EX2500-6 General Info
July 31, 2022 | Author: Anonymous | Category: N/A
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Contents INTRODUCTION CAB
..................................................................................................1 Right Conso Console le ........... ...................... ...................... ...................... ...................... ...................... .....................7 ..........7 Left Console ..............................................................................7 Electric Elect ric Lever Levers s ........... ...................... ...................... ...................... ...................... ...................... ....................9 .........9 Monitor Displ Monitor Display ay........... ...................... ...................... ...................... ...................... ...................... ................. ...... 11 Information Inform ation Displ Display ay Unit (IDU) ........... ...................... ...................... ...................... ................ ..... 11 Behind Behin d Opera Operator’s tor’s Seat .......... ..................... ...................... ...................... ...................... ................ .....13 13
AIR CONDITIONER UNIT
Compressor ............ ......................... .......................... .......................... .......................... .......................... ............. 15 Filters...................... Filters.......... ....................... ...................... ...................... ...................... ....................... .....................15 .........15 Receiver Tank..........................................................................17
ENGINE
Fuel Filters (St (Stage age 1) ............. ........................... ........................... .......................... ....................... .......... 19 5 Bar Electric Electric Priming & St Starting arting Assist Pump ............. ......................... ............ 19 Fuel Filter Wrench ...................................................................21 Left Bank .................................................................................23 Fuel Filters (St (Stage age 2) and Fue Fuell Supply Pump .............. .......................... ............ 23 Left Bank .................................................................................25 Fuel Supp Supply ly Pump ........... ...................... ...................... ...................... ...................... ...................... ............. 25 Fuel Line.............. Line......................... ....................... ....................... ...................... ....................... .......................27 ...........27 Fuel Filter Filters s ........... ....................... ....................... ...................... ...................... ...................... .......................27 ............27 Pre-Lube Pump .......................................................................29 Starti tarting ng Motor .......... ..................... ...................... ....................... ....................... ...................... ...................29 ........29 Pre-Lub Pump .........................................................................31 Engine .....................................................................................31 Specification ............................................................................33 Rightt Bank .......... Righ ..................... ...................... ...................... ...................... ...................... ...................... .............. ...35 35 Engine Engi ne Oil Filter Filters s .......... ..................... ...................... ....................... ....................... ...................... .............. ...35 35 Sensors ...................................................................................37 Alternator ............ ......................... .......................... .......................... .......................... .......................... ................. .... 39 Engine .....................................................................................39 Electric Supply Lines to Injector...............................................41 Exhaust Manifolds ...................................................................41
Contents Intake & Turbochargers ...........................................................43 Turbochargers Lubrication.......................................................43 LTA ..........................................................................................45 Water Pump Plumbing.............................................................45 Flywheel Crank Position Sensor 3...........................................47 Camshaft Speed & Position Sensor.........................................47 Exhaust Mufflers & Air Cleaners ............ ......................... .......................... ..................... ........ 49 Air Cleaners............ Cleaners ......................... .......................... .......................... .......................... .......................... ............. 49 Oil Reserve Tank .....................................................................51 Coolant Coola nt Rese Reservoir.................... rvoir............................... ...................... ...................... ...................... ............... ....53 53 Coolant Reservoir Sensors......................................................53 Coolant Coola nt Rese Reservoir.................... rvoir............................... ...................... ...................... ...................... ............... ....55 55 PUMP TRANSMISSION
Transmiss Transmission ion Oil Cooler............. Cooler.......................... .......................... .......................... .................... ....... 57 T/M Oil Filter Filter........... ...................... ...................... ...................... ...................... ....................... .....................57 .........57 T/M Oil Level Filter...................................................................59
PUMP
Main Pump Pumps s (MP1 to 6) ........... ...................... ...................... ...................... ....................... ............... ...61 61 4-UNIT PUMP..........................................................................61 Regulator Regu lator........... ...................... ...................... ....................... ....................... ...................... ...................... .............. ...63 63 Pump Drain Pressure Sensor & Contamination Sensor .......... 65
PUMP CONTROLS
EHC Valve ............ ......................... .......................... .......................... .......................... .......................... ............... .. 67
CONTROL VAL ALVE VE
............. .......................... .......................... .......................... .......................... .......................... .......................... .................. ..... 69
FRONT PIPING ............ ......................... .......................... .......................... .......................... .......................... .......................... ................... ...... 69 QUICK RESPONSE VAL ALVES VES ............. .......................... .......................... .......................... .......................... .......................... .......................... .................. ..... 71 (For Front) PILOT PANEL
........... ......................... ........................... .......................... .......................... .......................... .......................... ................... ...... 71
EHC VAL ALVE VE FOR ELECTRIC LEVER CONTROL ............. .......................... .......................... .......................... .......................... ............... .. 73 SWING DEVICE
............. .......................... .......................... .......................... .......................... .......................... .......................... .................. ..... 75 Swing Motor Motors s ........... ...................... ....................... ....................... ...................... ...................... ...................75 ........75
RADIATOR RADIA TOR FA FAN N
............ ........................ ......................... .......................... .......................... .......................... .......................... .................... ....... 79
RADIATOR RADIA TOR & LTA COOLER
............ ......................... .......................... ........................... ........................... .......................... .......................... .................. ..... 79
