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WZ03-7570E

Z-5

Electric Circuit (Lower)

Z-5

2. Comparison table (connector No., usage, description, coordinate and paragraph No.)

CN No.

Usage

Description

Electric

circuit

coordinate

Electric

circuit

diagram

Harness

diagram

Outrigger ext./ret. selection solenoid valve

CN020 Retracting (SL20)

H-6

Z-5 3.1

Z-13 1.2

CN021 Extending (SL21)

H-5

Outrigger jack/slide selection solenoid valve

CN022 Slide (FR) (SL22)

F-19

Z-5 3.1

Z-13 1.2

CN023 Jack (FR) (SL23)

CN024 Slide (FL) (SL24)

F-17

CN025 Jack (FL) (SL25)

F-18

CN026 Slide (RR) (SL26)

CN027 Jack (RR) (SL27)

CN028 Slide (RL) (SL28)

F-17

CN029 Jack (RL) (SL29)

Steering mode selection solenoid valve

CN030 Crab steering (steering mode 2) (SL30)

I-7

Z-5 3.1

Z-13 1.2

CN031 4-wheel steering (steering mode 1) (SL31)

I-6

CN041 PTO (SL41) and lock up (SL49) solenoid valve

H-12

Z-5 3.1

Z-13 1.2

Transmission selection solenoid valve

CN043 F1 (SL43)

G-7

Z-5 3.1 Z-13 1.2

CN044 R (SL42) and F2 (SL44)

CN045 F3 (SL45)

CN046 High (SL46) and low (SL47)

CN050 Air solenoid valve (parking brake) (SL50)

Energized: parking brake not apply

Z-5 3.3

Z-13 2.

CN051 Air solenoid valve (2/4-wheel drive shift) (SL51)

Energized: 4-wheel drive

CN054 Air solenoid valve (exhaust brake) (SL54)

Energized: brake apply

CN064 Air solenoid valve (differential lock) (SL64)

Energized: differential lock

CN408 Straight ahead detection switch

Output: straight ahead

B-21

Z-5 3.1

Z-13 1.3

CN409 Low pressure switch (engine oil)

Contact close: low pressure

E-2

Z-5 3.2

Z-13 1.2

CN410 Air pressure detector

Contact close: low pressure

Z-5 3.3

Z-13 2.

CN411 Air pressure detection switch (parking brake)

Contact close: brake apply

CN412 Coolant level detection switch

Output: turn on 2 sec. or engine coolant level low

state

E-3

Z-5 3.2

Z-13 1.2

CN413 4WD detection switch

Contact close: 4-wheel drive

E-8

Z-5 3.1

CN414 Remaining brake fluid detection switch

Contact close: low level (front)

Z-5 3.3

Z-13 2.

CN415

Contact close: low level (rear)

CN416 Water in fuel sensor

Contact close: draining water state

CN419 Torque converter oil pressure detector

D-8

Z-5 3.1

Z-13 1.2

CN420 Main speed sensor

G-6

CN421 Sub. Speed sensor (pick-up sensor)

CN422 Outrigger length detector (FL)

D-6

CN423 Outrigger length detector (FR)

D-7

CN424 Outrigger length detector (RL)

D-6

CN425 Outrigger length detector (RR)

D-7

CN427 Torque converter oil temp. sensor

H-12

CN428 Fuel sensor

Contact close: little quantity

Z-5 3.3

Z-13 2.

CN431

Centralized greasing switch

Power

N-22

Z-5 3.1

Z-16 5.1

CN432

Distributor

CN433

Distributor

CN458 Differential lock switch

Contact close: differential lock apply

B-21

Z-5 3.1

Z-13 1.3

CN555 Temperature switch (50°C/122°F)

Contact close: more than 50°C (122°F)

F-7

Z-13 1.2

CN556 Temperature switch (85°C/185°F)

Contact close: more than 85°C (185°F)

CN568 Air pressure switch (stop lamp)

Contact close: depressing brake pedal

Z-5 3.3

Z-13 2.

CN600

VCU CN1 (main board)

A-2

Z-5 3.1 Z-13 1.2

CN601

C-2

CN602

E-2

CN603

G-2

CN604 VCU CN1 (sub. board)

I-2

CN605 VCU CN2 (sub. board)

J-2

CN606 VCU CN3 (sub. board)

K-2

CN607 VCU CN4 (sub. board)

L-2

CN608 VCU CN5 (sub. board)

N-2

CN619 For VCU maintenance

A-3

CN No.

Usage

Description

Electric

circuit

coordinate

Electric

circuit

diagram

Harness

diagram

CN685 Engine ECU (A)

B-15

Z-5 3.2

Z-13 1.2

CN686 Engine ECU (B)

C-15

CN687 Engine ECU (C)

E-15

CN688 Engine ECU (D)

F-15

CN689 Engine ECU (E)

G-15

CN691 Maintenance connector (MUT3)

H-15

CN701 Head lamp (L)

E-21

Z-5 3.1

CN702 Head lamp (R)

E-22

CN704

Head lamp relay

High beam lamp

H-22

CN705

Low beam lamp

I-22

CN706

Low beam signal VCU

I-23

CN707

Battery relay

CN708

High beam signal VCU

H-23

CN709

Combination lamp (R)

Right turn signal lamp

E-23

CN710

Clearance lamp

CN711 Combination lamp (L)

Left turn signal lamp

E-21

CN712

Clearance lamp

CN717A

Rear combination lamp (L)

Left turn signal lamp

H-21

CN717B

CN718

Clearance lamp/stop lamp

CN719A

Rear combination lamp (R)

Right turn signal lamp

H-23

CN719B

CN720

Clearance lamp/stop lamp

CN721A

Backup lamp

Backup lamp power

H-21

CN721B

Backup lamp ground

CN723 License lamp (option)

License lamp

G-22

CN730 DIAG switch

Releasing the connector can display the DIAG code

D-3

Z-5 3.2

CN731 DIAG lamp (red)

Turn on: engine stop state or engine critical faults

state

D-2

CN732

CN733

DIAG lamp (orange)

Turn on: engine stop state or engine non-critical

faults state

CN734

CN735 Centralized greasing indicator

Indicator lamp

N-21

Z-5 3.1

Z-16 5.1

CN743 Distributor (with switch)

N-22

Z-16 5.2

CN744 Grease pump

M-22

Z-16 5.1

CN745 Air dryer heater

Turn on: heater active

Z-5 3.3

Z-13 2.

