Tadano GR-1600XL Service Manual Download Page 189

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Z-11.

WZ02-6702E

Electric Parts Location Diagram (Upper)

Z-11.

9.2 Indicator assy (jib angle detector)

IWZ02-6320E14a

343-637-31000

Isometric drawing

View B

Jib angle detector

CN1603

Connector (jib angle detector)

CN578

Cable (jib angle detector)

Summary of Contents for GR-1600XL

Page 1: ......

Page 2: ...and sales units in the parts catalog before replacing them 1 Applicable spec and serial number Spec No Applicable serial number GR 1600 2 00103 FE5027 GR 1600 2 00104 Separate service manual Separate Service Manual Publication No 1 General Cautions WA01 0121E 2 Load Moment Indicator AML C W301 0414E 3 Multiplex Data Transmitter MDT 9 W303 0582E 4 Torque Converter EXEDY to be published Transmission...

Page 3: ...e H type outrigger specification machine Front rear right and left are the directions viewed from a position when operator sits on operator s seat with the boom directed to the front of the frame Those directions remain invariant regardless of slewing direction of the superstructure ...

Page 4: ...6 Counterweight Self removable type 7 Outrigger Self removable type 8 Load moment indicator AML AML C 9 Auto stop solenoid valve energizing type Normally energized 10 Anti two block device Fitted 11 External warning lamp AML Fitted 12 Oil cooler Fitted 13 Air conditioner Fitted 14 ICF information controller Fitted 15 SCT satellite communications terminal Option 16 Eco mode system Fuel consumption ...

Page 5: ...1 07639 10 5 1 10 2 1 1 10 4 1 55 10 1 1 07639 10 3 1 10 6 1 10 4 1 1 55 10 3 1 07639 10 6 4516 10 2 6 4516 6 4516 10 4 1 6 94444 10 3 9 2903 10 4 9 2903 10 2 9 2903 10 2 1 44 10 2 1 Volume cubic centimeter cm 3 cc liter lit L cubic meter m 3 cubic inch in 3 cubic foot ft 3 gallon US gal 1 1 10 3 1 10 6 6 10237 10 2 3 53147 10 5 2 64172 10 4 1 10 3 1 1 10 3 6 10237 10 3 53147 10 2 2 64172 10 1 1 1...

Page 6: ...72 10 2 1 6 89475 10 2 1 10 5 1 10 2 1 10 1 1 01972 1 45038 10 1 Torque N cm N m kgf cm kgf m foot pound ft lbf inch pound in lbf 1 1 10 2 1 01972 10 1 1 01972 10 3 7 37562 10 3 8 85074 10 2 1 10 2 1 1 01972 10 1 01972 10 1 7 37562 10 1 8 85074 9 80665 9 80665 10 2 1 1 10 2 7 23301 10 2 8 67961 10 1 9 80665 10 2 9 80665 1 10 2 1 7 23301 8 67961 10 1 35582 10 2 1 35582 1 38255 10 1 38255 10 1 1 1 2...

Page 7: ...e the front view and draw the right side view on the right side of the front view Tridimensional shape can generally be drawn with the figures viewed from 3 directions For those which cannot be drawn with the figures viewed from 3 directions the additional figures such as left side view the figure viewed from the left D back view the figure viewed from the back E or bottom view the figure viewed f...

Page 8: ...7 WA04 5330E 6 Group index System Diagrams Data Adjustment and Checks Y Z Y Z ...

Page 9: ...Procedure Y 4 Adjusting Procedure Electric Y 5 Assembly Adjustment Crane Operation Y 6 Assembly Adjustment Traveling Device Y 7 Operation Check Crane Operation Y 8 Operation Check Traveling Device Y 9 Inspection and Maintenance Y 10 Boom Connecting Pin and Thread Size Table Y 11 System Diagrams Z Hydraulic Circuit Z 1 Torque Converter Circuit Z 2 Pneumatic Circuit Z 3 Electric Circuit Upper Crane ...

Page 10: ...ydraulic Parts Location Diagram Torque Converter Z 9 Pneumatic Parts Location Diagram Z 10 Electric Parts Location Diagram Upper Z 11 Electric Parts Location Diagram AML Two blocking Z 12 Electric Parts Location Diagram ICF SCT Z 13 Electric Parts Location Diagram Lower Z 14 Harness Diagrams Harness Upper Crane Z 15 Harness Upper Carrier Z 16 Harness Lower Z 17 Searchlight Anemometer Aviation Obst...

Page 11: ...nd replacement of vehicle 10 6 1 Power transmission device 10 6 2 Braking device 10 6 3 Steering device 11 7 Mass table 12 Y 2 Adjusting Pressure Hydraulic Pressure 13 1 Location position of relief valve etc 13 2 Items 15 2 1 Winch 15 2 2 Elevating 17 2 3 Telescoping 18 2 4 Steering 20 2 5 Slewing 21 2 6 Outrigger 22 2 7 Remote control pilot pressure 23 2 8 Flow control valve 24 2 9 Torque convert...

Page 12: ...in retraction detection switch CN573 41 5 Main winch drum rotation detection switch CN591 42 6 Aux winch drum rotation detection switch CN592 42 7 Over front detection switch CN521 43 8 Control lever stand position detection switch left CN529 43 9 Straight ahead detection switch CN408 44 10 Counterweight equipped detection switch left CN457 44 11 Counterweight equipped detection switch right CN994...

Page 13: ...2 3 Counterweight cylinder synchronization adjustment 63 3 1 Adjustment without counterweight rough adjustment 63 3 2 Adjustment with counterweight regular adjustment 64 Y 7 Assembly Adjustment Traveling Device 66 1 Service brake adjustment 66 1 1 Adjusting the brake pedal 66 1 2 Tightening the cap of reserve tank of service brake fluid 66 1 3 Check after replacing brake hose 66 2 Accelerator adju...

Page 14: ...ng 77 12 Outrigger slide plate adjustment 78 Y 9 Operation Check Traveling Device 79 1 Exhaust brake 79 2 Automatic transmission 79 3 Overshift prevention 80 4 Maximum allowable speed 80 5 Steering mode change 81 6 Emergency switch 81 6 1 Emergency transmission 81 6 2 Emergency accelerator 81 6 3 Emergency engine stop 81 7 Warning 82 8 Speedometer 82 9 Hydraulic suspension 83 9 1 Normal operation ...

Page 15: ...ke fluid Service brake 2 0 TADANO Genuine Brake Fluid DOT 5 1 Engine oil 13 15 API Service Classification SAE15W 40 class CJ or better SAE10W 30 for cold climates Grease 1 Daphne Eponex SR No 2 Idemitsu 1 NEW SL PM 70 2 DAIZO Nichimoly Division Fuel 300 Number 2 D of ASTM D 975 Amount of coolant Coolant Total volume 31 5 1 TADANO Genuine Long life Coolant Necessary volume of long life coolant 9 45...

Page 16: ...83 38 Eng 2860 40 Displacement cm 3 rev 52 2 31 1 Charging pump torque converter Speed reducing ratio 1 066 Idling min 1 629 23 Eng 670 25 Max min 1 2683 38 Eng 2860 40 Displacement cm 3 rev 33 2 Emergency steering pump Displacement cm 3 rev 14 56 3 2 Hydraulic motor 1 L min 2 64172 10 1 gal min Item Standard value Remarks Winch main auxiliary Displacement cm 3 rev 195 Maximum 140 Minimum Drain wh...

Page 17: ...d 3 After jack full extension and retraction operation approximately 10 mm set the crane horizontally with the jacks slightly extended 2 If any tire is not raised off the ground while setting the jacks use blocks to secure the remaining stroke Inspection method Check the displacement by measuring the dimensions again after 5 hours Set the crane considering the possibility of damaging the vehicle o...

Page 18: ...AML display after leaving as it is for 2 hours Check the jib length on the integrated information screen in the AML maintenance mode Displays the value to the second digit after decimal place Suspension On rubber 10 mm or less 15 hours Inspection conditions 1 Boom stowed over front 2 Suspension locked 3 On rubber 4 Stop the engine and turn off the power 5 Oil temperature normal temperature Inspect...

Page 19: ...h 0 pieces Telescopic section 1 Front Upper on upper part of side face Upper 16 Refer to Figure 1 1 Right Left each 1 piece Side 29 Lower on rounded face 24 Standard Right Left each 11 pieces or 22 Standard Right Left each 0 pieces Rear Upper on oblique face 60 Right Left each 1 piece Side 30 Right Left each 1 piece Lower on rounded face 27 Right Left each 2 pieces Lower center 17 1 piece Telescop...

Page 20: ...1 Right Left each 1 piece Side 29 Lower on rounded face upper 22 Standard Right Left each 3 pieces or 20 Standard Right Left each 0 pieces Lower on rounded face lower 24 Standard Right Left each 5 pieces or 22 Standard Right Left each 0 pieces Rear Upper on oblique face 60 Right Left each 1 piece Side 30 Right Left each 1 piece Lower on rounded face 27 Right Left each 2 pieces Lower center 17 1 pi...

Page 21: ... each boom section Lateral Base boom Telescopic section 1 Telescopic section 2 Telescopic section 3 Telescopic section 4 Telescopic section 5 C 12 C 12 C 12 C 11 C 11 C 11 C 1 0 L 1000 Indentations at boom overlap sections Bending at boom lower plate t D IWY01 001003 Telescopic section 1 Telescopic section 2 Telescopic section 3 Telescopic section 4 Telescopic section 5 In vertical direction D 4 D...

Page 22: ...than the standard described in this manual observe the local ones 1 mm 3 93701 10 2 in Item Standard value Limit value Remarks For main winch and auxiliary winch Wire rope diameter mm 19 Nominal diameter 17 7 Construction 16 P7 6 P7 6 P26WS 1 25Fi 1 370 018 09340 09350 P S 19 39 P 7 2 370 018 09880 09890 Number of broken wire pcs 9 1 or 10 2 Criteria for wire rope replacement 1 Replace the wire ro...

Page 23: ... damaging the wire rope Use a grinder to smooth and correct any sharp corners 2 Check whether or not the sheaves turn lightly If a sheave turns heavily the wire rope will slide against the sheave and the rope may be damaged If a sheave turns heavily inspect the sheave bearings and lubricate or replace them if necessary 3 Check that the sheave split pins and installation bolts are securely installe...

Page 24: ...Eco mode OFF When torque converter stalls Approx 2160 Reference value Check conditions PTO switch OFF Shift lever 2nd gear Drive selection switch 4WD High Service brake ON 6 2 Braking device 1 mm 3 93701 10 2 in Item Standard value Limit value Remarks Service brake Lining thickness mm 14 4 Not including back plate Disc thickness mm 20 17 5 Parking brake Lining thickness mm 6 5 3 Not including back...

Page 25: ...05 Rod side 38 0 025 0 05 Kingpin Clearance above and below axle mm 0 to 0 05 Wheel Camber 0 Caster 0 Kingpin angle 0 Toe in mm 1st axle 2 0 to 4 0 2nd axle 0 to 2 0 3rd axle Steering angle Inner wheel outer wheel 1st axle 26 0 0 1 21 04 2nd axle 10 0 0 1 9 15 3rd axle 16 0 0 1 14 06 Tire size 26 5 R25 Tire air pressure 650 100 000 kPa 6 5 1 0 kgf cm 2 92 5 14 5 00 psi ...

Page 26: ... including hydraulic motor 280 620 Center joint 80 180 Elevating cylinder 1600 3520 Winch assembly including hydraulic motor Main 560 1240 Auxiliary 560 1240 Boom assembly including telescoping cylinder Fix jib 15100 33220 Power tilt jib 15000 33000 Jib assembly Fix jib 1420 3130 Power tilt jib including tilt cylinder 1520 3350 Counterweight Standard 18200 40000 Extra 11100 24400 Outrigger assembl...

Page 27: ...13 WY02 2020E Y 2 Y 2 Adjusting Pressure Hydraulic Pressure Y 2 Adjusting Pressure Hydraulic Pressure 1 Location position of relief valve etc ...

Page 28: ...14 WY02 2020E Y 2 Y 2 Adjusting Pressure Hydraulic Pressure ...

Page 29: ...the auxiliary winch lever at its full stroke on the hoisting up side while the elevating lever is moved at its full stroke on the raising side 5 In this state set the engine speed to 2150 min 1 and check the pressure Winch hoisting up C 27 5 0 5 280 5 3980 70 2150 MAX 6 After adjusting the pressure for winch hoisting up B fully tighten the part A loosened above 2 7 Connect a pressure gauge to the ...

Page 30: ...16 WY02 2020E Y 2 Y 2 Adjusting Pressure Hydraulic Pressure ...

Page 31: ... increase engine speed Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm2 psi Boom lowering D 5 5 0 5 0 56 5 0 800 70 0 670 IDL 1 Deactivate the elevation slow stop circuit 1 2 Turn the PTO switch ON 3 Fully retract the elevating cylinder 4 Move the elevating lever at its full stroke on the lowering side 5 In this state check the pressure 1 To deactivate the elevation slow stop ...

Page 32: ...gize the solenoid valve for ESP telescoping high pressure selection by the external power supply 24V 5 Move the telescoping lever at its full stroke on the extension side 6 In this state set the engine speed to 2150 min 1 and check the pressure Boom extending F 13 7 0 5 140 5 1990 70 2150 MAX 7 Disconnect the connector CN232 of the solenoid valve for ESP telescoping high pressure selection 8 Move ...

Page 33: ...19 WY02 2020E Y 2 Y 2 Adjusting Pressure Hydraulic Pressure ...

Page 34: ...ve the steering cylinders to the end of the stroke 5 In this state set the engine speed to 2600 min 1 and check the pressure by the pressure gauge Note Adjustment is not possible If the pressure is out of the set pressure range replace the priority valve Steering I 17 2 0 1 175 0 10 2495 0 140 2600 1 Connect pressure gauges to the pressure check port I left and port I right 2 Turn the PTO switch O...

Page 35: ...rease engine speed Cancel registration of slewing range limit function in AML Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Slewing 1 J 23 5 0 5 240 5 3405 70 2150 MAX 1 Turn the PTO switch ON 2 Apply the slewing brake 3 Move the slewing lever at its full stroke on the right and left side 4 In this state set the engine speed to 2150 min 1 and check the pressure 2 K 26 ...

Page 36: ...ark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Outrigger relief valve L 20 6 0 5 210 5 2990 70 2150 MAX 1 Connect a pressure gauge to the pressure check port L 1 2 Turn the PTO switch ON 3 Fully extend the jack cylinders while the engine is idling 4 In this state set the engine speed to 2150 min 1 and check the pressure by the pressure gauge 1 The pressure check port C winch ...

Page 37: ...ON 3 Turn the air conditioner switch OFF 4 Make sure that constant pressure is being produced while engine is running 5 And check the pressure by the pressure gauge Note Adjustment is not possible If the pressure is out of the set pressure range replace the sequence valve 2 N 3 9 or less 40 or less 570 or less 2150 MAX 1 Connect a pressure gauge to the pressure check port N 2 Turn the PTO switch O...

