLSHOOTING / Troubleshooting F
Fig. 4.1 Normal Screens (1) - (6)
T5-8-10
TROUBLSHOOTING / Troubleshooting F
4.2 Menu Screen
off
for User
T5-8-11
TROUBLSHOOTING / Troubleshooting F
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.
Confirm each safety device stop as this table. The present hook height is set to 0.0ft.
Yes No
T5-8-12
TROUBLSHOOTING / Troubleshooting F
(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.
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
TROUBLSHOOTING / Troubleshooting F
4.2.2 Maintenance Menu
(1) Inspection Menu
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)
T5-8-14
TROUBLSHOOTING / Troubleshooting F
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
TROUBLSHOOTING / Troubleshooting F
2) Self-weight Correction
Hoist the boom until the insde of the start frame After moving the Boom hoist lever to
flushes in green color. Then, after moving the neutral, press <START> key.
boom hoist lever to neutral, press <START> key.
The Boom angle comes close to the correction Correction of the self-weight is complete.
point, Change the Boom lower speed to the After returning the boom hoist lever to neutral,
superfine speed mode. press <END> key.
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
T5-9-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the
wire itself. Release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-4-3.)
2) The water-resistant connectors keep water
out. If water enters them, water will not
easily drain from them. When checking the
water-resistant connectors, take extra care T107-07-06-002
T5-9-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
x Pull and Separate Type
x Push, Unlock and Separate Type
T107-04-05-004
x Raise Lock, Pull and Separate Type
Screw
Protruded Mark
T107-04-05-003
T107-04-05-005
T5-9-3
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
T5-9-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION
T324-04-05-002
T2BC-01-02-020
T5-9-5
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
T105-07-01-008
T5-9-6
TROUBLESHOOTING / Electrical System Inspection
Connection in Fuse Box 1
Fuse NO. Description Capacity Connected to Remarks
1 Air Conditioner Main Power Source 15 A Air Conditioner Main Power Source
2 Slewing Alarm Power Source 10 A Slewing Alarm Lamp Relay Power Source
3 Buzzer Power Source 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
TROUBLESHOOTING / Electrical System Inspection
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
TROUBLESHOOTING / Electrical System Inspection
HOW TO CHECK ALTERNATOR
T5-9-9
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE CHECK
1 3
T141-05-06-003
Measuring points
(1) ............ 24 V
(2) ............ 20 V
(3) .............. 0 V
Measurements do not reach the specified power volt-
age due to voltage drop caused by resistance of elec-
trical parts.
However, it can be judged that circuit up to measuring
point (where voltage is available) is normal.
T5-9-10
TROUBLESHOOTING / Electrical System Inspection
NOTE: As for the points to be checked, refer to the illustrations in the following pages.
T5-9-11
TROUBLESHOOTING / Electrical System Inspection
Power Source Circuit
3 2 1
Horn
MC2/A
MC2/B
Battery Relay
IDU
Key Switch
T2BC-05-09-001
T5-9-12
TROUBLESHOOTING / Electrical System Inspection
Preheat Circuit
Battery
Engine
Start Relay
MC2/A
8
7
Key Switch
Battery Relay
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
TROUBLESHOOTING / Electrical System Inspection
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
Engine Stop Relay Engine
Stop
Solenoid
16
17
Starter
Relay
20 Starter
Motor
Starter
Relay 2
Alternator
T25N-02-03-006
T5-9-14
TROUBLESHOOTING / Electrical System Inspection
Charging Circuit
Battery 8
Key Switch
Battery Relay
Off-Delay Relay
21
Alternator
Alternator
Relay
Alternator Indicator
T25N-02-03-004
T5-9-15
TROUBLESHOOTING / Electrical System Inspection
Surge Voltage Prevention Circuit
Battery
22
Key Switch
Battery Relay
23
Off-Delay Relay
Starter Relay 2
Alternator
Alternator
Relay
T25N-02-03-008
T5-9-16
TROUBLESHOOTING / Electrical System Inspection
Accessory Circuit
Battery
Key Switch
Battery Relay
24
Radio
Cigarette
Lighter
25
26
Air Conditioner
T2BC-05-09-002
T5-9-17
TROUBLESHOOTING / Electrical System Inspection
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.
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
TROUBLESHOOTING / Electrical System Inspection
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
three-polarity connector.
1 2 3
Connect
T107-07-05-011
T5-9-19
TROUBLESHOOTING / Electrical System Inspection
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
:
T5-9-20
TROUBLESHOOTING / Electrical System Inspection
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.
A a
B u b
C c
T107-07-05-005
T5-9-21
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