CN747 Starter relay

Key switch

K-2

Z-5 3.2

Z-13 1.2

CN748

Alternator

Battery relay (R)/CHG detect (L)

J-3

CN749

Battery relay

CN750

K-3

CN751 Back buzzer

H-22

Z-5 3.1

Z-13 1.2

CN755 Fuse (glow) (70A)

Glow plug for engine

J-4

Z-5 3.2

CN758

Battery relay (-)

Fuse box (1)

M-22

Z-5 3.1

CN759

Fuse 75A

K-4

Z-5 3.2

CN760

Fuse box (2), (3)/head lamp relay

M-23

Z-5 3.1

CN761

Fuse 75A upper power supply

M-22

CN762 Battery relay (+) (relay coil side)

L-4

Z-5 3.2

CN763 Battery relay (+)

Direct connect battery

M-23

Z-5 3.1

CN765 N adjust (Terminal assy)

PTO max. revolution adjust

C-2

Z-5 3.2

CN767

Fuse box (2)

K-22

Z-5 3.1

CN768

CN769

CN770

K-21

CN771

CN772

CN778 Fuse (upper power supply) (75A)

L-22

CN779 Fuse (main) (75A)

J-4

Z-5 3.2

CN780

Center joint

N-4

Z-5 3.1

CN781

P-4

CN782

CN783

N-4

CN784

O-4

CN785

“Electric circuit diagram” and “Harness diagram” show each

applicable paragraph No. of this manual’s contents.

Refer to the contents.

Содержание GR-500EXL-3

Страница 1: ......

Страница 2: ...nd sales units in the parts catalog before replacing them 1 Applicable spec and serial number Spec No Applicable serial number GR 500E 3 00102 541100 Separate service manual Separate Service Manual Pu...

Страница 3: ...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...

Страница 4: ...iter AML AML C 7 Auto Stop solenoid valve energizing type Normally energized 8 Anti two block device Fitted 9 External warning lamp AML Fitted 10 Oil cooler Fitted 11 Air conditioner Fitted 12 ICF inf...

Страница 5: ...4 9 2903 10 2 9 2903 10 2 1 44 10 2 1 Volume cubic centimeter cm 3 cc cubic meter m 3 cubic inch in 3 cubic foot ft 3 gallon gal cubic inch in 3 liter lit L 1 1 10 6 6 10237 10 2 3 53147 10 5 1 2 31...

Страница 6: ...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 10 1 12...

Страница 7: ...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 w...

Страница 8: ...7 WA04 4610E 6 Group index System Diagrams Data Adjustment and Checks Y Z Y Z...

Страница 9: ...eding 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 Devi...

Страница 10: ...lic Parts Location Diagram Lower Z 7 Hydraulic Parts Location Diagram Torque Converter Z 8 Pneumatic Parts Location Diagram Z 9 Electric Parts Location Diagram Upper Z 10 Electric Parts Location Diagr...

Страница 11: ...vice 9 6 2 Braking device 9 6 3 Steering device 10 7 Mass table 11 Y 2 Adjusting Pressure Hydraulic Pressure 12 1 Location position of relief valve etc 12 2 Items 13 2 1 Winch 13 2 2 Telescoping 14 2...

Страница 12: ...tion detection switch left CN529 32 Y 6 Assembly Adjustment Crane Operation 33 1 Adjusting boom telescoping wire ropes 33 2 Installing and adjusting anti buckling bolts for telescoping cylinders 37 Y...

Страница 13: ...Operation Check Traveling Device 48 1 Exhaust brake 48 2 Automatic transmission 48 3 Steering mode change 49 4 Overshift prevention 49 5 Checking differential lock operation interwheel differential lo...

Страница 14: ...1 Engine oil 15 API Service Classification SAE30 class CD or better SAE10W 30 for cold climates Grease 1 Daphne Eponex SR No 2 Idemitsu Grease centralized greasing 1 Nigtight LE 0 Nippon Grease Fuel...

Страница 15: ...8 Eng 2860 40 Displacement cm 3 rev 42 7 34 0 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 Emergenc...

Страница 16: ...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...

Страница 17: ...ML 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 Suspensio...

Страница 18: ...Lower 12 10 Rear Upper on oblique face 49 46 Lower side 12 10 Standard or 15 or 13 3rd boom section Front Upper on upper part of side face 28 26 Lower side 12 10 Lower on oblique face 15 13 Lower 12 1...

Страница 19: ...15 B 14 B 1 5 L 1000 L length of each boom section Lateral Base boom 2nd boom section 3rd boom section 4th boom section Top boom section C 10 C 10 C 10 C 10 C 9 5 C 1 0 L 1000 Indentations at boom ov...

Страница 20: ...iameter mm 16 Nominal diameter 14 9 Construction P S 19 39 P 7 370 018 09860 Number of broken wire pcs 10 4th boom extension Wire rope diameter mm 16 Nominal diameter 14 9 Construction IWRC 6 P WS 31...