Page 38: ...3 Turn the air conditioner switch OFF 4 Retract the jib lock pin cylinder fully to stroke end 5 In this state set the engine speed to 2150 min 1 and check the pressure by the pressure gauge 2 9 Torque converter oil pressure NOTICE Do not increase the torque converter oil pressure beyond 2 7 MPa 27 5 kgf cm 2 39 2 psi upper limit Item Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi...

Page 39: ...er relief valve NOTICE Oil temperature 50 5 C 122 9 F Hydraulic oil TADANO Hydraulic Oil LL Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Relief value P 12 0 0 5 122 5 1740 70 Already the pressure is set by the valve manufacturer Adjustment is not necessary ...

Page 40: ...ef valve NOTICE Oil temperature 50 5 C 122 9 F Hydraulic oil TADANO Hydraulic Oil LL Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Relief value Q 12 0 0 5 122 5 1740 70 Already the pressure is set by the valve manufacturer Adjustment is not necessary ...

Page 41: ...e speed min 1 Check procedure MPa kgf cm 2 psi Reducing value R 10 0 0 5 100 5 1450 70 670 IDL 1 Connect a pressure gauge to the pressure check port R 2 Turn the PTO switch ON 3 Disconnect the self seal joint for C W cylinder extending side 4 Extend the cylinders fully by pushing the DOWN button on the C W mounting dismounting remote controller 5 In this state check the pressure by the pressure ga...

Page 42: ...lay on the AML display panel Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Jib tilt lowering S 11 8 0 5 120 5 1710 70 670 IDL 1 Turn the PTO switch ON 2 Disconnect the self seal joint for jib tilt cylinder jib lowering side 3 Push the jib tilt side of the boom elevating jib tilt selection switch 4 Move the elevating jib tilt lever at its full stroke on the jib lowering...

Page 43: ... 830 29 20 8 5 0 3 0 2 120 4 3 Safety valve Cracking pressure 850 8 7 123 Must be no leakage within pressure regulator operation range 229 Full opening pressure 950 20 9 7 0 2 138 3 Air low pressure switch total air low pressure warning Light on pressure 540 10 49 5 5 0 1 0 5 78 1 5 7 226 Light off pressure 540 59 49 5 5 0 6 0 5 78 8 5 7 Air pressure switch stop lamp Operating pressure 29 20 10 0 ...

Page 44: ... bleeding from the suction side tighten the plug again 3 Start the engine with air conditioner OFF and PTO OFF and run it at idle approximately 670 min 1 for 1 minute to bleed the circuit 4 Start the engine and run in the pump for 10 minutes at idle 1 2 Variable piston pump 1 Fill the hydraulic oil tank with the hydraulic oil If the suction section is disassembled due to repair or other reasons bl...

Page 45: ...O switch OFF and start the engine After idling the engine for 5 seconds turn the PTO switch ON and OFF repeatedly and quickly and check for any abnormal noise 6 If any abnormality is found bleed the hydraulic pump again 7 If there is no abnormal noise turn ON the PTO switch and idle the engine for 5 minutes with no load 8 During the operation check for any abnormal noise or heat of the hydraulic p...

Page 46: ...int of auxiliary winch hoisting down side NOTICE After assembly do not perform hoisting operation Hereafter hoisting up operation by the main and auxiliary winches is prohibited until bleeding of the winch brakes is completed 2 Perform hoisting down operation of each main and auxiliary winch using the corresponding air bleed plug of the winch brake Engine speed idling 670 min 1 Corresponding contr...

Page 47: ...bles go out tighten the air bleed plug while letting the fluid flow out 4 Bleed the wheel cylinders in the calipers of the axles in the steps same as above NOTICE The vehicle has four air bleed plugs for the 1st axle and two for the 2nd and 3rd axles 4 Hydraulic motor assy 4 1 Slewing motor NOTICE Do not apply any load to the motor before completing air bleeding Bleed the slewing motor by followin...

Page 48: ...or Before operating the air conditioner motor pour the hydraulic oil from the drain port until the oil flows out 5 Winch counterbalance valve main and auxiliary NOTICE Bleed the main and auxiliary winch circuits by following the procedures below The procedures are common to the both circuits 1 Engine speed idling 670 min 1 2 Lever operation Repeat the slow hoisting up and slow hoisting down operat...

Page 49: ... same steps by moving the slewing lever to the left slewing side 2 Elevating Pull out the connector CN100 of the AML vent solenoid valve Move the boom elevating lever fully to the boom lowering side Keep the above conditions for 30 seconds or more for bleeding Proceed on the same steps by moving the boom elevating lever to the boom raising side 3 Telescoping Pull out the connector CN100 of the AML...

Page 50: ...de Keep the above conditions for 30 seconds or more for bleeding Proceed on the same steps by moving the jib tilt lever to the jib raising side 8 Positive control While any of the crane operations described in section 7 is performed loosen the air bleed plug near the lower pump to bleed the positive control circuit You can bleed the circuit at the same time with pilot circuit bleeding ...

Page 51: ...nd move the winch lever fully to the end of its stroke in the direction corresponding to the plug 2 When there are no more bubbles in the oil that flows out tighten the plug while the oil continues to flow 10 Cylinder circuits Loosen the air bleed plug on the pilot check valve for each cylinder described below In this state repeat each cylinder operation to retract or extend until no more air bubb...

Page 52: ...r Bleeding Procedure 38 WY05 5000E 4 Boom pivot pin mounting dismounting cylinder 5 Elevating pivot pin inserting extracting cylinder 6 Outrigger mounting dismounting cylinder Front side Rear side 1 345 807 13000 ...

Page 53: ... 0 mm 0 12 0 02 0 in from the position where the switch is ON in the state that C pin cylinder is fully extended at 10 MPa 102 kgf cm 2 1450 psi loading 3 B pin lock detection switch left CNC5 switch right CNC6 For reference Dimension E 5 5 mm 0 22 in Move the switch closer to the target by 1 5 0 5 0 mm 0 06 0 02 0 in from the position where the switch is ON in the state that B pin cylinder is ful...

Page 54: ...witch CNRL and CNLU CNLC Boom section detection switch left center CNLL Boom section detection switch left lower CNLU Boom section detection switch left upper CNRC Boom section detection switch right center CNRL Boom section detection switch right lower CNRU Boom section detection switch right upper Make sure that the dimension X is 336 3 mm 13 2 0 1 in Make sure that the dimension Y is 68 2 mm 2 ...

Page 55: ... 36 9 ft lbf NOTICE Make sure that the orange LED lights up when the switch is activated 4 Jib lock pin retraction detection switch CN573 Adjust the switch position so that the dimension A becomes 30 5 1 0 mm 1 2 0 04 0 in with the switch in free position 1 Apply a thread locking agent ThreeBond 1401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 4 to 6...

Page 56: ...401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 19 to 20 N m 1 93 to 2 04 kgf m 14 0 to 14 8 ft lbf NOTICE Make sure that the green 2 orange LED lights up when the switch is activated 6 Aux winch drum rotation detection switch CN592 Follow the same procedure as that in main winch drum rotation detection switch CN591 2 343 728 70000 2 343 728 80000 Ap...

Page 57: ... nut tightening torque 19 to 20 N m 1 93 to 2 04 kgf m 14 0 to 14 8 ft lbf NOTICE Make sure that the green 1 orange LED lights up when the switch is activated 8 Control lever stand position detection switch left CN529 Set the clearance B to minimum and adjust switch position so that the dimension A becomes 1 5 0 5 0 mm 0 06 0 02 0 in 1 Apply a thread locking agent ThreeBond 1401 or the equivalent ...

Page 58: ...up when the switch is activated 10 Counterweight equipped detection switch left CN457 Adjust the switch position so that the dimension A becomes 4 5 0 0 5 mm 0 18 0 0 02 in 1 Apply a thread locking agent ThreeBond 1401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 19 to 20 N m 1 93 to 2 04 kgf m 14 0 to 14 8 ft lbf NOTICE Make sure that the orange LED ...

Page 59: ... controller maintaining the counterweight horizontally as possible 2 Adjusting the switch Install the proximity switches right left to the base plate slewing table side under the cab Connect CN1538 to the switch right and CN1539 to the switch left Loosen the switch right and manually move it to a detection position from a non detection position When OFF turns ON orange move it 1 mm 0 04 in further...

Page 60: ...e boom at around 70 1 Installing the front side detection support Install the front detection support so that the bolt comes the center of the slotted hole 2 Adjusting the front side detection support height Add a shim t 1 6 if needed so that the clearances between the proximity switches right left and front side detection support becomes 4 1 0 mm 0 16 0 04 0 in ...

Page 61: ...ption CN595 Adjust the roller assy position by the bolt Z so that the dimension A becomes 6 mm 0 24 in and lock the bolt Z with a nut Squeeze the roller assy of switch upward further by 1 5 mm 0 06 in after the switch s contact is shifted opened closed One turn of the bolt X makes the switch move upward or downward by 1 5 mm 0 06 in Then lock the bolt X with the nut Y NOTICE Make the head surface ...

Page 62: ...6 3 1 Adjust the vehicle height to the normal traveling state 1 Direct the boom to the front or rear 2 Press the suspension up down switch so that the dimension H becomes 178 4 mm 7 01 0 16 in When the switch is released the suspension becomes locked 2 Adjust the length of rod assy so that the support slit and lever hole B become aligned Rear left 2 347 907 32000 1 347 908 52000 ...

Page 63: ...below When the switch is turned ON the LED lights up in green A orange Suspension cylinder H mm Rear left Rear right Left switch CN404 Right switch CN405 Left switch CN406 Right switch CN407 Retracted 138 to 174 OFF ON ON OFF Normal traveling state 174 to 182 ON ON ON ON Extended 182 to 238 ON OFF OFF ON Applicable serial No FE5102 A ...

Page 64: ...ent lever Then fix by using the nut Nut tightening torque 19 to 20 N m 1 93 to 2 04 kgf m 14 0 to 14 8 ft lbf 3 Adjusting right switch CN405 Adjust the clearance M between the right switch detection face and lever 2 5 mm 0 1 in so that the green A orange LED of right switch becomes extinguished when the support slit and lever hole C are aligned by the counterclockwise turning of adjustment lever T...

Page 65: ...ent lever Then fix by using the nut Nut tightening torque 19 to 20 N m 1 93 to 2 04 kgf m 14 0 to 14 8 ft lbf 3 Adjusting right switch CN407 Adjust the clearance M between the right switch detection face and lever 2 5 mm 0 1 in so that the green A orange LED of right switch becomes extinguished when the support slit and lever hole C are aligned by the counterclockwise turning of adjustment lever T...

Page 66: ... is 63 3 mm 2 48 0 12 in If the dimension is not within allowance adjust it with the adjusting bolt 1 Apply a thread locking agent ThreeBond 1401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 40 to 50 N m 4 1 to 5 1 kgf m 29 5 to 36 9 ft lbf NOTICE Make sure that the orange LED lights up when the switch is activated 0 343 553 62000 1 343 821 50000 2 34...

Page 67: ...olt At first the bolt should be tightened Then the nut should be tightened 1 2 Lower part of boom head The bolt should be touched softly to the surface Y Then tighten the nut Apply a thread locking agent ThreeBond 1305 or the equivalent to the threaded section The dimension X should be 1 5 mm 0 06 in or less by choice of suitable spacers Apply a thread locking agent ThreeBond 1305 or the equivalen...

Page 68: ...sembling 2 Unsuitable phenomenon for example one side hitting shall be improved If you grind the contact surface machining allowance shall be 2 mm 0 08 in or less 3 Check the contact condition between stopper and stopper bolt in front stopper Allowable the gap between the bolt center and the rotation stopper plate center shall be 3 mm 0 12 in or less ...

Page 69: ...ide plate and the guide 2 The dimension B which is from the top surface of the lower slide plate to B pin center shall be 287 1 mm 11 30 0 04 in The plate position shall be adjusted by inserting the shims 3 The dimension C between the upper and lower slide plate shall be 164 0 5 mm 6 46 0 02 in The adjustment of the dimension shall be by inserting shims to the upper slide plate side 4 Apply a thre...

Page 70: ...o the outer box until the slide plates are covered with the outer box 2 Check no interference between the slide plates and the retainer in the outer box 3 Apply a thread locking agent ThreeBond 1401 or the equivalent to the bolt Lightly tighten the bolt and then loosen it 1 4 turns Table 1 Standard number of shims TELE 1 1 mm shim 2 TELE 2 1 mm shim 2 TELE 3 1 mm shim 2 TELE 4 1 mm shim 1 TELE 5 N...

Page 71: ... is lifted certainly 3 Misalignment between the center of the inner box and the center of the outer box shall be less than 1 0 mm 0 04 in or less Adjust the alignment to move the shim Reference When moving a 1 2 mm shim from the one side to another side the boom moves 1 7 mm 0 07 in 4 Apply a thread locking agent ThreeBond 1401 or the equivalent to the bolt Table 2 Standard number of shims one sid...

Page 72: ...r box 2 The clearance shall be as minimum clearance 3 Apply a thread locking agent ThreeBond 1401 or the equivalent to the bolt Lightly tighten the bolt and then loosen it 1 4 turns 4 Refer to Table 3 about the amount of shim Table 3 Standard number of shims each side TELE 1 0 6 mm shim 1 1 mm shim 1 TELE 2 0 6 mm shim 1 1 mm shim 2 TELE 3 0 6 mm shim 1 1 mm shim 1 TELE 4 0 6 mm shim 1 1 mm shim 1...

Page 73: ...action 2 Make sure the difference between right and left of the dimension G shall be 2 mm 0 08 in or less Measure the dimension G at the about 50 mm 2 0 in lower position from the retainer lower end 3 Refer to Table 4 about the amount of shim Table 4 Standard number of shims each side Number of side plate each side Between base and TELE 1 0 6 mm shim 1 1 mm shim 5 12 Between TELE 1 and TELE 2 0 6 ...

Page 74: ... Standard number of shims lateral direction Between base and TELE 1 4 mm shim 5 1 mm shim 2 4 mm shim 1 1 mm shim 3 Between TELE 1 and TELE 2 4 mm shim 4 1 mm shim 1 4 mm shim 1 1 mm shim 2 Between TELE 2 and TELE 3 4 mm shim 2 1 mm shim 3 4 mm shim 1 1 mm shim 3 Between TELE 3 and TELE 4 4 mm shim 3 1 mm shim 3 4 mm shim 1 1 mm shim 2 Between TELE 4 and TELE 5 4 mm shim 3 1 mm shim 3 1 mm shim 2 ...

Page 75: ... locking agent ThreeBond 1401 or the equivalent to the bolt Table 6 Standard number of shims per point Between base and TELE 1 1 mm shim 3 0 6 mm shim 2 Between TELE 1 and TELE 2 1 mm shim 3 0 6 mm shim 2 Between TELE 2 and TELE 3 1 mm shim 3 0 6 mm shim 2 Between TELE 3 and TELE 4 1 mm shim 3 Between TELE 4 and TELE 5 1 mm shim 3 0 6 mm shim 2 4 In the state that the slide plates above 2 contact ...

Page 76: ...ween the slide plate and the outer box shall be as minimum clearance 0 5 mm 0 2 in or less Telescopic section 1 to Telescopic section 4 Extend the inner box fully In that state adjust the shims so that the inner box is aligned to the center of the outer box The clearance between the slide plate and the outer box shall be as minimum clearance 0 5 mm 0 2 in or less Then tighten the fitting bolt Appl...

