SM CC423 2018

542E-SM1812-00
SERVICE MANUAL
CRAWLER CRANE
CC423S-1
Serial No. 21001 and up
The parts numbers and lists written in this service manual are the
references for the services such as disassembling and assembling.
Be sure to ALWAYS refer to the latest parts catalog (the latest
information) before ordering any part, since the parts and the model
numbers are subject to change during the endless improvements and
changes of our Machine.
CONTENTS
Item Page
OVERVIEW 1-1
1. EXTERNAL VIEW 1-2
2. PRINCIPAL SPECIFICATIONS LIST 1-3
3. COMPONENT MASS LIST 1-5
4. LIST OF OIL QUANTITY 1-6
5. WORKING RANGE DIAGRAM 1-7
6. RATED TOTAL LOAD CHART 1-8
STRUCTURE AND MAINTENANCE PROCEDURE 2-1
1. ENGINE AND COOLING-RELATED COMPONENTS 2-2
1. 1 ENGINE 2-2
1. 2 ENGINE SPECIFICATIONS 2-2
1. 3 ENGINE MOUNT 2-3
1. 4 PTO (POWER TAKE-OFF) AND PUMP 2-4
1. 5 COOLING ASSEMBLY 2-5
1. 6 FUEL LINE 2-6
1. 7 FUEL TANK 2-7
2. POWER TRANSMISSION SCHEMATIC DIAGRAM 2-8
2. 1 HYDRAULIC SYSTEM DIAGRAM 2-8
2. 2 SWING CIRCLE 2-9
2. 3 SWING MACHINERY 2-10
3. UNDERCARRIAGE AND FRAME 2-12
3. 1 TRACK FRAME 2-12
3. 2 IDLER CUSHION 2-13
3. 3 IDLER 2-14
3. 4 TRACK ROLLER 2-16
3. 5 CARRIER ROLLER 2-17
3. 6 SPROCKET 2-18
3. 7 TRACK SHOE 2-19
4. HYDRAULIC SYSTEM 2-21
4. 1 HYDRAULIC UNITS LAYOUT DIAGRAM 2-21
4. 2 HYDRAULIC OIL TANK AND FILTER 2-23
4. 3 SWIVEL JOINT 2-24
4. 4 TRAVEL MOTOR 2-25
4. 5 3-FOLD SOLENOID VALVE (TRAVEL PPC, TRAVELLING 2-SPEED, CRANE PPC) 2-26
4. 6 2-FOLD SOLENOID VALVE (FOR WINCH) 2-27
4. 7 3-FOLD EPC VALVE (FOR DERRICKING, TELESCOPING) 2-28
4. 8 HYDRAULIC PUMP (MAIN PUMP) 2-29
4. 9 OPERATION VALVE (WITH BLADE) 2-30
4. 10 SLEWING MOTOR 2-32
4. 11 PPC VALVE 2-34
4. 12 SLEWING BRAKE RELEASE SHUTTLE VALVE 2-35
4. 13 WINCH MERGE LOW PRESSURE VALVE 2-36
4. 14 BYPASS CHECK VALVE 2-37
4. 15 WINCH MOTOR 2-38
4. 16 DERRICKING CYLINDER 2-39
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Item Page
4. 17 TELESCOPING CYLINDER 2-40
4. 17. 1 TELESCOPING CYLINDER HYDRAULIC SYSTEM DIAGRAM 2-41
4. 17. 2 COUNTERBALANCE VALVE 2-42
4. 17. 3 SEQUENCE VALVE 2-43
4. 17. 4 MECHANICAL CHECK VALVE 2-44
4. 18 BLADE CYLINDER 2-45
4. 19 TRAVELLING REMOTE CONTROL VALVE (TRAVEL PPC VALVE) 2-46
4. 20 HYDRAULIC PIPING DIAGRAM 2-47
4. 20. 1 SUCTION LINE (HYDRAULIC TANK TO PUMP) 2-47
4. 20. 2 PUMP LINE (PUMP TO OPERATION VALVE AND 3-FOLD SOLENOID VALVE) 2-48
4. 20. 3 RETURN LINE 01 (BYPASS CHECK VALVE TO HYDRAULIC TANK) 2-49
4. 20. 4 RETURN LINE 02 (CONTROL VALVE TO BYPASS CHECK VALVE, ETC.) 2-50
4. 20. 5 TRAVEL LINE (CONTROL VALVE TO SWIVEL JOINT) 2-51
4. 20. 6 TRAVEL PIPING (SWIVEL JOINT TO TRAVEL MOTOR) 2-52
4. 20. 7 SWING LINE (CONTROL VALVE TO SWING MACHINERY) 2-53
4. 20. 8 DERRICKING LINE (CONTROL VALVE TO DERRICKING CYLINDER) 2-54
4. 20. 9 TELESCOPING LINE (CONTROL VALVE TO TELESCOPIC CYLINDER) 2-55
4. 20. 10 WINCH LINE (WINCH MERGE VALVE TO BOOM LINE) 2-56
4. 20. 11 BOOM LINE (TELESCOPING LINE TO TELESCOPING CYLINDER AND WINCH LINE TO
2-57
WINCH MOTOR)
4. 20. 12 SUB LINE 01 (PPC BRACKET TO SLEWING BRAKE RELEASE SHUTTLE VALVE TO
2-58
SWING MACHINERY)
4. 20. 13 SUB LINE 02 (CONTROL VALVE TO WINCH MERGE VALVE) 2-59
4. 20. 14 SUB LINE 03 (2-FOLD SOLENOID VALVE AND 3-FOLD EPC VALVE TO CONTROL VALVE
2-60
AND T GROUPING BLOCK)
4. 20. 15 SUB LINE 04 (PPC BRACKET TO 2-FOLD SOLENOID VALVE AND 3-FOLD EPC VALVE) 2-61
4. 20. 16 SUB LINE 05 (LEFT PPC VALVE TO PPC BRACKET) 2-62
4. 20. 17 SUB LINE 06 (RIGHT PPC VALVE TO PPC BRACKET) 2-63
4. 20. 18 SUB LINE 07 (2-FOLD SOLENOID VALVE, 3-FOLD EPC VALVE AND 3-FOLD SOLENOID
2-64
VALVE TO CONTROL VALVE, ETC.)
4. 20. 19 SUB LINE 08 (TRAVELLING REMOTE CONTROL VALVE TO CONTROL VALVE AND
2-66
3-FOLD SOLENOID VALVE)
4. 20. 20 BLADE LINE 01 (CONTROL VALVE TO SWIVEL JOINT) 2-68
4. 20. 21 BLADE LINE 02 (SWIVEL JOINT TO BLADE CYLINDER) 2-69
5. WORK EQUIPMENT 2-70
5. 1 BOOM ASSEMBLY DIAGRAM 2-70
5. 1. 1 BOOM TELESCOPING MECHANISM 2-72
5. 2 HOOK ASSEMBLY DIAGRAM 2-73
5. 2. 1 4-FALL AND 2-FALL HOOK BLOCK ASSEMBLY 2-73
5. 3 INSPECTION OF HOOK BLOCK 2-74
6. ELECTRICAL UNITS 2-75
6. 1 TRAVEL CONTROL FUNCTION 2-75
6. 2 PPC LOCK FUNCTION 2-76
6. 3 CRANE OPERATION UNITS 2-77
6. 3. 1 MACHINE MONITOR 2-78
[1] STARTING SCREEN 2-78
[2] HOME SCREEN 2-79
[3] WARNING DISPLAY AND ERROR CODE DISPLAY 2-80
[4] USER MODE SWITCH 2-81
[5] LIST OF ERROR CODES 2-83
[6] I/O LIST 2-85
6. 4 FUSE 2-87
0-2
Item Page
6. 5 CONTROLLER 2-88
6. 5. 1 I/O LIST 2-88
6. 5. 2 MAIN HARNESS 2-92
6. 5. 3 FLOOR HARNESS 2-95
6. 6 SENSORS 2-96
6. 6. 1 ENGINE OIL PRESSURE SENSOR 2-96
6. 6. 2 COOLANT TEMPERATURE SENSOR 2-96
6. 6. 3 INCLINATION SENSOR 2-97
6. 6. 4 PRESSURE AND OIL TEMPERATURE SENSOR 2-98
6. 6. 5 PRESSURE SWITCH 2-99
6. 6. 6 FUEL LEVEL SENSOR 2-100
7. MOMENT LIMITER 2-101
7. 1 CONFIGURATION OF MOMENT LIMITER 2-101
7. 2 MONITOR DISPLAY OF MOMENT LIMITER 2-102
7. 3 SENSOR ASSEMBLY 2-103
7. 3. 1 LENGTH METER REEL 2-104
7. 3. 2 ANGLE DETECTOR 2-106
7. 3. 3 PRESSURE AND OIL TEMPERATURE SENSOR 2-108
7. 4 BOOM DERRICKING LIMIT SWITCH 2-110
7. 5 OVERWINDING PREVENTION DEVICE 2-111
7. 5. 1 OPERATING PRINCIPLES 2-111
7. 6 OVER UN-WINDING DETECTION DEVICE 2-112
7. 7 MOMENT LIMITER OVERVIEW AND SPECIFICATIONS 2-113
7. 7. 1 OVERVIEW 2-113
7. 7. 2 SPECIFICATIONS 2-113
7. 8 CALIBRATION OF MOMENT LIMITER 2-113
REFERENCE VALUES 3-1
1. TABLE OF ENGINE RELATED REFERENCE VALUES 3-2
2. CRANE OPERATING PRESSURE 3-3
3. TABLE OF MACHINE RELATED REFERENCE VALUES 3-4
4. TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES 3-7
INSPECTION AND ADJUSTMENT 4-1
1. MEASURING THE ENGINE REVOLUTION SPEED 4-2
2. INSPECTING AND ADJUSTING THE ENGINE 4-2
3. INSPECTING AND ADJUSTING THE FAN BELT TENSION 4-3
4. ADJUSTING THE ACCELERATOR PEDAL 4-4
5. INSPECTING AND ADJUSTING THE TRACK SHOE TENSION 4-5
6. INSPECTING AND ADJUSTING THE WORK EQUIPMENT AND TRAVEL CIRCUIT 4-7
7. MEASURING THE PPC VALVE OUTLET PRESSURE 4-8
8. ADJUSTING THE PPC VALVE 4-9
9. INSPECTING THE SLEWING PARKING BRAKE INLET PRESSURE 4-10
10. MEASURING THE CONTROL CIRCUIT PRESSURE (PPC A4 PORT PUMP OUTLET PRESSURE) 4-11
11. INSPECTING THE OIL LEAKAGE RATE 4-12
12. VENTING AIR FROM PARTS 4-13
13. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC CIRCUIT 4-15
14. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC OIL TANK 4-15
15. PRESSURISING THE HYDRAULIC OIL TANK 4-15
16. METHOD FOR RAISING THE UNDERCARRIAGE BY USING THE CRANE 4-16
17. REPLACING WIRE ROPE 4-17
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Item Page
DISASSEMBLING AND ASSEMBLING 5-1
1. DISMOUNTING AND MOUNTING THE RADIATOR AND OIL COOLER ASSEMBLY 5-2
2. DISMOUNTING AND MOUNTING THE ENGINE AND HYDRAULIC PUMP ASSEMBLY 5-3
3. DISMOUNTING AND MOUNTING THE SLEWING MOTOR AND SWING MACHINERY ASSEMBLY 5-6
4. DISMOUNTING AND MOUNTING THE SWING CIRCLE ASSEMBLY 5-7
5. OPENING AND MOUNTING THE TRACK SHOE ASSEMBLY 5-8
6. DISMOUNTING AND MOUNTING THE SPROCKET 5-9
7. DISMOUNTING AND MOUNTING THE TRAVEL MOTOR ASSEMBLY 5-10
8. DISMOUNTING AND MOUNTING THE COUNTERWEIGHT 5-11
9. DISMOUNTING AND MOUNTING THE REVOLVING FRAME ASSEMBLY 5-12
10. DISMOUNTING AND MOUNTING THE CENTRE SWIVEL JOINT ASSEMBLY 5-14
11. DISMOUNTING AND MOUNTING THE WORK EQUIPMENT ASSEMBLY 5-15
12. DISMOUNTING AND MOUNTING THE OPERATOR'S CANOPY ASSEMBLY 5-17
13. DISMOUNTING AND MOUNTING THE SEAT BRACKET ASSEMBLY 5-18
HYDRAULIC AND ELECTRIC CIRCUIT DIAGRAMS 6-1
HYDRAULIC CIRCUIT DIAGRAM 6-1
ELECTRIC CIRCUIT DIAGRAM (1/5) 6-2
SERVICE MODE S-1
(1) MONITORING S-3
(2) FUNCTIONS S-4
[1] CONTROL OUTPUT CHECK S-4
[2] CHECK CALIBRATION VALUE S-6
[3] INITIALIZE CALIBRATION S-6
(3) WORK HISTORY S-7
(4) ERROR HISTORY S-9
(5) INITIAL SETTING S-10
[1] PASSWORD ON/OFF AT START S-10
[2] PASSWORD CHANGE AT START S-10
[3] PASSWORD INITIALIZE AT START S-10
(6) CRANE CALIBRATION S-11
[1] LEVEL CALIBRATION S-11
[2] BOOM LENGTH CALIBRATION S-11
[3] BOOM ANGLE CALIBRATION S-12
[4] LOAD CALIBRATION S-12
(7) ML SETTING S-14
[1] SETTING OF FIXED NUMBER OF FALLS S-14
[2] SEARCHER HOOK PRESENT/ABSENT SETTING S-14
[3] SEARCHER HOOK SWITCHING SETTING S-14
0-4
Item Page
TROUBLESHOOTING T-301
1.TROUBLESHOOTING (ERROR CODES) T-302
EO02L 3-FOLD SOLENOID VALVE BOOM LOWER SOL OPEN (3-FOLD EPC VALVE) T-304
EO02H 3-FOLD SOLENOID VALVE BOOM LOWER SOL SHORT (3-FOLD EPC VALVE) T-304
EO03L 3-FOLD SOLENOID VALVE BOOM RAISE SOL OPEN (3-FOLD EPC VALVE) T-304
EO03H 3-FOLD SOLENOID VALVE BOOM RAISE SOL SHORT (3-FOLD EPC VALVE) T-304
EO04L 3-FOLD SOLENOID VALVE BOOM EXTEND SOL OPEN (3-FOLD EPC VALVE) T-305
EO04H 3-FOLD SOLENOID VALVE BOOM EXTEND SOL SHORT (3-FOLD EPC VALVE) T-305
EO05L PPC SOLENOID VALVE TRAVEL HI SOL OPEN (3-FOLD SOL VALVE) T-309
EO05H PPC SOLENOID VALVE TRAVEL HI SOL SHORT (3-FOLD SOL VALVE) T-309
EO06L WINCH LOW PRESSURE SHIFT SOL OPEN T-309
EO06H WINCH LOW PRESSURE SHIFT SOL SHORT T-309
EO09L 2-FOLD SOLENOID VALVE HOIST UP STOP SOL OPEN (2-FOLD SOL VALVE) T-310
EO09H 2-FOLD SOLENOID VALVE HOIST UP STOP SOL SHORT (2-FOLD SOL VALVE) T-310
EO10L 2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL OPEN (2-FOLD SOL VALVE) T-310
EO10H 2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL SHORT (2-FOLD SOL VALVE) T-310
EO12L PPC SOLENOID VALVE TRAVEL PPC SOL OPEN (3-FOLD SOL VALVE) T-311
EO12H PPC SOLENOID VALVE TRAVEL PPC SOL SHORT (3-FOLD SOL VALVE) T-311
EO15L SENSOR 12V POWER OPEN T-315
EO15H SENSOR 12V POWER SHORT T-315
ES02L DERRICK PRESSURE SENSOR 1 (LOW VOLTAGE) T-319
ES02H DERRICK PRESSURE SENSOR 1 (HIGH VOLTAGE) T-319
ES04L LENGTH SENSOR (LOW VOLTAGE) T-320
ES04H LENGTH SENSOR (HIGH VOLTAGE) T-320
ES05L ANGLE SENSOR (LOW VOLTAGE) T-320
ES05H ANGLE SENSOR (HIGH VOLTAGE) T-320
ES06L PUMP PRESSURE SENSOR 1 (LOW VOLTAGE) T-323
ES06H PUMP PRESSURE SENSOR 1 (HIGH VOLTAGE) T-323
ES09L PPC PRESSURE SENSOR (LOW VOLTAGE) T-324
ES09H PPC PRESSURE SENSOR (HIGH VOLTAGE) T-324
ES10L HYD. OIL TEMP SENSOR P1 (LOW VOLTAGE) T-325
ES10H HYD. OIL TEMP SENSOR P1 (HIGH VOLTAGE) T-325
ES11L INCLINATION SENSOR (LOW VOLTAGE) T-328
ES11H INCLINATION SENSOR (HIGH VOLTAGE) T-328
ES12L ACCELERATOR PEDAL (LOW VOLTAGE) T-328
ES12H ACCELERATOR PEDAL (HIGH VOLTAGE) T-328
ES13H FUEL SENSOR RESISTANCE (HIGH RESISTANCE) T-329
TTC36 CONTROLLER ABNORMALITY T-332
ECU ECU COMMUNICATION ABNORMALITY T-332
EV001 BATTERY VOLTAGE ABNORMALITY T-335
EV007 CHARGE ABNORMALITY T-335
EV008 TTC60 SENSOR POWER 5V0 ABNORMALITY T-337
EV009 TTC36X SENSOR POWER 5V0 ABNORMALITY T-337
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Item Page
EH01 HYDRAULIC OIL TEMPERATURE ABNORMALITY T-338
2.TROUBLESHOOTING (MATTERS OTHER THAN ERROR CODE DISPLAY)
2.1. TROUBLESHOOTING OF THE ENGINE BODY T-403
S-1 ENGINE START FAULT T-403
S-2 ENGINE STALL T-404
S-3 ENGINE HUNTING T-405
S-4 ENGINE OUTPUT SHORTAGE T-406
S-5 MUCH WHITE SMOKE IN EXHAUST GAS T-407
S-6 MUCH BLACK SMOKE IN EXHAUST GAS T-407
S-7 ABNORMAL NOISE FROM ENGINE T-408
S-8 SIGNIFICANT FUEL CONSUMPTION T-408
S-9 SIGNIFICANT OIL CONSUMPTION T-408
2.2. TROUBLESHOOTING OF THE ELECTRICAL SYSTEMS T-409
E-1 MONITOR DISPLAYS NOTHING T-409
E-2 MONITOR IS FROZEN AND INOPERABLE T-410
E-3 MONITOR SWITCHES INOPERABLE (EXCEPT FOR BEING FROZEN) T-410
E-4 MOMENT LIMITER INDICATION VALUES ON MONITOR ARE QUESTIONABLE T-410
E-5 FUEL GAUGE FAILS TO INDICATE NORMALLY T-411
E-6 MONITOR DOES NOT DISPLAY PARTIALLY T-411
E-7 SCREEN DOES NOT SWITCH TO SERVICE MODE T-412
E-8 ENGINE DOES NOT START (NO ENGINE-RELATED ERROR CODE DISPLAYED) T-412
E-9 GLOW LAMP DOES NOT FUNCTION T-413
E-10 HEAD LAMP DOES NOT TURN ON NORMALLY T-413
E-11 TRI-COLOUR ROTARY LAMP DOES NOT COME ON T-413
E-12 NONE OF THE WORK EQUIPMENT OR SLEWING/TRAVELLING WORKS T-414
E-13 TRAVEL SPEED CANNOT BE CHANGED T-414
E-14 HIGH SPEED OPERATION OF WINCH HOIST UP/DOWN CANNOT BE PERFORMED T-415
E-15 HOIST UP CANNOT BE PERFORMED WITH HOOK STOWAGE OPERATION T-415
NONE OF THE HOISTING UP, EXTENDING, RAISING OR LOWERING OPERATIONS CAN
E-16 BE PERFORMED EVEN WHEN THE MOMENT LIMITER IS CANCELLED WITH THE T-416
EMERGENCY RELEASE SWITCH
2.3. TROUBLESHOOTING OF THE HYDRAULIC PRESSURE AND MECHANICAL SYSTEMS T-417
ALL THE CRANE, SLEWING AND TRAVELLING SPEED IS LOW, OR THE FORCE IS
H-1 T-417
INSUFFICIENT
H-2 ENGINE REVOLUTION SPEED DROPS SIGNIFICANTLY, OR THE ENGINE STALLS T-417
H-3 NONE OF THE CRANE OR SLEWING/TRAVELLING WORKS T-418
H-4 ABNORMAL NOISE IS GENERATED FROM THE HYDRAULIC PUMP OR ITS PERIPHERY T-419
MICRO SPEED OPERABILITY IS UNSATISFACTORY, OR RESPONSIVENESS IS
H-5 T-419
INSUFFICIENT
H-6 HOIST UP/DOWN IS SLOW OR WEAK T-420
ABNORMAL SOUND OR VIBRATION IS GENERATED FROM WINCH MOTOR OR ITS
H-7 T-421
PERIPHERY
H-8 HOIST UP CANNOT BE PERFORMED T-421
H-9 HOIST DOWN CANNOT BE PERFORMED T-421
H-10 BOOM TELESCOPING IS SLOW OR WEAK T-421
H-11 BOOM DERRICKING IS SLOW OR WEAK T-422
H-12 BOOM EXTENDING/RETRACTING ORDER IS DISTURBED T-422
H-13 HUNTING OCCURS DURING BOOM RETRACTION T-422
H-14 EITHER BOOM NO. 2 OR 3 FAILS TO RETRACT T-422
H-15 NATURAL DESCENDING AMOUNT OF CRANE IS SIGNIFICANT T-423
H-16 TIME LAG OF CRANE IS SIGNIFICANT T-423
0-6
Item Page
H-17 TRAVEL DEVIATION IS OBSERVED T-424
H-18 TRAVEL SPEED IS LOW T-424
H-19 STEERING IS DIFFICULT OR WEAK T-425
H-20 TRAVEL SPEED CANNOT BE CHANGED, OR TRAVEL SPEED IS LOW/HIGH T-425
H-21 CRAWLER FAILS TO MOVE (ONE SIDE ONLY) T-425
H-22 DOES NOT SLEW T-426
H-23 SLEWING ACCELERATION IS UNSATISFACTORY, OR SLEWING SPEED IS LOW. T-427
H-24 OVERRUN AFTER STOP OF SLEWING IS SIGNIFICANT T-428
H-25 IMPACT AT STOP OF SLEWING IS SIGNIFICANT T-429
H-26 ABNORMAL NOISE GENERATED AT STOP OF SLEWING IS SIGNIFICANT T-429
H-27 NATURAL DESCENDING AMOUNT AT SLEWING IS SIGNIFICANT T-429
0-7
OVERVIEW
1. EXTERNAL VIEW 1-2
2. PRINCIPAL SPECIFICATIONS LIST 1-3
3. COMPONENT MASS LIST 1-5
4. LIST OF OIL QUANTITY 1-6
5. WORKING RANGE DIAGRAM 1-7
6. RATED TOTAL LOAD CHART 1-8
1-1
1. EXTERNAL VIEW
1-2
2. PRINCIPAL SPECIFICATIONS LIST
Equipment / Item CC423S-1
Machine mass 4,400 kg
Overall length × width × height 4,020 mm × 1,740 mm × 2,495 mm
Weight and Distance between centre idler and sprocket 1,650 mm

dimensions Track gauge 1,440 mm
Width of crawler 300 mm
Slewing radius at rear end of the machine 980 mm
Maximum rated total load × working radius 2.93 t × 1.5 m
Performance Maximum working radius 8.38 m
Maximum lifting height above ground 9.46 m
Swash plate axial piston motor, differential gear reduction, friction disc
Type
type brake and grooved drum
Number of falls of wire 4-fall/2-fall hooking wire, single fall (optional)
Winch system
Hook hoist speed 19 m/min (drum 4 layers, hook 4 fall)
Hoist wire rope IWRC 6 × Ws (26) 0/0 bare type B ϕ8 × 73 m
2 × Sequentially telescoping, double-acting hydraulic cylinder + 1 × Wire rope
Type telescoping system
Pentagonal cross-section, hydraulically automatic telescoping, 4
Telescoping Type of boom stages
system (Stage 2: Telescoping; Stages 3 and 4: Simultaneous telescoping)
Boom length 3.18 m – 5.03 m – 6.87 m – 8.71 m
Telescoping stroke / Extending time 5.53 m/14 sec
Boom hoist Type Double-acting hydraulic cylinder direct thrusting system
system Derricking angle / Time 0 to 80 deg./12 sec
Slewing Type Fixed capacity piston type, brake valve, with pivot axis brakes
system Slewing angle / Speed 360° (continuous)/2.4 min-1
Type Variable capacity piston type
Low speed Forward/backward travelling: 0 to 2.9 km/h
Travelling Travel speed
High speed Forward/backward travelling: 0 to 4.6 km/h
system
Grade ability 20°
Ground pressure [Shoe width] 42.2 kPa (0.43 kgf/cm2) [300 mm]
Hydraulic Hydraulic pump Variable capacity piston pump + gear pump + trochoid pump
system Hydraulic oil tank capacity 28.5 litres
Model Water-cooled diesel 3TNV88F-EPMBA (Yanmar)
Type 4-stroke cycle, water-cooled, series, direct injection
Displacement 1,642 cc
Engine
Rated output 17.5 kW/2,400 min-1 (23.8 PS/2,400 min-1)
High idle speed 2,430 ± 10 min-1
Fuel used / Fuel tank capacity Diesel fuel / 42 litres
Over-hoisting prevention device, over-unwinding prevention device, overload prevention device, slinging wire
rope detachment protector, hydraulic safety valve, telescoping cylinder hydraulic automatic locking device,
Safety device
derricking cylinder hydraulic automatic locking device, alarm buzzer, machine body inclination alarm, tri-colour
revolving working status lamp, levelling instrument, operation locking lever and emergency stop switch.
classification Mobile crane ISO4301/2 Group A1
1-3
Equipment/Item CC423S-1
Type Double-acting piston type
Cylinder bore mm 130
Derricking Piston rod bore mm 90

cylinder Stroke mm 408
Maximum distance between pins mm 1,142
Minimum distance between pins mm 734
Type 2-stage sequential telescoping double-acting piston type
1st cylinder bore mm 60
1st cylinder piston rod bore mm 45
1st cylinder stroke mm 1,850
1st cylinder maximum distance
mm 1,982
between pins
Telescopic 1st cylinder minimum distance
mm 132
cylinder between pins
2nd cylinder bore mm 60
2nd cylinder piston rod bore mm 45
2nd cylinder stroke mm 1,840
2nd cylinder maximum distance
mm 1,946.5
between pins
2nd cylinder minimum distance
mm 106.5
between pins
Type Double-acting piston type
Cylinder bore mm 95
Piston rod bore mm 45
Blade cylinder
Stroke mm 140
Maximum distance between pins mm 610
Minimum distance between pins mm 470
1-4
3. COMPONENT MASS LIST
Unit: kg
Item Mass
Engine assembly 200
• Engine (without coolant or oil) (175)
• PTO (No. 1 to 5) (15)
Hydraulic pump 31
Cooling assembly 29
Revolving frame 430
Upper slewing body
Operator’s canopy 60
Operator’s seat 25
Fuel tank (without fuel) 4 2,590
Hydraulic oil tank (without hydraulic oil) 43

Operation valve 20
Counter weight 1,220
Swing circle 38
Slewing machinery 23
Slewing motor 14
Derrick cylinder assembly 60
Track frame assembly 700
Carrier
Track shoe left and right set 350

1,250
Blade set 200
• Blade (170)
• Blade cylinder (30)
Boom assembly (with telescopic cylinder assembly) 430
• Telescopic cylinder (80)
• No. 1 boom (140)
Work equipment
• No. 2 boom (78)

• No. 3 boom (62)
• No. 4 boom (70) 560
Winch assembly (with piping, etc., without wire rope) 75

Wire rope (IWRC 6 × Ws (26) 0/0 Bare B type ø8 × 73 m) 25
Hook block assembly 30
Rubber pad left and right set 100

Option
Searcher hook set 30
1-5
4. List of Oil Quantity
Temperature-dependent
Mode of Use (°C) Recommended Authentic
Oiling Spot Oil Type
Oil
Minimum Maximum
-20 10 SAE 10WCF
-20 40 ★ SAE 10W30CF
Engine oil pan Engine oil
-15 40 SAE 15W40CF
0 40 SAE 30WCF
Travel motor reduction gear casing Power line oil (Note 1) -20 40 ★ SAE 30
Hydraulic oil system Power line oil (Note 1) -20 40 ★ SAE 10WCD
Winch motor reduction gear casing Gear oil -20 40 ★ ISO VG320
Super Coolant
Cooling system -30 40 ★ AF-NAC
Diluting water (Note 2)
ASTM** Grade No.1-D
S15
-30 20
ASTM Grade No.1-D
Fuel tank Diesel fuel S500
ASTM Grade No.2-D S15
-10 40 ASTM Grade No.2-D
S500
★ : Default on factory shipment
Oiling spot Specified oil quantity (L) Replacement oil quantity (L)
Engine oil pan 6.7 6.2
Travel motor reduction gear casing (1
0.6 0.6
each for left and right)
Hydraulic oil system 54 28.5
Winch reduction gear case 0.75 0.75
Cooling system 5.5 ---
Fuel tank 42 ---
Note 1: The power line oil and engine oil are different. Use the recommended oil for each.
Note 2: On the Super Coolant
(1) The Super Coolant is required to perform the important functions of an anticorrosion agent for the cooling system, as
well as the antifreezing functions.
Thus, use this Super Coolant continuously even in areas where the antifreezing properties are not required.
Use of any coolants other than the genuine Super Coolant (AF-NAC) is in principle not recommended. Otherwise a
serious failure may occur in the cooling system including the engine.
(2) The mixing proportion of Super Coolant and the diluting water is shown in the table below.
Min. temperature (°C) -10 or
Mixed quantity (L) -15 -20 -25 -30
more
Super Coolant quantity 1.7 2.0 2.3 2.5 2.8
Water amount 3.8 3.5 3.2 3.0 2.7

On factory shipment, the coolant is added with the genuine Super Coolant (AF-NAC) at a proportion of 30% or more
unless otherwise ordered, and there is no particular need to alter the concentration when used in a temperature down
to -10°C.
(3) To maintain the anticorrosion performance of the Super Coolant, always keep the concentration at 30% or higher.
1-6
5. WORKING RANGE DIAGRAM
4-FALL WIRE ROPE
1-7
6. RATED TOTAL LOAD CHART
[1] RATED TOTAL LOAD CHART FOR 4-FALL WIRE ROPE
Unit: kg
3.18 m Boom 5.03 m Boom 6.87 m Boom 8.71 m Boom
Working
Radius (m) Travelling Travelling
Stationary hoist Stationary hoist Stationary hoist Stationary hoist
hoist hoist
1.50 2,930 1,465 2,930 1,465 1,870 1,190
2.00 1,730 865 1,710 855 1,710 1,190
2.50 1,200 600 1,190 595 1,190 1,190
2.85 980 490 980 490 980 980
3.00 900 450 900 900
3.50 720 360 720 720
4.00 600 300 600 600
4.50 500 250 500 500
4.70 460 230 460 460
5.00 430 430
5.50 370 370
6.00 330 330
6.54 290 290
7.00 260
7.50 235
8.00 215
8.38 200
★ Boom length
3.18 m boom → Boom fully retracted
5.03 m boom → Boom length: 3.19 m to 5.03 m
8.71 m boom → Boom length: 6.88 m or more
★ The rated total load chart is based on the actual working radius including the deflection under load.
★ The rated total load chart indicates the load including the mass of hoisting accessories (hook mass: 30 kg).
1-8
[2] RATED TOTAL LOAD CHART FOR 2-FALL WIRE ROPE
Unit: kg
Working
Radius (m) Travelling Stationary Travelling
Stationary hoist Stationary hoist Stationary hoist
hoist hoist hoist
1.50 1,480 740 1,480 740 1,480 1,190
2.00 1,480 740 1,480 740 1,480 1,190
2.50 1,200 600 1,190 595 1,190 1,190
2.85 980 490 980 490 980 980
3.00 900 450 900 900
3.50 720 360 720 720
4.00 600 300 600 600
4.50 500 250 500 500
4.70 460 230 460 460
5.00 430 430
5.50 370 370
6.00 330 330
6.54 290 290
7.00 260
7.50 235
8.00 215
8.38 200
★ Boom length
1-9
[3] RATED TOTAL LOAD CHART FOR SINGLE-FALL WIRE ROPE
Unit: kg
Working
Radius (m) Stationary Travelling Stationary Travelling
Stationary hoist Stationary hoist
hoist hoist hoist hoist
1.50 750 375 750 375 750 750
2.00 750 375 750 375 750 750
2.50 750 375 750 375 750 750
2.85 750 375 750 375 750 750
3.00 750 375 750 750
3.50 720 360 720 720
4.00 600 300 600 600
4.50 500 250 500 500
4.70 460 230 460 460
5.00 430 430
5.50 370 370
6.00 330 330
6.54 290 290
7.00 260
7.50 235
8.00 215
8.38 200
★ Boom length
1-10
STRUCTURE AND
MAINTENANCE PROCEDURE
1. ENGINE AND COOLING-RELATED COMPONENTS 2-2
2. POWER TRANSMISSION SCHEMATIC DIAGRAM 2-8
3. UNDERCARRIAGE AND FRAME 2-12
4. HYDRAULIC SYSTEM 2-21
5. WORK EQUIPMENT 2-70
6. ELECTRICAL UNITS 2-75
7. MOMENT LIMITER 2-101
2-1
1. ENGINE AND COOLING-RELATED COMPONENTS
1.1 ENGINE
1.2 ENGINE SPECIFICATIONS

