MODEL LINK BELT 218 HSL CRANE 1059 BOOK No. LBCE SERIAL No.
Mitsubishi 6D24-LE2A Engine Workshop Manual begins on page 1200 Mitsubishi 6D24-TLE2A engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 2696731638
CRANE SERIAL NUMBER The crane serial number is on the Crane Rating Manual located inside the operator’s cab. The serial number should always be furnished when ordering parts for the crane or when corresponding with the distributor or factory concerning the crane. Providing the serial number is the only way of ensuring the correct parts and/or information can be furnished. In the event the serial number is not readable, a number is stamped on the upper revolving frame which can be used to identify the crane. This number is located on the front face of the upper frame, between the boom foot mounting lugs.
Link-Belt Construction Equipment Company
This Page Left Blank Intentionally
General Information and Manual Layout This manual is divided into 3 Sections separated by Tabs. The front Section is the Workshop Instruction portion of the manual. It contains the removal/installation (R&I) and the assembly/disassembly (Recondition) instructions for major crane components. These pages are coded with a “W” in front of the Section/Group/Page numbers. Example, the pages coded/numbered W2-4-1 through W24-64, 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 W1-11, 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 T13-4, 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 T1-21, T2-1-1, and T3-1-1. The Section behind Tab 2 contains Performance Tests/Standards and Troubleshooting for major components. There are “Contents” pages at the beginning of each sub-section, in front of pages T4-1-1 and T5-1-1.
BOOK1059 N6072508
Page 1 of 4
Terms/Terminology, Nomenclature, and Abbreviations The following terms/terminology, nomenclature, and abbreviations are given to help identify common terms/terminology, nomenclature, and abbreviations used in this manual that, due to language translations, may not be easily understood. Auxiliary Hoisting Mechanism Boom Pendant Rope Center Joint Crawler Shoe Derricking Derricking Drum Derricking Mechanism Derricking Motor Drive Tumbler Hoisting Drum Hoisting Drum Control Valve Hoisting Mechanism Hoisting Motor Pump Mechanism Screwed-In Connection Slewing Slewing Frame Slewing Mechanism Slewing Motor Slewing Pump Slewing Ring Stopper Take-Up Tumbler Travel Mechanism Upperstructure
= = = = = = = = = = = = = = = = = = = = = = = = =
Auxiliary Winch Assembly / Winch Drum Boom Pendants Rotating Joint Track Shoe Boom Hoist Boom Hoist Drum Boom Hoist System Boom Hoist Motor Travel Drive Sprocket Winch Drum Winch Drum Control Valve Winch Assembly / Winch Drum Winch Motor Pump Assembly Threaded Connection Swing Upper Revolving Frame Swing Reduction Unit Swing Motor Swing Pump Turntable Bearing Plug Track Take-Up Idler Travel Motor and Reduction Gears Crane Upper
Page 2 of 4
Conversion Tables Length Conversion Table millimeter, mm 1 10 1000 25.40 304.8
centimeter, cm 0.1 1 100 2.540 30.48
mile, mi 1 0.6214
kilometer, km 1.6093 1
meter, m 0.001 0.01 1 0.0254 0.3048
inch, in., " 0.03937 0.3937 39.37 1 12
foot, ft., ' 0.00328 0.03281 3.281 0.08333 1
square meter, m2
square inch, in2
square foot, ft2
0.000001 0.0001 1 0.000645 0.09290
0.00155 0.155 1550 1 144
0.001076 10.764 0.006944 1
Area Conversion Table square millimeter, mm2 1 100 1 000 000 645.2 92903.0
square centimeter, cm2 0.01 1 1 0000 6.452 929.03
Volume Conversion Table cubic centimeter, cm3, cc 1 1 000 000 16.39 28320
cubic meter, m3
cubic inch, in3
cubic foot, ft3
0.000001 1 0.0000164 0.02832
0.0610 61024 1 1728
0.0000353 35.31 0.000579 1
gallon, gal. 1 0.004329 0.2642
cubic inch, in3 231 1 61.02
liter, lit., l 3.785 0.01639 1
Page 3 of 4
Conversion Tables – (continued) Weight Conversion Table gram, g 1 1000 28.349 453.592 1 000 000 907185
kilogram, kg 0.001 1 0.02835 0.4536 1 000 907.2
ounce, oz 0.03527 35.27 1 16 35274 32 000
pound, lb. 0.0022 2.205 0.0625 1 2205 2000
metric ton, t
short ton, s.t.
0.001 0.00002835 0.0004536 1 0.9072
0.001102 0.00003125 0.0005 1.102 1
Pressure Conversion Table kg/cm3 1.0197 1 0.07031
bar 1 0.9807 0.06895
lb./in2, PSI 14.50 14.22 1
Work, Energy Conversion Table kg.cm 1 100 13.83 1.1525
kg.m 0.01 1 0.1383 0.01153
foot-pound, ft.-lb. 0.0723 7.233 1 0.08333
inch-pound,.in-lb. 0.8681 86.81 12 1
Centigrade-Fahrenheit Conversion Table °F -450 -400 -350 -300 -250
°C -267.78 -240.00 -212.22 -184.44 -156.67
°F -200 -150 -100 -50 0
°C -128.89 -101.11 -73.33 -45.56 -17.78
°F 5 10 15 20 25
°C -15.00 -12.22 -9.44 -6.67 -3.89
°F 30 35 40 45 50
°C -1.11 1.67 4.44 7.22 10.00
°F 55 60 65 70 75
°C 12.78 15.56 18.33 21.11 23.89
°F 80 85 90 95 100
°C 26.67 29.44 32.22 35.00 37.78
°F 150 200 250 300 350
°C 65.56 93.33 121.11 148.89 176.67
°F 400 450 500 550 600
°C 204.44 232.22 260.00 287.78 315.56
Page 4 of 4
INTRODUCTION TO THE READER x This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):
ADDITIONAL REFERENCES x Please refer to the materials listed below in addition to this manual.
• Operation Manual of the Engine • Parts Catalog of the Engine
• The Operator’s Manual • The Parts Catalog
PAGE NUMBER x Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5
Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual
W: Workshop Manual
IN-01
INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.
x
CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.
x IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.
x
NOTE: Indicates supplementary technical information or know-how.
UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
x SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.
Quantity Length Volume
Weight Force Torque
To Convert From mm mm L L m3 kg N N N혱m N혱m
Into in ft US gal US qt yd3 lb kgf lbf kgf혱m lbf혱ft
A table for conversion from SI units to other system units is shown below for reference purposees.
Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375
Quantity Pressure Power Temperature Velocity Flow rate
IN-02
To Convert From MPa MPa kW kW qC km/h min-1 L/min mL/rev
Into
Multiply By 2
kgf/cm psi PS HP qF mph rpm US gpm cc/rev
10.197 145.0 1.360 1.341 qCu1.8+32 0.6214 1.0 0.2642 1.0
SAFETY RECOGNIZE SAFETY INFORMATION x This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating practices.
001-E01A-0001-2
SA-001
UNDERSTAND SIGNAL WORDS x On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.
x CAUTION also calls attention to safety messages in this manual.
x To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.
x NOTE indicates an additional explanation for an element of information. 002-E01A-0461-6
S-1
SA-1223
SAFETY FOLLOW SAFETY INSTRUCTIONS x Carefully read and follow all safety signs on the machine and all safety messages in this manual.
x Safety signs should be installed, maintained and replaced when necessary.
• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).
SA-003
x Learn how to operate the machine and its controls correctly and safely.
x Allow only trained, qualified, authorized personnel to operate the machine.
x Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.
x The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003-5
PREPARE FOR EMERGENCIES x Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.
• Establish emergency procedure guidelines to cope with fires and accidents.
• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.
SA-437
004-E01A-0437-3
S-2
SAFETY WEAR PROTECTIVE CLOTHING x Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.
SA-438
• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.
x Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438-4
PROTECT AGAINST NOISE x Prolonged exposure to loud noise can cause impairment or loss of hearing.
• Wear a suitable hearing protective mechanism such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.
SA-434 006-E01A-0434-2
INSPECT MACHINE x Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter.
SA-435
007-E01A-0435-2
S-3
SAFETY USE HANDHOLDS AND STEPS x Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.
• Do not use any controls as handholds. • Never jump on or off the machine. Never mount or dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.
008-E01A-0439-3
ADJUST THE OPERATOR’S SEAT x A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.
• The seat should be adjusted whenever changing the operator for the machine.
• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.
• If not, move the seat forward or backward, and check again.
009-E01A-0464-3
S-4
SA-464
SAFETY FASTEN YOUR SEAT BELT (IF EQUIPPED) x If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.
• Be sure to remain seated with the seat belt securely
SA-237
fastened at all times when the machine is in operation to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every three years regardless of its apparent condition.
010-E02B-0237-3
OPERATE ONLY FROM OPERATOR’S SEAT x Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.
• Start the engine only from the operator’s seat. • NEVER start the engine while standing on the crawler shoe or on ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers are in neutral.
012-E01B-0444-3
S-5
SA-444
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 ENGINE” 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 machine.
013-E01A-0032-3
S-6
SAFETY PROTECT AGAINST FLYING DEBRIS x If flying debris hit eyes or any other part of the body, serious injury may result.
• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area before striking any object.
SA-432
031-E01A-0432-2
S-7
SAFETY PARK MACHINE SAFELY
•Engage all brake and drum locks. Shutdown the engine.
To avoid accidents:
•Remove the key from the key switch. Lock the cab and all access doors.
• Park machine on a firm, level ground. • Lower the boom to the ground. • In a work site where the boom cannot be lowered to
033-E04A-0470-3
the ground, secure the boom using guy ropes so as to minimize the wind effect on the boom,
• Run the engine at slow idle for five (5) minutes to cool the engine down.
HANDLE FLUIDS SAFELY᧩AVOID FIRES x Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when near open flame or sparks.
• Always shutdown the engine before refueling the machine.
• Fill the fuel tank outdoors. x All fuels, most lubricants, and some coolants are flam-
SA-018
mable.
• Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously.
SA-019
034-E01A-0496-4
S-8
SAFETY SAFE TRANSPORTATION x The danger of tipping is present when loading/unloading machine onto/from a truck or trailer bed.
• Be sure to observe local regulations when transporting the machine on public roads.
• Be sure to have a signal person when loading/unloading the machine.
• Provide an appropriate trailer for transporting the machine. Take the following precautions when loading/unloading the machine: 1) Select firm, level ground. 2)
Be sure to use a loading dock or ramp.
3)
When using a loading ramp, use one which has antislip bands on the surface.
4)
Drive the machine at very slow speed.
5)
Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.
6)
Do not operate any levers besides the travel levers when driving up or down the ramp.
7)
The top of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.
8)
Securely fasten chains or cables to the machine frame.
Less than 15q
SA-475A
035-E03A-0475-᧲
TOWING MACHINE x When towing the machine, be sure to attach tow wire ropes around the lower frames as illustrated. To prevent the wire ropes from being damaged, place protective material between the lower frames and the wire ropes. Pulling Rope
SA-605 061-E01A-0605-2
S-9
SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents:
• Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is moving.
• Keep hands, feet and clothing away from power-driven parts.
• Before servicing the machine: 1)
Park machine on a solid, level surface.
2)
Lower the boom to the ground. If the boom cannot be fully lowered, secure the boom with guy ropes to prevent the boom from being blown by wind.
3)
Run the engine at slow idle speed without load for 5 minutes.
4)
Apply all brakes and locks.
5)
Turn the key switch to OFF to shutdown engine.
6)
Remove the key from the switch.
7)
Move the pilot shut-off lever to the LOCK position.
8)
Attach a “Do Not Operate” tag on the cab door.
SA-028
• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.
• Securely support any machine elements that must be raised for service work. If the machine must be raised, place supporting blocks under the frame.
• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris.
• Disconnect battery ground cable (–) before making adjustments to electrical systems or before performing welding on the machine.
500-E07A-0497-8
S-10
SA-527
SAFETY WARN OTHERS OF SERVICE WORK x Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.
501-E01A-0287-2
SA-287
SUPPORT MACHINE PROPERLY x Never attempt to work on the machine without securing the machine first.
• Always lower the attachment to the ground before you work on the machine.
• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.
SA-527
519-E01A-0527-3
STAY CLEAR OF MOVING PARTS x Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.
SA-026
502-E01A-0026-2
S-11
SAFETY PREVENT BURNS Hot spraying fluids:
x After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.
• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be release before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:
x Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.
SA-225
• Wait for the oil and components to cool before starting any maintenance or inspection work.
505-E01B-0498-5
REPLACE RUBBER HOSES PERIODICALLY x Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. x Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. 506-E01A-0019-3
S-12
SA-019
SAFETY AVOID HIGH-PRESSURE FLUIDS x Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.
• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
• Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care
SA-031
to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.
SA-292
SA-044
507-E01A-0499-5
NEVER ATTEMPT TO MODIFY SAFETY MECHANISM, HYDRAULIC COMPONENTS, OR ELECTRICAL WIRING x Incorrect modification or adjustment may cause accident.
• Do not modify or adjust the preadjusted parts of hydraulic components or safety mechanism. If readjustment or modification is required, consult your authorized dealer. SA-019
x Alternation on electrical wiring may cause fire. • If modification or alternation of electrical wiring is required, consult your authorized dealer.
520-E01A-0019-3
S-13
SAFETY PREVENT FIRES Check for Oil Leaks:
Check Heat Shields:
x Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or dam-
x Damaged or missing heat shields may load to fires.
• Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02B-0019-9
aged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes or hoses. Check for Shorts:
x Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.
• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc. Clean up Flammables:
x Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately. Check Key Switch:
x If a fire breaks out, failure to shutdown the engine will escalate the fire, hampering fire fighting.
• Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.
• If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019-9
S-14
SA-019
SAFETY EVACUATING IN CASE OF FIRE x If a fire breaks out, evacuate the machine in the following way:
• Shutdown the engine with turning the key switch to the OFF position if there is time.
• Use a fire extinguisher if there is time. • Exit the machine. SA-393 518-E02A-0393-2
BEWARE OF EXHAUST FUMES x Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
• Be aware of California Proposition 65 Warning which reads “Diesel engine exhaust and some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm”. 509-E01A-0016-2
S-15
SA-016
SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES x Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to you and bystanders.
• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.
SA-030
AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.
• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.
510-E01B-0030-4
REMOVE PAINT BEFORE WELDING OR HEATING x Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.
SA-029
• Remove paint before welding or heating: 1)
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
2)
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
511-E01A-0029-4
S-16
SAFETY PREVENT BATTERY EXPLOSIONS x Battery gas can explode, resulting in serious injury. • Keep sparks, lighted matches, and flame away from the top of battery.
• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the battery to 16 qC (60 qF) first.
• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result
• Loose terminals may produce sparks. Securely tighten all terminals.
x Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If splashed in eyes, flush with water for 15 minutes. Get medical attention immediately.
• Be sure to wear eye protection when checking electrolyte specific gravity.
512-E01B-0032-4
S-17
SA-032
SAFETY HANDLE CHEMICAL PRODUCTS SAFELY x Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s on chemical products used with your machine.
515-E01A-0309-4
DISPOSE OF WASTE PROPERLY x Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or into any water source.
• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.
516-E01A-0226-4
S-18
SA-309
SECTION 1
GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ............................................ W1-1-1
Group 2 Tightening Torque Tightening Torque Specification ............... W1-2-1 Torque Chart............................................ W1-2-2 Piping Joint.............................................. W1-2-5 Periodic Replacement of Parts ................ W1-2-9
2BDW-1-1
(Blank)
2BDW-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING
DISASSEMBLING
• Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.
Precautions for Disassembling and Assembling
x Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.
x Precautions for Assembling
x Inspect the Machine Be sure to thoroughly read and understand all disassembling/assembling procedures before starting any repair work. Understanding these procedures will help avoid incorrect disassembling of components as well as the purchasing of unnecessary service parts. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.
x Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.
x Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary.
W1-1-1
• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Before assembling, coat all inner parts with clean hydraulic oil or gear oil. Especially coat the sliding surfaces with clean hydraulic oil or gear oil. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.
GENERAL INFORMATION / Precautions for Disassembling and Assembling 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 • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.
W24Y-01-01-001
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: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces.
(2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.
tears,
W105-03-05-019
B
breaks,
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.
Correct
Incorrect
D
(4) After installing the floating seal, check that seal surface (C) is parallel with the seal mounting bore end face (D) and O-ring (B) as illustrated.
W105-03-05-020
C Incorrect
Correct a
a
B
b
a=b
b
a㝛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 safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 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. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won't deteriorate with heat, sunlight, or chemicals.
Correct Eyehole Lifting Method
W24Y-01-01-002
Incorrect Eyehole Lifting Method
W24Y-01-01-003
Bent Sling
W1-1-4
W162-01-01-009
GENERAL INFORMATION / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.
Damaged Appearance
Broken Sewing Thread
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.
W162-01-01-002
Scuffing
W162-01-01-003
Fuzz
Broken Sewing Thread
W162-01-01-004
Broken Sewing Thread
W162-01-01-005
Broken Sewing Thread
Scoring
Separation of Belt
W162-01-01-006
Fuzz
Scuffing
W162-01-01-007
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
No. 1. 2.
Descriptions Swing Bearing Mounting Bolt Front Engine Mounting Bolt Rear
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Counterweight Mounting Bolt Cab Bed Mounting Bolt Cab Mounting Bolt Valve Bed Mounting Bolt Upper Roller Mounting Bolt Lower Roller Mounting Bolt Travel Device Mounting Bolt (Right/Left) Travel Motor Mounting Bolt (Right/Left) Hoist Device Mounting Bolt (Main/Aux.) Hoist Motor Mounting Bolt (Main/Aux.) Boom Hoist Device Mounting Bolt Boom Hoist Motor Mounting Bolt Swing Device Mounting Bolt (Front/Rear) Swing Motor Mounting Bolt (Front/Rear)
17.
Pump Assembly Mounting Bolt
18.
Main Pump Mounting Bolt
19. 20. 21. 22. 23.
Swing Pump Mounting Bolt Hydraulic Oil Tank Mounting Bolt Fuel Tank Mounting Bolt Radiator Mounting Bolt Radiator Stay Mounting Bolt
Bolt Dia. mm 36 16 22 16 39 16 16 16 16 27 33 18 36 20 36 20 20 16
Q’ty 87 4 2 4 6 15 4 15 24 104 52 4 4 8 4 20 36 4
Wrench Size mm 55 24 32 24 60 24 24 24 24 41 50 27 55 30 55 30 30 24
10
12
17
20
4
17
16
2
24
16 16 10 16 16
4 4 4 4 4
14 24 17 24 24
NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients. (2) Remove rust, dirt, and dust before installing fasteners. (3) Apply LOCTITE onto the boom hoist system mounting bolt, boom hoist motor mounting bolt, pump assembly mounting bolt, main pump mounting bolt and gear pump mounting bolt.
W1-2-1
Torque N m
kgf m
lbf ft
2940 175 740 265 1130 205 205 205 205 1370 2350 295 1570 539 1570 490 539 235 41 to 45 400 179 to 194 240 205 20 205 205
300 18 75 27 115 21 21 21 21 140 240 30 160 55 160 50 55 24 4.2 to 4.6 41 18.3 to 19.8 24.5 21 2 21 21
2170 130 540 195 830 152 152 152 152 1010 1740 215 1160 398 1160 360 400 170 17. 18. 132 to 143 19. 152 14.5 152 152
GENERAL INFORMATION / Tightening Torque TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolts, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.
Hexagon T Bolt
SA-040
Hexagon H Bolt
Hexagon M Bolt
Socket Bolt
W157-01-01-001
Specified Tightening Torque Chart T Bolt, Socket Bolt Bolt Wrench Hexagon Wrench Dia. Size N m kgf m lbf ft Size M 8 13 6 30 3.1 22 M 10 17 8 65 6.6 48 M 12 19 10 110 11.0 81 M 14 22 12 180 18.5 133 M 16 24 14 270 27.5 199 M 18 27 14 400 41.0 295 M 20 30 17 550 56.0 406 M 22 32 750 76.5 553 M 24 36 950 97.0 701 M 27 41 1400 143 1033 M 30 46 1950 200 1438 M 33 50 2600 265 1918 M 36 55 3200 325 2360
H Bolt N m 20 50 90 140 210 300 400 550 700 1050 1450 1950 2450
W1-2-2
kgf m 2.0 5.1 9.2 14.0 21.5 30.5 41.0 56.0 71.5 107 148 200 250
M Bolt lbf ft 15 37 66 103 155 221 295 406 516 774 1069 1438 1807
N m 10 20 35 55 80 120 170 220 280 400 550 750 950
kgf m 1.0 2.0 3.6 5.6 8.2 12.0 17.0 22.5 28.5 41.0 56.0 76.5 97.0
lbf ft 7.4 15 26 41 59 89 125 162 207 295 406 553 701
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.
Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately
Tighten from center and diagonally
Tighten diagonally
1
1,4
12
9
4
1
6
7
14
13
8
5
2
3
10
11
3
6 4
5 2
2,3
W105-01-01-003
W1-2-3
GENERAL INFORMATION / Tightening Torque Service Recommendations for Split Flange IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be removed, replace the component. (2) Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. (3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. (4) Tighten bolts alternately and diagonally, as shown, to ensure even tightening. (5) Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
RIGHT
WRONG
Do not bend it round
Bend along edge sharply
Nut and Bolt Locking
x Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.
RIGHT
RIGHT
WRONG
Bend along edge sharply
W105-01-01-009
RIGHT
RIGHT
WRONG
x Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. RIGHT
x Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction.
Loosen
WRONG
Tighten
W105-01-01-010
W1-2-4
GENERAL INFORMATION / Tightening Torque PIPING JOINT Pipe Thread Connection / Union Joint Tightening Torque Specifications
1
4
3
5
2
Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.
IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.
Joint Body M202-07-051
37q 30q
(2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting.
Type 30q Male Union Joint
37q Female Union Joint
Wrench Size Union Nut Joint Body 17 17 19 19 22 22 27 27 32 32 36 36 41 41 17 14 17 19 22 19 27 22 32 27 36 32 41 36
W1-2-5
Male Union Joint
Female Union Joint
W105-01-01-017
N m 24.5 29.5 39 93 137 175 205 24.5 29.5 39 93 137 175 205
Tightening Torque kgf m 2.5 3.0 4.0 9.5 14.0 18.0 21.0 2.5 3.0 4.0 9.5 14.0 18.0 21.0
Ibf ft 18 22 29 69 101 129 151 18 22 29 69 101 129 151
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. IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.
Joint Body
8
10 M104-07-033
Wrench Size Union Nut Joint Body
(3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage. (4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.
W1-2-6
19 22 27 32 36 41 46
17 19 22 27 30, 32 36 41
Tightening Torque N m kgf m Ibf ft 29.5 69 93 137 175 205 205
3.0 7.0 9.5 14.0 18.0 21.0 21.0
22 51 69 101 129 151 151
GENERAL INFORMATION / Tightening Torque Screwed-In Connection
PF
PT
IMPORTANT: Many types of screwed-in connec-tions are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.
30q
Male Straight Thread
Male Tapered Thread
W105-01-01-018
Wrench Joint Body 17, 19 19, 22 27, 22 36, 32 41 50 60 70 Seal Tape Application
Male Tapered Thread Tightening Torque N m kgf m 6 59 10 98 12 118 235 24 30 295 490 50 670 68 980 100
Ibf ft 43 72 87 134 215 360 490 720
Internal Thread
Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not over wrap.
External Thread
Clearance
W105-01-01-019
Leave one to two pitch threads uncovered
x Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.
M114-07-041
Low-Pressure-Hose Clamp Tightening Torque T-Bolt Type
Worm Gear Type
Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp. T-Bolt Type Band Clamp: 4.4 N m (0.45 kgf m, 3.25 lbf ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft ) M114-07-042
W1-2-7
M114-07-043
GENERAL INFORMATION / Tightening Torque Connecting Hose WRONG CAUTION: (1) When replacing hoses, be sure to use genuine manufacture parts. Using hoses other than genuine manufacture parts may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.
RIGHT
W105-01-01-011
WRONG
RIGHT Rubbing Against Each Other
W105-01-01-012
WRONG
Clamp
RIGHT 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 ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected through machine operation or visual inspection.
Part Location
Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.
Part to be Replaced
Q’ty
Pendant rope -
Front Attachment Winch Engine
Ball bearing (oil less bearing in the hook sleeve) Ball bearing (boom hoist winch pedestal) Fuel hose (between the fuel tank and filter) Fuel hose (between the fuel tank and injection pump)
IMPORTANT: Each hose has an individual service life. If any abnormalities are found during the regular interval check and/or maintenance service, be sure to replace with a new one.
W1-2-9
1 -
Interval (Hours or Period) Crane: 400 hrs /2 years Bucket, Lifting Magnet (Heavy Duty Work) : 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years
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 Dimensions of the Cab Glass .....................W2-1-9
for HYD. Tagline .................................W2-4-79 Disassemble Gear Pump for HYD. Tagline .................................W2-4-82
Group 2 Couterweight
Assemble Gear Pump for HYD. Tagline .................................W2-4-84
Remove and Install Counterweight .............W2-2-1
Group 5 Control Valve
Group 3 Upper Revolving Frame Remove and Install Upper Revolving Frame ........................................................W2-3-1
Remove and Install Front / Rear 4-Unit Control Valve.............................................W2-5-1 Disassemble Front / Rear 4-Unit Control Valve .........................................................W2-5-4
Group 4 Pump Assembly Remove and Install Main Pump ............... W2-4-1 Disassemble Main Pump ......................... W2-4-4
Assemble Front / Rear 4-Unit Control Valve .......................................................W2-5-10
Assemble Main Pump............................ W2-4-10
Remove and Install 4-Unit Control Valve .......................................................W2-5-17
Maintenance Standard........................... W2-4-16
Disassemble 4-Unit Control Valve ............W2-5-20
Disassemble Front Regulator ................ W2-4-18
Assemble 4-Unit Control Valve ...............W2-5-26
Assemble Front Regulator ..................... W2-4-24
Remove and Install 1-Unit Control Valve .......................................................W2-5-33
Disassemble Rear Regulator................. W2-4-28 Assemble Rear Regulator ..................... W2-4-34 Disassemble Reduction Gear ................ W2-4-40 Assemble Reduction Gear ................... W2-4-42 Maintenance Standard ......................... W2-4-44
Disassemble 1-Unit Control Valve ............W2-5-36 Assemble 1-Unit Control Valve .................W2-5-38 Remove and Install Hoisting Drum Control Valve (Optional) ........................W2-5-41
Remove and Install Swing Pump ........... W2-4-45
Disassemble Winch Drum Control Valve ......................................................W2-5-42
Disassemble Swing Pump ..................... W2-4-48
Assemble Winch Drum Control Valve .......W2-5-46
Assemble Swing Pump.......................... W2-4-52 Maintenance Standard ......................... W2-4-54 Disassemble Regulator ......................... W2-4-56
Group 6 Swing Mechanism
Assemble Regulator .............................. W2-4-62
Remove and Install Swing Reduction Unit............................................................W2-6-1
Remove and Install 2-Unit Gear Pump .. W2-4-69
Disassemble Swing Reduction Unit............W2-6-4
Disassemble 2-Unit Gear Pump ............ W2-4-72
Assemble Swing Reduction Unit.................W2-6-8
Assemble 2-Unit Gear Pump ................. W2-4-74
Disassemble Swing Motor ........................W2-6-14 Assemble Swing Motor .............................W2-6-18 Maintenance Standard ............................W2-6-20
2BDW-2-1
Group 7 Winch Assembly
Group 9 Remote Control Valve
Remove and Install Front And Rear Winch Assenbly ................................... W2-7-1 Disassemble Winch Assenbly.................. W2-7-8
Remove and Install Remote Control Valves for Hoisting, Raising/Lowering Drum and Travel .......................................W2-9-1
Assemble Winch Assenbly..................... W2-7-12
Remove and Install Swing Remote 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 Assemble Regulator .............................. W2-7-32 Disassemble Counterbalance Valve ...... W2-7-34 Assemble Counterbalance Valve ......... W2-7-36 Disassemble Brake Unit ........................ W2-7-38
Group 10 Solenoid Valve Remove and Install Solenoid Valve Unit..........................................................W2-10-1 Disassemble and Assemble Solenoid Valve Unit ................................................W2-10-2
Assemble Brake Unit ............................. W2-7-40 Remove
and
Install
Fourth
Group 11 Cylinder
Winch
Assenbly ............................................ W2-7-43 Disassemble Fourth Winch Assenbly..... W2-7-52 Assemble Fourth Winch Assenbly ......... W2-7-56 Disassemble Fourth Winch Motor.......... W2-7-62
Remove and Install Counterweight Installation / Removal Cylinder ............... W2-11-1 Disassemble Cylinder ............................... W2-11-4 Assemble Cylinder .................................... W2-11-8
Assemble Fourth Winch Motor .............. W2-7-68 Maintenance Standard ......................... W2-7-64 Disassemble Counterbalance Valve ...... W2-7-76 Assemble Counterbalance Valve ........... W2-7-78 Disassemble Regulator ......................... W2-7-80 Assemble Regulator ............................ W2-7-82 Disassemble Brake Unit ........................ W2-7-84 Assemble Brake Unit ............................. W2-7-86
Group 8 Raising/Lowering Mechanism Remove and Install Raising/Lowering Mechanism................................................W2-8-1 Disassemble Raising/Lowering Mechanism................................................W2-8-8 Assemble Raising/Lowering Mechanism ..W2-8-14 Disassemble Raising/Lowering Motor ......W2-8-20 Assemble Raising/Lowering Motor .........W2-8-22 Disassemble Brake Valve .........................W2-8-24 Assemble Brake Valve ..............................W2-8-26
2BDW-2-2
CRANE UPPER / Cab
REMOVE AND INSTALL CAB Removal
2
1
1. Remove bolts (1) (4 used) and remove seat (2). : 13 mm
2. Loosen screws (8) (19 used) and bolts (9) (4 used). Remove covers (3 to 7) behind the seat. : 17 mm
W24X-02-01-001
8 8 5 3
8
8 7
6 4 9
8
9
W2BD-02-01-001
3. Remove screws (18) (4 used) and bolts (19) (4 used). Remove covers (16, 17) on the bottom of front display. : 17 mm
16 14 18
12
14
4. Remove screws (14) (14 used) and socket bolts (15) (2 used). Remove covers (11 to 13) from left stand (10). : 4 mm
13 14 19
5. Loosen bolts (20) (4 used) of left stand (10). (in order to move the left stand) : 13 mm 20
6. Move left stand (10) about 20 mm to the inside.
10
11
14 15
17
W24X-02-01-003
W2-1-1
CRANE UPPER / Cab 7. Remove screws (25) (14 used) and socket bolts (26) (2 used). Remove covers (22 to 24) from right stand (21). : 4 mm
25 23 27
26
8. Loosen bolts (27) (4 used) of right stand (21). (in order to move the right stand) : 13 mm
24
25
26 25
9. Move right stand (21) about 20 mm to the inside.
25 21 27
22
W24X-02-01-004
10. Loosen bolts (31) (13 used). Remove under covers (28 to 30) in front of the right platform. : 17 mm
28 30
29
31
31
31
W2BD-02-01-002
11. Remove all connectors (32) of electric wiring for each equipment installed to the cab.
33
32
32
12. Loosen hose clamp (34). Remove air conditioner hoses (33) (2 used).
34 32
32
32
W2BD-02-01-003
W2-1-2
CRANE UPPER / Cab 36
13. Remove bolt (35) (5 used). Remove cover (36). : 10 mm 35
W2BC-02-01-002
14. Loosen hose clamps (37) (2 used). Remove hoses (38) (2 used). Disconnect connectors (39) (2 used).
39
W2-1-3
38
37
W2BC-02-01-003
CRANE UPPER / Cab 15. Remove bolt (40) and nuts (41) (7 used).
41
40
W2BD-02-01-002
16. Attach a wire rope on the lifting position (M12) (4 places) of the cab (42) head and support it with the crane. CAUTION: Cab weight: Approx. 230 kg(507lb) 17. Carefully lift the cab (42) not to hit against the rear stand, left stand, right stand and each equipment on the floor plate.
42
W2BD-02-01-004
W2-1-4
CRANE UPPER / Cab
Installation CAUTION: Cab weight: Approx. 230 kg(507lb) 1. Attach a wire rope onto the lifting position (4 places) on the top of cab (42) and lift it with the crane.
42
2. Carefully lower cab (42) in order not to touch the rear stand, the left stand, the right stand and other equipments on floor plate.
W2BD-02-01-004
3. Install bolt (40) and nuts (41) (7 used). : 24 mm : 68.1 to 79.4 N m (6.9 to 8.1 kgf m) (50 to 59 lbf ft)
41
40
W2BD-02-01-002
4. Tighten and install air conditioner hoses (33) (2 used) to the air conditioner with hose clamps (34) (2 used).
33
32
32
5. Install all connectors (32) of electric wiring for each equipment installed to the cab. 34 32
32
32
W2BD-02-01-003
W2-1-5
CRANE UPPER / Cab 36
6. Install cover (36) with bolts (35) (5 used). : 10 mm 35
W2BC-02-01-002
7. Tighten and install hoses (38) (2 used) with hose clamp (37). Connect connectors (39) (2 used).
W2-1-6
39
38
37
W2BC-02-01-003
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 N m (4.2 to 4.6 kgf m) (30 to 33 lbf ft)
28 30
31
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). : 13 mm
27
26
11. Install covers (22 to 24) to the right stand (21) with screws (25) (14 used) and socket bolts (26) (2 used). : 4 mm
24
25
26 25
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
14. Install covers (11 to 13) to left stand (10) with screws (14) (14 used) and socket bolts (15) (2 used). : 4 mm
22
W24X-02-01-004
16 14 18
12
15. Install covers (16 to 17) onto the bottom of front display with screws (18) (4 used) and socket bolts (19) (4 used). : 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m) (30 to 33 lbf ft)
14
13 14 19
20 10
11
14 15
17
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). : 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m) (30 to 33 lbf ft)
8 5 3
8
8 7
6 4 9
8
9
W2BD-02-01-001
17. Install seat (2) with bolts (1) (4 used). : 13 mm
1
2
8
W2-1-8
W24X-02-01-001
CRANE UPPER / Cab DIMENSIONS OF THE CAB GLASS Unit: mm
NOTE: JIS R3211, 3212 or equivalent 565.2 25
25
R30 R55
810
Thickness : 6.8 mm
517.7
776 26 22.5
25 466
166
R75.9
Thickness : 4 mm
22.5
R53
276.5
53 57.5
R75.9 I12.2
22
25
(134.7)
469.8
R5
857.5
26 22
42.5
Thickness : 4 mm
I11
64 32 88
897.5
122.5
Thickness: 5 mm
763 763 40
40 39.5 312.4
39.5 312.4
R5
R5
604.5
768 R5
376.6 Thickness: 5 mm R61 758
Thickness : 4 mm
558.5 R40
497.7 65.8
498
186.4
R61 R2519 Thickness : 4 mm
372.6
371.2
650.8 802.9 R61 233.5
123.2
735.9
406.8
Thickness : 4 mm 264.3
R61
251.6
Thickness : 4 mm
148.3
R61
648 623
667.7
Thickness : 4 mm 840
530 172.3
W2BC-02-01-001
W2-1-9
CRANE UPPER / Cab (Blank)
W2-1-10
CRANE UPPER / Counterweight REMOVE AND INSTALL COUNTERWEIGHT CAUTION: • Never allow the workers enter the space under the upper frame and the counterweights. • If the upper frame with the counterweights is rotated without extending the width of the side frames, the machine may tip over. • Do not hoist a set of counterweights A, R, and L. The slings and lugs may be broken, possibly resulting in falling of the counterweights. Removal The counterweight sling wire ropes are provided as follows : Wire ropes: I. 25 mm u 2.8 m 2 ropes
Counterweight
Weight: kg (lbs)
Counterweight A with cylinders
11,501 (25,360)
Counterweight R (2 pieces)
4,280 (9,440)
Counterweight L (2 pieces)
4,270 (9,420)
Total
The counterweights can be removed by using the counterweight installation/removal cylinders. Observe the following working conditions installing and removing counterweights.
for
1. Place the crane on firm, level ground and position the upper parallel to the side frames. 2. The side frames must be locked in the fully extended position. NOTE: The "Quick Draw" Self Assembly System can be used to lift and position the counterweights into position for lifting with the counterweight installation/removal cylinders. Refer to "Quick Draw" Self Assembly System of the Operator's Manual. 3. Engage the slewing lock and all lever locks.
W2-2-1
28,601 (63,065)
CRANE UPPER / Counterweight 4. Turn the CTWT Removal / Jacks Select Switch (1) to the "CTWT" position. 5. Turn accelerator dial (2) to the LOW IDLE position.
2
Acceleration
Deceleration
1
W2BC-02-02-001
6. Check that the Lock Lever (3) is in the UNLOCK position.
LOCK
3
UNLOCK
W2BC-02-02-002
7. Place the ladder (4) onto the platform (5) of the upper frame rear side.
6 5
8. Go up to the platform (5) by the ladder (4). 4
9. Set the chain (6) to prevent personnel falling accident.
W2BC-02-02-003
W2-2-2
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
9
12. Fully retract the cylinders (9). And then disconnect the ring pins (10) and remove the pins (11) from each side of platform.
10
11
W2BC-02-02-005
13. Lower the counterweights to ground by extending the cylinders (9).
9
4
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. 15. Fully retract the cylinders (9) as storage position. 9
W2BC-02-02-007
16. Disconnect the hoses (12) of counterweight installation/removal cylinders from the ports (13) on the rear of the upper frame. 17. Take off the ladder (4). 13 12
W2BC-02-02-008
W2-2-4
CRANE UPPER / Counterweight Installation
Observe the following working conditions installing and removing counterweights.
9
9
The counterweights can be installed by using the counterweight installation/removal cylinders. for 14
1. Place the crane on firm, level ground. 2. The side frames must be locked in the fully extended position. NOTE: The "Quick Draw" Self Assembly System can be used to lift and position the counterweights into position for lifting with the counterweight installation/removal cylinders. Refer to "Quick Draw" Self Assembly System of the Operator's Manual.
W2BC-02-02-009
16
18
19
3. Place the counterweight "A" (14) and the cylinders (9) on the ground.
11
4. Position the counterweights "R" (15) and “L� (16) onto the counterweight "A" (14) and connect with the link plates (17) and ring pins (18). 5. Remove the pins (11) and hung them from the brackets (19).
15 17
14
W2BC-02-02-010
18
6. Position the crane and/or counterweights so that counterweights can be lifted with the counterweight installation/removal cylinders. Position the upper parallel to the side frames.
W2BC-02-02-006
W2-2-5
CRANE UPPER / Counterweight 7. Engage the swing lock and all lever locks. 2
8. Turn the CTWT Removal / Jacks Select Switch (1) to the "CTWT" position.
Acceleration
Deceleration
9. Turn accelerator dial (2) to the LOW IDLE position.
1
W2BC-02-02-001
10. Check that the Lock Lever (3) is in the UNLOCK position.
LOCK
3
UNLOCK
W2BC-02-02-002
11. Connect the hoses (12) of counterweight installation/removal cylinders to the ports (13) on the rear of the upper frame.
13 12
W2BC-02-02-008
W2-2-6
CRANE UPPER / Counterweight 12. Place the ladder (4) onto the platform (5) of the upper frame rear side.
6
13. Go up to the platform (5) by the ladder (4).
5
14. Set the chain (6) to prevent personnel falling accident.
4
W2BC-02-02-006
15. Fully extend installation/removal switches (20).
the cylinders
counterweight by the control
6
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
17. Retract simultaneously both of the cylinders to lift up the counterweights.
W2BD-02-02-001
18. Install the pins (11) into the holes and connect the ring pins (10) to fix the counterweights. 10
11
W2BC-02-02-005
19. Extend the cylinders for approx. 3' and turn the cylinder rods (7) for 90 degrees. 7
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 REVOLVING FRAME
UPPER
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Lower the boom. Remove the (boom) pendants, extension and top section. (As for removal of the (boom) pendants, extension and top section, refer to the Operator's Manual.) 2. Remove the counterweight. As for removal of the counterweight, refer to W2-2 in this section.
1
3. Disconnect connector (1).
W2BC-02-03-001
4. Disconnect plugs on the terminal box (2). 5. Remove the live-mast, boom stop and boom.
W2BC-02-03-002
2
W2-3-1
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
CAUTION: Crane Upper weight: Approx. 18 t (40000 lb) 8. Level and hold the crane upper by using a wire rope and chain block. 9. Put the matching marks on the outer race of turntable bearing and upper revolving frame. 10. Loosen bolts (4) 10 mm (0.39 in) in the outer race of turntable bearing in both crawler frames, to the direction of center. Do the same procedures in case of rear side. (The illustration is seen from the front.) : 46 mm 11. Hoist and level the crane upper 10 mm (0.39 in).
W324-02-03-005
Center㩷
12. Remove bolts (4) in the outer race of turntable bearing in both side frames, to the direction of center. : 46 mm NOTE: As the length of bolt is different (two types), check each position. 13. Hoist and remove the crane upper.
4
4 W324-02-03-006
W2-3-2
CRANE UPPER / Upper Revolving Frame Installation CAUTION: Crane Upper weight: Approx. 18 t (40000 lb) 1. Level and hoist the crane upper. 2. Clean the mounting surface between upper revolving frame (5) and turntable bearing (6) and apply THREEBOND #1102. 3. Align the matching marks on the outer race of turntable bearing and upper revolving frame. Lower and hold the crane upper. 4. Insert bolt (4) into the outer race of turntable bearing. Install the washer and nut to bolt (4). 5. Tighten all the nuts temporarily. Lower the crane upper completely. NOTE: As the length of bolt is different (two types), check each position.
W324-02-03-005
5 Center㩷
6. Tighten the nuts diagonally and alternately. Install the stopper. : 46 mm : 1200 to 1300 N m (123 to 133 kgf m, 885 to 959 lbf ft) 7. Install all hoses to the rotating joint. Refer to W3-3 in the following section.)
6
4
4 W324-02-03-006
8. Install the base section. (As for installation of the base section, refer to the Operator's Manual.) 9. Install the backstop. (As for installation of the backstop, refer to the Operator's Manual.)
W2-3-3
CRANE UPPER / Upper Revolving Frame 10. Install the live-mast, boom stop and boom. 10
11. Connect plugs on the terminal box (11). 12. Connect connector (10). 13. Install the counterweight. (Refer to W2-2 in this section.) 14. Install the extension boom, upper boom, and (boom) pendants. (As for installation of the extension boom, upper boom and (boom) pendants, refer to the Operator's Manual.)
W2BC-02-03-001
W2BC-02-03-002
11
W2-3-4
CRANE UPPER / Pump Assembly REMOVE AND INSTALL MAIN PUMP 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
1. Shutdown the engine.䎃 Operate the lever several times and release the remaining pressure in the circuit.
2
2. Place a container (capacity: approx. 500 L (132 US gal)) under the drain plug (1) and drain off the hydraulic oil with removing the drain plug (1). Install the drain plug (1). : 19 mm Removal 1. Remove all hoses, pipes and wire harness from the pump device. Cap the removed hoses. : 22 mm, 27 mm, 36 mm : 8 mm, 10 mm 2. Attach a wire rope onto the main pump. Hold the main pump.
3
W2CM-02-04-001
CAUTION: Main pump weight: Approx. 190 kg (419 lb) 3. Remove bolts (2, 3). Lift main pump with the crane and remove them. : 24 mm : 17 mm
W2-4-1
CRANE UPPER / Pump Assembly CAUTION: Swing pump weight: Approx. 45 kg (99 lb) 4. Remove bolt (4). Lift swing pump with the crane and remove them. : 14 mm
2
Installation
4
CAUTION: Swing pump weight: Approx. 45 kg (99 lb) 1. Install swing pump and tighten with bolt (4). : 14 mm : 240 N m (24.5 kgf m, 177 lbf ft) CAUTION: Main pump weight: Approx. 190 kg (419 lb) 2. Lift the main pump with the crane and install it on the coupling and bracket. 3. Apply LOCTITE onto bolts (2, 3). Install bolts (2, 3). : 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m) (132 to 143 lbf ft) : 17 mm : 400 N m (41.0 kgf m, 295 lbf ft) 4. Install all hoses, pipes and wire harness to the main pump. : 22 mm : 39 N m (4.0 kgf m, 29 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18.0 kgf m, 129 lbf ft) : 8 mm : 48 to 50 N m (4.9 to 5.1 kgf m) (35 to 37 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft) 5. Remove the filler port cover of the hydraulic tank. Fill hydraulic oil to specified level.
W2-4-2
3
W2CM-02-04-001
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 N m (17.0 kgf m, 125 lbf ft)
5
7. Loosen air bleed plug (5). Release the pressure in the pump. : 36 mm 8. After releasing the air, tighten the air bleed plug (5) and check each operation at a low idling speed. Check the hydraulic oil level and any oil leakage. : 36 mm : 170 N m (17 kgf m, 125 lbf ft)
W2CM-02-04-001
W2-4-3
CRANE UPPER / Pump Assembly DISASSEMBLE MAIN PUMP 18
17
19 16 14, 15 12 11 10
9
8
20
13
22
23 24
63
3
27
26
5
43
27
5 2
44
25
7 6
21
4
45
28 42
29
10 51
26
1
52
41 39
53
40
38
31
32
35 33, 34
36
49
37 46
10 47
50 54 48
30
17 61 18
59
62
60
58
56 26 55 40
46
57
W2BD-02-04-001
W2-4-4
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 16 -
Socket Bolt (4 Used) Plate O-Ring Retaining Ring (2 Used) Spacer (3 Used) Bearing (2 Used) Shaft Lock Nut (2 Used) Setscrew (2 Used) Spring Pin (4 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Feedback Pin (2 Used) Tilt Pin (2 Used) Regulator
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -
Socket Bolt (4 Used) Socket Bolt (4 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Servo Piston (2 Used) O-Ring (4 Used) Plug (4 Used) Pump Casing (2 Used) O-Ring (4 Used) Plug (31 Used) Support (2 Used) Socket Bolt (8 Used) Plate (2 Used) Bushing (2 Used) Plate (2 Used)
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -
Piston (18 Used) Shoe (18 Used) Plate (2 Used) Bushing (2 Used) Spring (18 Used) Cylinder Block (2 Used) Valve Plate Bearing (2 Used) Gear Block Setscrew (2 Used) Nut (2 Used) Eyebolt (2 Used) Pin (2 Used) O-Ring (4 Used) Plug (2 Used)
W2-4-5
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -
O-Ring (2 Used) Valve (2 Used) O-Ring (2 Used) Pin (2 Used) Flange Socket (4 Used) Reduction Gear Valve Plate O-Ring (16 Used) Shaft Regulator O-Ring Oil Seal Cover Socket Bolt (4 Used) Block (4 Used)
CRANE UPPER / Pump Assembly
18
17 16
24
25
28 2
42
29
1 41 53 38 35 33, 34
36 54
30
17 61 18
62
60
58
W2BD-02-04-001
W2-4-6
CRANE UPPER / Pump Assembly Disassemble Main Pump
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the parts. 1. Select the place to disassemble. NOTE: Select the clean place. 2. Remove any dust and rust from the pump surface with using the washing oil. 3. Remove plug (24). Drain oil from pump casing (25). : 36 mm NOTE: Drain off the oil from each plug corresponded to the front and rear pump. 4. Remove socket bolts (17, 18) and flange socket (53). Remove regulators (16, 58) and reduction gear (54). : 6 mm, 12 mm NOTE: As for disassembly of regulators (16, 58) and reduction gear (54), refer to the corresponding section. 5. Remove the socket bolt (1) and remove the plate (2).
IMPORTANT: Place the rubber plate on the workbench in order not to damage the regulator mounting surface. 7. Place the pump onto the workbench horizontally with the regulator mounting surface facing downward. Separate pump casing (25) from block (42). NOTE: When separating block (42) from pump casing (25), remove gear (41) at the same time. IMPORTANT: Do not damage the sliding surfaces in cylinder block (38), bushing (36), shoe (34) and plate (30). 8. Remove cylinder block (38) from pump casing (25) straightly. Remove piston (33), plate (35), bushing (36) and spring (37). IMPORTANT: Do not damage oil seal (60) when removing cover (61). 9. Remove socket bolt (62). Remove cover (61). : 6 mm NOTE: In case inserting the bolt into the hole (M6 tap) on cover (61), cover (61) can be removed easily.
: 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 22
21
11 8
25
7
44
28 42
39
40
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). 11. Remove plates (30, 32) from pump casing (25). 12. Tap the ends of shafts (7, 57) with using a plastic hammer. Remove shafts (7, 57) from support (28). 13. Remove valve plates (39, 55) from block (42). NOTE: Valve plate (39, 55) may be removed at step 7. IMPORTANT: When removing tilt pin (15), use special tool in order not to damage the head of tilt pin (15). As LOCTITE has been applied onto the contacting part between tilt pin (15) and servo piston (22), do not damage servo piston (22). Do not remove bearing (40) unless necessary. As the setting of flow rate changes, do not loosen lock nut (8) and nut (44) in block (42) and support (28). 14. If necessary, remove stoppers (19, 11), servo piston (22) and tilt pin (15) from pump casing (25). Remove bearing (40) from block (42).
W2-4-9
CRANE UPPER / Pump Assembly ASSEMBLE MAIN PUMP 58
16
18
17
12
13
22
31 14 15 56 21
20
18
19
17
44
45
43
26
33
34
32
11 9 8 10 26 62
7 3 2
61 60
57 5 59 46 4 6
37 27
28
30
35
36
23, 24
40 55
41 49, 50
42
29
51 47, 48
39
38
25
54 53 67 66 52
65 64
63
68
1
W2BD-02-04-002
W2-4-10
CRANE UPPER / Pump Assembly
12345678910 11 12 13 14 15 16 17 -
Socket Bolt (4 Used) Plate O-Ring Retaining Ring (2 Used) Spacer (3 Used) Bearing (2 Used) Shaft Lock Nut (2 Used) Setscrew (2 Used) Spring Pin (4 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Feedback Pin (2 Used) Tilt Pin (2 Used) Regulator Socket Bolt (4 Used)
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -
Socket Bolt (4 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Servo Piston (2 Used) O-Ring (4 Used) Plug (4 Used) Pump Casing (2 Used) O-Ring (4 Used) Plug (31 Used) Support (2 Used) Socket Bolt (8 Used) Plate (2 Used) Bushing (2 Used Plate (2 Used) Piston (18 Used) Shoe (18 Used)
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -
Plate (2 Used) Bushing (2 Used) Spring (18 Used) Cylinder Block (2 Used) Valve Plate Bearing (2 Used) Gear Block Setscrew (2 Used) Nut (2 Used) Eyebolt (2 Used) Pin (2 Used) O-Ring (4 Used) Plug (2 Used) O-Ring (2 Used) Valve (2 Used) O-Ring (2 Used)
W2-4-11
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 -
Pin (2 Used) Flange Socket (4 Used) Reduction Gear Valve Plate O-Ring (16 Used) Shaft Regulator O-Ring Oil Seal Cover Socket Bolt (4 Used) Block (4 Used) Seat (4 Used) Steel Ball (4 Used) Stopper (2 Used) Stopper (2 Used) Reducing Valve
CRANE UPPER / Pump Assembly
22
31 14 15
19
33
34
11 7
62 61 60
57 5 59 46 4 6
37 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) and tilt pin (15), use special tool in order not to damage the head of tilt pin (15) and feedback pin (14). Apply Three Bond #1305N (medium intensity) onto the thread part. 1. Lightly tap and install support (28) to pump casing (25) with using a hammer. NOTE: When removing servo piston (22), tilt pin (15) and stoppers (19, 11), install them to pump casing (25) first. 2. Place pump casing (25) with the regulator mounting surface facing downward.䎃 Install bushing (31) in plate (30) to tilt pin (15).䎃 Install plate (30) to support (28). NOTE: Check if plate (30) can move smoothly by fingers. In case grease is applied onto plate (30) and support (28), shafts (7, 57) can be installed easily.
IMPORTANT: Do not damage oil seal (60). 4. Secure cover (61) to pump casing (25) with socket bolt (62). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft) NOTE: Apply a film of grease to oil seal (60) in cover (61). 5. Assemble the piston cylinder sub assembly (cylinder block (38), piston (33), shoe (34), plate (35), bushing (36) and spring (37)).䎃 Align the splines of bushing (36) and cylinder block (38).䎃 Insert the piston cylinder sub assembly into pump casing (25). IMPORTANT: Check the direction of suction and delivery in valve plate (55). 6. Align with pin (46) and install valve plate (55) to block (42).
IMPORTANT: Do not tap shaft (57) with using a hammer. 3. Install bearing (6), spacer (5) and retaining ring (4) onto shaft (57).䎃 Install shaft (57) to support (28). NOTE: Lightly tap the outer ring in bearing (6) with using a plastic hammer and install bearing (6) with using a steel bar completely.
W2-4-13
CRANE UPPER / Pump Assembly 58
16
18
17
18
17
14 15 7 2
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 N m (44 kgf m, 317 lbf ft) NOTE: Assemble the rear pump first. Insert gear (41) into block (42).䎃 Connect gear (41) to the contact spline in drive shaft of shafts (7, 57). IMPORTANT: Check regulators (16, 58) for the front and rear. 8. Install the swing pump (2) on the support of the rear side and tighten it with the socket bolt (1) and block (63). : 12 mm : 98 N m (10.0 kgf m, 72 lbf ft) 9. Insert feedback pin (14) in tilt pin (15) into the feedback lever in regulators (16, 58).䎃 Install regulators (16, 58) and reduction gear (54).䎃 Tighten socket bolts (17, 18) and flange socket (53). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft) : 12 mm : 33 N m (3.4 kgf m, 24 lbf ft) 10. Install plug (24). : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
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
0.035 (0.001)
0.062 (0.002)
d
D
W25N-02-04-005
2. Clearance between piston and shoe Unit: mm (in)
Ǭ
Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.012)
㱐 t
W25N-02-04-006
3. Shoe thickness Unit: mm (in)
t
Standard
Allowable Limit
4.9 (0.19)
4.7 (0.19)
4. Free length of cylinder spring Unit: mm (in)
L
Standard
Allowable Limit
39.5 (1.56)
38.7 (1.52)
L W25N-02-04-007
5. Height of plate and spherical bushing
H
h
Unit: mm (in)
H-h
Standard
Allowable Limit
23.0 (0.91)
22.0 (0.89)
W25N-02-04-008㩷
W2-4-16
CRANE UPPER / Pump Assembly (Blank)ã©·
W2-4-17
CRANE UPPER / Pump Assembly DISASSEMBLE FRONT REGULATOR 3 11 10 9 8 21
7
20
6 5 3 1
12
19
16
13
17
4
2
14
22
15
23 16
24 25 26
18
29 30
27 28
44 41
43 42 40 36
45
41
39
37 38
31 32
30
46
47 47
33
30
48
35 34
49
50
56 54 55 58
54
53
52 51
57
49
50
W2CH-02-04-001
W2-4-18
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -
Pin (2 Used)㩷 Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Springs㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (10 Used)㩷
31 32 33 34 35 36 37 38 39 40 41 42 43 44 㩷
Cover㩷 O-Ring㩷 O-Ring (3 Used)㩷 O-Ring㩷 Plug (5 Used)㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Lock Nut㩷
W2-4-19
45 46 47 48 49 50 51 52 53 54 55 56 57 58 㩷
Setscrew㩷 Casing㩷 Pin (2 Used)㩷 Plug㩷 O-Ring (2 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring (9 Used)㩷 O-Ring㩷 O-Ring㩷 Cover㩷 Socket Bolt (2 Used)㩷
CRANE UPPER / Pump Assembly
11 10 9 8
13 14 15
23 24 25 26
30
27 28
44 41
43 45 40 36
37
39
48 30
50
51
54 58
57
50
W2CH-02-04-001ã©·
W2-4-20
CRANE UPPER / Pump Assembly Disassemble Front Regulator • Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. IMPORTANT: Put the rubber plate or cloth on the workbench in order not to damage the parts. As the parts are small, do not lose the parts. 1. Select the place to disassemble. NOTE: Select the clean place.
IMPORTANT: When removing retaining ring (28), return spring (26) flies out.䎃 Do not lose return spring (26). 7. Remove retaining ring (28).䎃 Remove spring seat (27), return spring (26) and sleeve (23). NOTE: Retaining ring (24) is installed to sleeve (23).
2. Remove any dust and rust from the regulator surface with using the washing oil.
8. Remove retaining ring (50) and remove plugs (48, 51). NOTE: Plugs (48, 51) can be easily removed with using the bolt (M6).
IMPORTANT: Do not lose O-ring (54). 3. Remove socket bolts (36, 37).䎃 Remove the regulator from the pump. : 6 mm IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) are installed to cover (43).䎃As the setting flow rate changes, do not loosen the screw and nut. 4. Remove socket bolt (30) and remove cover (43). : 5 mm 5. After removing cover (43) subassembly, remove springs (9, 10) and spring seat (8) from the compensating part.䎃 Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part. NOTE: Adjusting rod (13) can be removed with using the bolt (M4) easily. 6. Remove socket bolts (30, 58).䎃Remove cover (57). Remove set spring (25) from the pilot part after removing cover (57). : 5 mm
W2-4-21
CRANE UPPER / Pump Assembly
21
7
20
6
19
16
5
17
22 16
29 30
31 30
30
W2CH-02-04-001ã©·
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. 10. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with using a thin steel bar in order not to touch with lever (21). IMPORTANT: Do not remove pin (16). 11. Remove lever (21). 12. Remove piston (29) and spool (22). 13. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of casing (5) and remove casing (5). 14. Remove the socket bolt (30) and remove the cover (31). : 5 mm
W2-4-23
CRANE UPPER / Pump Assembly ASSEMBLE FRONT REGULATOR
30
32 36
30
14
30
31
45 33
35 54
55
58
25 37 21
18
47 19
49
50
56
29 53
34
27 26
13
15
24
23
22
46
41
12
8
43
44 39 41 40
48
57 28
51
3
17
1
11
2
3 38
4
42
16
20
5
6
7
9
10
52
W25N-02-04-010
12345678910 11 12 13 14 15 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -
Pin (2 Used)㩷 Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Springs㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (10 Used)㩷
31 32 33 34 35 36 37 38 39 40 41 42 43 44 㩷
Cover㩷 O-Ring㩷 O-Ring (3 Used)㩷 O-Ring㩷 Plug (5 Used)㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Lock Nut㩷
W2-4-24
45 46 47 48 49 50 51 52 53 54 55 56 57 58 㩷
Setscrew Casing㩷 Pin (2 Used)㩷 Plug㩷 O-Ring (2 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring (9 Used)㩷 O-Ring㩷 O-Ring㩷 Cover㩷 Socket Bolt (2 Used)㩷
CRANE UPPER / Pump Assembly Assemble Front Regulator 1. Install rod (7) into the compensating hole on casing (46). 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 Install lever (21) into pin (47). IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (46) smoothly. Check the direction of spool (22).
5. Install piston (29) into the hole for negative control on casing (46). NOTE: Check if piston (29) moves smoothly. 6. Install pin (16) to lever (17).䎃Insert pin (16) into the groove of piston (29).䎃Install lever (17). IMPORTANT: Check the holes for plugs (48, 51). 7. Install pin (47) to plug (48).䎃Align pin (47) with the pin hole on lever (17) and install plug (48). Install retaining ring (50). 8. Insert plug (51).䎃Install retaining ring (50). NOTE: Check if feedback lever (20) has too big play or moves smoothly.
22㩷
20㩷 W25N-02-04-011
9. Install return spring (26) and spring seat (27) to the spool hole.䎃Install retaining ring (28).
3. Install spool (22) and sleeve (23) into the spool hole on casing (46). IMPORTANT: Check the direction of feedback lever (20). Lever (21) Side
Lever (17) Side (Plugs (48, 51) Side)㩷
W25N-02-04-012
4. Install feedback lever (20).䎃 Align the pin hole on feedback lever (20) and insert pin (19). NOTE: In case inserting pin (19) into feedback lever (20) a little first, install easily.
W2-4-25
CRANE UPPER / Pump Assembly 30
14
30
45 41
13
15
58
25
8
43
44 39 41 40
57
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 N m (1.2 kgf m, 8.9 lbf ft) IMPORTANT: Check the direction of spring seat (15). 11. Install spring seat (15), spring (14) and adjusting rod (13) to the pilot hole.䎃Install spring seat (8) and springs (10, 9) to the compensating hole. 12. Install adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) to cover (43).䎃 Install cover (43) and tighten socket bolt (30). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft) 13. Install the cover (31) and tighten the socket bolt (30). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
W2-4-27
CRANE UPPER / Pump Assembly DISASSEMBLE REAR REGULATOR 3 11 10 9 8 21
7
20
6
1
2
3
5
4
12
19
16
13
17 14
22
15
23 16
24 25 26
18
29 27 28 44
45 41
43 42
35 40
46
41
39 38 36
31
37
30
32
33
47
48 48
33 34 60 61
49 50
51
44 57 55 56 59
55
54
58
53 52 50
W2-4-28
51
W2CH-02-04-002
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 16 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷 Pin (2 Used)
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 -
Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Springs㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (4 Used)㩷 Valve Casing㩷
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 㩷
W2-4-29
O-Ring㩷 O-Ring㩷 O-Ring (2 Used)㩷 Solenoid Valve㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Socket Bolt (6 Used)㩷 Lock Nut㩷 Setscrew
47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 㩷
Casing㩷 Pin (2 Used)㩷 Plug㩷 O-Ring (2 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring (9 Used)㩷 O-Ring㩷 O-Ring㩷 Cover㩷 Socket Bolt (2 Used)㩷 Plug (7 Used) O-Ring㩷
CRANE UPPER / Pump Assembly
11 10 9 8
13 14 15
23 24 25 26
27 28 44
45 41
43 46 40
41
39 36
37
49 51 44
55 55 59
52
58
51
W2-4-30
W2CH-02-04-002
CRANE UPPER / Pump Assembly Disassemble Rear Regulator
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Put the rubber plate or cloth on the workbench in order not to damage the parts. As the parts are small, do not lose the parts. 1. Select the place to disassemble. NOTE: Select the clean place. 2. Remove any dust and rust from the regulator surface with using the washing oil. IMPORTANT: Do not lose O-ring (55). 3. Remove socket bolts (36, 37).䎃 Remove the regulator from the pump. : 6 mm IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (45), nut (41) and setscrew (46) are installed to cover (43).䎃As the setting flow rate changes, do not loosen the screw and nut. 4. Remove socket bolt (44) and remove cover (43). : 5 mm
5. After removing cover (43) subassembly, remove springs (9, 10) and spring seat (8) from the compensating part.䎃 Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part. NOTE: Adjusting rod (13) can be easily removed with using the bolt (M4). 6. Remove socket bolts (44,59).䎃Remove cover (58). Remove set spring (25) from the pilot part. : 5 mm IMPORTANT: When removing retaining ring (28), return spring (26) flies out.䎃 Do not lose return spring (26). 7. Remove retaining ring (28).䎃 Remove spring seat (27), return spring (26) and sleeve (23). NOTE: Retaining ring (24) is installed to sleeve (23). 8. Remove retaining ring (51) and remove plugs (49, 52). NOTE: Plugs (49, 52) can be easily removed with using the bolt (M6).
W2-4-31
CRANE UPPER / Pump Assembly
21
7
20
6
19
16
5
17
22 16
29
35
31 30
W2CH-02-04-002ã©·
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. 10. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with using a thin steel bar in order not to touch with lever (21). IMPORTANT: Do not remove pin (16). 11. Remove lever (21). 12. Remove piston (29) and spool (22). 13. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of casing (5) and remove casing (5). 14. Remove the socket bolt (30) and remove the valve casing (31). : 5 mm 15. Remove the solenoid valve (35) from the valve casing (31). : 32 mm
W2-4-33
CRANE UPPER / Pump Assembly ASSEMBLE REAR REGULATOR 35
32
34 30
34
36
33
60
60
14
44
44
46 31
60
55
55
56
59 57
25 37
18 21
48
19
50
51
61
29
54
27
26
24
23
22
15
13
47
8
58
49
28
52
3
12
43
41
45 39 41 40
17 16
1
20
2 4 5
6
7
9
10
11 3 38 42 53
W2CM-02-04-005
W2-4-34
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 16 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷 Pin (2 Used)
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 -
Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Springs㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (4 Used)㩷 Valve Casing
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 㩷
O-Ring㩷 O-Ring㩷 O-Ring (2 Used)㩷 Solenoid Valve㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Socket Bolt (6 Used) Lock Nut㩷 Setscrew㩷
W2-4-35
47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 㩷
Casing㩷 Pin (2 Used)㩷 Plug㩷 O-Ring (2 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring (9 Used)㩷 O-Ring㩷 O-Ring㩷 Cover㩷 Socket Bolt (2 Used)㩷 Plug (7 Used) O-Ring
CRANE UPPER / Pump Assembly
29
27 48 21
19
26
23
22
47
51 49
28
52
17 16 20 7
W2CM-02-04-005
W2-4-36
CRANE UPPER / Pump Assembly Assemble Rear Regulator 1. Install rod (7) into the compensating hole on casing (47). 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 Install lever (21) into pin (48). IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (47) smoothly. Check the direction of spool (22).
5. Install piston (29) into the hole for negative control on casing (47). NOTE: Check if piston (29) moves smoothly. 6. Install pin (16) to lever (17).䎃Insert pin (16) into the groove of piston (29).䎃Install lever (17). IMPORTANT: Check the holes for plugs (49, 52). 7. Install pin (48) to plug (49).䎃Align pin (48) with the pin hole on lever (17) and install plug (49). Install retaining ring (51). 8. Insert plug (52).䎃Install retaining ring (51). NOTE: Check if feedback lever (20) has too big play or moves smoothly.
22㩷
20㩷 W25N-02-04-011
9. Install return spring (26) and spring seat (27) to the spool hole.䎃Install retaining ring (28).
3. Install spool (22) and sleeve (23) into the spool hole on casing (47). IMPORTANT: Check the direction of feedback lever (20). Lever (21) Side
Lever (17) Side (Plugs (49, 52) Side)㩷
W25N-02-04-012
4. Install feedback lever (20).䎃 Align the pin hole on feedback lever (20) and insert pin (19). NOTE: In case inserting pin (19) into feedback lever (20) a little first, the feedback lever can be easily inserted.
W2-4-37
CRANE UPPER / Pump Assembly 35
14 30
44
44
46 31
59 15
13
8
25 58
41
43
45 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 N m (1.2 kgf m, 8.9 lbf ft) IMPORTANT: Check the direction of spring seat (15). 11. Install spring seat (15), spring (14) and adjusting rod (13) to the pilot hole.䎃Install spring seat (8) and springs (10, 9) to the compensating hole. 12. Install adjusting screws (39, 40), adjusting rod (11), lock nut (45), nut (41) and setscrew (46) to cover (43).䎃 Install cover (43) and tighten socket bolt (44). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft) 13. Install the solenoid valve (35) on the valve casing (31). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m) (29 to 36 lbf ft) 14. Install the valve casing (31) and tighten the socket bolt (30). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
W2-4-39
CRANE UPPER / Pump Assembly DISASSEMBLE REDUCTION GEAR 21 1 4
18
3
7
2
16
17 18
10
1
6 5
19 20
16 14 15 14 13 18 18 12 11 10 9 8
8
W2CM-02-04-006
123456-
Spacer (2 Used) Retaining Ring Bearing Gear Retaining Ring Shaft
78910 11 -
O-Ring Socket Bolt (2 Used) Cover O-Ring (2 Used) Plate
12 13 14 15 16 -
O-Ring Retaining Ring Ball Bearing (2 Used) Gear Pin (2 Used)
W2-4-40
17 18 19 20 21 -
Casing Flange Socket (4 Used) O-Ring Plug Socket Bolt (2 Used)
CRANE UPPER / Pump Assembly Disassemble Reduction Gear
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the parts. 1. Select the place to disassemble. NOTE: Select the clean place.
8. Remove retaining ring (13). Remove gear (15) and ball bearing (14). NOTE: Ball bearing (14) cannot be removed from gear (15).
2. Remove any dust and rust from the reduction gear surface with using the washing oil. 3. Remove plug (20). Drain oil from the pump casing. : 36 mm NOTE: Drain oil from the plug in front and rear pump respectively. 4. Remove the socket bolt (21) and remove the 2-unit gear pump. : 8 mm 5. Remove the socket bolt (8). Remove the cover (9) and plate (12). : 8 mm 6. Remove flange socket (18) and remove the reduction gear. : 12 mm 7. Remove retaining ring (5) and remove shaft (6). Remove gear (4), bearing (3) and spacer (1). NOTE: Bearing (3) cannot be removed from gear (4).
W2-4-41
CRANE UPPER / Pump Assembly ASSEMBLE REDUCTION GEAR 12
13
14
11 8
10 17
20
15
19
21 4 3 6
16
18
1 5
9
2 7
W2CM-02-04-007
123456-
Spacer (2 Used)㩷 Retaining Ring㩷 Bearing㩷 Gear㩷 Retaining Ring㩷 Shaft
78910 11 -
O-Ring㩷 Socket Bolt (2 Used)㩷 Cover㩷 O-Ring (2 Used)㩷 Plate㩷
12 13 14 15 16 -
W2-4-42
O-Ring㩷 Retaining Ring㩷 Ball Bearing (2 Used)㩷 Gear㩷 Pin (2 Used)㩷
17 18 19 20 21 -
Casing㩷 Flange Socket (4 Used)㩷 O-Ring㩷 Plug㩷 Socket Bolt (2 Used)㩷
CRANE UPPER / Pump Assembly Assemble Reduction Gear 1. Install gear (15) and ball bearing (14) to casing (17). Install retaining ring (13). 2. Install gear (4), bearing (3) and spacer (1) to casing (17). Insert shaft (6). Install retaining ring (5). 3. Install the O-ring (7) and reduction gear to the valve block in main pump. Tighten flange socket (18). : 12 mm : 33 N m (3.4 kgf m, 24 lbf ft) 4. Install the plate (11) and O-ring (12) on the reduction gear. 5. Install the cover (9) and O-ring (10) on the reduction gear and tighten the socket bolt (8). : 8 mm : 33 N m (3.4 kgf m, 24 lbf ft) 6. Install the 2-unit gear pump and O-ring (10) on the reduction gear and tighten the socket bolt (21) with LOCTITE applied. : 8 mm : 22 to 28 N m (2.2 to 2.9 kgf m) (16 to 21 lbf ft) 7. Install plug (20) and O-ring (19) to casing (17). : 36 mm : 74 N m (7.5 kgf m, 55 lbf ft)
W2-4-43
CRANE UPPER / Pump Assembly MAINTENANCE STANDARD Replacement Standard for Wear Parts Replace the parts when the pitting (beyond 1 mm (0.039 in) a pit, beyond 5 % on the rate of area) occurs in tooth of gears (4, 15). In case the pitting does not occur and the damage on general view is found, replace the parts.
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
1. Shutdown the engine.䎃 Operate the lever several times and release the remaining pressure in the circuit.
2. Place a container (capacity: approx. 500 L (132 US gal)) under the drain plug (1) and drain off the hydraulic oil with removing the drain plug (1). Install the drain plug (1). : 19 mm
2
Removal 1. Remove all hoses, pipes and wire harness from the pump device. Cap the removed hoses. : 22 mm, 27 mm : 10 mm 2. Attach a wire rope onto the swing pump. Hold the swing pump. 3
CAUTION: Swing pump weight: Approx. 45 kg (100 lb)
W2CM-02-04-008
3. Remove bolts (2, 3). Lift swing pump with the crane and remove them. : 24 mm : 14 mm
W2-4-45
CRANE UPPER / Pump Assembly Installation CAUTION: Swing pump weight: Approx. 45 kg (100 lb)
4 2
1. Lift the swing pump and install it on the main pump and bracket. 2. Install the swing pump mounting bolt (2) bolt (3) with LOCTITE applied. : 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m) (132 to 143 lbf ft) : 14 mm : 240 N m (24.5 kgf m, 177 lbf ft) 3. Install all hoses, pipes and wire harness to the swing pump. : 22 mm : 39 N m (4.0 kgf m, 29 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft) 4. Remove the filler port cover of the hydraulic tank. Fill hydraulic oil to specified level. 5. Remove air bleed plug (4) from the top of main pump. Fill hydraulic oil. Install air bleed plug (4). Start the engine and run at low idling speed. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft) 6. Loosen air bleed plug (4). Release the pressure in the pump. : 36 mm 7. After releasing the air, tighten the air bleed plug (4) and check each operation at a low idling speed. Check the hydraulic oil level and any oil leakage. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
W2-4-46
3
W2CM-02-04-008
CRANE UPPER / Pump Assembly (Blank)
W2-4-47
CRANE UPPER / Pump Assembly DISASSEMBLE SWING PUMP 19
20
18 16, 17 28
26
25
21 22 23
29
24 30
25
12 32
26
11 10 27
3
4
5
6
7
8
15
9
7
14 13
10 49
31
2
33
1
47 51 44
50
43 5 42 48
37, 38 12
36
46
39
35
45
34 41 40
W2CH-02-04-003
12345678910 11 12 13 -
O-Ring Socket Bolt (4 Used) Plate Oil Seal O-Ring (2 Used) Retaining Ring Spacer (2 Used) Bearing Shaft Lock Nut (2 Used) Setscrew Spring Pin (2 Used) Stopper
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Backup Ring O-Ring Feedback Pin Tilt Pin Regulator Socket Bolt (2 Used) Socket Bolt (2 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Pump Casing Nut Aye Bolt O-Ring Plug (7 Used) Support Socket Bolt (4 Used) Plate Bushing Plate Piston (9 Used) Shoe (9 Used) Plate
W2-4-48
40 41 42 43 44 45 46 47 48 49 50 51 -
Bushing Spring (9 Used) Cylinder Block Valve Plate Bearing O-Ring Pin O-Ring (9 Used) Cover Setscrew Cover Socket Bolt (2 Used)
CRANE UPPER / Pump Assembly Disassemble Swing Pump
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the parts. 1. Select the place to disassemble. NOTE: Select the clean place. 2. Remove any dust and rust from the pump surface with using the washing oil. 3. Remove plug (26). Drain oil from pump casing (27). : 27 mm 4. Remove socket bolts (19, 20).䎃 Remove regulator (18). : 6 mm NOTE: Refer to the corresponding section as for disassembly of regulator (18). 5. Loosen socket bolt (33) that connects support (32), pump casing (27) and cover (48). : 14 mm IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the mounting surface for regulator. 6. Place the pump onto the workbench horizontally with the mounting surface for regulator facing downward.䎃Separate pump casing (27) from cover (48).
IMPORTANT: Do not damage the sliding surfaces of cylinder block (42), bushing (40), shoe (38) and plate (34). 7. Remove cylinder block (42) from pump casing (27) straightly.䎃 Remove piston (37), plate (39), bushing (40) and spring (41). IMPORTANT: When removing cover (3), do not damage oil seal (4). 8. Remove socket bolt (2) and remove cover (3). : 5 mm 9. Lightly tap the mounting flange part for support (32) from the pump casing (27) side.䎃 Separate pump casing (27) from support (32). 10. Remove plates (34, 36) from pump casing (27). 11. Tap the shaft end part of shaft (9) with using a plastic hammer lightly.䎃 Remove shaft (9) from support (32). 12. Remove valve plate (43) from cover (48). NOTE: Valve plate (43) may be removed at the step 6.
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
13
14
15
42
24
38
20
35
16,17
37
23 22
21
47
45
49
11 10 43 12
48
30 䋱 2 4 7
51
9
8 6 3
50
5
5
34 32
31
36
39
40
33
27
25, 26, 28,29
41
46
44
W2CH-02-04-004
12345678910 11 12 13 -
O-Ring Socket Bolt (4 Used) Plate Oil Seal O-Ring (2 Used) Retaining Ring Spacer (2 Used) Bearing Shaft Lock Nut (2 Used) Screw Spring Pin (2 Used) Stopper
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Backup Ring O-Ring Feedback Pin Tilt Pin Regulator Socket Bolt (2 Used) Socket Bolt (2 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Pump Casing Nut Aye Bolt O-Ring Plug (7 Used) Support Socket Bolt (4 Used) Plate Bushing Plate Piston (9 Used) Shoe (9 Used) Plate
W2-4-52
40 41 42 43 44 45 46 47 48 49 50 51 -
Bushing Spring (9 Used) Cylinder Block Valve Plate Bearing O-Ring Pin O-Ring (9 Used) Cover Screw Cover Socket Bolt (2 Used)
CRANE UPPER / Pump Assembly Assemble Swing Pump IMPORTANT: When tightening servo piston (24) and tilt pin (17), use special tool in order not to damage the head of tilt pin (17) and feedback pin (16).䎃Apply Three Bond #1305N onto the thread part. 1. Lightly tap and install support (32) to pump casing (27) with using a hammer. NOTE: When removing servo piston (24), tilt pin (17) and stoppers (13, 21), install them to pump casing (27) first. 2. Place pump casing (27) with the mounting surface for regulator facing downward.䎃Install bushing (35) in plate (34) into tilt pin (17).䎃 Install plate (34) to support (32). NOTE: Check if plate (34) can move smoothly by fingers. In case grease is applied onto plate (34) and support (32), shaft (9) can be installed easily. IMPORTANT: Do not tap shaft (9) with using a hammer. 3. Install bearing (8), spacer (7) and retaining ring (6) onto shaft (9). Install shaft (9) to support (32). NOTE: Lightly tap the outer ring in bearing (8) with using a plastic hammer and install bearing (8) with using a steel bar completely.
IMPORTANT: Do not damage oil seal (4). 4. Secure cover (3) to pump casing (27) with socket bolt (2). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft) NOTE: Apply a film of grease onto oil seal (4) in cover (3). 5. Assemble the piston cylinder sub assembly (cylinder block (42), piston (37), shoe (38), plate (39), bushing (40) and spring (41)).䎃 Align the splines of bushing (40) and cylinder block (42) and insert the piston cylinder sub assembly into pump casing (27). IMPORTANT: Check the direction of suction and delivery in valve plate (43). 6. Align with pin (46) and install valve plate (43) on cover (48). 7. Install cover (48) on pump casing (27).䎃 Tighten socket bolt (33). : 14 mm : 240 N m (24.0 kgf m, 177 lbf ft) 8. Insert feedback pin (16) in tilt pin (17) into the feedback lever in regulator (18).䎃 Install regulator (18).䎃Tighten socket bolts (19, 20). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft) 9. Install plug (26). : 27 mm : 110 N m (11.0 kgf m, 81 lbf ft)
W2-4-53
CRANE UPPER / Pump Assembly MAINTENANCE STANDARD 1. Clearance between piston outer diameter and cylinder inner bore. Unit: mm (in)
D-d
Standard
Allowable Limit
0.028 (0.001)
0.056 (0.002)
d
D
W25N-02-04-005
2. Clearance between piston and shoe Unit: mm (in)
Ǭ
Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.12) 㱐 t
3. Shoe thickness W25N-02-04-006
Unit: mm (in)
t
Standard
Allowable Limit
3.9 (0.15)
3.7 (0.15)
4. Free length of cylinder spring Unit: mm (in)
L
Standard
Allowable Limit
31.3 (1.23)
30.5 (1.20)
L W25N-02-04-007
5. Height of plate and spherical bushing Unit: mm (in)
H-h
Standard
Allowable Limit
19.0 (0.75)
18.3 (0.72)
H h
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
20
6 5 3 1
12
19
16
13
17
4
2
14
22
15
23 16
24 25 26
18
29 30
27 28
44 41
43 42 40 36
45
41
39
37 38
31 49
30
46
33 35
47
57 34
48 49
50
47
56
35
55 4
32
59
54
53
49
58
52
51 49 50
W2CH-02-04-005
W2-4-56
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -
Pin (2 Used)㩷 Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Spring㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (8 Used)㩷
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 -
Cover㩷 Socket Bolt (5 Used)㩷 O-Ring (2 Used)㩷 O-Ring㩷 Plug (8 Used)㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Lock Nut㩷 Setscrew㩷
W2-4-57
46 47 48 49 50 51 52 53 54 55 56 57 58 59 㩷
Casing㩷 Pin (2 Used)㩷 Plug㩷 O-Ring (5 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring㩷 O-Ring㩷 O-Ring (12 Used)㩷 Solenoid Valve㩷 Cover㩷
CRANE UPPER / Pump Assembly
11 10 9 8
13 4 14 15
23 24 25 26
30
27 28
44 41
43 45 40 36
37
41
39
49
30
48 49
4 32
59
49
58
52
50
51 49 50
W2CH-02-04-005ã©·
W2-4-58
CRANE UPPER / Pump Assembly Disassemble Regulator
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
IMPORTANT: Place the rubber plate or cloth on the workbench in order not to damage the parts. As the parts are small, do not lose the parts. 1. Select the place to disassemble. NOTE: Select the clean place. 2. Remove any dust and rust from the regulator surface with using the washing oil. IMPORTANT: Do not lose O-ring (4). 3. Remove socket bolts (36, 37) and remove the regulator from the pump. : 6 mm IMPORTANT: Adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) are installed to cover (43). As the setting flow rate changes, do not loosen the screw and nut. 4. Remove socket bolt (30) and remove cover (43). : 5 mm 5. Remove springs (9, 10) and spring seat (8) from the compensating part. Remove adjusting rod (13), spring (14) and spring seat (15) from the pilot part. NOTE: Adjusting rod (13) can be removed with using the bolt (M4) easily.
6. Remove socket bolt (32) and remove cover (59). Remove set spring (25) from the pilot part after removing the cover (59). : 5 mm 7. Remove the solenoid valve (58) from the cover (59). : 32 mm IMPORTANT: When removing retaining ring (28), return spring (26) flies out. Do not lose return spring (26). 8. Remove retaining ring (28). Remove spring seat (27), return spring (26) and sleeve (23). NOTE: Retaining ring (24) is installed to sleeve (23). 9. Remove retaining ring (50) and remove plugs (48, 51). NOTE: Plugs (48, 51) can be removed with using the bolt (M6) easily. 10. Remove the plug (52) and remove the O-ring (49). : 19 mm
W2-4-59
CRANE UPPER / Pump Assembly
21
7
20
6
19
16
5
17
22 16
29
W2CH-02-04-005ã©·
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. 12. Remove pin (19) and remove feedback lever (20). NOTE: Push out pin (19) (pin dia. ø4) upward with using a thin steel bar in order not to touch with lever (21). IMPORTANT: Do not remove pin (16). 13. Remove lever (21). 14. Remove piston (29) and spool (22). 15. Remove casing (5), piston (6) and rod (7). NOTE: Push out rod (7) from the opposite side of casing (5) and remove casing (5).
W2-4-61
CRANE UPPER / Pump Assembly ASSEMBLE REGULATOR
58
49
62
60 61
30
31
36
32
35
14
30
59
49 33
45
4
57
55
56
49, 52
25 37
21
18
47
19
49
34
27
15
54
29
26
24
23
22
13
12
41
8
43
44
46
50
39 41 40
28 48 51
17 16 20
3
1
11
2
3 38
4
42
5
6
7
9
10
53
W2CG-02-04-008
W2-4-62
CRANE UPPER / Pump Assembly 12345678910 11 12 13 14 15 16 -
Pin㩷 Sleeve㩷 O-Ring (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Piston㩷 Rod㩷 Spring Seat㩷 Spring㩷 Spring㩷 Adjusting Rod㩷 O-Ring㩷 Adjusting Rod㩷 Spring㩷 Spring Seat㩷 Pin (2 Used)㩷
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -
Lever㩷 Pin㩷 Pin㩷 Feedback Lever㩷 Lever㩷 Spool㩷 Sleeve㩷 Retaining Ring㩷 Set Spring㩷 Return Spring㩷 Spring Seat㩷 Retaining Ring㩷 Piston㩷 Socket Bolt (8 Used)㩷 Cover㩷 Socket Bolt (5 Used)㩷
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 㩷
O-Ring (2 Used)㩷 O-Ring㩷 Plug (8 Used)㩷 Socket Bolt (2 Used)㩷 Socket Bolt (2 Used)㩷 O-Ring㩷 Adjusting Screw㩷 Adjusting Screw㩷 Nut (2 Used)㩷 O-Ring㩷 Cover㩷 Lock Nut㩷 Setscrew㩷 Casing㩷 Pin (2 Used)㩷
W2-4-63
48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 㩷
Plug㩷 O-Ring (5 Used)㩷 Retaining Ring (2 Used)㩷 Plug㩷 Plug㩷 Pin㩷 O-Ring㩷 O-Ring㩷 O-Ring㩷 O-Ring (12 Used)㩷 Solenoid Valve㩷 Cover㩷 Seat (2 Used)㩷 Stopper (2 Used)㩷 Ball (2 Used)㩷
CRANE UPPER / Pump Assembly
49
29
49, 52
27 21
47
19
49
26
23
22
46
50 48 51
17 16 20 7
W2CG-02-04-008
W2-4-64
CRANE UPPER / Pump Assembly Assemble Regulator 1. Install rod (7) into the compensating hole on casing (46). 2. Install pin (16) to lever (21). Insert pin (16) into the groove of rod (7). Install pin (47) to casing (46). Install lever (21) into pin (47). IMPORTANT: Check if spool (22) and sleeve (23) can move in casing (46) smoothly. Check the direction of spool (22).
5. Install piston (29) into the hole for negative control on casing (46). NOTE: Check if piston (29) moves smoothly. 6. Install pin (16) to lever (17). Insert pin (16) into the groove of piston (29). Install lever (17). IMPORTANT: Check the inserting hole of the plugs (48) and (51). 7. Install pin (47) to plug (51). Align pin (47) with the pin hole on lever (17) and install plug (51). Install retaining ring (50). 8. Insert plug (48). Install retaining ring (50). NOTE: Check if feedback lever (20) has too big play or moves smoothly.
22㩷
20㩷 W25N-02-04-011
3. Install spool (22) and sleeve (23) into the spool hole on casing (46). IMPORTANT: Check the direction of feedback lever (20). Lever (21) Side
9. Install the O-ring (49) and plug (52) on the casing (46). : 19 mm : 36 N m (3.7 kgf m, 27 lbf ft) 10. Install return spring (26) and spring seat (27) to the spool hole.䎃Install retaining ring (28).
Lever (17) Side (Plugs (48, 51) Side)
W25N-02-04-012
4. Install feedback lever (20).䎃 Align the pin hole on feedback lever (20) and insert pin (19). NOTE: In case inserting pin (19) into feedback lever (20) a little first, the pin can be inserted easily.
W2-4-65
CRANE UPPER / Pump Assembly
58
30
32
14
30
59
45 41
13
15
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 N m (4.5 to 5.0 kgf m) (29 to 36 lbf ft) 12. Install set spring (25) to the spool hole and install piston (6) and casing (5) to the compensating hole.䎃 Tighten cover (59) with socket bolt (32). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft) IMPORTANT: Check the direction of spring seat (15). 13. Install spring seat (15), spring (14) and adjusting rod (13) to the pilot hole.䎃Install spring seat (8) and springs (9, 10) to the compensating hole. 14. Install adjusting screws (39, 40), adjusting rod (11), lock nut (44), nut (41) and setscrew (45) to cover (43).䎃 Install cover (43) and tighten socket bolt (30). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
W2-4-67
CRANE UPPER / Pump Assembly (Blank)ã©·
W2-4-68
CRANE UPPER / Pump Assembly REMOVE AND INSTALL 2-UNIT GEAR PUMP
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
1
W24X-02-04-001
Preparation 1. Stop the engine.䎃Operate the lever several times and release the remaining pressure in the circuit.
2. Remove drain plug (1) and drain off hydraulic oil by using a container (500 L (132 US gal)). : 19 mm
2
Removal 1. Remove all hoses, pipes, and wire harness from the 2-unit gear pump. Cap the removed hoses. : 27 mm : 8 mm 2. Support the 2-unit gear pump. CAUTION: 2-unit gear pump weight: Approx. 7.6 kg (17 lb)
W2CM-02-04-013
3. Remove the 2-unit gear pump mounting bolt (2) and remove the 2-unit gear pump. : 8 mm
W2-4-69
CRANE UPPER / Pump Assembly Installation CAUTION: 2-unit gear pump weight: Approx. 7.6 kg (17 lb)
4
1. Install the 2-unit gear pump on the reduction gear of the main pump. 2. Install the 2-unit gear pump mounting bolt (2). : 8 mm : 22 to 28 N m (2.2 to 2.9 kgf m) (16 to 21 lbf ft) 3. Install all hoses, pipes, and wire harness to the 2-unit gear pump. : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 8 mm : 48 to 50 N m (4.9 to 5.1 kgf m) (35 to 37 lbf ft)
2
W2CM-02-04-013
4. Remove hydraulic oil tank cover. Fill hydraulic oil to specified level. 5. Remove air bleed plug (3) from the top of main pump. Fill hydraulic oil. Install air bleed plug (3). Start the engine and run at low idling speed. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft) 6. Loosen air bleed plug (3). Release the pressure in the pump. : 36 mm 7. Tighten air bleed plug (3). Do the work at low idling speed. Check the hydraulic oil level and any oil leakage. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
W2-4-70
CRANE UPPER / Pump Assembly (Blank)
W2-4-71
CRANE UPPER / Pump Assembly DISASSEMBLE 2-UNIT GEAR PUMP
10
9 7 6 14
5 4 3 2
13
1
8
7 6
5 4
4 11
10
4 5 6 4
7
17 4 16
4 5 6 7 15
4
W2CM-02-04-014
1-
Retaining Ring㩷
6-
Gasket (4 Used)㩷
10 - Body㩷
14 - Body㩷
2-
Oil Seal㩷
7-
Side Plate (4 Used)㩷
11 - Adapter Plate㩷
15 - Rear Cover㩷
3-
Front Cover㩷
8-
Driven Gear㩷
12 - Driven Gear㩷
16 - Washer (4 Used)㩷
4-
Bushing (8 Used)
9-
Drive Gear㩷
13 - Drive Gear㩷
17 - Socket Bolt (4 Used)㩷
5-
Gasket (4 Used)
W2-4-72
CRANE UPPER / Pump Assembly Disassemble 2-Unit Gear Pump
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
NOTE: Although gaskets (5, 6) and side plate (7) are the same type, the directions to install are different. Attach an identification tag for assembling. The orders of driven gears (8, 12) are symmetrical. Attach an identification tag onto the shaft part when disassembling. 1. Remove any dust and rust from the pump surface with using the washing oil. 2. Face the rear cover (15) side upward.䎃Clamp the mounting part of front cover (3) in a vise. 3. Put the matching marks on the matching part in the drive side of front cover (3), body (10), adapter plate (11), body (14) and rear cover (15). 4. Remove socket bolt (17). : 10 mm
9. Remove bushing (4), gaskets (5, 6) and side plate (7). 10. Remove adapter plate (11). 11. Remove bushing (4), gaskets (5, 6) and side plate (7). 12. Remove body (10). 13. Remove bushing (4), gaskets (5, 6) and side plate (7). 14. Remove drive gear (9) and driven gear (8). 15. Remove front cover (3) from the vise. 16. Remove retaining ring (1). 17. Remove oil seal (2).
5. Remove rear cover (15). 6. Remove bushing (4), gaskets (5, 6) and side plate (7).
2
7. Remove drive gear (13) and driven gear (12). 8. Remove body (14). 3
W25N-02-04-018
W2-4-73
CRANE UPPER / Pump Assembly ASSEMBLE 2-UNIT GEAR PUMP
9
1
2
10
3
5
7
8
6
11
4
14
13
16
12
15
18
17
19
W2CM-02-04-015
1-
Retaining Ring㩷
6-
Gasket (4 Used)㩷
11 - Adapter Plate㩷
16 - Washer (4 Used)㩷
2-
Oil Seal㩷
7-
Side Plate (4 Used)㩷
12 - Driven Gear㩷
17 - Socket Bolt (4 Used)㩷
3-
Front Cover㩷
8-
Driven Gear㩷
13 - Drive Gear㩷
18 - Plug㩷
4-
Bushing (8 Used)㩷
9-
Drive Gear㩷
14 - Body㩷
19 - O-Ring㩷
5-
Gasket (4 Used)㩷
10 - Body㩷
15 - Rear Cover㩷
㩷
W2-4-74
CRANE UPPER / Pump Assembly Assemble 2-Unit Gear Pump
• Replace all oil seals and gaskets with the new ones. Before assembling, clean each parts with using clean washing oil and dry. Apply clean hydraulic oil onto the inner parts.䎃 Specially apply hydraulic oil onto the sliding part in order not to seize. IMPORTANT: Install gasket (6) so that the flat surface is located in the bottom of groove. Assemble side plate (7) so that the yellow surface faces to the gear side and the long pulling-out hole faces to the suction side. Delivery Side Gears (8, 9, 12, 13) are asymmetrical.䎃 䎃 Mesh the gears with small notch each other and assemble them. Short Pulling-Out Hole㩷
NOTE: Secure gaskets (5, 6) and side plate (7) with applying grease in order not to twist and bind.䎃 Align the matching marks and assemble front cover (3), body (10), adapter plate (11), body (14) and rear cover (15).䎃 Check the direction of mark and install driven gears (8, 12). 1. Secure front cover (3) with the mounting surface for body (10) facing upward in a vise.
Suction Side㩷
Long Pulling-Out Hole㩷
W25N-02-04-022
Rotating Direction of Drive Gear㩷 Large Notch㩷 (No Bound Side)
Delivery Side㩷
Small Notch (Bound Side)
Suction Side
2. Install bushing (4), gaskets (5, 6) and side plate (7) on front cover (3). 3. Install body (10) to front cover (3).
Rotating Direction of Driven Gear㩷 W25N-02-04-023
W2-4-75
CRANE UPPER / Pump Assembly
9
1
3
2
10
5
7
8
6
11
4
14
13
12
16
15
18
17
19
W2CM-02-04-015
W2-4-76
CRANE UPPER / Pump Assembly 4. Install drive gear (9) and driven gear (8) onto body (10). 5. Install bushing (4), gaskets (5, 6) and side plate (7) to the front and rear of the adapter plate (11). 6. Install adapter plate (11) to body (10). 7. Install body (14) to adapter plate (11). 8. Install drive gear (13) and driven gear (12) to body (14). 9. Install bushing (4), gaskets (5, 6) and side plate (7) on the rear cover (15). 10. Install rear cover (15) to body (14). 11. Install socket bolt (17). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m) (65 to 69 lbf ft) 12. Turn over the pump with the side where oil seal (2) is installed facing upward. Clamp the pump in a vise.
2 Dust Lip 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
2 3
W2CM-02-04-016
15. Install retaining ring (1).
1
W2CM-02-04-017
W2-4-78
CRANE UPPER / Pump Assembly REMOVE AND INSTALL GEAR PUMP FOR HYD. TAGLINE
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Before draining hydraulic oil, lower the boom onto the ground. Apply each brake and the drum lock.
1
W24X-02-04-001
Preparation 1. Stop the engine.䎃Operate the lever several times and release the remaining pressure in the circuit.
2
2. Remove drain plug (1) and drain off hydraulic oil by using a container (500 L (132 US gal)). : 19 mm
Removal 1. Remove all hoses, pipes, and wire harness from the gear pump. Cap the removed hoses. 2. Support the gear pump. CAUTION: Gear pump weight: Approx. 2.3 kg (5.1 lb) 3. Remove the gear pump mounting bolt (2) and remove the gear pump. : 8 mm
W2-4-79
W2CM-02-04-018
CRANE UPPER / Pump Assembly Installation CAUTION: Gear pump weight: Approx. 2.3 kg (5.1 lb)
2 3
1. Install the gear pump on the reduction gear of the main pump. 2. Install the gear pump mounting bolt (2). 3. Install all hoses, pipes, and wire harness to the gear pump. 4. Remove hydraulic oil tank cover. Fill hydraulic oil to specified level. 5. Remove air bleed plug (3) from the top of main pump. Fill hydraulic oil. Install air bleed plug (3). Start the engine and run at low idling speed. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
W2CM-02-04-018
6. Loosen air bleed plug (3). Release the pressure in the pump. : 36 mm 7. Tighten air bleed plug (3). Do the work at low idling speed. Check the hydraulic oil level and any oil leakage. : 36 mm : 170 N m (17.0 kgf m, 125 lbf ft)
W2-4-80
CRANE UPPER / Pump Assembly (Blank)
W2-4-81
CRANE UPPER / Pump Assembly DISASSEMBLE GEAR PUMP FOR HYD. TAGLINE
9 7 6 5 4
8
3 2 1
14
13 12
11 10 6 7
W23F-02-04-012
1-
Retaining Ring㩷
5-
Gasket㩷
9-
2-
Oil Seal㩷
6-
Gasket (2 Used)㩷
10 - Bushing (2 Used)㩷
Drive Gear㩷
3-
Front Cover㩷
7-
Side Plate (2 Used)㩷
11 - 㪙㪸㫃㫃㩷(2 Used)㩷
14 - Socket Bolt (4 Used)㩷
4-
Bushing (2 Used)
8-
Driven Gear㩷
㩷
㩷
W2-4-82
12 - Rear Cover㩷 13 - Washer (4 Used)㩷
CRANE UPPER / Pump Assembly Disassemble Gear Pump
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
NOTE: Although gaskets (6) and side plate (7) are the same type, the directions to install are different. Attach an identification tag for assembling. The orders of driven gears (8) are symmetrical. Attach an identification tag onto the shaft part when disassembling. 1. Remove any dust and rust from the pump surface with using the washing oil.
8. Remove gaskets (5, 6) and side plate (7). 9. Remove ball (11) and bushing (4). 10. Remove front cover (3) from the vise. 11. Remove retaining ring (1). 12. Remove oil seal (2).
2. Face the rear cover (12) side upward.䎃Clamp the mounting part of front cover (3) in a vise. 3. Put the matching marks on the matching part in the drive side of front cover (3) and rear cover (12).
2
4. Remove socket bolt (14). : 10 mm 3
5. Remove rear cover (12). 6. Remove bushing (10), gaskets (6) and side plate (7). 7. Remove drive gear (9) and driven gear (8).
W2-4-83
W25N-02-04-018
CRANE UPPER / Pump Assembly ASSEMBLE GEAR PUMP FOR HYD. TAGLINE
9
3
4
11
7
10
10
1 6 2
4 6
7
5
12
8
13
14
W23F-02-04-014
1-
Retaining Ring㩷
5-
Gasket㩷
9-
2-
Oil Seal㩷
6-
Gasket (2 Used)㩷
10 - Bushing (2 Used)㩷
Drive Gear㩷
3-
Front Cover㩷
7-
Side Plate (2 Used)㩷
11 - 㪙㪸㫃㫃㩷(2 Used)㩷
14 - Socket Bolt (4 Used)㩷
4-
Bushing (2 Used)
8-
Driven Gear㩷
㩷
㩷
W2-4-84
12 - Rear Cover㩷 13 - Washer (4 Used)㩷
CRANE UPPER / Pump Assembly Assemble Gear Pump
• Replace all oil seals and gaskets with the new ones. Before assembling, clean each parts with using clean washing oil and dry. Apply clean hydraulic oil onto the inner parts.䎃 Specially apply hydraulic oil onto the sliding part in order not to seize. IMPORTANT: Install gasket (6) so that the flat surface is located at front cover (3) and rear cover (12). Assemble side plate (7) so that the opposite side to gasket (6) mounting surface faces the gear side and the pulling-out hole faces the delivery side. Gears (8, 9) are asymmetrical.䎃 䎃 Mesh the gears with small notch each other and assemble them. NOTE: Secure gaskets (5, 6) and side plate (7) with applying grease in order not to twist and bind.䎃 Align the matching marks and assemble front cover (3) and rear cover (12).䎃 Check the direction of mark and install driven gears (8). 1. Secure front cover (3) with the mounting surface for body (12) facing upward in a vise.
Delivery Side
Suction Side㩷
Pulling-Out Hole
W25N-02-04-022
Rotating Direction of Drive Gear㩷 Large Notch㩷 (No Bound Side)
Delivery Side㩷
Small Notch (Bound Side)
Suction Side
2. Install bushing (4) on front cover (3). 3. Install gaskets (5, 6) and side plate on front cover (3).
Rotating Direction of Driven Gear㩷 W25N-02-04-023
W2-4-85
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). 5. Install ball (11) on front cover (3). 6. Install bushing (10) on rear cover (12). 7. Install gaskets (6) and side plate (7) on the rear cover (12). 8. Install rear cover (12) to front cover (3). 9. Install socket bolt (14) with washer (13). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m) (65 to 69 lbf ft) 2
10. Turn over the pump with the side where oil seal (2) is installed facing upward. Clamp the pump in a vise.
Dust Lip Fill grease.
11. Fill grease main lip and dust lip in oil seal (2). Main Lip
W25N-02-04-021
Pipe
IMPORTANT: Do not damage oil seal (2). 12. Install oil seal (2) to front cover (3) with using a guide and pipe. Guide
2 3
W2CM-02-04-016
W2-4-87
CRANE UPPER / Pump Assembly 13. Install retaining ring (1).
1
W2CM-02-04-017
W2-4-88
CRANE UPPER / Control Valve REMOVE AND INSTALL FRONT / REAR 4-UNIT CONTROL VALVE CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. 2. Remove all hoses and pipes from control valves (1, 2) : 22 mm : 36 mm : 8 mm : 10 mm NOTE: Cap all the removed hoses and pipes. Attach an identification tag for assembling. 3. Remove bolt (3). : 19 mm
1 3
CAUTION: Control valve (1) weight: Approx. 80 kg (176 lb) Control valve (2) weight: Approx. 85 kg (187 lb)
2 3 W25N-02-05-001
4. Hoist and remove control valves (1, 2).
W2-5-1
CRANE UPPER / Control Valve Installation CAUTION: Control valve (1) weight: Approx. 80 kg (176 lb) Control valve (2) weight: Approx. 85 kg (187 lb) 1. Install control valves (1, 2) to the frame. Secure to the frame with bolt (3). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft) 2. Install all hoses and pipes to control valves (1, 2). : 22 mm : 39 N m (4.0 kgf m, 28.8 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 8 mm : 54 to 66 N m (5.5 to 6.7 kgf m, 40 to 49 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft) IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
W2-5-2
1 3 2 3 W25N-02-05-001
CRANE UPPER / Control Valve (Blank)
W2-5-3
CRANE UPPER / Control Valve DISASSEMBLE FRONT / REAR 4-UNIT CONTROL VALVE 14
13
20
13
12
16 17
11
12 11 9
B
15
12
13
49
15
54 48
21
C
7 22 6 23
5 4
24
3
25
47
55
46
56
45
57
44
58
42
43
Section Cã©·
59
E
2 1
7
26 41
52 53
19
8
51
11
18
10
35
50
60
27 30
35 36 18
40
14 11 12 13
17 39 38
37 12
11
13 F
27 61
32 11
16 19
Section E
13 12
34
A
28
28 30 29 31
33
D
76
62
62 85
34 63
37
75
63
63
74 73
63
39
9
64 84 83 82
64
67
38
36
81
77 72 78 71
64
70 32
65
64 41 62
69
80
66 Section B
67
79
68
Section A
Section D
W2-5-4
Section F
W2BC-02-05-002
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 71 - O-Ring㩷
7-
Valve Section㩷
29 - Plug (7 Used)㩷
50 - Socket Bolt (4 Used)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
W2-5-5
㩷
CRANE UPPER / Control Valve 14
13
15
12
13
20
13
12
16 17
11
12 11
B
49
15
19 8
51
11
18
10
35
50
48
21
C
47
7
57 Section Cã©· E
7 41
30
35 36 18
40
14 11 12 13
30
17 38
12
11
13 F
19
A
38
32 11
Section E
13 12 33
D
36
41 69
Section B
Section F
79
Section A
Section D
W2-5-6
W2BC-02-05-002
CRANE UPPER / Control Valve Disassemble Front / Rear 4-Unit Control Valve
• The disassembling and assembling procedures of 4-spool spool control valves for travel (left), third, rear and front are explained here. As the construction is similar, refer to this section when disassembling and assembling other 4-unit control valve. CAUTION: Control valve weight: Approx. 80 kg (176 lb)
CAUTION: Do not damage the holes on spool and valve section.
1. Place the control valve assembly on a workbench. IMPORTANT: Do not loosen the adjusting screw in solenoid valves (69, 79). 2. Remove solenoid valves (69, 79) (2 used for each) from end covers (15) (3 used) and (33). : 32 mm 3. Remove socket bolts (10) (16 used) and (21) (14 used). Remove end covers (14) (2 used), (15) (3 used), (16) and (33) from each valve section. : 5 mm
8. Turn and remove spools (32, 36, 38 and 41) from each valve section. NOTE: Do not remove plugs (20) and (40) (3 used) from spools (32, 38, 41) unless necessary. 9. Remove socket bolts (50) (4 used). Remove cover (49), springs (47, 48) and O-ring (57) from casing (35). : 8 mm CAUTION: Do not damage the holes on spool (51) and casing (35).
4. Remove spring seat (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (2 used) from end covers (14) (2 used).
10. Turn and remove the spool (51) assembly from casing (35).
5. Remove spring seat (19) (2 used), springs (17, 18) (2 used for each) and O-rings (30) (2 used) from end covers (16) (2 used).
IMPORTANT: Do not disassemble relief valve (8). 11. Remove relief valve (8) from valve section (7). : 30 mm
6. Remove spring seat (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (2 used) from end covers (15) (2 used). 7. Remove spring seats (13) (2 used), springs (11, 12) (2 used for each) and O-rings (30) (3 used) from end covers (15, 33).
W2-5-7
CRANE UPPER / Control Valve B
35
9
54 C
7 22
56
23
57
6 5 4 Section Cã©·
3 E
2 1
7
26 35
Section E
39
37
F
A
34
D
76
85
34
9
63
37
63
63
63
39
64 84 83 82
64
77 72 78 71
64
64
70
Section B
Section F
Section A
Section D
W2-5-8
W2BC-02-05-002
CRANE UPPER / Control Valve IMPORTANT: Do not disassemble relief valve (76). 12. Remove relief valve (76) from valve section (34). : 30 mm 13. Remove valve (85) from valve section (39). 14. Remove plugs (82, 70) from valve sections (39, 34). : 30 mm 15. Remove O-rings (84, 72, 83, 71) from plugs (82, 70). 16. Turn over the control valve. Remove plugs (64) (4 used).
20. Turn over the control valve. 21. Remove nuts (2) (4 used) and spring washers (1) (4 used).䎃 Remove bolts (3) (4 used) from each valve section. : 24 mm 22. Divide into each valve section (7, 9, 22, 34, 37, 39) and casing (3). 23. Remove O-rings (4) (6 used), (5) (6 used), (6) (12 used), (23) (2 used) and (26) (16 used) from each valve section (7, 9, 22, 34, 37, 39) and casing (35).
41 mm 17. Remove check valve (78) and spring (77) from valve section (37). 18. Remove O-rings (63) (4 used) from plugs (64) (4 used). 19. Remove socket bolts (56) (4 used). Remove cover (54) and O-ring (57) from casing (35). : 8 mm
W2-5-9
CRANE UPPER / Control Valve ASSEMBLE FRONT CONTROL VALVE 14
13
REAR B
15
12
13
4-UNIT
20
13
12
16 17
11
12 11 9
/
49
15
54 48
21
C
7 22 6 23
5 4
24
3
25
47
55
46
56
45
57
44
58
42
43
Section Cã©·
59
E
2 1
7
26 41
52 53
19
8
51
11
18
10
35
50
60
27 30
35 36 18
40
14 11 12 13
17 39 38
37 12
11
13 F
27 61
32 11
16 19
Section E
13 12
34
A
28
28 30 29 31
33
D
76
62
62 85
34 63
37
75
63
63
74 73
63
39
9
64 84 83 82
64
67
38
36
81
77 72 78 71
64
70 32
65
64 41 62
69
80
66 Section B
67
79
68
Section A
Section D
W2-5-10
Section F
W2BC-02-05-002
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 71 - O-Ring㩷
7-
Valve Section㩷
29 - Plug (7 Used)㩷
50 - Socket Bolt (4 Used)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
W2-5-11
㩷
CRANE UPPER / Control Valve
14
B
13
13
12
13
35
50
12
51
11
12 11
11 49
9
54 48 C
47
7 22
56
6 57
5 4 Section Cã©·
3 E
2 1
7
26 41
27 35 36
30
30
14 11 12 13
39 38
32 11
37 12
11
13 F
34
A
27 Section E
13 12 D
34
9
63
37
63
63
63
39
64 84 83 82
64
38
64
77 72 78 71
64
70 32
36
41
Section B
Section F
Section A
Section D
W2-5-12
W2BC-02-05-002
CRANE UPPER / Control Valve Assemble Front / Rear 4-Unit Control Valve 1. Install O-rings (4, 5) (6 used for each), (6) (12 used), (27) (2 used) and (26) (16 used) to each valve section (7, 9, 22, 34, 37, 39) and casing (35). 2. Arrange each valve section (7, 9, 39, 37), casing (35) and valve sections (34, 22) in this order. 3. Install bolts (3) (4 used) to each valve section (7, 9, 39, 37), casing (35) and valve sections (34, 22).䎃 Tighten spring washers (1) (4 used) with nuts (2) (4 used). : 24 mm : 110r10 N m (11.2r1.0 kgf m, 81r7.4 lbf ft) 4. Turn over the control valve. Install check valve (78) and spring (77) to valve section (37). 5. Install O-rings (63) (4 used) to plugs (64) (4 used). Install to valve sections (9, 39, 37, 34). : 41 mm : 200r10 N m (20r1.0 kgf m, 148r7.4 lbf ft) 6. Install O-ring (57) and cover (54) onto casing (35). Install cover (54) onto casing (35) with socket bolts (56) (4 used). 7. Turn over the control valve. 8. Install O-rings (71, 83, 72, 84) to plugs (70, 82).
9. Install plug (70) to valve section (34). : 30 mm : 75r50 N m (8.0r5.1 kgf m, 55r37 lbf ft) 10. Install plug (82) to valve section (39). : 30 mm : 110r10 N m (11.2r1.0 kgf m, 81r7.4 lbf ft) CAUTION: Do not damage the holes on spool and valve section. IMPORTANT: Check the inserting positions for spool (32, 36, 38, 41). 11. Insert spools (32, 36, 38, 41) into valve sections (34, 37, 39, 9). CAUTION: Do not damage the holes on spool (51) and casing (35). 12. Insert the spool (51) assembly into casing (35). Install springs (47, 48) to spool (51). 13. Install O-ring (57) to casing (35). Install cover (49) onto casing (35). Install cover (49) to casing (35) with socket bolts (50) (4 used). : 8 mm : 57r6.0 N m (5.8r0.6 kgf m, 42r4.4 lbf ft) 14. Install O-rings (30) (2 used), springs (11, 12) (2 used for each) and spring seats (13) (2 used) to end covers (14) (2 used).
W2-5-13
CRANE UPPER / Control Valve
14
13
13
13
12
16 17
11
12 11 9
B
15
12
11
18
10
8
15 21
C
7
Section Cã©· E
7
30 14 11 12 13
30 31
18 17 39
37 12
11
Section E
11
16
13 F
A
13 12
34 33
D
76
62
62 85
34
9
37 39
65 62
69
Section B
Section F
79
Section A
Section D
W2-5-14
W2BC-02-05-002
CRANE UPPER / Control Valve 15. Install the end cover (14) assemblies (2 used) to valve section (9). Install end cover (14) to valve section (9) with socket bolts (10) (4 used). : 5 mm : 21r1 N m (2.1r0.1 kgf m, 15r0.7 lbf ft) 16. Install O-rings (30) (3 used), (62) (6 used), springs (11, 12) (3 used for each) and spring seats (13) (3 used) to end covers (15) (3 used). 17. Install the end cover (15) assemblies (3 used) to valve sections (34, 39). Install end covers (15) (3 used) to valve sections (34, 39) with socket bolts (21) (6 used). : 5 mm : 16r1.0 N m (1.6r0.1 kgf m, 11.8r0.7 lbf ft) 18. Install O-rings (30) (2 used), springs (17, 18) (2 used for each) and spring seats (19) (2 used) to end covers (16) (2 used). 19. Install end covers (16) (2 used) assembly to valve section (37) with socket bolts (10) (4 used). : 5 mm : 12r1.0 N m (1.2r0.1 kgf m, 8.9r0.7 lbf ft)
23. Install relief valve (8) to valve section (7). : 30 mm : 74r5.0 N m (7.5r0.5 kgf m, 54.6r3.7 lbf ft) 24. Install relief valve (76) to valve section (34). : 30 mm : 74r5.0 N m (7.5r0.5 kgf m, 54.6r3.7 lbf ft) 25. Install valve (85) to valve section (39). : 30 mm : 110r10 N m (11.2r1.0 kgf m, 81.1r7.4 lbf ft) 26. Install solenoid valves (69, 79) (2 used for each) to end covers (15) (3 used) and (33). : 32 mm : 44r5.0 N m (4.5r0.5 kgf m, 32.5r3.7 lbf ft)
20. Install O-ring (30) to plate (65). 21. Install O-rings (62) (4 used), springs (11, 12) and spring seat (13) to end cover (33). 22. Install the end cover (33) assembly and plate (65) to valve section (34). Install end cover (33) to valve section (34) with socket bolts (31) (2 used). : 5 mm : 12r1.0 N m (1.2r0.1 kgf m, 8.9r0.7 lbf ft)
W2-5-15
CRANE UPPER / Control Valve (Blank)
W2-5-16
CRANE UPPER / Control Valve REMOVE AND INSTALL 4-UNIT CONTROL VALVE CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. 2. Remove all hoses and harness connectors from control valve (1). : 17 mm, 27 mm NOTE: Cap the removed hoses. Attach an identification tag for assembling. 3. Remove bolts (2) (3 used). : 17 mm
1 2
CAUTION: Control valve (1) weight: Approx. 22 kg (49 lb)
W2BC-02-05-001
4. Hoist and remove control valve (1).
W2-5-17
CRANE UPPER / Control Valve Installation CAUTION: Control valve (1) weight: Approx. 22 kg (49 lb) 1. Install control valve (1) to the frame with bolts (2) (3 used). : 17 mm : 50 N m (5.1 kgf m, 37 lbf ft) 2. Install all hoses and harness connectors to control valve (1). : 17 mm : 50 N m (5.1 kgf m, 37 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
W2-5-18
1 2 W2BC-02-05-001
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
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
19 W2BC-02-05-003
C
27 25
28
26
24
8
29 30
23
31
22
32 21 33
34 20
43
W2BC-02-05-005
Section B
42 41 40 35
36
37
Section C
W2-5-20
38
39 W2BC-02-05-006
CRANE UPPER / Control Valve 12345678910 11 -
Spool㩷 End Section 1㩷 Spring㩷 Plug (10 Used)㩷 O-Ring㩷 Plug㩷 Relief Valve㩷 Casing (2 Used)㩷 Casing (2 Used)㩷 End Cover (8 Used)㩷 Spring (8 Used)㩷
12 13 14 15 16 17 18 19 20 21 22 -
Spring Seat (8 Used)㩷 O-Ring (8 Used)㩷 Spring Washer (4 Used)㩷 Nut (4 Used)㩷 Bolt (4 Used)㩷 End Section 2㩷 Plate㩷 Spool (4 Used)㩷 O-Ring (22 Used)㩷 O-Ring (6 Used)㩷 Spool㩷
23 24 25 26 27 28 29 30 31 32 33 -
Spring㩷 O-Ring (4 Used)㩷 Plug (4 Used)㩷 O-Ring (18 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 O-Ring (2 Used)㩷 Check Valve (4 Used)㩷 Spring (4 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-5-21
34 35 36 37 38 39 40 41 42 43 㩷
Relief Valve (2 Used)㩷 Solenoid (8 Used)㩷 Spring (8 Used)㩷 O-Ring (8 Used)㩷 Spool (8 Used)㩷 O-Ring (8 Used)㩷 Plug (8 Used)㩷 Plug (24 Used)㩷 Socket Bolt (32 Used)㩷 O-Ring (16 Used)㩷
CRANE UPPER / Control Valve
8
9
10 11
1
2
12 3
4
14
13
15 16
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
19 W2BC-02-05-003
C
C
27 25
28
26
24
8
29 30
23
31
22
32 21 33
34 20
43
W2BC-02-05-005
Section B
42 41 40 35
36
37
Section C
W2-5-22
38
39 W2BC-02-05-006
CRANE UPPER / Control Valve Disassemble 4-Unit Control Valve The disassembling and assembling procedures of 4-spool control valves for counterweight, left travel motor and quick draw are explained here.
8. Remove spring seat (12) (8 used), springs (11) (8 used) and O-rings (13) (8 used) from end covers (10) (8 used).
CAUTION: Control valve weight: Approx. 22 kg (49 lb)
CAUTION: Do not damage the holes on casings (8, 9).
1. Place the control valve assembly on a workbench. IMPORTANT: Do not loosen the adjusting screw in solenoid (35). 2. Remove solenoids (35) (8 used) from end covers (10) (8 used). Remove O-rings (37) (8 used) from solenoids (35) (8 used). : 32 mm IMPORTANT: Do not disassemble relief valve (34). 3. Remove relief valves (34) (2 used) from casings (8) (2 used). : 30 mm 4. Remove plugs (40) (8 used) from end cover (10). Remove O-rings (39) (8 used) from plugs (40) (8 used). : 5 mm CAUTION: Do not damage the hole on end cover (10). 5. Remove spools (38) (8 used) and springs (36) (8 used) from end covers (10) (8 used). 6. Remove plugs (14) (16 used) from end covers (10) (8 used). : 5 mm
9. Turn and remove spools (19) (4 used) from casings (8, 9). 10. Remove plugs (32) (4 used) from casings (8, 9). Remove O-rings (33) (4 used) from plugs (32) (4 used). : 41 mm 11. Remove springs (31) (4 used) and check valves (30) (4 used) from casings (8, 9). 12. Remove plugs (27) (2 used) from casings (8) (2 used).䎃 Remove O-rings (28, 29) (2 used for each) from plugs (27) (2 used). : 30 mm 13. Remove plugs (25) (2 used) from the upper surface of end section 1 (2). Remove O-rings (24) (2 used) from plugs (25) (2 used). : 8 mm 14. Remove springs (3, 33) from end section 1 (2). 15. Remove plugs (25) (2 used) from the lower surface of end section 1 (2). Remove O-rings (24) (2 used) from plugs (25) (2 used). : 8 mm
7. Remove socket bolt (42). Remove end covers (10) (8 used) from casings (8, 9) (2 used for each). : 4 mm
W2-5-23
CRANE UPPER / Control Valve
8
9
4 1
2 4
14 15 16
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
W2BC-02-05-003
C
C
26
22 21
20
W2BC-02-05-005
Section B
W2BC-02-05-006
Section C
W2-5-24
CRANE UPPER / Control Valve CAUTION: Do not damage the holes on end section 1 (2). 16. Remove spools (1, 22) from end section 1 (2). IMPORTANT: Do not disassemble relief valve (7). Do not loosen the adjusting screw in relief valve (7). 17. Remove relief valve (7) from end section 1 (2). : 22 mm 18. Remove plug (6) from end section 1 (2). Remove O-ring (5) from plug (6). : 6 mm 19. Remove plugs (4) (6 used) from end section 1 (2). : 4 mm 20. Remove plugs (4) (4 used) from end section 2 (17). : 4 mm 21. Remove nuts (15) (4 used) and spring washers (14) (4 used). Remove end section 2 (17), plate (18) and casings (8, 9) (2 used for each) from bolt (16) in this order. : 13 mm 22. Remove O-rings (20) (22 used), (21) (6 used) and (26) (18 used) from end section 1 (2), casings (8, 9) (2 used for each) and plate (18).
W2-5-25
CRANE UPPER / Control Valve ASSEMBLE 4-UNIT CONTROL VALVE 8
9
10 11
1
2
12 3
4
14
13
15 16
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
19 W2BC-02-05-003
C
C
27 25
28
26
24
8
29 30
23
31
22
32 21 33
34 20
43
W2BC-02-05-005
Section B
42 41 40 35
36
37
Section C
W2-5-26
38
39 W2BC-02-05-006
CRANE UPPER / Control Valve 12345678910 11 -
Spool㩷 End Section 1㩷 Spring㩷 Plug (10 Used)㩷 O-Ring㩷 Plug㩷 Relief Valve㩷 Casing (2 Used)㩷 Casing (2 Used)㩷 End Cover (8 Used)㩷 Spring (8 Used)㩷
12 13 14 15 16 17 18 19 20 21 22 -
Spring Seat (8 Used)㩷 O-Ring (8 Used)㩷 Spring Washer (4 Used)㩷 Nut (4 Used)㩷 Bolt (4 Used)㩷 End Section 2㩷 Plate㩷 Spool (4 Used)㩷 O-Ring (22 Used)㩷 O-Ring (6 Used)㩷 Spool㩷
23 24 25 26 27 28 29 30 31 32 33 -
Spring㩷 O-Ring (4 Used)㩷 Plug (4 Used)㩷 O-Ring (18 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 O-Ring (2 Used)㩷 Check Valve (4 Used)㩷 Spring (4 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-5-27
34 35 36 37 38 39 40 41 42 43 㩷
Relief Valve (2 Used)㩷 Solenoid (8 Used)㩷 Spring (8 Used)㩷 O-Ring (8 Used)㩷 Spool (8 Used)㩷 O-Ring (8 Used)㩷 Plug (8 Used)㩷 Plug (24 Used)㩷 Socket Bolt (32 Used)㩷 O-Ring (16 Used)㩷
CRANE UPPER / Control Valve
8
9
10 11
1
2
12 3
4
14
13
15 16
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
19 W2BC-02-05-003
C
C
27 25
28
26
24
8
29 30
23
31
22
32 21 33
34 20
43
W2BC-02-05-005
Section B
42 41 40 35
36
37
Section C
W2-5-28
38
39 W2BC-02-05-006
CRANE UPPER / Control Valve Assemble 4-Unit Control Valve 1. Install O-rings (20) (2 used), (21) (6 used) and (26) (18 used) to end section 1 (2), casings (8, 9) (2 used for each) and plate (18). 2. Install casings (8, 9) (2 used for each), plate (18) and end section 2 (17) to bolts (16) (4 used) with end section 1 (2) attached in this order.䎃 Install spring washers (14) (4 used) to bolts (16) (4 used) and tighten with nuts (15) (4 used). : 13 mm : 20 to 25 N m (2.0 to 2.6 kgf m, 14.8 to 18.4 lbf ft) 3. Wind the seal tape onto plugs (4) (4 used). Install plugs (4) (4 used) to end section 2 (17). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m, 5.8 to 7.2 lbf ft) 4. Wind the seal tape onto plug (4). Install plugs (4) (6 used) to end section 1 (2). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m, 5.8 to 7.2 lbf ft) 5. Install O-ring (5) to plug (6). Install plug (6) to end section 1 (2). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m, 25 to 28 lbf ft)
IMPORTANT: Do not loosen the adjusting screw in relief valve (7). 6. Install relief valve (7) to end section 1 (2). : 22 mm : 41 to 47 N m (4.2 to 4.8 kgf m, 30 to 35 lbf ft) 7. Install O-rings (24) (2 used) onto plugs (25) (2 used). Install plugs (25) (2 used) to the lower surface of end section 1 (2). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58 lbf ft) IMPORTANT: Check the position and direction to insert spools (1, 22). 8. Install spools (1, 22) and springs (3, 23) from the upper side of end section 1 (2). 9. Install O-rings (24) (2 used) onto plugs (25) (2 used). Install plugs (25) (2 used) to end section 1 (2). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58 lbf ft) 10. Install O-rings (28, 29) (2 used for each) to plugs (27) (2 used). 11. Install plugs (27) (2 used) to casings (8) (2 used). : 30 mm : 39 to 49 N m (4.0 to 5.0 kgf m, 29 to 36 lbf ft)
W2-5-29
CRANE UPPER / Control Valve
8
9
10 11
1
2
12 3
4
14
13
15 16
B
5 17
7 Section A
6
18
W2BC-02-05-004
A
19 W2BC-02-05-003
C
C
27 25
28
26
24
8
29 30
23
31
22
32 21 33
34 20
43
W2BC-02-05-005
Section B
42 41 40 35
36
37
Section C
W2-5-30
38
39 W2BC-02-05-006
CRANE UPPER / Control Valve 12. Install check valves (30) (4 used) and springs (31) (4 used) to casings (8, 9) (2 used for each). 13. Install O-rings (33) (4 used) onto plugs (32) (4 used). Install plugs (32) (4 used) to casings (8, 9) (2 used for each). : 41 mm : 49 to 59 N m (5.0 to 6.0 kgf m, 36 to 44 lbf ft) IMPORTANT: Check the direction to insert spools (19) (4 used). 14. Install spools (19) (4 used) to casings (8, 9) (2 used for each). 15. Install springs (11) (8 used), spring seat (12) (8 used), O-rings (13) (8 used) and (43) (16 used) to end covers (10) (8 used).
20. Install relief valves (34) (2 used) to casings (8) (2 used). : 30 mm : 69 to 79 N m (7.0 to 8.0 kgf m, 51 to 58 lbf ft) IMPORTANT: Do not loosen the adjusting screw in solenoid (35). Check the position to install solenoid (35). 21. Install O-rings (37) (8 used) to solenoids (35) (8 used). Install solenoids (35) (8 used) to end covers (10) (8 used). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m, 29 to 36 lbf ft)
16. Install the end covers (10) (8 used) assembly to casings (8, 9) (2 used for each). Install end covers (10) (8 used) to casings (8, 9) (2 used for each) with socket bolts (42) (32 used). : 4 mm : 5.9 to 7.8 N m (0.6 to 0.8 kgf m, 4.4 to 5.8 lbf ft) 17. Wind the seal tape onto plug (41). Install plugs (41) (16 used) to end covers (10) (4 used). : 5 mm : 8.3 to 11 N m (0.8 to 1.1 kgf m, 6.1 to 8.1 lbf ft) 18. Install O-rings (39) (8 used) to plugs (40) (8 used). Install plugs (40) (8 used) to end covers (10) (8 used). : 5 mm : 13 to 17 N m (1.3 to 1.7 kgf m, 9.6 to 12.6 lbf ft) 19. Install springs (36) (8 used) and spools (38) (8 used) to end covers (10) (8 used).
W2-5-31
CRANE UPPER / Control Valve (Blank)
W2-5-32
CRANE UPPER / Control Valve REMOVE AND INSTALL 1-UNIT CONTROL VALVE CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. 2. Remove all hoses and pipes from control valve (1). : 8 mm, 10 mm : 22 mm, 36 mm, 41 mm NOTE: Cap all the removed hoses and pipes. Attach an identification tag for assembling. 1
Remove bolts (2) (3 used). : 19 mm 2 W25N-02-05-003
CAUTION: Control valve (1) weight: Approx. 38 kg (84 lb) 4. Hoist and remove control valve (1).
W2-5-33
CRANE UPPER / Control Valve Installation CAUTION: Control valve (1) weight: Approx. 38 kg (84 lb) 1. Install control valve (1) to the frame with bolts (2) (3 used). : 19 mm : 90 N m (9.2 kgf m) 2. Install all hoses and pipes to control valve (1). : 8 mm : 50 N m (5.1 kgf m, 36.9 lbf ft) : 10 mm : 90 N m (9.2 kgf m, 66 lbf ft) : 22 mm : 69 N m (7.0 kgf m, 51 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151.2 lbf ft)
1
2 W25N-02-05-003
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.
W2-5-34
CRANE UPPER / Control Valve (Blank)
W2-5-35
CRANE UPPER / Control Valve DISASSEMBLE 1-UNIT CONTROL VALVE 7 4 6 5
1
22
9
15
18
11
17
14
2
21
8
20 10 24 23
25
13 12
3
16
18
17
19 Section C W25N-02-05-004
1-
Inlet Section㩷
8 - O-Ring (2 Used)㩷
14 - O-Ring (2 Used)㩷
2-
Outlet Section㩷
9 - O-Ring (4 Used)㩷
15 - Socket Bolt (4 Used)㩷
21 - O-Ring㩷
3-
Valve Section㩷
10 - O-Ring (2 Used)㩷
16 - Spool㩷
22 - Relief Valve㩷
4-
Plug㩷
11 - End Cover (2 Used)㩷
17 - Spring (2 Used)㩷
23 - Bolt (4 Used)㩷
5-
Plug㩷
12 - Plug (2 Used)㩷
18 - Spring (2 Used)㩷
24 - Nut (8 Used)㩷
6-
O-Ring㩷
13 - O-Ring (2 Used)㩷
19 - Spring Seat (2 Used)㩷
25 - Spring Washer (8 Used)㩷
7-
O-Ring㩷
㩷
㩷
㩷
W2-5-36
20 - Cap㩷
CRANE UPPER / Control Valve Disassemble 1-Unit Control Valve CAUTION: Control valve weight: Approx. 38 kg (84 lb)
8. Turn over the control valve. Remove cap (20). : 41 mm
1. Place the control valve assembly on a workbench. 2. Remove socket bolts (15) (4 used). Remove end covers (11) (2 used) from valve section (3). : 5 mm 3. Remove spring seats (19) (2 used), springs (17, 18) (2 used for each) and O-rings (14) (2 used) from end covers (11) (2 used). CAUTION: Do not damage the holes on spool (16) and valve section (3). 4. Turn and remove spool (16) from valve section (3).
9. Remove O-ring (21) from cap (20). 10. Turn over the control valve. 11. Remove nuts (24) (4 used). Remove bolts (23) (4 used) from inlet section (1) and outlet section (2). : 24 mm 12. Divide each section into inlet section (1), valve section (3) and outlet section (2). 13. Remove O-rings (8) (2 used), (9)(4 used) and (10) (2 used) from valve section (3) and outlet section (2).
IMPORTANT: Do not disassemble relief valve (22). 5. Remove relief valve (22) from inlet section (1). : 30 mm 6. Remove plug (4) from plug (5). Remove O-ring (6) from plug (4). : 6 mm 7. Remove plug (5) from inlet section (1). Remove O-ring (7) from plug (5). : 21 mm
W2-5-37
CRANE UPPER / Control Valve ASSEMBLE 1-UNIT CONTROL VALVE 7 4 6 5
1
22
9
15
18
11
17
14
2
21
8
20 10 24 23
25
13 12
3
16
18
17
19 Section C W25N-02-05-004
1-
Inlet Section㩷
8 - O-Ring (2 Used)㩷
14 - O-Ring (2 Used)㩷
2-
Outlet Section㩷
9 - O-Ring (4 Used)㩷
15 - Socket Bolt (4 Used)㩷
21 - O-Ring㩷
3-
Valve Section㩷
10 - O-Ring (2 Used)㩷
16 - Spool㩷
22 - Relief Valve㩷
4-
Plug㩷
11 - End Cover (2 Used)㩷
17 - Spring (2 Used)㩷
23 - Bolt (4 Used)㩷
5-
Plug㩷
12 - Plug (2 Used)㩷
18 - Spring (2 Used)㩷
24 - Nut (8 Used)㩷
6-
O-Ring㩷
13 - O-Ring (2 Used)㩷
19 - Spring Seat (2 Used)㩷
25 - Spring Washer (8 Used)㩷
7-
O-Ring㩷
㩷
㩷
W2-5-38
20 - Cap㩷
㩷
CRANE UPPER / Control Valve Assemble 1-Unit Control Valve 1. Install O-rings (8) (2 used), (9) (4 used) and (10) (2 used) to valve section (3) and outlet section (2). 2. As for each section, arrange inlet section (1), valve section (3) and outlet section (2) in this order. 3. Install bolts (23) (4 used) to each section. Tighten to bolts (23) (4 used) with spring washers (25) (4 used) and nuts (24) (4 used). : 24 mm : 100 to 120 N m (10 to 12 kgf m, 74 to 89 lbf ft) 4. Turn over the control valve. Install O-ring (21) to cap (20). Install cap (20) to valve section (3). : 41 mm : 190 to 210 N m (19 to 21.5 kgf m, 140 to 155 lbf ft)
9. Install O-ring (14), springs (17, 18) (2 used for each) and spring seats (19) (2 used) to end covers (11) (2 used). 10. Install the end cover (11) assemblies (2 used) to valve section (3). Tighten the end cover (11) assemblies (2 used) with socket bolt (15). : 5 mm : 11 to 13 N m (1.1 to 1.3 kgf m, 8.1 to 9.6 lbf ft) 11. Install O-rings (2 used) to relief valve (22). Install to inlet section (1). : 30 mm : 120 to 140 N m (12 to 14 kgf m, 89 to 103 lbf ft)
5. Turn over the control valve. 6. Install O-ring (7) to plug (5). Install plug (5) to inlet section (1). : 21 mm : 370 to 410 N m (38 to 42 kgf m, 273 to 302 lbf ft) 7. Install O-ring (6) to plug (4). Install plug (4) to plug (5). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m, 25 to 28 lbf ft) CAUTION: Do not damage the holes on spool (16) and valve section (3). 8. Insert spool (16) into valve section (3).
W2-5-39
CRANE UPPER / Control Valve (Blank)
W2-5-40
CRANE UPPER / Control Valve REMOVE AND INSTALL WINCH DRUM CONTROL VALVE (OPTIONAL) CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. 2. Remove bolt (1). Remove all hoses and pipes from winch drum control valve (3). : 19 mm NOTE: Attach an identification tag onto the removed houses and pipes for assembling. Cap the open ends.
W2BC-02-05-007
CAUTION: Winch drum control valve weight: 40 kg (88 lb) 3. Remove bolts (2) (4 used). Hoist and remove winch drum control valve (3). : 19 mm
2
1
2
Installation 4 4
CAUTION: Winch drum control valve weight: 40 kg (88 lb) 1. Hoist and install winch drum control valve (3) with bolts (2) (4 used) : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
6
2. Install pipes (4 used) with bolts (4) : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft) 3. Install elbows (5) (2 used) to winch drum control valve (3). : 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m, 20 to 24.5 lbf ft) 4. Install bracket (6) with bolt (1) : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
W2-5-41
5
2
4
3
4
2
5 W2BC-02-05-008
CRANE UPPER / Control Valve DISASSEMBLE WINCH DRUM CONTROL VALVE 1
32
26 27 28
15
23 21
7
38
2
29
12 31 11 4 13 35 34 33 36
9
37
10
30
6
20 16 18
22
24 17 20
3
25 26 27 28
14
5
19
8 39
W2BC-02-05-009
12345678910 -
Inlet Section Outlet Section Valve Section Plug Plug Plug Plug O-Ring O-Ring O-Ring
11 12 13 14 15 16 17 18 19 20 -
O-Ring O-Ring O-Ring O-Ring Cover Valve Seat Plug Plug Plug O-Ring
21 22 23 24 25 26 27 28 29 30 -
W2-5-42
O-Ring O-Ring Socket Bolt Solenoid Valve Spool Spring Spring Spring Seat Valve Cap
31 32 33 34 35 36 37 38 39 -
O-Ring Relief Valve Bolt Nut Spring Washer Plate Pin Band Band
CRANE UPPER / Control Valve Disassemble Winch Drum Control Valve
• These procedures are explained for disassembly and assembly of winch drum control valve for optional winch drum.
CAUTION: Control valve weight: 40 kg (88 lb) 1. Place the control valve assembly on a clean workbench. IMPORTANT: Do not loosen the adjusting screw in solenoid valve (24). 2. Remove solenoid valve (24) from covers (15) (2 used) : 32 mm 3. Remove socket bolts (23). (8 used) Remove end covers (15) (2 used), from each valve section. : 5 mm 4. Remove spring seat (28), spring (26, 27) and O-ring (21) (2 used) and O-ring (22) (4 used) from end covers (15) (2 used). CAUTION: Do not damage the holes on spool and valve section. 5. Remove spool (25) from valve section (3). 6. Remove relief valve (32) from inlet section (1). : 30 mm NOTE: Do not disassemble relief valve (32).
W2-5-43
CRANE UPPER / Control Valve
1
32
26 27
28
15
23 21
7
38
2
29
12 31 11 4 13 35 34 33 36
9
37
10
30
6
20 16 18
22
24 17 20
3
25 26 27 28
14
5
19
8 39
W2BC-02-05-009
W2-5-44
CRANE UPPER / Control Valve 7. Remove valve (29) from valve section (3).䎃 8. Remove plugs (5, 6) from valve sections (2, 3). : 30 mm 9. Remove O-rings (8, 9, 10) from plugs (5, 6). 10. Turn over the control valve. Remove caps (30) from valve section (3). : 41 mm 11. Remove O-ring (31) from caps (30). 12. Turn over the control valve. 13. Remove nut (34) and remove bolts (33) (4 used) from valve section : 24 mm 14. Divide each section into inlet section (1), valve sections (3) and outlet section (2). 15. Remove O-rings (11) (2 used), (12) (4 used), (13) (2 used), (14) (8 used) from each section.
W2-5-45
CRANE UPPER / Control Valve ASSEMBLE WINCH DRUM CONTROL VALVE 1
32
26 27
28
15
23 21
7
38
2
29
12 31 11 4 13 35 34 33 36
9
37
10
30
6
20 16 18
22
24 17 20
3
25 26 27 28
14
5
19
8 39
W2BC-02-05-009
12345678910 -
Inlet Section Outlet Section Valve Section Plug Plug Plug Plug O-Ring O-Ring O-Ring
11 12 13 14 15 16 17 18 19 20 -
O-Ring O-Ring O-Ring O-Ring Cover Valve Seat Plug Plug Plug O-Ring
21 22 23 24 25 26 27 28 29 30 -
W2-5-46
O-Ring O-Ring Socket Bolt Solenoid Valve Spool Spring Spring Spring Seat Valve Cap
31 32 33 34 35 36 37 38 39 -
O-Ring Relief Valve Bolt Nut Spring Washer Plate Pin Band Band
CRANE UPPER / Control Valve Assemble Winch Drum Control Valve 1. Install O-rings (11) (2 used), (12) (4 used), (13) (2 used), (14) (8 used) to each section. 2. As for each section, arrange inlet section (1), valve section (2) and outlet section (2) in this order. 3. Install bolts (33) (4 used) to each section. Install spring washer (35) (4 used) and tighten with nut (34) (4 used). : 24 mm : 100 to 120 N m (10 to 12 kgf m, 74 to 89 lbf ft) 4. Install O-ring (31) onto caps (30) 䎃 Install cap (30) onto valve sections (3). : 41 mm : 190 to 210 N m (19 to 21.5 kgf m, 140 to 155 lbf ft) 5. Turn over the control valve. 6. Install O-rings (8, 9, 10) onto plugs (5, 6). 7. Install plug (5) on valve section (2). : 30 mm : 70 to 80 N m (7.1 to 8.2 kgf m, 52 to 59 lbf ft) 8. Install plug (6) on valve section (3). : 30 mm : 100 to 120 N m (10 to 12 kgf m, 74 to 89 lbf ft) CAUTION: Do not damage the holes on spool and valve section. 9. Insert spool (25) into valve sections (3).䎃
W2-5-47
CRANE UPPER / Control Valve
1
32
26 27 28
15
23 21
7
38
2
29
12 31 11 4 13 35 34 33 36
9
37
10
30
6
20 16 18
22
24 17 20
3
25 26 27 28
14
5
19
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). 11. Install the end cover (28) assembly to valve section (4) and tighten with socket bolt (38). : 5 mm : 15 to 17 N m (1.5 to 1.7 kgf m, 11 to 12.5 lbf ft) 12. Install relief valve (32) to inlet section (1). : 30 mm : 69 to 79 N m (7.0 to 8.1 kgf m, 51 to 58 lbf ft) 13. Install valve (29) to valve section (3). : 30 mm : 100 to 120 N m (10 to 12 kgf m, 74 to 89 lbf ft) 14. Install solenoid valve (24) to end covers (15) (2 used). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m, 28.5 to 36 lbf ft)
W2-5-49
CRANE UPPER / Control Valve (Blank)
W2-5-50
CRANE UPPER / Swing Reduction Unit REMOVE AND REDUCTION UNIT
INSTALL
SWING
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Preparation 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. Removal 1. Remove hoses (1 to 10) from the swing reduction unit. Cap the removed hoses. : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft)
10
8 7
4
1 2 3
9
2. Remove bolt (11). : 30 mm : 550 N m (56 kgf m, 410 lbf ft) 11
CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb) 3. Hoist and remove the swing reduction unit.
W2-6-1
6
5
W25N-02-06-001
CRANE UPPER / Swing Reduction Unit Installation NOTE: Refer to the Removal section for the wrench size and tightening torque.
10
7
CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb) 1. Apply liquid packing onto the reduction gear side and the mounting side for upper revolving frame. Hoist and install the swing reduction unit to the upper revolving frame.
8 4
1 2 3
9
2. Install bolt (11). 3. Install hoses (1 to 10) to the swing reduction unit. 11
6
5
W25N-02-06-001
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
1 17 28 2㩷
W25N-02-06-002
1-
Casing㩷
9-
Carrier㩷
17 - Bearing㩷
25 - Retaining Ring (3 Used)㩷
2-
Shaft㩷
10 - Pin (4 Used)㩷
18 - Bearing㩷
26 - Retaining Ring㩷
3-
Ring Gear㩷
11 - Pin (3 Used)㩷
19 - Needle Bearing (3 Used)㩷
27 - Retaining Ring㩷
4-
Planetary Gear (4 Used)㩷
12 - Side Plate (6 Used)㩷
20 - Socket Bolt (14 Used)㩷
28 - Bearing Seal㩷
5-
Sun Gear㩷
13 - Side Plate (4 Used)㩷
21 - Washer (14 Used)㩷
29 - Relief Fitting㩷
6-
Planetary Gear (3 Used)㩷
14 - Side Plate㩷
22 - Oil Seal㩷
30 - Grease Nipple㩷
7-
Sun Gear㩷
15 - Level Gauge㩷
23 - Plug㩷
31 - Motor㩷
8-
Carrier㩷
16 - Pipe㩷
24 - Spring Pin (4 Used)㩷
W2-6-4
㩷
CRANE UPPER / Swing Reduction Unit Disassemble Swing Reduction Unit CAUTION: Swing reduction unit assembly weight: 219 kg (490 lb)
IMPORTANT: Do not remove pins (11) (3 used) 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 check the powder because of wearing. 2. Put the matching marks on casing (1), ring gear (3) and motor (31). 3. Remove socket bolt (20). : 12 mm CAUTION: Motor weight: 70 kg (155 lb) 4. Remove motor (31).
IMPORTANT: Do not disassemble the carrier (8) assembly further.䎃 Inspect the parts in carrier (8) assembly in this condition. Although the carrier (8) assembly is replaced as an assembly, do the following procedures when replacing a part of assembly. Do not use pin (10) again. 14. Insert spring pin (24) further.䎃Remove pins (10) (4 used). 15. Remove planetary gears (4) (4 used) and side plates (13) (4 used) from the carrier (8) assembly horizontally.
5. Remove sun gear (7). 6. Remove the carrier (9) assembly with planetary gear (6) and so on attached from ring gear (3). 7. Put the marks on each planetary gear (6) and pin (11). 8. Remove retaining ring (25) from pins (11) (3 used) in the carrier (9) assembly.䎃 Remove side plate (12) of the upper side.
IMPORTANT: Do not damage the mating surfaces between casing (1) and ring gear (3). 16. Insert a screwdriver into the pulling-out notch (2 places) on the mating surfaces in casing (1) and ring gear (3).䎃 Remove ring gear (3) from casing (1). 17. Remove retaining ring (27) from shaft (2).
9. Remove planetary gear (6) and needle bearing (19) from pins (11) (3 used). 10. Remove side plate (12) of the lower side from pins (11) (3 used). 11. Remove side plate (14) from the carrier (9) assembly.
W2-6-5
CRANE UPPER / Swing Reduction Unit
18
22
1 17 28 2ã©·
W25N-02-06-002
W2-6-6
IMPORTANT: Shaft (2) falls off.䎃 Do not damage shaft (2). 18. Turn over casing (1).䎃 Support the flange part of casing (1) and place casing (1) on the workbench.䎃 Tap and remove shaft (2) by using a plastic hammer downward. NOTE: Bearing (18) is left in casing (1). IMPORTANT: Do not disassemble the shaft (2) assembly further. Inspect the parts in shaft (2) assembly in this condition. Although the shaft (2) assembly is replaced as an assembly, do the following procedures when replacing a part of assembly. Oil seal (22) and bearing seal (28) cannot be used again. 19. Support the shaft (2) assembly.䎃Remove bearing seal (28) and bearing (17) by using a press. NOTE: Use special tool.
176
CRANE UPPER / Swing Reduction Unit
146 166 㱢10㩷 㱢156㩷
Special Tool for Bearing (17) W25N-02-06-003
20. Remove oil seal (22) from casing (1). Press㩷
W25N-02-06-004
W2-6-7
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
1 17 28 2㩷
W25N-02-06-002
1-
Casing㩷
9-
Carrier㩷
17 - Bearing㩷
25 - Retaining Ring (3 Used)㩷
2-
Shaft㩷
10 - Pin (4 Used)㩷
18 - Bearing㩷
26 - Retaining Ring㩷
3-
Ring Gear㩷
11 - Pin (3 Used)㩷
19 - Needle Bearing (3 Used)㩷
27 - Retaining Ring㩷
4-
Planetary Gear (4 Used)㩷
12 - Side Plate (6 Used)㩷
20 - Socket Bolt (14 Used)㩷
28 - Bearing Seal㩷
5-
Sun Gear㩷
13 - Side Plate (4 Used)㩷
21 - Washer (14 Used)㩷
29 - Relief Fitting㩷
6-
Planetary Gear (3 Used)㩷
14 - Side Plate㩷
22 - Oil Seal㩷
30 - Grease Nipple㩷
7-
Sun Gear㩷
15 - Level Gauge㩷
23 - Plug㩷
31 - Motor㩷
8-
Carrier㩷
16 - Pipe㩷
24 - Spring Pin (4 Used)㩷
W2-6-8
㩷
CRANE UPPER / Swing Reduction Unit Assemble Swing Reduction Unit 1. Insert bearing seal (28) into shaft (2). 2
2. Apply much grease into the inside of bearing (17).䎃 Install bearing (17) to shaft (2) by using a press completely. NOTE: Use special tool.
Grease
17
3. Apply much grease to the upper surface on bearing (17). 4. Place casing (1) on the workbench horizontally. 5. Vertically hoist the shaft (2) assembly by using a thread in the shaft end of shaft (2) assembly.䎃 Install the shaft (2) assembly to casing (1). NOTE: Level the outer ring of bearing (17).䎃 Tap bearing (17) lightly and install the shaft (2) assembly.䎃If the shaft (2) assembly cannot be installed, remove the shaft (2) assembly, level the outer ring of bearing (17) and repeat the procedure.
IMPORTANT: Do not damage the lip of oil seal (22). 7. Insert oil seal (22) into casing (1). NOTE: Use special tool.
176
6. Turn over casing (1) with the shaft end of shaft (2) assembly facing downward. 䎃 Support the flange part of casing (1) and place casing (1) on the workbench.
W25N-02-06-005
146 166 㱢10㩷 㱢156㩷
Special Tool for Bearing (17) W25N-02-06-003
㱢125㩷
Special Tool for Oil Seal (22) W25N-02-06-006
W2-6-9
CRANE UPPER / Swing Reduction Unit
21 20
31
3 10 8 4 18 13 24 30
27
1
2ã©·
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. 9. Install retaining ring (27) to shaft (2).
㱢93㩷
11. Align with the pin (10) hole on carrier (8) and place side plates (13) (4 used).
㱢160㩷
10. Fill grease through grease nipple (30).
12. Insert planetary gears (4) (4 used) into carrier (8). 13. Align the pin (10) holes and insert pins (10) (4 used) into carrier (8) while tapping.䎃 Align the directions of holes in carrier (8) and pin (10) where spring pin (24) will be inserted.䎃
45
Special Tool for Bearing (18)
14. Apply liquid packing onto the mating surfaces between casing (1) and ring gear (3). IMPORTANT: Do not damage the mating surface for motor (31). 15. Align the matching marks and install ring gear (3) on casing (1).䎃Install washer (21) onto socket bolt (20).䎃 Tighten socket bolts (20) (4 used) temporarily. : 12 mm : 78.5 N m (8.0 kgf m, 58 lbf ft)
W2-6-11
W25N-02-06-007
CRANE UPPER / Swing Reduction Unit
21 20
9
31
5
7
26
14
11
25
12
19
6
15 16 12 3
8
23
1
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. 18. Place the carrier (9) assembly onto the stand horizontally. 19. Insert side plate (14) into the center of carrier (9) assembly. 20. Install side plate (12) to pins (11) (3 used). 21. Install needle bearing (19) and planetary gear (6) to pins (11) (3 used). 22. Install side plate (12) into pins (11)(3 used).䎃Install retaining ring (25). 23. Install the carrier (9) assembly to sun gear (5). NOTE: Check if side plate (14) is installed in the convex part in sun gear (5). 24. Install sun gear (7) to the carrier (9) assembly.
27. Hoist motor (31) vertically.䎃 Align the splines and install motor (31) to sun gear (7) and ring gear (3). Tighten socket bolt (20) and washer (21). : 12 mm : 196 N m (20 kgf m, 145 lbf ft) 28. Install plug (23) to casing (1). : 10 mm : 65 N m (6.6 kgf m, 48 lbf ft) NOTE: Wind the seal tape onto plug (23). 29. Add gear oil. Gear oil: Approx. 3.4 L (3.6 US qt) NOTE: Install pipe (16) and level gauge (15) temporarily.䎃Check the amount of gear oil.䎃 After installing the swing reduction unit to the machine frame, remove the seal tape from the thread part and wipe off grease. Attach the seal tape and install pipe (16) and level gauge (15).
25. Remove socket bolt (20) with washer (21), which was tightened temporarily at step 15.䎃Apply liquid packing onto the motor (31) mounting surface on ring gear (3). : 12 mm
W2-6-13
CRANE UPPER / Swing Reduction Unit DISASSEMBLE SWING MOTOR
17
8
6
2
1
29
25
28
32 26
9
24 20
7 11
27
12
3
14
21
13
18
22
15 23 31
5
30
34
16 10
19
4
35
33
36
W25N-02-06-008
1-
Piston (9 Used)㩷
10 - Valve Plate㩷
19 - Plug (2 Used)㩷
28 - Friction Plate (3 Used)㩷
2-
Shoe㩷
11 - Casing㩷
20 - O-Ring㩷
29 - Separator Plate (4 Used)㩷
3-
Valve Casing㩷
12 - Plunger (2 Used)㩷
21 - O-Ring (2 Used)㩷
30 - Plug㩷
4-
Pin (2 Used)㩷
13 - Spring (2 Used)㩷
22 - O-Ring (2 Used)㩷
31 - Plug㩷
5-
Shaft㩷
14 - Socket Bolt (4 Used)㩷
23 - Oil Seal㩷
32 - Plug㩷
6-
Cylinder㩷
15 - Bearing㩷
24 - Brake Piston㩷
33 - Plug㩷
7-
Spring㩷
16 - Bearing㩷
25 - O-Ring㩷
34 - Plug㩷
8-
Retainer㩷
17 - Pin㩷
26 - O-Ring㩷
35 - Relief Valve (2 Used)㩷
9-
Shoe Plate㩷
18 - Plug (2 Used)㩷
27 - Spring (20 Used)㩷
36 - O-Ring (2 Used)㩷
W2-6-14
CRANE UPPER / Swing Reduction Unit Disassemble Swing Motor CAUTION: Motor weight: 70 kg (155 lb) 1. Put the matching marks on valve casing (3) and casing (11). 2. Remove plug (30) from valve casing (3).䎃Drain off hydraulic oil. : 8 mm 3. Secure shaft (5) on the workbench with the shaft end facing downward. NOTE: Place the rubber plate or cloth on the workbench in order not to damage the parts. 4. Remove relief valve (35) from valve casing (3).䎃 Remove O-ring (36). : 41 mm NOTE: When loosening relief valve (35), O-ring (36) is damaged.䎃Replace O-ring (36).
IMPORTANT: Do not fall off valve plate (10) from valve casing (3). (Valve plate (10) may be attached on the cylinder (6) side.) Do not damage the mating surfaces between valve casing (3) and casing (11) by using a screwdriver. 6. Remove socket bolt (14).䎃 Remove valve casing (3) from casing (11). : 17 mm NOTE: When loosening socket bolt (14), valve casing (3) is floated by spring (27). 7. Remove valve plate (10) from valve casing (3). 8. Remove spring (27) from brake piston (24).
IMPORTANT: Do not damage the seat part of plunger (12). 5. Remove plug (19) from valve casing (3).䎃Remove O-ring (22), spring (13) and plunger (12). : 17 mm
W2-6-15
CRANE UPPER / Swing Reduction Unit
9
8
6
2
1
29 28
24 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. IMPORTANT: Do not damage the sliding surfaces of cylinder (6) and shoe (2). 11. Remove cylinder (6), piston (1), retainer (8) and spring (7) from shaft (5).
24 11
12. Remove friction plate (28) and separator plate (29) from casing (11). 13. Wind a vinyl tape onto the spline part of shaft (5) assembly in order not to damage oil seal (23). Remove the shaft (5) assembly and shoe plate (9) from casing (11). 14. Remove oil seal (23) from casing (11).
W25N-02-06-009
• Do the following procedures if necessary.䎃Do not use bearings (15, 16) again.
14 85㩷 75㩷
15. Remove the inner ring of bearing (15) from shaft (5). NOTE: Evenly tap and remove the inner ring of bearing (15) by using a steel bar. 35㩷
30㩷 15㩷
R12.5㩷
4㩷 8㩷
17. Remove bearing (16) from valve casing (3).
30㩷 14㩷
100㩷
M16 Penetration㩷
44㩷
16. Remove the outer ring of bearing (15) from casing (11). NOTE: Evenly tap and remove the outer ring of bearing (15) by using a steel bar.
M16 㱢8
Special Tool for Brake Piston (24) W25N-02-06-010
W2-6-17
CRANE UPPER / Swing Reduction Unit ASSEMBLE SWING MOTOR
17
8
6
2
1
29
25
28
32 26
9
24 20
7 11
27
12
3
14
21
13
18
22
15 23 31
5
30
34
16 10
19
4
35
33
36
W25N-02-06-008
1-
Piston (9 Used)㩷
10 - Valve Plate㩷
19 - Plug (2 Used)㩷
28 - Friction Plate (3 Used)㩷
2-
Shoe㩷
11 - Casing㩷
20 - O-Ring㩷
29 - Separator Plate (4 Used)㩷
3-
Valve Casing㩷
12 - Plunger (2 Used)㩷
21 - O-Ring (2 Used)㩷
30 - Plug㩷
4-
Pin (2 Used)㩷
13 - Spring (2 Used)㩷
22 - O-Ring (2 Used)㩷
31 - Plug㩷
5-
Shaft㩷
14 - Socket Bolt (4 Used)㩷
23 - Oil Seal㩷
32 - Plug㩷
6-
Cylinder㩷
15 - Bearing㩷
24 - Brake Piston㩷
33 - Plug㩷
7-
Spring㩷
16 - Bearing㩷
25 - O-Ring㩷
34 - Plug㩷
8-
Retainer㩷
17 - Pin㩷
26 - O-Ring㩷
35 - Relief Valve (2 Used)㩷
9-
Shoe Plate㩷
18 - Plug (2 Used)㩷
27 - Spring (20 Used)㩷
36 - O-Ring (2 Used)㩷
W2-6-18
CRANE UPPER / Swing Reduction Unit Assemble Swing Motor 1. Place casing (11) onto the workbench with the valve casing (3) side facing upward.
8. Install piston (1) to retainer (8).䎃 Install piston (1) into cylinder (6).
IMPORTANT: Check the direction of the flange in bearing (15). 2. Install bearing (15) onto shaft (5). NOTE: Shrink the inner ring.
9. Align the splines of cylinder (6) and shaft (5) and install the cylinder (6) assembly to shaft (5).
IMPORTANT: Check the direction to install oil seal (23).䎃 Do not damage the outer surface of oil seal (23). 3. Insert oil seal (23) to casing (11). NOTE: Apply grease to the lip part in oil seal (23). Use special tool. 4. Wind a vinyl tape onto the spline part of shaft (5) assembly in order not to damage the lip of oil seal (23). Install the shaft (5) assembly to casing (11).
10. Place casing (11) with the oil seal (23) side facing downward. 11. Install separator plates (29) (4 used) and friction plates (28) (3 used) to casing (11) alternately. Install separator plate (29) first. 12. Install O-rings (25, 26) onto casing (11). 13. Apply a film of grease to O-rings (25, 26). 14. Install brake piston (24) to casing (11). 15. Install spring (27) to brake piston (24).
5. Place casing (11) horizontally. 6. Insert shoe plate (9) into casing (11). NOTE: Face the larger chamfered side of shoe plate (9) to the inner side of casing (11). Apply grease onto the mating surface in order not to fall off.
16. Lightly tap and insert the outer ring of bearing (16) into valve casing (3) by using a steel bar. NOTE: Evenly tap and insert the outer ring of bearing (16) until the outer ring stops at the step part in valve casing (3).
7. Install retainer (8) and spring (7). Install piston (1) with shoe (2) attached.
W2-6-19
CRANE UPPER / Swing Reduction Unit
20
27
12
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). IMPORTANT: Check the direction to install valve casing (3). Do not fall off valve plate (10). Do not fall off spring (27). 18. Install O-ring (20) to valve casing (3).䎃 Install valve casing (3) to casing (11).䎃 Tighten socket bolt (14). : 17 mm : 430 N m (44 kgf m, 320 lbf ft) 19. Insert plunger (12) and spring (3) into valve casing (3). NOTE: Check if spool (12) moves smoothly. 20. Install O-ring (22) to plug (19).䎃Tighten plug (19) to valve casing (3). : 17 mm : 539 N m (55 kgf m, 400 lbf ft) 21. Install O-ring (36) onto relief valve (35).䎃 Install relief valve (35) to valve casing (3). : 41 mm : 177 N m (18 kgf m, 131 lbf ft)
W2-6-21
CRANE UPPER / Swing Reduction Unit MAINTENANCE STANDARD Swing Reduction Unit
• Replacement Standard for Gear Replace the parts when the pitting (beyond 1 mm a pit, beyond 5% on the rate of area) occurs in tooth of sun gears (5,7), planetary gears (4,6) and ring gear (3). In case the pitting does not occur and the damage on general view is found, replace the parts. Swing Motor 1. Clearance between piston outer diameter and cylinder inner bore. Unit: mm (in)
D-d
Standard
Allowable Limit
0.028 (0.001)
0.058 (0.002)
d
2. Clearance between piston and shoe
D
W25N-02-04-005
Unit: mm (in)
Ǭ
Standard
Allowable Limit
0 (0)
0.3 (0.012)
3. Shoe thickness Unit: mm (in)
t
Standard
Allowable Limit
5.5 (0.22)
5.3 (0.20)
㱐 t
4. Friction plate thickness W25N-02-04-006
Unit: mm (in) Standard
Allowable Limit
2.0 (0.079)
1.6 (0.063)
W2-6-22
CRANE UPPER / Winch Assembly REMOVE AND INSTALL FRONT AND REAR WINCH ASSEMBLY CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
Removal
3
1. Lower the boom and live-mast.䎃 2
4
2. Remove the wire rope from front and rear drums. 1
3. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.) 4. Remove bolts (3), (4) from the front and rear hoisting motors. Remove the washer tank, hose clamps (2 used) and cables in the right house (1). Hoist and remove right houses (1), (2). : 17 mm 5. Lower the live-mast.䎃Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.) 6. Remove the backstop. (As for removal of the backstop, refer to the Operator's Manual.)