Page 77: ... on the rod of the cylinder extending slower at the edge of the rod cover Then measure the distance between the edge of the rod cover and the mark when the cylinder extending slower reaches its stroke end by further cylinder extending operation NOTICE If the remaining stroke is 30 mm 1 2 in or less adjustment is not necessary If the remaining stroke exceeds 30 mm 1 2 in tighten the choke bolt on t...

Page 78: ...ght regular adjustment 1 Connect the counterweight cylinder rod end and the slewing table with the pin Retract the cylinders with the counterweight The counterweight is raised Check the stroke difference between the right and left cylinders A retracting cylinder is assumed to reach its stroke end when the upper face of the counterweight is 7 mm 0 28 in before from the lower face of the slewing fra...

Page 79: ...e choke bolt on the cylinder telescoping faster until it seats Then turn it back with 30 increment and add a little turning to reduce the stroke difference between the right and left cylinders to 20 mm 0 8 in or less If the cylinder adjusted without the counterweight as described in 3 1 is faster tighten the choke bolt which has been adjusted without the counterweight if it is slower loosen the ch...

Page 80: ...d After bleeding air pour the brake fluid up to a required level and tighten the cap until it stops at the stopper At this time the position of tank body and cap is as shown in the figure below The stopper might be broken when the cap is tightened too much 1 3 Check after replacing brake hose After you replace the brake hoses and so on make sure that any contact does not occur between the hoses an...

Page 81: ...h the nut 2 Move the accelerator sensor lever so that it contacts stopper C Then adjust nut H until there is no pedal play NOTICE Be sure to check that the accelerator switch operates 3 When at Max position accelerator sensor lever in contact with stopper D place bolt E in contact with the lever on the underside of the pedal and lock in place with the nut 1 347 112 70000 ...

Page 82: ...hten the hub nut with the tightening torque of 640 30 N m 65 3 kgf m 472 22 ft bf Put the retightening torque for the hub nuts the torque of the latest tightening on the hub nut torque check record 5 Adding oil to the torque converter and transmission NOTICE When checking the oil level turn PTO OFF and turn the air conditioner OFF Check at an oil temperature of 50 C 122 F once the oil level has st...

Page 83: ...justment 2 Measure the distances between the 1st axle and the 2nd axle as well as between the 1st axle and the 3rd axle right and left For dimensions refer to the figure below Difference between the dimensions on the right and left shall be within 10 mm 0 4 in 3 If there is a dimensional deviation adjust the length of the adjusting type torque rod of each axle Adjustment range 600 10 m 23 6 0 4 in...

Page 84: ... slip Side slip IN or OUT 3 mm m or less each axle If not satisfied adjust with the tie rod Axle slip L or R 4 mm m or less 2 and 3 axle If not satisfied adjust with the drag link Adjustment range 1080 15 mm 42 5 0 6 in 4 When adjusting the drag link adjust the steering lever with the dimensions as shown below 5 The length of the drag link changes 3 mm 0 12 in by one turn 6 If the length of the ti...

Page 85: ...with the 6 wheel steering to bleed air out from the cylinder 3 On the 1st axle perform the 2 wheel steering operation to adjust the steering angle in the direction A to 26 0 0 1 0 at stopper bolt A and in direction B to 26 0 0 1 0 at with the stopper bolt B 4 On the 3rd axle perform the rear steering operation to adjust the steering angle to 16 0 0 1 0 5 On the 2nd axle with the stopper bolt of th...

Page 86: ...er operation configuration After the suspension is extended to its stroke end lock the suspension 2 Extend the outrigger jacks to make the 6 wheels clear of the ground 3 After setting the outrigger extension retraction selector to the neutral press the suspension free switch NOTICE Before proceeding to the next step wait at least 20 seconds after you press the switch 4 Loosen the pipes 2 places co...

Page 87: ...f its stroke Use air pressure to move it to the end of its extension stroke Then adjust the position of end connect the chamber and brake lever 2 After connecting check that the clearance between the pad and disc plate becomes approximately 0 2 mm 0 008 in per side Then lock in place with the nut Operating stroke of the brake lever reference 17 to 24 mm 0 67 to 0 95 in 3 349 227 40000 ...

Page 88: ...switch Outriggers do not operate Operate the outrigger extend retract selector switch Icon flashes on the AML display Press all outrigger control switch Outriggers do not operate Main switch ON PTO ON Shift lever N position Outrigger extension width 8 2 m 26 9 ft Boom Over side Slewing angle 90 or 270 Operate the outrigger extend retract selector switch Main switch ON PTO ON Shift lever N position...

Page 89: ... NOTICE Extend the outrigger fully and set up the machine horizontally 1 Select the on rubber for outrigger set status on the AML when the counterweight is dismounted 2 The boom is retracted fully and is on the over side slewing angle 90 or 270 3 The boom lowering operation must be stopped at the load radius 6 1 m 20 0 ft automatically 4 The boom raising must be available 5 Outrigger emergency set...

Page 90: ...ounds at 100 when main switch is ON and PTO switch is ON Intermittent low tone sound occurs at 90 and above Two blocking warning Buzzer 4 CN817 2300 Hz Continuous high low tones Buzzer sounds when the two blocking detection switch contact of either the main or auxiliary winch is turned OFF by winch hoisting up operation Outrigger operation switch detection Buzzer 1 CN815 CN816 2300 Hz Intermittent...

Page 91: ...nt connector CN1212 to telescoping cylinder Check that warning code W0105 is not displayed on AML display Press the button of user on the AML display with above crane condition Select the maintenance telescoping Icon on AML display Operate telescoping cylinder to extension side move telescoping cylinder to the TELE 1 boom section Main switch ON PTO ON Disconnect the joint connector front CN1528 re...

Page 92: ...ust the slide plate with the bolts X so that the slide plate is 2 mm 0 08 in away from the upper surface of outer outrigger box bottom plate 3 If the slide plate is 2 mm 0 08 in or more away make sure that the bolts X do not protrude beyond the plane Z 4 Tighten the bolt Y slightly to fix the slide plate Then tighten the nut of the bolt Y hard 5 Tighten the nuts of the bolts X 5 346 116 66000 ...

Page 93: ...d to 1 000 min 1 or higher using the idling adjuster knob The pilot lamp illuminates OFF Not activated 2 Return the engine speed to idling and move the shift lever from N to D Adjust the engine speed to 1 000 min 1 or higher using the idling adjuster knob ON Activated 3 Depress the accelerator pedal OFF 4 Release the accelerator pedal ON 5 Adjust the engine speed to 1 000 min 1 or lower using the ...

Page 94: ...t downshift display D 3 Gradually reduce speed Check that transmission downshifts to 1st gear when the speed is 7 km h display 2 Meter speed Combination meter display 1 8 km h D 2 10 km h D 3 7 km h 2 4 Maximum allowable speed Units km h mph Combination meter display High position Low position 1 8 9 5 5 2 5 1 6 2 18 5 11 6 5 1 3 2 D 18 5 22 5 10 1 6 3 R 6 2 3 9 2 5 1 6 NOTICE Engine speed 2600 min...

Page 95: ...er supply Turn the emergency accelerator switch ON Depressing the accelerator pedal slightly make sure that the engine speed is 2860 40 min 1 6 3 Emergency engine stop Make sure that the engine stops when the emergency engine stop switch is pulled Change the steering mode switch to 6 wheel crab or rear steering Turn the steering wheel and check the steering Check that the indicator in the right bo...

Page 96: ...2700 min 1 Speed warning 2300 Hz Continuous and intermittent sounds It is not necessary to check because you cannot attach a step up gear Reference During accelerating Speedometer reading 16 km h Intermittent sound 20 km h Continuous sound During decelerating Speedometer reading 17 km h Intermittent sound 15 km h OFF Torque converter low pressure 2300 Hz Continuous beep Buzzer sounds if the torque...

Page 97: ...ve to a flat ground and then operate the suspension free switch again Operate in the following order 1 Down operation Flashes 20 seconds or less slowly 2 Up operation Flashes slowly 3 Down operation Lights up 20 seconds or over Locked after vehicle height is lowered Locked after vehicle height is raised Locked after suspension is fully retracted Vehicle height is raised or lowered while the switch...

Page 98: ...ights up Locked PTO OFF Lights up Locked Check that the suspension does not fall even if the suspension up down switch or suspension free switch is pressed while the boom is in an over side Turn ON the PTO switch After slewing the boom to the over front stow the jacks and slides Flashes slowly Locked Turn OFF the PTO switch Keep pressing the suspension free switch for 1 second or more Flashes slow...

Page 99: ...itch Leveling is impossible when the road surface is not flat In this case adjust to the lock state by operating the suspension up down switch move to a flat ground and then operate the suspension free switch again Press the suspension up down switch for a moment to put into a suspension lock state Flashes slowly Locked Suspension emergency free switch Shift the suspension emergency free switch to...

Page 100: ...eck that the suspension does not fall even if the suspension up down switch or suspension free switch is pressed while the boom is in an over side Turn ON the PTO switch After slewing the boom to the over front stow the jacks and slides Flashes slowly Locked Keep pressing the suspension free switch for 1 second or more Flashes fast Suspension emergency free Perform boom extending operation Flashes...

Page 101: ... to start engine Flashes slowly Locked Keep pressing the suspension free switch for 1 second or more Flashes fast Suspension emergency free Suspension emergency free switch Shift the suspension emergency free switch to Normal Flashes slowly Locked Keep pressing the suspension free switch for 1 second or more Flashes slowly during leveling Goes out after leveling Free after leveling Normal travelin...

Page 102: ...r sounds Steered a little 2 wheel Lit Continuous beep 4 Select the 6 wheel steering mode and check that the warning buzzer does not sound Steered a little 6 wheel Lit No beep 5 Set the rear wheel straight off straight ahead wheel indicator goes out and select the 2 wheel steering mode Straight ahead 2 wheel Not lit No beep 6 Select the crab steering mode and steer until the off straight ahead whee...

Page 103: ...circuit Clean 2 points 22 11 22 10 Winch high speed selection solenoid valve circuit Clean 1 point 22 12 Telescoping extension circuit Clean 1 point 22 13 Telescoping two pressure selection circuit Clean 1 point 22 14 Steering mode selection solenoid valve circuit Clean 1 point 22 15 Slewing lock circuit Clean 1 point 22 16 Main winch high speed selection circuit Clean 1 point 22 17 Aux winch high...

Page 104: ...n and Thread Size Table Note means that more than one spec No are applicable Unit mm 1 mm 0 039 inch Applicable spec No GR 1600 2 GR 1600 3 GR 1450E 2 GR 1450E 3 Part Name Diameter Thread size Elevating cylinder Rod end pin Ø150 Non manual Base pin Ø140 M30 3 5 Boom base pin Ø140 Non manual ...

Page 105: ...13 4 4 Electric circuit slewing table left 14 4 5 Electric circuit for separated transport 15 4 6 Electric circuit boom fix jib 16 4 7 Electric circuit boom power tilt jib 17 4 8 Electric circuit boom ESP 18 4 9 Electric circuit AML fix jib 19 4 10 Electric circuit AML power tilt jib 20 4 11 Electric circuit AML override 21 4 12 Electric circuit boom two blocking 22 4 13 Electric circuit jib singl...

Page 106: ...tion 43 4 Slewing 43 5 Return 44 6 Drain 45 7 Gauge 46 8 Pilot 47 9 Steering 48 10 Air conditioner 48 11 Operation assy operation valve 49 12 Pressure switch 49 13 Jib 50 14 Jib power tilt jib main body 52 15 Self removable C W 53 16 Removable boom system option 55 17 Cab tilt 56 Z 8 Hydraulic Parts Location Diagram Lower 57 1 Suction 57 2 Steering 58 3 Suspension 59 4 Outrigger H type 60 5 Outrig...

Page 107: ...Power tilt jib 82 2 Two blocking indicator assy boom 83 3 Two blocking indicator assy single top and jib 84 Z 13 Electric Parts Location Diagram ICF SCT 85 1 ICF 85 2 SCT 86 Z 14 Electric Parts Location Diagram Lower 87 1 H type outrigger 87 1 1 Relay and fuse box under the battery 88 1 2 Lower electric relay assy 89 2 Engine 90 3 Outrigger front 91 4 Outrigger rear 92 Z 15 Harness Upper Crane 93 ...

Page 108: ...ometer Aviation Obstruction Light Option 127 1 Structure 127 1 1 Searchlight 127 1 2 Anemometer aviation obstruction light cab boom 128 1 3 Anemometer aviation obstruction light jib 129 1 4 Anemometer cab 130 1 5 Anemometer boom 131 1 6 Aviation obstruction light boom 132 1 7 Parts assy cord reel 133 2 Electric circuit 134 2 1 Composition of the electric circuit diagram 134 2 2 Electric circuit bo...

Page 109: ...9 4 2 Harness searchlight 150 4 3 Harness slewing table right option 151 4 4 Harness common 152 4 5 Harness jib1 anemometer aviation obstruction light 153 4 5 1 FE5027 153 4 5 2 FE5028 154 4 6 Harness jib2 anemometer aviation obstruction light 155 4 6 1 FE5027 155 4 6 2 FE5028 156 4 7 Harness anemometer cab 157 4 8 Harness boom head anemometer aviation obstruction light 158 4 8 1 FE5027 158 4 8 2 ...

Page 110: ...oint B 6 Z 8 6 28 Hydraulic oil temperature switch 50 C 122 F CN555 CN1017 F 4 Z 8 7 29 Hydraulic oil temperature switch 85 C 185 F CN556 CN1018 30 Check valve for main pressure E 6 Z 7 7 31 Pressure sensor for main pressure CN581 D 6 32 1 Check valve G 3 Z 8 7 32 2 33 Oil cooler F 3 34 Filter for remote control valve pedal I 7 Z 7 11 35 Solenoid valve F 2 Z 8 4 Solenoid valve for outrigger mounti...

Page 111: ...G 16 Z 7 1 Solenoid valve for main winch high speed selection SL260 Solenoid valve for aux winch high speed selection SL261 91 1 Relief valve for C W cylinder and cab tilt cylinder C 11 Z 7 15 91 2 Relief valve for B C pin D 12 Z 7 5 92 1 Orifice for C W cylinder right B 11 Z 7 15 92 2 Orifice for C W cylinder left B 10 93 1 Solenoid valve for positive control SL96 H 6 Z 8 6 93 2 Solenoid valve fo...

Page 112: ...1 93 1 05 11 07 06 08 04 01 02 03 14 4 14 3 16 3 17 3 17 4 16 4 15 4 15 3 14 2 14 1 16 1 17 1 17 2 16 2 15 2 15 1 130 2 129 2 128 2 127 2 29 32 1 10 32 2 33 28 12 130 1 128 1 129 1 127 1 13 20 2 64 2 64 1 40 7 40 6 20 1 35 27 58 22 18 19 76 83 1 83 2 22 14 23 26 09 21 4 44 4 21 2 44 2 21 3 44 3 44 1 21 1 25 5 25 3 25 6 25 4 63 7 120 1 24 1 24 2 77 2 85 1 85 2 77 1 25 1 25 2 123 2 124 2 30 31 97 52...