Страница 21: ...mooth 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...

Страница 22: ...40 ON 2150 50 0 Eco mode OFF When torque converter stalls Approx 2240 Reference value Check conditions PTO switch OFF Shift lever 2nd gear Drive selection switch 4WD High Service brake ON 6 2 Braking...

Страница 23: ...dard value Remarks Steering cylinder Pin outer diameter mm Cylinder side 35 0 009 0 025 Rod side 35 0 009 0 025 Wheel Camber 0 Caster 0 Kingpin angle 6 Toe in mm 0 Steering angle Inner wheel 26 0 1 Ti...

Страница 24: ...t 5850 12870 Slewing bearing 560 1230 Slewing drive unit including hydraulic motor 170 380 Center joint 85 190 Elevating cylinder 400 2 880 2 Winch assembly including hydraulic motor Main 330 730 Auxi...

Страница 25: ...12 WY02 1870E Y 2 Y 2 Service Data Y 2 Adjusting Pressure Hydraulic Pressure 1 Location position of relief valve etc...

Страница 26: ...and hydraulic valve winch brake 2 Turn the PTO switch ON 3 Move the winch lever that is blocked at its full stroke on the hoisting up side while the elevating lever is moved at its full stroke on the...

Страница 27: ...speed min 1 Check procedure MPa kgf cm 2 psi Boom extending V 16 7 0 5 170 5 2420 70 2150 MAX 1 Turn the PTO switch ON 2 Fully extend the boom 3 Move the telescoping lever at its full stroke on the ex...

Страница 28: ...e Engine speed min 1 Check procedure MPa kgf cm 2 psi Boom raising D 27 5 0 5 280 5 3980 70 2150 MAX 1 Turn the PTO switch ON 2 Fully extend the elevating cylinder 3 Move the elevating lever at its fu...

Страница 29: ...tration of slewing range limit function in AML Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Slewing 1 G 20 6 0 5 210 5 2990 70 Already the pressure is set by the valve ma...

Страница 30: ...ing then increase engine speed Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Outrigger I 20 6 0 5 210 5 2990 70 2600 1 Connect a pressure gauge to the pressure check port...

Страница 31: ...edure MPa kgf cm 2 psi Steering J 19 6 1 0 200 10 2840 140 2600 1 Connect a pressure gauge to the pressure check port J 2 Turn the PTO switch OFF 3 Without jacking up turn the steering to the right si...

Страница 32: ...Turn the PTO switch ON 3 Make sure that constant pressure is being produced while engine is running 4 And check the pressure by the pressure gauge Note Adjustment is not possible If the pressure is o...

Страница 33: ...speed min 1 Check procedure MPa kgf cm 2 psi Torque converter oil pressure 1 4 or over 14 or over 200 or over 670 IDL 1 Turn the PTO switch OFF with the air conditioner OFF 2 Confirm set pressure on...

Страница 34: ...ressure 850 8 7 123 Must be no leakage within pressure regulator operation range 129 Full opening pressure 950 20 9 7 0 2 138 3 Air low pressure switch total air low pressure warning Light on pressure...

Страница 35: ...G1 4 on the suction flange of the main pump After 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 mi...

Страница 36: ...turn the PTO 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...

Страница 37: ...ake reduce the winch speed as far as the drum can rotate Once you start bleeding a winch brake you need not move the winch lever to and fro Keep the lever to the position so that the drum rotates at t...

Страница 38: ...ep the slewing circuit hydraulic pressure at approximately 4 9 MPa 50 kgf cm 2 710 psi for approximately 30 seconds 4 2 Winch motor NOTICE Do not apply any load to the motor before completing air blee...

Страница 39: ...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 t...

Страница 40: ...section 7 and the positive control See the section 8 are bled Conditions Engine speed Idling 670 min 1 PTO ON 1 Open the air bleed plug and move the winch lever fully to the end of its stroke in the...

Страница 41: ...itch fixing bolt tightening torque 4 to 6 N m 41 to 61 kgf cm 3 to 4 4 ft lbf 2 2nd boom full retraction detection switch CN553 Adjust the switch position so that its contact is shifted opened closed...

Страница 42: ...t tightening torque 40 to 50 N m 410 to 510 kgf cm 29 5 to 36 8 ft lbf NOTICE Make sure that the red LED lights up when the switch is activated 4 Jib connection pin detection switch CN572 1 Slewing th...

Страница 43: ...locking agent ThreeBond 1401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 19 to 20 N m 193 to 204 kgf cm 14 to 14 8 ft lbf NOTICE Make sure that the gree...

Страница 44: ...ghtening torque 19 to 20 N m 193 to 204 kgf cm 14 to 14 8 ft lbf NOTICE Make sure that the green LED lights up when the switch is activated 8 Straight ahead detection switch CN408 Set the rear wheels...

Страница 45: ...Note Make the head surface of the bolt X flat beforehand Use the bolt X and the nut Y of roller assy 10 Over unwinding detection switch aux winch option CN596 Follow the same procedure as that in ove...

Страница 46: ...ng boom telescoping wire ropes 1 With the boom fully retracted tighten the nut A until a tension is placed on the top boom section retraction wire rope to keep the boom fully retracted 2 Tighten the f...

Страница 47: ...section extends by 1 to 5 mm 0 04 to 0 2 in from the 4th boom section 4 Tighten the nut A until the top and 4th boom sections are fully retracted 5 Extend the boom by 200 to 300 mm 8 to 12 in by opera...

Страница 48: ...third turn equally 7 2 Extend the boom by 200 to 300 mm 8 to 12 in by operating the boom telescoping control lever and then retract it fully Check the boom is fully retracted OK END NG 8 1 Tighten nu...