W2-7-1
3
3 3 3
W2BD-02-07-001
CRANE UPPER / Winch Assembly 9. Remove bolts (9) (16 used) and remove drum covers (5), (6), (7), (8). : 19 mm
9
5
9
6
10. Turn the front and rear drum lock switches in operator's cab into the UNLOCK position.䎃Release the drum lock. NOTE: In case the claw is not removed, turn the hoisting lever into the HOISTING side a little with the drum lock switch in UNLOCK. 11. Remove the wire harness and all hoses from winch motor (10). Attach a plug onto the removed hoses. : 19 mm : 22 mm : 27 mm : 32 mm : 36 mm
9
9
9
9
7
9
9
8 9
9
12. Remove bolt (11).䎃 Remove brackets (12), (13) from the drum speed sensors. : 19 mm
9
9
9
9 9
9
9
9
W2BC-02-07-001
13
11
11
12
W2BD-02-07-002
W2-7-2
CRANE UPPER / Winch Assembly CAUTION: Main winch assembly weight: Approx. 2000 kg (4410 lb) Auxiliary winch assembly weight: Approx. 2000 kg (4410 lb) IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor. 13. Attach a wire rope onto the drum of winch assembly.䎃Hold the winch assembly. 14. Remove nuts (17) and remove bolts (18). : 24 mm 15. Remove retaining rings (15) (8 used).䎃 Remove pins (16) (8 used).䎃 Hoist and remove the hoist mechanism.
10 17, 18 16 15 10 17, 18 16 15 W2BC-02-07-002
16
15
16
16
15
16
16
15
18 18
W2-7-3
10
18
17 18
15
15
17
16
10
17
W2BC-02-07-003
CRANE UPPER / Winch Assembly Installation CAUTION: Main winch assembly weight: Approx. 2000 kg (4410 lb) Auxiliary winch assembly weight: Approx. 2000 kg (4410 lb) IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor. 1. Attach a wire rope onto the drum of winch assembly. Hoist and align the winch assembly with the upper revolving frame. 2. Install the winch assembly to the upper revolving frame with pins (16) (8 used).䎃 Install retaining rings (15) (8 used).
10 17,18 16 15
3. Adjust the position of bolts (18) (8 used) so that the flange of drum can mesh with the claw of drum lock.䎃Tighten nut (17) (8 used). : 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m) (132 to 143 lbf ft)
10 17, 18 16 15 W2BC-02-07-002
16
15
16
16
15
16
16
15
18 18
W2-7-4
10
18
17 18
15
15
17
16
10
17
W2BC-02-07-003
CRANE UPPER / Winch Assembly 4. Install brackets (12), (13) of the drum speed sensors to the winch assembly with bolts (11) (4 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
13
11
11
5. Install the wire harness and all hoses to winch motor (10). : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 32 mm : 137 N m (14 kgf m, 101 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft)
12
W2BD-02-07-002
9
6. Install drum covers (5), (6), (7), (8) onto the upper revolving frame with bolts (9) (16 used). : 19 mm : 72 to 78 N m (7.4 to 8.0 kgf m) (54 to 57 lbf ft)
9
9
5
9
9
9
7
9
9
9
9 9
18
17
17
18
9
8
9
9
9
6
9
9
9
W2BC-02-07-001
W2BC-02-07-014
W2-7-5
CRANE UPPER / Winch Assembly 7. Install the backstop. (As for installation of the backstop, refer to the Operator's Manual.)
8. Wind the boom hoist wire rope. Extend the live-mast. (As for winding the boom hoist wire rope, refer to the Operator's Manual.)
3
2
9. Hoist and install right houses (1), (2).䎃Tighten bolts (3), (4). : 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m) (31 to 33 lbf ft)
1 3
10. Install the washer tank, hose clamps (2 used) and cables in the right house (1).
3
11. Install the counterweight. (Refer to W2-2 in this section.)
3 3
12. Wind the wire rope into the front and rear drums. 13. Check the brake condition of front and rear drum and any oil leakage for winch motor.
4
W2BD-02-07-001
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 10
14
13
12
15
12 16
42
17 20
12 13 41
26
35
39 40
38
37
43
36
18
21
34
32
30
27
24
22
33
31
29
28
25
23
19
44 47
46
48
49
45
50
W2BD-02-07-003
12345678910 11 12 13 -
Drum㩷 Spacer㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷 Cork (2 Used)㩷 Bolt (28 Used)㩷 Washer (28 Used)㩷 Bolt (46 Used)㩷 Washer (46 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Air Breather㩷 Level Gauge㩷 Motor㩷 Bolt (2 Used)㩷 Lock Plate㩷 Plug㩷 Nut㩷 Bearing (2 Used)㩷 Pedestal㩷 Bracket㩷 Cover㩷 Plug (2 Used)㩷 Ring Gear㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Needle Bearing (6 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (4 Used)㩷 Needle Bearing (8 Used)㩷 Planetary Gear (4 Used)㩷 Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Carrier㩷 Retaining Ring㩷 Bearing㩷 Retainer㩷
W2-7-8
39 40 41 42 43 44 45 46 47 48 49 50 -
Bolt (18 Used)㩷 Washer (18 Used)㩷 Bracket㩷 Brake Unit㩷 Sleeve㩷 O-Ring㩷 Oil Seal㩷 O-Ring㩷 Sleeve㩷 Oil Seal㩷 Socket Bolt (8 Used)㩷 Retainer
CRANE UPPER / Winch Assembly Disassemble Winch Assembly
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Front winch assembly weight: Approx. 2000 kg (4410 lb) Rear winch assembly weight: Approx. 2000 kg (4410 lb)
9. Remove socket bolts (49) (8 used). Remove retainer (50) from pedestal (22). : 10 mm 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) : 14 mm NOTE: Drain off gear oil in the clean container and check the metal powder due wear. 2. Lift the winch assembly with the crane and place it on a workbench with placing the brake unit (42) downward. At this time, place the wooden block (200 mm square) under the bracket (41) to stable the winch assembly.
11. Remove bearing (21) from pedestal (22). 12. Remove sleeve (47) from cover (24). 13. Remove O-ring (46) from sleeve (47). 14. Remove bolts (10) (28 used) and remove cover (24). : 30 mm 15. Remove shaft (8). 16. Remove the carrier (4) assembly.
CAUTION: Winch motor (16) weight: Approx. 220 kg (485 lb) 3. Remove bolts (12) (4 used). Lift the motor (16) assembly with the crane and remove it. : 30 mm 4. Remove bolts (12) (12 used). Lift bracket (23) with the crane and remove it. : 30 mm
17. Remove spring pin (7). Remove pistons (29) (3 used) from carrier (4). 18. Remove planetary gears (6) (3 used), thrust plates (28) (6 used) and needle bearings (27) (6 used) from carrier (4). 19. Remove spacer (5) from carrier (4).
5. Remove bolts (17) (2 used) and remove lock plate (18). : 19 mm
20. Remove sun gear (3).
6. Remove nut (20).
22. Remove spring pin (30). Remove pins (34) (4 used) from carrier (35).
7. Remove the pedestal (22) assembly. 8. Remove bearing (21) from pedestal (22).
21. Remove the carrier (35) assembly.
23. Remove planetary gears (32) (4 used), thrust 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
41
26
35
39
38
43
37
36
44
45
W2BD-02-07-003
W2-7-10
CRANE UPPER / Winch Assembly 24. Remove spacer (2) from carrier (35). 25. Remove ring gear (26) from drum (1). 26. Remove bolts (39) (18 used). Lift drum (1) with the crane and remove it. : 19 mm 27. Remove retaining ring (36) from brake unit (42). Remove bearing (37). 28. Remove retainer (38). 29. Remove oil seal (45) from retainer (38). 30. Remove sleeve (43) from brake unit (42). 31. Remove O-ring (44) from sleeve (43). CAUTION: Brake unit (42) weight: Approx. 680 kg (1500 lb) 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 10
14
13
12
15
12 16
42
17 20
12 13 41
26
35
39 40
38
37
43
36
18
21
34
32
30
27
24
22
33
31
29
28
25
23
19
44 47
46
48
49
45
50
W2BD-02-07-003
12345678910 11 12 13 -
Drum㩷 Spacer㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷 Cork (2 Used)㩷 Bolt (28 Used)㩷 Washer (28 Used)㩷 Bolt (46 Used)㩷 Washer (46 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Air Breather㩷 Level Gauge㩷 Motor㩷 Bolt (2 Used)㩷 Lock Plate㩷 Plug㩷 Nut㩷 Bearing (2 Used)㩷 Pedestal㩷 Bracket㩷 Cover㩷 Plug (2 Used)㩷 Ring Gear㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Needle Bearing (6 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (4 Used)㩷 Needle Bearing (8 Used)㩷 Planetary Gear (4 Used)㩷 Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Carrier㩷 Retaining Ring㩷 Bearing㩷 Retainer㩷
W2-7-12
39 40 41 42 43 44 45 46 47 48 49 50 -
Bolt (18 Used)㩷 Washer (18 Used)㩷 Bracket㩷 Brake Unit㩷 Sleeve㩷 O-Ring㩷 Oil Seal㩷 O-Ring㩷 Sleeve㩷 Oil Seal㩷 Socket Bolt (8 Used)㩷 Retainer
CRANE UPPER / Winch Assembly Assemble Winch Assembly 1. Lift bracket (41) with the crane and place it onto the workbench. Place the wooden block (200 mm square) under bracket (41).
11. Install ring gear (26) to drum (1). 12. Place spacer (2) onto carrier (35). 13. Install planetary gears (32) (4 used), thrust plates (33) (8 used) and needle bearings (31) (8 used) to carrier (35).
CAUTION: Brake unit (42) weight: Approx. 680 kg (1500 lb) 2. Lift brake unit (42) with the crane and install it to bracket (41). Install washer (13) to bolts (12) (30 used). Tighten bolts (12) (30 used). : 30 mm : 539 N m (55 kgf m, 398 lbf ft) 3. Install O-ring (44) onto sleeve (43).
14. Install pins (34) (4 used) to carrier (35). Insert spring pin (30). Face the slit part of spring pin (30) to the shaft of winch assembly. 15. Install the carrier (35) assembly to ring gear (26) and brake unit (42). 16. Install sun gear (3) to the carrier (35) assembly.
4. Install sleeve (43) to brake unit (42).
17. Place spacer (5) onto carrier (4).
5. Install oil seal (45) to retainer (38). 6. Install retainer (38) into brake unit (42). 7. Install bearing (37) onto brake unit (42). Install retaining ring (36). 8. Apply liquid packing (ThreeBond #1389) on the mating surface of the drum (1) and the retainer (38). 9. Install the drum (1) on the brake unit (42) and tighten it with the bolts (39) (18 used) with the washer (40) applied LOCTITE #262. : 19 mm : 88 N m (9.0 kgf m, 64 lbf ft) 10. Apply liquid packing (ThreeBond #1389) on the mating surface of the ring gear (26) and the drum (1).
18. Install planetary gears (6) (3 used), thrust plates (28) (6 used) and needle bearings (27) (6 used) to carrier (4). 19. Install pins (29) (3 used) to carrier (4). Insert spring pin (7).䎃Face the slit part of spring pin (7) to the shaft of winch assembly. 20. Install the carrier (4) assembly to ring gear (26) and sun gear (3). 21. Install shaft (8) to the carrier (4) assembly. 22. Apply liquid packing (ThreeBond #1389) on the mating surface of the cover (24) and the ring gear (26).
W2-7-13
CRANE UPPER / Winch Assembly
8
11
13 10
13
12
12
17 20 12
26
13
18
21 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 (11) to bolts (10) (28 used). Tighten bolts (10) (28 used). : 30 mm : 539 N m (55 kgf m, 398 lbf ft)
32. Tighten nut (20) to cover (24) with placing the step part to the bearing (21) side. : 226 N m (23 kgf m, 167 lbf ft) 33. Rotate pedestal (22) clockwise counterclockwise 4 to 5 times.
and
24. Install O-ring (46) onto sleeve (47). 25. Install sleeve (47) on cover (24). 26. Install bearing (21) to the retainer (50) side of pedestal (22). 27. Install oil seal (48) to retainer (50).
34. Tap the end of pedestal (22) with using a plastic hammer. Tighten nut (20) to cover (24) again. (Repeat it twice.) Adjust dimension C to 14 to 16 mm. : 226 N m (23 kgf m, 167 lbf ft)
28. Apply liquid packing (ThreeBond #1389) on the mating surface of the pedestal (22) and the retainer (50).
35. Apply LOCTITE #262 onto bolts (17) (2 used). Install lock plate (18) onto nut (20) with bolts (17) (2 used). : 19 mm : 88 N m (9.0 kgf m, 65 lbf ft)
29. Install retainer (50) to pedestal (22). Apply LOCTITE #262 onto socket bolts (49) (8 used). Tighten socket bolts (49) (8 used). : 10 mm : 88 N m (9.0 kgf m, 651 lbf ft)
36. Lift the bracket (23) with the crane and tighten it with the bolts (12) (12 used) with the washer (13) attached. : 30 mm : 539 N m (55 kgf m, 398 lbf ft)
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 between the end of pedestal (22) and that of shaft (8) is 22 to 23 mm.
31. Install the pedestal (22) assembly to cover (24).
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). CAUTION: Winch motor (16) weight: Approx. 220 kg (485 lb) 39. Lift the motor (16) assembly with the crane and install it on the pedestal (22). Tighten it with the bolts (12) (4 used) with the washer (13) installed. : 30 mm : 539 N m (55 kgf m, 398 lbf ft) CAUTION: Front winch assembly weight: Approx. 2000 kg (4410 lb) Rear winch assembly weight: Approx. 2000 kg (4410 lb) 40. Lift the winch assembly with the crane and place it onto the workbench horizontally. 41. Add gear oil to the middle of level gauge (15) through the oil filler on cover (24). Gear oil: 22.5 L (5.9 US gal) 42. Install plug (25) on oil filler of cover (24). : 14 mm NOTE: Wind the seal tape onto plug (25).
W2-7-17
CRANE UPPER / Winch Assembly DISASSEMBLE WINCH MOTOR 1
2
3
4
5
6
7
8
9
10
11
13
12
14
15
16
17
18
19
20 21 46 22
45 44
23
43
A
42 41
24
25
40
39
38
37
35
36
34
33
32
31
30
29
28
27
26
27
19
28 A
12345678910 11 12 -
Spacer Retaining Ring Holder Pin Casing O-Ring (5 Used) Plug (5 Used) Rotor Valve Plate O-Ring (4 Used) Socket Bolt (6 Used) Sub Plate
13 14 15 16 17 18 19 20 21 22 23 24 -
Pin Valve Cover Socket Bolt O-Ring O-Ring O-Ring Casing O-Ring Brake Piston Retaining Ring Plug Spring (16 Used)
W2CM-02-07-006
25 26 27 28 29 30 31 32 33 34 35 -
W2-7-18
Cover Socket Bolt (12 Used) O-Ring (3 Used) Plug (3 Used) Friction Plate (7 Used) Plate (8 Used) Shim (1 Set) Coupling O-Ring Socket Bolt (9 Used) Needle Bearing
36 37 38 39 40 41 42 43 44 45 46 -
Spring (9 Used) Piston (9 Used) Plate Shoe (9 Used) Shoe Plate Bolt (4 Used) Bearing Shaft Oil Seal Front Cover O-Ring
CRANE UPPER / Winch Assembly Disassemble Winch Motor
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Winch motor weight: Approx. 175 kg (390 lb) 1. Place the winch motor on a workbench. Remove plug (7) from casing (5). Drain off hydraulic oil. : 36 mm 2. Remove socket bolts (11) (6 used) and remove sub plate (12) from valve cover (14). : 10 mm 3. Put the matching marks onto casing (5), valve cover (14), casing (19) and cover (25).
IMPORTANT: Do not drop valve plate (9) when removing valve cover (14). 10. Loosen socket bolts (15) and (34) (9 used). Remove valve cover (14) and O-rings (10) (4 used) from casing (5). : 14 mm 11. Remove valve plate (9) and O-ring (33) from valve cover (14). NOTE: Do not remove needle bearing (35) unless necessary.
4. Loosen socket bolts (26) (12 used). Remove cover (25) from casing (19). : 10 mm
IMPORTANT: Do not damage the sliding surfaces on rotor (8), holder (3) and shoe (39). 12. Remove rotor (8), piston (37) (9 used), shoes (39) (9 used), holder (3) and plate (38) from casing (5). 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 (21) from casing (19).
14. Remove shoe plate (40) from casing (5).
7. Remove casing (19) from valve cover (14). Remove O-rings (17, 18) from casing (19). 8. Remove retaining ring (22) and coupling (32) from shaft (43).
15. Loosen bolts (41) (4 used). Remove front cover (45) from casing (5). : 17 mm 16. Remove oil seal (44) and O-ring (46) from front cover (45). 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
14
2
43
A
42
35
A
W2-7-20
W2CM-02-07-006
CRANE UPPER / Winch Assembly 18. Remove retaining ring (2) and spacer (1) from shaft (43). Pull out bearing (42) with using a press. 19. Remove needle bearing (35) from valve cover (14) if necessary.
W2-7-21
CRANE UPPER / Winch Assembly ASSEMBLE WINCH MOTOR
1
2
3
4
5
6
7
8
9
10
11
13
12
14
15
16
17
18
19
20 21 46 22
45 44
23
43
A
42 41
24
25
40
39
38
37
35
36
34
33
32
31
30
29
28
27
26
27
19
28 A
12345678910 11 12 -
Spacer Retaining Ring Holder Pin Casing O-Ring (5 Used) Plug (5 Used) Rotor Valve Plate O-Ring (4 Used) Socket Bolt (6 Used) Sub Plate
13 14 15 16 17 18 19 20 21 22 23 24 -
Pin Valve Cover Socket Bolt O-Ring O-Ring O-Ring Casing O-Ring Brake Piston Retaining Ring Plug Spring (16 Used)
W2CM-02-07-006
25 26 27 28 29 30 31 32 33 34 35 -
W2-7-22
Cover Socket Bolt (12 Used) O-Ring (3 Used) Plug (3 Used) Friction Plate (7 Used) Plate (8 Used) Shim (1 Set) Coupling O-Ring Socket Bolt (9 Used) Needle Bearing
36 37 38 39 40 41 42 43 44 45 46 -
Spring (9 Used) Piston (9 Used) Plate Shoe (9 Used) Shoe Plate Bolt (4 Used) Bearing Shaft Oil Seal Front Cover O-Ring
CRANE UPPER / Winch Assembly Assemble Winch Motor 1. Install pin (4) to casing (5). 2. Fit bearing (42) on shaft (43) with shrinking. Install spacer (1) and retaining ring (2). 3. Fit the inner ring of needle bearing (35) to shaft (43) with shrinking. 4. Tap the outer race of bearing (42) with using a copper bar lightly and install shaft (43) to casing (5). 5. Insert oil seal (44) into front cover (45). Install O-ring (46). NOTE: Use the oil seal inserting tool. 6. Install front cover (45) onto casing (5) and install bolts (41) (4 used). : 17 mm : 57 N m (5.8 kgf m, 42 lbf ft) NOTE: Align the pin hole on shoe plate (40) with pin (4). 7. Install shoe plate (40) to casing (5). 8. Install springs (36) (9 used) to rotor (8). Install holder (3). 9. Install piston (37) (9 used) and shoes (39) (9 used) to plate (38). Insert piston (37) (9 used) and shoe (39) into rotor (8). 10. Align the rotor (8) assembly with shaft (43) spline and the spline of rotor (8) and holder (3) and install it to shaft (43). NOTE: Use the lifting tool for rotor.
11. Insert needle bearing (35) into valve cover (14). NOTE: Insert the needle bearing (35) until it stops at the step part of the valve cover (14) as tapping the outer ring evenly with a hammer through the needle bearing outer ring inserting tool. 12. Install pin (13) to valve cover (14). 13. Apply grease to valve plate (9). Align the pin (13) positions and install valve plate (9) on valve cover (14). 14. Install O-ring (33) to valve cover (14). 15. Install valve cover (14) onto casing (5) with socket bolts (15) and (34) (9 used). : 14 mm : 333 N m (34.0 kgf m, 246 lbf ft) 16. Install coupling (32) to shaft (43). Install retaining ring (22). IMPORTANT: Align the notches on plate (30) and friction plate (29). Adjust with shim (31) so that the dimension between the ends of valve cover (14) and plate (30) becomes 3.1 mm (0.12 in). 17. Install shim (31) to valve cover (14) and coupling (32). Install plates (30) (8 used) and friction plates (29) (7 used) in this order alternately. 18. Install O-ring (16) to valve cover (14). 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
14
12
19
20 21
23
A
24
25
28
27
26
27
28 A
W2-7-24
W2CM-02-07-006
CRANE UPPER / Winch Assembly 20. Install springs (24) (16 used) to brake piston (21). 21. Install O-rings (10) (4 used) to casing (5). 22. Install O-ring (20) onto cover (25). Install cover (25) onto casing (19). Install casing (19) and cover (25) onto casing (5) with socket bolts (26) (12 used). : 10 mm : 98 N m (10.0 kgf m, 72 lbf ft) 23. Install plug (23) to cover (25). : 8 mm : 44 N m (4.5 kgf m, 32 lbf ft) 24. Install O-ring (27) to plugs (28) (3 used). Install plugs (28) (3 used) to casing (19). : 19 mm : 36 N m (3.7 kgf m, 27 lbf ft) 25. Install O-ring (6) to plug (7). Install plug (7) to casing (5). : 36 mm : 167 N m (17.0 kgf m, 123 lbf ft) 26. Install sub plate (12) to valve cover (14) with socket bolts (11) (6 used). : 10 mm : 98 N m (10.0 kgf m, 72 lbf ft)
W2-7-25
CRANE UPPER / Winch Assembly Special Tool
160
45
25 20
M16 For lifting bolt
250 20 3
ĭ110㩷
130
ĭ60 70
Special Tool For Rotor㩷 W24X-02-07-007
25 25
10 10
ĭ57㩷
ĭ75
ĭ76
ĭ100
Special Tool When Inserting Oil Seal㩷
Special Tool When Inserting Outer Ring Of Needle Bearing㩷
W24X-02-07-008
W2-7-26
CRANE UPPER / Winch Assembly MAINTENANCE STANDARD
Dial Gauge㩷
1. Secure the plunger with the shoe attached in a vise. Install the dial gauge to the shoe. Move the shoe upward and downward and measure the clearance between shoe and spherical part of plunger. In case the measurement value is beyond allowable limit, replace the plunger and shoe assembly.
Clearance㩷
Guide
Unit: mm (in) Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.012)
Vise㩷
Soft Liner㩷 W309-04-05-002
Remedy: Replace the shoe and plunger as an assembly.
2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90° away from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.
㩷 㩷 W309-04-05-003
Unit: mm (in) Standard
Allowable Limit
0.039 (0.002)
0.078 (0.003)
Remedy: Replace the plunger or rotor. W309-04-05-004
3. Measure shoe thickness C with using a micro meter. Unit: mm (in) C
Standard
Allowable Limit
8.8 (0.35)
8.6 (0.34) Make sure that a scattering of shoes (9 used) is within 0.03 mm (0.001 in).
Remedy: Replace the shoe and piston as an assembly.
W2-7-27
C W309-04-05-005
CRANE UPPER / Winch Assembly 4. Measure heights of H and h. Unit: mm (in) H-h
Standard
Allowable Limit
32.2 (1.27)
31.6 (1.24)
Plate㊡
Holder
H h
Remedy: Replace the holder and plate as an assembly.
W309-04-05-006
5. Measure dimension (A). Unit: mm (in) A
Standard
Allowable Limit
3.1 (0.12)
3.6 (0.14)
A
Remedy: Adjust with the shims.
6. Measure the brake spring length.
W309-04-05-007
Unit: mm (in) Standard
Allowable Limit
54 (2.13)
53.2 (2.09)
Remedy: Replace the spring.
7. Measure the thickness of plate and friction plate. (15 used) Unit: mm (in) Standard
Allowable Limit
32.4 (1.28)
31.7 (1.25)
Remedy: Replace the plate and friction plate.
8. Measure the rotor spring length. Unit: mm (in) Standard
Allowable Limit
52.9 (2.08)
51.3 (2.02)
Remedy: Replace the spring.
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
10 13
37 39
12
38
11 25
35 33 3
34
36 22 23 19 21
14
31
28
20
18
24
30
27
26
32
5
W25N-02-07-009
12345678910 11 -
Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug㩷 Casing㩷 Socket Bolt (4 Used)㩷 Solenoid Valve㩷 Spring㩷 O-Ring㩷 Spring Seat㩷 Cover (2 Used)㩷 Socket Bolt (4 Used)㩷
12 13 14 15 16 17 18 19 20 21 22 -
Nut (2 Used)㩷 Adjusting Screw (2 Used)㩷 Pin㩷 Spring Seat㩷 Spool㩷 Sleeve㩷 Lock Pin㩷 Spring㩷 O-Ring㩷 Plug㩷 Sleeve㩷
23 24 25 26 27 28 29 30 31 32 33 -
Spool㩷 Spring Seat㩷 Spring Seat㩷 O-Ring㩷 Spring㩷 O-Ring㩷 O-Ring㩷 O-Ring㩷 Orifice㩷 Plug㩷 O-Ring㩷
W2-7-30
34 35 36 37 38 39 40 41 42 43 -
Piston㩷 Pin㩷 O-Ring㩷 Socket Bolt (6 Used)㩷 Cover㩷 O-Ring㩷 Sleeve㩷 Piston㩷 Lever㩷 Pin㩷
CRANE UPPER / Winch Assembly Disassemble Regulator 1. Remove solenoid valve (6) from casing (4). : 32 mm 2. Remove socket bolts (5) (4 used). Remove casing (4) from the winch motor. : 6 mm 3. Remove O-rings (28, 30) from casing (4). 4. Remove orifice (31) from casing (4). : 4 mm 5. Remove socket bolts (37) (6 used).䎃 Remove cover (38) from casing (4). : 5 mm 6. Remove O-rings (29, 36, 39) from casing (4). 7. Remove pin (35) and piston (34) from cover (38). 8. Remove piston (41) and sleeve (40) from cover (38). IMPORTANT: Do not disassemble adjusting screw (13) and nut (12). 9. Remove socket bolt (11).䎃Remove covers (10) (2 used) from casing (4). : 5 mm 10. Remove plug (32) from casing (4). 11. Remove O-ring (33) from plug (32). 12. Remove lever (42) from sleeve (17). 13. Remove spring seat (9), spring (7), spring seat (15), spool (16) and sleeve (17) from casing (4). 14. Remove O-ring (8) from spring seat (9). 15. Remove plug (21) from casing (4). Remove spring (19) and lock pin (18). : 13 mm 16. Remove O-ring (20) from plug (21). 17. Remove spring seat (25), spring (27), spring seat (24), spool (23) and sleeve (22) from casing (4). 18. Remove O-ring (26) from spring seat (25).
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
10 13
37 39
12
38
11 25
35 33 3
34
36 22 23 19 21
14
31
28
20
18
24
30
27
26
32
5
W25N-02-07-009
12345678910 11 -
Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug㩷 Casing㩷 Socket Bolt (4 Used)㩷 Solenoid Valve㩷 Spring㩷 O-Ring㩷 Spring Seat㩷 Cover (2 Used)㩷 Socket Bolt (4 Used)㩷
12 13 14 15 16 17 18 19 20 21 22 -
Nut (2 Used)㩷 Adjusting Screw (2 Used)㩷 Pin㩷 Spring Seat㩷 Spool㩷 Sleeve㩷 Lock Pin㩷 Spring㩷 O-Ring㩷 Plug㩷 Sleeve㩷
23 24 25 26 27 28 29 30 31 32 33 -
W2-7-32
Spool㩷 Spring Seat㩷 Spring Seat㩷 O-Ring㩷 Spring㩷 O-Ring㩷 O-Ring㩷 O-Ring㩷 Orifice㩷 Plug㩷 O-Ring㩷
34 35 36 37 38 39 40 41 42 43 -
Piston㩷 Pin㩷 O-Ring㩷 Socket Bolt (6 Used)㩷 Cover㩷 O-Ring㩷 Sleeve㩷 Piston㩷 Lever㩷 Pin㩷
CRANE UPPER / Winch Assembly Assemble Regulator 1. Install sleeve (22), spool (23), spring seat (24) and spring (27) to casing (4).
12. Install piston (34) 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). 3. Install cover (10) to casing (4) with socket bolt (11). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
14. Install pin (35) to cover (38). 15. Install sleeve (40) and piston (41) to cover (38).
4. Install lock pin (18) and spring (19) to casing (4).
16. Install cover (38) onto casing (4) with socket bolts (37) (6 used). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
5. Install O-ring (20) to plug (21).䎃Install plug (21) to casing (4). : 13 mm : 29 N m (3.0 kgf m, 21 lbf ft)
17. Install orifice (31) to casing (4).䎃Install O-rings (28, 30). : 4 mm : 9 N m (0.9 kgf m, 6.6 lbf ft)
6. Install sleeve (17) and spool (16) to casing (4).
18. Install casing (4) to the winch motor with socket bolts (5) (4 used). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft)
7. Install lever (42) to sleeve (17). 8. Install O-ring (33) to plug (32).䎃 Install plug (32) to casing (4). 9. Install spring seat (15) and spring (7) to casing (4).
19. Install solenoid valve (6) to casing (4). : 32 mm : 44 N m (4.5 kgf m, 32.5 lbf ft)
10. Install O-ring (8) to spring seat (9).䎃 Install spring seat (9) to casing (4). 11. Install cover (10) to casing (4) with socket bolt (11). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
W2-7-33
CRANE UPPER / Winch Assembly DISASSEMBLE COUNTERBALANCE VALVE 9
8
19
21
15
7 6
20
35 3
5 17
16
2
4
1
12
18
13 14
22 23 24 25 26
12 13
27 28
10 11
29 30 31 32
33 33
34
W25N-02-07-010
123456789-
Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Plug㩷 Spool㩷 Steel Ball㩷 Spring㩷 Orifice㩷
10 11 12 13 14 15 16 17 18 -
Plug㩷 O-Ring㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Socket Bolt (6 Used)㩷 Spring Washer (6 Used)㩷 Plug㩷 O-Ring㩷
19 20 21 22 23 24 25 26 27 -
W2-7-34
Air Bleed Valve㩷 O-Ring㩷 Plug㩷 Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Spring㩷 Seat㩷
28 29 30 31 32 33 34 35 -
Plunger㩷 Spring㩷 O-Ring㩷 Backup Ring㩷 Plug㩷 O-Ring (2 Used)㩷 Relief Valve㩷 Filter㩷
CRANE UPPER / Winch Assembly Disassemble Counterbalance Valve 1. Remove O-rings (33) (2 used) from casing (14). 2. Remove socket bolts (1, 22) (4 used for each). Remove covers (3, 24) from casing (14). : 10 mm 3. Remove plug (21) from cover (24). Remove O-ring (20) from plug (21). : 6 mm 4. Remove plug (10) from cover (3). Remove O-ring (10) from plug (11). : 6 mm 5. Remove springs (26) and O-rings (4, 25) from casing (14). 6. Remove the spool (6) assembly from casing (14). 7. Remove plug (5) from spool (6). Remove filter (35) from plug (5). 8. Remove orifice (9), spring (8) and steel ball (7) from spool (6). 9. Remove plug (32) from casing (14). : 50 mm 10. Remove O-ring (30) and backup ring (31) from plug (32). 11. Remove spring (29) and plunger (28) from casing (14). NOTE: Do not remove seat (27) unless necessary. 12. Remove relief valve (34) from casing (14). Remove O-ring and backup ring from relief valve (34). : 50 mm
W2-7-35
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 2
27
28
29
32
19
17
31
30
34
18
15 16
33
W25N-02-07-011
123456789-
Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Plug㩷 Spool㩷 Steel Ball㩷 Spring㩷 Orifice㩷
10 11 12 13 14 15 16 17 18 -
Plug㩷 O-Ring㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Socket Bolt (6 Used)㩷 Spring Washer (6 Used)㩷 Plug㩷 O-Ring㩷
19 20 21 22 23 24 25 26 27 -
W2-7-36
Air Bleed Valve㩷 O-Ring㩷 Plug㩷 Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Spring㩷 Seat㩷
28 29 30 31 32 33 34 35 -
Plunger㩷 Spring㩷 O-Ring㩷 Backup Ring㩷 Plug㩷 O-Ring (2 Used)㩷 Relief Valve㩷 Filter㩷
CRANE UPPER / Winch Assembly Assemble Counterbalance Valve 1. Install O-ring and backup ring to relief valve (34). 2. Install relief valve (34) to casing (14). : 50 mm : 166 to 186 N m (17 to 19 kgf m) (122 to 137 lbf ft) 3. Install O-ring (30) and backup ring (31) to plug (32). 4. Install spring (29) into plunger (28). Install plunger (28) to plug (32). 5. Install plug (32) to casing (14). : 50 mm : 181 to 211 N m (18.5 to 21.5 kgf m) (134 to 156 lbf ft)
12. Install cover (24) on casing (14). Tighten socket bolts (22) and spring washers (23) (4 used for each). : 10 mm : 88 to 108 N m (9 to 11 kgf m) (65 to 80 lbf ft) 13. Install O-ring (11) to plug (10). Install plug (10) on cover (3). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (25 to 28 lbf ft) 14. Install O-ring (20) to plug (21). Install plug (21) on cover (24). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (25 to 28 lbf ft)
6. Install filter (35) into plug (5). Install plug (5) to spool (6).
15. Install O-rings (33) (2 used) onto casing (14).
7. Install steel ball (7), spring (8) and orifice (9) to spool (6). IMPORTANT: Check if spool (6) moves smoothly. 8. Insert spool (6) into casing (14). 9. Install spring (26) to casing (14). 10. Install O-rings (4, 25) onto casing (14). 11. Install cover (3) to casing (14). Tighten socket bolts (1) and spring washers (2) (4 used for each). : 10 mm : 88 to 108 N m (9.0 to 11 kgf m) (65 to 80 lbf ft)
W2-7-37
CRANE UPPER / Winch Assembly DISASSEMBLE BRAKE UNIT
25 28 29 33 26 30 27
34 32
31
35 1
2
3
4
5
6
7
8 24 9 23
22 10 11 21 12 20
19
17
18
16
15
14
13
W25N-02-07-012
123456789-
Plug (3 Used)㩷 Spacer㩷 Casing㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Pedestal㩷 Bearing (2 Used)㩷 Retaining Ring㩷 Shaft㩷
10 11 12 13 14 15 16 17 18 -
Bolt (8 Used)㩷 Washer (8 Used)㩷 Retainer㩷 Bearing㩷 Brake Plate (26 Used)㩷 Friction Disc (25 Used)㩷 Spacer㩷 Packing㩷 Packing㩷
19 20 21 22 23 24 25 26 27 -
O-Ring㩷 Washer (24 Used)㩷 Bolt (24 Used)㩷 Spring (18 Used)㩷 Piston㩷 Cover㩷 Cork (2 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-7-38
28 29 30 31 32 33 34 35 -
O-Ring㩷 Adapter㩷 Rod㩷 O-Ring㩷 Spring㩷 Oil Seal㩷 Sleeve㩷 O-Ring㩷
CRANE UPPER / Winch Assembly Disassemble Brake Unit
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. 13. Remove adapter (29) from cover (24).
CAUTION: Brake unit weight: 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 (12). : 19 mm
16. Remove bolts (21) (24 used). Remove cover (24) from casing (3). : 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 pedestal (6) assembly from casing (3). : 12 mm
19. Remove spacer (2) from casing (3).
6. Remove bearings (7) (2 used), oil seal (33) and O-ring (4) from pedestal (6).
21. Remove packings (17, 18) from piston (23).
20. Remove piston (23) from casing (3).
7. Remove sleeve (34) from shaft (9). 8. Remove O-ring (35) from sleeve (34). 9. Remove shaft (9) from casing (3). 10. Remove brake plates (14) (26 used) and friction discs (15) (25 used) from casing (3). 11. Remove spacer (16) from casing (3). 12. Turn over and place the casing (3) assembly on a workbench.
W2-7-39
CRANE UPPER / Winch Assembly ASSEMBLE BRAKE UNIT
25 28 29 33 26 30 27
34 32
31
35 1
2
3
4
5
6
7
8 24 9 23
22 10 11 21 12 20
19
17
18
16
15
14
13
W25N-02-07-012
123456789-
Plug (3 Used)㩷 Spacer㩷 Casing㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Pedestal㩷 Bearing (2 Used)㩷 Retaining Ring㩷 Shaft㩷
10 11 12 13 14 15 16 17 18 -
Bolt (8 Used)㩷 Washer (8 Used)㩷 Retainer㩷 Bearing㩷 Brake Plate (26 Used)㩷 Friction Plate (25 Used)㩷 Spacer㩷 Packing㩷 Packing㩷
19 20 21 22 23 24 25 26 27 -
O-Ring㩷 Washer (24 Used)㩷 Bolt (24 Used)㩷 Spring (18 Used)㩷 Piston㩷 Cover㩷 Cork (2 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-7-40
28 29 30 31 32 33 34 35 -
O-Ring㩷 Adapter㩷 Rod㩷 O-Ring㩷 Spring㩷 Oil Seal㩷 Sleeve㩷 O-Ring㩷
CRANE UPPER / Winch Assembly Assemble Brake Unit 1. Place casing (3) on the workbench with the flange part facing upward.
15. Install O-ring (35) onto sleeve (34).
2. Install packings (17, 18) to piston (23).
16. Install sleeve (34) to shaft (9) with the larger 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 bolts (5) (30 used). : 12 mm : 140 N m (14 kgf m, 103 lbf ft)
5. Install springs (22) (18 used) to casing (3). 6. Install O-ring (19) on cover (24). 7. Install cover (24) onto casing (3). Install washer (20) to bolts (21) (24 used). Apply LOCTITE #262 on bolts (21) (24 used). Tighten bolts (21) (24 used). : 24 mm : 270 N m (27.5 kgf m, 199 lbf ft) 8. Insert rod (30) and spring (32) into cover (24). 9. Install O-rings (28, 31) to adapter (29).
19. Install bearings (7)(2 used) to shaft (9). 20. Install retaining ring (8) to shaft (9). 21. Install bearing (13) to pedestal (6). 22. Install retainer (12) to pedestal (6). Install washer (11) to bolts (10) (8 used). Apply LOCTITE #262 on bolts (10) (8 used). Tighten bolts (10) (8 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
10. Install adapter (29) to cover (24). 11. Turn over and place the casing (3) assembly on a workbench. 12. Install spacer (16) to casing (3). 13. Install brake plates (14) (26 used) and friction discs (15) (25 used) to casing (3). 14. Install shaft (9) to casing (3).
W2-7-41
CRANE UPPER / Winch Assembly (Blank)
W2-7-42
CRANE UPPER / Winch Assembly REMOVE AND INSTALL FOURTH WINCH ASSEMBLY (OPTIONAL) CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
1
2
Removal 3
1. Lower the boom and live-mast.䎃 2. Remove the wire rope from front and rear drums. 3. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.) 4. Remove bolts (3, 4) (8 used) from the tool box (1). Disconnect connector (4) in the right house (7). Hoist and remove tool box (1). : 17 mm
䎃
W2BC-02-07-004
4
W2-7-43
W2BC-02-07-005
CRANE UPPER / Winch Assembly 5. Remove bolts (5, 6) (8 used) from the right house (7). Hoist and remove the right house (7). 6. Lower the live-mast.䎃Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.)
7
7. Remove the backstop. (As for removal of the backstop, refer to the Operator's Manual.)
6
5
W2BC-02-07-006
W2-7-44
CRANE UPPER / Winch Assembly 8. Remove bolts (8) (3 used) and remove drum cover R (9). Remove bolts (10) (3 used) and remove drum cover L (11). : 19 mm
8
9
9. Turn the drum lock switches in operator's cab into the UNLOCK position.䎃Release the drum lock. NOTE: In case the claw is not removed, turn the hoisting lever into the HOISTING side a little with the drum lock switch in UNLOCK. 10. Remove the wire harness and all hoses from winch motor. Attach a plug onto the removed hoses. : 19 mm : 22 mm : 27 mm : 32 mm : 36 mm
8
10
W2BC-02-07-007
11
W2BC-02-07-008
W2-7-45
CRANE UPPER / Winch Assembly CAUTION: Main winch assembly weight: 1980 kg (4365 lb) Auxiliary winch assembly weight: 1980 kg (4365 lb) IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor. 11. Attach a wire rope onto the drum of winch assembly.䎃Hold the winch assembly. 12. Remove nut (14) (4 used) and remove bolt (15) (4 used). : 24 mm
13 12
13
12 W2BC-02-07-009
13. Remove retaining rings (12) (4 used).䎃 Remove pins (13) (4 used).䎃 Hoist and remove the hoist mechanism.
13
12 14
12
13
14
13
15
12
13
W2BC-02-07-010
12
12
13
14
W2BC-02-07-011
W2-7-46
CRANE UPPER / Winch Assembly Installation CAUTION: Main winch assembly weight: 1980 kg (4365 lb) Auxiliary winch assembly weight: 1980 kg (4365 lb) IMPORTANT: When hoisting the winch assembly, do not attach a wire rope onto the motor. 1. Attach a wire rope onto the drum of winch assembly. Hoist and align the winch assembly with the upper revolving frame.
13 12
13
2. Install the winch assembly to the upper revolving frame with pins (13) (4 used).䎃Install retaining ring (12) (4 used).
12 W2BC-02-07-009
3. Adjust the position of bolt (15) (4 used) so that the flange of drum can mesh with the claw of drum lock.䎃Tighten nut (14) (4 used). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
13
12 14
12
13
12
13
W2BC-02-07-010
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 motor. : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 32 mm : 137 N m (14 kgf m, 101 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) 5. Install drum cover R (9) onto the upper revolving frame with bolts (8) (3 used). Install drum cover L (11) onto the upper revolving frame with bolts (10) (3 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
8
9
8
10
W2BC-02-07-007
11
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.) 7. Wind the boom hoist wire rope. Extend the live-mast. (As for winding the boom hoist wire rope, refer to the Operator's Manual.
7
8. Hoist and install right house (7).䎃Tighten bolts (5, 6). : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft)
6
5
W2BC-02-07-006
W2-7-49
CRANE UPPER / Winch Assembly 9. Connect connector (4) in the right house (7). 10. Hoist and install tool box (1). Tighten bolts (2, 3) : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft) 11. Install the counterweight. (Refer to W2-2 in this section.) 12. Wind the wire rope into the front and rear drums. 13. Check the brake condition of front and rear drum and any oil leakage for winch motor.
4
W2BC-02-07-005
1
2
3
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 10
14
13
12
15
12 16
42
17 20
12 13 41
26
35
39 40
38
37
43
36
18
21
34
32
30
27
24
22
33
31
29
28
25
23
19
44 47
46
48
49
45
50
W2BD-02-07-004
12345678910 11 12 13 -
Drum㩷 Spacer㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷 Cork (2 Used)㩷 Bolt (28 Used)㩷 Washer (28 Used)㩷 Bolt (46 Used)㩷 Washer (46 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Air Breather㩷 Level Gauge㩷 Motor㩷 Bolt (2 Used)㩷 Lock Plate㩷 Plug㩷 Nut㩷 Bearing (2 Used)㩷 Pedestal㩷 Bracket㩷 Cover㩷 Plug (2 Used)㩷 Ring Gear㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Needle Bearing (6 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (4 Used)㩷 Needle Bearing (8 Used)㩷 Planetary Gear (4 Used)㩷 Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Carrier㩷 Retaining Ring㩷 Bearing㩷 Retainer㩷
W2-7-52
39 40 41 42 43 44 45 46 47 48 49 50 -
Bolt (18 Used)㩷 Washer (18 Used)㩷 Bracket㩷 Brake Unit㩷 Sleeve㩷 O-Ring㩷 Oil Seal㩷 O-Ring㩷 Sleeve㩷 Oil Seal㩷 Socket Bolt (8 Used)㩷 Retainer
CRANE UPPER / Winch Assembly Disassemble Fourth Winch Assenbly
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. 10. Remove oil seal (48) from retainer (50).
CAUTION: Fourth winch assenbly weight: 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) : 14 mm NOTE: Drain off gear oil in the clean container and check the metal powder due wear. 2. Lift the fourth winch assenbly with the crane and place it on a workbench with placing the brake unit (42) downward. At this time, place the wooden block (200 mm square) under the bracket (41) to stable the fourth drum.
12. Remove sleeve (47) from cover (24). 13. Remove O-ring (46) from sleeve (47). 14. Remove bolts (10) (28 used) and remove cover (24). 30 mm 15. Remove shaft (8). 16. Remove the carrier (4) assembly.
CAUTION: Fourth Winch motor (16) weight: Approx. 220 kg (485 lb)
17. Remove spring pin (7). Remove pistons (29) (3 used) from carrier (4).
3. Remove bolts (12) (4 used). Lift the motor (16) 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 used) from carrier (4).
4. Remove bolts (12) (12 used). Lift bracket (23) with the crane and remove it. : 30 mm
19. Remove spacer (5) from carrier (4).
5. Remove bolts (17) (2 used) and remove lock plate (18). : 19 mm
20. Remove sun gear (3). 21. Remove the carrier (35) assembly. 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 plates (33) (8 used) and needle bearings (31) (8 used) from carrier (35).
7. Remove the pedestal (22) assembly. 8. Remove bearing (21) from pedestal (22). 9. Remove socket bolts (49) (8 used). Remove retainer (50) from pedestal (22). : 10 mm
W2-7-53
CRANE UPPER / Winch Assembly 1
2
42 12
41
26
35
39
38
43
37
36
44
45
W2BD-02-07-004
W2-7-54
CRANE UPPER / Winch Assembly 24. Remove spacer (2) from carrier (35). 25. Remove ring gear (26) from drum (1). 26. Remove bolts (39) (18 used). Lift drum (1) with the crane and remove it. : 19 mm 27. Remove retaining ring (36) from brake unit (42). Remove bearing (37). 28. Remove retainer (38). 29. Remove oil seal (45) from retainer (38). 30. Remove sleeve (43) from brake unit (42). 31. Remove O-ring (44) from sleeve (43). CAUTION: Brake unit (42) weight: Approx. 680 kg (1500 lb) 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 10
14
13
12
15
12 16
42
17 20
12 13 41
26
35
39 40
38
37
43
36
18
21
34
32
30
27
24
22
33
31
29
28
25
23
19
44 47
46
48
49
45
50
W2BD-02-07-004
12345678910 11 12 13 -
Drum㩷 Spacer㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷 Cork (2 Used)㩷 Bolt (28 Used)㩷 Washer (28 Used)㩷 Bolt (46 Used)㩷 Washer (46 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Air Breather㩷 Level Gauge㩷 Motor㩷 Bolt (2 Used)㩷 Lock Plate㩷 Plug㩷 Nut㩷 Bearing (2 Used)㩷 Pedestal㩷 Bracket㩷 Cover㩷 Plug (2 Used)㩷 Ring Gear㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Needle Bearing (6 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (4 Used)㩷 Needle Bearing (8 Used)㩷 Planetary Gear (4 Used)㩷 Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Carrier㩷 Retaining Ring㩷 Bearing㩷 Retainer㩷
W2-7-56
39 40 41 42 43 44 45 46 47 48 49 50 -
Bolt (18 Used)㩷 Washer (18 Used)㩷 Bracket㩷 Brake Unit㩷 Sleeve㩷 O-Ring㩷 Oil Seal㩷 O-Ring㩷 Sleeve㩷 Oil Seal㩷 Socket Bolt (8 Used)㩷 Retainer
CRANE UPPER / Winch Assembly Assemble Fourth Winch Assenbly 1. Lift bracket (41) with the crane and place it onto the workbench. Place the wooden block (200 mm square) under bracket (41).
11. Install ring gear (26) to drum (1). 12. Place spacer (2) onto carrier (35). 13. Install planetary gears (32) (4 used), thrust plates (33) (8 used) and needle bearings (31) (8 used) to carrier (35).
CAUTION: Brake unit (42) weight: Approx. 680 kg (1500 lb) 2. Lift brake unit (42) with the crane and install it to bracket (41). Install washer (13) to bolts (12) (30 used). Tighten bolts (12) (30 used). : 30 mm : 539 N m (55 kgf m, 398 lbf ft) 3. Install O-ring (44) onto sleeve (43).
14. Install pins (34) (4 used) to carrier (35). Insert spring pin (30). Face the slit part of spring pin (30) to the shaft of winch assembly. 15. Install the carrier (35) assembly to ring gear (26) and brake unit (42). 16. Install sun gear (3) to the carrier (35) assembly.
4. Install sleeve (43) to brake unit (42).
17. Place spacer (5) onto carrier (4).
5. Install oil seal (45) to retainer (38). 6. Install retainer (38) into brake unit (42). 7. Install bearing (37) onto brake unit (42). Install retaining ring (36). 8. Apply liquid packing (ThreeBond #1389) on the mating surface of the drum (1) and the retainer (38). 9. Install the drum (1) on the brake unit (42) and tighten it with the bolts (39) (18 used) with the washer (40) applied LOCTITE #262. : 19 mm : 88 N m (9.0 kgf m, 65 lbf ft) 10. Apply liquid packing (ThreeBond #1389) on the mating surface of the ring gear (26) and the drum (1).
18. Install planetary gears (6) (3 used), thrust plates (28) (6 used) and needle bearings (27) (6 used) to carrier (4). 19. Install pins (29) (3 used) to carrier (4). Insert spring pin (7).䎃Face the slit part of spring pin (7) to the shaft of winch assembly. 20. Install the carrier (4) assembly to ring gear (26) and sun gear (3). 21. Install shaft (8) to the carrier (4) assembly. 22. Apply liquid packing (ThreeBond #1389) on the mating surface of the cover (24) and the ring gear (26).
W2-7-57
CRANE UPPER / Winch Assembly 8
11
13 10
12
17 20 26
18
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 (11) to bolts (10) (28 used). Tighten bolts (10) (28 used). : 30 mm : 539 N m (55 kgf m, 398 lbf ft)
32. Tighten nut (20) to cover (24) with placing the step part to the bearing (21) side. : 226 N m (23 kgf m, 167 lbf ft) 33. Rotate pedestal (22) clockwise counterclockwise 4 to 5 times.
and
24. Install O-ring (46) onto sleeve (47). 25. Install sleeve (47) on cover (24). 26. Install bearing (21) to the retainer (50) side of pedestal (22). 27. Install oil seal (48) to retainer (50).
34. Tap the end of pedestal (22) with using a plastic hammer. Tighten nut (20) to cover (24) again. (Repeat it twice.) Adjust dimension C to 14 to 16 mm. : 226 N m (23 kgf m, 167 lbf ft)
28. Apply liquid packing (ThreeBond #1389) on the mating surface of the pedestal (22) and the retainer (50).
35. Apply LOCTITE #262 onto bolts (17) (2 used). Install lock plate (18) onto nut (20) with bolts (17) (2 used). : 19 mm : 88 N m (9.0 kgf m, 65 lbf ft)
29. Install retainer (50) to pedestal (22). Apply LOCTITE #262 onto socket bolts (49) (8 used). Tighten socket bolts (49) (8 used). : 10 mm : 88 N m (9.0 kgf m, 65 lbf ft)
36. Lift the bracket (23) with the crane and tighten it with the bolts (12) (12 used) with the washer (13) attached. : 30 mm : 539 N m (55 kgf m, 398 lbf ft)
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 between the end of pedestal (22) and that of shaft (8) is 22 to 23 mm.
31. Install the pedestal (22) assembly to cover (24).
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). CAUTION: Fourth winch motor (16) weight: Approx. 220 kg (485 lb) 39. Lift the motor (16) assembly with the crane and install it on the pedestal (22). Tighten it with the bolts (12) (4 used) with the washer (13) installed. : 30 mm : 539 N m (55 kgf m, 398 lbf ft) CAUTION: Fourth winch assenbly weight: Approx. 2000 kg (4410 lb) 40. Lift the fourth winch assenbly with the crane and place it onto the workbench horizontally. 41. Add gear oil to the middle of level gauge (15) through the oil filler on cover (24). Gear oil: 22.5 L (5.9 US gal) 42. Install plug (25) on oil filler of cover (24). : 14 mm NOTE: Wind the seal tape onto plug (25).
W2-7-61
CRANE UPPER / Winch Assembly DISASSEMBLE FOURTH WINCH MOTOR 5 32 31
4 3
30
7
2
19
6
29
18 17
15
27 26
13
25
14
1
10 8
11
28
16
12 24
9 23
20
21 38
36
22
37 53
34 35
51
52
50
51
49 49
43 44
49
33
49
52
48
42
51
45
55 52
55 41
55
62
40
61
63
47
39
34
60 46
59 58 35 57
54
56
34 35
W2CM-02-07-009
W2-7-62
CRANE UPPER / Winch Assembly
12345678910 11 12 13 14 15 16 -
Bolt (4 Used)㩷 Front Cover㩷 Oil Seal㩷 O-Ring㩷 Output Shaft㩷 Bearing㩷 Retaining Ring㩷 Socket Bolt (4 Used)㩷 Cover㩷 Stopper㩷 O-Ring㩷 Piston㩷 Socket Bolt (4 Used)㩷 Regulator㩷 Piston O-Ring
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -
Stopper㩷 Cover㩷 Socket Bolt (4 Used)㩷 Front Casing㩷 O-Ring㩷 O-Ring (4 Used)㩷 Casing㩷 Pin㩷 Swash Plate㩷 Shoe Plate㩷 Plate㩷 Holder㩷 Spring (9 Used)㩷 Rotor㩷 Valve Plate Needle Bearing
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -
Socket Bolt (14 Used)㩷 O-Ring (5 Used)㩷 Plug (5 Used)㩷 Select Plate㩷 Socket Bolt (4 Used)㩷 Plunger (9 Used)㩷 O-Ring㩷 Pin㩷 Valve Cover㩷 Spring Washer (6 Used)㩷 Socket Bolt (6 Used)㩷 Counterbalance Valve㩷 Socket bolt㩷 O-Ring㩷 Shim (1 Set) Coupling
W2-7-63
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -
Plate (8 Used)㩷 Retaining Ring㩷 O-Ring (3 Used)㩷 Plug (3 Used)㩷 Casing㩷 Socket Bolt (9 Used)㩷 Friction Plate (7 Used)㩷 O-Ring㩷 O-Ring㩷 Piston㩷 Spring (16 Used)㩷 O-Ring㩷 Cover㩷 Socket Bolt (12 Used)㩷 Plug
CRANE UPPER / Winch Assembly
5 32 31
4
30
3 19
2
18 17 15
28
16
27
13 14
1
10 8
11
12
9 23
20 38
36 37
53 35 50 49 49
43 44
49
33
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
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Fourth winch motor Approx. 220 kg (485 lb)
weight:
10. Remove retaining ring (50) and coupling (48) from output shaft (5).
1. Place the fourth winch motor on a workbench.䎃 Remove plug (35) from casing (23). Drain off hydraulic oil. : 36 mm
11. Remove plates (49) (8 used), friction plates (55) (7 used), shim (47) and O-ring (46) from valve cover (41).
CAUTION: Regulator weight: Approx. 8.0 kg (18 lb) 2. Remove socket bolts (13) (4 used). Remove the regulator (14) from fourth winch motor. : 6 mm CAUTION: Counterbalance valve Approx. 20 kg (44 lb)
weight:
3. Remove socket bolts (43) (6 used) and spring washer (42) (6 used). Remove the counterbalance valve (44) from fourth winch motor. : 10 mm CAUTION: Select plate weight: Approx. 7.0 kg (15 lb) 4. Remove socket bolts (37) (4 used). Remove the select plate (36) from fourth winch motor. : 5 mm
IMPORTANT: Valve plate (31) may be removed with valve cover (41) together.䎃 Do not fall off valve plate (31). 12. Remove socket bolts (45) and (54) (9 used).䎃 Remove valve cover (41) from casing (23). : 14 mm 13. Remove valve plate (31) and O-ring (39) from valve cover (41). NOTE: Do not remove needle bearing (32) unless necessary. 14. Remove rotor (30), plungers (38) (9 used), holder (28) and plate (27) from casing (23). 15. Remove socket bolts (8) (4 used) and (19) (4 used). 䎃 Remove covers (9, 18) from casing (23). : 10 mm, 12 mm 16. Remove stoppers (10, 17) and pistons (12, 15) from casing (23). NOTE: Remove stoppers (10, 17) with using a screw (M6). 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 cover (61). 6. Remove socket bolts (62) (12 used).䎃 Remove cover (61) from casing (53). : 10 mm 7. Remove O-ring (60) from cover (61). 8. Remove springs (59) (16 used) and piston (58) from casing (53).
18. Remove bolts (1) (4 used). Remove front cover (2) from front casing (20). : 17 mm 19. Remove oil seal (3) and O-ring (4) from front cover (2). 20. Remove socket bolts (33) (14 used). Remove front casing (20) from casing (23). : 10 mm
9. Remove casing (53) from valve cover (41).䎃 Remove O-rings (56, 57) from casing (53).
W2-7-65
CRANE UPPER / Winch Assembly
5
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. 22. Remove output shaft (5) from front casing (20). 23. Remove retaining ring (7) from output shaft (5). Remove bearing (6) with using a press. 24. Remove swash plate (25) from casing (23). Remove shoe plate (26) from swash plate (25).
W2-7-67
CRANE UPPER / Winch Assembly ASSEMBLE FOURTH WINCH MOTOR 13
14 43 44
36 42
23 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 1 4 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
12345678910 11 12 13 14 15 16 -
Bolt (4 Used)㩷 Front Cover㩷 Oil Seal㩷 O-Ring㩷 Output Shaft㩷 Bearing㩷 Retaining Ring㩷 Socket Bolt (4 Used)㩷 Cover㩷 Stopper㩷 O-Ring㩷 Piston㩷 Socket Bolt (4 Used)㩷 Regulator㩷 Piston O-Ring
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -
Stopper㩷 Cover㩷 Socket Bolt (4 Used)㩷 Front Casing㩷 O-Ring㩷 O-Ring (4 Used)㩷 Casing㩷 Pin㩷 Swash Plate㩷 Shoe Plate㩷 Plate㩷 Holder㩷 Spring (9 Used)㩷 Rotor㩷 Valve Plate Needle Bearing
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -
Socket Bolt (14 Used)㩷 O-Ring (5 Used)㩷 Plug (5 Used)㩷 Select Plate㩷 Socket Bolt (4 Used)㩷 Plunger (9 Used)㩷 O-Ring㩷 Pin㩷 Valve Cover㩷 Spring Washer (6 Used)㩷 Socket Bolt (6 Used)㩷 Counterbalance Valve㩷 Socket bolt㩷 O-Ring㩷 Shim (1 Set) Coupling
W2-7-69
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -
Plate (8 Used)㩷 Retaining Ring㩷 O-Ring (3 Used)㩷 Plug (3 Used)㩷 Casing㩷 Socket Bolt (9 Used)㩷 Friction Plate (7 Used)㩷 O-Ring㩷 O-Ring㩷 Piston㩷 Spring (16 Used)㩷 O-Ring㩷 Cover㩷 Socket Bolt (12 Used)㩷 Plug
CRANE UPPER / Winch Assembly
23
10
8
11
12
23
15
17
16
18
19
40
41
45
29
30
39
31
54
9 22 21 1 4 3 5 7
6 2 20 33
25
26
27
28
38
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 swash plate (25) to casing (23). NOTE: Face the larger chamfered side of shoe plate (26) to the swash plate (25) side. 2. Install bearing (6) onto output shaft (5) with using a press. Install retaining ring (7). 3. Lightly tap the outer race of bearing (6) and install output shaft (5) to front casing (20) with using a copper bar. 4. Install O-ring (21) to front casing (20) and O-rings (22) (4 used) to casing (23) respectively. 5. Install front casing (20) and output shaft (5) onto casing (23). IMPORTANT: Check if swash plate (25) moves smoothly. 6. Install socket bolts (33) (14 used). : 10 mm : 98 N m (10 kgf m, 72 lbf ft)
12. Install cover (9) onto casing (23) with socket bolts (8) (4 used). : 10 mm : 98 N m (10 kgf m, 72 lbf ft) 13. Install springs (29) (9 used) to rotor (30). Install holder (28). 14. Install plungers (38) (9 used) to plate (27). Install plunger (38) to rotor (30). 15. Align the spline of output shaft (5) with that of rotor (30) and holder (28). Install the rotor (30) assembly to output shaft (5). 16. Apply grease onto valve plate (31).䎃Align it with pin (40) and install valve plate (31) on valve cover (41). Install O-ring (39) onto valve cover (41). 17. Place casing (23) on the workbench vertically. 18. Install valve cover (41) onto casing (23) with socket bolts (45) and (54) (9 used). : 14 mm : 333 N m (34 kgf m, 246 lbf ft)
7. Install oil seal (3) onto front cover (2). Install O-ring (4). 8. Install front cover (2) to front casing (20) with socket bolts (1) (4 used). : 17 mm : 57 N m (5.8 kgf m, 42 lbf ft) 9. Install piston (12) to the front casing (20) side of casing (23) and piston (15) to the valve cover (41) side. 10. Install O-ring (11) to stopper (10) and o-ring (16) to stopper (17) respectively. Install stoppers (10, 17) to casing (23). NOTE: Install stoppers (10, 17) until stoppers (10, 17) touch with the end of casing (23). 11. Install cover (18) onto casing (23) with socket bolts (19) (4 used). : 12 mm : 160 N m (16.5 kgf m, 118 lbf ft)
W2-7-71
CRANE UPPER / Winch Assembly
13
14 43 44
36 42
23 37
41
41
47
49
55
46
56
57 60
58 59
5
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 retaining ring (50). IMPORTANT: Align the notches on plate (49) and friction plate (55). Adjust shims (47) so that the dimension between end of valve cover (41) and plate (49) becomes 3.1 mm (0.12 in). 20. Install shims (47), plates (49) (8 used) and friction plates (55) (7 used) to valve cover (41) and coupling (48) in order.
CAUTION: Regulator weight: Approx. 8.0 kg (18 lb) 28. Install regulator (14) to casing (23) with socket bolts (13) (4 used). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft)
21. Install O-ring (46) onto valve cover (41). 22. Install O-rings (56, 57) onto casing (53). Install piston (58). 23. Install springs (59) (16 used) on piston (58). 24. Install O-ring (60) to cover (61). Install cover (61) to casing (53) with socket bolts (62) (12 used). : 10 mm : 98 N m (10 kgf m, 72 lbf ft) 25. Install O-ring (34) to plug (35). Install plug (35) to casing (23). : 36 mm : 167 N m (17 kgf m, 123 lbf ft) CAUTION: Select plate weight: Approx. 7.0 kg (15 lb) 26. Install select plate (36) to the casing (23) with socket bolts (37) (4 used). : 5 mm : 12 N m (1.2 kgf m) CAUTION: Counterbalance valve Approx. 20 kg (44 lb)
weight:
27. Install counterbalance valve (44) to valve cover (41) with socket bolts (43) (6 used) and spring washer (42) (6 used). : 10 mm : 69 N m (7.0 kgf m, 8.9 lbf ft)
W2-7-73
CRANE UPPER / Winch Assembly MAINTENANCE STANDARD Dial Gauge㩷
1. Secure the plunger with the shoe attached in a vise. Install the dial gauge to the shoe. Move the shoe upward and downward and measure the clearance between shoe and spherical part of plunger. In case the measurement value is beyond allowable limit, replace the plunger and shoe assembly.
Clearance㩷
Guide
Unit: mm (in) Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.012)
Vise㩷
Soft Liner㩷 W309-04-05-002
Remedy: Replace the shoe and plunger as an assembly.
2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90° away from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.
W309-04-05-003
Unit: mm (in) Standard
Allowable Limit
0.039 (0.002)
0.078 (0.003)
Remedy: Replace the plunger or rotor.
3. Measure shoe micrometer.
thickness
B
with
using
a
Unit: mm (in) Standard
Allowable Limit
8.8 (0.35)
8.6 (0.34)
W309-04-05-004
B W309-04-05-005㩷
W2-7-74
CRANE UPPER / Winch Assembly 4. Measure heights of H and h. Plate㊡
C=H-h
Holder
Unit: mm (in) Standard
Allowable Limit
32.2 (1.27)
31.6 (1.24)
H h
Remedy: Replace the holder and plate as an assembly. W309-04-05-006
5. Measure dimension (A). Unit: mm (in) Standard
Allowable Limit
3.1 (0.12)
3.6 (0.14) A
Remedy: Adjust the shims.
6. Measure the brake spring length. Unit: mm (in) Standard
Allowable Limit
54 (2.13)
53.2 (2.09)
W309-04-05-007
Remedy: Replace the spring.
7. Measure the thickness of plate and friction plate. (15 used) Unit: mm (in) Standard
Allowable Limit
32.4 (1.28)
31.7 (1.25)
Remedy: Replace the plate.
W2-7-75
CRANE UPPER / Winch Assembly DISASSEMBLE COUNTERBALANCE VALVE 9
8
19
21
15
7 6
20
35 3
5 17
16
2
4
1
12
18
13 14
22 23 24 25 26
12 13
27 28
10 11
29 30 31 32
33 33
34
W25N-02-07-010
123456789-
Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Plug㩷 Spool㩷 Steel Ball㩷 Spring㩷 Orifice㩷
10 11 12 13 14 15 16 17 18 -
Plug㩷 O-Ring㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Socket Bolt (6 Used)㩷 Spring Washer (6 Used)㩷 Plug㩷 O-Ring㩷
19 20 21 22 23 24 25 26 27 -
W2-7-76
Air Bleed Valve㩷 O-Ring㩷 Plug㩷 Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Spring㩷 Seat㩷
28 29 30 31 32 33 34 35 -
Plunger㩷 Spring㩷 O-Ring㩷 Backup Ring㩷 Plug㩷 O-Ring (2 Used)㩷 Relief Valve㩷 Filter㩷
CRANE UPPER / Winch Assembly Disassemble Counterbalance Valve
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Counterbalance valve Approx. 20 kg (45 lb)
weight:
1. Remove socket bolts (15) (6 used) and spring washers (16) (6 used). Remove counterbalance valve from the motor. : 10 mm 2. Remove O-rings (33) (2 used) from casing (14).
14. Remove spring (29) and plunger (28) from casing (14). NOTE: Do not remove seat (27) unless necessary. 15. Remove relief valve (34) from casing (14). : 36 mm 16. Remove O-ring and backup ring from relief valve (34).
3. Remove socket bolts (1, 22) (4 used for each). Remove covers (3, 24) from casing (14). : 10 mm 4. Remove plug (21) from cover (24). : 6 mm 5. Remove plug (10) from cover (3). Remove O-ring (10) from plug (11). : 6 mm 6. Remove O-ring (11) from plug (10). 7. Remove springs (26) and O-rings (4, 25) from casing (14). 8. Remove the spool (6) assembly from casing (14). 9. Remove plug (5) from spool (6). Remove filter (35) from plug (5). 10. Remove filter (35) from plug (5). 11. Remove orifice (9), spring (8) and steel ball (7) from spool (6). 12. Remove plug (32) from casing (14). : 41 mm 13. Remove O-ring (30) and backup ring (31) from plug (32).
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 2
27
28
29
32
19
17
31
30
34
18
15 16
33
W25N-02-07-011
123456789-
Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Plug㩷 Spool㩷 Steel Ball㩷 Spring㩷 Orifice㩷
10 11 12 13 14 15 16 17 18 -
Plug㩷 O-Ring㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Casing㩷 Socket Bolt (6 Used)㩷 Spring Washer (6 Used)㩷 Plug㩷 O-Ring㩷
19 20 21 22 23 24 25 26 27 -
W2-7-78
Air Bleed Valve㩷 O-Ring㩷 Plug㩷 Socket Bolt (4 Used)㩷 Spring Washer (4 Used)㩷 Cover㩷 O-Ring㩷 Spring㩷 Seat㩷
28 29 30 31 32 33 34 35 -
Plunger㩷 Spring㩷 O-Ring㩷 Backup Ring㩷 Plug㩷 O-Ring (2 Used)㩷 Relief Valve㩷 Filter㩷
CRANE UPPER / Winch Assembly Assemble Counterbalance Valve 1. Install O-ring and backup ring to relief valve (34). 2. Install relief valve (34) to casing (14). : 36 mm : 166 to 186 N m (17.0 to 19.0 kgf m) (122 to 137 lbf ft)
12. Install cover (24) to casing (14) with socket bolts (22) (4 used) and spring washers (23) (4 used). : 10 mm : 88 to 108 N m (9.0 to 11.0 kgf m) (65 to 80 lbf ft) 13. Install O-ring (11) to plug (10).
3. Install O-ring (30) and backup ring (31) to plug (32). 4. Install spring (29) to plunger (28). Install plunger (28) to plug (32).
14. Install plug (10) on cover (3). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (25 to 28 lbf ft) 15. Install O-ring (20) to plug (21).
5. Install plug (32) to casing (14). : 41 mm : 181 to 211 N m (18.5 to 21.5 kgf m) (134 to 156 lbf ft) 6. Install filter (35) to plug (5). Install plug (5) to spool (6).
16. Install plug (21) on cover (24). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (25 to 28 lbf ft) 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 Approx. 20 kg (45 lb)
IMPORTANT: Check if spool (6) moves smoothly. 8. Install spool (6) to casing (14).
weight:
18. Install counterbalance valve to motor with socket bolts (15) (6 used) and spring washers (16) (6 used). : 10 mm : 69 N m (7.0 kgf m, 51 lbf ft)
9. Install spring (26) to casing (14). 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 N m (9.0 to 11.0 kgf m) (65 to 80 lbf ft)
W2-7-79
CRANE UPPER / Winch Assembly DISASSEMBLE REGULATOR 1
2
3
4
5
6
7
8 9 7
10
33
11
32
34
12
35
13 14
31 30
15
29
16 17
28 36 4
27
26 25 24 23 22
38
39
1
21
20
9
40
19
18
37
41
W25N-02-07-009
12345678910 11 -
O-Ring (3 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 Plug (12 Used)㩷 Casing㩷 Solenoid Valve㩷 Sleeve㩷 Spool㩷 Spring Seat (2 Used)㩷 Spring㩷 O-Ring
12 13 14 15 16 17 18 19 20 21 -
Spring Seat㩷 Cover (2 Used)㩷 Adjusting Screw (2 Used)㩷 Nut (2 Used)㩷 Socket Bolt (4 Used)㩷 Spring Seat㩷 O-Ring㩷 Spring㩷 Lock Pin㩷 O-Ring㩷
22 23 24 25 26 27 28 29 30 31 -
Plug㩷 Spring㩷 Spool㩷 Sleeve㩷 O-Ring㩷 Piston㩷 Pin㩷 Cover㩷 O-Ring㩷 Socket Bolt (6 Used)㩷
W2-7-80
32 33 34 35 36 37 38 39 40 41 -
Piston㩷 Sleeve㩷 Pin㩷 Lever㩷 O-Ring㩷 Plug㩷 Pin㩷 Orifice㩷 O-Ring㩷 Socket Bolt (4 Used)㩷
CRANE UPPER / Winch Assembly Disassemble Regulator
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Regulator weight: Approx. 8.0 kg (18 lb)
16. Remove lever (21) from sleeve (22).
1. Remove socket bolts (41) (4 used). Remove regulator from the motor. : 6 mm
17. Remove spring seat (17), spring (19), spring seat (9), spool (24) and sleeve (25) from casing (5). 18. Remove O-ring (18) from spring seat (17).
2. Remove solenoid valve (6) from casing (5). : 32 mm 3. Remove O-rings (1, 40) from casing (5). 4. Remove orifice (39) from casing (5). : 4 mm 5. Remove socket bolts (31) (6 used).䎃Remove cover (29) from casing (5). : 5 mm 6. Remove O-rings (1, 26, 30) from casing (5). 7. Remove pin (28) and piston (27) from cover (29). 8. Remove piston (32) and sleeve (33) from cover (29). IMPORTANT: Do not disassemble adjusting screw (14) and nut (15). 9. Remove socket bolt (16).䎃Remove covers (13) (2 used) from casing (5). : 5 mm 10. Remove plug (37) from casing (5). : 8 mm 11. Remove O-ring (36) from plug (37). 12. Remove lever (35) from sleeve (7). 13. Remove spring seat (12), spring (10), spring seat (9), spool (8) and sleeve (7) from casing (5). 14. Remove O-ring (11) from spring seat (12). 15. Remove plug (22) from casing (5). Remove spring (23) and lock pin (20). : 13 mm
W2-7-81
CRANE UPPER / Winch Assembly ASSEMBLE REGULATOR 1
2
3
4
5
6
7
8 9 7
10
33
11
32
34
12
35
13 14
31 30
15
29
16 17
28 36 4
27
26 25 24 23 22
38
39
1
21
20
9
40
19
18
37
41
W25N-02-07-009
12345678910 11 -
O-Ring (3 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 Plug (12 Used)㩷 Casing㩷 Solenoid Valve㩷 Sleeve㩷 Spool㩷 Spring Seat (2 Used)㩷 Spring㩷 O-Ring
12 13 14 15 16 17 18 19 20 21 -
Spring Seat㩷 Cover (2 Used)㩷 Adjusting Screw (2 Used)㩷 Nut (2 Used)㩷 Socket Bolt (4 Used)㩷 Spring Seat㩷 O-Ring㩷 Spring㩷 Lock Pin㩷 O-Ring㩷
22 23 24 25 26 27 28 29 30 31 -
Plug㩷 Spring㩷 Spool㩷 Sleeve㩷 O-Ring㩷 Piston㩷 Pin㩷 Cover㩷 O-Ring㩷 Socket Bolt (6 Used)㩷
W2-7-82
32 33 34 35 36 37 38 39 40 41 -
Piston㩷 Sleeve㩷 Pin㩷 Lever㩷 O-Ring㩷 Plug㩷 Pin㩷 Orifice㩷 O-Ring㩷 Socket Bolt (4 Used)㩷
CRANE UPPER / Winch Assembly Assemble Regulator 1. Install sleeve (25), spool (24), spring seat (9) and spring (19) to casing (5). 2. Install O-ring (18) to spring seat (17). Install spring seat (17) to casing (5). 3. Install cover (13) to casing (5) with socket bolt (16). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
17. Install orifice (39) to casing (5).䎃Install O-rings (1, 40). : 4 mm : 9 N m (0.9 kgf m, 6.7 lbf ft) 18. Install solenoid valve (6) to casing (5). : 32 mm : 44 N m (4.5 kgf m, 32 lbf ft)
CAUTION: Regulator weight: Approx. 8.0 kg (18 lb)
4. Install lock pin (20) and spring (23) to casing (5). 5. Install O-ring (21) to plug (22).䎃Install plug (22) to casing (5). : 13 mm : 29 N m (3.0 kgf m, 21 lbf ft)
19. Install regulator to the motor with socket bolts (41) (4 used). : 6 mm : 29 N m (3.0 kgf m, 21 lbf ft)
6. Install sleeve (7) and spool (8) to casing (5). 7. Install lever (35) to sleeve (7). 8. Install O-ring (36) to plug (37).䎃 Install plug (32) to casing (5). : 8 mm : 44 N m (4.5 kgf m, 32 lbf ft) 9. Install spring seat (9) and spring (10) to casing (5). 10. Install O-ring (11) to spring seat (12).䎃Install spring seat (12) to casing (5). 11. Install cover (13) to casing (5) with socket bolt (16). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft) 12. Install piston (27) to casing (5). 13. Install O-rings (1, 26, 30) on casing (5). 14. Install pin (28) to cover (29). 15. Install sleeve (33) and piston (32) to cover (29). 16. Install cover (29) onto casing (5) with socket bolts (31) (6 used). : 5 mm : 12 N m (1.2 kgf m, 8.9 lbf ft)
W2-7-83
SWING MACHINERY / Winch Assembly DISASSEMBLE BRAKE UNIT
25 28 29 33 26 30 27
34 32
31
35 1
2
3
4
5
6
7
8 24 9 23
22 10 11 21 12 20
19
17
18
16
15
14
13
W25N-02-07-012
123456789-
Plug (3 Used)㩷 Spacer㩷 Casing㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Pedestal㩷 Bearing (2 Used)㩷 Retaining Ring㩷 Shaft㩷
10 11 12 13 14 15 16 17 18 -
Bolt (8 Used)㩷 Washer (8 Used)㩷 Retainer㩷 Bearing㩷 Brake Plate (26 Used)㩷 Friction Disc (25 Used)㩷 Spacer㩷 Packing㩷 Packing㩷
19 20 21 22 23 24 25 26 27 -
O-Ring㩷 Washer (24 Used)㩷 Bolt (24 Used)㩷 Spring (18 Used)㩷 Piston㩷 Cover㩷 Cork (2 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-7-84
28 29 30 31 32 33 34 35 -
O-Ring㩷 Adapter㩷 Rod㩷 O-Ring㩷 Spring㩷 Oil Seal㩷 Sleeve㩷 O-Ring㩷
SWING MACHINERY / Winch Assembly Disassemble Brake Unit
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. 13. Remove adapter (29) from cover (24).
CAUTION: Brake unit weight: 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 (12). : 19 mm
16. Remove bolts (21) (24 used). Remove cover (24) from casing (3). : 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 pedestal (6) assembly from casing (3). : 12 mm
19. Remove spacer (2) from casing (3).
6. Remove bearings (7) (2 used), oil seal (33) and O-ring (4) from pedestal (6).
21. Remove packings (17, 18) from piston (23).
20. Remove piston (23) from casing (3).
7. Remove sleeve (34) from shaft (9). 8. Remove O-ring (35) from sleeve (34). 9. Remove shaft (9) from casing (3). 10. Remove brake plates (14) (26 used) and friction discs (15) (25 used) from casing (3). 11. Remove spacer (16) from casing (3). 12. Turn over and place the casing (3) assembly on a workbench.
W2-7-85
SWING MACHINERY / Winch Assembly ASSEMBLE BRAKE UNIT
25 28 29 33 26 30 27
34 32
31
35 1
2
3
4
5
6
7
8 24 9 23
22 10 11 21 12 20
19
17
18
16
15
14
13
W25N-02-07-012
123456789-
Plug (3 Used)㩷 Spacer㩷 Casing㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Pedestal㩷 Bearing (2 Used)㩷 Retaining Ring㩷 Shaft㩷
10 11 12 13 14 15 16 17 18 -
Bolt (8 Used)㩷 Washer (8 Used)㩷 Retainer㩷 Bearing㩷 Brake Plate (26 Used)㩷 Friction Plate (25 Used)㩷 Spacer㩷 Packing㩷 Packing㩷
19 20 21 22 23 24 25 26 27 -
O-Ring㩷 Washer (24 Used)㩷 Bolt (24 Used)㩷 Spring (18 Used)㩷 Piston㩷 Cover㩷 Cork (2 Used)㩷 Plug (4 Used)㩷 O-Ring (4 Used)㩷
W2-7-86
28 29 30 31 32 33 34 35 -
O-Ring㩷 Adapter㩷 Rod㩷 O-Ring㩷 Spring㩷 Oil Seal㩷 Sleeve㩷 O-Ring㩷
SWING MACHINERY / Winch Assembly Assemble Brake Unit 1. Place casing (3) on the workbench with the flange part facing upward.
15. Install O-ring (35) onto sleeve (34).
2. Install packings (17, 18) to piston (23).
16. Install sleeve (34) to shaft (9) with the larger 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 bolts (5) (30 used). : 12 mm : 140 N m (14 kgf m, 103 lbf ft)
5. Install springs (22) (18 used) to casing (3). 6. Install O-ring (19) on cover (24). 7. Install cover (24) onto casing (3). Install washer (20) to bolts (21) (24 used). Apply LOCTITE #262 on bolts (21) (24 used). Tighten bolts (21) (24 used). : 24 mm : 270 N m (27.5 kgf m, 199 lbf ft) 8. Insert rod (30) and spring (32) into cover (24). 9. Install O-rings (28, 31) to adapter (29).
19. Install bearings (7)(2 used) to shaft (9). 20. Install retaining ring (8) to shaft (9). 21. Install bearing (13) to pedestal (6). 22. Install retainer (12) to pedestal (6). Install washer (11) to bolts (10) (8 used). Apply LOCTITE #262 on bolts (10) (8 used). Tighten bolts (10) (8 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
10. Install adapter (29) to cover (24). 11. Turn over and place the casing (3) assembly on a workbench. 12. Install spacer (16) to casing (3). 13. Install brake plates (14) (26 used) and friction discs (15) (25 used) to casing (3). 14. Install shaft (9) to casing (3).
W2-7-87
SWING MACHINERY / Winch Assembly (Blank)
W2-7-88
CRANE UPPER / Raising/Lowering Mechanism REMOVE AND MECHANISM
INSTALL
RAISING/LOWERING 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
W2BC-02-08-005
1. Lower the boom and live-mast. 2. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.) 3. Remove the boom hoist wire rope. (As for removal of the boom hoist wire rope, refer to the Operator's Manual.) 4. Set and secure hanger (1) in order not to lie down inside.
W2-8-1
CRANE UPPER / Raising/Lowering Mechanism 5. Disconnect connector (2). 2
W2BC-02-03-001
CAUTION: Boom stop lower frame weight : Approx. 200 kg (445 lb) 4
6. Attach a wire rope onto the boom stop lower-frame (3). Hold the boom stop lower frame (3).
5
7. Remove lock pins (4) (4 used). Remove pins (5) (4 used).
3 4
8. Hoist and remove the boom stop lower frame (3). 4
5
4
W2-8-2
5
W2BC-02-08-001
CRANE UPPER / Raising/Lowering Mechanism 9. Remove bolts (6) (3 used), (7) (1 used) and remove drum cover L (8). : 19 mm
8
6
7
10. Remove bolts (6) (3 used), (7) (3 used) and remove drum cover R (9). : 19 mm
6
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. : 19 mm
10 11
12. Remove the wire harness and all hoses from boom hoist system. : 27 mm : 41 mm
W25N-02-08-002
CAUTION: Raising/Lowering mechanism weight: Approx. 870 kg (1920 lb) 13. Attach a wire rope onto the boom hoist system. Hold the boom hoist system.
15 13
14. Remove nuts (13) (4 used) and remove bolts (12). : 24 mm 15. Remove retaining rings (14) (4 used). Remove pins (15) (4 used). Hoist and remove the boom hoist system. 14
12
W2BC-02-08-003
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 weight: Approx. 870 kg (1920 lb)
12
1. Attach a wire rope onto the boom hoist system. Hoist and align the boom hoist system with the upper revolving frame.
12
2. Install the boom hoist system to the upper revolving frame with pins (15) (4 used). Install retaining rings (14) (4 used).
15
3. Adjust the boom hoist system by using bolts (12) (4 used) so that the flange of drum can be aligned with the claw of drum lock. Tighten nuts (13) (4 used). : 24 mm : 179 to 194 N m (18.3 to 19.8 kgf m) (132 to 143 lbf ft)
13
13
12
15
W2BC-02-08-004
14
15 13
14
12
W2BC-02-08-003
4. Install bracket (10) in the drum speed sensor to the boom hoist system with bolts (11). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
10 11
W25N-02-08-002
W2-8-5
CRANE UPPER / Raising/Lowering Mechanism 5. Install all hoses to boom hoist motor. : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft)
8
6
7
6. Install drum cover L (8) to the upper revolving frame with bolts (6) (3 used), (7) (1 used). Install drum cover R (9) to upper revolving frame with bolts (6) (3 used), (7) (3 used). : 19 mm : 72 to 78 N m (7.4 to 8.0 kgf m) (54 to 57 lbf ft)
6
6
9
7
W2BD-02-08-001
W2-8-6
CRANE UPPER / Raising/Lowering Mechanism 7. Connect Connector (2) 2
W2BC-02-03-001
CAUTION: Boom stop lower frame weight : Approx. 200 kg (445 lb) 8. Attach a wire rope onto the boom stop lower-frame (3). Hoist and install boom stop lower frame (3).
4 5
9. Install pins (5) (4 used). Install lock pins (4) (4 used)
3 4 4
5
4
10. Set and install hanger (1).
W2BC-02-08-001
5
1
11. Wind the boom hoist wire rope. 12. Install the counterweight. (As for install of the counterweight, refer to W2-2 in this section.)
W2BC-02-08-005
W2-8-7
CRANE UPPER / Raising/Lowering Mechanism DISASSEMBLE RAISING/LOWERING MECHANISM 8
10
9
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
28
34 46
45
44
43
42
41
40
39
38 37 36 1 43 41 42
35
32 47
31
30
29 23
48 49 50 51 52 53
20 21 22 W25N-02-08-004
W2-8-8
CRANE UPPER / Raising/Lowering Mechanism
12345678910 11 12 13 14 -
Motor㩷 Bolt (20 Used)㩷 Washer (20 Used)㩷 Bracket㩷 Bolt (20 Used)㩷 Plug (6 Used)㩷 Spacer (3 Used)㩷 Drum㩷 Carrier㩷 Sun Gear㩷 Ring Gear㩷 Carrier㩷 Sun Gear㩷 Carrier
15 16 17 18 19 20 21 22 23 24 25 26 27 -
Cover㩷 Shaft㩷 Retaining Ring㩷 Bearing㩷 Pin㩷 Bolt (2 Used)㩷 Washer (2 Used)㩷 Retainer㩷 Bracket㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Needle Bearing (3 Used)㩷 Pin (3 Used)㩷
28 29 30 31 32 33 34 35 36 37 38 39 40 -
Thrust Plate (6 used)㩷 Bolt (16 Used)㩷 Spring Pin (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Needle Bearing (3 Used)㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Planetary Gear (3 Used)㩷 Bolt (28 Used)㩷 Needle Bearing (6 Used)㩷
W2-8-9
41 42 43 44 45 46 47 48 49 50 51 52 53 -
Bolt (2 Used)㩷 Lock Plate㩷 Nut㩷 Drum㩷 Bearing (2 Used)㩷 Floating Seal㩷 Bearing㩷 Retainer㩷 Washer (6 Used)㩷 Bolt (6 Used)㩷 Grease Nipple㩷 Oil Seal㩷 Sleeve㩷
CRANE UPPER / Raising/Lowering Mechanism
8
10
9
11
12
7 13 14
7 15 16
1
4
5ã©·
6
17 18 19
20
22
23 24 25 26 27
33
28
34 32
39 1
47
31
30
29 23
48 50 52 53
20
22 W25N-02-08-004
W2-8-10
CRANE UPPER / Raising/Lowering Mechanism Disassemble Raising/Lowering Mechanism
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Raising/Lowering mechanism weight: Approx. 870 kg (1920 lb)
1. Hoist and place the boom hoist system on a workbench. Remove plug (6) and drain off gear oil. Gear oil: 9.2 L (9.7 US qt) : 10 mm NOTE: Put gear oil in the clean container and check the metal powder because of wearing.
11. Remove pin (19) from cover (15). 12. Remove retaining ring (17) from cover (15). Remove bearing (18). 13. Remove shaft (16). 14. Remove the carrier (14) assembly. 15. Remove spring pin (25). Remove pins (27) (3 used) from carrier (14).
2. Remove bolts (20) (2 used) and remove retainer (22). : 19 mm
16. Remove planetary gears (24) (3 used), thrust plates (28) (6 used) and needle bearings (26) (3 used) from carrier (14).
3. Remove bolts (50) (6 used) and remove retainer (48). : 19 mm
17. Remove spacer (7) from carrier (14). 18. Remove sun gear (13). 19. Remove the carrier (12) assembly.
4. Remove oil seal (52) from retainer (48).
20. Remove spring pin (30). Remove pins (32) (3 used) from carrier (12).
5. Remove sleeve (53) from drum (8). 6. Hoist and remove bracket (23) from drum (8).
21. Remove planetary gears (34) (3 used), thrust plates (31) (6 used) and needle bearings (33) (3 used) from carrier (12).
7. Remove bearing (47) from bracket (23). 8. Hoist and place the boom hoist system on a workbench with motor (1) facing downward. Place the wooden block (200 mm square) under bracket (4). 9. Remove bolts (5) (20 used). Hoist and remove drum (8). : 30 mm
22. Remove spacer (7) from carrier (12). 23. Remove sun gear (10). 24. Remove bolts (39) (28 used). Hoist and remove ring gear (11). : 24 mm 25. Remove the carrier (9) assembly.
10. Remove bolts (29) (16 used) and remove cover (15). : 19 mm
W2-8-11
CRANE UPPER / Raising/Lowering Mechanism
9
1
46
45
2ã©·
44
7
4
43
42
41
40
38 37 36
35
1 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). 27. Remove planetary gears (38) (3 used), thrust plates (36) (6 used) and needle bearings (40) (6 used) from carrier (9). 28. Remove spacer (7) from carrier (9). 29. Remove bolts (41) (2 used) and remove lock plate (42). : 19 mm 30. Remove nut (43). 31. Remove drum (44) from motor (1). 32. Remove bearing (45) from drum (44). 33. Remove bearing (45) and floating seal (46) from motor (1). CAUTION: Motor (1) weight: Approx. 140 kg (308 lb) 34. Remove bolts (2) (20 used). Hoist and remove motor (1) from bracket (4). : 30 mm
W2-8-13
CRANE UPPER / Raising/Lowering Mechanism ASSEMBLE BOOM RAISING/LOWERING MECHANISM 8
10
9
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
28
34 46
45
44
43
42
41
40
39
38 37 36 1 43 41 42
35
32 47
31
30
29 23
48 49 50 51 52 53
20 21 22 W25N-02-08-004
W2-8-14
CRANE UPPER / Raising/Lowering Mechanism
12345678910 11 12 13 14 -
Motor㩷 Bolt (20 Used)㩷 Washer (20 Used)㩷 Bracket㩷 Bolt (20 Used)㩷 Plug (6 Used)㩷 Spacer (3 Used)㩷 Drum㩷 Carrier㩷 Sun Gear㩷 Ring Gear㩷 Carrier㩷 Sun Gear㩷 Carrier
15 16 17 18 19 20 21 22 23 24 25 26 27 -
Cover㩷 Shaft㩷 Retaining Ring㩷 Bearing㩷 Pin㩷 Bolt (2 Used)㩷 Washer (2 Used)㩷 Retainer㩷 Bracket㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Needle Bearing (3 Used)㩷 Pin (3 Used)㩷
28 29 30 31 32 33 34 35 36 37 38 39 40 -
Thrust Plate (6 used)㩷 Bolt (16 Used)㩷 Spring Pin (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Needle Bearing (3 Used)㩷 Planetary Gear (3 Used)㩷 Spring Pin (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Planetary Gear (3 Used)㩷 Bolt (28 Used)㩷 Needle Bearing (6 Used)㩷
W2-8-15
41 42 43 44 45 46 47 48 49 50 51 52 53 -
Bolt (2 Used)㩷 Lock Plate㩷 Nut㩷 Drum㩷 Bearing (2 Used)㩷 Floating Seal㩷 Bearing㩷 Retainer㩷 Washer (6 Used)㩷 Bolt (6 Used)㩷 Grease Nipple㩷 Oil Seal㩷 Sleeve㩷
CRANE UPPER / Raising/Lowering Mechanism
10
9
11
12
7 13 15
1
2ã©·
3
7
4
33 34 46
45
44
43
42
41
40
39
38 37 36
35
32
31
30
1 43 41 42
W25N-02-08-004
W2-8-16
CRANE UPPER / Raising/Lowering Mechanism Assemble Raising/Lowering Mechanism 1. Hoist and install bracket (4) on a workbench. Place the wooden block (200 mm square) under bracket (4).
10. Install spacer (7) to carrier (9). Install planetary gears (38) (3 used), thrust plates (36) (6 used) and needle bearings (40) (6 used). Face the grove side of planetary gear (38) to cover (15). 11. Install pins (37) (3 used) to carrier (9). Insert spring pin (35). Face the slit of spring pin (35) to cover (15).
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 washer (3) to bolts (2) (20 used). Apply LOCTITE #262 on bolts (2) (20 used). Tighten bolts (2) (20 used). : 30 mm : 490 N m (50 kgf m, 361 lbf ft) 3. Apply grease to floating seal (46). Install bearing (45) and floating seal (46) to motor (1).
13. Apply liquid packing (THREEBOND #1389B) onto the mating surface on drum (44) for ring gear (11). 14. Install ring gear (11) to drum (44). Apply LOCTITE #262 on bolts (39) (28 used). Tighten bolts (39) (28 used). : 24 mm : 265 N m (27 kgf m, 195 Ibf ft) 15. Install sun gear (10) to the carrier (9) assembly.
4. Install drum (44) to motor (1). 5. Install bearing (45) to drum (44). 6. Tighten nut (43) to motor (1) with the step part facing to bearing (45). : 490 N m (50 kgf m, 361 lbf ft) 7. Rotate drum (44) clockwise and counterclockwise and 4 to 5 times. 8. Tap the end of drum (44) by using a plastic hammer.䎃 Tighten nut (43) to motor (1) again. (Repeat it twice.) : 490 N m (50 kgf m, 361 lbf ft)
16. Place spacer (7) onto carrier (12). Install planetary gears (34) (3 used), thrust plates (31) (6 used) and needle bearings (33) (3 used). 17. Install pins (32) (3 used) to carrier (12). Insert spring pin (30). Face the slit of spring pin (30) to cover (15). 18. Install the carrier (12) assembly to ring gear (11) and sun gear (10). 19. Install sun gear (13) to the carrier (12) assembly.
9. Apply LOCTITE #262 on bolts (41) (2 used). Install lock plate (42) to nut (43) with bolts (41) (2 used). Align lock plate (42) with one notch on motor (1) and install lock plate (42). : 19 mm : 88.3 N m (9.0 kgf m, 65 lbf ft)
W2-8-17
CRANE UPPER / Raising/Lowering Mechanism
11
8
13 14
7 15 16
1
5ã©·
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 gears (24) (3 used), thrust plates (28) (6 used) and needle bearings (26) (3 used). Face the step part of planetary gear (24) to motor (1). 21. Install pins (27) (3 used) to carrier (14). Insert spring pin (25). Face the slit of spring pin (25) to cover (15).
29. Hoist and place the boom hoist system onto the workbench horizontally. 30. Install bearing (47) to bracket (23) with the seal surface facing inside. 31. Hoist and install bracket (23) to drum (8). 32. Install sleeve (53) to drum (8).
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. Check if shaft (16) can rotate by hands.
34. Apply liquid packing onto the mating surface on bracket (23) for retainer (48).
24. Install bearing (18) to cover (15). Install retaining ring (17).
35. Install retainer (48) to bracket (23). Install washer (49) to bolts (50) (6 used). Tighten bolts (50) (6 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
25. Install pin (19) to cover (15). 26. Apply liquid packing (THREEBOND #1389B) onto the mating surface on ring gear (11) on cover (15). 27. Install cover (15) onto ring gear (11). Install the washer to bolts (29) (16 used). Apply LOCTITE #262 on bolts (29) (16 used). Tighten bolts (29) (16 used). : 19 mm : 108 N m (11 kgf m, 80 lbf ft) 28. Hoist and install drum (8) to the boom hoist system. Install washer (3) to bolts (5) (20 used). Apply LOCTITE #262 on bolts (5) (20 used). Tighten bolts (5) (20 used). Align the hole (3 places) on drum (8) with plug (6) in the oil filler of boom hoist system. : 30 mm : 490 N m (50 kgf m, 361 lbf ft)
36. Apply liquid packing onto the mating surface on sleeve (53) for retainer (22). 37. Install washer (21) to bolts (20) (2 used). Tighten retainer (22) to the end of sleeve (53) with bolts (20) (2 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft) 38. Add gear oil through the oil filler. Install plug (6). Gear oil: 9.2 L (9.7 US qt) : 10 mm : 49.5 N m (5.0 kgf m, 37 lbf ft) 39. Apply grease through grease nipple (51) until grease comes out from the clearance of oil seal (52).
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
12345678-
Bearing Pin Plate Pin Brake Valve O-Ring O-Ring Piston (9 Used)
910 11 12 13 14 15 16 -
Spring (6 Used) Rotor Retainer Swash Plate Bushing Bearing Pin Retaining Ring (2 Used)
17 18 19 20 21 22 23 -
Housing Oil Seal Retaining Ring Shaft Friction Plate (6 Used) Plate (6 Used) Brake Piston
W2-8-20
24 25 26 27 28 29 30 -
Plug O-Ring O-Ring Disk Spring (2 Used) Valve Plate Socket Bolt (8 Used) Plug (2 Used)
CRANE UPPER / Raising/Lowering Mechanism Disassemble Raising/Lowering Motor • Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Raising/Lowering motor weight: Approx. 140 kg (310 lb) 1. Lift the raising/lowering motor with the crane and place it on a workbench. Remove plug (30). Drain off gear oil. : 10 mm NOTE: Drain off gear oil in the clean container and check the metal powder due to wear.
13. Remove pistons (8) (9 used) from retainer (11). 14. Remove friction plates (21) (6 used) and plates (22) (6 used) from housing (17). 15. Remove bushing (13) from shaft (20). 16. Remove retainer (11) from housing (17). 17. Remove swash plate (12) from housing (17). 18. Remove the shaft (20) assembly from housing (17).
CAUTION: Brake valve weight: Approx. 23 kg (51 lb) 2. Remove socket bolts (29) (8 used). Remove brake valve (5) from housing (17). : 17 mm
19. Remove retaining rings (16) (2 used) from shaft (20). Remove bearing (14). 20. Remove retaining ring (19) from housing (17). Remove oil seal (18).
3. Remove O-ring (7) from brake valve (5). 4. Remove O-ring (6) from housing (17). 5. Remove disk springs (27) (2 used) from brake piston (23). 6. Remove plate (3) from valve plate (28). 7. Remove bearing (1) from shaft (20). 8. Remove valve plate (28). 9. Remove brake piston (23) from housing (17). 10. Remove O-rings (25, 26) from brake piston (23). 11. Remove rotor (10) from shaft (20) and piston (8). 12. Remove springs (9) (6 used) from rotor (10).
W2-8-21
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
12345678-
Bearing Pin Plate Pin Brake Valve O-Ring O-Ring Piston (9 Used)
910 11 12 13 14 15 16 -
Spring (6 Used) Rotor Retainer Swash Plate Bushing Bearing Pin Retaining Ring (2 Used)
17 18 19 20 21 22 23 -
Housing Oil Seal Retaining Ring Shaft Friction Plate (6 Used) Plate (6 Used) Brake Piston
W2-8-22
24 25 26 27 28 29 30 -
Plug O-Ring O-Ring Disk Spring (2 Used) Valve Plate Socket Bolt (8 Used) Plug (2 Used)
CRANE UPPER / Raising/Lowering Mechanism Assemble Raising/Lowering Motor 1. Apply grease (Ocean #7) onto the inner surface of oil seal (18). Install oil seal (18) to housing (17). Install retaining ring (19).
13. Install valve plate (28) to plate (3). Install plate (3) to rotor (10). 14. Install bearing (1) to shaft (20) and plate (3).
IMPORTANT: Do not damage the sliding surface on oil seal (18) in shaft (20). 2. Install bearing (14) and retaining rings (16) (2 used) to shaft (20). At this time, install the bearing (14) so that the flange ring is positioned at the small diameter of the shaft (20).
15. Apply grease to O-ring (6). Install O-ring (6) to housing (17). 16. Apply grease to O-ring (7). Install O-ring (7) to brake valve (5).
3. Install the shaft (20) assembly to housing (17).
CAUTION: Brake valve weight: Approx. 23 kg (51 lb)
4. Install swash plate (12) to housing (17).
17. Install brake valve (5) to housing (17) and install with socket bolts (29) (8 used). : 17 mm : 400 N m (41.0 kgf m, 295 lbf ft)
5. Install retainer (11) to housing (17). 6. Install bushing (13) to shaft (20). 7. Install springs (9) (6 used) and pistons (8) (9 used) to rotor (10). 8. Install the rotor (10) assembly to shaft (20). 9. Install friction plates (21) (6 used) and plates (22) (6 used) to housing (17) and rotor (10). 10. Apply grease to O-rings (25, 26). Install O-rings (25, 26) to brake piston (23). 11. Install brake piston (23) to housing (17). 12. Install disk springs (27) (2 used) to brake piston (23) with taking care about the direction.
㩷
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
12345-
Retaining Ring㩷 Spring Guide㩷 Spring㩷 Ball㩷 Spool㩷
678910 -
Casing㩷 Stopper㩷 Spring (2 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷
11 12 13 14 15 -
Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug㩷
W2-8-24
16 17 18 19 20 -
Relief Valve㩷 Spring㩷 Poppet㩷 Spring㩷 Stopper㩷
CRANE UPPER / Raising/Lowering Mechanism Disassemble Brake Valve • Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
13. Remove O-rings (2 used) and backup rings (2 used) from relief valve (16). 14. Remove plug (15) from casing (6). : 41 mm
1. Remove plug (10) from casing (6). : 41 mm 2. Remove spring (8), O-ring (9) and plug (11) from plug (10). : 5 mm 3. Remove O-ring (12) from plug (11).
15. Remove O-rings (2 used) and backup rings (2 used) from plug (15). 16. Remove plugs (13) (2 used) from casing (6). : 6 mm 17. Remove O-ring (14) from plug (13).
4. Remove stopper (7) from casing (6). 5. Remove plug (10) from casing (6). : 41 mm 6. Remove springs (8, 19), O-ring (9) and plug (11) from plug (10). : 5 mm 7. Remove O-ring (12) from plug (11). 8. Remove stopper (20) from casing (6). 9. Remove spool (5) from casing (6). 10. Remove retaining ring (1) from spool (5). Remove spring guide (2) and ball (4). 11. Remove spring (3) from spring guide (2). 12. Remove relief valve (16) from casing (6). Remove spring (17) and poppet (18). : 41 mm
W2-8-25
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
㪈㩷㪄㩷 㪉㩷㪄㩷 㪊㩷㪄㩷 㪋㩷㪄㩷 㪌㩷㪄㩷
Retaining Ring㩷 Spring Guide㩷 Spring㩷 Ball㩷 Spool㩷
678910 -
Casing㩷 Stopper㩷 Spring (2 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷
11 12 13 14 15 -
Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Plug㩷
W2-8-26
16 17 18 19 20 -
Relief Valve㩷 Spring㩷 Poppet㩷 Spring㩷 Stopper㩷
CRANE UPPER / Raising/Lowering Mechanism Assemble Brake Valve 1. Apply grease to O-ring (14). Install O-ring (14) to plugs (13) (2 used). 2. Install plugs (13) (2 used) to casing (6). : 6 mm : 35 N m (3.6 kgf m, 26 lbf ft)
10. Install spool (5) to casing (6). 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 O-ring mounting part of plug (15). 4. Install plug (15) to casing (6). : 41 mm : 450 N m (46.0 kgf m, 332 lbf ft)
6. Install spring (17) to poppet (18). Install poppet (18) to casing (6).
8. Install spring (3) to spring guide (2).
12. Install plug (11) to plugs (10) (2 used). : 5 mm : 15 N m (1.5 kgf m, 11 lbf ft) 13. Apply grease to O-ring (9). Install O-ring (9) to plugs (10) (2 used).
5. Install O-rings (2 used) and backup rings (2 used) to relief valve (16). Apply grease to O-ring and the O-ring mounting part of relief valve (16).
7. Install relief valve (16) to casing (6). : 41 mm : 450 N m (46.0 kgf m, 332 lbf ft)
9. Install ball (4) and spring guide (2) to spool (5). Install retaining ring (1).
14. Install stopper (20) to casing (6). 15. Install springs (8, 19) to plug (10). Install plug (10) to casing (6). : 41 mm : 350 N m (36.0 kgf m, 258 lbf ft) 16. Install stopper (7) to casing (6). 17. Insert spring (8) into plug (10). Install plug (10) to casing (6). : 41 mm : 350 N m (36.0 kgf m, 258 lbf ft)
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
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
W24X-02-01-001
8
2. Remove bolts (1) (4 used) and remove seat (2). : 13 mm 3. Remove covers (3 to 6) from the right stand.
9
10
16 11
4. Remove the lever (8 to 10) assemblies and the harness connector for pressure sensors (23) (2 used).
15
5. Remove nuts (11) (2 used for each).䎃Remove the lever (8 to 10) assemblies from remote control valve (13).䎃Remove the lever (15, 16) assemblies from remote control valve (14). : 19 mm
11
W2BC-02-09-001
23 5 13 14
3
4 6
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. : 22 mm 7. Remove elbows (20) (8 used) and (21) (2 used) from remote control valve (13). : 19 mm 8. Remove hoses (25) (9 used) from elbow (21) and adapter (22) with remote control valve (14) attached. : 22 mm 9. Remove elbows (21) (3 used), adapters (22) (6 used) and pressure sensors (23) (2 used) from remote control valve (14). : 19 mm 10. Remove socket bolts (12) (12 used).䎃 Remove remote control valves (13, 14) from the right stand. : 6 mm
12
13
12
14
21
20
19
13
14
21 19
25
19
14
21
21 22 25
19
23
W2-9-2
25
19
20
W2BC-02-09-003
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 N m (2.0 kgf m, 14.5 lbf ft) 2. Install elbows (21) (3 used), adapters (22) (6 used) and pressure sensors (23) (2 used) to remote control valve (14). : 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m) (20 to 24.5 lbf ft) 3. Install hoses (25) (9 used) to elbow (21) and adapter (22) with remote control valve (14) attached. : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
21
20
19
13
14
21
4. Install elbows (20) (8 used) and (21) (2 used) to remote control valve (13). : 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m) (20 to 24.5 lbf ft) 5. Install hoses (19) (10 used) to elbows (20, 21) with remote control valve (13) attached. : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
19
25
19
14
21
21 22 25
19
23
W2-9-3
25
19
20
W2BC-02-09-003
CRANE UPPER / Remote Control Valve 6. Install the lever (8 to 10) assemblies to remote control valve (13). Install the lever (15, 16) assemblies to remote control valve (14). Tighten nuts (11) (2 used for each). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
8
9
10
16 11
7. Install the lever (8 to 10) assemblies and the harness connector for pressure sensors (23) (2 used).
15
8. Install covers (3 to 6) to the right stand. 11
9. Install seat (2) with bolt (1). : 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft)
W2BC-02-09-001
23 5 13 14
3
4 6
W2BC-02-09-002
1
2
W24X-02-01-001
W2-9-4
CRANE UPPER / Remote Control Valve REMOVE AND INSTALL SWING REMOTE CONTROL VALVE 1
2
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
W24X-02-01-001
2. Remove bolts (1) (4 used) and remove seat (2). : 13 mm 3. Remove covers (3, 5) and panel (12) from the left console.
11
4
7
12 14
8
3
6
4. Remove the harness connector from the lever (14) assembly. 5
5. Remove nut (13).䎃Remove the lever (14) assembly from remote control valve (16). : 19 mm
6 10
6. Remove hoses (18) (4 used) from elbow (17) and adapter (19) with remote control valve (16) attached. : 22 mm
3 9 4
7. Remove elbows (17) (2 used) and adapters (19) (2 used) from remote control valve (16). : 6 mm : 19 mm
W24X-02-01-003
14
13 15
8. Remove bolts (15) (2 used).䎃 Remove remote control valve (16) from the left console. : 13 mm
15 17 19 18 16
18
W2-9-5
W2BC-02-09-004
CRANE UPPER / Remote Control Valve Installation 14
1. Install remote control valve (16) to the left console with bolts (15) (2 used). : 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft)
15 15 17
2. Install elbows (17) (2 used) and adapters (19) (2 used) to remote control valve (16). : 6 mm : 34 N m (3.5 kgf m, 25 lbf ft) : 19 mm : 27 to 33 N m (2.8 to 3.4 kgf m) (20 to 24.5 lbf ft) 3. Install hoses (18) (4 used) to elbow (17) and adapter (19) with remote control valve (16) attached. : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft)
13
19 18 16
18
4
W2BC-02-09-004
11
7
12 14
8
3
6
4. Pass the lever part of lever (14) assembly through panel (12). Install the lever (14) assembly to remote control valve (16). Tighten nut (13). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
5 6 10
5. Pass and install the harness connector to the lever (14) assembly through panel (12). 6. Install covers (3, 5) and panel (12) to the left console.
3 9 4
W24X-02-01-003
7. Install seat (2) with bolt (1). : 13 mm : 10 N m (1.0 kgf m, 7.4 lbf ft)
1
2
W24X-02-01-001
W2-9-6
CRANE UPPER / Remote Control Valve (Blank)ã©·
W2-9-7
CRANE UPPER / Remote Control Valve DISASSEMBLE REMOTE CONTROL VALVE 38 36 37 35 8
33,49
7 6 5
31 31
1
9 3
4
1 2
2
44 30, 48 44 29 11 12 32 13 25
9
34
14 17 16 4
4
3
5
6
7
8
18
19 39
26
10 22 45 15 21
18
20 24 27 28 15 46
47
41 40 43 42
23 W25N-02-09-004
W2-9-8
CRANE UPPER / Remote Control Valve
12345678910 11 12 13 -
Steel Ball㩷 Holder㩷 O-Ring㩷 Washer㩷 Detent Plug㩷 Spring㩷 Lock Nut㩷 Adjusting Nut㩷 Bushing㩷 Spring Pin㩷 Plug㩷 O-Ring㩷 Washer㩷
14 15 16 17 18 19 20 21 22 23 24 25 -
Spring Seat㩷 Bolt㩷 Spring㩷 Spring㩷 Nut㩷 Spool㩷 Plug㩷 O-Ring㩷 Casing㩷 O-Ring㩷 Plate㩷 O-Ring㩷
26 27 28 29 30 31 32 33 34 35 36 37 -
W2-9-9
Casing㩷 Socket bolt㩷 Bushing㩷 Seal㩷 Cover㩷 Socket bolt㩷 Push Rods㩷 Disc㩷 Camshaft㩷 Set Screw㩷 Socket bolt㩷 Lever㩷
38 39 40 41 42 43 44 45 46 47 48 49 -
Boot㩷 Casing㩷 Seat㩷 Steel Ball㩷 Plug㩷 O-Ring㩷 Set Screw㩷 Plug㩷 Plate㩷 Socket bolt㩷 Cover㩷 Disc㩷
CRANE UPPER / Remote Control Valve Disassemble Remote Control Valve
• As the structure of remote control valve is same as for the front drum, rear drum, boom hoist drum, travel and swing, the remote control valve for rear drum is explained here.䎃 As spring seat (14), springs (16, 17), spool (19), cover (30) and disc (33) are different respectively, indicate by each remote control valve in order not to confuse the disassembled parts. • As the parts are made precisely, handle them carefully. • Clean the outer surface before disassembling. 1. Remove the lower end of boot (38) from covers (30, 48) upward. 2. Remove nut (18) and remove bolt (15).䎃Separate the remote control valve into one unit. : 13 mm
38
48 26, 25
3. Remove O-ring (25) from casings (26, 39).
15, 18 30 39, 25
W25N-02-09-005
4. Remove socket bolt (31).䎃Separate the cover (30) assembly from the casing (39) assembly. : 5 mm
31
30 39
W25N-02-09-006
W2-9-10
CRANE UPPER / Remote Control Valve CAUTION: Plug (11) may fly out by spring (17). 5. Remove plug (11) from casing (39).䎃Remove push rod (32) from plug (11).
32 11 39
W25N-02-09-007㩷
6. Align the matching marks on the spool (19) assembly, spring (17) and casing (39).䎃 Remove the spool (19) assembly and spring (17) from casing (39).
19 17 39
W25N-02-09-008
7. Remove socket bolt (27) and remove plate (24). : 6 mm 8. Remove O-ring (23) and bushing (28) from casing (39).
39 23 24 28
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 out washers (13) (2 used) by using a screwdriver.
13 14
19
W324-02-09-011
IMPORTANT: Handle the parts as an assembly by each port. Washer (4) is used when adjusting spring (16) for the setting of secondary pressure and the thickness is different according to the spool (19) assembly. 10. Remove spring seat (14), spring (16) and washer (4) from spool (19).
14 16 4 19
W333-02-09-001㩷
IMPORTANT: Do not damage the inner surface of plug (11). 11. Remove O-ring (12) and seal (29) from plug (11).
29 11 12
W324-02-09-013
12. Remove the detent plug (5) assembly from cover (30) slowly in order not to fly out steel ball (1), holder (2) and spring (6). : 24 mm
30 1
2
4
3
5 6 7 8
W324-02-09-014
W2-9-12
CRANE UPPER / Remote Control Valve 13. Remove socket bolt (36). Remove lever (37) from disc (33). : 6 mm
36 37
33
W324-02-09-015
14. Remove set screw (35) from disc (33). : 4 mm
35
15. Attach a round bar onto the end of camshaft (34). Lightly tap and remove camshaft (34) by using a hammer. Remove disc (33).
33
34
W324-02-09-016
16. Remove plug (42) from plate (24).䎃Remove steel ball (41) and seat (40). : 10 mm
24 41 40 43
17. Remove O-ring (43) from plug (42).
42
W25N-02-09-010
W2-9-13
CRANE UPPER / Remote Control Valve ASSEMBLE REMOTE CONTROL VALVE 49
48
47
46
38 37 36 35 34 31 33
1
2
4
3
5
7
8
6 9
44
11 10 12
32
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
12345678910 11 12 13 -
Steel Ball㩷 Holder㩷 O-Ring㩷 Washer㩷 Detent Plug㩷 Spring㩷 Lock Nut㩷 Adjusting Nut㩷 Bushing㩷 Spring Pin㩷 Plug㩷 O-Ring㩷 Washer㩷
14 15 16 17 18 19 20 21 22 23 24 25 -
Spring Seat㩷 Bolt㩷 Spring㩷 Spring㩷 Nut㩷 Spool㩷 Plug㩷 O-Ring㩷 Casing㩷 O-Ring㩷 Plate㩷 O-Ring㩷
26 27 28 29 30 31 32 33 34 35 36 37 -
W2-9-15
Casing㩷 Socket bolt㩷 Bushing㩷 Seal㩷 Cover㩷 Socket bolt㩷 Push Rods㩷 Disc㩷 Camshaft㩷 Set Screw㩷 Socket bolt㩷 Lever㩷
38 39 40 41 42 43 44 45 46 47 48 49 -
Boot㩷 Casing㩷 Seat㩷 Steel Ball㩷 Plug㩷 O-Ring㩷 Set Screw㩷 Plug㩷 Plate㩷 Socket bolt㩷 Cover㩷 Disc㩷
CRANE UPPER / Remote Control Valve Assemble Remote Control Valve 24
1. Install steel ball (41) and seat (40) to plate (24).
41
2. Install O-ring (43) to plug (42).䎃Install plug (42) to plate (24). : 10 mm : 24.5 to 29.4 N m (2.5 to 3.0 kgf m) (18 to 21.5 lbf ft)
40 43 42
W25N-02-09-010
3. Install bushing (28) and O-ring (23) to casing (39).䎃 Tighten plate (24) with socket bolt (27). : 6 mm : 27.4 to 31.4 N m (2.8 to 3.2 kgf m) (20 to 23 lbf ft)
39 23 24 28
27
W25N-02-09-009㩷
14 16
4. Install washer (4), spring (16) and spring seat (14) to spool (19) in this order.
4 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 facing upward so that washer (13) can mesh with the head of spool (19).
13
19
Sharp Edge Side
W324-02-09-018
IMPORTANT: When inserting the spool (19) assembly, do not attach the lower end of spool onto the corner of casing (39) strongly. 7. Insert spring (17) and the spool (19) assembly into casing (39).
19 17 39
W25N-02-09-008
8. Apply a film of grease to seal (29).䎃Install seal (29) and O-ring (12) to plug (11).
29 11 12
W324-02-09-013
9. Apply hydraulic oil onto the surface of push rod (32).䎃Insert push rod (32) into plug (11).
11
32
W324-02-09-019㩷
W2-9-17
CRANE UPPER / Remote Control Valve 10. Install the push rod (32) assembly to casing (39).
32
39
W25N-02-09-007㩷
11. Install disc (33) to cover (30). Insert camshaft (34).
33
30
34
W324-02-09-020
35
12. Apply LOCTITE #241 onto set screw (35). Tighten set screw (35) to disc (33). : 4 mm : 15.7 to 17.7 N m (1.6 to 1.8 kgf m) (11.5 to 13 lbf ft) NOTE: Check if the end of set screw (35) is inserted into the groove in camshaft (34).
33
W324-02-09-021
36
13. Install lever (37) to disc (33) and tighten with socket bolt (36). : 6 mm : 27.4 to 31.4 N m (2.8 to 3.2 kgf m) (20 to 23 lbf ft)
37 33
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 plug (5) to cover (30). : 24 mm : 38.3 to 44.1 N m (3.9 to 4.5 kgf m) (28 to 32.5 lbf ft)
2
4
3
5 6 7 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 N m (3.9 to 4.5 kgf m) (28 to 32.5 lbf ft)
W324-02-09-014
17. Install the end cover (39) assembly to casings (3, 4) and tighten with socket bolt (31). : 5 mm : 10.8 to 12.8 N m (1.1 to 1.3 kgf m) (8.0 to 9.4 lbf ft)
31
30 39
W25N-02-09-012
18. Install boot (38) to covers (30, 48). 19. Install O-ring (25) to casing (39) in remote control valve for rear drum and casing (26) in remote control valve for front drum.䎃 Place the remote control valve assembly (3-unit) on the flat workbench.䎃Align spring pin (10) with the pin hole and install bolts (15) (2 used). Tighten nut (18). : 13 mm : 15.7 to 17.7 N m (1.6 to 1.8 kgf m) (11.5 to 13 lbf ft)
38
30 48 26, 25 15, 18 22 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 CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. 2. Remove each harness of the solenoid valve from the connector.
2
1
3. Remove all hoses from solenoid valve unit (2). Remove the adapter, elbow and tee. : 19 mm : 22 mm : 27 mm 4. Remove socket bolts (1) (2 used). Remove solenoid valve unit (2). : 13 mm Installation
W24X-02-10-001
1. Install solenoid valve unit (2) with bolts (1) (2 used). : 13 mm : 10 N m (1.0 kgf m, 7.2 lbf ft) 2. Install the adapter, elbow and tee to solenoid valve unit (2). : 19 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (26 to 28 lbf ft) : 22 mm : 69 to 79 N m (7 to 8 kgf m, 51 to 58 lbf ft) 3. Install all hoses. : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) 4. Install each harness of the solenoid valve to the connector.
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 3
8㩷
7㩷
6㩷
5
4 W24X-02-10-002
1 - Solenoid (4 Used) 2 - Reducing Valve 3 - O-Ring (2 Used)
456-
Plug (2 Used) Casing Sleeve (4 Used)
789-
O-Ring (4 Used) Spool (4 Used) O-Ring (4 Used)
W2-10-2
10 - O-Ring (4 Used) 11 - O-Ring (4 Used) 12 - Spring (4 Used)
CRANE UPPER / Solenoid Valve Disassemble Solenoid Valve Block
Assemble Solenoid Valve Block
IMPORTANT: Do not loosen the adjusting screw in solenoid (1). 1. Remove solenoids (1) (4 used) from casing (5). : 32 mm NOTE: Solenoid (1) is removed as an assembly. 2. Remove O-rings (7, 9, 10 and 11) from solenoid (1) and sleeve (6). IMPORTANT: Do not loosen the adjusting screw in solenoid (1). 3. Secure sleeve (6). Loosen solenoid (1). Remove sleeve (6) from solenoid (1). : 32 mm 4. Remove spring (12) and spool (8) from sleeve (6). NOTE: Remove spool (8) slowly. IMPORTANT: Do not loosen the adjusting screw in reducing valve (2). 5. Remove reducing valve (2) from casing (5). : 22 mm 6. Remove plugs (4) (2 used) from casing (5). : 6 mm
1. Install spool (8) and spring (12) to sleeve (6). IMPORTANT: Do not loosen the adjusting screw in solenoid (1). 2. Secure sleeve (6) and install solenoid (1). : 32 mm : 27 to 33 N m (2.8 to 3.4 kgf m) (20 to 24 lbf ft) 3. Apply grease to O-rings (7, 9, 10 and 11). Install O-rings (7, 9, 10 and 11) to solenoid (1) and sleeve (6). IMPORTANT: Do not loosen the adjusting screw in solenoid (1). 4. Install solenoid (1) and sleeve (6) (4 units) to casing (5). : 32 mm : 39 to 49 N m (4 to 5 kgf m) (29 to 36 lbf ft) IMPORTANT: Do not loosen the adjusting screw in reducing valve (2). 5. Install reducing valve (2) to casing (5). : 22 mm : 39 to 49 N m (4 to 5 kgf m) (29 to 36 lbf ft)
7. Remove O-ring (3) from plug (4). 6. Apply grease to O-ring (3). Install O-ring (3) to plug (4). 7. Install plugs (4) (2 used) to casing (5). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m) (26 to 28 lbf ft)
W2-10-3
CRANE UPPER / Solenoid Valve (Blank)
W2-10-4
CRANE UPPER / Cylinder REMOVE AND INSTALL COUNTERWEIGHT INSTALLATION / REMOVAL CYLINDER CAUTION: Remove and install the cylinder on the level, solid ground. Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
A
5
5 1
1 4 3 2
3
Removal 1. Remove the counterweight. As for removal of the counterweight, refer to W2-2 in this section.
4
2. Remove hoses (1) (2 used/cylinder)
W2BC-02-11-001
CAUTION: Cylinder (1) weight: 200 kg (441 lb) 3. Attach a wire rope onto the cylinder rod (A). Hold cylinder (5). 4. Remove sprit pins (2) (2 used/cylinder). Remove pins (3) (2 used/cylinder).
5
5. Remove bracket (4) (2 used/cylinder).
3
6. Hoist cylinder (5) and remove it. 2
4 W2BC-02-11-002
W2-11-1
CRANE UPPER / Cylinder Installation 1. Install the counterweight. As for removal of the counterweight, refer to W2-2 in this section. A
5
2. Install hoses (1) (2 used/cylinder)
5
CAUTION: Cylinder (1) weight: 200 kg (441 lb) 3. Attach a wire rope onto the cylinder rod (A). Hoist cylinder (5) and install it.
1
1 4 3
4. Install bracket (4) (2 used/cylinder).
2
5. Install pins (3) (2 used/cylinder). Install sprit pins (2) (2 used/cylinder). 3
4 W2BC-02-11-001
5
3
2
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 7
1
17
2
W2BC-02-11-003
1234567-
Cylinder Tube Cylinder Rod Cover Piston Bushing Ring Wear Ring
8910 11 12 13 -
Wear Ring Packing Packing Backup Ring Dust Seal O-Ring
14 15 16 17 18 19 -
O-Ring Backup Ring O-Ring Set Screw Bushing Retaining Ring
W2-11-4
20 21 22 23 24 25 -
Plug O-Ring Valve Manifold O-Ring Socket Bolt
CRANE UPPER / Cylinder Disassemble Cylinder CAUTION: Cylinder weight: 200 kg (441 lb) 1. Hoist and secure the cylinder horizontally. Drain off hydraulic oil from the cylinder. 2. Pull out piston rod (2) approximately 200 to 300 mm (7.87 to 11.8 in). Remove the cover (3) assembly from cylinder tube (1). 3. Remove piston rod (2) from cylinder tube (1) straightly in order not to damage the sliding surface. 4. Secure piston rod (2) horizontally. Remove set screw (17) from piston (4). : 4 mm 5. Remove the piston (4) assembly from piston rod (2). 6. Remove O-ring (13) from the inner side of piston (4). 7. Remove wear rings (7, 8) from the outer side of piston (4). 8. Remove the cover (3) from piston rod (2).
W2-11-5
CRANE UPPER / Cylinder
19 18
23, 24 25
22 21, 20
12 3 16 6 11 10 15 14 5 4 13 8 9 7
1
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). 10. Remove O-rings (14, 16) and backup ring (15) from the outer side of cover (3). 11. Remove O-ring (13) from piston rod (2). 12. Remove bushing (18) and retaining ring (19) from piston rod (2).
W2-11-7
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 7
1
17
2
W2BC-02-11-003
1234567-
Cylinder Tube Cylinder Rod Cover Piston Bushing Ring Wear Ring
8910 11 12 13 -
Wear Ring Packing Packing Backup Ring Dust Seal O-Ring
14 15 16 17 18 19 -
W2-11-8
O-Ring Backup Ring O-Ring Set Screw Bushing Retaining Ring
20 21 22 23 24 25 -
Plug O-Ring Valve Manifold O-Ring Socket Bolt
CRANE UPPER / Cylinder Assemble Cylinder 1. Install bushing (5), packing (10), backup ring (11), ring (6) and dust seal (12) to the inner side of cover (3) in this order. 2. Install backup ring (15) and O-rings (14, 16) to the outer side of cover (3) in this order. 3. Install wear rings (7, 8) to the outer side of piston (4) in this order. 4. Install O-ring (13) to the inner side of piston (4). 5. Install the cylinder head (3) assembly to piston rod (2). 6. Secure the piston rod (2) assembly horizontally. Install the piston (4) assembly to piston rod (2) by using special tool. : 618 to 755 N m (63 to 77 kgf m) (460 to 560 lbf ft) 7. Install set screw (17) to piston (4). : 4 mm : 20 N m (2.0 kgf m, 14.5 lbf ft)
Special Tool㩷
8. Clamp cylinder tube (1) in a vise. Secure cylinder tube (1) horizontally. 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 7
1
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. 10. Tighten cover (3) to cylinder tube (1). : 750 to 917 N m (77 to 94 kgf m) (550 to 680 lbf ft)
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 (Reduction Gear) ......................................W3-2-4
Assemble Lower Roller............................. W3-5-14
Assemble Travel Mechanism (Reduction Gear) ......................................W3-2-8 Disassemble Travel Motor ........................W3-2-14 Assemble Travel Motor .............................W3-2-20 Maintenance Standard ..............................W3-2-30
Maintenance Standard.............................. W3-5-16
Group 6 Track Shoe Remove and Install Track Shoe ................. W3-6-1 Maintenance Standard................................ W3-6-5
Group 7 Cylinder
Group 3 Rotating Joint Remove and Install Rotating Joint ..............W3-3-1 Disassemble Rotating Joint ........................W3-3-4 Assemble Rotating Joint .............................W3-3-6 Maintenance Standard ................................W3-3-8
Remove and Install Retract Cylinder.......... W3-7-1 Disassemble Cylinder................................. W3-7-8 Assemble Cylinder.................................... W3-7-12 Remove and Install Track Adjustment 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 Disassemble Take-Up Tumbler ...................W3-4-2
Remove and Install Jack-up Cylinder (Optional)................................................ W3-7-27
Assemble Take-Up Tumbler........................W3-4-4
Disassemble Jack-up Cylinder ................. W3-7-30
Maintenance Standard ................................W3-4-6
Assemble Jack-up Cylinder...................... W3-7-32
Group 8 Control Valve Remove and Install 6-Unit Control Valve for Retract and Jack-up (Optional) ........... W3-8-1 Disassemble 6-Unit Control Valve .............. W3-8-2 Assemble 6-Unit Control Valve................... W3-8-4
2BDW-3-1
(Blank)
2BDW-3-2
BASE CARRIER / Turntable Bearing REMOVE AND BEARING
INSTALL
TURNTABLE
6 11
Before removing the turntable bearing, the upper revolving frame must be removed first. For removal and installation of the upper revolving frame, refer to “Remove and Install Upper Revolving Frame� section. In this section, the procedure starts on the premise that the upper revolving frame has already been removed.
7 2 3
1
Removal 1. Remove elbows (2) (2 used), hoses (3) (2 used) and block (4) from outer race (1). : 17 mm NOTE: Remove bolt (5) and remove block (4). 2. Remove bolts (6) (4 used) from outer race (1). Remove covers (7, 11) (2 used). : 24 mm
5
4 W2BC-03-01-001
8
Matching Mark
9
3. Put the matching marks on inner race (8) and lower frame (9).
W25N-03-01-002
10
4. Remove bolts (10) (48 used). 46 mm
W25N-03-01-003
W3-1-1
BASE CARRIER / Turntable Bearing CAUTION: Turntable bearing weight: 870 kg (1920 lb) 5. Attach a lifting tool onto outer race (1).䎃 Hoist and remove the turntable bearing.
1
W25N-03-01-004
W3-1-2
BASE CARRIER / Turntable Bearing Installation Clean the mounting surfaces of lower frame and turntable bearing. Apply THREEBOND #1102. CAUTION: Turntable bearing weight: 870 kg (1920 lb)
Matching Mark㩷
1. Hoist the turntable bearing and align the matching marks on lower frame (9) and inner race (8). NOTE: If the matching marks do not align, the position of soft zone of inner race (8) will be dislocated.
10
8
2. Tighten bolts (10) (48 used). : 46 mm : 1910 N m (195 kgf m, 1410 lbf ft)
9 W25N-03-01-005
3. Install covers (7, 11) (2 used) to outer race (1) with bolts (6) (4 used). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
6 11 7
4. Install elbows (2) (2 used), hoses (3) (2 used) and block (4) to outer race (1). : 17 mm : Bolt(5):50 N m (5.1 kgf m, 37 lbf ft) NOTE: Install block (4) with bolt (5).
2 3
1
5. Secure hoses (3) (2 used) onto hole (A) (4 places) on cover (7) with band clips (11) (4 used).
5
4 W2BC-03-01-001
㩷
W3-1-3
BASE CARRIER / Turntable Bearing DISASSEMBLE TURNTABLE BEARING
1
8
2
3
6
2
4
7
5
6 W25N-03-01-006
12-
Pin㩷 Seal㩷
34-
Inner Race㩷 Ball 㩿96 Used)㩷
56-
Outer Race㩷 Seal㩷
W3-1-4
78-
Support (96 Used)㩷 Plug㩷
BASE CARRIER / Slewing Ring Disassemble Turntable Bearing 1. Grind off the caulked part of pin (1). Tap and remove pin (1) from the bottom side of plug (8). 1
8 W25N-03-01-007
2. Remove plug (8). NOTE: Install the bolt into the screw hole (M10, Pitch 1.5) of plug (8).䎃Tap or pull out the bolt from the inner side. 8
W25N-03-01-008
CAUTION: Turntable bearing weight: 870 kg (1920 lb) 3. Horizontally hoist outer race (5) of turntable bearing a little. Remove seals (2, 6).
5
2
4
4. Rotate inner race (3) and remove ball (4) and support (7) from the plug (8) part. Remove ball (4) by using magnet (A). Use wire (B) and remove support (7).
3 A
6 W25N-03-01-009
B
7 W105-03-01-010㊡
W3-1-5
BASE CARRIER / Slewing Ring ASSEMBLE TURNTABLE BEARING
1
8
2
3
6
2
4
7
5
6 W25N-03-01-006
12-
Pin㩷 Seal㩷
34-
Inner Race㩷 Ball㩷 㩿96 Used)㩷
56-
Outer Race㩷 Seal㩷
W3-1-6
78-
Support (96 Used)㩷 Plug㩷
BASE CARRIER / Slewing Ring Assemble Turntable Bearing CAUTION: Turntable bearing weight: 870 kg (1920 lb) 1. Before installing the inner race and outer race of turntable bearing, wipe off grease from the groove part for seals (2, 6).䎃Apply THREEBOND #1735. Install seals (2, 6). 2. Apply grease to balls (4) and supports (7). Install balls (4) (96 used) and supports (7) (96 used) through the plug (8) part.䎃Install ball (4) first.
2 4
3. Install plug (8) into outer race (5). Install pin (1). Crimp the head of pin (1) by using a punch. Apply much grease (Alvania EP2 grease or equivalent) onto the turntable bearing.
6 W25N-03-01-011
7 W25N-03-01-012㩷
5
1
8
W25N-03-01-007
W3-1-7
BASE CARRIER / Slewing Ring (Blank)㩷 㩷
W3-1-8
BASE CARRIER / Travel Mechanism REMOVE AND MECHANISM
INSTALL
TRAVEL
CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal The procedure starts on the premise that the track shoe has already been removed. As for removal and installation of track shoe, refer to W3-6-1. IMPORTANT: After stopping the engine, remove and install the quick coupling. If the engine does not stop, the quick coupling cannot be inserted or O-ring in the quick coupling may be damaged because of the remaining pressure in the circuit. Before installing, clean the quick coupling. The quick coupling may be damaged if the quick coupling hits. Handle the quick coupling carefully. 1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit. Remove the quick couplings (4 places in one side, 8 places in total) of travel hydraulic hose. 2. Remove all pipes and covers. : 19 mm, 27 mm, 50 mm NOTE: Cap the removed pipes.
W25N-03-02-001
W3-2-1
BASE CARRIER / Travel Mechanism CAUTION: Travel mechanism weight: 890 kg (1970 lb) 3. Hoist travel device (1). Remove bolt (2). Remove travel mechanism (1) from side frame (3). : 19 mm
1
Installation CAUTION: Travel mechanism weight: 890 kg (1970 lb)
2
1. Hoist and install travel mechanism (1) onto side frame (3) with bolt (2). : 19 mm : 1400 N m (143 kgf m, 1030 lbf ft)
3 W25N-03-02-002
2. Install all the pipes. : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 50 mm : 306 to 374 N m (31 to 38 kgf m) (225 to 275 lbf ft) 3. Install the cover. : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
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). IMPORTANT: After installing the travel motor, fill hydraulic oil in the travel motor. After installing the travel motor or travel mechanism, in order to prevent the travel motor from seizing, perform the break-in operation. Check for any oil leaks.
W3-2-3
BASE CARRIER / Travel Mechanism DISASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR) 46
47
11
7
12
24
30
31
19
23
32
38 45 44
39
40 41
37 36 34 35 33
49
48
50
1
2㩷
4
3
6
5
8
9
10
21 20
42
14
18
28
15
16
26
29
22 13
17
25
27
43
W25N-03-02-003
12345678910 11 12 13 -
Housing㩷 Floating Seal㩷 Bearing (2 Used)㩷 Drum㩷 Travel Drive Sprocket㩷 Socket Bolt (34 Used)㩷 Cork (2 Used)㩷 Nut㩷 Lock Plate㩷 Bolt (2 Used)㩷 Carrier㩷 Spacer㩷 Planetary Gear (4 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Needle Bearing (8 Used)㩷 Spacer (4 Used)㩷 Thrust Plate (8 used)㩷 Spacer (4 Used)㩷 Spring Pin (4 Used)㩷 Sun Gear㩷 Ring Gear㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Carrier㩷 Spacer㩷 Planetary Gear (4 Used)㩷 Needle Bearing (4 Used)㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Spring Pin (4 Used)㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Needle Bearing (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷
W3-2-4
39 40 41 42 43 44 45 46 47 48 49 50 -
Cover㩷 Bearing㩷 Pin㩷 Bolt (18 Used)㩷 Spring Washer (18 Used)㩷 Plug (3 Used)㩷 Cork (2 Used)㩷 Coupling㩷 Retaining Ring㩷 Motor㩷 Socket Bolt (3 Used)㩷 O-Ring㩷
BASE CARRIER / Travel Mechanism Disassemble Travel Mechanism (Reduction Gear) CAUTION: Travel mechanism weight: 890 kg (1970 lb) Loosen the plug slowly and release the remaining pressure in the travel mechanism completely. As the plug or gear oil gush out, do not loosen the plug suddenly.䎃 Keep away from the plug. 䎃 1. Hoist the travel mechanism with plug (44) facing downward. Loosen plug (44-A) 2 to 3 turns and release the remaining pressure in the reduction gear. Remove plug (44) and drain gear oil out from the reduction gear. 2. Place the travel motor on the workbench with the travel motor facing upward. Remove the socket bolt. : 12 mm
44-B (Oil Filler Plug)
44-A
CAUTION: Travel motor weight: 100 kg (220 lb) Level
3. Remove socket bolt (49). Remove the motor from the travel mechanism. Remove O-ring (50). 4. Remove coupling (46) from shaft (38) in the travel mechanism. CAUTION: Travel mechanism gear) weight: 790 kg (1750 lb)
(reduction
44 W25N-03-02-004
5. Turn over the travel mechanism (reduction gear). Remove socket bolt (49) and remove cover (39). : 12 mm 6. Remove pin (41) from cover (39). Remove bearing (40). 7. Remove the first stage carrier (31) assembly with shaft (38). 8. Remove shaft (38) from the first stage carrier (31) assembly.
W3-2-5
BASE CARRIER / Travel Mechanism
11 19
24
30
23
32
31
37 36 34 35 33
1
2ã©·
4
3
6
5
9
10
21 20
14
18
28
15
16
26
29
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 stage carrier (23).
22. Remove pins (17) (4 used) from third carrier (11).䎃 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). : 17 mm 12. Remove O-ring (21) from drum (4). 13. Remove third stage sun gear (19) from third stage carrier (11). 14. Remove the third stage carrier (11) assembly. 15. Remove socket bolt (10). Remove lock plate (9) from housing (1). : 19 mm 16. Hoist and remove drum (4) with bearing (3) in the reduction side and travel drive sprocket (5) attached from housing (1).
24. Remove needle bearings (14) (8 used) from third stage planetary gears (13) (4 used). 25. Remove spring pins (29) (4 used) from the second stage carrier (23) assembly. 26. Remove pins (28) (4 used) from second stage carrier (23). Remove second stage planetary gears (25) (4 used) and thrust plates (27) (8 used). 27. Remove spacer (24) from second stage carrier (23). 28. Remove needle bearings (26) (4 used) from second stage planetary gears (25) (4 used). 29. Remove spring pins (37) (3 used) from the first stage carrier (31) assembly.
17. Remove bearing (3) from the motor side. 18. Remove floating seal (2). 19. Turn over drum (4). Remove socket bolt (6). Remove travel drive sprocket (5) from drum (4). : 19 mm
30. Remove pins (36) (3 used) from first stage carrier (31). Remove first stage planetary gears (33) (3 used) and thrust plates (35) (6 used). 31. Remove spacer (32) from first stage carrier (31).
20. Remove bearing (3) from the travel motor side. 21. Remove spring pins (18) (4 used) from the third stage carrier (11) assembly.
32. Remove needle bearing (34) from first stage planetary gears (33) (3 used).
W3-2-7
BASE CARRIER / Travel Mechanism ASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR)
46
47
11
7
12
24
30
31
19
23
32
38 45 44
39
40 41
37 36 34 35 33
49
48
50
1
2㩷
4
3
6
5
8
9
10
21 20
42
14
18
28
15
16
26
29
22 13
17
25
27
43
W25N-03-02-003
12345678910 11 12 13 -
Housing㩷 Floating Seal㩷 Bearing (2 Used)㩷 Drum㩷 Travel Drive Sprocket㩷 Socket Bolt (34 Used)㩷 Cork (2 Used)㩷 Nut㩷 Lock Plate㩷 Bolt (2 Used)㩷 Carrier㩷 Spacer㩷 Planetary Gear (4 Used)㩷
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Needle Bearing (8 Used)㩷 Spacer (4 Used)㩷 Thrust Plate (8 used)㩷 Spacer (4 Used)㩷 Spring Pin (4 Used)㩷 Sun Gear㩷 Ring Gear㩷 O-Ring㩷 Socket Bolt (30 Used)㩷 Carrier㩷 Spacer㩷 Planetary Gear (4 Used)㩷 Needle Bearing (4 Used)㩷
27 28 29 30 31 32 33 34 35 36 37 38 -
Thrust Plate (8 used)㩷 Pin (4 Used)㩷 Spring Pin (4 Used)㩷 Sun Gear㩷 Carrier㩷 Spacer㩷 Planetary Gear (3 Used)㩷 Needle Bearing (3 Used)㩷 Thrust Plate (6 used)㩷 Pin (3 Used)㩷 Spring Pin (3 Used)㩷 Shaft㩷
W3-2-8
39 40 41 42 43 44 45 46 47 48 49 50 -
Cover㩷 Bearing㩷 Pin㩷 Bolt (18 Used)㩷 Spring Washer (18 Used)㩷 Plug (3 Used)㩷 Cork (2 Used)㩷 Coupling㩷 Retaining Ring㩷 Motor㩷 Socket Bolt (3 Used)㩷 O-Ring㩷
BASE CARRIER / Travel Mechanism Assemble Travel Mechanism (Reduction Gear) 1. Install needle bearing (34) to first stage planetary gears (33) (3 used).
10. Install spacer (15) to third stage carrier (11).
3. Install first stage planetary gears (33) (3 used) and thrust plates (35) (6 used) to first stage carrier (31).
11. Install third stage planetary gears (13) (4 used) and thrust plates (16) (8 used) to third stage carrier (11). NOTE: Face the groove in end of third stage planetary gear (13) to cover (39).
4. Align with the spring pin hole on first stage carrier (31) and install pins (36) (3 used).
12. Align with the spring pin hole on third stage carrier (11) and install pins (17) (3 used).
2. Install spacer (32) to first stage carrier (31).
5. Install spring pins (37) (3 used) into first stage carrier (31) and pin (36). Face the slit of spring pin (37) to the end of first stage carrier (31) (cover (39) side). 6. Install spacer (24), second stage planetary gears (25) (4 used), needle bearings (26) (4 used) and thrust plates (27) (8 used) to second stage carrier (23) in the same procedures steps 1 to 3. 7. Align with the spring pin hole on second stage carrier (23) and install pins (28) (4 used). 8. Install spring pins (29) (4 used) into second stage carrier (23) and pin (28). Face the slit of spring pin (29) to the end of second stage carrier (23) (cover (39) side).
13. Install spring pins (18) (3 used) into third stage carrier (11) and pin (17). Face the slit of spring pin (18) to the end of third stage carrier (11) (cover (39) side). IMPORTANT: For handling floating seal (2), refer to the section “Precautions for Handling Floating Seal� on page W1-1-3. 14. Apply grease to floating seal (2). Install a pair of floating seal (2) to housing (1) by using bamboo spatula. 15. Install bearing (3) at travel motor side to housing (1).
9. Install needle bearings (14) (8 used) to third stage planetary gears (13) (4 used).
W3-2-9
BASE CARRIER / Travel Mechanism
11
30 19
23
31 38
33
1
2ã©·
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 to the section “Precautions for Handling Floating Seal” on page W1-1-3. 16. Apply grease to floating seal (2). Install other pair of floating seal (2) to drum (4) by using bamboo spatula. 17. Hoist and install travel drive sprocket (5) to drum (4). Apply LOCTITE #262 to socket bolts (6) (34 used). Tighten socket bolt (6). : 19 mm : 950 N m (97 kgf m, 700 lbf ft) 18. Apply grease to O-ring (21). Install O-ring (21) to drum (4). Hoist and install drum (4) to housing (1).
26. Apply grease into the spline in third stage carrier (11). Hoist and install the third stage carrier (11) assembly onto housing (1). 27. Install third stage sun gear (19) to third stage carrier (11). 28. Hoist ring gear (20). Mesh ring gear (20) with third stage planetary gear (13) and install ring gear (20) to drum (4). 29. Apply LOCTITE #262 to socket bolts (22) (30 used). Tighten socket bolt (22). : 17 mm : 750 N m (77 kgf m, 550 lbf ft)
19. Install bearing (3) to housing (1).
30. Hoist and install the second stage carrier (23) assembly onto third stage sun gear (19).
20. Tighten nut (8) to housing (1). : 800 N m (82 kgf m, 590 lbf ft)
31. Install second stage sun gear (30) to second stage carrier (23).
21. Rotate travel drive sprocket (5) clockwise and counterclockwise and 4 to 5 times.
32. Hoist and install the first stage carrier (31) assembly onto second stage sun gear (30).
22. Tap the end of travel drive sprocket (5) by using a hammer.
33. Install shaft (38) into the center of first stage carrier (31) and mesh with first stage planetary gear (33).
23. Tighten nut (8) again. : 800 N m (82 kgf m, 590 lbf ft) 24. Repeat steps 21 to 23. 25. Align with the notch on housing (1) and install lock plate (9). Apply LOCTITE #262 onto the bolt (2 used). Tighten the bolt. : 19 mm : 950 N m (97 kgf m, 700 lbf ft)
W3-2-11
BASE CARRIER / Travel Mechanism
46 38
44
39
40 41
42 43 49
20
50
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. 35. Apply THREEBOND #1215 onto the cover (39) mounting surface on ring gear (20). Install cover (39). 36. Install spring washers (43) (18 used) to socket bolts (42) (18 used). Tighten socket bolt (42). : 22 mm : 210 N m (21.5 kgf m, 155 lbf ft) 37. Wind the seal tape onto plugs (44) (3 used). Install plug (44) to cover (39). : 17 mm : 90 N m (9.2 kgf m, 66 lbf ft) CAUTION: Travel mechanism gear) weight: 790 kg (1750 lb)
(reduction
38. Turn over the travel mechanism (reduction gear) and add gear oil. Gear oil: 20 L (5.3 US gal) 39. Apply grease to O-ring (50). Install O-ring (50) to travel motor. 40. Apply grease to the spline of coupling (46). Install coupling (46) to shaft (38).
CAUTION: Travel motor weight: 100 kg (220 lb) 41. Align the spline of travel motor with the hole on coupling (46). Install the travel motor to the travel mechanism (reduction gear). 42. Tighten socket bolts (49) (3 used). : 12 mm : 180 N m (18.5 kgf m, 133 lbf ft)
W3-2-13
BASE CARRIER / Travel Mechanism DISASSEMBLE TRAVEL MOTOR 85 86 69
84
70
69
70
69
70 69
87 82 83 88
71
72 73
74
89 90 75 76
63
77
64
78
87
65
79 91
66
80 67
81 68
6 7
8
9
10
11
12
13
1 2 3
16 15
5
17 18 19 20 21
50 49 50 51
54 53 52
32
2
33
22 23 24 25
35
36
34
41 26
27 28 29 30
55 56
31
57 58
61 50
37
38 39
26
33
14
42 43
40
45 30
59 60
15 46
29
28
27
25
44
39 47
48
17 16
24
23 22 18 19 20 21
W25N-03-02-005
W3-2-14
BASE CARRIER / Travel Mechanism 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 -
Plug㩷 O-Ring (2 Used) Spring Guide㩷 Washer (2 Used) Spring㩷 Spool Assembly Spool㩷 Backup Ring㩷 O-Ring㩷 O-Ring㩷 Backup Ring㩷 Filter㩷 Retaining Ring㩷 Plug㩷 Cap Assembly (2 Used)㩷 Socket Bolt (2 Used)㩷 Cap (2 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Spring (2 Used)㩷 Steel Ball (2 Used)㩷 O-Ring (2 Used)㩷 Spring Seat (2 Used)㩷 Spring (2 Used)
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
-
Spring Seat (2 Used) Plunger Assembly㩷 Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Plunger㩷 Relief Valve (2 Used) Backup Ring (4 Used) O-Ring (2 Used) Poppet Seat (2 Used) Poppet (2 Used) Housing (2 Used) Piston (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spring Seat (2 Used) Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) O-Ring (2 Used) Plug (2 Used) Nut (2 Used) Adjusting Screw (2 Used)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71
-
W3-2-15
Socket Bolt (10 Used) Plug (12 Used) Plug (3 Used) Base Plate㩷 Orifice (2 Used) Orifice (2 Used) Pin (4 Used) Pin㩷 Spring (4 Used) Spring (8 Used) O-Ring (2 Used) Plug (2 Used) Plug㩷 Plug㩷 O-Ring㩷 Bearing㩷 Valve Plate㩷 Brake Piston㩷 D-Ring㩷 D-Ring㩷 Friction Plate (3 Used)㩷 Disc (4 Used)㩷 Retaining Ring㩷
72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
-
Spring Seat㩷 Spring㩷 Spring Seat㩷 Cylinder Block㩷 Pin (3 Used) Holder㩷 Retainer Plate㩷 Piston (9 Used) Swash Plate㩷 Steel Ball (2 Used) Shaft㩷 Bearing㩷 Oil Seal㩷 Piston (2 Used) Spring (2 Used)㩷 Plug (4 Used)㩷 Orifice㩷 O-Ring㩷 Casing㩷 O-Ring㩷 Adjusting Screw㩷 Plug (2 Used)㩷 Socket Bolt (3 Used)㩷
BASE CARRIER / Travel Mechanism
90 63 64 65
6
1 2 3
16
5
17 18 19 20 21
54 53 52
32
49 2 33
22 23 24 25
34
14
33
35
26
26 55 56
57 58
46 25
47
48
17 16
24
23 22 18 19 20 21 W25N-03-02-005
W3-2-16
BASE CARRIER / Travel Mechanism Disassemble Travel Motor IMPORTANT: As the relief set pressure changes, do not loosen nut (47) and adjusting scarew (48) in relief valve assembly (32). Do not remove relief valve assembly (32) unless necessary. 1. Remove plug (46). Remove relief valve assemblies (32) (2 used) from base plate (52). : 27mm
CAUTION: Slowly turn and remove spool assembly (6) in order not to damage the hole on base plate (52). 7. Remove plugs (1, 14). Remove O-rings (2) (2 used), spring guide (3), spring (5) and spool assembly (6). : 10mm
2. Remove poppet seats (35) (2 used), backup CAUTION: Pin (55) may be stuck by the screwdriver.
rings (33) (4 used) and O-rings (34) (2 used) from base plate (52). IMPORTANT: Push cap (17) by hands in order not to fly out cap (17) because of spring (24) and remove socket bolt (16). 3. Remove socket bolts (16) (8 used). Remove caps (17) (2 used) and O-rings (22) (2 used) from base plate (52). : 14mm
IMPORTANT: As base plate (52) is pushed upward by springs (57, 58), loosen socket bolt (49) evenly. 8. Remove socket bolts (49) (10 used). Remove base plate (52). : 12mm CAUTION: When removing pins (55, 56), do not damage the outer surface by using a pair of pliers. Do not damage the sliding surface on valve plate (65).
4. Remove spring seat (23), spring (24) and spring seat (25) from base plate (52). CAUTION: Do not damage the hole on base plate (52). 5. Slowly turn and remove plunger assembly (26) from base plate (52). 6. Remove plugs (18) (2 used), O-rings (19) (2 used), springs (20) (2 used) and steel balls (21) (2 used) from base plate (52). : 14mm
9. Remove valve plate (65), bearing (64), pins (55) (4 used), (56), O-ring (63), springs (57, 58), orifices (53) (2 used) and (54) (2 used) from base plate (52). NOTE: Springs (57, 58) and valve plate (65) may be left in casing (90).
W3-2-17
BASE CARRIER / Travel Mechanism 85 86 69
84
70
69
70
69
70 69 82 83 88
71
72 73
74 90 75 76 77 78 79 66
80 67
81 68
26
26 27 28 29 30
31
30
29
28
27
W25N-03-02-005
W3-2-18
BASE CARRIER / Travel Mechanism CAUTION: When removing brake piston (66) by using the compressed air, cover brake piston (66) by using a cloth in order to prevent brake piston (66) from flying out. Do not damage the sliding surface on valve cover. 10. Add the compressed air (294 to 490 kPa (3 to 5 kgf/ cm2, 42.7 to 71 psi) into the orifice (88) mounting part in casing (90). Remove brake piston (66) from casing (90). Remove D-rings (67, 68), friction plate (69) and disc (70).
CAUTION: Do not damage the surface on plunger (31).
sliding
IMPORTANT: Do not remove plunger assembly (26) unless necessary. 15. Insert a roud bar (dia. Çž10) through the hole in arrow part of plunger assembly (26). Clamp plunger assembly (26) in a vise. Remove plugs (27) (2 used). 16. Remove plugs (29) (2 used), check valves (30) (2 used) and O-rings (28) (2 used) from plunger (31).
CAUTION: Do not damage the sliding surfaces on cylinder block (75), the piston (75) assembly, swash plate (80). 11. Place casing (90) on the workbench horizontally. Remove retaining ring (71), spring seat (72), spring (73), spring seat (74), cylinder block (75), pins (76) (3 used), holder (77), retainer plate (78) and the piston (79) assembly from casing (90). 12. Remove pins (76) (3 used), holder (77), retainer plate (78) and the piston (79) assembly from cylinder block (75). 13. Remove retaining ring (71) from cylinder block (75). Remove spring (73) and spring seat (74). 14. Remove shaft (82) from casing (90). Remove swash plate (80), pistons (85) (2 used), springs (86) (2 used), steel balls (81) (2 used), bearing (83) and oil seal (84).
W3-2-19
BASE CARRIER / Travel Mechanism ASSEMBLE TRAVEL MOTOR 6 13
11
10
12
9
8
32
7
33
35
39
45
44
43
46
47 48
50
50
50
50
50
5
34
3
4
55 56 62
6 52
1
66
33 63
36 37 41 38 89
55
87
92
40
39 67
42 68
91 70 69 79 83 84
14 2
50
32
15 51 17 22
51
21 82 16 23
60
65
19
24 25
59
93 61
30 31
94
27 28 29
90 77 80 76
64
57
20 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 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 -
Plug㩷 O-Ring (2 Used)㩷 Spring Guide㩷 Washer (2 Used)㩷 Spring㩷 Spool Assembly㩷 Spool㩷 Backup Ring㩷 O-Ring㩷 O-Ring㩷 Backup Ring㩷 Filter㩷 Retaining Ring㩷 Plug㩷 Cap Assembly (2 Used)㩷 Socket Bolt (2 Used)㩷 Cap (2 Used)㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Spring (2 Used)㩷 Steel Ball (2 Used)㩷 O-Ring (2 Used)㩷 Spring Seat (2 Used)㩷 Spring (2 Used)㩷
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -
Spring Seat (2 Used)㩷 Plunger Assembly㩷 Plug (2 Used)㩷 O-Ring (2 Used)㩷 Spring (2 Used)㩷 Check Valve (2 Used)㩷 Plunger㩷 Relief Valve (2 Used)㩷 Backup Ring (4 Used)㩷 O-Ring (2 Used)㩷 Poppet Seat (2 Used)㩷 Poppet (2 Used)㩷 Housing (2 Used)㩷 Piston (2 Used)㩷 Backup Ring (2 Used)㩷 O-Ring (2 Used)㩷 Spring Seat (2 Used)㩷 Spring (2 Used)㩷 Spring Guide (2 Used)㩷 O-Ring (2 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 Nut (2 Used)㩷 Adjusting Screw (2 Used)㩷
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 -
W3-2-21
Socket Bolt (10 Used)㩷 Plug (12 Used)㩷 Plug (3 Used)㩷 㪙㪸㫊㪼㩷㪧㫃㪸㫋㪼㩷 Orifice (2 Used)㩷 Orifice (2 Used)㩷 Pin (4 Used)㩷 Pin㩷 Spring (4 Used)㩷 Spring (8 Used)㩷 O-Ring (2 Used)㩷 Plug (2 Used)㩷 Plug㩷 Plug㩷 O-Ring㩷 Bearing㩷 Valve Plate㩷 Brake Piston㩷 D-Ring㩷 D-Ring㩷 Friction Plate (3 Used)㩷 Disc (4 Used)㩷 Retaining Ring㩷
72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 -
Spring Seat㩷 Spring㩷 Spring Seat㩷 Cylinder Block㩷 Pin (3 Used)㩷 Holder㩷 Retainer Plate㩷 Piston (9 Used)㩷 Swash Plate㩷 Steel Ball (2 Used)㩷 Shaft㩷 Bearing㩷 Oil Seal㩷 Piston (2 Used)㩷 Spring (2 Used)㩷 Plug (4 Used)㩷 Orifice㩷 O-Ring㩷 Casing㩷 O-Ring㩷 Adjusting Screw㩷 Plug (2 Used)㩷 Socket Bolt (3 Used)㩷
BASE CARRIER / Travel Mechanism
66
67
68 70 69 79 83 84
82 90 77 80 76
57 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 seat (72) to cylinder block (75) in this order. Install retaining ring (71). 2. Apply grease onto pins (76) (3 used). Install pin (76) into the hole (3 places) on cylinder block (75). Install holder (77) to cylinder block (75). IMPORTANT: Install piston (79) so that the small diameter side of inner taper part in retainer plate (78) comes in contact with the shoe flange part of piston (79) assembly. 3. Install pistons (79) (9 used) to retainer plate (78). 4. Apply hydraulic oil onto the piston hole on cylinder block (75). Insert the piston (79) assembly.
IMPORTANT: Check if the cylinder block (75) assembly rotates smoothly and the piston (79) assembly reciprocates. 11. Place casing (90) on a workbench horizontally. Apply hydraulic oil onto swash plate (80). Insert the cylinder block (75) assembly into casing (90). 12. Install discs (70) (4 used) and friction plates (69) (3 used) to caing (90). Install disc (70) first. 13. Apply grease to brake piston (66). Install D-rings (67, 68). IMPORTANT: The pin hole (2 places) on brake piston (66) and the pin hole (2 places) on casing (90) should be in line. 14. Install brake piston (66) to casing (90).
5. Secure casing (90) on a workbench. 6. Install oil seal (84) to casing (90). NOTE: As for datails on special tools (C,B), refer to W3-2-29. 7. Install bearing (83) to casing (90). NOTE: As for datails on special tools (D,B), refer to W3-2-29.
15. Place special tool (A). Tap the head of special tool (A) by using a plastic hammer and insert into brake piston (66). NOTE: As for datails on special tools (A), refer to W3-2-28. 16. Install springs (57, 58) to brake piston (66).
8. Install steel balls (81) (2 used), springs (86) (2 used) and the piston (85) assemblies (2 used) to casing (90). CAUTION: Do not damage the lip of oil seal (84). 9. Install the shaft (82) assembly on casing (90). 10. Install swash plate (80) to casing (90).
W3-2-23
BASE CARRIER / Travel Mechanism
32 33
35
34
33
55 56
63
55
52
32 15 17 22 21 16 23
19
24
30 31
25
27 28 29
90
64 65
20 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). CAUTION: Do not damage the sliding surface on valve plate (65). IMPORTANT: Apply grease onto non-sliding surface on valve plate (65) and base plate (52). 18. Secure base plate (52) horizontally on a workbench. Install the outer race assembly of bearing (64), pins (55) (4 used), (56), orifices (53) (2 used), (54) (2 used) and valve plate (65). CAUTION: Do not fall off valve plate (65). Do not damage the cage of bearing (64). IMPORTANT: Apply hydraulic oil onto the sliding surface on the cylinder block (75) assembly and valve plate (65). Align pin (55) with the pin hole on casing (90). 19. Clamp casing (90) in a vise. Install base plate (52) to casing (90) with socket bolts (49) (10 used). : 12 mm : 176 to 206 N m (18 to 21 kgf m) (130 to 152 lbf ft) 20. Insert a round bar (dia. Ǿ10) through the hole in arrow part of plunger (31). Clamp plunger (31) in a vise and install check valve (30) and spring (29) in this order.