Page 113: ... oil temp Oil cooler G1 G1 Line filter 20μ G1 G3 8 G1 1 4 M14 1 5 G1 G3 4 G1 1 4 G3 8 G1 1 4 G1 Charging pump Pressure sensor Drain 258 Transmission case Lubrication relief valve Accumulator SL45 F3 260 261 259 SL43 F1 SL44 SL42 F2 SL49 Lock up SL41 P T O R Air cylinder 2 4 wheel drive shift Air cylinder High low shift Rc1 4 Rc1 4 F3 F2 R High Low F1 Torque converter inlet relief valve Main pressu...

Page 114: ... shift energized low Air solenoid valve exhaust brake energized exhaust brake actuated Air solenoid valve 2 4 wheel drive shift not energized 2 wheel drive To engine applicable to GR 1600 2 00101 00102 Unload valve applicable to GR 1600 3 00101 00102 225 Inflator 226 CN410 Air low pressure switch total air low pressure warning contact close low pressure Light on pressure 540 10 49 kPa 5 5 0 1 0 5 ...

Page 115: ...rcuit crane main Z 5 3 1 Electric circuit carrier main Z 4 4 5 Electric circuit for separated transport Z 4 4 8 Electric circuit boom ESP CN895 CN1526 CN1527 CN1212 CN509 CN657 CN693 CN699 CN899 CN1071 CN1750 CN888 CN993 CN1595 CN961 CN893 CN894 CN1193 CN1331 CN1332 CN1333 CN558 R48 CN1562 CN897 CN1779 CN1495 CN1635 CN1728 CN859 CN887 The electric circuit diagram of this machine is composed of Z 4...

Page 116: ...e to the shield line S AA Example S016 AA S016 AB 6 Joint label Same with Wire label J AA Example J001AA J035AA J106AA J1000AA JC01AA JS016AA JB01AA Wire 1 Indication of wire size Indicate the wire size other than the indication at NOTICE 2 Indication of wire type Indicate the wire type other than the indication at NOTICE 3 Indication of wire color Indicate the wire color as seen below and its com...

Page 117: ...witch power tilt jib only D 13 CN539 Jib tilt lowering detection switch power tilt jib only CN540 Slewing right detection switch C 12 CN541 Slewing left detection switch CN546 Main winch hoisting down detection switch A 12 CN547 Aux winch hoisting down detection switch B 12 CN558 To circuit AML override E 14 Z 4 4 1 1 Z 15 1 2 To circuit crane main Z 4 4 11 Z 15 7 CN559 Main winch high speed selec...

Page 118: ... 4 4 5 Z 15 6 CN1538 Counterweight boom mounting dismounting position detection switch right Z 4 4 3 Z 15 2 CN1539 Counterweight boom mounting dismounting position detection switch left CN1556 To circuit slewing table right F 1 Z 4 4 1 1 Z 15 1 2 To circuit crane main Z 4 4 3 Z 15 2 CN1557 C W mounting dismounting remote controller G 13 Z 4 4 4 Z 15 3 2 CN1559 Counterweight boom mounting dismounti...

Page 119: ...warning lamp relay P 9 R88 Air conditioner compressor block relay 2 D 4 R89 Cab tilt alarm buzzer disable relay B 12 R90 Cab tilt stowed detection relay B 13 JC01 Junction connector C 18 JC02 C 11 JC03 P 10 JC04 P 14 JC05 E 7 JC06 E 5 JC07 P 4 JC101 D 19 JC104 O 17 JC150 B 7 Z 4 4 2 Z 15 10 2 JC151 E 1 JC152 E 5 JC153 J 2 JC154 J 5 JC155 K 5 JC160 B 5 Z 4 4 1 1 Z 15 1 2 JC161 D 5 JC162 B 10 JC163 ...

Page 120: ...6 P3 7 2 2 7 P2A P2 8 2 2 8 P1A P1 9 2 2 9 Di25 10 2 2 10 Di26 11 2 2 11 Di27 12 2 2 12 Di28 13 2 2 13 FG 14 2 2 14 PSRC 15 2 2 15 P2B 16 2 2 16 P1B 1 3 1 5V 2 3 2 Ai1 3 3 3 AI2 4 3 4 AI3 5 3 5 AGND 6 3 6 SHIELD 7 3 7 5V 8 3 8 Ai4 9 3 9 Ai5 10 3 10 Ai6 11 3 11 AGND 12 3 12 SHIELD 4 1 FG 4 2 5V 4 3 Ai7 4 4 Ai8 4 5 AGND 4 6 SHIELD 1 5 1 Do1 2 5 2 Do2 3 5 3 Do3 4 5 4 Do4 5 5 5 Do5 6 5 6 Do6 7 5 7 Do7...

Page 121: ...AA R W 1150AA R W 1150AC R W 1150AC R W 1150AB R W 1150AB R W 1138AA LG Y 1139AA BR Y 1165AC L O B02AB B B02AB B 1160AD SB 1160AD SB 1160AC SB 1160AC SB 1160AB SB 1160AB SB 1160AA SB 1160AA SB B02AF B B02AF B 1164AF LG Y 1164AF LG Y 1164AG LG Y 1164AG LG Y 1164AH LG Y 1164AH LG Y 1164AJ LG Y 1164AJ LG Y B02AG B B02AG B B02AM B B02AM B B02AN B B02AN B B02AP B B02AR B B02AT B 1146AA L W 1146AA L W 1...

Page 122: ...N928 W 24V R Red Y Yellow G Green B GND CN1015 AML external indicator option CN929 CN927 1 2 3 4 1 2 3 4 CN890 CN828A External indicator lamp yellow 90 CN829A External indicator lamp red 100 CN828B CN829B CN852A Working lamp slewing table right 70W CN852B E001B S08AA B S08 011 W S08 011 W S08 010 R S08 010 R S08 012 B S08 012 B 130AA L Y 130AA L Y 786AA LG R 786AA LG R 781AA G R 781AA G R 787AA LG...

Page 123: ...mount cylinder retracting switch Boom pivot pin mount dismount cylinder extending switch Boom pivot pin mount dismount cylinder selection switch right Boom pivot pin mount dismount cylinder selection switch left Slewing brake ON signal C W lowering cylinder extending operation switch C W lifting up cylinder retracting operation switch C W selection switch right C W selection switch left ESP telesc...

Page 124: ...5mm2 B G R 4 3 2 1 W CN1527 B B01AN C01 004 C01 003 G O 331AA LG Y 470AA C01 002 LG Y 470AB BR W 279AA Over unwinding detection switch aux b contact normal close open over unwinding option CN596 1 1 3 3 2 2 CN592 1 3 3 1 Br L B Output C01 001 2 2 To circuit slewing table left Drum rotation detection switch aux winch contact close drum rotating 3 2 1 B W R LG Y 470AA BR W 279AA CN596 1 3 2 ...

Page 125: ...01 013 Y S01 015 R S01 015 R S01 014 W S01 014 W B 1 SB 1 R 1 G 1 Y 1 B 2 GR 2 R 2 G 2 Y 2 BR 2 L 2 output SHIELD SHIELD Cord reel Working lamp boom 70W CN853B CN853A E001A M6_1 25 2_Water proof E001B M6_1 25 2_Water proof 1 2 1 2 1 2 1 2 1 2 Jib retraction solenoid valve CN223 SL223 1 2 Jib extension solenoid valve CN222 SL222 1 2 Jib lock pin retraction solenoid valve CN193 SL193 1 2 Jib lock pi...

Page 126: ...1 To circuit AML power tilt jib 3 5 2 4 1 CN576 Telescoping cylinder stroke detector SHIELD2A SHIELD2B B 1 2 R 3 W 4 5 6 1 B 2 R 3 W 4 5 6 E003 M6_1 25 2_Water proof 1 2 1 2 1 2 CN363 Elevating pivot pin extracting solenoid valve SL363 1 2 CN364 Elevating pivot pin inserting solenoid valve SL364 1 2 1 2 1 2 3 4 5 1 2 3 4 5 CN1574 Boom angle detector 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8...

Page 127: ...ch left A B C D E F G H J K L M N P R S T U V W X Y Z a b c B L Br B L Br B L Br B L Br B L Br B L Br output 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 3 1 2 C pin unlock detection switch 1 contact close unlock CNC3 3 1 2 B pin lock detection switch left contact close lock CNC5 3 1 2 B pin lock detection switch right contact close lock CNC6 3 1 2 B pin unlock detection switch left contact close unlock CNC7 3 1...

Page 128: ...ector To circuit boom fix jib CN3 CN4 Pressure sender main pressure 1 3 1 5V 2 3 2 Ai1 3 3 3 AI2 4 3 4 AI3 5 3 5 AGND 6 3 6 SHIELD 7 3 7 5V 8 3 8 Ai4 9 3 9 Ai5 10 3 10 Ai6 11 3 11 AGND 12 3 12 SHIELD 1 4 1 FG 2 4 2 5V 3 4 3 Ai7 4 4 4 Ai8 5 4 5 AGND 6 4 6 SHIELD 1 2 3 4 5 6 7 8 9 10 11 12 CN653 1 2 3 4 5 6 CN654 Telescoping cylinder stroke Boom retracting operation pilot pressure input Boom extendi...

Page 129: ...D MBSRC power supply STM D RXP STM D DOSRC power supply STM D TXP SHIELD STM D power supply STM D output power supply SHIELD STM D RXP STM D TXP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN888 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN887 5 2 3 4 1 6 CN897 To circuit crane main 1 2 3 4 5 6 7 8 CN961 1 2 3 4 5 6 7 8 SHIELD39A SHIELD39B C01 001 B 1 C01 002 SB 1 C01 003 R 1 G 1 C01 0...

Page 130: ...tic return to PTO ON position To circuit slewing table left AML override input AML vent SOL PTO signal To circuit carrier main To circuit crane main To circuit crane main PTO power supply Emergency power supply PTO linked power supply emergency AML override 4 B 2 3 B 1b 1 1a B B 1 4 2 5 3 CN1104 PTO switch 1 4 2 5 3 2 1 CN558 1 2 CN509 2 1 3 CN1526 3 1 4 2 R48 335AB V 335AA V 335AA V 255AA R G 255...

Page 131: ... 2 1 Two blocking detection switch boom right contact open two blocking CN862 2 1 CN1094 Two blocking detection switch boom left 1 2 3 1 2 3 CN901 CN901 To circuit jib single top two blocking Connector CN901 5 2 3 4 1 6 CN859 To circuit boom fix jib To circuit boom power tilt jib 1 2 3 1 2 3 1 25 819AA Y 1 25 839AA R 1 25 839AA R C07 019 B C07 018 W 1 25 B60AA Ground B 1 25 816AA LG B When operati...

Page 132: ...9 B C06 019 B C06 018 W C06 018 W C09 019 B C09 019 B C09 018 W C09 018 W When operating Jib2 connect this connector When operating Jib2 connect this connector When operating Jib1 connect this connector To circuit jib single top two blocking When operating single top connect this connector Insert jib1 not used Insert jib2 not used 1 2 3 CN901A To circuit boom two blocking 1 2 3 CN901B 1 2 3 1 2 3 ...

Page 133: ... Electric circuit crane main Z 5 3 1 Electric circuit carrier main Z 5 3 4 Electric circuit ICF Z 5 3 5 Electric circuit SCT Z 5 3 3 Electric circuit accelerator CN1072 CN1070 CN895 CN1505 CN1503 CN1504 CN509 CN657 CN693 CN699 CN899 CN1071 Z 18 2 2 4 Electric circuit searchlight RA2 The electric circuit diagram of this machine is composed of Z 4 Upper Crane Z 5 Upper Carrier and Z 6 Lower mainly T...

Page 134: ...ndow motor P 4 Z 5 3 1 Z 16 1 2 CN837 Condenser C2 washer motor B 9 CN849 Washer motor roof CN850 Washer motor front B 10 CN868 Fuse box 3 P 13 CN869 O 13 CN870 Fuse box 2 O 12 CN871 CN872 P 12 CN873 CN875 Fuse box 1 O 13 CN876 O 12 CN877 P 13 CN878 P 12 CN880 Center joint N 19 CN881 CN882 P 19 CN883 CN884 N 19 CN885 O 19 CN895 To circuit slewing table right H 2 CN899 To circuit crane main M 16 CN...

Page 135: ...1 5A 2 5A 3 15A 4 10A 6 15A 7 10A 5 1 10A 2 10A 3 10A 4 15A 5 15A 1 2 3 4 6 7 5 1 2 3 4 5 1 5A 2 5A 3 15A 4 10A 6 15A 7 10A 5 1 10A 2 10A 3 10A 4 15A 5 15A 1 2 3 4 6 7 5 1 2 3 4 5 5 7 6 4 3 2 1 CN877 5 4 3 2 1 CN878 5 7 6 4 3 2 1 CN872 5 4 3 2 1 CN873 1 2 3 4 5 6 CN557 23 24 25 26 27 28 29 30 31 32 33 JC111 JC111 3 BLUE 1 2 3 4 5 6 7 8 9 10 11 JC111 JC111 1 BLUE 12 13 14 15 16 17 18 19 20 21 22 JC...

Page 136: ...e jack 1 2 3 4 5 6 7 8 9 10 11 JC17 JC17 1 2 1 CN513 Transmission selection switch shift lever lamp 1 2 3 4 5 6 7 8 9 10 11 JC211 12 13 14 15 16 17 18 19 20 21 22 JC17 JC17 2 1 2 3 4 5 6 7 1 2 1 2 3 CN1596 Emergency suspension free switch contact 3 to 1 close emergency suspension free operation 1 2 3 5 3 7 1 6 4 8 2 Suspension up down switch contact 3 to 1 close suspension down CN478 3 1 7 4 2 8 5...

Page 137: ...2 input 7 CN8 7 AGND Spare5 GND 15 CN8 15 SLD Spare5 GND 4 CN8 4 AVCC Spare5 5V 12 CN8 12 Ai4 Spare5 input 8 CN8 8 AGND Spare5 GND 16 CN8 16 SLD Spare5 GND 1 9 5 13 2 10 6 14 3 11 7 15 4 12 8 16 CN627 CN8 AMP040mk II Accelerator sensor 1 Accelerator sensor 2 Idle UP Accelerator OFF Accelerator ON IGN power supply Idle DOWN GND SLOW FAST 1 2 3 1 1 2 SHIELD20 SHIELD22 4 2 6 1 3 5 SHIELD21 2 1 CN548 ...

Page 138: ...KEUP_GND 10 C 10 E_DGND 11 C 11 MAIN_CANL 12 C 12 SUB_CANH 13 C 13 CHK_FG 14 C 14 MAIN_GND 15 C 15 MAIN_GND 16 C 16 E_LINE 17 C 17 RTC INT 1 2 3 4 5 6 CN1067 For maintenance terminal Dr T CN1065 ICF CN1066 1 2 3 4 5 6 7 8 CN1070 To circuit carrier main 006AC O 832AA L G 006AA O 006AA O 016AC Y L 830AA L R 831AA L W 006AB O 825AA W Y 825AA W Y 821AA W B B51AE B 824AA B W 824AA B W 823AA W G 823AA W...