RADIATOR RADIA TOR SENSORS
............ ......................... .......................... .......................... .......................... .......................... .......................... ................... ...... 81
OIL COOLER
............ ......................... .......................... .......................... .......................... .......................... .......................... ................... ...... 83
Contents OIL COOLER FAN MOTOR
............ .......................... ........................... .......................... .......................... .......................... .......................... .................. ..... 83 Oil Temperature Sensor...........................................................85
HYDRAULIC
High Pressure Strainers.......... Strainers........................ ........................... ........................... ...................... ........ 87 Pilot Filter.................................................................................87
ELECTRIC
Electric Equipment Box............. Box......................... ......................... .......................... ...................... ......... 89 Contamination Sensor Unit......................................................89
HYDRAULIC HYDR AULIC
Pilot Accum Accumulator ulators s .......... ..................... ...................... ....................... ....................... ...................... ............. 91
ENGINE FAUL AULT T INDICA INDICATOR TOR
............ ......................... .......................... .......................... .......................... ........................... ........................... .................. ..... 93
ELECTRIC
Electric Equipment Box............. Box......................... ......................... .......................... ...................... ......... 95 Ground Cut-off Switch .............................................................95
FUEL TANK
Fuel Level Sensor & Switches ............. .......................... .......................... ....................... .......... 97
HYDRAULIC OIL TANK
Full Flow Filter ............ ......................... .......................... .......................... .......................... ...................... ......... 99 Bypass Byp ass Filter.................. Filter............................. ...................... ...................... ...................... ...................... .............. ...99 99 Hydraulic Oil Tank..................................................................101 Stop Valves & Limit Switches.................................................103
GREASE SYSTEM
............ ......................... .......................... .......................... ......................... ......................... .......................... .................. ..... 105
FAST FA ST-FILL -FILL SYSTEM
............. .......................... .......................... .......................... .......................... .......................... ......................... ................ .... 111
AIR HORN
Air Compressor & Air T Tank....... ank..................... ........................... .......................... ................... ...... 115 Air Horns & Filter ............. .......................... .......................... .......................... .......................... ............... .. 115
WINDOW WASHER
Washe Washerr Tank ank............. .......................... .......................... .......................... .......................... ...................... ......... 117
FOLDING ST STAIRWA AIRWAY Y
............ ......................... .......................... ......................... ......................... .......................... .......................... .................. ..... 119 Switch Switc h Box.................. Box............................. ...................... ...................... ...................... ....................... ............... ...121 121
INTRODUCTION
0740-001
-1-
Line-Up of Excavators
Line-Up of Large Size Dump Trucks
-2-
INTRODUCTION
0740-002
-3-
250 ton Specification Comparison
Improved from -5 version
Manufacturer Model EX2500-6 Operating Weight (LD/BH) (t) 249／248 Manufacturer Cummins Engine Model QSKTA50-CE SAE J1995(gross)total (kW) 1044 SAE J1995(gross) (kw) 1044 e SAE J1349(net) (kw) 994 n i (l) 50.0 g Displacement n (min-1） 1800 E Rated Engine Speed Fuel Tank Capacity (l) 5000 Fuel Tank Capacity／gross (l/kW ) 4.79 Auxiliary Fuel Tank (l) Total Fuel Tank Capacity ／gross (l/kW ) 4.79 Relief Pressure Setting (MPa) 29.4
HITACHI EX2500-5 242／239 Cummins QSK45-C 1007 1007 971 45.0 1800 3600 3.57 770 4.34 29.4
KOMATSU LIEBHERR Ｏ＆Ｋ Ｏ＆Ｋ DEMAG PC3000 EX2500 RH120C RH120E R9250 239／236 250／253 234／228 282／284 253.5/249.1 Cummins KOMATSU Cummins Cummins Cummins KTA50-C SSA12V159 KTTA-19C QSK19-C CACx 2 QSK45 970 940 880 1008 960 970 940 2 x 440 2 x 504 935 2 x 423 2 x 504 50.3 18.9 18.9 45.0 1800 1800 1800 3600 4500 4600 5360 5440 3.71 4.79 5.23 5.32 5.67
←
31.0 29.4(Sw 34.3)
31.0
32.0
(Sw 35.0, Trv 37.0)
Pump Oil Flow At Rated Engine Speed c i l
u a r d y H
(Swing) (Combined)
Swing Circuit Front & Travel in Max. Swing in Max. Hydrauli Oil in the Tank Totla Hydraulic Oil Capacity
(l/min) (l/min) (l/min) (l/min) (l/min) (l) (l)
2350 2350 4ｘ375+2ｘ425 4ｘ375+2ｘ425 850 850 （Sw 2 x 425） （Sw 2 x 425） Combined Combined 2350 2350 850 850 1100 1100 2950 2950
←
← ← ← ← ← ←
3500 2016 3 x 900 4 x 504 800 764 (Sw １ x 800) (Sw 2 x 382) Combined Independent 2700 2016 800 764 2900 4400 3250 13.0
３
Bucket Capacity(2:1)
(m )
Bucket Capacity(1:1) Bucket Width
(m ) (mm)
15.0
15.0
3590
3590
14.0
←
15.0 17.4 3790
13.0 15.0 3960
2336 4 x 584 788 (Sw 4 x 197) Independent 2336 788 3500
2825 2121 704
2825 780 2281 4050
15.0 17.0 3960 27000 - 27500
Bucket Weight
(kg) 23100
r e d a o L
) E B ( e o h k c a B
M Bu ng Width Ma ax x.. D igcgkie ntgORpeeancih Max. Digging Reach on Ground Min. Leveling Distance on Ground Leveling Distance on Ground Max. Cutting Height Max. Dumping Height Arm Digging Force(SAE, P CSA) Bucket Digging Force (SAE, PCSA) Ｍａｘ．Break-out Force
((m mm m)) (mm) (mm) (mm) (mm) (mm) (kN) (kN) (kN)
Bucket Capacity (1:1)
(m )
20 16 50 0 14 12960 7980 4980 15010 10350 918 843 1175/1486
20 16 50 0 14 12960 7980 4980 15010 10350 918 843 1175/1486
← ← ← ← ← ← ← ← ←
12 35 40 00 0 12600 7630 4700 15000 10100 1100 1000 1000
(mm)
Bucket Weight
(kg)
13530 12270 7410 4860 13770 10630 1210 920
0 12 23 05 00 App.12200 App.8100 App.4100 11000 1210 935 1050
13.0 17.0(@1.6t/m^3)
３
Bucket Width
11 39 30 30 0 12000 6820 5180 12740 10050 900 900
15.0(@1.8t/m^3)
15.0 3180 12400
15.0 3180 12400
13.8
←
15.0 3400
13.0 15.0(@1.8t/m^3) 3170 2950 - 4500 14.1 - 15.9
Max. Digging Reach Max. Digging Reach on Ground Max. Digging Depth Max. Cutting Height Max. Dumping Height Arm Digging Force(SAE, P CSA)
(mm) (mm) (mm) (mm) (mm) (kN)
17050 16500 8570 16160 10360 745
17050 16500 8570 16160 10360 745
← ← ← ← ← ←
15600 15500 14860 7900 12000 7800 800
Bucket Digging Force (SAE, PCSA)
(kN)
751
751
←
850
750
820
859
Overall Height Height of Eye Level Center to center (Idler and Tumbler) Overall Length of Undercarriage Overall Width of Undercarriage Shoe Width s Overall Crawler Height n o No.of Rollers (Upper/Lower) i
(mm) (mm) (mm) (mm) (mm) (mm) (mm)
7250 6154 6120 7870 6000 1000 2060 3/8 179/178
7040 6240 6120 7870 6000 1000 2060 3/8 173/171
← ← ← ← ← ←
7930 6670 6000 7905 5600 800
7410 6550 5720 7500 5600 800
7250
← ←
3/8 229/232
2/7 231
7060 6150 6000 7640 5800 1000 1940 2/7 207/209
s n e m i D Ground
Pressure
16040 15500 7970 14960 10150 700
15200 14540 6200 14100 9770 910
16000 15500 8700 15200 10300 780
187/190 (1000mm)
(kPa)
6400 8240 5750 850 2180 2/9 208/204
257/259 ( 800mm) 173/175 (1200mm)
Rear Swing Radius Rear Length Min. Clearance Track Gauge Swing Speed m r Swing Torque o f r Travel Speed e P Traction Force Gradiability Grease Tank Capacity Wind Washer Tank Capacity
(mm) (mm) (mm) (mm) (rpm) (kN・m) (km/h) (kN) (％) (L) (L)
6290 6190 800 5000 3.8 1002 2.3/1.6 1330 60 200L 20.0L
6290 6190 800 5000 3.8 1002 2.3/1.6 1330 60 200L 7.6L
-4-
← ← ← ← ←
6500 5950 908 4800 4.6
6450 6200 1150 4800 4.3
6450 6310 880 4800 4.7
← ← ←
2.4
2.3 1542 72
2.6/1.4 1680 62 450L
70 200Lx2 7L
6140 6100 625 4900 4.1 860 3.2/2.0
75L
INTRODUCTION
0740-109
-5-
-6-
Cabine - Console Direito CAB – Right Console
Chave Emergência Emergency Stop Switch Engine Pot. Aceleração Control Dial Parada Motor Engine Stop Switch
Engine Start Motor Switch Partida
Work Light Switch Iluminação
DomeIluminação Light Switch
Maintenance Switch Iluminação
Iluminação Entrance Light Switch
Travel Tr avel Speed Switch Acion. 2ª Vel. Locom.