IMPORTANT: Check if plunger assembly (26) moves smoothly. 22. Apply hydraulic oil onto the sliding surface of plunger assembly (26). Slowly rotate and install plunger assembly (26) to base plate (52). 23. Install O-ring (22) on cap (17). 24. Install spring seat (25), spring (24) and spring seat (23) to base plate (52) in this order. IMPORTANT: Push cap (17) by hands in order not to fly out cap (17) because of spring (24) and tighten socket bolt (16). 25. Install cap assembly (15) to base plate (52) with socket bolts (16) (4 used). : 14 mm : 98 to 118 N m (10 to 12 kgf m) (72 to 87 lbf ft) 26. Install steel balls (21) (2 used), springs (20) (2 used), O-rings (19) (2 used) and plugs (18) (2 used) to base plate (52). 27. Install O-rings (34) (2 used) and backup rings (33)(4 used) onto poppet seats (35) (2 used). Install poppet seat (35) to base plate (52). 28. Install the relief valve (32) assembly to base plate (52). : 27 mm : 353 to 393 N m (36 to 40 kgf m) (260 to 290 lbf ft)
21. Install plug (27) with O-ring (28) attached to plunger (31). : 22 mm : 127 to 147 N m (13 to 15 kgf m) (94 to 108 lbf ft)
W3-2-25
BASE CARRIER / Travel Mechanism
6
5
4
3
6 52
1
14 2
W25N-03-02-006
W3-2-26
BASE CARRIER / Travel Mechanism CAUTION: Check the direction to install spool assembly (6). 29. Install spool assembly (6) to base plate (52). 30. Install O-ring (2) to plug (14). Install washers (4) (2 used) and plug (14) to base plate (52). : 10 mm : 112.1 to 123.9 N m (11.5 to 12.5 kgf m) (83 to 91 lbf ft) 31. Install spring (5), spring guide (3) and O-ring (2) to plug (1). Install plug (1) on base plate (52). : 10 mm : 112.1 to 123.9 N m (11.5 to 12.5 kgf m) (83 to 91 lbf ft)
W3-2-27
BASE CARRIER / Travel Mechanism Special Tool
x Special Tool (A): For position of the brake piston 274 200 28
28
20
37
30
150
5
18
370
175
4
3
2
1 㱢8
13
㱢12
8
18
㱢5
W25N-03-02-007㩷
㱢11㩷
30㫦㩷
2
2 3
22 M4㬍0.7 Screw Length 12 Bottom Hole Length: 17 or less㩷
30㫦㩷
4
9.8
㱢11㩷
30㫦㩷 10.2
㱢12㩷
22 M4㬍0.7 Screw Length 12 Bottom Hole Length: 17 or less㩷
3
7
2 3
㱢12㩷
7
㱢11㩷
3
㱢12㩷
M4㬍0.7 Screw Length 12 Bottom Hole Length: 17 or less㩷
2
10
㱢11㩷
30㫦㩷 9.5
㱢12㩷
M4㬍0.7 Screw Length 12 Bottom Hole Length: 17 or less㩷
1
2
7
3
22
7 22 W25N-03-02-008
NOTE: Unit: mm, 1 mm = 0.03937 in
W3-2-28
BASE CARRIER / Travel Mechanism
㱢23㩷
2
30㫦
㱢24㩷 30㫦
㱢23㩷
x Special Tool (B): For installation of the casing
2 27
27 180
W25N-03-02-009
x Special Tool (C): For installation of the oil seal 21 0.5
C3
4 C3
25
㱢78㩷
㱢46㩷
30㫦
㱢36㩷 㱢23㩷
(㱢18)㩷
30㫦
2
㱢49.6㩷 㱢71.6㩷
㱢23 Hole Depth㩷
25 54 W25N-03-02-010
x Special Tool (D): For installation of the bearing C3 25 C3
2
30㫦
㱢23㩷 㱢36㩷
(㱢18)㩷
㱢46㩷
㱢94㩷
C2
5
25 45 W25N-03-02-011
NOTE: Unit: mm, 1 mm = 0.03937 in
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)
D-d
Standard
Allowable Limit
Maximum 0.03 (0.001)
0.06 (0.002)
W117-02-02-009
Plunger㩷
2. Move the plunger of travel motor upward and downward. Measure clearance Ǭ between plunger and shoe.
Shoe㩷
Unit: mm (in) Standard
Allowable Limit
Maximum 0.15 (0.006)
0.4 (0.016)
㱐
W107-02-06-140
W3-2-30
BASE CARRIER / Rotating Joint REMOVE AND INSTALL ROTATING JOINT CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
3
4
2
1
9
11 12 13
Removal
5
1. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
14
2. Remove pipes (1 to 17), hoses. : 19 mm, 22 mm, 27 mm, 36 mm, 41 mm, 50 mm NOTE: Cap the pipes and hoses.
10
15 16
6
7
17 8
W2BC-03-03-001
26 28
3. Remove bolt (24) and remove plate (25). : 24 mm
27 24 25
4. Remove bolt (26) and remove plate (27). : 24 mm CAUTION: Rotating joint weight: 64 kg (140 lb)
W2BC-03-03-002
5. Hoist and hold the rotating joint. 6. Remove bolt (28). Remove the rotating joint. : 19 mm
W3-3-1
BASE CARRIER / Rotating Joint Installation 26
CAUTION: Rotating joint weight: 64 kg (140 lb)
28
27 24
1. Hoist and install the rotating joint with bolt (28). : 19 mm : 110 N m (11 kgf m, 81 lbf ft)
25
2. Install plate (27) to the rotating joint with bolt (26). : 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
W2BC-03-03-002
3. Install plate (25) to the upper revolving frame with bolt (24) so that the convex part of plate (27) can be inserted into the concave part of plate (25). : 24 mm : 270 N m (27.5 kgf m, 200 lbf ft) 4. Install bracket (23) with bolt (22). : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft) 5. Install pipes (1 to 17), hoses. : 19 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft) : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) : 36 mm : 175 N m (18 kgf m, 129 lbf ft) : 41 mm : 205 N m (21 kgf m, 151 lbf ft) : 50 mm : 306 to 374 N m (31 to 38 kgf m) (225 to 275 lbf ft)
11 12 13
14 15 16 17
7 W2BC-03-03-001
W3-3-2
BASE CARRIER / Rotating Joint (Blank)
W3-3-3
BASE CARRIER / Rotating Joint DISASSEMBLE ROTATING JOINT 9
1 3
2㩷
4 10
11
5
6 12
7
8
13
14
15
W25N-03-03-003㩷
1234-
Scraper㩷 O-Ring㩷 Socket bolt㩷 Cover㩷
5678-
O-Ring㩷 Socket bolt㩷 Thrust Plate㩷 Body㩷
910 11 12 -
Seal㩷 O-Ring㩷 V-Ring㩷 Shaft㩷
W3-3-4
13 - Flange㩷 14 - Plug㩷 15 - Plug㩷
BASE CARRIER / Rotating Joint Disassemble Rotating Joint
CAUTION: Rotating joint weight: 64 kg (140 lb) 1. Remove socket bolts (3) (2 used) from cover (4) diagonally. Hoist and install the rotating joint by using eyebolt. : 8 mm 2. Remove other socket bolts (3) (4 used). Remove cover (4). : 8 mm 3. Remove O-ring (5) from body (8). 2-㱢12Hole㩷
4. Remove socket bolts (6) (4 used) and remove thrust plate (7). : 8 mm
M20㬍350㩷
M20Tap 2-M10㬍100
(180) 151
57
30
IMPORTANT: Do not damage the seal sliding surface of shaft (12). 5. Remove shaft (12) from body (8) by using special tool (A) completely.
40
㱢25
6. Remove seals (9) (8 used), O-ring (10) and V-ring (11) from body (8). NOTE: Seal (5) can be removed easily by using two pins.
12
Spacer Protection Plate㩷
7. Remove scraper (1) and O-ring (2) from cover (4).
8
Special Tool (A) W25N-03-03-004
W3-3-5
BASE CARRIER / Rotating Joint ASSEMBLE ROTATING JOINT
2㩷
1
3
4
7 5 6 9 8 10 11 13
12 14
15
W25N-03-03-005
1234-
Scraper㩷 O-Ring㩷 Socket bolt㩷 Cover㩷
5678-
O-Ring㩷 Socket bolt㩷 Thrust Plate㩷 Body㩷
910 11 12 -
Seal㩷 O-Ring㩷 V-Ring㩷 Shaft㩷
W3-3-6
13 - Flange㩷 14 - Plug㩷 15 - Plug㩷
BASE CARRIER / Rotating Joint Assemble Rotating Joint IMPORTANT: When installing the seals, apply grease or hydraulic oil. 1. Install V-ring (11), O-ring (10) and seals (9)(8 used) to body (8). Apply grease onto the lip part of O-ring (11), dust seal (10) and seal (9). 2. Install shaft (12) to body (8). 3. Install body (8) to shaft (12) by using a press. 4. Install thrust plate (7) with socket bolts (6) (4 used). : 8 mm : 52 to 56.8 N m (5.3 to 5.8 kgf m) (38 to 42 lbf ft) 5. Install O-ring (5) to body (8). 6. Install O-ring (2) and scraper (1) on cover (4). NOTE: Evenly tap and install scraper (1) by using special tool (B).
㱢70 or more㩷 㱢56㩷 Press㩷
7
20
7. Install cover (4) and tighten with socket bolt (6). : 8 mm : 52 to 56.8 N m (5.3 to 5.8 kgf m) (38 to 42 lbf ft)
1 Special Tool (B) W25N-03-03-006
W3-3-7
BASE CARRIER / Rotating Joint MAINTENANCE STANDARD Item Body / Shaft
Allowable limit (basis for judgment)
Sliding surface and Scored or serious damage sealed part
Remedy Replace
Sliding surface of 1) Scored or abnormal wear of more Replace body and shaft, than 0.1 mm (0.004 in) except sealed part 2) Scored less than 0.1 mm (0.004 in) Repair and finish deep with oil stone Sliding surface and 1) Wear more than 0.5 mm (0.02 in) deep Replace and abnormal wear thrust plate 2) Wear less than 0.5 mm (0.02 in) deep
Repair and finish
3) Scored or abnormal wear less than 0.5 Repair and finish mm (0.02 in) and repairable Cover
Sliding surface and 1) Wear more than 0.5 mm (0.02 in) thrust plate 2) Wear less than 0.5 mm (0.02 in) deep
Replace Repair and finish
3) Scored or abnormal wear less than 0.5 Repair and finish mm (0.02 in) and repairable
W3-3-8
BASE CARRIER / Track Take-Up Tumbler REMOVE AND INSTALL TRACK TAKE-UP TUMBLER • In this section, the procedure starts on the premise that the track shoe has already been removed.䎃As for removal and installation of track shoe, refer to the “REMOVE AND INSTALL TRACK SHOE” section on W3-6. Removal CAUTION: Track take-up tumbler weight: 226 kg (500 lb) W324-03-05-001
1. Pry the track take-up tumbler by using a pry bar.䎃 Remove the track take-up idler and bearing from the side frame.
Track Take-Up Idler
2. Attach a wire rope onto the track take-up tumbler. Hoist and remove the track take-up tumbler assembly from the side frame. 3. When storing the track take-up tumbler for a while, place the track take-up idler horizontally on the wooden blocks as illustrated. Bearing㩷
Installation
W324-03-05-002
CAUTION: Track take-up tumbler weight: 226 kg (500 lb) IMPORTANT: Check the direction of bearing.䎃Clean and apply grease onto the sliding part of side frame and bearing. 1. Hoist and install the track take-up tumbler to the side frame. W324-03-05-003
㩷 㩷
W3-4-1
BASE CARRIER / Track Take-Up Tumbler DISASSEMBLE TRACK TAKE-UP TUMBLER
1
2㩷
3
4
5
6
7
8
W25N-03-04-001
12-
Idler㩷 Bushing (2 Used)㩷
34-
Shaft㩷 Floating Seal (2 Used)㩷
56-
O-Ring (2 Used)㩷 Pin (2 Used)㩷
W3-4-2
78-
Bearing (2 Used)㩷 Plug (4 Used)㩷
BASE CARRIER / Track Take-Up Tumbler Disassemble Track Take-Up Tumbler 1. Remove plug (8) and drain off engine oil. : 6 mm 2. Remove pin (6) from bearing (7) and shaft (3) by using a bar. 3. Remove shaft (3) from bearing (7) by using a press.䎃Shaft (3) and bearing (7) are removed from track take-up idler (1). IMPORTANT: For handling floating seal (4), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3. 4. Remove floating seal (4) from track take-up idler (1) and bearing (7). 5. Remove shaft (3) from bearing (7) by using a press. 6. Remove O-ring (5) from shaft (3). 7. Remove bushing (2) from track take-up idler (1).
W3-4-3
BASE CARRIER / Track Take-Up Tumbler ASSEMBLE TRACK TAKE-UP TUMBLER
1
2㩷
3
4
5
6
7
8
W25N-03-04-001
12-
Idler㩷 Bushing (2 Used)㩷
34-
Shaft㩷 Floating Seal (2 Used)㩷
56-
O-Ring (2 Used)㩷 Pin (2 Used)㩷
W3-4-4
78-
Bearing (2 Used)㩷 Plug (4 Used)㩷
BASE CARRIER / Track Take-Up Tumbler Assemble Track Take-Up Tumbler 1. Install bushing (2) to track take-up idler (1). 2. Install O-ring (5) to shaft (3). Align the pin (6) holes and install shaft (3) to bearing (7).
10. Apply LOCTITE #503 to plug (8). Install plug (8) to bearing (7). : 6 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
3. Install pin (6) into bearing (7) and shaft (3). IMPORTANT: For handling floating seal (4), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3. 4. Install a pair of floating seals (4) to track take-up idler (1) and bearing (7). 5. Insert shaft (3) into track take-up idler (1) from the side where floating seal (4) was installed. Install O-ring (5) to shaft (3). 6. Install the other floating seals (4) to track take-up idler (1) and bearing (7). 7. Align the pin (6) holes and install bearing (7) to shaft (3). 8. Tap pin (6) into bearing (7) and shaft (3). 9. Add engine oil through the plug (8) hole in bearing (7). Engine oil: Class CD, SAE 30 Engine oil amount: 1.4 L (1.5 US qt)
W3-4-5
BASE CARRIER / Track Take-Up Tumbler MAINTENANCE STANDARD Track Take-Up Tumbler
E
D
C
A
B
B
W25N-03-04-002
Unit : mm (in) Standard
Allowable Limit
A
56 (2.21)
-
B
27 (1.06)
-
C
20 (0.79)
-
D
730 (28.7)
709 (27.9)
E
262 (10.3)
-
Remedy
Build up and finishing
(Shaft / Bushing) Unit : mm (in) Shaft Bushing
Standard
Allowable Limit
Outer Dia.
120 (4.72)
118 (4.65)
Inner Dia.
120 (4.72)
121 (4.76)
6 (0.24)
-
Flange Thickness
W3-4-6
Remedy
Replace
BASE CARRIER / Track Take-Up Tumbler Travel Drive Sprocket
D
A
B C
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 • Remove the upper roller on the level, solid
1
ground. • Before removal of the upper roller, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, removal is easy.
2
Removal 1. Remove bolt (1). Remove cover (2) from the side frame. : 19 mm 2
1 W25N-03-05-001
2. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension.
4
3
When extending jack
When releasing jack
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7). : 24 mm
5
W25N-03-05-012㩷
6
7
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. 5. Remove bolt (9). : 19 mm
Crawler Shoe
8
CAUTION: Upper roller (8) weight: 22.6 kg (50 lb) 6. Remove upper roller (8) from the side frame.
Installation 1. Install upper roller (8) to the side frame with bolt (9). : 19 mm : 110 N m (11 kgf m, 81 lbf ft)
W25N-03-05-003㩷
8
9
2. Lower the track shoe and adjust the tension of track shoe. NOTE: As for tension adjustment of track shoe, refer to the “Install Lower Roller” section.
W324-03-06-004
W3-5-2
BASE CARRIER / Upper and Lower Rollers (Blank)
W3-5-3
BASE CARRIER / Upper and Lower Rollers DISASSEMBLE UPPER ROLLER 1 2㩷 3 4
5 6
7
6
8 3 2 5
1 4
W25N-03-05-007
12-
Wire (2 Used)㩷 Plug (2 Used)㩷
34-
Collar (2 Used)㩷 Pivot Seal (2 Used)㩷
56-
O-Ring (2 Used)㩷 Bushing (2 Used)㩷
W3-5-4
78-
Roller㩷 Shaft
BASE CARRIER / Upper and Lower Rollers Disassemble Upper Roller 1. Remove plug (2) and drain engine oil out from the upper roller. : 5 mm 2. Remove wire (1) from collar (3) and shaft (8) by using a bar. 3. Remove shaft (8) from collar (3) by using a press. Shaft (8) and collar (3) are removed from roller (7). 4. Remove two pairs of pivot seal (4) from roller (7) and collar (3). 5. Remove shaft (8) from collar (3) by using a press. 6. Remove O-rings (5) (2 used) from shaft (8). 7. Remove bushings (6) (2 used) from roller (7).
W3-5-5
BASE CARRIER / Upper and Lower Rollers ASSEMBLE UPPER ROLLER
5
3
2㩷
1
7
8
6
4
W25N-03-05-008
12-
Wire (2 Used)㩷 Plug (2 Used)㩷
34-
Collar (2 Used)㩷 Pivot Seal (2 Used)㩷
56-
O-Ring (2 Used)㩷 Bushing (2 Used)㩷
W3-5-6
78-
Roller㩷 Shaft
BASE CARRIER / Upper and Lower Rollers Assemble Upper Roller 1. Install O-ring (5) to shaft (8). Install shaft (8) to collar (3). 2. Install bushings (6)(2 used) to roller (7). 3. Install a pair of pivot seal (4) to roller (7) and collar (3). 4. Install shaft (8) to roller (7) from the side where pivot seal (4) was installed. Install O-ring (5) to shaft (8). 5. Install other pair of pivot seal (4) to roller (7) and collar (3). 6. Install collar (3) to shaft (8). 7. Install wire (1) to collar (3) and shaft (8). 8. Add engine oil through the plug (2) hole in roller (7). Engine oil: Class CD, SAE 30 Engine oil amount: 40 to 45 cm3 9. Apply LOCTITE #503 to plug (2). Install plug (2) to roller (7). : 5 mm : 14.7 N m (1.5 kgf m, 10 lbf ft)
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
A
70 (2.76)
B
30 (1.18)
C
220 (8.66)
200 (7.87)
Remedy
Cladding by welding and finish or replace
(Shaft / Bushing) Unit : mm (in)
Shaft
Bushing
Standard
Allowable Limit
Outer Dia.
35 (1.38)
34.3 (1.35)
Inner Dia.
35 (1.38)
Flange Thickness
3.8 (0.15)
W3-5-8
Remedy
Replace
BASE CARRIER / Upper and Lower Rollers REMOVE AND INSTALL LOWER ROLLER • Remove the lower roller on the level, solid ground. Remove the lower roller with the upper revolving frame parallel to the track shoe. • Before removal of the lower roller, travel the machine slightly forward. In case the slack of track shoe is located at the top of the travel drive sprocket, removal is easy.
1
2
Removal 1. Remove bolt (1). Remove cover (2) from the side frame. : 19 mm 2. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension.
2
1 W25N-03-05-001
4
3
When extending jack
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7). : 24 mm 4. Remove jack (4). Operate the travel and loosen the track shoe.
When releasing jack
5
W25N-03-05-012㩷
6
7
W25N-03-05-002
W3-5-9
BASE CARRIER / Upper and Lower Rollers 5. Remove bolt (8). : 36 mm 6. Hoist the machine. Place the wooden blocks (500 mm (19.7 in) square (4 used) under lower frame. Lower Frame
CAUTION: Lower roller (10) weight: 82.7 kg (180 lb) 7. Remove lower roller (10) from the track shoe by using a pry bar. Hoist and remove lower roller (10).
10 8 Crawler Shoe
9
Installation
W24X-03-05-006
CAUTION: Lower roller (10) weight: 82.7 kg (180 lb) 1. Hoist the machine. Place the wooden blocks (500 mm (19.7 in) square (4 used) under lower frame.
10
2. Hoist and install lower roller (10) to the bottom of side frame. 3. Align the bolt holes and tighten bolt (8). : 36 mm : 950 N m (97 kgf m, 700 lbf ft) W25N-03-05-006
W3-5-10
BASE CARRIER / Upper and Lower Rollers IMPORTANT: Make the track shoe in the specified tension. 5. Install jack (4) to bracket (3) in the side frame. Make the track shoe in tension. IMPORTANT: Make the shaft of track take-up idler parallel. 6. Install shim (7) to the side frame. Insert the shim selected from group B into the clearance. 7. Install plate (6) to the side frame with bolt (5). Secure shim (7). : 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
4
3
6
Group B
5
7
When extending jack
When releasing jack
W25N-03-05-012㩷
8. Remove jack (4). 9. Install cover (2) to the side frame with bolt (1). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
1
2
2
1 W25N-03-05-001
㩷
W3-5-11
BASE CARRIER / Upper and Lower Rollers DISASSEMBLE LOWER ROLLER
1
2
3
4
5
6
7
8
W25N-03-05-009
12-
Bushing (2 Used)㩷 Roller㩷
34-
Floating Seal (2 Used)㩷 O-Ring (2 Used)㩷
56-
Shaft㩷 Collar (2 Used)㩷
W3-5-12
78-
Stopper (2 Used)㩷 Plug (2 Used)㩷
BASE CARRIER / Upper and Lower Rollers Disassemble Lower Roller 1. Remove plug (8) and drain engine oil out from the lower roller. : 6 mm 2. Remove stopper (7) from collar (6) and shaft (5) by using a bar. 3. Remove shaft (5) from collar (6) by using a press. Shaft (5) and collar (6) are removed from roller (2). IMPORTANT: For handling floating seal (3), refer to the section “Precautions for Handling Floating Seal� on page W1-1-3. 4. Remove two pairs of floating seal (3) from roller (2) and collar (6). 5. Remove shaft (5) from collar (6) by using a press. 6. Remove O-rings (4) (2 used) from shaft (5). 7. Remove bushings (1) (2 used) from roller (2).
W3-5-13
BASE CARRIER / Upper and Lower Rollers ASSEMBLE LOWER ROLLER
1
2
3
4
5
6
7
8
W25N-03-05-009
12-
Bushing (2 Used)㩷 Roller㩷
34-
Floating Seal (2 Used)㩷 O-Ring (2 Used)㩷
56-
Shaft㩷 Collar (2 Used)㩷
W3-5-14
78-
Stopper (2 Used)㩷 Plug (2 Used)㩷
BASE CARRIER / Upper and Lower Rollers Assemble Lower Roller 1. Install bushings (1) (2 used) to roller (2). 2. Install O-ring (4) to shaft (5). Install shaft (5) to collar (6). IMPORTANT: For handling floating seal (3), refer to the section “Precautions for Handling Floating Seal” on page W1-1-3. 3. Install a pair of floating seal (3) to roller (2) and collar (6). 4. Insert shaft (5) to roller (2) from the side where floating seal (3) was installed. Install O-ring (4) to shaft (5). 5. Install other pair of floating seal (3) to roller (2) and collar (6). 6. Install collar (6) to shaft (5). 7. Add engine oil through the plug (8) hole in collar (6). Engine oil: Class CD, SAE 30 Engine oil amount: 250 cm3 8. Apply LOCTITE #503 to plug (8). Install plug (8) on collar (6). : 6 mm : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
W3-5-15
BASE CARRIER / Upper and Lower Rollers MAINTENANCE STANDARD Lower Roller
B
A
B
C
D
W25N-03-05-011
Unit : mm (in) Standard
Allowable Limit
A
60 (2.36)
B
75 (2.94)
C
20 (0.79)
12 (0.47)
D
270 (10.6)
255 (10.0)
Remedy
Cladding by welding and finish or replace
(Shaft / Bushing) Unit : mm (in)
Shaft
Bushing
Standard
Allowable Limit
Outer Dia.
70 (2.76)
69.3 (2.73)
Inner Dia.
70 (2.76)
Flange Thickness
4.5 (0.18)
W3-5-16
Remedy
Replace
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. Remove bolt (1). Remove cover (2) from the side frame. : 19 mm 2. Install jack (4) to bracket (3) in the side frame. Make track shoe (8) in tension.
1 W25N-03-05-001
4
3
When extending jack
3. Remove bolt (5) from the side frame. Remove plate (6). Remove all shims (7). 4. Remove jack (4). 5. Remove bolt (9) and nut (10) from track shoe (8). : 30 mm
When releasing jack
5
W25N-03-05-012
6
7
6. Place the wooden block under track shoe (8). Secure track shoe (8). Remove joint pin (11) from track shoe (8) by using a bar.
W25N-03-05-002
8 9 10 11
W333-03-07-001
W3-6-1
BASE CARRIER / Track Shoe 7. Operate the travel lever into the reverse position slowly. Extend track shoe (8). CAUTION: Track shoe weight: 3550 kg (7826 lb) 8. Hoist the machine and place wooden block (2 used) under the lower frame. 9. Remove track shoe (8).
W2BC-03-06-003
850 mm
Wooden Block W2BC-03-06-004
8
W324-03-05-001
W3-6-2
BASE CARRIER / Track Shoe Installation IMPORTANT: Check the direction of track shoe. 1. Hoist the machine and place wooden block (2 used) under the lower frame. 2. Install track shoe (8) under the machine so that the travel drive sprocket can mesh with the end of track shoe (8). 3. Hoist and mesh track shoe (8) with the travel drive sprocket.
4. Operate the travel lever for the track shoe (8) to be installed in the forward direction. Turn the travel drive sprocket and roll up track shoe (8).
W2BC-03-06-003
850 mm
Wooden Block W2BC-03-06-004
8
W2BC-03-06-005
8
Drive Tumbler Side㊡
Take-Up Tumbler Side
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 9
CAUTION: When aligning the joint pin (11) hole, do not insert the fingers into the hole. 6. Align the joint pin (11) hole on track shoe (8) and install joint pin (11).
10 11
7. Install bolt (9) and nut (10) to joint pin (11). : 30 mm : 550 N m (56 kgf m, 410 lbf ft)
W333-03-07-001
8. Weld bolt (9) and nut (10). IMPORTANT: Make track shoe (8) in the specified tension. 9. Install jack (4) to bracket (3) in side frame. Make track shoe (8) in tension. IMPORTANT: Make the shaft of track take-up idler parallel. 10. Install shim (7) to the side frame. Insert the shim selected from group B into the clearance. 11. Remove jack (4). 12. Install cover (2) onto the side frame with bolt (1). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
4
Group B㩷
3
6
5
7
When extending jack
When releasing jack
W25N-03-05-012
1
2
2
1 W25N-03-05-001
W3-6-4
BASE CARRIER / Track Shoe MAINTENANCE STANDARD Shoe
W2BC-03-06-001
Standard
Allowable Limit
A
80 (3.15)
B
26 (1.02)
C
50 (1.97)
D
15 (0.59)
E
60 (2.36)
47 (1.85)
F
142 (5.59)
G
73 (2.87)
H
39 (1.54)
I
18.5 (0.73)
W2BC-03-06-002
Unit: mm (in) Remedy
Cladding by welding and hand finishing, or replace
Joint Pin
A
B
Standard
Allowable Limit
A
38 (1.50)
34 (1.34)
B
311 (12.2)
W3-6-5
W324-03-07-004
Unit: mm (in) Remedy Replace
BASE CARRIER / Track Shoe (Blank)
W3-6-6
BASE CARRIER / Cylinder REMOVE AND CYLINDER
INSTALL
RETRACT
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame with parallel to the track shoe. Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order 1 to cool before starting any work. Removal 1. Remove sidewalk (1) (6 used) in the upper structure. 1
CAUTION: Upper Revolving Frame weight : Approx. 18 t (39683 lb)
W2BC-03-06-003
2. Hoist the machine horizontally. Place the wooden blocks (500 mm (19.7 in) square) (4 used) under lower frame (8) as illustrated. (4 places on both front and rear, right and left)
Wooden Block
850 mm W2BC-03-07-001
W3-7-1
BASE CARRIER / Cylinder 3. Remove retainers (3) (4 used) and remove pins (4) (4 used). 4. Operate SIDE FRAME switch (7) to extend side frame (10, 11). 5. Remove bolts (5) (8 used) and remove bracket (6) (4 used). 7
6. Remove all pipes from the travel motor. : 19 mm, 27 mm, 50 mm NOTE: Cap the removed pipe. 7. Place the lower frame (8) onto the wooden blocks.
W2BC-03-07-005
8. Remove retainer (8) (2 used) and remove pins (9) (2 used). 10 8 11
9 8
W2BC-03-07-002
W2BC-03-07-003
5
6
5 3
W3-7-2
4
W2BC-03-07-004
BASE CARRIER / Cylinder CAUTION: Side-frame weight : 3040 kg (6742 lb) 9. Hoist and remove side-frame (10, 11)
11
10
W2BC-03-07-013
10. Stop the engine. Operate the lever several times and release the remaining pressure in the circuit.
13
11. Hold the rod side of cylinder (12) by using a sub crane.
8
12. Remove nut (13). Remove U-bolt (15) from bracket (14) in lower frame (8). : 30 mm 13. Insert the wooden block between bottoms of cylinder (12) and lower frame (8).
Wooden Block
12
15
W2BC-03-07-010
14
14. Remove all hoses from cylinder (12). Cap the removed hoses. Attach an identification tag for assembling. : 22 mm 15. Remove pin (16) from cylinder (12). CAUTION: Cylinder (4) weight: 125 kg (275 lb) 16. Pull out cylinder (12) from lower frame (8). Hoist and remove cylinder (12). 17. Remove the procedures.
other
cylinder
in
the
same
W3-7-3
12 W2BC-03-07-011
BASE CARRIER / Cylinder Installation
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame with parallel to the track shoe. Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.
W2BC-03-06-003
CAUTION: Upper Revolving Frame weight : Approx. 18 t (39683 lb) 1. Hoist the machine horizontally. Place the wooden blocks (500 mm (19.7 in) square) (4 used) under lower frame (8) as illustrated. (4 places on both front and rear, right and left)
Wooden Block
850 mm W2BC-03-07-001
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) 3. Hoist cylinder (12) by using a sub crane and insert the tube side of cylinder (12) into lower frame (8) with the port part of cylinder (12) facing forward. 4. Install cylinder (12) to bracket (17) in lower frame (8) with pin (16).
Front
12 Wooden Block㩷
5. Install all hoses to cylinder (12).
W2BC-03-07-012
22 mm 8
: 39 N m (4.0 kgf m, 28.5 lbf ft)
12
6. Make cylinder (12) parallel by using a sub crane. Install U-bolt (15) to bracket (14) in lower frame (8) and support cylinder (12). : 30 mm : 170 N m (17 kgf m, 125 lbf ft)
W2BC-03-07-011
13 8
7. Install the other cylinder in the same procedures.
Wooden Block
12
15
14
W2BC-03-07-010
CAUTION: Side-frame weight : 3040 kg (6742 lb) 8. Hoist and install side-frame (10, 11)
11
10
W2BC-03-07-013
W3-7-5
BASE CARRIER / Cylinder 9. Install pins (9) (2 used) with retainers (8) (2 used). 10. Operate SIDE FRAME switch (7) to retract side-frame (10, 11). 11. Install all pipes to the travel motor. 12. Install bracket (6) (4 used) with bolts (5) (8 used). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
7
13. Install pins (4) (4 used) with retainers (3) (4 used). W2BC-03-07-005
10 8 11
9 8
W2BC-03-07-002
W2BC-03-07-003
5
6
5 3
W3-7-6
4
W2BC-03-07-004
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 9
8
4
7 3
6 5 2 1
W25N-03-07-007
123456-
Grease Fitting (3 Used)㩷 Piston Rod㩷 Boot Band㩷 Boot㩷 Boot Band㩷 Retaining Ring㩷
78910 11 12 -
Dust Wiper㩷 Cylinder Head㩷 Bushing㩷 Backup Ring㩷 Rod Seal㩷 O-Ring㩷
13 14 15 16 17 -
W3-7-8
Backup Ring㩷 O-Ring㩷 Backup Ring (2 Used)㩷 O-Ring㩷 Piston㩷
18 19 20 21 22 -
Wear Ring (2 Used)㩷 Piston Seal㩷 Set Screw㩷 Piston Nut㩷 Cylinder Tube㩷
BASE CARRIER / Cylinder Disassemble Cylinder
CAUTION: Cylinder weight: 125 kg (275 lb) 1. Hoist and secure the cylinder horizontally. Drain hydraulic oil out from the cylinder. 2. Loosen boot bands (3, 5). 3. Pull out piston rod (2) approximately 200 to 300 mm (7.87 to 11.8 in). Remove the cylinder head (8) assembly from cylinder tube (22). 4. Remove piston rod (2) from cylinder tube (22) straightly in order not to damage the sliding surface. 5. Secure piston rod (2) horizontally. Remove set screw (20) from piston (17). : 5 mm NOTE: Grind off the caulked part by using a grinder and remove set screw (20).
Special Tools (A, B)㊡
6. Remove piston nut (21) from piston rod (2) by using special tool (A). 7. Remove the piston (17) assembly from piston rod (2) by using special tool (B).
a
Dimension a㧌 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 9
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). 9. Remove wear rings (18) (2 used) and piston seal (19) from the outer side of piston (17). 10. Remove the cylinder head (8) assembly from piston rod (2). 11. Remove retaining ring (6), dust wiper (7), backup ring (10), rod seal (11) and bushing (9) from the inner side of cylinder head (8). 12. Remove O-rings (14, 12) and backup ring (13) from the outer side of cylinder head (8). 13. Remove boot bands (3, 5) and boot (4) from piston rod (2).
W3-7-11
BASE CARRIER / Cylinder ASSEMBLE CYLINDER
1
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
123456-
Grease Fitting (3 Used)㩷 Piston Rod㩷 Boot Band㩷 Boot㩷 Boot Band㩷 Retaining Ring㩷
78910 11 12 -
Dust Wiper㩷 Cylinder Head㩷 Bushing㩷 Backup Ring㩷 Rod Seal㩷 O-Ring㩷
13 14 15 16 17 -
W3-7-12
Backup Ring㩷 O-Ring㩷 Backup Ring (2 Used)㩷 O-Ring㩷 Piston㩷
18 19 20 21 22 -
Wear Ring (2 Used)㩷 Piston Seal㩷 Set Screw㩷 Piston Nut㩷 Cylinder Tube㩷
BASE CARRIER / Cylinder Assemble Cylinder 1. Install dust wiper (7), retaining ring (6), bushing (9), rod seal (11) and backup ring (10) to the inner side of cylinder head (8) in this order. 2. Install backup ring (13) and O-rings (12, 14) to the outer side of cylinder head (8). 3. Install piston seal (19) and wear rings (18) (2 used) to the piter side of piston (17). 4. Install O-ring (16) and backup rings (15) (2 used) to the inner side of piston (17). 5. Install boot bands (3, 5) and boot (4) to piston rod (2). 6. Install the cylinder head (8) assembly to piston rod (2). 7. Secure the piston rod (2) assembly horizontally. Install the piston (17) assembly to piston rod (2) by using special tool (B). : 1163 to 1187 N m (119 to 121 kgf m) (860 to 880 lbf ft) 8. Install piston nut (21) to piston rod (2) by using special tool (A). : 2812 to 2868 N m (285 to 295 kgf m) (2070 to 2120 lbf ft) 9. Tighten set screw (20) to piston (17). Caulk set screw (20) (3 places) by using a caulking in order not to pull out. : 5 mm : 22 to 27 N m (2.2 to 2.8 kgf m) (16 to 20 lbf ft) 10. Clamp cylinder tube (22) in a vise. Secure cylinder tube (22) horizontally.
W3-7-13
Special Tools (A, B)㩷
a
Dimension a㧦 Special Tool (A)=62mm (2.44 in) Special Tool (B)=90mm (3.54 in) W25N-03-07-008
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. 12. Tighten cylinder head (8) to cylinder tube (22). : 837 to 1023 N m (85 to 105 kgf m) (620 to 760 lbf ft) 13. Install boot (4) to piston rod (2) and cylinder tube (22) with boot bands (3, 5).
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 track shoe is located at the top of the travel drive sprocket, the track shoe can be removed easily.
W2BC-03-07-007
4
Removal 1
1. Remove bolts (1) (3 used). Remove cover (2) from the side frame. : 19 mm 2. Remove drain plug (3) from check valve (4) to drain hydraulic oil.
1 3
1
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). Secure track shoe (5). Remove joint pin (8) from track shoe (5) by using a bar.
6 7 8
W333-03-07-001
W3-7-17
BASE CARRIER / Cylinder CAUTION: Track take-up idler weight: 226 kg (500 lb)
Take-Up Tumbler
5. Pry the track take-up idler (9) by using a pry bar. Remove the track take-up idler (9) and bearing (10) from the side frame. 9
10
6. Attach a wire rope onto the track take-up idler (9). Hoist and remove the track take-up idler (9) assembly from the side frame.
Bearing
7. When storing the track take-up idler for a while, place the track take-up idler horizontally on the wooden blocks as illustrated.
W324-03-05-002
10 9
8. Remove nuts (12) (4 used) and remove yoke (11). : 65 mm 9. Remove hose (15) from adapter (16). : 19 mm 10. Remove adapter (16) from track adjustment cylinder (17). : 24 mm 11. Remove bolts (14) (4 used) from plate (13) (2 used) and remove plate (13) (2 used). : 24 mm
Wooden Block
9
11
W324-03-05-003
12
13
15
CAUTION: Take-up cylinder weight : 71 kg (157 lb)
14
16
12. Remove track adjustment cylinder (7).
17
12
13
14
W2BC-03-07-007
W3-7-18
11
12
13
14
W2BC-03-07-009
BASE CARRIER / Cylinder • Remove and install the track shoe in the right 9
procedures safely.
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 track shoe is located at the top of the travel drive sprocket, the track shoe can be removed easily.
16
Installation
17
12
13
14
W2BC-03-07-007
CAUTION: Take-up cylinder weight : 71 kg (157 lb)
11
12
13
14
1. Install track adjustment cylinder (17) to the side frame. 2. Install plate (13) (2 used) with bolts (14) (4 used). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft) 3. Install adapter (16) to track adjustment cylinder (17). : 24 mm 4. Install hose (15) to adapter (16). : 24 mm : 210 N m (21.5 kgf m, 155 lbf ft)
W2BC-03-07-009
Take-Up Tumbler
CAUTION: Yoke weight : 83 kg (183 lb) 5. Install yoke (11) to the side frame. 10
CAUTION: Track take-up idler weight : 226 kg (150 lb) 6. Hoist and install track take-up idler (9) to the side frame.
9
Bearing W324-03-05-002
W3-7-19
BASE CARRIER / Cylinder CAUTION: When aligning the joint pin (8) hole, do not insert the fingers into the hole. 5
7. Install bolt (6) to the track shoe and tighten nut (7). : 30 mm : 550 N m (56 kgf m, 410 lbf ft)
6 7 8
8. Install drain plug (3) to check valve (4). 9. Install cover (2) to the side frame with bolts (1) (3 used). : 19 mm : 90 N m (9.2 kgf m, 66 lbf ft)
Wooden Block W333-03-07-001
A
10. State the engine. Operate the travel lever to the front or revere direction to supply hydraulic oil to the track adjustment cylinder.
12
18
19
11. Turn nut (12) until nut (12) comes in contact with frame (A). 12. Stop the engine. Turn nut (12) by one turn clockwise. Tighten and lock nut (18) to not (12). NOTE: If nut (18) cannot be turned, loosen drain plug (3) and drain hydraulic oil a little.
W2BC-03-07-007
4
13. Apply grease onto the thread part of bolt (19). 14. Cover the thread part of bolt (19) with the heat shrinkable tube.
1 1 3
1
2
W3-7-20
15
W2BC-03-07-008
BASE CARRIER / Cylinder (Blank)
W3-7-21
BASE CARRIER / Cylinder DISASSEMBLE TRACK ADJUSTMENT CYLINDER
1 2 8 3 4 5 6
9
7
W2BD-03-07-001
1 - Bolt (4 Used)㩷 2 - Spring Washer (4 Used)㩷 3 - Retaining Ring㩷
4 - Dust Seal㩷 5 - Backup Ring㩷 㩷
6 - O-Ring㩷 7 - Cylinder Tube㩷 㩷
W3-7-22
8 - Cylinder Head㩷 9 - Piston㩷 㩷
BASE CARRIER / Cylinder Disassemble Track Adjustment Cylinder
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Cylinder weight: Approx. 71 kg (157 lb) 1. Lift the cylinder with the crane and secure it horizontally. Drain off the hydraulic oil in the cylinder. 2. Remove the bolts (1) (4 used) and washers (2) (4 used) and remove the cylinder head (8) assembly from the cylinder tube (7). : 13 mm 3. Remove the retaining ring (3) from the inside of the cylinder head (8). CAUTION: Pull out the piston rod (9) straightly not to damage the sliding surface. 4. Pull out the piston rod (9) from the cylinder tube (7). 5. Remove the dust seal (4), O-ring (6) and backup ring (5) from the inside of the cylinder tube (7).
W3-7-23
BASE CARRIER / Cylinder ASSEMBLE TRACK ADJUSTMENT CYLINDER
1
2
9
8
3
4
5
6
7
W2BC-03-07-014
1 - Bolt (4 Used)㩷 2 - Spring Washer (4 Used)㩷 3 - Retaining Ring㩷
4 - Dust Seal㩷 5 - Backup Ring㩷 㩷
6 - O-Ring㩷 7 - Cylinder Tube㩷 㩷
W3-7-24
8 - Cylinder Head㩷 9 - Piston㩷 㩷
BASE CARRIER / Cylinder Assemble Track Adjustment Cylinder 1. Apply Vaseline on the O-ring (6) and dust seal (4) and install the O-ring (6), backup ring (5) and dust seal (4) on the cylinder tube (7). IMPORTANT: Insert the piston rod (9) straightly with aligning with the center of the cylinder tube (7) not to damage the rings. 2. Apply Vaseline on the outer surface of the piston rod (9) and insert the piston rod (9) into the cylinder tube (7). 3. Install the retaining ring (3) on the inside of the cylinder head (8). 4. Install the cylinder head (8) assembly on the cylinder tube (7). 5. Install the washers (2) (4 used) and bolts (1) (4 used) on the cylinder head (8) assembly. : 13 mm
W3-7-25
BASE CARRIER / Cylinder (Blank)
W3-7-26
BASE CARRIER / Cylinder REMOVE AND INSTALL CYLINDER (OPTIONAL)
JACK-UP
CAUTION: Remove and install the cylinder on the level, solid ground. Remove and install the cylinder with the upper revolving frame vertical to the track shoe. Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Removal 2
1. Stop the engine. Operate the control lever several times and release the remaining pressure in the circuit.
3
2. Remove all hoses from cylinder (4). Cap the removed hoses. Attach an identification tag for assembling. : 22 mm 4
CAUTION: Jack-up cylinder (1) weight: 312 kg (688 lb)
W2BC-03-07-006
3. Hold jack-up cylinder (1) by using a sub crane. Remove stopper pin (2) and supporting pin (3) and remove jack-up cylinder (1). : 17 mm CAUTION: Cylinder (4) weight: 103 kg (227 lb)
5 4 6
4. Place jack-up cylinder (1) horizontally. Remove bolts (5) (6 used). Remove cylinder (4) from jack beam (6). : 19 mm 5. Drain hydraulic oil out from cylinder (4). W25N-03-07-012
W3-7-27
BASE CARRIER / Cylinder 6. Remove the other jack-up cylinder (3 places) in the same procedures.
Installation CAUTION: Cylinder (4) weight: 103 kg (227 lb) 1. Insert the valve side of cylinder (4) into the bottom of jack beam (6) and install with bolts (5) (6 used). : 19 mm : 110 N m (11 kgf m, 81 lbf ft)
5 4 6
CAUTION: Jack-up cylinder (1) weight: 312 kg (688 lb) 2. Hoist and install jack-up cylinder (1) to lower frame (7) with supporting pin (3) by using a sub crane. Secure with stopper pin (2). : 17 mm : 65 N m (6.6 kgf m, 48 lbf ft) NOTE: The numbers (1 to 4) are indicated on jack-up cylinder (1) and lower frame (7). Install jack-up cylinder (1) to the position where the number is matched. The position to secure jack-up cylinder (1) is the follows (3 places). • When retracting the side frame • When disassembling / assembling the side frame while working • When transporting 3. Install all hoses to cylinder (4). : 22 mm Hose : 39 N m (4.0 kgf m, 28.5 lbf ft) Piping Joint : 29.5 N m (3.0 kgf m, 21.5 lbf ft)
W25N-03-07-012
2
3
4
W2BC-03-07-006
4. Install the other jack-up cylinder (3 places) in the same procedures.
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 1234567-
Retaining Ring㩷 Dust Seal㩷 Plate㩷 O-Ring㩷 Bushing㩷 Backup Ring㩷 Backup Ring㩷
8910 11 12 13 -
O-Ring㩷 Rod Packing㩷 Plate㩷 Clip㩷 Cylinder Head㩷 Piston Rod㩷
14 15 16 17 18 19 -
W3-7-30
Cylinder Tube㩷 Piston㩷 Backup Ring (2 Used)㩷 Piston Seal (2 Used)㩷 O-Ring㩷 Wear Ring㩷
20 21 22 23 24 25 -
Set Screw㩷 Steel Ball㩷 Plug㩷 Check Valve㩷 Bolt㩷 Spring Washer㩷
BASE CARRIER / Cylinder Disassemble Jack-Up Cylinder CAUTION: Cylinder weight: 100 kg (220 lb) 1. Remove bolt (24) from cylinder tube (14). Remove check valve (22). : 13 mm 2. Remove the cylinder head (12) assembly from cylinder tube (14). 3. Remove O-rings (4, 8) and backup ring (7) from the outer side of cylinder head (12). 4. Remove retaining ring (6), dust seal (2), clip (11), plate (10), backup ring (6), rod packing (9) and bushing (5) from the inner side of cylinder head (12). 5. Remove piston rod (13) from cylinder tube (14) straightly in order not to damage the sliding surface. 6. Secure piston rod (13) horizontally. Remove set screw (20) and steel ball (21) from piston (15). : 5 mm 7. Remove the piston (15) assembly from piston rod (13). 8. Remove O-ring (18) from piston rod (13). 9. Remove piston seals (17) (2 used), backup rings (16) (2 used) and wear ring (19) from the outer side of piston (15).
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 1234567-
Retaining Ring㩷 Dust Seal㩷 Plate㩷 O-Ring㩷 Bushing㩷 Backup Ring㩷 Backup Ring㩷
8910 11 12 13 -
O-Ring㩷 Rod Packing㩷 Plate㩷 Clip㩷 Cylinder Head㩷 Piston Rod㩷
14 15 16 17 18 19 -
W3-7-32
Cylinder Tube㩷 Piston㩷 Backup Ring (2 Used)㩷 Piston Seal (2 Used)㩷 O-Ring㩷 Wear Ring㩷
20 21 22 23 24 25 -
Set Screw㩷 Steel Ball㩷 Plug㩷 Check Valve㩷 Bolt㩷 Spring Washer㩷
BASE CARRIER / Cylinder Assemble Jack-Up Cylinder 1. Install wear ring (19), piston seals (17)(2 used) and backup rings (16) (2 used) to the outer side of piston (15). 2. Install O-ring (18) to piston rod (13). 3. Install the piston (15) assembly to piston rod (13). : 588 to 637 N m (60 to 65 kgf m) (430 to 470 lbf ft) 4. Install steel ball (21) and set screw (20) to piston (15). Caulk set screw (20) (2 places) by using a punch. : 5 mm : 17.6 to 21.6 N m (1.8 to 2.2 kgf m) (13 to 16 lbf ft) 5. Secure cylinder tube (14) horizontally. Align piston rod (13) with the center of cylinder tube (14). Insert the piston rod (13) assembly into cylinder tube (14) straightly in order not to damage the rings. 6. Install bushing (5), rod packing (9), backup ring (6), plate (10), clip (11), dust seal (2) and retaining ring (1) to the inner side of cylinder head (12). 7. Install backup ring (7) and O-rings (4, 8) to the outer side of cylinder head (12). 8. Install the cylinder head (12) assembly to cylinder tube (14). : 539 to 588 N m (55 to 60 kgf m) (400 to 430 lbf ft) 9. Install check valve (22) to cylinder tube (14) with bolt (24). : 13 mm : 19 to 21 N m (1.9 to 2.1 kgf m) (14 to 15.5 lbf ft)
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 1. Remove bolts (2) (6 used) from cover (1). : 17 mm
5
2. Remove all hoses from control valve (5). Cap the removed hoses. Attach an identification tag for assembling. : 22 mm, 27 mm W2BC-03-08-001
3. Remove bolts (3) (3 used) from control valve (5). Remove control valve (5). : 13 mm
2
1
W2BC-03-08-002
Installation 5
1. Install control valve (5) and tighten with bolts (3) (3 used). : 13 mm : 20 N m (2.0 kgf m, 15 lbf ft)
3
2. Install all hoses and harness connectors to control valve (5). : 22 mm : 39 N m (4.0 kgf m, 28.5 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) W2BC-03-08-003
IMPORTANT: After completing the work, check the oil level. Check for any oil leaks. 3. Install cover (1) and tighten with bolts (2) (bused). : 17 mm : 50 N m (5.1 kgf m, 3.7 lbf ft)
W3-8-1
BASE CARRIER / Control Valve DISASSEMBLE 6-UNIT CONTROL VALVE
23
22
22
22
22
23 18
17
19
22 23
24
20 16 3 2
21
1
4
5 15
6 14 13 12
11
10
9
8
7
W2BD-03-08-001
1234567-
Plug O-Ring Housing Plug (2 Used) O-Ring Relief Valve Seal Holder (12 Used)
8910 11 12 13 14 -
Spool (6 Used) Spool End (6 Used) Spring Cover (6 Used) Spring (6 Used) Spring Holder (12 Used) Backup Ring (12 Used) O-Ring (12 Used)
15 16 17 18 19 20 -
W3-8-2
Screw (12 Used) Lever Bracket (6 Used) Retaining Ring (12 Used) Pin (6 Used) Socket Bolt (12 Used) Spring Washer (12 Used)
21 22 23 24 25 26 -
Link Joint (6 Used) Lever (4 Used) Lever (2 Used) Knob (6 Used) Plug (4 Used) O-Ring (4 Used)
BASE CARRIER / Control Valve Disassemble 6-Unit Control Valve
• Thoroughly
read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.
CAUTION: Control valve weight: Approx. 9 kg (20 lb) 1. Place the control valve assembly on a clean workbench. 2. Remove the plug (1) from the housing (3) and drain off the hydraulic oil. 3. Remove the O-ring (2) from the plug (1).
14. Remove the socket bolts (19) (12 used) and spring washers (20) (12 used) from the housing (3). : 4 mm IMPORTANT: Check the length of the levers (22) and (23) removed from the spool (8). 15. Remove the lever brackets (16) (6 used), link joints (21) (6 used), levers (22) (4 used), levers (23) (2 used) and knobs (24) (6 used) from the housing.
4. Remove the plugs (4) (2 used) from the housing (3). : 6 mm
16. Remove the knobs (24) (6 used) from the levers (22) (4 used) and levers (23) (2 used).
5. Remove the plugs (25) (4 used) from the housing (3).
17. Remove the seal holders (7) (6 used) from the housing (3).
6. Remove the O-rings (26) (4 used) from the plugs (25) (4 used).
18. Remove the spools (8) (6 used) from the housing (3).
7. Remove the relief valve (6) from the housing (3).
19. Remove the backup rings (13) (12 used) and O-rings (14) (12 used) from the housing.
8. Remove the O-ring (5) from the relief valve (6).
9. Remove the screws (15) (12 used) from the housing (3) and remove the spring covers (10) (6 used).
10. Remove the spool ends (9) (6 used) from the spools (8) (6 used). 11. Remove the spring holders (12) (12 used) and springs (11) (6 used) from the spools (8) (6 used). 12. Remove the seal holders (7) (6 used) from the housing (3). 13. Remove the retaining rings (17) (12 used) and pins (18) (6 used) from the spools (8) (6 used).
W3-8-3
BASE CARRIER / Control Valve ASSEMBLE 6-UNIT CONTROL VALVE
23
22
22
22
22
23 18
17
19
22 23
24
20 16 3 2
21
1
4
5 15
6 14 13 12
11
10
9
8
7
W2BD-03-08-001
1234567-
Plug O-Ring Housing Plug (2 Used) O-Ring Relief Valve Seal Holder (12 Used)
8910 11 12 13 14 -
Spool (6 Used) Spool End (6 Used) Spring Cover (6 Used) Spring (6 Used) Spring Holder (12 Used) Backup Ring (12 Used) O-Ring (12 Used)
15 16 17 18 19 20 -
W3-8-4
Screw (12 Used) Lever Bracket (6 Used) Retaining Ring (12 Used) Pin (6 Used) Socket Bolt (12 Used) Spring Washer (12 Used)
21 22 23 24 25 26 -
Link Joint (6 Used) Lever (4 Used) Lever (2 Used) Knob (6 Used) Plug (4 Used) O-Ring (4 Used)
BASE CARRIER / Control Valve Assemble 6-Unit Control Valve 1. Install the O-rings (14) (12 used) and backup rings (13) (12 used) on the housing.
11. Install the O-ring (5) on the relief valve (6). 12. Install the relief valve (6) on the housing (3).
2. Install the spools (8) (6 used) on the housing (3). 3. Install the seal holders (7) (6 used) on the lever side of the housing (3).
13. Install the O-rings (26) (4 used) on the plugs (25) (4 used). 14. Install the plugs (25) (4 used) on the housing (3).
4. Install the knobs (24) (6 used) on the levers (22) (4 used) and lever (23) (2 used). IMPORTANT: Check the length of the levers (22) and (23) removed from the spool (8). 5. Install the lever brackets (16) (6 used), link joints (21) (6 used), levers (22) (4 used), levers (23) (2 used) and knobs (24) (6 used) on the housing (3). Tighten them with the socket bolts (19) (12 used) with the spring washers (20) (12 used). : 4 mm
15. Install the plugs (4) (2 used) on the housing (3). : 6 mm 16. Install the O-ring (2) on the plug (1). 17. Install the plug (1) on the housing (3).
6. Install the levers (22) (4 used) and levers (23) (2 used) on the spools (8) (6 used) with the pins (18) (6 used) and retaining rings (17) (12 used). 7. Install the seal holders (7) (6 used) on the spring side of the housing (3). 8. Install the spring holders (12) (12 used) and springs (11) (6 used) on the spools (8) (6 used). 9. Install the spool ends (9) (6 used) on the spools (8) (6 used). 10. Install the spring covers (10) (6 used) on the housing with the screws (15) (12 used).
W3-8-5
BASE CARRIER / Control Valve
W3-8-6
SECTION 1
GENERAL —CONTENTS— Group 1 Specifications Specifications........................................................... (Refer to Link-Belt Technical Data Manual.)
Group 2 Component Layout Main Components ........................................ T1-2-1 Electric Component Layout .......................... T1-2-4
Group 3 Component Specifications Engine .......................................................... T1-3-1 Engine Accessories ...................................... T1-3-4 Hydraulic Equipment .................................... T1-3-5 Filters ............................................................ T1-3-9 Electrical Parts.............................................. T1-3-9 Lighting ....................................................... T1-3-10
2BCT-1-1
(Blank)
2BCT-1-2
GENERAL / Component Layout MAIN COMPONENT LAYOUT 1
Upper Structure
3
2
4
5
6
7 8 9 10
33 (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 19
(Under Cab Back)㩷
25
20
T2BC-01-02-010
24 1234-
Fuel Tank㩷 Boom Derricking Drum㩷 Slewing Control Valve㩷 Derricking Drum Lock Valve㩷 5 - 4-Spool Control Valve㩷 6-
Hydraulic Oil Tank㩷 7 - Drain Filter㩷 89-
Pilot Filter㩷 Gate Lock Valve㩷
10 11 12 13 -
21
23 22
Pump Mechanism㩷 1 Third Drum Control Valve* 㩷 Engine㩷 Pressure Compensator㩷
14 - Fourth Drum Brake Release Solenoid Valve (Optional)㩷 15 - Rear Drum Brake Release Solenoid Valve㩷 16 - Front Drum Brake Release Solenoid Valve㩷 17 - Radiator㩷 㩷
18 19 20 21 -
Oil Cooler㩷 Intercooler㩷 Battery㩷 Slewing Mechanism㩷
22 - Front Drum Brake Pedal Unit㩷 23 - Fourth Drum Brake Pedal Unit (Optional)㩷 24 - Rear Drum Brake Pedal Unit㩷 25 - Front Drum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
26 27 28 29 -
Shuttle Valve㩷 Front Control Valve㩷 1 Rear Control Valve* 㩷 Rear Drum㩷
30 - Slewing Remote Control Pressure Detection Valve㩷 31 - 4-Spool Solenoid Valve Unit㩷 32 - Fourth Drum (Optional)㩷 33 - Accumulator㩷 㩷
GENERAL / Component Layout
Base Carrier 1 2
8
3 4 5 6
13
7 8 12 9 11 Rear㩷
Left㩷
3
T2BC-01-02-001
7
Right㩷
Front㩷
10 6 1-
Slewing Bearing㩷
Retract Cylinder㩷
Take-Up Cylinder* (2 Used) (Optional)㩷 7 - Front Idler (2 Used)㩷
Jack-Up Cylinder (4 Used) (Optional)㩷 9 - Lower Control Valve (Optional)㩷 10 - Upper Roller (4 Used)㩷
Crawler Shoe㩷
㩷
㩷
2-
Center Joint㩷
34-
56-
Lower Frame㩷
8-
1
̪1㧦Installed in the side frame.
T1-2-2
11 - Lower Roller (20 Used)㩷 12 - Side Frame㩷 13 - Travel Mechanism (2 Used)㩷 㩷
GENERAL / Component Layout Cab Inside
1
2
3
4
5
6
7
8
10
9
11
13
12
T2BC-01-02-003
T2BC-01-02-002
12-
Front Drum Brake Pedal㩷 Fourth Drum Brake Pedal (Optional)㩷 3 - Rear Drum Brake Pedal㩷
56-
Front Drum Lever㩷 Rear Drum Lever㩷
7-
Boom Derricking Drum Lever㩷
4-
㩷
Accelerator pedal㩷
89-
Lock Lever㩷 Third/Fourth Drum Lever (Optional)㩷 10 - Left Travel Lever㩷
11 - Right Travel Lever㩷 12 - Slewing Lock Pedal㩷
㩷
㩷
T1-2-3
13 - Slewing Lever㩷
GENERAL / Component Layout ELECTRICAL COMPONENT LAYOUT
Solenoid Valve for Counterweight/Quick Draw / Retract (Refer to Counterweight/Quick Draw㩷 /㩷 Retract Control Valves.)㩷
Upperstructure 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) (Refer to Slewing Remote Control Pressure Sensor Block.)㩷
Around Drum㩷 (Refer to Drum.)
Around Engine (Refer to Engine.)㩷
4 Around Control Valve (Refer to Front / Rear Control Valves.)㩷
5 6
Around Battery㩷 (Refer to Batteries.)㩷 Inside Cab (Refer to Cab Inside Overall.)㩷
(Under Cab) Around Brake Pedal (Refer to Brake Pedal Unit.)㩷
1-
Oil Temperature Sensor㩷
23-
T2BC-01-02-013
4-
7 - Fuel Sensor㩷
EC Motor㩷
Fourth Drum Brake Release Solenoid Valve (Optional)㩷 5 - Rear Drum Brake Release Solenoid Valve
Air Filter Restriction Switch㩷
6-
8 - Derricking Rotation Detection Switch㩷 㩷
Front Drum Brake Release Solenoid Valve
T1-2-4
GENERAL / Component Layout 1
2
1
3
4
T2BC-01-02-004㩷
1-
Operation Stop Switch㩷
2-
Working Light (Right)㩷
3-
T1-2-5
Working Light (Left)㩷
4-
Slewing Alarm Lamp㩷
GENERAL / Component Layout Cab Inside Overall
Monitor Panel (Refer to Monitor Panel.)㩷
13 1 12
2 3 4
Brake Mode Display Panel㩷 (Refer to Brake Mode Panel.)㩷
8
Travel Lever
5 6
11
(Inside Cover)
10
7
9
T2BC-01-02-003
Left Control panel㩷 (Refer to Control Panel.) Right Control Panel㩷 (Refer to Control Panel.)㩷 T2BC-01-02-006
Side Overhead Panel (Refer to Overhead Panel.)㩷
14
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
12-
Accelerator pedal㩷
Front Drum Rotation Sensing㩷 3 - Rear Drum Rotation Sensing㩷 4 - Boom Derricking Drum Rotation Sensing㩷
5-
Front Drum Brake Mode Selection Switch㩷 6 - Lock Valve Limit Switch㩷
10 - Slewing Brake Switch㩷
14 - Antenna㩷
7-
11 - Accelerator grip㩷
15 - Air Conditioner Control Panel㩷 㩷
Rear Drum Brake Mode Selection Switch㩷 8 - Fourth Drum Brake Mode Selection Switch㩷
9-
Horn Switch㩷
12 - Moment Limiter Control Panel㩷
T1-2-6
13 - Moment Limiter㩷
GENERAL / Component Layout Monitor Panel
1 15
14 13
2
12 11 10
9
3
8 7
6 4 5
T2BC-01-02-007
1-
Coolant Temperature Gauge㩷 2 - Fuel Gauge㩷
5-
Cigarette Lighter㩷
9-
6-
Overheat Indicator㩷
3-
Hour Meter㩷
7-
10 - Engine Oil Filter Restriction Indicator㩷 11 - Alternator Indicator㩷
14 - Engine Oil Pressure Indicator㩷 15 - Pilot Pressure Indicator㩷
4-
Key Switch㩷
12 - Coolant Level Indicator㩷
㩷
Controller Failure Indicator㩷 8 - Air Filter Restriction Indicator㩷
T1-2-7
Glow Signal㩷
13 - Brake Unapplied Indicator㩷
GENERAL / Component Layout Control Panel
• Left Control Panel 1
2
3
4
5
7
6
8
9
T2BC-01-02-008
12
10
11
• Right Control Panel
T2BC-01-02-009
13 1-
Auto Stop Override Key Switch㩷 2 - Auto Stop Release Derricking Switch㩷 3 - Auto Stop Release Third/Fourth Drum Switch㩷 4 - Auto Stop Release Rear Drum Switch㩷
5-
14
Auto Stop Release Front Drum Switch㩷 6 - Brake Mode Select Key Switch㩷 7 - Remote Control Pressure Restoration Switch㩷 8 - Side Frame Extend/Retract Switch㩷
9-
15
16
Reeving Winch Switch㩷
13 - Accelerator Lock Switch㩷
10 - Quick Draw Extend/Retract Switch㩷 11 - Third/Fourth Drum Selection Switch㩷 12 - Counterweight/Jack-Up Switch (Optional)㩷
14 - Front Drum Lock Switch㩷
T1-2-8
15 - Rear Drum Lock Switch㩷 16 - Fourth Drum Lock (Optional)㩷
GENERAL / Component Layout Overhead Panel
• Rear Overhead Panel 1
2
4
3
5
6
7
T2BC-01-02-011
• Side Overhead Panel 9
8
10
11
12
T2BC-01-02-012
1-
FM/AM Radio㩷
4-
(Auxiliary)㩷
7-
2-
Working Light Switch㩷
5-
Electric Power socket㩷
3-
Drum Light Switch (Optional)㩷
6-
Front Wiper / Washer Switch㩷
Overhead Wiper / Washer Switch㩷 8 - Emergency Engine Stop Switch㩷 9 - Slow Speed Lock Switch㩷
10 - Hydraulic Tagline Switch (Optional)㩷 11 - Drum rotation sensing SW 12 - Travel Mode Switch㩷
Brake Mode Display Panel 2
1
3
T2BC-01-02-014
6 1-
Front Drum Free Mode 3 - Rear Drum Free Mode Lamp (Red)㩷 Lamp (Red)㩷 2 - Third / Fourth Drum 4 - Front Drum Auto Brake Free Mode Lamp (Red)㩷 Mode Lamp (Green)㩷
5
4 5-
Third / Fourth Drum Auto Brake Mode Lamp (Green)㩷
㩷
T1-2-9
6㩷
Rear Drum Auto Brake Mode Lamp (Green)㩷
GENERAL / Component Layout Relay Panel 1 2 3
12345678910 -
10 9 8 7
Third Drum Lowering Stop Relay (R10)㩷 Moment Limiter Buzzer Relay (R9)㩷 Third/Fourth Drum Selection Relay Lower (R8)㩷 Slewing Alarm Relay (R1)㩷 Engine Oil Pressure Relay (R2)㩷 Engine Start Relay (R3)㩷 Horn Relay (R4)㩷 Jack Relay (R5)㩷 Motor Cutoff Relay (R6)㩷 Third/Fourth Drum Selection Relay Upper (R7)㩷
6 T2BC-01-02-015
5 4
Controller Box 12 1
11 10 9
T2BC-01-02-016
8
7
6
5
4
3
1-
Preheat Controller㩷
4-
Memory Deletion Switch㩷
7-
MC2/A
23-
ECU Lamp (Red)㩷 ECU Lamp (Yellow)㩷
56-
Troubleshooting Switch㩷 IDU
89-
MC2/B Maintenance Key Switch㩷
T1-2-10
2 10 - Emergency Engine Stop Switch㩷 11 - Fuse Box㩷 12 - IDU
GENERAL / Component Layout Brake Pedal Unit
Cab Floor㩷
T2BC-01-02-017
TBC-01-02-030
1
1-
Front Brake Depressing Pressure Sensor㩷
2
2-
Fourth Brake (Optional) Depressing Pressure Sensor㩷
* Other Brakes are installed to the same positions.
4
3
3-
Rear Brake Depressing Pressure Sensor㩷
T1-2-11
4-
Rear Brake Applied Sensing Switch㩷
GENERAL / Component Layout Engine
1
2
3
4
5
6
7
8
9
10 Machine Front㩷
Machine Rear㩷
11 Machine Rear㩷
T25N-01-02-001
13
12
㩷
Machine Front㩷
14
T25N-01-02-003
12-
Overheat Switch㩷
Coolant Temperature Sensor㩷 3 - Air Heater㩷 4 - TCV ADV Solenoid Valve㩷
5 - TCV RTD Solenoid Valve㩷
9 - Engine Oil Filter Restriction Switch㩷 6 - Engine Stop Solenoid Valve㩷 10 - Engine Oil Pressure Switch
12 - Alternator㩷
7 - TDC Sensor㩷 8 - Engine Rotation Detection Sensor㩷
14 - Rack Sensor㩷 㩷
11 - Starter㩷 㩷
13 - Timing Sensor㩷
Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com
T1-2-12
䌔2䌂䌃-01-02-023
GENERAL / Component Layout Batteries
1 2 8
7
3
6
4
10
9
5
T25N-01-02-005
㩷
Machine Right㩷
Machine Upper㩷
㩷 T2BC-01-02-020
Machine Front㩷
Machine Rear㩷
Machine Rear㩷
Machine Front㩷
Machine Left㩷
Machine Lower
1-
Engine Stop Relay㩷
4 - Battery Relay㩷
7-
Load Dump Relay㩷
23-
Alternator Relay㩷 Fusible Link㩷
5 - Heater Relay㩷 6 - Starter Relay 2㩷
8㩷
Flasher㩷
T1-2-13
9-
Receiver Drier Condenser Fan Control Pressure Switch㩷 10 - Coolant Level Switch㩷 㩷
GENERAL / Component Layout Pump Mechanism Fourth Drum Brake Cooling / Hydraulic Tagline Drive / Reeving Winch Drive Pump㩷 (Optional)㩷
Pump for Counterweight/Quick Draw / Jack-Up / Retract㩷 Pilot Pump㩷
Slewing Pump
1
2 Machine Front㩷 䌔2䌂䌃-01-02-028
3 Machine Rear㩷 1-
Power Increase Solenoid Valve㩷
2-
Displacement Angle Proportional Solenoid Valve (Main Pump)㩷
T1-2-14
3-
Displacement Angle Proportional Solenoid Valve (Slewing Pump)㩷
GENERAL / Component Layout Front / Rear Control Valve Upper Side of Control Valve 1
1
3
2* 㩷
4*1
5
6
8
7
Machine Left Machine Rear㩷 Machine Machine Right㩷 Front㩷
Rear Control Valve T2BC-01-02-018
Front Control Valve㩷
Bottom Side of Control Valve Front Control Valve㩷
Rear Control Valve㩷
Machine Right Machine Rear㩷 Machine Left㩷
Machine Front㩷
T2BC-01-02-019
9*1㩷
1-
Front Drum Hoisting Proportional Solenoid Valve㩷 2 - Third Drum Hoisting Proportional Solenoid 1 Valve* 㩷 3 - Front Drum Lowering Proportional Solenoid Valve㩷 4 - Third Drum Lowering Proportional Solenoid 1 Valve* 㩷
10
11
1
12*
13
14
15
5 - Rear Drum Hoisting 9 - Third Hoisting Remote Proportional Solenoid Valve㩷 Control Pressure Sensor*1㩷 6 - Boom Derricking Drum 10 - Front Drum Hoisting Hoisting Proportional Remote Control Pressure Solenoid Valve㩷 Sensor㩷 7 - Rear Drum Lowering 11 - Front Drum Lowering Proportional Solenoid Valve㩷 Remote Control Pressure Sensor㩷 8 - Boom Derricking Drum 12 - Third Drum Lowering Lowering Proportional Remote Control Pressure 1 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
16
13 - Boom Derricking Hoisting Remote Control Pressure Sensor㩷 14 - Rear Hoisting Remote Control Pressure Sensor㩷 15 - Boom Derricking Lowering Remote Control Pressure Sensor㩷 16 - Rear Lowering Remote Control Pressure Sensor㩷
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 1-
Quick Draw Solenoid Valve (Extend)㩷 2 - Retract Solenoid Valve 1 (Extend)* 㩷 3 - Counterweight Solenoid Valve (Left/Extend)㩷 4 - Counterweight Solenoid Valve (Right/Extend)㩷
7
6
5
5-
Counterweight Solenoid Valve (Right/Retract)㩷 6 - Counterweight Solenoid Valve (Left/Retract)㩷 7 - Retract Solenoid Valve (Retract)㩷 8 - Quick Draw Solenoid Valve (Retract)㩷
*1: If the jack (optional) is installed, the lower power solenoid valve is installed here.
T1-2-16
GENERAL / Component Layout 2 Detailed Position C
Around Drum
3 1 Detailed Position B
Detailed Position A㩷
Drum Lock㩷 Motor㩷
Motor㩷
Machine Front㩷
T2BC-01-02-026
T2BC-01-02-027
Rotation Detection Sensor (One sensor is installed to the derricking drum.)㩷
Machine Rear T2BC-01-02-025
5
4
7
6
A
8
A
Machine Front㩷
A
C
C
C
Fourth Drum㩷 (Optional)㩷
Boom Derricking Drum㩷
Front Drum㩷
Rear Drum㩷
B
B
B
T2BC-01-02-024
9 1-
11
10
Motor Cutoff High Pressure 4 - Derricking Drum Rotation Solenoid Valve (Only Front Detection Switch㩷 / Rear Drums)㩷 2 - Brake Release 5 - Rear Drum Rotation Solenoid Valve㩷 Detection Switch (A)㩷 3 - Motor Displacement Angle 6 - Rear Drum Rotation Proportional Solenoid Valve㩷 Detection Switch (B)㩷
7-
Front Drum Rotation Detection Switch (A)㩷
8-
Front Drum Rotation Detection Switch (B)㩷 9 - Fourth Drum (Optional) Lock Motor㩷
T1-2-17
10 - Rear Drum Lock Motor㩷
11 - Front Drum Lock Motor㩷 㩷
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 Machine Right㩷
T25N-03-08-001
1-
Derricking Drum Unlocking Solenoid Valve㩷 2 - Slewing Brake Solenoid Valve:㩷
3 - High / Low Speed Selection Solenoid Valve㩷 4 - Second Overhoist Solenoid Valve㩷
Accumulator
Slewing Remote Control Pressure Sensor Block
Accumulator㩷
2
3
M25N-07-030
1
Slewing Remote Control Pressure Sensor Block㩷 T25N-01-02-019
1-
Primary Pilot Pressure Sensor㩷
2-
Right Slewing Remote Control Pressure Sensor㩷
T1-2-18
3-
Left Slewing Remote Control Pressure Sensor㩷
GENERAL / Component Specifications ENGINE Engine body Manufacturer ................................................................MITSUBISHI Motor Model ...........................................................................6D24-TLE2A Type..............................................................................4-cycle water-cooled in-line direct 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°
injection,
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
Link-Belt Crane Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com
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
Link-Belt Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com
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)
(82)
(590)
(HP) (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)
T1-3-3
T25N-01-03-002
GENERAL / Component Specifications ENGINE ACCESSORIES Radiator assembly Manufacturer .................................. Tokyo Radiator Type................................................ Radiator / oil cooler / intercooler in-line type Dry weight ...................................... 150 Kg (330 lb)
No. of core lines Fin pitch Fin shape Capacity Heat dissipation area Heat exchange capacity Resisting pressure Cap opening pressure
Radiator 5 4.0 Corrugated fin 8.1 L (2.14 US gal) 64.3 m2 (692.1 ft2) 452.1 × 106 J/h (108000 kcal/h) 100 kPa (1.0 kgf/cm2, psi) 49 kPa (0.5 kgf/cm2, 7.1 psi)
Oil cooler 1 3.0 Corrugated fin 4.1 L (1.1 US gal) 29.91 m2 (322 ft2) 343.3 × 106 J/h (82000 kcal/h) 1500 kPa (15.3 kgf/cm2, psi) −
Battery Type................................................ 195G51-MF (Hybrid type) Capacity ......................................... 170 Ah (20- hour rating) Voltage ........................................... 12 V Discharge current........................... 500 A (-15 °C) Duration.......................................... 4.8 minutes or longer 30-second voltage.......................... 9.4 V or more High × wide × long.......................... 257 × 222 × 508 mm (10.1 × 8.7 × 20 in) Weight ............................................ 41 kg (90 lb)
T1-3-4
Intercooler 1 5.0 Corrugated fin 12 L (3.17 US gal) 19.64 m2 (211.4 ft2) 150 × 106 J/h (35729 kcal/h) 250 kPa (2.6 kgf/cm2, psi)
GENERAL / Component Specifications HYDRAULIC EQUIPMENT Pump Mechanism Speed ratio ...................................................................Main pump (1, 2) Slewing pump Pilot pump
1.0 1.0 1.0
Main pumps (1, 2) Type..............................................................................Swash plate type variable displacement plunger pump Model ...........................................................................K5V140DTP Theoretical displacement .............................................28 to 140 cm3(1.7 to 8.5 in3)/rev Maximum oil flow rate (theoretical) ..............................280 L/min (73.9 GPM) Slewing pump Type..............................................................................Swash plate type variable displacement plunger pump Model ...........................................................................K5V80S Theoretical displacement .............................................48/80 cm3 (2.9/4.9 in3)/rev (two steps) Maximum oil flow rate (theoretical) ..............................160 L/min (42.2 GPM) Main pumps (1, 2) and slewing pump ..........................185 kg (408 lb) total Pilot pump Type..............................................................................Constant capacity type gear pump (2-spool) Model ...........................................................................SD1A3020 Theoretical displacement .............................................28.9/20.4 cm3(1.8/1.2 in3)/rev (front side / rear side) Maximum oil flow rate (theoretical) ..............................59.8/40.8 L/min (15.8/10.8 GPM) (front side/rear side) Reeving pump (hydraulic tagline / forth drum brake for cooling using combinedly) (optional) Type..............................................................................Constant gear pump Model ...........................................................................YP15A16A2H5-L Theoretical displacement .............................................15.9 cm3(1.0 in3)/rev Front control valve Type..............................................................................4-spool Model ...........................................................................MWP425S2CT758C Main relief setting .........................................................31.4 MPa (320 kgf/cm2, 4570 psi)@275 L/min (72.6 GPM) Weight ..........................................................................107 kg (235 lb) Rear control valve Type..............................................................................4-spool Model ...........................................................................MWP4253SC760B Main relief setting .........................................................31.4 MPa (320 kgf/cm2, 4570 psi)@275 L/min (72.6 GPM) Weight ..........................................................................85 kg (190 lb)
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) Lower control valve for jack-up and retract cylinder (optional) Type..............................................................................6-spool manual operation Main relief setting .........................................................19.6 MPa (200 kgf/cm2, 2850 psi)@54 L/min (14.2 GPM) Weight ..........................................................................9 kg (20 lb) Control valve for third drum (with fourth drum attached) Type..............................................................................Oil pressure pilot type Model ...........................................................................MW125T7196 Main relief setting .........................................................27.4 MPa (280 kgf/cm2, 3985 psi)@275 L/min (72.6 GPM) Weight ..........................................................................40 kg (88 lb) Slewing control valve Type..............................................................................1-spool oil pressure pilot type Model ...........................................................................MW125P5187A Main relief setting .........................................................31.9 MPa (325 kgf/cm2, 4620 psi)@155 L/min (40.9 GPM) Weight ..........................................................................38 kg (84 lb) Hoisting mechanism (front / rear) Type..............................................................................2-stage planetary gear reduction Reduction ratio .............................................................24.94 Main composition .........................................................Hoisting drum, reduction gear, hoisting motor and brake unit Weight.............................................................................. 1980 Kg (4365 lb) (front , rear) Hoisting motors (front / rear) Type..............................................................................Swash plate type variable displacement axial piston motor Model ...........................................................................M3B530BP-533/370-038B-V1 Theoretical displacement (at high / low speed) ...........370/533 cm3 (22.6/33 in3)/rev Overload relief setting ..................................................34.3MPa (350 kgf/cm2, 4990 psi)@30 L/min (7.9 GPM) Weight ..........................................................................214 kg (472 lb) Hoisting motor brakes (front / rear) Type..............................................................................Wet type spring-set Hydraulic-released multi-plate .....................................3.1 MPa (31.6 kgf/cm2, 450 psi) Hoisting brake units (front / rear) Type..............................................................................Wet type spring-set Hydraulic-released multi-plate .....................................9.8 MPa (100 kgf/cm2, 1025 psi) Boom derricking mechanism Type..............................................................................3-stage planetary gear reduction Reduction ratio .............................................................70.84 Main Composition ........................................................Derricking drum, reduction gear and derricking motor Weight ..........................................................................872 Kg (1925 lb)
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 Boom derricking motor brake Type..............................................................................Wet type spring-set Hydraulic-released multi plate......................................1.18 MPa (12 kgf/cm2, 172 psi) Slewing mechanism Type..............................................................................2-stage planetary gear reduction Reduction ratio .............................................................20.04 Main composition .........................................................Reduction gear and slewing motor Weight ..........................................................................219Ă—2 kg (483Ă—2 lb) Slewing motor Type..............................................................................Swash plate type constant displacement axial plunger motor Model ...........................................................................M5X180CHB Theoretical displacement .............................................158.9 cm3 (9.7 in3)/rev Slewing parking brake Type..............................................................................Wet type spring-set Hydraulic-released multi plate......................................3.4 MPa (35 kgf/cm2, 498 psi) Travel mechanism Type..............................................................................3-stage planetary gear reduction Reduction ratio .............................................................143.314 Main composition .........................................................Reduction gear and travel motor Weight ..........................................................................884 kg (1860 lb) Travel motors Type..............................................................................Swash plate type variable displacement axial plunger motor Model ...........................................................................MSF-230VP-15 Theoretical displacement (at high/low speed) .............130.7/228.9 cm3 (8.0/14.0 in3)/rev Overload relief seting ...................................................32.4 Mpa (330 kgf/cm2, 4710 psi) ) @40 L/min (10.6 GPM) Weight ..........................................................................100 kg (220 lb) Travel brake valve Relief valve setting .......................................................31.4 MPa (320 kgf/cm2, 4550 psi)@270 L/min (71.2 GPM) Travel parking brake Type..............................................................................Wet type spring-set Hydraulic-released multi plate......................................1.2 MPa (12 kgf/cm2, 170 psi) Reeving winch (hydraulic tagline using combinedly) (optional) Type..............................................................................NWA03F Relief valve setting .......................................................11.8 MPa (120 kgf/cm2, 1715 psi)
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) Jack-up cylinder (optional) Dia. .............................................................................Bore dia. : 125 mm (4.9 in) Rod dia. : 80 mm (3.1 in) Fully retracted length ...................................................1035 mm (40.7 in) Stroke ...........................................................................690 mm (27.2 in) Weight ..........................................................................103 kg (227 lb) Remote control valve hoisting and derricking Type..............................................................................3-spool PPC valve Model ...........................................................................TH40PC3068A Plunger stroke ..............................................................6.5 mm (0.3 in) Weight ..........................................................................13.5 kg (30 lb) Remote control valve for travel and third / fourth drum Type..............................................................................3-spool PPC valve Model ...........................................................................TH40PC3077 Plunger stroke ..............................................................3.5 mm (0.14 in) (travel) 6.5 mm (0.3 in) (third / fourth drum) Weight ..........................................................................9 kg (20 lb) Remote control valve for slewing Type..............................................................................1-spool PPC valve Model ...........................................................................TH40PC1042 Plunger stroke ..............................................................7.0 mm (0.3 in) Weight ..........................................................................4.5 kg (10 lb) Remote control valve for brake Type..............................................................................Foot-depression PPC valve Model ...........................................................................15049-0001A Plunger stroke ..............................................................13.0 mm (0.5 in) Center joint Type..............................................................................YV7224 4-spool solenoid valve for derricking drum lock, slewing brake, travel (high) and second overhoist Type..............................................................................4KWE5G-20/G24WS-420A Reducing pressure setting ...........................................4.9 Mpa (50 kgf/cm2, 712 psi) Weight ..........................................................................5.6 kg (12.3 lb) Gate lock solenoid valve Type..............................................................................CVB178-1 Relief pressure setting .................................................9.8 Mpa (100 kgf/cm2, 1425 psi)
T1-3-8
GENERAL / Component Specifications Reeving solenoid valve 1 (Hydraulic tagline using combinedly) (optional) Type .............................................................................DE6P10-208-WD24-C54 Reeving solenoid valve 2 (Hydraulic tagline using combinedly) (optional) Type .............................................................................DE6P10-208-WD24-C55 Reeving pressure gauge Type .............................................................................DMTG1 General pressure .........................................................5.9 to 11.3 Mpa (60 to 115 kgf/cm2, 860 to 1643 psi) Reeving relief valve (optional) Type .............................................................................DBDA10P-K12/200-115/25 Rated pressure ............................................................5.9 to 11.3 Mpa (60 to 115 kgf/cm2, 860 to 1643 psi) Accumulator Type .............................................................................Bladder type Model ...........................................................................Mu150-700 Capacity .......................................................................700 cm3 (42.7 in3) Weight ..........................................................................3.9 Mpa (40 kgf/cm2, 570 psi)
FILTERS Filtration grain size Return filter .............................................................. 10 μm 10 μm Line filter .................................................................. Suction filter ............................................................. 177 μm (80 meshes) Drain filter ................................................................ 10 μm
Remarks (Yamashin Industry Y-467500) (Yamashin Industry GT04L-30-15) (Yamashin Industry) (Yamashin Industry SP10-10-10)
ELECTRICAL PARTS Engine oil pressure switch Manufacturer ................................................................Mitsubishi Motors (ME049261) Operating pressure ......................................................OFF at 80±20 kPa (0.8±0.2 kgf/cm2, 11.4±2.84 psi) or less Overheat switch Manufacturer ................................................................Mitsubishi Motors (ME049264) Operating temperature.................................................101±2 °C (214±36 °F)
Link-Belt Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com www.HeavyEquipmentRestorationParts.com
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) Coolant level switch Method .........................................................................Float reed switch type Air cleaner restriction switch Manufacturer ................................................................NIPPON DONALDSON (KAX801244) Operating pressure ......................................................6.23 kPa (635 mmAq) Fuel sensor Resistance ...................................................................Idle : 90 Ω Upper limit : 10 Ω Front/rear boom derricking rotation sensor Model ...........................................................................YAMATAKE-Honeywell RL7M-8J6ND Battery relay Manufacturer 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 MITSUBISHI Motors (30890-03201) Voltage and current 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 24 V ⋅100 A Horn Manufacturer ................................................................DENSO Voltage and current ......................................................24 V ⋅1.5±0.5 A Sound pressure............................................................113±5 dB (A)/2 m Flasher Manufacturer ................................................................Niles Model ...........................................................................VF324L Voltage .........................................................................24 V
LIGHTING Side lamp Manufacturer ................................................................EVER WING (7031) Working lights Manufacturer ................................................................Night Beam (ML-B133H) Output ..........................................................................24 V ⋅ 70 W
Link-Belt Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com www.HeavyEquipmentRestorationParts.com
T1-3-10
SECTION 2
SYSTEM —CONTENTS— Group 1 Control System Outline .......................................................... T2-1-1 Engine Control ............................................. T2-1-2 Pump Control ............................................. T2-1-16 Other Control.............................................. T2-1-24
Group 2 Hydraulic System Outline .......................................................... T2-2-1 Pilot Circuit ................................................... T2-2-2 Gate Lock Circuit.......................................... T2-2-3 Main Circuit .................................................. T2-2-4 Neutral Circuit .............................................. T2-2-6 Hoisting Circuit ............................................. T2-2-7 Hoisting Brake Circuit................................. T2-2-20 Boom Derricking Circuit ............................. T2-2-29 Travel Circuit .............................................. T2-2-31 Slewing Circuit ........................................... T2-2-35 Counterweight / Quick Draw Circuit ........... T2-2-37 Jack-up (Optional) / Retract Circuit............ T2-2-39 Hydraulic Tagline Circuit............................. T2-2-41 Reeving Winch Circuit (Optional)............... T2-2-42 Take-up Circuit (Optional) .......................... T2-2-43
Group 3 Electric System Outline .......................................................... T2-3-1 Power Circuit................................................ T2-3-2 Preheating Circuit......................................... T2-3-4 Engine Starting Circuit ................................ T2-3-8 Charging Circuit ......................................... T2-3-10 Accessories Circuit..................................... T2-3-12 Engine Stop Circuit..................................... T2-3-13 Surge Voltage Prevention Circuit ............... T2-3-15 Drum Lock Circuit....................................... T2-3-17 Slewing Brake Release Circuit................... T2-3-19
2BCT-2-1
(Blank)
2BCT-2-2
SYSTEM / Control System OUTLINE Two MCs (Main Controllers) (2/A and 2/B each incorporating a microcomputer), IDU (Information Display Unit), and ECU (Engine Control Unit) are used to control the machine. Signals from the engine control accelerator, engine speed sensor and various switches go to MC2/A, MC2/B or ECU in which arithmetic operation is made, to drive the solenoid valve and control the engine and the pumps. Engine Control • Engine starting speed control • Low/high idle calibration • Engine rotational speed control • High idle cutting control • Fuel injection timing control • ECU failure diagnosis control • Rack zero calibration Pump Control • Main pump displacement angle control • Main pump power increase control • Power increase pressure calibration • Full rack calibration Other Control • Slewing alarm control • Drum rotation sensing control • Pilot pressure drop warning lamp control • Winch brake mode control • Engine start interlock control • Motor cutoff pressure control • Emergency operation control • Boom derricking drum auto stop control • Front drum auto stop control • Rear drum auto stop control • Fourth drum auto stop control • Second overhoist auto stop control • Front drum surge pressure reduction control • 2-speed tower jib raise/lower flow-combining control • Warning sound output control
T2-1-1
SYSTEM / Control System ENGINE CONTROL Engine Starting Speed Control Purpose: At engine starting, the governor motor is controlled so that the engine governor lever is set to the engine starting speed (1000 min-1) position. Operation: 1. When the key switch is turned ON, low idle is calibrated, and MC2/A controls the governor motor 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 (optional) or accelerator lock switch, exceeds the engine 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 control is completed when the engine speed reaches the engine start speed position set by the accelerator 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 including the accelerator pedal.
T2-1-2
SYSTEM / Control System
Accelerator Grip Accelerator Lock Switch
Accelerator Pedal
Key Switch
MC2/A
T25N-02-01-038
Governor Motor
T2-1-3
Engine Governor Lever
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.
Low idle calibration Operation: 1. When the key switch is turned ON, the power supply of MC2/A is turned ON. Then, MC2/A reverses the governor motor until the output of the governor motor potentio sensor becomes 2.4V or less. 2. 2. After that, MC2/A turns the governor motor in normal direction, and stores the position where the output of the governor potentio sensor becomes 2.5 V as a low idle position. Whenever the key switch is turned ON, the low idle calibration is automatically done.
High idle calibration Operation: 1. When the auto stop cancellation front drum switch is turned ON after completion of basic calibration operation (refer to T4), MC2/A calibrates the above-mentioned low idle. 2. In addition, MC2/A turns the governor motor in normal direction, and stores the position where the output of the governor motor potentio sensor for upper limit of governor becomes constant (i.e., the position where the engine governor lever contacts the high idle stopper). High idle calibration is carried out at the shipment from factory, and stored in EEPROM. Therefore, the subsequent calibration is not required. However, it is needed to carry out the high idle calibration in the following cases.
• When not reaching the specified high idle speed due to the expansion of a control cable or wear of the fork end. • When replacing controller MC2/A.
T2-1-4
SYSTEM / Control System
Key Switch Accelerator Grip
Accelerator Pedal
Accelerator Lock Switch
Drum Rotation Sensing Switch
MC2/A
Governor Motor Potentio Sensor MC2/B
Governor Motor
Engine Governor Lever
Auto Stop Cancellation Front Drum Switch
Auto Stop Cancellation Rear Drum Switch
Auto Stop Cancellation Fourth Drum Switch
T25N-02-01-039
T2-1-5
SYSTEM / Control System Engine Speed Control Purpose: Engine speed is controlled by turning the accelerator grip, depressing the accelerator pedal (optional) and handling the accelerator lock switch. Operation: 1. When turning the accelerator grip, depressing the accelerator pedal, or setting the accelerator lock switch to the accelerator lock position, voltage signals are sent to MC2/A from the accelerator grip, accelerator pedal or accelerator lock switch. 2. When the accelerator lock switch is OFF, voltage signal from the accelerator control switch becomes ineffective, and voltage signals from the accelerator grip and accelerator pedal becomes effective. 3. When accelerator lock switch is ON, voltage signals 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 engine 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 Lock Switch
ON
SET
MC2/A
T25N-02-01-014
Engine Governor Lever
Governor Motor
T2-1-7
SYSTEM / Control System High Idle Cut Control Purpose: At engine high idle, engine speed is controlled to prevent engine overspeed. Operation: When the command speed of the accelerator is 1920 min-1 or more, MC2/A turns the governor motor to maintain the engine speed, sensed by the engine speed sensor, at 2100 Âą 20 min-1.
ON
Accelerator Grip Accelerator Pedal
Accelerator Lock Switch
MC2/A
Engine Speed Detection Sensor
T25N-02-01-041
Governor Motor
T2-1-8
Engine Governor Lever
SYSTEM / Control System (Blank)
T2-1-9
SYSTEM / Control System Mitsubishi 6D24-TLE2A Fuel Injection Timing Control Purpose: ECU detects engine speed, load, coolant temperature and injection timing through various sensors to set optimum fuel injection timing.
Operation: ECU receives signals from the TDC sensor, timing sensor, the rack sensor, and coolant temperature sensor. According to these signals, ECU operates the TCV ADV solenoid valve or TCV RTD solenoid valve in order to regulate engine oil pressure which is transmitted to an electronic timer for control of fuel injection timing. ECU
To MC2/A
Coolant Temperature Sensor
Timing Sensor
TCV RTD Solenoid Valve TCV ADV Solenoid Valve To Engine
From Engine
TDC Sensor Rack Sensor
T25N-02-01-001
Electronic Timer
Link-Belt Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com www.HeavyEquipmentRestorationParts.com
T2-1-10
SYSTEM / Control System Operation of TCV Solenoid Valve To Advance Fuel Injection Timing: • TCV ADV solenoid valve: ON • TCV RTD solenoid valve: Stop When port P and port A are connected, oil pressure is transmitted to an electronic timer to advance fuel injection timing.
TCV ADV Solenoid Valve TCV RTD Solenoid Valve
Port P
Port A
To Retain Fuel Injection Timing: • TCV ADV solenoid valve: Stop • TCV RTD solenoid valve: Stop Each port is blocked to retain the oil pressure in the electronic timer at a certain level, keeping the state of the electronic timer.
T25N-02-01-004
TCV RTD Solenoid Valve TCV ADV Solenoid Valve
Port A
T25N-02-01-003
TCV RTD Solenoid Valve
To Retard Fuel Injection Timing: • TCV ADV solenoid valve: Stop • TCV RTD solenoid valve: ON When port A and R port are connected, oil pressure in the electronic timer is returned to the oil pan in order to retard fuel injection timing.
Port R TCV ADV Solenoid Valve
Port A
T2-1-11
T25N-02-01-002
SYSTEM / Control System ECU Failure Diagnosis Control
TDC Sensor
Purpose: Failure of the engine is detected through various sensors connected to ECU, and its information is displayed by blinking warning lamps.
Rack Sensor
Timing Sensor
Coolant Temperature Sensor
Failure Diagnosis Switch
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 corresponding 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-
Fault location
tion (blinking
Countermeasure by ECU (backup mode)
Operation
frequency) * 0-1 * 1-2
Normal
−
Feedback error (Actual advance angle of fuel
Both timer control valves: OFF
injection timing does not follow the target advance
Timer control (fuel injection timing control): Stop
{
angle.) * 1-4
Timing sensor
Both timer control valves: OFF 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 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.
* : (1-5)
Display
Display MC2/A Input/Output monitor
MC2A_ECU1 RECEIVE
NORMAL
TMR F. B.
ERROR
RACK P. S.
NORMAL
TIMING S.
ERROR
OVER H. S.
ERROR
TMR C. V.
NORMAL
↑↓ Page selection
× Return
Item
Item RECEIVE TMR F. B. RACK P. S. TIMINGS. TDC S. OVER H. S. TMR C. V.
Signal Name ECU Timer feedback Rack sensor Timing sensor TDC sensor Coolant temperature sensor Timer control valve
Display NORMAL ERROR ******
T2-1-13
Information Normal Error Communication error
{
SYSTEM / Control System Rack Zero Calibration Purpose: Makes MC2/A store zero point of the rack sensor. Operation: 1. After completion of basic calibration operation (refer to T4), when the auto stop cancellation rear drum switch is turned ON, signal from MC2/B is input to MC2/A. 2. MC2/A drives the governor motor, and sets the engine governor lever to the low idle position. 3. Three seconds later, signal from the rack sensor is input to MC2/A via ECU. MC2/A stores the zero point of the rack sensor.
T2-1-14
SYSTEM / Control System
Drum Rotation Sensing Switch
MC2/A
ECU
Rack Sensor MC2/B
Governor Motor
Engine Governor Lever
Auto Stop Cancellation Front Drum Switch
Auto Stop Cancellation Rear Drum Switch
Auto Stop Cancellation Third / Fourth Drum Switch
T25N-02-01-035
T2-1-15
SYSTEM / Control System PUMP CONTROL Main Pump Displacement Angle Control Purpose: Controls the delivery flow of the main pump according to the rotation of the accelerator grip, and the control direction and slowdown in control direction of the hoisting motor through M/L (Moment Limiter).
9. Even if returning the accelerator grip rapidly, MC2/A needs the primary time-lag for the rotating of the accelerator grip, thus preventing cavitation in the derricking motor. (Response time to rapid returning: About two seconds)
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 according 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 accelerator grip. 5. At this time, MC2/A sends a signal to the displacement angle proportional solenoid valve according 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 (maximum) 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 accelerator grip delivery flow for five seconds (maximum). As a result, a rapid speed increase is prevented.
T2-1-16
SYSTEM / Control System
Accelerator Grip
Accelerator Lock Switch
4-Spool Solenoid Valve Unit CAN
Displacement Angle Proportional Solenoid Valve
Pilot Pump
Engine Main Pump 1
Main Pump 2
T2BC-02-01-001
T2-1-17
SYSTEM / Control System Main Pump Power Increase Control Purpose: Regulates the delivery flow of the pump according to engine speed and load for effective use of engine horsepower. Operation: 1. The engine speed sensor sends the engine speed signal to MC2/A. 2. The rack sensor sends a voltage signal of rack position to MC2/A via ECU. 3. MC2/A sends a signal according to engine speed and load to the power increase solenoid valve. 4. The power increase solenoid valve supplies the pilot pressure oil according to this signal to the regulator for the main pump, thus increasing the pump absorption horsepower. 5. As a result, the pump delivery flow increases, and working speed of the actuator increases. 6. When the output from the rack sensor reaches engine stall prevention voltage (2.515 to 3.1 V), MC2/A sends a signal to the power increase solenoid valve to minimize the pump absorption horsepower.
T2-1-18
SYSTEM / Control System
Power Increase Solenoid Valve
Pilot Pump
Engine Main Pump 1
Main Pump 2
T2BC-02-01-002
Rack Sensor
Engine Speed Sensor
T2-1-19
SYSTEM / Control System Power Increase Pressure Calibration Purpose: Makes MC2/A store the power increase output calibration data. Operation: 1. After completion of basic calibration operation (refer to T4), start the engine. 2. When turning ON the auto stop cancellation front drum switch and auto stop cancellation rear drum switch, MC2/B sends a signal to MC2/A. 3. MC2/A makes the pilot pressure drop warning lamp blink. 4. If the pilot pressure drop indicator blinks at a cycle other that the specified cycle of 0.5-second ON and 0.5-second OFF, the auto stop cancellation front drum switch and the auto stop cancellation rear drum switch are turned OFF. 5. When turning the accelerator lock switch ON and OFF, calibration can be made. 6. When selecting the power increase pressure calibration mode, MC2/A changes the power increase 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 Accelerator Lock Switch
Auto Stop Cancellation Front Drum Switch Pilot Pressure Drop Indicator
Auto Stop Cancellation Rear Drum Switch
4-Spool Solenoid Valve Unit
Power Increase Solenoid Valve
Main Pump 1
Main Pump 2
Pilot Pump
T2BC-02-01-003
Rack Sensor
Engine Speed Sensor
T2-1-21
SYSTEM / Control System Full Rack Calibration Purpose: Makes MC2/A store the power increase output and the engine speed at full rack. Operation: 1. After completion of basic calibration operation (refer to T4), start the engine. 2. When the auto stop cancellation derricking drum switch is turned ON, the signal is input from MC2/B to MC2/A. 3. MC2/A turns ON and OFF the pilot pressure drop warning lamp. 4. If the pilot pressure drop indicator blinks at a cycle other than the specified cycle of 0.5-second ON and 0.5-second OFF, the auto stop cancellation derricking drum switch is turned OFF. 5. When turning the accelerator lock switch is turned ON and OFF, calibration can be made. 6. At this time, MC2/A sends signals to the governor motor and the power increase solenoid valve to reduce the power so that the engine speed is set to high idle, and main pump delivery flow to maximum. 7. When the engine speed is 2000 min-1 or higher, and the pilot pressure drop indicator blinks at a cycle of 0.1 second ON and 0.4 second OFF, MC2/A sends a signal to the power increase solenoid 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 solenoid 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 automatically 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 Pilot Pressure Drop Indicator
4-Spool Solenoid Valve Unit
Power Increase Solenoid Valve
Governor Potentio Sensor
Main Pump 1
Main Pump 2
Pilot Pump
T2BC-02-01-004
Rack Sensor Governor motor
Engine Speed sensor
T2-1-23
SYSTEM / Control System OTHER CONTROL Slewing Alarm Control Purpose: Lights the slewing warning lamp when the slewing lever is moved. Operation: 1. When the slewing control lever is moved, MC2/A receives voltage signal from the slewing remote control pressure sensor on the side where slewing is made. 2. MC2/A excites the slewing warning lamp relay. 3. As a result, current from the battery passes through the battery relay, slewing alarm lamp relay, and flasher relay, lighting the slewing warning lamp.
T2-1-24
SYSTEM / Control System
MC2/A
From Battery
Slewing Mechanism Battery Relay
Slewing Alarm Lamp Relay
Slewing Control Valve
Slewing Alarm Lamp (Left) Slewing Lever Slewing Pump Flasher Relay Slewing Alarm Lamp (Right)
4-Spool Solenoid Valve Unit
Pilot Pump T2BC-02-01-005
T2-1-25
SYSTEM / Control System Drum Rotation Sensing System Purpose: During superfine speed mode hoist/lower operation, the operator can accurately control the hook position without directly checking the drum movement. Operation: 1. When the drum is rotated with the drum rotation sensing switch OFF, the drum rotation detection sensor sends pulse voltage signals to MC2/A. 2. During a fixed time (30 m sec) only, MC2/A delivers pulse current to the rotation sensing solenoid installed to the front, rear and derricking levers. 3. The rotation sensing solenoid causes the rods installed 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 solenoid. 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 solenoid 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㩷
Rear㩷
Derricking
Vibration
Front Drum Rotation Detection Sensor A㩷
Front Drum㩷
Rod
Rod
Rod
Front Drum Rotation Detection Sensor B
Rear Drum Rotation Detection Sensor A㩷
Front Drum Rotaion Sensing Solenoid
Rear Drum Rotaion Sensing Solenoid
Derricking Rotaion Sensing Solenoid
Rear Drum㩷
Rear Drum Rotation Detection Sensor B
Boom Derricking Drum Rotation Detection Sensor A
MC2/A
Derricking Drum㩷
Drum Rotation Sensing Switch㩷
T25N-02-01-020
T2-1-27
SYSTEM / Control System Pilot Pressure Drop Alarm Lamp Control Purpose: Tells the operator of the pilot pressure drop by lighting the pilot pressure drop alarm lamp. Operation: 1. MC2/A receives a voltage signal from the primary pilot pressure sensor. 2. When the pilot pressure reaches the set pressure of 3MPa or lower, MC2/A lights the pilot pressure drop alarm lamp.
4-Spool Solenoid Valve Unit
Accumulator Primary Pilot Pressure Sensor
Pilot Pump
Pilot Pressure Drop Alarm Lamp
From Battery
T2BC-02-01-006
T2-1-28
SYSTEM / Control System Winch Brake Control Purpose: Controls the brake for the front drum, rear drum and fourth drum optional motors. Controls the brake mode for the front and fourth drum (optional). Locks the derricking drum. Operation:
• Motor Brake Control 1. When hoisting or lowering by the front, rear or fourth (optional), MC2/A receives a voltage signal from the remote control pressure sensor in the concerned pilot circuit. 2. MC2/A actuates the brake release solenoid valve for the concerned motor. 3. As a result, pressure oil from the pilot pump flows through the pressure-reducing valve and the brake release solenoid valve to the motor brake in order to release the motor brake.
T2-1-29
SYSTEM / Control System Brake Release Solenoid Valve
Brake
Front Drum
Brake Mode Selection Key Switch
Brake Release Solenoid Valve MC2/A Brake Rear Drum
Brake Release Solenoid Valve
Brake
Fourth Drum (Optional)
Front
Rear
Remote Control Pressure Sensor
Fourth (Optional)
4-Spool Solenoid Valve Unit
Pilot Pump
T2BC-02-01-007
T2-1-30
SYSTEM / Control System • Drum Brake Mode Control (Free Mode Control) IMPORTANT: The free mode is applicable only when the brake mode selection key switch is at the free brake position. 1. With the brake mode selection key switch set to the free brake position and the tower not hoisted or lowered, when fourth is selected by using the front, rear or third / fourth drum selection switch with the brake pedal for fourth (optional) depressed and the brake mode selection key switch for the concerned drum is turned ON, MC2/A receives a switch-ON signal from the brake mode selection key switch. 2. MC2/A actuates the drum brake release solenoid valve corresponding to the brake mode selection key switch for front, rear or fourth (optional) turned ON. 3. When releasing the brake pedal, pressure oil from the pilot pump flows through the brake valve and the drum brake release solenoid valve to the drum brake, thus releasing the drum brake. 4. As a result, the drum becomes free. 5. In addition, MC2/A stops the operation of the drum brake release solenoid valve and allow hoisting and lowering. NOTE: The free mode is switched to the auto brake mode under the following conditions. • The brake mode selection key switch is set to the auto brake position. • The free mode selection switch is OFF. • The primary pilot pressure is other than high pressure 3 MPa (31 kgf/cm2) (436 psi)). • The second overhoist stop is actuated. • The hoisting remote control pressure sensor fails.
T2-1-31
SYSTEM / Control System Third / Fourth Selection switch
Front Hoisting Remote Control Pressure Sensor Front Lowering Remote Control Pressure Sensor
Second Overhoist Limit Switch
Brake Mode Selection Key Switch
Rear Hoisting Remote Control Pressure Sensor Rear Lowering Remote Control Pressure Sensor Third / Fourth Hoisting Remote Control Pressure Sensor (Optional)
Front Drum Brake Mode Selection Switch
Rear Drum Brake Mode Selection Switch
Third / Fourth Lowering Remote Control Pressure Sensor (Optional)
MC2/A Third / Fourth Drum Brake Mode Selection Switch (Optional)
Brake Pedal (Fourth) (Optional)
Third Drum (Optional)
Rear Drum
Front Drum
Brake Pedal (Rear)
Brake Release Solenoid Valve (Third) (Optional) Fourth Brake Depressing Sensor (Optional)
Rear Brake Depressing Sensor
Pilot Pump
Brake Release Solenoid Valve (Rear)
Brake Pedal (Front)
Brake Release Solenoid Valve Front Brake Depressing Sensor (Front)
T2BC-02-01-008
T2-1-32
SYSTEM / Control System • Third Drum Free Mode Control IMPORTANT: The free mode is applicable only when the brake mode selection key switch is at the free brake position. 1. When third drum is selected by using the third/ fourth drum selection switch with the brake mode selection key switch at the free brake position and
third/fourth brake mode selection switch is turned ON, MC2/A receives a switch-ON signal. 2. When operating the third drum lever to lowering, MC2/A activates the solenoid valve in third drum motor and bypasses the holding pressure to the lowering side. 3. The third drum motor becomes free and the load falls freely.
Third / Fourth Drum Selection Switch Brake Mode Selection Key Switch Third / Fourth Hoisting Remote Control Pressure Sensor
MC2/A
Third / Fourth Lowering Remote Control Pressure Sensor
Third / Fourth Brake Mode Selection Switch
4-Spool Solenoid Valve Unit Third Drum Motor
(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 receives a voltage signal from the concerned remote 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 derricking drum unlocking solenoid valve to the derricking drum lock and derricking motor bake in order to release the lock and brake.
T2-1-34
SYSTEM / Control System
Derricking Motor Brake
Derricking Drum
Derricking Drum Lock
Derricking Motor
Derricking Drum Spool
Front Control Valve Derricking Drum Lowering Proportional Solenoid Valve
Remote Control Pressure Sensor
Derricking Drum Hoisting Proportional Solenoid Valve Pump 1
4-Spool Solenoid Valve Unit
Pilot Pump Derricking Drum Unlocking Solenoid Valve
T2-1-35
T2BC-02-01-009
SYSTEM / Control System Engine Start Interlock Control Purpose: Locks the engine when engine starting will result in dangerous state.
Front Drum Brake Mode Selection Switch
Operation: 1. When MC2/A receives a signal that indicates the slewing brake switch at the brake position, and brake mode selection switch for the front, rear and third / fourth (optional) at the auto brake position, MC2/A actuates the engine starting relay.
Rear Drum Brake Mode Selection Switch
MC2/A
Third / Fourth Drum Brake Mode Selection Switch (Optional)
2. When the key switch is set to the start position, voltage signal passes through the engine starting relay, thus actuating the starter relay 1 to turn the starter motor. As a result, the engine starts.
Slewing Brake Switch
3. With the engine starting relay OFF, when the key switch is set to the start position, MC2/A lights the interlock indication lamp for five seconds.
Key Switch
Interlock Indication Lamp
Engine Starting Relay
Starter Relay 1
Starter Motor
T25N-02-01-033
T2-1-36
SYSTEM / Control System Motor Cutoff Pressure Control
Front Lowering Remote Control Pressure Sensor
Purpose: Lowers the cutoff pressures of the front and rear motors to regulate the lowering speed.
Rear Lowering Remote Control Pressure Sensor
Operation: 1. MC2/A receives a voltage signal that indicates operating pressure of either of front or rear lowering remote control pressure sensor is 0.3 MPa or more, MC2/A stops the exciting current through the motor cutoff relay.
Motor Cutoff Relay
MC2/A
From Battery
2. As a result, the motor cutoff relay is turned OFF, so that current does not flow, and the motor cutoff high pressure solenoid valve stops. 3. When the motor cutoff high pressure solenoid valve stops, the motor cutoff pressure is reduced to regulate the lowering speed.
Front Drum
Motor Cutoff High Pressure Solenoid Valve (Front)
Rear Drum
Motor Cutoff High Pressure Solenoid Valve (Rear)
T2BC-02-01-016
T2-1-37
SYSTEM / Control System Emergency Operation Control Purpose: In the failure of MC2/A, changes over the brake release solenoid valve and releases the drum motor brake by setting the emergency operation switch to ON position. Operation: 1. If signal from MC2/A is blocked against brake release solenoid valve in the failure of MC2/A internal logic circuit, the brake release solenoid valve is changed over so that pilot pressure oil acting on drum motor brake is returned to hydraulic oil tank. 2. As a result, the drum motor brake is applied suddenly during hoisting, boom hoisting or slewing. 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 terminals 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 solenoid valve (optional) Terminal E17: Slewing brake release solenoid valve 5. As a result, each motor brake release solenoid valve and derricking drum unlocking solenoid valve for front / rear / fourth (optional) drums are changed over so that pressure oil from the pilot pump is applied to the drum motor brake. 6. As a result, the drum motor brake is released so that hoisting, boom hoisting and slewing can be done in the failure of the logic circuit in MC2/A.
T2-1-38
SYSTEM / Control System
Front Motor Brake Release Solenoid Valve
Front Motor Rear Motor Brake Release Solenoid Valve
Emergency Operation Switch
Rear Motor Fourth Motor Brake Solenoid Valve (Optional)
Fourth Motor (Optional)
Boom Derricking Motor
Slewing Motor
4-Spool Solenoid Valve Unit
Pilot Pump
T2BC-02-01-022
T2-1-39
SYSTEM / Control System Boom Derricking Drum Auto Stop Control Purpose: Controls the pilot pressure by actuating the derricking drum hoisting proportional solenoid valve or the derricking drum lowering proportional solenoid valve according to overhoist prevention switch signal, IDU data and release switch signal. Operation: 1. MC2/B receives voltage signals from the overhoist prevention switch, IDU and release switch. 2. MC2/B sends a voltage signal to the derricking drum hoisting proportional solenoid valve or the derricking drum lowering proportional solenoid valve. 3. As a result, the derricking drum hoisting proportional solenoid valve or the derricking drum lowering 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 position, 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
Auto Stop Release Derricking Switch
Livemast Lower Limit Prevention
Auto Stop Release Key Switch
Boom Overhoist Prevention Tower Upper Limit Overhoist Prevention Boom Second Overhoist Prevention
Crane Relay Box
Main Hook Overhoist Prevention
Derricking Drum Hoisting Stop
Sub Hook Overhoist Prevention
Derricking Drum 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-02-01-012
T2-1-41
SYSTEM / Control System Front Drum Auto Stop Control Purpose: Controls the pilot pressure by actuating the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve according to overhoist prevention switch signal, IDU data and release switch signal. Operation: 1. MC2/B receives a voltage signal from the overhoist 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 proportional 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
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lowering Proportional Solenoid Valve
Auto Stop Release Front Drum Switch Auto Stop Release Key Switch
Boom Second Overhoist Prevention
Crane Relay Box
Main Hook Overhoist Prevention
Front Drum Hoisting Stop
Sub Hook Overhoist Prevention
Front Drum Lowering Stop Tower Relay Box
Shouldering Prevention
Main Hook Overhoist Prevention Sub Hook Overhoist Prevention
Tower Jib Second Overhoist Prevention
T2BC-02-01-013
T2-1-43
SYSTEM / Control System Rear Drum Auto Stop Control Purpose: Controls the pilot pressure by actuating the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve according to overhoist prevention switch signal, IDU data and release switch signal. Operation: 1. MC2/B receives voltage signals from the overhoist prevention switch, IDU and release switch. 2. MC2/B sends a voltage signal to the derricking drum hoisting proportional solenoid valve or the derricking drum lowering proportional solenoid valve. 3. As a result, the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional 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
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lowering Proportional Solenoid Valve Auto Stop Release Rear Drum Switch Auto Stop Release Key Switch
Tower Upper Limit Overhoist Prevention Boom Second Overhoist Prevention
Crane Relay Box
Main Hook Overhoist Prevention
Rear Drum Hoisting Stop
Sub Hook Overhoist Prevention
Rear Drum Lowering Stop Shouldering Prevention
Tower Relay Box
Tower Breakage Prevention
Tower Jib Overhoist Prevention Tower Jib 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) Purpose: Controls the pilot pressure by actuating the fourth drum hoisting proportional solenoid valve or the fourth drum lowering proportional solenoid valve according to overhoist prevention switch signal, IDU data and release switch signal. Operation: 1. MC2/B receives voltage signals from the overhoist prevention switch, IDU and release switch. 2. MC2/B sends a voltage signal to the 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 proportional 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
Fourth Drum Hoisting Proportional Solenoid Valve
Fourth Drum Lowering Proportional Solenoid Valve
Auto Stop Release Fourth Drum Switch Auto Stop Release Key Switch
Boom Second Overhoist Prevention
Crane Relay Box
Main Hook Overhoist Prevention
Fourth Drum Hoisting Stop
Sub Hook Overhoist Prevention
Fourth Drum Lowering Stop
Shouldering Prevention
Tower Relay Box
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 Purpose: Controls the primary pilot pressure for the front, rear, third and boom raise/lower by turning ON and OFF the second overhoisting solenoid valve according to overhoist prevention switch signal and remote control pressure restoration switch signal. Operation: 1. MC2/B receives voltage signals from the overhoist prevention switch in the case of overhoisting, rope breaking or short-circuiting. 2. MC2/B turns OFF the second overhoisting solenoid 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 control 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 solenoid valve to deliver pressure oil from the pilot pump to the front, rear, fourth and boom derricking remote control valve.
T2-1-48
SYSTEM / Control System
Second Overhoist Solenoid Valve
Remote Control Pressure Restoration Switch
Boom Second Overhoist Prevention
Tower Relay Box
Tower Jib Second Overhoist Prevention
T2BC-02-01-018
T2-1-49
SYSTEM / Control System Front Drum Surge Pressure Reduction Control Purpose: Controls the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve in order to reduce the surge pressure caused at auto stop of the front drum, thus slowly reducing the remote control pressure applied to the front spool (low) in rear control valve. Operation: 1. MC2/B sends a voltage signal to the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve. 2. At auto stop of the front drum, the front drum hoisting proportional solenoid valve or the front drum lowering proportional solenoid valve delivers pressure oil from the front remote control valve to the hydraulic oil tank according to this voltage signal. As a result, the surge pressure is reduced.
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lowering Proportional solenoid Valve
Shouldering Prevention
T2BC-02-01-019
T2-1-50
SYSTEM / Control System 2-Speed Tower Jib Derricking Flow Combining Control Purpose: When the attachment is a tower, prevents 2-speed flow combining through the rear spool by using the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve. Also, slowly reduces the remote control pressure applied to the rear spool (low) in the front control valve by controlling the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve, thus reducing a surge pressure caused at auto stop of the rear drum. Operation:
• 2-Speed Flow Combining Prevention
2. The rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve delivers pressure oil from the rear remote control valve to the hydraulic oil tank according to this voltage signal. Thus, the 2-speed flow combining from the rear spool is prevented.
• Surge pressure reduction 1. MC2/B sends a voltage signal to the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve. 2. At auto stop of the rear drum, the rear drum hoisting proportional solenoid valve or the rear drum lowering proportional solenoid valve delivers pressure oil from the rear remote control valve to the hydraulic oil tank according to this voltage signal. As a result, the surge pressure is reduced.
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
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lowering Proportional Solenoid Valve
T2BC-02-01-020
T2-1-52
SYSTEM / Control System Warning Sound Output Control Purpose: Outputs the warning sound from buzzer unit according to IDU information and operating condition. Operation: 1. The voltage signal according to IDU information and operating condition is input to MC2/B. 2. MC2/B sends the output according to the voltage signal to the buzzer unit. 3. The buzzer unit selects the sound according to the output signal from MC2/B.
Buzzer Unit㩷
T2BC-02-01-021
Input Wiring
Usage
Sound
No. YB+Y9+Y22 Y8
Boom
overhoist/
Hook overhoist/ work range limit
Y22
switch
overloading
Others
Emergency bell sound (Plll㨯㨯㨯) Sound (Pipipi Pipipi㨯㨯㨯) Sound (Pirara Pirara Pirara)
T2-1-53
This Page Left Blank Intentionally
SYSTEM / Hydraulic System OUTLINE The hydraulic system consists of the pilot circuit, main circuit, A-frame raise/lower, jack-up and retract circuits, and hydraulic tag-line and reeving winch drive circuits. Pilot Circuit Hoisting Circuit (Rear, Front) Hydraulic System
Boom Derricking Circuit Jack-Up / Retract Circuit Slewing Circuit Main Circuit
Counterweight / Quick Draw Circuit
Reeving Winch Circuit (Hydraulic Tagline using cimbinedly) (Optional) Third Drum Circuit (Optional) Fourth Drum Circuit (Optional) Travel Circuit Take-Up Circuit
Pilot Circuit: Carries out spool selection in the control valve, pump control, valve control, motor control, and parking brake releasing control by using pressure oil from the pilot pump. Main Circuit: Drives each actuator by using pressure oil from pumps (1, 2), slewing pump, reeving pump and jack-up / retract pump. • Hoisting circuit: Drives the front and rear drums by using pressure oil from pumps (1, 2) in order to raise and lower the load. • Boom Derricking Circuit: Drives the boom derricking drum by using pressure oil from pumps (1, 2) in order to operate the boom derricking. • Jack-Up / Retract Circuit: Drives the jack-up cylinder or retract cylinder by using pressure oil from the jack-up / retract pump in order to jack up the machine or extend / retract the side frame. • Slewing Circuit: Drives the slewing mechanism by using pressure oil from the slewing pump in order to slew the upper structure.
• Counterweight / Quick Draw Circuit: Drives the counterweight cylinder or quick draw cylinder by using pressure oil from the jack-up / retract pump in order to remove / install the counterweight or raise / lower the load for the work assistance.
• Reeving Winch Circuit: Drives the reeving winch by using pressure oil from the reeving winch pump. In addition, the reeving winch is optional and used with the hydraulic tagline combinedly.
• Third Drum Circuit: Drives the third drum by using pressure oil from pumps (1, 2). In addition, the third drum is optional.
• Fourth Drum Circuit: Drives the fourth drum by using pressure oil from pumps (1, 2). In addition, the fourth drum is optional.
• Travel Circuit: Drives the travel mechanism by using pressure oil from pumps (1, 2) in order to travel the machine.
• Take-Up Circuit (optional): Pushes out the front idler by using the travel circuit pressure in order to give the shoe a constant tension.
T2-2-1
SYSTEM / Hydraulic System PILOT CIRCUIT The pilot circuit which pressure oil flows from the pilot pump to consists of the followings below.
Carries out delivery flow control of pump (1, 2) and slewing pump, spool selection in control valves, displacement angle control in motors and brake control of hoisting drum. NOTE: *Optional devices
Pilot pump
Accumulator
Pilot filter
Gate lock valve
Pressurereducing valve
Front motor brake release solenoid valve
Front motor
Rear motor brake release solenoid valve
Rear motor
*Fourth motor brake release solenoid valve
*Fourth motor
Regulator slewing pump Slewing pump displacement angle proportional solenoid valve
Relief valve
Regulator pump 1
Regulator pump 2
Pump displace-ment angle proportional solenoid valve Power increase solenoid valve Slewing remote control valve
Slewing control valve
Right travel remote control valve Left travel remote control valve Hydraulic tagline and reeving winch selection valve Second overhoist solenoid valve
Front control valve
Rear control valve
Front remote control valve
Front drum hoisting and lowering proportional solenoid valve
Rear control valve
Front control valve
Rear remote control valve
Rear drum hoisting and lowering proportional solenoid valve
Front control valve
Rear control valve
Derricking remote control valve
Boom derricking drum hoisting and lowering proportional solenoid valve
Front control valve
*Fourth remote control valve
*Fourth drum hoisting and lowering proportional solenoid valve
Rear control valve
High travel speed selection solenoid valve
Travel speed selection valve
Slewing brake solenoid valve
Slewing brake valve
Derricking drum unlocking solenoid valve
Derricking drum lock
T2-2-2
Brake valve (front drum)
Brake release solenoid valve (front drum)
Front drum brake
Brake valve (rear drum)
Brake release solenoid valve (rear drum)
Rear drum brake
*Brake valve (Fourth drum)
*Brake release solenoid valve (Fourth drum)
*Fourth drum brake
SYSTEM / Hydraulic System GATE LOCK CIRCUIT If the gate lock lever keeps downward (OFF position), the signal to the gate lock solenoid valve is input. As the circuit from pilot pump to hydraulic oil tank is blocked, the pilot circuit pressure keeps the pilot relief valve setting. Consequently each actuator can be operated.
If the gate lock lever keeps upward (ON position), the signal to the gate lock solenoid valve is not input. Pressure oil from the pilot pump flows to the hydraulic oil tank through the gate lock solenoid valve. Consequently pressure oil does not flow to the pilot circuit and each actuator cannot be operated. Gate lock lever: Upward (ON position)
Gate lock lever: Downward (OFF position)
Gate Lock Solenoid Valve
Gate Lock Solenoid Valve To Pilot Circuit
Pilot Pump
To Pilot Circuit
Pilot Pump
Pilot Filter
Pilot Filter
Pilot Relief Valve
Pilot Relief Valve
T2-2-3
T2BC-02-02-012
SYSTEM / Hydraulic System MAIN CIRCUIT Pressure oil from the slewing pump flows to the slewing motor. Return oil from pumps (1, 2) flows back to the hydraulic oil tank through the oil cooler. If oil temperature is low (with high viscosity), and flow resistance is large in the oil cooler, the cooler relief valve opens in order to feed the return oil directly to the hydraulic oil tank. The return oil from the slewing motor goes directly to the hydraulic oil tank. The fourth drum, tagline / reeeving pump circuit, lower control circuit and counterweight circuit are optional.
Pressure oil from main pump 1 flows to right travel motor, boom derricking motor, rear motor and front motor through the front control valve. Pressure oil from pump 2 flows to left travel motor, fourth drum motor (optional), rear motor and front motor through the rear control valve. Pressure oil from both pumps (1, 2) flows to the rear motor and front motor.
Rear Control Valve
Pump 2 Suction
Pump 1
Filter Slewing Pump
Left Travel
Travel Motor (Left)
Fourth Drum (Optional)
Fourth drum motor (Optional)
Rear (High)
Rear Motor
Front (Low)
Front Motor
Travel Right
Travel Motor (Right)
Counterweight / Quick Draw / Retract Pump㩷
Oil Tank
Front Control Valve
Hydraulic
Tagline / Reeving Winch Circuit (Optional)㩷
Cooler Relief Valve
Boom derricking㩷
Boom Derricking Motor
Rear (Low) Front (High)
Return Filter
Quick Draw Oil Cooler
Cylinder
Filter Tagline
/
Reeving
Pump Circuit Slewing
4-Spool Control Valve
Drain
Quick Draw㩷 Lower Control (Optional)㩷
Lower Control Circuit
Counterweight (Optional)㩷 Counterweight (Optional)㩷
Counterweight Circuit
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 Accumulator
4-Spool Control Valve Slewing
Slewing
Gate Lock Valve
Oil Cooler
Front Control Valve Right Travel Boom Derricking
Rear (Low) Pump 1 Counterweight / Quick Draw / Retract Pump
Front
Front (High)
Rear
Engine
Fourth Drum (Optional)
Pilot Pump
Rear Control Valve
Pump 2
Left Travel
Slewing Pump
Fourth Drum (Optional) Rear (High)
Hydraulic Oil Tank
Front (Low) Boom Derricking
Pilot Filter
Center Joint
Counterweight Cylinder Jack-up
Retract
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 When all control levers are at neutral positions, signal pressure from remote control valve does not act on each spool in the control valve. Then, pressure oil from pump 1 through the front control valve and pressure oil from pump 2 through the rear control valve return to the hydraulic oil tank through the oil cooler. Pressure oil from the slewing pump through the slew control valve returns to the hydraulic oil tank.
Front Control Valve
Rear Control Valve
Slewing Control Valve
Pump 1
Pump 2
Oil Cooler
Slewing Pump
Hydraulic Oil Tank
T2-2-6
T2BC-02-02-013
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 hydraulic tank through the front (low speed) spool. NOTE: The remote control valve is PPC valve. Although the primary pressure is constant, the secondary pressure rises according to the operating stroke of control lever PPC: Pressure Proportional Control
T2-2-7
SYSTEM / Hydraulic System Low-Speed Front Operation
Rear Motor
Front Motor
Rear Control Valve
Front Control Valve
Rear (Low Speed)
Pump 2
Front (High Speed)
Pump 1
Front Remote Control Valve (First Detent Position of Lever) 4-Spool Solenoid Valve Unit
Pilot Pump
Second Overhoist Solenoid Valve
T2-2-8
T2BC-02-02-014
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 procedures.
T2-2-9
SYSTEM / Hydraulic System High-Speed Operation Front Motor
Rear Motor
Rear Control Valve
Front Control Valve
Front (Low Speed)
Front (High Speed)
Pump 2 Pump 1
Front Remote Control Valve (Second Detent Position of Lever) 4-Spool Solenoid Valve Unit
Pilot Pump
T2BC-02-02-015
Second Overhoist Solenoid Valve
T2-2-10
SYSTEM / Hydraulic System Combined Operation Circuit The combined operation of front rear is explained here. NOTE: As pressure oil does not flow to the front motor during the combined operation of front low speed (1st gear) + rear high speed (2nd gear), the front motor does not turn. (Refer to the combined operation of front low speed (1st gear) + rear high speed (2nd gear).
• Front Low Speed (1st Gear) + Rear Low Speed (1st Gear) The front and rear remote control valves are at the first detent position. As the secondary pressure in each remote control valve is low, only low speed for front or rear in the control calve moves. (Refer to the hoisting signal operation.) Pressure oil from pump 2 flows to the front motor through the front low speed spool in rear control valve and the front drum turns. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve and the rear durum turns. The front drum and rear drum turn by using pressure oil from pump 2 and pump 1 respectively.
T2-2-11
SYSTEM / Hydraulic System Front Low-Speed Operation + Rear Low-Speed Operation Rear Drum
Front Drum
Front (Low Speed) Rear (Low Speed)
Rear Control Valve
Front Control Valve Rear (High Speed)
Pump 2
Front (High Speed)
Pump 1 Rear Remote Control Valve (First Detent Position of Lever)
Front Remote Control Valve (First Detent Position of Lever)
4-Spool Solenoid Valve Unit
Solenoid Overhoist Solenoid Valve
Pilot Pump
T2BC-02-02-022
T2-2-12
SYSTEM / Hydraulic System • Front High Speed (2nd Gear) + Rear High Speed (2nd Gear) The front and rear remote control valves are at the second detent position. As the secondary pressure in each remote control valve is high, both low and high speed for front and rear in the control valve move. (Refer to the hoisting single operation.) Pressure oil from pump 2 flows to the rear motor through the rear high speed spool in rear control valve. The return oil from rear motor flows to the front speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve. The return oil from rear motor flows to the front motor through the rear high speed or rear low speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Pressure oil from pumps (1, 2) are combined and pressure oil turns the front and rear drum at the high speed.
T2-2-13
SYSTEM / Hydraulic System Front High-Speed Operation + Rear High-Speed Operation
Rear Drum
Front Drum
Rear (Low Speed)
Rear (High Speed)
Rear Control Valve
Front Control Valve
Front (High Speed)
Front (Low Speed)
Pump 2
Pump 1 Rear Remote Control Valve (First Detent Position of Lever)
Front Remote Control Valve (First Detent Position of Lever)
4-Spool Solenoid Valve Unit
Solenoid Overhoist Solenoid Valve
Pilot Pump
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 position 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 hydraulic 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 Rear Drum
Front Drum
Front (Low Speed)
Rear (Low Speed)
Rear (High Speed)
Rear Control Valve
Front Control Valve
Pump 2
Front (High Speed)
Pump 1 Rear Remote Control Valve (Second Detent Position of Lever)
Front Remote Control Valve (Second Detent Position of Lever)
4-Spool Solenoid Valve Unit
Solenoid Overhoist Solenoid Valve
Pilot Pump
T2BC-02-02-024
T2-2-16
SYSTEM / Hydraulic System • Front High Speed (2nd Gear) + Rear Low Speed (1st Gear) The front remote control valve is at the second detent position and the rear remote control valve is at the first detent position. As the secondary pressure in front remote control valve is high, both low and high speed spools for front in control valve move. (Refer to the hoisting single operation.) Pressure oil from pump 2 flows to the front motor in the front low speed spool in rear control valve. Pressure oil from pump 1 flows to the rear motor in the rear low speed spool in front control valve. The return oil flows to the front motor through the front high speed spool. The return oil flows back to the hydraulic oil tank through the front high speed or low speed spool. Consequently the front drum turns at high speed and the rear drum turns at low speed.
T2-2-17
SYSTEM / Hydraulic System Front High-Speed Operation + Rear Low-Speed Operation Rear Drum
Front Drum
Front (Low Speed)
Rear (Low Speed)
Rear (High Speed)
Rear Control Valve
Front Control Valve
Pump 2
Front (High Speed)
Pump 1 Rear Remote Control Valve (Second Detent Position of Lever)
Front Remote Control Valve (Second Detent Position of Lever)
4-Spool Solenoid Valve Unit
Solenoid Overhoist Solenoid Valve
Pilot Pump
T2BC-02-02-033
T2-2-18
SYSTEM / Hydraulic System Fourth Motor Operation (Optional) When operating the fourth remote control valve, the secondary pressure of remote control valve moves the fourth drum spool in rear control valve. Pressure oil from pump 2 passes through the fourth drum spool and drives the fourth drum motor.
The return oil from fourth drum motor passes through the fourth drum spool and returns to the hydraulic oil tank through the third drum control valve (optional).
Fourth Drum
Fourth Drum Spool Rear Control Valve
Third Drum Control Valve (Optional) Pump 2
Third / Fourth Remote Control Valve Second Overhoist Solenoid Valve
4-Spool Solenoid Valve Unit
Pilot Pump
T2BC-02-02-020
T2-2-19
SYSTEM / Hydraulic System HOISTING BRAKE CIRCUIT Auto Brake Mode When the brake mode Selection key switch is at the auto brake mode position, pressure oil from the pilot pump is blocked by the brake release solenoid valve, avoiding flowing to the drum brake. Therefore, under this state, hydraulic oil from the drum brake is returned to the hydraulic oil tank through the brake release solenoid valve, applying the drum brake. The hoisting winch utilizes the planetary gear mechanism so that the drum rotates only when the hoisting motor is driven with the drum brake being engaged. As mentioned above, hoisting and lowering operations are done.
T2-2-20
SYSTEM / Hydraulic System
Brake Mode Selection Key Switch
Front Drum Brake Mode Switch
Rear Drum Brake Mode Switch MC2/A
Third / Forth Drum Brake Mode Selection Switch (Optional)
Fourth Drum Brake (Optional)
Rear Drum Brake
Brake Valve (Third Drum) (Optional)
Front Drum Brake
Fourth Drum (Optional)
Rear Drum
Front Drum
Brake Release Solenoid Valve (Fourth Drum) (Optional)
Brake Valve (Rear Drum)
Brake Release Solenoid Valve (Rear Drum) Brake Valve (Front Drum)
Brake Release Solenoid Valve (Front Drum) 4-Spool Solenoid Valve Unit
Pilot Pump
T2BC-02-02-016
T2-2-21
SYSTEM / Hydraulic System Free Mode With brake mode selection key switch at ON position, when the front, rear or fourth (optional) drum brake mode selection switch is turned ON, a signal comes to MC2/A. MC2/A actuates the brake release solenoid valve of the turned-ON brake mode selection switch. Pressure oil from the pilot pump passes through the brake valve and the brake release solenoid valve and flows to the front, rear or fourth (optional) drum brake in order to release the brake. Therefore, the free-fall becomes possible.
T2-2-22
SYSTEM / Hydraulic System
Brake Mode Key Switch
Front Drum Free Mode Switch
Rear Drum Free Mode Switch MC2/A
Third / Fourth Drum Free Mode Switch (Optional)
Fourth Drum Brake (Optional)
Rear Drum Brake
Brake Valve (Third Drum) (Optional)
Front Drum Brake
Third Drum (Optional)
Rear Drum
Front Drum
Brake Release Solenoid Valve (Fourth Drum) (Optional)
Brake Release Solenoid Valve (Rear Drum)
Brake 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 mechanism 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 Mode Key Switch
Front Drum Free Mode Switch
Rear Drum Free Mode Switch
MC2/A
Third / Fourth Drum Free Mode Switch (Optional)
Fourth Drum Brake (Optional)
Rear Drum Brake
Brake Valve (Fourth Drum) (Optional)
Front Drum Brake
Fourth Drum (Optional)
Rear Drum
Front Drum Brake Release Solenoid Valve (Fourth Drum) (Optional)
Brake Release Solenoid Valve (Rear Drum)
4-Spool Solenoid Valve Unit
Brake Valve (Rear Drum)
Brake Valve (Front Drum)
Brake Release Solenoid Valve (Front Drum)
Pilot Pump
T2BC-02-02-018
T2-2-25
SYSTEM / Hydraulic System Auto Stop Control When the front and rear are overhoisted and overloaded, the hoisting / lowering operations automatically stop. The hoisting operation of front motor is explained here. The lowering operation and that of rear motor are same. When the front hoisting operation is overhoisted or overloaded, MC2/B receives a signal from the overhoist switch or IDU. MC2/B stops the operation of the hoisting proportional solenoid valve that is provided in the circuit between remote control valve spool and control valve spool. The hoisting proportional solenoid valve blocks the secondary pressure from remote control pressure and returns the control valve spool to neutral position in order to stop the hoisting.
T2-2-26
SYSTEM / Hydraulic System Normal Operation Rear Drum
Front Drum
Front (Low Speed)
Rear Control Valve
Front Control Valve
Front (High Speed)
MC2/B From Front Remote Front Drum Hoisting Control Valve Pump 1 Proportional Solenoid Valve Rear Drum
Pump 2
Auto Stop
Front Drum
Front (Low Speed)
Remote Control Valve
Front Control Valve MC2/B
Pump 2
Front Drum Hoisting Proportional Solenoid Valve
From Front Remote Control Valve Pump 1
T2-2-27
Front (High Speed)
T2BC-02-02-021
SYSTEM / Hydraulic System Derricking (Lowering) In derricking (lowering) operation, the motor is likely to be rotated forcibly by the inertial force and self weight of the lifting load. The counterbalance valve controls derricking (lowering) speed by the oil feed quantity to prevent coasting. Pressure oil from the control valve passes through Port B of the counterbalance valve, and goes to the motor. The return oil from the motor is blocked by the check valve and the counterbalance valve. (Figure 1)
When the oil feed pressure rises, the counterbalance valve spool moves to open the return oil passage from the motor. Thus, the motor turns and the return oil comes to the tank via the control valve. (Figure 2) When the load begins to lower earlier than oil amount supplied from the control valve, pressure at port B side decreases, the counterbalance valve is closed and the load stops lowering. (Figure 3) When pressure at port B increases, the counterbalance valve is open and the load begins to lower again. In this way, the load lowers at the speed in proportion to oil amount from the control valve. As pressure oil from port A through the check valve flows to the motor during the hoisting, the speed is not controlled due to the counterbalance valve.
Counterbalance valve function
Figure 1
Figure 2
Figure 3
T2BC-02-02-019
T2-2-28
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 derricking drum lock and the boom derricking motor brake through the derricking drum unlocking solenoid valve. Pressure oil from pump 1 passes through the boom derricking spool and selects the counterbalance valve in boom derricking motor. When the counterbalance valve is selected, pressure oil from pump 1 drives the boom derricking motor.
Derricking Drum Lock
Boom Derricking Motor
Boom Derricking Motor Brake
Boom Derricking Motor
Counterbalance Valve
Boom Derricking Front Control Valve
Boom Derricking Remote Control Valve
Pump 1
Second Overhoist Solenoid Valve
Derricking Drum Unlocking Solenoid Valve
4-Spool Solenoid Valve Unit Pilot Pump
T2BC-02-02-025
T2-2-29
SYSTEM / Hydraulic System Auto Stop Control Circuit When the boom derricking drum is overhoisted or overloaded, MC2/B receives a signal from the overhoist switch or IDU. MC2/B stops the operation of proportional solenoid valve that is provided in the circuit between boom derricking remote control valve spool and front control valve spool. The proportional solenoid valve blocks the remote control pressure to the control valve spool, returns the control valve spool to neutral position and stops hoisting.
NOTE: While operating the with the derricking stopped, the boom derricking drum unlocking valve does not turn OFF due to pressure in the boom derricking remote control circuit (between spools of boom derricking remote control valve and front control valve.)
Boom Derricking Drum Lock
Boom Derricking
Front Control Valve
Boom Derricking Drum Hoisting Proportional Solenoid Valve 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 The delivery flow from pump 1 drives the travel motor (right), and the delivery flow from pump 2 drives the travel motor (left), releasing the parking brake. The travel motor is a variable displacement type. High speed and low speed are selected by the travel mode switch.
• Low Travel Speed When the travel mode switch is at the low speed position, electric current does not flow to the high travel speed selection solenoid valve. The pilot valve of the travel motor is not selected because the high-speed travel solenoid valve is not selected, so that pressure oil from the travel circuit of the control valve is not supplied to the tilt piston. As a result, the displacement angle of the travel motor becomes a large angle, so that the travel motor rotates at a low speed.
T2-2-31
SYSTEM / Hydraulic System Low Travel Speed Pilot Valve Tilt Piston
Pilot Valve Tilt Piston
Parking Brake
Travel Motor (Left)
Travel Motor (Right) Parking Brake
Travel (Left) Travel (Right)
Front Control Valve
Rear Control Valve
Left Travel Remote Control Valve
Pump 2
Right Travel Remote Control Valve
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 Pilot Valve
Tilt Piston
Pilot Valve
Travel Motor (Right)
Travel Motor (Left)
Parking Brake
Parking Brake
Rear Control Valve
Front Control Valve
Right Travel Remote Control Valve
Left Travel Remote Control Valve
Pump 2
Tilt Piston
Pump 1
4-Spool Solenoid Valve Unit
Pilot Pump
High Travel Speed Selection Solenoid Valve
T2-2-34
T2BC-02-02-028
SYSTEM / Hydraulic System SLEWING CIRCUIT When operating the slewing remote control valve, the spool in the slewing control valve moves, the delivery flow from the slewing pump passes through the slewing control valve, and goes to the slewing motor. The return oil from slewing motor returns to the hydraulic oil tank. In slewing operation, when the slewing motor is driven by the inertial force of the slewing frame, cavitation is caused in the motor because motor rotation is too fast, compared to the oil feed form the pump. In order to avoid this, a make-up valve is provided, sucks the oil from the return circuit and compensates the lack of oil feed. The slewing brake solenoid valve is driven by the slewing brake switch in order to release the slewing brake.
T2-2-35
SYSTEM / Hydraulic System
Slewing Brake
Make-Up Valve
Make-Up Valve
Slewing Brake
Slewing Motor
Slewing Control Valve
Slewing Pump Slewing Remote Control Valve
4-Spool Solenoid Valve Unit
Pilot Pump Slewing Brake Solenoid Valve
T2BC-02-02-029
T2-2-36
SYSTEM / Hydraulic System COUNTERWEIGHT / QUICK DRAW CIRCUIT 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 / retract pump flows into the 4-spool control valve. Pressure oil opens the sequence valve and flows to the neutral circuit. When all the spools in 4-spool control valve are in neutral, pressure oil from the pump flows into the front and rear drums in order to cool through the neutral circuit in each spool.
NOTE: The sequence valve is provided in order to keep the operating pressure for each spool in 4-spool control valve.
4-Spool Control Valve: Neutral
Front Drum
Quick Draw Cylinder
To Lower Control Valve (Optional) Quick Draw Spool
Rear Drum
Lower control Spool
Counterweight Cylinder (Left)
Counterweight Cylinder (Left) Spool
Counterweight Cylinder (Right) Spool
Counterweight Cylinder (Right)
4-Spool Control Valve Sequence Valve
Counterweight / Quick Draw / Retract Pump
T2-2-37
T2BC-02-02-031
SYSTEM / Hydraulic System 4-Spool Control Valve: Operating The operation retracting the quick draw cylinder is explained here. When turning the quick draw extend / retract switch in operator’s seat to retract, the solenoid valve (retract) in quick draw spool is operated. Pressure oil from the counterweight / quick draw / retract pump is reduced at the pressure-reducing valve and acts on the end of quick draw spool so that the spool moves. Consequently pressure oil from the counterweight / quick draw / retract pump opens the sequence valve through the quick draw spool and flows into the quick draw cylinder rod side.
This pressure oil retracts the quick draw cylinder. The return oil from cylinder returns to the hydraulic oil tank through quick draw spool.
NOTE: The Downsafety valve closes the check valve part and prevents the load from suddenly lowering when the flow rate increases abnormally due to the hose damage and so on. The downsafety valve is also installed to the counterweight cylinder.
Quick Draw Cylinder
Front Drum
Counterbalance Valve Quick Draw Spool
To Lower Control Valve (Optional)
Rear Drum Downsafety Valve Lower Control Spool
Counterweight Cylinder (Left)
Port Relief Valve Counterweight Cylinder (Left) Spool Port Relief Valve Counterweight Cylinder (Right) Spool
Counterweight Cylinder (Right)
Main Relief Valve Pressure Reducing Valve Sequence Valve
4-Spool Control Valve
Counterweight / Quick Draw Retract Pump
T2BC-02-02-032
T2-2-38
SYSTEM / Hydraulic System JACK-UP (OPTIONAL) / RETRACT CIRCUIT The operation extend the jack-up cylinder (right front) and retract cylinder (left) is explained here. The jack-up is optional. When turning the lower control switch in cab ON, the lower control valve spool in 4-spool control valve moves. Pressure oil from the pilot pump flows to the lower control valve through 4-spool control valve. When moving the control lever for jack-up (right front) and retract (right) to extend, pressure oil from the pilot pump flows to each cylinder and extends the cylinder. The maximum pressure in lower control valve circuit is regulated cy the relief valve.
T2-2-39
NOTE: The lower control valve, which is a manual control valve, is installed to the front part of track frame with the jack-up mechanism (optional) attached. The retract operation is performed cy using the side frame control switch in cab without the jack-up mechanism.
SYSTEM / Hydraulic System When Extending the Left Retract Cylinder, with Jack (Right Front) Extended Retract Cylinder Circuit Without Jack-Up
Retract Cylinder (Left)
Retract Cylinder (Right) Lower Control Valve T2BC-02-02-034
4-Spool Control Valve Retract (Left)
Quick Draw
Jack-Up Cylinder (Left Front) Jack-Up (Left Front)
Lower Control Jack-Up Cylinder (Left Rear) Jack-Up (Left Rear) Center Joint Jack-Up Cylinder (Right Rear) Jack-Up (Right Rear) Counterweight Jack-Up Cylinder (Right Front) Jack-Up (Right Front)
Pump for Counterweight / Quick Draw / Jack-Up / Retract
Retract (Right)
Relief valve
T2-2-40
T2BC-02-02-010
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 to the hydraulic oil tank after flowing through the fourth drum for cooling.
Fourth Drum
Hydraulic Oil Tank
Hydraulic Tagline Motor Reeving Winch
Hydraulic Tagline
Hydraulic Tagline / Reeving Winch Control Valve
Hydraulic Tagline / Reeving Winch Drive Pump
T2-2-41
T25N-02-02-020
SYSTEM / Hydraulic System REEVING WINCH CIRCUIT (OPTIONAL) When the reeving winch hoisting switch is turned ON, the reeving winch hoisting solenoid valve is selected by electric current from the reeving winch hoisting switch. As a result, pressure oil from the pilot pump passes through the reeving winch hoisting solenoid valve to move the spool in the hydraulic tagline / reeving winch control valve for switching. Pressure oil from the hydraulic tagline / reeving winch drive pump passes through the hydraulic tagline / reeving winch control valve, and goes to the reeving winch to move the spool in the reeving winch for switching, thus releasing the reeving winch brake and driving the reeving winch motor. The return oil from reeving winch passes through the hydraulic tagline / reeving winch control valve, flows through the fourth drum for cooling and then returns to the hydraulic oil tank.
Fourth Drum
Hydraulic Oil Tank
Hydraulic Tagline Reeving Winch Reeving Winch Brake Reeving Winch Motor
Spool
Reeving Winch Lowering Solenoid Valve
Spool From Reeving Winch Hoisting Switch Hydraulic Tagline / Reeving Winch Control Valve From Pilot Pump Reeving Winch Hoisting Solenoid Valve
T2-2-42
Hydraulic Tagline / Reeving Winch Drive Pump
T25N-02-02-021
SYSTEM / Hydraulic System TAKE-UP CIRCUIT (OPTIONAL) The take-up mechanism pushes the left and right front idlers forward by using the travel circuit pressure and gives a constant tension the track shoe. Travel circuit pressure is supplied to the bottom sides of left and right take-up cylinders through the shuttle valve. Consequently the front idler is pushed and the left and right track shoes are given a constant tension. When the excessive power acts on the front idler, the return check valve is open and release pressure oil from the bottom side of take-up cylinder in order to absorb the shock.
Take-Up Cylinder (Left)
Return Check Valve Shuttle Valve
Front Idler (Left)
Return Check Take-Up Cylinder Valve (Right)
Front Idler (Right)
Travel Motor (Left)
Travel Motor (Right)
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, the control circuit, the monitor circuit, the brake control circuit, the moment limiter, and the auto stop circuit.
Main circuit
• Electric circuit that is an electric power source for the electric system on the machine.
• Preheating circuit that assists the engine in starting in cold weather.
• Main circuit Engine-related circuit and accessories-related circuit
• Control circuit
Engine and pump control circuit consisting of actuators such as solenoid valves, controllers (MC and ECU), switch boxes, sensors and switches • Monitor circuit Circuit that displays operating status of the machine (consisting of monitor display, sensors, switches, etc.) • Moment limiter and auto stop circuit The circuit that warns of overloading and overhoisting, and makes auto stop of hoisting and boom derricking (consisting of the moment limiter that displays loading condition during crane operation and detects overloading; micro switch that detects boom and hook overhoisting; controller (MC) that performs auto stop; and solenoid valve). Here, major functions and construction of the main circuit will be described.
• Starting circuit that starts the engine. • Charging circuit that charges batteries, and supplies electricity to compensate power consumption.
• Engine stop circuit that stops the engine through the engine stop solenoid.
• Accessories-related circuit that is actuated when the key switch is at ON position.
• Surge voltage prevention circuit that prevents the occurrence of serge voltage when the engine is stopped. • Drum lock circuit that locks and releases the front, rear and fourth drum lock. • Slewing brake release circuit that releases the slewing motor brake by delivering the pilot pressure oil to the brake, with the slewing brake release solenoid valve ON.
T2-3-1
SYSTEM / Electric System POWER CIRCUIT With the minus terminal of the battery connected to the machine, the battery serves as a backup power supply for the radio and air conditioner when the key switch is at OFF position. Also, the battery serves as a main power supply for MC2/A, MC2/B, IDU, key switch, fuel feed pump switch, room light switch and horn relay. Battery
Fuel Feed Pump Switch
Room Light Switch
Horn Relay
Horn Switch
Horn
MC2/A
MC2/B Battery Relay
IDU
Radio
Air Conditioner Key Switch
T25N-02-03-001
T2-3-2
SYSTEM / Electric System (Blank)
T2-3-3
SYSTEM / Electric System PREHEATING CIRCUIT When setting the preheat key switch to ON position, terminal B is connected to terminal ACC in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excitedޔelectric current from the battery flows to terminals #7 and #8 of the preheat controller. When coolant temperature (resistance of the coolant temperature sensor) is 0 °C or lower, the preheat controller sets the preheating time (5 to 20 seconds) according to coolant temperature. In the preheating time, in order to excite the heater relay, the preheat controller lets battery current flow through the heater relay, lights a glow lamp, and turns on the air heater for preheating the engine.
T2-3-4
SYSTEM / Electric System Preheating Operation Battery
Engine Starting Relay MC2/A
Key Switch
Battery Relay
Alternator
Starter Relay 2
Coolant Temperature Sensor
Preheat Controller Glow Lamp
Heater Relay
Air Heater
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 follows. When the engine starts, electric current from terminal C of the key switch flows to MC2/A. As a result, MC2/A excites the engine start relay. When the engine starting relay is excited, electric current from terminal C of the key switch passes through the engine start relay and #6 terminal of the preheat controller. Also, when the engine is cranked, the alternator 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
Alternator
Starter Relay 2
Coolant Temperature Sensor
Preheat Controller Glow Lamp
Heater Relay
Air Heater
T25N-02-03-003
T2-3-7
SYSTEM / Electric System ENGINE STARTING CIRCUIT 8. At this time, when electric current is supplied from terminal S of starter relay 2 to terminal L of starter relay 1, electric current from terminal S of starter relay 1 flows to terminal S of the starter motor to turn the starter.
1. When setting the key switch to ON position, electric current from terminal ACC of the key switch excites the battery relay. 2. When the battery relay is excited, electric current from the battery flows through the battery relay, and goes to B terminal of the starter motor.
9. When the engine starts, the alternator generates power and electric current flows from terminals B, L and P of the alternator.
3. In addition, electric current from the terminal ACC excites the engine stop relay. 4. Therefore, the engine stop relay is turned ON, and the engine stop solenoid is turned OFF. The rack of the fuel injection pump, which is linked to the engine stop solenoid, is released from the engine stop position. As a result, the fuel is supplied to the engine, and the engine can start. 5. In addition, electric current from the key switch ACC flows to terminal R of starter relay 2.
10. Electric current from terminal P of the alternator goes to terminal P of starter relay 2 in order to block electric current flowing from terminal S of starter relay 2. 11. During the engine running (generating power by the alternator), electric current does not flow to terminal L of starter relay 1, so that the starter does not turn even when setting the key switch to START position.
6. When the slew brake switch is at the brake position, and the front, rear or third / fourth drum brake mode selection switch is at the auto brake position, 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, electric 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 Mode Selection Switch Rear Drum Brake Mode Selection Switch Third / Fourth Drum Brake Mode Selection Switch (Optional)
MC2/A
Slewing Brake Switch
Key Switch
Battery Relay
Engine Stop Relay
Engine Stop Solenoid
Starter Relay 1 Starter Motor
Alternator
Starter Relay 2
T25N-02-03-006
T2-3-9
SYSTEM / Electric System CHARGING CIRCUIT After starting the engine, when leaving the hand from the key switch, the key switch returns to ON position. With the key switch at ON position, terminal B is connected to terminal ACC in the key switch. Electric current from terminal B of the alternator charges the battery through battery relay. In addition, electric current flows to each circuit via a fuse. With the engine running, the alternator rotates to generate electrical current. Electric current from terminal L flows to terminal #2 of the charge relay. As a result, charge relay is turned OFF. The charge relay turned OFF, the charge lamp ground circuit goes OFF, and the charge lamp is turned OFF too.
T2-3-10
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
OFF Delay Relay
Alternator
Charge Relay
Charge Lamp
T25N-02-03-004
T2-3-11
SYSTEM / Electric System ACCESSORIES CIRCUIT When setting the key switch to ON position, terminal B and ACC are connected in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excited, electric current from the battery passes through the battery relay, and flows to the radio, clearance light (optional), dome light, work light and drum light. The power for horn and cigarette lighter is supplied from the battery circuit directly without the key switch. The cigarette lighter is a 12V specification.
Radio㩷 Battery
Horn Switch
Clearance Light (Optional)
Dome Light㩷
Horn Relay㩷
Horn㩷
Key Switch㩷
Work Light㩷
Battery Relay
Drum Light (Optional)
Cigarette Lighter㩷
T2BC-02-03-003
T2-3-12
SYSTEM / Electric System ENGINE STOP CIRCUIT Engine Stop Circuit Using Engine Stop Solenoid When setting the key switch to OFF position, exciting current does not flow from terminal ACC of the key switch to the engine stop relay. Because the exciting current disappears, the engine stop relay is turned OFF, electric current flows from the battery relay to the engine stop solenoid. The engine stop solenoid stops the fuel feed, and the engine stops. After that, the off delay relay goes OFF, and the battery relay also goes OFF, thus stopping the current to the engine stop solenoid.
T2-3-13
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
OFF Delay Relay
Engine Stop Relay
Engine Stop Solenoid
T25N-02-03-007
T2-3-14
SYSTEM / Electric System SURGE VOLTAGE PREVENTION CIRCUIT When stopping the engine (by turning the key switch OFF), electric current from terminal ACC of the key switch stops, and the battery relay turns OFF. Even if turning OFF the key switch, the engine does not stop at once, and rotates by the inertia, so that the alternator keeps generating power. Because the generated power current does not flow through the battery, the surge voltage (voltage rise) is generated in the circuit, causing failure of electronic equipment such as controller, and components. Therefore, the surge voltage prevention circuit is provided. The battery relay is excited by the off delay relay until the engine stops. As a result, the generated power current from terminal B of the alternator passes through the battery relay and goes to the battery, thus preventing the occurrence of serge voltage.
T2-3-15
SYSTEM / Electric System
Battery
Key Switch
Battery Relay
Off Delay Relay
Starter Relay2 Alternator
Charge Relay
T25N-02-03-008
T2-3-16
SYSTEM / Electric System DRUM LOCK CIRCUIT When setting the key switch to ON position, terminal B and ACC terminal are connected in the key switch. Electric current from terminal ACC excites the battery relay. When the battery relay is excited, electric current from the battery passes through the battery relay, and flows through terminal B of the front, rear and the fourth drum locks. Under this condition, when setting the front, rear or fourth drum lock switch (optional) to OFF position, electric current flows from terminal B of the drum lock connected to the switch to be set. This electric current passes through terminal P2 and lock switch, and goes to terminal A in order to unlock the drum. Similarly, when setting the front, rear or fourth drum lock switch (optional) to ON position, electric current from terminal B of the drum lock connected to the switch to be set passes through terminal P1, and goes terminal A in order to lock the drum.
T2-3-17
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
Rear Drum Lock
Rear Drum Lock Switch
Fourth Drum Lock (Optional)
Fourth Drum Lock Switch (Optional)
T25N-02-03-010
T2-3-18
SYSTEM / Electric System SLEWING BRAKE RELEASE CIRCUIT 1. When the slewing brake switch is at OFF position, the slewing brake indication lamp is turned on and the slewing brake is applied. 2. When the slewing brake switch is at ON position, electric current flows from the battery to MC2/A. 3. MC2/A turns off the slewing brake indication lamp. 4. At the same time, MC2/A passes electric current the slewing brake release solenoid valve and selects the slewing brake release solenoid valve. As a result, pressure oil from the pilot pump flows through the slewing brake release valve and goes to the slewing brake in order to release the brake. Slewing Brake Switch: ON Slewing Brake Indicator Lamp
Monitor Lamp Unit
Slewing Brake Switch: ON MC/2A
To Slewing Brake
Pilot Pump
Slewing Brake Release Solenoid Valve
T2-3-19
T2BC-02-03-002
This Page Left Blank Intentionally
SECTION 3
COMPONENT OPERATION —CONTENTS— Group 7 Slewing Mechanism
Group 1 Pump Mechanism Outline ..........................................................T3-1-1 Main Pump ...................................................T3-1-2 Slewing Pump ..............................................T3-1-4 Regulator......................................................T3-1-5 Solenoid Valve............................................T3-1-21 Pilot Pump, Pump for Counterweight / Quick Draw / Retract and Pump for Hydraulic Tagline and Reeving Winch ....T3-1-23
Group 2 Front / Rear Control Valve Outline ..........................................................T3-2-1 Composition .................................................T3-2-2 Internal Circuit ..............................................T3-2-6 Spool ............................................................T3-2-9 Main Relief Valve........................................T3-2-11 Pump Relief Valve ....................................T3-2-13 Make-up Valve............................................T3-2-15 Holding Valve .............................................T3-2-16 Pressure Compensation Valve...................T3-2-17
Group 3 Slewing Control Valve Slewing Control Valve ..................................T3-3-1
Group 4 Lower Control Valve Outline ..........................................................T3-4-1 Internal Composition ....................................T3-4-2 Relief Valve ..................................................T3-4-3
Group 5 4-Unit Control Valve Outline ..........................................................T3-5-1 Composition .................................................T3-5-2 Pressure-Reducing Valve.............................T3-5-4 Sequence Valve ...........................................T3-5-5 Solenoid Valve..............................................T3-5-6
Outline ......................................................... T3-7-1 Slewing Reduction Gear.............................. T3-7-2 Slewing Motor .............................................. T3-7-3 Slewing Parking Brake ................................ T3-7-4 Valve Unit..................................................... T3-7-6
Group 8 Hoisting Mechanism Outline ......................................................... T3-8-1 Motor............................................................ T3-8-2 Regulator ..................................................... T3-8-4 Counterbalance Valve.................................. T3-8-7 Brake ......................................................... T3-8-12 Hoisting Drum ............................................ T3-8-13 Reduction Gear.......................................... T3-8-14 Brake Unit .................................................. T3-8-15
Group 9 Boom Derricking Device Outline ......................................................... T3-9-1 Reduction Gear............................................ T3-9-2 Boom Derricking Motor................................ T3-9-3 Boom Derricking Brake................................ T3-9-4 Brake Valve.................................................. T3-9-6 Counterbalance Valve.................................. T3-9-7 Overload Relief Valve .................................. T3-9-9
Group 10 Remote Control Valve Outline ....................................................... T3-10-1 Travel Motor............................................... T3-10-2 Parking Brake ............................................ T3-10-4 Travel Reduction Gear............................... T3-10-6 Travel Brake Valve..................................... T3-10-7 Travel Speed Selection............................ T3-10-10
Group 6 Remote Control Valve Outline ..........................................................T3-6-1 Construction .................................................T3-6-4 Detent Function............................................T3-6-8 Operation....................................................T3-6-10
2BCT-3-1
Group 11 Others (Upper Structure) 4-Spool Solenoid Valve Unit.......................T3-11-1 Solenoid Valve............................................T3-11-3 Drum Unlocking Solenoid Valve.................T3-11-5 Gate Lock Valve .........................................T3-11-6 Brake Pedal Unit ........................................T3-11-9 Pressure-Reduction Valve........................T3-11-10 Counterweight Cylinder............................T3-11-16 Accumulator .............................................T3-11-17
Group 12 Others (Base Carrier) Outline ........................................................T3-12-1 Slewing Ring ..............................................T3-12-2 Center Joint ................................................T3-12-3 Retract Cylinder .........................................T3-12-4 Jack-Up Cylinder (Optional).......................T3-12-5 Take-Up Cylinder (Optional).......................T3-12-8
2BCT-3-2
COMPONENT OPERATION / Pump Mechanism OUTLINE The pilot pump (4), pump (3) for counterweight / quick draw / jack-up retract and pump (1) for hydraulic tagline / reeving winch are gear pumps. In addition, the PTO gearbox (2) is provided between pump 1(10) and pump 2 (8).
The pump device consists of main pump (pump 1 (10) and pump 2 (8)), slewing pump (6), pilot pump (4), pump (3) for counterweight / quick draw / jack-up / retract tagline / reeving winch / fourth drum for cooling and PTO gearbox (2) The main pump is a dual swash plate type variable displacement plunger pump, and the slew pump is a single swash plate type variable displacement plunger pump. These pumps deliver high pressure oil to the main circuit for operation.
1
2
3 4
10 9 8 7
6
T2BC-01-02-028
5
1 - Hydraulic Tagline / Reeving Winch Drive Valve (Optional) 2 - PTO Gearbox 3 - Pump For Counterweight / Quick Draw / Jack-Up / Retract
4-
5-
Pilot Pump
Displacement Angle Solenoid Valve (For Slew Pump) 6 - Slewing Pump
7-
Displacement Angle Solenoid Valve (For Main Pump)
9-
8-
Pump 2
10 - Pump 1
T3-1-1
Power Increase Solenoid Valve
COMPONENT OPERATION / Pump Mechanism MAIN PUMP The main pump is a dual swash plate type axial plunger pump and consists of pumps (1 and 2). Two shafts (1) are connected with gear (6), each provided with a pump of the same type. Cylinder block (5) is splined on shaft (1). Plunger (4) is inserted into cylinder block (5). The rotation of engine is transmitted through the coupling to shaft (1). When shaft (1) rotates, plunger (4) rotates with cylinder block (5). Plunger (4) slide over shoe plate (3) and reciprocates in the bore of cylinder block (5) according to the inclination of swash plate (2). By this reciprocation, suction and delivery of hydraulic oil are carried out.
Pump 2
Pump 1
1
2
3
4
4 5
6
T3-1-2
5
4
3
2
T1F3-03-01-003
COMPONENT OPERATION / Pump Mechanism Delivery Flow Adjustment The pump delivery flow is adjusted by changing the inclination angle of swash plate (2) in order to change the stroke of plunger (4). The servo piston is moved by the pressure oil from the regulator. Swash plate (2) is connected to the servo piston, so that the inclination angle of swash plate (2) is changed according to the movement of the servo piston in order to adjust the delivery flow.
Servo Piston
1
Valve Plate
5 4 2
T117-02-01-003
T3-1-3
COMPONENT OPERATION / Pump Mechanism SLEWING PUMP The Slewing pump is a one-spool swash plate type axial plunger pump. Shaft (1) is splined to shaft (1) of pump 2. The shaft (1) is provided with a pump whose type is the same as the main pump. Shaft (1) is splined to cylinder block (5) into which plungers are inserted. The rotation of engine is transmitted through pump 2 to shaft (1). When shaft (1) rotates, plunger (4) rotates with cylinder block (5). Plunger (4) slides over shoe plate (3) and reciprocates in the bore of cylinder block (5) according to the inclination of swash plate (2). By this reciprocation, suction and delivery of hydraulic oil are carried out. The slewing pump is used with the maximum displacement angle fixed.
