La jp we SERVICE MANUAL This Manual has been prepared for and is considered part of - 12000/12000E Cane Mode! Hhumbor 1200E1006 (Crane Soria Numbo? ‘This Manual is Divided into the following Sections: SECTION1 SAFETY SECTION 2 SPECIFICATIONS SECTION3 — WEAR DATA AND HYDRAULIC TEST PROCEDURES. SECTION 4 TORQUE VALUES AND METRIC CONVERSIONS SECTIONS POWER TRAIN SECTION 6 HYDRAULIC SYSTEM SECTION7 HOIST SYSTEM SECTION 8 BOOM HOIST SYSTEM SECTIONS SWING SYSTEM SECTION 10 PROPEL SYSTEM SECTION 11 ELECTRICAL SYSTEM SECTION 12 LOAD SAFETY DEVICE SECTION 13 GAUGE CLUSTER SECTION 14 TOTAL CONTROLLER NOTICE ‘The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service information. The crane serial number is identified on the builder's decal attached to the operator's cab. Always furnish erane serial number when ordering paris (of communicating service problems with your distributor or the factory. PAY ANNIE To prevent death or serious injury: ‘Avoid unsafe operation and maintenance. This crane must be operated and maintained by trained and experienced personnel. Manitowoc is not responsible for qualifying these personnel. Do not operate or work on this crane without first reading and understanding Operator's Manual and Rating Plate supplied with crane. ‘Store Operator's Manual in holder provided on crane. Attach laminated Capacity Charts supplied with crane to chain in operator's cab. lf Operator's Manual or Capacity Charts are missing from cab, contact your distributor for new ones. ee ee ee ee ee ee eee eeTo Contact Us: @ GROVE W NATIONAL CRANE MANLIFT Manitowoc Cranes, Inc. 2401 South 30th Street Manitowoc, WI 54220 (920) 684-6621 (920) 683-6277 (fax) Grove Worldwide 1565 Buchanan Trail East P.O. Box 21 Shady Grove, PA 17256 (717) 597-8121 (717) 597-4062 (fax) National Crane Corporation 1565 Buchanan Trail East P.O. Box 21 Shady Grove, PA 17256 (717) 597-8121 (717) 597-4062 (fax) Grove Worldwide 1565 Buchanan Trail East P.O. Box 21 Shady Grove, PA 17256 (717) 597-8121 (717) 597-4062 (fax) Q@anitowoc Crane CARE Technical Field Publications Service Factory Training Service12000/12000E SERVICE MANUAL TABLE OF CONTENTS ‘See end of this manual for Alphabetical Index SECTION 1 poco Safety Diesel Engine Exhaust 14 Safety Messages... "4 General... 4 Safety Alert Symbol » 4 Signal Words. ... . "1 Safety and information Labels os : Dien Location of Labels. "1 Maintaining Labels, oat Ordering Labels 1 Safe Maintenance Practices 42 Maintenance Instructions 12 Maintenance Precautions 12 Performance . Gpoccde ‘Outine Dimensions — Overall... 2... ssc svse need Outline Dimensions — Components ..........0.ccecees a cB Base Machine. ......2. 0.0.5 Deities Le Counterneight. 26 Atlachment . : 27 Stabilly while Swinging and Traveling. ane ‘Without Boom Base pars With Boom Base 214 SECTION 3..............Wear Data and Hydraulic Test Procedures Wear Data a4 Pins and Bushings 34 Springs 32 Sheaves 32 Propel Components 36 Crawler Shoo L368 Drive Tumbler 37 Idler. ae é | 38 Track Rollers eeeeeereeereeeeenean 39 Guide Roller : : me 340 Guide Bar... oe ae : 341 Gee 0G. Jaccsooacocusecoocosocedeocosuocesecoaooueacococd il Slewing Ring ..... eee Beer stia Performance Standard And Test Procedure 313 Operating Speed 313 System Pressures. a4 SECTION 4................ Torque Values And Metric Conversions ‘Tightening Torque for Cap Screws and Nuts. at Metric Coarse Threads en at Metric Fine Threads veotneeee 4a Coarse Threads UNG . aeons peeea Fine Threads UNF ...... : eeeeeeeeeeeees 42 Tightening Torque for Hydraulic Fittings <2...) _ 43 Bite Type Tube Fittings. 43 Split Flanges a ceeds Flare Type Tube Fittings (30° Flare, PF Threads) 43 Jubilee Clip (Low Pressure and Suction) a4 Parts Identification 45 (20006 Mantowce oct Upesied 200809:2" Conrl#e50.01 rae 9820219608TABLE OF CONTENTS 12000/12000E SERVICE MANUAL Boils... sees eee 45 O-Rings a0 46 Back-Up Rings. a7 Bite Fittings 48, Metric Conversions: a 4-10 Unit Conversions 4-10 Weight 4-10 Pressure soreeeeneerenenenEnEe pieces 410 Torque (Tightening) 5 Be geernee= 4710 Milimeter— Inch Conversion Tables 1.200002... I aa Meter ~ Foot Conversion Table... eos 413 Gradient Conversion Table 4n4 Table of Unit Weights ana Power Train 4 SECTION 5...... Location of Components, Introduction 3 Engine eer en _ 58 Engine Removal vectteteeenee foes 153 Engine Repair and Maintenance : ce 58 Engine Installation ceo eee ed Pump Drive Assembly : re BE Removing Pump Drive 56 Disassembling Power Divider 58 Inspecting and Repairing Power Divider 5-8 ‘Assembling Power Diver 58 Instaling Power Divider 58 SECTION 6...... oe - Hydraulic System Location of Main Hydraulic Components et Hydraulic Circuits and Components 62 Component Spectfications. 64 Location of Hydraulic Components 67 Hydraulic System Operation 6-16 Hydraulic Pumps oo pees 66 Ol Flow From No.1 and No.2 Pumps wees goootd 6-17 il Flow From No.3 and No.4 Pumps viet sees 618 Oil Flow From No.6 Pump (Control Pump) 619 Oil Flow From No.6 Pump (Secondary Pump) 621 Hydraulic Valves. 24 Front, Rear, Boom Drum, and Optional Third Drum 4-Section Vaive 624 Third, Front, Rear, and Boom Drum 8-Section Valve (With Shuttle Valve) 6:25 Front and Rear Drum Clutch 4-Section Valve Front and Rear Drum Free Fall -Section Valve... Front, Rear, and Boom Drum §-Section Valve ‘Swing and Propel 2-Section Valve ‘Swing Remote 1-Section Valve Hydraulic Acronym Table Hydraulic Circuit ‘Third Drum - Boom Pedal SECTION 7. Hoist System Components. Construction and Function Hydraulic Schematic Lifting a Load pore! @eniowoc12000/12000E SERVICE MANUAL, TABLE OF CONTENTS Holding a Raised Load... .2.00ceeeees ceveeteeeneeee 72. Lowering a Load (Powered Lowering) eee eee 72 Free Fall Operation. pee 72 Free Fall Acceleration... cies 73 Drum Lock. me TA ‘Adjustment of Drum Lock 75 Winch Assembly 76 ‘Winch Assembly / Reduction Unit Without Free Fall (Standard) 77 Reduction Unit Assembly 78 Winch Assembly With Free Fall (Option) 79 Brake Pedal 7-40 ‘Adjusting the Brake Pedal... 02.0... aa eerie) Bleeding Air From Brake Circuit... go0ecc60 ceetenee ee TAS: Hoist Hydraulic Schematic. .......0..scscevsstevseseesvsevenseresersees.TAS: Litting A Load. ae Dilteteseseevneens TAT, nolaing A Loaa. See Powered Lowering. 724 Free Fall 7-23 Free Fall Control... ne 7-25 Free Fall Speed Acceleration 727 SECTION 8....... Boom Hoist Components. ‘Construction and Function Hydraulic Schematic Raising the Boom Noutral (Maintaining the Boom Position) Lowering the Boom. . Boom Drum Lock ‘Adjusting the Boom Drum Lock Drum and Reduction Unit Boom Winch Assembly. Boom Drum and Reduction Unit Assembly. Boom Hoist Hydraulic Schematic . .. -Boom Hoist System Raising The Boom an Neutral (Maintaining Boom Position) ata Lowering The Boom, ats SECTION9...........022. sees .... Swing System ‘Swing System Components. on Construction and Function 92 Hydraulic Schematic 92 SWING «ee esesestvosvevvsnnnene UNEENNIIT 92 Stopping... UUUEEEEUEN EEE EE EEE ee Swing Reduction Unit» peat eae econ eeee ens | Swing Bearing 95 Method of Bot Tightening 96 Swing Lock 97 Swing Hydraulic Schematic : 99 Swing (Neutral Free Mod)... a : on ‘Swing (Neutral Brake Mode) |... : 943 ‘Stop (Neutral Froe Modo) : : 15, Stop (Neutral Brake Mode) |. EEUEEEEEEEI o7 SECTION 10......... Location of Main Components. a _ Propel System ve “10-41‘TABLE OF CONTENTS 12000/12000E SERVICE MANUAL Construction and Function 10.2 Hydraulic Schematic 102 Propeling (igh Side Forwarsh 102 Stopping 10-2 Propel Reduction Unit 10-3 ‘Motor and Reduction Unit 10-4 ‘Adjustment... fea 10-6 Propel Hydraulic Schematic. 10-7 Propeliing (Right Side Forward) 10-9 Stopping Travel ....... 10-11 Toc-4 SECTION 11........0000e000+ SECTION 12. Arrangement of Electrical Parts, Electrical Parts of Right Deck Electrical Parts of Floor Plate and Leit Side Standard Panel Elect Paits of Revolving Frame, Electrical Parts of Left Deck. Electrical Part of Left Guard. Electrical Parts Fuse Box... Wiper Control Unit ‘Swing Flasher Unit Pressure Switch Pressure Sensor Relay Box Relay Box Schematic Left Side Standard Panel (12000) Loft Side Standard Panel (12000E) ‘Troubleshooting of Exhaust Gas (Third Regulation Engine) Diagnostic Function How to Chock Faull Contents Table of Diagnosis Codes ‘Checking Blown-Off Diagnostic Lamps Engine ECU. ECU Terminal Number Input and Output Table Electrical Wiring Schematics Relay Box Schematics. Identilcation and Function of Components Load Safety Device — Front View. Configuration of Screens Data Transmission Between Controller and Cards Identification of Main Display Screen. Load Safety Device — Rear View ‘System Input and Output Connector Designations Digital inputs Digital Outputs. Output Spares Controller or Memory Card Replacement Stops Preparing for Use Turing Power On Upgrading Programs Procedures Upgrading Inciction Programs - Electrical System 12 114 114 - Load Safety Device 124 124 127 12-8 21240 rer 1244 1248 1249 12-20 212-20 Gonrowec412000/12000€ SERVICE MANUAL, TABLE OF CONTENTS. Upgrading Control Programs 12.24 Status Chack . 12-25 Signal Check... -- 12.26 Operation Progress. 12.27 ‘Communication Data 12.29 Indication of Adjustment Value 12.30 Load Record eee Gonouiscuosoacscuasanodt) J Erasing Load Records <2... 0... to tccesereveesenevarsvcereeseress 12:89 ‘Trouble Record 12-40 Erasing Trouble ROCOMdS «=... esses cee eeee — 1241 Choice of Language... .