Page 139: ...5 1 24 NC 4 1 25 NC 3 1 26 NC 2 1 27 NC 1 1 28 NC 16 1 29 CS1 15 1 30 NC 14 1 31 NC 13 1 32 NC 12 1 33 NC 11 1 34 NC 10 1 35 NC 9 1 36 NC 1 2 1 ANT_GPS 1 3 1 ANT_TXD CN1068 CN1072 006AC O 016AC Y L B51AH B 821AA W B B51AF B 006AC O 016AC Y L B51AF B B51AG B 822AA W R 821AA W B 822AA W R 826AA W L 826AA W L 12 5 7 6 8 9 19 16 20 10 18 14 1 11 13 15 17 3 2 4 8 12 10 11 9 4 6 7 5 2 3 1 Satellite comm...

Page 140: ...per Crane Z 5 Upper Carrier and Z 6 Lower mainly The electric circuit lower is shown by following block diagram CN1600 Z 6 3 4 Eletric circuit rear steering CN788 CN789 CN1528 CN1529 CN790 CN791 CN1500 CN1501 Z 6 3 6 Eletric circuit O R rear Z 6 3 3 Eletric circuit engine without DPF Z 6 3 1 Eletric circuit lower main Z 6 3 2 Eletric circuit lower air Z 6 3 5 Eletric circuit O R front IWZ03 7200E0...

Page 141: ...ower CN4 A 2 CN605 MDT lower CN5 G 2 CN606 MDT lower CN6 B 2 CN608 MDT lower CN7 L 2 CN609 MDT lower CN8 K 2 CN610 MDT lower CN9 H 2 CN611 MDT lower CN10 I 2 CN612 MDT lower CN11 J 2 CN619 For MDT maintenance G 2 CN685 Engine ECU B 13 Z 6 3 3 Z 17 3 CN686 C 13 CN687 E 13 CN688 F 13 CN689 G 13 CN690 Q ADJ Tier3 only A 10 CN691 MUT3 H 13 CN692 STM E D 17 Z 6 3 1 Z 17 1 2 CN701 Head lamp LH Z 6 3 5 Z...

Page 142: ...o circuit rear steering E 5 Z 6 3 1 Z 17 1 2 To circuit lower main Z 6 3 4 Z 17 4 CN1625 Diode PTO 3 0A J 15 Z 6 3 1 Z 17 1 2 CN1703 Working lamp FR N 22 CN1704 CN1705 Working lamp FL CN1706 CN1707 Working lamp RL N 23 CN1708 CN1709 Working lamp RR CN1710 CN1720 Return filter clogging detection switch GND A 3 RA7 Oil cooler relay P 10 RA8 Clearance lamp relay P 9 RA9 Battery power supply keeping r...

Page 143: ... 1 5 2 RC5 2 1 4 6 5 3 CN041 4 3 2 1 CN610 3 1 6 5 4 19 18 17 16 20 13 12 11 10 2 15 14 9 8 7 CN734 6 3 4 1 5 2 CN1050 1 2 3 1 4 2 CN758 12 GND CN3 12 11 Tr4 CN3 11 10 Tr3 CN3 10 9 Tr2 CN3 9 8 Tr1 CN3 8 7 CHG CN3 7 6 CHK CN3 6 5 GND CN3 5 4 RDX2 CN3 4 3 TDX2 CN3 3 2 RDX1 CN3 2 1 TDX1 CN3 1 18 GND CN7 18 1 RPOW15 CN7 1 2 RPOW16 CN7 2 17 RY56 CN7 17 16 RY55 CN7 16 15 RY54 CN7 15 14 RY53 CN7 14 13 RY...

Page 144: ... brake fluid detection switch contact close less fluid 2 1 CN745 Air dryer heater 2 1 CN051 Air solenoid valve 2 4 wheel drive shift not energized 2 wheel drive SL51 2 1 CN052 Air solenoid valve high low shift energized low SL52 2 1 CN568 Air pressure switch stop lamp contact close depressing brake pedal 3 2 1 CN428 Fuel sensor contact close little quantity 1 2 CN411 Air pressure detection switch ...

Page 145: ... 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 E001 E007 1 2 3 4 5 6 7 8 9 10 11 JC03 1 BLUE 12 13 14 15 16 17 18 19 20 21 22 JC03 2 BLUE 23 24 25 26 27 28 29 30 31 32 33 JC03 3 BLUE 601AB W Y 647AA B W 669AF G R 1 25 670AA Y R 1 25 601AC W Y B01AD B 1 25 092AC R Y 670AF Y R 1 25 609AA B Y 092AB R Y 669AE G R 1 25 601AA W Y 092AA R Y 609AB B Y 609AC B Y 647AB B W 669AD G R 1 25 67...

Page 146: ...E05a NOTICE 1 If not specified wire type is AVS and wire size is 0 5mm2 Straight ahead detection GND output 1 2 3 3 1 2 CN408 Straight ahead detection switch contact close straight ahead 1 2 3 4 5 6 CN1600 To circuit lower main S61 143 W S61 143 W S61 142 R S61 142 R S61 146 B S61 146 B Sensor power supply ...

Page 147: ... 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 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 26 27 28 29 30 31 32 CN1528 To circuit lower main JOINT1 0 85 009AA L R 0 85 009AA L R B10AF B 1 25 145AB BR W 1 25 145AB BR W B10AC B 1 25 146AB BR B 1 25 146AB BR B 0 85 013AA L B 0 85 013AA L B 0 85 142AB BR W 0 85 B10AE B S27 070 B 110AA R W 111AA R B 112AA R L 113AA R G ...

Page 148: ...ck buzzer 3 1 2 CN717A 3 1 2 CN721B CN721A Backup lamp CN719B 2 1 3 CN718 Rear combination lamp L 1 CN723 License lamp12W option 2 1 3 CN720 Rear combination lamp R 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 26 27 28 29 30 31 32 CN1529 To circuit lower main 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 26 27 28 29 30 31 32 JOINT1 S29 AA B 106AA Y W 107AA ...

Page 149: ...m Upper WZ07 3712E Z 7 Hydraulic Parts Location Diagram Upper 1 Winch Z 7 Z 7 40 IWZ07 3710E01 6 343 460 51000 80 1 A 22 16 B 70 90 69 Detail B 22 10 64 5 99 2 101 1 100 2 100 1 101 2 Detail A 80 2 103 1 102 1 98 2 SL261 SL260 FRONT 22 17 Detail C C ...

Page 150: ...2 342 115 11000 Hydraulic Parts Location Diagram Upper WZ07 3712E 2 Telescoping Z 7 Z 7 41 IWZ07 3710E02 59 4 116 115 59 3 75 114 Detail 114 124 8 112 1 113 112 2 74 2 SOLV4 SOLV5 FRONT ...

Page 151: ...60 52000 Hydraulic Parts Location Diagram Upper WZ07 3712E Z 7 Z 7 42 IWZ07 3710E03 1 343 460 40000 SL235 22 12 A 88 1 108 1 110 108 2 109 88 2 88 3 78 123 8 101 3 100 3 124 7 123 7 100 4 101 4 View A 79 FRONT ...

Page 152: ...Hydraulic Parts Location Diagram Upper WZ07 3712E 3 Elevation Z 7 Z 7 43 4 343 636 61000 3 343 460 53500 IWZ07 3710E04 IWZ07 3710E05a 4 Slewing 71 74 1 72 84 FRONT FRONT 53 54 55 SL121 SL120 SL162 SL161 B A BM AM P EF ...

Page 153: ...raulic Parts Location Diagram Upper WZ07 3712E 5 Return Z 7 Z 7 44 IWZ07 3710E06 1 343 460 42500 68 111 64 6 59 1 60 91 2 56 94 47 95 142 106 22 15 121 93 2 22 4 122 2 122 1 A Detail A SL389 SL185 SL164 SL160 SL102 FRONT ...

Page 154: ...4 343 464 14000 Hydraulic Parts Location Diagram Upper WZ07 3712E 6 Drain Z 7 Z 7 45 IWZ07 3710E07 6 343 460 55000 A Detail A 98 1 99 1 B Detail B 57 View C 58 C SL100 FRONT ...

Page 155: ...2 343 460 55500 Hydraulic Parts Location Diagram Upper WZ07 3712E 7 Gauge Z 7 Z 7 46 IWZ07 3710E08 A Detail A 31 30 FRONT ...

Page 156: ...am Upper WZ07 3712E 8 Pilot Z 7 Z 7 47 IWZ07 3710E09 4 343 464 11000 Fix jib Power tilt jib 67 2 22 11 22 9 62 65 22 8 22 7 64 4 120 1 120 2 119 2 119 1 118 22 13 67 1 64 3 22 2 22 1 SL232 SL148 SL149 SL143 SL144 SL124 SL125 SL136 SL137 FRONT FRONT ...

Page 157: ...ation Diagram Upper WZ07 3712E 9 Steering Z 7 Z 7 48 IWZ07 3710E10a 10 Air conditioner 1 345 113 11000 8 343 460 54000 IWZ07 3710E11a IN OUT P CF LS LS T P A 97 B FRONT 48 22 3 50 Detail B Detail A 49 L 52 R 86 89 37 38 SL386 SL280 FRONT ...

Page 158: ...3 2 Power tilt jib 63 1 Power tilt jib Jib tilt lowering detection Jib tilt raising detection Boom lowering detection Boom raising detection Main winch hoisting down detection Main winch hoisting up detection Aux winch hoisting down detection Aux winch hoisting up detection Boom extending detection Boom retracting detection Slewing right detection Slewing left detection FRONT 22 6 61 1 22 5 61 2 A...

Page 159: ...m Upper WZ07 3712E 13 Jib Z 7 Z 7 50 IWZ07 3710E14 0 343 466 96500 1 342 220 53000 3 342 220 27000 3 343 460 42000 A B C Detail A 126 1 Power tilt jib 123 2 124 2 125 1 Power tilt jib 123 1 124 1 126 2 Power tilt jib 125 2 Power tilt jib FRONT FRONT ...

Page 160: ... 3712E Z 7 Z 7 51 IWZ07 3710E15 1 342 220 53000 46 40 3 41 1 39 132 Power tilt jib 59 2 Power tilt jib 137 Power tilt jib 136 Power tilt jib 40 4 41 2 42 107 2 Power tilt jib 107 1 Power tilt jib Detail B Detail C SL223 SL193 SL364 SL222 SL192 SL363 FRONT FRONT ...

Page 161: ...4 342 220 51500 Hydraulic Parts Location Diagram Upper WZ07 3712E 14 Jib power tilt jib main body Z 7 Z 7 52 IWZ07 3710E16a 140 141 133 134 135 139 138 A Detail A FRONT FRONT ...

Page 162: ... Upper WZ07 3712E Z 7 Z 7 53 IWZ07 3710E17a 15 Self removable C W 43 2 17 6 92 2 91 1 87 1 87 2 87 3 45 124 4 123 4 124 6 123 6 123 5 123 3 124 5 124 3 B Detail B View A SL308 SL309 SL305 SL306 SL293 SL292 SL301 SL300 SL299 SL298 FRONT FRONT FRONT A ...

Page 163: ...IWZ07 3710E18a 7 343 460 41000 Hydraulic Parts Location Diagram Upper WZ07 3712E Z 7 Z 7 54 43 1 17 5 92 1 C Detail C FRONT FRONT ...

Page 164: ...3710E19 0 345 906 15000 2 343 460 46000 0 345 906 11000 Hydraulic Parts Location Diagram Upper WZ07 3712E 16 Removable boom system option Z 7 Z 7 55 B View B 131 41 3 40 5 40 2 18 2 36 2 40 1 36 1 18 1 A Detail A FRONT FRONT ...

Page 165: ...3 342 615 15000 3 343 460 57000 Hydraulic Parts Location Diagram Upper WZ07 3712E 17 Cab tilt Z 7 Z 7 56 IWZ07 3710E20 A Detail A 73 104 105 1 105 2 FRONT FRONT ...

Page 166: ...2 346 415 51000 Hydraulic Parts Location Diagram Lower WZ07 3722E Z 8 Z 8 57 IWZ07 3722E01 1 347 331 50000 1 347 334 10000 Z 8 Hydraulic Parts Location Diagram Lower 1 Suction 11 96 117 05 04 03 FRONT ...

Page 167: ...0 1 346 418 42000 Hydraulic Parts Location Diagram Lower WZ07 3722E 2 Steering Z 8 Z 8 58 IWZ07 3720E02a P4 P5 24 2 25 1 23 25 3 25 5 25 6 25 4 25 2 24 1 85 2 77 2 77 1 85 1 A Detail A FRONT Detail B SL33 SL31 SL30 B ...

Page 168: ...18 46000 Hydraulic Parts Location Diagram Lower WZ07 3722E 3 Suspension Z 8 Z 8 59 IWZ07 3720E03 22 14 44 1 21 1 21 3 21 2 21 4 44 3 44 2 44 4 A View A 19 83 1 83 2 76 26 09 22 18 SL03 SL05 SL02 SL04 SL13 SL11 SL14 SL12 FRONT ...

Page 169: ...8 43000 Hydraulic Parts Location Diagram Lower WZ07 3722E 4 Outrigger H type Z 8 Z 8 60 IWZ07 3720E04 129 1 127 1 20 1 64 1 40 6 13 35 FRONT 20 2 64 2 40 7 129 2 127 2 FRONT SL81 SL83 SL82 SL84 Detail A Front side Rear side A ...

Page 170: ...ower WZ07 3722E 5 Outrigger main body H type Z 8 Z 8 61 IWZ07 3720E05 5 346 415 57000 FRONT 16 1 14 2 130 1 128 1 17 1 15 1 14 1 15 2 16 2 17 2 17 4 16 4 14 3 130 2 128 2 14 4 15 4 17 3 16 3 15 3 L SL26 R SL27 L SL29 R SL28 L SL22 R SL23 L SL25 R SL24 ...

Page 171: ...0 Hydraulic Parts Location Diagram Lower WZ07 3722E 6 Center joint Z 8 Z 8 62 IWZ07 3720E07 8 346 415 55000 3 346 418 45000 IWZ07 3720E06 7 Return 12 10 93 1 FRONT 07 08 06 32 1 32 2 29 33 28 FRONT SL21 SL20 SL96 27 ...

Page 172: ...er WZ07 3733E Z 9 Hydraulic Parts Location Diagram Torque Converter 1 Torque converter related Z 9 Z 9 63 IWZ07 3730E01c 349 314 21000 11 10 349 227 30000 349 232 80000 2 254 250 253 251 SL41 SL49 257 A 258 256 View A SL43 R SL42 F2 SL44 SL45 259 261 260 255 FRONT ...

Page 173: ... Pneumatic Parts Location Diagram WZ08 0542E Z 10 Pneumatic Parts Location Diagram 1 Service brake related upper Z 10 Z 10 64 IWZ08 0540E01 5 347 222 30000 A FRONT 234 237 241 Detail A 240 238 243 239 235 236 242 SL60 ...

Page 174: ...00 Pneumatic Parts Location Diagram WZ08 0542E 2 Service brake related lower Z 10 Z 10 65 IWZ08 0542E01 208 SL50 207 245 FRONT 209 205 REAR 204 203 REAR 202 FRONT Detail A 200 201 200 201 244 246 206 FRONT A 244 222 ...