Splined to Pump 2
T25N-03-01-005
1
2
3
4
T3-1-4
5
COMPONENT OPERATION / Pump Mechanism REGULATOR Outline According to various pressure signals, the regulator controls the displacement angle of maim pump (pumps (1, 2)) and changes the flow rate in order not to exceed the engine horsepower. One regulator is provided to each of pump 1, pump 2, and slewing pump. The regulator in slewing pump fixes the maximum displacement angle for slewing pump and does not control the displacement angle.
The displacement angle proportional solenoid valve is attached to the pump 2 regulator and the displacement angle solenoid valve is attached to the slewing pump regulator. In addition, the power increase solenoid valve is attached to the PTO gearbox.
Displacement Angle Proportional Solenoid Valve Displacement Angle Solenoid Valve
PTO Gearbox
Pump 1 Regulator
Power Increase Solenoid Valve
Slewing Pump Regulator
Pump 2 Regulator
T25N-03-01-003
Layout Power Increase Solenoid Valve
Displacement Angle Proportional Solenoid Valve
Pump 2 Regulator
Pump 1 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) B
Pump 1
B
Pump 2
A
A
B
A
B
A
T25N-03-01-006
T25N-03-01-007
Section A-A 1
2
3
4
5
6
7 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
17
18
T1F3-03-01-008
123456-
Pilot Piston Pin Lever 2 Pin Pin Pilot Spring
78910 11 -
Feedback Lever Pin Return Spring Sleeve Spool
12 13 14 15 16 -
T3-1-7
Pin Lever 1 Pin Outer Spring Inner Spring
17 18 19 20 21 -
Servo Piston Pin Compensating Rod Compensating Piston Piston
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
123456-
Pilot Piston Pin Lever 2 Pin Pin Pilot Spring
20
78910 11 -
19
Feedback Lever Pin Return Spring Sleeve Spool
18
17
12 13 14 15 16 -
T3-1-9
Pin Lever 1 Pin Outer Spring Inner Spring
T25N-03-01-013
17 18 19 20 21 -
Servo Piston Pin Compensating Rod Compensating Piston Piston
COMPONENT OPERATION / Pump Mechanism Linkage Mechanism (Main Pump) The movement of pilot piston (1) is transmitted through pin (2) to lever 2 (3). Lever 2 (3) is turned about pin (5) which is fixed to the axial plug. The movement of compensating rod (19) is transmitted through pin (18) to the lever 1 (13). The lever 1(13) is turned about pin (12) which is fixed to the casing. Pin (4) is attached to feedback lever (7). Both ends of pin (4) are inserted into holes of lever 1 (13) and lever 2 (3).
Therefore, when lever 1 (13) or lever 2 (3) turns, pin (4) contacts the hole of the turned lever. Feedback lever (7) turns about pin (8) attached to servo piston (17). In addition, when servo piston (17) moves, feedback lever (7) is moved through pin (8). At this time, because neither lever 1 (13) nor lever 2 (3) move, feedback lever (7) turns about pin (4), and spool (11) moves. NOTE:
12
18 13
Casing
Displacement angle decrease Displacement angle increase
Hole
7
19
14 4 3
Hole
5 2
Axial Plug
11
8 1 17
T142-02-01-005
1234-
Pilot Piston Pin Lever 2 Pin
57811 -
Pin Feedback Lever Pin Spool
12 - Pin 13 - Lever 1 14 - Pin
T3-1-10
17 - Servo Piston 18 - Pin 19 - Compensating Rod
COMPONENT OPERATION / Pump Mechanism Regulator Control Functions
The regulator of main pump is explained here. That of slewing pump is omitted. The regulator has the following three control functions.
• Control by self pump pressure or companion pump pressure Self pump pressure P1 and companion pump pressure P2 are applied to the regulator. (The slewing pump uses only self pump pressure P3.) When the mean pressure of these two pump pressures exceed the preset P-Q curve, both pump delivery flow rates of both pumps are reduced to follow the P-Q curve. As a result, overloading to the engine is prevented. In addition, because the P-Q curve is preset by the mean pressure of both pumps, both pump delivery flow rates become almost equal. Therefore, higher pressure pump is subjected to larger load, while lower pressure pump to smaller load. Thus, the total becomes equal to the engine horsepower. (Summation control)
Flow Rate (Q)
Pressure Increase Flow Decrease
0
Pressure (P)
• Control by pilot pressure from power increase so-
lenoid valve (only main pump) MC2/A sends a signal according to engine speed and load to the power increase solenoid valve. The power increase solenoid valve operates according to this signal, and returns pressure oil, which acts on the compensating piston of regulator, to the hydraulic oil tank. As a result, the delivery flow is increased. (Power increase control) (Refer to "Control System".)
Flow Rate (Q)
T3-1-11
0
Pilot Pressure (Pi)
COMPONENT OPERATION / Pump Mechanism • Control by pilot pressure from displacement angle proportional solenoid valve
MC2/A sends a signal, which is proportional to the rotation of the acceleration grip (JOY-STICK LEVER : accelerator dial), to the displacement angle proportional solenoid valve. The displacement angle proportional solenoid valve sends pilot pressure, which depends on this signal, to the regulator to increase or decrease the pump delivery flow rate. (Displacement angle control) (Refer to "Control System".)
Flow Rate (Q)
0
Pr1
Main Pump Regulator
Psv
Pz
P2 P1
Increase Decrease Displacement Angle T25N-03-01-008
P1 - Pump 1 Delivery Pressure
Pz - Power Increase Control Pressure (From Power Increase Solenoid Valve)
P2 - Pump 2 Delivery Pressure
Psv - Pilot Pressure
Pr1 - Displacement Angle Proportional Pressure (From Displacement Angle Proportional Solenoid Valve.)
T3-1-12
COMPONENT OPERATION / Pump Mechanism Operation of Regulator
• Control by Self Pump Pressure and Companion 6. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensating rod (19) nor lever 1 (13) move, feedback lever (7) turns counterclockwise about pin (4) and moves spool (11) to the left. The notches of spool (11) and sleeve (10) are closed completely, so self pump delivery pressure does not act to the large diameter chamber side of servo piston (17) and the movement of servo piston (17) stops.
Pump Pressure NOTE: Reference: Control by self pump pressure and companion pump pressure is divided into the following two functions. x Flow reduction (overload prevention) When the load (pressure) increases, controls so that the load does not exceed the engine horsepower by reducing the pump delivery flow rate. x Flow rate increase (flow rate restoration) When the load (pressure) decreases, increases the pump delivery flow rate for efficient use of engine horsepower.
7. The pump delivery flow rate is decreased by these operations and the load to the pump is reduced.
• Flow reduction (overload prevention)
1. When self pump delivery pressure P1 and companion 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 counterclockwise 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). Although self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the right due to the difference in area. 5. The pump displacement angle reduces according to the movement of servo piston (17) and the pump delivery flow rate decreases.
Flow Rate (Q)
0
Pressure (P)
P2 P1
20 13
11 7 17
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
20
11
12
19
13
18
4
8
7
15
17
16
T25N-03-01-016
47810 -
Pin Feedback Lever Pin Sleeve
11 - Spool 12 - Pin 13 - Lever 1
15 - Outer Spring 16 - Inner Spring 17 - Servo Piston
T3-1-14
18 - Pin 19 - Compensating Rod 20 - Compensating Piston
COMPONENT OPERATION / Pump Mechanism • Flow rate increase (flow rate restoration)
1. When self pump delivery pressure P1 and companion pump delivery pressure P2 decrease, compensating piston (20) moves together with compensating rod (19) to the left, to the position where outer spring (15) force and inner spring (16) forces are balanced.
2. Compensation rod (19) moves lever 1(13) through pin (18). Lever 1 (13) turns clockwise about pin (12) fixed to the casing.
3. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 1(13). Therefore, feedback lever (7) rotates counterclockwise about pin (8) by the turning of lever 1 (13) and move spool (11) to the left.
4. When spool (11) moves, the large diameter chamber side of servo piston (17) is connected to the hydraulic oil tank through spool (11). As self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the left. 5. The pump displacement angle increases according to the movement of servo piston (17) and the pump delivery flow rate increases. 6. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensating rod (19) nor lever 1 (13) moves, feedback lever (7) turns clockwise about pin (4) and moves the spool (11) to the right. The notches of spool (11) and sleeve (10) are closed completely, so the large diameter chamber side of the servo piston (17) is not connected to the hydraulic oil tank and the movement of servo piston (17) stops.
0
Pressure (P)
15, 16
10
P2 P1
20 11 7
13
17
Increase Decrease Displacement Angle
T25N-03-01-025
7. By these movements, the pump delivery flow rate increases.
Flow Rate (Q)
T3-1-15
COMPONENT OPERATION / Pump Mechanism
10
To Hydraulic Oil Tank
11
12
13
4
15
16
P1
20
19
18
8
7
17
T25N-03-01-016
10
20
11
12
19
13
18
4
8
7
15
17
16
T25N-03-01-016
47810 -
Pin Feedback Lever Pin Sleeve
11 - Spool 12 - Pin 13 - Lever 1
15 - Outer Spring 16 - Inner Spring 17 - Servo Piston
T3-1-16
18 - Pin 19 - Compensating Rod 20 - Compensating Piston
COMPONENT OPERATION / Pump Mechanism Control by Pilot Pressure of Power Increase Solenoid Valve 7. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensating rod (19) nor lever 1 (13) moves, feedback lever (7) turns clockwise about pin (4) and moves spool (11) to the right. The notches of spool (11) and sleeve (10) are closed completely, so the large diameter chamber side of servo piston (17) is not connected to the hydraulic oil tank and the movement of servo piston (17) stops.
Power increase control pressure Pz from the power increase control solenoid valve acts and increases the pump delivery flow. 1. When the power increase solenoid valve is excited by a signal from MC2/A, the pilot pressure acting on pin (21) is transmitted to the hydraulic oil tank. 2. Compensating piston (20) is returned together with compensating rod (19) to the left, to the position that outer spring (15) and inner spring (16) are balanced. 3. Compensating rod (19) moves lever 1 (13) through pin (18). Lever 1 (13) turns clockwise about pin (12) fixed to the casing.
8. By these movements, the pump delivery flow rate increases.
4. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 1(13). Therefore, feedback lever (7) rotates counterclockwise about pin (8) by the turning of lever 1 (13) and move the spool (11) to the left.
5. When spool (11) moves, the large diameter chamber side of servo piston (17) is connected to the hydraulic oil tank through spool (11). As self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the left.
Flow Rate (Q)
0
Pump Control Pressure (Pi)
15, 16
6. The pump displacement angle increases according to the movement of servo piston (17) and the pump delivery flow rate increases.
10
Pz
P1
20 11 7
13
17
Increase Decrease Displacement Angle
T25N-03-01-027
T3-1-17
COMPONENT OPERATION / Pump Mechanism To Hydraulic Oil Tank
10
To Hydraulic Oil Tank
11
12
13
4
15
16
Pz
21
P
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
47810 -
Pin Feedback Lever Pin Sleeve
11 12 13 15 -
Spool Pin Lever 1 Outer Spring
16 - Inner Spring 17 - Servo Piston 18 - Pin
T3-1-18
19 - Compensating Rod 20 - Compensating Piston 21 - Pin
COMPONENT OPERATION / Pump Mechanism Control by Pilot Pressure from Displacement Angle Proportional Solenoid Valve 7. When servo piston (17) moves, feedback lever (7) is moved through pin (8). As neither compensation rod (19) nor lever 1 (13) moves, feedback lever (7) turns counterclockwise about the pin (4) and moves spool (11) to the left. The notches of spool (11) and sleeve (10) are closed completely, so self pump delivery pressure does not act to the large diameter chamber side of servo piston (17) and the movement of servo piston (17) stops.
1. When the displacement angle proportional solenoid valve is excited by a signal from MC2/A, pilot pressure acts to pilot piston (1). 2. When pilot pressure increases, pilot piston (1) moves to the right, to the position where pilot pressure is balanced with the pilot spring (6) force. 3. Pilot piston (1) moves lever 2 (3) through pin (2). Lever 2 (3) turns counterclockwise about pin (5) fixed to the axial plug. 4. Pin (4), which is attached to feedback lever (7), is inserted into the hole of lever 2 (3). Therefore, feedback lever (7) rotates clockwise about pin (8) by the turning of lever 2 (3) and moves spool (11) to the right. 5. When spool (11) moves, self pump delivery pressure P acts through spool (11) to the large diameter chamber side of servo piston (17). Though self pump delivery pressure P acts to the small diameter chamber side, servo piston (17) moves to the right due to the difference in area. 6. The pump displacement angle reduces according to the movement of servo piston (17) and the pump delivery flow rate decreases.
8. The pump delivery flow rate is decreased by these movements and the load to the pump is reduced.
Flow Rate (Q)
0
Pump Control Pressure (Pi)
Pilot Pressure
13
10
P1
11 7 17
1
T3-1-19
3
6
Increase Decrease Displacement Angle
T25N-03-01-028
COMPONENT OPERATION / Pump Mechanism
1
2
3
4
5
6
Pilot Pressure
7 8
T25N-03-01-015
10
11
13
4
P
19
8
7
17
T25N-03-01-016
1234-
Pilot Piston Pin Lever 2 Pin
567-
Pin Pilot Spring Feedback Lever
8 - Pin 10 - Sleeve 11 - Spool
T3-1-20
13- Lever 1 17- Servo Piston 19- Compensating Rod
COMPONENT OPERATION / Pump Mechanism SOLENOID VALVE The displacement angle proportional solenoid valve is attached to the pump 2 regulator. The power increase solenoid valve is provided to the PTO gearbox between pump 1 and pump 2. (Refer to Section "Control Functions of Regulator".) Operation of Displacement Angle Proportional Solenoid Valve
In Neutral State
1. In neutral state, port T and the output port are connected through the notch of spool (4) and pressure oil from port P is blocked completely by spool (4).
1
2
3
4
2. When electric current from MC2/A goes to solenoid (1), solenoid (1) is excited and pushes spool (4) to the right. 3. The output port is connected to port P through the notch of spool (4) and pressure oil from port P flows to the output port. 4. Spring chamber (5) is connected to port T through hole (3) of spool (4). As the left side (A) diameter of the notch of spool (4) is larger than the right side (B) diameter, spool (4) returns to the left.
T
Output Port
5
P
T25N-03-01-019
In Operation 1
2
5
3
T
A
Output Port
B
4
P
T25N-03-01-020
T3-1-21
COMPONENT OPERATION / Pump Mechanism Operation of Power Increase Solenoid Valve 1. In neutral state, port P and the output port are connected through the notch of spool (4).
1
2
3
4
2. When electric current from MC2/A goes to solenoid (1), solenoid (1) is excited and pushes spool (4) to the right. 3. The output port is connected to port T through the notch of spool (4) and the pressure in the output port decreases. 4. Spring chamber (5) is connected to port T through hole (3) of spool (4). As the left side (A) diameter of the notch of spool (4) is larger than the right side (B) diameter, spool (4) returns to the left.
5
T
P
Output Port
T25N-03-01-021
1
2
5
3
T
4
Output Port
A
P
B
T25N-03-01-022
T3-1-22
COMPONENT OPERATION / Pump Mechanism PILOT PUMP, PUMP FOR COUNTERWEIGHT / QUICK DRAW / RETRACT AND PUMP FOR HYDRAULIC TAGLINE AND REEVING WINCH
1
Suction Port
2
Drive gear (1) is driven through the transmission and driven gear (2) engaged therewith is also rotated.
Delivery Port
T137-02-03-005
1 - Drive Gear
T3-1-23
2 - Driven Gear
This Page Left Blank Intentionally
COMPONENT OPERATION / Front / Rear Control Valve OUTLINE The control valve controls the pressure, flow rate and flow direction in the hydraulic circuit. The front/rear control valve is a 4-spool type and consists of main relief valve, port relief valve, make-up valve, holding valve, pressure compensation valve, proportional solenoid valve, remote control pressure sensor and spool. The spool in front control valve is provided for travel (right), boom derricking, rear drum (low speed) and front drum (high speed). The spool in rear control valve is provided for travel (left), rear drum (high speed) and front drum (low speed). The spool is selected by pressure oil from the remote control valve and proportional solenoid valve in order to deliver pressure oil from the main pump (pumps 1, 2) to the travel mechanism, boom derricking mechanism and front/rear drums.
T3-2-1
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
1
2
5
17
7
16
13
15
14
13 12
8
11
10
12
16
T25N-03-05-030
14 1-
Main Relief Valve㩷
7-
Port Relief Valve (with Make-Up Function)㩷
2-
Right Travel Spool㩷
8-
Rear Drum (Low Speed) Spool㩷
3-
Make-Up Valve㩷
9-
Front Drum (High Speed) Spool㩷
4-
Pressure Compensation Valve (2 Used)㩷 5 - Boom Derricking Spool㩷
T2BC-03-02-001
10
10 - Holding Valve㩷 㩷
11
15
10 - Rear Drum Hoisting 14 - Boom Derricking Drum Proportional Solenoid Valve㩷 Hoisting Proportional Solenoid Valve㩷 11 - Rear Hoisting Remote 15 - Derricking Hoisting Control Pressure Sensor㩷 Remote Control Pressure Sensor㩷 16 - Derricking Drum Lowering 12 - Rear Drum Lowering Remote Control Pressure Remote Control Pressure Sensor㩷 Sensor㩷 13 - Rear Lowering 17 - Derricking Lowering Proportional Solenoid Valve㩷 Proportional Solenoid Valve㩷 㩷 㩷
T3-2-2
COMPONENT OPERATION / Front / Rear Control Valve
17 1
3
5
14
13
6
4
2
8 7 9
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 9
T2BC-03-02-006
1
2
4
17
14
17
16
5
7
9
1-
Main Relief Valve㩷
6-
2-
Left Travel Spool㩷
7-
3-
Make-Up Valve㩷
8-
4-
Third/Fourth Spool㩷
9-
5-
Rear Drum (High Speed) Spool㩷
10 -
15
14
12
T2BC-03-02-004
Port Relief Valve (with Make-Up Function)㩷 Front Drum (Low Speed) Spool㩷 Pressure Compensation Valve㩷 Front Drum Hoisting Proportional Solenoid Valve㩷 Front Hoisting Remote Control Pressure Sensor㩷
13 12
11
10
11
16
10
15
T2BC-03-02-005
11 - Front Lowering Remote 15 - Fourth Lowering Remote Control Pressure Sensor㩷 Control Pressure Sensor㩷 12 - Front Drum Lowering 16 - Fourth Hoisting Remote Proportional Solenoid Valve㩷 Control Pressure Sensor㩷 13 - Holding Valve㩷 17 - Third/Fourth Hoisting Solenoid Valve㩷 14 - Third/Fourth Lowering 㩷 Solenoid Valve㩷 㩷
T3-2-4
㩷
COMPONENT OPERATION / Front / Rear Control Valve
8 1
12 17 6
3 7 4
2
13
5
14
9
T2BC-03-02-007
T3-2-5
COMPONENT OPERATION / Front / Rear Control Valve INTERNAL CIRCUIT Pilot Pressure Control Circuit Pilot pressure oil from the remote control valve acts to the spool in control valve in order to move the spool.
Front Control Valve 12
11
T2BC-03-02-016
1
2
3
4
5
6
Rear Control Valve 5
6
T2BC-03-02-017
7
8
9
10
11
12-
Travel (Right Reverse)㩷 Travel (Right Forward)㩷
45-
Boom Derricking Hoisting㩷 Rear Drum Hoisting㩷
7 - Travel (Left Forward)㩷 8 - Travel (Left Reverse)㩷
3-
Boom Derricking Lowering㩷
6-
Rear Drum Lowering㩷
9 - Third Drum Hoisting㩷
T3-2-6
12
㩷
10 - Third Drum Lowering㩷 11 - Front Drum (Low Speed) Lowering㩷 12 - Front Drum (Low Speed) Hoisting㩷
COMPONENT OPERATION / Front / Rear Control Valve Main Circuit The internal circuits are arranged in the right travel and series circuits. 1. Each section is connected through passage. 2. With the spool in neutral, oil from the pump passes through passage and flows to the next section. 3. When the spool moves, pressure oil from port P passes through port B or port A and goes to the actuator. 4. The return oil from actuator flows through port A or port B and spool, and goes to the downstream passage. 5. Therefore, the full oil flow, after passing through upstream section and actuator, flows to the downstream section.
Front Control Valve
Port B㩷
A
B
P
T
T324-02-06-029
Rear Control Valve Port A㩷
Passage㩷
Port P㩷
Passage㩷
Passage
Port A㩷
T2BC-03-02-018
Port P㩷
T3-2-7
Port B㩷
T2BC-03-02-019
COMPONENT OPERATION / Front / Rear Control Valve Carry-Over Circuit (Optional) In case the fourth drum (optional) is provided, pressure oil to the fourth drum motor is supplied from port CO in end section of rear control valve.
Without Fourth Drum
With Fourth Drum To Fourth Drum Motor
T2BC-03-02-020
Remove the plug and port CO cover from the end section in rear control valve. Install the carry-over selection plug into the hole on plug.
Therefore, the return circuit from spool to port T is blocked and return oil flows to port CO.
Without Fourth Drum
With Fourth Drum Port T㩷
Port CO Cover㩷
Plug㩷
Port T㩷
Port CO㩷
Carry-Over Selection Plug㩷
T2BC-03-02-02
T3-2-8
COMPONENT OPERATION / Front / Rear Control Valve SPOOL The closed center type, open center type and semi-open center type are used for the spool.
P B
T A
• Closed Center Type Spool
2
When the spool is in neutral, oil in port A and B is blocked by spool (2). Therefore, oil in port A and B does not flow to port T. • Front drum (high speed) • Rear drum (high speed) 6
• Open Center Type Spool T
When the spool is in neutral, oil in port A or port B passes through passage (1) in the spool and port T, and flows to the hydraulic oil tank. • Travel (right) • Travel (left)
B
A
1
T 1
2 6
• Semi-Open Center Type Spool
B
A
T 1
The oil in port A flows to the hydraulic oil tank through passage (1) and port T in the spool. Oil in port B is blocked by spool (2). • Boom derricking • Rear drum (low speed) • Third/fourth drum • Front drum (low speed)
2 6
1-
T3-2-9
Passageã©·
2-
Spoolã©·
COMPONENT OPERATION / Front / Rear Control Valve Operation of Spool NOTE: The rear drum spool in the front control valve (low speed) is exemplified. 1. When spool (2) moves to the right by compressing spring (1), pressure oil from port P flows to the actuator through passage (3) and port B. 2. The return oil from actuator flows to port T through port A and passage (5). NOTE: As two upstream spools constitute a series circuit, when moving spools (2) and (4) simultaneously, for instance, and if the actuator for upstream spool (4) stops due to overloading, the actuator for downstream spool (2) also stops simultaneously.
Port T
B
A
1
2 5
3
6
2
Port P㊡
4 T25N-03-05-002
12-
Spring㊡ Spool (Rear Drum (Low Speed))㊡
3㊡
Passage㊡
4 - Spool (Boom Derricking)㊡ ㊡
T3-2-10
5 - Passage㊡ ㊡
COMPONENT OPERATION / Front / Rear Control Valve MAIN RELIEF VALVE The main relief valve serves so that the pressure in the main circuit does not exceed the set pressure when the actuator such as motor or cylinder is in operation. Thus, oil leak from hose and pipe joints as well as breakage of the actuator are prevented. Relief operation 1. Pressure in port HP (main circuit) acts to pilot poppet (4) through orifice (6) in the main poppet (1). 2. When pressure in port HP reaches pressure set by spring B (5), pilot poppet (4) moves to open a passage, so pressure oil flows into port LP (hydraulic oil tank). 3. At this time, pressure is generated between port HP and spring chamber (2) through orifice (6). 4. When this pressure difference reaches pressure set by spring A (3), main poppet (1) moves to open a passage, so pressure oil from port HP flows to port LP. 5. As a result, pressure in the main circuit decreases. 6. When pressure in the main circuit decreases to the fixed level, main poppet (1) moves to close a passage by the force of spring A (3).
T3-2-11
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
LP
6
T2BC-03-02-009
1
2
3
4
5
HP
6
LP T2BC-03-02-010
12-
Main Poppet㩷 Spring Chamber㩷
3 - Spring A㩷 4 - Pilot Poppet㩷
5 - Spring B㩷 㩷
T3-2-12
6㩷
Orifice㩷
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. Relief Operation
Make-Up Operation
1. Pressure in port HP (actuator circuit) acts to pilot poppet (6) through orifice (10) in piston (1).
1. When pressure in port HP (actuator circuit) decreases lower than pressure in port LP (hydraulic oil tank), sleeve (3) moves to the right due to pressure at port LP and the seat surface on sleeve (3) is opened.
2. When pressure in port HP reaches pressure set by spring B (7), pilot poppet (6) opens pressure oil from passage (8) in spring chamber (5) flows along the external circumference of sleeve (3) and goes to port LP (hydraulic oil tank). 3. At this time, a pressure difference is caused between port HP and spring chamber (5) due to orifice (10). 4. When this pressure difference reaches pressure set by spring A (4), main poppet (2) opens and pressure oil from port HP flows to port LP. 5. As a result, pressure in the actuator circuit decreases. 6. When pressure in the actuator circuit decreases to the fixed level, pilot poppet (6) is closed by the force of spring B (7) and pressure in spring chamber (5) increases. Main poppet (2) is closed by the force of spring A (4).
T3-2-13
2. Hydraulic oil in port LP flows into port HP in order to prevent cavitation. 3. When pressure in port HP rises to the fixed level, the seat surface on sleeve (3) is closed by the force of spring A (4).
COMPONENT OPERATION / Front / Rear Control Valve
Normal state 1
2
3
4
5
6
7
LP
T2BC-03-02-011
10
9
8
Relief State 1
2
10
9
3
4
5
6
7
T2BC-03-02-012
8 3
4
T2BC-03-02-013
123-
Piston㩷 Main Poppet㩷 Sleeve㩷
4 - Spring A㩷 5 - Spring Chamber㩷 6 - Pilot Poppet㩷
7 - Spring B㩷 8 - Passage㩷 㩷
T3-2-14
9 - Spring C㩷 10 - Orifice㩷 㩷
COMPONENT OPERATION / Front / Rear Control Valve MAKE-UP VALVE
Port T
The make-up valve is provided in the lowering circuit for boom derricking and third/fourth drum (optional). The make-up valve, when pressure in port B becomes minus, feeds the oil from port T in order to prevent cavitation.
Port B
Operation 1. When pressure in port B becomes minus, the poppet, which is pressed rightward, moves leftward by pressure in port T due to a difference in pressure-receiving areas (X>Y). 2. As a result, oil is fed from port T to port B in order to prevent cavitation. T2BC-03-02-014
Port B㩷
Port T㩷 㩷
Area Y
Poppet㩷
Area X㩷
T331-03-05-012
T3-2-15
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.
Low Speed Hoisting In low speed hoisting, only lower speed spool (1) works. High speed pool (2) is kept closed. 2
1 3
T2BC-03-02-022
High Speed Hoisting When shifting the hoisting lever from low speed to high speed position, pressure oil tends to flow backward from the motor side to the pump side, as pump side pressure is lower than motor side pressure at the start of opening of higher speed spool (2). In order to avoid this, holding valve (3) is utilized. 2
1
T2BC-03-02-023
3
1 - Spool (Low Speed Side) 2 - Spool (High Speed Side)
T3-2-16
3 - Holding Valve
COMPONENT OPERATION / Front / Rear Control Valve PRESSURE COMPENSATION VALVE The pressure compensation valve is a pressure compensation type flow rate adjusting valve and provided in the boom derricking, rear drum (low speed) and front drum (low speed) circuits. The pressure compensation valve compensates the required flow rate to the actuator regardless of the load. NOTE: Boom derricking operation is exemplified. Operation (with small lever stroke) 1. Pressure oil from port P flows to chamber C through the internal passage in control valve. Pressure oil flows into chamber E through the internal passage in compensating spool and acts to the end of compensating spool. 2. When moving the boom derricking lever, pressure oil through the spool flows to passage A and acts to spring chamber B. 3. With the lever operation small, pressure acting to spring chamber B is greatly reduced by the spool and a pressure difference between chambers C (E) and B is kept large. 4. When a pressure difference between chambers A (E) and B becomes large, the compensating spool compresses the spring in the spring chamber and moves up. 5. As a result, pressure oil from port P flows to Chamber D through chamber C and goes to the downstream section. 6. Thus, by releasing excess pressure, an optimum flow rate to the actuator is obtained.
Spring㩷
To Actuator㩷 To Downstream Section㩷
Pressure Compensation Valve
Spool (Boom Derricking)
From Port P㩷
T25N-03-05-041
Spring Chamber
Spring㩷
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 into chamber B through the internal passage in compensating spool and acts to the end of compensating spool. 2. When moving the boom derricking lever, pressure oil through the spool flows to passage A and acts to spring chamber B. 3. With the lever operation large, the reduced pressure is smaller by the spool, a pressure difference between chamber C (E) and B becomes small. 4. When a pressure difference between chambers C (E) and B becomes small, the compensating spool is compressed by the spring force in spring chamber B downward. 5. Consequently, as the passage between chambers C and D is blocked, a large quantity of oil flows to the actuator. 6. Thus, the oil flow rate is delivered to the actuator according to lever stroke.
Spring㩷
To Actuator㩷
Pressure Compensation Valve Spool (Boom Derricking)
From Port P㩷
T25N-03-05-040
Spring Chamber
Spring㩷
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, and consists of the main relief valve and spool. The spool in the slewing control valve is an open center 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.
NOTE: As for operation of the main relief valve and the spool, refer to "Front / Rear Control Valves".
Spool
Main Relief Valve
Main Relief Valve
T2BC-03-03-003
T2BC-03-03-002
Main Relief Valve Spool
T2BC-03-03-001
T3-3-1
This Page Left Blank Intentionally
COMPONENT OPERATION / Lower Control Valve OUTLINE The lower control valve is the direct-acting type control valve and the spools (6 used) and the relief valve are built in. The spool is selected by the lever operation and delivers pressure oil from port P to the jack-up cylinder and retract cylinder.
NOTE: The lower control valve is optional.
Port P㩷
Retract (Right)
Relief Valve㩷
Jack-Up (Right Front)
Jack-Up (Right Rear) Jack-Up (Left Rear)
Jack-Up (Left Front) Retract (Left)
Port T㩷 T2BC-03-04-001
T3-4-1
COMPONENT OPERATION / Lower Control Valve INTERNAL COMPOSITION The inside of lower control valve is a parallel circuit.䎃 Pressure oil from port P can be supplied to all the spools at the same time. The direct-acting type relief valve is installed behind port P.䎃 The relief valve regulates the maximum pressure in the lower control circuit.
1
2
3
4
5
6
7
T2BC-03-04-004
12-
Retract (Left)㩷 Jack-Up (Left Front)㩷
3 - Jack-Up (Left Rear)㩷 4 - Jack-Up (Right Rear)㩷
5 - Jack-Up (Right Front)㩷 6 - Retract (Right)㩷
T3-4-2
7 - Relief Valve㩷 㩷
COMPONENT OPERATION / Lower Control Valve RELIEF VALVE The relief valve is a direct-acting type and prevents the pressure in circuit from increasing beyond the setting during operation of the lower control valve. Thus, oil leak from hose and pipe joints and breakage of the actuator are prevented. Relief Operation 1. Pressure in port P (main circuit) acts to the end of poppet (3) through the orifice in plug (5). 2. When pressure at port P reaches the setting pressure for spring (2), poppet (3) moves to the left and the passage between poppet (3) and seat (4) is connected. 3. Pressure oil from port P flows to port T through this passage. 4. As a result, pressure at port P decreases. 5. When pressure at port P decreases to the fixed level, poppet (3) is closed by the force of spring (2). 6. The relief setting pressure is adjusted by adjusting screw (1).
Normal State: T
P
T2BC-03-04-005
1
2
3
4
5
Relief State: T
P
T2BC-03-04-006
1 123-
T3-4-3
2
3
Adjusting Screw㩷 Spring㩷 Poppet㩷
4
5 45㩷
Seat㩷 Plug㩷
This Page Left Blank Intentionally
COMPONENT OPERATION / 4-Unit Control Valve OUTLINE When operating the counterweight switch, the spool in counterweight is switched and pressure oil from the pump for counterweight/quick draw/retract flows to the counterweight cylinder in order to extend/retract the cylinder. When operating the quick draw switch and retract switch, pressure oil flows to the cylinder in order to operate the cylinder in the same procedures. When turning the lower power switch ON with the lower jack mechanism (optional) attached, the spool in lower power selection is switched and pressure oil from the pump for counterweight/quick draw/retract flows to the lower control valve (optional). NOTE: As for operation of main relief valve, port relief valve, holding valve and spool, refer to Section "Front / Rear Control Valves".
The 4-unit control valve is an electromagnetic-hydraulic pilot spool type and consists of main relief valve, sequence valve, pressure-reducing valve, holding valve, port relief valve, solenoid valve and spool. The spool in 4-unit control valve is a semi-open center type using parallel circuits. When the spool is in neutral, pressure oil from the pump for counterweight/jack-up/retract flows to the front and rear drums in order to cool the brake unit in front and rear drums.
1
2
3
12
10
4
3
5
3
6
3
7
T2BC-03-05-001
13 1-
Pressure-Reducing valve:㩷
2-
Sequence Valve㩷
3-
Holding Valve㩷
4-
Counterweight Solenoid Valve (Right/Retract)㩷
11
10
5-
Counterweight Solenoid Valve (Left/Retract)㩷 6 - Retract Solenoid Valve (Retract) *㩷 7 - Quick Draw Solenoid Valve (Retract)㩷 㩷
9
8
8-
Quick Draw Solenoid Valve (Extend)㩷 9 - Retract Solenoid Valve (Extend) *㩷 10 - Port Relief Valve㩷
11 - Counterweight Solenoid Valve (Left/Extend)㩷 12 - Counterweight Solenoid Valve (Right/Extend)㩷 13 - Main Relief Valve㩷
㩷
㩷
NOTE: *: If the jack-up (optional) is installed, the lower power solenoid valve is installed here.
T3-5-1
COMPONENT OPERATION / 4-Unit Control Valve COMPOSITION 4
5
12
11
6
7
2 1
13
1-
Pressure reducing valve:㩷
2-
Sequence Valve㩷
3-
Holding Valve㩷
4-
Counterweight Solenoid Valve (Right/Retract)㩷
5-
Counterweight Solenoid Valve (Left/Retract)㩷 6 - Retract Solenoid Valve (Retract) *㩷 7 - Quick Draw Solenoid Valve (Retract)㩷 㩷
9
8
T2BC-03-05-002
8-
Quick Draw Solenoid Valve (Extend)㩷 9 - Retract Solenoid Valve (Extend)*㩷 10 - Port Relief Valve㩷
11 - Counterweight Solenoid Valve (Left/Extend)㩷 12 - Counterweight Solenoid Valve (Right/Extend)㩷 13 - Main Relief Valve㩷
㩷
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
1 2
13
3
3
10
T2BC-03-05-008
T3-5-3
COMPONENT OPERATION / 4-Unit Control Valve PRESSURE-REDUCING VALVE
Pressure-Reducing Pressur 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. Operation 1. Pressure oil from port P flows to chamber E through passage (C). 2. Pressure oil flows to chamber G through notch (E) of spool (1) and acts to the solenoid valve. 3. Pressure oil in chamber G passes through spool (1) and acts to chamber D at the end of spool (1).䎃 Pressure oil flows to spring chamber (A) in the sequence valve through passage (B) and pushes spool (2) downward with the spring (2) force together. 4. When pressure acting to the lower surface of spool (1) exceeds the force of spring (1), spool (1) moves up to the position where pressure is balanced with the force of spring (1). 5. Spring chamber (J) is connected to the hydraulic oil tank. Pressure oil from chamber G flows to the hydraulic oil tank through notch (H) of spool (1) and pressure in chamber G decreases. 6. When pressure in chamber G decreases, the chamber D pressure acting to the surface of spool (1) decreases, too. 7. Spool (1) moves down by the force of spring (1) to the position where the force of spring (1) is balanced with pressure acting to the surface of spool (1) and pressure in chamber G increases again. 8. Therefore, pressure from port P becomes lower than pressure set by spring (1) and pressure through the solenoid valve keeps constant.
Sequence SEQUENCE Valve㩷
Spool 1 Spring 1 Spool 2㩷 Spring 2㩷
To Solenoid Valve
Spool 1 Spring 1 Spool 2㩷 Spring 2㩷
To Solenoid Valve Pressure-Reducing Valve㩷
To Solenoid Valve㩷
To Control Valve Spool㩷 T2BC-03-05-005
Sequence Valve㩷
To Solenoid Valve㩷
T2BC-03-05-004
T3-5-4
COMPONENT OPERATION / 4-Unit Control Valve SEQUENCE VALVE Pressure-Reducing Sequence Valve㩷 Valve㩷
The sequence valve blocks pressure oil from port P and the pressure-reducing valve is operated prior to the sequence valve. When pressure in the main circuit decreases rapidly, the sequence valve keeps the primary pressure in sequence valve (the primary pressure in pressure-reducing valve) and compensates operation of the solenoid valve.
Spring 2㩷 Spool 2㩷
Operation 1. Pressure in the pressure-reducing valve circuit always flows spring chamber (A) in the sequence valve through passage (B). 2. Spool (2) in the sequence valve is pushed down by the pressure-reduced oil and the force of spring (2). Therefore, pressure at port P (the primary pressure in sequence valve and pressure-reducing valve) keeps pressure which the secondary pressure in pressure-reducing valve acts to spring (2). Consequently the operating pressure of solenoid valve is always obtained. 3. Pressure oil from port P flows to chamber D in the sequence valve. 4. Pressure oil in chamber D passes through spool (2) and acts to chamber E at the end of spool (2). 5. When pressure in chamber D exceeds pressure in spring chamber (A) and the force of spring (2), spool (2) compresses spring (2) and moves up. 6. Pressure oil flows from chamber D to chamber K and goes to the spool in control valve. 7. Thus, by setting a time lag in operation between pressure-reducing valve and sequence valve, the primary pressure (output pressure) of pressure reducing valve is obtained. Pressure-Reducing Valve㩷
To Solenoid Valve
Spring 2㩷 Spool 2㩷
To Solenoid Valve
To Solenoid Valve
To Control Valve Spool㩷
To Control Valve Spool㩷
To Control Valve Spool㩷
Sequence Valve㩷 T2BC-03-05-006
To Solenoid Valve㩷
T2BC-03-05-004
T3-5-5
COMPONENT OPERATION / 4-Unit Control Valve SOLENOID VALVE Each solenoid valve in 4-unit control valve is an ON/OFF solenoid valve. When each selection switch is set to ON position, the solenoid valve is excited and switches the spool in solenoid valve. As a result, pressure oil from the pressure-reducing valve acts to the spool in control valve and switches the spool. Operation 1. When the operating switch is set to OFF position, pressure oil from port P (pressure- reducing valve) is blocked by the spool in solenoid valve. Chamber A or C is connected to the hydraulic oil tank. 2. When the operating switch is set to ON position, the solenoid is excited. 3. The spool in solenoid valve moves downward by compressing the spring. 4. As chamber B is connected to chamber C, pressure oil from port P flows to spring chamber (D) in the control valve. 5. As a result, the spool in control valve is switched.
In Neutral State Solenoid㩷
Control Valve Spool㩷
Solenoid㩷
Control Valve Spool㩷
Spring Solenoid Valve Spool
Exciting state
Spring Solenoid Valve Spool
T2BC-03-05-007
T3-5-6
COMPONENT OPERATION / Remote Control Valve OUTLINE The remote control valve controls the pilot pressure oil in order to move the spool in the control valve. There are three remote control valves: 3-section derricking valve, 3-section travel valve and 1-section slewing valve (7). The hoisting remote control valve consists of boom derricking (1), rear drum (2) and front drum (3). The travel remote control valve consists of third / fourth drum (4) (optional), left travel (5) and right travel (6). The hoisting and travel remote control valves are each made of three sections combined through spring pins. The hoisting and travel remote control valves are each provided with detent plugs (10). The travel remote control valve is provided with remote control pressure sensors (8) and (9). NOTE: These remote control valves have the same structure except for detent plug (10) and the shuttle valve block. 1
2
3
4
5
6
7
10
Shuttle Valve Block
9
7
T2BC-03-06-001
Hoisting Remote Control Valve
1 - Boom Derricking Remote Control Valve 2 - Rear Drum Remote Control Valve 3 - Front Drum Remote Control Valve
Travel Remote Control Valve
4 - Third Drum Remote Control Valve (Optional) 5 - Left Travel Remote Control Valve 6 - Right Travel Remote Control Valve
Slewing Remote Control Valve
7 - Slewing Remote Control Valve 8 - Travel Remote Control Pressure Sensor (R)
T3-6-1
9-
Travel Remote Control Pressure Sensor (L) 10 - Detent Plug
COMPONENT OPERATION / Remote Control Valve • Hoisting Remote Control Valve Parts Name
Port No. 1 2
Boom derricking
Hoisting Lowering Motor Hoisting Lowering Motor
3 4 8 5 6 9
Rear
Front
T P
4㩷
Boom Derricking㩷 2
Boom 㩷 㩷 Derricking Rear㩷 Front㩷
Connected to Hoisting Lowering
1
Rear㩷 8 3
4
6
Front㩷 9 5
2
6㩷 9㩷
8
5㩷
1 T2BC-03-06-002
3㩷 P T 㩷 T2BC-03-06-004
• Travel Remote Control Valve Port
Parts Name
Connected to
No.
Hoisting Lowering Fourth drum displacement angle control signal pressure
1 2 7
Third / fourth (optional)
Forward Reverse Remote control pressure Forward Reverse Remote control pressure
3 4 8 5 6 9
Travel (left)
Travel (right)
㩷 㩷 Travel Travel (left)㩷 (right)㩷
Third/Fourth (Optional)㩷
T P P
8
6
2㩷
9
7㩷 㩷 Travel (left)
Third/Fourth (Optional)㩷 2
7
1
4
8
㩷 Travel (right)㩷 3
6
9
5
1㩷
5
T25N-03-06-006
3㩷
P
P T
4
T25N-03-06-003
T3-6-2
COMPONENT OPERATION / Remote Control Valve • Slewing Remote Control Valve Parts Name Slewing
Port No. 1 2
Connected to Right Slewing Left Slewing T P
1
2
2 P T
T25N-03-06-004
1
T2BC-03-06-003
T3-6-3
COMPONENT OPERATION / Remote Control Valve CONSTRUCTION The remote control valve consists of screw joint (1), cam (2), detent plug (3), pusher (4), balance spring (6), return spring (7) and spool (8). Remote control valves for hoisting and travel are each made of three sections combined though spring pins (10). The control lever is attached to screw joint (1) that is bolted to cam (2) so that they move together. The bottom surface of head of spool (8) is supported by the top surface of spring guide (5). The two surfaces are mated through balance spring (6). Pusher (4) is lifted by return spring (7) through spring guide (5). Detent plug (3) maintains the control lever in the fixed position even when releasing the control lever and lets the actuator operate at a constant speed. Shuttle block (9) selects the secondary pilot pressure on control side and lets guide pressure oil flow to another output port.
T3-6-4
COMPONENT OPERATION / Remote Control Valve Hoisting Remote Control Valve
1 2 3 4
5 6 7 8
9
1 2 3
4
5 6 7 8
9
T2BC-03-06-005
123-
Screw Joint㩷 Cam㩷 Detent Plug㩷
4 - Pusher㩷 5 - Spring Guide㩷 6 - Balance Spring㩷
7 - Return Spring㩷 8 - Spool㩷 㩷
T3-6-5
9 - Shuttle Valve Block㩷 10 - Spring Pin㩷 㩷
COMPONENT OPERATION / Remote Control Valve Travel Remote Control Valve
1
2 3 4
5 6 7
8
9
1
2 3
4
5
T2BC-03-06-006
123-
Screw Joint㩷 Cam㩷 Detent Plug㩷
4 - Pusher㩷 5 - Spring Guide㩷 6 - Balance Spring㩷
7 - Return Spring㩷 8 - Spool㩷 㩷
T3-6-6
9 - Shuttle Valve Block㩷 10 - Spring Pin㩷 㩷
COMPONENT OPERATION / Remote Control Valve Slewing Remote Control Valve D
Section D
1
2
4
5 6 7 8
9
T25N-03-06-011
12-
Screw Joint㩷 Cam㩷
4 - Pusher㩷 5 - Spring Guide㩷
T25N-03-06-012
67-
T3-6-7
Balance Spring㩷 Return Spring㩷
89-
Spool㩷 Shuttle Valve Block㩷
COMPONENT OPERATION / Remote Control Valve DETENT FUNCTION The front, rear and third / forth remote control valves for hoisting are each provided with two detent plugs. The boom derricking and travel remote control valves for hoisting are each provided with one detent plug. The detent plug maintains the control lever in the fixed position even when releasing the control lever and lets the actuator operate at a constant speed. Operation 1. With control lever (1) in neutral, ball (3) and holder (4) are pressed to cam (2) through spring (5). 2. When tilting control lever (1), notch A of cam (2) reaches ball (3) and ball (3) and holder (4) are shifted at a distance of notch A by the force of spring (5). 3. With control lever (1) tilted, pusher (6) always acts to push cam (2) upward through return spring (7). 4. However, notch A of cam (2) is engaged with ball (3) so that cam (2) does not move. 5. As a result, control lever is held in the first detent position even when releasing control lever (1). 6. When tilting control lever (1) further from the first detent position, notch B of cam (2) reaches ball (3) and ball (3) and holder (4) are shifted at a distance of notch B by the force of spring (5). 7. As a result, cam (2) is engaged with ball (3) again control lever (1) is held in the second detent position even when releasing control lever (1) in a manner similar to the first detent position. 8. Thus, control lever (1) is held in the fixed position so that the actuator operates at a constant speed, and facilitates combined operations. NOTE: The first detent of front and rear remote control valves is used for low-speed operation and its second detent is for high-speed operation. (Refer to Derricking Circuit, HYDRAULIC SYSTEM). The detent plugs provided at boom derricking, left travel and right travel can be made the combined operations.
T3-6-8
COMPONENT OPERATION / Remote Control Valve
Control Lever Operating Control Force
1
2 A (First Detent Position)㩷
3
B (Second Detent Position)㩷
3 4 4
5
5
6
7
T25N-03-06-015
12-
Control Lever㩷 Cam㩷
3 - Ball㩷 4 - Holder㩷
5 - Spring㩷 6 - Pusher㩷
T3-6-9
7 - Return Spring㩷 㩷
COMPONENT OPERATION / Remote Control Valve OPERATION When control lever (1) in the operator’s cab is operated, the secondary pilot oil pressure is delivered in response to the control lever operation stroke. This delivered secondary pilot pressure is routed to spool (4) end of control valve (3) so that spool (4) is moved until the pilot pressure force balances with spring (5) force.
1
2
3
4
5
Port T (To hydraulic oil tank)
Port P (From pilot pump)
From main pump
To hydraulic oil tank
Output Port
T324-02-07-010
1 - Control Lever 2 - Remote Control Valve
3 - Control Valve
4 - Spool
T3-6-10
5 - Spring
COMPONENT OPERATION / Remote Control Valve Neutral Position 1. When in neutral, spool (2) is raised upward by return spring (1) force, the primary pilot pressure from port P is blocked. 2. The output port (secondary pilot pressure) is connected to port T (hydraulic oil tank).
1
Port T (Hydraulic Oil Tank)㊡
2
Port P (Primary Pilot Pressure)㊡
Output Port (Secondary Pilot Pressure)㊡ ăŞˆăŠˇăŞ„ăŠˇ Return Spring㊡
2 - Spool㊡
T3-6-11
6
COMPONENT OPERATION / Remote Control Valve Beginning to Deliver Secondary Pressure)
Output
(Increasing
3. When control lever (3) is operated, cam (4) is slanted so that pusher (5) is pushed downward in proportion to cam (4) slant amount, closing the oil passage to port T by spool (2). 4. The pressure oil from port P (primary pilot pressure side) is routed to the output port (secondary pilot pressure side) through the clearance around spool (2). 3
4
5
2
Port T
Primary Pilot Pressure Port P
Output Port Clearance 2 - Spool㊡
3 - Control Lever㊡
Secondary Pilot Pressure 4 - Cam㊡
T3-6-12
5 - Pusher㊡
6
COMPONENT OPERATION / Remote Control Valve Maintaining Secondary Pressure 5. Pressure oil from port P (primary pilot pressure) acts on diameters d1 and d2 in spool (2). 6. This pressure pushes spool (2) upward due to the difference of area (d1>d2). 7. Spool (2) is pushed upward and the output port is connected to port T. 8. The pressure in output port decreases and spool (2) is pushed downward again by the reaction force of balance spring (6).
9. After repeating these procedures, the pressure according to the stroke of control lever (3) is routed to the output port. 10. Balance spring (6) is compressed to the same amount as spool (2) was pushed downward. The pressure which the spring force and the force acting to spool (2) are balanced with is the output port pressure.
3
6
Port T
2
Clearance Primary Pilot Pressure Port P
Output Port 6
Secondary Pilot Pressure 㪉㊡㪄㊡ Spool㊡
3 - Control Lever㊡
6 - Balance Spring㊡
T3-6-13
This Page Left Blank Intentionally
COMPONENT OPERATION / Slewing Mechanism OUTLINE The slewing mechanism consists of the valve unit, the slewing motors and the slewing reduction gear. The valve unit prevents the cavitation in the slewing circuit. The slewing motor is a swash plate type axial plunger motor (with built-in slewing parking brake), which is driven by pressure oil from the pump, and is provided with the slewing reduction gear.
The slewing reduction gear turns the slewing motors with large torque at a low speed and slews the superstructure.
Valve Unit
Slewing Motor
Slewing Reduction Gear
T25N-03-02-008
T3-7-1
COMPONENT OPERATION / Slewing Mechanism SLEWING REDUCTION GEAR The slewing reduction gear is a two-stage planetary reduction gear. Ring gear (3) is monolithically built with housing (5) bolted to the superstructure, not allowing rotation. Shaft (1) of the slewing motor turns first stage sun gear (10) whose turning torque is transmitted to second stage sun gear (8) through first stage planetary gear (2) and first stage carrier (9). Second stage sun gear (8) turns shaft (6) through second stage planetary gear (4) and second stage carrier (7).
Shaft (6) is engaged with the internal gear of slew bearing fixed to the undercarriage in order to slew the superstructure.
1
10 2 9 3
8
4
7
5
6
T25N-03-02-001
1 - Shaft (Slewing Motor) 2 - First Stage Planetary Gear 3 - Ring Gear
4 - Second Stage Planetary Gear 5 - Housing 6 - Shaft
T3-7-2
7 - Second Stage Carrier 8 - Second Stage Sun Gear
9 - First Stage Carrier 10 - First Stage Sun Gear
COMPONENT OPERATION / Slewing Mechanism SLEWING MOTOR The slewing motor consists of the swash plate (6), rotor (11), plungers (10), valve plates (12), housing (8) and slewing parking brake (springs (1), brake piston (2), plate (3) and friction plate (4)). Shaft (7) is splined to rotor (11) into which plungers (10) are inserted.
When pressure oil is supplied from the pump, plunger (10) is pushed. Shoe (9) at the top of plunger (10) slides over the swash plate (6), so that rotor (11) rotates. The top of shaft (7) is splined to the first stage sun gear of slewing reduction gear. Therefore, the rotation of shaft (7) is transmitted to the slewing reduction gear.
12 1
11
2 3 4 10 5 9
6
8
7
T25N-03-02-002
1 - Spring 2 - Brake Piston 3 - Plate
4 - Friction Plate 5 - Retainer 6 - Swash Plate
7 - Shaft 8 - Housing 9 - Shoe
T3-7-3
10 - Plunger 11 - Rotor 12 - Valve Plate
COMPONENT OPERATION / Slewing Mechanism SLEWING PARKING BRAKE
The slewing parking brake is a wet type multiplate disc brake and a negative mechanism that releases the brake when brake release pressure acts in the brake piston chamber. The brake release pressure is supplied from the pilot pump only when the slewing brake switch is operated. In other cases (including engine stopping), the brake release pressure returns to the hydraulic oil tank, so that the brake is applied automatically by spring (1).
When Brake Is Applied
1. When the brake switch is set to OFF position, the slewing brake solenoid valve returns to neutral position, so that the pilot pressure, which is applied to port Pb, is returned to the hydraulic oil tank.
2. As a result, the force of spring (1) acts on friction plate (4), which is engaged with the external circumference of rotor (11), and on plate (3), which is engaged with the inside of housing (8), through brake piston (2). Thus, the external circumference of rotor (11) is secured with friction force.
2 1 Slewing Brake Switch
Slewing Brake Solenoid Valve
3. When the engine stops, the brake is applied automatically as pressure is not applied to port Pb.
Hydraulic Oil Tank
Pilot Pump
When Brake Is Released 1. When setting the slewing brake switch to ON position, the slewing brake solenoid valve is selected. Then, pilot pressure from the pilot pump is applied to port Pb.
T25N-03-02-009
2. Pilot pressure applied to port Pb acts to the brake piston chamber.
2 Brake Piston Chamber
3. Brake piston (2) moves by compressing spring (1).
Slewing Brake Switch
4. As a result, plate (3) and friction plate (4) are freed and the brake is released.
1 Slewing Brake Solenoid Valve
T3-7-4
Pilot Pump
T25N-03-02-010
COMPONENT OPERATION / Slewing Mechanism
When Brake is Applied:
When Brake is Released:
To Hydraulic Oil Tank
1
1
2
2
3
Pb
From Pilot Pump
4
8
Brake Piston Chamber
3
Pb
4
8
11
Brake Piston Chamber
T25N-03-02-006
11
T25N-03-02-006
1 - Spring 2 - Brake Piston
3 - Plate 4 - Friction Plate
8-
T3-7-5
Housing
11 - Rotor
COMPONENT OPERATION / Slewing Mechanism VALVE UNIT
The valve unit is provided with a make-up valve. The make-up valve prevents the cavitation in the circuit.
Make-Up Valve
Make-up valve In slewing stopping operation, the slewing motor is driven by the inertial force of slewing frame. The slewing motor is turned forcibly in excess of oil pressure from the pump, so that the cavitation may be generated in the motor. In order to avoid this cavitation, the poppet opens when pressure in the slewing circuit becomes lower than that in the return circuit (port M), and sucks the hydraulic oil in order to compensate the lack of oil feed.
Port M
Control Valve
T25N-03-02-007
Control Valve
Poppet
Make-Up Valve
Make-Up Valve
Port M
T25N-03-02-003
T3-7-6
COMPONENT OPERATION / Hoisting Mechanism OUTLINE Hoisting motor (2) consists of the motor, counterbalance valve (3), regulator (4), shuttle valve block, drum brake release solenoid valve and wet type multiplate brake. Regulator (4) is provided with the motor displacement angle proportional solenoid valve and motor cutoff high pressure solenoid valve. Hoisting drum (1) consists of two-stage planetary reduction gear (5), which is built in the drum, and brake unit (6).
The front drum and rear drum are driven separately. In crane operation, hosting and lowering (power lowering and free fall) of, and stopping (holding) of the load is done with the front drum using boom hook and with the rear drum using the jib hook. The front drum and rear drum consist of the same parts respectively. The following explanation is made in terms of the front drum. The front drum consists of the hoisting motor (2) and hoisting drum (1).
Front Drum
Rear Drum Jib Hook
Boom Hook
T324-02-04-001
1
2
3
4
T25N-03-03-003
6
5
1 - Hoisting Drum 2 - Hoisting Motor
3 - Counterbalance Valve 4 - Regulator
5-
T3-8-1
Reduction Gear (Two-Stage Planetary)
6-
Brake Unit
COMPONENT OPERATION / Hoisting Mechanism MOTOR The motor is a swash plate type variable displacement axial piston motor capable of selecting high/low speeds. The high/low speed selection of motor is controlled by the regulator. The wet type multiplate brake is built into the rear case (9) side of motor. The motor has plungers (1) (9 used). In each plunger (1), shoe (3) is crimped into rotor (2).
Plunger (1) slides over the slope of the shoe plate (4) in order to rotate rotor (2). Rotor (2) is splined to output shaft (7) in order to turn output shaft (7). Swash plate (5) is located between tilt pistons (8) (2 used). The displacement angle is chanced by the operation of regulator.
8
Wet Type Multiplate Brake
7
9
5
4
3 2 1 6
T324-02-04-003
1 - Plunger 2 - Rotor 3 - Shoe
4 - Shoe Plate 5 - Swash Plate
6 - Valve Plate 7 - Output Shaft
T3-8-2
8 - Tilt Piston 9 - Rear Case
COMPONENT OPERATION / Hoisting Mechanism Operation
1. Rotational speeds of the front and rear drums are changed according to the oil flow rate from pump.
2. When pressure oil from port A of valve plate (6) flows into the rotor (2) in order to push plunger (1). 3. Then, shoe (3) slides over shoe plate (4) on swash plate (5) in order to rotate rotor (2). 4. The turning torque of rotor (2) is transmitted to the reduction gear through output shaft (7). The return oil flows through delivery port B and returns to the hydraulic oil tank. 5. When high pressure oil comes in port B, the rotation is reversed. B
A
7 5
6
4
3
1
T324-02-05-029
2
1 - Plunger 2 - Rotor
3 - Shoe 4 - Shoe Plate
5 - Swashplate 6 - Valve Plate
T3-8-3
7 - Output Shaft
COMPONENT OPERATION / Hoisting Mechanism REGULATOR The regulator controls the larger motor displacement angle in proportion to the increasing pressure in hoisting motor circuit (Maximum Displacement Angle Lock Control).
Motor Displacement Angle
Maximum Displacement Angle Lock Control When delivery pressure from main pump (delivery pressure from pumps 1 and 2) increases, pressure oil to the large diameter chamber in tilt piston (2) is reduced. When delivery pressure increases further, pressure oil to the large diameter chamber returns to the hydraulic oil tank. As a result, the displacement angle is fixed to the maximum (minimum speed). In addition, the motor cutoff high pressure solenoid valve (3) controls the instructions for the maximum displacement angle in order to select the set pressure to the maximum displacement angles for hoisting and lowering operations.
0
Pump Delivery Pressure㩷
Speed㩷
0
Pump Delivery Pressure㩷
7
8
9
10
11
1
2 6
5
12
4 Pump 1㩷 Pilot Pump 1-
Hoisting Motor㩷
4 - Piston 1㩷
23-
Tilt Piston㩷 Motor Cutoff High Pressure Solenoid Valve㩷
5 - Spool 1㩷 6 - Spring 1㩷
Pump 2
3 T2BC-03-08-001
7 - Motor Displacement Angle 10 - Orifice㩷 Proportional Solenoid Valve㩷 8 - Piston 2㩷 11 - Spring 2㩷 9 - Spool 2㩷 12 - Shuttle Valve㩷
T3-8-4
COMPONENT OPERATION / Hoisting Mechanism • In Hoisting Operation 1. In hoisting operation, no signal comes to motor cutoff high pressure solenoid valve (3), so that motor cutoff high pressure solenoid valve (3) is not selected.
6. When pump delivery pressure increases further, spool 1 (5) is pushed by piston 1 (4) and pressure oil on the large diameter chamber side of tilt piston (2) passes through spool 1 (5) to the hydraulic oil tank.
2. Pilot pressure is applied through motor cutoff high pressure solenoid valve (3) to piston 1 (4).
7. As a result, the tilt piston (2) is pushed to the left and motor (1) is set to the maximum displacement angle.
3. Pump delivery pressure acts on piston 1 (4). 4. When pump delivery pressure exceeds the pilot pressure acting on piston 1 (4) plus spring 1 (6) force, piston 1 (4) moves to the left, to the position when pump delivery pressure is balanced with those pressures.
8. Thus, by setting the pressure of spool 1 (5) at higher level than that in lowering operation, an instruction for maximum displacement angle of motor (1) is retarded to retain the horsepower for hoisting operation. In addition, during the pump delivery pressure increasing, the maximum displacement angle of motor (1) is retained.
5. As spool 1 (5) is pushed by piston 1 (4), the line to the large diameter chamber side of tilt piston (2) is reduced.
Pump delivery pressure: Low
Pump delivery pressure: High
1
6
1
6 2
2
5
5
Pump Delivery Pressure
4 3
Pump Delivery Pressure
4
3
T25N-03-03-014
T25N-03-03-015
1 - Motor 2 - Tilt Piston
34-
Motor Cutoff High Pressure Solenoid Valve Piston 1
T3-8-5
5-
Spool 1
6-
Spring 1
COMPONENT OPERATION / Hoisting Mechanism • Lowering Operation 6. When the pump delivery pressure increases further, spool 1 (5) is pushed by piston 1 (4) and pressure oil in the large diameter chamber of tilt piston (2) flows through spool 1 (5) to the hydraulic oil tank.
1. For lowering operation, motor cutoff high pressure solenoid valve (3) is selected by a signal from MC2/A. 2. Pressure oil acting on piston 1 (4) passes through motor cutoff high pressure solenoid valve (3) to the hydraulic oil tank.
7. As a result, spool 1 (5) moves by the pump delivery pressure lower than that in hoisting operation, thus setting motor (1) at the maximum displacement angle.
3. Therefore, the force against pump delivery pressure acting on piston 1 (4) is only the force of spring 1 (6).
8. Thus, by setting the pressure for hoisting or lowering operation, the horsepower is retained for hoisting operation, or the motor speed is controlled for lowering operation.
4. When the pump delivery pressure becomes higher than the force of spring 1 (6), piston 1 (4) moves to the left to the position where pump delivery 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. Pump delivery pressure: Low
1
Pump delivery pressure: High
1
6
6
2
2 5
5
Pump Delivery Pressure
4 3
Pump Delivery Pressure
4
3
T25N-03-03-016
T25N-03-03-017
1 - Motor 2 - Tilt Piston
34-
Motor Cutoff High Pressure Solenoid Valve Piston 1
T3-8-6
5-
Spool 1
6-
Spring 1
COMPONENT OPERATION / Hoisting Mechanism COUNTERBALANCE VALVE
The counterbalance valve consists of counterbalance spool (4), spring (3), check valve (1) and relief valve (2).
1 2
3
4
T2BC-03-08-002
Functions of Counterbalance
1. The counterbalance valve is provided in the lowering 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 direction. 3. At this time, in the hoisting circuit, an internal pressure corresponding to this external force is generated.
2
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 counterbalance valve is used.
T2BC-03-08-003
1 - Check Valve
2 - Relief Valve
3 - Spring
T3-8-7
4 - Counterbalance Spool
COMPONENT OPERATION / Hoisting Mechanism In Hosting Operation 1. In hoisting operation, pressure oil from the pump passes through port A, pushes up the poppet of check valve (1), and flows through port D to the motor. 2. The return oil passes through ports C and B and return to the hydraulic oil tank. 3. In hoisting operation, only check valve (1) works.
Hoisting㩷
Hoisting㩷 C
1 D
C
D
4
A
B
A A
B
T2BC-03-08-004
㪈㩷㪄㩷 Check Valve㩷
4 - Counterbalance Spool㩷
T2BC-03-08-005
T3-8-8
COMPONENT OPERATION / Hoisting Mechanism Lowering Operation 1. In lowering operation, pressure oil from the pump passes through ports B and C, and flows to the motor.
8. On the contrary, when the oil flow rate decreases, passage resistance in counterbalance spool (4) decreases, lowering the feed pressure.
2. The pressure oil also flows into pilot passage (5) of counterbalance spool (4). The return oil is blocked by check valve (1), so that the motor does not turn, and the oil feed pressure increases.
9. Counterbalance spool (4) is returned, the passage is narrowed, lowering the motor speed.
3. This pressure oil passes through pilot passage (5) and moves counterbalance spool (4) leftward (rightward in circuit diagram). 4. The pressure oil opens ports D and A to return the return oil from the motor to the hydraulic oil tank through the control valve.
10. When lowering the load, the motor is likely to be turned in excess of the oil feed quantity, so that the feed pressure is lowered. 11. In order to avoid that the motor is turned in excess of the oil feed quantity, counterbalance spool (4) is returned, and the flow passage is narrowed. 12. Thus, the lowering speed changes according to the oil feed quantity.
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 counterbalance spool (4) further, widening the passage for higher motor speed.
Lowering
Lowering
C
1
D
D
5
䌄
4
C
A
4
A
A
B
B
1
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 1. When the spool in control valve is returned to neutral position, the hydraulic oil tank pressure is applied in port B and counterbalance spool (4) is returned to close the flow passage. 2. With check valve (1) closed, the internal pressure is generated corresponding to the lifting load to suspend the load in the air.
4
B
A
1
T2BC-03-08-007
1 - Check Valve
4 - Counterbalance Spool
T3-8-10
COMPONENT OPERATION / Hoisting Mechanism Relief Valve
Relief valve (2), provided in counterbalance valve (6), absorbs shock pressure caused by the inertial force when the motor stops.
6
2
1. Relief valve (2) is built into the lowering circuit. Poppet (3) in relief valve (2) closes flow passage with the force of spring (5). 2. When the control lever is returned to neutral position, the motor is likely to be turned in lowering direction by the inertial force of load.
3. The pressure in port D increases instantly, and when reaching the set pressure, poppet (3) in relief valve (2) moves and the pressure is released.
T2BC-03-08-002
2
5
T2BC-03-08-008
3
5
Port D
T324-02-04-023
2 - Relief Valve
3 - Poppet
5 - Spring
T3-8-11
6 - Counterbalance Valve Body
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) (Refer to Control System.)
3
Operation 4
1. Spline joint (4) is splined to output shaft (5). Spline joint (4) is splined to friction plates (7) (7 used). Disc plates (6) are splined to valve cover (1). Disc plates (6) and friction plates (7) are alternately installed.
5
2. With the hoisting lever in neutral position, pressure 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 contact to each other under pressure, the brake is applied.
7
6
T25N-03-03-012
4. When hoisting or lowering with the front (rear) lever, a signal from MC2/A is sent to brake release solenoid valve (8).
2
5. Then, brake release solenoid valve (8) is selected, so that pressure oil from pilot pump acts on brake piston (2) through port PR.
8
6. Brake piston (2) presses spring (3), so that disc plates (6) and friction plates (7) are freed. 7. As a result, the brake is released.
Pilot Pump
T25N-03-03-009
1 - Valve Cover 2 - Brake Piston
34-
Spring Spline Joint
56-
Output Shaft Disc Plate
T3-8-12
78-
Friction Plate Brake Release Solenoid Valve
COMPONENT OPERATION / Hoisting Mechanism HOISTING DRUM
The hoisting drum consists of reduction gear and brake unit. The reduction gear is a two-stage planetary reduction gear and converts the rotation, transmitted from the motor, to a low-speed large torque to rotate the drum. The brake unit is a wet type multiplate disc brake and applied with the brake pedal.
Hoisting Drum
Motor
T25N-03-03-003
Brake Unit
Reduction Gear
T3-8-13
COMPONENT OPERATION / Hoisting Mechanism REDUCTION GEAR
1. The reduction gear is a two-stage planetary reduction gear. The motor rotates propeller shaft (3).
2. This rotation is transmitted to ring gear (4) through first stage planetary gear (5), first stage carrier (6), sun gear (7), second stage planetary gear (8) and second stage carrier (9).
3. Ring gear (4) is fixed to drum (1) with bolts (2).
4. Therefore, when ring gear (4) turns, drum (1) also turns.
1
2
Motor
9
8
7
6
5
4
3
T25N-03-03-003
1 - Drum 2 - Bolt 3 - Propeller Shaft
4 - Ring Gear 5 - First Stage Planetary Gear
67-
First Stage Carrier Sun Gear
T3-8-14
89-
Second Stage Planetary Gear Second Stage Carrier
COMPONENT OPERATION / Hoisting Mechanism BRAKE UNIT With the brake mode selection key switch in the auto brake position, depress the brake pedal and turn ON the free mode switch for the drum. A signal is input to MC2/A in order to select the drum brake solenoid valve. (Free mode control) (Refer to Control System.) Brake Releasing 1. The top of shaft (6) is splined to the second stage carrier of reduction gear. Friction plates (5) are splined to shaft (6). Disc plate (4) is splined to casing (1). 2. When the brake pedal is depressed or when the drum brake solenoid valve is not selected, oil from brake chamber (A) passes through passage (2) to the hydraulic oil tank. 3. Brake piston (3) is pressed by the force of spring (8) to the right. 4. When brake piston (3) pushes spacer (7), and disc plate (4) and friction plates (5) contact closely to each other under pressure, the brake is applied. 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 compressing 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 Pedal
Drum Brake Solenoid Valve
1
2
3
4
5
6
Hydraulic Oil Tank Pilot Pump Reduction Gear
T25N-03-03-011
8
A
7
1 - Casing 2 - Passage
34-
Brake Piston Disk Plate
56-
T3-8-16
Friction Plate Shaft
78-
Spacer Spring
COMPONENT OPERATION / Boom Derricking Device OUTLINE The boom derricking device consists of the boom derricking motor, the reduction gear, the brake valve, the boom derricking drum and the derricking drum lock. The boom derricking motor is an axial plunger motor and the parking brake (wet type spring-set / hydraulic-released multiplate brake) is built in. The boom derricking motor is driven by pressure oil from the pump and transmits the rotation to the reduction gear.
The reduction gear is a three-stage planetary reduction gear and converts the rotation, transmitted from the boom derricking motor, to a low-speed large torque in order to rotate the boom derricking drum. The brake valve prevents overload to the boom derricking circuit and cavitation.
Derricking Drum Lock
Brake Valve
Reduction Gear
T25N-03-04-003
T3-9-1
Boom Derricking Motor
Boom Derricking Drum
T25N-03-04-001
COMPONENT OPERATION / Boom Derricking Device REDUCTION GEAR Housing (13) for the boom derricking motor is fixed with bolts to the track frame and fixed with bearing nut (11) to third stage carrier (2). Ring gear (1), drum (12) and the boom derricking drum are bolted respectively. Therefore, when ring gear (1) rotates, drum (12) and the boom derricking drum are also turned.
The reduction gear is a three-stage planetary reduction gear. The boom derricking motor rotates propeller shaft (7). This rotation is transmitted to ring gear (1) through first stage planetary gear (8), first stage carrier (6), second stage sun gear (5), second stage planetary gear (9), second stage carrier (4), third stage sun gear (3), third stage planetary gear (10) and third stage carrier (2).
1
2
3
4
5
6
7
T25N-03-04-002
13
12
11
10
9
8
1234-
Ring Gear Third Stage Carrier Third Stage Sun Gear Second Stage Carrier
5 - Second Stage Sun Gear 6 - First Stage Carrier 7 - Propeller Shaft
8 - First Stage Planetary Gear 9 - Second Stage Planetary Gear 10 - Third Stage Planetary Gear
T3-9-2
11 - Bearing Nut 12 - Drum 13 - Housing
COMPONENT OPERATION / Boom Derricking Device BOOM DERRICKING MOTOR The boom derricking motor is a swash plate type variable displacement axial plunger motor and consists of valve plates (1), swash plate (4), rotor (2), plunger (6) and shaft (3). Shaft (3) is splined to rotor (2) into which plungers (6) are inserted.
When pressure oil from the pump is supplied, plunger (6) is pushed. Shoe (5) at the top of plunger (6) slides over swash plate (4), so that rotor (2) rotates.
1
2
3
T25N-03-04-004
6
5
4
1 - Valve Plate 2 - Rotor
3 - Shaft 4 - Swash plate
5 - Shoe
T3-9-3
6-
Plunger
COMPONENT OPERATION / Boom Derricking Device BOOM DERRICKING BRAKE
The boom derricking brake is a wet type multiplate disc brake and a negative mechanism that releases the brake when brake release pressure acts in the brake piston chamber. The wet type multiplate disc brake and the derricking drum lock are provided in the same circuit and work at the same time.
When Brake is Applied 1. When the boom derricking lever is in neutral position, the derricking drum unlocking solenoid valve is not selected, so that pilot pressure fed to port C and the derricking drum lock return to the hydraulic oil tank.
Derricking Drum Unlocking Solenoid Valve
Pilot Pump
2. As a result, the force of disk spring (1) acts on plates (3) engaged with the inside of housing (6) and on friction plates (4) engaged with the external circumference of rotor (5) through brake piston (2). Thus, the external circumference of rotor (5) is retained with friction force. 3. In the derricking drum lock, pawl (9) is moved by torsion spring (8) and locks the boom derricking drum.
Hydraulic Oil Tank
Derricking Drum Lock T25N-03-04-006
When Brake is Released 1. When moving the boom derricking lever, the derricking drum lock solenoid valve is selected by a signal from MC2/A.
2. As a result, pilot pressure oil from the pilot pump is fed to port C and the derricking drum lock.
3. The pilot pressure fed to port C acts to the brake piston chamber.
Derricking Drum Unlocking Solenoid Valve
Pilot Pump
4. Brake piston (2) moves by compressing disc spring (1). 5. As a result, plate (3) and friction plate (4) are freed and the brake is released. 6. In the derricking drum lock, ball joint (7) is pushed by pilot pressure oil and pawl (9) moves.
Derricking Drum Lock
7. As a result, the boom derricking drum is unlocked.
T25N-03-04-005
T3-9-4
COMPONENT OPERATION / Boom Derricking Device When brake is applied
1
2
3
4
5
To Hydraulic Oil Tank
9
7 8
Brake Piston Chamber
C
T25N-03-04-008
To Hydraulic Oil Tank
T25N-03-04-003
6
When brake is released
1
2
3
4
5
From Pilot Pump
9
7 Brake Piston Chamber
8
C
T25N-03-04-008
From Pilot Pump
6
T25N-03-04-003
1 - Disk Spring 2 - Brake Piston 3 - Plate
4 - Friction Plate 5 - Rotor
67-
T3-9-5
Housing Ball Joint
89-
Torsion Spring Pawl
COMPONENT OPERATION / Boom Derricking Device BRAKE VALVE The brake valve, located at head of the boom derricking motor, consists of the following valves.
• Overload relief valve
• Check valve
Prevents overloading to the motor circuit and surge pressure.
• Counterbalance valve
Assists the counterbalance valve in operation and prevents cavitation in the motor circuit.
Prevents overturning of the motor caused by the load or self weight in lowering operation. Counterbalance Valve
Check Valve
T25N-03-04-007
Overload Relief Valve
T3-9-6
COMPONENT OPERATION / Boom Derricking Device COUNTERBALANCE VALVE
Provides back pressure for the sake of control when the boom derricking lever is operated and stops the motor when the control valve is in neutral. In boom lowering, the motor might be driven by the inertial force of load, but the counterbalance valve provides back pressure in order to prevent overturning of the motor.
Operation
• Boom hoisting
1. In boom hoisting operation, pressure oil from the pump passes through ports A and AM and flows to the motor.
BM
AM
2. Pressure oil goes into port A, opens the check valve and goes to port AM. 3. The return oil passes through ports BM and B and returns to the hydraulic oil tank. 4. As a result, the oil flow is not reduced in boom hoisting work.
Check Valve
A
B
T25N-03-04-010
• Boom lowering (power lowering)
1. In boom lowering operation, pressure oil from the pump passes through ports B and BM and flows to the motor.
BM
2. Pressure oil passes through the spool and goes to the spring chamber. 3. However, as the return oil from motor is blocked by the check valve, the motor does not turn. 4. As a result, back pressure is given to the circuit. 5. When the oil feed pressure rises, the spool moves by compressing the spring. 6. The return oil from motor returns to the hydraulic oil tank via the control valve. 7. As a result, the motor can turn so that the load can be lowered while applying the brake. This is called “Power Lowering”.
B
Spool
A T25N-03-04-009
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
The overload relief valve is provided in the hoisting circuit. The overload relief valve serves as a cushion to absorb shock caused by the inertial force when stopping the motor and prevents the overload to the motor.
Relief Operation 1. Normally, the poppet is closed by spring force. 2. When the control lever is returned to neutral, the motor is turned by the inertial force of load in lowering direction. 3. The pressure in port AM rises momentarily and when reaching the set pressure, the poppet moves to open and releases the pressure.
Poppet
Spring
Port AM
To Hydraulic Oil Tank
T3-9-9
T25N-03-04-012
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COMPONENT OPERATION / Travel Mechanism OUTLINE The travel mechanism consists of the travel motor, travel reduction gear and travel brake valve. The travel motor is an axial plunger motor and incorporates the parking brake of wet spring-set / hydraulic-released multiplate type. The travel motor operates by pressure oil from the pump and transmits the rotation to the travel reduction gear.
The travel reduction gear is a threee-stage planetary reduction gear and converts the rotation, transmitted from the travel motor, to a low-speed high torque in order to rotate the drive tumblers and crawler shoes. The travel brake valve prevents the overload to the travel circuit as well as cavitation.
Travel Brake Valve
Travel Reduction Gear
T25N-03-07-001
Travel Motor
T3-10-1
COMPONENT OPERATION / Travel Mechanism TRAVEL MOTOR Tilt pistons (4) (4 used) are provided in order to change the inclination of swash plate (7) by using balls (6). Rotor (8) is pressed to valve plate (1) by the force of spring (9).
The travel motor is a swash plate type variable displacement axial plunger motor and consists of valve plates (1), plungers (2), shoes (3), shaft (5), swash plate (7) and rotor (8). Shaft (5) is splined to rotor (8) into which plungers (2) are inserted.
4
1
2
3
5
T25N-03-07-003
9
8
7
6
1 - Valve Plate 2 - Plunger 3 - Shoe
4 - Tilt Piston 5 - Shaft
67-
T3-10-2
Ball Swash Plate
89-
Rotor Spring
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 B Port A
Port A
1 8 2
3 5
7 Valve Plate
T183-03-05-009
1 - Valve Plate 2 - Plunger
3 - Shoe 5 - Shaft
7-
T3-10-3
Swash Plate
8-
Rotor
COMPONENT OPERATION / Travel Mechanism PARKING BRAKE
The parking brake is a spring-set/hydraulic-released type that releases the brake when self pressure is applied to brake chamber M. The parking brake is always applied, except for travel mode. Friction plate (5) is splined to rotor (2) and plate (4) is splined to casing (6), respectively.
1
2
When Brake Is Applied 1. When the travel lever in neutral, brake chamber M is connected to the hydraulic oil tank. 2. Brake piston (3) is pushed down by the force of spring (1). 3. As a result, plate (4) is pressed to friction plate (5), rotor (5) does not turn. 4. Thus, the parking brake is applied.
Hydraulic Oil Tank T25N-03-07-004
When Brake Is Released 1. When moving the travel lever, self pressure in the main circuit acts to brake chamber M.
1
2
2. Brake piston (3) moves upward by compressing spring (1). 3. As a result, plate (4) and friction plate (5) are freed and the parking brake is released.
T25N-03-07-005
T3-10-4
COMPONENT OPERATION / Travel Mechanism When brake is applied
1
2
M
3 4 5
6
T2BC-03-10-002
When brake is released
1
2
M
3 4 5 6
T2BC-03-10-003
1 - Spring 2 - Rotor
3 - Brake Piston 4 - Plate
5 - Friction Plate
T3-10-5
6-
Casing
COMPONENT OPERATION / Travel Mechanism TRAVEL REDUCTION GEAR The travel reduction gear is a three-stage planetary reduction gear. Travel motor (1) rotates shaft (11) and its turning torque is transmitted to third stage carrier (6) and ring gear (5) through first stage planetary gear (12), first stage carrier (10), second stage sun gear (9), second stage planetary gear (13), second stage carrier (8), third stage sun gear (7) and third stage planetary gear (14).
Third stage carrier (6) is fixed to housing (2) of travel motor (1) and does not turn. Ring gear (5) and drive tumbler (3) are both bolted to drum (4) and turn together.
1
2
3
4
5
6
7
8
9
10
11
Third Stage
Second Stage
First Stage
14
13 12
T111-03-04-011 T25N-03-07-001
1234-
Travel Motor Housing (Travel Motor) Drive Tumbler Drum
5678-
Ring Gear Third Stage Carrier Third Stage Sun Gear Second Stage Carrier
9 - Second Stage Sun Gear 10 - First Stage Carrier 11 - Shaft
T3-10-6
12 - First Stage Planetary Gear 13 - Second Stage Planetary Gear 14 - Third Stage Planetary Gear
COMPONENT OPERATION / Travel Mechanism TRAVEL BRAKE VALVE The travel brake valve is located at the head of travel motor and consists of the following valves.
• Overload relief valve:
• Check valve:
Prevents overloading to the motor circuit and surge pressure.
• Counterbalance valve:
Assists the counterbalance valve in operation and prevents cavitation in the motor circuit.
• Travel motor displacement angle selection valve:
Makes starting and stopping of travel smoothly and prevents coasting when descending slope.
The tilt piston is controlled by pilot pressure from the high speed selection solenoid valve.
Travel Motor Displacement Angle Selection Valve
Overload Relief Valve
Overload Relief 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 into port P1 (4), check valve (2) opens and oil flows into motor port a1 (8).
1. When internal pressure of the circuit exceeds the set pressure of overload relief valve (9), this valve opens and release high pressure to the low pressure side in order to prevent the travel motor from overloading.
2. On the other hand, return oil from the travel motor returns to motor port a2 (7), but is blocked by check valve (2). 3. When pressure in port P1 (4) increases further, pressure oil goes through orifice (1) acts on the end of spool (3) and moves to the right. 4. As a result, return oil from the travel motor flows through the notch on external circumference of spool (3) and goes to port P2 (6). Now, pressure oil flows to turn the travel motor. 5. When moving the travel lever to neutral, spool (3) returns to original position by the spring force and blocks the circuit in order to stop the rotation of travel motor. When Descending Slope 1. When descending slope, the travel motor is turned forcibly by its self weight, acting as pumping.
2. In addition, this releases shock pressure caused by the inertial force at the stop of travel motor. 3. When the travel motor sucks oil by pumping action, check valve (2) opens (by make-up action) in order to prevent cavitation. Shuttle Function 1. When spool (3) moves, port P1 (4) or port P2 (6) is connected to port P3 (5) (for parking brake). Pressure oil goes into the parking brake chamber and the parking brake is released. 2. When the travel motor stops, spool (3) returns to neutral, port P3 (5) is closed. Pressure oil in the parking brake chamber flows to the drain port the parking brake is applied.
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 increases and the brake of the travel motor is functioned. 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 Valve
1
9
2
8
3
4
To Control Valve
5
6
10
7
T165-03-05-004
1 - Orifice 2 - Check Valve
4 - Port P1 5 - Port P3
3 - Spool (Counterbalance Valve)
6 - Port P2
7 - Port a2 8 - Port a1
T3-10-9
9 - Overload Relief Valve 10 - Travel Motor Displacement Angle Selection Valve
COMPONENT OPERATION / Travel Mechanism TRAVEL SPEED SELECTION Piston (1) is located next to swash plate (3) and changes the displacement angle of swash plate (3) according to the movement of piston (1) in order to select the travel speed.
3. Pressure oil from motor port a2 (7) or a1 (8) on high pressure side is blocked by spool (5) and oil in piston (1) returns to the hydraulic oil tank through spool (5).
• Low speed
4. Swash plate (3) is pushed by plunger in the travel motor until surface A of swash plate (3) contacts the casing.
1. When the high/low travel speed selection switch is set to low speed position, high travel speed selection solenoid valve is not selected, so that pilot pressure is not fed to port PS (4).
5. As a result, the displacement angle of swash plate (3) is maximized and plunger stroke increases so that the travel motor runs at a low speed.
2. As a result, spool (5) is pushed by spring (6) to the left. 6
4
5
6
T165-03-05-005
SurfaceA
1
3 2
8
7
Swash Plate Surface
Surface B
Valve Plate
T165-03-05-010
1 - Piston 2 - Steel Ball
3 - Swash Plate 4 - Port PS
5 - Spool 6 - Spring
T3-10-10
7 - Port a2 8 - Port a1
COMPONENT OPERATION / Travel Mechanism • High Speed
3. Pressure oil in motor port a2 (7) or a1 (8) on high pressure side acts on piston (1) through spool (5).
1. When the high/low travel speed selection switch 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 reduces the displacement angle of swash plate (3). Plunger stroke in the travel motor is reduced in order to run the travel motor at a high speed.
2. As a result, pilot pressure is fed from port PS (4) in order to move spool (5) to the right.
6
4
5
6
T165-03-05-007
Surface A
1
3 2
7
Swash Plate Surface
8 Valve Plate
Surface B
T165-03-05-011
1 - Piston 2 - Steel Ball
3 - Swash Plate 4 - Port PS
5 - Spool 6 - Spring
T3-10-11
7 - Port a2 8 - Port a1
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COMPONENT OPERATION / Others (Upper Structure) 4-SOOL SOLENOID VALVE UNIT Composition The 4-spool solenoid valve unit consists of the following valves.
• Derricking drum unlocking solenoid valve: By signal
• Pressure-reducing valve: Reduces pressure in the
from MC2/A, delivers pressure oil to boom derricking brake and boom derricking drum lock.
pilot circuit and supplies pressure oil. • Second overhoist solenoid valve: By signal from MC2/B, blocks pressure oil to front, rear, boom derricking 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 selection valve. • Slewing brake solenoid valve: By slewing brake switch, delivers pressure oil to the parking brake for slewing motor.
To Front, Rear, Derricking and Third/Fourth Remote Control Valves㩷 To Travel Displacement Angle Selection Valve㩷 To Slewing Parking Brake㩷 To Derricking Drum Lock㩷
From Pilot Pump㩷
1
1-
Second Overhoist Solenoid Valve㩷 2 - High-Speed Travel Solenoid Valve㩷
3㩷
2
3
Slewing Brake Solenoid Valve㩷
4
4-
Derricking Drum Unlocking Solenoid Valve㩷
㩷
T3-11-1
5
5㩷
T2BC-03-11-002
Pressure-Reducing Valve㩷
COMPONENT OPERATION / Others (Upper Structure) Internal Construction
1
2
3
4
5
T2BC-03-11-001
1-
Second Overhoist Solenoid Valve㩷
3 - Slewing Brake Solenoid Valve㩷
2-
High-Speed Travel Solenoid Valve㩷
㩷
4 - Derricking Drum Unlocking Solenoid Valve㩷 㩷
T3-11-2
5-
㩷
Pressure-Reducing Valve㩷
COMPONENT OPERATION / Others (Upper Structure) SOLENOID VALVE The solenoid valve is an ON/OFF solenoid valves of normally closed type. Operation 1. In neutral state, port T and the output port are connected through the notch of spool and pressure 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 output port. 5. When stopping electric current to solenoid, the spool returns by spring force to the original position.
T3-11-3
COMPONENT OPERATION / Others (Upper Structure) Neutral state
T
Output Port
P
Spool
Spring
Solenoid
T324-02-08-007
Exciting stage
T
Output Port
P
Spool
Spring
T3-11-4
Solenoid
T324-02-08-007
COMPONENT OPERATION / Others (Upper Structure) DRUM UNLOCKING SOLENOID VALVE The drum unlocking solenoid valve is an ON/OFF solenoid valve of normally closed type. Three drum unlocking solenoid valves are provided for front, rear and fourth (optional) drums. When setting the brake mode key switch to auto brake position, depress the brake pedal and turn ON free mode switch for drum. Signal from MC2/A is input to the solenoid for drum unlocking solenoid valve. As a result, the solenoid is excited to operate the drum unlocking solenoid valve.
NOTE: As for operation of drum unlocking solenoid valve, refer to the section for 4-spool unit.
Port 3 (From Pilot Pump) Port 2 (Output Port)
Port 1 (Hydraulic Oil Tank)
T3-11-5
T25N-03-08-008
COMPONENT OPERATION / Others (Upper Structure) GATE LOCK VALVE The gate lock valve consists of gate lock solenoid valve and pilot relief valve. The gate lock valve turns ON/OFF in the pilot circuit. The pilot relief valve keeps the pressure in pilot circuit.
Gate Lock Solenoid Valve Gate Lock Valve㩷
T2BC-03-11-003
Pilot Relief Valve㩷
Pilot Relief Valve㩷 Gate Lock Solenoid Valve㩷
T2BC-03-11-004
T3-11-6
COMPONENT OPERATION / Others (Upper Structure) Gate Lock Solenoid Valve The gate lock solenoid valve is operated by the gate lock lever operation and controls pressure oil which is supplied from the pilot pump to the pilot circuit. When the gale lock lever is at the LOCK position, the spool in solenoid valve is in neutral. As port P’ is connected to port A, pressure oil in the pilot pump flows to the tank from port T.䎃 Therefore, pressure at port P’ (output port) does not rise and operate the circuit. When the gate lock lever is at the UNLOCK position, the solenoid valve is operated and port P’ is connected to port B. Therefore, port P is blocked to the tank circuit and pressure oil is supplied to port P1 (outlet port) from the pilot pump. Consequently the circuit is operated.
Gate Lock Solenoid Valve㩷
Pilot Pump㩷
To Pilot Circuit㩷
Gate Lock: LOCK SoL.
Pilot Relief Valve㩷
T2BC-03-11-005
Gate Lock: UNLOCK Spool㩷
SoL.
Spool㩷
T2BC-03-11-006
T3-11-7
COMPONENT OPERATION / Others (Upper Structure) Pilot Relief Valve The pilot relief valve is a relief valve which keeps pressure in the pilot circuit.䎃When pressure in the pilot circuit becomes higher than the set pressure in pilot relief valve, pressure oil from the pilot pump flows to port T in order to decrease pressure in the pilot circuit. When pressure in the pilot circuit becomes lower than the set pressure in pilot relief valve, the pilot relief valve is closed and pressure oil from the pilot pump flows to the pilot circuit side. Gate Lock Solenoid Valve㩷
Pilot Pump
To Pilot Circuit㩷
To Pilot Relief Valve㩷
T3-11-8
T2BC-03-11-007
COMPONENT OPERATION / Others (Upper Structure) BRAKE PEDAL UNIT
The brake pedal unit consists of brake pedal (2), lock pedal (1) and pressure-reducing valve (5). With the drum brake release solenoid valve switched, when depressing brake pedal (2), pilot pressure acting to drum brake returns to the hydraulic oil tank, and drum brake is applied. (Spring-set/hydraulic-released control)
Fourth Brake Pedal Rear Brake (Optional) Pedal
Front Brake Pedal
T2BC-03-11-008
1
2
T2BC-01-02-017
7
6
5
4
3
1 - Lock Pedal 2 - Brake Pedal
3 - Brake Depressing Pressure Sensor 4 - Pressure-Reducing Valve
5-
Link
6-
Applied Sensing Switch
T3-11-9
7-
Lever
COMPONENT OPERATION / Others (Upper Structure) PRESSURE-REDUCING VALVE
The pressure-reducing valve delivers pressure according to the depressing amount of the brake pedal to apply and release the drum brake.
Output Curve: A-B Range 1. When brake pedal is not depressed, rod (1) is pushed rightward to stroke end.
2. Rod (1) compresses both balance spring (4) and return spring (5) through retainer (2) and spring guide (3).
3. As a result, balance spring (4) pushes spool (6) to the right through spring seat (7).
4. When spool (6) moves to the right and the notch of spool (6) reaches port P, pressure oil from port P flows to output port and pressure in output increases.
5. At the same time, pressure oil in port P flows to piston chamber through hole in spool (6) and moves piston (8) to the right.
6. When pressure in piston chamber is smaller than the force of balance spring (4), spool (6) moves to the right and pressure in output port increases continuously.
Drum Brake Release A Pressure
C
7. When pressure in piston chamber becomes greater than the force of balance spring (4), spool (6) compresses balance spring (4) through spring seat (7), and moves leftward. 8. However, rod (1) stops the leftward movement of spool (6) 9. Therefore, port P and the output port are kept connected. 10. As a result, pilot pressure acts to the drum brake and the brake is released. 11. This state continues until the notch of spool (6) is connected to port T.
T3-11-10
B
D E 0
F
Pedal Stroke
COMPONENT OPERATION / Others (Upper Structure)
1
2
3
4
5
6
7
8
Output Port
T25N-03-08-010
T
Hole
Piston Chamber
P
1 - Rod 2 - Retainer
3 - Spring Guide 4 - Balance Spring
5 - Return Spring 6 - Spool
T3-11-11
7 - Spring Seat 8 - Piston
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.
4. Pressure oil in output port flows to port T (hydraulic oil tank), so that pressure in output port decreases.
5. When pressure in output port decreases, pressure in piston chamber also decreases at the same time.
6. When pressure in piston chamber becomes smaller than the force of balance spring (4), spool (6) moves to the right by balance spring (4) through spring seat (7).
Drum Brake Release A Pressure
B C
D
7. When the notch of spool (6) reaches port P, port T and the output port are disconnected, while port P and the output port are connected. 8. Pressure oil from port P comes in, and pressures in output port and the piston chamber increase. 9. When pressure in piston chamber is smaller than the force of balance spring (4), spool (6) moves to the right and pressure in output port increases continuously. 10. When pressure in piston chamber becomes greater than the force of balance spring (4), spool (6) compresses balance spring (4) through spring seat (7), and moves to the left. 11. By repeating these steps, spool (6) is positioned depending on the movement of rod (1). 12. Thus, pressure is generated depending on the depressing amount of brake pedal.
T3-11-12
E 0
F
Pedal Stroke
COMPONENT OPERATION / Others (Upper Structure) When pressure decreases
1
2
3
4
5
6
7
8
Output Port
T25N-03-08-010
T
Hole
Piston Chamber
P
When pressure increases
1
2
3
4
5
6
7
8
Output Port
T25N-03-08-010
T
Hole
Piston Chamber
P
1 - Rod 2 - Retainer
3 - Spring Guide 4 - Balance Spring
5 - Return Spring 6 - Spool
T3-11-13
7 - Spring Seat 8 - Piston
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 port T and the output port are connected. 4. Pressure oil in output port flows to port T (hydraulic oil tank). In addition, pressure oil in piston chamber passes through hole of spool (6) at the same time, and goes to port T. 5. When pressure in piston chamber becomes smaller than the force of balance spring (4), spool (6) moves to the right by balance spring (4) through spring seat (7).
Drum Brake Release A Pressure
B C
D
6. However, when brake pedal is depressed fully to stroke end, port P and output port are kept disconnected. 7. Therefore, port T and output port are kept connected, so pressure in output port is equalized with pressure in port T (hydraulic oil tank). 8. As a result, pressure oil acting to drum brake flows to the hydraulic oil tank, so that brake is applied.
T3-11-14
E 0
F
Pedal Stroke
COMPONENT OPERATION / Others (Upper Structure)
1
2
4
5
6
7
8
Output Port
T25N-03-08-010
T
Hole
Piston Chamber
P
1 - Rod 2 - Retainer
45-
Balance Spring Return Spring
67-
Spool Spring Seat
T3-11-15
8-
Piston
COMPONENT OPERATION / Others (Upper Structure) COUNTERWEIGHT CYLINDER The counterweight cylinder extends and retracts due to pressure oil from the 4-unit control valve, and removes and install the counterweight. The pipes at cylinder head is equipped with valve block (15) and incorporates the down safety valve and slow return valve. The down safety valve blocks the circuit and prevents the counterweight from falling when the hose is damaged. The slow return valve reduces the lower side circuit and prevents the counterweight from lowering rapidly due to the counterweight own weight.
1
2
13
3
4
5
6
14
7
15
8
16
9
10
11
12
17
T2BC-03-11-009
12345-
Set Screw㩷 Wear Ring㩷 Packing㩷 Wear Ring㩷 O-Ring㩷
678910 -
O-Ring㩷 Backup Ring㩷 Bushing㩷 Packing㩷 Backup Ring㩷
11 12 13 14 㩷
Ring㩷 Dust Seal㩷 Piston㩷 Cylinder Tube㩷
T3-11-16
15 - Valve Block㩷 16 - Piston Rod㩷 17 - Cylinder Head㩷 㩷 㩷
COMPONENT OPERATION / Others (Upper Structure) ACCUMULATOR The accumulator is provided in pilot circuit, and functions to absorb hydraulic surge and retain pilot pressure (for a short time) immediately after the engine stops. The accumulator consists mainly of body (5), holder (4), poppet (1) and bladder (2) that contains nitrogen gas (N2) hermetically.
6
1
Nitrogen Gas (N2)
5
2
4
• Pressure oil from pilot pump passes through port A, and enters accumulator and compresses bladder (2) until pressure oil is balanced with nitrogen gas in bladder (2).
Pilot Pressure Oil
3
• If pressure oil is not obtained in circuit due to engine stalling or the like, compressed bladder (2) expands and delivers the accumulated oil through port A into pilot circuit. A
T105-02-10-003
1 - Poppet 2 - Bladder 3 - Oil Port
4 - Holder 5 - Body 6 - Gas Plug
GOVERNOR MOTOR
The governor motor is used for engine control. The governor motor incorporates worm gear that prevents operation of the governor motor outside its control 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".)
Output Gear
Output Shaft
Worm Gear
Motor
Sensor Gear
T3-11-17
Governor Potentio Sensor
Worm Wheel
T157-02-05-018
This Page Left Blank Intentionally
COMPONENT OPERATION / Others (Base Carrier) OUTLINE The base carrier performs travel and sustains self weight of the upper structure. The base carrier consists of lower frame (5), side frame (10), center joint (2), slewing bearing (3), front idler (6), upper roller (11), lower roller (9), crawler shoe (4), travel mechanism (12), retract cylinder (8), jack-up cylinder (1) (optional) and take-up cylinder (7) (optional).
3 4
2
5
1
6
12 11 10 9 8
T2BC-01-02-001
7
1-
Jack-Up Cylinder (4 Used) (Optional)㩷 2 - Center Joint㩷 3 - Slewing Ring㩷
4-
Crawler Shoe (2 Used)㩷
7-
Take-Up Cylinder (2 Used)㩷
10 - Side Frame (2 Used)㩷
56-
Lower Frame㩷 Front Idler (2 Used)㩷
89-
Retract Cylinder (2 Used)㩷 Lower Roller (20 Used)㩷
11 - Upper Roller (2 Used)㩷 12 - Travel Mechanism (2 Used)㩷
T3-12-1
COMPONENT OPERATION / Others (Base Carrier) SLEWING RING The slewing ring sustains self weight of the upper structure and makes smooth slewing. This ring is a single row type ball ring and consists of outer race (1), inner race (3), ball (7), supports (5, 6) and seals (2, 4). Outer race (1) is bolted to the upper structure and inner race (3) is bolted to the base carrier. The internal teeth of inner race (3) are enmeshed with output shaft of slewing reduction gear.
1
2
5 3
6 7 4
T135-03-02-001
12-
Outer Race㩷 Seal㩷
3 - Inner Race㩷 4 - Seal㩷
5 - Support㩷 6 - Support㩷
T3-12-2
㪎㩷㪄㩷 Ball㩷 㩷
COMPONENT OPERATION / Others (Base Carrier) CENTER JOINT The center joint is a full 360 qturn joint and delivers pressure oil to travel motors while preventing hoses from kinking when the upper structure slews. The spindle is fixed at the center of slew of the base carrier.
Pressure oil from each port of the body passes through spindle and flows to left and right travel motors and retract cylinders and jack-up cylinders (optional) through lower control valves. The seal provided between spindle and body prevents oil leakage.
H
A Body㩷
B C
E D G F Spindle㩷
A E
G
D B E T2BC-03-12-002
C
Port A -
Right Travel Forward㩷
Port D -
Left Travel Forward㩷
Port B -
Right Travel Reverse㩷
Port E -
Port C -
Left Travel Reverse㩷
Port F -
Retract Cylinder Extend (with Jack: Lower Circuit Hydraulic Source) Retract Cylinder Retract (with Jack: Lower Circuit Link Line)㩷
T3-12-3
H Port G -
High / Low Travel Speed Selection Pilot Pressure㩷 Port H - Travel Mechanism Drain㩷 㩷
COMPONENT OPERATION / Others (Base Carrier) RETRACT CYLINDER The retract cylinders are used to extend and retract the crawler frames by hydraulic cylinders. The crawler frames are extended for higher operating stability. Retraced the retract cylinder for convenience of transport. The retract cylinder is controlled by the retract cylinder extend / retract solenoid valve in 4-spool control valve as for the STD specification machine. When selecting the retract cylinder extend/retract solenoid valves, pressure oil is delivered to the retract cylinder through the spools in 4-spool control valve. The retract cylinder is controlled by the lower control valve (manual operation) with the jack-up (optional) attached.䎃 When operating the lever for retract operation, the spool is selected and pressure oil flows to the retract cylinder.
1
2
3
Retract Cylinder㩷
4
5
6
7
8
9
M25N-07-035
10
㩷 T25N-03-09-002
123-
Boot㩷 Cylinder Head㩷 Bushing㩷
4 - U-Ring㩷 5 - Cylinder Tube㩷 6 - Piston Rod㩷
7 - Piston㩷 8 - Piston Seal㩷 㩷
T3-12-4
9 - Wear Ring㩷 10 - Piston Nut㩷 㩷
COMPONENT OPERATION / Others (Base Carrier) JACK-UP CYLINDER (OPTIONAL) The jack-up cylinder consists of cylinder and pilot check. In addition, slow return check valve is provided in the return line on the jack-up cylinder retract side. The jack-up cylinders are used to disassemble the lower frame into upper and lower sections for transport of the machine, and reassemble them for operation. While the lower frame is lifted by jack-up cylinders, crawler frames are attached, or removed for loading onto a trailer.
Jack-Up Cylinder㩷
Lower Frame㩷
Crawler Frame
The jack-up cylinder is controlled by the lower control valve (manual operation). When operating the lever for jack-up, pressure oil flows to the jack-up cylinder through the spool in lower control valve.
M25N-07-034
Double Check Valve
1 2 3 4 5
6 7
8
T2BC-03-12-003
12-
Piston㩷 U-Ring㩷
3 - Wear Ring㩷 4 - Piston Rod㩷
5 - Cylinder Tube㩷 6 - Bushing㩷
T3-12-5
7 - Cylinder Head㩷 8 - U-Ring㩷
COMPONENT OPERATION / Others (Base Carrier) Double Check Valve
The double check valve maintains pressures on the rod side and the bottom side of jack-up cylinder. Thus, even if jack-up cylinders are subjected to external forces, extension and retraction of jack-up cylinders are prevented.
Jack-Up Cylinder
Operation 1. Pressure oil from port A (jack-up cylinder extend side) opens the check valve at slow return check valve and acts to the pilot check valve.
Check Valve
Check Valve
2. Pressure oil opens the check valve on jack-up cylinder extend side, flows to the bottom side of jack-up cylinder and acts to the check valve on jack-up cylinder retract side.
Check Valve
3. Pressure oil also opens the check valve on rod side (return side), so that pressure oil on the rod side passes through check valve and flows to the hydraulic oil tank.
B A
4. As a result, the jack-up cylinder extends. 5. When setting key switch to OFF position, jack extend/retract solenoid valve returns to neutral. 6. The main spool in lower control valve also returns to neutral, so that extend/retract of jack-up cylinder stops.
T25N-03-09-006
Jack-Up Cylinder
7. At this time, even if the jack-up cylinders are subjected to external forces, the jack-up cylinders are kept in position as the return line is blocked by the check valve. Check Valve
Check Valve
T25N-03-09-008
T3-12-6
COMPONENT OPERATION / Others (Base Carrier) Slow Return Check Valves
The slow return check valve is provided in the extend circuit of jack-up cylinder. By reducing the return line on the jack-up cylinder retract side in order to deliver pressure oil slowly, rapid lowering of the machine by self weight is prevented.
Jack-Up Cylinder
Operation 1. Pressure oil from port B flows to the rod side of jack-up cylinder. 2. On the other hand, pressure oil in return line passes through double check valve and acts to the check valve in slow return check valve.
Orifice Check Valve
3. Return oil is blocked by the check valve, so that return oil flows through the orifice to port A. 4. As a result, the jack-up cylinder retract speed is reduced and prevents rapid lowering of the machine.
B
A
T25N-03-09-007
Orifice
Check Valve
Slow Return Check Valve
To Lower Control Valve
From Jack-Up Cylinder
T25N-03-09-003
T3-12-7
COMPONENT OPERATION / Others (Base Carrier) TAKE-UP CYLINDER (OPTIONAL) The take-up cylinder pushes the left and right front idlers forward by using the travel circuit pressure and gives a constant tension the track shoe. The travel circuit pressure is supplied to the bottom side of take-up cylinder. Consequently, the front idler is pushed and the left and right track shoes are given a constant tension. When the excessive power acts on the front idler, the return check valve is open and release pressure oil from the bottom side of take-up cylinder in order to absorb the shock.
1
2
3
4
5
6
From Travel Circuit㩷
T2BC-03-12-001
12-
Head Cap㩷 Scraper㩷
34-
Scraper㩷 O-Ring㩷
5 - Housing㩷 㩷
T3-12-8
6㩷
Piston Rod㩷
SECTION 4
OPERATIONAL PERFORMANCE TEST —CONTENTS— Group 5 Component Test
Group 1 Introduction Operational Performance Tests .............. Preparation For Performance Tests ........ Precautions For Starting Engine .............
T4-1-1 T4-1-2 T4-1-3
Group 2 Standard Performance Standards ......................... Main Pump P-Q Diagram....................... Slewing Pump P-Q Diagram ..................
T4-2-1 T4-2-4 T4-2-6
Group 3 Engine Test Engine Speed ........................................ Engine Compression Pressure .............. Valve Clearance Adjustment .................. Nozzle Check ........................................
T4-3-1 T4-3-2 T4-3-3 T4-3-5
Pilot Circuit Primary Pilot Pressure ........ Brake Circuit Primary Pilot Pressure...... Remote Control Valve Secondary Pilot Pressure ................... High / Low Travel Speed Selection Pressure ............................. Slewing Brake Release Pressure........... Main Relief Valve Pressure .................... Port Relief Valve Pressure ..................... Main / Slewing Pump Flow Rate ............ Regulator Adjustment (Main Pump) ....... Regulator Adjustment (Slewing Pump) ...... Slewing Motor Drainage......................... Travel Motor Drainage ........................... Boom Dericking Motor Drainage ............
Group 4 Crane Test Travel Speed ......................................... Mistrack ................................................. Travel Parking Brake Drift...................... Slewing Speed....................................... Slewing ring Play ................................... Hoist / Lower Speeds (Front / Rear Drums) .......................... Regulator Adjustment ............................ Boom Derricking Speed ......................... Counterweight Cylinder Speed .............. Jack-Up (Optional) Speed ..................... Retract Speed........................................ Lifting Load Lowering By Front / Rear Drums ....................... Control Lever Operating Force .............. Control Lever Stroke............................. .
T4-4-1 T4-4-2 T4-4-3 T4-4-4 T4-4-5 T4-4-6 T4-4-7 T4-4-8 T4-4-9 T4-4-10 T4-4-11 T4-4-12 T4-4-13 T4-4-14
2BCT-4-1
T4-5-1 T4-5-3 T4-5-5 T4-5-7 T4-5-8 T4-5-9 T4-5-16 T4-5-17 T4-5-22 T4-5-25 T4-5-26 T4-5-28 T4-5-30
Group 6 Adjustment MC2/A Adjustment ................................. T4-6-1 High Idle Calibration .............................. T4-6-2 Rack Zero Calibration............................ T4-6-4 Power Increase Pressure Calibration .... T4-6-6 Full Rack Calibration ............................. T4-6-8 Brake Pedal Unit Adjustment ................. T4-6-10
2BCT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedures to quantitatively check all systems and functions on the machine. Kinds of Operational Performance Tests 1. System Performance and Function Test Each system such as engine, travel, swing, and hydraulic cylinder is individually tested. 2. Component Performance and Function Test Each component such as hydraulic pump, motor, and various valves is individually tested. Purpose of Operational Performance Tests 1. To evaluate the performance and function of a system or component by comparing the test results to the standard specifications. 2. According to the evaluation above, repair, adjust, or replace the system or component as necessary to restore the systems and functions to the required performance level. 3. To ensure safety and high efficiency operation. Standard Specifications New machine applied specifications are described in this manual for test evaluation purposes. Tolerances are indicated as necessary.
Precautions for the Test Result Evaluation 1. Besides determining whether the test results meet the standard specifications or not, check which level of standards the test results correspond to. 2. In compliance with how long and under what type of work or conditions the machine has operated, or the machine maintenance condition, the extent of deterioration of the machine’s performance may differ. Decide the degree of repair, adjustment, and/or replacement corresponding to the machine operation hours. NOTE: With the passage of time, the machine's operational performance deteriorates, so that the machine needs to be serviced periodically. Before servicing the machine, conduct performance tests to check the extent of deterioration and to decide what kind of service needs to be done referring to the standard specifications.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS
FOR
PERFORMANCE
Observe the following rules in order to carry out performance tests accurately and safely. 1. The Machine Before starting performance tests, perform a sight-inspection of the machine. Then, if any abnormalities such as oil or coolant leaks, loose bolts, or cracks are found, repair them. 2. Test Area and Measuring Instrument (1) Select a hard and level surface. (2) Secure enough space to allow the machine to run straight for more than 10 m (33 ft). (3) Secure enough space to allow the machine to make a full swing with the front attachment extended. (4) Provide equipment and measuring instruments suitable to the test to be performed. (5) If required, rope off the test area and provide signboards to keep unauthorized personnel away. (6) Provide measuring weights or equivalent ones. (7) Coordinate work signals and procedures with co-workers.
T105-06-01-003
3. Precautions (1) While testing, always monitor the work site conditions 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 hydraulic pipings, use oil pans to catch escaping oil. (4) After completing the tests, properly dispose of the waste oil or the used shop towels to protect the work site from pollution. 4. Precise Measurement (1) Accurately calibrate test instruments in advance to obtain correct data. (2) Carry out tests under the exact test conditions prescribed for each test item. (3) Repeat the same test and confirm that the test data obtained can be repeated. Use the average values of the measurements.
T4-1-2
SA-331
OPERATIONAL PERFORMANCE TEST / Introduction PRECAUTIONS FOR STARTING ENGINE
1. Check that lock lever (1) is placed in the LOCK position.
Lock Position
1
2. Check that all control levers are placed in the NEUTRAL position.
3. Check that front, rear and fourth (optional) brake pedals (5, 7 and 6) are applied, and front, rear and fourth (optional) drum brake mode selection switches (2, 3 and 4) are set to the “Auto Brake” mode. 4. Check that slewing brake switch (8) is ON (Brake position).
T2BC-04-04-001
2
8
3
1
NOTE: Engine starts when front, rear and fourth (optional) drum mode selection switches (2, 3 and 4) are set to the “Auto Brake” mode, and slewing brake switch (8) is turned ON (Brake position).
T2BC-04-01-002
7
6
5 4
T2BC-01-02-003
T4-1-3
This Page Left Blank Intentionally
OPERATIONAL PERFORMANCE TEST / Standards PERFORMANCE STANDARDS The performance standards show the required performance measurements. For details including measuring method, refer to T4-3 onward. Data in ( ) is given for reference.
Measuring conditions: Engine speed : High idle Hydraulic oil temperature : 50r5 qC (122r41qF)
Performance Standard
Performance Test Designation Engine Speed
min
Remarks
-1
T4-3-1
Maximum Speed (High Idle)
2070 to 2130
Minimum Speed (Low Idle)
760 to 820
Starting Speed
885 to 945
Engine Compression Pressure
2
MPa (kgf/cm , psi)
Valve Clearance
2.7 (28, 390)
mm
IN
0.4
EX
0.6
Nozzle Injection Pressure
2
MPa (kgf/cm , psi)
Travel Speeds
After Warming Up
T4-3-2
Cold
T4-3-3
25.5r1 (260r10, 3710r145)
T4-3-5 T4-4-1
sec/10 m
(Slow)
26.5 to 29.3
(Fast)
15.1 to 16.7
Mistrack
mm/10 m
60 or less
At High Speed Travel
Travel Motor Leakage turn
Motor Slippage When Parking Slewing Speed Slewing Ring Play
(1/6 or less)
mm/5 min
(0)
sec/3 turn
64.7 to 71.4
mm
Hoisting and Lowering Speeds
(5 to 6)
T4-4-4 Allowable Limit
16.1 to 17.8
Low Speed Lock Switch: Lock
Fixed High Speed
8.1 to 8.9
Low Speed Lock Switch: Lock
Normal Low Speed
11.2 to 12.4
Normal High Speed Fourth (Optional)
T4-4-5 T4-4-6
sec/Drum 6 turns
Fixed Low Speed
Boom Derricking Speed
T4-4-2 T4-4-3
Slippage Until Brake is Applied
Front / Rear
Reference Page
5.6 to 6.2 11.2 to 12.4
sec/Drum 6 turns
10.7 to 11.8
T4-2-1
T4-4-8
OPERATIONAL PERFORMANCE TEST / Standards Performance Standard
Performance Test Designation Counterweight Cylinder Speed
190 to 200
Retract
30 to 33
Jack-up (Optional) Speed
10 to 8
Retract
33 to 38
T4-4-11 38 to 41
Retract
30 to 38 mm/2 min
Control Lever Operating Control Force
N (kgf, lbf)
(0)
First Detent
4.4 to 15.1 (0.4 to 1.5, 1.0 to 3.4)
Second Detent
15.1 to 22.0 (1.5 to 2.2, 3.4 to 5.0)
First Detent
4.2 to 12.4 (0.4 to 1.3, 0.9 to 2.8)
Second Detent
12.4 to 19.0 (1.3 to 1.9, 2.8 to 4.3) 4.4 to 22.0 (0.4 to 2.2, 1.0 to 5.0)
Travel Lever
5.3 to 15.9 (0.5 to 1.6, 1.2 to 3.6)
Slewing Lever
7.5 to 16.1 (0.8 to 1.6, 1.7 to 3.6)
Front / Rear Drum Lever Third / Fourth Lever
Engine Speed: Low Idle T4-4-12 T4-4-18
Boom Derricking Lever
Control Lever Stroke
Engine Speed: Low Idle
sec/Full Stroke
Extend
Third / Fourth Lever
No Load T4-4-10
Extend
Front / Rear Drum Lever
Engine Speed: Low Idle
mm/290 min
Load Lowering By Front / Rear Drums
Reference Page T4-4-9
sec/Full Stroke
Extend
Retract Speed
Remarks
T4-4-14
mm
First Detent
49.5 to 51.6
Second Detent
84.9 to 87.1
First Detent
21.7 to 53.9
Second Detent
88.5 to 90.9
Boom Derricking Lever
84.9 to 87.1
Travel Lever
40.9 to 42.6
Slewing Lever
64.6 to 67.3
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standards Performance Test Designation
Performance Standard
Remarks
Reference Page
Hydraulic System Primary Pilot Pressure
2
MPa (kgf/cm , psi)
4.9 0.5 0 (50 5 0, 712 73 0)
Pilot Circuit Primary Pilot Pressure
9.8 0.5 0
Brake Circuit Primary Pilot Pressure
(100
5
73 0, 1420 0)
Remote control Valve Secondary Pilot Pressure
T4-5-1 T4-5-3 T4-5-5
2
MPa (kgf/cm , psi)
Front / Rear Lever
First Detent
(2.0r0.2) ((20r2, 290r29)
Second Detent (3.7r0.2) ((38r2, 529r29)) Boom Derricking
(3.7r0.2) ((38r2, 542r29))
Travel
(2.0r0.2) ((20r2, 290r29)) (2.9 0.5 0) ((30 5 0, 422 73 0))
Slewing High / Low Travel Speed Selection Pressure MPa (kgf/cm2, psi)
(1.5 (15.3, 218) or more) 73 0, 712 0))
T4-5-8
Front / Rear Control Valve
28.3 to 34.5 (289 to 352, 4110 to 5020)
T4-5-9
Slewing Control Valve
28.7 to 35.1 (293 to 358, 4170 to 5100)
T4-5-11
4-Spool Control Valve
20.6 (210, 2995)
T4-5-13
17.2 to 19.6 (175 to 200, 2500 to 2850)
T4-5-15
Slewing Brake Release Pressure (On)
MPa (kgf/cm , psi)
Main Relief Valve Pressure
MPa (kgf/cm , psi)
(50
2
Lower Control Valve Port Relief Valve Pressure
(4.9 0.5 0
T4-5-7
5
2
2
T4-5-16
MPa (kgf/cm , psi)
Front / Rear / Fourth (Optional)
(34.3r0.5) ((350r5, 4990r73)) (34.8 2 0) ((355 20 0, 5060 290 0))
Boom Derricking Travel
(32.4) ((330, 4710))
Main / Slewing Pump Flow Rate
㧙
T4-5-17
Slewing Motor Drain
L/min
㧙
T4-5-25
Travel Motor Drain
L/min
㧙
T4-5-27
Derricking Motor Drain
L/min
㧙
T4-5-29
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standards Main Pump P-Q Diagram P-Q control (Torque Control) (Reference: Measured at Test Stand)
• Rated pump speed: 2000 min-1 (rpm) • Hydraulic oil temperature: 50r5 qC (122r41 qF) • Power increase/displacement angle proportional solenoid valve current: “I” mA NOTE: Refer to T4-5-18.
Flow rate L/min
400
300
A
B
C I=800 mA
F 200
D G E
I=0 mA
100
H
0
5
10
15
20 25 30 2 Delivery pressure Mpa (kgf/cm )
P-Q point:I=800 mA
35
T25N-04-05-004
P-Q point: I=0 mA
Delivery Pressure MPa (kgf/cm2)
Flow Rate L/min
Delivery Pressure MPa (kgf/cm2)
Flow Rate L/min
A
7.0 (71)
276
F
3.9 (40)
239
B
11.8 (120)
273
G
5.0 (51)
224
C
21.1 (215)
267
H
31.4 (320)
56
D
25.3 (258)
211
E
31.4 (320)
172
Data in (
Data in (
) is given for reference.
T4-2-4
) is given for reference.
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) NOTE: Refer to T4-5-20.
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 valve current
Pilot Control Pressure
Flow Rate
MPa (kgf/cm2)
L/min
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
mA
OPERATIONAL PERFORMANCE TEST / Standards Slewing Pump P-Q Diagram P-Q control (Torque Control) (Reference: Measured at Test Stand)
• Rated pump speed:2000 min-1 (rpm) • Hydraulic oil temperature:50r5 qC (122r41 qF) NOTE: Refer to T4-5-18.
Flow rate L/min
200 A 150 B C
100
50
0
5
10
15
20
25
30 2
Delivery pressure MPa (kgf/cm )
P-Q point Delivery Pressure MPa (kgf/cm2)
Flow Rate 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
35
T25N-04-05-006
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) NOTE: Refer to T4-5-20.
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 valve current
Pilot Control Pressure
Flow Rate
MPa (kgf/cm2)
L/min
1.11r0.2 (11.3r2)
94r3
340r30
B
1.96r0.2 (20r2)
158r3
457r30
Data in (
) is given for reference.
A
T4-2-7
mA
This Page Left Blank Intentionally
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED
Measure the engine speed by using the moment limiter speed indicator.
NOTE: 1.If the engine speed is out of specification, all other measured performance data will also be out of specification. Accordingly, always measure the engine speed before performing any tests.. 2.The engine speed after starting, is the slow idle speed plus 125 min-1 (125 rpm). In order to reduce the engine speed to the slow idle speed, increase the engine speed faster than the starting speed by operating the accelerator dial. Then, return the accelerator dial to the slow idle speed position. Preparation: 1. Sufficiently warm up the machine until the engine coolant temperature reaches 50 qC (122 qF) or more, also, maintain the hydraulic oil temperature at 50r5 qC (122r9 qF). 2. Check that fuel injection pump governor lever (2) comes in contact with both slow and fast-idle stopper (1) when the accelerator lever in the left console is fully stroked to both sides. NOTE: Do not adjust stopper (1).
Measurement: Measure the slow and fast idle speeds.
Evaluation: Refer to Operational Performance Standard in T4-2.
Remedy: Refer to the engine shop manual.
T4-3-1
Slow Idle Speed Position
Fast Idle Speed Position
2 1
1
T333-04-02-001
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in each cylinder to check for a decline in engine power. 2. Check exhaust color and the amount of blow-by gas from the crankcase. Keep track of engine oil consumption. 3. Check the intake system, including the air filter, for any abnormalities. Preparations: 1. Check that the valve clearances are correct. 2. Charge the batteries are sufficiently charged. 3. Warm up (run) the engine until the coolant temperature reaches the operating range. 4. Remove the nozzle holders and injection lines from each cylinder. 5. Install adapter (MITSUBISHI MH061461) and a pressure gauge on the nozzle holder mounting opening. (Securely tighten them in order to prevent an air leak.) Measurement: 1. Turn the starter. Record compression pressure for each cylinder. 2. Repeat the measurement three times for each cylinder and calculate the mean values. Evaluation: Refer to Operational Performance Standard in T4-2.
Remedy: Refer to the engine shop manual.
T4-3-2
T333-04-02-002
OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE ADJUSTMENT Summary: 1. Measure when the engine is cool. 2. Clean the head cover mounting area in order to prevent any foreign material from entering the engine. Preparation: 1. Remove the head cover. 2. Locate top dead center (TDC) in compression stroke. Remove the lower left side flywheel housing cover. Align the pointer installed on the flywheel housing inspection hole edge with marked scale 1.6 on the flywheel. The piston in either cylinder No.1 or No.6 is at TDC in its compression stroke. Measure from either cylinder No. 1 or No. 6 that is TDC in its compression stroke.
T333-04-02-003
Measurement: 1. Insert a feeler gauge between the rocker arm and valve stem in order to measure the valve clearance. NOTE: The cylinders are arranged from No. 1 to No. 6 in this order as viewed from the fan side. 3. When measuring cylinder No.1, perform the same measurement for the valves marked with “{” in the table below. (When measuring from cylinder No.6, perform the same measurement for the valves marked with “u” in the table below.) Measure all valve clearances. Cylinder No.
No.1
No.2
No.3
No.4
No.5
No.6
Valve Layout
In.
Ex.
In.
Ex.
In.
Ex.
In.
Ex.
In.
Ex.
In.
Ex.
When the measurement is started from cylinder No.1
{
{
{
{
{
{
When the measurement is started from cylinder No.6
u
u
u
u
u
u
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: Standard Valve Clearance (Cold Engine): • Intake valve: 0.40 mm (0.016 in) • Exhaust valve: 0.60 mm (0.024 in)
Adjusting Screw Rocker Arm
Adjustment: If the measured valve clearances do not conform to the standard value, adjust the valve clearance in the same order of the measurement. 1. After loosening the lock nut on the rocker arm, completely loosen all adjust screws.
Lock Nut
Feeler Gauge
Valve Cap
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 N m (6 kgf m, 43 lbf ft) 3. Recheck the valve clearance after tightening the lock nut.
T4-3-4
T333-04-02-004
OPERATIONAL PERFORMANCE TEST / Engine Test NOZZLE CHECK Summary: 1. Check the injection pressure and the spray pattern 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 pipings 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 penetrates into the blood stream, it may cause blood toxication. IMPORTANT: Use clean diesel oil. 1. Injection pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure. If adjustment is required, loosen the lock nuts and adjust the adjusting screws. Turn clockwise to increase the pressure and counterclockwise to decrease the pressure. 2. Spray pattern For this test, turn the pressure tester knob to bypass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. 3. Oil tight condition Keep the pressure slightly below the injection pressure from nozzle tip. Check for fuel leak from around the nozzle tip.
T107-06-02-006
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: Refer to Operational Performance Standard in T4-2. 2. Spray Pattern • Large-size spray should not be visible to the naked 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.
Normal
Abnormal
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 motor) comprehensively.
2 m (6.5 ft)
Preparation: 1. Adjust both the right and left sags equally. 2. Prepare a level and solid test track 10 m (33 ft) long, with an extra length of 3 to 5 m (9.8 to 16 ft) on both ends of the test track for machine acceleration and deceleration. 3. The machine should be equipped with the basic boom with the hook. Set the boom angle to 60q, and hoist the hook until it reaches 2 m (6.5 ft) below the height at which the hoisting limiter buzzer starts to operate. (Or dismount the front attachment and counterweight.)
60q
T2BC-04-04-003
4. While maintaning hydraulic oil temperature at 50r5 qC (122r41 qF), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer. Measurement: Measure in both fast and slow travel modes. 1. Increase the engine speed to the maximum. 2. Start driving the machine from the acceleration zone with both the right and left travel levers at full stroke. 3. Measure the time required to travel the 10 m (33 ft) test track. 4. After measuring forward travel time, turn the upperstructure 180q. Then, measure the reverse travel time.
End AccelerationZone 3 to 5 m (9.8 to 16 ft)
5. Repeat the measurements three times. Calculate the average values.
10 m (33 ft)
Deceleration Zone 3 to 5 m (9.8 to 16 ft)
Start T324-06-03-002
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 between the right and left travel power line (from the hydraulic pump to the travel motor) performance. 2. Mistrack is generally reduced when measured on a concrete surface.
2m (6.5 ft)
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 acceleration and deceleration. 3. The machine should be equipped with the basic boom and hook. Hoist the hook to approx. 2m below the height which the hoisting limiter buzzer starts to operate.
T2BC-04-04-003
4. While maintaining hydraulic oil temperature at 50r5 qC (122r41 qF), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer. Measurement: Measure in both fast and slow travel modes. 1. Increase the engine speed to the maximum. 2. Start driving the machine from the acceleration zone with both the right and left travel levers at full stroke. 3. Measure the maximum distance from a straight 10 m (33 ft) line to the machine rut. 4. After measuring in forward travel, measure in reverse travel. 5. Repeat the measurement three times. Calculate the average values.
2 m (6.5 ft) Maximum Distance
10 m (33 ft)
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Extra Length for Acceleration 3 to 5 m (9.8 to 16 ft)
T324-06-03-003
Remedy: 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 and counterweight.)
20%
T2BC-04-04-004
4. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
Measurement: Measure in both fast and slow travel speed modes.
• Track movement (sprocket rotation) until the parking brake is applied. 1. Climb the slope and place the travel levers in neutral. 2. Measure the travel reduction gear cover mark movement from the position when the lever is placed in neutral to the position when the machine stops (when the brake is applied).
Position where the machine stops. comes to a stop. Position when the travel levers are in neutral. Movement (Rotation Angle) Mark
• Travel motor slip while parking
T107-06-03-002
3. Climb the slope and place the travel levers in neutral. 4. Stop the engine. 5. After parking the machine, put the matching marks on the shoe and side frame. 6. After 5 minutes have passed, measure the difference (3) between mark (1) on the side frame and mark (2) on the shoe. Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
T324-06-03-005
2
T4-4-3
3
1
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. Place the machine on a level and solid ground with ample space for swinging. Do not test on a slope. 3. Use the basic boom with the hook. Set the boom angle to 60q. (Or dismount the front attachment and counterweight.) 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.
2 m (6.5 ft)
60q
T2BC-04-04-003
Measurement: 1. Turn the slewing brake switch ON. 2. Run the engine at the maximum speed by using an accelerator grip.
Accelerator Grip Slewing Brake Switch
IMPORTANT: Do not operate the control lever rapidly. Otherwise, a large swing of the hook may result, potentially causing the hook to come in contact with the boom. 3. Operate the slewing control lever fully. 4. After the slewing speed becomes constant, measure the time required for the upperstructure to rotate three turns in one direction. 5. Measure on the right and left slewing. 6. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. 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 ring the slewing ring rotation is smooth and without noise. 3. Install a dial gauge on the upper surface on lower frame by using amagnetic base. 4. Position the upperstructure in the same direction as traveling the lower frame. 5. Position the dial gauge so that its needle point comes into contact with the bottom surface of slewing ring outer race. 6. Perform the measurement on level and solid ground. Use the basic boom with the hook. Set the boom angle to 60q. Apply a maximum lifting load (100 %) to the hook. 7. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
60q
T2BC-04-04-006
Position A
Needle Point
Detailed Position A
T324-06-03-013
Measurement of (h1) Measurement: 1. Before lifting a load, read the dial gauge indication (h1). 2. Lift up a weight (100 % load) until the bottom of the weight leaves the ground. Then, read the dial gauge indication (h2). 3. Obtain the slewing bearing play (H) by calculating the difference between (h1) and (h2). That is, H = h2-h1
60q
Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.
T2BC-04-04-006
Measurement of (h2)
60q
T2BC-04-04-007
T4-4-5
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 minutes before starting the test. 4. Check that the weight of the hoisting limiter functions at the specified position. NOTE: Depending on the number of the wire rope falls, the hook travel for six turns of the hoist drum varies. Start the measurement from the position having enough margin in stroke.
60q
T2BC-04-04-008
Measurement: 1. Turn the low speed lock switch LOCK.
Front Drum L ever
Rear Drum Lever
x
Fast Speed
x
Slow Speed
3. Operate the hoist lever (front and rear drum lever) corresponding to the drum to be measured.
x
Neutral Position
x
Slow Speed
4. After the drum rotation speed becomes constant, measure the time required to rotate six turns.
x
Fast Speed
2. Run the engine at the maximum speed by using an accelerator grip.
Hoisting
5. Repeat the measurements three times in each direction. Calculate the average values. 6. Release the low speed lock switch. Repeat steps 2 to 5 in order to measure.
Lowering
Slow Speed Lock Switch
M25N-04-008
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. T2BC-04-04-010
T4-4-6
OPERATIONAL PERFORMANCE TEST / Crane Test REGULATOR ADJUSTMENT Swash Angle Set Pressure and Power Set Pressure Adjustment Motor speed can be adjusted with adjusting screws (1) and (2) at regulator.
1
2
3
4
T25N-03-03-024
Adjustment Item 1. Swash angle set pressure Flow Rate
Adjustment Procedure Remarks Loosen lock nut (1) and turn ad- 1) Other control characteristics are justing screw (2). One turn of adnot influenced. justing screw (2) changes the pres- 2) Securely retighten lock nut (1) sure as follows. after adjustment. Front/rear drums: 530 kPa (5.4 kgf/cm2, 77 psi) 3rd drum (optional): 250 kPa (2.5 kgf/cm2, 36 psi)
Pilot Pressure
2. Power set pressure Pressure
: 13 mm : 16 N m (1.6 kgf m, 12 lbf ft)
Loosen lock nut (4) and turn ad- 1) Other control characteristics are justing screw (3). not influenced. 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 N m (1.6 kgf m, 12 lbf ft)
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 circuit for two minutes or longer.
60q
3. Check that the boom derricking drum brake functions properly. 4. Check that properly.
the
derricking
limiter
functions
T2BC-04-04-003
Measurement: 1. Run the engine at the maximum speed by using an accelerator grip.
2. Operate the boom derricking lever.
Accelerator Grip
3. After the boom derricking drum rotation speed becomes constant, measure the time required to rotate six turns.
Boom Derricking Lever
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 maximum 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) comprehensively. Preparation: 1. Lower the front attachment onto ground and remove the counterweight from the machine. 2. Deliver oil into the measured hydraulic circuit for two minutes or longer while making the counterweight cylinder operation at hydraulic oil temperature 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 respectively. 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 determine 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 extension length and check the operational performance of jack-up cylinder drive power system (from the pump for counterweight / jack-up / retract 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 determine the average of measurements.
T25N-04-04-004
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 extension length and check the operational performance 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 attachment and counterweight is acceptable.) 2. Deliver oil into the measured hydraulic circuit for two minutes or longer while making retract operation at hydraulic oil temperature of 50r5 qC (122r41 qF). 3. Place the wooden blocks under the cylinder tubes of retraction cylinders to be measured.
IMPORTANT: Place the wooden blocks under the cylinder tube in order not to wind the retract cylinder. 4. Pull out the pin from the rod side of retraction cylinder to be measured. (Do not remove the pin from the not-measured side of retract cylinder.) Measurement: Measure one side for each. 1. Set the engine speed to the minimum speed by using an accelerator grip. 2. Turn the retract switch to the EXTEND position. 3. Measure the required time length for extending retraction cylinder fully. 4. With the retract switches at the RETRACT position, measure the required time for retracting the retract cylinder fully. 5. Carry out measurement three times, and determine the average of measurements.
60q
T2BC-04-04-005
Pin
Cylinder Tube
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 minutes with the engine idling and check the load lowering by front (rear) motor. Check leakage in the motor circuit.
Preparation: 1. Use the basis boom with the hook. 2. Number of rope reeving at the boom hook is four or less. 3. Set the front / rear drum brake mode selection switches (1 and 2) to the “Auto Brake” position. 4. While maintaining hydraulic oil temperature at 50±5 qC (122±41 qF), make measurement after delivering hydraulic oil to the measured hydraulic circuit for two minutes or longer. 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 drum flange. Measure for two minutes. 6. Restore number of rope reeving as it was.
1 2
T2BC-04-04-011
60q
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. Remedy: Refer to TROUBLE SHOOTING in T5-4.
0.5 m (20 in) T2BC-04-04-012
T4-4-12
OPERATIONAL PERFORMANCE TEST / Crane Test CONTROL LEVER OPERATING FORCE Summary: 1. Check the operating function of each control lever and measure the operating force. 2. Measure the maximum operating force of the front attachment control lever. 3. Measure the operating stroke at the lever bottom of each control lever. Preparation: 1. Maintain the hydraulic oil temperature at 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
Slewing Lever
Hoisting Lever
Travel Lever Measurement Position
T2BC-04-04-018
T4-4-13
Measurement Position
T2BC-04-04-019
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
Slewing Lever
Hoisting Lever
Measurement Position
Measurement Position Travel Lever Measurement Position
Measurement Position
T2BC-04-04-019
T2BC-04-04-018
T4-4-14
OPERATIONAL PERFORMANCE TEST / Component Test PILOT CIRCUIT PRESSURE
PRIMARY
PILOT
Preparations: 1. Stop the engine. 2. Remove adapter 1 from port P1 (G 3/8) on the 4-spool solenoid valve unit. : 22 mm 3. Install a pressure gauge port P1. 4. Start the engine. Check for oil leaks at the pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
Measurement: 1. Run the engine at the maximum speed. 2. Measure the pilot pressure under no load condition by using a pressure gauge. 3. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
4-Spool Solenoid Valve Unit㩷
Adapter 1
Port P1㩷 T2BC-04-05-002
㩷
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test Adjustment Pressure
of
Pilot
Circuit
Primary
Pilot
Adjustment: Adjust the set pressure of pressure reducing valve provided on the 4-spool solenoid valve unit if necessary. 1. Loosen the lock nut. : 14 mm 2. Turn the adjusting screw. : 6 mm 3. Tighten the lock nut. : 14 mm : 7.8 N m (0.8 kgf m, 5.8 lbf ft) 4. Check the set pressure after adjustment.
Adjusting Screw㩷
Lock Nut㩷
T2BC-04-05-003
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test BRAKE CIRCUIT PRESSURE
PRIMARY
PILOT 㩷 㩷
Preparations: 1. Stop the engine. 2. Install a pressure gauge to the coupler for measurement in manifold (under the cab bed). 3. Start the engine. Check for oil leaks at the pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
㩷 㩷 㩷 㩷 㩷 㩷 㩷 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.
Under Cab Bed
Manifold㩷 Coupler for Measurement㩷
Brake Unit㩷
T2BC-04-05-004
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test Adjustment Pressure
of
Brake
Circuit
Primary
Pilot
㩷
Adjustment: Adjust the set pressure of pilot relief valve in gate lock valve by using a pressure gauge if necessary. 1. Loosen the lock nut. : 17 mm 2. Turn the adjusting screw. : 8 mm 3. Tighten the lock nut. : 17 mm : 10.8 N m (1.1 kgf m, 8 lbf ft) 4. Check the set pressure after adjustment.
Adjusting Screw
Pilot Relief Valve㩷
Gate Lock Valve㩷
Lock Nut
T2BC-03-11-004
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test REMOTE CONTROL VALVE SECONDARY PILOT PRESSURE Preparations: 1. Stop the engine. 2. Install a pressure gauge unit to the circuit to be measured. 2-1. Front / Rear / Boom Derricking Drums Circuit • Remove the plug from port 9 (G1/4) in the front remote control valve, port 8 (G1/4) in the rear remote control valve and port 3 (G1/4) in the boom derricking remote control valve respectively. Install a pressure gauge. : 19 mm
㩷
2-3. Sewing Circuit • Remove the plug from port 3 (G1/4) in the slewing remote control valve. Install a pressure gauge. : 6 mm 3. Start the engine. Check for oil leaks at the pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
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 N m (1.6r0.2 kgf m, 12r1.2 lbf ft) • Remove the hose and adapter from port 7 (G1/4) in the third / fourth remote control valve. Install a pressure gauge. : 19 mm
Boom Front Derricking㩷 Rear Drum㩷 Drum㩷
Travel Third / Fourth Travel (Left) (Right) Drum㩷
Slewing㩷
Port 9㩷
Port 9㩷
Port 3㩷
Port 3 Port 7
Port 8
Port 8
T4-5-5
T2BC-04-05-005
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. In case of measurement in the front / rear and boom derricking circuits, engage the respective drum locks. In case of measurement in the slewing circuit, turn the slewing lock pedal in the LOCK position and turn the slewing brake switch in ON. CAUTION: When measuring in the travel circuit near the rotating parts, take care not to allow your hand, foot, and/or clothes to become entangled in the rotating parts.
Slewing Brake Switch㊡
Lock Lever
Slewing Lock Pedal㊡
2. Lower the lock lever to the UNLOCK position. Operate the control lever corresponding to the circuit in which the secondary pilot pressure is to be measured at each detent position. Then, measure the pilot pressure at each detent position by using a pressure gauge. 3. Repeat the measurement three times at each detent position. Calculate the average value. Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. Remedy: In case the measured results are out of specifications, check the pilot circuit primary pilot pressure. When the primary pilot pressure is normal, the remote control valve may be faulty. NOTE: If it is difficult to measure at the port on bottom of remote control valve, measure at the spool end of control valve corresponding to each port.
T4-5-6
T2BC-01-02-006
OPERATIONAL PERFORMANCE TEST / Component Test HIGH / LOW TRAVEL SPEED SELECTION PRESSURE Travel Fast / Slow Speed Control Hose
Preparations: 1. Stop the engine. 2. Remove the travel speed control hose. 3. Install the adapter to the elbow. Install the hose and nipple to the adapter. Install the pressure gauge unit to the nipple. : 19 mm 4. Start the engine. Check for oil leaks at the pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). Measurement: 1. Measure the pressures by using a pressure gauge while the machine is traveling at both slow and fast speeds. 2. Repeat the measurement three times. Calculate the average value.
Elbow T2BC-04-05-007
NOTE: The illustration shows the left travel.
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2.
Pressure Gauge㩷
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
7/16-20 UNF (Hose)
7/16-20UNF㩷
Adapter㩷
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 port Pb (G 1/4) on the slewing motor. : 22 mm 3. Install the adapter to the tee. Install the hose and nipple to the adapter. Install the pressure gauge unit to the nipple. : 22 mm, 19 mm 4. Start the engine. Check for oil leaks at the pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
Slewing Motor
Tee㩷
Measurement: 1. With the slewing brake switch turned to both the ON and OFF positions, measure the slewing brake release pilot pressure. 2. Repeat the measurements three times. Calculate the average values.
Slewing Brake Release Hose
T25N-04-05-009
Pressure Gauge㩷
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. Remedy: In case the measured results are out of specifications, check the primary pilot pressure. When the primary pilot pressure is normal, the solenoid valve or electrical system may be faulty.
Nipple
9/16-18 UNF (Hose)
9/16-18UNF㩷
Adapter㩷
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 ports (a1, a2)(G1/4) at the delivery port side of main pump (pump 1, pump 2). : 6 mm 3. Measurement of the main relief valve set pressure on the front control valve (connected to pump 1): Remove pipe (3) for the forward of right travel motor and install the plug. Measurement of the main relief valve set pressure on the rear control valve (connected to pump 2): Remove pipe (1) for the forward of left travel motor and install the plug. 4. Start the engine. Check for oil leaks at the pipe connection part. 5. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). Measurement: 1. Run the engine at the maximum speed. 2. Measure main relief valve set pressure on the front control valve (connected to pump 1) with the right travel lever stroked in the FORWARD position. Measure main relief valve set pressure on the rear control valve (connected to pump 2) with the left travel lever stroked in the FORWARD position. Read the pressure when the relief valve relieves. 3. Repeat the measurements three times. Calculate the average values.
Pump 2㩷
Pump 1㩷
Port a2㩷
Port a1㩷
T2BC-04-05-006
Pipe for Forward Travel㩷 Pipe for Reverse Travel㩷
Travel Motor T2BC-04-05-007
NOTE: The illustration shows the right travel.
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. 1. Loosen the lock nut. : 22 mm 2. Turn the adjusting screw. : 6 mm 3. Tighten lock nut (3) : 22 mm : 16.7 to 19.6 N m (1.7 to 2.0 kgf m, 12 to 14 lbf ft) 4. Check the set pressure after adjustment.
Front Control Valve㩷
T25N-03-05-030
Rear Control Valve㩷
T2BC-03-02-004
Main Relief Valve㩷
Lock Nut㩷 Adjusting Screw㩷
Pressure Increase㩷
Pressure Decrease㩷 W107-02-05-129
Lock Nut㩷 Adjusting Screw㩷
Main Relief Valve㩷
T4-5-10
T326-06-04-002
OPERATIONAL PERFORMANCE TEST / Component Test Slewing Control Valve Preparations: 1. Stop the engine. 2. Install a pressure gauge to pressure check port (a4) (G 1/4) at the slewing pump delivery port. 3. Start the engine. Check for oil leaks at the pressure gauge unit connector. 4. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). Measurement: 1. Turn the slewing lock pedal in the LOCK position and lock the slewing function. 2. Run the engine at the maximum speed. 3. Relieve the oil pressure by slowly pushing or pulling the slewing control lever. Read the pressure at this time. 4. Repeat the measurement three times in each direction. Calculate the average values.
Port a4㩷
Port a4
T2BC-04-05-006
Slewing Pump
Evaluation: Refer to STANDARD SPECIFICATIONS in T4-2. Slewing Lever㩷
Slewing Lock Pedal㩷
T2BC-01-02-006
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Check the pressure gauge and adjust the set pressure of main relief valve if necessary. 1. Loosen the lock nut. : 19 mm 2. Turn the adjusting screw. : 6 mm 3. Tighten lock nut (3) : 19 mm : 31.4 N m (3.2 kgf m, 23 lbf ft) 4. Check the set pressure after adjustment.
Main Relief Valve T25N-01-02-021
Adjusting Screw
Lock Nut㩷
T326-06-04-002
Lock Nut㩷 Adjusting Screw㩷
Pressure Increase
Pressure 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 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. 1. Loosen the lock nut. : 13 mm 2. Turn the adjusting screw. : 6 mm 3. Tighten the lock nut. : 6.9 to 8.8 N m (0.7 to 0.9 kgf m, 5 to 6 lbf ft) 4. Check the set pressure after adjustment. T2BC-04-05-008 㩷
Relief Valve㩷
Lock Nut㩷 Adjusting Screw㩷
Pressure Increase
Pressure Decrease
W107-02-05-129
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test Lower Control Valve (Optional) Preparations: 1. Stop the engine. 2. Remove the plug from pressure check port (PT 1/4) in the lower control valve. : 6 mm 3. Install a pressure gauge to the open part. 4. Start the engine. Check for oil leaks at the pressure gauge unit connector. 5. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF).
Pressure Check Port㩷
Relief Valve
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. 1. 2. 3. 4.
Remove the cap from the relief valve. Turn the adjusting screw. Install the cap. Check the set pressure after adjustment. Section A
Relief Valve㩷
Adjusting Screw㩷
Cap㩷
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 x P-Q Control (Torque Control) Summary: Main (pump 1, pump 2) / slewing pump performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main (pump 1, pump 2) / slewing pump delivery port to be measured. Use the moment limiter and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5% than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparations: 1. Stop the engine. Push the air bleed valve in hydraulic oil tank and bleed air. Install a vacuum pump to the oil filler port. NOTE: Operate the vacuum pump with the pump flow rate test line connected. 2. Remove the delivery hose from the control valve side of pump to be measured. 3. Install a portable hydraulic tester to the delivery hose to be removed. 4. Connect the portable hydraulic pressure tester to the control valve by using a hydraulic hose for a test. 5. Install a pressure gauge to the pump to be measured.
7. Remove the vacuum pump. Loosen the air bleed plug on the top of pump casing. Bleed air from the pump casing until oil only comes out. 8. Fully open the loading valve of portable hydraulic tester. 9. Start the engine. Check for oil leaks at the pressure gauge unit connector. Measurement: 1. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). 2. Measure the maximum and minimum flow rates under no load. 3. Select each switch position as follows: Accelerator Grip Accelerator Lock Switch Fast Idle Slow Idle ON 4. Slowly close the loading valve of hydraulic tester. Measure the flow rates and engine speeds at each pressure point at the I=800 mA side in the P-Q curve. (Refer to T4-2.) 5. Repeat the measurements three times. Calculate the average values. Air Bleed Plug
T2BC-04-05-006
Outlet for Slewing Pump Pressure㩷
T4-5-17
Outlet for Pump 2 Outlet for Pump 1 Pressure㩷 Pressure㩷
OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the specified pump speed using the following formulas:
2. Standard Flow Rate Refer to STANDARD SPECIFICATIONS in T4-2.
Qc = NsuQ/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Pump Speed: 2000 min-1 Ne : Measured Engine Speed: Moment Limiter
Portable Hydraulic Tester
Pump㩷
Control Valve㩷
T2BC-04-05-012
Delivery Hose㩷
Loading Valve
Hydraulic Hose for Test
㩷
Pump 1㩷
Pump 2
Slewing Pump㩷
Power Increase Solenoid Valve㩷 Swash Angle Proportional Solenoid Valve㩷 T2BC-04-05-011
Swash Angle Solenoid Valve㩷
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test x Pilot Characteristics (Swash Angle Proportional Solenoid Valve) Summary: Main pump (pump 1, pump 2) performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main (pump 1, pump 2) pump delivery port to be measured. Use the moment limiter and a pressure gauge at the same time. As the maximum swash angle is fixed, the slewing pump need not be measured. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5% than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparations: 1. Check pilot circuit primary pilot pressure first. Adjust pilot circuit primary pilot pressure if necessary. (Refer to “Pilot Circuit Primary Pilot Pressure2� in this section.) 2. Referring to steps 1 to 4 on page T4-5-18, connect a hydraulic tester to the pump to be measured. 3. Remove the hose from port Pr1 in the swash angle proportional solenoid valve. : 19 mm, 17 mm 4. Remove hose (7/16-20 UNF) from port Pi in the pump to be measured. Pump 1: Port Pi1 Pump 2: Port Pi2 : 17 mm, 19 mm 5. Install the hose removed from port Pr1 to port Pi in the pump to be measured. At this time, use a conversion adapter because of difference of screw. : 17 mm, 19 mm NOTE: The screws for port Pr1 in the swash angle proportional solenoid valve and for port Pi in the pump are G1/4. Therefore, if removing the elbow from port Pr1 and replacing it with the elbow of port Pr1, the conversion adapter need not be used.
6. Remove the connector from displacement angle proportional solenoid valve. 7. Remove the hose for power increase solenoid valve. 8. Install a pressure gauge to the hose at secondary pressure side in 4-spool solenoid valve. 9. Remove the vacuum pump. Loosen the air bleed plug on the top of pump casing. Bleed air from the pump casing until oil only comes out. 10. Fully open the loading valve of hydraulic tester. 11. Start the engine. Check for oil leaks at the pipe connection part. Measurement: 1. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). 2. The pump flow rate in response to the external command pilot pressure is measured. 3. Select each switch position as follows: Accelerator Grip Accelerator Lock Switch Fast Idle ON 4. Adjust the set pressure of 4-spool solenoid valve to each pressure point specified along the main / slewing pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-5, 7) Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 5. Repeat the measurements three times. Calculate the average values.
T4-5-19
Pump 2
Pump 1
Air Bleed Plug
T2BC-04-05-013
OPERATIONAL PERFORMANCE TEST / Component Test Connection of Portable Hydraulic Tester Pump㩷
Portable Hydraulic Tester㩷
Control Valve㩷
T2BC-04-05-012
Delivery Hose㩷
Connection of Pressure Gauge
Loading Valve㩷
Hydraulic Hose for Test
4-Spool Solenoid Valve Unit㩷
Pressure Gauge㩷
Pilot Pump㩷
To Main Pump㩷
Tee
T2BC-04-05-017
Connecting Port Port Pi1㩷
Port Pr1
Swash Angle Proportional Solenoid Valve㩷
T2BC-04-05-014
Port Pi2㩷
T4-5-20
Hose for Power Increase㩷
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 Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Pump Speed:2000 min-1 Ne : Measured Engine Speed: Moment Limiter 2. Standard Flow Rate Refer to STANDARD SPECIFICATIONS in T4-2.
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test REGULATOR ADJUSTMENT (MAIN PUMP) x Minimum and Maximum Flow Rate Adjustment This regulator can adjust minimum and maximum flow rates by using adjusting screws (1) and (2) at each main pump body. 3 4
2
4
3
1
1
Main Pump 1㩷
1-
Adjusting Screw (For Minimum Flow)㩷
2-
Adjusting Screw (For Maximum Flow)㩷
Adjustment Item 1. Minimum Flow Rate Q
Main Pump 2㩷
3-
Lock Nut (For Minimum Flow)㩷
4-
T1F3-03-01-003
Lock Nut (For Maximum Flow)㩷
Adjustment Procedure Remarks Loosen lock nut (3) and turn • Other control characteristics remain adjusting screw (1). unchanged. Check that the required Rotating adjusting screw (1) 1/4 power is increased at maximum a turn clockwise increases the delivery pressure if tightened minimum pump flow rate by 5.0 excessively. • Securely retighten lock nut (3) after L/min. (305 in3/min). : 24 mm adjustment. : 130 N m (13.3 kgf m, 96 lbf ft) I
Loosen lock nut (4) and turn • Other control characteristics remain adjusting screw (2). unchanged, except that only Rotating adjusting screw (2) 1/4 maximum oil rate varies. a turn clockwise decreases the • Securely retighten lock nut (4) after adjustment. maximum pump flow rate by 6.2 L/min. (378 in3/min). 㧦 30 mm 㧦 240 N m (24.5 kgf m, 177 lbf ft)
2. Maximum Flow Rate
Q
I
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 6
10 7
T1F3-03-01-008
Adjustment Item 1. Outer Spring Adjustment
Adjustment Procedure Loosen lock nut (7) and adjusting screw (5).
Q
turn
Rotating adjusting screw (5) 1/4 a turn clockwise:
• Compensating:
P1+P2
Pd
2. Inner Spring Adjustment
+ 1.75 Mpa (17.8 kgf/cm2, 254 psi) • Torque: + 84.3 N m (8.6 kgf m, 62 lbf ft) : 46 mm : Lock Nut (7) : 160 N m (16.5 kgf m, 118 lbf ft) Loosen lock nut (10) and turn adjusting screw (6). Rotating adjusting screw (6) 1/4 a turn clockwise:
Q
• Pump flow rate: + 10.2 L/min.
P1+P2
Pd
(622 in3/min). • Torque: + 56.9 N m (5.8 kgf m, 42 lbf ft) : 13 mm : Lock Nut (10) : 16 N m (1.6 kgf m, 12 lbf ft)
T4-5-23
Remarks • When adjusting screw (5) is turned, inner spring (8) set-force varies. Therefore, when adjusting screw (5) is turned clockwise, turn adjusting screw (6) 2.17 times turns of adjusting screw (5) counterclockwise. • Securely retighten lock nut (7) and Lock nut (10) after the adjustment.
• Securely retighten lock nut (10) after the adjustment.
OPERATIONAL PERFORMANCE TEST / Component Test x Pilot Pressure Characteristics
11 12
T25N-03-01-011
Adjustment Item Pilot Pressure Characteristics
Adjustment Procedure Loosen lock nut (11) and turn adjusting screw (12).
Q
Rotating adjusting screw (12) 1/4 a turn clockwise:
• Pump flow rate: 16.2 L/min. (988 in3/min). rate control starting pressure: + 150 kPa (1.5 kgf/cm2, 21 psi) : 13 mm : Luck Nut (11) : 16 N m (1.6 kgf m, 12 lbf ft)
• Flow
Pi
T4-5-24
Remarks
• Securely retighten lock nut (11) after the adjustment.
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
2
T25N-03-01-005
1 - Lock Nut (For Maximum Flow)
Adjustment Item Maximum Flow Rate
2-
Adjusting Screw (For Maximum Flow)
Adjustment Procedure Loosen lock nut (1) and turn adjusting screw (2). Rotating adjusting screw (2) 1/4 a turn clockwise decreases the maximum pump flow rate by 3.2 L/min. (195 in3/min). : 24 mm : 130 N m (13.3 kgf m, 96 lbf ft)
Q
Pi
T4-5-25
Remarks control characteristics remain unchanged, except that only maximum oil rate varies. • Securely retighten lock nut (4) after the adjustment.
• Other
OPERATIONAL PERFORMANCE TEST / Component Test SLEWING MOTOR DRAINAGE Summary: Turn the slewing lock lever to the LOCK position and turn the slewing brake switch in ON. Operate the slewing lever and relieve the slewing relief valve. Under this condition, measure the drain oil amount from the slewing motor and check the slewing motor performance.
Drain Hose
1. Secure the inspectors’ safety during measurement. Take care not to damage any surrounding buildings or vegetation. 2. The amount of drain oil from the slewing motor will be greatly affected by the oil temperature. Maintain the oil temperature in the proper range.
Preparation: 1. Place the machine or a level and solid ground with ample space for slewing. Do not measure on a slope. 2. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). Rotate the slewing motor and warm the inside of motor. 3. Stop the engine. Disconnect drain hoses from the slewing motor at the return oil port to the hydraulic oil tank. Put plugs (1-7/16-12UN) to the removed return oil ports to the hydraulic oil tank. : 41 mm
T4-5-26
T25N-04-05-009
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: Amount of Oil Drained While Relieving Slewing. 1. Attach the basic boom with the boom angle set at 60q. (Or dismount the front attachment and counterweight.) 2. Turn the slewing lock lever placed to the LOCK position and turn the slewing brake switch in ON.
2m (6.5 ft)
3. Start the engine and run it at the fast idle speed. While operating the slewing lever full stroke, receive the hydraulic oil coming out of the drain hose and measure the time and the volume at the same time.
60q
4. Repeat the measurement three times each in both clockwise and counterclockwise directions and calculate the average value. 5. Take the measurement for more than 45 seconds.
T2BC-04-04-003
Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.
x Conversion of the Measured Values Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below:
'Q =
60 t
uq
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 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 (122r41 qF). Rotate the travel motor and warm the inside of motor. 2. Stop the engine. Remove drain hose (1) from the travel motor. Install plug (3/4-16UNF) to the removed hose end. Install drain measuring hose (3/4-16UNF) to the travel motor. : 27 mm
Drain Hose㊡
Travel Motor
T2BC-04-05-007
NOTE: The illustration shows the left travel.
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: CAUTION: When doing any work near the rotating parts, take care not to allow your hand, foot, and/or clothes to become entangled in the rotating parts. 1. Attach the basic boom with the boom angle set at 60q. (Or dismount the front attachment and counterweight.) 2. Insert a round bar (Dia. 100mm, Length 200mm) between drive tumbler and track link. 3. Start the engine. Run the engine at maximum speed. Operate the travel lever to FORWARD according to the guide and relieve the travel. 4. Receive the hydraulic oil coming out of the drain hose and measure the time at the same time. 5. Repeat the measurement three times each side and calculate the average value. 6. Take the measurement for more than 45 seconds. Evaluation: * Conversion of the Measured Values Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below:
2m (6.5 ft)
60q㊡
T2BC-04-04-003 ㊡
'Q =
u q 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. 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.
Derricking Drum Lock cylinder㩷
Port A㩷
Drain Hose㩷
Boom Derricking Motor㩷
Preparations: CAUTION: Check around the drum, the condition of boom and hook, and the safety around machine. 1. Rotate the boom derricking motor and warm the inside of motor. Maintain the hydraulic oil temperature at 50r5 qC (122r41 qF). 2. Stop the engine. Remove the drain hose from the boom derricking motor at the return oil port to the hydraulic oil tank. Install plug (13/16-16UN) to the removed return oil ports to the hydraulic oil tank. : 27 mm 3. Disconnect the derricking drum lock cylinder hose at port A. Install plug (9/16-18 UNF).
T4-5-30
T2BC-04-05-016
T2BC-04-05-015
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 seconds.
2m (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 converted drain oil amount using the formula below:
60q㊡
'Q =
u q V
T2BC-04-04-003
'Q : Drain Oil Amount (L/min) t : Measuring Time (sec) q : Measured Drain Oil Amount (L)
T4-5-31
This Page Left Blank Intentionally
OPERATIONAL PERFORMANCE TEST / Adjustment MC2/A ADJUSTMENT When the following repair or check is carried out, or when the engine speed is deviated, adjust MC2/A. Description When MC2/A is replaced
Adjusting items 1, 2, 3, 4
When the engine or fuel injection 1, 2, 4 pump is replaced When the engine control cable or 1 governor motor is replaced When engine high idle speed decreases When the pump or pump power 3 increase solenoid valve is replaced MC2/A adjustment falls into four below. Adjustment items 1. High idle calibration Makes MC2/A store the position where the output of governor potentio sensor becomes constant (or the engine governor lever gets in contact with high idle stopper) at upper limit of the governor. (Refer to Section "Engine Control, Control System".) 2. Rack zero calibration Makes MC2/A store zero calibration of the rack sensor at engine stopping. (Refer to Section "Engine Control, Control System".) 3. Power increase pressure calibration Makes MC2/A store power increase output calibration data. (Refer to Section "Engine Control, Control System".) 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 System".) IMPORTANT: Full rack calibration must be made when item 1 (high idle calibration), and item 3 (power increase pressure calibration) are carried out correctly. If the above-mentioned items are done incorrectly, wrong rack calibration is stored, reducing pump horsepower.
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment HIGH IDLE CALIBRATION Adjustment: 1. Turn drum rotation sensing switch (4) for front / rear / boom derricking drums to ON position. 2. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn key switch (2) to ON position under this condition. NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
Monitor Panel
1
3. After pilot pressure indicator (1) blinks, turn accelerator lock switch (3) to accelerator unlock position (OFF).
2
T2BC-04-06-001
Right Control Panel
3
T2BC-04-06-003
Side Overhead Panel
T2BC-04-06-002
T4-6-2
4
OPERATIONAL PERFORMANCE TEST / Adjustment Calibration Starting 1. Turn front drum auto stop cancellation switch (5) to ON position. NOTE: Now, MC2/A turns the governor motor in forward direction. (Refer to Section "Control System".)
Monitor Panel
1
2. If pilot pressure Indicator (1) at monitor panel blinks other than every 0.5 second, turn front drum auto stop cancellation switch (5) to OFF position. NOTE: Normal completion: Pilot pressure Indicator (1): ON Abnormal completion: Pilot pressure Indicator (1): Blinking every 0.1 second Normal completion condition: • Engine : Stop • Governor motor output : Available • Governor motor setting count: Motor rotation control range setting (145 to 356 counts (12.83q to 31.5q)
2
IMPORTANT: When turning the key switch to OFF position, record the completed calibration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time.
Left Control Panel
T2BC-04-06-001
5
3. Turn key switch (2) to OFF position and check if five seconds or longer pass.
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 ON position under this condition.
1
NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second. 3. After pilot pressure indicator (1) blinks, turn accelerator lock switch (3) to accelerator unlock position (OFF).
2
T2BC-04-06-001
Right Contorl Panel
3
T2BC-04-06-003
Side Overhead Panel
4
T2BC-04-06-002
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment Calibration Starting
1. Turn rear drum auto stop cancellation switch (6) to ON position.
Monitor Panel
NOTE: Now, MC2/A sets the governor lever to the low idle position. (Refer to Section "Control System".)
2. If pilot pressure indicator (1) at monitor panel blinks other than every 0.5 second, turn rear drum auto stop cancellation switch (6) to OFF position.