- ce cece : fevees 12042 Adjustments. ee A 12-42 Exposing DIP Switches. 12-42 Adjustment ......-... 12-43, Load Adjustment, 12-58 Adjustment Data Cany (Initialization) 12-860) Version Check 12-64 Enror Codes And Corrective Action 12-65 Control Output... . feos cee ee tar Controller Ouiput Signal (Type No. 01). : 5 212-67 Contre Output Sigal [Typ8 No 02). seve AQT Roleases 12-75 Release Function 12:75 ‘Mechanical Specifications 12-85 Environmental Performance Parameters 12-85 Load Cell (Crane) 12-85 Angle Sensor 12-87 Controller 12-88 Electric Schematic Diagram. 12.91 Crane Type 12-91 Luting Type 12.92 Controller Maltunction Emergency Measures 12.93 Load Safety Device Check Procedures. 12-93 SECTION 13. sees <+se+s++ Gauge Cluster Contiguration of Display 13-4 Priority 13:2 Status Display eer tio) Contents of Status Display aoe cece ee oo Table Notes. : : 219-10 Fault Log Display... 13411 Display Procedures. 0.0.2... ‘i 218-11 Deletion of Fault Logs... : 5 13-12 Notes on Fault Logs 13-12 Contents of Fault Log Display. 13.13 SECTION 14..... - Total Controller Location of Total Controller 144 Composition of System 142 Output Relation To Controller 143 Function of Total Controller veeeee en 144 Control of Main Body 144 Cluster Contro! : : ce fees 4 Adjustment Function... fies Gooecca 145 Total Controller Hardware Sage General 14-32 Bg‘TABLE OF CONTENTS 112000/12000E SERVICE MANUAL, Specications Of Total Contioller Output «+++ ceceeeeseneesees 188 Tota Conver Connectors... UINTIINIIIII eg tdonticaton of Total Conor Connector Pins... .ssssssssuscuoae. 1439 Propotional Solenoid Valve Measuring Postion... Js. ..sc cose. M8 Adjstmont Procedures for Total Contoler vay Nececsly ot Adustment : tear Adjustment Procedures of Total Cnioior tea Toes GanrowvoeTABLE OF CONTENTS Diesel Engine Exhaust. Safety Messages General Safety Alert Symbol Signal Words, ‘Safety and information Labels. Location of Labels....... Maintaining Labels, Ordering Labels Safe Maintenance Practices Maintenance Instructions Maintenance Precautions fea SECTION 1 SAFETY 412000/12000E SERVICE MANUAL SAFETY SECTION 1 SAFETY DIESEL ENGINE EXHAUST & cauironnia PROPOSITION 65 WARNING Diese! engine exhaust and some of its constituents are known to the State of California to cause cancer, birth detects, and other reproductive harm, General ‘The importance of safe operation and maintenance cannot be over emphasized. Carelessness or neglect on the part of operators, job supervisors and planners, rigging personnel and job site workers can result in their death or injury and costly damage to the crane and propery. To alert personnel to hazardous operating practices and maintenance procedures, safely messages are used throughout the manual. Each safety message contains a safely alert symbol and a signal word to identify the hazards degree of seriousness. Safety Alert Symbol Signal Words & oancer Identifies Imminent hazards that will result in death or serious injury if the message is ignored. & warnnc Identifies potential hazards that could result in death or serious Injury if the message is ignored. & caution Identifies potential hazards that could result in minor or moderate injury if the message is ignored, CAUTION Without the safety alert symbol, identifies potential hazards that could result in property damage if the message is ignored, NOTE: Highlights operation or maintenance procedures, SAFETY AND INFORMATION LABELS Location of Labels ‘See Operator's Manual or Parts Manual for identitication and location of all safety and information labets on this crane. Maintaining Labels ‘The crane owner/user shall make sure that all labels are legible and installed atthe proper locations on the crane. Ifa label has been defaced or removed, it must be replaced immediately Ordering Labels Order replacement signs from your local Manitowoc Dealer or from the factory at the following address: Manitowoc Crane CARE 2401 So. 30th St, Manitowoc, Wi 54220 Phone: 920-684-6621 Fax 920-683-6278 E-mail: parts @manitowoccranes.com When ofdering a label, give the crane model number, the serial number, and the name and part number of the label. oe)SAFETY 12000/12000E SERVICE MANUAL SAFE MAINTENANCE PRACTICES & warns Importance of safe maintenance cannot be over emphasized. Carolessness and neglect on part of maintenance personnel can result in their death or injury and costly damage to the crane or property Safety information in this publication is intended only as a {guide to assist qualified maintenance personnel in sate maintenance. Manitowoc cannot foresee all hazards that will arise in field; therefore, safety remains responsibility of maintenance personnel and crane owner. Maintenance Instructions To ensure safe and proper operation of Manitowoc cranes, thoy must be maintained according to the instructions. contained in the Service Manual provided with the crane. Crane maintenance and repair must be performed by personnel who by reason of training and experience are thoroughly familiar with the crane's operation and required maintenance. These personnel must read Operator's Manual and Service Manual before attempting any ‘maintenance procedure. | there is any question regarding maintenance procedures or specifications, contact your, Manitowoc distributor for assistance. Training/qualitication of maintenance personnel is responsibility of crane owner. Maintenance Precautions 4. Petform following steps (as applicable) before starting a maintenance procedure: a. Park crane where it wil not interfere with other equipment or operations . Lower all loads to ground or otherwise secure them against movement Lower boom onto blocking at ground level, it Possible, or otherwise secure boom against topping. 4. Move all controls to off and secure all functions against movement by applying or engaging all brakes, pawis, or other locking devices. fe. Stop engine and render starting means inoperative {Place a waming sign at start controls alerting other personnel that crane is being serviced and engine must not be started. Do nat remove sign until itis safe to retum crane to service. 12 2 10. 1. 12 Do not attempt to maintain or repair any part of crane ‘hilo engine is running, unloss absolutely necessary. If engine must be run, keep your clothing and all parts of your body away from moving paris. Maintain constant verbal communication between person at controls and person performing maintenance or repair procedure, ‘Wear clothing that is relatively tight and belted, Wear appropriate eye protection, approved hard hat, and safety shoos. Use proper tools that have been well maintained, ‘Take necessary precautions to prevent slipping and /or falling off crane during maintenance or other work. or death, "Never climb onto or off a moving crane. Climb onto and off crane only when it is parked and only with ‘operator's permission. Use both hands and handrails, steps and ladders provided to climb onto and off crane, Lift tools and other equipment which cannot be carried in pockets or tool betts onto and off crane with hand lines or hoists, Crane ownerluser must provide workers with approved Jadders or aerial work platforms to access those areas of crane and boom that cannot be reached from ground or from steps, ladders, catwalks, and platforms provided by Manitowoc. Adhere to local, state, and federal regulations for ‘handling personne! and for personne! fall protection. Boom and gantry are not intended as ladders. Do not aitempt to climb lattice work of boom or gantry to get to maintenance points. if boom or gantry is not equipped with an approved ladder, lower them before performing maintenance or repair procedures. Do not use top of boom (mast, ib, etc.) as walkways. Do not remove cylinders until working unit has been securely restrained against movement. Pinch points are impossible to eliminate; watch for them closely. Pressurized air and hydraulic oll can cause serious Injury. Make sure all air and hydraulic tines, fitings, and Components are tight and serviceable. Do not use your hands to check for air and hydraulic oil leaks: + Use a soap and water solution to check for air leaks, (apply to fittings and lines and watch for bubbles). Gennaro12000/12000E SERVICE MANUAL, 1. 14, 15, 16. W. 18, 19, 20. B88 24. 25. 26. 21. 28. 29. 