Item CC432S-1
Model Yanmar 3TNV88F-EPMBA
Type 4-stroke cycle, water-cooled series,direct injection
No. of cylinders - cylinder bore × stroke 3 - 88 mm × 90 mm
Total displacement 1,642 cc
Rated output 17.5 kW/2,400 rpm (23.8 PS/2,400 rpm)
Intermediate torque (Gross) 83.4 N·m/1,440 rpm (8.5 kgf·m/1,440 rpm)
Maximum revolution under no load 2,430 rpm
Minimum revolution under no load 1,250 rpm
Rate of fuel consumption 238 g/kWh (175 g/PSh)
Starter 12 V, 2.3 kW
Alternator 12 V, 40 A
Battery 95D31
Radiator Pressurized sealed system, aluminium radiator
* For the engine, refer to the Yanmar Service Manual
2-2
1.3 ENGINE MOUNT
542-1282600
2-3
1.4 PTO (POWER TAKE-OFF) AND PUMP
542-1282700
2-4
1.5 COOLING ASSEMBLY
542-1282800
2-5
1.6 FUEL LINE
542-1287500
2-6
1.7 FUEL TANK
542-1287500
2-7
2. POWER TRANSMISSION SCHEMATIC DIAGRAM
2.1 HYDRAULIC SYSTEM DIAGRAM
2-8
2.2 SWING CIRCLE
1. Outer race
2. Ball
3. Inner race
Specifications
Reduction gear ratio 92/11 = 8.36
Grease Lithium grease (Epnoc grease AP(N)-2)
Unit: mm
No. Item Criterion Remedy

Standard clearance Allowable clearance
4 Bearing clearance Replace
0.03 - 0.13 0.23
2-9
2.3 SWING MACHINERY
1. Slewing motor
2. No. 1 sun gear
Specifications
3. No. 1 planetary gear
Reduction gear ratio 17. 422
4. No. 2 sun gear
Slewing reduction ratio 140.94
5. Ring gear
6. No. 2 planetary gear Slewing speed (rpm) 8. 5
7. Swing machinery case Lubricating oil quantity (L) 0.9
8. Swing pinion
9. Tapered roller bearing
2-10
Unit: mm

Backlash of slewing motor shaft Standard clearance Allowable clearance
1
and No. 1 sun gear 0.04 - 0.11 -
Backlash of No. 1 sun gear
2 0.09 - 0.25 0.6
and No. 1 planetary gear
Backlash of No. 1 planetary gear
3 0.10 - 0.33 0.6
and ring gear
Backlash of No. 1 planetary carrier
4 0.10 - 0.21 -
and No. 2 sun gear
Replace
Backlash of No. 2 sun gear
5 0.09 - 0.25 0.6
and No. 2 planetary gear
Backlash of No. 2 planetary gear
6 0.10 - 0.33 0.6
and ring gear
Backlash of No. 2 planetary carrier
7 0.07 - 0.21 -
and swing pinion
Backlash of swing pinion and
8 0.17 - 1.72 2.0
and swing circle
Abrasion of oil seal sliding surface Basic dimensions Tolerance Allowable limit Repair or replace
9 on 0 hard chrome
42 -
swing pinion collar -0.074 plating
2-11
3. UNDERCARRIAGE AND FRAME
3.1 TRACK FRAME
9JE00369
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier roller 8. Idler cushion
4. Travel motor 9. Idler guard
5. Sprocket
2-12
3.2 IDLER CUSHION
1. Rod 6. Support
2. Cylinder 7. Cover
3. Recoil spring 8. Rear support
4. Idler 9. Nut
5. Support 10. Lubricator
Specifications
Grease: Lithium grease (Epnoc grease AP(N)-2)
Unit: mm

Basic dimensions Allowable limit
Mounting Mounting Mounting
Free length Free length
11 Recoil spring length load load Replace
19.7 kN 17.6 kN
257 213 251
{2,012 kg} {1,791 kg}
2-13
3.3 IDLER
2-14
Unit: mm
Outside diameter of Basic dimensions Allowable limit

1
protruding part 338 -
2 Outside diameter of tread 300 292

Repair by
3 Tread depth 19 23 overlay
welding, or
4 Tread thickness 8.7 4.7 replace it.
5 Tread width 18 22
6 Total width 64 -
Basic Tolerance Standard Allowable
Clearance between shaft dimensions Shaft Hole clearance clearance
7
and bushing -0.025 +0.142 0.105 to
35 -
-0.064 +0.080 0.206
Clearance between shaft -0.025 +0.060 0.025 to Replace
8 35 -
and support -0.064 0 0.124
Play in axial direction of Standard clearance Allowable clearance
9
idler 0.25 -
Track
95.5 100 Repair by
Vertical width of idler frame
10 overlay
guide section Idler
94 90 welding.
support
Track Repair by
161.5 165
Transverse width of idler frame overlay
11
guide section welding, or
Idler shaft 160 155 replace it.
2-15
3.4 TRACK ROLLER
Unit: mm
Outside diameter of Basic dimensions Allowable limit

1 Repair by
protruding part 108 102
overlay
2 Outside diameter of tread 85 77 welding, or
replace it.
3 Tread width 34 37
4 Flange width 26 20 -
5
and bushing 0 +0.183
25 0.144 - 0.196 1.5
-0.013 +0.144
Interference between dimensions Shaft Hole interference interference Replace
6
roller and bushing +0.073 +0.039
32 0.009 - 0.073 -
+0.048 0
Standard clearance Allowable clearance
7 Side clearance of shaft
0.20 0.74
Basic dimensions Allowable limit Repair by

Thickness of track roller overlay
8
tread 26.5 22.5 welding, or
replace it.
2-16
3.5 CARRIER ROLLER
Unit: mm

Basic dimensions Allowable limit
1 Outside diameter of tread Repair by
70 65
overlay
2 Tread thickness 9 6.5 welding, or
replace it.
3 Tread width 100 -
4
and support -0.050 +0.210
30 0.050 - 0.310 -
-0.100 0
Replace
Interference between shaft dimensions Shaft Hole interference interference
5
and seal 0 -0.200
30 0.148 - 0.400 -
-0.052 -0.400
2-17
3.6 SPROCKET
Unit: mm

Basic dimensions Tolerance Allowable limit
Abrasion of tooth root
1 +1.0
diameter 344.3 332
-2.0
Abrasion of tooth tip
2 386.2 ±1.5 374
diameter Repair by
overlay welding,
3 Abrasion of tooth tip width 20 - 18
or replace it.
Abrasion of tooth root +0.5
4 27 24
width -1.0
Thickness of tooth root +0.475
5 77.15 71
section -1.061
2-18
3.7 TRACK SHOE
2-19
Unit: mm

Basic dimensions Reverse limit Allowable limit If the allowable
limit is
1 Link pitch
102 - 107 exceeded,
replace the
bushings and
Outside diameter of pins or replace
2 32 - 26
bushing the entire link
assembly
Basic dimensions Allowable limit Weld the lug or
3 Grouser height
16.5 10 replace
Repair by
overlay
4 Link height 61 55
welding, or
replace it.
Interference between dimensions Shaft Hole interference interference
5
bushing and link +0.15 +0.05
32 0.07 - 0.15 -
+0.12 0
Interference between +0.15 +0.05
6 19 0.07 - 0.15 -
regular pin and link +0.12 0
Clearance between dimensions Shaft Hole clearance clearance Replace
7
master pin and link Shaft 18.93 +0.05 +0.05
0.02 - 0.12 -
Hole 19 0 0
Clearance between
Shaft 18.93 +0.15
8 regular pin and ±0.2 0.15 - 0.58 -
Hole 19.5 +0.12
bushing
Clearance between Shaft 18.93 +0.05
9 ±0.2 0.32 - 0.77 -
master pin and bushing Hole 19.5 0
Standard clearance Standard clearance Allowable clearance
Clearance between link (one side) (both sides) (one side)
10
mating surfaces
0.2 - 0.9 0.4 - 1.8 - Adjust
Projecting amount of
11 1.5
regular pin
Basic dimensions Allowable limit Weld the lug or
12 Grouser width
12 8 replace
Repair by
Link thickness
overlay
13 (Bushing press-fitted 15.5 9.5
welding, or
section)
replace it.
Reverse or
14 Bushing thickness 6.25 3.25
replace
Tightening torque of
15 - Re-tighten
shoe bolts
2-20
4. HYDRAULIC SYSTEM
4.1 HYDRAULIC UNITS LAYOUT DIAGRAM
2-21
2-22
4.2 HYDRAULIC OIL TANK AND FILTER
542-1288000
Specifications
Tank capacity (L) 45
Oil quantity in the tank (L) 28.5
Bypass valve set pressure 103 ± 19
(MPa {kg/cm2}) {1.05 ± 0.2}
2-23
4.3 SWIVEL JOINT
Ｔ１
Port Port
Port destination Port destination
name name
A1 From operation valve A6 port (right: backward) A2 To right travel motor A port
B1 From operation valve A5 port (left: backward) B2 To left travel motor B port
C1 From operation valve B6 port (right: forward) C2 To right travel motor B port
D1 From operation valve B5 port (left: forward) D2 To left travel motor A port
From operation valve with blade B1 port (blade
E1 E2 To blade cylinder head
raising)
From operation valve with blade A1 port (blade
F1 F2 To blade cylinder bottom
lowering)
From 3-fold solenoid valve A2 port (travelling To travel motor PP port (travelling 2-speed
G1 G2
2-speed switching) switching)
T1 To hydraulic oil tank T2 From travel motor drain port
No. Name
1 Shaft
2 Rotor
3 Slipper seal
4 Cover
Unit: mm
Clearance between rotor Basic dimensions Standard clearance Allowable clearance

5 Replace
and shaft 60 0.055 - 0.085 0.090
2-24
4.4 TRAVEL MOTOR
Port
Port destination
name
A From left travel motor, operation valve B5 port/from right travel motor, operation valve A6 port
B From left travel motor, operation valve A5 port/from right travel motor, operation valve B6 port
DR To tank
PP From 3-fold solenoid valve A2 port (travelling 2-speed switching)
Specifications
Model PHV-3B
Theoretical Hi 12.2
displacement volume
(cc/rev) Lo 22.1
Speed switching pressure
1.5 {15.3}
(MPa {kg/cm2})
Reduction gear ratio 45.2
2-25
4.5 3-FOLD SOLENOID VALVE
(TRAVEL PPC, TRAVELLING 2-SPEED, CRANE PPC)
S542G3562000
Port Specifications
Port destination
name P, A1, A2, A3 5.0
Rated pressure
P From hydraulic pump A4 port (MPa) T 0. 98
A1 To travelling remote control valve (travel PPC) P port +20%
Voltage (V) DC12
A2 To travel motor (travelling 2-speed) PP port -10%
A3 To crane PPC valve P port Power (W) 12

T1 To hydraulic oil tank Solenoid resistance (Ω) 12
T2 To travelling remote control valve (travel PPC) T port
2-26
4.6 2-FOLD SOLENOID VALVE
(FOR WINCH)
SAM04050
Port
Port destination No. Name
name
P1 From right PPC valve P2 port (hoist up) 1 Connector
P2 From right PPC valve P1 port (hoist down) 2 Block
A1 To operation valve Pb3 and Pb8 ports 3 Winch up solenoid valve
A2 To operation valve Pa3 and Pa8 ports 4 Winch down solenoid valve
G1 Port for pressure switch
G2 Port for pressure switch
T To tank via T grouping block
Specifications
Maximum service pressure
3.5
(MPa)
Maximum flow rate (L/min) 11
Voltage (V) DC12
Solenoid resistance (Ω) 7.5
2-27
4.7 3-FOLD EPC VALVE (FOR DERRICKING, TELESCOPING)
Port
name
A1 From right PPC valve P3 port (boom raising) 1 Connector
A2 From right PPC valve P4 port (boom lowering) 2 Block
A3 From left PPC valve P1 port (boom extending) 3 Raising solenoid valve
B1 To operation valve Pa4 port (boom raising) 4 Lowering solenoid valve
B2 To operation valve Pb4 port (boom lowering) 5 Extending solenoid valve
B3 To operation valve Pb7 port (boom extending)
T To tank via T grouping block
Specifications
Rated pressure A, B 3.9 (Maximum service pressure 3.14)
(MPa) T 0.5
A port push-in flow rate 11
Rated flow rate (L/min)
(A → B port flow rate 6)
Voltage (V) DC12
Rated current (A) 1.0
Solenoid resistance (Ω) 6.3
2-28
4.8 HYDRAULIC PUMP (MAIN PUMP)
S542I3548000
Port Port
name name
A1 Discharge port (to operation valve P1 port) S1 Suction port
A2 Discharge port (to operation valve P2 port) R1 Air venting port
A3 Discharge port (to operation valve P3 port)
A4 Discharge port (to 3-fold solenoid valve P port)
Specifications
Service A1, A2 24.5
pressure A3 20.6
(MPa) A4 2.9
A1, A2 19.0 × 2
Displacement
A3 4.5
(cm3)
A4 5.1
Discharge flow A1, A2 46.2 × 2
rate A3 10.9
(L/min) A4 12.4
2-29
4.9 OPERATION VALVE (WITH BLADE)
S542G3867000
Port Port
name name
A1 To blade cylinder bottom (blade lowering) P1 From main pump A1 port
A2 To slewing motor port (MB) (right slewing) P2 From main pump A2 port
A3 To winch motor port (A) (hoist down) P3 From main pump A3 port
A4 To derricking cylinder bottom (A port) (boom raising) Pa2 From left PPC valve P4 port (right slewing)
A5 To left travel motor B port (backward) Pa3 From control valve Pa8 port (hoist down)
A6 To right travel motor A port (backward) Pa4 From 3-fold EPC valve B1 port (boom raising)
To telescoping cylinder head (B port) (boom From left travelling remote control valve 1 port
A7 Pa5
retracting) (left side backward travel)
From right travelling remote control valve 3 port
A8 To winch motor port (A) (hoist down) Pa6
(right side backward travel)
B1 To blade cylinder head (blade raising) Pa7 From left PPC valve P2 port (boom retracting)
B2 To slewing motor port (MA) (left slewing) Pa8 2-fold solenoid valve A2 port (hoist down)
B3 To winch motor port (B) (hoist up) Pb2 From left PPC valve P3 port (left slewing)
B4 To derricking cylinder head (B port) (boom lowering) Pb3 From 2-fold solenoid A1 port (hoist up)
B5 To left travel motor A port (forward) Pb4 From 3-fold EPC valve B2 port (boom lowering)
From left travelling remote control valve 2 port
B6 To right travel motor B port (forward) Pb5
(left side forward travelling)
To telescoping cylinder bottom (A port) (boom From right travelling remote control valve 4 port
B7 Pb6
extending) (right side forward travel)
B8 To winch motor port (B) (hoist up) Pb7 From 3-fold EPC valve B3 port (boom extending)
T1 To bypass check valve T1 port Pb8 From control valve Pb3 port (hoist up)
T2 To bypass check valve T2 port
2-30
2-31
4.10 SLEWING MOTOR
9JS09454
Port Port
name name
B From slewing brake release shuttle valve C port S To operation valve T1 port
MA From operation valve B2 port (left slewing) T To tank
MB From operation valve A2 port (right slewing)
Specifications
Type LMF16
Theoretical displacement volume 16.1 cm3/rev
Rated revolution speed 1,600 rpm
Rated flow rate 19 L/min
Brake release pressure 0.37 ± 0.07 MPa {3.8 ± 0.7 kg/cm2}
Safety valve set pressure 18.1 MPa {185 kg/cm2}
2-32
Cross-section drawing
1. Output shaft 9. Cylinder

2. Housing 10. Brake piston
3. Shoe 11. Swash plate
4. Piston 12. Brake spring
5. Centre spring 13. Safety valve
6. Valve plate 14. Check valve
7. Disc 15. Hydraulic timer valve
8. Plate

Basic dimensions Allowable load
Mounting Mounting Mounting If damaged or
16 Check valve spring Free length Free length deformed, replace
length load load
1.96 N 1.57 N the spring
13.0 × 6.5 9.5 -
{0.2 kg} {0.16 kg}
2-33
4.11 PPC VALVE
Port
Port destination
name
P From 3-fold solenoid valve A3 port via P grouping block
To right PPC valve and 2-fold solenoid valve P2 port (hoist down)/to left PPC valve and 3-fold EPC valve A3 port (boom
P1
extending)
To right PPC valve and 2-fold solenoid valve P1 port (hoist up)/to left PPC valve and operation valve Pa7 port (boom
P2
retracting)
To right PPC valve and 3-fold EPC valve A1 port (boom raising)/to left PPC valve and operation valve Pb2 port (left
P3
slewing)
To right PPC valve and 3-fold EPC valve A2 port (boom lowering)/to left PPC valve and operation valve Pa2 port (right
P4
slewing)
T To tank via T port block
2-34
4.12 SLEWING BRAKE RELEASE SHUTTLE VALVE
S541G2600000
Port
Port destination
name
A From left PPC valve P4 port to control valve Pa2 (right slewing)
B From left PPC valve P3 port to control valve Pb2 (left slewing)
C To slewing motor B port (slewing brake release)
Specifications
Service pressure (MPa) 3.1
Maximum service flow rate (L/min) 13
2-35
4.13 WINCH MERGE LOW PRESSURE VALVE
S541G2571000
Port
name
A From operation valve A3 and A8 ports 1 Connector
A1 To winch motor A port (hoist down) 2 Block
B From operation valve B3 and B8 ports 3 Winch low pressure solenoid valve
B1 To winch motor B port (hoist up)
T To bypass check valve T2
Specifications
Maximum service pressure (MPa) 20.6
Voltage (V) DC12
Solenoid resistance (Ω) 12
2-36
4.14 BYPASS CHECK VALVE
S541G2605000
Port Port
name name
T1 From operation valve T1 port and slewing motor S port B To tank
T2 From operation valve T2 port and winch merge valve T port C To oil cooler
Specifications
Maximum service pressure (MPa) 1.0
Cracking pressure (MPa) 0.34
2-37
4.15 WINCH MOTOR
SAM04
060
Port
Port destination
name
A From winch merge valve A1 port (hoist down)
B From winch merge valve B1 port (hoist up)
D To tank
[*1]
Apply Loctite 262 during assembly.
[*2]
Assemble the winch case stepped part against the tap seat with no gaps.
Specifications
Model CH01A
Theoretical displacement volume (cc/rev) 17.27
Reduction gear ratio 26
2-38
4.16 DERRICKING CYLINDER
SAM04140
Port
name
A From operation valve A4 port (boom raising) 1 Grease nipple
B From operation valve B4 port (boom lowering) 2 Grease nipple
C Pressure transmitter 1 port Counterbalance valve
3
D Pressure transmitter 2 port (Cracking pressure: 1.5 to 1.2 MPa {15 to 12 kg/cm2}
[*1]: Stamped mark D.
Specifications
Size ø130 × ø90 - 408 st
Extension side 20.6
Service pressure (MPa)
Retraction side 20.6
When extended 273.4
Normal load (KN)
When retracted 142.4
Hydrostatic test Extension side 30.9
pressure (MPa) Retraction side 30.9
2-39
4.17 TELESCOPING CYLINDER
Port
name
Counterbalance valve
A Operation valve B7 port (boom extending) 1
(Cracking pressure: 1.5 to 1.2 MPa {15 to 12 kg/cm2})
2 Sequence valve
B Operation valve A7 port (boom retracting)
3 Mechanical check valve
[*1]: Caulk at two locations after tightening.

[*2]: Apply Loctite 262.
[*3]: Stamped mark T.
Specifications
T1 CYLINDER T2 CYLINDER
Size ø60 × ø45 - 1850 st ø60 × ø45 - 1840 st
Extension side 20.6 Extension side 20.6
Service pressure (MPa)
Retraction side 20.6 Retraction side 20.6
When extended 58.2 When extended 58.2
Normal load (KN)
When retracted 25.5 When retracted 25.5
Hydrostatic test Extension side 28.9 Extension side 28.9
pressure (MPa) Retraction side 28.9 Retraction side 28.9
2-40
4.17.1 TELESCOPING CYLINDER HYDRAULIC SYSTEM DIAGRAM
2-41
4.17.2 COUNTERBALANCE VALVE
For derricking cylinder ⇒ Identification stamp: D

For telescoping cylinder ⇒ Identification stamp: T
2-42
4.17.3 SEQUENCE VALVE
2-43
4.17.4 MECHANICAL CHECK VALVE
2-44
4.18 BLADE CYLINDER
Port
name
From operation valve with blade B1 port (blade
A 1 Grease nipple
raising)
From operation valve with blade A1 port (blade
B 2 Grease nipple
lowering)
Specifications
Size ø95 × ø45 - 140 st
2-45
4.19 TRAVELLING REMOTE CONTROL VALVE (TRAVEL PPC VALVE)
S558G3189000
Port
Port destination Port size Note
name
P 3-fold solenoid A1 port G1/4
1 To operation valve Pa5 port G1/4 Left: Backward
2 To operation valve Pb5 port G1/4 Left: Forward
3 To operation valve Pa6 port G1/4 Right: Backward
4 To operation valve Pb6 port G1/4 Right: Forward
5 Pressure switch G1/4
T To hydraulic oil tank via 3-fold solenoid T2 port G1/4
2-46
4.20 HYDRAULIC PIPING DIAGRAM
4.20.1 SUCTION LINE (HYDRAULIC TANK TO PUMP)
542-1284000
Joint Hose/Piping Joint

Connection
Equipment name Port Name Name Name Port
No. No. No. destination
Part No. Part No. Part No.
Hydraulic tank 1 Hose
-
(X262382381) 22F-62-11571
3 Tube
22F-62-11512
8 Suction hose (10) Suction flange Hydraulic pump
S1
542-3568700 542-3568900 (S542I3548000)
For the numbers in parentheses ( ) in No., refer to the part numbers in parentheses ( ) in Equipment name/Connection
destination
2-47
4.20.2 PUMP LINE (PUMP TO OPERATION VALVE AND 3-FOLD SOLENOID VALVE)
542-1284100

Connection
Tee Hose P2 4S (830L) Male connector
Hydraulic pump 542-4776800
A2 (14) 1 (9) 22611-11060
(S542I3548000) S557J2590000 “PA2808C+CR9×
“1067-08 HYDEX”
830L”
Bushing Control valve
(3) P2
S101J2061000 (S542G3867000)
Tee Hose P1 4S (680L) Male connector
542-4776900
A1 (13) 2 (9) 22611-11060 P1
S542J3825000 “PA2808C+CR9×
“1067-08 HYDEX”
680L” Control valve
Adjustable tee Hose P3 4S (680L) Nipple (S542G3867000)
Hydraulic pump 542-4777000
A3 (15) 3 (12) 22611-14150 P3
(S542I3548000) S542J3822000 “PA2806C+CR9×
1067-08A-06 HYDEX
680L”
Nipple Hose P4 4S (810L) Filter assembly
542-4777100 3-fold solenoid valve
A4 (16) 4 (44) P
S542J3781000 “PF0704, F4+F4R4× S542J3823000 (S542G3562000)
810L”
destination
2-48
4.20.3 RETURN LINE 01 (BYPASS CHECK VALVE TO HYDRAULIC TANK
542-1284200-01

Connection
45° elbow Hose Elbow
541-3466800 Oil cooler
C 22 22611-11280 1 (33) Inlet
“PA0716, F4+CR9× K417-855-1370 (K22F-03-11131)
“1072-16 HYDEX”
Bypass check 1270L”
valve 45° elbow Hose Elbow
(S541G2605000) 541-3466900
B 20 3FE-04-36910 2 “FUH0 (4) -
07235-10522
“Komatsu” METST+METST×
1940L” Hydraulic tank
(X262382381)
Tee Hose T4S Elbow
Swing machinery 542-3583900
T 1-D 3 (6) -
(21X-26-00042) 20T-62-71611 “PA0306 20Y-970-1731
F4+F4×2850L”
Nipple Hose Tee
Swivel joint 541-3467200 Swing machinery
T (21) 33 1-D T
(K703-06-23150) K22J-62-12230 “PA0306 20T-62-71611 (21X-26-00042)
F4+F4×390L”
Elbow Hose Nipple
Oil cooler Hydraulic tank
Outlet (32) K22F-62-13470 34 (2) -
(K22F-03-11131) 22F-62-11661 417-855-1360 (X262382381)
“Komatsu”
destination
2-49
4.20.4 RETURN LINE 02 (CONTROL VALVE TO BYPASS CHECK VALVE, ETC.)
542-1284200-02

Connection
Male 90° elbow with
Hose Tee
plate
Control valve
T2 (11) 27 22713SA6039 26
(S542G3867000) 22611-11160 22611-12060
“PA0308,
“1071-08 HYDEX” “9070-08 HYDEX”
C+CR9×390L”
Bushing Bypass check valve
23 T2
541-4608700 (S541G2605000)
Hose Tee
Valve assembly plate
winch merge valve T (11) 28 22713S86073 26 T2
22611-11160 22611-12060
(S541G2571000) “PA0308,
“1071-08 HYDEX” “9070-08 HYDEX” Bypass check valve
C+C×730L”
(S541G2605000)
Tee Hose Male connector
22713-F6054
T1 (4) 22611-12060 29 25 T1
“PA0308 C+ Block 22611-11060
Valve assembly “9070-08 HYDEX”
90°×540L”
control valve
Tee Hose Nipple
(S542G3867000)
22713-E6056 Swing machinery
T1 (4) 22611-12060 30 (1A) S
“PA0308, 3EG-66-65110 (21X-26-00042)
“9070-08 HYDEX”
C+CR4×560L”
Valve assembly Hose TTP 4S Nipple
plate
3-fold solenoid
T1 (74) 22611-11135 31 (8) - Hydraulic tank
valve 542-4777200
(S542G3562000) “1071-06-04 S542J3780000 (X262382381)
“PA0304 C+C×1800”
HYDEX”
Floor PPC piping Elbow Hose Nipple
and T grouping 541-3467100
- (12) 32 (10) -
block 07235-10311 “PA0306 204-62-33950
(21X-62-31890) F4+F4×1200L”
destination
2-50
4.20.5 TRAVEL LINE (CONTROL VALVE TO SWIVEL JOINT)
541-1232600
Port Joint Hose/Piping Joint

Connection
Equipment name No. Name No. Name No. Name Port
destination
Control valve Bushing
A6 (6)
(S542G3867000) 10P-62-11230
Nipple Hose (34) Nipple
(15) 5
20C-62-12820 541-3468900 K20T-62-71630
Elbow A1 Swivel joint
(10) (Backward
K07235-10420 right) (K703-06-23150)
Elbow Hose Union C1 Swivel joint
B6 (7) 6 (13) (Forward
Control valve 22W-62-21320 541-3469000 K20T-62-71150 right) (K703-06-23150)
(S542G3867000) Bushing
B5 (6)
10P-62-11230
Elbow Hose (13) Union D1 Swivel joint
(7) 7 (Forward
22W-62-21320 541-3469100 K20T-62-71150 left) (K703-06-23150)
A5 (6)
(S542G3867000) 10P-62-11230
Nipple Hose Nipple
(15) 8 (34)
20C-62-12820 541-3469200 K20T-62-71630
Elbow B1 Swivel joint
(10) (Backward
K07235-10420 left) (K703-06-23150)
destination
2-51
4.20.6 TRAVEL PIPING (SWIVEL JOINT TO TRAVEL MOTOR)
LC383M-5-083 (Parts)

Connection
Tee Hose Nipple
T2 (15) 1 (4) DR
K22L-62-21150 K22F-62-3110 K11Y-62-12140
Union Hose Nipple A
D2 (7) 2 (1)
K02781-00420 K22F-62-21911 K22L-62-21210 (Forward) Left travel motor
Union Hose Nipple B (21U-60-31300)
B2 (7) 2 (1)
K02781-00420 K22F-62-21911 K22L-62-21210 (Backward)
Tee Hose Nipple

G2 10 3 (4) PP
Swivel joint K22L-62-21150 K22L-62-21120 K11Y-62-12140
(K703-06-23150) Tee Hose Nipple
T2 (15) 1 (4) DR
K22L-62-21150 K22F-62-3110 K11Y-62-12140
Union Hose Nipple A
A2 (7) 2 (1)
K02781-00420 K22F-62-21911 K22L-62-21210 (Backward)
Right travel motor
Union Hose Nipple B (21U-60-31300)
C2 (7) 2 (1)
K02781-00420 K22F-62-21911 K22L-62-21210 (Forward)
Tee Hose Nipple

G2 10 3 (4) PP
K22L-62-21150 K22L-62-21120 K11Y-62-12140
destination
2-52
4.20.7 SWING LINE (CONTROL VALVE TO SWING MACHINERY)
541-1232700

Connection
Control valve Nipple Hose Elbow MA Swing machinery
B2 (13) 1 (1C)
(S542G3867000) 20M-62-11310 541-3469500 07235-10315 (Left) (21X-26-00042)
Control valve Long connector 3/8
A2 (8)
(S542G3867000) 349-4412500
Nipple 2 Hose (1C) Elbow MB Swing machinery
(13)
20M-62-11310 541-3469600 07235-10315 (Right) (21X-26-00042)
destination
2-53
4.20.8 DERRICKING LINE (CONTROL VALVE TO DERRICKING CYLINDER)
541-1232800

Connection
B4 (6)
(S542G3867000) 10P-62-11230
Male connector Hose Elbow B Derricking cylinder
(5) 6 (2)
22611-11050 541-3472800 22611-11150 (Lowering) (S541F2582000)
Control valve Male connector Hose Elbow A Derricking cylinder
A4 (5) 7 (2)
(S542G3867000) 22611-11050 541-3472900 07235-10315 (Raising) (S541F2582000)
destination
2-54
4.20.9 TELESCOPING LINE (CONTROL VALVE TO TELESCOPIC CYLINDER)
542-1288100

Connection
Control valve B7 Male connector Hose T pipe Boom line assembly
(5) 6 (1) -
(S542G3867000) (Extending) 22611-11050 541-3473000 541-2211300 (541-1230700)
Control valve A7 Male connector Hose T pipe Boom line assembly
(5) 7 (1) -
(S542G3867000) (Retracting) 22611-11050 541-3473100 541-2211300 (541-1230700)
destination
2-55
4.20.10 WINCH LINE (WINCH MERGE VALVE TO BOOM LINE)
541-1233000

Connection
B1 Hose WB pipe Boom line assembly
(11) plate 1 (3) -
(Up) (541-1230700)
Winch merge valve 22611-11160 541-3477200 541-3462500
(S541G257100) Male 90° elbow with
A1 Hose WA pipe Boom line assembly
(10) long plate 2 (2) -
(Down) (541-1230700)
22611-12360 541-3477300 541-3426400
Boom line WDr pipe Hose Nipple
Hydraulic tank
assembly Dr (4) 3 (12) -
541-3462600 541-3477400 20Y-62-88710 (X262382381)
(541-1230700)
destination
2-56
4.20.11 BOOM LINE (TELESCOPING LINE TO TELESCOPING CYLINDER AND WINCH LINE
TO WINCH MOTOR)
541-1230700

Connection
T pipe Hose Nipple
Telescoping line 22611-14150 Telescoping cylinder
Extending 1 12 20 A
(542-1288100) 541-2211300 541-3470000 “1067-06-67A (S541F2581000)
Yokohama”
T pipe Hose Nipple
Telescoping line 22611-14150 Telescoping cylinder
Retracting 1 13 20 B
(542-1288100) 541-2211300 541-3464900 “1067-06-67A (S541F2581000)
Yokohama”
WA pipe Hose Nipple
Winch line 22611-11055
Down 2 14 17
(541-1233000) 541-3462400 541-3465000 “1067-06-08
Yokohama”
Connector Winch motor
22 A
349-4413000 (S541A2560000)
WB pipe Hose Nipple
Up 3 15 17
(541-1233000) 541-3462500 541-3465100 “1067-06-08
Yokohama”
22 B
349-4413000 (S541A2560000)
WDr pipe Hose Nipple
Dr 4 16 19
(541-1233000) 541-3462600 541-3465200 “1067-06-67A
Yokohama”
Bushing
22031-35130
18
“2040-02-04
Yokohama”
8 D
541-4616800 (S541A2560000)
2-57
4.20.12 SUB LINE 01 (PPC BRACKET TO SLEWING BRAKE RELEASE SHUTTLE VALVE
TO SWING MACHINERY)
542-1283400-01