1
NOTE: Normal completion: Pilot pressure indicator (1): ON Abnormal completion: Pilot pressure indicator (1): Blinking every 0.1 second Normal completion condition: • Engine : Stop • Rack sensory output : Available • Rack sensor input : Rack sensory output normal range (0.25 to 4.75 V) • Rack sensor input voltage : Rack sensor zero point setting range (1.5 to 4.5 V) • Governor motor initial position setting: Normal completion
2
T2BC-04-06-001
IMPORTANT: When turning key switch (2) to OFF position, record the completed calibration to EEPROM (MC2/A) for five seconds. Do not operate the key switch (2) during this time.
Left Control Panel
3. Turn key switch (2) to OFF position and check if five seconds or longer pass.
T2BC-04-06-004
T4-6-5
6
5
OPERATIONAL PERFORMANCE TEST / Adjustment POWER INCREASE BRATION
PRESSURE
CALI-
Preparation: 1. Install a pressure gauge (5 Mpa) to the pressure check port. Adjustment: 1. Turn drum rotation sensing switch (4) for front / rear / boom derricking drums to ON position. 2. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn key switch (2) to ON position under this condition. NOTE: After this, pilot pressure indicator (1) at monitor panel blinks every 0.5 second.
T25N-04-06-001
Pressure Check Power Increase Port Solenoid Valve
Monitor Panel
3. After pilot pressure indicator (1) blinks, turn accelerator lock switch (3) to accelerator unlock position (OFF).
1
2
Side Overhead Panel
4
T2BC-04-06-001
Right Control Panel 3 T2BC-04-06-002
T2BC-04-06-003
T4-6-6
OPERATIONAL PERFORMANCE TEST / Adjustment Calibration Starting 1. Start the engine. 2. Turn front drum auto stop cancellation switch (5) and rear drum auto stop cancellation switch (6) to ON position. NOTE: Now, MC2/A blinks pilot pressure indicator (1) at monitor panel. (Refer to Section "Control System".) 3. If pilot pressure indicator (1) blinks other than every 0.5 second, turn front / rear drum auto stop cancellation switches (5, 6) to OFF position. 4. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF). NOTE: Now, the power increase pressure decreases gradually. Pilot pressure indicator (1) blinks a cycle of 0.4 second ON and 0.1 second OFF during this time.
IMPORTANT: When turning the key switch (2) to OFF position, record the completed calibration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time. 6. Turn the key switch (2) to OFF position and check if five seconds or longer passes. 7. Remove the pressure gauge. Monitor Panel
1
5. When the power increase pressure reaches the set pressure (0.3 MPa), turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF). NOTE: Normal completion: Pilot pressure indicator (1): ON Abnormal completion: Pilot pressure indicator (1): Blinking every 0.1 second Normal completion condition: • Power increase electric current offset d Offset adjusting range (150 mA) [Power increase electric current offset = Output current - Adjustment point power increase electric current (608 mA)] • Output current d Upper limit electric current (800 mA) Left Control Panel
6
2
T2BC-04-06-001
Right Control Panel
3
5
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 apply the slewing brake. 2. Disconnect the connector from front motor brake release solenoid valve (8).
Monitor Panel
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. 3. After pilot pressure indicator (1) blinks, turn accelerator lock switch (3) to accelerator unlock position (OFF). 2
Left Control Panel 7
T2BC-04-06-001
Right Control Panel 3
T2BC-04-06-004
Front Motor
8
T2BC-04-06-003
Side Overhead Panel
4
T2BC-04-06-002
T2BC-04-06-005
T4-6-8
OPERATIONAL PERFORMANCE TEST / Adjustment Calibration Stating 1. Start the engine. 2. Turn boom derricking drum auto stop cancellation switch (7) to ON position. NOTE: Now, MC2/A blink pilot pressure indicator (1) at monitor panel. (Refer to Control System / SYSTEM) 3. If pilot pressure indicator (1) blinks other than every 0.5 second, turn boom derricking drum auto stop cancellation switch (7) to OFF position. 4. Turn accelerator lock switch (3) to accelerator preset position (SET) and turn to accelerator unlock position (OFF). NOTE: As result, the engine speed becomes high idle and the main pump delivery flow is maximized.
IMPORTANT: When turning key switch (2) to OFF position, record the completed calibration to EEPROM (MC2/A) for five seconds. Do not operate key switch (2) during this time. 8. Turn key switch (2) to OFF position and check if five seconds or longer pass. 9. Connect the connector to front motor brake release solenoid valve (8).
5. When the engine speed reaches 2000 min-1 or more, pilot pressure indicator (1) at monitor panel blinks at cycle of 0.1 second ON and 0.4 second OFF. 6. After the blinking of pilot pressure indicator (1) changes, carry out hoisting by using the front drum lever while operating the slewing lever. NOTE: Pilot pressure indicator (1) blinks a cycle of 0.4 second ON and 0.1 second OFF. After this, when the engine speed reaches the set speed (1950 min-1) or less, MC2/A stores it as a full rack. 7. When the engine speed reaches the set speed (1950 min-1) or less, MC2/A automatically reads the rack date. After reading it, the engine speed becomes low idle. NOTE: Normal completion: Pilot pressure indicator (1): ON Abnormal completion: Pilot pressure indicator (1): Blinking every 0.1 second. Normal Completion condition: x Engine speed d Set speed (1950 min-1) • Rack sensor input voltage t Rated rack point adjustment lower limit (2.803 V) x Engine speed ! Set speed (1950 min-1) • Rack sensor input voltage t Rated rack point lower limit in full load (2.352 V) • Maximum power increase
T4-6-9
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
1. Tighten lock nut (1) so that dimension A becomes specification. Dimension A: 45r1 mm 2. Loosen lock nut (2). Tighten stopper bolt (3) until lever (4) is clear of stopper bolt (3). 3. At this time, confirm that rod (8) of pressure-reducing valve is pushed to its stroke end. 4. Confirm that floor plate (6) and height of pin (5) (dimension C) are set to specification. Dimension C: 80±2 mm (3.1±0.08 in) 5. If dimension C is different from specification, adjust as follows. 1-1. Loosen lock nut (7). 㧦17 mm
B
T25N-04-06-005
Brake Pedal
5
6
1
1-2. Set a spanner at width across flats (9) of rod (8) and turn rod (8) in the adjusting direction. 㧦14 mm 1-3. When dimension C becomes specification, loosen lock nut (7). 㧦17 mm 㧦19.5r2.0 N m (2.0r0.2 kgf m, 14.5±1.5 lbf ft) 6. Loosen stopper bolt (3) until stopper bolt (3) gets in contact with lever (4). 7. When stopper bolt (3) contacts lever (4), loosen stopper bolt (3) a half turn from that position and lock with lock nut (2).
4
3
2 T25N-04-06-005
7
8
IMPORTANT: When if dimensions B and C are different from specification, return to Step 2 above for readjustment. 9
8. Confirm that dimensions B and C meet specification. Dimension B: 27 to 28 mm (1.06 to 1.10 in) Pressure-Reducing Valve T25N-04-06-002
T4-6-10
OPERATIONAL PERFORMANCE TEST / Adjustment 9. Loosen lock nut (10) and tighten stopper bolt (11) sufficiently.
Lock Pedal
4
8
10. Lower lever (4) until rod (8) of pressure-reducing valve reaches its stroke end and hold lever (4) in position. 11. Loosen stopper bolt (11) until stopper bolt (11) gets in contact with lever (4). 12. When stopper bolt (11) contacts lever (4), loosen stopper bolt (11) a half turn from that position and lock with lock nut (10).
14
13
12
11
Pressure-reducing valve
10
Adjusting pedal lock position 13. Loosen two bolts (13).
T25N-04-06-006
IMPORTANT: If lock position is too low, unlocking is unlikely to be made. Adjust it with care. 14. By changing the thickness of shim (14) and by repositioning the latch (12), make adjustment so that stroke required for unlocking the pedal is obtained and locking at stroke end is achieved. Thicknesses of shims (14): 4.5 mm (0.18 in) 6.0 mm (0.24 in) 9.0 mm (0.35 in) 12.0 mm (0.47 in) 15. In pedal lock position, confirm that dimension D meets specification. Dimension D: 40 mm or more
D
T4-6-11
T25N-04-06-006
This Page Left Blank Intentionally
SECTION 5
TROUBLESHOOTING —CONTENTS— Group 1 Diagnosing Procedure
Failure of Front Drum
Introduction ........................................... T5-1-1 Diagnosing Procedure ...........................
T5-1-2
Power Supply Monitor ...........................
T5-1-4
Trobleshooting Monitor ..........................
T5-1-6
Auto Stop Control System .................. T5-3-109 Failure of Rear Drum Auto Stop Control System .................. T5-3-114 Failure of Third Drum Auto Stop Control System .................. T5-3-119
Group 2 Component Layout Main Components Layout ......................
T5-2-1
Electrical Components Layout ...............
T5-2-4
Failure of FourthDrum Auto Stop Control System (Optional) .................. T5-3-127 Failure of Second Overhoist Auto Stop Control System .................. T5-3-134
Group 3 Troubleshooting A Troubleshooting A Procedure ................
T5-3-1
Failure of Front and Rear Motor Speed Control System........................ T5-3-138
Failure of MC2/A or MC2/B Battery and Sensor System Power Supply ............ T5-3-10
Failure of Front Drum Surge Pressure Reduction Control System.................. T5-3-143
Failure of Engine Controller System ...... T5-3-25 Failure of Brake Control System ............ T5-3-32
Failure of Tower Jib Derricking 2-Speed Flow Combining Limit Control System ........ T5-3-145
Failure of Main Pump Delivery Flow Rate Control System .......................... T5-3-62 Failure of Main Pump Power Increase
Group 4 Troubleshooting B Troubleshooting B Procedure ................
Control System .................................. T5-3-65 Failure of Slewing Alarm Control System ........................ T5-3-68 Failure of Rotation
T5-4-1
Troubleshooting List...............................
T5-4-2
Engine System Troubleshooting ............
T5-4-3
Power Supply System Failure ................
T5-4-6
Actuator Troubleshooting ....................... T5-4-19
Sensing Control System..................... T5-3-72 Failure of Engine Start
Hoist Drum Troubleshooting .................. T5-4-20 Boom Derricking Drum Troubleshooting
Interlock Control System .................... T5-3-82 Failure of Pilot Pressure Drop Warning
T5-4-28
Slewing System Troubleshooting ........... T5-4-30 Travel System Troubleshooting.............. T5-4-33
Lamp Control System......................... T5-3-88
Other Troubleshooting ........................... T5-4-36
Failure of Monitor Cutoff Pressure Control System .................................. T5-3-90 Failure of Derricking Drum Auto Stop Control System .................. T5-3-92
2BCT-5-1
Group 5 Troubleshooting C Trobleshooting C Procedure ..................
Fault Code W47 ..................................... T5-6-27 T5-5-1
Malfunction of
Fault Code W48 ..................................... T5-6-30 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
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
Fault Code WA1..................................... T5-6-35
Malfunction of Engine Oil Filter Restriction Indicator ...........................
T5-5-9
Trobleshooting E Procedure ..................
Malfunction of Air Filter Restriction Indicator ...........................
Group 7 Troubleshooting E
T5-5-11
T5-7-1
How to Read Fault Code in ECU Engine Troubleshooting .............
Malfunction of Overheat Indicator .......... T5-5-13
T5-7-2
Group 8 Troubleshooting F
Malfunction of Controller Failure Indicator ................................. T5-5-15
Information Display Unit (IDU)
Malfunction of Preheat Indicator ............ T5-5-17 Malfunction of Alternator Indicator ......... T5-5-18 Malfunction of Brake Unapplied Indicator T5-5-20
Technical Manual ...............................
Group 9 Electrical System Inspection Precautions for Inspection
Malfunction of Pilot Pressure Drop Indicator .................................... T5-5-21 Malfunction of Hour Meter ..................... T5-5-22
Group 6 Troubleshooting D Troubleshooting D Procedure ................
T5-6-1
Fault Code Table ...................................
T5-6-2
Fault Code E20, E22 .............................
T5-6-4
Fault Code E21, E26 .............................
T5-6-5
Fault Code E30 .....................................
T5-6-7
Fault Code E31 .....................................
T5-6-9
T5-8-1
and Maintenance................................
T5-9-1
Instruction for Disconnecting Connectors
T5-9-3
Battery Voltage Check ...........................
T5-9-4
Fusible Link Inspection ..........................
T5-9-5
Fuse Inspection .....................................
T5-9-6
How to Check Alternator ........................
T5-9-9
Voltage Check........................................ T5-9-10 Check by False Signal ........................... T5-9-19 Continuity Check.................................... T5-9-20
Fault Code E40 ..................................... T5-6-12 Fault Code E43 ..................................... T5-6-12 Fault Code E44 ..................................... T5-6-13 Fault Code E45 ..................................... T5-6-14 Fault Code E50 (Crane) ........................ T5-6-16 Fault Code E50 (Tower)......................... T-5-6-18 Fault Code E51 ..................................... T5-6-20 Fault Code E52 ..................................... T5-6-22
2BCT-5-2
TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Inspection procedures for troubleshooting are presented in an orderly fashion in this section in order to enable you locate the source of any problems that may arise. The troubleshooting section consists of 9 groups: the diagnosing procedure, component layout, troubleshooting A (control system), troubleshooting B (base machine operation system), troubleshooting C (monitor system), troubleshooting D (IDU system), troubleshooting E (engine control system), troubleshooting F (crane monitor system) and electrical system inspection.
• Troubleshooting A (Control System) Use this group when a controller failure indicator on the monitor panel is blinking. Example: Abnormal accelerator control.
• Troubleshooting B (Base Machine Operation System) Use this group when any trouble exists in the base machine operation system except the main controller and/or auto-stop controller system. Example: Hoist and/or lower function is inoperable.
• Troubleshooting C (Monitor System) Use this group when any trouble regarding monitors such as gauges and/or indicators occur. Example: Fuel gauge is inoperable.
• Troubleshooting D (IDU System) Use this group when auto-stop is performed although auto-stop is not required.
• Troubleshooting E (Engine Control System) Use this group when blinking the ECU lamp and displaying the fault code. (ECU records the trouble condition of electrical signal system as a fault code by using a self-diagnosis function.)
• Electrical System Inspection Refer to this group when precautions and/or inspection data for the electrical system check is required.
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE
These six basic steps are essential for efficient troubleshooting:
1. Study the system Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are. 2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness --- the operator.
T107-07-01-001
(a) How is the machine being used? (Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what types of work the machine doing at that time? (c) What are details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (d) Did the machine have any other troubles previously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, cheek the machine’s daily maintenance points, as shown in the operator’s manual.
T107-07-01-002
Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without noticing a blown fuse, incorrect diagnosis may result along with a large amount of lost time. Be sure to check if any fuse has blown before starting troubleshooting. Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Always check fuses using a tester.
T107-07-01-003
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses.
5. Perform troubleshooting CAUTION: Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines. First identify in which group the trouble is present. Then, perform the troubleshooting, system by system, in accordance with the classification of Troubleshooting A, B, C, D and E as described in this group.
T324-07-01-002
6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions. T324-07-01-003
T5-1-3
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
Indication 1. Turn ON the maintenance key switch, press key on the ML window and indicate the maintenance menu.
Boom suspend
1-rope reeving
Jib suspend 4-rope reeving
Overheat
Hyd. oil temp.
Brake oil temp.
2. Select "Monitor" by pressing or key and press key in order to indicate the monitor menu.
Suspend selection
Menu
Maintenance Menu
Load Factor
1. Inspection Menu 2. Adjustment Menu 3. Monitor 4. Version Indication Menu 5. Record Menu 6. Spec Setting Menu 7. Service Manual
Selection
3. Select "Power Supply Monitor" in the monitor menu by using or key and press key.
Monitor Menu
Cancellation
Determination
Load Factor
1. Power Supply Monitor 2. Key Check 3. IDU Monitor 4. MC2/A Monitor 5. MC2/B Monitor
Selection
T5-1-4
Cancellation
Determination
TROUBLESHOOTING / Diagnosing Procedure Power Supply Monitor
Description
MC2/A Input / Output Monitor MC2/A
MC2/B
IDU
MAIN_B
NORMAL
MAIN_B
NORMAL
MAIN_B
5V
LOW ER
5V
1/1 xx. xxV
LOW ER
5V
24V_1
HI ER
24V_1
HI ER
10V
xx. xxV
24V_2
SHORT
24V_2
SHORT
24V
xx. xxV
24V_3
SHORT
24V_3
SHORT
x. xxV
χχ ω Page Selection Return Item
MC2/A
MC2/B
IDU
Description NORMAL LOW ER HI ER SHORT xx. xxV
Item MAIN_B 5V 24V_1 24V_2 24V_3 MAIN_B 5V
Signal Name Main power supply Analog sensor power supply For each switch input For throttle control switch For emergency operation switch Main power supply Analog sensor power supply For three-winding layer detector 24V_1 (No connection) 24V_2 For overhoist switch on machine 24V_3 For overhoist switch on attachment 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
Explanation Normal Lower limit error Upper limit error Short circuit A/D voltage conversion Communication error
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.
Indication 1. Turn ON the maintenance key switch, push the key on the ML screen and indicate the maintenance menu.
Maintenance Key Switch
T25N-05-01-001
Boom suspend
1-rope reeving
Jib suspend 4-rope reeving
Overheat
2. Select "Monitor" by using or switch and press key in order to indicate the monitor menu.
Hyd. oil temp.
Brake oil temp.
Suspend selection
Menu
Maintenance Menu
Load Factor
1. Inspection Menu 2. Adjustment Menu 3. Monitor 4. Version Indication Menu 5. Record Menu 6. Spec Setting Menu 7. Service Manual
Selection
3. Select the wanted item in the monitor Menu by using or key and press key.
Monitor Menu
Cancellation
Determination
Load Factor
1. Power Supply Monitor
2. Key Check 3. IDU Monitor 4. MC2/A Monitor 5. MC2/B Monitor
Selection
T5-1-6
Cancellation
Determination
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
THROT. FOOT NORMAL
DD LWR PRS
LOW ER
SL LFT PRS
LOW ER
RACK. P.
FD HST PRS
HI ER
PILOT PRS
NORMAL LOW ER
HI ER
THROL. M. P. NORMAL
FD LWR PRS
RSV ER
FD BRK PRS
SL CTRL SP
2.50 V
RD HST PRS
xMPa x.
RD BRK PRS
HI ER
LOW ER
RD LWR PRS
LOW ER
3D BRK PRS
RSV ER
HI ER
(AN_IN22)
NORMAL
(AN_IN23)
LOW ER
THRT. 3RD
TRPGT. PRS
HI ER
3D HST PRS
TRLFT. PRS
RSV ER
3D LWR PRS
Item
Item THROT. GRIP THROT. FOOT RACK. P. THROL. M. P. SL CTRL SP THRT. 3RD TRRGT.PRS TRLFT. PRS DD HST PRS DD LWR PRS FD HST PRS FD LWR PRS RD HST PRS RD LWR PRS 3D HST PRS 3D LWR PRS MC2/A AI3
MC2/A AI2
RSV ER
χ ω Page Selection Return
MC2/A AI1
x. xMPa
SL RGT PRS SL LFT PRS PILOT PRS FD BRK PRS RD BRK PRS 3D BRK PRS (AN_IN22) (AN_IN23)
Signal name Accelerator grip signal Accelerator pedal signal Rack position signal Governor motor potentio sensor signal Slewing speed dial signal (No connection) Third drum acceleration Right travel remote control pressure Left travel remote control pressure 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 Forrth drum hoisting remote control pressure Third / fourth lowering remote control pressure Slewing (right) remote control pressure Slewing (left) remote control pressure Primary pilot pressure Front brake depressing pressure Rear brake depressing pressure Fourth brake depressing pressure No connection No connection
T5-1-7
Description NORMAL LOW ER HI ER RSV ER
Explanation Normal Lower limit error Upper limit error Spare
x. xV LOW ER HI ER RSV ER
Normal (voltage) Lower limit error Upper limit error Spare
x. xMPa LOW ER HI ER DBL ER
Operating pressure Lower limit error Upper limit error Double errors
******
Communication error
NORMAL
Normal operation OFF
LOW ER
Lower limit error
HI er
Upper limit error
RSV ER
Normal operation ON
TROUBLESHOOTING / Diagnosing Procedure MC2/A Digital Inputs
Description
MC2/A Input / Output Monitor
MC2/A SWITCH
MC2/A CAN1
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
STOP
ENG. START OFF
RACK P. S.
x. xx V
DD PLS
THROT. FIX
MC2/A CAN2
2/4
RACK P. STP
x. xx V
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
ON
χ
ω Page Selection
Return
Item
Item MC2/A FD FREE SW SWITCH RD FREE SW 3D FREE SW ENG. START THROT. FIX THROT. PRE GATE LOCK SL BRK SW MC2/A CAN1 FD FREE MD RD FREE MD 3D FREE MD
Signal name Front drum free mode switch Rear drum free mode switch Third / fourth drum free mode switch Engine start signal Throttle lock switch Throttle preset switch Gate Lock Switch Slewing brake switch Front drum free mode control Rear drum free mode control Third / fourth drum free mode control RACK P. S. Rack position signal RACK P. STP Engine stop rack position RACK P. FUL Full rack position 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 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)
Description ON OFF BRAKE FREE x. xx V -xxxmA -xxxxx ROTATE STOP CANCEL NORMAL SHORT CRANE TOWER OPEN ******
T5-1-8
Explanation Open contact Closed contact Auto brake mode Free mode A/D voltage conversion Electric current offset Drum pulse counter Rotation Stop Cancellation Normal Short circuit Crane Tower Open circuit Communication error
TROUBLESHOOTING / Diagnosing Procedure MC2/A Digital Output
Description
MC2/A Input / Output Monitor
MC2/A D01
MC2/A D02
M PMP CUR
xxxxmA
FD PLS SOL
INC. TQ CUR
LOW ER
RD PLS SOL
SL RGT CUR
HI ER
DD PLS SOL
SL LFT CUR
RES ER
SL PMP CUR
CANCEL
FD BRK REL
xxxxmA
RD BRK REL
LOW ER
3D BRK REL
HI ER
3/4
ERROR
FM BRK REL
ERROR NORMAL
SL PRS SOL
ERROR
RM BRK REL 3M BRK REL
ERROR
CAL IB. CUR
NORMAL
MT CUT OFF
NORMAL
ENG. INTLCK
ERROR
3D BRK LP
NORMAL
SL ALAM LP
ERROR
NORMAL
NORMAL
χ ω Page Selection Return
MC2/A D03 DD LCK REL
NORMAL
Item
Item Signal name MC2/A M PMP CUR Main pump displacement angle D01 proportional solenoid valve INC. TQ CUR Power increase solenoid valve SL RGT CUR Slewing multi (right) proportional solenoid valve (No connection) SL LFT CUR Slewing multi (left) proportional solenoid valve (No connection) SL PMP Slewing pump swash angle proportional CUR solenoid valve (No connection) FD BRK REL Front drum brake release solenoid valve RD BRK REL Rear drum brake release solenoid valve 3D BRK REL Fourth drum brake release solenoid valve MC2/A FD PLS SOL Front drum rotation sensing solenoid D02 RD PLS SOL Rear drum rotation sensing solenoid DD PLS SOL Derricking drum rotation sensing solenoid SL PKS SOL Slewing remote control pressure hydraulic source Solenoid (No connection) CAL IB. CUR Calibration electric current MC2/A DD LCK REL Derricking drum unlocking solenoid valve D03 FM BRK REL Front motor brake release solenoid valve 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
Description xxxxmA LOW ER HI ER RES ER CANCEL
Explanation Control current Lower limit error Upper limit error Reset error Feedback cancellation
NORMAL LOW ER HI ER RES ER RSV
Normal Lower limit error Upper limit error Reset error Feedback cancellation
NORMAL LOW ER HI ER RES ER RSV
Calibration electric current Lower limit error Upper limit error Reset error Auxiliary
NORMAL ERROR ******
Normal Short circuit Communication error
TROUBLESHOOTING / Diagnosing Procedure ECU Status
Description
MC2/A Input / Output Monitor
MC2/A_ECU1
RECEIVE
NORMAL
TMR F. B.
ERROR
RACK P. S.
NORMAL
TIMING S.
ERROR
TDC S.
INVLD
OVER H. S.
ERROR
TMR. C. V.
NORMAL
Ĺ ĻPage Selection Return
Item
Item
MC2/A_ECU1
4/4
Signal name
Description
Explanation
RECEIVE
ECU
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
Normal
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 ALLOFF
RD CTRL SP
LOW ER
TR LET PRS x. xMPa
RD ROPE ED
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 MC2/B AI1 FD CTRL SP
Signal name Front drum speed setting dial signal (No connection) RD CTRL SP Rear drum speed setting dial signal (No connection) DD CTRL SP Derricking drum speed setting dial signal (No connection) (AN_IN3) No connection (AN_IN4) No connection (AN_IN5) No connection (AN_IN6) No connection (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
Description NORMAL LOW ER HI ER RSV x. xMPa DBL ER R. END ALLOFF ALLON ******
T5-1-11
Explanation Normal Lower limit error Upper limit error Spare Normal (pressure) Double errors Extra hoisting Open circuit Shorted harnesses Communication error
TROUBLESHOOTING / Diagnosing Procedure MC2/B Digital Inputs
Description
MC2/B Input / Output Monitor
MC2/B SWITCH1
DD REL SW
MC2/B SWITCH2
MC2/B DI
NORMAL
BM OVERH
NORMAL
DD HST STP
2/3 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
REL KEY SW
OH2 REL SW
JB FOLD
ATTACHMENT
ALLON
FD LWR STP
STOP
NORMAL
JB OVERH
NORMAL
RD HST STP
NORMAL
REL
JB OVERH2
OVERH
RD LWR STP
STOP
FOLD
HK OVERH
ALLOFF
3D HST STP
NORMAL
ALLON
3D LWR STP
STOP
CRANE
SWL OVERH
Item
Item DD REL SW FD REL SW RD REL SW 3D REL SW HM FIX SW OH2 REL SW JB FOLD ATTACHMENT BM OVERH BT OVERH2 TW OVERH BT LOWER L
MC2/B DI
MC2/B SWITCH2
χ ω Page Selection Return
MC2/B SWICH1
JB OVERH JB OVERH2 HK OVERH SWL OVERH DD HST STP DD LWR STP FD HST STP FD LWR STP RD HST STP RD LWR STP 3D HST STP 3D LWR STP
Signal name Derricking drum auto stop release Front drum auto stop release Rear drum auto stop release Third drum auto stop release Hoisting motor low speed lock Second overhoist restoration switch Jib folding Wiring detection Boom overhoist Boom / tower second overhoist (No connection) Tower overhoist Boom / tower lower limit (No connection) Jib overhoist Jib second overhoist Hook overhoist Tower jib backstop alignment Derricking drum hoisting stop Derricking drum lowering stop Front drum hoisting stop Front drum lowering stop Rear drum hoisting stop Rear drum lowering stop Fourth drum hoisting stop solenoid valve Fourth drum lowering stop solenoid valve
T5-1-12
Description NORMAL REL INHBIT
Explanation Auto stop Release operation Release prohibition
ON OFF
Closed contact Open contact
NORMAL REL
Auto stop Release operation
FOLD UNFOLD ALLOFF ALLON
Jib folding Jib unfolding Open circuit Shorted harnesses
SHORT CRANE TOWER OPEN
Short circuit Crane Tower Open circuit
NORMAL OVERH ALLOFF ALLON LOWER
Normal Overhoist Open circuit Shorted harnesses Lower limit
NORMAL STOP
Operation Stop
******
Communication error
TROUBLESHOOTING / Diagnosing Procedure MC2/B Digital Outputs
Description
MC2/B Input / Output Monitor
MC2/B D01
MC2/B D02
DD HST CUR
xxxxmA
GREEM LMP
DD LWR CUR
LOW ER
YELLOW LMP
FD HST CUR
HI ER
FD LWR CUR
RES ER
OVERH2 SOL
ERROR
RED LMP
NORMAL
ERROR
NORMAL
RD HST CUR
CANCEL
3D HST SOL
NORMAL
RD LWR CUR
xxxxmA
3D LWR SOL
ERROR
FM CAP CUR
LOW ER
CALIB. CUR
RM CAP CUR
HI ER
3/3
LOW ER
Ĺ ĻPage Selection Return
Item
Item MC2/B DD HST CUR D01 DD LWR CUR FD HST CUR FD LWR CUR RD HST CUR RD LWR CUR FM CAP CUR RM CAP CUR MC2/B GREEM LMP D02 YELLOW LMP RED LMP OVERH2 SOL 3D HST SOL 3D LWR SOL CALIB. CUR
Signal name Derricking drum hoisting proportional solenoid valve Derricking drum lowering proportional solenoid valve Front drum hoisting proportional solenoid valve Front drum lowering proportional solenoid valve Rear drum hoisting proportional solenoid valve Rear drum lowering proportional solenoid valve Front motor swash angle proportional solenoid valve Rear motor swash angle proportional solenoid valve External indicator green (No connection) External indicator yellow (No connection) External indicator red (No connection) Second overhoist solenoid valve Fourth drum hoisting solenoid valve Fourth drum lowering solenoid valve Calibration electric current
T5-1-13
Description xxxxmA LOW ER HI ER RES ER CANCEL NORMAL ERROR
Explanation Control current Lower limit error Upper limit error Reset error Feedback cancellation Normal Short circuit
NORMAL LOW ER HI ER RES ER RSV
Calibration electric current Lower limit error Upper limit error Reset error Auxiliary
******
Communication error
TROUBLESHOOTING / Diagnosing Procedure IDU Analog Inputs
Description
IDU Input / Output Monitor
IDU AI1
IDU AI3
IDU AI2
JB ANGLE
X.XXV
(AN_IN0)
X.XXV
JB ANGLE2
X.XXV
(AN_IN1)
X.XXV
BM ANGLE
X.XXV
(AN_IN2)
X.XXV
BM LOAD
X.XXV
(AN_IN3)
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
X.XXV
(AN_IN10)
X.XXV
(AN_IN11)
X.XXV
Item
IDU AI3
(AN_IN9)
1/3
Ĺ ĻPage Selection Return
IDU AI2
X.XXV
IDU AI1
(AN_IN8)
Item JB ANGLE JB ANGLE2 BM ANGLE BM LOAD JB LOAD JB ANGLE JB ANGLE2 BM ANGLE (AN_IN0) (AN_IN1) (AN_IN2) (AN_IN3) HYD THM FD BRK THM RD BRK THM 3D BRK THM (AN_IN8) (AN_IN9) (AN_IN10) (AN_IN11)
Signal name Jib angle sensor (S) (No connection) Jib angle (-) sensor (S) (No connection) Boom angle sensor (S) (No connection) Boom derricking tension sensor Jib derricking tension sensor Jib angle sensor (D) Jib angle (-) sensor (D) Boom angle sensor (D) No connection No connection No connection No connection Hydraulic oil temperature sensor Front brake temperature sensor Rear brake temperature sensor Third brake temperature sensor No connection No connection No connection No connection
T5-1-14
Description X.XX V ******
Explanation A/D voltage conversion Communication error
TROUBLESHOOTING / Diagnosing Procedure IDU Digital Inputs Description
IDU Input / Output Monitor
IDU DI1
CLAMSHELL
IDU DI/PI
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
IDU DI2 ON
2/3
Ĺ ĻPage Selection Return
Item
IDU DI1
IDU DI2
Item CLAMSHELL DRAGLINE JB CATCH BM OH LINE JB OH LINE (DG_IN13) REAR ADD CW1 ADD CW2 DEC CW1 DEC CW2 DEC CW3 DEC CW4
IDU DI/PI
OVERHEART (PLS_IN1) (PLS_IN2) (PLS_IN3) (PLS_IN4) (PLS_IN5) (PLS_IN6) (PLS_IN7)
Signal name Clamshell mode (No connection) Dragline mode(No connection) Jib catch detection(No connection) Overhoist wiring detection (boom) Overhoist wiring detection (jib) No connection Shift 1 (rear suspend) (No connection) Shift 1 (load increase 1) (No connection) Shift 3 (load increase 2) (No connection) Shift 4 (load decrease 1) (No connection) Shift 5 (load decrease 2) (No connection) Shift 6 (load decrease 3) (No connection) Shift 7 (load decrease 4) (No connection) Thermo switch No connection No connection No connection No connection No connection No connection No connection
T5-1-15
Description ON OFF CATCH REL. ALLOFF ALLON ******
Explanation Closed contact Open contact Jib catch Jib release Open circuit Shorted harnesses Communication error
TROUBLESHOOTING / Diagnosing Procedure IDU Digital Outputs
Description
IDU Input / Output Monitor
IDU D01
DD HST STP
CAN IDU
IDU D02 NORMAL
DD LWR STP
STOP
JB OVER T.
STOP
FD HST STP
NORMAL
(OC_OUT10)
ON
FD LWR STP
STOP
(OC_OUT11)
OFF
FD LWR SD%
XXX. %
RD HST STP
NORMAL
(OC_OUT12)
ON
RD HST SD%
XXX. %
(OC_OUT13)
OFF
RD LWR SD%
XXX. %
LAMP CHK
ON
3D HST SD%
XXX. %
BUZZER
OFF
3D LWR SD%
XXX. %
RD LWR STP
STOP
3D HST STP
NORMAL
3D LWR STP
STOP
XXX. %
FD HST SD%
XXX. %
Ĺ ĻPage Selection Return
Item
IDU CAN
DD LWR SD%
3/3
IDU D02
XXX. %
B/J LOW T.
IDU D01
DD HST SD%
NORMAL
Item DD HST STP DD LWR STP FD HST STP FD LWR STP RD HST STP RD LWR STP 3D HST STP 3D LWR STP B/J LOW T. JB OVER T. (OC_OUT10) (OC_OUT11) (OC_OUT12) (OC_OUT13) LAMP CHK BUZZER DD HST SD% DD LWR SD% FD HST SD% FD LWR SD% RD HST SD% RD LWR SD% 3D HST SD% 3D LWR SD%
Signal name M/L derricking drum hoisting stop M/L derricking drum lowering stop M/L front drum hoisting stop M/L front drum lowering stop M/L rear drum hoisting stop M/L rear drum lowering stop M/L fourth drum hoisting stop M/L fourth drum lowering stop M/L shouldering prevention M/L tower breakage prevention No connection No connection No connection No connection Lamp check relay Buzzer Derricking drum hoisting slow down % Derricking drum lowering slow down % Front hoisting slow down% Front lowering slow down% Rear hoisting slow down % Rear drum lowering slow down % Third drum hoisting slow down % Third drum lowering slow down %
T5-1-16
Description NORMAL STOP ON OFF ******
Explanation Normal Stop Drive Non-drive Communication error
TROUBLESHOOTONG / Component Layout MAIN COMPONENT LAYOUT 1
Upper Structure
3
2
4
5
6
7 8 9 10
33 (Under Fuel Tank)㩷
11*1
1
32*
12
(Broken Line Part)㩷
31 13
30 29
14
28*1
15 16
27 17 18 26 19
(Under Cab Back)㩷
25
20
T2BC-01-02-010
24 1234-
Fuel Tank㩷 Boom Derricking Drum㩷 Slewing Control Valve㩷 Derricking Drum Lock Valve㩷 5 - 4-Spool Control Valve㩷
6-
Hydraulic Oil Tank㩷 7 - Drain Filter㩷 89-
Pilot Filter㩷 Gate Lock Valve㩷
10 11 12 13 -
21
23 22
Pump Mechanism㩷 Third Drum Control Valve*1㩷 Engine㩷 Pressure Compensator㩷
14 - Fourth Drum Brake Release Solenoid Valve (Optional)㩷 15 - Rear Drum Brake Release Solenoid Valve㩷 16 - Front Drum Brake Release Solenoid Valve㩷 17 - Radiator㩷 㩷
18 19 20 21 -
Oil Cooler㩷 Intercooler㩷 Battery㩷 Slewing Mechanism㩷
22 - Front Drum Brake Pedal Unit㩷 23 - Fourth Drum Brake Pedal Unit (Optional)㩷 24 - Rear Drum Brake Pedal Unit㩷 25 - Front Drum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
26 27 28 29 -
Shuttle Valve㩷 Front Control Valve㩷 Rear Control Valve*1㩷 Rear Drum㩷
30 - Slewing Remote Control Pressure Detection Valve㩷 31 - 4-Spool Solenoid Valve Unit㩷 32 - Fourth Drum (Optional)㩷 33 - Accumulator㩷 㩷
TROUBLESHOOTONG / Component Layout Base Carrier 1 2
8
3 4 5 6
13
7 8 12 9 11
Rear㩷 Left
3
T2BC-01-02-001
7
Right㩷 Front㩷
10 6 1-
Slewing Ring㩷
5 - Lower Frame㩷
8-
2-
Center Joint㩷
3-
Retract Cylinder㩷
6 - Take-Up Cylinder*1 (2 Used) (Optional)㩷 7 - Front Idler (2 Used)㩷
Jack-Up Cylinder (4 Used) (Optional)㩷 9 - Lower Control Valve (Optional)㩷 10 - Upper Roller (4 Used)㩷
4-
Crawler Shoe㩷
㩷
㩷
̪1: Installed in the side frame.
T5-2-2
11 - Lower Roller (20 Used)㩷 12 - Side Frame㩷 13 - Travel Mechanism (2 Used)㩷 㩷
TROUBLESHOOTONG / Component Layout Cab Interior
1
2
3
4
5
6
7
8
10
9
11
13
12
T2BC-01-02-003
T2BC-01-02-002
12-
Front Drum Brake Pedal㩷 Fourth Drum Brake Pedal (Optional)㩷 3 - Rear Drum Brake Pedal㩷
56-
Front Drum Lever㩷 Rear Drum Lever㩷
7-
Boom Derricking Drum Lever㩷
4-
㩷
Accelerator pedal㩷
89-
Lock Lever㩷 Third/Fourth Drum Lever (Optional)㩷 10 - Left Travel Lever㩷
11 - Right Travel Lever㩷 12 - Slewing Lock Pedal㩷
㩷
㩷
T5-2-3
13 - Slewing Lever㩷
TROUBLESHOOTONG / Component Layout ELECTRICAL COMPONENT LAYOUT
Solenoid Valve for Counterweight / Quick Draw / Retract (Refer to Counterweight / Quick Draw / Retract Control Valves.)㩷
Upper Structure 8
1
Primary Pilot Pressure Sensor㩷(Refer to Accumulator.)㩷 (Under Fuel Tank)
Around Pump㩷(Refer to Pump Mechanism.)
7 2
4-Spool Solenoid Valve (Refer to 4-Spool Solenoid Valve Unit.)㩷
3 Slewing Remote Control Pressure Sensor㩷 㩷 (Refer to Slewing Remote Control Pressure Sensor Block.)㩷
Around Drum㩷 (Refer to Drum.)㩷 (Under Bed) Around Engine (Refer to Engine.)㩷
4 Around Control Valve (Refer to Front / Rear Control Valves.)㩷
5 6
Around Battery㩷 (Refer to Batteries.)㩷
Inside Cab (Refer to Cab Inside Overall.)㩷
Around Brake Pedal (Refer to Brake Pedal Unit.)㩷 (Under Cab Back)
T2BC-01-02-013
1-
Oil Temperature Sensor㩷
2-
EC Motor㩷
4 - Fourth Drum Brake Release Solenoid Valve (Optional)㩷 5 - Rear Drum Brake Release Solenoid Valve
3-
Air Filter Restriction Switch㩷
6 - Front Drum Brake Release Solenoid Valve
T5-2-4
7 - Fuel Sensor㩷 8 - Derricking Rotation Detection Switch㩷 㩷
TROUBLESHOOTONG / Component Layout 1
2
1
3
4
T2BC-01-02-004㩷
1-
Operation Stop Switch㩷
2-
Working Light (Right)㩷
3-
T5-2-5
Working Light (Left)㩷
4-
Slewing Alarm Lamp㩷
TROUBLESHOOTONG / Component Layout Cab Inside Overall
Monitor Panel (Refer to Monitor Panel.)
13 1 12
2 3 4
Brake Mode Display Panel㩷 (Refer to Brake Mode Panel.)㩷
8
Travel Lever㩷
5 6
11
(Inside Cover)
10
7
9
T2BC-01-02-003
Left Control Panel㩷 (Refer to Control Panel.)
Right Control Panel㩷 (Refer to Control Panel.)㩷 T2BC-01-02-006
Side Overhead Panel (Refer to Overhead Panel.)
14
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
12-
Accelerator Pedal㩷
Front Drum Rotation Sensing㩷 3 - Rear Drum Rotation Sensing㩷 4 - Boom Derricking Drum Rotation Sensing㩷
5-
Front Drum Brake Mode Switch㩷 6 - Lock Valve Limit Switch㩷
9-
10 - Slewing Brake Switch㩷
14 - Antenna㩷
7-
11 - Accelerator grip㩷
15 - Air Conditioner Control Panel㩷 㩷
Rear Drum Brake Mode Switch㩷 8 - Fourth Drum Brake Mode Switch㩷
Horn Switch㩷
12 - Moment Limiter Control Panel㩷
T5-2-6
13 - Moment Limiter㩷
TROUBLESHOOTONG / Component Layout Monitor Panel
1 15
14 13
2
12 11 10
9
3
8 7
6 4 5
T2BC-01-02-007
1-
Coolant Temperature Gauge㩷 2 - Fuel Gauge㩷
5 - Cigarette Lighter㩷
9 - Glow Signal㩷
13 - Brake Unapplied Indicator㩷
6 - Overheat Indicator㩷
3-
Hour Meter㩷
14 - Engine Oil Pressure Indicator㩷 15 - Pilot Pressure Indicator㩷
4-
Key Switch㩷
7 - Controller Failure Indicator㩷 8 - Air Filter Restriction Indicator㩷
10 - Engine Oil Filter Restriction Indicator㩷 11 - Alternator Indicator㩷 12 - Coolant Level Indicator㩷
㩷
T5-2-7
TROUBLESHOOTONG / Component Layout Control Panel
• Left Control Panel 1
2
3
4
5
7
6
8
9
T2BC-01-02-008
12
10
11
• Right Control Panel
T2BC-01-02-009
13 1-
Auto Stop Release Key Switch㩷 2 - Auto Stop Release Derricking Switch㩷 3 - Auto Stop Release Third/Fourth Drum Switch㩷 4 - Auto Stop Release Rear Drum Switch㩷
14
5 - Auto Stop Release Front Drum Switch㩷 6 - Brake Mode Select Key Switch㩷 7 - Remote Control Pressure Restoration Switch㩷 8 - Side Frame Extend/Retract Switch㩷
15
16
9 - Reeving Winch Switch㩷
13 - Accelerator Lock Switch㩷
10 - Quick Draw Extend/Retract Switch㩷 11 - Third/Fourth Drum Selection Switch㩷 12 - Counterweight/Jack-Up Switch (Optional)㩷
14 - Front Drum Lock Switch㩷
T5-2-8
15 - Rear Drum Lock Switch㩷 16 - Fourth Drum Lock (Optional)㩷
TROUBLESHOOTONG / Component Layout Overhead Panel
• Rear Overhead Panel 2
1
4
3
5
6
7
T2BC-01-02-011
• Side Overhead Panel 9
8
10
11
12
T2BC-01-02-012
1-
FM/AM Radio㩷
4-
Auxiliary㩷
2-
Working Light Switch㩷
5-
Electric Power Socket㩷
3-
Drum Light Switch (Optional)㩷
6-
Front Wiper / Washer Switch㩷
7 - Overhead Wiper / Washer Switch㩷 8 - Emergency Engine Stop Switch㩷 9 - Slow Speed Lock Switch㩷
10 - Hydraulic Tagline Switch (Optional)㩷 11 - Drum Rotation Sensing Switch㩷 12 - Travel Mode Switch㩷
Brake Mode Display Panel 1
2
3
T2BC-01-02-014
6 1-
Front Drum Free Mode 3 - Rear Drum Free Mode Lamp (Red)㩷 Lamp (Red)㩷 2 - Third / Fourth Drum 4 - Front Drum Auto Brake Free Mode Lamp (Red)㩷 Mode Lamp (Green)㩷
5
4 5 - Third / Fourth Drum Auto Brake Mode Lamp (Green)㩷 㩷
T5-2-9
6㩷
Rear Drum Auto Brake Mode Lamp (Green)㩷
TROUBLESHOOTONG / Component Layout Relay Panel 1 2 3
㪈㩷㪄㩷 Third Drum Lowering Stop Relay (R10)㩷 㪉㩷㪄㩷 Moment Limiter Buzzer Relay (R9)㩷 㪊㩷㪄㩷 Third/Fourth Drum Selection Relay Lower (R8)㩷 㪋㩷㪄㩷 Slewing Alarm Relay (R1)㩷 㪌㩷㪄㩷 Engine Oil Pressure Relay (R2)㩷 㪍㩷㪄㩷 Engine Start Relay (R3)㩷 㪎㩷㪄㩷 Horn Relay (R4)㩷 㪏㩷㪄㩷 Jack Relay (R5)㩷 㪐㩷㪄㩷 Motor Cutoff Relay (R6)㩷 㪈㪇㩷㪄㩷Third/Fourth Drum Selection Relay Upper (R7)㩷
10 9 8 7 6 T2BC-01-02-015
5 4
Controller Box 12 1
11 10 9
T2BC-01-02-016
8
7
6
5
4
3
1-
Preheat Controller㩷
4 - Memory Deletion Switch㩷
7 - MC2/A
23-
ECU Lamp (Red)㩷 ECU Lamp (Yellow)㩷
5 - Troubleshooting Switch㩷 6 - IDU
8 - MC2/B 9 - Maintenance Key Switch㩷
T5-2-10
2
10 - Emergency Engine Stop Switch㩷 11 - Fuse Boxes㩷 12 - IDU
TROUBLESHOOTONG / Component Layout Brake Pedal Unit
Cab Floor㩷
T2BC-01-02-017
TBC-01-02-030
1
1-
Front Brake Depressing Pressure Sensor㩷
2
2-
4
3
Fourth Brake (Optional) Depressing Pressure Sensor㩷
3-
Rear Brake Depressing Pressure Sensor㩷
T5-2-11
* Other Brakes are installed to the same positions.
4-
Rear Brake Applied Sensing Switch㩷
TROUBLESHOOTONG / Component Layout Engine
1
2
3
4
5
6
7
8
9
10 Machine Front㩷
Machine Rear
11 㩷
12 Machine Rear
Machine Front
T25N-01-02-001
13
䌔2䌂䌃-01-02-023
14
T25N-01-02-003
12-
Overheat Switch㩷
Coolant Temperature Sensor㩷 3 - Air Heater㩷 4 - TCV ADV Solenoid Valve㩷
5 - TCV RTD Solenoid Valve㩷 6 - Engine Stop Solenoid Valve 7 - TDC Sensor㩷 8 - Engine Rotation Detection Sensor㩷
9 - Engine Oil Filter Restriction Switch㩷 10 - Engine Oil Pressure Switch
12 - Alternator㩷
11 - Starter㩷 㩷
14 - Rack Sensor㩷 㩷
13 - Timing Sensor㩷
Link-Belt Engine parts contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.Link-Belt-Crane-Engine-Parts.com www.HeavyEquipmentRestorationParts.com
TROUBLESHOOTONG / Component Layout Around Battery
1 2 8
7
3
6
4
10
9
5
㩷
Machine Right㩷
㩷 T25N-01-02-005
T2BC-01-02-020
Machine Rear
Machine Front㩷
Machine Upper㩷
Machine Left㩷
Machine Rear
Machine Front Machine Lower㩷
1-
Engine Stop Relay㩷
4 - Battery Relay㩷
7 - Load Dump Relay㩷
23-
Alternator Relay㩷 Fusible Link㩷
5 - Heater Relay㩷 6 - Starter Relay 2㩷
8 - Flasher㩷 㩷
T5-2-13
9-
Receiver Drier Condenser Fan Control Pressure Switch㩷 10 - Coolant Level Switch㩷 㩷
TROUBLESHOOTONG / Component Layout Pump Mechanism Fourth Drum Brake Cooling / Hydraulic Tagline Drive / Reeving Winch Drive Pump (Optional)㩷 Pump for Counterweight/Quick Draw/Jack-Up/Retract㩷 Pilot Pump㩷
Slewing Pump㩷
1
2
Machine Front㩷
䌔2䌂䌃-01-02-028
3 Machine Rear 1-
Power Increase Solenoid Valve 㩷
2-
Displacement Angle Proportional Solenoid Valve (Main Pump)㩷
T5-2-14
3-
Displacement Angle Proportional Solenoid Valve (Slewing Pump)㩷
TROUBLESHOOTONG / Component Layout Front / Rear Control Valve Upper Side of Control Valve 1
2*1
3
4*1
5
6
8
7
Machine Left Machine Rear㩷 Machine Front㩷
Machine Right
Rear Control Valve T2BC-01-02-018
Front Control Valve㩷
Bottom Side of Control Valve Front Control Valve㩷
Rear Control Valve㩷
Machine Right Machine Rear㩷
Machine Left
Machine Front㩷
T2BC-01-02-019
1
9* 1-
Front Drum Hoisting Proportional Solenoid Valve㩷 2 - Third Drum Hoisting Solenoid Valve *1㩷 3-
Front Drum Lowering Proportional Solenoid Valve㩷 4 - Third Drum Lowering Solenoid Valve *1㩷
10
11
1
12*
13
5 - Rear Drum Hoisting Proportional Solenoid Valve 6 - Boom Derricking Drum Hoisting Proportional Solenoid Valve㩷 7 - Rear Drum Lowering Proportional Solenoid Valve 8 - Boom Derricking Drum Lowering Proportional Solenoid Valve㩷
14
15
9 - Third Drum Hoisting Remote Control Pressure Sensor*1㩷 10 - Front Drum Hoisting Remote Control Pressure Sensor㩷 11 - Front Drum Lowering Remote Control Pressure Sensor㩷 12 - Third Drum Lowering Remote Control Pressure 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
16 13 - Boom Derricking Hoisting Remote Control Pressure Sensor㩷 14 - Rear Hoisting Remote Control Pressure Sensor㩷 15 - Boom Derricking Lowering Remote Control Pressure Sensor㩷 16 - Rear Lowering Remote Control Pressure Sensor㩷
TROUBLESHOOTONG / Component Layout 4-Spool Control Valve
1 Machine Front㩷 Machine Left㩷
2*1
3
4
Machine Right㩷
Machine Rear㩷
T2BC-01-02-021
8 1-
Quick Draw Solenoid Valve (Extend)㩷 2 - Retract Solenoid Valve 1 (Extend)* 㩷 3 - Counterweight Solenoid Valve (Left/Extend)㩷 4 - Counterweight Solenoid Valve (Right/Extend)㩷
7
6
5
5-
Counterweight Solenoid Valve (Right/Retract)㩷 6 - Counterweight Solenoid Valve (Left/Retract)㩷 7 - Retract Solenoid Valve (Retract)㩷 8 - Quick Draw Solenoid Valve (Retract)㩷
*1: If the jack (optional) is installed, the lower power solenoid valve is installed here.
T5-2-16
TROUBLESHOOTONG / Component Layout 2
Detailed Position C 㩷
Around Drum
3 1
Detailed Position B 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 to the derricking drum.)
Machine Rear㩷
5
4
7
6
A
T2BC-01-02-025
8
Machine Front㩷
A
A
C
C
C
Fourth Drum (Optional)㩷
Boom Derricking Drum
Front Drum㩷
Rear Drum㩷
B
B
B
T2BC-01-02-024
9 1-
11
10
Motor Cutoff High Pressure 4 - Derricking Drum Rotation Solenoid Valve (Only Detection Switch㩷 Front/Rear Drums)㩷 2 - Brake Release Solenoid 5 - Rear Drum Rotation Valve㩷 Detection Switch (A)㩷 3 - Motor Displacement Angle 6 - Rear Drum Rotation Proportional Solenoid Valve㩷 Detection Switch (B)㩷
7-
Front Rotation Detection Switch (A)㩷
8-
Front Drum Rotation Detection Switch (B)㩷 9 - Fourth Drum (Optional) Lock Motor㩷
T5-2-17
10 - Rear Drum Lock Motor㩷
11 - Front Drum Lock Motor㩷 㩷
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 Right㩷
Machine Front㩷 T25N-03-08-001
1-
Derricking Drum Unlocking Solenoid Valve㩷 2 - Slewing Brake Solenoid Valve:㩷
3 - High / Low Speed Selection Solenoid Valve 4 - Second Overhoist Solenoid Valve㩷
Accumulator
Slewing Remote Control Pressure Sensor Block
Accumulator㩷
2
3
M25N-07-030
1
Slewing Remote Control Pressure Sensor Block㩷 T25N-01-02-019
1-
Primary Pilot Pressure Sensor㩷
2-
Right Slewing Remote Control Pressure Sensor㩷
T5-2-18
3-
Left Slewing Remote Control Pressure Sensor㩷
TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURES Use troubleshooting A when error is indicated as a result that IDU diagnoses MC2/A and MC2/B.
x How to read troubleshooting flowchart
YES(OK)
(2)
Perform inspection or measurement in box (1), and select YES (OK) or NO (NOT OK) according to (1), and go to the next box (2) or (3).
(1)
NO(NOT OK)
(3)
· Key switch: ON
Under the box is inspection or measuring method or references. Be careful that if inspection or measuring method is incorrect, finding the cause of failure becomes difficult or the equipment may be damaged.
The bold line box shows a cause of failure. The bold line tells a location where possible cause of failure is present.
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown. Harness Harness end connector
Mounting Surface
T6L4-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A Power Supply Monitor
Description
MC2/A Input / Output Monitor MC2/A
MC2/B
IDU
MAIN_B
NORMAL
MAIN_B
NORMAL
MAIN_B
5V
LOW ER
5V
1/1 xx. xxV
LOW ER
5V
24V_1
HI ER
24V_1
HI ER
10V
xx. xxV
24V_2
SHORT
24V_2
SHORT
24V
xx. xxV
24V_3
SHORT
24V_3
SHORT
x. xxV
χχ ω Page Selection Return Item
Item MC2/A MAIN_B 5V 24V_1 24V_2
Signal name Main power supply Analog sensor power supply For each switch input For throttle control switch For emergency operation 24V_3 switch MC2/B MAIN_B Main power supply 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)
Description NORMAL LOW ER HI ER SHORT xx. xxV
T5-3-2
Explanation Normal Lower limit error Upper limit error Short circuit A/D voltage conversion Communication error
TROUBLESHOOTING / Troubleshooting A MC2/A Analog Inputs
Description
MC2/A Input / Output Monitor
MC2/A AI1
MC2/A AI3
MC2/A AI2
1/4
THROT. GRIP NORMAL
DD HST PRS
x. xMPa
SL RGT PRS
THROT. FOOT NORMAL
DD LWR PRS
LOW ER
SL LFT PRS
LOW ER
RACK. P. S
FD HST PRS
HI ER
PILOT PRS
NORMAL
THROL. M. P. NORMAL
FD LWR PRS
RSV ER
FD BRK PRS
LOW ER
SL CTRL SP
2.50 V
RD HST PRS
x. xMPa
RD BRK PRS
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
RSV ER
3D LWR PRS
RSV ER
(AN_IN22)
NORMAL
TRLFT. PRS
HI ER
Item
Item THROT. GRIP THROT. FOOT RACK. P. S. THROL. M. P. SL CTRL SP THRT. 3RD TRRGT. PRS TRLFT. PRS DD HST PRS DD LWR PRS FD HST PRS FD LWR PRS RD HST PRS RD LWR PRS 3D HST PRS 3D LWR PRS MC2/A AI3
LOW ER
MC2/A AI2
(AN_IN23)
χ ω Page Selection Return
MC2/A AI1
x. xMPa
SL RGT PRS SL LFT PRS PILOT PRS FD BRK PRS RD BRK PRS 3D BRK PRS (AN_IN22) (AN_IN23)
Signal name Accelerator grip signal Accelerator pedal signal Rack position signal Governor motor potentio sensor signal Slew speed dial signal (no connection) Third Accelerator Travel (right) remote control pressure Travel (left) remote control pressure Derricking drum hoisting remote control pressure Derricking drum lowering remote control pressure Front drum hoisting remote control pressure Front drum lowering remote control pressure Rear drum hoisting remote control pressure Rear drum lowering remote control pressure Third / fourth drum hoisting remote control pressure Third / fourth drum lowering remote control pressure Slew (right) remote control pressure Slew (left) remote control pressure Primary pilot circuit pressure Front brake depressing pressure Rear brake depressing pressure Fourth brake depressing pressure No connection No connection
T5-3-3
Description NORMAL LOW ER HI ER RSV ER
Explanation Normal Lower limit error Upper limit error Performance errors
x. xV LOW ER HI ER RSV ER
Normal (voltage) Lower limit error Upper limit error Spare
x. xMPa LOW ER HI ER DBL ER
Operating pressure Lower limit error Upper limit error Double errors
******
Communication error
NORMAL
Normal operation: OFF
LOW ER
Lower limit error
HI ER
Upper limit error
RSV ER
Normal operation: ON
TROUBLESHOOTING / Troubleshooting A MC2/A Digital Inputs
Description
MC2/A Input / Output Monitor
MC2/A CAN2
MC2/A SWITCH
MC2/A CAN1
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
ENG. START OFF
RACK P. S.
x. xx V
THROT. FIX
RACK P. STP
ON
DD PLS
2/4
STOP
BRK MD SW
OFF
x. xx V
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 FD FREE SW RD FREE SW 3D FREE SW
Signal name MC2/A Front brake mode selection switch SWITCH Rear brake mode selection switch Third / fourth brake mode selection switch ENG. START Engine start signal THROT. FIX Throttle lock switch THROT. PRE Throttle preset switch GATE LOCK Gate lock switch SL BRK SW Slewing brake switch MC2/A CAN1 FD FREE MD Front brake mode selection control RD FREE MD Rear brake mode selection control 3D FREE MD Third / fourth brake mode selection control RACK P. S. Rack position signal RACK P. STP Engine stop rack position RACK P. FUL Full rack position 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
Description ON OFF BRAKE FREE x. xx V -xxxmA -xxxxx ROTATE STOP CANCEL NORMAL SHORT CRANE TOWER OPEN ******
Explanation Closed contact Open contact Auto brake mode Free mode A/D voltage conversion Electric current offset Drum pulse counter Rotation Stop Cancellation Normal Short circuit Crane Tower Open circuit Communication error
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
INC. TQ CUR
LOW ER
RD PLS SOL
ERROR
HI ER
DD PLS SOL
ERROR
FM BRK REL
SL RGT CUR
NORMAL
SL LFT CUR
RES ER
SL PRS SOL
ERROR
RM BRK REL 3M BRK REL
ERROR
SL PMP CUR
CANCEL
CAL IB. CUR
NORMAL
MT CUT OFF
NORMAL
ENG. INTLCK
ERROR
3D BRK LP
NORMAL
SL ALAM LP
ERROR
FD BRK REL
XxxxmA
RD BRK REL
LOW ER
3D BRK REL
HI ER
χ ω Page Selection Return
NORMAL
NORMAL
Item
Item Signal name MC2/A M PMP CUR Main pump displacement angle D01 proportional solenoid valve INC. TQ CUR Power increase solenoid valve SL RGT CUR Slewing multi (right) proportional solenoid valve (no connection) SL LFT CUR Slewing multi (left) proportional solenoid valve (no connection) SL PMP CUR Slewing pump displacement angle proportional solenoid valve (no connection) FD BRK REL Front drum brake release solenoid valve RD BRK REL Rear drum brake release solenoid valve 3D BRK REL Fourth drum brake release solenoid valve MC2/A FD PLS SOL Front drum rotation sensing solenoid D02 RD PLS SOL Rear drum rotation sensing solenoid DD PLS SOL Derricking drum rotation sensing solenoid SL PKS SOL Slewing remote control pressure hydraulic source solenoid (no connection) CAL IB. CUR Calibration electric current MC2/A DD LCK REL Derricking drum unlocking solenoid valve D03 FM BRK REL Front motor brake release solenoid valve RM BRK REL Rear motor brake release solenoid valve 3M BRK REL Fourht motor brake release solenoid valve MT CUT OFF Motor cutoff relay ENG. INTLCK Engine start interlock 3D BRK LP Third/fourth auto brake indicator SL ALAM LP Slewing alarm lamp relay
T5-3-5
Description xxxxmA LOW ER HI ER RES ER CANCEL
Explanation Control current Lower limit error Upper limit error Reset error Feedback cancellation
NORMAL LOW ER HI ER RES ER RSV
Normal Lower limit error Upper limit error Reset error Feedback cancellation
NORMAL LOW ER HI ER RES ER RSV
Calibration current Lower limit error Upper limit error Reset error Spare
NORMAL ERROR ******
Normal Short circuit Communication error
TROUBLESHOOTING / Troubleshooting A ECU Status
Description
MC2/A Input/Output Monitor
MC2/A_ECU1
RECEIVE
NORMAL
TMR F. B.
ERROR NORMAL
RACK P. S. TIMING S.
ERROR
TDC S.
INVLD
OVER H. S.
ERROR
TMR. C. V.
NORMAL
Ĺ ĻPage Selection Return
4/4
Item
Item
MC2/A_ECU1 RECEIVE
Signal name
Description
Explanation
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 AI1
FD CTRL SP
NORMAL
TR RGT PRS
RD CTRL SP
LOW ER
DD CTRL SP
HI ER
(AN_IN3)
MC2/B DI
MC2/B AI2
x. xMPa
FD ROPE ED
R. END
TR LET PRS
x. xMPa NORMAL
RD ROPE ED
ALLOFF
(AN_IN10)
RSV
(AN_IN11)
LOW ER
(DAN_IN20)
NORMAL
3D ROPE ED
ALLON
(AN_IN4)
NORMAL
(AN_IN12)
HI ER
(DAN_IN21)
ERROR
(AN_IN5)
LOW ER
(AN_IN13)
RSY
(DAN_IN22)
NORMAL
(AN_IN6)
HI ER
(DAN_IN23)
ERROR
(AN_IN7)
RSV
1/3
χ ω Page Selection Return
Item
Item MC2/B AI1
MC2/B DI
Description
Explanation
Front drum speed set dial signal (no connection)
NORMAL
Normal
LOW ER
Lower limit error
RD CTRL SP
Rear drum speed set dial signal (no connection)
HI
Derricking drum speed set dial signal (no connection)
x. xMPa
Normal (pressure)
DBL ER
Double errors
DD CTRL SP
MC2/B AI2
Signal name
FD CTRL SP
(AN_IN3)
No connection
(AN_IN4)
No connection
(AN_IN5)
No connection
(AN_IN6)
No connection
(AN_IN7)
No connection
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
FD ROPE ED
Front drum three-winding layer detection (no connection)
RD ROPE ED
Rear drum three-winding layer detection (no connection)
3D ROPE ED
Third drum three-winding layer detection (no connection)
(DAN_IN20)
No connection
(DAN_IN21)
No connection
(DAN_IN22)
No connection
(DAN_IN23)
No connection
T5-3-7
ER
RSV
Upper limit error Spare
R. END
Extra hoisting
ALLOFF
Open circuit
ALLON
Shorted harnesses
******
Communication error
TROUBLESHOOTING / Troubleshooting A MC2/B Digital Inputs
Description
MC2/B Input/Output Monitor
MC2/B SWITCH1
DD REL SW
MC2/B SWITCH2
DD HST STP
BT OVERH2
OVERH
DD LWR STP
STOP
TW OVERH
ALLOFF
FD HST STP
NORMAL
BT LOWER L
ALLON
BM OVERH
FD REL SW
REL
RD REL SW
NORMAL
3D REL SW
REL
OH2 REL SW
JB FOLD
ATTACHMENT
JB OVERH2
OVERH
RD LWR STP
STOP
HK OVERH
ALLOFF
3D HST STP
NORMAL
SWL OVERH
ALLON
3D LWR STP
STOP
REL FOLD
Item
MC2/B DI
STOP NORMAL
χ ω Page Selection Return
MC2/B SWITCH2
FD LWR STP
RD HST STP
JB OVERH
MC2/B SWICH1
NORMAL
NORMAL
NORMAL
CRANE
2/3
NORMAL
NORMAL
REL KEY SW
MC2/B DI
Item DD REL SW FD REL SW RD REL SW 3D REL SW HM FIX SW OH2 REL SW JB FOLD ATTACHMENT BM OVERH BT OVERH2 TW OVERH BT LOWER L JB OVERH JB OVERH2 HK OVERH SWL OVERH DD HST STP DD LWR STP FD HST STP FD LWR STP RD HST STP RD LWR STP 3D HST STP 3D LWR STP
Signal name Derricking drum auto stop release Front drum auto stop release Rear drum auto stop release Third drum auto stop release Hoisting motor low speed lock Second overhoist restoration switch Jib folding Wiring detection Boom overhoist Boom/tower second overhoist Tower overhoist Boom/tower lower limit (no connection) Jib overhoist Jib second overhoist Hook overhoist Tpwer jib backstop alignment Derricking drum hoisting stop Derricking drum lowering stop Front drum hoisting stop Front drum lowering stop Rear drum hoisting stop Rear drum lowering stop Fourth drum hoisting stop solenoid valve Fourth drum lowering stop solenoid valve
T5-3-8
Description NORMAL REL INHBIT
Explanation Auto stop Release operation Release inhibition
ON OFF
Closed contact Open contact
NORMAL REL
Auto stop Release operation
FOLD UNFOLD ALLOFF ALLON
Jib folding Jib unfolding Open circuit Shorted harnesses
SHORT CRANE TOWER OPEN
Short circuit Crane Tower Open circuit
NORMAL OVERH ALLOFF ALLON LOWER
Normal Overhoist Open circuit Shorted harnesses Lower limit
NORMAL STOP
Operation Stop
******
Communication error
TROUBLESHOOTING / Troubleshooting A MC2/B Digital Outputs
Description
MC2/B Input/Output Monitor
MC2/B D01
DD HST CUR
xxxxmA
GREEM LMP
DD LWR CUR
LOW ER
FD HST CUR
HI ER
FD LWR CUR
MC2/B D02
NORMAL
YELLOW LMP
ERROR
RED LMP
NORMAL
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
3/3
Item
Item MC2/B D01
MC2/B D02
Signal name
DD HST CUR
Derricking drum hoisting proportional solenoid valve
DD LWR CUR
Derricking drum lowering proportional solenoid valve
FD HST CUR
Front drum hoisting proportional solenoid valve
FD LWR CUR
Front drum lowering proportional solenoid valve
RD HST CUR
Rear drum hoisting proportional solenoid valve
RD LWR CUR
Rear drum lowering proportional solenoid valve
FM CAP CUR
Front motor displacement angle control proportional solenoid valve
RM CAP CUR
Rear motor displacement angle control proportional solenoid valve
GREEM LMP
External indicator green (no connection)
YELLOW LMP
External indicator yellow (no connection)
RED LMP
External indicator red (no connection)
OVERH2 SOL
Second overhoist solenoid valve
3D HST SOL
Fourth drum hoisting solenoid valve
3D LWR SOL
Fourth drum lowering solenoid valve
CALIB. CUR
Calibration current
T5-3-9
Description xxxxmA LOW ER HI ER RES ER CANCEL NORMAL ERROR
Explanation Control current Lower limit error Upper limit error Reset error Feedback cancellation Normal Short circuit
NORMAL LOW ER HI ER RES ER RSV
Calibration current Lower limit error Upper limit error Reset error Spare
******
Communication error
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 Description
Explanation
Countermeasure
MAIN_B
Item
Battery
Signal name
LOW ER
Lower limit error
Harness check
5V
Sensor 5V
HI
Upper limit error
Harness check
24V_2
Sensor 24V_2
*****
CAN communication failure
Harness check
24V_3
Sensor 24V_3
NORMAL
Normal
㧙
ER
T5-3-10
TROUBLESHOOTING / Troubleshooting A Battery
Battery Relay
Key Switch
MC2/A P1
P17
SOL_VB
E13
PWM_VB
D5 D16 D2 D3 D4
P17
KEY_SW
E12
D12
MC2/B P1
MAIN_B
MAIN_B
KEY_SW
E12
SOL_VB
E13
PWM_VB
D12
MAIN_G
D5
SENSOR_5V
D16
SENSOR_5V
D2
SENSOR_24V_1
D3
SENSOR_24V_2
SENSOR_5V IDU
SENSOR_5V SENSOR_24V_1 SENSOR_24V_2
SENSOR_24V_3
SENSOR_24V_3 CAN D20
D20
D9
D9
D15
D14
T25N-05-03-001
T5-3-11
TROUBLESHOOTING / Troubleshooting A Check of Battery System
x Check the wiring connections first. MC2/A side
YES
NO
Disconnect connector MCA-1 from MC2/A. Check if voltage between terminal D1 of harness end connector machine is 24 V. and
Disconnect harness from terminal plus (+) of battery. Check for continuity between terminal D1 of harness end connector of connector MCA-1 and machine.
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminals minus (-) and machine.
YES Faulty battery.
NO
Harness open circuit between battery and ground, or faulty ground. Faulty harness between MC2/A and battery, or open circuit at fuse #7.
NO
Faulty MC2/A. YES
MC2/B side YES
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminal X1 of harness end connector of connector MCB-1 and machine.
NO
Disconnect connector MCB-1 from MC2/B. Check if voltage between terminal X1 of harness end connector and machine is 24 V.
Disconnect harness from terminal minus (-) of battery. Check for continuity between terminal minus (-) and machine.
YES
NO
Faulty battery.
Harness open circuit between battery and ground, or faulty ground. Faulty harness between MC2/B and battery, open circuit at fuse #6.
NO
Faulty MC2/B. YES
Connector MC2/B Connector MCA-1 (harness end)
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-001
T2BC-05-03-002
T5-3-12
TROUBLESHOOTING / Troubleshooting A Check of Key Switch
x Check the wiring connections first. MC2/A side YES
Disconnect connec tor MCA-1 from MC2/A. Check if voltage between terminal of harness end D17 connector and ma is 24 V. chine ¡ Key switch: ON
Faulty MC2/A.
Connect terminal ACC in key switch to machine. Check for continuity between terminal D17 of harness end connector of connector MCA-1 and machine.
NO
YES
YES
Faulty key switch.
NO
Harness open circuit between key switch and battery.
Check if voltage between terminal B in key switch and machine is 24 V.
Harness open circuit between MC2/A and key switch, or open circuit at fuse #18.
NO
MC2/B side YES
Disconnect connector MCB-1from MC2/A. Check if voltage between terminal X17 of harness end connector and machine is 24 V. ¡ Key switch: ON
NO
Faulty MC2/B.
Connect terminal ACC in key switch to machine. Check for continuity between terminal X17 of harness end connector of connector MCB-1 and machine.
YES
YES
Faulty key switch.
NO
Harness open circuit between key switch and battery.
Check if voltage between terminal B in key switch and machine is 24 V.
Harness open circuit between MC2/B and key switch, or open circuit at fuse #18.
NO
Connector MC2/A Connector MCA-1 (harness end)
MC2/B Connector MCB-1 (harness end)
Monitor panel CN06F-W (harness end)
T2BC-05-03-001
T2BC-05-03-002
Terminal C Terminal B
T5-3-13
T2BC-05-04-002
Terminal ACC
TROUBLESHOOTING / Troubleshooting A Check of Solenoid and PWM Power Supply
x Check the wiring connections first.
YES
Faulty MC2/A.
MC2/A side
Disconnect connector MCA-6 from MC2/A. Check if voltage between terminal E12 or E13 of harness end connector and machine is 24 V. ¡ Key switch: ON Disconnect harness AV8 of battery relay connect to machine. NO Check for continuity between terminal E12 or E13 of harness end connector and machine.
Connect ground terminal of battery relay to machine. YES Check if voltage between terminal E12 or E13 and machine is 24 V. ¡ Key switch: ON
NO
(A)
YES
(A)
Harness open circuit between key switch NO and battery relay.
Harness open circuit between battery relay and ground, or faulty ground.
In case of no continuity at terminal E12, harness open circuit between terminal E12 of connector MCA-6 of MC2/A and battery relay, or open circuit at fuse #28. In case of no continuity at terminal E13, harness open circuit between terminal E13 of connector MCA-6 of MC2/A and battery relay, or open circuit at fuse #30.
NO
Disconnect harness from terminal plus (+) of battery. Check for continuity between terminal of harness 60B of battery relay and machine.
Disconnect harness 208 of battery relay and connect to machine. YES Check for continuity between terminal ACC in key switch and machine.
YES
Faulty battery relay.
NO
Harness open circuit between battery relay and battery
Connector MC2/A Connector MCA-6
T2BC-05-03-004
T5-3-14
TROUBLESHOOTING / Troubleshooting A
MC2/B Side YES
Faulty MC2/B.
Disconnect connector MCB-6 from MC2/B. Check if voltage between terminal Y12 or Y13 of harness end connector and machine is 24 V. ¡ Key switch: ON Disconnect harness AV8 of battery relay. Check for continuity beNO tween terminal YE12 or Y13 of harness end connector and machine.
Connect ground terminal of battery relay to machine. YES Check if voltage between terminal Y12 or Y13 and machine is 24 V. ¡ Key switch: ON
NO
Harness open circuit between battery relay and ground, faulty ground. In case of no continuity at terminal Y12, harness open circuit between terminal Y12 of connector MCB-6 of MC2/B and battery relay, or open circuit at fuse #27. In case of no continuity at terminal Y13, harness open circuit between terminal Y13 of connector MCB-6 of MC2/B and battery relay, or open circuit at fuse #30.
NO
(A)
YES Disconnect har(A) ness 208 of battery relay and connect YES to machine. Check for continuity between terminal ACC of key Harness open circuit switch and mabetween key switch chine. NO and battery relay.
Disconnect harness from terminal YES plus (+) of battery. Check for continuity between terminal of harness 60B of battery relay and machine. NO
Faulty battery relay
Harness open circuit between battery relay and battery
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㊡
Disconnect sensor from connector. Check if voltage between terminal R of harness end connector and machine is 5 V.
NO
Faulty MC2/A.
¡ Key switch: ON
Faulty sensor.
Harness D16
Harness D5 Sensor
Harness end connector
Accelerator grip
B W R Slew lever T25N-05-03-023
Accelerator pedal R
W B
T25N-05-03-024
Throttle position
motor B
W
R T25N-05-03-025
Sensor Derricking drum hoisting remote control pressure Derricking drum lowering remote control pressure Front drum hoisting remote control pressure Front drum lowering remote control pressure Rear drum hoisting remote control pressure Rear drum lowering remote control pressure Third / fourth drum hoisting remote control pressure Third / fourth drum lowering remote control pressure Slewing (right) remote control pressure Slewing (left) remote control pressure Primary pilot circuit pressure
Harness end connector R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R
W
B
R B W T25N-05-03-002
Front brake depressing pressure
R B W T25N-05-03-002
Rear brake depressing pressure
R B W T25N-05-03-002
Third brake depressing pressure
R B W T25N-05-03-002
T5-3-16
TROUBLESHOOTING / Troubleshooting A Check of 5V Sensor of MC2/B
YES㊡
Disconnect sensor from connector. Check if voltage between terminal R of harness end connector and machine is 5 V.
Faulty sensor.
Faulty MC2/B. NO
¡ Key switch: ON
Harness X16 Sensor Travel (right) remote control pressure Travel (left) remote control pressure
Harness end connector R
W
B
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 of brake mode selection switch. Check if voltage between machine and terminal #4 of harness end connector is 24 V. · Key switch: ON
YES㩷
Faulty brake mode selection switch.
Faulty MC2/A. NO
Harness D2 Sensor Front drum brake mode selection switch Rear drum brake mode selection switch
Harness end connector
T2BC-05-03-005
Third drum brake mode selection switch
Disconnect connector of brake mode selection switch. Check if voltage between machine and terminal #4 of harness end connector is 24 V.
YES㩷
Faulty brake mode selection switch.
Faulty MC2/A. NO
· Key switch: ON
Harness D2 Sensor Third / fourth drum brake mode selection switch
Harness end connector
T2BC-05-03-005
T5-3-18
TROUBLESHOOTING / Troubleshooting A Front, rear and fourth drum brake pedal
Disconnect connector of limit switch. Check if voltage between machine and terminal #1 of harness end connector is 24 V.
YES㊡
Faulty brake mode selection switch.
Faulty MC2/A. NO
¡ Key switch: ON
Harness D2 Sensor Fron, rear and fourth drum pedal limit switch
Harness end connector
T2BC-05-04-008
T5-3-19
TROUBLESHOOTING / Troubleshooting A Check of 24 V_2 Sensor on MC2/A
Disconnect connector 62C-12FW of right control panel. Check if voltage between machine and terminal #2 of harness end connector is 24 V.
YES㩷
Faulty accelerator control switch.
Faulty MC2/A. NO
· Key switch: ON
Harness D3 Sensor Accelerator control switch
Harness end connector
T2BC-05-03-006
Right control panel 62C-12F-W
Check of 24 V_3 Sensor on MC2/A
Disconnect connector of emergency operation switch. Check if voltage between machine and terminal #4 of harness end connector is 24 V.
YES㩷
Faulty emergency operation switch.
Faulty MC2/A. NO
· Key switch: ON
Harness D4 Sensor Emergency operation switch
Harness end connector
T2BC-05-03-007
T5-3-20
TROUBLESHOOTING / Troubleshooting A Check of 24 V_2 Sensor on MC2/B
Disconnect connector of limit switch. Check if voltage between machine and terminal #c of harness end connector is 24 V.
· Key switch: ON
YES㩷
Faulty limit switch.
Faulty MC2/B. NO
Harness X3 Sensor Boom overhoist switch
Harness end connector a
b
c
T25N-05-03-005
Tower overhoist switch
b
c a
Boom / tower second overhoist switch
T25N-05-03-003
c
b
a
T25N-05-03-029
T5-3-21
TROUBLESHOOTING / Troubleshooting A Check of Sensor 24 V_3 on MC2/B Jib overhoist, jib second overhoist, tower jib backstop alignment switches
Disconnect limit switch from connector. Check if voltage between machine and terminal #1 of harness end connector is 24 V. · Key switch: ON
YES㩷
Faulty limit switch.
Faulty MC2/B. NO
Harness X4 Sensor Harness end connector Jib overhoist switch
Jib second overhoist switch
T2BC-05-03-009
T2BC-05-03-008
Tower jib backstop alignment switch
T2BC-05-03-009
Hook overhoist switch
Disconnect limit switch from connector. Check if voltage between machine and terminal #1 of harness end connector is 24 V.
YES㩷
Faulty limit switch.
Faulty MC2/B. NO
· Key switch: ON
Harness X4 Sensor Hook overhoist switch
Harness end connector
T2BC-05-03-010
T5-3-22
TROUBLESHOOTING / Troubleshooting A Check of CAN between MC2/A and IDU
x Check the wiring connections first. x Check for continuity between terminal D9 of harness end connector of connector MCA-1 of MC2/A and terminal J14 of harness end connector of connector IDU-4 of IDU.
x Check for continuity between terminal D20 of harness end connector of connector MCA-1 of MC2/A and terminal J15 of harness end connector of connector IDU-4 of IDU. Connector MC2/A Connector MCA-1 (harness end)
T2BC-05-03-001
IDU Connector IDU-4 (harness end)
T2BC-05-03-011
T5-3-23
TROUBLESHOOTING / Troubleshooting A Check of CAN between MC2/B and IDU
x Check the wiring connections first. x Check for continuity between terminal X9 of harness end connector of connector MCB-1 of MC2/B and terminal J14 of harness end connector of connector IDU-4 of IDU.
x Check for continuity between terminal X20 of harness end connector of connector MCB-1 of MC2/B and terminal J15 of harness end connector of connector IDU-4 of IDU. Connector MC2/B Connector MCB-1 (harness end)
T2BC-05-03-012
IDU Connector IDU-4 (harness end)
T2BC-05-03-011
T5-3-24
TROUBLESHOOTING / Troubleshooting A FAILURE OF ENGINE CONTROL SYSTEM Abnormality
x By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supply". By using the MC2/A input/output monitor, check the sensor signal. Item THROT. GRIP THROT. FOOT THROT. M. P
Signal name Accelerator grip Accelerator pedal Governor motor Potentio
Description LOW ER HI ER LOW ER HI ER RSV ER
Explanation Lower limit error Upper limit error Lower limit error Upper limit error Operation error
State Controls as low idle input. Governor motor control stop
Countermeasure Harness check Sensor check Harness check Sensor check
0/3.3 to 8.5V Pulses 24V
Governor motor
1.0 to 2.4 V 5V Accelerator grip 0.7 to 4.3 V Accelerator pedal 2.4䌾4.6V Governor motor potentio
24 V 24 V (ON) Accelerator Control Switch 0 V (OFF) Accelerator Lock Accelerator Preset
0 to 6 V AC, 0 to 5.3 䌫Hz Engine Speed Detection
T2BC-05-03-058
T5-3-25
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 Reconnect the disaccelerator grip sensor end connector. connected connecx If input voltage from the accelerator grip sensor is 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 MC2/A and machine. ground line. Turn key switch Turn key switch ON. Faulty accelerator x Check the wiring connections first. OFF. Check if voltage grip sensor. 01㩷 Connect terminal W reaches specification of harness end when moving accel connector of accelerator grip. ;'5 erator to machine by ·Insert a test bar into using a clip. the rear of connector. Disconnect connec·Specification: 1.0 to tor MCA-3 of MC2/A. 24 V Check for continuity between terminal B5 of connector MCA-3 and machine. Turn key switch ON. Check if voltage beFaulty harness up tween terminals R to terminal W of ;'5㩷 and B of harness end accelerator grip connector of accelsensor. 01 erator grip sensor is 5r0.5 V. Turn key switch ;'5㩷 Faulty MC2/A. OFF. Check for continuity Turn key switch ;'5 between terminal B OFF. Turn key switch ON. of harness end Faulty harness up Disconnect connecCheck if voltage connector of accelto terminal B of tor of accelerator between machine erator grip sensor sensor. grip 01㩷 accelerator grip and terminal R of and machine. sensor. Check for continuity 01 harness end conbetween terminals R nector of accelerator Faulty harness up B of accelerator and grip sensor is 5r0.5 to terminal R of grip sensor. V. accelerator grip 01 sensor. Faulty accelerator grip sensor. 01㩷 Connector Accelerator grip sensor (accelerator grip sensor end)
MC2/A Connector MCA-3 (harness end)
T2BC-05-03-013
T2BC-05-03-014
Accelerator grip sensor (harness end)
T2BC-05-03-015
MC2/A Connector MCA-1 (harness end)
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 0.7 V or less, the cause of trouble may be harness open circuit between accelerator pedal sensor and MC2/A, or short circuit between sensor_ 5 V line and ground line. x Check the wiring connections first.
Reconnect the disconnected connector. Measures voltage ;'5㩷 Faulty MC2/A. between terminal B13 of connector of ;'5 MC2/A and machine. Turn key switch ON. Faulty accelerator Check if voltage pedal. Turn key switch OFF. 01㩷 reaches specification W Connect terminal when moving accelof harness end conerator pedal. nector of accelerator ·Insert a test bar into pedal sensor to mathe rear of connector. ;'5 chine by using a clip. ·Specification: 0.7 to Disconnect connector 4.3 V MCA-3 of MC2/A. Check for continuity B13 between terminal of connector MCA-3 and machine.
Turn key switch ON. Check if voltage be;'5㩷 tween terminals R and B of harness end connector of accelerator pedal sensor is 5r0.5 V.
Turn key switch PFF. Disconnect con nector of accelerator pedal sensor. Check for continuity between terminals R and B of accelerator pedal sensor.
Turn key switch OFF. Check for continuity ;'5 between terminal B of harness end Turn key switch ON. connector of accelCheck if voltage be erator pedal sensor tween machine and and machine. terminal R of harness 01 end connector of ac celerator pedal sensor is 5r0.5 V.
01
Connector
01
01㩷
Faulty harness up to W terminal of accelerator pedal sensor. ;'5㩷 Faulty MC2/A.
Faulty harness up to terminal B of accelerator pedal 01㩷 sensor. Faulty harness up to terminal R of accelerator pedal sensor. Faulty accelerator pedal sensor.
MC2/A
Accelerator pedal sensor (accelerator pedal sensor end)
Connector MCA-3 (harness end)
Accelerator pedal sensor (harness end)
T2BC-05-03-017
MC2/A Connector MCA-1 (harness end)
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 between governor potentio sensor and MC2/A, or short circuit between sensor 5 V_ line and ground line. x Check the wiring connections first.
Turn key switch OFF. Disconnect gover motor potentio nor sensor. Check if resistance between terminals R and B of con nector of governor motor potentio sensor is 2r0.6 :.
Turn key switch ON. Check if voltage beYES tween terminals R and B of harness end connector of governor motor potentio sensor is 5r0.5 V.
Connect a test harness between gov ernor motor potentio YES Faulty MC2/A. sensor and harness Turn key switch OFF. YES end connector of Connect terminal W machine. of harness end conTurn key switch ON. Faulty governor nector of governor Check if voltage motor potentio motor potentio sensor NO reaches specifica 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 harness end conector High idle: 4.6r0.3 V of connector MCA-3 of MC2/A.
Faulty harness up to terminal W of governor motor potentio sensor.
NO
Turn key switch ON. Check if voltage be tween machine and terminal R of harness end connector of NO governor motor po tentio sensor is 5r0.5 V.
Faulty harness up to terminal B of governor motor potentio sensor.
YES
Faulty harness up to terminal R of governor motor potentio sensor.
NO
Faulty governor motor potentio sensor.
NO
Connector Governor motor potentio sensor (governor motor potentio sensor end)
MC2/A Connector MCA-3 (harness end)
Red
T2BC-05-03-013 T2BC-05-03-019
Governor motor potentio sensor (harness end)
MC2/A Connector MCA-1 (harness end)
Black
Test Harness
V
T2BC-05-03-018
T107-07-03-009
T2BC-05-03-001
..
T5-3-28
TROUBLESHOOTING / Troubleshooting A Check of Accelerator Control Switches
x Check the wiring connections first.
NO
Check if voltage
between machine and terminal D3 of machine end con nector is 24 V㧚
· Key switch: ON
Reconnect the disconnected connector. Disconnect connector 62C-12FW of right control panel. YES Check if voltage between machine and terminal #2 of harness end connector is 24 V.
Harness open circuit between accelerator control switch and MC2/A.
NO
Disconnect connector MCA-4 of MC2/A. Connect terminal A6 of Accelerator harness end connector to lock switch machine. Check for continuity be tween machine and terminal #3 of harness end connector of connector 62C-12FW.
· Key switch: ON
YES
NO
Faulty accelerator lock switch. Harness open circuit between accelerator lock switch and MC2/A.
YES
Disconnect connector MCA-4 of MC2/A. Connect terminal A19 of harness end connector to machine. Accelerator Check for continuity bepreset switch tween machine and terminal #1 of harness end connector of connector 62C-12FW.
YES
NO
Faulty accelerator preset switch. Harness open circuit between accelerator preset switch and MC2/A.
Connector MC2/A
MC2/A
Faulty MC2/A.
Right control panel Connector 62C-12FW (harness end)
Connector MCA-4 (harness end)
Connector MCA-1 (Machine end)
T2BC-05-03-020
T2BC-05-03-021
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. Connect terminals F4 and F16 of harness end connector of YES connector MCA-5 to machine. Check for continuity between machine and terminals # 1 and #2 of harness end connector of engine rotation detection sensor.
Disconnect connector of engine
rotation detection sensor.
Check if resistance between terminals #1 and #2 of machine end connec tor is 2.3r0.2:.
YES
Faulty MC2/A. In case of no continuity at terminal #1, harness open circuit between terminal #1 of engine rotation detection sensor and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of engine rotation detection sensor and MC2/A.
NO
Faulty engine rotation detection sensor.
NO
Connector
Engine rotation detection sensor (harness end)
MC2/A Connector MCA-5 (harness end)
Engine rotation detection sensor (sensor end)
F4
#1
#2 T25N-05-03-008
#2
#1
F11
F1
F22
F12
T25N-05-03-004
F16
T5-3-30
TROUBLESHOOTING / Troubleshooting A Check of Governor Motor System
x Check the wiring connections first.
Connect terminals #2 to #4 of harness end connector of governor motor by YES using a clip. Check for continuity between termi nals E24 and E25 of harness end connector of Disconnect connector MCA-6. MCA-6 of MC2/A. Connect terminals E11 to E10 of har ness end connector of YES governor motor by using a clip. Check for continuity between terminals E10 and E11 of har ness end connector of Disconnect conMCA-6. nector of governor Connect terminal motor. E11 of harness Check if resisend connector of tances between MCA-6 to machine terminals #1 and # 3, and between by using a clip. Check for continu terminals #2 and NO ity between ma#4 are 5.7r0.57 :. chine and terminal ሩKey switch: OFF #1 of harness end connector of gov ernor motor.
YES
Faulty MC2/A.
Faulty harness up
YES㩷 to terminal E24 of
Connect terminal E25 of harness end connector of MCA-6 to machine by using a clip. Check for continuNO ity between machine and terminal #2 of harness end connector of governor motor.
connector MCA-6 of MC2/A.
Faulty harness up to terminal E25 of connector MCA-6 NO㩷 of MC2/A.
Faulty harness up to terminal E10 of connector MCA-6 of MC2/A.
YES
Faulty harness up to terminal E11 of connector MCA-6 of MC2/A.
NO
Faulty governor motor.
NO
Connector
Governor motor (governor motor end)
MC2/A Connector MCA-6 (harness end)
governor motor Connector (harness end)
E10 E11
2
1
1
2
4
3
3
4
E1
E13
E14
E26
E24
T5-3-31
E25
TROUBLESHOOTING / Troubleshooting A FAILURE OF BRAKE CONTROL SYSTEM
Abnormality
x By using the power supply monitor, check if all of battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supply". By using the MC2/A input/output monitor, confirm the solenoid valve signal. Item DD HST PRS DD LWR PRS FD HST PRS FD LWR PRS RD HST PRS RD LWR PRS 3D HST PRS 3D LWR PRS PILOT PRS
Signal name 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 drum hoisting remote control pressure Third drum lowering remote control pressure Primary pilot pressure
FD BRK PRS RD BRK PRS
Front brake depressing pressure Rear brake depressing pressure
DD LCK REL
Derricking drum unlocking solenoid valve Front motor brake release solenoid valve Rear motor brake release solenoid valve Fourth motor brake release solenoid valve Third/fourth auto brake indicator
FM BRK REL RM BRK REL 3M BRK REL 3D BRK LP
Description Explanation LOW ER Lower limit error HI ER DBL ER
Upper limit error Double errors
State Brake mode: Set to auto brake mode
Countermeasure Harness check Sensor check
Motor brake: Input control with lever in neutral
LOW ER
Lower limit error
Pressure drop
Harness check
HI ER LOW ER
Upper limit error Lower limit error
HI ER
Upper limit error
Input control Brake return Input control
Sensor check Harness check Sensor check
ERROR
Short circuit
̆
Harness check Solenoid valve check
ERROR
Short circuit
̆
Harness check Solenoid valve check
x For check of harness between MC2/A and IDU, refer to "Check of CAN between MC2/A and IDU" in Section "Failures of MC2/A or MC2/B Battery/Sensor System Power Supply". x The monitor does not correspond to breakdown of front, rear and fourth drum brake pedal limit switch. (Breakdown is not displayed on the monitor.)
T5-3-32
TROUBLESHOOTING / Troubleshooting A Free Indicator Front Drum Brake Release Solenoid Valve Rear Drum Brake Release Solenoid Valve
Derricking Drum Hoisting Remote Control Pressure Sensor
Fourth Drum Brake Release Solenoid Valve
Derricking Drum Lowering Remote Control Pressure Sensor Front Drum Hoisting Remote Control Pressure Sensor Front Drum Lowering Remote Control Pressure Sensor
Derricking Drum Unlocking Solenoid Valve
Rear Drum Hoisting Remote Control Pressure Sensor
Front Motor Brake Release Solenoid Valve
Rear Drum Lowering Remote Control Pressure Sensor
Rear Motor Brake Release Solenoid Valve
Third / Fourth Drum Hoisting Remote Control Pressure Sensor Third / Fourth Drum Lowering Remote Control Pressure Sensor
Fourth Motor Brake Release Solenoid Valve
Primary Pilot Pressure Sensor
Third / Fourth Free Indicator
Front Brake Depress Detection Rear Brake Depress Detection
Front Free Indicator Rear Free Indicator
Third Brake Depress Detection
Brake Mode Switch Front Brake Mode Selection Switch
Second Overhoist Stop Solenoid Release
Rear Brake Mode Selection Switch
Third Brake Mode Selection Switch Front Pedal Limit Switch Rear Pedal Limit Switch Third Pedal Limit Switch
T2BC-05-03-022
T5-3-33
TROUBLESHOOTING / Troubleshooting A
Check of Derricking Drum Hoisting Remote Control 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 between 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, the cause of trouble may be harness open circuit between derricking drum hoisting remote control pressure sensor and MC2/A, or short circuit be tween SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal W of har key switch Turn OFF. Disconnect connector of derricking drum hoisting re control presmote sure sensor. Check for continuity between terminals R and B of derricking drum hoisting remote control pressure
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of derricking drum hoisting remote control pressure sensor is 5r0.5 V.
Connector
ness end connector of derricking drum hoisting re ;'5 mote control pressure sensor to machine. Disconnect con- nector MCA-3 of MC2/A. Check for continuity between terminal B1 of connector MCA-3 and machine.
Turn key switch ON. Check if voltage between ma chine and terminal R of harness end connector of der 01 ricking drum hoist ing remote control pressure sensor is 5r0.5 V.
01㩷
Derricking drum hoisting remote control
pressure sensor (harness end)
MC2/A Connector MCA-3 (harness end)
Reconnect the disconnected connector. Check if voltage between ;'5 machine and terminal B1 of connector of MC2/A meets specification.
Faulty harness up to terminal W of derricking drum hoisting remote control pressure sensor
01 Turn key switch OFF. Check for continuity between machine and terminal B of harness ;'5 end connector of derricking drum hoisting remote control pressure sensor.
01
T2BC-05-03-013
T2BC-05-03-023
erricking drum hoisting remote control D pressure sensor (sensor end)
MC2/A
Connector MCA-1
(harness end)
T2BC-05-03-001
T2BC-05-03-024
T5-3-34
Faulty derricking drum hoisting re01㩷 mote control pressure sensor
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
;'5㩷 Faulty MC2/A
;'5㩷 Faulty MC2/A Faulty harness up to terminal B of derricking drum hoisting remote 01㩷 control pressure sensor Faulty harness up to terminal R of derricking drum hoisting remote control pressure sensor Faulty derricking drum hoisting remote control pressure sensor
TROUBLESHOOTING / Troubleshooting A Check of Derricking Drum Lowering Remote Control Pressure Sensor System x If input voltage from derricking drum lowering remote 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 between terminal D15 of MC2/A and terminal B (ground) of derricking drum lowering remote control pressure sensor end connector. x If input voltage from the derricking drum lowering remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between derricking drum lowering remote control pressure sensor and MC2/A, or short circuit be tween SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal Turn key switch OFF. Disconnect connector of derricking drum lowering remote control pressure sensor. Check for continuity between terminals R and B of derricking drum lowering remote control pressure sensor.
Connector
Turn key switch ON. Check if voltage between terminals R and B of harness end ;'5㩷 connector of derricking drum lowering remote control pressure sensor is 5r0.5 V.
W of harness end ;'5 connector of derricking drum low ering remote control pressure sen sor to machine. Disconnect connector MCA-3 of MC2/A. Check for continuity between ma chine and terminal B9 of connector MCA-3.
Turn key switch ON. Check if voltage between machine and terminal R of 01 harness end con nector of derricking drum lowering remote control is pressure sensor 5r0.5 V.
Reconnect the disconnected connector. Check if voltage ;'5 between machine and terminal B9 of connector of MC2/A meets specification.
Faulty harness up to terminal W of derricking drum lowering remote control pressure sensor.
01
Turn key switch OFF. Check for continuity between machine and terminal ;'5 B of harness end connector of derricking drum lowering remote control pressure sensor.
01
Derricking drum lowering remote control
pressure sensor (sensor end)
MC2/A Connector MCA-3 (harness end)
T2BC-05-03-013 T2BC-05-03-023
Derricking drum lowering remote control
pressure sensor (harness end)
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-024
T2BC-05-03-001
T5-3-35
Faulty derricking drum lowering 01㩷 remote control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
01㩷
;'5㩷 Faulty MC2/A.
;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of derricking drum 01㩷 lowering remote control pressure sensor. Faulty harness up to terminal R of derricking drum lowering remote control pressure sensor. Faulty derricking drum lowering remote control pressure sensor.
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 drum hoisting remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal W of harness end connector of front
Turn key switch OFF. Disconnect con nector of front hoisting redrum mote control pres sure sensor. Check for continu ity between termi R and B of nals front drum hoisting remote control pressure sensor.
Turn key switch ON. Check if voltage between terminals R and B of harness end ;'5㩷 connector of front drum hoisting remote control pressure sensor is 5r0.5 V.
drum hoisting re;'5 mote control pressure sensor to machine. Disconnect con of nector MCA-2 MC2/A. Check for continuity between ma chine and terminal C6 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of harness end con 01 nector of front drum hoisting re mote control pressure sensor is 5r0.5 V.
;'5㩷 Faulty MC2/A.
Faulty front drum hoisting remote 01㩷 control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V Faulty harness up to terminal W of front drum hoisting remote control pressure sensor.
01 Turn key switch OFF. Check for continu;'5 ity between machine and terminal B of harness end connector of front drum hoisting remote control pressure sensor.
01
;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of front drum hoisting remote control 01㩷 pressure sensor. Faulty harness up to terminal R of front drum hoisting remote control pressure sensor.
Connector
Reconnect the disconnected connector. Check if voltage ;'5 between machine and terminal C6 of connector of MC2/A meets specification.
01㩷
Front drum hoisting remote control pressure sensor (sensor end)
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-025 T2BC-05-03-023
Front drum hoisting remote control pressure sensor (harness end)
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-001
T2BC-05-03-024
T5-3-36
Faulty front drum hoisting remote control pressure sensor.
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 drum lowering remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal W Turn key switch OFF. Disconnect connector of front drum lowering remote control pressure sensor. Check for continuity between terminals R and B of drum lowering front remote control pressure sensor.
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of front drum lowering remote control pressure sensor is 5r0.5 V.
of harness end connector of front drum lowering re;'5 mote control pressure sensor to machine. Disconnect connector MCA-2 of MC2/A. Check for continuity between machine and terminal C12 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of 01 harness end connector of front drum lowering remote control pressure sensor is 5r0.5 V.
Reconnect the disconnected connector. Check if voltage ;'5 between machine and terminal C12 of connector of MC2/A meets specification.
01 Turn key switch OFF. Check for continuity between ma;'5 chine and terminal B of harness end connector of front drum lowering remote control pressure sensor.
01
Front drum lowering remote control
MC2/A
pressure sensor (sensor end)
(harness end)
Connector MCA-2
T2BC-05-03-025 T2BC-05-03-023
Front drum lowering remote control
pressure sensor (harness end)
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-001 T2BC-05-03-024
T5-3-37
Faulty harness up to terminal W of front drum lowering remote control pressure sensor.
;'5㩷 Faulty MC2/A.
01㩷
Faulty harness up to terminal B of front drum lowering remote control pressure sensor. Faulty harness up to terminal R of front drum lowering remote control pressure sensor.
01㩷
Faulty front drum lowering remote 01㩷 control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Connector
;'5㩷 Faulty MC2/A.
Faulty front drum lowering remote control pressure sensor.
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 nector. x If input voltage from the rear drum hoisting remote control pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between rear drum hoisting remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal Turn key switch OFF. Disconnect con nector of rear drum hoisting remote control pressure sensor. Check for continuity between termi nals R and B of rear drum hoisting remote control pressure sensor.
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of rear drum hoisting remote control pressure sensor is 5r0.5 V.
Faulty harness up to terminal W of rear drum hoisting remote control pressure sensor.
01
Turn key switch ON. Check if voltage between machine and terminal R of 01 harness end con nector of rear drum hoisting remote control pressure sensor is 5r0.5 V.
Turn key switch OFF. Check for continuity between ma;'5 chine and terminal B of harness end connector of rear drum hoisting remote control pressure sensor.
01
01㩷
Rear drum hoisting remote control pressure sensor (sensor end)
MC2/A ector MCA-2 Conn (h arness end)
T2BC-05-03-025 T2BC-05-03-023
Rear drum hoisting remote control pressure sensor (harness end)
MC2/A
Connector MCA-1
(harness end)
T2BC-05-03-024
T2BC-05-03-001
T5-3-38
;'5㩷 Faulty MC2/A.
Faulty rear drum 01㩷 hoisting remote control pressure sensor. ·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
W of harness end connector of rear ;'5 drum hoisting re mote control pressure sensor to machine. Disconnect con nector MCA-2 of MC2/A. Check for continu ity between ma chine and terminal C5 of connector MCA-2.
Connector
Reconnect the disconnected connector. Check if voltage between machine ;'5 and terminal C5 of connector of MC2/A meets specification.
;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of rear drum hoisting remote control 01㩷 pressure sensor. Faulty harness up to terminal R of rear drum hoisting remote control pressure sensor. Faulty rear drum hoisting remote control pressure sensor.
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 remote control sensor, or open circuit between terminal 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 ;'5㩷 connector. 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 of connector of MC2/A, or short circuit between SENSOR_5V line 01㩷 MC2/A meets and ground line. Turn key switch specification. x Check the wiring connections first. OFF. ·Insert a test bar into the Connect terminal W of harness end ;'5 connector of rear drum lowering re mote control pres sure sensor to machine. Disconnect connector MCA-2 of Turn key switch ON. MC2/A. Check if voltage be Check for continuity tween terminals R between machine and B of harness end and terminal C11 of ;'5㩷 connector of rear connector MCA-2. drum lowering remote control pressure Turn key switch sensor is 5r0.5 V. OFF. Turn key switch Disconnect con ON. nector of rear drum Check if voltage lowering remote between machine control pressure and terminal R of sensor. harness end conCheck for continu 01 nector of rear drum ity between termilowering remote R and B of nals control pressure rear drum lowering sensor is 5r0.5 V. remote control pressure sensor.
01 Turn key switch OFF. Check for continuity between ma;'5 chine and terminal B of harness end connector of rear drum lowering remote control pressure sensor.
01
MC2/A
Re ar drum lowering remote control pressu re sensor (sensor end)
Connector MCA-2
(harness end)
T2BC-05-03-025
T2BC-05-03-023
Rear drum lowering remote control
MC2/A
(harness end)
pressure sensor (harness end)
Connector MCA-1
T2BC-05-03-001 T2BC-05-03-024
T5-3-39
Faulty harness up to terminal W of rear drum lowering remote control pressure sensor. ;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of rear drum lowering remote control 01㩷 pressure sensor. Faulty harness up to terminal R of rear drum lowering remote control pressure sensor.
01㩷
Faulty rear drum lowering remote control pressure sensor.
rear of connector ·Specification: 0.5 to 4.5 V
Connector
Faulty MC2/A.
Faulty rear drum lowering remote control pressure sensor.
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 between 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 between third/fourth drum hoisting remote control pressure sensor and MC2/A, or short circuit be tween SENSOR_5V line and ground line. Turn key switch x Check the wiring connections first. OFF. Connect terminal Turn key switch OFF. Disconnect con nector of third / drum hoistfourth ing remote control pressure sensor. Check for continu ity between termi R and B of nals third / fourth drum hoisting remote control pressure sensor.
Connector
Turn key switch ON. Check if voltage between terminals R and B of harness end ;'5㩷 connector of third / fourth drum hoisting remote control pressure sensor is 5r0.5 V.
W of harness end connector of third / ;'5 fourth drum hoist ing remote control pressure sensor to machine. Disconnect connector MCA-2 of MC2/A. Check for continu ity between ma chine and terminal C4 of connector MCA-2.
Turn key switch ON. Check if voltage between terminals R and B of harness end connector of 01 third / fourth drum hoisting remote control pressure sensor is 5r0.5 V.
Reconnect the disconnected connector. ;'5 Check if voltage between machine and terminal C4 of connector of MC2/A meets specification.
Third / fourth drum hoisting remote
control pressure sensor (sensor end)
01
Turn key switch OFF. Check for continuity between ma;'5 chine and terminal B of harness end connector of third / fourth drum hoisting remote control pressure sensor.
01
Connector MCA-2 (harness end)
T2BC-05-03-025 T2BC-05-03-023
Third / fourth drum hoisting remote cont rol pressure sensor (harness end)
MC2/A
Connector MCA-1
(harness end)
T2BC-05-03-001
T2BC-05-03-024
T5-3-40
Faulty third / fourth drum hoisting remote 01㩷 control pressure sensor.
Faulty harness up to terminal W of third / fourth drum hoisting remote control pressure sensor.
MC2/A
Faulty MC2/A.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
01㩷
;'5㩷
;'5㩷
Faulty MC2/A.
Faulty harness up to terminal B of third / fourth drum hoisting remote control pres01㩷 sure sensor. Faulty harness up to terminal R of third / fourth drum hoisting remote control pressure sensor. Faulty third drum hoisting remote control pressure sensor.
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 between 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 between third / fourth drum lowering remote control pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch • Check the wiring connections first. OFF. Connect terminal Turn key switch OFF. Disconnect third / fourth drum lowering remote control pressure sensor. Check for continuity between terminals R and B of / fourth drum third lowering remote control pressure sensor.
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of third / fourth drum lowering remote control pressure sensor is 5±0.5 V.
W of harness end / connector of third fourth drum lower ;'5㩷 ing remote control to pressure sensor machine. Disconnect connector MCA-2 of MC2/A. Check for continuity between ma- chine and terminal C10 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of 01 harness end connector of third / fourth drum lower ing remote control pressure sensor is 5±0.5 V.
01㩷 Turn key switch OFF. Check for continuity between ma;'5㩷 chine and terminal B of harness end connector of third / fourth drum lowering remote control pressure sensor.
01㩷
Third / fourth drum lowering remote control pressure sensor (sensor end)
T2BC-05-03-023
Third / fourth drum lowering remote control pressure sensor (harness end)
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-025
T2BC-05-03-024
T5-3-41
Faulty harness up to terminal B of third / fourth drum lowering remote control 01㩷 pressure sensor. Faulty harness up to terminal R of third / fourth drum lowering remote control pressure sensor.
MC2/A Connector MCA-1 (harness end)
;'5㩷 Faulty MC2/A.
Faulty third / fourth drum lowering remote control pressure sensor.
Faulty third / fourth drum lowering re01㩷 mote control pressure sensor.
Faulty harness up to terminal W of third / fourth drum lowering remote control pressure sensor.
Connector
;'5㩷 Faulty MC2/A.
·Insert a test bar into the rear of connector ·Specification: 0.5 to 4.5 V
01㩷
Reconnect the disconnected connector. ;'5 Check if voltage between machine and terminal C10 of connector of MC2/A meets specification.
T2BC-05-03-001
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 harness open circuit primary pilot circuit pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch • Check the wiring connections first. OFF. Connect terminal end W of harness connector of primary pilot circuit to pressure sensor ;'5 machine. Disconnect con nector MCA-2 of MC2/A. Check for continu ity between machine and terminal C2 of connector Turn key switch ON. MCA-2. Check if voltage be tween terminals R ;'5㩷 and B of harness end connector of primary pilot circuit pressure sensor is 5±0.5 V. key switch Turn OFF. Turn key switch Disconnect con ON. nector of primary Check if voltage pilot circuit pres between machine sensor. sure Check for continu01㩷 and terminal R of harness end conity between termi nector of primary R and B of nals pilot circuit pres primary pilot circuit sure sensor is pressure sensor. 5±0.5 V.
Reconnect the disconnected connector. Check if voltage ;'5㩷 between machine and terminal C2 of connector of MC2/A meets specification.
Faulty harness up to terminal W of primary pilot circuit pressure sensor.
01㩷 Turn key switch OFF. Check for continu;'5 ity between machine and terminal B of harness end connector of primary pilot circuit pressure sensor.
01
MC2/A
Primary pilot circuit pressure sensor (harness end)
Connector MCA-2 (harness end)
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-025
T2BC-05-03-041
T2BC-05-03-040
T2BC-05-03-001
T5-3-42
Faulty harness up to terminal B of 01㩷 primary pilot circuit pressure sensor.
Faulty primary pilot circuit pressure sensor.
Primary pilot circuit pressure end) sensor (sensor
;'5 Faulty MC2/A.
Faulty harness up to terminal R of primary pilot circuit pressure sensor.
01㩷
Faulty primary pilot 01㩷 circuit pressure sensor.
·Insert a test bar into the rear of connector ·Specification: 0.5 to 4.5 V
;'5㩷 Faulty MC2/A.
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. • If input voltage from the front brake depressing pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between front brake depressing pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. Turn key switch • Check the wiring connections first. OFF. Connect terminal W of harness end connector of front
Turn key switch OFF. Disconnect connector of front brake depressing pressure sensor. Check for continu ity between terminals R and B of front brake de pressing pressure sensor.
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of front brake depressing pressure sensor is 5±0.5 V.
Faulty harness up to terminal W of front brake depressing pressure sensor.
01
Turn key switch ;'5㩷 Faulty MC2/A. OFF. Check for continuity between ma;'5㩷 chine and terminal Faulty harness up to B of harness end terminal B of front connector of front brake depressing brake depressing 01 pressure sensor. pressure sensor. Faulty harness up to terminal R of front brake depressing pressure sensor.
01
01㩷
Faulty front brake depressing pressure sensor.
Connector
Front brake depressing
pressure sensor (harness end)
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-025
T2BC-05-03-040
T5-3-43
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-041
Faulty front brake depressing pres01 sure sensor.
Front brake depressing pressure sensor (sensor end)
;'5 Faulty MC2/A.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
brake depressing ;'5㩷 pressure sensor to machine. Disconnect connector MCA-2 of MC2/A. Check for continu maity between chine and terminal C8 of connector MCA-2.
Turn key switch ON. Check if voltage between machine and terminal R of 01 harness end con nector of front brake depressing pressure sensor is 5±0.5 V.
Reconnect the disconnected connector. Check if voltage ;'5 between machine and terminal C8 of connector of MC2/A meets specification.
T2BC-05-03-001
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 pressure 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. • Check the wiring connections first. Turn key switch OFF. Connect terminal W of harness end connector of rear brake depressing pressure sensor to ;'5 machine. Disconnect connector MCA-2 of MC2/A. Check for continu ity between ma Turn key switch ON. chine and terminal Check if voltage beC1 of connector tween terminals R MCA-2. ;'5㩷 and B of harness end connector of rear key switch Turn brake depressing Turn key switch OFF. pressure sensor is ON. Disconnect con 5±0.5 V. Check if voltage nector of rear between machine brake and terminal R of depressing pressure sensor. 01 harness end conCheck for continu nector of rear ity between termibrake depressing R and B of nals pressure sensor is rear brake de5±0.5 V. pressing pressure sensor. 01㩷
Rear brake depressing pressure sensor (sensor end)
Turn key switch OFF. Check for continu;'5㩷 ity between machine and terminal B of harness end connector of rear brake depressing pressure sensor.
;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of rear brake de01 pressing pressure sensor.
01
Faulty rear brake depressing pressure sensor.
MC2/A
MC2/A
Connector MCA-2 (harness end)
(harness end)
Connector MCA-1
T2BC-05-03-025
T2BC-05-03-041
T2BC-05-03-040
Faulty rear brake depressing pres01㩷 sure sensor.
Faulty harness up to terminal R of rear brake depressing pressure sensor.
;'5 Faulty MC2/A.
·Insert a test bar into the rear of connector. Faulty harness up ·Specification: 0.5 to 4.5 V to terminal W of rear brake depressing pressure 01 sensor.
Connector brake depressing Rear pressure sensor (harness end)
Reconnect the disconnected connector. Check if voltage ;'5㩷 between machine and terminal C1 of connector of MC2/A meets specification.
T5-3-44
T2BC-05-03-001
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 depressing pressure sensor end connector. • If input voltage from the fourth brake depressing pressure sensor is less than 0.5V, the cause of trouble may be harness open circuit between fourth brake depressing pressure sensor and MC2/A, or short circuit between SENSOR_5V line and ground line. • Check the wiring connections first. Turn key switch OFF. Connect terminal W of harness end connector of fourth brake depressing pressure sensor to ;'5 machine. Disconnect connector MCA-2 of MC2/A. Check for continu ity between ma chine and terminal C7 of connector MCA-2.
key switch Turn OFF. Disconnect con of fourth nector brake depressing pressure sensor. Check for continuity between termi R and B of nals fourth brake depressing pressure sensor.
Turn key switch ON. Check if voltage between terminals R ;'5㩷 and B of harness end connector of fourth brake depressing pressure sensor is 5±0.5 V.
Turn key switch ON. Check if voltage between machine and terminal R of harness end con01㩷 nector of fourth brake depressing pressure sensor is 5±0.5 V.
Reconnect the disconnected connector. ;'5㩷 Check if voltage between machine and terminal C7 of connector of MC2/A meets specification.
01㩷 Turn key switch, OFF. Check for continuity between ma;'5 chine and terminal B of harness end connector of fourth brake depressing pressure sensor.
01
Fourth brake depressing
Fourth brake depressing
pressure sensor (sensor end)
pressure sensor (harness end)
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-025
T2BC-05-03-041
T2BC-05-03-040
T5-3-45
Faulty harness up to terminal B of fourth brake de01㩷 pressing pressure sensor.
MC2/A Connector MCA-1 (harness end)
;'5 Faulty MC2/A.
Faulty fourth brake depressing pressure sensor.
Connector
Faulty harness up to terminal W of fourth brake depressing pressure sensor.
Faulty harness up to terminal R of fourth brake depressing pressure sensor.
01㩷
Faulty fourth brake depressing pres01㩷 sure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
;'5㩷 Faulty MC2/A.
T2BC-05-03-001
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 derricking drum lowering remote control pressure sensors.
;'5㩷
Disconnect con nector of derricking drum unlocking solenoid valve. Check if voltage between terminals #1 and #2 of har ness end connector is 24 V.
· Derricking drum
hoisting or derrick ing drum lowering operation
Faulty derricking drum unlocking solenoid valve.
01㩷
Disconnect connector MCA-6 of MC2/A. Check if continuity between terminal #2 of harness end connector of derricking drum unlocking solenoid valve and terminal E4 of harness end connector of connector MCA-6.
;'5㩷
Connect connector MCA-6. Connect terminal #2 of harness end con of derricking nector drum unlocking sole noid valve to machine. Check if voltage be terminal #2 and tween machine is 24 V.
;'5
Faulty MC2/A. 01㩷
· Derricking drum hoisting or derricking drum lowering operation 01
Connector
Derricking drum unlocking solenoid valve (harness end)
MC2/A Connector MCA-6 (harness end)
T2BC-05-04-027 T2BC-05-04-010
T5-3-46
Faulty harness between ground and derricking drum unlocking solenoid valve, or faulty ground.
Faulty harness between MC2/A and derricking drum unlocking solenoid valve.
TROUBLESHOOTING / Troubleshooting A Check of Front Motor Brake Release Solenoid Valve
• Check the wiring connections first. • The cause of trouble may be failure of derricking drum hoisting remote control pressure sensor and derricking drum lowering remote control pressure sensor system. At first, check the front drum hoisting remote control pressure sensor and front drum lowering remote control pressure sensor.
Faulty front motor brake release solenoid valve.
;'5㩷
Disconnect con-
nector of front mo tor brake release
solenoid valve. Check if voltage between terminals #1 and #2 of har ness end connector is 24 V.
Disconnect connector MCA-6 of MC2/A. Check for continuity · Front drum hoisting or between terminal #1 front drum lowering of harness end connector of front motor operation 01㩷 brake release sole noid valve and terminal E18 of harness end connector of connector MCA-6.
;'5㩷
Connect connector MCA-6. Connect terminal #1 of harness end connector of front motor brake release solenoid valve to machine. Check if voltage between machine and terminal #1 is 24 V.
;'5
Faulty harness between ground and front motor brake release solenoid valve, or faulty ground.
Faulty MC2/A. 01㩷
· Front drum hoisting or front drum lowering operation
Faulty harness between MC2/A and front motor brake release solenoid valve.
01
Connector
MC2/A Connector MCA-6 (harness end)
Front motor brake release solenoid valve (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
• Check the wiring connections first. • The cause of trouble may be failure of rear drum hoisting remote control pressure sensor and rear drum lowering remote control pressure sensor system. At first, check the rear hoisting derricking drum lowering remote control pressure sensor and rear drum lowering remote control pressure sensor.
Faulty rear motor brake release solenoid valve.
;'5㩷
Disconnect con-
nector of rear motor brake release
solenoid valve.
Check if voltage
between terminals
#1 and #2 of har-
ness end connec-
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end connector of rear motor 01㩷 brake release solenoid valve and terminal E5 of harness end connector of connector MCA-6.
tor is 24 V. · Rear drum hoisting or rear drum lowering operation
;'5
Connect connector MCA-6. Connect terminal #1 of harness end connector of rear motor brake release solenoid valve to machine. Check if voltage between terminal #1 and machine is 24 V. · Rear drum hoisting or rear drum lowering operation
;'5㩷
Faulty harness between ground and rear motor brake release solenoid valve, or faulty ground.
Faulty MC2/A. 01 Faulty harness between MC2/A and rear motor brake release solenoid valve.
01㩷
Connector Rear motor brake release solenoid valve (harness end)
1
MC2/A Connector MCA-6 (harness end)
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 lowering remote control pressure sensor.
;'5㩷
Faulty fourth motor brake release solenoid valve.
Disconnect fourth
Connect connector
winch connector. Check if voltage between terminals #1 and #2 of har ness end connector is 24 V.
· Fourth drum hoisting or fourth drum
lowering operation
01㩷
Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #2 of harness end connector of fourth winch connector and terminal E19 of harness end connector of connector MCA-6.
;'5
MCA-6. Connect terminal #2 of harness end connector of fourth winch connector to machine. if voltage beCheck tween terminal #2 and machine is 24 V.
;'5㩷
drum hoist· Fourth ing or fourth drum lowering operation
Faulty MC2/A. 01㩷 Faulty harness between MC2/A and fourth motor brake release solenoid valve.
01
Connector
MC2/A
Fourth winch (harness end)
Connector MCA-6 (harness end)
T2BC-05-04-027
T2BC-05-03-026
T5-3-49
Faulty harness between ground and fourth motor brake release solenoid valve, or faulty ground.
TROUBLESHOOTING / Troubleshooting A Check of Third/Fourth Auto Brake Indicator (Optional)
• Check the wiring connections first. Disconnect connector MCA-6 of MC2/A. Check if third / fourth auto brake indicator goes OFF.
Faulty MC2/A.
;'5㩷
Faulty harness between MC2/A and third / fourth auto brake indicator.
01㩷
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
• Check the wiring connections first.
YES
Disconnect con-
nector MCA-4 from MC2/A.
Check if voltage between terminal A8 of harness end connector and ma chine is 24 V.
· Key switch: ON · Brake mode key switch: ON
Faulty MC2/A.
NO
Disconnect connector MCA-1 of MC2/A and connector 62C-16MW of left control panel. Connect terminals D2 and A8 of harness end connector of connectors MCA-1 and MCA-4 to machine. Check for continuity between machine and terminals #8 and #9 of harness end connector of left control panel.
YES
Faulty brake mode key switch.
In case of no continuity at terminal #8, harness open circuit between terminal #8 of left control panel and MC2/A. In case of no continuity at terminal #9, harness open circuit between terminal #9 of left control panel and MC2/A.
NO
Connector
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-001
T2BC-05-04-022
T2BC-05-03-020
T5-3-51
Left control panel Connector 62C-16MW (harness end)
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Brake Mode Selection Switch System
• Check the wiring connections first.
YES
Disconnect con-
nector MCA- of
MC2/A.
Check if voltage
between terminal A21of harness end connector and machine is 24 V. · Key switch: ON · Front drum brake mode selection switch: ON
NO
Disconnect connector MCA-1 of MC2/A and connector of front lever. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of front lever, terminal A21 of connector MCA-4 and terminal #3 of connector of front lever.
YES
Faulty front drum brake mode selection switch.
In case of no continuity at terminal #3, harness open circuit between front drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, harness open circuit between front drum brake mode selection switch and MC2/A.
NO
Connector
Faulty MC2/A.
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-4 (harness end)
Connector of front drum brake mode selection switch (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
Disconnect con-
nector MCA-4 of
MC2/A. Check if voltage between terminal A9 of harness end connector and ma chine is 24 V.
· Key switch: ON · Rear drum brake mode selection switch: ON
NO
Disconnect connector MCA-1 of MC2/A and connector of rear lever. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of rear lever, terminal A9 of connector MCA-4 and terminal #3 of connector of rear lever.
YES
Faulty rear drum brake mode selection switch.
In case of no continuity at terminal #3, harness open circuit between rear drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, harness open circuit between rear drum brake mode selection switch and MC2/A.
NO
Connector
Faulty MC2/A.
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-4 (harness end)
Connector of rear drum brake mode selection switch (harness end)
T2BC-05-03-001
T2BC-05-03-005
T2BC-05-03-020
T5-3-53
TROUBLESHOOTING / Troubleshooting A Check of Third / Fourth Drum Brake Mode Selection Switch System (Optional)
• Check the wiring connections first.
YES
Disconnect con-
nector MCA-4 of MC2/A. Check if voltage between terminal A22 of harness end connector and machine is 24 V.
· Key switch: ON · Third/fourth drum brake mode selection switch: ON
NO
Disconnect connector MCA-1 of MC2/A. Check for continuity between terminal D2 of connector MCA-1 and terminal #4 of connector of third / fourth lever, terminal A22 of connector MCA-4 and terminal #3 of connector of third / fourth lever.
YES
In case of no continuity at terminal #3, harness open circuit between third / fourth drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, harness open circuit between third / fourth drum brake mode selection switch and MC2/A.
Connector
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-001
Faulty third / fourth drum brake mode selection switch.
NO
Faulty MC2/A.
T2BC-05-03-005
T2BC-05-03-020
T5-3-54
Connector of third / fourth drum brake mode selection switch (harness end)
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 machine is 24 V.
· Key switch: ON · Front brake pedal
limit switch: ON
Disconnect connector MCA-1 of MC2/A and connector of front brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of 01㩷 connector of front brake pedal limit switch, terminal A11 of connector MCA-4 and terminal #2 of connector of front brake pedal limit switch.
;'5㩷
Faulty front brake pedal limit switch.
In case of no continuity at terminal #1, harness open circuit between front brake pedal limit switch and MC2/A. In case of no continuity at terminal #2, harness open circuit between front brake pedal limit switch and MC2/A.
01
Connector
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-4 (harness end)
Connector of front brake pedal limit switch (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
• Check the wiring connections first.
Disconnect con-
nector MCA-4 of MC2/A. Check if voltage between terminal A11 of harness end connector and machine is 24 V.
· Key switch: ON · Rear brake pedal limit switch: ON
Faulty MC2/A.
;'5㩷
Disconnect connector MCA-1 of MC2/A and connector of rear brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of 01㩷 connector of rear brake pedal limit switch, terminal A24 of connector MCA-4 and terminal #2 of connector of rear brake pedal limit switch.
;'5㩷
Faulty rear brake pedal limit switch.
In case of no continuity at terminal #1, harness open circuit between rear brake pedal limit switch and MC2/A. In case of no continuity at terminal #2, harness open circuit between rear brake pedal limit switch and MC2/A.
01
Connector
Connector of rear brake pedal limit switch (harness end)
MC2/A Connector MCA-4 (harness end)
MC2/A Connector MCA-1 (harness end)
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
Disconnect con-
nector MCA-4 of MC2/A. Check if voltage between terminal A9 of harness end connector and machine is 24 V.
· Key switch: ON · Fourth brake pedal limit switch: ON
Faulty MC2/A.
Disconnect connector MCA-1 of MC2/A and connector of fourth brake pedal limit switch. Check for continuity between terminal D2 of connector MCA-1 and terminal #1 of 01㩷 connector of fourth brake pedal limit switch, terminal A12 of connector MCA-4 and terminal #2 of connector of fourth brake pedal limit switch.
;'5㩷
Faulty fourth brake pedal limit switch.
In case of no continuity at terminal #1, harness open circuit between fourth brake pedal limit switch and MC2/A. In case of no continuity at terminal #2, harness open circuit between fourth brake pedal limit switch and MC2/A.
01
Connector
Connector of fourth brake pedal limit switch (harness end)
MC2/A Connector MCA-4 (harness end)
MC2/A Connector MCA-1 (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.
;'5㩷
Disconnect con nector of front drum brake release solenoid valve. Check if voltage between terminals #1 and #2 of harness end connec tor is 24 V.
· Key switch: ON
· Brake mode key switch: ON · Front drum free mode switch: ON
Faulty front drum brake release solenoid valve.
;'5㩷 Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end connector of front drum 01㩷 brake release solenoid valve and terminal E14 of harness end connector of connector MCA-6.
Connect connector MCA-6. Connect terminal #1 of harness end con of front drum nector brake release sole noid valve to machine. Check if voltage be terminal #1 and tween machine is 24 V.
;'5
Faulty MC2/A. 01㩷
· Key switch: ON · Brake mode key switch: ON · Front drum free mode switch: ON 01
Faulty harness between MC2/A and front drum brake release solenoid valve.
Faulty harness between ground and front drum brake release solenoid valve, or faulty ground.
Connector
Front drum brake release solenoid valve (harness end)
MC2/A 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 brake release solenoid valve.
;'5㩷
Disconnect con-
nector of rear drum brake release solenoid valve.
Check if voltage between terminals #1 and #2 of har ness end connector is 24 V.
· Key switch: ON
· Brake mode key switch: ON
· Rear drum free mode switch: ON
;'5㩷 Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end connector of rear drum 01㩷 brake release solenoid valve and terminal E1 of harness end connector of connector MCA-6.
Connect connector MCA-6. Connect terminal #1 of harness end connector of rear drum brake release solenoid valve to machine. Check if voltage between terminal #1 and machine is 24 V. · Key switch: ON · Brake mode key switch: ON · Rear drum free mode switch: ON
01
Connector
MC2/A Connector MCA-6 (harness end)
Rear drum brake release solenoid valve (harness end)
T2BC-05-03-004 T2BC-05-04-008
T5-3-59
;'5
Faulty harness between ground and rear drum brake release solenoid valve, or faulty ground.
Faulty MC2/A. 01㩷
Faulty harness between MC2/A and rear drum brake release solenoid valve.
TROUBLESHOOTING / Troubleshooting A Check of Fourth Drum Brake Release Solenoid Valve (Optional)
• Check the wiring connections first.
;'5㩷
Disconnect con nector of fourth drum brake release solenoid valve. Check if voltage between terminals #1 and #2 of harness end connec tor is 24 V.
· Key switch: ON
· Brake mode key switch: ON · Fourth drum free mode switch: ON
Faulty fourth drum brake release solenoid valve.
;'5㩷 Disconnect connector MCA-6 of MC2/A. Check for continuity between terminal #1 of harness end connector of fourth drum 01㩷 brake release solenoid valve and terminal E15 of harness end connector of connector MCA-6.
Connect connector MCA-6. Connect terminal #1 of harness end con of fourth drum nector brake release solenoid valve to machine. Check if voltage be terminal #1 and tween machine is 24 V.
;'5
Faulty MC2/A. 01㩷
· Key switch: ON · Brake mode key switch: ON · Fourth drum free mode switch: ON 01
Faulty harness between MC2/A and fourth drum brake release solenoid valve.
Connector
MC2/A Connector MCA-6 (harness end)
Fourth drum brake release solenoid valve (harness end)
T2BC-05-03-006 T2BC-05-04-010
T5-3-60
Faulty harness between ground and fourth drum brake release solenoid valve, or faulty ground.
TROUBLESHOOTING / Troubleshooting A Check of Harness between MC2/A and MC2/B
• Check the wiring connections first. • Check for continuity between terminal Y17 of harness end connector of connector MCA-4 of MC2/A and terminal Y17 of harness end connector of connector MCB-6 of MC2/B.
• Check for continuity between terminal R8 of harness end connector of connector MCA-4 of MC2/A and terminal R8 of harness end connector of connector MCB-4 of MC2/B.
• Check for continuity between terminal R21 of harness end connector of connector MCA-4 of MC2/A and terminal R21 of harness end connector of connector MCB-4 of 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". By using the MC2/A input/output monitor, confirm the sensor and solenoid valve signals. Item THROT. GRIP
Signal name Accelerator grip
M PMP GUR
Main pump displacement angle proportional solenoid valve
DD HST PRS
Derricking drum hoisting remote control pressure Derricking drum lowering remote control pressure Front drum hoisting remote control pressure Front drum lowering remote control pressure Rear drum hoisting remote control pressure Rear drum lowering remote control pressure Third/fourth drum hoisting remote control pressure Third/fourth drum lowering remote control pressure
DD LWR PRS FD HST PRS FD LWR PRS RD HST PRS RD LWR PRS 3D HST PRS
3D LWR PRS
Description LOW ER HI ER LOW ER HI ER RES ER LOW ER
Explanation Lower limit error Upper limit error Lower limit error Upper limit error Reset error Lower limit error
HI ER
Upper limit error
• For checks of derricking drum hoisting, derricking drum lowering, front drum hoisting, front drum lowering, rear drum hoisting, rear drum lowering, third / fourth drum hoisting and third/fourth drum lowering remote control pressure sensor systems, refer to Section "Failure of Brake Control System".
• For check of the accelerator grip, refer to Section "Failure of Engine Control System".
T5-3-62
State Controls as a minimum input. Controls current by controller internal data.
Countermeasure Harness check Sensor check Harness check Solenoid valve check
Controls with control lever in neutral.
Harness check Sensor check
TROUBLESHOOTING / Troubleshooting A 700 to 0 mA, 12.3 to 0 V Main Pump Displacement Angle Proportional SOL
24V
1.0 to 2.4V
5V
Accelerator Grip
IDU CAN_1L CAN_1H
1.0 to 2.4V
0V
5V
Derricking Drum Hoisting Remote Control Pressure Derricking Drum Lowering Remote Control Pressure Front Drum Hoisting Remote Control Pressure Front Drum Lowering Remote Control Pressure Rear Drum Hoisting Remote Control Pressure Rear Drum Lowering Remote Control Pressure Third / Fourth Drum Hoisting Remote Control Pressure Third / Fourth Drum Lowering Remote Control Pressure
24V 24V(ON) 0V(OFF) Accelerator Lock Accelerator Preset
T25N-05-03-013
T5-3-63
TROUBLESHOOTING / Troubleshooting A Main Pump Displacement Angle Proportional Solenoid Valve
x Check the wiring connections first.
Disconnect connector of main
angle proportional
solenoid valve. Check if electric current between terminals #1 and #2 of harness end connector is 700 to 0 mA in accelerator grip rotation range of 0 to 100%.
pump displacement
路 Accelerator lock switch: ON
Disconnect connector MCA-5 of MC2/A. Check if electric current between terminals F5 and F9 of machine end NO connector is 700 to 0 mA in accelerator grip rotation range of 0 to 100%.
路 Accelerator lock switch: ON
Faulty accelerator lock switch, or Check if voltage between terminal YES faulty harness between MC2/A D3 of connector Accelerator MCA-1 and terminal and accelerator lock switch A6 of connector lock switch. MCA-4 of MC2/A is 24 V. Faulty MC2/A. 路 Accelerator lock NO switch: ON 路 Insert a test bar into the rear of connector.
NO
Faulty harness between MC2/A and main pump displacement angle proportional solenoid valve.
YES
Faulty main pump displacement angle proportional solenoid valve.
YES
Connector
Accelerator grip
Refer to Section "Check of Accelerator Grip".
Main pump displacement angle proportional solenoid valve (harness end)
MC2/A Connector MCA-1 (machine end)
T2BC-05-03-021 T2BC-05-04-015
T2BC-05-03-030
MC2/A
Connector MCA-4 (machine end)
T2BC-05-03-028
T5-3-64
MC2/A Connector MCA-5 (machine end)
TROUBLESHOOTING / Troubleshooting A FAILURE OF MAIN PUMP INCREASE CONTROL SYSTEM
POWER
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". By using the MC2/A input/output monitor, confirm the solenoid valve signal. Item RACK P. S.
Signal name Rack sensor
INC. TQ CUR
Power increase solenoid valve
Description Explanation ERROR Error LOW ER HI ER RES ER
Lower limit error Upper limit error Reset error
State Controls pump torque according to engine speed. Controls current by controller internal data.
Countermeasure Harness check Sensor check Harness check Solenoid valve check
0 to 700 mA, 0 to 12.3 V Power Increase Solenoid Valve
24 V
1.9 to 3.1 V
Rack Sensor
0 to 6 VAC, 0 to 5.3 kHz Engine Speed Detection
T25N-05-03-014
x For check of engine rotation detection sensor, refer to "Check of Engine Rotation Detection Sensor" in Section "Failure of Engine Control System".
T5-3-65
TROUBLESHOOTING / Troubleshooting A Check of Rack Sensor System
x Check the wiring connections first.
YES
Diagnose ECU. Check if failure code of rack sensor is output.
YES
· Refer to Troubleshooting E.
Disconnect ECU connector 2. Check if voltage at terminal #1 of NO harness end connector is 24 V. · Key switch: ON
Reconnect the disconnected connector. Disconnect connector MCA-1 of YES MC2/A. Disconnect Connect terminal connector MCA-3 of D14 of machine MC2/A. end connector to Check for continuity machine. Check if between terminal NORMAL is NO B4 of harness end indicated. connector of MC2/A and terminal #8 of harness end connector of ECU NO connector 2.
Harness open YES circuit between
ECU and MC2/A, or faulty ground.
Faulty MC2/A. NO
Harness open circuit between ECU and MC2/A.
Connector
ECU connector 2 (harness end)
MC2/A Connector MCA-1 (harness end)
MC2/A Connector MCA-3 (harness end)
T2BC-05-04-029
Faulty ECU.
Follow the failure code.
T2BC-05-03-001
T2BC-05-03-013
T5-3-66
TROUBLESHOOTING / Troubleshooting A Check of Power Increase Solenoid Valve
x Check the wiring connections first.
Disconnect connector MCA-5 of MC2/A. Connect terminals F17 and F21 of harness end connector of MCA-5 ;'5㩷 to machine by using a clip. Check for continuity between machine and terminals #1 or #2 of Disconnect harness end connector of power connector of power increase solenoid increase solenoid valve. valve. Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect clip from terminal F21 of harness end connector of MCA-5. YES Check for continuity between machine and terminal #1 of harness end connector of power increase solenoid valve.
Harness short circuit between power increase solenoid valve and MC2/A.
YES
Faulty MC2/A. NO
In case of no continuity at terminal #1, harness open circuit between terminal #1 of power increase solenoid valve and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of power increase solenoid valve and MC2/A.
01
· Key switch: OFF
Faulty power increase solenoid valve.
01㩷
Connector
Power increase solenoid valve
MC2/A
Connector MCA-5 (harness end)
(machine end)
T2BC-05-03-031
Power increase solenoid valve
(harness end)
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". By using the MC2/A input/output monitor, confirm the sensor and relay signal. Item SL RGT PRS SL LFT PRS
SL ALAM LP
Signal name Slewing (right) remote control pressure Slewing (left) remote control pressure Slewing alarm lamp relay
Description LOW ER HI ER DBL ER
ERROR
Explanation Lower limit error Upper limit error Double errors
Short circuit
State Controls as input with lever in neutral. Controls as input by lever control. 㧙
Countermeasure Harness check Sensor check
Harness check Relay check
24 V (ON) 0 V (OFF) Slewing Alarm Lamp Relay
24 V
0.5 to 4.5 V
0V
5V
Slewing (Right) Remote Control Pressure Slewing (Left) Remote Control Pressure
T25N-05-03-016
T5-3-68
TROUBLESHOOTING / Troubleshooting A Check of Slewing (Right) Pressure Sensor System
Remote
Control
x Check the wiring connections first.
Disconnect connector of slewing (right) remote control pressure sensor. Check for continuity between terminals R and B of connector of slewing (right) remote control pressure sensor.
Check if voltage between terminals R and B of harness end ;'5㩷 connector of slewing (right) remote control pressure sensor is 5r0.5 V.
Reconnect the Connect terminal disconnected W of harness end connector. Check if ;'5㩷 connector of slewing (right) ;'5 voltage between machine and remote control terminal C3 of pressure sensor to connector of machine by using a 01㩷 MC2/A meets clip. specification. Disconnect ;'5 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 machine and terminal C3 of 01 harness end connector.
Check for continuity between machine and terminal B of ;'5 harness end connector of slew (right) remote control pressure sensor.
Check if voltage between machine and terminal R of harness end connector of 01 slewing (right) remote control pressure sensor is 5r0.5 V. ·Key switch: ON
01㩷
·Key switch: OFF
01
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-023
Slewing (right) remote control pressure sensor (harness end)
Faulty harness up to terminal W of slewing (right) remote control pressure sensor.
T2BC-05-03-025
T2BC-05-03-024
T5-3-69
;'5㩷 Faulty MC2/A. Faulty harness up to terminal B of slewing (right) 01㩷 remote control pressure sensor. Faulty harness up to terminal R of slewing (right) remote control pressure sensor. Faulty slewing (right) remote control pressure sensor.
Faulty slewing (right) remote control pressure sensor.
·Key switch: ON
Slewing (right) remote control pressure sensor (machine end)
Faulty MC2/A.
OFF ·Key switch:
Connector
TROUBLESHOOTING / Troubleshooting A Check of Slewing (Left) Remote Control Pressure Sensor System x Check the wiring connections first. Disconnect connector of slewing (left) remote control pressure sensor. Check for continuity between terminals R and B of connector of slewing (left) remote control pressure sensor.
Check if voltage between terminals R and B of harness end ;'5㩷 connector of slewing (left) remote control pressure sensor is 5r0.5 V. ·Key switch: ON
Connect terminal W of harness end connector of slewing (left) remote control pressure sensor to machine by using a clip. ;'5 Disconnect connector MCA-2 of MC2/A. Check for continuity between machine and terminal C9 of harness end connector.
01
·Key switch: OFF
01
MC2/A Connector MCA-2 (harness end)
T2BC-05-03-023
Slewing (left) remote control pressure sensor (harness end)
Faulty harness up to terminal W of slewing (left) remote control pressure sensor.
T2BC-05-03-025
T2BC-05-03-024
T5-3-70
;'5㩷 Faulty MC2/A.
Faulty harness up to terminal B of slewing (left) 01㩷 remote control pressure sensor. Faulty harness up to terminal R of slewing (left) remote control pressure sensor. Faulty slewing (left) remote control pressure sensor.
Slewing (left) remote control pressure sensor (machine end)
Faulty slewing (left) remote 01㩷 control pressure sensor.
·Insert a test bar into the rear of connector. ·Specification: 0.5 to 4.5 V
Check for continuity between machine and ;'5 terminal B of harness end connector of slew (left) remote control pressure sensor.
;'5㩷 Faulty MC2/A.
Check if voltage between terminal R of harness end connector of slewing (left) remote control 01 pressure sensor and machine is 5r0.5 V.
01㩷
Reconnect the disconnected connector. Check if voltage ;'5 between machine and terminal C9 of connector of MC2/A meets specification.
·Key switch: OFF
·Key switch: ON
Connector
TROUBLESHOOTING / Troubleshooting A Check of Slewing Alarm Lamp Relay System
x Check the wiring connections first.
;'5㩷
Disconnect connector of slewing alarm lamp relay. Check if voltage between machine terminal #1 of and harness end connector is 0 V.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and 01㩷 terminal E21 of machine end connector is 0 V.
switch: ON · Key
· Key switch: ON
;'5
Connector
Slewing alarm lamp relay (harness end)
MC2/A Connector MCA-6 (machine end)
2
Faulty MC2/A.
01
Faulty harness between MC2/A and slewing alarm lamp relay.
Faulty slewing alarm lamp relay.
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". By using the MC2/A input/output monitor, confirm the sensor and solenoid valve signals. Item
Signal name
FD PLS SOL Front drum rotation sensing solenoid RD PLS SOL Rear drum rotation sensing solenoid DD PLS SOL Derricking drum rotation sensing solenoid
Description ERROR
Explanation Short circuit
State 㧙
Countermeasure Harness check Solenoid check
Front Drum Rotation Sensing Solenoid Valve
Rear Drum Rotation Sensing Solenoid Valve
Front Drum Rotation Detection A Phase
Derricking Drum Rotation Sensing Solenoid Valve
Front Drum Rotation Detection B Phase Rear Drum Rotation Detection A Phase Rear Drum Rotation Detection B Phase Derricking Drum Rotation Detection A Phase
24 V: ON 0 V: OFF
Drum Rotation Sensing Cancellation Switch
T2BC-05-03-034
T5-3-72
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Rotation Sensing Solenoid System
x Check the wiring connections first.
;'5㩷
Disconnect connector of front lever. Check if voltage between terminal #6 of harness end connector and machine is 0 V.
· Key switch: ON · Drum rotation sensing cancellation switch: ON
;'5
01
Front lever (harness end)
MC2/A Connector MCA-6 (machine end)
T2BC-05-03-005
Faulty MC2/A.
Connector
Faulty harness between front drum rotation sensing solenoid and MC2/A.
Disconnect connector MCA-6 of MC2/A. Check if voltage switch: ON between machine and · Key · Drum rotation sensing 01㩷 terminal E2 of machine end cancellation switch: ON connector is 0 V.
Faulty front drum rotation sensing solenoid.
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
Disconnect connector of rear lever. Check if voltage between terminal #6 of harness end connector and machine is 0 V.
· Key switch: ON rotation · Drum sensing cancellation switch: ON
Faulty rear drum rotation sensing solenoid.
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and 01㩷 terminal E16 of machine end connector is 0 V.
· Key switch: ON · Drum rotation sensing cancellation switch: ON
;'5
Faulty harness between rear drum rotation sensing solenoid and MC2/A.
Faulty MC2/A.
01
Connector
Rear lever (harness end)
MC2/A Connector MCA-6 (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.
Disconnect connector of derricking lever. if voltage Check between terminal #1 of harness end connector and machine is 0 V.
· Key switch: ON rotation · Drum sensing cancellation switch: ON
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and 01㩷 terminal E3 of machine end connector is 0 V.
;'5
· Key switch: ON · Drum rotation sensing cancellation switch: ON
01
Faulty harness between derricking drum rotation sensing solenoid and MC2/A.
Faulty MC2/A.
Connector
Faulty derricking drum rotation sensing solenoid.
;'5㩷
Derricking lever (harness end)
MC2/A Connector MCA-6 (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.
Disconnect connector MCA-4 of MC2/A. Check if voltage between machine and terminal A15 of machine end connector is 24 V.
Reconnect the disconnected connector. Disconnect connector MCA-5 of MC2/A and connector 62C16F-W of left overhead panel. Connect terminal F16 of YES harness end connector of connector MCA-5 to machine. Check for continuity between machine and terminals A15, F16 of harness end connector of left overhead panel connector.
YES
NO
¡ Key Switch: ON
NO
Connector
MC2/A Connector MCA-5 (harness end)
T2BC-05-03-028
Faulty MC2/A.
MC2/A Connector MCA-4 (machine end)
In case of no continuity at terminal A15, harness open circuit between input end terminal of drum rotation sensing cancellation switch and MC2/A. In case of no continuity at terminal F16, harness open circuit between ground end terminal of drum rotation sensing cancellation switch and MC2/A.
Faulty drum rotation sensing cancellation switch.
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-033
T2BC-05-03-029
T2BC-05-03-020
T5-3-76
Left overhead panel Connector 62C16F-W (harness end)
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Rotation Detection Sensor A System
x Check the wiring connections first.
;'5㊡ rotation detection
sensor A with rear
Disconnect connector of front drum rotation detection sensor A as well as connectors MCA-4 and MCA-5 of MC2/A. Connect terminal A13 of harness end connector of MCA-4 and terminal F16 of harness end connector of MCA-5 connector to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of front drum rotation detection sensor A.
drum rotation
detection sensor A or derricking drum rotation detection sensor A. Check if error indication on monitor disappears. 01㊡
;'5
Faulty MC2/A.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum rotation detection sensor A and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum rotation detection sensor A and MC2/A.
01
Connector
Faulty front drum rotation detection sensor A.
Replace front drum
Front drum rotation detection sensor A (harness end)
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020 T2BC-05-04-008
MC2/A Connector MCA-5 (harness end)
T2BC-05-03-029
T5-3-77
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Rotation Detection Sensor B System
x Check the wiring connections first.
Faulty front drum rotation detection sensor B
;'5㊡
Replace front drum
rotation detection
sensor B with rear drum rotation
detection sensor B. Check if error
indication on monitor disappears.
01㊡
Disconnect connector of front drum rotation detection sensor B as well as connectors MCA-4 and MCA-5 of MC2/A. Connect terminal A26 of harness end connector of connector MCA-4 and terminal F16 of harness end connector of connector MCA-5 to machine. Check for continuity between machine and terminals #1 or #2 of harness end connector of front drum rotation detection sensor B.
;'5
Faulty MC2/A In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum rotation detection sensor B and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum rotation detection sensor B and MC2/A.
01
Connector Front drum rotation detection sensor B (harness end)
MC2/A Connector MCA-5 (harness end)
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020 T2BC-05-04-008
T2BC-05-03-029
T5-3-78
TROUBLESHOOTING / Troubleshooting A Check of Rear Drum Rotation Detection Sensor A System
x Check the wiring connections first.
Faulty rear drum rotation detection sensor A.
;'5㊡
Replace rear drum
rotation detection
sensor A with front
drum rotation detection
Disconnect connector of rear drum rotation detection sensor A as well as connector MCA-5 of MC2/A. Connect terminals F12 and F16 of harness end connector of MCA-5 to machine. Check for continuity between machine and terminals #1 or #2 of harness end connector of rear drum rotation detection sensor A.
sensor A or derricking
drum rotation detection
sensor A. Check if error indication on monitor disappears.
01㊡
Faulty MC2/A.
;'5
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum rotation detection sensor A and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum rotation detection sensor A and MC2/A.
01
Connector MC2/A Connector MCA-5 (harness end)
Rear drum rotation detection sensor A (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.
;'5㊡
Replace rear drum
rotation detection
sensor B with front
drum rotation de tection sensor B. Check if the error indication on moni tor disappears.
01㊡
Disconnect connector of rear drum rotation detection sensor B and connector MCA-5 of MC2/A. Connect terminals F1 and F16 of harness end connector of MCA-5 to machine. Check for continuity between machine and terminals # 1 or #2 of harness end connector of rear drum rotation detection sensor B.
;'5
Faulty MC2/A.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum rotation detection sensor B and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum rotation detection sensor B and MC2/A.
01
Connector
Rear drum rotation detection sensor B (harness end)
Faulty rear drum rotation detection sensor B.
MC2/A Connector MCA-5 (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.
Replace derricking
;'5㊡
drum rotation detection sensor A with front drum rotation detection sensor A or rear drum rota tion detection sensor A. Check if the error indication on monitor disappears.
Faulty derricking drum rotation detection sensor A.
01㊡
Disconnect connector of derricking drum rotation detection sensor A and connector MCA-5 of MC2/A. Connect terminals F13 and F16 of harness end connector of MCA-5 to machine. Check for continuity between machine and terminals # 1 or #2 of harness end connector of derricking drum rotation detection sensor A.
;'5
Faulty MC2/A.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of derricking drum rotation detection sensor A and MC2/A. In case of no continuity at terminal #2, harness open circuit between terminal #2 of derricking drum rotation detection sensor A and MC2/A.
01
Connector
Derricking drum rotation detection sensor A (harness end)
MC2/A 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". By using the MC2/A input/output monitor, confirm the relay signal.
Item ENG. INTLCK
Signal name Engine start relay
Description ERROR
Explanation Short circuit
State 㧙
Countermeasure Harness check Relay check
Start Relay 1
Engine Start Interlock Front Drum Brake Mode Selection Switch
Rear Drum Brake Mode Selection Switch
24V Third / Fourth Drum Brake Mode Selection Switch
Slewing Brake Switch
Starter Switch
T2BC-05-03-035
T5-3-82
TROUBLESHOOTING / Troubleshooting A Check of Engine Start Relay
x Check the wiring connections first.
;'5㩷
Disconnect connector of engine start relay. Check if voltage between machine and terminal #1 of harness end con nector is 24V.
Faulty engine start relay.
switch: ON · Key · Slewing brake switch: ON (brake applied) · Front drum free mode switch: OFF (auto brake) · Rear drum free mode switch: OFF (auto brake) · Third drum free mode switch: OFF (auto brake)
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and 01㩷 terminal E20 of machine end connector is 24 V. · Connect terminals E12, E13 and E26 of both connectors by using a clip or the like. · Key switch: ON
;'5
Faulty harness between MC2/A and engine start relay.
01
Faulty MC2/A.
Connector
Engine start relay (harness end)
MC2/A Connector MCA-6 (machine end)
1
4
2
5
3
T2BC-05-03-032
T5-3-83
TROUBLESHOOTING / Troubleshooting A Check of Slewing Brake Switch System
x Check the wiring connections first.
;'5㩷
Disconnect con nector MCA-4 of MC2/A. Check if voltage between terminal A18 of harness connector and end machine is 0 V. · Key switch: ON · Slewing brake switch: ON
;'5 Check if voltage between machine and 01㩷 terminal #8 of slewing lever connector is 0 V. · Insert a test bar into the rear of connector. · Key switch: ON · Slewing brake switch: ON
01
Connector
MC2/A Connector MCA-4 (harness end)
Slewing lever (slewing lever end)
T2BC-05-03-020
Faulty slewing brake switch.
Faulty harness between slewing brake switch and MC2/A.
Faulty MC2/A.
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
Disconnect con nector MCA-4 of MC2/A. Check if voltage between terminal of harness A21 end connector and machine is 0 V.
· Key switch: ON · Front drum free mode switch: OFF (auto brake)
Disconnect connector MCA-1 of MC2/A and front lever connector. Check for continuity between terminal D2 of connector MCA-1 01㩷 and terminal #4 of front lever connector, terminal A21 of connector MCA-4 and terminal #3 of front lever connector.
;'5
Faulty front drum brake mode selection switch.
In case of no continuity at terminal #3, faulty harness between terminal #3 of front drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, faulty harness between terminal #4 of front drum brake mode selection switch and MC2/A.
01
Connector
MC2/A Connector MCA-4 (harness end)
Faulty MC2/A.
Front lever (front lever end)
T2BC-05-03-020
MC2/A Connector MCA-1 (harness end)
T2BC-05-03-005
T2BC-05-03-001
T5-3-85
TROUBLESHOOTING / Troubleshooting A Check of Rear Drum Free Mode Switch System
x Check the wiring connections first.
Disconnect con nector MCA-4 of MC2/A. Check if voltage between terminal of harness A21 end connector and machine is 0 V. · ·
;'5㩷
switch: ON Key Rear drum free mode switch: OFF brake) (auto
Faulty MC2/A.
Disconnect connector MCA-1 of MC2/A and rear lever connector. Check for continuity between terminal D2 of connector MCA-1 01㩷 and terminal #4 of rear lever connector, terminal A9 of connector MCA-4 and terminal #3 of rear lever connector.
;'5
Faulty rear drum brake mode selection switch.
In case of no continuity at terminal #3, faulty harness between terminal #3 of rear drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, faulty harness between terminal #4 of rear drum brake mode selection switch and MC2/A.
01
Connector
MC2/A Connector MCA-4 (harness end)
Rear lever (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)
x Check the wiring connections first.
;'5㩷
Faulty MC2/A.
Disconnect conDisconnect connector MCA-1 of MC2/A and third/fourth lever connector. Check for continuity between terminal D2 of connector MCA-1 and terminal #3 of · Key switch: ON 01㩷 third / fourth lever · Fourth drum free mode connector, terminal switch: OFF A22 of connector (auto brake) MCA-4 and terminal #4 of third/fourth lever connector.
nector MCA-4 of MC2/A. Check if voltage between terminal A22 of harness end connector and machine is 0 V.
;'5
Faulty third/fourth drum brake mode selection switch.
In case of no continuity at terminal #3, faulty harness between terminal #3 of third / fourth drum brake mode selection switch and MC2/A. In case of no continuity at terminal #4, faulty harness between terminal #4 of third/fourth drum brake mode selection switch and MC2/A.
01
Connector
MC2/A Connector MCA-4 (harness end)
Third / fourth lever (third / fourth lever end)
T2BC-05-03-005
T2BC-05-03-020
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". By using the MC2/A input/output monitor, confirm the sensor signal. Item PILOT PRS
Signal name Primary pilot pressure
Description Explanation LOW ER Lower limit error HI ER Upper limit error
State Controls as pressure drop input.
Countermeasure Harness check Sensor check
24 V (ON) 0 V (OFF) 24 V Pilot Pressure Drop Indicator
0.5 to 4.5 V
0V
5V
Primary Pilot Pressure
T25N-05-03-019
x For check of primary pilot pressure sensor, refer to "Check of Primary Pilot Pressure" of "Failure of Brake Control System".
T5-3-88
TROUBLESHOOTING / Troubleshooting A Check of Pilot Pressure Drop Indicator
x Check the wiring connections first.
Even when pilot pressure drops below the set pressure, the indicator is not turned ON.
Disconnect connector 62C-16FW of monitor panel. Check if voltage between terminals E8 and #224 of harness end connector is 24 V.
switch: ON · Key
;'5㩷
;'5 Disconnect connector MCA-6 of MC2/A. Check for continuity 01㩷 between terminal E8 of harness end connector and terminal E8 of connector C62-16FW.
Faulty MC2/A.
Harness open circuit between MC2/A and pilot pressure drop indicator.
01
· Key switch: ON
;'5㩷
Disconnect con nector 62C-16FW of monitor panel. Check for continuity between terminals E8 and #224 of harness end connector.
Faulty MC2/A.
Harness short circuit between MC2/A and pilot pressure drop indicator.
01㩷
Connector
Monitor panel Connector 62C-16FW (harness end)
MC2/A Connector MCA-6 (harness end)
T2BC-05-03-037
Burn-out of pilot pressure drop indicator.
Even when pilot pressure is at the set pressure, the indicator is not turned OFF.
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 battery and sensor power supply of MC2/A are normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies" By using the MC2/A input/output monitor, confirm the sensor signal. Item FD LWR PRS RD LWR PRS
MT CUT OFF
Signal name Front drum lowering remote control pressure Rear drum lowering remote control pressure Motor cutoff high pressure relay
Description Explanation LOW ER Lower limit error HI ER Upper limit error ERROR Short circuit
State Controls as input with lever in neutral. 㧙
Countermeasure Harness check Sensor check
Harness check Solenoid valve check
24 V (ON) 0 V (OFF)
Motor Cutoff Relay
24 V
0.5 to 4.5 V
0V
5V
Front Drum Lowering Remote Control Pressure
Rear Drum Lowering Remote Control Pressure
T25N-05-03-020
x For check of front drum and rear drum lowering remote control pressure sensors, refer to "Check of Front Drum Lowering Remote Control Pressure Sensor" and "Check of Rear Drum Lowering Remote Control Pressure Sensor� of "Failure of Brake Control System".
T5-3-90
TROUBLESHOOTING / Troubleshooting A Check of Motor Cutoff Relay System
x Check the wiring connections first.
;'5㩷
nector of motor cutoff relay. if voltage Check between machine and terminal #1 of harness end con nector is 0 V.
· Key switch: ON
Faulty harness between MC2/A and motor cutoff relay.
· Connect terminals E12, E13 and E26 of both connectors by using a clip or the like. · Key switch: ON
01
Faulty MC2/A.
Connector
;'5
Disconnect connector MCA-6 of MC2/A. Check if voltage between machine and 01㩷 terminal E6 of machine end connector is 0 V.
Faulty motor cutoff relay.
Disconnect con-
Motor cutoff relay (harness end)
MC2/A Connector MCA-6 (machine end)
2
4
5
3
1
T2BC-05-03-032
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 normal. If error is indicated, refer to "Failure of MC2/A and MC2/B Batteries and Sensor Power Supplies" By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item JB FOLD
Signal name Jib folding (no connection)
ATTACHMENT
Wiring detection
Description Explanation ALL OFF Open circuit ALL ON Shorted harnesses SHORT Short circuit on both crane and tower OPEN
BM OVERH BM OVERH2 TW OVERH BT LOWER L JB OVERH JB OVERH2 HK OVERH SWL OVERH DD HST CUR DD LWR CUR
Boom overhoist Boom/tower second overhoist Tower overhoist Boom/tower lowest limit (no connection) Jib overhoist Jib second overhoist Hook overhoist Tower jib backstop alignment Derricking drum hoisting proportional solenoid valve Derricking drum lowering proportional solenoid valve
ALL OFF
State Controls as jib unfolding
Countermeasure Harness check
Priority is given to Harness check the selection by IDU during control or error control. Open circuit on both Priority is given to crane and tower the selection by IDU during control or disassembly position control. Open circuit Controls as over- Harness check hoist.
ALL ON
Shorted harnesses
LOW ER
Lower limit error
HI ER
Upper limit error
RES ER
Reset error
T5-3-92
PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric current feedback Electric current control by open loop
Harness check Solenoid valve check MC2/B hardware check
TROUBLESHOOTING / Troubleshooting A Derricking Drum Hoisting Proportional Solenoid Valve
Derricking Drum Lowering Proportional Solenoid Valve Auto Stop Release Derricking Drum Switch
Live Mast Lower Limit Prevention
Auto Stop Release Key Switch Boom Overhoist Prevention Tower Upper Limit Overhoist Prevention Boom Second Overhoist Prevention Crane Relay Box
Main Hook Overhoist Prevention
Derricking Drum Hoisting Stop
Sub Hook Overhoist Prevention
Derricking Drum 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-02-01-012
T5-3-93
TROUBLESHOOTING / Troubleshooting A Check of Wiring Detection Signal System
x Check the wiring connections first.
Crane Mode
NO
YES Disconnect connector MCB-1 of MC2/B. Check if voltage between machine and terminal X4 of connector of MC2/B is 24 V. · Connect terminals of both disconnected connectors by using a clip or the like. · D1 X1 · D17 M18 · D12 (B) · Key switch: ON
Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and terminal R8 of connector MCB-4.
· Key switch: OFF
YES
Connector
MC2/B
MC2/B Connector MCB-1 (machine end)
Connector MCB-4
(harness end)
Faulty MC2/B.
Disconnect connector MCA-4 of MC2/A. Check for continuity between terminal R8 of harness end connector of connector MCA-4 and terminal R8 of harness end connector of connector MCB-4.
NO
Check for continuity between terminals #1 and #2 of relay box.
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-021
T2BC-05-03-027
T2BC-05-03-038
T5-3-94
TROUBLESHOOTING / Troubleshooting A
NO
Faulty relay box.
YES
NO
Harness open circuit between MC2/B and relay box.
Harness open circuit between MC2/A and MC2/B.
Faulty MC2/A. YES
Connector Relay Box (machine end)
T2BC-05-03-039
MC2/A Connector MCA-4 (harness end)
T2BC-05-03-020
T5-3-95
TROUBLESHOOTING / Troubleshooting A Tower Mode
YES Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector MCB-1 and terminal R21 of connector MCB-4.
YES Disconnect connector MCB-1 of MC2/B. Check if voltage between machine and terminal X4 of connector of MC2/B is 24 V. · Connect terminals of both disconnected connectors by using a clip or the like. · D1 X1 · D17 M18 · D12 (B) · Key switch: ON
· Key switch: OFF NO
Check for continuity between terminals #1 and #3 of relay box.
Disconnect connector MCA-4 of MC2/A. Check for continuity between terminal R8 of harness end connector of connector MCA-4 and terminal R21 of harness end connector of connector MCB-4. Faulty MC2/B.
NO
Connector MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (harness end)
T2BC-05-03-021
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-027
T2BC-05-03-038
T5-3-96
TROUBLESHOOTING / Troubleshooting A
NO
Faulty relay box.
YES
Harness open circuit between MC2/B and relay box.