20. at. + Use a piece of cardboard or wood to check for hydraulic oi leaks. Roliove pressure before disconnecting air and hydraulic lines and fitings.. Many machine components (engine, hydraulic, radiator) remain hot immediately after shut down. Do not touch them, until they have cooled down, Do not remove radiator cap while coolant is hot or under Pressure. Stop engine, wait until pressure drops and Coolant cools, then slowly remove cap. Do not hydraulic tank cap while oll is hot or under pressure. Stop engine, wait until pressure drops and oil cools, then slowly remove cap. Provide positive ventilation when refilling oils or fuel, rinsing parts, and performing other maintenance procedures, Avoid battery explosion: do not smoke while performing battery maintenance, do not short actoss battery terminals to check its charge. Read safely information in battery manufacturer's instructions before aitempting to charge a battery. ‘Avoid battery acid contact with skin and eyes. f contact occurs, flush area with water and immediately consult a doctor. |. Stop engine before refueling crane. Do not smoke or allow open flames in refueling area, Use a satety-type can with an automatic closing cap and flame arrestor for refueling. Hydraulic oll can also be flammable. Do not smoke or allow open flames in area when fing hydraulic tanks. Never handle wire rope by hand. Use only genuine Manitowoc Crane CARE replacement parts and oils Keep oll containers clean. Prevent dirt or moisture trom entering them. Also, use only clean, fresh lubricants to fil crane components, Only use cleaning solvents which are non-volatile and ‘non-flammable Follow local, state, and federal regulations for disposing (of waste (oil, rags, etc.) Do not attempt to lift heavy components by hand. Use a hoist, jacks, or blocking to litt components. Use care while welding or burning on crane. Cover all hoses and components with non-flammable shields or blankets to prevent a fire or other damage. oe SAFETY 82. To prevent damage to crane parts (bearings, cylinders, swivels, slowing ring, computers, etc.) perform following steps before welding on crane: + Stop engi * Disconnect all cables from batteries. + Attach ground cable from welder directly to part boing welded or within 3 ft (1 m) wold area, ‘and tur off key switch, * If possible, remove total controller. Do not weld on engine or engine mounted parts (per engine manufacturer. 383, Disconnect and lock power supply switch before attempting to service high voltage electrical components and before entering tight areas (euch as carbody openings) containing high voltage components 34, When assembling and disassembling booms and jbs on ground (with or without support of boom rigging pendants or straps), securely block each section to provide adequate support and alignment Do not go under boom or Jib sections while connecting bolts or pins are being removed. 28, Unless authorized in writing by Manitowoc, do not alter crane in any way that affects crane’s performance (10 Include welding, cutting, or burning of structural members or changing pressures and flows of air’ hydraulic components). Doing so will invalidate all warranties and capacity charts and make crane owner! User liable for any resultant accidents. 36. Keep crane clean. Accumulations of dirt, grease, ol, rags, paper, and other waste will not only interfere with sale operation and maintenance but also create a fire hazard, ‘Take necessary precautions to prevent water from entering tanks, gear boxes, electrical components, etc., when steam or pressuring cleaning crane. 37. Store tools, oll cans, spare parts, and other necessary ‘equipment in tool boxes. Do not allow these items to ie around loose In operator's cab or on walkways and stairs. 38, 39, Do not rotuin crane to service at completion of maintenance or repair procedures until all guards and covers have been reinstalled, rapped air has been bled from hydraulic systems, salety devices have beon reactivated, and all maintenance equipment has been removed. 40. Perform a function check to ensure proper operation at ‘completion of maintenance or repair. Do not store flammable materials on crane. 13( SECTION 2 SPECIFICATIONS TABLE OF CONTENTS Porformance an Outline Dimensions — Overall... 22 Outline Dimensions — Components 24 Base Maching....... 24 Counterweight.. 2... 2... 26 Attachment . 27 ‘Stability while Swinging and boon vee BAZ ‘Without Boom Base Diiiiittinssscsesesesssescrssers BAB With Boom Base re ear)+12000/12000E SERVICE MANUAL SPECIFICATIONS. SECTION 2 SPECIFICATIONS PERFORMANCE Type 7 [Crawler mounted, fully revolving Max. lting capacity (Standard) 108 860 kg x 3.65 m (240,000 Ib x 12 feet) Max. liting capacity (European) 110-000 kg x 9.60 m (242,504 lo x 12 feet) Max. boom length [70.1 m (230 ft) Max. boom + sib length [61.0 mboom + 21.3 mjb (200 R boom + 70 fib) Basic boom length 15.2 m (50) Working weight (Including upper and lower machine, counterweiahts. carbody weiahts. 50 ft standard boom, hook [Approximately 99,000 ka (218.000 Ib) block) “Average ground pressure ipproximately 92.9kPa(13.5 pst) Gradeabiity fs036 es Engine [Hino P110-UN 247 kw/2000 min Hoist line speed (front and rear drum) +2 120 min. (299 een.) “Lowering line speed (tront and rear drum) #2 120 mimin. (988 hv) Boom raising rope speed "2 [48 min. (157 fin) Boom lowering rope speed "2 = [48 min, (157 flmin) ‘Swing speed * 3.2 min (3.2 rpm) Propel speed ' 1.47.0 kim (0.87/0,62 milesmnour) " Speeds will vary depending on load, 2 Rope speed is measured on first layer of drum. fey aSPECIFICATIONS. 12000/12000E SERVICE MANUAL OUTLINE DIMENSIONS — OVERALL Height above ground of cab ‘Width of upper machine with operator's cab Radius of rear end (with counterwoight) ‘Counterweight ground clearance Genter of rotation to boom foot pin Height above ground of boom foot pin Height to top of gantry (working position) ‘Overall length of crawlers Distance between centers of tumblers ‘Overall width of crawlers (extended) Wiath of crawler shoe Ground clearance of carbody 22 [3500 mm (1185-13716 in) [3 200mm (106 in) [5 000 mm (164-778 in) 1260 mm (4 4-5/8 in) 1100 mm (@ 87-5/16 in) [2200 mm (7 82-676 in) [7 360 mm (24 R 2-9/16 in) [6770 mm (22 8-1/2 in) [5.800 mm (19 05/16 in), [5300 mm (17 4-5/6 in) [900 mm (2 11-7716 in) [330 mm (414 in)SPECIFICATIONS Ta aac F 12000/12000E SERVICE MANUAL, UNIT : mim (ft inch) Tee aa (oz- erremm (2 = Ln 2) ar are Ce aE ie Re OOBELSPECIFICATIONS 1200/1200 SERVICE MANUAL OUTLINE DIMENSIONS — COMPONENTS Base Machine Name Dimension mm (in) Weight kg (ib) 215 0" 10.7% 8:00 07 4g") Base Machine = . a j*With wire rope E maw 3 i 0295 27 2-16) Base Machine ay j= ° | asa |-Without crawler 2 | (79,830) | swith wire rope g 033%) Base Machine -without crawler Without gantry 33880 }-Without boom: (74,690) rum rope -With front and rear = drum wire rope (10°74)SPECIFICATIONS {2000/2000 SERVICE MANUAL 2190 1511949776) oo Bey Base Machine : Jwin boombase | & ac 406 700 Jaw wie rope 5 2 (o0.6e8) -Without crawlers 3 a 2 aio 2208 ase fora *, ergs 2-016 @ oe 11900 cramer lees Ake ees 20 ransitor rans (850) th oat) (950 oF ass 654 220 rom)‘SPECIFICATIONS 12000/12000E SERVICE MANUAL Counterweight Name Dimension mm (tin) Weight kg (ib) > 8.200 (10119 a ICountermeight 10000 Number 1 q (22,050) 200 0") Ml Mm z : counterweight i 7.000 Number 2 and 3 a (15,435) g Lp iL oO 9 pot, og J12000/12000E SERVICE MANUAL SPECIFICATIONS S| * 3 Counterweight i 10000 Number 4 a (22,060) q H I rad Ay l Attachment — Weight kg) _] boom p a oontess ex, }3.0m (10°) 380 Boom insert (838) a7SPECIFICATIONS 12000/12000E SERVICE MANUAL 1,680 6.220 (20 ATi") sq be \6.1m (20°) J z 655 [Boom insert KK 6 (1,445) fl g q Si 9,265 (30 4-9/4") 9.1m (30°) = 925 Boom insert | yi é (2,040) Ly 2 f/f, g _ 9,265 (30 4-8/4") 9.1m 0 x a « 960 [Boom insert with 5 3 re 7 i 2 at s| JA Af & _ 1,980 12,310 (40° 4-"/69) (86-6) 12.2m (40") ] 1,195 |Boom insert W\ ii fs (2,635) i] uy 12.2m (40°) = i 1220 [Boom insert with 2 F lug 3 (2/690) 6.790 (23-469 500 Backstop (1,100) each 28 Contre12000112000 SERVICE MANUAL SPECIFICATIONS a 20 [svep all wn (2 77’) FIT is i ‘. 7 Fla 200 jp vase a L (2 | ‘ 3,415(10' 2-6") 295t2. 7, 100 }3.0m (10') = Lib insert \ ri N (220) 6,160(20' 2-"/") e527) 1.195 2am (0) : Libincer Dot i 2638) 3,620(11" 10-1") 5 250 ieee ws é - (650) d= = cad 3s i | =| 4 Oe 760 Jcanty 37) 29SPECIFICATIONS 12000/12000E SERVICE MANUAL 1,780 (6' 10-46") 305 (1") 300 Upper sproader 3, 1 t ® © © 25500) 1 nn lal / | il o 4 | Lower spreader 3) T| Wi 2 JhO GA § 905 (2 11-15") ” Genesee‘SPECIFICATIONS, 12007120008 SERVICE MANUAL = saree Wa Fae 00a) = 111929 Batok & 70 (1° 6.%2") pe S89, srcoumeunes gf oe 3 | Ss i@ eae) mea ~ A | 3 : {jaa +46 z 900 rourrusveatton] a Voy i 85 3 ce i Re ; & ) | i Toasty ewe 11425 Hk a } 1006-4 <=) |[0e oe anSPECIFICATIONS. STABILITY WHILE SWINGING AND TRAVELING Without Boom Base 1200/1200 SERVICE MANUAL 360° Swing Propeliing Gantry position | Counterweight | s.awier | When Jacked up a oe Without crawler Low gantry position None oO oO O ° High gantry position None ° ° ° ° Low gantry position | 10.0t(11 USI) ° x ° ° High gantry position | 70.0¢ (11 USI) ° x ° ° Low gantry position | 17.01 (19 USt) oO x oO oO High gantry position | 17.0 (19 USt) oO x ° ° Low gantry position | 24.01 (28 USI) ° t x ° ° High gantry position | 24.0 t(26 US!) ° [x Oo. ° Low gantry position | 34.0 t (37 US)) x x x x High gantry position | 94.0 ¢(37 USt) cease | EEE x x (©; Operation permitted X: Operation PROHIBITED, With Crawlers High gantry positio Low ganiry position 2ae Qenrowoc1200/1200 SERVICE MANUAL SPECIFICATIONS. [Jacked Up with One Crawlers 800M FOOT CRAWLER FRAME 3 Swing drecton means jhe irecton ofthe boom feat Lppar Soin fs parma only m shaded aoa 1. Table on the previous page and on next page shows: values for operation on a firm, level uniformly ay supporting surface. 2. Swinging on a trailer is prohibited. 