Страница 49: ...two nuts C by approximately a third turn equally 9 When only the 4th boom section is not fully retracted 9 2 Extend the boom by 200 to 300mm 8 to 12 in by operating the boom telescoping control lever...

Страница 50: ...inders 1 Connect the boom and telescoping cylinder using the pins A and B 2 Adjust the bolt C locked with nuts D and E so that it can be turned by hand and the clearance S is 0 5 mm 0 02in or less App...

Страница 51: ...vel and tighten the cap until it stops at the stopper At this time the position of tank body and cap should be as shown in Fig 1 In addition tighten the cap until the mark is aligned with the mark on...

Страница 52: ...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 ac...

Страница 53: ...6 14 5 0 800 100 0 8 0 1 0 116 14 5 0 4 2 Adjusting the steering angle 1 Jack up the vehicle Operate the steering cylinder 2 to 3 times with 4 wheel steering to bleed air out from the cylinder 2 Befor...

Страница 54: ...hometer and do not overrun the engine Max 2950 min 1 Drive speed selection must be done with the vehicle at a complete stop and with the brakes not applied The mechanism does not allow 2WD selection i...

Страница 55: ...er N position Operate the outrigger extend retract selector switch Icon flashes on the AML display Press all outrigger control switch Outriggers operate Main switch ON Shift lever Not in N position Op...

Страница 56: ...in the cab 2 Icon flashes on the AML display 3 Check that the extension width smaller than the detected value can be registered on AML manually 5 Jib side up function 1 Automatic stop by two blocking...

Страница 57: ...he limited AML override switch to ON With CN503 1 switch pressed extend the 3rd 4th and top boom by approximately 1m 3 3 ft each With CN503 1 switch pressed retract the 3rd top boom With CN503 2 switc...

Страница 58: ...the boom length reaches 18 43 m 60 5 ft With CN503 2 switch pressed retract the 2nd boom With CN503 1 switch pressed extend the 3rd 4th and top boom by approximately 1m 3 3 ft each With CN503 1 switch...

Страница 59: ...buzzer Sound Checking procedure AML limit Buzzer CN818 280Hz Continuous low tone Buzzer sounds at 100 when main switch is ON and PTO switch is ON Intermittent low tone sound occurs at 90 and above Tw...

Страница 60: ...ocation of the switch refer to Z 10 Electric Parts Location Diagram Upper 1 Inside cab While the PTO is engaged select the Eco mode 1 and Eco mode 2 and depress the accelerator pedal fully Then check...

Страница 61: ...t lever into the N position Adjust the engine speed to 1 000 min 1 or higher using the idling adjuster knob Exhaust brake indicator illuminates OFF Not activated 2 Return the engine speed to idling an...

Страница 62: ...speed to 22 km h Check that transmission does not downshift display 3 5 Gradually reduce speed Check that transmission downshifts to 2nd gear at 18 km h display 2 6 Maintain a speed of 11 km h Move t...

Страница 63: ...n when one is turned Differential lock OFF Check that the differential lock indicator is extinguished and that opposite wheel on the rear axle rotates in opposite direction when one is turned When the...

Страница 64: ...pressure 620 Hz Continuous beep high tone Buzzer sounds if the torque converter pressure is 1 0 MPa 10 2 kgf cm 2 145 psi or less while the parking brake is not applied 2WD 4WD select 620 Hz Continuou...

Страница 65: ...r at N position 2 Moving the shift lever D make sure that only D of gear position indicator on combination meter flashes When the emergency transmission switch is turned OFF D and 1 flash 3 Depressing...

Страница 66: ...sounds Steered a little 2 wheel Lit Continuous beep 4 Select the 4 wheel steering mode and check that the warning buzzer does not sound Steered a little 4 wheel Lit No beep 5 Set the rear wheel strai...

Страница 67: ...Aux winch telescoping and slewing pilot valve circuit Clean 1 point 30 7 Top cylinder selection hydraulic valve circuit Clean 1 point 30 8 Top cylinder retracting prevention hydraulic valve circuit C...

Страница 68: ...om Connecting Pin 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 500E 3 Part Name Diameter Thread size Elevating cylinder Rod...

Страница 69: ...c circuit 10 4 1 Electric circuit crane 10 4 2 Electric circuit carrier 11 4 3 Electric circuit slewing table right 12 4 4 Electric circuit slewing table left 13 4 5 Electric circuit boom jib single t...

Страница 70: ...rake related lower 36 3 Control parts lower 37 Z 10 Electric Parts Location Diagram Upper 38 1 Inside cab 38 2 Relay assy inside cab 39 3 Slewing table boom 40 4 Pressure switch installation diagram 4...

Страница 71: ...age and paragraph No 69 2 3 Electric circuit 70 2 3 1 Electric circuit slewing table left 70 2 3 2 Electric circuit boom 71 2 3 3 Electric circuit jib 72 3 General view anemometer 73 4 Harness anemome...

Страница 72: ...wing right proportional control valve SL120 Slewing left proportional control valve SL121 Solenoid valve for slewing free lock selection SL161 Slewing relief proportional control valve SL162 39 Hydrau...

Страница 73: ...3 05 12 2 13 2 10 2 RR RL RL RL RR RR 02 04 06 03 31 C A C A P A B SL24 SL22 B A P B4 A4 A3 B3 T2 A2 B2 B1 A1 50 85 65 66 A1 A2 01 a5 38 30 3 39 b5 30 4 a1 53 48 6 45 2 48 5 b5 a5 P T O 11 2 T P1 P2 D...