NO
Harness open circuit 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
Disconnect connector MCB-1 of MC2/B. Disconnect connec tor of boom overhoist YES Check if voltage at terminal D3 of ma switch. chine end connector Check for continuity is 24 V. between terminals ¡ Connect terminals D1 #b and #c of maand X1, D17 and M18, chine end connector. D12 and B of both When operating connectors by using a boom overhoist switch, check for clip or the like. ¡ Key switch: ON continuity between terminals #a and #c of machine end NO connector.
NO
Boom overhoist switch (machine end)
MC2/B Connector MCB-1 (machine end)
c
b
MC2/B Connector MCB-4 (harness end)
a
T25N-05-03-005
Faulty boom overhoist switch.
Connector
Harness open circuit between boom overhoist switch and MC2/B.
Faulty MC2/B.
Faulty MC2/B.
NO
YES
Connect boom overhoist switch. connector Disconnect MCB-4 of MC2/B. continuity Check for between terminal X3 of connector MCB-1 and terminal R16 of connector MCB-4. When operating boom switch, check overhoist for continuity between terminal X3of connector MCB-1 and terminal R3 of connector MCB-4.
T2BC-05-03-021
T2BC-05-03-027
MC2/B Connector MCB-1 (harness 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.
Disconnect connector MCB-1 of MC2/B. Disconnect connector Check if voltage at of boom / tower sec- YES terminal D3 of machine end connector ond overhoist switch. Check for continuity is 24 V. between terminals #1 ¡ Connect terminals D1 and X1, D17 and #2 of machine end connector. and M18, D12 and When operating B of both connecboom / tower second tors by using a overhoist switch, jumper line. check for continuity ¡ Key switch: ON between terminals #1 and #3 of machine NO end connector.
Connect boom / tower 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 connector MCB-4. When operating boom / tower second overhoist switch, check for continuity between terminal X3of connector MCB-1 and terminal R5 of connector MCB-4.
YES
NO
Faulty MC2/B.
Harness open circuit between boom / tower second overhoist switch and MC2/B. Faulty MC2/B.
NO
Faulty boom / tower second overhoist switch.
Connector MC2/B Connector MCB-1 (machine end)
Boom / tower second overhoist switch (machine end)
MC2/B Connector MCB-4 (harness end)
T2BC-05-03-021
T2BC-05-03-059
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-038
T2BC-05-03-027
T5-3-99
TROUBLESHOOTING / Troubleshooting A Check of Tower Overhoist Switch System x Check the wiring connections first.
Disconnect connec tor of tower overhoist switch. Check for continuity between terminals #b and #c of machine end connector. When operating tower overhoist switch, check for continuity between terminals #a and #c of machine end connector.
Disconnect connector MCB-1 of YES MC2/B. Check if voltage at terminal D3 of machine end connector is 24 V. ¡ Connect D1 and X1, D17 and M18, DR and B of both connectors by using a jumper wire. ¡ Key switch: ON
Connect connector of tower overhoist switch. Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X3 YES of connector MCB-1 and R17 of connector MCB-4. When operating tower overhoist switch, check for continuity between terminal X3 of connector MCB-1 and terminal R4 of connector MCB-4.
YES
NO
Harness open circuit between tower overhoist switch and MC2/B.
Faulty MC2/B. NO
Faulty tower overhoist switch.
NO
Faulty MC2/B.
Connector MC2/B Connector MCB-1 (machine end)
Tower overhoist switch (machine end)
c
b
MC2/B Connector MCB-4 (harness end)
T2BC-05-03-021
MC2/B Connector MCB-1 (harness end)
a
T25N-05-03-003
T2BC-05-03-038
T5-3-100
T2BC-05-03-027
TROUBLESHOOTING / Troubleshooting A Check of Jib Overhoist Switch System
x Check the wiring connections first.
Disconnect connector of jib overhoist
switch.
Check for continuity between terminals
#2 and #4 of machine end connector.
When operating jib
overhoist switch, check for continuity between terminals #1 and #3 of machine end connector.
Disconnect connector MCB-1 of MC2/B. YES Check if voltage at terminal D4 of machine end connector is 24 V. ¡ Connect D1 and X1, D17 and M18, D12 and B of both connectors by using a jumper wire. ¡ Key switch: ON
Connect connector of jib overhoist YES Faulty MC2/B. switch. Disconnect con of nector MCB-4 MC2/B. Check for continuity between terminal X4 of conYES nector MCB-1 and Disconnect conHarness open circuit R20 of connector nector CN1 of relay YES between jib overhoist MCB-4. box. switch and MC2/B. When operating jib Check for continuity overhoist switch, between terminals check for continuity #1 and #5 of relay between terminal box end. X4 of connector When operating jib MCB-1 and terminal overhoist switch, NO Faulty relay box. R6 of connector check for continuity MCB-4. NO between terminals #1 and #4.
Faulty MC2/B.
NO
Faulty jib overhoist switch.
NO
Connector
MC2/B Connector MCB-4 (harness end)
MC2/B Connector MCB-1 (machine end)
Jib overhoist switch (machine end)
T2BC-05-03-038 T2BC-05-03-042
T2BC-05-03-027
MC2/B Connector MCB-1 (harness end)
Relay box (machine 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 second over hoist switch. YES Faulty MC2/B. Disconnect con nector MCB-4 of MC2/B. Check for continuity between terminal X4 of connector YES MCB-1 and R22 of Disconnect con Harness open circuit connector MCB-4. nector CN1 of relay YES between jib second When operating jib box. overhoist switch and second overhoist Check for continuity MC2/B. Disconnect connec 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 conof jib second overhoist NO box end. When terminal D4 of manector MCB-1 and operating jib second switch. chine end connector terminal R24 of overhoist switch, Check for continuity Faulty relay box. is 24 V. between terminals #1 connector MCB-4. check for continuity NO between terminals ¡ Connect D1 and and #3 of machine #1 and #8. end connector. X1, D17 and M18, When operating jib Faulty MC2/B. D12 and B of both rhoist second ove connectors by using NO switch, check for cona jumper wire. tinuity between ter¡ Key switch: ON minals #1 and #2 of Faulty jib second machine end conoverhoist switch. NO nector.
Connector
Jib second overhoist switch (machine end)
1
2
3
4
MC2/B Connector MCB-1 (machine end)
T2BC-05-03-038
Relay box (machine end)
T2BC-05-03-021
T5-3-102
T2BC-05-03-027
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-039
MC2/B Connector MCB-4 (harness end)
TROUBLESHOOTING / Troubleshooting A Check of Hook Overhoist Switch System
x Check the wiring connections first.
YES
Faulty MC2/B.
Disconnect connec tor of hook overhoist switch. Check for
continuity between terminals #2 and #4
of machine end connector.
Connect connector of hook overhoist switch. Disconnect connector MCB-4 of YES MC2/B. Check for continuity between terminal X4 of connector MCB-1 and R9 of Disconnect conconnector MCB-4. nector MCB-1 of When operating YES MC2/B. hook overhoist Check if voltage at switch, check for terminal D4 of ma continuity between chine end connecterminal X4 of contor is 24 V. nector MCB-1 and ¡ Connect D1, D12 and terminal R11 of D17 terminals of both connector MCB-4. connectors by using a clip or the like. ¡ Key switch: ON
Disconnect MCB-4 Harness open circuit connector of YES between hook overMC2/B, connect A9 hoist switch and and A11 terminals MC2/B. (harness end) of connector to machine, and check for NO continuity between machine and #1 or #2 terminal (harness end) of conFaulty relay box. nector of hook overhoist switch. NO
Check for continuity
between terminals
#1 and #3 of machine end connector.
Faulty MC2/B.
NO
Faulty hook overhoist switch.
Connector
NO
Hook overhoist switch (machine end)
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-043
T2BC-05-03-027
T2BC-05-03-038
MC2/B Connector MCB-4 (harness end)
Relay box (machine end)
MC2/B Connector MCB-1 (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.
Disconnect connector of backstop alignment overhoist switch. Check for continuity between terminals #2 and #4 of machine end connector. When operating backstop alignment overhoist switch, check for continuity between terminals #1 #3 of machine and end connector.
Connect connector of backstop align ment overhoist YES Faulty MC2/B. switch. Disconnect connector MCB-4 of MC2/B. Check for continuity between terminal X4 Disconnect conYES of connector MCB-1 nector CN1 of relay Harness open circuit and R20 of connecYES between backstop box. tor MCB-4. When alignment overhoist Check for continuity operating backstop switch and MC2/B. between terminals alignment overhoist Disconnect connec#1 and #5 of relay switch, check for tor MCB-1 of MC2/B. box end. continuity between YES Check if voltage at NO When operating terminal X4 of con terminal D4 of mabackstop alignment nector MCB-1 and chine end connector overhoist switch, terminal R6 of conFaulty relay box. is 24 V. check for continuity nector MCB-4. NO between terminals ¡ Connect D1 and #1 and #4. X1, D17 and M18, Faulty MC2/B. D12 and B of both connectors by using NO a jumper wire. ¡ Key switch: ON Faulty backstop alignment overhoist NO switch
Connector
MC2/B
Connector MCB-1
Backstop alignment overhoist switch
MC2/B Connector MCB-4
(machine end)
(harness end)
T2BC-05-03-042
Relay box (machine end)
T2BC-05-03-039
T5-3-104
T2BC-05-03-027
MC2/B Connector MCB-1 (harness end)
T2BC-05-03-038
T2BC-05-03-021
TROUBLESHOOTING / Troubleshooting A Check of Derricking Drum Hoisting Proportional Solenoid Valve System
x Check the wiring connections first.
YES
YES
Disconnect connec tor of derricking drum hoisting proportional
Disconnect connector MCB-5 of MC2/B. Connect terminals Z5 and Z9 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals # 1, #2 of harness end connector of derricking drum hoisting proportional solenoid valve.
Connect terminal D3 of connector MCB-1 to terminal A3 of connector MCB-4 of MC2/B. Check if voltage between terminal Z9 of machine end connector of connector MCB-5 and machine is 0 V. · Key Switch: ON · Derricking drum auto stop release switch: OFF · Connect terminals D3 and A3 by using a jumper wire.
NO
Faulty derricking drum hoisting proportional solenoid valve.
Connector
In case of no continuity at terminal #l, harness open circuit between terminal #1 of derricking drum hoisting proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of derricking drum hoisting proportional solenoid valve and MC2/B.
NO
NO
Check for continuity between terminals #1 and #2 of machine end connector.
Derricking drum hoisting proportional solenoid valve (harness end)
MC2/B
MC2/B
Connector MCB-1
Connector MCB-4
(machine end)
(machine end)
T2BC-05-04-010
T2BC-05-03-021
Harness short circuit between derricking drum hoisting proportional solenoid valve and MC2/B.
Faulty MC2/B.
solenoid valve.
YES
T2BC-05-03-045
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.
YES
Disconnect connec tor of derricking drum lowering proportional
solenoid valve.
Disconnect connector MCB-5 of MC2/B. Connect terminals Z17 and Z21 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals # 1, #2 of harness end connector of derricking drum lowering proportional solenoid valve.
Connect terminal D3 of connector MCB-1 to terminal A3 of connector MCB-4 of MC2/B. YES Check if voltage be tween terminal Z21 of end conmachine nector of connector MCB-5 and machine is 0 V.
NO
Faulty derricking drum lowering proportional solenoid valve.
Connector
In case of no continuity at terminal #2, harness open circuit between terminal #2 of derricking drum lowering proportional solenoid valve and MC2/B, or faulty live mast lower limit switch. In case of no continuity at terminal #1, harness open circuit between terminal #1 of derricking drum lowering proportional solenoid valve and MC2/B.
Faulty MC2/B.
between terminals #1 and #2 of machine end connector.
Harness short circuit between derricking drum lowering proportional solenoid valve and MC2/B.
NO
· Engine: Running · Derricking drum auto stop release switch: OFF · Connect terminals D3 and A3 from the back by using a jumper wire. NO
Check for continuity
YES
Derricking drum lowering proportional solenoid valve (harness end)
MC2/B
Connector MCB-4
MC2/B Connector MCB-1 (machine end)
(machine end)
T2BC-05-03-021
T2BC-05-04-010
T2BC-05-03-045
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
x Check the wiring connections first.
YES
Disconnect connec tor 62C-16FW of left control panel. Check for continuity between terminals R1 and Z16 of panel end connector.
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R1 of harness end connector of connector MCB-4 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals R1, Z16 of harness end connector of connector 62C-16FW.
YES
NO
¡ Auto stop release selection key switch: ON
NO
Connector
In case of no continuity at terminal R1, harness open circuit between terminal R1 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
Faulty MC2/B.
Faulty auto stop release selection key switch.
Left control panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-4 (harness end)
T2BC-05-03-047
T2BC-05-03-027
MC2/B
Left control panel Connector 62C-16FW (harness end)
Connector MCB-5
(harness end)
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.
YES
Disconnect connec tor 62C-16FW of left control panel. Check for continuity between terminals S7 and Z16 of panel end connector. ¡ Derricking drum auto stop release switch: ON
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S7 of harness end connector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals S7, Z16 of harness end connector of connector 62C-16FW.
YES
NO
Connector
Left control panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-3 (harness end)
T2BC-05-03-047
T2BC-05-03-048
Left control panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-046
Faulty derricking drum auto stop release switch.
NO
In case of no continuity at terminal S7, harness open circuit between terminal S7 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
Faulty MC2/B.
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" By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item ATTACHMENT
Signal name Wiring detection
BT OVERH2
Boom/tower second overhoist Jib second overhoist Hook overhoist
JB OVERH2 HK OVERH
FD HST CUR FD LWR CUR
Front drum hoisting proportional solenoid valve Front drum lowering proportional solenoid valve
Description Explanation State Countermeasure SHORT Short circuit on both Priority is given to Harness check crane and tower the selection by IDU for control or error control OPEN Open circuit on both Priority is given to crane and tower the selection by IDU for control or disassembly position control Controls as over- Harness check ALLOFF Open circuit hoist ALLON
Shorted harnesses
LOW ER
Lower limit error
HI ER
Upper limit error
RES ER
Reset error
x For check of limit switch, attachment wiring and auto stop release selection key switch, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-109
PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric current feedback Current control by open loop
Harness check Solenoid valve check MC2/B hardware check
TROUBLESHOOTING / Troubleshooting A
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lowering Proportional Solenoid Valve
Auto Stop Release Front Switch Auto Stop Release Key Switch
Boom Second Overhost Prevention
Crane Relay Box
Main Hook Overhost Prevention Front Drum Hoising Stop
Sub Hook Overhost Prevention
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 Solenoid Valve System
x Check the wiring connections first.
YES
Disconnect connec tor of front drum
hoisting proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect connector MCB-5 of MC2/B. Connect terminals Z6 and Z10 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of front drum hoisting proportional solenoid valve.
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of YES MC2/B. Check if voltage between F10 of materminal chine end connector of connector MCB-5 and machine is 0 V.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum hoisting proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum hoisting proportional solenoid valve and MC2/B.
Connector
Faulty MC2/B.
NO
Faulty front drum hoisting proportional solenoid valve.
NO
Harness short circuit between front drum hoisting proportional solenoid valve and MC2/B.
NO
· Engine: Running · Front drum auto stop release switch: OFF · Connect terminals D3 and A5 by using a jumper wire.
YES
Front drum hoisting proportional solenoid valve (harness end)
MC2/B Connector MCB-1 (machine end)
T2BC-05-03-021
T2BC-05-04-010
T2BC-05-03-044
T5-3-111
T2BC-05-03-045
MC2/B Connector MCB-5 (harness end)
MC2/B Connector MCB-4 (machine end)
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Lowering Proportional Solenoid Valve System
x Check the wiring connections first.
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage between terminal F22 of machine end connector of connector MCB-5 and machine is 0 V.
YES
YES
Disconnect connec-
tor of front drum low-
ering proportional solenoid valve.
Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect connector MCB-5 of MC2/B. Connect terminals Z18 and Z22 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of front drum lowering proportional solenoid valve. · Front drum lock switch: OFF
NO
Connector
Front drum lowering proportional solenoid valve (harness end)
MC2/B
Connector MCB-1 (machine end)
T2BC-05-04-010
T2BC-05-03-045
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-044
T5-3-112
MC2/B Connector MCB-4 (machine end)
T2BC-05-03-021
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front drum lowering proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front drum lowering proportional solenoid valve and MC2/B, or faulty front drum lock switch. Faulty front drum lowering proportional solenoid valve.
NO
Faulty MC2/B. NO
· Engine: Running · Front drum auto stop re switch: OFF lease · Connect terminals D3 and A5from the connector back by using a clip. · Front drum lock switch: OFF
YES
Harness short circuit between front drum lowering proportional solenoid valve and MC2/B.
TROUBLESHOOTING / Troubleshooting A Check of Front Drum Auto Stop Release Switch
x Check the wiring connections first.
YES
Disconnect con-
nector 62C-16FW of left control panel.
Check for continuity between terminals S15 and Z16 of panel connector.
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S15 of harness end connector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals S15, Z16 of harness end connector of connector 62C-16FW.
YES
NO
release switch: ON
Connector
Left control panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-3 (harness end)
T2BC-05-03-046
T2BC-05-03-048
Left control panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-047
Faulty front drum auto stop release switch.
NO
In case of no continuity at terminal S15, harness open circuit between terminal S15 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
¡ Front drum auto stop
Faulty MC2/B.
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". By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item
Signal name
JB FOLD
Jib folding
ATTACHMENT
Wiring detection
Description ALL OFF
Explanation Open circuit
State Controls as jib un-
Countermeasure Harness check
ALL ON
Harness short circuit
folding
SHORT
Short circuit on both
Priority is given to the Harness check
crane and tower
selection by IDU for control or error control
OPEN
Open circuit on both
Priority is given to the
crane and tower
selection by IDU for control or disassembly position control.
RD EOPE ED BT OVERH2
ALL OFF
Open circuit
ALL ON
Harness short circuit
LOW ER
Lower limit error
Controls as overhoist Harness check
Boom/tower second overhoist
TW OVERH
Tower overhoist
JB OVERH
Jib overhoist
JB OVERH2
Jib second overhoist
HK OVERH
Hook overhoist
SWL OVERH
Tower jib backstop alignment overhoist
RD HST CUR
Rear drum hoisting proportional solenoid valve
RD LWR CUR
OFF (stop)
Rear drum lowering proportional solenoid
PWM output short
Harness check
circuit or open circuit Solenoid valve check HI ER
Upper limit error
valve
short circuit OFF (stop) RES ER
Reset error
Abnormal electric current feedback Current control by open loop
x For check of limit switch, attachment wiring and auto stop release selection key switch, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-114
MC2/B hardware
PWM output harness check
TROUBLESHOOTING / Troubleshooting A Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lowering Proportional Solenoid Valve
Auto Stop Release Rear Drum Switch Auto Stop Release Key Switch
Crane Relay Box
Main Hook Overhoist Prevention
Rear Drum Hoisting Stop
Sub Hook Overhoist Prevention
Rear Drum Lowering Stop Shouldering Prevention
Tower Relay Box Tower Breakage Prevention
Tower Jib Overhoist Prevention Tower Jib 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 Solenoid Valve System
x Check the wiring connections first.
YES
YES
Disconnect connector of rear drum
hoisting proportional
Disconnect connector MCB-5 of MC2/B. Connect terminals Z7 and Z11 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of rear drum hoisting proportional solenoid valve.
solenoid valve.
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage between terminal F11 of machine end connector of connector MCB-5 and machine is 0 V.
YES
Faulty MC2/B. NO
· Engine: Running · Rear drum auto stop release switch: OFF · Connect terminals D3 and A5 by using a jumper wire.
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum hoisting proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum hoisting proportional solenoid valve and MC2/B.
NO
Check for continuity
between terminals #1 and #2 of ma-
chine end connector.
Harness short circuit between rear drum hoisting proportional solenoid valve and MC2/B.
Faulty rear drum hoisting proportional solenoid valve.
NO
Connector
MC2/B Connector MCB-4 (machine end)
MC2/B Connector MCB-1 (machine end)
Rear drum hoisting proportional solenoid valve (harness end)
T2BC-05-04-010
T2BC-05-03-021
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-044
T5-3-116
T2BC-05-03-045
TROUBLESHOOTING / Troubleshooting A Check of Rear Drum Lowering Proportional Solenoid Valve System
x Check the wiring connections first.
Connect terminal connector D3 of MCB-1 and terminal A5 of connector YES MCB-4 of MC2/B. Check if voltage between machine and terminal E14 of machine end con of connector nector MCB-6 is 0 V.
Disconnect connec-
tor of rear drum low-
ering proportional solenoid valve. Check for continuity between terminals #1 and #2 of ma chine end connector.
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z19 of harness end connector of connector MCB-5 and terminal YES Y14 of harness end connector of connector MCB-6 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of rear drum lowering proportional solenoid NO valve. · Rear drum lock switch: OFF
Connector
Rear drum lowering proportional solenoid valve (harness end)
In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear drum lowering proportional solenoid valve and MC2/B. In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear drum lowering proportional solenoid valve and MC2/B, or faulty read drum lock switch. Faulty rear drum lowering proportional solenoid valve.
NO
Faulty MC2/B.
Harness short circuit between rear drum lowering proportional solenoid valve and MC2/B.
NO
· Engine: Running · Rear drum auto stop release OFF switch: · Connect terminals D3 and A5 by using a clip or the like at the rear of connector. · Rear drum lock switch: OFF
YES
MC2/B
Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (machine end)
T2BC-05-03-021
T2BC-05-04-010
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-045
T2BC-05-03-044
T2BC-05-03-003
T5-3-117
MC2/B Connector MCB-6 (harness end)
TROUBLESHOOTING / Troubleshooting A Check of Rear Drum Auto Stop Release Switch
x Check the wiring connections first.
YES
Disconnect con nector 62C-16FW
of left control panel.
Check for continuity between terminals
S8 and Z16 of
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S8 of harness end connector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminals S8, Z16 of harness end connector of connector 62C-16FW.
YES
Faulty MC2/B.
In case of no continuity at terminal S8, harness open circuit between terminal S8 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
NO
panel end connec ¡ Rear drum auto
stop release switch:
ON
Faulty rear drum auto stop release switch.
NO
Connector MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
T2BC-05-03-046
T2BC-05-03-048
Left control panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (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". By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item ATTACHMENT
Signal name Wiring detection
Description SHORT
OPEN
BT OVERH2 JB OVERH2 HK OVERH
3D HST SOL 3D LWR SOL
Explanation State Countermeasure Short circuit on both Priority is given to Harness check crane and tower the selection by IDU for control or error control. Open circuit on both Priority is given to crane and tower the selection by IDU for control or disassembly position control. Controls as over- Harness check Open circuit hoist
Boom/tower second overhoist Jib second overhoist Hook overhoist
ALLOFF
ALLON
Harness short circuit
Third drum hoisting solenoid valve Third drum lowering solenoid valve
ERROR
Short circuit
x For check of limit switches, attachment wiring and auto stop release selection key switches, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-119
OFF (stop)
Harness check Solenoid valve check
TROUBLESHOOTING / Troubleshooting A
Auto Stop Release Third / Fourth Drum Switch Auto Stop Release Key Switch
Boom Second Overhost Prevention
Crane Relay Box
Fourth Drum Hoisting Stop Third Drum Lowering Stop
Main Hook Overhoist Prevention
Shouldering Prevention
Sub Hook Overhoist Prevention
Third Drum Hoisting Solenoid Valve Fourth Drum Hoisting Solenoid Valve
Third Drum Lowering Solenoid Valve
Fourth Drum Lowering Solenoid Valve
T2BC-05-03-049
T5-3-120
TROUBLESHOOTING / Troubleshooting A Check of Third Drum Hoisting Solenoid Valve System
x Check the wiring connections first.
YES
YES
Disconnect connector of third drum
Disconnect connector third/fourth drum selection (upper) relay. Connect terminal 377 of connector to machine end. Check for continuity between machine and terminals #1, #2 of harness end of connector of third drum hoisting solenoid valve.
NO
NO
Faulty third drum hoisting solenoid valve.
Connector
In case of no continuity at terminal #1, harness open circuit between relay and third drum hoisting solenoid valve. In case of no continuity at terminal #2, faulty ground of third drum hoisting solenoid valve.
valve. Check for continuity between terminals #1 and #2 of machine end connector.
¡ Engine: Running ¡ Third / fourth selection switch: Third
hoisting solenoid
Check if voltage at terminal 387 of relay harness end connector is 24 V.
Third drum hoisting solenoid valve (harness end)
Third / fourth drum selection (upper) relay (harness end)
MC2/B Connector MCB-6 (harness end)
T2BC-05-03-003
T2BC-05-04-010
MC2/B
T2BC-05-03-050
Connector MCB-6 (machine end)
T2BC-05-03-032
T5-3-121
TROUBLESHOOTING / Troubleshooting A YES
YES
Disconnect connector MCB-6 of MC2/B. Connect terminal Y7 of harness end connector of connector MCB-6 to machine. Check for continuity between machine and terminal #1 of harness end connector of third drum hoisting solenoid valve.
YES
Faulty MC2/B.
Faulty harness between MC2/B and relay, or faulty relay.
NO
Harness short circuit between third drum hoisting solenoid valve and MC2/B.
NO
· Engine: Running · Third drum auto stop release switch: OFF · Connect terminals D3 and A5 by using a clip or the like at the rear of connector. · Third / fourth selection switch: Third
· Connect relay harness. · Third / fourth selection switch: Third
Connect terminal D3 of connector MCB-1 and ter minal A5 of connector MCB-4 of MC2/B. Check if voltage between machine and terminal Y17 of machine end connector of connector MCB-6 is 0 V.
NO
Faulty third / fourth selection switch.
Connector
MC2/B Connector MCB-1 (Machine end)
MC2/B
Connector MCB-4
(Machine end)
T2BC-05-03-021
T2BC-05-03-045
T2BC-05-03-003
T5-3-122
MC2/B Connector MCB-6 (Machine end)
TROUBLESHOOTING / Troubleshooting A Check of Third Drum Lowering Solenoid Valve System
In case of no continuity at terminal #2, faulty ground of third drum lowering solenoid valve. In case of no continuity at terminal #1, harness open circuit between relay and third drum lowering solenoid valve.
• Check the wiring connections first.
YES
Disconnect connec-
tor of third drum low ering solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect connector third drum lowering relay. Connect terminal 388 of connector to machine end. Check for continuity between machine and terminals #1, #2 of harness end of connector of third drum lowering solenoid valve.
NO
Check if voltage at terminal 295 of connector of third drum lowering stop relay is 24 V.
YES
¡ Third / fourth brake mode selection switch: AUTO
NO
Faulty third drum lowering solenoid valve.
Connector
Third drum lowering solenoid valve (harness end)
Third drum lowering stop relay (harness end)
Third / fourth drum selection (lower) relay (harness end)
T2BC-05-04-010
T2BC-05-03-052
T2BC-05-03-051
T5-3-123
TROUBLESHOOTING / Troubleshooting A
NO
NO
Check if third / fourth auto mode lamp (green) is turned on.
YES
YES
Check if voltage at terminal 378 of connector of third YES drum lowering stop relay is 24V.
YES
¡ Third / fourth drum selection switch: Third
NO
Disconnect connector of third / fourth drum selection (lower) relay. Check for continuity between terminal 378 of harness end connector of third / fourth drum selection (lower) relay and terminal 378 of harness end connector of third drum lowering stop relay.
NO
MC2/B Connector MCB-1 (machine end)
Connector of third / fourth drum selection (harness end)
MC2/B Connector MCB-4 (machine end)
T2BC-05-03-003
Faulty third / fourth drum selection (lower) relay or faulty third / fourth drum selection switch. Harness open circuit between third / fourth drum selection (lower) relay and third drum lowering stop relay.
Connector
NO
A
MC2/B Connector MCB-6 (harness end)
Check if voltage at terminal 378 between harness of third / fourth drum selection (lower) relay connector is 24V.
YES
Faulty third drum lowering stop relay.
Harness open circuit between free mode switch and third drum lowering stop relay.
Faulty MC2/A.
T2BC-05-03-021
Connector of third drum lowering relay (harness end)
T2BC-05-03-045
MC2/B Connector MCB-6 (machine end)
T2BC-05-03-032
T2BC-05-03-051
T2BC-05-03-060
T5-3-124
TROUBLESHOOTING / Troubleshooting A
YES
Connect disconnected relay harness. Disconnect connector MCB-6 of MC2/B. Connect terminal Y21 of harness end connector of connector MCB-6 to machine. Check for continuity between terminal #1 of harness end connector of third drum lowering solenoid valve and machine.
A
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. Check if voltage at terminal E21 of machine end of connector MCB-6 is 0 V.
Harness short circuit between third drum lowering solenoid valve and MC2/B.
YES
Faulty MC2/B. NO
· Engine: Running stop · Third drum auto release switch: OFF · Connect terminals D3 and A5 by using a clip or the like at the rear of connector.
Harness open circuit between MC2/B and relay.
NO
Connector
Third drum lowering solenoid valve (harness end)
MC2/B Connector MCB-6 (harness end)
MC2/B Connector MCB-4 (machine end)
T2BC-05-03-003
T2BC-05-04-010
T2BC-05-03-045
MC2/B Connector MCB-6 (machine end)
MC2/B Connector MCB-1 (machine end)
T2BC-05-03-021
T2BC-05-03-032
T5-3-125
TROUBLESHOOTING / Troubleshooting A Check of Third Drum Auto Stop Release Switch
x Check the wiring connections first.
YES
Disconnect connec tor 62C-16FW of left
control panel. Check
for continuity be-
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S16 of harness end connector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal S16, Z16 of harness end connector of connector 62C-16FW.
YES
Faulty MC2/B.
In case of no continuity at terminal S16, harness open circuit between terminal S16 of connector 62C-16FW of left control panel andMC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel andMC2/B.
NO
tween terminals S16
and Z16 of panel end
connector. ¡ Third / fourth drum auto stop release switch: ON
Faulty third / fourth drum auto stop release switch.
NO
Connector MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
T2BC-05-03-046
T2BC-05-03-048
MC2/B Connector MCB-5 (harness end)
Left control panel Connector 62C-16FW (panel end)
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". By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item ATTACHMENT
Signal name Wiring detection
Description SHORT
OPEN
BT OVERH2 JB OVERH2 HK OVERH
3D HST SOL 3D LWR SOL
Explanation State Countermeasure Short circuit on both Priority is given to Harness check crane and tower the selection by IDU for control or error control. Open circuit on both Priority is given to crane and tower the selection by IDU for control or disassembly position control. Controls as over- Harness check Open circuit hoist
Boom/tower second overhoist Jib second overhoist Hook overhoist
ALLOFF
ALLON
Harness short circuit
Fourth drum hoisting solenoid valve Fourth drum lowering solenoid valve
ERROR
Short circuit
x For check of limit switches, attachment wiring and auto stop release selection key switches, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-127
OFF (stop)
Harness check Solenoid valve check
TROUBLESHOOTING / Troubleshooting A
Auto Stop Release Third / Fourth Drum Switch Auto Stop Release Key Switch
Boom Overhoist Prevention
Crane Relay Box
Fourth Drum Hoisting Prevention Third Drum Hoisting Prevention
Main Hook Overhoist Prevention
Shouldering Prevention
Sub Hook Overhoist Prevention
Third Drum Hoisting Solenoid Valve Fourth Drum Hoisting Solenoid Valve
Third Drum Lowering Solenoid Valve Fourth Drum Lowering Solenoid Valve
T2BC-05-03-049
T5-3-128
TROUBLESHOOTING / Troubleshooting A Check of Fourth Drum Hoisting Solenoid Valve System
x Check the wiring connections first.
YES
YES
Disconnect connector of fourth drum
hoisting solenoid
Disconnect connector third / fourth drum selection (upper) relay. Connect terminal 379 of connector to machine end. Check for continuity between machine and terminals #1, #2 of harness end of connector of fourth drum hoisting solenoid valve.
valve. Check for continuity between terminals #1 and #2 of ma chine end connector.
Check if voltage at terminal 387 of relay harness end connector is 24 V.
¡ Engine: Running ¡ Third / fourth selection switch: Fourth
NO
NO
In case of no continuity at terminal #1, harness open circuit between relay and fourth drum hoisting solenoid valve. In case of no continuity at terminal #2, faulty ground of fourth drum hoisting solenoid valve.
Faulty fourth drum hoisting solenoid valve.
Connector
Fourth drum hoisting solenoid valve (harness end)
MC2/B Connector MCB-6 (harness end)
Third / fourth drum selection (upper) relay (harness end)
T2BC-05-03-003
T2BC-05-04-010
Fourth drum hoisting solenoid valve (machine end)
T2BC-05-03-050
T2BC-05-03-061
T5-3-129
TROUBLESHOOTING / Troubleshooting A
YES
YES
Disconnect connector MCB-6 of MC2/B. Connect terminal Y7 of harness end connector of connector MCB-6 to machine. Check for continuity between machine and terminal #1 of harness end connector of fourth drum hoisting solenoid valve.
NO
Faulty harness between MC2/B and relay, or faulty relay.
Faulty third / fourth selection switch.
NO
Connector
MC2/B
Faulty MC2/B.
Connector MCB-1 (machine end)
Harness short circuit between fourth drum hoisting solenoid valve and MC2/B.
NO
YES
· Engine: Running · Third drum auto stop release switch: OFF · Connect terminals D3 and A5 by using a clip or the like at the rear of connector. · Third / fourth selection switch: Fourth
· Connect relay harness. · Third / fourth selection switch: Fourth
Connect terminal D3 of connector MCB-1 to ter minal A5 of connector MCB-4 of MC2/B. Check if voltage between machine and terminal E7 of machine end connector of connector MCB-6 is 0 V.
MC2/B Connector MCB-4 (machine end)
T2BC-05-03-021
T2BC-05-03-045
T2BC-05-03-032
T5-3-130
MC2/B Connector MCB-6 (machine end)
TROUBLESHOOTING / Troubleshooting A Check of Fourth Drum Lowering Solenoid Valve System
• Check the wiring connections first.
YES
Disconnect connec-
tor of fourth drum
lowering solenoid
Disconnect connector of third/fourth drum selection (lower) relay. Connect terminal 380 of connector to machine end. Check for continuity between machine and terminals #1, #2 of harness end of connector of fourth drum lowering solenoid valve. · Fourth drum lock switch: OFF
valve. Check for continuity between terminals #1 and #2 of ma chine end connector.
YES
· Engine: Running · Third/fourth selection switch: Fourth
NO
NO
Connector
Fourth drum lowering valve (harness end)
solenoid
Third / fourth drum selection (lower) relay (harness end)
T2BC-05-04-010
T2BC-05-03-051
T5-3-131
In case of no continuity at terminal #1, harness open circuit between relay and fourth drum lowering solenoid valve, or faulty fourth drum lock switch. In case of no continuity at terminal #2, faulty ground of fourth drum lowering solenoid valve. Faulty fourth drum lowering solenoid valve.
Check if voltage at terminal 387 of relay harness end connector is 0 V.
TROUBLESHOOTING / Troubleshooting A YES
YES
Disconnect connector MCB-6 of MC2/B. Connect terminal Y21 of harness end connector of connector MCB-6 to machine. Check for continuity between terminal #1 of harness end connector of fourth drum lowering solenoid valve and machine.
YES
Faulty harness between MC2/B and relay, or faulty relay.
Faulty third/fourth selection switch.
Connector
MC2/B Connector MCB-1 (machine end)
MC2/B Connector MCB-4 (machine end)
Fourth drum lowering solenoid valve (harness end)
MC2/B Connector MCB-6 (harness end)
T2BC-05-03-021
Faulty MC2/B. NO
NO
Harness short circuit between fourth drum lowering solenoid valve and MC2/B.
YES
· Engine: Running · Third / fourth drum auto stop release switch: OFF · Connect terminals D3 and A5 by using a clip or the like at the rear of connector. · Third / fourth selection switch: Fourth
· Fourth drum lock switch: OFF · Engine: Running · Third / fourth selection switch: Fourth
Connect terminal D3 of connector MCB-1 to ter minal A5 of connector MCB-4 of MC2/B. Check if voltage at terminal E21 of machine end connector of connector MCB-6 is 0 V.
T2BC-05-03-045
T2BC-05-03-003
MC2/B 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.
YES
Disconnect connector 62C-16FW of left control panel.
Check for continuity between terminals
Disconnect connectors MCB-3 and MCB-5 of MC2/B. Connect terminal S16 of harness end connector of connector MCB-3 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal S16, Z16 of harness end connector of connector 62C-16FW.
YES
Faulty MC2/B.
In case of no continuity at terminal S16, harness open circuit between terminal S16 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
NO
S16 and Z16 of panel
end connector. ¡ Third / fourth drum auto stop release switch: ON
Faulty third / fourth drum auto stop release switch.
NO
Connector MC2/B Connector MCB-3 (harness end)
Left control panel Connector 62C-16FW (harness end)
T2BC-05-03-046
T2BC-05-03-048
Left control panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (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". By using the MC2/B input/output monitor, confirm the limit switch and solenoid valve signals. Item ATTACHMENT
Signal name Wiring detection
Description SHORT
OPEN
BT OVERH2 JB OVERH2 OVERH2 SOL
Boom/tower second overhoist Jib second overhoist
ALLOFF
Second overhoist solenoid valve
ERROR
ALLON
Explanation State Countermeasure Short circuit on both Priority is given to Harness check crane and tower the selection by IDU for control or error control. Open circuit on both Priority is given to crane and tower the selection by IDU for control or disassembly position control Controls as over- Harness check Open circuit hoist. Harness short circuit Short circuit OFF (stop) Harness check Solenoid valve check
x For check of limit switches and attachment wiring, refer to Section "Failure of Derricking Drum Auto Stop Control System".
T5-3-134
TROUBLESHOOTING / Troubleshooting A
Second Overhoist Solenoid Valve.
Remote Control Pressure Restoration Switch
Boom Overhoist Prevention
Tower Relay Box
Tower Jib Second Overhoist Prevention
T2BC-02-01-018
T5-3-135
TROUBLESHOOTING / Troubleshooting A Check of Second Overhoist Solenoid Valve System
x Check the wiring connections first.
Disconnect connec-
Disconnect connector MCB-6 of MC2/B. Connect terminals Y17 and Y26 of harness end connector of connector YES MCB-6 to machine. Check for continuity between machine and terminals #1, #2 of harness end connector of second overhoist solenoid valve.
Connect terminal D3 of connector MCB-1 to terminal A5 of connector MCB-4 of MC2/B. YES Check if voltage be terminal E17 tween of machine end connector of con MCB-6 and nector machine is 0 V.
NO
Connector
Second overhoist solenoid valve (harness end)
In case of no continuity at terminal #1, harness open circuit between terminal #1 of second overhoist solenoid valve andMC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of second overhoist solenoid valve andMC2/B, or faulty ground.
Faulty second overhoist solenoid valve.
NO
Faulty MC2/B.
hoist solenoid valve. Check for continuity between terminals #1 and #2 of ma chine end connector.
Harness short circuit between second overhoist solenoid valve and MC2/B.
NO
· Engine: Running · Second overhoist restoration switch: OFF · Connect terminals D3 and using a clip or the like A5 by at the rear of connector.
tor of second over-
YES
MC2/B
MC2/B
Connector MCB-1 (machine end)
(machine end)
Connector MCB-4
T2BC-05-04-010
T2BC-05-03-021
T2BC-05-03-045
MC2/B
MC2/B Connector MCB-6 (harness end)
Connector MCB-6
T2BC-05-03-003
T2BC-05-03-032
T5-3-136
(machine end)
TROUBLESHOOTING / Troubleshooting A Check of Second Overhoist Restoration Switch
x Check the wiring connections first.
YES
Disconnect connec-
tor 62C-16FW of left
control panel. Check for continuity be-
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R14 of harness end connector of connector MCB-4 and terminal Z16 of harness end connector of connector MCB-5 to machine. Check for continuity between machine and terminal R14, Z16 of harness end connector of connector 62C-16FW.
YES
Faulty MC2/B.
In case of no continuity at terminal R14, harness open circuit between terminal R14 of connector 62C-16FW of left control panel and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of connector 62C-16FW of left control panel and MC2/B.
NO
tween terminals R14 and Z16 of panel end
connector.
¡ Second overhoist
restoration switch: Cancellation
Faulty second overhoist restoration switch.
NO
Connector MC2/B Connector MCB-4 (harness end)
Left stand panel Connector 62C-16FW (harness end)
T2BC-05-03-046
T2BC-05-03-027
Left stand panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (harness end)
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". By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals. Item FM CAP CUR
RM CAP CUR
Signal name Front motor displacement angle control proportional solenoid valve
Rear motor displacement angle control proportional solenoid valve
Description LOW ER
Explanation Lower limit error
HI ER
Upper limit error
RES ER
Reset error
LOW ER
Lower limit error
HI ER
Upper limit error
RES ER
Reset error
T5-3-138
State PWM output short circuit or open circuit Minimum motor capacity PWM output harness short circuit Minimum motor capacity Abnormal electric current feedback Current control by open loop PWM output short circuit or open circuit Minimum motor capacity PWM output harness short circuit Minimum motor capacity Abnormal electric current feedback Current control by open loop
Countermeasure Harness check
Harness check Solenoid valve check MC2/B hardware check
Harness check
Harness check Solenoid valve check MC2/B hardware check
TROUBLESHOOTING / Troubleshooting A
Front Motor Displacement Angle Proportinal Solenoid Valve
Hoisting Displacement Angle Lock Switch
Rear Motor Displacement Angle Proportinal Solenoid Valve
T2BC-05-03-053
T5-3-139
TROUBLESHOOTING / Troubleshooting A Check of Front Motor Displacement Angle Control Proportional Solenoid Valve System
x Check the wiring connections first.
YES
Disconnect connec-
tor of front motor displacement angle control proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z8 of harness end connector of connector MCB-5 and terminal Y1 of harness end of connector MCB-6 to machine. Check for continuity between terminals #1, #2 of harness end connector of front motor displacement angle control proportional solenoid valve and machine.
Check if voltage terminal between Y1 of machine end YES connector of connector MCB-6 and machine is 0 V.
· Connect terminals E12 and Y12, E13 and Y13 by using a clip. · Key switch: ON low speed · Hoisting switch: OFF
NO
NO
Faulty front motor displacement angle control proportional solenoid valve.
Connector
In case of no continuity at terminal #1, harness open circuit between terminal #1 of front motor displacement angle control proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of front motor displacement angle control proportional solenoid valve and MC2/B.
Faulty MC2/B. NO
Harness short circuit between front motor displacement angle control proportional solenoid valve and MC2/B.
YES
Front motor displacement angle control proportional solenoid valve (harness end)
MC2/B Connector MCB-5 (harness end)
MC2/B Connector MCB-6 (harness end)
T2BC-05-03-003
T2BC-05-03-044 T2BC-05-04-010
MC2/B
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.
YES
Disconnect connector of rear motor dis-
placement angle control proportional solenoid valve. Check for continuity between terminals #1 and #2 of machine end connector.
Disconnect connectors MCB-5 and MCB-6 of MC2/B. Connect terminal Z20 of harness end connector of connector MCB-5 and terminal Y15 of harness end of connector MCB-6 to machine. Check for continuity between terminals #1, #2 of harness end connector of rear motor displacement angle control proportional solenoid valve and machine.
Check if voltage terminal between Y15 of machine end YES connector of connector MCB-6 and machine is 0 V.
Faulty MC2/B.
· Connect terminals E12 and Y12, E13 and Y13 by using a clip. · Key switch: ON low speed · Hoisting switch: OFF
NO
In case of no continuity at terminal #1, harness open circuit between terminal #1 of rear motor displacement angle control proportional solenoid valve and MC2/B. In case of no continuity at terminal #2, harness open circuit between terminal #2 of rear motor displacement angle control proportional solenoid valve and MC2/B.
NO
Harness short circuit between rear motor displacement angle control proportional solenoid valve and MC2/B.
YES
NO
Faulty rear motor displacement angle control proportional solenoid valve.
Connector
Rear motor displacement angle control
proportional solenoid valve (h arness end)
MC2/B Connector MCB-5 (harness end)
MC2/B Connector MCB-6 (harness end)
MC2/B
T2BC-05-03-044 T2BC-05-04-010
T2BC-05-03-003
Connector MCB-6
(machine end)
Rear motor displacement angle control proportional solenoid valve (machine end)
T2BC-05-03-032
T2BC-05-03-031
T5-3-141
TROUBLESHOOTING / Troubleshooting A Check of Hoisting Low Speed Lock Switch
x Check the wiring connections first.
YES
Disconnect connec-
tor 62C-16FW of side upper panel.
Check for continuity between terminals R15 and Z16 of panel end connector.
Disconnect connectors MCB-4 and MCB-5 of MC2/B. Connect terminal R15 of harness end connector of connector MCB-4 and terminal Z16 of harness end of connector MCB-5 to machine. Check for continuity between terminals R15, Z16 of harness end connector of connector 62C-16FW and machine.
YES
Faulty MC2/B.
In case of no continuity at terminal R15, harness open circuit between terminal R15 of side upper panel of connector 62C-16FW and MC2/B. In case of no continuity at terminal Z16, harness open circuit between terminal Z16 of side upper panel of connector 62C-16FW and MC2/B.
NO
¡ Hoisting low speed lock switch: ON
Faulty hoisting low speed lock switch.
NO
Connector Side upper panel Connector 62C-16FW (harness end)
MC2/B Connector MCB-4 (harness end)
T2BC-05-03-054
T2BC-05-03-027
Side upper panel Connector 62C-16FW (panel end)
MC2/B Connector MCB-5 (harness end)
T2BC-05-03-055
T2BC-05-03-044
T5-3-142
TROUBLESHOOTING / Troubleshooting A FAILURE OF FRONT DRUM SURGE PRESSURE REDUCTION 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". By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals. Item FD HST CUR
FD LWR CUR
Signal name Front drum hoisting proportional solenoid valve
Front drum lowering proportional solenoid valve
Description LOW ER
Explanation Lower limit error
HI ER
Upper limit error
RES ER
Reset error
LOW ER
Lower limit error
HI ER
Upper limit error
RES ER
Reset error
x For check of front drum hoisting proportional solenoid valve and front drum lowering proportional solenoid valve, refer to Section "Failure of Front Drum Auto Stop Control System".
T5-3-143
State PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric power feedback Controls electric current by open loop. PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric power feedback Controls electric current by open loop.
Countermeasure Harness check
Harness check Solenoid valve check MC2/B hardware check
Harness check
Harness check Solenoid valve check MC2/B hardware check
TROUBLESHOOTING / Troubleshooting A
Front Drum Hoisting Proportional Solenoid Valve
Front Drum Lock Switch
Front Drum Lowering Proportional Solenoid Valve
Shouldering Prevention
T2BC-05-03-056
T5-3-144
TROUBLESHOOTING / Troubleshooting A FAILURE OF TOWER JIB DERRICKING 2-SPEED FLOW COMBINING LIMIT 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". By using the MC2/B input/output monitor, confirm the sensor and solenoid valve signals. Item RD HST CUR
RD LWR CUR
Signal name Rear drum hoisting proportional solenoid valve
Rear drum lowering proportional solenoid valve
Description LOW ER
Explanation Lower limit error
HI ER
Upper limit error
RES ER
Reset error
LOW ER
Lower limit error
HI ER
Upper limit error
RES ER
Reset error
x For check of rear drum hoisting proportional solenoid valve and rear drum lowering proportional solenoid valve, refer to Section "Failure of Rear Drum Auto Stop Control System".
T5-3-145
State PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric power feedback Controls electric current by open loop PWM output short circuit or open circuit OFF (stop) PWM output harness short circuit OFF (stop) Abnormal electric power feedback Controls electric current by open loop
Countermeasure Harness check
Harness check Solenoid valve check MC2/B hardware check
Harness check
Harness check Solenoid valve check MC2/B hardware check
TROUBLESHOOTING / Troubleshooting A
Rear Drum Hoisting Proportional Solenoid Valve
Rear Drum Lock Switch
Front Drum Lowering Proportional Solenoid Valve
Shouldering Prevention
T2BC-05-03-057
T5-3-146
TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Troubleshooting procedures are used for failure diagnosis based on trouble phenomena.
x How to read troubleshooting flowchart YES(OK)
(2)
(1) According to the result of inspection or measurement in (1), select YES (OK) or NO (NO OK), and go to the next step (2) or (3).
(1)
NO(NOT OK)
(3)
· Key switch: ON
Under the box, inspection or measurement method, or reference may be added. Be careful that if incorrect inspection or measuring method will make it difficult to find the cause of failure, or may damage the equipment.
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 Failure sections
Failure phenomena E-1 Starter does not run. E-2 Starter runs but the engine does not start. E-3 Poor engine starting ability at low temperature (no preheating)
Engine system
E-4 After completion of preheating, after-heating does not work. E-5 Idle speed is too fast or slow. E-6 Maximum un-load speed is too slow. E-7 Engine does not stop.
Actuator system
A-1 Two or more actuators do not work. A-2 Even when moving control lever to neutral, actuator does not stop. M-1 Drum does not rotate. M-2 When moving hoisting lever to neutral, the lifting load lowers (in the auto brake mode). M-3 Even when setting brake mode key switch to auto brake position, auto brake indicator (green) is not turned ON.
Hoisting drum system
M-4 Even when switching to the free mode, auto brake indicator (green) is not turned OFF. M-5 Even when setting free mode switch of drum to ON position, free-fall cannot be done. M-6 Even when setting to the free mode, drum free indicator (red) is not turned ON. M-7 Even when setting to the auto brake mode, drum free indicator (red) is not turned OFF.
Boom derricking drum system
B-1 Drum does not rotate.
Slewing system
S-1 Slewing speed is too slow, or slewing is disabled.
Travel system
T-1 One-side track does not run, travel speed is too slow, or mistrack is caused. T-2 Travel speed cannot be shifted. O-1 Drum lock does not work. O-2 Counterweight (optional) cannot be removed and installed..
Miscellaneous
O-3 Jack-up (optional) cannot be done. O-4 Retraction cannot be done (with jack (optional) attached). O-5 Retraction cannot be done (by using a switch in cab).
T5-4-2
TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not run. • Check if front, rear, and third / fourth brake mode selection switches are set to the auto brake position, slewing brake switch is set to the brake position, and the emergency stop switch in side overhead panel is released. • Check the wiring connections first. • A failure that starter does not run is not related to electronic control systems such as MC2/A, MC2/B and IDU.
Broken harness between starter motor and ground, or faulty ground.
YES
Connect starter motor ground line to machine. Check if starter runs.
· Key switch: START
YES
Check if voltage between C terminal of key YES switch and machine is 24V or more.
Check for continuity between terminal B of starter motor and terminal B of starter relay 1. NO Check for continuity between terminal S of starter motor and terminal S of starter relay.
(A)
· Key switch: START · Insert a test bar into the rear of connector. Broken harness between terminal B of starter motor and terminal B of starter relay 1. NO Broken harness between terminal S of starter motor and terminal S of starter relay 1.
Check if voltage between machine
and terminal B of starter motor is 24V or more.
· Key switch: ON
To “Failure of power supply system”
NO
Connector
Key switch (Harness end)
Starter Relay 1
Starter Relay 1 Connector
Terminal C
Terminal B Terminal S
T333-05-04-012
T2BC-05-04-002
T5-4-3
Starter Motor
TROUBLESHOOTING / Troubleshooting B YES
Disconnect connector of engine starting relay. Check if voltage between machine and terminal #3 (harness end) of connector is 24 V or more.
Disconnect connector of starter relay. Connect terminal SW (harness end) YES of connector to machine. Check for continuity between terminal #5 (harness end) of connector of engine starting relay and machine.
· Key switch: START
N
NO
N
To “Failure of engine start interlock control system” in “Troubleshooting A”.
Broken harness between engine starting relay and starter relay 1. Broken harness between key switch and engine start relay.
· Key switch: START
(A)
Connect connector of engine starting relay. YES Check if voltage between machine and terminal SW (harness end) of connector is 24 V or more.
Connect terminal L (harness end) of connector of starter relay to machine. DisconYES nect connector of starter relay 2. Check for continuity between machine and terminal S (harness end) of connector.
Faulty key switch.
NO
Connector
Engine Starting Relay (Harness end)
Starter Relay 1 (Harness end)
Terminal L
Terminal SW
Terminal #3
T5-4-4
(B)
TROUBLESHOOTING / Troubleshooting B
Disconnect connector of starter relay 2. YES Check if voltage between machine and terminal R (harness end) of connector is 24 V or more.
YES
(B)
Connect connector of starter relay 2. Check if electric current at terminal L (harness end) of connector of starter relay 1 is 0A.
¡ Key switch: ON N
¡ Key switch: START
Broken harness between key switch and starter relay 2.
Faulty starter relay.
NO
Check if voltage between machine YES and terminal P (harness end) of Check for continuconnector of ity between maYES chine and terminal starter relay 2 is 0 E (harness end) of Broken harness connector of between starter starter relay 2. relay 2 and N ground, or faulty ground.
Broken harness between starter relay 2and starter relay 1.
N
YES
Faulty starter relay 2.
(C)
Faulty alternator, or short-circuited harness between alternator and starter relay 2.
N
Connector Starter Relay 2 (Harness end) Terminal S
Starter Relay 1 (Harness end) Terminal R
Terminal L Terminal E
Terminal SW
Terminal P
T5-4-5
(C)
TROUBLESHOOTING / Troubleshooting B POWER SUPPLY SYSTEM FAILURE
Broken harness between battery relay and starter motor‍ޕ‏
YES
Disconnect 206 harness of battery relay. Check if voltage at terminal (machine end) is 24V or more. ¡ Key switch: ON
YES
YES
NO
Check if battery voltage and specific gravity of battery electrolyte are normal.
Connect 206 harness. Connect terminal ( ) of battery to machine. Check if voltage between machine and terminal B of starter motor is 24V or more. ¡ Key switch: ON
Broken harness between battery relay and ground, or faulty ground.
Disconnect harness from terminal ( ) of battery to machine. Disconnect connector of key switch. NO Check for continuity between machine end terminal B (harness end) of connector.
NO
T5-4-6
Faulty battery.
TROUBLESHOOTING / Troubleshooting B
Connect the disconnected harness to connecYES tor. Check if voltage between machine and terminal ACC of key switch is 24V or
Disconnect 264 harness of battery relay. Connect 264 harness to machine. Check for continuity between machine and terminal ACC (harness end) of key switch connector.
YES
· Key switch: ON · Insert a test bar into the rear of connector.
Connect ground terminal of battery relay to machine. YES Check if voltage between machine and terminal B of starter motor is 24V or more. · Key switch: ON
Broken harness YES between battery relay and ground, or faulty ground.
N
Faulty battery relay.
Faulty key switch. N Broken harness or fuse #20 between key switch and battery relay.
NO
Broken harness between battery and key switch.
NO
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 during cranking. If normal, the cause of failure may be malfunction of engine itself. • Check the wiring connections first.
YES
Faulty engine.
Check if engine governor lever moves to the start position.
YES
Faulty battery.
· Key switch: ON
· Visual check
NO
Connect terminal GD2 (harness end) of engine stop solenoid to machine. Check if engine governor lever moves to the start position. · Key switch: ON · Visual check
NO
Check if voltage between machine and terminal 209 (harness end) of engine stop solenoid is 24V or more. · Key switch: ON
YES Faulty engine stop solenoid.
NO
Connect terminal #4 of engine stop relay to machine. Check if 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 stop relay and ground, or faulty ground.
YES
YES
Disconnect engine stop relay from connector. Check if voltage between machine NO and terminal #2 (harness end) of connector is 24 V.
Check if voltage between machine YES and terminal #1 (harness end) of connector of engine stop relay is 24 V or more. ¡ Key switch: ON
NO
Connect 209 harness of engine stop solenoid to machine. Check for continuity between terminal #6 (harness end) of connector of engine start relay and machine.
YES Faulty engine stop relay.
Broken harness between engine stop relay and enNO gine stop solenoid.
Broken harness between key switch and engine stop relay. Broken harness between engine stop relay and battery relay.
¡ Key switch: ON NO
T5-4-9
TROUBLESHOOTING / Troubleshooting B E-3 Poor engine starting ability at low temperature (no preheating)
• The machine is equipped with an automatic preheating system. This automatic preheating system is automatically turned ON only when setting key switch to ON position at coolant temperature of 0°C or lower. Notice that preheating is not carried out at coolant temperature of 0°C or higher. Also, preheating time changes depending on coolant temperature. For preheating, refer to Chapter “Electric system” in “Operational Principle”. • Check a fuse of heater relay first. YES • Check the wiring connections first.
· Key switch: ON · Check within 15 seconds after turning key switch ON.
YES
Check if voltage between machine and terminal 217 (harness end) of heater relay is
Check if voltage between machine and air heater power terminal of engine is 24V.
Broken harness YES between heater relay and air heater. Check if voltage between machine and terminal 206 NO (harness end)of heater relay is · Key switch: ON
· Key switch: ON Check if coolant temperature is 0 qC or lower.
NO
Faulty air heater or faulty ground.
Air heater does not work. (Normal)
NO
T5-4-10
TROUBLESHOOTING / Troubleshooting B
Faulty heater relay or faulty ground.
YES
Remove plug from heater relay. YES Check if voltage between machine and harness end plug is 24 V.
Broken harness between preheat controller and heater relay.
YES
· Key switch: ON
NO
Check if voltage between machine and terminal #1 of preheat controller is 24V.
Connect terminal #9 of preheat controller to machine. Check if voltage NO between terminal #1 and machine is 24V.
· Key switch: ON · Insert a test bar into the rear of connector.
· Key switch: ON · Connect to machine from the rear of connector. · Insert a test bar into the rear of connector.
NO
Broken harness between preheat controller and ground.
Check if voltage between machine and terminal #7 of preheat controller is 24V. · Key switch: ON
Broken harness between heater relay and battery relay.
YES Check if voltage between machine and terminal 206 NO (harness end) of battery relay is 24V. · Key switch: ON
YES
To ”Check of key switch and battery system”.
NO
Connector Preheat Controller (Harness end)
T2BC-05-04-003
T5-4-11
(A)
TROUBLESHOOTING / Troubleshooting B
YES
YES
(A)
Check if voltage between machine and terminal #2 or #3 of preheat controller is 24V.
Disconnect preheat controller from connector. Connect terminal #5 (harness end) of connector to machine. Disconnect coolant temperature sensor from connector Check for continuity between machine and terminal #2 (harness end) of connector.
YES
Check if coolant temperature sensor is normal. NO
Faulty preheat controller. Faulty coolant temperature sensor.
Broken harness between preheat controller and coolant temperature sensor.
NO
¡ Key switch: ON YES
NO
Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V. ¡ Key switch: ON
NO
Connector Preheat Controller (Harness end)
Coolant Temperature Sensor (Harness end)
1 2
T2BC-05-04-003
T5-4-12
Broken harness between preheat controller and battery relay. Go to "Check of key switch and battery system".
TROUBLESHOOTING / Troubleshooting B Check of key switches and battery system
NO YES
Check if voltage of battery and specific gravity of battery electrolyte are normal.
Connect terminal ( ) of battery to machine. Check if voltage beYES tween machine and terminal 206 (harness end) of battery relay is 24V.
Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V. · Key switch: ON YES
· Key switch: ON
NO
Broken harness between battery and battery relay Connect ground terminal of battery relay to machine. Check if voltage between machine and terminal 206 (harness end) of battery relay is 24V. · Key switch: ON
Broken harness between battery and ground, or faulty ground. Faulty battery.
NO
T5-4-13
TROUBLESHOOTING / Troubleshooting B
Broken harness battery and ground, or Faulty ground.
YES YES
Faulty battery relay
Disconnect 264 harness of battery relay. Check if voltage NO between machine and terminal (har ness end) is 24V.
Broken harness between key switch and battery relay.
YES
· Key switch: ON Check if voltage between machine and terminal ACC NO of key switch is 24V.
YES
· Key switch: ON · Insert a test bar into the rear of connector.
NO
Check if voltage between machine and terminal B of key switch is 24V. · Key switch: ON · Insert a test bar into the rear of connector.
Connector Key Switch (Harness end) Terminal B
T2BC-05-04-002
Terminal ACC
T5-4-14
NO
Faulty key switch.
Broken harness between key switch and battery.
TROUBLESHOOTING / Troubleshooting B E-4 After-heating is not made after completion of preheating. NO
Faulty alternator.
YES
Broken harness between preheat YES controller and alternator.
YES
Disconnect connector of preheat controller. Check if voltage between machine and terminal #7 (harness end) of connector is 0 V.
Check if voltage between machine and terminal L of alternator is 0 V.
· Key switch: START Check if voltage between machine and terminal #4 of preheat controller is 24V.
NO
· Key switch: ON · Insert a test bar into the rear of connector.
Faulty preheat controller.
· Key switch: ON · Insert a test bar into the rear of connector. Broken harness between engine starting relay and preheat controller.
NO
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.
NO
Idle speed is too fast or slow.
Check if engine governor lever gets in contact with low idle stopper bolt. · Key switch: ON · Set to low idle position by using an accelerator grip. · Visual check.
Check if control cable from governor motor, which is connected to governor lever, is set correctly.
YES
T5-4-16
YES
NO
Go to "Failure of engine control system” in “Troubleshooting A". Faulty adjustment of control cable that connects governor motor and governor lever. Faulty adjustment of engine governor lever.
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
NO
Carry out high idle calibration.
Check if high idle calibration is done. (A)
YES
Maximum un-load speed is too low.
Check if engine governor lever gets in contact with high idle stopper bolt. · Key switch: ON · Set to high idle position by using an accelerator grip. · Visual check.
YES Check if engine governor lever, rod YES or the like is deformed.
· Deformation of lever, rod or the like
NO
Faulty governor lever or faulty rod.
Faulty engine or faulty fuel system.
(A)
NO
Check if control cable, which connects governor motor and governor lever, is set correctly.
YES
T5-4-17
Faulty adjustment of control cable that connects governor motor and governor lever.
Go to "Failure of engine control system” in “Troubleshooting A".
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
Check if voltage
between machine and terminal 209 (harness end) of engine stop sole noid is 0 V.
· Key switch: OFF
Faulty engine stop solenoid.
YES
Disconnect engine stop relay. Check if voltage between machine NO and terminal #6 (harness end) of connector is 0 V.
Disconnect con of key YES nector switch. if engine Check stops.
Short-circuited harness between engine stop relay and engine stop solenoid.
NO
Connector
Engine Stop Relay (Harness end)
Short-circuited harness between key switch and battery relay, or faulty battery relay.
· Key switch: OFF
NO
Faulty key switch.
Key Switch (Harness end)
Terminal C Terminal B
T2BC-05-04-001
T2BC-05-04-002
Terminal ACC
T5-4-18
TROUBLESHOOTING / Troubleshooting B ACTUATOR TROUBLESHOOTING A-1 Two or more actuators do not work.
• Pilot system (pilot pump, gate lock valve, etc.) and relief valves may malfunction.
• If hoisting, lowering and derricking (lowering) drums are not activated, refer to “Troubleshooting A and D”.
YES
YES
Check if gate lock lever and emergency stop switch are in unlock position.
· Refer to Chapter "Performance Measurement".
Check if pilot circuit primary pilot pressure is normal. · Refer to Chapter "Performance Measurement".
NO
Check if gate lock valve, pressure-reducing valve and second overhoist solenoid valve in 4-spool solenoid valve unit are abnormal. · Disassembly
· Gate lock lever: Pull · Emergency Stop Switch: OFF
YES
NO
NO
YES
Faulty main pump. Incorrect pressure setting of main relief valve.
Faulty pilot pump. Faulty gate lock valve, pressure-reducing valve or second overhoist solenoid valve in 4spool solenoid valve. Set lock lever and emergency stop switch to unlock position.
NO
Check if main relief pressure corresponding to failure is normal.
A-2 Even when moving control lever to neutral, actuator does not stop.
• Spool in remote control valve or spool in control valve may be stuck.
YES
Faulty remote control valve.
· Even when control lever is in neutral, pilot pressure is transmitted to control valve (spool).
Check if actuator stops when setting lock lever to lock position.
Faulty control valve. NO · Pilot pressure is not transmitted to control valve (spool), but the oil passage is open due to sticking or the like.
T5-4-19
TROUBLESHOOTING / Troubleshooting B HOISTING DRUM TROUBLESHOOTING
M-1 Drum does not rotate
• Check the wiring connections first. • If pilot pump, pressure-reducing valve for 4-spool
solenoid valve unit, and gate lock valve are faulty, not only drum rotation but travel and slewing cannot be achieved. • When safety device or drum lock motor functions, drum stops. • Refer to “Troubleshooting A and D” . YES
YES Disconnect piping from A4 port of 4-spool solenoid valve unit. Install pressure gauge instead. Check if output pressure is 4.9 MPa.
Check if output pressure from control valve is 28.3 to 31.4 MPa.
Check if presYES sure at port PR of hoisting motor is 4.9 MPa.
· Install pressure gauge to NO Check if secport a or b of counter ondary pilot balance valve of hoisting pressure is motor. normal. · Port a during hoisting. · Refer to "Per· Port b during lowering. formance Measurement". NO
Faulty hoisting motor.
Faulty motor brake release solenoid NO valve. Stuck spool in control valve or proportional solenoid valve.
Faulty remote control valve.
YES
NO
Faulty second overhoist solenoid valve of 4-spool solenoid valve unit.
4-Spool Solenoid Valve Unit
Port 䌢(G3/8) Port a (G3/8)
Counterbalance Valve
Port A4
PR Port (G1/4)
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
Check if the lifting load lowers when depressing brake pedal.
YES
NO Check if pressure at port PR of hoisting
Faulty drum brake.
NO
motor is 0 MPa.
Check if output pressure at drum brake release solenoid valve is 0 MPa.
NO
Faulty hoisting motor multi-plate brake.
Faulty hoisting motor brake release solenoid valve.
· Install pressure gauge to port A of drum brake release solenoid valve to be checked.
YES
Faulty drum brake release solenoid valve.
Drum Brake Release Solenoid Valve
Port PR (G1/4)
Port A (G3/8) T25N-05-04-002
Hoisting 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 Control System" in “Troubleshooting A”.
YES
Faulty MC2/A.
YES
Connect the disconnected con nector. Check if voltage between ma E22 chine and terminal E9 or of connector MCA-6 of MC2/A is 24 V.
Disconnect connector of brake indicator of left stand. Connect terminals #7 and #8 (harness end) of connector to machine. Disconnect connector MCA-6 of MC2/A. Check for continuity between machine and terminal E9 or E22 (harness end) of connec tor.
· Key switch: ON · Brake mode selection switch: OFF (auto brake) · Front drum brake mode selection switch: OFF · Rear drum brake mode selec tion switch: OFF · Insert a test bar into the rear of connector.
NO
Connector
NO
If voltage between terminal E9and machine is not 24V, rear auto brake indicator bulb is burnt out. If voltage between terminal E22 and machine is not 24V, front auto brake indicator bulb is burnt out. In case of no continuity between terminal E9 and machine, broken harness between rear auto brake indicator and MC2/A. In case of no continuity between terminal E22 and machine, broken harness between front auto brake indicator and MC2/A.
MC2/A Connector MCA-6 (Harness end)
Brake Indicator Lamp (Harness end)
E9
Third / Fourth Rear
T2BC-05-04-006
E9
T2BC-05-04-005
Front
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.
· Free mode · Connect terminals E12 and E13 of both connectors by using clips or the like. · Front auto brake indicator: Make measurement between terminal E22 and machine. · Rear auto brake indicator: Make measurement between terminal E9 and machine.
Short-circuit harness between auto brake indicator and MC2/A.
NO
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 solenoid valve stopping, the free mode cannot be selected. • Refer to “Troubleshooting A”.
Follow correct free mode switching procedure.
YES
Check if brake mode switching procedure is correct. · Engine: Running · Brake mode key switch: ON (free position) · Brake pedal: Depressing · Brake mode selection switch: ON
YES
NO
Check if primary pilot pressure (9.8 Mpa) in brake circuit is normal. · Refer to "Performance Measurement".
NO
T5-4-24
Check pilot pump or relief valve in gate lock valve.
TROUBLESHOOTING / Troubleshooting B
YES
Check if pressure at port A of brake release solenoid valve is 9.8 MPa.
· Remove piping from port A of drum brake release solenoid valve. Install pressure gauge. · Engine: Running · Brake mode key switch: ON (free position) · Brake Pedal: No operation · Drum free mode switch: ON
NO
Drum Brake Release Solenoid Valve
Port P (G3/8)
Port A (G3/8)
T25N-05-04-002
T5-4-25
Faulty drum brake.
Faulty drum brake release solenoid valve.
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
YES
· Insert a test bar into the rear of connector. NO · Front drum free indicator: Make measurement between terminal #2 and machine. · Rear drum free indicator: Make measurement between terminal #6 and machine. · Third drum free indicator: Make measurement between terminal #5 and machine. · Free mode.
Check if voltage between machine and terminal of brake indicator connector of left stand is 24 V.
Check if free fall is possible.
Connector Connector Brake Indicator Lamp (Harness end) Front Drum Free Indicator
T2BC-05-04-006
Broken harness between drum free indicator and MC2/A.
Refer to M-5.
NO
Third / Fourth Drum Free Indicator
Burn out of drum free indicator bulb or faulty ground.
Rea Drum Free Indicator
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 of MC2/A. Check if voltage between machine and terminal (machine end) of connector is 24 V. · Key switch: ON · Brake mode switch: OFF (auto brake) · Connect terminals E12 and E13 of both connectors by using clips or the like. · Front drum free indicator: Make measurement between terminal E32 and machine. · Rear drum free indicator: Make measurement between terminal E9 and machine. · Third drum free indicator: Make measurement between terminal E7 and machine.
YES
Faulty MC2/A.
Short-circuited harness between drum free indicator and MC2/A.
NO
Connector MC2A Connector MCA-6 (Harness end)
E9
E7
T2BC-05-04-007
E22
T5-4-27
TROUBLESHOOTING / Troubleshooting B BOOM DERRICKING DRUM TROUBLESHOOTING 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”.
Check if primary pilot pressure in pilot circuit is normal. boom derricking drum lock. · Refer to “Performance Meas urement”.
YES
YES
Remove piping at port A4 in 4-spool solenoid valve unit. Install pressure gauge. Check if output pressure is 4.9 MPa.
Check if output pressure from YES control valve is 28.3 to 34.5 MPa. · Install pressure gauge to port AM or BM of boom derricking motor. · Port AM during boom derricking (housing). · Port BM during boom derricking (lowering). NO
Faulty second overhoist solenoid valve in 4-spool solenoid valve unit.
Faulty pressure-reducing valve in 4-spool solenoid valve unit.
NO
4-Spool Solenoid Valve Unit
Port A1
Port A4
NO
Stuck spool in front control valve, or faulty remote control valve for boom derricking.
T2BC-05-04-004
T5-4-28
TROUBLESHOOTING / Troubleshooting B
YES
Faulty boom derricking drum lock.
Check if there is abnormality in boom derricking drum lock.
NO
Faulty boom derricking motor.
Boom Derricking Drum Lock
From Pilot Pump
AM Port (G1/4)
BM Port (G1/4)
Pawl Ball Joint
Boom Derricking Motor
Torsion Spring
T25N-03-04-003
T5-4-29
TROUBLESHOOTING / Troubleshooting B SLEWING SYSTEM TROUBLESHOOTING
Port b (G 1/4)
S-1 Slewing speed is too slow, or slewing is disabled
• Check the wiring connections first. • If pilot pump, pressure-reducing valve of 4-spool solenoid valve unit and gate lock valve are faulty, not only slew but travel and drum rotation are deactivated.
M25N-07-023
Port a (G 1/4)
Slewing Motor
Check if secondary pilot pres sure to slewing valve control block is normal. · Refer to Group "Performance Measurement".
YES
YES
Check if input pressure from slewing control valve is 28.7 to 31.9 MPa.
NO Faulty slewing control valve. Check if output pressure at port A2 of 4-spool solenoid valve unit is 4.9 MPa.
· Install pressure A gauge to port a or b YES of slewing motor. · Port b at slew (CW). · Install pressure gauge to · Port a at slew port A2 of 4-spool solenoid valve unit. · Slewing brake switch: ON
Check if input pressure to slewing control valve is 28.7 to 31.9 MPa. · Install pressure gauge to pressure check port of slewing control valve.
B
NO Faulty slewing remote control valve.
NO
Slewing Control Valve
4-Spool Solenoid Valve Unit
Slewing Brake Solenoid Valve
Port A2
Pressure Check Port
T2BC-05-04-004
T2BC-04-05-008
T5-4-30
TROUBLESHOOTING / Troubleshooting B Connector Slewing Lever (Harness end)
Slewing Brake Solenoid Valve (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 (harunit. ness end) of Connect the dis connector of connected conBroken harness slewing brake nector. between ground solenoid valve. Disconnect conA and slewing NO brake solenoid nector from slewvalve of 4-spool NO ing brake solenoid valve of 4-spool solenoid valve solenoid valve unit. unit, or faulty Disconnect slewing Check if voltage ground. lever connector. between machine Connect terminals and terminal #2 #2 and #8 (harBroken harness (harness end) of ness end) of con between slewing connector is 24 V. YES nector. brake solenoid Check if output · Key switch: ON valve of 4-spool NO pressure at port A2 · Slewing brake solenoid valve of 4-spool solenoid switch: ON unit and slewing valve unit is 4.9 Check if voltage brake. MPa. between machine and terminal #2 of · Key switch: ON NO slewing lever connector is 24 V. Faulty slewing brake switch. YES · Insert a test bar into the rear of connector. Broken harness · Key switch: ON between slewing brake switch NO and battery.
T5-4-31
TROUBLESHOOTING / Troubleshooting B
YES
B
Disconnect connector of slewing pump swash angle solenoid valve. Check if electric current between terminal #1 and #2 is 700 mA.
Faulty slewing pump.
YES
NO
Disconnect connector MCA-5 of MC2/A. Check for continuity between terminals #1 and F11, #2 and F7. NO
Faulty MC2/A.
Faulty harness between MC2/A and slewing pump swash angle proportional solenoid valve.
Slewing Pump Swash Angle Solenoid Valve MC2/A Connector MC 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. • 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-
lief pressure at
NO
slower track is normal.
YES
Check if secondary travel pilot pressure is normal.
Check if failure phenomenon is reversed when exchanging left and right travel hoses at center joint.
Check if failure phenomenon is reversed when exchanging left and right travel relief valves.
Stuck spool in control valve.
· Refer to "Per-
formance Meas-
urement".
NO
YES
YES
NO
Faulty remote control valve.
Center Joint
Right Travel (Forward) Left Travel (Reverse) Right Travel (Reverse)
Left Travel (Forward)
T25N-05-04-006
T5-4-33
TROUBLESHOOTING / Troubleshooting B
YES Disassemble and clean counterbalance valve of travel motor. Check if failure phenomenon arises again.
Disassemble and clean servo piston of travel motor. Check if failure phenomenon arises again.
YES
NO
Faulty travel motor or travel reduction gear.
Faulty servo piston of travel motor.
NO
Faulty counterbalance valve.
NO
Faulty center joint.
YES
Faulty travel relief 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 nism of travel moCheck if input tor. YES pressure at port PS of travel motor is 4.9 MPa. Check if output Stuck in shuttle · Install tee and pres NO valve. YES pressure at port sure gauge to port A3 of 4-spool so- PS of travel motor. lenoid valve unit is · High / low travel 4.9 MPa. Faulty high travel speed selection Check for continuspeed selection switch: High speed · Install pressure gauge YES ity between masolenoid valve of to port A3 of 4-spool chine and terminal NO 4-spool solenoid solenoid valve unit. #1 (harness end) valve unit. Disconnect con· Travel Mode Switch: of connector. nector from high High speed travel Broken harness speed selection solenoid between high travel of 4-spool valve speed selection NO solenoid valve solenoid valve and unit. ground or fuse #23. Check if voltage at terminal #2 Broken harness YES (harness end) of between travel Disconnect con connector is 24V. mode switch and nector of travel battery or fuse #23. mode switch. · High / low travel speed selection Check for continuNO ity between ter switch: High Faulty travel mode minals #6 and #7. speed switch. NO · Travel Mode Switch: High speed
Connector High Travel Speed Selection Solenoid Valve (Harness end)
T2BC-05-04-010
4-Spool Solenoid Valve Unit
Travel Motor
PS Port (G 1/4)
M25N-07-032
T5-4-35
Port A3
T2BC-05-04-004
TROUBLESHOOTING / Troubleshooting B OTHER TROUBLESHOOTING
• Check the wiring connections first.
Drum lock is not applied.
Connect the disconnected con nector. YES Disconnect con nector of drum lock YES motor. Check for continuDisconnect con- ity between terminector SWP16F of nals #1 and #3 right control panel. (harness end) of NO Check for continu connector. ity between terminals (machine end) · Drum lock of connector. switch: ON
O-1 Drum lock does not work.
Broken harness between drum lock switch and drum lock motor.
· Drum lock switch: ON · Make measurement NO
YES
YES
Check if ground of drum lock motor is normal.
Faulty drum lock switch.
between terminals #8 and #6 of front drum. Connect the dis· Make measurement connected conbetween terminals #12 nector. YES Faulty drum lock and #10 of rear drum. Disconnect conmotor. · Make measurement between terminals #16 YES nector of drum lock motor. and #14 of fourth Broken harness Check for continudrum.
Disconnect con- nector SWP16F of right control panel. Check for continu ity between termi Drum lock nals (machine end) is not of connector.
between drum lock NO switch and drum lock motor.
ity between terminals #1 and #2 (harness end) of connector. · Drum lock switch: OFF
released.
Faulty drum lock switch.
· Drum lock switch: OFF NO · Make measurement between terminals #8 and #7 of front drum. · Make measurement between terminals #12 and #11 of rear drum. · Make measurement between of fourth terminals #16 and #15 drum.
Check if voltage between terminal #6 of drum lock motor and ma is 24V. chine
· Key switch: ON · Insert a test bar the rear of into connector.
Faulty ground of drum lock motor.
NO
Broken harness between drum lock motor and battery or fuse (front: #22, rear: #2, fourth: #40).
Faulty drum lock motor.
NO
Connector
Right Control Panel Connector SWP16F (Harness end)
Drum Lock Motor (Harness end)
T2BC-05-04-012
T2BC-05-04-013
T5-4-36
TROUBLESHOOTING / Troubleshooting B O-2 Counterweight (optional) cannot be removed and installed.
• Check the wiring connections first.
YES
Disconnect connector (62C-16FB) of left control panel. Check if voltage at terminal #2 (harness end) of connector is 24V.
· Key switch: ON
YES
· Counterweight / jack-up switch: Counterweight id
Broken harness between jack relay (R5) and terminal #2 (harness end) of connector.
NO
Check if quick draw or retract cylinder moves.
YES
Faulty jack relay (R5).
NO
Remove jack relay (R5). Check if voltage at terminal #3 is 24V.
Broken harness between fuse #39 or jack relay (R5) and battery relay.
· Key switch: ON
NO
Check for continuity between terminals #2 and #6 of connector.
Left Control Panel
Relay Panel
Connector (62C16FB) (Harness end)
T2BC-05-04-017
Jack Relay (R5)
T2BC-05-04-018
T5-4-37
TROUBLESHOOTING / Troubleshooting B
YES
NO
Disconnect relay connector (1P). Check if voltage at harness end terminal is 24V.
Disconnect relay (1P) or connector (4P). Check for continuity between each terminal (counterweight end) of control box relay connector (4P) and terminal (counterweight control box end) of relay con nector (1P).
YES
NO
YES
路 Terminal #1: Right cylinder extension 路 Terminal #2; Right cylinder retraction #3: Left 路 Terminal cylinder extension 路 Terminal #4: Left cylinder retraction
Broken harness between relay connector (1P) and connector in left control panel.
NO
Faulty counterweight / jack-up switch.
Faulty counterweight control box or harness.
Faulty counterweight solenoid valve, or broken harness between counterweight solenoid valve and relay connector (4P).
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
Replace jack relay
(R5) with horn relay (R4).
Faulty jack relay (R5).
Check if jack can be extended or retracted.
Check for continuity between terminal #2 of jack relay (R5) connector and machine.
YES
NO
Remove jack relay (R5). Check if voltage at terminal #3 (connector end) is 24V. · Key switch: ON
NO
Broken harness between jack relay (R5) and battery relay or fuse #39.
Jack Relay (R5)
Relay Connector (Harness end)
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)
Pressure Check Port
Hydraulic Selection Solenoid Valve
T2BC-05-04-015
T2BC-05-04-024
YES
YES
Disconnect connector from hydraulic selection solenoid valve of 4-spool control valve. Check if voltage at terminal #1 (harness end) of connector is 24V.
¡ Key switch: ON
Check for continuity between terminal #2 (panel end) of connector in left control panel and terminal #3 of 62C-16MW.
YES
Disconnect connector from left control panel. Check if voltage at harness end terminal #2 is 24V.
Faulty counterweight / jack-up switch.
NO
¡ Key switch: ON
Broken harness between jack relay (R5) and counterweight / jack-up switch.
NO
Control Panel Connector Left (Panel end) 62C-16MB
Control Panel Connector Left (Harness end)
T2BC-05-04-017
NO
Broken harness between counterweight / jack-up switch and hydraulic selection solenoid valve in 4-spool control valve.
62C-16MW
T2BC-05-04-023
T2BC-05-04-022
T5-4-40
TROUBLESHOOTING / Troubleshooting B
YES
Stuck spool.
NO
Faulty jack-up cylinder.
YES
YES
Check if jack-up spool in lower control valve moves.
Check if relief pressure in lower control valve is 19.6 Mpa. ¡ Refer to T4-5.
Faulty relief valve in lower control valve.
Check for continuity between machine and terminal #2 (harness end) of connector in hydraulic selection solenoid valve.
NO
Broken harness between hydraulic selection solenoid valve and machine, or faulty ground.
NO
T5-4-41
TROUBLESHOOTING / Troubleshooting B O-4 Retraction (with jack (optional) attached) cannot be done.
• Check the wiring connections first.
YES
Faulty jack relay (R5).
Replace jack relay (R5) with horn relay (R4). Check if jack can be extended or retracted.
Check for continuity between terminal #2 of jack relay (R5) connector and machine.
YES
NO
Remove jack relay (R5). Check if voltage at terminal #3 (connector end) is 24V. ¡ Key switch: ON Broken harness between jack relay (R5) and battery relay or fuse #39.
NO
Relay Connector (Harness end)
Jack Relay (R5) Horn Relay (R4)
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
Disconnect connector from hydraulic selection solenoid valve of 4-spool control valve. Check if voltage at terminal #1 (harness end) of connector is 24V. ¡ Key switch: ON
YES
YES
Disconnect connector from left control panel. Check if voltage at harness end terminal #2 is 24V.
Check for continuity between terminal #2 (panel end) of connector in left control panel and terminal #3 of 62C-16MW.
NO
YES
Faulty counterweight / jack-up switch.
NO
¡ Key switch: ON
Broken harness between jack relay (R5) and counterweight / jack-up switch.
NO
Left Control Panel Connector (Panel end) 62C-16MB
Left Control Panel Connector (Harness end)
T2BC-05-04-017
Broken harness between counterweight / jack-up switch and hydraulic selection solenoid valve in 4-spool control
62C-16MW
T2BC-05-04-023
T2BC-05-04-022
T5-4-43
TROUBLESHOOTING / Troubleshooting B
YES
YES
YES
Stuck spool.
NO
Faulty retract cylinder.
Check if retract spool in lower control valve moves.
Check if relief pressure of lower control valve is 16.9 MPa. ¡ Refer to T4-5.
Faulty relief valve in lower control valve.
Check for continuity between machine and terminal #2 (harness end) of connector of hydraulic selection solenoid valve.
NO
Broken harness between hydraulic selection solenoid valve and machine, or faulty ground.
NO
T5-4-44
TROUBLESHOOTING / Troubleshooting B O-5
Retraction cannot be done (by using a switch in cab).
• Check the wiring connections first.
YES
Faulty jack relay (R5). Broken harness between jack relay (R5) and battery relay or fuse #39.
YES
Replace jack relay (R5) with horn relay (R4). Check if retract cylinder can be extended or retracted. · Engine: Running · Side frame extend / retract switch: Extend or retract
Disconnect jack relay (R5) from connector. Check if voltage between terminal #3 (harness end) of connector and machine is 24V.
NO
· Key switch: ON YES
Relay Panel
NO
Check for continuity between machine and terminal #2 (harness end) of connector.
· Key switch: ON
NO
Jack Relay (R5)
Horn Relay (R4)
T2BC-05-04-018
Relay Connector (Harness end)
Panel Connector (62C-16FB) (Harness end)
T2BC-05-04-014
T2BC-05-04-025
T5-4-45
Connect the disconnected relay. Disconnect connector 62C-16FB of left control panel. Check if voltage between terminal #2 (harness end) of connector and machine is 24V.
Broken harness between jack relay (R5) and ground, or faulty ground.
TROUBLESHOOTING / Troubleshooting B 4-Spool Control Valve Side Frame Retract Solenoid Valve
Side Frame Extend Solenoid Valve (with optional attached)
NO
T2BC-05-04-024
YES
Disconnect connector 62C-16FW of left control panel. Check for continuity between connectors 62C-16MB and 62C-16MW.
Connect the disconnected connector. Disconnect connector of side frame extend solenoid valve in 4-spool control valve. Check if voltage at terminal #1 (harness end) of connector is 24V.
Check for continuity between maYES chine and terminal #2 (harness end) of connector.
YES
· Key switch: ON · Side frame extend / retract switch: Extend
· Side frame extend / retract switch: Extend between terminal #2 of connector 16MB and terminal #3 of connector 16MW · Side frame extend / retract switch: Retract between terminal #2 of connector 16MB and terminal #4 of connector 16MW
Disconnect connector of side frame retract solenoid valve. Check if voltage at terminal #1 (harness end) of connector is 24V. · Key switch: ON · Side frame extend / retract switch: Retract Broken harness between side frame extend / retract switch and side frame extend solenoid valve.
NO
Faulty side frame extend / retract switch.
NO
Panel Connector (62C-16MW) (Panel end)
Panel Connector (62C-16MB) (Panel end)
Broken harness between side frame extend solenoid valve and ground, or faulty ground.
Solenoid Connector (Harness end)
T2BC-05-04-023
T2BC-05-04-022
T5-4-46
T2BC-05-04-015
TROUBLESHOOTING / Troubleshooting B
YES
Install a pressure gauge to pressure YES check port in 4-spool control valve. Check if pressure is 20.6 MPa. NO Check for continuity YES between machine and terminal #2 (harness end) of connector.
Faulty retract cylinder.
Faulty relief valve in 4-spool control valve, or faulty pump for counterweight / quick draw / retract.
Broken harness between side frame extend solenoid valve and ground, or faulty ground.
NO
Broken harness between side frame extend / retract switch and side frame retract solenoid valve.
NO
4-Spool Control Valve
Side Frame Retract Solenoid Valve Connector (Harness end)
T2BC-05-04-015
T2BC-05-04-024
Pressure Check Port
T5-4-47
This Page Left Blank Intentionally
TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators malfunction.
x How to Read Troubleshooting Flow Charts
YES(OK)
•
(2)
•
(1)
After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
•
•
Special instructions or reference item are indicated in the spaces under the box. Incorrect measuring or checking methods will render troubleshooting impossible, 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.
¨ Key switch: ON
•
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
T5-5-1
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE
COOLANT
TEM-
• Check the wiring connections first.
Disconnect coolant temperature sensor. YES Connect harness end terminal #1 to machine. Check if needle swings to (H) side.
Gauge needle does not swing at all.
Check if coolant temperature sensor terminal is correctly connected.
¨ Key switch: ON
NO
YES
Gauge needle swings over scale.
Check if needle returns when coolant temperature sensor terminal is disconnected. ¨ Key switch: ON
With coolant tempera sensor disconture nected, disconnect connector C16F-W from monitor panel. NO Check for continuity between harness end connector terminal #12 and machine.
Gauge needle swings unstably.
Check if coolant temperature sensor terminal is correctly connected.
Disconnect coolant temperature sensor. YES Connect harness end terminal #1 to machine. Check if needle swings to (H) side and stays in that position. ¨ Key switch: ON
With coolant temperature sensor disconnected, disconnect connector C16F-W from monitor panel. Check for continuity NO between harness end connector terminal #12 and coolant temperature sensor terminal.
YES
NO
T5-5-2
YES
NO
YES
NO
TROUBLESHOOTING / Troubleshooting C
Faulty coolant temperature sensor.
YES
Faulty monitor panel.
NO
Faulty coolant temperature sensor terminal connection.
Faulty coolant temperature sensor.
1
2
Coolant Temperature and Electrical Resistance Coolant Temperature Electrical Resistance qC (qF) : 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)
Short-circuited harness between monitor panel and coolant temperature sensor.
Faulty monitor panel.
NOTE: Values in (
Faulty coolant temperature sensor.
Faulty monitor panel.
Coolant Temperature Sensor
T2BC-05-04-026
Monitor Panel (C16F-W)
Broken harness between monitor panel and coolant temperature sensor.
Connector (Harness end)
Faulty coolant temperature sensor terminal connection.
T5-5-3
) are reference only.
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Check the wiring connections first. YES
Disconnect fuel sensor. Connect harness end connector terminals #1 YES and #2. Check if gauge needle swings to (F) side.
Gauge needle does not swing at all.
¨ Key switch: ON ¨ Connect by using a clip.
Check if fuel sensor is correctly connected.
NO
NO
YES
Gauge needle swings over scale.
Disconnect fuel sensor. Check if needle swings back to zero. ¨ Key switch: ON
YES
With fuel sensor disconnected, disconnect connector C16F-W from monitor panel. NO Check for continuity between harness end connector terminal #2 and machine.
NO
YES
YES
Gauge needle swings unstably.
Disconnect fuel sensor. Connect harness end connector terminals #1 and #2. Check if gauge needle stably swings to (F) side. ¨ Key switch: ON ¨ Connect by using a clip.
Check if fuel sensor is correctly connected.
NO
T5-5-4
NO
With fuel sensor disconnected, disconnect connector C16F-W from monitor panel. Check for continuity between harness end connector terminal #4 and fuel sensor terminal #2.
TROUBLESHOOTING / Troubleshooting C
Faulty fuel sensor.
YES
Faulty monitor panel.
Connector (Harness end)
Fuel Sensor NO
Broken harness between monitor panel and fuel senFaulty fuel sensor connecter connection.
2
1
Monitor Panel (C16F-W)
T2BC-05-04-026
Faulty fuel sensor.
Float
FULL
Short-circuited harness between monitor panel and fuel sensor.
3/4
Fuel Sensor
257 mm 138.5 mm
22q R370
Faulty monitor panel.
33q
70.5 mm
1/2 228 mm
27q 28q Electrical Resistor
1/4
Faulty fuel sensor.
338 mm
EMPTY
T107-04-03-020
Faulty monitor panel.
NOTE: 1 mm = 0.03937 in Float Position and Electrical Resistance Float Position Resistance ( : ) Full 10r1.00.5 3/4 (19.5) 1/2 32r3 1/4 (49.5) Empty 80r2
Faulty fuel sensor terminal connection.
T5-5-5
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • Check the wiring connections first.
YES
Indicator is not turned ON although engine oil pressure is insufficient.
¨ Key switch: ON ¨ Engine: Stop
Disconnect plug from engine oil pressure switch. Connect terminals of harness 223 and GD2 harness. Check if indicator is turned ON. ¨ Key switch: ON
terminal of 223 With harness connected to machine. Disconnect connector C16F-W of monitor NO panel. Check for continuity between machine and terminal #6 (harness end) of connector.
YES
NO
Faulty monitor panel or burnt indicator bulb.
Broken harness between monitor panel and engine oil pressure switch.
YES
Indicator is not turned OFF although engine
Faulty engine oil pressure switch.
runs.
¨ Check if oil filter is clogged or not. (If clogged, engine oil restriction indicator is turned ON.)
Check if indicator is turned ON when plug from engine oil pressure switch is disconnected. ¨ Key switch: ON ¨ Engine: Stop
Faulty of engine oil pressure switch or engine hydraulic system.
Disconnect plug from engine oil pressure switch and connector C16F-W from monitor panel. NO Check for continuity between machine and terminal #6 (harness of connector. end)
YES
Faulty monitor panel. NO
Engine oil pressure switch Pressure About 78.4 KPa (0.8 kgf/cm2, 11 psi) or less About 78.4 KPa (0.8 kgf/cm2, 11 psi) or more
Connector (Harness end) Operation
Short-circuited harness between monitor panel and engine oil pressure switch.
Monitor Panel C16F-W
ON OFF
T2BC-05-04-026
T5-5-6
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT LEVEL INDICATOR
• Other indicators blink normally. • Check the wiring connections first. NO㩷
Disconnect connector of coolant level switch. Connect terminals #2 YES and #3 (harness end) of connector. Check if indicator is turned ON.
Indicator is not turned ON.
¨ Check if water level is
above Low level.
Check if indicator is turned ON when resetting key switch from OFF to ON position.
¨ Key switch: ON
Faulty coolant level YES㩷 switch.
YES㩷 Burnt indicator bulb.
¨ Key switch: OFF ļ ON
Check for continuity between machine and terminal #1 of connecNO tor C16F-W of monitor panel.
With terminals of coolant level switch connected. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #15 (harness end) of connector.
¨ Key switch: ON ¨ Insert a test bar into the rear of connector. ¨ Check within 3 seconds after turning key switch ON.
NO㩷
Disconnect connector IDU-5 of IDU. Connect terminal #3 (harness end) of connector to machine. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #1 (harness end) of connector.
Indicator is turned ON although water level is below the specified level.
Check if indicator is turned ON when connector of coolant level switch is disconnected.
With connector of coolant level switch disconnected. Disconnect connector YES C16F-W of monitor panel. Check for continuity between machine and terminal #15 (harness end) of connector.
¨ Key switch: ON NO
T5-5-7
Short-circuited harness YES㩷 between coolant level switch and monitor panel.
NO㩷
Check for continuity between machine and terminal #1 (harness end) of connector.
Faulty coolant level switch.
TROUBLESHOOTING / Troubleshooting C
Reserve Tank
YES㩷 Faulty monitor panel.
ON
FULL
LOW
Radiator
Broken harness between coolant level switch and monitor panel.
NO
OFF Coolant Level Switch
YES㩷
Connector (Harness end) Monitor Panel C16F-W
Faulty IDU.
T2BC-05-04-026
Broken harness between monitor panel and IDU.
NO
Coolant Level Indicator (Harness end)
Connect the disconnected connector. YES㩷 Disconnect connector IDU-5 of IDU. Check if indicator is turned ON. · Key switch: ON
YES㩷 Short-circuited harness between monitor panel and IDU.
1 3
Connector IDU-5 Of IDU
NO
Faulty IDU.
T2BC-05-04-027
T107-04-03-012
NO
Faulty monitor panel.
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.
YES
Indicator is not turned
ON although engine oil
filter is clogged.
Check if indicator is turned ON when resetting key switch from OFF to ON position.
Disconnect terminal of 227 harness of engine oil filter restriction switch. Connect terminal (harness end) to machine. Check if indicator is turned ON. · Key switch: ON
· Key switch: OFFņON
NO
Check for continuity between machine and terminal #1 of connector C16F-W of monitor panel. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector. ¨ Check within 3 seconds after turning key switch ON.
Connected the disconnected terminal. Connect terminal #5 of connector C16F-W of monitor panel to maNO chine. Check if indicator is turned ON. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector. YES Indicator bulb is burned out. Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of connector to machine. NO Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #1 (harness end) of connector.
YES
Faulty engine oil filter restriction switch.
Indicator is turned ON although engine oil filter is not clogged.
Check if indicator is turned OFF when terminal of engine oil filter restriction switch is disconnected. · Key switch: ON NO
Disconnect terminal of engine oil filter restriction switch and connector C16F-W of monitor panel. Check for continuity between machine and terminal #5 (harness end) of connector.
Short-circuited harness YES between monitor panel and engine oil filter restriction switch.
NO
T5-5-9
Check for continuity between machine and terminal #1 (harness end) of connector.
TROUBLESHOOTING / Troubleshooting C
Broken harness between monitor panel and engine oil filter restriction switch.
YES
Connector (Harness end) Monitor Panel C16F-W
T2BC-05-04-026
Faulty monitor panel.
NO
YES
Faulty IDU.
T2BC-05-04-027
Broken harness between monitor panel and IDU.
NO
Connect the disconnected con nector. YES Disconnect connector IDU-5 of IDU. Check if indicator is turned ON. ¡ Key switch: ON
Short-circuited harness YES between monitor panel and IDU.
NO
Faulty IDU.
NO
Connector IDU-5 of IDU
Faulty monitor panel.
T5-5-10
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
• Check the wiring connections first.
YES Faulty air filter restriction switch.
YES
Disconnect plug of air filter restriction switch. Connect plug 228 (harness end) to machine. Check if indicator is turned ON. ¨ Key switch: ON
Indicator is not turned
ON although air filter is
clogged.
Check if indicator is turned ON when resetting key switch from OFF to ON position. · Key switch: OFFlON
With plug of air filter restriction switch connected to machine, disconnect connector C16F-W of monitor NO panel. Check for continuity between machine and terminal #14 (harness end) of connector.
YES Burnt indicator bulb.
NO
Check for continuity between machine and terminal #1 of connector C16F-W of monitor panel. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector. ¨ Check within 3 seconds after turning key switch ON.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of conNO nector to machine. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #1 (harness end) of connector.
YES
Faulty air filter restriction switch.
Indicator is turned ON
although air filter is not clogged. ¨ Disassembly and visual check ¨ Confirm that air filter is not dampened.
Check if indicator is turned OFF when plug of air filter restriction switch is disconnected. · Key switch: ON NO
Disconnect plug of air filter restriction switch and connector C16F-W of monitor panel. Check for continuity between machine and terminal #14 (harness end) of connector.
T5-5-11
Short-circuited harness YES between monitor panel and air filter restriction switch.
NO
Check for continuity between machine and terminal #1 (harness end) of connector.
TROUBLESHOOTING / Troubleshooting C
Air filter restriction switch Pressure 6.25r0.5 kPa or less (635r58 mm H2O or less) 6.25r0.5 kPa or more (635r58 mm H2O or more)
YES
Faulty monitor panel.
Operation
Connector (Harness end)
Monitor Panel C16F-W
OFF ON
Broken harness between monitor panel and air filter restriction switch.
NO
T2BC-05-04-026
YES
Faulty IDU.
T2BC-05-04-027
Broken harness between monitor panel and IDU.
NO
Connect the disconnected con nector. YES Disconnect connector IDU-5 of IDU. Check if indicator is turned ON.
Short-circuited harness YES between monitor panel and IDU.
NO
Faulty IDU.
¡ Key switch: ON
NO
Connector IDU-5 of IDU
Faulty monitor panel.
T5-5-12
TROUBLESHOOTING / Troubleshooting C MALFUNKTION OF OVERHEAT INDICATOR • Check the wiring connections first. YES Faulty overheat switch.
YES
Disconnect terminal of overheat switch. Connect terminal (harness end) to machine. Check if indicator is turned ON. · Key switch: ON
Indicator is not turned
ON when overheating.
Check if indicator is turned ON when resetting key switch from OFF to ON position. · Key switch: OFFlON
With terminal of overheat switch connected to machine, disconnect connector C16F-W of NO monitor panel. Check for continuity between machine and terminal #10 (harness end) of connector.
YES Burnt indicator bulb.
NO
Check for continuity between machine and terminal #1 of connector C16F-W of monitor panel. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector. ¨ Check within 3 seconds after turning key switch ON.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of conNO nector to machine. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #1 (harness end) of connector.
YES
Faulty overheat switch.
Indicator is turned ON although coolant temperature is low.
Check if indicator is turned OFF when terminal of overheat switch is disconnected.
· Key switch: ON
NO
Disconnect terminal of overheat switch and connector C16F-W of monitor panel. Check for continuity between machine and terminal #10 (harness end) of connector.
T5-5-13
YES Short-circuited harness between monitor panel and overheat switch.
NO
Check for continuity between machine and terminal #1 (harness end) of connector.
TROUBLESHOOTING / Troubleshooting C
Overheat switch
Coolant temperature
Operation
Lower than 101 qC (214 qF)
OFF
101 qC (214 qF) or higher
ON
YES
Faulty monitor panel.
Connector (Harness end)
Monitor Panel C16F-W
Broken harness between monitor panel and overheat switch.
NO
T2BC-05-04-026
YES
Faulty IDU.
Connector IDU-5 of IDU
Broken harness between monitor panel and IDU.
NO
T2BC-05-04-027
Connect the disconnected con nector. YES Disconnect connector IDU-5 of IDU. Check if indicator is turned ON. · Key switch: ON
YES Short-circuited harness between monitor panel and IDU.
NO
Faulty IDU.
NO
Faulty monitor panel.
T5-5-14
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF CONTROLLER FAILURE INDICATOR
• Check the wiring connections first.
YES
YES
Indicator is not turned ON although abnormality is indicated by trou-
bleshooting monitor or
ECU lamp.
Disconnect ECU connector 2. Connect terminal #15 or #16 (harness end) of connector to machine. Check if indicator is turned ON.
Check if indicator is turned ON when resetting key switch from OFF to ON position. · Key switch: OFFlON
Faulty ECU.
Disconnect connector C16F-W of monitor panel. Connect terminal #13 (harness end) of connector to machine. NO Check for continuity between machine and terminal #15 or #16 (harness end) of ECU connector 2.
YES Burnt indicator bulb.
NO
Check for continuity between machine and terminal #1 of connector C16F-W of monitor panel. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector. ¨ Check within 3 seconds after turning key switch ON.
Disconnect connector IDU-5 of IDU. Connect terminal #E3 (harness end) of conNO nector to machine. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #1 (harness end) of connector.
YES
Faulty ECU.
Indicator is turned ON
ECU lamp.
Check if indicator is turned OFF when ECU connector 2 is disconnected.
· Key switch: ON
· Key switch: ON
although failure is not
indicated by trouble shooting monitor or
NO
Disconnect ECU connector 2. Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #13 (harness end) of connector.
T5-5-15
YES Short-circuited harness between monitor panel and ECU.
NO
Check for continuity between machine and terminal #1 (harness end) of connector.
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end) ECU Connector 2
T2BC-05-04-029
YES
Faulty monitor panel.
Monitor Panel C16F-W
In case of no continuity at terminal #15, broken harness between monitor panel and terminal #15 of ECU connector 2. In case of no continuity at terminal #16, broken harness between monitor panel and terminal #16 of ECU connector 2.
NO
T2BC-05-04-026
Connector IDU-5 of IDU
YES
Faulty IDU.
T2BC-05-04-027
Broken harness between monitor panel and IDU.
NO
Connect the disconnected con nector. YES Disconnect connector IDU-5 of IDU. Check if indicator is turned ON.
YES
NO
Short-circuited harness between monitor panel and IDU.
Faulty IDU.
¡ Key switch: ON
NO
Faulty monitor panel.
T5-5-16
TROUBLESHOOTING / Troubleshooting C MULFUNCTION OF PREHEAT INDICATOR • Check the wiring connections first. • If air heater does not work, refer to “Troubleshooting B”.
YES
Indicator is not turned
ON while engine is being preheated.
Check if voltage between machine and terminal #11 of connector C16F-W of monitor panel is 24 V. ¨ Insert a test bar into the rear of connector. ¨ Check within 15 seconds after turning key switch ON.
Disconnect connector C16F-W of monitor YES panel. Check for continuity between machine and terminal #8 (harness end) of connector. NO
NO
Faulty monitor panel or burnt indicator bulb.
Broken harness between monitor panel and ground, or faulty ground.
Broken harness between heater relay and monitor panel.
YES
Indicator is turned ON even after engine is
preheated.
Check if voltage between machine and terminal #11 of connector C16F-W of monitor panel is 24 V. · Insert a test bar into the rear of connector.
NO
Connector (Harness end) Monitor Panel (C16F-W)
T2BC-05-04-026
T5-5-17
Short-circuited harness between heater relay and monitor panel.
Faulty monitor panel.
TROUBLESHOOTING / Troubleshooting C MULFUNCTION OF ALTERNATOR INDICATOR
• Check the wiring connections first.
YES
Indicator is not turned ON although charging is insufficient.
Replace alternator relay with engine stop relay. Check if indicator is turned ON.
NO
Disconnect alternator relay. Connect terminal #2 (harness end) of con nector to machine. Check if indicator is turned ON.
YES㩷
· Key switch: ON
NO㩷
Broken harness between alternator relay and ground, or faulty ground. Connect terminal #7 of connector C16F-W of monitor panel to machine. Check if indicator is turned ON. ¨ Key switch: ON ¨ Insert a test bar into the rear of connector.
YES
Faulty alternator relay.
Indicator is not turned
Faulty alternator relay.
OFF even when engine runs.
· Engine: Running
Replace alternator relay with engine stop relay. Check if indicator is turned OFF.
· Engine: Running NO
Disconnect connector of alternator relay and connector C16F-W of monitor panel. Check for continuity between machine and terminal #7 (harness end) of connector of monitor panel.
Connector (Harness end)
Alternator Relay
YES㩷
Check for continuity between machine and terminal #2 (harness end) of connector of alternator relay.
Faulty monitor panel. NO㩷
Monitor Panel (C16F-W)
T2BC-05-04-026 T2BC-05-04-030
T25N-05-03-027
T5-5-18
TROUBLESHOOTING / Troubleshooting C
Broken harness between alternator relay and monitor panel.
YES㩷
Check if voltage between machine and terminal #1 (harness NO㩷 end) of connector of alternator relay is 24 V. · Key switch: ON
Check for continuity between machine and YES㩷 terminal #4 (harness end) of connector of alternator relay.
NO
YES
Faulty monitor panel, or burnt indicator bulb. Short-circuited harness between alternator and alternator relay. Broken harness between alternator relay and battery relay.
NO㩷
Short-circuited harness between alternator relay and monitor
YES㩷
Check if voltage between machine and terminal #1 (harness NO㩷 end) of connector of alternator relay is 24 V. · Key switch: ON
Disconnect connector of alternator. Connect terminal #2 (harness end) of conYES㩷 nector to machine. Check for continuity between machine and terminal #4 (harness end) of connector of alternator relay.
Faulty alternator.
NO
Broken harness between alternator and alternator relay. Broken harness between alternator relay and battery relay.
NO㩷
YES
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 o"Free mode" • Rear free brake mode selection switch YES o"Free mode" Indicator is not turned ON under indicator
lighting conditions. x Key switch: Start
NOTE: Turn ON slewing brake switch, set brake mode switch and front/rear free brake mode selection switch to "Auto brake mode", and confirm that engine can start.
Indicator is not turned
OFF even when engine
runs. ¨ Engine: Running
¨ Key switch: ON
Connect terminal #9 of connector C16F-W of monitor panel to machine. Check if indicator is turned ON. ¨ Key switch: ON ¨ Connect to machine from the rear of connector.
Disconnect connector C16F-W of monitor panel. Connect terminal #9 (harness end) of connector to machine. Disconnect connector MCA-6 of MC2/A. Check for continuity between machine and terminal #23 (harness end) of connector.
NO
Broken harness circuit between monitor panel and MC2/A.
Faulty MC2/A. YES
Faulty monitor panel or burnt indicator bulb.
NO
YES
Faulty MC2/A.
Check if indicator is turned OFF when connector MCA-6 of MC2/A is disconnected.
YES
· Key switch: ON NO
Connector (Harness end)
Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #9 (harness of connector. end)
Short-circuited harness between monitor panel and MC2/A.
Faulty monitor panel. NO
Monitor Panel (C16F-W)
Connector MCA-6 of MC2/A
(Harness end)
T2BC-05-04-026
T5-5-20
T2BC-05-04-027
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PILOT PRESSURE DROP INDICATOR Refer to "Check of Pilot Pressure Drop Indicator " in "Troubleshooting A".
Faulty pilot pressure drop indicator.
T5-5-21
TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOUR METER • Check the wiring connections first.
YES
Hour meter does not work.
¨ Key switch: ON
Disconnect connector C16F-W of monitor panel. Check for continuity between machine and terminal #8 (harness end) of connector. NO
Connector (Harness end)
Monitor Panel (C16F-W)
T2BC-05-04-026
T5-5-22
Faulty monitor panel (hour meter).
Broken harness between monitor panel and ground, or faulty ground.
TROUBLESHOOTING / Troubleshooting D TROUBLESHOOTING D PROCEDURE If IDU itself or sensors connected to IDU fail, failure codes will be displayed on the monitor window of IDU. If error code is indicated, find a page showing troubleshooting procedures corresponding to an error code from table on the next page, and follow the flowchart for inspection. Troubleshooting precautions: • Use a digital voltmeter for measurement of voltage or resistance. • "Measure XX between A and B" described in the flowchart implies that red tester stick of digital voltmeter is connected to A, and black tester stick to B. • When measuring, be careful to make connection to connector side and receptacle side correctly. • Before disconnecting connector, and turn OFF machine starter switch, and turn OFF IDU power.
Connector
T331-05-07-001
Receptacle
T331-05-07-002
T5-6-1
TROUBLESHOOTING / Troubleshooting D FAULT CODE TABLE Function Auto stop
Failure Boom angle Tower angle Jib angle Specification selection
Loads
Fault code E20 E21 E22 E26 E30 E31 E40 E43 E44 E45 E50
Control B communication failure Attachment wiring failure (open circuit)
E55
T5-6-13 T5-6-13 T5-6-14 T5-6-16 T5-6-18 T5-6-20 T5-6-22 㧙 㧙 㧙 T5-6-34 T5-6-35
W80 W81 W82 W83 W84 W88 W89
(Corresponding (Corresponding (Corresponding (Corresponding (Corresponding (Corresponding
㧙 㧙 㧙 㧙 㧙 㧙
W10 W11 W14 WA1 WA2 WA3 WA5 WB1 WB2 WB3 WB5
Control system
Reference page T5-6-4 T5-6-6 T5-6-4 T5-6-6 T5-6-8 T5-6-10
MC2/B communication status Wiring failure (open circuit) in non-disassembly position Hook overhoist wiring failure No hook overhoist wiring available on selection side Main power supply upper limit failure Monitoring voltage > Upper limit Main power supply lower limit failure Monitoring voltage < Lower limit Switch power supply short circuit failure 24V power supply monitoring voltage < Lower limit 2 Switch power supply 1 short circuit (Control A) 24V1 power supply monitoring (control A) voltage < Lower limit 2 Switch power supply 2 short circuit (control A) 24V2 power supply monitoring (control A) voltage < Lower limit 2 Switch power supply 3 short circuit (Control A) 24V3 power supply monitoring (control A) voltage < Lower limit 2 Sensor power supply short circuit (Control A) 5V power supply monitoring voltage (control A) < Lower limit 2 Switch power supply 1 short circuit (control B) Switch power supply 2 short circuit (Control B) 24V2 power supply monitoring (control B) voltage < Lower limit 2 Switch power supply supply 3 short (Control B) 24V3 power supply monitoring circuit (control B) voltage < Lower limit 2 Sensor power supply short circuit (Control B) 5V power supply monitoring voltage (control B) < Lower limit 2 (Corresponding to new version)
W49 Power supply
Boom angle > Upper limit Boom angle < Lower limit Tower angle > Upper limit Tower angle < Lower limit Jib angle > Upper limit Jib angle < Lower limit No data available corresponding to auto specification selection Crane is selected with tower attachment. Tower is selected with crane attachment. Wiring short circuit in non-disassembly position Boom/jib derricking force > Upper limit
W91 W47
E54
Specification selection
Boom angle upper limit failure Boom angle lower limit failure Tower angle upper limit failure Tower angle lower limit failure Jib angle upper limit failure Jib angle lower limit failure No ML data available
W90
E53
Communication
Judgment and conditions
Mode selection failure (tower) Mode selection failure (crane) Attachment wiring short circuit Boom/jib derricking force upper limit failure Boom/jib no-load derricking force failure Boom/jib derricking force < No-load criterion Boom/jib derricking force < Lower limit Boom/jib derricking force lower limit failure Load cell power supply upper limit failure 10 V power supply monitoring voltage > Upper limit Load cell power supply lower limit failure 10 V power supply monitoring voltage < Lower limit 1 Load cell power supply short circuit 10 V power supply monitoring voltage < Lower failure limit 2 Control A communication failure MC2/A communication status
E51 E52
Monitoring only
Failure explanation
to to to to to to
new new new new new new
version) version) version) version) version) version)
T5-6-2
T5-6-26 T5-6-32 㧙 㧙 㧙 T5-6-36 T5-6-36 T5-6-36 㧙 㧙 T5-6-37 T5-6-38 㧙 㧙
TROUBLESHOOTING / Troubleshooting D Failure Indication (Title Bar) FuncFailure tion Boom angle Auto stop Angle Tower angle Jib angle
Specification selection
Loads
Monitor- Communiing only cation
Angle wiring Specification selection Power supply
Control system
Fault code E20 E21 E27 E22 E26 E30 E31 E37 E40 E43 E44 E45 E50 E51 E52 E53 E54 E55 W90 W91 W38 W47 W48 W49 W10 W11 W14 WA1 WA2 WA3 WA5 WB1 WB2 WB3 WB5 W80 W81 W82 W83 W84 W88 W89
Failure indication (title bar) Red: Auto stop Orange: Monitoring and warning E20: Boom angle is abnormal E21: Boom angle is abnormal E27: Angle failure (open circuit) E22: Tower angle is abnormal E26: Tower angle is abnormal E30: Jib angle is abnormal E31: Jib angle is abnormal E37: Jib angle wiring failure (open circuit) E40: No data available E43: Tower selection E44: Crane selection E45: Cable reel short circuit E50: Load cell failure E51: Rope tension failure E52: Load cell failure E53: Load cell power supply failure E54: Load cell power drop E55: Load cell power supply short circuit W90: Communication A failure W91: Communication B failure W38: Jib angle wiring failure (open circuit) W47: Cable reel failure (open circuit) W48: Counterweight detection failure W49: Hook overhoist wiring failure W10: Power supply voltage failure W11: Power supply voltage drop W14: Sensor power supply short circuit(24V) WA1: Sensor power supply short circuit(24V1A) WA2: Sensor power supply short circuit (24V2A) WA3: Sensor power supply short circuit (24V3A) WA5: Sensor power supply short circuit (5VA) WB1: Sensor power supply short circuit (24V1B) WB2: Sensor power supply short circuit (24V2B) WB3: Sensor power supply short circuit (24V3B) WB5: Sensor power supply short circuit (5VB) W80: Engine control system failure W81: Horsepower control system failure W82: Brake control system failure W83: Slew control system failure W84: Operating pressure detection failure W88: Auto stop control system failure W89: Speed control system failure
T5-6-3
TROUBLESHOOTING / Troubleshooting D FAULT CODE E20, E22
E22
E20
Check if attachment of field machine is crane.
View B
NO
T25N-05-06-001
Controller (IDU)
YES
On the operation set window, select tower attachment.
Disconnect “1” connector (5P) of boom angle detector from machine relay box.
“3” 22P (female)
Check if E20 disappears.
YES (E21 or E26 indicated) Machine harness
NO
Boom angle detector failure
“2”16P (female, black)
1.6 m
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 detector
(No voltage, or 4V or
more)
YES
0.2 V
Machine relay box T25N-05-06-002
NO
Machine relay box failure
View A
Disconnect “3” connector (22P) of controller (IDU), connect machine harness to machine relay box, and measure resistance between terminals #4 and #7 of “2” connector (16P).
T25N-05-06-003
п (no resistance) Resistance
Connect terminal #6 of “3” connector (22P) of controller (IDU), machine relay box and machine harness, and check for continuity at terminal #6 of “2” connector (16P).
0ǡ to 1Mǡ
Machine harness failure
Absent
Continuity
Present
Controller (IDU) failure
T5-6-4
TROUBLESHOOTING / Troubleshooting D FAULT CODE E21, E26
E21, E26
Controller (IDU)
Check if “1” connector (5P) of boom angle detector is correctly connected.
Check if connection is correct.
“2” 5P (female)
YES
“1” 5 (male)
NO
1.6 m
Boom angle detector
Connect correctly connector of boom angle detector.
Machine relay box T25N-05-06-004
Check if E21 disappears.
NO
Disconnect “1” connector (5P) of boom angle detector. Measure voltage between terminals #1 and #4 of “2” connector (5P) of machine relay box.
“2” Connector (5P)
YES
T25N-05-06-021
4.4 V
Completion
NO
YES
Boom angle detector failure
T5-6-5
A
TROUBLESHOOTING / Troubleshooting D
A
E21, E26 (continued)
Connect machine harness to machine relay box, and measure voltage between terminals #4 and #7 of “3” connector (16P).
View B
T25N-05-06-001
View C
T25N-05-06-005
Controller (IDU)
4.4 V
YES
Machine relay box failure
NO
Disconnect “4” connector (22P) and “5” connector (26P) of controller (IDU), and measure resistance at terminal #4 of “4” connector and terminal #20 of “5” connector.
“5” 26P (female, white) “4” 22P (female, yellow) “3” 16P (female, black)
Resistance
1.6 m
Boom angle detector
0ǡ to Several 㧹ǡ
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.
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
Controller (IDU) failure
T5-6-6
View A
T25N-05-06-003
TROUBLESHOOTING / Troubleshooting D FAULT CODE E30 “1”, “6” Connectors (5P)
E30
Disconnect “1” connector (5P) and “6” connector (5P) of jib angle detector from boom-upper relay box, and measure voltage between terminals #2 and #4 of opposite “2” receptacle (5P) and “7” receptacle.
0.2 V (No voltage, or 4V or more)
T2BC-05-06-004
YES
Jib angle detector failure
NO
Disconnect “3” connector (24P) of cable reel wiring of boom-upper relay box, and measure voltage between terminals #17 and #19 and terminals #17 and #20.
“3” 24P (male)
“5” 24P (female) “7” 5P (female)
“4” 24P (male)
“2” 5P (female)
Machine relay box “6” 5P (male)
“1” 5P (male)
Boom-upper relay box
T2BC-05-06-007
“2”, “7” Receptacles (5P)
0.2 V
YES
(No voltage, or 4 V or more)
NO
Boom-upper relay box failure
T2BC-05-06-003
“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
0.2 V
(No voltage, or 4 V or NO more)
YES “5” Receptacle (24P)
Cable reel wiring failure
B
T2BC-05-06-001
T5-6-7
TROUBLESHOOTING / Troubleshooting D B
E30 (continued)
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 C
T25N-05-06-005
View B
T25N-05-06-001
Controller (IDU)
YES 0.2 V
(No voltage, or 4 V or NO more)
Machine relay box failure “10” 24P (female, white) “9” 22P (female, yellow) “8” 12P (female, black)
Disconnect “9” connector (22P) and “10” connector (26P) of controller (IDU), and measure resistance between terminal #4 of “9” connector (22P) and terminals #19, #7 of “10” connector (26P).
1.6 m
Machine relay box
T2BC-05-06-006
Resistance
0: to Several M:
View A
п (no resistance)
Check for continuity between terminal #4 of “8” connector (12P) and terminal #6 of “9” connector (22P).
Continuity
Continued
No continuity
Machine harness failure
Controller (IDU) failure
T5-6-8
T2BC-05-06-005
TROUBLESHOOTING / Troubleshooting D FAULT CODE E31
E31
Check if “1” connector (5P) and “6” connector (5P) of jib angle detector are correctly connected.
“7” 5P (female)
Check if connection is correct.
“6” 5P (male)
YES
“2” 5P (female) “1” 5P (male)
NO Connect correctly “1”, “6” connectors of jib angle detector.
Relay box
T2BC-05-06-008
“1”, “6” Connectors (5P)
T2BC-05-06-004
“2”, “7” Receptacles (5P)
Check if E31 disappears.
NO
Disconnect “1” connector (5P) and “6” connector (5P) of jib angle detector. Measure voltage between terminals #1 and #4 of “2” receptacle (5P) and “7” receptacle (5P) opposite to “1” connector (5P) and “6” connector (5P) of jib angle detector respectively.
T2BC-05-06-003
YES Completion
4.8 V
NO
C
T5-6-9
YES
Jib angle detector failure
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.
4.8 V
YES 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) Machine relay box
Disconnect “4” connector (24P) of cable reel wiring of machine relay box, and measure voltage between terminals #16 and #19, #16 and #20 of opposite “5” receptacle (24P).
Boom-upper relay box
T2BC-05-06-007
4.8 V
View A
YES
T2BC-05-06-005
NO
Cable reel wiring failure
“3” Connector (24P)
Connect machine harness to machine relay box, and measure voltage between terminals #2 and #5, #1 and #5 of “8” connector (12P).
T25N-05-06-023
“5” Receptacle (24P)
4.8 V
NO
YES
Machine relay box failure
T25N-05-03-028
D
T5-6-10
TROUBLESHOOTING / Troubleshooting D
D
E31 (continued)
With “8” connector (12P) disconnected, disconnect “10” connector (26P) and “9” connector (22P) of controller (IDU). Measure resistance between terminal #4 of “9” connector (22P) and terminal #7 of “10” connector (26P), terminal #4 of “9” connector (22P) and terminal #19 of “10” connector (26P).
View B
T25N-05-06-001
View C
T25N-05-06-005
Controller (IDU)
Resistance
0 : to Several M :
п (no resistance)
Machine harness failure “10” 26P (female, white) “9” 22P (female, yellow) Machine harness “8” 12P (female, black)
1.6 m
Machine relay box
T2BC-05-06-006
Disconnect “10” connector (26P) of controller Check for continuity between terminals (IDU). #19 and #2 of “8” connector (12P). Check for continuity between terminal #7 of “10” connector and terminal #1 of “8” connector (12P). (26P)
View A
Continuity
No continuity
Continued Machine harness failure
Controller (IDU) failure
T5-6-11
T2BC-05-06-005
TROUBLESHOOTING / Troubleshooting D FAULT CODE E40
E40
Controller (IDU) failure
FAULT CODE E43
E43
Check if attachment of field machine is a tower.
NO
YES Controller (IDU) failure On the operation set window, check the selection of attachment.
Check if tower is selected.
NO
YES
Controller (IDU) failure
On the operation set window, select tower attachment.
T5-6-12
TROUBLESHOOTING / Troubleshooting D FAULT CODE E44
E44
Check if attachment of field machine is a crane.
NO
YES Controller (IDU) failure On the operation set window, check the selection of attachment.
Check if crane is selected.
NO
YES
Controller (IDU) failure
On the operation set window, select tower attachment.
T5-6-13
TROUBLESHOOTING / Troubleshooting D FAULT CODE E45
E45
Disconnect “1” connector (24P) for cable reel wiring of machine relay box, and measure resistance at terminals #1, #2, and between terminals #1 and #3 of plug.
View A
T25N-05-06-012
View B
T25N-05-06-003
In case of crane, #1, #2 = 0: #1 to #3 = no resistance In case of tower, #1, #2 = no resistance #1 to #3 = 0:.
Controller (MC2/B)
NO
E To T5-6-17
YES
“3” 26P (female, yellow) “4” 16P (female, white)
Cable reel wiring
“2” 16P (male, white) 1.6 m
Reconnect “1” connector (24P) for cable reel wiring as it was. Connect machine harness to machine relay box, and measure resistance between terminals #5 and #7, and at terminals #6 and #7 of “2” connector (16P).
“1” 24P (male)
Machine relay box
Boom-upper relay box
#6, # 7 = 0: #5 to #7 = no resistance. In case of tower, #6, #7 = no resistance. #5 to #7 = 0:
NO
T25N-05-06-013
In case of crane,
YES
“1” Connector (24P)
With “2” connector (16P) disconnected, disconnect “3” connector (26P) of controller (MC2/B), and measure resistance between terminals #5 and #7, and at terminals #6 and #7 of “4” connector (16P).
T25N-05-06-023
Machine relay box failure
#5 to #7, # 6, # 7: no resistance
YES
NO (500 k: or more)
Machine harness failure
T5-6-14
Controller (MC2/B) failure
TROUBLESHOOTING / Troubleshooting D
E45 (continued)
E
“6” Receptacle (24P)
Disconnect “5” connector (24P) for cable reel wiring of boom-upper relay box, and measure resistance at terminals #1, #2, and between terminals #1 and #3 of “6” receptacle.
T25N-05-03-028
Controller (MC2/B)
In case of crane,
#1, #2 = 0: #1 to #3 = no resistance In case of tower, #1, #2 䋽 no resistance #1 to #3 = 0:.
NO
Boom-upper relay box failure YES
“6” 24P (female)
Cable reel wiring failure
Cable reel wiring “5” 24P (male)
Machine relay box
Boom-upper relay box T25N-05-06-013
T5-6-15
TROUBLESHOOTING / Troubleshooting D FAULT CODE E50 (CRANE)
E50
Controller (IDU)
Disconnect “1” connector (7P) from load cell.
“4” 26P (female, white)
Check if E50 disappears.
YES (E52 indicated)
Relay box harness
Machine harness “3” 16P
NO Load cell failure Reconnect “1” connector (7P) of load cell as it was. Disconnect “2” connector (4P) that connects load cell harness and relay box.
Relay box Crane Load cell
“4” 4P (male)
Load cell harness
“1” 7P (female)
Check if E50 disappears.
YES (E52 indicated)
NO
Load cell harness failure
A
T5-6-16
T2BC-05-06-009
TROUBLESHOOTING / Troubleshooting D
A
Controller (IDU)
Reconnect “2” connector of load cell as it was. Disconnect “3” connector of relay box harness.
“4” 26P (female, white)
Check if E50 disappears.
YES (E52 indicated)
Relay box harness
Machine harness “3” 16P
NO Relay box failure Reconnect “3” connector as it was. Disconnect “4” connector (26P) of controller (IDU).
Relay box Crane Load cell
“4” 4P (male)
Load cell harness
“1” 7P (female)
Check if E50 disappears.
NO
YES (E52 indicated)
Machine harness failure
Controller (IDU) failure
T5-6-17
T2BC-05-06-009
TROUBLESHOOTING / Troubleshooting D FAULT CODE E50 (TOWER)
E50
Controller (IDU)
Disconnect “1” connector (7P) from load cell.
Check if E50 disappears.
YES (E52 indicated)
“4” 26P (female, white)
Relay box harness “3” 16P
NO
Relay box
Load cell failure Reconnect “1” connector (7P) of load cell as it was. Disconnect “2” connector that connects load cell harness and relay box.
Tower jib load cell
“2” 7P (male)
Load cell harness “1” 7P (female)
Check if E50 disappears.
YES (E52 indicated)
NO
Load cell harness failure
A
T5-6-18
T2BC-05-06-009
TROUBLESHOOTING / Troubleshooting D
A
Controller (IDU)
Reconnect “2” connector of load cell as it was. Disconnect “3” connector of relay box harness.
“4” 26P (female, white)
Check if E50 disappears.
Relay box harness
YES (E52 indicated) “3” 16P
Relay box NO
Relay box failure Tower jib load cell
“2” 7P (male)
Reconnect “3” connector as it was. Disconnect “4” connector (26P) of connector (IDU).
Load cell harness “1” 7P (female)
Check if E50 disappears.
YES (E52 indicated)
NO
Machine harness failure
Controller (IDU) failure
T5-6-19
T2BC-05-06-009
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 setting is correct.
NO
On the operation set window, make the setting depending on field machine.
YES
Check the difference between
actual load and indication load at boom upper and boom lower.
Check if the difference is large (1 ton or more).
YES
Grease boom foot pin, live mast foot pin, hanger link pin, boom stop inner, etc.
NO Release load cell tension completely.
Select the IDU monitor window. Operation: 1. Turn ON maintenance key switch. 2. Press " ޚkey" on the ML window. 3. Select the monitor in the maintenance menu window. 4. Select the IDU monitor in the monitor menu window.
IDU monitor window IDU Monitor
Load cell output (crane) Check "BM LOAD" in the IDU monitor window (1/3 page). Check "JB LOAD" in case of tower.
Load cell output (tower)
IDU AI1 JB ANGLE JB ANGLE2 BM ANGLE BM LOAD JB LOAD JB ANGLE JB ANGLE2 BM ANGLE
Load factor 0.00 V 0.00 V 0.00 V 0.50 V 0.50 V 0.50 V 0.00 V 2.50 V
Move page
0.5 V r 0.04 V
YES
NO
F
Controller (IDU) failure
T5-6-20
IDU AI2 (AN_IN0) (AN_IN1) (AN_IN2) (AN_IN3) HYD THM
****** ****** ****** ****** 0.00 V FD BRK THM 0.00 V RD BRK THM 0.00 V 3D BRK THM 0.00 V Return
30% IDU AI3 (AN_IN8) (AN_IN9) (AN_IN10) (AN_IN11)
1/3 ****** ****** ****** ******
TROUBLESHOOTING / Troubleshooting D
Load cell zero point correction window
F
E51 (continued)
Load cell zero point correction Load factor Load cell output voltage
Corrected output voltage
Standard correction voltage Correctable voltage range
Select the load cell zero point correction
8 8 8 8
Detach the load cell from the hoist rope to completely eliminate the load ratio from the load cell. After detaching the load cell, press <START> key. Pay attention. Don̉t disconnect the connector from the load cell.
window.
Operation: 1. Turn ON maintenance key switch. 2. Press " ޚkey" on the ML window.
3. Select the adjustment menu in the
Cancel
maintenance menu window. 4. Select the load cell zero point correction in the adjustment menu window. In case of tower, select the jib load cell zero point correction.
Start
Load cell zero point correction completion window Load cell zero point correction Load factor
Load cell output voltage
Corrected output voltage
Press ޚkeys once.
30%
Standard correction voltage
Load cell zero point correction is completed.
Correctable voltage range
30%
8 8 8 8
Detach the load cell from the hoist rope to completely eliminate the load ratio from the load cell. After detaching the load cell, press <START> key. Pay attention. Don̉t disconnect the connector from the load cell.
Select the IDU monitor window. Operation:
1. Turn ON maintenance key switch. 2. Press " ޚkey" in the ML window.
Cancel
3. Select the monitor in the maintenance menu window. 4. Select the IDU monitor in the monitor menu window.
Start
IDU monitor window
IDU Monitor
IDU AI1 JB ANGLE JB ANGLE2 BM ANGLE BM LOAD JB LOAD JB ANGLE JB ANGLE2 BM ANGLE
Check "BM LOAD" in the IDU monitor window (1/3 page).
In case of tower, check "JB LOAD".
Load cell output (crane) Load cell output (tower)
Load factor 0.00 V 0.00 V 0.00 V 0.50 V 0.50 V 0.50 V 0.00 V 2.50 V
Move page
0.5 V r 0.04 V
NO
YES
Check if E51 disappears.
YES
Load cell failure
NO
Controller (IDU) failure
Completion
T5-6-21
IDU AI2 (AN_IN0) (AN_IN1) (AN_IN2) (AN_IN3) HYD THM
****** ****** ****** ****** 0.00 V FD BRK THM 0.00 V RD BRK THM 0.00 V 3D BRK THM 0.00 V Return
30% IDU AI3 (AN_IN8) (AN_IN9) (AN_IN10) (AN_IN11)
1/3 ****** ****** ****** ******
TROUBLESHOOTING / Troubleshooting D FAULT CODE E52
In case of crane
E52
Controller (IDU)
Check if “1” connector (7P) of load cell is correctly connected.
Check if connection is correct.
YES
Relay box NO Load cell Connect “1” connector (7P) of load cell correctly.
Load cell harness
“1” 7P (female)
Check if E52 disappears.
NO
Measure voltage between terminals #A and #D of “1” connector (7P) of load cell.
T2BC-05-06-009
Connector (7P)
YES
T25N-05-06-022
Completion
9.8 V
YES
NO
Load cell failure
G
T5-6-22
TROUBLESHOOTING / Troubleshooting D
G
E52 (crane) (continued) Controller (IDU)
Disconnect “2” connector (4P) of load cell harness, and measure voltage between terminals #1 and #3 of opposite “3” connector (4P).
“4” 22P (female, yellow) “5” 26P (female, white)
9.8 V
Machine harness
YES
“6” 16P “5” Connector
NO Load cell harness failure
Relay box “3” Connector
Connect relay box and machine harness. Disconnect “6” connector. Measure voltage at terminals #9, #11.
Load cell “2” Connector
Load cell harness
9.8 V
“1” 7P (female)
YES
T2BC-05-06-009
NO Relay box failure
H
T25N-05-06-020
View A
View B
T25N-05-06-001
View C
T25N-05-06-005
View D
T5-6-23
T2BC-05-06-010
TROUBLESHOOTING / Troubleshooting D
H Controller (IDU)
Disconnect “4” connector (22P) and “5” connector (26P) of controller (IDU), and measure resistance at terminal #14 of “4” connector and at terminal #18 of “5” connector.
“4” 22P (female, yellow) “5” 26P (female, white)
Machine harness “6” 16P
Resistance “5” Connector
п (no resistance)
Relay box “3” Connector
Make short circuit between terminals #9 and #11 of “6” connector (16P) by using jumper wire or the like.
Load cell “2” Connector
Load cell harness
Check for continuity terminal #3 of “4” connector (22P) of controller (IDU) and terminal #18 of “5” connector (26P).
“1” 7P (female)
T2BC-05-06-009
Continuity
No continuity
Continued
T25N-05-06-020
View A
Controller (IDU) failure
Controller (IDU) failure
View B
T25N-05-06-001
View C
T25N-05-06-005
View D
T5-6-24
T2BC-05-06-010
TROUBLESHOOTING / Troubleshooting D
In case of tower
E52 Controller (IDU)
Machine relay box
Check if “1” connector (7P) of load cell or “2” connector (7P) of machine relay box is correctly connected.
Check if connection is correct.
YES “1” 7P (female)
NO
Connect “1” connector or “2” connector correctly. Load cell
“2” 7P (male) T25N-05-06-018
“1” Connector (7P) Check if E52 disappears.
NO
Measure voltage betweenterminals #A and #D of “1” connector (7P) of load cell.
YES
T25N-05-06-022
Completion
9.8 V
YES
NO
Load cell failure
I
T5-6-25
TROUBLESHOOTING / Troubleshooting D
I
E52 (tower) (continued)
Controller (IDU)
Measure voltage between terminals #A and #D of “3” receptacle (7P) of machine relay box.
9.8 V
“6” 26P (female, white)
YES
Machine harness
NO
Load cell harness failure
“5” 22P (female, yellow)
“4” 16P (female, black)
1.6 m
Connect machine harness and machine relay box, and measure voltage between terminals #11 and #16 of “4” connector (16P). “3” 7P (female)
Machine relay box
9.8 V
YES
Load cell
Load cell harness
T25N-05-06-019
NO
Machine relay box failure
Disconnect “5” connector (22P) and “6” connector (26P) of controller (IDU), and measure resistance at terminal #14 of “5” connector and terminal #6 of “6” connector.
T25N-05-06-003
View A
Resistance
View B
T25N-05-06-001
View C
T25N-05-06-005
0: to Several M:
п (no resistance)
Make short circuit between terminals #11 and #16 of “4” connector (16P) by using
jumper wire or the like. “3” Receptacle (7P)
Check for continuity between terminal #3 of “5” connector (22P) of controller (IDU) and terminal #6 of “6” connector (26P).
T25N-05-06-022
Continuity
No continuity
Continued
Machine harness failure
Controller (IDU) 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 connection is correct.
NO
A
YES
Disconnect “1” connector (24P) for cable reel wiring of machine relay box, and measure
resistance at terminals #1, #2, and between terminals #1 and #3 of “1” connector (24P).
In case of crane, #1, #2 = continuity #1 to #3 = no continuity In case of tower, #1, #2 = no continuity #1-#3 = continuity
Controller (MC2/B)
NO Machine harness
B “3” 16P (male, white) 1.6 m
Cable reel wiring
YES Reconnect “1” connector (24P) for cable reel wiring as it was. Connect machine harness to machine relay box, and measure resistance between terminals #5 and #7, #6 and #7 of “3” connector (16P).
“1” 24P (male) “2” 24P (male) Machine relay box
Boom-upper relay box
T2BC-05-06-013
In case of crane, #6, #7 = continuity #5 to #7 = no continuity In case of tower, #6, #7 = no continuity #5 to #7 = continuity
YES
T25N-05-06-012
View A “1” Connector (24P)
C
NO
Machine relay box failure
T25N-05-06-023
T5-6-27
TROUBLESHOOTING / Troubleshooting D
A
W47 (continued)
Disassembly position (for transport)
YES
NO
Boom angle
30 q or more
Connect cable reel wiring correctly.
Less than 30 q or no angle gauge
Controller (IDU) failure
T5-6-28
Set boom angle at less than 30 q.
TROUBLESHOOTING / Troubleshooting D
B
W47 (continued)
“6” Receptacle (24P)
Disconnect “2” connector (24P) for cable reel wiring of boom-upper relay box, and check for continuity between terminals #1 and #2, terminals #1 and #3 of “6” receptacle.
T25N-05-03-028
Controller (MC2/B)
In case of crane, #1 to #2 = continued #1 to #3 = no continuity In case of tower, #1 to #2 = no continuity #1 to #3 = continued
NO
Boom-upper relay box failure YES
Cable reel wiring failure
“6” 24P (female)
Cable reel wiring
Machine relay box
“2” 24P (male)
Boom-upper relay box (crane) T25N-05-06-025
“6” 24P (female)
Cable reel wiring “5” 24P (male)
Machine relay box
Boom-upper relay box (tower)
T5-6-29
T2BC-05-06-012
TROUBLESHOOTING / Troubleshooting D
W47 (continued)
C
Reconnect “3” connector (16P) as it was. Disconnect “4” connector (22P) and “5” connector (26P) of controller (MC2/B), and check for continuity between terminal #4 of “4” connector (22P) and #8, #21 of “5” connector (26P).
View B
T25N-05-06-001
View C
T25N-05-06-005
In case of crane, #4 to #8 = continued #4 to #21 = no continuity In case of tower, #4 to #8 = no continuity #4 to #21 = continued
YES
Controller (MC2/B) failure
NO
Controller (MC2/B)
Machine harness failure
“5” 26P (female, yellow) Machine harness “4” 22P (female, yellow) “3” 16P (male, white) Cable reel wiring
1.6 m
Machine relay box
Boom-upper relay box
T5-6-30
T25N-05-06-033
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 connection is correct.
NO
Connect connector correctly.
YES
“2” 24P (female)
Check for continuity between terminals #5 and #6 of “1” connector (7P) for hook overhoist. “1” 7P (male) Machine relay box
No continuity
Continuity
Boom-upper relay box
T25N-05-06-026
“1” Connector (7P)
Hook overhoist connector failure
Continued
Reconnect “1” connector (7P) for hook overhoist as it was, and check for continuity between terminals #1 Check for continuity between and #14 (#1 and #15) of “2” terminals in ( ) in case of sub receptacle (24P) of boom-upper hook. relay box.
T2BC-05-03-010
“2” Receptacle (24P)
T25N-05-03-028
No continuity
Continuity
Continued
D
Boom-upper relay box failure
To T5-6-33
T5-6-31
TROUBLESHOOTING / Troubleshooting D
W49 (continued)
D
Reconnect “2” receptacle (24P) of boom-upper relay box as it was. Check for continuity between terminals #1 and #14 (#1 and #15) of “3” connector (24P) of machine relay box.
Controller (MC2/B) Controller (IDU)
Check for continuity between terminals in ( ) in case of sub hook.
Continuity
No continuity “5” 16P (female, yellow)
Continued
“6” 22P (female, yellow)
Cable reel wiring failure
Machine harness
“3” 24P (male) “2” 24P (female)
Reconnect “3” connector (24P) of machine relay box as it was. Connect machine harness to machine relay box. Disconnect “4” connector (16P), and check for continuity between terminals #7 and #10 (#7 and #9) of “4”connector (16P). Check for continuity between terminals in ( ) in case of sub hook.
“4” 16P (male, white)
Cable reel wiring Machine relay box
Boom-upper relay box
Continuity
T25N-05-06-027
No continuity
Continued
Machine relay box failure
T25N-05-06-012
View A
Reconnect “4” connector (16P) as it was. Disconnect “5” connector (16P) of controller (IDU) and “6” connector (22P) of controller (MC/2B). Check for continuity between terminal #10 (#3) of “5” connector (16P) of controller (IDU) and terminal #4 of “6” connector (22P) of controller (MC2/B).
View B
T25N-05-06-032
View C
T25N-05-06-001
Check for continuity between terminals in ( ) in case of sub hook.
Continuity
Continued
“3” Connector (24P)
No continuity
Machine harness failure
Controller (IDU) failure
T25N-05-06-023
T5-6-32
TROUBLESHOOTING / Troubleshooting D FAULT CODE W90
W90
Controller (MC2/A)
Controller (IDU)
Check for continuity between terminals #A and #A, between terminals #B and #B of connector for CAN communication (“1” and “2”, 3P) provided between controller (IDU) and controller (MC2/A). “4” 22P (female, yellow) “1” 3P (male)
Continuity
“3” 26P (female, yellow)
Machine harness “2” 3P (male)
No continuity
CAN cable failure
Continued
CAN cable (Connected to all controllers) T25N-05-06-028
Reconnect connector for CAN communication as it was. Check for continuity between terminal #14 of “3” connector (26P) of controller (IDU) and terminal #9 of “4” connector (22P) of controller (MC2/A).
View A
T25N-05-06-029
Continuity
No continuity
View B
T25N-05-06-005
View C
T25N-05-06-001
Continued
Check for continuity between terminal #15 of “3” connector (26P) of controller (IDU) and terminal #20 of “4” connector (22P) of controller (MC2/A).
Continuity
Continued
No continuity
Machine harness failure
Controller (IDU) failure or controller (MC2/A) failure
T5-6-33
TROUBLESHOOTING / Troubleshooting D FAULT CODE W91
W91
Controller (MC2/B)
Controller (IDU)
Check for continuity between terminals #A and #A, between terminals #B and #B of connector for CAN communication (“1” and “2”, 3P) provided between controller (IDU) and controller (MC2/B). “4” 22P (female, yellow) “1” 3P (male)
Continuity
“3” 6P female, yellow)
Machine harness “2” 3P (male)
No continuity
CAN cable failure
Continued
CAN cable (Connected to all controllers) T25N-05-06-028
Reconnect connector for CAN communication as it was. Check for continuity between terminal #14 of “3” connector (26P) of controller (IDU) and terminal #9 of “4” connector (22P) of controller (MC2/B).
View A
T25N-05-06-029
Continuity
No continuity
View B
T25N-05-06-005
View C
T25N-05-06-001
Continued
Check for continuity between terminal #15 of “3” connector (26P) of controller (IDU) and terminal #20 of “4” connector (22P) of controller (MC2/B).
Continuity
Continued
No continuity
Machine harness failure
Controller (IDU) failure or controller (MC2/B) failure
T5-6-34
TROUBLESHOOTING / Troubleshooting D FAULT CODE WA1
WA1
Disconnect connectors of free mode switch.
Check if WA1 disappears.
YES
NO Free mode switch wiring failure
Controller (MC2/A) failure
FAULT CODE WA2
WA2
Disconnect connectors of emergency stop switch.
Check if WA2 disappears.
YES
NO Emergency stop switch wiring failure
Controller (MC2/A) failure
FAULT CODE WA3 WA3
Controller (MC2/A) failure
T5-6-35
TROUBLESHOOTING / Troubleshooting D FAULT CODE WB2
WB2
Controller (MC2/B) failure
T5-6-36
TROUBLESHOOTING / Troubleshooting D FAULT CODE WB3 WB3
Controller (MC2/B)
Disconnect “1” connector (24P) of boom-upper relay box.
Check if WB3 disappears.
YES “3” 16P (male, white)
Boom-upper relay box failure
NO
“2” 24P (male) “1” 24P (male)
Disconnect “2” connector (24P) of machine relay box.
Cable reel wiring Machine relay box
Check if WB3 disappears.
YES
Boom-upper relay box T25N-05-06-030
Cable reel wiring failure NO
Connect machine harness to machine relay box. Disconnect “3” connector (16P).
Check if WB3 disappears.
NO
YES
Boom-upper relay box failure
Controller (MC2/B) failure
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).
NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the wire harness side are shown. Harness Harness end connector
Mounting Surface
T6L4-05-03-001
T5-7-1
TROUBLESHOOTING/Troubleshooting E HOW TO READ FAULT CODE IN ECU ENGINE TROUBLESHOOTING
IMPORTANT: Record all indicated fault codes, and verify that all recorded fault codes are correct by reference with the fault code table in the following page.
1. With engine stopped, turn the key switch to the ON position. 2. Reset the troubleshooting switch to the ON position. ECU lamp starts indicating failure codes. 3. The fault code is indicated by a combination of numbers (1 to 5) in two digits. The code number is indicated by the number of blinking of ECU lamp. ECU lamp is turned OFF in a short period between digits. When two or more fault codes are indicated, a two-digit fault number (showing one fault code) is indicated first, the lamp is turned OFF in a long period, and then the next fault code is indicated. 4. After all fault codes are indicated, the first fault code is indicated again. This cycle is repeated. 5. When turning the key switch OFF, the indication of fault codes is finished.
ECU Lamp
Troubleshooting Switch T25N-01-02-010
Example: Fault codes 2-1 and 2-3 The first digit is "2".
The final digit is "1".
The first digit is "2".
The final digit is "3".
Turn ON
Period between codes
Turn OFF
Fault code 2-1
Fault code 2-3
T5-7-2
T25N-05-07-007
TROUBLESHOOTING/Troubleshooting E Failure and Number of Blinking of ECU Lamp Failure (No. of Failure location㩷
Countermeasure by ECU (in backup mode)㩷
blinking)㩷 *
0-1
*
1-2
*
1-4
Normal㩷 Feedback error (Actual advance angle of fuel injection timing does not follow the target advance angle.)㩷 Timing sensor㩷
TDC sensor㩷 *
1-5
*
2-1
*
2-2
*
2-3
Coolant temperature sensor㩷 Rack sensor㩷 TCV ADV and TCV RTD solenoid valves㩷
䋭㩷
Both timer control valves: OFF㩷 Timer control (fuel injection timing control): Stop㩷 Both timer control valves: OFF㩷 Timer control (fuel injection timing control): Stop㩷 Determining engine speed from the number of timing pulses.㩷 Timer control (fuel injection timing control): Stop㩷 Keeping coolant temperature at 80C°.㩷 Locking rack to full load position.㩷 Timer control (fuel injection timing control): Stop㩷
| :Operable U: Operable in backup mode㩷 * :(1-5) implies that one-time blinking, one-time interruption, and five-time blinking of ECU lamp. IMPORTANT: Avoid long-hour operation or heavy load operation in the backup mode.㩷
T5-7-3
Operation
| U
U
U | | U
TROUBLESHOOTING/Troubleshooting E Checking: Check harness continuity and short circuit between ECU and each sensor according to the failure in Table. When harness is sound, the related sensor or ECU may be faulty.
Connectors of ECU and each sensor
TDC sensor (Harness end)
TCV ADV Solenoid Valve, TCV RTD Solenoid Valves (Harness end)
Ground
Sensor output
TCV ADV solenoid valve - Terminal
TCV RTD solenoid valve - Terminal
TCV RTD solenoid valve + Terminal
T2BC-05-04-008
TCV ADV solenoid valve + Terminal T2BC-05-07-002
Timing sensor (Harness end)
Ground
Troubleshooting Unit (Machine end)
Power supply
Sensor output
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16
T2BC-05-07-001
Rack sensor (Harness end)
Ground
K-Line
Ground
DUT
ECU Connector 1 (Harness end)
MDL
Timing sensor㩷
Ground
TCV ADV㩷 solenoid valve
OSC
T2BC-05-07-002
Terminal 䋫
T25N-05-07-006
Rack sensor
Sensor output㩷 Ground㩷 MDL㩷
OSC Ground
Terminal 䋭
1
Coolant temperature sensor (Harness end)
2
3
4
5
6
7
8
9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26 Sensor output
Ground Coolant temperature sensor㩷 TDC sensor
Coolant temperature output
Terminal 䋭 Terminal 䋫 TCV RTD solenoid valve㩷
T2BC-05-07-003
ECU Connector 2 (Harness end)
Troubleshootingunit K-Line
T5-7-4
1
11
12
22
TROUBLSHOOTING / Troubleshooting F Information Display Unit (IDU) Technical Manual 1. Outline of IDU IDU function consists of moment limiter(HSL-1) and monitor which shows various inputs and outputs. This manual explains the structure and the function of IDU.
1-1. Difference between HSL-1 and SML-10 (1) Software install HSL-1 Rewriting the controller CPU by personal computer. SML-10 Change the ROM on the controller. (2) Rated Capacity and Display Load In case of Boom hook and Jib hook both available. HSL-1 Subtract hook self weight which is not selected from rated capacity of selected hook. SML-10 Add hook selff weight which is not selected to display load of selected hook load. setting of jib none
boom hook boom hook weight + boom hook lifting load tip extension boom hook weight + boom hook lifting load jib
jib hook
jib hook weight + jib hook lifting load + boom hook weight
(3) Loadcell and Angle sensor
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
%QPGEVKQP $QZ
+&7
%CDNG 4GGN %QTF
%#0 *CTPGUU VQ /% # CPF /% $
&KURNC[
5YKVEJ $QZ
+PUKFG QH %CD
/CKP *CTPGUU
*CTPGUU 1WVUKFG QH % D
#PING 5GPUGT
%QPGEVKQP $QZ
Fig. 2.1 Compornents
T5-8-2
.QCFEGNN
TROUBLSHOOTING / Troubleshooting F 3. Structure and Function 3.1 Controller The controller is attached in the rear stand of operater's seat back. Four controllers are attached in the rear stand. ECU, IDU, MC2A, and MC2B are attached from upper side.
Indicated as IDU on a label
Table 3.1 controller inputs outputs item specification N0. note analogue inpu A/D 12bit 8 Loadcell Angle sensor 12 temperature sensor A/D 10bit 15 digital inputs +24V inputs 8 Switch Box pull up 5V inputs 8 thermo switch pull up 5V inputs 16 auto stop for MC2B digital outputs open collector output
T5-8-3
TROUBLSHOOTING / Troubleshooting F 3.2 Loadcell The Loadcell is attached at the rope end of the boom hoist rope.
Fig 3.2 Loadcell
Tbl 3.2 Load-Output Voltage Load(metlic ton) 0 3.0 6.0 Load(kips) 0 6.62 13.23 Output Voltage(V) 0.500 1.833 3.167
T5-8-4
9.0 19.85 4.500
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 Fig 3.3 Angle Sensor
Angle(deg) Output Voltage(V)
Tbl 3.3 Angle-Output Voltage -15 0 30 60 0.680 1.266 2.438 3.610
T5-8-5
90 4.782
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.
Fig 3.4.1 Switch Box
T5-8-6
TROUBLSHOOTING / Troubleshooting F connecter 8 䋱
:
ᛶ᛫ 㪈㪆㪋㪮䇭㪈㪢㱅
㪣㪜㪛䋱䌾䌌䌅䌄䋸
䋲
䌓䌗䋱
䋳
䌓䌗䋲
䋴
䌓䌗䋳
䋵
䌓䌗䋴
䋶
)0& 8
䋷
!
䋸
䌓䌗䋵
䋹
䌓䌗䋶
䋱䋰
䌓䌗䋷
䋱䋱
䌓䌗䋸
)0& 䋱䋲
Fig 3.4.2 Switch Box circuit
T5-8-7
TROUBLSHOOTING / Troubleshooting F 3.5 Display
The display is the general-purpose article for car navigation. (made from Panasonic).
Fig 3.5 Display
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. 4.1 Normal Screen (1) Normal Screen Shift Order Key switch ON
no Is attachment available?
Transport Configuration Screen w/o attachment
Transport Configuration Screen w/ attachment
yes no Is boom angle upper 10 deg? yes
(1)
Machine Specifications Screen
(2)
ML Screen
no Out of radius and no load ? yes (3)
3sec push botton
(4)
Erection/Fold Screen
no Is boom angle upper 10 deg? yes yes Out of radius? no
T5-8-9
TROUBLSHOOTING / Troubleshooting F Fig. 4.1 Normal Screens (1) - (6)
(4) Erection/Fold Screen
(1) Machine Specifications Screen
(2) ML Screen
(5) Transport Configuration Screen w/o attachment
(3) 3sec push botton
(6) Transport Configuration Screen w/ attachment
T5-8-10
TROUBLSHOOTING / Troubleshooting F 4.2 Menu Screen Menu Screen List Push the Menu botton
QP
for Service person
Maintenance Key Switch off for User
4.2.1 User Menu (1) Machine Specifications (2) Inspection (3) Hook Height Reset (4) Working Range Restriction (5) Gross Rated Load Table (6) Adjustment 1) Clock Adjustment 2) Hook Height Adjustment (7) Operation Instructions
4.2.2 Maintenance Menu (1) Inspection Menu 1) Inspection of BM Overhoist(Sensor) 2) Inspection of BM Overhoist(L/S) (2) Adjustment Menu 1) Angle Correction 2) Self-weight Correction 3) Loadcell Zero Point Correction (3) Monitor Menu 1) Electric Source Monitor 2) Switch Panel Key Check 3) IDU I/O Monitor 4) MC2A I/O Monitor 5) MC2B I/O Monitor 6) Load Computing Monitor (4) Specification Setting Men (can't use) (5) Record Menu (can't use) (6) Version Display (7) Service Manual (can't use) (8) Language Select (can't use)
T5-8-11
TROUBLSHOOTING / Troubleshooting F 4.2.1 User Menu (1) Machine Specifications
If you need change settings, use <SELECT> key and <CHANGE> key.
(2) Inspection
Move cursor to the item changed by the <CHANGE> key, and press the <SELECT> key.
(3) Hook Height Reset
Confirm each safety device stop as this table.
T5-8-12
The present hook height is set to 0.0ft. Yes No
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. (6)- 1) Clock Adjustment Skip (6)- 2) Hook Height Adjustment
(5) Gross Rated Load Table
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)
1) Inspection of BM Overhoist(Sensor)
Hoist the boom until the boom angle reaches approximately 78 degrees (boom overhoist sensor activation angle)
(2) Adjustment Menu 1) Angle Correction 2) Self-weight Correction 3) Loadcell Zero Point Correction
T5-8-14
2) Inspection of BM Overhoist(L/S)
Hoist the boom until the boom angle reaches approximately 80 degrees (boom overhoist limit switch activation angle)
TROUBLSHOOTING / Troubleshooting F 1) Angle Correction
After setting the boom angle to approximately 60 degrees press <START> key.
Measure the actual working range for the 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 selected hook, Then, press <CHANGE> key to input the actually measured value of the working range. After completing input, press <NEXT> key.
The correction value has been revised Press <END> 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 point, Change the Boom lower speed to the superfine speed mode.
Correction of the self-weight is complete. After returning the boom hoist lever to neutral, press <END> key.
3) Loadcell Zero Point Correction
Detach the loadcell from the hoist rope to Zero point adjustment of the load cell is completely eliminate the load ratio from the complete. load cell. Press <RETURN> key. After detaching the loadcell, press <START> key. Pay attention. Don't disconnect the connector from the loadcell.
T5-8-16
TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Remove the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting. 2. Color coding of wire harnesses. As for the color codes of wire harnesses in the electrical system, refer to the table below. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for base color, while the right initial stands for marking color.
Code R L Or
Color Red Blue Orange
Code W G Lg
Y Br Gr
Yellow Brown Gray
B P V
Color White Green Light green Black Pink Violet
NOTE: 1) Code BW indicates a black base wire with white fine-line marking. 2) Initials “O” and “Or” both stand for the color orange. 3) Wires with longitudinal stripes printed on them are not color coded. Do not confuse them with color coded wires.
T5-9-1
TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to “Instructions for Disconnecting Connector” on page T5-4-3.) 2) The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried. 3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting. 4) When connecting terminal connectors provided with a lock, insert them together until the lock “clicks.” 5) Pull the harness near the connector in order to check if it is correctly connected.
T107-07-06-002
4. Precaution for using a circuit tester. 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. 2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier. 3) When checking the connector by using a tester, insert a tester probe from the harness end of connector in order not to damage the terminal inside connector.
T5-9-2
Wind a Piece of Wire
Sharpen the end of the Wire
Tester Probe
T107-07-06-003
TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS
FOR
DISCONNECTING
x Pull and Separate Type
x Push, Unlock and Separate Type NOTE: Connectors will not be easily separated even if the lock is pushed while being pulled. Push the lock first before pulling the connectors. The lock is located on female side connector (harness end side).
T107-04-05-004
x Remove Screw, Pull and Separate Type NOTE: Use a spanner (10 mm). Tighten the bolt until torque mark (protruded) appears.
T107-04-05-002
x Raise Lock, Pull and Separate Type Screw Protruded Mark
T107-04-05-003
T107-04-05-005
T5-9-3
TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the machine (ground). Normal Voltage: 24 V or more NOTE: If voltage is abnormal, recharge or replace the battery.
T8HY-05-04-003
2. Start the engine. Check voltage between the battery positive terminal and the machine (fround).
Normal Voltage: 26 to 28.5 V NOTE: If voltage is abnormal, check the charging system.
T5-9-4
TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION Open the cap of fusible link and visually inspect the fusible link.
T324-04-05-002
Parts Name Fusible Link 45A
Fusible Link 65A
Capacity 45A
65A
Connected to Key Switch Fuse Box1 (#9, #14 to 20) Fuse Box1 (#1 to 6, #12, #13) Fuse Box2 (#21 to 30, #32 to 40)
Fusible Link 45A
Fusible Link 65A
Fusible Link 45A
T2BC-01-02-020
T5-9-5
TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a tester in order to correctly inspect fuse continuity. Inspect the fuse by following the instructions described below. 1. Turn Key Switch ON When the key switch is turned ON, current from terminal M of key switch activates the battery relay so that electric power is supplied to all circuits. (Refer to the circuit diagram.) 2. Remove the fuse box cover. Set the tester voltage in order to meet the circuit specification to be measured. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of the tester to the machine. Touch the terminals located away from the center of the fuse box with the positive probe of tester one at a time. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 V (battery voltage). NOTE: All terminals located along the lengthwise centerline of the fuse box are connected to the power source, while terminals located away from the center of the fuse box are connected to loads (accessories).
Power Source ( )
Accessories ( )
T105-07-01-008
T5-9-6
TROUBLESHOOTING / Electrical System Inspection Connection in Fuse Box 1 Fuse NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Description Capacity Connected to Air Conditioner Main Power Source 15 A Air Conditioner Slewing Alarm Power Source 10 A Slewing Alarm Lamp Relay Buzzer Power Source 5A Buzzer Relay Radio 5A Radio Pilot Shut-Off Lever / Operation Stop 5A Engine Oil Pressure Relay (R2), Alternator Relay Power Source Preheat Circuit Power Source 5A Preheat Controller ECU 10 A ECU, Memory Clear Switch, ECU Lamp Controller Key Switch 5A MC2/A, MC2/B, IDU Monitor Panel Power Source 5A Monitor Panel Battery Relay 10 A Battery Relay Preheat Indicator 5A Monitor Panel Rear Drum Lock SW Power Source 10 A Rear Drum Lock Third / Fourth Drum Selection Power 3A Third / Fourth Drum Selection Switch Source Room Lamp 5A Room Lamp Switch IDU 5A IDU MC2/B 5A MC2/B MC2/A 5A MC2/A Horn 10 A Horn Relay Back up Power Source 3A Radio, Air Conditioner Fuel Pump Power Source 10 A Fuel Pump
Remarks Main Power Source Power Source Power Source Power Source Power Source Power Source Power Source Key Switch ON Signal Power Source Power Source Power Source Power Source Power Source Power Source Main Power Source Main Power Source Main Power Source Power Source Back up Source 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
T5-9-7
7
8
9
10
TROUBLESHOOTING / Electrical System Inspection Connection in Fuse Box 2 Fuse NO. Description Capacity Connected to 21 Air Conditioner Power Source 3A Air Conditioner 22 Option 10 A Optional Amplifier for Microphone and 5 A Amplifier for Microphone, Anemometer Indicator 23 Speaker / Anemometer 24 Motor Output Limiter 5A Motor Cutoff Relay (R6) 25 Roof Wiper Power Source 5A Roof Wiper Switch, Timer, Roof Wiper Motor 26 Air Compressor Power Source 5A Air Compressor 27 Front Wiper Power Source 5A Front Wiper Switch, Timer, Front Wiper Motor 28 Lighter 20 A Lighter Quick Draw / Counterweight Switch Power 10 A Quick Draw / Counterweight Relay (R5) 29 Source 30 Fourth Drum Lock Switch Power Source 10 A Front Drum Lock 31 Engine Start Signal 10 A Engine Start Relay 32 Front Drum Lock Switch Power Source 10 A Front Drum Lock Travel Mode / Hyd. Tagline / Reeving 5A Travel Mode Switch, Hyd. Tagline Switch, Reeving 33 Winch Power Source Winch (Payout/Wind) Switch 34 Slewing Brake Power Source 3A Slewing Brake Switch 35 Work Light Power Source 20 A Work Light Switch 36 Clearance Light (Optional) 10 A Clearance Light Switch 37 Solenoid (MC2/B) 15 A MC2/B 38 Solenoid (MC2/A) 15 A MC2/A 39 PWM (MC2/B) 15 A MC2/B 40 PWM (MC2/A) 15 A MC2/A
Remarks Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source Power Source 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
T5-9-8
29 30
TROUBLESHOOTING / Electrical System Inspection HOW TO CHECK ALTERNATOR In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective. How to Check Alternator 1. Turn the key switch to the ON position. Confirm that the alternator indicator comes on. 2. Measure voltage between terminals B and E of the alternator. If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors of alternator circuit might be the cause of the malfunction. When voltage is 0 V, the wiring between fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if -the ground line is disconnected. 3. Next, start the engine and measure voltage generated while as the alternator rotates. As described above, measure voltage between terminals B and E on the side of alternator. If voltage is around 28 V, the alternator is operating normally. If the rated voltage is not being generated (around 24V), there is some trouble with the alternator or the regulator.