3. Maximum slope angles 16.7 degrees (30%). Traveling forward = counterweight and propel motors are toward downhill side of slope. Propaimoior/ Traveling forward 5. Traveling backward = counterweight and prope! motors ate toward uphill side of slope. oa Propel motor Traveling backwardSPECIFICATIONS 12000/12000E SERVICE MANUAL With Boom Base 360° Swing Propaling Gantrypostion | 82°" | counterweight] yan cau, [Wheni8350| —fovag | ommma Without crawtor Tow panty postion None of 0 3 o High genty poston None © ° ° © Tow garity poston Torii us| 0 x ° ° High ganty postion ioor(irus)| 0 x 3 © Loweantypeston |... [azoreusy fo |x 3 3 igh gantry poston ir01(i9us) | 0 x ° 3 Low gantry postion 24.01@6us) | 0 x ° 0 | Fgh gant postion 24.01 @6us)| 0 | xX ° Low gantry postion eor@7ua) | x x x x High gantry postion saoug7usy | x x x x O: Operation permitted. X: Operation PROHIBITED ign gnty poten Low ganty postion T Max angle 20 deg, ae GonrowoeSECTION 3 WEAR DATA AND HYDRAULIC TEST PROCEDURES. TABLE OF CONTENTS Wear Data Pins and Bushings Springs Sheaves Propel Components Crawler Shoe Drive Tumbler Idler Track roller Guide rotor Guide Bar . Propel Brake Plate Slewing Ring Porlormance Standard And Test Procedure Operating Speed. System Pressures.1200/1200 SERVICE MANUAL WEAR DATA AND HYDRAULIC TEST PROCEDURES. SECTION 3 WEAR DATA AND HYDRAULIC TEST PROCEDURES WEAR DATA Pins and Bushings 4 a Pin Bushing Unit: mm (in) Sta, dimension Usable limit See Name Location Item s Remeds _ | D L_¢ D e Y] Figure Troon rr Ce 73.82 1 Front, Rear Dum} 2 | lag, | Ee) | 1 Paw —| + Replace /Boom Drum 2 ae aaeel 3 (1.72) (1.764) 7 38.1 37.92 (1.50) (1.493) 130 72.85 ae (0.512) (0.506) Pin 10 130 72.85 Brake pedal (sw) (oso) Replace] 5 | 0000868 ae (o.394*20020"- (0.392) 7 10.0 9.96 (0.394) (0.392) 1147 114.04 Boom Foot [a fara hacen Replace] 6 440 “44.28 Paw (Front, Rear) 3 (1.732) (iis) | Reptace] 1 450 45.27 Bushing [Pat (Boom) 3 ae (jaa) [Rovace] 3 115.0 115.35 [Boom Foot 3 ines lacey [Replace] 6WEAR DATA AND HYDRAULIC TEST PROCEDURES 12000/12000E SERVICE MANUAL Springs Free Length. Free Length ‘Unit: mm (in) Usable iit of Location ttom | sta.Freetenatn | Usabletimof | Remedy | See Figure 7 @.885) a4 Front RearOrumpawi | 54 | (geass) ES 1 en 72 (eB) wea epiace pemaienoe 5 | compression) 229) Feel 8 61.5 242i) 338 Brake pedal 15 Eireon |e Gap 5) Sheaves Standard root lameter | _ : (CGroove Radius 40.deg. Unit: in) Sid, root 5 Groove , Equipment [tem] Sot] Userimit | Remedy | S°°¥° | see Figure 494 wi 155 ce 8 | ass) | case (st) 549 S46 155 ier 2 | ess (23.50) (01) A 204 20 155 Aniiaysteave | 10] gfe | afk fea 381 ter 379.5 | Replace! 11.0 Upperspreader | 1 per T | rs.00%2120-5| (1494 | or | (0.43) Lower spreader 5 31 *80r am 8 ey 8 a (15.00°°120-) | (14.94) (043) sib point 12 549 546 14.0 5 Jib strut 13, (21.61) (21.50) (0.55) agi *807-0 379.5 WS Gantry peak 6 me (15.00.12 0r-0) | (14.9.4) (0.45) e ” Genesee+12000/12000E SERVICE MANUAL WEAR DATA AND HYDRAULIC TEST PROCEDURES Wear Limit: 31 Front and Rear Drum Pant ~~ mm (0.118 inch FIGURE 3-1 LLLLA Boom Paw! 408 em RY (east) , LY | LSY Wear Limit: mm (0.118 Inch) y FIGURE 3-2 aWEAR DATA AND HYDRAULIC TEST PROCEDURES: 12000/12000E SERVICE MANUAL Brake Pedal | | FIGURE aa] Grane Boom 2 9 6S eal f 8 8 10 FIGURE 3-4 Cereae1200/1200 SERVICE MANUAL. WEAR DATA AND HYDRAULIC TEST PROCEDURES Crane sib FIGURE 3-5 FIGURE 3-6 35WEAR DATA AND HYDRAULIC TEST PROCEDURES. 12000/12000E SERVICE MANUAL PROPEL COMPONENTS Crawler Shoe Unit: min (in) item | Std. Dimension | Usable limit_| Remedy Build-up Pinhole (D)| 45.0 (1.77) | 46.0 (1.81) or Replace Pin 44.48 (1.75) _| 4.25 (1.67) Pitch (P)_| 228(8.98) | 234.6 (9.24) When six shoas are connected by shoe pins and hanging vertically, distance between pins should bo 1 378.0 mm (64.3 in). 3030 1 (1.18) A100. rf RFT 1505) I Aa 7009 \| Unit: mm (in) Wat Lit: 2 mm (0.079 in) Flomedy: Buld Up ar Feplace * Geuzsee12000/12000E SERVICE MANUAL, WEAR DATA AND HYDRAULIC TEST PROCEDURES Drive Tumbler Unit: mm in)WEAR DATA AND HYDRAULIC TEST PROCEDURES 12000/12000£ SERVICE MANUAL a8 Idler Unit: mm in Symbol] Wem Sid, Dimension Usabletimit| Remedy Bulkhup oF A fowtordameter 785 (20.9) 777 (a0) | ulin 0 Diameter Tolerance Saandard | “Atowable -0.036(0.001)| Gap ge [oappoweenctnat) | Stat [sort eso. | axrsitoor | _ cap Hole | 0-181 (0.006) to 1.0 (0.04) _| 40.139 (0.005) | 0.292 (0.009) __| Replace Shan | 70.117 (0.005) | Tightening caene ghtcning tolerance 30.092(0.008)| tolerance | Tighening C — fofsprocketand . 125 (4.92) 0.057 (0.002) | tolerance ousting Hote to 0 0.117(0.008) . ee29) poo) — 7 Tl Unit mn : 7 Wear Lit 2mm (0.079n) i_ ce | Fema Buld Up or Replace i | Gonrowoc12000/12000E SERVICE MANUAL WEAR DATA AND HYDRAULIC TEST PROCEDURES. ( Track Roller Unit: mm (in) Symbol iter Std, Dimension Usable limit] Remedy ic-up or A outer diameter 200 2.2 (11.4 + 0.08) 2eactt.ay | Bee? Diameter Tolerance Standard | Allowable sn “0.036 (0.00) Gap a [eapbewooncterat! gy | srat | Somnieasn | ozsetor) | cap | ReBice 5 |, [+0z800m ] to 08 (0.03) ole | 40.23 0.000) | 0.97 (0.014 __ shat | Sor oo0e) | teres ¢ [Mahtoning oterance | 105 aorsioooa | TMttenINg | clo ciroierand ousning | (13) | yy. | #0.095(000] 2% | roieranceo | PP8 a 0.42 (0,008) | A100.4)] eg — 764100 21269 29WEAR DATA AND HYDRAULIC TEST PROCEDURES. +12000/12000E SERVICE MANUAL Guide Roller Unit: mm (in) ‘Symbol Hem Sid. Dimension Usable limit Remedy A ‘Outer diameter 230 (9.1) 222 (8.7) Build-up or Replace R10(0.4) 5 (0.2) 340 Gextoxee12000/12000E SERVICE MANUAL WEAR DATA AND HYDRAULIC TEST PROCEDURES Guide Bar Unit: mm (in) ‘Symbol Hem ‘Std. Dimension Usable limit Remedy A Height of Guide Bar 85 (3.35) 65 (2.56) Build-up or Replace 2700 096) 00 (23.6) 45017.71 $00 (2. 6) 458107. 1 600 23.6 A A A yp DETAIL A Propel Brake Plate Unit: mm (in) ‘Std, Dimension Name of plates ron Wear iit (Tota) ‘Std, Brake torque Friction 4 21.2 (0.83) 52810712 Nm ‘Separator 5 22.7(0-89) | amount of woar: 1.5 (0.059) (489 to 525 fib) Separator plato / friction pate fed anWEAR DATA AND HYDRAULIC TEST PROCEDURES 1200/1200 SERVICE MANUAL SLEWING RING Measuring Condition Counterweight 84 t (87 USI) Boom length: 15.2 m (60) Radius: 9.14 m (80 f) Load: 96.8 1 (8,2500 Ib) REVOLVING FRAME Amount of play Less than 3 mm (0.21 in) WATHIN $00 om (3.097 LOWER FRAME Gerieuge12000/12000E SERVICE MANUAL WEAR DATA AND HYDRAULI PERFORMANCE STANDARD AND TEST PROCEDURE ‘Standard Value = Value when the crane was new. When this. value is exceeded, repair or replace the part as required to relum is to Like New periormance and or safety. IC TEST PROCEDURES Operating Speed Fectna | sen ete santos Sok [ Ewteentans Stacnogai sonnet 10 55°C (113 to 11°F) af Foret] omer i arena eee Straightness. ]+ Temperature of Hyd. oll: 45 to 58°C (113 t0 131°F) Boom Length: Std. Boom lpropeting a distance of 20 m (56). Star measuring ater machine has been propelled at least 2 m (6.6 t). Take average o 3 times. it Devi from 20m (66) within 600 ram (23.6 in) 343,WEAR DATA AND HYDRAULIC TEST PROCEDURES: ‘System Pressures Use an accurate hydraulic pressure gauge which has a surplus of more than 10 MPa (1,450 psi) for pressure to 1200/1200 SERVICE MANUAL Before attaching gauge to pressure port, clean all oll and dirt from port and connecting fittings. be measured. No.[__ttem [Test Condition Test Procedure Standard Value + [Main Engine revolution (min); righ | Lower rear hook onto ground. 31.9 MPa J+ Propel Right | ile 2. Lock rear drum. le) | Rear Drum |* Tomperatureot Hydraulic ol:45]5 ya :oar gram in lowering dveton Temper 3. Stall ear drum in lowering direct (113t0 191°F) PRESSURE GAUGE 2 [main Engine revoltion (min); Fign fl. Lower main hook onto ground aia MPa + Propotton | idling eae (4.626 psi) + Front Drum |» Temperature! Hydraulic oi 45 a Temper 13. Stall main drum in lowering direction, (11310 191°) PRESSURE GAUGE elt) RELIEF VALVE \ a4 G@onrowoe1200/1200 SERVICE MANUAL, WEAR DATA AND HYDRAULIC TEST PROCEDURES No. item _| Test Condition Test Procedure ‘Standard Value 3 [Boom > Engine evolution min); righ fi. Lower main hook onto ground: 31.9 MPa ae l2. Lock boom drum. (4826 psi) |+ Temperature of Hydraulic ol: JetegsO (Ste Tat) [%_ Stallboom cum in lowering cretion. RELIEF VALVE PRESSURE GAUGE PORT (PFI), 4 [Swing Engine revolution (min): High J?- Lower swing with swing lock pin and swing) 27.5 MPa | ide brake. (8988 psi + Temperature of Hydraulic of 45 10 55°C (11310 131°F} + Swing mode: Free high Siall swing by swinging in either direction, RELIEF VALVEWEAR DATA AND HYDRAULIC TEST PROCEDURES. 12000/12000E SERVICE MANUAL No. item Test Condition ‘Test Procedure ‘Standard Value IS |[Controt Circuit [+ Temperature of Hydraulic | Remove cap from plug installed in valve block,| Relief Valve [primary pressure) | olf: 4510 55°C (113 to and install pressure gauge. 7.0 MPa(1015psi) 131°F) {High idle) ACCUMULATOR RELIEF VALVE yy PRESSURE le! q REDUCING VALVE PRESSURE GAUGE _— RELIEF PRESSURE GAUGE PORT PORT 346 @entowoe1200/1200 SERVICE MANUAL WEAR DATA AND HYDRAULIC TEST PROCEDURES No. tem Test Condition Test Procedure 6 [Controi Circuit Engine revolution (min), |-Operate control lever for section to be measured (secondary pressure) | Low idle. + Temperature of Hydraulic ol: 45 10 55°C (119° to 131°F) 2. Operate speed adjusting knob to maximum position, Take pressure at quick coupler at end of control vaivel spool Standard value Boom 50 to 2.79 MPa (363 to 405 pel) Propel = 1.42 to 1.62 MPa (208 to 235 psi) | swing = 1.62 to 1.81 MPa (238 to 262 psi) Front & Rear Drum = 2.65 to 2.94 MPa (384 to 426 psi) |8rd. Drum (Optional) = 2.75 to 3.24 MPa (399 to 470 psi) | a7WEAR DATA AND HYDRAULIC TEST PROCEDURES 12000/12000E SERVICE MANUAL No item Test Condition Test Procedure Standard Value [7 |* Gantry raising” [+ Engine revolution (min), | Stall gantry by extending gantiy]?. Gantry Raise lowering High ie cylinders, 20.6 MPa (2,087 psi) J+ Lowercircuit |. Temperature of Hydraulic ol: |2. Stall gantry by retracting gantry}2. Gantry Lower 45 10 55°C (119 t0 131°F} oytnder, 4.9 MPa (711 psi) 13. Stall crawier by retracting crawiey|3. Lower Circuit eylinder. 