Страница 74: ...High SL46 F1 F2 R SL47 Low Front Lock up SL49 Accumulator SL41 P T O Line filter 20 M14 1 5 G1 G3 8 G3 8 Torque converter case M16 1 5 G1 G1 Oil cooler G3 8 G3 8 Torque converter inlet relief valve S...

Страница 75: ...lve Check valve Cracking pressure 850 kPa 8 7k gf cm2 123 psi Full opening pressure 950 20 kPa 9 7 0 2 kgf cm2 138 3psi Safety valve Air compressor Turning on pressure 710 20 kPa 7 2 0 2 kgf cm 103 3...

Страница 76: ...shown by following block diagram Z 4 4 3 Electric circuit slewing table right Center joint Z 5 Electric circuit lower cab CN894 CN1331 Z 4 4 7 Electric circuit SCT Z 4 4 6 Electric circuit GSMT CN1072...

Страница 77: ...e S AA Example S016 AA S016 AB 6 Joint label Same with Wire label J AA Example J001AA J035AA J106AA J1000AA JC01AA JS016AA JB01AA 7 Node name at diverging point N Wire 1 Indication of wire size Indica...

Страница 78: ...L G W L Y G B Exhaust brake switch Notice shows the momentary switch 3 6 1 4 1 4 3 6 3 Up Down Switch Lower outrigger operation jack slide selection Middle OFF 3 OFF Outrigger operation box illuminat...

Страница 79: ...horn D 2 CN532 Main winch hoisting up detection switch Contact open hoisting up Z 4 4 4 Z 12 3 CN533 Aux winch hoisting up detection switch Contact open hoisting up CN534 Boom extending detection swi...

Страница 80: ...GSMT Z 4 4 6 Z 12 6 CN1605 Air conditioner water pump Turn on water pump start M 1 Z 4 4 2 Z 12 1 2 CN No Usage Description Electric circuit coordinate Electric circuit diagram Harness diagram CN1610...

Страница 81: ...connector to slewing table left 3 2 1 4 5 6 3 1 4 6 5 2 CN580 Slewing angle detector SHIELD2B 1 2 3 4 5 6 7 8 9 10 11 JC11 JC11 1 12 13 14 15 16 17 18 19 20 21 22 JC11 2 23 24 25 26 27 28 29 30 31 32...

Страница 82: ...CN1067 1 2 3 4 5 6 CN639 4 6 8 2 5 9 1 3 7 1 2 1 CN588 1 2 3 CN587 2 1 CN548 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 4 2 6 1 3 5 6 5 4 3 2 1 CN586 SHIELD22 1 4 2 5 3 12 13 14 15 16 17 18 19...

Страница 83: ...1 W S03 023 R S03 023 R S04 026 R 1 25 S03 AA B 130AA L Y 130AA L Y S43 122 R S43 122 R S43 123 W S43 123 W S04 025 B S04 AA B B76AB B 1 25 B76AA B B76AA B 1 25 B76AD B B76AJ B Output Pressure sensor...

Страница 84: ...oportional control valve Slewing relief proportional control valve Slewing relief proportional control valve Boom angle detector Boom length detector Boom length and angle detector 5V Boom length and...

Страница 85: ...C06 019 B C06 018 W R G G B S62AB G B C06 019 B C06 018 W C06 019 B C06 018 W 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Working lamp boom option Jib lock pin detection s...

Страница 86: ...Instrument_GND 30 1 30 External_Instrument_CS 31 1 31 External_Instrument_RX 7 1 7 NC 2 1 2 GND 34 1 34 BATT_GND 1 1 1 NC 3 1 3 NC 19 1 19 WAKE_UP 4 1 4 NC 5 1 5 NC 6 1 6 NC 28 1 28 ICF_RX 8 1 8 NC 9...

Страница 87: ...1 20 RXD1 8 1 21 RS1 7 1 22 TERM_GND 6 1 23 NC 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...

Страница 88: ...cuit diagram of this machine is composed of Z 4 Electric Circuit Upper and Z 5 Electric Circuit Lower mainly The electric circuit lower is shown by following block diagram Center joint Z 5 3 1 Electri...

Страница 89: ...2 F Contact close more than 50 C 122 F F 7 Z 13 1 2 CN556 Temperature switch 85 C 185 F Contact close more than 85 C 185 F CN568 Air pressure switch stop lamp Contact close depressing brake pedal Z 5...

Страница 90: ...For A C water pump I 6 Z 13 1 2 CN1640 Resistance CAN J 15 Z 5 3 2 CN1680 Fuse box 1 J 22 Z 5 3 1 CN1681 CN1682 CN1683 J 21 CN1684 CN1685 CN1690 Fuse box 3 I 22 CN1691 CN1692 I 21 CN1693 CN1720 Return...

Страница 91: ...W8 4 CN4 4 RPOW9 7 CN4 7 Do25 8 CN4 8 Do26 9 CN4 9 Do27 3 CN4 3 Do28 10 CN4 10 RPOW10 2 CN4 2 Do29 1 CN4 1 Do30 6 CN4 6 Do31 12 CN4 12 GND 21 CN5 21 RPOW11 20 CN5 20 Do33 19 CN5 19 Do34 18 CN5 18 Do35...

Страница 92: ...LER SW 53 B 23 23 NEUTRAL SW 58 B 10 10 IDLE UP CANCEL SW 51 B 12 12 EXH BRAKE SW 49 B 13 13 STARTER SW S 48 B 15 15 STARTER SW M 1 46 B 18 18 STARTER SAFETY RELAY 43 B 20 20 ACCEL SW 61 B 22 22 COLD...