T5-9-9
Terminal E
Terminal B
T2BC-05-09-003
TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK
Check voltage in order to judge whether voltage is normally supplied to the measuring point, and whether circuit from power supply to measuring point is normal.
24-V Circuit Turn on each switch so that measuring voltage is supplied to a location to be measured, and then measure voltage.
Tester black terminal (minus): Vehicle frame (ground) Tester red terminal (plus): Position to be measured
Measurement Example 1: When electric current does not flow
When the specified voltage is supplied to measuring point, it can be judged that circuit from battery (alternator) to measuring point is normal. Notice that when electric current flows in this circuit, voltage may not reach the specified level (due to power consumption) in some cases.
Measuring Point
T141-05-06-002
When voltage does not reach the specified level, power supply failure, short circuit or open circuit may be caused. In this case, check circuit from the upstream side (or downstream side) in sequence in order to find a defect.
Specified Voltage (When Power Supply Is Normal) Engine stopping : Battery voltage About 25.5 V Engine running : Alternator voltage About 28 V
Measurements 24 V: Circuit from power supply to measuring point is normal. 0 V: Circuit from power supply to measuring point is open circuit or short circuit. Measurement Example 2: When electric current flows
2
1
3
T141-05-06-003
Measuring points (1) ............ 24 V (2) ............ 20 V (3) .............. 0 V Measurements do not reach the specified power voltage due to voltage drop caused by resistance of electrical parts. However, it can be judged that circuit up to measuring point (where voltage is available) is normal.
T5-9-10
TROUBLESHOOTING / Electrical System Inspection Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Preheat Circuit Stopped Stopped Stopped Stopped Stopped Stopped Stopped Starting Circuit Started Started Started Started Started Started Started Started Started Started Started Charging Circuit Fast Speed Fast Speed Sarge Voltage Prevention Circuit Slow Idle Slow Idle Accessory Circuit Stopped Stopped Stopped
Key Switch
Position to be Measured
Specifiation
OFF OFF OFF OFF OFF
Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Battery Between (4) and (E): Battery Relay Between (5) and (E): Fusile Link 45A
10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V
ON ON ON ON ON ON ON
Between (6) and (E): Key Switch (ACC) Between (7) and (E): Battery Relay (Coil) Between (8) and (E): Battery Relay (Switch) Between (9) and (E): Fusible Link 65A Between (10) and (E): Preheat Controller Between (11) and (E): Heater Relay Between (12) and (E): Air Heater
20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V
START START START START START START START START START START START
Between (6) and (E): Key Switch (ACC) Between (7) and (E): Battery Relay (Coil) Between (8) and (E): Battery Relay (Switch) Between (13) and (E): Engine Stop Relay (Terminal #2) Between (14) and (E): Engine Stop Solenoid Between (15) and (E): Engine Stop Relay (Terminal #1) Between (16) and (E): Starter Relay 2 (Terminal #3) Between (17) and (E): Starter (B) Between (18) and (E): Key Switch (C) Between (19) and (E): Engine Start Relay (Terminal #3) Between (20) and (E): Starter Relay 2 (Terminal #6)
20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 13 to 30 V
ON ON
Between (21) and (E): Alternator (B) Between (8) and (E): Battery Relay (Switch)
26 to 30 V 26 to 30 V
ON㧙OFF ON㧙OFF
Between (22) and (E): Battery Relay (Coil) Between (23) and (E): Off-Delay Relay
26 to 30 V 26 to 30 V
ON ON ON
Between (24) and (E): Radio Between (25) and (E): Lighter Between (26) and (E): Air Conditioner
20 to 25 V 10 to 12.5 V 20 to 25 V
NOTE: As for the points to be checked, refer to the illustrations in the following pages.
T5-9-11
TROUBLESHOOTING / Electrical System Inspection Power Source Circuit
3
2
1
Fusible Link 45A
Fuel Feed Pump Switch
Room Lamp Switch
Horn Relay
Horn Switch
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
6
Fusible Link 65A
9
Starter Relay 1
Alternator
Coolant Temp. Sensor
Preheat Controller
11 Preheat Lamp
10
Heater Relay
12
Air Heater
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 SW (optional)
Slewing Brake Switch
8 7
Key Switch
Battery Relay
6
18 15
13
14 Engine Stop Solenoid
Engine Stop Relay
16 17 Starter Relay Starter Motor
20
Alternator
Starter Relay 2
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
x Voltage between terminal #1 and the vehicle
Signal or Ground
Power Source 1
Two Polarities
frame (ground) With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the vehicle (ground) under the following conditions.
2
V
• Key switch: ON • Tester black probe (minus): Vehicle frame (ground)
• Tester red probe (plus):
T107-07-05-006
Terminal #1
Power Source Signal Ground 1 2 3
Three Polarities
Evaluation: If the measuring voltage is within 5r0.5 volts, the circuit up to terminal #1 is normal.
V
x Voltage between terminal #1 and the ground terminal With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the ground terminal (terminal #2 for two polarities, or terminal #3 for three polarities) under the following conditions.
T107-07-05-007
Two Polarities 1
2
V
• Key switch: ON • Tester black probe (minus): Ground terminal (terminal #2 or #3) • Tester red probe (plus): Terminal #1
T107-07-05-008
Three Polarities
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.
1
2
3
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 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, â&#x20AC;&#x153;ONâ&#x20AC;? is displayed. IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the vehicle frame (ground) when checking a three-polarity connector.
1
2
Connect
T107-07-05-010
Three Polarities
1
2
3
Connect
T107-07-05-011
T5-9-19
TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness
Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 : Continuity f : Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated. Continuity Discontinuity
a
:
Connect to the vehicle frame.
Connect to the vehicle frame.
If the ohm-meter reading is: 0 : f:
A
Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 : Short circuit is present. f : No short circuit is present.
a
A
:
a
A u
:
Short-circuit between the harness and the vehicle frame.
T107-07-05-003
T5-9-20
TROUBLESHOOTING / Electrical System Inspection Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is f :, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).
First short-circuit
a b c
A B C Second short-circuit
:
NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c). If the ohm-meter reading is: 0 : Line (B) - (b) has discontinuity. f : Line (A) - (a) has discontinuity.
T107-07-05-004
Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 : Short-circuit exists between the lines. f : No short-circuit exists between the lines. Short-circuit between harnesses. A B C
u
a b c
:
T107-07-05-005
T5-9-21
MITSUBISHI 6D24-TLE2A
Shop Manual
GROUP INDEX
GENERAL ....................................•
FOREWORD
ENGINE .......................................
This shop manual contains the specification, construction, operation, adjustment and service pro cedures of the Model 6024TLE2A diesel engine for service mechanics engaged in servicing of the Mitsubishi diesel engines. Please make the most of this shop manual to perform correct servicing and wasteless operations. Note that some of the contents of this shop manual are subject to change owing to improvements, etc. that may be introduced after publication of this shop manual.
LUBRICATION ............................... FUEL AND ENGINE CONTROL ........... · ELECTRONICALLY CONTROLLED FUEL SYSTEM .............
Im
11!1
COOLING ................................... . INTAKE AND EXHAUST .................... ENGINE ELECTRICAL ....................... CLUTCH ...................................... SPECIAL EQUIPMENT ......................
Mitsubishi 6D24TLE2A Engine Parts www.6D24.com Phone: 269 673 1638 Contact email: EngineParts@HeavyEquipmentRestorationParts.com www.HeavyEquipmentRestorationParts.com
COMPILATION OF THIS MANUAL CONTENTS 1. TERMS AND UNITS ............. .... ....... . ... 4 2. UNITS ........................................... 5 3. READING THE ILLUSTRATION ................. 6
3
COMPILATION OF THIS MANUAL - TERMS AND UNITS
1. TERMS AND UNITS The following terms and units are used throughout the entire texts of this manual. (1) Front and rear The terms "front" is the fan side and "rear" the fly wheel side of the engine. (2) Right and left The terms "right" and "left" shall be used to indi cate the side as viewed from the flywheel side of the engine. (3) Service standard terms • Nominal value Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an assembly, or the standard performance of an assembly. • Limit Shows the value of a part at which the part is no longer serviceable from the performance as well as strength viewpoints, requiring replacement or repair.
4
(4) lightening torque Over-or undertightening of bolts and nuts has criti cal effects on performance and functions. Tighten ing torque is therefore specified for some tighten ing points. All tightening torque specifications may be consid ered as "dry" unless "wet" is specified. Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts lightening Torque Table. (5) Units Length, weight, surface area and capacity are given in International Systems of Units with metric units indicated in ( ). Temperatures are given in degrees Celsius. For the conversion into the foot-pound system, refer to the following conversion table.
COMPILATION OF THIS MANUAL - UNITS 2. UNITS
lightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Systeme International d'Unites Example: 390 N · m {40 kgf · m}
-r- L LSI unit
Metric unit
Unit
SI unit {metric unit}
Force
Conversion factor
N {kgf}
9.80665 N {1 kgf}
N·m {kgf·m}
9.80665 N · m {1 kgf · m}
kPa {kgf/cm2}
98.0665 kPa {1 kgf/cm2}
kPa {mmHg}
0.133322 kPa {1 mmHg}
Pa {mmH2O}
9.80665 Pa {1 mmH2O}
Volume
3
dm {L}
1 dm3 {1 L}
Power
kW{PS}
0. 7355kW{1 PS}
Heat quantity
J {kcal}
4186.05 J {1 kcal}
W{kcal/h}
1.16279 W{1 kcal/h}
Moment of force Positive pressure Pressure
Vacuum pressure
Heat flow
0
Angle
-
-
Temperature
·c
Electric current
A
Voltage
V
-
w
-
Foot-pound unit
Conversion rate
n
Resistance Electric power
SI unit
Unit Force
N (Newton)
lbf
-
1 N = 0.2248 lbf
Moment of force
N·m
ft.lbs
1 N · m = 0.7375 ft.lbs
Pressure
kPa (kilopascal)
psi
1 kPa = 0.145 psi 1 kPa = 0.2953 in. Hg
Volume
L
gal.
cm3
oz
cm3
cu.in.
1 L = 0.2642 gal. (U.S.) 1 L = 0.220 gal. (Imp.) 1 cm3 = 0.033814 oz (U.S.) 1 cm3 = 0.035195 oz (Imp.) 1 cm3 = 0.061023 cu.in.
kW (kilowatt)
PS
1 kW= 1.3596 PS
Temperature
·c
t•c = ( 1.8t0c + 32)° F
Mass quantity of matter
kg g
•F
lb oz
1 kg = 2.2046 lb 1 g = 0.035274 oz
Dimension
m mm
ft. in.
1 m = 3.2808 ft. 1 mm = 0.03937 in.
Power
5
COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION
3. READING THE ILLUSTRATION (Ex. 1: Disassembly and Inspection)
*Protrusion from crankcase to surface NV 0.10 to 0.50
/
Indicates the service standards.
i.----3 Carbon deposits, scratches on outer surfaces, cracks, discoloration
9 c,aok,, o;
/
;ng
�
*Connecting rod end play NV 0.15 to 0.45 L 0.6
Indicates visual checks.
* Indicates inspection to be made before disassembly.
2
1 2 3 @ @
Connecting rod cap Connecting rod bearing Piston 1st compression ring 2nd compression ring
�
@ 7 8 9
Oil ring Snap ring Piston pin Connecting rod
NV .. Nominal Value L ..... Limit
Indicates that the disassembly procedures is explained in the text. A0014A
6
COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION (Ex. 2: Reassembly)
Gives instruction for jobs to ho doao at raassembly. ·• "'-.
' Apply engine oil.
2
1
Piston projection NV 0.48 to 0.74
/
98N-m {10 kgf-m} (Wet)
Specifies the tightening torque; (Wet) meaos the part m,st be Ughteoed lo wot "1/
\
Indicates a typical assembly sequence.
Face the oil groove toward the crankshaft End play NV 0.10 to 0.25 L 0.4
Indicates the service standards. NV .. Nominal Value L..... Limit
Assembly sequence
3➔@➔@➔7➔@➔@➔@➔2➔1
\
Indicates that the assembly procedure is explained in the text.
Illustrations (exploded views and assembly drawings) shows a typical service procedures if it is identical
A0013A
among various types of available systems and units. 7
GENERAL CONTENTS 1. EXTERNAL VIEW ............................ 2. MAJOR SPECIFICATIONS ................... 2.1 Major Specifications ...................... En_gine Outputs Classified by 2.2 Application ............ . ................... 3. ENGINE NUMBER AND CAUTION PLATE ........................................
2 3 3 3
4. KEY POINTS FOR MAINTENANCE WORK ....................... 5 5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE . .. ... . . . ... . 1 2
4
00-1
-
GENERAL - EXTERNAL VIEW
1. EXTERNAL VIEW Natural-aspirated engine
Turbocharged engine
A0243A
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS 2. MAJOR SPECIFICATIONS 2.1 Major Specifications It�
6D24-TLE2A
el
Type
Diesel, 4-cycle, water-cooled
Combustion method
Direct injection
No. and arrangement of cylinder
6, in-line
Cylinder bore x stroke mm
130 X 150
Total displacement
I
11945
cm 3
Engine dimension (with fan) Overall length
mm
1473
1473
1473
1473
Overall width
mm
866
881
881
869
Overall height
mm
1058
1169
1209
1246
Empty weight
kg*
905
930
960
940
* Empty weight as measured according to Mitsubishi Motors Corporation standard.
2.2 Engine Outputs Classified by Application
A
6D24
6D24-T
6D24-TLE2A
1500
114{115}
163{222}
182{247}
1800
136{185}
191{260}
207{282}
2000
144{196}
201{273}
217{295}
2200
151{205}
206{280}
228{310}
1500
104{141}
148{202}
165{224}
1800
124{168}
174{236}
188{256}
2000
131{178}
182{248}
197{268}
2200
137{186}
187{255}
207{282}
gine ed rpm
�
Intermittent rated kW(PS) output
Continuous rated output kW(PS)
NOTE: 1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.
00-3
GENERAL - ENGINE NUMBER AND CAUTION PLATE
3. ENGINE NUMBER AND CAUTION PLATE
(2) Caution plate
(1) Engine number
E0175 E0143
The engine number is stamped near the front of the crankcase on the left-hand side. It takes the following form:
1
The caution plate is attached to the portion shown in the illustration. The caution plate indicates the follow ing items.
Example: 6D24- 012345
j�---- Engine number Engine model
The engine number is important in knowing the history of the engine.
11
VALV E C LEARANC E (C O LD) 0.4mm(0.016in)l1 I NLET EXHAUST O.6mm(0. 02 4 in)f-1 FIRING ORDER 1-5-3-6-2-4-V--2 0 BTDC�3 FUELINJECTION TIMING
□
1 Valve clearance 2 Firing order 1-5-3-6-2-4 3 Fuel injection timing
A01668
00-4
GENERAL - KEY POINTS FOR MAINTENANCE WORK
-
4. KEY POINTS FOR MAINTENANCE WORK
•
In order to determine the condition of the vehicle ade quately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condi tion, what the customer's demand is, and other in formation that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.
WARNING,&.---------Check that the wire rope and crane are sufficiently strong.
17952
•
•
Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual. Perform maintenance work at a level area.
When removing or installing the engine, attach the lifting wire rope hooks to the engine's lifting eyes and hoist the engine slowly such that it does not touch other components.
00012
•
•
•
Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to acci dentally bump switches or levers. Check for oil leakage before cleaning the area hav ing the fault otherwise you might miss detecting the leakage. Prepare replacement part(s) beforehand.
00009
•
Prepa re general and special tools necessary for the maintenance work.
WARNING.&_---------Do not attempt to use tools other than special tools where use of special tools is specified in this manu al. This will avoid injury or damage.
00-5
-
GENERAL - KEY POINTS FOR MAINTENANCE WORK
/ 00015
•
Replace oil seals, packing, 0-rings and other rub ber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.
00017
Put alignment marks on part combinations before dis assembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where per formance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust.
CAUTION_&----------
• Take care to avoid mixing up numerous parts, simi lar parts, left and right, etc. • Keep new parts for replacement and original (re moved) parts separate.
00016
On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.
00018
Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly.
CAUTIONLb_---------Use only the specified oil, grease, etc. for lubricant. Remove the excess immediately after application with a piece of rag.
00-6
GENERAL - KEY POINTS FOR MAINTENANCE WORK
00022
00019
Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.
•
06701
Before carrying out maintenance work on the electric system, disconnect the negative terminals of the bat teries.
-
Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type con nector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.
00023
•
When washing the vehicle, cover the electric sys tem parts and instruments with waterproof materi al beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.
00021
•
Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. 00-7
-
GENERAL - KEY POINTS FOR MAINTENANCE WORK Measurement Procedures Using Connectors
B
06702
•
To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from O volt. Do not ap ply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always supplied with 24V.
Connect the test harness and connector A between these parts
02587
Test with connectors engaged (continuity through cir cuit obtained) <Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connec tor.
00027
•
When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.
02588
<Non-waterproof connector> Insert test probe C from the harness side of the connec tor. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.
00-8
GENERAL - KEY POINTS FOR MAINTENANCE WORK Connector Inspection Procedures
-
02589 Test with connectors disengaged
Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.
02590
Visual inspection
Check for loose connection and poor engagement.
Check if harnesses are broken by pulling gently around the terminals.
Using male pins Touch the pins directly using test probes.
CAUTION_&----------
Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit.
02593
Check for a decrease in contact pressure between the male and female terminals.
00-9
-
GENERAL - KEY POINTS FOR MAINTENANCE WORK
Check for poor contact caused by connector pins hav ing fallen out, rusted terminals or foreign particles.
Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present. The major causes of a short circuit are as follows: • Harness stuck onto the vehicle body. • Harness sheath damaged by friction or heat. • Water in connectors or circuits. • Mistakes (accidental short circuits)
02594
Connector pin fall out inspection Damaged connector pin stoppers can cause poor en gagement of the terminals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness gently.
A: Battery B:Fuse C: Loaded switch D:Load E: Short circuit Precautions for Handling Alternator
Inspection Procedures for Blown Fuses
A +
04746
B
When servicing the alternator, pay attention to the fol lowing: Do not connect the alternator with battery polari ties reversed. If the alternator is connected with re versed polarities, a large current flow from the bat tery to the alternator occurs, and the diode or regu lator might be damaged.
•
C D
02596
00-10
-
GENERAL - KEY POINTS FOR MAINTENANCE WORK •
Do not splash water over the alternator. If water is directly splashed over the alternator, in dividual components will be short-circuited and might be destroyed.
04747
•
While the engine is running, do not remove the bat tery terminals. If the battery terminals are removed at that time, a surge voltage is generated and the diode or regulator might be weakened.
04749
•
Do not short-circuit terminal Band terminal L while running the alternator. If the terminals are short-circuited while the alter nator is running, the diode trio might be destroyed.
f
I
/
02371
•
Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.
05166
•
Disconnect the battery terminals before quick charging the battery. Quick-charging without dis connecting the battery terminals might damage the diode or regulator.
05165
00-11
- GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE • • •
Use specified bolts and nuts and tighten them with the applicable torques according to the following table, unless otherwise specified. Threads and contact seats shall be dry. Where there is difference in strength classification between nut and bolt (or stud bolt), the torque specified for bolt shall apply.
Hex-head Bolt and Stud Bolt Unit: N•m {kgf-m} Stren th classi �ication n e-
I �
BT
7T
4T
©0 0 ©0 0 ®@ 0 (Stud)
-
(Stud)
-
4 to 6 {0.4to 0.6}
(Stud)
-
5to 7 {0.5to 0.7}
MS
2 to 3 {0.2to 0.3}
M6
4to 6{0.4to 0.6}
MB
9to 14{0.9to 1.4}
M10
19to 28{1.9to 2.8}
18to 26 {1.8to 2.7}
36to 52 {3.5to 5.5}
33to 49 {3.3to 5.0}
45to 60{4.5to 6.0}
41to 59 {4.3to 6.9}
M12
35 to 50{3.4to 5.0}
31to 46 {3.1to 4.7}
70to 95{7.0to 9.5}
65to 85 {6.5to 8.5}
85to 110{8.5to 11}
75to 100 {7.5to 10}
M14
60to 85{6.0to 8.5}
55to 75 {5.5to 7.5}
120to 160{12to 16}
110to 140 {11to 14}
130to 180{13to 18}
120to 160 {12to 17}
M16
90to 130{9.5 to 13}
90to 120 {9.0to 12}
180to 240{18to 24}
160to 220 {16to 22}
200to 270{20to 27}
190to 260 {19to 26}
M18
140to 190{14to 19}
120to 160 {12to 16}
260 to 340 {25 to 35}
220to 290 {22to 30}
290to 390{30to 40}
260to 340 {26to 35}
M20
190 to 260 {19 to 26}
170to 230 {17 to 23}
350to 470{36to 48}
320to 420 {32to 43}
410to 550 {41to 56}
370to 490 {37to 50}
M22
260 to 340 {26 to 35}
230to 300 {23 to 31}
470 to 640{48to 65}
430to 570 {43to 58}
550 to 740 {56to 75}
490to 670 {50to 68}
M24
340to 450{34to 46}
290to 390 {29to 40}
630to 840{63to 86}
540to 730 {55to 74}
730 to 980 {74to 100}
630to 840 {64to 86}
-
7 to 11 {0.7to 1.1} 17to 26 {1.7to 2.6}
-
8to 12 {0.8 to 1.2}
-
20 to 29{2.0to 3.0}
Hex-head Flange Bolt Unit: N-m {kgf-m}
n
-
-
I �
0
BT
7T
4T
Strength classification
�
�
-
8to 12 {0.8to 1.2}
0 -
� 9to 14{0.9 to 1.4}
0 -
M6
4to 6{0.4to 0.6}
MB
10 to 15 {1.0to 1.5}
M10
21to 30 {2.1to 3.1}
20 to 28 {1.9to 2.9}
39 to 58 {3.9 to 6.0}
37 to 53 {3.6to 5.4}
50 to 65 {5.0 to 6.5}
45 to 65 {4.5to 6.5}
M12
38 to 54 {3.8 to 5.5}
35 to 51 {3.4to 5.2}
80 to 110 {8.0 to 11}
70to 95 {7.0to 9.5}
90 to 120 {9.0to 12}
85 to 110 {8.5to 11}
00-12
19to 28 {1.9 to 2.8}
-
22 to 32 {2.2to 3.3}
GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE Hex-head Nut Unit: N-m {kgf-m } Strength classification
6T
4T
Representation
©
@
@
(DJ
([eJ]
Diameter symbol
Standard screw
MS
2 to 3 {0.2 to 0.3}
-
4 to 6{0.4 to 0.6}
MS
4 to 6{0.4 to 0.6}
-
MS
9 to 14{0.9 to 1.4}
-
7 to 11{0.7 to 1.1} 17 to 26{1.7 to 2.6}
-
M10
19 to 28{1.9 to 2.8}
18to 26{1.8to 2.7}
36to 52{3.5to 5.5}
33to 49{3.3 to 5.0}
M12
35 to 50{3.4 to 5.0}
31to 46{3.1to 4.7}
70to 95{7.0to 9.5}
65to 85{6.5 to 8.5}
M14
60 to 85{6.0 to 8.5}
55to 75{5.5to 7.5}
120to 160{12to 16}
110to 140{11to 14}
M16
90to 130{9.Sto 13}
90to 120{9.0to 12}
180to 240{18to 24}
160 to 220{16to 22}
M18
140 to 190 {14to 19}
120to 160 {12to 16}
260to 340{25to 35}
220to 290{22to 30}
M20
190 to 260 {19 to 26}
170to 230 {17to 23}
350to 470{36to 48}
320to 420{32to 43}
M22
260 to 340 {26 to 35}
230to 300 {23to 31}
470to 640{48to 65}
430to 570{43to 58}
M24
340 to 450 {34 to 46}
290to 390 {29to 40}
630to 840{63to 86}
540to 730{55to 74}
Coarse screw
Standard screw
Coarse screw
-
Hex-head Flange Nut Unit: N-m {kgf-m } 4T
Strength classification Representation
� Diameter symbol
Standard screw
Coarse screw
MS
4 to 6{0.4to 0.6}
MB
10to 15{1.0to 1.5}
-
M10
21to 30{2.1 to 3.1}
20to 28{1.9to 2.9}
M12
38 to 54{3.8 to 5.5}
35 to 51{3.4to 5.2}
00-13
-
GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABL E
lightening torque for flare nut for general purpose Pipe diameter
lighteningtorque
4>6.35 mm
4>4.7 6 mm
«j>Smm
39 {4.0}
25 {2.6}
17 {1.7}
«j>12mm
«j>10 mm 5
Unit: N-m {kgf-m} qi15mm
98 {10 .0}
88 {9.0}
9 {6.0}
lightening torque for air piping nylon tube for general purpose {DIN type} Standard diameter
lighteningtorque
6x1mm .9 6 20+5 { 2.0 +� } 0
10 x1.25 mm 34
+
10 0
{ 3.5 +�O }
Unit: N-m {kgf-m}
12x1.5 mm 10 49+ 0
{
5
.0 +�O }
15 x 1.5 mm 5
4
+5
0
Tightening torque for air piping nylon tube for general purpose {SAE type} Standard diameter
lighteningtorque
00-14
1/4in . 13
+4
0
{ 1.3
+g- 4 }
29
+5
0
5 { 3.o +g- }
Unit: N-m {kgf-m}
1/2in .
3/8in. 49
+5
0
5 { 5.o +g- }
5 { 5 .5 +g- }
5 +5 54 0
/8in.
5 { s.5 +g- }
ENGINE CONTENTS 1. GENERAL ................................ . ... 2 2. SPECIFICATIONS ............................ 8 3. SERVICE STANDARDS ...................... 9 Service Standards Table .................. 9 3.1 3.2 lightening Torque Table ................. 1 1 4. SPECIAL TOOLS ............................ 1 2 5. SERVICE PROCEDURES .................... 16 5.1 Measuring Compression Pressure ...... 16 5.2 Cylinder Head and Valve Mechanism ... 17 5.2.1 Disassembly ........................... 17 5.2.2 Inspection ............................. 19 5.2. 3 Reassembly ........................... 25
Flywheel, liming Gears, and Camshaft .................. ............... Disassembly ............ ............... 5.3.1 Inspection .............. ............... 5.3.2 Reassembly ............ ............... 5.3.3 5.4 Crankcase and Main Moving Parts ...... 5.4.1 Disassembly ........................ ... 5.4.2 Inspection ........ ...... ............... 5.4.3 Reassembly ...... . .................... 5.5 Inspecting and Adjusting Valve Clearances ................ ............... 6. TROUBLESHOOTING .. ...... ....... . ....... 5.3
29 29 33 39 45 45 49 59 65 67
Mitsubishi 6D24 6D24T 6D24TLE2A Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com Text message: 269 760 8652 Located in USA, Engine Parts delivery available in USA, Canada and worldwide. Mitsubishi Diesel Engine Parts Nissan Diesel Engine Parts Hino Diesel Engine Parts Isuzu Diesel Engine Parts Mercedes Benz Industrial Diesel Engine Parts
11-1
-
ENGINE - GENERAL
1. GENERAL
(1) Combustion chamber
Injection nozzle Cylinder head ----- 0-ring Nozzle tube Cylinder head gasket Water director
B0376A
Water directors pressed into the bottom of the cylinder head optimize cooling of the combustion chambers by directing the flow of coolant.
B0375C
The combustion chambers are formed by the cylinder head and pistons. The injection nozzles, sheathed by the nozzle tubes, are mounted on the cylinder head. The nozzle tubes hold the nozzles and protect them from cooling water. Since the nozzles are exposed to the water in the water jacket, they are sealed by 0-rings at the top and by staking at the bottom. Combustion is effected by compression of fuel injected directly into the combustion chambers.
11-2
-
ENGINE - GENERAL (2) Valve mechanism
Rocker cover
Rocker Valve cap Valve cotter :...----------- _____ Upper retainer _ ..- .. -- Valve spring outer ...., --· - -- Valve spring inner
Valve stem seal Oil passage
Rocker
Push rod
85040A Tappet Camshaft
B0375O
The valve mechanism is of an overhead-valve (OHV) type and is constructed as shown in the diagram. (a) Valve stem seals are fitted to the inlet and exhaust valve stems to control the amount of lubricant flowing onto the sliding surfaces of the valves and valve guides. (b) The inlet and exhaust valve springs are unevenly pitched. Two springs are mounted for each valve, and the inner and outer springs are wound in oppo site directions. (c) The rocker and rocker shaft are supported by the rocker shaft bracket and are installed indepen dently for each cylinder. The same type of rocker is used for both inlet and exhaust valves, and the cen ter of each rocker forms an oil passage. The rocker shaft is a hollow rod sealed by a thrust plate at each end. The inside of the rocker shaft forms an oil passage.
(d) A steel ball is welded to the bottom end of each push rod, and a spherical concave piece is welded to the top end. (e) The tappets are cylindrical. To help prevent local ized wear, the areas that make contact with the camshaft are curved. The overall design enables the tappets to be removed via the side of the crank case. (f) The camshaft is held by camshaft bushings that are pressed into the crankcase. The cam profiles are specially curved to achieve smooth acceleration.
11-3
-
ENGINE - GENERAL
(3) Crankcase and cylinder liner
(4) Piston and piston rings (a) Pistons
Weight mark
Ji
Size mark (A, B,C)
Part No.
Front indicated by "F" and arrow Cooling cavity
(a) Seven camshaft bushings are fitted in the camshaft bearing section of the crankcase. To facilitate removal and reinstallation of the camshaft, the diameter of each bearing is smaller toward the front. (b) Coolant is fed in from the water pump (located at the front left of the crankcase). After cooling the oil cooler, it flows through the water jacket holes and around the cylinders, then reaches the cylinder head.
43428
The piston is an aluminum casting, and a combustion space is recessed into its crown. A piston ring insert is cast into the 1st piston ring groove to improve durabil ity. Stamped on top of the piston are a size mark, a piston weight mark, the piston's part number, an identifica tion mark, plus an "F" and arrow, which indicate the piston installation direction. The size mark is provided to enable selection of the correct cylinder liner size. In the case of an oversize piston, the size mark shows the degree of oversize. The piston pin is fully floating and is held in position by a snap ring at either end. (b) Piston rings
� 1st compression ring � (full keystone type)
=:f ;;;;;;_;;;::;,,....____,,) (c) The cylinder liner is a removable wet type. It is press-fitted into the crankcase, with its top held by the top of the crankcase and its bottom held by the water jacket. Rubber rings and 0-rings are provided at the top and bottom of the cylinder liner to prevent the ingress of coolant. The water jacket has a water thrattling shelf to opti mize cooling performance.
11-4
2nd compression ring (typer faced inner cut type) Oil ring (dual type with an expander spring)
803740
Two compression rings and one oil ring are fitted to each piston. They are shaped as shown in the illustra tion.
ENGINE (5) Connecting rod and connecting rod bearing
-
GENERAL
(6) Crankshaft and crankshaft main bearings
Connecting rod bushing Balance weight
84206A
Connecting rod Connecting rod bearing (upper) Cylinder number, weight mark
"><¾?�
Connecting rod bolt
(a) The crankshaft is highly rigid and is cast in one piece with its balance. Between each journal and pin is an oil hole. Some of the main bearing oil is fed through this hole to lubricate the connecting rod bearing. <Axial lip type> Flywheel housing
45482
The connecting rod is a highly rigid I-section forging. A bushing is pressed into the small end, and a split-type plain bearing is used at the big end. Since it is a split-type bearing, the connecting rod bear ing has an upper half and a lower half. The upper half has an oil hole. This oil hole is in line with the oil pas sage inside the connecting rod. Engine oil for lubrica tion of the small end bushing is supplied via the oil hole and oil passage. An oil hole is provided at the top of the connecting rod to help cool the piston. The connecting rod and connecting rod cap are held together by four connecting rod bolts.
<Radial lip type>
Slinger
43654
Flywheel housing
Crankshaft gear
O-ring
Crankshaft Retainer
803518
(b) The crankshaft gear that drives the timing gears is press-fitted onto the rear of the crankshaft. Note that a radial- or axial-lip-type oil seal is fitted to the front and rear ends of the crankshaft.
11-5
ID
ENGINE - GENERAL (d) Main bearings Torsional damper
<Rubber type> • Single mass
,.,.
• Double mass
� Crankshaft pulley
Torsional damper Crankshaft pulley
<Viscous type>
Crankshaft pulley
Crankshaft
Upper main bearing
84489A
(c) The front end of the crankshaft is flanged, and the crankshaft pulley is bolted to the flange. A torsional damper is mounted on the crankshaft pulley to absorb the crankshaft's torsional vibration.
Thrust plate
80382A
Each main bearing is a split-type plain bearing made of special alloy-plated kelmet metal with backing mate rial. Since they are split-type bearings, the main bearings have upper halves and lower halves. Each upper half has an oil groove on its inside surface, plus an oil hole. The oil hole lines up with an oil hole in the crankcase. There are 7 main bearing pairs. A split-type thrust plate is fitted to the rearmost bearing.
Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com
11-6
lower main bearing
-
ENGINE - GENERAL (7) liming gears
Each idler gear is mounted onto the crankcase with an idler shaft bolt and is supported at the other end by the flywheel housing. The idler gears turn on the idler shafts by means of pressed-in bushings. The bushings are lubricated by oil that flows through the inside of the idler shafts via the crankcase oil holes. (8) Flywheel
Angle scale, cylinder number
r
11111111111)111111 ili11ili1111111fli111l1111lf111
Mr Idler gear C 2=68
inc Cylinder No.
=n
I I I I I j I 11 I 3j
Idler gear 2=47 Oil pump gear 2=53 B0383L
The timing gears are located in the flywheel housing at the rear of the engine. The geartrain is as shown in the illustration. The timing gears are helical, and each is stamped with a timing mark. The timing marks ensure that the gears mesh correctly when reassembled.
Flywheel __,,..- housing / ----- Idler gear "A"
-=--" -
¡
--Collar . Crankshaft
Thrust plate
Cylinder No.
I I I II 11 I I I 2j5
]II[
/
\.._ Valve timing "' check mark
j&n Hj j ! 11 t I
10355
The flywheel is made of cast iron, and at its center is a pilot bearing for the clutch shaft. The outer ring gear that meshes with the starter pinion is shrink-fitted. The ring gear teeth are chamfered on one side to ensure that the starter pinion fits easily. Cylinder numbers, an angle scale, and valve timing check marks are stamped on the outside of the fly wheel, as shown in the illustration.
80384A
The crankshaft gear is press-fitted onto the crankshaft and held in place by a dowel pin. The crankshaft gear drives the other gears.
11-7
-
ENGINE - SPECIFICATIONS
2. SPECIFICATIONS Specification
Item Engine model Type
6D24
6D24-T
6D24-TC
6-cylinder, in-line, water-cooled, 4-cycle diesel
r
r
6D24-TLE2A
r
Combustion chamber type
Direct injection
r
r
r
Valve mechanism
Overhead valve
r
r
r
130 X 150
r
r
r
11945
r
r
r
19.5
16.5
r
17.5
r
r
r
Cylinder bore x stroke (mm) Total displacement (cm ) 3
Compression ratio Fuel injection sequence Cylinder liner type Piston type
No. of piston rings
11-8
1-5-3-6 -2-4 Wet Trunk-type slipper skirt
Compression ring: 2 Oil ring: 1
.-.--
(with cooling cavity)
.--
r
.--
r
r
r
r
-
ENGINE - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table
Unit: mm Maintenance item Compression pressure (at 200rpm)
Rocker bushing-to-rocker shaft clearance Outer valve spring
Free length Installed load/installed length
Inner valve spring
Free length Installed load/installed length Squareness
Tappet-to-crankcase clearance
Limit
2750kPa {28kgf/cm 2}
1960kPa {20kgf/cm2}
(28] 0.03to 0.08
0.2
Replace bushing
89.38
85
Replace
450 N {46.1kgf} / 58.35
380N {39kgf} / 58.35
65.04
62
115 N {12kgf} / 50.35
100N {10.2kgf} / 50.35
-
2.5
0.5
Replace
0.07or less
0.08
130
129.8
Replace
Inlet
11.95to 11 .96
11.85
Replace
Exhaust
11.91to 11.93
[35] 0.06to 0.10
Valve stem-tovalve guide clearance
Inlet
(12] 0.05to 0.09
Exhaust
(12] 0.09to 0.12
Valve margin
Inlet Exhaust
Correct or replace
0.2
Replace valve guide
2.2
1.7
Reface or replace
2.5
2.0
45°
-
0.25to 0.75
1.0
--0.05to 0.45
0.7
2.69to 2.96
3.5
Between crankshaft gear and idler gear B
0.08to 0.20
0.4
Inspect
Between idler gear A and camshaft gear
0.07to 0.18
0.4
Inspect
Between idler gear A and idler gearC
0.07to 0.18
0.4
Inspect
Between injection pump gear and idler gearC
0.08to 0.20
0.4
Inspect
0.05 to 0.15
0.4
Replace thrust plate
Valve seat angle Inlet Exhaust
Valve seat insert seat width
Idler gear end play
Replace valve seat insert (- shows projection)
Correct or replace
0.05to 0.22
0.4
Friction surface distortion
0.1or less
0.2
Correct or replace
Distance from clutch cover mounting surface to friction surface
47.8to 48.2
49.5
Replace
-
0.2
Camshaft gear end play Flywheel
Replace
-
Height of cylinder head from top to bottom surface
liming gear backlash
Difference between cylinders: 390 KPa {4kgf/cm 2} or less
Replace
Cylinder head bottom surface distortion
Valve sinkage from cylinder head bottom surface
Remedy and remarks
0.2
Push rod runout
Valve stem outside diameter
Nominal value (Basic diameter in [ ])
Friction surface runout (when fitted)
Correct or replace
Idler gear A-to-idler shaft A clearance
(40) 0.03to 0.06
0.2
Replace bushing
Idler gearC-to-idler shaftC clearance
[46] 0.03to 0.06
0.2
Replace bushing
11-9
-
ENGINE - SERVICE STANDARDS Unit: mm Limit
Inlet
8.83
8.3
Replace
Lobe height: 56.167 Base circle diameter: 47.334
Exhaust
8.82
8.3
Replace
Lobe height: 56.036 Base circle diameter: 47.216
No.1
(65.00) 0.03 to 0.08
0.25
Replace bushing
No. 2
(65.25) 0.03 to 0.08
No. 3,4
(65.50) 0.03 to 0.08
No. 5,6
(65.75) 0.03 to 0.08
No. 7
(66.00) 0.03 to 0.08 0.08
Replace
Maintenance item Cam profile (difference between lobe height and base circle diameter)
Camshaft journal-to-camshaft bushing clearance
Remedy and remarks
Nominal value (Basic diameter in [ ])
0.05 or less
Camshaft bend Camshaft gear-to-camshaft interference Flywheel housing eccentricity Connecting rod end play
(40) 0.02 to 0.05
-
-
0.2
Correct
0.2 to 0.5
1.0
Replace
Can be reassembled up to 3 times
Projection of piston from top surface of crankcase
0.87 to 1.33
-
Crankshaft end play
0.09 to 0.23
-
0.4
Replace thrust plate
0.1
Replace crankcase
0.07 or less
0.2
Correct
130.014 to 130.054
130.25
Flatness of cylinder liner supporting flange Crankcase top surface distortion Cylinder liner
Inside diameter
0.01 to 0.08
Flange projection
0.02 or less
Cylindricity Piston-to-cylinder liner clearance Piston ring groove-topiston ring clearance
1st compression ring 2nd compression ring
-
Inspect
Replace or grind to oversize
Correct or replace cylinder liner,or replace piston
6D24
(130) 0.178 to 0.204
6D24TLE2A
(130) 0.193 to 0.219
-
6D24
0.09 to 0.13
0.25
Replace piston ring or piston
6D24TLE2A
0.02 to 0.10
6D24
0.05 to 0.08
0.25
Replace piston ring or piston
6D24TLE2A
0.07 to 0.10 0.03 to 0.06
Oil ring
0.15
1st compression ring
0.4 to 0.55
1.5
2nd compression ring
0.5 to 0.65
1.5
Oil ring
0.4 to 0.6
1.5
Piston pin-to-piston pin hole clearance
[50) 0.01 to 0.02
0.1
Replace piston or piston pin
Piston pin-to-connecting rod small end bushing clearance
(50) 0.02 to 0.05
0.1
Replace bushing
Piston ring end gap
Connecting rod
Bend
-
0.05 or less
Replace
Correct or replace
-
Less than 90.5
Connecting rod bearing-to-crankshaft pin clearance
[84) 0.07 to 0.13
0.25
Replace bearing
Main bearing-to-crankshaft journal clearance
(100) 0.08 to 0.15
0.25
Replace bearing
Torsion Connecting rod bearing span when free
Main bearing span when free
Engine Parts contact phone: 269 673 1638 11-10
-
0.1 or fess
Less than 106.5
Replace
Replace
Email: EngineParts2@gmail.com
-
ENGINE - SERVICE STANDARDS
Unit: mm
Maintenance item Crankshaft pin and journal
Nominal value (Basic diameter in I ])
Limit
Roundness
0.01 or less
0.08
Cylindricity
0.006 or less
-
0.04 or less
0.1
Crankshaft bend Valve clearance (when cold)
Inlet
0.4
Exhaust
0.6
Remedy and remarks Correct
Correct or replace
-
Adjust
3.2 lightening Torque Table Location tightened
Screw size 0. D.xpitch (mm)
lightening torque N-m{kgf-m}
M14x2
-
Rocker shaft bracket mounting bolt
M10x1.5
59{6}
Rocker cover bolt
M8x1.25
4.9{0.5}
Rocker adjusting screw lock nut
M10 x1.25
59{6}
Flywheel mounting bolt
M16x1.5
315{32}
Cylinder head bolt
Remarks
Wet. See item (6) of section 5.2.3 for tightening procedure.
Wet
Idler shaft bolt A
M16x2
155{16}
Idler shaft bolt C
M16x2
155{16}
Idler shaft nut (for mounting collar)
M16x1.5
98{10}
Flywheel housing bolt
M12x1.75
69{7}
Oil jet check valve
M12x1.75
34{3.5}
Cannot be reused
Connecting rod cap nut
M13 X 1.25
115{12}
Wet
Main bearing cap bolt
M18x2.5
-
Crankshaft pulley mounting bolt
M14x1.5
175{18}
M12 X 1.75
33{3.4}
Front cover mounting bolt
Wet. See item (7) of section 5.4.3 for tightening procedure.
Mitsubishi 6D24 6D24T 6D24TLE2A Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com Text message: 269 760 8652 Located in USA, Engine Parts delivery available in USA, Canada and worldwide. Mitsubishi Diesel Engine Parts Nissan Diesel Engine Parts Hino Diesel Engine Parts Isuzu Diesel Engine Parts Mercedes Benz Industrial Diesel Engine Parts 11-11
-
ENGINE - SPECIAL TOOLS
4. SPECIAL TOOLS Unit: mm Tool name
Unit: mm Shape
Tool name
Shape
Caulking Tool Body MH061360 Installing and caulking valve seat inserts
Compression Gauge Adapter MH061461 Measuring compression pres sure
Caulking Tool Body
Caulking Ring (Inlet) MH061650 Installing and caulking valve seat inserts Center distance 46 Valve Lifter MH061668 Removing and installing valve cotters Valve Lifter Hook MH061679 Removing and installing valve cotters
01942
Caulking Ring For inlet: cl> 59 For exhaust: cl> 54
Caulking Ring (Exhaust) MH061651 Installing and caulking valve seat inserts
Valve Lifter B5202A Valve Lapper 30091-07500 Valve lapping
D
I.D. 42 Valve Lifter Hook 01956 Nozzle Tube Stamp MH061229 Installing nozzle tubes
Nozzle Tube Remover MH061232 Removing nozzle tubes cl> 12.5 cl> 8.7
Nozzle Tube Installer Flange MH061416 Installing nozzle tubes Nozzle Tube Installer Bolt MH061231 Installing nozzle tubes
13597 Rocker Bushing Puller MH061236 Replacing rocker bushings
Nozzle Tube Installer Flange
85181A Valve Stem Seal Installer ME067431 Installing valve stem seals
cl> 12
10593 Valve Guide Puller 30091-08100 Replacing valve guides
cj>24 B5111A
11-12
85191A
-
ENGINE - SPECIAL TOOLS Unit: mm Idler Gear Bushing Puller MH061228
Unit: mm
Camshaft Bushing Extractor Bar MH062118
Replacing idler gear bushing (for idler gear A)
Removing camshaft bushings Nos. 1 to 6
4>39.5
03532
Idler Gear Bushing Puller MH062046
B4867A
Replacing idler gear bushing (for idler gear C)
Camshaft Bushing Extractor Guide MH062119 Removing camshaft bushings Nos. 1 to 6 4>45.5
B4384A
Gear Puller MH061061 Removing gears and pulleys B4868A
Maximum pulling outside dia. 200 B5071A
Camshaft Bushing Extractor Adapter MH062120 MH062121 MH062122 MH062123 Removing camshaft bushings Nos. 1 to 6
Socket Wrench MH061540 lightening cylinder head bolts cj,A
cl> B
Applicable bushing
MH062120
69.75
65
No.1
MH062121
70
65.25
No.2
MH062122
70.25
65.5
No.3,4
MH062123
70.75
65.7
No.5,6
B4869A
B0598A Socket Wrench MH063365
Camshaft Bushing Extractor MH062124
lightening main bearing cap bolts
Removing camshaft bushing No. 7
13204
Part No.
B4870A
11-13
Ill
ENGINE - SPECIAL TOOLS Unit: mm
Unit: mm Camshaft Bushing Installer MH06213 1 MH062143 Installing camshaft bushings Nos. 1 and 7
Camshaft Bushing Installer Bar MH062125 Installing camshaft bushings Nos. 2to 6
M24x 1.5 B487 1A Camshaft Bushing Installer Guide MH062127 Installing camshaft bushings Nos. 2to 6
cl>B
Applicable bushing
Part No.
cl>A
MH062131
70.75
65
No.T
MH062143
72.25
66
No.7
B4875A Oil Seal Slinger Installer MH06 1652 Installing rear oil seal slinger
B4872A Camshaft Bushing Installer Adapter MH062133 MH062134 MH062135 MH062136 MH062137 Installing camshaft bushings Nos. 2to 6
B5 16 1B Piston Ring Tool 3 1 19 1-02900 Removing piston rings Part No.
♦A
♦B
+c
Applicable
bushing
MH082133
71
MH082134
71.25
65.5
35
No.3
MH082135
71.5
65.5
43
Na.4
MH062136
71.75
85.75
51
No.5
MH082137
72
65.75
59
No.6
65.25
27
No.2
B4873A Camshaft Bushing Installer Nut MH062130 Installing camshaft bushings Nos. 2to 6
For<j,102to 178
p
020 13 Crankcase Table MH06 1889 Measuring flatness of cylin der-liner-supporting flanges on crankcase
M24x 1.5
B4874A
11-14
B 1480A
-
ENGINE - SPECIAL TOOLS Unit: mm Cylinder Liner Extractor MH061490 Removing cylinder liners
Unit: mm
Oil Seal Sleeve Installer 31191-07100 Installing rear oil seal sleeve
PE7264 B5131A Cylinder Liner Installer MH061759 Installing cylinder liners
Oil Seal Slinger Installer MH061817 Installing front oil seal slinger
85141A 80585A
Guide Plate Assembly MH063368 Removing bushings
connecting
Piston Guide Clamp MH061666
rod
Installing pistons
Mandrel 31291-75200 Removing bushings
connecting
Collar A MH063370 Removing connecting bushings Collar B MH062189 Removing bushings
connecting
Nut 31291-75500 Removing connecting bushings
Piston Guide Lever MH061658 Installing pistons
rod
I.D.: 130 rod
rod
B5171B
rod 85151A
Oil Seal Installer 31191-04300
Thickness Gauge MH061359 Measuring valve clearances
Installing rear oil seal (radial lip type)
PE7263
11605
11-15
-
ENGINE - SERVICE PROCEDURES
5. SERVICE PROCEDURES
5.1 Measuring Compression Pressure Compression pressure should be measured prior to disassembly of the engine. Take measurements regu larly and keep track of changes. During the engine's running-in period or after parts have been replaced, the compression pressure will increase slightly as the piston rings and valve seats fit snugly in position. T he pressure will come down as parts wear.
Compression pressure (at 200 rpm) NV 2750 kPa {28 kgf/cm2} L 1960 kPa {20 kgf/cm2} Difference between cylinders 390 kPa {4 kgf/cm2> maximum NV .. Nominal Value L ..... Limit
Measurement procedure
Compression Gauge Adapter MH061461
85561A 85554A
(1) Warm up the engine until the coolant temperature reaches 75 to 85° C, then turn off the ignition.
(3) Mount the Compression Gauge Adapter (special tool) onto an injection nozzle hole together with a gasket. Connect the compression gauge. (4) To prevent fuel from being pumped into the cylin der by the injection pump, pull the injection pump governor's stop lever fully in the "stop" direction. (5) Turn the engine over with the starter and measure the compression pressure at 200 rpm.
85560A
(2) Remove all injection nozzles from the cylinder head.
NOTE: Cover all mounting holes and injection pipes to pre vent the entry of dust and dirt.
11-16
NOTE: 1. Be sure to measure at the correct engine speed since changes in engine speed cause changes in compression pressure. 2. Since wear and other factors vary from one cylin der to another, measure the compression pressure in every cylinder.
-
ENGINE - SERVICE PROCEDURES 5.2 Cylinder Head and Valve Mechanism 5.2.1 Disassembly
2 Oil hole
JV/
�g vlear
Wear, damaged threads 17 Water leaks, gas leaks
Wear, damage 7
1
/
21
Wear, cracks
Corrosion
Disassembly sequence 1 Rocker cover 2 Rocker shaft bracket mounting bolt 3 Cylinder head bolt 4 Thrust plate Rocker Rocker shaft bracket 7 Push rod
8 Valve cap
Valve cotter Upper retainer Outer valve spring Inner valve spring Lower retainer Valve stem seal 15 Inlet valve
® 10 11 12 13 *114
16 *2 ® *218 *219 ® 21 22
Exhaust valve Nozzle tube Water director Sealing cap Cylinder head Crankcase side cover Tappet
For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with "*1" should be replaced and not reused, even if only the valve is removed. Parts marked with "*2" should not be removed unless defects are evident.
Engine Parts contact phone: 269 673 1638
13208
Email: EngineParts2@gmail.com 11-17
-
ENGINE - SERVICE PROCEDURES
Disassembly Procedure
The cylinder head is located on the top surface of the crankcase by dowel pins. To remove the cylinder head, lift it straight upward. Rocker cover Rocker shaft bracket mounting bolt
C1543B
(1) Before removing the bolts, loosen the adjusting screw on every rocker that is being pushed up by its push rod.
NOTE: 1. Remove the injection nozzles before taking off the cylinder head. (Refer to Group 13A, Fuel and Engine Control.) If the cylinder head is placed on a work bench with the nozzles still mounted, the ends of the nozzles projecting from the bottom of the cylinder head will be damaged. 2. When removing the cylinder head gasket, take care not to scratch or dent the cylinder head and crankcase mounting surfaces. (4) Removing valve cotters
(2) Removing rocker shaft bracket assembly
f
Valve Lifter Hook MH061679
â&#x153;&#x201C;
Rocker shaft bracket
�as,ombly
e cotter
II
Spring pin
C1544B
T he rocker shaft bracket assembly is held in place in the cylinder head by a spring pin. To remove the assembly, lift it straight upward. (3) Removing cylinder head assembly
B5282B
To remove the valve cotters, use the Valve Lifter and Valve Lifter Hook (special tools) to evenly compress the valve springs. (5) Removing nozzle tubes
Nozzle Tube Remover MH061232
C1527A
B90148
11-18
NOTE: Whenever a nozzle tube is removed, it must be replaced with a new one.
-
ENGINE - SERVICE PROCEDURES 5.2.2 Inspection Item Free length Rocker bushing to-rocker shaft clearance BO 28 NV 0.03 to 0.08 L 0.2
Installed load/ installed length
NV
L
Outer valve spring
89.38
85
Inner valve spring
65.04
62
Outer valve spring
450 N {46.1 kgf}/58.35
380 N {39 kgf}/58.35
Inner valve spring
115 N {12 kgf}/50.35
100 N {10.2 kgf}/50.35
-
Inner valve spring squareness
-
y � '
: --�&
2.5 BO .. Basic D iameter NV .. Nominal Value L. .... Limit
&
\f
e e Runout L 0.5
I I
Tappet-to-crankcase clearance BO 35 NV 0.06 to0.10 L 0.2
C ylinder head bottom surface distortion NV 0.07 or less L 0.08 Height of cylinder head from top to bottom surface NV 130 L 129.8
Item Valve stem 0. D.
NV
L
Inlet valve
11.95 to11.96
11.85
Exhaust valve
11.91 to 11.93
BO
Valve stem-to-valve guide clearance
Inlet valve
12
0.05 to0.09
Exhaust valve
12
0.09 to0.12
Valve seat insert seat width
Inlet valve
0.2
2.69 to2.96
3.5
Exhaust valve Valve sinkage from cylinder head bottom surface
Inlet valve
0.25 to0.75
1.0
Exhaust valve
-0.05 to0.45
0.7
Valve margin
Inlet valve
2.2
1.7
Exhaust valve
2.5
2.0
Valve seat angle
45
°
C27578
11-19
-
ENGINE - SERVICE PROCEDURES Measure the free length and installed load of each valve spring. Replace any spring that is not up to speci fication. With inner springs, check also for squareness.
Inspection Procedure
(1) Rocker bushing-to-rocker shaft clearance Measuring position
(4) Tappet-to-crankcase tappet hole clearance <Tappet measurement>
Measuring position
�
Measuring position
c2734A C2745A
If the clearance exceeds the specified limit, replace the rocker bushing. (2) Replacing rocker bushing To install
To remove Rocker Bushing Puller MH061236
---....=."-�:;..;; �.:c. =' iu l
Adjusting screw side
I'
_0__,�__,, Rocker oil hole
If the clearance exceeds the specified limit, replace the tappet. C27628
(5) Push rod runout
When installing a bushing, face the bushing's seam toward the rocker adjusting screw and align the bush ing and rocker oil holes. (3) Inspecting valve springs Squareness (inner spring only)
®01948
Check for runout and replace the push rod if the dial reading exceeds the specified limit.
11-20
ENGINE
ID
SERVICE PROCEDURES (8) Valve stem-to-valve guide clearance
(6) Cylinder head bottom surface distortion
Valve
21653
C3125A
If distortion exceeds the specified limit, correct it using a surface grinder. NOTE: Replace the cylinder head if grinding causes the height from its top surface to bottom surface to fall below 129.8mm.
Insert the valve in the valve guide and measure the play at the specified distance from the valve guide's top (as illustrated). If the amount of play exceeds the specified limit, replace the valve guide. (9) Replacing valve guide
(7) Valve stem outside diameter Valve Guide Puller 30091-08100
i+
Measuring position
Valve guide ., Seat the collar---Â â&#x20AC;˘,! of valve guide -- -'t-11-------..securely on cylinder head
To remove
C3102A
Replace the valve if its stem's outside diameter is below specification or if it is severely worn.
To install
C3113A
To install a valve guide, insert it with the Valve Guide Puller (special tool) until its flange sits securely on the cylinder head.
11-21
-
ENGINE - SERVICE PROCEDURES
(10)Contact between valve and valve seat insert
(11)Rectifying valve face
Valve margin
Valve seat angle
Valve 820248
(a) Apply an even coat of minium to the valve seat insert surface that comes into contact with the valve. (b) Using the Valve Lapper (special tool), strike the valve against the valve seat insert once.
C2708A
With a valve refacer, grind the valve face to achieve the specified valve seat angle. NOTE: 1. 2.
NOTE: 1. 2.
Do not turn the valve when striking it against the valve seat insert. The contact pattern should be checked whenever a valve guide is inspected or replaced.
C2710B
3.
Keep grinding to a minimum. If the valve margin is below specification after grinding, replace the valve. After grinding, be sure to lap the valve and valve seat insert. [See item (14) for details].
(12)Rectifying valve seat insert
000 Good
Bad
Bad
C2707A
Valve sinkage
C3127A
Valve Valve seat angle
If the minium indicates a poor contact pattern, rectify it as follows: Minor defect: Lapping Serious defect: Rectify valve and valve seat
Valve
11-22
C2710A
-
ENGINE - SERVICE PROCEDURES (al Using a valve seat cutter, cut the insert to achieve the specified valve seat angle and seat width. Use a 15° or 75 ° cutter first, followed by a 45° cutter.
NOTE:
1. 2.
Keep cutting to a minimum. If the valve sinkage exceeds the specified limit after cutting, replace the valve seat insert.
(bl After cutting, put some sandpaper of around #400 grade between the cutter and valve seat insert and grind the valve seat insert lightly.
Cylinder head 1.D. 57 +0.03 0 <Inlet>
NOTE:
Cylinder head I.D. 52 +0.03 0 <Exhaust> C3128B
After rectification, be sure to lap the valve and valve seat insert. [Refer to item (14) for details.]
Install
D
(13)Replacing valve seat insert Valve seats are installed by expansion fitting and should therefore be replaced according to the follow ing procedure.
Caulking
D
Caulking Tool Body MH061360 Caulking Ring Inlet MH061650 Exhaust MH061651
81111B
Cut off.
01973
(a) Grind the inside surface of the valve seat insert to reduce its thickness. Remove the valve seat insert at room temperature.
(b) Check that there is sufficient interference between the cylinder head and valve seat insert. (c) Cool the valve seat insert by immersing it in liquid nitrogen. Heat the cylinder head. (d) Install the valve seat insert using the Caulking Tool Body and Caulking Ring (special tools), and caulk the periphery of the valve seat insert.
NOTE:
When installing the valve seat insert, ensure that the chamfered side of the Caulking Ring faces the valve seat insert.
(el Reface the valve seat insert to achieve the specified seat width and valve sinkage. [See item (12) for details.]
11-23
ID
ENGINE - SERVICE PROCEDURES
(14)Lapping valve and valve seat insert Contact between the valve and valve seat insert must be even over the entire contact area. Lapping should be carried out whenever the valve or valve seat insert has been rectified or replaced.
Valve stem
Compound
ÂŽ01970
(a) Apply a thin, even coat of lapping compound to the seating surface of the valve. NOTE: 1. Ensure that no compound adheres to the valve stem. 2. Start with intermediate-mesh compound (120 to 150 mesh}, and finish with fine-mesh compound (200 mesh or more). 3. The addition of a small amount of engine oil makes lapping compound easier to apply.
C3130A
11-24
(b) Using the Valve Lapper (special tool), lightly strike the valve against the valve seat insert while turning it little by little. (c) Wash away the compound with gas oil or a similar fluid. (d) Apply engine oil to the contact surfaces and rub it in so that the contact surfaces are lubricated and mate together snugly. (e) Check that the valve is properly seated. [Refer to item (10) for details.]
-
ENGINE - SERVICE PROCEDURES 5.2.3 Reassembly
lightly wound end toward cylinder head
Tightly wound end toward cylinder head
Leak test: No leaks are allowed with 195 kPa {2 kgf/cm2} hydraulic pressure
7
17
Apply sealant to nozzle tube. (THREEBOND 1211 or equivalent) Apply sealant (HERMESEAL S-2 or equivalent)
4.9N-m {3.5 kgf-m}
21
15
16
3
20
Cylinder head bolt tightening sequence [refer to item (6).]
Assembly sequence @➔@➔@➔@➔®➔ 13➔12➔® ➔8➔7 ➔6➔5➔4➔3➔2➔1 16➔15j
22➔21
j
For parts with circled numbers, refer to the following section, "Reassembly Procedure."
10369
11-25
-
ENGINE - SERVICE PROCEDURES
Reassembly Procedure
(3) Valve stem seal installation
(1) Water director and sealing cap installation Water director Sealing cap Align notch with this line. F,;i.;.;z===;zf,
Valve Stem Seal Installer ME067431
Apply sealant (HERMESEAL S-2 or equivalent) 10363
Valve Stem Seal
Align each water director with the notch provided, as shown in the illustration. Cylinder head
(2) Nozzle tube installation Nozzle Tube Installer Bolt MH061231 Nozzle Tube Flange MH061416 Nozzle Tube Stamp MH061229
15 to 20 N-m {1.5 to 2.0 kgf-m} MS x 1.25
O-ring Nozzle tube ---
Apply engine oil. Apply sealant (THREEBOND 1211 or equivalent). 09178
(a) Clean the cylinder head nozzle tube holes. Take care to remove dirt, oil, water and carbon deposits from the seating surfaces. (b) Apply sealant to the new nozzle tube, and insert the nozzle tube into the cylinder head. (cl Using the Nozzle Tube Installer Flange (special tool), press the nozzle tube into the cylinder head. (d) Apply engine oil to the Nozzle Tube Stamp (special tool) and insert it into the nozzle tube. (e) Screw in the Nozzle Tube Installer Bolt (special tool) until the Nozzle Tube Stamp can be pulled out of the bottom of the cylinder head. (f) After installing the nozzle tube, carry out a leak test to verify air-tightness.
11-26
09179
To install a valve stem seal, first apply engine oil to the seal lip. T hen, push in the seal using the Valve Stem Seal Installer (special tool), striking the tool until it touches the cylinder head.
NOTE: 1. 2.
When installing a valve, apply a small amount of engine oil to its stem. After installing a valve stem seal, check that its spring has not been deformed or damaged.
ID
ENGINE - SERVICE PROCEDURES (4) Valve cotter installation
Install the rocker shaft bracket by positioning it on the spring pin in the cylinder head. Mount the cylinder head by positioning it on the dowel pins in the crank case. (6) lightening cylinder head bolts Valve Lifter Hook MH061679 Valve cotter
852828
Install the valve cotter while evenly compressing the spring using the Valve Lifter and Valve Lifter Hook (spe cial tools).
C6649A
NOTE:
Valve springs must be installed with their tightly wound portions toward the cylinder head. (5) Mounting rocker shaft bracket and cylinder head Rocker shaft Rocker shaft bracket bolt � bracket 59 N-m {6 kgf•m} � "-, �
� Spring pin ------<ti) o Cylinder head
�
lighten the cylinder head bolts to 175 N-m {18 kgf-m} (wet) in the order shown. After confirming that the bolts are tightened to 175 N-m {18 kgf-m}, give each one an extra turn in accordance with the following procedure.
Cylinder head bolt Rod (lo, exteosiool
r
Cylinder gasket
80654A
(a) Before fitting the Socket Wrench (special tool) over a cylinder head bolt, turn the holder counter-clock wise to tension the built-in socket spring.
Knock pin 89014C
Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com
11-27
-
ENGINE - SERVICE PROCEDURES
Socket Wrench
MH061540
09182
( b) Fit the socket over the cylinder head bolt and set it such that the built-in spring forces the rod against the rocker shaft bracket, an injection pipe, or another nearby part.
Scale inscribed on socket
Lines inscribed on holder
80656A
( c) Observing the inscribed lines on the holder and socket, turn the socket clockwise by 90 to110° (1 pitch = 10°) to fully tighten the bolt.
Engine Parts contact phone: 269 673 1638
11-28
Email: EngineParts2@gmail.com
-
ENGINE - SERVICE PROCEDURES 5.3 Flywheel, liming Gears, and Camshaft 5.3.1 Disassembly <With axial-lip-type oil seal>
<With electric speed sensor>
<With mechanical tachometer drive>
1 0A
1
�c (\\
r
_,
:,:
2
�
\
1
<With radial-lip-type oil seal>
3
7 Oil leaks 5 Wear/deterioration
Streaks/cracks/stepped wear on friction surface
®43651
<With mechanical tachometer drive>
Damage/abnormally worn gear teeth
9
8
3
5
Wear/deterioration
Disassembly sequence
Streaks/cracks/stepped wear on friction surface
1 *2 @ @ 5 @
7 Flywheel housing *8 Rear oil seal slinger <models with axial-lip type oil seal only> Sleeve <models with wet type clutch only>
Flywheel mounting bolt Pilot bearing Flywheel Oil seal retainer Oil seal Collar
7
*® 10 *1 OA 108
Ring gear Tachometer drive Speed sensor Cover
For parts with circled numbers, refer to the following section, uoisassembly Procedure." Parts marked with "*" should not be removed unless defects are evident.
C1926L
11-29
-
ENGINE - SERVICE PROCEDURES
* liming gear backlash NV
L
Between crankshaft gear and idler gear B
0.08 to 0.20
0.4
Between idler gear A and camshaft gear
0.07 to 0.18
0.4
Between idler gear A and idler gear C
0.07 to 0.18
0.4
Between injection pump gear and idler gear C
0.08 to 0.20
0.4
Item
Injection pump gear (Refer to Group 61, Special Equipment) NV .. Nominal Value L. .... Limit 21 Oil leaks
* Idler gear end play NV 0.05 to 0.15 L
0.4
* Camshaft gear end play NV 0.05 to 0.22
Wear
15
Disassembly sequence ® Camshaft assembly *® Camshaft *® Camshaft gear 14 Thrust plate
L
15 Idler shaft bolt
16 Thrust plate 17 Idler gear C 18 Idler gear A
0.4
19 Idler gear B
20 Idler shaft A 20A Idler shaft C *21 Rear plate
For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with should be inspected prior to disassembly. Parts marked with "*" should not be removed unless defects are evident.
"*"
C1927D
11-30
ENGINE - SERVICE PROCEDURES (3) Removing ring gear
Disassembly Procedure
-
(1) Removing flywheel Threaded hole for removal
Ring gear
B2356C C19288
To remove the flywheel, screw its mounting bolts into the threaded removal hole.
To remove the ring gear, heat it evenly with an acety lene torch, then tap around its entire periphery with a hammer and rod.
(2) Removing collar and oil seal retainer
(4) Measuring gear backlash
Threaded hole � for removal
(M4x0.7)
Collar �
� ()l'l 0
�C)
Thmaded hole � for removal
Oil seal retainer
• •
C1930A
43652
To remove the collar, screw M4 x 0.7 bolts into the threaded removal holes. To remove the oil seal retainer, screw its mounting bolts into the threaded removal holes. Remove the oil seal retainer with the oil seal attached. <Radial-lip-type oil seal only>
If backlash exceeds the specified limit, inspect the idler gear bushings and gears, and replace parts as required. NOTE: For any pair of gears, measure backlash at more than 3 points to determine whether it is acceptable.
11-31
-
ENGINE - SERVICE PROCEDURES
(5) Measuring idler gear and camshaft gear end play Idler gear
(7) Removing camshaft gear
â&#x2122;Ś
Camshaft gear
11824
If the end play exceeds the specified limit, replace the thrust plate. (6) Removing camshaft
10992
The camshaft gear is press-fitted onto the camshaft. To separate these parts, push out the camshaft using a press. NOTE: Do not attempt to remove the gear by striking it with a hammer. Be sure to use a press .
Thrust plate
Camshaft gear
Camshaft
Remove bolts through these holes
Thrust plate mounting bolt 10991
Remove the thrust plate mounting bolts via the holes in the camshaft gear. Remove the camshaft together with the camshaft gear and thrust plate.
11-32
-
ENGINE - SERVICE PROCEDURES 5.3.2 Inspection
Item
NV
L
Friction surface distortion
0.1 or less
0.2
Distance from clutch cover mounting surface to fric tion surface
47.8 to 48.2
49.5
®43653
Clearance BD 40 NV 0.03 to 0.06 L 0.2 Clearance BD 46 NV 0.03 to 0.06 L 0.2
BD .. Basic Diameter NV .. Nominal Value L ..... Limit NV
L
Inlet
8.83
8.3
Exhaust
8.82
8.3
0.05 or less
0.08
0.03 to 0.08
0.25
0.02 to 0.05
Can be reassembled up to 3 times
BD
Item Cam profile (difference between base circle diameter and lobe height) Camshaft bend Camshaft journal-to-camshaft bushing clearance
No. 1
65.00
No.2
65.25
No.3,4
65.50
No. 5,6
65.75
No. 7
66.00
Camshaft gear-to-camshaft interference
40
C2759D
11-33
-
ENGINE - SERVICE PROCEDURES (3) Idler gear-to-idler shaft clearance
Inspection Procedure
(1) Friction surface distortion Measuring position
Measuring position
EB
Dial indicator Surface plate
C3807B C3506A
Place the flywheel on a surface plate. To measure dis tortion, pass a dial indicator over the flywheel from its periphery toward its center. If distortion exceeds the specified limit, grind the fric tion surface as necessary. NOTE: If the ring gear appears abnormal in any way, replace it before measuring distortion. [For details, refer to item (3) of section 5.3.1.]
If the clearance exceeds the specified limit, replace the bushing in the idler gear.
(4) Replacing idler gear bushing
Press
Press
(2) Rectifying flywheel friction surface Idler Gear Bushing Puller MH061228 (for idler gear "A" MH062046 (for idler gear "C")
Clutch cover mounting surface Friction surface
Removal
Installation
C3509B
Grind the friction surface such that dimension B (the distance from the clutch cover mounting surface to the friction surface) is below the specified limit. The fric tion surface must be parallel with surface A to within 0.1 mm. If dimension B exceeds the specified limit, replace the flywheel.
11-34
C3808A
Install the bushing from the side of the idler gear whose internal diameter is chamfered. After installation, confirm that the bushing-to-idler shaft clearance is within the nominal value. If the clear ance is smaller than the nominal value, ream the bush ing.
ENGINE - SERVICE PROCEDURES (5) Cam profile (difference between base circle diame ter and lobe height)
Measuring position R1 obe �
)
9.5
9.5
(7) Replacing camshaft bushings
-
(a) Removal Remove the camshaft bushings in the following order: No.6 ➔ No.5 ➔ No.4 ➔ No.3 ➔ No.2 ➔ No.1 ➔ No.7. Remove them in accordance with the fol lowing instructions. 1) Removing camshaft bushings Nos. 6 to 1
he;ghl
M Base circle diameter
No. 7 camshaft bushing Camshaft Bushing Extractor Bar MH062118
C4101A
Measure the lobe heights and base circle diameters. Replace the camshaft if the difference between them is below the limit.
( Camshaft Bushing Extractor Guide MHD62119 84859A
NOTE:
Since the cams are tapered, they must be measured at the points shown in the illustration. (6) Camshaft journal-to-crankcase camshaft bushing clearance
Camshaft bushing
09166
If the clearance exceeds the specified limit, replace the camshaft bushing. [Refer to item (7) for details.]
Camshaft Bushing Extractor Adapter
No.1
MH062120
No.2
MH062121
No.3,4
MH062122
No.5,6
MH062123 84860A
Mount the Camshaft Bushing Extractor Adapter and Camshaft Bushing Extractor Guide (special tools) onto the Camshaft Bushing Extractor Bar (special tool). Insert this assembly into the crank case. When doing this, fit the Guide onto the No. 7 camshaft bushing to support the Bar. b) Hold the Camshaft Bushing Extractor Adapter against the No. 6 camshaft bushing. As shown in the illustration, remove the No. 6 bushing by strik ing the Bar with a hammer.
a)
11-35
-
ENGINE - SERVICE PROCEDURES
c) After removing the No. 6 bushing, remove bush ings Nos. 5 to 1 in that order using the appropriate Camshaft Bushing Extractor Adapter for each one.
2) Removing camshaft bushing No. 7
a) Mount the Camshaft Bushing Installer Adapters (special tool) and bushings Nos. 2 to 4 on the Cam shaft Bushing Installer Bar (special tool). When doing this, align the inscribed lines on the Adapters with the clinches (seams) on the bushings and position the oil holes as shown in the illustration.
Camshaft Bushin g Installer Guide MH062127
B4861A
<::' / Camshaft Bushin Installer Bar MH062125
g
09171
(b) Installation In accordance with the following instructions, install camshaft bushings Nos. 2, 3, and 4 simultaneously, then bushings Nos. 5 and 6 simultaneously, then bush ings Nos. 1 and 7 in that order. 1) Simultaneous installation of bushings Nos. 2, 3, and 4
No. 2 camshaft bushin g �ing
Camshaft Bushin g Installer Adapter MH062133
No
t:::'\ _,,- Arrow � m ark
/
No. 3 camshaft bushing ing pin � Camshaft Bushin g Installer Adapter MH062134
b) Fit the Camshaft Bushing Installer Guide (special tool) in the place where the No. 1 camshaft bushing is to be installed so that the Camshaft Bushing Installer Bar (special tool) may be supported by it. Then, insert the Camshaft Bushing Installer Bar into the crankcase, making sure that the arrow on it points toward the top of the crankcase. Camshaft Bushing Installer Nut MH062130
No. 2 camshaft bushin g
�� ;g � ViewA
-
Camshaft Bushin g Installer Adapter MH062135
� Clinch Oilhole�
ViewA
Engraved lin e (on camshaft bushin g installer adaptor) 84862D
11-36
�nm contact
09172
c) Confirm that the clinches (seams) on the bushings are aligned with the inscribed lines on the Cam shaft Bushing Installer Adapters [refer to item (a) for details]. Then, screw the Camshaft Bushing Installer Nut (special tool) onto the end of the Cam shaft Bushing Installer Bar, and tighten the Nut to press-fit the bushings. Continue turning the Nut until the Bar's flange touches the crankcase.
ENGINE - SERVICE PROCEDURES d) After installing the bushings, remove the Camshaft Bushing Installer Nut and gently withdraw the Camshaft Bushing Installer Bar.
3)
Installation of bushings Nos. 1 and 7
-·
�""'""""'-�;�:,;l sh ;ag
NOTE: When removing the Camshaft Bushing Installer Bar, take care not to damage the inside surfaces of the bushings.
hne
2) Simultaneous installation of bushings Nos. 5 and 6
Drive in until seated
Camshaft Bushing Installer MH062143
Camshaft Bushing Installer Bar MH062125 Camshaft Bushing Installer Adaptor MH062136
Drive in until seated
Camshaft Bushing Installer Adaptor MH062137
B4865A
B4866D
Install bushings Nos. 1 and 7 as follows: Align the inscribed lines on the Camshaft Bushing Installer (spe cial tool) with the clinches (seams) on the bushing and position the oil holes as shown in the illustration. Face the arrow on the Installer toward the top of the crank case. Drive in the Installer until its flange touches the crankcase.
Follow the procedure in section 1) using the appropri ate Camshaft Bushing Installer Adapters (special tool) for bushings Nos. 5 and 6.
11-37
-
ENGINE - SERVICE PROCEDURES (9) Camshaft-to-camshaft gear interference
(8) Camshaft bend
10995
11834
Measure the extent of bending in the crankshaft. If it exceeds the specified limit, replace the crankshaft.
If the interference is below the specified nominal value, replace the camshaft or camshaft gear.
NOTE:
NOTE:
Apply a dial indicator to the camshaft and turn the camshaft through one revolution. One-half of the dial indicator reading represents the amount of bending.
Even if the interference is up to specification, reas sembly should be carried out no more than 3 times.
11-38
-
ENGINE - SERVICE PROCEDURES 5.3.3 Reassembly
BD . . Basic Diameter NV .. Nominal Value L ..... Limit
Flywheel housing eccentricity / L 0.2
7
Bend lock washer
,:J_
Camshaft gear-to-camshaft interference BD 40 NV 0.02 to 0.05 L Reassemble max. 3 times
Idler gear end play NV 0.05 to 0.15 L 0.4
10
L.lr...,.,_ ,,_ _,;;,.)...,,.liitlrc,ill.lM �t.ti,,-��... -1,1L�12 Camshaft gear end play lll' , NV 0.05 to 0.22 1�13 11 L 0.4 f 14
<Radial-lip-type oil seal>
2
r--;i_;�,..,,,C__L11 1 315 N-m {32 kgf-m} (wet) 5
4 9 8
*10A
Apply engine oil or lithium-base grease to oil seal lip
10B
6
20 3-----� Flywheel friction surface runout L 0.2
86013A
6
19 18 98 N-m {10 kgf-m} 15 155 N-m {16 kgf-m}
Backlash NV 0.07 to 0.18 L 0.4
16
Backlash NV 0.07 to 0.18 L 0.4
Backlash NV 0.08 to 0.20 L 0.4
69 N-m {7 kgf-m} Assembly sequence
For parts with circled numbers, refer to the following section, "Reassembly Procedure. n For parts marked with"*" refer to Group 61, Special Equipment. B1902E
11-39
-
ENGINE - SERVICE PROCEDURES (3) Fitting camshaft gear
Reassembly Procedure (1) Mounting rear plate
Camshaft gear Thrust plate Camshaft
21921 C6230C
Mount the rear plate and gasket, ensuring that they are aligned with the locating pins on the crankcase. After the gasket is fitted, its bottom (oil pan mounting surface) will protrude. Cut off the protruding part of the gasket after fitting the flywheel housing. (2) Installing idler gears
155 N-m
(b) Press the camshaft gear until it sits snugly on the camshaft.
155 N:m
{16 kgf-m}
C6231D
Fit idler gear B and the crankshaft gear such that their "1" alignment marks are aligned with each other. Then, fit idler gears A and C such that their "2" align ment marks are aligned with each other. Tighten the idler shaft bolts to the specified torques. NOTE: 1. Align the "1" marks with pistons Nos. 1 and 6 at top dead center. 2. Ensure that the "1" marks are aligned before align ing the "2" marks.
11-40
B: Block
NOTE: Apply pressure to the middle part of the camshaft gear. Do not apply pressure to the gear's periphery since the gear would break.
Crankshaft gear
{16 kgf-m}
(a) With the alignment marks "4" facing away from the thrust plate, fit the camshaft gear using a press load A of 15.69 to 58.8 kN {1,600 to 6,000 kgf}.
22021
(c) Make a punch mark C on the middle part of the camshaft gear to show that reinstallation has been performed. NOTE: The camshaft gear and camshaft can be fitted together a maximum of three times. If three punch marks C have already been made, replace the camshaft gear and camshaft with new ones.
-
ENGINE - SERVICE PROCEDURES (4) Installing camshaft
the oil seal slinger until it is seated tightly on the crank shaft gear. (8) Fitting oil seal sleeve <With radial-lip-type oil seal> Correct sleeve position Dowel pin
Strike Camshaft gear Oil Seal Sleeve Installer 31191-07100
C6231C
Install the camshaft such that the "4" alignment marks on the camshaft gear and idler gear A are aligned with each other. NOTE: 1. When inserting the camshaft, take care not to damage the camshaft bushings. 2. Ensure that the "1" marks on the crankshaft gear and idler gear Bare aligned before aligning the "4" marks.
(5) Check the end play in the camshaft gear and idler gears. [Refer to item (5) of section 5.3.1 for details.) (6) Check the backlash in the gears. [Refer to item (4) of section 5.3.1 for details.] (7) Installing rear oil seal slinger <With axial-lip-type oil seal>
Crankshaft
85774A
Apply engine oil to the crankshaft and to the inside diameter of the sleeve. Using the Oil Seal Sleeve Installer (special tool), press the sleeve into position on the crankshaft. NOTE: 1. The sleeve's inside diameter is chamfered on one side. When fitting the sleeve, face the chamfered side toward the crankshaft. 2. Since the sleeve must be pushed into the correct position (shown in the illustration), you must use the Oil Seal Sleeve Installer. The sleeve is in the correct position when the Installer can be driven in no further.
(9) Fitting ring gear
Rear oil seal slinger Oil Seal Installer MH061652
Ring gear
Chamfered
C55298
Face the threaded groove toward the flywheel. Using the Oil Seal Slinger Installer (special tool), evenly press
Flywheel
B2357C
Using a piston heater, heat the ring gear to approxi mately 100°c for 3 minutes. Fit the ring gear with the non-chamfered side of its teeth toward the flywheel.
11-41
-
ENGINE - SERVICE PROCEDURES (11 )Checking flywheel housing eccentricity
(10)Fitting flywheel housing
Apply$2 mm sealant bead (THREEBOND 1207C)
B48570
(a) Apply a bead of sealant to the flywheel housing as shown in the illustration. Fit the flywheel housing within 3 minutes of applying the sealant.
NOTE: 1.
2. 3. 4. 5.
Apply a new bead of sealant whenever the fly wheel housing mounting bolts have been loos ened. Keep the flywheel housing sealing surface free of dirt and oil. Apply the sealant evenly and without breaks. When fitting the flywheel housing, hold it firmly in position to prevent spreading the sealant. After fitting the flywheel housing, wait at least 1 hour before starting the engine.
C6233B
lighten the flywheel housing mounting bolts to the specified torque. Then, rotate the flywheel and check for eccentricity at the flywheel housing joint. If eccen tricity exceeds the specified limit, remove the flywheel housing, refit it according to the instructions in item (10), and measure the eccentricity again. If the eccentricity exceeds the specified limit even after remedial measures have been taken, replace the fly wheel housing. (12)Installing oil seal <Axial-lip-type oil seal>
Locating pin
Rear oil seal
®27603 69N-m {7 kgf-m} C6230E
(b) Fit the flywheel housing such that it is aligned with the locating pins in the crankcase.
(a) Apply an even, unbroken bead of sealant A to sur face B of rear oil seal that contacts the flywheel housing when installed. (b) Fit the rear oil seal onto the flywheel housing within 3 minutes of applying the sealant A.
NOTE:
11-42
1.
Ensure that the sealant application position on the
2.
rear oil seal is clean before applying sealant. When fitting the rear oil seal, hold it firmly in posi tion to prevent spreading the sealant.
ENGINE - SERVICE PROCEDURES 3. 4.
After fitting the rear oil seal, wait at least an hour before starting the engine. Apply a new bead of sealant A whenever the mounting bolts of the rear oil seal have been loos ened.
(13)Checking flywheel runout
-
<Radial-lip-type oil seal>
315 N-m {32 kgf-m} Oil Seal Installer 31191-04300 Oil seal retainer
C6209C
(-)� Flywheel
C62368
After tightening the flywheel mounting bolts to the specified torque, rotate the flywheel and check for run out. If runout exceeds the specified limit, check the bolts' tightness and/or check the mounting surface. (14)Checking valve timing
(a) To install the oil seal, apply pressure evenly to its entire periphery using the Oil Seal Installer (special tool) until it reaches the step in the oil seal retainer.
If you need to recheck the valve timing after reassem bling the engine, do so according to the following pro cedure.
Rocker arm \ Oil Seal Installer 31191-04300
Oil seal retainer Oil seal
�
C6209D
(b) Turn the oil seal retainer over, then apply the Oil Seal Installer (special tool) to the oil seal from the opposite direction until the oil seal reaches the retainer's outer surface.
NOTE:
Different oil seals have different installation direc tions. Be sure to install the oil seal in the correct direc tion.
B5714C
(a) Bring cylinder No.1 to its compression-stroke top dead center position. (b) Insert a 3 mm shim between cylinder No.1's exhaust valve rocker arm and valve cap. Make any adjustments necessary using the adjusting screw, then tighten the lock nut.
11-43
-
ENGINE - SERVICE PROCEDURES
) Confirmation marks 10408
(c) Crank the engine in its normal direction of rotation (clockwise when viewed from the front). When cyl inder No.1 's exhaust valve begins to lift, confirm that the pointer on the flywheel housing is between the valve timing confirmation marks on the fly wheel's outer periphery. If the timing marks are in the wrong position, refer to items (2) and (4), and check the timing marks again.
11-44
ENGINE - SERVICE PROCEDURES 5.4 Crankcase and Main Moving Parts 5.4.1 Disassembly
e--
4
�6
Damage/discoloration
7
'\._
t\ 'J
b
Cracks
* NV Connecting rod end play 0.2 to 0.5 L
1.0
C)
9
I
I
NV .. Nominal Value L ..... Limit
0-- } 5
<;.J...__.,J.
-
Damage/
aboo,malwea,
Scratches on outer periphery/ cracks on top/ 8 discoloration/melting
*topProjection of piston from surface of crankcase NV 0.87 to 1.33
JJ-10 3 Scratches/corrosion/
peeling on inner and outer peripheries
Repair kit: Liner and Piston Kit
Disassembly sequence 1 2 3 @ @
Connecting rod cap Lower connecting rod bearing Upper connecting rod bearing 1st compression ring 2nd compression ring
@ Oil ring 7 Piston pin @ Piston ÂŽ Connecting rod *10 Connecting rod bolt
For parts with circled numbers, refer to the following section,"Disassembly Procedure." Parts marked with"*" should be inspected prior to disassembly. Parts marked with"*" should not be removed unless defects are evident. C2337G
11-45
-
ENGINE - SERVICE PROCEDURES
NV .. Nominal Value L ..... Limit
Clogged oil hole
26
/4 Scratches/co�r!sion/ peeling0!' inner and
outer penphenes
Y
20
✓
"
L'\
�-,, ,--...::
� ��� peehngon inner and
15 19
peripheries
L
R
J!i
0.4
Disassembly sequence Torsional damper Crankshaft pulley Front oil seal Front cover Front oil seal slinger Main bearing cap
�
* End play NV 0.09 to 0.23
11
11 12 *113 14 *115 16
�17
outer
Scratches, cracks, dents, seisure, clogged oil hole, corrosion
12
�
/\
17 18 19 20 1 *®
Thrust plate Lower main bearing Crankshaft Upper main bearing Crankshaft gear
*122 *223 24 25 26
Cylinder liner Check valve Oil jet Oil spray plug Crankcase
For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with u*" should be inspected prior to disassembly. Parts marked with "*1" should not be removed unless defects are evident. Parts marked with "*2" must not be reused since they are held in place by thread-lock cement and may be deformed during disassembly. 80599G
11-46
ENGINE - SERVICE PROCEDURES Disassembly Procedure
(3) Removing pistons
-
(1) Piston projection The piston projection measurements must conform with specifications, partly since they affect engine per formance, and partly since the pistons must not inter fere with the valves.
Fr.o
+ •
.
•
Measuring point
Withdraw the piston from the crankcase together with its connecting rod, working from the top surface of the crankcase. C23398
(a) Attach a dial indicator to the top surface of the crankcase and adjust it to zero. (b) Using the dial indicator, find the piston's top dead center position. (c) Take measurements at 4 points on the piston's top surface and determine their average. (d) If the piston projection does not conform with specifications, check the clearances between pis ton/connecting rod and neighboring parts.
NOTE:
When removing a piston, take care not to damage the cylinder liner. (4) Separating piston from connecting rod
(2) Connecting rod end play
Remove the snap rings, then use a rod and hammer to tap the piston pin out. If the piston pin is hard to remove, heat the piston in hot water or with a piston heater.
C2340A
Measure each connecting rod's end play. If any mea surement exceeds the specified limit, replace the con necting rod.
11-47
-
ENGINE - SERVICE PROCEDURES (7) Removing main bearing caps
(5) Removing piston rings
M10 x 1.5
801838
(6) Crankshaft end play
The rearmost main bearing cap is located on dowel pins and must therefore be removed with a slide ham mer. (8) Removing crankshaft gear Rear oil seal slinger
80181C
Before removing the main' bearing caps, measure the· end play in the crankshaft. If it exceeds the specified limit, replace the thrust plate with an oversized one. [Refer to item (3) of section 5.4.3 for details.]
(a) Split the rear oil seal slinger with a chisel and remove it from the crankshaft. (b) Remove the crankshaft gear from the crankshaft using the Gear Puller (special tool).
NOTE: Do not attempt to remove the crankshaft gear by strik• ing it.
Engine Parts contact phone: 269 673 1638
11-48
Email: EngineParts2@gmail.com
-
ENGINE - SERVICE PROCEDURES 5.4.2 Inspection End gap Item
Clearance BO 50 NV 0.01 to 0.02 L 0.1
0 0 0
NV
L
1st compression ring
0.4 to 0.55
1.5
2nd compression ring
0.5 to 0.65
1.5
Oil ring
0.4 to 0.6
1.5
Piston ring groove-to-piston ring clearance Item NV
Clearance BO 50 NV 0.02 to 0.05 L 0.1 Bend L 0.05 or less Torsion L 0.1 or less
1st compression ring 2nd compression ring
6024
0.09 to 0.13
6024-T, TC, TL
0.02 to 0.10
6024
0.05 to 0.08
6024-T, TC, TL
0.07 to 0.10
Oil ring
L 0.25
0.25
0.15
0.03 to 0.06
Crankcase top surface distortion NV 0.07 or less L 0.2 Flatness of cylinder liner supporting flange L 0.1 6024-T, TC, TL
BO
NV
130
0.178 to 0.204 0.193 to 0.219
Projection of cylinder liner from top surface of crankcase NV 0.01 to 0.08 Inside diameter NV 130.014 to 130.054 L 130.25 Cylindricity NV 0.02 or less
BO . . Basic Diameter NV .. Nominal Value L ..... Limit Connecting rod bearing-to-crankshaft pin clearance BO 84 NV 0.07 to 0.13 L 0.25 Connecting rod bearing span when free L Less than 90.5
C2760C
11-49
-
ENGINE - SERVICE PROCEDURES
BO .. Basic Diameter NV .. Nominal Value L ..... Limit
Bend NV 0.04 or less L 0.1 Roundness NV 0.01 or less L 0.08 Cylindricity NV 0.006 or less
Main bearing-to-crankshaft journal clearance BO 100 NV 0.08 to 0.15 L 0.25 Main bearing span when free L Less than 106.5 80599H
Inspection Procedure
(1) Flatness of cylinder-liner-supporting flange on crankcase
If the measured value is out of specification, replace the crankcase. 11-50
ENGINE
SERVICE PROCEDURES
(2) Distortion of crankcase top surface
(4) Cylinder liner flange projection
-
Measurement points
C If distortion of the crankcase top surface exceeds the specified limit, correct it with a surface grinder.
NOTE: When grinding the crankcase, take care thatthe piston projection does not exceed the specified nominal value. [Refer to item { 1) of section 5.4.1 for details.]
If any cylinder liner projection does not conform with its specified nominal value, replace the cylinder liner or crankcase. [Refer to item (5) for details of cylinder liner replacement.] (5) Replacing cylinder liner (a) Removal
(3) Cylinder liner inside diameter Cylinder Liner Extractor MH061490 Size mark 30 or more ---lh"7H .,.__ -t
70
or more
A: Direction of crankshaft axis B: Direction of right angle to crank shaft axis
C4414B
C4424A
Measure each cylinder liner's inside diameter at 6 points, as shown in the illustration. If the inside diame ter exceeds the specified limit, replace the cylinder liner or bore it to oversize. [Refer to item (5) for details of cylinder liner replacement.]
11-51
-
ENGINE - SERVICE PROCEDURES
(b) Installation Strike in.
Cylinder Liner Instal e l r MH061759 Cylinder liner
Piston Cylinder liner
C44278
C4813C
1)
Make sure the new cylinder liner bears the same size mark as that of the piston. Piston size mark
Cylinder liner size mark
B C
B C
A--------A
0-ring-=-➔ Rubber packing 0-ring --=::::iii I
>
Do not stretch 0-rings more than is necessary, and be careful not to damage them. 2. Contact with gas oil, kerosene, anti-corrosion oil, and similar fluids causes 0-rings to swell. Immedi ately wipe off any such fluids that come into con tact with the 0-rings. 3. After installing a cylinder liner, carry out a leak test to check for air-tightness. Apply thrust force to the cylinder liner flange.
Soapsuds to be applied
C44268
Fit new 0-rings and rubber packing to the cylinder liner, and apply soap suds to the crankcase and cyl inder liner at the points where they will touch each other.
11-52
Using the Cylinder Liner Installer (special tool), gently tap the cylinder liner down until its flange is securely seated on the crankcase.
NOTE: 1.
Soap suds to be applied
2)
3)
ENGINE
-
SERVICE PROCEDURES
(6) Selection of pistons and cylinder liners A piston may be either standard or oversized. Cylinder liners are selected accordingly. (a) Standard piston
(b) Oversized piston In accordance with the following instructions, bore the cylinder liner to suit the oversized piston to be used (+0.5, +0.75, or +1.00 mm). Cylinder liner I.D. Size mark stamped
30
or more
--4.......,.�..,--..i
j\ Size mark (A, B,C)
70
A:Axial direction of crank shaft 8: Direction at right angles to crankshaft
or more
Oversize piston O.D.
C4424A
102 <6D24>
97
<6D24-, TLE2A
Cylinder liner Piston
43429
1) The piston must bear the same size mark as that stamped on the cylinder liner. 2) The weight of all 6 of an engine's pistons must be within 10 g of the weight that is stamped on each piston's crown. NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.
C4428A
1) Determine the amount of metal to bore out. To do this, measure the inside diameter of every cylinder liner and find the most worn point. 2) Bore and hone-finish the cylinder liner to achieve the specified nominal clearance between the over sized piston and cylinder liner. NOTE: 1. Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diame ter. 2. Replace the piston rings with oversized piston rings that correspond to the increased cylinder liner dimension.
11-53
-
ENGINE
SERVICE PROCEDURES
(7) Piston-to-cylinder liner clearance
(9) Piston ring gap
If the clearance is out of specification, replace the pis ton or cylinder liner. [Refer to item (6) for details.] (8) Piston-to-piston ring clearance Piston
Piston ring
0 Cylinder liner C4807B
C4806B
If the clearance exceeds the specified limit, replace the piston or piston rings.
NOTE: 1. 2.
After removing any carbon deposits, measure the clearance around the piston's entire periphery. Always replace piston rings as a set, never individ ually.
Measure the piston ring gaps with the piston rings hor izontally pushed into a standard cylinder liner, either in or out of the crankcase. Replace the rings if any gap exceeds the specified limit. Standard cylinder liner inside diameter: 130 ± 0 mm
NOTE: Use a piston to push the piston rings into the cylinder liner for measurement.
(10)Piston pin-to•piston pin hole clearance Piston
1st compression ring
EB
Piston �
C4810D
Measure the 1st compression ring clearance while pressing the ring against the piston with a straight edge.
11-54
If the clearance exceeds the specified limit, replace the piston pin or piston.
NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.
ENGINE - SERVICE PROCEDURES (11) Piston pin-to-connecting rod small end bushing clearance
(a) Removing bushing
Guide Plate Assembly MH063368
Connecting rod bushing
Piston pin
C5203A
If the clearance exceeds the specified limit, replace the connecting rod bushing. (12)Replacing connecting rod bushing
1) Remove the bearing from the connecting rod's big end, then mount the connecting rod on the Base (special tool). 2) Fit the Mandrel and Collar A (special tools) onto the connecting rod's small end as shown in the illustra tion. Slowly apply pressure with a press that has a capacity of at least 49 kN {5,000 kgf}. (b) Press-fitting bushing Approx. 49 kN {5,000 kgf}
Collar B MH062189 __...,.,__..,,, Bushing Collar A MH063370
10976
Replace the bushing using the Connecting Rod Bush ing Puller (special tool). 10977
Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com
Set up the Mandrel, Collar B, Collar A, and the Nut (special tools) on the bushing as shown in the illustration. 2) Apply engine oil to the connecting rod's small end and to the bushing. 3) Using the press, apply pressure of approximately 49 kN {5,000 kgf} such that the bushing is pressed into the connecting rod's small end. 4) After press-fitting the bushing, remove the special tools. Then, ream the bushing to achieve the speci fied nominal clearance between the bushing and piston pin. 1)
11-55
-
ENGINE - SERVICE PROCEDURES
NOTE: When press-fitting the bushing, align the oil hole in the bushing with the oil hole in the connecting rod. 2. When the piston pin is inserted, ensure that it turns easily and without play. 1.
(13)Connecting rod bend and twist Bend
e = 100
e
C5209A
Connecting rod aligner
If the span is less than the specified requirement, replace the upper and lower bearings as a set.
NOTE: Do not attempt to manually expand a bearing if its span is insufficient.
Piston pin
C5205A
C5206A
(15)Connecting rod bearing-to-crankshaft pin clear ance Connecting rod bearing inside diameter Measuring position
e
C5207A
C5208A
Measure the amount of bend and twist in the connect ing rod using a special connecting rod aligner. If the measurements exceed the specified limits, replace the connecting rod or rectify it using a press.
NOTE: 1. Measurements must be made with the connecting rod bushing and upper and lower connecting rod bearings fitted in their respective positions. 2. Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. (14)Span of connecting rod bearings and main bear ings when free
01996 Crankshaft pin outside diameter Measuring position Measuring direction
C5223A
If the clearance exceeds the specified limit, replace the upper and lower bearings as a set.
NOTE: Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. 11-56
-
ENGINE - SERVICE PROCEDURES (16) Main bearing-to-crankshaft journal clearance
(18)Crankshaft bend
Main bearing inside diameter
Measuring direction
C5526A
C5524A
Crankshaft journal outside diameter
Measuring position
Measure the extend of bending in the crankshaft at the middle journal. If the measurement exceeds the speci fied limit, grind to undersize or replace the crankshaft.
NOTE:
C5523A
If the clearance exceeds the specified limit, replace the upper and lower bearings as a set.
With the dial indicator applied to the middle journal, turn the crankshaft through one revolution. One-half of the dial indicator reading represents the extent of bending in the crankshaft.
(19)Grinding crankshaft to undersize
42.0
(17)Roundness and cylindricity of crankshaft pin and journal Roundness
Cylindricity
Measuring direction
Measuring position
R5
RS
75±0.07
C5527A
C5523A
If roundness and cylindricity do not conform with the specified limits, grind to undersize. [Refer to item (19) for details.]
Any damaged or scorched journal or pin must be ground in accordance with the following instructions. If grinding is carried out, the main bearing must be replaced with an undersized one. (a) Grind such that the center distance between the journal and pin does not change. (b) Grind such that the width of the journal and pin does not change. (c) Finish the corner fillet smoothly and to the speci fied radius.
11-57
Ill
ENGINE - SERVICE PROCEDURES (e) When grinding, turn the crankshaft counter-clock wise as viewed from its front end. The grinder should also rotate counter-clockwise as viewed from the crankshaft's front end. (f) When finishing the crankshaft with sandpaper or a whetstone, turn the crankshaft clockwise.
(d) Use magnetic flaw detection to check for ground cracks. Also, check that the Shore hardness of the surface has not dropped below Hs 75.
Grinding
Finishing
Whetstone or sand paper
C5509A
Amount of undersize
Journal 0. D. finished dimension
Pin 0. D. finished dimension
Roundness
Cylindricity
--0.25
--0.08 99.75 --0.10
--0.06 83.75 --0.09
0.01 or less
0.006 or less
--0.50
-0.08 99.50 --0.10
--0.06 83.50 --0.09
--0.75
--0.08 99.25 --0.10
--0.06 83.25 --0.09
-1.00
--0.08 99.00 --0.10
-0.06 83.00 --0.09
Engine Parts contact phone: 269 673 1638
11-58
Email: EngineParts2@gmail.com
-
ENGINE - SERVICE PROCEDURES 5.4.3 Reassembly
Assembly sequence 26➔22➔®l➔@➔@➔(®J➔@➔@➔@➔@
7
NV .. Nominal Value L. .... Limit Cylinder liner flange projection NV 0.01 to 0.08
�@➔CD
@➔@➔7➔@➔@➔@➔@ -----�
@-1 ➔@➔14➔@➔12➔11 For parts with circled numbers, refer to the following section, "Reassembly Procedure."
10 Locating pin 34N-m {3.5kgf-m} 23
3 -"!----Hle-=::::::..,_JJ,
24 Lug direction 1-��.....c......-4- --""-t-"'--f-t--.- �CW--
2-�---,l--f!-, Expander spring ends
1st compression ring gap
Piston projection NV 0.87 to 1.33
115 N-m {12kgf-m}+60" (wet)
115N-m{12kgf-m} (wet)
33N-m {3.4kgf-m}
Rear oil seal slinger [Refer to item (7) of section 5.3.3] Oil seal sleeve [Refer to item (8) of section 5.3.3]
Locating pin 175 N,m {18kgf-m}
11 17 Side with oil groove faces sliding surface
13 Apply lithium-base grease to lip
Connecting rod end play NV 0.2 to 0.5 L 1.0
Crankshaft end play NV 0.09 to 0.23 L 0.4
C5835F
11-59
-
ENGINE - SERVICE PROCEDURES (3) Installing upper main bearing and thrust plate
Reassembly Procedure
(1) Installing oil spray plug
Thrust _plate_
C23358
Install the oil spray plug such that the arrow stamped on it points toward the top of the engine. (2) Installing oil jet and check valve
Install the upper main bearing such that the bearing lug is aligned with the lug groove on the crankcase. Install the rearmost thrust plate with its grooveless side facing the crankcase. NOTE: 1. The main bearing's upper part has an oil groove. The lower part does not have a groove. Take care
(
2.
0
I �.:
0
C5836C
Insert the oil jet's locating pin into the hole on the crank case, and tighten the check valve to the specified torque.
not to confuse the upper and lower parts. Oversized thrust plates are available for adjust ment of crankshaft end play [refer to item (6) of section 5.4.1 for details]. The oversized thrust plates available are +0.15, +0.30, and +0.45 mm. If any of these is used, ensure that the correct size thrust plate is fitted to the bearing cap [refer to item (7) for details].
(4) Installing crankshaft gear Dowel pin
NOTE: Check valves cannot be reused. Be sure to use a new one.
Crankshaft gear 84202A
(a) Heat the gear to approximately 100° c using a pis ton heater.
11-60
-
ENGINE - SERVICE PROCEDURES (b) Locate the gear such that the dowel pin on the crankshaft will fit into the notch in the gear. Fit the gear by lightly striking it with a soft hammer. (c) Fit the rear oil seal slinger (refer to item (7) of sec tion 5.3.3) or oil seal sleeve (refer to item (8) of sec tion 5.3.3). (5) Fitting front oil seal slinger <Axial-lip-type oil seal>
Oil Seal Slinger Installer MH061817
(7) Installing lower main bearings and main bearing caps Install the lower main bearings and main bearing caps in accordance with the following procedure.
i �� 7 cPI
Joo
Cr�nkshaft
0
axial
direction
Dowel pin 13192
80596A
(a) Drive the locating dowel pins into the rearmost main bearing cap in the direction shown in the illustration.
Fit the front oil seal slinger using the Oil Seat Slinger Installer (special tool). Main bearing cap
(6) Installing crankshaft
C5838G C5833A
Lift the crankshaft with a hoist. Keeping it horizontal, gently lower it into the crankcase.
B4222E
(b) Mate each main bearing with its main bearing cap, ensuring that the lugs on the bearings are aligned with the tug grooves in the caps.
11-61
-
ENGINE - SERVICE PROCEDURES counter-clockwise to tension the built-in socket spring.
(c) Only to the rearmost main bearing cap, install a thrust plate on each side, with the thrust plates' grooveless sides facing the main bearing cap.
NOTE: Thrust p l ate for front side of the bearing cap Thrust plate for rear -�·,,_� �deofthebeadag �,
��lw.7fi)'
"�,__ -�f,,�/J::, ---. \ . '{
'"-':.� )
r \, 1 \1
\
w£
l
�:�� �i::.
the
fc clc/
10505
\.!'./"
Thrust plate for rear side of the crankcase
C5838H
2)
If an oversized thrust plate is used, ensure that the bearing cap rear thrust plate and the rearmost thrust plate in the crankcase [refer to item (3)) are the same size. Note, however, that the bearing cap front and rear thrust plates may be of different sizes. (d) Fit the main bearing caps in the order of the num bers that are embossed on them, working from the front of the engine. Fit them such that the sides with lug grooves are toward the right of the engine. (e) Press down the main bearing caps until they touch the crankcase. lighten the main bearing cap mounting bolts to 115 N-m {12 kgf-m} (wet). After confirming that the bolts are tightened to the specified torque, give each one an extra turn in accordance with the following procedure.
13205
1)
Before fitting the Socket Wrench (special tool) over a main bearing cap mounting bolt, turn the holder
11-62
Fit the socket over the main bearing cap mounting head bolt. Set it such that the built-in spring forces the rod against the side of the crankcase.
Scale inscribed on socket
Lines inscribed on holder
3)
09183
Observing the inscribed lines on the holder and socket, turn the socket 60° clockwise (1 pitch= 10°) to fully tighten the bolt. After assembly, check that the crankshaft can be turned easily by hand. Also, check that the crankshaft's end play conforms with the specified nominal value. [Refer to item (6) of section 5.4.1 for details.]
ENGINE
-
SERVICE PROCEDURES NOTE:
(8) Installing connecting rod bolts
All the connecting rods in an engine must have the same weight mark. Weight marks are as follows:
Flattened side toward connecting rod
Heavy --------------- Light B C D E F G H J K
A
(10)Fitting piston rings
:::3/f::: Ends
Check for damage/burrs
890078
Checkthat there are no burrs or damage in the connect ing rod's bolt holes. Apply engine oil to the connecting rod bolts, then press fit the bolts such that the flattened side of their heads face inward. (9) Reassembling piston and connecting rod
\ Manufacturer mark stamped (Compression ring only)
C58418 Expander spring ends
Piston
Oil ring ends Connecting rod
Snap ring
Piston pin
C5843A
Using the Piston Ring Tool (special tool), fit the piston rings in the positions shown in the illustration. Ensure that the manufacturer's marks on the compression rings face upward. Fit the rings in the following order: 1. Oil ring 2. 2nd compression ring 3. 1st compression ring
Weight mark Lug groove mark
10361
Connect the piston to the connecting rod with the pis ton pin such that the piston's front mark "F" is on the same side as the connecting rod's lug groove mark. If the piston pin is difficult to insert, heat the piston in hot water or with a piston heater. 11-63
-
ENGINE - SERVICE PROCEDURES
(11)Installing upper and lower connecting rod bear足 ings Align these.
Align these.
NOTE: 1. Check that the size mark on the piston matches the size mark on the cylinder liner. 2. Ensure that the piston ring ends stay in their cor足 rect positions. 3. Slip some plastic tube over the connecting rod bolts to prevent them from damaging the cylinder liner and crankshaft pin. <Using the Piston Guide Clamp and Piston Guide Lever (special tools)> Piston Guide Clamp
B4223A
Install the upper connecting rod bearing such that its lug is aligned with the connecting rod's lug groove. Install the lower connecting rod bearing such that its lug is aligned with the connecting rod cap's lug groove. NOTE: The upper connecting rod bearing has an oil hole. The lower bearing does not have an oil hole. Take care not to confuse the upper and lower parts. Align the Piston Guide with the piston skirt and set the Piston Guide Lever in position. Turn the adjusting bolt such that the Clamp's inside diameter matches the pis足 ton's outside diameter. Next, remove the Clamp from the piston and apply engine oil to the outside of the pis足 ton, to the inside of the Clamp, and to the inside of the cylinder liner. Fit the Clamp over the piston such that it is flush with the piston's crown. Using a wooden mallet or block, tap the piston into the cylinder, taking care not to damage it.
(12)Installing piston and connecting rod
Piston Guide Lever MH061658
C5834B
Using the Piston Guide Clamp and Piston Guide Lever (special tools), install the piston and connecting rod such that the front mark on the piston's crown faces the front of the engine.
11-64
ENGINE - SERVICE PROCEDURES (13)Fitting connecting rod caps Connecting rod cap
-
5.5 Inspecting and Adjusting Valve Clearances
..
Valve clearances should be checked and adjusted when the engine is cold.
)
Front of engine
C5844B
Ensure that the alignment marks and lug groove marks on the connecting rod caps and connecting rods are aligned with each other. (14)Check the connecting rod's end play. [Refer to item (2) of section 5.4.1 for details.] (1 S)Check that the piston projections conform with specifications. [Refer to item (1) of section 5.4.1 for details.]
10404
(1) Crank the engine until the inscribed "1-6" mark on the flywheel is aligned with the pointer in the fly wheel housing inspection window. When this hap pens, the pistons whose push rods are not pushing up their rockers are at the top-dead-center (TDC) position of their compression stroke.
(16)Fitting front oil seal
Front oil seal
Press-fit Oil seal flange
B4187A
Press evenly around the oil seal's entire periphery until its flange is seated securely on the front cover.
11-65
-
ENGINE - SERVICE PROCEDURES
(2) When piston No. 1 is at the TDC position of its com pression stroke, check and adjust the clearances of the valves marked "o" in the following table. When piston No. 6 is at the TDC position of its com1
Cylinder No.
3
2
Valve arrangement
In.
Ex.
In.
No. 1 at TDC of compression stroke
0
0
0
No. 6 at TDC of compression stroke
Ex.
X
Valve clearance (when cold) 59 N-m {6 kgf-m}
pression stroke, check and adjust the clearances of the valves marked "x" in the table. Be sure to check and adjust every valve.
Inlet NV 0.4 Exhaust NV0.6
857148
In.
X
5
4 Ex.
In.
0
0
Ex.
In.
6 Ex.
In.
Ex.
X
X
0 X
X
(3) Using the Thickness Gauge (special tool), check that the rocker arm-to-valve cap clearance con forms to specifications. To measure the clearance, insert a gauge of the same thickness as the speci fied nominal clearance between the rocker arm and valve cap. The gauge should be able to move in the gap, but not loosely. If the clearance is incorrect, loosen the lock nut and turn the adjusting screw as required. When the clearance is correct, tighten the lock nut to the spe cified torque to secure the adjusting screw.
NOTE: After tightening the lock nut, confirm that the clear ance is still correct.
Mitsubishi 6D24 6D24T 6D24TLE2A Engine Maintenance Service Kits Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts. Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets, Replace filters, Replace V-belts. Mitsubishi 6D24 6D24T 6D24TLE2A Engine Parts www.6D24.com Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Located in USA, Engine Parts Delivery in USA, Canada and worldwide.
11-66
Ill
ENGINE - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Engine will not start
Probable cause Incorrect oil viscosity
Remedy Replace
Incorrect/defective fuel Low compression pressure • Incorrect valve clearance(s) • Defective cylinder head gasket
Reference Group 12 Group 13A
Adjust Replace
• Worn valve and valve seat/carbon deposits • Weakened valve spring • Worn/damaged piston ring(s) • Worn/damaged piston ring groove(s) • Worn piston(s)/cylinder liner(s) Defective preheater • Defective starter switch
Change to oversize Repair or replace
Group 16
Adjust
Group 13A
• Defective heater relay Incorrect injection timing Insufficient fuel injection volume • Defective injection pump
Repair or replace
Group 13A, E
Repair or replace
Group 14
Replace
Group 12
• Incorrect fuel injection volume Defective cooling system Rough idling
Incorrect oil viscosity Incorrect/defective fuel Defective cooling system
Group 13A Repair or replace
Group 14
Low compression pressure (see "Engine will not start") Incorrect injection timing Defective fuel system • Defective injection pump
Adjust Repair or replace
Group 13A Group 13A, E
• Defective injection nozzle • Air trapped in fuel system Abnormal exhaust gas color
Incorrect/defective fuel
Replace
Group 13A
Cooling system malfunctioning
Repair or replace
Group 14
Intake/exhaust system malfunctioning • Clogged air cleaner
Repair or replace
Group 15
Repair or replace
Group 13A, E
• Clogged muffler • Oil leaking into intake/exhaust pipes Low compression pressure (see "Engine will not start") Defective fuel system • Malfunctioning injection pump • Defective injection nozzle Incorrect injection timing
Adjust
Excessive engine oil
Adjust
Seizure of major moving parts
Group 12
Repair or replace
11-67
-
ENGINE - TROUBLESHOOTING Probable cause
Symptom Low power output
Incorrect oil viscosity
Remedy Replace
Reference Group 12 Group 13A, E
Incorrect/defective fuel Cooling system malfunctioning
Repair or replace
Group 14
Intake/exhaust system malfunctioning • Clogged air cleaner
Repair or replace
Group 15
Repair or replace
Group 13A, E
• Clogged muffler Low compression pressure (see "Engine will not start") Fuel system malfunctioning • Malfunctioning injection pump • Defective injection nozzle • Air trapped in fuel system Incorrect injection timing Excessive oil consumption
Oil leaking from lubrication system Oil leaking from engine and related parts • Defective gasket/oil seal
Adjust Inspect and/or repair Replace
Oil entering combustion chamber past piston • Worn cylinder liner(s)/piston(s)
Rectify or replace
• Piston ring(s) worn, damaged, or seized
Replace whole set
• Clogged piston/oil ring oil hole(s) Oil entering combustion chamber via valves • Worn valve stem(s)/valve guide(s)
Group 12
Clean Replace
• Worn valve stem seal(s) Abnormal engine noise
Noise emanating from outside parts of engine • Loose piping/hose connection(s) • Injection pump, alternator, other auxiliary unit(s) incorrectly mounted • Loose/damaged V-belt • Incorrectly mounted crankshaft pulley • Malfunctioning air cleaner and/or muffler Noise emanating from vicinity of rocker cover • Incorrect valve clearance(s) • Defective valve spring(s) • Defective rocker shaft/bracket • Improper lubrication of rocker shaft
11-68
Inspect Inspect and/or adjust Replace
Groups 13A, E and 16 Group 14
Inspect and/or adjust Repair or replace Adjust Replace Inspect and/or repair Inspect
Group 15
-
ENGINE - TROUBLESHOOTING Symptom Abnormal engine noise
Probable cause Noise emanating from vicinity of flywheel housing • Incorrect timing gear backlash • Incorrect lubrication of timing gears and idler shaft
Remedy
Reference
Replace Inspect
Noise emanating from cylinder head/crankcase • Low compression pressure lsee "Engine will not start") • Incorrect injection timing • Incorrect spray of injection nozzles • Worn connecting rod small end bushing(s) and piston pin(s)
Adjust
Group 13A
Repair or replace Replace
• Worn/damaged crankshaft pin(s) and connecting rod big end bearing(s) • Worn/damaged crankshaft journal(s) and main bearing(s) • Excessive crankshaft/camshaft end play • Worn tappet(s)/camshaft Turbocharger malfunctioning
Replace thrust plate(s) Replace worn part(s) Inspect and/or rectify
Group 15
11-69
LUBRICATION CONTENTS 1. GENERAL ............................... . ... 2 2. SPECIFICATIONS ............................ 9 3. SERVICE STANDARDS ..................... 10 3.1 Service Standards Table ................. 10 3.2 lightening Torque Table ................. 10 4. SERVICE PROCEDURE ..................... 1 1 4.1 Oil Pump ................................. 1 2 4.1.1 Removal and installation ............. 1 2
4.1.2 Disassembly and inspection .......... 4.1.3 Reassembly ........................... 4.2 Oil Filter and Oil Cooler .. . ..... . ..... . ... 4.2.1 Removal and installation ............. 4.2.2 Oil filter .......................... ...... 4.2.3 Oil cooler .............................. 4.3 Regulator Valve .......................... 5. TROUBLESHOOTING .......................
1 31 15 15 15 16 17 18 19
12-1
-
LUBRICATION - GENERAL
1. GENERAL Oil pressure gauge Warning lamp
0---··---,
Oil pressure Oil pressure ,__ ________s_ wit_c_h_�U-L.........J gauge unit Main oil gallery Regulator valve
*
Water pump
* Models with turbocharger Engine lubrication is accomplished by forced lubrica tion system using gear pump. The engine oil in the oil pan is drawn up th rough the oil strainer by the oil pump and force-fed to the oil filter and oil cooler to lubricate all parts.
B1539H
(1) Oil pump
Oil pump (with built-in relief valve}
B1540A
12-2
LUBRICATION - GENERAL The oil pump, of a gear pump type, is mounted in the rear bottom portion of the crankcase, driven by the crankshaft gear. The oil strainer at the suction port prevents entry of for eign matter in the oil pan and air. The engine oil is routed to the crankcase by the oil pipe connected to the delivery port.
Relief valve
Drive gear
81541A
The crankshaft gear drives the oil pump idler gear and oil pump gear to transmit rotation to the oil pump drive gear.
Delivery_ side
_ Suction side (oil strainer side)
B5693A
The oil pump is driven at a speed proportionate to the engine speed. Therefore, it is provided with a relief valve that prevents excessive pressure from being applied to the lubrication system when the engine is started in cold weather involving a surge in oil pump delivery pressure.
"::c::....1- Driven gear
B1505A
Inside the oil pump case, there are oil pump drive gear and driven gear which are in mesh with each other. When the drive gear is driven, the driven gear is caused to turn in an opposite direction. As the gears rotate with the gear teeth sliding on the inner surfaces of pump case, the resultant negative pressure causes the engine oil to enter the oil pump and the oil trapped in the space formed by the teeth and gear case inner wall is forced out through the deliv ery port.
12-3
m
LUBRICATION - GENERAL (3) Oil bypass alarm
(2) Oil filter
Element
Center bolt {Bypass filter) Center bolt {Full-flow filter)
81543A
The oil filter assembly consists of a full-flow filter and a bypass filter. Paper elements are used. Engine oil fed under pressure from the oil pump passes through the oil hole in the crankcase and enters the full flow and bypass filters via the oil filter head. Engine oil that passes through the full-flow filter is routed from the oil filter head to the oil cooler via the crankcase oil hole. Engine oil that passes through the bypass filter returns to the oil pan.
815448
When the oil filter element is plugged resulting in the difference in pressures between before and after the element exceeding a predetermined level, the valve overcomes the spring tension to move. As a result, unfiltered oil flows directly to the oil cooler. The oil bypass alarm has electric contacts that are closed to turn on the pilot lamp, warning the driver of clogged element when the valve is opened.
12-4
LUBRICATION - GENERAL (4) Oil cooler
Bypass valve
B1545C
The oil cooler is of the shell-and-plate (multi-plate) type. It is mounted in the coolant path on the left of the crankcase. Engine oil that has been forced through the oil filter flows through the inside of the oil cooler element. At
the same time, coolant from the water pump flows around the outside of the element. The engine oil in the element is thus cooled or heated before flowing to the main oil gallery.
Bypass valve
Regulator valve
Bypass valve
To main oil gallery
81530B
When the oil's viscosity is high at low temperatures or when the element is clogged and resists the oil's flow, the oil cooler's bypass valve opens, thus allowing oil to flow to the main gallery without passing through the cooler.
81529A
The regulator valve is fitted to the main oil gallery in the crankcase. If the oil pressure in the main gallery exceeds a specified level, the regulator valve allows the oil to escape to the oil pan, thereby protecting the lubrication system from excessive pressure. 12-5
m
LUBRICATION - GENERAL (b) Camshaft
(5) Lubrication of components
Engine oil routed to the main oil gallery lubricates the engine's various components as follows: (a) Main bearings, connecting rod bearings, and con necting rod bushings
6D24-TLE2A
·•.
Crankshaft main bearing
81547A
The camshaft bushings are lubricated via the crank case oil holes that extend to them from the periphery of the crankshaft main bearings. (c) Valve mechanism Conn ecting rod b earing
Rocker shaft bracket � ocker � �� Rocker bushin·g Rocker shaft From cylinder head
_ ..,.,- .-CY:.,.,,,To cylinder h ad <
.,,,...
43674
C
I
·�
e
Main�il.�v galle Ii' ?
l r�;\ � <lf'
An oil passage extends from the main oil gallery to the crankshaft main bearing and lubricates the main bear ing. Part of the oil that has lubricated the main bearing passes through the hole in the crankshaft and lubri cates the connecting rod bearing. It then goes through an oilway inside the connecting rod and lubricates the connecting rod small end bushing. In the 6D24-TLE2A there is also an oil hole in the top of the connecting rod. Oil spurts out of this hole onto the inside of the piston.
12-6
.....,..... \ ,
81548A
Engine oil that has lubricated the No. 7 camshaft bush ing flows to the cylinder heads via an oilway and holes in the top of the crankcase. Engine oil that is bound for the cylinder heads flows through oil holes in the rocker shafts and lubricates the rocker bushings. It then spurts out of a hole in the top of each rocker to lubricate the sliding surfaces of the valve caps, the valve stems, and the contact points of the valve stems, push rods, and adjusting screws. The oil then flows through the push rod holes in the cylinder head and crankcase to lubri cate the tappets and camshaft cams. Finally, the oil returns to the oil pan.
-
LUBRICATION - GENERAL
oil volume and the loss of oil pressure when the pres sure is already low. In the 6024-T, TC and TL, each piston has a cooling cav ity. Oil sprayed out of the oil jets enters these cavities to further cool the pistons.
(d) liming gears
Oil spray plug
Idler shaft installation section
(6) Lubrication of turbocharger Piston ring
Main oil gallery �-
-�"' B1549A
As shown in the illustration, the timing gear idler shaft bushings are lubricated via oil holes that extend from the main oil gallery and from the rearmost crankshaft main bearing. The gears are lubricated by the oil spray plug. {e) Cooling of pistons (oil jet)
Air int::::>
Piston ring
B4363A
Part of the engine oil is directed through the oil pipe from the crankcase into the turbocharger. The engine oil passes through the oil hole in the turbocharger bearing housing to lubricate the bearings. It is then returned through the oil outlet at the bottom of the bearing housing back to the crankcase and to the oil pan. A piston ring is installed on the outside of each bearing, serving as an oil seal.
6D24TLE2A only Piston
11921
An oil jet is fitted under the main oil gallery for each cyl inder. These oil jets spray engine oil onto the inside sur faces of the pistons to help cool the pistons. Each oil jet has a check valve that opens and closes at specified oil pressures, thus preventing decreases in 12-7
-
LUBRICATION - GENERAL The injection pump and air compressor are lubricated as follows:
(7) Injection pump and air compressor
l
Main oil gallery From oil cooler
I I
"-.
From crankcase oil main gallery To oil pan', '
Injection pum p
Oil cooler
Crankcase
Air compressor
I I
(.2
'o.
Gear train
B4364B
Oil pan �j�( -----� �--- _ _ _ _ ___
(8) Lubrication of water pump
Section B-B To oil pan
Section A-A From oil main gallery
The engine oil drawn by the pump is routed through the crankcase oil passage to the water pump. The engine oil delivered to the water pump flows through the oil hole of the water pump and lubricates the bear ings. The engine oil is then forced back from the drain port to the crankcase and returns to the oil pan.
12-8
D0052A
LUBRICATION - SPECIFICATIONS
2. SPECIFICATIONS Specification
Item
API classification class CC or better (without turbocharger) API classification class CD or better (with turbocharger)
Quality
Engine oil
Capacity
Oil pan
Approx. 27 L (for general use} Approx. 25 L (for construction machinery)
Oil filter
Approx. 4 to 4.5 L
Lubrication method
Forced lubrication by oil pump
Oil pump
Type
Forced lubrication by gear pump (integral relief valve)
Relief valve
Type
Ball valve
Full-flow filter element
Type
Filter paper type
Bypass filter element
Type
Filter paper type
Oil filter
Oil bypass alarm
Type
Piston valve type (integral electric contact)
Oil cooler
Type
Shell and plate type (multi-plate type)
Oil bypass valve
Type
Piston valve type
Regulator valve
Type
Piston valve type
Oil jet check valve
Type
Piston valve type
12-9
LUBRICATION - SERVICE STANDARDS
3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item
Nominal value (Basic diameter in I ))
Limit
Remedy and remarks Inspection
Oil pressure (Oil temperature 70° C to 9 0° C)
At idle
145 kPa {1.5 kgf/cm 2} or more
49 kPa {0.5 kgf/cm 2}
At maximum speed
295 to 490 kPa {3 to 5 kgf/cm 2}
195 kPa {2 kgf/cm 2}
Oil pump
Backlash between crankshaft gear and oil pump idler gear
0.08 to 0.2
0.4
Replace
Backlash between oil pump idler gear and oil pump gear
0.08 to 0.2
0.4
Replace
Difference between pump case depth and gear height
0.05 to 0.12
0.15
Replace
Gear tooth tip to pump case clearance
0.20 to 0.29
0.35
Replace
Drive gear shaft to cover clearance
(20) 0.04 to 0.07
0.15
Replace
Driven gear shaft to driven gear bushing clearance
(20) 0.04 to 0.07
0.15
Replace
Idler gear shaft to idler gear bushing clearance
(22) 0.03 to 0.05
0.15
Replace bushing
Relief valve opening pressure Relief valve spring load
I
Installed length: 47.7
Oil bypass alarm valve opening pressure (on start pressure)
1080 to 1270 kPa {11 to 13 kgf/cm2}
Replace spring
180 to 200 N {18.3 to 20.5 kgf}
-
340 to 390 kPa {3.5 to 4 kgf/cm2}
-
Replace
-
Replace
-
Replace
Oil cooler bypass valve
Valve opening pressure
420 to 460 kPa {4.3 to 4.7 kgf/cm2}
Regulator valve
Valve opening pressure
360 to 420 kPa {3.7 to 4.3 kgf/cm 2}
Spring load (Installed length: 48.3)
-
76 to 80 N V.8 to 8.2 kgf}
-
3.2 Tightening Torque Table Screw size 0. D.x pitch mm
Tightening torque N-m {kgf-m}
Oil pump idler shaft nut
M12x1.25
59 to 78 {6 to 8}
Apply LOCTITE No. 262
Oil pump cover mounting bolt
Ml0x1.25
39 to 49 {4 to 5}
Wet
Oil bypass alarm
M20x1.5
44 to 54 (4.5 to 5.5)
Oil filter center bolt
M16x1.5
59 to 69 (6 to 7)
Oil filter drain plug
Ml0xl.25
20 ± 4.9 {2 ± 0.5}
Oil cooler bypass valve plug
M20x1.5
15 to 20 (1.5 to 2.0)
Regulator valve
M27x1.5
98 to 115 {10 to 12}
Oil pan drain plug
M18x1.5
690}
Location tightened
12-10
Remarks
LUBRICATION - SERVICE PROCEDURE 4. SERVICE PROCEDURE
-
Oil Pressure Measurement At idle NV 145 kPa {1.5 kgf/cm2} or more L 49 kPa {0.5 kgf/cm2} At maximum speed NV 295 to 490 kPa {3 to 5 kgf/cm2 } L 195 kPa {2 kgf/cm2}
NV . . Nominal Value L · · · · · Limit 89016A
(1) With the oil pressure switch removed and pressure gauge installed, warm up the engine until the oil temperature reaches 70°C to 90 °C. (2) Measure the oil pressure at idle and maximum speeds. If the measurement is below the limit, overhaul the lubricating system.
12-11
LUBRICATION - SERVICE PROCEDURE 4.1 Oil Pump 4.1.1 Removal and installation Apply sealant to inner bead. NV .. Nominal Value L ..... Limit
B
Apply sealant (Threebond 1207C) and fit it within 3 minutes.
*Backlash from crankshaft gear NV 0.08 to 0.2 L 0.4 Section B
Section A-A
Pour engine oil into pump
C1160C
1 *2 *3 4
Oil pan Oil strainer Oil pipe Flange
11923
5 Relief valve 6 Oil pump 7 Drain plug
Bolt tightening sequence CD-+ÂŽ-+@ After installation, check that the oil pump gear can be turned smoothly by hand. Service items marked with* should be checked before and after the removal. Part marked with * should not be removed unless defects are evident. (Remove it with the oil pump as an assembly.)
NOTE: 1. Sealant application portion on the oil pan should be free of oil. 2. Apply sealant evenly without break. 3. When fitting the oil pan, do not move the oil pan to spread the sealant. 12-12
4. 5.
After installation, wait at least one hour before starting the engine. Reapply sealant whenever the oil pan mounting bolts have been loosened.
-
LUBRICATION - SERVICE PROCEDURE 4.1.2 Disassembly and inspection
3 Clogged oil hole *Backlash NV 0.08 to 0.2 L 0.4 Relief valve opening pressure NV 1080 to 1270 kPa {11 to 13 kgf/cm 2} Spring installed load (installed length: 47.7) NV 180 to 200 N {18.3 to 20.5 kgf}
Clearance BO 22 NV 0.03 to 0.05 L 0.15
Clearance BD 20 NV 0.04 to 0.07 L 0.15
2
Wear on bushing 1
Wear and damage on teeth, wear on bushing
Clearance BD 20 NV 0.04 to 0.07 L 0.15
*Difference between oil pump case depth and gear height NV 0.05 to 0.12 L 0.15 *Gear tooth tip to oil pump case clearance NV 0.2 to 0.29 L 0.35
BD .. Basic Diameter NV . . Nominal Value L..... Limit
Disassembly sequence G) 2 3 4
Oil pump cover Driven gear assembly Idler shaft Idler gear
5 Spring seat 6 Valve spring 7 Ball valve 8 Case and gear assembly
For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Service items marked with * should be checked before disassembly. 10374
12-13
-
LUBRICATION
SERVICE PROCEDURE
Disassembly and Inspection Procedures
(3) Gear tooth end to oil pump case clearance
(1) Removal of oil pump cover
C9521A 10375
T he oil pump cover is positioned with the dowel pin of the oil pump case. To remove the oil pump cover, tap on it with a plastic hammer or the like.
If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly. (4) Gear shaft to case, cover, and driven gear clear ance
(2) Difference between oil pump case depth and gear height
ÂŽ45484
C9520A
If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly.
12-14
If the measurement exceeds the limit, replace the part to which bushing is installed.
-
LUBRICATION - SERVICE PROCEDURE 4.1.3 Reassembly 39to 49N-m {4 to 5 kgf-m} Backlash NV 0.08 to 0.2
L
Section B-B
0.4
a u, -
�
Apply thread-lock cement (LOCTITE 262) to threads after degreasing
'-----------'4 59to 78 N•m {6 to 8 kgf-m}
Arrow and HUP" mark must face upward and align oil holes
3
Assembly sequence
5 6
7
1
/sect;on A-A\
8➔7➔6➔5➔4➔3➔2➔1
Shaft end surface must be flush with case
Section C-C NOTE: Hold the oil strainer 1 in position temporarily for subsequent attachment to the crankcase. ®45485
4.2 Oil Filter and Oil Cooler 4.2.1 Removal and installation
1 Oil filter 2 Oil cooler 3 Gasket
NOTE: Do not apply oil or grease to the 0-rings at the 1. oil cooler's water inlet and outlet. 2. After installation, run the engine and check for possible oil and water leak. C1158E
12-15
LUBRICATION - SERVICE PROCEDURE 4.2.2 Oil filter NOTE: The elements in the bypass and full-flow oil filters
replaced. For specific replacement intervals, refer to
should be replaced every other time the engine oil is
the Owner's Handbook.
(1) Disassembly and reassembly
1 Drain plug Clogging, deformation
6
6
Clogging, deformation
Hardening splitting
Cracks, deformation
Cracks, deformation
4
Center bolt Washer Oil filter case Element retainer 6 Oil filter element 7 Oil filter head 8 Oil bypass alarm
2 3 4 5
59to 69 N-m {6 to 7kgf-m}
2 59to 69 N-m {6 to 7kgf-m}
C9705 C
Inspection of oil bypass alarm Pressure gauge Valve opening pressure NV 340to 390kPa {3.5 to 4kgf/cm2}
U0700C
12-16
W ith no air pressure applied, check for continuity across the terminals as shown and replace the oil bypass alarm if there is continuity. Next, with the air pressure applied and gradually increasing, measure the air pressure when there is continuity. If the measurement is out of specification, replace the oil bypass alarm.
-
LUBRICATION - SERVICE PROCEDURE 4.2.3 Oil cooler
(1) Disassembly and reassembly 1 Scale, damage, cracks, oil leaks 3 Scale, cracks Valve opening pressure NV 420 to 460 kPa {4.3 to 4.7 kgf/cm 2}
0
1 Oil cooler element 2 Bypass valve 3 Oil cooler cover C9804E
(2) Cleaning (a) Check for carbon or sludge deposited in the oil pas sage of the oil cooler element and bypass valve. If contamination is evident, wash in a cleaning oil. (b) If there is a lot of scale on the element and cover, wash it away with tap water (preferably hot). (3) Pressure resistance test
NOTE: Never attempt to apply pressure exceeding the speci fied test pressure.
Check for possible leak by applying a 1470 kPa {15 kgf/ cm2} air pressure to the element. Replace the element if air or oil leak or any other faulty condition is evident as a result of the test.
Conduct the pressure resistance test to check for oil leak caused by damaged or cracked element.
12-17
IEI
LUBRICATION - SERVICE PROCEDURE
4.3 Regulator Valve 98to 115 N-m {1O to 12 kgf-m}
Set load (set length: 48.3) NV 76to 80 N {7.8to 8.2 kgf} Lost tension
1 1 2 3 4
Snap ring Valve Spring Body
�er
Regulator valve installation position: Left side of crankcase
12-18
Valve opening pressure NV 360to 420 kPa {3.7 to 4.3 kgf/cm 2 }
2
C9902A
LUBRICATION - TROUBLESHOOTING 5. TROUBLESHOOTING Probable cause
Symptom Overheating
Abnormal oil level • Oil leaks into coolant • Oil leaks Incorrect oil viscosity • Oil out of life • Fuel in oil
Oil pressure does not increase
Oil pressure switch not functioning properly Loaded oil filter element Loaded oil strainer, loose oil pump joint, cracked pipe
Remedy
Ref. group
Correct and fill to specified level
Replace Change oil after repair of faulty parts Replace Replace element Correct or replace
Relief valve, bypass valve not functioning properly Worn or damaged oil pump proper Excessive oil consumption
Replace
Oil leaks from engine
Correct or replace
Oil leaks from crankshaft front or rear oil seal
Correct or replace
Leaks to cooling system • Defective oil cooler water jacket
Correct or replace
Abnormal compression pressure
Check
Group 11
Group 11
12-19
FUEL AND ENGINE CONTROL CONTENTS 1. 2. 3. 3.1 3.2 4. 5. 5.1
GENERAL .................................... 2 SPECIFICATIONS ........................... 2 5 SERVICE STANDARDS ..................... 26 Service Standards Table ................. 26 lightening Torque Table ................. 27 SPECIAL TOOLS ............................ 28 SERVICE PROCEDURE ..................... 29 Removal and Installation of Injection Pump Assembly ......................... 29 5.2 Bleeding of Fuel System ..... ............ 32 5.3 Inspection and Adjustment after Installing the Injection Pump ...................... 32 5.3.1 Inspection and adjustment of fuel injection start timing ............. 32 5.3.2 Inspection and adjustment of minimum and maximum no-load speeds ..... . . 34
5.4
Pump Drive Case ....................... . . Removal and installation ............. Disassembly and inspection ... ....... Reassembly ..................... . .. . .. 5.5 Injection Nozzle ................... . ...... 5.5.1 Removal and installation ... . . . . ... . .. 5.5.2 Disassembly ........................... 5.5.3 Cleaning and inspection .... . ... ..... . 5.5.4 Reassembly and adjustment <KBL2.1 injection nozzle> ............ 5.5.5 Reassembly and adjustment <KBL2.4 injection nozzle> .... ........ 5.6 Fuel Filter ............ :............. . ..... 5.7 Water Separator .................... ..... 6. TROUBLESHOOTING ............ . ..........
5.4.1 5.4.2 5.4.3
35 35 35 361 37 37 37 38
40 46 52 54
55
13A-1
FUEL AND ENGINE CONTROL - GENERAL
1. GENERAL
---
Injection pipe
Injection nozzle
Governor Fuel leak-off--.., pipe
!
Fuel feed pipe
Fuel filter
Automatic timer
Fuel feed pipe
i-----
Feed pump
Water separator (option)
Fuel tank
82115A
The fuel system consists of the injection pump general assembly (injection pump proper, governor, automatic timer, feed pump and coupling), fuel filter, water sepa rator, injection nozzle, fuel leak-off pipe, etc.
13A-2
The injection pump is connected with the air compres sor or pump drive case by a coupling and driven at one half the engine speed.
-
FUEL AND ENGINE CONTROL - GENERAL (1) Injection pump proper (a) Injection pump
Delivery valve holder
Deflector Oil sump Control rod Control lPLI---sleeve �---- Upper spring seat Plunger spring Lower spring seat Tappet
1) The pump housing is a totally enclosed type. 2) The plunger barrel has an oblique hole made to return the fuel that has leaked to the oil sump to minimize the leakage of the fuel into the cam cham ber. 3) To prevent the fuel in the oil sump from leaking into the cam chamber, an 0-ring is provided on the outer circumference of the plunger barrel, thereby maintaining its tightness. 4) A deflector is provided on the outer circumference of the plunger barrel to prevent erosion of the pump housing that may be caused by counter flow of fuel at the end of an injection. (bl Plunger and plunger barrel The plunger has an obliquely cut groove (lead) and a vertical groove as illustrated. The plunger barrel has two fuel suction/discharge ports. Fuel fed into the injection pump is sent under pressure by the camshaft rotation, or the reciprocating motion of the plunger as follows.
Cam chamber Camshaft
Fuel drawn in 89083C
The camshaft driven at half the engine speed is sup ported by taper roller bearings at both ends. The cam shaft has a cam for operating the plunger and a cam for operating the feed pump. A tappet operating with the pump housing as the guide is in contact with the camshaft. The tappet changes the rotary motion of the cam to up-and-down motion which is transmitted to the plunger. The P type injection pump offers the following fea tures.
Beginning of pressure feed
Pressure feed
End of pressure feed 82204A
When the plunger moves down from the top dead cen ter and opens the suction/discharge ports in the plunger barrel, fuel is not only drawn into the barrel by a vacuum created during the plunger's downward stroke but also sent into the barrel under pressure by the feed pump. On the upward stroke, the plunger begins to compress fuel as it completely closes the suctional discharge ports in the plunger barrel. With the plunger further going up and with the fuel pressure increasing, the plunger overcomes the force of delivery valve spring, pushing up the delivery valve. This causes fuel to be sent under pressure through the injection pipe to the injection nozzle. 13A-3
-
FUEL AND ENGINE CONTROL - GENERAL
Effective stroke
Control rod
:,-:
B2205A
Driving face
B2206A
The amount of fuel injected will be changed according to the engine operating loads by turning the plunger a given angle to increase or decrease the effective stroke. To be more precise, operation of the control lever or governor moves the control rack (or control rod) to the right or left, which results in the control sleeve being turned. The bottom end of the control sleeve meshes with the driving face of the plunger; thus, as the control sleeve rotates, the plunger also rotates to vary the effective stroke, thereby increasing or decreasing the amount of fuel injected.
13A-4
As the plunger rises and its oblique groove (the reed) meets the inlet/outlet hole, fuel flows into the plunger's vertical groove and is expelled from the inlet/outlet hole. No pressure feed takes place thereafter, regard less of how much the plunger rises. The stroke length during which pressure feed takes place (from when the plunger closes the plunger bar rel's inlet/outlet hole until the plunger's oblique groove opens them) is known as the effective stroke.
-
FUEL AND ENGINE CONTROL - GENERAL (d) Overflow valve
(c) Delivery valve
Suction stroke Spring Spring seat To overflow pipe Beginning of Injection injection
Steel ball
End of End of injection injection (beginning of suction)
01827
The fuel highly pressurized by the plunger pushes the delivery valve up and gushes out. When delivery of the fuel under pressure by the plunger is completed, the delivery valve is pushed back by the delivery valve spring and closes the fuel passage to prevent counter flow of the fuel. The delivery valve is further brought down until it is held against the seat surface tightly. The amount of fuel corresponding to the stroke during the period is drawn back from above to instantly lower the residual pressure in the line between the delivery valve and nozzle. The draw-back effect improves the cutting of fuel from the nozzle and prevents after-injection drip足 ping. A delivery valve stopper, provided on the top of the delivery valve spring, limits the lift of the delivery valve to prevent the surging of the valve during high speed operation. It also reduces the dead volume between the delivery valve and nozzle and stabilizes the injec足 tion rate.
82208A
When the fuel pressure in the injection pump exceeds a predetermined pressure, the steel ball in the overflow valve is pushed up to let the fuel flow out from the injec足 tion pump and return to the fuel tank, thereby stabiliz足 ing the fuel temperature and temperature distribution in the injection pump and maintaining the injection rate into each cylinder constant.
13A-5
-
FUEL AND ENGINE CONTROL - GENERAL
(2) Governor
The construction and operation of the governor are the same regardless of the applicable model of the injec tion pump. (a) RSV type governor
Supporting lever shaft Guide lever
Governor housing
Tension lever
Start spring
Control lever
Governor spring
Camshaft,
Ungleich spring or idling spring
Stop lever Full-load stopper bolt
B2657B
The RSV type governor is a centrifugal type all-speed governor coupled to the camshaft of the injection pump. The governor not only controls the maximum and minimum speeds but also automatically controls the engine speed at any intermediate speed position.
13A-6
FUEL AND ENGINE CONTROL - GENERAL
whereas the top of the lever is coupled through the shackle to the control rack. The start spring, attached to the top end of the control lever, always pulls the control rack in the direction that fuel is increased.
Slider
Ball bearing
-
Guide lever
Governor sleeve
Flyweight
Flyweight supporting shaft
Start spring
Control rack
Control lever
Pressure spring Governor shaft
Return spring
Adjusting screw
82658C
The governor, as shown, consists of flyweights mounted to the injection pump camshaft. When the flyweights turning on the flyweight supporting shaft open outward, the slider mounted to the end of fly weight arm pushes the end of the sleeve in the axial direction. The governor sleeve, being made integral with the shifter through a bearing, moves only in the axial direction. The shifter is fixed to the end of the guide lever with a pin to prevent its rotation.
Supporting Pin lever
djusting lever
Stop lever
82659A
The control lever is mounted to the middle of the guide lever by the shaft with the bottom end as the fulcrum,
Governor spring
�-- Ungleich spring or idling spring
The turning shaft of the swivel lever is fitted into the bushing of the governor cover and' its center is eccen tric with respect to the mounting position of the gover nor spring installed to the tension lever. The governor spring is installed to the end of the swivel lever. When the governor spring receives tension, the bot tom end of the tension lever touches the adjustable full-load stopper bolt. When the angle of the adjusting lever is changed, the angle of the swivel lever is also changed and the ten sion of the governor spring changed. This is because the turning center of the swivel lever and the mounting position of the governor spring installed to the tension lever are eccentric to each other as mentioned above. An adjusting screw is also mounted to the swivel lever. Adjustment of the screw changes the tension of the governor spring, thereby making it possible to adjust the speed regulation. An Ungleich spring (or idling spring} is provided in the bottom portion of the tension lever. Adjust the tension of the spring by adding or removing shims. An idling sub spring adjustable from outside is pro vided in the middle of the governor cover. During 13A-7
FUEL AND ENGINE CONTROL - GENERAL idling, the spring always keeps in contact with the ten sion lever to maintain a constant idling speed. The stop lever, mounted through the supporting lever to the bottom end of the control lever, returns the con trol rack to the stop position with a slight pressure irre spective of the adjusting lever position.
2) Idling control
Start spring Idling
1) Start of engine
Governor spring Adjusting lever Starting
s=, l Shifter Guide lever
B2661A
B2660A
When the adjusting lever is moved to the start position (until it touches the maximum speed stopper), the swivel lever which moves with the adjusting lever pulls the governor spring and moves the tension lever until it touches the full-load stopper bolt. At that time, the flyweights are stationary, and the start spring with weak tension pulls the control lever in the direction that fuel is increased. At the same time, the shifter and governor sleeve push the flyweight slider to the left. As the result, the tension lever and shifter are spaced that much apart, and the corresponding amount of fuel is supercharged to facilitate starting.
13A-8
Once the engine is started and the adjusting lever returned to the idling position, the tension of the gover nor spring is drastically reduced. Now the flyweights can move outward even at a low speed, so the tension lever is pushed back until it touches the idling sub spring and places the control rack at the idling position. In this state, the centrifugal force of the flyweights and the weak-state governor spring and idling sub spring achieve balance and main tain smooth idling. When the speed falls, the centrifugal force decreases, the flyweights move inward, and the idling sub spring pushes the tension lever to the left and moves the con trol rack in the direction that fuel is increased. If the speed falls radically, the start spring with weak tension acts and moves the control rack in the direction that fuel is increased to maintain the idling speed.
-
FUEL AND ENGINE CONTROL - GENERAL 3)
position, thereby preventing over-speed operation of the engine. The RSV type governor controls the entire speed range from idling to maximum speed. If load increases or decreases at a certain speed determined by the posi tion of the adjusting lever, the governor automatically functions and maintains the engine speed constant at all times.
Maximum speed control
No-load Adjusting lever (Idling)
4)
Ungleich operation When max. injection is set at low-speed operation
---------
-,
\_
Idling sub spring
--=
Injection/ stroke
Ac;,,A'
Injection matched with air intake rate -
B
:..;...---'-----�.() 8'
When max. injection is set at high-speed operation Shifter
Full-load stopper bolt Engine speed 82662A
When the adjusting lever is moved to the full-load posi tion, the tension of the governor spring is increased and pulls the tension lever until it touches the full-load stopper bolt. When the engine exceeds the specified speed, the cen trifugal force of flyweights becomes larger than the force of the governor spring pulling the tension lever. So the tension lever is moved to the right and moves the control rack in the direction that fuel is reduced, thereby preventing the engine from exceeding the spe cified speed. If the speed further increases, the centrifugal force of flyweight increases and pushes the tension lever to the right and also compresses the idling sub spring to pull the control rack back to the no-load maximum speed
82663A
The air intake rate of the engine falls as the engine speed increases. The injection pump, on the other hand, increases the per-stroke injection as the speed increases, even with the control rack at the same posi tion. Therefore, if full-load is set at point A to derive enough output at low speeds, the injection will reach B as the speed increases, and the engine will produce black smoke. If full-load is set at point B' to prevent black smoke, the low speed injection will come down to A', allowing combustion of more fuel. So the Ungleich device accomplishes the function of setting full-load at point A to derive the largest possible torque in the low speed range, and changing it to adjust the injection to point B' in the high speed range.
13A-9
-
FUEL AND ENGINE CONTROL - GENERAL As the engine speed increases, the centrifugal force of flyweight increases. If it becomes larger than the pres sure of the Ungleich spring, the Ungleich spring is slowly compressed before the start of high speed con trol, and the control rack moves in the direction that fuel is reduced. The Ungleich stroke is completed at the position where the shifter directly touches the ten sion lever.
E E
.g
·;;; 0 0. ..>< (.)
"'
0::
5)
N2 N1 Pump speed (rpm) ---
Stopping of engine Stop position
�l'"'1' -t-........�
Adjusting lever
"'---:-
Without Ungleich effect
Control rack
N2 N1 Engine speed (rpm) --
B2664A
When the engine speed is low and the centrifugal force of flyweight smaller than the pressure of the Ungleich spring, the shifter is moved as much as the Ungleich stroke to the left, so the control rack moves in the direc tion that fuel is increased to increase the torque of the engine at low speeds. Full-load
ill!illy·----..,....-==-�::::::-.-.
Control rack
Ungleich spring
Shifter
13A-10
B2665A
Stop Stop lever
B2666A
When the stop lever is moved to the stop position, the control rack is moved to the stop position to stop the engine regardless of the position of the adjusting lever.
FUEL AND ENGINE CONTROL - GENERAL 6)
Operation of torque spring
t
C
t
D
E
D
in � � -"'
E C:
.g 'iii
-
Governor operating range
....a.:,
0
a.
-"'
(J
A
-
P1 -1---, i.,tp2 Engine speed (rpm)
P1 P2 Pump speed (rpm) -
Construction machinery engines are often subjected to a large load during operation, and reduced speeds often lead to stalls. To prevent this, a torque spring is provided. When the adjusting lever is fixed in the lever set posi tion, a sudden increase of load, if no torque spring is provided, will move the control rack along the 8-D curve as the speed falls. The rotational displacement at the time may be expressed as P1.
Torque spring
82667A
If a torque spring is provided, the control rack moves along 8-C, and the rotational displacement at the time may be expressed as P2. Therefore, large changes occur in P2 and engine speed, and because of increased fuel injection, the engine torque increases, and large combustion noise warns the operator of the increased load, enabling him to take proper action to prevent stopping the engine. In an abrupt increase of load occurs when the engine is running at continuous rating, the engine speed falls. So the flyweights are moved inward and the tension lever pulled to left by the control spring, causing the control rack to move in the direction that fuel is increased. At the time, the tension lever pin pushes the bottom of the torque control lever, and the lever moves with the pin "A" as the fulcrum, whereas the portion "B" is pushed to right. As the result, the torque spring per forms the function of reducing movement of the ten sion lever.
Full-load stopper
82668A
13A-11
-
FUEL AND ENGINE CONTROL - GENERAL
(b) RFD type governor
Governor cover
Stop lever
Governor housing
Flyweight Floating lever
Sliding lever
826828
The RFD type governor is a minimum-maximum gov ernor which controls only the minimum and maximum speeds. The RFD type governor make it possible to increase or reduce fuel by the load control lever which operates the control rod. Any desired speed can be set as a dis placement of the speed control lever changes the ten sion of the governor spring. Because of the construction described above, the RFD governor can be operated as an all-speed governor by holding the load control lever in the full position and operating the speed control lever. Flyweights are mounted on the injection pump cam shaft. Each of the flyweights pivots about a pin press fitted in the flyweight holder. When the flyweights move out, the slider fitted to the end of the flyweight arms pushes the sleeve end face axially. The sleeve which contacts the flyweight slider is coupled to the shifter by a snap ring. The guide lever suspended from 13A-12
the tension lever shaft holds the shifter, preventing it from turning. The guide lever has an intermediate shaft, on each side of which there is a floating lever mounted. A block is press-fitted in the bottom end of one floating lever and this block is fitted in the bottom of the sliding lever. The load control lever is fitted to this sliding lever through an eccentric shaft. The floating lever can be moved by operating the load control lever. At the upper end of the floating lever placed on the other side via a shaft, there is an injection pump control rack fitted via a floating lever link. A start spring is hooked at the lower end of the floating lever and the other end of the start spring is hooked at the spring eye on the governor housing side. The tension lever is suspended from the tension lever shaft from which the guide lever is suspended. A gov ernor spring is fitted across this tension lever and the swivel lever. Its tension is determined by the speed control lever mounted on the swivel lever shaft. Within
FUEL AND ENGINE CONTROL - GENERAL normal speed ranges, therefore, the lower end of the tension lever is always in contact with the stroke adjusting bolt. A pin is press-fitted in the side of the lower end of the tension lever. It fits into the groove in the upper part of the sliding lever. During high speed control, therefore, a greater lever ratio is obtained from the linkage formed by the pin, sliding lever, and floating lever. Built into the lower end of the tension lever is the idling spring that provides low speed control. 1)
-
The engine stop lever is fitted to the top of the gover nor, that moves the control rack to the non-injection position to stop the engine. The cancel spring is installed to prevent excessive force from being applied to the control rack at this time. Mounted on top of the governor cover is the smoke set assembly. It functions to ensure good starting by increasing the amount of fuel injected at starting and improve smoke condition in the practical full-load low speed range.
Control of engine start and idling Speed control lever Maximum speed position Guide lever
Control rack 11111111 Swivel lever Governor spring Load control lever Full position
Shifter
Idling spring B2670A
When the engine is not running, the flyweights are in the closed position, pushed by the governor spring, idling spring, and start spring. If, in this condition, the load control lever is moved all the way to the full posi tion (in the direction of greater fuel delivery), the start spring and idling spring cause the control rack to move to a point which is beyond the full-load position and provides the maximum amount of fuel injected, thus making it easier to start the engine. When the load control lever is returned to the idling position after the engine has started, the flyweights increase or decrease their centrifugal force as the engine speed changes. In the idle speed range, the cen trifugal force is such that it just compresses the idling spring. The centrifugal force of the flyweights balances the combined force of the idling spring and start
spring, which keeps the control rack at a given position. This results in the engine running at smooth idle speed. If the engine speed increases at this time, the centrifu gal force of the flyweights increases causing the fly weights to move out to push the shifter to the right. As a result, the guide lever and floating lever are moved, which in turn moves the control rack in the direction of smaller fuel delivery (to the right). If the engine speed decreases, on the other hand, the control rack is moved in the direction of greater fuel delivery. The governor controls the amount of fuel injected in this way to stabi lize the engine at idle speed.
13A-13
2)
FUEL AND ENGINE CONTROL - GENERAL 3) Control of maximum speed
Normal speed operation
Speed control lever Maximum speed position
Floating lever 11111111
Sliding lever 82671A
If the load control lever is moved in the full direction (for greater fuel delivery), the eccentric shaft coupled to the load control lever causes the sliding lever to pivot about pin D fitted in the bottom of the tension lever. At the same time, the floating lever pivots about point B to push the control rack in the direction of greater fuel delivery, which results in the engine speed increasing. When the engine speed reaches a point over the idling control range, the idling spring is completely com pressed in the tension lever, causing the shifter to be in direct contact with the tension lever. The tension lever, however, is in contact with the stroke adjusting bolt by the tension of the governor spring which is tightened by the speed control lever. Since the centrifugal force of the flyweights is small in the normal speed range, the tension lever is unable to move. This means that point B can not move either, and the operation of the load control lever is directly transmitted through the eccentric shaft, sliding lever, and floating lever to the control rack, thereby increasing and decreasing the amount of fuel injected.
13A-14
82672A
As the engine load varies and engine speed reaches a predetermined maximum speed, the centrifugal force of the flyweights overcomes the governor spring ten sion, causing the flyweights to start moving out. This motion results in the shifter and tension lever being moved to the right. Then, point B is moved to B' and point D in tension lever to D', which prevents the engine speed from exceeding the predetermined max imum level. If this governor is used as an all-speed governor, the engine speed is varied by operating the speed control lever with the load control lever fixed at the full posi tion. That is, a given engine speed is maintained as the speed control lever is tilted; if load changes, however, the governor automatically controls to keep the given speed. For example, suppose the speed control lever is tilted to a position which provides the maximum out put (where it contacts the maximum speed stopper bolt). When the engine speed increases in this condi tion, the centrifugal force of the flyweights becomes greater.
-
FUEL AND ENGINE CONTROL - GENERAL As the force becomes greater than the force of the gov ernor spring which pulls the tension lever, the fly weights start moving out. This motion of the fly weights causes the shifter and tension lever to be moved to the right. At the same time, point Bis moved to B', point D to D', and point C to C'. This results in the control rack being pulled in the direction of smaller fuel delivery, thus reducing the engine speed. If load increases to cause the speed to decrease, the centrifugal force of the flyweights becomes smaller than the governor spring tension. Then, point B' is moved to 8, point D' to D, and point C' to C. This results in the control rack being moved in the direction of greater fuel delivery. The governor automatically activates as load changes to maintain a given speed at all times. 4)
With smoke set assembly
Without smoke set ambi'
,,i
Rs.,____
'
Re \
Rack position (mm)
Start booster (smoke set assembly)
Pump speed (rpm) _,..
11111111
82673A
The smoke set assembly installed to the rear of the governor has a spring with setting force and a stopper as functional parts. It also has sleeve, stroke adjusting nut, spring adjusting nut and cap.
826748
As indicated by the governor characteristics shown above, when without the smoke set assembly, the shifter and floating lever are pushed back by the idling spring force, moving the control rack toward fuel increasing direction when pump speed reaches N1. Namely, N1 is the smoke limit in this case. When with the smoke set assembly, the spring force of the smoke set assembly overcomes that of the idling spring so that the floating lever motion is inhibited until the speed reaches N 2. Thus, the smoke limit decreases from N1 to N2. It is also possible to secure rack position Rs needed at time of start.
13A-15
5)
FUEL AND ENGINE CONTROL - GENERAL (3) Feed pump
Engine stop lever
Normal position
Stop -. -,::: O ''�'
Priming pump
\ ®'
�
Stop lever assembly Inlet check valve
To fuel filter
82675A
To stop the engine, the stop lever on top of the gover nor must be operated to cut off the fuel. The stop lever is cable-connected to the engine stop button on the driver's seat. The stop lever is operated by pulling the button. When the stop lever is rotated, the internal lever pushes the tab on the floating lever link, forcing the control rack to the non-injection posi tion to stop the engine. The stop lever returns to the normal position by the reaction of a built-in spring.
13A-16
83006A
Supply of fuel to the injection pump proper is accom plished by the feed pump mounted to the side of the injection pump proper and driven by the cam of the injection pump camshaft provided for the purpose. The priming pump mounted to the feed pump makes it possible to lift fuel manually when the engine is sta tionary.
FUEL AND ENGINE CONTROL - GENERAL (a) Suction stroke
(c) Stop
01837
01835
When the camshaft of the injection pump forces the push rod up, the fuel in the suction chamber is com pressed and opens the outlet check valve. Most of the fuel forced out is drawn into the pressure chamber above the position.
When the pressure in the pressure chamber exceeds specification, the piston cannot be brought back by the pressure of the piston spring and stops the pump func tion. So the pressure in the fuel filter is adjusted not to rise more than necessary.
(b) Pressure feed stroke
(4) Automatic timer
Piston spring
Pressure chamber
01836
When the cam, moved away by rotation of the cam shaft, ceases to push up, the piston is pushed back by the pressure of the piston spring and forces out the fuel from the pressure chamber and forces it into the fuel filter. At the time, the outlet check valve closes, and the inlet check valve opens, so the fuel is drawn into the suction chamber.
The interval between fuel injection into the cylinder and its ignition is called the ignition delay interval. The ignition delay interval is constant regardless of the engine speed. If the ignition timing is always constant, changes in the engine speed will vary the relation between the piston position and ignition timing, mak ing it impossible to obtain the best engine perfor mance. To maintain the relation between the piston position and ignition timing constant at all times, the injection timing must be changed to match the engine speed. The automatic timer is a device which automatically changes the injection timing according to the engine speed.
13A-17
-
FUEL AND ENGINE CONTROL - GENERAL
(a) SP type automatic timer <6D24, TC>
Injection pump side
Oil seal
0-ring
Flange
Cover
Spring seat Flyweight Timer housing
B3201A
Two flyweights are fitted on the pins of the timer hous ing and are held in the timer housing. On the other hand, the inject ion pump connection side flange has a curved surface, and the roller fitted on the pin installed in the flyweight touches the curved surface. Timer 1imer spring
When the engine is running at a low speed, the timer spring pressure is stronger than the centrifugal force of flyweight, so the roller of flyweight is held down by the flange, creating no advance state. When the engine reaches a high speed, the centrifugal force of flyweight becomes stronger, the roller of fly weight pushes the curved surface of flange with the timer housing pin as the fulcrum, and the flyweight opens outward, while compressing the timer springs. In this manner, the roller installed on the flyweight moves the flange in the turning direction and advances the injection timing.
Flange
Timer housing pin \
Advance angle
83202A
13A-18
springs are held between the spring seats fitted on the timer housing pins which extend through the flange and flyweight. These parts are housed in the timer housing and are totally enclosed with a cover, 0-ring and oil seal.
-
FUEL AND ENGINE CONTROL - GENERAL (b) SPG type automatic timer <6D24
\; \/
Cover Pilot pin
Timer holder
Timer housing
80023A
� � ��,�Flywo;ght _'.