Auto IdleAutomática Switch Acel.
Buzzer Stop Switch Silencia Alarme
Fast Fill Acionamento do System Switch
Sistema Fast Fill
KeyChave SwitchIgnição
0740-003
CAB – Left Console
A /C C o n tr o l ( R e a r )
A / C C o n t r ol ( F r o n t )
Key Pad
Display Radio
A/C Control (Side)
Wiper Washer Switch
Wiper Interval Contrast Switch Switch
0740-004
-7-
Cab Inside
1
2
T18G-01-02-053 T18M-01-02-004
29
3
4
5
28
6
27
7 8
26
9
25
10
24 23
11
22
12
21
13
20 14
19
1-
Monitor Display
9-
23-
56-
Hour Meter Left Control Lever/Horn Switch Right Control Lever/Horn Switch Pilot Control Shutoff Lever Emergency Switch
7-
Engine Control Dial
15 - Buzzer Stop Switch
8-
Engine Start Switch
4-
18
17
Dome Light Switch
16
15
13
T18M-01-02-005
16 - Travel Speed Switch
23 - Air Conditioner Control
10 - Entrance Light Switch 11 - Auto-Idle Switch
17 - Maintenance Switch 18 - Work Light Switch
(Front) 24 - Wiper/Washer Switch 25 - Wiper Interval Switch
12 - Fast Filling System Switch
19 - Engine Stop Switch
26 - Display Contrast Switch
13 - Auxiliary 14 - Key Switch
20 - Radio 21 - Air Conditioner Control (Rear) 22 - Air Conditioner Control (Side)
27 - Key Pad 28 - Engine Warn Warning ing Lamp (Yellow) 29 - Engine Stop Lamp (Red)
-8-
ELECTRIC LEVERS New Cab for New EX (EX1900 and UP)
0740-110
ELECTRIC LEVER Boom, Arm, Bucket, Swing 15 to 20°
Controller
Travel, Bucket Open/Close
15 to 20°
12.4°± 1°
12.4°± 1 °
To ELU T18G-03-04-001C T18G-03-04-002C
-9-
Boom, Arm, Bucket, Swing
90 %± 2 % Short Zone About 3°
o i t a R e g a t l o V t u p t u O
50 %±1.5 %
10 %± 2 %
Center ± 15 ° to ± 20 °
Mechanical Control Angle 2 (Yellow)
1 (Black)
3 (Red)
Short Zone
Short Zone
4 (Blue)
Resistor for Calibration
Resistor for Calibration
30 °± 5° Electrical Turning Angle Total Resistanc e 2k Ω±15 % + Direction on XY Axis
T18G-03-04-003
Travel, Bucket Open/Close (Control Curve 25±5 C) Control Torque
Output Voltage
N⋅ m
v
100
VOUT
16.0 15.3±1.5 Output Voltage Ratio
12.0
80 ±7.5 50 ±5 20 ±7.5
8.0 5.5 ±1.0
0
12.4±1
4.0
0
0
12. 4±1 deg T18M-03-04-004
Neutral Switch Voltage 12.4 ±1
0
12.4±1 deg T18M-03-04-003
deg T18G-03-04-006
-10-
Cabine - MonitorDisplay e Displays Câmeras CAB – Monitor
Displays Periphery watch Monitor Câmeras
Monitor
Monitor Display
Operação
0740-005
CAB – Information Display Unit (IDU)
IDU (Under Left Console) 0740-006
-11-
1
2
3 1-
Monitor Display
2-
IDU
3-
-12-
T18M-01-02-006
ELU
Cabine - Parte Posterior Banco CAB – Behind Operator’s Seat
Acend. Cigar
Cxa.
Lighter Cigarro
Fuse Box Fusível
ORBCOMM ORBCOMM
Data Data LinkLink Connector Conector (DLU) MpDr
(Option) Satélite
Conversor
Data Link
Data D ata
DC-DC Converter DC-DC
Data Link ECM Connector (ECM) CUMMINS
Data Logging L ogging Logging Unit Unit U nit
Ponte de
B u z ze r Alarme
Pow er Sour ce Terminal Terminais
0740-007
-13-
T18G-01-02-030
1
M18M-01-007
2
3
4
5
6
7 8 9 10
T18G-01-02-026
13
12
11
Layout of Power Source Terminal 1-
Fuse Box (Cab)
5-
2-
DC/DC Converter
6-
34-
Cigar Cigar Lighte Lighterr ORBCOMM (Option)
78-
Data Link Connector (Auxiliary) Data Link Connector (ECM) Da Data ta Link Link Con Connec nector tor (DLU) (DLU) Buzzer
9-
DC/DC Converter
10 - Power Source Terminal Terminal 11 - DLU 12 - Data Link Connector (MMS)
13 - Controller (View Camera)
T146-01-03-023
14
AIR CONDITIONER UNIT – Compressor Air Conditioner Compressor Drive Pump
Refrigerant Quantity: 1400 50 g 0740-008
AIR CONDITIONER UNIT – Filters
Air Conditioner Units with Filters
Air Circulating Filters
0740-009
-15-
ELECTRICAL COMPONENTS Left Frame 1
11 10 2 9
3
4
8
5
7 7
6
T18M-01-02-003
1-
Work Light (2 Used) (On the Cab)
4-
Fuel Level Switch (Fuel Gauge)
7-
Work Light (Left-Frame Front)
10 - Horn
2-
Air Conditioner Unit (3 Used) Fuel Tank
5-
Fuel Level Switch (Fuel Indicator) Electrical Equipment Box (Refer to T1-2-4)
8-
A/C Condenseｒ (3 Used) Condenser Fan Motor (6 Used) Receiver Dryer Control Pressure Switch (3 Used)
11 - Wiper Motor
3-
6-
9-
-16-
AIR CONDITIONER UNIT – Receiver Tank
0740-010
-17-
-18-
ENGINE – Fuel Filters (Stage 1)
7
Stage 1
Vent Cap
Inlet Check Valve
Water-in Fuel Sensor
0740-033
ENGINE – 5 Bar Electric Priming & Starting Assist Pump
Electric Priming & Starting Assist Pump Bypass Valve
0740-034
-19-
ISO 4402 Reported Sizes
Particle Size:
m
Critical Region
Bosch Target Cleanliness
12/9/6
Per 100 Milliliter Fluid Sample:
12 9
Up to 4000 particles > 4 μm ©
Up to 500 particles > 6 μm ©
Up to 64 particles > 14 μm ©
FILTRATION ISO 18-16-13 and 200 ppm Water 7µ S Stage tage 1 (Industrial Pros) and 3µ-in-3µ
･
Stage 2
･
95% free and emulsified Water Separation To provide most consistent filtration efficiency, we are specifying a 250 hour filter Change Interval
･
ISO 12-9-6
-20-
ENGINE – Fuel Filter Wrench
0740-035
-21-
Frequency
ISO Code Histogram WW Fuel Particulate < 4um
60
Cumulati Cumul ative ve % 120%
50
100%
40
80%
y c n e u 30 q e r F
60%
20
40%
10
20%
0
14
15
16
17
18
19
20
21
22
0%
2 3 Mor e
Source: SGS WW fuel survey
Bin 14 15 16 17
Frequency Cumulative % 6 2.76% 15 9.68% 24 2 0 . 7 4% 52 4 4 . 7 0%
18 19 20 21 22 23 More
42 29 17 16 13 3 0
6 4 . 0 6% 7 7 . 4 2% 8 5 . 2 5% 9 2 . 6 3% 9 8 . 6 2% 100.00% 100.00%
Only 64% meet ISO 18 Max.