Connection
Tee Hose
plate Pa2
A (55) 5 22714-A3045 (19)
22611-11130 (Right)
Slewing brake S541J2619000 “PA0704,
release shuttle C+CR9×450L” “1071-04 HYDEX” Control valve
valve Male 90° elbow with (S542G3867000)
(S541G2600000) Tee Hose
plate Pb2
B (55) 25 22714SA3060 (19)
22611-11130 (Left)
S541J2619000 “PA0704,
C+CR9×600L” “1071-04 HYDEX”
Hose Tee
Brown
26 541-3468000 (55) A
(Right) S541J2619000 Slewing brake
PPC bracket “PLT03, F6E9×1150L”
release shuttle valve
(21X-62-32310) Hose Tee
White (S541G2600000)
27 541-3468100 (55) B
(Left) S541J2619000
“PLT03, F6E9×1350L”
Slewing brake Elbow Hose Nipple
release shuttle Swing machinery
C (18) 28 541-3468200 (1A) B
valve 21P-62-11590 3EG-66-65110 (21X-26-00042)
“PA0704, F4+F4×510L”
(S541G2600000)
destination
2-58
4.20.13 SUB LINE 02 (CONTROL VALVE TO WINCH MERGE VALVE)
542-1283400-02

Connection
Male connector Hose 45° elbow
B3 22750-A5039
(5) 22611-11050 21 (54) 22611-11250 B
(Up) “NWP210-9,
“1067-06 HYDEX” “1072-08 HYDEX”
1005+ML90×390L”
Male connector Hose Male connector
A3 22714SA3060
(5) 22611-11050 22 (5) 22611-11050 A
(Down) “PA0704,
Control valve “1067-06 HYDEX” “1067-06 HYDEX” Winch merge valve
C+CR9×600L”
(S542G3867000) (S541G257100)
Male connector Hose Male connector
A8 22750SE5130
(5) 22611-11050 29 (5) 22611-11050 A
(Down) “NWP210-9,
“1067-06 HYDEX” “1067-06 HYDEX”
1005+ML45×1300L”
Male connector Male connector
B8
(5) 22611-11050 30 “NWP210-9, (5) 22611-11050 B
(Up)
“1067-06 HYDEX” 1005+ML90×1180L” “1067-06 HYDEX”
destination
2-59
4.20.14 SUB LINE 03 (2-FOLD SOLENOID VALVE AND 3-FOLD EPC VALVE TO CONTROL
VALVE AND T GROUPING BLOCK)
542-1283400-03

Connection
Tee with single male
Male connector Hose
branch plate Pa8
A2 (17) 9 (16)
22611-11030 22611-12030 (Down)
22749-A3045
“1067-04 HYDEX” “9070-04 HYDEX” Control valve
Tee with single male (S542G3867000)
2-fold solenoid Male connector Hose
branch plate Pb3
valve A1 (17) 10 (16)
22611-11030 22611-12030 (Up)
(S541G259600) 22749-A3080
“1067-04 HYDEX” “9070-04 HYDEX”
Nipple Hose Nipple
541-3465600
T (20) 11 (13)
20U-62-22290 “PF0704, 07230-20210
F4+F4R9×350L”
Adapter T grouping block
(8) -
21X-62-32210 (21X-62-31890)
45° elbow Hose Nipple
B2 (43) 12 541-3465700 (20) Pb4
07236-10210 “PF0704, 20U-62-22290 (Lowering)
F4+F4R9×900L” Control valve

45° elbow Hose Nipple (S542G3867000)
3-fold EPC valve 541-3465700 Pb7
B3 (43) 13 (20)
(S541G2594000) 07236-10210 “PF0704, 20U-62-22290 (Extending)
F4+F4R9×830L”
Nipple Hose Nipple
T (38) 15 541-3466000 (13)
07230-20210 “PA0704, 07230-20210
F4+F4R9×310L”
Adapter T grouping block
(8) -
21X-62-32210 (21X-62-31890)
destination
2-60
4.20.15 SUB LINE 04 (PPC BRACKET TO 2-FOLD SOLENOID VALVE AND 3-FOLD EPC
VALVE)
542-1283400-04

Connection
Hose Nipple
Black 541-3466100
16 (22) P2
(Down) “PLT03, 21U-62-24150
F6E9×720L” 2-fold solenoid
valve
Hose Nipple (S541G259600)
Yellow 541-3466200
17 (22) P1
(Up) “PLT03, 21U-62-24150
F6E9×640L”
PPC bracket Hose Elbow
(21X-62-32310) Blue 18 541-3466300 (42) A1
(Raising) S541J2652000
“PLT03, F6×510L”
Hose Elbow
Red 3-fold EPC valve
19 541-3466400 (42) A2
(Lowering)
S541J2652000 (S541G2594000)
“PLT03, F6×560L”
Hose Elbow
Orange 20 541-3466500 (42) A3
(Extending) S541J2652000
“PLT03, F6×540L”
destination
2-61
4.20.16 SUB LINE 05 (LEFT PPC VALVE TO PPC BRACKET)
LC383M-5-45 Parts
Connection
Joint Hose/Piping Joint Port
destination
Equipment name Port
Name Name Name
No. No. No.
Elbow Hose Orange
P1 (13) 1
K21U-62-24160 K21U-62-38230 (Extending)
Elbow Hose White

P3 (13) 1
K21U-62-24160 K21U-62-38230 (Left) PPC bracket
Elbow Hose Brown (21X-62-32310)
P4 (13) 1
K21U-62-24160 K21U-62-38230 (Right)
Left PPC valve Elbow Hose Green
(702-16-01181) P2 (13) 2
K21U-62-24160 K21U-62-38220 (Retracting)
Hose Nipple Green/

P grouping block
P 3 (13) red
K21X-62-34311 07230-20210 (21X-62-31890)
(P)
Hose Nipple Blue/
T grouping block
T 4 (13) white
K21X-62-34321 07230-20210 (21X-62-31890)
(T)
destination
2-62
4.20.17 SUB LINE 06 (RIGHT PPC VALVE TO PPC BRACKET)
LC383M-5-51 Parts

Connection
Hose Nipple Green/
P grouping block
P 1 (13) red
K20T-62-77791 07230-20210 (21X-62-31890)
(P)
Hose Nipple Blue/
T grouping block
T 1 (13) white
K20T-62-77791 07230-20210 (21X-62-31890)
(T)
Nipple Hose Black
Right PPC valve P1 (12) 2
K21A-62-12360 K21X-62-34342 (Down)
(702-16-01181)
Nipple Hose Yellow
P2 (12) 2
K21A-62-12360 K21X-62-34342 (Up)
PPC bracket
Nipple Hose Blue (21X-62-32310)
P3 (12) 2
K21A-62-12360 K21X-62-34342 (Raising)
Nipple 2 Hose Red
P4 (12) (Lower
K21A-62-12360 K21X-62-34342
ing)
destination
2-63
4.20.18 SUB LINE 07 (2-FOLD SOLENOID VALVE, 3-FOLD EPC VALVE AND 3-FOLD
SOLENOID VALVE TO CONTROL VALVE, ETC.)
542-1283400-05
2-64
Connection
Elbow Hose
branch plate
Control valve Pa8
Pa3 (19) 6 22714SE3125 (16)
(S542G3867000) 22611-12030 (Down)
K22X-61-18550 “PA0704,
“9070-04 HYDEX”
C+CR4×1250L”
45° elbow Hose Elbow Control valve
3-fold EPC valve 541-3465400 Pa4 (S542G3867000)
B1 (43) 7 (18)
(S541G2594000) 07236-10210 “PF0704, 21P-62-11590 (Raising)
F4+F4R9×400L”
Hose Nipple
PPC bracket Pa7
- 8 541-3465500 (22)
(21X-62-32310) 21U-62-24150 (Retracting)
“PLT03, F6×2050L”
Hose CP 4S Elbow
plate
P grouping block
A3 (39) 14 542-4776000 (11) -
Valve assembly 22611-11230 (21X-67-31890)
“PA0704, S542J3779000
3-fold solenoid “1072-04 HYDEX”
C+C×430L”
valve
(S542G3562000) Elbow Hose R2PP 4S Elbow
542-4776100 G Swivel joint
A2 (40) 23 (19) (Travelling
S542J3778000 “PF0704, K22X-61-18550 2-speed) (K703-06-23150)
F4+F4R9×1700L”
Hose Male connector
branch plate
Control valve Pb8 Control valve
Pb3 (16) 24 22714-83053 (17)
(S542G3867000) 22611-12030 22611-11030 (Up) (S542G3867000)
“PA0704,
“9070-04 HYDEX” “1067-04 HYDEX”
C+C×530L”
destination
2-65
4.20.19 SUB LINE 08 (TRAVELLING REMOTE CONTROL VALVE TO CONTROL VALVE
AND 3-FOLD SOLENOID VALVE)
542-1283400-06
2-66
Connection
Male 90° elbow with Male 45° elbow with
Valve assembly Hose SOP 4S
plate plate Travelling remote
3-fold solenoid
A1 (19) 31 542-4776200 (39) P control valve
valve 22611-11130 22611-11230
“PA0304, (S558G3189000)
(S542G3562000) “1071-04 HYDEX” “1072-04 HYDEX”
C+CR9×450L”
Male connector Hose TP 4S Male connector Valve assembly
542-4776300 22611-11035 3-fold solenoid
T (17) 22611-11030 32 (75) T2
“PA0304, “1067-06-04 valve
“1067-04 HYDEX”
C+CR9×450L” HYDEX” (S542G3562000)
Hose Male connector
plate Pb6
4 (39) 33 542-4776400 (17) (Forward
22611-11230 22611-11030 right)
“PA0304,
“1072-04 HYDEX” “1067-04 HYDEX”
C+CR9×900L”
Male long connector Hose
plate Pa6
Travelling remote
3 (71) 22611-52300 34 542-4776500 (19) (Backward
control valve 22611-11130 right)
“1067-04-65A “PA0304,
(S558G3189000) “1071-04 HYDEX”
HYDEX” C+C×300L” Control valve
Male 45° elbow with (S542G3867000)
Hose Male connector
plate Pb5
2 (39) 35 542-4776600 (17) (Forward
22611-11230 22611-11030 left)
“PA0304,
“1072-04 HYDEX” “1067-04 HYDEX”
C+CR9×850L”
Male 90° elbow with Male 45° elbow with
Hose
plate plate Pa5
1 (19) 36 542-4776700 (39) (Backward
22611-11130 22611-11230 left)
“PA0304,
“1071-04 HYDEX” “1072-04 HYDEX”
C+CR9×450L”
destination
2-67
4.20.20 BLADE LINE 01 (CONTROL VALVE TO SWIVEL JOINT)
542-1292900

Connection
Hose BLD 4S Elbow
long plate
F1
A1 (14) 22611-12250 1 (18)
(Down)
“1071-06-74A 542-3585700 K20Y-970-1731
Control valve HYDEX” Swivel joint
(S542G3867000) Male 90° elbow with (K703-06-23150)
Hose BLU 4S Nipple
plate E1
B1 (32) 2 (35)
22611-11150 (Up)
542-3585800 K22J-62-12230
“1071-06 HYDEX”
destination
2-68
4.20.21 BLADE LINE 02 (SWIVEL JOINT TO BLADE CYLINDER)
LC383M-5-083 (Parts)

Connection
Union Hose A
E2 (1) 4
Swivel joint K22L-62-21171 K22L-62-21812 (Up) Blade cylinder
(K703-06-23150) Union Hose B (707-00-0J772)
F2 (1) 5
K22L-62-21171 K22L-62-21822 (Down)
destination
2-69
5. WORK EQUIPMENT
5.1 BOOM ASSEMBLY DIAGRAM
SAM04160
2-70
1. No. 1 boom 19. Extension sheave assembly
2. No. 2 boom 20. Retraction sheave assembly
3. No. 3 boom 23. Foot pin
4. No. 4 boom 24. TC head pin
5. Wire rope 25. Pin
6. Extending wire rope 30. Point pin
7. Retracting wire rope 50. Extending wire adjuster bolt
8. Wire clip assembly 51. Grease nipple
9. Wedge 78. Side pad shim (1.0 t) *1
10. Wedge socket 79. Side pad shim (0.5 t) *1
11. Wedge socket pin 81. Shim *1
17. SSP shim *1 82. Foot pin shim
18. Sheave assembly 87. Grease nipple
[*1]: Adjust so that the clearance is 0 to 0.5 mm.
2-71
5.1.1 BOOM TELESCOPING MECHANISM
1. No. 1 telescopic cylinder

2. No. 2 telescopic cylinder
3. Counterbalance valve
4. Mechanical check valve
5. Sequential valve
6. Sheave (for boom No. 4 extension)
7. Sheave (for boom No. 4 retraction)
8. Wire rope (for boom No. 4 extension)
9. Wire rope (for boom No. 4 retraction)
Brief description
• The boom telescoping mechanism is configured of 2
telescoping cylinders (1) and (2), and boom No. 4
telescoping wire ropes, which serve for extending or
retracting each of the boom Nos.2, 3 and 4.
• Between boom No. 2 telescoping cylinder (1) and boom
No. 3 and No. 4 telescoping cylinder (2), a monolithic
cylinder is installed without any intermediary hydraulic
pipe, and between the oil channels, mechanical check valve
(4) and sequence valve (5) are installed to sequentially
telescope the boom Nos.3 and 4.
• In the hydraulic circuit of the above-mentioned telescoping
cylinders, a counterbalance valve (3) is installed to prevent
any violent fall of the boom caused by abnormal drop of
hydraulic pressure.
2-72
5.2 HOOK ASSEMBLY DIAGRAM
5.2.1 4-FALL AND 2-FALL HOOK BLOCK ASSEMBLY
SAM04190
1. Hook block 2. Sheave pin 3. Hook

4. Hook nut 5. Sheave 6. Sheave collar N
7. Sheave collar 35 L 8. Stopper plate 9. Top guard
10. Top plate 11. Thrust bearing 12. Spring pin
13. Hexagon socket button head screw 14. Spring washer 15. Hexagon socket head cap bolt
16. Plain washer 17. Stopper assembly 22. Grease nipple
23. Hexagon socket set screw
[*1]
Apply Loctite 262 during assembly.
[*2]
Apply Sekisui Silicone Sealant (clear) made by Sekisui Fuller (or equivalent).
2-73
5.3 INSPECTION OF HOOK BLOCK
Hook block is one of the important security parts. Inspect it by following the procedure below, and always use it in a safe
condition.
If any faulty point is found as a result of inspection, repair or replace it promptly.
For the replacement, altering inspection is required.
1. The surface of sheave grooves must be smooth so that the wire rope will not be damaged.
If any sharp edge is found, round it off by using a grinder or the like.
2. Check to ensure that the sheave can be turned smoothly.
If it is reluctant to turn, the wire rope will slip on the sheave grooves, and thus the wire rope may be damaged.
Inspect each sheave bearing, and if it does not turn smoothly, replace it.
3. Check each mounting bolt of the sheave to ensure that it is securely mounted without any damage.
If it is loosened, give it an additional tightening. If it is damaged, replace it.
4. Check the hook nuts to ensure that they are firmly mounted and that they are not damaged.
If it is loosened, give it an additional tightening. If any of the hook nuts is abraded or damaged, replace it.
5. Check the wire rope latch to ensure that it can function normally.
If it fails to function normally, repair or replace it.
6. Check for any crack on the hook by conducting a “magnetic crack detection test” at least once a year.
If any crack is detected, replace it promptly.
7. There are two “punched marks” on the hook. Measure the distance between the punched marks on the hook.
If the measurement results indicate that this dimension has increased by 2% more than the original dimension (dimension a),
replace the hook.
In addition, measure the dimension at the rope hooking part of the hook to determine the local abrasion of the hook.
If the measurement results indicate that this dimension has decreased by 3% below the original dimension (dimension c),
replace the hook.
The dimension between the “punched marks” on the

hook differs between each unit.
Check the original dimension from the “Hook
Structural Drawing” in the manufacturing inspection
documents of the corresponding machine.
XSM02330
2-74
6. ELECTRICAL UNITS
6.1 TRAVEL CONTROL FUNCTION
Function
Travel speed switching
Travelling speed increase Released Depressed
• Selection of the travel speed according to the work site or pedal (Low) (High)
work content has been made possible by employing a Travelling 2-speed
OFF ON
travel speed increase function operated with a travel switching solenoid valve
speed increase pedal. Travel speed
2.9 4.6
• When the travel speed increase pedal is released, the (km/h)
speed is low, and when the pedal is depressed, the speed Travel motor swash plate
Maximum Minimum
angle
is high.
• When the boom length exceeds 3.91 m and the actual load
is 0.3 t or more, the moment limiter control prevents the
speed from increasing even if the pedal is depressed.
2-75
6.2 PPC LOCK FUNCTION
SAM01830
Function
• The PPC lock switch is linked to the lock lever, and when the lock lever is moved to the “Lock” position, the PPC lock switch
turns “OFF”.
• When the PPC lock switch turns “OFF”, the current to the PPC lock solenoid valve is shut off, and the winch, boom derricking,
boom telescoping and slewing do not operate even if the left and right operation levers are operated.
2-76
6.3 CRANE OPERATION UNITS
(1) Operator’s seat (9) Machine monitor

(2) Light switch (10) Starter switch
(3) Lock lever (11) Travel speed increase pedal
(4) Left work equipment operation lever (12) Buzzer cancel switch
(5) Travel lever (13) Moment limiter cancel switch
(6) Accelerator pedal (14) Emergency stop switch
(7) Horn switch (15) Glow lamp
(8) Right work equipment operation lever (16) Foot light
2-77
6.3.1 MACHINE MONITOR
[1] STARTING SCREEN
• When the starter switch is turned “ON”, the starting screen is displayed.
• If the input setting for the operation lock password has been set, the Password for Operation Lock screen is displayed after the
starting screen.
• Then, the standby screen is displayed and the display changes to the home screen.
NOTES
When the engine is started, the battery voltage can suddenly decrease depending on the temperature and battery
condition.
In such a case, the machine monitor display can temporarily disappear, but this is normal.
2-78
[2] HOME SCREEN
(1) User Mode switch (5) Hour meter display

(2) Hook storage switch (6) Time display
(3) Travelling Mode selector switch (7) Working mode display
(4) Fuel gauge (8) Travel 1st speed/2nd speed display
2-79
[3] WARNING DISPLAY AND ERROR CODE DISPLAY
If the warning monitor illuminates in red, immediately stop the work and stop the engine or set it to low idle.
Then, immediately inspect the applicable part and take action for it.
Emergency stop items are those to which you have to pay attention during engine running and when an abnormality
occurs, items for which immediate action must be taken are displayed. When an abnormality occurs, the monitor of the
abnormal part illuminates in red and the buzzer sounds.
(1) Consumables display (5) Engine oil pressure abnormality

(2) Charged capacity abnormality (6) Engine system abnormality
(3) Hydraulic oil temperature abnormality (7) Error code display
(4) Engine coolant temperature abnormality
2-80
[4] USER MODE SWITCH
When the User Mode switch (1) is pressed on the home screen, the User Mode is displayed.
(1-1) Hook number of falls change (1-7) Language setting

(1-2) Working Mode change (1-8) Error history display
(1-3) Software version check (1-9) Switch tone ON/OFF change
(1-4) Consumables display (1-10) Home switch
(1-5) Monitor brightness adjustment (1-11) Display page change
(1-6) Time setting
[1-4] CONSUMABLES DISPLAY

When the switch (1-4) is pressed, the list of consumables can be viewed.
After replacing a consumable, select the replaced consumable with  or 
of the adjustment switch (1-4A). After selecting the consumable, press and
hold the replacement switch (1-4B) to update the replacement time. When
updated, Replaced is incremented up by one and Remaining is reset.
NOTES
• When the engine oil or engine oil filter is replaced, “Did you replace engine?” is
displayed. Select “YES” or “NO”.
• When the winch reduction gear case oil is replaced, “Did you replace winch
reduction gear?” is displayed. Select “YES” or “NO”.
• Usually, select “NO”. Select “YES” only if the engine or reduction gear has
been replaced, because the consumable time will change.
When Always or At startup is selected in the consumables icon display

selection (1-4C), remaining time of 30 h or 3 days is displayed with yellow
characters and a hollow white icon on the home screen, and remaining time
of 0 h or 0 days is displayed with red characters and a solid red icon on the
home screen.
Promptly replace such parts because danger is involved or the machine
body is adversely affected if they are used as they are.
2-81
NOTES
The recommended setting for the consumables icon display selection (1-4C)
is Always.
Always: The consumables icon is always displayed on the home screen
when the replacement timing is approaching or has elapsed.
At startup: The consumables icon is displayed for only 30 seconds after the
home screen starts up when the replacement timing is
approaching or has elapsed.
None: The consumables icon is not displayed on the home screen
when the replacement timing is approaching or has elapsed.
LIST OF CONSUMABLES
Item Replacement cycle
Hydraulic oil filter Every 250 hrs.
Engine oil filter Every 500 hrs. (50 hrs. first time)
Main fuel filter Every 500 hrs.
Cylinder packing ★ Every 3 yrs.
Boom slide plate Every 3 yrs.
Wire rope for hoisting up As required or every 3 yrs.
Wire rope for boom extension As required or every 3 yrs.
Wire rope for boom retraction As required or every 3 yrs.
★ The cycles marked with a “★ ” in Replacement cycle include a halt period.
[1-8] ERROR HISTORY DISPLAY

When the switch (1-8) is pressed, the error history can be viewed.
If a fault is currently occurring, it is displayed in red characters.
2-82
[5] LIST OF ERROR CODES
CC423S-1 LIST OF ERROR CODES (1/2)
Code Display Alarm

classification Error code Details of error display Remedy
icon buzzer
P1202/4 Rack Position Sensor (Low Voltage Abnormality) A 
★
P1203/3 Rack Position Sensor (High Voltage Abnormality) A 
P0122/4 Accelerator Sensor OUT2 (Low Voltage Abnormality)
P0123/3 Accelerator Sensor OUT2 (High Voltage Abnormality)
P0124/2 Accelerator Sensor OUT2 (Intermittent Fault)
P0668/4 ECU Temperature Sensor (Low Voltage Abnormality)
P0669/3 ECU Temperature Sensor (High Voltage Abnormality)
☆
P1664/2 ECU Temperature Sensor (Intermittent Fault)
P0634/0 ECU Temperature Raise Alarm
P0117/4 Coolant Temperature Sensor (Low Voltage Abnormality)
P0118/3 Coolant Temperature Sensor (High Voltage Abnormality)
P0119/2 Coolant Temperature Sensor (Intermittent Fault)
Stop work and wait with the engine
idling to lower the engine coolant
P0217/0 Engine Abnormality (Overheat) C 
temperature until the error
disappears.
P0642/4 Sensor 5V (Low Voltage Abnormality)
P0643/3 Sensor 5V (High Voltage Abnormality)
P1644/2 Sensor 5V (Intermittent Fault) ☆
P0562/1 ECU Power Voltage (Low Voltage Abnormality)
P0563/0 ECU Power Voltage (High Voltage Abnormality)
P0340/4 Revolution Sensor Abnormality A 
P0219/0 Overspeed Abnormality A 
★
P1222/4 Rack Actuator Relay Abnormality A A 
P1223/3 Rack Actuator Relay Abnormality B A 
P1224/2 Rack Actuator Relay Abnormality (Intermittent Fault)
P1232/4 Starting Auxiliary Relay Abnormality A
P1233/3 Starting Auxiliary Relay Abnormality B
P
P1234/2 Starting Auxiliary Relay Abnormality (Intermittent Fault) ☆
P1242/4 CSD Solenoid Valve Abnormality A
P1243/3 CSD Solenoid Valve Abnormality B
P1244/2 CSD Solenoid Valve Abnormality (Intermittent Fault)
P1402/4 EGR Valve Abnormality A (Step Motor A Phase) A 
P1403/3 EGR Valve Abnormality B (Step Motor A Phase) A 
P1412/4 EGR Valve Abnormality A (Step Motor B Phase) A 
P1413/3 EGR Valve Abnormality B (Step Motor B Phase) A 
★
P1422/4 EGR Valve Abnormality A (Step Motor C Phase) A 
P1423/3 EGR Valve Abnormality B (Step Motor C Phase) A 
P1432/4 EGR Valve Abnormality A (Step Motor D Phase) A 
P1433/3 EGR Valve Abnormality B (Step Motor D Phase) A 
Ｐ1198/1 Engine Abnormality (Engine Hydraulic Pressure Low) B  Check the engine oil level.
P1212/4 Rack Actuator (Low Current Abnormality) A 
P1213/3 Rack Actuator (High Current Abnormality) A 
★
P1211/7 Rack Actuator (Mechanical Fault) A 
P1214/2 Engine abnormality A 
P0605/12 ECU FlashROM Abnormality (Checksum A)
P1605/2 ECU FlashROM Abnormality (Checksum B)
P1606/2 ECU FlashROM Abnormality (Checksum C)
P1620/12 ECU Map Format Abnormality
P1601/2 ECU EEPROM Abnormality (Checksum)
P0601/12 ECU EEPROM Abnormality (Read/Write Fault) ☆
P1610/12 ECU Sub CPU Abnormality A
P1611/12 ECU Sub CPU Abnormality B
P1612/12 ECU Sub CPU Abnormality C
P0686/4 Main Relay System Abnormality
U0001/12 Controller abnormality
• If the error is not resolved even after performing the remedy, contact us or our sales service agency.
• For items indicated with ★ in Remedy, stop the machine immediately and contact us or our sales service agency.
• For items marked with ☆ in Remedy, some functions are restricted but work is possible. Display icon Content
　After finishing work, be sure to perform inspection and maintenance.
　If necessary, contact us or our sales service agency. A Engine abnormality
Low engine
B hydraulic pressure
Alarm for raised

C coolant temperature
(overheat)
2-83
CC423S-1 LIST OF ERROR CODES (2/2)
Rotary
Code Display Alarm
classification Error code Details of error display Lamp Remedy
icon buzzer
RED
EO02L 3-fold Solenoid Valve Boom Low er SOL Open (3-fold EPC Valve)  
EO02H 3-fold Solenoid Valve Boom Low er SOL Short (3-fold EPC Valve)  
EO03L 3-fold Solenoid Valve Boom Raise SOL Open (3-fold EPC Valve)  
★
EO03H 3-fold Solenoid Valve Boom Raise SOL Short (3-fold EPC Valve)  
EO04L 3-fold Solenoid Valve Boom Extend SOL Open (3-fold EPC Valve)  
EO04H 3-fold Solenoid Valve Boom Extend SOL Short (3-fold EPC Valve)  
EO05L PPC Solenoid Valve Travel Hi SOL Open (3-fold SOL Valve)
EO05H PPC Solenoid Valve Travel Hi SOL Short (3-fold SOL Valve)
EO06L Winch Low Pressure Shift SOL Open
EO
EO06H Winch Low Pressure Shift SOL Short
EO09L 2-fold Solenoid Valve Hoist Up Stop SOL Open (2-fold SOL Valve)
☆
EO09H 2-fold Solenoid Valve Hoist Up Stop SOL Short (2-fold SOL Valve)
EO10L 2-f old Solenoid Valv e Hoist Down Stop SOL Open (2-f old SOL Valv e)
EO10H 2-fold Solenoid Valve Hoist Down Stop SOL Short (2-fold SOL Valve)
EO12L PPC Solenoid Valve Travel PPC SOL Open (3-fold SOL Valve)
EO12H PPC Solenoid Valve Travel PPC SOL Short (3-fold SOL Valve)
EO15L Sensor 12V Power (Low Voltage)  
EO15H Sensor 12V Power (High Voltage)  
ES02L Derrick Pressure Sensor 1 (Low voltage)  
ES02H Derrick Pressure Sensor 1 (High voltage)  
ES03L Derrick P-Sensor 2 Voltage (Low)  
★
ES03H Derrick Pressure Sensor 2 (High voltage)  
ES04L Length Sensor (Low Voltage)  
ES04H Length Sensor (High Voltage)  
ES05L Angle Sensor (Low Voltage)  
ES05H Angle Sensor (High Voltage)  
ES06L Pump Pressure Sensor 1 (Low Voltage )
ES06H Pump Pressure Sensor 1 (High Voltage)
ES07L Pump Pressure Sensor 2 (Low Voltage)
ES ES07H Pump Pressure Sensor 2 (High Voltage)
ES08L Pump Pressure Sensor 3 (Low Voltage)
☆
ES08H Pump Pressure Sensor 3 (High Voltage)
ES09L PPC Pressure Sensor (Low Voltage)
ES09H PPC Pressure Sensor (High Voltage)
ES10L Hyd. Oil Temp Sensor(Low Voltage)
ES10H Hyd. Oil Temp Sensor (High Voltage)
ES11L Inclination Sensor (Low Voltage)  
★
ES11H Inclination Sensor (High Voltage)  
ES12L Accelerator Pedal (Low Voltage)
ES12H Accelerator Pedal (High Voltage) ☆
ES13H Fuel Sensor Resistance (High Resistance)
TTC36 Controller abnormality  
TTC ★
ECU ECU Communication Abnormality  
Inspect the battery voltage and
EV001 Battery Voltage Abnormality D  
specific gravity.
Inspect the alternator and fan belt
EV007 Charge Abnormality D 
tension.
EV
EV008 TTC60 Sensor Power 5V0 Abnormality   ★
EV009 TTC36X Sensor Power 5V0 Abnormality ☆
Stop work and wait with the engine

idling or stopped to lower the
EH ＥＨ０１ Hydraulic Oil Temperature Abnormality E 
hydraulic oil temperature until the
error disappears.
• If the error is not resolved even after performing the remedy, contact us or our sales service agency.
• For items indicated with ★ in Remedy, stop the machine immediately and contact us or our sales service agency.
• For items marked with ☆ in Remedy, some functions are restricted but work is possible.
　After finishing work, be sure to perform inspection and maintenance.
　If necessary, contact us or our sales service agency.
2-84
[6] I/O LIST
[PIN ARRAY: MACHINE MONITOR]
1 9
10 17
18 25
26 34
2-85
[I/O LIST: MACHINE MONITOR]
Value of Resistance Maximum Continuous
Pin
Signal name Type Signal logic Remarks resistance range current current
No.
[Ω] [Ω] [A] [A]
1 GND Power supply - 0.000
26 +12 V Power supply 9 V: 0.8 A, 12 V: 0.6 A 25 0.533 0.533
18 Ignition K15 Input 10,000 0.001 0.001
13 CAN0-H CAN Open - 0.000
5 CAN0-L CAN Open - 0.000
12 CAN1-H CAN - 0.000
4 CAN1-L CAN - 0.000
16 Front view camera - - 0.000
9 Front view camera - 0.150 0.150
14 Side view camera - - - 0.000
7 Side view camera - - 0.150 0.150
19 - - - - - 0.000
28 Ethernet TX + For debugging - 0.000
20 Ethernet TX - For debugging - 0.000
29 Ethernet RX + For debugging - 0.000
21 Ethernet RX - For debugging - 0.000
30 5 V power supply for USB For debugging - 0.000
22 USB D+ For debugging - 0.000
31 USB D- For debugging - 0.000
23 USB GND For debugging - 0.000
32 - - - - - 0.000
24 - - - - - 0.000
33 - - - - - 0.000
25 - - - - - 0.000
34 - - - - - 0.000
3 - - - - - 0.000
11 - - - - - 0.000
27 - - - - - 0.000
2-86
6.4 FUSE
Be sure to turn the power OFF (turn the starter switch to OFF) before replacing a fuse.
CAUTION
Fuses protect electrical components and wires from being burnt out.
If a fuse is corroded and shows white powder or there is looseness between the fuse holder and fuse, be
sure to replace the fuse.
Replace the fuse with a fuse of the same capacity.
The fuse box is located under the operator’s seat.
Fuse capacity and circuit name