Page 175: ...neumatic Parts Location Diagram WZ08 0542E Z 10 Z 10 66 IWZ08 0542E02 3 Control parts lower A Detail A 228 211 214 217 229 227 216 213 210 212 219 221 226 CN410 218 215 223 B 230 231 232 B 233 View B 220 224 FRONT FRONT ...

Page 176: ...8 R79 R80 R81 R82 R87 R89 R90 RB5 RC1 RC2 RC3 RC7 RC60 RF1 4c Terminal assy CN863 Emergency switch CN564 Engine stop switch CN517 Emergency susupention free CN1596 Fuse 1 CN875 CN876 CN877 CN878 Fuse 2 CN870 CN871 CN872 CN873 Fuse 3 CN868 CN869 Left CN620 CN621 CN622 CN623 CN624 Right CN625 CN626 CN627 CN629 CN630 CN631 Detail F Detail G View D Detail E Detail B AML C CN640 CN641 CN642 CN643 CN644...

Page 177: ... solenoid valve SL260 CN260 Aux winch high speed selection solenoid valve SL261 CN261 C W cylinder extending solenoid valve right SL308 CN308 Boom raising proportional control valve SL124 CN124 Boom lowering proportional control valve SL125 CN125 Boom lowering detection switch CN537 Boom raising detection switch CN536 Slewing left detection switch CN541 Slewing right detection switch CN540 AML ove...

Page 178: ...Boom lowering proportional control valve SL125 CN125 Boom lowering detection switch CN537 Boom raising detection switch CN536 2 0 0 5 2 2 1 1 Slewing lock detection switch CN1154 0 5 1 0 Jib mounting stowing operationally indicator lamp CN999 Jib mounting stowing switch CN488 Jib lock pin switch CN995 Elevating pivot pin inserting solenoid valve SL364 option CN364 Jib lock pin retraction solenoid ...

Page 179: ...R b contact Normal close type relay c contact Combination type relay c contact Combination type relay a contact Normal open type relay b contact Normal close type relay Carrier section relay a contact Normal open type relay b contact Normal close type relay R81 R80 R78 R36 Spare RB5 RA5 RA4 RA3 RA28 RA26 Fuse 2 Fuse 1 M R62 RA14 R26 RA6 R23 R22 RA2 Crane section relay R1 R77 R76 R75 310 LR M 253 L...

Page 180: ...02 6702E Z 11 Z 11 1 343 543 42900 71 3 2 Relay assy ESP 1 IWZ02 6702E02 R74 R73 R71 R68 R69 R70 R64 R65 R72 a contact Normal open type relay c contact Combination type relay b contact Normal close type relay b contact Normal close type relay ...

Page 181: ...tric Parts Location Diagram Upper WZ02 6702E Z 11 Z 11 0 343 543 41900 72 3 3 Relay assy ESP 2 IWZ02 6320E06a CN1478 CN1479 R88 R85 R84 R86 a contact Normal open type relay b contact Normal close type relay ...

Page 182: ...ering detection OFF ON ON h Raising detection ON ON OFF g Elevation Retracting detection ON ON OFF f Extending detection OFF ON ON e Telescoping Hoisting down detection OFF ON ON d Hoisting up detection ON ON OFF c Aux winch Hoisting down detection OFF ON ON b Hoisting up detection ON ON OFF a Main winch Push Neutral Pull Note Lever operation Switch name ON OFF indicates energization condition of ...

Page 183: ...i Slewing Lowering detection Raising detection Elevation Retracting detection Extending detection Telescoping Hoisting down detection Hoisting up detection Aux winch Hoisting down detection Hoisting up detection Main winch Push Neutral Pull Note Lever operation Isometric drawing k Jib tilt raising detection switch l Jib tilt lowering detection switch j e d c Boom extending detection switch Aux win...

Page 184: ...pper Z 11 Z 11 IWZ02 6320E09a 75 75 2 344 947 10000 5 Lamp assy AML marker lamp yellow and red Connector external indicator lamp CN890 Harness AML lamp External indicator lamp red G W CN829 External indicator lamp yellow G L CN828 Slewing center Front ...

Page 185: ...tric Parts Location Diagram Upper Z 11 Z 11 IWZ02 6320E10a 76 76 1 343 543 47000 6 Switch assy AML override AML override switch CN454 Using regularly For emergency View A AML override switch CN454 Movable range of switch A ...

Page 186: ...cation Diagram Upper Z 11 Z 11 IWZ02 6320E11b 77 77 2 343 543 50000 7 Switch assy counterweight equipped detection switch Front C W equipped detection switch right CN994 C W equipped detection switch left CN457 Counterweight fixing pin ...

Page 187: ...C7 A B View A View B Boom section detection switch left upper CNLU Boom section detection switch left center CNLC Boom section detection switch left lower CNLL Boom section detection switch right upper CNRU Boom section detection switch right center CNRC Boom section detection switch right lower CNRL TELE 1 TELE 2 TELE 3 TELE 4 TELE 5 B pin unlock detection switch right CNC8 Arrangement of detecti...

Page 188: ... 637 32000 Connecting detail cord reel Detail B CN578 CN579 View A CN671 CN859 Connector jib angle detector To circuit boom two blocking To circuit boom fix jib To circuit boom power tilt jib Cord reel jib angle detector Ground Cord reel STM D Cord reel jib angle detector CN579 Harness boom head STM D Cord reel jib angle detector A B ...

Page 189: ...n Diagram Upper Z 11 Z 11 9 2 Indicator assy jib angle detector IWZ02 6320E14a 1 343 637 31000 Isometric drawing View B Jib angle detector Jib angle detector Jib angle detector CN1603 Connector jib angle detector CN578 Cable jib angle detector B ...

Page 190: ...fix jib CN1595 To circuit boom fix jib CN993 To circuit boom fix jib CN888 Pressure sensor elevating cylinder boom raising CN584 Pressure sensor elevating cylinder boom lowering CN585 Pilot pressure sensor boom extending CN1189 Pilot pressure sensor boom retracting CN1190 A View A in the cab AML C ESP controller A Harness AML fix jib Slewing angle detector CN580 To circuit crane main CN1750 ...

Page 191: ...CN888 To circuit boom power tilt jib CN961 A A AML C ESP controller Pressure sensor main pressure CN581 Pressure sensor elevating cylinder boom raising CN584 Pressure sensor elevating cylinder boom lowering CN585 Pilot pressure sensor boom extending CN1189 Pilot pressure sensor boom retracting CN1190 Harness AML power tilt jib Slewing angle detector CN580 To circuit crane main CN1750 To circuit cr...

Page 192: ...M F M M CN862 CN1094 1 2 3 3 2 1 3 2 1 CN901 USE SINGLE TOP 1 2 3 CN901 USE BOOM CN902 CN901 CN900 CN901 1 2 3 1 2 3 USE JIB 1 2 3 1 25 LgB 1 25 YB 1 25 LgB 0 85 B 0 85 R 1 25 Y 1 25 YB 1 25 Y 1 25 Y 1 25 B Y B M6 Harness two blocking single top Plug Plug Plug Plug Plug From cord reel boom length detector CN859 Store connector Ground Boom right side Boom left side Two blocking detection switch rig...

Page 193: ...rcuit jib single top two blocking CN900 Harness two blocking boom Harness two blocking single top Harness two blocking single top To circuit boom two blocking CN901 To circuit boom two blocking CN901 Jib1 Jib2 To circuit jib single top two blocking CN948 To circuit jib single top two blocking CN902 Harness jib2 Harness jib1 To circuit boom two blocking CN901 To circuit jib single top two blocking ...

Page 194: ...43 546 30000 1 ICF CN1067 ICF To circuit SCT CN1070 CN1065 CN1066 For maintenance terminal Dr T CN1067 CN1070 CN1068 Controller To circuit SCT CN1072 SCT satellite communications terminal Harness ICF Harness carrier main Parts connection detail ICF CN1072 For maintenance terminal Dr T Harness ICF SCT satellite communications terminal ...

Page 195: ...ntenna Harness ICF CN1070 Harness carrier main For maintenance terminal Dr T CN1067 CN1066 Antenna for satellite communications Connector for satellite communications Controller Parts connection detail Antenna cable To circuit ICF CN1072 SCT satellite communications terminal GPS antenna ICF CN1068 CN1065 Harness SCT Harness SCT Controller satellite communications terminal Connector antenna cable c...

Page 196: ...ch CN730 Memory clear switch CN797 Detail M Suspension lock Suspension free Suspension P C lock Suspension P C free PTO and lock up solenoid valve Temperature switch 50 C 122 F Steering pump low pressure warning switch option Positive control solenoid valve Torque converter oil temp sensor T C oil temp detection switch 110 C 230 F Air pressure detection switch parking brake STM E Water in fuel sen...

Page 197: ...74 CN775 CN771 CN773 CN769 CN770 CN767 CN768 M F Connector No 7 F Right Left Fuse 5 F 2 F 1 M 7 F 5 F 2 F CN No Pole 2 M CN772 2 M CN708 BR R CN707 W CN706 BR Y Head lamp relay CN705 BR W Fuse air heater 70A Battery relay CN755 007AA B Yellow seal F B A D C E H G H G F E 5A 5A 10A 10A Fuse upper D C A B Location 15A 15A 30A 30A Fuse code Note Fuse upper Fuse right Fuse left CN1001 2 F CN776 CN1000...

Page 198: ... RB4 RB11 Spare Spare Spare Spare 1 2 3 4 5 6 7 10 9 8 DIAG lamp 1 red CN731 CN732 DIAG lamp 2 orange CN733 CN734 RF2 7 M Pole CN No 9 F 7 M Relay RF3 F M RF2 1 RF2 2 RF3 1 RC6 RC5 RC6 6 M RC5 6 M 9 F RF3 2 RSg 270Ω 6 81 W R 6 06 L Y 680Ω 2 2kΩ 1kΩ RSd Connection detail of terminal base 6 07 Y R 6 17 B 6 47 B W 10 9 8 7 6 5 4 3 2 1 6 47 LG B RSe RSc Condenser DIAG lamp Spare Detail A a contact Nor...

Page 199: ...CN790 CN791 CN1500 MUT3 CN691 Engine ECU CN685 CN686 CN687 CN688 CN689 Relay assy To circuit lower main CN1501 Fuse air heater 70A CN755 Fuse CN779 Battery relay CN759 CN792 CN793 CN794 CN795 Oil bypass alarm switch Engine oil filter Low pressure switch engine oil Coolant level detection switch Engine coolant temperature sensor Alternator Alternator ground Starter motor Starter motor ground B term...

Page 200: ...B B Ground Side turn signal LH CN945A GB CN945B B Outrigger length detector FR CN423 Slide FL SL24 CN024 Jack FL SL25 CN025 Outrigger length detector FL CN422 Head lamp RH CN702 LH CN701 Harness O R front Jack FR SL23 CN023 Slide FR SL22 CN022 Combination lamp LH CN711 G CN712 GB CN1008 Ground B A A Combination lamp RH CN709 GB CN710 G CN1009 Ground To circuit lower main CN1528 ...

Page 201: ...3 Ground Backup lamp CN721A R CN721B B Rear combination lamp R CN719A GY CN719B B CN720 Back buzzer CN751 R Harness O R rear Slide RL SL28 CN028 Outrigger length detector RR CN425 Jack RL SL29 CN029 Jack RR SL27 CN027 Slide RR SL26 CN026 To circuit lower main CN1529 Outrigger length detector RL CN424 Rear combination lamp L CN717A GY CN717B B CN718 A ...

Page 202: ...I 9 CN1333 I 12 CN1454 Slewing lock switch G 1 CN1477 Cab tilt warning lamp B 7 CN1478 Cab tilt alarm buzzer H 7 CN1479 CN1498 Boom elevating jib tilt selection switch D 1 CN1499 Boom elevating jib tilt selection switch indicator lamp D 2 CN1515 Diode 1 5A D 15 CN1516 To circuit for Europe not used G 11 CN1518 Diode 3 0A H 8 CN1523 Diode 1 5A E 15 CN1556 To circuit slewing table right J 9 CN1559 C...

Page 203: ...0AB LG 384AA L F CN558 336AC P 255AE R G F CN1715 LG 250BY LG 276AA CN1716 035AX BR B52AL B 80 1215AA BR R 1216AA BR Y 1 5A LG Y 1217AA CN1114 CN1722 1216AA BR Y 035BA BR F M CN1498 250BA LG 718AC Y W LG 250AX LG Y 1217AA CN1499 1215AA BR R B52AC B 80 CN1721 1213AA BR W 035BB BR F M CN485 250AF LG 337AC LG W 1212AA BR B 1213AA BR W 1 5A LG B 1214AA CN1113 LG 250CB LG B 1214AA CN922 1212AA BR B B52...

Page 204: ...N929 CN930 470AA LG Y CN1015 B01AK B CN521 Over front detection switch contact close over front 333AA B W B01AE B 156AA R Y CN890 Connector external indicator lamp B01AC B 412AA G W 411AA G L 233AA Y B CN949 External warning buzzer 259AA G B 250AA LG CN060 Air solenoid valve air horn B01AB B 130AA L Y CN386 B01AJ B 1180AA BR W CN1052 Steering filter clogging detection switch B01AF B 132AA Y R CN58...

Page 205: ...cylinder retracting solenoid valve left SL300 option D 10 CN301 Boom pivot pin mount dismount cylinder extending solenoid valve left SL301 option D 8 CN305 C W cylinder extending solenoid valve left SL305 C 10 CN306 C W cylinder retracting solenoid valve left SL306 C 8 CN308 C W cylinder extending solenoid valve right SL308 C 10 CN309 C W cylinder retracting solenoid valve right SL309 C 8 CN362 C ...

Page 206: ... CN994 372AA BR B01BC B 156AB R Y E001C B01AA B CN287 B02AA B 316AA LG B CN457 373AA BR W B01BB B 156AA R Y CN1527 C01 001 W C01 002 R C01 003 G C01 004 B SHIELD SHIELD01B S01 AA B 50 50 50 50 50 40 40 40 40 250 200 2700 5 0 150 550 200 50 350 50 50 300 50 1150 50 800 1000 1000 50 1000 50 50 50 50 450 50 50 50 N009 N010 N011 N012 N013 N090 N091 N092 N093 N100 N101 N102 N103 N104 N110 N111 1200 750...

Page 207: ...N573 785AA G L 781AA G R Ground E001A B01AA B Ground E002A B02AA B SHIELD SHIELD1A S01 AB L SHIELD SHIELD2A S06 AB BR SHIELD SHIELD2B S06 AA BR SHIELD SHIELD1B S01 AA L 50 1 2 0 50 1 2 0 120 120 50 50 50 50 200 200 1150 50 100 950 400 COTΦ10 COTΦ07 COTΦ13 50 6 0 7 0 50 6 0 7 0 CN853A 233AA Y B CN853B B01AB B COTΦ10 COTΦ07 COTΦ10 6200 1750 1450 COTΦ07 COTΦ07 N002 N003 N004 60 60 150 Plug M F Plug P...