-22-
ENGINE – Left Bank
0740-011
ENGINE – Fuel Filters (Stage 2) and Fuel Supply Pump High Hi gh Pr Pres essu sure re Fu Fuel el Pu Pump mp
Airr Ble Ai Bleed ed Val alve ve
Supply Line
Fuel Shut-off Cock
Drain Line
Fuel Filters (3 - in - 3 ) 0740-012
-23-
Model
EX3500-3 EX1900-5 EX1900-6
EPA
Engine Model
EX2500-1 EX2500-5 EX2500-6 EX3600-6 EX3600-5 EX3600-5 EX5500-1 EX5500-5 EX5500-6 EX8000-6
−
Tier1
Tier2
−
Tier1
Tier2
Tier1
Tier1
Tier2
KTA38
S12A2
QSK38
KTA50
QSK45
QSK50
S16R
QSK60
QSK60
37.7
33.9
37.7
50
45
50
65.37
60
60
Displacement
L
Cylinder
−
12
12
12
16
12
16
16
16
16
Bore
mm
159
150
159
159
159
159
170
159
159
Stroke
mm
159
160
159
159
190
159
180
190
190
Compression
−
13.8
15.0
13.8
13.8
16.5
13.8
15.0
16.5
16.5
Rated output
KW
656
765
810
969
1007
1044
1400
1491
1450
Rated Torque
N⋅m
3482
4061
4300
5144
5345
5542
8361
7915
7697
Rated Speed
-1
1800
1800
1800
1800
1800
1800
1600
1800
1800
-1
750
700
700
780
780
780
800
800
800
-1
1990
2000
2000
2080
2050
2050
1740
1900
1900
RAD
RAD+ Intercooler
RAD+ LTA
RAD
RAD+ LTA
RAD+ LTA
RAD
30 30
20
20(30)
20(30)
20(30)
20(30)
30
20(30)
20(30)
30 30
30
20(30)
20(30)
20(30)
20(30)
30
20(30)
20(30)
Low Idle High Idle
min min min
Cooling System Allowable Inclination (F/R)
°
Allowable Inclination (R/L)
°
Cold Start Cold Start with Aid
C °C
High Elevation
m
MCRS SYSTEM
0 -12.2 -20( -20(A/ A/H) H) -32( -32(et ethe her) r)
°
2400
2000
3300
RAD+ RAD+ Intercooler LTA
-12.2 -12.2 0 -12.2 -12.2 -32( -32(et ethe her) r) -32( -32(et ethe her) r) -20( -20(A/ A/H) H) -32( -32(et ethe her) r) -32( -32(et ethe her) r) 2000
4267
3300
2000
3353
3100
-24-
ENGINE – Left Bank ECM
0750-001
Fuel Supply Pump High Pressure Fuel Pump Recirculation Line
From Fuel Filter Stage 2
Fuel Accum Pressure Sensor
Supply Line From Fuel Filter Stage 1 0750-002
-25-
Model
EX3500-3 EX1900-5 EX1900-6
EPA
Engine Model
EX2500-1 EX2500-5 EX2500-6 EX3600-6 EX3600-5 EX3600-5 EX5500-1 EX5500-5 EX5500-6 EX8000-6
−
Tier1
Tier2
−
Tier1
Tier2
Tier1
Tier1
Tier2
KTA38
S12A2
QSK38
KTA50
QSK45
QSK50
S16R
QSK60
QSK60
37.7
33.9
37.7
50
45
50
65.37
60
60
Displacement
L
Cylinder
−
12
12
12
16
12
16
16
16
16
Bore
mm
159
150
159
159
159
159
170
159
159
Stroke
mm
159
160
159
159
190
159
180
190
190
Compression
−
13.8
15.0
13.8
13.8
16.5
13.8
15.0
16.5
16.5
Rated output
KW
656
765
810
969
1007
1044
1400
1491
1450
Rated Torque
N⋅m
3482
4061
4300
5144
5345
5542
8361
7915
7697
Rated Speed
-1
1800
1800
1800
1800
1800
1800
1600
1800
1800
-1
750
700
700
780
780
780
800
800
800
-1
1990
2000
2000
2080
2050
2050
1740
1900
1900
RAD
RAD+ Intercooler
RAD+ LTA
RAD
RAD+ LTA
RAD+ LTA
RAD
30 30
20
20(30)
20(30)
20(30)
20(30)
30
20(30)
20(30)
30 30
30
20(30)
20(30)
20(30)
20(30)
30
20(30)
20(30)
0
-12.2
-12.2
-12.2
0
-12.2
-12.2
min
Low Idle
min
High Idle
min
Cooling System Allowable Inclination (F/R)
°
Allowable Inclination (R/L)
°
Cold Start
°
Cold Start with Aid
°
High Elevation
m
MCRS SYSTEM
C
C
-20( -20(A/ A/H) H) -32( -32(et ethe her) r) 2400
2000
3300
RAD+ RAD+ Intercooler LTA
-32( -32(et ethe her) r) -32( -32(et ethe her) r) -20( -20(A/ A/H) H) -32( -32(et ethe her) r) -32( -32(et ethe her) r) 2000
4267
3300
2000
3353
3100
-26-
Engine – Fuel Line Intake Manifold Temp Sensing Line
Intake Manifold Temp Sensing Line
Air Bleed Va Valve lve
To Fuel Tank
0750-003
Engine – Fuel Filters
Vibration Isolation Inlet Line
Fuel Supply Pressure Sensing Line Fuel Supply Temp Sensing Line
Fuel Filters
0750-004
-27-
FILTRATION First Stage Off-Engine (? = 98.7%) QSK MCRS
M14
Vibration Isolation
M14 WIF Inlet Check Valve Water-in-Fuel Sensor
Temperature Sensor T IMV
M14 Gerotor P Pressure Sensor
Fuel Tank
Fault 2261- Fuel pump delivery Fault 2262- Fuel pump delivery Fault 261- Engine fuel pressure valid but above normal pressure valid but below normal temperature valid but above operating range operating range normal operating range QSK19
895 kPa (130 psi)
560 kPa (81 psi)
71 °C (160 °F)
QSK38
1000 kPa (145 psi)
560 kPa (81 psi)
76.6 °C (170 °F)
QSK50
1000 kPa (145 psi)
560 kPa (81 psi)
76.6 °C (170 °F)
QSK60
895 kPa (130 psi)
560 kPa (81 psi)
71 °C (160 °F)
-28-
Pre-Lube Pump
Pre-Lube Pump
0750-005
ENGINE – Starting Motor
Starting System: 50MT-400
0750-006
-29-
-30-
ENGINE – Pre-Lub Pump
0750-007
ENGINE
Interface Connector
0750-008
-31-
-32-
ENGINE – Specification
Camshaft Speed/Position Sensor
0750-009
-33-
-34-
ENGINE – Right Bank
Intake Manifold Temp Sensor Line
Coolant Filters 0750-010
ENGINE – Engine Oil Filters Pre Oil Filter Pressure
Engine Oil Filters
Engine Oil Rifle Pressure
0750-011
-35-
-36-
ENGINE – Sensors
Intake Manifold Temp. Sensing Line
Two Dan Foss Pressure Sensors One Per Bank
Four Temperature Sensors
0750-012
ENGINE – Sensors
Engine Oil Level Sensor Oil Temperature
0750-013
-37-
-38-
ENGINE – Alternator
Alternator: Leece Neville DC24V 140A
0750-014
ENGINE Return Fuel Plumbing
0750-015
-39-
Engine Protection
High Temperature
•
- Inlet Air Temp. - Fuel Temp. - Engine Oil Temp. - Coolant Temp.