Fuse
No. Connection table
capacity
(1) 10A Emergency operation power supply
(2) 5A Operation switch
(3) 20A Controller I/O power supply
(4) 5A Controller K15, monitor power supply
(5) 10A Headlamps, Boom working lamp
(6) - -
(7) 10A Horn
(8) - -
(9) - -
(10) - -
(11) 5A PPC lock
(12) - -
(13) - -
(14) 5A Multilayer rotary lamp, sound alarm
Controller control power supply, Monitor
(15) 5A
control power supply
(16) 10A ECU output power supply
(17) 5A IOT unit power supply
(18) 10A Starter SW B
(19) 5A Starter SW ACC secondary side
(20) 5A Starter SW C secondary side
2-87
6.5 CONTROLLER
6.5.1 I/O LIST
[PIN ARRAY: TTC60]
2-88
[I/O LIST: TTC60]
Pin
No.
[Ω] [Ω] [A] [A]
Pull-Up (1.2 kΩ)
P152 Fuel sender Resistice 0 to 65 kΩ E: 155 Ω to F: 1 Ω - 0.000
(Input error: ±3Ω)
Hydraulic oil temperature
P140 Voltage 0 to 5 V (Absolute) Variable range: 1 to 5 V Pull-Down (100 kΩ) - 0.000
sensor
Voltage 0 to 5 V (Ratiometric)
P151 Inclination sensor X Variable range: 0.5 to 4.5 VPull-Down (100 kΩ) - 0.000
Standard power supply port: 0
P139 Inclination sensor Y Variable range: 0.5 to 4.5 VPull-Down (100 kΩ) - 0.000
Voltage 0 to 5 V (Ratiometric) Variable range: 0.13 to
P150 Length meter Pull-Down (100 kΩ) - 0.000
Standard power supply port: 0 2.72 V
Voltage 0 to 5 V (Ratiometric) Variable range: 0.61 to
P138 Angle meter Pull-Down (100 kΩ) - 0.000
Standard power supply port: 0 2.15 V
P149 Derricking pressure sensor 1 Variable range: 0.5 to 4.5 VPull-Down (10 kΩ) - 0.000
P137 Derricking pressure sensor 2 Variable range: 0.5 to 4.5 VPull-Down (10 kΩ) - 0.000
P126 Pump pressure sensor 1 (P3) Voltage 0 to 5 V (Absolute) Variable range: 1 to 5 V Pull-Down (10 kΩ) -
P113 PPC pressure sensor Voltage 0 to 5 V (Absolute) Variable range: 1 to 5 V Pull-Down (10 kΩ) -
P124 Travel speed increase SW Voltage 0 to 15 V (Absolute) Hi: Active Pull-Up (10 kΩ)
PPC hydraulic pressure lock
P112 Voltage 0 to 15 V (Absolute) Hi: Active Pull-Down (10 kΩ)
(unlock) control (for display)
P123 Override SW Voltage 0 to 15 V (Absolute) Hi: Active Pull-Down (10 kΩ)
P111 - - - -
Pull-Up (10 kΩ)
Winch hoist down pressure
P275 Digital In (Pull Up) Low: Active (Pressure SW minimum current 1,500 0.009 0.009
SW
0.5 mA)
Pull-Up (10 kΩ)
P268 Winch hoist up pressure SW Digital In (Pull Up) Low: Active (Pressure SW minimum current 0.000 0.000
0.5 mA)
Pull-Up (10 kΩ)
P274 Derrick lowering pressure SW Digital In (Pull Up) Low: Active (Pressure SW minimum current 0.000 0.000
0.5 mA)
Pull-Up (10 kΩ)
P267 Derrick raising pressure SW Digital In (Pull Up) Low: Active (Pressure SW minimum current - 0.000
0.5 mA)
P263 Emergency release SW Digital In (Strong Pull Down) Hi: Active Pull-Down (1.8 kΩ) 1,500 0.009 0.009
P256 Emergency stop switch Digital In (Pull Up) Low: Active Pull-Up (9.1 kΩ) 1,500 0.009 0.009
P262 Buzzer cancellation SW Digital In (Strong Pull Down) Hi: Active Pull-Down (1.8 kΩ) 1,500 0.009 0.009
Pull-Up (9.1 kΩ)
Searcher extension detection
P255 Digital In (Pull Up) Low: Active (External Pull-Up resistance 120 Ω 1,500 0.009 0.009
LS
required)
Pull-Up (9.1 kΩ)
P261 Dead turns detection LS Digital In (Pull Up) Low: When normal (External Pull-Up resistance 120 Ω 1,500 0.009 0.009
required)
Pull-Up (9.1 kΩ)
P254 Overwind detection LS Digital In (Pull Up) Low: When normal (External Pull-Up resistance 120 Ω - 0.000
required)
Pull-Up (9.1 kΩ)
P260 Lowering detection LS Digital In (Pull Down) Hi: When normal - 0.000
(Very small load type LS used)
Pull-Up (9.1 kΩ)
P253 Raising detection LS Digital In (Pull Down) Hi: When normal - 0.000
P144 Travelling Hi/Low shift SOL Digital Out - - - 0.000
P132 Low pressure output SOL Digital Out - - 19 0.703 0.703
Hook stowage (Hoist up stop
P143 Digital Out - - 450 0.030 0.030
SOL)
P131 - - - - 8 1.688
P142 ML buzzer (Continuous) Digital Out - - 8 1.688
Inclination buzzer (Cooing
P130 Digital Out - - 8 1.688
sound)
Start relay lock (Password
P141 Digital Out - - - 0.000
lock)
Power supply output for
P129 Digital Out - Firm output - 0.000
inclination, pressure and LS
P118 - - - - - 0.000
P106 Boom lowering stop SOL Current FB 1 - - - 0.000
P117 Boom raising stop SOL Current FB 2 - - - 0.000
P105 Boom extension stop SOL Current FB 3 - - - 0.000
P116 Wind-down stop SOL - - - - 0.000 0.000
P104 Wind-down stop SOL - - - - 0.000 0.000
P115 PPC cut relay - - - - 0.000
P103 EMO Control Relay - - - - 0.000
P120 - - - - - 0.000
Boom lowering stop SOL
P108 Current Measurement Input 1 - - - 0.000
return
P119 Boom raising stop SOL return Current Measurement Input 2 - - - 0.000
Boom extending stop SOL
P107 Current Measurement Input 3 - - - 0.000
return
6.5 + 6.5 + 5 + 1 = 19 mA
P136 Sensor 5 V 2,300 0.006 0.006
(Pressure, angle, length sensor)
P148 Sensor 5 V - 0.000
P135 Sensor 5 V 2,500 0.005 0.005
P147 Sensor 5 V - 0.000
P133 AGND - 0.000
P134 AGND - 0.000
P145 AGND - 0.000
P146 AGND - 0.000
P279 CAN0-H CAN Open - 0.000
P273 CAN0-L CAN Open - 0.000
P272 CANO-H terminal resistance Terminal pin - 0.000
P280 CANO-L terminal resistance Terminal pin - 0.000
P271 Ignition K15 Input 10,000 0.001 0.001
P102 GND Max 17 A - 0.000
P101 +12 V 9 V: 0.15 A, 12 V: 0.11 A 135 0.100 0.100
P127 +12 V - 0.000
P128 +12 V - 0.000
2-89
[PIN ARRAY: TTC36X]
2-90
[I/O LIST: TTC36X]
Pin
No.
[Ω] [Ω] [A] [A]
P152 - - - - - 0.000
P140 - - - - - 0.000
P151 - - - - - 0.000
P139 - - - - - 0.000
P150 - - - - - 0.000
P138 - - - - - 0.000
P149 - - - - - 0.000
P137 Accelerator - Pull-Down (100 kΩ) - 0.000
P275 - - - - 1,500 0.009 0.009
P268 - - - - 0.000 0.000
P274 - - - - 0.000 0.000
P267 - - - - - 0.000
P116 - - - - 10,000 0.001 0.001
Pull-Up (10 kΩ)
(Pressure SW minimum current
P104 Travel pressure SW - - 0.5 mA) 10,000 0.001 0.001
(Beware of sneak circuit to power
supply)
P115 - - - - - 0.000
P103 - - - - - 0.000
P263 - - - - 1,500 0.009 0.009
Pull-Up (9.1 kΩ)
Telescope extension pressure
P256 Digital In (Pull Up) Low: Active (Pressure SW minimum current 1,500 0.009 0.009
SW
0.5 mA)
P262 - - - - 1,500 0.009 0.009
P255 - - - - 1,500 0.009 0.009
P261 Engine charge Digital In (Pull Down) Hi: Engine operating Pull-Down (9.1 kΩ) 1,500 0.009 0.009
Pull-Up (9.1 kΩ)
P254 Engine hydraulic pressure SW Digital In (Pull Up) Low: Low oil pressure - 0.000
(External Pull-Up resistance 120 Ω
required)
P260 - - - - - 0.000
P253 - - - - - 0.000
P144 Rotary Lamp: Red Digital Out - - 0.000 0.000
P132 Rotary Lamp: Yellow Digital Out - 19 0.703 0.703
P143 Rotary Lamp: Green Digital Out - 450 0.030 0.030
P131 - - - 8 1.688
P142 Audio output 1 Digital Out - 8 1.688
P130 Audio output 2 Digital Out - 8 1.688
P141 Audio output 3 Digital Out - - 0.000
P129 Travel PPC SOL Digital Out - - 0.000
P118 - - - - - 0.000
P106 - - - - - 0.000
P117 - - - - - 0.000
P105 - - - - - 0.000
P120 - - - - - 0.000
P108 - - - - - 0.000
P119 - - - - - 0.000
P107 - - - - 0.000
20 mA
P136 Sensor 5 V 2,300 0.006 0.006
(Accelerator sensor)
P148 Sensor 5 V - 0.000
P135 Sensor 5 V 2,500 0.005 0.005
P147 Sensor 5 V - 0.000
P133 AGND - 0.000
P134 AGND - 0.000
P145 AGND - 0.000
P146 AGND - 0.000
P279 CAN0-H CAN Open - 0.000
P273 CAN0-L CAN Open - 0.000
P272 CANO-H terminal resistance Terminal pin - 0.000
P280 CANO-L terminal resistance Terminal pin - 0.000
P271 Ignition K15 Input 10,000 0.001 0.001
P102 GND Max 17 A - 0.000
P101 +12 V 9 V: 0.15 A, 12 V: 0.11 A 135 0.100 0.100
P127 +12 V - 0.000
P128 +12 V - 0.000
2-91
6.5.2 MAIN HARNESS
(1/3)
542-1282900-2
2-92
(2/3)
542-1282900-2
2-93
(3/3)
542-1282900-3
2-94
6.5.3 FLOOR HARNESS
542-1283000
2-95
6.6 SENSORS
• The signals from the sensors are input directly into the panel.
• One side of the contact type sensors is always connected to the machine body ground.
Display classification Sensor type Sensor method When normal When abnormal
Caution Engine oil pressure Contact OFF (open) ON (closed)
Coolant temperature Resistance - -

Gauge
Fuel level Resistance - -
6.6.1 ENGINE OIL PRESSURE SENSOR
1. Plug 3. Contactor 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal
6.6.2 COOLANT TEMPERATURE SENSOR
SBP00379
1. Connector 2. Plug 3. Thermistor
2-96
6.6.3 INCLINATION SENSOR
1. Connector 2. Bullet type connector 3. Sensor
2-97
6.6.4 PRESSURE AND OIL TEMPERATURE SENSOR
S578J3277000
1. Mechanical structure
1. Connection screw M18 × 1.5 P (ISO 6149/2)
2. Medium contact part 17-4 PH Stainless Steel
3. Connector connection shape Deutsch DT04-4P
4. Protection structure IP67
5. Recommended tightening torque 70 to 77 N·m
6. Terminal arrangement Code 8
Pin No. Function
1 Common (0 V)
2 Power supply (+)
3 V out 2 (temperature output)
4 V out 1 (pressure output)
Specifications
Pressure range 0 to 40 MPa
Withstand pressure 80 MPa
Power supply voltage 12 VDC ± 10%
Mechanical accuracy ± 0.25% FS (Overall value of non-linearity, hysteresis, and reproducibility)
Operating temperature range -40 to +105°C
2-98
6.6.5 PRESSURE SWITCH
S578J3276000
Specifications
Service pressure range 0 to 3.9 MPa
OFF 0.294 ± 0.049 MPa
Operating pressure
ON 0.49 ± 0.098 MPa
Power supply voltage 5 to 32 VDC
Consumption current 0.5 mA to 1 A resistance load
Pressure drop 0.2 V or less at 1 A
Insulation resistance 100 MΩ minimum
2-99
6.6.6 FUEL LEVEL SENSOR
B4P21205
1. Float 3. Bracket
2. Connector 4. Variable resistor
2-100
7. MOMENT LIMITER
7.1 CONFIGURATION OF MOMENT LIMITER
(1) Boom length meter (left side of boom)

(2) Boom angle meter (left side of boom)
(3) Pressure sensor (derricking cylinder section) (2 pieces)
(4) Overwind detector (side of boom tip)
(5) 3-colour rotary lamp
(A) Red rotary lamp (warning lamp when load factor is 100% or more)
(B) Yellow rotary lamp (prediction lamp when load factor is 90 to less than 100%)
(C) Green rotary lamp (operation lamp when load factor is less than 90%)
(6) Moment limiter display part (machine monitor)
(7) Moment limiter cancelling switch
2-101
7.2 MONITOR DISPLAY OF MOMENT LIMITER
(1) Load factor display (9) Boom angle upper limit display
(2) Actual load display/rated total load display (10) Working radius upper limit display
(3) Boom angle display (11) Lifting height upper limit display
(4) Actual work radius display/rated work radius display (12) Lifting height upper limit switch
(5) Boom length display (13) Boom angle upper limit/lower limit switch
(6) Lifting height display (14) Working radius upper limit switch
(7) Number of wire falls display (15) Setting check/cancellation switch
(8) Boom angle lower limit display
2-102
7.3 SENSOR ASSEMBLY
542-2245700
2-103
7.3.1 LENGTH METER REEL
S541M2822000
Specifications
Cord wire diameter ø0.87
Main cord 15.15 m
Cord length
Sub-cord 0.43 m
Mass Approx.5 kg
Resistance value 5,000 ± 250 Ω
Potentiometer Electrical rotation angle 350 ± 1.5°
Mechanical rotation angle 360°
Reduction ratio of reduction gear 1/50
2-104
1. Case 18. Clip 35. Hexagon nut
2. Base plate 19. Clamp 36. Spring washer
3. Super lock 20. Terminal 37. Pan head small screw with washer
4. Flat spiral springs assembly 21. Terminal 38. Housing (male)
5. Contact ring assembly 22. Cable assembly 39. Plain washer
6. Contact assembly 23. Cord guide 40. Countersunk head small screw
7. Bearing 24. Packing 41. Vinyl tube
8. Snap ring 25. Packing 42. Protector
9. Snap ring 26. Packing 43. Pan head small screw with washer
10. Bearing case 27. Terminal 44. Hexagon nut
11. Reduction gear 28. Grommet 45. Irrax wire
12. Gear 29. Hexagon socket set screw 46. Irrax wire
13. Bracket 30. Nut 47. Irrax wire
14. Potentiometer 31. Countersunk head small screw 48. Lead wire
15. Return spring 32. Special washer 49. Main cord
16. Cover 33. Countersunk head small screw
17. Clip 34. Hexagon head bolt with washer
2-105
7.3.2 ANGLE DETECTOR
S556-M15410
Specifications
Rated voltage 5 VDC
Detection angle -12 to 98°
5 VDC across connectors 1 (red) and 3 (black)
Output voltage Across connectors 2 (white) and 3 (black) - Boom angle of 0 degree: 0.75 ± 0.023 V
Across connectors 2 (White) and 3 (Black) - Boom angle of 80 degrees: 1.92 ± 0.058 V
Across connectors 2 (white) and 3 (black) - Boom angle of 0 degree: 150.0 ± 4.5 Ω
Resistance value
Across connectors 2 (White) and 3 (Black) - Boom angle of 80 degrees: 385.0 ± 12.0 Ω
Sensitivity 0.0146 V/° (2.938 Ω/°)
2-106
1. Case 12. Terminal
2. Cap 13. Element
3. Weight 14. Print paper
4. Arm 15. Shaft
5. Terminal block 16. Bearing
6. O-ring 17. Plain washer
7. Damper oil 18. Rotor mould
8. Wire 19. Rotor arm
9. Cable tie 20. Slip spring plate
10. Potting 21. Collar
11. Element case
2-107
7.3.3 PRESSURE AND OIL TEMPERATURE SENSOR
S200J3315000
2-108
Specifications
Manufacturer model 3101T0250S2L8000 Danaher ICG Japan
Pressure range 0 to 25 MPa
Withstand pressure 50 MPa
Secular change ±0.1% FS/year
±0.25% FS
Mechanical accuracy
(Overall value of non-linearity, hysteresis and reproducibility)
±0.2% FS
Mechanical stability
(10,000,000 cycles, after application of FS pressure)
Temperature characteristics ±0.15% FS/10°C
Temperature output range -40 to +125°C
Temperature compensation range -40 to +105°C
Zero tolerance ±0.5% FS
Span tolerance ±0.5% FS
Response time 1 ms
Protection structure IP67
Vibration 40 G: Peak sine wave
Shock In conformity with the drop test of IEC68-2-32 procedure 1
Output 0.5 to 4.5 VDC
Input voltage 5 VDC ± 10%
Consumption current MAX 6.5 mA (with no load)
2-109
7.4 BOOM DERRICKING LIMIT SWITCH
542-1282900
1. Adjust the boom raising limit switch so that the boom raising motion stops at a boom angle of 80°+0
-1
while the machine body
is kept horizontal.
2. Adjust the boom lowering limit switch so that the boom lowering motion stops at a boom angle of 0°+1
-0 while the machine
body is kept horizontal.
2-110
7.5 OVERWINDING PREVENTION DEVICE
542-2250100
7.5.1 OPERATING PRINCIPLES

Over-hoisting the hook causes the hook to push up the protect weight that is hung via the wire rope and actuates the overwind
detector switch. The contact of the overwind detector switch (N. C) opens and the corresponding signal is input into the overwind
stop relay controller HY-TTC60 to stop the hoisting up and boom extension.
The hook displayed on the monitor display part flashes in red at the same time. When a hoisting up or boom extension operation
is input, a brief intermittent alarm sounds.
2-111
7.6 OVER UN-WINDING DETECTION DEVICE
SAM04250
When the hook is hoisted down and length of wire rope in the winch drum
becomes short:
• The winch displayed on the monitor flashes in red.
• When hook lowering operation is performed, the alarm issues an intermittent
sound “peep”.
• The hook lowering action is automatically stopped.
2-112
7.7 MOMENT LIMITER OVERVIEW AND SPECIFICATIONS
7.7.1 OVERVIEW
The derricking cylinder pressure is detected with the pressure and oil temperature sensor, the boom-to-ground angle is detected
with the angle detector, and the boom length is detected with the length meter, and the corresponding values are indicated on the
display part in the operator's cabin. When the hoisted load reaches the prediction zone or alarm zone of the rated load relative to
the working radius, the alarm and control signal are output.
7.7.2 SPECIFICATIONS
Item CC423S-1
Moment limiter type Automatic stop type
Crane rated load 0 to 2.9 t [Pressure range: 0 to 25 MPa {0 to 255 kg/cm2}]
Power supply 5 VDC
Calibration Electrical calibration
Operating temperature Display part -10 to 60°C

range Operator part -10 to 50°C
Storage temperature range -30 to 70°C
Humidity range 95% RH or less (no condensation)
7.8 CALIBRATION OF MOMENT LIMITER

• For the calibration procedure of the moment limiter, refer to the description under “CRANE CALIBRATION” in “SERVICE
MODE”.
2-113
REFERENCE VALUES
1. TABLE OF ENGINE RELATED REFERENCE VALUES 3-2
2. CRANE OPERATING PRESSURE 3-3
3. TABLE OF MACHINE RELATED REFERENCE VALUES 3-4
4. TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES 3-7
3-1
1. TABLE OF ENGINE RELATED REFERENCE VALUES
New Vehicle
Item Measurement Condition Unit Failure Criteria
Reference
High idling rpm 2,430 ± 50 -
Revolution speed
Low idling rpm 1,250 ± 50 -
Valve clearance Intake valve mm 0.15 to 0.25 -
(Ordinary temperature) Exhaust valve mm 0.15 to 0.25 -
Oil temperature: 40 to 60°C
Compression pressure 3.33 to 3.53 2.65 to 2.85
(Engine revolution speed: 250 MPa {kg/cm2}
(SAE30 oil) {34 to 36} {27 to 29}
rpm)
(Within coolant temperature
operating range) 0.34 to 0.49 0.2 or more
MPa {kg/cm2}
Engine lubricating oil At high idle {3.5 to 5.0} {2.0 or more}
pressure (SAE30W oil)
At low idle 0.06 or more 0.1 or more
MPa {kg/cm2}
(SAE30W oil) {0.6 or more} {1.0 or more}
Engine lubricating oil Entire revolution area
°C 120 or less 120 or less
allowable temperature (inside oil pan)
Between fan pulley and alternator When new: 5 to 8
Tension of fan belt pulley: Deflection amount with mm -
force of 98 N {10 kg} When used: 7 to 10
3-2
2. CRANE OPERATING PRESSURE
• Hydraulic oil temperature: 45 to 55°C
• Engine: High idling
• Operating under no load MPa {kg/cm2}
Measurement New Vehicle Failure
Operating Pressure Measurement Port
Condition Reference Criteria
3.4  1.0
Raising 0° to 80° Derricking cylinder A port -
{35  10}
Boom stage 1
20.6
Lowering 80° to 0° Derricking cylinder B port -
{210}
4.9
Stage 1  2 -
{50}
Extension Telescoping cylinder A port
7.4
Stage 1  4 Boom 60° -
{75}
21.1
Retractin Stage 4  1 Telescoping cylinder B port -
{215}
4.9 to 5.9
Hoisting up Winch B port -
Boom 60° {50 to 60}
Winch 4th layer 8.8
Hoisting down Winch A port -
{90}
Boom stage 1, 12.3
Slewing (left/right) Operation valve A2/B2 port -
fully raised {125}
3.9 to 4.4
1 speed Iron shoes -
Travelling {40 to 45}
Travel motor A/B port Flat cement road
(forward/backward) 5.4 to 6.4
2 speed surface -
{55 to 65}
Blade cylinder A port (head G. L to upper 15.2
Up -
side) limit {155}
Blade
Operation valve A1 port Upper limit to 4.4
Down -
(pressure sensor inlet) G. L {45}
3-3
3. TABLE OF MACHINE RELATED REFERENCE VALUES
New Vehicle
Reference
• Hydraulic oil temperature: 45 to 55℃
• Engine oil pressure: Within operating range
Engine revolution speed • Engine coolant temperature: Within rpm 2,060 or more -
(during pump relief) operating range
• Boom retraction relief
• Accelerator full
Operation lever stroke
Derricking operation • Oil temperature:
N  Raise/Lower 95 ± 10 95 ± 10
lever 45 to 55°C
Telescopic operation • Centre of lever
grip N  Extend/Retract 95 ± 10 95 ± 10
lever
Hoisting up/down • Pedal tip
• Read the N  Hoist up/down 95 ± 10 95 ± 10
operation lever
maximum value
Slewing operation lever N  Left/Right slewing 95 ± 10 95 ± 10
up to stroke end
Blade operation lever • Engine stop N  Up/Down mm 50 ± 5 50 ± 5
N
Travelling operation lever 135 ± 10 135 ± 10
Forward/Backward travel
Crane/Slewing 5 or less 5 or more
Play amount of operation
Travelling 4 or less 4 or more
lever
Blade operation 15 or less 15 or more
Operation lever force
Derricking operation • Engine high idling 14.7 ± 2.9 14.7 ± 5.88
lever • Hydraulic oil temperature: 45 to 55°C {1.5 ± 0.3} {1.5 ± 0.6}
Telescoping operation • Measure the operation lever by applying a 14.7 ± 2.9 14.7 ± 5.88
lever push-pull scale to the centre part of the grip. {1.5 ± 0.3} {1.5 ± 0.6}
Hoisting up/down • Read the maximum value up to stroke end 14.7 ± 2.9 14.7 ± 5.88
operation lever N {1.5 ± 0.3} {1.5 ± 0.6}
{kg} 14.7 ± 2.9 14.7 ± 5.88
Slewing operation lever
{1.5 ± 0.3} {1.5 ± 0.6}
20.6 ± 3.9 20.58 ± 7.84
Blade operation lever
{2.1 ± 0.4} {2.1 ± 0.8}
19.0 ± 3.9 19.0 ± 3.9
Travelling operation lever
{1.9 ± 0.4} {1.9 ± 0.4}
Oil pressure
• Hydraulic oil temperature: 45 to 55°C P1 1.3 ± 0.3 1.3 ± 0.3
• Engine high idling
P2 {13.5 ± 3.0} {13.5 ± 3.0}
• All operation levers at neutral
Unload pressure • Pump outlet pressure (operation valve P1, 1.0 ± 0.2 1.0 ± 0.2
P2, P3 port) P3
{10 ± 2} {10 ± 2}
• Return pressure (operation valve T1 or T2 0.5 ± 0.1 0.5 ± 0.1
port) MPa T
{5.0 ± 1} {5.0 ± 1}
Derricking relief pressure • Hydraulic oil temperature: 45 to 55°C {kg/cm2} 20.1 to 21.6 20.1 to 21.6
(A2 port) • Engine high idling Target {205 to 220} {205 to 220}
Telescopic relief pressure • Pump outlet pressure (pump A1, A2, A3 value 20.1 to 21.6 20.1 to 21.6
(A1 port) port) (range) {205 to 220} {205 to 220}
Blade relief pressure • Relieve pressure only from the circuit to be 20.1 to 21.6 20.1 to 21.6
(A3 port) measured. {205 to 220} {205 to 220}
Travelling relief pressure 24.0 to 25.5 24.0 to 25.5
(A1, A2 port) {245 to 260} {245 to 260}
control 2.8 to 3.2 2.8 to 3.2
(P port of PPC solenoid valve) {28.6 to 32.6} {28.6 to 32.6}
3-4
New Vehicle
Reference
Work speed
• Boom: Stage 1, fully raised 22.3 to 27.3
Time required for slewing 20.0 to 29.6
• No load (24.8)
• Time required for one turn (after preliminary
running for one turn)
• Speed increase pedal ON
7.0 to 8.6
Travel speed • Boom: Stage 1, Angle: 0 to 4° 6.2 to 9.4
(7.8)
• Time required for travelling 10 m after
preliminary running for 5 m or more on flat
ground
• Hydraulic oil temperature: Fully lowered 10.7 to 13.1
9.5 to 14.3
45 to 55°C to fully raised (11.9)
Derricking speed • Engine high idling
Fully raised to 25.7 to 31.5
• Boom length: Boom 22.7 to 34.5
fully lowered (28.6)
stage 1
Fully retracted sec
12.9 to 15.7
• Hydraulic oil temperature: to fully 11.4 to 17.2
(14.3)
45 to 55°C extended
Extension speed
• Engine high idling Fully extended
14.8 to 18.0
• Boom angle: 60° to fully 13.3 to 19.5
(16.4)
retracted
• Hydraulic oil temperature: 16.3 to 19.9
Hoisting up 14.7 to 21.5
45 to 55°C (18.1)
Hoisting up and down
• Boom length 5.0 m, Angle
speed 16.8 to 20.6
70° Hoisting down 15.2 to 22.2
(18.7)
• Hook on ground to
overwind stop
Up
1.9 to 2.5
(Ground to 1.6 to 2.8
• Hydraulic oil temperature: (2.2)
upper limit)
Blade speed 45 to 55°C
Down
• Engine high idling 2.3 to 2.9
(Upper limit to 2.0 to 3.2
(2.6)
ground)
Natural Descending Amount
Cylinder rod
Derricking cylinder 5 or less 5 or more
• Boom stage 2 displacement
• Working radius Displacement of the
Telescopic cylinder 1.5 m length meter wires and 5 or less 5 or more
• Total load 2.93 t the booms
• 10-minute Displacement of
Winch dwelling hoisting wire and boom mm 5 or less 5 or more
No. 1
• Hydraulic oil
• Cutting edge
temperature: 45 to
lowering amount
Blade 55°C 30 or less 36 or more
from maximum
• 15-minute
raised position
dwelling
Travel deviation inspection
• Allow the vehicle to be in a travelling posture.
★ The travelling posture should be such that the boom is fully retracted,
boom is kept horizontal, and the hook block is stowed.
Low speed: Low speed:
(See Fig.1.)
500 or less 550 or more
• Hydraulic oil temperature: 45 to 55°C mm
High speed: High speed:
300 or less 330 or more
• After preliminary running for 10 m or more, measure the swaying amount
during travel for 20 m.
• The ground shall be a hard, flat surface.
3-5
Fig. 1 Travel swaying
3-6
4. TABLE OF MOMENT LIMITER RELATED REFERENCE VALUES
New Vehicle
Reference
Boom length display • Boom fully retracted 3.18 ± 0 -
m
calibration value • Boom fully extended 8.71 ± 0 -
Boom angle display • Boom horizontal 0±1 -
°
calibration value • Boom fully raised 80 ± 1 -
Load display calibration • No load 0.03 ± 0.01 -
t
value • Lifting 1.0 t load 1.03 ± 0.01 -
• Boom fully extended (boom length 8.71 m)
Working radius check 2.8 ± 0.2 2.8 ± 0.2
• Boom angle 70.0 degrees
m
• Total load 0.35 t (lifted load 0.32 t + hook 5.38 to 6.18 5.38 to 6.18
Stop accuracy check
0.03 t) (5.79) (5.79)
• Lowering operation at slow speed
• No load (total load 0.03 t) 0.0 to 0.2 0.0 to 0.2
Load measurement check • Total load 0.35 t (lifted load 0.32 t + hook t
0.3 to 0.6 0.3 to 0.6
0.03 t)
Alarm signal operation • Total load 0.35 t (lifted load 0.32 t + hook • Short cycle sound at 90%
-
check 0.03 t) • Continuous sound and stop at 100%
• Lowering operation at slow speed
★ Check a stop with slow speed hoisting • Hoisting and extending operation
before actual measurement. short cycle sound
• Hoist up with engine in full operation • Hoisting and extending operation
stop
Over hoist detector • Overwinding LED flashes on the
-
operation check display part
• “Over Winding” voice guidance
• From upper part of hook to
undersurface of boom 0.05 m or
more
Raising Raising
(α - 3) to α (α - 3) to α
• Stop angle set value α°
Angle control operation Lowering Lowering
• Boom length 8.71 m °
check α to (α + 3) α to (α + 3)
• Micro speed raising and lowering operations
LED flashes when boom angle reaches
the upper limit or lower limit.
• Lift stop height set value Hm (H - 0.3) to H (H - 0.3) to H
Lifting height control
• Boom length 8.0 m m
operation check Lifting height upper limit LED flashes
• Micro speed extending and raising operations
• Stop radius set value Rm (R - 0.3) to R (R - 0.3) to R
Working radius control • Boom length 8.0 m
m Working radius upper limit LED
operation check • Micro speed extending and lowering
operations flashes
• Boom fully retracted 0.30 ± 0.10 0.30 ± 0.10
Boom length meter
• Boom fully extended 1.50 ± 0.10 1.50 ± 0.10
V
• Boom angle 0.0 degrees 0.75 ± 0.023 0.75 ± 0.023
Boom angle meter
• Boom angle 80.0 degrees 1.92 ± 0.058 1.92 ± 0.058
3-7
INSPECTION AND
ADJUSTMENT
1. MEASURING THE ENGINE REVOLUTION SPEED 4-2
2. INSPECTING AND ADJUSTING THE ENGINE 4-2
3. INSPECTING AND ADJUSTING THE FAN BELT TENSION 4-3
4. ADJUSTING THE ACCELERATOR PEDAL 4-4
5. INSPECTING AND ADJUSTING THE TRACK SHOE TENSION 4-5
6. INSPECTING AND ADJUSTING THE WORK EQUIPMENT AND TRAVEL CIRCUIT 4-7
7. INSPECTING AND ADJUSTING THE PPC VALVE OUTLET PRESSURE 4-8
8. ADJUSTING THE PPC VALVE 4-9
9. INSPECTING THE SLEWING PARKING BRAKE INLET PRESSURE 4-10
10. MEASURING THE CONTROL CIRCUIT PRESSURE 4-11
11. INSPECTING THE OIL LEAKAGE RATE 4-12
12. VENTING AIR FROM PARTS 4-13
13. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC CIRCUIT 4-15
14. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC OIL TANK 4-15
15. PRESSURISING THE HYDRAULIC OIL TANK 4-15
16. METHOD FOR RAISING THE UNDERCARRIAGE BY USING THE CRANE 4-16
17. REPLACING WIRE ROPE 4-17
4-1
1. MEASURING THE ENGINE REVOLUTION SPEED
★ Measuring instrument for engine revolution speed (Komatsu tool reference)
Symbol Item No. Part Name
A K799-205-1100 Tachometer kit
★ Measure the engine revolution speed under the following conditions.