Page 208: ...B02AF B 791AA B R CN363 B02AD B 1191AA L B CN364 B02AE B 1190AA L W CN193 B02AG B 792AA B G CN223 B02AJ B 787AA LG Y CN858 Ground E001B B01AA B Ground E003 B03AA B CN572 367AA G W B01AC B 250AA LG CN573 785AA G L 781AA G R Ground E001A B01AA B Ground E002A B02AA B 50 1 2 0 50 1 2 0 1 2 0 120 1150 50 950 400 COTΦ13 COTΦ07 50 6 0 7 0 50 6 0 7 0 COTΦ10 COTΦ07 COTΦ10 6200 1750 1450 COTΦ07 COTΦ07 N002 ...

Page 209: ...1 0 0 CN888 1 5 0 150 150 100 SHIELD SHIELD2B CN580 CN581 CN1189 S14 W W S14 B B S14 R R CN1190 S15 W W S15 B B S15 R R 100 100 N005 N006 CN584 CN585 2400 800 700 900 5900 COTΦ07 COTΦ07 800 700 4400 50 1 7 0 0 1700 SHIELD SHIELD15 S15 AA B R SHIELD SHIELD1A S06 AB L 30 30 30 1300 80 50 S05 AA Y S02 AA Y S03 AA Y S04 AA Y S01 AA Y S01 015 R S01 016 B S01 013 W S02 019 G S02 018 W S02 017 R S02 AB Y...

Page 210: ...COTΦ07 COTΦ07 800 700 4400 50 1 7 0 0 1700 SHIELD SHIELD15 S15 AA B R SHIELD SHIELD1A S06 AB L 30 30 30 1300 300 80 CN897 S39 107 B S39 109 R S39 108 GR S39 110 G S39 111 Y S39 AA B SHIELD SHIELD39A S39 AA B 80 30 S39 111 Y S39 109 R S39 108 GR S39 110 G S39 107 B S39 AB B SHIELD SHIELD39B S39 AB B 150 1 0 0 50 CN961 S05 AA Y S02 AA Y S03 AA Y S04 AA Y S01 AA Y S01 015 R S01 016 B S01 013 W S02 01...

Page 211: ...1AN B 470AB LG Y 470AA LG Y 279AA BR W C01 001 W C01 002 R C001 003 G C01 004 B 650 F F Plug M M B B Plug 2 343 543 42040 6 Harness for separated transport 102 IWZ04 5312E04 To circuit slewing table left Drum rotation detection switch aux winch Over unwinding detection switch aux COTΦ07 COTΦ7 ...

Page 212: ...AML override 370 80 CN1104 PTO switch CN558 CN509 R48 CN1526 2200 500 100 120 80 80 80 N001 022AA G 336AA P 154AA Y 335AA V 255AA R G 154AA Y 022AA G 336AA P 335AA V 255AA R G 335AB V F M M M F Plug To circuit crane main To circuit carrier main To circuit crane main To circuit slewing table left ...

Page 213: ...Y 839AA R 250 Vinyl Φ06 Φ07 50 1800 N001 N002 C07 018 W C07 019 B CN901 250 Ground E015 B60AA B 600 Vinyl Φ04 Φ05 200 COTΦ07 Plug Plug Plug Plug Plug F M M B B F F 8 1 Boom Two blocking detection switch To circuit boom fix jib Two blocking detection switch boom To circuit boom power tilt jib To circuit jib single top two blocking CN901 Connector CN901 1 2 3 0 5B ...

Page 214: ...Upper Crane WZ04 5312E Z 15 Z 15 0 343 728 50050 8 2 Single top 105 IWZ04 5110E15 C06 018 W C06 019 B CN901 1350 C06 018 W C06 019 B CN900 M F To circuit jib single top two blocking To circuit boom two blocking ...

Page 215: ...5312E Z 15 Z 15 1 343 728 61300 8 3 Jib1 106 IWZ04 5110E17 M F C08 018 W C08 019 B CN901 10800 C08 018 W C08 019 B CN948 To circuit jib single top two blocking To circuit boom two blocking 11500 Applicable serial No FE5029 1 1 ...

Page 216: ...er Crane WZ04 5312E Z 15 Z 15 0 343 728 61400 8 4 Jib2 107 M F 8500 C09 018 W C09 019 B CN948 C09 018 W C09 019 B CN902 To circuit jib single top two blocking To circuit jib single top two blocking IWZ04 5110E19a ...

Page 217: ...12AA G W CN852B B01AL B CN852A 233AB Y B CN890 B01AC B 412AA G W 411AA G L 233AB Y B 50 100 200 150 50 50 150 350 250 50 N001 N002 M External indicator lamp yellow External indicator lamp yellow External indicator lamp red External indicator lamp red Working lamp slewing table right Working lamp slewing table right Connector external indicator lamp ...

Page 218: ... C pin status indicator CN1418 C pin connected section indicator 2 6 2 3 E 1 CN1419 C pin connected section indicator 4 5 6 CN1588 To circuit crane main F 6 CN1589 E 6 CN1590 Emergency telescoping switch C 3 CN1591 Emergency telescoping switch lamp D 4 CN1592 B pin emergency operation indicator lamp D 3 CN1593 C pin emergency operation indicator lamp D 2 CN1719 Telescoping monitor switch lamp E 3 ...

Page 219: ...AA BR W 1138AA LG Y 293AA LG W B10AD B B10AE B CN658 CN8 832AA LG 830AA L R 834AA BR 833AA L B 831AA L W JC155 1 JC155 JC155 2 JC155 3 400 250 50 50 30 35 35 35 35 35 75 75 80 120 120 120 120 120 120 120 120 120 80 100 80 80 80 200 200 200 200 100 JC152 3 JC152 2 JC152 1 JC152 JC154 1 JC154 2 JC154 3 JC150 3 JC150 2 JC150 1 80 80 80 80 80 80 80 80 80 100 100 100 100 100 100 N001 JC153 JC153 1 JC15...

Page 220: ... G R Y Y W Y R Y G W W B R W G 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 3 4 1 V4 1 2 CNV4 1 CNV5 CN1211 2 V5 B W W B B B V GY 2 A B C D E F G H J K L M N P R S T U V W X Y Z a b B G G B G W G R Y Y W Y R Y G W W B W G R R G L W V GY B B c W L W V GY R B output output output output output output To cord reel ESP C pin unlock detection switch 1 B pin lock detection switch left B pin lock detection switch rig...

Page 221: ...395AA R L S44 125B W B26AC B B24AC B B24AB B 396AA G 397AA W S44 127B B S44 126B R S44 126A R S44 125A W S44 127A B S44 AB B Ground E026 B26AA B Ground E027 B27AA B SHIELD S44 AB B SHIELD S44 AA B 80 Ground E028 S44 AA B 100 50 650 50 270 F F M F Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plu...

Page 222: ... 0 370 027 11220 Harness Upper Crane WZ04 5312E Z 15 Z 15 113 13 Cable1 jib angle detector A B C D E F M 5 4 3 2 1 R Shield W B 5 4 3 2 1 E D B C A Shield CN578 CN1603 Connector jib angle detector Jib angle detector ...

Page 223: ...r J 1 CN836 Condenser C7 power window motor F 11 CN837 Condenser C2 washer motor I 2 CN849 Washer motor roof G 2 CN850 Washer motor front CN868 Fuse box 3 D 7 CN869 CN870 Fuse box 2 D 10 CN871 CN872 C 11 CN873 E 10 CN875 Fuse box 1 CN876 F 10 CN877 CN878 CN880 Center joint K 8 CN881 CN No Usage Harness diagram coordinate CN882 Center joint K 9 CN883 CN884 K 10 CN885 CN895 To circuit slewing table ...

Page 224: ...22AC G 022AG G 614AC L 558AD R W 558AC R W 558AB R W 558AA R W 632AA R 633AA W 157AC R G 627AA G B 626AA W B B30CB B 907AB P 911AA W L 005AA L Y 157ML R G 051AA Y B 050AA Y L B35FD B 035MS BR 157MX R G 508AA G L 1136AA R Y B32BB B S11 006 W S11 005 B S11AA B 365AA W B 233AB Y B 743AA SB G Y 402AA G R 317AA L Y 022AB G 388AA Y O 132AA Y R 327AA Y R 254AA L G 156AA R Y 130DN L Y 845AA R L 035NY BR S...

Page 225: ... 157AF R G 157AE R G 157AD R G 157AC R G 157AB R G 157AA R G 157AL R G 157AK R G 157AJ R G 157AO R G B35AF B B35AE B B35AD B B35AC B B35AB B B35AA B 030AD R L 030AB R L 030AA R L 035AF BR 035AE BR 035AD BR 035AB BR 035AA BR 031AA R Y 031AB R Y 031AC R Y 032AA R B 032AB R B 032AC R B 033AA R W 033AB R W 033AC R W 040AA R 040AB R 040AC R 170AA Y L 035AB BR B35AB B 040AB R 214AD Y 030AB R L 033AB R W...

Page 226: ...T upper CN8 CN588 Idling adjustment switch ground CN548 Accelerator switch CN1505 To circuit carrier main SHIELD SHIELD20 SHIELD SHIELD21 SHIELD SHIELD22 350 2050 710 610 350 50 100 80 80 80 80 8 0 8 0 COTØ13 N001 N002 S22 040 R S22 041 W S22 042 B S20 030 R S21 033 R S22 040 R S20 032 B S21 035 B S22 042 B S20 031 W S21 034 W S22 041 W S20AA B S21AA B S22AA B B35MA B B35HA B 626AA 626AA W B B35HA...

Page 227: ...821AA W B 822AA W R B51AD B 834AA BR 833AA L B 825AA W Y 823AA W G 832AA L G 824AA B W CN1067 For maintenance terminal Dr T 831AA L W 830AA L R 832AA L G 833AA L B 834AA BR CN1070 To circuit carrier main To circuit SCT S11 006 W S11 005 B 558AC R W 006AA O 016AB Y L B51AA B CN1072 016AC Y L 006AC O B51AE B 826AA W L 821AA W B 822AA W R 823AA W G 824AA B W 825AA W Y 100 400 50 100 2350 50 50 50 50 ...

Page 228: ...941 00101 5 Harness SCT 119 IWZ04 5120E03 F M 150 N005 CN1068 821AA W B 006AC O 016AC Y L 822AA W R 826AA W L B51AH B B51AG B B51AF B CN1072 016AC Y L 006AC O B51AE B 826AA W L 821AA W B 822AA W R 50 50 To circuit ICF Satellite communications terminal ...

Page 229: ... Fuse box upper B 15 CN777 CN778 Fuse upper power supply 75A B 14 CN780 Center joint C 6 CN781 CN782 C 7 CN783 CN784 C 8 CN785 C 9 CN788 To circuit lower air E 4 CN789 F 5 CN790 To circuit engine without DPF I 2 CN791 J 2 CN797 Memory clear switch F 2 CN940A T C oil temp detection switch 110 C 230 F G 15 CN940B CN944 Steering pump low pressure warning switch option A 2 CN957 1 to 1 spare circuit B...

Page 230: ... 039AA B B10FT R Y 092AG R Y 092AF R Y 092AD R Y 092AC R Y 092AE R Y 092AB W 105AD W 105AC W 105AB W 105AA R 040AD R 040AC R 040AB R 040AA R B 032AC R B 032AB R B 032AA R Y 031AA R Y 031AB R Y 031AC B B08AO B B08AI B B08AC B B08AN B B08AL G 094AC G 094AB G 094AA R L 095AD R L 095AC R L 095AB R L 095AA Y B 236AC Y B 236AB Y B 236AA L Y 1185AC L Y 1185AA L Y 1185AB R Y 124AF R Y 124AC R Y 124AB R Y ...

Page 231: ...inyl Φ04 Φ05 600 50 CN428 244AA Y O B20AI B 117AA G W 101AA W Y 124AA R Y CN414 B20AJ B 082AB B Y CN415 B20AD B 082AA B Y CN050 B20AC B 019AA W G CN411 083AA B L B20AH B 50 100 150 N004 N008 130 50 COTΦ10 COTΦ07 COTΦ07 COTΦ07 COTΦ07 COTΦ07 COTΦ07 COTΦ07 Plug Plug Plug Plug CN568 M M F F F F F F F F F F Remaining brake fluid detection switch Remaining brake fluid detection switch Air solenoid valve...

Page 232: ...25AA R G 026AA B G 655AA B W 681AA W R 617AA B 609AA B Y 054AA L O 600AC R 161AA Y R 638AA BR 637AA BR R 910AA W B 635AA L Y 092AB R Y 679AA L 118AA G L 085AA B R S15 044 B S15 043 W S15 AA B 092AA R Y 601AD W Y 052AA Y 021AA L G 601AC W Y 694AA Y W 626AA W B 680AA G L 693AA R W 601AB W Y 699AB B Y 647AB B W 636AA L R 022AA G 642AA LG Y B01AD B B02AA B B03AA B B04AA B B06AA B B07AA B S16 AA B 647A...

Page 233: ...1 349 314 21500 4 Harness rear steering 124 IWZ04 5130E04 CN408 S61 143 W S61 146 B S61 142 R CN1600 S61 142 R S61 143 W S61 146 B 50 50 460 N001 N002 50 310 Plug Plug Plug F M COTΦ07 To circuit lower main Straight ahead detection switch ...

Page 234: ...150 150 150 150 S35 001 B 2 S35 002 W 2 S35 003 R 2 S35 004 G 2 S35 005 Y 2 S35 006 BR 2 S35 007 L 2 S35 008 V 2 S35 009 GR 2 S35 010 P 2 S35 011 O 2 S35 012 SB 2 S35 013 B 2 S35 014 W 2 S35 015 R 2 S35 016 G 2 S35 017 Y 2 S35 018 BR 2 S35 019 B 1 S35 020 W 1 S35 021 O 1 S35 022 G 1 S35 023 Y 1 S35 SA B B10AD B 145AB BR W 146AB BR B 142AB BR W 013AA L B 013AA L B B10AE B B10AF B B10AK B B11AA B 03...

Page 235: ... B 2 S36 002 W 2 S36 007 L 2 S36 008 V 2 S36 009 GR 2 S36 010 P 2 S36 011 O 2 S36 012 SB 2 S36 013 B 2 S36 014 W 2 S36 015 R 2 S36 016 G 2 S36 017 Y 2 S36 022 G 1 S36 023 Y 1 S36 024 BR 1 S36 025 P 1 S36 026 V 1 S36 SA B 101AA W Y 142AA BR W B11AA B 035AA BR S36 SA B S28 AA B S29 AA B S36 SB B CN425 S29 075 W S29 076 B S29 074 R 50 50 50 100 200 50 COTΦ15 CN723 142AD BR W 700 1300 800 500 50 COTΦ0...

Page 236: ...SB W O L GR SB W Y BR G R B GR View B Connect RA1 connector of harness searchlight to RA1 Put terminal wire 427AA R of harness searchlight into No 3 pin of CN869 M Fuse box 3 Detail of relay assy Harness Inside Cab Inspection window RA2 No 3 pin Harness searchlight Remote controller Searchlight relay RA1 Relay assy Disconnect RA2 connector and connect CN1564A and CN1564B of harness searchlight to ...