Low Pressure
•
- Engine Oil Pressure - Coolant Pressure
High Pressure
- Blow – By Pressure
Low Level
- Coolant Level
• •
-40-
ENGINE – Electric Supply Lines to Injector
Injectors
Electric Supply Lines
Fuel Supply Lines 0750-016
ENGINE – Exhaust Manifolds
Exhaust Gas Temperature Sensors Lines
0750-017
-41-
-42-
ENGINE – Intake & Turbochargers Turbochargers
0750-018
–Turbochargers urbochargers Lubrication ENGINE –T
0750-019
-43-
-44-
ENGINE – LTA LTA Coolant Impeller
Engine Loop Bypass Tube
LTA Loop Bypass Tube
Engine Coolant Impeller
LTA Coolant Impeller 0750-020
ENGINE – Water Pump Plumbing
Suction Tube
Engine Coolant Impeller
LTA Coolant Impeller 0750-021
-45-
-46-
ENGINE – Flywheel Crank Position Sensor 3
0750-022
ENGINE – Camshaft Speed & Position Sensor
0750-023
-47-
-48-
ENGINE – Exhaust Mufflers & Air Cleaners
0750-024
ENGINE – Air Cleaners
0750-025
-49-
-50-
ENGINE – Oil Reserve Tank Pumping Unit
Shut-off Valve Engine Oil Reserve Tank Capacity: 220 L
Premium Oil Pan: 150 L Reserve: 85 L 0750-026
ENGINE – Oil Reserve Tank
To Engine Oil Oi l Pan Pump 2
Pump 1
To Reserve Tank
0750-027
-51-
Withdrawal Pipe
Suction Line
Pump Unit Screen
Pump 1 Screen
Pump 2
Float Switch
Engine Oil Pan
Return Line
Reserve tank
Shut-off Valve
Cock Drain Line
Supply Line Electric Circuit Diagram for Automatic Fill System
How to operate automatic fill system 1. Turn power switch (4) to ON position. 2. Turn start switch (5) to ON position. 3. The shut-off valve on the reserve tank opens. The shut-off valve open indicator (6) lights up. 4. Oil can begin filling the reserve tank through the valve. 5. shut-off When the oil in the reserve tank reaches the
7
6
4
5
proper full level, the shut-off valve closes and full indicator (7) lights up. 6. Turn power switch (4) to the OFF position to turn the power off.
M18M-01-020
-52-
ENGINE – Coolant Reservoir Cooling Water Capacity: 476 L
Sight Gloss
0750-028
ENGINE – Coolant Reservoir Sensors
Sight Gloss
Two Level Switches for Green Lamps
0750-029
-53-
-54-
ENGINE – Coolant Reservoir
Level Switch for Warning Lamp
0750-030
-55-
-56-
PUMP TRANSMISSION – Transmission Oil Cooler
Pump Transmission Radiador PTO
Air TSensores emperature
Cooler
Sensors Temperatura Ar
Fuel CoolerÓleo Radiador
Diesel
0750-031
PUMP TRANSMISSION – T/M Oil Filter Pump Transmission Oil Filter: 105 m Interval: 500 h
0750-032
-57-
-58-
PUMP TRANSMISSION – T/M Oil Level Filter Pump Transmission Engine Oil Capacity: 26 L
T/M Oil Level Switch
0750-033
-59-
-60-
PUMP – Main Pumps (MP1 to 6)
Main Pump (MP1 MP4) K3V280DTH4ZL 375 L/min Main Pump (MP5 MP6) K3V280DTH18ZL 425 L/min
0750-034
4-UNIT PUMP 4 Unit Pump K3V 112S (Fan Motor Drive Pump) KFP4156 (Pilot / Compressor / Transmission) Tandem Tandem gear Pump
Pilot P/P
Oil Cooler P/P Air Conditioner P/P
TM P/P 0750-035
-61-
Pump and Components 1
2
9
8
7
6
5
4
3 T18L-01-02-003
1-
2-
3-
Main Pump 1 (Transmission Side) Main Pump 2 (Pump End Side) Main Pump 3 (Transmission Side) Main Pump 4 (Pump End Side) Main Pump 5 (Transmission Side) Main Pump 6 (Pump End Side)
4-
4-Unit Pump
6-
Transmission Oil Filter
8-
Pilot Filter
5-
Transmission Oil Pump Bypass Check Valve
7-
Pilot Relief Valve
9-
EHC Valve (Main Pump Control)
-62-
PUMP – Regulator Pi: Flow Rate Control Pressure
Pz: Power Increasing Control Pressure
Adjustment of Pump Drive Torque
Psv: Pump Sero Assist Pressure Pf: Power Reducing Control Pressure
0750-036
PUMP – Regulator
Adjustment of Minimum Flow Rate 0750-037
-63-
MAIN PUMP P-Q CURVE • Hydraulic P-Q Control
Rated Pump Speed: 1547 min-1 (rpm) Pump Gear Reduction Ratio: 0.86 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
•
• •
NOTE: Refer to T4-5-12. Main Pump (1 to 4) P-Q Curve (Standard) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) A 4.9 (50, 710) 710) 376 (99.2 (99.2)) B 9.8 (100, 1420) 369 (97.4) C 14.7 (150, 2140) 362 (95.5) D 19.6 (200, 2850) 339 (89.4) E 24.5 (250, 3560) 264 (69.7) F 29.4 (300, 4270) 213 (56.2)
Q (Flow Rate) L/min
A
B
C
I
D
G E
J
H K L
Main Pump (1 to 4) P-Q Curve (Power Increase) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) G 24.5 (250, 3560) 307 (81.0) H
29.4 (300, 4270)
M
247 (65.2)
2
(kgf/cm )
Main Pump (1 and 3) P-Q Curve (Power Decrease) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) I 9.8 (100, 1420) 363 (95.8) J 14.7 (150, 2140) 281 (74.1) K 19.6 (200, 2850) 231 (61.0) L 24.5 (250, 3560) 181 (47.8) M 29.4 (300, 4270) 130 (34.3)
MPa T18L-04-02-001
P (Delivery Pressure)
MAIN PUMP P-Q CURVE •
-1 Pi-Q Control Hydraulic Rated Pump Speed: 1547 min (rpm) Pump Gear Reduction Ratio: 0.86 Hydraulic Oil Temperature: 50±5 °C (122±9 °F) •
•
•
NOTE: Refer to T4-5-14. Pi-Q Curve Flow Rate Control Pressure 2 MPa (kgf/cm , psi) 1.3 A (13.4, 190) 2.6 B (27, 380) 2.9 B’ (29.5, 420)
Q (Flow Rate) L/min
Flow Rate L/min (gpm)
Remarks
100 (26.4) 375 L/min (98.9) 425 L/min (112.1)
Main Pump 1 to 6 Main Pump 1 to 4 Main Pump 5 and 6
F
B’
400
B
300 200 A
100 0
10
20
30
Pi (Flow 2 Rate Control Pressure) kgf/cm
-64-
PUMP – Pump Drain Pressure Sensor & Contamination Sensor
Pump Drain Pressure Sensor
Contamination Sensor
0750-038
-65-
Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjust the screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjust screw (6). When resetting outer spring (1), loosen nut (3) and adjust screw (4).
NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.17 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Screw (4) : 13 mm : Nut (5) : 4 mm : Screw (6) 1
2 3
4 5
6
T117-05-04-005
Outer Spring Adjustment Date Adjusting Screw Screw Turn Turn Flow Rate Change Pressure Change Engine Torque Change (Pump Flow Rate) Q
1/4
35.4 L/min (9.35 US gal/min) 1.7 MPa (17.8 kgf/cm2, 253 psi) 74.5 N⋅m (7.6 kgf ⋅m, 55 lbf ⋅ft)
Inner Spring Adjustment Date Adjusting Screw Screw Turn Turn Flow Rate Change Pressure Change Engine Torque Change (Pump Flow Rate) Q
1/4
16.3 (3.59 USL/min gal/min) 1.8 MPa (18.4 kgf/cm2, 262 psi) 49.8 N⋅m (5.08 kgf ⋅m, 36.7 lbf ⋅ft)
Pd
(Pump Delivery Pressure)
Pd
(Pump Delivery Pressure)
-66-
PUMP CONTROLS – EHC Valve
0750-039
-67-
EHC Valve (For Main Pump Control)
8
1
7
2
6
3
5
4
T18M-03-07-005
12-
Main Pump Displacement Control (No.4 Main Pump) Main Pump Displacement Control (No.3 Main Pump)
3-
Radiator Fan Control
5-
Auxiliary
7-
Power Decrease Control
4-
Oil Cooler fan Control
6-
Main Pump Displacement Control (No.1, 2, 5, 6, 7, 8 Main Pump)
8-
Power Increase Control
Increase Control
Power Decrease Control
Amps to SOL.
Pz Pressure
219
0.93
155
0.11
50
3.51
400
0
50
0 1780
1800
Engine Speed
Control ON
OFF
Pf Pressure
Amps to SOL.
2.2
1900
1650
175 0
Engine Speed
1.3 400
0.9
0.5
50
-68-
CONTROL VALVE
Overload Valve
Make up Valve
0750-040
FRONT PIPING
Arm Rod Pressure Sensors 0750-041
-69-
CONTROL VALVE NOTE: This drawing indicates the arrangement viewed from the base machine front. Control Valve (Lower-Right)
1
2
9
3
10
4
11
5
6
7
8
12
13
14
15
18
Control Valve (Upper)
19
20
16 17 25 25
Control Valve (Lower-Right)
21
Control Valve (Lower-Left)
22 23
26 27
24
31
28 29 30
32 33 34
35
36
37
38 39
41 42
43
40
T18L-01-02-005
Control Valve (Upper)
1-
Overload Relief Valve (Boom Raise)
18 - Main Relief Valve
2-
Make-Up Valve (Boom Raise)
19 - Overload Relief Valve (Boom Raise)
3-
Overload Relief Valve (Bucket Tilt-In)
20 - Make-Up Valve (Boom Raise)
4-
Make-Up Valve (Bucket Tilt-In)
21 - Overload Relief Valve (LD: Bucket Open, BH: Bucket Roll-In)
5-
Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
22 - Make-Up Valve (LD: Bucket Open, BH: Bucket Roll-In)
6-
Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
23 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
7-
Overload Relief Valve (Right Swing)
24 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
8-
Make-Up Valve (Right Swing)
25 - Make-Up Valve (Boom Lower)
9-
Make-Up Valve (Boom Lower)
26 - Overload Relief Valve (Boom Lower)
10 - Overload Relief Valve (Boom Lower)
27 - Overload Relief Valve (LD: Bucket Close)
11 - Make-Up Valve (Bucket Tilt-Out)
28 - Overload Relief Valve (LD: Bucket Close, BH: Bucket Roll-Out)
12 - Overload Relief Valve (Bucket Tilt-Out)
29 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
13 - Make-Up Valve (BH: Arm Roll-Out)
30 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
14 - Overload Relief Valve (BH: Arm Roll-Out) 15 - Make-Up Valve (Left Swing) 16 - Overload Relief Valve (Left (Left Swing) 17 - Main Relief Valve
Control Valve (Lower-Left) 31 - Main Relief V Valve alve
38 - Make-Up V Valve alve (LD: Arm Retract, BH: Arm Roll-Out)
32 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
39 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
33 - Make-Up Valve Valve (LD: Arm Extend, BH: Arm Roll-In)
40 - Make-Up Valve Valve (Boom Lower)
34 - Overload Relief Valve Valve (Boom Raise)
41 - Overload Relief Valve Valve (Boom Lower)
35 - Make-Up Valve Valve (Boom Raise)
42 - Make-Up Valve Valve (Bucket Tilt-Out)
36 - Overload Relief Valve Valve (Bucket Tilt-In) 37 - Make-Up Valve Valve (Bucket Tilt-In)
43 - Overload Relief Valve Valve (Bucket Tilt-Out) Tilt-Out)
NOTE: LD: Loading Shovel BH: Backhoe
-70-
QUICK RESPONSE VALVE (For Front) Control Valve: KSU 1000 Main Relief: 29.4 MPa Overload Relief: 31.4 MPa BKT Close (L/D): 16.7 MPa
Quick Response Valve EHC Valve
0750-042
PILOT PANEL Travel Mode Solenoid Valve
Reducing Valve
Pilot Shut-off Solenoid Valve 0750-043
-71-
D.Q.R Spool Position When Control Lever is in Neutral:
D.Q.R Spool Position When Control Lever is Operated: Signal Pressure Oil Port (From the EHC Valve)
Spool Output Port
Spool
(To the control valve spool) Port T (To the hydraulic oil tank)
Output Port
Port P (From the EHC Valve)
Spring
Notch
Port P
T18B-03-05-003C
Passage
Spring
T18B-03-05-004C
Spool
Output Port
Port P
T18B-03-05-005C
Spring (Set Pressure: 0.15 MPa 2 (1.5 kgf/cm , 21 psi))
Spring Chamber
-72-
EHC VALVE FOR ELECTRIC LEVER CONTROL
0750-044
-73-
EHC Valve (For Electric Lever Control) EHC Valve (Left Side)
EHC Valve (Right Side) 17
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
T18M-03-04-001
12345-
Right Travel Forward Right Travel Reverse Left Travel Forward Auxiliary Arm Retract
6 - Bucket Open 7 - Bucket Close 8 - Left Travel Reverse 9 - Boom Raise
T18M-03-04-002
10 11 12 13 -
Left Swing Right Swing Bucket Tilt-In Arm Extend
14 15 16 17 -
Bucket Tilt-Out Boom Lower Auxiliary Gate Lock Pressure Sensor
D.Q.R Valve Electric Lever Spool
Port T ELU
Port P Pilot Pump
Actu ator
From Pilot Control Shutoff Lever Solenoid Valve Control Valve
Spring EHC Valve (For Electric Lever Control)
Spool
Main Pump
Hyd rauli c Oil Tank T18G-02-02-002
-74-
SWING DEVICE MX750 Relief Set Pressure: 27.4 MPa Parking Brake: 1.8 MPa
0750-045
Swing Motors Swing Device 2-Stage Planetary Reduction Device Gear Oil: 100 L × 2 Change Interval 1000 h
Brake Valve
Contamination Sensor
Parking Brake
Control Line
Drain Pressure Sensor 0750-046
-75-
Contamination Sensor Layout 3 1
4
2
5
6 Machine Front
A T18L-01-02-006
T18L-01-02-021
View A 7
8
Cross Section B 9
T18L-01-02-007
B
T18L-01-02-017
123-
Contamination Sensor (Main Pump 1) Contamination Sensor (Main Pump 2) Contamination Sensor (Main Pump 3)
45-
Contamination Sensor (Main Pump 4) Contamination Sensor (Main Pump 5)
67-
Contamination Sensor (Main Pump 6) Contamination Sensor (Rear Swing Motor)
89-
Contamination Sensor (Front Swing Motor) Contamination Sensor (Travel Motor)
-76-
C/J 絵
-77-
TRAVEL SHOCK ABSORBING / TRAVEL STOP CIRCUIT Purposes Protects the front idlers from shocks. Depending on shocks to the front idlers, the travel shock absorbing/travel stop circuit functions as fol-
Operation When subjected to ordinary shocks: When moving the travel lever, ELU activates the control solenoid valve (refer to Operation Circuit.)