Страница 93: ...CN428 Fuel sensor 1 2 CN411 Air pressure detection switch parking brake 2 1 CN051 SL51 Air solenoid valve 2 4 wheel drive shift 2 1 CN568 Air pressure switch stop lamp 2 1 CN064 SL64 Air solenoid valv...

Страница 94: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 23 WZ07 3970E Z 6 Hydraulic Parts Location Diagram Upper 1 Winch 2 Telescoping 2 343 466 11000 3 343 466 12000 1 342 116 00000...

Страница 95: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 24 WZ07 3970E 3 Elevation 4 Slewing 3 343 550 20000 0 342 411 80000 0 343 009 70000 1 343 466 13500...

Страница 96: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 25 WZ07 3970E 5 Return 6 Drain 4 343 466 14000 3 343 466 15000...

Страница 97: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 26 WZ07 3970E 7 Gauge 8 Winch brake 1 343 466 16000 2 343 466 16500...

Страница 98: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 27 WZ07 3970E 9 Pilot 10 Steering 3 343 466 17000 2 347 226 70000 0 347 223 81000...

Страница 99: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 28 WZ07 3970E 11 Air conditioner 12 Operation assy operation valve 2 345 115 01000 2 343 234 80000...

Страница 100: ...29 WZ07 3970E Z 6 Z 6 Hydraulic Parts Location Diagram Upper 13 Pressure switch 14 Jib side up and down 1 343 638 33000 2 343 466 82000...

Страница 101: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 30 WZ07 3950E Z 7 Hydraulic Parts Location Diagram Lower 1 Suction 0 346 418 01000 2 347 337 70000...

Страница 102: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 31 WZ07 3950E 2 Steering 2 346 418 02000...

Страница 103: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 32 WZ07 3950E 3 Outrigger H type 4 Center joint 5 346 418 04000 1 346 418 03000...

Страница 104: ...33 WZ07 3950E Z 7 Z 7 Hydraulic Parts Location Diagram Lower 5 Return 6 Outrigger main body H type 0 346 118 40000 4 346 418 05000...

Страница 105: ...34 WZ07 3960E Z 8 Z 8 Hydraulic Parts Location Diagram Torque Converter Z 8 Hydraulic Parts Location Diagram Torque Converter 1 Torque converter related 4 349 317 60000 3 349 232 50000...

Страница 106: ...Z 9 Z 9 Pneumatic Parts Location Diagram 35 WZ08 0590E Z 9 Pneumatic Parts Location Diagram 1 Service brake related upper 1 343 466 00000 0 347 226 00000...

Страница 107: ...Z 9 Z 9 Pneumatic Parts Location Diagram 36 WZ08 0590E 2 Service brake related lower 7 349 232 70000...

Страница 108: ...37 WZ08 0590E Z 9 Z 9 Pneumatic Parts Location Diagram 3 Control parts lower 4 349 232 60000...

Страница 109: ...oint connector to slewing table right CN894 CN1331 Joint connector to slewing table left CN887 CN889 CN890 CN891 CN1206 Slewing angle detector CN580 Joint connector to reserve CN921 Joint connector CN...

Страница 110: ...n Down Normal state c Emergency accelerator Push Emergency operation Release Normal state Push Emergency operation Release Normal state Up Emergency transmission operation Down Normal state Emergency...

Страница 111: ...2 CN102 Top cylinder selection solenoid valve SL230 CN230 AML vent solenoid valve SL100 CN100 Harness slewing table right Drum rotation detection switch main winch CN591 External indicator lamp 2 colo...

Страница 112: ...detection switch Boom extending detection switch Aux winch hoisting down detection switch OFF ON ON OFF ON ON OFF ON ON Left detection Right detection Extending detection Hoisting down detection d f...

Страница 113: ...to cancel the anti two block function Snap pin View C When not using main hook remove the weight CN862 Two blocking detection switch boom Harness boom head Main two blocking detection switch assy Circ...

Страница 114: ...ness single top CN900 Joint connecter Single top stowed state Harness single top FRONT CN901A Joint connecter CN900 Joint connecter Circuit diagram CN902 CN948 CN901B CN1495 CN900 CN901A CN901 CN862 B...

Страница 115: ...on switch assy Boom right side CN1778 Sub two blocking detection switch assy Harness jib 2 head Harness jib 1 Harness jib 2 bottom CN859 From cord reel boom length detector When operating jib CN948 Jo...

Страница 116: ...4 962 80000 Detail of device connection GPS antenna Main harness GPS antenna GPS antenna Harness GSMT Harness GSMT GSMT GPS antenna cable connection port ICF CN1065 CN1066 CN1072 CN1584 GSMT global sy...

Страница 117: ...erminal CN1065 CN1066 CN1068 CN1072 Detail of device connection GPS antenna Detail B View A SCT Antenna cable connection port Main harness Antenna cable Antenna for satellite communications Connector...

Страница 118: ...solenoid valve Extending SL21 CN021 Jack FL SL25 CN025 Outrigger jack side selection solenoid valve Outrigger jack side selection solenoid valve Slide FR SL22 CN022 Jack FR SL23 CN023 Outrigger length...

Страница 119: ...inal base b contact Normal close type relay a contact Normal open type relay View A 270 3 2 4 5 6 1 6 4 4 L G B 6 4 7 B W CN765 M 644 LG B 647 B W A Controller VCU RF2 connector No RF2 7 M Pole CN No...

Страница 120: ...704 CN1004 CN705 DIAG switch CN730 Memory clear switch CN797 S1 B S2 L1 S L2 Head lamp relay 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 H G F E D C A B 15A 5A 5A 5A Y X K 1A J 1A I 5A H 5...