• Engine coolant temperature: Within operating range
When installing and removing the measuring instrument, be careful not to touch high temperature areas of the
engine.
1. Open the engine side cover and attach the reflective tape [1]
of the tachometer kit (A) to the crank pulley.
2. Set the probe [3] with the stand [2] in alignment with the
position of the reflective tape [1] and connect the probe to the
measuring instrument [4].
(The figure is different from CC423S-1.)
3. Start the engine and measure the engine revolution speed

under the following conditions.
1) Measure the low idling and high idling revolution speed
★ Measure the revolution speed with the accelerator
pedal set in the low idling and high idling positions.
2) Measure the revolution speed during pump relief
★ Measure the revolution speed with the engine in full
operation and while relieving the main pump.
• Pump relief: Boom retraction relief
2. INSPECTING AND ADJUSTING THE ENGINE

★ Refer to the Service Manuals of the Yanmar engine.
4-2
3. INSPECTING AND ADJUSTING THE FAN BELT TENSION
Be sure to stop the engine before starting work.
Inspection
1. Press your finger between the belt and pulley (approximately 98 N {10
kgf}) and check whether the deflection amount (tension) is within the
standard range.
NOTES
• 3 inspection points (A, B and C) are available. Perform the work
in one location where the inspection work can be easily
performed.
• When inspecting the belt tension, also check the pulleys, V
groove and belt for damage and wear. In particular, make sure
that the belt is not in contact with the bottom of the V groove. If
the belt is in contact with the bottom of the V groove, replace the
belt.
Standard deflection amount (mm) of belt in use

(A) (B) (C)
10 to 14 7 to 10 9 to 13
NOTES
A “belt in use” means a belt that is installed in the engine and has
been operated for 5 minutes or longer.
2. If the result of the inspection indicates that the belt deflection amount is
outside the standard range, adjust the belt deflection amount (tension) by
referring to the tension adjustment section.
ADJUSTMENT
1. Loosen the alternator fixing bolt (1) and the related bolts and nuts.
2. Adjust the tension by moving the alternator with a wooden bar or similar
tool.
Standard deflection amount (mm) of new belt

(A) (B) (C)
8 to 12 5 to 8 7 to 11
Standard deflection amount (mm) of belt in use

(A) (B) (C)
10 to 14 7 to 10 9 to 13
3. After adjustment, tighten the related bolts and nuts, and then finally
tighten the fixing bolt (1).
NOTES
If the belt has been stretched to leave no allowance for adjustment
or it has scratches or cracks, replace the belt.
4-3
4. ADJUSTING THE ACCELERATOR PEDAL
1. Set the accelerator pedal (1) in the free condition and then set it to the low
idling position.
★ At this time, make sure that the injection pump lever (3) is in
contact with the low idling side stopper (4).
2. Move the accelerator pedal (1) to the position where the injection pump
lever (3) contacts the high idling side stopper (5). Adjust the stopper bolt
(2) so that the accelerator pedal (1) can be fixed in this position.
★ Do not adjust the high idling side stopper (5).
SAM02290
3. After adjusting the stopper bolt (2), tighten the fixing nut (6).
4. Check that the accelerator pedal (1) moves smoothly.
5. Start the engine and check the engine revolution speed.
• High idling: 2,430 ± 50 rpm

• Low idling: 1,250 ± 50 rpm
4-4
5. INSPECTING AND ADJUSTING THE TRACK SHOE TENSION
Inspection
1. Keep the engine at a low idling speed to travel forward for a distance
equal to the length of the crawler belt in contact with the ground, and
slowly stop travelling.
2. Place a square bar (3) that can bridge between the idler (1) and upper
carrier roller (2) on the crawler belt.
3. Measure the maximum sagging dimension between the upper plane of the
crawler belt and the bottom surface of the square bar.
• Reference value of sagging dimension
5 to 15 mm is the normal range for sagging dimension a.
If the tension differs from the standard value, adjust it in the following manner.
ADJUSTMENT
Do not loosen the plug (1) for more than one turn.
If the grease cannot be smoothly discharged, move the machine
back and forth slowly.
4-5
STRENGTHENING THE TENSION
Have a grease gun available.
1. Inject the grease from the grease fitting (2) using the grease gun.
2. To ensure that a proper tension is applied, keep the engine at a low idling
speed to move the machine forward slowly (for a distance equal to the
length of the crawler belt in contact with the ground), and then stop
travelling.
3. Inspect the tension of the crawler belt again, and if the tension is not
appropriate, make another adjustment.
4. Grease can be injected until dimension S reaches 0 mm, but if the tension
is still insufficient, the abrasion of pins and bushings has increased. In
this case, reverse or replace the pins and bushings.
LOOSENING THE TENSION

1. Slowly loosen the plug (1) to discharge the grease.
2. When loosening the plug (1), loosen it for only one turn at the maximum.
3. If the grease cannot be smoothly discharged, slightly move the machine
back and forth.
4. Screw in the plug (1).
5. To ensure that a proper tension is applied, keep the engine at a low idling
speed to move the machine forward slowly (for a distance equal to the
length of the crawler belt in contact with the ground), and then stop
travelling.
6. Inspect the tension of the crawler belt again, and if the tension is not
appropriate, make another adjustment.
4-6
6. INSPECTING AND ADJUSTING THE WORK EQUIPMENT AND
TRAVEL CIRCUIT
MEASUREMENT
★ Oil temperature at measurement: 45 to 55°C
Fully retract and fully lower the boom, set the blade onto the
ground and stop the engine. Then, gradually loosen the oil feed
cap of the hydraulic oil tank to release the pressure inside the
tank and set the safety lock lever in the lock position.
1. Remove the joints from the A1 discharge port (3), A2 discharge port (4)
and A3 discharge port (5) of the hydraulic pump, and then install the oil
pressure gauge (40 MPa {408 kg/cm2}) with the joints.
★ Port size: G1/2
SAM02300
2. Start the engine and measure the main relief hydraulic pressure at the set
flow rate.
• Regarding the condition of the actuators to be measured:
1) In the case of work equipment, position each cylinder at the stroke
end.
2) In the case of travel, clamp a block (1) at the grouser of the track
shoe. Alternatively, clamp the sprocket (2), lock the track shoe and
measure each side in turn.
ADJUSTMENT
★ Adjust the main relief valve of the operation valve for the work equipment and travel circuit.
1. Main relief valve of operation valve

1) MRV1: Travelling right/winch 1 : Set pressure 24.5 to 24.99 MPa {250 to 255 kg/cm2} at 30 L/min
2) MRV2: Travelling left : Set pressure 24.5 to 24.99 MPa {250 to 255 kg/cm2} at 30 L/min
3) MRV3: Slewing/blade : Set pressure 20.6 to 21.09 MPa {210 to 215 kg/cm2} at 23 L/min
4) ORV: Derricking/retracting : Set pressure 20.6 to 21.09 MPa {210 to 215 kg/cm2} at 20 L/min
5) ORV: Extending/winch 2 : Set pressure 20.6 to 21.09 MPa {210 to 215 kg/cm2} at 30 L/min
★ Be sure to set MRV1 and MRV2 to the same value.
2. Loosen the lock nut (2) and turn the adjuster screw (3) to adjust.
★ For adjuster screw (3):
• Turn to the right to raise the pressure.
• Turn to the left to lower the pressure.
Lock nut (2) tightening torque: 39.2 ± 1.96 {4 ± 0.2 kg·m}
★ After adjustment, measure the relief hydraulic pressure again.
4-7
7. MEASURING THE PPC VALVE OUTLET PRESSURE
★ Measuring instrument for PPC valve outlet pressure (Komatsu tool reference)
K799-101-5002 Hydraulic tester
R1
K790-261-1204 Digital hydraulic tester
R2 K790-261-1311 Adapter
★ Perform in the case of faults such as work equipment or slewing operating slowly or not at all.
1. Disconnect the outlet hose of the PPC valve to be measured, connect the
adapter (R2) between the hose and elbow, and install the oil pressure
gauge (R1) (60 kg/cm2) to the adapter (R2).
2. Operate the lever of the circuit to be measured with the engine in full
operation and measure the output pressure of the PPC valve.
• Measurement positions
1) Left PPC valve
Telescoping
Left/right slewing
2) Right PPC valve
Winch up/down
Derricking
★ The reference values are the same as for the control circuit hydraulic pressure (at full stroke of the operation lever).
4-8
8. ADJUSTING THE PPC VALVE
★ If the work equipment or slewing operation lever is significantly loose, adjust with the following procedure.
Fully retract and fully lower the boom, set the blade onto the
ground and stop the engine. Then, gradually loosen the oil feed
cap of the hydraulic oil tank to release the pressure inside the
tank and set the safety lock lever in the lock position.
1. Remove the PPC valve.

2. Remove the boot (1).
3. Loosen the lock nut (2) and screw in the disc (3) until it contacts the
heads of the 4 pistons (4).
At this time, do not perform a stroke movement of the piston.
4. Fix the position of the disc (3) and tighten the lock nut (2) with the
specified torque.
Lock nut: 107.9 ± 9.8 Nm {11 ± 1 kgm}
5. Install the boot (1).
★ As a result of the adjustment above, the clearance between the disc (3)
and piston (4) will be 0.
4-9
9. INSPECTING THE SLEWING PARKING BRAKE INLET PRESSURE
★ Inspection devices for slewing parking brake inlet pressure (Komatsu tool reference)
S1
R2 K799-101-5160 Nipple
R3 K790-261-1311 Adapter
Oil temperature at measurement: 45 to 55°C
1. Disconnect the hose (1).

2. Attach the adapter (S3) and nipple (S2), and then install the oil pressure
gauge (S1) (5.9 MPa {60 kg/cm2}).
3. Measure the inlet pressure while operating “left slewing” and “right
slewing” with the engine in full operation.
★ The reference values are the same as for the control circuit hydraulic
pressure (at full stroke of the operation lever).
REFERENCE
• If all the “left slewing” and “right slewing” PPC valve output pressures are
normal and one of the slewing parking brake inlet pressures is abnormal
during operation, a fault in the “slewing brake release shuttle valve” shall
be determined.
4-10
10. MEASURING THE CONTROL CIRCUIT PRESSURE (PPC A4
PORT PUMP OUTLET PRESSURE)
★ Inspection devices for slewing parking brake inlet pressure (Komatsu tool reference)
S1
R2 G1/8 × G1/4 Nipple
1. Remove the PPG port plug of the hydraulic pump, attach the nipple (R2),
and then install the oil pressure gauge (S1) (5.9 MPa {60 kg/cm2}).
2. Measure the inlet pressure with the engine in full operation.
★ The reference values are the same as for the control circuit hydraulic
pressure (at full stroke of the operation lever).
4-11
11. INSPECTING THE OIL LEAKAGE RATE
★ If the natural descending amount of the work equipment is outside the reference range, measure the amount of cylinder
internal leakage with the following procedure and determine whether the cause of natural descending is on the cylinder side or
the operation valve side.
• If the leakage amount is within the reference range, the cause is on the operation valve side.
• If the leakage amount is at the reference value or higher, the cause is on the cylinder side
1. INSPECTING THE DERRICKING CYLINDER LEAKAGE RATE

1) Set the derricking cylinder to the “Raising” stroke end and stop the engine.
Release the residual pressure from inside the piping on the derricking cylinder head side by referring to the
section “RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC CIRCUIT”. (However, operate the
lever in the derricking “Raising” direction only.)
2) Disconnect the hose on the cylinder head side and block the hose side with the plug.
Be sure not to disconnect the hose on the cylinder bottom side.
3) Start the engine and perform derricking “Raising” relief at high idling.
Be sure not to operate to the derricking “Lowering” side.
4) Start relief and wait for 30 seconds, then use a graduated cylinder or
similar tool available on the market to check the oil leakage rate for 1
minute.
5) After completing the inspection, return the parts to their original
condition.
BVP03446
4-12
12. VENTING AIR FROM PARTS
Air vent item Air vent procedure
1 2 3 4 5 6 7
Slewing Hydraulic oil
Pump Engine Cylinder Travel motor
motor tank Operation
Work description air venting start air venting air venting
air venting pressurising
• Replacement of hydraulic oil

✓ ✓ ✓ ✓ ✓ ✓ ✓
• Cleaning of strainer
(Note) (Note)
• Replacement of return filter
✓ ✓ ✓
element
• Replacement or repair of pump

✓ ✓ ✓ ✓ ✓
• Removal of suction piping
• Replacement or repair of
✓ ✓ ✓ ✓
operation valve
cylinder ✓ ✓ ✓ ✓
• Removal of cylinder piping
slewing motor
✓ ✓ ✓ ✓
• Removal of slewing motor
piping
• Replacement or repair of travel
motor and swivel
✓ ✓ ✓ ✓
• Removal of travel motor and
swivel piping
Note: Vent the air from the slewing motor and travel motor only after draining the oil from inside the motor case.
1. VENTING AIR FROM THE PUMP

1) Remove the oil feed cap of the hydraulic oil tank.
2) Loosen the air venting port (1) and check that the oil oozes out
from the port (air venting is completed).
3) After air venting is completed, tighten the air venting port.
Tightening torque: 7.9 ± 0.9 Nm {0.8 ± 0.09 kgm}
4) Tighten the oil feed cap of the hydraulic oil tank.
5) Fully retract and fully raise the boom, set the blade onto the ground,
mount the oil feed cap and pressurise the tank.
★ Cautions when starting the engine

When starting the engine after performing the work above, keep the engine in low idle for approximately 10 minutes
after starting the engine.
2. VENTING AIR FROM THE CYLINDER

1) While running the engine in low idling, extend and retract each cylinder for 4 to 5 times while making sure it does not
actually reach the stroke end (stopping it approximately 100 mm before the stroke end).
★ Make sure not to perform relief for the piston rod.
2) Then, allow each cylinder to reciprocate to the stroke ends for 3 to 4 times and perform relief.
3) Further allow each cylinder to reciprocate to the stroke ends for 4 to 5 times to fully vent the air.
4-13
3. VENTING AIR FROM THE SLEWING MOTOR
1) Operate left slewing for 3 turns with the engine in low idling.
2) Then, operate right slewing for 3 turns.
4. VENTING AIR FROM THE TRAVEL MOTOR

1) Raise one side of the track shoe by referring to the section “16. METHOD FOR RAISING THE UNDERCARRIAGE BY
USING THE CRANE”.
2) Run the raised track shoe freely in low idle for approximately 30 seconds.
3) Perform the same work for the track shoe on the opposite side.
5. PRESSURISING THE HYDRAULIC OIL TANK

1) Before pressurising the tank, fully retract all the cylinders and check the hydraulic oil level again.
2) Pressurise the hydraulic oil tank by referring to the section “15. PRESSURISING THE HYDRAULIC OIL TANK”.
4-14
13. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC
CIRCUIT
The accumulator is not installed, and therefore the residual pressure in piping other than the blade cylinder and
travel circuit piping cannot be released even if the operation lever is operated.
Be careful of the following when removing piping other than the piping described above.
★ Release the residual pressure in the blade cylinder and travel circuit piping by moving each operation lever
back and forth.
1. Run the engine in low idle, operate the hydraulic cylinder as close to the stroke end as possible without performing relief, fully
retract and fully lower the boom, set the blade onto the ground and stop the engine.
★ If the engine is stopped while the hydraulic cylinder is in the relieved state at the stroke end, do not perform work for 5 to 10
minutes.
2. When removing the piping, loosen the sleeve nuts of the piping gradually to slowly release the residual pressure from inside
the piping. When oil is no longer discharged, remove the piping.
14. RELEASING RESIDUAL PRESSURE FROM THE HYDRAULIC

OIL TANK
The hydraulic oil tank is a sealed type that is pressurised.
Before removing hoses or plugs connected to the hydraulic oil tank, release the residual pressure from the
hydraulic oil tank with the following procedure.
1. Fully retract and fully lower the boom, set the blade onto the ground and stop the engine.
2. Loosen the filler plug of the hydraulic oil tank gradually to release the residual pressure from inside the tank.
15. PRESSURISING THE HYDRAULIC OIL TANK
★ After removing the filler plug of the hydraulic oil tank, pressurise the hydraulic oil tank with the following procedure.
1. Run the engine in low idle to set the work equipment in the pressurised
posture. Posture when pressurising
2. Stop the engine, and open and then retighten the filler plug of the hydraulic oil tank
hydraulic oil tank.
★ This operation pressurises the hydraulic oil tank.
3. Start the engine, and fully retract and fully lower the boom.
4-15
16. METHOD FOR RAISING THE UNDERCARRIAGE BY USING THE
CRANE
Conduct the operations on flat and solid ground.
Place the lock lever at the lock position to prevent the machine from moving unexpectedly.
• Prepare a rectangular block (450 mm × 200 mm) that is to be put under the track frame.
1. Set the machine to the “Travelling posture” in the figure on the right.
2. Slew the boom for 90 degrees.
3. Apply a wire rope for slinging (A) to the boom and hoist the load slowly.
★ At this time, to prevent the boom from being damaged, insert a pad such as
a rectangular block (B) between the wire rope for slinging (A) and the
boom.
4. Insert the rectangular block (C) that has been prepared between the raised track
frame and the ground with good balance.
5. Hoist down the machine slowly.

In this stage, hoist down the machine while ensuring that the machine is well st
abilized.
4-16
17. REPLACING WIRE ROPE
★ The diameter of the wire rope is measured at points where the wire repeatedly runs through the sheave. A mean value needs
to be determined through 3-way measurement. (A measurement should be performed not only at 1 point but also at several p
oints with spacing between the points.)
CRITERIA FOR WIRE ROPE REPLACEMENT

A wire rope undergoes wear and tear over time.
Prompt replacement is required if any of the following appears in the wire
rope.
1. With respect to the total number of wires in the outermost strand
(excluding the filler wires), when the ratio of the number of broken wires
exceeds the following: XAM01050
1) 10% or more of a single twist of rope. However, when breakage
occurs in a single strand only, the ratio should be 5% or more.
2) 20% or more of 5 twists of rope.
2. A rope of which reduction in diameter due to abrasion exceeds 7% of the

nominal diameter.
★ Change the 9-mm diameter wire rope when reduced to 8.4 mm.
3. When either of the following is observed due to corrosion:

1) Pitching occurred on the wire surface, that has turned pockmarked.
2) Wires that have lost tension due to internal corrosion.
4. When either of the following is observed due to deformation: Undulation width

1) A strand that is kinked.
2) When the width of an undulation exceeds 4/3 d within a section that is
25 times of nominal diameter d.
3) When a wire rope is flattened by local crushing and the minimum
diameter is 2/3 of the maximum diameter or less.
4) A rope of which core wires or rope core is exposed.
5) A rope extremely bent.
6) A rope appearing like a cage.
7) A strand that has been intruded.
8) One or more strand is loosened.
9) Wires that are remarkably sticking out.
XAM01071
5. A faulty end socket is used.
4-17
REMOVING WINCH WIRE ROPE
Use the following procedure to remove the wire rope.

1. Place the machine on a horizontal and hard ground.
2. Operate the right work equipment operation lever to the “Raising” side
(pull to left) to raise the boom slightly.
3. Operate the right work equipment operation lever to the “Down” side
(push forward) and lower the hook block close to the ground.
4. Operate the right work equipment operation lever to the “Lowering” side
(push to right) and lower the hook block onto the ground.
5. Remove the wedge socket fixing bolt (2), pull out the wedge socket pin
(1), and remove the wedge socket (3).
6. Remove the wire clip (4).
7. Pull the wire rope (5) out of the wedge socket (3), following the
procedure below:
1) Bring a 4 to 6 mm round bar (6) into contact with the rope wedge (7).
2) Remove the rope wedge (7) by lightly tapping the round bar (6) with a
hammer in the direction indicated by the arrow (a).
8. Operate the right work equipment operation lever to the “Down” side
(push forward) to wind up the wire rope (5) from the winch drum.
9. After winding up the wire rope from the winch drum, detach the end of
the wire rope (5) fixed to the winch drum (8) by following the procedure
below:
1) Bring a 4 to 6 mm round bar (6) into contact with the rope wedge (9).
2) Remove the rope wedge (9) by lightly tapping the round bar (6) with a
hammer in the direction indicated by the arrow (b).
10. Wind up the remaining wire rope (5) completely.
Removal of the winch wire rope is completed with the above.
4-18
INSTALLING WINCH WIRE ROPE
★ Be sure to attach the rope wedge properly to secure the wire rope. Serious accidents may occur if the wire rope is detached
during crane operations.
★ Avoid irregular winding of the wire rope on the winch drum when winding up the wire rope.
★ Always hoist an object (2.9 to 4.9 kN {300 to 500 kg}) with the boom fully extended and fully raised immediately after
attaching a new rope. Repeat raising and lowering the hook several times until the new rope conforms.
★ The wire rope is coiled. Exercise caution not to form a kink in the rope when winding it up. Be sure to unravel by rotating the
rope to pull it out of the winch drum.
Use the following procedure to attach the wire rope.

1. Hold the end of wire rope and draw the wire rope (5) though the load
sheave (10) at the end of the boom, wire guide (11) of boom Nos. 2 and 3,
and snap sheave (12).
2. Draw the wire rope (5) through the rope attachment hole of the winch
drum (8). Secure the wire rope (5) to the winch drum (8), following the
procedure below.
1) Draw the slackened wire rope (5) through the winch drum (8).
2) The rope wedge (9) should be in position (a). Pass the wire rope (5)
around the rope wedge and yank at the rope in the direction indicated
by the arrow.
At this time, adjust the length of the wire rope (5) to keep the end of
XAM08640
the wire rope from protruding from the narrow hole in the winch drum
(8).
3. Slowly operate the right work equipment operation lever to the “Up” side
(pull toward you) to wind up the wire rope (5) onto the winch drum (8).
At this time, position the wire rope to be wound up between the irregular
winding prevention roller (B) and winch drum, and leave the wire rope
for about 10 m unwounded ahead of the boom end.
4-19
4. Depending on the number of falls of wire rope, pass the wire rope through the load sheave (10) at the end of the boom, the
hook block sheave (13), the weight (14) of the overwinding prevention device and the guide sheave (15) as shown in the
following diagrams.
4 fall 2 fall Single fall
5. Secure the end of the wire rope (5) to the wedge socket (3), following the
procedure below:
1) Draw the wire rope (5) through the wedge socket (3) as shown in the
diagram on the right.
2) The rope wedge (7) should be in position (a). Pass the wire rope (5)
around the rope wedge and yank at the rope in the direction indicated by
the arrow.
6. Attach the rope clip (4) to the wire rope (5).
7. Secure the wedge socket (3) to the boom by using the wedge socket pin (1),
and tighten the wedge socket pin fixing bolt (2).
8. Operate the right work equipment operation lever to the “Raising” side
(pull to left), or operate the left work equipment operation lever to the
“Extending” side (push forward) to raise the hook block.
★ Because there is a risk of irregular winding in the winch drum, do not
operate the winch until the hook block is raised.
9. With the boom fully extended and fully raised, operate the right work
equipment operation lever to the “Down” side (push forward) to adjust the
wire rope (5) until 3 to 4 turns of wire are left on the winch drum (8).
10. With the wire rope (5) held under tension, operate the right work
equipment operation lever to the “Up” side (pull toward you) to wind up
the wire rope (5) onto the winch drum (8).
4-20
INSPECTING AND ADJUSTING THE BOOM TELESCOPING WIRE ROPE
When the boom extending wire rope shows a following condition, adjust it
accordingly:
1. Fully retract the boom.
2. Remove the 3 mounting bolts (1) at the end of the boom and then remove
the cover (2).
3. Remove the lock bolt (6) at the end of the telescoping cylinder inside the
boom and turn the boom extending wire adjusting bolt (9) clockwise.
If boom No. 4 extends at the same time as the adjusting bolt (9) is turned,
the tension of the boom extending wire (8) is correct.
If boom No. 4 does not extend, adjust by referring to the section
“ADJUSTING BOOM TELESCOPING WIRE ROPES”.
4. Check for a 5 mm or more clearance between booms Nos. 3 and 4

(clearance (a) shown in the diagram on the right) when the booms are in a
fully retracted and horizontal position.
If the clearance is 5 mm or more, adjust by referring to the section
“ADJUSTING BOOM TELESCOPING WIRE ROPES”.
4-21
ADJUSTING BOOM TELESCOPING WIRE ROPES
★ When adjusting each wire rope, be careful of over-tension of the wire ropes.
One wire rope is used for extending the boom and one wire rope is used for retracting the boom. Adjustment of these wire ropes
must conform to the specified procedure. Be sure to use the following procedure for wire rope adjustment:
1. With the booms fully retracted in a horizontal position, extend the telescoping booms by approx. 2 m.
2. Retract the booms completely and at a slow speed.

Measure clearance (a) in this condition to check the following for
proper adjustment:
• If there is a clearance (a) of 5 mm or more, adjust the boom No. 4
retracting wire rope (5).
• If clearance (a) is “0 (zero)”, start the adjustment with step 5
“Adjusting boom No. 4 extending wire rope (8)”.
3. Remove the 3 mounting bolts (1) at the end of the boom and then
remove the cover (2).
4-22
4. Adjusting No. 4 boom retracting wire rope (5)
1) With the lock nut (3) loose, tighten the right and left adjusting nuts (4)
evenly in a direction (clockwise) where the retracting wire rope (5)
becomes tight until clearance (a) is closed.
2) If the retracting wire rope is slack or clearance (a) is 5 mm or more
after performing operation and measurement in steps 1 and 2,
readjustment is required.
5. Adjusting boom No. 4 extending wire rope (8)

1) Remove the lock bolt (6), and tighten the adjusting bolt (9) in a
direction (clockwise) where the boom No. 4 extending wire rope (8)
becomes tight until just before boom No. 4 begins to extend.
2) Retighten by 2 turns each of the right and left adjusting nuts (4) for the
boom No. 4 retracting wire rope (5).
3) Fix the adjusting nut (4) of the boom No. 4 retracting wire rope (5) by
using the lock nut (3).
4) Retighten the adjusting bolt (9) of the boom No. 4 extending wire rope
(8) for 2 turns by using the lock bolt (6).
6. After completing the adjustment, attach the cover (2) at the end of boom
with the 3 mounting bolts (1).
4-23
DISASSEMBLING AND
ASSEMBLING
1. DISMOUNTING AND MOUNTING THE RADIATOR AND OIL COOLER ASSEMBLY 5-2
2. DISMOUNTING AND MOUNTING THE ENGINE AND HYDRAULIC PUMP ASSEMBLY 5-3
3. DISMOUNTING AND MOUNTING THE SLEWING MOTOR AND SWING MACHINERY
5-6
ASSEMBLY
4. DISMOUNTING AND MOUNTING THE SWING CIRCLE ASSEMBLY 5-7
5. OPENING AND MOUNTING THE TRACK SHOE ASSEMBLY 5-8
6. DISMOUNTING AND MOUNTING THE SPROCKET 5-9
7. DISMOUNTING AND MOUNTING THE TRAVEL MOTOR ASSEMBLY 5-10
8. DISMOUNTING AND MOUNTING THE COUNTERWEIGHT 5-11
9. DISMOUNTING AND MOUNTING THE REVOLVING FRAME ASSEMBLY 5-12
10. DISMOUNTING AND MOUNTING THE CENTRE SWIVEL JOINT ASSEMBLY 5-14
11. DISMOUNTING AND MOUNTING THE WORK EQUIPMENT ASSEMBLY 5-15
12. DISMOUNTING AND MOUNTING THE OPERATOR'S CANOPY ASSEMBLY 5-16
13. DISMOUNTING AND MOUNTING THE SEAT BRACKET ASSEMBLY 5-17
5-1
1. DISMOUNTING AND MOUNTING THE RADIATOR AND OIL
COOLER ASSEMBLY
Stop the machine in a flat location, fully retract and fully
lower the boom, and set the blade onto the ground.
Disconnect the negative (-) terminal of the battery.
[DISMOUNTING]
1. Remove the seat bracket assembly by referring to the section
“DISMOUNTING AND MOUNTING THE SEAT BRACKET
ASSEMBLY”.
2. Remove the counterweight (1).
Counterweight assembly: 1,224 kg
(The figure is different from CC423S-1.)
3. Drain the coolant.
4. Disconnect the radiator lower hose (2) and upper hose (3) on
the water pump side.
5. Disconnect the air cleaner intake hose (4).
6. Remove the fan guard (5).
7. Remove the fan (6), pulley (7) and drive belt (8) together. [*1]
★ The pulley (7) and fan (8) are tightened together.
★ Remove in order to pull out the radiator.
8. Disconnect the coolant drain hose (9).
9. Disconnect the overflow hose (10).
10. Disconnect the oil cooler inlet hose (11) and outlet hose (12),
and then remove the oil cooler (13).
★ Removing the cooler makes dismounting easier because the
hose (11) does not bend.
11. Remove the radiator (14) by pulling it out.
Radiator assembly: 24 kg
[MOUNTING]
• Perform the mounting in the reverse order of dismounting.
[*1]
★ Adjust by referring to the section “INSPECTING AND
ADJUSTING THE FAN BELT TENSION” in INSPECTION
AND ADJUSTMENT.
FEEDING WATER
Feed water up to the lip of the radiator inlet and start the engine.
After the water temperature increases, check the level in the
reserve tank.
5-2
2. DISMOUNTING AND MOUNTING THE ENGINE AND HYDRAULIC
PUMP ASSEMBLY
Stop the machine in a flat location, fully retract and fully lower the boom, and set the blade onto the ground.
Loosen the cap of the hydraulic oil tank gradually to release the residual pressure from inside the tank.
★ The photograph and figure are different from CC423S-1.
[DISMOUNTING]
1. Remove the seat bracket by referring to the section
ASSEMBLY”.
2. Remove the counterweight (1) by using the hoisting bolt ①.
3. Drain the coolant.
4. Drain the hydraulic oil.
Hydraulic oil: 28.5 L
5. Disconnect the radiator outlet hose (2) and inlet hose (3).
[*1]
6. Disconnect the air cleaner intake hoses (4) and (5).
7. Remove the air cleaner (6) and then remove the bracket (7).
8. Remove the fan guard (8).
9. Remove the mounting bolt of the fan (9), and then remove the
fan belt (10) and pulley (11). [*2]
★ The fan (9) and pulley (11) are tightened together.
10. Disconnect the coolant drain hose (12).
5-3
11. Disconnect the radiator overflow hose (13).
12. Disconnect the oil cooler inlet hose (14).
13. Disconnect the oil cooler outlet hose (15), and then remove
the oil cooler (16).
14. Remove the radiator and oil cooler assembly (17).
★ Remove by pulling out to the outer side.
Radiator and oil cooler assembly: 25 kg
15. Disconnect the following 5 tubes and hoses (18) to (21) from
the hydraulic pump assembly.
• Suction hose: (18)

• Piston pump discharge hose: (19) 2 hoses
• Gear pump discharge hose: (20)
• PPC discharge hose: (21)
16. Disconnect the fuel control cable (23).
★ Remove the pin and disconnect from the bracket.
[*3]
★ Check the mounting dimensions before disconnection.
17. Disconnect the engine oil pressure switch wire (24) (T5).
18. Disconnect the fuel feed pump wire connector (25) (E4) and
engine stop solenoid wire connector (26) (E3).
19. Disconnect the fuel feed pump inlet hose (27) and fuel return
hose (28).
20. Disconnect the glow plug wire (29).
21. Disconnect the starter wire connector (30) (T4).
22. Remove the boot and disconnect the wire (31).
5-4
23. Disconnect the engine coolant temperature sensor wire
connector (32) (E7).
24. Disconnect the alternator wire connectors (33) (E1) and (E2).
25. Disconnect the alternator wire (34) (T3).
26. Disconnect the engine ground (36).
27. Remove the 4 engine mount bolts (37).
28. Hoist and remove the hydraulic pump assembly (38).
★ Hoist up horizontally while maintaining balance by using a
lever block or similar equipment.
Engine and hydraulic pump assembly: 250 kg
[MOUNTING]
[*1]
Radiator inlet and outlet hose clamps:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
★ Adjust the tension of the fan belt by referring to the section
“INSPECTING AND ADJUSTING THE FAN BELT
TENSION” in INSPECTION AND ADJUSTMENT.
[*3]
★ Adjust the fuel control cable by referring to the section
“ADJUSTING THE ACCELERATOR PEDAL” in
INSPECTION AND ADJUSTMENT.
• Refilling oil (hydraulic oil tank)

Refill oil from the filler port up to the specified level, start the
engine to circulate the oil, and then check the level again.
Hydraulic oil tank: Approx. 28.5 L (HDS-3 10W)
• Feeding water
Feed water up to the lip of the radiator inlet and start the engine.
After the water temperature increases, check the level in the
reserve tank again.
• Venting air
Vent the air from the hydraulic circuit by referring to the section
“VENTING AIR FROM PARTS” in INSPECTION AND
ADJUSTMENT.
5-5
3. DISMOUNTING AND MOUNTING THE SLEWING MOTOR AND
SWING MACHINERY ASSEMBLY
Loosen the cap of the hydraulic oil tank gradually to release
the residual pressure from inside the tank.
★ The photograph is different from CC423S-1.
[DISMOUNTING]
1. Remove the seat bracket assembly by referring to the section
ASSEMBLY”.
2. Disconnect the 4 hoses (1) between the operation valve and
centre swivel joint.
★ Disconnect the clamp (2).
3. Disconnect the hoses (1) to (6) from the slewing motor
assembly.
★ Before disconnection, attach tags or other markers to
confirm the installation positions.
★ Attach plugs to the disconnected tubes and hoses.
4. Temporarily hoist the slewing motor and swing machinery
assembly, and disconnect the assembly from the revolving
frame by using the 2 extracting bolts ①. [*1]
5. Hoist and remove the slewing motor and swing machinery
assembly (7).
[MOUNTING]
[*1]
Mounting bolts: Liquid adhesive (Loctite 262)
Mounting bolts: 110.3 ± 12.3 Nm {11.3 ± 1.3 kgm}

Refill oil from the filler port up to the specified level, start the engine to circulate the oil, and then check the level again.
• Venting air
Vent the air from the hydraulic circuit by referring to the section “VENTING AIR FROM PARTS” in INSPECTION AND
ADJUSTMENT.
5-6
4. DISMOUNTING AND MOUNTING THE SWING CIRCLE
ASSEMBLY
[DISMOUNTING]
1. Remove the revolving frame assembly by referring to the
section “DISMOUNTING AND MOUNTING THE
REVOLVING FRAME ASSEMBLY”.
2. Remove the 20 mounting bolts (1). [*1]
3. Attach the hoisting bolt, and hoist and remove the swing circle
assembly (2). [*2]
Swing circle assembly: 40 kg
[MOUNTING]
[*1]
Mounting bolts: Liquid adhesive (Loctite 262)
Mounting bolts: 117.6 to 137.2 Nm {12 to 14 kgm}
(Target: 127.4 Nm {13 kgm})
[*2]
★ Install the inner race soft zone (a) (S mark) and outer race soft
zone (b) in the positions shown in the diagram on the right.
Inner race tooth surface: Lithium grease No. 2
5-7
5. OPENING AND MOUNTING THE TRACK SHOE ASSEMBLY
[DISMOUNTING]
1. Raise the undercarriage by referring to the section
“METHOD FOR RAISING THE UNDERCARRIAGE BY
USING THE CRANE” in INSPECTION AND
ADJUSTMENT.
2. Loosen the valve (1) to discharge the grease, and then loosen
the tension of the track shoe. [*1]
Do not loosen the valve (1) for more than one turn, because
there is a risk of the valve flying out due to internal
high-pressure grease.
3. Remove the cover (2).
4. Hoist up the track shoe assembly (3) and then pull out the
assembly toward yourself.
Shoe: 170 kg
[MOUNTING]
[*1]
★ Adjust the tension of the track shoe by referring to the section “INSPECTING AND ADJUSTING THE TRACK SHOE
TENSION” in INSPECTION AND ADJUSTMENT.
5-8
6. DISMOUNTING AND MOUNTING THE SPROCKET
[DISMOUNTING]
1. Open the track shoe assembly by referring to the section
“OPENING AND MOUNTING THE TRACK SHOE
ASSEMBLY”.
2. Raise the undercarriage by referring to the section “METHOD
FOR RAISING THE UNDERCARRIAGE BY USING THE
CRANE” in INSPECTION AND ADJUSTMENT.
3. Set a block [1] between the track frame and track shoe.
4. Remove the 9 mounting bolts and then hoist and remove the
sprocket (1).
Sprocket: 10 kg per piece
[MOUNTING]
Threads of sprocket mounting bolts:

Liquid adhesive (Apply Loctite 262)
Sprocket mounting bolts:
98 to 123 Nm {10 to 12.5 kgm}
5-9
7. DISMOUNTING AND MOUNTING THE TRAVEL MOTOR
ASSEMBLY
[DISMOUNTING]
1. Remove the sprocket by referring to the section
“DISMOUNTING AND MOUNTING THE SPROCKET”.
3. Disconnect the travel speed increase hose (2).
4. Disconnect the drain hose (3).
5. Disconnect the forward/backward hoses (4) and (5).
6. Temporarily hoist the travel motor and remove the 8 mounting
bolts (6).
7. Hoist and remove the travel motor assembly (7).
Travel motor assembly: 37 kg
[MOUNTING]
Mounting bolts: Liquid adhesive (Apply Loctite 262)

Mounting bolts: 98.0 to 122.5 Nm {10.0 to 12.5 kgm}
• Venting air
Vent the air from the travel motor by referring to the section
ADJUSTMENT.

engine to circulate the oil inside the piping, and then check the
level again.
5-10
8. DISMOUNTING AND MOUNTING THE COUNTERWEIGHT

★ The figure is different from CC423S-1.
[DISMOUNTING]
1. Remove the engine hood (1).
2. Remove the machine covers (2), (3) and (4).
3. Remove the 4 mounting bolts (5) and then hoist and remove the
counterweight (6).
★ Disconnect from the revolving frame while maintaining
balance by using a lever block or bar.
[MOUNTING]
Mounting bolts: Apply Loctite 262

Mounting bolts: 490 to 608 Nm {50 to 62 kg}
5-11
9. DISMOUNTING AND MOUNTING THE REVOLVING FRAME
ASSEMBLY
★ Attach plugs to the disconnected hydraulic hoses.