20.6 MPa (2,987 psi) al | : ce = oz RELIEF VALVE (GANTRY RAISING) 10.6 MPa (2987 psi) ts mH =<] |e Jo, Me RELIEF VALVE (GANTRY BARING a PRESSURE GAUGE (GANTRY LOWERING) (GANTRY RAISING 8 PORT (PF) 4.9 MPa (711 psi) 20.6 MPa (2987 pst) SECTION 6-6 SECTION D-D 348 Gon “Gunecane( SECTION 4 TORQUE VALUES AND METRIC CONVERSIONS TABLE OF CONTENTS Tightening Torque for Cap Screws and Nuts. Motric Coarse Threads . Metric Fino Threads Coarse Threads UNC Fino Threads UNF oo... eso... Tightening Torque for Hydraulic Fitings Bite Type Tube Fittings Split Flanges Flare Type Tube Fittings (30° Flare, PF Threads) Jubilee Clip (Low Pressure and Suction) Parts Identification Bolts ‘O-Rings. Back-Up Rings Bite Fittings Metric Conversions Unit Conversions. Length Capacity Weight. Pressure Torque (Tightening) Millimeter ~ Inch Conversion Tables. 1 mm to 99mm Inch Fraction-Milimeter Meter ~ Foot Conversion Table Gradiont Conversion Table Tabio of Unit Weights at 44 142 242 43 43 43 43 a4 45 45 47 48 4-10 410 410 410 410 4-10 410 ant ant 412 413 ata 414 41200/1200 SERVICE MANUAL. ‘TORQUE VALUES AND METRIC CONVERSIONS SECTION 4 TORQUE VALUES AND METRIC CONVERSIONS TIGHTENING TORQUE FOR CAP SCREWS AND NUTS Uniess otherwise specified, torque all cap screws and nuts ‘on this machine to the values shown in the following tables Metric Coarse Threads Unit: kor (fa) ar a iT. Nominal size Tm ay eae ay es Me 0.45 (325) | 0.98 (2.75) | 0.9651) 0.8 (6.79) 17 (12.8) 1.5 (10.9) Ms 109(7.88 | 09651 | 2474) | 20145) | 4311) | 3660) Mito 22(159) | 18(130) | 47(40) | 40/89) | 05(615) | 7.2(62.1) owe 37268) | 92032) | 61686) | 6649.2) | 146(105) | 123/690) mia 59 (27) | 01062) | 128/026) | 10.8(7e1) | 23.0(165) | 195 (14 wmié| ~9.0(06.1) | 7.6 65.0) | 1955141) | 16.4 (118) | 9501283) | 200210) mie 12.4(807) | 105760) | 27.0(195) | 23.0 (166) | 49.0(54) | 47.0297) M20 17.5 (127) | 147 (106) | _38.0(275) | 32.0232) | 68.0(492) | 87.0 (412) Mz2 23.0(166) | 19.6(142)_| 51.0(269) | 4a.0(a1) | 92.0 (665) | 7.01657) M24 soo) | 240(t7a)_| 65.0170) | 3.01083) | 118.0 (654) | 96.0164) Maz 44.0816) | 36.0 (260) | 96.0(694)_| 78.0 (56a) _|_1730(1251) | 140.0 (1012) M30 60.0 (434) | 60.0(862) | 191.0848) | 110.0 (786) 5 mae 33 181.0 (686) | 68.0 (492) | 176.0(1273) | 148.0(1070) : 5 M36 105.0 (760) [_680(637) | - - 5 Metric Fine Threads Unit: kgem (tb) Nominal size 4 a wt Dy Lubricated | Dry | _Lubricatoa Dy | Lubricated m6, 147.965) | o4(2as) | 25 (152) | 21(152) | 45/926) | 98@7.5) M0 2a(e6) | 19037) | 49154 | 42(04 | soves4 | 751643) M2 40(288) | 34a) | 72a) | 730628) | 167 (114) | 132 (055) Mt6 9.0(65.1) | 7.1628) | 20.0(145) | 17.2(124) | 97.0 (268) | 310 (224) M20 19.0(157)_|_158(114) | 41.0 (297) | 94.0(246) | 74.0 (635) | 62.0 (448) Mea 32.0 (282) | 27.0(195)_| 70.0 (606) | 56.0 (405) | _126.0(011) | 105.0 (760) ——ws0 65.0(470) | 84.0 (91) | 142.0 (1027) | 118.0 (654) a : M36. 109.0 (788) | 91.0 (658) = = 5 e atTORQUE VALUES AND METRIC CONVERSIONS. 12000112006 OE SERVICE MANUAL Coarse Threads UNG Unit: kg-m fb) ——— Grade2 Grades Grade 8 Dy Lubricated Dy Lubicated Dy Lubricated wa 08167) | 07606 | 19/04) | 11796) | 18130) | _15(108) 36 te(6) | 14(101) | 26(tesy | 221159) | 36(260) | 3.1(224) a8 2oii0) | 2474) | 45026 | 3807s) | 6566) | 531983) 76 45(25) | 9875) | 7.0606) | 59427) | 9.90716) | 83(600) 12 7.0(606) | 59(427) | 108(76.1) | 9.1(658) | 152 (110) | 12.8(92.6) ane to.0(723) | 84(608) | 155 (112) | 13.0(940) | 22.0(15) | 18.4(199) 518 14.0(101) | 11.8(65.8) | 22.0(189) | 18.2(132) | s1.0(@24) | 26.0(188) sa [ 25.0161) | 27.0082) | 28. 32.0 (282) )_[ 48.0 (925) 78 28.0(210)_| 26.0(181) | 61.0141) | 51.0 (69) | 26.0 (622) | 72.0(621) 1 35.0253) | 0.0(217) | 91.0(658) | _76.0(550) | 128.0 (926) | 108.0 781) Te 51.0 (969)_| 43.0a11) | 114.0(825) | 95.0 (687) | 184.0 (1991) | 154.0(1114) 114 | 71.0(614)_|_59.0(427)_|_159.0(1150) | 133.0 (962)_| 257.0 (1859) | 216.0 (1562) aa 92.0673) | 78.0 (564) | 200.0(1512) | 176.0 (1266) | 398.0 (2445) | 284.0 (2054) Te 124.0,(@97) | 104.0 762) | 277.0 (2004) | 292.0 1678) | 449.0 (9248) | 976.0 (2720) ine Threads UNF Unit: kg (sb) Nominal size Grade Grades Grade 6 Dry Lubricated Dry Lubricated Dy, Lubricated v4 0.9 (6.51) 0.8 (6.79) 1.4 (10.1) 1.2 (8.68) 2.1 (18.2) 1.7 (12.3) 516 1.8(132) | 151108) | 28@03) | 2474) | 4000) | 340246) 318 32(231) | 27(195) | 49/954) | 41/207) | 7.0(60.6) | 5.8420) 7A6 5.0(362) | 42 (904) | 7.76557) | 641463) | 10.8(78.1) | 9.1 (65.8) ve [_77(857)_| 64.463) | 119/661) | saris) | 168(122) | 140 (101) ane _|_10.9(788) | 921665) | t69(122) | 14:1 (102) | 24074) [189 (144) 38 15.5(112) | 12.9(038) | 24.0(174 | 20.0(145) | 34.0(246)_| 28.0 (208) aia 27.0(195) | 22.0 (189) | 42.0(304) | 35.0(253) | 58.0(420) | _49.0(354) 718 31.024) | 25.0(161) | 660/477) | 550(s06) | 9.01673) | 77.0(557) 1 38.0(276) [31.0 (224) | 98.0(70s) | 82.0 (693) | 198.0 (998) | 116.0 (632) 1a 56.0(405) | 46.0(833) | 124.0(897) | 104.0(752) | 201.0 (1454) | 168.0 (1215) 14 7.01557) | 64.0 (463) | 153.0(1107) | 149.0 (1094) | 279.0 (2018) | 292.0 (1678) tar [103.0 (r45)_| 86.0 (622) | 281.0(1671) | 192.0(1389) | 374.0(2705) | 311.0 (2240) 1172 | 196.0 (984) | 118.0(617) | s040 (2199) | 253.0 (1830) | 493.0 (3566) | 410.0 (2966) 42 Gearewe12000/12000E SERVICE MANUAL. TORQUE VALUES AND METRIC CONVERSIONS TIGHTENING TORQUE FOR HYDRAULIC FITTINGS Tighten hydraulic fitings to the torque values given in this section to prevent leaks or damage to fitings Bite Type Tube Fittings Size — mm (inch) Tightening torque Remarks (Outside diameter X thickness gem (tbs) 410 (0.964) x 1.5 (0.059) 510 7 (8610 51) eee 15 (0.581) X2.0 (0.079) Tato 16 (94 to 116), 18 (0.708) X2.5 (0.098) 16 to 17 (11610 123) ‘Condon ater 22 (0.866)X3.0(0.118) | _20t0 22 (145 to 189) Tieng 28 (1.102) X 4.0 (0.187) 25 to 29 (181 to 210) wt ‘35 (1.978) X 5.0 (0.197) 33 10 36 (289 to 260) semoar | Split Flanges SAE Standard a Tightening torque — ko-m (f-labs) Z(H) | goaopel(2ro kgm?) | 60001 (420 ke/am?) v2 2to2.6 (14.5 to 19) - 7] SPLIT FLANGE aia 2.910.400 (211029) Bas t04.6 2510 39) 1 3.75 10 4.9 (27 10 35) 5.75110 6.9 (4210 50) id Tit [ 491068 (651048) | 8610 10.3 621074) ie ne 6.5108.0(45t058) | 16.1 0 18.4 (11610 135) yy 2 7.5109.5(54t069) | 27.610 30.0 (20010217) Flare Type Tube Fittings (30° Flare, PF Threads) Si Ta Tenn oe erm (ES Tema vf 251035 (81025) a8 507 (96 0 51) eae eel 7 io 80 \ j ca 2616716) tla 1 15 to 19 (108 to 137) _ 14 17 to 23 (123 to 166) Tre [rae isso) —] ™ 2 26 to 94 (185 to 246)TORQUE VALUES AND METRIC CONVERSIONS 12000/12000E SERVICE MANUAL Jubilee Clip (Low Pressure and Suction) ( a Diameter Recommendedtorque | Workng reseue ange BSS315 inch mm kg-om inbs gem? psi 2 we 35-18 oA 289 560 76 16 12-58 11-16 os 29 560 726 20 12-34 19-20 oS a9 560 786 2 i878 10-22 “87 387 se 786 2 w= 18:25 a57 oor 560 726 so [78-118 28-20 487 ear 6.0 706 a 1138 25-35 357 a7 S60 796 4018-158 27-40 457 a7 350 408 so [178 35-50 457 287 350 18 ss [e218 40-85 wo sea an 298 a ETE) 15-80 eo. wa 20 209 7 2-204 55-70 cos sea 168 220 eo | 23%-316 | 60-60 60.4 52d 168 239 co | aaa 70-00 50 99 188 8 oo [a vane 5100 600 59.9 168 9 120 | Sanaa | 90-20 00 380 105 149 140 448-512 | 110-140 69.0 59.9 10.5 149 160 [5-538 100-180, 90 sa 105 19 165 | Sim-01 [105-105 0.0 09 08 [199 100 | 64-7 ve | 160-180 on S09 a8 199 2is_[ 714-81 | 165-218 7B0 er m7 128 aio [a v4-91 | 208-240 780 77 7 128 210 94-101 | 206-270 a0 or 7 128 200__| W011 | 256-290 780 er 80 128 coo | —itv-ve1e | 208-20 780 o77 30 1a “ Genrowoe12000/12000E SERVICE MANUAL ‘TORQUE VALUES AND METRIC CONVERSIONS PARTS IDENTIFICATION Bolts Bolls are identified as shown below. ZS@@C @ @ TUT tr {showing the length of bolt. tr) ‘Showing nominal cimension. (6) C : Shows coarse screw threads, F : Shows fine screw threads. Showing strength and kind of bolt 11: shows 4T 12: shows 77 13 :ehows 10T shows hexagon socket head bolt ‘Some bolts are stamped strength class on the heads, 4t 77 | 10T zur | (@) |[ sir] @) | [zsnr 2861F Z350F 2853F A 4sTORQUE VALUES AND METRIC CONVERSIONS: 12000/12000E SERVICE MANUAL O-Rings O-Rings are identified as shown below, eer ee oo ‘Showing inside diameter. Classifing thickness of the ring, P: Shows for the use of moving part. G : For the use of stationary part. — Classifing quality of rubber. Not figures but points of blue, red, green and of yellow colours are put on Colour and quantity of points classify as follows 11:21 point of blue colour mean Hs70. 