Страница 121: ...16 CN837 Condenser washer motor J 2 CN838 CN839 CN849 Washer motor roof I 2 CN850 Washer motor front I 3 CN868 Fuse box 2 E 13 CN869 CN870 CN871 E 14 CN872 F 13 CN873 CN874 Fuse box 1 H 13 CN875 CN876...

Страница 122: ...p 035BK BR B30DI B CN467 Power window switch 127AA L 128AA L Y B30AM B 218AB Y G B30AN B 157AK R G 157AA R G 157AS R G 122AA R W 122AB R W 122AC R W B30CU B B30CX B B30CY B B30AI B B30CQ B 035AP BR 03...

Страница 123: ...W S03 022 B S03 AA B SHIELD SHIELD4 S04 AA B SHIELD SHIELD43 S43 AA B SHIELD SHIELD3 S03 AA B B76AA B 800 250 1100 300 2800 CN521 Over front detection switch 333AA B W B76AB B 156AA R Y CN890 Externa...

Страница 124: ...m telescoping aux winch control selection solenoid valve SL143 B75AD B 337AA LG W CN534 Boom extending detection switch 250AJ LG 263AA W G CN144 Boom telescoping aux winch control selection solenoid v...

Страница 125: ...etection switch 305AA R 250AB LG B01AC B 750 50 150 CN576 Boom length and angle detector S06 013 G S06 014 W S06 015 R S06 AA Y S06 016 B GR W GR CN858 Cord reel boom length detector 818AA W Y 304AA G...

Страница 126: ...ss boom head Two blocking detection switch boom Joint connector CN901 Connector CN901 1 2 3 0 5B Vinyl 04 05 Green tape 3rd top boom full retraction detection switch 320 Vinyl 05 07 0 75W 0 75B M F F...

Страница 127: ...Harness Upper WZ04 5300E Z 12 Z 12 1 345 006 82100 56 5 2 Harness single top IWZ04 5280E06 C06 018 W C06 019 B CN901A 800 C06 018 W C06 019 B CN900 M F Joint connector Joint connector COT 07...

Страница 128: ...1495 W B R G G B R G G B M M M C06 019 S62 147 S62 148 S62 147 S62AA S62AD S62 148 C06 018 W B C06 019 C06 018 Joint connector Joint connector Joint connector 550 COT 10 500 COT 07 8400 COT 10 SHIELD...

Страница 129: ...8 IWZ04 5280E08 5260 50 40 N001 COT 10 330 COT 10 CN948A F Joint connector CN1778 B Plug W B R G G B F 50 180 C06 019 W C06 018 R S62 147 G S62 148 G B S62AB Joint connector Yellow tape SHIELD SHIELD6...

Страница 130: ...1700 5 5 Harness jib 2 head 59 IWZ04 5280E09 Joint connector Joint connector Joint connector Yellow tape COT 10 COT 07 30 390 COT 10 330 CN1778 F F CN902 B C06 019 W B Plug Plug Plug Plug M W C06 018...

Страница 131: ...006AC O B51AE B 826AA W L 821AA W B 822AA W R B51AF B 822AA W R 016AC Y L 006AC O 826AA W L B51AH B 821AA W B B51AG B GSMT M 28 7 8 20 12 9 23 25 27 2 18 5 4 29 10 24 19 3 21 22 26 6 1 11 13 16 15 17...

Страница 132: ...344 941 00101 7 Harness SCT 61 IWZ04 5190E10 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...

Страница 133: ...ordinate CN720 Rear combination lamp R N 21 CN721A Backup lamp M 19 CN721B CN723 License lamp option L 19 CN730 DIAG switch C 21 CN731 DIAG lamp red D 20 CN732 CN733 DIAG lamp orange E 20 CN734 CN747...

Страница 134: ...CC B B08CD B B08CE B SHIELD SHIELD16 S16 AA B SHIELD SHIELD48 S48 AA B Combination lamp L CN1008 B10AT B Combination lamp R CN1009 B10AC B CN793 Engine harness B 653AA Y G 699AD B Y 693AB R W 641AA LG...

Страница 135: ...low tape F F Plug SHIELD SHIELD61 S61 AA B COT 07 760 N001 CN408 Straight ahead detection switch S61 143 Y S61 146 B S61 142 R 30 220 COT 05 CN1600 Joint connector rear axle S61 142 R S61 143 Y S61 14...

Страница 136: ...tial lock SL64 B20AE B 137AA R B 270 110 100 30 CN745 Air dryer heater B20AB B 556AA R W 250 250 50 70 450 COT 10 COT 05 COT 10 COT 07 COT 05 COT 05 COT 10 COT 05 CN054 Air solenoid valve exhaust brak...

Страница 137: ...CN1809 Circut diagram Detail E Harness slewing table left Harness boom Cap To cord reel To anemometer CN1635 CN634 Current voltage converter Detail A Harness crane and carrier Relay assy Harness slewi...

Страница 138: ...CN901B Joint connector CN1495 Joint connector CN901B Joint connector CN901B Joint connector CN1495 Joint connector JIB 2 JIB 1 JIB 1 CN948A Joint connector CN948A Joint connector JIB 1 JIB 1 JIB 2 An...

Страница 139: ...circuit diagram The electric circuit anemometer is shown by following block diagram CN1425 CN1635 Z 14 2 3 2 Electric circuit boom Z 4 4 1 Electric circuit crane Z 14 2 3 1 Electric circuit slewing t...

Страница 140: ...N948B Z 14 4 4 CN1425 Joint connector to boom Z 14 2 3 1 Z 14 4 1 Joint connector to slewing table left Z 14 2 3 2 Z 14 4 2 CN1426 Joint connector to jib Joint connector to boom Z 14 2 3 3 CN1495 Join...