[DISMOUNTING]
1. Remove the operator's canopy assembly by referring to the
OPERATOR'S CANOPY ASSEMBLY”.
2. Hoist and remove the work equipment assembly. [*1]
★ Shims are installed. Confirm their thickness, quantity and
installation positions.
Work equipment assembly: 570 kg
3. Remove the 2 derricking cylinder hoses (1).
4. With the derricking cylinder temporarily hoisted, remove the
derricking cylinder bottom side pin (2) and then take out the
derricking cylinder assembly (3). [*2]
Derricking cylinder assembly: 60 kg
5. Remove the slewing motor and swing machinery assembly by
referring to the section “DISMOUNTING AND MOUNTING
THE SLEWING MOTOR AND SWING MACHINERY
ASSEMBLY”.
6. Disconnect the 8 hoses (5) from the top side of the centre swivel
joint assembly.
★ If necessary, remove the elbow from the centre swivel joint.
7. Remove the workrest bracket (6) from the centre swivel joint
assembly.
8. Remove the cover on the front side of the revolving frame.
9. Disconnect the grease tube (7).
★ Remove the elbow from the revolving frame.
5-12
10. Temporarily hoist the revolving frame and remove the
mounting bolts (8). [*3]
★ Leave 2 mounting bolts at the front and rear.
11. Remove the 2 mounting bolts at the front and rear, and then
gradually hoist up and remove the revolving frame assembly
(9).
Revolving frame assembly: 2,400 kg
★ Hoist up while maintaining balance in all directions by using a
lever block or similar equipment.
★ Be careful not to damage the centre swivel joint.
[MOUNTING]
[*1], [*2]
When aligning the pin holes, be sure not to insert your finger
into the holes.
[*3]
Revolving frame assembly mounting bolts:
Liquid adhesive (Apply Loctite 262)
Revolving frame assembly mounting bolts:
98.0 to 122.5 Nm {10.0 to 12.5 kgm}
(Target 112.7 Nm {11.5 kgm})
Bushing inner surface when assembling the pins:
Apply Hyper White Grease No. 2
level again.
• Venting air
ADJUSTMENT.
5-13
10. DISMOUNTING AND MOUNTING THE CENTRE SWIVEL JOINT
ASSEMBLY
★ Attach plugs to the disconnected hoses.

[DISMOUNTING]
1. Remove the slewing motor and swing machinery assembly by
referring to the section “DISMOUNTING AND MOUNTING
THE SLEWING MOTOR AND SWING MACHINERY
ASSEMBLY”.
2. Disconnect the 10 hoses (1) at the bottom of the centre swivel
joint.
3. Remove the elbow (2).
4. Disconnect the 8 hoses (3) at the top of the centre swivel joint.
5. Disconnect the workrest bracket (4) from the centre swivel
joint.
6. Remove the mounting bolts and then remove the centre swivel
joint (5).
[MOUNTING]

level again.
• Venting air
ADJUSTMENT.
5-14
11. DISMOUNTING AND MOUNTING THE WORK EQUIPMENT
ASSEMBLY

★ Before disconnecting the connectors, attach tags or other
markers to confirm the installation positions.
★ Before starting work, stow the hook block in the simple
stowage position.
[DISMOUNTING]
1. Remove the operator’s canopy assembly by referring to the
OPERATOR’S CANOPY ASSEMBLY”.
2. Disconnect the 3 connectors (1) and 1 connector (2).
3. Remove the ground harness (3).
4. Remove the cover (4) and disconnect the 5 connectors (5).
5. Disconnect the 2 telescoping hoses (6).
6. Disconnect the 3 winch hoses (7).
7. Move the disconnected harnesses and hoses to a location where
they will not interfere with work.
8. Temporarily hoist the boom winch assembly and remove the
foot pin (8). [*1]
9. Remove the derricking cylinder head pin (9). [*1]
★ Confirm the shim positions and quantity.
10. Gently hoist and remove the work equipment assembly.
Work equipment assembly: 460 kg
5-15
[MOUNTING]
[*1]
Bushing inner surface when assembling the pins:
Apply Hyper White Grease No. 2
When aligning the pin holes, be sure not to insert your finger
into the holes.
• Venting air
ADJUSTMENT.
5-16
12. DISMOUNTING AND MOUNTING THE OPERATOR’S CANOPY
ASSEMBLY
[DISMOUNTING]
1. Remove the floor mat (1).
3. Remove the handrail (3).
4. Loosen the bolts (4), (5), (6) and (7), and then hoist and remove
the guard assembly (8).
Guard assembly: 49 kg
[MOUNTING]
5-17
13. DISMOUNTING AND MOUNTING THE SEAT BRACKET
ASSEMBLY
Stop the machine in a flat location, fully retract and fully raise
the boom, and set the blade onto the ground.
★ The photograph and figure are different from CC423S-1.
[DISMOUNTING]
1. Remove the hood [1] and side covers [2] and [3].
2. Remove the engine hood [4].

3. Remove the covers [5] and [6].
4. Remove the floor mat [7].
5. Remove the side cover [8].
6. Remove the speed increase pedal [9].

7. Remove the floor plate [10].
5-18
8. Remove the operator’s canopy assembly by referring to the
OPERATOR’S CANOPY ASSEMBLY”.
9. Remove the work equipment assembly by referring to the
section “DISMOUNTING AND MOUNTING THE WORK
EQUIPMENT ASSEMBLY”.
10. Remove the operator’s seat (1) and seat belt.
11. Disconnect the blade control linkage (2).

12. Disconnect the 9 connectors (3).
★ Confirm the installation positions before disconnection.
★ The figure is different from the actual work conditions.
13. Disconnect the ground (4).

14. Disconnect the 17 connectors (5) around the moment limiter.
★ If a crane operation recording device has been set, there are
18 connectors (5).
15. Disconnect the 12 left and right PPC hoses (9).

5-19
16. Disconnect the air duct (10) from the rear side of the seat
bracket.
17. Remove the all the mounting bolts (6), (7) and (8) of the seat
bracket assembly (11).
18. Push forward the derricking cylinder (13) to a position where
it will not interfere with work.
★ When pushing forward the derricking cylinder, use a pad to
prevent damage to hoses and other parts.
★ If the derricking cylinder (13) interferes with work, remove
it.
5-20
19. Hoist and remove the seat bracket assembly (12).
Seat bracket assembly: 130 kg
[MOUNTING]
• Venting air
ADJUSTMENT.
5-21
CC423S-1 HYDRAULIC CIRCUIT DIAGRAM
6-1
CC423S-1 ELECTRIC CIRCUIT DIAGRAM (1/5)
6-2
6-3
6-4
6-5
6-6
SERVICE MODE
CONTENTS
Item Page
SERVICE MODE S-2
(1) MONITORING S-3
(2) FUNCTIONS S-4
[1] CONTROL OUTPUT CHECK S-4
[2] CHECK CALIBRATION VALUE S-6
[3] INITIALIZE CALIBRATION S-6
(3) WORK HISTORY S-7
(4) ERROR HISTORY S-9
(5) INITIAL SETTING S-10
[1] PASSWORD ON/OFF AT START S-10
[2] PASSWORD CHANGE AT START S-10
[3] PASSWORD INITIALIZE AT START S-10
(6) CRANE CALIBRATION S-11
[1] LEVEL CALIBRATION S-11
[2] BOOM LENGTH CALIBRATION S-11
[3] BOOM ANGLE CALIBRATION S-12
[4] LOAD CALIBRATION S-12
(7) ML SETTING S-14
[1] SETTING OF FIXED NUMBER OF FALLS S-14
[2] SEARCHER HOOK PRESENT/ABSENT SETTING S-14
[3] SEARCHER HOOK SWITCHING SETTING S-14
Some of the descriptions and operating methods may differ from the actual machine.
Information relating to as yet unincorporated equipment still in the developmental stage may be included
herein.
S-1
SERVICE MODE
Press and hold the button located second from top on the right of the User Mode screen to display the Password Input
screen.
To display the Service Mode screen, input the password “2435” using the right and left buttons, then press the Enter
Button to transition to Service Mode.
If the display does not transition to the Service Mode screen, reconfirm the password. Input the password
and press the Enter
Button
Long
press
User Mode screen Password input screen
Service Mode screen
(1) Monitoring (5) Initial Setting

* (2) Function * (6) Crane Calibration
(3) Work History (7) ML Setting
(4) Error History
*: The display will move to the next screen only if the button is operated while the Maintenance Switch is turned ON.
(It is not necessary to press and hold the button)
The Moment Limiter function is cancelled during “Function” and “Load Calibration” operations. Work
carefully, paying particular attention in regard to overturning or breakage due to overload, and to hooks or
suspended loads falling, etc. due to over-winding.
NOTES
From this point onwards, illustrated sections show only the monitor screen, but as this is not of touch panel type, actual
operation should be performed using the corresponding buttons.
S-2
(1) MONITORING
You can check each of the output values and the ON/OFF status of each
sensor output.
The displayed page can be switched by pressing the top right button.
(A total of 4 pages)
[Monitoring list]
Page Item Display
-1
Target Engine Revolution ****min
-1
Actual Engine Revolution ****min
Engine Load Factor (Gross) ***%
EGR Valve Opening (Actual) ****%
Target Rack Position ****
Actual Rack Position ****
1/4 Target Rack Current ****mA
Engine Coolant Temperature ***°C
Ignition SW 1 ON/OFF
Engine Starter ON/OFF
Start Lock Signal ON/OFF
ECU Temperature °C
Battery Voltage **.**V
Hydraulic Oil Temperature ***.*°C
Pressure Sensor P1 **.**Mpa
PPC Pressure (P4) **.**Mpa
Fuel Sender Resistance Abnormality ***.*Ω
Boom Raise SOL Output Current *.***A
Boom Lower SOL Output Current *.***A
2/4
Boom Extend SOL Output Current *.***A
Hoist Up Stop SOL Output (Cancel) ON/OFF
Hoist Down Stop SOL Output (Cancel) ON/OFF
Crane PPC SOL Output (RY6) ON/OFF
Travel PPC SOL Output (RY7) ON/OFF
Travel 2 Speed SOL Output ON/OFF
Winch Low Pressure Cancel SOL Output ON/OFF
EMO SW ON/OFF
Emergency Release SW ON/OFF
Override SW ON/OFF
Maintenance SW ON/OFF
Boom Raise Operation Input ON/OFF
Boom Lower Operation Input ON/OFF
Hoist Up Operation Input ON/OFF
Hoist Down Operation Input ON/OFF
Boom Extend Operation Input ON/OFF
3/4
Boom Retract Operation Detection ON/OFF
Slew Operation Detection ON/OFF
Travelling Operation Input ON/OFF
Overwind Detection ON/OFF
Over Un-wind Detection ON/OFF
Boom Raise Limit ON/OFF
Boom Lower Limit ON/OFF
Searcher Hook Stowage Input ON/OFF
Lock Lever Lower Input (RY8) ON/OFF
Travel 2 Speed Switch ON/OFF
Buzzer Cancel SW ON/OFF
Derrick Pressure Sensor P1 *.***V
Derrick Pressure Sensor P2 *.***V
Length Sensor *.***V
Angle Sensor *.***V
Inclination Sensor F & R *.***V
4/4
Inclination Sensor L & R *.***V
Inclination, Pump Pressure, Derrick LS Sensor
*.***V
Power
Length, Angle, D Pressure Sensor Power *.***V
Accelerator Pedal Power *.***V
Accelerator Pedal Voltage *.***V
Charge ON/OFF
Engine Hydraulic Pressure Switch (Lower) ON/OFF
S-3
(2) FUNCTION
The function screen can only be displayed by pressing the button while
the Maintenance Switch is turned ON.
You can check the inputs and outputs, check calibration values, and
perform initialization for calibration.
In Function Mode, the Moment Limiter function is cancelled.

Work carefully, paying particular attention in regard to overturning or breakage due to overload, and to hooks
or suspended loads falling, etc. due to over-winding.
[1] CONTROL OUTPUT CHECK

Each control signal can be output and its operation checked.
The page can be changed by pressing the top right button.
(A total of 3 pages)
Select an item on which to perform an output check by using the up

and down buttons (highlights in white) and press the Enter Button
(check mark).
The screen will change for each item as illustrated in the following
output examples, and selecting “ON” activates the corresponding
output for checking on the actual machine.
Example outputs:
ON:
Buzzer beeps.
ON:
The red rotary lamp
illuminates.
S-4
[Function items list]
Page Output item Output value
Boom Raise Proportional SOL Valve 0. 00 - 1. 00 A
Boom Lower Proportional SOL Valve 0. 00 - 1. 00 A
Boom Extend Proportional SOL Valve 0. 00 - 1. 00 A
Hoist Up Stop SOL Valve(Cancel) ON/OFF
1/3 Hoist Down Stop SOL Valve(Cancel) ON/OFF
Travel Speed Selector SOL Valve (2-speed) ON/OFF
Low Pressure Selector SOL Valve ON/OFF
Travel PPC SOL valve ON/OFF
Crane PPC solenoid valve ON/OFF
Rotary Lamp: RED ON/OFF
Rotary Lamp: YELLOW ON/OFF
Rotary Lamp: GREEN ON/OFF
ML Buzzer (Continuous) ON/OFF
2/3
Inclination Buzzer (Cooing Sound) ON/OFF
EMO Control Relay ON/OFF
Engine Lock ON/OFF
Sensor Power ON/OFF
Over Winding Audio output
Set Boom To Travelling Posture Audio output
3/3 Overloading Audio output
Shifted to Travelling Mode Audio output
Stopped at Set Limit Audio output
S-5
[2] CHECK CALIBRATION VALUE
You can check the input values of calibration, input voltage and the
date and time of the last calibration.
[3] INITIALIZE CALIBRATION

The calibration values can be initialized.
Select “YES” using the left and right buttons (highlights in white),
press the Enter Button (check mark) and the confirmation screen will
be displayed again.
Select “YES” at the second confirmation (highlights in white) and
press the Enter Button (check mark) to complete the initialization.
Initializing turns the calibration values to the default values.
Default value
Item Default value Default voltage
Shortest 3.18 m 0.000 V
Boom length
Longest 8.71 m 2.720 V
Horizontal 0.0° 1.550 V
Boom angle
Most raised 80.0° 4.100 V
Sensor 1: 1.300 V
No load 0.03 t
Sensor 2: 1.000 V
Load
When weight is Sensor 1: 2.050 V
1.03 t
suspended Sensor 2: 1.000 V
After completing the initialization, be sure to perform the calibration.
S-6
(3) WORK HISTORY
You can check the Work History. (Up to 2,000 values for display are stored on a first in, first out basis.)
Values are displayed on the left and right pages, and when the number of values overflows, turn to the next page to display
more.
The display order is listed from the newest recording date and time.
Switch to next page
Switch pages
left and right
(A total of 3 pages:A/B/C)
[Operations and conditions that trigger recording (start and end time are recorded in a single line per trigger)]
Abbreviation Record Specification
Trigger Content
displayed classification classification
Records status at the instant
Emergency Japanese
ON when Emergency Release Instantaneous
Release ON models
1 turns ON
Records status at the instant Non-Japanese
Override SW ON RN Instantaneous
when Override SW turns ON models
Emergency Records status of Emergency Japanese
OF Continuous
Release OFF Release from ON to OFF models
2
Records status of Override Non-Japanese
Override SW OFF RF Continuous
SW from ON to OFF models
Continuously records while
3 Overload OL Continuous Common
load factor is 100% or more
Select number of Records instant of switching
4 FS Instantaneous Common
falls for hook the number of falls
Maker Mode Continuously records when in
5 MM Continuous Common
selection Maker Mode
Calibration Mode Continuously records when in
6 CL Continuous Common
selection Calibration Mode
Continuously records if
3° inclination
7 SS machine body is inclined by 3° Continuous Common
when standing still
or more while static
Continuously records if
15° inclination in
8 SM machine body is inclined by Continuous Common
Travelling Mode
15° or more in Travelling Mode
Function Mode Continuously records when in
9 FC Continuous Common
selection Function Mode
Maintenance SW Non-Japanese
10 MN when Maintenance SW turns Instantaneous
ON models
ON
Maintenance SW Non-Japanese
11 MF when Maintenance SW turns Continuous
OFF models
ON
SH Records status at the instant of
Non-Japanese
12 Present/Absent SH switching the searcher hook Instantaneous
models
Switch between present/absent
SH Position Records at instant of switching Non-Japanese
13 SP Instantaneous
Switch searcher hook models
Overseas (non-Japanese)
models only
S-7
[Record item]
Recorded details Record
Specification
Item Monitor display Record classification: Record classification: method and
classification
when instantaneous when continuous units
0 Trigger Trigger - - (Refer to table) Common
1 Recorded date Recorded date Recorded day ← Common
2 Start time Start time Record start time ← Common
3 End time End time Record end time ← Common
Value/state at time of Maximum value during
4 Load factor Load factor % Common
recording recording
Emergency Emergency Value/state at time of Y if there is input during Japanese
Y/N
Release Release recording recording models
5
Override SW Value/state at time of Y if there is input during Non-Japanese
OR Y/N
cancellation recording recording models
Raising Value/state at time of Y if there is input during
6 Raising Y/N Common
operation recording recording
Lowering Value/state at time of Y if there is input during
7 Lowering Y/N Common
Extending Value/state at time of Y if there is input during
8 Extension Y/N Common
Retracting Value/state at time of Y if there is input during
9 Contraction Y/N Common
Hoisting Value/state at time of Y if there is input during
10 Lifting Y/N Common
Hoisting down Value/state at time of Y if there is input during
11 Lowering Y/N Common
Slewing Value/state at time of Y if there is input during
12 Slewing Y/N Common
Travelling Value/state at time of Y if there is input during
13 Travelling Y/N Common
Value/state at time of Value at time of maximum
14 Boom length B Length m Common
recording load factor during recording
15 Boom angle B Angle ° Common
16 Actual load A.L. t Common
17 Rated total load Total load t Common
Actual working Value/state at time of Value at time of maximum
18 Actual W.R. m Common
radius recording load factor during recording
Inclination angle
Value/state at time of Maximum value during
19 Left or right Inclination X ° Common
recording recording
direction
Inclination angle
Forward or Value/state at time of Maximum value during
20 Inclination Y ° Common
backward recording recording
direction
Value/state at time of Y if there is input during
21 Range regulation Range Y/N Common
recording recording
C/F/-
Value/state at time of State at time of maximum C: Calibration
22 Mode selection MS Common
recording load factor during recording F: Function
-: Other
Value/state at time of State at time of maximum
23 Number of falls Number of falls 4/2/1 Common
Overwinding Value/state at time of Y if there is input during
24 Overwinding Y/N Common
Detection recording recording
Over Un-winding Over Value/state at time of Y if there is input during
25 Y/N Common
Detection Un-winding recording recording
Japanese Value/state at time of State at time of maximum
26 LS JP / CE Common
models/CE recording load factor during recording
Maintenance SW Value/state at time of Y if there is input during Non-Japanese
27 MT Y/N
cancellation recording recording models
28 SH Position SH 1/2/3/R/- Common
SH Stowage Value/state at time of State at time of maximum
29 SR Y/N/- Common
Detection recording load factor during recording
30 Oil Temperature Oil Temp °C Common
Overseas (non-Japanese)
models only
S-8
(4) ERROR HISTORY
You can check the Error History.
Red character displays indicate on going errors so take appropriate
measures.
When multiple errors are displayed, you can switch pages by pressing
the top right button.
Errors that have been resolved are displayed in white.
Select resolved error items using the up and down buttons on the left
and press the Delete Button to delete them.
[Details of an error display]

Sequential
order Error code Details of failure
Occurrence count Initial Latest

occurrence occurrence
time time
Take countermeasures according to the error code displayed.
NOTES
The Yanmar Engine Diagnostic Tool is required separately for engine-related diagnoses.
S-9
(5) INITIAL SETTING
There is a setting for whether or not a password is to be used at start,
and the password itself may be set.
[1] PASSWORD ON/OFF AT START

Whether or not a password shall be input after turning the key ON
can be set.
OFF: No need of password input (Black)
ON: Password input required (Highlighted in white)
[2] PASSWORD CHANGE AT START

The password that should be input can be changed.
Input in due order a 4-digit number that should be set.
One character can be deleted by pressing and holding any key.
NOTES
To cancel a password change, set the Starter Switch to “OFF” and
turn off the power supply.
[3] PASSWORD INITIALIZE AT START

This process initializes any arbitrarily set password.
Select “YES” by using the left and right switches (highlights in
white) and press Enter Button to complete the initialization.
When initialized, the password becomes “0000”.
S-10
(6) CRANE CALIBRATION
The Calibration screen can only be displayed by operating the button
while the Maintenance Switch is turned ON.
After moving to the Calibration screen, select an item using the up and
down buttons (black background) and press the Enter Button (check
mark) to proceed with calibration.
• Be sure to use horizontal and hard ground to conduct the Crane Calibration.
• Since the safety functions are cancelled during the calibration, be cautious of the risk of falling or damage of
the machine. Be sure to observe the monitor displays or the descriptions in the manual, and refrain from
unnecessarily hoisting larger loads or extending the working radius.
[1] LEVEL CALIBRATION

Move the machine to a horizontal location and fully lower the boom in
the 1st stage state.
Select “YES” by using the left and right buttons (highlights in white)
and press the Enter Button (check mark) to conduct the calibration.
[2] BOOM LENGTH CALIBRATION

[Calibrating the minimum boom length]
Fully retract the boom.
Adjust the value to “3.18” m using the up and down buttons and,
when the input voltage is stabilized, press the Enter Button (check
mark).
[Calibrating the maximum boom length]

Fully extend the boom.
Adjust the value to “8.71” m using the up and down buttons and,
when the input voltage is stabilized, press the Enter Button (check
mark).
S-11
[3] BOOM ANGLE CALIBRATION
Attach an angle meter to the boom.
[Calibrating boom angle in the horizontal state]
Set the boom angle to horizontal (aim for 0°).
Adjust the value to match the angle indicated on the angle meter
using the up and down buttons and, when the input voltage is
stabilized, press the Enter Button (check mark).
[Calibrating the fully raised boom angle]

Set the boom angle to fully raised state (aim for 80°).
Adjust the value to match the angle indicated on the angle meter
using the up and down buttons and, when the input voltage is
stabilized, press the Enter Button (check mark).
[4] LOAD CALIBRATION

[Preparing the weight for load calibration]
Prepare a weight of 1.00 t in a location with a working radius of
2.35 m.
(If a weight of 1.00 t is not available, prepare a precisely determined
weight within the range of 0.09 to 1.10 t.)
When the weight is ready, press the Enter Button (check mark).
[Checking the machine body state]

Move the machine body to check that the indicated values of boom
length and boom angle conform to the correct ones.
Display values These values shall match the correct ones.
Correct values (check the following four conditions):

When fully When fully
Boom length
retracted: 3.18 m extended: 8.71 m
When fully raised:
Boom angle When horizontal: 0° Matches the angle
meter value
If any value is deviated, be sure to calibrate the deviated conditions

and check again.
If satisfactory, press the Enter Button (check mark).
S-12
[Machine body state settings]
With no suspended load, adjust the boom to meet the following
conditions:
Boom length 5. 03 m
Boom angle 60° ± 0.1°
When the input voltage is stabilized press the Enter Button (check
mark).
[Load calibration (with no load)]

With no load suspended, adjust the boom length and boom angle so
that the boom matches the following condition:
Displayed load 0. 03 t (hook weight only)
*2
*1
Stop the hook swaying.
Adjust the displayed load (*1) to match the actual load using the up
and down buttons and press the Enter Button (check mark).
[Load calibration (with weight suspended)]

Load a weight whilst conditions for the Unloaded Load Calibration
remain satisfied.
Adjust the boom length and boom angle so that the boom matches the
*2
following condition: *1
Displayed load Weight + rigging + hook (0.03 t)
Stop the weight swaying.

Adjust the displayed load (*1) to match the actual load using the up
and down buttons and press the Enter Button (check mark). *1: The value entered for this
calibration
*2: The value calculated using the
previous calibration value (the
Load Calibration is completed with the above. default value for the case of
initial calibration)
NOTES
After calibration, check the “Check calibration value” screen under
“Function” to confirm calibration was performed correctly.
• Are the calibration values entered?
• Are the calibration time and date updated?
S-13
(7) ML SETTING
Various ML settings can be performed.
The white highlighted part is the current setting.
[1] SETTING OF FIXED NUMBER OF FALLS

It is possible to fix the selected number of falls for the hook
When any number other than “none” is selected, switching the
number of falls in the User Mode can be enabled for the set numbers
only.
[2] SEARCHER HOOK NONE/WITH SETTING

The searcher hook can be set as present or absent. Each time the
switch is pressed, the selection changes as
[none → with → none → with ...].