42:2 point of blue colour mean Hs90. Colour of point shows “Both blue and red to be of nitril rubber and biue io be used in the range of temperature of minus 25% tot20'¢(T7"F to 248°F) Ree for gasoline proof not to be used nomall. + Green to be of fluorine rubber and used in the range of temperature of minus 15eto 200%(59°F to 392° ) 1 point of blue : 201 1-—nitrl rubber Hs70 2 point of blue : ZD12-—nitril rubber Hs90 4 point of red nitrl rubber Hs70 1 point of yellow styrol rubber Hs70 4 point of green uorince rubber Hs70 Gentenge12000/12000E SERVICE MANUAL. TORQUE VALUES AND METRIC CONVERSIONS: ( Back-Up Rings ‘Size and kind of back-up ring are identified as shown below. fit-d) 10. wth | | ‘Showing inside diameter. ZD@@P @@@0 0 Ct —— Classifng wiath Bias out — showing shape acta inn 8 cbs cu 9 spel = = feaisy = Using 1 pee oF Using 2 poo of backup ang Dacleup fing fea? “7TORQUE VALUES AND METRIC CONVERSIONS Bite Fittings \ Nominal dlemeter 412000/12000E SERVICE MANUAL 22 2F83H22000 ZA82P22000 2K82P22000 ~ a fen Nominal Diameter Made by IHARA KOHATSU Made by NIHON AMC Made by NIHON AMC ~~ (2) (2a) (ze) 70 "ZFESP10000 ZABIP10000 ZKe3P10000 15 ‘ZFeaP 15000 ZAB3P15000 72K83P15000 18 ZFeaP1a000 ‘ZAB3P18000 7ZK63P18000 22 ZFeaP22000 Za8aP22000 ZK83P.22000 26 [ZF83P26000 ZA83P28000 "2KB3P28000 35; ZF8SP35000 ZAB3P35000 "2K83P35000 48 Geren1200/1200 SERVICE MANUAL, ‘TORQUE VALUES AND METRIC CONVERSIONS — | Nominal clameter Made by IHARA KOHATSU | Made by NIHON AMG Made by NIHON AMC Nominal Diameter i oy a 10 zFaan10000 ZAQGH1 0000 ZKGON: 15 ZFOSN15000 'ZABN15000 ZK93N15000 18 ZFO3N18000. ZAQ3N18000 ZK93N18000 22 "ZF93N22000 ZAGBN22000 ZK93NZ2000 - 28 ‘ZF93N28000 ZAGBN26000) ‘ZK93N28000 ‘2F93N35000 ZASN35000 ZK93N35000 | Nomina ameter Nominal Diameter | Mads byIHARAKOHATSU | Made by NIHON AMG Made by NIHON AMG ry (ZA) (20) 70 ZF98S10000 'ZA93S10000 "ZK93510000 45 '2F93815000 ZA3S18000 2K93815000 18 ____2F 98818000 ZA98S18000 2K93818000, 22 'ZF93S22000, 7ZA93S22000 293822000 28 ‘ZF93828000 ZAS3S28000_ __2K93828000 35 'ZF93835000 "ZA93535000 'ZK93835000 Tightening torque ZE + ZA Type Nominal Diameter 40 15 18 A 28 3% Tightening Torque et 1522 B22 28 B28 3545 kg-m (ft-lbs) (437) | (108214) | (190214) | (160214) | (20020) | (253+ 20) Tightening torque ZK Type Nominal Diameter 10 15 18 2 28 35 Tightening Torque eat O21 1222 17=2 2222 2825 kg-m (fttbs) 3=7) | 527 | @7=t4 | 123214) | (160214) | (200220) a 49TORQUE VALUES AND METRIC CONVERSIONS: +12000/12000E SERVICE MANUAL METRIC CONVERSIONS Unit Conversions Numbers in () equal the number of zeros that need to be added after the decimal point. For example: 0(2)1 = 0.001. Length Unit mam om m ken in ft ya rm 1 4 2.001 | 0.00001 | 0.03987_| 0.032808 | 0.0010936 | 0.(6)6214 em 10 4 0.01 | 0.0001 | 0.3937 | 0.032808 | 0.010996 | o.s)6214 m__|__ 1000 100 1 0.01 | __99.a7 | 3.28088 o.ayeat4 en 00000 | 1000 1 39370 _| 3280.83 | 0.62187 in 25.40 | 2540 | 0.0254 | 0.(4)254 1 0.0833 0.41878 304.8 0.48 | 0.5088 | O4S)S04S | 1 “fecayte04 oa | st4a | ooiaa | ogjo1a4 - 3 4 | 049)5682 - 1609347.0 | 160034.70 | 1600.35 | 1.60965 | 6as60 | 6260 1760 1 Capacity Unit om tte te in? ye? gal om? 1 oi | 0001 | ofa | o.0s102 | oxaasar | o(6)t308 | o(ajasae m__| 1000000 1 1000 7 | etozo | 531 | 108 | 26a tw 1000 0.001 4 0.001 61.02 | 0.03531 | 0.001308 | 0.2642 vat | 1000000 1 1000 1 “eroz0 | 3531 | 1908 | 2682 in? 1629 | oajrese | o01630 | ofaiese | 1 | o@s7e7 | oaaraa | 0.004400 #8 2eaz0 | oo2ese | ase | ooease | 1728 1__| o.0srea | 7.48086 ye | 7easoo | o76as | 7645 | o7eas | 46060 a 1 201.974 gal a7e5_| ooos7as | 3785 | ooca7es | 231 ox1aa7_| 0.000051 | 7 Unit kg oz ib USt (2000 tbs) | GBt (2240 ibs) t kg 1 35.2740 2.20462 e.01t02 | o4s)9842 0.001 oz | 0008ds 7 o.06250 | o.ajates | 0.42700 | oa)2ea b 0.48359 16 1 | 0.00050 0(3}4460 | _0.8)4596, ust 907.185, 32000) 2000 1 0.89286 0.90719 ‘GB 1016.05 35840) 2240 112) 1 7.07605 t 1000 35274) 2204.6 710281 0.98421 1 Metric ton — US = United States ton — GBt = (British Unit) Pressure Torque (Tightening) Unit MPa | __kPa psi tit kom feb MPa 1 1000 145 kgm 1 722, KPa 2.001 4 0.145 fb 0.1988 1 sl 0.0068 689 1 4-10 G@412000/12000E SERVICE MANUAL Millimeter - Inch Conversion Tables 1mm to 99mm ‘TORQUE VALUES AND METRIC CONVERSIONS 25.4 mm=1 in mm o 1 2 a 4 5 é 7 @ (0 | 0.0000 | 0.0304 | o.07e7 | 0.1181 | 0.1875 | o.1969 | 02362 | 0.2756 | 0.3180 | 0.3543 10 | 0.3937 | 0.4331 | 0.4724 | ostie | 0.8512 | 0.6906 | 0.6299 | 0.6693 | 0.7037 | 0.7480 20__| 0.7874 | 0.8268 | oaeat | 0.9055 | 0.9449 | 0.0843 | 1.0286 | 1.0830 | 1.1024 | 1.1417 30 [4.1811 | 1.2205 | 1.2508 | 1.2002 | 1.386 | 1.3780 | 1.4173 | 1.4567 | 1.4961 | 1.5054 40__| 1.5748 | 1.6142 | 1.0555 | 1.6029 | 1.7323 | 1.7717 | 1.8110 | 1.8504 | 1.8808 | 1.9201 ‘50 | 1.9685 | 2.0079 | 2.0472 | 2.0866 | 2.1260 | 2.1654 | 2.2047 | 2.2441 | 2.285 | 2.a208 7o_| 2.7659 | 2.7953 | 2.aa4s | 20740 | 2orce | 2asea | 29021 | 3.0915 | 3.0709 | 3.1102 80 | 3.1496 | 3.1800 | 3.2083 | 3.2677 | 3.3071 | 3.465 | 3.9858 | 3.4252 | 3.646 | 3.5039 30 | 3.5433 | 3.5807 | 3.6220 | 3.6614 | 3.7008 | 3.7402 | 3.795 | 3.8180 | 3.0563 | 3.8076 an‘TORQUE VALUES AND METRIC CONVERSIONS. 12000/12000E SERVICE MANUAL Inch Fraction-tMlimoter eo 2 | es | mt [esr eo [TO 0.000 0 401.600 | 127.000 | 152.400 | 177.800 | 203.200 | 228.600 0.897 101.997 | 107.397 | 150.797 | 178,197 | 208.597 | 228.957 0.708 102.304 | 127.798 | 169.104 | 17@.594 | 200.904 | 979.004 1586 103.188 | 126.56 | 150.909 | 179.968 | 204.788 | 200.108 ‘2a6t 103.981 | 120.261 | 154.781 | 100.181 | 205.501 | 290.081 3175 104.775 | 190.175 | 165.576 | 160.975 | 206.976 | 831.775 3.969 105.569 | 190,960 156.209 | 181.769 | 207.169 | 292.668 4763 106.969 | 191.769 | 167.169 | 182.569 | 207.969 | 299.963, 5.556 107.156 | 192.556 | 167.956 | 169.356 | 208.756 | 204.156 | 8.38 107.950 | 139.350 | 158.750 | 184.150 | 209.550 | 234.950 [7.144 108.744 | 134.144 | 159.544 | 184.944 | 210.344 | 235.744 [7998 109.508 | 194.998 | 160.998 | 165.738 | 211.198 | 296.598, 8731 140.301 [ 19571 | 161.191 | 186.501 | 211.961 | 297-991 9.525 117.125 | 136.525 | 161.925 | 187.428 | 212.726 | 28.125 ise | vo.ai9 Hir.919 | 197.310 | 162.719 | 108.119 | 219.519 | sa8.019 76 [1.013 a7.a19 | 12.719 | 199.119 | 169.510 | 180.919 | 214.910 | 200.710 1sia2 | 11.208 26.106 | 113.506 138.006 | 164.306 | 180.706 | 216.106 | 240.508 ve | 12.700 28-900 | 114.300 199.700-| 165.100] 120.800 | 215.800 | 241-200 172 | ia404 20.604 | 116.008 | 140.408] 165.004] 101.204 | 216.608 | 240.004 one | 14288 20.498 | 115.068 | 141.208" 166.008" 192.088 | 217.408 | 24.088 19732 | 16.081 or2st | 116.861 | 142.081 | 167.481 | 192881 | 216.261 | 243.681 58 | 15.875 212 | 16.669 ae | 17.463 parse | 18.256 a4 | 19.080 25/82 | 19.840 136 | 20.638 27is2_| 21.431 718__| 22.205 2932 | 23.019 15/6 | 23.813 31a2_| 24.606 92.075 | 117.475 | 142.875 | 168.275 | 193.675 | 219.075 | 244.47 192,869 | 118.269 | 149,669 | 169,069 | 194.469 | 219.860 | 245.269, [93.663 | 119.063 | 144.463 | 169.863 | 195.263 | 220.663 | 246.063 94.456 | 119.856 | 148.256 | 170.656 | 196.056 | 221.456 | 246.856 195.250 | 120.650 | 148.050 | 171.450 | 196.850 | 222.250 | 247.650 04a | 121.444 | 146.844 | 172.244 | 197.644 | 223,044 | 248.444 96.838 | 122.238 | 147.638 | 173.038 | 198.438 | 223.838 | 249.298 97.631 | 123.081 | 148.431 | 173.831 | 199.231 | 204.631 | 250.031 98.425 | 123.825 | 148.205 | 174.625 | 200.026 | 225.425 | 250.825 99.219 | 124.619 | 150.019 | 175.419 | 200.819 | 226.219 | 251.619 100.013 | 125.413 | 150.813 | 176.213 | 201.613 | 227.018 | 252.413 +100.806 | 126.206 | 151.606 | 177.006 | 202.406 | 227.806 | 259.208 an Gentoo.412000/12000E SERVICE MANUAL Meter — Foot Conversion Table ‘TORQUE VALUES AND METRIC CONVERSIONS. Foot Meter Foot Meter Foot Meter 5 1.52 185 47.24 355 108.20 10 3.05 160 48.7 360 109.73 16 | _457 165 50.29 365 111.25 20 6.10 170 51.82 370 112.78 25 7.62 175 53.34 375 114.30 30 3.14) 380 115.82 35 10.67 385 117.35 40. 12.19 380 118.87 45, 13.72 395 120.40 85 16.76 405 123.44 60 18.29 410 124.97 65 19.81 a5 126.43) 70 21.94 420 128.02 eee 22.86 25 129.54 80 24.38 230 480 181.06 85 25.91 235 435 192.59) Et 27.43 240 440. 194.41 95 28.96 245 445 138.64 100) 30.48 250 450 137.16 105, 32.00 255 455 198.68 110 93.53 ~ 260 460. 140.21 115 35.05 265 465 141.73 120 36.58 270 82.90 470 143.26 125 38.10) 275 63.82 475 14478 190 39.62 280 85.94 480 195 445, 285 86.87 485 7 140 267 290 28.39) 490 149.35 145, 44.20 295, 89.92 495 150.88 150 45.72 300 91.44 500 152.40 443‘TORQUE VALUES AND METRIC CONVERSIONS 12000/12000E SERVICE MANUAL Gradient Conversion Table Degree Percent Degree Degree Percent 1 18 16 _ a 60.1 2 as 17 625 3 52 18 649 4 70 19 34 675 3 a6. 35 70.0 6 105 36 727 7 12.3 37 | 8a a 1a a) 9 15.8 39 B10 10 176 40 339 1 194 44 869 12 213 #2 90.0 13 21 43 933 14 249 a4 96.6 15 268 46 100.0 Table of Unit Weights Metric Tons/m? none ee qusty") Material alles ead Ta 88) Sand 1908) Copper 8.9 (7.5) Coal cold 0.8 (0.67) Steel 7.8 (66) Goal powder 7.00.84) Castiron 72 (6.1) Coke 0.5 (0.42) ‘Aluminum 2723) ‘Oak (ary) 0.9076) Concrete 2.3 (1.9) Cedar (dry) 0.4 (0.34) Soil | 2.0(1.7) Cypress (dry) 0.4 (0.34) Gravel 1.9 (16) Paulownia (dry) 0.3 (0.25) ana Genrowce{ SECTION 5 POWER TRAIN TABLE OF CONTENTS Location of Components Introduction Engine Engine Removal Engine Repair and Maintenance. Engine Installation. Pump Drive Assembly... Removing Pump Drive . Disassembling Power Divider Inspecting and Repairing Power Divider Assembling Power Divider Instaling Power Divider12000/12000E SERVICE MANUAL SECTION 5 POWER TRAIN 00m ORM Rapiaron FONT ORM veroramc Tame ENGINE soitcooun/ earrery . aoe SEND REDUCTION URE PRORESDENON ohn // FUEL Yani REAR paUM MOTOR, Tuo ORL TuiRD AUN MOTOR (etion| Aub Repueron Unie ND REOUCTON UNIT (opr ‘CONTROL VALVE LOCATION OF COMPONENTS TaansueTER CYUNDER ‘ChaNLER cYUNDER REDUCTION UNIT POWER TRAIN FIGURE 5-1 BtPOWER TRAIN 52 THIS PAGE BLANK 12000/12000E SERVICE MANUAL Gexeeer+12000/12000E SERVICE MANUAL INTRODUCTION ‘The drive train consists of a diesel engine, a flywheel drive ‘coupling, a power divider, and several hydraulic pumps (see Figure 5:1 and Figure 5-3). ENGINE Engine Removal ‘See Figure 5:2 for following procedure. Proceed as follows to remove engine ram machine. NOTE: Flemove the pump dive assembly with engine, 4. Lower boom onto blocking at ground level and pin upper Lower gantry to travel position. Flemove battery grounding cable. Remove mutter Remove air inlet hose from engine and air cleaner. Femove air intercooler hase from engine and irom air Inter-cooler. 