lows. When subjected to ordinary shocks: The accumulators works to absorb shocks. When subjected to excessive shocks Refer to CONTROL SYSTEM/Cushion Cylinder End Travel Limit Control.
Pilot pressure routed to D.Q.R via the control solenoidisvalve. Thereby, pilotvalve pressure oil from the pilot pump is routed to the travel spool in the control valve via D.Q.R valve, thus moving the travel spool to open the travel port. Then, pressure oil from the main circuit is delivered to left and right travel motors, causing the machine to travel. At the same time, pressure oil from the main circuit is pressure-reduced by the pressure-reducing valve, and is delivered to the cushion cylinder. When the front idler is subjected to shocks, the cushion piston is pushed to deliver hydraulic oil from behind the cushion piston into accumulators. Then, bladders in accumulators are contracted to absorb shocks.
•
•
•
Cushion Piston Travel Stop Valve Cushion Cylinder
Cushion Cylinder End Pressure Sensor
Relief Valve
Pressure-Reducing Valve
Pilot Pump
Travel Spool in Control Valve
T18M-02-04-005
Center Joint
Pilot Pressure Select Sele ct Valve Valve
-78-
RADIATOR FAN
0750-047
RADIATOR & LTA COOLER Radiator × 1 LTA Cooler × 1
Air Temperature Sensor
0750-048
-79-
-80-
RADIATOR SENSORS Coolant Temperature Sensor (Inlet)
0750-049
Coolant Temperature Sensor (out)
0750-050
-81-
-82-
OIL COOLER
Pump T/M Cooler
Fuel Cooler
0750-051
OIL COOLER FAN MOTOR Oil Cooler Fan Motor A2FM63/61W
Oil Cooler Fan Motor
0750-052
-83-
-84-
OIL COOLER – Oil Temperature Sensor
Oil Temp Sensor (Inlet)
0750-053
Temperature emperature Sensor Senso r Oil T
Oil Temp Sensor (Out)
0750-054
-85-
Oil Cooler Fan Speed Control Fan Speed
1400
1150
900 200
60
70
80
Oil Temp. (Inlet)
90
°C
-86-
HYDRAULIC – High Pressure Strainers High Pressure Strainers: 95 m
0750-055
HYDRAULIC – Pilot Filter Pilot Filter: 10 m
Pilot Filter
0750-056
-87-
-88-
ELECTRIC – Electric Equipment Box
0740-078
ELECTRIC – Contamination Sensor Unit
1-6 17 18 21
MP1-MP6 Front Swing Motor Rear Swing Motor Travel Motor
0740-079
-89-
Electrical Equipment Box
T18M-01-02-003
10
11
12
13
9 8
7
6
5 Relay Arra ngeme nt (Refer to T1-2-15)
4 3 2 1
T18M-01-02-007
1234-
Fuse Fuse Fuse Fuse Fuse
Box2 Box 1 Box 4 Box 3
5678-
Aut Auto o Lubricator Lubricator Interv Interval al Switch Engine Fault Indicator MC Engine Diagnostic Switch
910 11 12 -
Fault code INC/DEC INC/DEC Switch HMU CSU Limit Switch (Box Light)
13 - Box Light
-90-
HYDRAULIC – Pilot Accumulators
0750-057
-91-
-92-
AULT T INDICAT INDICATOR OR ENGINE FAUL
Engine Maintenance Lamp
Engine Warning Lamp
Engine Stop Lamp
0740-080
-93-
HOW TO READ FAULT CODES 1. Stop the engine, and turn the key switch ON. 2. In case a fault code exists, the Engine Warning Lamp (Amber) alone is lit, but in case no fault code exists, none of the lamps are lit. 3. Turn the Engine Diagnostic Switch ON. 4. The Engine W Warning arning Lamp (Amber) flickers once, and in a second, the Engine Stop Lamp (Red) indicates the fault code at stake twice consecutively consecutively,, which is repeated. repeated. 5. A Fault code has four digits at the maximum. A numeral is indicated by the number of times of flickering of the Engine Stop Lamp (Red) for each digit, and remains unlit for 1 second between digit change. 6. When the key switch is turned off, indication of the fault code is finished. NOTE: In case a plural number of fault codes are in existence, the Engine Warning Lamp (Amber) flickers once each time indication of a fault code is over, and a second later, the Engine Stop Lamp (Red) indicates the next fault code twice, which is repeated repeated.. NOTE: When indication of all the fault codes is over, the Engine Warning Lamp (Amber) flickers once, and a second later, the Engine Stop Lamp (Red) repeats indication of the fault codes from the first one. NOTE: IN case the Fault Code INC/DEC Switch is moved toward INC once, indication of the next fault code begins. In case the Fault Code INC/DEC Switch is moved toward DEC once, indication is changed to the previous fault fault code.