Page 237: ...3 549 20000 Harness common FE5003 Harness slewing table right option To circuit slewing table right option CN1562 To circuit anemometer cab FE5003 CN1545 To circuit carrier main CN1563 To circuit crane main CN1728 To circuit boom fix jib To circuit boom power tilt jib CN1495 To circuit boom searchlight FE5003 CN1779 Harness slewing table right option B Detail B ...

Page 238: ...ight FE5028 Harness jib2 anemometer aviation obstruction light FE5027 Harness jib2 anemometer aviation obstruction light FE5028 To circuit boom head anemometer aviation obstruction light CN1496 To circuit jib1 anemometer aviation obstruction light CN1497 To circuit jib2 anemometer aviation obstruction light CN1497 Anemometer CN1425 Aviation obstruction light CN1732 Anemometer CN1425 Aviation obstr...

Page 239: ...F ON OFF ON A B D E F G H C G Y Z K E X J I H A B F D C G Y Z K E X J I H A B F D C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 16 Current voltage converter To circuit crane main CN1635 Harness slewing table right option Harness crane main To circuit slewing table right option CN1545 Harness anemometer cab FE5003 Relay assy Signal transmitter assy A Detail A ...

Page 240: ...ight Anemometer Aviation Obstruction Light Option 1 5 Anemometer boom Z 18 Z 18 4 344 957 32000 Anemometer Apply Threebond 1401 or equivalent Anemometer CN1425 Aviation obstruction light CN1732 A B Detail A View B Mounting direction of Anemometer ...

Page 241: ...E16a WZ02 6732E Searchlight Anemometer Aviation Obstruction Light Option Z 18 Z 18 3 344 957 42000 1 6 Aviation obstruction light boom Detail A Anemometer CN1425 Aviation obstruction light CN1732 Aviation obstruction light A ...

Page 242: ...2E03 Aviation obstruction light CN1732 Harness boom head anemometer aviation obstruction light FE5027 Harness boom head anemometer aviation obstruction light FE5028 Anemometer CN1425 To circuit jib1 anemometer aviation obstruction light CN1496 To circuit boom fix jib To circuit boom power tilt jib CN858 CN859 A Detail C Detail A Detail B C B ...

Page 243: ...2 3 1 Electric circuit boom head anemometer aviation obstruction light FE5027 Z 4 4 6 Electric circuit boom fix jib Z 4 4 7 Electric circuit boom power tilt jib Z 4 4 9 Electric circuit AML fix jib Z 4 4 10 Electric circuit AML power tilt jib Z 4 4 1 Electric circuit crane main Z 5 3 1 Electric circuit carrier main CN888 CN993 CN961 CN1595 Z 18 2 2 4 Electric circuit searchlight RA2 CN1563 CN1562 ...

Page 244: ... Searchlight power supply 1 UP 2 DOWN 3 R 4 L 5 Remote controller power supply LIGHT POWER Remote controller power supply 6 LIGHT POWER 7 POWER 8 COM 1 Power supply 2 GND 1 2 3 4 5 6 7 8 9 10 11 12 CN1779 To circuit common 1104AA W 1104AA W 1105AA Y 1105AA Y 1106AA BR 1106AA BR 1107AA G 1107AA G 1103AA O 1103AA O 1102AA L 1102AA L 1101AA GR 1101AA GR 1100AA SB 1100AA SB 1 25 233AB Y B 233AB Y B 0 ...

Page 245: ...6 7 8 9 10 11 12 13 14 CN1562 To circuit slewing table right option 1 2 3 4 1 2 3 4 CN1495 To circuit boom fix jib To circuit boom power tilt jib 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 CN1779 To circuit boom searchlight 1104AA W 1104AA W 1105AA Y 1105AA Y 1106AA BR 1106AA BR 1107AA G 1107AA G 1103AA O 1103AA O 1102AA L 1102AA L 1101AA GR 1101AA GR 1100AA SB 1100AA SB 1 25 233AB Y B ...

Page 246: ...R 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN1562 To circuit common 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 CN1728 To circuit crane main 1 2 3 4 5 6 7 8 9 10 CN1563 To circuit carrier main 1 2 CN1545 To circuit anemometer cab 1105AA Y 1105AA Y 1102AA L 1102AA L 1101AA GR 1101AA GR 1100AA SB 1100AA SB 1103AA O 1103AA O 1106AA BR 1106AA BR 1107AA G 1107AA G 1104AA W 1104AA W 1 25 233AB Y B 233AB Y B 0 85 B33AA...

Page 247: ...4A 1 2 3 4 5 6 7 8 9 10 CN1563 To circuit slewing table right option CN1569 CN1570 CN1571 CN1572 CN1568 CN1567 CN1566 CN1565 L R UP DOWN Remote controller power supply LIGHT POWER POWER COM 2 4 1 3 Searchlight relay 3 1 4 2 RA1 1104AA W 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB 1 25 152AA L Y 152AA L Y 1 25 233AA Y B 233AA Y B B033AB B B33AA B B33AC B B033AD B 167AC Y G Y G...

Page 248: ...N1 4 Ai4 4 CN1 5 Ai5 5 CN1 6 Ai6 6 CN1 7 Ai7 7 CN1 8 Ai8 8 CN1 9 AGND1 9 CN1 10 AGND2 10 CN1 11 AGND3 11 CN1 12 AGND4 12 CN1 13 N C 13 CN1 14 Ao1 14 CN1 15 Ao2 15 CN1 16 Ao3 16 CN1 17 Ao4 17 CN1 18 Ao5 18 CN1 19 Ao6 19 CN1 20 Ao7 20 CN1 21 Ao8 21 CN1 22 AGND5 22 CN1 23 AGND6 23 CN1 24 AGND7 24 CN1 25 AGND8 25 CN1 26 N C 26 1 2 3 4 5 6 CN1635 To circuit crane main 1 2 CN1545 To circuit slewing tabl...

Page 249: ...light power supply Anemometer signal Two blocking signal When operating boom connect this connector W R G B Y SHIELD Y R W G B SHIELD Cord reel 1 2 3 4 5 1 2 3 4 5 M6_1 25 2_Water proof E015 Ground 1 2 3 4 5 1 2 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 1 2 1 2 3 4 5 1 2 3 4 5 CN1496 To circuit jib1 anemometer aviation obstruction light Two blocking detection switch boom right contact open two b...

Page 250: ... G Aviation obstruction light GND Anemometer signal Anemometer power supply Aviation obstruction light power supply 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 CN1425 Anemometer 1 2 3 4 5 CN1497 1 2 3 4 5 CN1732 Aviation obstruction light 1 2 3 4 5 CN1496 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 C57 003 G C59 001 R C57 002 W C56 001 R C57 001 R C59 002 W C58 001 R C56 002 W C58 002 W C59 003 ...

Page 251: ... BR SLD W G To circuit jib1 anemometer aviation obstruction light Aviation obstruction light power supply Anemometer signal Anemometer power supply Aviation obstruction light GND 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 CN1732 Aviation obstruction light 1 2 3 4 5 CN1425 Anemometer 1 2 3 4 5 CN1497 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 C58 003 G C59 004 B C59 002 W C57 004 B C57 003 G C58 004 B C5...

Page 252: ...AA B G S63 147 R S65 147 R S65 149 GR W S63 149 GR W S63 171 G S65 171 G S65 172 B CAVS S63AB B Y CAVS S65AB B Y S63 172 B CAVS S75AB B Y SHIELD SHIELD Anemometer signal Aviation obstruction light power supply Aviation obstruction light GND Anemometer power supply Two blocking signal Aviation obstruction light GND Aviation obstruction light power supply Aviation obstruction light GND Aviation obst...

Page 253: ...1 428 066 22000 Searchlight Anemometer Aviation Obstruction Light Option WZ02 6732E Z 18 Z 18 144 3 General view 3 1 Searchlight IWZ02 5860E03a BR GR SB BR GR SB ...

Page 254: ...Searchlight Anemometer Aviation Obstruction Light Option WZ02 6732E Z 18 Z 18 2 344 957 32300 145 IWZ02 6233E04 3 2 Anemometer 3 2 1 FE5027 1 3 2 5 4 M CN1425 1 W SHIELD BR G 5 2 Harness ...

Page 255: ...Searchlight Anemometer Aviation Obstruction Light Option WZ02 6732E Z 18 Z 18 0 344 957 32200 146 IWZ02 6230E18c 3 2 2 FE5028 1 W SHIELD BR G 5 2 3 5 4 2 1 M 7 6 CN1425 Harness ...

Page 256: ...Searchlight Anemometer Aviation Obstruction Light Option WZ02 6732E Z 18 Z 18 1 344 957 42500 147 IWZ02 6230E19b M 1 2 3 4 5 3 3 Aviation obstruction light 3 3 1 FE5027 CN1732 G 1 0 3 4 B Harness ...

Page 257: ...Searchlight Anemometer Aviation Obstruction Light Option WZ02 6732E Z 18 Z 18 0 344 957 42600 148 IWZ02 6230E20c 3 3 2 FE5028 W 1 0 3 4 B M 4 5 3 2 1 6 7 CN1732 Harness ...

Page 258: ...arness boom searchlight CN1779 1104AA W 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB 233AB Y B B33AA B CN1561 1104AA W 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB CN1560 233AB Y B B33AA B 50 50 50 7900 COTØ10 M F F To circuit common Searchlight signal Searchlight power supply Plug Plug ...

Page 259: ...CN1570 CN1571 CN1572 CN1568 CN1567 CN1566 CN1565 CN1569 50 50 N001 650 350 CN869 152AA L Y 167AB Y G Y B B33AC B 152AA L Y 167AB Y G 233AA Y B B33AA B 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB 1104AA W F M 233AA CN1564A 50 50 50 50 50 50 50 100 To circuit slewing table right option R UP DOWN L Remote controller power supply LIGHT POWER POWER COM Working lamp carrier relay T...

Page 260: ...circuit anemometer cab FE5003 1100 50 N001 CN1562 CN1563 1104AA W 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB 233AB Y B B33AA B CN1728 1223AA Y B35AA B C56 001 B 1 C56 002 SB 1 C56 003 R 1 C56 004 G 1 C56 005 Y 1 C56 006 B 2 C56 007 GR 2 C56 008 R 2 C56 009 G 2 C56 010 Y 2 C56 011 BR 2 C56 012 L 2 C56 013 O 2 C56 014 V 2 CN1545 1221AA R 1222AA W 1500 8500 50 50 50 M M F M Yel...

Page 261: ...1 B 1 C56 002 SB 1 C56 003 R 1 C56 004 G 1 C56 005 Y 1 C56 006 B 2 C56 007 GR 2 C56 008 R 2 C56 009 G 2 C56 010 Y 2 C56 011 BR 2 C56 012 L 2 C56 013 O 2 C56 014 V 2 CN1779 1104AA W 1105AA Y 1106AA BR 1107AA G 1103AA O 1102AA L 1101AA GR 1100AA SB 233AB Y B B33AA B CN1495 B35AA B 1221AA R 1222AA W 1223AA Y N001 100 50 50 750 4250 COTØ13 COTØ07 CN1562 M F F M M Plug Plug Plug Plug Plug Plug Plug Plu...

Page 262: ...027 50 C59 001 R C59 002 W C59 003 G C59 004 B CN1496 C56 001 R C56 002 W C56 003 G C56 004 B C57 001 R C57 002 W C57 003 G C57 004 B C58 001 R C58 002 W C58 003 G C58 004 B CN1732 CN1425 CN1497 N001 12000 5 0 0 500 200 M F F F To circuit boom head anemometer aviation obstruction light Aviation obstruction light Anemometer To circuit jib2 anemometer aviation obstruction light ...

Page 263: ... BR S65AA B G CN1732 CN1425 Anemometer SHIELD SHIELD63A S63AA B G SHIELD SHIELD75A S75AA B G SHIELD SHIELD65A S65AA B G SHIELD SHIELD62A S62AA B G B Y B Y SHIELD SHIELD62B S62AB B Y SHIELD SHIELD63B S63AB B Y SHIELD SHIELD65B S65AB B Y SHIELD SHIELD75B S75AB B Y S62 147 R S62 149 GR W S62 171 G S62 172 B S62 184 Y S62 185 BR S62AA B G 500 500 200 CN1496 100 100 100 100 100 100 100 100 CN1497 Aviat...

Page 264: ...ess jib2 anemometer aviation obstruction light 4 6 1 FE5027 50 C57 001 R C57 002 W C57 003 G C57 004 B C58 001 R C58 002 W C58 003 G C58 004 B C59 001 R C59 002 W C59 003 G C59 004 B CN1425 CN1732 CN1497 2 0 0 2 0 0 8700 N001 F F M Anemometer Aviation obstruction light To circuit jib1 anemometer aviation obstruction light ...

Page 265: ...3 147 R S63 149 GR W S63 171 G S63 172 B S63 184 Y S63 185 BR S63AA B G S62 147 R S62 149 GR W S62 171 G S62 172 B S62 184 Y S62 185 BR S62AA B G 200 200 SHIELD SHIELD62A S62AA B G SHIELD SHIELD63A S63AA B G SHIELD SHIELD65A S65AA B G SHIELD SHIELD62B S62AB B Y SHIELD SHIELD63B S63AB B Y SHIELD SHIELD65B S65AB B Y CN1732 CN1425 CN1497 Anemometer 100 100 100 100 100 100 B Y B Y B Y B Y B Y B Y Yell...

Page 266: ...a Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug F F M CN1635 1221AA R 1226AA W B 1227AA B 1222AA W 1227AA B 1226AA W B CN1545 1221AA R 1222AA W 50 30 80 150 50 900 CN634 To circuit crane main To circuit slewing table right option Current voltage converter ...

Page 267: ...65A S65AA 1 0 0 B Y SHIELD B Y S65AA B S65 172 R S65 147 GR S65 149 G S65 171 SHIELD63A S63AA B Y 1 0 0 SHIELD R S63 147 GR S63 149 B S63 172 B Y S63AA G S63 171 CN1094 819AA Y 839AA R CN862 839AA R 816AA LG B CN859 816AA LG B 1223AB Y B35AB B 1221AB R 1222AB W CN1425 CN1732 CN1496 250 250 50 200 2 0 0 1800 N001 N002 C07 019 W C07 018 B CN901 E015 B60AA B 200 600 COTØ07 250 Two blocking detection ...

Page 268: ... S65AA B G B Y B Y B Y B Y B Y SHIELD SHIELD62A S62AA B G SHIELD SHIELD63B S63AB B Y S63 147 R S63 149 GR W S63 171 G S63 172 B S63AA B G S62 147 R S62 149 GR W S62 171 G S62 172 B S62AA B G S65 147 R S65 149 GR W S65 171 G S65 172 B S65AA B G CN1425 CN1732 CN1496 100 100 100 100 100 100 SHIELD SHIELD62B S62AB B Y 250 250 200 2 0 0 SHIELD SHIELD65B S65AB B Y Two blocking detection switch boom righ...

Page 269: ...n February 2016 History of revision 1 2 3 4 5 Head Office Ko 34 Sinden cho Takamatsu Japan Overseas Service Group Tadano Ryogoku Bldg 4 12 Kamezawa 2 chome Sumida ku Tokyo Japan Tel 81 3 3621 7765 Tel fax 81 3 3621 7785 ...

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Tadano GR-1600XL, Service Manual

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Summary of Contents for GR-1600XL

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