Страница 141: ...ND1 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...

Страница 142: ...e is AVS and wire size is 0 5mm2 2 2 1 2 3 4 5 6 CN1425 1 2 3 4 5 6 CN1426 E001 M6_1 25 2_Water proof Ground S66 147 S66 147 S66 148 B S66 148 B S66 171 R S66 171 R S66 172 G S66 172 G 1 25 S66AB B Y...

Страница 143: ...019 B C06 018 W R G G B S62AB G B 1 2 3 1 2 3 1 2 3 4 5 1 2 3 4 5 6 7 6 7 G G B R CN948A SHIELD62B SHIELD62A 1 2 3 4 5 1 2 3 4 5 6 7 6 7 1 2 3 4 5 6 C06 019 B S62 147 R S62 148 G S62AA G B S62AB G B C...

Страница 144: ...Anemometer Option WZ02 6810E Z 14 Z 14 3 344 961 21200 73 IWZ02 6540E07a 3 General view anemometer 1 W SHIELD G Harness 2 3 5 4 2 1 M 7 6 CN1495 or CN1497...

Страница 145: ...r to crane B02AA B S64AB B Y 50 COT 10 COT 07 4200 250 SHIELD SHIELD64A S64AA B Y CN634 S64 147 W 1419AA Y S64 171 R S64 172 G CN1425 Joint connector to boom S64 171 R S64 147 W S64 148 B S64 172 G S6...

Страница 146: ...41307 2 2 2 CN1425 S66 171 R S66 147 S66 148 B S66 172 G S66 151 Y S66AB B Y CN1426 S66 171 R S66 147 S66 148 B S66 172 G S66 151 Y S64AA B Y SHIELD SHIELD66 S66AB B Y Ground E001 S64AA B Y N001 7700...

Страница 147: ...CN1495 W B R G G B R G G B M M M C06 019 S62 147 S62 148 S62 147 S62AA S62AD S62 148 C06 018 W B C06 019 C09 018 Joint connector Joint connector Joint connector 550 COT 10 500 COT 07 8400 COT 10 SHIEL...

Страница 148: ...ter Option Z 14 Z 14 5300 50 N001 COT 10 330 COT 10 CN948A F Joint connector CN1778 B Plug W B R G G B F 50 180 06 019 W 06 018 R S62 147 G S62 148 G B S62AB Joint connector Yellow tape SHIELD SHIELD6...

Страница 149: ...B 30 M Plug S62 147 R S62 148 G S62AD G B CN902 Joint connector anemometer SHIELD SHIELD62B S62AB G B SHIELD SHIELD62C S62AC G B SHIELD SHIELD62E S62AE G B SHIELD SHIELD62D S62AD G B SHIELD SHIELD62F...

Страница 150: ...justment main menu 3 To terminate the adjustment mode press the key while the adjustment main menu is being displayed Note In detail refer to Chapter D Adjustment Mode in the separate service manual A...

Страница 151: ...p Option Z 15 Z 15 1 Structure beacon lamp Z 15 Beacon Lamp Option Z 15 Joint connector CN1796 Harness beacon lamp When not using beacon lamp connect plug connectors together Beacon lamp Plug connecto...

Страница 152: ...0 344 450 10100 IWZ02 6790E02 WZ02 6820E Z 15 Z 15 81 Beacon Lamp Option 2 Lamp beacon Beacon lamp Vinyl tape Plug connector 700 F W W Plug M W GR Plug GR 100 100 CN1795...

Страница 153: ...456 80200 IWZ02 6820E02 WZ02 6820E Z 15 Z 15 82 Beacon Lamp Option 3 Harness beacon lamp R B Plug R F Plug W W M B M 2200 100 CN1796 Joint connector CN1795 Plug connector 100 COT 07 30 Beacon lamp op...

Страница 154: ...ump The centralized greasing supply unit automatically supplies grease to the necessary points of the carrier by switch operation Detail A 4 FR King pin upper 6 FR Steering cylinder 2 FR Steering rod...

Страница 155: ...Centralized greasing switch CN431 CN432 CN433 Centralized greasing indicator CN735 CN1042 Grease pump CN744 Harness main and engine Harness main and engine Joint connector CN1798 CN744 Distributor wit...

Страница 156: ...box 2 CN770 1 2 3 4 CN768 2 3 1 2 3 1 CN743 Distributor with switch CN735 CN1042 Centralized greasing indicator CN432 CN431 1 2 CN433 Centralized greasing switch 2 3 1 CN1799 Haness main and engine 1...

Страница 157: ...acement 13cm 3 min or more Discharge pressure MAX 14 7MPa 150kgf cm 2 Tank capacity 400cm 3 Effective 300cm 3 Grease Grease used at shipment Equivalent Manufacturer Brand Manufacturer Brand Nippon Gre...

Страница 158: ...Item Specification Model U 8MT Displacement Switching pressure 0 9MPa 10kgf cm 2 or less Working pressure MAX 14 7MPa 150kgf cm 2 Thread size and tightening torque Sign Port Thread size Tightening tor...

Страница 159: ...N744 B01AC B 119AC L R CN1042 006AB O 139AB L Y B01AB B CN433 140AB L G 50 50 150 COT 07 1150 50 50 50 50 Centralized greasing indicator Grease pump Centralized greasing indicator Centralized gresing...

Страница 160: ...d Lubrication System Option WZ02 6800E Z 16 Z 16 89 5 2 Harness distributor M F 50 50 350 COT 07 CN1799 Joint connector centralized lubrication option 140AA L G 119AB L R 139AC L Y CN743 Distributor w...

Страница 161: ...on March 2015 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 f...

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