Flywo;ght p;, =-� Eccentric cam (larger) � Timer holder � Eccentric cam (smaller) �
I�
� Housing pin -,---U ···
Timer housing
Timer spring 80024A
The timer housing receives rotating motion of the engine through a coupling. The timer holder is directly connected to the injection pump camshaft. Two oppos ing pins are press-fitted in the timer housing. A small eccentric cam is mounted on each of the pins and a large eccentric cam is slid over the periphery of the small cam. The two holes in the timer holder fit over the large eccentric cams. Pins are pressed into the undersides of the flyweights. These flyweight pins fit into holes in the larger eccen tric cams. When the timer housing is rotated, the timer holder is rotated at the same time driving the injection pump.
80025A
The two flyweights have the timer holder in between and are provided with timer springs having the same set tension to keep the flyweights evenly in position. When the engine is not running or running at low speeds, the flyweights are pressed against the timer holder by the set tension of the springs.
13A-19
FUEL AND ENGINE CONTROL - GENERAL (5) Boost compensator <engine with turbocharger> Point A Boost pressure
Flyweight
Timer spring Inlet manifold Timer housing pin (point Cl
Flyweight pin cam
Small eccentric cam
Flyweight in fully lifted position
--tt--t--+-+� �-1-+--+-....1.L_.1.
Retard angle
43932
When the engine is not running, the flyweights are pressed against the timer holder by the timer spring set tension. When the engine is started, a centrifugal force is pro duced by the flyweights; however, it is less than the timer spring set tension keeping the flyweights remaining the original positions, without lifting. As the engine speed increases, the centrifugal force of the flyweights also increases and will be balanced with the spring tension. When the engine speed further increases, the centrifugal force overcomes the timer spring set tension, causing the flyweights to lift out ward. This causes the center (point B) of the large eccentric cam pivot about the center (point A) of the timer, moved in the rotating direction, by the small eccentric cam pivoting about the timer housing pin (point C). Since the large eccentric cam is fitted to the timer holder, that motion of the large eccentric cam is imparted to the timer holder. The maximum retard angle is obtained when the backs of the flyweights are against the inner wall of the timer housing.
13A-20
86012A
The boost compensators increase the engine's power output by increasing the rate of fuel injection to match increases in air intake caused by the turbocharger. To increase the amount of fuel injected, the boost com pensators utilize the boost pressure in the inlet man ifold. There are two boost compensators. One is fitted to the governor, and the other is fitted to the drive side of the injection pump.
FUEL AND ENGINE CONTROL - GENERAL (b) Drive-side boost compensator
(a) Governor-side boost compensator
-
Boost compensator set spring Connection pipe Boost Boost compensator
Inlet manifold
Floating lever
B2693C
Control rod. 82691A
As the boost pressure overcomes the compensator spring, the diaphragm and push rod are pushed to the left. Movement of the diaphragm is pivoted on point "A" of the compensator lever and moves the compen sator lever in the direction shown by the dotted lines. As the diaphragm and compensator lever move, the floating lever pivots counter-clockwise about point "B," thereby pushing the control rod in the fuel-in crease direction. The system is thus able to increase the fuel quantity irrespective of the governor.
Load control lever idling position
7
�
tingl�oc . CanceI sprmg Floatmg . I ever 1.mk Load control lever full position (turbocharger off) Control rod
:+
=
F.
[JC: :,.•.o �
Load control lever full position (turbocharger on)
:+
¥? [jt#:;;:g,_nn �
82693A
When the boost pressure rises above the boost com pensator spring set pressure by the action of the turbo charger, the diaphragm forces out the push rod. The cancel spring installed between the control rod and floating lever on the governor side is set so that it pushes, at all times, the control rod in the direction of greater fuel supply. This means that, when the push rod moves in the direction shown by the arrow, the control rod moves in the direction of greater fuel sup ply. This boost compensator also has a spring that increases fuel supply at engine start.
13A-21
-
FUEL AND ENGINE CONTROL - GENERAL (7) Injection nozzle Two models of hole type injection pumps are used. Their constructions are as follows. (a) KBL2.1 injection nozzle
Cap nut Adjusting screw Lock nut---
�..._.,,.,.,
Set screw---��=!�
�::;..._- Spacer
Control rod
82692A
Before the engine is started, the idling spring in the governor, forcing the control rod in the direction of more fuel supply overcomes the force of the smoke set spring and therefore the control rod moves to the start fuel increase position while forcing the arm. When the engine is started, the idling spring is compressed by the shifter and as a result, it loses the force to push out the control rod. Then, the smoke set spring forces the control rod back to the normal position. (6) Pump drive case
Pump drive shaft
Injection pump side
Flywheel housing side 84191A
The pump drive case, installed at the left of the fly wheel housing, is driven by the timing gear of the engine at half the engine speed. The pump drive shaft, with its end connected to the coupling of the injection pump, drives the injection pump. 13A-22
No. 2 spring
No. 2 push rod MU�--- Nozzle holder
No. 1 spring No. 1 push rod Nozzle Retaining nut
83406A
The nozzle has two springs and push rods, and a clear ance (prelift) is provided between two rods. When the high pressure fuel fed from the injection pump overcomes the 1st spring which determines the valve opening pressure, the needle valve opens to start the pre-injection and simultaneously moves the 1st push rod upward. When the 1st push rod moves through the prelift and contacts the 2nd push rod, the needle valve stops mov ing momentarily. As the fuel pressure further increases and overcomes the resultant force of the 1st and 2nd springs, the needle valve restarts moving upward for the main injection. Some of the high-pressure fuel is used to lubricate the needle valve and other components and is returned to the fuel tank via the leak-off pipe. Fuel injection pressure adjustments are made using the shim.
FUEL AND ENGINE CONTROL - GENERAL (b} KBL2.4 injection nozzle
No. 1 spring
From injection pump
OJ No. 1 valve opening pressure,--++�� adjusting shim
Push rod
No. 1 spring seat
No. 1 spring No. 2 spring No. 1 spring seat
No. 2 valve opening pressure adjusting shim No. 2 spring seat
Lift-piece Needle valve
Lift-piece
11933
With this nozzle, a prelift clearance is provided between the lift-piece and No. 2 spring seat, and the nozzle's injection starting pressure is determined by the force of the No. 1 spring.
Needle valve
01846
As the pressure of the fuel fed from the injection pump (i.e., the pressure in the nozzle tube} overcomes the No. 1 spring, the needle valve rises by the prelift distance. When the lift-piece rises by the prelift distance, it meets the No. 2 spring seat. Since the lift-piece and No. 1 spring seat are pressing together, the spring force at this time is that of the No. 1 and No. 2 springs com bined, and the needle valve momentarily stops rising. As the fuel pressure rises and the pressure in the nozzle tube overcomes the two springs, the needle valve rises further and the nozzle injects the remaining larger quantity of fuel. Fuel injection pressure adjustments are made using the shim.
13A-23
-
FUEL AND ENGINE CONTROL - GENERAL (9) Water separator
(8) Fuel filter
<6D24, T, TC>
-- Element
835018
83551A
83501C
<6D24-TL>
速28757
The fuel filter may be either the element replace type or the spin-on type which facilitates replacement of ele足 ment. It separates water content in the fuel fed under pres足 sure from the fuel feed pump of injection pump and eliminates dirt in the fuel by the element. 13A-24
The sedimenter type water separator separates gas oil and water centrifugally by taking advantage of their difference in specific gravity. The fuel that has flowed in from the inlet connector is squeezed by the fuel path of the head to increase the flow velocity and spins. The separated water is sedi足 mented in the case, whereas the water-separated fuel is drawn through the fuel path in the center of the head into the feed pump. The water separator sediments not only water but also mud components. A red float goes up and down with the water level in the semi-transparent case, making it possible to visually check the water quantity.
-
FUEL AND ENGINE CONTROL - SPECIFICATIONS 2. SPECIFICATIONS (1) Injection pump Specification
Item
BOSCH AUTOMOTIVE SYSTEMS
Manufacturer Injection
<6024>
<6D24-TC>
<6D24-T>
Pump
(Standard)
(Optional)
(Standard)
(Optional)
Type
Bosch in-line type
Bosch in-line type
Bosch in-line type
Bosch in-line type
Plunger diameter
Bosch in-line type
Bosch in-line type
p
p
p
p
p
p
Clockwise
Clockwise
Clockwise
Clockwise
Clockwise
Clockwise
12
12
12
12
12
12
RSV all-speed mechanical governor
RFD minimummaximumspeed mechanical governor
RSV all-speed mechanical governor
RFD minimummaximumspeed mechanical governor
RSV all-speed mechanical governor
RED-4 electronically controlled governor
K
K
K
K
K
KD
SP mechanical automatic timer
SP mechanical automatic timer
SPG mechanical automatic timer
SPG mechanical automatic timer
SP mechanical automatic timer
SPGH electronic timer
Model Direction of rotation (seen from drive side)
6O24TLE2A
mm
Governor Model and type
Feed pump model Model Automatic timer Model and type
(2) Injection nozzles Item
Specification
Manufacturer
BOSCH AUTOMOTIVE SYSTEMS <6D24>
Nozzle Type
<6O24-TC>
<6O24TLE2A
(Optional)
Hole-type (2-spring nozzle: KBL2.4)
Hole-type (2-spring nozzle: KBL2.4)
Hole-type (2-spring nozzle: KBL2. 1)
Hole-type (2-spring nozzle: KBL2.4)
Hole-type (2-spring nozzle: KBL2.4)
OLLA
OLLA
OLLA
OLLA
OLLA
5
5
5
5
5
0.32
0.36
0.36
0.36
0.30
157°
154°
150°
150°
151°
model No. of holes Hole diameter
<6O24-T> (Standard)
mm
Spray angle
(3) Others items Item
Specification
· Fuel filter type
Spin-on filter-paper type
Water separator type
Precipitation type
13A-25
FUEL AND ENGINE CONTROL - SERVICE STANDARDS
3. SERVICE STANDARDS 3.1 Service Standards Table (1) Injection pump Unit: mm Nominal value (Basic diameter in I ])
Maintenance item
Dependent on specification
Fuel injection start timing (BTDC) Eccentricity with respect to air compressor crankshaft (or pump drive shaft)
0.2 or less
Limit
Remedy and remarks
-
Adjust
-
Adjust shims
(2) Injection nozzle Unit: mm Nominal value (Basic diameter in I ])
Maintenance item 1st valve opening pressure
Prelift
All except 6O24-TL 6O24-TL
15.7 MPa {160 kgf/cm }
KBL 2.1
0.10 ± 0.02
KBL 2.4 2nd valve opening pressure ("open" pressure) 2nd valve opening pressure with 0.05mm needle valve lift ("cover" pressure)
13A-26
17.7 MPa {180 kgf/cm2} 2
0.07 ± 0.02 24.8 to 25.4 MPa {253 to 259 kgf/cm2}
KBL 2.1
23.0 to 23.5 MPa {235 to 240 kgf/cm2}
KBL2.4
22.6 to 23.6 MPa {230 to 240 kgf/cm2}
Limit
Remedy and remarks
-
Adjust
-
Adjust
-
Adjust
-
Adjust
-
Adjust
-
-
FUEL AND ENGINE CONTROL - SERVICE STANDARDS 3.2 lightening Torque Table Location tightened
Screw size O.D. x pitch (mm)
Tightening torque N-m {kgf-m}
Injection pump bracket mounting bolt
M10 x 1.5
35 to 53 {3.6 to 5.4}
Injection pipe union nut
On pump side
M14 x 1.5
29 to 49 {3 to 5}
On nozzle side
M12 x 1.5
29 {3}
Injection pump
Overflow valve
20 to 29 {2 to 3}
Injection pump fuel inlet side eyebolt
20 to 29 {2 to 3}
Lubricant (inlet) side eyebolt Lubricant (outlet) side eyebolt
20 to 29 {2 to 3} 12 to 15 {1.2 to 1 .5}
Fuel inlet side eyebolt
20 to 25 {2 to 2.5}
Fuel outlet side eyebolt
20 to 25 {2 to 2.5}
A bolt
B bolt
C bolt B3401A
6D24, T, TC
74 to 83 {7.5 to 8.5}
6D24TLE2A
83 to 93 {8.5 to 9.5}
6D24, T, TC
59 to 64 {6 to 6.5}
6D24TLE2A
83 to 93 {8.5 to 9.5}
6D24, T, TC
59 to 64 {6 to 6.5}
6D24TLE2A
83 to 93 {8.5 to 9.5} M24x 1.5
215 {22}
M8x1
9.8 to 15 {1 to 1.5}
M8 x 1.25
15 {1.5}
M19 X1
59 to 78 {6 to 8}
Cap nut
M22x 1.5
39 to 49 {4 to 5}
Inlet connector
M14 x1.5
69 to 78 {7 to 8}
Set screw
M22 x 1.5
49 to 59 {5 to 6}
Lock nut
M14 x1
20 to 25 {2 to 2.5}
Leak-off connector
M14x1
29 to 39 {3 to 4}
Retaining nut
M19x0.75
59 to 78 {6 to 8}
All except 6D24-TL
M14 x 1.5
25 {2.5}
6D24TLE2A
M14 x 1.5
25 to 35 {2.5 to 3.5}
All except 6D24-TL
MS x 1.25
7.8 to 12 {0.8 to 0.12}
6D24TLE2A
MS x1.25
9.8 ± 2 {1.0 ± 0.2}
Eye bolt
M14 x 1.5
25 {2.5}
Air plug
MS x 1.25
7.8 to 12 {0.8 to 1.2}
Injection pump gear mounting nut of pump drive case Injection nozzle
Leak-off pipe eyebolt Injection nozzle bolt (for attaching to cylinder head) 2-spring nozzle
Fuel filter connector bolt Air vent plug
Water separator
Retaining nut
Remarks
12 to 15 {1.2 to 1.5}
Boost compensator eyebolt Fuel feed pump
-
13A-27
FUEL AND ENGINE CONTROL - SPECIAL TOOLS
4. SPECIAL TOOLS Unit: mm Tool name
Shape
Filter Wrench MH061572 <All except 6D24-TL> Removal of fuel filter element
85222A Filter Wrench MH061572 <6D24> Removal of fuel filter element
� � ®01503 Injection Pump Centering Tool MH061340 Centering of bracket of injection pump
22338
13A-28
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5. SERVICE PROCEDURE
(2) Installation procedure
5.1 Removal and Installation of Injection Pump Assembly (1) Removal procedure (a) Ready a fluid receiver and waste cloth to ensure that the engine is not contaminated by fuel or engine oil. (b) Remove all pipes and harness connectors that make the removal job difficult or impossible.
NOTE: The following procedures assume that the injection pump is equipped with an air compressor. The same procedures apply to one with a pump drive case.
(a) Adjustment of injection pump bracket
Dial gauge Injection Pump Centering Tool MH061340 Air compressor $ 30 position 43739
(c) Remove the bolt shown from the coupling. (d) Remove the injection pump from the injection pump bracket.
Injection pump bracket
NOTE: 11929
1)
Make zero-point adjustment with Injection Pump Centering Tool (special tool) placed on the injec tion pump bracket and a dial gauge set on the man drel of the special tool.
C0557A
Keep the injection pump removed on wooden blocks so as to protect the automatic timer area from impact.
(e) Do not remove the injection pump bracket unless defects, such as cracks, are evident.
13A-29
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <When the measured value at point 8 is positive
(+)>
Insert shims evenly to four places. <When the measured value at point A is positive
(+)>
Insert shims to the lower side of point C. <When the measured value at point C is positive
(+)>
Insert shims to the upper side of point A.
Shim inserting requirements • C0597A
• 2)
Slide the dial gauge toward the air compressor and measure the misalignment between the mandrel of the special tool and the air compressor crank shaft at points shown in the figure.
Eccentricity NV 0.2 or less
•
The number of shims used in a single location must not exceed three. Top and bottom shims both at front and rear must be equal in thickness. The difference in number between the top and bottom shims must not exceed one.
4) After adjustment, tighten injection pump bracket to the specified torque before confirmation. (b) Installation of injection pump 1)
Crank the engine to bring the No. 1 cylinder piston to the fuel injection timing position. (Refer to Section 5.3.1.) Keyway
Dowel pin
NV .. Nominal Value
3)
C0598A
If the eccentricity between the mandrel and air compressor crankshaft is in excess of the nominal value, adjust by adding or removing injection pump bracket shims.
13A-30
2) At that time, verify that the keyway of air compres sor crankshaft faces upward. If not, rotate the crankshaft one complete turn.
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE • •
•
C0562A
3) Align the pointer of the injection pump and the inscribed mark on the automatic timer. 4)
Installation of injection pump
Fit the injection pump onto the injection pump bracket. Temporarily fit the timing adjustment bolt onto the driving coupling. Slide the driving coupling until there is clearance of 0.5 mm or less between it and the coupling plate. Then, tighten the cotter bolt to the specified torque. Confirm that the injection starting timing is cor rectly adjusted as per items (b) 1) to 3), then tighten the timing adjustment bolt to the specified torque.
u
20to29N-m {2to3 kgf-m}
20to29N -m {2to 3 kgf-m}___
_r,./
�/
20to25N•m {2to2.5 kgf- m}
29to49N-m {3to5 kgf-m} 20to29N-m k
/&1,.�
tt�: gfm}
\
'20to25 N-m 12to15N-m {2to2.5 kgf-m} {1.2to 1.5 kgf-m} 43741
(c) lighten each pipe to specification. (d) After the injection pump has been installed, be sure to check and adjust, if n_ecessary, the fuel injection start timing. (Refer to Section 5.3.1.)
liming adjustment bolt
Clearance
•
•
85893A
Loosen the cotter bolt and remove the timing adjustment bolt. Remove the driving coupling from the coupling plate. Fit the driving coupling onto the air compressor crankshaft and push it toward the air compressor.
13A-31
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.2
Bleeding of Fuel System
5.3
Perform fuel system air bleeding as follows.
Inspection and Adjustment after Installing the Injection Pump
5.3.1
Inspection and adjustment of fuel injection start timing
) .. ; j!!
85909A
(1) Loosen air plug of fuel filter.
r I
B6118A
(1) Crank the crankshaft more than 180° in forward direction to line up the pointer with the fuel injec tion start timing angle scale inscribed on the out side periphery of the flywheel. NOTE:
B4324A
(2) Turn counterclockwise the priming pump knob of injection pump so that it comes loose. (3) Move priming pump knob up and down to feed fuel until air bubble does not come out from air plug. (4) With no air bubble coming out in fuel, tighten air plug. (5) Move priming pump knob up and down several times, then screw in knob. NOTE: Sop up fuel spilt around.
(6) Actuate starter to discharge air in injection pump and pipe. NOTE: Do not actuate starter for more than 15 seconds.
13A-32
If the engine is turned in reverse direction (either when the engine is stopped or by cranking), the automatic timer will stay advanced and may not return to normal even if the engine is slightly cranked in the normal direction. Make sure that the engine is cranked manu ally more than 180° in the normal direction.
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Adjusting bolt <6O24,T,TC> 59 to 64 N-m {6 to 6.5 kgf-m} <6O24-TL> 83 to 93 N-m {8.5 to 9.5 kgf-m}
86117C
21839
If the timer is electronic, check at this time whether the inscribed lines are aligned. If they are not aligned, the timer is advanced; give the engine two turns in the for ward direction to return the timer to a non-advanced condition. If this action does not return the timer to a non-advanced condition, first loosen the eyebolt (see the drawing) to make it easier for residual hydraulic pressure in the timer to escape to the injection pump.
(3) If they are out of alignment, loosen the timing adjusting bolt of the coupling and adjust by turning the automatic timer. After adjustment, recheck by the procedures of steps (1) and (2), and tighten the timing adjusting bolt to the specified torque. NOTE: Do not loosen the bolts of the coupling except the tim ing adjusting bolt.
C0562A
(2) If the inscribed mark of the injection pump and the inscribed mark of the automatic timer are in align ment in the above condition (1), the fuel injection start timing is correct.
13A-33
5.3.2
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Inspection and adjustment of minimum and maximum no-load speeds
(2) RFD type governor
Start and idle the engine until it reaches normal operat ing temperature. Then, make the following checks. Stopper bolt
(1) RSV type governor Idling Full-speed position 1------, position Adjusting lever
Idling stopper bolt Full-load stopper bolt
Load control lever B63068
(a) Minimum speed
B6310B
(a) Minimum speed Make sure that the adjusting lever is in contact with the stopper bolt. In this condition, check that the minimum speed is within the specification. If the specification is not met, adjust with the stopper bolt. (b) Maximum speed Place the adjusting lever to the full-speed position. If the maximum speed is outside the specification in this condition, adjust with the maximum speed stopper bolt. NOTE: Quickly move the adjusting lever from the full-speed position to the idling position to make sure that the engine does not stall or develop hunting. If defects are evident, adjust within the specification.
13A-34
Check to see that the load control lever is in contact with the idling stopper bolt. In this state, check that the minimum speed is within specified limits. If not, adjust with the idling stopper bolt. (b) Maximum speed Set the load control lever at the full-load position (where it contacts the full-load stopper bolt). If the max imum speed is outside specified limits in this state, adjust with the maximum speed stopper bolt and stop per bolt. NOTE: 1. Never attempt to change the locked position of the full-load stopper bolt. 2. Quickly move the load control lever from the full load position to the idling position to make sure that the engine does not stall or develop hunting. If defects are evident, adjust within the specifica tion.
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.4 Pump Drive Case 5.4.1
-
Removal and installation
Pump drive case
84194A
(1) For removal and installation of the pump drive case, refer to Section 5.1 in Group 61 Special Equipment.
5.4.2
Disassembly and inspection 6
10 Deterioration, damage
Cracks, wear 84196A
Disassembly sequence 1 2 3 4
Sensor plate Injection pump gear Collar Bearing holder
5 Oil seal 6 Shaft 7 Bearing
8 Bearing 9 Cover 10 Crank case
13A-35
5.4.3
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Reassembly
5
Assembly sequence 10➔8➔6➔3➔®➔<D➔9 4➔7➔5 -1'
4
For parts with an encircled number, refer to Reassembly Procedure that follows.
10
7 B4197A
(1) Installation of injection pump gear Install the injection pump gear, sensor plate (or guide plate) and nut as shown. Align uo" and "U" marks
D9274B
13A-36
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
5.5 Injection Nozzle
5.5.2
5.5.1
<KBL2.1 injection nozzle>
Removal and installation
Disassembly
-
,-{j
Gasket -0 3� Cracks, deterioration
2--18111
4---=1 5
Nozzle identification mark stamped position
Wear6� � Shim (for prelift) _ � 1
1 Injection pipe 2 Leak-off pipe 3 Injection nozzle
4 Dust seal 5 Nozzle tip gasket C0577B
1 Cap nut 2 Adjusting screw 3 Lock nut 4 2nd spring 5 Set screw 6 2nd push rod 7 Spacer
12 11
Carbon deposits
--rf :---t./
Shim (for valve opening ---® pressure) ______§ Cracks, 8 -g dete,;o,at;oo g
Wear
o-,o
8 1st spring 9 1st push rod 10 Retaining nut 1l Nozzle 12 Needle valve 13 Nozzle holder 14 Inlet connector D7015A
13A-37
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <KBL2.4 injection nozzle>
Disassembly Procedure
T he following special tools should be used in disas sembly: Identification mark position
11-ij r-
Tool name
11
�10
16
Part No. (Zexel product No.)
Plate
157944-9520
Special Wrench
157914-2800
Removing retaining nut
:--- 9 8 � ©-
--·· Special Wrench (157914-2800)
15--® 14�
1a__i 12 01888 15449
G) 2 3 4 5 6 7 8 9
Retaining nut Needle valve Nozzle Pin (lj>3) Spacer Lift piece Pin (lj>2.5) Spring seat Shim (For adjust ment of second ary valve opening pressure)
10 11 12 13 14 15
2nd spring Push rod Callar Spring seat 1st spring Shim (For adjust ment of primary valve opening pressure) 16 Nozzle holder 17 Leak-off connector
NOTE: 1. Clean off any carbon deposits before disassem bling, reassembling, or adjusting any nozzle assembly. Note, however, that the spray pressure and shape should be inspected and the assembly checked for oil leaks first. If no abnormalities are apparent, do not commence disassembly. 2. Under no circumstances change the combination of needle valves and nozzles used. 13A-38
Secure the Plate (special tool) in a vise and fit the injec tion nozzle onto it. Loosen and remove the retaining _ nut using the Special Wrench (special tool). 5.5.3
Cleaning and inspection
(1) Cleaning
Nozzle Cleaning Tool 105789-0010
01891
After washing the nozzle in gas oil, remove deposited carbon using Nozzle Cleaning Tool (special tool) by the following procedures. NOTE: Never change the combination of the nozzle and needle valve.
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (2) Inspection
O7003A
(a) Remove the needle valve from the nozzle and clean the needle valve with the needle valve cleaning wood piece.
070058
Clean and immerse the nozzle in gas oil, slide the needle valve and check that it moves smoothly. Next, pull up the needle valve vertically about 1/3 of its entire stroke and check that it falls under its own weight. If it does not fall, replace the nozzle.
O7004A
(bl Insert, while turning, a cleaning needle into the injection orifice of the nozzle to remove carbon.
O7029A
(c) Clean the nozzle seat using the cleaning needle. (d) To remove burnt and hardened carbon, use FUSO Carbon Remover or equivalent. 13A-39
5.5.4
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Reassembly and adjustment <KBL2.1 injection nozzle>
Adjust while assembling the parts by the following procedures. As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment. The following special tools should be used when mak ing adjustments: Tool name Adjusting Device
1 39 to 49 N-m {4 to 5 kgf-m} 2 20to 25 N-m 3 {2 to 2.5 kgf-m} 5 49to 59 N-m {5 to 6 kgf-m}
4
Shim (for prelift)
14
Zexel product No .
7 6 13
u....-+--Shim (for valve opening pressure}
105789-0500
8 9 Adjusting Device (105789-0500) components
11 10
59to 78 N-m {6to 8 kgf-m}
D 7016C
Assembly sequence 13➔9➔8➔7➔5➔6-+4➔2➔3, 11➔12
____r 1O➔ 14➔1
NOTE: Never touch the sliding surface of the needle valve by hand.
Adjusting Steps
83942A 1
Adjusting device assembly
157892-0220
2
Dial gauge
157954-3800
3
Pint= 50 mm
157892-1200
4
Pin e = 60.5 mm
157892-1100
5
Connector assembly
157892-1320
6
Base
157892-1800
7
Gasket <for Retaining nut>
157892-1500
8
Retaining nut for adjustment
157892-1420
9
Gasket <for bolt of retaining nut>
026508-1140
13A-40
CD Adjustment of 1st valve opening pressure ® Selection of prelift adjusting shims @ Adjustment of 2nd valve opening pressure ("open" pressure) *@ Check of needle valve full lift @ Installation of prelift shims *@ Checking of prelift *(/) Adjustment of 2nd valve opening pressure ("cover" pressure) @ Inspection Inspection make operations marked with sary for inspection or confirmation.
* as neces
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (1) Adjustment of 1st valve opening pressure Set screw 49 to 59 N-m {5 to 6 kgf-m}
Nozzle holder
Spacer Shim (for 2nd valve opening pressure adjustment) 1st spring 1st push rod
Gasket A 157892-1500
D7018A D7017A
(a) Using the Retaining Nut for Adjustment (special tool), install the nozzle and needle valve to the nozzle holder.
(b) Insert 1st push rod, 1st spring, 1st valve opening pressure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the set screw to specified torque.
NOTE: 1. Make sure that the knock pin has seated com pletely in the nozzle before tightening the Retain ing Nut for Adjustment. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench. 2. Remove the bolt from the tip of the retaining nut.
Operate lever at 60 to 100 strokes/minute Injection pressure NV 17.7 MPa {180 kgf/cm2} NV .. Nominal Value
Keep bolt removed
D7019D
(c) Install the nozzle holder to nozzle tester and adjust the shim thickness for nominal injection pressure. 0.50 to 1.54 mm (in 0.02 mm steps)
13A-41
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
NOTE:
1. 2. 3.
When using a shim, be sure to check its thickness by a micrometer. Use same shim for prelift adjustment. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa {2.4 kgf/cm2}.
(2) Selection of prelift adjusting shim
Dial Gauge holder
(a) "O" point adjustment of adjusting device
Intermediate screw of Adjusting Device
Dial Gauge 157954-3800
Set screw
Adjusting Device 157892-0220 Pin 157892-1100 2nd push rod 2nd push rod Base 157892-1800 O7031A
D7030A
(c) Install the adjusting device to the set screw using its intermediate screw. After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly. Push down the gauge, holding its holder and read its lift h. NOTE:
Install Dial Gauge (special tool) to Adjusting Device (special tool). Install the 2nd push rod to Base (special tool) and install the assembly to a vice. Set the pin and Adjusting Device as indicated in the above illustration and adjust "O" point of the Dial Gauge. Use a 60.5 mm long pin. (b) Install the 2nd push rod to the nozzle holder. NOTE: Do not install the 2nd spring and prelift adjusting shim.
13A-42
Read to 1/100 mm.
(d) Selection of prelift adjusting shim t=t'+h where t: Shim thickness (measured) t': Prelift (0.10 Âą 0.02 mm) h: Dimension selected in step (c) T=t Âą 0.015 mm T: Thickness of shim to be used Shim thickness: 0.75 to 1.50 mm (in 0.01 mm steps) (e) Remove the Adjusting Device from the nozzle holder.
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (3) Adjustment of 2nd valve opening pressure ("open" pressure) 20 to 25 N-m {2 to 2.5 kgf-m}----1 Lock nut Adjusting screw----c;:;i
t
(4) Checking full lift of needle valve
-
DialGauge 157954-3800 39 to 49 N-m {4 to 5 kgf-m} Connector 157892-1320 Pin C= 50 mm 157892-1200
2nd spring ----flll
0
'Retaining Nut for Adjustment 157892-1420
Gasket B 026508-1140 ---® �Bolt
D7033A 07032A
Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. NOTE: Do not install the prelift adjusting shim. Operate lever at 60 to 100 strokes/minute Injection pressure NV 24.8 to 25.4 MPa {253 to 259 kgf/cm2} NV .. Nominal Value
(a) Install the special tools indicated in above illustra tion and set "O" point of the Dial Gauge. (b) Install the nozzle to the nozzle tester and operate the tester lever to bleed the inside of the retaining nut. Also check for fuel leaks. (c) Operate the tester lever to increase the pressure to about 34.3 to 44.1 MPa {350 to 450 kgf/cm2} so that the needle valve of the nozzle is fully lifted. Read this lift dimension "L" off the Dial Gauge. (d) Remove the Dial Gauge, Connector and Pin (spe cial tools). (5) Installation of prelift shim Adjusting screw Lock nut
Keep bolt removed 070190
Using a nozzle tester and turning the adjusting screw, adjust the 2nd valve opening pressure ("open" pres sure) until it complies with the nominal value. After adjustment, tighten the lock nut to specified torque.
Set screw 49 to 59 N-m {5 to 6 kgf-m}
07034A
13A-43
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
(a) Remove the set screw, lock nut and adjusting screw as an assembly from the nozzle holder.
(7) Checking 2nd valve opening pressure ("cover" pressure)
NOTE: Never loosen the lock nut as loosening it changes the 2nd valve opening pressure.
2nd valve opening pressure (lift 0.05) NV 23.0 to 23.5 MPa {235 to 240 kgf/cm 2}
(b) Install the prelift shim selected in Item (2) between the spacer and 2nd push rod. (c) Install the 2nd push rod and 2nd spring and tighten the set screw, lock nut and adjusting screw as an assembly to specified torque. (d) Check again that the needle valve full lift dimen sion "S" with the Dial Gauge by the procedures described in Item (4).
NV .. Nominal Value
O7035A
(6) Checking prelift Check the prelift based on dimension "L" measured in Item (4) and dimension "S" measured in Item (5). L-S=b.e where
e - 0.02 mm � b. e � e + 0.02 mm b. e: Prelift (measured) e: Prelift (0.1 mm)
L: Needle valve full lift dimension (measured) S: Needle valve lift dimension (measured) with prelift subtracted
(a) After checking the prelift in Item (6), increase the pressure again to about 34.3 to 44.1 MPa {350 to 450 kgf/cm 2} so that the needle valve of the nozzle is fully lifted.
NOTE: Retaining Nut for Adjustment (special tool) must have a bolt fitted at its tip.
t' =t + (f - b. f)
(b) When the nozzle tester lever operation is stopped with the nozzle needle valve fully lifted, the pres sure will start to drop and the needle valve will go down. (c) At the moment the nozzle lift has dropped to 0.05 mm, read the pressure gauge indication. (d) If the 2nd valve opening pressure ("open" pres sure) is out of specification, adjust it in accordance with item (3).
T=t' ± 0.015 mm
NOTE:
where t: Thickness of existing shim t': Shim thickness T: Thickness of shim to actually replace exist ing shim f: Prelift (0.1 mm)
Adjust without installing prelift shim.
e
e
If b. is outside of specified dimension ± 0.02 mm, replace the prelift adjusting shim as described in (5) and repeat steps (4) and (5) so that b. e will fall within f ± 0.02 mm. Select thickness t' of shim to be used as follows.
(e) Remove special tools. (8) Inspection (a) lighten the retaining nut and cap nut to specified torque.
NOTE: 1. 2.
13A-44
Make sure that the knock pin has seated com pletely before tightening the retaining nut. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (b) Spray condition 1
Good
2
Good
3
Poor I
I
2
Evenly sprayed from five injection orifices Even and symmetrical
5
Poor
I
\
�
i
�
'
Good 1
4
Poor
( �
\
-
6
Poor
I
�
l
i
f
Poor 3 4 5 6
Asymmetrical Branched Thin Irregular
O7009A
When adjusting the pressure with a nozzle tester, check also for clogged injection orifices, spray condition, and fuel leaks from the orifices. Replace the nozzle if defec tive. (c) Fuel tightness test
Test pressure
15.7 MPa {160 kgf/cm2}
O7010A
Install a nozzle that has been adjusted to specified injection start pressure to the nozzle tester. Slowly increase the pressure to the test pressure and keeping this condition, check for fuel leaks from the bottom of the nozzle. The nozzle is functioning normally if there is no leak.
Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com
13A-45
5.5.5
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Reassembly and adjustment <KBL2.4 injection nozzle>
The adjustment should be performed during reas sembly as described below. The prelift should be adjusted in 1/100 mm unit. Therefore the parts must be Tool name and shape
cleaned with the clear cleaning fluid to remove dust and foreign materials completely. For the adjustment, following special tools are required. Application
Part No. (Zexel product No.)
Adjusting Device
157892-4920
*1 Adjusting Device
157892-4420
*2 Holder
157892-4400
*2 Nut
157892-1000
*1 Dial Gauge
157954-3800
Securing Dial Gauge
*1 Pin
157892-4700
*1 Retaining Nut for Adjustment
157892-4020
*3 Retaining Nut for Adjustment
157892-4000
*3 Gasket
026508-1140
*3 Plug
157892-1600
*1 Gasket
157892-1500
Plate
157944-9520
Securing nozzle holder
Special Wrench (SW19)
157914-2800
Removal and installation of retaining nut
Special Wrench (SW22)
157914-0500
Removal and installation of Retaining Nut for Adjustment
Items marked "*1" are parts of Adjusting Device 157892-4920. Items marked "*2" are parts of Adjusting Device 157892-4420. Items marked "*3" are parts of Retaining Nut for Adjustment 157892-4020.
13A-46
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Reassembly and Adjustment Procedure
-
(1) Reassembly
29to 39 N-m {3 to 4 kgf-m}
17 16
Nozzle holder_
Plate / 157944-9520
15 14
11 9
7
13 01895
1,....-.;---12 H---r---10
4
(a) Secure the Plate (special tool) in a vise, then mount the nozzle holder on the Plate. Carry out reas sembly in the opposite of the disassembly sequence.
8 6
5
2
3 Gasket 157892-1500
1 59to 78 N-m {6 to 8 kgf-m} For reassembly, reverse the order of disassembly. NOTE: Do not touch the needle valve's sliding surfaces.
__ Special ,__ Wrench 157914-0500
11937
During reassembly, make adjustments and checks in the following sequence: (1) Adjust the No. 1 valve's opening pressure (2) Check the needle valve's total lift (3) Check the prelift amount
01896
(b) Fit the Gasket (special tool) onto the nozzle. Then, secure the nozzle on the nozzle holder using the Retaining Nut for Adjustment (special tool). Turn the Retaining Nut for Adjustment as far as possible by hand, then tighten it to the specified torque using the Special Wrench (special tool).
(4) Check the No. 2 valve's opening pressure (5) Adjust the No. 2 valve's opening pressure (6) Replace the retaining nut j (7) Make an overall inspection 13A-47
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
(2) Adjusting No. 1 valve opening pressure
Plate 157944-9520 //
Injection nozzle assembly Injection pressure <All except 6D24-TL> NV 17.7 MPa {180 kgf/ cm2} <6D24TLE2A NV 15.7 MPa {160 kgf/cm2}
NV
.. Nominal Value
15263 15262
(a) Fit the injection nozzle assembly onto the tester and measure the valve opening pressure.
(b) Mount the injection nozzle assembly upside-down on the Plate (special tool). Then, fit the Holder and Nut (special tools).
NOTE: Do not touch the spray that comes out of the nozzle.
(b) If the spray pressure is out of specification, adjust it using No. 1 valve opening pressure adjustment shim. (This shim has an outside diameter of 8.9 mm.) A 0.02 m m change in shim thickness causes a 235 kPa {2.4 kgf/cm 2} change in valve opening pres sure. Shim thickness: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70 (3) Checking needle valve total lift
Dial Gauge 1579543800
Pin 1578924700
Nut 157892-1000 Holder 157892-4400
Spring seat
15264
(a) Fit the Gasket and Plug (special tools) onto the Retaining Nut for Adjustment (special tool).
13A-48
(c) Fit the Pin (special tool) into the Dial Gauge (special tool). (d) Fit the Dial Gauge (special tool) onto the injection nozzle assembly and secure it with the Nut (special tool) such that the Pin (special tool) is touching the top surface of the No. 1 spring seat.
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE: 1. Secure the Dial Gauge such that a stroke of approximately 1.2 mm can be measured. 2. Do not overtighten the Nut. If the Nut is too tight, the Dial Gauge shaft will stick in one position.
(4) Checking prelift
-
E E
!t "' >
� -0 (1) Q)
z
Retaining Nut for Adjustment 157892-4000
"�" -�
Pressure gauge
Pipe pressure (MPa {kgf/cm2}) 01903
Plug 157892-1600
15265
(e) Fit the injection nozzle assembly onto the Nozzle Tester, then zero the Dial Gauge. Loosen the Plug (special tool) and operate the Nozzle Tester. Bleed the Retaining Nut for Adjust ment, and check for fuel leaks at the same time. After fully bleeding the Retaining Nut for Adjust ment, securely tighten the Plug.
(a) Once the needle valve is in its fully lifted position, the pipe pressure will start to drop if the Nozzle Tes ter handle is not moved. The needle valve lift mea surement (as shown by the Dial Gauge) will drop concomitantly. In the graph, A: Needle valve total lift amount
No_ 2 spring
I
E E
:lE �
NV 0.07
±
0.02
I
l'l=!::::�l,__l!::;i�:::::(I
Needle valve
NV .. Nominal Value
iii >
Q) -0 Q) Q)
A
z
C
-
:lE 34.3 to 44.1 {350 to 450}
Pipe pressure (MPa {kgf/cm }) 2
01902
(f) Operate the Nozzle Tester. When the pipe pressure is raised to 34.3 to 44.1 MPa {350 to 450 kgf/cm2}, the needle valve should lift completely. When this happens, make a note of the total lift measure ment. In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure NOTE: This check is necessary to check for abnormal wear on the nozzle seat.
G
> >
� Q) Q)
F
1/
---
C Pipe pressure (MPa {kgf/cm2}) 01904
(b) Read the Dial Gauge indication when the No. 2 spring stops acting and the needle valve stops dropping. T his point is labeled "F" in the above graph. Confirm that the reading conforms with the specified nominal value. 13A-49
-
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
T he prelift measurement point (labeled "G" in the graph) corresponds to C + approx. 980 kPa {10 kgf/ cm2}, where "C" is the No. 1 valve opening pres sure. In the graph,
E E Q) >
F+0.05
iij
>
A: Needle valve total lift amount C: No. 1 spring opening pressure F: Prelift G: Prelift measurement point
Q)
� a,
z
F i------,�-
C
J
34.3 to 44.1 {350 to 450}
Pipe pressure (MPa {kgf/cm2})
Pin
F+0.05
Needle valve
r----- Capsule
Nozzle
�---
01905
(c) If the prelift measurement is out of specification, replace the pin, lift-piece, spacer, nozzle, and needle valve with the Nozzle Service Kit. (5) Checking No. 2 valve opening pressure
Dial Gauge
A
Pressure gauge 01907
(b) Read the pressure gauge indi(?ation at the instant when the Dial Gauge indicates the specified nomi nal needle valve lift (normally prelift F + 0.05 mm). In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure F: Prelift J: No. 2 valve opening pressure (6) Adjusting No. 2 valve opening pressure
No. 2 valve opening pressure
NV .. Nominal Value
Shim--tfl J 15266
(a) After checking the prelift, operate the Nozzle Tester and raise the pipe pressure to 34.3 to 44.1 MPa {350 to 450 kgf/cm2} such that the needle valve lifts fully. If the Nozzle Tester handle is not moved, the pipe pressure will drop. T he needle valve lift measure ment (shown by the Dial Gauge) will drop concom itantly.
13A-50
01908
If the No. 2 valve opening pressure is out of specifica tion, disassemble the nozzle mounting side of the injection nozzle assembly and change the No. 2 valve
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE opening pressure adjustment shim. (This shim has an outside diameter of 9.9 mm.) Shims are available in the following thicknesses: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, and 0.70 mm. A 0.02 mm change in shim thickness causes a change in valve opening pressure of 196 kPa {2 kgf/cm2}.
(8) Inspection
-
NOTE: 1. 2.
Do not touch the spray that comes out of the nozzle. Changing the No. 1 valve opening pressure causes the No. 2 valve opening pressure to also change.
(7) Replacing retaining nut 15268 59to 78 N-m {6 to 8 kgf-m}
Fit the injection nozzle assembly onto the Nozzle Tes ter. Check the No. 1 valve opening pressure, the spray shape, and the oil-tightness of the seat. Check also that there are no leaks. NOTE:
- Retaining Nut for Adjust ment
1.
2.
If the No. 1 valve opening pressure does not con form to its specified nominal value, go through the adjustment procedure again from step (1). Do not touch the spray that comes out of the nozzle.
15267
Remove the Dial Gauge, Pin, Nut, and Holder. T hen, take off the Plug, the Gasket, and the Retaining Nut for Adjustment and its Gasket. Fit the regular retaining nut and tighten it to the specified torque using the Special Wrench (special tool). Special tools: 1. Special Wrench 2. Gasket 3. Retaining Nut for Adjustment 4. Gasket 5. Plug 6. Holder 7. Nut 8. Pin 9. Dial Gauge
(157914-0500) (157892-1500) (157892-4000) (026508-1140) (157892-1600) (157892-4400) ( 157892-1000) (157892-4700) (157954-3800)
13A-51
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.6 Fuel Filter <6D24, T, TC>
7.8 to 12 N-m {0.8 to 1.2 kgf-m}
�
li
i®
1§1(@)
25 N-m {2.5 kgf,m} 2 Cracks, threaded portion ()
Filter Wrench MH061572
Apply thin coat of engine oil when mounting.
43766
1
U
'-' I
43336
®28756
Cracks, threaded portion
7.Bto 12 N-m {0.8 to 1.2 kgf-m}
2
The element can be removed easily using the Filter Wrench (special tool).
{2.5 kgf-m}
1
43337
1 Fuel filter element 2 Fuel filter head
13A-52
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
-
<6D24-TL> 25 to 35 N-m {2.5 to 3.5 kgf,m} � 9.Sto 2 N-m {1.0 to 0.2 kgf-m}
2 Cracks, threaded portion
©
�
1
1 Fuel filter element 2 Fuel filter head
""
Apply thin coat of engine oil when mounting.
®43333
NOTE: 1. 2.
3. 4.
When removing the element, check for the gasket left behind on the head side. To mount, apply a thin coat of engine oil to the gas ket, and then secure the element by tightening 3/4 to 1 turn after the gasket comes in contact with the fuel filter head. After installation, bleed the fuel system. After bleeding the air, start the engine and check for fuel leaks.
13A-53
5.7
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
Water Separator
10 � 25N-m {2.5 kgf-m}
@ G-- 11
7.8 to 12 N-m {0.8 to 1.2 kgf-m}
12
�=w>�� 8�·
6 --&----ii
:� 9
�
� 10 25N-m {2.5 kgf-m}
4
2-<S
1�
1--43745
43744
1 Drain plug 2 0-ring 3 Ring nut 4 Case 5 0-ring 6 Baffle plate
®43369
7 Isolation plate 8 Screen assembly 9 Water level ring 10 Eyebolt 11 Air plug 12 Cover If the red water level ring in the translucent case rises to the level of the red line marked on the outer circumfer ence of the case, immediately loosen the drain plug to discharge water. It is not necessary to completely remove the drain plug, as water is discharged gradually through the groove of the loosened plug.
Red line Water level ring
NOTE: After draining, tighten firmly the drain plug before
Drain plug
bleeding the fuel system. 09278
13A-54
FUEL AND ENGINE CONTROL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Engine will not start
Probable cause Defective feed pump • Loaded gauze filter
Replace
• Seized or worn piston
Replace
• Seized push rod
Replace
• Worn tappet
Replace
• Incorrect installation (incorrect adjustment of injection timing) • Malfunctioning overflow valve Defective injection nozzle • Seized needle valve
Adjust Replace Replace Adjust
• Clogged injection orifice
Clean
Fuel tank empty Clogged fuel pipe or fuel leaks from connection Air or water trapped in fuel system
Correct or replace Supply fuel Correct or replace Bleed or replace
Loaded fuel filter
Replace
Open circuit, short circuit, or poor connection in engine speed sensor or backup engine speed sensor
Replace
Defective main relay or blown fuse
Replace
Clogged fuel filter Air or water trapped in fuel system Defective feed pump Defective injection pump operation • Defective pump
Engine knocks
Replace
• Valve opening pressure too low
• Nozzle not air-tight
Correct or replace Bleed or replace Check Replace
• Defective governor
Replace
• Clogged gauze filter
Clean
Injection timing too advanced
Adjust
Defective injection nozzle • Valve opening pressure too high
Adjust
• Clogged injection orifice • Nozzle not air-tight
Ref. group
Clean
• Check valve inoperative
Defective injection pump • Defective pump
Engine starts but soon stops
Remedy
-
Clean Correct or replace
Low quality fuel in use
Replace
Defective injection pump operation • Defective pump
Replace
• Defective governor
Replace
• Defective prestroke actuator
Replace
Poor connection in injection quantity adjusting resistor
Replace
Poor contact in idle speed adjustment variable resistor
Replace
13A-55
-
FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause
Symptom
Smoky engine exhaust and knocking
Defective injection pump • Incorrect injection timing • Worn plunger • Defective valve seat
Replace
Low quality fuel in use
Replace
Defective injection nozzle • Valve opening pressure too low
Adjust
• Clogged injection orifice Defective injection pump operation • Defective pump • Incorrect installation (incorrect adjustment of injection timing)
Replace Adjust
• Defective governor
Replace Replace
• Broken spring
Replace
• Incorrect valve opening pressure
Adjust
• Worn piston Air or water trapped in fuel system Loaded fuel filter Defective injection nozzle • Defective main body • Broken spring • Clogged injection orifice Defective injection pump operation • Defective main body
Replace Replace Bleed or replace Replace Correct or replace Replace Clean Replace
• Incorrect installation (incorrect adjustment of injection timing)
Adjust
• Defective prestroke actuator
Replace
• Defective governor
Replace
• Overflow valve malfunctioning
Replace
Accelerator pedal stopper bolt poorly adjusted
Adjust
Poor quality fuel in use
Replace
Defective injection nozzle • Clogged injection orifice • Nozzle not air-tight • Valve opening pressure too low Defective injection pump operation • Defective pump • Defective governor Accelerator pedal stopper bolt poorly adjusted
13A-56
Clean
Replace
Defective feed pump • Check valve not functioning properly
Engine not reaching max. speed
Replace
• Defective prestroke actuator
Defective injection nozzle • Poor sliding of needle valve
Insufficient engine output
Adjust Replace
• Broken spring
Unstable engine output
Remedy
Clean Correct or replace Adjust Replace Replace Adjust
Ref. group
FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause
Symptom Engine max. speed too high
Defective injection pump operation • Defective pump
Unstable engine idling
Defective injection pump operation
• Defective governor
• Incorrect installation (incorrect adjustment of injection timing)
Adjust
• Overflow valve malfunctioning
Replace
• Defective prestroke actuator
Replace
• Defective governor
Replace Bleed or replace
Poor-quality fuel in use
Replace
Defective feed pump • Defective check valve
Replace
• Loaded gauze filter Loaded fuel filter Defective injection nozzle • Clogged injection orifice
Fuel supply failure
Correct Replace
• Worn piston
Ref. group
Replace
• Defective pump
• Air or water trapped in fuel system
Engine cannot be stopped
Remedy
-
Replace Clean Replace Clean
• Deteriorated spring
Replace
• Nozzle not air-tight
Correct or replace
Broken or stretched engine stop cable
Replace
Poorly adjusted engine stop cable
Adjust
Damaged governor stop mechanism
Replace
Defective injection pump
Replace
Cracked fuel hose, pipe
Replace
Leaky fuel tank
Replace
13A-57
ELECTRONICALLV CONTROLLED FUEL SYSTEM CONTENTS
1. GENERA L ....................... . ............. 2 1.1 Principle of operation ...................... 2 1.2 Electronic Governor ....................... 3 Electronic Timer ............................ 4 1.3 Timer Control Valve . ....................... 5 1.4 1.5 Electronic Control System ........... ...... 6 1.6 ECU Terminal Configuration .............. 10 2. SPECIFICATIONS ............................ 1 4 3. T ROUBLESHOOTING ................... ..... 15 3.1 Inspection Procedures . ................... 15 3.1.1 Diagnostic function .................... 15 3.1.2 Inspection flowchart ................... 16 3.2 Connection of Multi-Use Tester II ........ 1 7 3.2.1 Special tools .......................... . 1 7 3.3 Reading and Elasing Diagnostic Trouble Codes ................ 19
Causes of Diagnostic Trouble Code Issue, and Inspection Items ...... ............... Diagnostic trouble codes ............. . 3.4.1 Diagnostic trouble code issue 3.4.2 conditions, and check items ........... Multi-Use Tester II Service Data ......... . 3.5 3.6 A ctuator Tests Using Multi-Use Tester II ................................... . lnspec-tion Using ECU Connector ....... . 3.7 3.7.1 ECU terminal configuration ........... . Inspection instructions ................ 3.7.2 3.8 Checks on Transient Troubles ........... . 4. INSPECTION OF ELECTRIC�L EQUIPMENT ..... ........ . ........... . ....... 3.4
21 21 21
28 271
29 29 29 31
32
13E-1
-
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
1. GENERAL
With the electronically controlled injection pump sys tem, electronic control is applied to the governor and timer (the components of the injection pump assem bly) to realize the optimum fuel injection timing and fuel injection rate.
The electronic governor ECU optimally controls the governor and timer in accordance with data signals from sensors mounted on the engine and other parts of the vehicle.
1.1 Principle of operation
7
f
19
1 2 3 4
.____,I: : --- : �:
Fuel supply line Fuel return line Electric line Hydraulic fine
RED-4 internal circuit Control rack position sensor Control rack Engine speed sensor 2 5 Electronic timer 6 Engine speed sensor 1 7 Engine ECU
11
8 Timer control valve 9 Injection nozzle 10 Combustion chamber 11 Fuel tank 12 Feed pump 13 Control sleeve
The extent of operation of the linear motor 17 and timer control valve 8 are determined by signals from the engine ECU 7. The linear motor 17 moves the control rack 3, thereby changing the fuel injection quantity. The timer control valve 8 controls the hydraulic pres sure applied to the electronic timer 5, thus adjusting the fuel injection timing. The RED-4 internal circuit 1 is incorporated into the electronic governor actuator 18. It contains a control 13E-2
g
14 Plunger 15 Camshaft 16 Injection pump
17 Linear DC motor 18 Electronic governor actuator 19 Fuel filter ®43638
rack position sensor processing circuit and a linear DC motor drive circuit, which are conventionally incorpo rated into the engine ECU. This arrangement elimi nates noise in the harness and thus prevents erro neous ECU operation. More accurate electronic control is possible as a result. The engine speed is sensed by engine speed sensor 1 6 and engine speed sensor 2 4. Each of these sensors acts as a backup if the other fails.
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.2 Electronic Governor
1
1 Cover
2 3 4 5 6 7 8 9
RED-4 internal circuit Control rack position sensor Housing Sensing gear Emergency engine stop lever Link Coil assembly Linear DC motor ®38928
(2) Control rack position sensor . The control rack position sensor 3 senses whether the control rack A is moved to the correct position by the linear DC motor 9. In the event of a discrepancy between the actual control rack position and the target control rack position (this is determined by the engine ECU and RED-4 internal circuit 2), the engine ECU causes the linear DC motor 9 to perform a corrective movement.
A
6
24952
(1) Linear DC motor The linear DC motor 9 moves the coil assembly 8 verti cally in accordance with signals from the engine ECU and RED-4 internal circuit. Via the link 7, this movement is transmitted to the control rack A, which moves longi tudinally to increase and decrease the fuel quantity.
(3) Emergency engine stop lever The emergency engine stop lever 6 is connected to the link 7. Via a wire, it enables the link to be moved from the driver's seat. In the event of a system fault that pre vents the engine from being stopped normally, opera tion of the emergency engine stop lever forces the con trol rack A to move to the position at which fuel injec tion is terminated. This operation takes place irrespec tive of the position of the linear DC motor 9.
13E-3
-
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
1.3 Electronic 1imer 1 15
2
1
�1 a
11-
10
i
L,.-
J 7
6 4
1 Cover Engine speed sensor 2 liming sensor Cap Disc Disc 7 Flange 8 Large eccentric cam 9 Small eccentric cam 10 Plate 11 Spring seat 12 Timer spring 13 Pilot pin 14 Cylinder 15 Piston 24960
The electronic timer uses an eccentric cam arrange ment to adjust the injection timing. The eccentric cams 8, 9 in the electronic timer are moved by hydraulic pres sure supplied from the timer control valve assembly.
02720
7
02721
13E-4
(1) The timer incorporates four pistons 15, which are activated by hydraulic pressure A. The pistons are arranged as two pairs, and each piston slides vertically in a cylinder 14. (2) Each pair of pistons 15 is linked to a plate 10. The two plates are pressed against each other by the timer springs 12. (3) When hydraulic pressure A acts upon the pistons 15, the pistons move toward the outside of the timer flange 7. (4) As the pistons 15 move outward, the plates 10 (thus far pressed together by the timer springs 12) also move outward. (5) The eccentric cams 8, 9 move in conjunction with the plates 10, thereby altering the fuel injection timing.
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.4 limer Control Valve
1 2 3 4 5 6 7
-
Seat Valve Plunger Spring Coil Pump-side solenoid valve Release-side solenoid valve
A: Port A P: Port P R: Port R
7
24961
The timer control valve controls the hydraulic pressure (engine oil) that activates the electronic timer assem bly. Internal oil passages emerge at port P (where engine oil enters the assembly), port A (which supplies engine oil to the timer), and port R (which returns engine oil to the oil pan). The oil passages are interrupted by two solenoid valves 6, 7, one on the pump side and the other on the release side. The solenoid valves control the hydraulic pressure reaching the timer. Each solenoid valve incor porates a plunger 3 and coil 5. When the solenoid valve is activated, the coil 5 attracts the plunger 3, which moves the valve 2 away from the seat 1, thereby open ing the oil passage. Opening and closing timing of the solenoid valves is controlled by the electronic timer control unit.
(1) Advancement of fuel injection timing
p
7 24963
The pump-side solenoid valve 6 is activated. The release-side solenoid valve 7 is not activated. With the solenoid valves in these conditions, ports P and A are connected, allowing the supply of hydraulic pressure to the timer. Thus, the fuel injection timing is advanced.
13E-5
-
ELECTRONICALLV CONTROLLED FUEL SYSTEM - GENERAL
(2) Maintenance of advanced (or retarded) fuel injec tion timing
(3) Retardation of fuel injection timing
6 6 7 24964
The pump-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is not activated. With the solenoid valves in these conditions, the ports are isolated from each other. Thus, the hydraulic pres sure in the timer stays constant and the timer remains in its current condition.
24965
The pump-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is activated. With the solenoid valves in these conditions, ports A and R are connected, allowing oil in the timer to return to the oil pan. Thus, the fuel injection timing is retarded.
1.5 Electronic Control System (1) System block diagram Input signals
Control rack position signal 1
�
RED-4 internal circuit (incorporated into electronic governor)
Engine ECU Engine speed signal 2 Engine start signal 3 Coolant temperature signal 4 Accelerator pedal position signal 5 Fault diagnosis signal 6 Fuel injection quantity signal 7 Boost pressure signal 8
Linear DC motor drive 9
]
Fuel injection quantity control j Fuel injection timing control Preheat control
Timer control valve drive 10 Warning lamp Heater relay Preheat lamp
Fault diagnosis function
13E-6
-1I,
Output signals
Tachometer output
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
Signal
Part
1
Control rack position signal
2
Engine speed signal
3
Engine start signal
---
Coolant temperature signal
5
Accelerator pedal position signal
6
Fault diagnosis signal
7
Fuel injection quantity signal
8
Boost pressure signal
10
..
Sensing of control rack position
.• Sensing of engine speed Use of two sensors allows for backup if one sensor fails. --·-·Recognition of engine startup with starter Starter switch switch in START position ---·- - --· -·-- ---- ----· ----------·--· -·-··-·----·· ·--Sensing of coolant temperature Coolant temperature sensor ------ -- -- . Sensing of extent of depression of accelerator Accelerator pedal position sensor pedal ---· ---····- .. - . . . . Detection o f pedal depressed/released condiAccelerator pedal switch tion (ON with pedal released) ·-·· · -... .. -------··········-·-·--· Callup of diagnosis codes Diagnosis switch -·-----·----- --------- - ·- -- . ----- .. --·· - -----··· - -- . . ..• - - Deletion of diagnosis codes; callup of past Memory clear switch diagnosis codes Engine speed sensors 1, 2
4
9
Control rack position sensor
Main function/operation
-
Fuel injection quantity adjusting resis- Correction of fuel injection quantity tor - -------· ··--·Detection of boost pressure Boost pressure sensor ---- ----· Moving of control rack Linear DC motor Timer control valve
Control of hydraulic pressure applied to electronic timer
Injection quantity adjusting resistor
A A: Resistor No.
02734
The injection quantity adjusting resistor makes fine ad justments to achieve optimal commensuration of in jectied fuel quantity with fuel feed from the common rail. NOTE: This resistor, selected as the best from among several types, determines the final injection quantity. DO NOT change it for any other type.
13E-7
-
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
(2) Control of fuel injection quantity
1
Control rack position sensor
• • • • •
I
-
Engine ECU
I I I I I
Engine speed sensor 1 Engine speed sensor 2 I Coolant temperature sensor Accelerator pedal position sensor Fuel injection quantity adjusting resistor
RED-4 inter- nal circuit -
I I
Target rack position Idling characteristics
�
Linear DC motor
Running characteristics
I I
Full rack characteristics Starting characteristics
(a) Control effected by engine ECU and RED-4 internal circuit
(b) Feedback control effected using control rack position sensor
The RED-4 internal circuit processes control rack posi tion signals and transmits the results to the engine ECU. The engine ECU effects control during engine opera tion using the stored idling characteristics or running characteristics, and it determines the target control rack position in accordance with signals issued by the RED-4 internal circuit. The control rack position signal issued by the engine ECU is returned to the RED-4 internal circuit. Via the servo circuit and drive circuit, it causes activation of the linear DC motor such that the control rack is moved.
The control rack position sensor enables the RED-4 internal circuit to calculate whether the linear DC motor has moved the control rack to the target position. This arrangement enables the RED-4'to ensure that the con trol rack position always corresponds to the target val ue. The engine ECU receives signals indicating the control rack's actual position from the RED-4 internal circuit and uses them to evaluate control rack position errors.
(3) Control of fuel injection timing Control rack position sensor Engine ECU
• • • •
Engine speed sensor 1 i----Engine speed sensor 2 Coolant temperature sensor Accelerator pedal position sensor
13E-8
I I
1
RED-4 internal circuit
Load timer characteristics Cold idling characteristics
I I
-
Timer control valve
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL (a) The engine ECU controls the fuel injection timing by controlling the activation of the timer control valve, which applies hydraulic pressure to the elec tronic timer. (b) The engine ECU controls the timer control valve by determining the target and actual advance angles, comparing them with each other and with charac teristics stored in its memory, and issuing drive signals to the timer control valve in accordance with the results. 1) Target advance angle: calculated by comparison of data signals from sensors with characteristics stored in engine ECU's memory 2) Actual advance angle: determined in accordance with signals from engine speed sensor 1 and engine speed sensor 2. (c) When the engine is cold, startability and post-start warmup are optimized by the use of cold idling characteristics in determination of the fuel injec tion timing.
(4) Preheat control Preheat control improves startability engine's coolant temperature is low.
when the
(a) Operating modes 1)
Engine coolant temperature higher than 0°C
Starter switch
STAR ON � OFF
Preheat lamp
OFF----------
ON
Running Not running ______.
Engine
ON OFF----------
Heater relay
®43717
No preheating is necessary at the time of engine startup, so the heater relay is kept OFF. 2)
Engine coolant temperature 0°C or lower
�rl�----
Starter switch
S T ART ,.___ ON OFF_j
Preheat lamp
g�F_j
Engine
I
Running Not running _____
Heater relay
g�F _j
I 7� ----.L
--------1 Preheat
Afterheat
®43718
"ts" seconds after the starter switch is turned ON, the heater relay is turned ON, causing preheating to begin. The preheat lamp illuminates simultaneously. When preheating finishes, the preheat lamp goes off to indicate that the engine can be started. The heater relay remains ON until the engine is started. When the engine is started, the engine ECU determines whether afterheating is necessary in accordance with the engine coolant temperature. If the engine ECU determines that afterheating is not necessary, preheat control is terminated. If it deems that afterheating is necessary, the heater relay remains ON for a certain period after engine startup to cause afterheating. 13E-9
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.6 ECU Terminal Configuration
A:CW32A
<>
B:CW25A
C: CW31A
D: CW16A
®43639
A: CW32A Terminal No.
ltem(s) to which terminal is connected
-
1 2 3
RED-4 ECU (PULL DOWN)
-
4
Terminal No.
ltem(s) to which terminal is connected
-
17 18
Boost pressure sensor (SIG)
19
Engine speed sensor 2 (GND), RED-4 ECU (SIGNAL GND-2)
20
-
21
Engine speed sensor 1 (GND)
6
Boost pressure sensor (+5V)
22
-
7
Engine speed sensor 2 (SIG)
23
8
Engine speed sensor 1 (SIG)
24
5
-
9
-
10
11 12 13
14 15 16
13E-10
Heater relay
-
RED-4 ECU (LIMP HOME)
-
-
-
25
-
26 27 28 29
Boost pressure sensor (GND)
30
Coolant temperature sensor (GND)
31
Timer control valve (ADV)
32
Timer control valve (RTD)
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
-
8: CW25A Terminal No.
ltem(s) to which terminal is connected
Terminal No.
ltem(s) to which terminal is connected
1
Warning lamp (orange)
14
RED-4 ECU (+5 VCC-2)
2
Accelerator pedal switch
15
RED-4 ECU (PWM SOL-2)
16
RED-4 ECU (V-IST)
4
Injection quantity adjusting resistor (SIG)
17
Frame ground (MN POWER GND)
-
3 5
RED-4 ECU (+5 VCC-1)
18
-
6
RED-4 ECU (PWM SOL-1)
19
-
7
RED-4 ECU (VB2)
20
8
RED-4 ECU (VB1)
21
9
Accelerator pedal position sensor 2 (SIG)
22
Shield (SHIELD) of VB-1, VB-2, GND-1, and GND-2
23
RED-4 ECU (SIGNAL GND-1)
-
10
-
11
12
-
13
Injection quantity adjusting resistor (GND)
------
MUT-11 connector (K-LINE)
24
RED-4 ECU (GND-2)
25
RED-4 ECU (GND-1)
---
-
C: CW31A Terminal No.
ltem(s) to which terminal is connected
-
1
Terminal No. 17
2
Engine speed output signal (NE OUT SIG)
18
3
Starter switch S terminal (STARTER SW S)
19
-
4
-
5
-
6
ltem(s) to which terminal is connected Accelerator pedal position sensor 1 (SIG)
-
Diagnosis switch
20 21 22
7
Battery relay (STARTER SW M-2)
23
8
Battery relay (STARTER SW M-1)
24
-
Battery ground (CASE GND)
-
9
-
25
10
MUT-11 connector (DCT)
-
26 27
Accelerator pedal position sensor 2 (GND)
Control rack position output signal (RAC OUT SIG)
28
Accelerator pedal position sensor 1 (GND)
29
Memory clear switch
11 12
-
13
-
14 15
Coolant temperature sensor (SIG)
16
-
Terminal No.
ltem(s) to which terminal is connected
-----30
31
Preheat lamp (PREHEAT LAMP)
-
D:CW16A Terminal No.
1
Engine ECU main power relay (+VB-2)
9
2
Engine ECU main power relay (+VB-1)
10
3
Warning lamp (red)
11
4
-
12
5
DDS-3 connector (DDS3)
13
6
Battery ground (GND-2)
14
7
Battery ground (GND-1)
15
8
Engine ECU main power relay (MAIN RELAY-1)
16
ltem(s) to which terminal is connected
-
Engine ECU main power relay (MAIN RELAY-2)
-
13E-11
-
ELECTRONICALLY CONTROLLED FUEL S YSTEM - GENERAL
Starter switch �· B 1-t,cc M 81 82 Sl OFF ACC ON START
-
-
T
Engine ECU main power relay
I
Battery�
.- :I
---
f -, ;
"''It_:" Battery
: ::-,
:
STARTER SWISI STARTER SWIM)-1 STARTER SWIMl-2 MAIN RELAY-1 MAIN RELAY-2 ECU P OWERl+VBl-1 ECU POWER(+VBl-2
CJ ca C? OB 013 Dl 02
GND-1 O? GND-2 06 GNOICA!':1= GNDI c 24 GNOIMN PWR GNDI B 17
-=-
\V
m
Engine speed sensor 1
Ill
II
Engine speed sensor 2 (TIMING)
Ill
II
m
Battery Frame ground ground
SIG AB GND A2l SIG A? GND AlS I
V 1ST PWM-SOL-1 PWM-SOL-2 PULL DOWN LIMP HOME VB-1 VB-2 I GND-1 GND·2 SHIELD +SV(VCCJ-1 +5V(VCC)·2 '-" "" "" o.-=-1 - l�----S-l_G_N�AL-'GN 1 - SIGNAL GN0-2
....
RED-4 internal circuit
RED-4 ECU
� L_::_-_-_::_-_::_-�-_-u_!_�_=_�_�_'"':_4_,1 -
:::
m-m
Timer control valve (ADV) Timer control valve (RTD)
w
Coolant temperature sensor
-
-
s
:�
Al4 BB 87 825 824 022 BS 814 823
A31 A32
w
Ill
Injection quantity adjusting resistor
816 BS
SIG GNO
B4
B13
SIG C15 GND AJO
Ill l:r---w-----==-i Ill
Boost pressure sensor
Ill
-��-
=l;---:i:
+SV A6 SIG A18 GND A29
::: .:::
Warning lamp (red) Warning lamp (orange) Memory clear switch L--------fli.--5-llll-------w w Diagnosis switch
03 B1 C29 C19
-
DATA DDS-3 connector oos-31-----m---------'='-' 05
.r
K·Line
B20 w--------:..::. OCT C10
MUT-11 connector IL1M_u_-r 21 1 ___Ill
Rack position output signal +------------ C12 Engine speed output signal ..-�------------i C2 '----
®45865-1
13E-12
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
-
En ine ECU
Preheat lamp "Tn..;----_.
�+
A111--------'-''
Heater relay
�
:
'
Heater relay Air heater
SIG Cl7 GND C28
r------
89 SIG GND C27
Accelerator pedal position sensor 2
o-,
B21----------'-o Depressed: OPEN, l Released: GND :, _____ _� _
CASEGND
Accelerator pedal position sensor 1
_J
Accelerator pedal switch
®45865-2
13E-13
ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS 2. SPECIFICATIONS Item Injection pump assembly
Specification BOSCH AUTOMOTIVE SYSTEMS
Manufacturer
Electronically controlled in-line pump
Model
NP-PE6P120
Injection pump model
RED-4 (RED-4 with internal circuit)
Governor model Timer model
SPGH KD
Feed pump model Timer control valve
BOSCH AUTOMOTIVE SYSTEMS
Manufacturer V
Rated voltage Pressure range kPa {kgf/cm } ECU
Manufacturer Rated voltage
13E-14
24 49 to 980 {0.5 to 10}
2
BOSCH AUTOMOTIVE SYSTEMS V
24
--
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3. TROUBLESHOOTING 3.1 Inspection Procedures 3.1.1 Diagnostic function Whenever the starting switch is placed at ON, the diag nostic function is activated to check all the sensors, etc. If any of them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same time, the fault location is stored in memory, and the system enters the backup mode. The stored fault location can be read as a diagnostic trouble code by the Multi-Use Tester II or the diagnostic switch. Warning lamp indications Warning lamp Safety-critical error (Vehicle must not be driven) Non-safety-critical error (Vehicle can be driven despite poor control feeling)
Red Orange
NOTE: • Check to ensure that the battery voltage is within the specified range. • Check all the harness and device connectors for looseness. Always remove a connector at least 20 seconds after placing the starting switch at the LOCK position.
-
• Do not forget to clear the diagnostic trouble code by the Multi-Use Tester II or memory clear switch after a fault has been rectified. • As a rule, inspection operations should be per formed with the starting switch at the LOCK posi tion. Some checks, however, may have to be made with the starting switch at the ON position. In such a case, use care to make sure that no short circuit develops between pins of the connectors or with the body. • The resistance value of each component is affected by the temperature and the accuracy of the tester. The reading, therefore, does not always fall within the standard limits. Note that the check values shown in the text are the values obtained at normal temperature (10 to 35°C). • Whether or not the system automatically returns to normal from the backup mode after a fault has been removed depends on the diagnostic trouble code (fault location). • Even when the fault has been removed and the sys tem has been automatically returned to the normal mode, the diagnostic trouble code of the fault remains stored in the engine control unit. • When a fault occurs at a point where the system is not automatically reset, perform the memory clear procedure to let the system exit from the backup mode. [O P13E-19
13E-15
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.1.2 Inspection flowchart T he system inspection can be performed effectively by use of the Multi-Use Tester II. The types of system inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic trouble code outputs.
I
(1) Inspections based on diagnostic trouble codes stored in the engine control unit (2) Inspections of transient troubles
Vehicle brought into workshop
I
I I
Read diagnostic trouble codes CO P13E-19
No communications can be made with Multi-Use Tester II.
Normal code output
Trouble code output
Normal code output after erasure Check for ' Identify cause for diagnostic transient troubles trouble code issue and recP13E-31 tify P13E-21 \
CO
CO
I â&#x20AC;˘ â&#x20AC;˘
,.
Driving test
I
I
,,
If no communications can be made with all the other systems, it is highly likely that the diagnostic circuit is f8'Ulty. If no communications can be made with this system only, an open circuit in the diagnostic output circuit or power supply circuit (including the ground circuit) of this system is suspected.
If the same diagnostic trouble code is issued during test driving, reexamine the cause for the diagnostic trouble code issue and rectify. P13E-21 If none of the diagnostic trouble codes stored in the engine control unit before the test driving is issued, perform the checks on transient troubles in addition to the checks based on the diagnostic trouble codes.
Erace the dianostic trouble codes. ffi P13E-19
13E-16
CO
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.2 Connection of Multi-Use Tester II
-
3.2.1 Special tools Unit: mm
Unit: mm Tool name
Shape
Tool name
Multi-Use Tester II MB991496 Inspection of system
Shape
Multi-Use Tester II harness MB991499 To use Multi-Use Tester II as a circuit tester
19492 Multi-Use Tester II harness (for communications) MC887252 To supply power to Multi-Use Tester II proper and commu nicate with vehicle side elec trical devices
20536 Battery clamp harness MK320193 Power supply to Multi-Use Tester II in vehicle without cigarette lighter; detection of start signal in vehicle without cigarette lighter
19141
20537
Read-only memory pack (MRI-El) MK369392 Data for inspection and con trol of engine control unit
� �
19493 Memory card (set in Multi Use Tester II proper) MB991500 To write data
20538
13E-17
-
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
T he Multi-Use Tester II typically draws power from the cigarette lighter. In a vehicle without a cigarette lighter, the power connection of the Multi-Use Tester II is differ ent depending on the type of the starter switch as fol lows: Multi-Use Tester II power supply connection
With cigarette lighter socket Starter switch type A*a
Cigarette lighter socket Battery *a *b
Starter switch type A*b
(2) Power supplied to Multi-Use Tester II from battery
Without cigarette lighter socket
0
-
-
-
0
0
E
With starter switch type A, power supply to cigarette lighter continues while engine is being cranked. With starter switch type B, power supply to cigarette lighter is suspended while engine is being cranked.
(1) Power supplied to Multi-Use Tester II from ciga rette lighter C
G
F ®35849
®41163
(a) Place the starting switch at the LOCK position. (b) Connect the � Multi-Use Tester II harness to� Multi-Use Tester II and insert the � read-only memory in the tester. (c) Connect the connector A to the cigar lighter socket. (d) Connect the Multi-Use Tester II connector C (16 pins) to the data link connector B (16 pins). NOTE: For the operating procedures for the Multi-Use Tester II, refer to the instruction manual for the Multi-Use Tes ter II.
13E-18
(a) Place the starter switch in the LOCK position. (b) Connect the � Multi-Use Tester II harness (for communication) to the� Multi-Use Tester II, then insert the� ROM pack. (c) Connect the EB clamp D (red) of the � battery clamp harness to the EB terminal E of the battery and the 8 clamp F (black) to the 8terminal G of the battery. (d) Fit the connector A into the socket Hof the� bat tery clamp harness. (e) Fit together the Multi-Use Tester II connector B (16 pins) and connector C (16 pins). NOTE: Connect the EB clamp D (red) of the � battery clamp harness before connecting the 8 clamp F (black).
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.3 Reading and Erasing Diagnostic Trouble Codes
(b) Reading diagnostic trouble code
Two types of methods are available for reading or eras ing a diagnostic trouble code; one using the Multi-Use Tester II and one using the vehicle side diagnostic func tions.
10s digit
(1) Method using Multi-Use Tester II OFF
(a) Current diagnostic trouble code 1)
Check to see that the memory clear switch 1 is con nected. 2) Set the starting switch to ON. 3) Operate the Multi-Use Tester II to read the current diagnostic trouble code and determine the fault location.
0.4 0.4
Set the starting switch to ON. Disconnect the memory clear switch 1. Operate the Multi-Use Tester II to read the past reg istered diagnostic trouble codes and determine the fault location.
Set the starting switch to ON. Operate the Multi-Use Tester II to erase all of the diagnostic trouble codes stored in the engine con trol unit.
(2) Method Not Using Multi-Use Tester II (Method Using Diagnostic Switch and Memory Clear Switch) (a) Current diagnostic trouble code 1) Set the starting switch to ON. 2) Disconnect the diagnostic switch 2. 3) T he diagnostic trouble code is displayed by flashes of the warning lamp 3.
l
0.4
Diagnostic switch disconnected
ON
First diagnostic trouble code displayed (Diagnostic trouble code 12)
2.4
2.4
H 2.4
Second ---• diagnostic 1 trouble code displayed 2.8
Ii-----J·
®13705
(c) Erasing diagnostic trouble codes 1) 2)
-----I I nJl
�
1.2
(b) Past diagnostic trouble code 1) 2) 3)
Units digit
�
ON
-
1)
Diagnostic trouble codes are indicated by the num ber of times the warning lamp 3 flashes and their duration. • T he flashing intervals also differ between the 10s digit and units digit. • 10s digit: 1.2 second interval • Units digit: 0.4 second interval • Each diagnostic trouble code is displayed from the 10s digit followed by the units digit. As for a code which has no 1Os digit, units digit only is displayed. 2) Each diagnostic trouble code is displayed three times in succession. 3) If there is no more code stored, the sequence is then repeated from the beginning with each code indicated three times. 4) When the diagnostic switch 2 is connected, the engine control unit will immediately stop display ing codes.
13E-19
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING (c) Past diagnostic trouble codes 1) After reading the current diagnostic trouble codes (with the diagnostic switch 2 disconnected), dis connect the memory clear switch 1. Then the O warning lamp 3 will restart flashing. 2) This time, the warning lamp displays the past diag nostic trouble codes. Determine the fault locations based on the indicated codes. (d) Erasing diagnostic trouble codes
◄
◄
A second 3 seconds or more
Connected
I
J I ,
•
Released .... ___._
t1
•
Memory cleared at this point
®02739
13E-20
Disconnect the memory clear switch 1 and the diag nostic switch 2 then reconnect them. Then all the diag nostic trouble codes stored in the engine control unit will be cleared. NOTE: • If the contents of memory are not to be cleared after display of the stored codes, set the starting switch to OFF with the memory clear switch 1 discon nected. Thereafter, connect the memory clear switch. • When you change the combination of the injection pump and engine control unit, you must rewrite the pump data stored in the engine control unit. For this purpose, be sure to perform the diagnostic trouble code erasing procedure. • Whenever the engine control unit has been replaced with a new one, be sure to erase the diagnostic trouble codes by disconnecting the memory clear switch 1 and diagnostic switch 2 after connecting all the connectors. Upon completing the procedure, confirm that no diagnostic trouble codes is stored.
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.4 Causes of Diagnostic Trouble Code Issue, and Inspection Items
-
3.4.1 Diagnostic trouble codes Multi-Use Tester II display Diagnostic trouble code
Message
07
OVER REV.
11
GOV. SERVO
14
SUB NE SNSR
15
NE SNSR
16
ACCEL. SNSR-2
17
TCV FEEDBACK
19
AIR PRES SNSR
21
WTR TEMP SNSR
22
RACKSNSR
Page of reference
Ll:i P13E-21
Multi-Use Tester II display Diagnostic trouble code
Message
23
T CV
24
ACCEL. SNSR-1
� P13E-22
32
BST PRES SNSR
33
ECU SYSTEM
CL P13E-23
34
Q RESISTOR
45
ENG.REVERSE
[Cl P13E-24
65
ACCELSW
78
HEATER RELAY
Page of reference
!J] P13E-24
2J P13E-25
LiJ P13E-26
3.4.2 Diagnostic trouble code issue conditions, and check items Perform service operations with reference to the diagnostic trouble code issue conditions and probable causes shown below. 07 OVER REV. Code issue condition [Reset condition]
Diagnostic trouble code 07 indicates that the engine speed is too high. [The code is reset when the engine speed returns to a specified range.]
Action taken by ECU
Governor operation is stopped.
Probable cause and check item
Injection pump assembly's control sleeve faulty • Over-revving of engine (for example, on downhill road) • ECU faulty
Inspection of injection pump assembly (Have inspection performed by Bosch Automotive Systems service station.)
11 GOV. SERVO Code issue condition [Reset condition)
Diagnostic trouble code 11 indicates that the difference between the target control rack position and actual control rack position is too large.
Action taken by ECU
Governor operation is stopped.
Probable cause and check item
• Control rack position sensor faulty
[No reset condition)
• ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 09: Measurement of target rack position No. 0A: Measurement of actual rack position • Inspection of control rack position sensor (Have inspection performed by Bosch Automotive Systems ser vice station.)
13E-21
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
14 SUB NE SNSR (injection pump side) Code issue condition [Reset condition]
Diagnostic trouble code 14 indicates that the number of pulses from engine speed sensor 2 (on the injec tion pump) is smaller than the number of pulses from engine speed sensor 1 (on the flywheel housing). [The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed sensor 2 returns to normal).
Action taken by ECU
• Normal control is effected using only engine speed sensor 1. • If engine speed sensor 1 is also faulty, governor operation is stopped.
Probable cause and check item
• Open circuit or short circuit in harness between ECU and engine speed sensor 2 • Engine speed sensor 2 faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. [D P13E-27 No. 02: Measurement of engine speed • Inspection using ECU connector P13E-29
LL:
m : Measurement of resistance of engine speed sensor 2
• Inspection of engine speed sensor 2 P13E-32: Inspection of Electrical Equipment�
CD
• Check of circuit between ECU and engine speed sensor 2 14 SUB NE SNSR (injection pump side) 15 NE SNSR (flywheel housing side) Code issue condition [Reset condition]
Diagnostic trouble codes 14 and 15 are both issued if engine speed sensor 1 (on the flywheel housing) and engine speed sensor 2 (on the injection pump) fail at the same time. [The code is reset when pulses are applied from engine speed sensor 1 or engine speed sensor 2 following engine startup.]
Action taken by ECU
Fuel injection timing control is stopped, and governor operation is stopped.
Probable cause and check item
• Open circuit or short circuit in harness between ECU and engine speed sensors 1 and 2 • Engine speed sensors 1 and 2 faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. (DP13E-27 No. 02: Measurement of engine speed
CD
• Inspection using ECU connector P13E-29 Measurement of resistance of eng1ne speed sensor 2 C!D : Measurement of resistance of engine speed sensor 1 • Inspection of engine speed sensors 1 and 2 P13E-32: Inspection of Electrical Equipment� • Check of circuit between ECU and engine speed sensors 1 and 2
m: ffi
15 NE SNSR (flywheel housing side) Code issue condition [Reset condition]
Diagnostic trouble code 15 indicates that the number of pulses from engine speed sensor 1 (on the fly wheel housing) is smaller than the number of pulses from engine speed sensor 2 (on the injection pump). [The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed sensor 1 returns to normal.]
Action taken by ECU
• Normal control is effected using only engine speed sensor 2. • If engine speed sensor 2 is also faulty, governor operation is stopped.
Probable cause and check item
• Open circuit or short circuit in harness between ECU and engine speed sensor 1 • Engine speed sensor 1 faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. QJ P13E-27 No. 02: Measurement of engine speed • Inspection using ECU connector P13E-29
CD
C!D : Measurement of resistance of engine speed sensor 1 • Inspection of engine speed sensor 1 [l} P13E-32 Inspection of Electrical Equipment� • Check of circuit between ECU and engine speed sensor 1
13E-22
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
-
16 ACCEL. SNSR-2 Code issue condition (Reset condition]
Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24 must also be performed.) The code is issued when accelerator position sensor 2 voltage is out of specified limits. [When accelerator position sensor 2 voltage is back within specified limits, a reset is made.]
Action taken by ECU
• Normal control is effected using only non-faulty accelerator pedal position sensor 1. • If accelerator pedal position 1 is also faulty, control is effected using assumptions of 100% with the pedal depressed and 0% with the pedal released.
Probable cause and check item
• Open or short circuit in harness between ECU and accelerator position sensor 2 • Accelerator position sensor 2 faulty or poorly adjusted • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. P13E-27
CJ
No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No. 5: Measurement of accelerator pedal position sensor's output voltage • Inspection of accelerator pedal position sensor • Check of circuit between ECU and accelerator pedal position sen sor 2
17 TCV FEEDBACK Code issue condition (Reset condition]
Diagnostic trouble code 11 indicates that the difference between the target and actual timer positions exceeds a specified limit. [After a return to a normal condition, the code is reset when the starter switch is turned from OFF to ON.]
Action taken by ECU
Fuel injection timing control is stopped.
Probable cause and check item
• Timer control valve faulty • Electronic timer faulty • Engine hydraulic system faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. [jJ P13E-27 No. 12: Measurement of timer angle difference • Inspection of timer control valve main body P13E-32: Inspection of Electrical EquipmentE
CO
CD
• Inspection of engine hydraulic system Gr 12 • Inspection of electronic timer (Have inspection performed by Bosch Automotive Systems ser vice station.)
19 AIR PRES SNSR Code issue condition [Reset condition]
Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air pressure sensor (built in ECU). The code is issued when air pressure sensor voltage is out of specified limits. [When air pressure sensor voltage falls back within specified limits, a reset is made.]
Action taken by ECU
Air pressure is defaulted to 100 kPa {760 mmHg}.
Probable cause and check item
• Air pressure sensor (built in ECU) faulty. • ECU faulty
• Perform checks on the basis of Multi-Use Tester II service data. (D P13E-27 No. 18: Air pressure measurement
13E-23
IBll
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
21 WTR TEMP SNSR Code issue condition [Reset condition)
Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor proper. The code is issued when water temperature sensor voltage is out of specified limits. [When water temperature sensor voltage falls back within specified limits, a reset is made.)
Action taken by ECU
Controls are continued assuming that coolant temperature is -20°C when engine is started and B0 °C when engine is running.
Probable cause and check item
• Open or short circuit in harness between ECU and water temperature sensor • Water temperature sensor faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. P13E-27 No. 16: Measurement of engine coolant temperature • Inspection using ECU connector CD P13E-29
C.iJ
(1D : Measurement of resistance of coolant temperature sensor • Inspection of coolant temperature sensor
CD
P13E-32: Inspection of Electrical Equipment P.lml • Check of circuit between ECU and coolant temperature sensor 22 RACKSNSR Code issue condition [Reset condition]
Diagnostic trouble code 22 indicates that the control rack position sensor's output voltage is outside speci fied limits. [No reset condition]
Action taken by ECU
Governor is temporarily stopped. (Feedback control is resumed after the engine is restarted.)
Probable cause and check item
• Control rack position sensor faulty • Control rack not moving smoothly • Governor actuator's link faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 0A: Measurement of actual rack position • Inspection of control rack position sensor and control rack (Have inspection performed by Bosch Automotive Systems ser vice station.)
23TCV Code issue condition [Reset condition]
Diagnostic trouble code 23 is issued in the following circumstances: The ECU issues a command to turn the timer control valve OFF following a short circuit in the timer control valve. [The code is reset when the timer control valve returns to normal.]
(1)
(2)
The ECU issues a command to turn the timer control valve ON following an open circuit in the timer control valve. [After the open circuit is rectified, the code is reset when the starter switch is turned from OFF to ON.]
Action taken by ECU
Fuel injection timing control is stopped.
Probable cause and check item
• Open circuit or short circuit in harness between ECU and timer control valve • Timer control valve faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. OJ P13E-27 No. 12: Measurement of timer angle difference • Inspection of timer control valve [O P13E-32: Inspection of Electrical Equipment� • Check of circuit between ECU and timer control valve
13E-24
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 24 ACCEL. SNSR-1 Code issue condition [Reset condition]
Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and faulty sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16 must also be performed.) The code is issued when accelerator position sensor 1 voltage is out of specified limits. [When accelerator position sensor 1 voltage falls back within specified limits, a reset is made.)
·------------+----------------- -------·--·----·--------------
Action taken by ECU
• Normal control is effected using only non-faulty accelerator pedal position sensor 2.
• If accelerator pedal position 2 is also faulty, control is effected using assumptions of 100 % with the pedal depressed and O % with the pedal released. Probable cause and check item
• Open or short circuit in harness between ECU and accel erator position sensor 1
• Perform checks on basis of Multi-Use Tester II service di.tl1J. L J P13E-27 No. 03, 04: Measurement of throttle opening indic1Jtr:d IJy accelerator pedal position sensor
• Accelerator position sensor 1 faulty or poorly adjusted
No. 5: Measurement of accelerator pedal position sensor's output voltage
• ECU faulty
• Inspection of accelerator pedal position sensor • Check of circuit between ECU and accelerator pedal position sen sor 1
32 BST PRES SNSR Code issue condition [Reset condition]
Diagnostic trouble code 32 indicates short or open circuit in boost pressure sensor harness and faulty sen sor proper. The code is issued when boost pressure sensor voltage is out of specified limits. [When boost pressure sensor voltage falls back within specified limits, a reset is made.)
Action taken by ECU
Control is effected with the boost pressure assumed to be fixed at O kPa {O mmHg}.
Probable cause and check item
• Open or short circuit in harness between ECU and boost pressure sensor
• Perform checks on basis of Multi-Use Tester II service data. lJ.J P13E-27 No. 20: Measurement of boost pressure
• Boost pressure sensor faulty
• Inspection of boost pressure sensor main body
• ECU faulty
L(j P13E-32: Inspection of Electrical Equipment Dill • Check of circuit between ECU and boost pressure sensor
33 ECU SYSTEM Code issue condition
Diagnostic trouble code 33 indicates a processing error or memory error in the ECU.
[Reset condition]
[No reset condition]
Action taken by ECU
Governor operation is stopped.
Probable cause and check item
ECU faulty
I
34 Q RESISTOR Code issue condition [Reset condition]
Diagnostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor harness and faulty adjusting resistor. The code is issued when injection quantity adjusting resistor voltage is out of specified limits. [When injection quantity adjusting resistor voltage falls back within specified limits, a reset is made.]
Action taken by ECU
Injection quantity correction value is fixed at No. 1 value.
Probable cause and check item
• Open or short circuit in har ness between ECU and injec tion quantity adjusting resistor • Injection quantity adjusting re sistor faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 14: Check of resistor number of fuel injection quantity adjusting resistor • Inspection using ECU connector CD P13E-29
m:
Measurement of resistance of fuel injection quantity adjusting resistor
• Inspection of fuel injection quantity adjusting resistor
.:m
W P13E-32: Inspection of Electrical Equipment1:f,.
• Check of circuit between ECU and fuel injection quantity adjusting resistor
13E-25
-
ELECTRONICALLY CONTROLLED FUEL S YSTEM - TROUBLESHOOTING
45 ENG. REVERSE Code issue condition [Reset condition)
Diagnostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that result ing from cranking with the starter) has been detected with the starter switch in the OFF position. [The code is reset when the engine speed is no longer detected with the starter switch in the OFF position or when the starter switch is turned to the ON position.)
Action taken by ECU
Governor operation is stopped
Probable cause and check item
• Operating error at time of engine startup • Poor matching of connected devices • ECU faulty
65ACCELSW Code issue condition [Reset condition)
Diagnostic trouble code 65 indicates short or open circuit in accelerator pedal switch harness and faulty accelerator switch. The code is issued when accelerator pedal is released (accelerator switch ON) and accelerator pedal open ing signal is input. [When accelerator pedal opening signal returns to normal, a reset is made.)
Action taken by ECU
Normal control is effected.
Probable cause and check item
• Open or short circuit in har ness between ECU and accel erator pedal switch • Accelerator pedal switch faulty • ECU faulty
• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No. 69: Check of operation of accelerator pedal switch • Inspection using ECU connector P13E-29
CO
(!D : Check of continuity of accelerator pedal switch • Inspection of accelerator pedal switch • Check of circuit between ECU and acceler,ator pedal switch 78 HEATER RELAY Code issue condition [Reset condition)
Diagnostic trouble code 78 is issued in the following circumstances: The ECU issues a command to turn the heater relay OFF following a short circuit in the heater relay. [The code is reset when the heater relay returns to normal.)
(1) (2)
The ECU issues a command to turn the heater relay ON following an open circuit in the heater relay. [No reset condition]
Action taken by ECU
Preheat control is stopped.
Probable cause and check item
• Open circuit or short circuit in harness between ECU and heater relay • Heater relay faulty • ECU faulty
13E-26
• Perform checks on basis of Multi-Use Tester II service data. QJ P13E-27 No. 92: Check of operation of heater relay
CD
• Actuator test using Multi-Use Tester II Pl 3E-28 No. BC: Check of operation of heater relay • Inspection of heater relay CO Gr 16 • Check of circuit between ECU and heater relay
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.5 Multi-Use Tester II Service Data Multi-Use Tester II display No.
Item BATT VOLTAGE
02
ENGINE SPEE D
■■.■■v ■■■■.rpm
03
ACCEL (%)
■■■.■ %
04
ACCEL (%) REAL
05
ACCEL (V)
09
TARGET RACK
DA
REAL RACK
12
TCV ANG. DIFF.
14
Q RESISTOR
16
WATER TEMP
18
AIR PRESS
2D
BOOST PRESS
4F
DIAGNOSIS SW
■■■.■ % ■.■■■v ■■.■■ mm ■■.■■ mm ■■.■■ °CA ■■.■■ deg
•••••
■■■.■ oc ■••.• OF ■■■■. kPa ■■■■.mmHg ■■■■. kPa ■■■■.mmHg ON/OFF
51
DIAG LAMP (U)
ON/OFF
52
DIAG LAMP (R)
ON/OFF
56
62
67
KEY SW
DIAG RESET SW
PULL DOWN
ON/OFF
ON/OFF
ON/OFF
Normal condition
Condition at time of inspection
Data
01
-
Idling
20to 30V
Racing (with engine running)
Same as tachometer indication
Accelerator pedal released
0%
Accelerator pedal gradually depressed
Gradually increases
Accelerator pedal fully depressed
100%
Accelerator pedal released
0%
Accelerator pedal gradually depressed
Gradually increases
Accelerator pedal fully depressed
100 %
Accelerator pedal gradually depressed from released position
Depends on vehicle specifications
Starter switch ON
3mm
Starter switch ON
3mm
Depends on vehicle specifications
Engine cold During engine warmup Engine stopped after warmup Altitude
□m
Same as number marked on fuel injection quantity adjusting resistor Approximately same as ambient temperature Gradually increases Gradually decreases 101kPa
Altitude 600m
95kPa
Altitude 1,200m
88 kPa
Running at high idle speed
Depends on vehicle specifications
Diagnosis switch ON (connected to connector)
ON
Diagnosis switch OFF (disconnected from connector)
OFF
Starter switch in ON position (engine not started)
ON
Starter switch in OFF position
OFF
Starter switch in ON position (engine not started)
ON
Starter switch in OFF position
OFF
Starter switch in ON position
ON
Starter switch in any position except ON
OFF
Memory clear switch ON (connected to connector)
ON
Memory clear switch OFF (disconnected from connector)
OFF
Normal condition
OFF
Abnormal condition (during pulldown control)
ON
13E-27
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Multi-Use Tester II display No.
69 73
91
92
Data
I tem ACCELSW STAR T SW
PRE-HEAT LAMP
HEATER RELAY
ON/OFF ON/OFF
ON/OFF
ON/OFF
Normal condition
Condition at time of inspection Accelerator pedal depressed
ON
Accelerator pedal released
OFF
E ngine cranked with starter switch in STAR T position
ON
Starter switch in any position except STAR T
OFF
Starter switch ON
Starter switch ON
Coolant temperature low
ON
Coolant temperature high
OFF
Coolant temperature low
ON
Coolant temperature high
OFF
3.6 Actuator Tests Using Multi-Use Tester II Multi-Use Tester II display Item
No. AC
Method of checking operation
DIAG LAMP (U)
• Create warning lamp illumination conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause warning lamp five times to be on for one second then off for one second.
AD
DIAG LAMP (R)
• Create warning lamp illumination conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause warning lamp five times to be on for one second then off for one second.
BB
PRE-HEAT LAMP
• Create indicator lamp illumination conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause indicator lamp five times to be on for one second then off for one second.
BC
HEATER RELAY
• Create air heater operating conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause air heater five times to be on for one second then off for one second.
13E-28
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
3.7 Inspection Using ECU Connector
-
These checks allow correct transmission of ECU signals via vehicle harnesses and connectors to be verified. They are intended to assist in troubleshooting. The numbers ( C!D, etc.) in the tables correspond to reference num
m,
bers in section 3.4, "Causes of Diagnostic Trouble Code Issue, and Inspection Items". 3.7.1 ECU terminal configuration
A:CW32A
<>
8: CW25A
C: CW31A
B
D: CW16A
C
®43639
No.
(!II
m m m m
Item
Page of reference
Resistance of engine speed sensor 2 Resistance of engine speed sensor 1 Resistance of coolant temperature sensor
lil P13E-30
Resistance of fuel injection quantity adjusting resistor Continuity of accelerator pedal switch
3.7.2 Inspection instructions NOTE: Some inspections are performed with the connector removed, and others are performed with the connec tor fitted. Note the following instructions: • Do not touch any terminal other than the ones spe cified for the inspections. Be particularly careful not to cause short circuits between terminals using the tester probes. • Terminal numbers shown in the tables are the num bers of terminals on the ECU. Be careful not to select the wrong terminals for inspections. 13E-29
11]1 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Method
Check item (!JI Resistance of engine speed sensor 2
ffl
ffl
m
[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal condition) Between terminals A 7 and A 19: 2.1 to 2.5 n
Resistance of engine speed sensor 1
[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal condition) Between terminals A a and A 21: 2.1 to 2.5 kn
Resistance of coolant temperature sensor
(Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal conditions) Between terminals C 1s and A 30: 2.3 to 2.6 kn (at 20°C) 0.3 to 0.34 kn (at 80°C)
Resistance of fuel injec tion quantity adjusting resistor
[Check conditions) • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. (Normal conditions] Between terminals B 4 and B 13: No.
ffl
13E-30
Continuity of accelera tor pedal switch
Resistance
No.
Resistance
2700
13000
5100
20000
8200
330011
No.
Resistance
8
15000 o
5&0on
(Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal conditions] Between terminals (EE) and 0) B 2 and D e: • Accelerator pedal depressed: Continuity does not exist. • Accelerator pedal released: Continuity exists.
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING •
3.8 Checks on Transient Troubles
Lightly move the connector up and down and to the right and left. • Lightly move the harness up and down and to the right and left. • Lightly shake the sensors and other devices by hand. • Lightly shake the wiring harness located in the moving components such as the suspension. T he connectors and other parts to be checked are iden tifiable from the descriptions in the Probable Causes or the Checking Procedures for the displayed diagnostic trouble code. 02597
7""
02598
lI)l I I
02599
A transient trouble often occurs in a specific condition. Therefore, pinpointing the condition will make it easy to estimate the cause. To pinpoint the condition for a transient trouble, ask the customer in detail about the driving condition when the trouble occures, weather, occurrence frequency and symptoms, and reproduce the symptoms of the trouble. Depending on the condition where the trouble occurs, determine whether the cause of the trouble is vibra tion, temperature or any other factor. If the probable cause is vibration, perform the following checks on the relevant connectors harnesses, etc. and check whether the symptoms of the trouble are reproduced.
13E-31
- ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT 4. INSPECTION OF ELECTRICAL EQUIP MENT lmfl Checking Water Temperature Sensor
2.3 ± 0.2 kn
Standard value (at 20° C)
(2) If the reading is out of the standard value range, replace the engine speed sensor. CC Gr 11 NOTE: If the sensor is not tightened sufficiently, it may not issue signals. Make sure the sensor's tightening torque is correct.
<Engine speed sensor 2> [Inspection]
®34629
(1) Put the water temperature sensor in a container filled with engine oil. (2) Heat the engine oil to various specified tempera tures while stirring the engine oil. (3) Measure the resistance value between pins 1 and 2 (body). Standard value
20°c
2.3 to 2.6 kQ
80°C
0.30 to 0.34 kQ
Referance value in parentheses
(4) If the reading is out of the standard value, replace the water temperature sensor.[() Gr 14
l:ml Checking Engine Speed Sensor
24984
(1) Measure the resistance between terminals if_. and l�:. Standard value
2.1 to 2.5 n
(2) Check for continuity between terminals ,J and:'�; between terminals��' and
:a,.
<Engine speed sensor 1>
Standard value
Continuity exists
(3) If either result is out of specification, replace the sensor. [Installation]
D 05049
(1) Measure the resistance value between pins 1 and 2.
13E-32
24985
ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Screw in engine speed sensor 2 A until it touches the protrusion on the timer flange 8. (2) Back off engine speed sensor 2 A by 0.8 to 1.0 turn to create a clearance C (1.2 to 1.5 mm) between the sensor and the protrusion B. (3) Tighten the lock nut D on engine speed sensor 2 A.
Unit:mm Shape
Tool name Inspection Harness MC854336
1JE1 Checking Boost Pressure Sensor <Checking by use of Multi-Use Tester II> CO P13E-27 NOTE: The boost pressure checking conditions differ be tween when the boost pressure is checked by use of the Multi-Use Tester II and when it is checked without use of the Multi-Use Tester II. So the standard values also differ.
<Checking without use of Multi-UseTester II>
8 A
C
it
02806
(2) Mount pressure gauge A for measurement of the boost pressure. C: To inlet manifold (3) Set the starting switch to ON. (4) Measure the output voltage of the boost pressure sensor 8 according to the following table. Connector Pin
Item
-
1 Power(+) Power voltage *Output voltage (Refer to the output characteristics shown at left.)
*·
B
-
2GND(-)
3 Output(+)
Start the engine before measurement.
D
®42415
(1) Disconnect the chassis side harness D and connect the � inspection harness between them.
13E-33
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Remove the connector from the timer control valve then connect a 24V DC power supply A and selector switch B. (2) Slightly loosen the eyebolt D on port C. (3) Run the engine at idling speed. (4) Turn the selector switch B to the port E setting and check that oil leaks from the eyebolt D of port C. (5) Turn the selector switch B to the port F setting and check that oil stops leaking. (6) After confirming that oil stops leaking, tighten the eyebolt D to the specified torque.
Output Characteristics
Temperature 25° C
� Ql
�
4.9 4.5 3.22 1.86 0.5 0 -34.3 33.7 {-255} {250}
98.7 163.7 {740} {1230}
lightening torque
Boost pressure (kPa {mmHg}) 02783
Standard Value
2-3
5V
1-2
0.5V/-34.3 kPa {-255 mmHg} 1.86V/33.7 kPa {250 mmHg} 3.22V/98.7 kPa {740 mmHg} 4.5V/163.7 kPa {1230 mmHg}
(5) If the results of the above mentioned checks show
any deviation from the standard values, replace the boost pressure sensor B.
ml Inspection of timer control valve
C: Engine oil outlet (hydraulic pressure supply to electronic timer) E: Engine oil inlet F: Engine oil return outlet (7) If this inspection reveals any abnormality, replace
the timer control valve. (D Gr 13A <Checking valve resistances> (1) Take resistance measurements between terminals :1 and '3 and between terminals ·4_ and :.i,. Deter mine whether the measurements comply with the standard value.
<Checking valve operation>
Standard value
A
B
n
DD Inspection of fuel injection quantity adjusting re
(DC24V)
[iJ
21.9 to 24.1
(2) Make sure that there is not continuity between ter minaIs r3. and ii:; between terminal::) and the body; and between terminal :4. and the body. (3) If these checks reveal any abnormality, replace the timer control valve. CO Gr 13A
(2) @
20 to 25 Nm (2 to 2.5 kgfm)
sistor No. ®24981
AL2A
E
02786 24982
13E-34
ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Measure the resistance of the fuel injection quan tity adjusting resistor. The standard value corre sponds to the resistor number marked on the case. Standard value (at 20°c)
Resistor No.
1
2700
2
510Q
3
a2on
4
1300Q
5
20000
6
3300fl
7
5600fl
8
150000
-
(2) If the measurement is out of specification, replace the fuel injection quantity adjusting resistor.
NOTE: The fuel injection quantity adjusting resistor is matched to the injection pump. Replace it only with one that has the same resistor number.
13E-35
COOLING CONTENTS 1. GENERAL .......... . ........................ 2 2. SPECIFICAT IONS ........................... 6 3. SERVICE STANDARDS ..................... 7 3.1 Service Standards Table ................. 7 lightening Torque Table ................. 7 3.2 4. SPECIAL T OOLS ............................ 8 5. SERVICE PROCEDURE ...................... 9 Removal and Installation of Cooling 5.1 Fan ......................................... 9 5.2 Water Pump ................................ 9 5.2.1 Removal and installation .............. 9 5.2.2 Disassembly and inspection .......... 10 5.2.3 Reassembly ........................... 13 5.3 Thermostat .............................. 14 5.3.1 Removal and installation ............. 14 5.3.2 Inspection .. ...... . .................... 14
Fan Drive .......................... ....... 5.4 5.4.1 Disassembly and inspection ..... . .... 5.4.2 Reassembly ........................... 5.5 Tension Pulley ........................... 5.5.1 Disassembly and inspection .......... 5.5.2 Reassembly .. .................. ....... 5.6 Inspection of Auto Cool Fan Coupling ................................. 5.7 Inspection of Radiator ................... 5.8 V-belt Tension ............................ 5.8.1 Inspection . ............................ Adjustment ........................... 5.8.2 5.9 Cleaning of Cooling System ............. 5.10 Gas Leak Test ........................... . 5.11 Bleeding the Cooling System ........... 6. T ROUBLESHOOTING ...................... .
15 15 16 16 16 17 17 18
191 20 19
21 23 23 24
14-1
Ill
COOLING - GENERAL
1. GENERAL
(2) Thermostat
The cooling system is of the water-cooling forced cir culation type consisting of a radiator, water pump, thermostat, and related parts.
When coolant temperature is high (bottom bypass valve is closed) \.
Radiator
When coolant temperature is low (bottom bypass valve is open)
817450
(1) Water pump
Impeller
From radiator
B1746C
The water pump, of the centrifugal type, is driven by V-belt from the crankshaft pulley. Mounted at one end of the water pump shaft is an impeller with blades and the coolant is sealed up by unit seal. For lubrication of the water pump, see Group 12 Lubrication.
14-2
81747A
The thermostat is of bottom bypass type with a valve controlled by special wax enclosed in a pellet. When the wax is heated, it passes from a solid to a liquid state with its volume changing. This change in volume regu lates the amount of coolant flowing into the radiator and water pump (bypass side), thereby controlling coolant temperature.
Bl
COOLING - GENERAL (3) Radiator
(4) Pressure cap
<With pressure release lever> Radiator
Pressure release lever Pressure spring
h
Reserve tank Pressure valve// Vent valve spring
B1716B 81740A
<Without pressure release lever> Pressure spring
The radiator, with a tube-and-corrugated-fin type core (and with a reserve tank on some models), not only cools the engine coolant but also separates vapor from liquid water and regulates pressure in the cooling sys tem.
Vent valve When vent valve is opened
B0295B
The pressure cap regulates the pressure in the cooling system. When the pressure builds up in the system that exceeds a predetermined level, the pressure valve compresses the pressure spring, releasing the exces sive pressure through the overflow pipe into the atmo sphere. 14-3
-
COOLING - GENERAL
If equipped with a reserve tank, the coolant that has overflowed is channeled into it. When the coolant temperature drops and negative pressure builds up in the system, the vent valve opens to take in air to prevent the radiator from becoming deformed. If equipped with a reserve tank, coolant is taken from the reserve tank to prevent the radiator from becoming deformed and to keep the quantity of coolant in the system constant. If equipped with a pressure release lever on the cap, raising the lever upright opens the pressure valve and releases the pressure in the cooling system.
is controlled by a bimetallic strip that moves in response to temperature changes. <When the temperature of the air passing through the radiator is low>
Operating chamber Control hole
(5) Auto cool fan coupling 80243A
Rotor Storage chamber
The valve fully closes the control hole of the divider plate. As a result, the silicone oil forced back from the pump hole is stored in the storage chamber and is not sent into the operating chamber. In the meantime, the silicone oil in the operating chamber decreases, and consequent slippage between the case and cover and the rotor causes the fan to rotate at a lower speed. <When the temperature of the air passing through the radiator rises>
Divider plate
80574C
Depending on the temperature of the air passing through the radiator, the auto cool fan coupling auto matically controls the rotating speed of the fan. The autocool fan coupling is constructed as follows: The rotor is mounted on the shaft and rotates between the case and cover. Viscous coupling material (silicone oil) enters the gap and turns the fan. A control hole in the divider plate allows silicone oil to pass from the storage chamber to the operating chamber. The hole is controlled by a valve. Opening and closing of the valve
14-4
B0244A
As the temperature rises, the valve slowly opens the control hole of the divider plate, allowing silicone oil to flow into the operating chamber. Therefore, the sili cone oil contacting area between the case and cover and the rotor slowly increases. So more torque is trans mitted to the fan, causing it to rotate at a higher speed.
DI
COOLING - GENERAL <When the temperature of the air passing through the radiator is high> Direct-couple fan
Autocool fan coupling (at high temperature) Autocool fan coupling (at medium temperature)
"0 Q) Q) C. <I)
"'
C u..
Autocool fan coupling (at low temperature)
Crankshaft speed (rpm)
80245A
The valve fully opens the control hole of the divider plate, and more silicone oil flows into the operating chamber. As a result, a maximum torque is transmitted from the shaft to the fan, causing the fan to rotate at a given maximum speed.
B1728B
E
e-
"0 Q) Q) C. <I)
"'
C u..
Temperature passing through the radiator (°C)
B0575A
14-5
ID
COOLING - SPECIFICATIONS
2. SPECIFICATIONS Item
Specification
Cooling system
Water-cooling forced circulation type
Coolant quantity (Engine-proper only)
6D24, T
Approx. 22 L
6D24TLE2A
Approx. 24 L
Water pump
Type Drive method
V-belt
Radiator
Type
Tube-and-corrugated-fin type or Tube-and-plate-fin type
Thermostat
Type
Wax pellet/bottom bypass type
Valve opening temperature x O'ty
Without jiggle valve: 76.5°C x 2
Type x Number of belts
Without fan drive
Low edge cog Btype x 1 or Btype x 2
With fan drive
Low-edge cogged type Bx 1 (for water pump) Low-edge cogged type C x 2 (for alternator)
Cooling fan V-belt
Centrifugal type
Suction type or blower type
Low-edge cogged type Bx 1 (for water pump) Low-edge cogged type Bx 2 (for alternator)
14-6
ID
COOLING - SERVICE STANDARDS
3. SERVICE STANDARDS
3.1 Service Standards Table Unit: mm Maintenance item
Nominal value (Basic diameter in I ))
Interference between pump shaft and flange Interference between pump shaft and impeller Thermostat
Valve opening temperature
(22) 0.05 to 0.08
-
(11.8) 0.03 to 0.06
-
74.5 to 78.5° C
-
°
10 or more/90 C
Valve lift/temperature Radiator inspection pressure (air pressure)
98 kPa {1 kgf/cm }
Pressure valve opening pressure
39 to 59 kPa {0.4 to 0.6 kgf/cm2}
V-belt deflection [with a push force of about 98 N (10 kgf)]
2
Without fan drive
17 to 22
With fan drive
10 to 15
Remedy and remarks
Limit
-
Up to second reassembly Up to second reassembly Replace
Correct or replace Pressure cap, replace Adjust
3.2 Tightening Torque Table Screw size O.D. x pitch (mm)
Tightening torque N-m {kgf,m}
Water pump pulley mounting bolt
M10 x 1.5
44 ± 8.8 {4.5 ± 0.9}
Fan drive flange mounting nut
M20 x 1.5
145 {15}
Tension pulley mounting nut
M16 x 1.5
98 {10}
Location tightened
14-7
Ill
COOLING - SPECIAL TOOLS
4. SPECIAL TOOLS Unit: mm Tool name
Shape
Unit: mm Tool name
Impeller Puller MH062192 Removal of water pump impeller
Shape
Water Pump Pulley Puller MH062411 Removing water pump flange
B5252C Unit Seal Installer MH062195 Water pump unit seal instal lation
C
�,A
B
�.c
28
9.6±0.03
12.5
85258A Belt Tension Gauge MH062345 Measuring V-belt tension
85094A 03612
14-8
COOLING - SERVICE PROCEDURE 5. SERVICE PROCEDURE
5.2 Water Pump
5.1 Removal and Installation of Cooling Fan
5.2.1 Removal and installation
m
89019B
1
2 O0914A
1 Plate 2 Fan 3 Spacer * Fan pulley
14-9
-
COOLING - SERVICE PROCEDURE
5.2.2 Disassembly and inspection
<6D24TLE2A
Repair kit: Water pump repair kit
14
7Corrosion, damage 13 Damage, wear
Cracks, wear in surface over which bearing fits, water leak, rust
BD .. Basic Diameter NV .. Nominal Value
Disassembly sequence 1 Water pump pulley ÂŽ Flange 3 Oil seal 4 Snap ring 5 Snap ring 6 Water pump cover (J) Impeller
Water pump shaft Bearing Spacer Bearing Oil seal Unit seal 14 Water pump case
8 9 10 11 12 13
For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow.
14-10
D0044G
m
COOLING - SERVICE PROCEDURE
BD .. Basic Diameter NV .. Nominal Value
<6D24-TC>
Bend, rust, wear in surface over which bearing fits 8 Rotation
Interference BD 11.8 NV 0.03 to 0.06 Reassembly no more than 2 times
Interference BD 25 NV 0.05 to 0.08 Reassembly no more than 2 times
Disassembly sequence 1 Water pump pulley @ Flange 3 Oil seal 4 Snap ring 5 Snap ring 6 Water pump cover (]) Impeller
8 9 10 11 12 13 14
Water pump shaft Bearing Spacer Bearing Oil seal Unit seal Water pump case
For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow.
D0044H
14-11
Ill
COOLING
SERVICE PROCEDURE (3) Flange to water pump shaft tightening margin
Disassembly and Inspection Procedures
(1) Removal of flange /
Water Pump ---1,�� Flange
13480
D0031B
If the tightening margin exceeds specification, replace the flange or water pump shaft.
Remove the water pump flange using the Water Pump Pulley Puller and Bolt (special tools). Slip an iron pipe or similar item over the handle to gain the necessary leverage.
NOTE: Do not reassemble more than three times even when the specification is met.
(2) Removal of impeller
(4) Impeller to water pump shaft tightening margin
09192
Using two threaded holes (MB x 1.25) in the impeller and the Water Pump Impeller Puller {special tool), pull off the impeller.
14-12
D0031C
If the tightening margin exceeds specification, replace the impeller or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.
-
COOLING - SERVICE PROCEDURE 5.2.3 Reassembly
Apply engine oil to lips.
12 Apply engine oil to external cylinder.
13
11
Installation load 39.2 kN {4000 kgf}
Installation load 39.2 kN {4000 kgf}
44±8.8 N-m {4.5 ± 0.9 kgf-m}
6
Assembly sequence
,,::..- -�
Apply engine oil to lips.
'----�!-+------
Ir
\
\ , ..., ,'
NOTE: 1. After reassembly, rotate the water pump pulley by hand to confirm that the impeller does not interfere with the water pump cover and water pump case. 2. When the impeller and flange are installed, confirm that they are not installed with a load of 4900 N {500 kgf}.
I I
127, 8➔11➔10➔9➔14➔7
d}_j For parts with an encircled number, refer to Reassembly Procedure that follows. D0047O
To install the unit seal. use the Unit Seal Installer (spe cial tool) as shown and press-fit the unit seal until the installed dimensions shown are obtained.
Reassembly Procedure <Installation of unit seal>
Unit seal Unit Seal Installer MH062195
Installation load 31 to 44 N {3. 2 to 4.5 kgf} Installation speed 14 to 28 mm/sec.
09194
14-13
-
COOLING - SERVICE PROCEDURE 5.3.2 Inspection
5.3 Thermostat
5.3.1 Removal and installation Thermostat marking For 76.5°C Valve opening temperature (°C)
74.Sto 78.5
Valve lift/ temperature (mml°C)
10 or more/90
Valve lift Stirring rod
Thermostat
�� Heat source
--1J
D0301B B9021B
Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use the fol lowing procedures. ( 1) Slowly heat water to the thermostat valve opening temperature. The valve opening temperature is stamped on the thermostat. Its nominal value is the stamped tem perature ± 2° c. (2) Keep this condition for about five minutes and make sure that the valve is open. (3) Raise the temperature further to heat the water to the valve lift measuring temperature correspond ing to the valve opening temperature. (See the table above.) Keep this state for five minutes and measure the bypass valve lift. (4) Lower temperature down to 65° C or below and ensure that the valve is fully closed. If the thermostat is found defective in any of the above items, replace it with a new one.
14-14
m
COOLING - SERVICE PROCEDURE 5.4 Fan Drive 5.4.1 Disassembly and inspection
4
8
7 Rotation
6 2
3
1
Disassembly sequence 1 2 3 4
Fan pulley Flange Snap ring Fan drive shaft
5 Bearing 6 Spacer 7 Bearing 8 Bearing case
B9023O
14-15
Ill
COOLING - SERVICE PROCEDURE
5.4.2 Reassembly
5.5 Tension Pulley 5.5.1 Disassembly and inspection
Sealing side to be faced outward. To be packed with grease (multipurpose grease)
4
Rotation
B9023E
· Disassembly sequence
3
5
1 Adjusting bolt 2 Tension pulley bracket 3 Snap ring 4 Tension pulley shaft 5 Tension pulley 6 Bearing
6 To be packed with approx. 86 g of grease (multipurpose grease)
Assembly sequence 8-+5➔3➔2➔1
4-+7-+6] 89024D
14-16
COOLING - SERVICE PROCEDURE
DI
5.6 Inspection of Auto Cool Fan Coupling
5.5.2 Reassembly
Sealing side to be faced outward. To be packed with grease (multipurpose grease)
98N-m {10 kgf-m}
4 To be packed with approx. 6 g of grease (multipurpose grease)
Fan axial runout or play, continuous high noise or unusually high noise of fan B9024E
NOTE:
1.
2.
Since the autocool fan coupling js constructed as a single unit, the silicone oil does not require main tenance. The autocool fan coupling cannot be dismantled. If defects become evident, the whole autocool fan coupling assembly must be replaced.
818558
14-17
Ill
COOLING - SERVICE PROCEDURE
5. 7 Inspection of Radiator
(1) Play in axial direction
(1) Cleaning
O1213A
When engine is cold, pinch the fan fitting portion and move it in axial direction. If the fan blade tip has exces sive runout or play is observed, replace the auto cool fan coupling, because the ball bearing is defective. (2) Cleaning bimetal
O0402A
Remove mud, bugs, etc., if present on the radiator core front surface, with a copper wire. During the removal work, use care to prevent damage to the tubes. Radiator inspection pressure (air pressure) NV 98 kPa {1 kgf/cm2} NV .. Nominal Value
O0409A D1214C
If dirt or dust is adhering to the bimetal, remove it care fully with a wire brush or the like. NOTE: Use care not to apply excessive force to the bimetal.
14-18
(2) Attach hose to the inlet of the radiator and cap the outlet. Then, immerse the radiator in a waterfilled tank . Using a radiator cap tester, send compressed air at the specified inspection pressure through the hose to check for leaks. If leaks are evident, re-solder or replace the radia tor.
Bl
COOLING - SERVICE PROCEDURE 5.8 V-belt Tension
(3) Inspection of radiator cap
5.8.1 Inspection Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf). <Without fan drive> Water pump Pressure valve opening pressure NV 39 to 59 kPa {0.4 to 0.6 kgf/cm 2}
Radiator cap tester Alternator
Crankshaft
Radiator cap
NV .. Nominal Value
B6525B
<With fan drive> 10 to 15 mm
D0420A
Check the spring tension and sealing condition of the pressure valve and vent valve. If defective, replace. Check the pressure valve opening pressure, using a radiator cap tester.
Alternator
Crankshaft B6527B NOTE: 1.
2.
A slack belt can be a cause of overheating and undercharge. An excessively tight belt may result in damaged bearings and belts.
14-19
-
COOLING - SERVICE PROCEDURE â&#x20AC;˘
5.8.2 Adjustment
Using Belt Tension Gauge (special tool)
( 1) Alternator 0-ring A
Belt Tension Gauge
Depression load scale
MH062345
0-ring B
Deflection gauge
03613
E0165
Loosen the upper and lower mounting bolts of the alternator. T hen, fit a wrench handle and move the alternator as necessary.
( 1) Set 0-ri ng A at the 98 N {10 kg} mark on the depres sion load scale. (2) Set 0-ring B at the V-belt's specified nominal deflection value (max.) on the lower scale.
NOTE: When moving the alternator, use care not to damage the stator coil between the front and rear brackets, and the through bolt.
(2) Tension pulley
Top of gauge Flange V-belt
Adjusting bolt
03614
(3) Apply the Belt Tension Gauge (special tool) to the V-belt's tension measurement point. Depress the top of the gauge until 0-ring A reaches the flange.
Mounting nut
E0166
Loosen the idler puller mounting nut, then turn the adjusting bolt to adjust the belt tension. (Turning the adjusting bolt moves the idler pulley.)
14-20
m
COOLING - SERVICE PROCEDURE 3.
4.
If much rust is found, water may leak from the ra diator after cleaning. Check carefully each section of the radiator after cleaning. If the coolant temperature is still very high, never attempt to remove the pressure cap. Coolant in use
03615
Cleaning interval
FUSO Diesel Long Life Coolant
Every 2 years
Anti-rust, anti-freeze
At time of coolant replacement of every 6 months or before and after use of anti-freeze
(1) Washing with water
(4) Measure the amount of deflection in the V-belt. Adjust the V-belt's tension if the amount of deflec tion is out of specification.
5.9 Cleaning of Cooling System
80426A
80429A
If the radiator is used for a long time, rust, scale, mud, etc. are deposited inside, resulting in overheat. Clean the cooling system with city water by using the follow ing procedures.
NOTE: 1.
2.
Use a cleaning solution if the radiator is seriously obstructed or coolant is seriously contaminated. When the cooling system is cleaned or washed with water, make sure that the coolant tempera ture is maintained at 90°C; the coolant tempera ture below the valve opening temperature closes the thermostat, resulting in poor coolant circula tion.
(a) Discharge coolant from the radiator, crankcase, and reserve tank. (b) After draining the system, fill it with tap water (pre ferably hot water) and, with the water temperature kept at around 90° C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until the drained water runs clear. (2) Washing with cleaning solution (When radiator clogging or coolant contamination are serious) (a) Discharge coolant from the radiator, crankcase, and reserve tank.
14-21
-
COOLING - SERVICE PROCEDURE (d) After discharging the solution, fill the system with tap water (preferably hot water) and with the water temperature kept at around 90°C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until drained water runs clear.
(b) Ready a mixture of FUSO Radiator Cleaner (Radi pet-7 or equivalent: 5 to 10%) and cooling water. Pour the specified amount of mixture into the radiator.
NOTE: 1. If the inside is heavily stained, washing with tap water before charging radiator detergent will be effective. 2. Running the engine at idle for longer than an hour with detergent left in engine could cause damage to the cooling system. Be sure to observe specified cleaning time. 3. After cleaning with detergent, fill with coolant as soon as possible.
(3) Cooling water (a) When Long Life Coolant is used:
B0428A
(c) Run the engine to raise the solution temperature to around 90°C. Let the engine run at idle for another 30 minutes, then remove the solution.
D1322B
In order to prevent freezing of cooling water and corro sion of the cooling system, add FUSO Diesel Long Life Coolant at a ratio of 30 to 60% of quantity of water. Replace the coolant once every two years to retain its anti-freeze and anti-rust effects. For usage of Long Life Coolant, refer to its instruction manual. NOTE: 1. Be sure to use FUSO Diesel Long Life Coolant. 2. Never mix it with DIAQUEEN Long Life Coolant or other commercial long life coolants, anti-freezes or anti-rusts.
B0426A
14-22
COOLING
SERVICE PROCEDURE 5.10 Gas Leak Test
(b) When anti-rust and anti-freeze are used:
-
Air or exhaust gas leaked into the coolant promotes corrosion and rust formation. Perform the following check and, if defects are found, take remedial action. (1) Inspection
01310A
1) After cleaning, add Fuso Radiator Anti-rust (Radi pet-98 or equivalent) at a ratio of 5% to the coolant quantity to prevent corrosion in summer. (a) Remove the pressure cap from the radiator. (b) Run the engine to raise the coolant temperature up to around 90 °C. (c) If bubbles continue forming in the coolant under the condition, it indicates that air or exhaust gas has leaked into the coolant. (2) Causes
D1322A
2)
In winter, add the Fuso Anti-freeze or equivalent at a ratio of 30 to 60% to prevent freezing. For usage of anti-rust and anti-freeze, see respec tive instruction manuals.
NOTE: When the anti-rust or anti-freeze is used, never use with other long life coolants.
(a) If air is trapped in coolant, check cylinder head bolts, water pump mounting bolts, and hose and its connections for looseness. Check also hoses for damage. (b) If the exhaust gas has leaked into coolant, check the cylinder head gasket or nozzle tube end stake for damage. Check also cylinder head for cracks.
5.11 Bleeding the Cooling System (1) With the pressure cap removed from the radiator, let the engine run at idle with coolant temperature of about 90° C to bleed the system completely. (2) After the system has been bled of air, add coolant to radiator and reserve tank as required.
14-23
Ill
COOLING - TROUBLESHOOTING
6. TROUBLESHOOTING Probable cause
Symptom Overheat
Defective V-belt • Incorrect tension • Broken belt Clogged cooling system
Remedy Adjust Replace Clean
Defective thermostat
Replace
Defective water pump • loose shaft to impeller engagement
Replace
• Loose shaft to flange engagement
Replace
• Improper clearance between impeller and water pump case
Correct
• Damaged impeller
Replace
Clogged radiator fins Defective autocool fan coupling • Damaged bimetal • Clogged bimetal • Defective autocool fan coupling proper Damaged cooling fan low coolant level
Clean Replace Clean Replace Replace Replenish
Overcool
Defective thermostat
Replace
Quick loss of coolant
Defective radiator hose • loose hose connection
Correct
• Worn or damaged hose
Replace
Defective radiator • Radiator proper not tight
Correct or replace
• Pressure cap not tight
Replace
14-24
Ref. group
Defective water pump • Defective unit seal
Replace
• Defective oil seal
Replace
• Pump mounted improperly
Correct
Defective oil cooler
Replace
Thermostat case or cover mounted improperly
Correct
Defective heater hose • loose hose connection
Correct
• Worn or damaged hose
Replace
Defective cylinder head gasket
Replace
Group 12
Group 11
INTAKE AND EXHAUST CONTENTS 1. 2. 3. 3.1 3.2 4. 5. 5.1
GENERAL ................................... 2 SPECIFICATIONS ........................... 6 SERVICE STANDARDS ..................... 7 Service Standards Table ................. 7 lightening Torque Table ................. 7 SPECIAL TOOL .. ............ . ............... 8 SERVICE PROCEDURE ...................... 9 Removal and Installation of Intake System .................................... 9 5.2 Removal and Installation of Exhaust System ................................... 13 5.3 Air Cleaner ............................... 15
5.3.1 Disassembly and reassembly ......... Inspection and cleaning .............. 5.3.2 5.4 Turbocharger ...... ...................... . 5.4.1 Disassembly ........................... 5.4.2 Cleaning and inspection .............. Reasse·mbly .. .......... ........ ....... 5.4.3 5.5 Aftercooler ......... ........ ............... 5.5.1 Disassembly and reassembly ......... Air pressure test ...................... 5.5.2 5.6 Bleeding of Aftercooler Coolant Circuit <6 D24-TC :Standard> ..................... 6. T ROUBLESHOOTING .......................
15 16 17 17 20 23 27 27 28 28 29
15-1
-
INTAKE AND EXHAUST - GENERAL
1. GENERAL
(1) Air cleaner <Single element type>
B0618A Outside air
The cyclone type air cleaner uses a filter paper type ele足 ment. Because of plastic coating and heat treatment, the ele足 ment is highly resistant to water and oil. Even if it is contaminated, its functions can be regained by clean足 ing. The intake air is given a spin by the vanes for centrifu足 gal separation of large particles of dust and dirt. Small particles of dust and dirt are filtered out by the filter paper element so that a clean air is drawn into the engine. The standard air cleaner is a single element type, and the double element type can be effective for operation safety under unusual conditions with a lot of dust and dirt. (2) Precleaner
Guide vane
<Double element type>
B0619A
Inner element
B0608C Outside air
B0620A
15-2
To air cleaner
80610A
The precleaner, coupled with the air cleaner, collects relatively large particles of dust contained in the air drawn in by engine. The air entering the precleaner is made to spin by the guide vanes of the precleaner to centrifugally separate large particles of dust before the air is drawn into the air cleaner. These dusts are collected in the precleaner.
m
INTAKE AND EXHAUST - GENERAL
body, indicating that it is time to clean or replace the element. After the element has been cleaned or replaced, depress the reset button on the top, and the signal will return to its original position.
(3) Vacuator valve
Warning lamp
Starter switch
Electrical dust indicator
-=- Battery
l
Valve to be opened by repulsion of rubber
806048
Centrifuged dust collects at the bottom of the air cleaner. A vacuator valve made of rubber is mounted to the bottom, which pulsates to automatically dis charges dust and water when the engine speed is below about 800 rpm. Namely when the engine is run ning at a speed higher than 800 rpm, the negative pres sure in the air cleaner keeps this valve closed but when the negative pressure drops as the engine speed decreases, the valve is made to open by rubber action, thereby discharging dust and water.
Air cleaner
81824A
With the electric dust indicator, its electric contact points close when the vacuum reaches 6.2 kPa {635 mmH20}. This turns on the warning lamp, warning the driver that it is time to clean or replace the element.
(4) Dust indicator
Reset button Indicator body Signal Transparent section
•
Negative pressure
806058
The dust indicator is mounted near the outlet of the air cleaner. The dust indicator operates on the negative pressure of the air drawn into the engine performing the function of indicating the time to clean or replace the element. When the element is plugged with dust and dirt, the suction resistance increases. When this vacuum reaches 6.2 kPa {635 mmH20}, the signal (red) is pulled down against the spring tension. The signal (red) is then visible through the transparent section in the 15-3
INTAKE AND EXHAUST - GENERAL (5) Turbocharger Bearing housing Compressor wheel
Exhaust outlet
Compressor cover "'
Air inlet
Compressor wheel Exhaust manifold
Inlet manifold
B1215A
The turbocharger utilizes the energy of the engine exhaust gas to feed more air into the engine, thereby offering advantages such as boosted engine power output, thrifter fuel consumption, and reduced engine noise. The exhaust gases discharged from the cylinder of the engine are led through the exhaust manifold into the turbocharger and are accelerated in the turbine hous ing and are blown against the turbine wheel. Accordingly, the turbine is made to rotate at a speed of scores of thousands of revolutions a minute, and turns the compressor wheel mounted on the same shaft as the turbine wheel. By rotation of the compressor wheel, a larger amount of air than without supercharg ing is forced into the cylinder of the engine, so a corre spondingly larger amount of fuel can be burnt. This increases the effective pressure during combustion (the pressure forcing the piston down) and thus increases the output.
15-4
Shaft-and turbine-wheel
Turbine housing
B1213A
The turbocharger can be divided into three basic sec tions: the turbine wheel that is driven by the exhaust gases, the compressor wheel which forces intake air into cylinders and the bearing housing which supports the shaft of these wheels. The shaft connecting the turbine wheel with the com pressor wheel is supported in floating type bearings, which absorb vibrations during high speed operation that are caused by slight imbalance of the shaft. The shaft axial load is borne by the thrust bearing. The bearing housing has its inside cooled and lubri cated by engine oil to prevent seizure and other troubles of the sliding parts. (Refer to Group 12 Lubrication.)
-
INTAKE AND EXHAUST - GENERAL (6) Aftercooler <6D24TLE2A
<6D24-TC>
Turbocharger
Turbocharger
Plate-and-corrugated-fin type water-cooling heat exchanger
lntercooler
80627A
The intake air cooling system, incorporating a plate and-corrugated-fin type heat exchanger, transfers heat from the intake air to the engine coolant. It has the same function as the intercooler on automobile engines. The system cools off the intake air, whose temperature has gone high due to compression by the turbochar ger, through heat exchanging with the engine coolant. This allows the density of intake air to be increased, admitting more air into the engine, which in turn increases the fuel injection rate and improves the com bustion efficiency. Thus the fuel economy and output are improved and the exhaust gases are reduced to a minimum.
®43534
The intercooler (attached to the front of the radiator) is a tube-and-corrugated-fin, air-to-air heat exchanger. It cools the intake air, which is hot, after being com pressed by the turbocharger, thereby making the intake air denser before it enters the cylinders. Com bustion efficiency is thus improved, resulting in higher fuel efficiency and output and in lower emissions of harmful gases.
15-5
-
INTAKE AND EXHAUST - SPECIFICATIONS
2. SPECIFICATIONS � Air cleaner element
Type
Supercharger
Type
el
Type
-
Model
-
Model Aftercooler
6D24
6D24-T
6O24-TC
Cyclone type paper element (Nippon Donaldoson Ltd. products) Turbocharger
-
Mitsubishi TD08H Plate and corrugated fin type, water-cooling (built in the inlet manifold, cooled by the engine coolant)
Engine Parts contact phone: 269 673 1638
15-6
6D24TLE2A
-
Tube-and-corrugated-fin type, air-cooling
C60
Email: EngineParts2@gmail.com
INTAKE AND EXHAUST - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item
Nominal value (Basic diameter in I ])
---·-�----
Dust indicator operating resistance Turbocharger
-
Bearing journal O.D. Shaft runout
Bearing
O.D. I.D.
---
---
Length Piston ring end gap in insert
Replace
20.506
Replace
11.996
Replace
0.015 20.382
-
-
-
0.08 to 0.28
Shaft-and-turbine-wheel axial play
0.075 to 0.155
Shaft-and-turbine-wheel to turbine back plate clearance
Replace
11.94
0.39 to 1.0
Compressor wheel to compressor cover clearance
Replace
- ---
12.042
0.05 to 0.25
Shaft-and-turbine-wheel to turbine housing clearance
Aftercooler
--
Remedy and remarks
-
6.2 ± 0.6 kPa {635 ± 58 mmH 2 O}
I.D. of section in bearing housing receiving bearing Shaft-and-turbine-wheel
Limit
0.48 to 0.92
-------
Core assembly air-tightness
6D24-TC
No leak is allowed with a 195 kPa {2 kgf/cm 2 } air pressure
lntercooler air-tightness
6D24TLE2A
No leak is allowed with a 150 kPa {1.5 kgf/cm2 } air pressure
-
Replace Replace Replace Replace Replace
---
--
Replace
3.2 lightening Torque Table Location tightened
Screw size O.D. x pitch (mm)
lightening torque N-m {kgf-m}
Inlet manifold mounting bolt <except 6O24-TC>
M10 x 1.5
35 {3.6}
Exhaust manifold mounting bolt
M10 x 1.25
41 {4.2}
Turbocharger mounting nut
Mounting nut
M10 x 1.25
26 {2.7}
Lock nut
M10 x 1.25
35 {3.6}
Turbocharger
Coupling mounting nut Shaft-and-turbine-wheel mounting lock nut
-
5.9 {0.6} 20 {2}
Remarks
Apply MOLYKOTE grease to threads.
15-7
-
INTAKE AND EXHAUST - SPECIAL TOOL
4. SPECIAL TOOL Unit: mm Tool name
Shape
Socket MH061242 For exhaust manifold attach ing nut
Width across flats 14 85341A
15-8
-
INTAKE AND EXHAUST - SERVICE PROCEDURE 5. SERVICE PROCEDURE 5.1 Removal and Installation of Intake System <6D24>
� � •
Install with the arrow mark facing toward the inlet manifold.
35N-m {3.6 kgf-m}
2 1 Ground plate
2 Inlet pipe 3 Air heater 4 Inlet manifold NOTE:
1. 2. 3.
Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.
84556A
15-9
INTAKE AND EXHAUST - SERVICE PROCEDURE
<6D24-T> 3
2
4
5
35N-m {3.6 kgf-m}
1 2 3 4 5
�� �gdown.
Ground plate Inlet pipe Rubber hose Air heater Inlet manifold
NOTE:
1. 2. 3.
Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installin g the air heater. For details of air heater inspections, refer to Group 16.
84557A
15-10
m
INTAKE AND EXHAUST - SERVICE PROCEDURE
<6D24-TC: Standard>
Install with the arrow mark facing toward the cylinder head.
9
1 2 3 4 5
Inlet pipe Air escape pipe Water inlet pipe Water return pipe Air cooler assembly
2
6 7 8 9
Ground plate Heater harness Air heater Rubber hose
NOTE:
1. 2. 3.
Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.
B4558C
15-11
INTAKE AND EXHAUST - SERVICE PROCEDURE
<6D24TLE2A
6 5
2
4
35 N-m {3.6 kgf-m}
1 Ground plate 2 Air inlet pipe B 3 Air heater
� �wfacing down.
4 Inlet manifold 5 Air inlet pipe A 6 Rubber hose
NOTE:
1. 2. 3.
Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.
®43535
15-12
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.2 Removal and Installation of Exhaust System
-
<6D24>
2 41 N-m {4.2 kgf-m}
2
Exhaust Seal rings manifold
"TOP" mark Install with stamped "TOP" mark facing manifold
l
Expansion rings
Gap
Seal ring
Install the seal rings such that their gaps are staggered by 180'. Install the expansion rings such that their gaps are opposite the seal ring gaps.
1 Heat insulator 2 Exhaust manifold 3 Seal ring
4 Expansion ring 5 Center exhaust manifold
84560A
Socket, MH061242 (special tool) is available to facili tate fitting of the exhaust manifold mounting nuts. Use
of this tool is recommended. 15-13
m
INTAKE AND EXHAUST - SERVICE PROCEDURE
<6D24TLE2A
4 35 N-m {3.6 kgf-m} 26 N-m {2.7 kgf-m}
� =-8
L. 5
8
"TOP" mark Install with stamped "TOP" mark facing manifold
Expansion rings
Seal ring Gap • Install the seal rings such that their gaps are staggered by 1ao·. • Install the expansion rings such that their gaps are opposite the seal ring gaps.
1 2 3 4
Heat insulator Oil pipe Oil return pipe Turbocharger
5 6 7 8
Exhaust manifold Seal ring Expansion ring Center exhaust manifold B4561A
Socket, MH061242 (special tool) is available to facili tate fitting of the exhaust manifold mounting nuts. Use of this tool is recommended.
15-14
NOTE: Some types of turbocharger fit onto the top of the exhaust manifold, while other types fit onto the bot tom of the exhaust manifold. Maintenance procedures for both types are the same.
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.3 Air Cleaner 5.3.1 Disassembly and reassembly Dust cup
<Single element type> Air cleaner body
e-,-- Dust indicator Air cleaner body
84563A
Dust cup
<Double element type>
. ,·. Installation ,__direction mark
�ir cleaner body _ Dust md1cato
Outer element Inner element
o
�
NOTE:
,.. •,:1.
Wing nut
e-- Vacuator valve
Remove the inner element only for replacement.
Gasket
��
�:�i:iI�:: \ , � ,, •:::;;:,:•: •::- • •:. ·
Clamp
Wing nut
�
Cover
,
1
Wing nut
84564A
15-15
-
INTAKE AND EXHAUST
5.3.2 Inspection and cleaning
SERVICE PROCEDURE (4) Clean the inside of the air cleaner body and dust cup, and discharge the deposited dust.
(1) When there is dry dust on the element
(5) Dust indicator
Operating resistance NV 6.2 ± 0.6 kPa {635 ± 58 mmH20}
Window (red signal) C7 207A
NV .. Nominal Value
If there is dry dust on the element, clean the dust by blowing 685 kPa {7 kgf/cm2} or lower compressed air against the element. Blow the compressed air from inside the element up and down along the frills of the filter paper and clean the whole element evenly. NOTE: 1. 2.
Do not strike the element or strike it against a hard object to loosen the dust. Do not clean, but replace, the inner element.
(2) When there is moist dust on the element If the element is contaminated with moist soot, replace it regardless of the specified replacement frequency. (3) Inspection of element
C7 209A
After the element has been cleaned, put an electric lamp inside the element to check for damage and pin holes. If there are thin portions in the filter paper, replace the element. If the packing on the top surface of the element is broken, replace the element. 15-16
C7210B
Start the engine and close the inlet port of air cleaner gradually to increase negative pressure. If the red sig nal is displayed at the dust indicator, or warning lamp lights for the electric type dust indicator, the dust indi cator is normal. NOTE: Perform this inspection after cleaning or replacement of the air cleaner element if the element is heavily clogged.
-
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4 Turbocharger 5.4.1 Disassembly
Wear in surface receiving thrust
Wear 1 16 7
B�de bend and damag� corrosion, marks of interference on back surface
4
Interference with compressor wheel, cracks, damege
13
Interference with turbine wheel, cracks due to overheat, pitching, deformation
Blade bend and damage, corrosion, marks of interference on back sur face, damage on piston ring groove, damage on bearing journal
Interference with turbine wheel, damage
18
Bearing hole surface roughness, damage, gas corrosion, clogged oil hole, turbine side flange deformation
Disassembly sequence
1 Coupling assembly
(?)
3 @ @ 6 (J)
8 9
Turbine housing Snap ring Compressor cover Compressor wheel Snap ring Insert Piston ring Oil deflector
10 Thrust sleeve 11 Thrust bearing
12 Thrust ring 13 Shaft-and-turbine-wheel 14 Piston ring 15 Turbine back plate 16 Bearing 17 Snap ring 18 Bearing housing
For parts with an encircled number, refer to Disassembly Procedure that follows. C8965B
15-17
m
INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Removal of compressor cover
Disassembly Procedure Alignment mark
Compressor cover
Turbine housing Bearing housing
C8982C
B2819D
(1) Before disassembling the turbocharger, make alignment marks on the compressor cover, bearing housing, and turbine housing so that they can be properly reassembled. (2) Removal of turbine housing
Remove the compressor cover by tapping it with . plastic hammer or similar tool which will not damag, the cover, with the snap ring loosened. NOTE: Use care not to damage the compressor wheel durin! the removal procedure.
(4) Removal of compressor wheel
Bearing housing
Turbine housing
Turbine housing B3946B
To remove the turbine housing, remove the coupling assembly and tap the housing with a plastic hammer or similar tool to prevent damage to it. NOTE: The turbine wheel blades are easy to bend. Use care not to damage them.
15-18
B2820C
(a) Clamp the turbine housing in a vise and fit the bear ing housing into the turbine housing with the turâ&#x20AC;˘ bine wheel side of the bearing housing facing the turbine housing.
INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Removal of insert
m
Snap ring
Shaft-and-turbine-wheel boss C8983C
(b) While holding the shaft-and-turbine-wheel boss, remove the lock nut that secures the compressor wheel.
C89788
(a) Snap off the snap ring that secures the insert onto the bearing housing.
NOTE: Retain the snap ring by hand to prevent it from spring ing out when slipping off the snap ring pliers.
� Comp,osso, wh"I
C8984C
(c) Slowly slide off the compressor wheel upward.
(b) Fit the tip of a screwdriver into the portion of the insert shown and carefully remove it from the bear ing housing.
15-19
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.2 Cleaning and inspection
Piston ring end gap NV 0.05 to 0.25
Clean Bearing 0.0. L 20.382 1.0. L
12.042
Length L 11.94
BearingjournalO.O. L 11.996 Shaft runout (total indi cator reading) L 0.0,5
Clean Bearing inserting portion 1.0. L 20.506
NOTE:
Before cleaning, visually inspect each component to find any scorching or rubbing that will not be apparent after cleaning. For details, refer to section 5.4.1.
C8988B
(a) Immerse all parts in a non-flammable solvent (DAIDO CHEMICAL INDUSTRY CO., LTD DAI CLEANER T-30 or equivalent) to clean oily contami nation.
(1) Cleaning
13628
15-20
NV .. Nominal Value L ..... Limit
INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Inspection of bearing housing
C8990A
(b) Blow clean compressed air against the entire inter nal and external surfaces.
C8993A
Measure I.D. of the area receiving the bearing. Replace the bearing housing if the measurement exceeds the limit. (3) Inspection of bearing
Measuring direction
Measuring position
C8991A
(c) Clean deposits, using a plastic scraper or bristle brush. After deposits have been removed, soak parts in a non-flammable solvent again; then, blow com pressed air against them.
C8971A
Measure I.D., O.D., and length of the bearing. If the measured values exceed the limit, replace.
NOTE: Use care to prevent damage to parts.
15-21
m
INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Inspection of insert
(4) Inspection of shaft
(a) Journal 0.0. Insert
B0467A 80465A
Measure the shaft-and-turbine-wheel journal diame ter. If the measured value is less than the limit, replace the shaft-and-turbine-wheel. (b) Shaft runout
B0466A
Set a dial indicator to the shaft as shown and turn the turbine wheel slowly to measure shaft runout. If the measurement exceeds the limit, replace the shaft-and-turbine-wheel. If the shaft journal is rough, clamp both centers on a lathe and lightly grind the journal surface with a sand paper #400 and engine oil with a spindle speed at 300 to 600 rpm. NOTE: After polishing the journal, measure its outside diame ter (the part that rotates in the bearing). If the outside diameter is beyond the service limit, replace the shaft and turbine wheel.
15-22
Fit a new piston ring in the insert bore and measure the end gap of the piston ring using a feeler gauge. If the end gap is out of the nominal value, replace the insert.
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.3 Reassembly
12
11
I
Apply engine ott]
5.9 N-m {0.6 kgf-m} • Molykote grease or equivalent to be applied to screw and seating surface in lock nut. • Hammer entire periphery. 2
15 14 j Apply engine oil
I
20 N-m {2 kgf-m} Molykote grease or equiva lent to be applied to screw
I
Apply engine oil
I
8
Compressor wheel to com pressor cover clearance NV 0.08 to 0.28
Shaft-and-turbine-wheel to turbine housing clearance NV 0 .39 to 1.0
13 Shaft-and-turbine-wheel axial play NV 0.075 to 0.155
Assembly sequence 18➔17➔16➔15 14➔13
}+12
9➔10➔r.a.➔7
�
11
. �;➔(�➔r4;-➔3-/2➔:1_.
NV .. Nominal Value
For parts with an encircled number, refer to Reassembly Procedure that follows.
C89748
Set the thrust sleeve into the oil deflector, and install the piston ring.
Reassembly Procedure (1) Installation of piston ring
NOTE: When mounting piston ring to the thrust sleeve, ensure that the ring is not expanded and ring ends are not twisted.
Thrust sleeve
Oil deflector Piston ring
80472C
15-23
Bl
INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Measurement of clearance between shaft-and-tur bine-wheel and turbine housing
(2) Installation of snap ring
Shaft-and turbine-wheel
C8978C C9001B
Set a dial indicator to the end of the shaft and move the shaft in the axial direction to measure the clearance. If the measurement is out of specification, disassemble and isolate the cause. (4) Installation of compressor wheel
Install the snap ring to the bearing housing with its taper up. After installation, using a screwdriver, drive the snap ring into the groove in the bearing housing by hum mering. NOTE: 1. Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pli ers. 2. Special care must be exercised, when tapping the snap ring into position, to prevent damage to the bearing housing by the screwdriver.
Bearing housing
Turbine housing
B2820C Lock nut �
20 N-m {2.0 kgf-m} ____._..,
Compressor wheel� " " Shaft-and-turbine=----fl wheel
C9002C
(a) Holding the turbine housing in a vice, set the tur bine wheel side of the bearing housing into the tur bine housing.
15-24
INTAKE AND EXHAUST - SERVICE PROCEDURE (bl Coat threads in the shaft-and-turbine-wheel with molybdenum disulfide base grease Li soap and mount the compressor wheel onto the shaft. (c) Holding the boss on the turbine wheel side, tighten the compressor wheel lock nut to the specified torque.
m
(6) Measurement of clearance between the turbine back plate and shaft-and-turbine-wheel back sur face
NOTE:
'
Set the bearing housing carefully to prevent damage on the turbine wheel blades.
.,,..-Bearing housing
(5) Measurement of axial play in shaft-and-turbine wheel Compressor cover
t
B2830C
Shaft-and turbine-wheel
Shaft-and turbine wheel
""'�,:;::--
Compressor wheel
Compressor cover
C90038
Set a dial gauge on the shaft-and-turbine-wheel end. With compressor wheel moved in the axial direction, measure the end play. If the play is out of specification, disassemble and check to locate the cause.
C9004A
Temporarily mount the bearing housing to the com pressor cover from the compressor wheel side. Mea sure the clearance between the turbine back plate and shaft-and-turbine-wheel back surface. If the clearance is out of specification, disassemble and isolate the cause. NOTE: Be sure to use two thickness gauges and take mea surement at the tip of the blades.
15-25
INTAKE AND EXHAUST (7) Compressor wheel to compressor cover clearance
SERVICE PROCEDURE (8) Installation of turbine housing and compressor cover
Alignment mark
84468A
Coupling assembly Snap ring Compressor cover 5.9 N•m (0.6 kgf·m) B2819E
Check by the following procedures. (a) Move up and down the compressor wheel to measure runout (R). NOTE: Do not measure runout by turning the compressor wheel.
(b) Measure compressor cover inside diameter (D) and compressor wheel outside diameter (d) at places indicated in the illustration. (c) Calculate the clearance by the equation given below. If it is out of specification, disassemble and check again. Clearance= 1/2 (D - d - R)
15-26
Make sure that the alignment marks are aligned and secure the parts with the coupling assembly and snap ring. Install the coupling assembly by the following proce dures. (a) lighten the coupling assembly to specified torque. (b) Hammer the coupling assembly all around. (cl lighten again the coupling assembly to specified torque. (9) After reassembly, turn the turbine wheel and com pressor wheel by hand and check for smooth rota tion. If the wheels turn heavily, or bind, disassemble, and locate the cause of trouble.
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.5 Aftercooler 5.5.1 Disassembly and reassembly ( 1) Water-cooled type <6D24-TC :Low profile type>
<6D24-TC :Standard>
2
5
1 Connector 2 Cover 3 Plate
4 Core assembly 5 Inlet manifold
4
Damage, water leaks, dirt on fins, water scale and rust inside core C9305C
(2) Air-cooled type <6D24TLE2A
1 Air intake hose 2 lntercooler
84157A
15-27
m
INTAKE AND EXHAUST - SERVICE PROCEDURE 5.6 Bleeding of Aftercooler Coolant Circuit <6024-TC :Standard>
5.5.2 Air pressure test (1) Inspection of core assembly <6D24-TC> Conduct the air pressure test to check for water leaks due to damaged element. To check, apply an air pres sure of 390 kPa {4 kgf/cm2} to the core assembly. Replace the core assembly if it is leaking air or other wise defective.
� Air vent plug � Water return pipe
NOTE: Never apply pressure over specification.
(2) Inspection of intercooler <6D24-TL>
E0329
C9303A
(a) Remove the intercooler and use copper wire or the like to remove mud, insects, etc. from the front side of intercooler core, using care not to damage the tube. (c) Air-tightness check
Pressure for inspection of intercooler (compressed air) NV 150 kPa {1.5 kgf/cm2}
NV .. Nominal Value C9009A
Immerse the intercooler in a water tank with one open ing for air closed and with the other opening connected to a hose. Send compressed air at specified test pres sure through the hose and make sure that there is no air leak. 15-28
(a) Remove the air vent plug from the water outlet pipe. (b) Pour coolant into the radiator until coolant flows out from the air vent. Install the air vent plug. (c) With the pressure cap left removed from the radia tor, run the engine at idle, keeping coolant temper ature of about 90°C, to thoroughly bleed the sys tem. (d) After the air in the coolant circuit has been thor oughly bled, add coolant as necessary to the radia tor and reservoir tank.
INTAKE AND EXHAUST - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Low output
Probable cause Insufficient intake air • Loaded air cleaner element
Remedy
---·--- ..
• Air suction (with dust and other foreign matter) from intake system
Clean
---�--- --·
Correct
• Defective turbocharger • Turbocharger rotation failure • Seized bearing • Carbon deposit on turbine wheel
Check Check
• Seized thrust sleeve and/or thrust bearing • Incorrect sliding between inside parts due to clogged lubrieating oil pipe
Clean
·-
Replace
Check Replace
Incorrect injection timing
Adjust
Group 13A, E
Low compression pressure
Check
Group 11
Poor quality fuel
Replace
Defective turbocharger • Oil leaks due to worn piston ring, and/or insert
Replace
• Damaged oil seal due to clogged oil return pipe
Abnormal noise and/or vibration from intake and exhaust system
Clean, check
Replace
• Damaged turbine wheel
Dark and much exhaust gas
·-·
Replace
• Damaged turbine wheel
• Defective turbocharger • Turbocharger rotation failure (See above.)
..
Check
Replace
Low exhaust efficiency • Deformed front pipe, muffler and/or tail pipe (large exhaust resistance)
·-
Replace
• Damaged compressor wheel
• Foreign matter on front surface of intercooler core 6D24TLE2A
gas
Clean
• Turbine wheel and turbine back plate interfering
• Compressor wheel and compressor housing interfering
Whitish and much exhaust
Replace
• Turbine wheel and turbine housing interfering • Bent shaft-and-turbine-wheel
Ref. group
Loaded air cleaner element
Group 13A
Replace Clean
Trouble in engine proper
Check
Group 11
Nonuniform fuel injection amount to cylinders
Adjust
Group 13A, E
Incorrect injection timing
Adjust
Group 13A, E
Poor connection of intake and exhaust systems
Correct
Deformed front pipe, muffler or tail pipe (large exhaust resistance)
Replace
Defective turbocharger (See above.)
Check
15-29
Mitsubishi 6D24T-C 6D24TC Mitsubishi 6D24 TC-1AT.1 Mitsubishi 6D24-TC1 6D24TC1 Mitsubishi 6D24-TCE 6D24TCE Mitsubishi 6D24-TCE1 6D24TCE1 Mitsubishi 6D24-TCE2 6D24TCE2 Mitsubishi 6D24-TCEA 6D24TCEA Mitsubishi 6D24-TCEB 6D24TCEB Mitsubishi 6D24-TCEC 6D24TCEC Mitsubishi 6D24-TCED 6D24TCED Mitsubishi 6D24-TCEE 6D24TCEE Mitsubishi 6D24-TCEF 6D24TCEF Mitsubishi 6D24-TCEG 6D24TCEG Mitsubishi 6D24-TCEH 6D24TCEH Mitsubishi 6D24-TCET 6D24TCET Mitsubishi 6D24T-CU 6D24TCU Mitsubishi 6D24T-CUD 6D24TCUD Mitsubishi 6D240 Mitsubishi 6D240P Mitsubishi 6D240PT Mitsubishi 6D240PT 0G5226 Generator Mitsubishi 6D240PT 0G5227 Generator Mitsubishi 6D241 6D24-1 Series Mitsubishi 6D242 6D24-2 Series Mitsubishi 6D243 6D24-3 Series Mitsubishi 6D244 6D24-4 Series Mitsubishi 6D24A Mitsubishi 6D24-AT 6D24AT Mitsubishi 6D24B Mitsubishi 6D24CE Mitsubishi 6D24-CE1 Mitsubishi 6D24D Mitsubishi 6D24-DT 6D24DT Mitsubishi 6D24-DT040 6D24DT040 Mitsubishi 6D24-DT049 6D24DT041 0A5399 Mitsubishi 6D24-DT050 6D24DT050 Mitsubishi 6D24-DT051 6D24DT051 0D5451 Mitsubishi 6D24E Mitsubishi 6D24-E1 Mitsubishi 6D24L11.9 Mitsubishi 6D24-M Marine Mitsubishi 6D24-O Mitsubishi 6D24T
Mitsubishi 6D24T Series 03 Mitsubishi 6D24T Series 13 Mitsubishi 6D24T Series 23 Mitsubishi 6D24-T- 4405998 Hitachi Mitsubishi 6D24T1 6D24T-1 Series Mitsubishi 6D24T2 6D24T-2 Series Mitsubishi 6D24T3 6D24T-3 Series Mitsubishi 6D24T4 6D24T-4 Series Mitsubishi 6D24T Series 13 Mitsubishi 6D24TCE Mitsubishi 6D24T-CE1 6D24TCE1 Mitsubishi 6D24T-TE1.12 Sumitomo Mitsubishi 6D24TE Mitsubishi 6D24-TEB Mitsubishi 6D24-TE1 Mitsubishi 6D24TE1 Series 1 Mitsubishi 6D24TE1 Series 2 Mitsubishi 6D24TE1.022 Mitsubishi 6D24TE1.023 Hitachi Mitsubishi 6D24-TE1.12 Mitsubishi 6D24TE1 .23 Mitsubishi 6D24-TE1 .24 Mitsubishi 6D24-TE1 .50 Mitsubishi 6D24-TE1 .51 Mitsubishi 6D24-TE1 .52 Mitsubishi 6D24-TE2 Mitsubishi 6D24TEB-1AT1.0 Mitsubishi 6D24TEB-1AT1.1 Mitsubishi 6D24TL Mitsubishi 6D24TL Series 11 Mitsubishi 6D24TL Series 12 Mitsubishi 6D24TL Series 13 Mitsubishi 6D24-TLC Mitsubishi 6D24TLC-113 Mitsubishi 6D24TLC-114 Mitsubishi 6D24TLC-115 Mitsubishi 6D24TL-1AT.4 Hitachi Sumitomo Mitsubishi 6D24TL-1AT.5 Mitsubishi 6D24TL-1AT1.3 Mitsubishi 6D24-TLA 6D24TLA Mitsubishi 6D24-TLA1 6D24TLA1 Mitsubishi 6D24-TLA2 6D24TLA2 Mitsubishi 6D24-TLA2A 6D24TLA2A
Mitsubishi 6D24-TLA2B 6D24TLA2B Mitsubishi 6D24-TLA2C 6D24TLA2C Mitsubishi 6D24-TLA2D 6D24TLA2D Mitsubishi 6D24-TLA2E 6D24TLA2E Mitsubishi 6D24-TLA2F 6D24TLA2F Mitsubishi 6D24-TLA2J 6D24TLA2J Mitsubishi 6D24-TLA2K 6D24TLA2K Mitsubishi 6D24-TLA2O 6D24TLA2O Mitsubishi 6D24–TLA2E.01 Mitsubishi 6D24–TLA2E.02 Mitsubishi 6D24–TLA2E.03 Mitsubishi 6D24-TL2 6D24TL2 Mitsubishi 6D24-TLE 6D24TLE Mitsubishi 6D24-TLEA 6D24TLEA Mitsubishi 6D24-TLE Series 1 Mitsubishi 6D24-TLE1 6D24TLE1 Mitsubishi 6D24-TLE2 6D24TLE2 Mitsubishi 6D24-TLE2A 6D24TLE2A Mitsubishi 6D24-TLE2A .20 Mitsubishi 6D24-TLE2A .21 Mitsubishi 6D24-TLE2A .22 Mitsubishi 6D24-TLE2A .23 Mitsubishi 6D24-TLE2A .24 Hitachi Sumitomo Mitsubishi 6D24-TLE2A .25 Hitachi Sumitomo Mitsubishi 6D24TLE2A .56 Hitachi Sumitomo Mitsubishi 6D24TLE2A .57 Hitachi Sumitomo Mitsubishi 6D24-TLE2B 6D24TLE2B Mitsubishi 6D24-TLE2B.01 6D24TLE2B.01 AIRMAN Mitsubishi 6D24-TLE2B.02 6D24TLE2B.02 Mitsubishi 6D24-TLE2B.03 6D24TLE2B.03 Mitsubishi 6D24-TLQ2C Mitsubishi 6D24-TLU Mitsubishi 6D24-TLUA Mitsubishi 6D24-TLUB Mitsubishi 6D24-TLUC Mitsubishi 6D24-TLUD Mitsubishi 6D24-TLUE Mitsubishi 6D24-TLUF Mitsubishi 6D24-TLUG Mitsubishi 6D24-TLU2 6D24TLU2 Mitsubishi 6D24-TLU2A Mitsubishi 6D24-TLU2B Mitsubishi 6D24-TLU2C
Mitsubishi 6D24-TLU2D Mitsubishi 6D24-TLU2E Mitsubishi 6D24-TLU2F Mitsubishi 6D24-TLU2G SANY Mitsubishi 6D24-TLU20 Mitsubishi 6D24-0AT Mitsubishi 6D24-0AT1 Mitsubishi 6D24-0AT2 Mitsubishi 6D24-0AT3 Mitsubishi 6D24-0AT4 Mitsubishi 6D24-1AT Mitsubishi 6D24-1AT1 Mitsubishi 6D24-1AT2 Mitsubishi 6D24-1AT3 Mitsubishi 6D24T Series 13 Mitsubishi 6D24-T- 4405998 Hitachi Mitsubishi 6D24T.50 Mitsubishi 6D24T.55 Mitsubishi 6D24T-1AT.1 Mitsubishi 6D24T-1AT1.1 Mitsubishi 6D24T-1AT1.2
Notes: Mitsubishi 6D24
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