NOTES
When the optional searcher hook is installed, set it to “with”.
If this is not set, Searcher Hook Mode will not be displayed on the
monitor.
[3] SEARCHER HOOK SWITCHING SETTING

You can set automatic/manual switching with Searcher Hook
Detection.
Each time the switch is pressed, the selection changes as
[manual → automatic → manual → automatic...].
NOTES
Automatic switching is not possible unless automatic switching
detection equipment is installed.
S-14
TROUBLESHOOTING
CONTENTS
Item Page
1. TROUBLESHOOTING (ERROR CODES) T-302
2. TROUBLESHOOTING (MATTERS OTHER THAN ERROR CODE DISPLAY) T-401
T-301
1. TROUBLESHOOTING (ERROR CODES)
Conduct troubleshooting for the corresponding error code.
Error codes (CC423S-1)
Error code Content Page
3-FOLD SOLENOID VALVE BOOM LOWER SOL OPEN (3-FOLD EPC
EO02L T-304
VALVE)
3-FOLD SOLENOID VALVE BOOM LOWER SOL SHORT (3-FOLD EPC
EO02H T-304
VALVE)
3-FOLD SOLENOID VALVE BOOM RAISE SOL OPEN (3-FOLD EPC
EO03L T-304
VALVE)
3-FOLD SOLENOID VALVE BOOM RAISE SOL SHORT (3-FOLD EPC
EO03H T-304
VALVE)
3-FOLD SOLENOID VALVE BOOM EXTEND SOL OPEN (3-FOLD EPC
EO04L T-304
VALVE)
3-FOLD SOLENOID VALVE BOOM EXTEND SOL SHORT (3-FOLD EPC
EO04H T-304
VALVE)
EO05L PPC SOLENOID VALVE TRAVEL HI SOL OPEN (3-FOLD SOL VALVE) T-309
EO05H PPC SOLENOID VALVE TRAVEL HI SOL SHORT (3-FOLD SOL VALVE) T-309
EO06L WINCH LOW PRESSURE SHIFT SOL OPEN T-309
EO06H WINCH LOW PRESSURE SHIFT SOL SHORT T-309

2-FOLD SOLENOID VALVE HOIST UP STOP SOL OPEN (2-FOLD SOL
EO09L T-310
VALVE)
2-FOLD SOLENOID VALVE HOIST UP STOP SOL SHORT (2-FOLD SOL
EO09H T-310
VALVE)
2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL OPEN (2-FOLD
EO10L T-310
SOL VALVE)
2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL SHORT (2-FOLD
EO10H T-310
SOL VALVE)
EO12L PPC SOLENOID VALVE TRAVEL PPC SOL OPEN (3-FOLD SOL VALVE) T-311
PPC SOLENOID VALVE TRAVEL PPC SOL SHORT (3-FOLD SOL
EO12H T-311
VALVE)
EO15L SENSOR 12V POWER OPEN T-315
EO15H SENSOR 12V POWER SHORT T-315
ES04L LENGTH SENSOR (LOW VOLTAGE) T-320
ES04H LENGTH SENSOR (HIGH VOLTAGE) T-320
ES05L ANGLE SENSOR (LOW VOLTAGE) T-320
ES05H ANGLE SENSOR (HIGH VOLTAGE) T-320
T-302
Error code Content Page
ES09L PPC PRESSURE SENSOR (LOW VOLTAGE) T-324
ES09H PPC PRESSURE SENSOR (HIGH VOLTAGE) T-324
ES10L HYD. OIL TEMP SENSOR P1 (LOW VOLTAGE) T-325
ES10H HYD. OIL TEMP SENSOR P1 (HIGH VOLTAGE) T-325
ES11L INCLINATION SENSOR (LOW VOLTAGE) T-328
ES11H INCLINATION SENSOR (HIGH VOLTAGE) T-328
ES12L ACCELERATOR PEDAL (LOW VOLTAGE) T-328
ES12H ACCELERATOR PEDAL (HIGH VOLTAGE) T-328
ES13H FUEL SENSOR RESISTANCE (HIGH RESISTANCE) T-329
TTC36 CONTROLLER ABNORMALITY T-332
ECU ECU COMMUNICATION ABNORMALITY T-332
EV001 BATTERY VOLTAGE ABNORMALITY T-335
EV007 CHARGE ABNORMALITY T-335
EV008 TTC60 SENSOR POWER 5V0 ABNORMALITY T-337
EV009 TTC36X SENSOR POWER 5V0 ABNORMALITY T-337
EH01 HYDRAULIC OIL TEMPERATURE ABNORMALITY T-338
[Note]
• The sequential order given under assumed cause and diagnostic method does not necessarily match the order of
checking. Select the item(s) to be checked in accordance with the status of the subject that can be determined by
observing the vehicle and service conditions.
• Before starting repair work, visually check the following points:
1. • Is there any fault in appearance?
① Check of wiring
Is there any damage in wiring?
Is there any over-stretched part in wiring?
Is there any breakage in wiring?
② Check of connectors
Is there any disengaged connector?
Is there any disengaged wiring on connectors?
③ Is there any part that is blackened or melted due to a short circuit?
④ Is there any inclusion of condensed water?
T-303
ERROR CODE [EO02L] 3-FOLD SOLENOID VALVE BOOM LOWER SOL OPEN
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom lower SOL open circuit (3-fold EPC
Error code EO02L
failure valve)
Failure-determining Solenoid resistance exceeded 20 kΩ (when output is OFF).
conditions Short circuit to power supply line detected (when output is OFF).
Cause Diagnostic method and action to be taken
Open circuit in harness
1 Check the related circuits for any open circuit.
Assumed cause and related to lowering SOL
diagnostic method 2 Fault of lowering SOL Check if the solenoid functions normally.
Harness short circuit to
3 Check the related circuits for any short circuit to power supply.
power supply line
[Additional information] Refer to T-306, 307 for related electric circuit and T-308 for location
ERROR CODE [EO02H] 3-FOLD SOLENOID VALVE BOOM LOWER SOL SHORT
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom lower SOL short circuit (3-fold EPC
Error code EO02H
failure valve)
Failure-determining
Solenoid resistance undershot 4 Ω (when output is ON).
conditions
Assumed cause and 1 Fault of lowering SOL Check if the solenoid functions normally.
diagnostic method Short circuit in harness Check the related circuits for any short circuit in lowering SOL
2
related to lowering SOL wiring.
ERROR CODE [EO03L] 3-FOLD SOLENOID VALVE BOOM RAISE SOL OPEN
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom raise SOL open circuit (3-fold EPC
Error code EO03L
failure valve)
Assumed cause and related to raising SOL
diagnostic method 2 Fault of raising SOL Check if the solenoid functions normally.
power supply line
ERROR CODE [EO03H] 3-FOLD SOLENOID VALVE BOOM RAISE SOL SHORT
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom raise SOL short circuit (3-fold EPC
Error code EO03H
failure valve)
Failure-determining
conditions
Assumed cause and 1 Fault of raising SOL Check if the solenoid functions normally.
diagnostic method Short circuit in harness
2 Check the related circuits for any short circuit in raising SOL wiring.
related to raising SOL
T-304
ERROR CODE [EO04L] 3-FOLD SOLENOID VALVE BOOM EXTEND SOL OPEN
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom extend SOL open circuit (3-fold EPC
Error code EO04L
failure valve)
Assumed cause and related to extending SOL
diagnostic method 2 Fault of extending SOL Check if the solenoid functions normally.
power supply line
ERROR CODE [EO04H] 3-FOLD SOLENOID VALVE BOOM EXTEND SOL SHORT
(3-FOLD EPC VALVE)
Details of 3-fold solenoid valve boom extend SOL short circuit (3-fold EPC
Error code EO04H
failure valve)
Failure-determining
conditions
Assumed cause and 1 Fault of extending SOL Check if the solenoid functions normally.
diagnostic method 2 Short circuit in harness Check the related circuits for any short circuit in extending SOL
related to extending SOL wiring.
T-305
[Related electric circuits]
T-306
[Related electric circuits (by function)]
Lowering Raising
stop/speed control stop/speed control
Extending
stop/speed control
T-307
[Location information] (Standard)
T-308
ERROR CODE [EO05L] PPC SOLENOID VALVE TRAVEL HI SOL OPEN
(3-FOLD SOL VALVE)
Details of
Error code EO05L PPC solenoid valve travel Hi SOL open circuit (3-fold SOL valve)
failure
Open circuit in harness related
to travel Hi SOL
Assumed cause and
diagnostic method 2 Fault of travel Hi SOL Check if the solenoid functions normally.
Harness short circuit to power
supply line
[Additional information] Refer to T-312 for related electric circuit and T-314 for location
ERROR CODE [EO05H] PPC SOLENOID VALVE TRAVEL HI SOL SHORT

(3-FOLD SOL VALVE)
Details of
Error code EO05H PPC solenoid valve travel Hi SOL short circuit (3-fold SOL valve)
failure
Failure-determining
conditions
Assumed cause and 1 Fault of travel Hi SOL Check if the solenoid functions normally.
diagnostic method
Short circuit in harness related
2 Check the related circuits for any short circuit in travel Hi SOL wiring.
to travel Hi SOL
ERROR CODE [EO06L] WINCH LOW PRESSURE SHIFT SOL OPEN

Details of
Error code EO06L Winch low pressure shift SOL open circuit
failure
1 to winch low pressure shift Check the related circuits for any open circuit.
Assumed cause and SOL
diagnostic method Fault of winch low pressure
2 Check if the solenoid functions normally.
shift SOL
supply line
ERROR CODE [EO06H] WINCH LOW PRESSURE SHIFT SOL SHORT

Details of
Error code EO06H Winch low pressure shift SOL short circuit
failure
Failure-determining
conditions
Fault of winch low pressure
Assumed cause and 1 Check if the solenoid functions normally.
shift SOL
diagnostic method Short circuit in harness related
Check the related circuits for any short circuit in winch low pressure shift
2 to winch low pressure shift
SOL wiring.
SOL
T-309
ERROR CODE [EO09L] 2-FOLD SOLENOID VALVE HOIST UP STOP SOL OPEN
(2-FOLD SOL VALVE)
Details of
Error code EO09L 2-fold solenoid valve hoist up stop SOL open circuit (2-fold SOL valve)
failure
to hoist up stop SOL
Assumed cause and
diagnostic method 2 Fault of hoist up stop SOL Check if the solenoid functions normally.
supply line
ERROR CODE [EO09H] 2-FOLD SOLENOID VALVE HOIST UP STOP SOL SHORT
(2-FOLD SOL VALVE)
Details of
Error code EO09H 2-fold solenoid valve hoist up stop SOL short circuit (2-fold SOL valve)
failure
Failure-determining
conditions
Assumed cause and 1 Fault of hoist up stop SOL Check if the solenoid functions normally.
diagnostic method
2 Short circuit in harness related Check the related circuits for any short circuit in hoist up stop SOL
to hoist up stop SOL wiring.
ERROR CODE [EO10L] 2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL OPEN
(2-FOLD SOL VALVE)
Details of 2-fold solenoid valve hoist down stop SOL open circuit (2-fold SOL
Error code EO10L
failure valve)
to hoist down stop SOL
Assumed cause and
diagnostic method 2 Fault of hoist down stop SOL Check if the solenoid functions normally.

supply line
ERROR CODE [EO10H] 2-FOLD SOLENOID VALVE HOIST DOWN STOP SOL SHORT
(2-FOLD SOL VALVE)
Details of 2-fold solenoid valve hoist down stop SOL short circuit (2-fold SOL
Error code EO10H
failure valve)
Failure-determining
conditions
Assumed cause and 1 Fault of hoist down stop SOL Check if the solenoid functions normally.
diagnostic method
2 Short circuit in harness related Check the related circuits for any short circuit in hoist down stop SOL
to hoist down stop SOL wiring.
T-310
ERROR CODE [EO12L] PPC SOLENOID VALVE TRAVEL PPC SOL OPEN
(3-FOLD SOL VALVE)
Details of
Error code EO12L PPC solenoid valve travel PPC SOL open circuit (3-fold SOL valve)
failure
to travel PPC SOL
Assumed cause and
diagnostic method 2 Fault of travel PPC SOL Check if the solenoid functions normally.
supply line
ERROR CODE [EO12H] PPC SOLENOID VALVE TRAVEL PPC SOL SHORT
(3-FOLD SOL VALVE)
Details of
Error code EO12H PPC solenoid valve travel PPC SOL short circuit (3-fold SOL valve)
failure
Failure-determining
conditions
Assumed cause and 1 Fault of travel PPC SOL Check if the solenoid functions normally.
diagnostic method
2 Short circuit in harness related
Check the related circuits for any short circuit in travel PPC SOL wiring.
to travel PPC SOL
T-311
T-312
T-313
T-314
ERROR CODE [EO15L] SENSOR 12V POWER OPEN
Details of
Error code EO15L Sensor 12V power open circuit
failure
Failure-determining Short circuit to power supply line detected (when output is OFF).
conditions Open circuit in power supply line detected (when output is OFF).
related to power supply line
Assumed cause and Harness short circuit to
diagnostic method 2 Check the related circuits for any short circuit to power supply.
power supply line
Fault of controller
3 Replace controller HY-TTC60.
HY-TTC60
[Additional information] Refer to T-316 for related electric circuit and T-316, 317, 318 for location
ERROR CODE [EO15H] SENSOR 12V POWER SHORT

Details of
Error code EO15H Sensor 12V power short circuit
failure
Failure-determining Short circuit to grounding line detected (when output is OFF).
conditions
Fault of controller
Assumed cause and 1 Check if controller HY-TTC60 functions normally.
HY-TTC60
diagnostic method
2 Short circuit in harness Check the related circuits for any short circuit in wiring related to
related to power supply line grounding line.
[Additional information] Refer to T-316 for related electric circuit and T-316, 317, 318 for location
T-315
[Location information] (Boom)
T-316
T-317
[Location information] (Pump)
[Location information] (Floor harness)
T-318
ERROR CODE [ES02L] DERRICK PRESSURE SENSOR 1 (LOW VOLTAGE)
Details of Derrick pressure sensor 1 voltage abnormality (Low voltage
Error code ES02L
failure abnormality)
Failure-determining
Derrick pressure sensor 1 voltage undershot 0.5 V.
conditions
Fault of a circuit related to
Assumed cause and 1 Check the circuits related to derrick pressure sensor 1.
derrick pressure sensor 1
diagnostic method
Fault of derrick pressure
2 Check the output voltage of derrick pressure sensor 1.
sensor 1
ERROR CODE [ES02H] DERRICK PRESSURE SENSOR 1 (HIGH VOLTAGE)

Details of
Error code ES02H Derrick pressure sensor 1 voltage abnormality (High voltage abnormality)
failure
Failure-determining
Derrick pressure sensor 1 voltage exceeded 4.5 V.
conditions
diagnostic method
sensor 1
ERROR CODE [ES03L] DERRICK PRESSURE SENSOR 2 (LOW VOLTAGE)

Details of
Error code ES03L Derrick pressure sensor 2 voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Derrick pressure sensor 1 voltage undershot 0.5 V.
conditions

diagnostic method
sensor 2
ERROR CODE [ES03H] DERRICK PRESSURE SENSOR 2 (HIGH VOLTAGE)

Details of
Error code ES03H Derrick pressure sensor 2 voltage abnormality (High voltage abnormality)
failure
Failure-determining
Derrick pressure sensor 1 voltage exceeded 4.5 V.
conditions
diagnostic method
sensor 2
T-319
ERROR CODE [ES04L] LENGTH SENSOR (LOW VOLTAGE)
Details of
Error code ES04L Length meter sensor voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Length meter sensor voltage undershot 0.1 V.
conditions

Assumed cause and 1 Check the circuits related to length meter sensor.
length meter sensor
diagnostic method
2 Fault of length meter sensor Check the output voltage of length meter sensor.
ERROR CODE [ES04H] LENGTH SENSOR (HIGH VOLTAGE)

Details of
Error code ES04H Length meter sensor voltage abnormality (High voltage abnormality)
failure
Failure-determining
Length meter sensor voltage exceeded 3 V.
conditions
Assumed cause and 1 Check the circuits related to length meter sensor.
length meter sensor
diagnostic method
2 Fault of length meter sensor Check the output voltage of length meter sensor.
ERROR CODE [ES05L] ANGLE SENSOR (LOW VOLTAGE)

Details of
Error code ES05L Angle meter sensor voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Angle meter sensor voltage undershot 0.5 V.
conditions
Assumed cause and 1 Check the circuits related to angle meter sensor.
angle meter sensor
diagnostic method
2 Fault of angle meter sensor Check the output voltage of angle meter sensor.
ERROR CODE [ES05H] ANGLE SENSOR (HIGH VOLTAGE)

Details of
Error code ES05H Angle meter sensor voltage abnormality (High voltage abnormality)
failure
Failure-determining
Angle meter sensor voltage exceeded 3 V.
conditions
Assumed cause and 1 Check the circuits related to angle meter sensor.
angle meter sensor
diagnostic method
2 Fault of angle meter sensor Check the output voltage of angle meter sensor.
T-320
T-321
T-322
ERROR CODE [ES06L] PUMP PRESSURE SENSOR 1 (LOW VOLTAGE)
Details of
Error code ES06L Pump pressure sensor 1 voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Pump pressure sensor 1 voltage undershot 0.8 V.
conditions

Assumed cause and 1 Check the circuits related to pump pressure sensor 1.
pump pressure sensor 1
diagnostic method
Fault of pump pressure sensor
2 Check the output voltage of pump pressure sensor 1.
1
ERROR CODE [ES06H] PUMP PRESSURE SENSOR 1 (HIGH VOLTAGE)

Details of
Error code ES06H Pump pressure sensor 1 voltage abnormality (High voltage abnormality)
failure
Failure-determining
Pump pressure sensor 1 voltage exceeded 4.95 V.
conditions
diagnostic method
1

Details of
failure
Failure-determining
conditions
diagnostic method
2

Details of
failure
Failure-determining
conditions
diagnostic method
2
T-323
Details of
failure
Failure-determining
conditions

diagnostic method
3

Details of
failure
Failure-determining
conditions
diagnostic method
3
ERROR CODE [ES09L] PPC PRESSURE SENSOR (LOW VOLTAGE)

Details of
Error code ES09L PPC pressure sensor voltage abnormality (Low voltage abnormality)
failure
Failure-determining
PPC pressure sensor voltage undershot 0.8 V.
conditions
Assumed cause and 1 Check the circuits related to PPC pressure sensor.
PPC pressure sensor
diagnostic method
2 Fault of PPC pressure sensor Check the output voltage of PPC pressure sensor.
ERROR CODE [ES09H] PPC PRESSURE SENSOR (HIGH VOLTAGE)

Details of
Error code ES09H PPC pressure sensor voltage abnormality (High voltage abnormality)
failure
Failure-determining
PPC pressure sensor voltage exceeded 4.95 V.
conditions
Assumed cause and 1 Check the circuits related to PPC pressure sensor.
PPC pressure sensor
diagnostic method
2 Fault of PPC pressure sensor Check the output voltage of PPC pressure sensor.
T-324
ERROR CODE [ES10L] HYD. OIL TEMP SENSOR (LOW VOLTAGE)
Details of Hydraulic oil temperature sensor P1 voltage abnormality (Low voltage
Error code ES10L
Failure-determining
Hydraulic oil temperature sensor voltage undershot 0.8 V.
conditions
Assumed cause and 1 hydraulic oil temperature Check the circuits related to hydraulic oil temperature sensor.
diagnostic method sensor
Fault of hydraulic oil
2 Check the output voltage of hydraulic oil temperature sensor.
temperature sensor
ERROR CODE [ES10H] HYD. OIL TEMP SENSOR (HIGH VOLTAGE)

Details of Hydraulic oil temperature sensor P1 voltage abnormality (High voltage
Error code ES10H
Failure-determining
Hydraulic oil temperature sensor voltage undershot 4.95 V.
conditions
Assumed cause and 1 hydraulic oil temperature Check the circuits related to hydraulic oil temperature sensor.
diagnostic method sensor
2 Check the output voltage of hydraulic oil temperature sensor.
temperature sensor
T-325
T-326
T-327
ERROR CODE [ES11L] INCLINATION SENSOR (LOW VOLTAGE)
Details of
Error code ES11L Inclination sensor voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Inclination sensor voltage undershot 0.03 V.
conditions
Assumed cause and 1 Check the circuits related to inclination sensor.
inclination sensor
diagnostic method
2 Fault of inclination sensor Check the output voltage of inclination sensor.
ERROR CODE [ES11H] INCLINATION SENSOR (HIGH VOLTAGE)

Details of
Error code ES11H Inclination sensor voltage abnormality (High voltage abnormality)
failure
Failure-determining
Inclination sensor voltage exceeded 4.97 V.
conditions
Assumed cause and 1 Check the circuits related to inclination sensor.
inclination sensor
diagnostic method
2
Fault of inclination sensor Check the output voltage of inclination sensor.
ERROR CODE [ES12L] ACCELERATOR PEDAL (LOW VOLTAGE)

Details of
Error code ES12L Accelerator pedal voltage abnormality (Low voltage abnormality)
failure
Failure-determining
Accelerator pedal voltage undershot 0.1 V.
conditions
1 Check the circuits related to accelerator
accelerator
Assumed cause and Fault of accelerator
diagnostic method 2 Check the output voltage of accelerator potentiometer.
potentiometer
Fault of accelerator pedal
3 Check the parts around the accelerator pedal for any abnormality.
parts
ERROR CODE [ES12H] ACCELERATOR PEDAL (HIGH VOLTAGE)

Details of
Error code ES12H Accelerator pedal voltage abnormality (High voltage abnormality)
failure
Failure-determining
Accelerator pedal voltage exceeded 4.9 V.
conditions
1 Check the circuits related to accelerator
Assumed cause and accelerator
diagnostic method Fault of accelerator
2 Check the output voltage of accelerator potentiometer.
potentiometer
Fault of accelerator pedal
3 Check the parts around the accelerator pedal for any abnormality.
parts
T-328
ERROR CODE [ES13H] FUEL SENSOR RESISTANCE (HIGH RESISTANCE)
Details of
Error code ES13H Fuel sensor resistance abnormality (High resistance abnormality)
failure
Failure-determining
Fuel sensor resistance exceeded 300 Ω for 60 seconds.
conditions
Assumed cause and Fault of a circuit related to
1 Check the circuits related to fuel sensor.
diagnostic method fuel sensor
2 Fault of fuel sensor Check the resistance of fuel sensor.
T-329
T-330
T-331
ERROR CODE [TTC36] CONTROLLER ABNORMALITY
Details of
Error code TTC36 Controller abnormality
failure
Failure-determining
Communication abnormality detected in CAN communication circuit with TTC36
conditions
Fault of CAN
Assumed cause and 1 Check the CAN communication circuit.
communication circuit
diagnostic method
2 Fault of TTC36 controller Replace the TTC36 controller.
ERROR CODE [ECU] ECU COMMUNICATION ABNORMALITY

Details of
Error code ECU ECU communication abnormality
failure
Failure-determining
Communication abnormality detected in CAN communication circuit with ECU
conditions
Assumed cause and Fault of CAN
1 Check the CAN communication circuit.
diagnostic method communication circuit
2 Fault of ECU controller Replace the ECU controller.
T-332
T-333
T-334
ERROR CODE [EV001] BATTERY VOLTAGE ABNORMALITY
Details of
Error code EV001 Battery voltage abnormality
failure
Failure-determining Battery voltage undershot 13.5 V, or exceeded 15 V (when engine is turned ON).
conditions Battery voltage undershot 11 V (when engine is turned OFF)
Open or short circuit of
Assumed cause and 1 Check the battery circuit.
battery circuit
diagnostic method Check if battery voltage has dropped.
2 Battery capacity shortageReference value = Voltage (1 piece): 12 V or more; Specific gravity (1
piece): 1.26 or more
ERROR CODE [EV007] CHARGE ABNORMALITY

Details of
Error code EV007 Charge abnormality
failure
Failure-determining
No charge signal could be received from the alternator after engine start.
conditions
Assumed cause and 1 Fault of alternator circuit Check the circuits in the range from alternator (generator) to TTC36.
diagnostic method
2 Fault of alternator Check if the alternator functions normally.
T-335
T-336
ERROR CODE [EV008] TTC60 SENSOR POWER 5V0 ABNORMALITY
Details of
Error code EV008 TTC60 sensor power 5V0 abnormality
failure
Failure-determining
Either 4.9 V or less or 5.1 V or more has been detected for TTC60 sensor power supply 5V.
conditions
Open or short circuit in
Assumed cause and 1 TTC60 sensor power supply Check the circuits in the range from TTC60 to length meter sensor.
diagnostic method 5V circuit
If there is no problem in the circuit, fault of TTC60 controller is
2 Fault of TTC60 controller
conceivable.
ERROR CODE [EV009] TTC36X SENSOR POWER 5V0 ABNORMALITY

Details of
Error code EV009 TTC36X sensor power 5V0 abnormality
failure
Failure-determining
Either 4.9 V or less or 5.1 V or more has been detected for TTC36 sensor power supply 5V.
conditions
Open or short circuit in
Check the circuits in the range from TTC36 to accelerator
1 TTC36 sensor power supply
Assumed cause and potentiometer.
5V circuit
diagnostic method
If there is no problem in the circuit, fault of TTC36 controller is
2 Fault of TTC36 controller
conceivable.
T-337
ERROR CODE [EH01] HYDRAULIC OIL TEMPERATURE ABNORMALITY
If error code [ES10L] is displayed simultaneously with the subject code, the former should be prioritized.
Details of
Error code EH01 Hydraulic oil temperature abnormality
failure
Failure-determining
Hydraulic oil temperature sensor detected 100°C or more.
conditions
1 Overheat Lower the hydraulic oil temperature.
Assumed cause and Fault of hydraulic oil
diagnostic method 2 Check the circuit of hydraulic oil temperature sensor (P1).
temperature sensor circuit
3 Check if the hydraulic oil temperature sensor (P1) functions normally.
temperature sensor
T-338
2. TROUBLESHOOTING (MATTERS OTHER THAN ERROR
CODE DISPLAY)
If any error cord is displayed on the monitor, prioritize the diagnosis and countermeasures for it.
No. Symptom Page
2.1. TROUBLESHOOTING OF THE ENGINE BODY T-403
S-1 ENGINE START FAULT T-403
S-2 ENGINE STALL T-404
S-3 ENGINE HUNTING T-405
S-4 ENGINE OUTPUT SHORTAGE T-406
S-5 MUCH WHITE SMOKE IN EXHAUST GAS T-407
S-6 MUCH BLACK SMOKE IN EXHAUST GAS T-407
S-7 ABNORMAL NOISE FROM ENGINE T-408
S-8 SIGNIFICANT FUEL CONSUMPTION T-408
S-9 SIGNIFICANT OIL CONSUMPTION T-408
2.2. TROUBLESHOOTING OF THE ELECTRICAL SYSTEMS T-409
E-1 MONITOR DISPLAYS NOTHING T-409
E-2 MONITOR FROZEN AND INOPERABLE T-410
E-3 MONITOR SWITCHES INOPERABLE (EXCEPT FOR BEING FROZEN) T-410
MOMENT LIMITER INDICATION VALUES ON MONITOR ARE
E-4 T-410
QUESTIONABLE
E-5 FUEL GAUGE FAILS TO INDICATE NORMALLY T-411
E-6 MONITOR DOES NOT DISPLAY PARTIALLY T-411
E-7 SCREEN DOES NOT SWITCH TO SERVICE MODE T-412
ENGINE DOES NOT START (NO ENGINE-RELATED ERROR CODE
E-8 T-412
DISPLAYED)
E-9 GLOW LAMP DOES NOT FUNCTION T-413
E-10 HEAD LAMP DOES NOT TURN ON NORMALLY T-413
E-11 TRI-COLOUR ROTARY LAMP DOES NOT COME ON T-413
NONE OF THE WORK EQUIPMENT OR SLEWING/TRAVELLING
E-12 T-414
WORKS
E-13 TRAVEL SPEED CANNOT BE CHANGED T-414
HIGH SPEED OPERATION OF WINCH HOIST UP/DOWN CANNOT BE
E-14 T-415
PERFORMED
HOIST UP CANNOT BE PERFORMED WITH HOOK STOWAGE
E-15 T-415
OPERATION
NONE OF THE HOISTING UP, EXTENDING, RAISING OR LOWERING
OPERATIONS CAN BE PERFORMED EVEN WHEN THE MOMENT
E-16 T-416
LIMITER IS CANCELLED WITH THE EMERGENCY RELEASE
SWITCH
T-401
No. Symptom Page
2.3. TROUBLESHOOTING OF THE HYDRAULIC PRESSURE AND MECHANICAL
T-417
SYSTEMS
ALL THE CRANE, SLEWING AND TRAVELLING SPEED IS LOW, OR
H-1 T-417
THE FORCE IS INSUFFICIENT
ENGINE REVOLUTION SPEED DROPS SIGNIFICANTLY, OR THE
H-2 T-417
ENGINE STALLS
H-3 NONE OF THE CRANE OR SLEWING/TRAVELLING WORKS T-418
ABNORMAL NOISE IS GENERATED FROM THE HYDRAULIC PUMP
H-4 T-419
OR ITS PERIPHERY
MICRO SPEED OPERABILITY IS UNSATISFACTORY, OR
H-5 T-419
RESPONSIVENESS IS INSUFFICIENT
H-6 HOIST UP/DOWN IS SLOW OR WEAK T-420
ABNORMAL SOUND OR VIBRATION IS GENERATED FROM WINCH
H-7 T-421
MOTOR OR ITS PERIPHERY
H-8 HOIST UP CANNOT BE PERFORMED T-421
H-9 HOIST DOWN CANNOT BE PERFORMED T-421
H-10 BOOM TELESCOPING IS SLOW OR WEAK T-421
H-11 BOOM DERRICKING IS SLOW OR WEAK T-422
H-12 BOOM EXTENDING/RETRACTING ORDER IS DISTURBED T-422
H-13 HUNTING OCCURS DURING BOOM RETRACTION T-422
H-14 EITHER BOOM NO. 2 OR 3 FAILS TO RETRACT T-422
H-15 NATURAL DESCENDING AMOUNT OF CRANE IS SIGNIFICANT T-423
H-16 TIME LAG OF CRANE IS SIGNIFICANT T-423
H-17 TRAVEL DEVIATION IS OBSERVED T-424
H-18 TRAVEL SPEED IS LOW T-424
H-19 STEERING IS DIFFICULT OR WEAK T-425
TRAVEL SPEED CANNOT BE CHANGED, OR TRAVEL SPEED IS
H-20 T-425
LOW/HIGH
H-21 CRAWLER FAILS TO MOVE (ONE SIDE ONLY) T-425
H-22 DOES NOT SLEW T-426
SLEWING ACCELERATION IS UNSATISFACTORY, OR SLEWING
H-23 T-427
SPEED IS LOW
H-24 OVERRUN AFTER STOP OF SLEWING IS SIGNIFICANT T-428
H-25 IMPACT AT STOP OF SLEWING IS SIGNIFICANT T-429
ABNORMAL NOISE GENERATED AT STOP OF SLEWING IS
H-26 T-429
SIGNIFICANT
H-27 NATURAL DESCENDING AMOUNT AT SLEWING IS SIGNIFICANT T-429
[Note]
• The sequential order given under assumed cause and diagnostic method does not necessarily match the order of
checking. Select the item(s) to be checked in accordance with the status of the subject that can be determined by
observing the vehicle and service conditions.
T-402
2.1 TROUBLESHOOTING OF THE ENGINE BODY
Perform engine inspection, disassembly and assembly based on the Yanmar Diesel Engine (3TNV88F)
Service Manual.
As a common cause of troubles in the engines, when none of the following symptoms applies, the below-listed causes
should be suspected:
・Abnormality in main body such as engine seizure caused by overload services or poor maintenance.
・Adverse effects of unauthorised components (such as radio receiver and lamps).
・Faulty grounding of ECM (engine controller) and CPU failure.
S-1 [ENGINE START FAULT]

Cranking revolution is low.
Symptom While cranking runs properly, engine does not start.
While engine starts, the engine revolution cannot be stabilized and maintained.
・ Check to ensure that fuel is filled.
・ Check to ensure that specified fuel and oil are used.
1 Fuel or oil abnormality ・ Check the fuel for any sign of freezing. If frozen, defrost or
replace it with a low temperature-withstanding fuel.
・ Check the fuel for any water inclusion.
・ Check fuel line for any air inclusion.
Abnormality in fuel piping
2 ・ Check fuel filter for any clogging.
and filter
Assumed cause ・ Check to make sure the fuel pump is running.
and action to be ・ Check if battery voltage has dropped.
taken 3 Battery capacity shortage Voltage (1 piece): 12 V or more; Specific gravity (1 piece):
1.26 or more
・ Check air cleaner for any clogging.
4 Intake system abnormality
・ Check air intake piping for any abnormality.
Electrical wiring
5 ・ Check engine and fuel circuit.
abnormality
・ Check to ensure that hydraulic pump functions properly
6 Hydraulic unit abnormality
and there is no abnormality that may cause engine overload.
Fuel injection pump ・ Check the fuel injection pump for fuel pressurisation for
7
abnormality any sign of pump starting fault.
[Additional information]
Note on the use of unauthorized fuels:
・Using a low-viscosity fuel such as kerosene may cause a delivery failure because of accelerated abrasion of fuel
injection pump plunger, resulting in a starting fault.
・Fuels preserved for a long time or mixed with a biofuel containing organic substances are prone to be oxidised, and
accelerate abrasion of camshaft-related parts inside the fuel injection pump causing a starting fault due to insufficient
delivery.
・While replacement of the fuel injection pump is required in the case of fault mentioned above, continued use of
unauthorised fuels may cause the faults to recur. Thus, give guidance to the users that the specified fuel should be
used.
T-403
[Location information]
S-2 [ENGINE STALL]

Although engine performs cranking it fails to start for a long period of time.
Symptom
The engine stops soon after starting.
Assumed cause 2 ・ Check fuel filter for any clogging.
and filter
and action to be ・ Check to make sure the fuel pump is running.
taken ・ Check air cleaner for any clogging.
Electrical wiring
abnormality
・ Check to ensure that hydraulic pump functions properly and
there is no abnormality that may cause engine overload.
Fuel injection pump ・ Check the fuel injection pump for fuel pressurisation for any
6
abnormality sign of pump starting fault.
T-404
S-3 [ENGINE HUNTING]
Unevenness in engine idling is observed, or idling revolution speed varies.
Symptom
Engine or the machine body vibrates.
2 ・ Check fuel filter for any clogging.
and filter
Assumed cause ・ Check to make sure the fuel pump is running.
and action to be ・ Check if battery voltage has dropped.
taken 3 Battery capacity shortage Voltage (1 piece): 12 V or more; Specific gravity (1 piece):
1.26 or more
・ Check air cleaner for any clogging.
Electrical wiring
abnormality
Fuel injection pump ・ Check the fuel injection pump for fuel pressurisation for
7
abnormality any sign of pump starting fault.
・Using a low-viscosity fuel such as kerosene may cause a delivery failure because of accelerated abrasion of fuel
injection pump plunger, resulting in a starting fault.
・Fuels preserved for a long time or mixed with a biofuel containing organic substances are prone to be oxidised, and
accelerate abrasion of camshaft-related parts inside the fuel injection pump causing a starting fault due to insufficient
delivery.
・While replacement of the supply pump is required in the case of fault mentioned above, continued use of unauthorised
fuels may cause the faults to recur. Thus, give guidance to the users that the specified fuel should be used.
When engine stalls after hunting:

・Since abnormality in the fuel injection unit is conceivable, execute an engine stall diagnosis.
T-405
S-4 [ENGINE OUTPUT SHORTAGE]
Engine output is below target value, output remains unchanged and the responsiveness is bad even
Symptom
when depressing the accelerator pedal.
Assumed cause 2 ・ Check fuel filter for any clogging.
and filter
and action to be ・ Check to make sure the fuel pump is running.
taken ・ Check air cleaner for any clogging.
・ Check the exhaust system including silencer and exhaust
4 Exhaust system abnormality
pipe for any abnormality.
Electrical wiring
abnormality
When engine stalls:
・Since abnormality in the fuel injection unit is conceivable, execute an engine stall diagnosis.
Probability of output loss due to overheat:

・When engine coolant temperature is 95 °C or more, output decrease due to fuel flow rate limitation may be the case.
Probability of output shortage because of a highland operation:

・In the case of a highland operation at an altitude of 2000 m or more, output decrease due to fuel flow rate limitation
may be the case.
T-406
S-5 [MUCH WHITE SMOKE IN EXHAUST GAS]
Symptom Much white smoke in exhaust gas.

1 Fuel or oil abnormality ・ Check to ensure that specified fuel and oil are used.
2 Fuel piping abnormality
・ Check fuel piping for any damage.
Assumed cause ・ Check air cleaner for any clogging.
and action to be ・ Check air intake piping for any abnormality.
taken ・ Check the exhaust system including silencer and exhaust
Electrical wiring ・ Check engine and fuel circuit for any faulty connection in
5
abnormality the injector connector.
・ Check to ensure that the injector of injection unit is
6 Injector abnormality
functioning properly.
・ Use of a low viscosity fuel such as kerosene may cause an abnormal injection due to an abnormal abrasion of
injector seat, resulting in generation of white smoke.
・ In the case of fault mentioned above, replacement of injector is required. Give guidance to the users that the
specified fuel should be used after replacement.
S-6 [MUCH BLACK SMOKE IN EXHAUST GAS]

Symptom Much black smoke in exhaust gas.

1 Fuel or oil abnormality ・ Check to ensure that specified fuel and oil are used.
2 Fuel piping abnormality
Assumed cause ・ Check fuel piping for any damage.
and action to be ・ Check air cleaner for any clogging.
taken ・ Check air intake piping for any abnormality.
・ Check the exhaust system including silencer and exhaust
Electrical wiring
abnormality
T-407
S-7 [ABNORMAL NOISE FROM ENGINE]
Symptom Engine combustion sound is abnormal.