7. Remove guard over engine and pump drive. & vancer Hot oll and coolant can burn personnel. Do not drain oll or coolant while itis hot, Wait until they cool before draining, 8. Drain engine oil, hydraulic oll and coolant water. 9. Remove cap screws holding fan guard to radiator and, take off radiator assembly. 10. Label and then remove hydraulic hoses from hydraulic pumps, All ports and hoses should be capped or plugged to prevent dirt and moisture from getting into them, 11, Label and then remove control cable (if equipped), fuel line and electric harness trom engine. Cap all fuel lines to prevent dirt and moisture from getting into them, 42, Recheck to be sure that no electrical lines, mechanical connections, oF uel pipes are remaining to Interfere with removal of engine, 13, Attach a sultabe hiting device to three designated iting Points on engine. Combined weight of engine and power divider is approximately 1 500 kg (3,307 Ib). 14. Remove nuts, washers and bolts from rubber mounts of ‘engine and power divider. a POWER TRAIN 45. Slowly lit engine and pump drive assembly from machine 16. Check rubber mounts and replace them if necessary. Engine Repair and Maintenance Refer to engine manufacturer's manuals for rep. ‘maintenance Instructions, and Engine Installation ‘See Figure 5-2 for following procedure, Proceed as follows to reinstall engine 1. Check to make sure that no cables, fuel lines, coolant water hoses, mechanical connections or other Items will interfere with reinstallation It rubber mounts were removed, replace them. Attach a suitable iting device to three designated iting Points on engine. Combined weight of engine and power divider Is approximately 1 500 kg (3,307 Ib). 4, Use Loctite #271 on rubber mount holding bolts and jorque them to 859 = 59 Nm (412 « 44 feb), 5. Install radiator assembly and fan guard. Space between fan shroud and fan should be even al around. Use Loctite #271 on bolts of radiator assembly and torque them to 314 = 31 Nm (232 + 25 fb). 6. Connect all electric lines that were disconnected when engine was removed. 7. Install all uel ines and control cables (it equipped) that ‘were removed when engine was removed & vancen Avoid battery explosion. Keep open flame and sparks away from batteries, Battery electrolyte is dilute sulturic acid! Avoid battery acid contact with skin, eyes, or clothing. If accidently contacted, immediately flush area with water and consult a doctor. ‘Wear safety glasses to protect eyes when working with olectrotyte. Install guard over engine and pump drive. 9. Connect battery cable. 10, Install ar inlet hose and mutter. 111. Attach hydraulic hoses to hydraulic pumps. 12. Refill engine with coolant water and engine oil 10 required levels 53POWER TRAIN 12000/12000E SERVICE MANUAL 18. Refill hydraulic tank to required level. 15. Start engine and run at low idle. Check for water and fuel, leaks, and any strange noises. 14, Remove alr from fuel lines. & warnne Before stating engine, check all electrical, uel, water, and hydraulle connections as well as mechanical connections. Be prepared to stop engine immediately i needed, a oe i J 8 Sol Ton if LC = - Es of i =n AIR CLEANER HOIST POSITION RUBBER MOUNT ENGINE TURN SENSOR Tightening torque coal eeee te 314331 Nem (232823 bbs-A) INT ENGINE TURN SENSOR (Apply LOCKTITE #271) (FOR ENGINE ECU) FIGURES? ( B Gentowoe1200/1200 SERVICE MANUAL POWER TRAIN Tightening torque : 121312 Nem (8.38.9 ibs-f) Apply LOCKTITE #274 Tightening torque : 121+ 12 Nem (89.336.9 ibe) ‘Apply LOCKTITE #271 Tightening torque : 559:+59 N-m (412.3 243.5 lbs-t) Apply LOCKTITE #271 Tightening torque : 669: 50 N-m (412.3 243.5 lbs) Apply LOCKTITE #271 ewe ‘Tightening torque : 284: 29 N-m (209.5 21-4 bs-t) Tightening torque : 28429 Nem ‘Apply LOCKTITE #271 (209.5 21.4 Ibs-f) Apply LOCKTITE #271 Tightening torque : 559-459 Nm (212.3 43.5 ibs-) Apply LOGKTITE #271 (412.5 243.5 bse) Apply LOCKTITE #271, VIEWS FIGURE 5-2 continued af? 5s ] Tightening torque : 559-469 NemPOWER TRAIN PUMP DRIVE ASSEMBLY Removing Pump Drive See Figure 5-3 for following procedure. Proceed as follows to remove pump drive assembly. & woanne Remove pump drive assembly from engine only after ‘engine has been removed from machine as described in this section, 4. Drain oil from power divider through drain cock in bottor 2. Remove each pump, 56 12000/12000E SERVICE MANUAL Main pump 124 kg (273 Ibs) ‘Swing/Boom pump [124k9 (2731s) Gear pump (Control) 7.4 kg (16.3 Ibs) "| 8.4kg (18.5 Ibs) Gear pump (Cooling) (OPTION) ‘Attach a suitable iting device to suspension screws, provided on power divider (size M16). Approximate ‘weight of power divider is 130 kg (287 Ibs). Remove cap screws attaching power divider to tlywheet housing and move power divider slowly away from engine. divider (connected to power divider sha), Gentenee1200/1200 SERVICE MANUAL, POWER TRAIN POWER DIV a / PUMP: GR. oruM HoisT, PROPEL) SEAR PUMP, a (CONTROL, AUXILIARY, ACTUATOR) eH O ane GEAR PuMe (OPTION) fORUMERAKE COL) ESiic coon ee isthe om TRAN ET soto thoow tO ITE #242) nseRr a e.evenr -feourtne sega EE acme) ponerse ‘poly LOCKE #242) ofa? 87POWER TRAIN Disassembling Power Divider ‘See Figure 5-4 (on four pages) for following procedure. Proceed as follows to disassemble poner divider. 41. Set power divider on a block with pump side facing up. 2. Use screw holes provided (size M8) when removing support (8) witha puller. Remove O-ring (15) 3. Remove gear (6) and remove bearings (11 and 18) on both sides, i necessary. 4. Use scrow holes provided (size M8) when removing support (20) with a puller. Remove O-ting (18). 5. Remove gear (33) and remove bearings (31 and 32) on both sides, it necessary. 6. Now, tun assembly over and sat power divider on a block with flywheel side facing up. 7. Remove cap scrow (23), insert cap screw (size M10) into screw hole for removing support (2}, and remove ‘suppor (2) Remove shalt (8) and gear (5) Remove ail seal (17), O-ring (15) and outer race of bearing (10) from suppor (2). Retain and keep all shims (27, 28, and 29) together. 410. If necessary, remove inner race of tapered roller bearing (10) from shatt (8). Inspecting and Repairing Power Divider Inspect all parts prior to reassembling power divider. All questionable parts should be replaced to maximize reassembled power divider's service life and to avoid further break downs. 1. Clean all parts with fresh cleaning oll and blow them dry. 2. Check bearing balls, rollers, inner and outer races to so if there is piting, scratches, or other damage. Replace detective bearings, Replace any bearings that develop rattles due to excessive clearances toward shaft or toward external side. 4. Check teeth of all gears and replace any that show signs. of pitting, scratches, excessive friction wear, peeting, or cracking, 5. Check shatts and replace any that show signs of cracking, deformation, excessive wear at contact surfaces, or bearing slippage. 6. Check splines of shafts and gears. Replace or fic any that show signs of cracking, excessive wear, or impact damage. 112000/12000E SERVICE MANUAL 7. Check bearing casings and replace any that show slip, wear or other deformations. B. Check gear casings and replace or fix any that show cracks, deformation, or scratches. 9. Replace all O-rings and oil seals with new ones. 10, Check screw throads and screw hole threads. Replace or repair any that show signs of cross-threading or strippage. Assembling Power Divider See Figure 5-4 (on four pages) for following procedure. Reverse disassembly steps to assemble power divider. Be sure to perform following steps, 1. Apply cloan ollto each part before assembling, 2. When assembling shaft (8), drive gear (6), tapered roller bearing (10) and support (2), adjust with shims (27, 28, 28) to 0 mm to 0.15 mm (0 in to 0.006 in) clearance at point S 3. Install support (2) in housing (36) so that oll hole is at lowest point Apply Loctite #242 to bolts (23) for support (2) and torque them to 70 =7 Nm (52 2 5 ft). '5. Install bearing (11), insert gear (6) and install support (3) In which bearing (13) is inserted, 6. Install bearing (31), insert gear (83) and install support (80) in which the bearing (82) is inserted, 7. After assembly is complete, make sure input shalt tuins, easily by hand and no noise is emitted, Installing Power Di ‘See Figure 5-5 for following procedure. Assemble coupling to pump dive as follows: 1. Grease spline of input shat (8) and insert coupling hub (2) until it contacts shoulder on shat Install and torque set screws to 206 # 9.8 Nm (18227 f- Ibs), 3. Assemble coupling n following order: ‘a. Put spring pins (8) into coupling hub (2), b. Then install inserts (R)(4). ‘Torque cap screws (6) to 451 = 29 Nm (332 «21 fb) (On ftywheo! side, install insert (A)(9). Use spring pins (12) 0 align. Torque cap scrows (5) 10 451 29 Nm (332 221 fb), ier 6. Attach pump drive to engine as follows: Geneage12000/12000E SERVICE MANUAL 7. Attach a suitable Iiting device to suspension screws Provided on power divider (size M16). Approximate ‘weight of power divider is 120 kg (287 1b). Litt power divider into position at rear of engine. Align inserts (F4) with insert (A3) and slide power divider Into position against engine. 