Engine Diagnostic Switch
Fault Code INC/DEC Switch
Engine Stop Lamp (Red) Engine Maintenance Lamp (Yellow)
T18M-05-04-003
Engine Warning Lamp (Amber)
Example: Flickering of Engine Stop Lamp (Red) in case of Fault Code 132 100s digit
10s digit
1s digit
Lit
Unlit 1 second
1 second
T141-05-03-004
-94-
ELECTRIC – Electric Equipment Box
0750-058
ELECTRIC – Ground Cut-off Switch
0750-059
-95-
Relay Box
1
2 3 4 T18M-01-02-010
5
6
25 24 23
7 8 9
22
10
21
11
20 12 19
13 18
1-
Battery Relay (3 Used)
8-
2-
9-
5-
Fusible Link 10A (Engine Oil Reserve Tank Valve) Fusible Link 30A (Zener Diode) Fusible Link 5A (IDU Pre-lube Signal) Safety Relay
12 -
6-
Engine Pre-lube Timer
13 -
7-
Engine Oil Reserve Tank
34-
10 11 -
Engine Oil Reserve Tank System Relay 2 Fusible Link6 (75A) (Fuse Box) Fusible Link7 (45A) (Option) Fusible Link8 (75A) (Starter Relay) Fusible Link9 (45A) (ECM Main Power) Fusible Link10 (75A) (Sliding Fold-In Ladder Relay)
14 - Fusible Link5 (75A) (Fuse Box) 15 - Fusible Link4 (75A) (Fuse Box) 16 - Fusible Link3 (75A) (Fuse Box) 17 - Fusible Link2 (75A) (Fuse Box) 18 - Fusible Link1 (75A) (Fuse Box) 19 - Starter Relay (Upper)
17
16
15
14
T18M-01-02-011
20 - Starter Relay (Lower) 21 - Engine Pre-lube Relay 22 - Circuit Breaker 23 - Fusible Link 250A (Sliding Fold-In Ladder Motor (Rear)) 24 - Fusible Link 250A (Sliding Fold-In Ladder Motor (Front)) 25 - Fusible Link 400A (Engine Pre-lube Relay)
System Relay 1
-96-
FUEL TANK Lev el Sensor & Switches Sw itches TANK – Fuel Level Fuel Tank: 4800 L
0750-060
Tank Capacity: 7450 L
Fuel Level Switch (Full)
Fuel Level Switch
Fuel Level Sensor
0740-089
-97-
FAST FILLING DEVICE 1
2
3
T18M-03-07-004
4
5
6
7
8
9
10
11
22 21
12
13
20
1-
Lift Cylinder (2 Used)
2-
Fast-Filling Panel
3-
Proximity Switch
4-
Fuel Fill Indicator
5-
Engine Oil Reserve Reserve Tank Fill Indicator Engine Oil Reserve Reserve Tank
6-
Shut-off Valve Open Indicator
19
18
7-
Engine Oil Reserve Tank Filling System Power Switch 8 - Engine Oil Reserve Tank Filling System Control Switch 9 - Engine Oil Out (Reserve Tank) 10 - Engine Oil (Engine Oil Pan) 11 - Hyd. Oil 12 - Gear Oil (Front Right Side Swing Device)
17
16
15
13 - Auxiliary 14 - Pump Transmission Oil 15 - Grease
14
T18M-03-07-003
18 - Gear Oil (Front Left Side Swing Device) 19 - Coolant (Radiator Engine Side) 20 - Fuel
16 - Gear Oil (Rear-Right)
21 - Coolant (Radiator Outside)
17 - Gear Oil (Left-Right)
22 - Engine Oil In (Reserve Tank)
-98-
HYDRAULIC OIL TANK TANK – Full-Flow Filters
Drain Ffilter
0750-061
HYDRAULIC TANK – Bypass Filter Bypass Filter: 5 m
0750-062
-99-
-100-
HYDRAULIC OIL TANK Hydraulic Tank: 2950 L
Solenoid Valve
Air Release Valve
Stop Valve
0750-063
HYDRAULIC OIL TANK
Hydraulic Oil Level Switch For Green Lamp
Hydraulic Oil Level Switch For Green Warning
0750-064
-101-
-102-
HYDRAULIC OIL TANK TANK – Stop Valves & Limit Switches
Limit Switch
Stop Valve 0750-065
-103-
-104-
GREASE SYSTEM
Auto-Lubrication Grease Pump
Auto-Lubrication Solenoid Valve Vent Valve
0750-066
GREASE SYSTEM Reducing Valve 3 MPa
Auto-Lubrication Hydraulic Motor
0750-067
-105-
-106-
GREASE SYSTEM Grease Pressure Switch for Auto Greasing 17.6 MPa
Auto/Manual Selector Switch
0750-068
GREASE SYSTEM
Grease Pressure Switch for Manual Greasing 33.5 MPa
Auto/Manual Selector Switch
0750-069
-107-
-108-
GREASE SYSTEM
Hose Reel for Manual Greasing
0750-070
GREASE SYSTEM
Injectors
Grease Line to Boom Foot Pin 0750-071
-109-
-110-
FAST-FILL SYSTEM
Lift Cylinders
0750-072
FAST-FILL SYSTEM
Fast-Fill Solenoid Valve
0750-073
-111-
-112-
FAST-FILL SYSTEM
Slow Return Valve
Check Valve
0750-074
FAST-FILL SYSTEM Fast-Filling Panel
Proximity Switch
0750-075
-113-
FAST-FILLING SYSTEM Refilling coolant, hydraulic oil, fuel, engine oil, swing device gear oil, pump transmission oil and grease can be achieved through this system. The major components of this system are the fast-filling switch, fast-filling panel, fast-filling solenoid valve, lift cylinders and proximity switch. (Refer to the SYSTEM / Control System group.)
Lift Cylinder
Fast-Filling Panel
A
Proximity Switch
T18M-03-07-004
Filler Port Layout on Fast-Filling Panel (View A) Engine Oil Reserve Tank Fill Indicator
Engine Oil Reserve Tank Shut -off Valve Open Indicator
Engine Oil Reserve Tank Filling System Power Switch
Engine Oil Reserve Tank Filling System Control Switch
Engine Oil Out (Reserve Tank)
Fuel Fill Indicator Engine Oil In (Reserve Tank)
Engine Oil (Engine Oil Pan) Hyd. Oil
Coolant (Radiator Outside)
Gear Oil (Front Right Side Swing Device)
Fuel Auxilia Auxi lia ry Pump Transmission Oil
Coolant (Radiator Engine Side)
Gear Oil (Front Left Side Swing Device)
Gear Oil (Left-Right)
Grease Gear Oil (Rear-Right)
T18M-03-07-003
-114-
AIR HORN – Air Compressor & Air Tank Tank
Air Compressor
Air Tank
0740-106
AIR HORN – Air Horns & Filter
0740-107
-115-
-116-
WINDOW WASHER – Washer Tank
0740-108
-117-
-118-
FOLDING STAIRWAY
0740-111
-119-
45
°
0740-112
-120-
FOLDIN FOLDING G STAIRWA STAIRWAY – Switch Box
SW (1) Lowering
SW (2) Raising
SW (3) Emergency
0740-086
FOLDIN FOLDING G STAIRWA STAIRWAY – Switch Box
0740-087
-121-
From Battery Sliding Fold-In Ladder Cylinder Sliding Fold-In Ladder Relay 1
Sliding Fold-In Sliding Fold-In Ladder Relay 2 Ladder Relay 3
Storage Switch
Extend Switch
Holding Valve Holding Valve
Sliding Fold-In Ladder Relay 4
Sliding Fold-In Ladder Pump Unit 2
Sliding Fold-In Ladder Solenoid Valve 1
Sol. b Sliding Fold-In Ladder Pump Unit 1
Orifice A
Sol. a Sliding Fold-In Ladder Solenoid Valve 3 Sliding Fold-In Ladder Solenoid Valve 2
Limit Switch 1 Limit Switch 2 (For Expansion(For Expansion Detection) Slowdown Control)
Stop Valve (Normally Closed)
Limit Switch 3 Limit Switch 3 (For Storage (For Storage Slowdown Control) Detection)
Air Condi tion er Motor
Limit Switch 5 (For Lock Lever)
MC
Pilot Pump 76-58 76-19
Pilot Control Shutoff
Air Condi tion er Compressor Drive Pump
Limit Switch
From Battery
76-58
ELU T18M-02-02-012
-122-
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