Abnormality in fuel piping ・ Check fuel line for any air inclusion.
2
Assumed cause and filter ・ Check fuel piping for any damage.
Electrical wiring
and action to be 3 ・ Check engine and fuel circuit.
taken abnormality
・ Check to ensure that EGR valve and other components in
5 EGR valve abnormality
the intake system are functioning properly.
S-8 [SIGNIFICANT FUEL CONSUMPTION]

Symptom Fuel consumption rate remarkably exceeds the specified value.

・ Check the fuel for any sign of freezing. If frozen, defrost or
1 Fuel or oil abnormality replace it with a low temperature-withstanding fuel.
・ Check the fuel for any water inclusion. If it is the case,
perform water draining.
・ Check each item to ensure that replacement of engine oil,
Assumed cause Maintenance service
2 engine oil filter, air cleaner element and fuel filter is
and action to be pending
executed periodically.
taken Electrical wiring
abnormality
・ Check to ensure that EGR valve and other components in
5 EGR valve abnormality
the intake system are functioning properly.
Reference value of fuel consumption rate Rated output (17.5 kW/2,400 rpm): 4.2 L/h
S-9 [SIGNIFICANT OIL CONSUMPTION]

Symptom Oil consumption rate remarkably exceeds the specified value.

Assumed cause ・ Check to ensure that specified fuel and oil are used.
and action to be 1 Fuel or oil abnormality ・ Check if specified amount of engine oil is filled. If not,
taken replenish it, wait and see how it goes.
Oil inclusion in coolant ・ Check for any oil inclusion in the coolant water. If it is
2
water detected, identify the cause of oil leakage.
Reference value of oil consumption rate 0.002 L/h (0.2 L/100 h) or less
If oil is lost at a higher rate, a warning may be displayed before due oil replacement timing.
T-408
2.2. TROUBLESHOOTING OF THE ELECTRICAL SYSTEMS
E-1 [MONITOR DISPLAYS NOTHING]
Content When turning the starter key on, nothing is displayed on the monitor.

Power off by emergency ・ Check the emergency stop switch to see if the power has
1
stop switch been shut down.
・ Check if battery voltage has dropped.
2 Battery capacity shortage Voltage (1 piece): 12 V or more; Specific gravity (1 piece):
1.26 or more
・ Check if fuse has been blown off. If it is the case, short
Assumed cause 3 Fuse blown off circuit to ground may have occurred, and thus check the
and action to be circuit.
Open circuit fault of harness
taken ・ Check to ensure that there is no open circuit in the monitor
4 (Open circuit or connector
power circuit.
contact fault)
Harness short circuit fault
・ Check to ensure that there is no short circuit to ground in
5 (Contact with grounding
the monitor power circuit.
circuit)
・ When no problem is found under 1 through 5, monitor fault
6 Monitor fault is conceivable.
(The internal fault prevents the diagnosis to be executed.)
T-409
E-2 [MONITOR IS FROZEN AND INOPERABLE]
Content Screen on the monitor remains frozen and cannot be operated.

・ Turn the key off to check if screen disappears.
・ If the screen remains displayed even when the key is turned
Processing capacity
1 off, shut down the power supply by using the emergency
insufficient
Assumed cause stop switch or by pulling off the connector (CN-MON1) of
and action to be the monitor.
taken ・ If the phenomenon appears frequently, a software error may
2 Software error have occurred. Accordingly, update to the latest version.
・ If the phenomenon appears frequently even if the software
3 Monitor fault is updated, monitor fault is conceivable.
E-3 [MONITOR SWITCHES INOPERABLE (EXCEPT FOR BEING FROZEN)]

While monitor screen is displayed, switch operating function is disabled or inoperable (except for
Content
being frozen).
Processing capacity
1 ・ Turn off the key once and restart it to check the operability.
insufficient
Assumed cause ・ If the phenomenon appears even after the system is
and action to be restarted, a software error may have occurred. Accordingly,
taken 2 Software error
update to the latest version.
Monitor fault ・ If the phenomenon appears again after the system is
2
(Switch fault) restarted, a switch fault or monitor fault is conceivable.
Note on disassembling the monitor:
・Since there is likelihood that performance of the monitor will fail to be rendered, do not disassemble.
E-4 [MOMENT LIMITER INDICATION VALUES ON MONITOR ARE QUESTIONABLE]

When an error code of any sensors is displayed, prioritize the diagnosis and countermeasures for it.
Content Moment limiter indication values on monitor are questionable (no error of sensors shown).

Processing capacity ・ Turn off the key once and restart it again to check the
1
insufficient operability.
・ If no abnormality is found in sensors, the operation fault of
Assumed cause software is conceivable, and thus the software should be
and action to be 2 Operation fault (software)
updated to the latest version.
taken (The internal fault prevents the diagnosis to be executed.)
・ If the phenomenon appears even after the software has been
Operation fault (of main rewritten, fault of controller (TTC60 or TTC36X) that
3
body) constitutes the operating function is conceivable.
Note on calibration data of the moment limiter:
・Calibrated data are basically retained even if software is rewritten, so re-calibration is not required.
(However, re-calibration may be required depending on the details of the software.)
T-410
E-5 [FUEL GAUGE FAILS TO INDICATE NORMALLY]
When an error code of any fuel sensors is displayed, prioritize the diagnosis and countermeasures for it.
Content The meter does not function even after refuelling or consuming the fuel.

1
・ Check if the float of the fuel level sensor is operating
2 Fuel level sensor fault
Assumed cause normally.
and action to be ・ If no problem is found in fuel sensor or harness, a software
taken error may have occurred. Accordingly, rewrite the
3 Software error
software.
・ If the phenomenon appears even after the software is
4 Monitor fault rewritten, monitor fault is conceivable.
E-6 [MONITOR DOES NOT DISPLAY PARTIALLY]

Content Monitor screen does not display partially.

1
・ If the phenomenon appears again even after the system is
Assumed cause restarted, a software error may have occurred. Accordingly,
and action to be 2 Software error
rewrite the software.
taken (The internal fault prevents the diagnosis to be executed.)
・ If the phenomenon is observed even after the software has
been rewritten, fault of either liquid crystal display panel or
3 Monitor fault
monitor itself is conceivable.
[Additional description]
Characteristics of liquid crystal display:
・Although there may be some black spots (unlit dots) and bright spots (dots remaining lit), 10 or less black or bright
spots are not considered faulty.
T-411
E-7 [SCREEN DOES NOT SWITCH TO SERVICE MODE]
Before starting a diagnosis, ensure that there is no difference in the way of accessing the Service Mode screen again and
the input password.
Content Screen does not switch to Service Mode.

1
Assumed cause ・ If the phenomenon appears again even after the system is
and action to be restarted, a software error may have occurred. Accordingly,
2 Software error
taken rewrite the software.
・ If the phenomenon appears even after the software is
3 Monitor fault rewritten, monitor fault is conceivable.
E-8 [ENGINE DOES NOT START (NO ENGINE-RELATED ERROR CODE DISPLAYED)]
If an error code is displayed, prioritize the diagnosis and countermeasures for it.
Content The engine does not start.

・ Check if battery voltage has dropped.
1 Battery capacity shortage Voltage (1 piece): 12 V or more; Specific gravity (1 piece):
1.26 or more
circuit to ground may have occurred, and thus check the
2 Fuse blown off
circuit.
Starter fuse 60 A, glow fuse 80 A
3 Starter switch fault ・ Check if the starter switch functions properly.
・ Check to make sure that the lock lever is not in free
4 Lock lever switch fault position.
Assumed cause ・ Check if the micro switch functions properly.
and action to be
・ Check to make sure that the emergency stop switch has not
taken
5 Emergency stop switch fault been pressed.
・ Check if the emergency stop switch functions properly.
6 Starter relay fault ・ Check if the starter relay functions properly.
7 Starter fault ・ Check if the starter functions properly.
8 Alternator fault ・ Check if the alternator functions properly.
9 (Open circuit or connector ・ Check the starter circuit for any open circuit.
contact fault)
・ Check to ensure that no short circuit to ground is found in
the starter circuit.
circuit)
T-412
E-9 [GLOW LAMP DOES NOT FUNCTION]
When engine does not start, prioritize the diagnosis and countermeasures for E-8 [ENGINE DOES NOT START].
Glow lamp does not function.
Content
Glow lamp does not come on even if the key is turned on (at a low temperature).
・ Check if glow fuse has been blown off. If it is the case,
short circuit to ground may have occurred, and thus check
1 Blown glow fuse
the circuit.
Glow fuse: 80 A
Assumed cause
and action to be 2 Glow relay fault ・ Check if the glow relay functions properly.
taken Open circuit fault of harness
3 (Open circuit or connector ・ Check the starter circuit for any open circuit.
contact fault)
the starter circuit.
circuit)
E-10 [HEAD LAMP DOES NOT TURN ON NORMALLY]

Content Head lamp does not come ON.

1 Switch fault ・ Check if the ON/OFF switch functions properly.
2 (Open circuit or connector ・ Check the power circuit of head lamps for any open circuit.
Assumed cause contact fault)
and action to be Harness short circuit fault
taken ・ Check to ensure that no short circuit to ground is found in
the head lamp power circuit.
circuit)
・ Check for any burnt out filament of bulb.
4 Working lamp fault ・ If the filament of bulb is not burnt out, failure of lamp body
is conceivable.
E-11 [TRI-COLOUR ROTARY LAMP DOES NOT COME ON]

Content All tri-colour rotary lamp does not come ON.

1 (Open circuit or connector ・ Check tri-colour rotary lamp circuit for any open circuit.
contact fault)
Assumed cause
and action to be ・ Check to ensure that no short circuit to ground is found in
taken the tri-colour rotary lamp circuit.
circuit)
3 Tri-colour rotary lamp fault ・ Check if the tri-colour rotary lamp functions properly.
Fault of controller ・ If no problem is found under 1 through 3, controller
4
(HY-TTC36X) (TTC36X) fault is conceivable.
Content One or two lamps of tri-colour rotary lamp do not come ON.

1 (Open circuit or connector ・ Check tri-colour rotary lamp circuit for any open circuit.
contact fault)
Assumed cause
and action to be ・ Check to ensure that no short circuit to ground is found in
taken the tri-colour rotary lamp circuit.
circuit)
3 Tri-colour rotary lamp fault ・ Check if the tri-colour rotary lamp functions properly.
Fault of controller ・ If no problem is found under 1 through 3, controller
4
(HY-TTC36X) (TTC36X) fault is conceivable.
T-413
E-12 [NONE OF THE WORK EQUIPMENT OR SLEWING/TRAVELLING WORKS]
Content None of the work equipment or slewing/travelling works

・ Check to make sure that the lock lever is not in free
1 Lock lever switch fault position.
・ Check if the micro switch functions properly.
Assumed cause Open circuit fault of harness
and action to be 2 (Open circuit or connector ・ Check lock lever signal circuit for any open circuit.
taken contact fault)
the lock lever signal circuit.
circuit)
Emergency stop does not
4 ・ Cancel the emergency stop switch.
function
E-13 [TRAVEL SPEED CANNOT BE CHANGED]

Content Switching travel speeds does not change the travel speed.

Fault of speed increase pedal ・ Check if the speed increase pedal switch functions
1
switch properly.
Fault of travel 2-speed shift ・ Check if the travel 2-speed shift solenoid (travel speed shift
2
solenoid valve) functions properly.
・ Check the travel 2-speed shift solenoid and speed increase
Assumed cause 3 (Open circuit or connector
pedal switch related circuits for any open circuit.
and action to be contact fault)
taken Harness short circuit fault ・ Check to ensure that no short circuit to ground is found in
4 (Contact with grounding the travel 2-speed shift solenoid and speed increase pedal
circuit) switch related circuits.
・ When no problem is found in the diagnoses under 1 through
5 Monitor fault
4, fault of monitor is conceivable.
・ When no output is found in the diagnoses under 1 through
6 Controller fault 5, fault of controller (TTC60) is conceivable. (CN-C1-124
and 144)
T-414
E-14 [HIGH SPEED OPERATION OF WINCH HOIST UP/DOWN CANNOT BE
PERFORMED]
Content High speed operation of winch hoist up/down cannot be performed.

Operation fault of crane
・ Check for any operation fault in the spool of the crane
1 control valve winch
control valve winch operation valve.
operation valve (spool)
Assumed cause ・ Measure the piston pump A3 port pressure.
and action to be 2 Fault of piston pump Pilot pressure: 3.1 MPa {32 kg/cm2}
taken ・ Replace the piston pump.
Operation fault of winch
3 ・ Replace the winch motor.
motor
Fault of controller ・ Check if controller (HY-TTC60) functions properly. If not,
4
(HY-TTC60) replace HY-TTC60.
E-15 [HOIST UP CANNOT BE PERFORMED WITH HOOK STOWAGE OPERATION]

Content Hoist up cannot be performed with hook stowage operation (the hook cannot be stowed).

Fault of right work ・ Check if hoisting up of the right work equipment operation
1
equipment operation lever lever functions properly.
Fault of winch merge valve ・ Check if the 2-fold SOL (A1) solenoid and winch merge
2
(low pressure shift) solenoid valve (low pressure shift) solenoid function properly.
Assumed cause ・ Check the 2-fold SOL (A1) solenoid and winch merge
and action to be valve (low pressure shift) circuits for any open circuit.
contact fault)
taken Harness short circuit fault ・ Check to ensure that no short circuit to ground is found in
4 (Contact with grounding the 2-fold SOL (A1) solenoid and winch merge valve (low
circuit) pressure shift) circuits.
・ When no problem is found in the diagnoses under 1 through
5 Monitor fault
4, fault of monitor is conceivable.
Fault of controller ・ When no output is found in the diagnoses under 1 through
6
(HY-TTC60) 5, fault of controller (TTC60) is conceivable.
T-415
E-16 [NONE OF THE HOISTING UP, EXTENDING, RAISING OR LOWERING
OPERATIONS CAN BE PERFORMED EVEN WHEN THE MOMENT LIMITER IS
CANCELLED WITH THE EMERGENCY RELEASE SWITCH]
None of the hoisting up, extending, raising or lowering operations can be performed even when the
Content
moment limiter is cancelled with the emergency release switch.
1 Fuse blown off circuit to ground may have occurred, and thus check the
circuit.
Emergency stop switch fault
2 or emergency stop switch ・ Check if the emergency stop switch functions properly.
does not function
Fault of emergency release
Assumed cause 3 ・ Check if the emergency release switch functions properly.
and action to be switch
taken ・ Check the emergency release switch and emergency stop
circuits for any open circuit.
contact fault)
the emergency release switch and emergency stop circuits.
circuit)
・ When no output is found in the diagnoses under 1 through
Fault of controller
6 5, fault of controller (TTC60) is conceivable. (CN-C2-256,
(HY-TTC60)
263)
T-416
2.3. TROUBLESHOOTING OF THE HYDRAULIC PRESSURE AND
MECHANICAL SYSTEMS
H-1 [ALL THE CRANE, SLEWING AND TRAVELLING SPEED IS LOW, OR THE FORCE IS
INSUFFICIENT]
Content All the crane, slewing and travelling speed is low, or the force is insufficient.

★ Stop engine to perform preparations and conduct diagnosis at a
high engine idling speed.
Assumed cause Faulty adjustment or Operation lever at relief
and action to be 1 operation of main relief Travelling relief pressure: 24. 5 + 0. 5/0 MPa
taken valve {250 + 5/0 kg/cm2}
Crane relief pressure: 20. 6 + 0. 5/0 MPa
{210 + 5/0 kg/cm2}
・ When no problem is found above, performance degradation,
2 Fault of piston pump
operation fault or internal fault of piston pump is conceivable.
H-2 [ENGINE REVOLUTION SPEED DROPS SIGNIFICANTLY, OR THE ENGINE

STALLS]
Content Engine revolution speed drops significantly, or the engine stalls.

Assumed cause Faulty adjustment or Operation lever at relief
and action to be 1 operation of main relief Travelling relief pressure: 24. 5 + 0. 5/0 MPa
taken valve {250 + 5/0 kg/cm2}
Crane relief pressure: 20. 6 + 0. 5/0 MPa
{210 + 5/0 kg/cm2}
2 Engine output shortage ・ Check the items in S-4 ENGINE OUTPUT SHORTAGE.
T-417
H-3 [NONE OF THE CRANE OR SLEWING/TRAVELLING WORKS]
Content None of the crane or slewing/travelling works.

★ Stop engine to perform preparations and conduct diagnosis
at a high engine idling speed.
Operation fault of crane Operation lever at neutral
1
control valve Output pressure: 0 MPa {0 kg/cm2}
Assumed cause Operation lever during operation: Pilot pressure:
and action to be Pilot pressure: 2.9 MPa {30 kg/cm2} or more
taken Measure the piston pump A3 port pressure.
Pilot pressure: 2.9 MPa {30 kg/cm2} or more
Since piston pump operation fault or internal fault is
2 Fault of piston pump conceivable, conduct the diagnosis as follows:
・ Remove the main hydraulic pressure measurement plug and
allow engine to perform cranking.
→ When oil flows out, it is normal.
T-418
H-4 [ABNORMAL NOISE IS GENERATED FROM THE HYDRAULIC PUMP OR ITS
PERIPHERY]
Content Abnormal noise is generated from the hydraulic pump or its periphery.

Decrease in hydraulic oil
1 ・ Check if there is 45 L of hydraulic oil.
level
・ Since air inclusion in the hydraulic oil is conceivable, inspect
2 Fault of hydraulic oil
Assumed cause directly.
and action to be Clogging of hydraulic oil ・ Since the hydraulic tank cap is clogged resulting in a negative
taken 3
tank cap internal pressure of the tank is conceivable, inspect directly.
Clogging of hydraulic oil ・ Since the hydraulic tank suction filter resulting in a negative
4
tank suction filter pressure of the suction circuit is conceivable, inspect directly.
・ Since internal fault of piston pump is conceivable, inspect it
directly.
H-5 [MICRO SPEED OPERABILITY IS UNSATISFACTORY, OR RESPONSIVENESS IS

INSUFFICIENT]
Content Micro speed operability is unsatisfactory, or responsiveness is insufficient.

Assumed cause Operation fault of crane ・ Check for any operation fault in the crane control valve, and
and action to be 1
control valve check if the pilot pressure changes in proportion.
taken ・ Measure the piston pump A3 port pressure.
T-419
H-6 [HOIST UP/DOWN IS SLOW OR WEAK]
Content Hoist up/down is slow or weak.

・ Check for any operation fault in the spool of the crane control
Assumed cause 1 control valve winch
valve winch operation valve.
and action to be operation valve (spool)
taken ・ Measure the piston pump A3 port pressure.
motor
T-420
H-7 [ABNORMAL SOUND OR VIBRATION IS GENERATED FROM WINCH MOTOR OR
ITS PERIPHERY]
Content Abnormal sound or vibration is generated from winch motor or its periphery.

Air remains in the circuit and
Assumed cause 1 ・ Vent the air in the circuit.
motor
and action to be Generation of piping
taken 2 ・ Check the piping clamps tightening.
vibration
motor
H-8 [HOIST UP CANNOT BE PERFORMED]

Content Hoist up cannot be performed.

Assumed cause
and action to be Operation fault of 2-fold ・ Check for any operation fault in the 2-fold SOL (A1)
2
taken SOL (A1) solenoid valve solenoid valve.
3 ・ Check for any operation fault in the winch motor brake.
motor brake
motor
Note: When the overwinding prevention device and overload prevention device are not operating under electronic contr
ol.
H-9 [HOIST DOWN CANNOT BE PERFORMED]

Content Hoist down cannot be performed.

Assumed cause Operation fault of 2-fold ・ Check for any operation fault in the 2-fold SOL (A1)
and action to be 2
SOL (A1) solenoid valve solenoid valve.
taken Operation fault of winch
motor
Fault of over un-winding
・ Check for any operation fault in the over un-winding
4 detection limit switch
detection limit switch.
operation
H-10 [BOOM TELESCOPING IS SLOW OR WEAK]

Content Boom telescoping is slow or weak.

Operation fault of boom
・ Check for any operation fault in the spool of the boom
1 telescoping operation valve
telescoping valve.
(spool)
Assumed cause ★ Stop engine to perform preparations and conduct diagnosis
and action to be at a high engine idling speed.
taken ・ Boom telescoping cylinder during retraction relief.
Fault of boom telescoping Cylinder leakage rate: 10 cc/10 min
2
cylinder ・ Check for any operation fault in the counterbalance of the
boom telescoping cylinder.
・ Check for any deformation or operation fault in the boom
telescoping cylinder.
T-421
H-11 [BOOM DERRICKING IS SLOW OR WEAK]
Content Boom derricking is slow or weak

Operation fault of boom
・ Check for any operation fault in the spool of the boom
1 derricking operation valve
derricking valve.
(spool)
Assumed cause ★ Stop engine to perform preparations and conduct diagnosis
and action to be at a high engine idling speed.
taken ・ Boom derricking cylinder during retraction relief
Fault of boom derricking Cylinder leakage rate: 5 cc/10 min
2
cylinder ・ Check for any operation fault in the counterbalance of the
boom derricking cylinder.
・ Check for any deformation or operation fault in the boom
derricking cylinder.
H-12 [BOOM EXTENDING/RETRACTING ORDER IS DISTURBED]

Content Boom extending/retracting order is disturbed.

Assumed cause Operation fault of sequence
and action to be 1 ・ Check for any operation fault in the sequence valve.
valve
taken Operation fault of ・ Check for any operation fault in the mechanical check
2
mechanical check valve valve.
H-13 [HUNTING OCCURS DURING BOOM RETRACTION]

Content Hunting occurs during boom retraction.

Assumed cause Operation fault of
and action to be 1 ・ Check for any operation fault in the counterbalance valve.
counterbalancing valve
taken Grease run-out on boom ・ Since grease run-out on the boom sliding surface is
2
sliding surface conceivable, apply grease.
H-14 [EITHER BOOM NO. 2 OR 3 FAILS TO RETRACT]

Content Either boom No. 2 or 3 fails to retract.

Assumed cause Operation fault of ・ Check for any operation fault in the mechanical check
and action to be 1
mechanical check valve valve.
taken Fault of mechanical check ・ Check for any operation fault in the push button of the
2
valve push button mechanical check valve.
T-422
H-15 [NATURAL DESCENDING AMOUNT OF CRANE IS SIGNIFICANT]
Content Natural descending amount of winch is significant.

Assumed cause Operation fault of winch
and action to be 1 ・ Check for any operation fault in the winch motor brake.
motor brake
taken Operation fault of winch
motor
Content Natural descending rate of boom telescoping cylinder is significant.

Fault of boom telescoping at a high engine idling speed.
1
Assumed cause cylinder Boom telescoping cylinder during retraction relief
and action to be Cylinder leakage rate: 10 cc/10 min
taken Leakage from ・ Check for any leakage from the seat of the counterbalance
2
counterbalance valve valve.
Leakage from sequence
・ Check for any leakage from the sequence valve and
3 valve and mechanical check
mechanical check valve.
valve
Content Natural descending rate of boom derricking cylinder is significant.

Assumed cause Fault of boom derricking at a high engine idling speed.
and action to be 1
cylinder Boom derricking cylinder during retraction relief
taken Cylinder leakage rate: 5 cc/10 min
Leakage from ・ Check for any leakage from the seat of the counterbalance
2
counterbalance valve valve.
H-16 [TIME LAG OF CRANE IS SIGNIFICANT]

Content Time lag of crane is significant.
Assumed cause Cause Diagnostic method and action to be taken

and action to be Operation fault of control ・ Check for any operation fault in the spool of the control
taken 1
valve operation valve (spool) valve operation valve.
T-423
H-17 [TRAVEL DEVIATION IS OBSERVED]
Content Travel deviation is observed.

Travel lever at neutral
Output pressure: 0 MPa {0 kg/cm2}
Travel lever at operation
Operation fault of control
1 Pilot pressure: 2.9 MPa {30 kg/cm2} or more
valve
Max. operating pressure: 24. 5 MPa {250 kg/cm2}
・ Check for a difference in the pilot pressure between the left
and right travel operations.
Assumed cause ・ Check for a difference in the operating pressure between
and action to be the left and right travel operations.
taken Operation fault of travelling ・ Check for any operation fault in the travelling remote
2
remote control valve control valve.
3
Travel lever at travel relief
4 Fault of travel motor Travel motor leakage rate: 1.65 L/min
(Determined by the presence of abnormal noise or
abnormal heating and metallic powder inclusion in the
drain oil)
H-18 [TRAVEL SPEED IS LOW]

Content Travel speed is low.

Operation fault of control Travel lever at operation
1
valve Pilot pressure: 2.9 MPa {30 kg/cm2} or more
Max. operating pressure: 24. 5 MPa {250 kg/cm2}
・ Check if the pilot pressure of the travel operation is normal.
Assumed cause ・ Check if the operating pressure of the travel operation is
and action to be normal.
taken Operation fault of travelling ・ Check for any operation fault in the travelling remote
2
remote control valve control valve.
3
4 Fault of travel motor Travel motor leakage rate: 1.65 L/min
(Determined by the presence of abnormal noise or
abnormal heating and metallic powder inclusion in the
drain oil)
T-424
H-19 [STEERING IS DIFFICULT OR WEAK]
Content Steering is difficult or weak.

Operation fault of control Pilot pressure: 2.9 MPa {30 kg/cm2} or more
1
valve Max. operating pressure: 24. 5 MPa {250 kg/cm2}
Assumed cause ・ Check if the operating pressure of the travel operation is
and action to be normal.
taken ・ Check for any operation fault in the spool of the travel
operation valve.
Operation fault of hydraulic ・ Check for any operation fault or sealing fault in the hydraulic
2
pump pump.
3
・ Check for any operation fault in the travel motor.
Operation fault of travel (It may be determined by switching between forward and
4
motor backward rotational direction of the same motor or between
left and right motors.)
H-20 [TRAVEL SPEED CANNOT BE CHANGED, OR TRAVEL SPEED IS LOW/HIGH]

Content Travel speed cannot be changed, or travel speed is low/high.

Assumed cause Operation fault of travel Travel speed, travel lever: Lo (position 1 speed), at neutral
and action to be 1
2-speed shift solenoid Output pressure: 0 MPa {0 kg/cm2}
taken Travel speed, travel lever: Hi (position 2 speed), at operation
Operation fault of travel
2 ・ Check for any operation fault in the travel motor.
motor
H-21 [CRAWLER FAILS TO MOVE (ONE SIDE ONLY)]

Content Crawler fails to move (one side only).

Operation fault of control Pilot pressure: 2.9 MPa {30 kg/cm2} or more
1
valve Max. operating pressure: 24. 5 MPa {250 kg/cm2}
・ Check if the operating pressure of the travel operation is
Assumed cause normal.
and action to be ・ Check for any operation fault in the travelling remote control
taken valve.
Travel motor leakage rate: 1.65 L/min
・ Check for any operation fault in the travel motor.
2 Fault of travel motor
(It may be determined by switching between forward and
backward rotational direction of the same motor or between
left and right motors.)
(Determined by the presence of abnormal noise or abnormal
heating and metallic powder inclusion in the drain oil)
T-425
H-22 [DOES NOT SLEW]
Content Neither left nor right side fails to slew.

Check if the crane PPC valve ・ Check if the crane PPC valve of the 3-fold solenoid valve is
1 (A3 port) of the 3-fold operating normally.
solenoid valve is normal. Pilot pressure: 2.9 MPa {30 kg/cm2} or more
control valve slewing operation valve.
Slewing lever at neutral
2 control valve slewing
Assumed cause Slewing lever at operation
taken Operation fault of slewing ・ Check for any operation fault in the slewing brake release
3
brake release shuttle valve shuttle valve.
Operation fault of slewing at a high engine idling speed.
4
motor Operation lever at slew relief
Slewing motor leakage rate: 6 L/min or less
・ Check for any operation fault in the swing machinery.
Operation fault of swing (May be determined by the presence of abnormal noise or
5
machinery abnormal heating and metallic powder inclusion in the
lubricating oil)
Content Only one side fails to slew.

Check if the crane PPC valve ・ Check if the crane PPC valve of the 3-fold solenoid valve is
1 (A3 port) of the 3-fold operating normally.
solenoid valve is normal. Pilot pressure: 2.9 MPa {30 kg/cm2} or more
Slewing lever at operation
Assumed cause Pilot pressure: 2.9 MPa {30 kg/cm2} or more
and action to be
Operation fault of slewing ・ Check for any operation fault in the slewing brake release
taken 3
4
5
lubricating oil)
T-426
H-23 [SLEWING ACCELERATION IS UNSATISFACTORY, OR SLEWING SPEED IS LOW]
Content Slewing acceleration is unsatisfactory, or slewing speed is low for both of left and right sides.

Operation fault of slewing ・ Check for any operation fault in the slewing brake release
1
Assumed cause Operation fault of slewing at a high engine idling speed.
and action to be 2
taken Slewing motor leakage rate: 6 L/min or less
3
lubricating oil)
Content Slewing acceleration is unsatisfactory, or slewing speed is low for only one side.

Assumed cause Operation fault of slewing ・ Check for any operation fault in the slewing brake release
and action to be 2
taken ★ Stop engine to perform preparations and conduct diagnosis
3
4
lubricating oil)
T-427
H-24 [OVERRUN AFTER STOP OF SLEWING IS SIGNIFICANT]
Content Overrun after stop of slewing is significant for both of left and right sides.

2
3
lubricating oil)
Content Overrun after stop of slewing is significant for only one side.

2
3
lubricating oil)
T-428
H-25 [IMPACT AT STOP OF SLEWING IS SIGNIFICANT]
Content Impact at stop of slewing is significant.

Assumed cause Output pressure: 0 MPa {0 kg/cm2}
and action to be operation valve (spool)
taken Pilot pressure: 2.9 MPa {30 kg/cm2} or more
2
lubricating oil)
H-26 [ABNORMAL NOISE GENERATED AT STOP OF SLEWING IS SIGNIFICANT]

Content Abnormal noise generated at stop of slewing is loud.

Assumed cause operation valve (spool)
and action to be
taken
2
lubricating oil)
3 Fault of slewing bearing ・ Check for any operation fault in the slewing bearing.
H-27 [NATURAL DESCENDING AMOUNT AT SLEWING IS SIGNIFICANT]

Content Natural descending amount at slewing is significant even when slewing motor brake is operating.

・ Check if the output pressure is 0 MPa {0 kg/cm2}
Assumed cause ・ Check for any operation fault in the brake section of the
and action to be slewing motor.
taken Brake release pressure 0.37 MPa {3.8 kg/cm2} + drain line
Operation fault of slewing pressure
2
motor ★ Stop engine to perform preparations and conduct diagnosis
Operation lever at slew relief
・ Check if the inclination angle of the lifted load is within 3
3 There is an overload
degrees.
T-429
SERVICE MANUAL for MAEDA CRAWLER CRANE CC423S-1
Document Number 542E-SM1812-00

Provisional version December 7th, 2018
Issued by MAEDA SEISAKUSHO CO., LTD.

1095, Onbegawa, Shinonoi, Nagano City,
Nagano Prefecture, 388-8522 Japan
Any reproduction or reprinting without permission is prohibited.

SM CC423 2018

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542E-SM1812-00

Weight and Distance between centre idler and sprocket 1,650 mm

Derricking Piston rod bore mm 90

Hydraulic oil tank (without hydraulic oil) 43

Track shoe left and right set 350

• No. 2 boom (78)

Winch assembly (with piping, etc., without wire rope) 75

Rubber pad left and right set 100

Searcher hook set 30

Water amount 3.8 3.5 3.2 3.0 2.7

1.2 ENGINE SPECIFICATIONS

No. Item Criterion Remedy

No. Item Criterion Remedy

1. Idler 6. Track roller

No. Item Criterion Remedy

No. Item Criterion Remedy

Outside diameter of Basic dimensions Allowable limit

2 Outside diameter of tread 300 292

No. Item Criterion Remedy

Outside diameter of Basic dimensions Allowable limit

Basic dimensions Allowable limit Repair by

No. Item Criterion Remedy

No. Item Criterion Remedy

No. Item Criterion Remedy

No. Item Criterion Remedy

Clearance between rotor Basic dimensions Standard clearance Allowable clearance

A3 To crane PPC valve P port Power (W) 12

1. Output shaft 9. Cylinder

No. Item Criterion Remedy

[*1]: Stamped mark D.

[*1]: Caulk at two locations after tightening.

For derricking cylinder ⇒ Identification stamp: D

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Port Joint Hose/Piping Joint

Joint Hose/Piping Joint

Tee Hose Nipple

Tee Hose Nipple

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

F4+F4R9×900L” Control valve

Joint Hose/Piping Joint

Elbow Hose White

Hose Nipple Green/

Joint Hose/Piping Joint

Joint Hose/Piping Joint

Joint Hose/Piping Joint

[*1]: Adjust so that the clearance is 0 to 0.5 mm.

1. No. 1 telescopic cylinder

1. Hook block 2. Sheave pin 3. Hook

The dimension between the “punched marks” on the

(1) Operator’s seat (9) Machine monitor

(1) User Mode switch (5) Hour meter display

(1) Consumables display (5) Engine oil pressure abnormality

(1-1) Hook number of falls change (1-7) Language setting