10. Align screw holes in power divider and engine. POWER TRAIN 11. Apply Loctite #242 to capscrews (10) and torque to 66.7 6.9m (69 = 5.1 ft 412. install pumps in proper positions on power divider. Apply Locite #242 to the respective cap screws and torque them to values given in Figure 5-3 13, Fill power divider to specified level with gear oil (see Operator's Manual). 14, Install engine assembly. See procedure in this section,POWER TRAIN 12000/12000E SERVICE MANUAL Tight 98109.8 (66.4 to 7.2 Ibs (Apply Lee #877) oa i a torque ‘SWING /BOOM PUMP Tightening torque 18. 4.910 48 Nem Ni (381072 ben) (apply LOCKTITE #516) 24 te Tightening torque Tightening torque 88.210 107-8 Nom (65.0 10 79.5 bse 285 19323 Nem (210 to 252 s-8) VLOCRTTE ae 28510 38 Nm 210102 (Goply LOcKTITE S871) 16 FIGURE S4 510 Geneve412000/12000E SERVICE MANUAL |. Housing ‘Support ‘Support Goar Gear Shaft 10. nh 13. 15, 16. 17. Bearing Bearing Bearing ‘o-ring O-ring Oil seal Cil level gauge Plug Capscrew Capscrew Plate Rivet DIRECTION OF OIL GROOVE Shim Shim Shim ‘Support Ball bearing Ball bearing 23 al 36. teri POWER TRAIN TP sn (47 to 57 bs) (Apply LOCKTITE #242) Gear Cover Cover Breather "B* Tube Elbow 40. Cap 41. Tube 42. Drain cock 43. Connector FIGURE 5-4 continued aPOWER TRAIN 18, 29, 28,27, "3! shim adjust 0 (0 0°48 nm (0 100.008 inch) 542 at 12000/12000E SERVICE MANUAL, " 6 SECTION D-D a8 — 30 FIGURE 5-4 continued (12000/12000E SERVICE MANUAL, POWER TRAIN 16, « SECTION EE 1. Housing 10. Bearing 18, Cillevelgauge 27. Shim 93, Gear 40. Cap 2. Support 11. Bearing 19, Plug 28. Shim 34. Cover 41. Tube 8. Support 19. Bearing 23. Capscrew 29. Shim 85. Cover 42. Drain cock 8. Gear 15. Oring 24. Capscrew 30. Support 37. Breather"B* 43. Connector 6. Gear 16, Oxring 25. Plate 31, Ballbearing 98, Tube 8. Shaft 17. Ollseal 28. Rivet 32, Ballbearing 39, Elbow FIGURE 5-4 continued ofa? 513POWER TRAIN, 12000/12000E SERVICE MANUAL Tghtening toraue 6 451229 Nm (332.6221.4 best) a 2 , 2 Tightening torque 2062 8.8 Nem (1519472 bs-f) 5 Tahening erque ye 294 Nm (392.6: 21.68 lbs-t) 3 to Tightening torque 66.769 Nm (49.245.1 bat) 1. Element 7. Glamping screw (M20 x 25 mm) 2. Hub 8 Spring Pin 3. Insort (A) 9% Shaft 4. Insert (A) 10. Cap Screw 8. Cap Screw (M20X 65mm) 11. Flywheel 6. Cap Screw (M20X 65mm) 12._—_-Spring Pin FIGURE 5-5 on GenieSECTION 6 HYDRAULIC SYSTEM TABLE OF CONTENTS Location of Main Hydraulic Components: Hydraulic Circuits and Components Component Spectications Location of Hydraulic Components. Hydraulic System Operation Hydraulic Pumps. Oil Flow From No.1 and No.2 Pumps. ll Flow From No.3 and No.4 Pumps il Flow From No.5 Pump (Control Pump) ll Flow From No.6 Pump (Secondary Pumo) Hydraulic Valves... . eee A Front, Rear, Boom Drum, and Optional Third Drum 4-Section Valve. Third, Front, Rear, and Boom Drum 8-Section Valve (With Shuttle Valve) Front and Rear Drum Glutch 4-Section Valve. Front and Rear Drum Free Fall 3-Section Valve. Front, Rear, and Boom Drum §-Section Valve ‘Swing and Propel 2-Section Valve ‘Swing Remote 1-Section Valve Hydraulic Acronym Table. 64 62 64 167 616 616 617 618 6-49) et end 2.624 625 626 627 628 629 6-30 6-31412000/12000E SERVICE MANUAL HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM LOCATION OF MAIN HYDRAULIC COMPONENTS ‘See table of hydraulic acronyms at end of this section. ent PoweR oWigeR REAORUM FRONT RUM. wormuerane eee ORG} 4c NOTOR RESucnon ur ‘00m oR HoTOR ND REDUCTION UN rue ra ‘eaont own soroR SiS MeO ERE nano onus’ JegO DRUM WoTER prom NO REDUCTION LT (OPTION) commencrinote eoueHON UT FIGURE 6-1 fap «1HYDRAULIC SYSTEM 1200/1200 SERVICE MANUAL Hydraulic Circuits and Components See Figure 6-2, Figure 6-3, below and Figure 6-27, Figure 6-28 at end ofthis section. EAE Bi ere soi FRONT uno ||| | fet] Be) soi Teen | 1 | @ yoo i 2A CRAWLER EXTIRET. | i vera FIGURE 6-2 ” Genius (12000/12000E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 6-3HYDRAULIC SYSTEM 112000/12000E SERVICE MANUAL tem numbers in table correspond to circled numbers in figures above and at end of section. ‘Name of Component ‘Specification 1 |Pump (Front & Rear Drum, Propel) ‘Swash Plate Type, Variable Capacity Maximum Delivery: 67 gal/min X 2 (252 It/min X 2) Maximum Working Pressure: 4627 psi (31.9 MPa) 3 |Pump (Swing / Boom) [Swash Plate Type, Variable Capacity ‘Swing: Born: [Maximum Delivery | 46 gavimin (176 it/min)- 67 gavin (252 he. /min IMaximum Working Pressure |9989 psi (27.5 MPa) - 4641 psi (32.0 MPa) 4. |Gear Pump (Control / Auxiliary Actuator) Contra: ‘Auxiliary Actuator ‘Maximum Delivery [16 gatimin (64 lt-min) - 14 gal/min (40 it/min) ‘Maxinnurn Working | pea 1015 psi (7.0MPa) = 9046 psi (21.0 MPa) 5 _|Gear Pump (Drum Brake Cooling) (OPTION) s Maximum Delivery: 19 gal/min X 2 (73 Nr/min X 2) 8 [Motor (Front & Rear Drum & Third or Jib) [Swash Plate Type, Variable Capacity Maximum Oil Flow: 67 gal/min (252 ltr/min) Maximum Working Pressure: 4627 psi (31.9 MPa) 40 | Motor (Boor) Bent Axis Type, Fixed Capacity Maximum Oil Flow: 67 gal/min (252 ltr /min) Maximum Working Pressure: 4641 psi (32.0 MPa) 12 |Motor (Swing) [Swash Plate Type, Fixed Capacity (Maximum Oil Flow: 48 gal/min (175 kr./min) Maximum Working Pressure: 3989 psi (27.5 MPa) 13. |Motor (Propel) ‘Swash Plate Type, Variable Capacity (2-Speed Type) Maximum Oil Flow: 67 gal/min (252 It./min) Maximum Working Pressure: 4627 psi (31.9 MPa) 14 | Motor (Tagtine) (OPTION) Internal Gear Type, Fixed Capacity Maximum Oil Flow: 14 gal/min (40 IteJmin) Maximum Working Pressure: 1987 psi (13.7 MPa) 15. [Motor (Reeving) (OPTION) Radial Plunger Type, Fixed Capacity Maximum Oil Flow: 11 galimin (40 It. /min) Maximum Working pressure: 1841 psl (12.7 MPa) 16. [Flow Control Vaive (Tagine) (OPTION) (Maximum Oil Flow: 11 galfmin (40 l/min) 17 | Contro! Valve (Front & Rear Drum, Propel) [Maximum Oit Flow: 67 gal/min (252 itr/min) ‘Set Pressure: 4627 psi (31.9 MPa) 18 |Conirot Valve (Boom) ‘Maximum Oil Flow: 67 gal/min (252 Itr/min) Set Pressure: 4641 psi (32.0 MPa) 49 |Control Valve (Third Drum or Jib) (OPTION) Maximum Oil Flow: 67 gal/min (252 i./min) Set Pressure: 4641 psi (92.0 MPa) 20 |Control Valve (Swing) Maximum Oil Flow: 45 gal/min (175 le/min) |Set Pressure: 3916 psi (27.5 MPa) 22 |Controt Valve (Gantry & Circuit-change) [Maximum Oil Flow: 11 gain (40 Renin) [Set Pressure:2988 psi (20.6 MPa) 23 |Control Valve (Transiter) [Maximum Oi Flow 14 gavimin 40 Wri) [Set Pressure: 2988 psi (20.6 MPa) 24 |Control Valve (Counter-Weight Removal) [Maximum Oil Flow: 14 gal/min (40 trJmin) [Set Pressure: 3046 psi (21.0 MPa) Gentenge+12000/12000E SERVICE MANUAL HYDRAULIC SYSTEM 25 [Control Valve (Boom Foot Pin & Reeving) |(OFTION) ‘Maximum Ol Flow: 17 galimin (40 itrJmin) Sot Pressure: 1841 psi (12.7 MPa) ‘8-Section Valve (Automatic Stop & Speed [ard Drum (ib) Drum Lower Gontrol Pressure Reduce (OPTION) {ard Drum (ib) Drum Hoist Control Pressure Reduce (OPTION) Front Drum Lower Control Pressure Reduce Front Drum Hoist Control Pressure Reduce 27 | adjusting) Rear Drum Lower Control Pressure Reduce Rear Drum Hoist Control Pressure Reduce [Boom Lower Control Pressure Reduce [Boom Raise Control Pressure Reduce [Boom Raise Stop (No.2) [Boom Lower Stop (No.2) 28 |5- Section Vahe Rear Drum Hoist Siop (No.2) Front Drum Hoist Stop (No.2) re Dy () Drum Hist Sop (No.2) (OPTION) Front Drum Motor Parking Brake 1 Negative Brake) Rear Drum Motor Parking Brake 29 |4-Section Valve (Motor Negative Brake) Bees a ea aaa ee 31d Drum (ib) Brum Motor Parking Brake (OPTION) Funetion Lock / Swing Parking Brake 30 2 Section Valve Suing Pressure Changeover / Propel Speed Changsover, 3i_|-Seetion Vawve Swing Reaction Rear Drum Clutch On/Ott | 4ag_|4-Section Valve (Free Fall Changeover) Roar Drum Emergency Siop | (OPTION) Front Drum Emergency Stop ____|Rear Drum Clutch Ono i Front Drum Free Fall Acceleration 34 [2 Sectln Va (Fre Fal Accelerator) sar Drum Fee Fall Acceleration {rd Drum Free Fall Acceleration = 37_|Pon Rete valve E 38_|Slow Retum Check Valve FE 9 |2-Section Valve (Free Fall Changeover) ‘ra Drum Ciutch On/OH OPTION) {rd Drum Emergency Stop Pilot Valve (3rd Drum Motor Negative Brake) 40 | option, ee rd Drum (Jip) Drum Motor Parking Brake “ay [Solenoid Valve (8rd Drum Automatic Stop & [31d Drom (sib) Brum Lower Gonivol Pressure Reduce Speed Adjusting) (OPTION) 8rd Drum (Jib) Drum Hoist Control Pressure Reduce: 42 _| Solenoid Valve (3rd Drum Limit Stop) (OPTION) [3rd Drum (sib) Drum Hoist Stop (No.2) Front Drum 45. |Remote Control Valve Rear Drum Boom [swing ioe | ere cate 3rd Drum (ib) (OPTION) 47_[ Remote Control Valve Propet 48_|[ Brake Master Valve (OPTION) Foot Brake 49_| emote Contol Vale (OPTION) [Boom Control Pedal 140 dlameter/ 110 diameter X 700 length 51. | Cylinder (Transitter) Prasgunat 2068 pel 20 MPa) Ses 160 diameter 75 diameter X 1246 length Pressure: 2466 to 2988 psi (17 MPa to 20.6 MPa) ie 65